Home

mmGPS 3D Paver Reference Manual

1. A 4 mmGPS 3D Paver Reference Manual Appendix B Specifications The sections in this appendix give the features and specifications for the physical components of the mmGPS 3D Paver system Control Box The 9168 control box is backward compatible with System Four and System Five sensors and remote switches Table B 1 lists specification details for the 9168 control box Table B 1 9168 Control Box Specifications Housing Cast aluminum Weight 11 75 Ib 5 3 kg Display Color LEDs 6 1 4 diagonal sunlight viewable 640 x 480 enhanced color 1300 nit Touch screen Three color linear grade indicators with automatic adjustable brightness Supply Voltage 10 to 30 VDC Operating Current Typical 3 0 A Maximum 15 A Operating 20 to 60 C 4 to 140 F Temperature Moisture MIL standard 810D Valve Drive Progammable dual hydraulic control External data storage One slot for compact flash card to download upload job files P N 7010 0781 B 1 Specifications Table B 1 9168 Control Box Specifications Continued USB Port One port for keyboard or mouse hookup Connectors Four connectors for power valves RS485 RS232 Speaker For the tones beeps and chimes of audible alerts Computer Board 300 MHz processor 28 MB SDRAM Operating System Microsoft Windows CE NET Figure B 1 shows the dimensions of the 9
2. Enclosure Cast aluminum Weight 4 7 Ibs 2 13 kg Supply Voltage 12 VDC for 9221 24 VDC for 9220 Operating Current Typical 0 5A Maximum 10 5A Operating 0 to 60 deg C 32 to 140 deg F Temperature _ Figure B 9 Trackerjack Dimensions B 12 mmGPS 3D Paver Reference Manual Sonic Tracker II Sonic Tracker Il The Sonic Tracker II has ruggedly sealed electronics a field replaceable sonic transducer and temperature compensation for atmospheric disturbances that contribute to industry standard accuracies With bright grade indication lights and a patented working window it s easy to use and see for controlling grade Table B 10 lists specification details for the Sonic Tracker II Table B 10 Sonic Tracker II Specifications Housing Cast aluminum Epoxy sealed electronics Connector 1 for power and communication Display Raise lower on grade LED s Supply Voltage 10 to 30 VDC Operating Current Typical 200 mA Operating 0 to 60 deg C 32 to 140 deg F Temperature Range Adjustable from 14 to 55 inches 35 5 to 140 cm Working Window On grade adjustable Course 0 15 ft Fine 0 05 ft Resolution 0 0025 ft Transducer Frequency 50 kHz with 40 Hz maximum repetitive rate P N 7010 0781 B 13 Specifications Figure B 10 shows the dimensions of the Sonic Tracker II a 4 0 ____ AF TOPCON 4 5
3. LEFT ie gt O RIGHT C AEA A TOPCON Misael yO O lt 7 6 lt 18 0 8 7 SENSING AXIS Figure B 2 Blade Slope Sensor Dimensions Simple Auto Manual Knob The Simple Auto Manual Knob mounts on the control lever for easy access Table B 3 lists specification details for the Simple Auto Manual Knob Table B 3 Simple Auto Manual Knob Specifications Details Profile Epoxy Switches One for switching between Auto and Manual control Mounting Threads 375 16 x 60 inch deep course threads mmGPS 3D Paver Reference Manual B 4 MC 2 5 Receiver Box Figure B 3 shows the dimensions of the Simple A M Knob Le 90 5 I k 2 5 0 Figure B 3 Simple Auto Manual Knob Dimensions MC 2 5 Receiver Box The MC 2 5 Receiver provides the industry s most advanced GLONASS and GPS dual frequency satellite tracking system in a heavy duty construction design with a shock absorbing mounting bracket Four high power bottom mounted magnets keep receiver in place on machine The receiver also features compliance with CMR and RTCM industry standards and has optional advanced multipath mitigation and optional in band interference rejection Table B 4 lists specification details for the MC 2 5 Receiver Box Table B 4 MC 2 5 Receiver Box Specifications Housing Cast aluminum Weight 12 10 Ib 5 5 kg LEDs Three LEDs
4. Figure B 7 shows the dimensions of the Trackerjack Vibration Pole gt at ry a a Figure B 7 Trackerjack Vibration Pole Dimensions P N 7010 0781 B 9 Specifications Laser Tracker The Laser Tracker features bright indication lights built in valve drivers for indicate and proportional automatic control and a motor drive for attachment to the Trackerjack Table B 8 lists specification details for the Laser Tracker Table B 8 Laser Tracker Specifications Housing Base cast aluminum Body polycarbonate Detector Height 5 1 2 in Mounting Thread 5 8 11 in Supply Voltage 10 to 30 VDC Operating Current Typical 200 mA Operating 0 to 60 deg C 32 to 140 deg F Temperature On grade Zone 0 013ft variable with beam spot Beam Acceptance 360 B 10 mmGPS 3D Paver Reference Manual Laser Tracker Figure B 8 shows the dimensions of the Laser Tracker 3 8 10 0 N O 5 Sail m 6 5 Figure B 8 Laser Tracker Dimensions P N 7010 0781 B 11 Specifications Trackerjack The Trackerjack has driving capabilities on a Trackerjack Vibration Pole is lightweight and has manual override buttons for pole installation Table B 9 lists specification details for the Trackerjack Table B 9 Trackerjack Specifications
5. 2 28 mmGPS 3D Paver Reference Manual mmGPS Operations with Pocket 3D 3 Walk several feet away from the transmitter and face the sensor towards the transmitter Figure 2 28 SS 10 ft Cr cSSSSSSSSSS Figure 2 28 Setup Transmitter and Sensor In Pocket 3D tap Setup gt mmGPS transmitters On the Channel tab press Edit Channel 6 Tap the Resection button on the channel setup dialog box Figure 2 29 on page 2 30 7 Optionally enter the following measurement parameters on the resection dialog box Figure 2 29 on page 2 30 e Duration secs enter the duration in seconds in which to measure the point e H Precision V Precision enter a horizontal vertical precision in the project s units with which to measure the point The point name is automatically added to the list of control points as TX n Resected where n is the channel number P N 7010 0781 2 29 Setting up the Jobsite and Pocket 3D 8 Subsequent resections with the same transmitter overwrites any previous points K Channel 2 Pt TX 2 Resected Transmitter Control point PP3 v Measured pts Duration secs 1 H Precision 100 150 Precision TX height 5 600 Status Measured to Mark Slant Pts in calculation 0 Benchmark check H Error Resection J V Error Cancel Figure 2 29 Begin Resection Press Measure
6. Lengths Travel Length Travel 6 Tow Arm 5 Tow Arm 4 Tow Arm 3 Tow Arm Lengths Travel Lengths Travel Lengths Travel Lengths Travel Figure 4 4 Tow Arm Travel P N 7010 0781 4 3 Paving Principles The same is true when making elevation changes with the manual thickness cranks Figure 4 5 Change in Screed Angle of Attack 63 2 Tow Arm Lengths Travel 4 1 Tow Arm Length Travel 6 Tow Arm Lengths Travel 4 5 Tow Arm Lengths Travel 4 4 Tow Arm Lengths Travel 8 Tow Arm Lengths Travel Figure 4 5 Manually Changing Mat Thickness Always check mat depth in several locations before making any elevation corrections The surface being paved may have wheel ruts dips and ridges that give an untrue indication of overall mat depth Check several spots to get an average Figure 4 6 If an elevation change is made wait 3 tow arm lengths for full correction Too much cranking and stabbing causes raising and lowering changes that produces an uneven mat surface Figure 4 6 Checking Mat Thickness 4 4 mmGPS 3D Paver Reference Manual Paver Components The screed has four main forces acting on it at all times whether paving in manual or with automatics Figure 4 7 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 the paving
7. 18 mmGPS 3D Paver Reference Manual GPS Localization GPS Localization After you have setup all the hardware components and initialized the Base Station you need to localize the GPS coordinates to the jobsite s coordinates This section gives information on the principles of GPS localization and entering GPS localization into the Control Box Principles of GPS Localization The GPS system is capable of precise positioning but the positions it computes are relative to a global reference system defined in terms of a geographic latitude longitude and height above a representation of the earth s surface To be useful for local site work global GPS coordinates need to be converted into local site coordinates defined in terms of a distance north and east of some origin point and some distance above an elevation datum These north east and elevation coordinates often abbreviated to NEZ coordinates may be those of a regional coordinates system for example a state plane system in the United States or the project s survey crew may arbitrarily define these coordinates for the specific site NEZ coordinates must be defined in terms of the construction design data In either case a mathematical conversion is necessary to turn global GPS coordinates into NEZ coordinates relative to a locally defined coordinate system The basic approach to calculating the mathematical conversion is to provide pairs of point coordinates for ea
8. Change to Elev Ok Cancel Figure 5 10 Adjust Slope Setting the Valve Offsets The valve offset calibration determines the minimum electrical signal required to begin moving the machine s hydraulic cylinder to return the screed to on grade Valve offsets simply determines the electrical requirement valve gain determines the speed of the cylinder The system requires four valve offsets which must be individually calibrated upon initial setup or after hydraulic maintenance If valve offsets are set too low the screed will not reach on grade Likewise if the valve offsets are set too high the screed moves too far and overshoot on grade 5 16 mmGPS 3D Paver Reference Manual Machine Sensor Calibrations Factory preset for valve offsets 0 elevation and slope valve gains If valve offset is altered valve gain adjustments need to be performed again Perform valve offset calibrations before adjusting When using the control box on different machines gt perform valve offset calibrations and valve gain adjustments for each machine 1 Raise the screed so that both sides rest a few inches above the ground At the control box tap Topcon Logo gt Control gt Valve offsets 3 Press the Raise left Set button to enable the entry box and calibrate the left valve offset value Figure 5 11 The control box begins sending a raise signal to the left valve and the grade indicators display the currently a
9. select the sensitivity level for detecting the transmitter usually Auto Select a different setting when working at very short or very long distances or during inclement weather that can affect laser detection e Transmitter selection select the channel to scan for mmGPS connection The All selection allows the sensor to independently select the transmitter with the closest proximity to the receiver If the PZL is not being used in the current setup it should be deactivated within 3DMC If setting up only one transmitter but the job has been P N 7010 0781 3 53 Setting up the Machine and 3DMC configured for multiple transmitters select the individual ID of the transmitter for the sensor to detect e LaserZone aided init select to use the mmGPS signal to assist in initializing the mmGPS receiver This option is useful to decrease the initialization time when satellite visibility is limited for example tracking only four or five satellites e Calc LaserZone GPS weighted elevations select to combine Lazer Zone elevations and mmGPS elevations When selected this option forces the receiver sensor to always consider the angle and distance when determining the elevation then combine the two elevations accordingly This option works well at large 300m distances and steep angles 2 Press Ok to save this information and temporarily overwrite current PZS MC receiver information Receiver port Serial Po
10. 7 Turn off the control box wait a couple seconds and then turn on the control box to activate the new passwords Device identification 555555 va Registered user name JON DOE Authorization code 1 12345A6B78912345 1 2 3 4 amp 6 7 8 9 0 QW EJ R T Y U 1 Oj P A s D F G H J K L Ok Authorization code 2 Z X C V B NM lt 1A2B3C4D5E6F789G Cancel _ gt Ok Cancel Figure 3 95 Enter New Authorization Codes Setting the Elevation Offset and Locking On grade Once the Sonic Tracker has been positioned over the reference the control box is used to set the Sonic Tracker to on grade l Fas Use zero as the on grade reference Set the sonic tracker over the grade reference point 2 Position the screed at a known height typically just above the surface 3 Press the Elevation Control key then press the Elevation set point Set button Enter the elevation offset using the pop up keyboard or the up down arrows Figure 3 96 on page 3 88 4 Press Survey to quickly lock on grade Figure 3 96 on page 3 88 P N 7010 0781 3 87 Setting up the Machine and 3DMC 5 Press Ok to return to the main screen Figure 3 96 Elevation left edge Elevation right edge Elevation valve gain 75 Set gt Elevation set point 0 200 Set o gt survey Zero QO _ etree te step gt 0k Cancel Figure 3 96 Survey On grade Elevation Example
11. 1 With both sides in elevation control pave to the intersection Figure 6 25 Figure 6 25 Paving Through Intersections 2 Just before the right tracker reaches the end of the curb switch the A M Knob into manual mode 3 Without stopping continue paving until the right tracker is on the base material of the intersecting road To quickly lock on grade to the new reference press the Elevation Control key then press Survey Figure 6 26 and switch the A M Knob to put control box back into automatic control Elevation left edge Elevation right edge Elevation valve gain 75 Set i i 0 55 Press Survey Eevanen z point Set tolock ___ Survey Zero on grade T gt Change to Slope Ok Cancel Figure 6 26 Survey to On grade and Return to Automatic Control P N 7010 0781 6 21 2D Paving Applications 4 Pave through the intersection and just before the tracker reaches the curb on the other side Figure 6 27 switch the A M Knob into manual mode Figure 6 27 Paving Through Intersection 5 Without stopping continue paving until the tracker is back on the lip of the curb Survey the tracker on grade Figure 6 26 on page 6 21 and put back into 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 ba
12. Power red Satellite status green for GPS green and red GPS and GLONASS Radio status yellow Supply Voltage 10 to 30 VDC P N 7010 0781 B 5 Specifications Table B 4 MC 2 5 Receiver Box Specifications Radio Built in UHF or Spread Spectrum Radio Frequency Band UHF 450 to 470 MHz Spread Spectrum 915 Channels 14 for Pacific Crest PDL 6 for TeleDesign TS4000 Channel Switching Manual for Pacific Crest PDL Clear channel scan for TeleDesign TS4000 Baud Rate Up to 38400 bps RTK Update Rate 10 Hz GPS Tracking 20 channels GPS L1 L2 GLONASS Channels Figure B 4 shows the dimensions of the MC 2 5 Receiver Box 3 5 Figure B 4 MC 2 5 Receiver Box Dimensions mmGPS 3D Paver Reference Manual PZS MC Sensor PZS MC Sensor The PZS MC sensor combines the MC A1 GPS antenna with laser sensor technology The sensor attaches to a GPS vibration pole on the machine blade and cables connect the receiver to the control box Table B 5 lists specification details for the PZS MC Sensor Table B 5 PZS MC Sensor Specifications Beam Detection 10 by 10 window Channels 4 Weight 6 6 lbs 3kg Power Supply DC 8V DC 32V Waterproof IPX6 Operating Temperature 20 C to 50 C 4 F to 122 P Figure B 5 shows the dimensi
13. Slope Control Key Blade slope 0 0 Set Slope gain 25 Set Survey Change to Elev Ok Cancel Figure 3 99 Adjust Slope Dialog Box 2D Control Setting the Slope Offset and Locking On grade 1 Press the Slope Control key then press the Blade slope Set key Enter the slope offset using the pop up keyboard or the up down arrows Figure 3 100 Press Survey to quickly lock on grade Figure 3 100 Press Ok to return to the Main Screen Figure 3 100 Blade slope 0 0 Set Slope gain 25 Set gt Survey _ _Changetofleut Ok Cancel Figure 3 100 Survey On grade Slope Example P N 7010 0781 3 91 Setting up the Machine and 3DMC Pop up Menu The 3DMC pop up menu provides quick access to elevation information and the steering or grading to polyline functions Pop up menu selections depend on active files or the selected object To access the pop up menu press anywhere on the 3DMC Main Screen Figure 3 101 e Design Elevation displays the elevation of the point tapped on the Main Screen e Steer to Polyline available for linework files controls the machine steering it along the selected polyline e Grade to Polyline available for linework files with elevation information controls the machine paving along the selected polyline Design elev 69 994 Steer to polyline Grade to polyline Figure 3 101 Pop up Menu Changing
14. The tracker is positioned over the lip of the 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 elevations 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 A cross section design of a 36 foot wide street with a 2 0 slope produces a 36 foot rise at centerline Figure 6 19 36 RISE Figure 6 19 Paving with Cross Slope If the curbs are at different elevations a 36 foot rise at centerline produces incorrect slopes Figure 6 20 B6 RISE a 3 LL Qua 23 l 1 7 _ 6 Figure 6 20 Curbs with Different Elevations 6 18 mmGPS 3D Paver Reference Manual Paving City Streets with Cross Slope When the system is used to pave a true 2 0 slope the crown of the street is not at the centerline Figure 6 21 New Centerline at 2 0 Grade Cut eS Original Centerline Figure 6 21 Curb with Same Slope To pave from uneven curbs using slope control choose the side of the road with the highest curb and position the tracker over the curb Set the other side for the cross slope you want and begin pavi
15. Weight of Screed Force W Tow Point Force P Reaction of Material Under Screed Force R Figure 4 7 Forces Affecting the Screed Tow Point Force P The tow point force P is the resistance to forward travel Figure 4 8 Tow Point Force P Figure 4 8 Tow Point Force P 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 leave 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 the mat thickness P N 7010 0781 4 5 Paving Principles 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 4 9 Do not start and stop the paver Figure 4 9 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 1 Stop the mix delivery truck close but not too short of the paver Always allow the paver to pickup
16. components are in place when not using the cables Water accumulating on the connectors can cause electrical shorts e Place system cables in their appropriate storage connectors after removing the control box e 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 e Check for oil leaks in hydraulic assemblies and hoses e Check for loose components due to physical damage e Use proper battery supplies for components isolated from the machine Base Station Transmitter Keep the machine s battery in good condition e Check the Sonic Tracker II Transducer daily to make sure the Filter Foam and Transducer are clean and free of debris If the Filter Foam is clogged with dirt replace it If the Transducer appears to be covered with debris and performance is being 1 18 mmGPS 3D Paver Reference Manual Daily Care and Preventative Maintenance affected clean or replace it using the steps listed in Care and Maintenance of the Sonic Tracker on page 6 9 P N 7010 0781 1 19 Introduction Notes 1 20 mmGPS 3D Paver Reference Manual Chapter 2 Setting up the Jobsite and Pocket 3D Pocket 3D field software which is required for some mmGPS operations runs on a portable hand held controller and uses files common with other equipment on the jobsite U
17. f TOPCON mmGPS 3D Paver Reference Manual TOPCON POSITIONING SYSTEMS mmGPS 3D Paver Reference Manual Part Number 7010 0781 Rev A Copyright Topcon Positioning Systems Inc June 2007 All contents in this manual are copyrighted by Topcon All rights reserved The information contained herein may not be used accessed copied stored displayed sold modified published or distributed or otherwise reproduced without the express written consent from Topcon ECO 3067 TOC Table of Contents PRCLAGCE sciscsacssavenannpansanntsduscssnabnnnddadassacaabeoandnabinaatans vii Terms and Conditions 0 0 eeeeeeesseeseceseeeneeeneeeeeeseeeees vii Manual Conventions 000 eeesseesseceeceeeeeseeeseeeneeeaeeeeeeaes ix Chapter 1 lntrodUctioN sisiisssisniinenininiiesantinnnonnnuniienane nennen naintn 1 1 mmGPS 3D Paver Components ssesseseeeeeeesereereerereeree 1 1 Jobsite Components esiseina 1 3 Hand held Controller with Pocket 3D oe 1 5 Machine Components 0 0 ce eesesseceeceeeceeeeeneeeneeeeeeseeeees 1 6 Daily Care and Preventative Maintenance cee 1 18 Chapter 2 Setting up the Jobsite and Pocket 3D 2 1 Hand held Controller and Pocket 3D oo eee eeeeeeee 2 1 Setting Up the Base Station eseese 2 2 Base Station Initialization 2 9 General Base Station Setup Rules and Notes 2 11 Setting Up PAL AL urere eree a a Bos ation E aiai 2 12 Equipment Setup GPS oo
18. for a more accurate measurement keep the mast as vertical as possible when measuring the point 1 Press Topcon Logo gt File gt Surfaces gt Working or Reference and press New Enter and select the following information for the new surface file Press Next Figure 3 27 on page 3 32 e Configuration name enter a name for the file e Surface type select sloping plane surface compound slope P N 7010 0781 3 31 Setting up the Machine and 3DMC Configuration nary SlopePlane_1 Surface type Flat plane surface New Copy Raise lower existing surface Subgrade of existing road Next Cancel Figure 3 27 Create New Surface File 2 Move the machine to point A and position the sensor on the cutting edge on the selected point 3 When the cutting edge rests on the point press A to measure the point the Measuring dialog box displays during the measurement process Figure 3 28 on page 3 33 4 Move to B point and position the sensor on the cutting edge on the selected point 5 When the cutting edge rests on the point press B to measure the point the Measuring dialog box displays during the measurement process Figure 3 28 on page 3 33 Once the A and B point measurements finish 3DMC determines the Mainfall orientation and grade connecting the A measurement toward the B measurement see Figure 3 26 on page 3 31 If needed you can re measure the points 3DMC saves the A and
19. information mode between Normal Mode and Extended Information Mode See below for details P N 7010 0781 1 11 Introduction e Aux LED and FN Button only active in Dual GPS applications Main LED Red Green Aux Function Button Main Function Button Radio RX LE Red Green Figure 1 13 MC 2 5 Receiver Box Indicators In normal mode the LED indicates the number of tracked satellites and the position s computation status The MC 2 5 Receiver Box also has an extended information mode EIM used for receiver testing purposes In this mode the receiver continues to work as usual but the LED indicates extended information using a delimiter The delimiter is a distinguishable double blink that shows the overall status of tests performed in EIM The LED color for delimiter is calculated from the colors of other LED blinks e Orange at least one blink is orange e Red no orange blink and at least one red blink e Green all other cases The delimiter double blink is followed by six LED blinks corresponding to six receiver tests where each blink indicates the following information Blink 1 Sufficient data for position computation Blink 2 GPS S N ratios are good Blink 3 GLONASS S N ratios are good Blink 4 Oscillator s frequency offset is less than three ppm Blink 5 Oscillator s Allan Variance is better than 2 7e 10 Blink 6 Continuous tracking time is more than 15 minutes 1 1
20. minus sign if working in the western hemisphere e g USA Re enter the coordinates The range pole was unsteady If the errors are decimeter level in magnitude it may point to either inaccurately measured local site coordinates or not holding the range pole vertical when measuring the GPS coordinates Inaccurate local site coordinates or erroneous GPS measurement P N 7010 0781 If error values of the first few points are reasonable but increase when a new point is measured the point just measured must have either inaccurate local site coordinates or erroneous GPS measurement Troubleshooting Problem Causes Use for horizontal GPS localization and or Use for vertical GPS localization check boxes may not have been selected just measured must have either inaccurate There are no H Error and V Error values To isolate the error disable horizontal and or vertical localization for each Control Point in turn and observe the set of errors When the errors become acceptable due to certain isolation the point isolated is most likely to detract from the quality of the localization Also as a general rule if error values of the first few points are reasonable but increase when a new point is measured the point local site coordinates or erroneous GPS measurement Once a problematic Control Point is discovered try to re measure the point again to see
21. 2 on page 1 2 P N 7010 0781 1 1 Introduction Figure 1 2 displays the setup of components on a screed MC 2 5 GPS Receiver Box 2 9168 Control Box i 3 Laser Tracker amp Trackerjack 4 mmGPS PZS MC 5 Slope Sensor 6 Junction Box 7 Sonic Sensor Il Figure 1 2 mmGPS 3D Paver Component Placements mmGPS 3D Paver Reference Manual 1 2 Jobsite Components Jobsite Components Topcon s LazerZone and Millimeter GPS mmGPS products provide unparalleled measuring accuracy at the jobsite and is up to 300 more accurate than standard GPS The LazerZone transmitter provides wide vertical measurement area of 600m 2000ft diameter and 10m 33ft height The system provides multiple rover support for machine and pole mounted sensors and the technology works with existing Topcon GPS systems Base Station Kit The Base Station Kit Figure 1 3 sends position corrections to an unlimited number of machines or survey Rovers The kit includes Topcon s Legacy E receiver with PG A1 antenna and external radio modem or a HiPer brand receiver tribrach cables and a hard carrying case The type of options on the Base Station kit can be customized based on individual needs some kits support GPS positioning with RTK measurement and others support normal GPS positioning with RTK measurement If used with a portable foundation like a tripod daily setup and daily height measurements are required Le
22. 20 Max Vertical RMS 0 30 Max GPS errors point measurement Max Horizontal RMS 0 10 Max Vertical RMS 0 20 Back Next Cancel Figure 3 47 Enter GPS Precisions 5 Select the following radio information and press Next Figure 3 48 e Radio type use the same radio type used in the Base setup e Connected to the serial port the radio is connected to usually Serial Port B e Baud rate usually 38400 e Format use the same format used in the Base setup usually CMR Radio type Internal Spread Spectrum Connected to Serial Port B Baud rate 38400 Format ICMR Back Next Cancel Figure 3 48 Enter Antenna Information 6 For mmGPS configurations select the following information Figure 3 49 on page 3 50 Then press Next e GPS port select the port used for GPS communication between receiver and sensor typically port C P N 7010 0781 3 49 Setting up the Machine and 3DMC e Sensitivity select the sensitivity level for detecting the transmitter usually Auto Select a different setting when working at very short or very long distances or during inclement weather that can affect laser detection e Channels select the channel to scan for mmGPS connection The All selection allows the sensor to independently select the transmitter with the closest proximity to the receiver If the PZL is not being used in the current setup it should be deactivat
23. 3 25 contours at intervals 3 25 linework 3 41 3 51 points 3 42 polylines 3 51 triangle mesh 3 25 Display Options 3 71 Dozer cross slope 5 15 mmGPS Paver 3D Reference Manual Edit files 3 10 Editing a Plane Surface File 3 27 EIM 1 12 LED blink indications 1 13 Elevation adjust for 3D 3 78 adjust in 2D 3 79 3 89 3 90 key 3 76 Elevation reference 3 74 Elevation reference point 3 30 Equipment Setup machine components 5 6 Equipment Setup and Calibration 5 3 PZL 1 transmitter 2 12 5 3 F FC 100 1 6 Files 3 13 copy 3 10 delete 3 11 design surface 3 24 edit 3 10 new 3 10 G GPS coordinates 3 17 GPS information 3 82 3 85 planning 3 85 screed edge position 3 83 status 3 83 GPS Localization 3 19 5 18 GPS mask angle 3 84 GPS status mask angle 3 84 receiver ID 3 84 satellites 3 84 Grade adjustment knob operation 3 4 Grade indicator 3 67 3 69 3 75 and elevation reference 3 74 and offset change 3 73 change 3 73 change extents 3 75 P N 7010 0781 Index change on grade 3 75 cut fill 3 73 display 3 68 purpose 3 73 Grade indicators 3 3 Head of material force M 4 5 J Joystick operation 3 81 K Keyboard connect using USB 3 7 pop up 3 11 L Laser height 5 24 location advice 5 24 Laser control above grade 5 30 below grade 5 31 on grade 5 30 receiver 5 30 transmitter 5 30 LEDs 1 14 2 8 2 10 on MC 2 5 1 11 Light bar 3 71 and alignment file 3 71 display 3 14 3 69 steer to polyline 3
24. 3D Paver Reference Manual 3DMC Delete Removes an existing file or element from the internal memory To delete a file or select it and press the Delete key Once you delete a file it no longer exists The file must be created from the beginning Next Displays the next step or dialog box during an operation after all applicable settings have been entered Back Displays the previous step or dialog box during an operation Ok Applies settings and inputs and exits the dialog box and or operation or used to change files or apply settings in sub screens Cancel Cancels or pauses an operation without applying changes or edits vues figration st PDL UHF B New Edit Copy Delete Ok Cancel Back Next Cancel Dialog Box Buttons Figure 3 7 Example Dialog Box Buttons When entering text or numbers one of the following two pop up keyboards display Figure 3 8 on page 3 12 e Alphanumeric keyboard for entering letters and numbers e Numeric keyboard for entering numbers File and point names can be up to 32 characters long point descriptions up to 64 characters long When you press Ok on the keyboard entered information becomes valid and the keyboard leaves the screen P N 7010 0781 3 11 Setting up the Machine and 3DMC Backspace Negative Sign lt s Alphanumeric Keyboard 1 2 3 4 5 6 7 8 9 0 Q wie R Tl y ul iol a
25. 85 Use Numeric Keyboard to Change Offset 4 Press Ok to set the new offset value and return to the 3DMC Main Screen 3 80 mmGPS 3D Paver Reference Manual Elevation Control Key Adjusting Valve Gain A Valve Gain adjustment allows the operator to speed up or slow down the response of the hydraulic valves and can be adjusted on the fly while in Automatic Control e If the screed seems to be moving too slow and the Grade Indicators take too long to reach on grade increase the gain value to cause the hydraulics to respond faster e If the screed is moving too fast and the Grade Indicators run past on grade decrease the gain value to cause the hydraulics to respond slower To change the valve gain first change the elevation valve gain then change the slope gain 1 On the 3DMC Main Screen press the Elevation Control key 2 Press the Elevation valve gain Set key changing it to red Figure 3 86 Elevation left edge 56 277 Elevation right edge 56 178 E i i S Set Elevation set point 0 0U0 Set Match Zero GPS info Ok Cancel Figure 3 86 Press Elevation Control Key then Set 3 Change the offset using the numerical keyboard the buttons on the joystick or the up down arrows next to the entry field e Press the Elevation valve gain entry box enter a new offset value on the numeric keyboard and press Ok Figure 3 87 on page 3 82 A negative value is a Cut a posit
26. Channel Figure 5 3 Enter Transmitter Channel and Control Point Data Equipment Setup Machine Components After setting up the Base Station and PZL 1 transmitter set up the following machine components C Attach the PZS MC Sensor to the GPS Vibration Pole Attach the MC 2 5 Receiver Box to the machine and connect the cables Connect the Control Box to the machine and connect the cables Accurately measure the PZS MC Sensor on the machine Set up 3DMC for the machine and jobsite OoOdda Oa Select the PZL 1 Transmitter for the jobsite 5 6 mmGPS 3D Paver Reference Manual Equipment Setup Machine Components PZS MC Setup After mounting the PZS MC receiver to the vibration pole use 3DMC to configure the receiver for the machine Figure 5 7 on page 5 11 shows the mounting and cable connections for the PZS MC receiver The PZS MC receiver has the following setup gt requirements e Face the receiver s logo and LEDs forward face the connectors towards the machine e Connect the right angle end of the serial cable to the PZS MC receiver 1 With the screed placed on level ground position the GPS vibration pole vertically 2 Attach the PZS MC receiver to the pole and position it with the LEDs facing forward Figure 5 4 on page 5 8 Tighten the hand knob 3 Connect the cables to the receiver and then to the MC 2 5 Receiver Box antenna cable to the connector on the left e serial cable
