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P O S I T I O N I N G S Y S T E M S X-22 Excavator Indicate System Installation and Calibration Manual Part Number 7010-1019 Rev A ©Copyright Topcon Positioning Systems, Inc. June, 2011 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, distributed, or otherwise reproduced without express written consent from Topcon.
Terms and Conditions Thank you for buying this Topcon product. This manual has been prepared to assist you with the care and operation of the product and its use is subject to these Terms and Conditions and those more fully set forth in the Operator’s/User’s Manual. Usage and Safety This product is designed for use by professionals. Always use safety precautions when operating this or any Topcon product.
TOC Table of Contents Chapter 1 Introduction .......................................................... 1-1 System Components ........................................................ 1-1 Chapter 2 Installation and Calibration ................................. 2-1 Getting Started ................................................................. Step 1: Charge the Sensors ........................................ Step 2: Attach the Brackets ....................................... Bracket for Boom Sensor ...
Table of Contents Check that X-22 is Measuring Correctly ................... Backup ....................................................................... Applications ............................................................... Arm (Stick) Sensor with Laser Detector ................... Handling Damaged Sensors ....................................... Important Information On Use ......................................... Charger ......................................................................
Chapter 1 Introduction Congratulations on your new X-22 System. System Components Measuring and installation equipment is also available separately (not shown).
Notes: 1-2 X-22 Installation and Calibration Manual
Chapter 2 Installation and Calibration Getting Started Before you can start using your X-22 System for excavation, you need to set it up. Read on to find out how to install X-22 on your excavator in nine simple steps. Step 1: Charge the Sensors The first thing you must do is charge the sensors for several hours (i.e. overnight). The charger’s LEDs may briefly turn on and off as the sensors go through their charging cycle. This is normal. Leave the sensors on the charger to ensure a full charge.
Step 2: Attach the Brackets Attach the aluminum brackets using the self-tapping screws provided. The drill and bit for the screws are also included. The drill is 4.6 mm and the screws Taptite M5x10 have a recessed head. NOTICE Rub a little grease or oil onto the screws before screwing them in. NOTICE When determining the location of the sensor brackets, make sure you allow room to install and uninstall the sensors onto the brackets.
Installation and Calibration The bracket for the boom sensor must be attached to a face of the boom that does not slant in relation to the boom bolt. The following picture shows how the boom is widest down by the boom bolt and gets narrower towards the center. The bracket must not therefore be attached in this area. Figure 2-3. Do Not Install Bracket on Slanted Area of Boom The bracket for the ArticBoom sensor should be attached to the articulated (extended) boom, if the machine has one, in the same way.
It makes no difference to the wireless communication or angle measurements for the sensors whether the bracket for the boom sensor is positioned as shown in Figure 2-4, Figure 2-4. Boom Sensor Bracket Orientation or as shown in Figure 2-5. Figure 2-5.
Installation and Calibration Bracket for Arm (Stick) Sensor with Laser Detector The bracket for the arm (stick) sensor must be attached to the side of the arm (stick) that faces the cab. Position the bracket so that the sensor is roughly vertical when the laser hits it. Take care not to attach the bracket too high on the arm (stick) to avoid problems with getting the laser beam to hit the sensor.
Bracket for Bucket Sensor The best place to attach the bracket for the bucket sensor depends on the size of the excavator and if the joints are tight or loose. It is easiest to make X-22 measure accurately if the bucket sensor is attached directly on the bucket/quick coupler. This is especially the case if the joints are loose. Alternative 1: The inside of the quick coupler/bucket If the excavator is large enough, the bracket for the bucket sensor can be attached on the inside of the quick coupler/bucket.
Installation and Calibration NOTICE If the bucket sensor is attached on the inside of the quick coupler/bucket, the sensor direction of the bucket sensor must be changed from Normal to Reverse. Select Main Menu Setup Hardware Sensors and mark the bucket sensor. Then select Details. Select Sensor direction and press Edit. Alternative 2: The outside of the quick coupler/bucket The bracket for the bucket sensor can also be attached on the outside of the quick coupler / bucket.
Alternative 3: The inside of the control arm (dog-bone) If the excavator is large enough and the joints are tight, the bracket for the bucket sensor can be attached on the inside of the control arm (dog-bone). Attach the bracket on the control arm closest to the cab. NOTICE Fully extend and retract the bucket cylinder before fitting and make sure that the sensor do not meet any obstructions. Figure 2-9.
