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P-32 Operator`s Manual - Accurate Laser Systems

1. Figure 163 Mark Lath with Hike up Height 2 Secure an anchor pin at each end of the stringline and pull the stringline tight Setting Elevated Stringline P 32 and P 32 Operator s Manual P N 1001547 01 89 3 At each station staple or Ty wrap the stringline directly to the witness lath at the desired hike up Figure 164 Hub O A A ae Figure 164 Stringline Attached to Lath 4 Due to the height of some stakes raise the Tracker or cut off the tops of the stakes Setting Projected Slope Stringline Jobs with slope transitions or super elevations have the stringline set to the projected slope As the profiler cuts the Sonic Tracker and mill follow the slope of the job preventing elevation errors at the edge of the road as the slope changes To set the stringline to the projected slope 1 Set up the string at the desired elevation as shown in Setting Elevated Stringline on page 86 2 Raise or lower the stringline to compensate for the percentage of slope and the distance from the edge of the road to the stringline Rise Run X Slope Percentage e f the road rises away from the stringline lower the stringline Figure 165 2 0 Slope X 2 00 Offset 04 Projecteg Slope Lower 2 0 Offset Figure 165 Lower Stringline 2 Cross Slope with 2 Foot Offset Setting Projected Slope Stringline P 32 and P 32 Operator s Manual P N 1001547 01 90 SERENATA
2. a lt Y ot a o am N 1 Stop the mix delivery truck close but not too short of the paver Always allow the paver to pickup trucks on the run 2 Never allow the truck to bump the paver Allowing trucks to bump the paver when backing up can drive the screed into the mat and produces bumps and ridges which may not roll out 3 Trucks applying and holding their brakes excessively while dumping their load may cause the paver to slow which in turn causes the screed to rise The truck driver should apply only light pressure on the brakes sufficient to maintain contact with the paver 4 Dumping of material in front of the paver as the truck pulls away after emptying its load into the hopper can cause the paver to ride over the pile of material with subsequent adverse effects on mat quality Avoid trucks pulling away prior to completely dumping all material Use a dump person to monitor and regulate truck movements in front of the paver Head of Material M One of the primary functions of the paver tractor is to convey and distribute paving material onto the ground in front of the entire width of the screed This material once deposited in front of the screed is the head of material over which the screed passes One of the keys to smooth paving is to maintain this head of material as constant as is possible The resistance to forward motion exerted by the head of material M is one of the major component of resistance to forwar
3. e f the road slopes down from the stringline raise the stringline Figure 166 3 0 Slope X 2 00 Offset 06 e eT projected SIOP 06 2 0 Offset Figure 166 Raise Stringline 3 Cross Slope with 2 Foot Offset 3 Repeat step 2 for each station Verifying Grade Verifying grade requires measuring the distance from the cut ground to the sonic stringline To check grade use a Grade Checking Lath to check the levelness and depth of cut with the sonic stringline The following figures show an example of a hub offset of 1 5 feet from the edge of the road and a hike up of 2 0 feet 1 Construct a Grade Checking Lath using a lath a level bubble nails and standard hand tools as shown in Figure 167 Ty wrap or Tape Level Bubble to Lath Figure 167 Grade Checking Lath Verifying Grade P 32 and P 32 Operator s Manual P N 1001547 01 91 dnjyas auljsulys 2 Set the Grade Checking Lath on the edge of the newly cut ground so the level bubble extends over the sonic stringline Figure 168 dnjyes aulsuiys Finished Grade Finished Grade Correct Approx 05 Too High Figure 168 Check Finished Grade 3 Tilt the Grade Checking Lath to center the level bubble Finished grade is correct if the level just touches the sonic stringline Figure 168 Verifying Grade P 32 and P 32 Operator s Manual P N 1001547 01 92 Maintenance This secti
4. D ay et Cc a D N Q a Y Y et 5 2 Slope Gain raise 25 3 Valve Offsets lower 25 4 Elev Deadband 5 Slope Deadband min 1 6 Averaging max 200 7 Machine Type g default 25 Figure 55 Gain Elevation Slope Gain This setting determines the speed at which your Topcon P 32 or P 32 System allows the tow point cylinders to adjust to a change in slope For faster hydraulic response increase the gain value For slower hydraulic response decrease the gain value O 0 WN Ul A o s et 2 g O x 0 ay et Cc D N Q an Y Y et 5 The objective is to set the gain so the screed reacts to the change in grade quickly but without overshooting On Grade Slope Gain should not be set at a higher value than the Elevation Gain on the other side of the paver e Gain Elevation Value Range 1 100 e Factory Preset 25 Before setting the Slope Gain ensure the machine s hydraulic flow control valves are adjusted for proper cylinder speed according to the manufacturer s recommendations Do not set slope gain at a higher value than the elevation gain on the other side of the paver A higher value may cause the slope to be over reactive 1 Elev Gains 3 Valve Offsets 4 Elev Deadband 5 Slope Deadband min 1 6 Averaging max 100 7 Machine Type default 25 Figure 56 Slope Gain Performance Menu P 32 and P 32 Operator s Manual P N 1001547
5. n Loa E E E ZZ aa WW y y y u SI ue e 32 and P 32 System Operator s Manual a aia i a i aaia a a SDM Od A A A e e e aenn annann aannemen 2014 Topcon Positioning Ata ine All rights reserved No unauthorized duplication
6. 1 Ensure that haul trucks take the shortest most practical route to the paver Make certain that all trucks take the same route to the paver 2 Make sure that the trucks arrive at the same order in which they were loaded at the asphalt plant Ensure that no bunching of trucks occurs at the paver with several trucks waiting to dump their loads 4 Match lay down rate to material delivery rate y ay eje y 2 e o D UN Q a A o lt Y a o a N td trip to the paver They can be the result of temperature variations at the plant If this is not addressed prior to delivery of material to the paver waviness in the mat results Temperature problems may occur before the time the material is loaded into the trucks or during the Weight of Screed W For the weight of screed force W to remain constant the weight of the screed or the downward pressure exerted by the screed on the paving material should not change Figure 22 The weight of the screed is measured in pounds per square inch Weight of Screed W Figure 22 Weight of Screed Members of the paving crew climbing on and off the screed also have some affect on the weight of screed force How a Screed Works P 32 and P 32 Operator s Manual P N 1001547 01 12 The primary factor affecting this force is changing the width of the screed Figure 23 Extendible screeds weigh the same whether they are fully retracted or fu
7. For a review of how the Sonic Tracker works see Sonic Control on page 14 If the Sonic Tracker tracks the ground but not a 1 8 inch diameter stringline clean or replace the transducer See Chapter 7 for this procedure Setting Surface Stringline Sonic Tracker II The ST 3 is not capable of using a surface stringline Only use a surface stringline when using a A surface stringline provides a low impact reference and averaging solution for steering and grade control Because it rests close to the surface trucks and other traffic can drive over the stringline without causing control problems and reference damage As a grade reference pavers use the Sonic Tracker to track the stringline producing a consistent and constant cut When sighting down the stringline problem areas can be spotted and marked or fixed before paving begins Surface stringline replaces a contacting averaging ski when a reference Is unavailable or impractical Averaging skis average out the irregularities of the surface being cut but can be impractical bulky complex and fragile Surface stringline is simple more practical and easier to maintain than an averaging ski When stretched over the ground surface stringline levels the high places and bridges the low Figure 152 creating a natural average over a distance as long as 500 feet Surface String Low Spot High Spot Figure 152 Surface String Averaging A surface stringline is a verifiable
8. en Y Y eb 5 Slope Control 1 Ifthe Control Box is connected to a Slope Sensor press the Elevation Slope Button the yellow slope indicator LED below the slope symbol illuminates 2 Turn the Grade Adjustment Knob to set the desired slope Survey Button Press the Survey Button Figure 46 to lock On Grade Figure 46 Survey Button Auto Button The AUTO Button Figure 47 switches your Topcon P 32 or P 32 System between Automatic and Manual Mode Auto N 2 Figure 47 Auto Button Control Box Features P 32 and P 32 Operator s Manual P N 1001547 01 26 Automatic Mode In Automatic Mode Auto the tow point cylinders are automatically adjusted up or down to maintain proper grade To enter Auto press AUTO The red LED lights up showing that the Control Box Is in Auto Manual Mode In Manual Mode Manual the LCD displays grade corrections without adjusting the tow point cylinders In this mode the operator manually adjusts the tow point cylinders to reach On Grade To enter Manual press AUTO The red LED goes dark unlit showing that the Control Box is in Manual Jog Up Down Button The Jog Up Down Button Figure 48 manually moves the tow cylinder up or down and is always active when the Control Box is turned on To raise the tow cylinder press Jog Up A R WN Ul A O t 9 0 e A gt 0 ay eb a M v an a To lower the tow cylinder press Jog Down
9. 0 0 es 12 Simple steps to take to control temperature variations 12 Weight o Screed WE sora rra Wow oh ad ae Oe adan 12 Qualy OF Paving Bases cana tae heer DA ROR REE ey ee RS 13 ROING VCCAMIGUECS tr iia Ge device ive Homa ae oo eo 13 Controlling Mat Quality aoaaa aaa 13 Control Methods a 2 2 4 0 hava ria PE dob ee ek Ae che ae eh ed 14 SOME COMMON e mar rra dae arde adi a Da Bad ha eae ad 14 EJ 15 SUD net iio io da aa e 16 SIONS CONO irc a aaa a 17 GC 35 Control Box Features and Setup ssssssssssssssssss 19 Control BOX Features ct bcad 45k pba ean hd brasa dw Oe eae od adhd 19 COIO LED DISPLAY a ea ana ne ota she de eke WEAR dd oh oR kent ah oe Bethe heme Gate a a 20 GIVE SEN SOM mirar dd a oe een ae 20 Power BUTTON i craneal eee 21 Powering the Control Box On Off auauua es 21 Table of Contents P 32 and P 32 Operator s Manual P N 1001547 01 vi Grade Adjustment Knob anaana aaaea aaa ee eee eens 22 Grade Adjustment Direction ArrowS oaaae es 23 Grade Adjustment LEDS 1 1 cc eens 23 MENU Set BUON yain eds ath ahha aa Ry PS DASE Ga A 24 NCW ced AA 24 SO sn Kae eA eS SOR A IA e CoS CREASE SEERA HERERO EES 24 Cross Communication BUON iia idad a be eA ea ae wey Gee a 24 Elevation Slope Button 1 0 ee ees 26 Elevacion COMO tarada aa a rara Ha a bios 26 SOPE CONTO ratas ar tras ad dla abia rra ia 26 SU BUON RR hee et 26 AUTO BURON ee ee ee ee ee ee ce ta eee a n eee
10. Machine is incorrectly wired or hydraulically connected 1 Check that the machine is properly wired and hydraulically connected to the valve A raised jog switch Should make the cylinder go up lowering the jog switch should make the cylinder go down 2 Check that the proper cables have been supplied for your machine 3 Make sure the screed lift cylinders are in the float position and not supporting the screed Control Box Symptom 6 The tow point cylinder is moving too fast or too slow Probable Cause The paving machine s hydraulic flow adjustment is incorrect or the Slope Sensor Valve Offsets or Gain Adjustments are not correct Control Box Symptoms P 32 and P 32 Operator s Manual P N 1001547 01 100 1 Refer to paver manufacturers recommended flow adjustment setting for the speed of the hydraulics typically between 12 to 15 seconds Moving the cylinder completely up down on one side can damage the screed 2 Adjust Gain Performance Settings The factory setting Is 25 3 Adjust Valve Offsets Refer to Valve Offset section in the Performance Section within this Manual Control Box Symptom 7 The system intermittently drives the cylinder all the way up or down when tracking a mechanical ski Probable Cause Tracker is intermittently picking up signals from the ski 1 Your valve settings may be incorrect Check the Config number displayed on the Startup screen Startup Screen Startup Screen 2 TOPCON 2
11. Raise and Lower on page 30 and Slope Gain on page 31 SAS Symptom 5 A tracker is picking up head of material Probable Cause Improper placement of Tracker 1 Move tracker forward of the material Rotate Tracker to front of bracket or drill a hole in the beam far enough forward to move tracker away from material 2 Check the balance point The balance point shifts when moving a tracker SAS Symptoms P 32 and P 32 Operator s Manual P N 1001547 01 110 o o D UN p o En 2 eje Safety Warnings General Warnings This product should never be used e Without the operator thoroughly understanding this manual Y e After disabling safety systems or altering the product e With unauthorized accessories e Without proper safeguards at the job site e Contrary to applicable laws rules and regulations TPS products should never be used in dangerous environments Use in rain or snow for a limited period is permitted warranty e Do not attempt to open the unit and modify any of its internal components e Do not short circuit Y Tampering with the unit by the operator or non factory authorized technicians voids the unit s Safety Warnings P 32 and P 32 Operator s Manual P N 1001547 01 111 Specifications The following chapter describes the specifications for the main and optional components of the P 32 and P 32 system GC 35 Table 3 GC 35 Specifications Supply
12. Reaction of Material Under Screed Force R Figure 16 Forces Affecting the Screed Tow Point Force P The tow point force P is the resistance to forward travel Figure 17 Tow Point Force P Figure 17 Tow Point Force P How a Screed Works P 32 and P 32 Operator s Manual P N 1001547 01 8 y ay eje y l a a Y UN Q a A o eb a 2 Z Y ama Dy an V The P force remains constant if the paver is kept moving at a consistent speed at all times If the paver is allowed to stop the screed settles in the fresh mat and leaves a mark The mark cannot be fully smoothed out by the roller and a bump ends up in the mat that shows up in the profilograph readings Changing the speed of the paver also causes the screed to rise and fall affecting mat thickness The optimum paving speed is determined by the depth and width being paved and the rate at which material can be delivered to the job Calculate the tons hour into feet per minute Figure 18 Do not start and stop the paver Figure 18 Travel Speed to Reduce Tow Point Force P Truck Exchange Another Tow Point Force It is very important that truck exchanges be carried out as smoothly as possible to avoid disturbing the smooth uninterrupted forward motion of the paver The following lists some steps to take to avoid disturbance of the paving operation by trucks Y ay eje y 2i BF D UN Q a A o
13. and P 32 Systems include two Control Boxes two Sonic Trackers ST 3 for P 32 and Sonic Tracker II for P 32 and a single Dual Port Slope Sensor When setup and connected the Control Boxes control either the left or right side of the machine for either elevation or slope GC 35 Control Box MEN NE NOME The GC 35 Control Box Figure 3 is the operator s interface to the Topcon P 32 System The Control Box receives signals from the sensors Sonic Tracker Laser Tracker and or Slope Sensor and uses these signals to determine if grade or slope corrections are necessary If a change in grade or slope Is required the Control Box sends a signal to the valve controlling the tow point cylinder on the appropriate side of the machine to raise or lower thus maintaining correct mat thickness The Control Box connects to the Sonic Tracker the Slope Sensor and to the paver through electrical cables The Control Box easily attaches to its mounting bracket with one clamp and at the end of the day should be removed for storage Figure 3 Control Box Sonic Tracker Whether you are using the ST 3 P 32 or the Sonic Tracker II P 32 the Sonic Tracker Figure 4 measures and controls the elevations of the screed A transducer s located in the bottom of the Sonic Tracker generates sound pulses like a speaker and listens for returned echoes like a microphone The Tracker measures the distance and controls grade from a physical grade reference such
14. 01 32 Valve Offsets Raise and Lower Valve Offsets is the minimum amount of electrical signals sent to the valve which causes the hydraulic cylinder to move If the valve offset is too small the sensor will not reach On Grade Likewise if the valve offset value is too large the sensor will move too much and overshoot On Grade Set the Valve Offsets first before setting any other Performance Menu items Valve offsets should be set before adjusting elevation and slope gains and averaging The paver should be run until the hydraulic oil is at normal operating temperature before setting the valve offsets Once they are set you should not need to readjust the valve offsets unless the Control Box is moved to a new paver or the hydraulic performance changes e Valve Offset value range 1 to 999 e Factory preset 135 1 Select Valve Offsets gt raise 2 Turn the Grade Adjustment Knob counter clockwise decreasing the Valve Offset raise value until the hydraulic cylinder no longer moves Then slowly rotate the Grade Adjustment Knob clockwise until the hydraulic cylinder just begins to move up 3 Repeat for Valve Offsets gt lower O 0 WN Ul A o s et 2 g O x A D ay et Cc D N Q an Y Y et 5 1 Elev Gains 2 Slope Gain raise 135 3 Valve Offsets lower 135 4 Elev Deadband 5 Slope Deadband min 1 6 Averaging ma x 999 7 Machine Type default 135 F
15. 2 1 2 feet off the ground Slide the locking collar up to the ski and lock in place The ski is easier to mount if the end beams are folded in Bend the L bars so they are aligned in the DES Same position and fold inwards so they are close to the paver Make sure the clamp handles are loose enough so bars can move 5 Lower each of the Tracker hangers on the SAS and mount a Sonic Trackers using the L handle bolt Figure 107 An extra washer may need to be added so the L handle does not block the cable connection Figure 107 Mounting Sonic Trackers to SAS 6 Connect the SAS coil cable to each tracker Figure 108 A a SY W e D E Qe Q J gt l Za NS aN 2 3 Ms kun ail Figure 108 SAS Cable Connectors to Sonic Trackers 7 Attach temperature bails to each tracker and begin paving VI Optional Smoothtrac SAS Placement and Setup P 32 and P 32 Operator s Manual P N 1001547 01 61 dn S SVS Pue Jae DIUOS Positioning the SAS The SAS should be positioned so the Sonic Trackers are 14 to 24 inches from the grade reference Figure 109 As with single tracker operation the lower the better is a good rule of thumb for paving applications This helps to minimize the variable temperature conditions that can cause erratic signals The beam does not have to be perfectly level because each tracker averages the distance to the reference individually Figure 109 Positioning SAS
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17. Block and then select Off 8 Display 9 Units 10 System Info 11 Sonic Tracker 3 12 Slope Res Figure 128 Slope Calibration Block 6 Return to the Control Screen Figure 129 7 Press and hold the Menu Set button while turning the Grade Adjustment Knob to change the display to match the slope of surface Figure 129 Release Menu Set to save the value A TOPCON Figure 129 Setting the Slope Value Using Menu Set to change the slope value does not change the slope it only changes the slope value viewed on the display 8 Enter the Performance Menu again and choose Slope Cal Block Set Slope Cal Block back to On Control Box Setup for Slope Control P 32 and P 32 Operator s Manual P N 1001547 01 73 3NBdH 0 pe y 3unjan 9 Press the Auto button to put the Control Box into Automatic mode Figure 122 The Auto LED lights up INT A Auto Figure 130 Selecting Automatic Mode 10 Once the Slope Sensor is calibrated and you are ready to begin paving you may find the existing surface does not have the same slope as the finish design In order to produce a smooth transition begin paving at the existing slope and slowly turn the Grade Adjustment Knob to change the cross slope to the correct percentage we TOPCON Figure 131 Producing a Smooth Slope Transition If a smooth transition is not required then dial in the desired slope and begin paving Control Box Setup for Slope
18. Control Once the Sonic Tracker has been positioned over the reference the Control Box can now Survey to On Grade 1 With the power on press the Survey button Figure 120 0 20 Survey Figure 120 Setting the Tracker On grade 2 To make the display read the same value as the depth of mat to be laid press and hold the Menu Set button while turning the Grade Adjustment Knob to change the display to the height of the blocks under the screed Figure 121 3 Release Menu Set to save the value Se TOPCON Figure 121 Saving Elevation Value A Using Menu Set does not change the existing mat thickness it only changes the reference number viewed on Z ES the display Control Box Setup for Elevation Control P 32 and P 32 Operator s Manual P N 1001547 01 69 O O et ag 00 A O O a lt et O Y y lt O 4 Press the Auto button to put the Control Box into Automatic mode Figure 122 The Auto LED lights up Auto Figure 122 Selecting Automatic Mode 5 Begin paving After you begin paving check the mat depth to ensure the desired thickness is being laid Figure 123 The blocks initially placed under the screed may cause the mat to be too thick or too thin Check the mat several times to get an average before making any corrections O O et ag 00 A O Y a lt ep O Y Q lt O Figure 123 Checking Pad Thickness For example if a 2 50 inch mat is required but a 3
