The Agl 2500 Pipe Laser Owners Manual

Transcript

GradeLight 2500 PIPE LASER Operator's Manual CONSTRUCTION LASERS & MACHINE CONTROL SYSTEMS 2202 Redmond Road Jacksonville, AR 72076 USA Telephone 501-982-4433, FAX 501-982-0880 www.agl-lasers.com [email protected] GL2500om_AGL 1 5/14/02, 1:46 PM GL2500_om 7/20/04 6:13 PM Page 1 Table of Contents IMPORTANT NOTICE The owner/operator of the GradeLight 2500 Pipe Laser is expected to follow all operating instructions, periodically check the accuracy of the unit, and make checks on control as the work progresses. The manufacturer, its distributors, or its agents assume no responsibility for improperly controlled work GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . 2-3 Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Control Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8 Self Leveling / SpeedLevel Display . . . . . . . . . . . 4 Reading Grade / Grade Entry . . . . . . . . . . . . . . . 5 Azimuth Adjustment . . . . . . . . . . . . . . . . . . . . . . 6 Using the AutoLine Wireless Remote . . . . . . . . . 6-7 Laying Pipe . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 TRANSFERRING ELEVATION . . . . . . . . . . . . . . . . . . . . . 9 ALIGNMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-13 SETUP METHODS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-20 CALIBRATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21-22 LIMITATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 SAFETY STOP (As required by Federal Regulations) . . . . . . . . . . 25-26 BEFORE USING YOUR AGL LASER YOU MUST DO TWO THINGS! 1. Record the serial number and keep it in a safe place. 2. Complete and return the owner registration card. If your registration card is missing, call1-800-643-9696. 1 General Information Features 9 1. Attached Lens Cover - Protects output window when unit is not in use. Lower cover when ready to use beam. 8 2. Beam Output Window. 3. Securing Knobs for adjustable legs. 4. Feet for 6"(150 mm) pipe - Short points allow 6"(150 mm) in-the-pipe setup. No other attachments needed. 5. Remote AutoLine Receiver window. 8 6. Leg Slots - For adjustable leg sets. Align reference line to marks on adjustable legs. 7. Centerline-of-Beam Marks - Indicate horizontal beam centerline for setup purposes. 8. Accessory Mount - Attachment point for Handle/Rod Mount, Handle/Scope, and Stringline Eye. 5 2 3 3 9. Lighted Pivot Point - Green LED indicates line (azimuth) pivot point. Highly visible in dark setup conditions. 10.Rear Handle - Provides convenient secure way for carrying instrument or lowering into manholes. 11. Power Pack-"On-Board" Rechargeable battery for cordless operation. Fully charged battery will operate the GradeLight 5 2500 for approximately 1 week. 1 4 8 6 10 7 6 3 3 11 2 GL2500om_AGL 6 5/14/02, 1:46 PM General Information Control Panel 1. Azimuth Indicator - Displays horizontal beam position relative to azimuth adjustment range. 2. Positive and Negative Grade Readout Window Shows positive or negative grade entered. 3. Battery Indicator - Shows available supply voltage.(Recharge when last bar is reached). 4. SpeedLevel Indicator - Speeds setups by showing whether unit is within self leveling range and if not, which direction to adjust the unit. 5. Calibration port - allows access to calibration push button switch. 6. Rear Remote AutoLine Receiver Window. 7. Positive Grade Switch - Grades below 10.00%, input positive grade in 0.001% increments. Grades 10.00% and above input grade in 0.01% increments. 8. Negative Grade Switch - Input negative grade in 0.001% increments down to (-)10.00% grade. 9. Left & Right Azimuth Switchpads. 10. Lighted Cross-Axis Rough Level Vial - Indicates cross axis level position. Lighted for easy visibility even in dark setup conditions. 11. Power Connector 12. Purge Screw - For factory service only - Do Not Remove! If opened, dry nitrogen purge of the unit will be lost and moisture will contaminate the unit. 13. Display Backlight Switchpad - Backlight is activated anytime any function is in use. 14. Power On/Off Switchpad. 6 2 4 1 3 13 9 7 8 13 10 14 12 11 5 NOTE To immediately center the Beam and Azimuth indicator, momentarily press both Azimuth switchpads at the same time. (See # 9 Left & Right Azimuth switchpads) NOTE To immediately set the grade to 0 %, press the positive & negative grade switchpads at the same time to automatically set the grade back to 0 % grade. (See # 7 & 8 positive and negative grade switchpads) The control panel switchpads incorporate positive tactile feedback for simple and more accurate operation. When pressed they "click" to indicate switch action. 