ROC L6 L8 SystemDescriptionBosal

ROC L7 40, L7 40CR, L830, L630 with Bosal cabin

Subject

Content

Tab

ROC L

Hydraulics, general

1

Electrics, general

2

Operating

3

CAN general

4

Diesel engine Pumps & pilot pressure; Cooling fans

5 6

Tramming; Positioning

7

Compressor

8

Pre-heating

9

Feed

10

Rotation

11

Rapid feed; Rod coupling

12

Impact & Flushing air; ECL/HECL

13

Damper

14

DCT

15

Protective functions

16

Length measurement

17

RHS 102; RHS 140

18

Options; Adjustments/calibration

19

PLC descriptions

20

Hydraulic diagrams with number indication Electrial & pneumatical diagrams

Training program in SWEDEN for SC Technicians

ROC L740, L740CR, L830

5 days

COURSE DESCRIPTION: .........................................................................................................................................1 01 BASIC: ROC L740, L740CR, L830[MONDAY] ...................................................................................................2

1. 2. 3. 4. 5. 6. 7. 8.

INTRODUCTION...............................................................................................................................................2 INTRODUCTION OF SDE.................................................................................................................................2 GENERAL ELECTRIC.......................................................................................................................................2 GENERAL HYDRAULIC....................................................................................................................................2 COMPONENTS.................................................................................................................................................2 CAN BUS........................................................................................................................................................2 DISPLAY..........................................................................................................................................................2 PLC.................................................................................................................................................................2

02 SYSTEMS: ROC L7 40, L740CR, L830 [TUESDAY, WEDNESDAY]...............................................................3

9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. 20. 21.

OPERATING.....................................................................................................................................................3 START ENGINE................................................................................................................................................3 ENGINE SPEED CONTROL................................................................................................................................3 PILOT PRESSURE.............................................................................................................................................3 PUMPS.............................................................................................................................................................3 TRAMMING.....................................................................................................................................................3 POSITIONING...................................................................................................................................................3 COMPRESSOR..................................................................................................................................................3 DRILLING PRINCIPLE......................................................................................................................................3 FEED & RAPID FEED .......................................................................................................................................3 ROTATION & THREADING..............................................................................................................................3 IMPACT & FLUSHING AIR ...............................................................................................................................3 ECL, HECL, ECG .........................................................................................................................................3

03 SYSTEMS: ROC L7 40, L740CR, L830[THURSDAY] ........................................................................................4

22. 23. 24. 25. 26. 27. 28. 29. 30. 31. 32. 33. 34.

DAMPER & DPCI ...........................................................................................................................................4 DCT................................................................................................................................................................4 RPC-F TH........................................................................................................................................................4 ANTI-JAMMING...............................................................................................................................................4 LENGTH MEASUREMENT................................................................................................................................4 RHS TH..........................................................................................................................................................4 RHS CR/DTH................................................................................................................................................4 ANGLE INSTRUMENT......................................................................................................................................4 OPTIONS..........................................................................................................................................................4 SAFETY ...........................................................................................................................................................4 MAINTENANCE...............................................................................................................................................4 ACTIV IEW.......................................................................................................................................................4 END TEST........................................................................................................................................................4

04 ROCK DRILL: ROC L740, L740CR, L830[FRIDAY] ........................................................................................4

35. 36. 37.

ROCK DRILL....................................................................................................................................................4 EVALUATION..................................................................................................................................................4 PRACTICAL DRILLING(IF RIG IS AVAILABLE)................................................................................................4

Course description: After having completed this training the participants shall:

Target

- Understand the basic theories behind Atlas Copco’s HCS system on L-Mk2. - Understand function and design of the HCS system on the rig. - Understand the basic theories behind Atlas Copco’s HEC 3 system. - Understand function and design of the HEC 3 system on the rig. - The participants shall also be able to carry out fault-finding, with the f ault-finding aids provided. Atlas Copco Service Personnel

Target group Time Training

5 days Lessons led by a teacher and self studies of theoretical parts mixed with practical exercises on the rig.

G:\Training\01 SDE Courses\06 ROC L\ROC LMk2 Content v1.doc 07-11-28 16:15

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L7 , L7 CR

Hydraulic system, general

Hydraulic system, general General – L740, L740CR The hydraulic system of the ROC L740 and L740CR is an electrical and pilot pressure controlled system, with 6 hydraulic pumps. Hydraulic pumps 1, 2, 3 and 4 are in-line assembled and direct driven by the diesel engine over a flexible coupling. The hydraulic pumps 5 and 6 are combined to a double pump with a common suction line. They are driven by the diesel engines extra power-take-off. The pressure on these pumps is regulated with fixed or variable pressure relief valves. Pump 1 is an axial piston pump with variable displacement. During drilling pump 1 is regulated by the pressure relief valves for high/low percussion. During tramming pump 1 is connected to two flow sharing compensated directional control valves. The pump pressure is controlled by whichever load there is on the tramming motors.

9

Electrical valves: Drilling

Impact

Logic Valves Drill feed

RPCF

Tramming control via PLC

Main valve block Traction left

Rapid feed

Traction right

Rotation Preheating

Pressure Control Panel & Gauges

Extra oil only when drilling

Rod Handling

Dust Collector Extra oil to rotation Postioning during tramming

Postioning during drilling

Cooler motor Compressor/Hydraulic oil Cooler motor Engine water/ATAC 1

2

3

4

5

6

3

L8

Hydraulic system, general

General – L830 30

The hydraulic system of the ROC L8 is an electrical and pilot pressure controlled system, with 6 hydraulic pumps. Hydraulic pumps 1, 2, 3 and 4 are in-line assembled and direct driven by the diesel engine over a flexible coupling. The hydraulic pumps 5 and 6 are combined to a double pump with a common suction line. They are driven by the diesel engines extra power-take-off. The pressure on these pumps is regulated with fixed or variable pressure relief valves. Pump 1 is an axial piston pump with variable displacement. During drilling pump 1 operates on constant pressure. During tramming pump 1 is connected to two flow sharing compensated directional control valves. The pump pressure is controlled by whichever load there is on the tramming motors.

9

Electrical valves: Drilling

Logic Valves

Tramming control via PLC

Main valve block Drill feed

Traction left

Rapid feed

Traction right

Rotation Preheating

Pressure Control Panel & Gauges

Extra oil only when drilling

Rod handling

Dust Collector Extra oil to rotation Postioning during tramming

Postioning during drilling

Cooler motor Compressor/Hydraulic oil Cooler motor Engine water/ATAC 1

2

3

4

5

6

4

Hydraulic system, general

Hydraulic pumps

L740

L7 CR, L8

Figure: Test connections for checking the hydraulic circuits.

Pump 1 The main pump 1 in the hydraulic system is an axial piston pump. The pump supplies hydraulic power to the following functions: 40

L7 • • • • • • • • • • •

Rock drill impact Rock drill feed Rock drill damper Rock drill stroke position Positioning Rod handling Tramming Pilot pressure Hydraulic jack Service winch Track oscillation

40

L7 CR Rock drill impact • • Rock drill feed Rock drill damper • Rock drill stroke position • Positioning • Rod handling • Tramming • Pilot pressure • Hydraulic jack • Service winch • Track oscillation •

30

L8 • • • • • • • •

Rock drill feed Positioning Rod handling Tramming Pilot pressure Hydraulic jack Service winch Track oscillation

Pump 2, 3 and 4 These gear pumps are combined to a triple pump unit. Pump 2 supplies oil to the rotation unit, but is also used for pre-heating of hydraulic oil and rock-drill impact components (only in L740 & L740CR). Pump 3 supplies oil to the dust collector suction fan motor. Pump 4 supplies oil to the positioning during tramming, also additional oil to the rotation motor when drilling. Pump 5 and 6 Pump 5 drives the cooler motor for the combined hydraulic oil/compressor oil cooler, also used for enabling the floating mode in track oscillation. Pump 6 drives the cooler motor for engine radiator and intercooler.

5

Hydraulic system, general

Pump capacities Rig type Rpm Pump Pump Pump Pump Pump

1 2 3 4 5

Pump 6

40

40

30

L7

L7 CR

L8

@ 2000 rpm engine speed Flow(l/min) P (bar, max.) 275 250 115 170 65 170 35 250 30/*45 210/*225

@ 2000 rpm engine speed Flow(l/min) P (bar, max.) 260 250 115 170 65 170 35 250 30/*45 190/*225

@ 1800 rpm engine speed Flow(l/min) P (bar, max.) 235 250 110 170 65 170 40 250 32/*45 190/*225

30/*45

30/*45

32/*45

210/*225

190/*225

*Higher figure refer to the 55 °C ambient temperature option.

190/*225

Pilot pressure The pilot pressure signals from the drill lever are transferred to the main valve block and to the pressure control panel via logic valves. The pressure gauge panel shows the impact pressure, feed pressure and rotation pressure in the main valve block. The pressure control 40 panel controls the working pressure of pump 1 (only in L7 & L740CR), feed and the rotation functions in the main valve block. The gauges & panel are located in the cab for easy use. The tramming controls are mounted close to the operator’s seat, and control the main tramming valves proportionally.

Return oil and oil cooler The hydraulic oil tank has a capacity of 410 litres, which means there is often a “stock” of

oil in the tank. There are two filter oilfilter from that the return-/drain oil system. filtersthat returnand drain circuits and oil used to fill the There is the alsohydraulic a breather prevents contaminated air entering the tank when the level of hydraulic oil fluctuates. The thermostats ensure that the oil flows through the oil cooler when the temperature is above 40ºC and directly to the tank when the temperature is below 40ºC. The by-pass valve protects the oil cooler from exposing to high pressure. The oil cooler cools the hydraulic oil so that the rig can work at full load in ambient temperatures up to 55°C (optional). The cooling fan is driven by a fan motor that is supplied with oil by pump 5. The pressure to the fan motor is controlled by a proportional pressure relief valve. The control system regulates the pressure, and thereby the fan speed depending on the cooling demands.

T-Return oil is a collection block that collects return oil from the various circuits and leads this to the thermostats. D-Drain oil is a collection block that collects oil from the various circuits and leads this to the return oil filter. L-Leakage oil is the oil that goes directly to tank for minimum resistance in the circuits. The filler pump is used to fill the system. There is acheck valve that prevents return oil from leaking out through the filler pump. A level sensor (B143) detects the level of hydraulic oil in the tank. Should this drop below a certain level, the diesel engine is switched off automatically. The sensor signal from B143 goes via PLC input X11-8.

6

Hydraulic system, general The temperature sensor (B362) senses the hydraulic oil temperature and the temperature will be shown on the display. The engine will shut down automatically if the hydraulic oil temperature exceeds 90ºC. The sensor signal fromB362 goes via PLC input X16-5. The drain cock is used to remove water of condensation or to empty the hydraulic oil tank.

7

Hydraulic system L7TH, CR

1

Hydraulic system L8

2

1

Electrical system, general

Electrical system, general General ROC L740, L740CR, L830 are equipped with a 24-volt electrical system for monitoring and fault indication, electric power is also used for controlling a number of hydraulic and pneumatic valves. The composition of the electrical system is illustrated in the block diagram.

Battery charging Power supply to the electrical system consists of two, serie-connected 12 volt / 185 Ah batteries. These are charged by a 3-phase A/C alternator. The batteries are connected to the system by a manually operated battery switch.

Main fuse The feed to the electrical cabinet is fused by a 63 A main fuse (F100).

Electrical cabinet The electrical cabinet A1 contains 34 ATO fuses (when all options are included) that limit the current intensity to the different sub-circuits, two auxiliary relays (K18, K178) to handle large currents above 4 Amp, stop relay for the emergency stop circuit (K11), remote shutdown relay (K200), start relay (K5A), main fuse and a PLC (CPU1-3).

ECM (Caterpillar) Electronic Control Module is used for monitoring the engine’s functions and sensors. It receives analogue and digital information fromthe thediesel engine. The automatically information is ifprocessed transferred in J1939 protocol. The ECM stops engine a specificand fault occurs. A specific fault is for example low oil pressure which could cause major damage to the engine.

8

Electrical system, general

Electrical supply Start engine

M1 starter motor

ECM

One of the conditions to activate K5A

K5A t i u c ir c

PLC outputs & relays

Start position

0 5

CAN nodes D550, 551, 552, 553, 554 E-stops

K11

15 circuit

Ignition position

PLC t i u c ir c

processor & sensor inputs

5 2

Radio, cabin lights, utility light

Main switch ON Timer, diesel heater Alternator

Batteries

9

Electrical system, general The power source consists of two 12V/185Ah batteries connected in series and an alternator. Before the main switch is switched on, there is power to t he diesel fire heater & timer. When the main switch is switched on, there is power supply to the radio, cabin lights, utility lights and ECM (48,52,53) thorough teminals 10 and 25. Power is also supplied to the starter motor switch, but the switch is triggered by the starter motor relay via PLC. When the key is in the ignition position power is supplied to the emergency stop circuit, CAN nodes, display, PLC processor and its sensor inputs through terminal 15. If the emergency stops are intact, relay K11 is activated. Power is now supplied to t he ECM (70), PLC outputs and relays, working lights/wiper, seat heating and the climate system in the cabin through terminal 50. When the key is in the start position the diesel engine is started via starter motor M1, and starter motor is powered by relay K5A. K5A is activated if the conditions for starter motor are fulfilled. ECM is supplied with power both before and after ignition. The difference is, before ignition, ECM is powered to boot its memory, but its monitoring functions are not started at this level. Only after the key is in the ignition position, ECM starts working properly. If any of the emergency stops is activated, it will deactivate switchK11, causing all the functions at the ignition level except the CAN nodes, display and CPU processor & sensor inputs to be without power, since they are connected parallel with the emergency stop circuit. Turn the key back to 0 position before re-start. Note: The electrical system’s ground cables are not isolated by the main switch. This means that the system consumes a small current even when no functions are activated.

10

Electrical system, overview Start motor

Batteries

Ignition key

MAIN ELECTRICAL CABINET Engine stop

Main battery switch

M12-boxes

CPU 1-3

Sensor Compressor

Sensor Hyd. oil level

Sensor Hyd. oil temp

Sensor Air filters

Sensors Diesel engine Main fuse

ATO-fuses

ECM Cat Electronic Control Module

Cabin modules

Sensors Rod handling

Drilling panel (left) Drill lever Switches Dust collector

Drill steel support

Switches Tramming

Joy-stick Rod handling

Inputs

Drilling panel (right)

PLC Programmable logic control

Switches

Switches Tramming

Engine speed

Track oscillation

Outputs Break out

Flush air

table Suction hood

Compressor load

Hyd. valves Rod handling

2

Hyd. valves Feed

Hyd. valves Anti-jamming

Air valves Impact/Fl. air

Dust collector

Pre-heating

ECL&(HECL) Pumps

Terminal 50 Refer to page 6 coordinates 3E Electrical cabinet X1

3

See page 7

3

Contact

From previous page: coordinates 3E, page 6

4

Distribution box X36, Contact 7, signal 2 (S2)

Indicator card no.

1 Terminal 8

2

5

1

2

6

Electrical cabinet

7

Overview – rig right side

14

Overview – rig left side

15

Operating

Cabin heat and AC

1. Working lightscab, front 2. Working lightsrig, rear 3. Working lightsfeeder 4. Lightingengine c ompartment 5. Windscreen washer, upper 6. Windscreen wiper, upper increases speed in steps. 7. Windscreen wiper, upper reduces speed in steps. Switch off by depressing and holding the button for 2 seconds. 8. Front windscreen washers 9. Windscreen wiper, front reduces speed in steps. Switch off by depressing and holding the button for 2 seconds. 10. Windscreen wiper, front increases speed in steps. 11. Windscreen wiper, right reduces speed in steps. Switch off by depressing and holding the button for 2 seconds. 12. Windscreen wiper, right increases speed in steps. 13. Windscreen washer, right 14. Seat heatingin two steps 15. Air condition 16. Fan, air conditioning reduces speed in steps. 17. Fan, air conditioning increases speed in steps. 18. Temperaturereduces the temperature. 19. Temperatureincreases the temperature. 20. Fan, heaterincreases speed in steps. 21. Fan, heaterreduces speed in steps. 22. Not used 23. Not used

1

Operating

ROC L740

2

1

Operating

ROC L740CR

3

Operating

ROC L830

Not used

4

2

Operating

Drill control panel

S139 Ignition key S130 Switch for drilling/tramming/oil heating S170 Not used on ROC L S448 Water mist. S209 Support leg. S186 Signal horn S449 Thread greasing. S176 Track oscillation, (left). S445 Track oscillation (locking). S177 Track oscillation, (right). S180 Compressor. S189 Rpm control (variable). S130 a: Drilling b: Tramming low speed c: Tramming high speed d: Oil pre-heating.

5

Operating

6

3

Operating

7

Operating

8

4

Operating

1. Drill feed pressure 2. Flushing air pressure 3. Rock drill lubrication pressure, ECL(L7), HECL (L6, L8) 4. Return pressure filter 5. Rotation pressure 6. Percussion pressure 7. Damper pressure

9

Operating

10

5

CAN, general

CAN, general This is an overview of the CAN communication network. If communication is down in any of the units, the unit will show in red, and a warning for communication breakdown will be shown on the status bar.

CAN There are various types of control modules (PLC, ECM, main display, CAN nodes etc.). Common to all of these is that they each contain a separate processor. The modules communicate with each other over a CAN bus. The CAN bus uses serial communication. One piece of data at a time is sent over the bus until all the data has been transmitted. This is a simple method that requires only 4 conductors (CAN+, CAN-, CAN high, CAN low) and a screen. The CAN network is supplied with 24 V, and the CAN high / low signal lies at approximately 2.6 V and 2.4 V respectively.

Display D501 All CAN data is handled by the display shown graphically or digitally. The program for the HEC (Hole/Engine Control) system is stored in the display and the software is downloaded via a PC or a USB-flash drive (see installation instructions in a separate section). The display shows engine data, angle/hole information and the status of switches/sensors, etc. CPU2 receives the information sent from ECM inJ1939 protocol and translates this to CANopen protocol, which is then shown on the display. Other information is sent directly from the CPUs, CAN nodes, D169 module and D171 module to the display by using CANopen protocol.

PLC The PLC system consists of three CPU units (CPU1, CPU2, CPU3). They are each programmed to handle certain inputs and outputs together with inputs from CAN nodes, and for some functions inputs from the HEC software is required. There is a led installed on each CPU unit, a green blinking signal at 2 Hz indicates the CPU is working normally; a green blinking signal at 5 Hz indicates no operating system is loaded; a green stable signal indicates a PLC stop. If the led appears to be red or yellow, then the CPU is experiencing error, contact the factory in this case. And if the led does not light at all, check the power supply. All the direct PLC input/output signals are connected to the PLC via 9 indication cards (marked X10-X18), the led on the indication cards will light in red if the corresponding input/output is being activated.

11

CAN, general

CAN nodes The CAN nodes (D550, D551, D552, D553, D554) translate all the input signals for all the switches located on the operating panels; also the output signals for all the leds and magnets located in the drill lever, so the modules can communicate in CAN “high”/“low” signals directly. Every input/output on the CAN nodes each has its own led. The led will light in constant yellow when their corresponding input/output is activated. There are also two CAN communication leds on every CAN node, one lights in green and the other one lights in red. A green stable signal indicates the CAN node is in its preoperational mode; a green blinking signal indicates that the CAN node is in operation, but both signals can not indicate whether the CAN node is correctly installed to match the CAN Node ID number shown in the display. The CAN node ID number has to be set manually on the module when installed. When a communication fault occurs during operation, the red led will be activated.

ECM CAT’s engine control module that controls engine operation.

D169/D171/D173 Module D169 module is a CAN-based aiming device that communicates with the display directly. D171 module is a CAN-based angle sensor that communicates with the display directly. D173 module (option) is a CAN-based GPS compass that communicates with the display directly.

Terminal plug At the start and end of the CAN network there are terminal plugs installed. A terminal plug consists of a resistor (120 Ω) which terminates the network’s both ends in the correct way so that the signal does not “bounce back to the system”. There are 4 terminal plugs installed in the CAN network (see figure below).

12

CAN, general

CAN system overview X5 X6 X7 RIG CONTROL SYSTEM

F1

X2

F2

D501

F3

X1 it u c ir c 5 1

F4 ESC

End plug

X4

X3

D554

D169 D173 option

Ignition

D552 D171

D553 i t u c ir c

End plug

5 1

D551

CAN +/CAN H/L J1939

D550 F23

CPU3

To PLC processor & input sensors

End plug CPU2

ECM

CPU1

End plug

13

CAN, general

Sensor/switch monitoring system The CAN system can present switch and sensor status on the display screen. The analogue sensors are connected via the CPUs, except potentiometer R189 (adjusting engine revolution) is connected via the CAN node and the coolant water level sensor B361 is connected directly to the ECM, though sensor B361 is powered from external power source (M12 box X34:8). The digital (ON/OFF) switches are connected via the CAN nodes, and the digital sensors are connected via the CPUs, except sensor B379 (operator in chair) is connected via CAN node. By selecting a module with the curse on the screen, and press the enter button, status of each module could be checked (in the event of a red module).





