Release Notes for Cat® Terrain v5.2 On-board Software {7605} Caterpillar

Machine Control & Guidance Products

TERRAIN GRADING (S/N: TFE1-UP)

TERRAIN LOADING (S/N: TFL1-UP)

TERRAIN OFFICE (S/N: TER1-UP)

Introduction

This document contains the following information:

• Changes to the manuals, system, and on-board software

• Hardware considerations

• Known issues

Important Safety Information

Do not perform any procedure in this Special Instruction until you have read this Special Instruction and you understand this information. Use only proper tools and observe all precautions that pertain to the use of those tools. Failure to follow these procedures can result in personal injury. The following procedures should also be observed:

1. Always set the parking brake of the machine before any work is performed on the machine.

2. Always shut off the engine before loading the on-board software on the machine.

Work safely. Most accidents that involve product operation, maintenance, and repair are caused by failure to observe basic safety rules or precautions. An accident can often be avoided by recognizing potentially hazardous situations before an accident occurs.

A person must be alert to potential hazards. This person should also have the necessary training, skills, and tools to perform these functions properly.

Safety precautions and warnings are provided in this instruction and on the product. If these hazard warnings are not heeded, bodily injury or death could occur to you or to other persons. Caterpillar cannot anticipate every possible circumstance that might involve a potential hazard.

Therefore, the warnings in this publication and the warnings that are on the product are not all inclusive. If a tool, a procedure, a work method, or operating technique that is not recommended by Caterpillar is used, ensure that it is safe for you and for other people to use.

Ensure that the product will not be damaged or the product will be made unsafe by the operation, lubrication, maintenance, or the repair procedures that are used.

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Personal injury or death can result from fumes, gases and ultraviolet rays from the weld arc. Welding can cause fumes, burn skin and produce ultraviolet rays. Keep your head out of the fumes. Use ventilation, exhaust at the arc, or both, to keep fumes and gases from your breathing area. Wear eye, ear and body protection before working. Protect yourself and others; read and understand this warning. Fumes and gases can be dangerous to your health. Ultraviolet rays from the weld arc can injure eyes and burn skin. Electric shock can cause death. Read and understand the manufacturer's instructions and your employer's safety practices. Do not touch live electrical parts. See "American National Standard Z49.1, Safety in Welding and Cutting" published by the American Welding Society. American Welding Society 2501 N.W. 7th Street Miami, Florida 33125 See "OSHA Safety and Health Standards, 29 CFR 1910", available from U.S. Department of Labor. U.S. Department of Labor Washington, D.C. 20210

Illustration 1	g00037860

Use steps and handholds whenever mounting the machine. Use steps and handholds whenever dismounting the machine. Before mounting the machine, clean the step and the handholds. Inspect the step and handholds. Make all necessary repairs.

Changes to the System

Microsoft Windows Server 2012

The MCU Server, MCU Client, and MCU services v5.2 now function with Microsoft .NET Framework 4.5 and can be run on Microsoft Windows Server 2012.

The MCU Server, MCU Client, and MCU services v5.0 and earlier do not work on computers or servers using Microsoft .NET Framework 4.5, for example Microsoft Windows 8 on a PC.

New Executable File

Note: This software does not support blade control for TTT. If the machine is equipped with blade control, continue to use the v5.1 on-board software.

In previous versions of the on-board software, installers could choose from the following executable files:

• TerrainInstaller

• TerrainUpgrade

From v5.2 onwards, only the following installer executable file is supplied for Terrain for grading and loading applications:

• TerrainGLExtractorx.x.xxx.exe

This executable file is used in the following situations:

• Installing a new G610 display module

• Swapping a monitor display for a new display module

• Upgrading an existing display module that is running Terrain on-board software

Complete these steps to download and install the on-board software:

1. Download the "TerrainGLExtractor" executable file from the website or USB memory module.

2. Install the extractor on the office PC.

3. Run the extractor.

   1. Accept the license agreement.

   2. Extract the following executable file onto the office PC.

      • TerrainInstaller.x.x.xxx.exe

      By default, the extractor wizard extracts the executable file to the following default folder:

      • C:\TerrainUpgrade\Version x.x.xxx.xxxxx.

4. Transfer the executable file to each display that is being upgraded or installed with Terrain.

5. Follow the install instructions to complete the installation.

Reference: For more installation instructions and information about transferring files, refer to Special Instruction, REHS9109, "Installation and Configuration of Cat^® Terrain v5.2 On-board Software".

New Dialog: "System Shutdown"

Illustration 2	g03659277
"System Shutdown" message

The on-board software now shows the "System Shutdown" warning message in Illustration 2 whenever the display is shutdown by either of the following methods:

• The operator cycles (turns off) the power.

• The office initiates a shutdown/reboot.

The message notes that the system is shutting down safely. Terrain saves all required data automatically.

The display still uses an improper shutdown process if the battery backup unit (BBU) is not connected. For more information about the improper shutdown process, refer to "Shutdown Improper - Display"in the MCU Help file.

New Machine Model: Caterpillar Electric Rope Shovel

Terrain v5.2 now includes support for 3-D bucket tip guidance on certain Cat 7495 electric rope shovels (Cat ERS). This feature integrates with the PLC on the machine to provide Terrain with parameters from the machine.

The integrated Terrain grading and loading with Cat ERS systems provides:

• Continuous dipper tip position.

• Dig cycle visualization and recording

• Identification of material loaded into the dipper during the dipper dig stage

• Visualization of the dipper information including position relative to design material loaded in the dipper

New Hydraulic Pressure Sensor

The 364-5409 Pressure Switch, also called a dig sensor or pressure sensor, is sold separately or as part of the high accuracy dipper positioning system. The new sensor replaces all previous dig sensors. The new sensors are more reliable and improve accuracy of both the dig count and the material identification.

The pressure sensors, which are included in the 451-8741 Pressure Sensor Group, are used on excavators and hydraulic front shovels that are running the G610 display module, a dual antenna positioning system, and have full body and linkage sensors. The pressure sensor triggers a signal when the hydraulic system is loaded to a predefined pressure, indicating that the machine is digging.

Note: The pressure sensors must be installed on the high-pressure side of the hydraulic circuit.

The pressure sensor is affected by the following:

• The hardness or softness of the material being dug: Softer material means that the system can be run at lower dig pressure.

• The size of the hydraulic working pressure of the excavator or hydraulic shovel: Lower working pressure means that the system can be run at lower dig pressure.

The sensor is supported by a robust, semi-automated, on-board process that is completed from inside the cab with the machine powered on. The process allows the installer or operator to alter the pressure at which the software shows that the machine is digging, based on the environment in which the machine is working.

Note: Typically, the sensors do not require manual calibration.

Glossary of Terms

Table 1

Term	Description
Pressure Sensor	An electronic transducer installed in a hydraulic circuit to determine the pressure in the circuit.
States	Devices connected to the on-board software (sensors, ECM, receivers and so on) send information to the software about the status of the device. The status can be complex and is not limited to "ON" and "OFF". The information in these messages is called the "states".
"Dig" state	The state "Dig" is one of a set of descriptions for the Dig State, an option in the Digital window. The dig state value describes whether the machine is in a "Dig", "Idle", or "Dump" state. The Dig State is also used internally by the on-board software for certain features. A dig state is triggered when both hydraulic lines show high pressure.
"Deactuate" state	When the pressure in the sensor is below 15% of the pressure required (trigger point) for more than 300 ms, then the sensor sends out a "deactuate" state message.
Peak Pressure	Maximum pressure in the hydraulic line as recorded by the sensor in one cycle. Operators load the dipper in various ways, producing different peak pressures.
Trigger Point	The value (in bar) at which the dig point is determined, either by operator calibration or automatic calibration.
Debounce time	A value must meet or exceed the target value for this length of time to be considered in an ON or OFF state. Default = 300ms

System Operation

The 364-5409 Pressure Switches (pressure sensors) are installed in both the stick and dipper hydraulic lines. The pressure sensors provide analog outputs to the 459-1754 CAN Interface Module. The module reads the sensor values and provides these values to the on-board software.

Illustration 3	g03772216
Dig states: Dig (green), Dump (blue), and Idle (yellow)

The on-board software uses trigger points and the pressure sensor output to determine the dig state of the bucket, shown in the Digital Window item Dig State (DS) as shown in Illustration 3.

The on-board software reads the pressure sensor channels and compares each value to the user-set or automatic set trigger points. If the trigger points are met, or exceeded, on both channels for a set time (Dig Debounce Durations), then the on-board software recognizes this combination as the "Dig" dig state. When one of the pressure values falls below its trigger point for the specified time, the software removes the "Dig" dig state .

For more information refer to "Dig Sensors for Stick and Dipper" in the MCU Help file.

Manuals

The Operation and Maintenance Manual, SEBU8822, "Cat^® Terrain for Grading and Loading" has been updated to describe the process to alter the pressure at which the software shows that the machine is digging.

The MCU Help file describes the following settings that are used in the install process:

Dig Debounce Durations

• Actuate Dipper

• Actuate Stick

• Deactuate Dipper

• Deactuate Stick

The settings apply to dual antenna hydraulic shovels and excavators using the high accuracy dipper position system.

Note: To revert to using the previous dig sensor prior to v 5.2, enable the "Use Dig Switch" setting to enable use of the legacy dig switch.

Installing the Pressure Sensor Components

Illustration 4	g03762976
451-8741 Pressure Sensor Group components (1) 459-1754 Interface Module As (CAN Data Link) (2) 459-8167 Cover (3) 8T-4171 Bolt (4) 8T-4224 Hard Washer (5) 3S-2093 Cable Strap (6) 392-9004 Module (Memory, USB) (7) 364-5409 Pressure Switch (pressure sensor) (8) 7X-2535 Bolt (9) 451-8738 Mounting Block (10) 459-8166 Housing Bracket (11) 451-8740 Sensor Harness As (12) 451-8739 Sensor Harness As

The CAN interface module (1) interfaces to pressure sensors (7) that are installed on the head end of the hydraulic lines to read the following:

Stick - Reads "stick in"

Bucket - Reads "bucket curl"

Note: The bucket configuration for a hydraulic excavator is opposite that of the front shovel.

The module mounts to a housing bracket (10) and can be installed using weld bosses or on top of an existing inclination sensor bracket.

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NOTICE
Welding on the machine or jump starting the machine can damage the electronics in the display or the battery backup unit (BBU). To avoid damaging the electronics or BBU, disconnect the BBU from the power supply before welding or jump starting. If welding, reconnect the BBU to the power supply once welding is finished. If jump starting, reconnect the BBU to the power supply once the machine starts and the jumpers have been disconnected.

To install the system components of the 451-8741 Pressure Sensor Group, complete these steps:

1. Remove all stored energy in the machine.

2. Install the 459-8166 Mounting Bracket to the machine on top of an existing inclination sensor bracket or alternatively use weld bosses to install the mounting bracket.

   Refer to Illustration 4 and use the following hardware:

   • Two 451-8738 Mounting Blocks (9)

   • Four 8T-4171 Bolts (3)

   • Four 8T-4224 Hard Washers (4)

   When choosing a location, consider the following:

   • The sensor harness is installed in line with the existing inclination sensor harness.

   • Ensure that the chosen location allows you to reach both the hydraulic manifold and the inclination sensor harness.

   • Select a position where the body of the module will be protected from damage.
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   Illustration 5	g03708681
   CAN interface module (13) Mounting holes

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   Illustration 6	g03763017
   Mounting bracket and CAN interface module installed on top of inclination sensor bracket.

3. Mount the 459-1754 CAN Interface Module to the mounting bracket through the mounting holes (13) using two 7X-2535 Bolts and two 8T-4224 Hard Washers.
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   Illustration 7	g03749606
   Installed pressure sensors (7)

4. Install the 364-5409 Pressure Switches (pressure sensors) (7) into a two-circuit hydraulic manifold that connects to the head ends of the supply lines for the stick and bucket.

5. Install the 451-8740 Pressure Sensor Harness.
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   Illustration 8	g03762998
   451-8740 Pressure Sensor Harness (7) Pressure sensors (14) "S2" (15) "S3" (16) "P1"

   1. Insert the 4-pin plugs "S2" (14) and "S3" (15) of the 451-8740 Pressure Sensor Harness into the receptacles of the pressure sensors (7).

   2. Using the supplied parts from the attached plastic bag, wire receptacle "P1" (16) as follows:

      Ground - 205-BK(Black)

      Switched power - A116-YL(Yellow)

      Analog 1 - K472-OR(Orange)

      Analog 2 - K473-BR(Brown)

      Note: "P1" can be cut in the field to fit and then the connector can be installed.

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   Illustration 9	g03763016
   451-8739 Pressure Sensor Harness. (17) "P1" (18) "S3" (19) "S2" (20) "S4"

6. Install the 451-8739 Pressure Sensor Harness.

   1. Install the pressure sensor harness to the existing inclination sensor harness.

      Note: The pressure sensor harness uses receptacle "P1" (17) and plug "S2" (19) to tee into the inclination sensor harness at any existing connection in the harness.

   2. Connect plug "S3" (18) to the integrated 12-pin connector on the CAN interface module.

   3. Connect the 4-pin plug "S4" (20) to receptacle "P1" of the 451-8740 Pressure Sensor Harness that was wired in Step 5.b.
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   Illustration 10	g03761459
   Secured pressure sensor harnesses

7. Secure the harnesses properly using weld links and cable straps.

   Ensure the following:

   • Route and secure the harnesses so that the harnesses do not obstruct the service panels or cause a tripping hazard.

   • Protect the harnesses from mechanical damage.

   • Protect the harnesses when the harnesses pass over or through any sharp metal edges.

   • Avoid locations that are near a source of heat.
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   Illustration 11	g03749610
   CAN interface module installed using weld bosses (2) Cover (10) Mounting bracket

8. Refer to Illustration 4 and use the following hardware to attach the 459-8167 Cover (2) to the 459-8166 Mounting Bracket:

   • Four 8T-4171 Bolts (3)

   • Four 8T-4224 Hard Washers (4)

Configuring the Pressure Sensors

1. Install the Terrain v5.2 on-board software.

   • Refer to Special Instruction, REHS9109, "Installation and Configuration of Cat^® Terrain v5.2 On-board Software"

   Note: If your machine is using legacy dig switches (no longer available), then enable the "Machine" > "Switches" > "Use Dig Switch" setting. This setting overrides the presence of the "Dig Debounce Durations" settings and is required when using the "old" dig selection method.

2. Install the dig sensor hardware for a stick and a bucket hydraulic pressure sensor.

3. Obtain a v5.0 security key.

4. Open the MCU and enter the new security key and the following settings:

   • "Machine" > "Security"

   • "Machine" > "Sensors" > "Dig Debounce Durations" > "Actuate Dipper / Deactuate Dipper". Default = 300ms.

   • "Machine" > "Sensors" > "Dig Debounce Durations" > "Actuate Stick / Deactuate Stick". Default = 300ms.

   Refer to MCU Help, "DIg Debounce Durations (ms)" for detailed information about these settings.

5. Send the new mach_cfg.txt file to the G610 display module and restart the on-board software.

Automatic Trigger Points (Recommended)

To use automatic (default) trigger points, complete these steps:

1. Power up the machine after installing the new Terrain software, then start the on-board software on the G610 display module.

2. The default trigger pressure for the first dig is 75 bar. (1 bar is equivalent to 100 kPa (14.5 psi).)

3. The default pressure for the second dig is 50% of the maximum pressure for the first dig.

4. The default pressure for any consecutive dig is 50% of the maximum pressure for the previous dig.

Manually Setting the Trigger Points

Note: Using the manual process to set the trigger points requires the use of the 444-5691 Alarm As.

Menu - Opens the main menu

To manually set both trigger points simultaneously, complete these steps:

1. Power up the machine after installing the new Terrain software, then start the on-board software on the G610 display module.
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   Illustration 12	g03709514
   "Calibrate Dig Sensors" dialog

2. In the main menu, select "Ore Control" > "Calibrate Dig Sensors".

   This menu item has no toolbar button. The "Calibrate Dig Sensors" dialog appears.

3. Complete one dig cycle.

   When both sensors are next in the “actuate” state an audible signal sounds.

   Note: When both sensors are in the actuate state, the software assumes that the machine is digging.

4. Observe the relationship between the audible signal and dipper digging. Perform one normal dig within 15 seconds of starting recording.

   During this time the on-board software records data of pressure (in bar) for stick and bucket sensors in the DiagMsgLog file. The default for the first dig is 75 bar.

   Note: 1 bar is equivalent to 100 kPa (14.5 psi).

5. Complete a second dig cycle.

   The default for the second dig cycle is 50% of the maximum pressure of the first dig.