3 GL2500om_AGL 7 5/14/02, 1:46 PM Operation Self Leveling The GradeLight 2500 uses an electronic self leveling system that provides simple accurate setups. Grade axis self-leveling range is ±10%. SpeedLevel™ Self Leveling Indicator Setups are further simplified by the three light SpeedLevel display on the control panel which lets you know immediately when the unit is within the self leveling range (Figure A). The indicator is read as follows: Arrow (top or bottom) - The arrows indicate which direction to tilt back of unit to be within self leveling range. Center Bar- Indicates unit is positioned correctly and will self-level. The GradeLight 2500 Self leveling system also includes a blinking beam "failsafe" which alerts you when the unit is out of level. When the beam stops blinking, the unit has leveled and work can proceed. If the blinking continues, the unit is out of the self leveling range and must be repositioned using the indicator. Figure A Three Light SpeedLevel™ Display IMPORTANT The owner/operator of the GradeLight 2500 Pipe Laser is expected to follow all operating instructions, periodically check the accuracy of the the unit, and make checks on line and grade as the work progresses. The manufacturer, its distributors, or its agents assume no responsibility for improperly laid pipe. 4 GL2500om_AGL 8 5/14/02, 1:46 PM Operation Reading the Grade Counters The digits on the counter to the left of the decimal point (1) represent whole units of percent grade. The first digit to the right of the decimal shows tenths(2), the second digit to the right shows hundredths(3) and the third digit to the right shows thousandths(4). 1 2 3 4 Grade Entry The GradeLight 2500 grade range is from positive 40% to negative 10%. Grade can be set in increments as small as .001%. The lighted grade display shows the exact grade setting and whether it is positive or negative. Figure B Positive Direction desired grade value value shown in counter desired grade value Negative Direction Grade Entry Method Grade is set electronically by pressing the positive or negative grade switchpads. The counter speed will increase as long as the pad is pressed until maximum speed is attained. For automatic grade entry press either the positive or negative grade switchpad. Hold for a few moments and release. The grade will continue in the selected direction until you press either grade switchpads. Finish the grade entry in small increments by pressing the pad momentarily without holding it down (you should feel or hear the tactile feedback "click"). The desired grade value should always be approached from the lower side to assure the highest degree of grade accuracy. For positive grade, always raise the numbers shown on the counter to arrive at the desired value. For negative grade entry, first run the counter down past the desired value (more negative) then decrease the numbers shown on the counter (go towards positive) to arrive at the desired value. (see Figure B) 5 GL2500om_AGL 9 5/14/02, 1:46 PM GL2500_om 7/20/04 6:13 PM Page 2 Operation Azimuth Adjustment The horizontal line (azimuth) range of the GradeLight 2500 is 20’ at 100’ (6m at 30m). The azimuth indicator shows beam position in the adjustment range. Before each setup push both azimuth switch pads on the control panel at the same time to center the beam and azimuth indicator (this allows maximum adjustment range in each direction). 3 1 2 4 To move the beam, use the AutoLine Remote Control (Figure C) or azimuth switch pads on the control panel. Movement will start slow, then speed up as long as the switch pad is pressed. AutoLine™ Wireless Remote Line Control 5 Features 1. Output Window. 2. Power ON Switch Pad. (Green LED on) (Power will automatically turn OFF Approx. 1 minute after last switch pad is pushed) 6 Figure C 3. Power ON / OFF Indicator. 4. Left and Right Azimuth Switch Pads. When operating from front of laser, arrows correspond to direction of beam movement. 5. Stand-By-Mode Switch Pad. To turn ON or OFF push and hold switch pad for approx. 3 seconds. 6. Power Source, one 9 volt. Battery. 