By selecting in/outputs for the CPUs or the CAN nodes modules on the screen, status for all inputs and outputs could be checked in the system. An actuated function is displayed as “1” while and un-actuated function is displayed as “0”. Note that for an input, “0” or “1” is the status that is received by the CPUs; while “0” and “1” for an output is the signal sent from the CPUs. I.e. there is not any confirmation that the signal actually is received by the valve, etc. Broken cables are not noticed by the system.

14

Control panel

Control panel The control panel is comprised of a touch panel user interface and a power board for function actuation. Before ignition, the power board is powered with 24 V via fuse F25, the button for light in engine compartment and the indication lamp for battery start to blink in green. After ignition, the power board is powered with 24 V via fuses F4, F5 and F10, and the power board is lit up in white. A CAN cable is used as the communication media between the power board to the touch panel; also used to power up the touch panel. This CAN network exists as a separate circuit, aside from the CAN network mentioned in the chapter before.

15

Diesel engine

Diesel engine The engine on ROC L740, L740CR is a turbocharged, water cooled C13 diesel engine from Caterpillar. Rated power at 2000 rpm is 328 kW. The engine on L830 is a t urbocharged, water cooled C15 diesel engine from Caterpillar. Rated power at 2000 rpm is 402 kW.

Battery switch, OFF The diesel fire heater and the timer are connected before the battery switch S300 via fuses F02 and F03. The generator G2 (B+) is connected directly to the batteries.

Battery switch, ON When the battery switch S300 is switched on there is 24V to: Utility lights in engine compartment, cabin • lights, instrumental lights, radio and cell phone outlets via fuse F25, F26 in A1 cabinet. ECM is also powered via fuseF25, but the • communication between ECM and rest of S300 the system has not yet started.

ON

OFF

ROC

S300

Ignition position When the ignition key S139 is in the ignition position the contacts 30-15 and 30-75 are closed. Thethat ignition relayK11 stops is activated and the relay contacts are closed under the conditions the emergency are intact. Before the K11 relay contacts are closed, the display and the emergency stop circuit are supplied with voltage via fuseF25. PLC processor and sensor inputs are supplied with voltage via fuse F14; CAN nodes are supplied with voltage via fuseF23. When the K11 relay contacts are closed, the ECM is supplied with voltage via fuseF13, ECM is now functional. PLC outputs and relays are supplied with voltagevia F15-F22.



The above figures show the display transition during ignition, several symbols for the rig functions can be lit (only the symbol for communication breakdown is shown here in the above example) for a few seconds before going off since the ECM has been waiting to be booted.

16

Diesel engine

Start position Conditions for activation of starter motor: Emergency stops S132A and S132B not activated => PLC input X10-8/ON • Fuses F100, F3, F13, F14, F15, F23 are intact. • S130 in tramming mode => D552-CH2 or CH3/ON • Compressor switch S180 OFF => D552-CH9/OFF • Ignition key S139 in start position => D550-CH4/ON • Only for L830: Start preventing pressure sensor B336 OFF => PLC input X13-4/OFF • When all the above conditions are met, this will result in: Start relay K5A is activated and the re lay contact is closed, hence activating starter motor M1, • i.e. engine is cranking. Conditions for starting the diesel engine: Compressor temperature B366 < 120°C (~17.5mA). • Hydraulic oil level sensorB143 activated, which indicates the oil level is normal. • Hydraulic oil temperature B362 < 90°C (~15mA). • If the conditions above are fulfilled: • K200 activated, enables engine start. When the ignition key S139 is turned to the start position and the engine fails to start, check which symbol(s) are displayed and rectify the fault. Turn the key back to position 0 before trying again.

ECM overview ECM is functional when the battery is switched (1) and the ignition key is position (2). To start the diesel engine, K200 has to be activated (3) so ECM 44 is not grounded (refer to page 15 for more information on automatic engine shut-down), and the Caterpillar sensors (4) must be working normally.

PLC

Remote shut down

Ignition key switched

S139

Loss of condition 3 and 4 automatically shuts down the engine. Activation of emergency stop shuts down the engine, ECM, PLC, CAN nodes, working

K200

e-stop

2

3

(ECM 44)

key

ECM Battery ON

1

lights/wiper, seat heating and the climate system, but the display is still working. Manually switching off the ignition key shuts down all the above mentioned functions including the display.

4

S300 CAT sensors

Batteries

To cut off ECM power supply completely, dis-engage the battery switch S300.

17

Diesel engine

Engine speed The engine speed can be de- or increased by flicking switchS189 up- or downwards. Digital signal is sent directly into the CAN node D554, then to CPU2 through CAN open protocol, and at last sent to the ECM through J1939 protocol.

b a

CPU2 can support 7 engine revolutions, and it can store 3 separate engine speeds, one for tramming, one for rod handling and one for drilling. CPU2 remembers the engine speeds for rod handing and drilling even when the battery switch is turned off. In tramming mode the system will always start at 1200 rpm. The speeds can all be set individually within the range specified below.

c d

a b c

Condition for revolution between 1200-2000 Tramming mode Switch S130 NOT in drilling position Condition for revolution between 1500-2000 RHS mode Switch S130 in drilling position and reduced flushing air NOT activated (Y116/OFF) Condition for revolution between 1700-2000 Drill mode Switch S130 in drilling position and reduced flushing air activated (Y116/ON) The engine starts on idling speed 1200 rpm, flicking the switch once upwards should increase the speed to 1500 rpm, then the engine speed increases with 100 rpm per flick upwards until it reaches the maximum speed 2000 rpm. It is also possiblethe to hold thespeed switch for the several seconds in order to reach the of maximum speed. To decrease engine from idling speed, flick the switch once downwards takes down the speed step by step just like upwards. When changing from tramming position to drilling, the engine speed automatically increases to engine speed set for drilling and vice versa.

18

Diesel engine

Control instrumentation The ECM controls and monitors all engine data and diagnostic information from the diesel engine. This information is sent via CPU2 to the display, where all the necessary engine information is presented. CPU2 also translates the information from J1939 to CAN open so it can be presented on the display. Signals from the rig sensors are sent via the CPUs directly to the display, where information can be viewed. (See figure) A red warning lamp on the status bar means that the problem is critical, and the engine will be shut automatically. A yellow warning lamp means the engine needs to be switched off manually, and the fault needs to be checked and rectified. Refer to “Switches and sensors that automatically and manually stop the diesel engine” for a list of sensors that automatically and manually shut down the engine. Status bar

Engine monitoring A number of sensors and switches on the engine do not generate warnings on the status bar in the event of a fault. A direct code system has been introduced, this allows you to go directly to the CAT fault diagnosis table to interpret the codes. The table will only present information when a fault arises. The ECM or the engine sensor symbol on the status bars indicates that a fault has been detected. This can be found in the menu for ECM sensors. The fault is displayed as a 3 digit SPN code and 2 digit FMI code. (See figure)

Ex: SPN code 164. According to the CAT manual, 164 is the injection actuator pressure sensor. The SPN code indicates the faulty component . FMI code 02. According to the CAT manual, 02 means that the sensor does not have a signal. The FMI code indicates the nature of the problem . Note: The CAT fault diagnosis table will only show faults t hat are related to the motor. That is to say some faults indicated on the status bar can be found in the table, but not all the faults show in the table can be found on the status bar.

19

Diesel engine

Switches and sensors that automatically and manually stop the diesel engine Automatically stopping (or shutting down) the diesel engine does not mean that the whole system also goes off. All functions at the key ignition level are still working. To shut down the whole system including the display, turn the key back to the 0 position.

Manual: • •

Start key (S139) Emergency stop (S132A, S132B)

Automatic: These are indicated by a red lamp on the status bar and switch the engine off automatically. Hydraulic oil level (B143) • The level switch sends a signal to PLC input X11-8 when the level is normal. If the level is below normal, the loss of X11-8 will result in a loss of PLC output X11-3 which is connected to relay K200. ECM 44 gets grounded and shuts down the engine. Hydraulic oil temperature (B362) • The temperature sensor sends a signal to PLC input X16-5. If the temperature has reached 80°C, a yellow warning is shown first, and if the temperature has reached 90°C, this will result in a loss of PLC output X11-3 which is connected to relayK200. ECM 44 gets grounded and shuts down the engine. Compressor temperature (B366) • The temperature sensor sends a signal to PLC input X16-7 and PLC input X16-6 (for DTH rigs). If the temperature has reached 117°C, a yellow warning is shown first, and if the temperature has reached 120°C, this will result in a loss of PLC output X11-3 which is connected to relay K200. ECM 44 gets grounded and shuts down the engine. Engine oil pressure (B353) • The engine oil pressure sensor is part of the Caterpillar system and connected to the ECM. Should abnormal pressure occur, the ECM shuts the engine down and a warning is shown on the status bar. Engine coolant temperature (B354) • The engine coolant temperature sensor is part of the Caterpillar system and connected to ECM. theatcoolant reachto105°C, yellow warning at is 107°C shownthe on ECM the display after 10Should seconds; 106°C temperature the engine starts de-rate aafter 10 seconds; shuts down the engine after 10 seconds and a red warning is shown on the status bar. Coolant water level (B361) • The engine coolant level switch is part of the Caterpillar system and connected to the ECM. Should a low level occur, a yellow warning is shown on the display after 10 seconds; another 10 seconds later the engine starts to de-rate; and 10 more seconds after de-rate the ECM shuts down the engine and a red warning is shown on the status bar.

20

Diesel engine

Switches and sensors that only indicate a fault Compressor air filter (B365) Connected to PLC input X13-8. •

Engine air filter (B360) Connected to PLC input X13-7. •

Fuel temperature The engine fuel temperature sensor is part of the Capterpillar system and connected to the ECM. Should the fuel temperature reach 80°C, a warning is shown on the status bar. •

Battery voltage Should the battery voltage fall below 24 V, a warning is shown on the status bar. •

Air inlet temperature The inlet air temperature sensor is part of the Caterpillar system and connected to the ECM. Should the temperature reach 75°C, a warning is shown on the status bar. •

21

Diesel engine

Warning symbol related to the engine Symbols

AC designation

Description

Yellow sign stage

Red sign stage

B353

Engine oil pressure

Too low pressure

B361

Engine water level

Too low level

B143

Hydraulic oil level

Too low level

B354

Engine coolant temperature

105°C

B366

Compressor temperature

117°C

120°C

B362

Hydraulic oil temperature

80°C

90°C

B360

Engine air filter

Plugged filter

B365

Compressor air filter

Plugged filter

Fuel temperature

80°C

Battery voltage

< 24 V

Air inlet temperature

75°C

22

Main switch OF

1

S300

Main switch ON

2

Cabin control panel Utility light Radio 24 V outlet

Main switch ON

3

+ battery (unswitched)

Main switch ON

4

To D550

K11

Main switch on/25 circuit Key in ignition pos. but before emergency stops/15 circuit Ground connection

5

Key in ignition pos.

To M1

F100

Main switch on/25 circuit Key in ignition pos./50 circuit Ground connection

6

Key in ignition pos.

Main switch on/25 circuit Key in ignition pos./50 circuit Ground connection

7

Key in ignition pos.

+ battery (switched) + battery (unswitched)

Main switch on/25 circuit Key in ignition pos./50 circuit Ground connection

8

Key in ignition pos.

S139

Basic conditions on fuses: Fuses F100, F3, F13, F14, F15, F23 are intact.

S132A

S132B

Main switch on/25 circuit Key in ignition pos. but before emergency stops/15 circuit Key in start pos. Ground connection

9

Starter motor conditions

CH2 or CH3

S130

24V input

Starter motor conditions

10

S180 CH9 OFF

24V input

L830 B336 X13-4 OFF

24V input

11

Starter motor condition

K5

K5 needs to be activated in order to activate cranking.

24V output Ground connection

Starter motor conditions

12

M1

Engine cranking

K5

From F2, page 4

Main switch on/25 circuit Key in ignition pos./50 circuit Ground connection

13

Starter motor conditions

B143 B362

B366A B366B

24V supply Input signal

Engine start conditio

14

K200

K200 gets activated when all the required sensors (B143, B362, B366) are working normally.

24V output Ground connection

Engine started

15

K200

ECM 44 not grounded, enables engine start. Main switch on/25 circuit Key in ignition pos./50 circuit Ground connection

16

Engine started

Pumps & Pilot Pressure

L7 , L7 CR

Pumps & Pilot Pressure Pump 1 – L740, L740CR 40

40

Pump 1 is the main pump in the hydraulic system of ROC L7 , L7 CR. It is an axial piston pump with a variable displacement. The pump is pressure compensated, which means that the pressure is maintained constant irrespective of the flow. The pump pressure can be controlled by either pressure relief valves connected to the control panel when impact is started, or by pressure control valve 4d.

Pressure relief valves in the control panel – L740, L740CR During drilling, pump 1 pressure is controlled by two pressure relief valves (47e & 47f) for high and low impact. These are connected to the pump control system when impact valveY101A is activated. When impact is not switched on, pump 1 operates on constant pressure set by pressure relief valve 4d + the Delta-p preset pressure.

Pressure control valve “4d” – L740, L740CR During tramming, pump 1 is working in load sensing mode, which means that the pump pressure depends on the load on the tramming motors. The maximum pressure of pump 1 can be adjusted by pressure relief valve4d. Drilling mode Tramming mode (constant pressure) (varying pressure) Impact ON Impact OFF Pressure relief valves Pressure control valve Max pressure limited by pressure 47e & 47f control pump 4d + ∆p set pump 1 control valve 4d + ∆p 1 pressure pressure

“P max” valve – L740, L740CR The “P max” valve located on the pump limits the maximum pump output pressure, but this pressure would not be reached since pressure relief valve4d which is set to be lower than “P max”, is there to limit the system pressure. Valve 4d should be used when adjusting the pump 1 working pressure within the system. “P max” is set to be higher than “4d” by factory setting, so it’s usually not necessary to change the setting on “P max”, this way “P max” would not interfere with the LS signal. In order to avoid starting the diesel engine with pump 1 pressurized, the Drilling/Tramming switch must be in the Tramming position when starting. In this position, pump 1 runs at standby pressure, 23 bar. Starting with the switch in Drilling position is also electrically blocked.

23

L8

Pumps & Pilot Pressure

Pump 1 – L830 30

Pump 1 is the main pump in the hydraulic system of ROC L8 . It is an axial piston pump with a variable displacement. The pump is pressure compensated, which means that the pressure is maintained constant irrespective of the flow. The pump pressure can be controlled by pressure control valve4d.

Pressure control valve “4d” – L830 During tramming, pump 1 is working in load sensing mode, which means that the pump pressure depends on the load on the tramming motors. The maximum pressure of pump 1 can be adjusted by pressure relief valve4d. During drilling, pump 1 operates on constant pressure set by pressure relief valve4d + the Delta-p preset pressure.

“P max” valve – L830 The “P max” valve located on the pump limits the maximum pump output pressure, but this pressure would not be reached since pressure relief valve 4d which is set to be lower than “P max”, is there to limit the system pressure. Valve 4d should be used when adjusting the pump 1 working pressure within the system. “P max” is set to be higher than “4d” by factory setting, so it’s usually not necessary to change the interfere setting onwith “P max”, way “P max” would not the LSthis signal. In order to avoid start the diesel engine with pump 1 pressurized, the Drilling/Tramming switch must be in the Tramming position when starting. In this position, pump 1 runs at standby pressure, 23 bar. Starting with the switch in Drilling position is also electrically blocked.

24

Pumps & Pilot Pressure

Pump 1 pressure settings Checking / Setting the stand-by pressure “Delta-p”. Start the engine and set the engine speed to 1500 rpm. Move the switch Drilling/Tramming to position Tramming. Make sure no functions are activated, so the rig stands still. Pressure gauge 34 connected to pump 1 pressure line should show 23 bar. 5. Adjust the “Delta-p” set screw on the pump regulator if necessary. •

1. 2. 3. 4.

•

1. 2. 3. 4.

Delta-p

P Max

Checking / Setting the pressure relief valve “4d”. Start the engine and set the engine speed to 1500 rpm. Move the switch Drilling/Tramming to position Drilling. 40 40 Make sure no functions are activated. (Especially important for L7 and L7 CR) The reading from gauge 34 should be 250 bar (LS return pressure + delta-p). If not, adjust the screw on 4d until the gauge reads 250 bar. Note: If it happens that the reading is lower than 250 bar, and by adjusting 4d the gauge reading stays the same. This means that the “P max” valve is not correctly adjusted. Adjust “P max” valve according to the instructions below, then adjust “4d” until the gauge reads 250 bar.

Checking / Setting the maximum pump pressure “P max”. • 1. Start the engine and set the engine speed to 1500 rpm. 2. Move the switch Drilling/Tramming to position Drilling. 40

40

3. Make sure no functions are activated. (Especially important for L7 and L7 CR) 4. Screw pressure relief valve 4d to its end position, so it would not limit the system pressure produced by pump 1. 5. Screw the “P max” set screw clockwise (if the pressure is too low) or anti-clockwise (if the pressure is too high), while watching gauge34 until it reads 270 bar. 6. When this is done, re-adjust the screw on 4d until the gauge reads 250 bar, to get back to its normal setting.

Pumps 2, 3 and 4 Pumps 2, 3 and 4 are combined to a triple gear pump, mounted on pump 1. The maximum pressure of pump 2 is set by relief valves4x and 4y in the drill rotation circuit. The pressure of pump 3 can be set on a variable relief valve13a in the DCT valve block. The pressure of pump 4 is set by a fixed relief valve4c in the main valve block. Pump 2 & 3 are running unloaded in different ways when switch S130 is in Tramming position.

Pumps 5 and 6 Pumps 5 and 6 are gear pumps and driven by an extra power take off on the side of the diesel engine. The maximum pressure is set by an electro proportional relief valve mounted in each cooler fan motor. These pumps are loaded 15 seconds after engine start.

25

Pumps & Pilot Pressure

Pilot pressure Pilot pressure is supplied by pump 1 and generated in the main valve block by pressure reducing valve 4b set to 35 bar, and then out to the pilot circuits. Solenoid valve Y169 control whether the pilot pressure goes to the drilling circuit or to the tramming circuit. Solenoid valveY169 is activated when the Drilling/Tramming switch S130 is in tramming position and deactivated when the switch is in drilling position.

26

S L

1

Shuttle valve

m a r /T e d e F

2

230 bar

3

4

Cooling fans

Cooling fans The rig is equipped with two standard fan drives, one for cooling the compressor/hydraulic oil, and one for cooling the engine water/air inlet. High ambient temperature fan drive for warmer environment is available as an option. Conditions for starting the compressor/hydraulic oil temperature cooler fan: •

Compressor temperature sensor B366 => PLC input X16-7

OR Hydraulic oil temperature sensor B362 => PLC input X16-3 Results in: PLC output X16-9 => Y504 activated • •

Conditions for starting the engine water/ATAC temperature cooler fan: •

Engine coolant temperature sensor B354 (CAT system)

OR Air inlet temperature(CAT system) Results in: PLC output X17-4 => Y501 activated • •

The signal input to solenoids Y504 and Y501 varies between 50mA – 510mA depending on the cooling demands. Revolution

Rig type L7 L8

max

0

Full rpm at 95 °C 120 °C

mA 50

510

27

Tramming

Tramming Conditions for tramming function: •

•

•

Drilling/Tramming switch S130 must be in a tramming position*. => D552-CH2 or CH3/ON The hydraulic jack must be fully retracted, sensorB184 activated. => PLC input X107/ON (Optional equipment) Tramming paddles S174 or/and S175 must be activated. => D553/CH13 or CH14/ON

Result in: *Y121A/B activated (directly after S130 being put in tramming position) • *Y169 activated (directly after S130 being put in tramming position) • Y206, Y207 activated by respective level. • Tramming direction and speed is controlled via the tramming paddles (S174/S175 see figure). These controls send a signal to the electrical pilot valves for tramming forward or backward. The pilot pressure changes the directional valves’ position proportionally and pump 1 supplies the tramming motors’ hydraulic circuits with oil.

S174

S175

The output range of the proportional electrical pilot valves for tramming can be adjusted in the menu for “Tramming valve current” under the rig control icon, thus varying the tramming speed.

The output range lies between 330mA – 500mA.

28

Tramming

Activating the tramming function When the Drilling/Tramming switch S130 is in any Tramming position (high or low), the following solenoid valves are activated. Activation of Y121A: - It allows pump 1 pressure to connect to pressure compensator 4p and 4r in the main valve block, 4p and 4r also have the functions of dividing the oil flow equally. The tramming pressure is limited by pressure relief valve4d set to 230 bar. Activation of Y121B: - The oil flow from pump 4 goes through pressure relief valve4c set to 250 bar. The pressure is then delivered to positioning functions. Activation of Y169: - It allows pilot pressure to come through to the tramming circuit. The tramming direction and speed are controlled by means of pilot pressure controlling the proportional directional valves. And these directional valves are controlled by solenoid valves Y206A, Y206B, Y207A and Y207B. The valve block included in the tramming motor66 contains a shuttle valve66a, a pilot operated directional valve66b and a pressure reducing valve66c for releasing the tramming brake when the motor is pressurized. To prevent the motors from increasing speed when tramming down a slope, the over centre valve66d serves as hydraulic brakes by means of creating counter pressure in the motor return line when the pressure in the motor pressure line drops.

Reverse warning Warning signal/flash H185 is activated when tramming backwards.

Tramming high/low speed The Drilling/Tramming switch S130 position high tramming, activates solenoid valve Y122. Pilot pressure is then led to directional valve66f in each traction motor. This connects system pressure to the traction motors displacement device, which reduces the motor displacement and results in increase of traction motor speed.