6. Use the "Calibrate Dig Sensors" dialog to increment the sensitivity of the sensor to digging. Refer to Illustration 13.

   The Increment (up arrow) and Decrement (down arrow) buttons used in this dialog increase and decrease the trigger point by 5 bar.

   • If the audible signal lasts longer than the time period the dipper appears to be digging, then decrease the dig sensitivity.

   • If the audible signal does not last as long as the time period the dipper appears to be digging, then increase the sensitivity.

7. Close the dialog box.

8. In the main menu deselect the "Ore Control" > "Calibrate Dig Sensor" option.

   The audible signal will not sound.

9. Select "OK".

   The on-board software stores the new values.

10. Set up the Dig State (DS) option in a Digital window.

11. Set up the Stick Pressure (StP) and Bucket Pressure (BuP) option in a Digital window.

    StP and BuP are the current values for the pressure of the stick and bucket sensors. The values update continuously.

Reverting to Automatic Trigger Points

To revert from manually set trigger points to automatic trigger points, in the main menu select "Ore Control" > Reset to Default Calibration.

When the pressure sensor value is 300ms (default), the pressure sensor value must be above the current trigger point for more than 300ms before the pressure sensor state changes from "deactuate" to "actuate". When the dig sensor values drop below the trigger point by more than 15% of peak pressure for more than 300ms (default), the pressure sensor state changes from "actuate" to "deactuate".

The software records peak pressure and trigger point values in the DML for each dipper load. The audible dig state sound is not affected by the "Machine" > "Alarms" or the "Detect" > "Alarms" settings in the MCU.

Operator Instructions: Setting the Trigger Point

Menu - Opens the main menu

To reset the trigger point at any time, complete these steps:

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Illustration 13	g03709514
"Calibrate Dig Sensors" dialog

1. In the main menu, select "Ore Control" > "Calibrate Dig Sensors".

   The "Calibrate Dig Sensors" dialog appears.

2. Complete one dig.

   When both sensors are digging, an audible signal sounds. The default pressure for the first dig is 75 bar.

   Note: 1 bar is equivalent to 100 kPa (14.5 psi).

3. Observe the relationship between audible signal and dipper digging.

4. Complete a second dig.

   The default pressure for the second dig is 50% of the maximum pressure of the first dig.

5. Use the "Calibrate Dig Sensors" dialog to increment the sensitivity of the sensor to digging. Refer to Illustration 13.

   The Increment (up arrow) and Decrement (down arrow) buttons used for this calibration increase and decrease the trigger point by 5 bar.

   • If the audible signal lasts longer than the time period the dipper appears to be digging, then decrease the dig sensitivity.

   • If the audible signal does not last as long as the time period the dipper appears to be digging, then increase the sensitivity.

6. Close the dialog box.

7. In the main menu deselect the "Ore Control" > "Calibrate Dig Sensor" option. The audible signal will not sound.

The on-board software records all dig cycles completed while the "Calibrate Dig Sensors" dialog is open as production dipper loads.

The audible dig state sound is not affected by the Mute Alarms settings.

Improvements

Detect

The on-board software now calculates, and draws, the Body region (circular) of the machine from the center of rotation (COR) and not from the origin. Once set in the office software, the values are contained in the machine and machine type *.mwf files. This change fixes an issue where the Detect machine Body region would appear, on the display, to move erratically as the machine rotated.

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NOTICE
Do not use the machine icon on the display as an indication of safety near the machine.

Note the following:

• The user does not need to change the machine configuration file or machine dimensions in Fleet.

• As with any Detect regions, the user must check that the Body region is large enough to cover the full rotation of the machine body based around the COR.

• As the machine rotates, there may sometimes be a small overlap between the line representing the Body region of the machine and the line representing the back of the machine. The larger the distance between the boom pin and the COR, the larger the overlap.

The following feature was added:

The following was altered:

Filtering Zones by Machine Type - The office software can assign machine types to a zone to specify the types of machine that can see the zone and set off the alarm when entering the zone. With no machine types assigned, the zone applies to all machine types.

Example: If the site assigns a dozer to work in an area and does not want any light vehicles moving through the area, then add the Supervisor Truck machine type to a zone describing the area to set off the alarm. Similarly, if the site does not want Track-Type Tractors to enter a sealed section of road, then add the Track-Type Tractor machine type to a zone bounding the road to set off the alarm.

Command

The following improvements were made to the Command options:

Use of Max Bucket Log Count - Do not use Max Bucket Log Count on a site with Command for autonomous hauling. A validation error message occurs if the MCU detects the site is a Command site and this setting is enabled.

Altered custom loading - The spot reference data in the "Custom Loading" dialog is rearranged to read as center, rear axle, and rear tray.

Truck aligned with spot reference point - The truck outline that is visible at the spot location will line up over the center, rear axle, or rear tray, as specified in the "Custom Loading" dialog.

Visible truck outline - The truck outline that is visible at the spot location will be the size of the largest truck that is listed in the machine.mwf or machinetype.mwf file.

New icon for autonomous hauling - Command for autonomous hauling uses multiple Perception Based Localization (PBL) targets to position trucks.

Update Cleanup Zone List - Use this feature with Terrain v5.2 for grading and loading with MineStar (Fleet) v4.1. When the operator logs in, the on-board software checks with the office to ensure that the G610 displays all of the locked cleanup zones which were started by this operator.

Note: The Update Cleanup Zone List feature is used exclusively on sites that are running Command for hauling and does not work with versions before Terrain v5.2 or with earlier MineStar (Fleet) office software.

The PBL is approximately 0.5 m diameter and 1 m high. Due to this small size, take care to avoid a potentially hazardous situation around the PBL. In addition, the site can define the size and shape of a PBL in a *.mwffile which is sent to the G610 display module.

At full size on the display module the PBL target appears as a brown/cream polygon with 16 sides and 16 vertices (hexadecagon). When zoomed out, the hexadecagon looks like a circle,usuallysurrounded by red, blue, and white Detect Strategy regions.

Illustration 14	g03659302
Dozer with three regions next to a PBL target with three regions

In Illustration 14, the orange exclamation mark shows that the dozer has not received recent information about the PBL target position.

Avoidance Buffers for Excavator Linkages

In previous versions of the on-board software, the machine buffers were often smaller than the full reach of the arm of the excavator. Warning messages associated with avoidance zones and surfaces often only appeared after the body of the machine entered the zone or surface.

Alternatively, the site had to configure long, narrow machine buffers around the machine to estimate where the bucket might move. From Terrain v5.2 onwards, the installer can configure each section of the excavator arm to have individual avoidance buffers.

Avoidance buffers: Turning on the buffers

To turn on buffers, complete the following steps:

1. Set up independent, rectangular buffers around the boom, stick, or bucket.

   Draw a buffer around the boom, stick, or bucket, based on the boom origin / stick origin / bucket origin. Draw a machine buffer around the machine body, based around the machine origin

2. Set up between one to five buffers in the MCU. To make sure that the machine uses the Avoidance Strategy, set up at least one machine body buffer before setting up the boom, stick, or bucket buffers.

The following settings apply:

• Ignore No Machine Buffers

• Machine Buffer - version 4.0 and later

• Boom Buffer - version 5.2 and later

• Stick Buffer - version 5.2 and later

• Bucket Buffer - version 5.2 and later

• Display Machine Regions - version 5.2 and later

Avoidance buffers: Understanding the display

Illustration 15	g03709528

On the Plan Window, the installer can allow the operator to decide whether the buffers appear on the display. The buffers interact with avoidance zones or avoidance surfaces, in effect, the Avoidance Strategy, and not with the Body, Avoidance, and Path Regions of the Detect Strategy.

Avoidance buffers - diagnostics and reporting

Incidents are reported in numerous diagnostic processes:

• Communications Diagnostics - general information.

• DML - all times when zones/surfaces and buffers cross are logged in the DML.

• All times when the zones/surfaces and buffers cross are reported in the "Avoid" productivity record.

The warning dialogs, as described in the Operation and Maintenance Manual, SEBU8841, "Cat^® Terrain for Mining (for v5.2)" appear.

Improved SCU for Gauge and Grade Windows

The instructions for using the Screen Configuration Utility to add a Gauge window and a Grade Plan window have been simplified as follows.

To add a Gauge / Grade Plan window to another screen:

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Illustration 16	g03710005

1. Open the screen to which you want to add the Gauge / Grade Plan window.

2. Press the "Alt" key to bring up the main menu. In the menu, select "Configuration" > "Plan" > "Gauge / Grade Plan". The Select Grade Colors dialog appears.

3. Enter a value in the Grade Color Range box. The default value is 1.00 m. This value evenly spreads the fill (blue), grade (green), and cut (red) areas.

4. Under Color Range, select one of the following:

   • "Few" for blue, green, and red only.

   • "Default" for a medium range of shades of blue and red.

   • "Many" for a large range of shades of blue and red. A darker red or blue indicates that the area needs more cutting and filling. A lighter red or blue indicates that the area is approaching grade.

5. Select "OK". The window appears.

6. Using the cursor, resize the window to the desired resolution.

7. Using the cursor, move the window to the desired location.

8. Click the window.

   A blank toolbar appears.

9. Double-click inside the empty toolbar.

   The "Customize Toolbar" dialog appears.

10. Add the required toolbar buttons and select "Close".

Improved Troubleshooting: Machine Configuration File

To aid in troubleshooting, the Machine Configuration Utility (MCU) now automatically saves a copy of the machine configuration file, "mach_cfg.txt", in the Terrain office software (Cat MineStar System Control Center software).

The MCU sends a file with the following name format when "File" > “Send (all) to Cat MineStar” is selected:

• mach_<siteid>_<machid>.txt

The file is saved each time the machine configuration file is edited and overwrites the previous file with the same machine ID.

TerrainDemo User Guide

The "TerrainDemo User Guide" has been updated. The guide now includes the new Cat ERS 7495 machine type as a playback demo (no GPS Sim version).

Find the user guide in the TerrainDemo folder in the following location:

C:\Users\<computer name>\AppData\Local\TerrainDemo

TerrainDemo can now read *.gwm files containing TMAC messages from the office. Specifically, the on-board software will read in the AMP message containing the positions of all other machines. TerrainDemo also uses machine.mwf and machine_type.mwf files.

The demo machine uses VPG for its position, but can be configured to use either the position of the machine in the AMP message or the position in the GSOF playback. The default is VPG Customers can use their own playbacks *.gwm and *.mwf files.

Terrain cannot read truck positions. Therefore, there is no loading demonstration software for the Command feature set in Terrain.

Measuring Operator Productivity

Sites use data to track productivity. The data is provided by the on-board software and is used by other software, such as Cat Tools, or the third-party database or spreadsheets used by the site.

There are two types of productivity data:

• Productivity files: These files are described in detail in "Introduction to Productivity Files" in the MCU Help file.

• Current Elevation Key Performance Indicator (CE KPI) csv file - "~CEKPI_UTC_machineID.csv": This file is explained below and is described in "Introduction to Productivity Files" in the MCU Help file.

About CE KPI CSV Files

The CE KPI csv file is called "~CEKPI_UTC_machineID.csv" The file is stored in the CAES/temp folder. The time in the csv file is measured in UTC time or seconds since 00:00:00 on the 1st January 1970. This is the same time format that is used in other productivity records generated by Terrain.

The tasks or events recorded in the CE KPI csv file include:

• An operator logs on.

• The operator or office changes which "Elevation Design" file is "Prime".

• The operator edits the design offset.

• The operator requests a surface update.

• The operator or office resets current elevation.

The CE KPI csv file contains one or two lines per event. Each line contains the following information:

• Time stamp (UTC)

• Machine ID / Name

• Reason for change: "Design offset change", "Operator change (Log in)", "Prime elevation [design] change"and others

• Flag indicating design type is "flat plane", "incline" (inclined plane), or "elevation design".

• % of CE KPI file that is "on grade" now

• % of CE KPI file that is "below grade" now

• % of CE KPI file that is "above grade" now

• Area (m²) of the cells in the CE KPI file that were used to calculate the above percentages

• Area (m²) of the cells In the CE KPI file that is "Off Design".

Note: To use this line, sites must have third-party software which will extract this number regularly and calculate the difference.

There is no data written to the CE KPI csv file about volume, about the length of time an operator spent "On Grade", "Below Grade" or "Above Grade", or about the distance the machine was above or below grade.

Note: Read the MCU feature "Mapping" > "Current Elevation" > "On Grade Tolerance" > "Tolerance" to find out about the definition of "On Grade", "Below Grade", and "Above Grade" used by the site.

Workflow for CE KPI CSV Files

The on-board software extracts data at 6-hour intervals, compares the Current Elevation Key Performance Indicator (CE KPI) file with the elevation in the "Elevation Design" file selected as "Prime" on the machine, and writes to the CE KPI csv file. The software stores the CE KPI csv file in CAES\temp and names the file "~KPIReportTemp.csv".

The software renames the CE KPI csv file "~CEKPI_UTC_machineID.csv" and sends the file at regular 6-hour intervals when the machine is on, whether there is data in the CE KPI csv file or there is no data. The office software stores the file in the "machine\<machine number>\other" folder.

The software continues to record data if the machine is out of radio contact. Due to this feature, the CE KPI csv file may bevery large if the machine is out of radio contact for a long time.

When calculating the % of CE KPI file above/below/on grade, the software keeps track of the area (m²) of cells off design, but does not use these off design cells in the above/below/on grade calculations.

Once the machine comes back into radio contact, the software sends the CE KPI csv file at the 6-hour interval to the office software where it is stored in machine\other.

Once the software sends the CE KPI csv file, the on-board software creates a new CE KPI csv file immediately and continues recording.

The file is recorded for all machine types that work on grading tasks, in effect, those machines that use a Current Elevation file as "Prime".

Sites must set up third-party software to upload and use data in the *.csv file.

Example

The on-board software reports 10000 m² outside the design at the start of the recording period and 12000 m² outside the design at the end of the recording period. Using these two records drawn from the CE KPI csv file, use third-party software to calculate that 2000 m² of the CE KPI file was recorded outside the design during that reporting period.

Note: Read the MCU feature "Mapping" > "Current Elevation" > "On Grade Tolerance" > "Tolerance" to find out about the site's definition of "On Grade", "Below Grade", and "Above Grade".

Operator Instructions

The operator does not open or use the CE KPI csv file.

Diagnostics

If a CE KPI csv file cannot be sent immediately, then the software continues to write to the file and attempts to transfer the file at the next 6-hour check. The file is sent even if the file is empty (in effect, no work is recorded in the last 6 hours).

Training

Use the following sections to learn more about AMP messages, automatic load and dump, and the difference between guidance points and the machine origin.

AMP Messages

The All Machine Positions (AMP) message, from office to machine, comes in the following types:

• Full AMP

• AMP update

The full AMP message is sent from the office each time the machine restarts. This message contains the full list of all monitored machines on site, including machines that are shutdown. A monitored or "other" machine is one which works nearby your machine and appears on the display.

The AMP update message is sent from the office as part of the regular contact between the office and the machine. This AMP update message contains the status and position of all monitored machines that have recently contacted the office as follows:

• If a machine position changes, the AMP update message includes the new position information.

• If the machine has lost contact with the office, the machine is still included in the AMP message but flagged as "loss of heartbeat". The on-board software of other machines marks the machine on-screen with a red exclamation mark to indicate that the position of the machine is not up to date/current. The machine will remain in this state on the display of other machines until an up-to-date PR2 message or a shutdown message is received from the machine that lost contact.

• When a machine is shutdown and the office receives the shutdown message the machine remains in the AMP message, but is marked as shutdown.

The on-board software retains a copy of the full list of all monitored machines on site and appends details of each machine until the software receives another full list at the next restart.

Automatic Load and Dump

The on-board software automatically senses when an excavator, cable shovel, hydraulic shovel, or wheel loader is loaded with material or is dumping material.

The software uses the following inputs:

• Direction of machine travel

• Material that the bucket is over

• Whether material is "mined out"

• Whether there is material in the bucket

To use the automatic load and dump feature instead of Load or Dump physical switches, complete these steps:

1. Complete one normal load / dump cycle

   1. On the first load cycle notice that, once the machine reverses after digging, the bucket on the screen appears filled and is the color of the material.

   2. On the first dump cycle notice that, when the machine reverses after dumping, the bucket on the screen appears empty.

2. Reverse to trigger the on-board software to record the load or the dump in the relevant productivity file.

If using an unusually small turn angle, notice whether the bucket on the screen changes color as above. Notify the site supervisor immediately if not, as a physical Load switch and Dump switch may need to be installed for this scenario.

