System Five-3Di
Reference Manual
EQUIPMENT AUTOMATION
P O S I T I O N I N G
S Y S T E M S
System Five-3Di
Reference Manual
GPS Indicate Systems
Part Number 7010-0680
Rev. A
©Copyright Topcon Positioning Systems
August, 2004
All contents in this manual are copyrighted by Topcon. All rights reserved.
The information contained herein may not be used, accessed, copied, stored,
displayed, sold, modified, published, or distributed, or otherwise reproduced
without express written consent from Topcon.
ECO#2288
Table of Contents
Preface .................................................................... vii
Terms and Conditions .......................................................... vii
Manual Conventions ............................................................ x
Chapter 1
Introduction ............................................................ 1-1
System Five-3Di Components ............................................. 1-1
Control Box ................................................................... 1-4
GPS MC-2.5 Receiver Box ........................................... 1-5
Machine GPS MC-A1 Antenna .................................... 1-5
GPS Vibration Pole ....................................................... 1-6
Base Station Kit ............................................................. 1-7
Pocket-3D ...................................................................... 1-8
System Five-3Di Elevation Overview ................................. 1-9
Chapter 2
Component Functions ........................................... 2-1
Control Box .........................................................................
Control Box Front Panel ...............................................
Grade Adjustment Knobs .......................................
Grade Adjustment Direction Arrows ......................
Brightness Sensor Window ....................................
Touch Screen Display .............................................
Control Box Back and Side Panels ...............................
Compact Flash Card Slot ........................................
Speaker ...................................................................
Cooling Fan Inlet and Outlet ..................................
USB Port .................................................................
Power Switch ..........................................................
Control Box Connectors ................................................
P/N 7010-0680
2-1
2-1
2-2
2-2
2-3
2-3
2-6
2-6
2-7
2-7
2-8
2-8
2-9
i
Table of Contents
Control Box Display Functions ...........................................
Topcon Logo Key .........................................................
File Menu ...............................................................
Control Menu .........................................................
Tools Menu ............................................................
View Menu .............................................................
Elevation Control Key ..................................................
Adjust Elevation .....................................................
GPS Info .................................................................
Control Box Authorization and Options .............................
Viewing Control Box Options ......................................
Updating Control Box Options .....................................
MC-2.5 GPS Receiver Box Functions ................................
Receiver Box Normal Mode .........................................
Receiver Box Extended Information Mode ..................
2-9
2-10
2-11
2-12
2-12
2-12
2-13
2-14
2-15
2-15
2-15
2-16
2-17
2-18
2-18
Chapter 3
Building Job Files ................................................... 3-1
Control Point Files ..............................................................
Using Pocket-3D To Create a Control Point File .........
Using System Five-3Di To Create a Control Point File
Design Surface Files ............................................................
Creating a Plane Surface Model ..........................................
3-1
3-1
3-6
3-10
3-11
Chapter 4
Jobsite Setup .......................................................... 4-1
Base Station Setup ...............................................................
Base Station Antenna Setup ..........................................
Connecting Base Station Cables ...................................
Base Station Power Setup .............................................
Base Station Initialization .............................................
General Base Station Setup Rules and Notes ...............
Machine Setup .....................................................................
Control Box Installation ...............................................
MC-A1 Antenna Installation ........................................
Machine Radio Antenna Installation ............................
MC-2.5 Receiver Box Installation ................................
Machine Configuration Files ........................................
ii
4-1
4-2
4-3
4-5
4-5
4-9
4-10
4-10
4-11
4-13
4-13
4-15
System Five-3Di Reference Manual
Table of Contents
Setting Blade Control .................................................... 4-18
Setting the Steer Indication ........................................... 4-19
GPS Localization ................................................................. 4-20
Principles of GPS Localization ..................................... 4-20
Methods of GPS Localization ....................................... 4-21
Method One: Localize with an
RTK Rover and Pocket-3D ................................. 4-22
Method Two: Enter Coordinates from a
Third Party ........................................................... 4-26
Method Three: Localize with the
Control Box and Machine ................................... 4-28
Chapter 5
Indicate Grading Application ................................ 5-1
Before Grading Checklist .................................................... 5-2
Beginning to Grade .............................................................. 5-3
Changing the View .............................................................. 5-4
Main Window Views .................................................... 5-4
Lower Window Views .................................................. 5-6
Left Window Views ...................................................... 5-8
Changing Cut/Fill Offsets .................................................... 5-10
Changing Offsets Using the Grade Adjustment Knob .. 5-10
Changing Offsets Using the Elevation Control Key ..... 5-10
Changing the Grade Indicator Scale .................................... 5-12
Checking the Blade’s Position ............................................. 5-13
Changing the Display Options ............................................. 5-14
Design Surface Display Options ................................... 5-14
Alignment Display Options ........................................... 5-16
Linework Display Options ............................................ 5-17
Point Display Options ................................................... 5-18
Changing the Background Color ................................... 5-19
Display Units Options ................................................... 5-20
Viewing GPS Information ................................................... 5-21
Viewing GPS Status and Quality .................................. 5-21
Viewing Cutting Edge Position ..................................... 5-22
Viewing Satellite Location and
Changing the Mask Angle ......................................... 5-22
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Table of Contents
Viewing Receiver Information and
Resetting the Receiver ...............................................
Viewing Satellite Planning Information .......................
Copying Files ......................................................................
Changing Radio Channels ...................................................
Steering and Grading to Polyline ........................................
Steering to Polyline .......................................................
Grading to Polyline .......................................................
Performing Topographic Surveys .......................................
Clearing the MC 2.5 Box NVRAM ....................................
5-23
5-23
5-24
5-26
5-28
5-28
5-30
5-31
5-33
Chapter 6
Maintenance & Troubleshooting ........................... 6-1
Daily Care ...........................................................................
Preventative Maintenance ...................................................
Touch Screen Display Cleaning ...................................
Pole-dampening Bushing Replacement on
GPS Vibration Pole ...................................................
Lubricating Quick Removal Knobs ..............................
Troubleshooting System
Five-3Di Components ......................................................
Base Station ..................................................................
MC-2.5 Receiver Box ...................................................
GPS Localization ..........................................................
Control Box ..................................................................
6-1
6-2
6-2
6-3
6-5
6-5
6-6
6-9
6-11
6-13
Appendix A
Safety Information .................................................. A-1
General Precautions .............................................................
Radio Usage Information ....................................................
General Usage Warnings .....................................................
Base Station Precautions .....................................................
Internal Battery Pack Warnings ..........................................
iv
A-1
A-3
A-4
A-5
A-6
System Five-3Di Reference Manual
Table of Contents
Appendix B
Specifications ......................................................... B-1
Control Box .........................................................................
MC-2.5 Receiver Box ..........................................................
MC-A1 GPS Antenna (Machine) ........................................
Base Station Kit ...................................................................
Legacy-E Receiver ........................................................
Radio Modem ................................................................
PG-A1 Antenna (Base Station) .....................................
B-1
B-2
B-5
B-6
B-6
B-7
B-8
Appendix C
Limited Warranty .................................................... C-1
Electronic and Mechanical Components .............................
Return and Repair ................................................................
Warranty Disclaimer ............................................................
Service Information .............................................................
C-1
C-1
C-1
C-2
Index
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Table of Contents
Notes:
vi
System Five-3Di Reference Manual
Preface
This manual has been developed to provide machine operators or
superintendents with information necessary to operate and maintain
the TOPCON System Five-3Di. Proper service and use is important
for reliable operation of the equipment. The sections provided in this
manual include information necessary for the correct operation, care,
and troubleshooting of this product.
NOTICE
NOTICE
Please read these Terms and Conditions carefully.
Terms and Conditions
USE – Please study this manual carefully. The benefits this product
provides can be greatly influenced by your applications knowledge.
Always wear the required safety attire (safety shoes, hard hat, etc.)
when operating or around equipment.
COPYRIGHT – All information contained in this Manual is the
intellectual property of, and copyrighted material of TPS. All rights
are reserved. You may not use, access, copy, store, display, create
derivative works of, sell, modify, publish, distribute, or allow any
third party access to, any graphics, content, information or data in this
Manual without TPS’ express written consent and may only use such
information for the care and operation of your product. The
information and data in this Manual are a valuable asset of TPS and
are developed by the expenditure of considerable work, time and
money, and are the result of original selection, coordination and
arrangement by TPS.
P/N 7010-0680
vii
Preface
TRADEMARKS – System Five-3Di™, MC-A1™, PG-A1™,
Topcon®, and Topcon Positioning Systems™ are trademarks or
registered trademarks of TPS. CE.NET™, Microsoft®, and
Windows® are trademarks or registered trademarks in the United
States and/or other countries. Product and company names mentioned
herein may be trademarks of their respective owners.
DISCLAIMER OF WARRANTY – EXCEPT FOR ANY
WARRANTIES IN AN APPENDIX OR A WARRANTY CARD
ACCOMPANYING THE PRODUCT, THIS MANUAL AND THE
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 INCIDENTAL
OR CONSEQUENTIAL DAMAGES RESULTING FROM THE
FURNISHING, PERFORMANCE OR USE OF THIS MATERIAL
OR THE PRODUCT. SUCH DISCLAIMED DAMAGES INCLUDE
BUT ARE NOT LIMITED TO LOSS OF TIME, LOSS OR
DESTRUCTION OF DATA, LOSS OF PROFIT, SAVINGS OR
REVENUE, OR LOSS OF THE PRODUCT’S USE. IN ADDITION
TPS IS NOT RESPONSIBLE OR LIABLE FOR DAMAGES OR
COSTS INCURRED IN CONNECTION WITH OBTAINING
SUBSTITUTE PRODUCTS OR SOFTWARE, CLAIMS BY
OTHERS, INCONVENIENCE, OR ANY OTHER COSTS. IN ANY
EVENT, TPS SHALL HAVE NO LIABILITY FOR DAMAGES OR
OTHERWISE TO YOU OR ANY OTHER PERSON OR ENTITY
IN EXCESS OF THE PURCHASE PRICE FOR THE PRODUCT.
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).
viii
System Five-3Di Reference Manual
Terms and Conditions
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.
MISCELLANEOUS – The above Terms and Conditions may be
amended, modified, superseded, or canceled at any time by TPS. The
above Terms and Conditions will be governed by, and construed in
accordance with, the laws of the State of California, without reference
to conflict of laws.
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.
P/N 7010-0680
ix
Preface
Manual Conventions
This manual uses the following conventions:
Example
Description
File Exit
Enter
Machine files
Name
TIP
Press the File menu, then press Exit.
Press the button or key labeled Enter.
Indicates the name of a dialog box or screen.
Indicates a field or tab on a dialog box or screen.
TIP
Supplementary information that can help you configure,
maintain, or set up a system.
NOTICE
NOTICE
Supplementary information that can have an affect on
system operation, system performance, measurements,
personal safety.
CAUTION
CAUTION
Notification that an action has the potential to
adversely affect system operation, system
performance, data integrity, or personal health.
WARNING
WARNING
Notification that an action will result in system damage,
loss of data, loss of warranty, or personal injury.
DANGER
DANGER
UNDER NO CIRCUMSTANCES SHOULD THIS ACTION BE
PERFORMED.
x
System Five-3Di Reference Manual
Chapter 1
Introduction
Topcon’s System Five-3Di™ for scraper, dozer, and compactor
indicate systems is a productive, indicate grading system providing
3D elevation grade control. 3D indicate is a three-dimensional, GPS
system using the System Five™ and GPS technology to precisely
locate the cutting edge of the machine, in real time, anywhere on the
construction site, reducing the need for costly stakeout and survey.
System Five-3Di Components
The System Five-3Di package consists of the following components:
• Machine Components:
Control Box
Cables
Mounting hardware
• GPS Components:
Machine antenna
Machine MC-2.5 receiver box
Straight pole/GPS vibration pole (machine dependent)
Base station kit
• Other Components:
Pocket-3D
Supporting accessories and software/hardware
Additional options
Figure 1-1 on page 1-2 and Figure 1-2 on page 1-3 illustrate the
System Five-3Di on a scraper and dozer. For compactors, the setup
and components are the same as a dozer system.
P/N 7010-0680
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Introduction
Figure 1-1. Scraper System Five-3Di
1-2
System Five-3Di Reference Manual
System Five-3Di Components
Figure 1-2. Dozer System Five-3Di
P/N 7010-0680
1-3
Introduction
Control Box
The Control Box (Figure 1-3) is the operator’s interface, as well as the
primary control for the System Five-3Di components. The Control
Box combines the System Five platform with a computer graphic
display into a single, rugged unit that provides three-dimensional,
stakeless GPS control.
• The high-resolution, bright touch screen display easily adapts to a
variety of machine applications, providing the operator with easyto-view graphical information.
• A mounting bracket and one side or double side clamps secure
the Control Box in the cab. The clamps provide easy attachment
at the beginning of the day and easy removal for storage in the
carrying case at the end of the day.
• All cables attach in the back and remove easily with quickdisconnect connectors.
Figure 1-3. System Five-3Di Control Box
1-4
System Five-3Di Reference Manual
System Five-3Di Components
GPS MC-2.5 Receiver Box
The GPS MC-2.5 Receiver Box (Figure 1-4) attaches to the machine
with shock isolated magnetic mounts. The MC-2.5 Receiver Box can
be easily removed at the end of each day for storage, and contains no
manual adjustment.
The MC-2.5 Receiver Box combines Topcon’s GPS receiver module
and a radio module into a single, rugged housing. When used in
conjunction with a Base Transmitter, this combination provides the
Control Box and operator with Real Time Kinematic (RTK)
measurements. The Control Box processes these real time
measurements to compute grade and graphical mapping information.
Figure 1-4. MC-2.5 Rover GPS Receiver Box
Machine GPS MC-A1 Antenna
In GPS indicate applications, the machine’s GPS MC-A1 Antenna
(Figure 1-5 on page 1-6) affixes to the top of the mounting pole
installed on the implement, blade, or scraper. The antenna should be
removed at the end of each day for storage.
The rugged antenna is specially designed to perform on earth-moving
machinery.
P/N 7010-0680
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Introduction
Figure 1-5. MC-A1 GPS Antenna
GPS Vibration Pole
The GPS Vibration Pole (Figure 1-6) installs on the dozer or
compactor’s machine blade with several types of mounts.
The GPS Vibration Pole provides a lightweight, fixed mount for the
MC-A1 antenna, and utilizes shock isolation and vibration
dampening.
Figure 1-6. GPS Vibration Pole
1-6
System Five-3Di Reference Manual
System Five-3Di Components
Base Station Kit
The Base Station Kit (Figure 1-7) sends position corrections to the
machines or survey Rover. As a remote system, an unlimited number
of machine or Rovers can use the Base Station. The kit includes
Topcon’s Legacy-E receiver, PG-A1 antenna, radio modem, tribrach,
cables, and a hard carrying case. In spread spectrum applications, the
HiPer Lite or HiPer Lite+ replaces the Legacy-E and PG-A1 antenna,
providing simple, one button, cable free operation.
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.
Figure 1-7. Base Station Kit – Legacy-E
P/N 7010-0680
1-7
Introduction
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 controller
that runs Pocket-PC (Figure 1-8) and uses files common with other
equipment on the job site, allowing multiple users to work at the same
time.
Using Pocket-3D on an FC-100 (or other Pocket-PC based hand-held
controller), you can:
• Set up and initialize the Base Station
• Create and edit Control Point files and Design Surface files
• Create and edit Machine Configuration files and radio
configuration files
• Create and edit Point files and Linework files
• Import and export files
• Perform stakeout and grade check
• Perform topographic surveys
Figure 1-8. Pocket-3D on the FC-100
1-8
System Five-3Di Reference Manual
System Five-3Di Elevation Overview
System Five-3Di Elevation
Overview
When measuring an elevation, System Five-3Di assumes the antenna
is perpendicular to the Design Surface (Figure 1-9).