Rear jack (Option) The rear jack is controlled by on/off switchS209, which energizes solenoid valveY410A/B. In order to protect the rear jack from becoming bent, it is not possible to tram the drill rig unless the jack is fully retracted, activating the inductive proximity switch B184, this will also generate a warning on the display.

29

Tramming Input / Signal 

Switch S130 in a Tramming pos.



Tramming paddles S174 or 175

activated Hydraulic jack retracted, B184 activated (option) 

S174

1

S175

Tramming Input / Signal 

S130/3 or 5 - D552, CH 2 or 3/ON



S174 or 175 - D553, CH 13 or 14/ON

Output on indicator card

2



X11-13 Y121A



X17-1



X11-14 Y122



X11-1

Y121B

Y169A

Y121A Y122

Y121B

Tramming hig

3

Y169A

Trammin

4

. s o p 4 P

Y169A

Y122 Y121B

Y121A

Pump 4

5

Y473

Pump 5 Y419

6

Y420

Positioning

Positioning The positioning circuit is mainly supplied with oil from pump 1. However, since the tramming circuit is also supplied from pump 1, it is necessary to use pump 4 for positioning during tramming. Since pump 1 is bigger and operates at higher pressure than pump 4, it means that positioning is quicker in Drill mode than it is in Tramming mode.

Boom and feed positioning 65

The cylinders are dump directly controlled byare directional valve over-center in the cabin. The positioning boom lift (BL ) and feed (FD ) cylinders equippedcontrol with internal valves, which protect the cylinders from over load and acts as load holding valves. The feed swing (FS), feed extension (FE) and boom swing (BS) cylinders have built in double pilot operated check valves. The BL cylinder is also equipped with throttle/check valve64, on the piston rod side. This is used to adjust the lowering speed of the boom to be equal to the elevating speed.

Positioning during tramming During tramming, pump 4 is delivering oil to the positioning circuit, the pressure is limited by the pressure relief valve 4c set to 250 bar. When the Drilling/Tramming switch S130 is in tramming position, solenoid valveY121B is activated. This pressurizes the pump 4 circuit.

Track oscillation The track oscillation solenoid valves Y419 and Y420 are controlled by switch S176 and S177 respectively. The oscillation cylinders are hydraulically linked by a two positioned solenoid valve, Y473, controlled by switch S445. - ON, Floating When solenoids valve Y473 is activated with switchS445 in position (a), the valve is open allowing system pressure to open the over centre valves in the Track Oscillation valve block68. c b d a Both cylinders are inter-connected to enable oil to flow between the two cylinders. This valve position is used during tramming so that ground unevenness can be compensated between the a cylinders. b - OFF, Locked When solenoid valve Y473 is de-activated, the connection c between the two cylinders is blocked. Both cylinders can still be operated individually by switchesS176 and S177. This valve position should be used all the time except when the rig is trammed in order to ensure a stable set-up.

30

Positioning Input / Signal

1



Track oscillation left S176, right S177



Track oscillation float/lock switch S445



Hydraulic jack S209

Positioning Input / Signal 

S176/A1 or A3 – D552, CH 5 or 6/ON



S177/A1 or A3 – D552, CH 7 or 8/ON



S445/A3 – D554, CH 2/ON (fl oating)



S209/A1 or A2 – D552, CH11 or 12/ON

Output on indicator card

2



X13-9, X13-10

Y419A/B



X15-5, X15-6

Y420A/B



X15-7

Y473



X12-6, X12-7

Y410A/B

S L

3

Y121A m a r/ T d e e F

4

r a b 0 3 2

Y419

5

Y420

Y473 . s o p 4 P

Y419

Track oscillation / positioning are supplied by pump 4 when tramming

6

Y420

. s o p 4 P

Y121B

Pump 4

7

Air System & Compressor

Air System & Compressor Air System Compressed air is used for the following rig functions: Flushing air • Full flushing and reduced flushing air. Transportation of drilled cuttings from the hole to the surface. The reduced flushing is mainly used during collaring through fissured ground, to prevent the air from destroying the hole walls. •

•

•

•

•

•

•

•

ECL, rock drill lubrication Distribution of lubrication oilsystem inside the rock drill. HECL, DTH Hammer lubrication system Distribution of lubrication oil inside the DTH Hammer. HECL, COPROD head and sections lubrication system Distribution of lubrication oil inside the COPROD head and sections. ECG, thread greasing systems (option) Distribution of lubrication oil onto the drill rod threads. Spray greasing system (option) Distribution of lubrication oil into the flushing air. DCT, dust collector Cleaning of the DCT filters. Extra air-outlet Provides air for running tools or grinders. Water-mist system (option) Pressurization of the air/water tank.

Flushing air – L740, L740CR Conditions for the flushing air function: Switch S130 in Drilling position => input D552-CH1/ON • Sensor B118 activated, RHS arm in carousel => PLC input • X10-5/ON Switch S100 in position reduced (b) or full (a) => input • D551-CH1/ON or OFF Switch S446A in Impact position => input D550-CH9/ON • (To start only flushing, press the impact switch S446A for shorter than 0.5 seconds. To start low impact, press the switch for longer than 0.5 seconds. Pressing the switch again for shorter than 0.5 seconds would deactivate flushing.)

a

S100

b

The volume of flushing air is controlled by the Flush air switch

Figure: example, L740 left panel

S100, but activation of flushing air is done with Impact switch S446.

There are two air flushing modes,reduced and full air flushing, activated by their respective solenoid valves Y116 and Y115. When full air flushing is activated, both the valves are open and when reduced air flushing is activated onlyY116 is open. When a low flushing air pressure and flow is required, e.g. collaring in fractured rock, the flushing air can be used in reduced mode by setting switch S100 in position (b). In this position only Y116 will be activated.

31

Air System & Compressor

Flushing air – L830 Conditions for the flushing air function: Switch S130 in Drilling position => input D552-CH1/ON • Sensor B118 activated, RHS arm in carousel => PLC input X10-5/ON • Switch S446A/B in Impact position => input D550-CH9/ON or CH10/ON • There are two air flushing modes,reduced and full air flushing, activated by solenoid valves Y116 and Y115. When full air flushing is activated byS446B , both the valves are open; and when reduced air flushing is activated byS446A, only Y116 is open.

32

Air System & Compressor

ECL, rock drill lubrication system See section “ECL, rock drill lubrication system” under chapter “Drilling”.

HECL, DTH hammer lubrication system See chapter “HECL, DTH hammer lubrication system” under “Drilling”.

HECL, COPROD head and sections lubrication system See section “HECL, COPROD head and sections lubrication systems” under chapter “Drilling”.

ECG, Thread lubrication systems (Option) See chapter “ECG, thread lubrication with oil (Option)”.

Spray greasing system (option) The lubrication is injected into the flushing air and dissipates through the treads of the drill rods to keep them lubricated. See chapter “Spray greasing system (Option)”.

DCT, dust collector See chapter “Dust collector, DCT”.

Extra air-outlet The rig is equipped with two air outlets where a grinder or tool can be connected. The air pressure is limited to 7 bar by a pressure reducing valve.

Water-mist system (option) See chapter “Water mist systems (Option)”.

Compressor General – L740, L740CR The on board compressor is a single stage, oil-injected screw compressor. The normal working pressure has been set to 12 bar, whereas the maximum pressure is 14 bar. The maximum free air delivery (FAD) is 252.7 l/sec at 12 bar working pressure with 20°C ambient temperature.

General – L830 The on board compressor is a double stage, oil-injected screw compressor. The normal working pressure has been set to 30 bar, which also is the maximum pressure. The maximum free air delivery (FAD) is 434.2 l/sec at 30 bar working pressure with 20°C ambient temperature.

Compressor element – L740, L740CR The compressor element contains two rotors, one female and one male rotor, mounted on roller as well as ball bearings. The female rotor is driven by the diesel engine, and powers the male rotor. The rotors are lubricated by oil, injected and mixed with the air. This also increases the efficiency as the oil seals between the rotor-tips and housing. The compressor elements are of Atlas Copco type OIS M-07. The gear ratio is 1.625.

33

Air System & Compressor

Compressor element – L830 The compressor element contains two rotors, one female and one male rotor, mounted on roller as well as ball bearings. The female rotor is driven by the diesel engine, and powers the male rotor. The rotors are lubricated by oil, injected and mixed with the air. This also increases the efficiency as the oil seals between the rotor-tips and housing. The compressor elements are of Atlas Copco type OIS N-02 and OIS J-33. The gear ratio is 2.195.

Air flow Intake air is drawn in through the air filter and the inlet valve to the compressor element. The air is mixed with injected oil and after compression is passed through the check valve into the air receiver. The check valve prevents back-flow of compressed air when the compressor is stopped. In the air receiver, most of the oil is removed from the air/oil mixture by the oil separator. The flow of compressed air then passes through the minimum pressure valve out into the drill rigs air system. The minimum pressure valve prevents the pressure in the air receiver to drop below the minimum working pressure of the compressor before the air is released, in order to ensure proper function of the oil system. Air Atmospheric Pressure Air Regulating Pressure Air Working Pressure Air/Oil Mixture Oil

34

Air System & Compressor

Cooling and oil system Oil is used for lubrication, sealing, cooling and is boosted by air pressure, there is no oil pump. The lower part of the air receiver serves as oil tank. Air pressure forces the oil from the air receiver through the oil cooler, oil filter and the oil stop valve to the different injection points of the compressor element. The air/oil mixture then leaves the compressor element and re-enters the air receiver, where the oil is separated from the air by centrifugal or cyclone forces and the oil separator element. Oil that is collected in the bottom of the oil separator is returned to the oil system by way of the scavenge line and flow restrictor. The oil stop valve prevents the compressor element from flooding with oil when the unit is stopped. 40

Note: A thermostatic valve bypasses the oil cooler when the oil is below40 °C for L7 , 40 30 L7 CR, and 80 °C for L8 .

Regulating system – L740, L740CR The compressor control system contains a regulating valve. This valve serves to adapt the volume of air supplied by the compressor to the air consumption, while simultaneously maintaining the working pressure within the limits. The control system also includes a loading solenoid valveY210 which is activated by switch S180 on the right hand control panel.

Regulating system – L830 The compressor control system contains two regulating valves. These valves serve to adapt the volume of air supplied by the compressor to the air consumption, while simultaneously maintaining the working pressure within the limits. The control system also includes a load solenoidY210A and a high/low pressure solenoid valve Y210B . Y210A is activated by switch S180 on the right hand control panel. One pressure switch B336 prevents the engine to start with the compressor loaded, which implies there should be less than 1 bar in the air receiver before starting the engine. The second pressure switch B337 prevents the compressor to load below 5 bar. Solenoid valve Y210B is activated when high impact switch S446B is activated.

Instrumentation & fault indication – L7 40, L740CR The compressor air pressure delivered from the compressor can be read-off pressure gauge. The compressor has also a temperature indicator-switch, B366, which automatically generate a warning on the display if the compressor temperature has reached +117°C, and cuts the diesel engine if the compressor temperature has reached +120°C.

Instrumentation & fault indication – L8 30 The compressor air pressure delivered from the compressor can be read-off pressure gauge. The compressor has also 2 temperature indicator-switches, B366A and B366B, which automatically generate a warning on the display if the compressor temperature has reached +125°C, and cuts the diesel engine if the compressor temperature has reached +130°C.

35

Compressor Input / Signal Switch S130 in any position after engine start 



Compressor load switch S180 activated For L6, L8 only – Minimum loading pressure switch B337 activated 

Compressor temperature normal – B366A/B below limits 

1

Compressor Input / Signal 

S180/A3 - D552,CH 9/ON



For L8 30 only, B337 - X13-3/ON

Output on indicator card

2



X18-8

Y210A (for all)



X12-1

Y210B (for L8 30)

Y210 Regulating valve

Inlet valve

B366

B365

Min pressure Oil filter & thermostat

3

safety valve

valve

Y210A Regulating valves

Y210B

B366A

Inlet valve

safety valve B366B

B365 Oil filter & thermostat

Min pressure valve

4

L740, L740CR, L8 Y210A

Compressor loaded & Low impact

5

Y210 Regulating valve

Inlet valve

B366

safety valve

B365 Oil filter & thermostat

Oil cooler

6

Main air flow

Y210A Regulating valves

Y210B

B366A

Inlet valve

safety valve B366B

B365 Oil filter & thermostat

7

L8 Y210A Y210B

Compressor loaded & High impact

8

Y210A Regulating valves

Y210B

B366A

Inlet valve

safety valve B366B

B365 Oil filter & thermostat

Oil cooler

9

Oil pre-heating

L7 , L7 CR

Oil pre-heating Oil pre-heating – L740, L740CR Pump 2 is used for pre-heating the hydraulic oil and the rock-drill impact components. Normal operating temperature of the hydraulic oil is 40°C. Before operating the drill rig the oil should be pre-heated to minimum operating temperature, 20°C. When switch S130 is in the pre-heating position, solenoid valve Y121A and Y121B are activated. Solenoid valves Y120A, Y120B and Y120C are also activated in order to perform pre-heating. Pre-heating the hydraulic oil: When activating Y120A, pressure is generated in the pressure chamber of4x. This pressure is limited by 4y to 170 bar. The flow of pump 2 goes through the shunt valve4x with a pressure of 170 bar + spring pressure (11 bar). Pre-heating the rock-drill components: Y120B blocks the impact return line from the

rock-drill, Y120C opens and oil flow from pump 2 is fed through the hammer return line and back to the tank through the hammer pressure line. Note: It’s possible to tram the rig at the same time warming up the hydraulic oil, solenoid valve Y169 can also be activated when S130 in pre-heating position.

36

Oil pre-heating

L8

Oil pre-heating – L830 Pump 2 is also used for pre-heating the hydraulic oil. Normal operating temperature of the hydraulic oil is 40°C. Before operating the drill rig the oil should be pre-heated to minimum operating temperature, 20°C. When switch S130 is in the pre-heating position, solenoid valve Y121A and Y121B are activated. Solenoid valves Y120A in the main valve block is also activated in order to perform pre-heating. When activating Y120A, pressure is generated in the pressure chamber of 4x. This pressure is limited by4y to 170 bar. The flow of pump 2 goes through the shunt valve4x with a pressure of 170 bar + spring pressure (11 bar). Note: It’s possible to tram the rig at the same time warming up the hydraulic oil, solenoid valveY169 can also be activated when S130 in pre-heating position.

37

Oil pre-heating Input / Signal 

1

Switch S130 in Oil preheating pos.

Oil pre-heating Input / Signal 

S130/7 - D552,CH 4/ON

Output on indicator card 

X11-13 Y121A



X17-1



X11-12 Y120A, Y120B, Y120C

Y121B

(Y120B/C only ROC L7)

2

Y120B/C only for L7TH+CR

Y120A,B,C Page 35

Oil pre-heat

Y121A

Y121B

Page 34 3

Oil pre-heati

Y121B

Y121A Y120A

4

Y120B

Y120C

5

Drilling functions

Drilling functions Activation of drilling functions – L740, L7 40CR When S130 is in drilling position,Y121A and Y121B are not activated, Y169 is deactivated to let through pilot pressure to the drilling circuits. De-activation of Y121A: - It allows pump 1 pressure to connect to LS/pump pressure line directly. If impact is activated, the pump pressure will be according to the preset values of the hammer/pump pressure pressure relief valves (47e and 47f) in the logic block. If impact is not activated, the working pressure is limited by pressure relief valve 4d. De-activation of Y121B: - The pump 4 pressure supplied to positioning functions during tramming, is now used for rotation function together with pump 2. This is simply to assist pump 2 for a better rotation output. De-activation of Y169: - Pilot pressure is now led to the drill lever through logic valve and to the DCT circuit, PLC output X11-1/OFF. The Drilling functions such as Drill feed, Rapid feed, Rotation and Threading functions are all controlled by one drill lever.

Activation of drilling functions – L830 When S130 is in drilling position,Y121A and Y121B are not activated, Y169 is deactivated to let through pilot pressure to the drilling circuits. De-activation of Y121A: - It allows pump 1 pressure to connect to LS line directly. The working pressure is limited by pressure relief valve 4d. De-activation of Y121B: - The pump 4 pressure supplied to positioning functions during tramming, is now used for rotation function together with pump 2. This is simply to assist pump 2 for a better rotation output. De-activation of Y169: - Pilot pressure is now led to the drill lever through logic valve and to the DCT circuit, PLC output X11-1/OFF. The Drilling functions such as Drill feed, Rapid feed, Rotation and Threading functions are all controlled by one drill lever.

38

Drilling functions

Drill feed The drill feed circuit includes functions for feeding down- and upwards and controlling the feed pressure during collaring and drilling. The hydraulic power is supplied from pump 1. The Anti-Jamming circuit is described separately, see chapter “Protective functions”. •

Drill feed direction, Up-/Downwards

The drill feed/rotation lever45 controls the directional valve4f via the logic block. Solenoids Y179A and Y179B are to control the magnetic locks for drill lever feed and rotation functions. Drill feed

Led green H452 Rapid/ drill feed S452 Impact low S446A

Magnetic holding

Led yellow H446

A

Magnet off S453

6 G D

Impact high S446B

Drill rotation

5B

Magnetic holding

E

7 H

F C

8I

L740 Drill mode: E: neutral B: rotation anti-clockwise B+A: rotation anti-clockwise and feed forward (magnet function) B+C: rotation anti-clockwise (magnet function) and feed backward. D: Feed forward (magnet function) F: Feed backward H: rotation clockwise H+G: rotation clockwise and feed forward H+I: rotation clockwise and feed backward

Rapid feed/threading mode: E: neutral B: Threading B+A: rotation anti-clockwise and rapid feed forward B+C: rotation anti-clockwise and rapid feed backward D: Rapid feed forward F: Rapid feed backward H: Unthreading H+G: rotation clockwise and feed forward H+I: rotation clockwise and feed backward

Diode H452 is lit in this mode.

There is no diode indication in this mode.

39

Drilling functions

L740CR, L830 Drilling mode: E: neutral B: rotation clockwise B+A: rotation clockwise and feed forward (magnet function) B+C: rotation clockwise (magnet function) and feed backward. D: Feed forward (magnet function) F: Feed backward H: rotation anti-clockwise H+G: rotation anti-clockwise and feed forward H+I: rotation anti-clockwise and feed backward

Rapid feed/threading mode: E: neutral B: Threading B+A: rotation clockwise and rapid feed forward B+C: rotation clockwise and rapid feed backward D: Rapid feed forward F: Rapid feed backward H: Unthreading H+G: rotation anti-clockwise and feed forward H+I: rotation anti-clockwise and feed backward

Diode H452 is lit in this mode.

There is no diode indication in this mode.

Magnetic holding on rotation during drilling or/and feeding forwards can only be achieved when the control lever is being pulled to the end position, and whenS452 is not activated (Led H452 = ON). Pulling the lever only half way and then release would result in lever springed back to the neutral position, which also marks the end of the movement.

Conditions for drill feed with magnetic holding: • •

Switch S130 in drilling position => D552-CH1/ON Switch S452 in feed/rotation mode, not activated => D550-CH11/OFF

Result in: Relay K178/OFF • Y179A/B, H452 activated • To unlock the magnetic lock and get the lever back to the neutral sector, activate switch S453 or shift the lever to Rapid feed position with switch S452.

Conditions for deactivation of magnetic holding: •

Switch S453 activated => D550-CH12/ON

OR Switch S452 in rapid feed/threading mode => D550-CH11/ON Result in: Y179A/B deactivated • •

When switch S453 is pressed once on the drill lever the magnets will be temporarily deactivated and the drill lever returns to neutral position which results in the actual feed and rotation being switched off, with impact and air flushing remains on. Magnetic holding can also be switched off onceS452 is activated, thus shifting to rapid feed/threading mode where magnetic holding is not supported. The actual impact and air flushing at this point will also be switched off. Note: Magnetic holding will be automatically reactivated after a delay of 0.2 seconds if switch S453 is deactivated. This means that the next time the drill lever is moved to one of these sectors (sector for drill feed or drill rotation), magnetic holding will be activated again.

40

Drilling functions The feed circuit is supplied with oil from pump 1. In drill mode the electrical pilot valves Y178A-F are not activated. When feed is activated with the drill lever the pilot pressure is directed first via either directional valves Y178A or B depending on the choice of feed direction, then via directional valve Y109 which changes the feed direction in case of antijamming and out to the directional valve in the drill feed block. Anti-jamming is described later. •

Main valve block 4

The pilot operated directional valve 4f in the main valve block, directs the hydraulic power to the feed cylinder. The pilot operated pressure compensator 4e regulates the feed working pressure. •

Feed pressures

The pressure for forward feeding can be read on pressure gauge33. The feed pressure is generated from the system (Feed/Tram) pressure by pump 1, and it is regulated by pressure relief valve4d. When feeding forwards, the pressure relief valves 47a or 47b limits the maximum pressure to the feed cylinder. If these pressure relief valves would for some reasons fail to work, then the check valve4n would limit the maximum pressure.

