Operator'S Manual: Cat Accugrade Uts System For Asphalt Pavers
Operator'S Manual: Cat Accugrade Uts System For Asphalt Pavers
®
Cat AccuGrade UTS System
TM
Version 1.00
Revision A
Part Number xxxxx-00-ENG
June 2009
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C WARNING – This alert warns of a potential hazard which, if not avoided, can cause severe
injury.
Trimble® cannot anticipate every possible circumstance that might involve a potential
hazard. The warnings in this publication and on the product are, therefore, not all
inclusive. If a tool, procedure, work method or operating technique that is not
specifically recommended by Cat is used, you must satisfy yourself that it is safe for
you and for others. You should also ensure that the product will not be damaged or be
made unsafe by the operation, lubrication, maintenance or repair procedures that you
choose.
The information, specifications, and illustrations in this publication are on the basis of
information that was available at the time that the publication was written. The
specifications, torques, pressures, measurements, adjustments, illustrations, and other
items can change at any time. These changes can affect the service that is given to the
product. Obtain the complete and most current information before you start any job.
Cat dealers have the most current information available.
Failure to heed this warning can lead to premature failures, product damage, personal injury or
death.
2 Preparing to Work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
2.1 Pre-power up checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
2.1.1 Power up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
2.1.2 Control box power up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
2.2 Work preparation checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
2.2.1 Restore machine settings . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
2.2.2 Display brightness. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
2.2.3 Mast extensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
2.2.4 Benching the system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
2.3 2D machine control considerations . . . . . . . . . . . . . . . . . . . . . . . . . . 25
2.3.1 AccuGrade 2D system icons are missing or grayed out . . . . . . . . . . . 25
2.3.2 Machine control procedure for 2D systems . . . . . . . . . . . . . . . . . . 25
Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
1
Using the Control Box 1
Softkeys
Softkey label area
LCD screen
Escape key
Next key Zoom-in
Beeper
Power
Data card
Zoom-out
slot
Menu key OK key
Arrow keys
LCD screen —
Next key N View the next guidance screen or select the next field in a dialog.
Arrow keys ( Pan a guidance view, select an item in a list, or enter data in a
field.
)
[
]
OK key \ Save changes made in a dialog, and exit the dialog.
Escape key = Exit from a dialog without saving changes, or exit from a menu.
C CAUTION – The contents of a data card, or the data card itself, may be damaged if the card is
removed from the card slot immediately after the card slot door is opened. When there is a data
card in the card slot, and the card slot door is opened, a full screen warning message on a red
background appears. Wait until the warning message disappears before you remove the card.
A data card is a microchip that can store large amounts of data without the need for a
permanent power supply. Figure 1.2 shows a typical data card used in the system.
Use data cards to transfer designs between the office, where the designs are created,
and the system in the field, where the designs are used to generate guidance
information.
You can use SiteVision® Office software to view and retrieve the files on a data card.
Data cards also store the following configuration files:
• Machine configuration
• Control box settings
• Log files and *.zsnap (system snapshot) files
Note – You cannot write to or read from a data card when the data card slot door is
open. For example, if a design is loaded from a data card and the slot door is opened,
then the design will be unloaded.
Because of the rugged environments in which the system operates, data cards are
exposed to shock, vibration, and wide temperature variations. Most data cards will
work in the system but may not survive for long periods in such a rugged
environment.
Cat recommends the following data cards as suitable for operation in the system:
• ST Micro SMC128BFD6E
• White Electronics W7P128CFA70P0330
• The operator configuration of the system. The menus and screens selected for
you by your site supervisor affect the setup information you can view and
modify. This manual only covers the menu options that are available to
operators by default. Any configuration and guidance options not covered in
this manual are described in the AccuGrade UTS System for Asphalt Pavers
Site Supervisor’s Manual.
Softkey labels
Figure 1.3 Example softkey labels on a guidance screen
Some softkey labels appear in more than one screen, in which case the function of the
softkey they identify is always the same.
As a softkey’s function relates to particular screens or dialogs, that functionality is
only available when the appropriate screen or dialog appears.
