Topcon Paver System 5, Paver Smoothtrac Operator's Manual

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POSITIONING SYSTEMS

Paver System Five

Operator’s Manual

Part Number 7010-0341

Rev F

©Copyright Topcon Positioning Systems, Inc.

April, 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#2223

Table of Contents

Preface .................................................................. vii

Terms and Conditions ...................................................... vii

Manual Conventions ........................................................ x

What’s New... ........................................................ xi

Chapter 1

System Overview .................................................. 1-1

Getting Acquainted .......................................................... 1-3

Control Box ............................................................... 1-3

Sonic Tracker II ......................................................... 1-4

Slope Sensor .............................................................. 1-5

Smoothtrac Sonic Averaging System (SAS) ............. 1-6

Laser Tracker & Trackerjack ...... .............................. 1-7

Care and Preventive Maintenance ................................... 1-8

Chapter 2

Paving Principles & Control Methods ................ 2-1

Paver Components ........................................................... 2-1

How a Screed Works ....................................................... 2-2

Tow Point Force (“P”) .............................................. 2-5

Truck Exchange, Another Tow Point Force ....... 2-6

Head of Material (“M”) ............................................. 2-7

Reaction of Material Under Screed (“R”) ................. 2-9

Gradation Mix Characteristics ............................ 2-9

Mix Temperature Characteristics ....................... 2-11

Weight of Screed (“W”) ............................................ 2-12

Quality of Base Being Paved .................................... 2-13

Rolling Techniques ............................................. 2-14

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Table of Contents

Controlling Mat Quality ...................................... 2-14

Control Methods .............................................................. 2-15

Sonic Control ............................................................. 2-15

Working Window and Sonic “Footprint” ........... 2-16

Sonic Tracker Operation and its Position ........... 2-18

Sonic Tracker and Temperature Changes ........... 2-22

Laser Control ............................................................. 2-24

Slope Control ............................................................. 2-26

Chapter 3

Stringline Setup ................................................... 3-1

Setting Surface Stringline ................................................ 3-2

Setting Elevated Stringline .............................................. 3-5

Making a Cut/Fill Lath .............................................. 3-7

Attaching Stringline to the Grade Stake .................... 3-9

Setting Projected Slope Stringline ................................... 3-10

Verifying Grade ............................................................... 3-12

Chapter 4

Operation & Menu Settings ................................. 4-1

Control Box ...................................................................... 4-2

LCD ........................................................................... 4-3

Light Sensor for LED Display ................................... 4-3

Power Switch ............................................................. 4-3

Grade Adjustment Knob ............................................ 4-4

Grade Adjustment Direction Arrows ........................ 4-5

Grade Adjustment LEDs ........................................... 4-5

Function Indicator LEDs ........................................... 4-6

Set/Menu Button ........................................................ 4-7

Using the Set Mode ............................................. 4-7

Using the Menu Mode ........................................ 4-8

Cross Communication Button ................................... 4-8

Slope/Elevation Button .............................................. 4-11

Slope Mode ......................................................... 4-11

ii

Elevation Mode ................................................... 4-11

Topcon Paver System Five Operator’s Manual

Table of Contents

Survey/Indicate Button .............................................. 4-12

Using the Survey Function ................................. 4-12

Using the Indicate Function ................................ 4-12

Auto/Manual Button .................................................. 4-13

Using Automatic Mode ...................................... 4-13

Using Manual Mode ........................................... 4-13

Making Selections in the Performance Menu ..... 4-14

Jog Button ................................................................. 4-14

Other Control Box Components ................................ 4-14

Performance Menu Settings ............................................. 4-16

Gain (Elevation) ........................................................ 4-20

Gain (Slope Control) ................................................. 4-21

Valve Offset .............................................................. 4-23

Averaging .................................................................. 4-26

Deadband Elevation .................................................. 4-27

Deadband Slope ........................................................ 4-29

Beeper Alarm ............................................................ 4-31

Unit ............................................................................ 4-32

Test ............................................................................ 4-34

Chapter 5

Getting Ready to Pave ......................................... 5-1

Control Box Setup ........................................................... 5-2

Screed Setup .................................................................... 5-3

Sonic Tracker Setup ......................................................... 5-4

SAS Setup ........................................................................ 5-6

