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System Five-3D Reference Manual

1. Notes ea A TOPCON Topcon Positioning Systems Inc 7400 National Drive Livermore CA 94551 800 443 4567 www topconpositioning com ISO 9001 2000 FM 68448 System Five 3D Reference Manual P N 7010 0491 Rev D 03 07 300 2007 Topcon Corporation All rights reserved No unauthorized duplication
2. 10 0 Upgrade Figure 1 36 Mainfall Sensor Function mmGPS Control Overview mmGPS uses Topcon s unique Lazer Zone technology to produce millimeter accuracy Lazer Zone technology combines the simplicity of a rotating laser the accuracy of a robotic total station and the flexibility and multiple user capabilities of GPS into one complete jobsite solution Figure 1 37 on page 1 34 e The PZL 1 laser transmitter emits a unique laser beam that provides a working range up to 2000ft 600m e The PZS MC laser sensor and GPS receiver at the machine detects the laser beam and satellite signals sending millimeter accurate positioning data to the control box for correction control e The PZS 1 sensor and GPS receiver detects the laser beam and satellite signals providing millimeter accurate spot checks throughout the jobsite P N 7010 0491 1 33 Introduction Figure 1 37 mmGPS at the Jobsite Placing Transmitters at the Jobsite The physical location of the laser transmitter on the jobsite should be outside the actual grading area if possible When choosing a location to place the laser transmitter remember the following two recommendations 1 Minimize the working distance from the laser transmitter As the distance from the laser transmitter increases grade accuracy decreases The following factors affect gra
3. 64 0 E ooo d ys 13 0 16 0 Figure C 13 TM 1 Telescoping Mast Dimensions C 17 Specifications GRT 2000 Robotic Total Station The GRT 2000 Robotic Total Station has a digital fan beam transmitter and full capability as an auto tracking total station A radio for radio transmission can be optionally added Table C 14 lists specification details for the GRT 2000 Robotic Total Station Refer to your total station s documentation for more details Table C 14 GRT 2000 Robotic Total Station Specifications Housing Cast aluminum Weight 19 8 Ibs 9 0 kg Port 1 external RS232C port for communication Supply Voltage 12 VDC Power Requirement 5 to 18 W Operating 20 to 50 deg C 4 to 122 deg F Temperature Moisture Waterproof 3D Controlling Range Approx 10 to 300m Distance Measurement 20 mm Accuracy Data Update Ratio Approx 100 msec Laser Classification Class II Telescope 30 X Magnifications Radio Type optional Satellite 2ASd Radio Channels 16 total Radio TX RX 433 400 to 433 775 MHz Frequency Range Radio Channel 25 kHz Spacing Radio Power 1W C 18 System Five 3D Reference Manual Sonic Tracker II Figure C 14 shows the dimensions of the GRT 2000 Robotic Total Station
4. 2 Cancel Figure A 12 Connect to GPS Rev B A 9 Pocket 3D Getting Started Guide Equipment Setup LPS Pocket 3D creates an equipment configuration for a motor grader with an LS 2000 receiver Refer to the Pocket 3D User s Manual for more information Step 1 Create an Equipment Configuration File 1 Tap Setup gt Equipment 2 Tap New Enter a configuration name and equipment information Press Next 3 Enter blade measurements for the motor grader Press Next Configuration name 14H GRADER LPS Machine type Motor grader sd Sensor LS2000 receiver 7 Location Left M Units Feet X Equipment Station setup LS2000 receiver Units Exit Topcon Pocket 3D 1 45 Setup Image ext Cancel 1 Blade width 14 00 2 Height of prisms above cutting edge 12 00 3 Offset of mast behind cutting edge 1 50 4 Offset of mast from edge of blade 1 50 Cancel Figure A 13 Enter Configuration Type Check Sensor Information Enable Machine has 3D display Press Next 5 Press Finish to complete A 10 Pocket 3D Getting Started Guide Equipment Setup LPS 9 Topcon Pocket 3D 2 23p k E Topcon Pocket 30 46 1 46 Machine has 3D display Machine configuration is complete Press Finish to GRT2000 controlled save the configuration
5. Cancel P Figure A 10 Enter Antenna Information for GPS or mmGPS Rover Step 6 for mmGPS Setup the mmGPS Receiver For mmGPS setup the mmGPS receiver 1 Tap Setup gt mmGPS receiver 2 Enter mmGPS parameters See Pocket 3D or 3DMC manuals for important information about these settings Press Ok Equipment Radios Antenna Base station mmGPS transmitters GPS port Serial D Sensitivity High v Channels All v Firmware Advanced v mmGPS aided initialization Calc weighted mmGPS GPS elevation Figure A 11 Enter mmGPS Information for mmGPS Rover A 8 Pocket 3D Getting Started Guide Equipment Setup GPS Step 7 Connect to the Rover After setting up the rover connect to the GPS receiver to begin using Pocket 3D at the jobsite Figure A 12 1 On the main screen tap the GPS setup button 2 Once the connection has been established press OK Notice that the GPS setup button changes color from red to green indicating successful communication between the Base and Rover Topcon Pocket 3D 4 2 39 9 Topcon Pocket 30 4 2 39 eg T Connecting to GPS 1 aoee Cancel J Topcon Pocket 3D 10 35 BG Topcon Pocket 3D 4 2 39 Fix Position Satellitd 4 y Initialized Total sats tracked GPS sats used GLONASS sats used Horz RMS 0 05 Vert RMS 0 07
6. Figure 7 7 Connect Cables to MC 2 5 Receiver Box and Control Box 7 10 System Five 3D Reference Manual Machine Setup Control Box Setup The control box is designed for quick attachment at the beginning of the day and quick removal at the end of the day After installing the control box in the cab connect the various cable to the back for communication with the machine s components See Figure 5 11 on page 5 14 for further details C Power cable to first top connector O For graders valve cable to second connector O For graders junction box cable to third connector O For dozers mainfall cable to third connector L MC 2 5 receiver box cable to fourth bottom connector Activating mmGPS Control in 3DMC To activate the control box for mmGPS control applications ensure the correct options have been activated in the control box To check and or update control box options see Viewing and Updating 3DMC Options on page 10 34 for details If needed contact your Topcon dealer with questions The desired control application is activated when selecting or creating a machine configuration file For mmGPS applications select and enter antenna information radio information and Lazer Zone sensor information Step 1 Apply a mmGPS Machine Configuration The Machine Configuration file provides vital information about the type of machine the setup of the components on the machine machine measurem
7. e iV 7 Figure C 14 GRT 2000 Robotic Total Station Dimensions Sonic Tracker II The Sonic Tracker II has ruggedly sealed electronics a field replaceable sonic transducer and temperature compensation for atmospheric disturbances that contribute to industry standard accuracies With bright grade indication lights and a patented working window it s easy to use and see for controlling grade Table C 15 on page C 20 lists specification details for the Sonic Tracker II P N 7010 0491 C 19 Specifications Table C 15 Sonic Tracker II Specifications Housing Cast aluminum Epoxy sealed electronics Connector 1 for power and communication Display Raise lower on grade LED s Supply Voltage 10 to 30 VDC Operating Current Typical 200 mA Operating 0 to 60 deg C 32 to 140 deg F Temperature Range Adjustable from 14 to 55 inches 35 5 to 140 cm Working Window On grade adjustable Course 0 15 ft Fine 0 05 ft Resolution 0 0025 ft Transducer Frequency Figure C 15 shows the e 4 0 ___ AF TOPCON Sonic Tracker IT Figure C 20 50 kHz with 40 Hz maximum repetitive rate dimensions of the Sonic Tracker II a 4 5 gt as 3 4 10 THREAD ja 6 5 gt C 15 Sonic Tracker II Dimensions System Five 3D Reference Manual Laser Tracker Laser Tracker The Laser Tracker features bright indic
8. Ready to connect Press the FINISH button to connect to GPS receiver Base started OK Figure 5 5 Enter Base Station Information and Start Base System Five 3D Reference Manual Equipment Setup Base Station General Base Station Setup Rules and Notes e Every time the Base Station is setup a new slant measurement must be taken since the height of antenna will be different unless using a fixed height tripod or other permanent mount If using a permanent mount you will only need to measure the height of the antenna once and initialize the Base Station once using Pocket 3D The Topcon receiver will remember the initial settings However if any setting stored in the receiver has been changed or initialized like a reset function you will need to re initialize the Base Station e When the receiver tracks a sufficient number of satellites the receiver takes only a few seconds to process and report the successful start See Troubleshooting on page 12 1 if the receiver fails to respond or fails to initialize e Ideally the Base Station should be placed in an area free of objects that can obstruct signals from satellites and degrade positioning accuracy Obstructions can include trees buildings vehicles or fences e Ideally the radio antenna should not be placed too close to the receiver For large job sites or sites with hilly terrain use a tall tripod or a sturdy structure to raise the radio antenna
9. amp F Topcon Pocket 3D 9 53p Point GRT2000 cross hairs to edge of blade below LS2000 Figure A 16 Setup the LS 2000 Receiver A 12 Pocket 3D Getting Started Guide Equipment Setup LPS Step 4 Start LPS Control and Check Status To start LPS control tap Control gt Start Stop LPS control 2 Tap the LPS Status button to view LPS status information change search area or change track sensitivity and speed Refer to the Pocket 3D Reference Manual for more information 3 Press OK to exit Aa Topcon Pocket 3D 2 13p k Tracking H Angle V Angle S Dist Northing Easting AVA Start LPS control Blade control VY Surface Offset Elevation 204 OK 280 93 0 13 5 Search wait secs Set search area at GRT Ta amp Track sensitivity L7 1 Tracking speed Figure A 17 Start LPS Control RevB Topcon Pocket 3D 4 10 45 Position Search rack High M Medium A 18 Pocket 3D Getting Started Guide Localizing with Pocket 3D After setting up the Base Station localize the jobsite coordinates with GPS coordinates 1 Ensure the control point file for the jobsite is selected Data gt Control and select the equipment configuration for the current setup Setup gt Equipment Figure A 18 2 Tap Data gt Control gt Control poin
10. Delete __Ok Heamnceh O Figure 3 15 Applying a Working Surface File 3 Press Topcon Logo gt File gt Surfaces gt Reference 4 If needed select the reference surface file for the jobsite and press Ok Figure 3 16 6220 A12 Grade Work Inner perimeter of lake LAGOS 4a New Copy Delete Ok VEERE Figure 3 16 Applying a Reference Surface File P N 7010 0491 Building Job Files Creating a New Plane Surface File Occasionally a flat or sloping plane surface may need to be adjusted to fit current conditions at the jobsite 1 Onthe 3DMC main screen press Topcon Logo gt File gt Surfaces gt Working or Reference Select the desired plane surface file and press New Figure 3 17 3 Enter the name of the surface Press Next ___ Suffacefies j 5220 A 2 Grade Work Surface Name ani ype Inner perimeter offlake r 7 LAGOS Configuration name ee Selah PAD17 SLOPING Surface type Sloping plane surface E New Copy Next Cancel Figure 3 17 Editing a Plane Surface File 4 Depending on the type of plane surface edit the following properties Press Next then press Finish to save the changes Flat Plane Surface Sloping Plane Surface e Point on surface e Point on surface and or Main fall e Grid interval direction grade e Grid interval and or Crossfall Grade Flat Plane Surface Point o
11. GPS port Serial PortC Sensitivity Auto Channels Al Advanced LazerZone aided initialization gt Calc LazerZone GPS weighted elevations L Back Next Cancel Figure 3 13 Enter Lazer Zone Information for mmGPS Configurations 7 Press Finish to save the machine configuration file 8 Select the machine configuration file on the Machine files dialog box and press Ok to set this as the machine for the job so will result in losing all information and require D You must press Finish to save the file Failure to do you to repeat the process 12 System Five 3D Reference Manual Selecting Jobsite Files Selecting Jobsite Files Besides control point surface and machine files the following files may also be available for the jobsite e Alignments alignments define the route of a road utility line water way etc and may include cross sectional information e Linework linework are polyline entities that can represent features or object within a project such as building pads curbs sidewalks top and toe of slope or a project s boundary Linework files are often comprised of layers where each layer has a unique name and color e Points points can represent topographic information backup control coordinates as build information etc Depending on the selected surface file some file types may not be available for selection 1 When the 3DMC main screen displays press
12. Channel 1 Transmitter TX3 Control point Known elevation of Rover PP3 k TX height 5 000 Transmitter height Measured to Base v Previous 6 560 Benchmark check New height Resection Vert Difference Cancel Figure 7 17 Begin Height Check 7 22 System Five 3D Reference Manual Operations for mmGPS Control 7 Press Ok When done the Transmitter height fields displays the calculated difference between the height originally specified for the transmitter and the calculated height Figure 7 18 Known Rover control point PP3 x O Known elevation of Rover m Transmitter height Previous 6 560 New height 6 250 Vert Difference 0 310 Figure 7 18 Measure Height of Transmitter 8 To apply this change to the transmitter setup press Ok Or press Cancel to exit without saving the measurement Transmitter Adjustment The adjustment function fixes errors in incline in the self leveling mechanism of the transmitter applying an offset to the transmitter 1 Set up the transmitter and tripod at an known control point 2 At the transmitter hold the plumb beam key then press and release the power key to put the transmitter into calibration mode 3 Turn the front of the transmitter towards the sensor 4 Set up the PZS 1 sensor at the same level as the transmitter on relatively level ground and approximately 50 meters 100 feet away Power on the sensor and re
13. For dozers the distance of the antenna from the right edge of the blade For graders the distance of the antenna beyond the outside edge of the blade The distance of the antenna behind the cutting edge If known the width of the blade i DISTANCEFROMRIGHT gt EDGE OF BLADE DOZERS 1 DISTANCE BEYOND gt DE a OUTSIDE EDGE OF gt 6 E CUTTING hit BLADE GRADERS EDGE Figure 5 7 Measure Antenna Placement on Blade of Machine Incorrect measurements or data entry errors have a gt direct affect on grading accuracy Take each measurement twice to ensure accuracy P N 7010 0491 5 11 3D GPS Applications Setup and Usage Radio Antenna Installation The radio antenna is attached to the machine s roof using a magnetic mount and generally stays on the machine The antenna should be positioned vertically and as high as possible on the machine to maximize signal reception Figure 5 8 1 Attach the radio antenna to the roof of the machine 2 Connect the radio antenna cable When the system has not been used for several days or months the antenna might have been removed for storage or transportation To reinstall the radio antenna set it up as described above and ensure the magnet mount attaches to an even and smooth surface Rover Radio Antenna Figure 5 8 Machine Radio Antenna Setup 5 12 System Five 3D Reference Manual Machine Setup MC 2 5 GPS Receiver B
14. L Ok c Use for vertical GPS localization Measure Ok Cancel Figure 5 29 Control Point Coordinates and GPS Localization Press OK to return to the Control point files dialog box 8 Repeat step 4 to step 7 for all listed control points When finished check the horizontal H Error and vertical V Error values listed on the Control points dialog box They should be within acceptable tolerances Figure 5 30 Name H Error V Error MAGGIE 0 023 0 001 LISA 0 016 0 047 BART 0 006 0 048 MARGE 0 010 0 010 HOMER Lel 4 Add Edit Delete Ok Cancel Figure 5 30 Control Point Files with GPS Localization 9 Press Ok until you return to the 3DMC main screen saving the control point localization information and the control points file At this time make a backup copy of the control point file on a USB device 30 System Five 3D Reference Manual Chapter 6 Dual GPS Application Setup and Usage In addition to standard GPS benefits dual GPS applications provide the following added benefits e Constant heading Dual GPS immediately establishes a heading instead of waiting for the machine to begin traveling Dual GPS excels in tight areas when changing directions often Dual GPS maintains the correct heading when sliding sideways on a steep slope e Back blade in auto Dual GPS maintains correct elevation and cross
15. Figure 11 8 on page 11 8 displays an assembly diagram for the following procedure 1 Remove the three screws and washers securing the top ring cap and remove the ring cap over the pole 2 Remove the four screws and washers securing the bottom cap and carefully remove the bottom ring cap through the cast housing while holding the entire pole assembly Because the pole assembly is heavy avoid dropping it on other pieces of hardware or parts of the body 3 Remove the Bushing and the Support and replace them with new parts Depending on the age of your vibration pole and the type of application the bushing and support for your pole will differ The following replacement parts can be ordered through Topcon s local dealer or contact your dealer with questions e For newer Round Vibration Poles either 2150 0207 low temperature BUSHING blue or 2150 0208 high temperature BUSHING yellow e For older Round Vibration Poles 2150 0164 BUSHING 1 75 ID CONTROL 1 pc each e 2150 0206 BUSHING SUPPORT 2 pcs each P N 7010 0491 11 7 Maintenance 4 Place the cast housing back over the pole and hold up the pole using the bottom cap Then align the screw holes to the threads on the bottom of the cast housing and replace the three screws and washers Tighten until firm 5 Replace the top ring cap and the three screws Tighten until firm s ag N N j k Pole Ae Top Ring Cap l CF Pole dampening i om B
16. P O Box 1714 Rockville MD 20849 1714 e Atlas License Company and Data Services 1725 A North Shadeland Avenue Indianapolis IN 46219 http www alcds com P N 7010 0491 B 3 Safety Information Notes B 4 System Five 3D Reference Manual Appendix C Specifications The sections in this appendix give the features and specifications for the physical components of the System Five 3D Control Box The 9168 control box is backward compatible with System Four and System Five sensors and remote switches Table C 1 lists specification details for the 9168 control box Table C 1 Control Box Specifications Housing Cast aluminum Weight 11 75 Ib 5 3 kg Display Color LEDs 6 1 4 diagonal sunlight viewable 640 x 480 enhanced color 1300 nit Touch screen Three color linear grade indicators with automatic adjustable brightness Supply Voltage 10 to 30 VDC Operating Current Typical 3 0 A Maximum 15 A Operating 20 to 60 C 4 to 140 F Temperature Moisture MIL standard 810D Valve Drive Progammable dual hydraulic control External data storage One slot for compact flash card to download upload job files P N 7010 0491 c 1 Specifications Table C 1 Control Box Specifications USB Port One port for keyboard or mouse hookup Connectors Four connectors for power valves
17. 4 7 Method Two Position the Blade ee 4 8 Blade Trim Adjustments Graders Only eee 4 10 Chapter 5 3D GPS Applications Setup and Usage 5 1 Equipment Setup Base Station seese 5 2 Base Station Initialization 0 0 eee eeseceseceeeeeeeeeee 5 7 General Base Station Setup Rules and Notes 5 9 Machinie Sep henra ina aa a 5 10 MC A1 GPS Antenna Setup seese 5 10 Blade and Antenna Measurements cs eeeeeeeeee 5 11 Radio Antenna Installation 00 0 eseeeseeeeeeeeee 5 12 MC 2 5 GPS Receiver Box Setup for GPS Applications 20 0 0 eeeseeceseceeeeeeeeeeeeeeeeeeees 5 13 Control Box Setup oo cee eeeseceeceseceeeeeseeeaeeeeeeeeeeaes 5 14 Activating GPS Control in 3DMC seses 5 15 Applying a GPS Machine Configuration 5 15 Creating a GPS Machine Configuration 5 16 Operations for GPS Control sesers 5 19 Setting Blade Control oo ee eeeeeeeseeeeceneceeeeeeeeaees 5 19 Viewing GPS Information sssr 5 21 GPS Status and Quality oe eeeeseceseeereeeeee 5 21 Cutting Edge Position s es 5 22 Monitor Satellites and Enter Mask Angle 5 22 View Receiver Information or Reset Receiver 5 23 Satellite Planning Information 0 eee 5 24 Changing Radio Channels s s s 5 24 GPS Localization 2 intsse edness destin 5 26 P N 7010 0491 iii Table of Contents Principles of GPS Localization ice ceeeeseseeeeeees 5 26 Entering Localized GPS Coordinates
18. Automatic Control and other screen features remain 1 Press Topcon Logo gt Linework select the correct Linework file and press OK 2 Press Topcon Logo gt View gt Display options gt Linework select the polylines to display and press Ok See Linework Display Options on page 10 25 for more information 3 On the main screen tap and hold the polyline to use for grading to then tap Grade to polyline the pop up menu Graphical crss lines display along the polyline Figure 10 35 4 Being grading Figure 10 35 As needed repeat step 3 above to grade to another polyline Figure 10 35 Grade to Polyline Main Screen P N 7010 0491 10 31 Grading Application Performing Topographic Surveys 3DMC has the ability to perform an on the fly topographic survey of the whole project or any portion thereof This would be helpful when creating as build surfaces to determine amount of material to move 1 Tap Topcon Logo gt File gt Point files to display the Point files dialog box Create a new point file or select an existing point file Press Ok to return to the Main Screen 2 Tap Topcon Logo gt Tools gt Topo survey and enter or select the following information Figure 10 36 on page 10 33 Press Ok when done e Log by select between minimum distance or time interval Minimum distance measures each point at a set distance from the previous logged point Time interval measures point
19. Display Cleaning on page 11 2 for more information an The surface of the Touch Screen Display has a 2 6 System Five 3D Reference Manual Control Box Control Box Back and Side Panels The control box back and side panels Figure 2 3 include a USB slot and cable connectors for communication a cooling fan a speaker and the power switch Compact Flash Card Slot Speaker Power Switch Cooling Fan Outlet USB Port g Cooling Fan Slot Inlet Figure 2 3 Control Box Back and Side Panel Compact Flash Card Slot The compact flash card slot allows you to transfer files from the control box to a computer via a compact flash card The internal interface driver is compatible with commercially available compact flash cards A rubber flap seals the compact flash card slot preventing dust water etc from entry Keep the rubber flap closed at all times even during use to prevent dust from entering the slot When copying files to or deleting files from a compact flash card the control box screen displays an hourglass indicating the system is busy Once the hourglass goes away you can remove the compact flash card detect the compact flash card during a hot swap procedure If this occurs turn off and restart the control box an Occasionally the control box may not properly P N 7010 0491 2 7 Component Functions The card can be damaged if you remove it before completing the copying deleting proces
20. New Edit Copy Delete amp _ Ok Cancel Figure 9 9 Selecting an LPS Machine Configuration Creating a 2D Machine Configuration File 1 Press Topcon Logo gt Control Machine setup 2 Press New to create a new machine configuration file or select an existing machine configuration file and press Edit 3 Enter or select the following configuration and equipment parameters Figure 9 10 on page 9 8 Then press Next e Configuration name enter a name for the machine For easy identification later include the application type e Machine type select the type of machine P N 7010 0491 9 7 2D Application Setup and Usage 14H GRADER LPS 14H GRADER DUAL GPS Configuration nameltype DOZER D6 MC A1 DOZER D6 MMGPS Configuration name GRADER RIGHT GPS DOZER 2D DOZER D6 2D LASER Machine type Bulldozer Sensor LS2000 receiver New Edit Copy De ree IT Ok 4 Units of measure Feet eg Next Cancel Figure 9 10 Creating the Machine File 4 Press Next until the Machine Configuration Complete dialog box displays then press Finish to save the file Other machine configuration measurements and TE settings are not required for 2D control applications 5 Select the machine configuration file on the Machine files dialog box and press Ok to set this as the machine for the job You must press Finish to save the file Failu
21. RS485 RS232 Speaker For the tones beeps and chimes of audible alerts Computer Board 300 MHz processor 28 MB SDRAM Operating System Microsoft Windows CE NET Figure C 1 shows the dimensions of the 9168 control box Figure C 1 Control Box Dimensions C 2 System Five 3D Reference Manual Remote Smart Knobs Remote Smart Knobs The Remote Smart Knobs mount on the left and right control lever for easy access Table C 2 lists specification details for the Remote Smart Knobs Table C 2 Remote Smart Knob Specifications Housing Black ABS plastic Buttons Two each for grade and elevation control Switches One each for Manual Auto control a momentary switch to control slope or toggle set points Operating 0 to 60 C 32 to 140 F Temperature Supply Voltage 10 to 30 VDC Supply Current 100 mA typical operating current Figure C 2 shows the dimensions of the Remote Smart Knobs 0 45 n D 2 oO h Figure C 2 Remote Smart Knob Dimensions P N 7010 0491 C 3 Specifications Simple Auto Manual Knob The Simple Auto Manual Knob mounts on the control lever for easy access Table C 3 lists specification details for the Simple Auto Manual Knob Table C 3 Simple Auto Manual Knob Specifications Details Profile Epoxy Switches One for switching between Auto
22. and routine maintenance will prevent many problems before they occur Daily Care The following guidelines provide for trouble free operation Keep the carrying case clean and dry Do not leave it open and exposed to the elements Clean and dry all components prior to placing them into the carrying case Ensure that protective connector caps provided on some components are in place when not using the cables Water accumulating on the connectors can cause electrical shorts Place System Five 3D cables in their appropriate storage connectors after removing the control box Do not use high pressure spray water steam cleaner hoses directly on cables and components The components can be used in the rain or light spraying Check for oil leaks in hydraulic assemblies and hoses Check for loose components due to physical damage Use proper battery supplies for components isolated from the machine e g Base Station LPS Station Keep the machine s battery good condition P N 7010 0491 11 1 Maintenance Preventative Maintenance Preventive maintenance will help to keep your System Five 3D components running Touch Screen Display Cleaning The Touch Screen Display should be cleaned often in order to maintain a quality image and prevent faulty operation free of dirt dust fingerprints and other materials D The front surface of the touch screen should be kept that could degrade optical properties Long term contact wi
23. f TOPCON System Five 3D Reference Manual TOPCON POSITIONING SYSTEMS System Five 3D Reference Manual Part Number 7010 0491 Rev D Copyright Topcon Positioning Systems March 2007 All contents in this manual are copyrighted by Topcon All rights reserved The information contained herein may not be used accessed copied stored displayed sold modified published or distributed or otherwise reproduced without express written consent from Topcon ECO 2959 TOC Table of Contents da ETE E E E A E A E TA Terms and Conditions eeeessesesessserscsseeseessorreseseseessrssseree Manual Conventions ccccececccccccccccesssseseecececcccesesseenenes Chapter 1 Introduction ciictecetantaneccnedeccticiadeedenittccmandunesodls System Five 3D Components 2 00 cece eeeesecesecereeeeeeeees Machine Components 00 0 0 eseesceseeeeeereeeneeeneeeseeeees Sensor and Hydraulic Components 0 0 0 0 cesses 3D GPS Components iiinneag ei MMGPS Components 2 0 eee esceseceseeereeeeeceeeeeeeees 3D LPS Components 000 cee eeeeseesceeseceeeeeneeeeeeneees 2D Component sssri iiri e i Pocket 3D Optional ssessessesssssssssesesseessesssesssesses Elevation Control Overview cecceesscesseceeseeeeeeeeeeesees 3D GPS Control Overview 0 eee eeeesceeceneeereeeeees 3D LPS Control Overview cceeccceescceeseceneeceeeeeees 2D Sonic Control Overview 0 0 ceeccesscceseeceneeeeeeeees 2D Laser Contro
24. kK Point files Point files lt ncne gt lt none gt ne Control PT4 lt 4 MANHOLES Surffice Line vork lt none gt Layers Listing Import Export Copy ok New Layers Copy Delete Rename Save As Cancel Cancel Figure A 21 Create Points File Rev B A 15 Pocket 3D Getting Started Guide 4 Press New Enter a name for the layer and the layer s parameters Press Ok 5 Repeat step 4 for any other layers 6 Press Ok to save the file Press Yes to apply the file to the current jobsite AJ Topcon Pocket 3D 4 10 11 amp F Topcon Pocket 3D 10 12 Layers Defa vISEWER ELECTRIC Layer name LECTRIC Show point numbers Show point descriptions Show point elevations Symbol 4a New Edit Delete Cancel Figure A 22 Add Layers to Points File Creating a Linework File 1 Tap Data gt Linework gt lt none gt or file name Press New Figure A 23 Enter a name for the linework file and press Ok 3 Press Layers Topcon Pocket 3D P i AJ Topcon cket 30 4217 YD New linework file name ROAD Control Surface Alignment New Layers Copy Delete Cancel Figure A 23 Create Linework File A 16 Pocket 3D Getting Started Guide Collecting Data Press New Enter a name for the layer
25. r LazerZone aided initialization Calc LazerZone GPS weighted elevations Back Next Cancel Figure 7 9 Select LaserZone Information 7 When finished be sure to press Next to save machine configuration file and store the antenna settings 1 Note the following exception If using more than one transmitter and all transmitters have been previously calibrated and initialized selecting All will cause Pocket 3D 3DMC to search for the transmitter with the smallest error rate even if the physical unit is not set up In this case the sensor will not detect the transmitter P N 7010 0491 7 13 mmGPS Application Setup and Usage Step 2 Copy and or Select the mmGPS Control Point File For mmGPS applications the control point file also stores transmitter information including calibration data setup location and height data This information is copied from a Pocket 3D controller to the control box via a compact flash card 1 Save the Pocket 3D control point file to a compact flash card 2 Insert the CF card that contains the mmGPS control point file into the CF card slot on the control box 3 Tap Topcon Logo gt File gt Control points and tap Copy Select from data card to internal disk and the file to copy from the Project files list Figure 7 10 Tap OK Copy from data card to internal disk Project files icherry PP topo Nov20 Ok Cancel Figure 7 10
26. these transitions e Ona valley road System Five 3D prevents the cutting edge from undercutting the valley When the blade passes over the P N 7010 0491 1 37 Introduction centerline the opposite edge raises to prevent the blade from cutting into the other side of the road Figure 1 41 This transition occurs once the blade passes over the centerline This preventive performance works best when the machine travels slowly 2 Figure 1 41 Cutting Edge on Valley Road e On a crown road System Five 3D prevents the cutting edge from undercutting at the centerline Once the center of the blade passes the centerline the cutting edge flips to the other side of the slope Figure 1 42 The location of the sensor does not affect this performance Figure 1 42 Cutting Edge on Crown Road 1 38 System Five 3D Reference Manual Elevation Control Overview Control Using Single Point on Blade When grading an area where the Design Surface is smaller than the blade itself it is easier to control grade when using a specific or single point on the cutting edge In this blade control method System Five 3D looks only at a selected point on the blade rather than the entire cutting edge Figure 1 43 Control Point on Blade Blade l Sidewalk Figure 1 43 Cutting Edge as Single Point on Blade For example when grading a narrow sidewalk the Best fit method may cause the blade to try and fit the a
27. 000 Volumes Cubic yards Coordinates North East Elev F __Ok _ Cancel Figure 10 31 Display Units Dialog Box 10 28 System Five 3D Reference Manual Steering or Grading to Polyline Steering or Grading to Polyline 3DMC can be used to steer the machine to and cut to a polyline layered in the Linework file Typically you use an Alignment file to cut along an alignment line The polylines represent features or objects such as building pads curbs sidewalks top and toe of slopes or any boundary on the project If the polyline is composed of three dimensional information at each transition point it can be selected on the main screen and used as the alignment line to steer to or can be used as the design elevation to control the cutting edge Steer to Polyline 1 Press Topcon Logo gt Linework select the Linework file for the job and press Ok 2 Press Topcon Logo gt View gt Display options gt Linework and select the polylines to display 3 View the steering light bar and left section view Topcon Logo gt View gt Lower window gt Light bar Topcon Logo gt View gt Left window gt Section 4 Tap and hold the polyline to use for steering then tap Steer to polyline on the pop up menu graphical cross lines display along the selected polyline Figure 10 32 shows an example of the main screen after completing the above steps Distance to edge of polyline Stationing Figure 10 32 Steer To Po
28. 1 mast height the sensor height must be updated at the both ends Failure to update the sensor height directly affects the quality of machine grading accuracy D Use identical sensor height measurements between 5 Select LPS control options and press Next Figure 8 18 on page 8 20 e GRT2000 controlled by Pocket 3D enable if using a Pocket 3D controller to initialize and load download files to the GRT 2000 total station P N 7010 0491 8 19 3D LPS Application Setup and Usage e GRT2000 controller remotely via radio link enable if using a radio link to initialize and load download files to the GRT 2000 total station Select the following radio parameters Radio type set the same radio type used at the Total Station Baud rate usually 38400 GRT2000 controlled by Pocket 3D LPScontroloptions GRT2000 controlled remotely via r GRT2000 controlled by Pocket 3D GRT2000 controlled remotely via radio link Radio type Pacific Crest PDL UHF Baud rate 38400 Back Next Back Next Cancel Figure 8 18 Select LPS Control Options 6 Press Finish to save the machine configuration file Figure 8 19 Machine configuration is complete Press Finish to save the configuration file Back Finish Cancel Figure 8 19 Save Machine Configuration 7 Select the machine configuration file on the Machine files dialog box and press Ok to set this as the machine for
29. 10 19 for details Elevation set point displays the current cut fill offset or amount of additional height applied to the Design Surface Match sets the current Design Surface to the elevation of the cutting edge changing the cut fill reading to zero The cut fill Offset number then displays the distance from the new matched grade to the original Design Surface This key allows you to quickly adjust the grade to a more manageable cut or fill Zero sets the elevation set point value to zero GPS info displays the GPS information dialog box see Viewing GPS Information on page 5 21 for details Elevation left edge 66 088 Elevation right edge 67 963 Elevation valve gain 75 Set Elevation set point 0 000 GSE Match z5 Zero GPS info Ok Cancel Figure 2 14 Open Adjust Elevation Dialog Box for 3D GPS Control P N 7010 0491 2 19 Component Functions See Changing Cut Fill Offsets on page 10 14 for details on adjusting the elevation while grading Adjust Elevation in 3D LPS Control To display the following elevation settings for 3D LPS applications Figure 2 15 press the Elevation Control Key Elevation left edge displays the elevation of the left edge of the blade based on local site coordinates Elevation right edge displays the elevation of the right edge of the blade based on local site coordinates Elevation valve gain disp
30. 12 18 System Five 3D Reference Manual Blade Response Blade Response This section lists possible Blade Response problems you may encounter If you still have problems after trying the solutions listed here contact TPS customer support Problem Blade is moving too slowly The blade seems to move too slowly in Control Mode The Grade Indicator takes too long to reach grade Causes Solutions The Valve Gain setting Increase the Valve Gain setting which is too low will cause the hydraulics to respond quicker See Adjusting Valve Gain on page 10 19 for details Check which control is slow before adjusting the Valve Gain Remember that the larger number setting or turning the knob clockwise speeds up the response Problem Blade is moving too fast The blade seems to move too fast in Control Mode The Grade Indicator skips through on grade Causes Solutions The Valve Gain setting Decrease the Valve Gain setting which is too high will cause the hydraulics to respond slower See Adjusting Valve Gain on page 10 19 for details Check which side control is fast before adjusting the Valve Gain Remember that the lower number setting or turning knob the counterclockwise slows down the response P N 7010 0491 12 19 Troubleshooting Problem Blade reacts but does not reach On Grade Causes Solutions Valve Offsets are too small Assume that Valve Offsets are too small a
31. 18 Linework 3 13 10 25 10 29 display options 10 25 Localization See also Control point with third party coordinates 5 28 Location 1 34 large project 1 36 small project 1 35 working distance 1 34 working height 1 35 Lock on grade 2 26 Lock slope 2 23 Machine configuration files 3 7 3 12 5 15 5 19 6 8 7 11 8 17 8 20 9 7 Machine orientation 10 7 Machine setup blade control 5 19 8 22 Manual control Simple A M Knob control 2 29 Smart Knob control 2 25 Mask angle 5 22 MC 2 5 receiver box 2 30 clear NVRAM 10 35 EIM mode 2 31 LEDs 2 30 normal mode 2 31 Index Measure antenna on blade 5 16 cutting edge 4 7 LPS station 8 5 points for plane surface 3 18 3 21 3 22 sensor on blade 3 9 8 18 Menus 2 13 2 15 Control 2 14 2 15 File 2 14 pop up 2 16 Tools 2 15 View 2 15 New files 2 11 NEZ coordinates 3 5 3 18 3 22 NVRAM 10 35 clear 10 35 Oo Offset 2 17 2 19 2 20 2 21 change 10 15 10 20 On grade 2 3 lock 2 26 P PDL radio 1 12 Plane surface edit 3 16 see Design surface Pocket 3D 1 21 units A 1 Points 3 13 display 10 26 Position check 10 21 PZS MC sensor icon color 10 6 Index Radio antenna 5 12 6 6 7 9 base station 5 2 6 2 7 2 change channel 5 24 connection tip 5 26 LED 5 8 licensing B 3 machine 5 10 6 3 PDL 1 12 select channel 5 6 signal 2 30 Teledesign 1 12 usage B 3 Range D 2 Receiver mask angle 5 22 reset 5 23 Receiver ID GPS 5
32. 23 Red 10 6 Reset receiver 5 23 Right window 10 11 See also Views S Satellites 5 24 Satellites GPS 5 22 Sensors 1 9 1 10 1 31 1 32 calibration 4 3 laser 1 16 1 20 Set points 2 28 Slope gain 2 22 2 23 key 2 21 green 2 22 red 2 22 locked 2 23 Slope control 2 11 Slope control system calibration 4 3 Slope key green 10 6 red 10 6 System Five 3D Reference Manual Steer indication steer to polyline 10 29 Steering options 10 30 Surface plane edit 3 16 Surface Files Creating a Flat Plane Surface 3 17 Editing a Plane Surface File 3 14 Survey see also Topographic survey Survey mode activate 2 26 Swap 2 27 System range D 2 T Teledesign radio 1 12 Test 2 31 EIM 2 31 TM 1 mast installation 8 13 Tools menu 2 15 Topcon logo 2 13 Topo survey display points 10 26 Topographic survey 10 32 10 33 stop 10 33 U UHF usage D 2 Units 10 28 A 1 USB 2 8 v Valve gain 2 22 2 23 adjust 10 19 speed 2 22 2 23 Valve offset 4 1 calibration 4 2 4 3 factory setting 4 2 Vibration pole installation 9 4 9 5 Views 2 15 10 7 10 10 grade indicator 10 11 right window 10 11 P N 7010 0491 Index Ww Warnings touch screen 2 2 Working distance 1 34 large project 1 36 small project 1 35 Working height 1 35 Working window 1 26 1 27 1 28 Index Notes Index System Five 3D Reference Manual Notes
33. 3D GPS mmGPS control Unlike conventional applications using a laser control system using the 3DMC to create a surface model eliminates the required repetitive setup of a transmitter at the job site 3DMC can create the following surfaces e Flat plane surface Creates a planar surface with a 0 cross slope and mainfall This surface is primarily used for building pads e Sloping plane surface Creates a sloping surface with cross slopes and mainfall based on a reference elevation In paving applications you can create this surface when a 3D design surface is not available e Raise lower existing surface Raises or lowers the current surface This function will display the reference cut fill value from 0 zero rather than the distance between current and desired surfaces e Subgrade of existing road Creates a surface with a cross slope different from the design road surface For most road surfaces the cross slopes for the finish design surface will be different than the subgrade design slopes 3 14 System Five 3D Reference Manual Surface Files Selecting Surface Files When setting up 3DMC design files first select the working surface then select the reference surface 1 On the 3DMC main screen press Topcon Logo gt File gt Surfaces gt Working 2 Select the working surface file for the jobsite and press Ok Figure 3 15 6220 A12 Grade Work Inner perimeter of lake a 2a LAGO8 New Copy
34. 4 pc each Figure 11 10 on page 11 10 shows the assembly diagram for the following procedure 1 Remove the screw the washers and the reflecting strip 2 Place the new strip on the instrument and secure the strip with the screw Plane Washer Spring Washer Screw WA bo Reflecting Strip Screw Spring Washer Plane Washer Spring Washer Orientation Figure 11 10 Replace LS 2000 Reflecting Strips 11 10 System Five 3D Reference Manual Preventative Maintenance Sonic Tracker Il Transducer Cleaning This procedure is not meant to be a regular maintenance procedure Clean the Transducer only z when contamination is suspected or evident Cleaning the transducer too much will result in a shortened Transducer life and or water damage to the Sonic Tracker 1 Hold the Sonic Tracker II in an upright position to prevent moisture from inadvertently entering the Sonic Tracker 2 Mix a mild detergent with water and place the mixture in a spray bottle use Simple Green where available 3 With the Sonic Tracker upright thoroughly spray the Transducer with the detergent solution 4 After spraying the Transducer with the detergent fill the spray bottle with clean water and rinse any residual detergent off of the Transducer 5 Allow the Sonic Tracker to thoroughly dry P N 7010 0491 11 11 Maintenance Sonic Tracker Il Transducer Replacement If the ability of the So
35. 8 18 Step 2 Copy and or Select the Control Pomt File seeni ieiet 8 21 Step 3 Select the GRT 2000 Location 8 22 Setting Blade Control sesers 8 22 Operations for LPS Control 0 ceeecceeceecceceeeceeeeeeeees 8 24 Viewing GRT Information eessen 8 24 P N 7010 0491 v Table of Contents Chapter 9 2D Application Setup and Usage s 9 1 Machine Setup isscesessivesietsvevssnchassdcdsctaheeevtehebesisbeaeetangaseeees 9 1 Machine Setup Sonic Tracker s es 9 1 Machine Setup Trackerjack ocene 9 4 2D Control Box Setup oe eee ceeeseceneeereeeeeeneeenaeens 9 6 Activating 2D Control in 3DMC oseere 9 7 Step 1 Apply a 2D Machine Configuration 9 7 Creating a 2D Machine Configuration File 9 7 Step 2 Activate 2D Control oe ee eeeeeeeeeees 9 9 2D Control Operations 20 cece cess eseeeneceseceseseneeaeenaeens 9 10 Locking On grade Maisnie minan aeie inas 9 10 Changing Control Methods 2 0 0 eee eeceseeeeeeseenseees 9 11 Chapter 10 Grading Application cccssceeceeeeseeeeeeteeeeees 10 1 Set p CHECKUStS cesses sided iann a iain 10 1 Changing the Display View seeeeseececereesrerereereree 10 7 Main Window Views ssesecsssesrersrresierisrssresrssns 10 7 Left Window Views ee eeceeseeseeseceteeeeeeeeeesaecneeees 10 9 Right Window View sessessssceeserereerrsrssresrerrsrreseses 10 11 Lower Window Views eesssseesrsreeriersereerrresresse 10 12 Changing Cut Fill Offsets oo ce