19. Control P 32 and P 32 Operator s Manual P N 1001547 01 74 3NBdH 0 Apesy 3unjan Paving Applications The type of controls you decide to use elevation sensors or Slope Sensor and elevation sensor for paving depends on the result required for the finished product Some projects require e smoothness and improved rideability e consistent mat thickness e the new asphalt to match curb and gutter e the new asphalt to match existing grades The following sections describe a few examples of paving projects using your Topcon P 32 or P 32 System If you are using an ST 3 for elevation control make sure the correct setting is selected in the Control Box Performance Menu See Sonic Tracker 3 P 32 System only on page 39 Paving City Streets with Sonics When paving city streets the general requirement is to lay a mat that is so many inches above the base at the centerline and to match curb and gutter Figure 132 For this application sonic control is used on both sides SUBGRADE oe i I CENTERLINE OF ROAD Figure 132 Paving to Center Line and to Match Curb 1 Before paving make sure the machine is properly setup cross slope is calibrated and trackers are set in the correct position See Chapter 5 and Chapter 6 for details 2 Position right tracker over lip of gutter and left Tracker past the centerline on the base material Figure 133 SUBGRADE CENTERLINE OF ROAD Figure 133 Positioning Tracker Over
20. Figure 169 by mixing a mild detergent with water and placing the mixture in a spray bottle use Simple Green where available 2 Thoroughly spray the bottom of the ST 3 with the detergent solution and wipe with a soft cloth After spraying with detergent fill the spray bottle with clean water and rinse any residual detergent off of the ST 3 4 Allow the ST 3 to dry Clean Dirt and Debris from Transducers Ea ear ST 3 EE f Bottom View Clean Dirt and Debris from Ridges Figure 169 Clean Transducer Area of ST 3 Maintenance P 32 and P 32 Operator s Manual P N 1001547 01 93 Sonic Tracker II Transducer Cleaning This procedure is not meant to be a regular maintenance procedure Clean the Transducer only when contamination is suspected or evident Cleaning the transducer too much results in a shortened Transducer life and or water damage to the Sonic Tracker 22UBU3SJUIBIN 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 s
21. Figure 175 on page 97 7 Start the mounting screws into the holes and tighten each until firm Figure 175 on page 97 DO NOT OVER TIGHTEN Use a cross X pattern when tightening the screws DO NOT use Loctite on the mounting screws Loctite attacks and degrades the plastic retaining ring Y Over tightening the screws distorts the transducer metallic material and may crack the retaining ring The O ring provides tightness while preventing vibration from loosening the mounting screws Sonic Tracker II Transducer Replacement P 32 and P 32 Operator s Manual P N 1001547 01 96 a22UBU3SJUIBIN 22UBU3SJUIBIN Figure 175 Replace and Tighten Mounting Screws 8 Ensure the metallic surface inside the transducer has no visible wrinkles If distortion is evident repeat steps 5 on page 96 to step 8 9 Place a new filter foam over the transducer The Sonic Tracker is now ready for operation Sonic Tracker Transducer Replacement P 32 and P 32 Operator s Manual P N 1001547 01 97 Troubleshooting Control Box Symptoms 7 The system intermittently drives the cylinder all the way up or down when tracking a mechanical ski 8 The Control Box SAS icons numbered 1 2 3 or 4 are red 9 The grade lights flash high and low and do not stay On Grade 10 The valve is driving the hydraulic cylinder too far overshooting grade 11 The valve does not drive hydraulic cylinder far enough t
22. Gutter Paving Applications P 32 and P 32 Operator s Manual P N 1001547 01 75 3 Turn on the Control Boxes then Survey and Set the displays to read the depth of asphalt to be laid Figure 134 y 00 gt y y y O 5 T Figure 134 Control Box Displays Depth of Asphalt 4 Put both Control Boxes in automatic mode and begin paving Check the depth of mat at centerline and verify joint matches at lip of gutter After compaction make the necessary adjustments at the Control Box Z If the road width varies it is easier to keep the Tracker over the gutter if the Tracker is mounted to oO the extension on the screed 5 To pave the other side of the road position the left tracker over the lip of the gutter and place the right tracker over the new mat Figure 135 Subgrade Centerline of Road 0 20 a Mat Depth 0 20 Figure 135 Paving Other Side of Road 6 Survey both Control Boxes On Grade and Set the displays to read the depth of asphalt to be laid Put the Control Boxes in automatic mode and begin paving Check to make sure joints match after compaction Paving City Streets with Cross Slope Another option is to pave the street using cross slope and sonic control The tracker is positioned over the lip of gutter on one side and cross slope is dialed in for the crown on the other This method may have to be modified due to the fact that in many cases the curbs may be poured at different e
23. However there is no feedback from the tow point cylinder which is used to make the grade control changes Grade Reference Incorrect Placement Figure 84 Incorrect Placement at Screed Pivot Point If the tracker gets closer to the reference it sends a raise correction signal to the valve and the tow point cylinder begins to move up Because the screed floats it does not react immediately to the tow point movement so the tracker continues to send raise correct signals to the valve By the time the screed gets to grade approximately 3 tow arm lengths the tow point cylinder has moved too far causing the screed to continue raising The tracker senses this over correction and sends a lower signal to the tow point cylinder repeating the whole process in the other direction Therefore with the tracker mounted at the screed pivot point long waves in the mat are produced because there Is no feedback from the tow point cylinder to the screed Figure 85 Grade Reference Average profile of mat with Sonic Tracker mounted at Screed Figure 85 Tracker at Screed Pivot Point Causes Erroneous Corrections Example 2 Tracker Placed Incorrectly at Tow Point At this point where grade corrections are being made the Laser Receiver is kept at an exact distance from the grade reference Figure 86 on page 49 Any tracker elevation changes cause the tow point cylinder to move immediately The problem with the tracker placed here is the lack o
24. On both Control Boxes press Auto on set both Control Boxes to Automatic 3 Pave to the intersection Figure 142 Figure 142 Paving Through I ntersections 4 Just before the right tracker reaches the end of the curb press Auto on the right side Control Box to Switch to manual mode Figure 143 lt q Press to Switch to Manual Mode N N Figure 143 Control Box in Manual Mode 5 Without stopping continue paving until the right tracker is on the base material of the intersecting road Paving Streets Through Intersections P 32 and P 32 Operator s Manual P N 1001547 01 79 suone gt 1 ddy Sued 6 On the right side Control Box press Survey to take an elevation reading of the new reference Figure 144 and then press Auto to switch to Automatic mode 2 TOPCON Figure 144 Survey to On grade and Return to Automatic Control 7 Pave through the intersection and just before the right side Tracker reaches the curb on the other side of the intersection Figure 145 press Auto to switch to Manual mode Figure 145 Paving Through I ntersection 8 Without stopping continue paving until the tracker is back on the lip of the curb Survey to On Grade Figure 146 and press Auto to switch to Automatic control Paving Streets Through Intersections P 32 and P 32 Operator s Manual P N 1001547 01 80 suone gt 1 ddy Sued 2 TOPCON Figure 1
25. P N 1001547 01 85 dnjyas auljsulys Figure 155 Stringline Reference e When the Slope Sensor sends out a sound wave the first thing the tracker sees is the reference stringline e Since the stringline is pulled tight any small irregularities in the existing surface are spanned Figure 156 SERIE Figure 156 Stringline Spans Surface rregularities As a verifiable grade reference potential problems can be pointed out to the inspector before paving Setting Elevated Stringline Elevated stringline is positioned 1 2 feet above the finished grade using referencing hubs or lath placed by the surveyor Figure 157 gt A m Figure 157 Elevated Stringline Once positioned the Sonic Tracker tracks the stringline providing a verifiable slope and cut reference l The ST 3 indicates the location of the stringline by using left right arrows and On Grade centered BS LEDs See Stringline Mode on page 54 for more information N The ST 3 LEDs help guide the operator to manually shift the screed in out Accurate setup of the stringline is crucial for proper operation of the ST 3 Do not disturb the hubs Setting Elevated Stringline P 32 and P 32 Operator s Manual P N 1001547 01 86 Your local Topcon dealer carries the following supplies for setting elevated stringline e Sonic stringline 1000 roll p n 7020 0101 e Sonic grade clips box of 1
26. Surface Tracker Connected Faulty Tracker Detecting Surface Figure 178 SAS I cons 3 If more than one SAS icon is red check trackers individually by plugging Slope Sensors directly into the single tracker coil cord to determine if trackers or SAS cable is source of error 4 The defective tracker or SAS cable should be repaired but SAS can still be operated without all four trackers Remember the balance point changes if a tracker is removed Control Box Symptom 9 The grade lights flash high and low and do not stay On Grade Probable Cause If problem is only in automatic mode Hydraulic Performance Settings my be incorrect 2 Verify paving machines hydraulic flow adjustments time for hydraulic cylinder to travel full stroke are set to manufactures recommendations 3 Check that the Valve Offsets are set correctly 4 Check that the Gain setting is too high Factory setting is 25 If problem is in manual mode Verify that temperature bails are clean and securely attached Verify temperature bail symbol T is displayed on face of Tracker If not clean or replace transducer Check that Trackers are between 14 and 24 inches from reference If there are gusty winds lower Tracker closer to reference Approximately 14 to 16 inches Move Tracker away from gusty heat source such as engine fan exhaust Verify Tracker is not picking up erroneous signals from undesired reference Example Head of material end gate s
27. Tail Road Crown The contour of the trailing edge of the screed Cut off Shoe A detachable plate used to reduce the paving width of a screed Density Compactness of paving material Edger Plate A vertical plate at each end of the screed used to confine the head of material Elevation The vertical height or depth of the surface being laid Elevation is measured in centimeters inches or feet P 32 and P 32 Operator s Manual P N 1001547 01 121 Glossary Feeders n Y Y O lt The auger conveyors on the right and left hand sides of a paving machine Grade The base surface road bed over which paving is being laid The elevation of a fresh mat in relation to the base The incline of a paving surface in the direction of travel expressed by stating the rise or fall as a percent age of horizontal distance i e 6 grade 6 of elevation change in 100 of horizontal longitudinal run Grade Control A means of controlling the elevation of a mat as it is being laid Grade Sensor An electric device which detects positive and negative changes in elevation from a grade reference 1 e surface string floating beam mat reference adjacent mat or curb surface Head of Material The volume of paving material directly in front of and across the entire length of the screed Hopper The area at the front of the paving machine which receives the paving material Hydraulic Liquid in motio
28. Tracker II Figure 81 Tracker amp Mechanical Ski Placement Placement When Using Elevated Stringline Some jobs may require the mat be laid to a specified elevation In an application like this an elevated stringline or wire may be set up The Sonic Tracker has a built in working window that prevents the screed from diving if the tracker loses the stringline reference Position the tracker over the stringline and set the distance between 18 and 24 inches Figure 82 Figure 82 Tracker Position Mat laid at Specific Elevation Sonic Tracker Placement P 32 and P 32 Operator s Manual P N 1001547 01 47 Placement in Relation to the Screed As a tracker is moved closer to or further away from the screed the response of the screed to an elevation correction changes A rule of thumb is to place the tracker about 1 3 to 2 3 the length of the tow arm forward of the screed pivot point Figure 83 on page 48 2 3 3 Grade Reference ro Grade Screed Pivot Point Figure 83 Correct Tracker Placement in Relation to Screed If the tracker is not placed between these points then incorrect screed responses could result The following examples describe the possible incorrect placements and the errors that would occur Example 1 Tracker Placed I ncorrectly at Screed Pivot Point f the tracker is placed directly at the screed pivot point Figure 84 you can see exactly where the screed is relative to the grade reference
29. a personal non exclusive non transferable license to use such Software under the terms stated herein and in any case only with a single product 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 the use of the product 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 UU a Y ay A Y 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 shall restrict you from disclosing Confidential Information to your employees as may be necessary or appropriate to operate or care for the product Such employees must also keep the Confidentiality Information confidential In the event you become legally compelled to disclose any of the Confidential Information
30. as a curb stringline or existing road surface A bail is used to compensate for rapid air temperature changes In paving applications a bail should always be used Getting Acquainted P 32 and P 32 Operator s Manual P N 1001547 01 2 The Sonic Tracker attaches to the system through one quick connect cable and attaches to the machine with a single bolt At the end of the day Sonic Tracker should be removed for proper storage in the carrying case ST 3 Sonic Tracker II with Temperature Bail with Temperature Bail P 32 System Only P 32 System Only Figure 4 ST 3 and Sonic Tracker ll Dual Port Slope Sensor The Dual Port Slope Sensor Figure 5 is a precision electronic sensor which functions much like a precision carpenter s level The Slope Sensor reads the inclination tilt of the screed and sends the signal to the Control Box The Slope Sensor measures slopes from 20 to 20 The Slope Sensor connects to each Control Box through an electrical cable and requires no adjustments and is the only component of your Topcon P 32 System that can be used to control either side of the paver The Slope Sensor is a sealed component and once attached to the Paver should not be removed Figure 5 Dual Port Slope Sensor Getting Acquainted P 32 and P 32 Operator s Manual P N 1001547 01 3 MEN NE NOME Getting Acquainted Smoothtrac Sonic Averaging System Optional Add on System The Smoothtrac Sonic Averaging Sy
31. button Figure 42 allows you to remotely control a secondary Control Box Cross communication is only available when the Cross Communication Indication Arrows icon is visible Figure 44 If a secondary Control Box is connected and the icon is not visible see Troubleshooting on page 94 2 Cross Communication Button Figure 42 Cross Communication Button Control Box Features P 32 and P 32 Operator s Manual P N 1001547 01 24 Primary Control Box Primary Control Box Secondary Control Box lt Cross Communication Press and Hold to Make Changes to Secondary Control Box Cross Communicaton Indication Arrows Figure 43 Cross Communication I ndication Arrows During Cross Communication the Control Box that initiates the communication primary displays and controls the settings of the secondary Control Box in the bottom half of the screen While in Cross Communication mode you can make the following changes to the secondary Control Box Switch the secondary Control Box into Automatic or Manual mode Adjust the slope or elevation values using the Grade Adjustment Knob Survey to On Grade e Select slope or elevation sensor e Jog up down 1 Press and hold the Cross Communication Button Figure 44 Red double arrows display on the screen once cross communication with the secondary Control Box is established The bottom half of the display shows the settings of the secondary box O 0 WN Ul A o
32. ce eee ees 64 Getting Ready to Pave iia iii iii cided ak eo da a A Bae a a 66 Control BOX SQUID iu a HE Eons Vane dee ae de 66 S16 slo hs 210 0 teat ae nn we eae eee ee ee es ae ee 67 SONIC Tracker SCID os a We ARAS A AAA See we a ae a 68 SAS CD pios A bees hed baa Ao bed eae toe 68 Control Box Setup for Elevation Control o o ooooooooo ee 69 Control Box Setup for Slope Control anana 72 Paving Applications ia aterra aaa 75 Paving City Streets with SONICS o ooooooooooorran ees 75 Table of Contents P 32 and P 32 Operator s Manual P N 1001547 01 vili Paving City Streets with Cross Slope aaae 76 Paving Streets Through Intersections anaoa aaa 79 Method 1 for Paving Intersections 1 0 cee eee 79 Method 2 for Paving Intersections 1 0 0 0 eee 81 Paving Intersections with Cross Slope auaa aaae 82 SOUP APACS SUN cara iaa ates a se ere aR ae 84 Setting SUTACe SNINE viera o ii a Rep a ak a 84 Setting Elevated Stringlie ee eas 86 Making a CUG IN EQEN usaras ra PALA hati a ak ee 88 Attaching Stringline to the Grade Stake ee 89 Setting Projected Slope Stringline 1 ee nes 90 Ven WC GAGS ded oie hh ar eh oe Wad A ds eds tra dee a a ates 91 MaintenanGe tira eae ee eae he ee ee 93 Preventative Maintenance Daily Care es 93 Spd A E A Gh dea ae a 93 Sonic Tracker Il Transducer Cleaning 0 00 eee eee ee ees 94 Sonic Tracker Il Transducer
33. eee eee eee eee BEB BEER EERE EER RR ERE RRR RR RR RR RE RRR RERE BR RR RRR RRR ERR ER ER EER EEE EE EEE EE EE EE EE EE MM ee Uone a eee ee eee eee eee ee eee eee eee ee eee a a a eee ll a 00000000000 a A a a a a a m e a a a a a a a a a a a aaa aaa aaa e e 06000020000 0mm AS a ee ee eS B BS Fo eee 7 aa aana mam saaa aaas aaa O ee panes BwePQtewweae Leal Leal HEHEHHE E wee Lia EEEE Mo CMA AA 0000000000005 25 so yy E E E EE E E E y a E E E E yw E E E EEEE A EE EEEE EE es ee ee ee E E U E 8 EHEN mw EET m uE bail E W EEN had 2 8 ee 8 eB ee ZBaeEeuaRuaRuaB wewWeeeweeReReReeeweweeesesee E ww Lal E weer EEEE EEN Zeer E na eee bod m a baa WETEN NE EHEHEHE E E E E badd H E EETHEN wr m Teese E m EEEE EEEE ENENE EEE EEHEEHE EHEHEHEH EHEHE bad baa 7 Te eeeeeee eS w uE m Zeeee Uy WWU Y wyw wyw w wu E W y Ll eres EENE eee uE U UEN WEE W _ NM WU UY EEE r o ZePePreee A ff amp se m y w E ETETE u y EHEHE Ng EEKE had m EE E Y N m wT ePenRreeeeeeeeeeeeeee eee ee eee eee uwy EEUE g re ww 7 2 EH UNO A Se eS Se i ee ee ee 7 BeePreeBeeeeeS S amp S 28 fe Zs PTeTeeeee ee EErEE E w u a regag Baars Y oe oe ZT wTeTReeeereHReHFRTteHrTteHeHReHReHReHeHewTeHeHTeheaTaeeHeeTeRreHreHFTeeweHeHeHTeHReHTHTreereHeeeeeeeee fe WU UP UN a ee ee ee A a a i 0 0 0 ee ee ee ee ee ee ee ee ee aa ek se se ee eS ee ee ee i i i i i i i i Uu u Ss Ferreatrtet tm mm EHEHEHEH EE
34. faces and edges 50G saw tooth 6ms 600 total U 5 O af A O 7 O UY Hot Start 80 C 176 F Cold Start 40 C 40 F Temperature Humidity 20 C to 60 C 4 F to 140 F 95 R H 30 cycles Cycle Temperature Shock 40 C to 80 C 40 F to 176 F 12 cycles Humidity 96 R H at 40 C 10 days Salt Fog 5 NaCl 48 hours 300 hours Chemical Diesel hydraulic oil ethylene glycol Compatibility e Sonic Tracker II 9142 Connector Cable e GC 35 Control Box 9259 using Stringline Mode and Surface Mode e All other Topcon Control Boxes using Surface Mode Only Sonic Tracker II P 32 System Only Table 5 Sonic Tracker Il Specifications Supply Voltage 10 32 VDC Supply Current 200mA typical operating current Emissions Applicable regulation EN55022 1994 30 230MHz 40dB mV m Max at 10m 230 1000MHz 47dB mV m Max at 10m Immunity Applicable regulation EN50082 1 1992 ESD 8KV RF 27 to 500MHz 3V m Fast transient 0 5KV capacitively coupled Transducer Frequency 50kHz burst 40Hz max rep rate 6 in minimum diameter at 2 ft Sonic Tracker P 32 System Only P 32 and P 32 Operator s Manual P N 1001547 01 114 Table 5 Sonic Tracker Il Specifications Working Window Patented 4733355 Adjustable Coarse 0 15ft 4 5cm Fine 0 05ft 1 52cm Ongrade Adjustable U 5 O af A 0 7 O V Physical Display LEDs 1 ea Bail 11 ea Raise Lower Ongrade Housing Powder coated cast