For example: If grading begins on a flat surface and then moves to
grading up a 5% hill, System Five-3Di calculates the slope of the
mast. Once you begin grading uphill, System Five-3Di knows the
mast tips backward at a 5% slope, making the proper calculations to
maintain the correct grade.
With the added accuracy of RTK providing quick corrections from the
Base Station, the cut/fill reading precisely provides, in real time, the
difference between the cutting edge and the design elevation
(Figure 1-9).
Figure 1-9. GPS Design Application
P/N 7010-0680
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Introduction
Notes:
1-10
System Five-3Di Reference Manual
Chapter 2
Component Functions
The System Five-3Di™ components constantly communicate with
each other to provide accurate, real-time measurements. Each
component has specific function to provide operator control,
graphical jobsite displays, or GPS measurements for quick and easy
grading.
Control Box
The Control Box is the operator’s main interface with the System
Five-3Di, and provides the following functionality:
• displays the machine’s position and orientation, as well as the
distance between the cutting edge and finish grade
• translates user input into system commands
• communicates with system sensors, and processes information
• acts as a “personal computer” to support digital data
In indicate grading applications, the System Five-3Di controls
elevation.
Control Box Front Panel
The operator control System Five-3Di operation using the following
parts on the front of the Control Box (Figure 2-1 on page 2-2):
• Grade Adjustment Knobs – see page 2-2
• Grade Adjustment Direction Arrows – page 2-2
• Display Brightness Sensor – see page 2-3
• Touch Screen Display – see page 2-3
P/N 7010-0680
2-1
Component Functions
The Automatic Operation Indicators and Grade Indicators are not
active for System Five-3Di applications.
Figure 2-1. Control Box – Front Panel
Grade Adjustment Knobs
The grade adjustment knobs make measured adjustments to the
elevation settings, applying a Cut/Fill Offset to the Design Surface.
• Turn the knob clockwise to apply a cut, lowering the blade.
• Turn the knob counter clockwise to apply a fill, raising the blade.
Grade Adjustment Direction Arrows
During some maintenance and configuration operations, the grade
adjustment direction arrows indicate flash to indicate that the grade
adjustment knob is active to make the desired changes.
TIP
TIP
The grade adjustment direction arrows are not active
during grading operations for System Five-3Di.
2-2
System Five-3Di Reference Manual
Control Box
Brightness Sensor Window
The brightness sensor window allows an internal optical sensor to
measure ambient light, providing automatic adjustment of the
display’s backlight.
NOTICE
NOTICE
Blocking the brightness sensor may cause incorrect
adjustments of the display’s brightness level.
Touch Screen Display
The touch screen display provides textual information, graphic
symbols and graphic mapping, all of which the operator can use to
prepare a job, to apply changes on screens and functions, and to
perform machine grading. For every operation (except value changes
using the Grade Adjustment Knobs), simply tap the screen with a
finger to make selections or enter information.
The screen’s backlight varies automatically, depending on ambient
light, so the operator can always view the screen’s information under
optimum brightness.
NOTICE
NOTICE
The surface of the Touch Screen Display has a durable
coating, but avoid contact with metal or abrasive objects.
Prevent hardware from contacting the display. Do not rub
or force dust from the surface. See “Touch Screen Display
Cleaning” on page 6-2 for more information.
Also, avoid striking the display with heavy or sharp objects.
The various dialog boxes have buttons to perform operations, such as
creating, updating, copying, or deleting files (Figure 2-2 on page 2-4).
Any and all information the operator can access will be stored and
continuously updated to either the internal memory or a compact
flash card.
• New – Creates a new file or element.
• Edit – Changes an existing file or element. To edit a file, select a
file or element, then press the Edit key.
P/N 7010-0680
2-3
Component Functions
• Copy – Copies a file either from the compact flash card to the
internal memory or from the internal memory to the compact
flash card. To copy a file, select a file, then press the Copy key.
Copy new or edited files to the compact flash card to backup the
file.
• Delete – Removes an existing file or element from of the internal
memory. To delete a file or element, select a file and press the
Delete key.
NOTICE
NOTICE
Once you delete a file, it no longer exists. The file will need
to be created from the beginning.
• Next – Displays the next step or dialog box during an operation
after all applicable settings have been entered.
• Back – Displays the previous step or dialog box during an
operation.
• OK – Applies settings and inputs and exits the dialog box and/or
operation, or used to change files or apply settings in sub-screens.
• Cancel – Cancels or pauses an operation without applying
changes or edits. However, changes or edits on the previous
screen will still be applied.
Dialog Box Buttons
Figure 2-2. Example Dialog Box Buttons
2-4
System Five-3Di Reference Manual
Control Box
When entering text or numbers, one of the following two pop-up
keyboards displays:
• Alphanumeric keyboard – for entering letters and numbers
(Figure 2-3).
• Numeric keyboard – for entering numbers (Figure 2-4).
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.
Figure 2-3. Alphanumeric Pop-up Keyboard
Figure 2-4. Numeric Pop-up Keyboard
P/N 7010-0680
2-5
Component Functions
Control Box Back and Side Panels
The back and side panels of the Control Box (Figure 2-5) have the
following parts:
• Compact Flash Card Slot – see page 2-6
• Speaker – see page 2-7
• Cooling Fan Inlet – see page 2-7
• USB Port – see page 2-8
• Cooling Fan Outlet – see page 2-7
• Power Switch – see page 2-8
Figure 2-5. Control Box – Back and Side Panel
Compact Flash Card Slot
The compact flash card slot transfers files from the Control Box to a
computer or hand-held controller via a compact flash card. The
internal interface driver is compatible with commercially available
compact flash cards. A rubber flap seals the slot, preventing dust,
water, etc. from entry.
CAUTION
CAUTION
Keep the rubber flap closed at all times, even during
use, to prevent dust from entering the slot.
2-6
System Five-3Di Reference Manual
Control Box
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.
NOTICE
NOTICE
Occasionally, the control box may not properly detect the
compact flash card during a hot-swap procedure. If this
occurs, simply turn off and restart the control box.
CAUTION
CAUTION
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 air-cooling system to keep it from
overheating. When powered on, the Cooling Fan rotates, bringing air
in through the cooling fan inlet. The air then circulates through the
Control Box, cooling down components, and out the cooling fan
outlet. Air within the enclosure constantly circulates, automatically
cooling the internal heat sink plate.
NOTICE
NOTICE
Do not place objects that can obstruct air circulation near
the inlet and outlet.
P/N 7010-0680
2-7
Component Functions
USB Port
The USB port allows you to connect with a commercial keyboard or
mouse. You can use a keyboard or mouse in the same way you use the
touch screen: to navigate through menus and enter information. A
rubber flap seals the USB port, preventing dust, water, etc. from entry.
CAUTION
CAUTION
Keep the rubber flap closed while not in use to prevent
dust from entering the port.
Power Switch
The power switch (Figure 2-6) turns on the Control Box, as well as
the sensors installed on the machine. After a few moments, the Main
Screen of Topcon’s 3DMC application program appears on the touch
screen display and is ready to use.
Figure 2-6. Power Switch
The Control Box saves and stores previous settings, cut/fill offsets,
and the cross-slope calibration. Upon power-up, the Control Box
applies these settings, offsets, and calibrations. Except for the height
of the receiver measurements and blade wear calibrations, you can
use saved calibrations and adjustments for several weeks or months.
2-8
System Five-3Di Reference Manual
Control Box Display Functions
Control Box Connectors
The connectors (Figure 2-7) supply power to System Five-3Di
machine and link system sensors and components installed on the
machine with the Control Box.
Figure 2-7. Control Box – Connectors
Control Box Display Functions
The Control Box screen is the software interface between the operator
and the System Five-3Di components, and displays the menus needed
to configure and use your System Five-3Di components. The menus
and keys allow files to be created, updated, superimposed, copied, or
deleted. Information and files the operator can access will be stored
and continuously updated to either the internal memory or a compact
flash card.
The Main Screen (Figure 2-8 on page 2-10) of the Control Box
displays a graphical view of the current Design Surface, the machine,
and status information.
The main screen has the following components:
• Display – a graphical representation of the design surface and the
machine. Views include a superimposed triangle mesh, contour
lines, alignment lines and points, and a partial blade cross section
view and machine profile view. “Changing the Display Options”
on page 5-14 describes the different displays available to view
jobsite and grade information. Units can be in feet or metric.
P/N 7010-0680
2-9
Component Functions
• Pop-up Menus – tapping anywhere on the display screen brings
up a pop-up menu. Depending on the view, the pop-up menu
provides various functions, including design elevation at point
tapped, steer/grade to polyline, move control, and grade indicator
changes. For some pop-up menus, you may have to tap and hold
for up to one second.
• Topcon Logo Key – accesses the menus that control System
Five-3Di functions. See “Topcon Logo Key” on page 2-10 for
more information on the key and its menus.
• Zoom In Key – increases the magnification of the design view.
The zooming pivot is the center of the screen.
• Zoom Out Key – decreases the magnification of the design. The
zooming pivot is the center of the screen.
• Elevation Control Key – displays elevation control information
and indicates the status of the connected sensor. Tap this key to
view or edit elevation information. See “Elevation Control Key”
on page 2-13 for more information on this key and its menu.
Topcon Logo
Zoom In
Display
Zoom Out
Elevation Control
Key
Figure 2-8. Main Screen
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
(Figure 2-9 on page 2-11).
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Control Box Display Functions
Figure 2-9. Topcon Logo Menus
Unless used, the menus disappear after 10 seconds.
File Menu
The File menu (Figure 2-10) contains five primary functions and one
quick operation for:
• creating, editing, and deleting control point files
• creating, editing, and selecting design surface files
• selecting alignment files
• selecting linework
• creating, editing, and deleting point files
• exiting 3DMC
To access the File menu, tap Topcon Logo
File.
Figure 2-10. File Menu
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Component Functions
Control Menu
The Control menu (Figure 2-11) for Indicate systems contains the
machine setup, blade control, and steer indication functions.
To access the Control menu, tap Topcon Logo
Control.
Figure 2-11. Control Menu
Tools Menu
The Tools menu (Figure 2-12) contains three functions for:
• collecting topographic points
• checking the position
• configuring the radio
To access the Tools menu, tap Topcon Logo
Tools.
Figure 2-12. Tools Menu
View Menu
The View menu (Figure 2-13 on page 2-13) contains three primary
functions and one quick operation for:
• displaying Plan, Section, and Profile views in the Main Window
• viewing a lower window for Profile, Section, or Light bar
• viewing a left window for Profile, Section, or the Grade indicator
• viewing and selecting display options for design surface, points,
linework, background, and units; selections depend on the files
selected for display
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Control Box Display Functions
• viewing 3DMC information, authorization codes, and options
To access the View menu, tap Topcon Logo View.
Figure 2-13. View Menu
Elevation Control Key
The Elevation Control key displays cut/fill readings and the cut/fill
offsets for the elevation of the blade. The key also indicates the status
of the connected sensor with graphics, informational messages, and
colors (Figure 2-14 on page 2-13).
• Left number – displays the current cut/fill offset, and can be
changed at any time using the left Grade Adjustment Knob.
• Right number – displays the current cut/fill reading, or distance
from finish grade. The number continuously updates according to
the elevation difference between the cutting edge and the Design
Surface.
• Elevation Control Key color – the background color of the
elevation control key indicates sensor status. Green: sensor status
suitable for grading; Red: an error status.
When pressing the Elevation Control key, the Adjust elevation dialog
box displays, containing elevation information and elevation
configuration functions. See “Indicate Grading Application” on
page 5-1 for more details on using this dialog box.
Figure 2-14. Elevation Control Key
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Component Functions
Adjust Elevation
To display the Adjust elevation dialog box, press the Elevation
Control Key. The Adjust elevation dialog box (Figure 2-15) displays
the following:
• Elevation (left edge) – displays the elevation of the left edge of
the blade based on local site coordinates.
• Elevation (right edge) – displays the elevation of the right edge of
the blade based on local site coordinates.
• Elevation set point – displays the current cut/fill offset, or amount
of additional height applied to the Design Surface.
• Match – sets the current Design Surface to the elevation of the
cutting edge, changing the cut/fill reading to zero. The cut/fill
Offset number then displays the distance from the new, matched
grade to the original Design Surface. This key allows you to
quickly adjust the grade to a more manageable cut or fill.
• Zero – sets the elevation set point value to zero.
• GPS info – displays the GPS information dialog box.
Figure 2-15. Open Adjust Elevation Dialog Box
See “Changing Cut/Fill Offsets” on page 5-10 for details on adjusting
the elevation while grading.
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System Five-3Di Reference Manual
Control Box Authorization and Options
GPS Info
To view the GPS information dialog box and tabs (Figure 2-16),
press the Elevation control key, then press the GPS info button. For
more information on the various tabs, see “Viewing GPS
Information” on page 5-21.
Figure 2-16. GPS Information Dialog Box
Control Box Authorization and
Options
The Control Box and 3DMC software uses authorization codes to
enable the desired options. For most applications, these codes are
initially entered at the factory, but will need to be updated if updating
the options.
Viewing Control Box Options
To view the enabled options for your Control Box, press Topcon
Logo View About 3DMC. The about 3DMC dialog box displays
version number, copyright date and publisher, registered user, and
authorization codes (Figure 2-17 on page 2-16).
To view the options enabled for the Control Box (Figure 2-17 on
page 2-16), press Options. See the following section for details on
modifying the options for system upgrades or updates.
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Component Functions
Figure 2-17. About 3DMC and Control Box Options for System Five-3Di
Updating Control Box Options
Control Box options enable specific functions for different
applications. Sometimes, you may want to update the Control Box to
include other application functions.
1. To modify Control Box options, navigate to the Options dialog
box and press Modify (Figure 2-17).
2. From the ControlBox dialog box, record the Device identification
number to give to your Topcon representative. Contact your
Topcon representative to obtain new authorization codes for the
desired applications.
3. When you have received the new authorization codes, enter the
codes in the ControlBox dialog box using the alpha-numeric
keyboard (Figure 2-18 on page 2-17).
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System Five-3Di Reference Manual
MC-2.5 GPS Receiver Box Functions
Figure 2-18. Enter New Authorization Codes
4. Press Ok to apply the new codes and options. Press Ok on each
screen to return to the Main Screen.
5. Turn off, wait a couple seconds, and then on the Control Box to
activate the new passwords.
MC-2.5 GPS Receiver Box
Functions
Three LED indicators on the MC-2.5 GPS Receiver Box provide
status on power, satellites, and radio signal (Figure 2-19 on page 218). Two function (FN) buttons provide diagnostic and reset for the
internal receiver boards.
• Radio RX LED – radio status indicator. This LED blinks green
when receiving data from the Base Station, typically once per
second.
• Main LED and FN Button – power and satellite indicator.
– When the MC-2.5 box is hooked up to power, but is not
connected to a GPS antenna and therefore not tracking any
satellites, only the red LED blinks.
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Component Functions
– When the MC-2.5 box is attached to an MC-A1 GPS antenna,
green blinks indicate the number GPS satellites being
tracked. A pause precedes each repetition of blinks.
– Pressing the FN button changes the Main receiver board’s
information mode between Normal Mode and Extended
Information Mode. See “Receiver Box Extended Information
Mode” on page 2-18 for details.
• Aux LED and FN Button – only active in dual GPS applications.
Figure 2-19. MC-2.5 GPS Receiver Box Indicators
Receiver Box Normal Mode
In normal mode, the LED indicates the number of tracked satellites
and the position’s computation status.
Receiver Box Extended Information
Mode
EIM is 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.