Installation and Calibration Alternative 4: The outside of the control arm (dog-bone) If the excavator is too small to fit the bracket with the bucket sensor on the inside of the control arm and the joints are tight, the bracket can be attached on the outside of the control arm. Attach the bracket on the control arm closest to the cab. NOTICE Fully extend and retract the bucket cylinder before fitting and make sure that the sensor do not meet any obstructions. Figure 2-10.
Bracket for Tilt Bucket Sensor (Optional) The bracket for the tilt bucket sensor must be attached so that the sensor rotates sideways or lengthways. Alternative 1: Sideways When the tilt bucket sensor is installed sideways, the long axis of the sensor is used to measure how much the bucket is tilted to the side. NOTICE The long axis must move as shown in the pictures below when the bucket is tilted to the side, or else the sensor will not measure correctly. Figure 2-11.
Installation and Calibration Example of sideways installation on a tilt bucket: Figure 2-13.
Alternative 2: Lengthways When the tilt bucket sensor is installed lengthways, the short axis of the sensor is used to measure how much the bucket is tilted to the side. Note that the short axis must move as shown in the pictures below when the bucket is tilted to the side, or else the sensor will not measure correctly. Figure 2-14. Lengthways Installation Figure 2-15.
Installation and Calibration Example of lengthways attachment: Figure 2-16. Lengthways Installation Step 3: Attach the Mast for the PitchRollCompass A mast is supplied with X-22 for the PitchRollCompass sensor. We recommend mounting the mast on the back of the machine’s counterweight. Position the bracket on top of the mast, parallel with the tracks of the machine. The optional welding mast ring (sold separately) is to be welded to the machine. Bolts and nuts are supplied with the mast.
mast ring is in place, attach the aluminium bracket firmly to the mounting ring with the M8x30 Allen screws provided. Figure 2-17. Mast and Mast Ring Installation NOTICE 2-14 Position the mast (or mast ring) so that it holds the mast steady and vertical on the excavator.
Installation and Calibration Step 4: Attach the X-22 Display You can easily attach the X-22 Display to the side window in the cab using the suction cup provided. Clean the glass before attaching the suction cup. This prevents air from getting into the suction cup. Figure 2-18. X-22 Display - Side View NOTICE P/N 7010-1019 Check regularly that the suction cup is firmly attached and take it off when it is not being watched.
The X-22 Display’s on/off switch is on the bottom of the unit. Bottom View On/Off Switch Power Cable Connector USB Port for Coordinator Back View RAM Mount Coordinator Slot Figure 2-19.
Installation and Calibration Step 5: Measure the Excavator Turn the X-22 Display on and select Main menu Excavators New to enter your excavator. Setup Figure 2-20. Create a New Machine Later in this manual you will find a list of the measurements you need to take. Use it for reference and making notes while measuring. You will find a tape measure in the case. NOTICE It is important to measure the excavator accurately. If the dimensions are wrong, X-22 will not measure as accurately as it should.
NOTICE It is important to take all the sensors out of the charger before starting to enter them on the X-22 Display. The radio for the sensors is switched off when they are in the charger. Each sensor has a unique serial number, which can be found on the back of the sensor preceded by “SN:”. It is important to keep the serial numbers of all the sensors for reference, and we recommend making a note of them in the table below. It is not possible to communicate with the sensor without the serial number.
Installation and Calibration Figure 2-21. Serial Number Label Step 7: Attach the Sensors to the Excavator Now you are ready to attach the sensors to the excavator. Slide the boom sensor into the bracket you have attached to the boom, the arm (stick) sensor into the bracket on the arm and the bucket sensor into the bracket on the control stick. If you have a PitchRollCompass sensor, an ArticBoom sensor, and/or a Tilt sensor, then attach them in the same manner.
Figure 2-22. Install Sensors onto Brackets NOTICE 2-20 The sensors only go into the brackets one way. Slide the sensor into the bracket with the charging pins on the sensor pointing away from the bracket.
Installation and Calibration Slide the PitchRollCompass sensor into the bracket on top of the mast. If needed, loosen the fastening screws of the mast base, and rotate the mast until sensor is pointing straight ahead. Then tighten the fastening screws so that the mast stays in this position. Figure 2-23.
