Trainning D7 Bosal

ROC-D HCSwith Bosal cabin © Copyright 2007, Atlas Copco Rock Drills AB, Sweden Any unauthorized use or copying of the contents or any part thereof is prohibited. This applies in particular to trademarks, model denominations, part numbers and drawings ROC D HCS trainee binder - with Bosal cabin, PMI NR: 9852 9591 01 Subject Content Tabs ROC D MkII Hydraulics, general Electrics, general Operating Compressor Flushing, DCT Engine start Pumps & pilot pressure Tramming & winch Positioning Oil-heating & rotation Drill feed Drilling, collaring & full RPC-F Anti-jamming DPCI Back hammer Rapid feed & rod coupling Rod handling system HQS PLC System description Drawings 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 Training program in SWEDEN for SC Technicians ROC D 5 days COURSE DESCRIPTION: .........................................................................................................................................1 01 BASIC: ROC D [MONDAY, TUESDAY] ...........................................................................................................2 1. 2. 3. 4. 5. 6. 7. 8. INTRODUCTION ...............................................................................................................................................2 INTRODUCTION OF SDE .................................................................................................................................2 HYDRAULIC GENERAL....................................................................................................................................2 BASIC ELECTRIC .............................................................................................................................................2 BASIC H YDRAULIC .........................................................................................................................................2 COMPONENTS .................................................................................................................................................2 OPERATING .....................................................................................................................................................2 PLC.................................................................................................................................................................2 02 SYSTEMS: ROC D [WEDNESDAY]...................................................................................................................3 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. 20. PUMPS.............................................................................................................................................................3 PILOT PRESSURE .............................................................................................................................................3 START ENGINE ...............................................................................................................................................3 ENGINE SPEED CONTROL................................................................................................................................3 TRAMMING .....................................................................................................................................................3 COMPRESSOR..................................................................................................................................................3 FLUSH AIR AND DCT SYSTEM .......................................................................................................................3 ECL, ECG AND GREASE BRUSHES ................................................................................................................3 DRILLING PRINCIPLE ......................................................................................................................................3 ROTATION .......................................................................................................................................................3 FEED ...............................................................................................................................................................3 IMPACT ...........................................................................................................................................................3 03 SYSTEMS: ROC D [THURSDAY] ......................................................................................................................4 21. 22. 23. 24. 25. 26. 27. 28. 29. 30. DPCI...............................................................................................................................................................4 DRILLING ........................................................................................................................................................4 RPC-F ..............................................................................................................................................................4 ANTI-JAMMING ...............................................................................................................................................4 RAPID FEED AND THREADING ........................................................................................................................4 RHS TH..........................................................................................................................................................4 ANGLE INSTRUMENT ......................................................................................................................................4 SAFETY ...........................................................................................................................................................4 MAINTENANCE ...............................................................................................................................................4 ACTIV IEW.......................................................................................................................................................4 04 ROCK DRILL: ROC D [FRIDAY] ......................................................................................................................4 31. 32. ROCK DRILL ....................................................................................................................................................4 EVALUATION ..................................................................................................................................................4 Course description: Target After having completed this training the participants shall: - Understand the basic theories behind Atlas Copco’s HCS system. - Understand function and design of the HCS system on the rig. - The participants shall also be able to carry out fault-finding, with the fault-finding aids provided. Atlas Copco Service Personnel 5 days Lessons led by a teacher and self studies of theoretical parts mixed with practical exercises on the rig. Target group Time Training G:\Training\01 SDE Courses\04 ROC D\ROC D Content v1 06.09.18.doc 07-11-28 16:06 1 01 Basic: ROC D [Monday, Tuesday] Section 1. Introduction Target • • Know the goal of the training Be aware of the training materiel supplied. Method / Activity • • • • • • • • • • • • • Hand out: Manual, Course and writing material to students. Present course leader and participants. Present course goal, Content and the practical arrangements. Factory tour and classroom talk about our products. Use basic hydraulic course short version. Participants read trough Show and explain the different symbols at drawing. Show the system in real at rig Show and explain the different symbols at drawing. Show the system in real out in production Show pictures and at rig Show pictures and at rig Show drawings, PLC explanation and practical at rig Material, Course leader Time Ap. 2. 3. 4. Introduction of SDE Hydraulic general Basic Electric • • • • • • • Increase participants’ knowledge of SDE. Check participants knowledge of hydraulic system Know how to read and understand drawings. Know how to read and understand drawings. Know where components are located at rig Know the function of the different buttons, levers and switches Know the principle of the PLC and how to read the PLC explanation Power point presentation Power point presentation 5. Basic Hydraulic Power point presentation 6. 7. 8. Components Operating PLC Power point presentation, Rig Power point presentation, Rig Schedules G:\Training\01 SDE Courses\04 ROC D\ROC D Content v1 06.09.18.doc 07-11-28 16:06 2 02 Systems: ROC D [Wednesday] Section 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. 20. Pumps Pilot pressure Start Engine Engine speed control Tramming Compressor Flush air and DCT system ECL, ECG and grease brushes Drilling principle Rotation Feed Impact Target • • • • • • • • • • • • Know the function and location of the pumps Know the function and control of pilot pressure Know the basic principle of start sequence Know the function of the engine speed control Know the function of the tramming system Know the function of the compressor system Know the function of the flush air and the DCT system Know the function of the lubricate system Know the drilling principle Know the function of the rotation system Know the function of the feed system Know the function of the impact system Method / Activity • • • • • • • • • • • Show drawings and check practical at rig Show drawings and check practical at rig Show drawings and check practical at rig Show drawings and check practical at rig Show drawings and check practical at rig Show drawings and check practical at rig Show drawings and check practical at rig Show drawings and check practical at rig Material, Course leader Schedules Schedules Power point presentation Power point presentation Power point presentation Power point presentation Power point presentation Power point presentation Power point presentation Power point presentation Power point presentation Power point presentation Time Ap. Show drawings and check practical at rig Show drawings and check practical at rig Show drawings and check practical at rig G:\Training\01 SDE Courses\04 ROC D\ROC D Content v1 06.09.18.doc 07-11-28 16:06 3 03 Systems: ROC D [Thursday] Section 21. 22. 23. 24. 25. 26. 27. 28. 29. 30. DPCI Drilling Rpc-f Anti-jamming Rapid feed and threading RHS TH Angle instrument Safety Maintenance ActiView Target • • • • • • • • • • Know the function of the DPCI system Know the function of the full drilling sequence Know the function of the Rpcfsystem Know the function of the antijamming system Know the function of threading and rapid feed Know the function of the RHS 51 system Know the function and how to use the inclination system Know the safety instructions Know the important of maintenance Know how to use this tool Method / Activity • • • • • • • • • • Show drawings and check practical at rig Show drawings and check practical at rig Show drawings and check practical at rig Show drawings and check practical at rig Show drawings and check practical at rig Show drawings and check practical at rig Show operators manual and practical at rig Show the operator’s manual and safety chapter Show the operator’s manual and the maintenance chapter Show how to find parts in the program Material, Course leader Power point presentation System description Power point presentation Power point presentation Power point presentation Power point presentation Time Ap. Operator’s manual Operator’s manual ActiView program 04 Rock drill: ROC D [Friday] Section 31. 32. Rock drill Evaluation Target • • Know the function and system of the rockdrill Feedback of training Method / Activity • • One day at Rocktec. Talking and practical opening 2560 Questionnaire Material, Course leader Time Ap. G:\Training\01 SDE Courses\04 ROC D\ROC D Content v1 06.09.18.doc 07-11-28 16:06 4 Hydraulic system – General overview D-Mk I D-Mk II w. Volvo D-Mk II w. Bosal D RCS Mk II Batteries Main battery switch Electrical system – General overview MAIN ELECTRICAL CABINET Auto fuses Remote control box Roc D7 Sensors Diesel Engine Note: CCU only with Winch or non cab version Winch control Input CCU Can Control Unit Output Sensor Compressor Sensor Hyd. sys. Positioning Tramming Start motor Sensors Rod handling Sensors Rapid feed Switches Hyd. sys. Stop solenoid Drilling panel (left) Switches Steel support Switches Drilling Joystick Rod handling Switches Inputs PLC Programmable Logic Control Outputs Drilling panel (Right) Switches Dust collector Switches Drilling Switches tramming Switches Pulse relay Drill steel support Air flush Engine speed Pre-heating Hyd. valves Rod handling Hyd. valves Feed Hyd. valves Anti-Jamming Air valves Impact/Fl. air Pulse unit Dust collector ECL & (ECG) Pumps Compressor load Track oscillation Axx = Connection box Bxx = Sensor Fxx = Fuse Gxx = Generator, Battery Hxx = Lamp Kxx = Relay Mxx = Motor Pxx = Gauge Rxx = Resistor Sxx = Switch Yxx = Solenoid Name of the cable: W50B Plastic marking: 6 Printed on leader: 6 Connection points KC50C/29 are socket connections Terminal X40 in A40 box, connection point 27 Relay contact Relay see page 5 Drawing number and page number Operating Cabin 1 1. Left control panel 2. Right control panel 3. Tramming levers 4. Positioning levers 5. Drilling lever 6. VDO instrument 7. Electrical panel for operator’s cab 8. Emergency hammer 9. Fire extinguisher 10. Air conditioning 11. Gradient meter 12. Fire extinguisher. 1 Operating Gauge panel 1 2 3 4 5 6 7 8 9 1250 0177 16 2 1. Drill feed pressure 2. Flushing air pressure 3. Rock drill lubrication pressure (ECL) 4. Return pressure filter 5. Tank meter 6. Tachometer (VDO instrument) 7. Rotation pressure 8. Percussion pressure 9. Damper pressure 2 Operating Control instruments H180 H207 H211 H213 H203 H381 R354 H212 H214 H215 H382 P352 P354 S354 3 P354: ECM (engine monitoring system), rpm counter and display. S354: Button for display. R354: Button for adjusting the display contrast. P352: Fuel gauge with low level indicator lamp. H207: Indication lamp for clogged airfilter diesel engine/compressor. H180: Indication lamp when compressor is loaded. H211: Indication lamp for diesel engine guard, lamps indicate when a fault code apper. H212: Indication lamp for diesel engine guard, lamps indicate when a fault code apper that shut down the engine. H213: Indication lamp for rig guard, lamp indicate when alarm occur. H214: Indication lamp for rig guard, lamp indicate when an alarm that shut down the engine occur. H203: Indication lamp for low hydraulic oil level. H215: Indication lamp for low engine coolant level. H381: Indication lamp for ECL collection, lamp indicat on low pressure in return line, go off when correct pressure occur. H382: Indication lamp for ECL collection, lamp indicat on high pressure in return line, go off when correct pressure occur. 3 Operating Pressure setting panel This panel controls the pressure for feed, threading and impact. Rotation speed (COP). RPCF (Rotation Pressure Controlled Feed). 8 4 2 RPCF 7 3 5 6 1 1250 0177 18 4 1: Rotation speed. 2: RPCF, lower the feed pressure when rotation pressure gets above the adjusted value. 3: Low drill feed pressure. 4: High drill feed pressure. 5: Threading pressure. 6: Unthreading pressure. 7: Low impact pressure. 8: High impact pressure. 4 Operating Tramming levers 1250 0129 84 a b c 5 5 Operating Positioning levers a d b c 1250 0082 42 e 14 15 16 6 Positioning levers: 14: Feed dump and feed swing. 15: Boom swing and boom extension. 16.Boom lift and feed extension. 6 Operating Drill controls, rod handling and drill steel support (A51) 15 16 17 18 a 19 a c b e f d b ? 20 c 21 14 13 1250 0128 41 23 22 7 Drilling controls left arm wrest: 13: Switch for remote control or cabin control (option). 14: Light for remote control (see previous). 15: Upper drill steel support. 16: Lower drill steel support. 17: Automatic stop, pick up function for drill steels. 18: Sleeve retainer. 19: Rod handling controller 20: Suction hood. 21: Air flushing. 22:Remote button for diesel engine parameters. 7 Operating Drill panel S139 Ignition key S130 Switch for drilling/tramming/oil heating S170 Dust collector hatch open/closed S448 Water mist. S209 Support leg. S186 Signal horn S449 Thread greasing. S176 Track oscillation, (left). S445 Track oscillation (locking). S177 Track oscillation, (right). S180 Compressor. S189 Rpm control (variable). S130 a: Drilling b: Tramming low speed c: Tramming high speed d: Oil pre-heating. 8 8 Operating Drill level Magnetic holding A D 6 G Drill rotation Magnetic holding 5 B E 7 H F C 8 I 9 Drill mode: E: neutral B: rotation anti-clockwise B+A: rotation anti-clockwise and feed forward (magnet function) B+C: rotation anti-clockwise (magnet function) and feed backward. D: Feed forward (magnet function) F: Feed backward H: rotation clockwise H+G: rotation clockwise and feed forward H+I: rotation clockwise and feed backward Diode H452 is lit in this mode. Rapid feed/threading mode: E: neutral B: Threading B+A: rotation anti-clockwise and rapid feed forward B+C: rotation anti-clockwise and rapid feed backward D: Rapid feed forward F: Rapid feed backward H: Unthreading H+G: rotation clockwise and feed forward H+I: rotation clockwise and feed backward There is no diode indication in this mode. 9 Operating Cabin heat and AC 1. Working lights cab, front 2. Working lights rig, rear 3. Working lights feeder 4. Lighting engine compartment 5. Windscreen washer, upper 6. Windscreen wiper, upper increases speed in steps. 7. Windscreen wiper, upper reduces speed in steps. Switch off by depressing and holding the button for 2 seconds. 8. Front windscreen washers 9. Windscreen wiper, front reduces speed in steps. Switch off by depressing and holding the button for 2 seconds. 10. Windscreen wiper, front increases speed in steps. 11. Windscreen wiper, right reduces speed in steps. Switch off by depressing and holding the button for 2 seconds. 12. Windscreen wiper, right increases speed in steps. 13. Windscreen washer, right 14. Seat heating in two steps 15. Air condition 16. Fan, air conditioning reduces speed in steps. 17. Fan, air conditioning increases speed in steps. 18. Temperature reduces the temperature. 19. Temperature increases the temperature. 20. Fan, heater increases speed in steps. 21. Fan, heater reduces speed in steps. 22. Not used 23. Not used 10 10 Compressor b a c d Tab.05 compressor.ppt S180 Air system Unload Engine speed cont., page 3 Main air flow, page 2 Main air flow, page 2 DCT blow down, page 3 Watermist blow down, page 2 Tab.05 compressor.ppt Tab.05 compressor.ppt Air system Load Engine speed cont., page 3 Main air flow, page 2 Main air flow, page 2 DCT blow down, page 3 Watermist blow down, page 2 Tab.05 compressor.ppt Tab.05 compressor.ppt Area 4:1 Air system Blowdown Engine speed cont., page 3 Main air flow, page 2 Main air flow, page 2 DCT blow down, page 3 Watermist blow down, page 2 Tab.05 compressor.ppt Tab.05 compressor.ppt Air flushing & water mist DCT Unit, page 3 Main air flow, page 1 Main air flow, page 1 Watermist blow down, page 1 Tab.05 compressor.ppt ECL Main air flow, page 1 Tab.05 compressor.ppt Pressure gauge panel cab See hydraulic system cab: DCT Unit, page 3 Main air flow, page 1 Tab.05 compressor.ppt ECG DCT hatch open & thread greasing Thread grease page 3 Pressure supply DCT Pressure supply, page 1 Pressure supply DCT hatch, page 3 Tab.05 compressor.ppt Flushing air b a c d a c e f d b ? PLC input – flushing/DCT on To Switch S130 To switch take up rod string S181 B118 Tab.06 Flushing.ppt Open DCT hatch Arm in carousel PLC input – flushing/DCT on See next page Switch S130 in position drilling Flush air reduced Flush air full Impact pressure low Impact pressure high Tab.06 Flushing.ppt Flushing is controlled ON / OFF by switch S446 PLC input – flushing/DCT on To PLC X24 S130 in postion drilling Tab.06 Flushing.ppt Y250 Fan runnin g PLC outputs Y251A-C Y253 Tab.06 Flushing.ppt DCT cleaning after drilling Y115 Y116 Pumps – drilling RHS-system, page 5 Feed/Impact, page 2 Positioning, page 4 Tab.06 Flushing.ppt DCT on DCT pressure supply, page 1 Tab.06 Flushing.ppt Flushing on DCT unit, page 3 Main air flow, page 1 Main air flow, page 1 Tab.06 Flushing.ppt DCT off, filter cleaning DCT Pressure supply, page 2 Tab.06 Flushing.ppt Engine start OFF ON b a c d a S300 S300 b c Main switch off G2 alternator Diesel heater Timer Heater fan & water Tab.07 Engine start Cat-E.ppt Main switch on 1 Start motor 24 V – 25 circuit M18 Work lights ECM R1 preheating Tab.07 Engine start Cat-E.ppt Tab.07 Engine start Cat-E.ppt Main switch on 2 Tab.07 Engine start Cat-E.ppt Main switch on 3 Start engine 1 H214 See next page Tab.07 Engine start Cat-E.ppt K4A K4B K4C Main switch Start key 1 Start engine 2 K4A K4B K4B K4C 24 V – 50 circuit X1/83 Tab.07 Engine start Cat-E.ppt Main switch Start key 1 R241 has been introduced in order to provide a more stable signal to the PLC during engine start PLC X41 Start engine 3 – conditions to activate K330 B143 B361 Tab.07 Engine start Cat-E.ppt No fault Ignition pos. Main switch Start key 1 Start engine 4 – conditions to activate K330 B362 B366 Tab.07 Engine start Cat-E.ppt X1/83 B362 & B366 must be working normally in order to get 24 V out to PLC input X41, otherwise EMS 21 will be grounded. Main switch Start key 1 Start engine 5 – activating K330 K330 Tab.07 Engine start Cat-E.ppt Main switch Start key 1 Start engine 6 – activating K330 K330 ECM via F12 Tab.07 Engine start Cat-E.ppt Main switch Start key 1 Start engine 7 ECM via F12 Tab.07 Engine start Cat-E.ppt K4A K4B K4C Main switch Start key 1 Start engine 8 – Conditions for starter motor S180 Tab.07 Engine start Cat-E.ppt K4A K4B K4C Main switch Start key 1 Start key s Start engine 9 – Conditions for starter motor Tab.07 Engine start Cat-E.ppt S130 tramming pos. X24 OFF Main switch Start key 1 Start key s Start pos. Start engine 10 – starter motor activated K5B Tab.07 Engine start Cat-E.ppt Main switch Start key 1 Start key s Start engine 11 – starter motor activated K5B Tab.07 Engine start Cat-E.ppt Main switch Start key 1 Start key s Start engine 12 – starter motor activated K5B K4A K4B K4C K5A On M1 On cranking Tab.07 Engine start Cat-E.ppt Main switch Start key 1 Start key s Pumps and pilot pressure 1 2 3 4 5 6 7 8 Main pumps RHS-system, page 5 Feed/Impact, page 2 Positioning, page 4 Pump Control-p, Page 3 Rotation, Page 2 Wimch/positioning, Page 5 Dustfan motor Tab.08 Pumps and pilot pressure.ppt