• Orange – at least one blink is orange.
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MC-2.5 GPS Receiver Box Functions
• Red – no orange blink and at least one red blink.
• 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 (not applicable for
System Five-3Di).
Blink 4. Oscillator’s frequency offset is less than three ppm.
Blink 5. Oscillator's Allan Variance is better than 2.7e-10.
Blink 6. Continuous tracking time is more than 15 minutes.
The color of the blink indicates that information for test is unavailable
(orange), the receiver passed the test (green), or the receiver failed the
test (red).
1. To switch to EIM, press and quickly release (within one second)
the Main FN button.
2. Watch for the delimiter double-blink. With good receiver,
antenna, and observation conditions, all blinks should be green
within 15 minutes of powering on.
• Green – ok
• Orange – wait
• Red – some tests failed
3. To switch back to normal mode, press the Main FN button.
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Component Functions
Notes:
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System Five-3Di Reference Manual
Chapter 3
Building Job Files
Before beginning to work with the System Five-3Di™, you must have
job files that contain the various information needed to accurately
grade the jobsite. The job files you need include control point files
and design surface file. Using System Five-3Di, you can also create a
plane surface model to use for the design surface.
Control Point Files
The first task, when setting up the System Five-3Di on a new jobsite,
is to create a new Control Point file. You can use either Pocket-3D or
the Control Box to create your Control Point files.
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.
Using Pocket-3D To Create a Control
Point File
This section describes how to create the Control Point file using
Control Point information and Pocket-3D. The Control Point file
created here may be tentative, but will provide a beginning from
which to create a more thorough file later.
NOTICE
NOTICE
The accuracy of the surveyor’s measurements for local
site coordinates of Control points directly affects the quality
of grade.
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Building Job Files
1. On a hand-held controller (such as the FC-100) open Pocket-3D
and press Setup Units (Figure 3-1) to set unit parameters for
the job.
Figure 3-1. Pocket-3D – Open Units
2. On the Units dialog box, select the desired units for each item
from the drop-down lists (Figure 3-2). Press Ok to continue;
Pocket-3D saves the entered units.
Figure 3-2. Select Units
You can change these units at any time while operating Pocket3D; Pocket-3D automatically saves the changes.
TIP
TIP
Determine the units prior to selecting your desired values.
3. Press Data Control <none or file name> to select or create a
Control Points file (Figure 3-3 on page 3-3).
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System Five-3Di Reference Manual
Control Point Files
Figure 3-3. Select Control Point File
4. On the Control files dialog box, press New to create a Control
Point file (Figure 3-4).
5. On the New control file name dialog box (Figure 3-4), press the
blank entry box to display a pop-up keyboard. Enter the name for
the Control Point file and press Ok on the pop-up keyboard.
6. Press Ok to return to the Control files selection dialog box
(Figure 3-4).
Figure 3-4. Create a New Control Point File
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Building Job Files
7. Select your newly created control point file and press Ok
(Figure 3-5). When you press Ok, a verification screen displays
verifying that you want to use this Control Point file for the
current project (Figure 3-5).
Press Yes to use this file for your current jobsite and return to the
main screen. You may return to this screen later if you decide to
select a different Control Point file or to perform GPS
localization.
Figure 3-5. Select Control Point File and Apply to Current Jobsite
8. Press Data Control Control points to edit the selected
control point file.
9. On the control points dialog box (Figure 3-6 on page 3-4), press
Add to enter a control point and its respective information.
10. On the add control point description dialog box, enter a name,
description (if preferred), and local site coordinates for the
Control Point (Figure 3-6 on page 3-4).
Figure 3-6. Add Control Point Information
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System Five-3Di Reference Manual
Control Point Files
When you press an entry box, a pop-up keyboard displays in
which to type required information. Remember to press Ok on
the pop-up keyboard to set that information and return to the
Control Point description dialog box.
Once you have entered all information for this Control Point,
press Ok to return to the Control Points dialog box.
11. Repeat steps 9 and 10 for all available Control Points.
12. When finished entering available Control Points (Figure 3-7),
press Ok to save the Control Point file.
Figure 3-7. Entered Control Points
NOTICE
NOTICE
Data entry errors have a direct affect on grading accuracy.
NOTICE
NOTICE
You must press Ok to save the file. Failure to do so results
in losing all information and will require you to repeat the
process.
TIP
TIP
If you have been provided with precise global GPS
coordinates (latitude, longitude, and height) for each
Control Point, enter those values using the GPS tab. See
“GPS Localization” on page 4-20 for more details.
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Building Job Files
Using System Five-3Di To Create a
Control Point File
This section describes how to create the Control Point file using
Control Point information and the System Five-3Di Control Box. The
Control Point file created here may be tentative, but will provide a
beginning from which to create a more thorough file later.
If a Control Point file has already been created on a computer or the
Pocket-3D, and you want to transfer the file to the Control Box, you
will need the file on a compact flash card before copying it into the
Control Box. See “Copying Files” on page 5-24 for the copying
procedure.
NOTICE
NOTICE
The accuracy of the surveyor’s measurements for local site
coordinates of a Control Point directly affects the quality of
grade.
1. Power on the Control Box and allow the Topcon 3DMC
application program to start up.
2. Press Topcon Logo File Control Points. The Control point
files dialog box displays (Figure 3-8).
3. Press New to create a new Control Point file (Figure 3-8).
Figure 3-8. Create New Control Point File
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System Five-3Di Reference Manual
Control Point Files
4. Tap the “Name” entry box to display the alphanumeric pop-up
keyboard. Type a name for the Control Point file and press OK.
The new file displays on the Control point files dialog box
(Figure 3-9).
Figure 3-9. Control Files Dialog Box
5. Press Edit to display the Control points information dialog box
(Figure 3-10).
6. Press Add to display the Control point dialog box (Figure 3-10).
Figure 3-10. Control Points Information Dialog Box
7. Enter the following information (Figure 3-11 on page 3-8):
• Name – tap and enter a name for the control point.
• Site coords – tap in each site coordinate entry box and enter
the coordinates for northing (N), easting (E) and elevation
(Z).
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Building Job Files
• Check boxes – unless currently performing a GPS
localization, disable (uncheck) the two GPS localization
check boxes.
Figure 3-11. Control Point Coordinates Without GPS Localization
8. If necessary, press Measure to calculate precise WGS84 GPS
coordinates. On the Measure control point dialog box, select the
antenna type, enter the antenna height, and press Ok
(Figure 3-12).
During the measuring process, the Measuring dialog box
displays. When finished, the Control Point dialog box displays
the results (Figure 3-12).
Figure 3-12. Measure Control Point
9. Press Ok to save this control point. Repeat steps 6 through 9 for
all available control points.
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System Five-3Di Reference Manual
Control Point Files
10. Once you have added all control points (Figure 3-13), press OK
to save the control point file.
Figure 3-13. Control Points
NOTICE
NOTICE
Data entry errors have a direct affect on grading accuracy.
NOTICE
NOTICE
You must press Ok to save the file. Failure to do so will
result in losing all information and require you to repeat the
process.
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3-9
Building Job Files
Design Surface Files
For GPS applications, the project engineer provides a Design Surface
file for the jobsite. Before grading, the correct file must be copied
from a compact flash card to the System Five-3Di Control Box and
selected (see “Copying Files” on page 5-24 for details).
Once the Control Box contains the correct Design Surface file, select
it and apply it to the machine. Available Design Surface files depends
on the jobsite and project.
1. With the Control Box on, press Topcon Logo File Surfaces.
2. On the Surface files dialog box (Figure 3-14), select the correct
Design Surface file and press Ok to apply it to the machine. The
main screen updates with the file’s information.
Figure 3-14. Design Surface Files
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System Five-3Di Reference Manual
Creating a Plane Surface Model
Creating a Plane Surface
Model
System Five-3Di has the ability to create a plane surface model using
a unique, on-site method. The plane surface model is created on the
machine, in real-time, and can be used as a Design Surface file for
grading. Unlike conventional applications using a laser, using System
Five-3Di to create a surface model eliminates the required, repetitive
setup of a transmitter at the job site.
The plane surface model is composed of four basic factors: a mainfall
orientation, a mainfall grade, a crossfall grade, and a reference
elevation point on the plane. Just like aligning the rotating laser plane
and adjusting the laser receiver height, the operator needs to be
prepared with a set of relative information to fulfill the four factors.
This information is composed of three points: A, B, and an elevation
reference point.
Figure 3-15 on page 3-12 illustrates the basic factors needed for a
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.
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Building Job Files
Figure 3-15. Plane Surface Diagram
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System Five-3Di Reference Manual
Creating a Plane Surface Model
1. Follow the directions in “Machine Setup” on page 4-10 to setup
the System Five-3Di components for the procedures that follow.
2. Press Topcon Logo File Surfaces to display the Surface files
dialog box (Figure 3-16).
Figure 3-16. Design Surface Files
3. On the Surface files dialog box, press New to open the Surface
Name and Type dialog box (Figure 3-17), set the following
information, and press Next:
• Configuration name – tap and enter a name for the file.
• Surface type – select either flat plane surface (no slope) or
sloping plane surface (compound slope). If you select “flat
plane surface”, skip to the step 8 on page 3-15.
Figure 3-17. Surface Name and Type Dialog Box
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Building Job Files
4. Move the machine to point A and position the cutting edge on the
selected point. The Control Box accurately measures the point on
the cutting edge directly below the MC-A1 antenna and does not
compensate for a slant error of the sensor mast. Therefore, for a
more accurate measurement, keep the mast as vertical as possible.
5. On the Sloping Plane Surface dialog box, and when the cutting
edge rests on the point, press A to measure the point; the
Measuring dialog box displays during the measurement process
(Figure 3-18).
6. Move to B point and position the sensor on the cutting edge on
the selected point. On the Sloping Plane Surface dialog box, and
when the cutting edge rests on the point, press B to measure the
point; the Measuring dialog box displays during the
measurement process (Figure 3-18).
Press A/B to
measure mainfall
Figure 3-18. Measure Points A and B
Once the A and B point measurements finish, the Control Box
determines the main fall orientation and grade connecting the A
measurement toward the B measurement (see Figure 3-15 on
page 3-12).
If needed, re-measure the points; the Control Box saves the A and
B point coordinates separately. Also, it allows the operator to
manually type in a desired grade by pressing the entry box.
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System Five-3Di Reference Manual
Creating a Plane Surface Model
A positive sign (+) designates an upgrade from A to B, and the
negative (-) sign designates a downgrade from A to B
(Figure 3-19).
Figure 3-19. Points A and B Mainfall Grade Determined
7. Press the Crossfall Grade entry box, type in a desired cross fall
grade on the numeric pop-up keyboard, and press Ok
(Figure 3-20).
Enter crossfall
Figure 3-20. Enter Crossfall Grade
The cross fall grade is the grade that falls across at a 90° angle to
the line of main fall (see Figure 3-15 on page 3-12), and together
with the main fall, determines the plane with the compound slope.
A positive (+) sign designates a fall from right to left, and a
negative (-) sign designates a fall from left to right.
8. Move the machine to the elevation reference point. The
measurement of this point brings the entire plane up or down to
intersect with the plane and determine its relative elevation.
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Building Job Files
TIP
TIP
Use point A or point B for the elevation reference point.
9. On the Sloping Plane Surface dialog box, and when the cutting
edge rests on the elevation reference point, press Measure pt to
measure the elevation reference point (Figure 3-21). The
measuring dialog box briefly displays.
Measure Point
on surface
Figure 3-21. Measure Elevation Reference Point
TIP
TIP
If you have NEZ coordinates for the elevation reference
point, press the applicable entry box and manually enter
the information.
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System Five-3Di Reference Manual
Creating a Plane Surface Model
10. Press the Grid interval entry box, type in a desired grid interval to
be represented on the Main Screen, and press Ok (Figure 3-22).
Enter grid interval
Figure 3-22. Enter Grid Interval
11. Press Next to review the created surface plane (Figure 3-23).
12. Press Next then Finish to save the created file and complete the
plane surface (Figure 3-23).
Figure 3-23. Review Surface and Save
NOTICE
NOTICE
Failure to press the Finish key will result in a loss of all the
measurements and require the entire process to be
repeated.
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Building Job Files
Notes:
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System Five-3Di Reference Manual
Chapter 4
Jobsite Setup
For indicate applications, first set up the machine components, then
setup and initialize the Base Station, and finally, localize the GPS
coordinates before grading.
Base Station Setup
The Base Station always sets up over a Control Point on the jobsite; to
ensure accuracy, the Base Station GPS+ antenna must be positioned
directly over the top of the Control Point.
The Base Station can be set up and taken down on a daily basis, or
can be mounted on a permanently fixed pole and left for the duration
of the project. A permanent setup prevents errors due to incorrect
antenna height measurements.
When setting up the Base Station, make sure you select the correct
point from the Control Points file and verify the point has a northing,
easting, and elevation coordinate. The more accurate these
coordinates are, the tighter the control while grading.
The Base Station setup checklist includes:
†
Install the Base Station over a control point – see page 4-2
†
Measure the antenna height – see page 4-2
†
Connect all Base Station components – see page 4-3
†
Select the correct radio settings – see page 4-5 (refer to your Base
Station documentation for specific radio configuration
procedures)
†
Initialize the Base station – see page 4-5
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Jobsite Setup
Once you have set up the Base Station, simple checks ensure the
machine receives corrections from the Base Station: if the elevation
control key is green, the Base Station is ready. Figure 4-1 on page 4-3
shows a completed Base Station setup.
Base Station Antenna Setup
1. Place the tripod over the Control Point, ensuring the head plate of
the tripod is close to level. Attach the tribrach to the head plate
and affix lightly with the centering screw.
TIP
TIP
Use a plumb bob for quick and easy setup, especially if
the ground is uneven.
2. Moving only two legs, place the tripod so the center dot viewed
through the optical plummet is over the Control Point. Plant the
legs firmly into the ground.
3. Extend or shorten the same two legs to level the head plate using
the bubble of the circular level vial.
Repeat step two if necessary.
4. Secure the extension knobs or hooks at the midsection of the legs.
5. Attach the Legacy-E receiver and the radio modem with brackets
or hardware to the tripod legs. Attach the radio antenna with a
bracket to the tripod.
6. Affix the PG-A1 antenna to the spacer and the tribrach.
7. To level the tribrach, turn the leveling screws to precisely center
the bubble level.
8. Loosen the centering screw and move the tribrach so the center
dot in the optical plummit is directly over the Control Point.
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System Five-3Di Reference Manual
Base Station Setup
Figure 4-1. Base Station – Legacy-E
Connecting Base Station Cables
Attach all cables to the Legacy-E receiver, then connect them to the
other components (Figure 4-2 on page 4-4):
• PG-A1 Antenna – Connect the antenna cable to the receiver’s
ANT port, then to the LegAnt antenna.
• Power – Connect the cable with 5-pin circular connector and
alligator clamps to the receiver’s PWR1 or PWR2 port. Attach the
alligator clamps to the battery: RED to positive, BLACK to
negative.
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Jobsite Setup
• Radio Modem – Connect the Y-cable with 7-pin connector to the
receiver’s port C, and the other end to the radio modem. Connect
the other Y-end to the battery.
• Hand-held controller – Connect the 7-pin end of the serial cable
to the receiver and other end to the controller. The FC-100 with
Pocket-3D initializes the Base Station. See “Base Station
Initialization” on page 4-5 for details.
Figure 4-2. Base Station Cable Connections
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System Five-3Di Reference Manual
Base Station Setup
Base Station Power Setup
1. Turn on the controller. Turn on the radio and select the correct
channel on the radio modem.
2. Press the PWR button on the Legacy-E receiver for one to two
seconds; the power LED illuminates. The power LED starts
flashing red then rapidly green.