Figure 2-24.
Installation and Calibration Step 8: Calibrate the Sensors The sensors should now be in position on the excavator. Press Start digging in the Main Menu and you are asked to calibrate the sensors. Follow the on-screen instructions. NOTICE It is important to calibrate the sensors accurately. If calibration is not done correctly, X-22 will not measure as accurately as it should.
Calibrating the Stick Sensor Attach a magnet in the center of the stick bolt and hang a plumb line from it. When the plumb bob is still and the line passes through the center of the bucket bolt, the stick is vertical. Figure 2-25.
Installation and Calibration Figure 2-26. Calibrate Control Arm (Dog-bone) Sensor Directly on the quick coupler / bucket If the bucket sensor has been attached directly on the quick coupler / bucket, the sensor is calibrated by positioning the bucket vertically. Calibrating the Tilt Bucket Sensor (Optional) If the excavator has a tilt bucket, the tilt bucket sensor is calibrated by positioning the tilt bucket horizontally. Follow the on-screen instructions.
To enter the excavator’s buckets, select Main Menu Buckets New. NOTICE Setup It is important to measure the buckets accurately. If the dimensions are wrong, X-22 will not measure as accurately as it should. Each bucket also has to be calibrated. Follow the instructions on the X-22 Display. The bucket teeth/blade can be worn down and become shorter with time. In this case the bucket radius should be measured again and the bucket recalibrated.
Installation and Calibration Wizards also start up when you select the type of digging work. How to Return to the Main Menu To return to the previous menu, press the Back button in the bottom left-hand corner, as shown in Figure 2-27. If you are following a wizard, you can also go back a step by pressing Back button. If you press Back several times, you ultimately return to the Main Menu. Figure 2-27.
Before You Start to Dig Check that X-22 is Measuring Correctly Once you have X-22 ready for digging work, we recommend checking that the system is measuring as accurately as it should. This can be done by running through the verification routine. The first time you press Start digging in the Main Menu, you are asked to verify the calibration. Otherwise, you can start the verification routine from the menu in the digging window by pressing Check Verify.
Installation and Calibration Arm (Stick) Sensor with Laser Detector You should be aware that the laser detector of the arm (stick) sensor has some limitations. It is designed for rotary lasers with laser diodes of 1mW or more, and 630nm wavelength (visible red light). It cannot be guaranteed that the laser detector will work with other rotary lasers, nor if the sun shines directly onto it.
Important Information On Use This section describes how the equipment should be handled. If the guidelines are not followed, there might be a risk of explosion, fire, injury or damage to the equipment. Charger The charger is for indoor use only. Avoid moisture. Batteries charge faster at lower temperatures, but the sensors must never be charged at temperatures below 0°C (32°F).
Installation and Calibration Sensors The sensors are waterproof, but are not designed for digging in water. The wireless connection does not work in water either, so remove the bucket sensor and stick sensor if you intend to dig in water. Operating temperature -20°C to +60°C -4°F to +140°F Charging temperature +5°C to +35°C -41°F to +95°F Storage temperature -20°C to +35°C -4°F to +95°F Operating time approx.
X-22 Display and Power Supply The kit contains a power cable for the X-22 Display with a cigarette lighter plug, which can be used for both 12V and 24V supply. Operating temperature 0°C to +50°C 35°F to +122 Storage temperature -20°C to +70°C 35°F to +158°F Not waterproof Machine and Bucket Measurements On the next several pages there are pictures illustrating all excavator and bucket measurements that must be taken.
Installation and Calibration Figure 2-28.
