1. PCS400 Software Phil Jackson Training Manager January 2009

2. Paving Display Software Softkeys Menus Guidance Screens

3. Paving Softkeys

4. Increment Decrement During runtime: – In Manual Drives the tow point cylinder up/down (unless paver is stationary and has in-motion relay which ignores commands from automatic systems) – In Auto Pressing & releasing will increment / decrement the control offset once Holding this button will keep increasing / decreasing the control offset until it is released During configuration: – Pressing & releasing this button will move up / down to the previous / next menu item – Holding this button will scroll up / down the menu For slope control mode – Left side slope increment raises the left side of the screed – Left side slope decrement lowers the left side of the screed – Right side increment raises the right side of the screed – Right side decrement lowers the right side of the screed

5. Home, Auto/Manual, OK Home – Toggles between any menu screen and runtime screen Auto/Manual – Only in runtime screen. – Toggles the system between manual and automatic control – System will always start in manual control – Press and hold on Auto/Man button puts the system in measure mode – You can tell you are in measure mode as the little ruler is displayed in the runtime area OK or Menu Select – Only in config screen – Selects the menu item which is highlighted – Also used to accept the configuration changes

6. Escape, Forward, Elevation Select Escape or Menu Cancel – Only in config menus – Returns to the parent menu – Also used to cancel the configuration changes Cursor Movement – Only in config screens during number or string edit – Button press moves the cursor forward to next editable character or number Elevation select – Only in the runtime screen – Single press on Elevation select lets you edit the elevation run time number or calibrate the slope sensor if in slope mode – Press and hold on Elevation select swaps control between elevation and slope mode

7. Left Null, Right Null Left Null Only at runtime screen Nulls the left side elevation or slope – press and hold to null – LED goes green and long beep Right Null Only at runtime screen nulls the right side elevation or slope – press and hold to null – LED goes green and long beep Null is the preferred paving term – = Bench in the Grading world

8. Null or Nulling In the documentation for this product we should refer to this process as Nulling Zeroing is second choice Benching is not a common term in the asphalt paving world

9. Menu Lock, Menu Unlock Menus Locked Softkey Menus Unlocked Softkey Affects Menu Items in the Menu Screens By default this is OFF

10. Menu Lock, Menu Unlock To Enable: Go to: Configuration / Advanced Options / Supervisor Password / Enable Key in the Password Undocumented Password is: 8024

11. Menu Lock, Menu Unlock To Lock Menus: Hold down the Padlock softkey to Unlock it Key in the Password With the Padlock symbol showing Unlocked: Highlight the menu you want to lock Tap the padlock softkey – A Padlock symbol appears in front of the menu item Repeat for all Menus you want to lock Hold down the Padlock softkey until it changes to a Locked padlock Menus with a Padlock symbol are now locked

12. Menu Lock, Menu Unlock To Unlock Menus Press and hold the Padlock softkey Key in Password All items are now Unlocked and Cleared

13. Menu Lock, Menu Unlock To Disable Menu Lock Go to: Configuration / Advanced Options / Supervisor Password / Disable Key in the Password Press OK – Padlock Icon disappears

14. Hidden Installation Menu Installation Menu is hidden Why: To prevent accidental mistakes in system settings An undocumented key sequence will be required to access the hidden menu system entries.

15. Hidden Configuration Menus – On Real Display To enter the Installation menu: Start in the Configuration menu: Simultaneously: – press + release left bottom button – press + release right second from top button – press + release right second from bottom button

16. Hidden Configuration Menus – On Emulator To enter the Installation menu: Start in the Configuration menu: Hold Ctrl key down – click left bottom button – click right second from top button – click right second from bottom button

17. Units of measure The following units of measures are supported with the listed resolution and min max ranges UnitsFormatResolutionMinMax Elevation: Meters#.### m0.001 m-9.9999.999 Elevation: Decimal Inches##.## in0.05 in-99.9999.99 Elevation: Decimal Feet#.## ft0.01 ft-9.999.99 Slope: 0.1%##.# %0.1%-10.0%10.0% Slope: 0.01%##.## %0.01%-10.00%10.00% Note: Negative sign is used for negative runtime elevation numbers. Icons are used for positive, negative and zero runtime slope numbers.