Control Box Setup for Elevation ..................................... 5-7

Control Box Setup for Cross Slope ................................. 5-11

Chapter 6

Tracker and SAS Placement ................................ 6-1

Sonic Tracker Positioning in Relation to Reference ........ 6-2

L-bar Positioning ....................................................... 6-3

Cub and Gutter Tracking .................................... 6-5

Joint Matching and Tracking Sub-grade ............ 6-5

Placement When Using a Temperature Bail ............. 6-6

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iii

Table of Contents

Placement When Using a Mechanical Ski ................ 6-6

Placement When Using Elevated Stringline ............. 6-7

Placement When Using Surface Stringline ............... 6-8

Sonic Tracker Placement in Relation to Screed ............... 6-8

Smoothtrac SAS Placement and Setup ............................ 6-13

Positioning the SAS ......................................................... 6-16

Placement of SAS on Paver ............................................. 6-19

Chapter 7

Paving Applications ............................................. 7-1

Paving City Streets with Sonics ....................................... 7-1

Paving City Streets with Cross Slope .............................. 7-4

Paving Streets Through Intersections .............................. 7-7

Method 1 for Paving Intersections ............................ 7-7

Method 2 for Paving Intersections ............................ 7-9

Paving Intersections with Cross Slope ............................. 7-10

Chapter 8

Maintenance ......................................................... 8-1

Preventative Maintenance & Daily Care ......................... 8-1

Sonic Tracker II Transducer Cleaning ............................. 8-2

Sonic Tracker II Transducer Replacement ...................... 8-3

Chapter 9

Troubleshooting ................................................... 9-1

Control Box Symptoms .................................................... 9-1

Tracker Symptoms ........................................................... 9-11

Slope Sensor Symptoms .................................................. 9-14

SAS Symptoms .......................................... .... .................. 9-17

Appendix A

Safety Precautions ............................................... A-1

iv

Topcon Paver System Five Operator’s Manual

Table of Contents

Appendix B

Limited Warranty .................................................. B-1

Electronic and Mechanical Components ......................... B-1

Return and Repair ............................................................ B-1

Warranty Disclaimer ........................................................ B-1

Service Information ......................................................... B-2

Glossary

Index

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Table of Contents

Notes:

vi

Topcon Paver System Five Operator’s Manual

Preface

This manual has been developed to provide the operator with
information necessary to operate and maintain TOPCON products.
Proper service and use is important to the reliable operation of the
equipment. The procedures described herein are effective methods
for performing service and operation of this system.

NOTICE

Terms and Conditions

USE – Please study this manual carefully. The benef its this product
provides can be greatly influenced by your applications knowledge.

COPYRIGHT – All information contained in this Manual is the
intellectual property of, and copyrighted material of Topcon
Positioning Systems (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
Topcon’s 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.

NOTICE

Please read these Terms and Conditions
carefully.

vii

P/N 7010-0341 www.topconpositioning.com

Preface

TRADEMARKS – System Five™, Topcon® and Topcon
Positioning Systems™ are trademarks or registered trademarks of
TPS. Windows® is a registered trademark of Microsoft
Corporation. 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 MANU AL 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.

viii

Topcon Paver System Five Operator’s Manual

Terms and Conditions

WEBSITE and OTHER STATEMENTS – No statement
contained at the TPS website (or any other website) or in any other
advertisements or TPS literature or made by an employee or
independent contractor of TPS modifies these Terms and
Conditions (including the Software license, warranty and limitation
of liability).

SAFETY – Improper use of the Product can lead to injury to
persons or property and/or malfunction of the product. The product
should only be repaired by authorized TPS warranty service
centers. Users should review and heed the safety warnings in
Manual.

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.

TOPCON POSITIONING SYSTEMS, Inc.
5758 W. Las Positas Blvd.
Pleasanton, CA 94588
925 / 460 1300
925 / 460 1315 FAX

P/N 7010-0341 www.topconpositioning.com

ix

Preface

Manual Conventions

This manual uses the following conventions:

TIP

TIP

Supplementary information that can help to
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

x

UNDER NO CIRCUMSTANCES SHOULD THIS ACTION

BE PERFORMED.

Topcon Paver System Five Operator’s Manual

What’s New...

This manual includes the changes for version 1.7 of the 9256
Control Box code.

In this version:

The range of the following settings has changed:

• Gain (Elevation) range is now 1–200

• Gain (Slope) range is now 1–200

See “Performance Menu Settings” on page 4-16 and Table 4-2
on page 4-16 for more information on menu settings.

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xi

What’s New...

Notes:

xii

Topcon Paver System Five Operator’s Manual

Chapter 1

S

ystem

F

ive

System Overview

System Five™ is a complete, non-contacting control system which
combines both elevation control and slope control into a simple,
easy to use package (Figure 1-1).

The primary function of System Five is to provide screed control so
that the paving material is placed into position at the correct
elevation and slope.