Machine Dimension Measurement Boom 1 Articulated boom Machine Dimension Measurement Arm (Stick) 2 2-34 X-22 Installation and Calibration Manual
Installation and Calibration Machine Dimension Measurement Control Arm (Dog-bone)3 Machine Dimension Measurement Bucket bolt to control arm bolt 4 P/N 7010-1019 2-35
Machine Dimension Measurement Arm (Stick) axis to control arm (dog-bone) bolt 5 Machine Dimension Measurement Link 6 2-36 X-22 Installation and Calibration Manual
Installation and Calibration Machine Dimension Measurement Roll length 7 Machine Dimension Measurement Height to boom pin 8 P/N 7010-1019 2-37
Machine Dimension Measurement Pitch length 9 Machine Dimension Measurement Bucket Web 10 2-38 X-22 Installation and Calibration Manual
Installation and Calibration Machine Dimension Measurement Bucket Front 11 Machine Dimension Measurement Bucket Width 12 P/N 7010-1019 2-39
Machine Dimension Measurement Bucket bolt to tilt axis 13 Machine Dimension Measurement Bucket tip to tilt axis 14 2-40 X-22 Installation and Calibration Manual
Installation and Calibration Machine Dimension Measurement Bucket bolt to laser sensor 15 Machine Dimension Measurement Arm (Stick) axis to laser sensor 16 P/N 7010-1019 2-41
Measure Additional Buckets Name of Bucket: Bucket Dimension Measurement Web 10 Front 11 Width 12 Bucket bolt to tilt axis 13 Bucket tip to tilt axis 14 Name of Bucket: Bucket Dimension Measurement Web 10 Front 11 Width 12 Bucket bolt to tilt axis 13 Bucket tip to tilt axis 14 2-42 X-22 Installation and Calibration Manual
Installation and Calibration Name of Bucket: Bucket Dimension Measurement Web 10 Front 11 Width 12 Bucket bolt to tilt axis 13 Bucket tip to tilt axis 14 Name of Bucket: Bucket Dimension Measurement Web 10 Front 11 Width 12 Bucket bolt to tilt axis 13 Bucket tip to tilt axis 14 P/N 7010-1019 2-43
Notes: 2-44 X-22 Installation and Calibration Manual
Chapter 3 Troubleshooting In this section you will find answers to the following questions: The X-22 Display is not responding, what should I do?....... page 3-1 The sensors are not responding, what should I do?...............page 3-1 A sensor is damaged, what should I do?..............................page 3-1 How do I recalibrate a sensor?...........................................page 3-1 The system is not measuring accurately, what should I do?..
How do I recalibrate a sensor? If you have already calibrated the sensors and want to recalibrate one, proceed as follows: Select Main menu Setup Hardware Sensors and highlight the sensor you want to calibrate. Select Details. Then select Calibrated and press Change. The system is not measuring accurately, what should I do? If the system is not measuring accurately, a dimension or calibration value is probably wrong. Select Verify from the menu in the digging window, and press Troubleshooting.
Troubleshooting heading measurements from the compass will now disappear and you will have to keep track of the heading yourself. In situations where there are large fluctuations in the magnetic field around the machine all the time, the compass calibration will not be able to compensate for the disturbances.
Notes: 3-4 X-22 Installation and Calibration Manual
Specifications X-22 Sensor The following section provides specifications for the X-22 Sensor. Table A-1. X-22 Sensor General Specifications General Details Enclosure Xenoy CL 100 Polycarbonate Resistant to hydraulic fluids, diesel and UV exposure IP67 Color Topcon Yellow Dimensions W: 112 mm x H: 48 mm x D: 68 mm W: 4.4 in. x H: 1.89 in. x D: 2.68 in. Weight 230g (standard sensor) 0.5 lbs.
X-22 Display The following section provides specifications for the X-22 Fanless 8.9” WSVGA TFT Multifunctional Touch Panel PC. Table A-2. X-22 Sensor General Specifications Display Screen LCD Size 8.9” Display Type WSVGA TFT Resolution 1024 x 600 Color 256K Pixel Pitch 0.1905mm (H) x 0.
Table A-2. X-22 Sensor General Specifications (Continued) Rear Panel I/O Serial Port 1 x RS-232, 1 x RS-232 or Optional RS-422/ 485 Ethernet 2 x RJ-45 (Realtek RTL8101L LAN) WIFI Optional USB WiFi 802.11 b/g (Occupies One USB Port) VGA 1 x DB-15 Audio Line-out, Mic-in USB 2 x USB 2.
Notes: A-4 X-22 Installation and Calibration Manual
Appendix B Safety Warnings General Warnings 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 brackets while the machine is running. 4. DO NOT allow any X-22 system component to limit the visibility of the operator. 5.
NOTICE NOTICE Disconnect all Topcon system electrical cables prior to welding on the machine. All mounting bracket welds must be secure and strong to prevent 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.
WARNING Tampering with the batteries by end users or nonfactory authorized technicians will void the battery’s warranty. • Do not attempt to open the sensors. • Do not disassemble the sensor. • 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.