6 GL2500_om 7/20/04 6:13 PM Page 3 Operation Operation The Remote Transmitter is a line-of-sight control using infrared light. Transmitter must be pointed directly at receiver on GradeLight 2500 - Conditions that impede light transmission such as rain, fog, or dirty windows on transmitter or GradeLight 2500, can reduce operating range. Do not clean plastic windows or painted surfaces with acetone. 1. Setup Gradelight 2500 at proper offset, elevation and grade. 2. Push power on switch pad. (green LED on) Point remote control directly at the front or rear receiver window on the Gradelight 2500. 3. Push left or right Azimuth switch pad to move beam. If beam does not move in the desired direction, push the other switch pad to align beam. 4. To activate Gradelight 2500 Stand-By Mode, Push power on switch pad (green LED on). Push and hold Stand-By switch pad for approx. 3 seconds (Laser beam off). Return Gradelight 2500 to normal operation, push and hold Stand-By switch pad for approx. 3 seconds (Laser beam on), NOTE: Remote Control will automatically turn off approx. (1) minute after last switch pad is pushed. Transmitter Power Source Transmitter uses one 9 volt battery. To change battery, slide battery compartment cover open. Remove old battery. Insert new battery, observing proper polarity. Replace cover. 7 Operation Laying Pipe The three basic steps to successfully setup the Gradelight 2500 for laying pipe are: A. Dial in the correct grade. B. Transfer of Elevation- Position the laser at the correct elevation. C. Alignment - Align the beam to the forward manhole. Before Starting Attach the necessary mounting accessories such as the Handle/Rod Mount, Trivet, Legs, or Tripod Adaptor mount etc. to the unit. Power up unit. Adjust azimuth to the center of its range. At the beginning of a pipelaying job, you should consider the following tips for improved performance: • The GradeLight 2500 can be used to check the hubs prior to actually starting the work. This is an opportunity to catch potential errors before using the hubs as a reference to lay pipe. • Place grade pole or marker at the forward manhole . • When the last joint of pipe has been laid approaching a manhole, bring the GradeLight 2500 forward so that as soon as the manhole is in place, you can setup again without delay. IF THE REGISTRATION CARD IS MISSING, CONTACT AGL TOLL FREE AT 1-800-643-9696 TO REGISTER YOUR LASER! YOU MAY ALSO USE THIS NUMBER TO REPORT A STOLEN LASER. 8 GL2500om_AGL 12 5/14/02, 1:46 PM Transfer of Elevation Special Transit Method Manhole Setup This is an ideal method to use when the offset hub is too far from the manhole center to transfer elevation with a batterboard or other means. The special transit is set up using the Rod and Crossbrace System. 1. Mount the Special Transit on the calibrated rod and point it to the manhole hub. The top edge of the transit mounting bracket is the elevation reference and is the same as the horizontal crosshair (centerline) of the transit. 2. Level the special transit using the adjust knob and the level vial. Use the forward marker knob to adjust the transit so that it is pointed exactly to an engineer’s rule or calibrated rod section held at the manhole hub. 3. After reading the engineer’s rule or calibrated rod, measure down from the top edge of the transit mounting bracket (transit centerline) to the correct invert elevation. Figure D HI ROD 1st reading 2nd Reading Elevation of Manhole Base Engineer's Level Method HUB 1. Mount the level on a tripod outside the manhole or open cut. Adjust it to level and point at the manhole hub. Take a reading from a rod held at the hub.This reading is sometimes called the "backsight" reading. (Figure D) 2. Now take a rod reading at the manhole center. If a manhole is in place read the elevation of the base. In an open cut it is necessary to place an object in the cut which can be used as a reference. A brick, stone, or board placed at manhole center will work for marking a reference elevation, and as a starting point for the placement of the laser or the trivet. 9 GL2500om_AGL 13 5/14/02, 1:46 PM Alignment After the laser is set up at the correct elevation and the correct grade is entered, the only step remaining is to align the beam to the forward manhole. Special Transit Method This method uses the Rod and Crossbrace system. The laser is mounted with the Handle/Rod Mount. 