When feeding forwards during drilling, pressure compensator 4e in the main valve block is controlled by either pressure relief valve 47a or 47b for low and high feed pressure respectively. The impact switch controlS446A and S446B determines which valve controls the pressure as below:

41

Drilling functions -

-

-

Low feed pressure (collaring) When the impact control switch S446A is activated (impact pressure low), solenoid valve Y101C is deactivated, which allows the low feed pressure relief valve47a to control pressure compensator 4e in the main valve block. High feed pressure (drilling) When the Impact control switch S446B is activated (impact pressure high), solenoid valve Y101C is activated, which allows the high feed pressure valve47b to control pressure compensator 4e in the main valve block. Feeding backwards When feeding backwards, solenoid valveY101C is deactivated, which allows the low feed pressure relief valve47a to control pressure compensator 4e in the main valve block. But if feeding backwards is activated in connection with anti-jamming, solenoid valve Y101C remains activated and the high feed pressure relief valve47b will control pressure compensator 4e in the main valve block.

•

Feed cylinder valve block 5

The feed valve block 5 contains one over-centre valve5b. The overcentre valve 5b works as load holding valve when the cylinder is pressurized for feeding forwards.

•

Feeding speed

The drill feed speed is set to correspond to a drill feed speed of 15 m/min upwards and 8 m/min downwards.

42

Drill feed Drill feed Magnetic holding

Input / Signal 

Switch S130 in Drilling pos.



Drill lever in a feed position 

Feed forward – D



Feed backward – F

A D

Output

Drill rotation

Feed forward magnetic holding

Magnetic



5B

E

holding

– D550, CH8/ON Y179A Drill lever in drill mode – D550, CH15/ON H452

F



(No magnetic holding in pos. F)

1

C

7 H

Y169

m a r /T d e e F

Feed p.

2

. p d e e F

Pilot lever

O

3

. p d e e F

Pilot lever

O

Y101C

4

Drilling functions Drill rotation •

Drill rotation, clockwise/anticlockwise

Conditions for drill rotation with magnetic holding: Switch S130 in drilling position => D552-CH1/ON Switch S452 in feed/rotation mode, not activated => D550-CH11/OFF Result in: Relay K178/OFF • • Y179A/B activated, H452 activated • •

Note: When Y179A/B is activated the magnetic holding is obtained when the drill lever is moved to the sectors for drill rotation or/and drill feed.

Conditions for switching off rotation and magnetic holding: •

Switch S453 activated => D550-CH12/ON

OR Switch S452 in rapid feed/threading mode => D550-CH11/ON Result in: Y179A/B deactivated • •

When switch S453 is pressed once on the drill lever the magnets will be temporarily deactivated and the drill lever returns to neutral position which results in feed and rotation being switched off, with impact and air flushing remains on. Magnetic holding can also be switched off onceS452 is activated, thus shifting to rapid feed/threading mode where magnetic holding is not supported. The actual impact and air flushing at this point will also be switched off. Note: Magnetic holding will be automatically reactivated after a delay of 0.2 seconds if switch S453 is deactivated. This means that the next time the drill lever is moved to one of these sectors (sector for drill feed or drill rotation), magnetic holding will be activated again.

When rotation is activated (with the drill lever) the pilot pressure is directed, via electrical pilot valve Y178C or D depending on the choice of rotation direction, then to the directional valve 4w in the main valve block. If clockwise rotation (for drilling) is activated the pilot pressure passes via pilot valveY178D through a flow regulator (see figure below) which 40 40 regulates the rotation speed for drilling. In ROC L7 and L7 CR, the pilot pressure also activates the DPC-I system. (For further information, refer to section “DPC-I” under chapter “Damper & DPC-I system”.)

43

Drilling functions

•

Rotation speed 40

40

30

- L7 Anti-clockwise rotation (drilling); L7 CR & L8 Clockwise rotation (drilling) When the drill lever is in “Drill-rotation” position, the setting of the flow regulator controls how much the directional valve4w will open. The flow to the rock drill rotation motor is proportional to the opening of the directional valve 4w. 40 40 30 - L7 Clockwise rotation; L7 CR & L8 Anti-clockwise rotation The drill lever controls the rotation speed. The main directional valve 4w opens in correspondence to the lever angel. The flow regulator is not connected. The adjustment knob for flow regulator can be seen in chapter “Adjustment/calibration”. •

Rotation pressures

The rotation pressure is generated by pump 2 with the assistance of pump 4 when drilling. Depending on the direction of rotation, the pressure relief valve 4u or 4t is activated to limit the maximum pressure for clockwise and anti-clockwise rotation respectively. 40 L7 : The maximum pressure for rotation anti-clockwise is limited to 125 bar (valve 4t), and the maximum pressure of rotation clockwise is limited to 160 (valve4u) bar. 40 30 L7 CR & L8 : The maximum pressure for rotation clockwise is limited to 125 (valve4t) bar, and the maximum pressure of rotation anti-clockwise is limited to 160 (valve 4u) bar.

44

Rotation Drill feed Magnetic holding

Input / Signal 

Switch S130 in Drilling pos.



Drill lever in a feed position 

Rotation drilling –



Rotation unthreading – H

D

B

Output 

A

Drill rotation magnetic holding

Drill rotation

5B

Magnetic

E

holding

– D550, CH7/ON Y179B Indication of drill lever in drill mode – D550, CH15/ON H452 

(No magnetic holding in pos. H)

1

F C

7 H

Pilot pressure

D

2

Y169

11 bar 170 bar

Pump 2 Pump 4 extra flow

3

Drilling functions

Rapid feed •

Rapid feed direction, Up-/Downwards

When the lever is in the rapid feed/threading mode, magnetic holding is not available.

Conditions for rapid feed: Switch S130 in drilling position => D552-CH1/ON Switch S452 in rapid feed/threading mode, activated => D550-CH11/ON Result in: Relay K178 /ON Y178 activated • Y179A/B deactivated • • •

→

In rapid feed mode the electrical pilot valves Y178A-F are activated (see figure right). When rapid feed is activated with the drill lever the pilot pressure is directed via solenoid Y178A or B depending on the choice of direction, to the directional valve in the main valve block. •

Main valve block 4

The proportional directional valve 4j directs the hydraulic power to the feed cylinder. The pilot operated pressure compensator 4i regulates the rapid feed working pressure. •

Rapid feed pressures

The feed pressure for rapid feed is generated from pump 1, and it is regulated by pressure relief valve4d. Depending on the direction of rapid feed, the pressure relief valves 4l or 4k limits the maximum pressure to the feed cylinder, forward and reverse respectively. The maximum pressure for feed forward is limited to 220 bar, and the maximum pressure of feed backward is limited to 170 bar. If these pressure relief valves would for some reasons fail to work, then the check valves 4n and 4m would limit the maximum pressure. When rapid feeding forwards, the logic valveR is activated by the forward pilot pressure. The return oil from the feed cylinder is being directed to both directional valve 4j for drainage back to the tank and via the activated Y178F to logic-R for drainage back to the tank. This is in order not to run all the return flow from the piston side though the directional control valve, so the cylinder can reach a higher speed.

45

Drilling functions •

Feed cylinder valve block 5

The feed valve block 5 contains one over-centre valve5b. The over-centre valve 5b works as load holding valve when the cylinder is pressurized for feeding forwards. •

Logic valve P

When rapid feeding backwards, logic valveP is act ivated by the pilot pressure. The activated logic valve blocks the forward feeding action, which is part of the threading function when pulling the drill lever to the left in order to achieve some rotation (ex. when cleaning the drilled hole). In other words, if logic-P is not activated, and rotation (anti-clockwise rotation only, clockwise rotation would cause the threads to come loose) is needed for rapid feed backwards. This would result in feed direction valve4f giving out feed forward pressure and rapid feed direction valve4j giving out rapid feed backward pressure, logic-P blocks the pilot signal to 4f. •

Rapid feed stops – L740

M4 M3 M2

M1

Stop forward (M1) – Rapid feed stop forward above the upper drill steel support, so the rock drill can be threaded into the rod caught in the drill steel support. Stop lower uncoupling (M2) – Rapid feed stop backward, when the coupling sleeve is in the upper drill steel support in order to unthread the rods. Stop upper uncoupling (M3) – Rapid feed stop backward, when the rod is in correct position to be inserted into the magazine. Stop backward (M4) – Rapid feed stop backward, at a position above the RHS magazine, but before mechanical stop. This stop is used prior to adding/removing a rod to/from the drill centre.

46

Drilling functions •

Rapid feed stops – L830

M4 M3 M2

M1

Stop forward (M1) – Rapid feed stop forward above the breakout table, so the rock drill can be threaded into the tube caught in the lower breakout jaw. Stop lower uncoupling (M2) – Rapid feed stop backward, when the joint between two tubes is between the breakout jaws in order to break the tube threads. Stop upper uncoupling (M3) – Rapid feed stop backward, when the tube is in correct position to be inserted into the magazine. Stop backward (M4) – Rapid feed stop backward, at a position above the RHS magazine, but before mechanical stop. This stop is used prior to adding a new tube into the drill centre.

The rapid feed stops are software stops that are controlled by the PLC. All the stop distances can be set in the display.

Figure: L740 & L830 rapid feed stop settings

47

Drilling functions •

Rapid feed stops – L740CR

M4 M3 M2

M1M0

Impact stop (M0) – Feed stop forward between M1 and the mechanical stop forward. No impact is allowed if the rock drill is too near the mechanical stop. Stop forward (M1) – Rapid feed stop forward just above the breakout table, so the rock drill can be threaded into the tube caught in the lower breakout jaw. Stop lower uncoupling (M2) – Rapid feed stop backward, when the joint between two tubes is between the breakout jaws in order to break the tube threads. Stop upper uncoupling (M3) – Rapid feed stop backward, when the tube is in correct position to be inserted into the magazine. Stop backward (M4) – Rapid feed stop backward, at a position above the RHS magazine, but before mechanical stop. This stop is used prior to adding a new tube into the drill centre.

The rapid feed stops are software stops that are controlled by the PLC. All the stop distances can be set in the display.

Figure: L740CR rapid feed stop settings

Rapid feed stop activation When the measured distance happens to equal to the distance set in S113 the display, solenoid valvesY149 (backward) or Y150 (forward) in the logic valve block is activated by PLC output X16-10 or X17-2. Solenoid valve Y149 gets activated by M2, M3 and M4, where as solenoid valve Y150 only gets activated by M1. If any of the two solenoid valves is activated, the pilot connection between the drill lever 45 and the directional valve 4j for t he corresponding rapid feed direction will be blocked. Consequently the rapid feed movement stops. The input from stop lower/upper uncoupling a (M2 & M3) will only result in a rapid feed stop if switchS113 (take up rod string) is activated, position (b). This is to allow the cradle to be fast fed unstopped to the top when adding a drill steel. b Once a feed stop is activated, the system holds the stop signal for two seconds at each stop. If the lever is still being held in after two Figure: example, L740 left panel seconds, the movement will start again.

48

Drilling functions Calibrating B172 In order for these build-in software stops to work, calibration sensor B104 is used to calibrate the depth encoder B172. The depth encoder B172 is an optical encoder which through sending out pulses defines the position of the cradle on the beam.

Note: The menu illustration shown does not correspond to the actual position. The distance to be entered in the display is the cradle travel distance between the rear end mechanical stop and when the indicator plate actuates sensorB104. This value can be put in manually or automatically.

Manual input Operator needs to use a ruler to manually measure the distance between the front of the rock drill cradle indicator plate and the calibration sensor B104 , when the rock drill is in its rear end stop. Automatic input The cradle needs to be moved back to the upper most position at the mechanical stop. To carry out this movement, the drill lever needs to work in drill mode. Once the cradle has reached the top end, reset the position of the cradle. Then mark the check-box for “Auto set sensor position”, now move the drill lever forward slowly so the cradle can pass through the calibration sensor B104 at a maximum speed of 4m/min. Once B104 is activated, a value is presented on the display. Note: It’s recommended that both manual and automatic input is done to ensure a better precision. This distance is a factory setting, it is not necessary to change the distance unless sensor B104 has been moved, or if the rock drill’s rear-end mechanical stop has been changed, i.e. if the feed ropes have been replaced or tensioned.

Calibration is done every time the cradle passes through B104 from above, a distance is then achieved. This distance (measured by B172) is being compared with the preset value of B104 in the display. If these two distances differ from each other, the B104 value will then overwrite the B172 measured value, so measurement can be carried on correctly from this point. In other words, B104 can be seen as a control factor in length measuring.

49

Drilling functions

Threading Threading and un-threading When the lever is in the rapid feed/threading mode, magnetic holding is not available. •

Conditions for threading/unthreading: Switch S130 in drilling position => D552-CH1/ON Switch S452 in rapid feed/threading mode, activated => D550-CH11/ON Result in: Relay K178 /ON Y178 activated • Y179A/B deactivated • • •

→

In threading mode the electrical pilot valvesY178A -F are activated just as in rapid feed mode. The threading function is a combined activation of both drill feed and rock-drill rotation by one lever stoke. When threading is activated with the drill lever the pilot pressure is directed via the activated solenoid Y178C or D depending on the choice of threading direction, and then to the directional valve in the drill feed and rotation block respectively.

Rod coupling feed p ressures Threading and unthreading functions need two different feed pressures since unthreading requires higher pressure than threading. Pressure relief valves 47d and 47c control the maximum rod coupling feed pressure for feed forward L7 ( 40: threading – anti-clockwise; 40 30 L7 CR & L8 : threading – clockwise) and backward (L740: unthreading – clockwise; •

40

30

L7 CR & L8 : unthreading – anti-clockwise) respectively. Depending on the choice of threading, pressure relief valves 47c and 47d will then in turn control pressure compensator 4e in the main valve block.

By pulling the lever to the left (threading), logic valveG is activated, which connects the feed pressure to the pressure relief valve for thread feed forward 47d. And by pulling the lever to the right (unthreading), logic valve H is activated, which connects the feed pressure to the pressure relief valve for thread feed backward47c.

Drill feed and rotation speed when threading • Rotation: When rotation is activated by the threading lever, the flow regulator which controls the rotation pilot pressure signal is excluded from the circuit. This means that the rotation speed is on full rpm. Feed: As earlier mentioned in Rapid feed, all of the electrical pilot valves Y178A-F are activated when the switch for switching to rapid feed/threading S452 is activated. Y178A-D affect the choice between drill and feed mode, andY178E-F affect the drill feed speed since it will be much slower than feed and rapid feed. The feed speed can be changed by adjusting the flow regulators 10 located in respective feed direction. They shall be set to match the pitch of the drill string threads.

50

Rapid feed

Drill feed Magnetic holding

Input / Signal Switch Drill

S130 in Drilling pos. A

lever in rapid feed mode

S452 activated – D550, CH/11/ON Drill

D

lever in a rapid feed position Rapid

feed forward – D

Rapid

feed backward – F Drill rotation

5B

Magnetic

Output on indicator card Relay

holding

K178 activated

– X12-2

K178



F

Y178A-E C

1

E

7 H

K178 Y178A-F

Rapid feed coupling

2

Pilot lever Y178D

Y178B Y178A

Y178C

3

Y169 Y178E,F

R

m ra /T d e e F

4

Y149 Y150

Note: Only one of them (Y149, Y150) is activated at a time.

Rapid feed sto

5

Pilot lever

Y149 Y150

6

Rod coupling

Drill feed Magnetic holding

Input / Signal Switch Drill

S130 in Drilling pos. A

lever in rapid feed mode

S452 activated – D550, CH/11/ON Drill

D

lever in a rod coupling position Threading

–B

Unthreading

–H

Drill rotation

5B

Magnetic

Output on indicator card Relay

holding

K178 activated

– X12-2

K178



F

Y178A-E C

7

E

7 H

Pilot lever

Rotation Feed

8

. p d e e F

FEED

Y169 Y178E,F

ROTATION

Pump 2

9

. p d e e F

Pilot lever

P

10

Drilling functions

L7 , L7 CR

Impact with air flushing – L740, L740CR Conditions for the impact function: • • • • • •

Switch S130 in drilling position => D552-CH1/ON Compressor load switch S180 must be on => D552-CH9/ON Flushing air switch S100 in reduced or full position => D551-CH1/ON or OFF Sensor B118 activated, RHS arm in carousel =>PLC input X10-5/ON Impact switch S446A or S446B must be activated => D550-CH9/10/ON The rock drill damper pressure must be between 45 and 120 bar. (DPC-I)

The impact circuit includes function for activating the rock drill impact mechanism and controlling the pressure for collaring and drilling (low and high pressure). The circuit also activates the Impact hour counter (a function of the HEC software in the display). The hydraulic power is supplied from pump 1. To protect the rock drill and drill steel, the DPC-I system can shut off or lower the impact pressure if certain conditions are met. The DPC-I system is described separately, refer to chapter “Damper & DPC-I system”.

Activation of Impact Pressing the impact control switch S446A/B for longer than 0.5 secondsactivates low respective high impact under the condition that high impact is achieved after first using low impact. Otherwise if starting directly on high impact, the button for high impact activation S446B must be held in at all time. Logic valvesI and J in the DPC-I system sense the rock drill damper pressure. If the damper pressure is lower than the preset value of logic-I or higher than the preset value of logic-J, the valves will prevent activation of impact. When impact is activated, pump 1 system pressure is also led to logic valveB, which allows any of the two impact pressure relief valves47e and 47f to take control over the pump 1 pressure. In ROC L740CR, there is also a logic valveO that will stop/prevent impact when feed pressure is below its preset value. S446A/B controls the activation of solenoid valvesY115, Y116 in the air system, but it is S100 that controls the combination of Y115 and Y116. It’s recommended to keep S100 activated to allow full flushing air pressure as soon as S446 is activated. S100 should be switched off (changing to reduced flushing air) only when drilling through a weaker complex of the rock layer. S446A/B also control three solenoids valves in the hydraulic system, Y101A, for activating impact, Y101B, for activating low impact,Y101C, for switching between high/low feed pressure.

Impact hammer, feed and air pressures - Low impact pressures When the low impact control switchS446A is activated, the following will take place in respect to all the pressures needed for the impact function. LedH446 will be activated to give blinking signals. Impact/pump 1 pressure: Logic valve B is activated since solenoid valveY101A is ON, logic valve E is not activated since solenoid valveY101B is ON. This connects the pump 1Loading Sensing line to the low impact relief valve47e.

51

Drilling functions

L7 , L7 CR

Air flushing: Solenoid valve Y116 (or Y116+Y115) is activated to engage reduced (or full) air pressure depending on the status of Y100, and the air pressure is directed to the regulating valve for air pressure regulation. Drill feed: The drill feed low pressure solenoid valveY101C is not activated in order to engage low feed pressure.

-

High impact pressure When the high impact control switchS446B is activated, the following will take p lace in respect to all the pressures needed for the impact function. Led H446 will be activated to give stable signal. Impact/pump1 pressure: Logic valve B is activated since solenoid valveY101A is ON, logic valve E is activated since solenoid valveY101B is OFF, logic valve D is activated by rotation pressure, and damper pressure now meets logic valveA. If the damper pressure is high enough to overcome the preset value of logic-A,pump 1 Load Sensing line is connected to the high impact relief valve 47f. Otherwise logic-A is deactivated, thus connecting the pump 1 Load Sensing line to the low impact relief valve47e. Air flushing: Solenoid valve Y116 (or Y116+Y115) is activated to engage reduced (or full) air pressure depending on the status of Y100, and the air pressure is directed to the regulating valve for air pressure regulation. Drill feed: The drill feed low pressure solenoid valveY101C is now activated in order to engage high feed pressure, under the condition that the RPC-F valvelogic-B is not activated. Refer to RPC-F under “Protective functions”.

Deactivation of impact Impact can be deactivated by pressingS446A/B for shorter than 0.5 seconds. If the lever is situated in magnetic holding position, impact will be switched off with the lever returning to the neutral position, thus also switching off feed, rotation and air flushing. Impact hour counter The impact hour counter is a build-in function of the HEC system. As long as either of the impact switches S446A or S446B is activated, t he counter in the software keeps counting.

Impact hour count since last reset.

Accumulated impact hours

52

Drilling functions

L8

Impact – L830 Conditions for the impact function: • • • •

Switch S130 in drilling position => D552-CH1/ON Compressor load switch S180 must be on => D552-CH9/ON Sensor B118 activated, RHS arm in carousel =>PLC input X10-5/ON Impact switch S446A or S446B must be activated => D550-CH9/10/ON

The impact circuit includes function for activating the DTH hammer impact mechanism and controlling the pressure for collaring and drilling (low and high pressure). The circuit also activates the Impact hour counter (a function of the HEC software in the display).

Activation of Impact Pressing the impact control switch S446A/B for longer than 0.5 secondsactivates low respective high impact. The impact control switchS446A/B , positions low and high, control three solenoid valves in the air system, Y116, low impact, Y115, high impact and Y210B, high/low air pressure regulation. They also control one solenoid valve in the hydraulic system,Y101C, switching between high/low feed pressure.

Impact feed and air pressures - Low impact pressure When the low impact control switchS446A is activated, the following will take place in respect to all the pressures needed for the impact function. LedH446 will be activated to give blinking signals. Air pressure for impact and flushing: When the impact control switch S446A is activated, solenoid valveY116 is activated to give reduced flushing air, and the air pressure is being controlled by the regulating valve set to 18 bar via the un-activated compressor high pressure solenoid valve Y210B . Drill feed pressure: The drill feed low pressure solenoid valveY101C is not activated in order to engage low feed pressure. -

High impact pressure When the high impact control switchS446B is activated, the following will take p lace in respect to all the pressures needed for the impact function. Led H446 will be activated to give stable signal. Air pressure for impact and flushing: When the impact control switch S446B is activated, both solenoid valveY115 and Y116 are activated, which gives full flushing air. The compressor high pressure solenoid valve Y210B is now activated and directs the air flow to the regulating valve set to 30 bar for air pressure regulation. Drill feed pressure: The drill feed low pressure solenoid valveY101C is now activated in order to engage high feed pressure.