Notes: B-4 X-22 Installation and Calibration Manual
Appendix C Regulatory Information The following sections provide information on this product’s compliance with government regulations for use. FCC Compliance This device complies with Part 15 of the FCC rules. Operation is subject to the following two conditions: 1. This device may not cause harmful interference, and 2. This device must accept any interference received, including interference that may cause undesired operation.
CAUTION Any changes or modifications to the equipment not expressly approved by the party responsible for compliance could void your authority to operate such equipment. FCC Compliance This equipment complies with FCC radiation exposure limits set forth for uncontrolled equipment and meets the FCC radio frequency (RF) Exposure Guidelines in Supplement C to OET65. This equipment has very low levels of RF energy that it deemed to comply without maximum permissive exposure evaluation (MPE).
• Plug the equipment into an outlet on a circuit different from that to which the receiver is powered. • Consult the dealer or an experienced radio/television technician for additional suggestions. CAUTION Any changes or modifications to the equipment not expressly approved by the party responsible for compliance could void your authority to operate such equipment.
Canadian Emission Labeling Requirements This equipment complies with IC radiation exposure limits set forth for uncontrolled equipment and meets RSS-102 of the IC radio frequency (RF) Exposure rules. This equipment has very low levels of RF energy that it deemed to comply without maximum permissive exposure evaluation (MPE). But it is desirable that it should be installed and operated with at least 20cm and more between the radiator and person’s body (excluding extremities: hands, wrists, feet and ankles).
Community of Europe Compliance The product described in this manual is in compliance with the R&TTE and EMC directives from the European Community. European Community Declaration of Conformity with R&TTE Directive 1999/5/EC The following standards were applied: (R&TTE Directive 1999/5/EEC) • • • • EN 301 489-1 V1.8.1 (2008-04) EN 301 489-17 V1.3.2 (2008-04) EN 300 328 V1.7.
Declaration of Conformity with Regard to the R&TTE Directive 1999/5/EC cs esky [Czech] da Dansk [Danish] de Deutsch [German] et Eesti [Estonian] (Topcon) tímto prohlašuje, že tento (HiPer II) je ve shod se základními požadavky a dalšími píslušnými ustanoveními smrnice 1999/5/ES. Undertegnede (Topcon) erklærer herved, at følgende udstyr (HiPer II) overholder de væsentlige krav og øvrige relevante krav i direktiv 1999/5/EF.
it Italiano [Italian] la Latviski [Latvian] Con la presente (Topcon) dichiara che questo (HiPer II) è conforme ai requisiti essenziali ed alle altre disposizioni pertinenti stabilite dalla direttiva 1999/5/CE. Ar šo (Topcon) deklar, ka (HiPer II) atbilst Direktvas 1999/5/EK btiskajm prasbm un citiem ar to saisttajiem noteikumiem. Lietuvi [Lithuanian] Šiuo (Topcon) deklaruoja, kad šis (HiPer II) atitinka esminius reikalavimus ir kitas 1999/5/EB Direktyvos nuostatas.
fi Suomi [Finnish] sv Svenska [Swedish] (Topcon) vakuuttaa täten että (HiPer II) tyyppinen laite on direktiivin 1999/5/EY oleellisten vaatimusten ja sitä koskevien direktiivin muiden ehtojen mukainen. Härmed intygar (Topcon) att denna (HiPer II) står I överensstämmelse med de väsentliga egenskapskrav och övriga relevanta bestämmelser som framgår av direktiv 1999/5/EG.
Appendix D Warranty Terms TPS laser and electronic positioning equipment are guaranteed against defective material and workmanship under normal use and application consistent with this Manual. The equipment is guaranteed for the period indicated, on the warranty card accompanying the product, starting from the date that the product is sold to the original purchaser by TPS’ Authorized Dealers.1 During the warranty period, TPS will, at its option, repair or replace this product at no additional charge.
Notes: D-2 X22 Installation and Calibration Manual
Topcon Positioning Systems, Inc. 7400 National Drive, Livermore, CA 94550 800∙443∙4567 www.topconpositioning.com ISO 9001:2000 FM 68448 X-22 Installation and Calibration Manual P/N: 7010-1019 Rev A 06/11 ©2011 Topcon Positioning Systems, Inc. All rights reserved. No unauthorized duplication.
