AC Explorac 220 RC specification

Atlas Copco Exploration Products

26000080 A

Explorac - Reverse circulation drilling

Explorac 220 RC Safety and Operating instructions

© 2012 Atlas Copco Craelius AB | 6991 5073 01b | 2012-05-15

Contents

Contents Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Safety instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Safety signal words . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10 Personal precautions and qualifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10 Hoisting and transport . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Storage, repair, maintenance and disposal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Personal protective equipment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Drugs, alcohol or medication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Safety area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11 Hoisting and transport . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11 Operation, precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11 Maintenance, precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12

Signs and stickers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Prohibition signs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14 Warning signs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14 Regulatory signs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15 Information signs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18 Other signs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19

Quick guide - Engine start and tramming . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 Engine start procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20 Jack control levers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21 Tramming mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22

Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 Design and function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24 RC pro . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 RC con . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 Direct air percussion drilling with Down the Hole Hammers. . . . . . . . . . . . . . . . . . . . . . . 25 Additional guides and adapters required . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 General dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26 Main parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27 Explorac R220 basic unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 Rig control system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .28 Layout CAN-system E220 RCS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .31 Menu overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .32 Direct Menus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .33 D1:1 - Direct Menu Drilling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33 © 2012 Atlas Copco Craelius AB | 6991 5073 01 | 2012-05-15

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Contents D1:2 - Direct Menu Operator Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33 D3 - Direct Menu Compressor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33 D4 - Direct Menu Service Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34 Safety Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34 M1 - Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34 System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .35 M2 System Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 M2:1 - Module Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 I/O-Module Diagnostic Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 Operator Panel Diagnostic Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 ECM Diagnostic Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 M2:2 - I/O-Module Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36 M2.2.1 D510 PWM Output Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36 M2.2.1.1 D510 Digital Output Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36 M2.2.1.1.1 D510 Input Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36 M2:3 - ECM Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37 M2:4 - Operator Panel Lever Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37 Lever Calibration Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37 M2:5 - Rod Loader Lever Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37 Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .38 M3.3 - Service Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38 M3.3.1 - Parameter Settings Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38 M3.3.1.2 Fast Feed Settings Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39 M3.3.1.3 Rotation Settings Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39 M3.3.1.4 Water and Air Settings Menu. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39 M3.3.1.5 Winch Settings Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39 M3.3.1.6 Fan Motor Settings Menu (ACP-Level) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39 M3.3.1.8 Hydraulic Oil Settings Menu (ACP-Level) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40 M3.3.2 – Set Persistent Data Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40 M3.4 – Sensor Override Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40 M3.5 – Save Log Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41 Lever Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .42 Program and Parameter Loading . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .43 General. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43 Save of Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43 Load Program. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44 START PROCEDURE (before actually starting the diesel engine) . . . . . . . . . . . . . . . . . 46 Engine start. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .47 Engine running . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .48 Caterpillar engine monitoring system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .49 Coolant system level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49 Coolant system temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49 4

© 2012 Atlas Copco Craelius AB | 6991 5073 01 | 2012-05-15

Contents Engine speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50 Fuel pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50 Fuel temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50 Fuel conservation practices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50 Engine air intake temp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51 Engine oil pressure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51 Atmospheric pressure sensor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51 Engine stop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .52 Emergency stop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .52 After engine stop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .53 Mode selector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .54 Driller’s control panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .54 Drill rig positioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .55 Before compressor start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .56 Compressor start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .56 Compressor stop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .56 Rapid feed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .57 Rotation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .57 Making a thread with the rotation unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57 Disconnect a thread with the rotation unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57 Rotation motor operation mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .58 Main handling winch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .58 Winch arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .59 Compressed air delivery valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .60 Drilling lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .60 Set spindle torque and speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .61 Maximum lifting force . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .61 Setting the maximum lifting force . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61 Down feed and hold back . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .62 Water pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .63 Line oiler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .64 Hydraulic slips . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .64 Spanner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .65 Break-out tong . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .65 Rod rest . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .66 Cyclone . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .67 Stop watch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .68 Horn . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .69 Drill string bleed valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .69

Rod handler. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70 Joystick for rod manipulating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .70 Basic functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70 © 2012 Atlas Copco Craelius AB | 6991 5073 01 | 2012-05-15

5

Contents Rod bin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .72 Rod support up/down. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72 Cup rotation, low speed sector. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72

Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74 Hydraulic and electrical systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .74 Replacing hydraulic components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74 Replacing a hydraulic cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74 Adding hydraulic oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .74 Feed chain tensioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .76 Lubrication oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76 Elongation of feed chains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .76 Rotation unit alignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .77 Electric welding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .78 Before welding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78 Safety Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .78 Preventive maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .79 Lubricants, coolants and propellants . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .82 Hydraulic oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82 Propellants . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83 Coolants . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83

Trouble shooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84 Disposal and environmental instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89 Oil and Grease . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89 Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89 Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89 Batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89 Electrical components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89 Chemicals. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89 Dust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89 Metals (steel, aluminum, etc.) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89 Plastics and rubber. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89 Material Safety Data Sheets (MSDS/SDS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89

Technical specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90 Measurements and weights truck version . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .90 Measurements and weights crawler version . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .91 Mast . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .92 Feed system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .92 Rotation unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .92 Slips and breakout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .92 Tool handling hoisting winch BW 1500 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .92 6

© 2012 Atlas Copco Craelius AB | 6991 5073 01 | 2012-05-15

Pipe rack . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .92 Hydraulic jacks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .92 Cooler system. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .92 Cyclone RC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .92 On-board compressor XRX 12 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .92 Line oiler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .92 Foam pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .92 Power pack . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .92 Hydraulic system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .93 Electrical system 24 V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .93 Control system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .93 Radio Remote Control for crawler rig only . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .93

Safety and operating instructions

Introduction

These instructions are intended for operators of the Atlas Copco equipment. The aim of the instructions is to provide you with knowledge of how to use the equipment in an efficient and safe way. These instructions also give you advice and tell you how to perform regular maintenance on the equipment. It does not replace thorough training of operator, it is a complement. For further information concerning service measures, please contact your nearest Atlas Copco representative. Always read these instructions carefully and make sure that you understand all of them before starting for the first time. The owner of the equipment is granted the permission to take copies of this publication solely for internal use. It is recommended, however, to order additional copies from Atlas Copco representative in order to benefit from the latest revision. Atlas Copco Craelius AB reserves the right to make changes in its products in order to improve design or performance characteristics without notice. The information in this publication is assumed to be accurate at the time of publication, but is subject to changes in order to remedy detected deficiencies or to follow changes in the product. Any user of this publication is requested to inform Atlas Copco Craelius AB about deficiencies found, particularly in matters concerning product safety.

© 2012 Atlas Copco Craelius AB | 2012-05-15 Introduction

Safety and operating instructions

Safety instructions

To reduce risk of serious injury or death to yourself or others, read these safety instructions before operating the machine. Post these safety instructions at work locations, provide copies to employees, and make sure that everyone reads the safety instructions before operating or servicing the machine. Comply with all safety regulations. All possible hazards cannot be covered here, but we highlight some of the most important. For additional safety information consult:  Other documents and information packed with this machine.  Appropriate standards as refered to in the EC Declaration of Conformity, if provided.

Safety signal words The safety signal words Danger, Warning and Caution have the following meanings: DANGER

WARNING

CAUTION

Indicates a hazardous situation which, if not avoided, will result in death or serious injury. Indicates a hazardous situation which, if not avoided, could result in death or serious injury. Indicates a hazardous situation which, if not avoided, could result in minor or moderate injury.

Storage, repair, maintenance and disposal Storage, repair, maintenance and disposal of the equipment may only be undertaken by persons who:  are aware of all the relevant national safety instructions and accident prevention instructions  and have read and understood the Safety and operating instructions.

Operation Operation of the equipment may only be undertaken by qualified drill rig operators. Operators are qualified if they:  have undergone theoretical and practical training on the equipment in conformity with the national directives,  are aware of all the relevant national safety instructions and accident prevention instructions  and have read and understood the Safety and operating instructions.

Personal protective equipment WARNING Entanglement hazard Loose fitting clothing and jewelry can get caught in the moving parts of the machinery and cause serious injury or death. ►Do not wear jewelry and loose fitting clothes. Always use approved protective equipment. Operators and all other persons in the working area must wear protective equipment, including at a minimum:  Protective helmet

Personal precautions and qualifications

 Hearing protection in accordance with occupational health and safety regulation

Only qualified and trained persons may operate or maintain the equipment. Always use your common sense and good judgement.

 Respiratory protection when appropriate

 Impact resistant eye protection with side protection  Protective gloves  Proper protective boots

Hoisting and transport Hoisting and transport of the equipment may only be undertaken by persons who:  are authorized to operate a crane or fork-lift truck in conformity with the applicable national directives,  are aware of all the relevant national safety instructions and accident prevention instructions  and have read and understood the safety and hoisting and transport chapters of this manual.

10

Drugs, alcohol or medication WARNING Drugs, alcohol or medication Drugs, alcohol or medication may impair your judgment and powers of concentration. Poor reactions and incorrect assessments can lead to severe accidents or death. ►Never use the machine when you are tired or under the influence of drugs, alcohol or medication.

© 2012 Atlas Copco Craelius AB | 2012-05-15 02 Safety Instructions Ed.1

Safety and operating instructions ►Prevent other people from using the machine if they are under the influence of drugs, alcohol or medication.

►When lifting, make sure that the sling will not damage the hydraulic hoses, mechanical components etc. ►Use a spreader bar to lift the drill unit.

Safety area WARNING Falling objects can cause serious injury or death During operation, falling objects from great heights can cause bodily injury and extensive damage. ►Close off the working area. ►Before starting always make sure no unauthorized persons are within the working area of the drill rig in use. ►Immediately stop operation when persons are present in the danger area.

Operation, precautions WARNING Hydraulic oil at high pressure Thin jets of hydraulic oil under high pressure can penetrate the skin and cause permanent damage. ►Immediately consult a doctor if hydraulic oil has penetrated the skin. ►Never use your fingers to check for hydraulic fluid leaks. ►Keep your face away from any possible leaks.

►Make sure that no loose pieces of equipment or other objects are lying on the feed.

WARNING Dust hazard When drilling with compressed air, the rock cuttings are carried out of the bore in the form of small cuttings, and dust, which can cause serious injury.

Hoisting and transport WARNING Heavy equipment can cause serious injury ►Use a sling dimensioned for the load it is to carry.

Some dusts, fumes or other airborne material created during use of the machine may contain chemicals known to the state of California to cause cancer and birth defects or other reproductive harm. Some examples of such chemicals are:

►Use only straps that are whole and intended for the load in question.

 Crystalline silica, cement and other masonry products.

►Never use a damaged rope/sling.

 Arsenic and chromium from chemically-treated rubber.

►Fasten straps in lifting eyes when present. ►Always lift at the centre of gravity.

 Lead from lead-based paints.

►Always make sure that nobody is under or anywhere near a suspended load or within the swing radius of the rope/sling.

►To reduce your exposure to these chemicals, work in a well ventilated area and work with approved safety equipment, such as dust masks that are specially designed to filter out microscopic particles.

►Observe great care when strapping and lifting heavy objects.

►Use a dust collector, or spray water with a water/ foam pump.

WARNING Unexpected movement can cause serious injury If the rig is left unattended or disconnected from the transport unit an unexpected movement of the drill unit can cause serious injury or death

WARNING Heavy equipment can cause serious injury ►Make sure that the drill is anchored to withstand the set forces.

►Lock the articulated steering before hoisting ►Make sure that the hydraulic jacks are grounded or wedge the wheels of the carrier NOTICE

Sling can damage components

►Make sure that the rig is stable before starting to drill. WARNING Unexpected movement can cause serious injury If control levers and switches are not set to neutral position, start of the machine can lead to unexpected movements and can therefore cause injury. ►Set control levers and switches to the neutral positions prior to starting up. WARNING Noise hazard High sound levels may cause permanent hearing loss. ►Use hearing protection in accordance with occupational health and safety regulations.

© 2012 Atlas Copco Craelius AB | 2012-05-15 02 Safety Instructions Ed.1

11

Safety and operating instructions WARNING Compressed air When drilIing with compressed air, the rock cuttings are carried out of the bore in the form of small cuttings, and harmful dust. In order to reduce the injurious effect. ►Wear a breathing mask, use a dust collector, or spray water with a waterlfoam pump, use hearing protection in accordance with occupational health and safety regulations

When overhead electrical power lines exist at, or near a drilling site, consider all wires to be alive and dangerous. If the rig comes in contact with electric circuits or other electrical power sources, there is a risk of severe injury or death. ►Always look up to check for overhead electrical power lines when raising the mast. ►Never work in the proximity of electric circuits or other electrical power sources.

WARNING Rotating parts Rotating drillpipes, tools and particularly soil augers are extremely dangerous to handle. Augers turn with high torque and can cause severe injury if personel is caught by extruding parts.

►Make sure there are no hidden electric circuits in your working area.

►Never touch a rotating auger or any part of an auger string.

►Alert people in the area; order them to stay out of the immediate area and not to touch any of your equipment, including the support container.

►Never reach behind, or around an auger. ►Don't try to remove cuttings from a rotating auger. Augers may be cleaned only when brought to full stop. WARNING Emergency situation An emergency situation can occur due to material failure or incorrect handling.

►Do not step off grid mat if such are used. If you stand on ground, stay put and do not touch any equipment.

►Ask the supervisor to contact utility company in order to switch off the system. ►If the strike occurred during drilling, retract down-hole tool. Do not attempt to break any rod connection. ►Do not add or remove any drill pipes.

►Stop the operation by pushing the emergency stop button or if available pull the trip wire.

WARNING Gas line pressurized, Explosion hazard If the equipment comes in contact with gas lines and explosives, an explosion could occur. Explosions will lead to severe injuries or death. ►Never operate the machine in any explosive environment.

71000005 A

►Check proper function of the safety equipment at least once beginning of each shift.

►Never use the machine near flammable materials, fumes or dust.

Maintenance, precautions

►Make sure that there are no undetected sources of gas or explosives.

WARNING Hydraulic oil Spilled hydraulic oil can cause burns, accidents by slippery conditions and will also harm the environment.

►When working in areas where gas lines are buried, make sure that your equipment is placed on the windward side.

►Take care of all spilled oil and handle it according to your safety and environment regulations.

►Shut down all combustion engines, like hydraulic power pack, generators etc.

►Never dismount the hydraulic components when the hydraulic oil is hot.

►Leave the machine immediately.

WARNING Hydraulic system under high pressure Maintenance and repair on the machine and the hydraulic equipment under pressure can lead to severe injuries. Connections can loosen suddenly, parts can suddenly move and hydraulic oil can be ejected.

►Warn people to evacuate the area. ►Contact emergency personnel. ►Contact the gas company to shut the gas off. ►Stay out of the area until the gas company declares the area to be safe. WARNING

12

Electric Shock

© 2012 Atlas Copco Craelius AB | 2012-05-15 02 Safety Instructions Ed.1

Safety and operating instructions ►Depressurize the hydraulic system before performing maintenance on the hydraulic equipment. ►Never replace high pressure hoses with hoses of lower quality than the original or with hoses that have removable couplings Pressure settings are always performed on a pressurized system. ►Always exercise the greatest caution. ►Pressure settings must only be performed by trained personnel. WARNING Machine modification Any machine modification may result in bodily injuries to yourself or others. ►Always contact your Atlas Copco Customer Center before you modify the machine. ►Always use original parts and accessories approved by Atlas Copco. WARNING Heavy machine can cause serious injury ►During service and maintenance work, all components that may be brought into motion or fall must be supported or tied secure. WARNING Thermal cracks may arise when welding ►Do not do any welding on the equipment without consulting Atlas Copco. WARNING The paint contain substances hazardous to health Substances are formed when the paint is heated which are hazardous to health.