If a softkey has no function in a screen or dialog, the softkey label is blank.
By convention, this manual refers to a softkey/function combination by softkey label.
Menus
Menus let you choose another menu or a dialog from a list. To move up or down the
list of menu items use the ] or [ keys. Once you highlight the item you want to
view, press \ to select it. See Figure 1.4 for an example.
To leave a menu without making a selection, press =.
Highlighted menu
item
Dialogs
Dialogs let you enter data into the system. Dialogs can contain any of the following
items:
• Text fields. Text fields let you enter text information, such as the name of a
machine. Once you select a field, you can enter data into it. A selected field
appears as white text on a blue background.
• Number fields. Number fields let you enter numerical values, such as the
height of a mast extension. Once you select a field, you can enter data into it. A
selected field appears as white text on a blue background. See Figure 1.5.
• Lists. Lists let you select a single item from a list of items, such as a list of 3D
designs.
• Check lists. Check lists let you select one or more items, or no items, from a list
of items, such as a list of sensors.
• Information to help you make your selection.
To move between fields in a dialog, press the N key.
Figure 1.5 Dialog showing number fields and how to move between fields.
To enter data into a text or number field, use the arrow keys as follows:
• To scroll through the alphabet (upper case A through Z), numbers (0 through
9), the decimal point (.), a space ( ), and back to A, press [ or ].
Note – Available values depend on the type of field that is selected. For
example, the only values available for number fields are 0 through 9 and the
decimal point (.).
When you change a character in a field, the keys ] and [ start stepping
from the existing character.
• ) steps to the next character to the right.
In fields that allow spaces, press ) twice to insert a space.
• ( steps back one character to the left. This deletes the character in the space to
the left.
To select an item from a list, press [ or ], and press \. See Figure 1.6.
To leave the dialog without saving the new data or selection, press =. If you have
made changes to a dialog setting, and you choose to exit without saving those
changes, the following warning appears:
To confirm that you really do want to abandon the changes you have made to the
dialog, press \.
Optional text
information area
Guidance
view area
Guidance
settings area
Softkey label area
Figure 1.7 Guidance screen components
If there is no text information configured for that view, the text information
does not appear.
• The guidance view area. The guidance view area displays the machine relative
to the surface being worked. There is no guidance view area in the text screens.
• The guidance settings area. The guidance settings area displays the vertical and
horizontal offsets. For more information, see Guidance settings, page 17.
Machine icons
The system uses icons to identify the machine in the plan and cross-section views.
The screed edge in an icon corresponds exactly to the screed edge of the machine.
As you move the machine, the icon mimics the movements on the screen.
The red square on the screed icon indicates the side being used for 3D positioning.
The green line on the screed cross-section view icon indicates the vertical guidance
point, which is at the bottom of the mast at screed height.
Table 1.2 Machine type and icon
Asphalt paver
Guidance settings
To display guidance settings, the system uses icons to identify the vertical and
horizontal offsets, and text to display numerical values. See Figure 1.8 and Table 1.3.
Figure 1.8 Example guidance setting area for an asphalt paver system
No vertical offset
No horizontal offset
UTS Tracking the UTS loses lock on the machine target. Once only:
• 200 msec on.
2
Preparing to Work 2
2.1.1 Power up
ATTENTION – When working in cold environments, when you start the machine to warm it up,
C turn on the paving control system as well.
When you power up the control box to begin work, observe the system’s start-up
sequence to make sure that all components function correctly. See the following list
of basic checks.
3. Enter a value, as read from the measurement scale on the mast, in the Left/Right
mast extension field.
4. To confirm the settings, press \; to exit without saving the changes, press
=.
Two manual masts mounted on both left and right – (English/Imperial or Metric)
1. From any guidance screen, press M.
2. Highlight Mast Extension, and press \:
To clear an existing bench, press Clear Bench. The Setup Menu – Configuration
menu appears.
3. Before benching, return the screed crown angle and extensions to the same
positions they were in when the machine measurements were taken.