Once powered up, the number of flashes indicates the number of
GPS satellites being tracked.
After the Base Station has power and is tracking satellites, you need
to initialize the Base station and measure the antenna height.
To turn the Legacy-E receiver off at the end of the day, press PWR for
one to two seconds until all LEDs are off.
Base Station Initialization
1. Open Pocket-3D on the controller, press Setup Units and check
the values stored on the units dialog box, then press Ok
(Figure 4-3).
Figure 4-3. Check Jobsite Units
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Jobsite Setup
2. Press Data Control, select the correct Control Point file for the
jobsite, and press Ok (Figure 4-4).
3. Press Setup Base Station to start the initialization process
(Figure 4-4).
Figure 4-4. Select Control Point File
4. On the Control point dialog box, select the control point the Base
Station occupies from the drop-down list (Figure 4-5). Press Next
to continue.
Figure 4-5. Select Base Station’s Control Point
5. On the antenna setup dialog box, select the Antenna type from
the drop-down list. The standard antenna type is Topcon PG-A1
(Figure 4-6 on page 4-7).
6. Accurately measure the height of the antenna above the control
point. This measurement must be one of the following:
• the slant distance from the control point to an outermost
position on the rim of the antenna
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System Five-3Di Reference Manual
Base Station Setup
• the vertical distance from the control point to the base of the
antenna
7. On the antenna setup dialog box, enter the following information
(Figure 4-6):
• Antenna height – tap the entry box, type the measured value
on the pop-up key keyboard, and press Ok.
• Measure to – select either “Rim” for the slant measurement
or “Base” for the vertical measurement.
Figure 4-6. Enter Antenna Measurements
8. Ensure the measurement is correct, then press Next to continue
(Figure 4-6).
NOTICE
NOTICE
Cancel will not enter the new antenna height; you must
press Next. Incorrect measurements or data entry errors
directly affect grading accuracy.
9. On the radio setup dialog box, set the following parameters
(Figure 4-7 on page 4-8):
• Radio type – the type of radio used with the Base Station.
• Port – the port used for radio connection. The standard port
selection is “Serial Port C”.
• Baud rate – the speed of communication rate between the
radio unit and the GPS receiver. The standard baud rate is
“38400”.
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Jobsite Setup
• Format – the information format should be set according to
the type of GPS system you have and required system
compatibility. The standard format is “CMR”. Current
Topcon GPS+ or GPS systems are capable of either CMR or
RTCM2.1 operation. Both of these are industry standards that
offer compatibility with other GPS systems.
Figure 4-7. Enter Radio Information
10. Press Configure to view and check the internal settings of a PDL
radio modem. Press Next to continue.
11. On the ready to connect dialog box, press Finish to initialize the
Base Station.
12. After Pocket-3D reports a successful start (Figure 4-8), the main
screen displays.
Figure 4-8. Base Initialized Message
13. Check that the TX LED on the radio flashes once a second. This
indicates data transmission.
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System Five-3Di Reference Manual
Base Station Setup
General Base Station Setup Rules
and Notes
• Every time the Base Station is setup, a new slant measurement
must be taken since the height of the antenna will be different.
• If a fixed-height tripod, or something permanent is used, you only
need to measure the height of the antenna once. You will need to
use Pocket-3D only for the initial processing since the GPS
receiver will remember the initial settings. However, if any setting
stored in the receiver has been changed or initialized (like a reset
function), you will need to re-initialize the Base Station.
• When the GPS receiver tracks a sufficient number of satellites,
the receiver takes only a few seconds to process and report a
successful start. See “Troubleshooting System Five-3Di
Components” on page 6-5 if the receiver fails to respond or fails
to initialize.
• While the Base Station is in use, ensure that no vehicles or
machines are near or pass too close to the Base Station. Any
object that can obstruct signals from satellites will degrade the
ability to determine positioning. Obstructions includes trees,
buildings, vehicles, or fences. Ideally, control points should be
located with an open view of the sky in all directions.
• Ideally, the radio antenna should not be placed too close to the
GPS 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.
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4-9
Jobsite Setup
Machine Setup
Machine setup for System Five-3Di control application is quick and
easy. First install the Control Box, then install the MC-A1 and Radio
antennas, next install the MC-2.5 Receiver Box, and lastly connect
the cables.
Control Box Installation
The Control Box is designed for quick attachment at the beginning of
the day and quick removal at the end of the day.
1. Use the hand knob to attach the Control Box to the in-cab bracket
(Figure 4-9).
2. Connect the various electrical cables (Figure 4-9).
Figure 4-9. Attach Control Box and Cables
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System Five-3Di Reference Manual
Machine Setup
MC-A1 Antenna Installation
The MC-A1 GPS Antenna is designed for quick setup at the
beginning of the day and quick removal at the end of the day.
Figure 4-10 and Figure 4-11 on page 4-12 illustrate the antenna setup
for a scraper application or dozer/compactor application.
1. Ensure the pole is positioned vertically on the blade when the
machine is placed on level ground.
2. Mount the antenna on the pole and connect the antenna cable to
the antenna. Tighten the hand knob firmly.
Figure 4-10. Scraper Antenna Attachment
P/N 7010-0680
4-11
Jobsite Setup
Figure 4-11. Dozer/Compactor Antenna Attachment
When the system has not been used for several days or months, the
pole and cables might have been removed for storage or
transportation.
The following procedure describes the re-installation process (see
also Figure 4-10 on page 4-11 and Figure 4-11).
1. Install the GPS Vibration Pole or straight pole, depending on the
machine.
2. Make sure that the pole is straightened vertically, and then tighten
all screws completely.
3. Attach the coil-cord end to the cable mount plate. Connect the
antenna cable to the mating connector on the machine.
4. Mount the antenna on the pole and connect the antenna cable to
the antenna. Tighten the hand knob firmly.
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System Five-3Di Reference Manual
Machine Setup
Machine Radio Antenna Installation
The machine radio antenna is attached to the machine’s roof using a
magnetic mount, and generally stays on the machine. The antenna
should be positioned vertically and as high as possible on the machine
to maximize signal reception (Figure 4-12).
Figure 4-12. Rover Antenna Setup
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 Rover Radio Antenna, set it up in the correct position and
ensure the magnet mount attaches to an even and smooth surface.
MC-2.5 Receiver Box Installation
The MC-2.5 Receiver Box is designed for quick installation at the
beginning of the day and quick removal at the end of the day.
1. Place the MC-2.5 Receiver Box in a suitable location where all
four magnets attach to the machine. The LED lights should be
visible to the operator, and all ports should be accessible to
connect the cables.
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4-13
Jobsite Setup
2. Attach the following cables to the appropriate ports on the
MC-2.5 Box (Figure 4-13):
• The System Five-3D port to the Control Box.
• The MC-A1 Antenna cable to the Main GPS Antenna port on
the MC-2.5 Box.
• The Rover Radio Antenna cable to Radio Antenna port on the
MC-2.5 Box.
Figure 4-13. MC-2.5 Box Cable Connections
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System Five-3Di Reference Manual
Machine Setup
Machine Configuration Files
The Machine Configuration file provides vital information about the
type of machine, the setup of the components on the machine,
machine measurements, and radio configuration information.
NOTICE
NOTICE
You must have a machine configuration file before
beginning to grade.
1. With the Control Box on, press Topcon Logo Control
Machine setup to display the Machine files dialog box
(Figure 4-14).
Figure 4-14. Machine Files Dialog Box
2. Press New to display the Configuration name/type dialog box to
begin creating a Machine Configuration file (Figure 4-15 on
page 4-16). Enter the following information and press Next:
• Configuration name – tap the entry box to display the
alphanumeric keyboard. Type a name for the machine
configuration and press OK.
• Machine type – select the type of machine (Bulldozer or
Scraper).
• Sensor – only “GPS antenna” available.
• Location – only “Middle” available.
• Units of measure – select the unit of measure (meters, feet,
inches, centimeters).
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Jobsite Setup
Figure 4-15. Sample Machine Configuration Information
3. On the antenna information dialog box (Figure 4-16), enter the
following information using the same units of measure entered in
the previous step:
• Antenna – select the Topcon MC-A1 antenna type.
• Height – enter the height of the antenna from the leading
edge of the antenna ot the cutting edge.
• Behind – enter the distance of the centerline of the antenna
behind the blade. Use a positive value if behind the blade; use
a negative value if in front of the blade.
• Width – enter the width of the blade.
• From right – enter the distance of the antenna from the right
side of the blade.
Figure 4-16. Sample Antenna Information Dialog Box
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System Five-3Di Reference Manual
Machine Setup
NOTICE
NOTICE
Incorrect measurements or data entry errors directly affect
grading accuracy. Take each measurement twice to ensure
accuracy.
4. Tap Next to display the GPS radio configuration dialog box
(Figure 4-17). For a standard radio configuration, select the
following information, and tap Next:
• Radio type – the radio type, typically Pacific Crest PDL UHF
or TeleDesign UHF (examine the MC-2.5 box for a label
indicating the internal radio type)
• Connected to – the serial port the radio is connected to,
usually Serial Port B
• Baud rate – 38400
• Format – CMR
Figure 4-17. Radio Configuration Dialog Box
5. On the Configuration complete dialog box, press Finish to
complete and save the machine configuration file and return to
the Machine setup dialog box.
NOTICE
NOTICE
You must press Finish to save the file. Failure to do so will
result in losing all entered information.
6. Select the desired machine file, then press Ok.
P/N 7010-0680
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Jobsite Setup
Setting Blade Control
The blade control function selects the point on the blade at which to
control the position of the machine’s cutting edge. (The Automatic
best-fit selection is not active for System Five-3Di.)
To quickly change the blade control point using the section view:
• To move to the far left or far right edge of the blade, press and
hold the edge of the blade for one second. On the pop-up menu,
tap Move control left or Move control right. The blade control
arrow moves accordingly.
• Press and hold a point on the blade for one second. On the pop-up
menu, tap Move control. The blade control arrow moves
accordingly. Figure 4-18 illustrates this process.
Figure 4-18. Move Blade Control Point Using Section View
To change the blade control point using the menu:
1. Press Topcon Logo Control Blade control.
2. With Control using single point on blade selected, hold the
slider button and move it left or right to select the point from
the side of the blade (Figure 4-19).
3. Press OK to apply this point to the machine file.
Figure 4-19. Blade Control Using Single Point on Blade
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System Five-3Di Reference Manual
Machine Setup
Setting the Steer Indication
The steer indication sets up the light bar options. This menu option is
only available when the project has an alignment file.
1. Press Topcon Logo Control Steer indication.
2. On the Steer indication dialog box, select the following options
(Figure 4-20 on page 4-19):
• Point of interest – select either the left edge or right edge of
blade to steer the blade to
• Alignment feature – select feature to steer the blade to
• Additional steer offset – if needed, enter an offset to apply to
the edge of the blade
• Light bar green zone – set the width of the “green zone” (ongrade) when viewing the light bar
3. Press OK to apply the selections and return to the main screen.
Figure 4-20. Steering Indication
4. To view the light bar, click Topcon Logo
window Light bar.
P/N 7010-0680
View
Lower
4-19
Jobsite Setup
GPS Localization
After you have set up all the hardware components and initialized the
Base Station, you need to localize the GPS coordinates to the jobsite’s
coordinates.
This section gives information on the principles of GPS localization
and methods of GPS localization, as well as the procedures needed to
localize using either Pocket-3D and an RTK Rover system, or the
Control Box and machine.
Principles of GPS Localization
The GPS system is capable of precise positioning, but the positions it
computes are relative to a global reference system defined in terms of
a geographic latitude, longitude and height above (a representation of)
the earth’s surface. To be useful for local site work, global 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 coordinate system—e.g., 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 the 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:
• local NEZ coordinates for the point (obtained from the project’s
survey crew)
• global latitude, longitude, and height coordinates for the point
(measured as described in this section or obtained from the
project’s survey crew)
These point pairs are needed to calculate a precise mathematical
conversion formula for converting all global GPS coordinates
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System Five-3Di Reference Manual
GPS Localization
generated in the GPS receiver to local NEZ coordinates for a
particular project.
The following steps will help to ensure a high-quality localization
suitable for centimeter-level machine grading with System Five-3Di.
• First, the surveyor’s local control points must be precisely
measured. The quality of measurements directly affects grade
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,
the results will be less than ideal.
A good rule of success is to locate control points evenly
distributed around a perimeter of the site or grading area. While
not directly related to quality of localization, locate control points
that are elevated, easily accessible, and are not frequently
obstructed by trees, buildings, other structures, moving vehicles,
etc.
• GPS localization requires a minimum of three control points, but
at least four or more points should be used for the localization.
Methods of GPS 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. The control point file can be
localized using one of the following ways:
• Measuring each control point with a Topcon GPS+ or GPS RTK
Survey Rover System and Pocket-3D.
See “Method One: Localize with an RTK Rover and Pocket-3D”
on page 4-22 for this procedure.
• Entering global GPS coordinates from third party sources directly
into the Control Box.
See “Method Two: Enter Coordinates from a Third Party” on
page 4-26 for this procedure.
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Jobsite Setup
• Measuring each control point with the Machine and Control Box.
See “Method Three: Localize with the Control Box and Machine”
on page 4-28 for this procedure.
Method One: Localize with an RTK Rover and
Pocket-3D
The easiest and most ideal way to localize each control point, this
method involves measuring control points with a Topcon GPS+ or
GPS RTK Survey Rover System and Pocket-3D. Then you save the
information to a compact flash card and copy it into the internal
memory of the Control Box using the compact flash card slot.
Because this method deals with Control Point files, see “Using
Pocket-3D To Create a Control Point File” on page 3-1 for further
information.
Before beginning, have the following ready:
• A Topcon GPS+ or GPS RTK Rover system, powered up and
ready to go. Refer to your Rover’s operator’s manual for more
information.
• The location of all control points on the jobsite.
• A machine configuration file for the range-pole and RTK Rover
system. Refer to your Pocket-3D operator’s manual for more
information.
1. With your Topcon GPS+ or GPS RTK Rover system, move to any
control point on the job site. Double check that the Pocket-PC is
connected to the Rover system.
You can start with any control point and localize in any order, but
you must localize all points on the project.
2. Open Pocket-3D and press Data Control to select the correct
control point file.
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System Five-3Di Reference Manual
GPS Localization
3. Press Setup Equipment to open the Equipment dialog box and
select the correct machine configuration file (Figure 4-21).
Figure 4-21. Select Machine Configuration File
4. Press Data Control Control points to open the control
points dialog box.
5. On the Control Points dialog box, select the current Control
Point, and press Edit (Figure 4-22).
6. On the Control Point description dialog box, check that the
current point already has NEZ coordinates (Figure 4-22).
Figure 4-22. Select Control Point and Check NEZ Coordinates
If you need NEZ coordinates, see “Using Pocket-3D To Create a
Control Point File” on page 3-1.
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Jobsite Setup
7. Press the GPS tab and enable the “Use horizontal” and “Use
Vertical” check boxes (Figure 4-23).
Figure 4-23. Enable Localization Check Boxes
In general, these boxes should be enabled for each point.
However, certain scenarios may require only one of the
localization check boxes to be enabled. For example, the project
surveyor may indicate a certain control point has an elevation
error, or you find the vertical error for a control point to be out of
the tolerance range after localizing.
8. Place the tip of the range pole on to the control point; ensure the
range pole is vertical and steady for the entire duration of the
measurement.
TIP
TIP
Use a bi-pod for steady measurements with the range
pole.
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System Five-3Di Reference Manual
GPS Localization
9. On the GPS tab, press Measure when ready. The measurement
dialog box opens and the Rover begins to measure the control
point (Figure 4-24).