►Only qualified electricians should perform any electrical troubleshooting or maintenance. Remove all watches and rings that could contact live electric circuits. ►Make sure all power to the system has been cut before carrying out any maintenance work. ►All electric cabinets should remain locked when not under direct control of qualified electrician. ►Do not use the cabinets as a toolbox or spare parts storage container. The inherent vibration and magnetism associated with transformer and motor starters can cause inadvertent contact of foreign objects with live circuits. ►Some electrical components may have power when the main circuit breaker is open, verify that power is disconnected before servicing. ►Do not tamper with safety interlock circuits, safety guards or other safety devices, except as required during normal maintenance and troubleshooting. ►Confirm that all safety devices and circuits are replaced and functioning before operation is resumed. ►Shut of electrical power while making or breaking electrical cables. CAUTION Skin eczema Hydraulic oil can cause eczema when it comes in contact with the skin. ►Avoid getting hydraulic oil on your hands. ►Always use protective gloves when working with hydraulic oil.

►Welding, grinding and other hot work involving paint being heated must only be carried out where sufficient ventilation can be used. ►Always use compressed air powered breathing protection, eye protection and gloves. WARNING Hot engine parts can cause burn ►Make sure the engine is turned off before all maintenance work and before refueling ►Be careful when draining hot oil and fluids ►Do not handle flammable fluids in the vicinity of hot surfaces, sparks or naked flames. WARNING Pressure vessel can cause serious injury ►Discarded accumulators must be rendered harmless. ►A discarded pressure vessel that has not been punctured must be treated like a pressure vessel. ►Take care when evacuating the accumulator. WARNING Electric shock ►Only authorized electricians may carry out work on the electrical system. © 2012 Atlas Copco Craelius AB | 2012-05-15 02 Safety Instructions Ed.1

13

Safety and operating instructions

Signs and stickers

The machine is fitted with signs and stickers containing important information about personal safety and machine maintenance. The signs and stickers shall always be easy to read. GDE00004 A

Prohibition signs

There is a risk of scalding and pressure which can cause severe injuries or death. ♦ The pressure must be released before the cap can be removed

GDE00000 A

♦ No admittance ♦ No admittance for unauthorized personnel. ♦ Violation can cause personal injury.

GDE00005 A

The air pressure can cause severe injuries or death. ♦ The pressure must be released before the cap is removed.

GDE00001 A

♦ Don't step here GDE00006 A

Warning signs General warning signs

Moving and rotating parts can cause severe injuries. ♦ Keep out of the machine's working area when it is in operation

GDE00002 A

GDE00007 A

High noise level can cause permanent hearing impairment. ♦ Use approved ear protectors.

Slip risk

Swinging and crushing parts can cause severe injuries. ♦ Keep out of the hazardous area during operation.

GDE00034 A GDE00003 A

Preprogrammed cycle can cause severe injuries.

14

© 2012 Atlas Copco Craelius AB | 2012-05-15 03 Signs and stickers Ed.0

Safety and operating instructions

Service work

Regulatory signs General regulatory signs

GDE00008 A

In the event of breakdown or during service work the boom falls diagonally, which can cause injuries and damage to machinery. ♦ During service work the boom must be secured in place with straps or supports.

Stability

GDE00011 A

♦ Read the instructions. ♦ Incorrect use of the machine can cause personal injury and damage to machinery. ♦ Observe the indications given by the warning signs and follow given instructions in order to avoid serious injuries.

Max. Max.

GDE00009 A

Electrical system

GDE00012 A

GDE00010 A

♦ Read the instructions. Be aware of high voltage, incorrect handling can be fatal. ♦ All work on the electrical system must be carried out by electricians accredited for the purpose.

♦ The rig is equipped with a battery switch.

GDE00013 A

♦ Read the instructions. ♦ The carrier's battery supplies the hydraulic oil level switch with current. ♦ The battery switch must be turned on when drilling is in progress. ♦ Switch off the battery switch when rig is not in operation. If this is not done the battery will be discharged. © 2012 Atlas Copco Craelius AB | 2012-05-15 03 Signs and stickers Ed.0

15

Safety and operating instructions

GDE00014 A

GDE00017 A

♦ Read the instructions.

♦ Read the instructions.

♦ The hydraulic system must be filled with hydraulic oil.

♦ Fill with lubricant.

GDE00018 A GDE00015 A

♦ Read the instructions. ♦ Read the instructions.

♦ Emergency stop.

♦ Fill with engine oil

GDE00019 A

♦ Use safety belt.

GDE00016 A

♦ Read the instructions. ♦ Fill with brake fluid.

16

© 2012 Atlas Copco Craelius AB | 2012-05-15 03 Signs and stickers Ed.0

Safety and operating instructions A

C

Alternating current generator B

D

A. The foot protection symbol means that you have to wear boots.

GDE00020 A

B. The eye, ear and head protections symbol means that you have to wear a hard hat, eye and ear protection.

♦ Read the instructions.

C. The hand protection symbol means that you have to wear hand protection.

♦ Disconnect the battery cables before removing the generator or regulator and when giving the battery a booster charge.

D. The instruction book symbol means that you have to read the Safety and Operating instrictuins before the equipment is used for the first time.

♦ When performing electrical welding of the rig or fitted equipment, detach the charging regulator cable as well.

♦ This rig is equipped with an alternating current generator (alternator).

Rig with PLC cabinet

PLC GDE00021 A

♦ Read the instructions. ♦ This rig is equipped with data boxes. ♦ Isolate or remove data boxes when giving the battery a booster charge or carrying out welding on the rig.

© 2012 Atlas Copco Craelius AB | 2012-05-15 03 Signs and stickers Ed.0

17

Safety and operating instructions

Information signs

Fuel cock

Fire extinguisher

GDE00028 A

GDE00022 A

Battery switch

Actuator for the fire fighting system

GDE00029 A

GDE00023 A

Draining

Lifting eye

GDE00030 A

GDE00024 A

Washer fluid

Water inlet

GDE00031 A

GDE00025 A

Emergency reverse button

Air intake

GDE00032 A

GDE00026 A

Fuel

GDE00027 A

18

© 2012 Atlas Copco Craelius AB | 2012-05-15 03 Signs and stickers Ed.0

Safety and operating instructions

Other signs Rig data plate See the Technical specifications section for further information. Atlas Copco Craelius AB MÄRSTA - SWEDEN

A B

Name Type Serial No. Max. pull up Rotation speed Power installed Gross weight

kN r/m kW kg

xxxx xxxx xx

Made in Sweden

C D

GDE00033 A

A. B. C. D.

Machine type Serial number The warning symbol together with the book symbol means that the user must read the safte and operating instructions before the machine is used for the first time. The CE symbol means that the machine is CE-approved. See the CE Declaration of Conformity which is delivered with the machine for more information.

E.

Identity plates All elecrical components have their own sign with an identifying name.

© 2012 Atlas Copco Craelius AB | 2012-05-15 03 Signs and stickers Ed.0

19

Safety and operating instructions

Quick guide - Engine start and tramming Engine start procedure Unpack and install the control panel. It is located in the yellow box, placed at the front end of the rig. ►Place the control panel in the swing arm located at the rear end of the rig. ►Connect the cable between the control panel (A) and connection box (B) on the rig. ►Connect the joystick cable to the connection box (B) on the rig.

A)

B)

26000151 A

1. Turn ON main power switch. Check that switch 2 is in position DRILL.

2

26000152 A

2. Tic the box on the control panel display by pressing the RETURN button

26000153 A

3. Press the ESC button

20

© 2012 Atlas Copco Craelius AB | 2012-05-15 E220 RC Engine start and tramming position quick guide SOI version Ed.2

Safety and operating instructions 4. ►Turn until click ►Push approx. 10 seconds

26000154 A

►Turn again

Jack control levers

26000156 A

The rig jacks must be in transport position before switching to Tramming Mode. Use the Jack Control Levers for setting the jacks in the correct position.

© 2012 Atlas Copco Craelius AB | 2012-05-15 E220 RC Engine start and tramming position quick guide SOI version Ed.2

21

Safety and operating instructions

Tramming mode

NOTE: Make certain that the rig’s mast is in the correct tramming position!

26000157 A

26000158 A

1. Turn on the radio transmitter by pulling out the Emergency Stop Button and pushing the ON button (A)

A

2. Push and hold the button OVERRIDE (1). Turn switch (2) to RRC position. Turn switch (3) to LO-position.

1

2

3

26000160 A

3. Hold buttons until the green LED indicates ready.

22

© 2012 Atlas Copco Craelius AB | 2012-05-15 E220 RC Engine start and tramming position quick guide SOI version Ed.2

Safety and operating instructions

26000161 A

4. Push the ON button (A) again to activate the remote control.

A

26000162 A

5. Set selector (B) in Tramming Mode

B

6. Activate positioning button on the control panel

7. Tram the rig using levers (C) and (D). D

26000163 A

C

© 2012 Atlas Copco Craelius AB | 2012-05-15 E220 RC Engine start and tramming position quick guide SOI version Ed.2

23

Safety and operating instructions

Overview Design and function Atlas Copco has a history of designing and manufacturing a great number of drilling rigs since the early fifties. Atlas Copco Craelius is a division within Atlas Copco dedicated primarily to mineral investigations with preference for underground core drilling. The Explorac 220 RC is a 22 ton rig intended for 150200 mm RC drilling. A rigid platform equipped with four powerful hydraulic jacks provides the necessary strong base for mounting of the rig components. The frame design allows convenient adaption to lorries and trailers with a capacity of 20 ton. The Explorac 220RC functions are powered by four independent hydraulic pumps, three in-line mounted on the Caterpillar engine main shaft flange and one mounted on the cam shaft PTO. These pumps provides hydraulic oil at high pressure and are used for positioning of the rig, for rotation of the drill unit spindle, for pull down and retraction of the drill string, and for auxiliary functions such as pipe tongs and water flush pumps. The rig is installed in drilling position by hydraulic, steel encased hydraulic jacks. The mast is supported and pivoted in a welded ”H-frame”. Two hydraulic cylinders elevates the mast to drilling position (45° to vertical). The rig set-up operation is carried out using a manually operated valve block assembly located at the right hand side of the rig. Two hydraulic feed cylinders mounted inside the mast pull the rotation cradle by means of chains and pulleys. The basic rig is intended for max. 6 m. (20 ft) long drill pipes. Hydraulic motors drives the drill spindle via a heavy duty mechanical gearbox. The spindle is provided with a threaded adapter, for the joining of drill pipes and hammers, and with a swivel for injecting compressed air, foam or water into the drill string. The feed and rotation functions are conveniently monitored by digital gauges and governed by hydraulic gauges and valves grouped in the main control panel mounted on the left hand side of the drill mast.

The dual-wall method uses flush-jointed double-wall pipe. Compressed air is fed between the two pipes to the hammer- or three cone drill bit and the cuttings moves through the center tube back to the surface without any direct contact with the surrounding formation. The external pipe specification must be in level with drill pipes for conventional rotary drilling and also able to take the expected tensile, column and collapse pressure foreseen for the actual bore hole. The internal rod is under little physical stress but is worn by the abrasion from cuttings moving with high speed upwards inside the tube. The speed when using compressed air must be 25 to 30 m/s. The multiple seal inner tube is easily replaceable when necessary. Atlas Copco uses special DTH hammers for RC drilling. The compressed air fed through the annular space between the tubes enters the hammer and drives the piston to strike on the drill bit anvil. The exhaust leaves the piston cylinder at the shoulder of the drill bit and returns through the center of the bit and hammer and back to the surface through the inner drill pipe tube. The design of the bit and hammer screens the air from flowing via the outside of the hammer/drill pipe back to surface. Back pressure produced by the formation will also act as a seal during drilling. After moving back via the inner tube and through a top head swivel the air with the formation sample is separated in a cyclone and dumped through a door into the sample bag for the geologist to examine.

RC pro  Continuous representative formation samples obtained  Aquifer yield at many depths  Fast penetration through coarse alluvials and broken rocks  Reduced or eliminated problems with lost circulation  Washout zones reduced or eliminated

Drill pipes are stored in a pipe rack on the platform deck until needed. A hydraulically operated winch, lifting over the jib boom pulley in the top of the mast facilitates handling of heavy hammers, drill bits, collars, and casings.

RC con

The break-out table which is fitted in the lower end of the mast guides the drill string and provides support and hold for making and breaking of threaded tool joints. The mast may be hydraulically shifted 1900 mm up/down to a comfortable working position.

The Explorac 220RC will also perform well using conventional methods like direct rotary drilling, DTH drilling, solid stem auger and hollow stem auger drilling.

The Explorac 220RC has been designed with focus on mineral exploration drilling with dual pipe reversed circulation.

24

 Limited hole diameter  Requires high air volume and pressure.

Direct rotary mud drilling requires a mud circulation system (optional). Limitation of drilling diameter and depth is the rig’s lifting force (22 tons), rotation speed and torque. The bit producer recommends 0,5 to 2 tons per inch bit diameter depending on formation, and a mud lift velocity of 0,3 m/s. As the bit weight should © 2012 Atlas Copco Craelius AB | 2012-05-15 04 Overview Explorac 220 RC Ed.0

Safety and operating instructions be obtained by collars and stabilizers near the drill bit and not by machine pull-down, the diameter of the direct drilling bit in average formation would be max 20” in soft formation. Mud speed and volume are calculated using drill pipe diameter and bore diameter. The required mud pump pressure depends on friction and geometry of the drill string.

Direct air percussion drilling with Down the Hole Hammers DTH drilling is fast and simple in hard crystalline formations. The limiting factors are the rig’s pull-back capacity and the compressor’s air delivery and pressure. The air flow speed must be 25 to 30 m/s to carry the cuttings unless chemicals (foam) is used. The volume of air required for a 12” hole is something like 1500 dm3 /s FAD (Free Air Delivery, or air expanded to atmospheric pressure).

26000062 A

Solid-stem Auger drilling performance is limited by the size of the break-out table, the physical strength of the augers and the torque of the drill rig.

Additional guides and adapters required Hollow-stem augers offers access to the bottom of the bore for retrieving undisturbed samples and can be used for temporary work casing in loose formations such as sand and clay. Please consult the nearest Atlas Copco representative for additional information.

Diagram, size vs. depth Geological conditions changes from one site to another, drilling accessories used are not always the same and the operators skill and experience varies. Regard this chart as a reference only. Contact your local Atlas Copco dealer for further information regarding suitable drilling tools and expected performance under local conditions.