1. Mount the Special Transit - With the rod plumbed, and laser leveled, mount the Special Transit on the rod. Position the transit where it is possible to see the forward manhole marker, yet as low as possible on the rod. Secure the rod mounting bracket with the secure knob. 2. Align Transit to Forward Manhole Marker - Use the forward marker knob to adjust the vertical crosshair until it is aligned with the forward manhole marker. 3. Align transit to Laser - Tilt the transit down and sight on the green LED on the laser. Use the laser centerline knob to adjust the vertical crosshair until it is exactly aligned with the green LED on the laser. Repeat steps 2 and 3 until the crosshair is on the forward manhole marker and the green LED on the laser. 4. Align the laser beam to the Transit - Place a target in the ditch approximately 15' (5 M) out in front of the laser. Tilt the transit down to view the target. Adjust the beam left or right using the azimuth buttons on the Autoline Remote until the beam is exactly centered on the vertical crosshair. You should be able to swing the transit from the beam, to the green LED, or forward manhole marker, with each being exactly aligned to the crosshair. Repeat steps 2, 3, and 4 if necessary. When all three are accurately aligned, pipelaying can proceed. 10 GL2500om_AGL 14 5/14/02, 1:46 PM Alignment Manhole Transit Method This method can be used with either the Special Transit or any standard surveyor’s transit. Use the Manhole Transit Clamp system to support the transit. The laser is set up in the manhole using leg sets, or the trivet. 1. Secure the clamp body and mast (see Figure E). Position the clamp (1) over the top edge of the manhole so the mast (2) is plumb enough to easily level the transit when mounted. Tighten the clamp screw (3), until the clamp points are firmly embedded in the sides of the manhole. The mast can be further adjusted to plumb using the lever (4) locking the mast pivot. Figure E 6 5 2 7 8 4 1 3 Figure F Secure the Arm - Slide the arm clamp support (5) and the arm clamp (6), over the mast and secure. Insert the arm (7) into the clamp. The clamp allows complete flexibility to raise, extend, and position the arm so the transit mount (8) is over the manhole center. The transit mount is a 3 1/2 - 8 threaded ring for mounting a standard transit. The AGL Special Transit is mounted, using a tripod adapter and rod stub. Aligning the Beam with the AGL Special Transit 2. Align the transit to the Forward Manhole - Mount the tripod adaptor to the transit mount at the end of the arm. Adjust the arm so the transit is roughly over pipe centerline and in line with the laser (see Figure F). Adjust the vertical crosshair exactly to the forward manhole marker using the forward marker knob. 11 GL2500om_AGL 15 5/14/02, 1:46 PM Alignment Manhole Transit Method (continued) Aligning the Beam with the AGL Special Transit 3. Align Transit to Laser - Tilt the transit down and sight the green LED. Use the laser centerline knob to adjust the vertical crosshair until aligned exactly with the green LED. Repeat steps 2 and 3 until the vertical crosshair is on both the forward manhole marker and the green LED on the unit. 4. Align the Laser Beam to the Transit - Place a target in the ditch approximately 15' (5 M) in front of the laser. Looking through the transit at the target, adjust the beam left or right using the azimuth buttons on the Autoline remote control until exactly centered on the vertical crosshair. You should be able to swing the transit from the beam, to the green LED, or forward manhole marker, with each being exactly aligned to the crosshair (see Figure G). Repeat steps 2, 3 and 4 if necessary. When all three are accurately aligned, pipelaying can proceed. Aligning the beam with a standard Transit 1. Align the Transit over the Instrument - Mount the standard transit to the transit mount at the end of the arm). Using a plumb bob, adjust the arm so the transit is directly over the centerline of pipe. Level the transit. Position the laser so the green LED is exactly under the plumb bob. If the transit has an optical plummet, use it instead of the plumb bob. 2. Align Transit to Forward Manhole - Pivot the transit until the vertical crosshair is exactly aligned to the forward manhole marker. 