53

Drilling functions

L8

Deactivation of impact Impact can be deactivated by pressingS446A/B for shorter than 0.5 seconds. If the lever is situated in magnetic holding position, impact will be switched off with the lever returning to the neutral position, thus also switching off feed, rotation and air flushing. Impact hour counter The impact hour counter is a build-in function of the HEC system. As long as either of the impact switches S446A or S446B is activated, t he counter in the software keeps counting.

Impact hour count since last reset.

Accumulated impact hours (can not be reset)

54

Drilling functions

L7 , L7 CR

Impact stroke length The stroke length of the COP 4050, COP 4050CR impact piston is electrically controlled through switch S400. When S400 is in position (a) => D553-CH7/ON: - Solenoid valve Y175 is not activated, only short stroke length is available. When S400 is in position (b) => D553-CH7/OFF: -

If low impact S446A is activated,Y175 is not activated, only short stroke length is available If high impact S446B is activated, Y175 is activated, only long stroke length is available.

a S400

b Figure: example, L740 left panel

When solenoid valve Y175 (PLC output X17-15) is activated, it is not open to allow pump 1 impact pressure to affect the stroke position valve in the rock-drill, the rockdrill will use long stroke length. When Y175 is deactivated, it is open to the pump 1 impact pressure line and the rock-drill will use the short stroke length. Which position to use has to be decided from the rock condition. Drilling in softer formations, each stroke can contain more energy than can be absorbed by the rock. In such cases it can be better to use only the short stroke length.

55

Impact / Flushing air Input / Signal 

Switch S130 in Drilling pos.



Gripper sensor B118 in carousel pos.



Impact switch S446A or B activated

Compressor load switch S180 activated (mandatory for L6, L8) 

Drill feed Magnetic holding

2 1 4 3

A

6

6 G

D

5

Drill rotation Magnetic

5B

E

7 H

holding

F C 1

8I

Impact / Flushing air Input / Signal S130/1 - D552,CH 1/ON



S180/A3 - D552,CH 9/ON



S100/A3 - D551, CH1/ON or OFF



S446A or B - D550, CH9 or 10/ON



B118 - X10-5/ON



Output on indicator card Drilling - D550, CH16/ON H446



X17-13

Y115

X17-14

Y116

X11-9

Y101A







X13-12

Y101B

X11-15

Y101C

X18-8

Y210A

X12-1

Y210 B









2

L740, L740CR, L8 Y116

Reduced flushing air, also impact low L

Page 38

L740, L740CR, L8 Y210A

Compressor loading, also impact low L

Page 40

L740, L7 Y101A Y101B Page 34 3

Impact low

B142 L7TH/CR only

Y115

Y116

w o fl ir a n i a M 4

7 bar

w o lf ir a n i a M

5

6

. p d e e F

Y175

Pilot lever Pump p.

B Q O C D

I J

Y101B

7

Y101A

Impact low on ROC L7 40

8

Y115

L740, L740CR, L8

Y116

Full flushing air, also impact high L8

Page 38

L740, L740CR, L8 Y101C

Y210A

Max feed pressure, impact h

Page 34

L740, L7 Y101A

Page 34 9

Impact hig

Y210A Y210B

Impact hig

10

re u t x im ri a li/ O

B142 L7TH/CR only

Y115

Y106 Tank

11

Y116

w o fl ir a n i a M

Y210A

Y210B

12

Y101C

13

. p d e e F

Y175

Pilot lever Pump p.

B Q O C D

I J

Y101C

Y101B

high

14

Y101A

Impact high on ROC L7 40

15

Drilling functions

L7 , L7 CR

ECL, rock drill lubrication system Function ECL pump Y106 starts to pump as soon as Impact is turned ON. The ECL pump is an electrical piston pump, controlled by the PLC output X17-9 which sends out pulses to the pump. Lubrication oil is then fed through a small plastic hose inside the air hose to the rock drill, where the oil and air are mixed. A pressure reducing valve set to 5.5 bar limits the amount of air used for the ECL system. The ECL lubrication pressure gauge is located in the cabin. There are two sensor switches which control the ECL oil collection pressure, B381 for limiting the low collection pressure and B382 for limiting the high collection pressure. The ECL oil collection system is optional. Conditions for the ECL function: Switch S130 in drilling position => D552-CH1/ON Compressor load switch S180 must be on => D552-CH9/ON Sensor B118 activated, RHS arm in carousel =>PLC input X10-5/ON • Impact switch S446A or S446B must be activated, to obtain percussion => D550• CH9/10/ON Result in: PLC output X17-9/ON => Y106 activated • • •

Note:

The ECL pump works for an extended time after the percussion is switched off. This time delay can be adjusted via the HEC3 display.

Adjustable p arameters Time pulse – length of the pulse, i.e. the signal time. Pulses/minute – how many pulses there is per minute Extended time – total time of the pumping cycle (after air flushing stop). •

•

•

56

Drilling functions

L8

HECL, DTH hammer lubrication system Function The HECL pump Y165 is a hydraulic driven lubrication pump that starts pumping as soon as the Impact/Flushing air is turned ON. The pump receives pulses from the HECL PLC output X11-16 (30-40 pulses/min) in the electrical cabinet. Lubrication oil is then led through a ¼” hose to the rotation unit, where the lubricating oil and air is mixed. The HECL lubrication pressure gauge is in the cab. Conditions for the HECL function: Switch S130 in drilling position => D552-CH1/ON Compressor load switch S180 must be on => D552-CH9/ON Sensor B118 activated, RHS arm in carousel =>PLC input X10-5/ON • Impact switch S446A or S446B must be activated => D550-CH9/10/ON • Result in: PLC output X11-16/ON => Y165 activated • • •

Note:

The HECL pump works for an extended time after the percussion is switched off. This time delay can be adjusted via the HEC3 display.

Adjustable p arameters Time pulse – length of the pulse, i.e. the signal time. •

•

•

Pulses/minute – how many pulses there is per minute Extended time – total time of the pumping cycle (after air flushing stop).

57

Drilling functions

L7 CR

HECL, COPROD head and sections lubrication system Function The HECL pump Y165 is a hydraulic driven lubrication pump that starts pumping as soon as the Flushing air is turned ON. The pump receives pulses from the HECL PLC output X11-16 (30-40 pulses/min) in the electrical cabinet. Lubrication oil is then led through a ¼” hose to the flushing air connection at the rock drill, where the lubricating oil and air is mixed. There is no pressure gauge for the HECL lubrication pressure. Conditions for the HECL function: Switch S130 in drilling position => D552-CH1/ON Compressor load switch S180 must be on => D552-CH9/ON Sensor B118 activated, RHS arm in carousel =>PLC input X10-5/ON • Impact switch S446A or S446B must be activated, to obtain air flushing => D550• CH9/10/ON Result in: PLC output X11-16/ON => Y165 activated • • •

Note:

The HECL pump works for an extended time after the percussion is switched off. This time delay can be adjusted via the HEC3 display.

Adjustable parameters Time pulse – length of the pulse, i.e. the signal •

•

•

time. Pulses/minute – how many pulses there is per minute Extended time – total time of the pumping cycle (after air flushing stop).

58

Y165

Y106

HECL tank

1

Damper & DPC-I system

L7 , L7 CR

Damper & DPC-I system Damper The rock-drill damper circuit is supplied with oil from Pump1 through a constant flow regulator. The flow regulator is adjusted to correspond to a pressure of 25 bar at the damper hose connection on the rock-drill. The damper pressure during drilling shows the actual feed force on the drill bit. The pressure can be read on the pressure gauge in the cabin.During drilling, the damper pressure controls certain logic valves, which in turn controls the impact pressure (hammer pressure). This is described below as the DPC-I system.

Adjusting the damper pressure Adjustment of the damper pressure must be done with the damper piston in its rested, forward position. To ensure this, the shank adapter can be pulled out to its most forward position. Adjustment of the damper pressure should only be done with the hydraulic oil has reached normal working temperature, 40ºC (104ºF). 1. Connect a pressure gauge between the damper hose connection and the damper hose on the rock-drill. 2. Start the diesel engine and let it run at 1500 rpm. 3. Make sure that the shank adapter is in its forward position, i.e. the damper piston is in its forward position. 4. Turn switch S130 to Drilling position. 5. Loosen the lock screw (8b) and adjust the damper pressure by turning the adjustment screw (8a) clockwise to decrease and anticlockwise to increase the pressure. 6. Tighten the lock screw when the correct setting is achieved. Read on the gauge on the damper connection the pressure should be: COP 4050 & COP 4050CR, 25 bar The corresponding pressure read on the cabin gauge: (happens to be higher than the one read on the damper connection because it has a smaller pressure drop) COP 4050 & COP 4050CR, 30 bar NOTE! The percussion should stop if the damper pressure exceeds 120 bar of if it is lower than 45 bar.

Warning! Wronged adjusted damper pressure can cause damage to rock-drill, drill rig and drill string. Adjustments should only be performed by a qualified Atlas Copco service technician.

59

Damper & DPC-I system

L7 , L7 CR

DPC-I System Function The DPC-I system (Damper Pressure Controlled Impact) controls the impact function by sensing the damper pressure during drilling. Depending on the damper pressure, impact can be allowed, stopped or changed between high and low impact pressure. This is done by a number of logic valves in the rig hydraulic system. •

Logic-I. Prevents activation of impact if the damper pressure is below 45 bar, or stops impact if the damper pressure drops below 45 bar in case of, e.g., hose rupture, valve malfunction or drilling into cavity.

•

Logic-J. Stops impact if the damper pressure exceeds 120 bar in case of, e.g., excessive feed pressure or mechanical failure of the damper.

•

Logic-A. During normal drilling with high impact pressure, the logic proportional valve A is activated by the damper pressure through logic valveD. If the damper pressure falls below the preset value of logic-A, it is deactivated. The Pump 1 pressure provided by the high impact relief valve47f is then connected to the low impact relief valve 47e, thus the low impact relief valve47e controls the pump pressure. 40

ROC L7 CR: Logic-O. Allows activation of impact when the feed pressure has reached 45 bar and stops • impact when feeding backwards or entering a cavity in the rock.

Warning! Wronged adjusted damper pressure can cause damage to rock-drill, drill rig and drill string. Adjustments should only be performed by a qualified Atlas Copco service technician.

Setting the DPCI system The DPCI system can be adjusted either in the workshop or on the drill site. Adjusting in the workshop generally gives a more exact setting. On the other hand, adjusting during drilling can result in a setting well adapted to the rock conditions and other system settings. In general, logic-I and logic-O should be set as high as possible without making it difficult to start impact. 40

ROC L7 : Guidelines for setting logic valves. (Optimum setting might be higher). Logic-I 45 bar

Logic-J 120 bar

Logic-A 50 bar

40

ROC L7 CR: Guidelines for setting logic valves. (Optimum setting might be higher). Logic-I 45 bar

Logic-J 120 bar

Logic-A 50 bar

Logic-O (Feed pressure) 45 bar (or 2-5 bar below low feed pressure).

60

Damper & DPC-I system 

Setting during drilling – L7

L7

40

Logic-I, Setting during drilling: 1.

Check that the damper pressure is adjusted according to “Adjusting the damper pressure”.

2.

Start drilling on low impact pressure and collaring feed pressure.

3.

Adjust the feed pressure slowly towards 0 while observing the damper pressure gauge.

4.

When the damper pressure drops below 45 bar as a result of the low feed pressure, impact should be stopped automatically.

5.

If needed, adjust logic-I CW to increase the setting or CCW to decrease it.

6.

Test the function by starting drilling on low impact pressure and collaring feed pressure. When the drill cradle comes to a stop against the mechanical end stop, impact should shut of immediately. If not, the setting of logic-I should be increased.

NOTE! The setting of logic-I should be the highest possible without making it difficult to start impact. This means that high collaring feed and damper pressures calls for a higher setting of logic-I.

Logic-A, Setting during drilling: 1.

Check that the damper pressure is adjusted according to “Adjusting the damper pressure”.

2.

Start drilling. Make a good collaring, and then activate high impact pressure.

3.

Slowly decrease the feed pressure while observing the damper pressure gauge.

4.

The impact pressure should change from high to low when the damper pressure drops below 50 bar.

5.

If needed: Adjust logic-A CCW to lower the setting and CW to increase it.

Logic-J, Setting during drilling: 1. Check that the damper pressure is adjusted according to “Adjusting the damper pressure”. 2.

Start drilling on low impact pressure.

3.

Increase the feed pressure towards maximum while observing the damper pressure gauge.

4.

When the damper pressure exceeds 120 bar, impact should be stopped automatically.

5.

If needed, adjust logic-J CCW to lower the setting or CW to increase it.

NOTE! During this adjustment there is an increased risk of getting stuck in the hole due to the increased feed pressure. NOTE! In soft rock conditions it can be difficult to force the damper pressure high enough. In this case the damper pressure regulator can be adjusted temporarily to 120 bar.



Setting in workshop – L7

40

Logic-I, Setting in workshop: 1. 2.

Disconnect and plug the impact pressure hose on the rock-drill. Start the diesel engine, increase the rpm to 1500 and turn switch S130 to Drilling position.

3.

Adjust the damper pressure to 45 bar, read on the damper pressure gauge in the cabin.

4.

Activate low impact pressure. Check the pressure on the impact pressure gauge in the cabin.

5.

Slowly adjust logic-I in and out to find the activation point where the impact pressure disappears from the gauge. CW increases the activation point and CCW lowers it. Finally, adjust slowly CCW until the impact pressure appears on the gauge again.

61

Damper & DPC-I system

L7

6.

Verification: Increase and decrease the damper pressure a few times in order to verify that impact is stopped when the damper pressure is below 45 bar.

7.

De-activate impact and turn off the diesel engine.

8.

Tighten the lock nut on logic-I without changing the setting and reconnect the impact pressure hose on the rock-drill.

9.

Adjust the damper pressure according to “ Adjusting the damper pressure”. Verify through test drilling that impact can not be activated unless the drill bit is pressed against the rock.

Logic-A, Setting in workshop: 1.

Disconnect and plug the impact pressure hose on the rock-drill.

2.

Start the diesel engine, increase the rpm to 1500 and turn switch S130 to Drilling position.

3.

Adjust the damper pressure to 50 bar, read on the damper pressure gauge in the cabin.

4.

Activate drill rotation.

5.

Activate high impact pressure. Check the pressure on the impact pressure gauge in the cabin.

6.

Slowly adjust logic-A in and out to find the activation point where the impact pressure changes from high to low. CW increases the activation point and CCW lowers it. Finally, adjust slowly CW until the impact changes to low.

7.

Verification: Increase and decrease the damper pressure a few times in order to verify that the impact pressure changes when the damper pressure passes 50 bar.

8.

De-activate impact and turn off the diesel engine.

9.

Tighten the lock nut on logic-A without changing the setting and reconnect the impact pressure hose on the rock-drill.

10. Adjust the damper pressure according to “ Adjusting the damper pressure”. Verify through test drilling that the impact pressure changes from high to low when the damper pressure drops below 50 bar if the feed pressure is lowered.

Logic-J, Setting in workshop: 1.

Disconnect and plug the impact pressure hose on the rock-drill.

2.

Start the diesel engine, increase the rpm to 1500 and turn switch S130 to Drilling position.

3.

Adjust the damper pressure to 120 bar, read on the damper pressure gauge in the cabin.

4.

Activate low impact pressure. Check the pressure on the impact pressure gauge in the cabin.

5.

Slowly adjust logic-J in and out to find the activation point where the impact pressure disappears from the gauge. CW increases the activation point and CCW lowers it. Finally, adjust slowly CW until the impact pressure disappears from the gauge again.

6.

Verification: Increase and decrease the damper pressure a few times in order to verify that impact is stopped when the damper pressure exceeds 120 bar.

7.

De-activate impact and turn off the diesel engine.

8.

Tighten the lock nut on logic-J without changing the setting and reconnect the impact pressure hose on the rock-drill.

9.

Adjust the damper pressure according to “Adjusting the damper pressure”. Verify through test drilling that impact is stopped when the damper pressure exceeds 120 bar if the feed pressure is increased to maximum.

62

Damper & DPC-I system

L7

Related logic-valves •

•

Logic-D. It is activated by the pilot signal for drill rotation anti-clockwise. This means that the DPC-I system is only in effect when drill rotation is active. When logic-D is closed to damper pressure it is open to the Pump 1 system pressure. This means that when rotation is not active, the impact pressure will be according to the position of the impact control switch S446A/B, irrespective of the damper pressure. Logic-C. It is activated through Y101B (impact low pressure activated) or when feeding backwards. This excludeslogic-E from getting activated. Consequently, in these cases there can only be low impact pressure. Feeding backwards and activating impact is the

case when back hammer function is switched on. It does not matter which impact button (high or low) is pushed, the impact pressure will stay low anyway.

Note: Impact pressure has the same pressure as the pump pressure, since impact pressure comes from pump 1. In the diagram they are being distinguished by two different colours to identify their own circuits.

When activating button S446B for high impact, solenoid valve Y101A is then activated. The oil from Y101A activates logic-B, allowing the pump pressure to come through. The adequate damper pressure activates logic-I, leading the impact pressure to logic-Q and logic-E. The activated logic-Q ensures the hammer pressure gets delivered. The activated logic-E leads the pump pressure to pressure relief valve 47f under the condition that logic-A is activated. The meaning with DPC-I is that the pump 1 pressure is controlled by the damper pressure. The adequate damper pressure activates logic-A when anti-clockwise rotation is active. But when the damper pressure falls below the preset valve of logic-A (adjustable), the pump pressure is then led from pressure relief valve 47f to 47e. (see figure above)

63

Damper & DPC-I system 

L7 CR

40

Setting during drilling – L7 CR

Logic-I, Setting during drilling: 1.

Check that the damper pressure is adjusted according to “Adjusting the damper pressure”.

2.

Disable logic-O by turning its adjustment screw 3-4 turns CCW. If this is not done, impact will be stopped due to too low feed pressure during the setting of logic-I.

3.

Start drilling on low impact pressure and collaring feed pressure.

4.

Adjust the feed pressure slowly towards 0 while observing the damper pressure gauge.

5.

When the damper pressure drops below 45 bar as a result of the low feed pressure, impact should be stopped automatically.

6.

If needed, adjust logic-I CW to increase the setting or CCW to decrease it.

7.

Verify that impact can not be activated without rock contact, and that impact can be activated when the bit is pressed against the rock with collaring feed pressure.

8.

Readjust logic-O by turning its adjustment screw CW the same number of turns as it was turned CCW in point 1, or according to instruction.

9.

Test the function by going into the display and change the setting for “impact stop” (position M0) by adding 0.5 m in menu “Rapid feed stop”. This will deactivate the automatic impact stop. Write down the srcinal setting! Impact should then cease immediately when the rock drill cradle stops against the mechanical end stop. If not, the setting of logic-I should be increased.

10. Re-enter the parameter setting for “impact stop”. NOTE! The setting of logic-I should be the highest possible without making it difficult to start impact. This means that high collaring feed and damper pressures calls for a higher setting of logic-I. NOTE! Excessive drilling with too low feed pressure can cause damage to COPROD sections and rock drill.

Logic-O, Setting during drilling: 1.

Start drilling on low impact pressure and your normal collaring feed pressure.

2.

Adjust logic-O CW until impact is stopped and then CCW until impact just starts again.

3.

Reverse the feed direction. Impact should stop immediately without free hammering.

4.

Restart drilling and check that impact starts easily. If not, the setting of logic-O may need to be lowered slightly.

NOTE! The setting of logic-O should be the highest possible without making it difficult to start impact.

Logic-A, Setting during drilling: 1.

Check that the damper pressure is adjusted according to “Adjusting the damper pressure”.

2.

Start drilling. Make a good collaring, and then activate high impact pressure.

3.

Slowly decrease the feed pressure while observing the damper pressure gauge.

4.

The impact pressure should change from high to low when the damper pressure drops below 50 bar.

5.

If needed: Adjust logic-A CCW to lower the setting and CW to increase it.

Logic-J, Setting during drilling: 1.

Check that the damper pressure is adjusted according to “Adjusting the damper pressure”.

2.

Start drilling on low impact pressure.

64

Damper & DPC-I system

L7 CR

3.

Increase the feed pressure towards maximum while observing the damper pressure gauge.

4.

When the damper pressure exceeds 120 bar, impact should be stopped automatically.

5.

If needed, adjust logic-J CCW to lower the setting or CW to increase it.

NOTE! During this adjustment there is an increased risk of getting stuck in the hole due to the increased feed pressure. NOTE! In soft rock conditions it can be difficult to force the damper pressure high enough. In this case the damper pressure regulator can be adjusted temporarily to 120 bar.



Setting in workshop

Logic-I, Setting in workshop: 1.

Disconnect and plug the impact pressure hose on the rock-drill.

2.

Start the diesel engine, increase the rpm to 1500 and turn switch S130 to Drilling position.

3.