Recommended equipment Method

Cutting, recommended additional equipment

DTH hammer drilling (in hard crystalline rock & consolidated formations)

DTH- hammer, drill pipes, compressor, bits, dust collector

Rotary drilling with mud, water or air flushing (cementary rocks; slate, sandstone, limestone and similar)

3-cone bits, mud pump, stabilizers, drill pipes

ODEX and Symmetrix Methods: simultaneous drilling/casing method (decomposed rock, moraine, gravel, sand, chist formations)

DTH hammer, drill bits, casing, drill pipes, compressor, foam pump

RC drilling method

Hammer, bit, drill pipe, cyclone, rotation head adaption, compressor, sampler

© 2012 Atlas Copco Craelius AB | 2012-05-15 04 Overview Explorac 220 RC Ed.0

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Safety and operating instructions

General dimensions 10 560 2 520

4 350

Travel length 7 680

26000073 A

12 400

General dimensions, truck version Weight, mounted on 8x8 Scania carrier 33 000 kg Total length in transport position

12 400 mm

Height in transport position

4 350 mm

Width

2 520 mm

Height w. mast in vertical position

10 560 mm

Gradeability (climbing capacity)

Weight, mounted on IVA crawler carrier 33 000 kg Total length in transport position

11 200 mm

Height in transport position

4 500 mm

Width

3 200 mm

Height w. mast in vertical position

10 562 mm

12 400

26000075 A

General dimensions, crawler version

Gradeability (climbing capacity)

26

© 2012 Atlas Copco Craelius AB | 2012-05-15 04 Overview Explorac 220 RC Ed.0

Safety and operating instructions

Main parts Explorac R220 basic unit A. Mast B. Winch and jib boom

P Q

C. Engine/compressor/hydraulics canopy

N

D. Integrated fire extinguisher E. Hydraulic jack F. Auxiliary air connections

M O

G. Sample hose H. Cyclone I.

Splitter

J. Hydraulic jack K. Fuel tank with platform

R

26000074 A

L. Hammer oil tank

S

M. Rod handler N. Rotation unit O. Sample hose P. Upper hose chain Q. Lower hose chain R. Engine start panel S. Slips table

© 2012 Atlas Copco Craelius AB | 2012-05-15 04 Overview Explorac 220 RC Ed.0

27

Safety and operating instructions

Operation Rig control system

Display w. processor

The RCS (Rig Control System) monitors and governs the drill rig functions. It is intended for the following use:  Comparing important parameters against preset values  Reporting rig performance data to Operator’s control panel

Control panel Cable from rig to control panel

I/O module

 Forwarding of information given through Operator’s panel instructions to rig components

The “CAN” protocol (Controller Area Network) was defined in the mid eighties for improved serial communication. The aim was to reduce the complexity, number and weight of wires used in automobile vehicles. Today CAN is widely spread in many technological fields e.g. industrial automatization, medical electronics and networks with relatively small amounts of data in need of reliable serial communication.

24 V fuse & check box

Engine surveillance unit

Rig control system

26000167 A

The control system used in Atlas Copco Explorac 220 consists of a processor with a rigid 141 x 77 mm screen, a control panel with five joysticks and a number of on-off buttons. The control panel is connected to the drill rig via a 10 m cable. A separate 24 volt DC system provides current to four “I/O” (Input / Output) modules, to an engine surveillance unit and to a separate multi function joystick for rod handling. From the I/O units current is directed through wires to hydraulic valve block control spools and system sensors. CAN serial wires carries instructions from the control panel and reports data back to the control panel. Operator’s control panel connected to rig

26000166 A

Data communication is constantly taking place in the system. The information is tagged with an address and will be read by all I/O modules, but ignored by receivers not affected. Signals from, for instance, a temperature gauge will travel through the system to the control panel as soon as it detects a gap in the traffic. The gap required might be no more than a microsecond. The control panel processor is also used for diagnosing and programming of the parameters used for hydraulic valve blocks and gauges settings.

26000076 A

The control system using CAN technology comprises the operator’s panel with the main computer and a rigid display, a number of I/O modules and sensors, solenoids and hydraulic valve blocks.

Computer display with navigation/input buttons

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© 2012 Atlas Copco Craelius AB | 2012-05-15 06 Operation Explorac 220 RC Ed.1

Safety and operating instructions 12. Cyclone knife open 13. Cyclone trap door close 14. Cyclone trap door open

26000168 A

15. Slips holder close 16. Slips holder open 17. Rod rest out 18. Rod rest in 19. Rotation torque, drill 20. Rotation torque, drill + 21. Rotation torque, break 3

5

7

22. Rotation torque, break +

9

1

23. Fast feed pressure up 24. Fast feed pressure up + 25. Horn

2

4

6

10

26. Down feed decrease (joystick)

27

27. Down feed increase (joystick)

8

33

29

28. Hold-back decrease (joystick) 29. Hold-back increase (joystick) 30

30. Spanner break-out function (joystick)

26

31

28

32

31. Spanner break-out function (joystick) 11

12

19

20

13

14

21

22

15

16

23

24

17

18

25

32. Spanner in (joystick)

26000164 A

33. Spanner out (joystick)

Operator’s control panel, left side

1. Winch arm in 2. Activate drilling 3. Winch arm out 4. Activate positioning 5. Compressor load/unload 6. Winch 7. Engine rpm decrease 8. Blow down mode control button 9. Engine rpm increase 10. Blow down mode control button 11. Cyclone knife close © 2012 Atlas Copco Craelius AB | 2012-05-15 06 Operation Explorac 220 RC Ed.1

29

Safety and operating instructions H. Hammer oil ON 2 liters/h I.

Hammer oil ON 3 liters/h

26000169 A

J. Hammer oil ON 4 liters/h K. Stop watch start/stop L. - (not used) M. Stop watch reset N. Rotation in parallel A

B

C

O. Drill string balance

E

D

P. Rotation in series Q. Feed start (joystick) F

J G

H

R. Feed stop (joystick)

I

S. Rotation decrease (joystick)

L

K

T. Rotation start/increase (joystick) N

M

U. Rotation stop (joystick)

P

O Q

S

U R

26000165 A

T

Operator’s control panel, right side

A. Water pump off B. Water pump on C. Water pump bleed D. Water pump flow control E. Water pump flow control + F. Hammer oil OFF G. Hammer oil ON 1liter/h

30

© 2012 Atlas Copco Craelius AB | 2012-05-15 06 Operation Explorac 220 RC Ed.1

Safety and operating instructions

26000184 A

Layout CAN-system E220 RCS

© 2012 Atlas Copco Craelius AB | 2012-05-15 06 Operation Explorac 220 RC Ed.1

31

Safety and operating instructions

Menu overview Direct menus

Safety menu

Drill

Operator Settings

Information Main menu

Engine

Compressor

System

Settings

Service Information 32

© 2012 Atlas Copco Craelius AB | 2012-05-15 06 Operation Explorac 220 RC Ed.1

Safety and operating instructions

Direct Menus

The menu is viewed when button F2 is pressed.

D1:1 - Direct Menu Drilling The menu is viewed when F1 is pressed.

Left column: Fuel level. Middle left column: Coolant temperature. Left column from above: Intermediate pressure, receiver pressure, air valve indication (yellow in crack position and green in fully open position) and down the hole pressure. Middle left column from above: Net drill feed pressure, hold back pressure and down feed pressure. Middle right column from above: Main pump pressure (gauge and digits).

Middle right column from above: Rpm, oil pressure, boost pressure and engine hours. Right column from above: Engine load, boost temperature and engine battery voltage.

D3 - Direct Menu Compressor The menu is viewed when button F3 is pressed.

Right column from above: Hammer oil indication (green when hammer oil is on), hammer oil pump pulse, water indication (green when water is on) and water flow (%).

D1:2 - Direct Menu Operator Settings The menu is viewed when button F1 is pressed. Button F1 toggles between D1:1 and D1:2.

From above: Intermediate pressure, receiver pressure, low stage temperature and high stage temperature.

The percentage settings are related to the min. and max currents in the parameter settings menu. 0% = Min. current and 100%. = Max. current. D2 - Direct Menu Engine © 2012 Atlas Copco Craelius AB | 2012-05-15 06 Operation Explorac 220 RC Ed.1

33

Safety and operating instructions

D4 - Direct Menu Service Information

M1 - Information

The menu is viewed when button F4 is pressed.

Left column from above: Engine oil, engine oil filter, engine air filter and engine fuel filter.

Left column from above: Fuel rate, fuel pressure and fuel temperature. Right column: Hydraulic oil temperature.

Middle column from above: Hydraulic oil, hydraulic oil filter, compressor oil, compressor oil filter. Right column from above: Compressor air filter, water filter, engine hours and drill hours.

Safety Menu The safety menu is displayed after startup of the control system.

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© 2012 Atlas Copco Craelius AB | 2012-05-15 06 Operation Explorac 220 RC Ed.1

Safety and operating instructions

System M2 System Menu

M2:1 - Module Menu In the module menu the CAN-nodes are symbolized with boxes. If a box is red it has no CAN communication or there is another fault. All modules except for the rod loader have a diagnostic menu. Mark the box and press enter to go to the diagnostic menu.

I/O-Module Diagnostic Menu Below is showed the diagnostic menu for D510. The menus for the other 3 modules are similar.

Operator Panel Diagnostic Menu Below is showed the diagnostic menu for the left decoder module in the operator panel D510:1. The menu for the right decoder module is similar.

ECM Diagnostic Menu

© 2012 Atlas Copco Craelius AB | 2012-05-15 06 Operation Explorac 220 RC Ed.1

35

Safety and operating instructions

M2:2 - I/O-Module Menu

M2.2.1.1 D510 Digital Output Menu

For each I/O-module there are 3 menus, one for PWMoutputs, one for digital outputs and one for inputs. Below is showed the menus for D510, the other modules are similar.

Each row from left: Contact name, description, input field for output (0 = off, 1 = on) when actuating manually, the output (0 = off, 1 = on) and valve name.

M2.2.1 D510 PWM Output Menu

Each output can be actuated manually when logged in at AC-level. Set 1 in the field for actuation, go to “actuate desired value” and press enter. The output is now set to on.

M2.2.1.1.1 D510 Input Menu

Each row from left: Contact name, description, input field for output current when actuating manually, the output current and valve name. Each output can be actuated manually when logged in at AC-level. Set the desired current in the field for actuation current, go to “actuate desired value” and press enter. The current in the output field is now actuated on the output.

Each row from left: Contact name, description, input field for coefficient, input field for offset, value on the input and sensor name. Typical values for coefficient and offset: 50 bar pressure sensor: Coefficient 0.061 and offset 102. 350 bar pressure sensor: Coefficient 0.427 and offset 102. Level sensor prototype: Coefficient 0.098 and offset 0. Level sensor rig 1: Coefficient 0.279 and offset 0.

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© 2012 Atlas Copco Craelius AB | 2012-05-15 06 Operation Explorac 220 RC Ed.1

Safety and operating instructions

M2:3 - ECM Menu

Lever Calibration Menu

The SPN (Suspect Parameter Number) and FMI (Failure Mode Indication) for the fault codes sent from the engine.

The bars show the scaled lever values and the digits the lever raw values. Calibration is started when the box “Calibration mode” is ticked with enter. See separate chapter regarding lever calibration.

Each row from left: The CAT sensor number, sensor name and sensor status. With arrow up and down it is possible to scroll the menu.

M2:5 - Rod Loader Lever Menu M2:4 - Operator Panel Lever Menu

Left: The statuses of the lever buttons are showed, 0 = off and 1 = on. The 3 upper rows from left: Analogue lever name, scaled lever X (forward/backward) value, scaled lever Y (left/right) value, scaled lever Z (lever button up/ down) value and status of the lever. The lever status can be “Ok”, “Not Calibrated”, “Mid pos. Error” and “End pos. Error”.

Right: The values from the lever are displayed (X = forward/backward, Y = left/right). NOTE: This lever is factory set and does not require calibration.

The 2 lower rows from left: Digital lever name and lever value (right = 1, left = 2, forward = 4, backward = 8).

© 2012 Atlas Copco Craelius AB | 2012-05-15 06 Operation Explorac 220 RC Ed.1

37

Safety and operating instructions

Settings M3 - Settings Menu

M3.3.1 - Parameter Settings Menu This is the main menu for the parameter settings. Most of the parameter settings are min. and max. currents for a valve. The min. current corresponds to 0% and the max current corresponds to 100%. Only the parameters that are not min. or max currents are described below.

Left column from above: Access level login and save of logged data. Right column: SI/Imperial units, date and time, screen brightness and service.

M3.3.1.1 Slow Feed Settings Menu

M3.3 - Service Menu

Slow feed pressure down, max current requires ACPlogin.

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© 2012 Atlas Copco Craelius AB | 2012-05-15 06 Operation Explorac 220 RC Ed.1

Safety and operating instructions

M3.3.1.2 Fast Feed Settings Menu

M3.3.1.5 Winch Settings Menu

The “Fast feed speed, boost level” is the lever value there the fast feed boost is turned on. “Fast feed pressure limit, down” and “Fast speed, acc limit” requires ACP-login.

M3.3.1.6 Fan Motor Settings Menu (ACP-Level)

M3.3.1.3 Rotation Settings Menu

M3.3.1.7 Rod Handler Settings Menu

“Rotation speed, acc limit” requires ACP-login.

M3.3.1.4 Water and Air Settings Menu

© 2012 Atlas Copco Craelius AB | 2012-05-15 06 Operation Explorac 220 RC Ed.1

39

Safety and operating instructions

M3.3.1.8 Hydraulic Oil Settings Menu (ACPLevel)

M3.4 – Sensor Override Menu If one of the sensors for oil level, oil temperature, compressor low stage temperature or compressor high stage temperature is out of function the rig can be operated temporarily if the not working sensor is overridden. The override does not stay in memory if the control system is turned off.

M3.3.2 – Set Persistent Data Menu

The drill hours can be set on this menu.

The hydraulic oil level sensor can be overridden at operator level. The other 3 sensors needs login at AClevel.

40

© 2012 Atlas Copco Craelius AB | 2012-05-15 06 Operation Explorac 220 RC Ed.1

Safety and operating instructions

M3.5 – Save Log Menu The logs can be saved to the USB memory stick. The event log remains in memory when the control system is shut down. Developer log and assert log is for the software developer.

If a sensor is overridden a warning message and a crossed over sensor symbol is displayed. The warning message is also displayed every time the diesel engine is started.

© 2012 Atlas Copco Craelius AB | 2012-05-15 06 Operation Explorac 220 RC Ed.1

41

Safety and operating instructions

Lever Calibration The purpose of the lever calibration is to adjust for tolerances in the mounting of the levers. Calibration has to be done when a new operator panel is attached. Once calibrated the calibration values are stored in the parameter file. Perform the calibration with the engine off. Login as SE and step down through the menus as described below.

To calibrate the levers tick the box “Calibration mode”. After that move the 3 levers (winch/air, drill and fast feed) to their end positions in left – right (Y) and forward – backward (X) direction. Also move the buttons (Z) on the levers to their end positions. Hold the lever/ button in each end position for a short time (1 second is enough). When the levers are moved the lever values are displayed on the screen with the bars. When all levers and lever buttons are moved as described above remove the tick in the box or just leave the menu and the calibration is ready.

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© 2012 Atlas Copco Craelius AB | 2012-05-15 06 Operation Explorac 220 RC Ed.1

Safety and operating instructions

Program and Parameter Loading General The settings, “parameters” in the display can be saved to a file, the parameter file. The parameters can also be loaded back in to the display.

After calibration the statuses of the levers are set to “Ok”.