3. Go to step 4 above, from previous method. Figure G 2 4 3 12 GL2500om_AGL 16 5/14/02, 1:46 PM Alignment Sight Line Method FORWARD MANHOLE MARKER The sightline provides a quick, easy method of beam alignment. Place a target in the ditch approximately 50' (15 M) out from the laser. Attach a string to the eyelet located on top of the Gradelight 2500 and keeping it plumb, hold it taut, vertically above the unit (see Figure H). Stand behind the string and visually center it on the forward manhole. Lower your gaze to the target and adjust the beam left or right until exactly centered behind the stringline using the Autoline remote control. When you can see the stringline centered on the forward manhole marker and on the beam in the ditch, alignment is complete. STRINGLINE HELD VERTICAL TARGET BEAM EYELET Plumb Bob Method This method of alignment can be used if the cut is not too deep and as long as the wind is relatively calm. The laser must be set up at the correct elevation and exactly on pipe centerline. Place a target in the ditch approximately 50' (15 M) out from the laser. Measure over from an offset hub to the pipe center line and drop a plumb bob down to the target. Figure H Mark where the plumb bob strikes the target and adjust the beam left or right until it is centered on the plumb mark. 13 GL2500om_AGL 17 5/14/02, 1:46 PM Setup Methods Rod Mounting System Manhole Setup 1. Prepare the laser for use: Attach Handle/Rod Mount, apply power, and center the azimuth. Pivot the lens cover to either side. 2. Mount crossbrace inside the manhole, perpendicular to the centerline of pipe being laid. Use the level vial on the crossbrace to position it level. Holding the two points firmly against the manhole wall, extend and tighten the adjusting screw point against the opposite wall. Tighten until the crossbrace is solid, with the points planted firmly into the concrete. 3. Secure Alignment Element to the crossbrace using the secure knob. Hang the alignment element on the crossbrace so that the line control and front secure knobs face the forward manhole. Measure manhole width where the crossbrace is mounted and use the center as reference. Place the right edge of the alignment element 2 1/4" left of manhole center. 4. Slide the calibrated rod with point attached through the alignment element, plumb it using a level, then tighten the secure knob. Pull up on the crossbrace as you tighten the alignment element, then release after it is tight. This places downward tension on the rod and increases its stability. 5. Establish invert elevation and beam height (see page 9, transferring elevation, Special Transit method). 6. Secure the laser to the rod at the correct elevation. If grade is greater than 10%, tilt the unit according to the 3-light SelfLeveling readout. Allow to self-level. 7. Align beam to the forward manhole (see page 10). Recheck alignment steps to assure accuracy. Check for level unit and accurate grade setting. Proceed with laying pipe. 14 GL2500om_AGL 18 5/14/02, 1:46 PM Setup Methods Height Adjustable Legs Manhole Base Setup 1. Prepare laser for use: Attach leg set with centerline leg at front and two side legs at rear. Apply power, center the azimuth, enter desired grade and pivot lens cover to either side.. 2. Transfer Elevation from Hub to Manhole Base. 3. Set the front (centerline) leg to the desired height: After determining the desired beam height above manhole base, adjust the front leg so the beam will be projected at that height. 4. Set the unit in place: Position the point of the front leg on pipe centerline, 2” (5 cm) in front of the manhole center, toward the pipe being laid (see Figure I) for accurate alignment. Manhole Center Place Front Leg Point here Pipe GradeLight 2000 Direction 5. Level the Instrument: The unit is rough leveled by loosening the rear leg knobs and sliding the unit up or down until a center bar is obtained in the SpeedLevel Display. Tighten the legs. 6. Align laser to the forward manhole (see pages 11,12, or 13). 7. Recheck for level and accurate grade setting and proceed to lay pipe. 4" Figure I. 15 GL2500om_AGL 19 5/14/02, 1:47 PM Setup Methods Height Adjustable Legs (continued) Top-of-the-Pipe Setup When using the top-of-the-pipe setup, be sure the joint of pipe used is accurately placed for line and elevation. Set the centerline leg for desired beam height above the invert. Then proceed to set up the unit as described in the Manhole Base Setup. The Large Adjustable Pipe Target is recommended for aligning the pipe. In-the-Pipe Setup When set up in-the-pipe, be sure the joint of pipe used for the setup is accurately placed for line and elevation. Setup in 6"(150mm) pipe: 1. Remove Handle/Rod Mount, Stringline Eye, and Legs. Power up the Gradelight 2500. Center the azimuth and enter desired grade. 