If the screen has the following Digital window options, notice that the values increase with every load until the operator selects a Clear truck or Send Truck button:

Material Dipper Count (BC) - Number of dippers or buckets of the predominant material (MT)

Dipper Count (DC) - Total number of dippers or buckets contained in a truck

Clear Truck - The Clear Truck button resets the bucket and the material count windows.

Send Truck - When the load is complete, selecting the Send Truck button sends the truck at the top of the list in the "Waiting Truck" window.

If the site has configured the Digital window to show Load Material as the background color, then the color of the predominant load appears in the background of the Digital window.

Guidance Point Versus Origin

The origin (also called machine origin or boom/stick/bucket origin) is the point to which all machine offsets are measured. The origin is used in the "Position" Diagnostic window, in PR2 messages, and in dimensions windows. See the MCU Help file, "Origin" for diagrams of the position of the origin on each machine type.

North (N), East (E) and elevation (Z), as shown in the Digital window, refer to a point on the machine which is specific to the particular machine type. The point is not necessarily the same as the origin. The point is called the Blade position or the guidance point. See the MCU Help file, "About Digital Windows" for diagrams of the position of the guidance point on each machine type.

For example, the origin and guidance point on a wheel loader are as follows:

Illustration 17	g03710686
Origin (1) on wheel loader

The origin (1) is the black dot shown above at the center of the front axle taken to the ground along the machine center line.

Illustration 18	g03710687
Guidance point (2) on wheel loader

The guidance point (2) represented in the Digital window is the black dot shown above at the midpoint of the line along the front of the tires and along the machine centerline.

New Reference Material

Entering Pitch and Roll Offset Data - Dual Antenna Machine

There is no change to this process in v5.2 but the reference data has been expanded.

The installer uses the following files when programming a sensor to measure pitch and roll on a dual antenna machine:

master.txt - The installer adds $ Calibration Menu to this text file to access wizards and sensor ID information in the on-board software.

mach_config.txt - The MCU adds a series of keys (type of sensor, offset of sensor from origin) into this text file and sets up the on-board software to search for the calibration.txt file.

calibration.txt - The calibration wizard stores data in this text file.

Special Instruction, REHS5195, "Installation of the Pitch and Roll Angle Sensor for Cat^® Terrain v5.0"

Entering Pitch and Roll Offset Data - Single Antenna Machine

In v5.0, the installer added the "Calibration File Name" to the MCU, but this requirement has been removed for v5.2 for a single antenna machine.

The installer uses only the following file when programming a sensor to measure pitch and roll on a single antenna machine:

mach_cfg.txt - The MCU adds a series of keys (type of sensor and offset of sensor from origin) into this text file.

Reference: For more information, refer to Special Instruction, REHS5195, "Installation of the Pitch and Roll Angle Sensor for Cat^® Terrain v5.0".

Changes to the On-board Software

Deleted Key

$ No Last Material

New Keys

The keys in Table 2 have been added.

Table 2

New Keys in Terrain v5.2

$ Ant Count =<number> $ Auto Delay =<time> $ Avoidance Boom/Stick/Bucket Zone Back <count> =<distance> $ Avoidance Boom/Stick/Bucket Zone Front <count> =<distance> $ Avoidance Boom/Stick/Bucket Zone Left <count> =<distance> $ Avoidance Boom/Stick/Bucket Zone Right <count> =<distance> $ Avoidance Boom/Stick/Bucket Surface High <count> =<distance> $ Avoidance Boom/Stick/Bucket Surface Low <count> =<distance> $ CAES Bind IP Address =<IP address> $ Debounce Actuate Dipper =<duration> $ Debounce Actuate Stick =<duration> $ Debounce Deactuate Dipper =<duration> $ Debounce Deactuate Stick =<duration> $ Dipper Capacity $ Disable Mined Material in Dipper =<value> $ Dig Maximum Angle =<degrees> $ Dump Maximum Angle =<degrees> $ Dump Minimum Angle =<degrees> $ Distance To Front Idler =<distance> $ Distance To Track Edge =<distance> $ Electric Rope Shovel MTAlpha Offset -<length> $ ERS Dipper Weight Offset =<number> $ ERS Spot Dump Distance =<distance> $ Excavator Bucket Move Threshold =<meters> $ Excavator Dump Minimum Distance =<distance> $ Excavator Dump Minimum Time =<time> $ Excavator Load Wait Time =<time> $ Excavator Maximum Load Distance =<distance> $ Excavator Maximum Load Time =<time> $ Excavator Minimum Load Distance =<distance> $ Excavator Minimum Load Time =<time> $ Force Activity $ OPC Server =<computer name> $ Target Pitch Tolerance =<distance> $ Target Roll Tolerance =<distance> $ Target Tolerance -<distance> $ Use Cat ERS Dipper Weight =<value> $ Use Dig Switch =<value>

Refer to the section entitled "Machine Configuration Utility (MCU) Release Notes" later in this document for additional information.

Altered Keys

The following keys have been altered:

• $ Buzzer Tone

• $ Buzzer Max Duration

• $ Buzzer Repeat Delay

• $ GPS UTC Offset

• $ Ignore No Avoidance Zones

• $ Max Bucket Log Count

• $ Profile Update Interval

Refer to the section entitled "Machine Configuration Utility (MCU) Release Notes" later in this document for additional information.

Master keys

There are no new master keys in this release.

Note: Special Instruction, REHS4674, "Release Notes for Cat^® Terrain v5.1 On-board Blade Control Software" described the $ GCG TTT master key that is used for Terrain with blade control features. Blade control is not supported in Terrain v5.2.

Windows in the Terrain on-board software (G610 Display) can only be resized when the $ Development Menu key is present in master.txt file. Affected windows include the following types:

• Digital

• Dipper Load History

• Gauge

• KPI

• Materials

• Plan

• Profile

• Truck Load

• Truck Load History

• Waiting Trucks

This key is present by default in TerrainDemo and Terrain Screen Configuration Utility software only.

For more information about this key, refer to "Master Configuration Development Keys" in the MCU Help file.

Menu Items

"Ore Control" > "Calibrate Dig Sensor"

Updated: Recent Overrides Toolbar

There are three types of Materials toolbars:

Fixed Materials - The materials that are available on the toolbar always remain the same.

Recent Overrides - The toolbar is populated in historical order as the operator applies overrides. The material in the left-most position in the toolbar is the most recently used override. When the software shuts down, the toolbar clears.

Recent Materials - The toolbar is populated with the materials that are identified for the most recent loads. The toolbar is populated in historical order as the trucks are sent. The material in the left-most position in the toolbar is the most recently identified material.

The state of the toolbar is saved when the on-board software closes.

Fixed: "Material Selection - All Materials" Dialog

Illustration 19	g03749299

The "Material Selection - All Materials" dialog now correctly shows the name of the material in the "Selected Material" field.

New Windows

"Forced Activity Select" Dialog

The "Forced Activity Select" dialog appears if the operator does not select an activity after logging on when Forced Activity is enabled.

Refer to the section entitled "Force Activity" later in this manual.

Dipper Load History Window

A Dipper Load History window displays a bar graph of the dipper loads for a selected number of previous dippers. Sites can monitor the ability of the loader operator to load the dippers to capacity (height of each bar).

For additional information about setting up the window, refer to "New: Dipper Load History Window".

Diagnostic Message Log Window

Illustration 20	g03659305
Portion of "Diagnostic Message Log" window showing representative diagnostic information

The "Diagnostic Message Log" window contains diagnostic information such as shown in Illustration 20. Use the window to provide information that is used to diagnose problems.

The on-board software updates the window as events are written to the Diagnostics Message Log File (DML). The DML is stored on-board and can be appended to a Diagnostic file, if required.

The on-board software stores the DiagMsgLog File in [drive name]:\\caes\diag.

The following actions can be performed:

Open the window - Open the main menu and select "Diagnostics" > "Diagnostic Message Log".

Pause the scrolling list - Touch or click any list item except the last item.

Restart the scrolling list - Either select the last item or else double-click anywhere inside the window to resume the scrolling text.

"OPC DA Messages" Diagnostic Window

Illustration 21	g03710743
"OPC DA Messages" diagnostic window

Use the "OPC DA Messages" diagnostic window for the Cat ERS 7495. The window is described in the MCU Help, the Operation and Maintenance Manual, the Systems Operation, and in Special Instruction, REHS7426, "Installation of G610 Hardware for Cat Terrain for Certain Cat Electric Rope Shovels".

Altered Windows

Options for Digital Windows

Operator Option (OP) - The "OP" (Operator) option has been removed from the list of Digital window options. "OP" will not appear on Digital windows currently configured with this option. There is no follow-up required from the user.

Cat ERS Digital Window Options

The following Digital window options have been added for Caterpillar Electric Rope Shovel (Cat ERS) 7495:

The following options have been added:

• Dipper Weight Now (DWN)

• Load Count (TC)

• Truck Tons (TT)

• Truck Overload (OL)

Dipper Weight Now (DWN) - This value is the current dipper weight provide by the Cat ERS 7495 PLC system. The dipper weight value at dump is calculated based on average of the dipper weight read by the PLC system while swinging a loaded dipper over to the truck until the dipper is tripped. The value is passed to the on-board software after the dipper is tripped The value is part of the early warning system for truck weight.

Load Count (TC) - This value is the number of trucks that have been loaded.

Truck Tons (TT) - This value is the current payload of the truck in units as defined by the site by using Payload Conversion.

The TT value is derived from either or a combination of the following conditions:

• In a VIMS enabled truck, the truck sends the truck weight as the truck suspension linkage is loaded, which generally occurs during gear changes while the truck is moving.

• Terrain accumulates the dipper weights as the dipper dumps.

TT has no units. Use the Payload Conversion setting to convert the payload value to reflect units used on your site.

If the on-board software receives the weight from the truck (truck weight), the software detects overloading by adding the current dipper weight to the truck weight and comparing the sum to the known truck capacity. Once the truck has been filled and sent, then the on-board software reverts to using the truck weight.

Truck Overload (OL) - This value shows how far the operator went over the weight capacity limit of the truck when loading using the Cat ERS 7495 machine type.

Truck Load Window

This window cannot be used with Caterpillar electric rope shovel (Cat ERS) model 7495 machine types. The window shows "Next Dipper 100%".

Altered Dialogs

"Create Materials Window" Dialog

Illustration 22	g03659861
"Create Materials Window" dialog

The values for dipper weight (8) can now be added to the Materials windows, if required.

"Intensity Control" Dialog

Illustration 23	g03659309
"Intensity Control" dialog at 50% brightness

Brightness (or screen intensity) settings remain over shutdown unless the screen brightness is too dim. In this case, when the software restarts, the slide bar control will default to just below 50% brightness as shown in Illustration 23.

TTT Cycle Time Symbol

The symbol for the Digital window option "TTT Cycle Time" is now "CT". CT is the total time that is taken for the number of cycles performed by the Track-Type Tractor since the last operator reset.

"Material Selection" Dialog: New List Order

Use the "Material Selection" dialog to override the material that was selected by the on-board software.

Material Selection - Opens the "Material Selection" dialog

Menu - Opens the main menu.

Open the "Material Selection" dialog using one of the following methods:

Material Selection - Touch the button.

Menu - Open the main menu and select "Ore Control" > "Material Selection".

Reference: For additional information on the "Material Selection" dialog, refer to the "Material Selection" section of Operation and Maintenance Manual, SEBU8841, "Daily Tasks (Material/Ore)".

Illustration 24	g03659313
V5.0 list with two materials of the same color listed together.

The order in which materials are listed in the dialog has changed.

Prior to Terrain v5.2, this list was alphabetical and could be confusing. Note the two yellow materials side by side in Illustration 24.

In Terrain v5.2, the dialog lists the materials as follows:

Illustration 25	g03659311
No "Prime" file: four mach_cfg.txt materials, listed in reverse alphabetical order

Illustration 26	g03659312
One or more Prime files: two Material design materials followed by four mach_cfg.txt materials

• If no Material Design file is selected as "Prime", the dialog includes the name and color of materials listed in the mach_cfg.txt file, in reverse alphabetical order. This simple list is shown in Illustration 25.

• If one or more Material Design / Material Mined files is selected as "Prime", then the dialog includes the name and color of materials from the Material Design file (first set) and then the mach_cfg.txt file (second set), in reverse alphabetical order as shown in Illustration 24.

"Select Grade Colors" Dialog

Previously when setting up the colors representing fill/cut/on grade in the Gauge window and the Grade Plan window, the installer used the "Select Grade Tolerance" dialog. This dialog has been removed and replaced with the "Select Grade Colors" dialog which is accessed from the Plan menu item.

Perform the following steps to alter the colors shown in either window:

Show/hide table

Illustration 27	g03711221
"Select Grade Colors" dialog

1. In the main menu, select "Plan" > "View" > "Select Grade Colors". The "Select Grade Colors" dialog appears.

2. Enter a value in the "Grade Color Range" box. The default value is 1.00 m. This value evenly spreads the fill (blue), grade (green), and cut (red) areas.

1. Under "Color Range", select one of the following:

   • "Few" = blue, green, and red only.

   • "Default" = a medium range of shades of blue and red.

   • "Many" = a large range of shades of blue and red. A darker red or blue indicates that the area needs more cutting and filling. A lighter red or blue indicates that the area is approaching grade.

2. Select "OK".

New DiagMsgLog (DML) Messages

There are new messages in the DML, relating to ERS, new hydraulic sensor (dig sensor), 14 Day License, and Cat ERS 7495 (for example the ERS dipper overloading truck).

New Buttons

Create New Target - Select this button to show a new wick hole target at the implement position.

Mark Target Done - Select this button to mark a wick hole target as completed.

New Machine Type: Wick Hole Excavator

New Wick Hole Excavator features appear for an excavator machine type with the wick hole machine model. Refer to "Plan Window "Display" Options".

Reference: For additional information, refer to Special Instruction, REHS9107, "Installation of G610 Software for Cat^® Terrain for Wick Hole Excavators" for additional information.

New: Advanced Swathing for Dozers

The on-board software uses the Advanced Swath Method (ASM) as the primary method of swathing for all Track-type Tractors (dozers) from v 5.2. ASM provides highly accurate as-built surfaces to the information appearing on the Plan window. Terrain uses ASM with blade control, dual antenna, or single antenna dozers. Blade control is not supported in Terrain v5.2. Ideally for support of ASM, use a dual axis (AS460) sensor to measure pitch and roll of the machine body.

Note: ASM improves accuracy for dozers with a single antenna and/or no sensor, but will not be as accurate as dozers with a pitch/roll sensor.

Installing Advanced Swathing

In Terrain v5.2, machines that are not Track-type Tractors continue to use the current method. Track-type Tractors automatically start using ASM with either default or installed dimensions. Dozers without blade control will swath using ASM for any direction of travel.

To install ASM, configure the following settings, depending on machine type:

• "Dimensions" > "Distance to Track Edge"

• "Dimensions" > "Distance to Front Idler"

• "Swath Options" > "Swath Point"

• "Mapping" > "Surface Files"

• "Dimensions" > "Blade Width"

• "Dimensions" "Antenna Count" =2 (for a dual antenna system)

For additional information regarding these settings refer to "Advanced Swath Method - Reference" in the MCU Help file.

Note: Machines prior to Terrain v5.2 will use the current center of blade swath point and cannot use ASM.

New: Force Activity and Auto Delay

To begin work on a machine that has the Force Activity feature enabled, complete these steps:

1. Start the machine and the display module to open the on-board software.

2. Log in, if required.
   Show/hide table

   Illustration 28	g03716966

3. Select the name of an activity such as "Loading" from the list in the "Activity Select" dialog.

4. Select "OK" to open the selected activity. This is the current activity that you are working on.

   Note: To make the"Activity Select" dialog open automatically on startup, in the MCU select "Force Activity".

The on-board software continuously monitors the length of time the machine position is stationary. From v 5.2 onwards, when the machine position is stationary for more than the Auto Delay time, the "Select Delay" dialog appears. The operator must enter a delay code for the screen to return to normal. The new delay takes effect from the time the machine position became stationary

Note: The auto delay feature back dates the delay. For example, if the system is configured to force a delay after 5 minutes and prompts the operator with a dialog and they do not select a delay code for 15 minutes the delay will show 20 minutes when selected, as this is the total time the machine was stationary.

To start a machine that has the Auto Delay feature enabled, complete these steps:

Show/hide table

Illustration 29	g03716957

1. After the machine is stationary for more than the time used at the site, the "Select Delay" dialog appears with the "Automatic Delay" (or similar) item highlighted.