Before loading program the parameter file shall be saved. Loading program will set the parameters to default values. After the program is loaded the parameters are loaded back again. If doing so no settings are lost. When program is loaded the program in the display is always loaded. The I/O-modules and operator panel is loaded with program if the program on them is not of correct version. Note that a new I/O-module or operator panel do not have a correct program loaded. This means that if an I/O-module or operator panel is replaced it needs to be loaded with the current program.

Save of Parameters Connect the cable to the back of the display (X7). The USB memory for the parameters can be inserted before the power is turned on or after that the display has fully started up. Login in as SE. Go to the menu “Service” and choose “Load/save parameters”. Choose the upper button and press enter, se below. The parameters are now saved to the USB memory.

© 2012 Atlas Copco Craelius AB | 2012-05-15 06 Operation Explorac 220 RC Ed.1

43

Safety and operating instructions

Load Program Turn off the power. Insert the USB memory for the program. Turn on the power. The program is now loading and you can follow the loading on the screen. I/Omodules and operator panel will also be loaded with program if they do not have the correct program on. When loading is ready it will write “reboot”. Turn off the power and remove the USB memory for the program. Turn on the power. When a program is loaded the parameter settings is lost so it is important to reload the parameters, see below. Load Parameters Insert the USB memory for the parameters. Login in and go to the menu “Service” and “Load/save parameters”. Choose the lower button and press enter. The parameters are now loaded from the USB memory.

When loading is ready, remove USB memory and cable.

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© 2012 Atlas Copco Craelius AB | 2012-05-15 06 Operation Explorac 220 RC Ed.1

Safety and operating instructions

Pre-start procedure NOTE b1

Do not start the engine if there is a DO NOT OPERATE” tag attached to the start switch or on any of the rig controls!

b4 b3

Before starting the main diesel engine, certain checks and measures must be carried out in order to prevent accidents, unnecessary stops or breakdown. Some of these measures must be carried out regularly as a part of the preventive maintenance schedule.

26000078 A

►Make a thorough inspection of the engine before starting.

b2

►Look for oil leaks, coolant leaks, loose bolts and damaged parts.

Engine filter compartment: fuel priming pump (b1), secondary fuel filter (b2), primary fuel filter (b3), engine oil filter (b4)

►Keep the engine compartment clean. Remove any waste objects. Inspect the alternator belt and accessory drive belts for cracks, breaks or any other damage.

►Check the coolant level. Maintain the coolant level within 12-13 mm off the bottom of the filler pipe.

►Inspect the wiring for loose connections and for worn or exposed wires! ►Check the engine lubrication oil level. Maintain the oil level between “ADD” mark and “FULL” mark on the oil level stick (a2). Oil viscosity and quality recommendations are given in the CAT engine manufacturers manual.

►Check the engine air intake filter. Clean or replace cartridge. The turbine pre-cleaner need no pre-start attention. (Empty bowl according to preventive maintenance schedule). ►Check oil level in hydraulic oil tank (level indicator b3) Add as required using the fill pump.

a1

b2

b3 b4

Engine oil check: oil level stick (a1), oil fill cap (a2) ►Check the fuel supply. Fuel consumption during RC drilling is approximately 100 l/h. The tanks hold 500 liters. ►Open fuel supply valve. Drain condensate from the prefilter water separator (b1).

26000079 A

a2

26000077 A

b1

Compressor oil tank (b1), oil fill tube (b2), level indicator (b3), compressor oil filter (b4) NOTE All valves in the fuel return line must be open before and during engine operation in order to prevent incorrect fuel pressure. (To high fuel pressure could damage the filter housing etc).

© 2012 Atlas Copco Craelius AB | 2012-05-15 06 Operation Explorac 220 RC Ed.1

45

Safety and operating instructions ►Check the compressor air intake filter. Replace cartridge if necessary. The turbine pre-cleaner need no pre-start attention. (Empty bowl according to preventive maintenance schedule).

START PROCEDURE (before actually starting the diesel engine) 1. Ensure that the master switch is in OFF position. 2. Connect control panel (and rod handler control if the rig is equipped with rod handler). 3. Place the controls well clear of the machine. 4. Turn the master switch to ON.

c1

5. The rig control system (RCS) will boot within approximately. 15 seconds. 6. Read and tic SAFETY NOTICE on operator’s screen.

c3

26000081 A

c2

Compressor module. Air intake cleaning turbine (c1), filter (c2), compressor air loading valve (c3)

►Reset all Emergency Stop buttons. ►Set all hydraulic valve block levers to neutral. ►Connect the drill rig control panel. ►Activate master circuit switch MCS1.

46

© 2012 Atlas Copco Craelius AB | 2012-05-15 06 Operation Explorac 220 RC Ed.1

Safety and operating instructions

Engine start ►Make sure the RCS (Rig Control System) is running. 26000082 A

►Set all hydraulic valve block levers to neutral. ►Clear areas around engine and drill rig rotating parts. ►Turn the ignition handle to position “1”. The “CHECK ENGINE/DIAGNOSTIC“ lamp will flash while the engine is cranking. The lamp should turn off when the proper engine oil pressure is achieved. If the lamp fails to flash, consult your authorized Caterpillar dealer. If the lamp continues to flash, the ECM (Electronic Control Module) has detected a problem in the system. Refer to the Caterpillar Operation and Maintenance Manual “Diagnostic Flash Code Retrieval” (Operation section) for more information on engine diagnostics. ►Push and turn the ignition handle in clockwise direction in order to crank the engine. Do not move the throttle controls while the engine is cranked! The system will automatically provide the correct amount of fuel needed to start the engine. ►If the engine fails to start within 30 seconds, release the start handle. Wait for two minutes in order to allow the starter motor to cool before attempting to start the engine again. ►Allow the engine to idle for approximately 3 minutes when it has started. Idle the engine until the engine coolant temperature gauge has begun to rise. (Drillers control panel, main menu, next F1: menu D2). Oil pressure and fuel pressure should be in the normal range. Do not apply a load, e.g. starting the compressor “load” or moving a hydraulic valve block lever. (Drillers control panel, main menu, next F1: menu D2). ►At temperatures below +10º C starting performance will be improved if a cylinder block coolant heater, coolant air heater or crankcase oil heater is used.

Ignition handle NOTE The “CHECK ENGINE/DIAGNOSTIC “ lamp may come on also after the engine is started. If this occurs, the ECM system has detected a problem with the engine system. Refer to the Caterpillar Operation and Maintenance Manual “Diagnostic Flash Code Retrieval” (Operation section) for more information on engine diagnostics! NOTE Disconnect any battery charger that is not protected against the high current drain that is created while the electric starter motor is engaged! NOTE Do not engage the starting motor when the flywheel is turning! Do not start the engine under load! NOTE Engine oil pressure should rise within 15 seconds after the engine start. Do not increase engine speed until the oil pressure gauge (Menu D2) indicates normal. If oil pressure is not indicated on the gauge within 15 seconds, DO NOT operate the engine. Stop the engine, investigate and correct the cause. NOTE

►Prime the fuel system. Fuel may have drained if the engine hasn’t been in operation for some time (weeks, months). Air may have moved into the filter housing. Also, when fuel filters have been changed, some air will be left in the filter housing. Refer to Caterpillar Operation and Maintenance Manual (fuel system - PRIME).

Improper jump start cable connections can cause an explosion resulting in personal injury. Prevent sparks near the batteries. Sparks could cause vapors to explode. Do not allow jump cable ends to contact each other or the engine. After jump starting the alternator might not be able to fully recharge batteries that are severely discharged.

►If batteries are down it might be necessary to start the engine from an external electrical source. First determine the reason that makes it necessary to start with an external source. Refer to Caterpillar Special instruction SEHS7768: use of starting/ charging analyzer.

NOTE

© 2012 Atlas Copco Craelius AB | 2012-05-15 06 Operation Explorac 220 RC Ed.1

Do not use ether (starting fluids) unless specifically instructed to do so. If the engine is equipped with an air inlet heater (electrically or fuel ignited manifold heater) do not use ether (starting fluids) at any time. The use could result in engine damage and/or personal injury!

47

Safety and operating instructions

Engine running 1

2 3

►Check for any fluid or any air leaks at idle speed and at ½ speed (no load) before operating the engine under load.

4

7

5

8

►Operate the engine at low idle speed until all systems achieve operating temperature and pressure. Check all gauges during the warm-up period

6

9

►Gauge readings should be observed and data should be recorded frequently while the engine is operating. Comparing the data over time will help to determine normal readings for each gauge. Comparing data over time will also help to detect abnormal operating developments. Significant changes in the readings should be investigated.

10

11

12

26000083 A

Observe the following conditions when the engine is idling during warm-up:

13

Driller’s control panel, engine surveillance 1. Fuel level. (1/1 equals 500 liters) 2. Engine water jacket temperature. (87-98°C)

NOTE In ambient temperatures from 0 to 60°C, the warmup time is three to five minutes. Additional warmup time may be required in temperatures below 0°C.

3. Engine crankshaft speed in rpm. 4. Engine lubrication oil pressure. (3-6 bar) 5. Turbo pressure. (2,5-7 bar) 6. Engine operating hours.

NOTE Ensure that the self test for the monitoring system is completed before operating the engine under load.

7. Engine load factor (percent of max). 8. Combustion air intake temperature. (Max. 85°C) 9. Battery voltage.

26000084 A

10. Red color: Extremely low fuel level 11. Red color: Compressor failure 12. Red color: Surveillance system error 13. Red color: Engine air intake filter clogged

26000085 A

Increase and decrease engine speed. Push “+” button one to four times for speed 1000, 1200, 1500 or 1800 rpm

Select menu D2 (press F2)

48

© 2012 Atlas Copco Craelius AB | 2012-05-15 06 Operation Explorac 220 RC Ed.1

Safety and operating instructions

Caterpillar engine monitoring system The engine monitoring system incorporates the following features:  Coolant system level  Coolant temperature  Engine speed  Fuel pressure  Fuel temperature  Inlet manifold air temperature  Oil pressure The engine is programmed for warning, derate and stop:

Coolant system level

Correct coolant level is of vital importance. The engine may be seriously damaged if the coolant level is too low and the engine is allowed to overheat. Fault type

FMI

Warning

Result

Coolant level low

17

Yellow warning

Warning

Coolant level low

18

Yellow warning

Engine derate

Coolant level low

1

Red warning

Engine stop

Coolant system temperature

I Warning. Orange icon Warning icon on driller’s control panel turn on in order to alert the operator that one or more of the engine parameters is not within normal operating range. II Warning - Derate. Orange Icon Warning icon on driller’s control panel turn on in order to alert the operator that one or more of the engine parameters is not within normal operating range. After the warning the engine will derate speed and power output. Fully derated, the engine speed will be 1350 r/min and output max. 120 kW. The icon will flash during the derate phase. III Warning - Derate-Stop. Red Icon Warning icon on driller’s control panel turns on in order to alert the operator that one or more of the engine parameters is not within normal operating range. After the warning the engine will derate speed and power output until a shutdown of the engine occurs. A shutdown of the engine may occur within 20 seconds. The engine can be restarted after a shutdown for use in an emergency. However, if the cause of the initial shutdown still exists, the engine may shut down again within 20 seconds.

© 2012 Atlas Copco Craelius AB | 2012-05-15 06 Operation Explorac 220 RC Ed.1

The engine coolant temperature sensor monitors the temperature of the engine coolant. The coolant temperature signal is sent to the ECM for engine monitoring and for improved engine control. The signal is used by the ECM for all of the following engine functions: Engine timing control, operating mode and engine protection. The ECM is capable of adjusting the engine timing relative to the engine operating temperature. The concept of dynamic timing provides the engine with the ability to control exhaust emissions. Timing control also aids in white smoke cleanup during cold engine operation. The ECM also uses the signal from the engine coolant temperature sensor to determine the mode of operation for the engine. Several aspects of engine operation are affected by the engine operating mode: acceleration ramp rates, engine timing, and fuel injection timing. Fault type Sensor error

FMI -

Warning Yellow warning

Result ECM error

Coolant temp high

15

Yellow warning

Engine high temp

Coolant temp high

16

Yellow warning

Engine derate

Coolant temp high

0

Red warning

Engine stop

49

Safety and operating instructions

Engine speed

Fuel temperature

The engine speed governor monitors the throttle position and the actual engine speed in order to help control the following items: engine speed, response, torque output, and smoke limiting. The engine speed governor also helps to maintain constant engine speed. The engine speed is controlled by the governing of the fuel injection duration of the electronic unit injectors. Throttle input is used to calculate the desired engine speed. Fault type Engine speed high

FMI -

Warning Red warning

Result Engine stop

Fuel pressure

The fuel pressure sensor monitors filtered fuel pressure. Although fuel pressures that are outside the normal operating range may adversely affect engine performance, there should not be any noticeable reduction in the engine horsepower. Abnormal fuel pressure will not cause an engine shutdown. A low filtered fuel pressure may indicate that the low pressure fuel system requires maintenance. The fuel pressure sensor measures the fuel pressure after the fuel has been filtered. The sensor connector for the fuel pressure sending unit is located on the machine side of the machine connector. For more information, refer to the Caterpillar Troubleshooting Guide for this engine. ,Please refer to the maintenance section in Caterpillar Operation and Maintenance Manual for further information on fuel system maintenance. Fault type Fuel pressure over max

FMI 16

Warning Red warning

Result Engine stop

Fuel pressure high

15

Yellow warning

Engine derate

Fuel pressure below min

18

Yellow warning

Low fuel level

Fuel pressure over max

0

Yellow warning

-

Yellow warning

ECM error

Fuel pressure sensor

50

The fuel temperature sensor monitors the inlet fuel temperature. The ECM utilizes the signal from the fuel temperature sensor to provide fuel temperature compensation for the engine fuel control system. Fuel temperature compensation provides stable rated power and accurate fuel consumption rates e.g. optimum fuel consumption. Changes in the temperature of the fuel effect the power output of the engine. The ECM adjusts the engine fuel rate according to the temperature of the fuel. This feature allows full engine power to be realized by the operator at any fuel temperature. Fuel temperature will also affect the calculation of fuel consumption rate that is performed by the ECM. The ECM utilizes the fuel temperature signal to provide an adjusted value for these calculations. High fuel temperature is an undesirable condition. The “High Fuel Temperature” parameters are programmed to warn, derate and shutdown the engine in order to protect the engine. Fault type Fuel temp over max

FMI 0

Warning Red warning

Result Engine stop

Fuel conservation practices The efficiency of the engine can affect the fuel economy. Follow the recommended procedures in order to attain performance for the life of the engine.  Cold engines consume excess fuel. Thermostats and coolers must be kept in good working condition.  Observe the service indicator. Replace air and fuel filters according to program.  Avoid spilling fuel. Fuel expands when the fuel is warmed up. The fuel may overflow from the fuel tank. Inspect fuel lines and connections for leaks. Repair as needed.  Be aware of the properties of the different fuels. Use only the recommended fuels. Refer to Caterpillar’s Operations and Maintenance manual: Fuel recommendations.  Avoid necessary idling. Shut off the engine rather than idle for long periods of time.  Maintain batteries and electrical system in good order.  Ensure that belts are properly adjusted and in good condition.  Do not engage driven components unless required (compressor loading, water pumps etc.).