Adjust the damper pressure to 45 bar, read on the damper pressure gauge in the cabin.

4.

Activate drill-feed forward. This is required to enable activation of impact on COPROD rigs (logic-O). When the rock-drill almost reaches its lower end position, impact will be stopped by the impact stop check. This can be avoided by adding 0.5 m to the parameter for “impact stop”. Write down the srcinal setting!

5.

Activate low impact pressure. Check the pressure on the impact pressure gauge in the cabin.

6.

Slowly adjust logic-I in and out to find the activation point where the impact pressure disappears from the gauge. CW increases the activation point and CCW lowers it. Finally, adjust slowly CCW until the impact pressure appears on the gauge again.

7.

Verification: andpressure decreaseisthe damper pressure a few times in order to verify that impact is stopped whenIncrease the damper below 45 bar.

8.

De-activate impact and feed and turn off the diesel engine.

9.

Tighten the lock nut on logic-I without changing the setting, re-enter the parameter setting for “impact stop” and reconnect the impact pressure hose on the rock-drill.

10. Adjust the damper pressure according to “Adjusting the damper pressure”. Verify through test drilling that impact can not be activated unless the drill bit is pressed against the rock, and that impact can be activated when the bit is pressed against the rock with collaring feed pressure.

Logic-O, Setting in workshop: 1.

Disconnect and plug the impact pressure hose on the rock-drill.

2.

Start the diesel engine, increase the rpm to 1500 and turn switch S130 to Drilling position.

3.

Adjust the damper pressure to 50 bar in order to overcome logic-I (allow activation of impact without rock contact).

4.

Activate drill-feed forward. This is required to enable activation of impact on COPROD rigs (logic-O). When the rock-drill almost reaches its lower end position, impact will be stopped by the impact stop check. This can be avoided by adding 0.5 m to the parameter for “impact stop”. Write down the srcinal setting!

5.

Activate low impact pressure. Check the pressure on the impact pressure gauge in the cabin.

6.

Adjust the collaring feed pressure to 5 bar below the normal setting, e.g. 45 bar.

7.

Slowly adjust logic-O in and out to find the activation point where the impact pressure disappears from the gauge. CW increases the activation point and CCW lowers it.

65

Damper & DPC-I system

L7 CR

8.

Verification: In-crease and de-crease the collaring feed pressure in order to verify that impact is stopped at the set value.

9.

De-activate impact and feed and turn off the diesel engine.

10. Tighten the lock nut on logic-O without changing the setting, re-enter the parameter setting for “impact stop” and reconnect the impact pressure hose on the rock-drill. 11. Adjust the damper pressure according to “Adjusting the damper pressure”. Verify through test drilling that impact is stopped immediately when drill feed is stopped or reversed.

Logic-A, Setting in workshop: 1.

Disconnect and plug the impact pressure hose on the rock-drill.

2.

Start the diesel engine, increase the rpm to 1500 and turn switch S130 to Drilling position.

3.

Adjust the damper pressure to 50 bar, read on the damper pressure gauge in the cabin.

4.

Activate drill-feed forward. This is required to enable activation of Impact on COPROD rigs (logic-O). When the rock-drill almost reaches its lower end position, impact will be stopped by the impact stop check. This can be avoided by adding 0.5 m to the parameter for “impact stop”. Write down the srcinal setting!

5.

Activate drill rotation.

6.

Activate high impact pressure. Check the pressure on the impact pressure gauge in the cabin.

7.

Slowly adjust logic-A in and out to find the activation point where the impact pressure changes from high to low. CW increases the activation point and CCW lowers it. Finally, adjust slowly CW until the impact changes to low.

8.

Verification: Increase and decrease the damper pressure a few times in order to verify that the impact

9.

pressure changes when the damper pressure passes 50 bar. De-activate impact and feed and turn off the diesel engine.

10. Tighten the lock nut on logic-A without changing the setting, re-enter the parameter setting for “impact stop” and reconnect the impact pressure hose on the rock-drill. 11. Adjust the damper pressure according to “Adjusting the damper pressure”. Verify through test drilling that the impact pressure changes from high to low when the damper pressure drops below 50 bar if the feed pressure is lowered.

Logic-J, Setting in workshop: 1.

Disconnect and plug the impact pressure hose on the rock-drill.

2.

Start the diesel engine, increase the rpm to 1500 and turn switch S130 to Drilling position.

3.

Adjust the damper pressure to 120 bar, read on the damper pressure gauge in the cabin.

4.

Activate drill-feed forward. This is required to enable activation of impact on COPROD rigs (logic-O). When the rock-drill almost reaches its lower end position, impact will be stopped by the impact stop check. This can be avoided by adding 0.5 m to the parameter for “impact stop”. Write down the srcinal setting!

5.

Activate low impact pressure. Check the pressure on the impact pressure gauge in the cabin.

6.

Slowly adjust logic-J in and out to find the activation point where the impact pressure disappears from the gauge. CW increases the activation point and CCW lowers it. Finally, adjust slowly CW until the impact pressure disappears from the gauge again.

7.

Verification: Increase and decrease the damper pressure a few times in order to verify that impact is stopped when the damper pressure exceeds 120 bar.

8.

De-activate impact and feed and turn off the diesel engine.

66

Damper & DPC-I system 9.

L7 CR

Tighten the lock nut on logic-J without changing the setting, re-enter the parameter setting for “ impact stop” and reconnect the impact pressure hose on the rock-drill.

10. Adjust the damper pressure according to “Adjusting the damper pressure”. Verify through test drilling that impact is stopped when the damper pressure exceeds 120 bar if the feed pressure is increased to maximum.

Related logic-valves •

•

Logic-D. It is activated by the pilot signal for drill rotation clockwise. This means that the DPC-I system is only in effect when drill rotation is active. When logic-D is closed to damper pressure it is open to the Pump 1 system pressure. This means that when rotation is not active, the impact pressure will be according to the position of the impact control switch S446A/B, irrespective of the damper pressure. Logic-C. It is activated through Y101B (impact low pressure activated).

Note: Impact pressure has the same pressure as the pump pressure, since impact pressure comes from pump 1. In the diagram they are being distinguished by two different colours to identify their own circuits.

When activating button S446B for high impact, solenoid valve Y101A is then activated. The oil from Y101A activates logic-B, allowing the pump pressure to come through. The adequate damper pressure activates logic-I, leading the impact pressure to logic-Q and logic-E. The activated logic-Q ensures the hammer pressure gets delivered. The activated logic-E leads the pump pressure to pressure relief valve 47f under the condition that logic-A is activated. The meaning with DPC-I is that the pump 1 pressure is controlled by the damper pressure. The adequate damper pressure activates logic-A when clockwise rotation is active. But when the damper pressure falls below the preset valve of logic-A (adjustable), the pump pressure is then led from pressure relief valve 47f to 47e. (see figure above)

67

. p d e e F

Y175

Pilot lever Pump p.

B Q O C D

I J

Y101C

Y101B

high

1

Y101A

. p d e e F

Y175

Pilot lever Pump p.

B Q O C

A D

I J

Y101C

Y101B

low

2

Y101A

DPCI on ROC L740

3

Dust collector, DCT

Dust collector, DCT Conditions for the DCT suction functions: • • • •

•

Switch S130 in drilling position => D552-CH1/ON Sensor B118 activated, RHS arm in carousel => PLC input X10-5/ON Compressor load switch S180 must be on => D552-CH9/ON Flushing/Impact switch S446A or S446B must be activated, in either flushing or impact mode => D550-CH9/10/ON Switch S181 must be in suction position => D552-CH12/ON

The DCT system includes functions for starting the fan, controlling suction ON/OFF and cleaning the filters. The hydraulic power is supplied from pump 3.

DCT hydraulic system When the drilling/tramming switch S130 is in drilling position, it activates DCT fan motor solenoid Y250. This means that the fan is running as soon as the switch is in drilling position but there will not be any suction until the fan housing outlet is opened. The running speed of the DCT fan motor 14 is set by the pressure relief valve13a to around 5800 rpm @ 150 bar 40 40 30 for L7 , L7 CR; and to around 5000 rpm @ 150 bar forL8 . The speed can be changed by adjusting the screw on pressure relief valve 13a. When the fan motor is stopped by turning switchS130 away from drilling position, t he pilot operated relief valve 13b acts as a brake. It creates counter pressure in the return line when it is no longer pilot opened by the pump pressure and is set to stop the fan wheel in 8 seconds. The stop time can be changed by adjusting the screw on pressure relief valve 13b. The fan motor drain connection is fitted with restrictor15 to keep a sufficient amount of oil inside the housing for cooling purposes.

40 Figure: example, DCT circuits from L7 & L740CR

68

Dust collector, DCT

DCT electrical system Starting the DCT suction The fan housing outlet is operated by a hydraulic cylinder controlled by solenoid valve Y253. Y253 is controlled by PLC output X18-7, and will be activated ifS181 is ON (input D551CH12) and S446 is in reduced or full air/impact position (input D550 CH-9/10). To activate flushing air only, press S446A for shorter than 0.5 seconds, to start impact, press S446A for longer than 0.5 seconds. Normally, switch S181 is kept in the ON position to allow the suction to be automatically controlled by the impact switch. •

DCT filter cleaning When PLC output X18-7 is activated, it also activates the four filter cleaning valves Y251AD alternately. The filter cleaning valves quickly opens and closes to create pressure shocks of compressed air to clean the filters. The length of each cleaning pulse can be adjusted in the “Time pulse” data entry field in the display. The time between each pulse can be adjusted in the “Pulses/minute” data entry field in the display. The pulse time is set to 0.5 seconds (can be set up to 1 second) and the pulse can be set between 6 to 20 times per minute, depending on moisture of the drill dust. If the dust is moist the pulse is set to maximum 20 times, if the drill dust is very dry the pulse time is set to minimum 6 times. Factory setting is 10 pulses/minute. •

When the DCT switch S181 is OFF or when impact is shut off byS446, the control system activates valves Y251A-D simultaneously to clean the DCT filters. The cleaning time can be adjusted in the “Extended time” data entry field in the display.

DCT air system The air supply to the DCT is limited to 7 bar by pressure reducing valve and protected by a 8.5 bar safety valve. Solenoid valvesY251A-D opens alternately to clean the DCT filters.

DCT adjustable parameters •

•

•

Time pulse – length of the pulse, i.e. the signal time. Pulses/minute – how many pulses there is per minute Extended time – total time of the cleaning cycle (after drill stop).

69

DCT System Input / Signal

1



Switch S130 drilling position



Compressor load switch S180 on



Flushing/impact switch S446A or B on



DCT switch S181 on

DCT System Input / Signal 

S130/1 – D552, CH 1/ON



S180/A3 – D552, CH 9/ON



S446/A/B – D550, CH 9/10/ON



S181 – D551, CH 12/ON

Output on indicator card



2



X18-2

Y250



X18-7

Y253



X18-3

Y251A



X18-4

Y251B



X18-5

Y251C



X18-6

Y251D

Y250 Y253 Y251A

DCT fan on

hatch open

3

h c t a h T C D

Y253

Pump 3

170 bar

Y250 100 bar

4

Y251A Pressure vessel

5

Y251A-D

DCT filt

DCT filt

DCT filt

DCT filt

DCT off,

cleaning

6

h c t a h T C D

Y250

7

Y251C Y251D Y251A Y251B

8

Y250 100 bar

9

Protective functions

L7

Protective functions RPC-F system – L740 RPC-F, Rotation Pressure Controlled Feed. When drilling, the drill string must have a certain rotation torque in order to keep all the rod couplings tightened. Loosened joints increases the loss of impact energy transmitted to the drill bit and leads to damage of the threads with drill steel breakage as a possible result. However, too high rotation torque also has disadvantages: •

•

•

The couplings can get “over-tightened”, which makes it difficult to loosen the couplings when withdrawing the drill string. Higher load on the rock drills rotation driver, thus shorter life length. Jerky rotation could cause the anti-jamming to activate often.

Rotation torque is achieved by feed force, and will vary depending on different rock layers. The RPC-F system will adapt the feed force during drilling, maintaining only the required rotation torque. The RPC-F valve, 44, senses the pressure in the rotation circuit (rotation torque) and varies the feed pressure between the settings of the high feed pressure valve 47b and the low feed pressure valve47a to maintain the required rotation torque.

The working relation between RPC-F and anti-jamming is that, RPC-F tries to prevent the activation of anti-jamming. But once RPC-F can not bear it anymore, i.e. the drill-bit gets stuck, anti-jamming takes over the control over feed and rotation pressure while maintaining the required rotation torque.

70

Protective functions

Anti-Jamming system Devices The drill rig is equipped with two types of anti-jamming device. Flushing air flow switch – L740, L740CR Rotation pressure switch – All types Both changes the direction of feed from forward to backward, if activated by insufficient flushing air or too high rotation pressure, in order to avoid getting stuck. • •

Logic function of drill lever Since the anti-jamming inverts the feed direction, pulling the drill lever for feeding backwards would result in feed forward movement. To avoid this there is a pressure switch, B262, connected to the pilot pressure line for feed backwards. B262 is connected to PLC input X1616, which, when active, inhibits the anti-jamming output X11-11. Flushing air flow switch, B142 – L7 40, L7 40CR Conditions for the flow switch activated anti jamming function: • • • • •

Switch S130 in drilling position => D552-CH1/ON Sensor B118 activated, RHS arm in carousel =>PLC input X10-5/ON Compressor load switch S180 must be on => D552-CH9/ON Flushing air switch S100 must be in full flushing position => D551-CH1/ON Flushing/Impact switch S446A or S446B must be activated, in either flushing or impact mode => D550-CH9/10/ON

Pressure switch B262 not activated => PLC input X16-16/OFF Signal from flow switch B142 => PLC input X11-7/ON Result in: PLC output X11-11/ON => Solenoid Y109 activated • NOTE: The anti-jamming will be activated for at least 2 sec. • •

The flow switch is connected after the flushing air valves and senses the pressure drop over a restriction, venture pipe, in the flushing air line. The difference in pressure between the two connections is keeping the contact of the flow switch open. A too small or lost flow, e.g. if the drill-bit is clogged, means that the pressure drop decreases or is lost. This will allow the contact to close and send a signal to PLC input X11-7. Given solenoid this signal, the PLC output X11-11 activates Y109, which inverts the pilot signal from the drill lever. In such an event, the rock-drill will reverse the feed direction until the pressure drop/air flow is back to normal. When drilling is re-started after an anti-jamming action, it will be on collaring pressures for a period of 4 seconds before going back to full pressures.

71

Protective functions

Adjusting B142 – L7 40, L7 40CR The flushing air flow switch can only be set during drilling and only with full flushing air activated. 1. Unscrew the cover of the flow switch. 2. Drill almost down to the greatest depth that will be drilled on the site. Make sure full flushing is activated, switch S100, position (a). (see figure below) 3. Turn the adjustment screw (1) anti-clockwise until the rock-drill starts to back up. The higher the figure on the adjustment scale, the more sensitive the flow switch will be. Factory setting is 30 mbar. 4. Turn the adjustment screw (1) back clockwise until the rock-drill returns downwards. 5. Drill another whole to verify that the flow switch is not unintentionally activated due to too sensitive setting. If so, back the adjustment screw off a little bit more. 6. Assemble the cover of the flow switch. When changing dimension of drill-bit or drill steel, or if the hole depth is changed, it can be necessary to re-adjust the flow switch in order to maintain a good anti-jamming protection. L7

a

L7 CR

S100

S100

a

b b

Rotation pressure switch, B134 – L7 40, L7 40CR, L8 30 Conditions for the rotation pressure activated anti-jamming function: Switch S130 in drilling position => D552-CH1/ON Sensor B118 activated, RHS arm in carousel =>PLC input X10-5/ON Impact switch S446A or S446B must be activated => D550-CH9/10/ON • Pressure switch B262 not activated => PLC input X16-16/OFF • Signal from pressure switch B134 => PLC input X11-6/ON • Result in: PLC output X11-11/ON => Solenoid Y109 activated • NOTE: The anti-jamming will be activated for at least 2 sec. • •

The rotation pressure switch B134 senses the rotation pressure during drilling. A drastically increased rotation pressure can be an indication that the drill bit is getting stuck. If the rotation pressure exceeds the preset value of the rotation pressure switch which is 80 bar (factory setting), the rotation pressure switch will be activated and send a signal to PLC input X11-6. Given this signal, the PLC output X11-11, which inverts the pilot signals from the drill lever by activating solenoid valveY109. The result is that the rock-drill reverses the feed direction until the rotation pressure has dropped below the set value. When drilling is re-started after an anti-jamming action, it will be on collaring pressures for a period of 4 seconds before going back to full pressures. 72

Protective functions

Adjusting B134 Setting of the activation pressure of the anti-jamming is done on the pressure switch B134 itself. The activation pressure can be difficult to adjust during drilling because it is usually difficult to force the rotation pressure high enough. In stead, a simulation can be done. Warning! During the setting, the rock-drill will reverse automatically. 1. Turn the knob for adjustment of the drill rotation speed anti-clockwise until the spring pressure is released. The rotation speed will now be 0 rpm. 2. For CR and DTH: Feed the rock drill down until the coupling sleeve of the drill steel is in the upper break out table. Close the upper break out table to lock the sleeve.

3. 4. 5.

6.

7.

8. 9.

For TH: Feed the rock drill down until the drill bit is in the upper drill steel support. Close the upper drill steel support to lock the drill bit. Activate drill rotation. Activate drill feed. Slowly turn the rotation speed control clockwise while observing the drill rotation pressure gauge. When the pressure exceeds the preset value of the pressure switch B134, the feed direction will change. This can be seen as the feed pressure turns to 0 and the rock drill tries to pull out of the drill steel support. Turn the rotation speed control anti-clockwise to lower the rotation pressure and allow the feed to change back to downwards. If the setting needs to be changed this can be done by turning the adjustment screw on B134 clockwise to increase the activation pressure or anti-clockwise to decrease it. Repeat point 1 – 6 to verify the new setting. Re-adjust the rotation speed to normal.

Feed & p ump pressure during anti-jam ming – L7 40, L7 40CR Impact/pump 1 pressure: When feed backwards is automatically activated during anti-jamming, PLC deactivates output X11-9 for impact activation. This deactivates Y101A, and leaves logic valve B idle hence blocking the access to the pressure relief valves47e and 47f which control the pump 1 pressure. The pump 1 system pressure is then limited by pressure relief valve4d, together with the delta-p pressure, pump 1 will be working at 250 bar (LS return line + delta-p). Feed pressure: The pump 1 pressure going to the drill feed directional valve 4f is then being limited by a check valve 4m set to 190 bar for feeding backwards.

Feed pressure during anti-jammi ng – L8 30 The pump 1 pressure going to the drill feed directional valve 4f is then being limited by check valve 4m set to 190 bar for feeding backwards.

73

RPCF for L740 

1

Maintaining only the required rotation torque for drilling

Anti-jamming 

Two anti-jamming devices – Monitoring of the flushing air flow (L740, L740CR) – Monitoring of the rotation pressure





Inverts the feed direction incase of insufficient air flow or too high rotation pressure Factory settings: – 30mBar pressure drop over the venturi – 80 Bar rotation pressure

2

Anti-jamming Input / Signal 

S130/1 - D552,CH 1/ON



S180/A3 – D552, CH 9/ON



S446/A/B – D550, CH 9/10/ON



S100/A3 – D551, CH 1/ON



X11-7

B142



X11-5

B134

Output on indicator card





3

X11-11 Y109

B142

Y115

Y116

w lo f ir a in a M 4

Y169

B134

Y121A

Pump 4

5

L740, L740

Page 28

B142

L740, L740CR, L8 B134

Page 27

Y109 is activated by either B142 or B134.

Page 35 6

L740, L740CR, L8 Y109

Anti-jammi

Pilot lever

Feed backwards

7

Y109

C

L740, L740CR, L8 B262

Page 27

L740, L740CR, L8 Y109 gets de-activated by B262.

Y109

Page 35

Anti-jamming re 8

Pilot lever

Feed backwards

Y109 B262

9

C

Length measurement

Length measurement Hole depth measurement Data from pulse sensor B172 is handled for measuring hole length, with stop signal for drilling when set length is reached. A choice can be made between hole depth and hole length which stops the drilling.

The first row in the menu view to the right (figure 2, 3) shows actual length/depth of the hole. Hole length is the actual number of metres that have been drilled. Hole depth is the vertical distance from ground level to the bottom of the hole. Hole length and hole depth can be set on a menu, push enter key according to the selection on figure 1. •

Figure 1

•

The value in the square box shows the required hole length/hole depth. The length or depth can be set from 0.1m- 99.9m. When the hole has reached the required depth/length the PLC automatically sets the drill output “low”. The drilling can continue by restarting the drilling functions.

Figure 2

The second row displays the penetration rate. The third row displays the position of the drill bit. EXAMPLE: If the hole is 10m the first row shows 10m. If the drill steel is run backward the drill bit’s position starts to count backward to inform the operator of the distance from the bit to the bottom of the hole.

: Reset of the hole depth

Figure 3

: Numbers of performed couplings

The last row displays the total number of drilled metres. This parameter can be reset. : Laser sensor activation (Refer to chapter “Laser sensor (Option)”) The hole length measurement system works in close relation with sensor B104. Every time the cradle passes through sensor B104 from above, the cradle position is being calibrated, so the cradle always finds itself at the correct position on the beam. Refer to section “Rapid feed”, paragraph “Calibrating B172” for more information.