35. proper elevations and percent slope The Topcon P 32 System provides paver operators with automatic grade and slope control B Bitumen A thick viscous petroleum based substance used as a bonding agent in asphaltic mixes Bail A wire frame added to the Tracker that acts as a fixed target to compensate for rapid air temperature changes C Calibration Setting the elevation reading or Slope Sensor reading to match the actual position of the screed Compaction To press tightly thereby increasing the density of paving material Glossary P 32 and P 32 Operator s Manual P N 1001547 01 120 Glossary Cone Pattern of distribution of the Sonic Tracker II sound waves The sound waves leave the Tracker in a circular pattern that gets wider as it gets further from the Tracker n Y Y O lt Conveyor The assembly used to move paving material from the hopper to the auger Cross Slope The angle of slope required to produce a desired surface slope Cross slope is measured in percent Crown The transverse contour of a finished mat The contour of the screed plate The transition line between 2 different slopes i e between lanes or between lanes and shoulders Lead Crown The contour or profile from side to side of the leading edge of the screed Negative Crown Contour which is higher at the edges than at the center of a mat Positive Crown Contour which is higher at the center than at the edges of a mat
36. reference for any job replacing cumbersome averaging skis In coordination with the Sonic Tracker stringline acts as 5 to 500 foot long virtual and more accurate averaging ski Stringline Setup P 32 and P 32 Operator s Manual P N 1001547 01 84 Sometimes the surface to be paved contains pot holes or surfaces too broken to use as a joint match reference Setting elevated stringline would be too time consuming especially for small divided projects In these applications surface stringline provides a simple easy alternative Position the tracker 14 to 18 inches above the stringline Figure 153 Figure 153 Position of Tracker in Correlation to Stringline It is important to use a stringline with a diameter at least 1 8 thick The Slope Sensor can detect a smaller diameter stringline but when stretched on the surface to be paved the surface below the stringline will be within the working window therefore you want to make sure you have a strong return signal To setup surface stringline in two simple steps 1 Drive a concrete nail into the existing surface to be cut Figure 154 and tie the stringline to the concrete nail Figure 154 Setup Concrete Nails 2 Roll out the stringline to the desired length Pull tight and secure to another nail at the opposite end The tightened stringline rests on top of the existing surface Figure 155 es ee Setting Surface Stringline P 32 and P 32 Operator s Manual
37. s et 9 UY O x 0 ay et Cc D N Q al va Y et 5 Primary Control Box Display Area Secondary Control Box Display Area Cross Communicaton 3 gt Indication Arrows Menu Set gt Unavailable for Secondary Control Box lt q Cross Communication Press and Hold to Make Changes to Secondary Control Box Figure 44 Cross Communication Established Secondary Control Box Control Enabled 2 While holding Cross Communication view or make changes to the settings in the secondary box The Menu Set Button and access to the secondary Control Box s Performance Menu Is disabled while in Cross Communication Control Box Features P 32 and P 32 Operator s Manual P N 1001547 01 25 3 When finished or to apply new settings to the secondary box release Cross Communication Elevation Slope Button Use the Elevation Slope Button Figure 45 to switch your Topcon P 32 or P 32 System between slope and elevation control Elevation Indicator LED t _ gt lt 4 Slope Indicator LED Elevation Slope Button Figure 45 Elevation Slope Button Elevation Control 1 Press the Elevation Slope Button The green elevation indicator LED below the elevation symbol illuminates 2 Turn the Grade Adjustment Knob to set the desired elevation O 0 WN Ul A o eb o UU O x lt TI 0 ay eb D UN Q
38. the Sonic Tracker s transducer emits a sound wave the tracker records the time to the bail and continues to listen for the grade reference If a temperature variation occurs such as heat off a freshly paved mat a difference in time to the temperature bail is recorded The correction for the speed of sound is then applied to the grade reference signal preventing a change in mat depth The tracker corrects for temperature variations with every sound wave 39 times per second Figure 78 illustrates this concept STOPWATCH STOPWATCH On Grade On Grade Target Reference A E Temperature Bail Heat Induced 2 J Temperature Bail Target Reference Target Error ramet E ae Wind Blown Heat Off of Freshly Paved mat Figure 78 Working with Sonic Trackers and Temperature Changes Working Window and Sonic Footprint P 32 and P 32 Operator s Manual P N 1001547 01 45 In the upper right hand corner of the Sonic Tracker II faceplate is a small symbol used to represent the use of the temperature bail The LED symbol automatically illuminate when the bail is connected to the tracker The tracker is cast with holes on each side for the bail to snap and lock into place Figure 79 im Figure 79 Sonic Tracker and Components Temperature Bail Sonic Tracker Placement Placement When Using a Temperature Bail Temperature and atmospheric conditions have an effect on the speed of sound In paving applications you can get a
39. the terms and conditions carefully Terms and Conditions Preface 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 Copyrights All information contained in this Manual is the intellectual property of and copyrighted material of TPS All rights are reserved Do 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 the product 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 Trademarks P 32 P 32 GC 35 ST 3 Sonic Tracker 11 Smoothtrac SAS Tracker ack LS B110 Topcon and Topcon Positioning Systems are trademarks or registered trademarks of TPS Windows is a registered trademark of Microsoft Corporation The Bluetooth word mark and logos are owned by Bluetooth SIG Inc and any use of such marks by Topcon Positioning Systems Inc is used under license Other product and c
40. thus maintaining correct mat thickness You can control and monitor the slope and thickness of the mat using the buttons and display located on the front panel of the Control Box Auto Indicator LCD Auto Button Light Sensor i AUTO Survey Button E aO SA Elevation Indicator LED Green Menu Selection Buttons N gt Slope Indicator LED Yellow Pe a S Grade Adjustment Arrows A O Grade Adjustment Knob AMO Ll Jog Up Down Buttons Power On Off Button Grade Indicator LEDs Slope Elevation Figure 32 GC 35 Control Box GC 35 Control Box Features and Setup P 32 and P 32 Operator s Manual P N 1001547 01 19 Color LCD Display The color LCD display Figure 33 allows the operator to view the Topcon P 32 or P 32 System s elevation and or slope settings menus and information about the Control Box See Control Screen on page 29 and Performance Menu on page 29 for information on your Topcon P 32 or P 32 System s user interface Color LCD eT 0 1 5 O 0 WN Ul A o s et 2 g O x lt 0 ay et Cc D N Q an Y Y et 5 22 TOPCON Figure 33 Color LCD Display Light Sensor The light sensor Figure 34 monitors ambient light to adjust the brightness of the color LCD display for better visibility The light sensor is located to the left of the LCD display Light Sensor Figure 34 Light Sensor Control Box Features P 3
41. to cut or damage the wires A AA L CAREFULLY REMOVE WIRE CONNECTORS Figure 172 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 NOT pinch the wires Figure 173 on page 96 Sonic Tracker Transducer Replacement P 32 and P 32 Operator s Manual P N 1001547 01 95 a22UBU3SJUIBIN FA CAREFULLY PLACE WIRE CONNECTORS ON TABS TRIM EXCESS TY WRAP PLACE NEW TY WRAP AROUND WIRES AND TIGHTEN Figure 173 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 174 on page 96 SS WIRE CONNECTOR PINS Figure 174 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
42. to indicate the direction to turn the knob to reach On Grade Rotate Knob Clockwise To Reach Grade Rotate Knob Counterclockwise To Reach Grade Figure 39 Grade Adjustment Direction Arrows Grade Adjustment LEDs The Grade Adjustment LEDs Figure 40 indicate raise On Grade and lower information and corrections See Table 1 for a description of the Grade Adjustment LED indications O 0 WN Ul A o s et 2 g O x lt 0 ay et Cc D N Q an Y Y et 5 Figure 40 Grade Adjustment LEDs Table 1 describes grade adjustment LED indications The values listed in Table 1 are default factory values Table 1 LED I ndications for Elevation Slope Control LED Display Elevation Description Slope Description Slowly iincna vellow down blinking yellow down a Outsideor Working Window beyond of Working Window beyond Outside of Working Window arrow 0 2 ft above grade no valve control beyond 2 above grade Solid yellow down arrow v Above grade between 0 05 ft and 2 ft Above grade between 1 and 2 Blinking yellow down arrow Above grade between 0 02 ft and 05 ft Above grade between 0 5 and 1 Blinking yellow down arrow Within 0 02 ft of grade Within 0 5 of grade w green bar Blinking red up arrow w Within 0 02 ft of grade Within 0 5 of grade green bar Blinking red up arrow Below grade between 0 02 ft and 0 05 Below grade between 0 5 ft and 1 Solid red up arrow ra Below g
43. 0 7 O YU solenoid On Off Mode 1 13 225 1950 Hz programmable Programmable dither 0 105 Hz 0 15 Programmable current limit Sink or source operation Danfoss 50 available voltage as neutral Proportional Mode gt 50 Raise lt 50 Lower Programmable dither 0 105 Hz 0 15 ST 3 P 32 System Only Table 4 GC 35 Specifications Resolution 0025 ft Supply Voltage 10 32 VDC Supply Current 300mA typical operating current Emissions FCC Part 15 Subpart B Class A CISPR 11150 13766 EN 13309 Immunity ISO 13766 for radiated RF immunity and ESD Transducer Frequency 50kHz burst Target Range 14 in to 36 in Detection Zone 9 in x 6 in at 2 ft Stringline mode 8 in x 6 in at 2 ft Surface mode Physical Display LEDs 1 ea Status 11 ea Left Right Centered Stringline mode Raise Lower Ongrade Surface mode Housing Powder coated cast aluminum Switches 1 ea sealed 32 position rotary encoder w gold contacts 7 ea momentary push button elastomer over stainless domes 1 ea sealed latching push button power Connector 11 pin bayonet shell size 18 Weight 3 0 lbs Environmental Operating Temperature 0 C to 80 C 32 F to 176 F Storage Temperature 40 C to 100 C 40 F to 212 F ST 3 P 32 System Only P 32 and P 32 Operator s Manual P N 1001547 01 113 Table 4 GC 35 Specifications Ingress Protection 1P 67 P 69K Vibration Random 10 2000Hz 10Grms 30 min per axis Shock Drop from 500mm
44. 0 inch mat is being laid then an adjustment is necessary You must first get the box to display the same number as the mat depth Actual mat thickness adjustment value may vary depending on paving conditions To change the mat depth being laid 1 Press the Auto button to put the Control Box and Paver into manual mode The Auto LED goes dark Control Box Setup for Elevation Control P 32 and P 32 Operator s Manual P N 1001547 01 70 2 Press and hold the Menu Set button while turning the Grade Adjustment Knob to read 3 00 inches Figure 124 Release the Menu Set button to apply the setting 3 00 3 00 3NBdH 0 pe y 3unjan Press Menu Set Button O N A TOPCON Figure 124 Adjusting Grade 3 Press Auto to switch the Control Box to Automatic mode 4 With the paver moving and the Control Boxes in Automatic slowly dial the display from 3 inches down to 2 5 inches Figure 125 How fast you turn the knob depends on how smooth you want the transition to take place Highways require gradual changes parking lots require quick changes The display should now read the depth of the mat being laid 2 TOPCON Figure 125 Slowly Adjusting Grade Control Box Setup for Elevation Control P 32 and P 32 Operator s Manual P N 1001547 01 71 Control Box Setup for Slope Control The Slope Sensor should already be mounted on the transverse beam of the paver The sensor can talk to both Slope Sens
45. 00 p n 7020 0121 e Cut fill offset tape feet tenths p n 7000 1026 e Cut fill offset tape metric p n 7000 1027 Although Topcon s Sonic Tracker works with many sizes and types of stringline for best results use an 1 8 inch diameter nylon stringline Using steel wire or a plastic coated stringline with a smooth surface can cause erroneous results 1 Place the sonic grade clips on stakes and drive the stakes approximately 6 to 8 inches away from but in line with the hubs Do Not disturb the hubs Figure 158 Figure 158 Place Clips and Position Stakes 2 Using an anchor pin at each end roll out the sonic stringline the length of the working area and pull the stringline tight 3 After the stringline has been pulled tight place it into the fingers of each Sonic Grade Clip Figure 159 Figure 159 Place Stringline in Clip 4 Decide what the sonic stringline hike up the distance from finished grade to the sonic stringline should be in this example two feet Setting Elevated Stringline P 32 and P 32 Operator s Manual P N 1001547 01 87 dnjyesg auljsulys Making a Cut Fill Lath Once you have the stringline setup fine tune the height of the stringline above the grade To do this make a cut fill lath using a lath and a Topcon cut fill decal 1 Assemble the required number of laths for the job 2 Measure from the bottom of the lath to the desired height above grade and make a mark at that point P
46. 2 and P 32 Operator s Manual P N 1001547 01 20 Power Button The power button Figure 35 for the Control Box turns it on and off Power ZN Figure 35 Power Button Powering the Control Box On Off O 0 WN Ul A o s et 2 g O x lt 0 ay et Cc D N Q an Y Y et 5 Startup Screen Shutdown Screen A TOPCON Shutting Down GC 35 config 21 Power On Off Button Figure 36 Power On Off Control Box Features P 32 and P 32 Operator s Manual P N 1001547 01 21 Grade Adjustment Knob The Grade Adjustment Knob Figure 37 makes measured adjustments to elevation and slope settings or cycles through menu options Turn the Grade Adjustment Knob to adjust the grade height while in elevation control Figure 37 Figure 37 Grade Adjustment Knob Adjust Elevation Turn the Grade Adjustment Knob to adjust the percentage of slope while in slope control Figure 38 Figure 38 Grade Adjustment Knob Adjust Slope Control Box Features P 32 and P 32 Operator s Manual P N 1001547 01 22 O 0 WN Ul A e eb o UU O x lt TI 0 ay eb D UN Q en Y Y eb 5 Grade Adjustment Direction Arrows The Grade Adjustment Direction Arrows are located at the upper left and upper right of the Grade Adjustment Knob When your Topcon P 32 or P 32 System is set to Manual control the Grade Adjustment Direction Arrows Figure 39 light up in red
47. 25 ES Af TOPCON Press Enter J Turn Grade Adjustment Knob Figure 54 Changing and Storing the Value 4 Press NA to store the value Figure 54 or press Sa to cancel and revert back to the original value If power is interrupted to the Control Box within two seconds after making an adjustment the Control Box does not have time to store the new setting and reverts to previous or original settings 5 To access other Performance Menu items turn the Grade Adjustment Knob 6 To exit the Performance Menu and return to the Control Screen press UU Performance Menu Item Descriptions The following sections describe each menu item in detail Elevation Gains Raise and Lower Elevation Gains Figure 55 determines the speed at which your Topcon P 32 or P 32 System allows the tow point cylinders to adjust to a change in elevation For faster hydraulic response increase the gain value For slower hydraulic response decrease the gain value The objective is to set the gain so the screed reacts to the change in grade quickly but without overshooting the new elevation e Gain Elevation Value Range 1 200 e Factory Preset 25 Before setting the Elevation Gain make sure the machine s hydraulic flow controls valves are adjusted for proper cylinder speed according to the manufacturer s recommendations Performance Menu P 32 and P 32 Operator s Manual P N 1001547 01 31 O 0 WN Ul A o s et 9 UY O x
48. 4 al 5 ts Press Jog Lower to Lower the Tow Cylinder Figure 48 J og Up Down Button USB Port The USB Port Figure 51 is used to update the Control Box s firmware See Updating Firmware on page 39 for instructions on updating firmware USB Port USB Cap Removed Figure 49 USB Port Control Box Features P 32 and P 32 Operator s Manual P N 1001547 01 27 Connectors The Control Box connectors Figure 51 connect to the Sonic Tracker s the Slope Sensor optional and power Power Connector Sonic Tracker Slope Sensor Connector a Sonic Tracker Slope O 0 WN Ul A o s et 2 g O x 0 ay et Cc D N Q an va Y et 5 Sensor Connector Right Side View Figure 50 Connectors Jaw Mount A Control Box bracket attaches to the Jaw Mount Figure 51 and allows easy removal of the Control Box from the machine Da Jaw Mount Ma Figure 51 Jaw Mount Control Box Features P 32 and P 32 Operator s Manual P N 1001547 01 28 Control Screen Figure 52 is an example of the GC 35 Box s Control Screen The Control Screen is your interface with the components of your Topcon P 32 or P 32 System The Control Screen changes depending on how you have configured your Control Box and your Topcon P 32 or P 32 System The screen also changes if you are using a Secondary Control Box and are using Cross Communication See Display on page 36 and Cross Communication Butto
49. 46 Survey to On Grade and Return to Automatic Control You may find after surveying that for the tracker on the curb the number has changed slightly from the curb on the other side of the intersection This is due to the different depth of the base below the lip of curbs While paving slowly dial the display back to the previous number Method 2 for Paving Intersections 1 Sometimes the base of the intersecting road is too rough to use as a reference An alternative is to use a simple piece of stringline 2 Take a section of 1 8 diameter string and nail or secure it to the curb 3 Pull the string tight through the intersection and nail or secure it to the other curb Figure 147 x If the intersecting road has a crown hike the stringline up in the middle of the road to place the a string at the proper height A hub or a stake with a piece of wire to hold the stringline works fine Figure 147 Paving Through ntersection Using Hub This constant reference gives you complete control through the intersection and ensures that you tie in perfectly to both curbs Paving Streets Through Intersections P 32 and P 32 Operator s Manual P N 1001547 01 81 suone gt 1 ddy Sued Paving Intersections with Cross Slope When paving with slope intersections do not require any adjustments if the mainline cross slope does not change If the slope does change then use a combination of slope and elevation Figure 148
50. 7 01 105 Slope Sensor Symptoms Cross Slope displays Error on the Control Box s Control Screen l 2 3 Cross Slope drives cylinder in the wrong direction o o D UN p o o F eje 4 Cross Slope does not lock On Grade 5 The Cross Slope being laid is not correct Slope Sensor Symptom 1 Slope lights flash between raise and lower and do not stay On Grade Cross Slope displays Error on the Control Box s Control Screen Probable Cause Both Control Boxes are selected for slope or have a defective cable 1 Cross slope operates one side at a time Verify only one Control Box has been selected for slope 2 Verify that the slope cable is connected securely and properly 3 Swap slope cable from other side to check cable Slope Sensor Symptom 2 Cross Slope drives cylinder in the wrong direction Probable Cause Slope sensor installed incorrectly 1 Verify the Slope Sensor is positioned correctly on the transverse beam Slope Forward Decal must be in direction of travel 2 Check that the machine is properly wired and hydraulically connected to the valve Raised jog switch should make the cylinder go up lower jog switch should make the cylinder go down Refer to the paver manufacturers manual Slope Sensor Symptom 3 Slope lights flash between raise and lower and do not stay On Grade Probable Cause Incorrect Performance Setting adjustments or a loose transverse
51. EKR EHR HEHEHEHEH EEHEEHE 00 0 50 00 50 EN heal W UN p hi me ck fh se MO u y MN y y ee ee ee a ee a ee ee ee ee eae ee aaa ak aa ae ae ae ae ee eR ee Raa ks es es Ss fs 8 2 Se EREEREER ee ee ee 30 00 50 0 0 0 0 rTFTrTerRreHReteFTtrFrTteHTeHaTehFTtheRTeHRTeHReTeRTeReSeRewTeHRreHeHREeHTeheHeHTheHThHTheHTteHTteHTteTeHTreheHTtheHTeaTeaTeaTreHaThrTaeaeeweHerFrrRrerRrterFrtenReteHeteHeteFethSTeheSFehSe SP ePe eee eRe RPC Reem 2 A 2 2 ff 2S 0 5 ke EEHEHE y E 3 y YU Y MY 4 M4 ME E MN M 50 1 ll Y 12 10 56 106 ff fs 2 fs 21 210 2 00 S C CS SR SE SS SS SS 210 2 M0 0 20 2 0 2 ee ee ee nwWTFeFT 7 T EE O OO SO NOOO OO DO IO oO 4 NS WS WYUUMU UNMYMMMIUI9IO O 3OO O YO U UOUOG4GG GOO OOOO 2 UP 3 DUO PP U gt P P O2 S0S 8 s D O Op a 2 0 0 0 0 SS Sa aa eee eee 50000000 0000000800000 0000000 80 50 50 0 0 310 0 SS ee ee ee ee ee ee ee Me E E a a eee u au au n 4 UU Se ee se eae ae ae ae ae eae se se Ss Se ee ee ee ee ee ee 28282 2B Be Bea ERR ERR BR BRR BR AaR RRR RR RR RRR RRR RRR EAE EEE E88 28 8 8 8 8 8 8 228 A A 2 MM ee ee ee A anaE A H a i tr pmm mm pr A ae eee eS O O O A an E E EEE HEHEHEHEHE O O O O O A A O A O A A A A O O A O O p EE Se gt Mm ru Il u UEa O lh o LS SO NO O E A A O E O E E O E W SN Y GS A y UY l Y Y UH Y Y tt E y fF Y YE ME O YE y E E YO YO y y MN l l y r a g ExT gt Wa SEY a i i