2. Select "OK" to open the highlighted item.
   Show/hide table

   Illustration 30	g03716958

3. Select a reason for the delay, such as "Behind Delayed Machine".
   Show/hide table

   Illustration 31	g03716959

4. Select "OK".

   The "Delayed" dialog appears. The timer in the "Delay Time" field of the dialog begins to count down from the time that is specified for the chosen delay. Once the specified delay count reaches 0 (zero), the timer continues with a negative count.

5. When ready to work, the operator brings the machine to speed and selects "End Delay" which stops the timer.

Note: If the machine is stationary or not up to speed, the "Select Delay" dialog appears again.

Example - Assuming that the reasonable delay for a machine to remain stationary is 2 minutes, the specified delay for "Behind Delayed Machine" is 3 minutes, the machine is at speed, and the operator selected the "End Delay" button at 4 minutes and 1 second, then the total delay that will be sent to the office is 9 minutes and 1 second.

Note: If the auto delay runs over shutdown, select a delay that describes the shift changing, then select "End Delay" once the machine is up to speed and working.

Note: To make the "Activity Select" dialog open after a set period of delay, in the MCU select"Auto Delay".

New: 14 Day Trial License

From v5.2 onwards, the installer can use a 14 Day Trial License for new installations and upgrades.

Sites generate a 14 Day Trial License in the MCU. The license allows users to operate the display while counting down from 14 days to 0 (zero) days. At day 0, the software stops working.

Reference: Refer to Special Instruction, REHS9109, "Installation and Configuration of Cat^® Terrain v5.2 On-board Software" for information on generating and installing the temporary license.

New: Caterpillar Electric Rope Shovel

This section applies to the following Caterpillar electric rope shovel (Cat ERS) 7495 machine types:

• 7495 with HydraCrowd (Electric Rope Shovel)

• 7495 RopeCrowd HD (Electric Rope Shovel)

Terrain on-board software accesses data from the OPC server via Ethernet. The on-board software works with dual GNSS receivers, a body sensor for pitch/roll (also called an inclination sensor), and Cat MineStar office software.

Note: Dual-receiver systems are only available for 160 Series or greater Cat ERS machines.

Information related to the Cat ERS 7495 has been added to Systems Operation, KENR8277, "Cat^® Terrain v5 for Grading and Loading" and MCU Help files.

Settings

The following MCU settings are available:

OPCServer Address - Address for OPC Server

Use Cat ERS Dipper Weight - If a site does not have MineStar Fleet installed, select to use the accumulated dipper weights from the ERS to determine the total weight of material in the truck, rather than using the weight provided by the truck in the Peer to Peer message.

Spot Dump Distance - This setting specifies the distance away from the location of a "spot" wherein Terrain considers a dipper trip signal is equivalent to the operator dumping a load into the truck. The Terrain software will add the dipper weight to the total weight of the truck.

Dipper Weight Offset (%) - Create an offset to correct any persistent inconsistency in the dipper weight as defined by the MTDipperWeightNow tag.

MTAlpha Offset - Create an offset to account for any difference between the MTAlpha angle measured and the MTAlpha angle supplied by the Programmable Logic Controller (PLC).

Dipper Capacity (cu. yd.) - Enter the volume of the bucket as provided by the manufacturer as “dipper capacity”.

Pitch Brace Length (inches) - Use the length of the pitch brace to adjust the dipper angle (raked angle) relative to the center line of the crowd.

Truck Weight - The Use Cat ERS Dipper Weight setting is available. The setting can also be configured to use the VIMS messages that are communicated to Terrain from the on-board system on Caterpillar trucks.

Machine Type and Machine Model - The on-board software uses Machine Type and Machine Model to represent monitored machines working nearby as an icon on the display. If machine type / model for a monitored machine is not set, the machine appears as an arrow on the display.

Pitch and roll angle sensors - Machines often work on a slope. The on-board software knows the elevation of the antenna, but must calculate the elevation of any other point on the machine, in general, a swath point or a dozer blade.

For additional information regarding these settings, refer to "Cat ERS - Reference" > "Settings" in the MCU Help file.

On the Display

Illustration 32	g03717427
Cat ERS windows (A) Plan (B) Digital (C) Materials (D) Profile (E) Dipper Load History

There are icons and options for the listed Cat ERS windows.

Start-up

On start-up, the Terrain on-board software on the Cat ERS 7495 checks the following:

• The machine type and machine model values are present in the mach_cfg.txt file. Machine Type =2, Machine Model =3.

• The OPCClient.dll file is present in the d://caes/exe folder.

• The heartbeat, tagged as MTHeartBeat, from the OPC server is present. The heartbeat alternates from "TRUE" to "FALSE" every second showing there is a connection.

• The heartbeat is "good" quality. The OPC Server sends the heartbeat every second, whereas other tags are only sent when the data changes. The on-board software assumes previously "good" data remains "good" until informed by OPC Server that the quality has changed.

Dimensions

The on-board software uses information in the mach_cfg.txt file, along with information from the GNSS receiver and inclination sensor (pitch/roll sensor), to determine the origin (COR) and all offsets. Information enters the mach_cfg.txt file through the MCU or as pre-existing defaults for this machine type.

The following settings are entered through the MCU:

• Dipper Weight Offset

• Dipper Capacity

• Pitch Brace Length

• ERS Spot Dump Distance

Additional values are hard-coded through the Programmable Logic Controller (PLC) and appear grayed-out in the MCU.

For a complete listing of these hard-coded values refer to "Cat ERS Dimensions - Reference" in the MCU Help file.

Load/Overload

Set Spot Location 1 - Select this button to set a location for the truck to be loaded.

Position the dipper of the machine where the truck will be loaded, then to load complete one of the following:

• Set a Command spot location if Command is enabled.

• Set a spot location using the Set Spot Location 1 button by using either the G610 display module or the switched input, if wired as such. By default the on-board software draws a 25 m rectangle on the Plan window around the truck position for loading.

• Replace an old spot location #1 with a new spot location #1 - Shift the center of the dipper tip to the new location, press the Set Spot Location 1 button. The old spot #1 disappears and the new spot #1 appears. Load trucks one at a time. Do not alternate between trucks.

Note: Any dipper that is dumped outside of the spot location box will not be counted by the system. Ensure that the load is dumped inside the box if the truck is loading to prevent inaccuracies in the data.

Reference: For additional information when using the system with Command for hauling, refer to Operation and Maintenance Manual, SEBU8841, "Cat Command" in the section entitled "Setting a Spot".

Note: When dumping material, consider the spot dump distance.

Carry Back

Carry back refers to the amount of material that remains stuck in the dipper after the dipper is tripped. Carry back can, in worst cases, be 30% of the weight of the load in the dipper.

Neither the ERS system nor the Terrain system provides a way to measure carry back. However, use Dipper Weight Offset to correct any persistent inconsistency in dipper weight, if required.

Sensor

Terrain uses the current Cat ERS 7495 inclination sensor and does not use extra sensors on the stick, boom, or bucket.

TMAC Messages

Terrain outputs the following TMAC messages:

• DipperRecord

• DipperReport2

• LoadReport

• LoadReport2

• TmpsDipper

• TmpsLoad

• TmpsDipper2

Origin

Both PR2 messages and AMP messages use the center of rotation (COR) as the origin.

Truck Overloaded

The on-board software receives the weight of the truck from two sources:

• A message from the truck using the Fleet on-board software, stating the current strut weight.

• The summary of "Dipper Weight" values for this load, read directly from the ERS computer system.

The on-board software adds the weights of all dippers since the last Send Truck command or reboot, then reports this weight as the truck weight in the units set in "Terrain Display Units" setting. Ask your site supervisor which system the machine uses to calculate truck weight.

The operator is notified in the following ways when an overload situation will soon occur:

Illustration 33	g03716972

• As shown in Illustration 33, a visual indication appears on the screen stating "Current dipper will overload truck".

• An audible signal occurs to alert the operator to the overload situation.

• The Digital window option Truck Overloaded (OL) for a Cat ERS 7495 machine, which remains blank if not in an overload state, shows the following situation: DWN + TT > TC.

Where:

DWN - This value is the current dipper weight as established after 3.5 seconds and is generated from the PLC on the Cat ERS.

TT - Value for truck tons or truck weight (various methods)

TC - Value for truck capacity as shown in the MineStar file

The overload warning is written to the Diagnostic Message Log (DML) file.

Troubleshooting

The following warning messages may appear during work:

• OPC Client not installed

• OPC Server not connected

• Lost connection to OPC server

• Cat ERS 7495 GPS <x, y, z> value must equal <number>

• Various Cat ERS 7495 diagnostic messages

Refer to MCU Help, "Cat ERS - Reference" > "Troubleshooting" for information on why these messages occurred and the resolution for the message.

New: Dipper Load History Window

A Dipper Load History window displays a bar graph of the dipper loads (bucket loads) for a selected number of previous dippers. Sites can monitor the ability of the loader operator to load the dippers to capacity (height of each bar). The installer can set up the window to filter for various size buckets.

Illustration 34	g03717501
Dipper Load History window

Illustration 34 shows a Dipper Load History window. Each bar is a dipper. The window indicates that six out of the last 15 buckets have been consistently loaded within capacity (within the dotted lines).The most recent dipper load is on the left. The numbers are in tenths of tons because this site uses the Caterpillar Vital Information Management System (VIMS) and does not use Payload Conversion.

The colors of the bars specify the following:

Red - Overload

Green - Within range

Yellow - Underload

Adding a Dipper Load History Window

Menu - Opens the main menu.

To add a Dipper Load History window, complete these steps:

Show/hide table

Illustration 35	g03717502
"Dipper Load History" window

1. Open the on-board menu and select "Configuration" > "Dipper Load History".

   The "Dipper History Setup" dialog appears.

2. .Set up the fields and warning colors as described below:

   "Dipper Overload" - If set up with a Dipper Overload value of 110% and the color red, any dipper filled to 110 tons (110% of 100 tons) or greater will appear as a red bar that reaches above the top dotted line. In most situations the software calculates the dipper weight as the difference between the truck weight before the dipper load is dumped into the truck and the truck weight after the dipper load is dumped. If using the Cat ERS 7495, the PLC supplies the dipper weight directly to the on-board software.

   "Dipper Underload" - If set up with an Underload value of 90% and the color yellow, any dipper load filled to 90 tons (90% of 100 tons) or less will appear as a yellow bar. The bar will reach below the underload capacity line. The dipper weight is calculated as for the Dipper Overload field.

   "Dipper Capacity" - This field acts as a filter. Any dipper with a capacity that matches the number in this field is displayed in the Dipper Load History window. For instance, if the Dipper Load History window is to show only the dippers with a capacity of 60 tons, type 60 in this field. If no value is set in this field, then the history for all dippers is displayed in the window.

   "Dipper Count" - The Dipper Count field specifies the number of dipper loads that are displayed in the Dipper Load History window. Select a value between 1 and 20. The dipper loads are not retained over shutdown. The bar on the left is the most recent dipper.

   "Range [+/-]" - The Range [+/-] fields specify the maximum and minimum weight ranges that are displayed in the bar graph. If the left ("+" = high) value is 140, then the vertical bar for a load filled to more than 140% of dipper capacity may reach beyond the top of the display window. If the right ("-" = low) value is 0, then the value for a dipper filled to less than 0% dipper capacity will register at the baseline of the vertical bar.

3. Select "OK".

Once created, the Dipper Load History window can be deleted, but cannot be edited.

Example

Illustration 36	g03717506

Illustration 36 shows the weight of the first two dippers out of a possible ten dipper loads that will fit on the graph. The most recent dipper load is the left-hand bar on the graph and is overloaded

The number on the top is the dipper capacity, in this case 100 tons because Display Units are metric for this machine.

The number at the bottom is the average of all the dippers that are shown on the left-hand side of the graph. The average dipper load is 157 tons.

Note: In this example, the site uses VIMS and the Payload Conversion factor 0.1 so that the top and bottom numbers reflect actual values and not tenths of tons.

The top and bottom broken lines represent 110% and 90% of the dipper capacity. The x axis of the graph shows data between 0% and 140% of the dipper capacity, in this example 0-140 tons.

Payload Capacity

This section is for sites that do not use VIMS.

The truck.mwf file contains the maximum working payload or each truck. By default, the on-board software reads weight from the *.mwf file as tenths of tons. Tenths of tons are used to match with the Caterpillar Vital Information Management System (VIMS) that is used on trucks.

If your site does not use VIMS, add a conversion factor to be applied to each weight by setting Payload Conversion. The weight in the Truck Load History window, and the Truck Tons (TT) value in the Digital window, will then appear in the units used by your site.

Reference Material

Wick Hole Excavator

The wick hole machine is a modified excavator used to install a textile wick vertically into a leach pad for extracting leachate.

Wick hole software runs on the G610 display, on a single antenna machine, using *.csv files created in the office and sent to the machine or on-board by the operator by creating points as the machine moves.

When sending a *.csv file from the wick hole excavator to the office, the following applies:

Action - The on-board software sends the current *.csv file to the office whenever an operator logs out.

Outcome - When Terrain sends a csv file to the office, the file overwrites any file with the same name currently stored in the office. Therefore, if the same csv file is sent to the office multiple times, the file will overwrite the previous copy stored in the office.

Note: The operator cannot delete holes, only complete, add, or edit holes. The data about each hole is not lost, but the productivity data is lost. Backing up the *.csv file regularly in the office ensures that the productivity data is available.

For more information about the wick hole excavator, refer to "Wick Hole Excavator - Reference" in the MCU Help file.

Reference: Refer to Special Instruction, REHS9107, "Installation of G610 Software for Cat^® Terrain for Wick Hole Excavators" for additional information.

Caterpillar Electric Rope Shovel (Cat ERS) 7495

The following Cat ERS 7495 machine types are supported:

• 7495 with HydraCrowd

• 7495 RopeCrowd HD

For detailed information regarding these machine types refer to "Cat ERS - Reference" in the MCU Help file.

Machine Type Numbers

The MCU Help topic "Machine Type" now lists machine type numbers alongside the names of the machine types. When problem solving, technicians and installers check the mach_cfg.txt file for anomalies. One anomaly that is easy to spot is an incorrect Machine Type name that is entered in the office software.

Open the mach_cfg.txt file and check the $ Machine Type =<number> key. Compare the <number> to the list in the topic "Machine Type" in the MCU Help file.

Advanced Swath Method

Use Advanced Swath Method (ASM), as the primary method of swathing for all Track-type Tractors (dozers) from v 5.2. ASM provides highly accurate as-built surfaces and cleaner edges to the information appearing on the Plan window.

For additional information refer to "Advanced Swath Method - Reference" in the MCU Help file.

Service Kit Training Videos

There are a series of videos available for the 291-1391 CAES Tool Gp.

Subjects include the following:

• Service Kit Components

• Terminology and connectors

• Recommendation kit changes - Component Testing

• Radio

• GPS receiver

• Display - Subsystem Testing

• GPS and Radio Test - Full System Testing

• GPS, Radio, Display - Miscellaneous

• HEX Sensor Test

• Ethernet Cable

Fixed in Terrain v5.2

Forced Send of *.mwf Files

Terrain on-board software v4.2, 4.5 and 5.0 appended a "\" (backward slash) character to the machine2.mwf file name which was written in the FileStatus2 message. The addition of this character caused the office software to send *mwf files when not needed. The backward slash character will not occur in v5.2. Any inconsistencies created in the office software by the extra "\" character should now be resolved.

Incorrect Processing of Zone Update Messages

Terrain on-board software did not process Zone Update messages if the zone had a long name. This situation has been resolved.

Note: Cat MineStar System software accepts long zone names, sometimes up to 1020 characters.

Receiver Stuck in "Autonomous"

If Terrain stops sending CMR messages to the GNSS receiver, and the receiver changes into "Autonomous", Terrain will now reopen the socket and continue.

Remote Control System

A Remote Control System (RCS) works with the Avoidance Strategy and may also work with the Detect Strategy. Remote operators use the RCS to determine if an incident has occurred because a machine region of the remote machine has crossed into a machine region of another machine.

These systems rely on CAN Messages between the on-board software and the RCS console and use a series of visible alarms and optional beeps to notify the remote operator when there is an incident.

Reference: For a description of the machine regions, the associated CAN messages, and the incident alarms, refer to Systems Operation, KENR8277, "Cat^® Terrain v5 for Grading and Loading", "Remote Control System".

Terrain Mobile Software Release Notes

The Terrain v5.2 mobile software application is compatible with and will run on Microsoft Windows 8.1.

Note: If, on windows 8.1, the customer installed an earlier version of the Terrain mobile software that did not work, and the customer updates to Terrain v5.2, then the Terrain mobile software will still not function because the supplied DLL caused Terrain to crash. Complete a fresh install to resolve the problem.

