Leica Geosystems iCONgrade iCP32 User manual

Leica iCONgrade iCP32
User Manual
Version 1.0
English

2iCONgrade, Introduction
Introduction
Purchase Congratulations on your purchase of iCONgrade machine control system. iCONgrade System
is an ideal tool for increasing productivity in all aspects of the construction earthmoving
industry.
This manual contains important safety directions as well as instructions for setting up the
system and operating it. Refer to the chapter "4 Safety Directions" for further information.
Read carefully through the User Manual before you switch on the product.
To ensure safety when using the system, please also observe the directions and instructions
contained in the User Manual and Safety Handbook issued by the:
• Machine manufacturer.
Product identification The type and serial number of your products are indicated on the label on the base of the
unit.
Enter the model and serial number in your manual and always refer to this information when
you need to contact your agency or Leica Geosystems authorised service workshop.
Type: iCP32 Control Box Serial No.: _________________________
Type: MMB1300 Cradle Serial No.: _________________________

iCONgrade, Introduction 3
Symbols The symbols used in this manual have the following meanings:
Validity of this manual This manual applies to the Control Box iCP32 and the 2D part of the Control Box iCP42.
Type Description
Danger Indicates an imminently hazardous situation which, if not avoided, will
result in death or serious injury.
Warning Indicates a potentially hazardous situation or an unintended use
which, if not avoided, could result in death or serious injury.
Caution Indicates a potentially hazardous situation or an unintended use
which, if not avoided, may result in minor or moderate injury and/or
appreciable material, financial and environmental damage.
Important paragraphs which must be adhered to in practice as they
enable the product to be used in a technically correct and efficient
manner.

4iCONgrade, Table of Contents
Table of Contents
In this manual Topic Page
1 Product Overview 6
1.1 Product Description and Features 6
1.2 Getting Started 11
1.3 Sensor Setup Keys 13
2Operation 16
2.1 Pre-power up checks 16
2.1.1 Best operation practice for Grader Systems 17
2.1.2 Mast orientation 18
2.1.3 No Articulation, circle center shift, or wheel lean on Grader 19
2.1.4 Grader blade cushioning off 21
2.1.5 No blade rotation on Dozer 22
2.2 Select the Input Source 23
2.3 Setting a Reference Height 26
2.4 Using the MUS1300 Tri-Sonic Sensor 28
2.4.1 Installation and Set Up Tri-Sonic Sensor 32
2.4.2 Operation with the Tri-Sonic Sensor 34
2.4.3 Swap Function 37
2.5 Using the Laser Sensor 39
2.6 SP14 Sensor 41
2.7 3D Sensors 43
2.8 Setting the Value for Gain and Deadband 45
2.9 Sensor Calibration Wizard 48
2.10 Machine Setups 55

iCONgrade, Table of Contents 5
3 Care and Transport 58
3.1 General Notices 58
3.2 Transport 58
3.3 Storage 58
3.4 Cleaning and Drying 59
4SafetyDirections 60
4.1 General 60
4.2 Intended Use 60
4.3 Limits of Use 61
4.4 Responsibilities 61
4.5 Hazards of Use 62
4.6 Electromagnetic Compatibility EMC 66
4.7 Labelling 68
5TechnicalData 74
5.1 iCP32 Technical Data 74
5.2 Conformity to National Regulations 81
6 International Limited Warranty, Software License Agreement 82

6iCONgrade, Product Overview
1ProductOverview
1.1 Product Description and Features
General The control panel has keys surrounding the screen for user input. The 3.5" colour display,
incorporates a state of the art LCD colour screen, making it easy to use, even in bright, sunny
conditions.
The rugged IP56 enclosure is designed for harsh environments.
Power supply, commu-
nication
The control panel is powered from a cradle based on a sophisticated induction solution,
while data is transferred wirelessly via infrared between the MMB1300 cradle and the iCP32
control panel. The MMB1300 will be called the "Cradle" throughout this manual.

iCONgrade, Product Overview 7
iCP32 control panel
Warning This product may be installed on building machinery only by an appropriately trained and
qualified specialist.
a) Graphical display
b) Grade indication LEDs
c) Left/Right side sensor setup
d) Speaker
e) Menu key
f) Function keys
g) Enter key
iCP32_001
a
bb
cc
d
ef g

8iCONgrade, Product Overview
Warning Unauthorized modification of machines by mounting the product may alter the function and
safety of the machine.
Precautions:
Follow the instructions of the machine manufacturer. If no appropriate instruction is avail-
able, ask the machine manufacturer for instructions before mounting the product.
Keys Up key
Down key
Enter key
Auto/Manual key
Menu key
Sensor select key
Fuction keys

iCONgrade, Product Overview 9
Display
a) Side shift alignment indication
b) Above grade
c) Left/Right on-grade indication
d) Below grade
iCP32_002
a
bb
cc
dd