52. O lt TI 0 ay eb D UN Q en Y Y eb 5 Figure 58 Averaging Elevation Deadband Elevation Deadband is the area of the Working Window that is On Grade While the reference is within that area the paver s valves are idle closed Therefore the wider the Elevation Deadband On Grade area the more a reference can move up or down without a correction being initiated Once the signal from the reference is out of the deadband your Topcon P 32 or P 32 System drives the hydraulics to place the reference back in the center of the deadband e Elevation Deadband value range 1 mm to 30 mm e Factory preset 3 mm 0 01 ft or 1 8 in Select the amount of Elevation Deadband carefully Too small of an Elevation Deadband causes the tow point cylinder to constantly hunt up and down while the sensor tries to find On Grade Too large of an Elevation Deadband does not allow the sensor to send grade corrections to the values causing unwanted variations in mat thickness 1 Elev Gains 2 Slope Gain 3 ee 3 Valve Offsets 5 Slope Deadband min 1mm 6 Averaging max 30mm 7 Machine Type g default 3mm Figure 59 Elevation Deadband Performance Menu P 32 and P 32 Operator s Manual P N 1001547 01 34 Slope Deadband Deadband is the area of the Working Window that is On Grade While the reference is within that area the paver s valves are idle closed Therefore the wider the Slope Deadband On Gra
53. OM A AS 41 SOPE Callbration BIOCK o acido cid ordinal la ceda 41 Sonic Tracker and SAS Setup 0 00 c eee eee ees 42 Working Window and Sonic Footprint 0 0 ee eee 42 Sonic Tracker Operation and Position 0000 eee eee eee eee 43 Sonic Tracker and Temperature Changes 000 ooo 45 SONIC Tracker placement ria rad amp ak Pane done aA Ak a a a 46 Placement When Using a Temperature Ball o oo 46 Placement When Using a Mechanical SkKl oooooooo o 47 Placement When Using Elevated Stringline o oooooo o o 47 Placement in Relation to the Screed o oooooooooooorrar eee 48 LsBar POSION 4413 Yara tarada aaa da 50 Cur anda Guter Track us rada dai po sti E A as 51 Joint Matching and Tracking Sub grade cee ees 52 A E gen abe day Pol eh eee ee AO 53 Setting Surface or Stringline Mode for the ST 3 0 cee ee es 53 SS ONGNtGtOM sit ati did e aka Ae de a 54 SU Mace MOde bil day OVEN daa bared bea ORES amp kd aaa d 54 E 54 SEEINGIMG Mode irritada 56 ST 3 Orientation e cal AA DAA AA 58 Sonic Tracker SPECIES i tora aros lia aaa 58 Sonic Tracker Positioning in Relation to Reference o ooo 59 Placement When Using Surface Stringline ooo ee 59 Optional Smoothtrac SAS Placement and Setup 0 00 oo 60 POSIKIONING TNC SAD nae wa eee ENE AWA A RR aa 62 Placement of SAS on Paver
54. P 32 and P 32 System i dj i Y 4 Y mus 2 TOPCON Operator s Manual ff TOPCON P 32 and P 32 Operator s Manual Part Number 1001547 01 Rev A Copyright Topcon Positioning Systems I nc March 2014 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 Table of Contents Preface Terre AAA Ae AA A eee ee ee x System OVervieW ccoo 1 CENO ACUAN cir arial dai eee 2 6C 35 Control BOX criar a AA ARA AA A 2 SON WC CM atera Era a to o da aa 2 Dial Port SIPE SENSO ici Past DAA a aa 3 Smoothtrac Sonic Averaging System Optional Add on System 4 Laser Receiver Optional Add on Component 0000 eee ee eee 4 Car yInd CdSe ve tuto a eed A awa R eke R ee SHAK O Oh eee Eee 5 Paving Principles and Control Methods 0 0c0ocooo ooo 6 Paver Components vasos astra a Sed Gree Se ee ee 6 HOW a screed WOK ei siare iaa e eaa aS aah Wie Pee ee ak ee a a 6 TOWPOINGFORCEUP os ord baat oO dea ese PAS a ee RS 8 Truck Exchange Another Tow Point Force oaaae aa 9 Head Or Maternal acia bed eat ae eae aes Oh Rw ee BR 9 Reaction of Material Under Screed R 0 00 ce ee ees 10 Gradation Mix Characteristics 0 0 cee ee eee 11 Mix Temperature Characteristics
55. Press Auto to Switch to Manual Mode suolesddy Sued Survey Press Elevation Slope to Switch to Slope Mode 2 TOPCON Figure 148 Paving ntersections with Cross Slopesv 1 Just before the slope of the intersection begins to change press Auto to switch the slope side of Paver in Manual mode Figure 149 e Press Auto to Switch to Manual Mode 22 TOPCON Figure 149 Switching to Elevation Control and Surveying On grade Paving Intersections with Cross Slope P 32 and P 32 Operator s Manual P N 1001547 01 82 2 Press the Elevation Slope button to switch from slope to elevation control on the Control Box and Survey to On Grade Figure 150 lt i Survey suone gt 1 ddy Sued C Elevation Slope 2 TOPCON Figure 150 Surveying to On grade 3 Press Auto and pave through the intersection with the Control Box in Automatic mode 4 Upon reaching the end of the intersection Figure 151 press Auto to switch to Manual mode press Elevation Slope to switch to slope control and press Survey Press Auto to Switch to Manual Mode Survey Press Elevation Slope to Switch to Slope Mode 2 TOPCON Figure 151 Paving Through Intersection 5 Press Auto If the slope is not as desired use the rotary knob to gradually change the slope percentage to the desired slope the slope of the mat you just laid down as displayed on the Contr
56. Replacement 0 00 eee ees 94 TFOUDICSNOOEING usina ieee ie ee ee ee ee 98 Safety Warnings sosa daa tenn airada 111 General Warni asa ma Hoe dicas Ch He a OES SRA oe rd 111 SDECINCALONS iia a a AAA 112 US Da nr hod Wh eae ed a Rae ds the hay he amp Ge arth ow MORI da a chy hate oe 112 A 7 A dehyde EA eich era eae a E aca a hk 113 Sonic Tracker II P 32 System Only 0 0 es 114 Dual P OTE SIODE SeN yardas SH ae a ake A aa ees 115 LS B110 Laser Receiver Optional 0 0 0 0 eee ee ees 116 9130 Laser Receiver Optional 0 cee eee ees 117 Regulatoria ica ne ee ee eee 118 Federal Communications Commission FCC 0 00 oo 118 Industry Canada Compliance IC aaa 118 COMMUNIO Europe CE sna ydoctcuk cee ra AAA A 118 Australian Communications and Media Authority Compliance ACMA 118 WEEE DIRCCIV G2 3 us adan Pee ee od eae SO a ea ae acacia ee 118 Waranty weird diari aaa steno eee eared ai 119 Cie ee ee ee ee ee ee ee eras 120 Table of Contents P 32 and P 32 Operator s Manual P N 1001547 01 IX 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 are designed to assist owners with the use of the product and its use is subject to these terms and conditions the Terms and Conditions Please read
57. Sensor and the screed slope Control Methods P 32 and P 32 Operator s Manual P N 1001547 01 17 y 0d eje y BF a Y V Q a A o eb e z Z Y ama Dy an V Figure 31 Using the GC 35 Control Box to Adjust the Slope y ay eje y 2 e D UN Q a A o lt Y ot p a UN See GC 35 Control Box Features and Setup on page 32 for information on using the GC 35 Control Sa Box Control Methods P 32 and P 32 Operator s Manual P N 1001547 01 18 GC 35 Control Box Features and Setup This chapter describes the features and setup of your GC 35 Control Box including e The buttons grade adjustment knob and color LCD screen on the GC 35 Control Box e How to change settings access information and take readings using the Control Box e A description of the Control Screen e The menus available in the Performance Menu e How to access change settings and apply features using the Performance Menu Control Box Features The Control Box is your user interface to the Topcon P 32 or P 32 System The Control Box receives signals from elevation sensors and an optional Slope Sensor and uses these signals to determine if grade or slope corrections are necessary If the paving requires a change in grade or slope the Control Box sends a signal to the valve controlling the tow point cylinder on the appropriate side of the paver to raise or lower
58. TOPCON GC 3 3 Config Number config 21 External Config Number Figure 177 Config Number Located on Startup Screen Each number represents a specific valve type The most common numbers are 21 sink 15 prop source and 9 source Contact your Topcon support representative and provide the Config number to determine if your Control Box is configured with the correct valve setting 2 Verify string is at least 4 inches above the surface of the ski The ski pulls away from the paver and can get in Tracker s Working Window if the string Is too close The ski also tilts to one side when traveling through a super elevation or slope transition 3 Fora multi foot ski make sure foot spring pin is not within the sonic footprint as the ski surges back and forth Control Box Symptom 8 The Control Box SAS icons numbered 1 2 3 or 4 are red Probable Cause Defective Sonic Tracker or SAS cable 1 Check SAS cable connections at each tracker 2 Turn Control Box off and swap tracker whose corresponding SAS icon is red Figure 178 with another tracker on the SAS Tracker number is on the cable at the tracker connector Turn the Control Box on to reset SAS If any of the SAS icons 1 4 are red the problem is the tracker If the SAS icon remains the same the problem is the SAS cable Control Box Symptoms P 32 and P 32 Operator s Manual P N 1001547 01 101 3Uulooysa3 qno1 Tracker Functioning but Not Detecting
59. The trackers can be placed so all four are over the reference or the back tracker can be set over the freshly laid mat The best method is the one you are presently using or the one in which you are most comfortable Figure 110 DO BAS ils Figure 110 Example Placement of SAS Trackers Over Reference With SAS be careful when the screed Is raised that the front tracker does not hit the ground If needed the tracker bracket can be temporarily folded back when raising the screed to keep the tracker from hitting obstructions Figure 111 Optional Smoothtrac SAS Placement and Setup P 32 and P 32 Operator s Manual P N 1001547 01 62 Y o O om Q A lt Y Q a Y gt Y Y Y et 5 Y o 2 om Q A s Y Q a Y gt UN Y Y eb 5 Figure 111 Example of Raising the Tracker Bracket to Avoid Obstructions In some applications a grade reference outside the screed extension may not be in satisfactory condition such as the shoulder of a road or the broken and warped edge of pavement Traditionally the screedman would manually adjust mat thickness on that side of the paver The non contacting SAS can be set up over the screed so full automation can be used The first three trackers reference the existing grade and the back tracker references the mat just laid Figure 112 Figur
60. Voltage 10 30 VDC Supply Current 10 5A max operating current Switched Output Power 10A valve output power 5A sensor output power 10A total combined output power USB RS 485 RS 232 CAN 2 Digital input Applicable regulation CE ISO 13766 FCC Part 15 Subpart B C ISPRI I Class A 2009 IC ICES 003 CISPRI Class A 2009 C Tick Physical Display 240 x 320 color TFT enhanced brightness Powder coated cast aluminum Switches 1 ea sealed 32 position rotary encoder w gold contacts 7 ea momentary push button elastomer over stainless domes 1 ea sealed latching push button power Connectors 3 ea MIL C 5015 cylindrical connectors gold plated contacts conductive anticorrosive plated housing 1 ea USB Weight 2 0 lbs Environmental Operating Temperature 40 C to 80 C 40 F to 176 F Moisture 240 Hours Shock 50G 11 ms Y sine wave each axis Vibration 10 400 Hz sweep 5G 1 oct min 10 400 Hz random 5G each axis Salt Fog Test 48 hours ASTM B117 97 I I o I o I E o I Valve Outputs One Valve Output One Bidirectional Hydraulic Cylinder Current Controlled 7 4 V 5000 mAh Proportional Mode lg Specifications P 32 and P 32 Operator s Manual P N 1001547 01 112 Table 3 GC 35 Specifications Pulse Width Modulated 1 13 225 1950 Hz programmable Proportional Mode Programmable dither 0 105 Hz 0 15 Programmable current limit Sink or source operation V 5 O s A
61. acket Connect Cables Power On Figure 115 Attach Control Box and Connect Cables Due to different types of machine configurations cable connections may vary Getting Ready to Pave P 32 and P 32 Operator s Manual P N 1001547 01 66 Screed Setup To start paving with your Topcon P 32 or P 32 System set up the paver just as you would under manual control 1 Place the screed on blocks or lath set for the desired paving thickness Figure 116 make sure to account for material compaction Figure 116 Place Screed on Blocks 2 Center the tow point cylinders to maximize travel in raise or lower directions Figure 117 use the jog switch on the Control Box or the switch provided with the Paver Cylinder Cylinder Cylinder Fully Raised Fully Lowered in the Center Figure 117 Center the Tow Point Cylinders 3 Using the manual thickness adjustment cranks or hand cranks on the paver null the screed and set the proper angle of attack Figure 118 Make sure both cranks are set the same Thickness Cranks Correct Head of Material Figure 118 Manually Adjust Thickness of Mat 4 Next turn on the auger feeder controls to place the asphalt in front of the screed Screed Setup P 32 and P 32 Operator s Manual P N 1001547 01 67 3NBdH 0 pe y 3unjan Sonic Tracker Setup The following steps describe installing and positioning the Sonic Tracker on the Paver For more information see Sonic Tracker Placement o
62. ade indicators display left right and centered arrows You can select the mode through the GC 35 Slope Sensor using firmware version 1 1 or newer under the Sonic Tracker 3 menu item The GC 35 screen displays an icon as a reminder of which mode is active STOPWATCH Transducer Generates Echo Bounces Off Tracker Uses Echo s Return Time To Sound Pulse Physical Grade Reference Calculate Distance To Grade Reference Sonic Tracker II shown Both the ST 3 and Sonic Tracker II use similar technology Y ay eje y 2 e o D UN Q a a o zz Z Y F o a UN Figure 25 Timed Sound Pulses Determine Distance ST 3 and Sonic Tracker Il Laser Control For Laser Control a laser transmitter is used to produce a plane of light which becomes the grade control reference for the job site The Laser Receiver controls the screed to lay a mat parallel to the laser beam reference When the laser beam is in the center of the receiver it indicates an On Grade signal Figure 26 EN UY Figure 26 Laser Control On Grade As the screed Is raised the beam of light hits the Laser Receiver below the center and a lower signal is indicated Figure 27 on page 16 Control Methods P 32 and P 32 Operator s Manual P N 1001547 01 15 Ei EA UR A Figure 27 Laser Control Above Grade As screed is lowered the beam of light hits the Laser Receiver above the center a raise s
63. al P N 1001547 01 109 o 2 D UN D o y je SAS Symptom 4 SAS is not producing a smooth surface Probable Cause Improper setup or Performance Menu Settings 1 Verify that temperature bails are clean and securely attached Verify temperature bail symbol T is displayed on face of Tracker Sonic Tracker 11 If not clean or replace the transducer See Maintenance on page 88 to clean or replace the transducer if necessary Check that Trackers are between 14 and 24 inches from reference If there are gusty winds lower SAS to get Trackers closer to reference Move the Tracker away from gusty heat source such as engine fan exhaust Verify that the Trackers are not picking up erroneous signals from undesired reference Example Head of material end gate shoulder grade or material spillage from hopper JE ee oo Verify that the center of the SAS beam is between the midpoint and the forward 2 3 point of the tow arm 8 Check to see if Averaging in Performance Menu is set too low Factory setting is 50 See Averaging on page 32 9 Check that Deadband in Performance Menu is not less than 3mm See Elevation Deadband on page 33 and Slope Deadband on page 34 10 Check that the Valve Offsets are set properly Valve Offsets Raise and Lower on page 32 11 Check that the Gain setting in the Performance Menu Is not set too high Factory setting Is 25 Elevation Gains
64. aluminum Connector 11 pin bayonet shell size 18 Weight 2 0 Ibs Environmental Operating Temperature 0 C 32 F to 60 C 140 F Dual Port Slope Sensor Table 6 Dual Port Slope Sensor Specifications Resolution 0 025 slope High resolution mode 0 00625 slope Supply Voltage 10 30 VDC Supply Current 85mA typical operating current Emissions Applicable regulation EN55022 1994 30 230MHz 40dB mV m Max at 10m2 30 1000MHz 47dB mV m Max at 10m Immunity Applicable regulation EN55024 ESD 8KV RF 27 to 500MHz 3V m Fast transient 0 5KV capacitively coupled Topcon proprietary RS 485 network port Physical Display LEDs 1 ea Status bi color yellow green Housing Powder coated cast aluminum Dual Port Slope Sensor P 32 and P 32 Operator s Manual P N 1001547 01 115 Table 6 Dual Port Slope Sensor Specifications Connector MIL C 5015 cylindrical connectors Silver plated contacts Conductive anti corrosive coating UN 5 4 oF a A ad 2 ea 10 pin screw sy O V Environmental Operating Temperature 20 C to 60 C 4 F to 140 F 5 100Hz sweep 5G all axis Half sine 11ms 50G all axis Moisture MIL STD 810D method 506 95 humidity at 60 soak LS B110 Laser Receiver Optional Table 7 LS B110 Laser Receiver Specifications Detective Precision 3mm 0 009ft 6mm 0 019ft 15mm 0 049ft 30mm 0 098ft External Power Supply Power External Pow
65. arities indicate that the homogeneous characteristics of the material in the mat have been interrupted which usually results in bumpiness and premature failure of the pavement in those areas Segregation can also be the result of excessively worn augers Center Streak segregation can be caused by worn Kicker Paddles at the center chain cause or near the outside auger bearings In fact center streak segregation is frequently caused by incorrect arrangement of the auger segments adjacent to the auger chain case Consult the Manufacturers Manual How a Screed Works P 32 and P 32 Operator s Manual P N 1001547 01 11 Center Streak segregation is also caused by feeder gates being set to tow Adjust as necessary to provide sufficient uniform material at the center of the paver Center Streak segregation can be limited and even eliminated by slowing paving speed Mix Temperature Characteristics A common paving problem is inconsistent temperatures in the asphalt mix As the material cools it loses its viscosity making it more difficult to compact If the resistance to compaction increases the screed naturally increases its angle of attack and begin to float up This changes the mat depth resulting in bumps in the surface If the mix and or screed temperature are too low the screed may no longer slide smoothly over the material and a tearing of the mat occurs Simple steps to take to control temperature variations
66. at power up checked or Use at power up unchecked unchecked Tech Menu O 0 WN Ul A o s eF 2 g o x lt 0 ay et Cc D N Q an Y Y et 5 Default settings are preset values that run most pavers If your machine does not perform properly within those preset values adjust the setting accordingly until you have satisfactory machine performance Selecting Performance Menu Items Follow these steps to access the Performance Menu select Performance Menu items and make changes 1 From the Control Screen press the Menu Set button Figure 53 2 Rotate the Grade Adjustment Knob to scroll through the menu selections displayed on the screen Figure 53 and press the Enter button PIN to select a menu item 2 Slope Gain 3 Valve Offsets 4 Elev Deadband 5 Slope Deadband 12 Slope Gain Valve Of fsots Elev Deadband Slope Deadband Averaging Machine Type y 6 Averaging 7 Machine Type y 2 TOPCON Press Menu Set Button Turn Grade Adjustment Knob Press Enter Button Figure 53 Accessing the Performance Menu 3 Press ed to highlight the value in blue Figure 54 and then use the Grade Adjustment Knob to change the value Performance Menu P 32 and P 32 Operator s Manual P N 1001547 01 30 raise 28 lower 25 raise 25 lower 25 raise 28 lower 25 min 1 max 200 defaults 25 min 1 max 200 default 25 min 1 max 200 default
67. away from gusty heat source such as engine fan exhaust Verify Tracker is not picking up erroneous signals from undesired reference Example Head of material end gate shoulder grade or material spillage from hopper If using Stringline verify line is not bouncing Check to see if Averaging in Performance Menu is set too low Factory setting is 50 9 Check that Deadband in Performance Menu is not less than 3mm Pr PI a eS O co N Tracker Symptom 4 The Sonic Tracker is not matching joint or curb Probable Cause Tracker is too far forward on the tow arm 1 Position the Tracker at 1 3rd the tow arm length just in front of auger 2 Gain for tracker may be set too low Adjust Gain to a minimum of 25 3 Brackets and L bars have not been securely tightened Also check for excessive play or slop where tracker is attached to the paver Tow arm or end gate Tracker Symptom 5 The Sonic Tracker picks up the ground but does not pick up a stringline Probable Cause 1 Tracker is too close to a reference or transducer is weak 2 Verify that tracker is at least 14 from the stringline 3 Smooth steel wire is not recommended Use minimum 1 16 diameter string for elevated stringline or averaging ski Use 1 8 string for Surface Stringline 4 If using an ST 3 make sure the Sonic Tracker 3 is set to Stringline in the Control Box s Performance Menu Sonic Tracker Symptoms P 32 and P 32 Operator s Manual P N 100154