36. 8 9 3D LPS Application Setup and Usage e Search wait set the length of time for the GRT 2000 to hold before beginning to search The default is five seconds e Set search area at GRT enable check if the GRT 2000 has the RC 2 option Disable uncheck to limit the searching area to four selected angles designating the area in which the GRT 2000 will search e Obs press the observation key to set the four limit angles for the search area Left Right Up and Down 4 Press the Track tab to adjust the tracking performance of the GRT 2000 Refer to the GRT 2000 instruction manual for details on adjustment The following parameters are standard for most applications Figure 8 7 e Track sensitivity select Medium e Tracking speed select Fast 5 After setting the searching and tracking parameters press Ok to continue MAGGIE j Al Pocket 3D 8 19p b Position Search Track all Search wait secs Track sensitivity Medium Set search area at GRT Tracking speed Fast Left 132 45 34 Obs Right 182 00 33 Obs Up 77 36 47 _ Obs Down 89 42 54 Obs Cancel Ok CEET Figure 8 7 Set GRT 2000 Search and Track Parameters 6 Position the machine so the blade faces squarely toward the GRT 2000 keeping the TM 1 mast as vertical as possible and with the machine LS 2000 and the GRT 2000 60 t
37. 9 2D Application Setup and Usage 2D control applications consist of either a sonic tracker tracking a feature or stringline or a laser receiver tracking a rotating laser When the control box and 3DMC are in 2D mode unnecessary functions are disabled for quick access to 2D specific functions Machine Setup For 2D control applications machine setup is quick and simple After installing the control box install the chosen method of grade control either sonic or laser tracker and then align the sonic tracker or laser tracker with the grade reference Machine Setup Sonic Tracker When setting up the Sonic Tracker consider the following e The Tracker has a total working range of 14 inches to 55 inches 41 inches of adjustment allowing the Tracker to be set over a stringline on one pass then match grade on the next pass without moving the tracker Therefore the job application determines the position of the Tracker For example when using a stringline reference keep the Tracker about two feet above the string giving the operator about six inches of lateral movement to keep the Tracker over the string When tracking a curb you may want to lower the Tracker to keep it over the lip of the curb and avoid the Tracker from seeing the top or face of the curb P N 7010 0491 9 1 2D Application Setup and Usage e When setting up the Tracker over a grade reference consider the size of the Sonic Cone or the foo
38. Activating GPS Control in 3DMC To activate the control box for GPS control applications ensure the correct options have been activated in the control box To check and or update control box options see Viewing and Updating 3DMC Options on page 10 34 for details If needed contact your Topcon dealer with questions The desired control application is activated when selecting or creating a machine configuration file For GPS applications select and enter antenna and radio information Applying a GPS Machine Configuration The Machine Configuration file provides vital information about the type of machine the setup of the components on the machine machine measurements and radio configuration information You must have a machine configuration file before beginning to grade 1 Press Topcon Logo gt Control Machine setup 2 Select the desired GPS configured machine file and press Ok 3DMC will connect to the GPS components and the Elevation Control key will display an single antenna icon DOZER 2D Dozer D6 GPS dual T Grader right GPS LPS MACHINE MMGPS Connecting to GPS COTINO Cancel New Edit Copy Del o gt 0k Cancel Figure 5 12 Selecting a GPS Machine Configuration P N 7010 0491 5 15 3D GPS Applications Setup and Usage Creating a GPS Machine Configuration 1 Press Topcon Logo gt Control gt Machine setup 2 Press New to create a new machine confi
39. Antenna Location Information direct affect on paving accuracy Take each D Incorrect measurements or data entry errors have a measurement twice to ensure accuracy P N 7010 0491 3 9 Building Job Files 4 Select the desired GPS precisions for measuring moving and static points Press Next to continue Max GPS errors roving Max Horizontal RMS 0 20 Max Vertical RMS 0 30 Max GPS errors point measurement Max Horizontal RMS 0 10 Max Vertical RMS 0 20 Back Next Cancel Figure 3 11 Enter GPS Precisions 5 Select the following radio information and press Next Figure 3 12 on page 3 10 e Radio type use the same radio type used in the Base setup e Connected to the serial port the radio is connected to usually Serial Port B e Baud rate usually 38400 e Format use the same format used in the Base setup usually CMR Radio type Internal Spread Spectrum Connected to Serial Port B Baud rate 38400 Format CMR Back Next Cancel Figure 3 12 Enter Antenna Information 3 10 System Five 3D Reference Manual Machine Configuration Files 6 For mmGPS configurations select the following information Figure 3 13 on page 3 12 Then press Next GPS port select the port used for GPS communication between receiver and sensor typically port D Sensitivity select the sensitivity level for detecting the transmitter usually Auto Select a different set
40. Figure 4 5 on page 4 5 Place the cutting edge so it gently rests on the ground and mark the ground position at each edge may lift the front of the machine and cause an error an Do not push the blade firmly into the ground as it in the Mainfall calibration Rest blade on flat surface and mark ground position at each edge Press Next to continue Back Next Cancel Figure 4 5 First Blade Position P N 7010 0491 4 5 Calibrations 4 Press Next and wait five seconds until the Second blade position dialog box displays Figure 4 6 Turn the machine around 180 degrees and gently reposition the blade on the same marks If needed rotate or side shift the blade to place it on the same marks Move machine around 180 so that blade is repositioned on same ground marks then press Next to continue Back Next Cancel Figure 4 6 Second Blade Position 5 Press the Next key and wait five seconds Figure 4 7 on page 4 6 6 Press Finish to apply the calibrations Figure 4 7 e Press Back to perform the blade calibrations again e Press Cancel to use previous calibrations Blade slope adjustment 0 0 Blade rotation adjustment 0 Mainfall slope adjustment 0 0 Press Finish to apply new calibration Back Finish Cancel Figure 4 7 Blade Calibration Complete 4 6 System Five 3D Reference Manual Sensor
41. Files The machine configuration file provides vital information about the type of machine the setup of the components on the machine machine measurements and radio configuration information You must have a machine configuration file before beginning to grade 1 Machine configuration files reference the machine and equipment to a 3D jobsite for control purposes For 2D applications a machine configuration file is not required Selecting a Machine Configuration When selecting a machine file check that the machine and equipment in the file match the physical machine and equipment setup for the jobsite Use the Edit button on the Machine files dialog box to view the selected configuration s setup screens and parameters 1 When the 3DMC main screen displays press Topcon Logo gt Control gt Machine setup 2 Select the machine file and press Ok Figure 3 8 Dozer D6 GPS Grader right GPS aO TLS MOTORGRADER GPS TLS MOTORGRADER LPS New Edit Copy Delete Ok 6aneett O Figure 3 8 Applying a Machine Configuration P N 7010 0491 3 7 Building Job Files Creating a Machine Configuration 1 When the main screen displays press Topcon Logo gt Control gt Machine setup 2 Press New and enter or select the following information Figure 3 9 Then press Next e Configuration name enter a name for the machine Include the application and or sensor type in the mac
42. For machine control applications the PZL 1 transmitter attaches to either a standard tripod or a fixed 2m tripod over a surveyed point To locate the transmitter over an unknown point see Performing a Resection on page 7 19 The following setup requires Pocket 3D to activate and initialize the transmitter For more information on the Pocket 3D software refer to the Pocket 3D User s Manual and Pocket 3D Reference Manual 1 Locate a control point over which to set up the PZL 1 transmitter See page 5 2 for detailed notes on how to setup and level a tripod 7 2 System Five 3D Reference Manual Equipment Setup Attach the transmitter to the tripod 3 Turn on the transmitter s power and select a channel for the transmitter Figure 7 1 To assign a channel to the transmitter press the channel button until the corresponding LED lights up 4 Connect the transmitter and Pocket 3D controller Figure 7 1 FC 100 Press button to select channel for transmitter Connect Pocket 3D controller and transmitter Figure 7 1 Setup PZL 1 Transmitter Select Channel and Connect Controller P N 7010 0491 7 3 mmGPS Application Setup and Usage 5 7 In Pocket 3D check that a mmGPS enabled machine configuration is loaded Then tap Setup gt mmGPS Transmitters to set up from one to four transmitters On the Transmitters tab select the connection method used between the controller and transmit
43. GPS coordinates need to be converted into local site coordinates defined in terms of a distance north and east of some origin point and some 5 26 System Five 3D Reference Manual GPS Localization distance above an elevation datum These north east and elevation coordinates often abbreviated to NEZ coordinates may be those of a regional coordinates system for example a state plane system in the United States or the project s survey crew may arbitrarily define these coordinates for the specific site NEZ coordinates must be defined in terms of the construction design data In either case a mathematical conversion is necessary to turn global GPS coordinates into NEZ coordinates relative to a locally defined coordinate system The basic approach to calculating the mathematical conversion is to provide pairs of point coordinates for each Control Point on the project A point pair consists of the following coordinates e a local NEZ coordinates for the point obtained from the project s survey crew e b global latitude longitude and height coordinates for the point measured as described in this section or obtained from the project s survey crew These pairs of points are needed to calculate a precise mathematical conversion formula for converting all global GPS coordinates generated in the GPS or GPS receiver to local NEZ coordinates for a particular project The following steps will help to ensure a high quality l
44. GPS receiver Base started OK GPS receiver settings O Use co op tracking O Use multipath reduction MV Use GLONASS satellites Cancel Figure A 4 Enter Base Station Information and Start Base A 4 Pocket 3D Getting Started Guide Equipment Setup GPS For a mmGPS transmitter enter transmitter information 1 Connect the controller and transmitter Check the channel of the transmitter Tap Setup gt mmGPS transmitters 2 Tap the Transmitters tab and press Download to retrieve calibration data from the connected transmitter Refer to the Pocket 3D User s Manual to calibrate or adjust the transmitter 3 Tap the Channel tab and press Edit Channel to select the channel the transmitter description the transmitter ID and the control point over which the transmitter is installed Enter the height of the tripod 4 Press Ok Transmitter information is stored in the control point file copy this file to the machine for mmGPS grading applications Transmitters Channel Equipment Radios Antenna Base station i i 15 600 mmGPS receiver Mark Slant Units Serial Cable on COM1 iw inchmark check Exit add Deletel fx calibration JBownload Resection Cancel Figure A 5 Enter Base Transmitter Information Rev B A 5 Pocket 3D Getting Started Guide Step 3 Create a Range Pole Equipment Conf
45. MMGPS Configuration name GRADER RIGHT GPS 14H GRADER LPS Machine type Motorgrader z Sensor Ls2000 receiver New Edit Copy D Units of measure Feet Q Next Cancel Figure 8 16 Creating the Machine File Location Right 4 Select and enter sensor information then press Next Figure 8 17 on page 8 19 When entering measurements use the same units of measure selected in the previous step e Height enter the height of the sensor above the cutting edge Use the most vertical distance between an outermost position on the metal rim of the antenna and the cutting edge 8 18 System Five 3D Reference Manual Machine Setup e From right for dozers enter the distance of the antenna from the outer edge right side of the blade e Beyond for graders enter the distance of the antenna beyond the outside edge of the blade e Behind enter the distance of the antenna behind the blade e Width enter the width of the blade soi Height 12 05 Behind ete Behind 0 20 gt From right 7 35 gt i Width maas Back Next a Width 14 17 k Back Next Cancel Figure 8 17 Enter Antenna Information Incorrect measurements or data entry errors have a direct affect on grading accuracy the LPS station and the control box while in 3D LPS control Any time you reset the TM
46. PDL UHF Connected to Serial Port B Baud rate 38400 Format CMR Back Next Cancel Figure 5 16 Enter Antenna Information and Save File 5 18 System Five 3D Reference Manual Operations for GPS Control 7 Press Finish to save the machine configuration file Figure 5 17 Machine configuration is complete Press Finish to save the configuration file Back Finish Cancel Figure 5 17 Save Machine Configuration 8 Select the machine configuration file on the Machine files dialog box and press Ok to set this as the machine for the job You must press Finish to save the file Failure to do gt so will result in losing all information and require you to repeat the process Operations for GPS Control Some 3DMC operations such as setting blade control viewing GPS information and changing the radio s channel are only available while in GPS control These functions are discussed on the following pages Other application independent functions are discussed in Chapter 10 Setting Blade Control The blade control function selects the point on the blade at which to control the position of the machine s cutting edge See Automatic Best fit Blade Control on page 1 37 and Control Using Single Point on Blade on page 1 39 for a discussion on the blade control method to use for a jobsite P N 7010 0491 5 19 3D GPS Applications Setup and Usage To quickly change the blade cont
47. Reference Manual Preface Preface Thank you for purchasing this Topcon product The materials available in this Manual the Manual have been prepared by Topcon Positioning Systems Inc TPS for owners of Topcon products and is designed to assist owners with the use of the receiver and its use is subject to these terms and conditions the Terms and Conditions E Please read these Terms and Conditions carefully Terms and Conditions USE This product is designed to be used by a professional The user should have a good knowledge of the safe use of the product and implement the types of safety procedures recommended by the local government protection agency for both private use and commercial job sites COPYRIGHT All information contained in this Manual is the intellectual property of and copyrighted material of TPS All rights are reserved You may not use access copy store display create derivative works of sell modify publish distribute or allow any third party access to any graphics content information or data in this Manual without TPS express written consent and may only use such information for the care and operation of your receiver The information and data in this Manual are a valuable asset of TPS and are developed by the expenditure of considerable work time and money and are the result of original selection coordination and arrangement by TPS P N 7010 0491 Xi Preface TRADEMAR
48. S ui c On Grade T gt TT FTSP REEL 30 0 10 20 30 Tilt Angle Figure 6 9 GPS Dual Antenna Accuracy Range P N 7010 0491 6 11 Dual GPS Application Setup and Usage GPS Operations Some 3DMC operations such as setting blade control viewing GPS information and changing the radio s channel are only available while in GPS control Other application independent functions are discussed in Chapter 10 Operations for GPS Control on page 5 19 discusses the following GPS specific 3DMC operations in more detail e Setting blade control via the Profile view or the Topcon Logo gt Control gt Blade control menu option e Viewing GPS information via the Elevation Control key e Changing Radio Channels 6 12 System Five 3D Reference Manual Chapter 7 mmGP Application Setup and Usage Millimeter GPS mmGPS combines the elevation accuracy of a laser with the horizontal and vertical accuracy of GPS receivers to provide millimeter accuracy while grading or surveying The system provides multiple rover support for machine and pole mounted sensors l See mmGPS Control Overview on page 1 33 for digi a discussion on placing transmitters around the jobsite and for using up to four transmitters Equipment Setup mmGPS applications require both a GPS Base Station and a Base Transmitter the first to transmit GPS corrections and the second to transmit a laser plane An optional Rov
49. Sensor should be removed at the end of each day for storage With 360 laser tracking the LS B2 and LS B4 track laser beams from a rotating laser anywhere on the jobsite sending grading information to 3DMC Figure 1 23 LS B2 and LS B4 Laser Sensors Round Vibration Pole The round vibration pole Figure 1 24 installs on the machine s blade and provides a lightweight fixed mount for the laser sensor Figure 1 24 Round Vibration Pole 1 20 System Five 3D Reference Manual System Five 3D Components Trackerjack Vibration Pole The Trackerjack vibration pole Figure 1 25 provides a sturdy lightweight fixed mount for the Laser Tracker and Trackerjack for use in rough applications Figure 1 25 Trackerjack Vibration Pole Pocket 3D Optional Optional field software for all control applications Pocket 3D assists superintendents operators or grade checkers when staking or checking grade on a site This software runs on a portable field controller Figure 1 26 on page 1 22 and uses files common with other equipment on the job site allowing multiple users to work at the same time This software is required for some mmGPS operations Using Pocket 3D on a field controller you can Set up the Base Station the mmGPS Transmitter and the mmGPS Rover Create and edit Control Point files and Design Surface files Create and edit Machine Configuration files and radio configuration files Create and edit Point f
50. Slope Control Key on page 2 21 for more information on this key and its menu Using 3DMC The various dialog boxes throughout 3DMC have buttons to perform operations such as creating updating copying or deleting files Figure 2 7 on page 2 12 Any and all information the operator can access will be stored and continuously updated to either the internal memory or a compact flash card e New Creates a new file or element e Edit Changes an existing file or element To edit a file select a file or element then press the Edit key e Copy Copies a file either from the compact flash card to the internal memory or from the internal memory to the compact flash card To copy a file select a file then press the Copy key Copy new or edited files to the compact flash card to backup the file P N 7010 0491 2 11 Component Functions Delete Removes an existing file or element from of the internal memory To delete a file or element select a file and press the Delete key Once you delete a file it no longer exists The file will need to be created from the beginning Next Displays the next step or dialog box during an operation after all applicable settings have been entered Back Displays the previous step or dialog box during an operation OK Applies settings and inputs and exits the dialog box and or operation or used to change files or apply settings in sub screens Cancel Cancels or p
51. TXV3____ PP6____ Ch 2 lt none gt ch 3 lt none gt Ch 4 lt none gt Channel 1 Transmitter TXV3 Control point PP6 TX height 6 800 Measured to Mark Slant lt Benchmark check Resection Figure 7 3 Enter Transmitter Channel and Control Point Data PZS 1 Sensor Setup and Initialization For machine control applications the PZL 1 transmitter attaches to either a standard tripod or a fixed 2m tripod over a surveyed point The following procedure requires a mmGPS enabled machine configuration file to be selected in Pocket 3D Setup gt Equipment 1 Connect the GPS receiver to the 5 8inch plug on the PZS 1 sensor Connect the PZS 1 to the range pole 2 Connect the serial cable from port D of the GPS receiver to the serial port on the PZS 1 sensor 3 Turn on the power to both the receiver and sensor 4 Connect the Pocket 3D controller and GPS receiver using one of the following techniques e A serial cable connected to port A of the receiver e Bluetooth wireless technology P N 7010 0491 7 5 mmGPS Application Setup and Usage Figure 7 4 Connect Receiver and Sensor 5 In Pocket 3D tap Setup gt mmGPS receiver 6 Select the following mmGPS parameters Figure 7 5 on page 7 7 GPS port select the port used for GPS communication between receiver and sensor typically port D Sensitivity select Auto to automatically control the mmGP
52. Topcon Logo gt File gt Control 2 When the 3DMC main screen displays navigate to the desired file type dialog box Topcon Logo gt File gt Linework Topcon Logo gt File gt Point files 3 Select the file for the jobsite and press Ok Figure 3 14 _____Linework files lt none gt el rE lt n Copy Delete _ Ok Heancei O Figure 3 14 Applying a Linework File P N 7010 0491 3 13 Building Job Files Surface Files In 3D control applications the project engineer provides a design surface file for the jobsite Before paving the correct file must be copied into the control box and selected as the surface for the jobsite 3DMC supports the selection of two design surface files working and reference The working surface is the surface that the machine will pave to while the reference surface is simply a visual reference on screen in relation to the working surface Typically the reference surface will be an optional selection depending on the requirements of the job while using the 3DMC system The reference surface could be the final design surface which may be different than the current working surface or could be a surface used to monitor the progress of the current surface 3DMC also has the ability to create surface model using a unique onsite method The surface model is created on the machine in real time and can be used as a design surface file for grading in
53. Vibration Pole Specifications Housing Base Cast aluminum Pole OD 1 75 in extruded aluminum Range 5 ft 5 1 2 in 169cm Weight 19 9 Ibs 9 05 kg Figure C 10 shows the dimensions of the Round Vibration Pole 1 75 45 i Figure C 10 Round Vibration Pole Dimensions P N 7010 0491 C 13 Specifications Trackerjack Vibration Pole The Trackerjack Vibration Pole has a lightweight shock isolation and vibration dampening design and is reinforced for rough applications Table C 10 lists specification details for the Trackerjack Vibration Pole Table C 11 Trackerjack Vibration Pole Specifications Housing Base Cast aluminum Pole OD 1 75 in extruded aluminum Range 5 ft 1 1 2 in 156 2cm Weight 22 3lbs 10 15kg Figure C 10 shows the dimensions of the Trackerjack Vibration Pole gt nae 1 75 ry YS oe 11 5 Figure C 11 Trackerjack Vibration Pole Dimensions C 14 System Five 3D Reference Manual GPS Vibration Pole GPS Vibration Pole The GPS Vibration Pole features a steel pole with a larger diameter to improve stiffness Increased temperature range is provided by the use of high or low temperature bushings Table C 10 lists specification details for the GPS Vibration Pole Table C 12 GPS Vibration Pole Specifications Housing Base Cast
54. and reused recycled or otherwise managed to ensure that the mercury in the product does not become mixed with other solid waste or wastewater P N 7010 0491 XV Preface Notes xvi System Five 3D Reference Manual Chapter 1 Introduction Topcon s System Five 3D is a productive automated grade control system used on a variety of grading machines providing both 3D and 2D elevation grade control e 3D control a three dimensional GPS mmGPS LPS control system using the System Five and either GPS mmGPS technology or a robotic laser transmitter 3D control precisely positions the cutting edge of the machine in real time anywhere on the construction site reducing the need for costly stakeout and survey e 2D control a conventional dual control system using a combination of the Sonic Tracker II a Trackerjack system laser sensors or a cross slope system and the control box This chapter discusses System Five 3D components as well as how those components work separately and together to provide elevation grade control Also in this chapter is a discussion on the different types of grade control and how to use them on your jobsite P N 7010 0491 1 1 Introduction System Five 3D Components Table 1 1 lists System Five 3D components at a glance Table 1 1 System Five 3D Components Components Machine Base Control
55. and the layer s parameters Press Ok Repeat step 4 for any other layers Press Ok to save the file Press Yes to apply the file to the current jobsite 9 Topcon Pocket 3D 12 38 fok Layers Default CENTERLINE ROAD EDGE Layer name CENTERLINE Si S 4a Mew Edit Delete Cancel Figure A 24 Add Layers to Linework File Collecting Data Pocket 3D can be used to collect points create polylines or measure a control point When collecting data the project must be localized Collecting Points The following procedure collects individual points Figure A 25 on page A 18 1 2 3 4 Tap Survey gt Measure pts gt Topo shot Enter a point number and point descriptor Select a layer in which to add the point Press Ok to measure the point and return to the main screen Rev B A 17 Pocket 3D Getting Started Guide Topo shot Pt number Pt descriptor Add to layer Topo shot Topo shot w offset GROUND Reference line E Start polyline Start tape dimension Options Cancel Figure A 25 Measure a Point Creating Polylines The following procedure collects points along a line creating a polyline in a linework layer Figure A 26 on page A 19 1 Tap Survey gt Measure pts gt Start polyline 2 Select a layer in which to add the polyline 3 Press Ok to collect the point 4
56. dealer to purchase a new cable Solutions Check that the fan is rotating If the fan is not rotating it may be damaged and needs to be replaced with new one Contact your dealer Contact your dealer for information on replacing the fan 12 12 System Five 3D Reference Manual Control Box Problem Screen display gets dim by itself Causes The fan may not be rotating Solutions Check that the fan is rotating If the fan is not rotating it may be damaged and needs to be replaced with new one Contact your dealer for information on replacing the fan The control box has the self adjusting ability of screen brightness Problem Brightness may be reduced when the control box gets over heated with high temperature around the cab as well as when the ambient light becomes dim The backlight also reduces when the ambient light becomes dim Screen has transferred to operating system Causes Exit 3DMC function may have been pressed unexpectedly or incorrectly Solutions If the screen displays the desktop the My Computer folder should be visible 1 Double tap My Computer folder 2 Look for the folder named Disk C and double tap on it 3 Look for the Control Box icon and double tap on it The application program will open and return to the Main Screen P N 7010 0491 12 13 Troubleshooting Problem Causes Not enough Co
57. displays indicating that the system is busy Copy from data card to internal disk Project files SIMPSON S RANCH CONTROL 4a _OktHEance O Figure 3 2 Select and Copy File 5 When finished copying the desired file s select the files and press Ok to apply the data to the current job 3 2 System Five 3D Reference Manual Control Point Files Control Point Files The first task when setting up the 3DMC system on a new jobsite is to create a new control point file You can use either use the machine to create a control point file or copy a control point file from a Pocket 3D controller For more information on Pocket 3D see the Pocket 3D Getting Started Guide on page A 1 or the Pocket 3D manuals The control point file consists of descriptions local site coordinates global GPS coordinates and units of measurements for each Control Point located on the site Typically the project s survey team provides control point information after accurately measuring these points with a surveying instrument Selecting a Control Point File 1 When the 3DMC main screen displays press Topcon Logo gt File gt Control points 2 Select the control point file for the jobsite and press Ok Figure 3 3 SIMPSON FAMILY RANCH SIMPSON S RANCH CONTROL New Edit Copy Delete okdek O Figure 3 3 Applying a Control Point File P N 7010 0491 3 3 Building Job Files Creating
58. eee 5 28 Chapter 6 Dual GPS Application Setup and Usage 6 1 Equipment Setup Base Station cee eeeeeeeseeereeeeees 6 2 Machine Setup amp 22 6 astieetiite ta aceasta hoe 6 3 Dual GPS Antenna Installation eee eeeeeeeeeee 6 3 Blade and Antenna Measurements 0 0 0 0 ee eeeeeeeee 6 4 Dozer Dual Antenna Measurements 6 4 Motorgrader Dual Antenna Measurements 6 5 Radio Antenna Installation eee eeeeseeneeeeeeees 6 6 MC 2 5 GPS Receiver Box Setup for Dual GPS Applications onanan aeaa n ae 6 6 Control Box Setup 4 c 6is ccsiie giat kas 6 7 Activating Dual GPS Control in 3DMC 6 8 Step 1 Apply a Dual GPS Machine Configuration 6 8 Creating a Dual GPS Machine Configuration 6 8 Step 2 Dual Antenna Slope Calibration 6 9 Step 3 Dual Antenna Orientation Calibration 6 10 Recommended Tilt Angles for the MC A2 6 11 GPS Operations ni sas tiie ee del hank e ie ii 6 12 Chapter 7 mmGPS Application Setup and Usage 7 1 Equipment SetuP cce nariai aan na ka 7 1 GPS Base Station Setup seeeeeeseneeeeeeereerereerresereses 7 1 PZL 1 Transmitter Setup and Calibration 0 00 00 7 2 PZS 1 Sensor Setup and Initialization ee 7 5 Machine Setup serrera eainiie 7 7 PZS MC Setup vcatiee a tea een heehee one 7 7 Blade and Antenna Measurements 0 0 0 0 ceeeeeeeeeee 7 9 Radio Antenna Installation eeeeeeseeneeeteeees 7 9 MC 2 5 GP
59. end of the cable to the controller The controller will initialize the Base Station See Base Station Initialization on page 5 7 for details GPS Antenna Wa KX X Radio Modem Field Controller Figure 5 3 PG A1 Base Station Cable Connections Step 4 start the Base Station 1 Turn on the controller For a PG A1 base station turn on the radio and select the correct channel on the radio modem 2 Press the PWR button on the GPS receiver for one to two seconds The power LED flashes red then rapidly green Once powered up the number of successive red and green flashes indicates the number satellites being tracked e GPS only green flashes e GPS GLONASS green flashes followed by red flashes To turn off the receiver press PWR button for one to two seconds until LEDs are off 5 6 System Five 3D Reference Manual Equipment Setup Base Station Step 5 measure the antenna height from the control point to the rim slant or ARP vertical of the antenna Figure 5 4 This measurement will be used when initializing the Base Station HiPer Lite Slant Height to Edge of Antenna Vertical Height to ARP Slant Height to SHMM Vertical Height to ARP Station Marker Station Marker Figure 5 4 Measure Base Station Antenna Height Base Station Initialization Before initializing the Base Station check the Units used in the current jobsite Setup Units and that the correc
60. highest point on the machine If the Rover machine gets too far from the Base Station elevate the radio antenna at the Base Station or move it to a closer Control Point GPS Localization This section lists possible GPS localization problems you may encounter If you still have problems after trying the solutions listed here contact TPS customer support Problem Causes The machine may be blocking satellite signals to the range pole or tripod mounted antenna Measurement takes too long Solutions Watch the status of the measurement screen If the status indicates waiting for satellites move the machine away from the antenna P N 7010 0491 12 9 Troubleshooting The Control Point may be located too close to obstructions Move to an alternative Control Point or have the surveyor place a new Control Point away form the obstructions The Rover GPS has not yet initialized the system may be tracking many satellites The status indicates waiting for better precision The Rover GPS may take several minutes to initialize The range pole was unsteady Problem Localization produces large errors Causes Solutions A typographical error If errors are 10s or 100s of feet or meters it occurred is likely that a typographical error has Make sure that the pole is held steady while measurement is taking place Any movement will make for
61. hoses and wires secured and away from possible wear or pinch points Use eye protection whenever welding cutting or grinding is being done on the machine P N 7010 0491 B 1 Safety Information 7 Protect yourself at all times and wear protective clothing when working on or near hydraulic lines Hydraulic lines can be under extreme pressure even when the machine is turned off Relieve all pressure in the hydraulic lines before disconnecting or removing any lines fittings or related components If injury does occur seek medical assistance immediately gt 8 Avoid direct exposure to your eyes when using laser control DO NOT stare into the laser beam or view the beam directly with optical equipment p 9 Use appropriate welding precautions and practices when welding After welding all paint all affected areas with a rust inhibitor DO NOT weld near hydraulic lines or on any equipment when in operation gt Disconnect all Topcon system electrical cables prior to welding on the machine All mounting bracket welds must be secure and strong to prevent the sensor equipment from vibrating excessively or from becoming detached at the weld during operation Q 10 To prevent vandalism or theft do not leave removable Topcon components on the machine at night Remove the components each evening and store appropriately in the Carrying Case 11 Keep the Carrying Case dry at al
62. indicator e viewing a lower window that displays the Profile Section Light bar or Cut fill history for mmGPS applications e viewing and selecting display options for various data menu options depend on the files selected for display e viewing 3DMC information authorization codes and options P N 7010 0491 2 15 Component Functions Pop up Menu The 3DMC pop up menu provides quick access to the elevation information and the steering or grading to polyline functions Pop up menu selections depend on active files or selected object To access the pop up menu press anywhere on the 3DMC Main Screen Figure 2 10 Design Elevation displays the elevation of the point tapped on the Main Screen Steer to Polyline available for linework files controls the machine steering it along the selected polyline Grade to Polyline available for linework files with elevation information controls the machine grading along the selected polyline in the linework file Design elev 69 994 Steer to polyline Grade to polyline Figure 2 10 Pop up Menu 2 16 System Five 3D Reference Manual 3DMC Functions Elevation Control Key The Elevation Control key displays cut fill readings and the cut fill offsets for the elevation of the blade The key also indicates the status of the connected sensor with graphics informational messages and colors The information displayed will be different depending on the cont
63. nor normally a recommended operation there are times when clearing the NVRAM can eliminate communication or tracking problems Clearing the NVRAM can be interpreted as a soft boot of your computer After clearing the NVRAM your receiver will require some time to collect new ephemerides and almanacs around 15 minutes Clearing the NVRAM of the MC 2 5 receiver box will reset the box to factory default values 1 Ephemeris ephemerides Data giving the coordinates of a celestial body at a number of specific times during a given period P N 7010 0491 10 35 Grading Application In addition the NVRAM is used to keep information about the receiver file system Note that after clearing the NVRAM the receiver s LED s will flash orange for a few seconds indicating that the receiver is scanning and checking the file system 1 Turn off power to the MC 2 5 Box by unplugging the power cable 2 Press and hold the Main FN key for a single box or the AUX key for a dual box Figure 10 40 on page 10 36 3 Plug the power cable from the MC 2 5 Box to return power The LED corresponding to the pressed FN key or AUX key turns green 4 Wait until the Main LED blinks orange about three seconds Figure 10 40 Hold FN Key While Turning PWR On to Clear NVRAM 5 Release the FN key or Aux key while the LED blinks orange 10 36 System Five 3D Reference Manual Chapter 11 Maintenance Good daily care preventive maintenance
64. on the machine Check the connection at the GPS Antenna port on the Receiver Box If the cable is damaged contact your dealer to purchase a new cable The antenna has poor PDOP Check that the Rover Antenna has a clear view of the sky The receiver is collecting an almanac Problem Causes The Base Station and or Base Station radio has a problem Radio Status indicator does not flash yellow If this is the first time connecting to the Receiver Box no LED flashing may persist for several minutes while the GPS receiver obtains a new almanac Solutions Check that the Base Station is running correctly and the TX light on the radio modem flashes on 12 8 System Five 3D Reference Manual GPS Localization Different channels are used between the Base Station and the Rover machine The antenna at the Rover or Base may be too low incorrectly placed or too far away Check that the Base Station and Machine use the same radio channel e For the Base Station use the button on the radio modem or use GPS Radio Configuration program with the Pocket 3D connected See Equipment Setup Base Station on page 5 2 e For the machine use the control box function See Changing Radio Channels on page 5 24 If the yellow LED flashes when near the Base Station but not when farther away check that the Rover Radio Antenna mast is mounted vertically at the
65. oo eee eeeeseceseeeeeeseeeseecaeeneeees A 10 Step 1 Create an Equipment Configuration File A 10 Step 2 Setup the Station eseese A 11 Step 3 Setup the LS 2000 Receiver eee A 12 Step 4 Start LPS Control and Check Status A 13 Localizing with Pocket 3D ooo eee eeseeseeeeeeeeeneeeneeeeeees A 14 Creating Files in Pocket 3D oo eee eeeceseeeeeneeeneeeneeees A 15 Creating a Points File oo eee eeceseeeeeeeeeeneeeneeeeeeees A 15 Creating a Linework File 0 eee ceeeeeeeeeeneeeeeees A 16 Collecting Data nsina a oleciteeceeetetee A 17 Collecting Points reran ceanna nein A 17 Creating Polylines onenian A 18 Performing a Survey 00 ceesesseeeseceeceeeeeeeesaeenaeees A 19 Performing a Stakeout 0 eee eeseesecsneceeeeeeeeseecnaeeneeees A 20 Staking out Points 20 eee cee eee cneeceeeeeeeeneeeaaecneeees A 20 Checking the Surface cee csceseceseeeeeneeenseeneeees A 22 Calculating the Inverse Between Two Points A 22 Appendix B Safety Information ccccsesesseeeeeeeeesseeeeeeeeeeeees B 1 General Precautions 0 eee ceseeeceseeeseeeeceeceeseneesaessaeens B 1 Radio Usage Information cee eseeeseceeceeeeeneeeneeeeeees B 3 Appendix C Specifications sihisee ase aiia dpi ia C 1 Control BOR eeror cheese vicehe EE a E E SE C 1 viii System Five 3D Reference Manual Table of Contents Remote Smart Knobs cccccccscccessececseceeeceeeeeeseeeeeneaes C 3 Simple Auto Manual K
66. out Measure stake V Surface Offset 1 000 Match grade Next Save Cancel Options Figure A 28 Stakeout Point 5 To stop the stakeout press Ok and tap Survey gt Stakeout gt Stop stake out Figure A 28 Rev B A 21 Pocket 3D Getting Started Guide Checking the Surface 1 Tap Survey gt Stake out gt Surface check Figure A 29 2 View the cut or fill and current elevation 3 Tap Survey gt Stake out gt Stop stake out Surface check y Point list Alignment Polyline Coordinate Control point Create custom point list Stop stake out N Measure stake Cut 0 00 Elev 100 00 V Surface Offset 1 000 SNe Options V Surface Offset 1 000 Match grade Options Figure A 29 Perform a Surface Check Calculating the Inverse Between Two Points An inverse calculation in Pocket 3D calculates the opposite direction and distance between two points Figure A 30 on page A 23 1 Tap the Selection Window icon and drag a selection box around two points Tap Survey gt Cale wizard 3 With Inverse between two pts selected press Next The results of the calculation display Press Cancel to exit the results screen 5 Tap Survey gt Clear selection A 22 Pocket 3D Getting Started Guide Topcon Pocket BD RevB Calculating the Inverse Between Two Points Topcon Pocket 3D gt 4y_1 Con
67. press Topcon Logo gt View gt Main window Figure 10 1 then tap the desired view a check mark indicates the active view Plan Section Left window Profile Right window Lower window Display options About 3DMC Figure 10 1 Main Window Display Menu Selections The Plan view Figure 10 2 on page 10 8 displays the jobsite from above the machine and the main window is always oriented in the forward direction of machine travel e The point on the cutting edge below the location of the GPS antenna is always in the center of the main window e This view allows for additional representations of triangle mesh and contour lines in a desired color as well as superimposing Linework Alignment lines and Topo points P N 7010 0491 10 7 Grading Application Figure 10 2 Plan View on Main Window The Section view Figure 10 3 displays a cross section view of the cutting edge and the selected Design Surface where the right side of the Main Screen is the right side cutting edge e The cut fill readings are provided on both sides of the blade and represent how far the cutting edge is from on grade e When a road surface model is selected the centerline and the elements on the template are presented in red e Additionally the section view displays steering information from a target alignment line to a target edge and the longitudinal distance along the road lt 46 08 18 00 83 8200 72 0 00 ga 2
68. product changes at any time without notice Comments suggestions and questions about TOPCON products are welcomed Contact your local TOPCON representative or a representative at our corporate facility TOPCON POSITIONING SYSTEMS Inc 7400 National Dr Livermore CA 94551 925 245 8300 925 245 8583 FAX Manual Conventions This manual uses the following conventions Example Description File gt Exit Click tap press the File menu then click tap press Exit Enter Click tap press the button or key labeled Enter Further information to note about the configuration NOTE maintenance or setup of a system l Supplementary information that can help you configure maintain or set up a system xiv System Five 3D Reference Manual Manual Conventions on system operation system performance D Supplementary information that can have an affect measurements or personal safety adversely affect system operation system performance data integrity or personal health Notification that an action will result in system damage loss of data loss of warranty or personal injury Notification that an action has the potential to Under no circumstances should this action be performed Mercury Warning The LCD display in the 9168 Topcon Control Box contains mercury The Control Box should not be disposed of or placed in a waste stream destined for disposal until the mercury is removed
69. remain visible NOTE when showing Left Lower window views P N 7010 0491 10 11 Grading Application Lower Window Views Display options for the lower window include a Profile view a Section view a Cut fill history view for mmGPS applications and a Light bar To access the desired lower window view press Topcon Logo gt View gt Lower window Figure 10 9 then tap the desired view a check mark indicates the active view None indicates no lower window is active Main window Left window Right window vNone Lower window Profile Display options Section About 3DMC Cut fill history Light bar Figure 10 9 Lower Window Menu Selections incl mmGPS Selecting one of the options adds the view as a small window above the Elevation Control Key Figure 10 10 on page 10 13 The Profile view displays a side view of the machine where the right side of the screen is always the forward direction of machine travel The buttons increase and decrease magnification for this Lower window view The Section view displays a cross section view of the cutting edge and the selected Design Surface where the right side of the view is the right side cutting edge The cut fill readings are provided on both sides of the blade and represent how far the cutting edge is from on grade The buttons increase and decrease magnification for this Lower window view The Cut fill history view for mmGPS app