27. Control Methods In 2D control applications the Adjust elevation and Adjust slope dialog boxes can be used to change the control method to either slope or elevation To change the elevation side of the machine to slope Figure 3 86 on page 3 81 1 Press the Elevation Control key 2 Press Change to Slope to use the slope method for control 3 92 mmGPS 3D Paver Reference Manual Chapter 4 Paving Principles This chapter describes the components of pavers and the basics in paving principles Paver Components Modern pavers Figure 4 1 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 Aor eo eae et Tractor 1 m Tow Point Screed Pivot Point Screed Figure 4 1 Paver Components P N 7010 0781 4 1 Paving Principles 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
28. Rover System and Pocket 3D Then entering this information into 3DMC See Localizing with Pocket 3D on page 2 24 for this procedure e Entering global GPS coordinates directly into 3DMC See Entering Localized GPS Coordinates below for this procedure Entering Localized GPS Coordinates GPS localization is processed in the control point file created prior to beginning each project This control point file contains the formula necessary for the mathematical conversion between global GPS coordinates and NEZ coordinates The control point file can be localized by entering global GPS coordinates directly into the 9168 control box One of the following sources can measure points and provide coordinates e Each control point is measured with a Topcon GPS or GPS RTK Survey Rover System and Pocket 3D e A third party source provides GPS coordinates If the control point file in 3DMC needs to be updated with localized coordinates the operator can enter global GPS coordinates directly into the 9168 control box The control box then processes the localization as the operator sits in the cab Because this method deals with control point files see Creating a Control Point File on page 3 15 for further information 1 Power on the control box and allow the 3DMC application program start up Have the measurements for each Control Point available 5 20 mmGPS 3D Paver Reference Manual GPS Localization 2 Press Topcon
29. Sensing equipment used on paving machines to set and maintain proper elevations and percent slope The mmGPS 3D Paver system provides paver operators with automatic grade and slope control B Bail A wire frame added to the Tracker that acts as a fixed target to compensate for rapid air temperature changes P N 7010 0781 E 1 Glossary 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 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 Conveyor The assembly used to move paving material from the hopper to the auger Cross Slope The angle of slope required to produce a selected 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 two different slopes that is between lanes or between lanes and shoulders D Density Compactness of paving material Elevation The vertical height or depth of the surface being laid Elevation is measured in centimeters inches or feet E 2 mmGPS 3D Paver Reference Manual Glossary G Grade The base surface road bed over which paving is being laid The elevation of a fresh mat in relation to the
30. The Measuring dialog box displays during the measurement When done the Pts in calculation field increments by one Move to the next point and repeats step 7 and 8 Continue until at least three points evenly located around the transmitter have been measured To clear the measurements and begin again press Reset After three points have been successfully measured horizontal and vertical errors for the measured point displays Further measurements should improve the positional error 10 Press OK when done Checking the Transmitter s Height 1 3 Set up the transmitter and tripod at a known control point Power on the transmitter and select a channel to transmit on Set up the PZS 1 sensor over a known point Power on the sensor and receiver Connect the sensor and Pocket 3D controller Use a bi pole to ensure the sensor remains steady throughout the calibration process In Pocket 3D tap Setup gt mmGPS transmitters 2 30 mmGPS 3D Paver Reference Manual mmGPS Operations with Pocket 3D 4 On the Channel tab press Edit Channel 5 Press Benchmark check Figure 2 30 6 On the transmitter height dialog box select one of the following and press Start to measure Figure 2 30 During the measurement the Measuring dialog box displays e If the transmitter is set up over a known control point tap the first radio button then select the control point from the drop down list e If the transmitter is set
31. When changing the depth of the mat being laid the speed of turning the Grade Adjustment knob determines the smoothness of the transition from one depth to another Slope Control Key The Slope Control Key displays the design reference cross slope and indicates sensor status with graphics messages and colors Figure 3 97 on page 3 89 While paving the design cross slope continuously changes according to the design surface e Design Cross Slope displays the current cross slope In mmGPS this number is based on the design reference surface in 2D the operator enters the number e Type of Control Application displays either mmGPS or 2D for the current control application e Color of Slope Key the background color of the Slope Control Key indicates sensor status Green indicates sensor status suitable for paving Red indicates an error status and Automatic Control is disabled 3 88 mmGPS 3D Paver Reference Manual Slope Control Key Type of Control Application Angle of Blade Design Cross Slope Figure 3 97 Slope Control Key Adjust Slope in mmGPS Control To display the following slope settings for mmGPS applications Figure 3 98 on page 3 90 press the Slope Control Key e Blade slope the current percentage of slope for the slope sensor e Mainfall slope only for graders the current degree of rotation for the rotation sensor Slope gain displays the current valve
32. Window Display Menu Selections Selecting the option adds the indicated view as a window at the right side of the main window Figure 3 71 on page 3 69 3 68 mmGPS 3D Paver Reference Manual View Menu The Grade indicator view acts as an infinitely scrolling grade tape displaying the amount of cut or fill in regards to the design surface For details on the Grade indicator pop up menu see Changing the Grade Indicator on page 3 73 Figure 3 71 Right Window View ES The selected Right window view remains visible Noze when showing Left Lower window views Lower Window Display options for the lower window include a Profile view a Section view a Cut fill history view for mmGPS applications and a Light bar To access the lower window view press Topcon Logo gt View gt Lower window Figure 3 72 on page 3 70 then tap the view you want a check mark indicates the active view None indicates no lower window is active P N 7010 0781 3 69 Setting up the Machine and 3DMC Main window Left window Right window vNone Lower window Profile Display options Section About 3DMC Cut fill history Light bar Figure 3 72 Lower Window Menu Selections incl mmGPS Selecting one of the options adds the view as a small window above the elevation and slope control keys Figure 3 73 on page 3 71 The Profile view displays a side view of the machine where the right side of the screen is
33. always the forward direction of machine travel The buttons increase and decrease magnification for this Lower window view The Section view displays a cross section view of the screed and the selected Design Surface where the right side of the view is the right side of the screed The cut fill readings are provided on both sides of the screed and represent how far the screed is from on grade The buttons increase and decrease magnification for this Lower window view The Cut fill history view for mmGPS applications displays the on going highs and lows of the project as determined by both laser and GPS readings The red line indicates mmGPS detection the blue line indicates GPS only detection In the example below the background color of the main screen was changed to better display the cut fill history 3 70 mmGPS 3D Paver Reference Manual View Menu The Light bar is used for steering indication where the green zone indicates on grade For details on the Light Bar pop up menu see Changing the Light Bar Scale on page 3 75 gt 12 290 10 77 364 0 000 20 000 10 000 Figure 3 73 Lower Window Views Display Options To set the type of units used in the job press Topcon Logo gt View gt Display options gt Display units to display the Display Units dialog box Figure 3 74 on page 3 72 Using this dialog box change the type of units displayed on the screen or update preset un
34. any improvement If it is still suspect and affects the acceptable tolerance the horizontal and or vertical localization for this point may be disabled Solutions These check boxes need to be selected for a minimum of three points Note that the error value is calculated once three Control Points are measured and used for the GPS localization This troubleshooting is useful when the Pocket 3D is being used to perform GPS localization as well as the control box mmGPS 3D Paver Reference Manual 9168 Control Box 9168 Control Box This section lists possible 9168 control box problems you may encounter If you still have problems after trying the solutions listed here contact TPS customer support Problem Causes The cable is the wrong cable incorrectly connected or damaged Problem Causes The fan may be damaged causing the control box to overheat Control box does not power on Screen display turns off by itself Solutions Check that the power cable supplies 12 to 24 VDC and is negative conductive e A socket positive 12 to 24 VDC e E socket Ground Check that the power cable is connected to the correct port Connectors on page 3 8 and see that the ends are securely fastened If the cable is damaged contact your dealer to purchase a new cable Solutions Check that the fan is rotating If the fan is not rotating it may be damaged and needs to be replaced with
35. as close as 14 inches and as far as 55 inches from the grade reference consider the job application for the best set up For example when tracking multiple references using elevated string on one pass then matching 6 4 mmGPS 3D Paver Reference Manual Using Sonic Control at the Jobsite ground on the next pass consider the Tracker position so it works for both applications without having to move the Tracker Figure 6 4 Position L Bar and Tracker Over Grade Reference Step 2 Set up 9168 Control Box After attaching the control box to the machine and connecting cable configure 3DMC for paving with the Sonic Tracker In 2D control applications only the machine configuration file is relevant Other files settings and selections have no affect in this mode The machine configuration file provides vital information about the type of machine selected All other sensor settings and measurements are ignored You must have a machine configuration file before beginning to pave 1 Use the hand knob to attach the control box to the machine Figure 6 5 on page 6 6 2 Connect the various electrical cables Figure 6 5 on page 6 6 Cable connections differ depending on the machine type P N 7010 0781 6 5 2D Paving Applications Power Cable to Junction Box Communication Cable to Junction Box Cable to MC 2 5 Receiver Figure 6 5 Attach 9168 Control Box to Machine and Attach Component Cables 3 Turn on the control
36. attaches to an even and smooth surface 1 14 mmGPS 3D Paver Reference Manual Machine Components Figure 1 15 Machine Radio Antenna Setup Simple Auto Manual Knob The Simple Auto Manual Knob Figure 1 16 mounts on the control lever for easy access and allows the operator to switch between Automatic and Manual control e Automatic Control Flip the switch forward to activate this control mode e Manual Control Flip the switch backwards to activate this control mode Flip Lever Forward for Auto Flip Lever Backward for Manual Figure 1 16 Simple Auto Manual Knob The knob is normally placed just below the control box for easy access allowing the operator s hands to stay near the thickness cranks and screed controls In 2D control applications the 9168 control box supports sonic and laser control applications P N 7010 0781 1 15 Introduction Sonic Tracker II The Sonic Tracker II Figure 1 17 measures and controls the elevations of the screed and should be removed at the end of each day for proper storage in the carrying case The Sonic Tracker contains no manual adjustments and may require periodic maintenance of the transducer The Sonic Tracker measures distance controlling grade from a physical grade reference such as a curb stringline or existing road surface A transducer located in the bottom of the Tracker generates sound pulses like a speaker and listens for retu
37. base The incline of a paving surface in the direction of travel expressed by stating the rise or fall as a percentage of horizontal distance that is 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 H 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 motion under pressure the flow of which causes work to be accomplished L LCD Liquid Crystal Display LCD is used in the display window on the 9168 Control Box and Sonic Tracker II to show numbers and symbols for mmGPS 3D Paver functions LED Light Emitting Diodes These are the red lights seen on the faces of the PZS MC Sensor the PZL 1 Laser Transmitter the 9168 Control Box the Sonic Tracker II and the Laser Tracker P N 7010 0781 E 3 Glossary Mat The material being placed by a paver finisher O On Grade When a surface is at the selected elevation or slope it is referred to as being on grade Overlay Paving over an existing mat Percent Slope The unit of measure used for cross slope S Screed The assembly behind the tractor The screed strikes off smooths and compacts the paving material into a semi finished mat Slope The incline of a paving s
38. but should be updated if updating the options for other application functions 1 To view information about 3DMC press Topcon Logo gt View gt About 3DMC The about 3DMC dialog box displays version number copyright date and publisher and registered user Figure 3 94 To view the enabled options press Options on the about 3DMC dialog box Figure 3 94 To modify 3DMC options press Modify on the Options dialog box Figure 3 94 G 3DMC 6 11 Control firmware 0 Options OS date Single tow scraper No gt Generic machine No Copyright C 2002 2006 Excavator dual gps No Topcon Positioning Syste Asphalt paver Yes Registered to JON DOE GPS Topcon RTK Yes LPS GRT2000 controlled No LaserZone millimeter GPS Yes Automatic blade control Yes options Sensor inputs Yes Modify ok Figure 3 94 About 3DMC and 9168 Control Box Options for 3DMC From the ControlBox dialog box record the Device identification number to give to your Topcon representative Contact your Topcon representative to obtain new authorization codes for the selected applications When you have received the new authorization codes enter the codes in the ControlBox dialog box using the alpha numeric keyboard Figure 3 95 on page 3 87 3 86 mmGPS 3D Paver Reference Manual Viewing and Updating 3DMC Options 6 Press Ok to apply the new codes and options Press Ok on each screen to return to the Main Screen
39. corrections to the 9168 control box es Dummy connectors are Sold Separately They do NOTE not come in the Kit 1 6 mmGPS 3D Paver Reference Manual Machine Components 0 Figure 1 7 PZS MC Machine Control mmGPS Sensor GPS Vibration Pole The GPS vibration pole Figure 1 8 installs on the machine sliding onto the pivot post attached to the tow arm The GPS vibration pole provides a lightweight fixed mount for the PZS MC and utilizes shock isolation and vibration dampening Figure 1 8 GPS Vibration Pole Slope Sensor The slope sensor Figure 1 9 on page 1 8 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 P N 7010 0781 1 7 Introduction The slope sensor connects to the control box through an electrical cable and requires no adjustments and 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 0 0 COo G T sioe mo E 2 0 SLOPE oo E CONTROL BOX LCD DISPLAY 2 0 SLOPE Figure 1 9 Slope Sensor mmGPS 3D Paver Junction Box The junction box Figure 1 10 on page 1 9 allows the various components and hydraulics to be linked together for accurate paving The junction box and assoc
40. current surface allows you to more accurately display current screed information on the screen For example if you want to lower a finish grade design surface to 6 below the current surface lower the surface in 3DMC so that the cut fill reference is from O zero rather than from 6 negative six 1 Press Topcon Logo gt File Surfaces gt Working or Reference and press New Enter and select the following information for the new surface file Press Next Figure 3 32 on page 3 36 e Configuration name enter a name for the file e Surface type select Raise lower existing surface P N 7010 0781 3 39 Setting up the Machine and 3DMC Configuration nary NewSurface_1 Surface type Flat plane surface r Sloping plane surface New Copy Raise lower existing Xurface Subgrade of existing road Next Cancel Figure 3 32 Create New Surface File 2 Select the surface to use as the reference from which to raise or lower the new surface Figure 3 33 on page 3 37 3 Enter an elevation adjustment Press Next Figure 3 33 on page 3 37 e A positive number raises the subgrade in comparison to the working reference surface This value is applied to the centerline of the working reference surface e A negative number lowers the subgrade in comparison to the working reference surface This value is applied to the centerline of the working reference surface 3 36 mmGP
41. file check that the machine and equipment in the file match the physical machine and equipment setup for the jobsite Use the Edit button on the Machine files dialog box to view the selected configuration s setup screens and parameters 1 On the 3DMC main screen press Topcon Logo gt Control gt Machine setup 2 Select the machine file and press Ok Figure 3 44 PAVER SONIC EIO Figure 3 44 Applying a Machine Configuration 3 46 mmGPS 3D Paver Reference Manual Control Menu Creating a Machine Configuration 1 When the main screen displays press Topcon Logo gt Control gt Machine setup 2 Press New and enter or select the following information Figure 3 45 Then press Next e Configuration name enter a name for the machine Include the application and or sensor type in the machine name to easily identify the configuration e Machine type select the type of machine Asphalt paver e Sensor select the type of sensor attached to the machine GPS antenna e Location select the sensor s location on the machine right or left side e Units of measure select the unit of measure used to take machine measurements meters feet inches centimeters feet inches Configuration name PAVER MMGPS Machine type Asphalt Paver Sensor type GPS antenna F New Edit Copy Den ok Units of measure Feet gt Next Er F
42. grade such as with laser beam bounce on windy days a gt Averaging does not affect slope control 3 56 mmGPS 3D Paver Reference Manual Control Menu Valve Offsets The valve offset calibration determines the minimum electrical signal required to begin moving the machine s hydraulic cylinder to return the screed to on grade Valve offsets simply determines the electrical requirement valve gain determines the speed of the cylinder The system requires four valve offsets which must be individually calibrated upon initial setup or after hydraulic maintenance If valve offsets are set too low the screed will not reach on grade Likewise if the valve offsets are set too high the screed moves too far and overshoots on grade Factory preset for valve offsets 0 elevation and slope valve gains If valve offset is altered valve gain adjustments need to be performed again Perform valve offset calibrations before adjusting perform valve offset calibrations and valve gain When using the control box on different machines adjustments for each machine 1 Raise the screed so that both sides rest a few inches above the ground 2 At the control box tap Topcon Logo gt Control gt Valve offsets Since the screed is about to move automatically HANDS and FEET should be clear of the screed 3 Press the Raise left Set button to enable the entry box and calibrate the left valve offset value Figure 3 56 on p
43. lines Show station labels Station interval 100 000 Ok Cancel Figure 3 37 Alignment Display Options This dialog box has the following selections for displaying information on the main screen e Alignment centerline color sets the color of the centerline e Alignment feature line color sets the color for feature lines 3 40 mmGPS 3D Paver Reference Manual GPS Localization e Show regular station lines displays graphical cross lines relative to the horizontal alignments on the main screen Press the Station interval entry box to specify the longitudinal interval between lines e Show station labels displays station labels for each station on the Main Screen Linework Display Options When using a Linework file press Topcon Logo gt View gt Display options gt Linework to display the Linework layers dialog box Figure 3 38 Show StakeoutOffset StakeoutOffset StakeoutOffset Show Cancel Figure 3 38 Linework Layers Linework files contains layers composed of a group of lines each identified with a color All layers are listed in the Linework layers dialog box 1 To display layers on the Main Screen select the layer and press Show Yes displays in the Show column Press Show again to not display the layer on the Main Screen No displays in the Show column P N 7010 0781 3 41 Setting up the Machine and 3DMC 2 Press OK to re
44. 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 P N 7010 0781 4 9 Paving Principles are all areas that the material may encounter 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 T The areas listed above where segregation can occur 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 irregularities indicate that the homogeneous characteristics of the material in the mat have been interrupted which usually results in bumpine
45. new one Contact your dealer Contact your dealer for information on replacing the fan P N 7010 0781 7 9 Troubleshooting Problem Causes The fan may not be rotating Screen display goes dim by itself Solutions Check that the fan is rotating If the fan is not rotating it may be damaged and needs to be replaced with new one Contact your dealer for information on replacing the fan The control box has the self adjusting ability of screen brightness Problem Causes Exit 3DMC function may have been pressed unexpectedly or incorrectly Brightness may be reduced when the control box gets over heated with high temperature around the cab as well as when the ambient light becomes dim The backlight also reduces when the ambient light becomes dim Screen has transferred to operating system Solutions If the screen displays the desktop the My Computer folder should be visible 1 Double tap My Computer folder 2 Look for the folder named Disk C and double tap on it 3 Look for the Control Box icon and double tap on it The application program opens and returns to the Main Screen 7 10 mmGPS 3D Paver Reference Manual 9168 Control Box Problem Control file has no GPS localization message Causes Not enough Control Points used for localization Solutions Press the Ok pad to exit the message screen Chec
46. process Point on surface Grid interval N 8523 585 50 000 E 10995 233 Zz 59 669 gt measure pt Back Next Cancel Figure 3 25 Measure Elevation Reference Point and Enter Grid Interval Creating a Sloping Plane Surface The sloping plane surface model is composed of four basic factors e a mainfall orientation e amainfall grade e acrossfall grade and e areference elevation point on the plane Just like aligning the rotating laser plane and adjusting the laser receiver height the operator needs to be prepared with a set of 30 mmGPS 3D Paver Reference Manual GPS Localization relative information to fulfill the four factors This information is composed of three points A B and an elevation reference point Figure 3 26 illustrates the basic factors needed for a sloping plane surface model The following is the most common method using three reference points prepared at the site two points A and B are measured to determine a Mainfall orientation and the other point elevation reference point is measured to determine an elevation 0 tig Doing Mainfall lt Peas Orientation se Elevation Reference Point oo a Grade Ss A K Na Grade pee Crossfall lt A 0 Orientation Figure 3 26 Sloping Plane Surface Diagram 3DMC accurately measures the point directly below the sensor but does not compensate for a slant error of the sensor mast Therefore
47. section of the reference surface Maximum extension only active if at least one side has Continue selected in the Extend slope entry box 6 Press Next Figure 3 35 sangre ot extn rog Road 6220 A12 Grade Work Elevation adjustment 3 281 Q gt crade s Left side Right side Manual 10 000 10 000 Copy from OC Extend slope Vertical Vertical _ Maximum extension gi am __1 eam j Next Figure 3 35 Select Grade and Slope Extension Parameters 7 Press Finish to save the new surface file and end the process On the section view the new road has the same centerline as the reference surface The new cross section consists of grade elements with the same user defined grade value Figure 3 36 on page 3 40 as the subgrade If the cross section of the new subgrade intersects those of the reference grade the subgrade shows a new feature line Dotted lines in the section window indicates surface information outside of the last feature line P N 7010 0781 3 39 Setting up the Machine and 3DMC gt 1 721 0 002 682 0 516 daaa 9 000 Figure 3 36 New Road Subgrade Alignment Display Options When using either a road surface model or an alignment file press Topcon Logo gt View gt Display options gt Alignment to display the Alignment dialog box Figure 3 37 Alignment centerline color Alignment feature line color Color Show regular station
48. the paver 2 Make sure that the trucks arrive at the same order in which they were loaded at the asphalt plant 3 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 the material is loaded into the trucks or during the 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 machine waviness in the mat is the result T Temperature problems may occur before the time P N 7010 0781 4 11 Paving Principles 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 4 13 The weight of the screed is measured in pounds per square inch Weight of Screed Force W Figure 4 13 Weight of Screed Members of the paving crew climbing on and off the screed also has some affect on the weight of screed force The primary factor affecting this force is changing the width of the screed Figure 4 14 Extendible screeds weigh the same whether they are fully retracted or fully 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
49. the Base station make sure you select the correct point from the control points file and verify the point has a northing easting and elevation coordinate The more accurate these coordinates are the tighter the control while paving Use the following checklist for quick setup of the Base Station C Select a control point and install the Base station over it Measure the antenna height Connect all Base Station components and cables 0o00 Select the correct radio settings Refer to your Base Station s documentation for specific radio configuration procedures The Base and Machine must use the same radio settings C Initialize the Base station Once you have set up the Base Station simple checks at the machine ensure the machine receives corrections from the Base station if the elevation control key is green the Base Station is ready See Setting up the Jobsite and Pocket 3D on page 2 1 for more information on using Pocket 3D to set up the jobsite using for mmGPS 3D Paver 5 2 mmGPS 3D Paver Reference Manual Equipment Setup and Calibration PZL 1Transmitter Equipment Setup and Calibration PZL 1 Transmitter For machine control applications the PZL 1 transmitter attaches to either a standard tripod or a fixed 2m tripod over a surveyed point To locate the transmitter over an unknown point see Performing a Resection on page 2 28 The following setup requires Pocket 3D to activate and initialize the trans
50. the cable is damaged contact your dealer to purchase a new cable The antenna has poor PDOP Check that the Machine GPS antenna has a clear view of the sky The receiver is collecting an almanac Problem Causes The Base Station and or Base Station radio has a problem Radio Status indicator does not flash yellow If this is the first time connecting to the MC 2 5 Receiver Box no LED flashing may persist for several minutes while the MC 2 5 Receiver Box obtains a new almanac Solutions Check that the Base Station is running correctly and the TX light on the radio modem flashes on P N 7010 0781 7 5 Troubleshooting Different channels are used between the Base Station and the Rover machine Check that the Base Station and Machine use the same radio channel e For the Base Station use the button on the radio modem See Base Station Initialization on page 2 9 e For the machine use the control box function See Configure Radios on page 3 63 The radio antenna at the Rover or Base may be too low incorrectly placed or too far away If the yellow LED flashes when near the Base Station but not when farther away check that the Rover radio antenna mast is mounted vertically at the highest point on the machine If the Rover machine gets too far from the Base Station elevate the radio antenna at the Base Station or move it to a closer Cont
51. time This software is required for some mmGPS operations Using Pocket 3D on a portable hand held controller you can e Set up the Base Station the mmGPS Transmitter and the mmGPS Rover e Create and edit Control Point files and Design Surface files e Create and edit Machine Configuration files and radio configuration files e Create and edit Point files and Linework files e Import and export files e Perform stakeouts and grade checks e Perform topographic surveys When enabled for mmGPS Pocket 3D has the following added functionality e Set up machine files for mmGPS equipment e Set up the PZS 1 sensor e Check the height of the transmitter e View a history of surface activity To enable Pocket 3D for mmGPS contact your local Topcon representative to obtain the upgrade P N 7010 0781 1 5 Introduction A TOPCON Figure 1 6 Pocket 3D Main Screen on the FC 100 Machine Components Regardless of the application the machine requires the following components PZS MC Sensor The PZS MC sensor Figure 1 7 on page 1 7 replaces the machine mounted GPS antenna The PZS MC sensor combines the MC A1 GPS antenna with laser sensor technology into a total package LazerZone technology allows the sensor to detect up to four different PZL 1 laser transmitters for increased range The sensor attaches to a GPS vibration pole on the machine blade and cables connect the receiver to the MC 2 5 Receiver Box for sending
52. to the connector on the right P N 7010 0781 5 7 Getting Started r a FORWARD Level GPS Vibration Pole Figure 5 4 Level the GPS Vibration Pole and Attach the PZS MC Sensor 5 8 mmGPS 3D Paver Reference Manual Equipment Setup Machine Components Screed and Antenna Measurements Take the following measurements for the antenna and machine record these measurements for entering into 3DMC Figure 5 5 e Above 1 enter the vertical distance from the metal rim of the antenna to the bottom edge of the screed when elevated to the proper mat thickness e Inside 2 enter the horizontal distance from the metal rim of the antenna to the outer edge of the screed e Behind 3 enter the horizontal distance from the metal rim of the antenna to the back edge of the screed e Width 4 enter the horizontal distance from the left edge to the right edge of the screed Width Inside Edge of Screed Figure 5 5 Measure Antenna Placement on Screed Incorrect measurements or data entry errors have a direct affect on paving accuracy Take each measurement twice to ensure accuracy P N 7010 0781 5 9 Getting Started Radio Antenna Installation The radio antenna is attached on the machine using a magnetic mount and generally stays on the machine The antenna should be po