2. Slide the unit into the pipe. It should rest on the three fixed short leg points. Rough level the unit in the crossaxis direction using the lighted cross-axis level vial on the rear control panel. 3. Align the beam to the forward manhole using the azimuth control on the AutoLine remote transmitter. Setup in 8", 10"(200mm, 250mm) and larger pipe: 1. Remove Handle/Rod Mount, power up the Gradelight 2500 center the azimuth, and enter desired grade. 2. Attach the appropriate leg set with two side legs at the front and the centerline leg at the rear. Set all three legs so the appropriate pipe size mark is aligned with the centerline-of-beam mark beside each leg slot. 3. Open lens cover and slide unit into pipe. Rough level unit in the cross-axis direction using the cross-axis level vial on rear control panel. 4. Align beam to forward manhole using the azimuth control on the AutoLine remote transmitter. 5. The beam should now be projected at pipe centerline. Allow unit to self-level, then proceed to lay pipe. 16 GL2500om_AGL 20 5/14/02, 1:47 PM Setup Methods Height Adjustable Legs (continued) Invert Setup Position the legs the same as you would if setting up inside the pipe. Place the laser in the invert and complete the setup as outlined in the Manhole Base Setup. Open Cut Setup When using the height adjustable legs in an open cut, a stable base such as a concrete block, brick, or board must be placed in the cut at the manhole center and marked. This is best done when transfering elevation (see page 9). Place one of the blocks at manhole center. The front leg will be positioned on this block 2" (5 cm) in front of the center mark. Place the other blocks, etc. so that they provide support for the rear legs. GradeLight 2000 Beam Centerline Invert Elevation Manhole NOTE In open cut setups the long leg set is usually required. Set up the unit for laying pipe as described in Manhole Base Setup (see page 19). 17 GL2500om_AGL 21 5/14/02, 1:47 PM Setup Methods Figure J. Invert Peg Setup (Open Cut) This method is commonly used in open ditches. The cut should be excavated approximately 6" below invert elevation. 1. Place a stake at invert elevation. 2. Prepare the laser for use: Power up, center the azimuth, and enter desired grade. Attach leg set with centerline leg at the front and two side legs at the rear. GradeLight 2000 Beam Centerline Invert Elevation Manhole 3. Set the front centerline leg for correct pipe size using the marks on the legs. 4. Place the laser in the trench with the single front leg on the stake (peg). Rest the rear legs on blocks, bricks, or the ground. Using the 3-light SpeedLevel display on the rear panel, adjust the rear side legs to level the unit (see Figure J). 6. Align the beam to the forward manhole. 7. Recheck for accurate grade settings and level unit. Proceed to lay pipe. 18 GL2500om_AGL 22 5/14/02, 1:47 PM Setup Methods Trivet Manhole Base Setup 1. Prepare the laser for use: Attach Handle/Rod Mount, power up, center the azimuth, and enter desired grade. Mount the height adjustable rod (center the rod height in its adjustment range) to the trivet. Open the lens cover. 2. Transfer Elevation from Hub to Manhole Base. 3. Position the Trivet over the manhole center: Place the front leg of the trivet on the centerline-of-pipe, 5” (13 cm) in front of the manhole center mark. 4. Secure the laser to the rod at the approximate elevation. 5. Level the unit: Rough level the unit using the adjustable legs of the trivet. If grade is greater than 10%, use the handle/rod mount to tilt the unit using the SpeedLevel Display. Allow unit to self-level. 6. Use the height adjustable rod to precisely adjust beam elevation. The centerline of beam marks on the side of the unit are convenient for establishing correct elevation. 7. Align the beam to the forward manhole. Recheck all the alignment steps to assure accuracy. Check for level unit and accurate grade setting. Proceed with laying pipe. 19 GL2500om_AGL 23 5/14/02, 1:47 PM Setup Methods Above Ground Setups Figure K ABOVE GROUND GRADE POLE ROD READING (Backsight Elevation) HUB ELEVATION CUT TO INVERT Tripod Mounting System - Grades Less than 10% 1. Prepare laser for use - mount the Handle/Scope and attach 5/8"x11 Tripod Adaptor Mount. Power up and center the azimuth. Set grade at exactly zero. Open the lens cover. 