How to Export a Design Model from n4ce and Upload to the Trimble GCS900

Machine Control System

Pre-requisites
 This process only works if the site coordinate system is OS based. If there is a local coordinate
system in use on the project then contact Sitech to get a grid shift file for the local coordinate
system.

 Ensure that you have a .mch file that matches the make, model and serial number of the
machine you will be uploading to. DO NOT upload a model if you do not have this. You may
contact the machine owner or Sitech to get this file. Further details on this point are covered in
Step 6.

 The following software is required to be installed to complete this process. It is assumed that
the user is competent in using n4ce to create a model or has a ready-made n4ce model to start
from.
o N4ce – Lite version is sufficient
o Trimble File Flipper – Free download here
https://community.trimble.com/servlet/JiveServlet/downloadBody/34287-102-1-
43732/Trimble.CEC.FileFlipper.Setup.1.3.0.20190116121435+%281%29.msi+%282%29.z
ip
o Trimble Business Center – Free download here
https://go2.trimble.com/downloadTBC.html
o Trimble GCS900 Emulator – Free download here
https://www.sitechsolutions.com/wp-content/uploads/2016/03/Trimble-simulator-
CB460-GCS900-V12.80-RC2-95380-setup.exe_.zip

Introduction
The starting point for this process is an n4ce model. The end point is the creation of three files, namely
the *.svd, *.svl and *.cal files which are imported to the GCS900 machine control system. The *.svd file
is the surface file, the *.svl is the linework file and the *.cal file contains the coordinate system
parameters. The surface file is invisible to the operator while the linework file serves as a site map for
the operator.

As per usual, follow good file management techniques to keep things in good order.

Step 1 – Export from n4ce

If necessary, renumber the points in the model to ensure all point numbers in your model are unique.
The LandXML export will fail if there are duplicate point numbers.

From the model view in n4ce export two files (.dxf and .xml) by the following steps
 DXF Export

Select View > Layer Override and turn off all layers except lines.

Export > AutoCAD Standard > Save as type : AutoCAD DXF Files (*.dxf)

Select the DXF export options shown here.

LandXML Export

Select View > Layer Override and turn off all layers except triangles.

Export > Other > LandXML > Answer NO to the prompt shown here

Step 2 – DXF tidy up

Open up the newly created *.dxf file in AutoCAD or whatever software available to edit CAD files. Edit
the drawing so that it only shows linework that will serve as a visual aid to the machine operator. Once
the editing is complete move all the data in the drawing to the 0 layer. In the layer definitions for layer 0
set the linetype to CONTINOUS and line color to 252. Run the CLEAN command to delete all extraneous
data from the file. When you are finished this process, you should have only one layer (0) in your
drawing with all relevant information on it.

Save the file in the R2000 binary dxf format.

Step 3 – File Conversion to *.svd and *.svl

This step is accomplished using Trimble File Flipper. From the opening page click browse and navigate
to where you have stored the *.dxf and *.xml files. Select one of the relevant files and then click the +
button in the upper right hand corner to add the other file. Once both files are added ensure they both
have tick marks next to them. Your screen should now like the one on the following page at this point.
Click on CONTINUE

Select Metres for the project units then click on CONTINUE

Click on SURFACE

Select the model then click CONTINUE. Note that the model name may not be the same as the name of
the .xml file you exported but it will be the same as the original n4ce model you exported from.

Answer NO to this prompt.

Click on the GCS900 Icon.

Answer YES to “Will you be using GPS?”

Click on the Coordinate System Library icon

Select United Kingdom from the country list

Select the Ordnance Survey coordinate system

Select OS National Grid (OSTN02) or OS National Grid (OSTN15) depending upon which OS coordinate
system the project is based upon.

Answer yes to “Will you be using a Geoid”

Select the OSGM02 (United Kingdom) model and click CONTINUE

Click on SAVE and navigate to an appropriate folder to store the results. The software will automatically
create a sub-folder here called Machine Control Data with another sub-folder call All where the GeoData
folder and the individual project folder and files will be stored.

Review the GCS900 selections and click on SAVE. The message shown below should appear.

Click on DONE.

Navigate to the folder you stored the results in and there should be two folders. One folder will be
called GeoData and the other will the name of the project that you specified in File Flipper. The
GeoData folder will contain the geoid grid file.

The folder with the project name will contain three files *.cal, *.svd and *.svl.
The .cal file created by File Flipper does not work with the GCS900. You will need to create ASCII file
that contains the following text. To do this open a new text file with note pad then copy the text from
the box below into the text file. Then save this file with a .cal extension and copy it to the folder that
contains your .svd and .svl files.