53. up on a unique channel The channel button on the transmitter determines the channel that the transmitter broadcasts on Transmitters Channel Adjusted ABC Serial Cable on COM1 v Add Eelete fx Calibration ownioad Figure 2 8 Load Transmitters into Pocket 3D 7 To enter transmitter setup information tap the Channel tab and select the connected transmitter then press Edit Channel Set the following parameters and tap Ok Figure 2 9 on page 2 15 e Transmitter select the ID of the transmitter e Control Point select the control point over which the transmitter is set up e TX height enter the height of the transmitter 9 14 mmGPS 3D Paver Reference Manual Equipment Setup GPS e Measured to select where on the transmitter Base or Mark Slant the height was measured 8 If needed repeat steps 6 and 7 for up to three other transmitters 9 Press OK when done Channel 1 Transmitter TXV3 lt none gt Control point lt none gt PP6 v lt gt ies TX height 6 800 Measured to Mark Slant Benchmark check Edit Channel Figure 2 9 Enter Transmitter Channel and Control Point Data Equipment Setup GPS Equipment setup consists of jobsite files to ensure correct data is used for positioning activities and a machine file to ensure the correct measurements are taken Step 1 Create a Control Point File First create a control point file F
54. 0 0781 2 27 Setting up the Jobsite and Pocket 3D For information on collecting points creating polylines or measuring a control point refer to the Pocket 3D Reference Manual or the Pocket 3D User s Manual mmGPS Operations with Pocket 3D Pocket 3D software although optional is required for some operations Pocket 3D runs on a hand held controller such as Topcon s FC 100 Performing a Resection The resection function measures an unknown transmitter location using the rover and three or more points In general the results from a resection are adequate for horizontal positioning of the transmitter an error estimate also displays Performing a height check and adjustment fine tunes the calculated elevation When performing a resection use the following guidelines to ensure accurate measurements at the Rover points e take measurements at three or more points around the Base transmitter in a balanced symmetrical pattern not clustered in one area e have the sensor facing towards the transmitter during each measurement e angle the sensor between 6 higher or lower than the transmitter s beam not straight on 1 Set up the transmitter at an unknown location Power on the transmitter and select a channel to transmit on 2 Setup the PZS 1 sensor Power on the sensor and receiver Connect the sensor and Pocket 3D controller Use a bi pole to ensure the sensor remains steady throughout the calibration process
55. 0781 Setting up the Jobsite and Pocket 3D 8 Follow the on screen instructions pressing Next to measure Figure 2 35 If indicated check the setup listed on screen Turn right face of mmGPS Turn back face of mmGPS Turn left face of mmGPS transmitter to receiver transmitter to receiver transmitter to receiver Angle Angle Time to go Time to go Figure 2 35 Transmitter Adjustment Process When the adjustment completes the Adjustment dialog box displays the offsets Figure 2 36 on page 2 35 e If both Axis measurements are less than 10 no adjustment is needed at the transmitter e If either or both Axis measurements are more than 10 disconnect from the sensor and connect to the transmitter Press Finish to upload the adjustments to the transmitter When finished uploading the transmitter applies the adjustments and turn off 2 34 mmGPS 3D Paver Reference Manual mmGPS Operations with Pocket 3D J Topcon Pocket 3D M 1 46 Adjustment Axis 1 0200 5 Axis 2 0 00 18 Back Finish Cancel Figure 2 36 Adjustment Results the transmitter re calibrate to check the system The transmitter may need to be calibrated a couple of times depending on site conditions l After loading the new self leveling offset data into Note that this process only applies an offset to the self leveling mechanism to ensure correct grade the control point file is not affected P N 7010
56. 0781 2 39 Setting up the Jobsite and Pocket 3D Notes 2 36 mmGPS 3D Paver Reference Manual Chapter 3 Setting up the Machine and 3DIMC The components of the mmGPS 3D Paver provide real time elevation and slope information to the 9168 control box The control box then takes this information and applies various algorithms to calculate and display accurate current surface information This chapter introduces the various features and general functions of components that the operator uses including the following e The features of the 9168 control box and how they operate The functions of the 3DMC software and how to use it conditions the system s components control box transmitter receiver tracker and cables must be thoroughly dried BEFORE placing them in the carrying case at the end of the day When operating in rainy weather or in wet Any moisture in the carrying case causes condensation on the inside of the components which may severely affect accurate operation during the next paving application P N 7010 0781 3 1 Setting up the Machine and 3DMC 9168 Control Box Buttons and Features The control box is the operator s interface to mmGPS 3D Paver receiving signals from the sensors and using these signals to determine if grade or slope corrections are necessary If the machine requires a change in elevation or slope
57. 0781 3 33 Setting up the Machine and 3DMC 7 Move the machine to the elevation reference point The measurement of this point brings the entire plane up or down to intersect the plane and determine its relative elevation Substitute point A or point B for the elevation reference point If you have the NEZ coordinates for the elevation reference point press the corresponding entry box and type in the information qi 8 When the antenna rests over the point press Measure pt to measure the elevation reference point Figure 3 30 The Measuring dialog box briefly displays 9 Enter a grid interval and crossfall for the main screen Press Next Figure 3 30 Point on surface Main fall A gt B N 2064431 76 Direction 315 37 54 E 6178673 67 Grade 1 697 2 423 21 AIIE gt Measure pt Si Grid interval Crossfall Qp 20 00 Grade 1 500 ir Dmca Sash gt Next Cancel Figure 3 30 Measure Elevation Reference Point and Enter Grid Interval 10 Review the created surface plane Figure 3 31 on page 3 35 If needed press Back to change parameters or measurements for the surface Press Next 11 Press Finish to save the new surface file and end the process 3 34 mmGPS 3D Paver Reference Manual GPS Localization Back Next 4 OD Figure 3 31 Surface Review Raising or Lowering the Existing Surface Creating a surface by raising or lowering it based on the
58. 1 Getting Started Control Box Setup The 9168 control box is designed for quick attachment at the beginning of the day and quick removal at the end of the day 1 Use the hand knob to attach the control box to the machine Figure 5 8 2 Connect the various electrical cables Figure 5 8 Power Cable to Junction Box Communication Cable to Junction Box Cable to MC 2 5 Receiver Figure 5 8 Attach 9168 Control Box to Machine and Component Cables 5 12 mmGPS 3D Paver Reference Manual Equipment Setup Machine Components 3DMC Setup Once the hardware components are set up installed and connected apply 3DMC machine and job files Chapter 2 describes in more detail the items in the following checklist O O O Select the correct Machine Configuration file Topcon Logo gt Control gt Machine setup Select the Control Point file Topcon Logo gt File gt Control Select the Working and or Reference Surface files Topcon Logo gt File gt Surfaces gt Working Topcon Logo gt File gt Surfaces gt Reference As needed select the Alignment file Topcon Logo gt File gt Alignment As needed select the Linework file Topcon Logo gt File gt Linework Select the Points file Topcon Logo gt File gt Points After selecting the information to view on the Main Screen begin paving See Chapter 3 for details on the different data and screen views available P N 7010 0781 5 13 Getting St
59. 1 3 61 Setting up the Machine and 3DMC 2 Select the Point of interest either Left cutting edge Mid cutting edge or Right cutting edge and press Measure Figure 3 60 the Measuring dialog box displays during measurement Point of interest Left cutting edge _ North East Elev Cut to design surface Alignment stationing Measure cance Cancel Figure 3 60 Select Point of Interest and Press Measure 3 When finished the Position Check dialog box displays the point on the job at the selected edge of the blade Figure 3 61 Press Cancel to return to the Main Screen Point of interest Left cutting edge North 11043 1111 East 8593 878 Elev 67 543 Fill to design surface 0 000 Alignment stationing 10 77 364 Measure Cancel Figure 3 61 Position of Point of Interest 3 62 mmGPS 3D Paver Reference Manual Tools Menu Configure Radios If needed you can use 3DMC to temporarily change the radio channel of the radio modems The MC 2 5 Receiver Box stores radio settings including the radio channel The original settings from the machine configuration file are restored after turning off then back on the 9168 control box Some radio modems such as Teledesign have an NOTE automatic channel scanning feature allowing them 4 to automatically detect and connect with a Base Station 1 Press Topcon Logo gt Tools Configure radio and pre
60. 168 control box Figure B 1 Control Box Dimensions B 2 mmGPS 3D Paver Reference Manual Blade Slope Sensor Blade Slope Sensor The Blade Slope Sensor provides superior accuracy and repeatability is free adjusting and has a rugged sealed design Table B 2 lists component specification for the Blade Slope Sensor Table B 2 Blade Slope Sensor Specifications Resolutions 0 025 slope Range 9151 0 20 slope 9153 0 100 slope Supply Voltage 10 to 30 VDC Supply Current 100 mA 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 Network Topcon proprietary RS 485 network port Housing Cast aluminum Note See envelope dimensions section Connectors MIL C 5015 cylindrical connectors Gold Plated Contacts Conductive anticorrosive coating 9151 10 pin screw 9153 11 pin bayonet w dust caps Operating Temperature 0 C to 60 C P N 7010 0781 Specifications Figure B 2 shows the dimensions of the Blade Slope Sensor
61. 2 mmGPS 3D Paver Reference Manual Machine Components The color of the blink indicates that information for test is unavailable orange the receiver passed the test green or the receiver failed the test red 1 To switch to EIM press and quickly release within one second the Main FN button 2 Watch for the delimiter double blink With good receiver antenna and observation conditions all blinks should be green within 15 minutes of powering on e Green ok e Orange wait e Red some tests failed 3 To switch back to normal mode press the Main FN button Clearing the MC 2 5 Receiver Box NVRAM The receiver s Non Volatile Random Access Memory NVRAM holds data required for satellite tracking such as ephemeris data and receiver position The NVRAM also keeps the current receiver s settings such as active antenna input elevation masks and recording interval and information about the receiver s internal file system Even though clearing the NVRAM is not a common nor normally a recommended operation there are times when clearing the NVRAM can eliminate communication or tracking problems Clearing the NVRAM can be interpreted as a soft boot of your computer After clearing the NVRAM your MC 2 5 Receiver Box requires some time to collect new ephemerides and almanacs around 15 minutes Clearing the NVRAM of the MC 2 5 Receiver Box resets the box to factory default values In addition the NV
62. 24 Paving Principles amp Control Methods 4 1 PDL radio 1 10 placement 5 24 Placing Transmitters at the Jobsite 5 24 Plane surface edit 3 27 see Design surface Planing angle 4 2 Pocket 3D 1 5 1 6 units 2 1 mmGPS Paver 3D Reference Manual Points display 3 43 Polylines steer to 3 51 Position check 3 61 purpose 3 61 power switch 3 8 PZL 1 Transmitter setup in 3DMC 3 54 5 14 PZL 1 transmitter information copying 3 55 PZS MC sensor Change settings 3 53 Radio antenna installation 1 14 5 10 base station 2 2 5 2 change channel 3 63 connection tip 3 64 LED 2 10 licensing A 3 PDL 1 10 select channel 2 8 signal 1 11 Teledesign 1 10 usage A 3 Range C 1 Reaction of material under screed 4 8 Reaction of material force R 4 5 4 8 Receiver mask angle 3 84 reset 3 84 Receiver ID GPS 3 84 Reference elevation 3 76 Regulatory information Canadian Emission Labeling Requirements C 3 FCC rules C 2 UHF Radio Usage C 1 WEEE Directive C 4 Resection function of 2 28 measurement parameters 2 29 P N 7010 0781 Index performing 2 28 Reset receiver 3 84 Right window 3 68 See also Views S Satellites 3 85 Satellites GPS 3 84 Screed and angle of attack 4 2 measure slope of 5 15 operation 4 2 4 5 Screed tilt measuring w slope sensor 1 7 Selecting a Control Point File 3 15 Selecting a machine configuration 3 46 Sensors calibration 5 15 Slope control 5 26 5 27 gain 3 89 3 90 key 3 88 gree
63. 3 27 Setting up the Machine and 3DMC 3 If needed change the name of the surface Press Next 6220 A 2 Grade Work Inner pf rimeter offlake New Edit Copy Figure 3 22 Editing a Plane Surface File LAGOS Configuration name ZO PAD17 SLOPING Surface type Sloping plane surface Next Cancel 4 Depending on the type of plane surface edit the following properties Press Next then press Finish to save the changes Flat Plane Surface Sloping Plane Surface Point on surface e Grid interval Point on surface Grid interval X 8792 611 1 000 Y 11003 426 Z 3 338 Measure pt Back Next Cancel Point on surface and or Mainfall direction grade Grid interval and or Crossfall Grade Point on surface Main fall A gt B X 2064431 760 Direction 315 37 00 Y 6178673 670 Grade 1 697 Z 423 210 A B Measure pt Grid interval Crossfall 20 000 Grade 1 500 Back Next Cancel Creating a Flat Plane Surface The flat plane surface model is composed of a reference elevation point through which the plane intersects The operator should be prepared with the elevation reference point to fulfill the requirements for creating the surface 3 28 mmGPS 3D Paver Reference Manual GPS Localization Figure 3 23 illustrates the factor needed for a plane surface model L Gr Figur
64. 3DMC information authorization codes and options File Menu Before beginning to work with the mmGPS 3D Paver you must have job files that contain various information needed to accurately grade the jobsite The job files you need include control point files design surface files and machine configuration files This chapter discusses how to create and access these files Control Point Files The first task when setting up the mmGPS 3D Paver on a new jobsite is to create a new Control Point file You can use either the machine to create a control point file or copy a control point file from a Pocket 3D controller For more information on Pocket 3D see Hand held Controller and Pocket 3D on page 2 1 The Control Point file consists of descriptions local site coordinates global GPS coordinates and units of measurements for each Control Point located on the site Typically the project s survey team provides Control Point information after accurately measuring these points with a surveying instrument 3 14 mmGPS 3D Paver Reference Manual File Menu Selecting a Control Point File 1 When the 3DMC main screen displays press Topcon Logo gt File gt Control 2 Select the control point file for the jobsite and press Ok Figure 3 10 cherry POINT43 SIMPSON FAMILY RANCH lt New Edit Copy Delete Ok AEs Figure 3 10 Applying a Control Point File Creating a Con
65. 4 6 17 Clear NVRAM 1 13 Components 1 2 slope sensor 1 7 Connectors 3 8 3D GPS 6 5 base station 2 7 Sonic Tracker II 6 3 Control box 3 2 9168 control box 1 9 apply new codes 3 86 authorization codes 3 86 operation 3 2 options 3 86 setup of 5 12 viewing and updating 3 86 Control menu 3 13 Control methods Sonic Tracker II 5 29 Control point accuracy 3 20 5 19 localization 3 20 3 21 5 20 location 3 20 5 19 Control point files control box 3 15 3 17 Controlling Mat Quality 4 14 Cooling fan 3 7 Coordinates elevation reference 3 30 3 34 GPS 3 17 NEZ 3 16 3 30 3 34 Copy files 3 10 Creating a 2D Machine Configuration File 6 7 Creating a flat plane surface 3 28 Creating a Linework File 2 27 Index Creating a Machine Configuration 3 47 Configuration name 3 47 Location 3 47 Machine type 3 47 Radio information 3 49 Type of antenna 3 47 Units of measure 3 47 Creating a sloping plane surface 3 30 Cross slope 5 15 adjust 5 15 5 15 5 16 Crossfall grade 3 33 Cut fill 3 76 See also Offset adjust elevation 3 78 and grade indicator 3 74 change 3 80 3 81 grade indicator 3 73 in from edge 3 74 left edge 3 74 negative 3 80 3 81 offset 3 78 positive 3 80 3 81 reading 3 78 section view 3 66 3 67 3 70 Delete files 3 11 Design elevation 3 76 Design surface 3 24 Design surface file create plane model 3 29 3 30 3 313 34 3 35 3 37 3 37 3 39 Display 3 71 alignments 3 40 boundaries breaklines
66. 51 Linework 3 41 3 42 3 51 display options 3 41 Localization See also Control point with third party coordinates 3 21 5 20 Location 5 24 large project 5 25 Index small project 5 24 working distance 5 24 working height 5 24 Lock slope 3 89 Machine Components 9168 control box 1 6 calibration of 5 15 Slope Sensor 1 7 Machine configuration files 3 45 3 50 6 5 Machine orientation 3 65 Main screen components display 3 9 elevation control key 3 10 slope control key 3 10 Topcon logo key 3 10 zoom in 3 10 zoom out 3 10 Manual control Simple A M Knob control 1 15 Manual mode and paving 6 21 6 22 Mask angle 3 84 Mat depth 4 4 6 17 Mat surface 4 4 MC 2 5 Receiver Box 1 10 setup of 5 11 MC 2 5 receiver box 1 11 clear NVRAM 1 13 EIM mode 1 12 LEDs 1 11 normal mode 1 12 Measure cutting edge 5 15 points for plane surface 3 30 3 32 3 34 sensor on blade 3 47 Menus 3 12 3 14 Control 3 13 File 3 13 pop up 3 92 Tools 3 13 Index Mix characteristics gradation 4 9 segregation 4 9 temperature 4 11 mmGPS Components Base Station Kit 1 3 mmGPS Control 5 23 New files 3 10 NEZ coordinates 3 16 3 30 3 34 NVRAM 1 13 clearing 1 13 Oo Offset 3 76 3 78 change 3 80 3 81 On grade 3 3 P Paver Components 4 1 Paver machine and truck exchange 4 6 components 4 1 forces 4 5 4 12 Paving using cross slope 6 18 using sonic control 6 19 Paving Intersections Method 1 6 21 Method 2 6 22 using cross slope 6
67. 6 Setting the Elevation Offset and Locking On grade 3 87 P N 7010 0781 iii Table of Contents Slope Control Key rennes unis be aia i 3 88 Adjust Slope in mmGPS Control sses 3 89 Adjust Slope in 2D Control oe ee eeeeeeseereeeeeenseees 3 90 Setting the Slope Offset and Locking On grade 3 91 Pop Up Men isccss cs oe sis ireen E E a 3 92 Changing Control Methods 0 cece ceeeeseeeeeeseenseees 3 92 Chapter 4 Paving Principles ccccssesseeeeeeeeeeeeeeeeeeeeeeeneeeeees 4 1 Paver Components ose c esseaveectiecseeactenetet wetetieaaeseieaeees 4 1 How a Screed Works seeseseeseseeeeerersereerreresressn 4 2 Tow Point Forced P arena EE 4 5 Truck Exchange Another Tow Point Force 4 6 Head of Material M Y cceccccceecessceseenteeeneteeenenes 4 7 Reaction of Material Under Screed R 4 8 Gradation Mix Characteristics ceeeeeseeseeees 4 9 Mix Temperature Characteristics ce eeeeeee 4 11 Weight of Screed SW oii ceeceeececsseceesteeeneceeeeeeteeeens 4 12 Quality of Base Being Paved neneeese 4 13 Rolling Techniques 0 0 ce eescesecsseeeeeeeeeneeeeeees 4 14 Controlling Mat Quality oseese 4 14 Chapter 5 GETING Started sacsceitiavssercctecisseeedlateaadiveawenceterens 5 1 Equipment Setup and Initialization Base Station 5 2 Equipment Setup and Calibration PZL 1Transmitter 5 3 Equipment Setup Machine Components cseeeee 5 6 PZS2 MG Setup isis i
68. 76 mmGPS 3D Paver Reference Manual Elevation Control Key Red indicates an error status and automatic control will be disabled Orange in mmGPS applications indicates low GPS precisions e Icon color for mmGPS applications the icon color will be BLUE when the system is receiving a mmGPS signal and GRAY when a mmGPS signal is unavailable e Icon status a crossed out icon indicates the corresponding sensor receiver is not available A flashing radio icon indicates the radio link is between three and ten seconds old weak signal Cut fill Offset Cut fill Reading PZS MC Status Radio Status Figure 3 80 Elevation Control Key for mmGPS Applications Elevation Setting Laser Sensor Status Sonic Tracker Status Figure 3 81 Elevation Control Key for 2D Applications The Elevation Control Key also provides access to elevation information and elevation configuration functions The information and available selections depend on the current control application and are described in the following sections P N 7010 0781 3 77 Setting up the Machine and 3DMC Adjust Elevation in mmGPS Control To display the following elevation settings for mmGPS applications Figure 3 82 press the Elevation Control Key Elevation left edge displays the elevation of the left edge of the screed based on local site coordinates Elevation right edge displays the elevation of the right edge of the screed based
69. B point coordinates separately Also it allows the operator to manually type in a grade by pressing the entry box A positive sign designates an upgrade from A to B and the negative sign designates a downgrade from A to B 3 32 mmGPS 3D Paver Reference Manual GPS Localization Point on surface Main fall A gt B N Direction 0 00 00 E Grade View Measured Mainfall Z r ya AS BS Direction and Grade Measure pt Grid interval cros Sloping Plane Surface 50 00 Gra Point on surface Main fall A Back fi i Direction 315 37 54 ac JHE Grade 1 697 ea To EN Measure pt Grid interval Crossfall 50 00 Grade 0 000 Back Next Cancel Figure 3 28 Measure Points A and B to Determine Mainfall 6 Press the Crossfall Grade entry box and enter a crossfall Figure 3 29 The crossfall grade is the grade that falls across at a 90 angle to the line of Mainfall see Figure 3 26 on page 3 31 and together with the Mainfall determines the plane with the compound slope A positive sign designates a fall from right to left and a negative sign designates a fall from left to right Point on surface Main fall A gt B N Direction 315 37 54 E Grade 1 697 z aa B Enter Grade Measure pt gt at 90 angle z of mainfall Grid interval Crossfall 50 00 Grade 1 500 Back Next Cancel Figure 3 29 Enter Crossfall Grade P N 7010
70. Box to connect the coil cord For example when selecting the right side for elevation control use the right side connector on the Junction Box to connect the coil cord Wrong control mode __ Deactivate 2D Control Mode tap Topcon selected Logo gt Control gt 2D Control 7 14 mmGPS 3D Paver Reference Manual Appendix A Safety Information It is your responsibility to be completely familiar with the cautions described in this manual These messages advise against the use of specific methods or procedures which can result in personal injury damage to the equipment or unsafe operating conditions Remember most accidents are caused by failure to observe basic safety precautions General Precautions 1 Read and become familiar with the machine manufacturer s operating instructions including safety information before installing or using your Topcon equipment Use extreme caution on the jobsite Working around heavy construction equipment can be dangerous DO NOT attach system brackets or hose connections while the machine is running DO NOT allow any mmGPS 3D Paver system component to limit the visibility of the operator Use Ty wraps supplied with the mmGPS 3D Paver system to keep hoses and wires secured and away from possible wear or pinch points Use eye protection whenever welding cutting or grinding is being done on the machine P N 7010 0781 A 1 Safety Information 7 Protect yourself a
71. Figure 4 14 Width of Screed Affects Weight of Screed 4 12 mmGPS 3D Paver Reference Manual Paver Components Quality of Base Being Paved 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 you have to work with what you 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 allowing some of the irregularities to be rolled back onto the mat Figure 4 15 To minimize this problem lay a leveling course in the low spots or pave multiple lifts to average out the irregularities Mat Before Rolling a Vas ee Figure 4 15 Differential Compaction P N 7010 0781 4 13 Paving Principles Rolling Techniques A well laid mat ends up with a poor ride quality if proper rolling methods are not followed Consult your compaction equipment manufacture 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 mmGPS 3D Paver is
72. Logo gt File gt Control The Control point files dialog box displays Figure 5 13 3 Select the correct control points file and press Edit The Control points dialog box displays listing all control points for the file and jobsite Figure 5 13 4 Select a control point and press Edit the Control points dialog box displays This control point file should already have local site coordinates from the selected control point file Figure 5 14 on page 5 22 H Error V Error HOMER Q tew edit Copy 1 4 Ok Add Edit Delete Ok Cancel Figure 5 13 Control Point Files Dialog Box 5 Tap in each WGS84 coordinate entry box to display the numeric pop up keyboard and enter the coordinates for latitude Lat longitude Lon and height Hgt Figure 5 14 on page 5 22 6 Tap the two GPS localization check boxes to enable check them for performing the GPS localization mathematical conversion Figure 5 14 on page 5 22 P N 7010 0781 5 21 Getting Started Name MAGGIE Site coords WGS84 N 2065148 010 Lat N37 39 32 75938 E 6178836 880 Lon W121 49 21 40995 _ Z 376 790 Hgt 295 40 ri Use for horizontal GPS localization Use for vertical GPS localization Measure Ok temr Figure 5 14 Control Point Coordinates and GPS Localization 7 Press Ok to return to the Control point files dialog box 8 Repeat step 4 on page 5 21 an
73. RAM is used to keep information about the receiver file system Note that after clearing the NVRAM the receiver s LED s flashes orange for a few seconds indicating that the receiver is scanning and checking the file system 1 Ephemeris ephemerides Data giving the coordinates of a celestial body at specific times during a given period P N 7010 0781 1 13 Introduction 1 Turn off power to the MC 2 5 Receiver Box by unplugging the power cable 2 Press and hold the Main FN key for a single box or the AUX key for a dual box Figure 1 14 3 Plug the power cable from the MC 2 5 Receiver Box to return power The LED corresponding to the pressed FN key or AUX key turns green 4 Wait until the Main LED blinks orange about three seconds Figure 1 14 Hold FN Key While Turning PWR On to Clear NVRAM 5 Release the FN key or Aux key while the LED blinks orange The Radio Antenna The radio antenna is attached on the machine using a magnetic mount and generally stays on the machine The antenna should be positioned vertically and as high as possible on the machine to maximize signal reception Figure 1 15 on page 1 15 1 Attach the radio antenna to the roof of the machine 2 Connect the radio antenna cable When the system has not been used for several days or months the antenna might have been removed for storage or transportation To reinstall the radio antenna set it up as described above and ensure the magnet mount
74. S 3D Paver Reference Manual GPS Localization Existing fiurface LAGOS Elevation adjustment 10 000 Figure 3 33 Select Existing Surface and Enter Adjustment 4 Press Finish to save the new surface file and end the process Creating a Subgrade of the Existing Road Subgrades are temporary intermediate surfaces that can be selected when building the final design surface reference surface A subgrade road that lies below fill surface or above cut surface the reference surface can be created The subgrade road copies location horizontal and vertical information from the reference surface and only change the cross section information This function is only available if the reference surface is a road surface 1 Press Topcon Logo gt File gt Surfaces gt Working or Reference and press New Enter and select the following information for the new surface file Press Next Figure 3 34 on page 3 38 e Configuration name enter a name for the file e Surface type select Subgrade of existing road surface P N 7010 0781 3 37 Setting up the Machine and 3DMC Configuration nary NewSubgrade 1 Surface type Flat plane surface Sloping plane surface New Copy Raise lower existing Wirface fg Subgrade of existing road OE Next Cancel Figure 3 34 Create New Surface File 2 Select the road surface to use as the reference from which to create the surface Enter a
75. Sonic Tracker II ar a 3 4 10 THREAD 6 5 gt Figure B 10 Sonic Tracker Il Dimensions B 14 mmGPS 3D Paver Reference Manual Appendix C Regulatory Information The following sections provide information on this product s compliance with government regulations for use UHF Radio Usage me Using a UHF radio requires a license Operating a UHF radio without a license may result in fines or other penalties Be sure you comply with all local laws before operating a UHF radio Contact your local authorities such as the FCC in the United States for details Surveying in RTK mode has made UHF the most popular choice for communications between Base and Rover receivers Know the strengths and weaknesses of this technology to get the best use out of your receiver The quality and strength of the UHF signals translates into range for UHF communications 1 The system s range greatly depends on the local conditions Topography local communications and even meteorological conditions play a major role in the possible range of RTK communications If needed use a scanner to find clear channels 2 The system s range increases by adjusting the Base station s antenna using the following methods e Ensure the Base radio has a fully charged battery e Use directional antennas and or repeaters to increase your system s range Directional antennas concentrate the signal power within a more narr
76. TAL 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 WEBSITE and 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 Manual Viii mmGPS 3D Paver Reference Manual Terms and Conditions MISCELLANEOUS The above Terms and Conditions may be amended modified superseded or canceled at any time by TPS The above Terms and Conditions are governed by and construed in accordance with the laws of the State of C
77. a position on the screed an entered distance from the left edge Tap to display the numeric pop up keyboard to enter a distance from the left edge The In from edge selection determines the point on the screed to measure regardless of where the elevation point is located Example At Left Edge P N 7010 0781 3 73 Setting up the Machine and 3DMC When using the Left Edge Figure 3 76 the grade tape follows the cut fill status of the left side of the screed regardless if elevation reference point is at the middle or right edge of the screed The cut fill number in the elevation control key is tied directly to the Elevation Reference point The Elevation Control Key reflects the elevation reference point Grade Indicator reports cut fill number of left edge of the screed even if elevation reference red arrow is on the right edge of the screed n iT Figure 3 76 Example Grade Indicator and Left Edge Cut fill Example In From Edge When using In From Edge Figure 3 77 the grade tape follows the cut fill of the entered distance from the left side of the screed regardless if elevation reference point is at the middle or right edge of the screed The cut fill number in the elevation control key is tied directly to the Elevation Reference point The Elevation Control Key reflects the elevation reference point Grade Indicator reports cut fill number of edge of screed in from left edge 1 25Ft even if eleva
78. ackers iioa naa e e e e Eaa B 10 Wrackerack o t ees As is B 12 Sonic Tracker M secs chen seins tee aa B 13 Appendix C Regulatory Information cccccessssseeeeeeeeeeeeeees C 1 WHE Radio Usage inset reniei eE tAE C 1 FCC Compliance mosso araneae a C 2 Community of Europe Compliance s s s C 3 Canadian Emission Labeling Requirements C 3 WEEE DireCtivesicc est ateideane Gots ft eel eit wn dat C 4 Appendix D Warranty Terms sssseeeeeeeeeseeeeeeeeeeseneeeeeeeeees D 1 Appendix E Glossary nia e eaaa a ae aiaia E 1 Index vi mmGPS 3D Paver Reference Manual Terms and Conditions Preface This manual has been developed to provide the operator with information necessary to operate and maintain TOPCON products Proper service and use is important to the reliable operation of the equipment The procedures described herein are effective methods for performing service and operation of this system E Please read these Terms and Conditions carefully Terms and Conditions USE This product is designed to be used by a professional The user should have a good knowledge of the safe use of the product and implement the types of safety procedures recommended by the local government protection agency for both private use and commercial job sites COPYRIGHT All information contained in this Manual is the intellectual property of and copyrighted material of TPS All rights are reserved You may not use acce