2. Measure over from an offset hub and set up a 5/8"x11 tripod directly over the pipe centerline trying to keep the top of the tripod as level as possible. Use a plumb bob if needed. Spread the tripod legs sufficiently and plant them firmly into the ground to provide a stable base. 3. If using the Tangent Base, screw it to the tripod, then mount the laser to the Tangent Base. If not, mount the laser directly to the tripod. Rough level the laser by adjusting the tripod legs. 4. Allow the laser to self level. 5. Loosen the tripod securing handle or release the tangent rotation lock. Turn the laser and scope to a rod or scale held at the manhole hub. Tighten the lock, then use the tangent adjust to align the beam exactly to the rod. Take a reading (sometimes called "backsight" elevation) at the beam centerline. This measurement plus the “cut” at that hub will be the HI (instument height) above flowline. If the grade pole is used on top of the pipe, allow for the difference when setting it up (see Figure K). Set the Above Ground Target (see page 16) at the correct 6. Enter the desired percent grade. 7. Loosen the tripod securing handle on the tangent 20 GL2500om_AGL 24 5/14/02, 1:47 PM Calibration Stake A Stake B 100' Figure L 1. Establish two benchmarks: Select a reasonably level area and set up the GradeLight 2500. Level the unit and set the grade at exactly 0.000%. Drive two stakes (A & B) in line with the laser beam, but low enough for the beam to pass over both stakes. Stake “A” should be about 1'(.3M) from the unit, and stake “B” about 100' (30M) away (Figure L). 2. Check the instrument: A. Place a short “2 x 4” or something similar on stake “A”, and mark where the beam strikes. Call this mark”A1". B. Place the same “2 x 4” on stake “B” and again mark where the beam strikes. Call this mark “B”. (Figure M) A1 B Stake A Stake B Figure M 3. Move the laser to the far side of stake “B” so the beam will cross over both stakes as before, but in reverse order. A. Be sure height of the unit is set so when the “2 x 4” is placed on stake “B”, the beam will strike at mark “B”. B. Now place the “2 x 4” on stake “A”. If the beam strikes at mark "A1", the unit is calibrated (see Figure N) and you should proceed to step 5. If beam strikes at a different height than "A1", then the calibration will need to be adjusted. Proceed to step A1 Stake A Note B Stake B Calibration is easier if the single centerline leg is in front or when using a trivet with height adjustable rod. Figure N 21 GL2500om_AGL 25 5/14/02, 1:47 PM Calibration 4. Make the beam project level: A. Mark the “2 x 4” where the beam strikes when placed on stake”A” (see Figure O). Call this mark “A2”. Make a new mark halfway between mark “A1” and mark “A2”. Call this mark “C”. This is the correct beam center. B. Remove the black decal and screw that covers the calibration port on the right rear of the unit. The calibration push button switch is accessible through this port (see Figure P). NOTE Do not remove the purge screw on the left rear of the unit. It is recessed and covered with a black decal. If this screw is removed, the moisture free nitrogen purge of the unit will be lost. A2 CORRECT A2 B INCORRECT 5. Replace calibration port cover screw. CALIBRATION Purge Screw DO NOT OPEN! Figure P 26 Calibration Port Remove screw to access push button switch NOTE If the beam cannot be brought to desired position, unit may be out of field calibration range and should be returned to an authorized service center. Contact your AGL distributor or call Toll Free 1-800-643-9696, for location of the nearest service center. 22 GL2500om_AGL ADJUSTMENT Figure O C Use the positive or negative switchpads to move the beam until it is exactly centered on mark “C”. Use a small blunt object less than 1/8" diameter, such as a pen tip or hex tool, reset the grade display to 0.000% by depressing the reset button. When the beam is centered on mark"C", repeat steps 1 & 2 to check the new calibration. NOTE Insure that the Gradelight 2500 instrument housing is level by placing a small carpenters level on top of the unit before setting calibration. A1 C A2 B A1 A1 B 5/14/02, 1:47 PM Calibration Limitations Bending or Movement of the Laser Beam Certain atmospheric conditions can cause phenomena known as “refraction” and “scintillation” to