Pump regulation RHS-system, page 5 Feed/Impact, page 2 Positioning, page 4 Pump Control-p, Page 3 Rotation, Page 2 Tab.08 Pumps and pilot pressure.ppt DMP/Feed, page 3 Feed/Impact, page 1 Pilot-p, page 3 Tab.08 Pumps and pilot pressure.ppt Tab.08 Pumps and pilot pressure.ppt Pilot-p, page2 Tramming b a c d 1250 0129 84 a b c Tab.09 Tramming.ppt Pumps – tramming Tramming main flow Tab.09 Tramming.ppt Tramming pilot pressure Tramming main flow Tramming high/low Tram high, page 4 Pilot-p, page 2 Tram, page 2 Tab.09 Tramming.ppt Positioning, Tramming low speed Start to open at 7 bar and is fully open at 30 bar over the return line pressure. Diff is the diff between pressure and return line 30 bar is maximum pressure before closing to save sealings Tab.09 Tramming.ppt Tram flow, page 2 Tram high, page 3 Positioning, Tramming high speed Tram flow, page 2 Tab.09 Tramming.ppt Positioning, Track oscilation, open When tramming over a rock the track move 10 degree and the second track move 5 degree and the frame moves 5 degree, and the cabin is not in a steady position. Tab.09 Tramming.ppt Positioning, page 1 Winch, page 5 Positioning, Track oscilation, closed Tab.09 Tramming.ppt Positioning, page 1 Winch, page 5 Positioning, Winch, maximum pressure Winch/Positioning, page 1 Positioning, page 4 Tab.09 Tramming.ppt Positioning, Winch, regulation Winch/Positioning, page 1 Positioning, page 4 Tab.09 Tramming.ppt Positioning a d b c e Positioning – tramming Winch/Positioning, page 5 Tab.10 Positioning.ppt Positioning – tramming Winch/Positioning, page 1 Positioning, page 4 Tab.10 Positioning.ppt Positioning – Boom ”tramming” Tab.10 Positioning.ppt Winch, page 5 Positioning – drilling RHS-system, page 5 Feed/Impact, page 2 Positioning, page 4 Tab.10 Positioning.ppt Positioning – Boom ”drilling” Tab.10 Positioning.ppt Positioning, page 1 Rotation & oil pre-heating Drill feed b a c d Magnetic holding A D 6 G Drill rotation Magnetic holding 5 B E 7 H F C RPCF 8 I Tab.11 Oilheating and rotation.ppt Oil heating, electrical cab Y120 Preheating Hyd. Oil Drilling valve, Oil pre-heating Restrictor 2,0mm max flow appr 810 l/min, rest from pump appr 60 l/min throw 11 bar shunt valve Tab.11 Oilheating and rotation.ppt Appr 10 bar different over restrictor Feed/Impact, page 1 Pilot-p, page 3 Rotation, Page 1 Rot(+)-p, Page 3 Feed/Impact, page 1 Drilling valve, Rotation Pilot-p, page 3 Rotation+, Page 3 Rotation, Page 1 Tab.11 Oilheating and rotation.ppt Rotation Pilot-p, page 2 Rotation+, page 2 Pump Control-p, page 1 Tab.11 Oilheating and rotation.ppt Rot(+)-p, page 2 Drill feed Drill feed Magnetic holding A D 6 G Drill rotation Magnetic holding 5 B E 7 H F C RPCF 8 I Main pumps RHS-system, page 5 Feed/Impact, page 2 Positioning, page 4 Pump Control-p, Page 3 Tab.12 Drill feed.ppt Feed pressure DMP/Feed, Page 3 Feed/Impact, page 1 Pilot-p, page 3 Feed-p, Page 3 Feed+, Page 3 Tab.12 Drill feed.ppt Feed pressure Pilot-p, page 2 Feed+, page 2 DMP or Feed, page 2 Pump Control-p, page 1 Feed-p, page 2 Tab.12 Drill feed.ppt Drilling, collaring & full b a c d Magnetic holding A D 6 G Drill rotation Magnetic holding 5 B E 7 H F C RPCF 8 I Main pumps RHS-system, page 5 Feed/Impact, page 2 Positioning, page 4 Pump Control-p, Page 3 Rotation, Page 2 Tab.13 Drilling, collaring and full.ppt Rot(+)-p, Page 3 Feed/Impact, page 1 Drilling valve, Rotation Pilot-p, page 3 Rotation+, Page 3 Rotation, Page 1 Tab.13 Drilling, collaring and full.ppt Feed pressure DMP/Feed, Page 3 Feed/Impact, page 1 Pilot-p, page 3 Feed-p, Page 3 Feed+, Page 3 Tab.13 Drilling, collaring and full.ppt Impact pressure DMP/Feed, Page 3 Rot(+)-p, Page 3 Feed/Impact, page 1 Pilot-p, page 3 Feed-p, Page 3 Feed+, Page 3 Impact, Page 3 Rotation+, Page 3 Rotation, Page 1 Tab.13 Drilling, collaring and full.ppt Tab.13 Drilling, collaring and full.ppt Low impact X50 Off S452 Low impact S446A B118 S100 Tab.13 Drilling, collaring and full.ppt X3 Arm in carousel X25 or X26 On X27 On Page 7 Page 8 Tab.13 Drilling, collaring and full.ppt Y42 Y43 Y41 Low impact Y179A, B H452 H446 Low impact Y22 Y23 Y17 Y20 Tab.13 Drilling, collaring and full.ppt Y115 Y116 Y101B Y101A Y115 is activated when full air is chosen (PLC X26 On) Y101B is only activated during low impact (PLC X27 On) Low impact Impact, page 2 Pilot-p, page 2 Feed+, page 2 Rotation+, page 2 DMP or Feed, page 2 Pump Control-p, page 1 Feed-p, page 2 Rot(+)-p, page 2 Tab.13 Drilling, collaring and full.ppt High impact Impact, page 2 Pilot-p, page 2 Feed+, page 2 Rotation+, page 2 DMP or Feed, page 2 Pump Control-p, page 1 Feed-p, page 2 Rot(+)-p, page 2 Tab.13 Drilling, collaring and full.ppt RPC-F Rotation Pressure Controlled Feed DMP/Feed, Page 3 Rot(+)-p, Page 3 Feed/Impact, page 1 Feed/Impact/Rotation on Pilot-p, page 3 Feed-p, Page 3 Feed+, Page 3 Impact, Page 3 Rotation+, Page 3 Rotation, Page 1 Tab.14 RPC-f.ppt RPC-F working Impact, page 2 Pilot-p, page 2 Feed+, page 2 Rotation+, page 2 DMP or Feed, page 2 Pump Control-p, page 1 Feed-p, page 2 Rot(+)-p, page 2 Tab.14 RPC-f.ppt Bar Without Rpc-f With Rpc-f Anti-jamming set on 70 bar 70 80 Feed. p 70 60 50 50 70 70 Rotation p. 60 50 40 30 50 Tab.14 RPC-f.ppt Min How the RPCF and Anti-jamming works Anti-jamming B134 Rotation pressure Antijamming B142 Anti-jamming PLC inputs Air flow antijamming Tab.15 Anti-jamming.ppt Anti-jamming PLC output Drillfeed backwards Y109 Tab.15 Anti-jamming.ppt Anti-jamming working DMP/Feed, Page 3 Rot(+)-p, Page 3 Feed/Impact, page 1 Pilot-p, page 3 Feed-p, Page 3 Feed- Page 3 Impact, Page 3 Rotation+, Page 3 Rotation, Page 1 Tab.15 Anti-jamming.ppt Anti-jamming working Impact, page 2 Pilot-p, page 2 Feed-, page 2 Rotation+, page 2 DMP or Feed, page 2 Pump Control-p, page 1 Feed-p, page 2 Rot(+)-p, page 2 Tab.15 Anti-jamming.ppt Feed pressure go to zero when Anti.jamming get activated DPCI Damper Pressure Controlled Impact High impact, damper pressure >QDS I & < QDS J Impact, page 2 Pilot-p, page 2 Feed+, page 2 Rotation+, page 2 DMP or Feed, page 2 Pump Control-p, page 1 Feed-p, page 2 Rot(+)-p, page 2 Tab.16 DPCI.ppt Damper pressure < QDS A, High impact Low impact Impact, page 2 Pilot-p, page 2 Feed+, page 2 Rotation+, page 2 DMP or Feed, page 2 Pump Control-p, page 1 Feed-p, page 2 Rot(+)-p, page 2 Tab.16 DPCI.ppt Damper pressure < QDS I, Impact STOP Damping pressure below QDS I gives no pilot pressure to impact spool Impact, page 2 Pilot-p, page 2 Feed+, page 2 Rotation+, page 2 DMP or Feed, page 2 Pump Control-p, page 1 Feed-p, page 2 Rot(+)-p, page 2 Tab.16 DPCI.ppt Damper pressure < QDS I, Impact STOP Tab.16 DPCI.ppt Feed/Impact, page 1 Pilot-p, page 3 No pilot pressure to the impact spoole if the damping pressure is below the setting of the QDS I. Back hammer Feed/Impact, page 1 Pilot-p, page 3 Feed-, Page 3 Back hammer, Page 3 Tab.17 Back hammer.ppt Pilot-p, page 2 Backhammer, page 2 Feed-, page 2 Tab.17 Back hammer.ppt Rapid feed & Rod coupling Drill feed Magnetic holding A D 6 G a c e f d b ? Drill rotation Magnetic holding 5 B E 7 H F RPCF C 8 I Rapid feed Pump 1, page 1 Pilot-p, page 3 RFeed+, page 3 Tab.18 Rapid & Rod coupling.ppt Rapid feed Pilot-p, page 2 RFeed+, page 2 Pump Control-p, page 1 Tab.18 Rapid & Rod coupling.ppt Rapid feed X12 Rapid feed stop Forward X13 Rapid feed stop Backward un-coupling X14 Rapid feed stop Backward B122 B126 B127 Tab.18 Rapid & Rod coupling.ppt Rapid feed Y149 Y150 Y3 Rapid feed stop Backward Y4 Rapid feed stop Forward Tab.18 Rapid & Rod coupling.ppt Rod coupling Pump 1, page 1 Pilot-p, page 3 Feed-p, page 3 Feed+, page 3 Rotation+, Page 3 Rotation, Page 1 Tab.18 Rapid & Rod coupling.ppt Rod coupling Pilot-p, page 2 Feed+, page 2 Rotation+, page 2 Pump Control-p, page 1 Feed-p, page 2 Tab.18 Rapid & Rod coupling.ppt Rod handling a c e f d b ? Tab.19 Rod hangling system.ppt S111 Rodhandling lever input K6 K7 K10 K11 K6 K7 K10 K11 Y303 Y300 Y306 Y301 Tab.19 Rod hangling system.ppt Rodhandling lever output Tab.19 Rod hangling system.ppt Rod arm to drill center input X16 Arm to drill center K10 K10 Y301B Tab.19 Rod hangling system.ppt Rod arm to drill center output RHS-system, page 5 Feed/Impact, page 2 Positioning, page 4 Tab.19 Rod hangling system.ppt Rod handling Tab.19 Rod hangling system.ppt RHS-system, page 1 Rod arm to drill center Tab.19 Rod hangling system.ppt RHS-system, page 1 Loose grip Tab.19 Rod hangling system.ppt RHS-system, page 1 Open grip How to use angle instrument HQS 11-12 Angle mode: Upper display shows Feed tilt angle: Lower display shows Feed swing angle: ROC D7 Length mode: Upper display shows Penetration rate: Lower display shows Hole dept / length: Set length value On / Off Total Set Length Drilling On / Off Switch power on in position ON activates the angle instrument. When press button “ Total “ is pressed the upper display shows penetration rate of the last rod and the lower display shows total drilled meters in rock. To zero set the total drilled length press button total and set at the same time. Set length. Drill bit against the rock. Press button Set (display shows S LE) and turn the knob Set length to desired hole depth. The drilling will automatically stops when the present hole depth is achieved or the depth from the lazer plane. Note: When the desired depth has been reached the drilling stops automatically. Manually return the levers for feed and rotation to neutral position and press button on feed lever to stop impact. Switch length measurement is controlling the angle and length mode as follow: In Off position the display shows angles for feed tilt and feed swing. In On position (drilling) the upper display shows penetration rate and the lower display shows position of the drill bit. When drill steel support is closed and unthreading is activated the display go into angle mode: When rod handling is completed and the upper drill steel opens the system will automatically go into drilling mode and the display will again show penetration rate and hole length. 1 1 MANUAL Hole Quality System HQS General description General data Operation How to use HQS 10 How to use HQS 11 How to use HQS 12 Principle of operation Drilling angles definition Drilling signals Laser Trouble shooting mode Trouble shooting angle system Trouble shooting length system Trouble shooting laser system Electric connection drawing Page 2 3 4 5-6 7-8 9-10 11 11 12 13 14 -15 16 17 18 19 Atlas Copco Rock Drills AB S-701 91 Örebro SWEDEN Phone +46(0)19-6707000 Fax +46(0)19-6707070 HQS.rtf1; 06-11-23 2 1 GENERAL HQS is a complete angle and length measuring instrument for benching rigs. The system is built in modules which makes it easy to upgrade. HQS 10 Complete instrument for angle measurement. HQS 11 Complete instrument for angle measurement, hole length and penetration rate. HQS 12 Complete instrument for angle measurement, hole length from a laser plane and penetration rate. HQS.rtf1; 06-11-23 3 2 GENERAL DATA 16 - 33 VDC 0,2A -20 - +50°C IP65 2 × ± 30° ± 0,3° Power supply Power consumption Working temperature Environmental protection Angle measuring: Measurement range Accuracy Hole length/penetration rate measuring: Measurement range hole length Measurement range penetration rate Measurement range total hole length Accuracy length measurement Type of laser for detection 0 - 99.9 m 0 - 9.99 m/min 0-999.9 m ± 1%, min 0.05 m Rotating visible red. Wavelength: 630 – 680 nm HQS.rtf1; 06-11-23 4 3 3.1 OPERATION Display Arrow downwards Arrow upwards Angle mode position. Display shows on upper display, inclination angle and on lower display, side angle. Length mode position. Display shows on upper display, rate of penetration and on lower display, length. 3.2 Control Box Power On / Off Total Length measurement On / Off Set length On Off -/+ Set length Switch “Power On/Off” turns the power On/Off for the complete system. When button “Total”(Σm) is pressed the system shows on the lower display total drilled meters in rock and on the upper display penetration rate for the last rod. To zero set total drilled length press both “Total” and “Set Length” at the same time. Note: Max total length is 999.9 meters. “Set Length”(-/+). The “Set Length” mode stops the drilling when the pre-set hole length is achieved . I.e. if the pre-set length is set to 15,0 m the system will stop the drilling 15,0 m from the collaring point or 15,0 m below the laser plane. When button “Set Length” is pressed the system shows SLE on upper display, and hole length on lower display. By turning the knob “-/+“ the hole length is adjusted. Note: When the “Set length”( hole depth is reached, percussion, rotation and feed will stop. Drill levers must manually be returned to neutral, before rod removal begins. Switch ”Length measurement” is controlling length measurement. In OFF position the displays shows angles (Angle Mode ). In ON position the lower display shows position of the drill bit and the upper display shows penetration rate. When Unthreading becomes active the system goes to show angles. ( Rod handling Begins ). When Upper drill steel guide open is activated, the system to go back to length mode. ( Rod handling finished ). Note: Max hole length is 99.9 meters. HQS.rtf1; 06-11-23 5 3.3 How to use: HQS 10 Drilling position S et cra w ler a t p o sitio n fo r first h o le Aiming position 10.0 02.5 Angles position See how to use next page HQS.rtf1; 06-11-23 6 How to use HQS 10 1. Set the crawler in position for the first hole. 2. Aim with the sight at a point which is located as far as possible from the crawler position. All drilling direction angles are related to this aiming direction. 3. Manually position the feeder to the drill angles for the hole. 4. Drill the hole to desired depth. 5. Take the rods up from the hole. 6. Manoeuvre the drill rig to position for next hole. HQS.rtf1; 06-11-23 7 3.4 How to use HQS 11 Drilling position S et cra w ler a t position for first hole Aiming position 1 0 .0 0 2 .5 Angles position 02.2 11.3 Drill bit position See how to use next page HQS.rtf1; 06-11-23 8 How to use HQS 11 1. Set the crawler in position for the first hole. 2. Aim with the sight at a point which is located as far as possible from the crawler position. All drilling direction angles are related to this aiming direction. 3. Manually position the feeder to the drill angles for the hole. 4. Press the “Pre-set length” button and adjust to desired drilling length by turning the knob “Set length” (+/-). 5. Manoeuvre the drill bit against the collaring point. 6. Set the switch “length measurement” to position ON. This means that the system goes into length measurement mode and at the same time, the drill bit position set’s to zero. (Instrument shows penetration rate and drill bit position). 7. Drill first rod. 8. Close drill steel support and unthread the adapter. The instrument goes to mode showing angles and length measuring is stopped. Note that the system is measure the length between signal “Upper drill steel support open” and signal “Unthreading”. So this signals most be active at the beginning and at the end of the rod. 9. Manoeuvre a new rod into drilling position. 10. When the upper drill steel support is opened the instrument starts to show length measurement again. 11. Drill hole to desired depth. 12. The system automatically stops the drilling when desired hole depth have been reached. ( Only if “Set length” is used). Note: To de-activate the length measuring set length to 0.00. 13. Put the drill controls back to neutral. 14. Set switch “Length measuring” back to position OFF. 15. Take the rods up from the hole. 16. Manoeuvre the drill rig to position for next hole. HQS.rtf1; 06-11-23 9 3.5 How to use HQS 12 Drilling position S et cra w ler a t position for first hole Aiming position 1 0 .0 0 2 .5 Angles position 02.2 11.3 Drill bit position Laserplan 1.26 Drilling with laserplane 1.02 Laserplan 1.20 5:03 Hit by laserplane Drill bit distance pre-set to 5.03m HQS.rtf1; 06-11-23 10 See how to use next page How to use HQS 12 1. Set the crawler in position for the first hole. 2. Aim with the sight at a point which is located as far as possible from the crawler position. All drilling direction angles are related to this aiming direction. 3. Manually position the feeder to the drill angles for the hole. 4. Press the “Pre-set length” button and adjust to desired drilling length by turning the knob “Set length” (+/-). 5. Manoeuvre the drill bit against the collaring point. 6. Set the switch “length measurement” to position ON. This means that the system goes into length measurement mode and at the same time set the drill bit position to zero. ( Instrument shows penetration rate and drill bit position ). 7. Drill first rod. ( When the laser receiver on the cradle reaches the laser plane, the length display shows by changing the decimal point to colon, that the length starts to count from this position). 8. Close drill steel support and unthread. The instrument goes to mode showing angles and length measuring is stopped. Note that the system is measure the length between “ Upper drill steel support guide open” and signal “Unthreading”. So this signals must be active at the beginning and the end of the rod. 9. Manoeuvre a new rod into drilling position. 10. When the upper drill steel support is opened the instrument starts to show length measurement again. 11. Drill hole to desired depth. 12. The system automatically stops the drilling when desired hole depth have been reached. ( Only if “Set length” is used) Note: To de-activate the length measuring set length to 0.00. 13. Put the drill control back to neutral. 14. Set switch “Length measuring” back to position OFF 15. Take the rods up from the hole. 16. Manoeuvre the drill rig to position for next hole. HQS.rtf1; 06-11-23 11 4 Principle of operation The system comprises separate functions for A: showing drilling angles and B: showing length measurement. 4.1 Drilling angles definition The drilling angles system comprises: Transducer to measure the swing movement of the boom versus the carrier. (boom joint transducer). Transducer to measure the angles of the feed beam in X- and Y direction. (angle transducer). Transducer to measure the decided aiming direction (sight) versus the carrier. Indicator with two displays, showing the angles. (indicator) Signal cables for connecting the transducers to the central unit and the indicator. All angles are calculated against the aiming direction. This means that if the boom and the sight point straight forward, the angles are shown according to fig 3A. If the boom is moved , the system will detect the movement and calculate so that angles, still are in the same aiming direction as the sight. See fig 3B If you now move the sight, the system will detect the movement and calculate so that the angles are according to the new aiming direction. See fig 3C The angles shown on the display is referring to the direction of the drill bit. I.e. if the sight is pointing strait forward, the upper display is showing +100 and the lower shows -1.20. This means that the drill bit is pointing 100 forward and 1.20 to the left in sight direction, seen from the inside of the cabin. Fig. 3A-C HQS.rtf1; 06-11-23 12 4:2 Drilling signal for controlling the length measurement. Input signals, used for controlling the length measurement are connected to “Upper drill support guide open” and “Unthreading” of the adapter (Drilling signal 1 and 2). When the switch “Length measurement” is ON the system begins to show position of the drill bit. In length measurement mode the systems holds a steady check of the drill bit. If the drill bit is moving backwards, the system begins to count down the position of the drill bit. When the signal “Unthreading” is activated, length measurement is turned off, and the system goes into angle measurement mode.. When the signal “Upper drill steel support open” is activated the length measurement is resumed. When the hole is finished, the length measurement is set to zero when the switch “length measurement” is switch to OFF. Note that the system is measuring the length between the signal “Upper drill steel support open” and the signal “Unthreading”. So this signals must be active at the beginning and the end of the rod. HQS.rtf1; 06-11-23 13 4:3 Laser The laser sends out a laser beam which rotates horizontally. When the laser is set up, it’s very simply to adjust, to give an exact horizontal plane. This plane can be used as a reference to height measurement. The laser is set up at a known height from the bottom. See fig 4 Hole length from a laser plane On the cradle there is a sensor which signals to the instrument when it is hit by a laser beam from the rotating laser that has been set up at a known height from the bottom. When mounting the system, the distance from the drill bit to the laser sensor is measured. To program this value see Set-up and Trouble shooting mode. Laserplan 1.26 1.02 Fig 5 Laserplan 1.20 5:03 Fig 6 When drilling starts, the instrument measures the hole length from the collaring, See fig 5. When the sensor is hit by the laser plane, which must be during drilling the first rod, it signals to the instrument, which then sets the programmed drill bit to laser distance and continues the length measuring from this point, See fig 6. The now displayed length, is from the laser plane. This is indicated by that the decimal point being changed to a colon, on the length display. HQS.rtf1; 06-11-23 14 5 TROUBLE SHOOTING MODE Trouble shooting mode, input signal check and laser distance setting mode: To get into trouble shooting mode; Turn the system OFF. Note that switch “length measurement ON/OFF” has to be in position OFF. Activate button SET LENGTH, turn the system ON and then release SET LENGTH. Now the instrument goes in to trouble shooting mode. The upper display shows the checking number and the lower display shows the value from chosen transducer or the input signals to the system. To get to the next check, activate Total (Εm) and release it. All directions is referring to the top of the feeder. Upper display 0001 Lower display Side angle transducer. When the feeder is in plumb line the value shall be approx. 0°( +3° ). When the top of the feeder is inclined to the left, the value shall be negative and when the top of the feeder is inclined to the right, the value shall be positive. Inclination angle transducer. When the feeder is in plumb line the value shall be approx. 0°( +3° ). When the top of the feeder is inclined forward, the value shall be negative and when the top of the feeder is inclined backwards, the value shall be positive. Boom joint transducer. When the boom is straight forwards the value shall be approx. 