79. acks and degrades the plastic retaining ring Over tightening the screws can distort the transducer metallic material and may crack the retaining ring The O ring provides tightness while preventing vibration from loosening the mounting screws O 6 14 mmGPS 3D Paver Reference Manual Care and Maintenance of the Sonic Tracker Figure 6 14 Replace and Tighten Mounting Screws 8 Ensure the metallic surface inside the transducer has no visible wrinkles If distortion is evident repeat step 5 on page 6 13 to step 8 Place a new filter foam over the transducer The Sonic Tracker II is now ready for operation P N 7010 0781 6 15 2D Paving Applications 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 the curb and gutter Figure 6 15 For this application sonic control is used on both sides Subgrade 4 1 TA L a Centerline of Road Figure 6 15 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 3 for details 2 Position right tracker over lip of gutter and left tracker past the centerline on the base material Figure 6 16 Subgrade Centerline of Road Figure 6 16 Positioning Tracker Over Gutter 3 Pr
80. age 3 58 The control box begins sending a raise signal to the left valve and the grade indicators display the currently active offset P N 7010 0781 3 57 Setting up the Machine and 3DMC Raise left vy 20 Gap Lower left 999 Set Raise right 999 Set Lower right 999 Set Ok Cancel Figure 3 56 Begin Valve Offset If the screed is moving turn the Grade Adjustment Knob counterclockwise until the screed stops 4 Slowly turn the Grade Adjustment Knob clockwise until the screed just begins moving Figure 3 57 e Turning clockwise increases the valve offset value e Turning counterclockwise decreases the valve offset value Raise left a 1200 Set Lower left v 99 Ga Raise right 999 Set Lower right 999 Set Ok Cancel Figure 3 57 Setting Valve Offset Values 5 Press the Set key for each of the remaining selections repeating step 3 on page 3 57 and step 4 above until all four valve offsets are complete 3 58 mmGPS 3D Paver Reference Manual Tools Menu 6 Press OK to store the calibrations otherwise automatic control will not work You must press Ok to save and store valve offsets correctly 2D Control When using the mmGPS 3D Paver system for 2D control applications only the Control menu the View menu the Elevation Control key and the Slope Control key are relevant to 2D control applications Other files settings and selections have no affect in this
81. alibration calibrates the slope control system of the machine s screed The sensor attached to the machine also needs to be calibrated The sensor is attached to moving parts that wear at different rates In order for the system to work correctly it has to be told what changes have occurred on the machine The control box saves calibration settings in its memory until the operator or technician changes them Pavers require only one sensor to control cross slope This sensor must be calibrated to accurately measure the slope of the screed 1 At the control box press the Slope Control Key 2 Place a precision carpenter s level along the bottom of the screed Then manually tilt the screed until it is level 3 Once the screed is dead level press the Blade slope Set key to adjust the slope Figure 5 10 on page 5 16 4 Enter 0 0 and press OK The Blade slope value displays as 0 0 on the Adjust Slope dialog box Figure 5 10 on page 5 16 P N 7010 0781 5 15 Getting Started 5 Press OK to apply the new calibration Press Cancel to use the previous calibrations measure the slope of the screed simply press the Set key and enter the actual slope into the Blade Slope window If you have an instrument that can accurately Blade slope 0 5 s L AdjustSlope Blade slope 0 0 E Slope gain 60 s Slope locked 0 0 S Slope gain e0 Set Change to Elev Ok Can Slope locked 0 0 Set j
82. alifornia without reference to conflict of laws All information illustrations and applications contained herein are based on the latest available information at the time of publication TOPCON reserves the right to make product changes at any time without notice Comments suggestions and questions about TOPCON products are welcomed Contact your local TOPCON representative or a representative at our corporate facility TOPCON POSITIONING SYSTEMS Inc 7400 National Drive Livermore CA 94551 Phone 800 443 4567 www topcon com Mercury Warning The LCD display in the 9168 Topcon Control Box contains mercury The Control Box should not be disposed of or placed in a waste stream destined for disposal until the mercury is removed and reused recycled or otherwise managed to ensure that the mercury in the product does not become mixed with other solid waste or wastewater P N 7010 0781 ix Preface Manual Conventions This manual uses the following conventions Example Description File gt Exit Click the File menu and then click Exit Connection Indicates the name of a dialog box or screen Frequency Indicates a field on a dialog box or screen or a tab within a dialog box or screen Enter Press or click the button or key labeled Enter Supplementary information that can help to configure maintain or set up a system qi Supplementary information that can have an affect on system operation system per
83. all four points 6 Center Using the Optical Plummet Telescope Adjust the eyepiece of the optical plummet telescope to your eyesight P N 7010 0781 2 5 Setting up the Jobsite and Pocket 3D Slide the instrument by loosening the tripod screw place the point on the center mark and then tighten the tripod screw Slide the instrument carefully to prevent any dislocation of the bubble Point Centermark 7 Level the Instrument Level the instrument as in step 4 Rotate the instrument checking that the bubble is in the center of the plate level regardless of telescope direction Then tighten the tripod screw to lock in position Step 2 attach additional components to the tripod Figure 2 3 on page 2 7 Attach and or prepare additional Base Station components These components vary depending on the type of Base Station e For the PG A1 Base Station attach the radio modem radio antenna MC 2 5 Receiver Box and power source optional e For the HiPer Lite Base Station attach a power source optional 2 6 mmGPS 3D Paver Reference Manual Setting Up the Base Station PG A1 Base Station with Legacy E GPS receiver HiPer Lite Base Station Figure 2 3 Base Station Setup Step 3 connect component cables to the receiver Legacy E or HiPer Lite then connect the cables to other components Figure 2 4 on page 2 8 e If using Bluetooth wireless technology to c
84. ap this key The zooming pivot is the center of the screen e Zoom Out Key decreases the magnification of the design view each time you tap this key The zooming pivot is the center of the screen e Elevation Control Key displays elevation control information and indicates the status of the connected sensor Tap this key to view or edit elevation information See Elevation Control Key on page 3 76 for more information on this key and its menu e Slope Control Key displays cross slope control information and indicates the status of the connected sensor Tap this key to view or edit slope information See Slope Control Key on page 3 88 for more information on this key and its menu Using 3DMC The various dialog boxes throughout 3DMC have buttons to perform operations such as creating updating copying or deleting files Figure 3 7 on page 3 11 Any and all information the operator can access is stored and continuously updated to either the internal memory or a compact flash card e New Creates a new file or element e Edit Changes an existing file or element To edit a file select a file or element then press the Edit key e Copy Copies a file either from the compact flash card to the internal memory or from the internal memory to the compact flash card To copy a file select the file then press the Copy key Copy new or edited files to the compact flash card to back up the file 3 10 mmGPS
85. approximately 50 meters 100 feet away Power on the sensor and receiver Figure 2 32 Connect the sensor and Pocket 3D controller Use a bi pole to ensure the sensor remains steady throughout the calibration process Hold Plumb Beam Key then turn on power SS 50 m 100 ft S eS SS SS Figure 2 32 Setup Transmitter and Sensor 2 32 mmGPS 3D Paver Reference Manual mmGPS Operations with Pocket 3D 5 In Pocket 3D tap Setup gt mmGPS transmitters and press TX Calibration Figure 2 33 If indicated check the setup listed on screen Figure 2 33 Pocket 3D Please check 1 mmGPS transmitter in calibration mode 2 mmGPS receiver is level with mmGPS transmitter Serial Cable on COM1 3 mmGPS receiver 100 add Deletelfrx calibration Download from mmGPS transmitter Cancel Figure 2 33 Begin Field Calibration Adjustment 6 If needed adjust the height of the sensor so the angle is less than 1 Once the angle is okay tap Next Figure 2 34 7 Press Next to begin the first phase of the adjustment Figure 2 34 Nt Turn front face of mmGPS transmitter to receiver Angle Time to go Figure 2 34 Begin Adjustment If the sensor experiences excessive movement gt during any stage of the adjustment an error message displays Press Cancel and stabilize the Rover pole Then press Adjust again P N 7010
86. arted Setting up the PZL 1 Transmitter in 3DMC PZL 1 Transmitter information is saved in the control point file Ensure the correct control point file is selected for the jobsite 1 Press Topcon Logo gt Control gt PZL 1 transmitters 2 Tap the channel tab that corresponds to the channel at the transmitter Figure 5 9 3 Enter the following information and press Ok Figure 5 9 e Select the serial number of the transmitter on this channel e Select the control point over which the transmitter is installed e Enter the height of the transmitter e Select the method used to measure the height of the transmitter PZLA Transmitters Ch 1 Ch 2 Ch 3 Ch 4 Transmitters Transmitter S N 900026 Control point PP3 Height of transmitter 6 560 Measured to Mark Slant Ok Cancel Figure 5 9 Set up PZL 1 Laser Transmitter in 3DMC 5 14 mmGPS 3D Paver Reference Manual Machine Sensor Calibrations Machine Sensor Calibrations Calibrating machine components ensures accurate consistent and efficient paving Operators or technicians perform calibrations in the following instances e Upon initial installation of machine components e After servicing the system performing maintenance or replacing a component e When the machine no longer paves the correct cross slope e After installing a PZS MC sensor antenna on the machine Calibrating the Sensors Using the Slope Control Key Sensor c
87. box When 3DMC starts up press Topcon Logo gt Control gt 2D Control to activate 2D control mode Figure 6 6 3DMC connects to the 2D components and the Elevation Control key displays a sonic tracker 5 2D Figure 6 6 2D Control on the Plan View Press Topcon Logo gt Control gt Machine setup 5 Select the machine file and press Ok Figure 6 7 on page 6 7 Only the type of machine is important other sensor settings are ignored 6 6 mmGPS 3D Paver Reference Manual Using Sonic Control at the Jobsite To create a 2D machine configuration file see Creating a 2D Machine Configuration File on page 6 7 PAVER MMGPS 5a PAVER SONIC New Edit Copy Delete _ k Cancel Figure 6 7 Select Machine Configuration File 3DMC Operations for Sonic Tracker Applications When using the mmGPS 3D Paver system for 2D control applications only the Control menu the View menu the Elevation Control key and the Slope Control key are relevant to 2D control applications Other files settings and selections have no affect in this mode Creating a 2D Machine Configuration File 1 Press Topcon Logo gt Control Machine setup 2 Press New to create a new machine configuration file or select an existing machine configuration file and press Edit 3 Enter or select the following configuration and equipment parameters Figure 6 8 on page 6 8 Then press Next e Configuration
88. ce where the right side of the Main Screen is the right side of the screed e The cut fill readings are provided on both sides of the screed and represent how far the screed is from on grade e When a road surface model is selected the centerline and the elements on the template are presented in red e Additionally the section view displays steering information from a target alignment line to a target edge and the longitudinal distance along the road gt 12 290 10 77 364 0 000 3D SESE WA WE A ee Figure 3 66 Section View on Main Window The Profile view Figure 3 67 displays a side view of the machine where the right side of the screen is always the forward direction of machine travel Figure 3 67 Profile View on Main Window 3 66 mmGPS 3D Paver Reference Manual View Menu Left Window Display options for the left window include a Profile view a Section view and a Grade indicator To access the lower window view press Topcon Logo gt View gt Left window Figure 3 68 then tap the view you want a check mark indicates the active view None indicates no left window is active Main window vNone Profile Right window Section Lower window Grade indicator Display options About 3DMC Figure 3 68 Left Window Display Menu Selections Selecting one of the options adds the view as a window at the left side of the main window Figure 3 69 on page 3 68 The Profile view disp
89. ceceeeeeeeeeeeseeeeaeeeneeaes 2 15 Step 1 Create a Control Point File oe 2 15 Step 2 Setup and Initialize a Base Station Transmitter oo eee eseeseecneceseeeneeeeees 2 17 Step 3 Create a Range Pole Equipment Configuration eee eseeeeecseecseeeeeeseeeseecseesseeeaes 2 19 Step 4 Setup the Rover Radio 2 21 Step 5 Setup the Rover Antenna secere 2 22 Step 6 for mmGPS Setup the mmGPS Receiver 2 22 Step 7 Connect to the Rover eseese 2 23 Localizing with Pocket 3D oo cee eeeeseeseeeseceneeeeeeenee 2 24 Creating Files in Pocket 3D ieee eeeeeeseeneceneeeeeeenee 2 25 Creating a Points File oe eeeeeeeeseesseceeeeeeeees 2 25 P N 7010 0781 i Table of Contents Creating a Linework File 0 eeeeseeseceneeeeeeees 2 27 mmGPS Operations with Pocket 3D sser 2 28 Performing a Resection 000 ce ceeeecceeeeeseeeeceteeeeeeees 2 28 Checking the Transmitter s Height 0 eee 2 30 Transmitter Adjustment s es 2 32 Chapter 3 Setting up the Machine and 3DMC 0 3 1 9168 Control Box Buttons and Features eee 3 2 Pront Panel oeae Seis ie Get nade ken 3 2 Back and Side Panels 0 ee eeeeesceseceseeeeeeeeenseeneeees 3 6 CONNECTORS esc ish Reed sets eA ts tee 3 8 SDMC ii Ea eaS annie ial Nasties 3 9 Using SDMO ites item esd edocs eerste 3 10 Topcon Logo Key srir naniii asirna ais 3 12 Pile Mem niteen E at ante R eE 3 14 Control Point Files oserei niii 3 14 Selecting a Control Point File 0 ee eeeees
90. ch Control Point on the project A point pair consists of the following coordinates e a local NEZ coordinates for the point obtained from the project s survey crew e b global latitude longitude and height coordinates for the point measured as described in this section or obtained from the project s survey crew These pairs of points are needed to calculate a precise mathematical conversion formula for converting all global GPS coordinates generated in the MC 2 5 Receiver Box to local NEZ coordinates for a particular project P N 7010 0781 3 19 Setting up the Machine and 3DMC The following steps help to ensure a high quality localization suitable for centimeter level machine paving with mmGPS 3D Paver e First the surveyor s local Control Points must be precisely measured The quality of measurements directly affects paving accuracy Second the Control Points need to be located more or less evenly around the site Generally the more Control Points the better but if they are clustered together or are all at one section of the site then the results are less than ideal Locate Control Points evenly distributed around a perimeter of the site or paving area While not directly related to the quality of localization locate Control Points that are elevated easily accessible and not obstructed by trees buildings other structures moving vehicles and so forth Third GPS localization requires a minimum of three Co
91. closed at all times even during use to prevent dust from entering the slot When copying files to or deleting files from a compact flash card the control box screen displays an hourglass indicating the system is busy Once the hourglass goes away you can remove the compact flash card 3 6 mmGPS 3D Paver Reference Manual 9168 Control Box Buttons and Features detect the compact flash card during a hot swap procedure If this occurs simply turn off and restart the control box Occasionally the control box may not properly The card can be damaged if you remove it before completing the copying deleting process Speaker The control box produces sounds through the speaker to indicate certain activities such as selecting a menu option or changing a selection on the 3DMC main screen Cooling Fan Inlet and Outlet The control box has an efficient cooling system to keep it from overheating When powered on the cooling fan rotates bringing air in through the cooling fan inlet The air then circulates through the control box cooling down components and out the cooling fan outlet Air within the enclosure constantly circulates automatically cooling the internal heat sink plate Do not place objects that can obstruct air circulation near the inlet and outlet USB Port The USB port allows you to transfer files to from a control box and to connect with a commercial keyboard or mouse You can use a keyboard or mou
92. column To add a transmitter tap Add and enter a transmitter serial number or other description e To delete a transmitter select a transmitter and tap Delete e To calibrate the transmitter see Transmitter Adjustment on page 2 32 Once the Transmitters tab contains a list of transmitters each transmitter must be set up on a unique channel The channel button on the transmitter determines the channel that the transmitter broadcasts on ABC Serial Cable on COM1 ladd Delete frx Calibration al ownioad Figure 5 2 Load Transmitters into Pocket 3D 7 To enter transmitter setup information tap the Channel tab and select the connected transmitter then press Edit Channel Set the following parameters and tap Ok Figure 5 3 on page 5 6 e Transmitter select the ID of the transmitter e Control Point select the control point over which the transmitter is set up e TX height enter the height of the transmitter P N 7010 0781 5 5 Getting Started e Measured to select where on the transmitter Base or Mark Slant the height was measured 8 If needed repeat steps 6 and 7 for up to three other transmitters 9 Press OK when done Transmitters Channel Channel 1 Transmitter h K PP6 TXV3 cCh 2 lt none gt Control point Ch 3 lt none gt PP6 v TXheight 6 800 Measured to Mark Slant Ch 4 lt none gt lt Benchmark check Edit
93. connections at the System Five port the problem on the MC 2 5 Receiver Box and Connector D bottom on the 9168 control box Problem Elevation Control key displays Solutions Check that the Base Station is working correctly See Equipment Setup and Initialization Base Station on page 5 2 to troubleshoot Base Station problems Also check that the Rover radio antenna on the machine and its cable connections are properly connected Make sure that the radio channel is identical between the Base Station and the machine rover and that the radio is correctly configured on the control box See Equipment Setup and Initialization Base Station on page 5 2 and Equipment Setup Machine Components on page page 5 6 for information 7 12 mmGPS 3D Paver Reference Manual 9168 Control Box Problem Causes The MC 2 5 Receiver Box has not been successful tracking enough valid satellites Elevation Control key displays Waiting for Initialization Solutions Check that the rover GPS antenna has a clear view of the sky Check for obstructions such as trees buildings and vehicles that can block or reflect satellite signals The system is still in the process of determining a solid position Problem Out of design area Causes The machine is out of the Design Surface area Problem No GPS localization Causes The Control Points file currently s
94. ction displays the reference cut fill value from 0 zero rather than the distance between current and selected surfaces Subgrade of existing road Creates a surface with a cross slope different from the design road surface For most road surfaces the cross slopes for the finish design surface is different from the subgrade design slopes 3 24 mmGPS 3D Paver Reference Manual GPS Localization Working Surface Display Options When using a TIN surface model file press Topcon Logo gt View gt Display options gt Working surface to display the Working surface dialog box Figure 3 18 Show triangle mesh Show boundaries breaklines Show contours at interval 1 000 Ok Cancel Figure 3 18 Working Surface Display Options This dialog box has the following selections for displaying information on the main screen Figure 3 19 on page 3 26 Show triangle mesh displays triangle lines on the Main Screen according to the TIN Surface Model Show boundaries breaklines displays boundary lines and breaklines outlining the Design Surface Show contours at intervals displays contour lines on the Main Screen tap the entry box to display the numeric pop up keyboard and specify the elevation spacing interval between lines Color press to display the Color Selection dialog box Tap a color to select it and press Ok You can change the color of the alignment centerline alignment feature line and th
95. ctive offset Raise left vy 20 Gap Lower left 999 Set Raise right 999 Set Lower right 999 Set Ok _ Cancel Figure 5 11 Begin Valve Offset If the screed is moving turn the Grade Adjustment Knob counterclockwise until the screed stops 4 Slowly turn the Grade Adjustment Knob clockwise until the screed just begins moving Figure 5 12 on page 5 18 e Turning clockwise increases the valve offset value P N 7010 0781 5 17 Getting Started e Turning counterclockwise decreases the valve offset value Raise left a 1200 Set Lower left v 99 a Raise right 999 Set Lower right 999 Set Ok Cancel Figure 5 12 Setting Valve Offset Values 5 Press the Set key for each of the remaining selections repeating step 3 and step 4 on page 5 17 until all four valve offsets are complete 6 Press OK to store the calibrations otherwise automatic control will not work T You must press Ok to save and store valve offsets correctly GPS Localization After you have setup all the hardware components and initialized the Base Station you need to localize the GPS coordinates to the jobsite s coordinates This section gives information on the principles of GPS localization and entering GPS localization into the Control Box Principles of GPS Localization The GPS system is capable of precise positioning but the positions it computes are relative to a global reference system
96. d Figure 6 1 Align L bars 6 2 mmGPS 3D Paver Reference Manual Using Sonic Control at the Jobsite 3 Connect the coil cord to the Sonic Tracker Figure 6 2 Figure 6 2 Attach Coil Cord to Tracker 4 Bolt the Tracker to the bracket and visually check to get the L Bar and Tracker plumb Figure 6 3 on page 6 4 5 Loop the coil cable through the U hangers or make one wrap of the coil cord around the L Bar to act as a strain relief for the Tracker s connector Figure 6 3 on page 6 4 6 Snap the temperature bail into place an LED on the front illuminates Figure 6 3 on page 6 4 The Tracker is casted with holes on each side for the bail to snap and lock into place P N 7010 0781 6 3 2D Paving Applications Figure 6 3 Bolt Tracker to Bracket and Attach Temperature Bail 7 Position the L Bar horizontally so the Tracker rests over the reference for the jobsite Figure 6 4 on page 6 5 For example when tracking a stringline offset from the edge of the road set the end of the moldboard at the edge of the road and slide the L Bar so the Tracker is over the stringline Figure 6 4 on page 6 5 When tracking a curb keep the L Bar in close to keep the Tracker over the lip of the curb 8 Raise or lower the Tracker bracket to position it at a proper height above the grade reference Figure 6 4 on page 6 5 Although the Tracker can be set
97. d v mmGPS aided initialization Calc weighted mmGPS GPS elevation Figure 2 19 Enter mmGPS Information for mmGPS Rover 2 2 mmGPS 3D Paver Reference Manual Equipment Setup GPS Step 7 Connect to the Rover After setting up the rover connect to the GPS receiver to begin using Pocket 3D at the jobsite Figure 2 20 1 On the main screen tap the GPS setup button 2 Once the connection has been established press OK Notice that the GPS setup button changes color from red to green indicating successful communication between the Base and Rover opcon Pocket 3D 2 39 fok T Connecting to GPS pae Topcon Pocket 3D 4 239 Fix Position Satellite a Initialized mm GPS Total sats tracked GPS sats used GLONASS sats used 5 _ Horz RMS 0 049 Vert RMS 0 066 2 Cancel Figure 2 20 Connect to GPS P N 7010 0781 2 23 Setting up the Jobsite and Pocket 3D Localizing with Pocket 3D After setting up the Base Station localize the jobsite coordinates with GPS coordinates 1 Ensure the control point file for the jobsite is selected Data gt Control and select the equipment configuration for the current setup Setup gt Equipment Figure 2 21 2 Tap Data gt Control gt Control points Select the point to edit and press Edit 3 Check the local coordinates and press the GPS tab MESIG Coords GPS unary por A North 5000 000 gt mpo
98. d should flash every second It may take several seconds after connection for this flashing to commence MC 2 5 Receiver Box This section lists possible MC 2 5 Receiver Box problems you may encounter If you still have problems after trying the solutions listed here contact TPS customer support Problem Causes The power cable may be incorrectly connected Power indicator does not flash red Solutions Power is supplied through the cable connected on the power port Check that the cable is properly connected The control box does not have power The MC 2 5 Receiver Box turns on only while the control box is powered on 7 4 mmGPS 3D Paver Reference Manual MC 2 5 Receiver Box The MC 2 5 Receiver Box receives power from another source which is not on Problem Causes The cable is incorrectly connected or damaged Satellite Status indicator does not flash green If power is supplied through another cable connected to the power port check that the origin of the power cable and other connectors are secure The power cable may be connected to an ignition switch or a master circuit on the machine if so turn on the power source Solutions Check that the antenna cable is not cross threaded at the antenna and is connected to the intermediate cable installed on the machine Check the connection at the GPS antenna port on the MC 2 5 Receiver Box If
99. d step 7 above for all listed control points When finished check the horizontal H Error and vertical V Error values listed on the Control points dialog box They should be within acceptable tolerances Figure 5 15 Name H Error V Error MAGGIE 0 023 0 001 LISA 0 016 0 047 MARGE 0 006 0 048 HOMER 0 010 0 010 BART Add Edit Delete Ok Cancel Figure 5 15 Control Point Files with GPS Localization 9 Press Ok until you return to the 3DMC main screen saving the control point localization information and the control points file At this time make a backup copy of the control point file on a CF card 5 22 mmGPS 3D Paver Reference Manual Control Methods Control Methods The following sections describe the four types of control possible with the mmGPS 3D Paver mmGPS slope sonic and laser mmGPS Control mmGPS uses Topcon s unique LazerZone technology to produce millimeter accuracy LazerZone technology combines the simplicity of a rotating laser the accuracy of a robotic total station and the flexibility and multiple user capabilities of GPS into one complete jobsite solution Figure 5 16 e The PZL 1 laser transmitter emits a unique laser beam that provides a working range up to 2000ft 600m e The PZS MC laser sensor and GPS receiver at the machine detects the laser beam and satellite signals sending millimeter accurate positioning data to the control box for correctio
100. d with localized coordinates the operator can enter global GPS coordinates directly into the 9168 control box The control box then processes the localization as the operator sits in the cab Because this method deals with control point files see Creating a Control Point File on page 3 15 for further information 1 Power on the control box and allow the 3DMC application program start up Have the measurements for each Control Point available 2 Press Topcon Logo gt File gt Control The Control point files dialog box displays Figure 3 15 on page 3 22 3 Select the correct control points file and press Edit The Control points dialog box displays listing all control points for the file and jobsite Figure 3 15 on page 3 22 P N 7010 0781 3 21 Setting up the Machine and 3DMC 4 Select a control point and press Edit the Control points dialog box displays This control point file should already have local site coordinates from the selected control point file Figure 3 15 3a Simpson family ranch H Error V Error O arew edit Copy 1 Ok Add Edit Delete Ok Cancel Figure 3 15 Control Point Files Dialog Box 5 Tap in each WGS84 coordinate entry box to display the numeric pop up keyboard and enter the coordinates for latitude Lat longitude Lon and height Hgt Figure 3 16 6 Tap the two GPS localization check boxes to enable check them fo
101. data from the connected transmitter Refer to the Pocket 3D User s Manual to calibrate or adjust the transmitter Figure 2 13 on page 2 19 3 Tap the Channel tab and press Edit Channel to select the channel the transmitter description the transmitter ID and the control point over which the transmitter is installed Enter the height of the tripod 2 18 mmGPS 3D Paver Reference Manual Equipment Setup GPS 4 Press Ok Transmitter information is stored in the control point file copy this file to the machine for mmGPS grading applications Equipment Radios ABC Antenna Base station mmGPS receiver ke Units Serial Cable on COMi wy inchmark check Exit Foamy Add Deletelftx calibration Jownload Resection Cancel Figure 2 13 Enter Base Transmitter Information Step 3 Create a Range Pole Equipment Configuration Pocket 3D creates an equipment configuration for a range pole Rover Figure 2 14 and Figure 2 15 on page 2 20 A Rover can be used to check and verify grade 1 After initializing the Base connect the Pocket 3D controller to the Rover GPS receiver Tap Setup gt Equipment 2 Tap New Enter a configuration name and equipment information Press Next P N 7010 0781 2 19 Setting up the Jobsite and Pocket 3D Maqnine files Configuration name HIPER MMGPS11 Machine type Range pole v Equipment Radios Sensor GPS Antenna v A
102. de 2D over 2 ft above grade Triple Solid g Above grade Above grade Yellow S GPS between 05 and 4 ft Between 1 and 2 2D between 05 and 2 ft Double Solid g Above grade Above grade Yellow amp Between 03 and 05 ft Between 5 and 1 Single Solid 8 Above grade Above grade Yellow amp Within 03 ft Within 5 Blinking On grade On grade Green Bar Within deadband Within deadband Single Solid Red oooe Below grade Within 03 ft Below grade Within 5 Double Solid Below grade Below grade Red 8 Between 03 and 05 ft Between 5 and 1 Triple Solid Below grade Below grade Red s GPS between 05 and 4 ft Between 1 and 2 2D between 05 and 2 ft Slow Blinking Out of range Out of range Red 8 GPS over 4 ft below grade 2D over 2 ft below grade Over 2 below grade P N 7010 0781 Setting up the Machine and 3DMC Grade Adjustment Knobs The grade adjustment knobs make measured adjustments to the cross slope or elevation settings Table 3 2 describes knob operation for the different control modes Table 3 2 Grade Adjustment Knob Operation Control Mode Grade Adjustment Knob Usage mmGPS The knob assigned to elevation control applies an offset to the Design Surface that is elevation setting e Turn the knob clockwise to apply less material lowering the screed e Turn the knob counterclockwise to apply more material raising the screed Th
103. defined in terms of a geographic latitude longitude and height above a representation of the earth s surface To be useful for local site work global GPS coordinates need to be converted into local site coordinates defined in terms of a distance north and east of some origin point and some distance above an elevation datum These north east and elevation coordinates often 5 18 mmGPS 3D Paver Reference Manual GPS Localization abbreviated to NEZ coordinates may be those of a regional coordinates system for example a state plane system in the United States or the project s survey crew may arbitrarily define these coordinates for the specific site NEZ coordinates must be defined in terms of the construction design data In either case a mathematical conversion is necessary to turn global GPS coordinates into NEZ coordinates relative to a locally defined coordinate system The basic approach to calculating the mathematical conversion is to provide pairs of point coordinates for each Control Point on the project A point pair consists of the following coordinates e a local NEZ coordinates for the point obtained from the project s survey crew e b global latitude longitude and height coordinates for the point measured as described in this section or obtained from the project s survey crew These pairs of points are needed to calculate a precise mathematical conversion formula for converting all global GPS co