Figure 4-24. Measuring the Control Point
After a successful measurement, measured GPS coordinates will
display in the Lat (latitude), Lon (longitude), and Hgt (height)
entry boxes.
10. Press OK to save the measurements (Figure 4-25) and return to
the control points dialog box.
Figure 4-25. Control Point Measured
NOTICE
NOTICE
Be sure to press Ok to save the measurements in the
Control Point file.
11. On the control points dialog box, select the next control point to
measure, then repeat step 5 on page 4-23 to step 9 on page 4-25
until all control points have been measured.
P/N 7010-0680
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Jobsite Setup
12. 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 4-26).
Figure 4-26. Localized Control Points
13. Press Ok to save the Control Point file and return to the
Pocket-3D the main screen.
Use this control point file, updated with GPS localization, for file
setup in the Control Box.
Method Two: Enter Coordinates from a Third
Party
If a third party—such as a different brand of GPS equipment or a
surveying crew—provides the measurements for each Control Point,
the operator can enter the global GPS coordinates directly into the
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 “Using System
Five-3Di To Create a Control Point File” on page 3-6 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 File Control Points. The Control point
files dialog box displays (Figure 4-27 on page 4-27).
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System Five-3Di Reference Manual
GPS Localization
3. On the Control point files dialog box, select the correct control
points file, and press Edit. The Control points dialog box
displays, listing all control points for the file and jobsite
(Figure 4-27).
Figure 4-27. Control Point Files Dialog Box
4. Select a control point and press Edit, the Control point dialog
box displays. This control point file should already have local site
NEZ coordinates (Figure 4-28).
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 4-28).
6. Tap the two GPS localization check boxes to enable (check) them
for performing the GPS localization mathematical conversion
(Figure 4-28).
Figure 4-28. Control Point Coordinates and GPS Localization
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Jobsite Setup
7. Press Ok to return to the Control point files dialog box.
8. Repeat step 4 on page 4-27 to step 7 on page 4-28 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 4-29 on
page 4-28).
Figure 4-29. 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.
TIP
TIP
At this time, make a backup copy of the control point file on
a compact flash card.
Method Three: Localize with the Control Box
and Machine
This method involves moving the machine to each control point and
using the on-board System Five-3Di GPS system to localize the point.
The Control Box then processes the localization as the operator sits in
the cab.
Because this method deals with control point files, see “Using System
Five-3Di To Create a Control Point File” on page 3-6 for further
information.
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System Five-3Di Reference Manual
GPS Localization
1. Move the machine to one of the control points on the job site. You
can start with any control point and localize in any order, but you
must localize all points on the project.
2. Remove the MC-A1 GPS antenna from the Round Vibration Pole
and disconnect the antenna cable. Attach the MC-A1 antenna to a
range pole with bipod or a tripod. Set up the range pole or tripod
over the control point as accurately as the Base Station setup (see
“Base Station Setup” on page 4-1).
NOTICE
NOTICE
Measuring the control point with the MC-A1 antenna
mounted on the machine’s blade could cause incorrect
measurements, directly affecting grade accuracy. Be sure
to measure the control point with a range pole.
3. Remove the site calibration cable from the Field Calibration Kit
and connect the MC-A1 antenna to the GPS cable junction on the
machine (Figure 4-30). The GPS cable should already be
connected to the MC-2.5 Receiver Box.
Figure 4-30. Machine and Range Pole Station Setup
P/N 7010-0680
4-29
Jobsite Setup
4. Power on the Control Box and allow the 3DMC application
program start up.
5. Press Topcon Logo File Control Points. The Control point
files dialog box displays (Figure 4-31).
6. Select the correct control points file, and press Edit. The Control
points dialog box displays, listing all control points for the file
and job site (Figure 4-31).
Figure 4-31. Control Points
7. Select a control point and press Edit, the Control point dialog
box displays. This control point file should already have local site
NEZ coordinates (Figure 4-32 on page 4-31).
8. Press the two GPS localization check boxes to enable (check)
them for performing the GPS localization mathematical
conversion. Then press Measure (Figure 4-32 on page 4-31).
In general, these boxes should be enabled for each point.
However, certain scenarios may require only one of the
localization check boxes to be enabled. For example, the project
surveyor may indicate a certain control point has an elevation
error, or you find the vertical error for a control point to be out of
the tolerance range after localizing.
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System Five-3Di Reference Manual
GPS Localization
Figure 4-32. Control Point Coordinates and GPS Localization
9. On the Measure control point dialog box, enter the following
information, then press Ok (Figure 4-33):
• Antenna type – select “Topcon MC-A1”.
• Measure height – Accurately measure the height of the Rover
GPS antenna above the control point. This measurement must
be the slant or sloping distance from the control point to an
outermost position on the rim of the antenna. Tap the entry
box to display the numeric pop-up keyboard; enter the
measured height of the antenna and press Ok.
After you press Ok, the Control Box begins to measure the
control point (Figure 4-33). This may take a few seconds or
minutes, depending on the satellite status.
Figure 4-33. Measure Control Point
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Jobsite Setup
When finished, the Control point dialog box displays with the
measured WGS84 coordinates (Figure 4-34)
Figure 4-34. Control Point With GPS Localization
10. Press Ok to save the control point file.
TIP
TIP
Press Ok twice more and close the Control Point file
screen, returning to the Control point files dialog box, in
order to save these measurements to the Control Point file.
NOTICE
NOTICE
Pressing Cancel will not save the antenna height to the
new, corrected value. Incorrect measurements or data
entry errors directly affect grading accuracy.
11. Move to another control point. Repeat step 6 on page 4-30 to step
10 on page 4-32 until all control points have been measured.
12. 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 4-35 on
page 4-33).
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System Five-3Di Reference Manual
GPS Localization
Figure 4-35. Control Point Files with GPS Localization
13. Press Ok until you return to the 3DMC main screen, saving the
control point localization information and the Control Points file.
TIP
TIP
At this time, make a backup copy of the control point file on
a compact flash card.
P/N 7010-0680
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Jobsite Setup
Notes:
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System Five-3Di Reference Manual
Chapter 5
Indicate Grading
Application
Once you have your System Five-3Di™ set up, most grading
operations remain the same. This chapter discusses operations
typically performed while grading:
• changing the views
• changing cut/fill offsets
• changing the grade indicator scale
• checking position
• changing the display options
• viewing GPS information
• copying files
• changing radio channels
Other application and operation functions described include the
following:
• Steering and grading to a polyline
• Performing a topographic survey
• Clearing the NVRAM of the MC-2.5 Box
P/N 7010-0680
5-1
Indicate Grading Application
Before Grading Checklist
Before beginning to grade at the job site, review setup procedures and
ensure all steps have been completed.
†
†
†
†
Base station is set up and functioning (page 4-2):
†
All cables securely attached (page 4-3)
†
Base station has power (page 4-5)
†
Base station initialized (page 4-5)
Machine components attached and functioning:
†
Machine MC-A1 antenna (page 4-11) and Radio
antenna (page 4-13) attached and cables connected
†
MC-2.5 Box attached and cables connected (page 4-13)
†
Control Box attached and cables connected, and
Control Box powered on (page 4-10)
Correct job files are installed and active:
†
Control Point file (page 3-1)
†
Design Surface file (page 3-10)
†
Machine Configuration file (page 4-15)
Check the color of the Elevation key to ensure all sensors are
communicating and functioning:
• GREEN – all sensors function properly
• RED – a part of the system is working improperly; text or
graphical information indicates the problem
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System Five-3Di Reference Manual
Beginning to Grade
Beginning to Grade
Once all components are attached, connected to the Control Box and
functioning, you can begin grading (Figure 5-1).
System Five-3Di determines the machine’s orientation once it begins
moving; therefore, start the machine in motion to establish the
machine’s location on the project.
Figure 5-1. Indicate Grading with Scraper
While grading, you may want to change the radio channel or change
the display to suit the situation. See the following sections for details
on these functions.
P/N 7010-0680
5-3
Indicate Grading Application
Changing the View
The Control Box can display several types of views, each of which
contain useful information. Some options require specific files,
provided from the design engineer or other sources on the project.
Main Window Views
Display options for the main window include a Plan view, a Section
view, and a Profile view.
To access the desired main window view, press Topcon Logo
View Main window (Figure 5-2), then tap the desired view; a
check mark indicates the active view.
Figure 5-2. Main Window Display Menu Selections
The Plan view (Figure 5-3 on page 5-5) displays the jobsite from
above the machine, and the main window is always oriented in the
forward direction of machine travel.
• The point on the cutting edge below the location of the GPS
antenna is always in the center of the main window.
• This view allows for additional representations of triangle mesh
and contour lines in a desired color; as well as superimposing
Linework, Alignment lines, and Topo points.
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System Five-3Di Reference Manual
Changing the View
Figure 5-3. Plan View on Main Window
The Section view (Figure 5-4) displays a cross section view of the
cutting edge and the selected Design Surface where the right side of
the Main Screen is the right side cutting edge.
• The cut/fill readings are provided on both sides of the blade and
represent how far the cutting edge is from on-grade.
• When a road surface model is selected, the centerline and the
elements on the template are presented in red.
• Additionally, the section view displays steering information from
a target alignment line to a target edge and the longitudinal
distance along the road.
Figure 5-4. Section View on Main Window
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Indicate Grading Application
The Profile view (Figure 5-5) displays a side view of the machine
where the right side of the screen is always the forward direction of
machine travel.
Figure 5-5. Profile View on Main Window
Lower Window Views
Display options for the lower window include a Profile view, a
Section view, and a Light bar.
To access the desired lower window view, press Topcon Logo
View Lower window (Figure 5-6), then tap the desired view; a
check mark indicates the active view. None indicates no lower
window is active.
Figure 5-6. Lower Window Display Menu Selections
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System Five-3Di Reference Manual
Changing the View
Selecting one of the options adds the indicated view as a small
window above the Elevation Control Key (Figure 5-7).
• The Profile view displays a side view of the machine where the
right side of the screen is always the forward direction of machine
travel. The “+/-” buttons increase and decrease magnification for
this Lower window view.
• The Section view displays a cross section view of the cutting edge
and the selected Design Surface where the right side of the view
is the right side cutting edge. The cut/fill readings are provided on
both sides of the blade and represent how far the cutting edge is
from on-grade. The “+/-” buttons increase and decrease
magnification for this Lower window view.
• The Light bar is only available when the job includes alignment
information.
Figure 5-7. Lower Window Views
P/N 7010-0680
5-7
Indicate Grading Application
Left Window Views
Display options for the left window include a Profile view, a Section
view, and a Grade indicator.
To access the desired lower window view, press Topcon Logo
View Left window (Figure 5-8), then tap the desired view; a check
mark indicates the active view. None indicates no left window is
active.
Figure 5-8. Left Window Display Menu Selections
Selecting one of the options adds the indicated view as a small
window at the upper left of the main window (Figure 5-9 on
page 5-9).
• The Profile view displays a side view of the machine where the
right side of the view is always the forward direction of machine
travel. The “+/-” buttons increase and decrease magnification for
this Left window view.
• The Section view displays a cross section view of the cutting edge
and the selected Design Surface where the right side of the view
is the right side cutting edge. The cut/fill readings are provided on
both sides of the blade and represent how far the cutting edge is
from on-grade. The “+/-” buttons increase and decrease
magnification for this Left window view.
• The Grade indicator view acts as an infinitely scrolling grade
tape, displaying the amount of cut or fill in regards to the design
surface. For details on the Grade indicator pop-up menu, see
“Changing the Grade Indicator Scale” on page 5-12.
5-8
System Five-3Di Reference Manual
Changing the View
Figure 5-9. Left Window Views
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5-9
Indicate Grading Application
Changing Cut/Fill Offsets
The cut/fill offset can be manually adjusted, on the fly, relative to the
Design Surface. After each pass, the cut/fill offset can be updated as
necessary while approaching the final design surface.
TIP
TIP
When changing the cut/fill offset, both the Elevation Control
Key and Grade Indicator reflect the new value.
Changing Offsets Using the Grade
Adjustment Knob
To quickly change the cut/fill offset, turn the left Grade Adjustment
Knob until the you reach the desired elevation (Figure 5-10). The cut/
fill offset number increases/decreases as you turn the knob.
Figure 5-10. Changing Offset Using Grade Adjustment Knob
Changing Offsets Using the Elevation
Control Key
1. On the 3DMC Main Screen, press the Elevation Control key to
display the Adjust elevation dialog box (Figure 5-11 on
page 5-11).
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System Five-3Di Reference Manual
Changing Cut/Fill Offsets
2. Press the Elevation set point Set key, changing it to red.
1. Press Elevation
Control Key.
2. Press Set.
Figure 5-11. Press Elevation Control Key then Set
3. Change the offset using the numerical keyboard or the Grade
Adjustment Knob.
• Press the Elevation set point entry box, enter a new offset
value on the numeric keyboard, and press Ok (Figure 5-12).
A negative value is a Cut; a positive value is a Fill.
• Turn the Grade Adjustment Knob to quickly increase or
decrease the offset value. Turn clockwise to increase the Cut
value; turn counter clockwise to decrease the Fill value.
Figure 5-12. Use Keyboard to Change Offset
4. Press Ok to set the new offset value and return to the 3DMC
Main Screen.
P/N 7010-0680
5-11
Indicate Grading Application
Changing the Grade Indicator
Scale
The Grade Indicator acts as an infinitely scrolling grade tape,
displaying the amount of cut or fill in regards to the design surface.
To view the grade indicator, press Topcon Logo
window Grade indicator.
View Left
To change the on-grade (green zone) or extents (unit spacing), press
and hold the grade indicator for one second, then tap the desired
menu option (Figure 5-13).
• On-grade – displays the current on-grade zone width. Tap to
display the numeric pop-up keyboard to change the on-grade
zone.
• Extents – displays the current scale for the grade indicator. Tap to
display the numeric pop-up keyboard to change the unit spacing.
Red = Fill
Green =
On-grade
Blue = Cut
Figure 5-13. Grade Indicator Pop-up Menu
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System Five-3Di Reference Manual
Checking the Blade’s Position
Checking the Blade’s Position
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 blade, press Topcon Logo Tools
Position check.
2. On the Position check dialog box, select the Point of interest
(either left edge or right edge of blade), and press Measure
(Figure 5-14); the Measuring dialog box displays during
measurement.
Figure 5-14. Select Point of Interest and Press Measure
3. When finished, the Position check dialog box displays the point
on the job of the selected edge of the blade (Figure 5-15). Press
OK to return to the Main Screen.
Figure 5-15. Position of Point of Interest
P/N 7010-0680
5-13
Indicate Grading Application
Changing the Display Options
The Control Box also contains settings for the various displays
available that can be changed to fit the job. Some options require
specific files, provided from the design engineer or other sources on
the project.
Design Surface Display Options
When using a TIN surface model file, press Topcon Logo
View Display options Design Surface to display the Design
surface dialog box (Figure 5-16).
Figure 5-16. Design Surface Display Options
This dialog box has the following selections:
• Show triangle mesh – displays triangle lines on the Main Screen
according to the TIN Surface Model (Figure 5-17).
Figure 5-17. Triangle Mesh Design Surface
5-14
System Five-3Di Reference Manual
Changing the Display Options
• Show boundaries/breaklines – displays boundary lines and
breaklines outlining the Design Surface (Figure 5-18).
Figure 5-18. Boundaries/Breaklines Design Surface
• Show contours at intervals – displays contour lines on the Main
Screen (Figure 5-19); tap the entry box to display the numeric
pop-up keyboard and specify the elevation spacing interval
between lines.
Figure 5-19. Contours at Intervals Design Surface
• Color – press to display the Color Selection dialog box
(Figure 5-20 on page 5-16). You can change the color of the
triangle mesh, boundary/breaklines, and contours to the
operator’s preference, or to maintain consistency between the
office and the field.