occur inside a pipe. Refraction is the bending or deflection of a laser beam from a straight line caused by air settling in layers of different temperature (see Figure Q). The beam tends to bend toward the denser cooler air. Hot pipe placed in a cool ditch can create layers of air with different densities. Equipment exhaust or gasket compound fumes can also settle in the ditch and cause bending of the beam. Scintillation is the dancing or wavering of the beam as it passes through air layers of different temperature, similar to the shimmering effect seen when looking down a paved road on a hot day. Scintillation can also be caused by variations in air density due to velocity of air movement (see Figure R). With no air flow, refraction or temperature scintillation may occur and with too much air flow, velocity scintillation may occur. The intensity and frequency of these effects can vary with the depth of cut, the type of pipe, weather conditions, length of the run, Refraction and the position of the sun. The AGL Blower is used to blend the layers of air and reduce the effects on the beam. In addition, the following field procedures have been found to reduce refraction and scintillation problems: 1. Keep the pipe backfilled as it is laid. This helps insulate the pipe and prevents extreme temperature variations. 2. Mount the blower just outside the pipe. Adjust leg height and blower position to direct maximum airflow through the pipe. Adjust the blower speed for the pipe size. 3. Turn the blower on after laying 50' of pipe out from a manhole. On second day setups, turn the blower on for a few minutes prior to laser use to stir up the air in the pipe and purge the pipeline. 4. The desirable air velocity through a pipe for laser use is approximately 4 - 6 mph. In severe conditions, even with the effectiveness of the blower, the working range of the laser can be limited. BEAM Layers of Air Figure Q Scintillation Varying Air Density BEAM Figure R 23 GL2500om_AGL 27 5/14/02, 1:47 PM GL2500_om 7/20/04 6:13 PM Page 4 Specifications GradeLight 2500 Beam: Beam Accuracy: Grade Range: SL Range: Azimuth Range: Operating Temperature: Waterproof: Rough Level Indication: Line Indication: Control Panel: Pivot Point: Dimensions: Weight: Internal Battery Pack: External Power Station: Visible Laser Diode, 635 nm ±1/16” @ 100’ = ±.005% +40% to -10% ±5.7° (±10%) grade axis 20’ @ 100’ (6M at 30M) -18°C (0°F) to 50°C (120°F) Yes, purged with dry nitrogen Grade - 3 light SpeedLevel display Cross axis - lighted level vial Backlit indicator on control panel Tactile feedback, integrates line, grade, and low battery indicator Yes, LED 12.5”L x 5.25”D 9.8 lbs. Approx. 1 week Approx. 2 weeks AutoLine Wireless Remote Control Operating Range: Battery: Indicator: Dimensions: Weight: 24 600’ front (thru the pipe) 25’ from rear One 9 volt alkaline battery Power ON (green) 5.125”L x 1.875”W x 1.0625”D 35 oz. Safety As required by Federal Regulation A CLASS 3A LASER PRODUCT Max. Output Power: 5 mW, 670 nM LASER LIGHT. Do not stare into beam. Use: This manual explains the use of all controls, adjustments, and operating procedures to be performed by the user. CAUTION: the use of controls or adjustments, or performance of procedures other than those specified herein, may result in hazardous radiation (light energy) exposure. This product conforms to European Laser Safety Standard EN60825, Sept. 1991. B Service: To avoid possible exposure to radiation in excess of acceptable emission limits, all repairs requiring the opening of the sealed laser case must be performed by the manufacturer or its authorized representative. C Maximum Radiant Power: Less than 5 mW. D AGL Maintenance: The GradeLight 2500 conforms to the amended standards of 21CFR, parts 1000 and 1040 laser products, effective September 19, 1985. No schedule of maintenance is required to keep it in compliance. MODEL / SN DATE MANUFACTURED Location of Safety Notices and Devices NOTE Laser warning signs are included in the instrument case for posting on the jobsite. A. Power Classification Label - see reproduction Located underside B. Aperture exposure label - Front End Cap C. BRH - Interlock Warning Label - Located underside D. Serial Number Tag - Located underside B C A D 25 GL2500om_AGL 29 5/14/02, 1:47 PM 26 GL2500om_AGL 30 5/14/02, 1:47 PM © Copyright 2001 All rights reserved GL2500om5-15 AGL GL2500om_AGL 32 5/14/02, 1:47 PM