Machine Configuration Utility (MCU) Release Notes

Altered Settings

Buzzer

This section describes the new buzzer sounds that are available for sites running Detect office software and Detect with Terrain.

New Detect Buzzer Sounds - For sites running Detect, the Terrain proximity buzzers have been aligned with the Detect Proximity Awareness buzzers that are running on the Color Marine Power Display (CMPD). This update applies at site level, so the installer must send out new mach_cfg.txt files to all machines on site for this update to take effect. Plan the MCU upgrade appropriately.

The following three keys have two new options, visible in the mach_cfg.txt file as buzzer numbers "21" and "26":

• $ Buzzer Tone 21/26 =<tone bytes>

• $ Buzzer Max Duration 21/26 =<time>

• $ Buzzer Repeat Delay 21/26 =<delay>

These keys are added to the mach_cfg.txt file by default and are turned off by deselecting the "Buzzer Output" setting in the MCU.

Change Path Highlight Setting

The Change Path Highlight setting (key = $ BeeGone) now removes the strident yellow and black crosshatching completely. Previous to v5.2, the key replaced the crosshatching with lighter crosshatching. The Status bar icons remain unchanged. The alarms remain as configured.

Dozer

This section describes mapping surface data for creating improved productivity records.

New Dozer Swath Options - For sites running MCU v5.2, all new Track-Type Tractors include the setting "Track-Type Tractor Swath Option 5" which contains the following:

• Swath Point - "All Points"

• Category - "Ore Status"

• Swath Point Function - "Mined Out"

Access the “Mined Out” setting in the MCU by selecting "Mapping" > "Swath Settings" > "Swath Options".

Use with the following settings to create a default as-built surface file to map material status (also called the "ore status") "Not Mined", "Mining in Progress", or "Mined Out":

• "Surface Files" > "Material Status With Time"

• "Ore Status" > "Ore Mined Color"

Note: Enter "Swath Options" at site level or machine level, but enter the data file type, "Material Status With Time", at site level.

Existing Dozer Swath Options - For sites running MCU v5.2, all existing Track-Type Tractors retain the previous settings until edited as explained below.

To improve the information gathered in the as-built surface files, complete these steps:

1. In the MCU, select "Mapping" > "Swath Settings" > "Swath Options".

2. Select the site name.

3. Configure a new "Track-Type Tractor Swath Option 5" as above.

4. Create a "Material Status With Time" file.

5. Resend the mach_cfg.txt file to all dozers on site.

Note: Enter "Swath Options" at site level or machine level, but enter a "Surface File" for "Material Status With Time" at site level.

All Machines

Activity Category Map > Group ID

For each type of coverage as-built surface file, set up the types of coverage such as "radio latency", "SV", and "pass count" to map to separate groups. When mapping to separate groups, the data is stored in separate *.cat coverage files. In v5.2 the MCU no longer stops the user from configuring more than one coverage type to be mapped to one group.

Ignore No Machine Buffers

The setting remains the same. However, while a machine works as a remote control machine, use the Avoidance Strategy and not the Detect Strategy for zone and surface alarms. Detect proximity alarms are still possible, but the predominant alarming in the remote control working area comes from Avoidance Strategy alarms.

Volume Design Limited

This setting now requires a swath option category called "Original Elevation" to be set. The MCU reminds the user with a validation error message

UTC Offset Settings

$ GPS UTC Offset now updates automatically. Universal Coordinated Time (UTC) is the most commonly used time system in the world and is the one used by satellites and sent to the MS series receivers.

To keep UTC time in line with the rotation of the earth, the International Earth Rotation and Reference Systems Service (IERS), formerly the International Earth Rotation Service, inserts “leap seconds” on either June 30th or December 31st, when required, and notifies the public generally within 6 months before the update. Users of MS series receivers must update any software that communicates with the receivers with the new time, usually by including an offset from a set point in time.

Example The current (as of March 2014) number of “leap seconds” used in Terrain for grading and loading is 16.

From v 5.2 the following occurs:

• A G610 display module using CAN GNSS communication automatically uses the receiver for the correct UTC time.

• A G610 display module using serial GNSS communication relies on office staff to edit the application file.

Editing the Application File

If using a G610 display module, MS series receiver, and serial communication with the receiver, complete these steps:

1. Open Configuration Toolbox (CToolbox).

2. Set up a new GSOF Output with the following settings:

   • "Message type:" - GSOF

   • "Port:" - Port number for serial communications with receiver

   • "Frequency:" - 5 Hz

   • "Message subtype:" - Current Time / UTC Offset

3. Save and Close.

   The on-board software uses the UTC time from the receiver.

Command

Max Bucket Log Count

Do not use this setting on a site with Command for autonomous hauling. If the MCU detects the site is a Command site and this setting is enabled, then a validation error message occurs for all versions of the on-board software.

New Settings

This section describes the new settings shown in Table 3.

Table 3

New Settings in Terrain v5.2

Acceptable Pitch Acceptable Roll Actuate Dipper / Deactuate Dipper Actuate Stick / Deactuate Stick Address (CAES Bind IP) Address (OPC server) Antenna Count Auto Delay Avoidance Zone / Avoidance Surface Buzzer Output Cable Shovel Machine Dimensions Circle Radius Dig Maximum Angle Dipper Capacity (no corresponding key) Distance to Front Idler Distance to Track Edge Do Not Use Mined Material in Dipper Dump Maximum Angle Dump Minimum Angle ERS Dipper Weight Offset Excavator Bucket Move Threshold Excavator Dump Minimum Distance Excavator Dump Minimum Time Excavator Load Wait Time Excavator Maximum Load Distance Excavator Maximum Load Time Excavator Minimum Load Distance Excavator Minimum Load Time Force Activity MTAlpha Offset Spot Dump Distance Payload Conversion Pitch Brace Length (no corresponding key) Profile Update Interval Use Cat ERS Dipper Weight Use Dig Switch

Acceptable Pitch

Use this setting to enter the tolerance for the pitch (forward/back) value of the wick hole implement.

Table 4

Acceptable Pitch
Possible Values	0 - 360
Default	5
Data Type	Floating point
Units	Degree
Syntax	$ Target Pitch Tolerance =<degrees>
Go To:	"Display" > "Target Window"

Example Acceptable Pitch =5

If the value for pitch is ±5 degrees from the required pitch, the wick hole implement is on target.

Reference: Refer to Special Instruction, REHS9107, "Installation of G610 Software for Cat^® Terrain for Wick Hole Excavators".

Acceptable Roll

Use this setting to enter the tolerance for the roll (side to side) value of the wick hole implement.

Table 5

Acceptable Roll
Possible Values	0 - 360
Default	5
Data Type	Floating point
Units	Degree
Syntax	$ Target Roll Tolerance =<degrees>
Go To:	"Display" > "Target Window"

Example: Acceptable Roll =5

If the value for roll is ±5 degrees from the required roll, the wick hole implement is on target.

Reference: Refer to Special Instruction, REHS9107, "Installation of G610 Software for Cat^® Terrain for Wick Hole Excavators".

Actuate Dipper and Deactuate Dipper

Use these settings to enter the minimum time (in milliseconds) that must elapse before the on-board software accepts the "actuate" or the "deactuate" state for the dipper.

Table 6

Actuate Dipper Deactuate Dipper
Possible Values	None listed
Default	300
Data Type	Floating point
Units	Milliseconds
Syntax
$ Debounce Actuate Dipper =<duration> $ Debounce Deactuate Dipper =<duration>
Go To:	"Machine" > "Sensors" > "Dig Debounce Durations"

Example Actuate Dipper =300

The pressure in the dipper sensor must stay above the trigger point for 300 ms before the on-board software accepts the "actuate" state.

Actuate Stick and Deactuate Stick

Use these settings to enter the minimum time (in milliseconds) that must elapse before the on-board software accepts the "actuate" or the "deactuate" state for the stick.

Table 7

Actuate Stick Deactuate Stick
Possible Values	None listed
Default	300
Data Type	Floating point
Units	Milliseconds
Syntax
$ Debounce Actuate Stick =<duration> $ Debounce Deactuate Stick =<duration>
Go To:	"Machine" > "Sensors" > "Dig Debounce Durations"

Example Deactuate Stick =300

The pressure in the stick sensor must stay below the trigger point for 300 ms before the on-board software accepts the "deactuate" state.

Address (OPC Server)

This section applies toCat ERS 7495 only.

Use this setting to enter the full file path (URL), or IP address, that the on-board software uses to connect to the computer running the OPC Server software on the Cat ERS 7495.

Table 8

Address
Possible Values	A file name (URL) up to 256 characters long, or IP address
Default	Blank
Data Type	String
Syntax	$ OPC Server =<computer name>
Go To:	"Machine" > "OPC Server"

A validation error occurs if the field is left blank. Enter the URL carefully. Server address is subject to change by Siemens (manufacturers of the WinCC software) at any time, and should be verified before install.

Example 1: Address =opcda://<Computer Name>/Server.OPC.DA/{2E565242-B238-11D3-842D-0008C779D775}

The URL for the “OPC server is opcda://<computer name>/Server.OPC.DA/{2E565242-B238-11D3-842D-0008C779D775}”, where <computer name> is either the name of the machine that the server is running on or the IP address. Find the name in the "Computer Properties" dialog.

Example 2: Address =192.167.0.5

The IP address for the OPC server is 192.167.0.5.

Address (CAES Bind IP)

The G610 display module may work as part of a private network, connected to a network router. The private network may include any number of devices such as a wireless radio, a G610 display, cameras, or a Remote Control Module (RCM).

The wireless radio becomes the device that uses this Address setting, not the G610 network port as in earlier versions of Terrain for grading and loading. Enter Address to force the G610 to listen to the network router instead of the G610 listening to the network.

Table 9

Address
Possible Values	Any valid IP address. Valid position broadcast addresses are defined from 192.168.0.0 through 192.168.255.255.
Default	N/A
Data Type	String
Syntax	$ CAES Bind IP Address =<IP Address>
Go To:	"Communications" > "IP Settings" > "Bind Address"

Example Address =192.168.255.255

The display listens for the network router on 192.168.255.255

Antenna Count

This setting is used with dual antenna Track-Type Tractors and dual antenna cable shovels.

Enable the Antenna Count setting when using a dual antenna machine to make the Slave GPS X, Y, and Z settings visible.

Table 10

Antenna Count
Possible Values	1 or 2
Default	1
Data Type	Integer
Units	NA
Syntax	$ Ant Count =<number>
Go To:	"Machine" > "Machine Dimensions" > "Antenna Count"

Example Antenna Count =2

This machine is a dual antenna machine. The user can now enter the X, Y, and Z offsets for the slave antenna.

Auto Delay

Use this value to specify the length of time that the machine is stationary before the "Delay" dialog appears.

Table 11

Auto Delay
Possible Values	Positive number
Default	300
Data Type	Integer
Units	Seconds
Syntax	$ Auto Delay =<time>
Go To:	"Operator Interaction" > "Operator Input" > "Delays" > "Auto Delay"

The on-board software continuously monitors the length of time the machine position is stationary.

In v5.0, the on-board software used a delay sent from the office in preference to a delay, of the same name, entered by the operator. This enabled the office to extend the length of a delay, if required.

In v5.2 this remains the same, except when related to an automatic delay. When an operator selects a delay in the "Auto Delay" dialog, this delay is recorded by the system and cannot be extended by a delay of the same name sent from the office.

From v5.2 onwards, when the machine position is stationary for more than the "Auto Delay" time, the "Delay" dialog appears. For more information about using the "Delay" dialog, refer to Operation and Maintenance Manual, SEBU8841 in the section entitled "Entering Delay Codes". The operator must enter a delay from the list for the screen to return to normal. The new delay takes effect from the time that the machine position became stationary.

The following rules apply:

• The software retains existing delays, auto or otherwise, over shutdown but may not retain the delay over a software crash.

• The office can override any delay with a new delay. If the "Select Delay" dialog is open and showing "Automatic Delay", then the override closes the dialog and incorporates the time into the new delay.

• The names of the delays are contained in a delays.mwf file.

Avoidance Zone / Avoidance Surface

This section does not apply to the Detect Strategy

This section contains information about systems running an Avoidance Strategy based on *.cat files

Terrain v5.2 contains 18 keys defining the size of avoidance buffers around the boom, stick, and bucket for machines using the Avoidance Strategy.

In Table 12, the following variables apply:

A - Boom, Stick, or Bucket

B - Front, Back, Left, or Right

C - High (upper) or Low (lower)

Table 12

Avoidance [A] Zone [B] Avoidance [A] Surface [C]
Possible Values	Any positive number
Default	0
Data Type	Floating point
Units	Meters
Syntax
$ Avoidance [A] Zone [B] <count> =<distance> $ Avoidance [A] Surface [C] <count> =<distance>
Go To:	"Machine" > "Avoidance Configuration" > "Boom, Stick, and Bucket Buffer"

Illustration 37	g03659878
Boom origin (29)

Illustration 38	g03669576
Bucket and stick origin (29)

• The origin (29) is the dot shown in Illustrations 37 and 38. Origin is described in the topic "Origin" in the MCU Help file.

• Enter the distance (in meters or configured units) from the origin of the boom, stick, or bucket [A] to the front/back/left/right-hand side [B] of the boom, stick, or bucket buffer. The value of [A] increases for each successive Machine Buffer (0-4).

• Enter the distance (in meters or configured units) from the origin of the boom, stick, or bucket [A] to the top, or bottom [B] of the boom, stick, or bucket buffer. The value of High/Low increases/decreases for each successive Machine Buffer (0-4).

Examples:

Avoidance Boom Zone Front 0 =2

The warning zone for the front, buffer 0, of the defined area around the boom is set to 2 m.

Avoidance Bucket Zone Left 3 =6

The warning zone for the left-hand side (facing forward), buffer 3, of the defined area around the bucket set to 6 m.

Avoidance Stick Surface High 1 =2

The warning zone for the upper surface, buffer 1, of the defined area around the stick is set to 2 m. An avoidance surface 2 m above the machine will set off the warnings.

Avoidance Boom Surface Low 2 =4

The warning zone for the lower surface, buffer 2, of the defined area around the boom is set to four m. An avoidance surface 4 m below the machine will set off the warnings.

Buzzer Output

This setting applies to the Detect Strategy.

Use this setting to enable the "critical" and the "high" alarm tones for Detect Strategy avoidance alarms to be continuous rather than discrete.

Table 13

Buzzer Output
Possible Values	Discrete - adds 6 keys. Two 0.5 second sounds for "High" alarm; one 1.5 second sound for "Critical."" alarm. Continuous - removes 6 keys
Default	$ Buzzer Max Duration 21 =1800
Data Type	Standard enumeration (enum) parameter
Syntax	"High" $ Buzzer Tone 21 =<ff,ff,ff,ff,ff,ff,ff,ff,ff,ff,ff,ff> $ Buzzer Max Duration 21 =<1800 milliseconds> $ Buzzer Repeat Delay 21 =<1000 milliseconds> "Critical" $ Buzzer Tone 26 =<ff> $ Buzzer Duration 26 =<1500 milliseconds> $ Buzzer Repeat Delay 26 =<0 milliseconds>
Go To: site level	"Detect" > "Alarms" > "Proximity Tones" > "Buzzer Output"

Cable Shovel Machine Dimensions

"Machine Dimensions" > "Cable Shovel Machine Dimensions" now includes the following three options for machine type:

• Single antenna

• Dual antenna

• Electric Rope Shovel

Circle Radius

Use this setting to enter the radius of the target that appears on the Target window (a type of Plan window).

Table 14

Circle Radius
Possible Values	Any positive number
Default	Enabled
Data Type	Number
Units	Meters
Syntax	$ Target Tolerance =<distance>
Go To:	"Display" > "Target Window"

Example Target Tolerance =0.3

The target circle shown on the Target window is 0.3 m radius (0.6 m diameter). When the wick hole implement enters the circle, the two circles “snap'” together showing the operator that the implement is on target.

Reference: Refer to Special Instruction, REHS9107, "Installation of G610 Software for Cat^® Terrain for Wick Hole Excavators" for additional information.

Dig Maximum Angle

The maximum excavator or hydraulic front shovel bucket angle up to which the bucket can be considered to be digging. If the bucket angle is less than the value for the Dig Maximum Angle at the end of the digging process, the on-board software considers the bucket is loaded.

Table 15

Dig Maximum Angle
Possible Values	0 - 360
Default	60
Data Type	Integer
Units	Degrees
Syntax	$ Dig Maximum Angle =<degrees>
Go To:	"Machine" > "Machine Dimensions" > "Excavator Machine Dimensions"

The main purpose of this setting is to stop the software from creating a productivity record when the machine is cleaning up and not loading a truck.