P/N 7010-0680
5-15
Indicate Grading Application
Figure 5-20. Color Selection
Alignment Display Options
When using either a road surface model or an alignment file, press
Topcon Logo View Display options Alignment to display the
Alignment dialog box (Figure 5-21).
Figure 5-21. Alignment Display Options
This dialog box has the following selections:
• Alignment centerline color – sets the color of the centerline.
• Alignment feature-line color – sets the color for feature lines.
• Show regular station lines – displays graphical cross lines relative
to the horizontal alignments on the Main Screen (Figure 5-22 on
page 5-17). Press the Station interval entry box to specify the
longitudinal interval between lines.
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System Five-3Di Reference Manual
Changing the Display Options
Figure 5-22. Alignments – Main Screen
• Show station labels – displays station labels for each station on
the Main Screen.
Linework Display Options
When using a Linework file, press Topcon Logo View Display
options Linework to display the Linework layers dialog box
(Figure 5-23).
Figure 5-23. Linework Layers
The Linework file contains layers composed of a group of lines, each
identified with a color. All layers will be listed in the Linework layers
dialog box.
1. To display desired layers on the Main Screen, select the layer and
press Show, “Yes” displays in the Show column. Press Show
again to not display the layer on the Main Screen; “No” displays
in the Show column.
P/N 7010-0680
5-17
Indicate Grading Application
2. Press Ok to return to the Main Screen (Figure 5-24).
Figure 5-24. Linework Display – Main Screen
Point Display Options
When using a Point file, press Topcon Logo View Display
options Points to display the Points dialog box (Figure 5-25).
Figure 5-25. Points Display Options
• Layer – lists available layers.
• Show point symbols on this layer – displays all points for the
selected layer on the Main Screen (Figure 5-26 on page 5-19).
Active measure points also display while performing the Topo
Survey function.
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System Five-3Di Reference Manual
Changing the Display Options
Figure 5-26. Topo Points on Main Screen
• Show point numbers on this layer – displays the point numbers
over the symbols for each point (Figure 5-27). The numbers will
display while in the Topo Survey function.
Figure 5-27. Point Numbers on Main Screen
Changing the Background Color
1. To change the background color of the Main Screen, press
Topcon Logo View Display options Background color to
display the Color Selection dialog box.
2. Select a color from the Color Selection dialog box and press Ok
to apply the change.
P/N 7010-0680
5-19
Indicate Grading Application
Display Units Options
To set the type of units used in the job, press Topcon Logo View
Display options Display units to display the Display Units dialog
box (Figure 5-28).
Figure 5-28. Display Units Dialog Box
Using this dialog box, change the type of units displayed on the
screen, or update preset units in the files currently being used. Note
that any conversion will not affect grade accuracy.
• Distances – select either Meters, US survey feet, or International
feet
• Angles – select either DDº MM’SS”, NDDº MM’SS”, or Gons
• Grades – select either Percent (%) or Run : Rise
• Stations – select either 100.000, 1+00.000, or 10+0.000
• Volumes – select either Cubic meters or Cubic yards
• Coordinates – select either North-East-Elev, East-North-Elev, or
X-Y-Z
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System Five-3Di Reference Manual
Viewing GPS Information
Viewing GPS Information
To view the GPS information dialog box and tabs, press the
Elevation control key, then press the GPS info button (Figure 5-29).
1. Press Elevation
Control Key.
2. Press GPS Info.
Figure 5-29. View GPS Information
The following sections describe the GPS information tabs.
Viewing GPS Status and Quality
The Fix tab displays satellite status and positioning quality based on
GPS satellites currently being tracked (Figure 5-30). Once a GPS
solution is initialized, the Control Box reports the Fix status. The
positioning quality is an estimation computed from valid satellite
status (RMS: Root Mean Square).
Figure 5-30. GPS Info – Fix Tab
P/N 7010-0680
5-21
Indicate Grading Application
Viewing Cutting Edge Position
The Position tab displays current locations for the left and right sides
of the cutting edge (Figure 5-31). 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.
Figure 5-31. GPS Info – Position Tab
Viewing Satellite Location and
Changing the Mask Angle
The Satellites tab displays the current location of all available GPS
satellites (Figure 5-32).
To set or change the mask angle, tap the Mask angle entry field and
enter the angle of degrees above the horizon to track satellites above
(usually 15), and press Ok.
Figure 5-32. GPS Info – Satellites Tab
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System Five-3Di Reference Manual
Viewing GPS Information
Viewing Receiver Information and
Resetting the Receiver
The ID tab displays identification information and firmware revision
level for the internal GPS receiver of the MC-2.5 Box (Figure 5-33).
The Reset receiver key clears all data and resets all settings stored in
the GPS receiver (that is, clears the NVRAM).
Figure 5-33. GPS Info – ID Tab
Viewing Satellite Planning
Information
The Planning tab displays the estimated grading precisions on an
hourly scale (Figure 5-34 on page 5-24).
• Press the Next key to display the chart for the next day.
• Press the Prev key to display the chart for the previous day.
The Planning tab provides useful information for predicting GPS
solution accuracy for grading. The red vertical line marks the current
time.
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5-23
Indicate Grading Application
Figure 5-34. GPS Info – Planning Tab
Copying Files
You can copy any of the file types from a compact flash card to the
Control Box, and from the Control Box to a compact flash card.
The examples below use the Surface files dialog box found at
Topcon Logo File Surfaces, but any Control point, Surfaces,
Alignment, Linework, Points, or Machine Configuration file can be
copied.
1. Insert a compact flash card into the compact flash card slot on the
Control Box, and turn on the Control Box.
NOTICE
NOTICE
Occasionally, the control box may not properly detect the
compact flash card during a hot-swap procedure. If this
occurs, simply turn off and restart the Control Box.
2. When the 3DMC main screen displays, navigate to the desired
file type (Figure 5-35 on page 5-25).
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System Five-3Di Reference Manual
Copying Files
Figure 5-35. Surface Files Dialog Box
3. Press Copy to display the Copy files dialog box.
• To copy from the CF card to the Control Box, select “from
data card to internal disk” from the Copy drop-down list, then
select the Design Surface file from the displayed files
(Figure 5-36).
• To copy from the Control Box to the CF card, select “from
internal disk to data card” from the Copy drop-down list.
Figure 5-36. Select File To Copy
4. Tap the desired file from the displayed files and press Ok to begin
the copy process. An hourglass displays, indicating that the
system is busy.
P/N 7010-0680
5-25
Indicate Grading Application
Changing Radio Channels
If needed, you can use the Control Box to change the radio channel of
PDL and other types of radio modems.
NOTICE
NOTICE
Some radio modems, such as Teledesign, have an
automatic channel scanning feature, allowing
them to detect and connect with the Base Station
without having to manually select the radio
channel using the Control Box.
Since the MC-2.5 receiver box stores radio settings, including the
radio channel, follow the steps below to change the radio channel
setting.
1. Tap Topcon Logo Tools Configure radio.
2. On the radio setup dialog box, press Configure (if available) to
run the radio setting program (Figure 5-37).
Figure 5-37. Run Radio Setting Program
This program may take a few seconds to a few minutes to connect
to the radio module and check the current setting.
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System Five-3Di Reference Manual
Changing Radio Channels
When the current setting is confirmed, the radio’s channel and
frequency information displays (Figure 5-38).
Figure 5-38. Radio Configuration Information
3. Press the Channel drop-down list to display the channel selection
window. Use the arrow key to select the desired channel number.
The frequency of the channel changes automatically depending
on the selected channel.
4. 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.
TIP
TIP
If you have difficulty connecting to the radio module when
changing radio configurations, disconnect the radio
antenna cable at the MC-2.5 Box. The Base Station radio
can interfere with the Machine Radio when making
changes.
P/N 7010-0680
5-27
Indicate Grading Application
Steering and Grading to
Polyline
The Control Box can be used to steer the machine to and cut to a
polyline layered in the Linework file. Typically, you use an
Alignment file to cut along an alignment line. The polylines represent
features or objects such as building pads, curbs, sidewalks, top and
toe of slopes, or any boundary on the project. If the polyline is
composed of three dimensional information at each transition point, it
can be selected on the Main Screen and used as the alignment line to
steer to, or can be used as the Design Elevation to control the cutting
edge.
Steering to Polyline
1. Press Topcon Logo Linework, select the correct Linework file,
and press Ok.
2. Press Topcon Logo View Display options Linework,
select the polylines to display, and press Show. See “Linework
Display Options” on page 5-17 for more information.
3. View the steering light bar and left section view:
• Topcon Logo
View Lower window
Light bar
• Topcon Logo View Left window Section
4. Tap the polyline to use for steering on the Main Screen, and tap
Steer to polyline on the pop-up menu; graphical cross lines
display along the selected polyline.
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System Five-3Di Reference Manual
Steering and Grading to Polyline
Figure 5-39 shows an example of the Main Screen after
completing the above steps. In this example, the machine needs to
move left 3.51’.
Distance to
edge of polyline
Stationing
Grade at edge
Figure 5-39. Steer To Polyline
5. Press Topcon Logo View Display options Alignment to
change the interval between cross lines and the steering
indication (Figure 5-40).
Figure 5-40. Polyline Alignment Options
6. To change to another polyline to steer to, repeat step 4 on
page 5-28.
7. To change the alignment file, tap Topcon Logo File
Alignments. The polyline currently being used is substituted as
“Polyline alignment” in the file list, select the new Alignment file
you want to use and press Ok.
P/N 7010-0680
5-29
Indicate Grading Application
Grading to Polyline
1. Press Topcon Logo Linework, select the correct Linework file,
and press Ok.
2. Press Topcon Logo View Display options Linework,
select the polylines to display, and press Show. See “Linework
Display Options” on page 5-17 for more information.
3. Tap the polyline to use for grading and tap Grade to polyline on
the pop-up menu; graphical cross lines display along the polyline
(Figure 5-41).
Figure 5-41. Grade To Polyline
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System Five-3Di Reference Manual
Performing Topographic Surveys
Performing Topographic
Surveys
System Five-3Di has the ability to do an “on the fly” topographic
survey of the whole project, or any portion thereof. This is helpful
when creating as-build to determine the amount of material to move.
1. Tap Topcon Logo File 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 Tools Topo survey to display the Topo
survey dialog box (Figure 5-42 on page 5-32), enter or select the
following information, and press Ok:
• Log by – select either 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.
• Minimum distance – available when minimum distance
selected; enter the minimum distance by which to log points.
• Time interval (secs) – available when time interval selected;
enter the time interval in seconds in which to log points.
• Log to layer – stores measured points to the selected layer.
• Log at – determines the measurement point relative to the
cutting edge.
• Lower all elevations by – used when keeping the blade a
certain distance above ground to prevent the cutting edge
from digging into the surface. Manually measure the height
between the ground and the target position on the cutting
edge, then tap the entry box to display the numeric pop-up
keyboard, enter the measured height value, and press Ok. Use
a positive value when the cutting edge is above the design
surface.
P/N 7010-0680
5-31
Indicate Grading Application
Figure 5-42. Topo Survey Options
3. Press Ok to start logging measurement data. When the machine
begins to move, it will begin measuring and logging the data.
4. To stop topo measurements, press Topcon Logo Stop topo
survey (Figure 5-43). Otherwise, System Five-3Di continues
logging measurements.
Figure 5-43. Stop Topo Survey
NOTICE
NOTICE
Measurement data will be saved in the Point file currently
being used.
5. Copy the point file to a compact flash card for office analysis.
5-32
System Five-3Di Reference Manual
Clearing the MC 2.5 Box NVRAM
Clearing the MC 2.5 Box
NVRAM
The receiver’s Non-Volatile Random Access Memory (NVRAM)
holds data required for satellite tracking, such as ephemeris1 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 receiver will require some time to
collect new ephemerides and almanacs (around 15 minutes). Clearing
the NVRAM of the MC-2.5 Box will reset the box to factory default
values.
In addition, the NVRAM is used to keep information about the
receiver file system. Note that after clearing the NVRAM, the
receiver's LED(s) will flash orange for a few seconds indicating that
the receiver is scanning and checking the file system.
1. Turn off power to the MC-2.5 Box using one of the following:
• If the MC-2.5 Box is connected to the Control Box, turn off
the control box.
• Unplug the power cable from the MC-2.5 Box.
2. Press and hold the Main FN key (Figure 5-44 on page 5-34).
3. Return power to the MC-2.5 Box using one of the following:
• If the MC-2.5 Box is connected to the Control Box, turn on
the control box.
• Plug the power cable from the MC-2.5 Box.
The LED corresponding to the pressed FN key turns green.
1. Ephemeris (ephemerides): A table giving the coordinates of a celestial
body at a number of specific times during a given period.
P/N 7010-0680
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Indicate Grading Application
4. Wait until the Main LED blinks orange (about three seconds).
Figure 5-44. Hold FN Key While Turning PWR On to Clear NVRAM
5. Release the FN key while the LED blinks orange.
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System Five-3Di Reference Manual
Chapter 6
Maintenance &
Troubleshooting
Good daily care, preventive maintenance, and routine maintenance
will prevent many problems before they occur.
Daily Care
The following guidelines provide for trouble-free operation:
• Keep the carrying case clean and dry. Do not leave it open and
exposed to the elements. Clean and dry all components prior to
placing them into the carrying case.
• Ensure that protective connector caps, provided on some
components, are in place when not using the cables. Water
accumulating on the connectors can cause electrical shorts.
• Place System Five-3Di cables in their appropriate storage
connectors after removing the Control Box.
• Do not use high-pressure spray, water, or steam cleaner hoses
directly on cables and components. The components can be used
in the rain or light spraying.
• Check for loose components due to physical damage.
• Use proper battery supplies for components isolated from the
machine (such as the Base Station). Keep the machine’s battery in
good condition.
P/N 7010-0680
6-1
Maintenance & Troubleshooting
Preventative Maintenance
Preventive maintenance will help to keep your System Five-3Di
components running smoothly and efficiently.
Touch Screen Display Cleaning
The Touch Screen Display should be cleaned often in order to
maintain a quality image and prevent faulty operation.
NOTICE
NOTICE
The front surface of the touch screen should be kept free of
dirt, dust, fingerprints and other materials that could
degrade optical properties.
Long term contact with abrasive materials will scratch the front
surface, and image quality will be detrimentally affected. For best
results, use a clean, damp, non-abrasive cloth towel and any
commercially available window cleaner to regularly clean the surface.
Apply the cleaning solution to the towel rather than the surface of the
touch screen. Many touch screens have air vents and are not designed
with water tight bezels. Fluid ingress may occur from behind the
panel if it is not cleaned properly.
1. Dust the Touch Screen Display lightly with a non-abrasive cloth
towel.
2. Dampen the towel with water or a very diluted mild/neutral
detergent solution.
NOTICE
NOTICE
Never use alcohol, ether, benzene, acetone or any sort of
solvent. Do not use a high-pressure spray. Do not spray
towards the screen, the speaker, or the fan.
3. Wipe residual dust off with the damp towel.
6-2
System Five-3Di Reference Manual
Preventative Maintenance
4. Clean any residual detergent solution off by using a cloth
dampened with only water. Then wipe water and damp area
completely dry around the screen.
5. Allow to dry thoroughly and store the Control Box in its carrying
case.
Pole-dampening Bushing
Replacement on GPS Vibration Pole
The pole-dampening bushing and the bottom support should be
periodically replaced depending on its fatigue level. To identify a
fatigued part, observe the clearance and play between the pole rim
and the bushing bore. The two bottom support pieces should be
replaced at the same time. Fatigued bushing and supports may affect
the performance of satellite tracking or may cause hardware damage.
Figure 6-1 on page 6-4 displays an assembly diagram for the
following procedure.