104. e 3 23 Flat Plane Surface Diagram 3DMC accurately measures the point directly below the sensor but does not compensate for a slant error of the sensor mast Therefore for a more accurate measurement keep the mast as vertical as possible when measuring the point 1 Press Topcon Logo gt File gt Surfaces gt Working or Reference and press New Enter and select the following information for the new surface file Press Next Figure 3 24 e Configuration name enter a name for the file e Surface type select flat plane surface no slope Configuration nary FlatPlane_1 Surface type P Sloping plane surface New Copy Raise lower existing surface Subgrade of existing road Next Cancel Figure 3 24 Create New Surface File P N 7010 0781 3 29 Setting up the Machine and 3DMC 2 Move the machine to the elevation reference point The measurement of this point brings the entire plane up or down to intersect the point and determine its relative elevation reference point press the corresponding entry box l If you have the NEZ coordinates for the elevation and enter in the information 3 When the sensor is over the point press Measure pt to measure the elevation reference point Figure 3 25 The Measuring dialog box briefly displays 4 Enter a grid interval for the main screen Press Next Figure 3 25 5 Press Finish to save the new surface file and end the
105. e 3 75 About 3DMC Dialog Box 3 72 mmGPS 3D Paver Reference Manual Changing Cut Fill Offsets Changing Cut Fill Offsets The cut fill offset can be manually adjusted on the fly relative to the Design Surface After each pass the cut fill offset can be updated as necessary while approaching the final design surface For safety reasons 3DMC limits the amount of vertical movement possible while in automatic control The maximum cut fill movement working window while in automatic is 20 of a foot for 2D control and 40 of a foot for mmGPS control To pave in automatic within a significant cut or fill the operator must manually apply a cut fill offset Elevation Control Key and Grade Indicator reflect l When changing the cut fill offset both the the new value Changing the Grade Indicator The Grade Indicator acts as an infinitely scrolling grade tape and displays the amount of cut or fill in regards to the design surface To view the grade indicator press Topcon Logo gt View gt Left or Right window gt Grade indicator This process applies to both the left and right Grade Indicators To change the grade display press and hold the grade indicator for one second tap Grade display then the selected option This option applies a cut fill reference for a position on the screed e At left edge the grade tape follows the position at the left edge of the screed In from edge the grade tape follows
106. e knob assigned to slope control is disabled during paving operation except while making changes in a menu function 2D The knob assigned to elevation control applies an adjustment to the set point that is elevation setting Turn the knob clockwise to apply less material lowering the screed e Turn the knob counterclockwise to apply more material raising the screed The knob assigned to slope control adjusts the percentage of slope in the direction of the knob s rotation e Turn the knob clockwise to tilt the screed to the right Turn the knob counterclockwise to tilt the screed to the left Grade Adjustment Direction Arrows The grade adjustment direction arrows Figure 3 2 illuminate red indicating the direction of knob rotation to reach on grade They also illuminate to indicate that you can use the grade adjustment knobs to change values while in adjustment and calibration modes Rotate Knob Counterclockwise To Reach Grade Rotate Knob Clockwise To Reach Grade Figure 3 2 Grade Adjustment Arrows 3 4 mmGPS 3D Paver Reference Manual 9168 Control Box Buttons and Features Brightness Sensor Window This window allows an internal optical sensor to measure ambient light providing automatic adjustment of the display s backlight Blocking the brightness sensor may cause incorrect Nore adjustments of the display s brightness level Touch Screen Display The touch screen display prov
107. e selection of two design surface files working and reference The working surface is the surface that the machine paves to while the reference surface is simply a visual reference on screen in relation to the working surface Typically the reference surface is an optional selection depending on the requirements of the job while using the 3DMC system The reference surface could be the final design surface which may be different than the current working surface or could be a surface used to monitor the progress of the current surface P N 7010 0781 3 23 Setting up the Machine and 3DMC 3DMC also has the ability to create a surface model using a unique onsite method The surface model is created on the machine in real time and can be used as a design surface file for grading in 3D GPS mmGPS control Unlike conventional applications using a laser control system using 3DMC to create a surface model eliminates the required repetitive setup of a transmitter at the job site 3DMC can create the following surfaces Flat plane surface Creates a planar surface with a 0 cross slope and mainfall This surface is primarily used for building pads Sloping plane surface Creates a sloping surface with cross slopes and mainfall based on a reference elevation In paving applications you can create this surface when a 3D design surface is not available Raise lower existing surface Raises or lowers the current surface This fun
108. e station line to the operator s preference or to maintain consistency between the office and the field P N 7010 0781 3 25 Setting up the Machine and 3DMC A Triangle Mesh Boundaries Breaklines Contours at Intervals Figure 3 19 Working Surface on the Main Screen Selecting Surface Files When setting up 3DMC design files first select the working surface then select the reference surface 1 On the 3DMC main screen press Topcon Logo gt File gt Surfaces gt Working 2 Select the working surface file for the jobsite and press Ok Figure 3 20 on page 3 27 3 26 mmGPS 3D Paver Reference Manual GPS Localization 6220 A12 Grade Work Inner perimeter of lake 2a LAGO8 New Copy Delete Ok Gancet Eis 3 20 Applying a Working Surface File 3 Press Topcon Logo gt File gt Surfaces gt Reference 4 If needed select the reference surface file for the jobsite and press Ok Figure 3 21 6220 A12 Grade Work Inner perimeter of lake New Copy Delete Ok de Figure 3 21 Applying a Reference Surface File Editing a Plane Surface File Occasionally a flat or sloping plane surface may need to be adjusted to fit current conditions at the jobsite 1 On the 3DMC main screen press Topcon Logo gt File gt Surfaces gt Working or Reference 2 Select the plane surface file and press Edit Figure 3 22 on page 3 28 P N 7010 0781
109. easurements When setting up the Base station make sure you select the correct point from the control points file and verify the point has a northing easting and elevation coordinate The more accurate these coordinates are the tighter the control while grading Use the following checklist for quick setup of the Base Station C Select a control point and install the Base station over it Measure the antenna height Connect all Base Station components and cables OoOd Select the correct radio settings Refer to your Base Station s documentation for specific radio configuration procedures The Base and Machine must use the same radio settings O Initialize the Base station 9 2 mmGPS 3D Paver Reference Manual Setting Up the Base Station Once you have set up the Base Station simple checks at the machine ensure the machine receives corrections from the Base station if the elevation control key is green the Base Station is ready Figure 2 2 on page 2 4 shows a completed Base Station setup Use a plumb bob for quick and easy setup of the tripod especially if the ground is uneven Step 1 set up the tripod and GPS receiver antenna over a control point accurately level the tripod as described below 1 Over a control point extend the extension legs of the tripod to suitable lengths Tighten the leg screws 2 Attach the universal tribrach to the tripod securing it in place Figure 2 2 on page 2 4 and insert the t
110. ed 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 6 12 on page 6 13 6 12 mmGPS 3D Paver Reference Manual Care and Maintenance of the Sonic Tracker CAEFUDLPLACE WIRE CONNESS ON KBS TRIM EXCESS y LA2 PLACE MEW VRAP AROUNWIRES AND TIGHTEN Figure 6 12 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 6 13 on page 6 14 P N 7010 0781 6 13 2D Paving Applications WIRE CONNER PINS Figure 6 13 Replace Wires Transducer and O ring 6 Place the black retaining ring over the transducer assembly with the beveled edges out and the flat surface against the Sonic Tracker II base Line up the holes for the mounting screws The mounting screw holes are set to an irregular pattern ensuring the retaining ring only lines up with the mounting holes one way Figure 6 14 on page 6 15 7 Start the mounting screws into the holes and tighten each until firm Figure 6 14 on page 6 15 DO NOT OVER TIGHTEN Use a cross X pattern when tightening the screws DO NOT use Loctite on the mounting screws Loctite att
111. ed within 3DMC If setting up only one transmitter but the job has been configured for multiple transmitters select the individual ID of the transmitter for the sensor to detect e LazerZone aided initialization select to use the mmGPS signal to assist in initializing the MC 2 5 Receiver Box This option is useful to decrease the initialization time when satellite visibility is limited for example tracking only four or five satellites e Calc LazerZone GPS weighted elevations select to combine LazerZone elevations and GPS elevations When selected this option forces the receiver sensor to always consider the angle and distance when determining the elevation then combine the two elevations accordingly This option works well at large 300m distances and steep angles GPS port Serial PortC Sensitivity Auto Channels Al Advanced LazerZone aided initialization Calc LazerZone GPS weighted elevations L Back Next Cancel Figure 3 49 Enter Lazer Zone Information for mmGPS Configurations 7 Press Finish to save the machine configuration file 3 50 mmGPS 3D Paver Reference Manual Control Menu 8 Select the machine configuration file on the Machine files dialog box and press Ok to set this as the machine for the job You must press Finish to save the file Failure to do so results in losing all information and require you to repeat the process Steer Indication 3DMC can be used to ste
112. eeneeees 3 15 Creating a Control Point File oe eee eeeseeneeens 3 15 GPS Localization is siict seep ienn aei aaa 3 19 Principles of GPS Localization cee ceeeeeeeeeeeeees 3 19 Entering Localized GPS Coordinates eee 3 21 Surlace Piles nen pre eparina aun eet dae 3 23 Working Surface Display Options 00 0 ee eee 3 25 Selecting Surface Files 0 0 eee eeseeeeeeeeeseeeneeees 3 26 Editing a Plane Surface File o n 3 27 Creating a Flat Plane Surface eee eeeee 3 28 Creating a Sloping Plane Surface 0 0 0 3 30 Raising or Lowering the Existing Surface 3 35 Creating a Subgrade of the Existing Road 3 37 Alignment Display Options cece eeeeeeeereeeneeees 3 40 Linework Display Options 00 0 0 eee eeeeeeeeereeneeeneeees 3 41 Point Display Options 0 0 cece eeceseceseeereeeeeenseenaeens 3 42 Changing the Background Color cee eeeeeeeseeeeeees 3 43 Point Piles Sieniniai e esis 3 44 Exit 3DM orenian aa n hee ade aaa 3 45 Control Men iroi senp chia ihe ts 3 45 Machine Setup vreau A RE R nid 3 45 ii mmGPS 3D Paver Reference Manual Table of Contents Selecting a Machine Configuration 0 0 0 0 3 46 Creating a Machine Configuration 0 0 3 47 Steer IndicatiOM seiirt stoves passstetastesetsesesesssceee 3 51 Steer to Rolyline satscisvrticcticnvaes ata a 3 51 PZS MG Receiver tereo intei EEE eset niet 3 53 PZL 1 Transmitters eee eecceeeeeseeseeceneceeeeeeeeenees 3 54 Copyi
113. eft window view the grade indicator from the Right window display the Profile Section Light bar or Cut fill history for mmGPS applications from the Lower window select Display options for various data depending on the files selected for display view 3DMC information authorization codes and options 3 64 mmGPS 3D Paver Reference Manual View Menu Main Window Display options for the main window include a Plan view a Section view and a Profile view To access the selected main window view press Topcon Logo gt View gt Main window Figure 3 64 then tap the appropriate view a check mark indicates the active view Plan Section Left window Profile Right window Lower window Display options About 3DMC Figure 3 64 Main Window Display Menu Selections The Plan view Figure 3 65 displays the jobsite from above the machine and the main window is always oriented in the forward direction of machine travel e The point on the screed below the location of the GPS antenna is always in the center of the main window e This view allows for additional representations of triangle mesh and contour lines in a selected color as well as superimposing Linework Alignment lines and Topo points Figure 3 65 Plan View on Main Window P N 7010 0781 3 65 Setting up the Machine and 3DMC The Section view Figure 3 66 displays a cross section view of the screed and the selected Design Surfa
114. egacy E or Hiper Lite is switched on The cable may be incorrectly connected Problem Causes The cable is incorrectly connected or damaged Pocket 3D is waiting for satellites Check that the cable is connected to the COM port on the computer and Port A on the Legacy E If still no connection try to reset the computer and repeat Solutions Check that the antenna cable is not cross threaded and is screwed in all the way If the cable is damaged contact your dealer to purchase a new cable The antenna has poor PDOP Check that the antenna has a clear view of the sky The receiver is collecting an almanac If this is the first time connecting to the Legacy E or if an internal reset has recently been performed this message may persist for several minutes while the Legacy E obtains a new almanac P N 7010 0781 Troubleshooting Problem Causes The cable is incorrectly connected or damaged Radio modem light is not flashing Solutions Check that the cable from the Legacy E is properly connected to the radio If the cable is damaged contact your dealer to purchase a new cable The radio does not have a TX LED Some radios may not have a TX Transmit LED so the radio may in fact be functioning The radio has a TX LED but it is not yet flashing All radio types specifically listed for the Base Station kit have a TX light an
115. elected has not been localized properly Elevation Control key displays Elevation Control key displays If this is the very first time for operation this message may persist for several minutes while the Legacy E or Hiper Lite obtains a new almanac Solutions Make sure that the correct Control Point File and Design Surface file is selected Move into the Design Surface area so the operator can start grading Solutions Make sure that the correct Control Point file currently is selected P N 7010 0781 7 18 Troubleshooting You are in a process of Disregard the message until the localization building a Control is complete See GPS Localization on Point file or just page 5 18 to perform localization starting the process Problem Slope Control key displays Slope sensor not connected Causes Solutions Cross slope system is Check cable connections from the not connected Connector C on the 9168 control box third properly from the top to the Junction Box and from the Junction Box to the slope sensor Problem Elevation Control key displays ELEV sensor not connected Causes Solutions 2D Control sensor is Use the correct coil cord not properly connected Ensure the cable connections between the Junction Box dozer and the elevation sensor are correct and secure Use the correct location at the Junction
116. ent 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 your supplier where you purchased the product or consult c 4 mmGPS 3D Paver Reference Manual Appendix D Warranty Terms TPS laser and electronic positioning equipment are guaranteed against defective material and workmanship under normal use and application consistent with this Manual The equipment is guaranteed for the period indicated on the warranty card accompanying the product starting from the date that the product is sold to the original purchaser by TPS Authorized Dealers During the warranty period TPS will at its option repair or replace this product at no additional charge Repair parts and replacement products are furnished on an exchange basis and are either reconditioned or new This limited warranty does not include service to repair damage to the product resulting from an accident disaster misuses abuse or modification of the product Warranty service may be obtained from an authorized TPS warranty service dealer If this product is delivered by mail purchaser agrees to insure the product or assume the risk of loss or damage in transit to prepay shipping charges to the warranty service location and to use the original shipping container or equivalent A letter s
117. er Radio Configuring the range pole Rover radio Figure 2 17 ensures proper communication with the Base 1 Tap Setup gt Radios 2 Select the radio type and enter its communication settings If needed press Configure to select the channel 3 Press Ok Equipment Antenna Base station Units Exit Radio type Pacific Crest PDL UHF Connected Baud rate Format Channel Serial Frequency 38400 CMR Set Figure 2 17 Enter Radio Parameters P N 7010 0781 T 464 550 Mhz Advanced Cancel 2 21 Setting up the Jobsite and Pocket 3D Step 5 Setup the Rover Antenna Setup the Rover antenna s type and measurements Figure 2 18 1 Tap Setup gt Antenna 2 Select the type of antenna and enter its measurement information Press Ok Antenna type Topcon HiPer Lite y Antenna height 6 56 Measured to Rim v Units Feet v Base station 2 Units Exit Figure 2 18 Enter Antenna Information for GPS or mmGPS Rover Step 6 for mmGPS Setup the mmGPS Receiver For mmGPS setup the mmGPS receiver Figure 2 19 1 Tap Setup gt mmGPS receiver 2 Enter mmGPS parameters See Pocket 3D or 3DMC manuals for important information about these settings Press Ok GPS port Serial D v Sensitivity High v Equipment Radios Channels All v Antenna Firmware Base station mmGPS transmitters mmGPS receiver Advance
118. er from e Alignment feature the feature to steer to e Additional steer offset an offset from the feature to apply Alignment Polyline alignment Point of interest Left cutting edge ff Alignment feature Centerline Additional steer offset 0 000 Ok Cancel Figure 3 51 Steering Options 6 Press Topcon Logo gt View gt Display options gt Working surface to change the color of the centerline feature line or station lines Also use this screen to show station labels and change the interval between cross lines Figure 3 52 on page 3 53 3 52 mmGPS 3D Paver Reference Manual Control Menu Alignment centerline color Alignment feature line color Color Show regular station lines Show station labels Station interval 50 000 Ok Cancel Figure 3 52 Polyline Alignment Options Begin paving As needed repeat step 4 on page 3 51 to steer to another polyline PZS MC Receiver If needed you can use 3DMC to temporarily change the settings of the PZS MC sensor The original settings from the machine configuration file are restored after turning off the 9168 control box 1 At the control box press Topcon Logo gt Control gt PZS MC receiver and select the following receiver parameters Figure 3 53 on page 3 54 e Receiver port select the port used for GPS communication at the MC 2 5 Receiver Box usually Serial Port C e Receiver sensitivity
119. er steam cleaner hoses directly on cables and components The components can be used in rain or light spraying Check the Sonic Tracker II transducer daily to make sure the filter foam and transducer are clean and free of debris If the filter foam is clogged with dirt replace it see Sonic Tracker II Transducer Cleaning on page 6 9 If the transducer appears to be covered with debris affecting performance clean or replace the transducer see Sonic Tracker II Transducer Replacement on page 6 10 Sonic Tracker II Transducer Cleaning maintenance procedure Clean the Transducer only This procedure is not meant to be a regular when contamination is suspected or evident shortened Transducer life and or water damage to Cleaning the transducer too much results in a the Sonic Tracker 1 Hold the Sonic Tracker II in an upright position to prevent moisture from inadvertently entering the Sonic Tracker 2 Mixa mild detergent with water and place the mixture in a spray bottle use Simple Green where available P N 7010 0781 6 9 2D Paving Applications 3 With the Sonic Tracker upright thoroughly spray the Transducer with the detergent solution 4 After spraying the Transducer with the detergent fill the spray bottle with clean water and rinse any residual detergent off of the Transducer 5 Allow the Sonic Tracker to thoroughly dry Sonic Tracker Il Transducer Replacement If
120. er the machine to and pave to a polyline layer in the Linework file Typically you use an Alignment file to pave along an alignment line The polylines represent features or objects such as building pads curbs sidewalks top and toe of slopes or any boundary on the project If the polyline is composed of three dimensional information at each transition point it can be selected on the main screen and used as the alignment line to steer to or can be used as the design elevation to control the screed Steer to Polyline 1 Press Topcon Logo gt File gt Linework select the Linework file for the job and press Ok 2 Press Topcon Logo gt View gt Display options Linework and select the polylines to display 3 View the steering light bar and left section view Topcon Logo gt View gt Lower window gt Light bar e Topcon Logo gt View gt Left window gt Section 4 Tap and hold the polyline to use for steering to then tap Steer to polyline on the pop up menu graphical cross lines display along the selected polyline P N 7010 0781 3 51 Setting up the Machine and 3DMC Figure 3 50 shows an example of the main screen after completing the above steps Distance to edge of polyline amp Figure 3 50 Steer to Polyline 5 Press Topcon Logo gt Control gt Steer indication to change the following Figure 3 51 Press Ok when done e Point of interest the edge of the screed side of the machine to ste
121. esienizhiest aneia dette 5 7 Screed and Antenna Measurements 0 0 0 0 ceeeeeeeeeee 5 9 Radio Antenna Installation ceeeeeseeeneeeeeeees 5 10 MC 2 5 Receiver Box Setup for mmGPS Applications 5 11 Control Box Setup oo eee eeesessceseceneeeeeeeeeeaeeneeees 5 12 3DMG Setup tects Saniora ee ds T 5 13 Setting up the PZL 1Transmitter in 3DMC 5 14 Machine Sensor Calibrations 00 0 eeceseeeeeeeeeneeenseees 5 15 Calibrating the Sensors Using the Slope Control Key 5 15 Setting the Valve Offsets oc ee eeseceseeeeeneeenseens 5 16 GPS MocaliZatronl co ciseciassivesbetisabhaceiveladsdessedaseel tiescetblesuel ius 5 18 iv mmGPS 3D Paver Reference Manual Table of Contents Principles of GPS Localization s es 5 18 Entering Localized GPS Coordinates 0 0 0 eee 5 20 Control Methods sss tesccsasesctteudsbisteseasselesticadeet slaves sias ates 5 23 mmGPS Control ws cccat china wis edie 5 23 Placing Transmitters at the Jobsite 0 5 24 Using Multiple Transmitters 0 0 eee 5 26 Slope Control 30 25 ai eke waiver et aes 5 26 SONIC Conto l is nininini e Res 5 29 Laser Control sisiesex checte dt adsiseeise detec taeeieh eh 5 30 Chapter 6 2D Paving Applications cccccesssseeeeeeeeeeeees 6 1 Using Sonic Control at the Jobsite eee eeeeeeeeeeeee 6 1 Step 1 Attach the Sonic Tracker oes 6 2 Step 2 Set up 9168 Control BOX sssr 6 5 3DMC Operations for Sonic Tracker Applications 6 7 Creating a 2D Machine Conf
122. ess the Elevation Control key Figure 6 17 on page 6 17 4 Enter an offset value into the Elevation set point Set entry box 5 Press Survey to quickly lock on grade 6 Press Ok to return to the Main Screen 6 16 mmGPS 3D Paver Reference Manual Paving City Streets with Sonics Elevation left edge Elevation right edge Elevation valve gain 75 Set survey Zero ronsetesiope Ok Cancel Figure 6 17 Set the Depth of Asphalt to be Laid 7 Switch the A M Knob into automatic and begin paving Check the depth of mat at centerline and verify joint matches at lip of gutter After compaction make the necessary adjustments tracker over the gutter if the tracker is mounted to l If the road width varies it is easier to keep the the extension on the paver 8 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 6 18 Subgrade Centerline of Road Figure 6 18 Paving Other Side of Road 9 Survey the control box on grade and set the displays to read the depth of asphalt to be laid see Figure 6 17 on page 6 17 Put the control box in automatic mode and begin paving Check to make sure joints match after compaction P N 7010 0781 6 17 2D Paving Applications Paving City Streets with Cross Slope Another option is to pave the street using cross slope and sonic control
123. ference and reflect 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 5 22 e When the Tracker is on grade the cutting drum is at the desired depth e If the cutting drum and Tracker start to raise the Tracker and control box indicate a down correction arrow and the lower hydraulic valve corrections bring the Tracker back on grade If the cutting drum and Tracker start to lower the Tracker and control box indicate a raise correction arrow and the raise hydraulic valve corrections bring the Tracker back on grade Figure 5 22 Sonic Tracker Il Control See Chapter 6 for more details about using a sonic sensor as the control method at the jobsite P N 7010 0781 5 29 Getting Started Laser Control For Laser Control a laser transmitter is used to produce a plane of light which becomes the grade control reference for the jobsite The laser receiver will control 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 5 23 Figure 5 23 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 5 24 on page 5 31 5 30 mmGPS 3D Paver Reference Manual Contr
124. ference Manual File Menu e WGS84 if you have precise GPS coordinates enter the coordinates for latitude Lat longitude Lon and height Hgt e Localization check boxes only enable these if currently performing a GPS localization 6 Press Ok to save this control point Name MAGGIE Control point Site coords wess4 Name MAGGIE g 7 N 2065148 01 Lat Site coords WGS84 E 6178836 88 Lon N 2065148 01 Lat N37 39 32 75938 Z 376 79 Hgt E 6178836 88 Lon W121 49 21 40995 Use for horizontal GPS localizati Z 376 79 Hgt 295 40 Use for vertical GPS localization Use for horizontal GPS localization Measure Ok Use for vertical GPS localization Measure Ok Cancel Figure 3 13 Control Point Coordinates Without and With GPS Localization 7 Press Add on the Control points dialog box and repeat steps 5 and 6 above for all control points 8 After adding all control points Figure 3 14 on page 3 18 press OK to save the control points file P N 7010 0781 3 17 Setting up the Machine and 3DMC Name H Error V Error MAGGIE LISA BART MARGE HOMER Add Edit Delete Ok Cancel Figure 3 14 Save Control File After Adding Control Points Data entry errors have a direct affect on paving accuracy You must press Ok to save the file Failure to do so results in losing all information and require you to repeat the process
125. formance measurements personal safety Q Notification that an action has the potential to adversely affect system operation system performance data integrity or personal health P Notification that an action will result in system damage loss of data loss of warranty or personal injury gt Under no circumstances should this action be performed 0 mmGPS 3D Paver Reference Manual lt Chapter 1 Introduction mmGPS 3D Paver is a complete non contacting control system which combines elevation control and slope control into a simple easy to use package Coupled with the precision of mmGPS paving applications gain greater control over mat thickness and material management The mmGPS 3D Paver system provides multiple 3D and 2D options for control applications Figure 1 1 Regardless of the option s selected the control box analyzes design data and cross references it with current sensor data to provide real time information for immediate operator and or hydraulic response Figure 1 1 mmGPS 3D Paver Components mmGPS 3D Paver Components The mmGPS 3D Paver system includes various hardware options for controlling mat thickness including sonic laser slope and mmGPS solutions The 9168 control box in conjunction with 3DMC software provides a visual interpretation and on the fly control of the jobsite as well as real time elevation slope information Figure 1
126. function of any paving operation Head of Material Force M Figure 4 10 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 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 is the general result 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 4 11 on page 4 8 P N 7010 0781 4 7 Paving Principles Indicates Centerline of Auger L Correct Depth of Mat Maintained Correct Head o gt A ee M oy L Screed Rises mis Due To Increased Resistance Head of Material _ Toti ar L Screed Settles iY Due To Decreased Head of oy Resistance Material gt gE Too Lo
127. gacy E HiPer Lite Base Station Base Station Figure 1 3 Base Station Kit P N 7010 0781 1 3 Introduction PZS 1 Sensor and GPS Receiver optional The PZS 1 sensor Figure 1 4 instantly computes precise vertical information from the PZL 1 laser transmitter Using Lazer Zone technology the PZS 1 automatically determines elevation based on jobsite control Mounting the PZS 1 to a range pole and attaching a GPS receiver allows the sensor to receive the PZL 1 laser signal and wirelessly transmit data to the receiver Figure 1 4 Receiver and PZS 1 PZL 1 Laser Transmitter The PZL 1 laser transmitter Figure 1 5 operates similar to a standard rotating laser but transmits a unique signal to provide a working range of 2000ft and a measuring area of 33ft in height Up to four laser transmitters can be linked for use on large sites Each PZL 1 laser transmitter also supports multiple rovers even at different elevations for continuous production Figure 1 5 PZL 1 Laser Transmitter 1 4 mmGPS 3D Paver Reference Manual Jobsite Components Hand held Controller with Pocket 3D Optional field software for all control applications Pocket 3D assists superintendents operators or grade checkers when staking or checking grade on a site This software runs on a portable hand held controller Figure 1 6 on page 1 6 and uses files common with other equipment on the job site allowing multiple users to work at the same
128. gain setting for slope control The valve gain setting determines the speed of the hydraulic valve response while in automatic control A higher setting speeds up the response a lower setting slows down the response Slope locked used to pave at a constant fixed slope keeping the elevation side in mmGPS control Enabling the check box locks the cross slope to the value entered into the box The screed stays at the same slope until the percentage of slope changes using the grade adjustment knob or entering a new value in the slope locked box P N 7010 0781 3 89 Setting up the Machine and 3DMC Blade slope 0 0 Set Mainfall slope Slope gain 35 Set a r Slope locked 0 0 _ Set Ok Cancel Change to Elev Figure 3 98 Adjust Slope Dialog Box mmGPS Control Adjust Slope in 2D Control To display the following slope settings for 2D applications Figure 3 99 on page 3 91 press the Slope Control Key e Blade slope the current percentage of slope for the slope sensor e Slope gain displays the current valve gain setting for slope control The valve gain setting determines the speed of the hydraulic valve response while in automatic control A higher setting speeds up the response a lower setting slows down the response e Survey used to quickly lock the screed on grade e Change to Elevation used to switch to 2D elevation control 3 90 mmGPS 3D Paver Reference Manual