After the hydraulic pressure triggers the dig switch, the software checks both Dump Minimum Distance and Dump Minimum Time. If the bucket has traveled the minimum distance, but the bucket has not dumped the load within the minimum time, then the software checks the bucket angle against the Dig Maximum Angle and the following applies:

• If the bucket angle is less than the Dig Maximum Angle, then the load is valid. The operator took longer than expected to dump the load.

• If the bucket angle is more than the Dig Maximum Angle, the material in the bucket is not a load being moved to truck. The operator is cleaning up.

Example Dig Maximum Angle =60

The software considers the bucket is digging up until 60 degrees. Above this angle the software considers the bucket is not digging.

Dipper Capacity

This setting is used in the MCU to calculate other settings, but is not used by the on-board software. The information will not appear in the mach_cfg.txt file.

Table 16 lists the values for dipper capacity.

Table 16

Dipper Capacity
Possible Values	Any positive number
Default	The first dipper capacity value in the dimensions table from the manufacturer
Data Type	Floating point
Units	Shown in MCU in cubic yards, used by MCU in cubic meters.
Syntax	No key exists
Go To:	"Machine" > "Machine Dimensions"

The values are entered in the MCU in the imperial units (cubic yards) specified by the manufacturer and outputted by the MCU in metric units (cubic meters) to the mach_cxfg.txt file for use by the on-board software.

For example, if the Dipper Capacity value in the MCU is 67 cubic yards, this value is converted into cubic meters and used by the on-board software, but does not appear in the mach_cfg.txt file.

Disable Mined Material in Dipper

Use this setting to enable the on-board software to stop using the material ID of the material under the cells designated "Mined Out" as the material in the dipper (bucket).

Table 17

Disable Mined Material in Dipper
Possible Values	Yes or No
Default	No
Data Type	N/A
Syntax	$ Disable Mined Material in Dipper =<value>
Go To:	"Productivity Output" > "Bucket Load Material"

Example Disable Mined Material in Dipper =Yes

The on-board software always lists the material in the bucket as "unidentified" when the software is mapping material status (mined out status).

Distance to Front Idler

This section applies to Terrain v5.2 and later.

This setting is used to enter the distance (in meters) from origin to the front idler along the dozer X-axis center line.

Note: The dozer origin is in the center of the rear drive wheel taken to the ground along the machine center line.

Table 18

Distance to Front Idler
Possible Values	Any positive number
Default	4.44
Data Type	Floating point
Units	Meters
Syntax	$ Distance To Front Idler =<distance>
Go To:	"Machine" > "Machine Dimensions" > "Distance to Front Idler"

Example Distance To Front Idler =4.44

The distance from the origin to the front idler along the dozer X-axis center line is 4.44 m.

Distance to Track Edge

This section applies to Terrain v5.2 and later.

This setting is used to enter the distance (in meters) from the dozer origin to edge of the track.

Note: The dozer origin is in the center of the rear drive wheel taken to the ground along the machine center line.

Table 19

Distance to Track Edge
Possible Values	Any positive number
Default	1.8
Data Type	Floating point
Units	Meters
Syntax	$ Distance To Track Edge =<distance>
Go To:	"Machine" > "Machine Dimensions" > "Distance to Track Edge"

Example Distance To Track Edge =1.8

The distance from the origin to the edge of the track line is 1.8 m.

Dump Maximum Angle

The maximum bucket angle at which the software considers the bucket is unloading material.

Used with the Dump Minimum Angle and other settings.

Note: This settling usually applies to excavators only, as operators of hydraulic front shovels usually trigger the dump by opening the dipper door and not by tipping the bucket.

Table 20

Dump Maximum Angle
Possible Values	0 - 360
Default	180
Data Type	Integer
Units	Degrees
Syntax	$ Dump Maximum Angle =<degrees>
Go To:	"Machine" > "Machine Dimensions" > "Excavator Machine Dimensions"

Example Dump Maximum Angle =180

The software considers the bucket unloaded when the bucket angle is greater than the Dump Minimum Angle and less than 180 degrees.

Dump Minimum Angle

The minimum bucket angle at which the software considers the bucket is unloading material.

Used with the Dump Maximum Angle and other settings.

Note: This settling usually applies to excavators only, as operators of hydraulic front shovels usually trigger the dump by opening the dipper door and not by tipping the bucket.

Table 21

Dump Minimum Angle
Possible Values	0 - 360
Default	90
Data Type	Integer
Units	Degrees
Syntax	$ Dump Minimum Angle =<degrees>
Go To:	"Machine" > "Machine Dimensions" > "Excavator Machine Dimensions"

Example Dump Minimum Angle =90

The software considers the bucket unloaded when the bucket angle is greater than 90 degrees and less than the Dump Maximum Angle.

ERS Dipper Weight Offset

This section applies to Cat ERS 7495 only.

Use this setting to create an offset to correct any persistent inconsistency in the dipper weight as defined by the MTDipperWeightNow tag.

Table 22

ERS Dipper Weight Offset
Possible Values	Any number
Default	0
Data Type	Floating point
Units	Percentage
Syntax	$ ERS Dipper Weight Offset =<number>
Go To:	"Machine" > "Machine Dimensions"

Add or subtract the ERS Dipper Weight Offset percentage as required. The "Dipper weight" value is represented in Terrain Display Units.

Example ERS Dipper Weight Offset =-10 (negative 10)

The on-board software calculates 10% of the MTDipperWeightNow value and then subtracts the value from the MTDipperWeightNow value to arrive at the weight of the current load in the dipper.

Excavator Bucket Move Threshold

The minimum distance (in meters) that the excavator or hydraulic front shovel bucket tip must travel to trigger a swath update.

This feature is used for mapping.

Table 23

Excavator Bucket Move Threshold
Possible Values	Positive number
Default	2
Data Type	Floating point
Units	Meters
Syntax	$ Excavator Bucket Move Threshold =<meters>
Go To:	"Mapping" > "Swath Settings"

Example Excavator Bucket Move Threshold =2

When the excavator bucket tip moves 2 m from the dig point, the software considers the excavator is digging and has useful information to show in the as-built surface files.

Excavator Dump Minimum Distance

The minimum distance (in meters) between changes in the excavator or hydraulic front shovel bucket position which can trigger a change of dig state to “Dumping” (if other pre-requisites are met).

Use with Excavator Dump Minimum Time.

Table 24

Excavator Dump Minimum Distance
Possible Values	Positive Number
Default	8
Data Type	Floating Point
Units	Meters
Syntax	$ Excavator Dump Minimum Distance =<distance>
Go To:	"Machine" > "Truck Loading"

Example Excavator Dump Minimum Distance =8

The software will not recognize a change of dig state from "Dig" to "Dump" within 8 m of the initial dig point for this dig cycle. The operator is digging in an area 8 m from the initial dig point and must move further than 8 m to the truck.

Excavator Dump Minimum Time

The minimum time (in milliseconds) between changes in the excavator or hydraulic front shovel bucket angle which can trigger a change of dig state to “Dumping” (if other pre-requisites are met).

Use with Excavator Dump Minimum Distance.

Table 25

Excavator Dump Minimum Time
Possible Values	Positive Number
Default	3000
Data Type	Integer
Units	Milliseconds
Syntax	$ Excavator Dump Minimum Time =<time>
Go To:	"Machine" > "Truck Loading"

Example Excavator Dump Minimum Time =3000

The software will not recognize a change of dig state from “Dig” to “Dump” within 3000 milliseconds (3 seconds) of a change in bucket angle. The operator is assumed to be digging for 3 seconds and any change in bucket angle during the 3 seconds does not count as a dump signal.

Excavator Load Wait Time

The time (in milliseconds) the on-board software waits before changing the excavator or hydraulic front shovel dig state from "Dig" (if other pre-requisites are met). The time is measured from the last time the hydraulic pressure sensor showed that the machine was digging. This is the first pre-requisite for the software deciding whether the machine has finished digging.

Table 26

Excavator Load Wait Time
Possible Values	Positive Number
Default	2000
Data Type	Integer
Units	Milliseconds
Syntax	$ Excavator Load Wait Time =<time>
Go To:	"Machine" > "Truck Loading"

Example Excavator Load Wait Time =2000

When the excavator has been digging and has stopped digging for 2000 milliseconds (2 seconds), the software can consider other data and decide whether the machine has finished digging.

Excavator Maximum Load Distance

The maximum distance in (meters) that the excavator or hydraulic front shovel bucket tip can travel, while digging, to trigger a change in dig state (if other pre-requisites are met).

Use with Dig Maximum Angle.

Table 27

Excavator Maximum Load Distance
Possible Values	Positive Number
Default	15
Data Type	Floating Point
Units	Meters
Syntax	$ Excavator Maximum Load Distance =<distance>
Go To:	"Machine" > "Truck Loading"

If the machine is between the Excavator Minimum Load Distance and Excavator Maximum Load Distance, and between the Excavator Minimum Load Time and the Excavator Maximum Load Time, the machine is loading a truck. Outside this range of values, the machine is considered to be moving but not loading a truck. For example, the machine may be cleaning up or moving between locations.

Example Excavator Maximum Load Distance =15

When the excavator bucket tip moves more than 15 m from the dig point, the software considers the excavator is not digging or dumping.

Excavator Maximum Load Time

The maximum elapsed time (in milliseconds) that the dig state must be "Dig" before the on-board software can consider the excavator or hydraulic front shovel bucket has finished digging (if other pre-requisites are met).

Use with Dig Maximum Angle.

Table 28

Excavator Maximum Load Time
Possible Values	Positive Number
Default	300
Data Type	Integer
Units	Milliseconds
Syntax	$ Excavator Maximum Load Time =<time>
Go To:	"Machine" > "Truck Loading"

If the machine is between the Excavator Minimum Load Distance and Excavator Maximum Load Distance, and between the Excavator Minimum Load Time and the Excavator Maximum Load Time, the machine is loading a truck. Outside this range of values, the machine is considered to be moving but not loading a truck. For example, the machine may be cleaning up or moving between locations.

Example Excavator Maximum Load Time =6000

When 6000 milliseconds (60 seconds) has elapsed with the dig state "Dig", the software considers that the dig state is now not "Dig".

Excavator Minimum Load Distance

The minimum distance in (meters) that the excavator or hydraulic front shovel bucket tip must travel, after digging, to trigger a dig state "Dump" (if other pre-requisites are met).

Use with Dig Maximum Angle.

Table 29

Excavator Minimum Load Distance
Possible Values	Positive Number
Default	0.5
Data Type	Floating Point
Units	Meters
Syntax	$ Excavator Minimum Load Distance =<distance>
Go To:	"Machine" > "Truck Loading"

If the machine is between the Excavator Minimum Load Distance and Excavator Maximum Load Distance, and between the Excavator Minimum Load Time and the Excavator Maximum Load Time, the machine is loading a truck. Outside this range of values, the machine is considered to be moving but not loading a truck. For example, the machine may be cleaning up or moving between locations.

Example Excavator Minimum Load Distance =0.5

When the excavator bucket tip moves more than 0.5 m from the dig point, the software considers the excavator is not digging or dumping.

Excavator Minimum Load Time

The minimum elapsed time (in milliseconds) that the dig state must be "Dig" before the on-board software can consider the excavator or hydraulic front shovel bucket has finished digging (if other pre-requisites are met).

Table 30

Excavator Minimum Load Time
Possible Values	Positive Number
Default	300
Data Type	Integer
Units	Milliseconds
Syntax	$ Excavator Minimum Load Time =<time>
Go To:	"Machine" > "Truck Loading"

If the machine is between the Excavator Minimum Load Distance and Excavator Maximum Load Distance, and between the Excavator Minimum Load Time and the Excavator Maximum Load Time, the machine is loading a truck. Outside this range of values, the machine is considered to be moving but not loading a truck. For example, the machine may be cleaning up or moving between locations.

Use with Dig Maximum Angle.

Example Excavator Minimum Load Time =3000

When 3000 milliseconds (3 seconds) has elapsed with the dig state "Dig", the software considers that the bucket has finished digging.

Force Activity

Use this setting to enable or disable the "Activity Select" dialog to appear at start-up.

Table 31

Force Activity
Possible Values	No - Disables dialog Yes - Enables dialog
Default	No
Data Type	NA
Units	No column
Syntax	$ Force Activity =<value>
Go To:	"Operator Interaction" > "Operator Input" > "Activity" > "Force Activity"

The "Activity Select" dialog appears after the operator log-on. The activities are contained in an activities.mwf file.

Reference: For additional information on the "Delayed" dialog, refer to the "Entering Delay Codes" section of Operation and Maintenance Manual, SEBU8841, "General Information (Operator Utilities)".

Click the checkbox to enable this setting. Clear the check box to disable the setting.

Example Force Activity =enabled

At startup, the "Activity Select" dialog opens and the operator is forced to select an activity.

MTAlpha Offset

This section applies to Cat ERS 7495 only.

Use this setting to create an offset to account for any difference between the measured MTAlpha angle and the MTAlpha angle that is supplied by the Programmable Logic Controller (PLC).

Table 32

MTAlpha Offset
Possible Values	Any number
Default	5
Data Type	Integer
Units	Degrees
Syntax	$ Electric Rope Shovel MTAlpha Offset =<angle>
Go To:	"Machine" > "Machine Dimensions"

Example MTAlpha Offset =5

The MTAlpha offset is set to 5 degrees. The 5 degree offset corrects a persistent inconsistency in the MTAlpha angle that is supplied by the PLC.

Spot Dump Distance

This section applies to Cat ERS 7495 only.

This setting is not a Command setting.

Use this setting to specify the distance, in meters, from the spot location that the operator can trip the dipper and be considered a dump to the truck.

Table 33

Spot Dump Distance
Possible Values	Any number
Default	25
Data Type	Floating point
Units	Meters
Syntax	$ ERS Spot Dump Distance =<number>
Go To:	"Machine" > "Machine Dimensions"

The software adds the weight to the loaded weight of the truck. The setting is enabled and defaults to 25 m with or without selecting the Spot Dump Distance check box.

Set Use Cat ERS Dipper Weight to specify the source of the dipper weight value.

Example Spot Dump Distance =4

The operator can dump the dipper load within 4 m of the spot location and the software adds the weight of the load to the truck weight.

Payload Conversion

The default value is now 1.0.

Note: This default is applied in the on-board software even when the setting is not enabled. Enabling the setting overwrites the value at the site level.

Pitch Brace Length

Use the length of the pitch brace to adjust the dipper angle relative to the centerline of the crowd system.

Table 34 the lists the values for pitch brace length.

Table 34

Pitch Brace Length
Possible Values	Any positive number
Default	The first pitch brace length value in the dimensions table from the manufacturer
Data Type	Floating point
Units	Shown in MCU in inches and used by MCU in meters.
Syntax	No key exists
Go To:	"Machine" > "Machine Dimensions"

Use the Pitch Brace Length to adjust the dipper angle relative to the centerline of the crowd system. The manufacturer provides the initial "Pitch Brace Length" and brace widths in inches. These values are dependent on the dipper capacity selected from the dimensions table from the manufacturer.

The Dipper Capacity value is used by the MCU to calculate "Dipper Angle" but the value is not used by the on-board software and the information will not appear in the mach_cfg.txt file.

Illustration 39	g03659859
Adjusting the Pitch Brace Length

Plates are added or removed (7) as shown in Illustration 39 to adjust the length of the pitch brace (6), which in turn adjusts the raked angle.

The values are entered in the MCU in imperial units (inches) specified by the manufacturer and outputted by the MCU in metric units (meters) to the mach_cxfg.txt file for use by the on-board software.

Example If the Pitch Brace Length value in the MCU is 63.0 inches, this value is converted into meters and used by the on-board software.

Profile Update Interval

The Profile Update Interval setting specifies the interval in seconds that a Profile window is to be updated. The value in the MCU for v5.2 has been hard-coded to 20ms.

A Profile window is updated when the machine moves only if the time elapsed since the last update is greater than or equal to this threshold interval.

Note: The setting is still available for versions prior to v5.0, but Caterpillar recommends using a value of 0.20 seconds and not the stated default of 1 second.

Table 35 lists the values for the profile update interval.

Table 35

Profile Update Interval
Possible Values	Pre v5.0 - Any positive number
Default	Pre v5.0 - 1 v5.2 - hard coded to 0.20 (20ms)
Data Type	Integer
Units	Seconds
Syntax	$ Profile Update Interval =<interval>
Go To:	"Display" > "Profile"

Use Cat ERS Dipper Weight

Select the setting to use the accumulated dipper weights of the Cat ERS 7495 to determine the total weight of material in the truck, rather than the truck weight in the Peer to Peer message.