74

Length measurement Basic conditions for measurement: Correct length of drill steel must be chosen in the drill steel menu. • The length measurement system must be reset before the start of drilling. • Impact must be activated for measuring hole length/depth. Bit position will be • measured even without impact.

During rod handling, the HEC system pause the drill length/depth measuring. This means that negative distance created when backing up to add a new rod is not taken into consideration by the system. The start of the pause is defined by a signal coming from a pressure switch B128 along with other conditions (see below). B128 is activated when unthreading the rock drill from the rod. Conditions for blocking: Upper drill steel support closed (for RHS 102); lower break out table closed (for RHS • 140). Unthreading activated => B128 activated. • Impact interrupted. •

To exit standby and re-enter measuring mode after adding a drill steel, the following conditions must be fulfilled. Conditions for restarting measurement after rod handling: Upper drill steel support opened (for RHS 102); lower break out table opened (for • RHS 140). • •

Impact activated. The cradle must be retracted to the upper position, i.e. 90% of the length for the chosen rod.

Drill stop activation for reached depth Drill stop activation for reached depth is a build-in function of the HEC system. When the drilled metre on the display equals to the metre that has been entered , all drilling functions will be stopped. The drill lever is then automatically shifted to rapid feed/threading mode.

75

Rod Handling System, RHS 102

L7

Rod Handling System, RHS 102 Conditions common for all RHS functions: • •

•

Switch S130 in drilling position => D552-CH1/ON Switch B379 (operator in chair) must be activated => D550-CH1/ON The impact control switchS446A/B must be OFF => D550-CH9/10/OFF

S111

The functions of the different rod handling movements are electrically operated by the RHS control lever S111. The control lever sends a signal to the PLC which, when the right inputs are present, activates the corresponding hydraulic valve in order to perform one of the following movements: RHS control lever S111: ROD CAROUSEL TRANSFER ROTATION -To carousel -Clockwise -To drill centre -Anti-clockwise

ROD GRIPPER -Hard grip -Guide grip -Open

The hydraulic power is supplied from Pump 1 and is limited to 200 bar by pressure reducing valve 91. Some functions have individual pressure reducers to further limit the pressure. RHS arm

→

carousel/hard grip Button for opening gripper claws

Carousel rotation clockwise

Carousel rotation anti-clockwise

RHS arm drill centre/hard grip (Note: lever has a latch in this position) →

Rod transfer Since moving to/from the carousel/drill centre applies to different set of conditions, the movement sequences will be described at different stages.

To drill centre with a rod

CLAIM: The carousel loaded, the grippers are in the carousel holding on to the rod which is going to moved, the initial holding state should be hard grip.

76

Rod Handling System, RHS 102

L7

Control lever S111 is mechanically latched during this movement, that is to say one push on the lever and the lever stays there, instead of a spring return to centre position. With the lever in position it will carry out the whole movement until the rod is moved into the drill centre. The function has been introduced to prevent grippers to automatically switch to loose grip moved into the drill centre. Loose grip can be achieved by pulling the lever back to the neutral position, when the arm reached its end position (drill centre).

Hard grip stage

S111 back to neutral

Loose grip stage

NOTE! Always put the rod grippers in loose grip before the threads meet in order to let the rod in the rod gripper rotate. The threads will otherwise be easily damaged.

Additional conditions: - Sensor B118 activated, PLC input X10-5/ON. (Arm in carousel.) - The rod grippers should be in hard grip during this movement as the PLC output X128 and X12-3 are OFF. This is also the normal condition of the grippers. - RHS control lever S111 to position (b), input D551-CH3/ON. When all the conditions are met, these two functions will take place in its order: Solenoid valve Y301B will be activated by PLC output X12-5. The cylinder speed is • limited by restrictors 82. (Rod transfer towards dill centre starts.) When the rod transfer arm have reached position drill centre, sensor B120 will be activated, PLC input X10-3/ON. This results in: PLC output X12-5/ON, Y301B activated. (Rod transfer towards drill centre • stops mechanically.) SEQUENCE COMPLETE

77

Rod Handling System, RHS 102

L7

To carousel without a rod

CLAIM: The carousel could still have rods in it or not, arm has to move back to carousel in order to get the next rod to drill; also to allow drilling. Additional conditions: - Sensor B120 activated, PLC input X10-3/ON. (Arm in drill centre.) - RHS control lever S111 top button pushed, input D551-CH6/ON. The rod grippers should be in open grip during this movement. - RHS control lever S111 to position (a), input D551-CH2/ON. When all the conditions are met, this function will take place: Solenoid valve Y300 will be activated by PLC output X12-3. (Rod grippers are open.) • Solenoid valve Y301A will be activated by PLC output X12-4. The cylinder speed is • limited by restrictors 82. (Arm transfer towards carousel starts.) When the rod transfer arm have reached position carousel, sensor B118 will be activated, PLC input X10-5/ON. This results in: PLC output X12-4/ON, Y301A activated. (Arm transfer towards carousel stops • mechanically.) SEQUENCE COMPLETE

To carousel with a rod

CLAIM: The carousel empty or not, rods are supposed to be put back to the carousel. Additional conditions: - Sensor B120 activated, PLC input X10-3/ON. (Arm in drill centre.) - The rod grippers should be in hard grip during this movement as the PLC output X128 and X12-3 are OFF. This is also the normal condition of the grippers. - RHS control lever S111 to position (a), input D551-CH2/ON. When all the conditions are met, these two functions will take place in its order: Solenoid valve Y301A will be activated by PLC output X12-4. The cylinder speed is • limited by restrictors 82. (Rod transfer towards carousel starts.) When the rod transfer arm have reached position carousel, sensor B118 will be activated, PLC input X10-5/ON. This results in: PLC output X12-4/ON, Y301A activated. (Rod transfer to wards carousel stops • mechanically.) SEQUENCE COMPLETE

78

Rod Handling System, RHS 102

L7

To drill centre without a rod

CLAIM: The carousel could be empty or not, the grippers are in hard grip state in carousel. This is the case when drilling has been done, rods are being pulled out and need to be picked up from the drill centre. Loose grip is needed first when the grippers have been moved into the drill centre, because only loose grip can allow the upper rod to rotate out of the lower rod/drill bit which is being held in the drill steel support. Loose grip can be achieved by pulling the lever to the neutral position. Manual switching is needed here since the lever is latched in this position. Once the upper rod has been unthreaded, hard grip needs to be activated in order to allow the rock drill to be unthreaded. Hard grip can be achieved by pulling the lever backwards to the “arm to drill centre” position, thus breaking the conditions for loose grip.

Loose grip stage

S111 to arm to drill centre 

Hard grip stage

Additional conditions: - Sensor B118 activated, PLC input X10-5/ON. (Arm in carousel.) - RHS control lever S111 top button pushed, input D551-CH6/ON. The rod grippers should be in open grip during this movement. - RHS control lever S111 to position (b), input D551-CH3/ON. When all the conditions are met, this function will take place: Solenoid valve Y300 will be activated by PLC output X12-3. (Rod grippers are open.) • Solenoid valve Y301B will be activated by PLC output X12-5. The cylinder speed is • limited by restrictors 82. (Arm transfer towards dill centre starts.) When the rod transfer arm have reached position drill centre, sensor B120 will be activated, PLC input X10-3/ON. This results in: PLC output X12-5/ON, Y301B activated. (Arm transfer towards drill centre • stops mechanically.) SEQUENCE COMPLETE 79

Rod Handling System, RHS 102

L7

Carousel rotation Additional conditions: The rod gipper arms must be in carousel position, sensor switchB118 ON, PLC input • X10-5/ON. RHS control lever S111, top button pushed, input X550-CH6/ON. • RHS control lever S111, to position (c) or (d), input X550-CH4 or CH5/ON. • The carousel stop positions are determined by the two sensors B182 (CCW) and B183 (CW). The carousel rotation motor solenoid valveY303A/B is activated by PLC output X15-2 (CWW) and X15-1 (CW). When rotation is activated it will continue until the corresponding sensor is activated, giving input to PLC X14-8 and X13-1 respectively. The rotation speed is limited by restrictors 84. To facilitate the rotation of the carousel, the rod grippers must be the rod grippers must be at the carousel position to allow rotation, i.e. B118 activated.

Rod grippers There are three rod gripper positions, which are controlled by solenoid valves Y300 and Y306. o Hard grip Additional conditions: None. Hard grip is the normal state of the grippers. None of the solenoid valves are activated with the result that system pressure, 200 bar, is acting to keep the gripper closed. o Open grippers Additional conditions: RHS control lever S111, top button pushed, input X550CH6/ON. Solenoid valve Y300 is activated by PLC output X12-3. o Guide grip (loose grip) Additional conditions: RHS control lever S111 must be in middle position, no signal • from the RHS switch to the PLC. Sensor B120 activated, PLC input X10-3/ON. • Guide grip can only be achieved when the rod grippers are in the drill-centre position and when there is no signal from RHS switch to the PLC. Solenoid valve Y306 in the guide grip valve block80, is activated by PLC output X12-8. In this case, the gripper pressure is set by the pressure relief valve 80a set to 10 bar (adjustable, see figure right and below). The 0.6 mm restrictor 80b limits the amount of oil passing over the relief valve. •

The pressure to the cylinders would be just to support the weight of the drill rod without obstructing the rod from rotating inenough the grippers.

80

Rod Handling System, RHS 102

L7

Sleeve retainer (Option) Additional conditions: Sleeve retainer switch S182 ON, input D551-CH13/ON. • Solenoid valve Y309 is activated by PLC output X15-3. The cylinder speed is limited by restrictors 83. The sleeve retainer can only be folded out when the rod grippers are in drill centre position and in hard grip mode. The rod transfer movements which include “arm to carousel” function are electrically blocked as long as the sleeve retainer is activated.

Drill steel supports & suction hood Conditions for these functions: The Drilling/Tramming switch S130 must be in drilling position • o Drill steel supports, upper and lower The drill steel supports are controlled by switchesS119 (upper) and S187 (lower), which operates solenoid valvesY361A-B and Y350A-B respectively. The cylinder speed is limited by restrictors 85 and 86. o Suction hood The suction hood is controlled by switchS167, which operates solenoid valveY357. The hydraulic pressure downwards is limited by pressure reducing valve88 set to 40 bar, and the cylinder speed is limited by restrictor 87. NOTE: It’s important that during drilling, the drill steel supports should be carefully operated to prevent the drill rods colliding with them.

Service winch (Option) The service winch is a pure hydraulic function that works aside of the PLC. Solenoid valve Y208 controls the moving direction of the winch, and it is activated by a lever that sits on the lower drill steel support.

81

RHS 102 – L7 40 Input / Signal

1



Switch S130 in Drilling pos.



Operator in chair switch B379



Flushing/impact switch S446A or B off

RHS 102 – L7 40 Input / Signal S130/1 - D552, CH 1/ON



B379 - D550, CH 1/ON



S446A/B - D550, CH 9/10/OFF



S111 - D551, CH 2/3/4/5/6/ON



X10-5

B118

X10-3

B120

X15-2

B182

X15-1

B183









Output on indicator card X17-1



Y301A/B

X13-11 Y303A/B



X12-3

Y300

X12-8

Y306





2

1

B118

Page 33

2

Page 31

B120 1

Page 41 3

Y301B

Rod transfer from carou

200 bar

Y301B

4

) 1 p m u p m o r (f S H R

Y303A

1

2 Rotation stops for 1 second.

Page 41

B182

Page 32

5

2

Carousel rotation C

200 bar

Y300

Y303A

6

) 1 p m u p m ro f( S H R

Y306

200 bar

Y300

7

) 1 p m u p m ro f( S H R

L8 , L7 CR

Rod Handling System, RHS 140

Rod Handling System, RHS 140 Conditions common for all RHS functions: • •

•

Switch S130 in drilling position => D552-CH1/ON Switch B379 (operator in chair) must be activated => D550-CH1/ON The impact control switchS446A/B must be OFF =>

S111

D550-CH9/10/OFF The functions of the different rod handling movements are electrically operated by the RHS control lever S111. The control lever sends a signal to the PLC which, when the right inputs are present, activates the corresponding hydraulic valve in order to perform one of the following movements: RHS control lever S111: ROD CAROUSEL TRANSFER GATE -To carousel -Open -To drill centre -Closed

CAROUSEL ROTATION -Clockwise -Anti-clockwise

ROD GRIPPER -Hard grip -Guide grip -Open

Figure: example, L830 left panel

GRIPPER ROTATION -To carousel -To drill centre

The hydraulic power is supplied from Pump 1 and is limited to 200 bar by pressure reducing valve 97. Some functions have individual pressure reducers to further limit the pressure. RHS arm

→

carousel/hard grip Button for opening gripper claws

Carousel rotation clockwise

Carousel rotation anti-clockwise

RHS arm drill centre/hard grip (Note: lever has a latch in this position) →

Tube transfer The pressure to the tube transfer cylinders is limited to 100 bars by the pressure reducing valve 83. The carousel gates (lower and upper) need to be opened at the same time to let in and let out drill rods, and this action has to take place before drill rod has been delivered into the carousel and taken out to the drill centre. The function is activated in connection with the tube transfer activation. Since moving to/from the carousel/drill centre applies to different set of conditions, the movement sequences will be described at different stages.

82

Rod Handling System, RHS 140

L8 , L7 CR

To drill centre with a tube

CLAIM: The carousel loaded, the grippers are in the carousel holding on to the tube which is going to moved, the initial holding state should be hard grip. Control lever S111 is mechanically latched during this movement, that is to say one push on the lever and the lever stays there, instead of a spring return to centre position. With the lever in position it will carry out the whole sequence until the tube is moved into the drill centre. The function has been introduced to prevent grippers to automatically switch to loose grip when moved into the drill centre. Loose grip can be achieved by pulling the lever back to the neutral position, when the arm reached its end position (drill centre).

Hard grip stage NOTE!

S111 back to neutral

Loose grip stage

Always put the rod grippers in loose grip before the threads meet in order to let the

tube in the rod gripper rotate. The threads will otherwise be easily damaged.

83

Rod Handling System, RHS 140

L8 , L7 CR

Additional conditions: - Sensor B118 activated, PLC input X10-5/ON. (Arm in carousel.) - The rod grippers should be in hard grip during this movement as the PLC output X128 and X12-3 are OFF. This is also the normal condition of the grippers. - RHS control lever S111 to position (b), input D551-CH3/ON. When all the conditions are met, these two functions will take place in its order: Solenoid valve Y310 will be activated by PLC output X15-4. The cylinder speed is • limited by restrictors 86. (Carousel door opens.) Solenoid valve Y301B will be activated by PLC output X12-5. The cylinder speed is • limited by restrictors 82. (Tube transfer towards dill centre starts.) When the tube transfer arm has reached the position between the carousel and drill centre, sensor B119 will be activated, PLC input X10-2/ON. This results in: PLC output X12-5/OFF, Y301B deactivated. (Tube transfer t owards drill • centre stops.) PLC output X16-12/ON, Y311B activated. (This will rotate t he rod grippers • from facing the carousel to facing the drill centre.) The gripper rotation sequence will continue for 3 seconds, after that: PLC output 16-12/ON, Y311B activated. (Even though Y311B is activated, • but the gripper rotation has stopped mechanically.) PLC output X15-4/OFF, Y310 deactivated. (Carousel door closes.) • PLC output X12-5/ON, Y301B activated again. (Tube transfer towards • drill centre continues.) When the tube transfer arm have reached position drill centre, sensor B120 will be activated, PLC input X10-3/ON. This results in: PLC output X12-5/ON, Y301B activated. (Tube transfer t owards drill • centre stops mechanically.) PLC output X16-12/ON, Y311B activated. (Gripper rot ation has stopped • mechanically.) PLC output X12-8/OFF and X12-3/OFF, Y306 and Y300 deactivated. • (Hard grip) SEQUENCE COMPLETE

84

Rod Handling System, RHS 140

L8 , L7 CR

To carousel without a tube

CLAIM: The carousel could still have tubes in it or not, arm has to move back to carousel in order to get the next tube to drill; and/or moving back to carousel to allow drilling. Additional conditions: - Sensor B120 activated, PLC input X10-3/ON. (Arm in drill centre.) - RHS control lever S111 top button pushed, input D551-CH6/ON. The rod grippers should be in open grip during this movement. - RHS control lever S111 to position (a), input D551-CH2/ON. When all the conditions are met, this function will take place: Solenoid valve Y310 will be deactivated by PLC output X15-4. (Carousel door is • closed.) Solenoid valve Y300 will be activated by PLC output X12-3. (Rod grippers are open.) • Solenoid valve Y301A will be activated by PLC output X12-4. The cylinder speed is • limited by restrictors 82. (Arm transfer towards carousel starts.) When the tube transfer arm has reached the position between the carousel and drill centre, sensor B119 will be activated, PLC input X10-2/ON. This results in: PLC output X12-4/OFF, Y301A deactivated. (Arm tr ansfer towards carousel • stops.) PLC output X18-1/ON, Y311A activated. (This will rotate the rod grippers • from facing the drill centre to facing the carousel.) The gripper rotation sequence will continue for 3 seconds, after that: PLC output 18-1/ON, Y311A activated. (Even though Y311A is activated, • but the gripper rotation has stopped mechanically.) PLC output X12-4/ON, Y301A activated again. (Arm transfer towards • carousel continues.) When the tube transfer arm have reached position carousel, sensor B118 will be activated, PLC input X10-5/ON. This results in: PLC output X12-4/ON, Y301A activated. (Arm transfer towards • carousel stops mechanically.) PLC output X18-1/ON, Y311A activated. (Gripper rotation has sto pped • mechanically.) SEQUENCE COMPLETE

85

Rod Handling System, RHS 140

L8 , L7 CR

To carousel with a tube

CLAIM: The carousel empty or not, tubes are supposed to be put back to the carousel. Additional conditions: - Sensor B120 activated, PLC input X10-3/ON. (Arm in drill centre.) - Sensor B178 deactivated, PLC input X16-1/OFF. (No tube in carousel outlet.) - The rod grippers should be in hard grip during this movement as the PLC output X128 and X12-3 are OFF. This is also the normal condition of the grippers. - RHS control lever S111 to position (a), input D551-CH2/ON. When all the conditions are met, these two functions will take place in its order: Solenoid valve Y310 will be activated by PLC output X15-4. The cylinder speed is • limited by restrictors 86. (Carousel door opens.) Solenoid valve Y301A will be activated by PLC output X12-4. The cylinder speed is • limited by restrictors 82. (Tube transfer towards carousel starts.) When the tube transfer arm has reached the position between the carousel and drill centre, sensor B119 will be activated, PLC input X10-2/ON. This results in: PLC output X12-4/OFF, Y301A deactivated. (Tube transfer stops.) • PLC output X18-1/ON, Y311A activated. (This will rotate the rod grippers • from facing the drill centre to facing the carousel.) The gripper rotation sequence will continue for 3 seconds, after that: •

•

PLC output 18-1/ON, activated. (Even though Y311A is activated, but the gripper rotationY311A has stopped mechanically.) PLC output X12-4/ON, Y301A activated again. (Tube transfer to wards carousel continues.)

When the tube transfer arm have reached position carousel, sensor B118 will be activated, PLC input X10-5/ON. This results in: PLC output X12-4/ON, Y301A activated. (Tube transfer to wards • carousel stops mechanically.) PLC output X18-1/ON, Y311A activated. (Gripper rotation has sto pped • mechanically.) PLC output X15-4/OFF, Y310 activated. (Carousel door closes.) • SEQUENCE COMPLETE

86

Rod Handling System, RHS 140

L8 , L7 CR

To drill centre without a tube

CLAIM: The carousel could be empty or not, the grippers are in hard grip state in carousel. This is the case when drilling has been done, tubes are being pulled out and need to be picked up from the drill centre. Loose grip is needed first when the grippers have been moved into the drill centre, because only loose grip can allow the breakout table to take place and then allow the upper tube to rotate out of the lower tube/drill bit which is being held in the lower breakout table. Loose grip can be achieved by pulling the lever to the neutral position. Manual switching is needed here since the lever is latched in this position. Once the upper rod has been unthreaded, hard grip needs to be activated in order to allow the rotation unit to be unthreaded. Hard grip can be achieved by pulling the lever backwards to the “arm to drill centre” position, thus breaking the conditions for loose grip.