18. Nulling – Elevation Control Press and Hold the null button to null the display – Display of green LED and a beep will indicate to the user that the nulling was successful For elevation control the stored reference elevation becomes the Null Elevation Number

19. Nulling – Slope Control Press and Hold the null button to null the display – Display of green LED and a beep will indicate to the user that the nulling was successful For Slope control, when we null we take samples of the slope readings, average the samples, and display the average number – The averaged number becomes the control set point

20. Slope Sensor Calibration In this screen enter the measured slope The difference between this value and the slope sensor reading is the calibration offset This is stored and used until it is done again Slope calibration is performed same as elevation runtime number edit – Tap elevation/slope button, number highlights – Use up/down errors to adjust number to measured slope – Tap elevation/slope button to exit slope calibration – Note: Sensor calibration is stored in the sensor

21. Indicate Mode - Enter To enter indicate mode: Press and hold the Auto/Manual button for three (3) seconds When in indicate mode the runtime screen will display a ‘ruler’ icon to the left of the runtime number being displayed

22. Indicate Mode - Exit To exit indicate mode: Tap the Auto/Manual button – Nulls the height or slope – Puts you in Auto Press and hold the Auto/Manual button for three (3) seconds – Return to runtime screen without nulling and remain in manual mode

23. Runtime Screen Runtime Mode is the mode you are normally in The number displayed is the “Runtime Number

24. Single & Dual Side Screens Single Side ScreenDual Side Screen (Left side)

25. Paving Runtime Screen Icons

26. Paving Runtime Icons Screed This icon represents the machine’s screed This icon is always displayed at the top of the screen Zero Slope Indicates zero slope Positive Slope – Indicates positive slope – Positive slope means that right side of the screed above level Negative Slope – Indicates negative slope – Negative slope means that left side of the screed is above level

27. Paving Runtime Icons Slope Control Indicates the slope is being controlled using a slope sensor This icon is displayed on the System Config Status Window when slope mode is selected by pushing Elevation/Slope select soft button One sonic sensor over string line To indicate one sonic sensor is detected in the bus and is configured for string line operation NOT One sonic sensor over string line To indicate one sonic sensor was detected and was configured as sonic over string line operation after power up but disconnected later

28. Paving Runtime Icons Side Identification Indicates the left or right side assignment the Display detects via function instance. E.g., when left side is detected this icon is displayed on the left side of the machine icon. One sonic sensor over surface To indicate one sonic sensor is detected in the bus and the system is configured as sonic over surface This icon is displayed to the left or right of ‘screed’ icon based on the function instance of the sensor. NOT One sonic sensor over surface To indicate one sonic sensor was detected and was configured as sonic over surface operation after power up but disconnected later Two sonic sensors over surface To indicate two sonic sensors are detected in the bus and the system is configured as sonic over surface This icon is displayed to the left or right of ‘screed’ icon based on the function instance of the sensor. NOT Two sonic sensors over surface To indicate two sonic sensors were detected and were configured as sonic over surface operation after power up but disconnected later

29. Paving Runtime Icons Three sonic sensors over surface To indicate three sonic sensors are detected in the bus and the system is configured as sonic over surface. This icon is displayed to the left or right of ‘screed’ icon based on the function instance of the sensor. NOT Three sonic sensors over surface To indicate three sonic sensors were detected and were configured as sonic over surface operation after power up but disconnected later Contact sensor To indicate one contact sensor is detected in the bus This icon is displayed to the left or right of ‘screed’ icon based on the function instance of the sensor NOT Contact sensor To indicate one contact sensor was detected in the bus after power up but disconnected later This icon is displayed to the left or right of ‘screed’ icon based on the function instance of the sensor.

30. Paving Runtime Icons Move right To indicate that the screed should move to the right to stay centered over the stringline This user feedback is only available when using a single sonic ski over a stringline. Move left To indicate that the screed should move to the left to stay centered over the stringline This user feedback is only available when using a single sonic ski over a stringline. Auto control To indicate the machine is running in the automatic control Manual control To indicate the machine is running in the manual control

31. Single Side Control Mode Single Side Control Mode is one of the display modes of the runtime screen Only one side of the screed will be controlled The side to control is automatically determined from the function instance

32. Single Side Control Mode The Display side from function instance is displayed by an icon on the corresponding side of the screen Display controls sensor icon for that side Light bar is used to display grade guidance for that side LED’s of only one side of the display are lit In Elevation Control Mode the Elevation is adjusted by applying an offset using the increment/decrement soft switches

33. Single Side Control Mode In Slope Control Mode the Slope is adjusted by applying an offset using the increase/decrease soft switches In slope control mode, positive, negative, or zero slope icons indicate the sign of the slope In elevation control mode ‘-’ signs will be used to indicate a negative elevation number Auto / Manual state is displayed Can cycle through the control modes