Table 36

Use Cat ERS Dipper Weight
Possible Values	Yes - Use Cat ERS accumulated weight from OPC No - Use weight in Peer to Peer message weight from truck
Default	No
Data Type	NA
Syntax	$ Use Cat ERS Dipper Weight =<value>
Go To:	"Productivity Output" > "Truck Weight"

Example: Use Cat ERS Dipper Weight =Yes

The on-board software adds the weights of all dippers determined by the OPC system on the Cat ERS since the last Send Truck command or reboot, and then reports this weight as the truck weight.

Use Dig Switch

Select this setting to enable or disable the dig switch in machines that are using sensors prior to Terrain v5.2.

Note: The MCU will find a mismatch between machines using dig sensors and mach_cfg prior to Terrain v5.2 and the new MCU and will alert the office to an incorrect mach-cfg.

Note: For machines using the high accuracy dipper position system (Danfoss 364-5409 Pressure Switch), use the Dig Debounce Durations settings. Do not select Use Dig Switch because Use Dig Switch overrides all Dig Debounce Durations settings.

The dig state describes whether the machine is "Dig", "Idle", or "Dump". Digital windows can have the color function set to show the dig state, and the dig state can also be added to a digital window as a text item. The dig state is also used internally by the on-board software for certain features.

Table 37

Use Dig Switch
Possible Values	Yes or No
Default	Yes
Data Type	NA
Syntax	$ Use Dig Switch =<value>
Go To:	"Machine" > "Switches"

Example Use Dig Switch =yes

The dig switch is enabled and the machine uses legacy sensors to decide what dig state the dipper is in.

Validation Error Messages

Table 38 lists validation error messages and the action to take when the message occurs.

Table 38

Validation Error Messages
Error Message	Required Action
CAT ERS 7495 GPS x value must equal -4.645.	Enter the master GPS x, y, z offsets specified for the Cat 7495 electric rope shovel. The slave offsets are hardcoded.
CAT ERS 7495 GPS y value must equal 7.824.
CAT ERS 7495 GPS z value must equal 12.205.
Disable Max Bucket Log Count when using Command security settings.	If using Command, then disable "Max Bucket Log Count" because an operator must manually send the truck.
Disable Save Activity when using Force Activity.	If using Force Activity then disable Save Activity. Do not use these settings at the same time.
If Machine Model is set to "CAT ERS 7495", then OPC Server must be enabled.	Enable the OPC Server setting.
If OPC Server is enabled, then Machine Model must be set to "CAT ERS 7495".	Select "Machine Model" in the MCU as "Cat ERS 7495"
Must have body buffer enabled.	Enable machine buffer and a boom/stick/bucket buffer.
Must not be blank.	One or more of the "Machine" > "Security" > "Security" fields is invalid or the "ERS URL" field is blank.
Must select "Original Ground" as the Category.	The volume record in the productivity file needs Category = Original Ground.
The value must be a multiple of 100.	The value must be a multiple of 100 to use the CAN port. Use with Send Avoidance Messages setting.
This machine now records data from the whole site.	Select an original elevation design file, a swath option for original elevation, and enable the Volume Design Limited setting.

Cat Tools Release Notes

Productivity File Processing replaces the Cat 2DB functionality that was previously a separate tool. This functionality is now part of the office software, and is accessible by Administrator users only.

For additional information, refer to Systems Operation, RENR9562, "Terrain Office Software" or the on-line help in the office software

Cat FTPserver Release Notes

There are no Cat FTPserver release notes for v5.2.

Cat Office Services (CatOS) Release Notes

There are no Cat Office Services release notes for v5.2.

CAES Database Release Notes

There are no CAES Database release notes for v5.2.

Task List Management System (TLMS) Release Notes

The tasks that are shown in the task list are those tasks that are positioned within a radius around the machine. The radius is the value in the "Show Tasks Within" field. Tasks that are assigned as "On Hold" or "In Progress" are not filtered. The Operation and Maintenance Manual has been updated to clarify that assigned tasks are not filtered.

Receivers

Changes in v5.2

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NOTICE
MS980 receivers are not supported in Terrain v5.2. If using Terrain v5.2, Caterpillar strongly recommends replacing all MS980 receivers that are in the field with newer supported receivers.

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NOTICE
Do not use the automatic upgrade feature with an MS980 receiver. The upgrade process will stop the MS980 receiver from working. The stopped receiver cannot be fixed.

The on-board software now uses a more advanced GNSS receiver handling process. This process requires minimum firmware on the receivers. The Terrain software checks the receiver, captures the model and firmware version, and then notifies the user to update, if necessary. Also, the Terrain v5.2 software installer (TerrainGLExtractor .5.2.exe) places the latest firmware in the caes\temp folder.

The following user input will be required at the time of upgrading to v5.2:

• If sites wish to upgrade firmware, restart the software and accept the Upgrade Firmware message. The upgrade may take up to 30 minutes per receiver.

• If sites do not desire to upgrade the current firmware, and the current firmware is above the minimum firmware version, remove the latest firmware from the caes\temp folder to stop the upgrade process from beginning at every startup.

Serial versus CAN for v5.2

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NOTICE
The more advanced GNSS/GPS handling process requires CAN communication to the receiver. Although some receivers listed in Table 39 have been tested with serial communications, Caterpillar recommends that the on-board software communicates with the receiver over a CAN bus for optimum performance.

Table 39 provides the support matrix for the GPS/GNSS receivers.

Table 39

Receiver Device	Communications
	Serial	CAN
MS972	No	Yes
MS980	Yes	Yes
MS990	Yes	Yes
MS992	Yes	Yes
7400	Yes	-
4000	Yes	-

Note: Factory fit machines use serial communications with the receiver.

Reference: Refer to Special Instruction, REHS9109, "Installation and Configuration of Cat^® Terrain v5.2 On-board Software", "Firmware Matrix" for additional information on configuring satellite receivers.

Firmware for v5.2

Use v5.2 Terrain for grading, loading, and mobile applications with the minimum firmware listed in Table 40.

Table 40

Receiver	Minimum firmware version(1)	Latest firmware included on USB
MS9x0 Series
MS990	3.9	4.49/3.81 "MS990449.s"
MS980(2) Dual antenna	Remove for v5.2.	NA
MS980(2) Single antenna	Remove for v5.2.	NA
MS9x2 Series
MS992 Single and Dual antenna	4.45/0.42	4.89 “MS9x2489.s”
MS972
MS952

(1)	First number listed is application firmware version, second number is monitor version
(2)	Do not use the automatic upgrade feature with a MS980 receiver. The upgrade process will stop the MS980 receiver from working. The stopped receiver cannot be fixed.

The on-board software installer, TerrainGLExtractor.5.2.exe, places the latest firmware in the caes\temp folder during the install/upgrade process. At each start-up, the on-board software compares the latest firmware in the caes\temp folder to the firmware on the receiver. If the version numbers are different, the software asks the user whether to upgrade.

Automatically Check Receiver Firmware

This section applies to G610 display modules with CAN GNSS communication. This section does not apply to factory-fit machines or to v3.x.

Illustration 40	g03662148
“Upgrade Firmware” request dialog

At each start-up, the on-board software compares the latest firmware in the caes\temp folder to the firmware on the receiver.

Note: The software upgrades dual antenna systems one receiver at a time. Allow 1 hour to upgrade both receivers.

If the version number is a higher version than already installed on the receiver, the software displays a dialog requesting whether the user wants to upgrade.

Illustration 41	g03662153
"Upgrade Firmware" lower version dialog

If the firmware found in the caes\temp folder is a lower version than already installed on the receiver, the on-board software checks before beginning to downgrade and presents the user with a dialog confirming whether to proceed. The upgrade process is described in the following section.

Upgrading Receiver Firmware

Each site will create a plan for upgrading the receiver firmware.

The receiver firmware must be upgraded if the current firmware is below the minimum firmware for your receiver.

Do not upgrade receiver firmware until asked by the Terrain Site Champion, a site manager, or the Terrain dealer.

To upgrade the MS9xx receiver to the latest version, complete these steps:

1. Place the new firmware in the caes\temp folder or verify that the firmware exists.

   When installing Terrain v5.2 and above, the install process automatically adds the latest receiver firmware to the caes\temp folder. It is not necessary to add the firmware to the caes\temp folder.

   Note: Prior to Terrain v5.2, the new firmware must be added to the caes\temp folder, usually by copying from the USB memory module. Do not store multiple firmware files in the caes\temp folder. For best practice, there should be only one file in the caes\temp folder.

2. Start the on-board software and clear any position-based error messages, so the office and other machines know the position of the machine while stationary.

3. For G610 display modules using CAN GNSS communication, at each start-up the on-board software compares the firmware in the caes\temp folder to the firmware on the receiver. If the on-board software finds more than one file, the lowest versions are ignored.
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   Illustration 42	g03662159
   "Upgrade Firmware" to higher version message dialog

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   Illustration 43	g03662160
   "Upgrade Firmware" to lower version message dialog

4. If the firmware versions are different, one of the messages in Illustration 42 or 43 appears:

5. Select the appropriate response.

   OK - Select "OK" to upgrade the firmware to a higher or a lower version than the version that is currently on the receiver. This upgrade may take up to 30 minutes for each receiver. If the process is canceled or disrupted, then the receiver uses the current firmware. Do not move or work during this time.

   Cancel - Exit without upgrading the firmware. When using Terrain v5.2 and above, select "Cancel" if an MS980 receiver is still attached to the harness. Remove the receiver, replace with a valid receiver, and start the upgrade process again.

   Show/hide table

   Illustration 44	g03663314
   "GPS Configuration" cannot configure dialog

6. If the on-board software is communicating with the receiver over CAN and does not finish the upgrade correctly, the error message in Illustration 44 (stated below) appears on the display:

“The on-board software cannot configure the receiver because the receiver firmware is too old or the receiver does not have the features required. Contact your supervisor.”

If for some reason the firmware is not available in caes\temp, the following occurs:

• The red-colored "No GPS" icon appears on lower Status bar.

• The system does not calculate your position, the gauge window is yellow, and digital windows showing position accuracy as the background color change from green to another color.

• An error message stating that the receiver firmware is not up to date appears on the display module. This error indicates that the software cannot calculate your GPS position.

Firmware for v5.2

Use v5.2 Terrain for grading, loading, and mobile applications with the minimum firmware and recommended firmware listed in Table 41:

Table 41

Receiver	Minimum firmware version (1)	Recommended firmware included on USB
MS9x0 Series
MS990 (application / monitor)	3.9/0.42	4.49/3.21 “MS990449.s”
MS980 (application / monitor)	1.5/0.04	1.62/1.10 “MS980162.s”
MS9x2 Series
MS992 Single and Dual antenna	4.45/0.42	4.89 “MS9x2489.s”
MS972
MS952

(1)	first number listed is application firmware version, second number is monitor version

Configuration Toolbox for v 5.2

There are no updates for this release.

Known Issues

Activity Category Mapping Produces Inconsistent Colors

There are many possible methods to set up mapping based on activity, but many of these methods produce inconsistent colors on the screen while swathing and during updates.

To show consistent colors when setting up the Activity category Mapping feature, complete the following steps:

1. Enable the Activity Category Map.

2. Set one "Swath Option" > "Category setting" to "Coverage".

3. Set the associated "Swath Option" > "Swath Point" to "All Points".

BC and DC Options Reset Unnecessarily

This Known Issue applies to the following Digital window options:

Material Dipper Count (BC) - This value is the number of dippers or buckets of the predominant material (MT).

Dipper Count (DC) - This value is the total number of dippers or buckets contained in a truck.

Digital windows provide the operator with information such as the truck name and the dipper count. When the operator opens and closes, or cycles through, a diagnostic screen, the v5.0 software resets both the "BC" and "DC" values in the Digital window to "0" (zero).

The correct values appear after the next load/dump cycle.

Cable Shovel Jumps in Fleet Window

In the "Fleet" > "Machine Types" tab, the Cable Shovel (single antenna) machine type can move erratically in some configurations of Fleet.

Complete the workaround below to resolve the erratic behavior:

1. Open the Fleet office software, MineStar Client.

2. Select "Contents" > "Pit Link" > "Machine Finder".

3. Highlight the required machine class, then right-click and select "Open Class".

4. Highlight the "Cable Shovel" machine class.

5. In the "Machine Types" tab, do not select the "Use Center of Rotation" checkbox.

   Note: Deselecting the checkbox does not alter the function or configuration of the machine, nor does it alter the measurements that are entered.

This workaround has been tested with the following software:

• Fleet v4.0

• Terrain on-board v5.2

Crash Report - Maximum Size

Software developers use error reports to solve the problems that cause the software to crash. CrashReport is the error reporting function which adds built-in diagnostic capability for the Terrain v5.2 on-board software.

If the on-board software crashes, the following files appear in the CAES\CrashReport folder:

• A screen snap

• caes_IllegalShutdown.txt

• crashdump.dmp

• crashrtp.xml

• file_cfg.txt

• mach_cfg.txt

• master_cfg.txt

This folder can be large, in general > 20 mb. If the CrashReport is large, the transfer to the office may fail. Keep the CrashReport folder on the machine to a minimum to ensure that, in the unlikely event of a crash, the software can send the CrashReport to the office quickly and efficiently.

The CrashReport also includes the following folders:

• config

• diag

• MineStar

• snip

• temp

Consider deleting unwanted files from these folders to ensure that the CrashReport file remains as small as possible.

Deleting a Task Affects Reports

The Task List Management System archives all completed and canceled tasks for reporting purposes. Deleted tasks are archived but with a blank “Task Action” field.

Note: Tasks are deleted for various reasons, for example to remove the task completely or to correct an incorrectly entered and saved Task Action. Understand how your site deletes tasks before reading a report.

Duplicate "Send Avoidance Messages" Setting

Illustration 45	g03662178

As shown in Illustration 45, the "Send Avoidance Messages" setting appears twice. The repetition is cosmetic and does not affect the way the machine works.

Remove this unusual repetition from the MCU by completing these steps:

1. De-select "Send Avoidance Messages".

2. Restart the MCU server.

3. Select "Send Avoidance Messages".

   The setting appears once.

ERS Hoist Rope Force

The PLC system measures the force on the hoist rope continuously and this value is displayed in the "Diagnostics" > "OPC" screen. The force on the hoist rope would be expected to be about "0" (zero) while the dipper is at rest on the ground, and to have a positive value while the dipper is digging or swinging.

Icon Names in Material Toolbar are Incorrect

A Material Toolbar with the "Recent Materials" option selected may have incorrectly named icons. The correct number of icons appears on the toolbar, the icons change color when the operator selects "Send Truck" and the material that is stored in the productivity files is correctly named. However, the icon names (if shown) may be incorrect.

For additional information, refer to "Unexpected Functions in Material Toolbar"

Incorrect Timestamp for Position

Timestamps are digital date and time information that are attached to digital data. Both the satellite receiver and the internal Position Report2 (PR2) messaging components of the system create timestamps.

On rare occasions, the timestamp from the satellite receiver differs from the timestamp associated with the PR2 message. The cause is unknown and the difference can persist for up to 2 minutes. There is no work-around for this known issue.

The error occurs on all machine types on a site and for all applications including:

• Drills

• Draglines

• Grading

• Loading

• Supervisor Trucks

Illustration 46	g03387093
GPS Diagnostics window (24) Position status = Autonomous (25) GPS Warning icon

When the difference between the timestamp from the satellite receiver and the timestamp associated with the PR2 message is greater than 4 seconds, the following actions occur:

• The Position status (24) changes to "Autonomous".

• The yellow or red GPS warning icon (25) in the status bar appears.

Menu - Opens the main menu

• The position error in the PR2 message is "100.90 m". In the main menu, open "Diagnostics" > "Detect". The "Accuracy" = "100.90".

• Information appears in the DiagMsgLog File. In Windows Explorer, open C:\\caes\diag and look for the information in Table 42.

Table 42

DiagMsgLog File Error - Incorrect Timestamp for Position
In Microsoft Windows Explorer open C:\\caes\diag and look for:
Warning, 17:11:30, 1400, GPS, <-- Terrain and GPS Time lagging Started DbgLvl2, 17:11:34, 1398, Postion Sent, Timer DbgLvl2, 17:11:39, 1398, Postion Sent, Timer DbgLvl2, 17:11:44, 1398, Postion Sent, Timer 'CAESip.exe': Loaded 'C:\Windows\SysWOW64\rasapi32.dll' 'CAESip.exe': Loaded 'C:\Windows\SysWOW64\rasman.dll' 'CAESip.exe': Loaded 'C:\Windows\SysWOW64\rtutils.dll' 'CAESip.exe': Loaded 'C:\Windows\SysWOW64\SensApi.dll' DbgLvl2, 17:11:49, 1398, Postion Sent, Timer DbgLvl2, 17:11:54, 1398, Postion Sent, Timer Warning, 17:11:55, 1400, GPS, Terrain, and GPS Time lagging Ended

There is no work-around for this known issue. This issue is also described in Systems Operation, KENR8277, "Cat^® Terrain for Grading and Loading", "Error Codes and Diagnostic Messages".