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Figure 1-1. Paver System Five Components

P/N 7010-0341 www.topconpositioning.com

1-1

System Overview

S

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Figure 1-2 displays the setup of components on a screed.

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Figure 1-2. Paver System Five Top View

Topcon Paver System Five Operator’s Manual

Getting Acquainted

S

ystem

F

ive

Getting Acquainted

A standard System Five Paver system includes two Control Boxes,
two Sonic Trackers and a single Slope Sensor. When setup and
connected, the Control Boxes control either the left or right side of
the machine for either elevation or slope.

Control Box

The Control Box (Figure 1-3) is the operator’s interface to
System Five. The Control Box recei ves signals from the sensors
(Sonic Tracker II™, Laser Tracker, and/or Slope Sensor), and
uses these signals to determine if grade or slope corrections are
necessary. If a change in grade or slope is required, the Control
Box sends a signal to the valve controlling the tow point
cylinder on the appropriate side of the machine to raise or
lower, thus maintaining correct mat thickness.

The Control Box connects to the Sonic Tracker II™, the Slope
Sensor, and to the paver through electrical cables. The Control
Box easily attaches to its mounting bracket with one clamp, and
at the end of the day should be removed for storage.

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Figure 1-3. Control Box

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1-3

System Overview

Sonic Tracker II

The Sonic Tracker II™ (Figure 1-4) measures and controls the
elevations of the screed. A transducer, located in the bottom of
the Sonic Tracker II™, generates sound pulses like a speaker
and listens for returned echoes like a microphone. The Tracker
measures the distance, and controls grade from a physical grade
reference, such as a curb, stringline, or existing road surface. A
bail is used to compensate for rapid air temperature changes. In
paving applications a bail should always be used.

The Sonic Tracker II attaches to the system through one quick
connect cable and attaches to the machine with a single bolt. At
the end of the day, Sonic Tracker II should be removed for
proper storage in the carrying case.

1-4

II

racker

T

onic

S

II

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T

onic

S

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Figure 1-4. Sonic Tracker II

Topcon Paver System Five Operator’s Manual

Getting Acquainted

Slope Sensor

The slope sensor (Figure 1-5) is a precision electronic sensor
which functions much like a precision carpenter's level. The
slope sensor reads the inclination (tilt) of the screed and sends
the signal to the Control Box. The slope sensor measures slopes
from +20% to -20%.

The slope sensor connects to each Control Box through an
electrical cable and requires no adjustments, and is the only
component of System Five that can be used to control either
side of the paver. The slope sensor is a sealed component, and
once attached to the Paver, should not be removed.

F

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SLOPE

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Figure 1-5. Slope Sensor

P/N 7010-0341 www.topconpositioning.com

1-5

System Overview

Smoothtrac Sonic Averaging System (SAS)

The Smoothtrac® SAS (Figure 1-6) is an elevation control
system that combines multiple sonic trackers to calculate an
average of the physical reference. Each tracker sends its
distance measurement to the Control Box which then averages
those measurements and sends a correction signal to the tow
point cylinder . The Smoothtrac replaces the mechanical ski that
drags on the ground.

The Smoothtrac connects to the Control Box through the
tracker cable.

1-6

Figure 1-6. Smoothtrac Sonic Averaging System (SAS)

Topcon Paver System Five Operator’s Manual

Getting Acquainted

Laser Tracker & Trackerjack

The laser tracker (Figure 1-7) is an elevation control sensor that
measures and controls the elevation of the screed. After
receiving a signal from a rotating laser, the laser tracker sends a
signal to the Control Box, which then sends a raise or lower
signal to the tow point cylinder.

The Trackerjack attaches to the laser receiver and then mounts
to a vibration pole (Figure 1-7). Use the same cable from the
Sonic Tracker II to power the laser tracker/Trackerjack system.

The laser trackerjack should be removed at the end of each day
and stored in its carrying case.

OPTIONAL

LS

-

B

2

4

1 2 3

Figure 1-7. Laser Tracker & Trackerjack

P/N 7010-0341 www.topconpositioning.com

1-7

System Overview

Care and Preventive Maintenance

In general, follow these guidelines when using System Five:

• Always clean and thoroughly dry the removable components
before storing them in carrying cases. Use a clean, soft cloth
moistened with a neutral detergent or water.

• Keep carrying cases clean and dry. Do not leave them open and
exposed to the elements.

• Some moisture on the Control Box and its components is
acceptable during working conditions. Do not spray water or
use high pressure steam cleaner hoses directly on cables and
components.

• Use protective connector caps on cables when not using the
System Five for a period of time. Water accumulating on the
connectors can cause electrical shorts.