ATTENTION – Ensure the screed controls are in manual and the machine is stationary during
C the benching process. Tow point movement and an inaccurate bench may result if the screed
controls are in auto.
ATTENTION – Due to subtle changes in the screed’s operating angle between a stationary
C measure up position and a working/floating position, the operator will occasionally need to
adjust the system to ensure the mat is laid on-grade. To make this adjustment, enter a control
system offset into the 2D control box. The head of material, mix change, or other parameters
can also cause the 2D system to be on-grade, but the 3D system to be off grade.
For example, after paving for 10 meters a grade check may show that the mat is 3 mm
too low. Based on this, the operator should enter a 3 mm increment control system
offset into the 2D system (a CD625 control box on an AccuGrade 2D system or a
DLSII display on a MOBA-matic 2D system). This 3 mm control system offset will
force the screed to raise by 3 mm. Subsequent grade checks should show the screed to
now be on-grade (on design).
Increment button
Decrement button
3
Using 3D Guidance in the Field 3
UTS status
Battery charge
Note – The Target ID softkey is only available when the UTS is stopped.
Note – For systems with two masts, see 3.1.4 Two mast systems.
b. Enter the selected target ID into the Target ID: field. By convention, target
IDs of 9 through 16 are used for machine control applications, with IDs of
1 through 8 reserved for surveying applications. Ask your site supervisor
which target ID you should use. To set the default value of 9, press Default.
c. To confirm the settings, press\; to exit without saving changes,
press=. The UTS start-up dialog appears.
3. Press Start. The UTS system starts and the UTS instrument automatically
searches for the target in the area bounded by the search window defined
during UTS set up.
When the target is acquired, the UTS dialog changes to its “Tracking” layout,
shown below:
Tip – If the UTS takes too long to find the target, press = to stop the search and the UTS
B start-up.
B Tip – The state of an SPSx30 instrument’s power supply is automatically measured and
displayed in the Battery: field. If an external battery is used to power the UTS instrument, the
UTS battery status is not available.
Problem Action
No Start softkey in the UTS The machine data radio has not synchronized with the UTS instrument data radio.
dialog To check that the UTS components are connected and running, see 4.5 Running
system diagnostics.
Check that the UTS instrument data radio is turned on.
Check the instrument battery.
UTS fails to start Ask your site supervisor to check that the system radio channel and network are
compatible with the UTS radio settings. See 3.1.3 Connect to a different UTS
instrument, or to check your current settings, see 4.5 Running system diagnostics.
See Table 4.4 on page 47 for a description of the UTS dialog UTS status: field values.
4. Set the radio channel and network ID to match a different UTS instrument.
Your site supervisor will advise you of the correct settings.
Press N to move between the fields in this dialog.
5. To confirm the settings, press\; to exit without saving changes,
press=.
An Updating message is displayed. The Setup Menu – Installation menu
appears.
6. Press = again to return to the guidance screen.
7. To continue using 3D guidance, you need to reconnect to the UTS instrument
before you restart paving. See 3.1.2 Start UTS machine positioning.
Note – The Target ID softkey is only available when the UTS is stopped.
2. To toggle between the left and right targets, press Change Target.
3. To set the target ID:
a. Press the Target ID softkey:
b. Enter the selected target ID into the required Left and Right target ID:
fields. By convention, target IDs of 9 through 16 are used for machine
control applications, with IDs of 1 through 8 reserved for surveying
applications. Ask your site supervisor which target ID you should use. To
set the left target default value to 9, or the right target default value to 10,
select the required field and press Default.
c. To confirm the settings, press\; to exit without saving changes,
press=. The UTS start-up dialog appears.
B Tip – If several lines are grouped closely, move the cross-hairs to an area where the lines are
more easily seen. To move the cross-hairs large distances across the screen, zoom out and
then hold down an arrow key. This lets you move rapidly across the design.
2. To select the line for horizontal guidance, press Select. The line closest to the
center of the cross-hairs is selected. The selected guidance line appears as a
thick red line:
B Tip – To select a different horizontal guidance line on the same design, you need to unload the
current design (by selecting None), reload the same design, and then reselect the required
horizontal guidance line.