© 2012 Atlas Copco Craelius AB | 2012-05-15 06 Operation Explorac 220 RC Ed.1

Safety and operating instructions

Engine air intake temp

The air inlet temperature sensor detects the temperature of the air that is passing through the inlet manifold. A signal is sent to the ECM for interpretation. The ECM uses the information from the inlet air temperature sensor in order to accurately control the emissions level of the engine. As the inlet air temperature changes, the fuel injection timing is advanced. This is done in order to maintain the exhaust emission standards. Excessive inlet air temperature is an undesired operating condition. The “High Engine Air Inlet Temperature” parameter is programmed for warning and derate for protection of the engine. Fault type Intake air over max

FMI -

Warning Yellow warning

Result High temp

Intake air over max

15

Yellow warning

High temp

Intake air over max

16

Yellow warning

Engine derate

Air filter stop

-

Yellow warning

Air filter, engine

Fault type Oil pressure below min

FMI 17

Warning Yellow warning

Result Low oil pressure

Oil pressure below min

18

Yellow warning

Engine derate

Oil pressure below min

1

Red warning

Engine stop

Engine oil sensor error

-

Yellow warning

ECM- error

Atmospheric pressure sensor The atmospheric pressure sensor measures the pressure in the engine crankcase. This sensor assumes that crankcase pressure is a representation of atmospheric pressure. A signal is sent to the ECM. The ECM utilizes the value that is read by the atmospheric pressure sensor for the following functions:  Reference source for pressure sensor calibrations  Calculating the operation altitude  Calculating boost pressure  Checking for air inlet restriction

Engine oil pressure

Typical oil pressure for an engine at rated speed with SAE 10W30 or SAE 15W40 is 3-6 bar. A lower oil pressure is normal at low idle. If the load is stable and the gauge reading changes, check the oil level: remove the load, reduce speed to idle, shut down the engine and allow time for the lubrication oil to settle. Check the oil level. Maintain the oil level at the recommended level. Low engine oil pressure is an undesirable operating condition. When a low oil pressure condition occurs in the engine there is a possibility of major engine failure. The Low Engine Oil Pressure parameter for the monitoring system is programmed to Derate or Shutdown in order to protect the engine against damage from low engine oil pressure.

© 2012 Atlas Copco Craelius AB | 2012-05-15 06 Operation Explorac 220 RC Ed.1

When the ECM is powered, all of the pressure sensors that are used for engine monitoring receive an automatic calibration. The ECM uses the value that is received from the atmospheric pressure sensor to calculate the pressure offset value. The ECM also utilizes atmospheric pressure to determine the active engine derate during high altitude operation. The engine monitoring system compares the current atmospheric pressure value to the programmed derate set point. The engine is derated by limiting the fuel delivery at a rate approximately 3 % for each 300 m (1000 ft) of altitude. Actual boost pressure is calculated by subtracting the atmospheric pressure from the turbocharger outlet pressure. Boost pressure is used for calculating fuel system adjustments. ECM = Electronic Control Module FMI = Failure Mode Identifier

51

Safety and operating instructions

Engine stop 1. Move all hydraulic control valves to neutral position. 2. Close compressor discharge valve. 3. Set engine speed control to minimum. 4. Allow the engine to run at idle speed a couple of minutes for temperature balance. 5. Turn the ignition key counter-clockwise to stop position. (0). Press engine stop button. 6. Lock engine main switch if you are leaving the rig unattended

Emergency stop Use the emergency stop for bringing the engine to a full stop if an emergency situation should occur. The engine stops immediately when a stop-button is pushed. There is a stop-button on each control panel and also on the hydraulic jack casings. NOTE Check proper function of the rig safety equipment at least once at the beginning of each shift. Make sure all emergency stop buttons are unengaged before you try to start the engine

26000099 A

Note! The emergency stop switches are not intended for regular engine stop.

26000150 A

Emergency stop-button on driller’s control panel

Emergency stop-button on rig start control panel

52

© 2012 Atlas Copco Craelius AB | 2012-05-15 06 Operation Explorac 220 RC Ed.1

Safety and operating instructions

After engine stop ►Wait at least 10 minutes in order to allow the engine oil to return to the oil pan. Check the crankcase oil level. ►Fill the fuel tank to avoid accumulation of moisture in the fuel. Do not overfill. ►Check the coolant level (Allow the engine to cool). ►If freezing temperatures are expected, check the coolant for proper anti-freeze protection. ►Perform any minor adjustments such as repair leaks and tighten loose bolts. ►Check the operating hours on menu D2, Drillers control panel. Carry out the maintenance called for in “Maintenance interval Schedule”.

26000100 A

►Perform all required periodic maintenance on the drilling rig. Refer to “Maintenance Schedule”.

Emergency stop button on hydraulic jack

© 2012 Atlas Copco Craelius AB | 2012-05-15 06 Operation Explorac 220 RC Ed.1

53

Safety and operating instructions

When the drill rig is started, the control panel immediate mode is “Rig Setup”. None of the drilling control panel functions are operative - with exception for the drilling mode button. When the setup procedure is completed, drilling can start upon pushing drilling mode button.

Driller’s control panel 2

4

3

5

6

7

1

12 8

11 10

9

26000093 A

Mode selector

Driller’s control panel Activate drilling button

1. Main air valve. Winch control. 2. Break-out control. 3. Down feed-hold back control. 4. Engine rpm. 5. Water pump & oil injection pump controls. 6. Drilling lever. Controls slow feed, up & down and drilling rotation.

Activate positioning button The valve blocks for setup are now disabled in order to avoid any undesired movements of the unit.

7. Fast feed /rotation lever. Toggle switch on lever: Controls thread in/out and make up/break out torque. 8. Rotation serial/parallel buttons. 9. Emergency stop 10. Feed & torque limiter.

NOTE Do not stop the engine from full load unless in an emergency!

54

11. Slips- and centralizer control. 12. Cyclone control.

© 2012 Atlas Copco Craelius AB | 2012-05-15 06 Operation Explorac 220 RC Ed.1

Safety and operating instructions 6. Raise the mast to the required position using the mast tilt lever.

Drill rig positioning

26000143 A

26000136 A

1. Press the positioning button on the driller’s control panel. Positioning mode is activated.

Positioning button on driller’s control panel

Mast tilt lever

2. Level the drill site for the drill rig unit and for supply vehicles. Provide free space around the rig for convenient access to the entire rig. Place heavy timber under the hydraulic jacks to avoid that jacks or entire machine sinks during the drilling.

7. Lock the mast elevation cylinders by turning the tilt lock push button in counter-clockwise direction. 8. Adjust the mast in lengthwise position the mast dump lever for adjusting the slips table to a convenient height relative to the ground.

3. Move in the drill rig to the exact position for the drill hole.

26000137 A

26000135 A

4. Place the rig in horizontal position, using the jacks.

Mast dump lever 9. Lower the mast foot towards the ground using the mast foot extend/retract lever

Jack control levers

26000131 A

26000133 A

5. Release mast lock by pushing and turning the tilt lock push button in clockwise direction.

Tilt lock pull/push button

Mast foot extend/retract lever 10. Move the cyclone into working position (see 17. Cyclone). 11. Secure the mast foot with heavy timber for maximum stability. The ground may cave in around the bore hole when drilling in lose formation. 12. Place the control panel in a suitable and safe position.

© 2012 Atlas Copco Craelius AB | 2012-05-15 06 Operation Explorac 220 RC Ed.1

55

Safety and operating instructions

Before compressor start Check the oil level in the oil separator before start of the diesel engine. Add oil if necessary.

Compressor stop 1. Press the start/stop button (2).

NOTE Make certain that the system is NOT under pressure when the refill plug is removed! Otherwise the refill plug may fly off at dangerously high speed.

Compressor start/stop button on driller’s control panel 2. Allow the unit to run a few minutes to cool down.

Check the air cooler coolant fluid level.

3. Stop the engine.

Before activating the compressor module: 1. Allow the engine to warm up during a couple of minutes. 2. Emergency stop buttons must be in operating mode. (Turn and pull). 3. Air discharge valve in closed position.

1. Press the compressor start/stop button on the driller’s control panel.

26000098 A

Compressor start

Menu D3: Compressor surveillance. Intermediate stage pressure and temperature, final pressure and temperature Compressor start/stop button on driller’s control panel 2. The unloader valve opens and air enters the compressor elements. When the pressure in the air receiver reaches the preset pressure value, the unloader valve closes the access of air until the receiver compressed air is discharged. 3. The compressor is monitored at the driller’s control panel; inter stage pressure and temperature and final pressure and temperature. Press Main, then button F3. 4. Check the setting of regulating valve (RV) and adjust if needed. Note that the pressure by necessity will be lower than idle pressure when the discharge valve is fully open and the compressor is working without any resistance. 5. Check fuel level in order to avoid stop during operation.

56

© 2012 Atlas Copco Craelius AB | 2012-05-15 06 Operation Explorac 220 RC Ed.1

Safety and operating instructions

Rapid feed

Rotation

This lever controls rapid feed up and down. Speed is proportional to the lever deflection. The final 10 % of the lever deflection adds additional speed to up and down travel.

Left and right motion of this lever control CW and CCW of the rotation head spindle. The rotation speed is proportional to lever deflection.

The hydraulic oil is supplied from hydraulic pump OP1 to valve block 1V0. Two of the valve sections (1V1B and 1V1C) are run in tandem by remote control and delivers oil to hydraulic cylinders 1FC1 and 1FC2. Speed is proportional to the lever deflection. Boost. Oil from pump OP3 is added via valve block 3V1; section 3V1E

The hydraulic oil is supplied from hydraulic pump OP1 to valve block 1V0. The lever can be moved in any direction to produce any combination of rotation and fast feed motion. Toggle switch is used with rotation to produce a very slow feed in and out to simplify the making and releasing a drill string joint.

Boost

A Fast up

CCW

CW

B 26000101 A

26000102 A

Fast down

Rod handling lever

Rapid feed lever

Making a thread with the rotation unit Joy-stick 31, switch B. Thread compensation up/down. (Preset torque).

Max travel speed

Normal

+20% Boost

Fast up

44 m/min

53 m/min

Disconnect a thread with the rotation unit

Fast down

34 m/min

41 m/min

Switch A make up/break preset torque. Page 29 D1:2.

© 2012 Atlas Copco Craelius AB | 2012-05-15 06 Operation Explorac 220 RC Ed.1

57

Safety and operating instructions

Rotation motor operation mode

Main handling winch

The rotation head designed for the Explorac 220 is a single reduction gearbox fitted with two hydraulic rotation motors. These motors are of geroler type with each a displacement of 630 cm3 and they can be hydraulically connected in parallel or serial mode in order to obtain an extended range of speeds and torques.

The Explorac E220 is equipped with a hydraulically driven handling winch. The winch is provided with an overload protection valve and a brake which will hold the load when the operator releases the lever or in case of power failure. The winch drum has an automatic stop which prevents from paying out all the wire rope, which might damage the rope attachment.

Motors operating*

Serial

Parallel

Spindle speed rpm

0-101

0-50

Spindle torque Nm

7000

1

2

14000

26000104 A

*) At 240 bar, oil flow 240 l/min. Hydraulic pump OP1 342 l/min, max 280 bar.

Winch with wind off preventing device (1) and overload & cavitation prevention valve (2)

Serial mode

58

26000103 A

Parallel mode

Winch data Max pull on empty drum (layer 1)

20 kN

Pull on layer 4

15 kN

Lifting speed on layer 1

40 m/min

Max speed on layer 4

52 m/min

Max working pressure

175 bar

Max feed flow

65 l/min

Hyd. motor displacement

32 cm3/rev

Reduction gear ratio

31,22 : 1

Wire rope diameter

10 mm

Max capacity

54,5 m

© 2012 Atlas Copco Craelius AB | 2012-05-15 06 Operation Explorac 220 RC Ed.1

Safety and operating instructions

Winch arm The handling winch is mounted on a slewing ring to assist with positioning of the hanging load (with the mast in vertical position). The arm’s left and right turning is controlled by two buttons, 19a and 19b.

19a Pay out

Winch arm control buttons 19a and 19b

26000105 A

Hoist

19b

26000106 A

The winch boom is mounted on a slewing ring providing reach between the drilling center line to the rod rack. Press lever forward for paying out cable and pull for hauling. The winch speed is responding proportionally to the lever deflection.

Main handling winch lever

© 2012 Atlas Copco Craelius AB | 2012-05-15 06 Operation Explorac 220 RC Ed.1

59

Safety and operating instructions

Compressed air delivery valve

Drilling lever

Compressed air is used for drilling with DTH hammers and air rotary drilling. The air is used for working the hammer mechanism and as a media for carrying cuttings to the surface. The proportional type control lever is opening and closing the air control valve via a hydraulic cylinder (2EAC).

This is the principal lever intended for start of the drilling procedure.

The upper switch (Bleed) on the control lever opens a discharge to the atmosphere in order to vent the compressed air trapped, or slowly escaping from the drill string, in order to safely disconnect a hammer or drill pipe connection. Never attempt to open a thread with tubes containing compressed air! The blow-out of air, water or cuttings might seriously injure you or any of the rig crew.

By moving the lever to the right the following settings are automatically chosen: Max CW rotation torque, max lifting force, max down feed force and max holdback force. By moving the lever to the right, CW rotation is activated. Repeated lever movements to the right will increase the rotation speed and to the left will decrease the rotation speed. Moving the lever to the right rotation torque will also be adjusted to previous set level . The speed will initially be the same as used earlier, before an eventual halt in the drilling. Rotation can be brought to a halt by holding the lever to the left or toggling switch on the joy-stick. By pushing the lever forward the slow feed down function starts at previous selected values . By holding the lever in backwards position, maximum “slow feed up” will be activated

Bleed open

Close

Open

26000107 A

Bleed close

Slow feed down

Rotation stop button

Control lever, compressed air delivery

Slow feed up

26000108 A

Activate/increase rotation speed

Reduce rotation speed

Control lever, drilling

60

© 2012 Atlas Copco Craelius AB | 2012-05-15 06 Operation Explorac 220 RC Ed.1

Safety and operating instructions

Set spindle torque and speed

Maximum lifting force

The rotation unit rotates the drill string in clockwise direction during the drilling and counter-clockwise for breaking the joints between drill pipes, hammers and bits. The torque in CW (Clockwise) direction can be adjusted to provide a suitable torque for drilling and to meet recommendations for making of individual threads and to provide protection against material failure in down-the-hole equipment.

The Explorac 220 has a lifting capacity of 220 kN (22 tons). This is in most cases more than enough for retrieving the drill string. An average drill pipe (4½ OD, heavy duty) has a weight of 25 kg / m, which is enough for lifting approximately 800 m pipe (friction and buoyancy not considered). Slimmer pipes however, might not take the pull from the Explorac 220. For this reason it is convenient to be able to reduce the max lifting force.

This is called “Rotation Torque Low” and applies to CW as well as CCW rotation. This torque is adjusted on screen D.1.2 using arrow buttons on the display unit. The display indicates the torque as a percentage of maximum torque e.g. 40, 50, 60 etc. percent. The torque in CCW (Counter-clockwise) direction can be set higher and will be activated by “Toggle up” when CCW rotation is applied. This is called “Rotation torque break” on screen D.1.2. This torque is adjusted with buttons (+) and (-) on the control panel or on screen using arrow buttons on the display unit. The display indicates the torque as a percentage of the max, e.g. 40, 50, 60 etc. percent.