At the end of the day, performing general maintenance and storing
mobile parts will help to keep the System Five in top condition.

• Remove the Control Box and the Laser T racke r and dust with a
dry or damp non-abrasive, soft cloth.

1-8

• Insert cables into appropriate storage connectors after removing
the Control Box.

A Carrying Case is provided with each System Five. The Carrying
Case is lined and includes pre-cut sections for each Sonic Tracker II
and the Control Boxes. A cut-out section is also provided for
storing coil cords (Figure 1-8 on page 1-9).

Topcon Paver System Five Operator’s Manual

Care and Preventive Maintenance

Figure 1-8. Carrying Case

NOTICE

NOTICE

Keep the carrying case dry and store in a dry
location. Never let the interior of the carrying
case become wet. If the case does become wet,
remove the components and let it dry.

P/N 7010-0341 www.topconpositioning.com

1-9

System Overview

Notes:

1-10

Topcon Paver System Five Operator’s Manual

Chapter 2

Tractor

Screed

Screed Pivot PointTow Point

Paving Principles &

Control Methods

This chapter describes the components of pavers and the basics in
paving principles, as well as control methods used for paving.

Paver Components

Modern pavers (Figure 2-1) consist of two major units: the Tractor
and the Screed.

The primary function of the tractor is to propel the truck or paver
feeding device, to convey and distribute the paving material and to
tow the screed. The function of the screed is to strike off the
material in preparation for further compaction. The screed is
mounted to the tow arms at the screed piv ot points and is attached to
the paver at the tow points.

Figure 2-1. Paver Components

P/N 7010-0341 www.topconpositioning.com

2-1

Paving Principles & Control Methods

How a Screed Works

The screed on all modern pavers is of the “floating, self leveling”
type. As the paver tows the screed unit forward, paving material
flows under the screed. This causes the screed to float on the mat of
material, thus establishing mat thickness. Since the screed is
mounted to the paver only at the tow points, the screed is
completely free to float up or down (Figure 2-2). The screed will
always seek it's own “Planing An gle”, or angle of attack, dependen t
on the combination of forces acting upon the screed (Figure 2-2).

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Figure 2-2. Tow Point Path and Planning Angle

• If the screed angle of attack is increased the screed rises,
increasing the mat thickness (Figure 2-3).

• If the angle of attack is decreased, the screed will settle,
providing a thinner mat surface (Figure 2-3).

Figure 2-3. Screed Determines Mat Thickness

Topcon Paver System Five Operator’s Manual

How a Screed Works

Lengths Travel

Lengths Travel

Lengths Travel

Lengths Travel

Elevation

Because the screed floats, it will not immediately react to a change
in the tow point. It needs a certain amount of time or distance to
make a correction in the mat thickness (Figure 2-4).

• If the tow point is changed by a unit of one, the paver must

move one tow arm length before the screed will correct 63% of
the elev ation.

• After 2 tow arm lengths 83% of the correction is made and 3

tow arm lengths would account for 95%.

• It takes 6 tow arm lengths to achieve 100% of the elevation

change.

Considering that 95% of the change takes place after 3 tow arm
lengths, this can be used in practical applications to qualify for full
correction.

Change to

Tow Point Path

Tow Point Path

2 Tow Arm

Lengths Travel

87%

1 Tow Arm

Length Travel

63%

Tow Point Path

98%99%100%

6 Tow Arm

P/N 7010-0341 www.topconpositioning.com

5 Tow Arm

Figure 2-4. Tow Arm Travel

4 Tow Arm

95%

3 Tow Arm

2-3

Paving Principles & Control Methods

The same is true when making elevation changes with the manual
thickness cranks (Figure 2-5).

Change in Screed

Angle of Attack

from Crank

Tow Point Path

2 Tow Arm Lengths Travel

87%

100%

1 Tow Arm Length Travel

63%

Tow Point Path

99%

4 Tow Arm Lengths Travel5 Tow Arm Lengths Travel6 Tow Arm Lengths Travel

98%

3 Tow Arm Lengths Travel

95%

Figure 2-5. Manually Changing Mat Thickness

Always check mat depth in several locations before making any
elevation corrections. The surface being paved may have wheel
ruts, dips and ridges that will give an untrue indication of overall
mat depth. Check sev eral sp ots t o get an average (Figure 2-6). If an
elevation change is made, wait 3 to w arm lengths for full correction.
T oo much cranking and stabbing will cause raise and lo wer changes
that will produce an uneven mat surface.

2-4

Figure 2-6. Checking Mat Thickness

Topcon Paver System Five Operator’s Manual