10iCONgrade, Product Overview
MMB1300 Cradle
a) Power and data transfer LED indicators
b) Holding magnets
c) On/off switch
d) Release key for control panel
iCP32_003
abc
d

iCONgrade, Product Overview 11
1.2 Getting Started
System start To get the system started complete the following steps:
1. Snap control panel onto cradle.
To connect the control panel to the cradle:
1. Put the control panel on the holding
hooks in the bottom of the cradle.
2. Then snap the control panel onto the
cradle by pressing it towards the cradle.
iCP32_004
1
1
2

12iCONgrade, Product Overview
2. Turn on the control panel.
To turn the system on and off, use the power
switch on the right side of the cradle. This is
the master switch for the entire system.
Removing the panel will also turn off
the power.
To release the control panel simply
press the release key at the bottom of
the cradle and pull the control panel
towards you and then lift it up.
iCP32_005
iCP32_006
2
1

iCONgrade, Product Overview 13
1.3 Sensor Setup Keys
Sensor setup keys The sensor setup keys are used to choose the type of sensor that the system should run
with, and to find and set the reference point for that sensor.
The left and right hydraulic channel has four sensor setup keys each:
• Auto/Manual key,
• upkey,
• downkey,
• sensor select key.
External Multi Switch
for Grader
The system can also be fitted with an External Multi Switch. This switch has
three keys on it. One Auto/Manual key (Red) and a set of up and down
keys (green). These keys have the same function as the corresponding
keys on the control panel.

14iCONgrade, Product Overview
External switch for
Dozer
Toggle the master switch to AUTO to enable automatic control on all chan-
nels selected on the control panel. Toggling the master switch to MAN
places all channels in manual control regardless of selection on the control
panel.

iCONgrade, Product Overview 15

16iCONgrade, Operation
2Operation
2.1 Pre-power up checks
State of the machine Before the system is powered up, please check the state of the machine to make sure that
it is configured to function correctly.
Check and set When? To learn how, see …
Mast perpendicular to wheelbase. For Graders without mast
slope sensor, and for
Dozers, every time the
blade changes attack
angle (pitch).
"2.1.2 Mast orientation"
No articulation and circle side shift
on Grader.
Every time a job is to be
made with a single eleva-
tion sensor + cross slope
sensor on a Grader.
"2.1.3 No Articulation,
circle center shift, or
wheel lean on Grader"
Turn Grader blade cushioning off. Every time you want to
use automatic controls on
a Grader.
"2.1.4 Grader blade cush-
ioning off"
Dozer blade square. Every time you begin a job
with a single elevation
sensor + cross slope
sensor on a Dozer
"2.1.5 No blade rotation
on Dozer"

iCONgrade, Operation 17
2.1.1 Best operation practice for Grader Systems
Hint for best
performance
Below you will find a list of things that will help achieve the best results when operating a
Grader system.
• Ensure that mast is perpendicular to the wheelbase, or use a mast slope sensor.
• Keep the circle centered under the gooseneck.
• Do not lean the wheels.
• Do not articulate the machine.
• Where possible, move the machine in one direction only; do not turn around.
• Where possible, set the blade rotation and leave it in the same position.
• Where possible, run with the slope sensor trailing, not leading.

18iCONgrade, Operation
2.1.2 Mast orientation
Mast orientation For Dozers and Graders without mast slope sensor, you must make sure that the mast is at
the “as measured” position (that is, the position the mast or masts were in during the mast
measure up).
On a Dozer this means that the mast should not be mechanically sloped. If for some reason
the mast is actually mechanically sloped, a new mast measure up must be done.
On a Grader the blade should be tipped back towards its end stop, if that was the original
measure position.

iCONgrade, Operation 19
2.1.3 No Articulation, circle center shift, or wheel lean on Grader
Articulation, circle
Centershift, and wheel
lean
For Grader systems that rely on the cross slope sensor, and a single elevation sensor, you
must make sure that the machine is not articulated and that there is no side shift applied
to the circle. The front wheels must be upright (not leaned).
Okay Articulated

20iCONgrade, Operation
Wheel lean introduces an error in the reading from the mainfall sensor. Articulation and
circle Centershift introduce unmeasured blade rotation.
Operating with wheel lean, circle centershift or articulation can cause inaccuracy in the cross
slope being cut.
Circle center shifted Wheel leaned