Setting the maximum lifting force Lifting force: Push buttons (+) or (-) until the desired value is obtained. The display indicates the force as a percentage of max, e.g. 40, 50, 60 etc. percent. The feed down is pre-set to 90 bar. The Feed is manoeuvred using the drilling lever on the driller’s control panel. The force is automatically adjusted according to settings with buttons (-) and (+).

26000110 A

Normally the torque in CCW rotation is set slightly above the CE setting thereby making it more easy to break the joint.

Set lifting force buttons

Break-out torque

26000109 A

Drilling torque

Driller’s control panel, drilling torque and break-out torque buttons

NOTE Carry out the instructions given in the section: ”Extra safety check”. Special care and attention should be given to damaged or worn components, which could cause structural fatigue cracks or even fracture in materials.

© 2012 Atlas Copco Craelius AB | 2012-05-15 06 Operation Explorac 220 RC Ed.1

61

Safety and operating instructions

Down feed and hold back Down feed is the force applied to push the drill string down (additional to the weight of the drill string). Hold back is the force pulling the drill string up. Down feed on the drill string is increased by moving the down feed/hold back lever forward and decreased by moving it back.

With the rotation head and drill string free from rod spanners, rod brakes, hydraulic restrictions and hanging in the hole off the bore hole bottom, slow feed should be applied. (Push drill lever forward). The drill string will move slowly up or down. By increasing or decreasing down feed or hold back, the movement of the drill string will halt. The drill string is now balanced. Press the balance button on the driller’s control panel. The gauge will point at 0.

Hold back is increased by moving the down feed/hold back lever to the right and decreased by moving it to the left.

26000112 A

The values of these forces are presented on the monitor in kN (kilo Newton).

Balance button on driller’s control panel NOTE All slow feed and rotation can be instantly stopped with “Toggle up” on the “Drill” lever. NOTE

Hold back increase

“Fast feed” will override “slow feed” with no effect afterwords on the slow feed settings. NOTE When resuming drilling after a stop by engaging the “Drilling” lever the rig will begin rotation and feed with the same speed and torque as before the stop.

Down feed increase

Hold back decrease

NOTE 26000111 A

Down feed decrease

The feed settings must be re-balanced or adjusted if weight has been added or removed from the drill string.

Down feed/hold back lever on driller’s control panel 1 kN equals approximately 100 kg 10 kN equals approximately 1 ton (UK) Decreasing hold back has the same effect as increasing the down feed and vice-versa. Desired bit load is achieved by correct balance between hold back and down feed. This balance is indicated on window D1.1. Zero balance is achieved when down- and up forces (including drill string weight, buoyancy etc.) are equal.

62

© 2012 Atlas Copco Craelius AB | 2012-05-15 06 Operation Explorac 220 RC Ed.1

Safety and operating instructions

Water pump The water pump can be used to inject water into the drill string or to a wash down hose. The nominal capacity is 75 l/min (clear water, 0 suction height). Water and water based additives can be injected to help with drilling and dust suppression. 26000115 A

The pump is started by pressing button 2 and stopped by pressing button 1. The pump speed is regulated by buttons 4 and 5. If the pump needs bleeding press button 3. The pump performance is shown in window D1.1 (Press button F1 on the computer display).

1

2

3

4

5

Water pump Dynaset

26000113 A

The flow speed in percent of maximum flow speed is shown below the water pump icon. In the range 0 - 15% the increments are 1% and from there on the increments are 5%.

26000114 A

Water pump control buttons

Window D1.1 Water pump performance in percent

© 2012 Atlas Copco Craelius AB | 2012-05-15 06 Operation Explorac 220 RC Ed.1

63

Safety and operating instructions

Line oiler

Hydraulic slips

The air system for Explorac E220 provides compressed air for pneumatic Down-The-Hole hammers as well as for flushing of the bore hole. The system is designed for a maximum working pressure of 30 bar.

The Explorac 220 is fitted with hydraulic slips which allows guiding of the drill string and holding of drill string tools for break-out.

The impact mechanism of a DTH hammer normally requires about 1 ml of oil per m3 of free air (FAD) for bench and anchoring drilling.

To guide drill string, close slips so spring loaded guide blocks are closed. Further closing of slip jaws will clamp the drill string.

Experience shows that when drilling deeper holes and water wells where water is present in the formation, an increased dosage is required (see Atlas Copco COP manual for DTH hammers for additional information). The pump can be set to run at four different rates 1-4 with the relevant buttons on the driller’s control panel.

Slip hydraulic cylinder

3

4

5

Rate control buttons on driller’s control panel

Slips holder

1

2

26000119 A

2

26000116 A

Off

26000118 A

5

26000117 A

Slips holder control buttons, slips in (1), slips out (2)

Air lubrication oil tank, mounted on the rig’s left hand side, in front of the deck engine fuel tank. Capacity 50 liters

64

© 2012 Atlas Copco Craelius AB | 2012-05-15 06 Operation Explorac 220 RC Ed.1

Safety and operating instructions

Spanner

Break-out tong

The spanner is used to lock the drill string in the slips table by sliding it into the keyway (flats) on the drill rod.

The hydraulic break-out is used with spanner or slips to break threads of drill string components. It also provides additional torque to rotation head when used for breaking drill string joints.

Pushing lever forward moves the spanner towards the rod. Pulling the lever back, retracts the spanner from the rod.

26000121 A

26000123 A

Spanner cylinder

The tong is set on suitable height by a hydraulic cylinder. This cylinder is activated by a valve selector lever located on left hand side, behind the break-out table and up-down by the control lever.

Slips table

26000124 A

Valve selector lever

In

Valve selector lever

Out

26000120 A

The tong is manually placed on the drill pipe/hammer.

Spanner control lever NOTE Make certain that the spanner is fully engaged to the rod before applying torque or rod weight! © 2012 Atlas Copco Craelius AB | 2012-05-15 06 Operation Explorac 220 RC Ed.1

65

Safety and operating instructions

Rod rest

On

26000125 A

With the mast in inclined position, from vertical to 45 degrees, drill pipes can be supported by the Rod Rest in order to support the drill pipe in position for threading up.

Off

26000122 A

Rod rest (lower)

Break-out tong control lever NOTE

26000126 A

Stay clear of the tong when in operation!

Rod rest control buttons

NOTE! Rigs equipped with Rod handler have a second rod rest further up the mast to accommodate the drill pipe to the rotation head spindle thread. This rod rest is automatically activated when the rod handler is slewed into the mast.

66

© 2012 Atlas Copco Craelius AB | 2012-05-15 06 Operation Explorac 220 RC Ed.1

Safety and operating instructions

Cyclone The sampling Cyclone fitted on the Explorac 220RC has been designed for use with large air volumes. The cyclone consists of two compartments, the “snail” with cone and the drop box. A knife valve is fitted between the cone and the drop box. The drop box outlet (bottom) has a double trap door.

3

1

2 4

Manual sequencing of the knife valve and the trap door can be used to isolate a sample for processing while drilling continuously. 5

7

5

A

4

1

2

C

Cyclone with “snail” (1), cone (2), sample air inflow (3), hydraulic cylinders for knife valve (4), pneumatic cylinder for trap door (5), drop box (6), emergency stop (7) 26000127 A

3

B

26000128 A

6

Drilling mode (5), knife valve (3,4) and trap door (1,2) control buttons

Stay clear of doors during operation. For cleaning lock trap doors with manual isolation valve (three way valve that blow fog into air). The cyclone can, for transport and maintenance purposes, be shifted and rotated using the valves mounted on the front left hand jack. © 2012 Atlas Copco Craelius AB | 2012-05-15 06 Operation Explorac 220 RC Ed.1

A

B

C

26000132 A

NOTE

Cyclone lever functions: slew unit in/out (A), raise/ lower unit (B), tilt unit (C)

67

Safety and operating instructions

Blow down valve

Stop watch

The blow down valve re-directs the airflow into the RC inner tube. This airflow will clear blockages from the inner tube, the hammer and the drill hole (outside of the drill string). Ensure air is bled off from the drill string before unscrewing any drill string tool joint!

The stopwatch is activated/deactivated with button 1. Button 2 will reset display to 00:00:00. Stopwatch is displayed on screen D1.2, bottom line (Press F1 twice).

If the outside of the drill string is blocked, a lot of air may go into the formation at 30 bar, and up to 70 bar pressure when a booster is used!

1

2

26000141 A

2

26000130 A

1

Stop watch control buttons. Activate/deactivate (1), reset (2)

Blow down mode control buttons

Press and hold button 2 for five seconds for blow down mode. 26000140 A

Press and hold button 1 for five seconds for returning to normal air direction (compressed air down between the outer and the inner RC tube).

Stop watch position on display

68

© 2012 Atlas Copco Craelius AB | 2012-05-15 06 Operation Explorac 220 RC Ed.1

Safety and operating instructions

Drill string bleed valve

For safety purposes. Make members of the crew aware of imminent danger.

The upper switch (Bleed) on the lever opens the bleed valve in order to vent the compressed air locked, or slowly escaping from the drill string. This in order to safely disconnect a hammer or drill pipe connection.

26000139 A

Horn

Horn Bleed valve open

26000138 A

Bleed valve close

NOTE Non authorized persons are not permitted in the drilling area. Drill string bleed switches

NOTE Do not attempt to open a thread with tubes containing compressed air! The blow-out of air, water or cuttings might seriously injure you or any of the rig crew.

© 2012 Atlas Copco Craelius AB | 2012-05-15 06 Operation Explorac 220 RC Ed.1

69

Safety and operating instructions

Rod handler Danger using the rod handler for anything outside the intended use and specific lifting capacity is considered prohibited use which, if not avoided, will result in death or severe injury. Use the specific lifting capacity of the rodhandler. The specific lifting capacity is as follows:  3.0” to 4.5” outside diameter 26000134 A

 up to 9 m long  up to 200 kg max. weight per rod Avoid prohibited use of the rod handler. The Rod handler is NOT:  a general lifting device  designed to handle diamond core rods  for handling any other types of materials aside from the rods listed above.

Joystick for rod manipulating The rod handler is designed for safe and labor saving transfer of drill pipes (to and from the drill rig rack or a support truck) to the drilling position. The system includes a computer supported joystick, a rod holder and functions for maneuvering the rig’s rod bin.

Joystick, dead man’s switch ►The joystick must be in the neutral position when the joystick functions are enabled using the dead man switch before any actuations to the valves are made. ►The Clamp grips or releases a drill pipe with jaws operated by a hydraulic cylinder. Use only when drill pipes are in horizontal position in the pipe bin. To grip: press the button (A). ►The Clamp Travel Motor is activated by moving the joystick forward or backwards. The clamp trams towards or away from the cup and drags the drill pipe with it when the button (A) is pressed. ►Tilt Cup. When the drill pipe is loaded into the cup it is rotated to drilling angle using the joystick (left/ right) while keeping the button (A) pressed. ►The Base Table can be raised and lowered up to 1890 mm in order to find a convenient height using the joystick (forward/backwards) with the button (B) pressed. ►Clamp Arm Rotation. The arm must be rotated around the drill pipe in order to ensure that the arm does not interfere with the mast during loading. Press the button (B) and move the joystick left/right. The clamp arm should be in position right above the drill pipe while loading a pipe from the bin. ►The Base Table is slewed from its location behind the pipe bin to the drilling position in front of the mast by moving the joystick (left/right) with the button (C) pressed.

Rod handler control joystick

Basic functions

►The Rod Bin Base and Sides are maneuvered for lining up for charging or discharging a drill pipe. Press the button (D) and move the joystick.

The rod handler functions are enabled when the joystick’s dead man’s switch button is pressed. The diesel engine must be running. If no functions have been used for 30 seconds or if the engine is stopped, the system has to be enabled again. 70

© 2012 Atlas Copco Craelius AB | 2012-05-15 06 Operation Explorac 220 RC Ed.1

Safety and operating instructions Tram clamp out

1

Tilt cup CW

26000147 A

Tilt cup CCW

Tram clamp in

2 4

Rod handler control joystick standard functions Rod bin

raise

Slew table in

6

out

3

lower down D

C

A

B raise

open / close Table

lower Rotate arm

in

Overview, control joystick additional functions

out

5

26000145 A

Clamp

up

26000146 A

Fence

Rod handler, main parts: Slew motion motor (1), clamp (2), arm rotation motor (3), tension support brace (4), base table (5), rod support (6) ♦ If the diesel engine is started the rod handler functions are enabled when the dead man switch is pressed. The lever functions are disabled when no functions have been used for 30 seconds or if the diesel engine is stopped. ♦ If the lever is not in neutral when it is enabled with the dead man switch, it must be moved back to neutral before any actuations to the valves are made. ♦ If the CAN-messages from the lever fail to appear, the rod handler lever functions are disabled and the actuations are turned off. ♦ For the three proportional functions -cup rotation, - clamp tram, -and table slew the current to the respective valves is, depending on the lever position, between a min and a max current. The min and max currents are adjustable parameters.

© 2012 Atlas Copco Craelius AB | 2012-05-15 06 Operation Explorac 220 RC Ed.1

71

Safety and operating instructions

Rod bin 2

Rod support up/down.

26000148 A

1

The table has an inductive sensor that indicates its inner position. When the table is slewed in and the sensor indicates, the rod support cylinder is pressurized upwards for three seconds. When the table is slewed out and the sensor does not indicate, the rod support is pressurized downwards for 3 seconds.

Cup rotation, low speed sector The cup rotation has a low speed sector around its centre position. In the slow speed sector the speed is 30 % of the normal speed. When changing from low speed to normal speed the transition is gradually made within one second. The change from normal speed to low speed takes 0,1 second. The low speed section is indicated by 2 inductive sensors:

Rod handler with cup (1), clamp (2)

- The backward low speed sensor. If the cup is rotated CW and the sensor indicates, the slow speed sector is entered. If the cup is rotated C-CW and the sensor indicates, the low speed sector is left. - The forward low speed sensor. If the cup is rotated CW the sensor indicates the slow speed sector is left. If the cup is rotated CCW and the sensor indicates the slow speed sector is entered.

1

26000149 A

- The cup rotation has an inductive sensor indicating its centre position. If the cup is rotated and the sensor indicates, the movement stops for two seconds. When his time has expired the movement continues if the lever still orders “cup rotation”

Rod handler, base table (1)

26000240 A

A

Rod bin and base tilt (A)

72

© 2012 Atlas Copco Craelius AB | 2012-05-15 06 Operation Explorac 220 RC Ed.1

Safety and operating instructions

© 2012 Atlas Copco Craelius AB | 2012-05-15 06 Operation Explorac 220 RC Ed.1

73

Safety and operating instructions

Maintenance

Adding hydraulic oil

Hydraulic and electrical systems

Oil must be added when the level falls beneath the minimum, as indicated on the gauges. Position the rig horizontally for correct reading. Use recommended oils!

Before removing or disconnecting hydraulic or electrical components, carefully tag and mark the items position in order to remount correctly. Refer to the hydraulic and/or electrical diagrams when mounting or connecting removed components..

Avoid mixing oils of different brands.