3.3 Offsets
Design offsets are the vertical and horizontal changes applied to the 3D design.
Offsets ensure that the screed height (elevation), and the horizontal alignment both
match the required design.
For example, a negative vertical offset value tells the system to build a subgrade, and
a positive vertical offset value tells the system to allow for compaction.
To set the vertical and/or horizontal offsets:
1. From any of the guidance views, press Offsets:
2. Enter the required vertical offset value. The field label changes from No offset
to Above design.
Press +0.010 to increase or –0.010 to decrease the value in 10 mm increments.
2. Enter the required horizontal offset value. The field label changes from No
offset to Right of guidance line.
Press +0.010 to increase or –0.010 to decrease the value in 10 mm increments.
Press Set 0.000 to set the value to No offset.
3. To set the offset to the left of the guidance line, press Left / Right. This changes
the field label from Right of guidance line to Left of guidance line.
4. To confirm the settings, press\; to exit without saving changes,
press=.
4
Troubleshooting in the Field 4
– Does the UTS have the correct firmware loaded? See 4.5 Running system
diagnostics to check that all firmware is correct.
• Check that the correct model of radio is installed. For SPSx30 UTS instrument,
use an CR2400 radio.
• Use the information in 4.4.1 CR2400 data radio status indicators, to check the
following:
– Is the data radio getting power?
– Is the data radio synchronized?
• Use the information in the UTS dialog to check the following:
– Is the UTS tracking?
– Does the UTS have adequate power?
• Is the UTS instrument free from vibrations, caused by passing machinery or the
wind? Complete the following procedure:
a. Stop the machine.
b. Put the automatic controls in Manual.
c. Rest the screed on the ground.
d. To view the Machine Target screen of the Diagnostics – UTS dialog, see
4.5 Running system diagnostics, particularly 4.5.2 UTS diagnostics.
e. Observe the Northing, Easting, and Elevation values. At a distance of
150 m (490 ft) you would not expect to see any variation in the Northing
and Easting values, and no more than ±5 mm (0.2 inches) variation in
elevation.
• Observe the site and work area, and check the following:
– Is the MT900 machine target between 15 m (50 ft) and 300 m (985 ft)
from the UTS instrument?
– Does the UTS instrument have a continuous line of sight to the MT900
machine target? Check for occasional passing vehicles or dust clouds
which could block the line of sight. Check that the line of sight is
maintained for all machine orientations across the whole work area.
– Is the work area within the search window specified when the UTS was
set up?
– Are the lenses of the UTS instrument clean?
Poor results
It is beyond the scope of this manual to cover troubleshooting poor results in detail.
However, when you talk about the problem with your site supervisor or Cat dealer,
consider that poor results may be caused by poor guidance information. For more
information on adjusting the system to improve results, see 2.3.2 Machine control
procedure for 2D systems.
Noisy or inaccurate guidance information can result in an uneven or inaccurate final
surface. If you suspect poor guidance information, consider the following possible
causes:
• Incorrect mast extension data. See 2.2.3 Mast extensions.
• Incorrect guidance from the automatic system.
• Incorrect installation.
• Inaccurate machine measure up.
• Incorrect UTS instrument setup.
A system error has occurred. The application has been shut down for safety.
On start-up, one or more of the system’s software components failed to start.
Contact your site supervisor.
No Data
The system is not receiving any information from a sensor.
Try one of the following:
• Check the cable connections.
• Inspect the sensor for physical damage.
• To check that all the required components are responding, see 4.5 Running
system diagnostics.
• Switch off the power and then switch it on again.
No data card
The system is attempting to log information to the data card, but there is no data card
inserted. Insert a data card, or make sure that the card is inserted correctly and then
continue with the current task.
Out of memory!
The control box has run out of memory.
Try one of the following actions:
• Shut down the control box and then restart it.
• Ask the design staff to reduce the size of the files.
Read/write error
Contact your site supervisor to check the program log and data card for errors.