34. Control sensor status window Screed icon Sample – Single Display Mode Screen Runtime number display window Display side identification icon Control sensor icon Runtime number Menu soft button Implement Enabled icon Cat Factory Fit Only Increase soft button Decrease soft button Elevation select soft button Auto/Manual soft button Null soft button Units of measure Auto/Manual control status icon Auto/Manual control status window

35. Sample – Single Display Mode Screen Above figure shows a sample display for the Single Display Mode and the following configuration: Display mounted on left side Elevation select soft button pressed to control slope System running in auto control; ‘0.01%’ units of measure – Note the negative height icon – Note that elevation select functionality is not available when the system is running in automatic control

36. Paving Menu Structure

37. Config Menu – Two Displays Following slides list all of the menu options First the top level menu is shown Then the options for each entry Defaults are shown in BOLD

38. Configuration Menu – Two Displays ST200 Configuration Display Mode (ONLY Dual Display system) Sensor Selection Customize Diagnostics Advanced Option

39. Config Menu – Two Displays ST200 Configuration String Line Surface

40. Config Menu – Two Displays Display Mode Single Side Dual Side

41. Config Menu – Single Display Sensor Selection Single Sensor – ST200 – CS200 MUST select the sensor you want – Remembers the last sensor you used

42. Config Menu – Single Display Sensor Selection Averaging Ski – All ST200 – Center Only – Front and Back MUST select the sensor you want – Remembers the last sensor you used

43. Config Menu – Two Displays Customize On Grade Deadband Units of Measure Audio Cross Coupling Brightness Contrast

44. Config Menu – Two Displays Customize On Grade Deadband Elevation +/- 3.0mm (0.1 mm – 5.0 mm) Slope +/-0.05% (0.01% – 0.50%) Units of Measure Elevation Decimal Feet0.01 Meters0.001 Decimal Inches0.05 Slope 0.1 Percent 0.01 Percent

45. Config Menu – Two Displays Customize Audio Audio Volume 12 (0% - 100%) Elevation Alert On Off Slope Alert On Off

46. Config Menu – Two Displays Customize Cross Coupling 100 (0% - 100%)

47. Elevation Change Explanation of Cross Coupling With 100% Cross Coupling, when elevation is corrected, the cylinder controlled by the Slope Sensor changes by the same amount as the cylinder controlled by the Elevation Sensor So when height changes, the cross slope side changes as well to keep cross slope true Elevation controlled side Slope controlled side Start Position Halfway Position End Position

48. Elevation Change Explanation of Cross Coupling With 0% Cross Coupling, the cylinder controlled by the Slope Sensor only reacts to the Slope Sensor So when height changes, the cross slope also changes until the Slope Sensor detects it and changes the Slope cylinder Elevation controlled side Slope controlled side Start Position Halfway Position End Position

49. When to use Cross Coupling When a paver has stable crossfall, use 100% – Surface it is running over has a constant Crossfall When paver is oscillating side to side, use 0% – Surface it is running over has varying crossfall – Should not happen Used a lot when grading with dozers and graders In ‘normal’ paving it is hard to see the improvement, but it is there – 100% is the default and normal setting

50. Config Menu – Two Displays Customize Brightness Push Button 80 (0% - 100%) Screen 50 (0% - 100%) Contrast 50 (0% - 100%)

51. Config Menu – Two Displays Diagnostics Sensor Connectivity graphical sensor connections Test Valves 100% - side arrow increments Hour Meter Operating hours and Control hours Software Versions list of connected devices Sensor Data list of connected sensors data Fault History log of last five faults – Press OK to expand fault Machine Voltage voltage number Test Control Box switches and LEDs

52. Config Menu – Single Display Diagnostics – Sensor Connectivity 3x ST200 on Sonic Ski Single Display AS200 CS200

53. Config Menu – Single Display Diagnostics – Test Valves

54. Config Menu – Single Display Diagnostics – Hour Meter

55. Config Menu – Single Display Diagnostics – Software Versions

56. Config Menu – Single Display Diagnostics – Sensor Data

57. Config Menu – Single Display Diagnostics – Fault History

58. Config Menu – Single Display Diagnostics – Machine Voltage

59. Config Menu – Single Display Diagnostics – Test Control Box Lights scroll in pairs from bottom to top Buttons show as pressed in main screen AND invoke the function shown

60. Hidden Configuration Menu – On Real Display To enter the Installation menu: Start in the Configuration menu: Simultaneously: – press + release left bottom button – press + release right second from top button – press + release right second from bottom button