0° ( +3° ). When the boom is moved to the left, the values shall be negative and when the boom is moved to the right, the value shall be positive. Swinging cabin transducer. When the cabin is straight forward the value shall be approx. 0° ( +3° ). When the cabin is moved to the left, the value shall be negative and when the cabin is moved to the right, the value shall be positive. Cabin sight. When the sight is straight forward the value shall be approx. 0° ( +3° ). When the sight is moved to the left, the value shall be negative and when the sight is moved to the right, the value shall be positive. Signals from drilling and length transducer are shown: The 1000 digit shows “1” when the drilling signal 1 is 1 0 00 active and “0” when inactive. (Percussion) The 100 digit shows “1” when the drilling signal 2 is 0 100 active and “0” when inactive.(upper drill steel guide) The 10 digit shows “1” when the drilling signal 3 is 0010 active and “0” when not. (Unthreading) The 1 digit is counting between 0 -9 to indicate the length transducer is working, when the cradle is moved. 0 0 0 7 HQS.rtf1; 06-11-23 0002 0003 0004 0005 0006 15 Cont. 0007 Laser receiver signal and measurement resolution. The 1000 digit shows “1” when the laser signal is active and “0” when inactive. By switching the button length measurement on and off you set the measurement resolution in the angle measurement mode. It is possible to choose between 0.1, 0.2, 0.5 degrees resolution Shows programmed length from laser receiver to drill bit. To change programming do: Step the cm digit with the length measurement switch (off/on) to desired value. To get to the next digit, activate Total (Εm) and release it Step the 10 cm digit with the length measurement switch (off/on) to desired value. To get to the next digit, activate Total (Εm) and release it. Step the 1 m digit with the length measurement switch (off/on) to desired value. To get to the next digit, activate Total (Εm) and release it. Step the 10 m digit with the length measurement switch (off/on) to desired value. To get to the next digit, activate Total (Εm) and release it. Setting this check to 0000 switches OFF the laser function. Max drill steel length is the max length that the system is measuring between upper drill guide open and unthreading. I.e. the length of one drill steel. Shows max drill steel length. To change programming do: Step the cm digit with the length measurement switch (off/on) to desired value. To get to the next digit, activate Total (Εm) and release it Step the 10 cm digit with the length measurement switch (off/on) to desired value. To get to the next digit, activate Total (Εm) and release it. Step the 1 m digit with the length measurement switch (off/on) to desired value. To get to the next digit, activate Total (Εm) and release it. Step the 10 m digit with the length measurement switch (off/on) to desired value. To get to the next digit, activate Total (Εm) and release it. 0008 0008 0080 0800 8000 0009 0009 0090 0900 9000 HQS.rtf1; 06-11-23 16 6 Fault TROUBLE-SHOOTING ANGLE SYSTEM Action Check power supply between + and - in the central unit. Should be between 16V-33VDC. (Input voltage). See drawing 0002330 If no voltage check the fuse in the main electrical cabinet and check that there is +24 VDC on terminal 25. If voltage OK check the switch ON/OFF in the control box and the control box cable. The indicator shows nothing. And the lights in the displays are off. If lights in the display is on. If power supply is OK, check that there is +12V DC between 1 and 2 in the central unit on one of the connector to the transducers. See drawing 0002330. Change the central unit. Power supply and +12 V correct but the displays shows nothing. If no +12V DC between 1 and 2 in the central unit. Display on the indicator shows unrecognisable characters. Disconnect the feeder cable, sight and boom-joint transducer’s in the central unit. Turn the power switch OFF and ON. Connect one cable at the time and check when the fault appears. Then disconnect the transducer from it’s cable and check if the fault disappears . If not, change signal cable. If yes, change transducer. Try with a spare cable/transducer See drawing 00022330. Display for inclination or side unstable shows incorrect value. Run the trouble shooting mode and try to locate the faulty transducer. See chapter 5 Connect a spare (lose) cable to the faulty transducer. If function OK, change signal cable If not change transducer. If the measurement still doesn't work correct, change the central unit. HQS.rtf1; 06-11-23 17 7 Fault TROUBLE-SHOOTING LENGTH SYSTEM Action Run the trouble shooting mode and try to locate the fault. Mode 6 See chapter 5 Length measurement doesn't work Missing signal from the length transducer. Check the wire on the length transducer. Check that the proximity switches in the length transducer is ok by using trouble shooting mode 6. If the transducer don’t work in trouble shooting mode 6, measure voltage inside the connection box on the feeder. See drawing 0002330 Trouble shoot the control signal connections in the A1 Electrical cabinet. See drawing 00022330 If no drilling signals HQS.rtf1; 06-11-23 18 8 TROUBLE-SHOOTING LASER SYSTEM Action Run the trouble shooting mode and try to locate the fault. See chapter 5 Connect B-C in the laser cannon plug and see if the display indicates laser signal. If the indicator indicates laser signal measure A-B =12 VDC, B-C 4.7 VDC. If power is OK change laser-receiver. Fault No laser indication If no indication on the display or if one voltage is missing. Measure voltage on the laser side in the connection box for the laser. (On the feeder) Red-white = +12 VDC. Blue-white = 4.7 VDC. If power OK change cable between the laser connection box and the laser receiver. If no power change the cable between the connection box for the laser and the connection box on the length transducer. See drawing 00022330 HQS.rtf1; 06-11-23 08-01-25, PLC Programme, ROC D5,D7 Bosal PLC-PROGRAMME EXPLANATION PLC TYPE: MITSUBISHI MELSEC FX1N PLC PART NUMBER: E-EPROM PART NUMBER: DRILLRIG TYPE: D5/D7 CAT-C7 1. GENERAL FUNCTIONS..............................................................................................................................................2 1.1 POWER SUPPLY ............................................................................................................................................................2 1.2 LAMP TEST....................................................................................................................................................................2 1.3 PUMP 3 UNLOAD ..........................................................................................................................................................2 1.4 ACTIVATING ECM........................................................................................................................................................2 1.5 ENGINE CRANKING .......................................................................................................................................................2 2.DRILLING FUNCTIONS...............................................................................................................................................3 2.1.A DCT SUCTION ...........................................................................................................................................................3 2.1.B DCT CLEANING AFTER DRILLING ..............................................................................................................................3 2.2 ECL-PUMP ...................................................................................................................................................................3 2.3 ECG-PUMP ..................................................................................................................................................................3 2.4 ANTI-JAMMING ACTIVATED BY HIGH ROTATION PRESSURE..........................................................................................4 2.5 ANTI-JAMMING ACTIVATED BY FLUSHING ....................................................................................................................4 2.6.A LOW FEED PRESSURE SETTING PUMP 1 .....................................................................................................................4 2.6.B LOW IMPACT ACTIVATION WITH FUNCTION SELF-HOLDING ......................................................................................4 2.6.C HIGH IMPACT ACTIVATION WITH FUNCTION SELF-HOLDING .....................................................................................5 2.6.D DEACTIVATION OF MAGNETIC HOLDING FOR DRILL LEVER.......................................................................................5 2.7 IMPACT HOUR COUNTER ...............................................................................................................................................5 2.8 AUTOMATIC DRILL STOP FUNCTION..............................................................................................................................5 3. RAPID FEED STOP FUNCTIONS.............................................................................................................................6 3.1.A FORWARD STOP AT DRILLSTEEL SUPPORT ................................................................................................................6 3.1.B BACKWARD STOP, AT UNCOUPLING ..........................................................................................................................6 3.1.C BACKWARD STOP, AT INTAKE MAGAZINE..................................................................................................................6 3.1.D BACKWARD, MAX, STOP ...........................................................................................................................................6 4. RODHANDLING FUNCTIONS...................................................................................................................................6 4.1.A OPEN GRIPPER ..........................................................................................................................................................6 4.1.B LOOSE GRIP ...............................................................................................................................................................6 4.1.C HARD GRIP ................................................................................................................................................................6 4.2.A SLEEVE RETAINER ACTIVATION .................................................................................................................................7 4.2.B SLEEVE RETAINER DEACTIVATION .............................................................................................................................7 4.3.A RHS, ARM TOWARDS DRILLCENTER .........................................................................................................................7 4.3.B RHS, ARM TOWARDS CAROUSEL ..............................................................................................................................7 4.4.A RHS, CAROUSEL ROTATION, CLOCKWISE. ................................................................................................................7 4.4.B RHS, CAROUSEL ROTATION, COUNTER CLOCKWISE. ................................................................................................8 5. SUPERVISION FUNCTIONS ......................................................................................................................................8 5.1 LOW HYDRAULIC OIL LEVEL, ENGINE SHUTDOWN .......................................................................................................8 5.2 COOLANT LEVEL, ENGINE SHUTDOWN .........................................................................................................................8 5.3 CLOGGED AIRFILTE FOR DIESELENGINE AND COMPRESSOR, WARNING .......................................................................8 1(8) 08-01-25, PLC Programme, ROC D5,D7 Bosal Function Signal from/position PLC input/status PLC output Valve 1. GENERAL FUNCTIONS 1.1 Power supply S139/Ignition ON Fuse F13/On Fuse F15/ON X1/100 K4A + 24V + 24V* - ground connection When ignition key S139 is in position 1, ignition ON, relay K4A is activated to allow power supply to fuse F13. Ground connection also bridged to connection S/S and 0V. *+24V to supply COM1 to COM7 and exp-unit COM1. Without power from F15 output signal from PLC will be indicated by LED although no signal will be present on output connections. F15 supplies relays inside PLC. 1.2 Lamp test S139/Ignition X42/ON Y31/ON Y32/ON Y33/ON Y27/ON H203 H215 H207 H213 H214 H381 H382 When ignition key S139 is in position 1, the mentioned lamps will be flashing for two seconds. Other warning lamps (H211, H212) on the diesel panel are lamp tested by the ECM. 1.3 Pump 3 unload S130/Tramming pos. S139/Ignition S139/Engine start S139/Ignition X24/OFF X42/ON X34/ON X42/ON Y26/ON Y26/OFF Y26/ON Y187 Y187 Note! When the ignition switch (S139) is released from starting position and re-springed back to ignition position, the output Y26 is ON again. 1.4 Activating ECM S139/Ignition pos B143/Active B361/Active No shutdown signal 1.5 Engine cranking S130/Tramming pos. S139/Start pos X24/OFF X34/ON* Y24/ON K5B X34/ON X36/ON X37/ON X41/ON Y30/ON K330 *Note! When S180 is open (compressor on), there will be no input on X34. 2(8) 08-01-25, PLC Programme, ROC D5,D7 Bosal Function Signal from/position PLC input/status PLC output Valve 2.DRILLING FUNCTIONS 2.1.a DCT suction S130/Drilling pos. B118/Arm in carousel S100/Flush air pos. *S446/Flushing pos. S181/Suction pos. X24/ON X3/ON X25/ON or X26/ON X27/ON or X30/ON X2/ON Y21/ON Y253 *To start flushing and DCT, press the impact switch (S446A) for shorter than 0.5 sec. To start low impact, press the switch (S446A) for longer than 0.5 sec. To start high impact without self holding, press the switch (S446B) all the time. 2.1.b DCT cleaning after drilling S130/Drilling pos. *S100/Flush air pos. *S446/Flushing pos. X24/ON X25/OFF or X26/OFF X27 OFF or X30/OFF Y21/OFF Y251A Y251B Y251C *To achieve cleaning, the first condition is to have the DCT suction on, Y21/ON (see 2.1a). The second condition is Y21 must be then be OFF (DCT hatch closed) by having one of: X25, X26, X27, X30 OFF. Just by switching off S181 will not start DCT cleaning; in other words, to start DCT cleaning, drilling must be deactivated. If DCT hatch is not ON from the beginning (Y21/OFF), then no cleaning will be achieved at all. 2.2 ECL-pump S130/Drilling pos. B118/Arm in carousel S100/Flush air pos. *S446/Flushing pos. X24/ON X3/ON X25/ON or X26/ON X27/ON or X30/ON Y0/ON Y106 *To start flushing and DCT, press the impact switch (S446A) for shorter than 0.5 sec. To start low impact, press the switch (S446A) for longer than 0.5 sec. Note! The ECL-Pump (Y106) works with an extended time of 60 seconds when the flush air switch S100 or impact switch S446 have been shut-off after drilling. This time is set on the external ECL-relay and is not affected by a lost in output signal Y0. 2.3 ECG-pump S130/Drilling pos. B118/Arm in carousel S100/Flush air pos. *S446/Flushing pos. X24/ON X3/ON X25/ON or X26/ON X27/ON or X30/ON Y1/ON Y107 *To start flushing and DCT, press the impact switch (S446) for shorter than 0.5 sec. To start low impact, press the switch (S446) for longer than 0.5 sec. Note! The ECG-pump (Y107) does not work with an extended time. But it is possible to adjust on the external ECG-relay if needed. 3(8) 08-01-25, PLC Programme, ROC D5,D7 Bosal Function Signal from/position PLC input/status PLC output Valve 2.4 Anti-jamming activated by high rotation pressure S130/Drilling pos. X24/ON B118/Arm in carousel X3/ON S446/Impact pos. X27 or X30/ON B134/ACTIVE X0/ON Y2/ON Y109 The minimum activation time for output Y2 is set by the PLC internally to 0.8sec. Note: When anti-jamming has been de-activated low feed and low impact pressure will be activated for 6 sec. before going to high feed and high impact pressure. 2.5 Anti-jamming activated by flushing S130/Drilling pos. B118/Arm in carousel *S100/Full flush air pos. S446/Flushing pos. B142/Active X24/ON X3/ON X26/ON X27 or X30/ON X1/ON Y2/ON Y109 *The flow switch is only functioning during full flushing. The minimum activation time is set by the PLC internally to 0.8sec. Note: When anti-jamming has been de-activated low feed and low impact pressure will be activated for 6 sec. before going to high feed and high impact pressure. 2.6.a Low feed pressure setting pump 1 S130/Drilling pos. X24/ON Y17/ON Y101B *When switch (S130) is in drilling position, valve 101B for low feed and impact pressure is activated. 2.6.b Low impact activation with function self-holding Magnetic holding on rotation anti-clockwise and feeding forwards can only be achieved when the control lever is being pulled to the end position, pulling the lever only half way and then release would result in lever springed back to the neutral position. S130/Drilling pos. S180/Compressor activated B118/Arm in carousel S100/Flush air pos. S452/Rapid feed mode off X24/ON X3/ON X25/ON or X26/ON X50/OFF Y17/ON Y101B S446A/Low impact. X27/ON Y41/ON Y41/ON Y42/ON Y20/ON Y23/ON Y22/ON Y43/ON Y179A Y179B H452 Y101A Y116 *Y115 H446 *Solenoid Y115 gets activated when S100 is in full flushing position. To activate impact, press S446A for longer than 0.5 sec, pressing the button once more for shorter than 0.5 sec would deactivate impact/flushing and the lever returns to the neutral position. Diode H446 gives blinking signals when drilling with low impact. Note: It is possible to start percussion while rapid feeding backwards (if the rig is equipped with a extractor), in that case S446A must be held in at all time and only low percussion will be available. This is typically the case when cleaning the hole. 4(8) 08-01-25, PLC Programme, ROC D5,D7 Bosal Function Signal from/position PLC input/status PLC output Valve Y17/ON Y101B 2.6.c High impact activation with function self-holding S130/Drilling pos. X24/ON S180/Compressor activated B118/Arm in carousel X3/ON S100/Flush air pos. X25/ON or X26/ON S452/Rapid feed mode off X50/OFF S446A/Low impact. X27/ON ⇓ S446B/High impact. ⇓ X30/ON Y41/ON Y41/ON Y42/ON Y20/ON Y23/ON Y22/ON Y43/ON ⇓ Y17/OFF Y20/ON Y23/ON Y22/ON Y43/ON Y179A Y179B H452 Y101A Y116 *Y115 H446 ⇓ Y101A Y116 *Y115 H446 *Solenoid Y115 gets activated when S100 is in full flushing position. To shift to high impact from low impact, press S446B for longer than 0.5 sec, pressing the button once more or shorter than 0.5 sec would deactivate impact/flushing and the lever returns to the neutral position. When changing back to low impact, press the low impact pressure switch S446A for longer than 0.5 sec, otherwise the impact will be shut off. Diode H446 gives stable signal when drilling with high impact. When starting directly with high impact, impact is activated as long as switch S446B is pressed. 2.6.d Deactivation of magnetic holding for drill lever S453/Magnets off drill lever OR S452/Rapid feed mode 2.7 Impact hour counter S130/Drilling pos. S446/Impact. pos. 2.8 Automatic drill stop function S130/Drilling pos. Drill depth reached X51/ON X50/ON Y41/OFF X24/ON X27/ON or X30/ON Y20/ON P108 X24/ON X43/ON H452 *Solenoid Y115 gets activated when S100 is in full flushing position. Drilling can be re-started once the HQS is reset, or by pressing the impact switch S446 for shorter than 0.5 sec, then drilling can be re-activated (HQS will continue counting). Y17/ON Y41/OFF Y20/OFF Y23/ON Y22/ON Y43/OFF Y42/ON Y101B Y116 *Y115 5(8) 08-01-25, PLC Programme, ROC D5,D7 Bosal Function Signal from/position PLC input/status PLC output Valve 3. RAPID FEED STOP FUNCTIONS 3.1.a Forward stop at drillsteel support S130/Drilling pos. B122/Active 3.1.b Backward stop, at uncoupling S130/Drilling pos. S113/Take up rod string B126/Active 3.1.c Backward stop, at intake magazine S130/Drilling pos. S113/Take up rod string B126/Active 3.1.d Backward, max, stop S130/Drilling pos. B127/Active X24/ON X12/ON X24/ON X22/ON X13/ON X24/ON X22/ON X13/ON X24/ON X14/ON Y4/ON Y150 Y3/ON Y149 Y3/ON Y149 Y3/ON Y149 If sleeve retainer switch (S182), X23/ON is activated then rapid feed stop backward (Y149), Y3/ON and rapid feed stop forward (Y150), Y4/ON will be automatically activated. 4. RODHANDLING FUNCTIONS 4.1.a Open Gripper S130/Drilling pos. *S446/Impact switch B379/Operator seat active S111/Top button pushed X24/ON X27 and X30/OFF X31/ON X21/ON Y6/ON K6 Y300 *Flushing is deactivated automatically when switching impact off, this enables rod handling. 4.1.b Loose grip S130/Drilling pos. *S446/Impact switch B379/Operator seat active S111/Neutral pos. B118/Dis-ACTIVE X24/ON X27 and X30/OFF X31/ON All functions OFF X3/OFF Y7/ON K7 Y306 *Flushing is deactivated automatically when switching impact off, this enables rod handling. 4.1.c Hard grip S130/Drilling pos. X24/ON Hard grip is the normal condition. No active inputs or outputs are required. Exceptions are Open gripper and Loose grip. 6(8) 08-01-25, PLC Programme, ROC D5,D7 Bosal Function Signal from/position PLC input/status X24/ON X27 and X30/OFF X31/ON X16/ON X23/ON PLC output Valve 4.2.a Sleeve retainer activation S130/Drilling pos. *S446/Impact switch B379/Operator seat active S111/Pos, backwards. **S182/Sleeve retainer Y5/ON Y309 *Flushing is deactivated automatically when switching impact off, this enables rod handling. ** Sleeve retainer activation is time delayed in PLC, to secure that the rod grippers are out in drill centre before activation. 4.2.b Sleeve retainer deactivation S130/Drilling pos. *S446/Impact switch **S182/Sleeve retainer X24/ON X27 and X30/OFF X23/OFF Y5/OFF *Flushing is deactivated automatically when switching impact off, this enables rodhandling. **Rod gripper transportation to carousel is time delayed in PLC, to secure that the sleeve retainer is back in neutral position. 4.3.a RHS, arm towards drillcenter S130/Drilling pos. *S446/Impact switch B379/ACTIVE S111/Pos, backwards. X24/ON X27 and X30/OFF X31/ON X16/ON Y6 & Y7/OFF Y10/ON K10 Y301B *Flushing is deactivated automatically by switching of the impact which enables rodhandling. 4.3.b RHS, arm towards carousel S130/Drilling pos. *S446/Impact switch B379/ACTIVE S111/Pos, forward. X24/ON X27 and X30/OFF X31/ON X15/ON Y11/ON K11 Y301A *Flushing is deactivated automatically by switching of the impact which enables rodhandling. 