Lengthy Logoff When Using CE KPI CSV

When an operator logs off, Terrain updates the KPI values in the CE KPI csv file by making a copy of the current elevation as-built surface file, "CAES\data\currelevtime.cat", that is "Prime" up until the time of log-off.

The larger the Current Elevation design file is, then the longer the software takes to copy the file. This delay may become especially noticeable at operator logoff when using a current elevation file of 50 MB or greater. For example, a 50 MB Current Elevation design file may delay the logoff by up to 10 seconds, while a similar 90 MB file may delay the logoff by up to 30 seconds.

Machine Buffers Reappear

This known issue describes the use of machine buffers and does not describe the Body, Avoidance, or Path regions used in sites that are running office software with Detect enabled.

Menu - Opens the main menu

The operator can stop the avoidance buffers from appearing on the Plan window by opening the main menu and de-selecting "Plan" > "Display" > "Machine Buffers".

When the operator changes screens, or opens a full page window such as a diagnostic window, the buffers reappear.

"Machine Name" Menu Item Does Not Work with Position Awareness or Detect

In the on-board software main menu, the item "Plan" > "Display" > "Machine Name" makes the name of all machines visible on the Plan window.

This item works for machines that are not using Position Awareness or Detect, in general legacy machines using early versions of the on-board or office software.

This item will not work for machines on a site running Terrain with Detect or using Fleet office software. The nature of Position Awareness or Detect on these sites requires the machine name to be visible at all times. The operator will not always have the option to turn OFF or ON the machine name.

Manual Dig State Not Consistent

Manual Dig State button

The Manual Dig State button was designed to give the operator visual feedback in two ways:

• The button changes color when selected (toggles ON and OFF).

• The background color of a Digital window changes when the Manual Dig State is selected and indicates whether the machine state is "Dig", "Idle", or "Dump".

In Terrain v4.2, 4.5 and 5.x the button does not change color and the green "Dig" background color only appears briefly before reverting to the yellow "Idle" or the blue "Dump" state.

Reference: Refer to Operation and Maintenance Manual, SEBU8822, "Cat^® Terrain v5 for Grading and Loading", "Advanced Tasks (Material/Ore)" in the section entitled “Manually Triggering a Dig State” for more information about the manual dig button.

MS740 Series Receivers with Fleet

Sites running Position Awareness (Cat MineStar System Control Center office software) and Site Awareness (Fleet) must check the series of receivers being used on machines running Terrain for grading, loading, and mobile applications.

The MS740 series receiver, and receivers older than the MS740 series, cannot send some values that are required for the messages used between the office and on-board software.

Sites must note the following:

• Sites running Site Awareness must remove MS740 (or older) receivers and use a GNSS receiver which supports "SiteVision Position Error Statistics" in the GSOF Output. Talk to your Cat dealer about which receivers to use.

• Sites running Position Awareness can continue to use old receivers but should note that the machine responds as noted in Table 43:

Table 43

Position Status	Reported Numeric Error	Appearance in Plan Window
"RTK Fixed"	2 cm	No change to size of machine regions
"RTK Float"	20 cm
"DGPS"	1 m
"Autonomous"	3 m	Whichever is bigger of: - Outer machine region - Single region, radius = 3 m
"No GPS"	100 m	Machine regions merge into a single region, radius = 100 m
"Error"	100 m	Machine regions appear as a single region, 100 m radius

Menu - Opens the main menu

To view the machine regions on the display, open the main menu and select "Plan" > "Display" > "Machine Regions".

Payload Conversion

If using VIMS for truck tons, check the Payload Conversion setting in the MCU. The default values in the on-board software and in the MCU have changed. Truck Tons is "TT" in the Digital window.

Payload Conversion Key

The value for the Payload Conversion key in the MCU is currently set to "0.1". If using this key, reset this value to "1" or the conversion will be incorrect.

Plan Window "Display" Options

Menu - Opens the main menu.

Illustration 47	g03662167
Navigating to "Machine Buffers" in main menu

In the main menu select "Plan" > "Display". The features in Illustration 47 appear.

A check mark to the left of the feature indicates that the feature is selected.

Textual Information

The following features display textual information for the operator:

"Text" - Names of material on Material Plan window

"Target Text" - Identities (ID) for wick holes on Target window

"Legend" - A small window that describes the materials present on the current Material Plan window

"Machine Names" - Name of each machine

There are two choices to turn off the textual options. The option can be turned off either temporarily or permanently.

Temporary - While on the current screen, turn off the option. The text associated with the option disappears, but returns again when the operator changes the screen or opens a diagnostic window.

Permanent - To turn off the option so the option stays off, consecutively turn off the option from each screen before returning to the original screen.

Line Work

The following features display line work:

"Machine Buffers" - Line work that is around a machine when using Avoidance Strategy

"Machine Regions" - Line work that is around a machine when using Detect Strategy

"Tin Lines" - Line work on the design used by surveyors

While on any screen, turn off (uncheck) the option to remove the line work from all screens.

Illustration 48	g03662176
Turn off machine buffers and line work disappears

For example, to stop the avoidance buffers from appearing on the Plan window, turn off "Plan" > "Display" > "Machine Buffers". The line work disappears as shown in the bottom Plan window in Illustration 48.

Position Error = "1.022": Workaround

Illustration 49	g03417097

A system working with High accuracy will report a "Position Error" value in the GPS Diagnostics window similar to the "0.003" shown in Illustration 49. For systems working at Medium or Low accuracy, technicians and installers may notice that a Position Error that is repeatedly reported as "1.022". A mismatch may also be noted between known accuracy and reported accuracy, and the regions of the machine may expand incorrectly as accuracy decreases. The unusual repetition of 1.022 occurs only for software with an up-to-date app file which includes a "SiteVision Position Error Stats" (SVPE Stats) GSOF output.

Illustration 50	g03417098

Users should not be concerned because the on-board software functions as intended. If the site wishes to stop this unusual repetition from occurring, edit the app file to include the Message subtype "Error Covariance data" as an extra GSOF output.

The SVPE Stats output is a small message providing Position Error values up to a maximum of 1.022. This value provides enough information to the on-board software for High accuracy positions.

If you wish to receive Position Error values for Medium and Low accuracy positions, enable the "Error Covariance data" output. The "Error Covariance data" output is a larger message containing Position Error values ("Position Sigma Info") outside the range of values contained in SVPE Stats.

Reference: For more information about configuring an app file, refer to the "CToolbox User Guide.pdf", which is available on the Terrain USB memory module.

Productivity Reset Button with Utilization Window

Productivity Reset - Select this button to reset the productivity information.

The Productivity Reset button/function when used for resetting times on a Machine Utilization screen does not perform a complete reset.

The following known issue occurs:

• If you are moving, the Productivity Reset button resets the "Stationary" time and the stationary component of "On" time to zero.

• If you are stationary, the Productivity Reset button sets the "Moving" time and the moving component of "On" time to zero.

Reducing the Distance Between Avoidance Zones

Site managers use avoidance zones and avoidance surfaces to remind the operator to avoid entering specific areas on the site. When two avoidance areas are within close proximity, the acknowledge icon and the mute alarm icon may not work as expected.

Zones are created in two separate strategies:

Avoidance Strategy - Uses zones and surfaces stored in *.cat files that are generated from DXF files in Terrain office software

Proximity Strategy - Uses zones stored in *.mwf files created in Command, Detect, and Fleet office systems

The on-board software from v5.0 onwards supports both types of files.

- Known issue

This known issue relates to the following:

• Avoidance Strategy only and may apply in systems using the Avoidance Strategy with a Remote Control Console

• Avoidance Strategy, using *.cat files, and the Status bar icons

Illustration 51	g03387092
(20) Mute Alarms: All allowable alarms now and in the future (21) Unmute Alarms: All allowable alarms now and in the future (22) Acknowledge Alarm: Single alarm for this instance

Table 44 shows the effect of moving in out of the zones for a series of operator actions for both strategies.

Note: For simplicity, both zones and surfaces are referred to as zones.

Table 44

Operator Action	Effect - Avoidance Strategy (*.cat files)	Effect - Proximity Strategy (*.mwf files)
1. Move into a zone.	Alarm sounds and Icons appear	Alarm sounds and icons appear
2. If allowed, acknowledge and/or mute the alarm.	Alarm silenced /muted	Alarm is silenced /muted; Acknowledgment is sent to office and written to message files
3. Move out of the zone, but in doing so, move into an additional, second zone. Avoidance buffers intersect both zones.	No alarm and no icons	Alarm sounds and icons appear
4. Move out of the first zone but stay in the second zone.	Undefined behavior: Alarms may or may not sound and icons may or may not appear	No further change

To resolve this proximity issue:

• Place avoidance zones and avoidance surfaces far enough apart so that the biggest machine, with avoidance buffers configured, can move between zones at any angle.

• Train all operators to be careful when moving near or into avoidance zones or under avoidance surfaces.

• Stress to operators that the Acknowledge Alarm icon and Mute Alarm icon do not restore unless the machine moves completely outside one zone before moving into another zone.

Spanish Diacritic Missing in Task Server Messages

A diacritic is an ancillary mark added to letters in some languages, for example Spanish and French. When Cat MineStar System passes error messages from Task Server to Terrain, the Spanish diacritics disappear.

Suspended Machines Receive Messages

Machines which are shown as "Suspended" in the Terrain office software receive pop-up messages, scrolling messages, and tasks. There are no known adverse effects from the suspended machine receiving these messages. To avoid messages stacking up on the suspended machine, reassign the task to a machine that is working.

TerrainDemo

TerrainDemo now includes the new Cat ERS 7495 machine type as a playback demo (no GPS Sim version).

See the "TerrainDemo User Guide.pdf" for Known Issues associated with this software. Find the user guide on the PC where the Terrain mobile software is installed in the following location:

C:\Users\<user name>\AppData\Local\TerrainDemo

Using Sensors on a Single Antenna Machine

When using a sensor for pitch or roll on a single antenna machine, the "GPS x", "GPS y", "GPS z" offsets in the on-board software are not applied correctly. These offsets affect position data in the "Sensors" diagnostic window and the "CAN Debug" diagnostic window.

This issue has been fixed in v5.2.

To work around the issue for v5.0, enter the following key by hand into the mach_cfg.txt file:

$ Calibration File = mach_cfg.txt

When the mach_cfg.txt file is altered by hand, the following error message appears on the display:

“Configuration warning for machine <machine name>: The machine config has been corrupted. Output a new machine config from the MCU”

Warn the office staff that this error message will occur and should be ignored in this instance.

Unexpected Functions in Material Toolbar

When using a "Material Toolbar" dialog with the "Recent Materials" option selected, the toolbar occasionally does not work as expected.

Illustration 52	g03749354
Material toolbar, before starting work, showing five blank Recent Materials icons

Before starting work, the Material toolbar by default shows blank icons. Selecting "Send Truck" places the color of the material that is currently in the bucket into the first icon on the left. All subsequent "Send Truck" commands add material colors to the left or else shift previously used colored icons further left.

There are two ways in which this toolbar may not work as expected:

• The toolbar may contain icons on one end of the toolbar that do not work.

• The names that are associated with the colors may be incorrect. This remains a known issue in v5.2.

Complete the following steps to create a toolbar that works as expected:

1. Delete the current Material toolbar.
   Show/hide table

   Illustration 53	g03749350
   "Recent Materials" option selected when setting up toolbar

2. In the main menu, select "Configuration" > "Material Toolbar" to create a "Material Toolbar" dialog.

3. Select the "Recent Materials" radio button.

4. Set the number of desired materials buttons in the "Maximum Recent Materials" field.

5. Select the "OK" button to create a new gray (blank) toolbar.

6. Double-click inside the gray toolbar.

   The "Customize Toolbar" dialog opens.

7. In the "Customize Toolbar" dialog, select toolbar icons consecutively using the "Add ->" button, starting from the top and working down without skipping an icon.

8. Select "Close".

9. Resize the toolbar.

The correct number of icons appears on the toolbar. The icons change color when the operator selects "Send Truck".

Note: The icon names (if shown) may or may not be correct, but the material stored in the productivity files is correctly named.

Hardware Considerations

Audible Alarm

There is no change in this release.

Network Router

The G610 display module may work as part of a private network, connected to a network router. The private network may include any number of devices such as a wireless radio, a G610 display, cameras, or a Remote Control Module (RCM).

Contact your Cat dealer for information about machine network routers or configuring network managers. Terrain grading and loading software can only work with the network router of the machine or the network manager as long as these network devices have been correctly installed and configured.

Cat ERS Radio

Use the Terrain on-board software with the current radio installed on the Cat ERS 7495, if required. The system uses the radio to receive position corrections (CMRs) and to carry out two-way communication with the office software. The radio and G610 display module can be connected by using either a router or a switch.

Antenna Installation Kits

The following kits are new or have been upgraded:

Hydraulic Mining Shovel Dig Sensor

If using an existing dig sensor on an excavator or hydraulic front shovel, replace the previous sensor with the 459-8741 Pressure Sensor Gp.

Table 45

451-8741 Pressure Sensor Gp
Qty	Part Number	Description
25	3S-2093	Cable Strap
2	364-5409	Pressure Switch
1	392-9004	Module USB flash drive containing Terrain grading and loading documentation
2	451-8738	Mounting Block
1	451-8740	Sensor Harness As
1	459-1754	Interface Module As
1	459-8166	Housing Bracket
1	459-8167	Cover
2	7X-2535	Bolt
8	8T-4171	Bolt
10	8T-4224	Hard Washer

Existing machines must use a harness for the sensors that is from a CAESultra / Terrain kit for v3.2 or more recent.

Resolving Problems: Before Contacting Support Personnel

The more information that can be provided to support personnel, the less time will be required to solve an issue. Provide the following information:

• Version of applicable on-board and office software

• Screen shot or video of the error(s)

• Background details of issue

• Zip file from the CAES\CrashReport folder on the D:\ drive of the display on the machine

Note: Generating the CrashReport files on-board (available on on-board software running on G610 displays) will gather the required files from the system.

Extra files might be required depending on the issue. For further information or assistance, submit a case through the customer service web portal given below:

http://caterpillar.my.salesforce.com/

Menu - Opens the main menu

To generate a screen snap and record certain information, complete these steps:

1. In the main menu, select "System" > "System Snap".

   This action saves the required files to the CrashReport folder.

2. Restart the on-board software.

   This action sends the files to the machine folder in the office software.

3. Send the files from the office to the Terrain Site Champion, describing the problem in as much detail as possible.

Crash Report

Software developers use error reports to solve the problems that cause the software to crash. CrashReport is the error reporting function which adds built-in diagnostic capability for the Terrain v5.0 on-board software.

If the on-board software crashes, the following new files appear in CAES\CrashReport:

• A screen snap

• caes_IllegalShutdown.txt

• crashdump.dmp

• crashrtp.xml

• file_cfg.txt

• mach_cfg.txt

• master_cfg.txt

If the on-board software crashes, the software automatically restarts and attempts to recover as follows:

• If the software recovers, the application opens and functions.

• If the software crashes and does not recover, resulting in a second crash, the application will not enter a crash loop. In effect, the software does not autostart if the software has restarted in the previous 60 seconds.

Note: If the software does not recover, the operator can still access the files through the display module.

In either case, the operator notifies the office and the office updates the CrashReport folder and emails the folder to the Terrain Site Champion. There is no error message sent to the office.

To transfer the CrashReport folder to the office software, perform one of the following actions:

• Restart the on-board software. The CrashReport files are named with a globally unique identifier and sent to the office soon after startup.

• Use FTP to transfer the files from the G610 display module to the office computer. For more information, refer to Special Instruction, REHS2992, "Installation and Configuration of Cat^® Terrain v5.0 On-board Software", "Transferring Files Using an FTP Client".

Firmware Matrix

Reference: Refer to Special Instruction, REHS9109, "Installation and Configuration of Cat^® Terrain v5.2 On-board Software", "Firmware Matrix".

Current Documentation

Reference: Refer to Special Instruction, REHS9109, "Installation and Configuration of Cat^® Terrain v5.2 On-board Software", "Current Documentation".

End User License Agreement

Reference: Refer to Special Instruction, REHS7395, "End User License Agreements for CAES and Terrain" for notices related to software usage.