129. gins to change 2 Press the Slope Control Key to switch from slope to elevation control on the control box 3 Press Survey on the Adjust Elevation dialog box to survey the tracker on grade Figure 6 30 on page 6 25 6 24 mmGPS 3D Paver Reference Manual Paving Intersections with Cross Slope Elevation left edge Elevation right edge Elevation valve gain 35 Set All Elevation set point 2 50 Set Survey Ea Zero Change to Slope Ok Cancel Figure 6 30 Switching to Elevation Control and Surveying On grade 4 Pave through the intersection with the sonic tracker in automatic Figure 6 31 Figure 6 31 Paving Through Intersection 5 Upon reaching the end of the intersection Figure 6 31 switch the A M Knob into manual 6 Press the Elevation Control key 7 Press Change to Slope and Survey the slope to get an on grade signal Figure 6 32 on page 6 26 P N 7010 0781 6 25 2D Paving Applications Blade slope 0 0 Set Slope gain 25 Press Survey Set to lock Survey on grade Change to Elev Ok Cancel Figure 6 32 Switching to Slope Control and Surveying On Grade number displayed is not the same as the cross slope you want This occurs if the surface being paved is not also at the slope you want z You may find after surveying the slope that the To get back to the correct slope continue paving in a
130. he machine reference point a certain distance above ground Manually measure the height between the ground and the target position on the machine reference point enter the measured height value and press Ok Use a positive value when the screed is above the design surface For Lower all elevations by always enter a positive value Log by minimum distance Minimum distance 30 000 Log to layer GROUND Log at Left cutting edge Lower all elevations by 0 000 Ok _ Cancel Figure 3 58 Enter Parameters for a Topo Survey 3 Press Ok to start the topo survey function 4 Begin paving When the machine begins to move 3DMC begins measuring and logging the data 60 mmGPS 3D Paver Reference Manual Tools Menu 5 To stop topo measurements press Topcon Logo gt Stop topo survey Figure 3 59 Otherwise 3DMC continues to log measurements Stop topo survey Position check Configure radios Figure 3 59 Stop Topo Survey Measurement data is saved in the currently selected point file 6 Copy the point file to an external memory card for analysis or design work in the office Position Check The position check option provides a daily benchmarking tool to verify that the calculated elevation and position are repeatable 1 To check the position of the screed press Topcon Logo gt Tools Position check The Position Check dialog box displays Figure 3 60 on page 3 62 P N 7010 078
131. hould accompany the package furnishing a description of the problem and or defect The purchaser s sole remedy shall be replacement as provided above In no event shall TPS be liable for any damages or other claim including any claim for lost profits lost savings or other incidental or consequential damages arising out of the use of or inability to use the product 1 The warranty against defects in Topcon battery charger or cable is 90 days P N 7010 0781 D 1 Warranty Terms Service Information Service assistance can be provided by contacting your local TOPCON dealer or by calling the Corporate Service Center Phone 800 443 4567 8 a m to 5 p m Pacific Time Monday through Friday FAX 925 460 1329 Travel charges are applied for any on site service whether warranty or non warranty in nature D 2 mmGPS 3D Paver Reference Manual Appendix E 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 Grade and Slope Controls
132. iated cables are installed when first installing the system onto a Paver No adjustments are necessary but ensure that caps are in place on unused connectors 1 8 mmGPS 3D Paver Reference Manual Machine Components Figure 1 10 Junction Box 9168 Control Box The 9168 control box Figure 1 11 on page 1 10 is the operator s interface as well as the primary control for the mmGPS 3D Paver components The 9168 control box combines the System Five platform with a computer graphic display into a single rugged unit that provides dual hydraulic control for stakeless 3D GPS mmGPS and 2D control e The high resolution bright touch screen display easily adapts to a variety of machine applications providing the operator with easy to view graphical information A mounting bracket and one side or double side clamps secure the control box to the machine The clamps provide easy attachment at the beginning of the day and easy removal for storage in the carrying case at the end of the day All cables attach in the back and remove easily with quick disconnect connectors P N 7010 0781 1 9 Introduction Figure 1 11 mmGPS 3D Paver 9168 Control Box MC 2 5 Receiver Box The MC 2 5 Receiver Box Figure 1 12 on page 1 11 attaches to the machine with shock isolated magnetic mounts No manual adjustments are required and it can be removed at the end of the day for storage The MC 2 5 Receiver Box combines Topcon s GPS receiver mod
133. ides textual information graphic symbols and graphic mappings all of which the operator can use to prepare a job to apply changes on screens and functions and to perform machine paving For every operation simply tap the screen with a finger to make selections or enter information The screen s backlight varies automatically depending on ambient light so the operator can always view the screen s information under optimum brightness durable coating but avoid contact with any metal or abrasive object Prevent any hardware from contacting the touch screen display Do not rub or force dust from the surface z The surface of the touch screen display has a P N 7010 0781 3 5 Setting up the Machine and 3DMC Back and Side Panels The 9168 control box back and side panels Figure 3 3 include a compact flash card slot cable connectors for communication a cooling fan a speaker and the power switch Compact Flash Card Slot Speaker Power Switch Cooling Fan Outlet USB Port Cooling Fan Inlet Figure 3 3 9168 Control Box Back and Side Panel Compact Flash Card Slot The compact flash card slot allows you to transfer files to from the control box to a computer via a compact flash card The internal interface driver is compatible with commercially available compact flash cards A rubber flap seals the compact flash card slot preventing dust water and so forth from entry Keep the rubber flap
134. iguration File 6 7 Care and Maintenance of the Sonic Tracker 6 9 Sonic Tracker II Transducer Cleaning eee 6 9 Sonic Tracker II Transducer Replacement 6 10 Paving City Streets with Sonics 0 ieee eeeeseereeteceeeeees 6 16 Paving City Streets with Cross Slope eseese 6 18 Paving Streets Through Intersections ee eeeeeeeeeeeeee 6 20 Method 1 for Paving Intersections 0 0 0 eee 6 21 Method 2 for Paving Intersections 0 0 0 eee 6 22 Paving Intersections with Cross Slope essees 6 24 Chapter 7 Troubleshooting aiciihctisnctewtucrrcnttsnnicoienndemesdautvaewts 7 1 Base Station chica edie tian dancin sini it 7 2 MG 2 5 Receiver BOX croio eeii et Ea dei ascend 7 4 GPS Localization sister ncaa e e i 7 6 9168 Control Box iet sdet idee eel eel eieleceste 7 9 Appendix A Safety Information ccccccssseeeeeeeeeeeesseeceeeeeeeeeeeees A 1 General Precautions 2 0 0 ccc eeceseeseeseceseeeeeeeseeaecnseeneeeees A 1 Radio Usage Information seeeeseeeeeeseeeeseseeerrereeresresreees A 3 P N 7010 0781 v Table of Contents Appendix B Specifications nisihi ee ieaiaia reai B 1 Control BOX Aeree anea erae Aese ei aE a iei B 1 Blade Slope Sensors nere carn iar nne a aa B 3 Simple Auto Manual Knob sesers B 4 MC 2 5 Receiver BOX eocen E N a B 5 PZS MC Sens r ennei eei B 7 GPS Vibration Polesian es B 8 Trackerjack Vibration Pole seseeeseceeseerereererseresereess B 9 E ser Tr
135. igure 2 10 on page 2 16 1 Tap Data gt Control gt lt none gt or file name 2 Tap New to create a control point file 3 Enter a name for the file and press Ok 4 Select the control point file and press Ok P N 7010 0781 2 15 Setting up the Jobsite and Pocket 3D 5 Press Yes to apply the file to the jobsite Control points Import Export Options lew Info Copy a Info Copy Delete Rename Save As Cancel Figure 2 10 Create a Control Point File Then enter control point data into the file Figure 2 11 on page 2 17 1 Tap Data gt Control gt Control points 2 Tap Add to enter the local coordinates for the control point 3 Enter a name and description for the control point and its local coordinates Press Ok Repeat steps 2 and 3 for each control point 5 Press Ok to save the data 2 16 mmGPS 3D Paver Reference Manual Equipment Setup GPS H Error V Error Control points Import Export Options Coords GPS North 5000 000 East 5000 000 Elev 100 000 Figure 2 11 Enter Control Points Step 2 Setup and Initialize a Base Station Transmitter For a GPS Base Station enter antenna and radio information Figure 2 12 on page 2 18 1 2 Connect the controller and receiver Tap Setup gt Base station Select the control point over which the base statio
136. igure 3 45 Enter Sensor Information Lal Mounting location Right side of blade 3 Select and enter the following antenna information then press Next Figure 3 46 on page 3 48 When entering measurements use the same units of measure selected in the previous step e Antenna select the type of antenna Topcon PZS MC P N 7010 0781 3 47 Setting up the Machine and 3DMC Above 1 enter the vertical distance from the metal rim of the antenna to the bottom edge of the screed when elevated to the proper mat thickness e Inside 2 enter the horizontal distance from the metal rim of the antenna to the outer edge of the screed e Behind 3 enter the horizontal distance from the metal rim of the antenna to the back edge of the screed e Width 4 enter the horizontal distance from the left edge to the right edge of the screed Antenna Topcon PZS MC mmGPS Above 1 11 79 Inside 2 4 92 Behind 3 0 00 ee Width 4 9 84 Back Next Cancel 2 3 Figure 3 46 Enter Antenna Location Information direct affect on paving accuracy Take each T Incorrect measurements or data entry errors have a measurement twice to ensure accuracy 4 Select the GPS precisions for measuring moving and static points Press Next to continue Figure 3 47 on page 3 49 3 48 mmGPS 3D Paver Reference Manual Control Menu Max GPS errors roving Max Horizontal RMS 0
137. ition tab displays current locations for the left and right sides of the screed Figure 3 90 These values are based on the local site coordinates providing quick position and elevation checks at particular points on the project The Z values on this tab match the elevation numbers on the Adjust elevation dialog box Fix _ Position Satellites Info Planning N 11372 771 E 8878 018 Z 56 178 N 11372 771 E 8868 176 Z 56 277 Ok Cancel Figure 3 90 GPS Info Position Tab P N 7010 0781 3 83 Setting up the Machine and 3DMC Monitor Satellites and Enter Mask Angle To monitor the current distribution of satellites or enter the mask angle for satellites press the GPS status button then tap the Satellites tab on the GPS status dialog box The Satellites tab displays the following information Figure 3 91 e Satellite plot displays used and unused satellites and the current mask angle Blue dots GPS satellites Red with cross dots GLONASS satellites Black dots unused satellites Red mask circle satellites inside are used for positioning e Mask angle enter the mask angle for the jobsite Fix _ Position Satellites Info Planning Mask angle 10 Ok Cancel Figure 3 91 GPS Info Satellites Tab View Receiver Information or Reset Receiver The Info tab displays the following Figure 3 92 on page 3 85 e Identification information firmware
138. its in the files currently being used Note that any conversion will not affect grade accuracy e Distances select either Meters US survey feet International feet or Feet Inches measures to a fraction of an inch If using Feet Inches all values show as 1 11 1 2 where 12 inches equal 1 foot and any value smaller than an inch shows as a fraction of an inch e Distances decimal places select the number of decimal places from zero to four e Angles select either DD MM SS NDD MM SS or Gons e Grades select either Percent Run Rise or Rise Run P N 7010 0781 3 71 Setting up the Machine and 3DMC e Stations select either 100 000 1 00 000 10 0 000 or 1 000 000 e Volumes select either Cubic meters or Cubic yards e Coordinates select either North East Elev East North Elev or X Y Z Display Units Distances EEEE 3 d p Angles DD MM SS Grades Percent F Stations 1 000 000 E Volumes Cubic yards 7 Coordinates North East Elev 5 Ok Cancel Figure 3 74 Display Units About 3DMC To view About 3DMC information press Topcon Logo gt View gt About 3DMC The About 3DMC dialog box displays the version number copyright date and publisher and registered user Figure 3 75 GA 3DMC 6 11 Control firmware 0 OS date Copyright C 2002 2006 Topcon Positioning Systems Registered to JON DOE Options Ok Figur
139. ive value is a Fill e Press the buttons on the joystick to quickly increase or decrease the offset value P N 7010 0781 3 81 Setting up the Machine and 3DMC 7 8 lt lt 5 6 4 1 2 3 G ok Cancel Figure 3 87 Enter New Offset on Numeric Keyboard 4 Press OK to set the new offset value and return to the 3DMC Main Screen Viewing GPS Information To view the GPS information dialog box and tabs press the Elevation control key then press the GPS info button Figure 3 88 Elevation left edge 56 277 Elevation right edge 56 178 1a Elevation valve gain 75 Set Elevation set point U 0U0 Set Match Zero O GPS info Ok Cancel Figure 3 88 View GPS Information The following sections describe the GPS information tabs 3 82 mmGPS 3D Paver Reference Manual Elevation Control Key GPS Status and Quality The Fix tab displays satellite status and positioning quality based on GPS satellites currently being tracked Figure 3 89 Once a GPS solution is initialized 3DMC reports the Fix status The positioning quality is an estimation computed from valid satellite status RMS Root Mean Square Fix Position Satellites Info Planning Initialized mm GPS Total sats tracked 16 GPS sats used 9 GLONASS sats used 5 Horizontal RMS 0 049 Vertical RMS 0 066 Onn Cancel Figure 3 89 GPS Info Fix Tab Screed Edge Position The Pos
140. k that the Control Points file used has a minimum of three localized points Perform the localization process again No GPS localization has been performed for the project Plan to implement the GPS localization See GPS Localization on page 5 18 for detailed instructions Problem Loading or Building message Causes Solutions The program in the control box is in the middle of loading files or making graphics If the pointer on the Main Screen moves when you tap in different places the control box is computing When the system is busy the pointer becomes an hourglass Wait for a few minutes to let it complete the process Remember computing takes longer when a larger file is selected If the pointer does not move the control box may have a computing problem Switching off the control box can fix the computing problem P N 7010 0781 Troubleshooting Problem Elevation Slope Control pad displays GPS receiver not connected Waiting for radio link Causes Radio transmission radio antenna lights status on the Legacy E receiver and or power may have a problem Causes Solutions Either the GPS signal For GPS signal check cable connections or radio signal is along the GPS antenna cable from the GPS invalid antenna port on the MC 2 5 Receiver Box The graphic may to the rover antenna indicate what causes Check
141. l Elevation valve gain displays the current valve gain setting for elevation control The valve gain setting determines the speed of the hydraulic response during automatic control A higher setting speeds up the response a lower setting slows down the response Survey used to quickly lock the screed on grade e Change to Slope used to switch to 2D slope control Elevation left edge Elevation right edge Elevation valve gain 75 Set Elevation set point _ 0 200 Set Survey Zero Change to Slope Ok Cancel Figure 3 83 Adjust Elevation Dialog Box 2D Control Changing Offsets Using the Elevation Control Key 1 On the 3DMC Main Screen press the Elevation Control key 2 Press the Elevation set point Set key changing it to red Figure 3 84 on page 3 80 P N 7010 0781 3 79 Setting up the Machine and 3DMC Elevation left edge 66 088 Elevation right edge 67 963 Elevation valve gain 75 Set Zero Elevation set point 0 000 GPS info Ok Cancel Figure 3 84 Press Elevation Control Key then Set 3 Change the offset using the numerical keyboard or the up down arrows next to the entry field Press the Elevation set point entry box tap in a new offset value and press Ok Figure 3 85 A negative value is a Cut a positive value is a Fill 7 8 lt lt 4 6 6 1 2 3 a Ok Cancel Figure 3
142. lashes e GPS GLONASS green flashes followed by red flashes To turn off the receiver press the PWR button for one to two seconds until LEDs are off Step 5 measure the antenna height from the control point to the rim slant or ARP vertical of the antenna Figure 2 5 on page 2 9 This measurement is used when initializing the Base Station 2 8 mmGPS 3D Paver Reference Manual Setting Up the Base Station Slant Height to Edge of Antenna Vertical Height to ARP Slant Height to SHMM Vertical Height to ARP Station Marker Station Marker Figure 2 5 Measure Base Station Antenna Height Base Station Initialization Before initializing the Base Station check the Units used in the current jobsite Setup Units and that the correct Control Point file is selected Data gt Control Figure 2 6 on page 2 10 shows the procedure listed below 1 Connect the controller and receiver Tap Setup gt Base station 2 Select the control point over which the Base Station is installed and the connection between controller and receiver Press Next 3 Enter antenna type and height information Press Ok Enter radio type and communication information If using a Pacific Crest PDL UHF radio press Configure to select channel information and press Set Press Next 5 Press Finish to initialize the GPS receiver and start the Base P N 7010 0781 2 9 Setting up the Jobsite and Pocket 3D 6 Immedia
143. lays a side view of the machine where the right side of the view is always the forward direction of machine travel The buttons increase and decrease magnification for this Left window view The Section view displays a cross section view of the screed and the selected Design Surface where the right side of the view is the right side of the screed The cut fill readings are provided on both sides of the screed and represent how far the screed is from on grade The buttons increase and decrease magnification for this Left window view The Grade indicator view acts as an infinitely scrolling grade tape displaying the amount of cut or fill in regards to the design surface For details on the Grade indicator pop up menu see Changing the Grade Indicator on page 3 73 P N 7010 0781 3 67 Setting up the Machine and 3DMC gt 12 290 Figure 3 69 Left Window Views The selected Left window view remains visible nore when showing Right and Lower window views Right Window Only the grade indicator is available as a view in the right window To access the right window view have the Plan view visible and press Topcon Logo gt View gt Right window Figure 3 70 then tap the view you want a check mark indicates the active view None indicates no right window is active Main window Left window vNone Right window Grade indicator Lower window Display options About 3DMC Figure 3 70 Right
144. lso removable components 1 18 2D control machine configuration files 3 45 6 5 setup 6 6 2D Paving applications Sonic control 6 1 3D control machine configuration files 3 45 6 5 3DMC about 3 86 setup of 5 13 3DMC buttons back 3 11 Cancel 3 11 copy key 3 10 delete key 3 11 edit key 3 10 New 3 10 next 3 11 Ok 3 11 3DMC Functions 3 9 3DMC Operations for Sonic Tracker Applications 6 7 Creating a 2D Machine Configuration File 6 7 9168 Control box compact flash card slot 3 6 control box front panel 3 2 9168 control box features 3 1 P N 7010 0781 Index A A and B point measurements 3 32 About 3DMC 3 86 Adjust slope 5 15 Alignment files and grading 3 51 display options 3 40 Angle of attack 4 2 Antenna and MC 2 5 LEDs 1 11 radio 1 14 5 10 Authorization codes 3 86 Automatic control Simple A M Knob control 1 15 Automatic mode and paving 6 17 Background change color 3 43 Base quality 4 13 controlling mat 4 14 differential compaction 4 13 rolling techniques 4 14 Base station LEDs 2 8 Quick setup checklist 5 2 Base Station Initialization steps to 2 9 2 10 Base Station Kit GPS Vibration Pole 1 7 GPS Receiver 1 4 PZL 1 Laser Transmitter 1 4 PZS 1 Sensor 1 4 PZS MC Sensor 1 6 Base Station Setup Rules 2 11 Benchmark 3 61 Index Index Cc Change color 3 25 radio channel 3 63 units 3 71 Change the light bar scale 3 75 Changing Offsets using the Elevation Control key 3 79 Checking mat depth 4
145. mitter For more information on the Pocket 3D software refer to the Pocket 3D User s Manual and Pocket 3D Reference Manual 1 Locate a control point over which to set up the PZL 1 laser transmitter See page 2 4 for detailed notes on how to setup and level a tripod 2 Attach the transmitter to the tripod 3 Turn on the transmitter s power and select a channel for the transmitter Figure 5 1 on page 5 4 To assign a channel to the transmitter press the channel button until the corresponding LED lights up 4 Connect the transmitter and Pocket 3D controller Figure 5 1 on page 5 4 P N 7010 0781 5 3 Getting Started Press button to select channel for transmitter Connect Pocket 3D controller and transmitter Figure 5 1 Setup PZL 1 Laser Transmitter Select Channel and Connect Controller 5 In Pocket 3D check that a mmGPS enabled machine configuration is loaded Then tap Setup gt mmGPS Transmitters to set up from one to four transmitters 5 4 mmGPS 3D Paver Reference Manual Equipment Setup and Calibration PZL 1Transmitter 6 On the Transmitters tab select the connection method used between the controller and transmitter Then perform one of the following functions Figure 5 2 To load transmitter data for the first time tap Download to retrieve calibration data from the connected transmitter The download is complete when the firmware version displays in the Firmware
146. mode Tools Menu The Tools menu contains options for collecting topographic points checking the position of the screed and configuring the radio This menu is not active for 2D applications Topo Survey 3DMC has the ability to perform an on the fly topographic survey of the whole project or any portion thereof This would be helpful when creating as build surfaces to determine amount of material to move 1 Tap Topcon Logo gt File gt Point files to display the Point files dialog box Create a new point file or select an existing point file Press Ok to return to the Main Screen 2 Tap Topcon Logo gt Tools gt Topo survey and enter or select the following information Figure 3 58 on page 3 60 Press Ok when done e Log by select between minimum distance or time interval Minimum distance measures each point at a set distance from the previous logged point Time interval measures points at a constant time interval P N 7010 0781 3 59 Setting up the Machine and 3DMC e Minimum distance available when minimum distance selected enter the minimum distance by which to log points e Time interval secs available when time interval selected enter the time interval in seconds in which to log points e Log to layer stores measured points to the selected layer e Log at determines the measurement point relative to the screed edge e Lower all elevations by used when keeping t
147. n 3 88 red 3 88 locked 3 89 measuring 1 7 Slope control system calibration 5 15 Slope sensor 1 7 1 8 5 26 Sloping plane surface creating 3 30 Sonic Control Setup Attach the Sonic Tracker 6 2 Set up 9168 Control Box 6 5 Sonic Tracker Applications change elevation side to slope 3 92 change slope side to elevation 3 92 changing control methods 3 92 Elevation Offset 3 87 Locking on grade 3 87 slope offset 3 91 Sonic Tracker II control method 5 29 transducer cleaning 6 9 Index transducer replacement 6 10 Specifications Blade Slope Sensor B 3 Control Box B 1 GPS vibration pole B 8 MC 2 5 Receiver B 5 PZS MC sensor B 7 Simple Auto Manual Knob B 4 Sonic Tracker II B 13 Trackerjack B 12 Trackerjack Vibration Pole B 9 Steer indication steer to polyline 3 51 Steering options 3 52 point of interest 3 52 Subgrade road creating 3 37 3 39 Maximum extension 3 39 Surface plane edit 3 27 Surface Files Creating a Flat Plane Surface 3 28 Flat plane surface 3 24 Raise lower existing surface 3 24 reference surface 3 23 Sloping plane surface 3 24 Subgrade of existing road 3 24 Survey see also Topographic survey System range C 1 T Teledesign radio 1 10 Test 1 12 EIM 1 12 Tools menu 3 13 Topcon logo 3 12 Topo survey display points 3 43 Topographic survey 3 59 3 61 stop 3 61 Touch screen display 3 5 Tow point 4 2 force P 4 5 Index P force 4 5 Tow point force truck exchange 4 5 Tow point path 4 2 Transmitter se
148. n control e The PZS 1 sensor and GPS receiver detects the laser beam and satellite signals providing millimeter accurate spot checks throughout the jobsite Figure 5 16 mmGPS 3D Paver at the Jobsite P N 7010 0781 5 23 Getting Started Placing Transmitters at the Jobsite The physical location of the laser transmitter on the jobsite should be outside the actual paving area if possible When choosing a location to place the laser transmitter remember the following two recommendations 1 Minimize the working distance from the laser transmitter As the distance from the laser transmitter increases paving accuracy decreases The following factors affect paving at long distances e Ground vibration from machinery working near the laser transmitter e Calibration error e Laser movement from blowing wind e Atmospheric conditions Keep the laser transmitter as low as possible Keeping the laser transmitter low where you can reach it will make setup and occasional adjustments easier The transmitter and laser receiver on the machine will also be more stable On windy days you may need to anchor the tripod to keep the laser transmitter from moving The laser transmitter does not need to be above the machinery on the job The benefits of keeping it low as well as GPS capabilities far outweigh the momentary loss of the laser beam due to passing equipment On small projects place the laser transmitter off the worki
149. n elevation adjustment Figure 3 35 on page 3 39 e A positive number raises the subgrade in comparison to the working reference surface e A negative number lowers the subgrade in comparison to the working reference surface e This value is applied to the centerline of the working reference surface 3 Select the type of grade Figure 3 35 on page 3 39 e If selecting Manual enter the percentage of the left right side of the subgrade element This determines the slope for the left right side of the machine or road If selecting Copy from use the gradient grade of the reference cross section element that matches the entered offset value lateral offset from centerline The left right grade is copied from the existing road 4 Select the slope extension for both the left and right side Figure 3 35 on page 3 39 3 38 mmGPS 3D Paver Reference Manual GPS Localization e If selecting Vertical the cross section of the subgrade stops at the same horizontal offset as the cross section of the reference surface e If selecting Continue the last element of both surfaces selected in the Maximum extension entry box is continued Select this option if there are more intersection points expected beyond the end of the cross section 5 If selecting Continue for either the left right side slope extension enter the Maximum extension This is the distance limit of how far the extension goes beyond the end of the cross
150. n is installed and the connection between controller and receiver Press Next Enter antenna type and height information Press Next Enter radio type and communication information If using a Pacific Crest PDL UHF radio press Configure to select channel information and press Set Press Next Select GPS receiver settings Press Finish to initialize the GPS receiver and start the Base P N 7010 0781 2 17 Setting up the Jobsite and Pocket 3D 6 Immediately disconnect the Pocket 3D controller from the receiver Performing any other activities while connected converts the Base to a Rover Control point Antenna type opcon PG Al Antenna height esc Equipment Measured to Base v Radios Units Fet Antenna F Base station ARETA et 3ll GPs receiver settings Pacific Crest PDL UHF FOM4 C Use co op tracking 4 Port Serial Port C J Use multipath reduction Sd y v Use GLONASS satellites Baud rate 38400 M CMR he Ready to connect Press the FINISH button to connect to GPS receiver Base started OK CTT TTT Figure 2 12 Enter Base Station Information and Start Base For a mmGPS transmitter enter transmitter information 1 Connect the controller and transmitter Check the channel of the transmitter Tap Setup gt mmGPS transmitters 2 Tap the Transmitters tab and press Download to retrieve calibration
151. name enter a name for the machine For easy identification later include the application type e Machine type select the type of machine P N 7010 0781 6 7 2D Paving Applications Configuration name PAVER SONIC Machine type Asphalt Paver Sensor type GPS antenna New J l Edit CORY L De Mounting location Right side of blade Ok Units of measure Feet eq ___ Next Cancel Figure 6 8 Creating the Machine File 4 Press Next until the Machine Configuration Complete dialog box displays then press Finish to save the file Other machine configuration measurements and settings are not required for 2D control L applications 5 Select the machine configuration file on the Machine files dialog box and press Ok to set this as the machine for the job so results in losing all information and require you T You must press Finish to save the file Failure to do to repeat the process 6 8 mmGPS 3D Paver Reference Manual Care and Maintenance of the Sonic Tracker Care and Maintenance of the Sonic Tracker The following guidelines provide for trouble free operation e Clean and dry all components prior to placing them into the carrying case Ensure that protective connector caps provided on some components are in place when not using the cables Water accumulation on the connectors can cause electrical shorts Do not use high pressure spray wat
152. nd allow it to thoroughly dry before storing any components Radio Usage Information All users must obtain an FCC Federal Communications Commission license before operating the GPS system GPS RTK Real Time Kinematic or simultaneous calculation of Global Positioning System and Global Navigation Satellite System The Federal Communications Commission is at http www fcc gov The rules are at http www access gpo gov nara cfr waisidx_00 47cfr90_00 html There have been many problems in the past with RTK base radio modems interfering with voice users The issue finally culminated with the FCC refusing to grant licenses until something was done to ensure that surveyors did not interfere with voice users The solution was to stop using frequencies in the 469MHz range to add an identifier to the broadcast message and other measures designed to minimize interference with voice users The user and his employer are subject to fines of up to 82 500 confiscation of surveying equipment and legal action if the rules are ignored Topcon cannot obtain the license for the user There are companies to assist with licensing Two are listed here Professional Licensing Consultants Inc P O Box 1714 Rockville MD 20849 1714 e Atlas License Company and Data Services 1725 A North Shadeland Avenue Indianapolis IN 46219 http www alcds com P N 7010 0781 A 3 Safety Information Notes
153. ng Figure 6 22 Subgrade O g y i I Centerline of Road Figure 6 22 Paving Uneven Curbs with Slope Control To keep the centerline in the middle of the road the second pass has to be set up with 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 6 23 on page 6 20 The cross is not consistent on this side of the roadway but the joints will match P N 7010 0781 6 19 2D Paving Applications Subgrade Centerline of Road Figure 6 23 Second Pass when Paving Uneven Curbs 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 6 24 Spot check every 25 50 feet by moving the laser Figure 6 24 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 6 20 mmGPS 3D Paver Reference Manual Paving Streets Through Intersections Method 1 for Paving Intersections For this method the base of the intersecting road is used as the reference