4.4.a RHS, carousel rotation, clockwise. S130/Drilling pos. *S446/Impact switch B379/Operator seat active S111/Top button pushed. S111/Pos, to the left. B118/ACTIVE START B183/ACTIVE B183/Dis-ACTIVE ⇓ STOP B183/ACTIVE X24/ON X27 and X30/OFF X31/ON X21/ON X17/ON X3/ON X7/ON X7/OFF X7/ON Y13/ON Y13/OFF Y303A *Flushing is deactivated automatically when switching impact off, this enables rodhandling. 7(8) 08-01-25, PLC Programme, ROC D5,D7 Bosal Function Signal from/position PLC input/status X 24/ON X27 and X30/OFF X31/ON X21/ON X20/ON X3/ON X6/ON X6/OFF X6/ON PLC output Valve 4.4.b RHS, carousel rotation, counter clockwise. S130/Drilling pos. *S446/Impact switch B379/Operator seat active S111/Top button pushed. S111/Pos, to the right. B118/ACTIVE START B182/ACTIVE B182/Dis-ACTIVE ⇓ STOP B182/ACTIVE Y12/ON Y12/OFF Y303B *Flushing is deactivated automatically by switching of the impact which enables rodhandling. 5. SUPERVISION FUNCTIONS 5.1 Low hydraulic oil level, engine shutdown B143 off. X36/OFF *Y30/OFF **Y31/ON K330 H203 *Note! Output Y30 located at Y0 on the extention unit (slave unit). **Note! Output Y31 located at Y1 on the extention unit (slave unit). When K330 is deactivating the power supply from fuse F12 to the ECM-control module, the engine shuts down. 5.2 Coolant level, engine shutdown B361 off. X37/OFF Y30/OFF *Y32/ON K330 H215 *Note! Output Y32 located at Y2 on the extention unit (slave unit). When K330 is deactivating the power supply from fuse F12 to the ECM-control module, the engine shuts down. 5.3 Clogged airfilte for dieselengine and compressor, warning B360 or B365 on. X40/ON *Note! Output Y33 located at Y3 on the extention unit (slave unit). *Y33/ON H207 8(8) Atlas Copco ROC DMK-II TH (with Bosal cabin) System description © Copyright 2007, Atlas Copco Rock Drills AB, Sweden Any unauthorized use or copying of the contents or any part thereof is prohibited. This applies in particular to trademarks, model denominations, part numbers and drawings ROC DMK-II TH (with Bosal cabin) system description, PMI NR: 9853 1129 01 Introduction Introduction Abbreviations RAS RCS RHS ECM EMS CCU DPCI RPCF ECL ECG DCT DTH TH CR PWM PTO Rod Adding System Rig Control System Rod Handling System Engine Control Module Engine Monitoring System CAN Control Unit Damper Pressure Controlled Impact Rotation Pressure Controlled Feed Electrically Controlled Lubrication Electrically Controlled Greasing Dust Collector Down The Hole Top Hammer COPROD Pulse With Modulation Power Take Out Signal types Digital input – 24 V input signal Digital output – 24 V output signal Data protocol types Can Bus – Data protocol between remote control box and the CAN control unit 1 Contents Contents INTRODUCTION .......................................................................................................................................... 1 ABBREVIATIONS ........................................................................................................................................... 1 SIGNAL TYPES ............................................................................................................................................... 1 DATA PROTOCOL TYPES ................................................................................................................................ 1 CONTENTS.................................................................................................................................................... 2 TECHNICAL DATA ...................................................................................................................................... 4 HYDRAULIC SYSTEM, GENERAL ............................................................................................................ 6 GENERAL ..................................................................................................................................................... 6 PILOT PRESSURE ........................................................................................................................................... 6 RETURN OIL AND OIL COOLER ........................................................................................................................ 7 TEST CONNECTIONS FOR THE HYDRAULIC CIRCUITS ........................................................................................ 8 ELECTRICAL SYSTEM, GENERAL........................................................................................................... 9 GENERAL ..................................................................................................................................................... 9 BATTERY AND CHARGING .............................................................................................................................. 9 MAIN FUSE ................................................................................................................................................... 9 ELECTRIC CABINET ....................................................................................................................................... 9 PLC ........................................................................................................................................................... 11 DIESEL ENGINE......................................................................................................................................... 12 BATTERY SWITCH, OFF ................................................................................................................................ 12 BATTERY SWITCH, ON ................................................................................................................................. 12 IGNITION POSITION ...................................................................................................................................... 12 START POSITION.......................................................................................................................................... 13 CONTROL INSTRUMENTATION ...................................................................................................................... 13 FAULT INDICATORS ..................................................................................................................................... 14 ENGINE SPEED ............................................................................................................................................ 15 COMPRESSOR............................................................................................................................................ 16 COMPRESSOR UNIT ...................................................................................................................................... 16 AIR FLOW ................................................................................................................................................... 16 COOLING AND OIL SYSTEMS......................................................................................................................... 17 REGULATOR SYSTEM ................................................................................................................................... 17 INSTRUMENT AND FAULT INDICATION .......................................................................................................... 17 PUMPS AND PILOT PRESSURE ............................................................................................................... 18 PUMP 1....................................................................................................................................................... 18 INTERNAL PRESSURE VALVE ........................................................................................................................ 18 EXTERNAL PRESSURE VALVE ....................................................................................................................... 18 PUMP 1, PRESSURE SETTING ......................................................................................................................... 18 PILOT PRESSURE ......................................................................................................................................... 19 TRAMMING ................................................................................................................................................ 20 CONDITIONS ............................................................................................................................................... 20 TRAMMING WARNING ................................................................................................................................. 22 HYDRAULIC JACK ....................................................................................................................................... 22 POSITIONING ............................................................................................................................................. 23 BOOM AND FEED POSITIONING ..................................................................................................................... 23 TRACK OSCILLATION ................................................................................................................................... 24 OIL PRE-HEATING .................................................................................................................................... 25 DRILLING.................................................................................................................................................... 26 2 Contents AIR FLUSHING ............................................................................................................................................. 27 ROTATION .................................................................................................................................................. 28 DRILL FEED ................................................................................................................................................ 30 PERCUSSION ............................................................................................................................................... 32 RAPID FEED ................................................................................................................................................ 34 THREADING ................................................................................................................................................ 36 DAMPER AND DPC-I SYSTEM ................................................................................................................. 38 ADJUSTING DAMPER PRESSURE .................................................................................................................... 38 DPC-I SYSTEM............................................................................................................................................ 38 LOGIC BLOCK 1........................................................................................................................................... 42 LOGIC BLOCK 2........................................................................................................................................... 42 LOGIC BLOCK 3........................................................................................................................................... 42 PROTECTIVE PROTECTIONS ................................................................................................................. 43 ANTI-JAMMING ........................................................................................................................................... 43 RPCF ......................................................................................................................................................... 44 AIR SYSTEM ............................................................................................................................................... 45 AIR SYSTEM ................................................................................................................................................ 45 ECL, ROCK DRILL LUBRICATION SYSTEM ..................................................................................................... 45 ECG, THREAD LUBRICATION ....................................................................................................................... 45 DCT, DUST COLLECTOR .............................................................................................................................. 46 HQS (HOLE QUALITY SYSTEM) ............................................................................................................. 48 RHS, ROD HANDLING SYSTEM .............................................................................................................. 49 GENERAL ................................................................................................................................................... 49 SYSTEM PRESSURE ...................................................................................................................................... 49 CAROUSEL ROTATION ................................................................................................................................. 50 RHS ARM ................................................................................................................................................... 51 GRIPPER CLAWS (ON RHS ARMS)................................................................................................................. 51 OPEN GRIPPER CLAWS ................................................................................................................................. 51 LOOSE GRIP ................................................................................................................................................ 52 TIGHT GRIP ................................................................................................................................................. 52 DRILL-STEEL SUPPORT AND SUCTION HOOD................................................................................... 54 UPPER DRILL STEEL SUPPORT ....................................................................................................................... 54 LOWER DRILL STEEL SUPPORT ..................................................................................................................... 54 SUCTION HOOD ........................................................................................................................................... 54 OPTIONS...................................................................................................................................................... 55 WATERMIST SYSTEM (OPTION) .................................................................................................................... 55 WINCH (REMOTE CONTROL BOX, OPTION) .................................................................................................... 57 EXTRACTION UNIT (OPTION) ........................................................................................................................ 60 ECG, THREAD LUBRICATION WITH OIL (OPTION) .......................................................................................... 61 THREAD LUBRICATION WITH GREASE BRUSHES (OPTION) .............................................................................. 61 ADJUSTMENT/CALIBRATION ................................................................................................................ 63 ADJUSTABLE PARAMETERS, DCT ................................................................................................................ 63 ADJUSTABLE DRILLING PARAMETERS ........................................................................................................... 64 SEARCH LIST ............................................................................................................................................. 65 3 Technical data Technical data Weight (without drill steels) ROC D5/D7/D9 Performance Diesel engine, CAT C7 output at 2200 rpm Temperature range in operation Tramming speed (low/high gear) Traction force (low/high gear) Ground pressure, average Ground clearance Max. hydraulic pressure Track oscillation Noise level (inside cab) Drilling (2000 rpm) Noise level (outside cab) Idling (1500 rpm) Max. engine speed (2200 rpm) Drilling (2000 rpm) Vibration in operator’s seat during drilling (weighted average) Weight 14 500 Kg 168 kW -25° to +50°C 1.5/3.1 km/h 115/81 kN 0.091 N/mm2 455 mm 250 bar 12° 78.8 dB(A) 109 dB(A) 114 dB(A) 127 dB(A) 0.14 m/s2 Gradients D5/D7/D9 -1X Note Stability is specified with respect to CE standards stipulating that rigs must not be operated on inclines steeper than 20 degrees without the use of a winch. ANGLES MUST NOT BE COMBINED! Tilt angles for drill rig when drilling: Longitudinally, max. (Downward/Upward) lateral (left/right). laterally, (left/right), in extreme positions. Tilt angles - tramming (in direction): downward/upward, max. without winch laterally, max. (Left/Right) downward/upward, with winch 20°/20° 17°/13° 17°/11° 20°/20° 20°/20° 30° Hydraulic system Hydraulic oil cooler for max. ambient temperature Electrical system Voltage Batteries Voltage Working lights Voltage Generator Voltage +50°C 24 V 2 * 12 V/185 Ah 24 V/70 W 28 V/95 Ah 4 Technical data Air system D5 Compressor Max. Air pressure Free air delivery at 8.5 bar Working pressure Air system D7 Compressor Max. Air pressure Free air delivery at 10.5 bar Free air delivery at 10.5 bar (USA version) Working pressure Air system D9 Compressor Max. Air pressure Free air delivery at 10.5 bar Working pressure Capacities Hydraulic oil reservoir, min/max level Hydraulic system, total Fuel tank Traction gear Compressor oil Lubrication oil tank Diesel engine oil Engine cooling system Air conditioning Red Dot Refrigerant, type Refrigerant, quantity Miscellaneous Fire extinguisher A-B-C powder G 106GD 10.5 bar 82 l/s 10.5 bar G 106GD 10.5 bar 105 l/s 127 l/s 10.5 bar G 106GD 10.5 bar 135 l/s 10.5 bar 220/260 l 300 l 370 l 3l 24 l 10 l 28 l 31 l R134A 2.53 kg 1 * 6 kg 5 Hydraulic system, general Hydraulic system, general General The hydraulic system on the ROC D5/D7/D9 is an electrical and pilot pressure controlled system. The system comprises 4 hydraulic pumps. Hydraulic pumps 1 and 2 are driven directly by the diesel engine via a flexible coupling. The remaining pumps (3 and 4) are fitted as a double pump on the engine's power take off (PTO). Feed cylinder 9 ? Logic Valves Main Drill block Drill feed Rapid feed Impact Rotation Tramming Pre-heat Flow divider Tramming control RPCF Traction left Traction right Remote control box Pressure Control Panel & Gauges Positioning during drilling Rod handling Dust collector Winch/ Positioning during tramming Cooler motor 1 2 3 4 Pilot pressure The pilot pressure is generated in the main drilling block and winch block. This pressure supplies the drilling block's directional valves with oil. This pilot pressure also supplies the tramming block’s directional valves with oil and the directional valves for high-speed tramming and winch freewheel. The pressure control panel controls the working pressure to pump 1, the feed pressure and rotation speed in the main drilling block. 6 Hydraulic system, general Return oil and oil cooler The Hydraulic oil tank has a capacity of 260 litres which means that there is always a “stock” of oil in the tank. In addition to storage it serves to separate water and dirt. There are two holders with 3 filters in each which filters hydraulic oil from the return- and drain circuit and the oil during filling. There is also a ventilation filter which prevents contaminated air from entering the tank when the hydraulic oil level is changed. Thermostats ensure that the oil flows through the oil cooler when the temperature is above 40ºC and directly to the tank when the temperature is below 40ºC. The by-pass valve protects the oil cooler from exposing to high pressure. The oil cooler cools the hydraulic oil so that the rig can work at full load in ambient temperatures up to 50°C. The cooling fan is driven by a hydraulic motor that is supplied with oil from pump 4 at a maximum pressure of 160 bars (D5) or 220 bar (D7). T- Return oil is a collection block that collects return oil from the various circuits and leads it to the thermostats and to the return oil filter. D-Drain oil is a collection block that collects oil from the various circuits and leads directly to the return oil filter. L-Leakege oil is oil that goes directly to tank for minimum resistance in the circuits. The filler pump is used to fill the system. There is a stop valve that prevents return oil from leaking out through the filler pump. A level sensor (B143) detects the level of hydraulic oil in the tank. Should this drop below a certain level, the diesel engine is switched off automatically. The sensor signal from B143 goes via PLC input X36. Temperature sensor (B362) sense the hydraulic oil temperature and the temperature will be shown on the display. The engine will automatically stop if the hydraulic oil temperature exceeds 90ºC. Note: This signal is connected directly to the EMS. The drain cock is used to remove water of condensation or to empty the hydraulic oil tank. Thermostats By-pass valve Oil cooler T-Return Check valves Refill pump D-Drain Ventilation filter Drain cock Hydraulic oil tank Return- / drain oil filter 7 Hydraulic system, general Test connections for the hydraulic circuits 1 2 3 4 5 6 7 8 Figure: Test connections for checking the hydraulic circuits. Connect the test connections to the various outlets (see table below). 1. 2. 3. 4. 5. 6. 7. 