68. beam Check the Valve Offsets for proper operation See Valve Offsets Raise and Lower on page 32 2 Check the Gain settings Factory setting is 25 See Elevation Gains Raise and Lower on page 30 and Slope Gain on page 31 3 Slope Deadband set too low Increase Slope Deadband The Factory Setting is 0 075 See Slope Deadband on page 34 Check for excess vibration in the Transverse Beam due to poor connection at Tow Arm 5 Make sure the Slope Sensor is mounted directly to the Transverse Beam and Is not elevated or supported by additional brackets Slope Sensor Symptoms P 32 and P 32 Operator s Manual P N 1001547 01 106 Slope Sensor Symptom 4 Cross Slope does not lock On Grade Probable Cause Loose Transverse Beam or incorrect Performance Setting adjustments 1 Verify that the Slope Sensor is not moving or vibrating when trying to survey slope on grade 2 Slope Deadband set too low Increase Slope Deadband The Factory Setting is 0 075 See Slope Deadband on page 34 3 Stop the paver make sure the screed is on the ground and turn the vibrators off o cy D UN p o F je Slope Sensor Symptom 5 The Cross Slope being laid is not correct Probable Cause Incorrect Slope Sensor calibration 1 Calibrate the Slope Sensor as described in Control Box Setup for Slope Control on page 68 2 Check that the Transverse Beam is mounted according to the manufact
69. ble as well as changing sensor characteristics to optimize the detection zone based on application The two modes are Surface Mode and Stringline Mode Setting Surface or Stringline Mode for the ST 3 When using a Sonic Tracker 3 ST 3 you can select either Surface or Stringline mode from the Performance Menu Use Surface mode when tracking a surface or Stringline when tracking a stringline with your ST 3 By checking the Use at power up check box the Control Box remembers your preferred setting at power up The default setting is Surface 1 From the Performance Menu select Sonic Tracker 3 and press the press the Enter button ed l 2 Press either Surface or Stringline 3 Check the Use at power up check box to lock this setting when the Control Box powers on and off if desired Y o O om Q A lt Y Q a Y gt Y Y Y et 5 Stringline Use at power up 8 Display 9 Units 10 System Info 12 Tech Menu Surface Stringline y Figure 94 Selecting Surface or Stringline Mode ST 3 Specifics P 32 and P 32 Operator s Manual P N 1001547 01 53 ST 3 Orientation For optimal performance make sure the ST 3 is parallel to the surface stringline within 5 in any direction Figure 95 ST 3 Orientation Surface Mode Surface Mode is used to detect the ground or curb While in Surface Mode the grade Indicators display up down arrows and On grade centered LEDs Typica
70. cable at the tracker connector Turn the Control Box back on to reset SAS If error number moved positions with the swapped tracker then the tracker is the problem See Chapter 8 to replace the transducer if necessary If error continues to display for the same position even after trackers have been swapped the tracker connector or SAS cable is the problem The defective tracker or SAS cable should be repaired but SAS can still be operated without all four trackers operating Remember balance point changes if a tracker is removed SAS Symptom 3 SAS does not lock on grade Probable Cause Tracker too close to reference or defective transducer in Tracker 1 2A 3 SAS Symptoms Verify that all cable connections are properly and securely connected Verify the SAS icons on the Control Box Figure 180 on page 107 Check that all trackers are sending out sound waves transducer is making ticking sound and grade lights are flashing If tracker is not working check that transducer and foam filter are clean and free from damage See Maintenance on page 88 to replace the transducer if necessary SAS beam and trackers may be too close to reference Bottom of tracker must be minimum of 14 inches from reference You may be using a non SAS compatible tracker Verify that the Tracker has SAS compatible decal near the serial number label Figure 183 Figure 183 SAS Compatibility Label P 32 and P 32 Operator s Manu
71. cent Slope The unit of measure used for cross slope Pull Points See Tow Points Push Roller Rollers mounted at the front of the paver to control the contact area between he paver and the asphalt truck tires Quarter Points Points on the screed midway between the center and the ends Ripples Short frequent changes in the elevation of a mat surface Screed The assembly behind the tractor The screed strikes off smooths and compacts the paving material into a semi finished mat Screed Extensions Attachments for increasing screed width Screed Heaters Burners Devices which preheat the screed plate to a temperature approximately that of the material to be laid Screed Plate The bottom plate of the screed Slope The incline of a paving surface perpendicular to the direction of travel expressed by stating the rise or fall of a percentage of horizontal distance i e 2 slope 2 of elevation change in 100 of lateral run Slope Control A means for controlling the transverse elevation of the fresh laid mat in relation to the grade P 32 and P 32 Operator s Manual P N 1001547 01 124 n Y Y O lt Slope Sensor An electrical device which detects positive and negative change in lateral elevation using the grade controlled side of the machine as a reference 2 O V Y O lt Survey Function used to show the current elevation when in CAL mode Also used in Laser Tracker op
72. d motion Figure 19 Control of this force is a basic and necessary function of any paving operation Head of Material Force M Figure 19 Head of Material Force M The volume and consistency of the head of material determines how much paving material flows under the screed and influences mat thickness and surface texture How a Screed Works P 32 and P 32 Operator s Manual P N 1001547 01 9 The most common factor affecting force M the head of material is incorrectly adjusting the Automatic Feeder Controls These systems whether of the hanging paddle type or the sonic sensor type should be adjusted to operate the auger conveyor assemblies 95 to 100 of the time On off operation of the auger system causes fluctuation in the head of material The highest quality mat generally results when a constant head of material is maintained across the entire width of the screed and the material almost covers the auger shaft If the volume of paving material is too high there is resistance to the travel of the screed This causes the screed to rise and can result in ripples auger shadows and long waves It also results in increased auger wear Figure 20 Indicates Centerline of Auger y ay eje y a a Y UN Q a A o eb a Z Y ee p an V Correct 4 Qe Head of im Mate e r POL Screed Rises Al Due To P Increased Head of Resistance Material gt A
73. de area the more a reference can move up or down without a correction being initiated When the Slope Deadband changes it adds or takes away from the fine correction region 1 above or below On Grade of the Slope Sensor it does not add this distance to the overall working range e Slope Deadband value range 0 025 to 0 75 e Factory preset 0 075 Select the amount of Slope Deadband carefully Too small of a Slope Deadband causes the tow point cylinder to constantly hunt up and down while the sensor tries to find On Grade Too large of a Slope Deadband does not allow the sensor to send grade corrections to the values causing unwanted variations in mat thickness 1 Elev Gains 2 Slope Gain 0 075 3 Valve Offsets 4 Elev Deadband O 0 WN Ul A o s et 2 g O x 0 ay et Cc D N Q an Y Y et 5 min 0 025 6 Averaging max 0 75 7 Machine Type g default 0 075 Figure 60 Slope Deadband Machine Type Displays the type of machine configuration not selectable 1 Elev Gains 2 Slope Gain 3 Valve Offsets 4 Elev Deadband 5 Slope Deadband 6 Averaging Figure 61 Machine Type Paver Performance Menu P 32 and P 32 Operator s Manual P N 1001547 01 35 Display Display allows you to choose the amount of information available to the operator on the Control Screen This section describes the three selections available Set Point Sensor and B
74. dramatic and rapid change in air temperature A temperature bail is attached to the Tracker to compensate for these variations If you are on a job where there are high winds and or large temperature fluctuations lower the tracker closer to the reference Figure 80 ST 3 Sonic Tracker II Figure 80 Temperature Conditions and Tracker Placement Sonic Tracker Placement P 32 and P 32 Operator s Manual P N 1001547 01 46 Y o O om Q A lt Y Q a Y gt Y Y Y et 5 Placement When Using a Mechanical Ski If using a mechanical ski with an elevated string or wire make sure the string wire reference is a minimum of 4 inches above the ski Figure 81 When paving with a mechanical ski through super elevations the ski tends to pull away from the paver and may even tip to one side Elevating the string at least 4 inches ensures that the ski stays out of the working window Also remember to place the Tracker in the center of the ski to maximize the averaging length If using a 30 foot ski place the sensor 15 feet from the end of the ski For every 1 foot positioning error from the center of the ski you lose 2 feet of effectivity of the ski For example if the sensor is moved foreword or backward 2 2 feet 12 feet from the end you are using a 25 foot ski dn S SYS Pue Jae DIUOS String or Wire Min of 4 Above Ski String or Wire Min of 4 Above Ski O i ag ST 3 Sonic
75. e 112 SAS Setup when Screed Extension is Unsatisfactory When paving with the screed extensions out there may be a large head of material which could be picked up by the Sonic Tracker If this happens determine how far forward the tracker must be placed on the beam to not pickup the mix and drill a new mounting hold for the tracker hanger Figure 113 on page 64 The SAS coil cable easily reaches the tracker Optional Smoothtrac SAS Placement and Setup P 32 and P 32 Operator s Manual P N 1001547 01 63 dn S SVS Pue Jae DIUOS Figure 113 Repositioning the Sonic Tracker Placement of SAS on Paver The center connection point of the SAS is the balance point The position of the balance point to the tow arm is very critical By moving the balance point the performance of the system is greatly affected The balance point of the beam should be located 1 3 to 2 3 the distance from the pivot point of the screed to the tow point cylinder Placing the balance point closer to the 2 3 point near the tow point cylinder causes the system to have a slower reaction time This would be good for smoothness or for mainline paving Placing the balance point near the back 1 3 closer to screed causes the system to have a faster reaction time This would be good for a combination of smoothness and joint matching Optional Smoothtrac SAS Placement and Setup P 32 and P 32 Operator s Manual P N 1001547 01 64 To determine where to positi
76. e Sonic Tracker is ticking but does not adjust to grade Note The ticks may not be audible with ST 3 This is normal ST 3 transducers are not as loud as the transducer in the Sonic Tracker II 3 The Tracker s grade lights flash high and low and do not stay On Grade 4 The Sonic Tracker is not matching joint or curb 5 The Sonic Tracker picks up the ground but does not pick up a stringline Tracker Symptom 1 The Sonic Tracker does not power on Probable Cause Defective cable or tracker 1 Check coil cord is plugged in correctly and securely 2 Inspect Coil cord for any physical damage 3 Turn Control Box on and watch the tracker lights to make sure they go through the power up sequence All the lights on the tracker should flash at once followed by a flash of an arrow pointing to the left The T symbol should also be displayed in the upper right hand corner of the tracker faceplate when a Temperature Bail is attached If the tracker does not go through this sequence then the tracker is not getting power or is defective 4 One at atime swap tracker and then coil cord from opposite side to determine the problem Tracker Symptom 2 The Sonic Tracker is ticking but does not adjust to grade Probable Cause Tracker is too close to reference minimum working distance is 14 inches 1 Tracker is too close to reference point Position tracker 14 to 24 inches from grade reference 2 Connect track
77. ee 26 Automatic Mode estirada de hea TRE a 27 Manual Mode iia meea ad dees a we At ee idad 27 109 UP DOWN BUTOI lt a ia toe wr VA day aod raet aaa be WM ew oh ac ad A 21 USD Ositos diia uo ta ae da ba ce ee ee E Go dio a 21 CONHECLORS atienda eal he ate ae db 28 Jaw MOUND ace sot ietia te oa rerperr Ae we OE a e aG 28 Control creeo ia tae et we aE eR ee ew Oe Oe he as 29 Performance MeCN ies ue sei pera Era ae PA ee eee EA 29 Selecting Performance Menu Items cc 30 Performance Menu Item Descriptions onnaa es 31 Elevation Gains Raise and Lower 0 cee eee eee eens 31 A A Bawah aE A Hee ae ae 32 Valve Offsets Raise and Lower 000 ees 33 PVG AGIA O aio aie a ia o ace ard Poh eB ae Gor ee ek ee a ae dic 33 Elevation Deadband ccc eens 34 SODE DeadHand Yara aaa Bea ob haa aa ees 35 Machine LYDE haora aaa aa 35 DIS eee cic A bi E OEA Es 36 DISCO ateo daba bado eri 36 PP NA 36 BOEVSIGGS dismi al datada do eid 36 Display SIOPE drid wha dew do cba back ww a had Gack dh dow 37 UNNS 000002 sh eae Weta nr e cme che eGo seth GB Bh de Bt eshte a Me Gee tb 38 SV SECM UNG atu d ache hub eto Gone ANO 38 Updating Firmware ii arabe ae ek Bae a a a AA 39 Sonic Tracker 3 P 32 System only 00 eee ee eee 40 Table of Contents P 32 and P 32 Operator s Manual P N 1001547 01 vil Sultace Mode rascas a dd cha ee heh eee ee eee 40 SINGING MOE caricia da 40 Slope RESOIUTIO scada AAA PR
78. ensor Both sides Display slope Xx Set Point with Display Slope Sensor with Display Slope O 0 WN Ul A o s eF 9 UY O x A MD Q et Cc a D N Q an Y Y et 5 0 15 0 15 Both Sides with Display Slope Both Sides with Display Slope Using ST 3 in Surface Mode SAS Figure 63 Display Slope Performance Menu P 32 and P 32 Operator s Manual P N 1001547 01 37 Units Units sets the display to read in feet inches or centimeters e Display Value Range Centimeters Inches or Feet e Factory Default Inches 8 Display Centimeters 10 System Info Inches 11 Sonic Tracker 3 12 Slope Res 13 Slope Cal Block O 0 WN Ul A o s et 2 g O x 0 ay et Cc D N Q an va Y et 5 Figure 64 Units System Info System Info displays the Topcon logo copyright date and current firmware version The System Info menu item is also the interface that allows you to update Control Box firmware 1 From the Performance Menu press the Enter button PIN to select System I nfo Figure 65 and view the copyright date and firmware version 8 Display a AF Topcon 9 Units Copyright 2014 11 Sonic Tracker 3 ae 12 Slope Res 13 Slope Cal Block Figure 65 System I nfo Performance Menu P 32 and P 32 Operator s Manual P N 1001547 01 38 Updating Firmware 1 Unscrew the USB cap 2 Insert a USB key into the Control Box s USB port Fig
79. er Supply 10 30 VDC Internal Battery C size dry cells 4 pcs Battery pack BT 68Q sold separately Continuous Operating Approx 80 hours using alkaline manganese dry cells Time Approx 40 hours using battery pack BT 68Q Immunity Applicable regulation EN55022 Class A Physical Display LEDs On Grade Zone 0 08 0 24 0 47 1 18 inches 2 6 12 30 mm LED Grade Indicators Red up arrow Green Red down arrow LED Grade Patterns 5 grade 2 lost beam 1 low battery 1 level alert C CI Dimensions 158mm x 166mm x 357mm 6 2in x 6 5in x 14 0in with mechanical clamp Weight without cells 2 0kg 4 4lbs built in magnet mount grade rod clamp attachment Buttons 3 ea 1 power 1 3 ea 1 power 1 mode 1 3 ea 1 power 1 mode 1 beeper Dual tone loud and soft LS B110 Laser Receiver Optional P 32 and P 32 Operator s Manual P N 1001547 01 116 Table 7 LS B110 Laser Receiver Specifications Operating Temperature 20 C to 50 C 4 F to 122 F Storage Temperature 30 C to 60 C 22 F to 140 F U 5 O af A O 7 O UY Humidity 5 40 C 48H Half Sine 11ms 50G All Axis 9130 Laser Receiver Optional Table 8 9130 Laser Receiver Specifications Emissions Applicable regulation EN50081 1 1992 30 230MHz 40 0dB mV m Max at 10m 230 1000MHz 47 0dB mV m Max at 10m Immunity Applicable regulation EN50082 1 1992 ESD 8KV RF 27 500MHz 3 V m Fast transient 0 5KV capacit
80. er to other side of paver to determine if problem stays with tracker 3 If problem stays with tracker clean or replace transducer or foam filter Refer to the Transducer and filter cleaning and replacement information in the Maintenance section of this manual 4 If problem does not move with tracker inspect coil cord for damage and swap with cord from other side Sonic Tracker Symptoms P 32 and P 32 Operator s Manual P N 1001547 01 104 Tracker Symptom 3 The Tracker s grade lights flash high and low and do not stay On Grade Probable Cause If problem is only in Automatic Mode then Hydraulic Performance Settings are incorrect o 2 D UN D o y je 1 Verify paving machines hydraulic flow adjustments time for hydraulic cylinder to travel full stroke are set to manufacturers recommendations Typically 12 to 15 seconds 2 Check Valve Offsets are set correctly Refer to setting valve offsets 3 Make sure Gain Setting is not too high Factory setting is 25 If problem exists in manual mode then Tracker is setup incorrectly or Performance Settings are incorrect Verify that temperature bails are clean and securely attached Verify temperature bail symbol T is displayed on face of Tracker If not clean or replace transducer Check that Trackers are between 14 and 24 inches from reference If there are gusty winds lower Tracker closer to reference Approximately 14 to 16 inches Move Tracker
81. erations in conjunction with he Enter Button to move the Tracker receiver up and down T Thickness Control Screws The adjusting crank located at the rear of each side arm used to control the angle of attack of the screed Tow Points Pull Points The points where the side arms of the screed are attached to the Tractor unit Transverse Beam A steel bar connected to the side arms of a screed for mounting the Slope Sensor Temperature Bail A wire frame added to the Tracker that acts as a fixed target to compensate for rapid air temperature changes V Vibrators A rotating shaft and eccentric weight assembly mounted on the screed that produces vibration W Wave Long repeating changes in the elevation of the mat surface Working Window Adjustable region of measurement used by the Sonic Tracker to determine if elevation correction is required Glossary P 32 and P 32 Operator s Manual P N 1001547 01 125 rc nn mm p u on on oa ua aa ee r gt a lt on een ro rs En n nr nr a ra ra pan rm r ro r F pa pa ra PP ma mm nn mm zs Ss Ss eS SS OS A A g z z w g E O O Anangga gaga a ua g w T ES CC a A A n r E z Z u a v ee a ee z r fam _ pg ma pma a ma E O um e e n n EEEE ee A ee N DO w n A eS Ue eS US Ue eS 3 RF wT FTHReFteFeoFRteFRtewBewFewrFepFfFpFepF Feq eoqoq onfqgeqgee e nb nmfmFi fRI iwhrrebprmh_ Tfmi
82. f elevation has been selected one at a time swap the ST 3 or Sonic Tracker II and cables from the Opposite side to locate the error 4 Refer to Tracker Symptom 1 5 If slope has been selected check that slope has not been selected on the other Control Box Only one box at a time can have slope turned on 6 Swap slope cable from opposite side 7 Disconnect cable at Slope Sensor and connect to other side of sensor to check Slope Sensor pins Control Box Symptom 3 Cannot adjust to On Grade when elevation control is selected Probable Cause Tracker is too close to control reference 1 Check that the ST 3 or Sonic Tracker II is at least 14 inches away from the control reference 2 Check for unwanted objects within the sonic footprint Control Box Symptoms P 32 and P 32 Operator s Manual P N 1001547 01 99 3 Make sure tracker is not positioned in front of a gusty heat source such as the engine fan exhaust 4 Stop the paver make sure the screed is on the ground and turn the vibrators off Check the sensor readings on the Control Box Set the display to Sensor or Both Sides See Display on page 49 5 If using a Sonic Tracker Il check for contamination on the Sonic Tracker II transducer or foam filter Refer to Transducer and Filter Cleaning and replacement information in the Maintenance and Parts section of this manual 6 Swap the Tracker with the unit on the opposite side 7 Averaging may be set too low if t
83. f feedback from the screed Sonic Tracker Placement P 32 and P 32 Operator s Manual P N 1001547 01 48 dn S SVS Pue Jay3e1 DIUOS Grade Reference Desired Grade Incorrect Placement Figure 86 Incorrect Placement of Tracker at Tow Point If any of the forces acting on the screed change then the screed rises or falls without the tracker sensing the movement For example if the amount of material in front of the screed was decreased the head of material force M also decreases and the screed would begin to fall Figure 87 However the Tracker would keep the tow point cylinder on grade but not the screed since there Is no feedback Y o om Q A lt Y Q a Y gt Y Y Y et 5 Incorrect Placement Figure 87 Tracker at Tow Point Causes Erroneous Corrections The best place for the tracker is in the 1 3 to 2 3 zone but where do we position the tracker within that area That depends on what end result of paving you are trying to achieve As the tracker is moved further back towards the screed it becomes more reactive At the 1 3 point a 1 4 inch correction at the tracker causes a 3 4 inch correction at the tow point Figure 88 Another way to look at it is the Net Tow Arm Length A paver with a 9 foot tow arm and no Laser Receiver takes 27 feet 9 feet x 3 tow arm lengths to see 96 of the elevation change If a tracker is placed at the 1 3 point or 3 feet in front of the screed