70. right side of the blade Figure 8 23 3 Press OK to apply this blade control point to the machine Automatic best fit whole blade Control using single point on blade From left 2 854 From right 6 988 Ok Cancell Figure 8 23 Blade Control Using Single Point on Blade P N 7010 0491 8 23 3D LPS Application Setup and Usage Operations for LPS Control Some 3DMC operations such as viewing GRT information are only available while in LPS control These functions are discussed on the following pages Other application independent functions are discussed in Chapter 10 Viewing GRT Information To view GRT information press the Elevation control key then press the GRT info button Figure 8 24 aoa Elevation left edge 384 93 Elevation right edge 384 44 Elevation valve gain 75 Set Elevation set point 0 00 Set Zero Q gt SAT info Ok Cancel Figure 8 24 View GRT Information The Position tab displays current locations for the left and right sides of the cutting edge in real time Figure 8 25 These values are based on the local site coordinates providing quick position and elevation checks at particular points on the project Position N 2064673 42 E 6178930 41 Z 384 44 N 2064673 42 E 6178944 40 Z 384 93 Ok Cancel Figure 8 25 View Position Information 8 24 System Five 3D Reference Manual Chapter
71. speeds up the response a lower setting slows down the response See Adjusting Valve Gain on page 10 19 for details on setting the valve gain Elevation set point displays the cut fill offset or amount of additional height applied to the Design Surface Survey used to quickly lock the blade on grade e Change to Slope used to switch to 2D slope control ___Adjustelevation Elevation left edge Elevation right edge Elevation valve gain 75 Set Elevation set point _ 0 55 Survey Zero Change to Slope Ok Ei Figure 2 16 Adjust Elevation Dialog Box 2D Control Slope Control Key The Slope Control Key displays the Design Cross slope and indicates sensor status with graphics messages and colors Figure 2 17 While grading the Design Cross slope continuously changes according to the Design Surface P N 7010 0491 2 21 Component Functions e Design Cross Slope Displays the current cross slope In 3D this number is based on the Design Surface in 2D control the number is entered by the operator e Type of Control Application Displays either 3D or 2D for the current control application e Color of Slope Key the background color of the slope control key indicates sensor status Green indicates sensor status suitable for grading Red indicates an error status and Automatic Control will be disabled Type of Control Application Angle of Bl
72. the job so will result in losing all information and require D You must press Finish to save the file Failure to do you to repeat the process 20 System Five 3D Reference Manual Machine Setup Step 2 Copy and or Select the Control Point File For LPS applications the control point file also stores GRT 2000 information including initialization information setup location and height data This information is copied from a Pocket 3D controller to the control box via a compact flash card 1 Save the Pocket 3D control point file to a compact flash card 2 Insert the CF card that contains the control point file into the CF card slot on the control box 3 Tap Topcon Logo gt File gt Control points and tap Copy Select from data card to internal disk and the file to copy from the Project files list Figure 8 20 Tap OK During the copy process an hourglass displays to indicate the system is busy Copy from data card to internal disk Project files cherr SIMPSON S RANCH CONTROL PP topo Nov20 Ok Cancel Figure 8 20 Copy File 5 When done select the copied file on the Control point files dialog box and tap OK P N 7010 0491 8 21 3D LPS Application Setup and Usage Step 3 Select the GRT 2000 Location After loading a control point file set up 3DMC and the machine to use GRT 2000 total station 1 Tap Topcon Logo gt Control gt GRT2000 location and select the Co
73. the tripod securing it in place Attach the GRT 2000 on the head plate and affix lightly with the centering screw through the head plate 3 Check the tripod so the center dot viewed through the optical plummet built in the left side of the GRT 2000 is close to the ground point 4 Extend or shorten two legs to level the head plate so the bubble of the circular level vial is close to center Repeat step 2 as needed 5 Secure the extension knobs or hooks at the midsection of the legs and plant the legs firmly and evenly in the ground 6 Turn the leveling screws leveling the tribrach so the bubble is precisely centered 7 Move and align the tribrach while slightly loosening the centering screw superimposing the center dot in the optical plummet over the ground point Ensure the bubble is still centered Repeat step 4 as needed 8 To accurately level the instrument slowly turn the two leveling screws until the bubble in the linear level vial on the GRT 2000 consistently rests in the center when rotating 180 in a direction parallel to the line that connects two leveling screws The Al and A2 positions in Figure 8 1 illustrate this leveling process 8 2 System Five 3D Reference Manual Equipment Setup GRT 2000 9 Repeat step 8 in the perpendicular direction B1 and B2 positions in Figure 8 1 Check repeatedly and be sure to level in both directions The bubble may not center exactly in both positions due to the linear lev
74. you have set up the Base Station simple checks ensure the machine receives corrections from the Base station if the elevation control key is green the Base Station is ready 6 2 System Five 3D Reference Manual Machine Setup Machine Setup Machine setup for GPS control application is quick and easy First install the machine antenna single or dual then install the radio antenna and finally connect the cables Dual GPS Antenna Installation 1 Mount the GPS vibration pole using the indexing tabs for consistent orientation 2 Attach the MC A2 antenna to the GPS vibration pole Orient the dual antenna with the label pointing forward Figure 6 1 3 Connect the MC A2 antenna cables to the antenna Figure 6 1 and then to the antenna cable connector on the machine e The main GPS antenna connection is marked with yellow indicators and must be attached to the forward antenna e The auxiliary GPS antenna connection is marked with black indicators and must be connected to the rear antenna Figure 6 1 Mount Dual Antenna to GPS Vibration Pole P N 7010 0491 6 3 Dual GPS Application Setup and Usage Blade and Antenna Measurements Dual GPS antenna systems require three measurements for accurate grading the antenna height and antenna behind distance and the distance of the antenna from the side of the blade The following sections describe taking these two me
75. 0 00 Grade 0 000 Back Next Cancel Figure 3 23 Measure Points A and B to Determine Main fall P N 7010 0491 3 21 Building Job Files 6 Press the Crossfall Grade entry box and enter a crossfall Figure 3 24 The crossfall grade is the grade that falls across at a 90 angle to the line of main fall see Figure 3 21 on page 3 20 and together with the main fall determines the plane with the compound slope A positive sign designates a fall from right to left and a negative sign designates a fall from left to right Point on surface Main fall A gt B N Direction 315 37 54 E Grade 1 697 Zz A f B Enter Grade Measure pt eik i at 90 angle of main fall Grid interval Crossfall 50 00 Grade 1 500 Back Next Cancel Figure 3 24 Enter Crossfall Grade 7 Move the machine to the elevation reference point The measurement of this point brings the entire plane up or down to intersect the plane and determine its relative elevation l 3 Substitute point A or point B for the elevation reference point l If you have the NEZ coordinates for the elevation Fas reference point press the corresponding entry box and type in the information 8 When the antenna rests over the point press Measure pt to measure the elevation reference point Figure 3 25 on page 3 23 The Measuring dialog box briefly displays 3 22 System Five 3D Reference Manual Surface Files 9 E
76. 00 Figure 10 3 Section View on Main Window 10 8 System Five 3D Reference Manual Changing the Display View The Profile view Figure 10 4 displays a side view of the machine where the right side of the screen is always the forward direction of machine travel Figure 10 4 Profile View on Main Window Left Window Views Display options for the left window include a Profile view a Section view and a Grade indicator To access the desired lower window view press Topcon Logo gt View gt Left window Figure 10 5 then tap the desired view a check mark indicates the active view None indicates no left window is active Main window vNone Profile Right window Section Lower window Grade indicator Display options About 3DMC Figure 10 5 Left Window Display Menu Selections Selecting one of the options adds the view as a window at the left side of the main window Figure 10 6 on page 10 10 P N 7010 0491 10 9 Grading Application The Profile view displays a side view of the machine where the right side of the view is always the forward direction of machine travel The buttons increase and decrease magnification for this Left window view The Section view displays a cross section view of the cutting edge and the selected Design Surface where the right side of the view is the right side cutting edge The cut fill readings are provided on both sides of the blade and represent how f
77. 10 37 Otherwise 3DMC will continue to log measurements Stop topo survey Configure radios Figure 10 37 Stop Topo Survey Measurement data will be saved in the currently selected point file 6 Copy the point file to an external memory USB card for analysis or design work in the office P N 7010 0491 10 33 Grading Application Viewing and Updating 3DMC Options 3DMC and 3DMC software uses authorization codes to enable the desired options For most applications these codes are initially entered at the factory but will need to be updated if updating the options for other application functions 1 To view information about 3DMC press Topcon Logo gt View gt About 3DMC The about 3DMC dialog box displays version number copyright date and publisher registered user and authorization codes Figure 10 38 2 To view the enabled options press Options on the about 3DMC dialog box Figure 10 38 3 To modify 3DMC options press Modify on the Options dialog box Figure 10 38 3DMC 6 11 Control firmware 0 Options e OS date Bulldozer Yes Motorgrader No Copyright C 2002 2006 Elevating scraper No Topcon Positioning Systems Single tow scraper No Registered to WORKER BOE Generic machine No Excavator dual gps No GPS Topcon RTK Yes LPS GRT2000 controlled No lo tions LaserZone millimeter GPS Yes P Autamatic hlada control o Vae Ee Modify Ok Figure 10 3
78. 168 combines the System Five platform with a computer graphic display into a single rugged unit that provides dual hydraulic control for three dimensional stakeless GPS and LPS control and 2D control The high resolution bright touch screen display easily adapts to a variety of machine applications providing the operator with easy to view graphical information A mounting bracket and one side or double side clamps secure the control box in the cab The clamps provide easy attachment at the beginning of the day and easy removal for storage in the carrying case at the end of the day All cables attach in the back and remove easily with quick disconnect connectors Figure 1 5 System Five 3D 9168 Control Box P N 7010 0491 1 7 Introduction Remote Smart Knob Used most often on motor graders the Remote Smart Knob Figure 1 6 is a remote switching unit for controlling the left a right sides of the blade The knob functions symmetrically and mounts on a motorgrader s control levers for easy access keeping the operator s hands at the levers Figure 1 6 Remote Smart Knobs Simple Auto Manual Knob Used most often on dozers the simple auto manual knob Figure 1 7 is a remote mounted on the control lever or in another convenient location The A M knob allows the operator to switch between Automatic Control and Manual Control Figure 1 7 Simple Auto Manual Knob 1 8 System Five 3D Reference Manual System F
79. 5 8 an2eHs Pog LQosszreSssns O5neSLOoS o ECHKDEEVSIE o 00ans OHSS CoxCcr JoMo rAOFHoONADOe Figure 1 2 Grader System Five 3D LPS 2D 1 4 System Five 3D Reference Manual System Five 3D Components UNEN LI JY We J24 O ELV AN d Dx KS a Z Je K ZZ IS v LQ gt ZN OR 4 Dozer System Five 3D GPS Jj jb j T J 2 NY p o 4 gt ASF o 2 2 j 222 iS osooso Sn2zecc gc x Gt ecef6 c SER H28Ge9 maSoon SENSE m 1a a8 6a 959 VlSH Sas oaks gt 20 rota o SEBESSSORRS OnmM Te SS060au Bt dP ay ages oe eat al we o ANTA ON OO Sr Figure 1 3 Dozer System Five 3D GPS P N 7010 0491 1 5 Introduction oNN KS S IA VF ae A Y EEG Dozer System Five 3D LPS or 2D a a G D 2 f3 a 2 2 z 7 2 lt T E i z g 2 59 9 Ba HF 20906 8 5Sa 5 2 Sox Se oaos gt t oomees oz S38 oa 39 LIN T aug ok HAsoESea I MOnTrO 1 2 3 4 5 6 7 Figure 1 4 Dozer System Five 3D LPS 2D 1 6 System Five 3D Reference Manual System Five 3D Components Machine Components The machine components for System Five 3D varies depending on the type of application However every machine will have a control box loaded with 3DMC software for precise grading control System Five 3D Control Box The control box Figure 1 5 is the operator s interface as well as the primary control for the System Five 3D components The 9
80. 7 shows the dimensions of the Trackerjack aa Figure C 17 Trackerjack Dimensions P N 7010 0491 C 23 Specifications PZS MC Sensor The PZS MC sensor combines the MC A1 GPS antenna with laser sensor technology The sensor attaches to a GPS vibration pole on the machine blade and cables connect the receiver to the control box Table C 18 lists specification details for the PZS MC Table C 18 PZS MC Specifications Beam Detection 10 by 10 window Channels 4 Weight 6 6 lbs 3kg Power Supply DC 8V DC 32V Waterproof IPX6 Operating Temperature 20 C to 50 C 4 F to 122 F Figure C 18 shows the dimensions of the PZS MC C 24 LL MACHINE MOUNT 1 750 015 DIA Figure C 18 PZS MC Dimensions System Five 3D Reference Manual Appendix D Regulatory Information The following sections provide information on this product s compliance with government regulations for use FCC Compliance This device complies with Part 15 of the FCC rules Operation is subject to the following two conditions 1 This device may not cause harmful interference and 2 This device must accept any interference received including interference that may cause undesired operation This equipment has been tested and found to comply with the limits for a digital device pursuant to Part 15 of the FCC rules These limits are designed to provide reasonable protect
81. 8 About 3DMC and Control Box Options for 3DMC 4 From the ControlBox dialog box record the Device identification number to give to your Topcon representative Contact your Topcon representative to obtain new authorization codes for the desired applications When you have received the new authorization codes enter the codes in the ControlBox dialog box using the alpha numeric keyboard Figure 10 39 on page 10 35 10 34 System Five 3D Reference Manual Clearing the MC 2 5 Box NVRAM 6 Press Ok to apply the new codes and options Press Ok on each screen to return to the main screen 7 Turn off the control box wait a couple seconds and then turn on the control box to activate the new passwords Device identification 555555 Registered user name Alan Smith Authorization code 1 12345A6B78912345 1 2 3 4 amp 6 7 8 9 0 QW EJ R T Y U 1 Oj P A s D F G H J K L Ok Authorization code 2 ZX C V B NM 1A2B3C4D5E6F789G Cancel oe _0x_ Cancel Figure 10 39 Enter New Authorization Codes Clearing the MC 2 5 Box NVRAM The receiver s Non Volatile Random Access Memory NVRAM holds data required for satellite tracking such as ephemeris data and receiver position The NVRAM also keeps the current receiver s settings such as active antenna input elevation masks and recording interval and information about the receiver s internal file system Even though clearing the NVRAM is not a common
82. Box Blade Slope Sensor Mainfall Sensor Rotation Sensor Hydraulic Valve Kit Remote Smart Knobs or Simple Auto Manual Knob Cables Mounting hardware 3D GPS Rover Antenna Rover Receiver Box Round Vibration Pole Base Station Kit mmGPS PZS MC Sensor PZL 1 Laser Transmitter 3D LPS LS 2000 Laser Sensor TM 1 Mast GRT 2000 Robotic Total Station 2D Sonic Tracker II Trackerjack system LS B4 or LS B2 Vibration pole Other Pocket 3D Supporting accessories and software hardware Additional options Figure 1 1 on page 1 3 through Figure 1 4 on page 1 6 illustrate the System Five 3D setup for both 3D GPS mmGPS and 3D LPS 2D control applications on a grader or dozer 1 2 System Five 3D Reference Manual System Five 3D Components Grader System Five 3D GPS re x 5S n M Fa 0 Qe aio o De 2 oo 33 Ta Gosteaa ig raoa gsescscsoc G c amp cc Oc x oopSSH OOSE oFaGZ GH ne ORe a o Noon Fonts oanSaesuottogs Oo Qseslrrasson EBQerefSoacs o CES ESED SREANG eGdSOBROOQOONQOG Ormnrsatrastzezacoa Be a a ee Ne Sy ora rAOFT HONDO Figure 1 1 Grader System Five 3D GPS P N 7010 0491 1 3 Introduction LA Grader System Five 3D LPS or 2D 2 a c 25 JE ee rs Low yx D Sg lt 55 25 i 2 Do 2 cx 3 60 on o ss N oF amp Hn no A 0 5 2 I NOFLE ke 50290 io 2r2a28 x 2 2 8550 E nE Ls aHA G conor ESS8 2 56
83. Calibrations Dozer Cross Slope Calibration Dozers only require one sensor to control cross slope the Blade Slope Sensor The Blade Slope Sensor must be calibrated to accurately measure the slope of the cutting edge The dozer system has two methods for calibrating the blade sensor e The preferred method requires measuring the cutting edge with an accurate carpenter s level or an instrument e The second method requires setting the blade on the ground for a slope reading and then turning the dozer around and taking another reading Method One Measure the Cutting Edge At the control box press the Slope Control key 2 Manually raise the blade and place a precision carpenter s level along the bottom of the cutting edge Then manually tilt the blade until the cutting edge is level 3 Once the cutting edge is dead level press the Blade slope Set key to adjust the slope Figure 4 8 on page 4 8 4 Press the display window next to the Set key to display the Small Pop up keyboard Enter 0 0 and press OK The Blade slope value displays as 0 0 on the Adjust Slope dialog box Figure 4 8 5 Press OK to apply the new calibration Press Cancel to use the previous calibrations 1 If you have an instrument that can accurately measure the slope of the cutting edge simply press the Set key and enter the actual blade slope into the Blade Slope window P N 7010 0491 4 7 Calibrations a a Blade slope Slope gain Slo
84. Complete P N 7010 0491 4 9 Calibrations Blade Trim Adjustments Graders Only The blade trim calibration allows the operator to make blade wear adjustments to the cutting edge on the motor grader The operator performs this adjustment while cutting grade right on the jobsite and can be completed in less than five minutes Daily adjustments ensure a perfect cross slope calibration and verify System Five 3D grades 1 2 Using the control box tap Topcon Logo gt Control gt Blade trim Using the Remote Smart Knobs switch cross slope control to Auto and grade a smooth finish pass at least 50 feet long The amount of slope dialed in does not matter but it is best to dial in a slope that will closely match the area being graded The dialed in slope displays at the lower left of the dialog box Figure 4 12 If the ground is fairly rough back up and grade two or three passes until you have a smooth finish grade Adjust slope and make a smooth finish pass in automatic 2 0 Next Cancel Figure 4 12 Blade Trim First Pass Press Next Turn the machine around 180 degrees and position the blade over the first finish pass Leaving the cross slope control in Auto slowly lower the blade on the elevation side and observe to see if the cutting edge matches the previous pass 4 10 System Five 3D Reference Manual Blade Trim Adjustments Graders Only 5 Check the slope at the lower left corner of the dia
85. Component Functions Grade Adjustment Direction Arrows The grade adjustment direction arrows Figure 2 2 illuminate red indicating the direction of knob rotation to reach on grade They also illuminate to indicate you can use the grade adjustment knobs to change values while in adjustment and calibration modes Rotate Knob Clockwise To Reach Grade Rotate Knob Counterclockwise To Reach Grade Figure 2 2 Grade Adjustment Arrows Brightness Sensor Window This window allows an internal optical sensor to measure ambient light providing automatic adjustment of the display s backlight Blocking the Brightness Sensor may cause incorrect adjustments of the display s brightness level Touch Screen Display The touch screen display provides textual information graphic symbols and graphic mappings all of which the operator can use to prepare a job to apply changes on screens and functions and to perform machine grading For every operation except value changes using the grade adjustment knobs simply tap the screen with a finger to make selections or enter information The screen s backlight varies automatically depending on ambient light so the operator can always view the screen s information under optimum brightness durable coating but avoid contact with any metal or abrasive object Prevent any hardware from contacting the Touch Screen Display Do not rub or force dust from the surface See Touch Screen
86. Configuration nary FlatPlane_1 Surface type Sloping plane surface New Copy Raise lower existing surface Subgrade of existing road Next Cancel Figure 3 19 Create New Surface File 2 Move the machine to the elevation reference point The measurement of this point brings the entire plane up or down to intersect the point and determine its relative elevation If you have the NEZ coordinates for the elevation reference point press the corresponding entry box and enter in the information 3 When the sensor is over the point press Measure pt to measure the elevation reference point Figure 3 25 on page 3 23 The Measuring dialog box briefly displays 4 Enter a grid interval for the main screen Press Next Figure 3 25 on page 3 23 18 System Five 3D Reference Manual Surface Files Point on surface Grid interval N 8523 585 50 000 E 10995 233 z 59 669 Q gt measure pt Back Next Cancel Figure 3 20 Measure Elevation Reference Point and Enter Grid Interval 5 Press Finish to save the new surface file and end the process Creating a Sloping Plane Surface The sloping plane surface model is composed of four basic factors a mainfall orientation a mainfall grade a crossfall grade and a reference elevation point on the plane Just like aligning the rotating laser plane and adjusting the laser receiver height the operator needs to be prepared with
87. Copy File During the copy process an hourglass displays to indicate the system is busy 5 When done select the copied file on the Control point files dialog box and tap OK 7 14 System Five 3D Reference Manual Machine Setup Step 3 Setup the PZL 1 Transmitter in 3DMC 1 Press Topcon Logo gt Control gt PZL 1 transmitters 2 Tap the channel tab that corresponds to the channel at the transmitter Figure 7 11 3 Enter the following information and press Ok Figure 7 11 e Select the serial number of the transmitter on this channel e Select the control point over which the transmitter is installed e Enter the height of the transmitter e Select the method used to measure the height of the transmitter Ch 1 Ch 2 Ch 3 Ch 4 Transmitters Transmitter S N 900026 8 Control point PP3 Height of transmitter 6 560 Measured to Mark Slant Ok _ Cancel Figure 7 11 Set up PZL 1 Transmitter in 3DMC 4 To view firmware and adjustment status for the transmitter s tap the Transmitters tab Figure 7 12 The Adjusted column shows whether the transmitter has been adjusted to compensate for significant changes in ambient temperature This information is included in the Control Point file P N 7010 0491 7 15 mmGPS Application Setup and Usage Ch 1 Ch 2 Ch 3 Ch 4 Transmitters SIN Firmware Adjusted a Ok Cancel Figure 7 12 Transmitter D
88. KS System Five Millimeter GPS mmGPS Pocket 3D HiPer Sonic Tracker II Topcon and Topcon Positioning Systems are trademarks or registered trademarks of TPS Microsoft Windows and CE NET are trademarks or registered trademarks in the United States and or other countries Product and company names mentioned herein may be trademarks of their respective owners DISCLAIMER OF WARRANTY EXCEPT FOR ANY WARRANTIES IN AN APPENDIX OR A WARRANTY CARD ACCOMPANYING THE PRODUCT THIS MANUAL AND THE RECEIVER ARE PROVIDED AS IS THERE ARE NO OTHER WARRANTIES TPS DISCLAIMS ANY IMPLIED WARRANTY OF MERCHANTABILITY OR FITNESS FOR ANY PARTICULAR USE OR PURPOSE TPS AND ITS DISTRIBUTORS SHALL NOT BE LIABLE FOR TECHNICAL OR EDITORIAL ERRORS OR OMISSIONS CONTAINED HEREIN NOR FOR INCIDENTAL OR CONSEQUENTIAL DAMAGES RESULTING FROM THE FURNISHING PERFORMANCE OR USE OF THIS MATERIAL OR THE RECEIVER SUCH DISCLAIMED DAMAGES INCLUDE BUT ARE NOT LIMITED TO LOSS OF TIME LOSS OR DESTRUCTION OF DATA LOSS OF PROFIT SAVINGS OR REVENUE OR LOSS OF THE PRODUCT S USE IN ADDITION TPS IS NOT RESPONSIBLE OR LIABLE FOR DAMAGES OR COSTS INCURRED IN CONNECTION WITH OBTAINING SUBSTITUTE PRODUCTS OR SOFTWARE CLAIMS BY OTHERS INCONVENIENCE OR ANY OTHER COSTS IN ANY EVENT TPS SHALL HAVE NO LIABILITY FOR DAMAGES OR OTHERWISE TO YOU OR ANY OTHER PERSON OR ENTITY IN EXCESS OF THE PURCHASE PRICE FOR THE RECEIVER LICENSE AGREEMENT Use of any comput
89. Manual Setup Checklists Table 10 2 Dual GPS Setup Checklist Setup Page Number Complete Building Job Files page 3 1 Control Point Files page 3 3 Surface Files page 3 14 Machine Configuration Files page 3 7 Dual GPS Application Setup and Usage page 6 1 Equipment Setup Base Station page 5 2 Machine Setup page 6 3 Dual GPS Antenna Installation page 6 3 GPS Localization page 5 26 Calibrations page 4 1 Valve Offset Calibration page 4 1 Sensor Calibrations page 4 3 Step 2 Dual Antenna Slope page 6 9 Calibration Step 3 Dual Antenna page 6 10 Orientation Calibration Now continue on page 10 6 for further grading information and grading application procedures P N 7010 0491 10 3 Grading Application Table 10 3 mmGPS Setup Checklist Setup Page Number Complete Building Job Files page 3 1 Control Point Files page 3 3 Surface Files page 3 14 Machine Configuration Files page 3 7 mmGPS Application Setup and Usage page 7 1 Equipment Setup Base Station page 5 2 PZL 1 Transmitter Setup and page 7 2 Calibration Machine Setup page 7 7 PZS MC Setup page 7 7 PZS 1 Sensor Setup and page 7 5 Initialization optional Rover setup GPS Localization page 5 26 Calibrations page 4 1 Valve Offset Calibration page 4 1 Sensor Calibrations page 4 3 PZL 1 Transmitter Setup and page 7 2 Cal
90. Move to the next point and press the Enter button on the controller to collect the next point Repeat this step for all points in the polyline 5 At the end of the polyline tap Survey gt Measure pts gt End polyline 6 If collecting three or more points to create a closed polygon tap Survey gt Measure pts gt Close polyline to connect the first and last points A 18 Pocket 3D Getting Started Guide Collecting Data AJ Topcon Pocket 30 4 5 12 Add to layer BOUNDARY New layer Topo shot Topo shot w offset Reference line Start polyline Start tape dimension Options J Topcon Pocket 3D 4 12 45 QD Collect the next point Disconnect from GPS 5 End polyline Close polyline 6 Options Figure A 26 Collect a Polyline Using Pocket 3D on an FC 100 Controller Performing a Survey The following procedure is for performing an auto topo survey based on distance traveled Figure A 27 on page A 20 1 Tap Survey gt Auto topo gt By distance 2 Enter a minimum distance for measuring points and select a method to check the distance between points 3 Select a layer in which to add the surveyed points and enter a point number to start with If desired enter a point descriptor Press Start to collect the first point 5 Travel in a regular pattern to survey the desired area 6 When done tap Survey gt Stop auto topo Rev B A 19 Pocket 3D Gettin
91. NOT pinch the wires Figure 11 14 on page 11 14 P N 7010 0491 11 13 Maintenance CAREFULLY PLACE WIRE CONNECTORS ON TABS TRIM EXCESS TY WRAP PLACE NEW TY WRAP WDaF AROUND WIRES AND TIGHTEN Figure 11 14 Replace Transducer Connectors and Ty Wrap 5 Feed the wires back up into the Sonic Tracker II and seat the Transducer into place the two wire tabs have to sit down into the extra deep area of the recess Place the new O ring around the Transducer and seat firmly between the Transducer and the Sonic Tracker II Transducer recess Figure 11 15 on page 11 15 11 14 System Five 3D Reference Manual Preventative Maintenance TRANSDUCER WIRE CONNECTOR PINS Figure 11 15 Replace Wires Transducer and O ring 6 Place the black Retaining Ring over the Transducer assembly with the beveled edges out and the flat surface against the Sonic Tracker II base Line up the holes for the mounting screws The mounting screw holes are set to an irregular pattern ensuring the retaining ring only lines up with the mounting holes one way Figure 11 16 on page 11 16 7 Start the mounting screws into the holes and tighten each until firm Figure 11 16 on page 11 16 DO NOT OVER TIGHTEN Use a cross X pattern when tightening the screws DO NOT use Loctite on the mounting screws x Loctite will attack and degrade the plastic retaining ring Over tightening the screws can distort the Transduce
92. Refer to your Base Station s documentation for specific radio configuration procedures The Base and Machine must use the same radio settings C Initialize the Base station Once you have set up the Base Station simple checks ensure the machine receives corrections from the Base station if the elevation control key is green the Base Station is ready Figure 5 2 on page 5 5 shows a completed Base Station setup Use a plumb bob for quick and easy setup of the tripod especially if the ground is uneven 5 2 System Five 3D Reference Manual Equipment Setup Base Station Step 1 set up the tripod and GPS receiver antenna over a control point accurately level the tripod as described below 1 Over a control point extend the extension legs of the tripod to suitable lengths Tighten the leg screws 2 Attach the universal tribrach to the tripod securing it in place Figure 5 1 and insert the tribrach adapter into the tribrach 3 Insert the horizontal spacer into the adapter and securely attach the GPS antenna to the spacer HiPer Lite receiver PG A1 antenna a Horizontal Spacer gt Tribrach Adapter precision Sa Universal Tribrach Figure 5 1 Base Station Setup P N 7010 0491 5 3 3D GPS Applications Setup and Usage 4 Roughly Level the Antenna Using the Circular Level Turn leveling screws A and B to move the bubble in the circular level The bubble is now located on a line per
93. Rover pole Then press Adjust again 8 Follow the on screen instructions pressing Next to measure Figure 7 22 If indicated check the setup listed on screen Turn right face of mmGPS Turn back face of mmGPS Turn left face of mmGPS transmitter to receiver transmitter to receiver transmitter to receiver Angle Angle Angle Time to go Time to go Time to go Figure 7 22 Transmitter Adjustment Process P N 7010 0491 7 25 mmGPS Application Setup and Usage When the adjustment completes the Adjustment dialog box displays the offsets Figure 7 23 e If both Axis measurements are less than 10 no adjustment is needed at the transmitter e If either or both Axis measurements are more than 10 disconnect from the sensor and connect to the transmitter Press Finish to upload the adjustments to the transmitter When finished uploading the transmitter will apply the adjustments and turn off AJ Topcon Pocket 3D M 1 46 QD Adjustment Axis 1 0 00 15 Axis 2 0 00 18 Back Finish Cancel Figure 7 23 Adjustment Results l After loading the new self leveling offset data into the transmitter re calibrate to check the system The transmitter may need to be calibrated a couple of times depending on site conditions Note that this process only applies an offset to the self leveling mechanism to ensure correct grade the control point file is not affected 7 26 System Five 3D Referen
94. S Receiver Box Setup for MMGPS Applications 0 0 eee ese ceseceseeeeeeeeeeaees 7 10 Control Box Setup oo eee insnet 7 11 iv System Five 3D Reference Manual Table of Contents Activating mmGPS Control in 3DMC ossee 7 11 Step 1 Apply ammGPS Machine Configuration 7 11 Creating ammGPS Machine Configuration 7 12 Step 2 Copy and or Select the mmGPS Control Point File oo eee eeesseceseceeeeeeeeeees 7 14 Step 3 Setup the PZL 1 Transmitter in 3DMC 7 15 Operations for mMGPS Control seeen 7 16 Changing the PZS MC Settings in 3DMC 7 17 Copying PZL 1 Transmitter Information 0 7 18 Performing a Resection eee ceeeeeeeseeereeneeeeeeeees 7 19 Checking the Transmitter s Height ee 7 22 Transmitter Adjustment 0 elec ese ereeteeeeeeeees 7 23 Viewing a Cut Fill History eese 7 27 Chapter 8 3D LPS Application Setup and Usage 8 1 Equipment Setup GRT 2000 oo eee eeeeseeneeseeeteeeees 8 1 LPS Station Initialization eee eeeeeseerreeeeeeees 8 6 Alternative Methods to Determine LPS Coordinates 8 8 Activating LPS Control in Pocket 3D oe 8 9 Machine Setup sccscservesteee coches e 8 13 LS 2000 Installation cece ceeeeseeeeceeceeeeeeeeeaes 8 13 Blade and Antenna Measurements seen 8 15 Control Box Installation 8 16 Activating LPS Control in 3DMC owes 8 17 Step 1 Apply an LPS Machine Configuration 8 17 Creating an LPS Machine Configuration File
95. S receiver s detection level of the transmitter s signal Channels select the channel to scan for mmGPS connection See page 7 4 for more details Advanced select advanced mmGPS options mmGPS aided initialization select to use the mmGPS signal to assist in initializing the GPS receiver See Activating mmGPS Control in 3DMC on page 7 11 for details Calc weighted mmGPS GPS elevation select to combine mmGPS elevations and GPS elevations See Activating mmGPS Control in 3DMC on page 7 11 for details 7 Tap Ok 7 6 System Five 3D Reference Manual Machine Setup Firmware Advanced v mmGPS aided initialization Calc weighted mmGPS GPS elevation Figure 7 5 Select mmGPS Information Machine Setup When setting up the machine for mmGPS the control box and 3DMC software provides the interface for building machine files entering PZS MC receiver information and selecting channels for one or more transmitters Transmitter information such as serial number Bal description firmware and adjusted status comes from a copied Pocket 3D control point file Except for the mmGPS sensor setup the machine s components are installed as with standard GPS applications see Machine Setup on page 5 10 other exceptions are noted below PZS MC Setup After mounting the PZS MC receiver to the vibration pole use 3DMC to configure the receiver for the machine Figu
96. Thread 5 8 11 in System Five 3D Reference Manual MC A1 Antenna Figure C 8 shows the dimensions of the MC A1 Antenna EE Do e MACHINE MOUNT 1 750 015 DIA 8 00 a oe N FEMALE RF CONNECTOR Figure C 8 MC A1 Antenna Dimensions P N 7010 0491 C 11 Specifications LS 2000 Laser Sensor The LS 2000 Laser Sensor is a rugged waterproof design that detects optical and digital beams has height resolution using the linear sensor and detects conventional rotating lasers Table C 9 lists specification details for the LS 2000 Laser Sensor Table C 9 LS 2000 Laser Sensor Specifications Housing Base cast aluminum Body extrusion plastic Operating 20 to 50 C 4 to 122 F Temperature Waterproof IPX6 Beam Detection 360 Prism Constant 31mm prism constant value 31 Mounting Clamp ID 1 75 in Detector Height 200mm Figure C 9 shows the dimensions of the LS 2000 Laser Sensor 442 mm LS 2000 190 mm Figure C 9 LS 2000 Laser Sensor Dimensions C 12 System Five 3D Reference Manual Round Vibration Pole Round Vibration Pole The Round Vibration Pole has a lightweight shock isolation and vibration dampening design as well as a high vertical range Table C 10 lists specification details for the Round Vibration Pole Table C 10 Round
97. Upon power up the control box applies these settings offsets and calibrations Except for the height of receiver and blade wear calibrations you can use saved calibrations and adjustments for several weeks or months Control Box Connectors The connectors Figure 2 5 supply power to System Five 3D machine and link system sensors and components installed on the machine with the control box A ay a 1 0 Bus E p Valves i ae Port Valves ao RS232 Port Figure 2 5 Control Box Connectors Depending on your control application the connectors used during operation will vary See your control application s chapter for details on connecting cables to the control box P N 7010 0491 2 9 Component Functions 3DMC Functions 3DMC is the software interface between the operator and the machine s components The menus and keys allow files to be created updated superimposed copied or deleted Information and files the operator can access will be stored and continuously updated to the internal memory The main screen Figure 2 6 displays a graphical view of the current design surface the machine and status information of connected components Topcon Logo Menu Zoom In Zoom Out Slope Control Key Elevation Control Key Figure 2 6 Main Screen The main screen has the following components e Display a graphical representation of the design surface and the machine The display varies
98. a Control Point File This section describes how to create the control point file using control point information The control point file created here may be tentative but will provide a beginning from which to create a more thorough file later When creating a control point file neither the receiver box nor any sensors need to be attached or ready to use at this stage The accuracy of measurements for local site a gt coordinates of a control point directly affects the quality of grade Turn on the control box 2 When the 3DMC main screen displays press Topcon Logo gt File gt Control 3 Press New and enter a name for the control point file then press Ok Figure 3 4 Name H Error V Error Name SIMPSON FAMILY RANCH Add Edit Delete Ok gt Ok Cancel Figure 3 4 Press New and File Name 3 4 System Five 3D Reference Manual Control Point Files 4 Select the newly created file and press Edit Then press Add Figure 3 5 SIMPSON FAMILY RANCH SIMPSON S RANCH CONTROL Name H Error V Error Edit u yAdd Edit Delete Ok Cancel Figure 3 5 Edit Selected File 5 Enter the following information for the control point Figure 3 6 e Name enter a unique name e Site coords enter the coordinates for northing N easting E and elevation Z e WGS84 if you have precise GPS coordinates enter the coord
99. a lengthy initialization and or measurement occurred If coordinates are manually entered check that longitudes are correctly prefixed with a minus sign if working in the western hemisphere e g USA Re enter the coordinates The range pole was unsteady If the errors are decimeter level in magnitude it may point to either inaccurately measured local site coordinates or not holding the range pole vertical when measuring the GPS coordinates Inaccurate local site coordinates or erroneous GPS measurement 12 10 If error values of the first few points are reasonable but increase when a new point is measured the point just measured must have either inaccurate local site coordinates or erroneous GPS measurement System Five 3D Reference Manual GPS Localization To isolate the error disable horizontal and or vertical localization for each Control Point in turn and observe the set of errors When the errors become acceptable due to certain isolation the point isolated is most likely to detract from the quality of the localization Also as a general rule if error values of the first few points are reasonable but increase when a new point is measured the point just measured must have either inaccurate local site coordinates or erroneous GPS measurement Once a problematic Control Point is discovered try to re measure the point again to see any improvement If it is still suspect and affe
100. a set of relative information to fulfill the four factors This information is composed of three points A B and an elevation reference point Figure 3 21 on page 3 20 illustrates the basic factors needed for a sloping plane surface model The following is the most common method using three reference points prepared at the site two points A and B are measured to determine a mainfall orientation and the other point elevation reference point is measured to determine an elevation P N 7010 0491 3 19 Building Job Files 0 wv 2 Mainfall ae Orientation gt se ae Reference Point ih Se Grade es BS Ne Grade Crossfall a Orientation Figure 3 21 Sloping Plane Surface Diagram 3DMC accurately measures the point directly below the sensor but does not compensate for a slant error of the sensor mast Therefore for a more accurate measurement keep the mast as vertical as possible when measuring the point 1 Press Topcon Logo gt File gt Surfaces gt Working or Reference and press New Enter and select the following information for the new surface file Press Next Figure 3 22 e Configuration name enter a name for the file e Surface type select sloping plane surface compound slope Configuration nary SlopePlane_1 Surface type Flat plane surface lt 2 New Copy Raise lower existing surface Subgrade of existing road Next Cancel F
101. according to the type of design surface file and selected display options Views include a superimposed triangle mesh contour lines alignment lines and points a partial blade cross section view and a machine profile view The sections in Changing the Display View starting on page 6 3 describe the different displays available to view jobsite information and grade information Units can be in feet or metric Tapping anywhere on the display screen brings up a pop up menu see Pop up Menu on page 2 16 for details 2 10 System Five 3D Reference Manual 3DMC Functions Topcon Logo Key provides access to menus that control a variety of functions See Topcon Logo Key on page 2 13 for more information on the key and its menus Zoom In Key increases the magnification of the design view each time you tap this key The zooming pivot is the center of the screen Zoom Out Key decreases the magnification of the design view each time you tap this key The zooming pivot is the center of the screen Elevation Control Key displays elevation control information and indicates the status of the connected sensor Tap this key to view or edit elevation information See Elevation Control Key on page 2 17 for more information on this key and its menu Slope Control Key displays cross slope control information and indicates the status of the connected sensor Tap this key to view or edit slope information See
102. achine The receiver also features compliance with CMR and RTCM industry standards and has optional advanced multipath mitigation and optional in band interference rejection Table C 7 lists specification details for the Rover GPS Receiver Box Table C 7 Rover GPS Receiver Box Specifications Housing Cast aluminum Weight 12 10 lb 5 5 kg LEDs Three LEDs Power red Satellite status green for GPS green and red GPS and GLONASS Radio status yellow Supply Voltage 10 to 30 VDC Radio Built in UHF or Spread Spectrum Radio Frequency Band UHF 450 to 470 MHz Spread Spectrum 915 Channels 14 for Pacific Crest PDL 6 for TeleDesign TS4000 Channel Switching Manual for Pacific Crest PDL Clear channel scan for TeleDesign TS4000 Baud Rate Up to 38400 bps RTK Update Rate 10 Hz GPS Tracking 20 channels GPS L1 L2 GLONASS Channels P N 7010 0491 Specifications Figure C 7 shows the dimensions of the Rover GPS Receiver Box a Figure C 7 Rover GPS Receiver Box Dimensions MC A1 Antenna The MC A1 Antenna is specifically designed to mount on the machine s blade Table C 8 lists specification details for the MC A1 Antenna Table C 8 MC A1 Antenna Specifications Antenna Type Aluminium ground plane with plastic dome Mounting Clamp ID 1 75 in Mounting
103. acy P N 7010 0491 8 15 3D LPS Application Setup and Usage Control Box Installation The control box is designed for quick attachment at the beginning of the day and quick removal at the end of the day 1 Using the hand knob attach the control box to the bracket Figure 8 13 Figure 8 13 Attach Control Box 2 Connect the various electrical cables Figure 8 14 Cable connections differ depending on the machine type Power Cable Cable to Mainfall Grader 3D LPS Control Power Cable Cable to Valve Cable to Junction Box Dozer 3D LPS Control Figure 8 14 LPS Control Application Control Box Cable Connections 8 16 System Five 3D Reference Manual Machine Setup Activating LPS Control in 3DMC To activate the control box for GPS control applications ensure the correct options have been activated in the control box To check and or update control box options see Viewing and Updating 3DMC Options on page 10 34 for details If needed contact your Topcon dealer with questions The desired control application is activated when selecting or creating a machine configuration file For 3D LPS applications select and enter LS 2000 information and select the location of the GRT 2000 Step 1 Apply an LPS Machine Configuration The Machine Configuration file provides vital information about the type of machine the setup of the components on the machine machine measurements and radio configurati