8. Hydraulic pump 1: Percussion, Drill feed, Rapid feed, Tramming, Positioning, RHS system Hydraulic pump 2: Rotation Hydraulic pump 3: DCT or Winch and positioning Hydraulic pump 4: Cooler - hydraulics, compressor and diesel engine Not used Extractor unit * Pilot pressure Not used Note * Extra equipment 8 Electrical system, general Electrical system, general General ROC D5/D7/D9 is equipped with a 24 volt electrical system for monitoring and fault indication. The electrical system is also used for controlling a number of hydraulic- and pneumatic valves. The structure of the electrical system is illustrated in a block diagram. Battery and charging The power source for starting the engine is two 12 V/185 Ah batteries that are connected in series. These are charged by a generator. The batteries are connected to the system via a manual battery switch. Main fuse The power supply to the electric cabinet is fused by a 60 A main fuse (F300) and a 100 A main fuse (F304). Electric cabinet The electrical cabinet (A1) contains 17 fuses, of which one automatic circuit breaker that limit the intensity to the various sub-circuits, some auxiliary relays, a CCU and a PLC. ECM ECM (Electronic Control Module) is used for monitoring the engine’s functions and sensors. It receives analogue and digital information from the engine and the rig. The ECM stops the diesel engine automatically if a specific fault occurs. A specific fault is for example low oil pressure which could cause major damage to the engine. EMS The ECM also indicates specific faults through indicator and warning lamps on the diesel panel and EMS (Electonic Monitoring System) LED-display. CCU Winch control unit is a system for controlling the winch from the remote control box. The system consists of two parts, the CCU (CAN Control Unit) and the remote control box. There is a CAN serial communication between the CCU and the remote control box. The CCU is located in the large electric cabinet (A1) and controls the hydraulic valves for tramming, positioning (boom lift and boom swing) and the winch. 9 Electrical system, general Electrical supply Emergency stop Start engine Relay K5A Relay Start ECM K330 ? ? PLC, CCU ??? ??? ??? ??? ? ? ? ? ? ? ? ? ?? A1 B1 5 1 t 2 Preheating Ignition, start position 50 Circuit ? ? ? ? t 1 1 6 1 8 2 A ? ? ? Relay K4A Ignition position ECM 25 Circuit The power source consists of 2 12V/185Ah batteries connected in series. Before the main switch is switched on there is power to the diesel heater + timer. When the main switch is switched on the circuit 25 is activated which supplies power to parts of the ECM, the EMS and working lights. Ignition position activates circuit 50 which supplies the diesel panel, preheating, the ECM, the CCU and the PLC via K4A with power. Note: The purpose of the signal from circuit 50 is only to close the relay contact to K4A. In the start position the engine is started via relay K5A. Main switch ON Timer. Diesel heater Batteries Note: The electrical system's ground cables are not isolated. This means that the system consumes a small current even when no functions are activated. 10 Electrical system, general PLC The PLC handles logic functions for rod-handling, rapid-feed stops, percussion, air flushing, DCT, high/low speed on the diesel engine, hydraulic oil level, coolant level, air filter diesel / compressor and for anti-jamming functions. The logic for the PLC is saved in an EEPROM (Program). PLC Exp. unit Impact led (H446) Rapid/drill feed led (H452) Drill mode magnets (Y179A,B) Rapid feed/threading relay (K178) 3 (43) 2 (42) 1 (41) 0 (40) 3 (53) 2 (52) 1 (51) Magnet off drill lever (S453) Rapid feed/threading (S452) Input X Output Y PLC Exp. unit N189/H N189/F N189/E Air filter clogged (H207) Coolant level low (H215) Hydr. oil level (H203) Diesel engine enable (K330) 7 (37) 6 (36) 5 (35) 4 (34) 3 (33) 2 (32) 1 (31) 0 (30) Output Y PLC Base unit Lamp test ECL-collection (K327) Pump 3 positioning/winch (Y187) Hydraulic jack out (K180) Rpm diesel engine low rpm (K5B) Flush air reduced (Y116) Flush air full (Y115) DCT Hatch open (Y253) Impact hour counter (P108) Impact on (Y101A) Impact low (Y101B) DCT filter 3 cleaning (Y251C) DCT filter 2 cleaning (Y251B) DCT filter 1 cleaning (Y251A) Carousel rotation CW (Y303A) Carousel rotation CCW (Y303B) Arm to carousel (K11) Brush greasing (K449) Arm to drillcenter (K10) Loose rodgrip (K7) Open rodgrip (K6) Sleeve retainer (Y309) Rpd feed Stop backward (Y149) Drillfeed backwards (Y109) ECG Pump (Y107) ECG Relay ECL Pump (Y106) ECL Relay 27 26 25 24 23 22 21 20 17 16 15 14 13 12 11 10 7 6 5 4 3 2 1 0 23 22 21 20 17 16 15 14 13 12 11 10 7 6 5 4 3 2 1 0 HQS drill stop Startkey in ignition position (S139) Shutdown Air filter clogged engine/compressor (B360, B365) Coolwater level (B361) Hydraulic oil level normal (B143) Low rpm diesel engine (S189) Startkey in startposition (S139) Drill feed backwards (B262) High rpm dieselengine (S189) Operator chair (B379) Impact pressure high (S446B) Impact pressure low (S446A) Flush air full (S100) Flush air reduced (S100) Switch S130 in position drilling Sleeve retainer (S182) Take up rodstring (S113) Open gripper (S111) Carousel rotation counter clockwise (S111) Carousel rotation clockwise (S111) Arm to drillcenter (S111) Arm to carousel (S111) Rpd feed stop upper (B127) Rpd feed stop uncoupling (B126) Rpd feed stop lower (B122) Adjust extended time (S459) Adjust pause time (S458) Carousel stop from the gripper (B183) Carousel stop towards gripper (B182) Adjust pulse time (S457) Increase/decrease DCT time (S456) Arm in carousel (B118) Open DCT (S181) Flow switsch (B142) Rotation pressure (B134) Output Y Input X 11 Diesel engine Diesel engine The engine on the ROC D7 is a turbocharged, water cooled diesel engine from Caterpillar called C7. The output at 2200 r/min is 168 kW. Battery switch, off Before the battery switch (S300) is switched on there are 24V to the cabin fan (activated with diesel heater), the diesel heater and the timer via the fuses F201, F202 and F203. The generator G2 (B+) is connected directly to the batteries. Battery switch, on When the battery switch (S300) is switched on there is 24 V to: ECM EMS Emergency stops and ignition Lighting and volt tester in A1 cabinet Electric fuel pump OFF ON S300 S300 Ignition position When the ignition key S139 is in the ignition position the contacts 30-15 and 30-75 are closed. The ignition relays K4A, K4B and K4C are activated and the relay contacts are closed. When the relay contact K4A is closed the ECM is supplied with voltage via fuse F12 under the condition that relay K330 is activated by the PLC output Y30. PLC outputs are supplied with voltage via F15 and remote control with winch via F14. Conditions for activation of K330: Emergency stops S132A, S132B and S132C are not triggered Fuses F300, F1, F11, F12, F13 and F15 are not triggered Cooling water level sensor (B361) Hydraulic oil level sensor (B143) No shutdown signal from EMS Ignition key (S139) in ignition position (contacts 30-15, 30-75 closed) PLC/X37-On PLC/X36-On PLC/X41-On PLC/X42-On 12 Diesel engine When the relay contacts K4B and K4C are closed the control panel in the cab is supplied with voltage, which regulates working lights and seat heating amongst other things. During the ignition phase, the fault indications lamps on the diesel panel are flashing for 2 seconds while the ECM conducts a self test, PLC outputs Y27, Y31, Y32, Y33 are also activated for lamp test. During this time the engine will not be able to start. Start position Conditions for activation of starter motor: Emergency stops S132A, S132B and S132C are not triggered Fuses F300, F1, F11, F12, F13 and F15 are not triggered S130 in tramming mode PLC/X24-Off Compressor switch (S180) off H180 off Ignition key (S139) in start position PLC/X34-On (contacts 30-15, 30-50 closed) Note: PLC/X34 can only be activated when the compressor switch (S180) is not activated, otherwise the S180 contact will block the input signal to PLC/X34. If the conditions above are fulfilled, PLC output Y24 is on which activates K5B which in turn precontrols relay K5A. When relay K5A closes, the starter motor (M1) is activated. PLC/Y24-On→ K5B relay→ K5A relay→ M1 is activated, i.e. engine is cranking. The ECM is normally powered through PLC ouput operated by K330. When turning the starter motor there will be voltage drop in the system which can temporarily cause the PLC to shut down. To ensure power supply to the ECM, which is necessary for starting the engine, one of the contacts of K5B is bridging the contatct of K330. This allows the ECM to be powered from the main electrical system. During the starting phase, the ECM blocks any signal from the oil pressure switch for 15 seconds. This is to prevent the engine from stopping if the start key is released as soon as the engine has started, but the engine has not yet built up the correct oil pressure. Control instrumentation Following instruments monitors the diesel engine. Diesel fuel gauge P352 The fuel transducer B352 in the fuel tank sends a signal to the fuel gauge, proportional to the fuel level. There is an adjusting screw on the backside of P352 for calibrating the true fuel level. The lamp comes on when there are 75 litres remaining. Engine Monitoring System P354 VDO, tachometer with display. The EMS monitors and processes engine operating parameters and diagnostic information. The unit has a digital LCD display which can read out the different engine parameters monitored and display fault symbols when faults occur. Press button (S354) on the VDO instrument in order to scroll between the menus on the display. Depress button (S354) for 5 seconds to zero or acknowledge, and doubleclick in order to access Caterpillar's fault codes for an alarm situation. Button for display S354 Contrast adjustment knob R354 13 Diesel engine Fault indicators The rig has monitoring functions to check that all data is relevant and correct. In the event of certain faults, the diesel engine is turned off automatically. Other faults are merely indicated, which requires the engine to be switched off and the fault rectified. Indicator lamp H207 Indicator lamp for clogged air filter for diesel engine and compressor. The lamp comes on when the filters are clogged. Indicator lamp H211 Alarm lamp for diesel engine monitoring. The lamp comes on in the event of a fault code H207 from the diesel engine. H211 H180 H212 H214 H215 H382 P352 P354 Indicator lamp H212 H213 Alarm lamp for diesel engine monitoring. The lamp comes on in the event of a falut code H203 from the diesel engine that switches off the H381 engine. Indicator lamp H213 Alarm lamp for rig monitoring. The lamp comes on in the event of an alarm. R354 S354 Indicator lamp H214 Alarm lamp for rig monitoring. The lamp comes on in the event of an alarm that switches off the engine. Indicator lamp H203 Signal lamp, low hydraulic oil level. The lamp comes on when the oil level is too low and the engine is switched off. Indicator lamp H215 Indicator lamp for engine coolant level. The lamp comes on when the coolant level is too low. Indicator lamp H381 Indicator lamp for ECL collection. The lamp indicates inadequate pressure in the return line. It comes on when drilling starts until the correct pressure is achieved. Indicator lamp H382 Indicator lamp for ECL collection. The lamp indicates excessive pressure in the return line. The can be due to the return tank is being full. Note: All faults should be checked thoroughly and rectified. 14 Diesel engine Engine speed The engine speed can be de- or increased by flicking switch S189 upor downwards. By flicking the switch different times, this puts the N189 connections (Din0-2) in different set of combinations, hence providing the different engine revolutions, and this is controlled by the PLC output Y35-Y37 respectively. PLC can support 8 engine revolutions, and it can store 3 separate engine speeds, one for tramming, one for rod handling and one for drilling. The PLC remembers the engine speeds for rod handling and drilling even when the battery switch is turned off. In tramming mode the system will always start on 1200 rpm. The speeds can all be set individually within the range specified below. Condition for revolution between 1200-2200 tramming position Switch S130 NOT in drilling position Condition for revolution between 1500-2200 Switch S130 in drilling position and reduced flushing air NOT activated (Y116/OFF) Condition for revolution between 1800-2200 Switch S130 in drilling position and reduced flushing air activated (Y116/ON) The engine starts on idling speed 1200 rpm, flicking the switch once upwards should increase the speed to 1500 rpm, one more flick increases the speed to 1700 rpm, then the engine speed increases with 100 rpm per flick upwards until it reaches the maximum speed of 2200 rpm. It is also possible to hold the switch for several seconds in order to reach the maximum speed. To decrease the engine speed from the idling speed, flick the switch once downwards takes down the speed step by step just like upwards. When changing from tramming position to drilling, the engine speed automatically increases to engine speed set for drilling and vice versa. Engine revolution combinations from PLC Y35-Y37 PLC Y35 PLC Y36 PLC Y37 Engine speed RPM /N189 Din2 /N189 Din1 /N189 Din0 Low Low Low 1200 RPM Low Low High 1500 RPM Low High High 1700 RPM Low High Low 1800 RPM High High Low 1900 RPM High High High 2000 RPM High Low High 2100 RPM High Low Low 2200 RPM b a c d a b c 15 Compressor Compressor General The built-in compressor is a single-stage compressor. Its normal working pressure is 10.5 bar with the Caterpillar diesel engine. Compressor unit The compressor unit comprises two rotors: a drive rotor and a slide rotor mounted on rollers and ball bearings. The drive rotor is driven by the diesel engine and transfers power to the slide rotor. The rotors are lubricated with oil that is injected and mixed with the air. This increases efficiency since the oil forms a seal between the rotor blade and the housing. The compressor unit is an Atlas Copco type G106 screw compressor. The gear ration is 1.55. Air flow The intake air is drawn through the air filter and an over centre valve to the compressor unit. The over centre valve also prevents oil returning into the system. The air is mixed with injected oil and goes directly from the compressor to the air receiver. In the air receiver, the majority of the oil is separated from the air/oil mixture using an oil separator. This oil is removed by a separator unit. The flow of compressed air passes through a pressure valve to the drill rigs air system. The pressure valve prevents the pressure in the air receiver dropping below the lowest working pressure for the compressor (approx. 2.8 bar), even when the air outlet valves are open, to ensure the correct function of the oil system. Air Atmospheric Pressure Air Regulating Pressure Air Working Pressure Air/Oil Mixture Oil 16 Compressor Cooling and oil systems Oil is used for lubrication, sealing and cooling. There is no oil pump with pressure provided by the air pressure. The lower part of the air receiver acts as an oil tank. The air pressure means that the oil is transported from the air receiver through the oil cooler and oil filter to the compressor unit. The compressor unit has an oil platform at the bottom of the sleeve. The oil for rotor lubrication, cooling and sealing is injected through a hole in this oil platform. The bearings are lubricated by oil injected into the bearing housing. The air/oil mixture leaves the compressor unit and returns to the air receiver, where the oil is separated from the air. The oil that is collected at the bottom of the oil separator returns to the oil system through a cleaning line that has a flow limiter. Note: A thermostat valve bypasses the oil cooler when the oil is below 70°C. Air Atmospheric Pressure Air Regulating Pressure Air Working Pressure Air/Oil Mixture Oil Regulator system The compressor control system comprises a regulator valve. This valve controls the air volume supplied by the compressor for air consumption whilst also keeping the working pressure within a certain range. The control system also includes a load valve that is activated by a switch on the diesel control panel. The load valve allows the diesel engine to warm up before engaging the compressor. Instrument and fault indication The pressure of the compressed air delivered from the compressor can be read from the pressure gauge. The compressor also has a temperature indicator switch (B366), which automatically provides indication and displays in plain text on the display that the temperature has risen. The system switches off the diesel engine if the compressor temperature exceeds +120°C. 17 Pumps and pilot pressure Pumps and pilot pressure Pump 1 Main pump 1 in the hydraulic system is an axial piston pump with variable displacement that delivers oil to control the pilot pressure. The pump is pressure compensated, which means that the pressure is constant irrespective of the flow, so long as the flow is below the maximum capacity of the pump (150 l/min). The pump pressure can be controlled using external pressure valves or the internal pressure control valve (DR). The pump delivers hydraulic power to the following functions: Percussion Feeding Feed positioning Boom positioning Tramming RHS system During drilling, pump 1 is controlled by the actual output pressure. During tramming, it is connected to an open circuit system with a flow distributor that distributes the flow equally to left and right tramming motors. Internal pressure valve During tramming or positioning the internal pressure control valve (DR) checks the pump pressure. The DR valve also limits the max. working pressure (250 bar) for the pump. DR: Max. pressure LS: Standby pressure External pressure valve During drilling, the pump pressure is controlled by two relief valves for high and low percussion. These are connected to the pump control system. Pump 1, pressure setting Checking/determining standby pressure “LS” 1. Disconnect pilot hose P1X1 from the “LS” valve and plug the hose. 2. Connect the text gauge hose to outlet 1 on the test panel. 3. Start the engine and set the speed to 1500 rpm. 4. Set the drilling/tramming switch to drilling. 5. The pressure on the tester should be 20-25 bar. 6. Adjust the “LS” screw on the pump regulator if required. 7. Switch off the diesel engine and refit hose PIX 1 to the “LS” valve. Checking/determining max. pump pressure ”DR” 1. Connect the tester hose to the connection on pump 1. 2. Start the engine and set the speed to 1500 rpm. 3. Set the drilling/tramming switch to drilling. 4. The pressure on the tester should be max. 250 bar. 5. Adjust the “DR” screw on the pump regulator if required. 18 Pumps and pilot pressure Pump 2 Pump 2 delivers oil to the rock drill’s rotation motor. The maximum pump pressure for pump 2 is set via the relief valve in the drill rotation circuit. Pump 3 and 4 Pumps 3 and 4 are fitted as a double pump on the diesel engine’s power take off. Pump 3 delivers oil to the dust collector’s fan motor during drilling, or to the positioning/winch circuit during tramming. During drilling, the pressure of pump 3 can be set on a relief valve in the DCT valve block. During tramming, the pressure of pump 3 is set constant at 210 bar. Pump 3 is unloaded at engine start-up. Pump 4 drives the cooler motor for cooling the hydraulic oil, compressor oil as well as engine’s intake air and cooling water. It also delivers oil to the track oscillation lock mechanism. Pump 4 is a gear pump and is driven by the power take off on the side of the diesel engine. The pressure of pump 4 cannot be adjusted but is controlled by the relief valve for the cooling fan. This is set to 160 bar for D5 and 220 bar for D7. This pump is permanently active. Pilot pressure The oil that controls the pilot pressure comes from pump 1 and pump 3. The oil is led to the main drilling block/winch block from respective pump through a pressure reducing valve (set to 35 bar), through a strainer and out to the pilot circuit. The oil in the main drilling block is led through solenoid valve Y121, which guides the pilot pressure either to the drilling or tramming circuit. To protect the pilot system against pressure surges, there is a pressure limiting valve set to 50 bar. The oil is then led to the solenoid valve Y169, which shuts off the pilot pressure supply to tramming and impact functions in the event of an emergency stop situation or when the automatic drill-stop function is used. P1→ P3→ 35 bar (pilot) → 35 bar (pilot) → Drilling function, tramming function, tramming speed control Winch function, positioning function 19 Tramming Tramming Conditions The tramming circuit includes functions for activating hydraulic functions that maintain the tramming circuit and control the hydraulic power to the tramming motors. Condition for Tramming: - Drilling/Tramming switch S130 must be in a tramming position. The pilot pressure is led through solenoid valve Y169, the function of which is to cut the pilot pressure flow to tramming and impact functions in an emergency. When solenoid valve Y169 is activated, the oil is led to valve Y121 which then leads the pilot pressure to either the drilling circuit or tramming circuit. Y121 is controlled by switch S130 (see Fig. 1). High and low speed can be selected. If low speed is selected, the pilot pressure is led through solenoid valve Y121 and then to the directional valve in the main drilling block (see Fig. 2). If high speed is activated, the pilot pressure is led through valve Y122 and on to the valve block for the tramming motors (see Fig. 4). Y169 Y122 Y121 Fig. 1: See full diagram for other parts No.: 9840 0423 56 page 3(16) The pilot pressure then activates the directional valve (see Fig. 2) in the main drilling block and supplies the tramming block via the flow regulator with oil (see Fig. 3). 