154. ng editing copying and deleting machine setup files if a road file is selected as the reference surface setting road subgrade properties selecting the steering indication configuring the PZS MC receiver configuring up to four PZL 1 laser transmitters calibrating the slope sensor applying valve offsets enabling 2D control creating editing copying and deleting machine setup files calibrating the slope sensor applying valve offsets Topo survey Position check Configure radios Valve offsets e disabling 2D control v2D Control Tools menu e collecting topographic points checking the position configuring the radio The Tools menu is not active for 2D applications P N 7010 0781 3 13 Setting up the Machine and 3DMC Table 3 3 3DMC Menus Description Continued Menu Available Functions View menu e displaying Plan Section and Profile A views in the Main Window Main window fe viewing a left window that displays the Left window Profile Section or Grade indicator Right window e viewing a right window that displays Lower window the Grade Indicator i 3 7 e viewing a lower window that displays Display options the Profile Section Light bar or Cut About 3DMC fill history for mmGPS applications viewing and selecting display options for various data menu options depend on the files selected for display e viewing
155. ng PZL 1 Transmitter Information 3 55 Calibrate Sensors Averaging ceeeeeesceeeceeeeeeees 3 56 Averaging Value Range 1 100 oe eee 3 56 Valve Offsets nennen aided aaa 3 57 2D Control sia Se eee 3 59 LOOIS Men Foennec imanan ei a a suite ates 3 59 TODO S TVE J anie ap Manan winnie 3 59 Position Check ameninte iea ie ict 3 61 Configure Radios 0 ce eececeseeseeereeeeceeeeeeeeneeesees 3 63 Mew Ment seeiis nitatean ene ane eaa nie 3 64 Main Window riaria neta e A ER 3 65 Eeft Window sirro sniscinremecaie ii a 3 67 Right WaindOw inene es 3 68 Lower Window 3 2 055 cette ti deen ene enieeee 3 69 Display Options is nasses niinniin riis 3 71 About 3DM CG weiss stiches iaa 3 72 Changing Cut Fill Offsets eeeeeeeeneereerrrerrrrereeen 3 73 Changing the Grade Indicator oe eeeeeeneeeeees 3 73 Changing the Light Bar Scale eee 3 75 Elevation Control Key oo cee ceeeeseeseeeeceseceeeeeeeeeeeenaees 3 76 Adjust Elevation in mmGPS Control eee 3 78 Adjust Elevation in 2D Control sser 3 79 Changing Offsets Using the Elevation Control Key 3 79 Adjusting Valve Gain cece seeeeseeeseeeseceeeeeneeenees 3 81 Viewing GPS Information n se 3 82 GPS Status and Quality oseese 3 83 Screed Edge Position o e 3 83 Monitor Satellites and Enter Mask Angle 3 84 View Receiver Information or Reset Receiver 3 84 Satellite Planning Information eee 3 85 Viewing and Updating 3DMC Options eee 3 8
156. ng area Figure 5 17 on page 5 25 The working distance from your laser will indicate the type of project small or large 5 24 mmGPS 3D Paver Reference Manual Control Methods Figure 5 17 Laser Transmitter Placement Small Project On larger projects place the laser transmitter in the center of the project to maximize the area you can pave and minimize the distance from the laser Figure 5 18 Figure 5 18 Laser Transmitter Placement Larger Project For particularly large projects you can use up to four PZL 1 laser transmitters to increase the working range of the sensors P N 7010 0781 5 25 Getting Started Using Multiple Transmitters Up to four PZL 1 laser transmitters can be used for a single job increasing the range of the sensors to cover nearly 8000ft 2438m in distance or up to 130ft 40m of elevation changes When using multiple transmitters you will use 3DMC and the Pocket 3D hand held controller to configure the PZS MC and PSZ 1 for detecting each transmitter When using multiple transmitters place each transmitter so that its beam will partially intersect the beam of its neighbor transmitter Figure 5 19 The PZL 1 laser transmitters can be placed on either level or hilly ground Figure 5 19 Multiple Laser Transmitter Placement Slope Control mmGPS 3D Paver uses a slope sensor mounted to the transducer beam on the paver to measure and control the sl
157. none gt a Control PT44 MANHOLES Surffice Line vork lt none gt Layers Listing Import Export New Layers Copy Delete Copy ok Rename Save As Cancel Cancel Figure 2 24 Create Points File 4 Press New Enter a name for the layer and the layer s parameters Press Ok Figure 2 25 5 Repeat step 4 for any other layers 6 Press Ok to save the file Press Yes to apply the file to the current jobsite Layer name LECTRIC I SEWER ELECTRIC Show point numbers Show point descriptions Show point elevations Symbol Dot 4a lew Edit Figure 2 25 Add Layers to Points File 2 26 mmGPS 3D Paver Reference Manual Creating Files in Pocket 3D Creating a Linework File 1 Tap Data gt Linework gt lt none gt or file name Press New Figure 2 26 Enter a name for the linework file and press Ok 3 Press Layers PP_ftopo_Nov20 New Layers Copy Delete Rename Save As Figure 2 26 Create Linework File 4 Press New Enter a name for the layer and the layer s parameters Press Ok Figure 2 27 5 Repeat step 4 for any other layers 6 Press Ok to save the file Press Yes to apply the file to the current jobsite Layer name E Z CENTERLINE CENTERLINE IROAD EDGE 4a New Edit Figure 2 27 Add Layers to Linework File P N 701
158. ntenna Location _ Base station Top of pole i Units New Edit Copy Delete Rename Save As Units Figure 2 14 Enter Configuration Type 3 Enter antenna information for the range pole Press Next 4 Enter radio information Press Next Radio type 3 Antenna type Pacific Crest PDL UHF v Topcon HiPer Plus mmGF Port Serial Port C v Antenna height 16 6 Baud rate 38400 J Measured to Base Format CMR S Connection Pocket 3D Serial Cable on COM1 E Cancel Figure 2 15 Enter Antenna Information and Measurements 5 ForammGPS Rover PZS 1 and receiver enter mmGPS parameters Refer to the Pocket 3D User s Manual for important information about these settings Press Next 6 Select the configuration and press Ok Press Yes Figure 2 16 on page 2 21 2 20 mmGPS 3D Paver Reference Manual GPS port Serial Port D Sensitivity Auto Channels All Advanced v mmGPS aided initialization Calc weighted i mmGPS GPS elevation Machine files HIPER MMGPS DOZER MMGPS Equipment Setup GPS Pocket 30 Set HIPER MMGPS to be the current equipment This will cancel all measurement operations Edit Copy Delete Rename Save As Back Next Cancel ok that may be active Figure 2 16 Enter Radio and mmGPS Information Set As Equipment Step 4 Setup the Rov
159. ntrol Points but at least four or more points should be used for the localization GPS localization is processed in the control point file created prior to beginning each project This control point file contains the formula necessary for the mathematical conversion between global GPS coordinates and NEZ coordinates A control point file can be localized using one of the following methods e Measuring each control point with a Topcon GPS or GPS RTK Survey Rover System and Pocket 3D Then entering this information into 3DMC See Localizing with Pocket 3D on page 2 24 for this procedure e Entering global GPS coordinates directly into 3DMC See Entering Localized GPS Coordinates on page 3 21 below for this procedure 3 20 mmGPS 3D Paver Reference Manual GPS Localization Entering Localized GPS Coordinates GPS localization is processed in the control point file created prior to beginning each project This control point file contains the formula necessary for the mathematical conversion between global GPS coordinates and NEZ coordinates The control point file can be localized by entering global GPS coordinates directly into the 9168 control box One of the following sources can measure points and provide coordinates e Each control point is measured with a Topcon GPS or GPS RTK Survey Rover System and Pocket 3D e A third party source provides GPS coordinates If the control point file in 3DMC needs to be update
160. o ES LO ED LA OD KS S 7 g 9 lt lt z x c v B N M 4 5 6 Space Bar 1 2 3 Numeric Keyboard p gt 0 gl Ok Cancel Accept Entry Cancel Entry Figure 3 8 Keyboards Topcon Logo Key The Topcon Logo key at the top right corner of the Main Screen displays a pop up bar of four menus File Control Tools and View To access the Topcon Logo menus tap the Topcon Logo in the far right corner The four menus display Figure 3 9 Unless used the menus disappear after 10 seconds 2D oy Press Topcon Logo Key to view menus Figure 3 9 Topcon Logo Menus 3 12 mmGPS 3D Paver Reference Manual 3DMC Table 3 3 describes the functions available under each menu Table 3 3 3DMC Menus Description Linework Point files Exit 3DMC Menu Available Functions File menu creating editing and deleting control point files Control creating editing and selecting Surfaces working and reference design surface Alignments files selecting alignment files selecting linework files creating editing and deleting point files exiting 3DMC Control menu mmGPS applications Machine setup Road subgrade Steer indication PZS MC receiver PZL 1 transmitters Calibrate sensors Valve offsets 2D Control Control menu 2D applications Machine setup Calibrate sensors creati
161. oblem Legacy E or Hiper Lite receiver does not power on Causes Solutions The PWR button was Make sure you hold the PWR button down pressed too quickly for at least one second A quick press will not activate the receiver The power cable is Check that the power cable is correctly incorrectly connected connected to the battery RED to positive or damaged and BLACK to negative and that the battery is charged Check that the RED dots on the power cable connector and the socket on the receiver are aligned and the cable is pushed in as far as it can go If the power cable is damaged contact your dealer to replace it Problem Radio modem does not power on Causes Solutions The power cable is Check that the power cable is correctly incorrectly connected connected to the battery RED to positive or damaged and BLACK to negative and that the battery is charged If the power cable is damaged contact your dealer to purchase a new cable 7 2 mmGPS 3D Paver Reference Manual Base Station The radio receives power through the Legacy E receiver Problem Causes The Legacy E or Hiper Lite may be off Pocket 3D does not connect to Legacy E or Hiper Lite Some radios do not require a separate power supply but are supplied power through the port on the Legacy E For these radios check that the Legacy E is also switched on Solutions Check that the L
162. ol Methods Figure 5 24 Laser Control Above Grade As the screed is lowered the beam of light hits the laser receiver above the center a raise signal is indicated Figure 5 25 Figure 5 25 Laser Control Below Grade P N 7010 0781 5 31 Getting Started Notes 5 32 mmGPS 3D Paver Reference Manual Chapter 6 2D Paving Applications The type of controls you should use for paving depends on the end result or the finished product you want Some projects require smoothness and improved rideability Others are concerned with mat thickness and some require new asphalt to match curb and gutter or existing grades Once you have determined the job s requirements you can set up the correct system and begin paving e Some applications require a 2D set up This chapter discusses using 2D for curbs and joint matching job requirements e Some applications can simply use a mmGBPS set up See Chapter 3 for paving with mmGPS Using Sonic Control at the Jobsite If using a Sonic Tracker II at the jobsite first attach the Sonic Tracker then set up the control box When setting up a standard Sonic Tracker II system 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
163. on local site coordinates Elevation valve gain displays the current valve gain setting for elevation control The valve gain setting determines the speed of the hydraulic response during automatic control A higher setting speeds up the response a lower setting slows down the response Elevation set point displays the current elevation offset or amount of additional height applied to the design surface Match sets the current design surface to the elevation of the screed changing the elevation offset to zero The surface offset number then displays the distance from the new matched grade to the original design surface This key allows you to quickly adjust the machine to a more manageable surface Zero sets the elevation set point value to zero GPS info displays the GPS information dialog box see Viewing GPS Information on page 3 82 for details Elevation left edge 66 088 Elevation right edge 67 963 Elevation valve gain 75 Set Elevation set point 0 000 Set Match gt O Zero GPS info Ok Cancel Figure 3 82 Adjust Elevation Dialog Box mmGPS Control 3 78 mmGPS 3D Paver Reference Manual Elevation Control Key Adjust Elevation in 2D Control To display the following elevation settings for 2D applications Figure 3 83 press the Elevation Control Key Elevation left edge disabled for 2D control Elevation right edge disabled for 2D contro
164. on the transmitter s power and select a channel for the transmitter Figure 2 7 on page 2 13 To assign a channel to the transmitter press the channel button until the corresponding LED lights up 4 Connect the transmitter and Pocket 3D controller Figure 2 7 on page 2 13 9 12 mmGPS 3D Paver Reference Manual Setting up PZL 1 Press button to select channel for transmitter Connect Pocket 3D controller and transmitter Figure 2 7 Setup PZL 1 Laser Transmitter Select Channel and Connect Controller 5 In Pocket 3D check that a mmGPS enabled machine configuration is loaded Then tap Setup gt mmGPS Transmitters to set up from one to four transmitters P N 7010 0781 2 13 Setting up the Jobsite and Pocket 3D 6 On the Transmitters tab select the connection method used between the controller and transmitter Then perform one of the following functions Figure 2 8 To load transmitter data for the first time tap Download to retrieve calibration data from the connected transmitter The download is complete when the firmware version displays in the Firmware column To add a transmitter tap Add and enter a transmitter serial number or other description To delete a transmitter select a transmitter and tap Delete e To calibrate the transmitter see Transmitter Adjustment on page 2 32 Once the Transmitters tab contains a list of transmitters each transmitter must be set
165. onnect a controller and the HiPer Lite receiver refer to the controller s or receiver s documentation e Connect the following cables for the following components to the Legacy E receiver then to the component GPS antenna connect the antenna cable to the receiver s ANT port then to the GPS antenna Power connect the power cable to the receiver s PWR1 or PWR2 port Attach the alligator clamps to the battery RED to positive BLACK to negative P N 7010 0781 2 7 Setting up the Jobsite and Pocket 3D Radio Modem connect the radio modem cable to the receiver s port C and the radio modem Connect the other end to the battery Controller connect the cable with 7 pin circular connector to the receiver s port A Connect the other end of the cable to the controller The controller initializes the Base Station See Base Station Initialization on page 2 9 for details Y X N GPS Antenna A WN Power Battery Radio Modem Field Controller Figure 2 4 PG A1 Base Station Cable Connections Step 4 start the Base Station 1 Turn on the controller For a PG A1 Base Station turn on the radio and select the correct channel on the radio modem 2 Press the PWR button on the GPS receiver for one to two seconds The power LED flashes red then rapidly green Once powered up the number of successive red and green flashes indicates the number satellites being tracked e GPS only green f
166. ons of the PZS MC Sensor LL MACHINE MOUNT 1 750 015 DIA Figure B 5 PZS MC Sensor Dimensions P N 7010 0781 B 7 Specifications GPS Vibration Pole The GPS Vibration Pole features a steel pole with a larger diameter to improve stiffness Increased temperature range is provided by the use of high or low temperature bushings Table B 6 lists specification details for the GPS Vibration Pole Table B 6 GPS Vibration Pole Specifications Housing Base Cast aluminum Pole OD 1 75 in extruded aluminum Range 6 ft 7 1 2 in 201 9cm Weight 29 0 Ibs 13 0 kg Figure B 6 shows the dimensions of the GPS Vibration Pole 2 0 gt m lt 1 75 015 CI E fe CABLE MOUNT MOUNTING POST K 2 00 NOM Sea kel 04 5 gt p m 11 5 CA Figure B 6 GPS Vibration Pole Dimensions B 8 mmGPS 3D Paver Reference Manual Trackerjack Vibration Pole Trackerjack Vibration Pole The Trackerjack Vibration Pole has a lightweight shock isolation and vibration dampening design and is reinforced for rough applications Table B 7 lists specification details for the Trackerjack Vibration Pole Table B 7 Trackerjack Vibration Pole Specifications Housing Base Cast aluminum Pole OD 1 75 in extruded aluminum Range 5 ft 1 1 2 in 156 2cm Weight 22 3lbs 10 15kg
167. ope of the mat being laid Figure 5 20 on page 5 27 The sensor contains an electronic level vial that acts as a precision carpenter s level Slope control with this electronic level vial is very accurate and repeatable 5 26 mmGPS 3D Paver Reference Manual Control Methods Figure 5 20 Position of Slope Control on Paving System If the slope changes or to make required slope changes do the following e If the required slope changes while in automatic mode the two point cylinder on the slope side will raise or lower until the slope sensor measures the new slope Figure 5 21 on page 5 28 e The slope may be changed manually with the grade adjustment knobs if the Slope locked box has been enabled on the Adjust Slope screen see Adjust Elevation in mmGPS Control on page 3 78 e The slope may be adjusted at any time while in 2D mode using the grade adjustment knobs P N 7010 0781 5 27 Getting Started Figure 5 21 9168 Control Box Directing Where the Slope Sensor Paves 5 28 mmGPS 3D Paver Reference Manual Control Methods Sonic Control The Sonic Tracker II measures and controls the elevation of the machine controlling grade from a physical grade reference such as a curb stringline or existing road surface The Sonic Tracker II sends out sound pulses 39 times per second 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 re
168. ordinates generated in the MC 2 5 Receiver Box to local NEZ coordinates for a particular project The following steps help to ensure a high quality localization suitable for centimeter level machine paving with mmGPS 3D Paver e First the surveyor s local Control Points must be precisely measured The quality of measurements directly affects paving accuracy e Second the Control Points need to be located more or less evenly around the site Generally the more Control Points the better but if they are clustered together or are all at one section of the site then the results are less than ideal Locate Control Points evenly distributed around a perimeter of the site or paving area While not directly related to the quality of localization locate Control Points that are elevated easily accessible and not obstructed by trees buildings other structures moving vehicles and so forth e Third GPS localization requires a minimum of three Control Points but at least four or more points should be used for the localization P N 7010 0781 5 19 Getting Started GPS localization is processed in the control point file created prior to beginning each project This control point file contains the formula necessary for the mathematical conversion between global GPS coordinates and NEZ coordinates A control point file can be localized using one of the following methods e Measuring each control point with a Topcon GPS or GPS RTK Survey
169. ow direction significantly increasing the range of your system P N 7010 0781 c 1 Regulatory Information e Check the TPS accessory line for items to raise the Base radio FCC Compliance This device complies with Part 15 of the FCC rules Operation is subject to the following two conditions 1 This device may not cause harmful interference and 2 This device must accept any interference received including interference that may cause an unwanted operation This equipment has been tested and found to comply with the limits for a digital device pursuant to Part 15 of the FCC rules These limits are designed to provide reasonable protection against harmful interference in residential installations This equipment generates uses and can radiate radio frequency energy and if not installed and used in accordance with the instructions may cause harmful interference to radio communications However there is no guarantee that interference will not occur in a particular installation If this equipment does cause interference to radio or television equipment reception which can be determined by turning the equipment off and on the user is encouraged to try to correct the interference by one or more of the following measures e Reorient or relocate the receiving antenna e Move the equipment away from the receiver e Plug the equipment into an outlet on a circuit different from that to which the receiver is powered e Consult
170. pass then match grade on the next pass without moving the tracker Therefore the job application determines the position of the Tracker For example when using a stringline reference keep the Tracker about two feet above the string giving the operator about six inches of lateral movement to keep the Tracker over the string When tracking a curb lower the Tracker to keep it over the P N 7010 0781 6 1 2D Paving Applications 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 is 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 Step 1 Attach the Sonic Tracker 1 Position the machine next to the reference 2 Bend the L bars to align in the same direction and fold inward towards the screed Figure 6 1 Loosen the clamp handles if neede
171. r performing the GPS localization mathematical conversion Figure 3 16 Name MAGGIE Site coords WGS84 N 2065148 010 Lat N37 39 32 75938 E 6178836 880 _Lon W121 49 21 40995 4 Z 376 790 Hgt 295 40 Use for horizontal GPS localization Q Use for vertical GPS localization Measure Ok temr O Figure 3 16 Control Point Coordinates and GPS Localization 7 Press Ok to return to the Control point files dialog box 3 22 mmGPS 3D Paver Reference Manual GPS Localization 8 Repeat step 4 and step 7 on page 3 22 for all listed control points When finished check the horizontal H Error and vertical V Error values listed on the Control points dialog box They should be within acceptable tolerances Figure 3 17 Name H Error V Error MAGGIE 0 023 0 001 LISA 0 016 0 047 MARGE 0 006 0 048 HOMER 0 010 0 010 BART Add Edit Delete Ok Cancel Figure 3 17 Control Point Files with GPS Localization 9 Press Ok until you return to the 3DMC main screen saving the control point localization information and the control points file At this time make a backup copy of the control point file on a CF card Surface Files In mmGPS control applications the project engineer provides a design surface file for the jobsite Before paving the correct file must be copied into the 9168 control box and selected as the surface for the jobsite 3DMC supports th
172. re 3 42 Color Selections Points can represent topographic information backup control coordinates as build information and so forth See Creating a Points File on page 2 25 for more information 3 44 mmGPS 3D Paver Reference Manual Control Menu Exit 3DMC To exit mmGPS 3D Paver tap Topcon Logo gt File gt Exit 3DMC Figure 3 43 Control Surfaces Alignments Linework Point files Exit 3DMC Figure 3 43 Exit 3DMC Control Menu In the Control menu you can create edit copy and delete machine setup files If a road file is selected as the reference surface you can set road subgrade properties It is here also where the PZS MC receiver and the PZL 1 laser transmitters are configured In addition the slope sensor can be calibrated valve offsets are applied and 2D control is enabled Machine Setup The machine configuration file provides vital information about the type of machine the setup of the components on the machine machine measurements and radio configuration information You must have a machine configuration file before beginning to pave P N 7010 0781 3 45 Setting up the Machine and 3DMC and equipment to a mmGPS jobsite for control purposes For 2D applications a machine configuration file only determines the machine to display on the screen l Machine configuration files reference the machine Selecting a Machine Configuration When selecting a machine
173. revision and radio link information type latency and quality for the GPS receiver in the MC 2 5 Receiver Box e Reset RTK press to reset RTK ambiguities e Reset receiver press to clear all data and reset all settings stored for the MC 2 5 Receiver Box 3 84 mmGPS 3D Paver Reference Manual Elevation Control Key Fix Position Satellites Info Planning Receiver ID 1234567 Firmware Version 2 2 Radio link CMR age 3s 100 ResetRTK Reset receiver Ok Cancel Figure 3 92 GPS Info Info Tab Satellite Planning Information The Planning tab displays the estimated grading precisions on an hourly scale Figure 3 93 e Press the Next key to display the chart for the next day e Press the Prev key to display the chart for the previous day The Planning tab provides useful information for predicting GPS solution accuracy for paving The red vertical line marks the current time Fix Position Satellites Info Planning 02 Estimated precisions for F i Friday September 1st 2006 _Next Prev or 0 0 0000 0200 0400 0600 0800 1000 1200 1400 1600 1800 2000 2200 2400 Ok Cancel Figure 3 93 GPS Info Planning Tab P N 7010 0781 3 85 Setting up the Machine and 3DMC Viewing and Updating 3DMC Options 3DMC software uses authorization codes to enable the options screen For most applications these codes are initially entered at the factory
174. ribrach adapter into the tribrach P N 7010 0781 2 3 Setting up the Jobsite and Pocket 3D 3 Insert the horizontal spacer into the adapter and securely attach the GPS antenna to the spacer PG A1 antenna HiPer Lite receiver lt Horizontal Spacer Bhu Tribrach Adapter precision Universal Tribrach Figure 2 2 Base Station Setup 4 Roughly Level the Antenna Using the Circular Level Turn leveling screws A and B to move the bubble in the circular level The bubble is now located on a line perpendicular to a line running through the center of leveling screws A and B 9 4 mmGPS 3D Paver Reference Manual Setting Up the Base Station Leveling screw C Levelin 4 g screw A i 7 Leveling Gerd Turn leveling screw C to center the bubble in the circular level 5 Center Using the Plate Level Rotate the instrument horizontally using the horizontal motion clamp screw and place the plate level parallel with the line connecting leveling screws A and B Turn leveling screws A and B to bring the bubble to the center of the plate level Leveling Leveling screw A screw B Qs Rotate the instrument 90 around its vertical axis and turn leveling screw C to center the bubble once more C Leveling LA screw C 90 Repeat step 4 for each 90 rotation of the instrument and check that the bubble correctly centers at
175. rned echoes like a microphone Figure 1 17 Sonic Tracker Il 1 16 mmGPS 3D Paver Reference Manual Machine Components Trackerjack Vibration Pole The Trackerjack vibration pole Figure 1 18 provides a sturdy lightweight fixed mount for the Laser Tracker and Trackerjack for use in rough applications Figure 1 18 Trackerjack Vibration Pole System Configuration Figure 1 19 shows the system configuration for the mmGPS 3D Paver mil Figure 1 19 mmGPS 3D Paver System Configuration P N 7010 0781 1 17 Introduction Daily Care and Preventative Maintenance A good daily care and preventative maintenance routine prevents many problems before they occur The most important part of daily care for the system is to clean it and keep it free of debris and to thoroughly dry removable components PZS MC Sonic Tracker II control box and cables before storing them in the carrying case In addition the following procedures ensures trouble free operation e 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 e Keep the control box s touch screen clean to prevent scratching and from getting debris caught around the screen s edges pas A dirty screen or debris caught in the screen s edges KOJE can cause incorrect touch screen operation e Ensure that protective connector caps provided on some
176. rol Point GPS Localization This section lists possible GPS localization problems you may encounter If you still have problems after trying the solutions listed here contact TPS customer support Problem Causes The machine may be blocking satellite signals to the range pole or tripod mounted antenna Measurement takes too long Solutions Watch the status of the measurement screen If the status indicates waiting for satellites move the machine away from the antenna The Control Point may be located too close to obstructions Move to an alternative Control Point or have the surveyor place a new Control Point away from the obstructions 7 6 mmGPS 3D Paver Reference Manual GPS Localization The Rover GPS has not yet initialized the system may be tracking many satellites The status indicates waiting for better precision The Rover GPS may take several minutes to initialize The range pole was unsteady Problem Localization produces large errors Causes Solutions A typographical error If errors are 10s or 100s of feet or meters it occurred is likely that a typographical error has Make sure that the pole is held steady while measurement is taking place Any movement makes for a lengthy initialization and or measurement occurred If coordinates are manually entered check that longitudes are correctly prefixed with a
177. rrent above below grade yellow zone width Tap to change the above below grade zone P N 7010 0781 3 75 Setting up the Machine and 3DMC Extents displays the current scale unit spacing for the light bar Tap to change the unit spacing a TT TTA HTT TTT Green 5 000 0 000 10 000 20 0 Yellow 25 000 3D Extents 50 000 Figure 3 79 Light Bar Scale Indicators Elevation Control Key The Elevation Control Key displays elevation offsets The key also indicates the status of the connected sensor with graphics informational messages and colors The information displayed will be different depending on the control application Figure 3 80 and Figure 3 81 on page 3 77 Upper number in mmGPS control displays the current elevation offset and can be changed at any time If the machine is incapable of paving to the design elevation the operator dials an offset into 3DMC raising or lowering the design surface for a more manageable surface Lower number in mmGPS control displays the current surface reading The number continuously updates according to the elevation difference between the screed edge and the design reference surface Single number in 2D control displays the current elevation setting and can be changed at any time Elevation Control Key color the background color of the elevation control key indicates sensor status Green indicates sensor status suitable for paving 3
178. rt C Receiver sensitivity tT Transmitter selection Any Firmware version LaserZone aided initialization Calc LaserZone GPS weighted elevations Ok Cancel Figure 3 53 Temporarily Change PZS MC Receiver Information PZL 1 Transmitters PZL 1 Transmitter information is saved in the control point file Ensure the correct control point file is selected for the jobsite 1 Press Topcon Logo gt Control gt PZL 1 transmitters 2 Tap the channel tab that corresponds to the channel at the transmitter Figure 3 54 on page 3 55 3 54 mmGPS 3D Paver Reference Manual Control Menu 3 Enter the following information and press Ok Figure 3 54 e Select the serial number of the transmitter on this channel e Select the control point over which the transmitter is installed e Enter the height of the transmitter e Select the method used to measure the height of the transmitter PZLA Transmitters Ch 1 Ch 2 Ch 3 Ch 4 Transmitters Transmitter S N 900026 Control point PP3 Height of transmitter 6 560 Measured to Mark Slant Ok Cancel Figure 3 54 Set up PZL 1 Laser Transmitter in 3DMC Copying PZL 1 Transmitter Information The control point contains PZL 1 transmitter information Occasionally this information may need to be updated depending on day to day operations and possible setups As the job progresses the transmitter s position may have to be mo
179. rt Export East 5000 000 Optio Eley 100 000 Cale wizard it Delete mport Clear selection Figure 2 21 Select Control Point to Localize 4 Enable Use horizontal and Use Vertical and press Measure Press Ok to save the measurement Figure 2 22 Name PP3 Measuring Description Number of sats IIR H Precision Coords GPS V Precision s N33 14 52 00000 pial ee on eae aaa 320 00 Use horizontal Initialized se horizontal Use Vertical TTL Measurements Figure 2 22 Measure Control Point 2 24 mmGPS 3D Paver Reference Manual Creating Files in Pocket 3D 5 Repeat steps 2 3 and 4 for each control point 6 View the results and press Ok to save the control point file Figure 2 23 H Error V Error 0 038 0 022 0 094 0 007 0 005 0 022 Figure 2 23 Localized Control Points Creating Files in Pocket 3D In preparation for collecting point and polyline data create a points file and a linework file for the jobsite Creating a Points File 1 Tap Data gt Points gt lt none gt or file name Press New 2 Enter a name for the points file and press Ok 3 Press Layers Figure 2 24 on page 2 26 P N 7010 0781 2 25 Setting up the Jobsite and Pocket 3D O 2 New point file name MANHOLES E Poirt files Point files zpr 6484 lt ncne gt lt