104. ade Design Cross Slope Figure 2 17 Slope Control Key Adjust Slope in 3D Control To display the following slope settings for 3D applications Figure 2 18 on page 2 23 press the Slope Control Key e Blade slope the current percentage of slope for the blade slope sensor e Blade rotation only for graders the current degree of rotation for the rotation sensor e Mainfall slope only for graders the current percentage of slope for the mainfall sensor e Slope Gain displays the current Valve Gain setting for slope control The Valve Gain setting determines the speed of the hydraulic valve response while in Automatic Control A higher setting speeds up the response a lower setting slows down the response See Adjusting Valve Gain on page 10 19 for details on setting the valve gain 2 2 System Five 3D Reference Manual 3DMC Functions e Slope Locked used to grade at a constant fixed slope keeping the elevation side in 3D control Enabling the check box locks the cross slope to the value entered into the box The cutting edge stays at the same slope until the percentage of slope changes using the Grade Adjustment Knob or entering a new value in the Slope Locked box Blade rotation 2 Blan slope 0 0 Set Mainfall slope 3 9 Slope gain 25 r Slope locked 0 0 Slope gain 45 Set Cok Slope locked 0 0 Set 3D GPS Control Ok Cancel Figure 2 18 Adju
105. ading information and grading application procedures Along with the setup checklist confirm all sensors are communicating and functioning before you start grading Simply check the color of the Elevation and Slope keys on the bottom of the screen e The background color will be GREEN when all sensors function properly e The background color will be RED when a part of the system is working improperly 3DMC will display text or graphical information indicating which sensor is causing the problem e for mmGPS applications the icon color will be BLUE when the system is receiving ammGPS signal and GRAY when a mmGPS signal is unavailable 10 6 System Five 3D Reference Manual Changing the Display View System Five 3D determines the machine s orientation once it begins moving therefore start the machine in motion before switching to Automatic Control After moving a few feet the system will know the machine s location on the project and access the Design Surface to calculate the exact cross slope This feature is especially important on steep slopes Changing the Display View 3DMC can display several types of views each of which contain useful information Some options require specific files provided from the design engineer or other sources on the project Main Window Views Display options for the main window include a Plan view a Section view and a Profile view To access the desired main window view
106. aluminum Pole OD 1 75 in extruded aluminum Range 6 ft 7 1 2 in 201 9cm Weight 29 0 Ibs 13 0 kg Figure C 10 shows the dimensions of the GPS Vibration Pole 2 0 gt pi m lt 1 75 015 4 4 ni Al 92 _ CABLE MOUNT G _ MOUNTING POST K 2 00 NOM l TER E Sg K 12 5 A Te 4 5 m m 11 5 Figure C 12 GPS Vibration Pole Dimensions P N 7010 0491 C 15 Specifications TM 1 Telescoping Mast The TM 1 Telescoping Mast is a heavy duty design with high resolution ramping acceleration and electric brake and feedback servo positioning with no slipping Table C 13 lists specification details for the TM 1 Telescoping Mast Table C 13 TM 1 Telescoping Mast Specifications Housing Base cast aluminum Extension and main tube extruded aluminum Top pole OD 1 75 in DELRIN Travel Range 42in 1 06m Weight 64 Ibs 29 kg Mounting Pins 3 00 in diameter tube 4 bolt plate with dowel Supply Voltage 10 to 32 VDC Power Requirement Operating Temperature Power 10A at 12 VDC 0 to 50 deg C 32 to 122 deg F Over current overload and over voltage protection C 16 System Five 3D Reference Manual TM 1 Telescoping Mast Figure C 13 shows the dimensions of the Round Vibration Pole P N 7010 0491 O
107. ampening P N 7010 0491 1 11 Introduction Figure 1 13 GPS Vibration Pole GPS MC 2 5 Receiver Box In 3D GPS and mmGPS control applications the GPS MC 2 5 Receiver Box Figure 1 14 slides into shock isolated magnetic slots in the trunk of the machine Once installed it requires no manual adjustments and can remain in the trunk compartment The MC 2 5 Receiver Box combines Topcon s GPS receiver module and a radio module into a single rugged housing e When used in conjunction with a Base Station the MC 2 5 Receiver Box provides 3DMC and operator with Real Time Kinematic RTK measurements e When used in conjunction with a the PZL 1 and PZS MC the MC 2 5 Receiver Box provides 3DMC and the machine with millimeter level accuracy 3DMC processes these real time measurements to compute grade and graphical mapping information 1 12 System Five 3D Reference Manual System Five 3D Components Figure 1 14 MC 2 5 Rover GPS Receiver Box Base Station Kit In 3D GPS control applications the Base Station Kit Figure 1 15 sends position corrections to an unlimited number of machines or survey Rovers The kit includes Topcon s Legacy E receiver with PG A1 antenna and radio modem or Hiper receiver tribrach cables and a hard carrying case The type of options on the Base Station kit can be customized based on individual needs some kits support GPS positioning with RTK measurement and others support norma
108. an You must press Ok to save and store Valve Offsets correctly Sensor Calibrations Sensor calibration calibrates the slope control system of the machine s blade The sensors attached to the machine blade rotation and mainfall also need to be calibrated These sensors are attached to moving parts that wear at different rates In order for System Five 3D to work correctly it has to be told what changes have occurred on the machine The control box saves calibration settings in its memory until the operator or technician changes them P N 7010 0491 4 3 Calibrations Grader Cross Slope Calibration For correct grader cross slope the blade slope sensor rotation sensor and mainfall sensor need to be calibrated All three sensors work together to maintain the desired cross slope providing accurate and consistent grade A motor grader machine file must be selected for this function to be available 1 At the control box tap Topcon Logo gt Control gt Calibrate sensors Figure 4 3 oe Rotate blade to chisel marks on frame so that blade is square to machine Press Next to continue Next Cancel Figure 4 3 Calibrate Sensors Blade Rotation Dialog Box 2 Rotate the machine s blade to the chisel marks the installer provided on the A frame assembly Figure 4 4 4 4 System Five 3D Reference Manual Sensor Calibrations Figure 4 4 Rotate Blade to Chisel Marks 3 Press Next
109. and Manual control Mounting Threads 375 16 x 60 inch deep course threads Figure C 3 shows the dimensions of the Simple A M Knob 90 5 io 5 0 Figure C 3 Simple Auto Manual Knob Dimensions C 4 System Five 3D Reference Manual Blade Slope Sensor Blade Slope Sensor The Blade Slope Sensor provides superior accuracy and repeatability is free adjusting and has a rugged sealed design Table C 4 lists component specification for the Blade Slope Sensor Table C 4 Blade Slope Sensor Specifications Housing Cast aluminum Epoxy sealed electronics Supply Voltage 10 to 30 VDC Supply Current 200 mA typical operating current Operating 0 to 60 C 32 to 140 F Temperature Resolutions 0 025 slope Range 9150P 0 to 20 slope 9152P 0 to 100 slope Figure C 4 shows the dimensions of the Blade Slope Sensor r 5 0 Figure C 4 Blade Slope Sensor Dimensions P N 7010 0491 C 5 Specifications Rotation Sensor The Rotation Sensor provides precise angle measurement and has a rugged sealed design Table C 5 lists specification details for the Rotation Sensor Table C 5 Rotation Sensor Specifications Housing Cast aluminum Color Topcon yellow Supply Voltage 5 VDC Supply Current 1 mA typical ope
110. ansmitters to increase the working range of the sensors Using Multiple Transmitters Up to four PZL 1 transmitters can be used for a single job increasing the range of the sensors to cover nearly 8000ft 2438m in distance or up to 130ft 40m of elevation changes When using multiple transmitters you will use 3DMC and Pocket 3D to configure the PZS MS and PSZ 1 for detecting each transmitter see the following chapters for details When using multiple transmitters place each transmitter so that its beam will partially intersect the beam of its neighbor transmitter Figure 1 40 on page 1 37 The PZL 1 transmitters can be placed on either level or hilly ground 1 36 System Five 3D Reference Manual Elevation Control Overview Figure 1 40 Multiple Laser Transmitter Placement Automatic Best fit Blade Control In 3D GPS LPS Control Automatic Best fit Blade Control allows for precision grading when a design surface that has break lines This is an automatic feature of the software developed for System Five 3D The three dimensional Design Surface has of a multitude of triangle planes or poly lines with cross section templates In either case the Design Surface may have several break lines Breaklines can be flow lines in a parking lot shoulders or curbs on a road and in between building pads When an operator needs to grade along these breaklines System Five 3D has the ability to prevent undercutting in
111. ar the cutting edge is from on grade The buttons increase and decrease magnification for this Left window view The Grade indicator view acts as an infinitely scrolling grade tape displaying the amount of cut or fill in regards to the design surface For details on the Grade indicator pop up menu see Changing the Grade Indicator on page 10 16 lt 45 82 ge 17 89 27 0 00 17 88 Figure 10 6 Left Window Views 10 10 System Five 3D Reference Manual Changing the Display View Right Window View Only the grade indicator is available as a view in the right window To access the right window view have the Plan view visible and press Topcon Logo gt View gt Right window Figure 10 9 then tap the desired view a check mark indicates the active view None indicates no right window is active Main window Left window vNone Right window p Grade indicator Lower window Display options About 3DMC Figure 10 7 Lower Window Display Menu Selections Selecting the option adds the indicated view as a window at the right side of the main window Figure 10 8 The Grade indicator view acts as an infinitely scrolling grade tape displaying the amount of cut or fill in regards to the design surface For details on the Grade indicator pop up menu see Changing the Grade Indicator on page 10 16 _ p _ Figure 10 8 Right Window View The selected Right window view will
112. ard facing antenna Connect this cable to the MAIN GPS antenna port on the MC 2 5 receiver box e The auxiliary GPS antenna connection is marked with black indicators and is connected to the rear antenna Connect this cable to the AUX GPS antenna port on the MC 2 5 receiver box 3 Connect the radio antenna cable to the RADIO ANTENNA port Connect the control box cable to the MAIN A port 6 6 System Five 3D Reference Manual Machine Setup Radio Antenna Black Yellow Rear Forward MC 2 5 System Five 3D Figure 6 4 Connect Cables to MC 2 5 Receiver Box and Control Box Control Box Setup The control box is designed for quick attachment at the beginning of the day and quick removal at the end of the day After installing the control box in the cab connect the various cable to the back for communication with the machine s components See Figure 5 11 on page 5 14 for further details C Power cable to first top connector O For graders valve cable to second connector O For graders junction box cable to third connector O For dozers mainfall cable to third connector L MC 2 5 receiver box cable to fourth bottom connector P N 7010 0491 6 7 Dual GPS Application Setup and Usage Activating Dual GPS Control in 3DMC To activate the control box for Dual GPS control applications ensure the correct options h
113. as high as possible for better radio transmission range P N 7010 0491 5 9 3D GPS Applications Setup and Usage Machine Setup Machine setup for GPS control application is quick and easy First install the machine antenna single or dual then install the radio antenna and finally connect the cables MC A1 GPS Antenna Setup The MC A1 GPS antenna is designed for quick setup at the beginning of the day and quick removal at the end of the day Figure 5 6 shows an example of mounting the MC A1 antenna and connecting the antenna cable 1 Ensure the GPS vibration pole is positioned vertically on the blade when the machine is placed on level ground 2 Mount the antenna on the pole and connect the antenna cable to the antenna Tighten the hand knob firmly 3 Connect the GPS antenna cable to the antenna and machine Figure 5 6 rea TOP POLE CLAMP i BOTTOM POLE CLAMP SERVICE LOOP STRAIN RELEIF ADD DUST CAP TO MATING CONNECTOR m e HOOD MOUNT WELD ON L HANDLE INDEXING RING Figure 5 6 MC A1 Antenna Mounting on GPS Vibration Pole Dozer Example 5 10 System Five 3D Reference Manual Machine Setup Blade and Antenna Measurements Take the following measurements for the antenna and machine and record these measurements for entering into 3DMC Figure 5 7 The height of the antenna from the outermost position on the metal rim of the antenna to the cutting edge
114. assigned to the elevation control side make adjustments to the Cut Fill Offset 3D GPS mmGPS Control adjustments made to the Design Surface Each time you press either button the Cut Fill Offset changes one step The outside Raise button raises the moldboard applying a Fill the inside Lower button lowers the moldboard applying a Cut 3D LPS Control adjustments made to the original mast height Each time either button is pressed the height of the TM 1 with the LS 2000 will change by one step The outside Raise button raises the moldboard shortening the mast the inside Lower button lowers the moldboard extending the mast e Adjust Slope Elevation Settings In 2D Control applications the Raise Lower buttons assigned to the elevation control side make measured adjustments to slope or elevation settings Each time you press either button the slope elevation changes by one step The outside Raise button raises the moldboard shortening the measurement the inside Lower button lowers the moldboard extending the measurement Survey Buttons Survey is enabled only when in 2D control and is used to quickly lock on grade The Sonic Tracker will search and trap the stringline curb or any other physical reference The Slope Control System will lock on to and display the slope the moldboard is setting on To activate Survey mode hold both the Raise and Lower buttons for one second 2 26 System Five 3D Refer
115. asurements for dozers and motor graders These values will then be entered during machine setup see Activating Dual GPS Control in 3DMC on page 6 8 Incorrect measurements or data entry errors have a E direct affect on grading accuracy Take each measurement twice to ensure accuracy Dozer Dual Antenna Measurements 1 To measure the height value measure the distance from the cutting edge to the leading edge of the leading antenna 2 To measure the behind value pull a stringline from the top of the pole to the cutting edge keeping the stringline centered to the pole Measure the distance from the stringline to the cutting edge Figure 6 2 3 Measure the distance of the antenna from the right edge of the blade See Figure 5 7 on page 5 11 for an example Measure BEHIND value Measure HEIGHT value Figure 6 2 Measure Antenna for Dozer 6 4 System Five 3D Reference Manual Machine Setup Motorgrader Dual Antenna Measurements edge measure Height and Behind values carefully Incorrect values will cause exaggerated elevation errors when tilted D If mounting the dual antenna behind the cutting 1 To measure the behind value determine the mid range of blade tilt for normal use 2 Loosen the L bar slightly and pivot vibration pole until approximately vertical Tighten the L bar 3 Pulla stringline from the top of the pole to the cutting edge keeping the st
116. ating the equipment Figure 1 10 Mainfall Sensor Hydraulic Valve and Manifold Assembly The hydraulic valves and manifold assemblies Figure 1 11 are mechanically tied into the machine s hydraulic system and are also electrically connected to the control box and should not be removed Initial adjustment is required when first installed and at periodic maintenance The hydraulic valves and manifold assemblies automatically cause electric hydraulic actions to produce the desired grade Figure 1 11 Hydraulic Valve and Manifold Assembly 1 10 System Five 3D Reference Manual System Five 3D Components 3D GPS Components For 3D GPS applications the machine requires a GPS antenna and a GPS receiver A Base Station is installed over a control point to determine corrections and transmit them to the machine MC A1 or MC A2 Antenna In 3D GPS control applications the Rover GPS antenna Figure 1 12 affixes to the top of the GPS vibration pole mounted on the machine s blade These antennas are specially designed to perform on earth moving machinery and should be removed at the end of the day for safety MC A1 MC A2 Figure 1 12 MC A1 and MC A2 Antennas GPS Vibration Pole The GPS vibration pole Figure 1 13 on page 1 12 installs on the machine s blade with several types of mounts The GPS vibration pole provides a lightweight fixed mount for the GPS antennas or PZS MC and utilizes shock isolation and vibration d
117. ation lights built in valve drivers for indicate and proportional automatic control and a motor drive for attachment to the Trackerjack Table C 16 lists specification details for the Laser Tracker Table C 16 Laser Tracker Specifications Housing Base cast aluminum Body polycarbonate Detector Height 5 1 2 in Mounting Thread 5 8 11 in Supply Voltage 10 to 30 VDC Operating Current Typical 200 mA Operating 0 to 60 deg C 32 to 140 deg F Temperature On grade Zone 0 013ft variable with beam spot Beam Acceptance 360 P N 7010 0491 c 21 Specifications Figure C 16 shows the dimensions of the Laser Tracker 3 8 10 0 N O 5 NG Mi gt 6 5 Figure C 16 Laser Tracker Dimensions Trackerjack The Trackerjack has driving capabilities on a Trackerjack Vibration Pole is lightweight and has manual override buttons for pole installation Table C 17 lists specification details for the Trackerjack Table C 17 Trackerjack Specifications Enclosure Cast aluminum Weight 4 7 Ibs 2 13 kg Supply Voltage 12 VDC for 9221 24 VDC for 9220 Operating Current Typical 0 5A Maximum 10 5A C 22 System Five 3D Reference Manual Trackerjack Table C 17 Trackerjack Specifications Operating 0 to 60 deg C 32 to 140 deg F Temperature Figure C 1
118. auses an operation without applying changes or edits However changes or edits on the previous screen will still be applied pear ffigration st PDL UHF New Edit Copy Delete Ok Cancel Back Next Cancel Dialog Box Buttons Figure 2 7 Example Dialog Box Buttons When entering text or numbers one of the following two pop up keyboards displays Figure 2 8 on page 2 13 e Alphanumeric keyboard for entering letters and numbers e Numeric keyboard for entering numbers File and point names can be up to 32 characters long point descriptions up to 64 characters long 9 12 System Five 3D Reference Manual 3DMC Functions When you press OK on the keyboard entered information becomes valid and the keyboard leaves the screen Backspace Negative Sign i Alphanumeric E Keyboard 1 2 3 4 5 6 7 8 9 o0 Q w E R T Yy u i joj A s D F G H I K L 7 g 9l lt lt z x c v B N M i 4 5 6 Space Bar 1 2 3 Numeric Keyboard ol Ok Cancel Accept Entry Cancel Entry Figure 2 8 Keyboards Topcon Logo Key The Topcon Logo key at the top right corner of the Main Screen displays a pop up bar of four menus File Control Tools and View To access the Topcon Logo menus tap the Topcon Logo in the far right corner the four menus display Figure 2 9 Unless used the menus disappear after 10 seconds aay P
119. ave been activated in the control box To check and or update control box options see Viewing and Updating 3DMC Options on page 10 34 for details If needed contact your Topcon dealer with questions The desired control application is activated when selecting or creating a machine configuration file For Dual GPS applications select and enter antenna and radio information Step 1 Apply a Dual GPS Machine Configuration The Machine Configuration file provides vital information about the type of machine the setup of the components on the machine machine measurements and radio configuration information You must have a machine configuration file before beginning to grade 1 Press Topcon Logo gt Control Machine setup 2 Select the desired GPS configured machine file and press Ok 3DMC will connect to the GPS components and the Elevation Control key will display an MC A2 antenna icon Creating a Dual GPS Machine Configuration See Creating a GPS Machine Configuration on page 5 16 for more information on the fields available during machine configuration activities For easy identification later include the application type in the name of the configuration 1 During machine setup select Topcon MC A2 dual from the Antenna list on the lt machine type gt w GPS dialog box Figure 6 5 on page 6 9 2 Enter the measurements taken during antenna setup see Blade and Antenna Measurements on page 6 4 f
120. ce Manual Operations for mmGPS Control Viewing a Cut Fill History For mmGPS applications both 3DMC and Pocket 3D have an option to view the cut fill history of the loaded project In3DMC tap Topcon Logo gt View gt Lower window gt Cut fill history e In Pocket 3D tap Display gt Cut fill history The cut fill window Figure 7 24 displays the on going highs and lows of the project as determined by both laser and GPS readings The red line indicates mmGPS detection the blue line indicates GPS only detection AJ Topcon Pocket 3D 10 48 GD Ks E 116 0 10 Figure 7 24 Cut fill History Windows for 3DMC and Pocket 3D P N 7010 0491 7 27 mmGPS Application Setup and Usage Notes 7 28 System Five 3D Reference Manual Chapter 8 3D LPS Application Setup and Usage 3D LPS applications use an laser transmitter to transmit an optical laser beam at a pre defined elevation a virtual stringline that represents the design surface A laser sensor on the machine detects the beam and establishes the design elevation Through the control box the laser sensor keeps the cutting edge at the correct elevation Daily setup of LPS equipment includes the following Laser Transmitter set up height measured and Laser Transmitter initialized Machine laser sensor and receiver box installed with cables connected to the contro
121. ce eeeeseceseeeeeeeeneeeneeees 10 14 Changing Offsets Using the Control Knobs 10 14 Changing Offsets Using the Elevation Control Key 10 15 Changing the Grade Indicator 0 eee eeeeeeeeereeseeenseees 10 16 Changing the Light Bar Scale 10 18 Adjusting Valve Gain oc ceecesesseesseceseeseeeseeeeecnaeeeeeees 10 19 Checking the Blade s Position ccceccceeseceeeeceeeeeteeees 10 21 Changing Display Options 0 0 eee eeeceseeereeeeeeneeeaeees 10 22 Working Surface Display Options eee eee 10 22 Alignment Display Options 20 0 ce eeeeeeseeneeeneeees 10 24 Linework Display Options s s s 10 25 Point Display Options 0 0 eee escesecsseeeeeeeeeeseenaeens 10 26 Changing the Background Color sses 10 27 Display Units Options 0 0 eee ceeeseceseeeeeeeeenseeneeees 10 28 vi System Five 3D Reference Manual Table of Contents Steering or Grading to Polyline 10 29 Steer to Polyline 35vsvises i iseasedcisaces idee these cdent 10 29 Grade to Polylme vc sticessstadectedesetbssetestetesoenssered blesteecd 10 31 Performing Topographic Surveys sesser 10 32 Viewing and Updating 3DMC Options sesse 10 34 Clearing the MC 2 5 Box NVRAM serere 10 35 Chapter 11 MaINtONnanGe iisssciccscissccensdaasaesscsatabetaundansddedsnadcnsnaann 11 1 Daily Care nren Santina nt ees 11 1 Preventative Maintenance 00 ee eesceseseeeereeeneeeneeeeeeees 11 2 Touch Screen Display Cleaning n se 11 2 Rotation Sensor Clea
122. ceiver Figure 7 19 Connect the sensor and Pocket 3D controller l Use a bi pole to ensure the sensor remains steady throughout the calibration process P N 7010 0491 7 23 mmGPS Application Setup and Usage Hold Plumb Beam Key then turn on power SSS 30 m 100 ft t e ASS SS SSS Figure 7 19 Setup Transmitter and Sensor 5 In Pocket 3D tap Setup gt mmGPS transmitters and press TX Calibration Figure 7 20 If indicated check the setup listed on screen Figure 7 20 Pocket 3D Serial Firmw Adjusted Please check 1 mmGPS transmitter in calibration mode 2 mmGPS receiver is level with mmGPS transmitter Serial Cable on COM1 v 3 mmGPS receiver 100 add Delete rx caltration bownload from mmGPS transmitter Cancel Figure 7 20 Begin Field Calibration Adjustment gt 6 If needed adjust the height of the sensor so the angle is less than 1 Once the angle is ok tap Next Figure 7 21 7 24 System Five 3D Reference Manual Operations for mmGPS Control 7 Press Next to begin the first phase of the adjustment AOT Figure 7 21 Turn front face of mmGPS transmitter to receiver Angle Time to go Figure 7 21 Begin Adjustment If the sensor experiences excessive movement E during any stage of the adjustment an error message will display Press Cancel and stabilize the
123. ceiver and or power may have a problem GPS receiver not connected Causes Solutions Either the GPS signal For GPS signal check cable connections or radio signal is along the GPS antenna cable from the GPS invalid Antenna port on the Receiver Box to the The graphic may Rover Antenna indicate what causes Check connections at the System Five port the problem on the Receiver Box and Connector D bottom on the control box Problem Elevation Control key displays pad displays Solutions Check that the Base Station is working correctly See Base Station on page 12 2 to troubleshoot Base Station problems Also check that the Rover Radio Antenna on the machine and its cable connections are properly connected Make sure that the radio channel is identical between the Base Station and the Machine Rover and that the radio is correctly configured on the control box See Equipment Setup Base Station on page 5 2 and Machine Setup on page page 5 10 for information P N 7010 0491 12 15 Troubleshooting Problem Causes The GPS receiver has not been successful tracking enough valid satellites Elevation Control key displays Waiting for Initialization Solutions Check that the Rover Antenna has a clear view of the sky Check for obstructions such as trees buildings and vehicles that can block or reflect satellite signals The syst
124. check option provides a daily benchmarking tool to verify that the calculated elevation and position are repeatable 1 To check the position of the blade press Topcon Logo gt Tools gt Position check 2 Select the Point of interest either left edge or right edge of blade and press Measure Figure 10 20 the Measuring dialog box displays during measurement Point of interest Right edge of blade O East North Elev Cut to design surface Alignment stationing Measure 4 Cancel Figure 10 20 Select Point of Interest and Press Measure 3 When finished the Position check dialog box displays the point on the job at the selected edge of the blade Figure 10 21 Press OK to return to the Main Screen Point of interest Right edge of blade East 9129 570 North 11267 444 Elev 58 454 Cut to design surface 0 02 Alignment stationing 15 45 465 Measure Cancel Figure 10 21 Position of Point of Interest P N 7010 0491 10 21 Grading Application Changing Display Options 3DMC has several types of display options each of which contain useful information Some options require specific files provided from the design engineer or other sources on the project Available display options depend on the type of files loaded into 3DMC and the type of control application 3D GPS mmGPS or 2D To view available options tap Topcon Logo gt View gt Display options pa
125. choice for communications between Base and Rover receivers Know the strengths and weaknesses of this technology to get the best use out of your receiver The quality and strength of the UHF signals translates into range for UHF communications 1 The system s range will greatly depend on the local conditions Topography local communications and even meteorological conditions play a major role in the possible range of RTK communications If needed use a scanner to find clear channels 2 The system s range will increase by adjusting the Base station s antenna using the following methods e Ensure the Base radio has a fully charged battery e Use directional antennas and or repeaters to increase your system s range Directional antennas concentrate the signal power within a more narrow direction significantly increasing the range of your system e Check the TPS accessory line for items to raise the Base radio D 2 System Five 3D Reference Manual Community of Europe Compliance Community of Europe Compliance The product described in this manual is in compliance with the R amp TTE and EMC directives from the European Community WEEE Directive Following information is for EU member states only The use of the symbol indicates that this product may not be treated as household waste By ensuring this product is disposed of correctly you will help prevent potential negative consequences for the environment and human healt
126. cleaner Do not attempt to repair equipment yourself Doing mull so will void your warranty and may damage the hardware P N 7010 0491 12 1 Troubleshooting Base Station This section lists possible Base Station problems you may encounter also refer to the Base Station s documentation If you still have problems after trying the solutions listed here contact TPS customer support Problem Legacy E or Hiper receiver does not power on Causes Solutions The PWR button was Make sure you hold the PWR button down pressed too quickly for at least one second A quick press will not activate the receiver The power cable is Check that the power cable is correctly incorrectly connected connected to the battery RED to positive or damaged and BLACK to negative and that the battery is charged Check that the RED dots on the power cable connector and the socket on the receiver are aligned and the cable is pushed in as far as it can go If the power cable is damaged contact your dealer to replace it Problem Radio modem does not power on Causes Solutions The power cable is Check that the power cable is correctly incorrectly connected connected to the battery RED to positive or damaged and BLACK to negative and that the battery is charged If the power cable is damaged contact your dealer to purchase a new cable 12 2 System Five 3D Reference Manual Base Stat
127. contains layers composed of a group of lines each identified with a color All layers will be listed in the Linework layers dialog box 1 To display desired layers on the Main Screen select the layer and press Show Yes displays in the Show column Press Show again to not display the layer on the Main Screen No displays in the Show column 2 Press Ok to return to the main screen Figure 10 27 Figure 10 27 Linework Display Main Screen P N 7010 0491 10 25 Grading Application Point Display Options When using a Point file press Topcon Logo gt View gt Display options gt Points to display the Points dialog box Figure 10 28 Layer GROUND Show point symbols on this layer r Show point numbers on this layer Ok _ Cancel Figure 10 28 Points Display Options Point files contain information about surveyed points and may represent topographic information control coordinates as build information etc A point file can contain one or more layers 1 To display the desired points layer on the main screen select the layer and press Ok 2 To display points and or point numbers during a topographic survey select the corresponding check box and press Ok Figure 10 29 Figure 10 29 Topo Points on Main Screen 10 26 System Five 3D Reference Manual Changing Display Options Changing the Background Color Note that changing the background color does not affect the colo
128. cts the acceptable tolerance the horizontal and or vertical localization for this point may be disabled Problem There are no H Error and V Error values Causes Solutions Use for horizontal These check boxes need to be selected for a GPS localization and minimum of three points Note that the or Use for vertical error value will be calculated once three GPS localization Control Points are measured and used for check boxes may not the GPS localization This troubleshooting have been selected is useful when the Pocket 3D is being used to perform GPS localization as well as the control box P N 7010 0491 12 11 Troubleshooting Control Box This section lists possible control box problems you may encounter If you still have problems after trying the solutions listed here contact TPS customer support Problem Causes The cable is the wrong cable incorrectly connected or damaged Problem Causes The fan may be damaged causing the control box to overheat Control box does not power on Screen display turns off by itself Solutions Check that the power cable supplies 12 to 24 VDC and is negative conductive e A socket positive 12 to 24 VDC E socket Ground Check that the power cable is connected to the correct port Control Box Connectors on page 2 9 and the ends are securely fastened If the cable is damaged contact your
129. culation field will increment by one 9 Move to the next point and repeats step 7 and 8 Continue until at least three points evenly located around the transmitter have been measured To clear the measurements and begin again press Reset After three points have been successfully measured horizontal and vertical errors for the measured point will display Further measurements should improve the positional error 10 Press OK when done P N 7010 0491 7 21 mmGPS Application Setup and Usage Checking the Transmitter s Height 1 Set up the transmitter and tripod at an known control point Power on the transmitter and select a channel to transmit on 2 Set up the PZS 1 sensor over a known point Power on the sensor and receiver Connect the sensor and Pocket 3D controller l Use a bi pole to ensure the sensor remains steady throughout the calibration process In Pocket 3D tap Setup gt mmGPS transmitters On the Channel tab press Edit Channel Press Benchmark check Figure 7 17 DN E On the transmitter height dialog box select one of the following and press Start to measure Figure 7 17 During the measurement the Measuring dialog box displays e If the transmitter is set up over a known control point tap the first radio button then select the control point from the drop down list e If the transmitter is set up over a point with a known elevation tap the second radio button then enter the elevation
130. d a smart laser sensor establishes the Design Elevation This system works like a traditional laser control system but control software in the Pocket PC manipulates the laser beam on the GRT 2000 essentially creating a virtual stringline in the air This stringline becomes an exact replica of the Design Surface Figure 1 29 a GRT 2000 Virtual Stringline Figure 1 29 3D LPS Design Control As the machine moves across the jobsite the GRT 2000 tracks the LS 2000 continuously measuring horizontal positions X and P N 7010 0491 1 25 Introduction Y Once the GRT 2000 determines the machine s position on the site the control software accesses the 3D jobsite model provided during setup determining the elevation of the Design Surface at that point The GRT 2000 then emits a fan laser beam that strikes the LS 2000 sensor keeping the cutting edge at the correct elevation As the machine continues over the Design Surface the control software calculates the new elevation and provides a vertical angle adjustment to the GRT 2000 changing the position of the fan beam on the LS 2000 If the fan beam strikes above or below the center of the sensor the hydraulics move the blade up or down to achieve an on grade reading The GRT 2000 also sends additional 3D digital information To communicate the Design Cross slope for the cutting edge to the LS 2000 the GRT 2000 uses a modulated fan beam similar to a lightho
131. d cables connect the receiver to the MC 2 5 receiver box for sending corrections to the 9168 PZL 1 Laser Transmitter The PZL 1 laser transmitter Figure 1 16 on page 1 15 operates similar to a standard rotating laser but transmits a unique signal to provide a working range of 2000ft and a measuring area of 33ft in height Up to four laser transmitters can be linked for use on large sites Each PZL 1 transmitter also supports multiple rovers even at different elevations for continuous production 1 14 System Five 3D Reference Manual System Five 3D Components Figure 1 16 PZS MC Sensor and PZL 1 Transmitter PZS 1 Sensor and GPS Receiver optional The PZS 1 sensor Figure 1 17 instantly computes precise vertical information from the PZL 1 laser transmitter Using Lazer Zone technology the PZS 1 automatically determines elevation based on job site control Mounting the PZS 1 to a range pole and attaching a GPS receiver allows the sensor to receive the PZL 1 laser signal and wirelessly transmit data to the receiver Figure 1 17 Receiver and PZS 1 on Rover Pole P N 7010 0491 1 15 Introduction 3D LPS Components LS 2000 Laser Sensor The LS 2000 laser sensor Figure 1 18 affixes to the top of the TM 1 telescoping mast and should be removed at the end of each day for storage The LS 2000 detects the fan beam laser transmitted from the GRT 2000 and sends digital s
132. de at long distances e Ground vibration from e Laser movement from machinery working near the blowing wind laser transmitter e Atmospheric conditions Calibration error 1 34 System Five 3D Reference Manual Elevation Control Overview 2 Keep the laser transmitter as low as possible Keeping the laser transmitter low where you can reach it will make setup and occasional adjustments easier The transmitter and laser receiver on the machine will also be more stable On windy days you may need to anchor the tripod to keep the laser transmitter from moving The laser transmitter does not need to be above the machinery on the job The benefits of keeping it low as well as GPS capabilities far outweigh the momentary loss of the laser beam due to passing equipment On small projects place the laser transmitter off the working area Figure 1 38 The working distance from your laser will indicate the type of project small or large Figure 1 38 Laser Transmitter Placement Small Project P N 7010 0491 1 35 Introduction On larger projects place the laser transmitter in the center of the project to maximize the area you can grade and minimize the distance from the laser Figure 1 39 The working distance from your laser transmitter will indicate the type of project large or small Figure 1 39 Laser Transmitter Placement Larger Project For particularly large projects you can use up to four PZL 1 laser tr
133. determine the difference between the cutting edge and the design surface and control the blade to move just the right amount of material Daily setup of GPS equipment includes the following Base Station set up antenna height measured and Base Station initialized Machine GPS antenna radio antenna and receiver box installed with cables connected to the control box Control point surface and machine setup files selected in 3DMC P N 7010 0491 5 1 3D GPS Applications Setup and Usage Equipment Setup Base Station The Base Station always sets up over a Control Point on the jobsite to ensure accuracy the Base Station GPS antenna must be positioned directly over the top of the Control Point The Base Station can be set up and taken down on a daily basis or can be mounted on a permanently fixed pole and left for the duration of the project A permanent setup prevents errors due to incorrect antenna height measurements When setting up the Base station make sure you select the correct point from the control points file and verify the point has a northing easting and elevation coordinate The more accurate these coordinates are the tighter the control while grading Use the following checklist for quick setup of the Base Station C Select a control point and install the Base station over it Measure the antenna height Connect all Base Station components and cables 0o00 Select the correct radio settings
134. ditional components to the tripod Figure 5 2 Attach and or prepare additional Base Station components These components will vary depending on the type of base station e For the HiPer Lite base station attach a power source optional e For the PG A1 base station attach the radio modem radio antenna GPS receiver and power source i PG A1 Base Station with HiPer Lite Base Station Legacy E GPS receiver Figure 5 2 Base Station Setup Step 3 connect component cables to the receiver Legacy E or HiPer Lite then connect the cables to other components Figure 5 3 on page 5 6 e If using Bluetooth wireless technology to connect a controller and the HiPer Lite receiver refer to the controller s or receiver s documentation P N 7010 0491 3D GPS Applications Setup and Usage e Connect the following cables for the following components to the Legacy E receiver then to component GPS antenna connect the antenna cable to the receiver s ANT port then to the GPS antenna Power connect the power cable to the receivers PWR1 or PWR2 port Attach the alligator clamps to the battery RED to positive BLACK to negative Radio Modem connect the radio modem cable to the receiver s port C and the radio modem Connect the other end to the battery Controller connect the cable with 7 pin circular connector to the receiver s port A Connect the other
135. djacent road surface as well as the sidewalk The Single point on blade method forces blade slope and elevation to be that of a single point on the design surface The operator must specify the location of the point on the blade using the slider bar and while grading ensure the blade is positioned so that the point remains on the desired surface e g sidewalk To illustrate this in the sectional sub view a small red arrow indicates where the controlling point position on the blade see The Section view on page 10 8 for details on this view To use this method simply measure a distance from the end of the blade to the desired point then enter this value into the Blade Control dialog box simply drag the pointer across the screen to the measured value see Setting Blade Control on page 5 19 for details P N 7010 0491 1 39 Introduction Notes 1 40 System Five 3D Reference Manual Chapter 2 Component Functions The components of the System Five 3D work together to provide the control needed for precise grading applications The System Five 3D is capable of dual hydraulic control and is used in the following applications In 3D GPS mmGPS and 3D LPS Control with grader applications one side of the control box directs elevation control and the other side directs slope control The operator selects the side to use for elevation con
136. dulations in the grade or sharp blade movements can also cause tracking loss especially at short distances Problem Causes The RC 2 is not connected to the GRT 2000 RC 2 remote does not resume tracking If this is the case balance the material in manual control then change back to automatic when the grade is somewhat close to the Design Surface Solutions First check that RC 2 CONNECTED displays when powering up the GRT 2000 and that you answer YES The GRT 2000 does not ask to if an RC 2 is connected If there is no message the internal search settings are incorrect contact customer support to enable the RC setting The RC 2 is outside its working range being blocked or moving excessively The RC 2 working range is up to 250 meters Prevent obstacles from interfering with the infrared beam pass Hold the remote controller steady as its emitting window faces toward the GRT 2000 especially great distances 12 6 System Five 3D Reference Manual Rover GPS Receiver Box Reflective object interfere with the transmission of the infrared beam Try not to shoot through the cab s window glass If there is a prism e g backsite close to the machine or in close alignment on the machine move away and try again The searching parameters in Pocket 3D and on the GRT 2000 are incorrect Change the searching parameters for RC 2 usage a
137. e 8 3 This measurement will be used when initializing the GRT 2000 using Pocket 3D Figure 8 3 Measure Base Station Antenna Height P N 7010 0491 8 5 3D LPS Application Setup and Usage LPS Station Initialization Once the GRT 2000 Robotic Total Station has been setup and Pocket 3D has been loaded with an equipment configuration file determine the LPS station s position coordinates and set the circle orientation using either e an accurate geometric measurement of a backsight e an accurate geometric measurement of several resection points The following method gives one way to determine the location of the LPS Station on the jobsite Alternative Methods to Determine LPS Coordinates on page 8 8 provides additional methods for locating the station on the jobsite Incorrect measurements or data entry errors directly affect grading accuracy Before initializing the GRT 2000 check the Units used in the current jobsite Setup Units and that the correct Control Point file is selected Data gt Control If needed create an equipment file in Pocket 3D see Step 1 Create an Equipment Configuration File on page A 10 for details Figure 8 4 on page 8 7 shows the procedure listed below 1 In Pocket 3D tap Setup gt Station setup 2 Select Known station amp BS pts from the drop down list and press Next See Alternative Methods to Determine LPS Coordinates on page 8 8 for a descrip