20 Tramming Drill feed Rapid feed Percussion Y120A Rotation Directional valve Fig. 2: See full diagram for other parts No.: 9840 0423 56 page 2(16) Tramming direction and speed is controlled by means of pilot pressure controlling the proportional directional valves. There directional vavles are controlled by the tramming levers in the cabin (see Fig. 3). Tramming direction and speed can also be controlled using the tramming controls on the remote control box (see chapter “Option”). These controls send a signal to the control valves (Y206, Y207) for tramming forward or backward. The pilot pressure alters the position of the directional valves proportionally. When the remote control box is activated, the tramming controls in the cab are blocked. Y206A Y206B Y207A Y207B Pump 1 Flow regulator Fig. 3: See full diagram for other parts No.: 9840 0423 56 page 4(16) Pilot pressure 21 Tramming The valve block integrated in the tramming motors comprises a reversing valve, pilot brake valve and a pilot sequence valve for releasing the tramming brake once the motor is pressurized. The pressure regulator protects the brake cylinder from high pressure. For high-speed tramming, the valves are activated by the pilot pressure as in the figure below. Pilot pressure, high speed Brake cylinder Reversing valve Brake valve Reversing valve Sequence valve Pressure regulator Fig. 4: See full diagram for other parts No.: 9840 0423 56 page 4(16) Tramming warning When tramming backwards the pressure switches B174 and B175 gives a signal to the reversing warning signal (H185, H186) / flash. The warning signal can also be activated manually by using switch S186. Hydraulic jack The rear jack is controlled by switch S209, which energizes solenoid valves Y410A/B. Unlike the other rigs, it is possible to tram with the rear jack while it is out. 22 Positioning Positioning The positioning circuits (including track oscillation circuit) are primarily supplied with oil by pump 1. Since the tramming circuit is also supplied with oil by pump 1, pump 3 has to be used for positioning during tramming, even when the rig is standing still in tramming mode. Since pump 1 (250 bar) is larger and works at a higher pressure than pump 3 (160 bar), positioning is more rapid and powerful in drilling mode than during tramming. The flow from pump 1 is greater than from pump 3. Boom and feed positioning During tramming, pump 3 delivers oil to the positioning circuit. When the rig is in tramming mode, solenoid valve Y187 is activated. This pressurizes the pump 3 circuit and connects it via a pressure limiting valve to the positioning circuit (see Fig.). When the rig is not in tramming mode, the positioning circuit is supplied with oil from pump 1, because pump 3 is then used for supplying the DCT circuit. The positioning cylinders are controlled directly from the positioning levers inside the cab. Lever movement results in valve activation and the pump pressure can pass out to the cylinder. Positioning can also be handled electrically from the remote control box (see chapter “Option”). To boom & feed positioning To track oscillation See full diagram for other details No.: 9840 0423 56 page 4(16) Pump 3 23 Positioning Track oscillation The track oscillation cylinders are controlled by directional valves Y419 and Y420 via the control (S176, S177) in the cab. The oscillation cylinders are hydraulically linked by a solenoid valve Y473, controlled by switch S445. This valve has two positions: Open position (floating) When Y473 is activated, pilot pressure is delivered to the over centre valves. The ratio between the over centre valves is 1/13, which means that 25 bar is needed for them to permit oil flow to the cylinders connected in parallel. This position is used for tramming so that unevennesses in the ground are compensated for between the two cylinders (see Fig.). Closed position (locked) When valve Y473 is inactivated there is no flow between the cylinders (over centre valves are closed). This valve position is used make the rig stable for drilling. Over centre valves Y473 Over centre valves Y473 Y410B Y410A Y410B Y410A Y419A Y419B Y420A Y420B Y419A Y419B Y420A Y420B Figure: Open position See full diagram for other details No.: 9840 0423 56 page 4(16) Figure: Closed position Over centre valves Y473 24 Oil pre-heating Oil pre-heating Pump 2 is used for pre-heating the hydraulic oil. Normal operating temperature of the hydraulic oil is 40°C. Before operating the drill rig the oil should be pre-heated to minimum operating temperature, 20°C. When switch S130 is in the pre-heating position, solenoid valve Y120A in the main drill block is activated. The oil must pass through a 2 mm restriction and create a pressure by the pressure limiting valve (170 bar). The oil heats up. (See red marker in figure.) Y120A Shunt valve Pressure limiting valve Pressure valves Directional valve See full diagram for other details No.: 9840 0423 56 page 2(16) 25 Drilling Drilling Conditions for drill lever: PLC in → Input → S130 drilling PLC/X24-On S452 drilling mode PLC/X50-Off PLC ut→ PLC/Y40-Off PLC/Y41-On PLC/Y42-On PLC/Y40-On PLC/Y41-Off PLC/Y42-Off Output K178 deactivated Y179A, Y179B activated H452 activated K178 activated → Y178A-D activated Y179A, Y179B deactivated H452 deactivated Or S452 in rapid feed/ threading mode PLC/X50-On Drill feed Magnetic holding Led green H452 Led yellow H446 Magnet off S453 Impact high S446B A D 6 G Rapid/ drill feed S452 Drill rotation Magnetic holding 5 B E 7 H Impact low S446A F C Drill mode: E: neutral B: rotation anti-clockwise B+A: rotation anti-clockwise and feed forward (magnet function) B+C: rotation anti-clockwise (magnet function) and feed backward. D: feed forward (magnet function) F: feed backward H: rotation clockwise H+G: rotation clockwise and feed forward H+I: rotation clockwise and feed backward Diode H452 is lit in this mode. 8 I Rapid feed/threading mode: E: neutral B: threading B+A: rotation anti-clockwise and rapid feed forward B+C: rotation anti-clockwise and rapid feed backward D: rapid feed forward F: rapid feed backward H: unthreading H+G: rotation clockwise and feed forward H+I: rotation clockwise and feed backward There is no diode indication in this mode. Magnetic holding on rotation during drilling or/and feeding forwards can only be achieved when the control lever is being pulled to the end position, and when S452 is not activated (Led H452 = ON). Pulling the lever only half way and then release would result in lever springed back to the neutral position, which also marks the end of the movement. 26 Drilling Air flushing Conditions for air flushing: Input → PLC in → S130 drilling PLC/X24-On S180 compressor activated B118 arm in carousel PLC/X3-On S100 reduced air flushing PLC/X25-On Or S100 full air flushing PLC/X26-On S446 activated* PLC/X27-On PLC ut→ Output Y6A activated PLC/Y23 or PLC/Y22, Y23-On Y116 activated or Y115, Y116 activated *When S446 is activated for shorter than 0.5 seconds, only air flushing is activated. When S446 is activated for longer than 0.5 seconds air flushing and percussion are activated. Note: The air flushing mode (Full/Reduced or off) that is obtained with activation of S446 (percussion/air flushing) depends on the position of S100. Activating switch S446 for again for shorter than 0.5 seconds would deactivate flushing. B142 B115 Y116 See full diagram for other details No.: 9840 0423 22 page 2(3) Air flushing modes Air flushing is controlled by an electrical switch, S100; there are three air flushing modes: reduced, full and off. These activate the solenoid valves Y116 and Y115. When reduced air flushing is selected Y115 is switched off and the air flows via Y116 and can then be regulated with a control valve (see figure). Flow switch When full flushing (Y115 and Y116 activated) is selected the flow switch (B142) functions as protection against clogging the drill bit when drilling through clay or softer layers of rock. The pressure increases when the bit clogs and the difference over a restrictor decreases. The contact to B142 will close and drill feed backward is activated via valve Y109 in the drill feed hydraulic circuit. This is controlled via the PLC. 27 Drilling Rotation Condition for rotation: - Drilling/Tramming switch S130 must be in drilling position → PLC/X24-On - Switch S452 must be in drilling mode → PLC/X50-Off The hydraulic oil for drill rotation is supplied from pump 2. The drill rotation circuit includes functions for rotation direction and controlling the rotation speed. The anti-jamming system is partly included in the rotation circuit. That circuit is described later. Activating the drill rotation function When the Drilling/Tramming switch S130 is in drilling position, the solenoid valve Y121 is not activated. This allows the pilot pressure to connect to hydraulic components in the drilling system like the rotation lever. A 6 G Rotation direction D The rotation sector, position (B) and (H), controls the main directional valve for clockwise or anti-clockwise rotation via the rotation flow control and the LOGIC-2 block. 7 H 5 B E Main drill block The pilot operated directional valve (see Fig.), directs both the hydraulic power to the rotation motor of the rock drill and acts as a constant flow regulator together with the shunt valve. The F two-pressure relief valves (see Fig.) limit the maximum pressure 8 I C to the rotation motor. Y120A Shunt valve Pressure limiting valve Pressure valves Directional valve See full diagram for other details No.: 9840 0423 56 page 2(16) Rotation pressures The rotation pressure is generated by pump 2. Depending on the direction of rotation, a pressure relief valve is activated to limit the maximum pressure for anti-clockwise and clockwise rotation respectively. The maximum pressure for rotation anti-clockwise is limited to 125 bar, and the maximum pressure of rotation clockwise is limited to 160 bar. 28 Drilling Rotation speed - Anti-clockwise rotation (drilling) The pilot pressure passes a flow regulator (see Fig.) which regulates the rotation speed. The setting of the flow regulator controls how much the directional valve will open. The flow to the rock drill rotation motor is proportional to the opening of the directional valve. The forward rotation pilot pressure also activates the DPC-I system (For further information, refer to section “DPC-I system” under chapter “Damper & DPC-I system”). - Clockwise rotation The drill lever controls the rotation speed. The main directional valve opens in correspondence to the lever angel. The flow regulator is not connected. The adjustment knob for flow regulator can be found in chapter “Adjustment/calibration”. Pilot-p R+ Controls the pilot pressure See full diagram for other details No.: 9840 0423 56 page 3(16) Pressure, pump 1 RotationImpactRpd feedDrill feedTo tank 160bar Y120 160bar 11bar Pressure, pump 2 125bar 250bar 160bar Figure: Drilling block 29 Drilling Drill feed Condition for drill feed: - Drilling/Tramming switch S130 must be in drilling position → PLC/X24-On - Switch S452 must be in drilling mode → PLC/X50-Off The feed circuit is supplied with oil by pump 1 and includes functions for feeding the rock drill cradle up and down the feed beam and controlling the feed pressure during collaring and drilling (high and low pressure). The anti-jamming circuit is described seperately. Activating the drill feed function When the Drilling/Tramming switch S130 is in drilling position, the solenoid valve Y121 is not activated. This allows the pilot pressure to connect to hydraulic components in the drilling system like the feed lever. Drill feed direction, up-/downwards The drill feed sector, position (D) and (F), controls the main directional valve for drill feed via the LOGIC-2 block. NOTE: The anti-jamming system can automatically change the feed direction. See chapter “Anti-jamming”. Main drill block The pilot operatered directional valve (see Fig.) in the main drill block, directs the hydraulic power to the feed cylinder. The pilot operated pressure reducing valve (see Fig.) regulates the feed working pressure. A D 6 G 5 B E 7 H F C 8 I Directional valve Pressure reducing valve See full diagram for other details No.: 9840 0423 56 page 2(16) Pressure relief valves 30 Drilling Feed pressures The feed pressure can be read on pressure gauge in the cab. Two pressure relief valves (100 and 230 bar) limit the max. pressure to the feed cylinder, downwards and upwards respectively. When feedling downwards (drilling), the pressure reducing valve in the main drill block is controlled by either pressure relief valve for low or high feed pressure respectively (see Fig.). The impact control switch S446 position determines which valve is controlling the pressure as follow: o Low feed pressure (collaring) When switch S130 is in Drilling position, solenoid valve Y101B is activated. This activates QDS valve E, which allows the low feed pressure relief valve to control the pressure reducing valve in the main drill block. This is also the case when the impact control switch S446 is in low impact position. o High feed pressure (drilling) When the impact control switch S446 is in high impact position, Y101B is de-activated. This means that QDS-E is de-activated and the high feed pressure relief valve controls the pressure reducing valve in the main drill block. o Feeding upwards The QDS valve F is activated when feeding upwards. This prevents the two pressure relief valves for high and low feed pressure to control the feed pressure reducing valve in the main drill block. In this case the feed pressure is limited by the pressure relief valve for feed backwards (230 bar) in the rapid feed section of the main drill block. Pressure relief valve, low feed pressure Pressure relief valve, high feed pressure See full diagram for other details No.: 9840 0423 56 page 2(16) 31 Drilling Percussion Conditions for low percussion with air flushing with function self-holding: Input→ PLC in→ PLC ut→ Output S130 drilling Y101B activated PLC/X24-On PLC/Y17-On S180 compressor activated Y6A activated B118 arm in carousel PLC/X3-On S100 air flushing PLC/X25 or X26-On Y179A, Y179B activated S452 drilling mode PLC/X50-Off PLC/Y41-On H452 activated PLC/Y42-On S446A low percussion* Y101A activated PLC/X27-On PLC/Y20-On H446 blicking signal PLC/Y43-On PLC/Y23 or/and Y22- Y116 or/and Y115 activated On * S446A (low percussion) must be activated for longer than 0.5 seconds. Conditions for high percussion with air flushing with function self-holding: Input→ PLC in→ PLC ut→ Output S130 drilling Y101B activated PLC/X24-On PLC/Y17-On S180 compressor activated Y6A activated B118 arm in carousel PLC/X3-On S100 air flushing PLC/X25 or X26-On Y179A, Y179B activated S452 drilling mode PLC/X50-Off PLC/Y41-On H452 activated PLC/Y42-On Y101A activated S446A low percussion* PLC/X27-On PLC/Y20-On ⇓ Y101B deactivated S446B high percussion* PLC/X30-On PLC/Y17-Off Y101A activated PLC/Y20-On H446 stable signal PLC/Y43-On PLC/Y23 or/and Y22- Y116 or/and Y115 activated On * S446A/B (high/low percussion) must be activated for longer than 0.5 seconds. NOTE: Magnetic holding on rotation during drilling or/and feeding forwards can only be achieved when the control lever is being pulled to the end position. Pulling the lever only half way and then release would result in lever springed back to the neutral position. Conditions for percussion without air flushing: Note: Switch S446A/B must be held in at all time, since no self-holding is available here. Input→ PLC in→ PLC ut→ Output S130 drilling Y101B activated PLC/X24-On PLC/Y17-On B118 arm in carousel PLC/X3-On S100 air flushing off PLC/X25 and X26-Off S452 drilling mode PLC/X50-Off S446 percussion activated PLC/X27 or X30-On Y101B activated* PLC/Y17-On (switch held in at all time) Y101A activated PLC/Y20-On *Y101B is activated only during low percussion. The percussion circuit includes functions for activating the rock drill’s percussion mechanisms and checking the pressure for collaring and drilling (low and high pressure). The percussion pressure is supplied by hydraulic pump 1. To protect the rock drill and drill steel, the DPC-I system can switch off or lower the percussion pressure if certain conditions are not fulfilled. The DPC-I system is described separately. 32 Drilling Activating percussion The directional valve in the main drilling block has two functions: to lead the oil to the rock drill’s percussion mechanism and to lead the oil to the tramming circuit. The directional valve is controlled by Y101A via the two QDS valves I and J (see figure below). If the damper pressure is lower than 35 bar, valve QDS-I will close. If the pressure exceeds 120 bar, valve QDS-J will close. These QDS valves are part of the DPC-I system and sense the rock drill’s damper pressure. If the damper pressure does not agree, the valves close to prevent the activation of the directional valve. When the percussion pressure is activated, the pilot pressure is also led to QDS valve B which permits one of the pressure relief valves to take control of the pressure of pump 1. To activate low percussion, press switch S446A (button to the left) for longer than 0.5 seconds. Press the button one more time for shorter than 0.5 seconds would deactivate percussion. To activate high percussion, press switch S446B (button to the right) for longer than 0.5 seconds under the condition that low percussion is activated first, or percussion would stop. Otherwise if starting directly on high percussion, the button for high percussion activation S446B must be held in at all time. S446A/B controls the activation of solenoid valves Y115, Y116 in the air system, but it is S100 that controls the combination of Y115 and Y116. It’s recommended to keep S100 in full flushing air position as soon as S446 is activated. S100 should be changed to reduced flushing air position only when drilling through a weaker complex of the rock layer. S446A/B also control two solenoids valves in the hydraulic system, Y101A, for activating percussion, Y101B, for activating low percussion. Percussion pressure The percussion pressure can be read from the pressure gauge in the cab. The pressure for low and high percussion can also be adjusted there, see chapter “Adjustment/calibration”. Low percussion pressure (pump 1): QDS valve B is activated once both solenoid valves Y101A and Y101B have been activated when switch S446 is in position for low percussion. This connects control line “DP” for pump 1 to the pressure relief valve for high percussion, and if QDS valve A is not activated, to the pressure relief valve for low percussion. In the low percussion position, QDS valve C is active, which prevents QDS valve A being activated. Subsequently, the pressure relief valve for low percussion controls the pressure of pump 1. Note: In the low percussion position, QDS valve E is also activated to ensure low feed pressure. High percussion pressure (pump 1): QDS valve B is still activated since solenoid valve Y101A is ON when switch S446 is activated for high percussion. Since Y101B is OFF, QDS valve C is no longer activated, which means QDS valve A is controlled by the rock drill’s damper pressure (DPC-I system). Normally, the rock drill’s damper pressure is greater than 50 bar during drilling. This activates QDS valve A which prevents the relief valve for low percussion from controlling the pump pressure. The pump pressure is instead controlled by the relief valve for high percussion. Impact hour counter The PLC output Y20 gives a signal to the impact hour counter in the main electrical cabinet. Y101B Y101A Figure: Percussion valves Figure: QDS valve 33 Drilling Rapid feed Conditions for the rapid feed functuion: - Drilling/Tramming switch S130 must be in drilling position → PLC/X24-On - Switch S452 must be in rapid feed/threading mode → PLC/X50-On The rapid feed circuit includes functions for rapidly feeding upwards and downwards, and to stop the cradle in the correct positions for rod handling. The hydraulic power is supplied from Pump 1. Activating the rapid feed function When the Drilling/Tramming switch S130 is in drilling position, the solenoid valve Y121 is not activated. This allows the pilot pressure to connect to hydraulic components in the drilling system like the threading/rapid feed lever. Rapid feed direction up-/downwards. The rapid feed sector, positions (D) and (F), controls the main directional valve for rapid feed via the LOGIC-2 valve block. The feed speed is proportional to the stroke of the lever. Main drill block The pilot operated directional valve (see Fig.) in the main drill block, directs the hydraulic power to the feed cylinder. The pilot operated pressure reducing valve (see Fig.) regulates the feed working pressure. The pressure relief valves (see Fig.) for rapid feed (100 and 230 bar) limit the maximum pressure to the feed cylinder, downwards and upwards respectively. A D 6 G 5 B E 7 H F C 8 I Pressure reducing valve Pressure relief valves Directional valve See full diagram for other details No.: 9840 0423 56 page 2(16) 34 Drilling Rapid feed stops The rapid feed stop function is controlled by three inductive proximity switches connected to the PLC. B122 – Rapid feed stop downward just above the drill steel support. B127 – Rapid feed stop upwards, at a position above the RHS magazine, but before mechanical stop. B126 – Rapid feed stop when the coupling sleeve is inside the upper drill steel support (sensor lug A), and when the rod is in correct position to be inserted into the magazine (sensor lug B). S113 a a B127 B126 B122 e f d b ? b c c B127 and B122 sensor plate B126 sensor plates Indicator plate (A) (B) B122, B126 and B127 are connected to PLC inputs X12, X13 and X14 respectively. Provided these inputs, the solenoid valves Y149 (upwards) or Y150 (downwards) in the LOGIC-2 valve block are activated by PLC output Y3 or Y4. Once activated, the rapid feed is stopped for 2 seconds. If the solenoid valves Y149 or Y150 are activated, the pilot connection between the rapid feed lever and the directional valve for the corresponding rapid feed direction will be blocked. Consequently the rapid feed movement stops. Once activated, the rapid feed is stopped for 2 seconds The input from B126 will only result in a rapid feed stop if switch S113 is in position (a). This is to allow the rock-drill to be fast fed unstopped to the top when adding a drill steel. 35 Drilling Threading Condition for drill feed: - Drilling/Tramming switch S130 must be in drilling position → PLC/X24-On - Switch S452 must be in rapid feed/threading mode → PLC/X50-On The threading function is a combined activation of both the feed cylinder and drill rotation motor in a common sector. The hydraulic force to the feed function is supplied by pump 1 and by pump 2 to the rotation function. Activating the threading function When the Drilling/Tramming switch S130 is in drilling position, the solenoid valve Y121 is not activated. This allows the pilot pressure to connect to hydraulic components in the drilling system like the threading/rapid feed lever. Threading (Feeding downwards and Rotating CCW) The rapid feed/threading sector, position (B), controls the main directional valves for drill feed and rotation via the LOGIC-2 valve block. It will also activate QDS valve G, which connects the pilot operated pressure reducer with the pressure relief valve for thread feed forward. The pressure relief valve is set to give a feed pressure that corresponds to a feed speed that matches the pitch of the drill steel threads. When the rotation is activated by the threading lever, the rotation flow control is excluded from the circuit. This means that the rotation speed is on full rpm. A D 6 G 5 B E 7 H F C 8 I Unthreading (Feeding upwards and Rotating CW) The rapid feed/threading sector, position (H), controls the main directional valves for drill feed and rotataion via the LOGIC-2 valve block. It will also activate QDS valves H and F, which connects the pilot operated pressure reducer with the pressure relief valve for thread feed backwards. The pressure relief valve is set to give a feed pressure that corresponds to a feed speed that matches the pitch of the drill steel threads. 