61. Hidden Configuration Menu – On Emulator To enter the Installation menu: Start in the Configuration menu: Hold Ctrl key down – click left bottom button – click right second from top button – click right second from bottom button

62. Config Menu – Two Displays Advanced Option About control box info Supervisor Password Enable Disable Service Agreement Password password entry box

63. Installation Menu – Two Displays Installation menu is unaffected by 'Reset to Defaults' menu; it can be set to defaults by pressing Left and Right lowermost buttons together

64. Installation Menu – Two Displays Language Machine Setup Calibration Valve Speed Reset to Defaults

65. Installation Menu – Two Displays Language English Chinese Russian Espanol Deutsch Francais Italiano Nederlands Portugues Svenska Norsk Dansk Japanese Polish Press and hold left and right bottom buttons while powering up and you will be brought to this screen

66. Installation Menu – Two Displays Machine Setup Machine Type Asphalt Screed

67. Installation Menu – Two Displays Calibration Auto Valve Calibration wizard Manual Valve Calibration wizard Don’t use unless you REALLY have to

68. Installation Menu – Valve Calibration Mount ST200 at the Tow Point Cylinder Select the Left side

69. Installation Menu – Valve Calibration Center the Tow Points – Use the arrows at top left – After a pause the OK symbol on the screen changes

70. Installation Menu – Valve Calibration Set Cylinder Lower Limit – Use the arrow second from top on the left – After a pause the OK symbol on the screen changes

71. Installation Menu – Valve Calibration Set Cylinder Upper Limit – Use the arrow at the top on the left – After a pause the OK symbol on the screen change

72. Installation Menu – Valve Calibration Do you want to Start? – Do you have hot oil? – Do you have full revs?

73. Installation Menu – Valve Calibration First 5% is spent finding the Lower cracking current – Can take a couple of minutes

74. Installation Menu – Valve Calibration Next 5% is spent finding the Raise cracking current – Can take a couple of minutes

75. Installation Menu – Valve Calibration Then it proceeds to find the rest of the values quite fast – You can see the bar on the left move with the ram

76. Installation Menu – Valve Calibration Press OK to save when complete

77. Valve Calibration – When? Required at Installation Required when hydraulics are serviced Recommended at the beginning of each paving season

78. AS200 Calibration Two ways to do this: – Rest screed on starter boards Measure Screed Slope From the Runtime Screen tap & set the angle Tap to Accept & exit – OR the preferred method: – While paving in Auto and everything is stable Measure Mat Slope From the Runtime Screen tap & set the angle Tap to Accept & exit

79. Installation Menu – Two Displays Calibration Valve Calibration Storage – Different rules for different systems AccuGrade Factory Fit – Stored in the A4:M1 – Can put any display in any position – BUT Must recalibrate if you swap from two display to One Or vice-versa PCS400 & AccuGrade Aftermarket – Stored in the Display – CanNOT swap displays to other side Warning if you put a Right side display on the Left – CanNOT swap displays to other machines

80. Installation Menu – Two Displays Calibration Valve Calibration Storage PCS400 & AccuGrade Aftermarket Can calibrate Left CB440 for left & right sides – But only for the instance that the CB440 has – So if it is the Left display out of two, then it is OK – But if you then make it the Left Display Only you need different valve calibrations – And vice-versa for the right side display

81. Installation Menu – Two Displays Calibration If a display fails, what can you do? – Topcon must replace the display – They can only operate one side with one display We have two choices for the aftermarket system – Stop, Reconfigure remaining display for both sides and recalibrate the valves – Or carry one hot spare display, previously calibrated for the valves on both sides

82. Installation Menu – Stop, Reconfigure, & Recalibrate One display fails – Disconnect it from Harness – Disconnect & reconnect remaining display Power cycles teaches it that it is the only display – Calibrate Left valve – Calibrate Right valve Can be in either order – Start Paving again No extra equipment needed

83. Installation Menu – Hot Spare Display One display fails – Disconnect & Remove BOTH displays – Mount & connect spare display – Start Paving Requires spare display to have Valve Calibrations performed previously for both left & rights sides – Cannot use the remaining display OR Have two hot spares – One for Left & one for Right

84. Installation Menu – Two Displays Valve Speed Elevation <-Elevation Valve Speedonly on LH Display 100 (0% - 100%) Elevation Valve Speed->only on RH Display 100 (0% - 100%) Slope Slope Valve Speed 100 (0% - 100%)

85. Installation Menu – Two Displays Reset to Defaults ESC and OK