138. e centerline as the reference surface The new cross section consist of grade elements with the same user defined grade value Figure 3 31 as the subgrade If the cross section of the new subgrade intersects those of the reference grade the subgrade will show a new feature line Dotted lines in the section window indicates surface information outside of the last feature line gt 1 721 0 002 682 f r0 516 etm 0 000 Figure 3 31 New Road Subgrade 3 28 System Five 3D Reference Manual Editing the Road Subgrade Editing the Road Subgrade On most road surfaces the cross slopes for the finish design surface will be different than the subgrade design slopes Quickly changing the elevation or grade of the current road surface will allow you to grade at the correct slope elevation This function is only available if the reference surface is a road surface 1 2 Press Topcon Logo gt Control gt Road subgrade Select the road surface to use as the reference from which to create the surface Enter an elevation adjustment Figure 3 32 on page 3 30 e A positive number raises the subgrade in comparison to the working reference surface e A negative number lowers the subgrade in comparison to the working reference surface e This value will be applied to the centerline of the working reference surface Select the type of grade Figure 3 32 on page 3 30 e If selecting Manual enter the percentage of the left righ
139. e moldboard raises or lowers the tracker measures exactly how far it is above or below the desired grade reference Built into the Tracker is an operational zone or Working Window 2 feet above and below the grade reference Figure 1 31 on page 1 28 The grade lights on the Sonic Tracker and control box continuously display this grade information to the operator P N 7010 0491 1 27 Introduction NO CORRECTION MADE OUT OF WORKING WINDOW SLOW BLINKING UP ARROW amp SOLID UP ARROW COARSE 2 a BLINKING UP ARROW CORRECTION y lt BLINKING UP ARROW ON GRADE AUTOMATIC S i ON GRADE L i i a BLINKING DOWN ARROW ON GRADE 2 __ BLINKING DOWN ARROW a SOLID DOWN ARROW FINE CORRECTION AUTOMATIC SLOW BLINKING DOWN ARROW Figure 1 31 Sonic Tracker Working Window e If the Tracker is on grade the cutting edge will be at the desired grade e If the moldboard and the Tracker start to raise the Tracker and control box indicate a down correction arrow and apply lower hydraulic valve corrections to bring the Tracker back to on grade e If the moldboard and Tracker start to lower the Tracker and control box indicate a raise correction arrow and apply raise hydraulic valve corrections to bring the Tracker back to on grade e If the Tracker side shifts off a stringline or sees an obstruction closer than the reference signal the Tracker is out of
140. een when receiving data from the Base Station typically once per second Main LED and FN Button power and satellite indicator When the MC 2 5 box is hooked up to power but is not connected to a GPS antenna and therefore not tracking any satellites only the red LED blinks When the MC 2 5 box is attached to an MC A1 GPS antenna green blinks indicate the number GPS satellites being tracked while red blinks indicate Glonass satellites A pause precedes each repetition of blinks Pressing the FN button changes the Main receiver board s information mode between Normal Mode and Extended Information Mode See below for details e Aux LED and FN Button only active in dual GPS applications Main LED Red Green Aux Function Button P O O LEA Radio RX LED Red Green Figure 2 25 MC 2 5 GPS Receiver Box Indicators Main Function Button 2 30 System Five 3D Reference Manual MC 2 5 GPS Receiver Box Functions In normal mode the LED indicates the number of tracked satellites and the position s computation status The MC 2 5 receiver box also has an extended information mode EIM used for receiver testing purposes In this mode the receiver continues to work as usual but the LED indicates extended information using a delimiter The delimiter is a distinguishable double blink that shows the overall status of tests performed in EIM The LED color for delimiter is calculated from the co
141. el marks Figure 6 7 Square Blade with Yellow Antenna Arrow Forward 2 Drive the machine several feet forward and in a straight line System Five 3D will calculate a heading during travel and display the result in the Machine orientation field Figure 6 8 3 Once the machine orientation has been determined usually 10 to 15 seconds press Match to orient the antenna to the machine Figure 6 8 Press Ok to complete the calibration MC A2 Alignment Antenna slope 0 Zero Machine orientation i Antenna orientation 0 Matc With blade perpendicular drive machine forward to estimate machine orientation Ok Cancel Figure 6 8 Orient Machine and Antenna to Same Alignment 6 10 System Five 3D Reference Manual Machine Setup Recommended Tilt Angles for the MC A2 Elevation accuracy with GPS depends on the ability of the GPS antenna to see the satellites As the antenna tilts some satellites will no longer be in view and the ability of System Five 3D to consistently calculate precise elevations reduces accordingly Before grading with different tilt angles determine the GPS accuracy range for the dual antenna This accuracy range is the degree to which the antenna can tilt without affecting grade accuracies While GPS conditions vary generally the accuracy range is between 15 backward and 15 forward Figure 6 9
142. el vial being slightly unlevel with the instrument base In this case place the bubble symmetrically at both positions C1 and C2 in Figure 8 1 A me Figure 8 1 Leveling Vial and Screw Example P N 7010 0491 8 3 3D LPS Application Setup and Usage Step 2 attach the controller and power source and connect the cables Figure 8 2 1 Connect the controller cable with the 3 pin circular connector to SIG port Connect the other end to the controller Connect the power cable with the 2 pin circular connector to the DC IN port Connect the alligator clamps to the battery RED to positive BLACK to negative AER GRT 2000 Pocket PC Tripod Control sm Point Figure 8 2 GRT 2000 Setup 8 4 System Five 3D Reference Manual Equipment Setup GRT 2000 Step 3 start the GRT 2000 1 Press the POWER key to turn on the GRT 2000 and allow the instrument to go through its zero set routine 2 Turn on the Pocket 3D controller Before proceeding further you may need to E perform a field inspection and calibration of the GRT 2000 to ensure proper finish grade See GRT 2000 Inspection and Calibration on page 11 9 for inspection and calibration details Step 4 measure the GRT 2000 from the control point to the center index of the GRT 2000 using the slant distance shown in Figur
143. elect the following information for the new surface file Press Next Figure 3 27 e Configuration name enter a name for the file e Surface type select raise lower existing surface Configuration nary NewSurface_1 Surface type Flat plane surface Sloping plane surface New Copy Raise lower existing Mirface Subgrade of existing road Next Cancel Figure 3 27 Create New Surface File 2 Select the surface to use as the reference from which to raise or lower the new surface Figure 3 28 on page 3 25 3 24 System Five 3D Reference Manual Surface Files 3 Enter an elevation adjustment Press Next Figure 3 28 e A positive number raises the surface above the existing surface e A negative number lowers the surface below the existing surface Existing fiurface LAGOS Elevation adjustment 10 000 Figure 3 28 Select Existing Surface and Enter Adjustment 4 Press Finish to save the new surface file and end the process Creating a Subgrade of the Existing Road On most road surfaces the cross slopes for the finish design surface will be different than the subgrade design slopes Creating a subgrade surface of an existing road will allow you to enter the cross slopes required to pave at the correct slope 3DMC accurately measures the point directly below the sensor but does not compensate for a slant error of the sensor mast Therefore for a more accurate
144. em is still in the process of determining a solid position Problem Out of design area Causes The machine is out of the Design Surface area Problem No GPS localization Causes The Control Points file currently selected has not been localized properly Elevation Control key displays Elevation Control key displays If this is the very first time operation this message may persist for several minutes while the Legacy E or Hiper obtains a new almanac Solutions Make sure that the correct Control Point File and Design Surface file is selected Move into the Design Surface area so the operator can start grading Solutions Make sure that the correct Control Point file currently is selected 12 16 System Five 3D Reference Manual Control Box You are in a process of Disregard the message until the localization building a Control Point file or just starting the process Problem Slope Control key displays Slope sensor not connected Causes Cross slope system is not connected properly Problem Elevation Control key displays LS2000 not connected Causes The incorrect cables or cords are used is complete See GPS Localization on page 5 26 to perform localization Solutions Check cable connections from the Connector C on the control box third from the top the Mainfall Sensor the Rotat
145. ence Manual Chapter 4 Calibrations Calibrating machine components ensures accurate consistent and efficient grading Operators or technicians perform calibrations in the following instances e Upon initial installation of machine components e After servicing the system performing maintenance or replacing a component e When the machine no longer cuts the correct cross slope e For Blade Trim on motorgraders on a daily basis to ensure the most accurate grading possible e After installing an MC A2 antenna or PZS MC antenna on the machine Valve Offset Calibration The valve offset calibration determines the minimum electrical signal required to begin moving the machine s hydraulic cylinder to return the cutting edge to on grade Valve offsets simple determine electrical requirement valve gain determines the speed of the cylinder System Five 3D requires four valve offsets which must be individually calibrated upon initial setup or after hydraulic maintenance If valve offsets are set too low the cutting edge will not reach on grade Likewise if the valve offsets are set too high the cutting edge will move too far and overshoot on grade P N 7010 0491 4 1 Calibrations Factory preset for valve offsets 0 Elevation and Slope Valve Gains If Valve Offset is altered Valve Gain adjustments need to be performed again an Perform Valve Offset calibrations before adjusting perform Valve Offset calibrations a
146. ence Manual Remote Smart Knobs Operation Swap Buttons The swap operation is enabled only when in 2D control and is activated when pushing the left side toggle switch inward for one second Swap performs two functions at once it reverses the sensor functions being used from one side of the machine to the other Essentially the Slope Control System reverses the direction of fall and switches the side of the machine controlling elevation Swapping machine sensor function sides is commonly used when turning the machine around at the end of a pass Figure 2 22 Notice that the slope of the blade is the same Despite the direction of the machine When you swap sensor control sides Front View Back View Figure 2 22 Swapping Sensor Sides The swap function only affects sensor control not elevation control For example if the current elevation setting on the left side is 0 0 ft and the right side is 0 5 ft activating the Swap function leaves the left side elevation at 0 0 ft and the right side elevation at 0 5 ft control from the left to right side the elevation grade setting used previously on each side remains the same D Although Swap switches elevation and slope P N 7010 0491 2 27 Component Functions Set Points Buttons In 2D Control applications only the right knob controls the Set Points feature This feature allows the operator to preset up to 3 different elevation and slope settings Operator
147. ensor applying valve offsets enabling 2D control 2 14 System Five 3D Reference Manual 3DMC Functions Table 2 3 3DMC Menus Description Continued Menu Available Functions Control menu 3D LPS applications Machine setup Blade control Road subgrade Steer indication Calibrate sensors Blade trim Valve offsets 2D Control creating editing copying and deleting machine setup files e selecting the steering indication e selecting the station control point over which the GRT 2000 is installed e calibrating the slope sensor making blade wear adjustments to the cutting edge e applying valve offsets e enabling 2D control Control menu 2D applications Machine setup Calibrate sensors Blade trim Valve offsets 2D Control creating editing copying and deleting machine setup files e calibrating the slope sensor e applying valve offsets e disabling 2D control Tools menu Topo survey Position check Configure radios e collecting topographic points e checking the position e configuring the radio The Tools menu is not active for 2D applications View menu Main window Left window gt Right window gt Lower window Display options gt About 3DMC e displaying Plan Section and Profile views in the Main Window e viewing a left window that displays the Profile Section or Grade
148. ents and radio configuration information You must have a machine configuration file before beginning to grade 1 Press Topcon Logo gt Control Machine setup 2 Select the desired mmGPS configured machine file and press Ok 3DMC will connect to the machine components and the Elevation Control key will display a PZS MC sensor icon P N 7010 0491 7 11 mmGPS Application Setup and Usage Creating a mmGPS Machine Configuration See Creating a GPS Machine Configuration on page 5 16 for more information on the fields available during machine configuration activities For easy identification later include the application type in the name of the configuration 1 During machine setup select GPS antenna from the Sensor list on the Configuration name type dialog box Press Next 2 Select Topcon PZS MC mmGPS from the Antenna list on the lt machine type gt w GPS dialog box Figure 7 8 3 Enter the measurements taken during antenna setup see Blade and Antenna Measurements on page 7 9 for details Press Next ae Antenna eee Se eos a Above 1 11 79 Inside 2 4 92 Behind 3 0 00 Width 4 9 84 Back Next Cancel Figure 7 8 Enter MC A2 Antenna Information During Machine Setup 4 Select the desired GPS precisions for measuring moving and static points Press Next to continue 5 Enter radio information and press Next 6 Select Lazer Zone informatio
149. er programs or software supplied by TPS or downloaded from a TPS website the Software in connection with the receiver constitutes acceptance of these Terms and Conditions in this Manual and an agreement to abide by these Terms and Conditions The user is granted a personal non exclusive xii System Five 3D Reference Manual Terms and Conditions non transferable license to use such Software under the terms stated herein and in any case only with a single receiver or single computer You may not assign or transfer the Software or this license without the express written consent of TPS This license is effective until terminated You may terminate the license at any time by destroying the Software and Manual TPS may terminate the license if you fail to comply with any of the Terms or Conditions You agree to destroy the Software and manual upon termination of your use of the receiver All ownership copyright and other intellectual property rights in and to the Software belong to TPS If these license terms are not acceptable return any unused software and manual CONFIDENTIALITY This Manual its contents and the Software collectively the Confidential Information are the confidential and proprietary information of TPS You agree to treat TPS Confidential Information with a degree of care no less stringent that the degree of care you would use in safeguarding your own most valuable trade secrets Nothing in this paragraph s
150. er surveying setup provides a GPS receiver radio and a laser sensor in one package for various site checking activities GPS Base Station Setup The Base Station always sets up over a Control Point on the jobsite to ensure accuracy the Base Station GPS antenna must be positioned directly over the top of the control point When setting up the Base Station make sure you select the correct point from the control points file and verify the point has a northing easting and elevation coordinate The more accurate these coordinates are the tighter the control while grading P N 7010 0491 7 1 mmGPS Application Setup and Usage for detailed instructions on setting up the Base D See Equipment Setup Base Station on page 5 2 Station for GPS applications Use the following checklist for quick setup of the Base Station C Select a control point and install the Base station over it Measure the antenna height Connect all Base Station components and cables 0o00 Select the correct radio settings Refer to your Base Station s documentation for specific radio configuration procedures The Base and Machine must use the same radio settings C Initialize the Base Station using Pocket 3D Once you have set up the Base Station simple checks ensure the machine receives corrections from the Base station if the elevation control key in 3DMC is green the Base Station is ready PZL 1 Transmitter Setup and Calibration
151. eration ce eeeeeeeeeees 2 29 MC 2 5 GPS Receiver Box Functions 2 30 Chapter 3 Building Job Files sssseeeeeeeeeeeeeeeeeeeeeeeeeeeeees 3 1 Copying 3D MG Biles cri sees nati ee Geese ie Uaioe etal 3 1 Control Point Piles 2 25 ctseai nee hive iver deve dines 3 3 Selecting a Control Point File oo ee eeeeeeeneeees 3 3 Creating a Control Point File 0 ee eeeeesecneeees 3 4 Machine Configuration Files ccc eeeceseeeeeeereeneeeeseees 3 7 Selecting a Machine Configuration o 3 7 Creating a Machine Configuration 0 cece 3 8 Selecting Jobsite Files oo eee esecsseeeeceeeeeeeeeeeseeees 3 13 Surface Files inune aide ahd eee eee 3 14 Selecting Surface Files o e 3 15 Creating a New Plane Surface File 0 eee eeeee 3 16 Creating a Flat Plane Surface oseere 3 17 Creating a Sloping Plane Surface n se 3 19 Raising or Lowering the Existing Surface 3 24 ii System Five 3D Reference Manual Table of Contents Creating a Subgrade of the Existing Road 3 25 Editing the Road Subgrade o eee eeececeeeeeeeeeneeeeees 3 29 Chapter 4 Calibrations iiwsacasisctolsncbuties cacaniaeiabicewsdantasnadantaunenene 4 1 Valve Offset Calibration ie ceeceeeeseeereeeeceeeeeneeees 4 1 Sensor Calibrations sesei iieceiicriieteiiieririse ienien 4 3 Grader Cross Slope Calibration oseese 4 4 Dozer Cross Slope Calibration s es 4 7 Method One Measure the Cutting Edge
152. es from third party sources directly into the Control Computer See Entering Localized GPS Coordinates on page 5 28 for this procedure Entering Localized GPS Coordinates GPS localization is processed in the control point file created prior to beginning each project This control point file contains the formula necessary for the mathematical conversion between global GPS coordinates and NEZ coordinates The control point file can be localized by entering global GPS coordinates directly into the 9168 control box One of the following sources can measure points and provide coordinates e Each control point is measured with a Topcon GPS or GPS RTK Survey Rover System and Pocket 3D e A third party source provides GPS coordinates If the control point file in 3DMC needs to be updated with localized coordinates the operator can enter global GPS coordinates directly into the 9168 control box The control box then processes the localization as the operator sits in the cab Because this method deals with control point files see Creating a Control Point File on page 3 4 for further information 5 28 System Five 3D Reference Manual GPS Localization 1 Power on the control box and allow the 3DMC application program start up Have the measurements for each Control Point available 2 Press Topcon Logo gt File gt Control Points The Control point files dialog box displays Figure 5 28 3 On the Control point files dia
153. etails Operations for mmGPS Control Some 3DMC operations such as setting blade control viewing GPS information and changing the radio s channel are only available while in GPS control Other application independent functions are discussed in Chapter 10 Operations for GPS Control on page 5 19 discusses the following GPS specific 3DMC operations in more detail e Setting blade control via the Profile view or the Topcon Logo gt Control gt Blade control menu option e Viewing GPS information via the Elevation Control key e Changing Radio Channels The following sections describe mmGPS specific operations such as performing a resection or calibrating the PZL 1 transmitter Both 3DMC and Pocket 3D when enabled for mmGPS include an option to view the on going highs and lows of the project as determined by both laser and GPS readings 7 16 System Five 3D Reference Manual Operations for mmGPS Control Changing the PZS MC Settings in 3DMC If needed you can use 3DMC to temporarily change the settings of the PZS MC sensor The original settings from the machine configuration file will be restored after turning off then back on the control box 1 At the control box press Topcon Logo gt Control PZS MC receiver and select the following receiver parameters Figure 7 13 on page 7 18 e Receiver port select the port used for GPS communication at the MC 2 5 Receiver Box usually Serial Port C e Receive
154. ference Manual Machine Setup e From right for dozers enter the distance of the antenna from the outer edge right side of the blade e Beyond for graders enter the distance of the antenna beyond the outside edge of the blade e Behind enter the distance of the antenna behind the blade e Width enter the width of the blade Antenna ALIAN Above 1 11 79 Above 1 11 79 Inside 2 4 92 Behind 3 0 00 Width 4 9 84 Back Next Cancel Figure 5 14 Enter Antenna Information Incorrect measurements or data entry errors have a direct affect on grading accuracy P N 7010 0491 5 17 3D GPS Applications Setup and Usage 5 Select the desired GPS precisions for measuring moving and static points Press Next to continue Figure 5 15 Max GPS errors roving Max Horizontal RMS 0 20 Max Vertical RMS 0 30 Max GPS errors point measurement Max Horizontal RMS 0 10 Max Vertical RMS 0 20 Back Next Cancel Figure 5 15 Enter GPS Precisions Information and Save File 6 Select radio information and press Next Figure 5 16 e Radio type use the same radio type used at the Base Station e Connected to the serial port the radio is connected to usually Serial Port B e Baud rate usually 38400 e Format use the same format used during Base Station setup usually CMR Radio type Pacific Crest
155. file by Pocket 3D controller remotely via radio link Radio type Pacific Crest PDL UHF Baud rate Cancel Figure A 14 Select In Cab Display Option Step 2 Setup the Station Tap Setup gt Station Setup Select a setup method Press Next Enter or select backsight setup parameters and press Next Enter station coordinates and press Finish Sight the backsight and press OK The backsight results display oe Go ho Bcket 3D 44230 Setup method known station amp Instrument height 6 56 Units Equipment Backsight has prism Station setup ght 5 00 stant 0 00 Station coordinates North 5000 00 East 5000 00 100 00 M Sight backsight and press OK to start measurement Next Cancel Elev Back Finish Cancel Ok Figure A 15 Setup LPS Station Cancel Rev B A 11 Pocket 3D Getting Started Guide Step 3 Setup the LS 2000 Receiver 1 Tap Setup gt LS2000 Receiver 2 Follow the instructions on each screen Press Next to continue 3 Enter height of receiver and press Finish Equipment Station setup LS2000 receiver J topcon Pocket 3D 9 53p R LS2000 height measurement is complete Press Finish to accept the new height Topcon Pocket 3D 8 52p 9 05p 1k Topcon Pocket 3D
156. following information Figure 5 23 on page 5 23 e Satellite plot displays used and unused satellites and the current mask angle Blue dots GPS satellites Red with cross dots GLONASS satellites Black dots unused satellites Red mask circle satellites inside will be used for positioning e Mask angle enter the mask angle for the jobsite 5 22 System Five 3D Reference Manual Operations for GPS Control Fix Position Satellites Info Planning Mask angle Figure 5 23 GPS Info Satellites Tab View Receiver Information or Reset Receiver The JD tab displays the following Figure 5 24 e Identification information firmware revision and radio link information type latency and quality for the receiver e Reset receiver press to clear all data and reset all settings stored for the GPS receiver e Reset RTK press to reset RTK ambiguities Fix Position Satellites Info Planning Receiver ID 1234567 Firmware Version 2 2 Radio link CMR age 3s 100 Reset RTK Figure 5 24 GPS Info ID Tab P N 7010 0491 5 23 3D GPS Applications Setup and Usage Satellite Planning Information The Planning tab displays the estimated grading precisions on an hourly scale Figure 5 25 e Press the Next key to display the chart for the next day e Press the Prev key to display the chart for the previous day The Planning tab provides useful infor
157. g Started Guide opcon Pocfet 3D 42 33 Min distance 5 00 Check dist to last point Check dist to all points Disconnect from GPS Measure pts By time GROUND Stop auto topo By elevation aea aE Stake out Polyline St eran I y Starting from 14127 r a Pt descriptor Cancel Figure A 27 Perform an Auto topo Survey by Distance Performing a Stakeout Among the most common stakeouts performed with Pocket 3D are point and surface check stakeouts Staking out Points Tap Survey gt Stake out gt Point list 2 Select the layer and the point to stakeout Press Ok If needed travel to the point using the main screen directions 3 Position the Rover at the point and tap Survey gt Stake out gt Measure stake After measuring the point view the results 4 To stakeout the next point in the list press Next Figure A 28 on page A 21 A 20 Pocket 3D Getting Started Guide Performing a Stakeout LECTRIC 4 Description A NTZOV34Y NTZOV34 Point list Alignment Polyline Coordinate Measure stake Control point Stake out previous point Create custom point list Stake out next point V Surface Offset 1 000 V Surface Offset 1 000 Option i b A 0 000 Offset Fior Elev 6 908 Fill 2577 991 Pt number 1440 Pt descriptor NTZOV34Y Stop stake
158. ge 10 22 Main window Left window Right window Lower window Working surface Display options Linework About 3DMC Points Background color Display units Figure 10 22 Display Options All Working Surface Display Options When using a TIN surface model file press Topcon Logo gt View gt Display options gt Working Surface to display the Working surface dialog box Figure 10 23 Alignment centerline color Alignment feature line color Color Show regular station lines Color r Show station labels Station interval 50 000 Ok Cancel Figure 10 23 Working Surface Display Options 10 22 System Five 3D Reference Manual Changing Display Options This dialog box has the following selections for displaying information on the main screen Figure 10 24 e Show triangle mesh displays triangle lines on the Main Screen according to the TIN Surface Model e Show boundaries breaklines displays boundary lines and breaklines outlining the Working Surface e Show contours at intervals displays contour lines on the main screen tap the entry box to display the numeric pop up keyboard and specify the elevation spacing interval between lines e Color press to display the Color Selection dialog box Tap a color to select it and press Ok You can change the color of the alignment centerline alignment feature line and the station line to the operator s preference o
159. guration file or select an existing machine configuration file and press Edit 3 Enter or select the following configuration and equipment parameters Figure 5 13 Then press Next e Configuration name enter a name for the machine For easy identification later include the application type e Machine type select the type of machine e Sensor select the type of sensor attached to the machine GPS antenna e Location select sensor s location on the machine middle for dozers left or right for graders e Units of measure select the unit of measure meters feet inches centimeters or feet inches DOZER 2D Dozer D6 GPS dual Configuration nameltype rader rg oP3 Configuration name LPS MACHINE MMGPS SYS 5 3D DOZER GPS Machine type Bulldozer J Sensor type GPS antenna New Euit Copy De Mounting location Middle of blade Ok Units of measure Feet Next_ Cancel Figure 5 13 Creating the Machine File 4 Select and enter antenna information then press Next Figure 5 14 on page 5 17 When entering measurements use the same units of measure selected in the previous step e Antenna select the type of antenna e Height enter the height of the antenna above the cutting edge Use the most vertical distance between an outermost position on the metal rim of the antenna and the cutting edge 5 16 System Five 3D Re
160. h which could otherwise be caused by inappropriate waste handling of this product For more detailed information about the take back and recycling of this product please contact your supplier where you purchased the product or consult P N 7010 0491 D 3 Regulatory Information Notes D 4 System Five 3D Reference Manual Appendix E Warranty TPS laser and electronic positioning equipment are guaranteed against defective material and workmanship under normal use and application consistent with this Manual The equipment is guaranteed for the period indicated on the warranty card accompanying the product starting from the date that the product is sold to the original purchaser by TPS Authorized Dealers During the warranty period TPS will at its option repair or replace this product at no additional charge Repair parts and replacement products will be furnished on an exchange basis and will be either reconditioned or new This limited warranty does not include service to repair damage to the product resulting from an accident disaster misuses abuse or modification of the product Warranty service may be obtained from an authorized TPS warranty service dealer If this product is delivered by mail purchaser agrees to insure the product or assume the risk of loss or damage in transit to prepay shipping charges to the warranty service location and
161. hall restrict you from disclosing Confidential Information to your employees as may be necessary or appropriate to operate or care for the receiver Such employees must also keep the Confidentiality Information confidential In the event you become legally compelled to disclose any of the Confidential Information you shall give TPS immediate notice so that it may seek a protective order or other appropriate remedy WEBSITE OTHER STATEMENTS No statement contained at the TPS website or any other website or in any other advertisements or TPS literature or made by an employee or independent contractor of TPS modifies these Terms and Conditions including the Software license warranty and limitation of liability SAFETY Improper use of the receiver can lead to injury to persons or property and or malfunction of the product The receiver should only be repaired by authorized TPS warranty service centers Users should review and heed the safety warnings in an Appendix MISCELLANEOUS The above Terms and Conditions may be amended modified superseded or canceled at any time by TPS The above Terms and Conditions will be governed by and construed in P N 7010 0491 xiii Preface accordance with the laws of the State of California without reference to conflict of laws All information illustrations and applications contained herein are based on the latest available information at the time of publication TOPCON reserves the right to make
162. he Legacy E is properly connected to the radio If the cable is damaged contact your dealer to purchase a new cable The radio does not have a TX LED Some radios may not have a TX Transmit LED so the radio may in fact be functioning The radio has a TX LED but it is not yet flashing All radio types specifically listed for the Base Station kit have a TX light and should flash every second It may take several seconds after connection for this flashing to commence LPS Station This section lists possible LPS Station problems you may encounter If you still have problems after trying the solutions listed here contact TPS customer support Problem Causes The cable is incorrectly connected or damaged The GRT 2000 does not power on Solutions Check that the power cable is correctly connected to a fully charged battery RED to positive and BLACK to negative A weak battery can cause intermittent errors If the power cable is damaged contact your dealer to purchase a new cable The fuse may be blown Check that the fuse placed in the base plate of the GRT 2000 is not blown 12 4 System Five 3D Reference Manual LPS Station Problem Pocket 3D does not communicate with the GRT 2000 Causes Solutions The GRT 2000 may be Check that they are turned on turned off or may have no power The cable may be The GRT 2000 serial cable gray 3 pins incor
163. he machine s position and orientation as well as the distance between the cutting edge and finish grade e Translates user input into system commands e Communicates with system sensors processes information e Sends correction signals to the machine s hydraulic system e Acts as a personal computer to support digital data The surface of the touch screen has a durable gt coating but avoid contact with metal or abrasive objects Prevent hardware from contacting the display Do not rub or force dust from the surface Avoid striking the display with heavy or sharp objects The following sections more thoroughly describe the various features and functions of the control box and 3DMC software 9 2 System Five 3D Reference Manual Control Box Control Box Front Panel The control box front panel Figure 2 1 includes components for viewing grade information adjusting the grade and making 3DMC selections Auto Operation Indicators ae N R AUTO e Grade Grade Indicators Indicators Grade Grade Adjustment Adjustment Direction T Direction Arrows And 9 Arrows And Knob Knob Display Brightness Touch Screen Sensor Display Figure 2 1 Control Box Front Panel Automatic Operation Indicators The automatic operation indicators the AUTO LEDs located above the grade indicators illuminate when activating one or both Auto Manual switches for automatic grade control The AUTO LEDs are inde
164. hine name to easily identify the configuration e Machine type select the type of machine e Sensor select the type of sensor attached to the machine e Location select the sensor s location on the machine e Units of measure select the unit of measure used to take machine measurements meters feet inches centimeters feet inches Configuration name mmGPS Dozer Machine type Bulldozer d Sensor type GPS antenna New Edit lean eg Mounting location Middle of blade Units of measure Feet 4 o ____ gt Net Cancel Figure 3 9 Enter Sensor Information 3 8 System Five 3D Reference Manual Machine Configuration Files 3 Select and enter the following antenna information then press Next Figure 3 10 When entering measurements use the same units of measure selected in the previous step e Antenna select the antenna type e Above 1 enter the height of the antenna from the outermost position on the metal rim of the antenna to the blade e Inside 2 enter the distance of the antenna from the outer edge right side of the blade e Behind 3 enter the distance of the antenna behind the blade e Width 4 enter the width of the blade Antenna Topcon PZS MC mmGPS Above 1 lt 11 79 Inside 2 4 92 Behind 3 0 35 Width 4 9 84 Back Next Cancel Figure 3 10 Enter
165. ial Port D eee HIPER MMGPS 2 Sensitivity Auto DOZER MMGPS Channels All Set HIPER MMGPS to be the Advanced v current equipment This will cancel all measurement operations mmGPS aided initialization that may be active Calc weighted i New Edit Copy J Delete Save As Back Next Cancel Figure A 8 Enter Radio and mmGPS Information Set As Equipment Step 4 Setup the Rover Radio Configuring the range pole Rover radio Figure A 9 ensures proper communication with the Base 1 2 Tap Setup gt Radios Select the radio type and enter its communication settings If needed press Configure to select the channel Press Ok Radio type Pacific Crest PDL UHF ch anne T Connected Serial Por Frequency 464 550 Mhz Baud rate 38400 on Pocke o7 ok Equipment Format CMR Advanced Antenna Base station Units Exit Back Next Set Cancel Figure A 9 Enter Radio Parameters Rev B A 7 Pocket 3D Getting Started Guide Step 5 Setup the Rover Antenna Setup the Rover antenna s type and measurements Figure A 10 1 Tap Setup gt Antenna 2 Select the type of antenna and enter its measurement information Press Ok Base station Units Exit amp F Topcon Pocket 3D 1 41 ok Antenna type Antenna heiaht 6 56 Measured to Rim Units Feet
166. ibration Step 3 Setup the PZL 1 page 7 15 Transmitter in 3DMC Now continue on page 10 6 for further grading information and grading application procedures 10 4 System Five 3D Reference Manual Table 10 4 3D LPS Setup Checklist Setup Checklists Graders Only Setup Page Number Complete Building Job Files page 3 1 Control Point Files page 3 3 Surface Files page 3 14 Machine Configuration Files page 3 7 3D LPS Application Setup and Usage page 8 1 Equipment Setup GRT 2000 page 8 1 Activating LPS Control in page 8 9 Pocket 3D Operations for LPS Control page 8 24 Activating LPS Control in page 8 17 3DMC Calibrations page 4 1 Valve Offset Calibration page 4 1 Sensor Calibrations page 4 3 Blade Trim Adjustments page 4 10 Now continue on page 10 6 for further grading information and grading application procedures P N 7010 0491 10 5 Grading Application Table 10 5 2D Setup Checklist Setup Page Number Complete Building Job Files page 3 1 Control Point Files page 3 3 Machine Configuration Files page 3 7 2D Application Setup and Usage page 9 1 Machine Setup page 9 1 Activating 2D Control in page 9 7 3DMC Calibrations page 4 1 Valve Offset Calibration page 4 1 Sensor Calibrations page 4 3 Blade Trim Adjustments page 4 10 Graders Only Now continue on page 10 6 for further gr
167. icator The Grade Indicator acts as an infinitely scrolling grade tape and displays the amount of cut or fill in regards to the design surface To view the grade indicator press Topcon Logo gt View gt Left window gt Grade indicator This process applies to both the left and right Grade Indicators To change the grade display press and hold the grade indicator for one second tap Grade display then the desired option This option applies a cut fill reference for a position on the screed e Best fit the grade tape allows for precision paving when a design surface has break lines Only available if Automatic best fit whole blade is selected from the Blade Control dialog box in the Control menu e At left edge the grade tape follows the position at the left edge of the screed e In from edge the grade tape follows a position on the screed an entered distance from the left edge Tap to display the numeric pop up keyboard to enter a distance from the left edge The In from edge selection determines the point on the screed to measure regardless of where the elevation point is located Example At Left Edge When using the Left Edge Figure 10 14 on page 10 17 the grade tape will follow the cut fill status of the left side of the screed regardless if elevation reference point is at the middle or right edge of the screed The cut fill number in the elevation control key is tied directly to the Elevation Refere
168. ign Control For example If grading begins on a flat surface and then moves to grading up a 5 hill System Five 3D calculates the slope of the mast Once you begin grading uphill System Five 3D knows the mast tips backward at a 5 slope making the proper calculations to maintain the correct grade With the added accuracy of RTK providing quick corrections from the Base Station the Cut Fill Reading precisely provides in real time the difference between the cutting edge and the design elevation Figure 1 27 During Automatic Control the control box continuously sends corrections to the hydraulic valve based on the Cut Fill readings The hydraulic valve then raises or lowers the blade keeping the Cut Fill Reading at or very close to zero allowing the machine to accurately cut grade anywhere on the Design Surface 2 Continuously computing a Design Cross slope based on the machine s orientation and location P N 7010 0491 1 23 Introduction As the construction design from the site project the Design Cross slope is the true grade The Design Cross slope precisely provides in real time the desired slope on the design surface System Five 3D continuously provides calculated Cross slope readings using measurement information provided from the Slope Control System sensors the Blade Slope Rotation and Mainfall sensors The control box continuously sends corrections to the hydraulic valve to tilt the blade keeping the cross s
169. ignals to the 9168 for grade control information and adjustments Figure 1 18 LS 2000 Laser Sensor TM 1 Telescoping Mast In 3D LPS control or 2D laser control applications the TM 1 Telescoping Mast Figure 1 19 on page 1 17 installs on the machine s blade with several types of mounts The TM 1 Mast provides a fast accurate and rugged mounting platform for the laser receivers The height can be remotely adjusted from the 9168 1 16 System Five 3D Reference Manual System Five 3D Components Figure 1 19 TM 1 Telescoping GRT 2000 Robotic Total Station The GRT 2000 Figure 1 20 on page 1 18 is a remote instrument independent from the machine The GRT 2000 is a robotic auto tracking total station combined with a fan beam laser capable of transporting digital control data specifically for three dimensional positioning It also performs the same functions as an individual surveying instrument so it can be utilized on any typical surveying project The GRT 2000 instrument should be stored in its carrying case at the end of each day and set up at the beginning of the next day When setting up the GRT 2000 you must enter the height of the instrument for accurate grade control P N 7010 0491 1 17 Introduction Figure 1 20 GRT 2000 Robotic Total Station 2D Components For 2D applications either sonic or laser technology can be used for grading accuracy For sonic control a sonic tracker and str
170. iguration Pocket 3D creates an equipment configuration for a range pole Rover Figure A 6 to Figure A 8 A Rover can be used to check and verify grade 1 After initializing the Base connect the Pocket 3D controller to the Rover GPS receiver Tap Setup gt Equipment 2 Tap New Enter a configuration name and equipment information Press Next Maqnine files Configuration name HIPER MMGPS11 Machine type Equipment Range pole F Radios Sensor GPS Antenna v Antenna Location Base station Top of poe Units New Edit Copy Delete a i Rename Save As Units 5 Exit _ Figure A 6 Enter Configuration Type 3 Enter antenna information for the range pole Press Next 4 Enter radio information Press Next AJl Topcon Pocket 30 41 36 Radio type 3 Antenna type Pacific Crest PDL UHF Topcon HiPer Plus mmGF v Connected to Serial Port C Antenna height 6 6 Baud rate 38400 Measured to Base Fomai CMR Connection Pocket 3D Serial Cable on COM1 v Cancel Cancel Figure A 7 Enter Antenna Information and Measurements A 6 Pocket 3D Getting Started Guide Equipment Setup GPS For ammGPS Rover PZS 1 and receiver enter mmGPS parameters Refer to the Pocket 3D User s Manual for important information about these settings Press Next Select the configuration and press Ok Press Yes Pocket 30 GPS port Ser
171. igure 3 22 Create New Surface File 3 20 System Five 3D Reference Manual Surface Files 2 Move the machine to point A and position the sensor on the cutting edge on the selected point 3 When the cutting edge rests on the point press A to measure the point Figure 3 23 the Measuring dialog box displays during the measurement process 4 Move to B point and position the sensor on the cutting edge on the selected point 5 When the cutting edge rests on the point press B to measure the point Figure 3 23 the Measuring dialog box displays during the measurement process Once the A and B point measurements finish 3DMC determines the mainfall orientation and grade connecting the A measurement toward the B measurement see Figure 3 21 on page 3 20 If needed you can re measure the points 3DMC saves the A and B point coordinates separately Also it allows the operator to manually type in a desired grade by pressing the entry box A positive sign designates an upgrade from A to B and the negative sign designates a downgrade from A to B Point on surface Main fall A gt B N Direction 0 00 00 E Grade View Measured Main A A J B J fall Direction and Grade Measure pt Grid interval cros Sloping Plane Surface 50 00 Gra Point on surface Main fall A 3 gt N Direction 315 37 54 Back gt JN E Grade 1 697 a TEEN Measure pt Grid interval Crossfall 5