84. gle of attack dependent on the combination of forces acting upon the screed Existing Surface Figure 11 Tow Point Path and Planning Angle e Ifthe screed angle of attack is increased the screed rises increasing the mat thickness Figure 12 e Ifthe angle of attack is decreased the screed settles providing a thinner mat surface Figure 12 Paving Principles and Control Methods P 32 and P 32 Operator s Manual P N 1001547 01 6 Figure 12 Screed Determines Mat Thickness Because the screed floats it does not immediately react to a change in the tow point It needs a certain amount of time or distance to make a correction in the mat thickness Figure 13 e fthe tow point is changed by a unit of one the paver must move one tow arm length before the screed corrects 63 of the elevation e After 2 tow arm lengths 83 of the correction is made and 3 tow arm lengths would account for 95 e t takes 6 tow arm lengths to achieve 100 of the elevation change Considering that 95 of the change takes place after 3 tow arm lengths this can be used in practical applications to qualify for full correction Elevation Change to Tow Point Path y weoccced Tow Point Path y 0 2 Tow Arm 1 Tow Arm A Lengths Travel Length Travel 6 Tow Arm o Tow Arm 4Tow Arm 3 Tow Arm Lengths Travel Lengths Travel Lengths Travel Lengths Travel Figure 13 Tow Arm Travel The same Is true when making elevation changes
85. he Tracker over the string When tracking a curb lower the Tracker to keep it over the lip of the curb preventing the Tracker from seeing the top or face of the curb e When setting up the Tracker over a grade reference consider the size of the Sonic Cone or the footprint For example at about two feet from the Tracker the footprint or cone will be about six inches e The Tracker compensates for temperature changes only within the bail range Placing the Tracker too far from the reference may cause Inaccurate temperature compensation e Temperature and atmospheric conditions affect the speed of sound In paving applications the air temperature can change rapidly and dramatically A temperature bail attached to the tracker compensates for these variations If the jobsite has high winds and or large temperature fluctuations lower the Tracker closer to the reference The following sections detail the positioning tracker in relation to the grade reference as well as on the machine Sonic Tracker II Specifics P 32 and P 32 Operator s Manual P N 1001547 01 58 Y o om Q A lt Y Q a Y gt Y Y Y et 5 Sonic Tracker II Positioning in Relation to Reference Raise or lower the tracker bracket to position the tracker at the proper height above the grade reference Figure 102 The tracker has a total working range of 14 to 55 inches For paving applications the recommended working height wo
86. houlder grade or material spillage from hopper If using Stringline verify line is not bouncing Check to see if Averaging in Performance Menu is set too low Factory setting is 50 10 Check Deadband in Performance Menu is not less than 3mm ees Se A IS Control Box Symptom 10 The valve is driving the hydraulic cylinder too far overshooting grade Probable Cause Valve Offset in Control Box are set too high Control Box Symptoms P 32 and P 32 Operator s Manual P N 1001547 01 102 o 2 D UN Dy o o y je 1 AS Your valve settings may be incorrect Check the Config or Ext external number displayed on the Startup screen Startup Screen Startup Screen Ar TOPCON A TOPCON Config Number External GC 35 conf Number config 21 Figure 179 Config Ext Number Located on Startup Screen Each number represents a specific valve type The most common numbers are 21 sink L5 prop source and 9 source Contact your Topcon support representative and provide the Config Ext number to determine if your Control Box is configured with the correct valve setting Lower the Valve Offset value until the sensor no longer overshoots grade Setting Valve Offsets section in this manual For Servo and solenoid valves lower the value by 2 to 5 numbers then check the hydraulic performance For Proportional valves lower the value by 10 to 15 numbers then check hydraulic performances Control Bo
87. ignal is indicated Figure 28 Figure 28 Laser Control Below Grade Setup For the first pass use slope control on one side of the screed and a Laser Receiver on the other side Figure 29 on page 17 Make sure that the slope percentage of the laser and Slope Sensor are equal or the joints will not match For all subsequent passes replace slope control with elevation control by using a Sonic Tracker Continue to use a Laser Receiver on the other side of the screed Control Methods P 32 and P 32 Operator s Manual P N 1001547 01 16 y ay eje 0 e D UN Q a A o zz lt Y a o a UN Using a Slope Sensor allows you to evenly match the joints between passes over large areas Figure 29 Laser Control Setup Slope Control Your Topcon P 32 or P 32 System uses a Slope Sensor mounted to the transducer beam on the paver to measure and control the slope of the mat being laid Figure 30 The sensor contains an electronic level vial that acts as a precision carpenter s level Slope control with this electric level vial is very accurate and repeatable Figure 30 Position of Slope Control on Paving System If the required slope changes the screed operator dials the new slope into the Control Box Figure 31 The tow point cylinder on the slope side raises or lowers until the Slope Sensor measures the new slope Cranking affects the relation between the Slope
88. igure 57 Valve Offsets The offset value on one side of the paver may differ from the offset value on the other side of the paver You must verify the offset values before swapping boxes Use the Left and Right labels provided Never attempt to use Valve Offsets to compensate for a slower raise or lower speed of your hydraulic valves as it causes undershooting or overshooting in Slope Mode and can adversely affect the quality of the mat Averaging Averaging changes the amount of damping or filtering applied to Sonic Tracker and Laser Receiver measurements You can think of it as a calculation of the running average of the elevation measurement over a period of time Performance Menu P 32 and P 32 Operator s Manual P N 1001547 01 33 A lower value averages fewer elevation measurements allowing the system to react more quickly to smaller grade changes This makes the system more susceptible to fluctuations in temperature or small obstructions A larger value averages more elevation measurements preventing the system from reacting to undesirable items close to the reference This also makes the system less susceptible to fluctuations in temperature or small obstructions e Averaging value range 1 to 100 e Factory preset 50 1 Elev Gains 2 Slope Gain 50 3 Valve Offsets 4 Elev Deadband 5 Slope Deadband min 1 max 100 7 Machine Type g default 50 O 0 WN Ul A o eb o UU
89. ively coupled Physical G96 5mm x 166mm x 254mm 3 8in x 6 5in x 10 0in with connector attached Environmental Operating Temperature 0 C to 60 C 30 F to 140 F Valve Outputs PWM Sink Source Solenoid Sink Source Servo 9130 Laser Receiver Optional P 32 and P 32 Operator s Manual P N 1001547 01 117 Regulatory The following sections provide information on this product s compliance with government regulations for use Federal Communications Commission FCC The product described in this manual is in compliance with the Federal Communications Commission directives from the United States of America e FCC Part 15 Subpart B C ISPRII Class A 2009 Industry Canada Compliance IC This class A digital apparatus complies with Canadian IC CES 003 CISPRII Class A 2009 Cet appareil num rique de la classe A est conforme la norme ICES 003 CISPRII du Canada Community of Europe CE The product described in this manual is in compliance with the EMC directives from the European Community e EN 300 440 2 V1 4 1 The following CE mark is affixed to the device 4 Australian Communications and Media Authority Compliance ACMA The product described in this manual is in compliance with the EMC directives from the Australian Communications and Media Authority e C Tick N 13813 The following C Tick mark is affixed to the device Y N 13813 WEEE Directive Following information is for EU member
90. l ski If the setup procedures are followed correctly paving with the SAS can and should start in Automatic The SAS system is designed to discontinue operating when one of the Trackers fails When a failure occurs the color of the SAS icon on the Control Box s Control screen changes from green or yellow to red Figure 119 on page 68 The number 1 2 3 and 4 represents each connected Tracker If a Tracker is disconnected the corresponding icon disappears from the screen Tracker Functioning but Not Detecting Surface Tracker Connected E Faulty Tracker Detecting Surface i in Figure 119 SAS Icons Sonic Tracker Setup P 32 and P 32 Operator s Manual P N 1001547 01 68 To reset the Slope Sensor once a new tracker has been installed or if the tracker has been removed and only three trackers are used turn the power off then on The Slope Sensor reconfigures to the number of trackers Changing the number of trackers may change the average distance Press Survey to lock SAS On Grade Once one of the Trackers has been eliminated from the averaging the balance point of the beam changes If the faulty Tracker is not replaced the beam must be repositioned to adjust for the new balance point It is strongly recommended if the first or last Tracker fails to replace it with one of the Trackers from the middle of the beam This insures that the balance point is not outside of the 1 3 to 2 3 rule Control Box Setup for Elevation
91. lace the cut fill decal on the lath with 0 at the marked point Figure 160 a I 1 Eng LOS Y X BTS ae mgs Lath Set 0 on Decal at 2 0 Mark from Bottom of Lath Bottom I I I I I I I I I I I I I I I I I I I i Lath Figure 160 Measure Height Above Grade and Place Cut Fill Decal x The ST 3 is capable of indicating the center of the sensor to the stringline Accurate placement of the a stringline helps to operate the screed shifting in out by using the ST 3 feature 3 Set the cut fill lath on the hub and read the cut or fill from the grade stake next to the hub Adjust the clip up or down until the stringline crosses the cut fill lath at that point Figure 161 grade A cut of 25 feet igh u 5 gl Es pee Figure 161 Adjust Clip and Stringline to Desired Cut Fill The stringline is now set to 2 feet above finished grade Setting Elevated Stringline P 32 and P 32 Operator s Manual P N 1001547 01 88 U et 2 5 ga 5 0 VY M et U 4 Repeat step 3 on page 88 at each station before starting to cut Figure 162 PERENNE 2 0 Offset Figure 162 Stringline Set at Desired Elevation Attaching Stringline to the Grade Stake Some jobs may require the stringline to be secured directly to the grade stake rather than attached to the clip 1 Mark the lath with the desired hike up above grade Figure 163 AA A
92. lc LScreed Settles AI Due To ecrease Head of tO Material A 1 Resistance Too Low Figure 20 Head of Material Affects Mat Reaction of Material Under Screed R Ideally every truck load of material delivered to the paver would be exactly like every other load with no variation However as a practical matter changes in mix characteristics such as mix temperature density gradation A C Content segregation etc affects the internal stresses developed within the mix which in turn affects the resistance of the mix to flow under the screed also known as the reaction of material under screed How a Screed Works P 32 and P 32 Operator s Manual P N 1001547 01 10 R The key element to bear in mind is that the screed passing over the paving material compacts the material to a certain degree Variables in the resistance of the material to compactive forces causes changes in the screed s angle of attack which in turn affects mat thickness and therefore mat smoothness Figure 21 Reaction of Material Under Screed R Figure 21 Reaction of Material Under Screed Gradation Mix Characteristics Y ay eje y 2 e D UN Q a a o Z Y ot a o am N This aspect of the paving material varies according to the intended use of the material as abase course binder course or the final wearing surface Normally maximum aggregate size ratio of aggregates fines content and most importa
93. levations on either side of the street Even though the curb was poured out of tolerance it may have passed inspection and the asphalt needs to match the curb and gutter If the curbs are at different elevations it is impossible to pave a typical design slope on both sides of the street Paving City Streets with Cross Slope P 32 and P 32 Operator s Manual P N 1001547 01 76 A cross section design of a 36 feet wide street with a 2 0 slope produces a 36 feet rise at centerline Figure 136 0 36 ft Rise suone gt 1 ddy Sued Figure 136 Paving with Cross Slope If the curbs are at different elevations a 36 feet rise at centerline produces incorrect slopes Figure 137 0 36 ft Rise A AA 36 0 ft Figure 137 Curbs with Different Elevations When using your Topcon P 32 or P 32 System to pave a true 2 0 slope the crown of the street will not be at the centerline Figure 138 New Centerline at 2 0 Grade Cut Figure 138 Curb with Same Slope Paving City Streets with Cross Slope P 32 and P 32 Operator s Manual P N 1001547 01 77 To pave from uneven curbs using slope control choose the side of the road with the highest curb and position y the tracker over the curb Set the other side for the desired cross slope and begin paving Figure 139 2 Subgrade ojo gt 5 Y al a i O Centerline of Road UY Slope Percentage e z a Eleva
94. line Mode the grade indicators display left right and centered arrows The Stringline Mode icon displays on the Control Screen Figure 68 If you select Use at power up the Control Box powers up in your chosen setting Surface or Stringline If not after shutting down the Control Box powers up in Surface Mode e Display Value Range Surface Stringline e Factory Default Surface O 0 WN Ul A o s et 2 g O x 0 ay et Cc D N Q an Y Y et 5 8 Display 9 Units 10 System Info 12 Slope Res 13 Slope Cal Block Stringline Use at power up L Surface J Stringline ST 3 Stringline Mode Icon Figure 68 Sonic Tracker 3 Surface and Stringline Mode Performance Menu P 32 and P 32 Operator s Manual P N 1001547 01 40 Slope Resolution Slope Resolution adjusts the slope percentage increment amount the percentage of slope displayed on the Control Box e Slope Resolution Value Range 0 1 0 05 e Factory Default 0 1 8 Display 9 Units 10 System Info 0 05 11 Sonic Tracker 3 dnias pue s 1n e 4 xog OIJUO GS D 13 Slope Cal Block Figure 69 Slope Resolution Slope Calibration Block Slope Calibration Block allows you to block the operator s ability to calibrate the slope value from the Control Screen Pressing the Menu Set button and turning the Grade Adjustment Knob will not change the slope value on the Control Screen This feature preve
95. lly the direction of travel is not critical while in Surface Mode unless you are paving around a CE tight curb ed Lower On Grade Raise Figure 96 ST 3 Surface Mode LEDs ST 3 Specifics P 32 and P 32 Operator s Manual P N 1001547 01 54 dn S SVS Pue Jae DIUOS ST 3 Specifics Base of Housing Temperature Pat eal 14 Minimum Distance Adjustable Adjustable Working Deadband C _ aes ee o Window alloration at 24 E Ongrade Fa Flashing f Arrow Detection Zone Centered Under Temperature Bail Solid 36 Arrow Maximum Distance Simplified representation of detection zone Actual range may vary slightly Figure 97 ST 3 Surface Mode P 32 and P 32 Operator s Manual P N 1001547 01 55 dn S SVS Pue Jae DIUOS Stringline Mode Stringline Mode Is used to detect an elevated stringline While in Stringline Mode ST 3 indicates the location of the stringline by using left right arrows and centered above stringline LEDs The ST 3 LEDs help guide the operator to manually shift the screed in out Right Above Stringline Left Figure 98 ST 3 Stringline Mode LEDs In Stringline Mode make sure the ST 3 is oriented in line with the direction of travel Figure 99 Direction of Travel Direction of Travel SS eC Figure 99 ST 3 Stringline Mode Direction of Travel O The ST 3 cannot detect a surface stringline You must use a
96. lly extended The difference is the wider the extension of the screed the greater the surface area of paving material to support An extended screed has fewer psi which means less compaction causing the screed to raise Figure 23 Width of Screed Affects Weight of Screed Quality of Paving Base y ay eje y a a Y UN Q a A o eb a 2 Z Y ama Dy a V There are factors other than the four main forces that can have an effect on the quality of the mat An important one is the quality of the base to be paved It makes more sense to build smoothness from the base up than to try to smooth a road in the last lift of paving However on overlay paving jobs we have to work with what we have Remember that a mat which appears smooth immediately behind the paver may actually contain areas of considerably varying thickness of material as a result of undulations in the base being paved Due to the principle of Differential Compaction high spots do not compact as much as the low therefore allowing some of the irregularities to be rolled back onto the mat Figure 24 To minimize this problem lay a leveling course in the low spots or pave multiple lifts to average out the irregularities S Before Rolling Mat Before Rolling Y fa After Rolling Figure 24 Differential Compaction Rolling Techniques A well laid mat can end up with a poor ride quality if proper rolling methods are not followed Cons
97. n on page 24 for more details Elevation Set Point Value Elevation Icon Units ft in cm ST 3 Surface Stringline Mode Icon gt Primary Control Box Display Area Display Slope Box Actual Elevation Sensor Reading Positive Negative Slope Indicator Icon a O 0 WN Ul A o s et 2 g O x lt 0 ay et Cc D N Q an Y Y et 5 Slope Set Point Value Actual Slope Sensor Reading Slope Icon gl Auto Icon Secondary Control Box Display Area On Grade Icon Cross Communication Menu Set Button Function Display Area Figure 52 Control Screen Example Performance Menu The items listed in the Performance Menu allow you to modify your Topcon P 32 or P 32 System settings for operator or performance enhancement The Control Box automatically stores all operating information For some machine configurations some menu selections are inaccessible Table 2 lists the Performance Menu items and their settings Table 2 Performance Menu Settings C E CA Control Screen P 32 and P 32 Operator s Manual P N 1001547 01 29 Table 2 Performance Menu Settings Continued Display Set point Sensor Both sides Sensor Show slope unchecked Show slope checked or unchecked System Info Displays the Topcon logo copyright date and current firmware version Interface to Update Control Box Firmware Sonic Tracker 3 Surface Stringline Surface Use
98. n elevated stringline ST 3 Specifics P 32 and P 32 Operator s Manual P N 1001547 01 56 dn S SYS Pue Jae DIUOS Direction of Travel Base of Housing Temperature Bail Y o om Q A lt Y Q a Y gt Y Y Y et 5 14 Minimum Distance 3 Factory 3 Calibration at 24 36 Maximum Distance Centered 7 Flashing ES Arrow Non optimal Non optimal Solid Performance Zone Detection Zone Performance Zone Arrow Slow Flashing Arrow Figure 100 ST 3 Stringline Mode ST 3 Specifics P 32 and P 32 Operator s Manual P N 1001547 01 57 ST 3 Orientation For optimal performance make sure the ST 3 is parallel to the surface stringline within 5 in any direction Figure 101 ST 3 Orientation Sonic Tracker II Specifics Whether setting up a standard Sonic Tracker II system or a Smoothtrac SAS using the Sonic Tracker consider the following for each Tracker 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 t
99. n page 45 Connect the coil cord to the Tracker ST 3 or Sonic Tracker Il 2 Bolt the Tracker to the bracket and visually check to get the Sonic Tracker plumb Make one wrap of the coil cord around the L Bar Sonic Tracker II only This acts as a strain relief for the connector on the Tracker 4 Always snap the temperature bail into place 5 Place the Sonic Tracker over the reference raise or lower the Tracker bracket to position it at a proper height above the grade reference 6 Press the Survey button on the Control Box to lock trackers On Grade 7 Press and hold the Set button while dialing in mat depth 8 Put the Control Box in Auto and begin paving SAS Setup Once the SAS has been installed the Slope Sensor automatically configures for SAS when powered on The box checks to see how many trackers are connected and average over that amount Getting the Control Box ready to pave is the same as with one tracker O O et En 00 A O Y a lt ep O Y Q lt O 1 Connect each tracker as described in Sonic Tracker Setup on page 68 but using the SAS coil cord 2 Place the SAS trackers over the reference raise or lower the trackers bracket to position it at a proper height above the grade reference 3 Press and hold the Set button while dialing in mat depth 4 Put the Control Box in Auto and begin paving It is not necessary to start paving in manual as is traditionally done when using a mechanica