Some settings are missing or invalid, and will be reset to factory defaults
On start-up, or after restoring a machine settings file, some of the settings on the
control box are missing or invalid. These will be set to the default values.
Try one of the following actions:
• To restore the settings file for your machine, see 2.2.1 Restore machine
settings.
• Ask your site supervisor to configure the system for use on your machine. Save
the new settings in a settings file.
There are no appropriate settings files on the data card. Please insert a data card with settings
files.
You have tried to restore a machine settings file from the data card. There might not
be any settings files on the card for the option you have selected.
Contact your site supervisor and check that you have the correct settings files on your
data card.
There is a problem with the data card – please insert a valid card. Check the program log for
details.
The control box cannot read any data from the data card. You cannot load any designs
from the data card.
Remove the data card and then reinsert it correctly into the control box. If this fails,
contact your site supervisor.
Unexpected error
Contact your site supervisor to check the program log and data card for errors.
Data/Power
indicator LED
The LED can flash in a number of different patterns depending on the situation, as
shown in Table 4.3.
Table 4.3 CR2400 data radio flashing LED patterns
LED pattern Status
Off No power to radio
On solid Power is available, but the radio is not synchronized
Status indicator
The indicator patterns showing the machine target’s status are as follows.
The control box lists the devices that are currently connected to the system.
The Diagnostics dialog lists each device and reports the following information:
– the device name
– the status of the device
– the application firmware version number
– the loader firmware version
The application firmware must be the correct version before the device can be
used in the system.
The application firmware version number indicates which devices are detected
and which devices have the correct version of the firmware loaded.
Note – When none of the devices display “old version”, you can use the system.
If either the firmware or the loader is too old, the device is detected, but you
cannot use the system until the device firmware is updated. The Status column
displays the minimum firmware required.
If the message Not found appears beside a device, the system is configured to
use the device, but the device was not detected.
You cannot use the system if a device is not found.
2. Press Recheck at any time to refresh the data in this screen.
3. Press = to exit to the Setup Menu – Diagnostics menu.
The first screen in the Diagnostics – UTS dialog is the Machine Target screen.
This is the screen that appears when you press Machine Target. See Table 4.5
for an explanation of the fields in this screen.
Table 4.5 Machine Target screen fields
Field Explanation
Northing The computed location of the machine target, in terms of
Easting northing, easting, and elevation.
Elevation
Slope distance The observed location of the machine target relative to the
Horizontal angle UTS, in terms of slope distance, horizontal angle, and vertical
Vertical angle angle.
Tracking status UTS tracking status. See Table 4.6.
Search window The position of the machine target, relative to the search
window specified during UTS set up.
The UTS instrument reports its tracking status to the system. UTS tracking
status message are listed in Table 4.6.
Table 4.6 UTS Tracking status messages
Tracking status Meaning
N/A No data being received from the instrument.
No signal No target is being tracked.
Tracking A target is being tracked.
2. From any screen in the Diagnostics – UTS dialog, press UTS. The UTS screen
appears:
This screen displays the name of the point at which the UTS instrument was set
up and, if the point has a name, the UTS <name>. For example, UTS South.
See Table 4.7 for an explanation of the fields in this screen.
Table 4.7 UTS screen fields
Field Explanation
Northing The known or measured setup location of the UTS instrument, in terms
Easting of northing, easting, and elevation.
Elevation
Compensator The instrument’s compensator status.
Inst. height The installed setup height of the instrument.
Scale factor The scale factor.
PPM Parts per million. The instrument’s Electronic Distance Meter (EDM) is
affected by the temperature and pressure at which the instrument is
being operated. Accurate entry of the ambient air temperature and
barometric pressure correctly adjusts the EDM measurements for the
PPM (parts per million) error associated with this effect.
3. From any screen in the Diagnostics – UTS dialog, press Backsight. The
Backsight screen appears.
This screen displays information about the backsight taken to establish the
orientation of the UTS instrument. See Table 4.8 for an explanation of the
fields in this screen.