172. iles and Linework files Import and export files Perform stakeouts and grade checks Perform topographic surveys P N 7010 0491 1 21 Introduction TOPCON Figure 1 26 Pocket 3D on Topcon s FC 100 Elevation Control Overview System Five 3D provides several types of elevation control using 3D GPS mmGPS 3D LPS and 2D control systems This section discusses the concepts and functions behind each control system application as well as gives an overview of the functions behind slope control automatic control of the blade and control using a single point on the blade 3D GPS Control Overview 3D GPS Control controls grade elevation with three processes comparing the cutting edge and design elevation computing design cross slope based on machine orientation and location and knowing prior and coming grade surfaces 1 Comparing the elevation of the cutting edge to the elevation of the Design Surface or design elevation 1 22 System Five 3D Reference Manual Elevation Control Overview Since GPS measurements are made at the Rover GPS antenna you must enter the antenna s offset elevation to know the elevation at the cutting edge Figure 1 27 When measuring an elevation System Five 3D assumes the antenna is perpendicular to the Design Surface Offset from Antenna to Cutting Edge Design Surface Elevation of Cutting Edge TES Design Elevation Figure 1 27 3D GPS Des
173. inates for latitude Lat longitude Lon and height Hgt e Localization check boxes only enable these if currently performing a GPS localization 6 Press OK to save this control point Name MAGGE Control point Site coords WGS84 ee MAGGIE N 2065148 01 Lat Site coords WGS84 E 6178836 88 Biton N 2065148 01 Lat _N37 39 32 75938 Z 376 79 Hgt E 6178836 88 Lon W121 49 21 40995 Z 376 79 Hgt 295 40 Use for horizontal GPS localizati Use for vertical GPS localization E Use for horizontal GPS localization z Use for vertical GPS localization Measure Ok A l Measure Ok Cancel Figure 3 6 Control Point Coordinates Without and With GPS Localization P N 7010 0491 3 5 Bu ilding Job Files Press Add on the Control points dialog box and repeat steps 5 and 6 on page 3 5 for all control points After adding all control points Figure 3 7 press OK to save the control points file Name H Error V Error MAGGIE LISA BART MARGE HOMER Add Edit Delete Ok Cancel Figure 3 7 Save Control File After Adding Control Points Data entry errors have a direct affect on grading accuracy will result in losing all information and require you an You must press Ok to save the file Failure to do so to repeat the process 6 System Five 3D Reference Manual Machine Configuration Files Machine Configuration
174. ingline or some other consistent reference line is all that is required For laser control a laser sensor on the machine tracks the beam emitted from a rotating laser set at a specific plane Sonic Tracker II The Sonic Tracker II Figure 1 21 on page 1 19 attaches to an L bar on the moldboard and should be removed at the end of each day for storage The Sonic Tracker contains no manual adjustments and may require periodic maintenance of the transducer The Sonic Tracker measures distance controlling grade from a physical grade reference such as a curb stringline or existing road surface adjusting the elevation of the moldboard A transducer located in the bottom of the Tracker generates sound pulses like a speaker and listens for returned echoes like a microphone 1 18 System Five 3D Reference Manual System Five 3D Components Figure 1 21 Sonic Tracker Il Laser Tracker and Trackerjack The Laser Tracker attaches to the Trackerjack Figure 1 22 which then mounts onto a vibration pole The Laser Tracker and Trackerjack should be removed at the end of each day for storage The Laser Tracker receives a signal from a rotating laser then sends that signal through the Trackerjack and to the control box Figure 1 22 Laser Tracker and Trackerjack P N 7010 0491 1 19 Introduction LS B2 and LS B4 Laser Sensors The LS B2 or LS B4 Laser Sensor Figure 1 23 attaches to a vibration pole or the TM 1 mast The Laser
175. ings 2 Select the desired channel number The frequency of the channel changes automatically depending on the selected channel 3 Press Set to activate and save the new radio channel setting The radio setting program may take a few seconds to a few minutes to program and complete the process P N 7010 0491 5 25 3D GPS Applications Setup and Usage Channel 6 Frequency 464 650 Mhz Set Cancel Figure 5 27 Radio Configuration Information l If you have difficulty connecting to the radio module when changing radio configurations disconnect the radio antenna cable at the MC 2 5 receiver box Signals from the Base Station s radio can interfere with the machine s radio when making changes GPS Localization After you have setup all the hardware components and initialized the Base Station you need to localize the GPS coordinates to the jobsite s coordinates This section gives information on the principles of GPS localization and methods of GPS localization as well as the procedures needed to localize using either the Pocket 3D and an RTK Rover system or the control box and Rover 3D machine Principles of GPS Localization The GPS system is capable of precise positioning but the positions it computes are relative to a global reference system defined in terms of a geographic latitude longitude and height above a representation of the earth s surface To be useful for local site work global
176. ion The radio receives power through the Legacy E receiver Problem Causes The Legacy E or Hiper may be off The cable may be incorrectly connected Problem Causes The cable is incorrectly connected or damaged Pocket 3D does not connect to Legacy E or Hiper Pocket 3D is waiting for satellites Some radios do not require a separate power supply but are supplied power through the port on the Legacy E For these radios check that the Legacy E is also switched on Solutions Check that the Legacy E or Hiper is switched on Check that the cable is connected to the COM port on the computer and Port A on the Legacy E If still no connection try to reset the computer and repeat Solutions Check that the Legant antenna cable is not cross threaded and is screwed in all the way If the cable is damaged contact your dealer to purchase a new cable The antenna has poor PDOP Check that the LegAnt antenna has a clear view of the sky The receiver is collecting an almanac If this is the first time connecting to the Legacy E or if an internal reset has recently been performed this message may persist for several minutes while the Legacy E obtains a new almanac P N 7010 0491 Troubleshooting Problem Causes The cable is incorrectly connected or damaged Radio modem light is not flashing Solutions Check that the cable from t
177. ion Sensor and to the Blade Sensor Solutions Make sure the correct coil cords are used The cable connections may be incorrect or loose Problem Elevation Control key displays Waiting on data from GRT Causes The LS 2000 is not receiving correct position data on the fan beam from the GRT 2000 Check cable connections on the LS 2000 the TM 1 the Junction Box and the Connector C on the control box Solutions If the machine is close to the GRT 2000 move away from it and check the progress of the machine Check that the Pocket PC is working properly and ensure that the correct Design Surface file is selected in the Pocket 3D P N 7010 0491 12 17 Troubleshooting Problem Causes 2D Control sensor is not properly connected Elevation Control key displays ELEV sensor not connected Solutions Use the correct coil cord Ensure the cable connections between the Mainfall Sensor grader or the Junction Box dozer and the elevation sensor are correct and secure Use the correct location at the Mainfall Sensor or the Junction Box to connect the coil cord For example when direction the right side for elevation control use the right side connector on the Mainfall Sensor to connect the coil cord Wrong control mode selected If in 3D GPS or 3D LPS Control deactivate 2D Control Mode select Topcon Logo gt Control gt 2D Control
178. ion against harmful interference in residential installations This equipment generates uses and can radiate radio frequency energy and if not installed and used in accordance with the instructions may cause harmful interference to radio communications However there is no guarantee that interference will not occur in a particular installation If this equipment does cause interference to radio or television equipment reception which can be determined by turning the equipment off and on the user is encouraged to try to correct the interference by one or more of the following measures e Reorient or relocate the receiving antenna e Move the equipment away from the receiver e Plug the equipment into an outlet on a circuit different from that to which the receiver is powered e Consult the dealer or an experienced radio television technician for additional suggestions P N 7010 0491 D 1 Regulatory Information expressly approved by the party responsible for compliance could void your authority to operate such equipment Any changes or modifications to the equipment not UHF Radio Usage D Using a UHF radio requires a license Operating a UHF radio without a license may result in fines or other penalties Be sure you comply with all local laws before operating a UHF radio Contact your local authorities such as the FCC in the United States for details Surveying in RTK mode has made UHF the most popular
179. ive 3D Components Sensor and Hydraulic Components Blade Slope Sensor The blade slope sensor Figure 1 8 is installed on the machine s blade and should not be removed other than for service and has no manual adjustments The blade slope sensor provides precise slope measurements of the cutting edge The control box provides steps to calibrate the sensor To ensure correct slope perform a sensor calibration before operating the equipment Figure 1 8 Blade Slope Sensor Rotation Sensor The rotation sensor Figure 1 9 is installed on the hydraulic swivel of a grader s blade and should not be removed other than for periodic maintenance and has no manual adjustments The rotation sensor provides precise angle measurements of the blade s rotation allowing the operator to rotate the blade at any time while the System Five 3D continues to maintain an accurate cross slope To ensure correct angles perform a sensor calibration before operating the equipment Figure 1 9 Rotation Sensor P N 7010 0491 1 9 Introduction Mainfall Sensor The mainfall sensor Figure 1 10 typically mounts on the main frame of a motor grader and should not be removed other than for service and contains no manual adjustment The mainfall sensor provides precise slope measurements in the direction of machine travel and serves as a junction box to sensors and hydraulic valves To ensure correct slope perform a sensor calibration before oper
180. k several feet away from the transmitter and face the sensor towards the transmitter Figure 7 15 SS 10 ft SS ee SS Figure 7 15 Setup Transmitter and Sensor In Pocket 3D tap Setup gt mmGPS transmitters On the Channel tab press Edit Channel Tap the Resection button on the channel setup dialog box Figure 7 16 on page 7 21 If desired enter the following measurement parameters on the resection dialog box Figure 7 16 on page 7 21 e Duration secs enter the duration in seconds in which to measure the point e H Precision V Precision enter a horizontal vertical precision in the project s units with which to measure the point 7 20 System Five 3D Reference Manual Operations for mmGPS Control The point name will be automatically added to the list of control points as TX n Resected where n is the channel number Subsequent resections with the same transmitter will overwrite any previous points ik Channel 2 Pt TX 2 Resected Transmitter x Control point Ps Measured pts Duration secs 1 H Precision 100 V Precision 150 ight 5600 TX height 5 600 status Measured to Mark Slant Pts in calculation 0 Benchmark check H Error Resection V Error Cancel Figure 7 16 Begin Resection 8 Press Measure The Measuring dialog box displays during the measurement When done the Pts in cal
181. l GPS positioning with RTK measurement If used with a portable foundation like a tripod daily setup and daily height measurements are required HiPer Lite Legacy E Base Station Base Station Figure 1 15 Base Station Kit P N 7010 0491 1 13 Introduction mmGPS Components Topcon s Lazer Zone and Millimeter GPS mmGPS products provide unparalleled measuring accuracy at the jobsite and is up to 300 more accurate than standard GPS The Lazer Zone transmitter provides wide vertical measurement area of 600m 2000ft diameter and 10m 33ft height The system provides multiple rover support for machine and pole mounted sensors and the technology works with existing Topcon GPS systems In addition to standard GPS components Base Station and MC 2 5 Receiver Box mmGPS applications consists of two primary machine components the PZL 1 transmitter set up over a control point and the PZS MC sensor installed on the machine A PZS 1 sensor on a range pole with a GPS receiver provides survey rovers with the same mmGPS functionality as the PZS MC PZS MC Sensor The PZS MC Figure 1 16 on page 1 15 replaces the machine mounted GPS antenna The PZS MC combines the MC A1 GPS antenna with laser sensor technology into a total package Lazer Zone technology allows the sensor to detect up to four different PZL 1 transmitters for increased range The sensor attaches to a GPS vibration pole on the machine blade an
182. l Overview o eeeeeeeseceteceeeeeteeees Slope Control Overview cceeecesseeseceseceeeeeeeeees Blade Slope Sensor ee ceeeeeceeeeeseeereeeneeeeeeeees Rotation SEnsOr eines aneii Mainfall S nsoryc s csceevescatiesteoteeehschesnttutecessccenss mmGPS Control Overview ccececceessecesteceeneeeeeees Placing Transmitters at the Jobsite 0 Using Multiple Transmitters 00 0000 Automatic Best fit Blade Control ee eeeeeeeeees Control Using Single Point on Blade ee P N 7010 0491 Table of Contents Chapter 2 Component FUNCTIONS sseeeeeeeeeeeeeeeeeeeeeees 2 1 Control S10 SEE aeoieleiwensieve sels 2 1 Control Box Front Panel 0 0 cece eeeeeeceseeeeeneeenseens 2 3 Control Box Back and Side Panels cece 2 7 Control Box Connectors ee eeeeseceseeeneeeeeeneeeeeees 2 9 SD MG Functions eieiei no eneeier 2 10 Using SDMO aee naeta a ea oa ia Eeee 2 11 Topcon Logo Key oo eee n 2 13 PopsUp Menu seriinin ee eA e 2 16 Elevation Control Key sesseeseseseeererresrereresresrsen 2 17 Adjust Elevation in 3D GPS Control 2 19 Adjust Elevation in 3D LPS Control 0 0 0 2 20 Adjust Elevation in 2D Control s s s 2 21 Slope Control Key oo cece ceeeeseeeeceseceeeeseeeaeecnaeens 2 21 Adjust Slope in 3D Control sassen 2 22 Adjust Slope in 2D Control sassen 2 23 ADOUE DMG Nehre o e ieee tele nadie 2 24 Remote Smart Knobs Operation sesers 2 25 Simple Auto Manual Knob Op
183. l box Control point surface and machine setup files selected in 3DMC Equipment Setup GRT 2000 The LPS Station consists of the GRT 2000 and Pocket 3D installed on the Pocket PC For precise grading the GRT 2000 must have accurate coordinates for its location and an accurate azimuth angle for its orientation on the project When you set up the LPS Station over a known Control Point this point must be included in the Control Point File used for the project This Control Point must have complete northing easting and elevation values to be useful as a station point To setup an LPS station accurately measure the height of the GRT 2000 over the Control Point then determine the station position and circle orientation and finally select the appropriate Control Point in P N 7010 0491 8 1 3D LPS Application Setup and Usage the Pocket 3D Once set up simple checks ensure that it successfully transmits information to the machine Refer to the GRT 2000 Instruction Manual for specific GRT 2000 setup and operation information Figure 8 2 on page 8 4 shows a completed GRT 2000 setup l Use a plumb bob for quick and easy setup of the tripod especially if the ground is uneven Step 1 set up the tripod over a control point accurately leveling the tripod as described below 1 Place the tripod over the Control Point station point and center the head plate roughly plumb to the ground point 2 Attach the universal tribrach to
184. l differences are within acceptable tolerances if using a prism measurement then press Ok 8 Press Finish to store the coordinates and initialize and set the LPS Station P N 7010 0491 8 7 3D LPS Application Setup and Usage orientation resets and a new initialization will be required If the GRT 2000 is powered off accidentally or unintentionally the initialization procedure must be performed again D Each time you turn off the GRT 2000 the circle EF Topcon Pocket 3D 6 37p a amp F Topcon Pocket 3D 4 43p a Backsight Station coordinates MAGGIE 2063953 55 Differences 6178537 18 H Angle 0 00 16 437 42 V Angle 00 00 08 S Dist Figure 8 5 GRT 2000 Initialized Alternative Methods to Determine LPS Coordinates When you reach step 2 page 8 6 of the initialization process you can choose from several options screen 2 in Figure 8 4 on page 8 7 to determine the station s position and the circle orientation The following is a description of the different methods available to determine the LPS Station s coordinates e Known station and backsight points The most common method Select a station point and backsight point from the list of Control Points for the job site Specify if a check to a prism on the backsight is required e Known station and backsight azimuth Choose a station point from the list of Control Points and enter an azimuth value for the orie
185. l offsets e Adjusting the valve gain e Viewing different displays e Steering and grading to polylines Once you have your System Five 3D control application components setup you can also perform surveys and create design files This chapter also discusses e Performing topographic surveys e Creating a plane surface model Setup Checklists Before beginning to grade at the job site the operator should review setup procedures and ensure all steps have been completed for the type of control application See the following checklists e 3D GPS Control Table 10 1 on page 10 2 e mmGPS Control Table 10 3 on page 10 4 e Dual GPS control Table 10 2 on page 10 3 e 3D LPS Control Table 10 4 on page 10 5 e 2D Control Table 10 5 on page 10 6 P N 7010 0491 10 1 Grading Application Table 10 1 3D GPS Setup Checklist Setup Page Number Complete Building Job Files page 3 1 Control Point Files page 3 3 Surface Files page 3 14 Machine Configuration Files page 3 7 3D GPS Applications Setup and Usage page 5 1 Equipment Setup Base Station page 5 2 Machine Setup page 5 10 GPS Localization page 5 26 Calibrations page 4 1 Valve Offset Calibration page 4 1 Sensor Calibrations page 4 3 Blade Trim Adjustments page 4 10 Graders Only Now continue on page 10 6 for further grading information and grading application procedures 10 2 System Five 3D Reference
186. l times DO NOT allow moisture to get inside the case Moisture trapped in the case can adversely affect components 2 System Five 3D Reference Manual Radio Usage Information If moisture does enter the Carrying Case leave it open and allow it to thoroughly dry before storing any components Radio Usage Information All users must obtain an FCC Federal Communications Commission license before operating the GPS system GPS RTK Real Time Kinematic or simultaneous calculation of Global Positioning System and Global Navigation Satellite System The Federal Communications Commission is at http www fcc gov e The rules are at http www access gpo gov nara cfr waisidx_00 47cfr90_00 html There have been many problems in the past with RTK base radio modems interfering with voice users The issue finally culminated with the FCC refusing to grant licenses until something was done to ensure that surveyors did not interfere with voice users The solution was to stop using frequencies in the 469MHz range to add an identifier to the broadcast message and other measures designed to minimize interference with voice users The user and his employer are subject to fines of up to 82 500 confiscation of surveying equipment and legal action if the rules are ignored Topcon cannot obtain the license for the user There are companies to assist with licensing Two are listed here Professional Licensing Consultants Inc
187. lays the current Valve Gain setting for elevation control The valve gain setting determines the speed of the hydraulic response during Automatic Control A higher setting speeds up the response a lower setting slows down the response See Adjusting Valve Gain on page 10 19 for details Elevation set point displays the current cut fill offset or amount of additional height applied to the Design Surface Zero sets the elevation set point value to zero GRT info displays the GRT information dialog box see Viewing GRT Information on page 8 24 for details Elevation left edge 66 088 Elevation right edge 67 963 Elevation valve gain 75 Set Elevation set point 0 55 Set Zero GRT info Ok Cancel Figure 2 15 Open Adjust Elevation Dialog Box for 3D LPS Control See Changing Cut Fill Offsets on page 10 14 for details on adjusting the elevation while grading 2 20 System Five 3D Reference Manual 3DMC Functions Adjust Elevation in 2D Control To display the following elevation settings for 2D applications Figure 2 16 on page 2 21 press the Elevation Control Key Elevation left edge disabled for 2D control Elevation right edge disabled for 2D control Elevation valve gain displays the current Valve Gain setting for elevation control The valve gain setting determines the speed of the hydraulic response during Automatic Control A higher setting
188. lications displays the on going highs and lows of the project as determined by both laser and GPS readings The red line indicates mmGPS detection the blue line indicates GPS only detection In the example below the background 10 12 System Five 3D Reference Manual Changing the Display View color of the main screen was changed to better display the cut fill history The Light bar is used for steering indication where the green zone indicates on grade For details on the Light Bar pop up menu see Changing the Light Bar Scale on page 10 18 lt 45 82 gua 17 89 27 17 88 81 0 00 0 00 Figure 10 10 Lower Window Views P N 7010 0491 10 13 Grading Application Changing Cut Fill Offsets The cut fill offset can be manually adjusted on the fly relative to the Design Surface After each pass the cut fill offset can be updated as necessary while approaching the final design surface For safety reasons 3DMC limits the amount of vertical movement possible while in automatic control The maximum cut fill movement working window while in automatic is 20 of a foot for 2D control and 40 of a foot for 3D GPS mmGPS control To grade in automatic within a significant cut or fill the operator must manually apply a cut fill offset When changing the cut fill offset both the Pas Elevation Control Key and Grade Indicator reflect the new value Changing Offsets Using the Control Knob
189. log box Figure 4 13 on page 4 11 e If the slope of the cutting edge matches the previous pass no adjustment is needed e If the slope of the cutting edge differs from the previous pass continue below to calibrate the cutting edge Make another pass in automatic and turn grade knobs until blade matches 2 0 Back Next Cancel Figure 4 13 Blade Trim Second Pass Dialog Box 6 If the cutting edge does not match turn either Grade Adjustment Knob to get the blade to match Figure 4 14 The Slope indication at the lower left of the dialog box changes accordingly Blade trim second pass Make another pass in automatic and turn grade knobs until blade matches 2 0 Back Next Cancel Figure 4 14 Adjust Blade Slope 7 Press Next with the blade matching to the previous pass 8 Press Finish to apply the new adjustment Figure 4 15 on page 4 12 Press Cancel to use previous adjustments P N 7010 0491 4 11 Calibrations Blade slope adjustment 0 0 Press Finish to apply new calibration Figure 4 15 Blade Trim Complete 4 12 System Five 3D Reference Manual Chapter 5 3D GPS Applications Setup and Usage 3D GPS applications use satellite signals to determine location A radio connection between a GPS Base Station and the GPS machine allows the control box to receive GPS corrections from the Base Station With the corrections the control box can accurately
190. log box select the correct control points file and press Edit The Control points dialog box displays listing all control points for the file and jobsite Figure 5 28 Simpson family ranch Name H Error V Error New Edit Copy Del Ok Add Edit Delete Ok Cancel Figure 5 28 Control Point Files Dialog Box 4 Select a control point and press Edit the Control point dialog box displays This control point file should already have local site coordinates from the selected control point file Figure 5 29 on page 5 30 5 Tap in each WGS84 coordinate entry box to display the numeric pop up keyboard and enter the coordinates for latitude Lat longitude Lon and height Hgt Figure 5 29 on page 5 30 6 Tap the two GPS localization check boxes to enable check them for performing the GPS localization mathematical conversion Figure 5 29 on page 5 30 P N 7010 0491 5 29 3D GPS Applications Setup and Usage Control point ou ee __Controt point Site coords WGS84 N 2065148 0 Lat Name MAGGIE E 6178836 88 Lon Site coords wess4 z 376 79 Hgt N 2065148 01 Lat N37 39 32 75938 E 6178836 88 Lon W121 49 21 40995 r Use for horizontal GPS localization z 37679 Hat 298 40 r Use for vertical GPS localization Use for horizontal GPS localization Measure
191. lope reading at or very close to the Design Cross slope 3 Knowing how prior and coming grade surfaces look Similar to an operator manually cutting grade over one hub and looking ahead to the next hub to determine where the cutting edge needs to be System Five 3D has unique software that computes the cut grades while anticipating the Design Elevation in front of the machine providing a smooth and accurate graded surface Figure 1 28 Predicted Point Uo ry Latest Point Predicted Distance Logged Data of Cut Surface Figure 1 28 3D GPS Calculated Predictions Just as when grading manually balancing material and maintaining a constant speed improves grading results when using System Five 3D Grading accuracies can equal GPS RTK measurement accuracies in surveying 1 24 System Five 3D Reference Manual Elevation Control Overview 3D LPS Control Overview Except for the following differences 3D LPS Control functions similarly to 3D GPS Control 1 In 3D LPS Control applications Pocket 3D calculates the Design Elevation and Design Cross slope With 3D LPS Control the control box communicates with the LS 2000 Laser Sensor and the Slope Control System controlling the hydraulic valves and providing an in cab display of design and current information Rather than determining the Design Elevation using digital communication as with GPS an optical laser beam from a laser transmitter an
192. lors of other LED blinks e Orange at least one blink is orange e Red no orange blink and at least one red blink e Green all other cases The delimiter double blink is followed by six LED blinks corresponding to six receiver tests where each blink indicates the following information Blink 1 Sufficient data for position computation Blink 2 GPS S N ratios are good Blink 3 GLONASS S N ratios are good Blink 4 Oscillator s frequency offset is less than three ppm Blink 5 Oscillator s Allan Variance is better than 2 7e 10 Blink 6 Continuous tracking time is more than 15 minutes The color of the blink indicates that information for test is unavailable orange the receiver passed the test green or the receiver failed the test red 1 To switch to EIM press and quickly release within one second the Main FN button 2 Watch for the delimiter double blink With good receiver antenna and observation conditions all blinks should be green within 15 minutes of powering on e Green ok e Orange wait e Red some tests failed 3 To switch back to normal mode press the Main FN button P N 7010 0491 2 31 Component Functions Notes 2 32 System Five 3D Reference Manual Chapter 3 Building Job Files Before beginning to work with the System Five 3D you must have job files that contain the various info
193. lyline P N 7010 0491 10 29 Grading Application 5 Press Topcon Logo gt Control gt Steer indication to change the following Figure 10 33 Press Ok when done e Point of interest the edge of the blade to steer from e Alignment feature the feature to steer to e Additional steer offset an offset from the feature to apply Steer Indication Alignment Polyline alignment Point of interest Left cutting edge pi Alignment feature Centerline Additional steer offset 0 000 Ok Cancel Figure 10 33 Steering Options 6 Press Topcon Logo gt View gt Display options gt Alignment to change the color of the centerline feature line or station lines Also use this screen to show station labels and change the interval between cross lines Figure 10 34 Show sections at interval 100 00 Steering indication From To Centerline Light bar green zone 0 20 83 Ok Cancel Figure 10 34 Polyline Alignment Options 7 Begin driving As needed repeat step 4 on page 10 29 to steer to another polyline 10 30 System Five 3D Reference Manual Steering or Grading to Polyline Grade to Polyline This selection and feature is available only in GPS mmGPS control applications While the Design Elevation is determined depending on the vertical profile of the polyline the Design Cross slope is predetermined with a constant 0 flat cross slope When grading to a polyline
194. m from gt copy a Figure 7 14 S N Firmware Adjusted F ransmitters S N Firmware Adjusted All PZL 1 transmitter and calibratjon data will be transferred to the current projfct Press OK to continue 7 P Ok Cancel Copy Transmitter Data Performing a Resection The resection function measures an unknown transmitter location using the rover and three or more points In general the results from a resection are adequate for horizontal positioning of the transmitter an error estimate will also display Performing a height check and adjustment will fine tune the calculated elevation When performing a resection use the following guidelines to ensure accurate measurements at the Rover points e take measurements at three or more points around the Base transmitter in a balanced symmetrical pattern not clustered in one area e have the sensor facing towards the transmitter during each measurement e angle the sensor between 6 higher or lower than the transmitter s beam not straight on P N 7010 0491 7 19 mmGPS Application Setup and Usage 3 mom Set up the transmitter at an unknown location Power on the transmitter and select a channel to transmit on Set up the PZS 1 sensor Power on the sensor and receiver Connect the sensor and Pocket 3D controller l Use a bi pole to ensure the sensor remains steady throughout the calibration process Wal
195. mation for predicting GPS solution accuracy for grading The red vertical line marks the current time Fix Position Satellites ID Planning 2 4 Estimated precisions for ext Thursday June 15 2006 Next z Prev otr 0 0 0000 0200 0400 0600 0800 1000 1200 1400 1600 1800 2000 2200 2400 Ok Cancel Figure 5 25 GPS Info Planning Tab Changing Radio Channels If needed you can use 3DMC to temporarily change the radio channel of PDL radio modems The MC 2 5 receiver box stores radio settings including the radio channel The original settings from the machine configuration file will be restored after turning off then back on the control box Some radio modems such as Teledesign have an automatic channel scanning feature allowing them to automatically detect and connect with a Base Station 5 24 System Five 3D Reference Manual Operations for GPS Control 1 Press Topcon Logo gt Tools gt Configure radio and press Configure if available to run the radio setting program 3DMC may take a few seconds to a few minutes to connect to the radio module and check the current setting When the current setting is confirmed the radio s channel and frequency information displays Figure 5 27 on page 5 26 Radio type Pacific Crest PDL UHF Connected to Serial Port B Baud rate 38400 Format CMR Configure Ok Cancel Figure 5 26 Temporarily Change Radio Sett
196. measurement keep the mast as vertical as possible when measuring the point P N 7010 0491 3 25 Building Job Files 1 Press Topcon Logo gt File gt Surfaces gt Working or Reference and press New Enter and select the following information for the new surface file Press Next Figure 3 29 on page 3 26 e Configuration name enter a name for the file e Surface type select raise lower existing surface Configuration nary NewSubgrade_1 Surface type Flat plane surface Sloping plane surface New Copy Raise lower existing Subgrade of existing r ad Next Cancel Figure 3 29 Create New Surface File 2 Select the road surface to use as the reference from which to create the surface Enter an elevation adjustment Figure 3 30 on page 3 28 e A positive number raises the subgrade in comparison to the working reference surface e A negative number lowers the subgrade in comparison to the working reference surface e This value will be applied to the centerline of the working reference surface 3 26 System Five 3D Reference Manual Surface Files 3 Select the type of grade Figure 3 30 on page 3 28 e If selecting Manual enter the percentage of the left right side of the subgrade element This will determine the slope for the left right side of the machine or road e If selecting Copy from use the gradient grade of the reference cross section element that ma
197. n Figure 7 9 on page 7 13 and press Next e GPS port select the port used for GPS communication on the MC 2 5 receiver box usually Serial Port C e Sensitivity select the sensitivity level for detecting the transmitter usually Auto Select a different setting when 7 12 System Five 3D Reference Manual Machine Setup working at very short or very long distances or during inclement weather that can affect laser detection e Channels select the channel to scan for mmGPS connection The All selection will allow the sensor to independently select the transmitter with the smallest error rate If setting only one transmitter but the job has been configured for multiple transmitters select the individual ID of the transmitter for the sensor to detect e LaserZone aided init select to use the mmGPS signal to assist in initializing the GPS receiver This option is useful to decrease the initialization time when satellite visibility is limited for example tracking only four or five satellites e Calc LaserZone GPS weighted elevations select to combine Lazer Zone elevations and GPS elevations When selected this option will force the receiver sensor to always consider the angle and distance when determining the elevation then combine the two elevations accordingly This option works well at large 300m distances and steep angles GPS port SerialPortC Sensitivity Auto 7 Channels Al Advanced
198. n grade 0 200 lt 3 713 Extents 3 000 0 00 002 _ a Figure 10 16 Grade Indicator Pop up Menu Changing the Light Bar Scale The light bar displays the distance to the grade reference Much like the sonic tracker working window Figure B 3 on page B 3 green indicates on grade status yellow indicates above grade status and red indicates below grade or out of range To view the light bar scale press Topcon Logo gt View gt Lower window gt Light bar Figure 10 17 To change the light bar scale press and hold the light bar scale for one second then tap the desired menu option Figure 10 17 on page 10 19 e Green displays the current on grade green zone width Tap to change the on grade zone e Yellow displays the current above below grade yellow zone width Tap to change the above below grade zone 10 18 System Five 3D Reference Manual Adjusting Valve Gain e Extents displays the current scale unit spacing for the light bar Tap to change the unit spacing Green 0 250 Yellow 0 750 Extents 1 500 Figure 10 17 Light Bar Scale Indicators Adjusting Valve Gain A Valve Gain adjustment allows the operator to speed up or slow down the response of the hydraulic valves and can be adjusted on the fly while in Automatic Control e If the blade seems to be moving too slow and the Grade Indicators take too long to reach on grade increase the Gain value to ca
199. n surface Grid interval Sloping Plane Surface X 8792 611 1 000 Point on surface Main fall A gt B Y 11003 426 X 2064431 760 Direction 315 37 00 Z 3 338 Y 6178673 670 Grade 1 697 Measure pt Z 423 210 Tan EBM Measure pt Grid interval Crossfall Back Next Cancel 20 000 Grade 1 500 Back Next Cancel 3 16 System Five 3D Reference Manual Surface Files Creating a Flat Plane Surface The flat plane surface model is composed of a reference elevation point through which the plane intersects The operator will need to be prepared with the elevation reference point to fulfill the requirements for creating the surface Figure 3 18 illustrates the factor needed for a plane surface model Ltisting Grong w 0 Elevation Reference Point Figure 3 18 Flat Plane Surface Diagram 3DMC accurately measures the point directly below the sensor but does not compensate for a slant error of the sensor mast Therefore for a more accurate measurement keep the mast as vertical as possible when measuring the point 1 Press Topcon Logo gt File gt Surfaces gt Working or Reference and press New Enter and select the following information for the new surface file Press Next Figure 3 19 on page 3 18 e Configuration name enter a name for the file e Surface type select flat plane surface no slope P N 7010 0491 3 17 Building Job Files
200. nce point 10 16 System Five 3D Reference Manual Changing the Grade Indicator Grade Indicator reports cut fill number of left edge of blade even if elevation reference red arrow is on the right edge of the blade HULL Figure 10 14 Example Grade Indicator and Left Edge Cut fill Example In From Edge When using In From Edge the grade tape will follow the cut fill of the entered distance from the left side of the blade regardless if elevation reference point is at the middle or right edge of the blade The cut fill number in the elevation control key is tied directly to the Elevation Reference point The Elevation Control Key reflects the elevation reference point Grade Indicator reports cut fill number of edge of blade in from left edge 1 25Ft even if elevation reference red arrow is on the right edge of the blade ia o Q N Figure 10 15 Example Grade Indicator and In From Left Edge Cut fill P N 7010 0491 10 17 Grading Application To change the on grade or extents press and hold the grade indicator for one second then tap the desired menu option Figure 10 16 e On grade displays the current on grade green zone width Tap to change the on grade zone e Extents displays the current scale unit spacing for the grade indicator Tap to change the unit spacing Red Fill Arrow Current Position of Edge e a Green On grade Grade display Blue Cut O
201. ncel Figure 9 12 Survey On grade Elevation Example 9 10 System Five 3D Reference Manual 2D Control Operations Changing Control Methods In 2D control applications the Adjust elevation and Adjust slope dialog boxes can be used to change the control method to either slope or elevation To change the elevation side of the machine to slope Figure 9 13 1 Press the Elevation Control key 2 Press Change to Slope to use the slope method for control Elevation left edge 4 Elevation right edge Elevation valve gain 75 Set Elevation set point 0 55 Set Survey Zero ange to Slope Ok Cancel Figure 9 13 Change to Slope To change the slope side of the machine to elevation Figure 9 14 1 Press the Slope Control key 2 Press Change to Elev to use the elevation method for control Blade slope 0 0 Set Slope gain 25 Set Survey Change to Elev Ok Cancel Figure 9 14 Change to Elevation P N 7010 0491 9 11 2D Application Setup and Usage Notes 9 12 System Five 3D Reference Manual Chapter 10 Grading Application Once you have your System Five 3D setup for the desired control application most grading operations remain the same This chapter discusses the following operations typically performed while grading e Changing Cut Fil
202. nd Usage elevation then combine the two elevations accordingly This option works well at large 300m distances and steep angles 2 Press Ok to save this information and temporarily overwrite current PZS MC information Receiver port Serial Port C Receiver sensitivity High Transmitter selection Any Firmware version LaserZone aided initialization Calc LaserZone GPS weighted elevations Ok Cancel Figure 7 13 Temporarily Change PZS MC Receiver Information Copying PZL 1 Transmitter Information The control point file contains PZL 1 transmitter information Occasionally this information may need to be updated depending on day to day operations and possible setups As the job progresses the transmitter s position may have to be moved or multiple transmitters set up To change the transmitter s channel information see PZL 1 Transmitter Setup and Calibration on page 7 2 To copy transmitter information from an existing control point file first make sure the desired control point file has been copied to the control box from Pocket 3D 1 Press Topcon Logo gt Control gt PZL 1 transmitters 2 Tap the Transmitters tab and press Copy Figure 7 14 on page 7 19 7 18 System Five 3D Reference Manual Operations for mmGPS Control 3 Select an existing control point file that contains mmGPS transmitter data Press Ok Figure 7 14 on page 7 19 900026 Sopy Trans
203. nd Valve Gain me When using the control box on different machines adjustments for each machine 1 Raise the machine blade so that both sides of the cutting edge rest a few inches above the ground At the control box tap Topcon Logo gt Control gt Valve offsets Press the Raise left Set button to enable the entry box and calibrate the left valve offset value Figure 4 1 The control box begins sending a raise signal to the left valve and the grade indicators display the currently active offset Raise left 0 Set Lower left 0 Set Raise right 0 Set Lower right 0 Set Ok Cancel Figure 4 1 Begin Valve Offset l If the blade is moving turn the Grade Adjustment Knob counterclockwise until the blade stops 4 2 System Five 3D Reference Manual Sensor Calibrations 4 Slowly turn the Grade Adjustment Knob clockwise until the blade just begins moving Figure 4 2 on page 4 3 e Turning clockwise increases the Valve Offset value e Turning counterclockwise decreases the Valve Offset value Raise left v 97 E Lower left 999 Set Raise right a99 Set Lower right 999 Set More Ok Cancel Figure 4 2 Setting Valve Offsets 5 Press the Set key for each of the remaining selections repeating steps 3 and 4 on page 4 2 until all four valve offsets are complete 6 Press OK to store the calibrations otherwise automatic control will not work
204. nd perform a Valve Offsets Calibration See Adjusting Valve Gain on page 10 19 Problem Blade reacts but overshoots around On Grade Causes Solutions Valve offsets are too Assume that Valve Offsets are too large large and perform a Valve Offsets Calibration See Adjusting Valve Gain on page 10 19 12 20 System Five 3D Reference Manual Appendix A Pocket 3D Getting Started Guide Pocket 3D is grade and staking control software for hand held controllers At the jobsite Pocket 3D provides a way to make quick changes and updates to files double check control points initialize the GPS base and many other useful functions 3DMC and Pocket 3D save files in the same format making it simple to share files and updates between surveyors machine operators grade checkers etc l Refer to the Pocket 3D User s Manual and Pocket 3D Reference Manual for further details Before performing any Pocket 3D configuration or application function check the units used at the job Units are the method of measurement used for measuring various data To check change or apply units to the project tap Setup gt Units Figure A 1 Distances US Survey feet Decimal Places FJ Angles DD MM SS Equipment Areas Square feet v Radios Volumes Cubic yards Antenna Coords North East Elev Base station s e a Stations 1 00 000 Grades Percent v Cancel Figure A 1 Setup Unit