Return oil filter (1 of 2)

Replacing hydraulic components If the hydraulic system breaks down at a work site, or if components need to be replaced, fitted or serviced, contact an adequately equipped workshop. Pay attention to the following recommendations when replacing hydraulic components: Before removal, clean the surface around the part thoroughly. Pay special attention to hose- and pipe couplings. Make a sketch of the connections for each component before removal. Always keep a selection of plugs available so that hoses, couplings and connections can be plugged in order to prevent ingress of dirt to the parts or the system. 26000229 A

When dismounting parts take care not to lose or damage o-rings or seal rings.

Replacing a hydraulic cylinder Before removing the hydraulic cylinder secure the machine part upon which the cylinder is acting. Use strong wood or steel beams which can take the full weight of the machine components.

Hydraulic oil tank with return oil filters OF1 and OF2. The filters are equipped with a manometer for condition control.

Check that the support is well balanced so that no force is applied to the cylinder connecting points.

NOTE

Disconnect the cylinder rod end from the moved part. Start the rig’s diesel engine and, using the corresponding lever on the control panel, fully withdraw the piston rod. (This protects the rod against damage during removal and transport). Disconnect and plug the hoses. Plug the hydraulic connections to the cylinder. Dismount the cylinder and carry out the repair.

74

The oil level must never exceed the maximum level indicated on the gauge. Dust easily sticks if oil is splashed on the breather filter. A clogged filter could cause vacuum in the deposit which in turn might result in cavitation of the hydraulic pumps. Low price oils are often not sufficiently pure, and therefore cause rapid clogging of the return line filters. Always change filter cartridges when changing the hydraulic oil.

© 2012 Atlas Copco Craelius AB | 2012-05-15 07 Maintenance Explorac 220 RC Ed.1

Safety and operating instructions NOTE Filter cartridge condition must be checked when the hydraulic oil has a temperature of + 20°C or more: see ”Pre-start procedure”. If the warning lamp then doesn’t go out, replace the filter. The filter is equipped with a check valve which opens at 3 bar pressure in order to prevent a clogged filter from bursting. The hydraulic oil is now being circulated without filtration. Replace filter immediately!

26000231 A

26000230 A

Tank

Hydraulic oil tank, engine and compressor

C1 C2

26000232 A

C1

26000233 A

Tank level visual level gauges, electronic minimum level warning device

Hydraulic oil tank, from below. Gate valves to four hydraulic pumps (C2), condensate drain valves (C1)

Hydraulic oil filling pump

© 2012 Atlas Copco Craelius AB | 2012-05-15 07 Maintenance Explorac 220 RC Ed.1

75

Safety and operating instructions

Feed chain tensioning Normally, chain tension is adjusted by the top adjusters, one for each upper chain. Lower adjusters can also be used but access to the top ones is better. Lower adjusters can be used when top adjusters run out of adjustment. Ensure that lower chains always are evenly tensioned. Check by measuring the exposed thread of the lower adjusters.

Top sprocket Upper chain tensioner bolt

NOTE Upper adjusters will have different exposed length due to off synch sprocket mounting of the tuning shaft. Difference will be approximately 25 mm.

Chain sag 75mm below mainframe upper level

Keep the mast travel chains correctly tensioned. Slack chains could rub against the mast frame or hydraulic cylinders. Adjust chains as follows:

3. Adjust the tensioner bolts at the top of the mast (A) until the centre-line of the upper chains is approximately 75 mm below the top of the main mast member. Tighten locknuts on tensioner bolts after completing adjustments. 4. After accomplishing the correct tension check the alignment of the rotation gearbox relative to the slips table.

Rotation gearbox

Lower sprocket

26000239 A

2. Lower the mast to the horizontal position.

Lower chain tensioner bolt

Horizontal line

1. Place the rotation head near the slips table.

Feed chain tensioning

Lubrication oil

Lubrication oil In order to increase the life of the feed chain use a engine oil which will penetrate into the links. The viscosity depend on the ambient temperature. See lubricant recommendation.

Elongation of feed chains The feed system consists of two hydraulic cylinders moving the drilling rotation unit with roller chains via a 1:2 transmission over a timing tube with two sprockets. There are two sets of chains. Each set consists of an upper and a lower chain. The load on the upper chain is higher, and the rating is consequently higher: ANSI 160. The lower one is ANSI 140. The static elongation is indicating the wear of the chain. A chain is stretched to its limit when it has become 1,5 % longer than nominal length (no rig force applied). Measure 10 links for a proper average.

10

76

26000234 A

In order to increase the life of the feed chain use a engine oil which will penetrate into the links. The viscosity depend on the ambient temperature. See lubricant recommendation.

© 2012 Atlas Copco Craelius AB | 2012-05-15 07 Maintenance Explorac 220 RC Ed.1

Safety and operating instructions Chain

RS140

RS160

Std length

444,5 mm

508,0 mm

Max (1,5%)

451,2 mm

515,6 mm

10. If the saver sub was aligned to the right of the slips, then slide an additional washer up the adjuster and place adjuster back in the frame.

A template may be used to check the condition of the chain. The template shows a mark for ANSI 140. Six links should not reach this point.

11. If the saver sub was aligned to the left of the slips, then slide an additional washer down the adjuster and place adjuster back in the frame 12. Replace adjuster retainer bolt 13. Disengage slow feed and run rotation head up and down the mast 14. Recheck alignment and repeat procedure if necessary

26000235 A

15. Do not attempt to remove nut (5) during this operation!

3 6

The template shows another mark for ANSI 160, five links should not reach this point. When a chain has stretched beyond the recommended maximum it should be replaced. The risk for failure is imminent!

2 1 4

When replacing a chain also check the sprockets. A damaged or worn sprocket will wear the chain at a faster rate than normal. Inspect the chains for alignment. Twisted or bent chains wear faster than normal.

Rotation unit alignment

5

26000236 A

The saver sub on the rotation head main shaft must enter and run centralized in the slips table assembly. Adjust the alignment of the rotation gearbox to achieve this, as follows (note item 15!): 1. Raise the mast to vertical position. 2. Lower the rotation head until the main shaft saver sub is about to enter the slips liner; check if saver is aligned centrally or, to the left or right (fig). 3. Place a strong wooden block across the slips table

26000237 A

4. Lower rotation head onto the block and apply downfeed with slowfeed to 100 bar for the duration of this operation 5. The top chains will now be untensioned, chains will have some slack. 6. Loosen washer locknut (6) 7. Remove adjuster retainer bolt (1) See pos 15!

Alignment of rotation unit

8. Count the number of washers (2) above the frame (4) 9. Slide adjuster (3) out of the frame. © 2012 Atlas Copco Craelius AB | 2012-05-15 07 Maintenance Explorac 220 RC Ed.1

77

Safety and operating instructions

Electric welding

Safety Checks

In order to meet the high standards that apply to Atlas Copco products, welding should only be carried out by an authorised welder. Pay special attention to components which could cause injury or serious damage if repair isn’t properly done.

Check for damage and wear which could cause structural weakness or fracture/failure.

After repair make sure that the rig has been inspected and approved by the proper authorities before brought back to normal operation. Never make alterations or modifications to components of the unit which might have hazardous consequences, particularly to the safety systems. The manufacturer should be informed about all kind of modifications done to the unit for approval.

Check also for cracks or fractures in material or weldings. Pay particular attention to the following components: ♦ Air hoses (whip checks) ♦ Booster connections, pipes, fittings ♦ Sample hoses (whip checks) ♦ Hydraulic cylinder pins and attachments ♦ Rotation unit

Before welding ♦ Disconnect battery terminals. ♦ Disconnect power connections to I/O modules (F1 F5) at the power distribution box. Disconnect operator’s control panel

♦ Feed chain and attachment to rotation unit ♦ A-frame and mast attachment ♦ Slip box ♦ Spanner, spanner travel mechanism

♦ Remove alternator connections.

♦ Break-out tong, links and pins

♦ Remove rust or paint carefully from the welding area and chamfer edges for welding.

♦ Hydraulic jacks, mountings

♦ Connect the welding earth clamp as close as possible to the welding area. Provide good contact by cleaning or grinding paint or rust. Welding near ball bearings, couplings or bushes is not recommended. If these cannot be removed, make a double earth connection at each end of the welding area.

♦ Winches, wire cable, sheaves, hooks ♦ Rod loader connection points ♦ Rod loader cup ♦ Towing hook ♦ Rod rack

♦ No modification or reinforcement should be made to the mast and support beams without prior authorisation from Atlas Copco.

♦ Cyclone mounting

♦ Do not electroweld weld on the hydraulic oil reservoir, hydraulic assemblies, compressed air tanks or air circuits. The fuel tank must be removed, cleaned and welded outdoors in accordance with fire prevention regulations. For work on the diesel engine, contact a service centre authorised by the manufacturer.

NOTE

♦ Always keep a fire extinguisher (of the type suitable for oil fires) within reach during electrowelding, cutting and sanding.

Repairs to the rig may only be carried out by engineers or mechanics experienced and familiar with the rig. Welding work must be carried out by an authorized welder and according to the instruction ”welding” After repairing, the rig must be inspected and approved by the proper authorities before being put back into work.

♦ Provide adequate protection for rubber hoses, electrical wires and delicate components. ♦ Evacuate compressed air conducts and vessels on the rig before welding.

NOTE When welding casing tubes (ODEX, SYMMETRIX etc) place the ground clamp to the casing – not to the drill rig

78

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Safety and operating instructions

Preventive maintenance Check point ENGINE

Check procedure Look for

Delivery check

Daily 8h

Engine oil level

Lub. oil level





Engine oil

Weekly Monthly 60h 240h





Oil filter Fuel filter*

500h

1000h

Note







Check

  

   

   

Change

Air filter (combustion) Alternator belt

Wear, tension





 

 

 

Level, condition











Exhaust system Engine coolant

Replace Replace Replace

= Check = Change/replace *Available kits - engine maintenance Article number

Contents

3717 0024 23

Fuel filter

3717 0033 85

Fuel filter and water separator

Check point Check procedure COMPRESSOR Look for Oil level

Oil level

Oil

Replace

Oil filter Air filter

Dust

Delivery check

Daily 8h

   



Weekly Monthly 60h 240h





Oil separator Water drain

Condensate







500h

1000h

Note



Check

  

     

500h

1000h

Note





Check

Change Replace Replace Replace

= Check = Change/replace

Check point HYDRAULIC SYSTEM

Check procedure Look for

Delivery check

Daily 8h

Oil level

Oil level





Oil change

Change

Weekly Monthly 60h 240h





Change every 2000h

Oil filter Water drain

Condensate







 

Replace

= Check = Change/replace

© 2012 Atlas Copco Craelius AB | 2012-05-15 07 Maintenance Explorac 220 RC Ed.1

79

Safety and operating instructions

Oil fill Gear box ventilator

Lower seal cover Timing shaft Winch slew Timing shaft bearings

Travel sprocket

Feed cylinder upper pin

Feed cylinder upper pin

26000238 A

Lower sprocket

80

© 2012 Atlas Copco Craelius AB | 2012-05-15 07 Maintenance Explorac 220 RC Ed.1

Safety and operating instructions Check point ROTATION HEAD

Check procedure Look for

Delivery check

Daily 8h

Oil level

Oil level





Oil change

Change

Air swivel



Lower seal cover

Weekly Monthly 60h 240h

  

  

500h

1000h

Note



   

Check

 

Change

= Check = Change/replace

Check point GREASE POINTS MAST

Check procedure Look for

Lower sprockets

Delivery check

Daily 8h



Travel sprockets

Weekly Monthly 60h 240h

500h

1000h























Timing shaft bearing Feed cylinder lower pins











Feed cylinder upper pins











 

 

 

Winch slew Mast tilt cylinders = Grease inject

© 2012 Atlas Copco Craelius AB | 2012-05-15 07 Maintenance Explorac 220 RC Ed.1

Note

81

Safety and operating instructions

Lubricants, coolants and propellants This chapter contains recommendation on hydraulic fluids, lubricants, diesel oils and coolants. The following applies in addition to the recommendations:  Never mix oils of varying type and grade.  Dispose of excess oil in an environmentally friendly manner prescribed by the authorities. If in doubt concerning hydraulic fluids, lubricants etc., get in touch with your Atlas Copco representatives.

Hydraulic oil Hydraulic systems Use mineral based hydraulic oil with good rust, wear, oxidizing and foam inhibitive properties and good air and water separation ability. Select an oil with viscosity grade (VG) and viscosity index (VI) that corresponds to the ambient temperature and ISO 3448. Oil with high viscosity index is less temperature dependent. Hydraulic oil Ambient temp. °C (°F)

Viscosity grade (VG)

Viscosity index (VI)

+25 to +40 (77 to 104)

ISO VG 68

Min. 150

0 to +25 (32 to 77)

ISO VG 46

Min. 150

-30 to 0 (-22 to 32)

ISO VG 32

Min. 150

Use of flame proof or biodegradable oil, please contact nearest Atlas Copco representative for information. Diesel engine See the Caterpillar instruction manual for further information on the recommended lubrication oil for the diesel engine.

Lubrication grease Lubrication grease - Electrical system Application

Type of grease

Properties

Contacts

Contact grease with addatives to prevent corrosion and oxidation.

NLGI number: 1-2 Drop point: 200 °C Operating temperature: -40 to +130 °C

82

© 2012 Atlas Copco Craelius AB | 2012-05-15 07 Maintenance Explorac 220 RC Ed.1

Safety and operating instructions Lubrication grease - Drill Application

Type of grease

Properties

Feeder sliding surfaces

Molybdenum disulphide

Wire line hoist with level wind

Universal grease with EP additives

NLGI number: 2 Drop point: 180 °C Base oil viscosity: 150 cSt/40 °C Operating temperature: -30 to +110 °C

Propellants Diesel engine See the Caterpillar instruction manual for further information on the recommended propellants for the diesel engine.

Coolants Diesel engine cooling system See the Caterpillar instruction manual for further information on the recommended coolants for the diesel engine.

Oils and fluids Fluid

Engine oil

Type

Cat DEO SAE Statoil Hydraway Statoil Hydraway 15W-40 HVXA 46 White 22

Volume

Hydraulic oil

34

© 2012 Atlas Copco Craelius AB | 2012-05-15 07 Maintenance Explorac 220 RC Ed.1

400

Hammer oil

Transmission oil

Compressor oil

Rotation unit: BP PAROIL S 68 Energaer Hypo XL 80W-90 50

18

77

83

Safety and operating instructions

Trouble shooting Trouble shooting is a logical sequence of activities to locate a fault, thereby making it possible to rectify the fault as soon as possible. Always try to investigate the location of the fault in order to limit fault finding to a certain system or function. Atlas Copco engineers spent much effort in the design of Explorac 220 RC with the vision to produce a powerful and flexible equipment suitable for operation under the most difficult conditions. Special emphasis was laid on reliability and comprehensive service as well as training of drilling supervisors and service personnel. However well run and serviced, malfunction still might occur. The most frequent reason for malfunction is that impurities enters the hydraulic system. Other common faults are excessive condensate or air in the oil, low level in the tank, clogged filters etc. Regular inspection and preventive maintenance will reduce shut down time to a minimum. Pay full attention to the following items:  Check the hydraulic oil  Check the hydraulic tank for leaks  Check and replace oil filters and breathers  Drain condensate  Check hoses and couplings for leaks  Check condition of motors and hyd. cylinders A fault should be corrected as soon as possible in order to limit hazardous consequences. The trouble shooting chart is compiled from years of experience gained by Atlas Copco service personnel at carrying out trouble-shooting all over the world.