1. Remove the three screws and washers securing the top ring cap
and remove the ring cap over the pole.
2. Remove the four screws and washers securing the bottom cap and
carefully remove the bottom ring cap through the cast housing
while holding the entire pole assembly.
CAUTION
CAUTION
Because the pole assembly is heavy, avoid dropping it
on other pieces of hardware or parts of the body.
3. Remove the bushing and the support and replace them with new
parts. Depending on the age of your vibration pole and the type of
application, the bushing and support for your pole will differ. The
following replacement parts can be ordered through Topcon’s
local dealer, or contact your dealer with questions.
• For newer GPS Vibration Poles – either 2150-0207 low
temperature BUSHING (blue) or 2150-0208 high
temperature BUSHING (yellow)
P/N 7010-0680
6-3
Maintenance & Troubleshooting
• For older Round Vibration Poles – 2150-0164 BUSHING,
1.75 ID CONTROL 1 pc/each
• 2150-0206 BUSHING, SUPPORT 2 pcs/each
4. Place the cast housing back over the pole, and hold up the pole
using the bottom cap. Then align the screw holes to the threads on
the bottom of the cast housing and replace the three screws and
washers. Tighten until firm.
5. Replace the top ring cap and the three screws. Tighten until firm.
Figure 6-1. GPS Vibration Pole Assembly
6-4
System Five-3Di Reference Manual
Troubleshooting System Five-3Di Components
Lubricating Quick Removal Knobs
Periodically lubricate the quick removal knobs to prevent galling
caused by tightening too strongly or through repetitive use
(Figure 6-2).
Figure 6-2. Lubricate Control Box and Antenna Knobs
Simply apply a lubricant, such as normal grease, to the threads of the
knob attachment.
Troubleshooting System
Five-3Di Components
In general, as long as you follow the maintenance and safety
instructions provided in this manual, you should have few problems
with your System Five-3Di™. This section will help you diagnose
and solve some common problems you may encounter with the
various components.
Before contacting TPS customer support about any problems, try the
following and see the following sections:
• Check that the various components (radio, MC-2.5 Box, Control
Box, Base Station, etc.) have power and are powered up.
• Check that all cables are securely and properly connected to the
various components of the System Five-3Di (control box, GPS
Vibration Pole, antenna, etc.). See“Jobsite Setup” on page 4-1 for
details.
• Disconnect cables and inspect them for damage or contamination.
Clean all connections with an electrical contact cleaner.
P/N 7010-0680
6-5
Maintenance & Troubleshooting
WARNING
WARNING
Do not attempt to repair equipment yourself. Doing so
will void your warranty and may damage the hardware.
Base Station
This section lists possible Base Station problems you may encounter
(also refer to the Base Station’s documentation). If you still have
problems after trying the solutions listed here, contact TPS customer
support.
Problem
Legacy-E receiver does not power on.
Causes
Solutions
The PWR button was
pressed too quickly.
Make sure you hold the PWR button down
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 or connected to the battery—RED to positive
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.
6-6
System Five-3Di Reference Manual
Troubleshooting System Five-3Di Components
Problem
Radio modem does not power on.
Causes
Solutions
The power cable is
Check that the power cable is correctly
incorrectly connected or connected to the battery—RED to positive
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.
The radio receives
power through the
Legacy-E receiver.
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.
Problem
Pocket-3D does not connect to Legacy-E.
Causes
Solutions
The Legacy-E may be
off.
Check that the Legacy-E is switched on.
The cable may be
incorrectly connected.
Check that the cable is connected to the
COM port on the Pocket-3D controller and
Port A on the Legacy-E.
If still no connection, try to reset the
computer and repeat.
Problem
Pocket-3D is waiting for satellites.
Causes
Solutions
The cable is incorrectly Check that the antenna cable is not crossconnected or damaged. threaded and is screwed in all the way.
If the cable is damaged, contact your
dealer to purchase a new cable.
P/N 7010-0680
6-7
Maintenance & Troubleshooting
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.
Problem
Radio modem light is not flashing.
Causes
Solutions
The cable is incorrectly Check that the cable from the Legacy-E is
connected or damaged. properly connected to the radio.
If the cable is damaged, contact your
dealer to purchase a new cable.
The radio does not have Some radios may not have a TX
a TX LED.
(Transmit) LED so the radio may in fact
be functioning.
The radio has a TX
LED, but it is not yet
flashing.
6-8
All radio types specifically listed for the
Base Station kit have a TX light and
should flash every second. It may take
several seconds after connection for this
flashing to commence.
System Five-3Di Reference Manual
Troubleshooting System Five-3Di Components
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
All LEDs off.
Causes
Solutions
The power cable may
be incorrectly
connected.
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 Box turns on only when the
Control Box is also powered on.
Problem
Satellite Status indicator does not flash green.
Causes
Solutions
The cable is incorrectly Check that the antenna cable is not crossconnected or damaged. 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 Box.
If the cable is damaged, contact your
dealer to purchase a new cable.
The antenna has poor
PDOP.
Check that the Machine Antenna has a
clear view of the sky.
The receiver is
collecting an almanac.
If this is the first time connecting to the
MC-2.5 Box, the LED may not flash for
several minutes while the GPS receiver
obtains a new almanac.
P/N 7010-0680
6-9
Maintenance & Troubleshooting
Problem
Radio Status indicator does not flash green.
Causes
Solutions
The Base Station and/or Check that the Base Station is running
Base Station radio has a correctly and the TX light on the radio
problem.
modem flashes on.
Different channels are
used between the Base
Station and the
machine.
Check that the Base Station and Machine
use the same radio channel.
• For the Base Station, use the button on
the radio modem or use the “GPS
Radio Configuration” program with
the Pocket-3D connected. See “Base
Station Setup” on page 4-1.
• For the machine, use the Control Box
function. See “Changing Radio
Channels” on page 5-26.
The antenna at the
Rover or Base may be
too low, incorrectly
placed, or too far away.
If the green LED flashes when near the
Base Station, but not when farther away,
check that the Machine Radio Antenna
mast is mounted vertically at the highest
point on the machine.
If the machine gets too far from the Base
Station, elevate the radio antenna at the
Base Station or move it to a closer Control
Point.
6-10
System Five-3Di Reference Manual
Troubleshooting System Five-3Di Components
GPS Localization
This section lists possible GPS localization problems you may
encounter.
Problem
Measurement takes too long.
Causes
Solutions
The machine may be
blocking satellite
signals to the rangepole or tripod-mounted
antenna.
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 form the obstructions.
The MC-2.5 Box has
The MC-2.5 Box may take several minutes
not yet initialized; the to initialize.
system may be tracking
many satellites.
The range-pole was
unsteady.
Make sure that the pole is held steady
while measurement is taking place. Any
movement will make for a lengthy
initialization and/or measurement.
Problem
Localization produces large errors.
Causes
Solutions
A typographical error
occurred.
If errors are 10s or 100s of feet or meters,
it is likely that a typographical error has
occurred.
If coordinates are manually entered, check
that longitudes are correctly prefixed with
a minus sign if working in the western
hemisphere (e.g. USA).
Re-enter the coordinates.
P/N 7010-0680
6-11
Maintenance & Troubleshooting
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.
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.
To isolate the error, disable horizontal and/
or vertical localization for each Control
Point in turn and observe the set of errors.
When the errors become acceptable due to
certain isolation, the point isolated is most
likely to detract from the quality of the
localization.
Also, as a general rule, if error values of
the first few points are reasonable but
increase when a new point is measured,
the point just measured must have either
inaccurate local site coordinates or
erroneous GPS measurement.
Once a problematic Control Point is
discovered, try to re-measure the point
again to see any improvement. If it is still
suspect and affects the acceptable
tolerance, the horizontal and/or vertical
localization for this point may be disabled.
6-12
System Five-3Di Reference Manual
Troubleshooting System Five-3Di Components
Problem
There are no H.Error and V.Error values.
Causes
Solutions
“Use for horizontal
GPS localization” and/
or “Use for vertical
GPS localization”
check boxes may not
have been selected.
These check boxes need to be selected for
a minimum of three points. Note that the
error value will be 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.
Control Box
This section lists possible Control Box problems you may encounter.
Problem
Control Box does not power on.
Causes
Solutions
The cable is the wrong Check that the power cable supplies 12 to
cable, incorrectly
24 VDC.
connected, or damaged.
• A socket (positive) = 12 to 24 VDC
• E socket = Ground
Check that the power cable is connected to
the correct port (see “Control Box
Connectors” on page 2-9) and the ends are
securely fastened.
If the cable is damaged, contact your
dealer to purchase a new cable.
P/N 7010-0680
6-13
Maintenance & Troubleshooting
Problem
Screen display turns off by itself.
Causes
Solutions
The fan may be
damaged, causing the
Control Box to
overheat.
Check that the fan is rotating.
Supply voltage too
high.
Check the battery voltage on pins A and E
of the power cable. If over 33V, the
Control Box will shut off. Correct the
supply voltage on the machine.
If the fan is not rotating, it may be
damaged and needs to be replaced with
new one. Contact your dealer.
Problem
Screen display goes dim by itself.
Causes
Solutions
The fan may not be
rotating.
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
Brightness may be reduced when the
the self-adjusting ability Control Box gets over-heated with high
of screen brightness.
temperature around the cab, as well as
when the ambient light becomes dim.
The backlight also reduces when the
ambient light becomes dim.
6-14
System Five-3Di Reference Manual
Troubleshooting System Five-3Di Components
Problem
Screen has transferred to operating system.
Causes
Solutions
“Exit 3DMC” function
may have been pressed
unexpectedly or
incorrectly.
If the screen displays the desktop, the “My
Computer” folder should be visible.
1. Double-tap “My Computer” folder.
2. Look for the folder named “Disk C”
and double-tap on it.
3. Look for the “Control Box” icon and
double-tap on it. The application
program will open and return to the
Main Screen.
Problem
“Control file has no GPS localization” message.
Causes
Solutions
Not enough Control
Points used for
localization.
Press Ok to exit the message screen.
Check that the Control Points file used has
a minimum of three localized points.
Perform the localization process again.
No GPS localization
Plan to implement the GPS localization.
has been performed for See “GPS Localization” on page 4-20 for
the project.
detailed instructions.
P/N 7010-0680
6-15
Maintenance & Troubleshooting
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
more minutes to let it complete the
process.
Remember, computing will take longer
when a larger file is selected.
If the pointer does not
move, the Control Box
may have a computing
problem.
Switching off the Control Box can fix the
computing problem.
Problem
Elevation Control key displays: “GPS receiver not connected!”
Causes
Solutions
Either the GPS signal or For GPS signal, check cable connections
radio signal is invalid. along the GPS antenna cable from the
GPS Antenna port on the MC-2.5 Box to
The graphic may
indicate what causes the the Machine Antenna.
problem.
6-16
Check connections at the System Five-3D
port on the MC-2.5 Box and Connector D
on the Control Box.
System Five-3Di Reference Manual
Troubleshooting System Five-3Di Components
Problem
Elevation Control key displays: “Waiting for radio link”.
Causes
Solutions
Radio transmission,
radio antenna, lights
status on the Legacy-E
receiver, and/or power
may have a problem.
Check that the Base Station is working
correctly. See “Base Station” on page 6-6
to troubleshoot Base Station problems.
Also check that the Machine 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, and that the radio is correctly
configured on the Control Box. See “Base
Station Setup” on page 4-1 and “Machine
Setup” on page 4-10 for information.
Problem
Elevation Control key displays: “Waiting for Initialization”.
Causes
Solutions
The GPS receiver has
not been successful
tracking enough valid
satellites.
Check that the Machine 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 If this is the very first time for operation,
process of determining this message may persist for several
a solid position.
minutes while the Legacy-E obtains a new
almanac.
P/N 7010-0680
6-17
Maintenance & Troubleshooting
Problem
Elevation Control key displays: “Out of design area”.
Causes
Solutions
The machine is out of
the Design Surface
area.
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.
Problem
Elevation Control key displays: “No GPS localization”.
Causes
Solutions
The Control Points file
currently selected has
not been localized
properly.
Make sure that the correct Control Points
file currently is selected.
You are in a process of
building a Control Point
file or just starting the
process.
Disregard the message until the
localization is complete. See “GPS
Localization” on page 4-20 to perform
localization.
6-18
System Five-3Di Reference Manual
Appendix A
Safety Information
You are responsible for becoming 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.
2. Use extreme caution on the jobsite. Working around heavy
construction equipment can be dangerous.
3. DO NOT attach System Five-3Di brackets or hose connections
while the machine is running.
4. DO NOT allow any System Five-3Di component to limit the
visibility of the operator.
5. Use Ty-wraps, supplied with System Five-3Di, to keep hoses and
wires secured and away from possible wear or pinch points.
6. Use eye protection whenever welding, cutting or grinding is
being done on the machine.
7. Protect yourself at all times, and wear protective clothing, when
working on or near hydraulic lines. Hydraulic lines can be under
extreme pressure, even when the machine is turned off.
P/N 7010-0680
A-1
Safety Information
WARNING
WARNING
Relieve all pressure in the hydraulic lines before
disconnecting or removing any lines, fittings or related
components. If injury does occur, seek medical
assistance immediately.
8. Use appropriate welding precautions and practices when welding.
After welding, paint all affected areas with a rust inhibitor.
WARNING
WARNING
DO NOT weld near hydraulic lines or on any equipment
when in operation.
NOTICE
NOTICE
Disconnect all Topcon system electrical cables prior to
welding on the machine.
NOTICE
NOTICE
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.
9. 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.
10. Keep the Carrying Case dry at all times.
NOTICE
NOTICE
DO NOT allow moisture to get inside the case. Moisture
trapped in the case can adversely affect components.
If moisture does enter the Carrying Case, leave it open and allow
it to dry thoroughly before storing any components.
A-2
System Five-3Di Reference Manual
Radio Usage Information
Radio Usage Information
All users must obtain an FCC (Federal Communications
Commission) license before operating the GPS+ or 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
• Atlas License Company and Data Services
1725-A North Shadeland Avenue
Indianapolis, IN 46219
http://www.alcds.com/
P/N 7010-0680
A-3
Safety Information
General Usage Warnings
CAUTION
CAUTION
If any System Five-3Di component has been dropped,
altered, transported or shipped without proper
packaging, or otherwise treated without care,
erroneous measurements, calculations, or display may
occur.
Periodically test System Five-3Di components to
ensure accurate measurements and operation.
Inform TPS immediately if any product does not
function properly.
CAUTION
CAUTION
Only allow authorized TPS warranty service centers to
service or repair this product.
WARNING
WARNING
The touch screen and LCD on the Control Box can be
damaged if struck with sufficient force.
A-4
System Five-3Di Reference Manual
Base Station Precautions
Base Station Precautions
WARNING
WARNING
TPS receivers are designed for machine control,
survey, and survey related uses (i.e., surveying
coordinates, distances, angles and depths, and
recording such measurements). This product should
never be used:
– Without the user thoroughly understanding this
manual.
– After disabling safety systems or altering the
product.
– With unauthorized accessories.
– Without proper safeguards at the survey site.
– Contrary to applicable laws, rules, and regulations.
DANGER
DANGER
TPS RECEIVERS SHOULD NEVER BE USED IN DANGEROUS
ENVIRONMENTS. USE IN RAIN OR SNOW FOR A LIMITED PERIOD
IS PERMITTED.
P/N 7010-0680
A-5
Safety Information
Internal Battery Pack
Warnings
For the Base Station or MC-2.5 Receiver Box:
WARNING
WARNING
Tampering with the internal batteries by end users or
non-factory authorized technicians will void the
receiver’s warranty.
– Do not attempt to open the battery pack or replace it.
– Do not disassemble the battery pack.