100. n under pressure the flow of which causes work to be accomplished Hydrostatic Transmission Power transmitted by a positive displacement pump through a liquid under pressure to a positive displacement motor Inclinometer See Slope Sensor P 32 and P 32 Operator s Manual P N 1001547 01 122 Glossary Joint Matcher See Automatic Level Control LCD Liquid crystal display LCD is used in the display window on the Control Box to show numbers and symbols for Paver control functions LED Light Emitting Diode These are the red lights seen on the faces of the Control Box ST 3 Sonic Tracker II and Laser Tracker Line of Shear The lateral line of contact in the paving material at the leading edge of the screed pre strike off where material divides to pass beneath the screed plate or moves upward along the face of the screed into the augured material for later placement Mat The material being placed by a paver finisher Null A condition which exists when components are at rest Null Screed A screed resting flat on the mat and having no angle of attack On Grade When a surface Is at the desired elevation or slope it is referred to as being On Grade Overlay Paving over an existing mat Paddle Box The sensing device used with automatic feed control to measure and control the head of material P 32 and P 32 Operator s Manual P N 1001547 01 123 n Y Y O lt Glossary Per
101. nce is not a constant width and requires the extension to be moved in and out Mounting to the extension makes it easier to keep the tracker over the reference Figure 90 Position of L Bar with Tracker on Bracket Sonic Tracker Placement P 32 and P 32 Operator s Manual P N 1001547 01 50 Curb and Gutter Tracking When tracking a curb and gutter keep the tracker 14 to 24 inches above the lip of gutter Figure 91 If the tracker is placed too high the sonic cone may pick up an unwanted surface such as the face of the curb Figure 91 Tracking a Curb and Gutter If you are paving around a tight curb using an ST 3 make sure to orient the ST 3 in line with the NES direction of travel Figure 92 oO Direction of Travel a Curb and Gutter Figure 92 ST 3 Direction of Travel Tracking Curb and Gutter Sonic Tracker Placement P 32 and P 32 Operator s Manual P N 1001547 01 51 dn S SVS Pue Jae DIUOS Joint Matching and Tracking Sub grade For joint matching and tracking sub grade or most surfaces keep the tracker between 14 to 24 inches Figure 93 A good rule of thumb is to set the tracker about 18 inches from the reference dn S SVS Pue Jae DIUOS Figure 93 J oint matching amp Tracking Sub Grade Sonic Tracker Placement P 32 and P 32 Operator s Manual P N 1001547 01 52 ST 3 Specifics The ST 3 has two detection modes to ensure the best accuracy possi
102. ntly asphaltic binder content is specified by the contracting agency Adherence to mix design specifications is usually the responsibility of the material supplier Segregation is a material deficiency caused by a separation of the larger aggregate sizes from the bulk of the paving material This condition is encountered especially in mixes with relatively large maximum size aggregate example 1 and larger the so called large particle mixes When paving material is deposited in piles as in an asphalt plant silo a haul truck a paver hopper on the ground in front of the paver in a windrow or on the ground in the auger chamber segregation can and does frequently occur before being laid down as a mat Therefore these areas of segregation must be addressed prior to any paving The screed cannot rectify segregation during the paving process The areas listed above where segregation can occur are all areas that the material may encounter Segregation can also be the result of improper hopper dumping During normal operation the vibration of the pavers hopper causes segregation Therefore dumping the hopper after each truck should be avoided because material that has rolled to the outside of the hopper the large aggregate fills the conveyors and auger chamber and result in a segregated area behind the paver with a noticeable difference in surface texture If it doesn t look right it isn t right Surface and texture irregul
103. nts you from accidentally calibrating the slope sensor that you turn Slope Cal Block back On before continuing to work to avoid accidentally calibrating the Topcon recommends that after turning Slope Calibration Block Off and calibrating the slope sensor slope sensor from the Control Screen e Slope Calibration Block Range Off On e Factory Default On 8 Display 9 Units Off 10 System Info 11 Sonic Tracker 3 12 Slope Res Figure 70 Slope Calibration Block Performance Menu P 32 and P 32 Operator s Manual P N 1001547 01 41 Sonic Tracker and SAS Setup You can use either the Topcon s ST 3 P 32 System or the Sonic Tracker II P 32 System as a sonic control elevation reference for your system The following sections describe how to set up a Sonic Tracker For specifics on each type of Sonic Tracker ST 3 Specifics on page 53 and Sonic Tracker II Specifics on page 58 Working Window and Sonic Footprint Built into the Tracker is an operational zone or Working Window The default value is 0 20 ft above and below the grade reference Figure 71 The grade lights on the Sonic Tracker and Control Box continuously display this grade information to the operator ST 3 Sonic Tracker II 1 Working FA Window Adjustable 20 y E Ongrade Flashing Up Down Arrow Solid Up Down Arrow Out of Range Figure 71 Sonic Tracker Working Window Sonic Tracker and SAS Se
104. o get sensor On Grade 12 The Control Box displays red dashes instead of the actual elevation when in elevation mode 13 The Auto light on the Control Box intermittently flashes on and off Control Box Symptom 1 The Control Box LCD does not display Probable Cause No power to the Control Box 1 Check that the machine power is on and all switches for automatic control on the paver are in the proper position 2 Check that all cables are properly and securely connected to the Control Box and the paver 3 Disconnect cables and inspect them for damage or contamination Clean all connections with an electrical contact cleaner Do not use electrical contact cleaner to clean the Tracker s transducer 4 Swap Control Boxes from left to right side 5 For System Four bypass Junction Box by plugging coil cord from paver to J Box directly into Control Box Troubleshooting P 32 and P 32 Operator s Manual P N 1001547 01 98 Control Box Symptom 2 The Control Box LCD displays Error 25 4 ERROR 3UIOOysa3 qno1 Figure 176 Error Display Probable Cause No communication with the sensor selected 1 Check that all cables are properly connected to the Control Box and sensors 2 Disconnect cables and inspect them for damage or contamination Clean all connections with an electrical contact cleaner Do not use electrical contact cleaner to clean the Tracker s transducer 3 I
105. ol Box does not match your desired slope To get back to the correct slope continue paving in automatic and slowly dial the display to the desired slope Failing to press Survey when changing back to slope control could result in a bump in the mat DO After surveying the slope because of the switch from slope to elevation control you may find that Paving Intersections with Cross Slope P 32 and P 32 Operator s Manual P N 1001547 01 83 Stringline Setup Sonic stringline provides an inexpensive easy to set up continuous reference that takes the best advantage of the non contacting feature of the Sonic Tracker Stringline takes a few minutes to setup and becomes a constant grade reference The stringline also becomes a visual reference for the job allowing any mistakes in a hub elevation to be quickly spotted by sighting down the string Sonic stringline is both a reference and an averaging solution e As a reference surface and elevated stringline provides consistent results for level and sloped surfaces e As an averaging solution surface stringline takes the place of averaging skis The sonic stringline setup consists of readily available materials and up to 500 feet of nylon stringline Topcon s Sonic Tracker works with many sizes and types of stringline for best results use an 1 8 inch diameter nylon stringline results Using steel wire or a plastic coated stringline with a smooth surface can provide erroneous
106. ompany 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 PRODUCT 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 PRODUCT 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 PRODUCT P 32 and P 32 Operator s Manual P N 1001547 01 x License Agreement Use of any computer programs or software supplied by TPS or downloaded from a TPS website the Software in connection with the product constitutes acceptance of these Terms and Conditions in this Manual and an agreement to abide by these Terms and Conditions The user is granted
107. on contains information regarding preventative maintenance and daily care of your Topcon P 32 or P 32 System Also included are e Cleaning procedures for the Sonic Tracker Transducer e Replacement procedures for the Sonic Tracker II Transducer Preventative Maintenance amp Daily Care A good preventative maintenance and daily care routine prevents many problems before they occur The most important part of daily care for your Topcon P 32 or P 32 System is to clean it and keep it free of debris and to thoroughly dry removable components ST 3 Sonic Tracker the Control Box and cables before storing them in the Carrying Case In addition the following procedures ensure trouble free operation 1 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 2 Be sure cables left on the paver are attached to protective connector caps not in use Water accumulating on the connectors can cause electrical shorts 3 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 4 Check the Sonic Tracker transducer s daily to make sure the transducer s are clean and free of debris See ST 3 Cleaning on page 93 and Sonic Tracker II Transducer Cleaning on page 94 ST 3 Cleaning 1 Remove any dirt of debris from the bottom of the ST 3
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109. on the SAS on the paver start by measuring the length of the tow arm Divide the total length by three This gives you the placement of the balance point of the SAS on your machine Figure 114 dn S SVS Pue Jae DIUOS Balance Point of Beam Center of Beam Figure 114 Placement of SAS Optional Smoothtrac SAS Placement and Setup P 32 and P 32 Operator s Manual P N 1001547 01 65 Getting Ready to Pave This chapter is designed to get the paving crew started using your Topcon P 32 or P 32 System The job application and the desired results determine what type of non contacting controls should be used i e sonic slope laser and SAS e For Sonic Tracker and SmoothTrac SAS setup first attach the Sonic Trackers then setup the Control Box e For Slope Sensor setup first attach and power up the Control Box then check the sensor s calibration to ensure correct grade e For Laser Tracker setup first setup the laser transmitter attach the Laser Tracker to the machine then setup the Control Box The components should be mounted on the paver and then the paver itself must be properly set up Control Box Setup Use the following steps to install the Control Box Figure 115 1 Attach the Control Box to the Control Box Bracket 2 Connect the cables to the Control Box 3 Turn on the Control Box Power Connector 2X Sonic Tracker Slope Sensor Connector Jaw Mount for Bracket Connect Br
110. ores but only one at a time The sensor communicates to the Control Box through the cable To pave using slope control you must first calibrate the Slope Sensor to the screed 1 Find a smooth area where the screed can rest evenly across its entire surface Using a laser a Smart Level or a Slope board that itself has been calibrated check the slope and direction of fall of the ground Figure 126 O O et ag 00 A O Y a lt ep O Y Q lt O Figure 126 Checking Slope 2 Place the screed on the ground and null it out 3 With the Control Box on press the Elevation Slope button until the yellow LED below to the slope symbol illuminates Figure 127 lt a Elevation Slope 2 TOPCON Figure 127 Setting the Control Box to Slope Mode 4 To display the actual slope percentage press Survey e f the On Grade bar is illuminated and the screen displays a slope value that Is identical to the laser or Smart Level press the Auto button to put the Control Box into Automatic control and begin paving e If the slope displayed in the box does not match the surface then you must calibrate the Slope Sensor Sensor You must turn Off Slope Calibration Block in the Performance Menu before calibrating the Slope Control Box Setup for Slope Control P 32 and P 32 Operator s Manual P N 1001547 01 72 5 From the Performance Menu choose Slope Cal
111. oth Sides Figure 62 You can also check Display slope to allow the Slope Sensor to display the slope value even when it Is in elevation mode Also see Control Screen on page 29 for a description of the Control Screen e Display Value Range Set Point Sensor Both Sides and Display Slope e Factory Default Sensor oom 0 20 425 42 2 o 0 9 Units i s 10 System Info 0 20 2 2 11 Sonic Tracker 3 12 Slope Res 13 Slope Cal Block O 0 WN Ul A o s et 2 g O x 0 ay et Cc D N Q an Y Y et 5 Set Point Sensor Both Sides Figure 62 Display Set Point If you choose Set point as the display type the Control Screen only displays the elevation or slope set point Sensor If you choose Sensor as the display type the Control Screen displays e the elevation or slope set point e the actual elevation or Slope Sensor reading Both Sides If you choose Both sides as the display type the Control Screen displays e the elevation or slope set point e the actual elevation or slope set point e alive view of the secondary Control Box s screen in the lower half of the screen Elevation or slope set point Actual sensor readings Auto indication On Grade arrow indication Performance Menu P 32 and P 32 Operator s Manual P N 1001547 01 36 Display Slope Check Display slope to show the slope value even when you are in Elevation Mode S
112. oved positions with the swapped tracker the tracker is the problem See Chapter 8 to replace the transducer 3 Check to see if a Tracker without SAS code is attached to the cable Verify that the tracker has a SAS compatible decal near the S N label Figure 181 on page 108 i Figure 181 SAS Compatible Decal Location on Sonic Tracker 4 Tracker can also be checked by verifying the code revision For the Sonic Tracker II Turn box off and back on Watch the temperature bail symbol in the top right portion of the tracker Figure 182 The T symbol flashes a certain number of times pause and flashes again to indicate the revision of its code IN Sonic Tracker II Figure 182 Temperature Bail Symbol I ndicating Code Revision Example Flash twice pause flash twice means the code in the Tracker is 2 2 SAS requires trackers with code of 2 2 or higher For the Sonic Tracker Il From the GC 35 Control Box check the firmware revision by following the instructions in System Info on page 50 SAS Symptoms P 32 and P 32 Operator s Manual P N 1001547 01 108 SAS Symptom 2 A Tracker stops working Probable Cause Defective Tracker 1 2 3 Check SAS cable connections at each tracker Verify the SAS icons on the Control Box Figure 180 on page 107 Turn off Control Box and swap tracker showing error with another tracker on the SAS Tracker number is on the
113. pivot point then the paver must move 9 feet 3 feet x 3 tow arm lengths for 96 of the elevation change The tracker is measuring the distance to the reference so its position along the tow arm becomes the net tow arm length A more reactive screed would be beneficial for applications where it is important to match the reference such as tracking a curb and gutter or matching a joint I I Net Tow Arm Length Figure 88 Correct Placement of the Sonic Tracker As the tracker is moved further forward the screed becomes less reactive A tracker placed at the 2 3 point and looking for a 1 4 inch correction only causes the tow point to move 3 8 inch The net tow arm length is now 18 feet 6 feet x 3 tow arm lengths This would be a better tracker position for applications where smoothness is desired such as mainline paving or when using a mechanical or non contacting SAS ski Sonic Tracker Placement P 32 and P 32 Operator s Manual P N 1001547 01 49 L Bar Positioning Position the L Bar horizontally so the tracker is over the reference For example when tracking a curb and gutter place the screed or extension flush with the edge of gutter and slide the L Bar so the Tracker is over the lip of the gutter Figure 89 dn S SVS Pue Jae DIUOS Figure 89 Positioning the L Bar with Tracker The L Bar can also be mounted to a bracket on the screed extension Figure 90 This would work well in applications where the refere
114. pray 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 Sonic Tracker II Transducer Replacement If the ability of the Sonic Tracker II to see a sonic stringline or other reference 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 170 Figure 170 Remove Filter Foam 2 Remove the four screws and the black retaining ring Remove and discard the O Ring Figure 171 on page 95 Always remove and discard used O Rings Used O Rings are distorted and can loose elasticity due to weather or exposure to diesel fumes Sonic Tracker II Transducer Cleaning P 32 and P 32 Operator s Manual P N 1001547 01 94 The Transducer Replacement Kit includes an O Ring and four replacement screws however use the original screws and keep the four supplied in the kit for replacements in the event one or more are lost Figure 171 Remove Screws Retaining Ring and O ring 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 172 on page 95 When cutting the Ty Wrap be careful not
115. racking an uneven reference Factory setting is 50 o 2 D UN o o F 2 eje Control Box Symptom 4 The tow point cylinder does not move up or down Probable Cause Machine electrical switches are not in the proper position or hydraulics to the cylinder are not active 1 Check that all locking pins have been removed and that all hydraulic blocking valves are in the open and correct position for automatic control Refer to the paver manufacturer s manual 2 Check that all machine electrical switches and in motion circuits are in the correct position for automatic control Refer to the paver manufacturers manual Press the jog switch up and down on the Control Box to make sure there Is a current going to the valve Cylinder should move in the same direction the jog switch iS pressed 3 Check that the Auto Switch is in Auto and that the Auto Symbol is illuminated on the front panel 4 Disconnect cables and inspect them for damage or contamination Clean all connections with an electrical contact cleaner 5 Swap the Control Box with the unit on the opposite side If a Control Box is replaced make sure the configuration and performance settings are correct 7 Ifa cable is replaced make sure it is the right part number A cable with the incorrect resistor could set the Control Box to have the wrong configuration Control Box Symptom 5 The tow point cylinder is moving in the wrong direction Probable Cause
116. rade between 0 05 ft and 0 2 ft Below grade between 1 and 2 Slowly blinking red up arrow Outside of Working Window beyond Outside of Working Window 0 2 ft below grade no valve control beyond 2 below grade Control Box Features P 32 and P 32 Operator s Manual P N 1001547 01 23 Menu Set Button The Menu Set Button Figure 41 has two functions e Menu used to access the Performance Menu e Set used to change the reference number viewed on the display Menu Set Button _ _ Figure 41 Menu Set Button Menu Press the Menu Set Button to enter the Performance Menu The Performance Menu allows you to set valve offsets units of measurements elevation and slope deadband and other useful functions See Performance Menu on page 29 for information on using the menu settings O 0 WN Ul A o s et 2 g O x 0 ay et Cc D N Q an Y Y et 5 Set Set is used to change the reference number viewed on the display for elevation or slope By using Set you are only changing the reference number viewed on the display leaving the existing cutting depth unchanged 1 From the Control Screen press and hold the Menu Set Button 2 Turn the Grade Adjustment Knob to change the reference number The reference number turns red to indicate the Control Box is in Set Mode 3 Release Menu Set to save the value Cross Communication Button If enabled the Cross Communication
117. rying Case Topcon provides a Carrying Case Figure 8 and Figure 9 with your system The case includes cutouts that fit the components MEN NE NOUS Figure 8 P 32 System Carrying Case Figure 9 P 32 System Carrying Case Carrying Case P 32 and P 32 Operator s Manual P N 1001547 01 5 Paving Principles and Control Methods This chapter describes the components of pavers and the basics In paving principles as well as control methods used for paving Paver Components Modern pavers Figure 10 consist of two major units the Tractor and the Screed The primary function of the tractor is to propel the truck or paver feeding device to convey and distribute the paving material and to tow the screed The function of the screed is to strike off the material in preparation for further compaction The screed is mounted to the tow arms at the screed pivot points and is attached to the paver at the tow points Tow Point Screed Pivot Point Screed Figure 10 Paver Components How a Screed Works The screed on all modern pavers is of the floating self leveling type As the paver tows the screed unit forward paving material flows under the screed This causes the screed to float on the mat of material thus establishing mat thickness Since the screed is mounted to the paver only at the tow points the screed is completely free to float up or down Figure 11 The screed always seeks it s own Planing Angle or an