00TMSC V10-70 0 05/18/2020 13:47113111

10TMUntitled Job 122212

78TM11

D5TM

D8TMOSTN02

64TM349.0000000000000-2.00000000000000.00000000000000-
100000.00000000400000.0000000000.000000000000000.99960127170000

65TM6378137.00000000298.257222101000

49TM36378137.00000000298.2572235630000.000000000000000.000000000000000.00000000000
0000.000000000000000.000000000000000.000000000000000.00000000000000

81TM20.000000000000000.000000000000000.000000000000000.000000000000000.00000000000
000OSGM02 (United Kingdom)

C8TM4United Kingdom/Ordnance Survey OS National Grid (OSTN02) Ordnance Survey

The *.cal contains data related to the project coordinate system and as mentioned earlier the *.svd is
the surface file and the *.svl is the linework file.

Step 4 – Inspect files in Trimble Business Centre (TBC)

Start TBC

Select File > New and click on OK to start a new project

Using MS File Explorer drag and drop the .svl file onto the Plan View screen. You should only see the
line work that was included in your exported .dxf file.

Now drag and drop the .svd file onto the Plan View screen. Now you should also be able to see the
vertices of the triangulated surface model as shown below.
Since we are using the free version of TBC there is very little functionality available but select the
Surfaces tab then click on the Surface Slicer View icon. Then draw sections across the model in plan
view to see how it looks in cross section as shown below.

This is useful as a gross blunder check only. If you discover any problems they will need to be rectified
in n4ce because the free version of TBC has no editing privileges.

If you are happy with the way things look then close down TBC and proceed to step 5.
Step 5 – Upload Files to GCS900 Simulator
This step is not necessary to complete the process but it does ensure the upload files are correctly
formatted to avoid embarrassment on site. Is worthwhile getting used to the simulator before trying to
navigate your way around it for the first time on site. Additionally, this process allows you to see what
the operator will see when the model is loaded on to the GCS900.

Firstly, it is necessary to copy the model files to a location where the simulator software will find them.

There will be a folder in the root of the drive where you installed the software called “MCGData-CB460-
trmb_(V12.80)”

Copy the folder containing your .cal, .svd and .svl files to this folder

Start the GCS simulator. It consists of two windows, one is an identical copy of the GCS900 operator
screen, the other window is a machine control screen whereby you can simulate inputs to the machine
and see how it affects the operators display.

For the purposes of this exercise we will be working exclusively with the GCS900 operator screen as
shown below on the following page.
 ZOOM OUT BACKUP MENU

When the simulator first starts a number of error messages will appear saying “Check Machine Radio” or
“Some system devices not responding”. You will need to press the OK button a few times to clear these.
On some occasions the Machine Radio warning will continue to flash but just ignore this and carry on.

Press the MENU button

Use your mouse to highlight the Select Design option at the top and press OK

You will see a list of design files and yours should be one of them.

Select your design file and press OK

Press the back up button and the linework for your design should appear. If you can’t see your linework
then press and hold the zoom out button, this will fit your design extents to the centre of the screen,
similar to the screen display above.

Step 6 – Copy files to USB and upload to GCS900 on site

On the root directory of the usb stick you are using for upload create a directory called Machine Control
Data and under this a sub directory call All.

In the All directory you must copy the .mch file that is unique to the make, model and serial number of
the machine you are uploading to. If the name of the .mch file does not match the machine then do not
proceed any further. Contact the machine owner or the company who installed the gps equipment on
the machine, this is usually Sitech. The Sitech field reps in the area are :

Mark Prince 07736 632144 or Simon Cannon 07717 788993

Under the All folder there must also be a sub-folder called GeoData which contains the relevant Geoid
Grid Files (.ggf) for the project.

Also under the All folder will be a sub-folder for your project. This must contain the .svl, .svd and .cal
files.

The directory structure on your USB should be as shown below.

Once you get to site simply have the operator insert the USB into the GCS900 control panel. A prompt
will come up with two options.

Copy from USB or Copy to USB.

Select copy from USB

Once the process has completed remove the USB and load the model.

Step 7 – Verify all is working OK on site

Ideally, take a SmartNet GPS system loaded with the design points with you to site.

Find a location that is likely to remain undisturbed but it accessible to the machine then set a stake and
measure the top of this stake and record the location.

Have the operator gently put the left corner of the blade on the top of the stake and compare the
coordinates from the GCS900 against your recorded values for the station.

Pass the coordinates of this station to the operator so he can do daily checks on the integrity of the
onboard positioning system.

Then set out a few points from the model and have the operator take the machine to these stakes.
Ensure that there is horizontal and vertical agreement between the set out stakes and the model loaded
on the machine. Everything should match up to within 20mm. Enjoy a well-earned cuppa!