– Do not charge in conditions different than specified.
– Do not use other than the specified battery charger.
– Do not short circuit.
– Do not crush or modify.
DANGER
DANGER
NEVER ATTEMPT TO OPEN THE RECEIVER ’S CASING OR
REPLACE THE BATTERIES! LITHIUM-ION BATTERIES CAN BE
DANGEROUS IF MISHANDLED!
DANGER
DANGER
DO NOT INCINERATE OR HEAT BATTERY PACK ABOVE 212
DEGREES FAHRENHEIT (100 DEGREES CELSIUS). EXCESSIVE
HEAT CAN CAUSE SERIOUS DAMAGE AND POSSIBLE
EXPLOSION.
A-6
System Five-3Di Reference Manual
Appendix B
Specifications
The sections in this appendix give the features and specifications for
the physical components of the System-Five 3Di™.
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. Control Box Specifications
Housing
Cast aluminum
Weight
11.75 lb. (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
Temperature
-20 to +60°C (-4 to 140° F)
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 7010-0680
B-1
Specifications
Table B-1. 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 9168 Control Box:
Figure B-1. Control Box Dimensions
MC-2.5 Receiver Box
The Rover GPS MC-2.5 Receiver Box provides the industry’s most
advanced GPS dual-frequency satellite tracking system in a heavyduty construction design with a shock absorbing mounting bracket.
Four, high-power, bottom mounted magnets keep the 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.
B-2
System Five-3Di Reference Manual
MC-2.5 Receiver Box
Table B-2 lists specification details for the MC-2.5 Receiver Box.
Table B-2. MC-2.5 Receiver Box Specifications
Housing
Cast aluminum
Weight
12.10 lb. (5.5 kg)
LEDs
Three LEDs: Radio transmission (red for no signal;
green for signal); Two satellite status lights for Main
and Aux (green for GPS)
Function buttons
Two function (FN) keys for switching information
modes at the Main and Aux boards
Supply Voltage
10 to 30 VDC
Radio
Built in PDL or Teledesign radio modem
Radio Frequency
Band
UHF 450 to 470 MHz (typical)
Channels
14 for Pacific Crest PDL
6 for TeleDesign TS4000
Channel Switching
Manual for Pacific Crest PDL
Clear channel scan for TeleDesign TS4000
RX Frequencies
(Pacific Crest PDL)
Ch.0 464.550 MHz
Ch.1 464.500 MHz
Ch.2 464.600 MHz
Ch.3 461.025 MHz
Ch.4 464.625 MHz
Ch.5 461.075 MHz
Ch.6 464.650 MHz
Ch.7 461.100 MHz
Ch.8 464.700 MHz
Ch.9 462.125 MHz
Ch.10 464.725 MHz
Ch.11 462.375 MHz
Ch.12 464.750 MHz
Ch.13 462.400 MHz
Baud Rate
Up to 38400 bps
RTK Update Rate
10 Hz
P/N 7010-0680
B-3
Specifications
Table B-2. MC-2.5 Receiver Box Specifications (Continued)
GPS+ Tracking
Channels
20 channels GPS L1+L2+GLONASS
Figure B-2 shows the Machine GPS Receiver Box dimensions:
Figure B-2. MC-2.5Receiver Box Dimensions
B-4
System Five-3Di Reference Manual
MC-A1 GPS Antenna (Machine)
MC-A1 GPS Antenna (Machine)
The MC-A1 GPS Antenna is specifically designed with
environmental sealing and shock isolation for use on the machine’s
blade. Table B-3 lists specification details for the MC-A1 GPS
Antenna.
Table B-3. MC-A1 GPS Antenna Specifications
Antenna Type
Zero-centered flat round plane
Mounting Clamp
ID 1.75 in
Mounting Thread
5/8 - 11 in
Figure B-3 shows the dimensions of the MC-A1 GPS Antenna:
Figure B-3. MC-A1 GPS Antenna Dimensions
P/N 7010-0680
B-5
Specifications
Base Station Kit
The Base Station kit includes a GPS+ receiver, an antenna, a powerful
radio modem, supporting hardware, and cables. Topcon’s Base
Station kit has the most advanced GPS and GLONASS, dualfrequency satellite tracking system available. The following sections
give specification information for the Legacy-E receiver, the radio
modem, and the PG-A1 antenna. Two RS232 serial ports allow for
communication with a computer or hand-held controller.
Legacy-E Receiver
The Legacy-E Receiver processes signals received from the antenna
and sends the information to the computer for user access. The
receiver also has optional advanced multipath mitigation and optional
in-band interference rejection. Table B-4 lists basic specification
details for the Legacy-E Receiver.
Table B-4. Legacy-E Receiver Specifications
Dimensions
W:9.45 x H:4.33 x D:1.38
Weight
1.32 lbs (0.6 kg)
Connectors
Five connectors for power (2), computer, antenna, and
an external radio/modem
LEDs
Two LEDs: STAT for satellite tracking and REC data
status
Supply Voltage
6 to 28 VDC
Power Consumption
Less than 3.3W
Operating
Temperature
-40 to +55°C (-40 to 131° F)
Enclosure
Waterproof
Connectors
Connectors for power (2), computer, antenna, and an
external radio/modem.
LEDs
Two LEDs: STAT for the status of the receiver and
satellites; REC for data recording status and mode
B-6
System Five-3Di Reference Manual
Base Station Kit
Table B-4. Legacy-E Receiver Specifications (Continued)
GPS+ Tracking
Channels
20 channels GPS L1+L2 + GLONASS
OR
20 channels GPS L1+L2
Update Rate RTK
1 Hz
Real Time Data
Output
RTCM 104 version 2.2 ana/or CMR2
ASCII Output
NMEA 0183 version 2.3
Data Output Rate
1Hz standard; 5, 10, 20Hz optional
Radio Modem
Table B-5 lists basic specification details for the Radio Modem.
Table B-5. Radio Modem Specifications
Housing
Molded plastic
LED
One LED for radio status
Radio Modem Type
Pacific Crest PDL
TeleDesign TS4000
Frequency Band
UHF 450 to 470 MHz
Channels
14 for Pacific Crest PDL
6 for TeleDesign TS4000
Channel Switching
Manual for Pacific Crest PDL
Clear channel scan for TeleDesign TS4000
P/N 7010-0680
B-7
Specifications
Table B-5. Radio Modem Specifications
TX Frequencies
(Pacific Crest)
Ch.0 464.550 MHz
Ch.1 464.500 MHz
Ch.2 464.600 MHz
Ch.3 461.025 MHz
Ch.4 464.625 MHz
Ch.5 461.075 MHz
Ch.6 464.650 MHz
Ch.7 461.100 MHz
Ch.8 464.700 MHz
Ch.9 462.125 MHz
Ch.10 464.725 MHz
Ch.11 462.375 MHz
Ch.12 464.750 MHz
Ch.13 462.400 MHz
Baud Rate
Up to 38400 bps
Power
35 W
Operating
Temperature
-40 to +55°C (-40 to 131° F)
PG-A1 Antenna (Base Station)
Table B-6 lists basic specification details for the PG-A1 Antenna.
Table B-6. PG-A1 Antenna Specifications
Weight
1.08 lbs
Operating
Temperature
-40 to +50°C (-40 to 122° F)
Antenna Type
Zero-centered flat ground plane
Phase Center Offsets
L1 54.3 mm from base thread
L2 60.5 mm from base thread
Mounting Thread
5/8 – 11 in
B-8
System Five-3Di Reference Manual
Base Station Kit
Figure B-4 shows the dimensions of the PG-A1 Antenna:
Figure B-4. PG-A1 Antenna Dimensions
P/N 7010-0680
B-9
Specifications
Notes:
B-10
System Five-3Di Reference Manual
Appendix C
Limited Warranty
Electronic and Mechanical
Components
TOPCON warrants that the electronic components manufactured by
TOPCON shall be free of defects in materials and workmanship for a
period of one year from the original date of shipment to the dealer.
TOPCON warrants that all valves, hoses, cables and mechanical parts
manufactured by TOPCON shall be free of defects in materials and
workmanship for a period of 90 days from the date of installation.
Return and Repair
During the respective warranty periods, any of the above items found
defective may be shipped to TOPCON for repair. TOPCON will
promptly repair the defective item at no charge, and ship it back to
you. Calibration of components, labor and travel expenses incurred
for in-field removal and replacement of components are not covered
under this warranty policy. Damage to components due to negligence,
abuse or improper use is NOT covered under this warranty.
Warranty Disclaimer
The above warranties are in lieu of all other warranties, whether
expressed or implied, including all warranties or merchantability, or
fitness for a particular purpose. In no event will Topcon Laser
Systems, Inc. or its Representative be liable for lost profits or other
consequential damages arising from the purchase or use of
TOPCON’s components or any performance hereunder or any claims
of negligence, even if TOPCON has been advised of the possibility of
such damages.
P/N 7010-0680
C-1
Limited Warranty
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
Travel charges will be applied for any on-site service whether
warranty or non-warranty in nature.
C-2
System Five-3Di Reference Manual
Index
A
C
Alignment files
and grading 5-28
and steer indication 4-19
applying 5-29
copy 5-24
display options 5-16
Antenna
and MC-2.5 LEDs 2-18
base station B-8
base station setup 4-2, 4-6
machine 1-5, 4-11, B-5
machine setup 4-12, 4-16
MC-A1 1-5
measurement notes 4-9
measurements 4-16
radio 4-13, 4-14
Authorization codes 2-15
Cables
base station setup 4-3
control box 4-10
machine antenna 4-11, 4-12
MC-2.5 box 4-14
Carrying case notes 6-1
Change
color 5-15
display 5-4, 5-14
radio channel 5-26
units 5-20
Clear NVRAM 5-23, 5-33
Compact flash card 2-6, 5-24
copy files from 5-24–5-25
slot location 2-6
Components 1-1
and dozer 1-1, 1-3
and scraper 1-2
troubleshooting 6-5
Connectors 2-9
base station 4-3
control box 4-10
receiver box 4-14
Control box 1-4, 2-1–2-9, 4-10, B-1
authorization codes 2-15
connectors 2-9
display 2-9
flash card 2-6
knobs 2-2
options 2-15
USB 2-8
Control menu 2-12
Control point
See also Control point files 3-1
accuracy 4-21
B
Background, change color 5-19
Base station
attach radio 4-2
Base station kit 1-7, B-6
Base station setup 4-1–4-9
antenna 4-2
cables 4-3
checklist 5-2
initialization 4-5
LEDs 4-5
notes 4-9
Benchmark 5-13
Blade control 4-18
P/N 7010-0680
Index
Index
localization 3-7, 4-21, 4-30–4-32
location 4-21
new 3-4, 3-7
Control point files 3-1
control box 3-6–3-9
copy 5-24
new 3-3, 3-6
Pocket-3D 3-1–3-5
Coordinates
elevation reference 3-16
GPS 3-8
NEZ 3-7, 3-16, 4-23
Copy files 2-4, 5-24–5-25
Cut/fill 2-2, 2-13
See also Offset
adjust elevation 2-14
change 5-10, 5-11
elevation control key 2-13
grade indicator 5-12
negative 5-11
offset 2-13, 2-14
positive 5-11
reading 2-13, 2-14
section view 5-5, 5-7, 5-8
D
Delete files 2-4
Design surface 1-9, 3-11
See also Surface files
create plane model 3-13–3-17
display options 5-14
files 3-10
Display 5-14–5-20
See also Views
alignments 5-16
boundaries/breaklines 5-15
cleaning the touch screen 6-2
contours 5-15
linework 5-17, 5-28, 5-30
points 5-18
polylines 5-28, 5-30
triangle mesh 5-14
warning A-4
Index
E
Edit files 2-3
EIM 2-18
LED blink indications 2-19
Elevation
adjust 2-14
key 2-13
green 2-13
red 2-13
Elevation control 2-10
F
FC-100 1-8
Files 2-11
copy 2-4
delete 2-4
design surface 3-11
edit 2-3
new 2-3
Firmware 5-23
G
GPS coordinates 3-8
GPS information 2-15, 5-21–5-23
cutting edge position 5-22
firmware 5-23
planning 5-23
receiver ID 5-23
satellites 5-22
status 5-21
Grade Adjustment Knob
change offset 5-10
operation 2-2, 5-11
Grade indicator 5-8, 5-12
and offset change 5-10
change extents 5-12
change on-grade 5-12
cut/fill 5-12
System Five-3Di Reference Manual
Index
I
Initialization, of base station 4-5
K
Keyboard
connect using USB 2-8
pop-up 2-5
L
LEDs 2-17, 4-5, 4-8, 5-33, 5-34
Light bar 5-7
and alignment file 5-7
display 2-12, 5-6
options 4-19
steer indication 4-19
steer to polyline 5-28
Linework 5-17–5-18, 5-28
copy 5-24
display options 5-17
Localization 3-7, 4-20–4-33
See also Control point
principles of 4-20
with machine 4-28
with RTK rover 4-22
with third party coordinates 4-26
MC-2.5 receiver box 1-5, 2-17, B-2
attach 1-5
cable connections 4-14
clear NVRAM 5-33
EIM mode 2-18
information 5-23
LEDs 2-17
normal mode 2-18
reset 5-23
Measure
antenna on blade 4-16
base station antenna 4-6
points for plane surface
3-14–3-16
Menus 2-10–2-13
Control 2-12
File 2-11
Tools 2-12
View 2-12
N
New files 2-3
NEZ coordinates 3-7, 3-16, 4-23
NVRAM 5-33
clear 5-23, 5-33
O
M
Machine configuration files 4-15–4-17
antenna measurements 4-16
Machine orientation 5-3, 5-4
Machine setup 4-10–4-19
antenna 4-11
blade control 4-18
checklist 5-2
configuration files 4-15
control box 4-10
MC-2.5 receiver box 4-13
pole 4-12
radio antenna 4-13
steer indication 4-19
Mask angle 5-22
P/N 7010-0680
Offset 2-13, 2-14
base station antenna B-8
change 2-2, 5-10, 5-11
save 2-8
steering 4-19
store 2-8
P
PDL radio 1-5, 1-7, 4-17
See also Radio
change channel 5-26
select 4-7, 4-17
Plane surface
See Design surface
Pocket-3D 1-8
Index
Index
Point files 5-31
copy 5-24, 5-32
Position check 5-13
R
Radio
antenna 4-13, 4-14
antenna placement note 4-9
attach to base station 4-2
base station 4-1, 4-4
change channel 5-26
configure 4-7, 4-17
connection tip 5-27
LED 4-8
licensing A-3
PDL 1-5, 1-7
select channel 4-5
signal 2-17
Teledesign 1-5, 1-7
usage A-3
Receiver box
See MC-2.5 receiver box
Topcon logo 2-10
U
Units 3-2, 5-20
USB 2-8
V
Views 2-12, 5-4–5-8
W
Warnings
battery pack A-6
touch screen 2-3, A-4
usage A-4
WGS84 3-8
S
Satellites 5-22, 5-23
and mask angle 5-22
Save files 5-25
to Control Box 5-25
Steer indication 4-19
steer to polyline 5-28
Surface files 3-10
See also Design surface
applying 3-10
copy 3-10
Surveying 5-31–5-32
T
Teledesign radio 1-5, 1-7, 4-17
See also Radio
change channel 5-26
select 4-7, 4-17
Test 2-18, A-4
EIM 2-18
Index
System Five-3Di Reference Manual
TOPCON
Topcon Positioning Systems, Inc.
Phone: 800 • 443 • 4567
7400 National Blvd., Livermore, CA 94551
©2004 Topcon Corporation. All Rights Reserved.
No unauthorized duplication.
System Five-3Di Reference Manual
P/N: 7010-0680 Rev. A Printed in the U.S.A. 08/04 70
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