84

© 2012 Atlas Copco Craelius AB | 2012-02-10 08 Trouble shooting Explorac 220 RC Ed.0

Safety and operating instructions Trouble shooting (General) Fault Foamy oil

Oil tank overflows when hyd. cylinders are operated

Possible cause

Procedure

Remedy

The hyd. pump draws air

Check oil level in the tank

Fill oil to correct level. Use recommended oil only

Air enters the suction line

Check pump suction line for leaks.

Tighten hose nipples. Replace suction hose

Wrong oil quality

Check last added oil for brand and quality

Drain and replace with correct oil

Excessive amount of condensate

Stop the unit for 10 hours to allow water to collect in the bottom of the tank.

Drain the condensate. Add oil to normal level.

Level in tank too high

Retrieve all hydraulic cylinders to their end position. Check level.

Drain excess oil.

Return oil filter manometer Hyd. oil temperature below shows above 1.5 bar (red 20°C zone)

Run the system until oil temperature reaches 20°C. Read the manometer.

Filter clogged.

Return oil filter manometer Filter cartridge damaged shows little or no pressure. Manometer damaged Hydraulic hose swells visibly

Dispose of old filter in an enviromentally accepted way. Remove filter

Replace filter

Remove filter, check for damage

If filter is OK, replace the manometer

Steel core in the hose damaged

Replace hose

Rubber casing punctured

Replace hose

Excessive pressure in the section

Reduce pressure or replace hose with one having approved rating.

Hydraulic cylinder cusions. Air in the section Movements are jerky

Check suction line for the hyd. pump in this section.

Tighten couplings. Replace damaged hoses. Vent the hyd. cylinder by running it to end positions several times.

Low oil level in hyd. tank

Check oil level

Fill oil of recommended quality to correct level

Defective pressure relief valve

Read the manometer for this section

Replace defective relief valve

Control lever spool jerks or Lack of lubrication seizes Dirt in the valve Reset spring damaged Very little or no responce when control lever is activated

Lubricate all moving parts Remove valve spool Remove the valve

Suction cock closed

Inspect and clean the spool Replace the faulty spring Open cock

Suction strainer clogged

Open control hatch on tank

Clean or replace the strainer

Defective hyd. motor or cylinder

Check function of other motors /cylinders in this section

Repair/replace defective component

© 2012 Atlas Copco Craelius AB | 2012-02-10 08 Trouble shooting Explorac 220 RC Ed.0

85

Safety and operating instructions Trouble shooting (General) Fault

Possible cause

Procedure

Remedy

Pressure relief valve defective

Check system pressure in this section

Clean or replace the relief valve

Very little or no responce when control lever is activated (cont.)

Hydraulic pump defective

Check with a pressure flow gauge

Repair or replace the pump.

Hydraulic cylinder moves when lever is in neutral position

Hyd. lock (double check valve) defective

Replace valve

External leakage: hoses nipples or seals

Tighten connections. Replace seals or hoses

Internal leakage in the cylinder

Open cylinder, replace seals.

Trouble shooting (slow feed circuit) Fault Poor or total lack of feed force

Possible cause

Procedure

Remedy

Incorrectly set regulating valves in feed circuit

Read instructions in Operator’s instructions

Defective pressure relief valve in valve block

Check system pressure in this section

Defective servo-circuit in the pump

Check with a pressure/flow Refer to manufacturer’s gauge connected to pump instructions

Mechanical defect in drill mast

Remove inspection hatches

Remedy as necessary

Defective “Down feed” or “Hold back” pressure regulating valve

Dismantle and inspect valve

Clean and repair valve

Heavy internal leakage in the feed cylinder

Run the cylinder to an end position. Open return line and check for leakage

Replace defective seals

Clean or replace relief valve

Trouble shooting (rotation circuit) Fault No rotation or poor torque

Malfunction in the speed control regulator

86

Possible cause

Procedure

Remedy

Defective pressure relief valve in valve block

Dismantle and inspect the valve

Defective hydraulic pump

Check with a pressure/flow Repair/replace defective gauge connected to pump pump section

Defective hydraulic motor

Dismantel and inspect motor

Clean/replace defective components or entire motor

Defective rotation pressure Dismantle and inspect relief valve

Clean/replace defective components or valve

Mechanical defect in rotation gearbox

See separate overhaul & repair instructions for the rotation gearbox

Flow regulator for rotation defective

Dismantle and inspect

Clean / replace defective components

Clean/replace defective components or valve

© 2012 Atlas Copco Craelius AB | 2012-02-10 08 Trouble shooting Explorac 220 RC Ed.0

Safety and operating instructions Trouble shooting (fast feed circuit) Fault Speed insufficient/force low

Possible cause

Procedure

Remedy

Defective pressure relief valve

Check functions of winch, Clean/replace defective rod breaker. If malfunction, components or valve dismantle valve

Defective pump

Check with a pressure/flow Clean/replace defective gauge connected to pump pump section

Heavy internal leakage in the feed cylinder

Run the cylinder to an end position. Open return line and check for leakage

Replace defective seals

Trouble shooting (winch) Fault Winch inoperative, slow speed or little force

Possible cause

Procedure

Remedy

Defective pressure relief valve Defective pressure relief valve

Check functions of fast feed, rod breaker and aux. functions. If malfunction, dismantle valve

Defective pump

Check with a pressure/flow Clean/replace defective gauge connected to pump pump section

Hyd. motor defect

Dismantle and inspect

Mechanical defect

Clean/replace defective components or valve

Clean/replace defective components or entire motor See manufacturer’s instruction

Trouble shooting (break out cylinder) Fault Insufficient force, slow speed

Possible cause

Procedure

Remedy

Defective pressure relief valve

Check functions of fast feed, rod breaker and aux. functions. If malfunction, dismantle valve

Defective pump

Check with a pressure/flow Clean/replace defective gauge connected to pump pump section

Heavy internal leakage in the feed cylinder

Run the cylinder to an end position. Open return line and check for leakage

© 2012 Atlas Copco Craelius AB | 2012-02-10 08 Trouble shooting Explorac 220 RC Ed.0

Clean/replace defective components or valve

Replace defective seals

87

Safety and operating instructions Trouble shooting (cylinders for mast raising and longitudinal shift) Fault Cylinder moves slowly or not at all.

Possible cause Control lever “Aux. functions” not activated

Procedure

Remedy

Check

Activate

Pressure relief valve in the Check functions of jacks, valve bank defective. elevation, DCT etc in the same sector. In case of malfunction, dismantle valve

Clean/replace defective component or entire valve

Defective hyd. pump

Check with a pressure/flow Clean/replace defective gauge connected to pump pump section

Heavy internal leakage in the cylinder

Run the cylinder to an end position. Open return line and check for leakage

Replace defective seals

Trouble shooting (hydraulic jack cylinders) Fault Cylinders move slowly or not at all

Cylinder function extremely slow

88

Possible cause Control lever "Aux. functions" not activated

Procedure

Remedy

Check

Activate

Pressure relief valve in the Check functions of jacks, valve bank defective elevation DCT etc. in the same sector. In case of malfunction, dismantle valve

Clean/replace defective component or entire valve

Heavy internal leakage in the feed cylinder

Run the cylinder to an end position. Open return line and check for leakage

Replace defective seals

Hyd. lock (double check valve) defective

Dismantle and inspect

Clean/replace

External leakage; hoses, nipples or seals

Check for oil leaks

Tighten, replace

© 2012 Atlas Copco Craelius AB | 2012-02-10 08 Trouble shooting Explorac 220 RC Ed.0

Safety and operating instructions

Disposal and environmental instructions Always follow the local regulations in force for the handling and disposal of waste.

Oil and Grease Leaking hydraulic connections and lubrication grease are environmentally hazardous. Changing oils, replacing hydraulic hoses and different types of filter can be environmentally hazardous. ♦ Always collect oil residue, oil spillage, waste with oil content, and lubrication grease residue and spillage. Treat in accordance with local regulations. ♦ Use biodegradable hydraulic fluids and lubrication oils for Atlas Copco products wherever possible. Contact your local Atlas Copco office for further information.

Engine Engine exhausts are poisonous and environmentally hazardous. ♦ Good ventilation is essential when the diesel engine is running. ♦ Well-maintained air filters help to keep down emission levels.

Fuel Fuel spillage is environmentally hazardous and a fire risk.

Chemicals Chemicals such as flushing additives, other additives and coolants can be environmentally hazardous. ♦ Dispose of chemicals such as drilling additives, other additives, glycol etc. according to the manufacturer’s instructions. ♦ Treat in accordance with local regulations for both handling and waste disposal. ♦ Avoid the use of leaning agents containing solvents like carbon tetrachloride. There are environmentally better alternatives now available on the market.

Dust Rock dust can pose a health danger. ♦ Use dust binding oil.

Metals (steel, aluminum, etc.) ♦ These products are recyclable and should be taken care of according to national regulations.

Plastics and rubber ♦ These products are often labeled according to different classes. In those cases they are recyclable and should be taken care of according to national regulations.

Material Safety Data Sheets (MSDS/ SDS)

♦ Always collect fuel residue and spillage. Treat in accordance with local regulations.

Material Safety Data Sheets (MSDS/SDS) for the chemical products included in the delivery are available at the:

Batteries

Atlas Copco Safety Data Sheets Repository

Batteries contain acids and heavy metals. For this reason, expended batteries can be hazardous to the environment and to health.

Full link

♦ Expended batteries must be sent for destruction in accordance with local regulations.

http://www-1.atlascopco.com/__C125712A0045C780. nsf/CustViewProd20?OpenView

Electrical components

Please download the specifications from this link.

Some electronic components contain batteries and other components which could be hazardous to the environment and personal health. Certain types of work lighting contain mercury and could therefore constitute environmental and health hazards. ♦ Treat according to local regulations in force for destruction and waste disposal.

© 2012 Atlas Copco Craelius AB | 2012-05-15 09 Disposal Ed.0

89

Safety and operating instructions

Technical specifications Measurements and weights truck version

Explorac 220 RC Truck Weight (kg) Drill rig

22 000

Carrier

11 000

Total

33 000

Dimension (mm)

12 400 x 4 350 x 2 500 (length x height x width)

90

© 2012 Atlas Copco Craelius AB | 2012-02-10 11 Technical Specifications Explorac 220 RC Ed.0

Safety and operating instructions

Measurements and weights crawler version

3200

4500

11200

Explorac 220 RC Crawler Weight (kg) Drill rig

22 000

Carrier

10 700

Total

32 700

Dimension (mm)

11 200 x 4500 x 3200 (length x height x width)

© 2012 Atlas Copco Craelius AB | 2012-02-10 11 Technical Specifications Explorac 220 RC Ed.0

91

Safety and operating instructions

Mast

Pipe rack

 Feed beam with hydraulic rams

Holds 15 pipes OD 4½”, length 20 ft

 Guide chain for hyd. hoses  Mast dump

Hydraulic jacks

Angle drilling vertical to

45 º

Total length, incl. jib boom

10 520 mm

Front

Two hyd, jacks ext. 1 200 mm

Rear

Two hyd. jacks ext. 1 200 mm

Feed system Pullback

220 kN

Feed force (restricted)

75 kN

Travel length

7 680 mm

Drilling speed, max

2,4 m/min

Fast travel down, max

34 m/min

Fast travel lift

44 m/min

Cooler system V-cooler with twin 900 mm fans, computer controlled speed Ambient temp to + 50 ºC

Cyclone RC Capacity: 850 l/s or 1 800 ft3/m

Rotation unit Single reduction gearbox fitted with two 630 cm3 hydraulic geroler motors.

On-board compressor XRX 12

 Spindel adaptor thread

Atlas Copco two stage screw compressor

4½” IF

 Integrated RC swivel for air and sample with blow down valve r/min

Torque (Nm) at 240 bar, 240 l/min

Serie

0-101

7 000

Parallell

0-50

14 000

Slips and breakout

Capacity free air delivery FAD

570 l/s at 24 bar

Capacity free air delivery FAD

510 l/s at 30 bar

Pressure max.

30 bar

Line oiler Electrically activated line oiler

4 speed

Capacity adjustable

from 0,4 to 2 l/h

 TRC slipstable max. opening 12 in. 305mm  Hydraulically activated slips with integrated holding clamp  Hydraulically operated sliding key  Hydraulically operated handsfree breakout system

Foam pump Hydraulically direct driven 2 cylinder reciprocating foam/water pump with control valves, suction- and delivery hose Rated capacity

Tool handling hoisting winch BW 1500 Cable rope

10 mm x 30 m

Pull on first layer

15 kN

Speed on first layer

40 m/min

Includes automatic brake and shut-off for minimum rope on drum winchboom is mounted on slewing ring providing reach from drilling centerline to rod rack (approx. 180 º). 92

75 l/min at 90 bar max. 3 m suction lift

Power pack Cat 4-stroke watercooled, twin turbocharged aftercooled, diesel engine Model

CAT C-18 ACERT ATAAC

Power rating

522 kW @ 1 800-2 100 r/min

© 2012 Atlas Copco Craelius AB | 2012-02-10 11 Technical Specifications Explorac 220 RC Ed.0

Safety and operating instructions Torque

2 769 Nm at 1 800 r/min

Control system

Fuel consumption

219.4 g/kWh @ 1 800 r/ min (approx. 136.5 l/h at full load)

RCS system (Rigg Control System)

Cylinders

6, in line

Bore / Stroke

145 / 183 mm

Displacement

18.1 l

Electrical system

24V

Weight

1332 kg

 Forwards information given through Operator's panel instructions to rig components

Capacity

900 litres

 CAN technology (Controller Area Network)

Fuel tank located under deck on right hand side

 Compares important parameters against preset values.  Report rig performance data to Operator's control panel.

 Separate 24 V DC support system  I/O modules (Input/Output)

Hydraulic system Hydraulic pump, Rotation Parker and fast feed PV180L1L1T1NFFP

Radio Remote Control for crawler rig only

Hydraulic pump Aux. function

Parker PV080L1L1T1NFFP

Supply voltage

10-30 V DC

Power consumption

Max 10 W

Hydraulic pump Slow feed

Parker PV046L1L1T1NMFC

Serial interfaces

CANopen, Profibus-DP, RS485, DeviceNet

Valve block Rotation (remote control)

Rexroth Type M4-15

Operating temp. range

-25 ºC - 70 ºC (-13 ºF 158 ºF)

Valve block Winch, Waterpump

Rexroth Type NG6

Valve block Aux.(remo te control)

Rexroth Type M4-12

Valve block Slow feed (remote control)

Rexroth Type NG6

Valve block Set up (direct Parker Series P70 operated) Tank, with breather and electrical filling pump

400 litres

Electrical system 24 V Starter motor

24 V

Alternator

28 V, 60 A

Batteries starter

2 pcs (B1, B2), each: 12 V, 206 Ah

Batteries control system

2 pcs (B2, B3), each: 12 V, 60 Ah

© 2012 Atlas Copco Craelius AB | 2012-02-10 11 Technical Specifications Explorac 220 RC Ed.0

93

www.atlascopco.com

6991 5073 01b

Märsta, Sweden, 15 May 2012

© Copyright 2012, Atlas Copco Craelius AB Märsta, 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. Illustrations and photos in this document may show equipment with optional extras. Specifications and equipment subjects to change without notice. Consult your Atlas Copco Customer Center for specific information.