205. nformation The following sections describe the GPS information tabs GPS Status and Quality The Fix tab displays satellite status and positioning quality based on GPS satellites currently being tracked Figure 5 21 Once a GPS solution is initialized 3DMC reports the Fix status The positioning quality is an estimation computed from valid satellite status RMS Root Mean Square Fix Position Satellites ID Planning initialized Total sats tracked 16 GPS sats used 9 GLONASS sats used 5 Horizontal RMS 0 05 Vertical RMS 0 07 Ok Cancel Figure 5 21 GPS Info Fix Tab P N 7010 0491 5 21 3D GPS Applications Setup and Usage Cutting Edge Position The Position tab displays current locations for the left and right sides of the cutting edge Figure 5 22 These values are based on the local site coordinates providing quick position and elevation checks at particular points on the project The Z values on this tab match the elevation numbers on the Adjust elevation dialog box Fix Position Satellites ID _ Planning X 8454 67 Y 10865 37 Z 58 34 X 8464 24 Y 10867 05 Z 59 91 Ok Cancel Figure 5 22 GPS Info Position Tab Monitor Satellites and Enter Mask Angle To monitor the current distribution of satellites or enter the mask angle for satellites press the GPS status button then tap the Satellites tab on the GPS status dialog box The Satellites tab displays the
206. nic Tracker II to see a sonic stringline continues to be impaired the transducer may be damaged and needs replaced 1 Remove and discard the Filter Foam a new Filter Foam is provided in the Transducer Replacement Kit Figure 11 11 Figure 11 11 Remove Filter Foam 2 Remove the four screws and the black Retaining Ring Remove and discard the O Ring Figure 11 12 The Transducer Replacement Kit includes an O Ring and four replacement screws however you should use the original screws and keep the four supplied in the kit for replacements in the event one or more are lost Figure 11 12 Remove Screws Retaining Ring and O ring 11 12 System Five 3D Reference Manual Preventative Maintenance O Rings are distorted and can loose elasticity due Always remove and discard used O Rings Used to weather or exposure to diesel fumes 3 Gently pull out the Transducer and use a SMALL pair of dikes to gently cut the Ty Wrap then remove the small wire connectors from their tabs Figure 11 13 When cutting the Ty Wrap be careful not to cut or damage the wires CAREFULLY REMOVE WIRE CONNECTORS Figure 11 13 Remove Transducer Cut Ty Wrap and Remove Connectors 4 Place the wire connectors of the new Transducer firmly on their tabs the gray wire connector is placed on the elevated tab Place the Ty Wrap in the slot next to the elevated gray wire tab tighten and trim DO
207. ning and Lubrication 11 3 Pole dampening Bushing Replacement on Round Vibration Pole oeer 11 7 Lubricate Quick Removal Knob 0 0 eeeeeeeeeseeeeees 11 9 GRT 2000 Inspection and Calibration 1 0 11 9 LS 2000 Reflecting Strips Replacement 0 0 11 10 Sonic Tracker II Transducer Cleaning ee 11 11 Sonic Tracker II Transducer Replacement 11 12 Chapter 12 Troubleshooting eeeeeeeeeeeeeeeeeeeeeeeeeneeseeeeeeeeeees 12 1 Base Station tccsi tides ttenecsdeedteene ete ent ee 12 2 EPS Staton ene nea e e naa a 12 4 Rover GPS Receiver BOX oo cee ceeeeseeeseeseceseceeeeeneeaes 12 7 GPS Localization encient in 12 9 Control BOX iora siiowathins lei gsleestg A EAE E 12 12 Blade Response s d s cs2eeistetarsslasssbshesbeuth stecbel ieetalsdicbolaststes 12 19 P N 7010 0491 vii Table of Contents Appendix A Pocket 3D Getting Started Guide 00 A 1 Equipment Setup GPS oo eee eseeseeneceseeeeeeeeeesaeenaeens A 2 Step 1 Create a Control Point File oe A 2 Step 2 Setup and Initialize a Base Station Transmitter eee eeeeeseeeeeeeeeneeees A 4 Step 3 Create a Range Pole Equipment Configuration s sienen ranna eestor ete A 6 Step 4 Setup the Rover Radio n se A 7 Step 5 Setup the Rover Antenna 0 0 eeeeeeeeeee A 8 Step 6 for mmGPS Setup the mmGPS Receiver A 8 Step 7 Connect to the Rover wo eee ceseeeeeseeeneeees A 9 Equipment Setup LPS
208. nob cee eeeeeseeseceeeeeeeeeeeeneees C 4 Blade Slope SensOr sissi steessoscseetadectanssivwss pristenssgseeeseeseeese C 5 Rotation Sensor zegororiiokasns ear EO A C 6 Mainfall Sensor ccccecesceecesscecesecececssaeeeceeseeeessaeeenaes C 7 Rover GPS Receiver BOX cccccsscceesseceeesteeeeeseeeeneaes C 9 MG AL Antenna i diced neti e A ATA AO AE C 10 LS 2000 Laser Sensor oroade C 12 Round Vibration Pole ccccccccccceesseceeenceeeesneceseneeeeenees C 13 Trackerjack Vibration Pole 00 0 eseeseceseeeeeeeeeenaees C 14 GPS Vibration Pole o aiaa AR iA A C 15 TM 1 Telescoping Mast 0 eee esesseceseceeeeeeeeneeenaees C 16 GRT 2000 Robotic Total Station 0 0 0 ceescecesseeeeeeees C 18 Sonic Tracker IT woke wah teas el wtih hel hel A C 19 Laser Trackets 1c sssusiiteccasedeiaieds EET A C 21 TrackerjacK sss seicesst igeskttedeh e eae lass leeds iesea enie C 22 PZS MC Sensor naunan eaa iment A went ee C 24 Appendix D Regulatory Information cccccsesseeeeeeeeeeeseeeeeees D 1 ECC Compliance wicciccssaicericctti annette ni deinen eeiite D 1 UHF Radio Usage oree nie een i i D 2 Community of Europe Compliance 0 eee ceeeeeeeeeeee D 3 WEEE Direc Hve iien nran TEE clea T D 3 Appendix E Warranty cisccccnctinccntarstextacnatcedncaandasecavecvenasmonuueennbs E 1 Index P N 7010 0491 ix Table of Contents Notes X System Five 3D
209. ns on page 10 34 for details If needed contact your Topcon dealer with questions 2 24 System Five 3D Reference Manual Remote Smart Knobs Operation Remote Smart Knobs Operation The Remote Smart Knobs allow the operator to perform several System Five 3D functions quickly Figure 2 21 without having to reach up to the control box The smart knobs mount on the grader s control levers for easy access and allow the operator to keep his hands where they belong on the control levers LEFT RIGHT Auto Manual Manual Auto _ Swa Da Set Point 2D Control 2D Control Survey Survey Figure 2 21 Remote Smart Knobs Operation Auto Manual Switch The Auto Manual switch allows the operator to switch between Automatic Control and Manual Control When not in use leave the Auto Manual switch in Manual Control e Automatic Control Push the left and right Smart Knob toggle switch outward for Automatic Control The AUTO LED indicator illuminates when control is in Automatic e Manual Control Push the left and right Smart Knob toggle switch inward for Manual Control P N 7010 0491 2 29 Component Functions Raise and Lower Buttons Depending on the control application the raise and lower buttons control cut fill offset or slope and elevation adjustments In 2D Control applications these buttons also control on grade locking e Adjust Cut Fill Offsets In 3D Control applications the Raise Lower buttons
210. ntation 8 8 System Five 3D Reference Manual Equipment Setup GRT 2000 e New station by resection Add a Control Point to the resection and take a measurement to each point Measurements may be a combination of horizontal angle horizontal and vertical angles or horizontal and vertical angles and slope You can use any number of points but at least three points need to be used for an accurate resection Once computed the new resected point can be added to the Control Point file as a Control Point Activating LPS Control in Pocket 3D After you have setup and initialized your LPS Station you need to load LPS control application files and begin tracking the machine and LS 2000 1 Open Pocket 3D on the controller and select the following jobsite files Figure 8 6 e Control point file Data Control e Machine file Setup gt Equipment e Design surface file Data gt Surface ALLGEN Surfaces lt none gt Simpson s ranch DTM E topcon GE Eo 14H GRADER LPS SIMPSON FAMILY RANCH New Edit Copy Delete New Copy Delete New Info Copy Delete Figure 8 6 Select Jobsite Files 2 On the Pocket 3D main screen press the red GRT 2000 icon to open the LPS control dialog box and set the searching and tracking parameters for 3D LPS control 3 Press the Search tab and set the following parameters Figure 8 7 P N 7010 0491
211. nter a grid interval and crossfall for the main screen Press Next Figure 3 25 Point on surface Main fall A gt B N 2064431 76 Direction 315 37 54 E 6178673 67 Grade 1 697 Z 423 21 A B qQ gt Measure pt Grid interval Crossfall Q p 20 00 Grade 1 500 Less Next Cancel Figure 3 25 Measure Elevation Reference Point and Enter Grid Interval 10 Review the created surface plane Figure 3 26 If needed press Back to change parameters or measurements for the surface Press Next 11 Press Finish to save the new surface file and end the process NORTH Back Next 4 ancen 10 Figure 3 26 Surface Review P N 7010 0491 3 23 Building Job Files Raising or Lowering the Existing Surface Creating a surface by raising or lowering it based on the current surface allows you to more accurately display current blade information on the screen For example if you want to lower a finish grade design surface to 6 below the current surface lower the surface in 3DMC so that the cut fill reference will be from O zero rather than from 6 negative six 3DMC accurately measures the point directly below the sensor but does not compensate for a slant error of the sensor mast Therefore for a more accurate measurement keep the mast as vertical as possible when measuring the point 1 Press Topcon Logo gt File gt Surfaces gt Working or Reference and press New Enter and s
212. ntrol Points used for localization Control file has no GPS localization message Solutions Press the Ok pad to exit the message screen Check that the Control Points file used has a minimum of three localized points Perform the localization process again No GPS localization has been performed for the project An LPS application is the current job The program in the control box is in the middle of loading files or making graphics Problem Loading or Building message Causes Solutions Plan to implement the GPS localization See GPS Localization on page 5 26 for detailed instructions Create or select the correct LPS Machine Configuration file so the Control Points file will require no GPS localization If the pointer on the Main Screen moves when you tap in different places the control box is computing When the system is busy the pointer becomes an hourglass Wait for a few more minutes to let it complete the process Remember computing will take longer when a larger file is selected If the pointer does not move the control box may have a computing problem Switching off the control box can fix the computing problem 12 14 System Five 3D Reference Manual Control Box Problem Elevation Slope Control Waiting for radio link Causes Radio transmission radio antenna lights status on the Legacy E re
213. ntrol Point station point over which the GRT 2000 is installed Figure 8 21 2 Press Ok to activate the station location in 3DMC GRT2000 station location LD a Ok Cancel Figure 8 21 Select GRT 2000 Station Location Control Point GRT 2000 initialization An incorrect selection will have a direct affect on the quality of machine grading accuracy D Select exactly the same control point as used during Setting Blade Control The blade control function selects the point on the blade at which to control the position of the machine s cutting edge See Automatic Best fit Blade Control on page 1 37 and Control Using Single Point on Blade on page 1 39 for a discussion on the blade control method to use for a jobsite To quickly change the blade control point using the section view e To move to the far left or far right edge of the blade press and hold the edge of the blade for one second On the pop up menu tap Move control left or Move control right 8 22 System Five 3D Reference Manual Machine Setup e Press and hold a point on the blade for one second On the pop up menu tap Move control Figure 8 22 illustrates this process To change the blade control point using the Control menu 1 Press Topcon Logo gt Control gt Blade control 2 With Control using single point on blade selected hold the slider button and move it left or right to select a point at a distance from the left
214. o 90 feet apart 8 10 System Five 3D Reference Manual Equipment Setup GRT 2000 7 Press Setup gt LS 2000 receiver to begin the receiver setup and press Next when the machine is ready step 6 is complete Figure 8 8 ALLGEN Equipment Station setup Q 52000 receiver Move machine so blade is facing GRT2000 and mast is Figure 8 8 Setup gt LS 2000 and Position Machine Blade 8 Accurately sight the GRT 2000 telescope on the LS 2000 prism and press Next to measure the sensor position Figure 8 9 9 Move the GRT 2000 telescope so the cross hairs rest on the cutting edge Press Next to measure the vertical height from the prism to the cutting edge Figure 8 9 When the GRT 2000 finishes the measurement the height of the LS 2000 from the cutting edge displays on the LS 2000 height dialog box Figure 8 9 P N 7010 0491 8 11 3D LPS Application Setup and Usage 10 Press Finish to save the new sensor height Pocket 3D updates the sensor height stored in the Machine Configuration file ALLGEN ALLGEN I Point GRT2000 crdis hairs to edge of blade belofy LS2000 Figure 8 9 Measure Height of LS 2000 I Enter the new sensor height in the control box at this time See Machine Configuration Files on page 3 7 for this procedure 11 Sight the GRT 2000 telescope on the LS 2000 prism again and press Control gt Start LPS Control to start 3D LPS c
215. ocalization suitable for centimeter level machine grading with System Five 3D GPS e First the surveyor s local Control Points must be precisely measured The quality of measurements directly affects grade accuracy e Second the Control Points need to be located more or less evenly around the site Generally the more Control Points the better but if they are clustered together or are all at one section of the site then the results will be less than ideal Locate Control Points evenly distributed around a perimeter of the site or grading area While not directly related to the quality of localization locate Control Points that are elevated easily accessible and not obstructed by trees buildings other structures moving vehicles etc P N 7010 0491 5 27 3D GPS Applications Setup and Usage e GPS localization requires a minimum of three Control Points but at least four or more points should be used for the localization GPS localization is processed in the control point file created prior to beginning each project This control point file contains the formula necessary for the mathematical conversion between global GPS coordinates and NEZ coordinates A control point file can be localized using one of the following methods e Measuring each control point with a Topcon GPS or GPS RTK Survey Rover System and Pocket 3D See Localizing with Pocket 3D on page A 14 for this procedure e Entering global GPS coordinat
216. om the outermost position on the metal rim of the antenna to the cutting edge For dozers the distance of the PZS MC receiver from the right edge of the blade For graders the distance of the PZS MC receiver beyond the outside edge of the blade The distance of the PZS MC receiver behind the cutting edge If unknown the width of the blade Radio Antenna Installation The radio antenna is attached to the machine s roof using a magnetic mount and generally stays on the machine The antenna should be positioned vertically and as high as possible on the machine to maximize signal reception See Radio Antenna Installation on page 5 12 for more details P N 7010 0491 7 9 mmGPS Application Setup and Usage MC 2 5 GPS Receiver Box Setup for mmGPS Applications The MC 2 5 receiver box is designed for quick attachment at the beginning of the day and quick removal at the end of the day When connecting cables to the receiver box Figure 7 7 ensure that the cables do not impede machine operation 1 If needed attach the MC 2 5 box to a convenient location on the machine Connect the PZS MC antenna cable to the MAIN GPS port Connect the PZS MC serial cable to the MAIN C port Connect the radio antenna cable to the RADIO ANTENNA port Connect the control box cable to the MAIN A port we YN PZSMC back view Radio re Antenna z
217. on Pocket 3D 1 54 fok H Error Y Error TEST Control points Import Export Options Calc wizard Coords GPS North 5000 000 East 5000 000 Eley 100 000 Cancel Figure A 3 Enter Control Points Rev B A 3 Pocket 3D Getting Started Guide Step 2 Setup and Initialize a Base Station Transmitter For a GPS Base Station enter antenna and radio information Figure A 4 1 Connect the controller and receiver Tap Setup gt Base station 2 Select the control point over which the base station is installed and the connection between controller and receiver Press Next 3 Enter antenna type and height information Press Next 4 Enter radio type and communication information If using a Pacific Crest PDL UHF radio press Configure to select channel information and press Set Press Next 5 Select GPS receiver settings Press Finish to initialize the GPS receiver and start the Base 6 Immediately disconnect the Pocket 3D controller from the receiver Performing any other activities while connected will convert the Base to a Rover Control point Antenna type opcon PG Al v Antenna height esc Measured to Base v Units Feet v Equipment Radios Antenna Base station Radio type Pacific Crest PDL UHF 8l Port Serial Portc Baud rate 38400 CMR Ready to connect Press the FINISH button to connect to
218. on information You must have a machine configuration file before beginning to grade 1 Press Topcon Logo gt Control Machine setup 2 Select the desired GPS configured machine file and press Ok 3DMC will connect to the LPS components and the Elevation Control key will display GRT 2000 and LS 2000 icons 2a SRADER LPS 14H GRADER DUAL GPS DOZER D6 MC A1 DOZER D6 MMGPS GRADER RIGHT GPS New Edit Copy Delete o _ gt 0k Cancel Figure 8 15 Selecting an LPS Machine Configuration P N 7010 0491 8 17 3D LPS Application Setup and Usage Creating an LPS Machine Configuration File 1 Press Topcon Logo gt Control gt Machine setup 2 Press New to create a new machine configuration file or select an existing machine configuration file and press Edit 3 Enter or select the following configuration and equipment parameters Figure 8 16 Then press Next e Configuration name enter a name for the machine For easy identification later include the application type e Machine type select the type of machine e Sensor select the type of sensor attached to the machine LS2000 receiver e Location select sensor s location on the machine middle for dozers left or right for graders e Units of measure select the unit of measure meters feet inches or centimeters GRADER LPS 14H GRADER DUAL GPS Configuration nameltype DOZER D6 MC A1 DOZER D6
219. ontrol Figure 8 10 on page 8 12 12 Check the GRT 2000 and LS 2000 icons they should turn from a red status to a green status indicating that 3D LPS control functions correctly Figure 8 10 on page 8 12 E Pocket 3D MAGGIE RUSTY Bence KRUSTY Figure 8 10 Start 3D LPS Control and Check Status 8 12 System Five 3D Reference Manual Machine Setup Machine Setup Machine setup for 3D LPS control application is quick and easy First install the control box then install the laser sensor LS 2000 Installation The LS 2000 Laser Sensor is designed for quick setup at the beginning of the day and quick removal at the end of the day 1 With the machine placed on level ground position the TM 1 Mast vertically on the blade Using the light coil cord connect the LS 2000 and TM 1 mast Plug the right angle connector into the LS 2000 Mount the LS 2000 on the post of the TM 1 and tighten the securing knob firmly Plug the other end of the light coil cord into the top connector on the TM 1 Make one wrap of the coil cord around the strain relief spool Using the heavy coil cord connect the TM 1 mast to either the Mainfall Sensor or Junction Box e For graders connect the heavy coil cord to the Mainfall Sensor e For dozers connect the heavy coil cord to the right connector on the Junction Box The cross slope cable connects to the left connector on the Junction Box Hang the snap hook on the hanger plate in
220. or details 6 8 System Five 3D Reference Manual Machine Setup 3 Press Next and continue with other configuration activities as needed 4 When finished be sure to press Finish to save machine configuration file and store the antenna settings Motorgrader wIGPS Antenna 23 Above 1 11 79 Inside 2 4 92 Behind 3 0 00 Width 4 9 84 Back Next Cancel Figure 6 5 Enter MC A2 Antenna Information During Machine Setup Step 2 Dual Antenna Slope Calibration After saving the machine setup file calibrate the antenna s slope 1 Place a level on the GPS vibration pole and tilt the blade until level Figure 6 6 2 At the control box press Topcon Logo gt Control gt MC A2 alignment to enter the calibration screen 3 Press Zero on the MC A2 Alignment dialog box Figure 6 6 T S MC A2 Alignment Antenna slope 0 Zerd Machine orientation ie Antenna orientation 0 Match With blade perpendicular drive machine q forward to estimate machine orientation Ok Cancel Figure 6 6 Level GPS Vibration Pole and Zero Out Antenna Slope P N 7010 0491 6 9 Dual GPS Application Setup and Usage Step 3 Dual Antenna Orientation Calibration After calibrating the slope calibrate the antenna s orientation to the machine 1 Square the blade to the machine Figure 6 7 for motorgraders rotate the blade to the chis
221. ox Setup for GPS Applications The MC 2 5 receiver box is designed for quick attachment at the beginning of the day and quick removal at the end of the day When connecting cables to the receiver box Figure 5 9 ensure that the cables do not impede machine operation 1 If needed attach the MC 2 5 box to a convenient location on the machine 2 Connect the MC A1 antenna cable to the MAIN GPS port 3 Connect the radio antenna cable to the RADIO ANTENNA port Connect the control box cable to the MAIN A port i Radio Antenna MC A1 GPS Antenna Figure 5 9 Connect Cables to MC 2 5 Receiver Box and Control Box P N 7010 0491 5 13 3D GPS Applications Setup and Usage Control Box Setup The control box is designed for quick attachment at the beginning of the day and quick removal at the end of the day 1 Use the hand knob to attach the control box to the in cab bracket Figure 5 10 Figure 5 10 Attach Control Box to Machine 2 Connect the various electrical cables Figure 5 11 Cable connections differ depending on the machine type Power Cable Cable to Mainfall Cable to GPS Box Grader GPS Control Power Cable Cable to Valve Cable to Junction Box GPS Control Cable to GPS Box Figure 5 11 Control Box Cable Connections for GPS Applications 5 14 System Five 3D Reference Manual Machine Setup
222. pe locked 0 5 SS Blade slope 0 0 Set 60 _ Se 0 0 C S Siope gain Ok Canc Slope locked 60 Set 0 0 Set Ok Cancel Figure 4 8 Adjust Slope Method Two Position the Blade 1 At the control box tap Topcon Logo gt Control gt Calibrate sensors 2 Place the cutting edge of the blade firmly on the ground and mark the location at both edges 3 Press Next Figure 4 9 Rest blade on flat surface and mark ground position at each edge Press Next to continue Next Cancel Figure 4 9 Calibrate Sensor First Blade Position Dialog Box 4 Wait five seconds until the Second blade position dialog box displays Figure 4 10 System Five 3D Reference Manual Sensor Calibrations 5 Turn the machine around 180 degrees and reposition the blade on the same marks If needed rotate the blade to place the cutting edge on the same marks Move machine around 180 so that blade is repositioned on same ground marks then press Next to continue Back Next Cancel Figure 4 10 Second Blade Position 6 Press Next and wait five seconds until the Blade calibration complete dialog box displays Figure 4 11 7 Press Finish to apply the new calibrations Press Cancel to use the previous calibration Blade slope adjustment 0 0 Press Finish to apply new calibration Figure 4 11 Blade Calibration
223. pendent of each other Grade Indicators The grade indicators visually translate in real time the distance of the cutting edge to on grade Table 2 1 on page 2 4 describes the visual patterns to on grade P N 7010 0491 2 3 Component Functions Table 2 1 Grade Indicators LED Action Elevation Indicator Slope Indicator Slow Blinking Out of range Out of range Yellow 8 GPS over 4 ft above grade Over 2 above grade LPS 2D over 2 ft above grade Triple Solid g Above grade Above grade Yellow S GPS between 05 and 4 ft Between 1 and 2 LPS 2D between 05 and 2 ft Double Solid g Above grade Above grade Yellow Between 03 and 05 ft Between 5 and 1 Single Solid 8 Above grade Above grade Yellow amp Within 03 ft Within 5 Blinking On grade On grade Green Bar Within deadband Within deadband Single Solid Red Below grade Within 03 ft Below grade Within 5 Double Solid Below grade Below grade Red Between 03 and 05 ft Between 5 and 1 Triple Solid F Below grade Below grade Red s GPS between 05 and 4 ft Between 1 and 2 LPS 2D between 05 and 2 ft Slow Blinking Out of range Out of range Red 8 GPS over 4 ft below grade LPS 2D over 2 ft below grade Over 2 below grade 2 4 System Five 3D Reference Manual Control Box Grade Adjustment Knobs The grade adjustment knobs make measured adjustments to the cross slope or ele
224. pendicular to a line running through the center of leveling screws A and B Turn leveling screw C to center the bubble in the circular level 5 Center Using the Plate Level Rotate the instrument horizontally using the horizontal motion clamp screw and place the plate level parallel with the line connecting leveling screws A and B Turn leveling screws A and B to bring the bubble to the center of the plate level Leveling screwA GW Rotate the instrument 90 around its vertical axis and turn leveling screw C to center the bubble once more LA Leveling screw C 90 Repeat step 4 for each 90 rotation of the instrument and check that the bubble correctly centers at all four points 6 Center Using the Optical Plummet Telescope Adjust the eyepiece of the optical plummet telescope to your eyesight Slide the instrument by loosening the tripod screw place the point on the center mark and then tighten the tripod screw Slide the instrument carefully to prevent any dislocation of the bubble Point Centermark 7 Level the Instrument Level the instrument as in step 4 Rotate the instrument checking that the bubble is in the center of the plate level regardless of telescope direction Then tighten the tripod screw to lock in position 5 4 System Five 3D Reference Manual Equipment Setup Base Station Step 2 attach ad
225. perating around excessively dusty or gritty materials D Cleaning and lubricating of the Rotation Sensor 1 Place the moldboard perpendicular to the frame of the motor grader and lower the cutting edge to the ground 2 Remove the four screws securing the two halves of the retaining ring and remove the retaining rings Figure 11 1 Remove Four 4 Screws And Two 2 Halves Of Retainer Figure 11 1 Remove Retainer Rings P N 7010 0491 11 3 Maintenance 3 Remove the shoulder screw washer and jam nut from the sensor arm Figure 11 2 Remove Shoulder Screw Washer Aand Jam Nut From L Bracket Figure 11 2 Remove Sensor Arm 4 Carefully lift the Rotation Sensor from its base plate Figure 11 3 Gently Lift Rotation Sensor From Base Plate And Wipe Surfaces Clean Figure 11 3 Carefully Remove Rotation Sensor Do not force or pry the sensor from the base plate The sensor pin may bend or break 11 4 System Five 3D Reference Manual Preventative Maintenance 5 Using a clean rag thoroughly clean the base plate and bottom of the sensor 6 Pack the base plate reservoir and pin cavity with fresh grease Figure 11 4 Pack Sensor Channel Aand Pin Slot With Fresh Grease Figure 11 4 Pack Sensor Channel with Fresh Grease 7 Place the sensor back on the base plate Make sure the rotation pin seats firmly in the pin cavity the pin will seat correctly only one way Figu
226. r metallic material and may crack the Retaining Ring The O ring provides tightness while preventing vibration from loosening the mounting screws P N 7010 0491 11 15 Maintenance Figure 11 16 Replace and Tighten Mounting Screws 8 Ensure the metallic surface inside the Transducer has no visible wrinkles If distortion is evident repeat step 5 on page 11 14 to step 8 9 Place a new Filter Foam over the Transducer The Sonic Tracker II is now ready for operation 11 16 System Five 3D Reference Manual Chapter 12 Troubleshooting In general as long as you follow the maintenance and safety instructions provided in this manual you should have few problems with your System Five 3D This chapter will help you diagnose and solve some common problems you may encounter with the various components Before contacting TPS Customer support about any problems try the following and see the following sections e Check that the various components radio Rover Receiver Box control box Base Station receiver GRT 2000 etc have power and are powered up Check that all cables are securely and properly connected to the various components of the System Five 3D control box TM 1 mast Round Vibration Pole laser receiver antenna valves sensors etc See the Machine Setup section for your control application Disconnect cables and inspect them for damage or contamination Clean all connections with an electrical contact
227. r of linework TIN alignments or point information Select a color that contrasts with on screen information 1 To change the background color of the Main Screen press Topcon Logo gt View gt Display options gt Background color 2 Select a color and press Ok Figure 10 30 Figure 10 30 Color Selections P N 7010 0491 10 27 Grading Application Display Units Options To set the type of units used in the job press Topcon Logo gt View gt Display options gt Display units to display the Display Units dialog box Figure 10 31 Using this dialog box change the type of units displayed on the screen or update preset units in the files currently being used Note that any conversion will not affect grade accuracy Distances select either Meters US survey feet International feet or Feet Inches measures to a fraction of an inch If using Feet Inches all values will show as 1 11 1 2 where 12 inches equal 1 foot and any value smaller than an inch will show as a fraction of an inch Angles select either DD MM SS NDD MM SS or Gons Grades select either Percent or Run Rise Stations select either 100 000 1 00 000 10 0 000 or 1 000 000 Volumes select either Cubic meters or Cubic yards Coordinates select either North East Elev East North Elev or X Y Z Distances Hae i Angles DD MM SS Grades Percent Stations 1 00
228. r sensitivity select the sensitivity level for detecting the transmitter usually Auto Select a different setting when working at very short or very long distances or during inclement weather that can affect laser detection e Transmitter selection select the channel to scan for mmGPS connection The Any selection will allow the sensor to independently select the transmitter with the smallest error rate If setting up only one transmitter but the job has been configured for multiple transmitters select the individual ID of the transmitter for the sensor to detect e LaserZone aided init select to use the mmGPS signal to assist in initializing the GPS receiver This option is useful to decrease the initialization time when satellite visibility is limited for example tracking only four or five satellites e Calc LaserZone GPS weighted elevations select to combine Lazer Zone elevations and GPS elevations When selected this option will force the receiver sensor to always consider the angle and distance when determining the 1 Note the following exception If using more than one transmitter and all transmitters have been previously calibrated and initialized selecting Any will cause the 3DMC program to search for the transmitter with the smallest error rate even if the physical unit is not set up In this case the sensor will not detect the transmitter P N 7010 0491 7 17 mmGPS Application Setup a
229. r to maintain consistency between the office and the field Figure 10 24 Working Surface on the Main Screen P N 7010 0491 10 23 Grading Application Alignment Display Options When using either a road surface model or an alignment file press Topcon Logo gt View gt Display options gt Alignment to display the Alignment dialog box Figure 10 25 Alignment centerline color Alignment feature line color Show regular station lines Show station labels Station interval 100 00 Ok Cancel Figure 10 25 Alignment Display Options This dialog box has the following selections for displaying information on the main screen e Alignment centerline color sets the color of the centerline e Alignment feature line color sets the color for feature lines e Show regular station lines displays graphical cross lines relative to the horizontal alignments on the main screen Press the Station interval entry box to specify the longitudinal interval between lines e Show station labels displays station labels for each station on the main screen 10 24 System Five 3D Reference Manual Changing Display Options Linework Display Options When using a Linework file press Topcon Logo gt View gt Display options gt Linework to display the Linework layers dialog box Figure 10 26 Layer Show Show Ok Cancel Figure 10 26 Linework Layers Linework files
230. rading up and downhill with a rotated blade e Grader System Five 3D uses the cross slope system to measure the cross slope of the cutting edge and reports a measured slope as the cross slope reading e Dozer System Five 3D uses only the Blade Slope Sensor to control cross slope During automatic control the control box sends corrections to the hydraulic valve to tilt the blade to the desired cross slope In 3D control applications the machine position and orientation combined with Design Surface information determines the design cross slope This cross slope continually updates while the machine travels within the design surface In 2D control the operator manually dials in the cross slope fixing the angle of the blade for grading until the operator changes the slope setting 1 30 System Five 3D Reference Manual Blade Slope Sensor Elevation Control Overview The Blade Slope Sensor contains an electronic level vial that acts like a precision carpenter s level As the blade tilts the Blade Slope Sensor measures the slope of the cutting edge and sends this blade slope data to the control box Figure 1 34 10 0 25 COO R B O 10 0 35 Figure 1 34 Blade Slope Sensor Function P N 7010 0491 1 31 Introduction Rotation Sensor The Rotation Sensor contains an electric potentiometer As the blade rotate
231. rating current Operating 0 to 60 C 32 to 140 F Temperature Resolutions 0 5 degrees Range 360 degrees Figure C 5 shows the dimensions of the Rotation Sensor 2 6 6 25 MOUNTING P PLATE TYPICAL Figure C 5 Rotation Sensor Dimensions C 6 System Five 3D Reference Manual Mainfall Sensor Mainfall Sensor The Mainfall Sensor provides superior accuracy and repeatability is free adjusting and has a rugged sealed design Table C 6 lists specification details for the Mainfall Sensor Table C 6 Mainfall Sensor Specifications Housing Cast aluminum Supply Voltage 10 to 30 VDC Operating Current Typical 100 mA Operating 0 to 60 C 32 to 140 F Temperature Resolutions 0 025 slope Range 0 to 20 slope P N 7010 0491 c 7 Specifications Figure C 6 shows the dimensions of the Mainfall Sensor H ad em lt EU pa Geile p 5 0 SENSING AXIS IER Control Box 2 TOPCON 13 0 gt Figure C 6 Mainfall Sensor Dimensions c 3 System Five 3D Reference Manual Rover GPS Receiver Box Rover GPS Receiver Box The Rover GPS Receiver provides the industry s most advanced GLONASS and GPS dual frequency satellite tracking system in a heavy duty construction design with a shock absorbing mounting bracket Four high power bottom mounted magnets keep receiver in place on m
232. re 11 5 RA J Place Rotation Sensor On Base Plate F Ensure Rotation Pin Aligns Correctly Figure 11 5 Replace Sensor on Base Plate P N 7010 0491 11 5 Maintenance 8 Place the two halves of the retaining rings on the base plate with the screw holes aligned and replace the four screws Figure 11 6 Tighten until firm Place Both Halves Of Retainer Ring On Rotation Sensor Base And Re install Screws Figure 11 6 Replace Retainer Rings 9 Realign the sensor arm with the L bracket and replace the shoulder screw washer and jam nut Figure 11 7 Tighten until firm Rotate Sensor Until Arm Lines Up With L Bracket And Install Shoulder Screw Washer And Jam Nut Figure 11 7 Replace L Bracket Before returning the Rotation Sensor to work the Rotation Sensor must be calibrated again See Sensor Calibrations on page 4 3 for this procedure 11 6 System Five 3D Reference Manual Preventative Maintenance Pole dampening Bushing Replacement on Round Vibration Pole The Pole dampening Bushing and the Bottom Support should be periodically replaced depending on its fatigue level To identify a fatigued part observe the clearance and play between the pole rim and the Bushing bore The two Bottom Support pieces should be replaced at the same time Fatigued Bushing and Supports may affect the performance of satellite tracking or may cause hardware damage
233. re 7 7 on page 7 10 shows the mounting and cable connections for the PZS MC receiver P N 7010 0491 7 7 mmGPS Application Setup and Usage The PZS MC receiver has the following setup E requirements e Face the receiver s logo and LEDs forward face the connectors towards the machine e Connect the right angle end of the serial cable to the PZS MC receiver 1 With the blade placed on level ground position the pole vertically 2 Attach the PZS MC receiver to the pole and position the it with the LEDs facing forward Figure 7 6 Tighten the hand knob 3 Connect the cable to the receiver and then to the machine antenna cable to the connector on the left e serial cable to the connector on the right LED s _ gt FORWARD Level GPS Vibration Pole Figure 7 6 Level GPS Vibration Pole and Attache PZS MC 7 8 System Five 3D Reference Manual Machine Setup Blade and Antenna Measurements mmGPS antenna systems require the same measurements as for standard GPS setups These values will then be entered during machine setup see Activating mmGPS Control in 3DMC on page 7 11 D Incorrect measurements or data entry errors have a direct affect on grading accuracy Take each measurement twice to ensure accuracy See Figure 5 7 on page 5 11 for an illustration of the following measurements e The height of the PZS MC receiver fr
234. re to do gt so will result in losing all information and require you to repeat the process System Five 3D Reference Manual Machine Setup Step 2 Activate 2D Control Press Topcon Logo gt Control gt 2D Control to activate 2D control mode Figure 9 11 3DMC will connect to the 2D components and the Elevation Control key will display either a laser receiver icon or a sonic tracker Figure 9 11 2D Control on the Plan View P N 7010 0491 9 9 2D Application Setup and Usage 2D Control Operations Some 3DMC operations such as quickly locking on grade and changing the control mode are only available while in 2D control These functions are discussed on the following pages Other application independent functions are discussed in Chapter 10 Locking On grade The Survey button is used to quickly lock on grade performing the same function as the Remote Smart Knobs feature See Remote Smart Knobs Operation on page 2 25 for details To lock the elevation on grade Figure 9 12 1 Press the Elevation Control key 2 Press Survey to quick lock on grade 3 Press Ok to return to the Main Screen To lock the slope on grade 1 Press the Slope Control key 2 Press Survey to quick lock on grade 3 Press Ok to return to the Main Screen Elevation left edge Elevation right edge Elevation valve gain 75 Set Elevation set point 0 55 Set oO survey Zero Change to Slope Ok Ca
235. rectly connected DB9socket and the iPAQ serial cable black iPAQ connector DB9pin should be firmly connected Check that the battery has a full charge If still no connection try to reset the computer and repeat The cable settings in Check that the RS 232 settings at the GRT the GRT 2000 may be 2000 are as follows incorrect BIT FORMAT D8 S1 NONE TRANSMIT SPEED 38400 TERMINATE EXT CRLF If still no connection try to reset the computer and repeat Problem GRT 2000 displays an error code Causes Solutions The GRT 2000 has an internal error Refer to chapter 10 Error Displays in the GRT 2000 Instruction Manual for help diagnosing the error code Problem GRT 2000 loses signal or tracking Causes Solutions The GRT 2000 is out The working range of the LPS system is 10 of range to 300 meters approximately 35ft 1 000ft in optimum conditions P N 7010 0491 12 5 Troubleshooting Environmental conditions are affecting the working range The system applies a high rate optical scanning and measuring technology that although free from electromagnetic noise radio interference dusty hot and other environmental conditions may affect the working range during operation If this occurs turn off automatic control and grade manually until you are back with the working range or where the environmental conditions no longer affect the signal Excessive un
236. ress Topcon Logo Key to view menus Figure 2 9 Topcon Logo Menus P N 7010 0491 2 13 Component Functions Table 2 3 describes the functions available under each menu Table 2 3 3DMC Menus Description Menu Available Functions File menu creating editing and deleting control oint files Control ae a creating editing and selecting Surfaces 3 working and reference design surface Linework files Point files selecting alignment files selecting linework Exit 3DMC creating editing and deleting point files exiting 3DMC Control menu mmGPS applications Machine setup Blade control Road subgrade Steer indication PZS MC receiver PZL 1 transmitters Calibrate sensors Valve offsets 2D Control creating editing copying and deleting machine setup files setting blade control if a road file is selected as the reference surface setting road subgrade properties selecting the steering indication configuring the PZS MC receiver configuring up to four PZL 1 transmitters calibrating the slope sensor applying valve offsets enabling 2D control Control menu 3D GPS applications Machine setup Blade control Road subgrade Steer indication Calibrate sensors Valve offsets 2D Control creating editing copying and deleting machine setup files setting blade control selecting the steering indication calibrating the slope s
237. ringline centered to the pole Measure the distance from stringline to cutting edge Figure 6 3 4 To measure the height value keep the antenna in the same position and measure the distance from the cutting edge to the leading edge of the leading antenna Figure 6 3 5 Measure the distance of the antenna beyond the outside edge of the blade See Figure 5 7 on page 5 11 for an example Measure BEHIND value Measure HEIGHT value Figure 6 3 Measure Antenna for Motorgrader P N 7010 0491 6 5 Dual GPS Application Setup and Usage Radio Antenna Installation The radio antenna is attached to the machine s roof using a magnetic mount and generally stays on the machine The antenna should be positioned vertically and as high as possible on the machine to maximize signal reception See Radio Antenna Installation on page 5 12 for more details MC 2 5 GPS Receiver Box Setup for Dual GPS Applications The MC 2 5 receiver box is designed for quick attachment at the beginning of the day and quick removal at the end of the day When connecting cables to the receiver box Figure 6 4 on page 6 7 ensure that the cables do not impede machine operation 1 If needed attach the MC 2 5 box to a convenient location on the machine 2 Connect the MC A2 antenna cables to the following ports e The main GPS antenna connection is marked with yellow indicators and is connected to the forw
238. rmation needed to accurately grade the jobsite The job files you need include control point files design surface files and machine configuration files This chapter discusses how to create and access these files Copying 3DMC Files You can copy the following files between the 9168 control box and other applications using a Compact Flash card e Control point files e Alignments e Surface files e Points e Linework e Machine configurations 1 Insert the compact flash card and turn on the control box 2 When the 3DMC main screen displays navigate to the desired file type dialog box Figure 3 1 on page 3 2 shows an example of copying a control file Topcon Logo gt File gt Control e Topcon Logo gt File gt Surfaces gt Working or Reference Topcon Logo gt File gt Linework Topcon Logo gt File gt Alignments e Topcon Logo gt File gt Point files Topcon Logo gt Control gt Machine setup P N 7010 0491 3 1 Building Job Files 3 Press Copy and select the location of the file to copy from the Copy drop down list Figure 3 1 either from data card to internal disk or from internal disk to data card re Copy KOIR ELEKE em Com lelciderimel iid Project files New Edit Copy Di Ok Ok Cancel Figure 3 1 Copying File to the GMU Internal Disk 4 Select the file to copy and press Ok Figure 3 2 During the copy process an hourglass