118. st and click Enter Refer to the Topcon Quick Guide Further information to note about system configuration maintenance or setup performance data integrity measurements or personal safety Terms and Conditions Notification that an action has the potential to result in system damage loss of data loss of warranty or personal injury Supplementary information that can have an adverse effect on system operation system P 32 and P 32 Operator s Manual P N 1001547 01 xii Y D n O O Y System Overview Your Topcon P 32 and P 32 Systems are complete non contacting control systems which combine both elevation control and slope control into a simple easy to use package Figure 1 The primary function of the Topcon P 32 and P 32 Systems are to provide screed control so that the paving material is placed into position at the correct elevation and slope TA WI O Neer P 32 System P 32 System ST 3 GC 35 Slope Sensor Sonic Tracker II GC 35 Slope Sensor wh ll ate Figure 1 Topcon P 32 and P 32 System Components Figure 2 displays the setup of the P 32 and P 32 System components on a screed 1 GC 35 Control Box 2 ST 3 P 32 System Sonic Tracker II P 32 System 3 Dual Port Slope Sensor Figure 2 Topcon P 32 and P 32 System on Screed System Overview P 32 and P 32 Operator s Manual P N 1001547 01 1 Getting Acquainted Standard Topcon P 32
119. st mat thickness on the Slope Sensor while standing on the screed The Smoothtrac is mounted to the tow arm of the paver and connects to your Topcon P 32 or P 32 System with the same coil cord used for the Sonic Tracker Es Y o O om Q A lt Y Q a Y gt Y Y Y et 5 3 a qe il ae 7 N Figure 104 Smoothtrac SAS When mounting the SAS to the paver follow these simple steps 1 Ifthe ski is in pieces connect them together Figure 105 Figure 105 Connecting SAS Pieces 2 Next mount the L bars to the brackets on the tow arm The outside L bar can be attached so it points up or down The position depends on how tall the tow arm is off the ground e For pavers with a tall tow arm mount the L bar in the downward position e For shorter tow arms mount in the upward position Place locking collars on the bars and adjust so they are parallel with one another before tightening with an Allen wrench This allows the ski to move freely when adjustments need to be made without falling off Optional Smoothtrac SAS Placement and Setup P 32 and P 32 Operator s Manual P N 1001547 01 60 3 Bend the L bars so they are aligned in the same position and fold inwards so they are close to the paver Figure 106 Make sure the clamp handles are loose so the bars can move Figure 106 Position of L bars 4 Lift the ski and slide it over the L bars Adjust the ski so it is approximately
120. states only The use of the symbol below indicates that this product may not be treated as household waste By ensuring this product is disposed of correctly to help prevent potential negative consequences for the environment and human health 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 a supplier where you purchased the product or consult Regulatory P 32 and P 32 Operator s Manual P N 1001547 01 118 Warranty Topcon 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 Topcon s Authorized Dealers During the warranty period Topcon 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 Topcon warranty service dealer If this product is delivered by mail purchaser agrees to in
121. stem SAS Figure 6 is an optional add on elevation control system that combines multiple Slope Sensors to calculate an average of the physical reference Each tracker sends its distance measurement to the Control Box which then averages those measurements and sends a correction signal to the tow point cylinder The Smoothtrac replaces the mechanical ski that drags on the ground The Smoothtrac connects to the Control Box through the tracker cable NS SANs B la OM Figure 6 Optional Smoothtrac Sonic Averaging System SAS Laser Receiver Optional Add on Component The Laser Receiver Figure 7 is an optional add on elevation control sensor that measures and controls the elevation of the screed After receiving a signal from a rotating laser the Laser Receiver sends a signal to the Control Box which then sends a raise or lower signal to the tow point cylinder The Tracker ack attaches to the Laser Receiver and then mounts to a vibration pole Use the same cable from the Sonic Tracker to power the Laser Receiver Tracker ack system The Laser Receiver should be removed at the end of each day and stored in its carrying case Optional LS B110 Laser Receiver Optional TrackerJack Laser Receiver on Vibration Pole Figure 7 Optional Laser Receivers P 32 and P 32 Operator s Manual P N 1001547 01 4 MEN NE NOME Car
122. stem as a sonic control elevation reference for your system The Trackers measure and control the elevation of the screed controlling grade from a physical grade reference such as a curb stringline or existing road surface For both the ST 3 and Sonic Tracker II a transducer located in the Tracker generates a number of sound pulses per second and listens for returned echoes like a microphone As soon as the Tracker sends out a sound wave it starts a stop watch The sound waves go down bounce off of a physical reference and reflects back to the Tracker The Tracker measures the time it takes for the sound wave to return to the Tracker Knowing the speed of sound the Tracker accurately calculates the exact distance to the grade reference Figure 25 The ST 3 is Topcon s new generation Sonic Tracker The ST 3 was designed after years of experience with non contacting sonic grade controls in the construction industry The ST 3 has two detection modes to ensure the best accuracy possible as well as changing sensor characteristics to optimize the detection zone based on the application The two modes are Surface Mode and Stringline Mode Surface Mode Is used to detect the ground or curb While in Surface Mode the grade indicators display the traditional up down and ongrade arrows Stringline Mode Is used to detect an elevated stringline Control Methods P 32 and P 32 Operator s Manual P N 1001547 01 14 While in Stringline Mode the gr
123. sure the product or assume the risk of loss or damage in transit to prepay shipping charges to the warranty service location and 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 Topcon 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 a Topcon battery charger or cable is 90 days Warranty P 32 and P 32 Operator s Manual P N 1001547 01 119 Glossary A Aggregate Various hard inert materials such as sand gravel pebbles etc used as the bulk material in asphaltic mixes Angle of Attack The angle that exists between the bottom of the screed and the grade over which the screed is traveling Auger The broad spiral flange on a screed which rotates and spreads paving material evenly in front of the screed Auger Shadows The dark and light areas along the length of a mat surface caused by the compaction of materials having different densities and textures Automatic Feed Controls The dual feed system on a paving machine used to maintain a constant head of material in front of the screed Automatic Grade and Slope Controls Sensing equipment used on paving machines to set and maintain
124. tTm Fwy g ma ma uw ar lt n w Eo T T Ta a a Ce _ _ kand m r u E i O ae m re a Tat wm A 85 a3 En em 24 ma mm ma mm SF A ngg e E A A A MO UA A A A M UE Y 0 MM a Tay w E A A A A UA A YA A DA A A 0 0 UE e q 0 0 ee 0 0 Ue UN Ls SS ra ma ar ma farad en rr y er uu al om _ lt gt re re eC _ m ad me 4 A rr m e _ had g gt rr Tre Faded r rmm rn rm nm im on e m re a ma gt r en em DD y A A A A A A A A A A 5 0000000000000 100 0mu Y0USySSO5DONSOA NSSONA9 9 995650959799 94 2 Y M Y U N eee 9 on EENEN gt ONO NANI 90 ee ee _ lt e ee 3 m i i a ee ee W u gag ee ee ee ee ee E a E _ aoe fF fee eee eRe 0050000000350550050 0 0330 ee Gal u y Ca um mm kaad 5 UN Lan un Ll fs Mm E Linad lial na we mM m kaiii w pa mm re Kai Hunga g wT FTT TFiFFfTftitT H ya m a fas es m tl 7 a y fF nm E W a CE A fk Se ee ee ees ss E To i UA A EEUE fk fs O gk Se Se O A A ee ee al ae ae Lal ll peon Positioning Systems Ine raea PA TATATATA rane ReeReeeee eee eee a se eee reee eee eee ee eRe eee eee ee ee ee il Pm a e i me mo 74 00 Nat tion mm jal Roy ii m e Liv srme re CA 94550 94550 a iaia aoda dod a aiai aa ain i d ai an ain i d a a ee eee ee re aa e nrn e n ae ive PO a OA a aa mamom a m a aa 7800 44 56 SANIA m 7 TEA Zeeeeereeneese oe
125. ter time Figure 75 The Tracker and Control Box indicate a raise correction arrow and raise hydraulic valve corrections are applied to bring the Tracker back to On Grade STOPWATCH Figure 75 Sonic Tracker Below Grade If the Sonic Tracker is side shifted off a stringline the sound waves reflect off the ground and the Tracker s stopwatch indicate a longer time Figure 76 on page 45 The Tracker is out of the Working Window and no On Grade corrections are applied STOPWATCH Working Window and Sonic Footprint P 32 and P 32 Operator s Manual P N 1001547 01 44 dn S SVS Pue Jae DIUOS Figure 76 Sonic Tracker Scanning Outside of Stringline If the Tracker sees an obstruction closer than the reference signal such as a grade pin the watch stops at an even shorter time Figure 77 The Tracker is out of the Working Window and no On Grade correction signals are applied STOPWATCH dn S SVS Pue Jae DIUOS Figure 77 Obstructions within the Sonic Tracker s Working Window Sonic Tracker and Temperature Changes Since temperature affects the speed of sound the Tracker has a built in temperature sensor for applications with gradual temperature changes such as on graders or dozers In paving applications you can get a more dramatic and rapid change in air temperature To compensate for these variations a temperature bail is positioned below the tracker When
126. tion ft Figure 139 Paving Uneven Curbs with Slope Control To keep the centerline in the middle of the road you must set up the second pass using Sonic Control on each side of the paver The left tracker matches the lip of the curb and the right side tracker follows the new mat Figure 140 The cross is not consistent on this side of the roadway but the joints match Prevent moving the Sonic Tracker away from the crown as that changes the elevation Subgrade Centerline of Road Mat Depth gt 0 20 E 0 20 y Mat Depth Figure 140 Second Pass when Paving Uneven Curbs Paving City Streets with Cross Slope P 32 and P 32 Operator s Manual P N 1001547 01 78 The curb elevations can be easily spot checked using a fast leveling RL HB rotating laser Set the laser at the lip of one curb then use the detector and a folding rule to take a reading on the other curb Figure 141 Spot check every 25 50 feet by just moving the laser Figure 141 Checking Curb Elevations Paving Streets Through Intersections As you pave city streets you will come upon intersections where the curb stops There are a couple of methods for controlling grade through the intersection Method 1 for Paving Intersections For this method the base of the intersecting road is used as the reference 1 On both Control Boxes press the Elevation Slope button to set them to Elevation control 2
127. tup P 32 and P 32 Operator s Manual P N 1001547 01 42 When setting up the Sonic Tracker over a grade reference you must consider the size of the Sonic Cone or Footprint Figure 72 As an example at about two feet from the tracker there is a footprint or cone of about six inches in diameter As the Tracker is positioned closer to the grade reference the Footprint decreases in size As the Tracker is moving farther away from the grade reference the Footprint increases in size UN o 2 om Q A s Y Q a Y gt UN Y Y eb 5 4 lt 060 Sonic Footprint Figure 72 Sonic Tracker Footprint Sonic Tracker Operation and Position On the paver the Sonic Tracker II is positioned above the grade reference to maintain an exact distance from the tracker to the reference Figure 73 on page 43 If the Tracker is On Grade the mat being laid Is at the desired depth Figure 73 Sonic Tracker On Grade Working Window and Sonic Footprint P 32 and P 32 Operator s Manual P N 1001547 01 43 If the screed and the Sonic Tracker II start to raise the watch stops at a longer time Figure 74 The Tracker and Control Box indicates a down correction arrow and lower hydraulic valve corrections are applied to bring the Tracker back to On Grade STOPWATCH Figure 74 Sonic Tracker above Grade If the screed and Sonic Tracker are lowered the watch stops at a shor
128. uld be from 14 to 24 inches At 55 inches the sonic footprint would be very large and the tracker may pick up an undesired reference The tracker also compensates for temperature changes only within the bail range Placing the tracker too far from the reference may not allow for accurate temperature compensation dn S SVS Pue Jae DIUOS Recommended Height for Paving Total Tracker 140cm Range Figure 102 Recommended Sonic Tracker II Placement Placement When Using Surface Stringline Sometimes the surface to be paved contains pot holes or the surface is too broken up to use as a joint match reference Setting an elevated stringline is too time consuming especially for small divided up projects In these applications surface stringline would be a good alternative Figure 103 See Setting Surface Stringline on page 23 for further details Figure 103 Sonic Tracker II Placement Pot Holes Sonic Tracker II Specifics P 32 and P 32 Operator s Manual P N 1001547 01 59 Optional Smoothtrac SAS Placement and Setup Topcon s Smoothtrac Sonic Averaging System SAS is a non contacting averaging system that uses multiple Sonic Trackers ST 3 or Sonic Tracker 11 to smooth out the bumps and dips in a mat surface Figure 104 The non contacting design allows full maneuverability of the paver when turning around backing up or passing over obstacles without lifting or removing the beam The screed man can adju
129. ult your compaction equipment manufacturer s manuals and handbooks on compaction techniques Controlling Mat Quality The primary purpose of the asphalt paver is to place a smooth mat of material The primary function of your Topcon P 32 or P 32 System is to control the vertical position of the screed in relation to the surface being paved Automatic grade and slope control systems can help tremendously in controlling mat smoothness but mat quality is also dependent on the following factors How a Screed Works P 32 and P 32 Operator s Manual P N 1001547 01 13 e Non stop continuous operation of paver e Constant speed of paver e Truck exchange e Head of material e Mix characteristics Gradation Segregation Mix Temperature e Screed Compaction e Quality of Base Being Paved e Rolling Techniques mat quality If changes must be made make them as gradually as possible Abrupt changes in any of the above factors produce rapid changes in mat thickness adversely affecting mat quality Changes in any of these factors cause a change in mat thickness density surface appearance and Control Methods y ay eje y 2 BF D UN Q a A o lt Y ot a o a N The following sections describe the three types of control possible with your Topcon P 32 or P 32 System sonic laser and slope Sonic Control You can choose either Topcon s ST 3 P 32 System or the Sonic Tracker II P 32 Sy
130. ure 66 USB Key Figure 66 I nsert USB Key 3 From the Performance Menu press the Enter button PIN to select System Info Figure 67 4 Press Update and then press Load Figure 67 EF Topcon Current Firmware Copyright 2012 1 1 2012 Firmware e 1 1 New firmware 2 0 2014 Figure 67 Updating Firmware 5 Wait for several seconds for the firmware update process to complete The Control Box displays the progress of the update reboots and then displays the Control Screen 6 When the Control Screen displays remove the USB key and replace the USB cap your Control Box is updated and ready to use When updating firmware your settings may revert back to their default values Performance Menu P 32 and P 32 Operator s Manual P N 1001547 01 39 O 0 WN Ul A o s et 2 g O x 0 ay et Cc D N Q an Y Y et 5 Sonic Tracker 3 P 32 System only Sonic Tracker 3 allows you to select between two detections modes for the ST 3 Surface Mode or Stringline mode These two detection modes change the sensor s characteristics to optimize the detection zone based on the application Surface Mode Surface Mode is used to detect the ground or curb While in Surface Mode the grade indicators display the traditional up down and ongrade arrows The Surface Mode icon displays on the Control Screen Figure 68 Stringline Mode Stringline Mode is used to detect an elevated stringline While in String
131. urer s instructions and that it is not loose or damaged 3 Recheck slope using a good reference such as a laser or level Wait at least three tow arm lengths before checking the slope after a change has been made 4 If you use the paver s mat thickness controls or hand crank the screed you may need to adjust the slope calibration to correct any offset between the Slope Sensor and the screed This can occur after buying back cylinder SAS Symptoms 1 When the SAS is connected Control Box SAS icons display red When the SAS is connected the Control Box SAS icons display red A Tracker stops working 4 SAS is not producing a smooth surface 2 3 SAS does not lock on grade 5 A tracker is picking up head of material Tracker Functioning but Not Detecting Surface Tracker Connected Faulty Tracker Detecting Surface Figure 180 SAS I cons SAS Symptoms P 32 and P 32 Operator s Manual P N 1001547 01 107 SAS Symptom 1 When the SAS is connected the Control Box SAS icons display red Probable Cause 3UulOOysa3 qno1 Defective tracker or cable tracker with incorrect code 1 Verify that all trackers are correctly and securely plugged into the SAS cable by checking the SAS icons on the Control Box Figure 180 on page 107 2 Turn Control Box off and move the Tracker to a different position on the SAS cable Turn the Control Box on to reconfigure SAS If error number m
132. with the manual thickness cranks Figure 14 Change in Screed Angle of Attack from Crank 100 6 Tow Arm Lengths Travel 5 Tow Arm Lengths Travel 4Tow Arm Lengths Travel 3 Tow Arm Lengths Travel Figure 14 Manually Changing Mat Thickness How a Screed Works P 32 and P 32 Operator s Manual P N 1001547 01 7 y ay eje y 2 BF o D UN Q a A o zz lt Y a o a N cs Avoid cranking while in Auto mode and keep the left and right rotation the same Always check mat depth in several locations before making any elevation corrections The surface being paved may have wheel ruts dips and ridges that gives an untrue indication of overall mat depth Check several spots to get an average Figure 15 If an elevation change is made wait 3 tow arm lengths for full correction Too many set point changes and stabbing causes raise and lower changes that produces an uneven mat surface Figure 15 Checking Mat Thickness The screed has four main forces acting on it at all times whether paving in manual or with automatics Figure 16 A change in any one of the forces causes the screed to rise or fall changing the mat depth The key to smoother paving is to keep these forces as constant as possible The following sections review these forces and the factors that have an effect on paving Weight of Screed Force W Head of Material Tow Point Force M Force P
133. x Symptom 11 The valve does not drive hydraulic cylinder far enough to get sensor On Grade Probable Cause Valve offsets in Control Box are set too low 1 2 3 Raise the Valve Offset Value till the sensor is driven to grade Refer to Setting Valve Offsets section in this Manual For Solenoid valves raise the value by 2 to 5 numbers then check hydraulic performance For Proportional valves raise the value by 10 to 15 numbers then check hydraulic performance Control Box Symptom 12 The Control Box displays red dashes instead of the actual elevation when in elevation mode Probable Cause Sonic Tracker is reporting no echo 1 2 3 4 Verify that the Sonic Tracker is ticking Make sure tracker is pointing at a target with the working range recommended 14 to 24 inches Transducer may be dirty or damaged Refer to the Transducer and Filter section within this manual Power or ground connection at transducer may be loose Remove transducer and check wires Control Box Symptoms P 32 and P 32 Operator s Manual P N 1001547 01 103 o 2 D UN o o y je Control Box Symptom 13 The Auto light on the Control Box intermittently flashes on and off Probable Cause External Auto signal from the machine is preventing control o 2 D UN D o F eje 1 Check the machine switches Sonic Tracker Symptoms 1 The Sonic Tracker does not power on 2 Th
134. 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 product can lead to injury to persons or property and or malfunction of the product The product 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 accordance with the laws of the State of California without reference to conflict of laws Terms and Conditions P 32 and P 32 Operator s Manual P N 1001547 01 xi Manual Conventions This manual uses the following conventions Convention Description Example Bold Menu or drop down menu selection File gt Exit Click the File menu and click Exit Name of a dialog box or screen From the Connection screen Button or key commands Click Finish Mono Italic User supplied text or variable Reference to another manual or help document Type gue

P-32 Operator`s Manual - Accurate Laser Systems

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