Table 4.8 Backsight screen fields
Field Explanation
Northing The known location of the control point used for the
Easting backsight, in terms of northing, easting, and elevation
Elevation
Slope distance The observed location of the control point relative to the UTS,
Horizontal angle in terms of slope distance and horizontal angle
2. Raise the right hand side of the screed and make sure that the cross slope value
increases.
3. Take note of the mast lean field values to make sure they accurately reflect the
lean of the mast(s).
Note – The above dialog shows the mast lean fields for a two mast system.
3. Press and hold ‰ and ´ respectively, and make sure the machine moves
up or down as required. This confirms that the left elevation output controller is
configured for 3D grade control.
4. Press = to exit to the Diagnostics – Controller Outputs menu.
5. Select Right Elevation and press \ to show the following screen:
6. Press and hold ‰ and ´ respectively, and make sure the machine moves
up or down as required. This confirms that the right elevation output controller
is configured for 3D grade control.
7. Press = to exit to the Diagnostics – Controller Outputs menu.
8. Select Slope and press \ to show the following screen.
Softkey 1
Softkey 2
9. Press Softkey 1 and Softkey 2 respectively, and make sure the machine moves in
the correct direction. This confirms that the slope output controller is
configured for 3D slope control.
10. Press = to exit to the Diagnostics – Controller Outputs menu.
11. Press = again to exit to the Setup Menu – Diagnostics menu.
Numerics keys 10
machine icons 17
2D machine control 25 menus 14
AccuGrade systems 26 power key 11
icons missing or grayed out 25 power up checks 20
MOBA-matic systems 26 problems, see common problems
procedure for 2D systems 25 softkey labels 13
softkeys 13
using 10
A controller outputs diagnostics 53
AccuGrade 2D machine control systems 26
audible alarm, see beeper
D
data card 11
B data radio status indicators, CR2400 46
battery state, UTS 29 diagnostics
beeper, using 18 controller outputs 53
brightness, control box 22 running 49
sensors 52
UTS 50, 54
C Diagnostics – About dialog 54
Diagnostics – Controller Outputs dialog 53
CD700 control box, see control box Diagnostics – Sensors dialog 52
checks Diagnostics – UTS dialog
control box brightness 22 Backsight 52
control box power up 20 Machine Target 50
machine settings 21 UTS 51
mast extensions 22 Diagnostics dialog 49
power up 20 dialogs
work preparation 21 Bench UTS 24
common problems Diagnostics 49
control box does not start 20 Diagnostics – About 54
control box start up Diagnostics – Controller Outputs 53
device not responding 20 Diagnostics – Sensors 52
machine dimensions 20 Diagnostics – UTS
machine settings, invalid file 21 Backsight 52
machine settings, no suitable settings 21 Machine Target 50
no UTS Start softkey 30 UTS 51
UTS fails to initialize 30 Horizontal Offset 36
control box Machine Radio Configuration 30
brightness 22 Machine Settings 21
dialogs 14 Machine Target ID 29, 31
display brightness 22 Mast Extension 22, 23
display information overview 12 Select Design File 32
guidance icons 17 Select Guidance Line 34
guidance screens 16 Select Offset Type 35
guidance settings 17
H
horizontal guidance line, select 33 P
Horizontal Offset dialog 36 power key 11
How To power supply state, UTS 29
change the machine radio configuration 30 power up checks 20
check the UTS instrument power 29 program log 55
connect to a different UTS instrument 30
insert a data card 32
load or create a design 32 S
run diagnostics 49
select a design 32 screen shots 55
select a guidance line 33 select a horizontal guidance line 33
select a guidance line design 34 Select Design File dialog 32
select a horizontal guidance line 33 Select Guidance Line dialog 34
set the SPSx30 UTS target ID 29, 31 Select Offset Type dialog 35
start a UTS 28 sensors
turn off UTS guidance 36 diagnostics 52
prepare 3D sensors 28
set up a UTS system 28
U
UTS
battery state 29
diagnostics 50, 54
flashing warning messages 41
power supply state 29
setting MT900 machine target ID 29, 31
setting up 28
starting 28
status messages 51
target status indicators 47
troubleshooting 38
turn off guidance 36
UTS dialog 28, 31