180. se below the lip of curbs While paving slowly dial the display back to the previous number Method 2 for Paving Intersections 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 1 Take a section of 1 8 diameter string and nail or secure it to the curb 2 Pull the string tight through the intersection and nail or secure it to the other curb Figure 6 28 on page 6 23 6 22 mmGPS 3D Paver Reference Manual Paving Streets Through Intersections stringline up in the middle of the road to place the string at the proper height A hub or a stake with a piece of wire to hold the stringline works fine If the intersecting road has a crown hike the Figure 6 28 Paving Through Intersection Using Hub This constant reference gives you complete control through the intersection and ensures that you tie in perfectly to both curbs P N 7010 0781 6 23 2D Paving Applications 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 a combination of slope and tracker should be used Figure 6 29 Figure 6 29 Paving Intersections with Cross Slopes 1 Switch the A M Knob into manual mode just before the slope of the intersection be
181. se in the same way you use the touch screen to navigate through menus and enter information A rubber flap seals the USB port preventing dust water and so forth from entry Keep the rubber flap closed while not in use to prevent dust from entering the port P N 7010 0781 3 7 Setting up the Machine and 3DMC Power Switch The power switch Figure 3 4 turns on the control box as well as the sensors installed on the machine After a few moments the 3DMC software appears on the touch screen display and is ready to use orr E on Figure 3 4 Power Switch The control box saves and stores previous settings elevation offsets and the cross slope calibration Upon power up the 9168 control box applies these settings offsets and calibrations Except for variable day to day measurements of the receiver and the screed you can use saved calibrations and adjustments for several weeks or months Connectors The connectors Figure 3 5 supply power to the mmGPS 3D Paver machine and link system sensors and components installed on the machine with the 9168 control box A N On Power I O Bus A B ey Valves O C Ko A RS485 Port Valves Q V O D GO RS232 Port Figure 3 5 9168 Control Box Connectors Depending on your control application the connectors used during operation varies 3 8 mmGPS 3D Paver Reference Manual 3DMC 3DMC 3DMC is the software interface between the opera
182. sing Pocket 3D allows multiple users to work at the same time Hand held Controller and Pocket 3D Pocket 3D is grade and staking control software for hand held controllers At the jobsite Pocket 3D provides a way to make quick changes and updates to files double check control points initialize the GPS base and many other useful functions 3DMC and Pocket 3D save files in the same format which makes it easier for surveyors machine operators and grade checkers to share files and to update software l Refer to the Pocket 3D User s Manual and Pocket 3D Reference Manual for further details Before performing any Pocket 3D configuration or application function check the units used at the job Units are the method of measurement used for measuring various data To check change or apply units to the project tap Setup gt Units Figure 2 1 on page 2 2 P N 7010 0781 2 1 Setting up the Jobsite and Pocket 3D Distances US Survey feet Decimal Places J Angles DD MM SS Equipment Areas Square feet v Radios Volumes Cubic yards Antenna Coords North East Elev Base station S eminiecan Stations 1 00 000 Grades Percent v Cancel Figure 2 1 Setup Units Setting Up the Base Station The Base Station can be set up and taken down on a daily basis or mounted on a permanently fixed pole and left for the duration of the project A permanent setup prevents errors due to incorrect antenna height m
183. sitioned vertically and as high as possible on the machine to maximize signal reception Figure 5 6 1 Attach the radio antenna to the roof of the machine 2 Connect the radio antenna cable When the system has not been used for several days or months the antenna might have been removed for storage or transportation To reinstall the radio antenna set it up as described above and ensure the magnet mount attaches to an even and smooth surface Rover Radio Antenna Figure 5 6 Machine Radio Antenna Setup 5 10 mmGPS 3D Paver Reference Manual Equipment Setup Machine Components MC 2 5 Receiver Box Setup for mmGPS Applications The MC 2 5 Receiver Box is designed for quick attachment at the beginning of the day and quick removal at the end of the day When connecting cables to the receiver box Figure 5 7 ensure that the cables do not impede machine operation 1 If needed attach the MC 2 5 Receiver Box to a convenient location on the machine 2 Connect the PZS MC Sensor antenna cable to the MAIN GPS port 3 Connect the PZS MC Sensor serial cable to the MAIN C port Connect the radio antenna cable to the RADIO ANTENNA port 5 Connect the control box cable to the MAIN A port PZS MC Sensor back view i Radio SS Antenna ZSE MC 2 5 Receiver Box Figure 5 7 Connect Cables to MC 2 5 Receiver Box and 9168 Control Box P N 7010 0781 5 1
184. ss Configure if available to run the radio setting program 3DMC may take a few seconds to a few minutes to connect to the radio module and check the current setting When the current setting is confirmed the radio s channel and frequency information displays Figure 3 62 Radio type Pacific Crest PDL UHF Connected to Serial Port B Baud rate 38400 Format CMR Configure Ok Cancel Figure 3 62 Temporarily Change Radio Settings 2 Select the channel number The frequency of the channel changes automatically depending on the selected channel 3 Press Set to activate and save the new radio channel setting The radio setting program may take a few seconds to a few minutes to program and complete the process Figure 3 63 on page 3 64 P N 7010 0781 3 63 Setting up the Machine and 3DMC Channel 6 E Frequency 464 650 Mhz Set Cancel Figure 3 63 Radio Configuration Information module when changing radio configurations disconnect the radio antenna cable at the MC 2 5 Receiver Box Signals from the Base Station s radio can interfere with the machine s radio when making changes If you have difficulty connecting to the radio View Menu 3DMC can display several types of views each of which contain useful information From the View menu you can display the Plan Section and Profile views in the Main window display the Profile Section or Grade Indicator from the L
185. ss copy store display create derivative works of sell modify publish distribute or allow any third party access to any graphics content information or data in this Manual without TPS express written consent and may only use such information for the care and operation of your produce 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 System Five Topcon and Topcon Positioning Systems mmGPS Millimeter GPS Pocket 3D and Sonic Tracker II are trademarks or registered trademarks of TPS Windows is a registered trademark of Microsoft Corporation The P N 7010 0781 Vii Preface 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 Product and company names mentioned herein may be trademarks of their respective owners DISCLAIMER OF WARRANTY EXCEPT FOR ANY WARRANTIES IN AN APPENDIX OR A WARRANTY CARD ACCOMPANYING THE PRODUCT THIS MANUAL AND THE PRODUCTS 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 INCIDEN
186. ss 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 auger chain case 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 Refer to the Manufacturer s Manual for details Center Streak segregation is also caused by feeder gates being set too low 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 4 10 mmGPS 3D Paver Reference Manual Paver Components 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 1 Ensure that haul trucks take the shortest most practical route to the paver Make certain that all trucks take the same route to
187. t all times and wear protective clothing when working on or near hydraulic lines Hydraulic lines can be under extreme pressure even when the machine is turned off disconnecting or removing any lines fittings or related components If injury does occur seek medical assistance immediately fm Relieve all pressure in the hydraulic lines before 8 Avoid direct exposure to your eyes when using laser control DO NOT stare into the laser beam or view the beam directly with optical equipment 9 Use appropriate welding precautions and practices when welding After welding all paint all affected areas with a rust inhibitor DO NOT weld near hydraulic lines or on any equipment when in operation Disconnect all Topcon system electrical cables prior to welding on the machine All mounting bracket welds must be secure and strong to prevent the sensor equipment from vibrating excessively or from becoming detached at the weld during operation 10 To prevent vandalism or theft do not leave removable Topcon components on the machine at night Remove the components each evening and store appropriately in the carrying case 11 Keep the carrying case dry at all times DO NOT allow moisture to get inside the case Moisture trapped in the case can adversely affect components 2 mmGPS 3D Paver Reference Manual Radio Usage Information If moisture does enter the carrying case leave it open a
188. tely disconnect the Pocket 3D controller from the receiver Performing any other activities while connected to the Base Station converts the Base to a Rover 7 Check that the TX LED on the Base radio flashes once a second This indicates data transmission Antenna type 3 Antenna height esc Measured to Base 4 Units Feet M Control point Equipment Radios Connection Pocket 3D Serial Cable on COM1 Next Radio type GPS receiver settings Pacific Crest PDL UHF v v Use co op tracking z Use multipath reduction Port Serial PortC G Use GLONASS satellites Baud rate 38400 v Format CMR M Ready to connect Press the FINISH button to connect to GPS receiver Connecting to GPS ak pe ne Eed Enh Ence 4 Figure 2 6 Enter Base Station Information and Start Base PG A1 and Legacy E Example 2 10 mmGPS 3D Paver Reference Manual Setting Up the Base Station General Base Station Setup Rules and Notes e Every time the Base Station is setup a new slant measurement must be taken since the height of the antenna is different unless using a fixed height tripod or other permanent mount If using a permanent mount you only need to measure the height of the antenna once and initialize the Base Station once using Pocket 3D The Topcon receiver remembers the initial settings However if any setting stored in the receiver has been changed or initiali
189. 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 6 9 Figure 6 9 Remove Filter Foam 2 Remove the four screws and the black retaining ring Remove and discard the O Ring Figure 6 10 on page 6 11 O Rings are distorted and can loose elasticity due Always remove and discard used O Rings Used to weather or exposure to diesel fumes 6 10 mmGPS 3D Paver Reference Manual Care and Maintenance of the Sonic Tracker 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 6 10 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 6 11 on page 6 12 When cutting the Ty Wrap be careful not to cut or damage the wires P N 7010 0781 6 11 2D Paving Applications IQ AFL CARFUML Ve REMOVE WIRE COMIECORS Figure 6 11 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 plac
190. 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 thus maintaining correct mat thickness In 2D control the operator can control and monitor the slope and thickness of the mat using the knobs and displays located on the front panel of the 9168 control box Front Panel The control box front panel Figure 3 1 displays information about grade displays the 3DMC software and makes quick changes to offsets and other settings Auto Operation Grade Grade Indicators Indicators Grade Grade Adjustment Adjustment Direction p Direction Arrows And C Arrows And Knob Knob Display Brightness Touch Screen Sensor Display Figure 3 1 Control Box Front Panel Automatic Operation Indicators The automatic operation indicators the AUTO LEDs located above the grade indicators illuminate when activating one or both Auto Manual switches for 3 2 mmGPS 3D Paver Reference Manual 9168 Control Box Buttons and Features automatic grade control The AUTO LEDs are independent of each other Grade Indicators The grade indicators visually translate in real time the distance of the screed to on grade Table 3 1 describes the visual patterns to on grade Table 3 1 Grade Indicators LED Action Elevation Indicator Slope Indicator Slow Blinking Out of range Out of range Yellow 8 GPS over 4 ft above grade Over 2 above gra
191. the dealer or an experienced radio television technician for additional suggestions expressly approved by the party responsible for compliance could void your authority to operate such equipment Any changes or modifications to the equipment not C 2 mmGPS 3D Paver Reference Manual Community of Europe Compliance Community of Europe Compliance The product described in this manual is in compliance with the R amp TTE and EMC directives from the European Community Canadian Emission Labeling Requirements 1 Operation is subject to the following two conditions 1 this device may not cause interference and 2 this device must accept any interference including interference that may cause an unwanted operation of the device 2 To reduce potential radio interference to other users the antenna type and its gain should be so chosen that the equivalent isotropically radiated power e i r p is not more than that permitted for successful communication 3 This Class B digital apparatus meets all requirements of the Canadian Interference Causing Equipment Regulations Cet appareil num rique de la classe B respecte conform a la norme NMB 003 du Canada P N 7010 0781 c 3 Regulatory Information WEEE Directive Following information is for EU member states only The use of the symbol indicates that this product may not be treated as household waste By ensuring this product is disposed of correctly you help to prev
192. 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 4 2 The screed always seek it s own Planning Angle or angle of attack dependent on the combination of forces acting upon the screed Figure 4 2 Existing Surface Figure 4 2 Tow Point Path and Planning Angle e If the screed angle of attack is increased the screed rises increasing the mat thickness Figure 4 3 e If the screed angle of attack is decreased the screed settles providing a thinner mat surface Figure 4 3 Figure 4 3 Screed Determines Mat Thickness 4 2 mmGPS 3D Paver Reference Manual Paver Components 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 4 4 e If the 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 It 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 T N Gh 35 Tow Point Path 4 y S o 0 2 Tow Arm 1 Tow Arm
193. tion reference red arrow is on the right edge of the screed EEEL T Figure 3 77 Example Grade Indicator and In From Left Edge Cut fill 3 74 mmGPS 3D Paver Reference Manual Changing Cut Fill Offsets To change the on grade or extents press and hold the grade indicator for one second then tap the menu option you want Figure 3 78 e On grade displays the current on grade green zone width Tap to change the on grade zone e Extents displays the current scale unit spacing for the grade indicator Tap to change the unit spacing Red Fill Arrow Current Position of Edge Green On grade pm omni _ pms Grade display On grade 0 500 y Extents 3 000 Blue Cut Figure 3 78 Grade Indicator Pop up Menu Changing the Light Bar Scale The light bar displays the distance to the grade reference Much like the sonic tracker working window Figure 3 79 on page 3 76 green indicates on grade status yellow indicates above grade status and red indicates below grade or out of range To view the light bar scale press Topcon Logo gt View gt Lower window gt Light bar Figure 3 79 on page 3 76 To change the light bar scale press and hold the light bar scale for one second then tap the menu option of your choice Figure 3 79 on page 3 76 e Green displays the current on grade green zone width Tap to change the on grade zone e Yellow displays the cu
194. to control the vertical position of the screed in relation to the surface being paved Automatic grade and slope control systems helps tremendously in controlling mat smoothness but mat quality is also dependent on the following factors 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 thickness density surface appearance and mat quality If changes must be made make them as gradually as possible Abrupt changes in any of the above factors produces rapid changes in mat thickness adversely affecting mat quality z Changes in any of these factors causes a change in 4 14 mmGPS 3D Paver Reference Manual Chapter 5 Getting Started Millimeter GPS mmGPS combines the elevation accuracy of a laser with the horizontal and vertical accuracy of GPS receivers to provide millimeter accuracy while paving or surveying The system provides multiple rover support for machine and pole mounted sensors See Control Methods on page 5 23 for a dine discussion on placing transmitters around the jobsite and for using up to four transmitters mmGPS applications require both a GPS Base Station and a Base Transmitter the first to transmit GPS corrections and the second to transmit a laser plane An optional Rover surveying set
195. tor and the machine s components The menus and keys allow files to be created updated superimposed copied or deleted Information and files the operator can access are stored and continuously updated to the internal memory The main screen Figure 3 6 displays a graphical view of the current design surface the machine and status information of connected components Topcon Logo Key Zoom In Zoom Out Slope Control Key Elevation Control Key Figure 3 6 Main Screen The main screen has the following components e Display a graphical representation of the design surface and the machine The display varies according to the type of design surface file and selected display options Views include a superimposed triangle mesh contour lines alignment lines and points a partial blade cross section view and a machine profile view The sections in Display Options on page 3 71 starting describe the different displays available to view jobsite information and grade information Units can be in feet or metric Tapping anywhere on the display screen brings up a pop up menu see File Menu on page 3 14 for details P N 7010 0781 3 9 Setting up the Machine and 3DMC e Topcon Logo Key provides access to menus that control a variety of functions See Topcon Logo Key on page 3 12 for more information on the key and its menus Zoom In Key increases the magnification of the design view each time you t
196. trol Point File This section describes how to create the Control Point file using existing control point information The control point file created here may be tentative but provides a beginning from which to create a more thorough file later When creating a control point file neither the MC 2 5 Receiver Box nor any sensors need to be attached or ready to use at this stage The accuracy of measurements for local site a gt coordinates of a control point directly affects the quality of grade Turn on the control box 2 When the 3DMC main screen displays press Topcon Logo gt File gt Control 3 Press New and enter a name for the control point file press Ok on the keyboard then press OK again Figure 3 11 on page 3 16 P N 7010 0781 3 15 Setting up the Machine and 3DMC care Name SIMPSON FAMILY RANCH New Edit Copy Ok Cancel Figure 3 11 Press Copy and Select Location of Files 4 Select the newly created file and press Edit Then press Add Figure 3 12 POINT43 IMPSON FAMILY RANCH Name H Error V Error New Edit Copy De Ok wAdd Edit Delete SP Ok Cancel Figure 3 12 Edit Selected File 5 Enter the following information for the control point Figure 3 13 on page 3 17 e Name enter a unique name e Site coords enter the coordinates for northing N easting E and elevation Z mmGPS 3D Paver Re
197. 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 4 6 mmGPS 3D Paver Reference Manual Paver Components 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 forward motion Figure 4 10 Control of this force is a basic and necessary
198. tup information 2 14 5 5 to add 2 14 5 5 to calibrate 2 14 5 5 to delete 2 14 5 5 Transmitter adjustment 2 32 Transmitter height check 2 31 TX Calibration 2 33 U UHF usage C 1 Units 2 1 3 71 USB 3 7 v Valve gain 3 89 3 90 adjust 3 81 speed 3 89 3 90 Valve offset 3 57 5 16 calibration 3 57 3 59 5 17 5 18 factory preset 3 57 5 17 Views 3 14 3 67 grade indicator 3 69 Plan view 3 65 profile view 3 66 right window 3 68 section view 3 66 Ww Warranty Terms D 1 Warranty terms D 1 Weight of screed force W 4 5 4 12 Working distance 5 24 large project 5 25 small project 5 24 Working height 5 24 Working surface mmGPS Paver 3D Reference Manual Index definition 3 23 display options 3 25 P N 7010 0781 Index Notes Index mmGPS Paver 3D Reference Manual ae lA TOPCON Topcon Positioning Systems Inc 7400 National Drive Livermore CA 94550 800 443 4567 www topconpositioning com 3110384 9Y ISO 9001 2000 FM 68448 mmGPS 3D Paver Reference Manual P N 7010 0781 Rev A 6 07 20 2007 Topcon Corporation All rights reserved No unauthorized duplication
199. turn to the Main Screen Figure 3 39 Figure 3 39 Linework Display Main Screen Point Display Options When using a Point file press Topcon Logo gt View gt Display options gt Points to display the Points dialog box Figure 3 40 Layer GROUND Show point symbols on this layer Show point numbers on this layer ok Cancel Figure 3 40 Points Display Options Point files contain information about surveyed points and may represent topographic information control coordinates as build information and so forth A point file can contain one or more layers 1 To display the points layer on the Main Screen select the layer and press Ok Figure 3 40 3 42 mmGPS 3D Paver Reference Manual GPS Localization 2 To display points and or point numbers Figure 3 41 select the corresponding check box Figure 3 40 on page 3 42 and press Ok Figure 3 41 Topo Points on Main Screen Changing the Background Color Note that changing the background color does not affect the color of linework TIN alignments or point information Select a color that contrasts with on screen information 1 To change the background color of the Main Screen press Topcon Logo gt View gt Display options gt Background color 2 Select a color and press Ok Figure 3 42 on page 3 44 P N 7010 0781 3 43 Setting up the Machine and 3DMC Point Files i i Ok Cancel Figu
200. ule and a radio module into a single rugged housing e When used in conjunction with the PZL 1 laser transmitter and the PZS MC sensor the MC 2 5 Receiver Box provides 3DMC and the machine with millimeter level accuracy e When used in conjunction with a Base Station the MC 2 5 Receiver Box provides 3DMC and operator with Real Time Kinematic RTK measurements 1 10 mmGPS 3D Paver Reference Manual Machine Components 3DMC processes these real time measurements to compute paving and graphical mapping information Figure 1 12 MC 2 5 Rover GPS Receiver Box MC 2 5 Receiver Box Functions Three LED indicators on the MC 2 5 Receiver Box provides status on power satellites and radio signal Figure 1 13 on page 1 12 Two function FN buttons provide diagnostic and reset for the internal receiver boards e Radio RX LED radio status indicator This LED blinks green when receiving data from the Base Station typically once per second e Main LED and FN Button power and satellite indicator When the MC 2 5 Receiver Box is hooked up to power but is not connected to a GPS antenna and therefore not tracking any satellites only the red LED blinks When the MC 2 5 Receiver Box is attached to a GPS antenna green blinks indicate the number GPS satellites being tracked while red blinks indicate GLONASS satellites A pause precedes each repetition of blinks Pressing the FN button changes the Main receiver board s
201. up over a point with a known elevation tap the second radio button then enter the elevation Channel 1 Transmitter PP3 TX3 Control point O Known elevation of Rover PP3 EE TX height 5 000 Transmitter height Measured to Base v Previous 6 560 Benchmark check New height Resection Vert Difference Cancel Figure 2 30 Begin Height Check 7 Press Ok The Transmitter height fields displays the calculated difference between the height originally specified for the transmitter and the calculated height Figure 2 31 Known Rover control point PP3 O Known elevation of Rover Transmitter height Previous 6 560 New height 6 250 Vert Difference 0 310 Figure 2 31 Measure Height of Transmitter P N 7010 0781 2 31 Setting up the Jobsite and Pocket 3D 8 To apply this change to the transmitter setup press Ok Or press Cancel to exit without saving the measurement Transmitter Adjustment The adjustment function fixes errors in incline in the self leveling mechanism of the transmitter applying an offset to the transmitter 1 Set up the transmitter and tripod at an known control point 2 At the transmitter hold the plumb beam key then press and release the power key to put the transmitter into calibration mode 3 Turn the front of the transmitter towards the sensor Set up the PZS 1 sensor at the same level as the transmitter on relatively level ground and
202. up provides a GPS receiver radio and a laser sensor in one package for various site checking activities This chapter is designed to get the paving crew started using the mmGPS 3D Paver system The job application and the actual results determines what type of controls should be used that is mmGPS sonic slope or laser e For mmGPS setup first set up the PZL 1 laser transmitter over a control point then the PZS 1 sensor on a range pole then install the PZS MC sensor on the machine with a MC 2 5 receiver e For Sonic Tracker II setup attach the sonic trackers then setup the control box See Using Sonic Control at the Jobsite on page 6 1 for details e For laser tracker setup first setup the laser transmitter attach the laser tracker to the machine 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 P N 7010 0781 5 1 Getting Started Equipment Setup and Initialization Base Station The Base Station always sets up over a Control Point on the jobsite to ensure accuracy the Base Station GPS antenna must be positioned directly over the top of the Control Point The Base Station can be set up and taken down on a daily basis or can be mounted on a permanently fixed pole and left for the duration of the project A permanent setup prevents errors due to incorrect antenna height measurements When setting up
203. urface perpendicular to the direction of travel expressed by stating the rise or fall of a percentage of horizontal distance that is 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 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 E 4 mmGPS 3D Paver Reference Manual Glossary 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 W Wave Long repeating changes in the elevation of the mat surface Working Window Adjustable region of measurement used by the Sonic Tracker II to determine if elevation correction is required P N 7010 0781 E 5 Glossary Notes E 6 mmGPS 3D Paver Reference Manual Index Numerics 2D Components Sonic Tracker II 1 16 Trackerjack Vibration Pole 1 17 See a
204. utomatic and slowly dial the display to the slope you want Failing to survey when changing back to slope control could result in a bump in the mat 6 26 mmGPS 3D Paver Reference Manual Chapter 7 Troubleshooting In general as long as you follow the maintenance and safety instructions provided in this manual you should have few problems with your mmGPS 3D Paver system This chapter helps you diagnose and solve some common problems you may encounter with the various components Before contacting TPS Customer support about any problems try the following and see the following sections e Check that the various components radio Receiver Box control box Base Station receiver Base Transmitter and so forth have power and are powered up e Check that all cables are securely and properly connected to the various components of the mmGPS 3D Paver system control box transmitter receiver valves sensors and so forth e Disconnect cables and inspect them for damage or contamination Clean all connections with an electrical contact cleaner so voids your warranty and may damage the m Do not attempt to repair equipment yourself Doing hardware P N 7010 0781 7 1 Troubleshooting Base Station This section lists possible Base Station problems you may encounter also refer to the Base Station s documentation If you still have problems after trying the solutions listed here contact TPS customer support Pr
205. ved or multiple transmitters set up To change the transmitter s channel information see Setting up the PZL 1Transmitter in 3DMC on page 5 14 To copy transmitter information from an existing control point file first make sure the control point file has been copied to the control box from Pocket 3D 1 Press Topcon Logo gt Control gt PZL 1 transmitters 2 Tap the Transmitters tab and press Copy Figure 3 55 on page 3 56 P N 7010 0781 3 59 Setting up the Machine and 3DMC 3 Select an existing control point file that contains mmGPS transmitter data Press Ok Figure 3 55 Sransmitters S N Firmware Adjusted 900026 Sopy Transmit from gt copy IPP_topo_Nov20 Si S N Firmware Adjusted All PZL 1 transmitter and calibratjon data will be transferred to the current proj ct Press OK to continue Ok Cancel Figure 3 55 Copy Transmitter Data Calibrate Sensors Averaging The Average setting change the amount of dampening or filtering applied to the laser receiver or elevation sensor measurements Averaging can be thought of as the time period over which a running average of the elevation measurement is calculated Averaging Value Range 1 100 A lower value averages fewer elevation measurements allowing the system to react more quickly to grade changes A larger value averages more elevation measurements making the system less reactive to fluctuations in
206. w Figure 4 11 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 and segregation affects the internal stresses developed within the mix which in turn affects the resistance of the mix to flow under the screed reaction of material under screed 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 4 8 mmGPS 3D Paver Reference Manual Paver Components which in turn affects mat thickness and therefore mat smoothness Figure 4 12 Reaction of Material Under Screed Force R Figure 4 12 Reaction of Material Under Screed Gradation Mix Characteristics This aspect of the paving material varies according to the intended use of the material as a base course binder course or the final wearing surface Normally maximum aggregate size ratio of aggregates fines content and most importantly 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
207. zed like a reset function you need to re initialize the Base Station When the receiver tracks a sufficient number of satellites the receiver takes only a few seconds to process and report a successful start See Chapter 7 if the receiver fails to respond or fails to initialize e Ideally the Base Station should be placed in an area free of objects that can obstruct signals from satellites and degrade positioning accuracy Obstructions can include trees buildings vehicles or fences e Ideally the radio antenna should not be placed too close to the receiver For large job sites or sites with hilly terrain use a tall tripod or a sturdy structure to raise the radio antenna as high as possible for better radio transmission range P N 7010 0781 2 11 Setting up the Jobsite and Pocket 3D Setting up PZL 1 For machine control applications the PZL 1 transmitter attaches to either a standard tripod or a fixed 2m tripod over a surveyed point To locate the transmitter over an unknown point see Performing a Resection on page 2 28 The following setup requires Pocket 3D to activate and initialize the transmitter For more information on the Pocket 3D software refer to the Pocket 3D User s Manual and Pocket 3D Reference Manual 1 Locate a control point over which to set up the PZL 1 laser transmitter See page 2 4 for detailed notes on how to setup and level a tripod Attach the transmitter to the tripod 3 Turn

mmGPS 3D Paver Reference Manual

Contents

Download Pdf Manuals

Related Search

Related Contents