239. rol 2 29 Smart Knob control 2 25 Background change color 10 27 Base station LEDs 5 6 Benchmark 10 21 Blade control 1 37 1 39 5 19 8 22 Blade trim 4 10 adjustment 4 11 Blue 10 6 Cc Change color 10 23 display 10 7 10 22 radio channel 5 24 units 10 28 Clear NVRAM 10 35 Compact flash card 3 1 copy files from 3 1 Connectors 2 9 2D 9 6 3D GPS 5 14 3D LPS 8 16 base station 5 5 LPS station 8 4 sonic tracker 9 2 trackerjack 9 4 Index Index Control box 1 7 authorization codes 10 34 dozer 2 1 grader 2 1 options 10 34 Control menu 2 14 2 15 Control point accuracy 5 27 localization 5 28 location 5 27 Control point files control box 3 6 Coordinates elevation reference 3 18 3 22 GPS 3 5 LPS station 8 6 8 8 NEZ 3 5 3 18 3 22 Copy files 2 11 3 1 Copying 3DMC Files 3 1 Creating a Linework File A 16 Cross slope 4 3 adjust 4 7 4 7 4 8 4 9 calibrate 4 4 4 6 grader 4 4 4 6 Cut fill 2 17 See also Offset adjust elevation 2 19 2 20 2 21 and grade indicator 10 16 10 17 change 10 15 10 20 grade indicator 10 16 in from edge 10 17 left edge 10 16 negative 10 15 10 20 offset 2 19 2 20 2 21 positive 10 15 10 20 reading 2 19 2 20 2 21 section view 10 8 10 10 10 12 Delete files 2 12 Design surface 3 14 display options 10 22 Index Design surface file create plane model 3 17 3 19 3 20 3 23 3 24 3 25 3 26 3 28 Display 10 22 10 28 See also Views alignments 10 24 boundaries breakline
240. rol application Figure 2 11 Figure 2 12 and Figure 2 13 Upper number in 3D control displays the current the Cut Fill Offset and can be changed at any time If the machine is incapable of cutting to the Design Elevation the operator dials an offset into 3DMC raising or lowering the Design Surface for a more manageable cut or fill Lower number in 3D control displays the current Cut Fill Reading or distance from finish grade The number continuously updates according to the elevation difference between the cutting edge and the Design Surface Single number in 2D control displays the current elevation setting and can be changed at any time Elevation Control Key color the background color of the elevation control key indicates sensor status Green indicates sensor status suitable for grading Red indicates an error status and Automatic Control will be disabled Orange in GPS mmGPS applications indicates low GPS precisions Icon color for mmGPS applications the icon color will be BLUE when the system is receiving ammGPS signal and GRAY when a mmGPS signal is unavailable Icon status a crossed out icon indicates the corresponding sensor receiver is not available A flashing radio icon indicates the radio link is between three and ten seconds old weak signal P N 7010 0491 2 17 Component Functions Cut Fill Offset Cut Fill Reading GPS Status Radio Status PZS MC Statu
241. rol point using the section view e To move to the far left or far right edge of the blade press and hold the edge of the blade for one second On the pop up menu tap Move control left or Move control right e Press and hold a point on the blade for one second On the pop up menu tap Move control Figure 5 18 illustrates this process _ 66 15 13 0 03 Figure 5 18 Move Blade Control Point Using Section View To change the blade conirol point using the Control menu 1 Press Topcon Logo gt Control gt Blade control 2 With Control using single point on blade selected hold the slider button and move it left or right to select a point at a distance from the left right side of the blade Figure 5 19 on page 5 20 3 Press OK to apply this blade control point to the machine Automatic best fit whole blade Control using single point on blade From left 2 854 From right 6 988 Ok Cancel Figure 5 19 Blade Control Using Single Point on Blade 5 20 System Five 3D Reference Manual Operations for GPS Control Viewing GPS Information To view the GPS information dialog box and tabs press the Elevation control key then press the GPS info button Figure 5 20 eel Elevation left edge 63 50 Elevation right edge 65 24 i i 75 Elevation valve gain Set Elevation set point 0 550 Set Match Zero 0 e info Ok Cancel Figure 5 20 View GPS I
242. s Speaker The control box produces sounds through the speaker to indicate certain activities such as selecting a menu option or changing a selection on the 3DMC main screen Cooling Fan Inlet and Outlet The control box has an efficient air cooling system to keep it from overheating When powered on the cooling fan rotates bringing air in through the cooling fan inlet The air then circulates through the control box cooling down components and out the cooling fan outlet Air within the enclosure constantly circulates automatically cooling the internal heat sink plate Do not place objects that can obstruct air circulation near the inlet and outlet USB Port Slot The USB port slot allows you to connect with a commercial keyboard or mouse You can use a keyboard or mouse in the same way you use the touch screen to navigate through menus and enter information A rubber flap seals the USB port slot preventing dust water etc from entry Keep the rubber flap closed while not in use to prevent dust from entering the port Power Switch The power switch Figure 2 4 turns on the control box as well as the sensors installed on the machine After a few moments the 3DMC software appears on the touch screen display and is ready to use Figure 2 4 Power Switch 2 8 System Five 3D Reference Manual Control Box The control box saves and stores previous settings Cut Fill Offsets and the cross slope calibration
243. s Rev B A 1 Pocket 3D Getting Started Guide Equipment Setup GPS Equipment setup consists of jobsite files to ensure correct data is used for positioning activities and a machine file to ensure the correct measurements are taken Step 1 Create a Control Point File First create a control point file Figure A 2 1 Tap Data gt Control gt lt none gt or file name Tap New to create a control point file Enter a name for the file and press Ok Select the control point file and press Ok A ees Press Yes to apply the file to the jobsite B Topcon Pocket 3D 41 52 T46 Control point files PP_topo_Nov20 SIMPSON S RANCH CONTROL Control points Import Export Cale wizard Clear gum ig Topcon Pocket 3D Control point files PP_topo_Nov20 SIMPSON S RANCH CONTROL New control file name TEST Info Copy Delete Rename Save As Cancel Figure A 2 Create a Control Point File A 2 Pocket 3D Getting Started Guide Equipment Setup GPS Then enter control point data into the file Figure A 3 1 Tap Data gt Control gt Control points 2 Tap Add to enter the local coordinates for the control point 3 Enter a name and description for the control point and its local coordinates Press Ok Repeat steps 2 and 3 for each control point 5 Press Ok to save the data opc
244. s To quickly change the cut fill offset turn the grade adjustment knob until the you reach the desired elevation Figure 10 11 The cut fill offset number increases decreases and the scale on the grade indicator updates Grade Indicator also updates ili Figure 10 11 Changing Offset Using Joystick Buttons 10 14 System Five 3D Reference Manual Changing Cut Fill Offsets Changing Offsets Using the Elevation Control Key 1 On the 3DMC Main Screen press the Elevation Control key 2 Press the Elevation set point Set key changing it to red Elevation left edge 66 088 Elevation right edge 67 963 Elevation valve gain 75 Set a Elevation point 0 000 Set ch Zero GPS info Ok Cancel Figure 10 12 Press Elevation Control Key then Set 3 Change the offset using the numerical keyboard the buttons on the joystick or the up down arrows on next to the entry field e Press the Elevation set point entry box tap in a new offset value and press Ok Figure 10 13 A negative value is a Cut a positive value is a Fill e Press the buttons on the joystick to quickly increase or decrease the offset value 25 7 8 9 lt lt 4 6 6 1 2 3 Oe Ok Cancel Figure 10 13 Use Keyboard to Change Offset 4 Press OK to set the new offset value and return to the 3DMC Main Screen P N 7010 0491 10 15 Grading Application Changing the Grade Ind
245. s commonly use Set Points when the job application requires multiple settings from one pass to another Each time the operator toggles the right side switch inward the current Set Point number appears on the main screen above the control keys Figure 2 23 When holding the toggle switch inward for one second the control box cycles to the next Set Point and the number on the screen changes accordingly Figure 2 23 Set Points Selection 2 28 System Five 3D Reference Manual Simple Auto Manual Knob Operation Simple Auto Manual Knob Operation The Simple Auto Manual Knob allows the operator to switch between Automatic and Manual control during operation Figure 2 24 e Automatic Control Flip the switch forward to activate this control mode e Manual Control Flip the switch backwards to activate this control mode Flip Lever Forward for Auto Flip Lever Backward for Manual Figure 2 24 Simple Auto Manual Knob The knob is normally placed just below the blade control lever for easy access allowing the operator s hands to stay near the control lever P N 7010 0491 2 29 Component Functions MC 2 5 GPS Receiver Box Functions Three LED indicators on the MC 2 5 GPS Receiver Box provide status on power satellites and radio signal Figure 2 25 Two function FN buttons provide diagnostic and reset for the internal receiver boards Radio RX LED radio status indicator This LED blinks gr
246. s the Rotation Sensor monitors the rotation of the blade and sends this rotation data to the control box Figure 1 35 Since the desired cross slope is perpendicular to the direction of the machine travel the control box uses the rotation data to compensate for the difference between the cross slope and the blade slope Note that the more the blade is rotated the bigger the difference is between the cross slope and blade slope 10 0 Slope Cross Slope Reading 10 0 y iy Blade Slope Angle gt tb Direction a N piin is moving AS wy Figure 1 35 Rotation Sensor Function Mainfall Sensor The Mainfall Sensor contains an electronic level vial just like the Blade Slope Sensor As the machine travels uphill on ascent or downhill on descent the Mainfall Sensor measures the longitudinal slope of the machine and sends this mainfall data to the control box Figure 1 36 on page 1 33 Again the desired cross slope is perpendicular to the machine travel The control box uses the mainfall data as well as the rotation data to compensate for the difference generated when the machine is uphill or downhill with the blade angled Note that the steeper the hill is the bigger the difference is between the mainfall slope and rotation slope 1 32 System Five 3D Reference Manual Elevation Control Overview Cross Slope Reading Blade Slope Angle eee a l p
247. s 10 23 contours 10 23 linework 10 25 10 29 10 31 points 10 26 polylines 10 29 10 31 triangle mesh 10 23 Dozer 2D control 1 6 2 1 3D control 1 5 1 6 2 1 cross slope 4 7 Edit files 2 11 EIM 2 31 LED blink indications 2 31 Elevation adjust for 3D 2 19 2 20 adjust in 2D 2 21 2 22 2 23 key 2 17 Elevation control 2 11 Elevation key blue 10 6 green 10 6 red 10 6 Elevation reference 10 16 10 17 F Files 2 14 control point 3 3 copy 2 11 delete 2 12 design surface 3 14 edit 2 11 new 2 11 System Five 3D Reference Manual G GPS coordinates 3 5 GPS information 5 21 5 24 8 24 cutting edge position 5 22 planning 5 24 status 5 21 GPS mask angle 5 22 GPS status receiver ID 5 23 satellites 5 22 Grade adjustment knob operation 2 5 Grade indicator 10 10 10 11 10 18 and elevation reference 10 16 10 17 and offset change 10 14 change extents 10 18 change on grade 10 18 cut fill 10 16 display 10 11 Grade indicators 2 3 Grader 2D control 1 3 1 4 2 1 3D control 1 3 1 4 2 1 cross slope 4 4 4 6 Green 10 6 J Joystick operation 10 15 10 20 K Keyboard connect using USB 2 8 pop up 2 12 L Laser height 1 35 location advice 1 34 placement 1 34 P N 7010 0491 Index Laser sensor 1 16 installation 8 13 LEDs 5 6 5 8 10 36 on MC 2 5 2 30 Level LPS station 8 2 Light bar 10 13 10 18 and alignment file 10 13 display 2 15 10 12 steer to polyline 10 29 Light Bar Scale 10
248. s Radio Status i Dual GPS Status Radio Status Figure 2 11 Elevation Control Keys for 3D GPS Applications Cut Fill Offset Cut Fill Reading GRT Status LS2000 Status Figure 2 12 Elevation Control Key for 3D LPS Applications Elevation Setting Laser Sensor Status Sonic Tracker Status Figure 2 13 Elevation Control Key for 2D Applications The Elevation Control key also provides access to elevation information and elevation configuration functions The information and available selections depend on the current control application and are described in the following sections See Changing Offsets Using the Elevation Control Key on page 10 15 for more details on using this dialog box 2 18 System Five 3D Reference Manual 3DMC Functions Adjust Elevation in 3D GPS Control To display the following elevation settings for 3D GPS applications Figure 2 14 press the Elevation Control Key Elevation left edge displays the elevation of the left edge of the blade based on local site coordinates Elevation right edge displays the elevation of the right edge of the blade based on local site coordinates Elevation valve gain displays the current Valve Gain setting for elevation control The valve gain setting determines the speed of the hydraulic response during Automatic Control A higher setting speeds up the response a lower setting slows down the response See Adjusting Valve Gain on page
249. s at a constant time interval e Minimum distance available when minimum distance selected tap the entry box to display the small pop up keyboard and enter the minimum distance by which to log points Time interval secs available when time interval selected tap the entry box to display the small pop up keyboard and enter the time interval in seconds in which to log points Log to layer stores measured points to the selected layer Log at determines the measurement point relative to the cutting edge Lower all elevations by used when keeping the blade a certain distance above ground to prevent the cutting edge from digging into the surface Manually measure the height between the ground and the target position on the cutting edge then tap the entry box to display the small pop up keyboard enter the measured height value and press Ok Use a positive value when the cutting edge is above the design surface 10 32 System Five 3D Reference Manual Performing Topographic Surveys Log by minimum distance if Minimum distance 30 00 Logtolayer GROUND Log at Left edge of blade p Lower all elevations by 0 00 Ok Cancel Figure 10 36 Enter Parameters for a Topo Survey 3 Press Ok to start the topo survey function 4 Begin driving When the machine begins to move 3DMC will begin measuring and logging the data 5 To stop topo measurements press Topcon Logo gt Stop topo survey Figure
250. s follows 1 First ensure the Pocket 3D search parameter Set search area at GRT is checked ON 2 Then ensure the GRT 2000 search parameters are set as follows SEARCH PATTERN is set at HIGH and SEARCH AREA is set toH 5 V 15 Rover GPS Receiver Box This section lists possible Rover GPS Receiver Box problems you may encounter If you still have problems after trying the solutions listed here contact TPS customer support Problem Causes The power cable may be incorrectly connected The control box does not have power P N 7010 0491 Power indicator does not flash red Solutions Power is supplied through the cable connected on the Power port Check that the cable is properly connected The Receiver Box turns on only while the control box is powered on 12 7 Troubleshooting The Receiver Box receives power from another source which is not on Problem Causes The cable is incorrectly connected or damaged Satellite Status indicator does not flash green If power is supplied through another cable connected to the power port check that the origin of the power cable and other connectors are secure The power cable may be connected to an ignition switch or a master circuit on the machine if so turn on the power source Solutions Check that the antenna cable is not cross threaded at the antenna and is connected to the intermediate cable installed
251. slope when a dozer or motordromes travels backwards in automatic control e Dozer blade rotation Dual GPS allows six way blades on dozers to rotate freely e Grader blade tilt Dual GPS maintains correct elevation even when the blade is tilted See Recommended Tilt Angles for the MC A2 on page 6 11 for details on tilt angles P N 7010 0491 6 1 Dual GPS Application Setup and Usage Equipment Setup Base Station The Base Station always sets up over a Control Point on the jobsite to ensure accuracy the Base Station GPS antenna must be positioned directly over the top of the Control Point When setting up the Base station make sure you select the correct point from the control points file and verify the point has a northing easting and elevation coordinate The more accurate these coordinates are the tighter the control while grading for detailed instructions on setting up the Base D See Equipment Setup Base Station on page 5 2 Station for GPS applications Use the following checklist for quick setup of the Base Station C Select a control point and install the Base station over it Measure the antenna height Connect all Base Station components and cables 000 Select the correct radio settings Refer to your Base Station s documentation for specific radio configuration procedures The Base and Machine must use the same radio settings C Initialize the Base Station using Pocket 3D Once
252. st Slope Dialog Box 3D LPS and GPS Control Adjust Slope in 2D Control To display the following slope settings for 2D applications Figure 2 19 on page 2 24 press the Slope Control Key e Blade slope the current percentage of slope for the blade slope sensor e Slope Gain displays the current Valve Gain setting for slope control The Valve Gain setting determines the speed of the hydraulic valve response while in Automatic Control A higher setting speeds up the response a lower setting slows down the response See Adjusting Valve Gain on page 10 19 for details on setting the valve gain e Survey used to quickly lock the blade on grade e Change to Elevation used to switch to 2D elevation control P N 7010 0491 2 23 Component Functions Blade slope 0 0 Set Slope gain 25 Set Survey Change to Elev Ok Cancel Figure 2 19 Adjust Slope Dialog Box 2D Control About 3DMC To view About 3DMC information press Topcon Logo gt View gt About 3DMC The About 3DMC dialog box displays the displays version number copyright date and publisher registered user and authorization codes Figure 2 20 3DMC 6 11 Control firmware 0 OS date Copyright C 2002 2006 Topcon Positioning Systems Registered to WORKER BOB Options Co Figure 2 20 About 3DMC Dialog Box To check and or update control box options see Viewing and Updating 3DMC Optio
253. stalled around the cylinder on the motor grader or around the nose of the bulldozer Plug the female connector to the middle connector on the TM 1 Mast P N 7010 0491 8 13 3D LPS Application Setup and Usage Figure 8 11 shows the machine setup for 3D LPS control applications Heavy Coil Cord Z ooo fo Figure 8 11 LS 2000 Grader and Dozer Setups 8 14 System Five 3D Reference Manual Machine Setup Blade and Antenna Measurements Take the following measurements for the sensor and machine and record these measurements for entering into 3DMC Figure 8 12 e The height of the sensor from the outermost position on the metal rim of the antenna to the cutting edge e For dozers the distance of the sensor from the right edge of the blade e For graders the distance of the sensor beyond the outside edge of the blade The distance of the sensor behind the cutting edge If unknown the width of the blade DISTANCE FROM RIGHT gt EDGE OF BLADE DOZERS gt DISTANCE i BEHIND CUTTING EDGE DISTANCE BEYOND ie OUTSIDE EDGE OF a BLADE GRADERS Figure 8 12 Measure Sensor Placement on Blade of Machine Incorrect measurements or data entry errors have a E direct affect on grading accuracy Take each measurement twice to ensure accur
254. t Control Point file is selected Data Control Figure 5 5 on page 5 8 shows the procedure listed below 1 Connect the controller and receiver Tap Setup gt Base station 2 Select the control point over which the base station is installed and the connection between controller and receiver Press Next 3 Enter antenna type and height information Press Next 4 Enter radio type and communication information If using a Pacific Crest PDL UHF radio press Configure the select channel information and press Set Press Next P N 7010 0491 5 7 3D GPS Applications Setup and Usage 5 Press Finish to initialize the GPS receiver and start the Base 6 Immediately disconnect the Pocket 3D controller from the receiver a Performing any other activities while connected to the Base Station will convert the Base to a Rover 7 Check that the TX LED on the Base radio flashes once a second This indicates data transmission Equipment Radios Aia Topcon Pocket 3D Pacific Crest PDL UHF Port Serial Port C Baud rate 38400 Format CMR Configure Cancel Control point PP3 Connection Pocket 3D Serial Cable on COM1 Antenna type opcon PG A1 v Antenna height 6 56 Measured to Base v v Feet 412 Ready to connect Press the FINISH button to connect to GPS receiver J Topcon Pocket 3D Cancel ALLEEN 6 37p Ok
255. t side of the subgrade element This will determine the slope for the left right side of the machine or road If selecting Copy from use the gradient grade of the reference cross section element that matches the entered offset value lateral offset from centerline The left right grade will be copied from the existing road Select the slope extension for both the left and right side Figure 3 32 on page 3 30 e If selecting Vertical the cross section of the subgrade at will stop at the same horizontal offset as the cross section of the reference surface e If selecting Continue the last element of both surfaces selected in the Maximum extension entry box will be continued Select this option if there are more intersection points expected beyond the end of the cross section P N 7010 0491 3 29 Building Job Files 5 If selecting Continue for either the left right side slope extension enter the Maximum extension This is the distance limit of how far the extension goes beyond the end of the cross section of the reference surface Maximum extension only active if at least one side has Continue selected in the Extend slope entry box Elevation adjustment 3 281 O Grade Left side Right side Manual 10 000 10 000 Copy from Extend slope Vertical Continue Maximum extension 32 808 Figure 3 32 Select Grade and Slope Extension Parameters 3 30 System Five 3D Refer
256. tches the entered offset value lateral offset from centerline The left right grade will be copied from the existing road 4 Select the slope extension for both the left and right side Figure 3 30 on page 3 28 e If selecting Vertical the cross section of the subgrade at will stop at the same horizontal offset as the cross section of the reference surface e If selecting Continue the last element of both surfaces selected in the Maximum extension entry box will be continued Select this option if there are more intersection points expected beyond the end of the cross section 5 If selecting Continue for either the left right side slope extension enter the Maximum extension This is the distance limit of how far the extension goes beyond the end of the cross section of the reference surface Maximum extension only active if at least one side has Continue selected in the Extend slope entry box 6 Press Next Figure 3 30 on page 3 28 P N 7010 0491 3 27 Building Job Files grade oF ein rag J Road 6220 A12 Grade Work Elevation adjustment 3 2810 EQ gt crade Left side Right side Manual 10 000 10 000 Copy from 0 327 0 327 Q gt Extena slope Vertical Maximum extension zz Next Figure 3 30 Select Grade and Slope Extension Parameters 7 Press Finish to save the new surface file and end the process On the section view the new road has the sam
257. ted string on one pass then matching grade on the next pass consider the Tracker position so it works for both applications without having to move the Tracker P N 7010 0491 9 3 2D Application Setup and Usage Machine Setup Trackerjack 1 Bolt the vibration pole to the L Bar installed on the machine s blade For graders visually check to get the L Bar and vibration pole plumb Attach the laser tracker or LS B4 to the Trackerjack Attach the coil cord to the Trackerjack then attach the cables to the control box Turn on the control box 4 Place the Trackerjack on the vibration pole so the four wheels slide into the slots at the bottom of the pole Figure 9 4 Figure 9 4 Attach Trackerjack to Vibration Pole 5 Raise the Trackerjack until its magnetic pickup sensor is above the magnet at the bottom of the pole Figure 9 5 on page 9 5 The magnets at the top and bottom of the pole keep the Trackerjack on the pole 9 4 System Five 3D Reference Manual Machine Setup Magnetic Sensor Figure 9 5 Attach Laser Tracker System to Machine 6 Position the vibration pole vertically so the Trackerjack is at an optimum height for the job application Figure 9 6 For graders position the L Bar horizontally so the Laser Tracker is near the end of the moldboard y 9 8 Figure 9 6 Laser Tracker Machine Setup l For most jobs position the vibration pole so the Fas receiver is just above
258. ter Then perform one of the following functions Figure 7 2 To load transmitter data for the first time tap Download to retrieve calibration data from the connected transmitter The download is complete when the firmware version displays in the Firmware column To add a transmitter tap Add and enter a transmitter serial number or other description e To delete a transmitter select a transmitter and tap Delete e To calibrate the transmitter see Transmitter Adjustment on page 7 23 Once the Transmitters tab contains a list of transmitters each transmitter must be set up on a unique channel The channel button on the transmitter determines the channel that the transmitter broadcasts on Serial Cable on COM1 Figure 7 2 Load Transmitters into Pocket 3D To enter transmitter setup information tap the Channel tab and select the connected transmitter then press Edit Channel Set the following parameters and tap Ok Figure 7 3 on page 7 5 Transmitter select the ID of the transmitter 7 4 System Five 3D Reference Manual Equipment Setup e Control Point select the control point over which the transmitter is set up e TX height enter the height of the transmitter e Measured to select where on the transmitter Base or Mark Slant the height was measured 8 If needed repeat steps 6 and 7 for up to three other transmitters 9 Press OK when done Transmitters Channel Ch 1_
259. th abrasive materials will scratch the front surface and image quality will be detrimentally affected For best results use a clean damp non abrasive cloth towel and any commercially available window cleaner to regularly clean the surface The cleaning solution should be applied to the towel rather than the surface of the touch screen Many touch screens have air vents and are not designed with water tight bezels Fluid ingress may occur from behind the panel if it is not cleaned properly 1 Dust the Touch Screen Display lightly with a non abrasive cloth towel 2 Dampen the towel with water or a very diluted mild neutral detergent solution Never use alcohol ether benzene acetone or any E sort of solvent Do not use a high pressure spray Do not spray towards the screen the speaker or the fan 3 Wipe residual dust off with the damp towel 4 Clean any residual detergent solution off by using a cloth dampened with only water Then wipe water and damp area completely dry around the screen 5 Allow to dry thoroughly Store the control box in its carrying case 11 2 System Five 3D Reference Manual Preventative Maintenance Rotation Sensor Cleaning and Lubrication The Rotation Sensor base plate should be periodically cleaned and greased Although the sensor does not need lubrication the grease will keep contaminations from accumulating in the base plate and binding the sensor may need to be more frequent if o
260. the Working Window and no on grade correction signals will be applied 1 28 System Five 3D Reference Manual Elevation Control Overview 2D Laser Control Overview In 2D Laser Control a rotating laser transmitter produces a plane of laser beam which becomes the grade control reference for the job site The laser receiver controls the blade to cut grade parallel to the laser beam reference Figure 1 32 Figure 1 32 Laser Grade Control Reference As the plane of laser beam hits the laser receiver LED lights indicate the direction of movement for the moldboard to reach on grade Figure 1 33 on page 1 30 e When the laser beam hits the center of the receiver it indicates an On Grade signal As the blade raises the laser beam hits the receiver below the center and indicates a lower signal The control box then applies lower hydraulic valve corrections to bring the receiver back to on grade As the blade lower the laser beam hits the receiver above the center and indicates a raise signal The control box then applies raise hydraulic valve corrections to bring the receiver back to on grade P N 7010 0491 1 29 Introduction On Grade Above Grade Below Grade Lower Blade Raise Blade Figure 1 33 Laser Tracker Grade Indicators Slope Control Overview The slope control system consists of three individual sensors blade rotation and mainfall installed on the machine eliminating error caused when g
261. the machine frame when the Trackerjack is at the lowest position P N 7010 0491 9 5 2D Application Setup and Usage 2D Control Box Setup The control box is designed for quick attachment at the beginning of the day and quick removal at the end of the day 1 Using the hand knob attach the control box to the bracket Figure 9 7 Figure 9 7 Attach Control Box 2 Connect the various electrical cables Figure 9 8 Cable connections differ depending on the machine type Power Cable Cable to Mainfall Grader 2D Control Power Cable Cable to Valve Cable to Junction Dozer 2D Control Figure 9 8 2D Control Application Control Box Cable Connections 9 6 System Five 3D Reference Manual Machine Setup Activating 2D Control in 3DMC When using the System Five 3D for 2D control applications only the equipment file is relevant to 2D Control applications Other files settings and selections have no affect in this mode Step 1 Apply a 2D Machine Configuration The Machine Configuration file provides vital information about the type of machine selected All other sensor settings and measurements are ignored You must have a machine configuration file before beginning to grade 1 Press Topcon Logo gt Control Machine setup 2 Select the desired GPS configured machine file and press Ok 14H GRADER LPS 14H GRADER DUAL GPS DOZER D6 MC A1 DOZER D6 MMGPS GRADER RIGHT GPS 2a OOZER D6 2D LASER
262. ting when working at very short or very long distances or during inclement weather that can affect laser detection Channels select the channel to scan for mmGPS connection The All selection will allow the sensor to independently select the transmitter with the smallest error rate If setting up only one transmitter but the job has been configured for multiple transmitters select the individual ID of the transmitter for the sensor to detect LazerZone aided initialization select to use the mmGPS signal to assist in initializing the GPS receiver This option is useful to decrease the initialization time when satellite visibility is limited for example tracking only four or five satellites Calc LazerZone GPS weighted elevations select to combine LazerZone elevations and GPS elevations When selected this option will force the receiver sensor to always consider the angle and distance when determining the elevation then combine the two elevations accordingly This option works well at large 300m distances and steep angles 1 Note the following exception If using more than one transmitter and all transmitters have been previously calibrated and initialized selecting All will cause the Pocket 3D program to search for the transmitter with the smallest error rate even if the physical unit is not set up In this case the sensor will not detect the transmitter P N 7010 0491 3 11 Building Job Files
263. tion of the other setup methods 3 Enter instrument height measured in step 1 and the units used for measurement Press Next 4 Select the following control points e The control point over which the GRT 2000 is installed e The control point that will be used to measure the position of the GRT 2000 relative to the point it occupies 8 6 System Five 3D Reference Manual Equipment Setup GRT 2000 5 Ifthe reference backsight has a prism enable this check box and enter both the target height from the Control Point to the center of prism at backsight and the prism constant 6 Sight the backsight prism or the vertical reference if the backsight has no prism through the telescope exactly placing the cross hairs in the center of the prism Press Ok to measure J Topcon Pocket 14 6 Setup method Known station amp BS pts Instrument height 5 50 Units Feet 4 Known station amp BS pts Known station amp BS pts Known station amp azimuth New station by resection Station setup LS2000 receiver Units i D 0 E amp F topcon Pocket 3D 4142 JC Next Cancel ene Station HOMER bd Backsight Sight backsight and press MAGGIE OK to start measurement v Backsight has prism Target height 3 00 Prism constant 0 00 Figure 8 4 Enter Base Station Information and Start Base 7 Check that the backsight point is correct and al
264. to use the original shipping container or equivalent A letter should accompany the package furnishing a description of the problem and or defect The purchaser s sole remedy shall be replacement as provided above In no event shall TPS be liable for any damages or other claim including any claim for lost profits lost savings or other incidental or consequential damages arising out of the use of or inability to use the product 1 The warranty against defects in Topcon batteries chargers or cables is 90 days P N 7010 0491 E 1 Warranty Notes E 2 System Five 3D Reference Manual Index Numerics 2D control 1 1 2 1 checklist 10 6 control box 2 1 machine configuration files 3 7 5 15 6 8 7 11 8 17 9 7 setup 9 9 Smart Knob control 2 26 2 28 3D control 1 1 2 1 control box 2 1 control point files 3 3 GPS checklist 10 2 10 3 10 4 LPS checklist 10 5 machine configuration files 3 7 5 15 6 8 7 11 8 17 9 7 Smart Knob control 2 26 3DMC about 10 34 A About 3DMC 10 34 Adjust cut fill using Smart Knobs 2 26 Adjust elevation using Smart Knobs 2 26 Adjust slope 4 7 using Smart Knobs 2 26 Alignment files and grading 10 29 applying 10 30 display options 10 24 Antenna and MC 2 5 LEDs 2 30 radio 5 12 6 6 7 9 rover 5 10 P N 7010 0491 Index Authorization codes 10 34 Automatic control Simple A M Knob cont
265. tprint For example at about two feet from the tracker you will have a footprint or cone of about six inches 1 Connect the coil cord to the Sonic Tracker Figure 9 1 Figure 9 1 Attach Coil Cord to Tracker 2 Bolt the Tracker to the bracket and visually check to get the L Bar and Tracker plumb Figure 9 2 PLUMB Ko ee Figure 9 2 Bolt Tracker to Bracket 9 2 System Five 3D Reference Manual Machine Setup 3 Make one wrap of the coil cord around the L Bar Figure 9 2 This will act as a strain relief for the connector on the Tracker Ensure the coil cord snap hook is in place and secure 5 Position the L Bar horizontally so the Tracker rests over the reference for the jobsite Figure 9 3 Figure 9 3 Position L Bar and Tracker Over Grade Reference For example when tracking a stringline offset from the edge of the road set the end of the moldboard at the edge of the road and slide the L Bar so the Tracker is over the stringline Figure 9 3 When tracking a curb keep the L Bar in close to keep the Tracker over the lip of the curb 6 Raise or lower the Tracker bracket to position it at a proper height above the grade reference Figure 9 3 Although the Tracker can be set as close as 14 inches and as far as 55 inches from the grade reference consider the job application for the best set up For example when tracking multiple references using eleva
266. trol In 3D GPS mmGPS and 3D LPS Control with dozer applications the left side always directs elevation control and the right side always directs slope control In 2D Control with grader applications the operator controls the right and left sides separately so either side can be assigned to either elevation or slope control In 2D Control with dozer applications the left side always directs elevation control and the right side directs either slope or elevation control Control Box The control box is an integral part of System Five 3D and contains a display panel buttons for controlling 3DMC options a light sensor cable connectors and a machine mount The touch screen display panel displays Topcon s 3DMC software Simply tap the screen to make a selection or enter information e The buttons provide access to a menu of programs moving between selecting options and brightening dimming the screen P N 7010 0491 2 1 Component Functions e The light sensor monitors ambient light to automatically control the screen s backlight e The cable connector provides the communication link between the control box and the machine s components e The machine mount allows the control box to be conveniently mounted inside the cab for easy access and grade monitoring The control box and 3DMC software is the operator s main interface with the various system components and provides the following function e Displays t
267. trol Surface Alignment Linework From Point B To Point 7 Horiz dist 121 030 Slope dist 121 050 Azimuth 223 37 38 Gradient 1 826 Delta X 83 506 Delta Y 87 607 Delta Z 2 210 Back opcon Pocket 3D 6 30 fok Control Surface Alignment Linework Points Calc wizard Clear selection Figure A 30 Perform an Inverse Calculation A 28 Pocket 3D Getting Started Guide Notes A 24 Pocket 3D Getting Started Guide Appendix B Safety Information It is your responsibility to be completely familiar with the cautions described in this manual These messages advise against the use of specific methods or procedures which can result in personal injury damage to the equipment or unsafe operating conditions Remember most accidents are caused by failure to observe basic safety precautions General Precautions 1 Read and become familiar with the machine manufacturer s operating instructions including safety information before installing or using your Topcon equipment Use extreme caution on the jobsite Working around heavy construction equipment can be dangerous DO NOT attach System Five 3D brackets or hose connections while the machine is running DO NOT allow any System Five 3D component to limit the visibility of the operator Use Ty wraps supplied with System Five 3D to keep
268. ts Select the point to edit and press Edit 3 Check the local coordinates and press the GPS tab opcon Pocket 3D 46154 Coords GPS Control points North 5000 00 Options Eley 100 000 Calc wizard Clear selection Figure A 18 Select Control Point to Localize 4 Enable Use horizontal and Use Vertical and press Measure Press Ok to save the measurement Figure A 19 Name PP3 J Measuring Description Number of sats IR H Precision Coords GPS V Precision N33 14 52 00000 W111 25 45 00000 Measurements 320 00 Use horizontal Initialized se horizontal Use Vertical Serene rer Duration secs Figure A 19 Measure Control Point 5 Repeat steps 2 3 and 4 for each control point A 14 Pocket 3D Getting Started Guide Creating Files in Pocket 3D 6 View the results and press Ok to save the control point file V Error 0 038 0 022 0 094 0 007 0 005 0 022 Add Edit Delete fmport Figure A 20 Localized Control Points Creating Files in Pocket 3D In preparation for collecting point and polyline data create a points file and a linework file for the jobsite Creating a Points File 1 Tap Data gt Points gt lt none gt or file name Press New 2 Enter a name for the points file and press Ok 3 Press Layers O 2 x E New point file name MANHOLES
269. use sending Morse Code The Design Cross slope depending on the machine position and orientation is sent to the control box which then sends the appropriate corrections to the hydraulic valves Employing the Slope Control System System Five 3D controls the cutting edge to the Design Cross slope 3 Along with Design Surface information the fan beam transmits steering information This data provides the operator with simple graphics to help follow a curb line or the shoulder on a road If using 3D LPS control and the cutting edge gets outside the Working Window 20 of a foot the GRT 2000 continues to track the LS 2000 but System Five 3D no longer grades in automatic control 1 26 System Five 3D Reference Manual Elevation Control Overview 2D Sonic Control Overview In 2D Sonic Control the Sonic Tracker II measures and controls the elevations of the moldboard A transducer located in the bottom of the Tracker generates ultrasonic pulses like a speaker and listens for returned echoes like a microphone Figure 1 30 The Tracker measures the distance and controls grade from a physical grade reference such as a curb stringline or existing road surface Transducer Echo Bounces Tracker Uses Echo s Generates Off Physical Return Time To Calculate Ultrasonic Pulse Grade Reference Distance To Grade Reference Figure 1 30 Tracker Measuring Distance to Grade Reference The Sonic Tracker II mounts to the moldboard and as th
270. use the hydraulics to respond faster e If the blade is moving too fast and the Grade Indicators run past on grade decrease the Gain value to cause the hydraulics to respond slower To change the valve gain first change the elevation valve gain then change the slope gain 1 On the 3DMC Main Screen press the Elevation Control key 2 Press the Elevation valve gain Set key changing it to red Figure 10 18 on page 10 20 P N 7010 0491 10 19 Grading Application ies Elevation left edge 63 50 Elevation right edge 65 24 aa Elevation valve gain 75 g v Set Elevation set 0 550 Set Match Zero GPS info Ok Cancel Figure 10 18 Press Elevation Control Key then Set 3 Change the offset using the numerical keyboard the buttons on the joystick or the up down arrows next to the entry field e Press the Elevation valve gain entry box enter a new offset value on the numeric keyboard and press Ok Figure 10 13 on page 10 15 A negative value is a Cut a positive value is a Fill e Press the buttons on the joystick to quickly increase or decrease the offset value 25 AE 0 Ok Cancel Figure 10 19 Use Keyboard to Change Offset 4 Press OK to set the new offset value and return to the 3DMC Main Screen 10 20 System Five 3D Reference Manual Checking the Blade s Position Checking the Blade s Position The position
271. ushing Cast Housing Bottom Support Aye a Bottom Cap a Figure 11 8 Vibration Pole Assembly 11 8 System Five 3D Reference Manual Preventative Maintenance Lubricate Quick Removal Knob Periodically lubricate the several Quick Removal Knobs to prevent galling caused by tightening too strongly or through repetitive use Figure 11 9 Figure 11 9 Lubricate Antenna Control Box and Laser Receiver Knobs Simply apply a lubricant such as normal grease to the threads of the knob attachment GRT 2000 Inspection and Calibration The GRT 2000 should be periodically cleaned inspected and calibrated in order to provide the best performance You need to periodically check the following three items to maintain desired system performance e Vertical Angle Zero Datum can be performed without equipment installed on machine e Optical Axis For Auto tracking can be performed without equipment installed on machine e Fan Beam Axis must be performed with equipment installed on machine For operation and maintenance procedures refer to the GRT 2000 Instruction Manual P N 7010 0491 11 9 Maintenance LS 2000 Reflecting Strips Replacement The reflecting strips of the LS 2000 can be periodically replaced the surface gets hazy or scratched All four strips should be replaced at same time and can be ordered through Topcon s local dealer 32960 11800 REFLECTION TAPE UNIT
272. vation settings Table 2 2 describes knob operation for the different System Five 3D control modes Table 2 2 Grade Adjustment Knob Operation Control Mode Grade Adjustment Knob Usage 3D GPS The knob assigned to elevation control applies a Cut Fill Offset mmGPS to the Design Surface that is elevation setting Turn the knob clockwise to apply a cut lowering the blade Turn the knob counterclockwise to apply a fill raising the blade The knob assigned to slope control is disabled during grading operation 3D LPS The knob assigned to elevation control applies a Cut Fill Offset to the original mast height that is elevation setting Turn the knob clockwise to raise the mast lowering the blade Turn the knob counterclockwise to lower the mast raising the blade The knob assigned to slope control is disabled during grading operation 2D The knob assigned to elevation control applies an adjustment to the set point that is elevation setting e Turn the knob clockwise to increase the depth of cut lowering the cutting edge e Turn the knob counterclockwise to decrease the depth of cut raising the cutting edge The knob assigned to cross slope control adjusts the percentage of slope in the direction of the knob s rotation e Turn the knob clockwise to tilt the blade more to the right Turn the knob counterclockwise to tilt the blade more to the left P N 7010 0491 2 5

System Five-3D Reference Manual

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