36 Drilling QDS I QDS J Y101A Y101B Y109 F+ R+ DP QDS D QDS C QDS B FP QDS A Drill feed Threading Impact Figure: Threading See full diagram for other details No.: 9840 0423 56 page 3(16) Y109 Y150 Y149 Y149 Y109 Y150 Figure: Logic block 2 37 Damper and DPC-I system Damper and DPC-I system The rock drill's damper circuit is supplied with oil by pump 1 through a constant flow regulator. The flow regulator is adjusted to a pressure of 35 bars at the damper hose connection on the rock drill. The damper pressure during drilling indicates the actual feed force on the drill bit. The pressure can be read off from the pressure gauge in the cab on the rig. During drilling, the damper pressure controls certain QDS valves, which in turn control the percussion pressure. This is described further under DPC-I system. Adjusting damper pressure The adjustment of damper pressure must take place with the damper piston in floating position. To ensure that the piston is in floating position the shank adapter must be pulled out as far as possible. Adjusting damper pressure should not be performed before the hydraulic oil has reached normal working temperature, 40ºC (104ºF). 1. Connect a pressure gauge between the damper hose connection and the damper hose on the rock drill. 2. Start the diesel engine and let it run at 1500 rpm. 3. Make sure that the shank adapter is fully withdrawn, i.e. the damper piston is in the floating position. 4. Set S130 in drilling position. 5. Undo the lock screw (8b) on the knob and adjust the damper pressure by turning the knob (8a): clockwise to lower the pressure and anticlockwise to raise it. 6. Tighten the lock screw once the pressure is correct. Damper pressure 8a 8b Note: Percussion should be stopped if the damper pressure exceeds 120 bars or drops below 35 bars. Figure: Damper pressure DPC-I system Function The DPC-I system (Damper Pressure Controlled Impact) controls the percussion function by sensing the damper pressure during drilling. Depending on the damper pressure, percussion may be permitted, stopped or switched between high and low percussion pressure. This is made possible by three sequence valves (QDS valves) in the rig's hydraulic system. QDS-I: Blocks the pilot pressure from percussion valve Y101A to the directional valve if the damper pressure is too low. In this case, the activation of percussion is prevented if the damper pressure is below 35 bars or percussion stops if the damper pressure drops below 35 bars during drilling in cavities, a hose ruptures or a valve malfunctions. QDS-J: Blocks the pilot pressure from percussion valve Y101A to the directional valve if the damper pressure exceeds 120 bars. This may occur if the feed pressure is abnormally high or if a mechanical fault arises in the damper. QDS-A: During normal drilling with high percussion pressure, QDS valve A is activated by the damper pressure through QDS valve C and D. If the damper pressure drops below 50 bars, QDS-A is deactivated. This means that the relief valve for low percussion controls the pump pressure instead of the relief valve for high percussion pressure. 38 Damper and DPC-I system Warning! Incorrect adjustment of the DPC-I system may damage the rock drill, rig and drill steels. Adjustment should only be made by a qualified technical engineer from Atlas Copco. Setting the DPC-I system The DPCI system can be adjusted either in the workshop or on the drill site. Adjusting in the workshop generally gives a more exact setting. On the other hand, adjusting during drilling can result in a setting well adapted to the rock conditions and other system settings. In general, QDS-I should be set as high as possible without making it difficult to start impact. Guidelines for setting QDS-valves. (Optimum setting might be higher). QDS-I QDS-J QDS-A 35 bar 120 bar 50 bar Setting during drilling QDS-I, Setting during drilling: 1. 2. 3. 4. 5. 6. Check that the damper pressure is adjusted according to “Adjusting the damper pressure”. Start drilling on low impact pressure and collaring feed pressure. Adjust the feed pressure slowly towards 0 while observing the damper pressure gauge. When the damper pressure drops below 35 bar as a result of the low feed pressure, impact should be stopped automatically. If needed, adjust QDS-I CW to increase the setting or CCW to decrease it. Test the function by starting drilling on low impact pressure and collaring feed pressure. When the drill cradle comes to a stop against the mechanical end stop, impact should shut of immediately. If not, the setting of QDS-I should be increased. NOTE! The setting of QDS-I should be the highest possible without making it difficult to start impact. This means that high collaring feed and damper pressures calls for a higher setting of QDS-I. QDS-A, Setting during drilling: 1. 2. 3. 4. 5. Check that the damper pressure is adjusted according to “Adjusting the damper pressure”. Start drilling. Make a good collaring, and then activate high impact pressure. Slowly decrease the feed pressure while observing the damper pressure gauge. The impact pressure should change from high to low when the damper pressure drops below 50 bar. If needed: Adjust QDS-A CCW to lower the setting and CW to increase it. QDS-J, Setting during drilling: 1. 2. 3. 4. 5. Check that the damper pressure is adjusted according to “Adjusting the damper pressure”. Start drilling on low impact pressure. Increase the feed pressure towards maximum while observing the damper pressure gauge. When the damper pressure exceeds 120 bar, impact should be stopped automatically. If needed: Adjust QDS-J CCW to lower the setting and CW to increase it. NOTE! During this adjustment there is an increased risk of getting stuck in the hole due to the increased feed pressure. NOTE! In soft rock conditions it can be difficult to force the damper pressure high enough. In this case the damper pressure regulator can be adjusted temporarily to 120 bar. 39 Damper and DPC-I system Setting in workshop QDS-I, Setting in workshop: 1. 2. 3. 4. 5. Disconnect and plug the impact pressure hose on the rock-drill. Start the diesel engine, increase the rpm to 1500 and turn switch S130 to Drilling position. Adjust the damper pressure to 35 bar, read on the damper pressure gauge in the cabin. Activate low impact pressure. Check the pressure on the impact pressure gauge in the cabin. Slowly adjust QDS-I in and out to find the activation point where the impact pressure disappears from the gauge. CW increases the activation point and CCW lowers it. Finally, adjust slowly CCW until the impact pressure appears on the gauge again. Verification: Increase and decrease the damper pressure a few times in order to verify that impact is stopped when the damper pressure is below 35 bar. De-activate impact and turn off the diesel engine. Tighten the lock nut on QDS-I without changing the setting and reconnect the impact pressure hose on the rock-drill. Adjust the damper pressure according to “Adjusting the damper pressure”. Verify through test drilling that impact can not be activated unless the drill bit is pressed against the rock. 6. 7. 8. 9. QDS-A, Setting in workshop: 1. 2. 3. 4. 5. 6. Disconnect and plug the impact pressure hose on the rock-drill. Start the diesel engine, increase the rpm to 1500 and turn switch S130 to Drilling position. Adjust the damper pressure to 50 bar, read on the damper pressure gauge in the cabin. Activate drill rotation. Activate high impact pressure. Check the pressure on the impact pressure gauge in the cabin. Slowly adjust QDS-A in and out to find the activation point where the impact pressure changes from high to low. CW increases the activation point and CCW lowers it. Finally, adjust slowly CW until the impact changes to low. Verification: Increase and decrease the damper pressure a few times in order to verify that the impact pressure changes when the damper pressure passes 50 bar. De-activate impact and turn off the diesel engine. Tighten the lock nut on QDS-A without changing the setting and reconnect the impact pressure hose on the rock-drill. Adjust the damper pressure according to “Adjusting the damper pressure”. Verify through test drilling that the impact pressure changes from high to low when the damper pressure drops below 50 bar if the feed pressure is lowered. 7. 8. 9. 10. QDS-J, Setting in workshop: 1. 2. 3. 4. 5. Disconnect and plug the impact pressure hose on the rock-drill. Start the diesel engine, increase the rpm to 1500 and turn switch S130 to Drilling position. Adjust the damper pressure to 120 bar, read on the damper pressure gauge in the cabin. Activate low impact pressure. Check the pressure on the impact pressure gauge in the cabin. Slowly adjust QDS-J in and out to find the activation point where the impact pressure disappears from the gauge. CW increases the activation point and CCW lowers it. Finally, adjust slowly CW until the impact pressure disappears from the gauge again. Verification: Increase and decrease the damper pressure a few times in order to verify that impact is stopped when the damper pressure exceeds 120 bar. De-activate impact and turn off the diesel engine. Tighten the lock nut on QDS-J without changing the setting and reconnect the impact pressure hose on the rock-drill. Adjust the damper pressure according to “Adjusting the damper pressure”. Verify through test drilling that impact is stopped when the damper pressure exceeds 120 bar if the feed pressure is increased to maximum. 6. 7. 8. 9. 40 Damper and DPC-I system Related QDS valves QDS-D: Activated by the pilot signal for drill rotation. In other words, the DPC-I only works when drill rotation is active. When valve QDS-D is closed to damper pressure, it is open to the control line (DP) for pump 1. This means that the DP pressure pilot controls QDS-A, which closes the pressure control valve for low percussion. System pressure P1 is thus controlled by the pressure control valve for high percussion. QDS-C: Activated via Y101B (S130 in drilling position or low percussion being activated) or with reverse feed. This facilitates control of percussion pressure via the pressure control valve for low pressure. 41 Damper and DPC-I system Logic block 1 QDS-B QDS-D QDS-E QDS-F QDS-G QDS-H QDS-C QDS-A Logic block 2 Y109 Y150 Y149 Y149 Y109 Y150 Logic block 3 Y169 Y122 Y121 QDS-K QDS-J QDS-I 42 Protective protections Protective protections Anti-jamming The anti-jamming protection is an automatic monitoring function that is always active during drilling. The anti-jamming function is activated by high rotation pressure or lack of air flushing flow during drilling. Logic function of the lever Since the anti-jamming inverts the feed direction, pulling the drill lever for feeding backwards would result in feed forward movement. To avoid this there is a pressure switch, B262, connected to the pilot pressure line for feed backwards. B262 is connected to PLC input X33, which, when active, inhibits the anti-jamming output Y2. Function When the anti-jamming protection is activated, the rock drill backs off until the jamming conditions with regard to rotation pressure (B134) and air flushing (B142) cease to exist. The rock drill backs off until the rotation pressure returns to the permitted value (80 bars) or the air flushing is activated. Conditions for anti-jamming protection with regard to high rotation pressure: Input→ PLC in→ PLC ut→ Output S130 drilling PLC/X24-On B118 arm in carousel PLC/X3-On S446 percussion activated PLC/X27 or X30-On B134 activated Y109 activated PLC/X0-On PLC/Y2-On* *The minimum activation time for output Y2 is set by the PLC to 0.8 seconds. If the rotation pressure exceeds 80 bars, sensor B134 is activated via QDS-K (see figure). The signal is sent to the PLC (see preceding conditions) and the directional valve Y109 which controls the direction of feed is activated. Y109 See full diagram for other details No.: 9840 0423 56 page 3(16) B134 Rotation Pressure QDS-K 43 Protective protections Conditions for anti-jamming protection with regard to lack of air flushing: Input→ PLC in→ PLC ut→ S130 drilling PLC/X24-On B118 arm in carousel PLC/X3-On S100 full air flushing PLC/X26-On S446 percussion activated PLC/X27 or X30-On PLC/Y22 and Y23-On B142 activated PLC/X1-On PLC/Y2-On* *The minimum activation time for output Y2 is set by the PLC to 0.8 seconds. To drill bit Output Y115, Y116 activated Y109 activated Y116 Y109 B142 Y115 See full diagrams for other details No.: 9840 0423 56 page 3(16) No.: 9840 0423 22 page 2(3) If there is no air flushing, sensor B142 is activated. A signal is sent to the PLC (see conditions above) and directional valve Y109 which controls feed direction is activated. RPCF Function RPCF controls the feed pressure to maintain a constant rotation pressure (torque). If the rotation pressure exceeds an adjustable nominal value, the RPCF valve will be opened and the feed pressure reduced proportionally via the pressure control valve for low feed pressure. The feed pressure will always lie between the values for low feed pressure and high feed pressure. Feed pressure RPCF-valve Pressure control valves See full diagrams for other details No.: 9840 0423 56 page 3(16) Note: The RPCF valve only controls the feed pressure when high percussion/feed pressure is activated. 44 Air system Air system Air system Compressed air is used for the following rig functions: Flushing air: Used to transport cuttings from the hole up to the surface. Reduced flushing is primarily used during collaring and drilling in porous or poor rock to prevent the air from damaging the walls of the hole. ECL, rock drill lubrication system ECG, thread lubrication (option) DCT, dust collector Watermist system (option) External air outlet, used for example for grinding equipment to drill bits ECL, rock drill lubrication system Conditions: Input→ S130 drilling B118 arm in carousel S100 reduced/full air flushing S446 air flushing activated PLC in→ PLC/X24-On PLC/X3-On PLC/X26 or X25-On PLC/X27 or X30-On PLC ut→ Output PLC/Y23 or/and Y22-On Y116 or/and Y115 activated Y106 activated PLC/Y0-On Note: The air flushing obtained with activation of S446 (percussion/air flushing) depends on the position that switch S100 is in (Full or Reduced). Note: The ECL pump works with a delay of 60 seconds after S100 or the percussion is switched off after drilling. ECL pump Y106 starts to pump as soon as the air flushing is turned on. The pump receives pulses from the ECL module in the electric cabinet. Lubrication oil is then fed through a small plastic hose inside the air hose to the rock drill, where the oil and air are mixed. The lubrication pressure gauge is located on the pressure control panel. Note: See the manual for adjusting number of pulses/min. ECG, thread lubrication See description in “Options” section. 45 Air system DCT, dust collector Conditions for intake (open hatch): Input→ PLC in→ S130 drilling PLC/X24-On B118 arm in carousel PLC/X3-On S100 reduced/full air flushing PLC/X26 or X25-On S446 air flushing activated PLC/X27 or X30-On S181 activated PLC/X2-On PLC ut→ Output Y250 activated PLC/Y23 or/and Y22-On Y116 or/and Y115 activated Y253 activated PLC/Y21-On Note: The DCT's fan motor starts by means of the activation of S130 in drilling position (not controlled by the PLC). Suction starts only when the hatch to the fan housing is opened by means of the activation of Y253 as described above. Conditions for cleaning the DCT filter after drilling: See above+below Input→ PLC in→ PLC ut→ S100 deactivated PLC/Y25 and Y26-Off PLC/Y21-Off (cleaning after drilling) PLC/Y14-On PLC/Y15-On PLC/Y16-On Or S446 deactivated PLC/X27 or X30-Off PLC/Y21-Off (cleaning after drilling) PLC/Y14-On PLC/Y15-On PLC/Y16-On *The valves are activated at the same time with an adjustable time interval. Output Y253 deactivated Y251A active* Y251B active* Y251C active* Y253 deactivated Y251A active* Y251B active* Y251C active* Note: To obtain cleaning the first condition is that suction must be on (Y21/On). The other condition is that the suction is then switched off (Y21/Off) by using switch S100 or S446, which mean that all filters are cleaned at the same time. If suction is on (Y21/ON), and just by closing the DCT hatch (S181/OFF) would not result in cleaning of the filters. This is considered when drilling into water, when drilling still needs to be continued, but cleaning is not wanted before drilling ends. 46 Air system The air supply to the DCT is limited to 7.5 bars by a pressure reducing valve. The solenoid valves Y251A-C are opened at the same time to clean the DCT filters. Dust collection starts when the air cylinder opens the fan outlet hatch. This is controlled via the DCT switch when the dust collector is in position ON and S446 is in reduced or full air flushing position, which in turn activates solenoid valve Y253 (DCT hatch) (See Fig.). Y253 Air valve Y251A-C Solenoid valves See full diagram for other details No.: 9840 0423 22 page3(3) 47 HQS (Hole Quality System) HQS (Hole Quality System) This document only covers the interface between the HQS system and the rig system. For detailed information of the HQS system, refer to the HQS section in the Operators manual. HQS is a complete system for gradient measurement, hole depth measurement on bench drill rigs. There are three kinds of HQS equipments to choose from. HQS 10 - Complete instrument for hole inclination measurement. HQS 11 - Complete instrument for measuring angles, hole depth and drilling rate. Hole depth measurement. HQS 12 - Complete instrument for measuring angles, hole depth and drilling rate from laser reference. The HQS system is linked to the rig system for power supply, activation of the drill stop function and definition of impact / rodhandling. Power supply The power supply for the HQS unit is connected to terminal X1/50 (24V) and X1/100 (Ground) in the A1 electrical cabinet. Drill stop activation The HQS supports a function to automatically stop the impact when a predefined drill depth is reached. The HQS electronic unit sends a 24V signal to activate PLC input X43. It will then deactivate PLC output Y41, thus freeing up the drill level from the magnets (Y179A, Y179B) and returning it to the neutral position; it will also deactivate PLC outputs Y20 (Y101A), thus shutting off impact, though flusing air remains activated. To make the HQS continue counting when the drill depth is reached, press the impact switch S446 for shorter than 0.5 seconds, and then re-activate drilling. Otherwise drilling can be re-started once the HQS is reset, PLC input X43 also goes off. Impact definition The impact definition signal is connected to the PLC output for the impact hour counter, Y20. The HQS uses this signal to calculate penetration rate per rod. Rod handling During rod handling, the HQS pauses the drill depth measuring. This means that negative distance created when backing up to add a new rod is not taken into consideration by the instrument. The start of the pause is defined by a signal coming from a pressure switch, B128. B128 is activated by pilot pressure when unthreading the shank adapter from the rod. The end of the pause is defined by a signal coming from switch S119 when opening the upper drill steel support. 48 RHS, Rod handling system RHS, Rod handling system General The functions for the different rod handling movements are controlled manually from the left-hand panel on the seat. All actuation signals run via the PLC out to the respective valve for the RHS functions (see figure below). There are a number of sensors on the feed beam which then gauge the activity in the system and send signals in to the PLC (see the explanation of how the sensors work at the end of this section). System pressure Max. pressure for the rod handling circuit is determined by a pressure reducing valve at 200 bars. There is also a separate pressure regulating valve to the suction hood (40 bars) to prevent the cylinder breaking and one for the grip function (10 bars) which limits the pressure for “loose grip” (see hydraulic diagram). RHS arm → carousel /hard grip Button for opening gripper claws/loose grip. Carousel rotation clockwise Carrousel rotation anticlockwise RHS arm → Drill centre/hard grip 49 RHS, Rod handling system Carousel rotation Conditions for rotation clockwise: Input→ PLC in→ S130 drilling PLC/X24-On S446 percussion deactivated PLC/X27 and X30-Off B379 seat sensor activated PLC/X31-On B118 arm in carousel PLC/X3-On S111 top button active PLC/X21-On S111 in left position PLC/X17-On B183 activated PLC/X7-On B183 inactivated PLC/X7-Off Conditions for stopping rotation clockwise: That the above conditions are fulfilled Input→ PLC in→ B183 activated PLC/X7-On Conditions for anticlockwise rotation: Input→ PLC in→ S130 drilling PLC/X24-On S446 percussion deactivated PLC/X27 and X30-Off B379 seat sensor activated PLC/X31-On B118 arm in carousel PLC/X3-On S111 top button active PLC/X21-On S111 in right position PLC/X20-On B182 activated PLC/X6-On B182 inactivated PLC/X6-Off Conditions for stopping rotation anticlockwise: That the above conditions are fulfilled Input→ PLC in→ B182 activated PLC/X6-On PLC ut→ Output PLC/Y13-On Y303A activated PLC ut→ PLC/Y13-Off Output Y303A deactivated PLC ut→ Output PLC/Y12-On Y303B activated PLC ut→ PLC/Y12-Off Output Y303B deactivated Carousel rotation is controlled by valves Y303A and B. Valve Y303A controls clockwise rotation and valve Y303B anticlockwise rotation. Two restrictors limit the rotation speed (see hydraulic diagram). Sensors detect whether rotation is clockwise or anticlockwise. Sensor B183 detects clockwise rotation and sensor B182 anticlockwise rotation. B182 B183 B118 50 RHS, Rod handling system RHS arm Conditions: Input→ S130 drilling S446 percussion deactivated B379 seat sensor activated S111 backward Or S111 forward PLC in→ PLC/X24-On PLC/X27 and X30-Off PLC/X31-On PLC/X16-On PLC ut→ Output PLC/Y10-On PLC/Y11-On Y301B Y301A PLC/X15-On Note: The air flushing is deactivated automatically when the percussion is switched off and rod handling is facilitated. The RHS cylinders are controlled by the solenoid valves Y301A and Y301B. Y301A controls the RHS arm to carousel and Y301B controls the arm to drill centre. Similarly with carousel rotation there are also two restrictors here which control the cylinder speed. There is a sensor (B118) which detects if the RHS arm is in carousel position. Pressure reducing valve (200bar) Y306 Y301B Y303B Y361B Y350B Y357B Y300 Y301A Y309 Y303A Y361A Y350A Y357A See full diagram for other details No.: 9840 0423 56 page 5(16) Gripper claws (on RHS arms) The gripper claws are controlled by the valves Y300 and Y306 which are controlled from the lever on the left-hand control panel. Open gripper claws Conditions: Input→ S130 drilling S446 percussion deactivated B379 seat sensor activated S111 top button active PLC in→ PLC/X24-On PLC/X27 and X30-Off PLC/X31-On PLC/X21-On PLC ut→ Output PLC/Y6-On Y300 The gripper claws are opened through activating the button on the steering lever (S111). To move the RHS arm to drill centre the lever is pulled (backward). To move the arm to the carousel the lever is moved forward. 51 RHS, Rod handling system Loose grip Conditions for loose grip: Input→ S130 drilling S446 percussion deactivated B379 seat sensor activated S111 neutral position B118 arm not in carousel PLC in→ PLC/X24-On PLC/X27 and X30-Off PLC/X31-On PLC/X15,16,17,20,21-Off PLC/X3-Off PLC ut→ Output PLC/Y7-On Y306 activated Loose grip is controlled by valve Y306 and a pressure control valve which limits the pressure to 10 bars (adjustable). Pressure reducing valve (200bar) Y306 Y301B Y303B Y361B Y350B Y357B Y300 Y301A Y309 Y303A Y361A Y350A Y357A See full diagram for other details No.: 9840 0423 56 page 5(16) Tight grip Conditions for tight grip: Input→ S130 drilling PLC in→ PLC/X24-On PLC ut→ Output Tight grip is the normal condition and no activated PLC inputs/outputs are activated. The gripper claws are in tight grip when the valves Y300 and Y306 are not activated. To obtain tight grip in the carousel the RHS lever is moved forward and to obtain tight grip in drill centre the lever is moved backward. 52 RHS, Rod handling system The following is a short explanation of how the sensors work on the ROC D-TH: B118 senses when the rod handing arm is in the carousel. This sensor must be activated to enable percussion during drilling. B122 This sensor protects the drill steel from being hit by the rock drill cradle during taking up the drill string. B126 is activated when the rock drill cradle is in position for unthreading the rod in the upper position and for unthreading the rock drill so that the drill steel can be entered into the carousel. B127 is activated when the rock drill cradle is in the highest position on the feed beam. This is the position for moving out a new drill steel from the carousel out to drill centre. Used mainly during drilling to prevent the rock drill cradle from crashing against mechanical stop. B182 is activated when the carousel rotation to the gripper (anticlockwise) has stopped in the correct position for taking a drill steel out to drill centre. B183 is activated when the carousel rotation from the gripper (clockwise) has stopped in the correct position for fitting a new drill steel in the B118 carousel from drill centre. B316 is a laser receiver B122 B182 B183 H322 B316 B127 B126 H323 53 Drill-steel support and suction hood Drill-steel support and suction hood Upper drill steel support Conditions: Input→ S130 drilling S119 forward S119 backward PLC in→ PLC/X24-On PLC ut→ Output - Y361A activated Y361B activated When S119 is moved forward the upper drill-steel support is closed (Y361A). When S119 is moved backward the upper drill-steel support is opened (Y361B). Lower drill steel support Conditions: Input→ S130 drilling S187 forward S187 backward PLC in→ PLC/X24-On PLC ut→ Output - Y350A activated Y350B activated When S187 is moved forward the lower drill-steel support is closed (Y350A). When S187 is moved backward the lower drill-steel support is opened (Y350B). Suction hood Conditions: Input→ S130 drilling S167 hood up S167 hood down PLC in→ PLC/X24-On PLC ut→ Output - Y357A activated Y357B activated Y357A and Y357B control lifting and lowering the suction hood respectively. An adjustable pressure control valve limits max. pressure to 40 bars for this function. (see further on the hydraulic diagram). S119 S187 S167 54 Options Options Watermist system (option) Conditions for preset water flushing with automatic activation (reduced flushing): Input→ PLC in→ PLC ut→ Output S130 drilling 24V available for S448 PLC/X24-On S180 compressor activated Y6A activated S448 centre position Y112A activated, Y112B deactivated Conditions for full water flushing with manual activation (full flushing): Input→ PLC in→ PLC ut→ Output S130 drilling 24V available for S448 PLC/X24-On S180 compressor activated Y6A activated S448 forward position Y112A activated, Y112B activated Conditions for stopping water flushing: Input→ PLC in→ S130 drilling PLC/X24-On S180 compressor activated S448 off position - PLC ut→ - Output 24V available for S448 Y6A activated Y112A/B deactivated The water mist system is used to stabilise the drilled hole when drilling through loose and porous rock by adding water to the air flushing. In general a small amount of water is used to dampen the cuttings and bind them together into larger particles, for dust control, or to bind the dust to the hole wall to obtain better hole stability. The quantity of water is controlled by two directional valves and a flow regulator, as follows: The watermist system: When directional valve Y112A is open and Y112B is closed, the amount of water is controlled by an adjustable throttle valve (see figure). Full water supply is only used at short intervals to flush the water on dry clay to obtain sludge which can be used for better stabilisation. The directional valves Y112A and Y112B are open/activated. OFF: Both directional valves, Y112A and Y112B, are closed. 55 Options Y112B Y112A Throttle valve Y112A Y112B Shut off valve Pressure relief valve Water tank See full diagram for other details No.: 9840 0423 22 page 2(3) If a larger quantity of water needs to be added, for example when reaching a pocket of clay, full water flushing can be selected (S448) on the right-hand control panel. To avoid suction hoses and dust collector filters clogging during the use of the water mist system the DCT must be switched off when the dust is very wet or if water is spurting up from the hole. 56 Options Winch (Remote control box, option) Conditions for using the winch: S130 must remain in position for tramming Remote control box (A60) must be activated. Make sure the switch in the cab and the switch on the box are in position for remote control. Make sure the winch switch is in the correct position (S172). Use the winch motor switch (S173) to reel the cable in and out. Or The winch can be automatically activated by using the tramming levers on the remote control box. See the operator's manual for instructions on activation and deactivation The winch's hydraulic circuit includes functions for reeling in and out the cable, regulating the pulling force of the winch and release of the winch brake. The system has a protection device that protects the winch in the event of a fault. This is controlled by relay S464. When the protection device is activated (CCU/114-On), the winch in signal CCU/203 is blocked. Only the winch out function is possible The remote control box has switches and controls for the following functions: Boom swing cylinder, Left/Right Boom lift cylinder, Up/Down Track oscillation cylinder, Up/Down Warning signal Winch, In/Out Winch power control Tramming, Left/Right Jacks, In/Out Winch/Tramming, Low/High Emergency stop; Fault LED; activation/deactivation of remote control box S500 57 Options Winch block The winch's hydraulic circuit includes functions for reeling in and out the cable, regulating the pulling force of the winch and release of the winch brake and plunger. The block comprises solenoid valve Y209 (controls brake disc release), Y215 (activates tramming with winch), Y224 (controls the winch plunger), two pressure relief valves that limit the maximum pressure (125 bar), a remote-controlled proportional pressure relief valve (Y214) for controlling the pulling force, and Y208A (winch in) and Y208B (winch out) which are control valves for the directional valve. Solenoid valves Y208A and B control the directional valve (see figure) as follows: Unreeling the cable: Solenoid valve Y208B and brake release valve Y209 are activated simultaneously by switch S173 on the remote control box. Unwinding can also be done manually with switch S500, which activates valve Y224 to release the winch plunger. Reeling in the cable: Solenoid valve Y208A and brake release valve Y209 are activated simultaneously, either manually by using switch S173 or automatically which happens when the rig is trammed from the remote control box. Manual: Switch S173 activates the valves abovementioned valves and closes the flow to the proportional relief valve Y215. Subsequently, the pressure is being limited to 125 bar by one of the pressure relief valve. (See figure) Automatic: Solenoid valves Y208A and Y209 are activated automatically when the tramming lever on the remote control box is operated (forward or backward). Valve Y215 is activated for tramming with the winch. A counter pressure builds up (manually set on Y214 + spring force) that helps open pressure relief valve (A) to the tank. The pressure is then determined by the remote controlled proportional pressure relief valve (Y214). This relief valve is adjusted manually with the potentiometer on the remote control box. Automatic reeling Manual reeling in Plunger catch Multi-disc brake Y209 Y224 Y208B Y208A Y209 Y224 Y208B Y208A Pressure relief valves A Pump 3 winch/pos. Y215 Y214 Directional valve Pump 3 winch/pos. Y215 Y214 Directional valve See full diagram for other details No.: 9840 0423 56 page 5(16) 58 Options Boom swing and boom lift cylinder The adjacent switches are located on the remote control box and control boom swing and boom lift, as well as activate the associated solenoid valves Y426 and Y425. (See hydraulic diagram for details.) Boom lift Track oscillation The adjacent switches are located on the remote control box and control track oscillation left and right, as well as activate the associated solenoid valves Y419 and Y420. (See hydraulic diagram for details.) Note: The track lock is locked/unlocked from the left-hand armrest in the cab. Manual winch control Conditions for using the winch only: Winch switch S172 in position ON When switch S173 is used, the tramming controls are locked and the following solenoid valves activated: Brake valve (reversing valve that controls the brake) Y209 Winch motor valve Y208 Boom swing Left (On) S172 Right S173 Tramming without winch Functions that are activated: Switch S172 must be in tramming position. Tramming controls (see following) activate solenoid valves Y206 and Y207. Tramming with winch When tramming with the winch, switch S172 must be in the winch position, which in turn activates the following functions: Brake valve Y209 is activated. Winch motor valve Y208A is activated. Tramming direction valves Y206 and Y207 are activated. Note: All valves can be found on the corresponding block diagrams. 59 Options Extraction unit (option) The extractor unit is used when the rock conditions vary a lot and there is a large risk of jamming. The function of the extractor unit is to provide reverse percussion to the shank adapter and thus the drill sting and drill bit. The shank adapter for rock drills equipped with an extractor unit has a special flange that receives the reverse percussion force. Since the shank adapter is pressed into the rock drill by the feed force during normal drilling, it works without the flange meeting the extractor piston. Conditions for extraction unit: The rig must be in drilling mode. Percussion must be activated. For the extraction unit to be activated the above conditions must be fulfilled. When there is a risk of drill jam, activate drill feed backward. The pilot pressure then activates the QDS-L valve and the pump pressure is directed via a restrictor valve (ø2,0) to the extraction unit. (See figure) QDS-L Y178B Throttle valve Pump 1 See full diagram for other parts No.: 9840 0423 56 page 3(16) No.: 9840 0423 56 page 2(16) 60 Options ECG, thread lubrication with oil (option) The ECG pump Y107 starts to pump as soon as the air flushing is turned on. The pump receives pulses from the ECG module in the electric cabinet. ECG injects a small amount of lubricating oil into the air flushing. The oil creeps along the walls of the flushing hole and out into the threaded joints. Atlas Copco recommends the use of COP OIL for all ECG and ECL lubrication. Conditions: Input→ S130 drilling B118 arm in carousel S100 reduced/full air flushing S446 air flushing activated PLC in→ PLC/X24-On PLC/X3-On PLC/X26 or X25-On PLC/X27 or X30-On PLC ut→ Output PLC/Y23 or/and Y22-On Y116 or/and Y115 activated Y107 activated PLC/Y1-On Thread lubrication with grease brushes (option) Conditions for thread lubrication: Input→ PLC in→ S130 drilling PLC/X24-On S449 in automatic pos. S111 arm to drill centre PLC/X16-On PLC ut→ Output PLC/Y10-On Y301B activated K449 activated → Y552 activated Conditions for manual thread lubrication: S449 in manual position→ Y552 activated Conditions for stopping thread lubrication: S449 in Off position→ Y552 deactivated Note: When S449 is in manual mode, 24V is fed directly to the thread lubrication valve (Y552). 24V K449 K449 22/6B 50 11 14 12 KC502-18 A1 S449 S449 B5 B6 H 0 A Y552 KC50 26 26 W50A 23 KC502 18 W50A 18 17 KC50 18 KC502 26 26 KC502-26 X1 36 KC301-3 KC301 3 3 W30 Gy 4 X30:4 4 Y552 1 A1 Y552 A2 61 Options Function The drill steel threads are lubricated with two brushes (A) located on the lower part of the feed beam, between the carousel and drill steel support. The drill steel passes these prior to threading. b a c d A a b c The grease is supplied by a pump placed in the front of the wagon frame. The pump is powered by compressed air from the rig’s compressor and controlled through solenoid valve Y552. Activation of Y552 can be done either automatically or manually and is controlled by the switch S449 on the diesel panel. Operation Under normal conditions, the system operates automatically. The lubricant pump is activated when the rod handling process is in position to move a drill steel to drill centre (tight grip). The result is that every time a drill steel is removed from the carousel, a quantity of lubricant is pumped into the brushes that the threads of the drill steel pass through. If further lubrication is required, the system can be operated manually. In such a case, the lubricant pump is activated so long as the switch S449 is kept in position (a). If thread lubrication is not required, the system can be switched off by putting switch S449 in position (c). The maximum pressure to the pump is adjusted to 7.5 bars by the pressure regulator 3. (See right figure) The system can be switched off by blocking the air supply with ball cock valve 8 or by the electrical switch on the diesel panel. We recommend the use of Atlas Copco Secoroc thread lubricant A for the lubrication of drill steel threads. See full diagram for other parts No.: 9840 0423 22 page 3(3) 62 Adjustment/calibration Adjustment/calibration Adjustable parameters, DCT Pulse duration - length of the pulse, i.e. the signal time Pause time - time between pulses Cleaning time - total time of the cleaning cycle (after drill stop). To adjust the above times the conditions for the DCT must be fulfilled Basic conditions for adjusting DCT times: Input→ PLC in→ PLC ut→ Output S130 drilling Y250 activated PLC/X24-On B118 arm in carousel PLC/X3-On S100 red./full air flushing PLC/X26 or X25-On S446 percussion activated PLC/X27 or X30-On PLC/Y23 or/and Y22-On Y116 or/and Y115 activated S181 activated Y253 activated PLC/X2-On PLC/Y21-On PLC/X4-Off (decrease) S456 decrease/increase or On (increase) DCT time Conditions for adjusting Pulse time: 1. The basic conditions for adjusting the DCT must be fulfilled 2. S457 activated→ PLC/X5-On→ increases/decreases* the pulse time with 50ms/button press Note: Factory setting is 300ms. Conditions for adjusting Pause time: 1. The basic conditions for adjusting the DCT must be fulfilled 2. S458 activated→ PLC/X10-On→ increases/decreases* the pause time with 1s/button press. Note: Factory setting is 5s. Conditions for adjusting Cleaning time: 1. The basic conditions for adjusting the DCT must be fulfilled 2. S459 activated→ PLC/X11-On→ increases/decreases* cleaning time with 5s/button press. Note: Factory setting is 30s. * Depending on which setting is on S456 (decrease/increase) ? ? ? ? ? ? ? ? ? ? ? ? ? ? ? ? ? ? ? ?? ? ? ? ? A1 B1 15 t 2 ? ? ? ? t 1 16 18 A2 ? ? ? ? ? S456 S457 S458 S459 ? ? ? ? ? ? ? ? ? ? ? ? ? ? ? ? ? ? S456 S457 S458 S459 X4 X5 X10 X11 ? ?? ? ? ? ? ? 63 Adjustment/calibration Adjustable drilling parameters High impact pressure Low impact pressure High feed pressure Low feed pressure RPC-F system RPCF Threading pressure Rotation speed Unthreading pressure 64 Search list Search list Sensor: B118 B122 B126 B127 B128 B134 B142 B143 B174 B175 B182 B183 B262 B316 B352 B360 B361 B362 B365 B366 B367 B379 B381 B382 B541 Lamps: H101 H102 H127 H129 H180 H185 H186 H203 H207 H211 H212 H213 H214 H215 H217 H314 H315 H316 H317 H322 H323 H381 H382 RHS arm to carousel Rapid feed (+) stop Rapid feed (-) stop Rapid feed (-) stop/reduced speed upper Pause/Start - Unthreading Rotation pressure Air flushing switch Hydraulic oil level Tramming, backward-left Tramming, backward-right Stop carousel rotation to grip Stop carousel rotation from grip Drill feed - backward Laser sensor (Option) Fuel level Pressure switch, air filter (engine) Cooling water level, Engine Hydraulic oil tempterature Pressure switch, air filter (Compressor) Compressor temperature Level switch (Option) Sensor for Operator's seat ECL collector - low ECL collector - high Condensor pressure switch Lighting, A1 cabinet Lighting, A1 cabinet Hydraulic jack Out Indicator lamp for winch Compressor load Warning, backward tramming (lamp + signal) Warning, backward tramming (signal) Low hydraulic oil level Clogged air filter for diesel engine and compressor Alarm lamp for diesel engine monitoring Alarm lamp for diesel engine monitoring – engine off Alarm lamp for rig monitoring Alarm lamp for rig monitoring – enging off Engine coolant level Engine heating Working lights, valve plate Working lights DCT Working lights, rear right of roof Working lights - roof left-hand rear side Working lights, feeder Working lights, feeder ECL collection low ECL collection high 65 Search list H511 H512 H513 H514 H515 Working lights, Cab-upper edge Working lights, Cab-upper edge Working lights, Cab-lower edge Working lights, Cab-lower edge Working lights-Cab Relays: K1 K4A K4B K4C K5A K5B K6 K7 K10 K11 K18 K169 K178 K180 K198A K198B K213 K214 K330 K327 K449 Motors/pumps: M1 M18 M20 M512 M516 M517 M518 M519 M520 Potentiometers: R106 R354 Relay, air heater Ignition relay Ignition relay Ignition relay Start relay Start relay Open gripper relay Loose grip relay RHS-arm to drill centre relay RHS-arm to carousel relay Filler pump relay Drill stop – pilot pressure cut down Rapid feed/threading relay Hydraulic jack out Relay work lights on feed Relay rear work lights Relay alarm lamp for rig monitoring Relay alarm lamp for rig monitoring – enging off Relay diesel engine enable Relay lamp test ECL-collection Relay brush greasing Starter motor Filler pump (option) Automatic lubrication system (option) Wiper motor - right-hand side Wiper motor - front side Wiper motor - Roof Water pump - front side Water pump - Roof Chair tipping Potentiometer- Winch force VDO contrast adjustment knob 66 Search list Switches: S18 S100:1 S100:2 S100:3 S111 S113 S119 S130 S132A S132B S132C S139 S167 S170 S172 S173 S176 S177 S180 S181 S182 S186 S187 S189 S209 S300 S445 S446 S448 S449 S450 S452 S453 S456 S457 S458 S459 S464 S500 S507 S508 S509 S515 S520 S521 S525 S526 S527 S542 Switch, filler pump Reduced air flushing Full flushing Air flushing off Rod handling (multi-function lever) Taking up steel Upper drill steel support Mode selector (drilling, tramming-positioning, hydraulic oil heating) Emergency stop, winch Emergency stop, Feeder Emergency stop, cab Ignition key Suction hood Switch, cab/remote control Winch enable Winch (In/Out) Track oscillation, left track Track oscillation, right track Compressor charging DCT On/Off Sleeve grippers Warning signal Lower drill steel support Button, engine speed Jacks (Out/In) Battery switch Track oscillation switch Percussion pressure, low/high Water flushing (full/reduced) Switch for lubrication with brushes Scroll ECM display Rapid feed/threading mode Magnet off drill lever DCT time, decrease/increase Adjusting pulse time Adjusting pause time Adjusting cleaning time Winch protection Unlock winch Working lights front, upper edge/lower edge Working lights rear, right/left Lighting- valve plate/DCT Switch, cab door for lighting Chair tipping Water pump Light cabin Wiper, front Wiper, roof Timer, diesel heater 67 Search list Resistors/contacts: R1 R241 R529 X535 Valves: Y6A Y60 Y101A Y101B Y106 Y107 Y109 Y112A Y112B Y115 Y116 Y120 Y121 Y122 Y149 Y150 Y169 Y170 Y178 Y179 Y187 Y206A Y206B Y207A Y207B Y208A Y208B Y209 Y210 Y214 Y215 Y224 Y250 Y251A Y251B Y251C Y253 Y300 Y301A Y301B Y303A Y303B Y306 Y309 Y350A Y350B Y357A Resistor - inlet heater Resistor - shutdown, PLC X41 Seat heater (option) connector socket Compressor charging Cooler compressor (AC) Percussion flow Percussion pressure, low ECL pump ECG pump (option) Anti-jamming Watermist, automatic Watermist, manual Air flushing, full flushing Air flushing, reduced flushing Preheating Tramming, main flow Tramming, high speed Rapid feed stop, backward Rapid feed stop, forward Pilot pressure Hydraulic tramming off Rapid feed/threading Drill mode magnets Pump 3 positioning/winch Tramming, left forward Tramming, left backward Tramming, right forward Tramming, right backward Winch motor, In Winch motor, Out Winch brake, release Compressor load Variable winch force Max winch force Unlock winch DCT, fan motor DCT, filter clean A DCT, filter clean B DCT filter C DCT, outlet hatch Open gripper RHS arm to carousel RHS arm to drill centre Carousel rotation clockwise Carousel rotation anticlockwise Gripper claws, loose grip Sleeve grippers Lower drill steel support, open Lower drill steel support, closed Suction hood up 68 Search list Y357B Y361A Y361B Y410A Y410B Y419A Y419B Y420A Y420B Y425A Y425B Y426A Y426B Y473 Y552 Suction hood down Upper drill steel support open Upper drill steel support closed Jack Up (Option) Jack Down (Option) Track oscillation, left Up Track oscillation, left Down Track oscillation, right Up Track oscillation, right Down Boom swing, left (Option with winch) Boom swing, right (Option with winch) Boom lift, Up (Option with winch) Boom lift, Down (Option with winch) Track oscillation, floating Lubrication brushes Last updated 15 October 2008 69