Loose grip stage 

S111 to arm to drill centre 

Hard grip stage

87

Rod Handling System, RHS 140

L8 , L7 CR

Additional conditions: - Sensor B118 activated, PLC input X10-5/ON. (Arm in carousel.) - RHS control lever S111 top button pushed, input D551-CH6/ON. The rod grippers should be in open grip during this movement. - RHS control lever S111 to position (b), input D551-CH3/ON. When all the conditions are met, this function will take place: Solenoid valve Y310 will be deactivated by PLC output X15-4. (Carousel door is • closed.) Solenoid valve Y300 will be activated by PLC output X12-3. (Rod grippers are open.) • • Solenoid valve Y301B will be activated by PLC output X12-5. The cylinder speed is limited by restrictors 82. (Arm transfer towards dill centre starts.) When the tube transfer arm has reached the position between the carousel and drill centre, sensor B119 will be activated, PLC input X10-2/ON. This results in: PLC output X12-5/OFF, Y301B deactivated. (Arm transfer towards dill centre • stops.) PLC output X16-12/ON, Y311B activated. (This will rotate t he rod grippers • from facing the carousel to facing the drill centre.) The gripper rotation sequence will continue for 3 seconds, after that: PLC output X16-12/ON, Y311B activated. (Even though Y311B is • activated, but the gripper rotation has stopped mechanically.) PLC output X12-5/ON, Y301B activated again. (Arm t ransfer towards drill • centre continues.) When the tube transfer arm have reached position drill centre, sensor B120 will be activated, PLC input X10-3/ON. This results in: PLC output X12-5/ON, Y301B activated. (Arm transfer towards drill • centre stops mechanically.) PLC output X16-12/ON, Y311B activated. (Gripper rot ation has stopped • mechanically.) SEQUENCE COMPLETE

Carousel rotation Additional conditions: The rod gipper arms must be in drill centre position or in the middle position, sensor • switch B120 or B119 ON, PLC input X10-3 or X10-2/ON. RHS control lever S111, to position (c) or (d), input X550-CH4 or CH5/ON. • The carousel stop positions are determined by the two sensors B182 (CCW) and B183 (CW). The carousel motor solenoid valveY303A/B is activated by PLC output X15-2 (CWW) ANDrotation X15-1 (CW). When rotation is activated it will continue until the corresponding sensor is activated, giving input to PLC X14-8 and X13-1 respectively. The rotation speed is limited by restrictors 85. To facilitate the rotation of the carousel, the rod grippers must be at the drill centre or at the middle position, i.e. B120 or B119 activated.

88

Rod Handling System, RHS 140

L8 , L7 CR

Rod grippers There are three rod gripper positions, which are controlled by solenoid valves Y300 and Y306. o Hard grip Additional conditions: None. Hard grip is the normal state of the grippers. None of the solenoid valves are activated with the result that system pressure, 200 bar, is acting to keep the gripper closed. o Open grippers Additional conditions: RHS control lever S111, top button pushed, input X550• CH6/ON. Solenoid valve Y300 is activated by PLC output X12-3. o Guide grip (loose grip) Additional conditions: RHS control lever S111 must be in middle position, no signal • from the RHS switch to the PLC. Sensor B120 activated, PLC input X10-3/ON. • Guide grip can only be achieved when the rod grippers are in the drill-centre position and when there is no signal from RHS switch to the PLC. Solenoid valve Y306 in the guide grip valve block80, is activated by PLC output X12-8. In this case, the gripper pressure is set by the pressure relief valve 80a set to 10 bar (adjustable, see figure right and below). The 0.6 mm restrictor 80b limits the amount of oil passing over the relief valve. The pressure to the cylinders would be just enough to support the weight of the drill rod without obstructing the rod from rotating in the grippers.

89

Rod Handling System, RHS 140

L8 , L7 CR

Drill steel supports & suction hood Conditions for these functions: The Drilling/Tramming switch S130 must be in drilling position • o Drill steel supports, upper and lower – L830 The drill steel supports are controlled by switchesS119 (upper) and S187 (lower), which operates solenoid valvesY361A-B and Y350A-B respectively. The cylinder speed is limited by restrictors 91 and 92. o Drill steel support, upper and lower – L7 40CR Both the upper and lower drill steel supports are controlled by one switch S187, which operates solenoid valvesY361A-B. The cylinder speed is limited by restrictor91. o Suction hood The suction hood is controlled by switchS167, which operates solenoid valveY357. The hydraulic pressure downwards is limited by pressure reducing valve94 set to 40 bar, and the cylinder speed is limited by restrictor 93.

Breakout table and rock drill lock Conditions for these functions: The Drilling/Tramming switch S130 must be in drilling position • o Breakout wrench, clockwise and anti-clock wise rotation The Breakout wrench is controlled by switchS258, which opens solenoid valvesY352AB respectively. The cylinder speed is limited by restrictors 87. o Breakout table, upper and lower The breakout table is controlled by switch S260 (upper) and S259 (lower), which operates solenoid valves Y356A-B and Y354A-B respectively. The pressure to the upper breakout table cylinder limited by pressure reducing valve88, and the pressure to the lower breakout table cylinder is limited by pressure reducing valve89. o Rock drill lock rotation – L7 40CR only The rock drill lock is controlled by switchS257, which opens solenoid valveY359. The hydraulic pressure to the cylinder is limited by pressure reducing valve98 set to 50 bar.

Service winch (Option) The service winch is a pure hydraulic function that works aside of the PLC. Solenoid valve Y208 controls the moving direction of the winch, and it is activated by a lever that sits on the lower drill steel support.

90

RHS 140 – L7 40CR, L830 Input / Signal

1



Switch S130 in Drilling pos.



Operator in chair switch B379

RHS 140 – L7 40CR, L830 Input / Signal S130/1 - D552, CH 1/ON



B379 - D550, CH 1/ON



S111 - D551, CH 2/3/4/5/6/ON



X10-5 X10-2

B118 B119

X10-3

B120

X15-2

B182

X15-1

B183











Output on indicator card X11-13

Y310

X17-1

Y301A/B

X11-14

Y311A/B

X13-11

Y303A/B

X12-3

Y300

X12-8

Y306













2

L830, L7 1

B118

Page 33

1

Y310

Page 42

Tube transfer from carou

3

L830, L7 Y301B 2

Page 41

3

3 Off for 3 seconds when B119 is activated.

B119

Page 31

3 On when B119 is activated.

Y311B

Page 42 4

Tube transfer from carou

L830, L7 Y301B 2

Page 41

3

3 Off for 3 seconds when B119 is activated.

B119

Page 31

3 On when B119 is activated.

Y311B

Page 42 5

Tube transfer from carou

L830, L7 Y301B 4 3 seconds later.

Page 41

5

B120

Page 31

Tube transfer from carou

6

200 bar

Y310 Y301B Y311B

7

L830, L7

Y303A

1

2 Rotation stops for 1 second.

Page 41

B182

Page 32

8

2

Carousel rotation C

200 bar

Y303A

9

Y306

200 bar

Y300

10

L7

Extractor unit (Option)

Extractor unit (Option) The extractor function of the rock-drill consists of a hydraulic piston in the front part of the rock-drill and a logic valve for the activation of it, the unit is also known as the back hammer. The hydraulic power is supplied from Pump 1. The extractor unit is used when the rock conditions vary a lot and there is a large risk of jamming. The function of the extractor unit is to provide reverse percussion to the shank adapter and thus the drill string and drill bit. The shank adapter for rock-drills equipped with an extractor unit has a special flange that receives the reverse percussion force. Since the shank adapter is pressed into the rock-drill by the feed force during normal drilling, it works without the flange meeting the extractor piston. The extractor piston lifts the shank-adapter to enable the impact piston to reach it when feeding backwards in a jam situation (see picture below).

extractor piston

shank adapter

impact piston

Activating the extractor During normal drilling, with a damper pressure above 50 bar, logic-L closes the extractor return connection and the system is closed. The main reason is to minimize oil consumption and heat. In case of a sudden loss of damper pressure, e.g. drilling into weak formations or cavity, logic-L opens. This allows the extractor piston to move forward to avoid being hit by the flange on the shank adapter. At the same time, the oil trapped in front of the extractor piston serves as a cushion to prevent from mechanical contact between piston and front. When the damper pressure drops, the impact pressure will be reduced or cut off by the DPC-I system. When feeding backwards, the feed force works in the other direction as the shank adapter extends out of the rock-drill since it is stuck, logic-L opens due to the loss of damper pressure and the extractor system is pressurized since the extractor piston is pulled by the shank adapter to close the outlet ducts in the extractor housing. When pressurized, the extractor piston lifts the shank adapter high enough to be struck by the impact piston. Once the impact piston hits the shank adapter, backward shock wave would be generated from the extractor piston thus causing the reverse percussion.

91

Extractor unit (Option)

L7

When feeding backwards, the damper pressure is below the minimum limit to allow impact, set by the DPC-I system. To make it possible to activate impact when using the extractor it is necessary to override the DPC-I system. This is done by push-buttonS451, which activates solenoid valveY176, which bypasses logic valves I and J. Consequently, impact can be activated at any damper pressure. The oil flow to the extractor unit is limited by flow regulator 9 to correspond to a pressure of 22 bar with unloaded shank adapter and logicL not activated. The pressure can be read on gauge outlet 8 on the service panel.

S451

Pump pressure when using the extractor It should be noticed that only low hammer/pump pressure is available when using back hammer function. Logic valveC gets activated by reverse feed pilot pressure if high impact is activated (see figure below left); and by pump pressure if low impact is activated (see figure below right), this prevents activation of logic-E. Without logic-E being activated, the pump pressure control. line going through logic-B will only lead oil to pressure relief valve 47e for pump 1 pressure

92

TED-Extractor unit for COPROD (Option)

L7 CR

TED-Extractor unit for COPROD (Option)

The Rock drill can be equipped with a separate, air-powered extractor unit. The function of the extractor unit is to generate and transmit reverse percussion into the housing and thereby to the drill string and bit. The extractor unit, which is fitted in front of the rock drill, is powered by the flushing air.

93

Water mist system (Option)

Water mist system (Option) Water mist can only be activated with reduced flushing air.

Water-mist system 225 Litres The 225 litre water-mist system is a pressurized system. The water is injected into the flushing air after it has been pressurized by the compressed air. The system consists of: 1. 2. 3. 4. 5. 6. 7. 8. 9.

Tank Safety valve Drain valve Blow down valve Isolation valve Filter Needle valve Solenoid valves Check valves

The system is controlled by switchS448 as follows: OFF – None of the solenoid valvesY112A-B are activated. • AUTO – Solenoid valve Y112A is activated. The amount of water • injected is limited by the needle valve7. MANUAL – Both of solenoid valvesY112A-B are activated. The • amount of water injected is limited by the isolation valve5.

b

c d

a

a b

The water-mist system is primarily used for hole stabilization and dust control by adding water into the flush air. Generally a small amount of water is used in order to make the drill dust moist and bind into larger particles, for dust control, or to bind to the hole wall, for hole stabilization. In this case switch S448 should be in position AUTO (b). The amount of injected water should be adjusted bythe needle valve to match the dust characteristics. Different settings may be necessary on different sites and different applications.

c

If there is a need to add a larger amount of water, for example when entering a clay pocket, switch S448 can be pushed to MANUAL position released.(a). The MANUAL position springs back to AUTO when

a S181

When the hole is stabilized or the dust is under control, S448 should be switched back to OFF position (c).

b Figure: example, L740 left panel

To prevent clogging of suction hoses and dust collector filters when using water-mist, the dust collector suction (switch S181) should be switched off (position b) if the dust is very wet or if water is flushing out of the hole.

94

Water mist system (Option)

Water-mist system 400 Litres The 400 litre water-mist system is a non-pressurized system. The water is pumped into the flushing air circuit by a pneumatic piston pump. The system consists of: 1. Tank 2. Pneumatic piston pump 3. Solenoid valves 4. Drain valve 5. Isolation valve 6. Filter 7. Needle valve 8. Check valves The system is controlled by switchS448 as follows: OFF – None of the solenoid valvesY112A-C are activated. • AUTO – Solenoid valve Y112A is activated. Y112A • activates the pump. The amount of air to power the pump is limited by the needle valve7. MANUAL – All of the solenoid valvesY112A-B are • activated. The amount of air to power the pump is limited by the isolation valve 5. BLOW OFF – Double push on S448 forwards to blow out all • the water remaining in the system so the hose does not freeze.

95

ECG, thread lubrication with oil (Option)

L7

ECG, thread lubrication with oil (Option) Function The ECG pump Y107 starts pumping as soon as Flushing air is turned ON. The ECG pump is an electrical piston pump, controlled by the PLC output X11-16 which sends out pulses to the pump. ECG injects a small amount of lubricating oil into the flushing air. The oil creeps along the walls of the flushing hole and out into the threaded joints. Atlas Copco recommends the use of COP OIL for all ECG and ECL lubrication. Conditions for the ECG function: Switch S130 in drilling position => D552-CH1/ON Sensor B118 activated, RHS arm in carousel =>PLC input X10-5/ON Compressor load switch S180 must be on => D552-CH9/ON • Impact switch S446A or S446B must be activated, to obtain air flushing => D550• CH9/10/ON Result in: PLC output X11-16/ON => Y107 activated • • •

Adjusting •

•

Time pulse – length of the pulse, i.e. the signal time. Pulses/minute – how many pulses there is per minute

96

Thread lubrication with grease brushes (Option)

L7

Thread lubrication with grease brushes (Option) Function Lubrication of the drill steel threads is done by two brushes (A) mounted on the lower RHS carousel bracket. The grease is supplied by a pump placed in the front of the wagon frame. The pump is powered by compressed air from the rig compressor and controlled through solenoid valve Y552. Activation of Y552 can be done either automatically or manually and is controlled by the switch S449 on the drilling control panel.

A Conditions for the automatic function: •

Switch S130 in drilling position => D552-CH1/ON Compressor load switch S180 must be on => D552-CH9/ON Brush greasing switch S449 in automatic mode, position (b) => D554-CH10/ON • RHS control lever S111 in arm to drill centre position => D551-CH3/ON • Result in: PLC output X17-9/ON => Y552 activated for 2 seconds • •

When S449 is put in manual mode, no input from S111 is needed to cause the activation of Y552.

97

Thread lubrication with grease brushes (Option)

L7

Operating •

•

•

In normal operation, the system works in automatic mode. The grease pump is activated when the rod handling leverS111 is in position to transfer a rod to drill centre. The result is that each time a rod is removed from the carousel, a quantity of lubricant is pumped into the brushes that the threads of the drill rod pass through. If there is a need to additional grease, the system can be run manually. In this case the grease pump is activated as long as switchS449 is kept in position (a). If there is no need for thread greasing the system can be turned off by putting switch S449 in position (c).

b a

c d

a b c

The maximum pressure to the pump is adjusted to 7 bars by the pressure regulator 21 which is displayed by the pressure gauge 22. The system can be switched off by blocking the air supply with ball cock valve 8 or by the electrical switch in the cabin. We recommend the use of “Atlas Copco Secoroc thread lubricant A” for the lubrication of drill steel threads.

98

Spray greasing system (Option)

L8 , L7 CR

Spray greasing system (Option) Function Lubrication of the drill steel threads is done by an air spray and a grease injector mounted on the lower RHS carousel bracket. The grease is injected by a pump placed in the front of the wagon frame. The grease pump is powered by compressed air from the rig compressor and controlled through solenoid valve Y552A. Compressed air is also used for the spraying, and it’s controlled by solenoid valveY552B. When functioning, solenoid valve Y552B for air spray is set to start first before solenoid valve Y552A for grease pump. The air then sprays grease onto the thread. When shutting off the function, Y552A is set to be turned off first before Y552B. Activation of Y552 is done manually and is controlled by the switch S449 on the drilling control panel. Conditions for the function: Switch S130 in drilling position => D552-CH1/ON Compressor load switch S180 must be on => D552-CH9/ON Spray greasing switch S449 activated, position (a) => D554-CH9/ON • Result in: o X11-10/ON => Y552B activated for 1 second X15-8/ON => Y552A activated after 400 ms, then activated for 200 ms o • •

The maximum pressure to the pump is adjusted to 7 bars by the pressure regulator 21 which is displayed by the pressure gauge 22. The system can be switched off by blocking the air supply with ball cock valve 8 or by the electrical switch in the cabin. We recommend the use of “Atlas Copco Secoroc thread lubricant A” for the lubrication of drill steel threads.

99

Laser sensor (Option)

Laser sensor (Option) Laser sensor B316 on the rock drill cradle sends in data signals viaCPU3 which are processed by the display for showing the correct hole length/hole depth information as per preview. The laser sensor is most often used in undulating terrain to maintain as level a hole bottom as possible for blasting.

Laser sensor position Laser level 4m

Drill bit position

10m

Hole bottom

Ex:

A rotary laser is placed at m). the highest point in the area. here,B316 the depth holedrill bottom is measured (in this case 10 When the rotary laser hitsFrom the sensor on thetorock cradle, the length between the sensor and drill bit (in this case 4 m) is automatically shown on the display, irrespective of how many metres that has been drilled. This is done every time the hole depth is reset. In this case, we know that there are 6 metres left to hole bottom (10-4=6 m). If it takes one meter for B316 to be hit by the rotary sensor in the above example, the following describes the transaction which will take place on the display.



Before hitting the sensor (i.e. before reaching one meter), the display shows the drilling information like usual.

Hitting moment, 1 meter reached.

The preset value for sensor to drill bit distance over-writes the measured distance. The lamp for laser sensor turns green. And depth measuring carries on from 4 m.

100

Y176

B Q C A D

I J

Y101B

low

1

Y101A

Watertank

Y112A

Water/air mixture

Y116

w o lf ri a n i a M 2

Adjustment/calibration

Adjustment/calibration Calibrating of positioning instruments Calibration of laser sensor The manually measured length value between the drill bit and laser sensor when the drill bit is applied to the ground. This value is entered in the menu for calibrating the laser sensor. Calibration of aiming device The aiming device is set in straight-forward position in the track’s extension. By selecting the button for the aim device in the menu sensor/calibration and pressing enter the function is calibrated. Calibration of length sensor Run the rock drill cradle to the feeder’s upper mechanical stop. Mark the button for cradle position in the sensor/calibration menu and press Enter to calibrate the function. Calibration of angle sensor on feed beam Position the in the vertical position. the button forfeeder feed swing and/or feed dumpMark in the sensor/calibration menu and press Enter to calibrate the function. Calibration of boom joint sensor Position the boom in the straight ahead position. Mark the button for boom swing angle in the sensor/calibration menu and press Enter to calibrate the function.

101

Adjustment/calibration

Adjustable drilling parameters ROC L7 , L7 CR with Bosal cabin

High impact pressure

Low impact pressure

Low feed pressure

High feed pressure

RPCF system 40 (only in L7 )

Threading pressure RPCF

Rotation speed

Unthreading pressure

ROC L830 with Bosal cabin

Not used

High feed pressure

Not used

Low feed pressure

Threading pressure

Rotation speed

Unthreading pressure

Last updated 21 October 2008

102

40

2008-10-21 PLC Programme, ROC L7 (Bosal cabin)

PLC-PROGRAMME EXPLANATION DRILLRIG TYPE: ROC L740 PLC TYPE: IFM CR0200/CR0020 PLC PART NUMBER : 3176 0001 50/3176 0001 55 INDEX INDEX.........................................................................................................................................................................................1 1. GENERAL FUNCTIONS....................................................................................................................................................2 1.1 Power supply.....................................................................................................................................................................2 1.2 Engine cranking.................................................................................................................................................................2 1.3 Start Conditions for diesel engine....................................................................................................................................2

1.4 Pump 4 unload..................................................................................................................................................................2 1.5 Hydraulic oil pre-heating..................................................................................................................................................2 1.6 Indication for hydraulic jack (option)..............................................................................................................................2 1.7 Diesel filler pump stop .....................................................................................................................................................2 2. TRAMMING F UNCTIONS.................................................................................................................................................3 2.1 Tramming low speed.........................................................................................................................................................3 2.2 Tramming high speed........................................................................................................................................................3 3. DRILLING FUNCTIONS....................................................................................................................................................3 3.1 Flushing, reduced..............................................................................................................................................................3 3.2 Flushing, full.....................................................................................................................................................................3 3.3 Dust Collector, suction control .......................................................................................................................................3 3.4 ECL-pump.........................................................................................................................................................................4 3.5a ECG-pump (option)........................................................................................................................................................4 3.5b Thread lubrication with grease brushes, automatic mode (option)..............................................................................4 3.6a Anti-jamming activated by high rotation pressure.........................................................................................................4 3.6b Anti-jamming activated by flushing...............................................................................................................................5 3.7 Feed lever, logic direction when anti-jamming is active ................................................................................................5 3.8a Low percussion with function self-holding...................................................................................................................5 3.9a High percussion with function self-holding..................................................................................................................6 3.8/3.9b Deactivation of magnetic holding for drill lever....................................................................................................6 3.10 Impact hour counter........................................................................................................................................................6 3.11 Automatic drill stop function.........................................................................................................................................7 3.12 Impact stroke...................................................................................................................................................................7 3.13 Water mist system (option) ............................................................................................................................................7 4. RAP ID FEED STOP F UNCTIONS ...................................................................................................................................8 4.1 Rapid feed stop, forward ..................................................................................................................................................8 4.2 Rapid feed stop, backwards, at break out position..........................................................................................................8 4.3 Rapid feed stop, backwards, at magazine level................................................................................................................8 4.4 Rapid feed stop, backwards, max.....................................................................................................................................8 5. ROD HANDLING FUNCTIONS........................................................................................................................................9 5.1 Open Gripper.....................................................................................................................................................................9 5.2 Guide grip..........................................................................................................................................................................9 5.3 Hard grip............................................................................................................................................................................9 5.4 RHS, arm towards drill-centre .........................................................................................................................................9 5.5 RHS, arm towards carousel..............................................................................................................................................9 5.6 RHS, carousel rotation, clockwise.................................................................................................................................10 5.7 RHS, carousel rotation, anti-clockwise.........................................................................................................................10 5.8 Sleeveretainer retainerde-activation............................ activation................................................................................................................................................10 5.9 Sleeve ..............................................................................................................10 6. MONITORING FUNCTIONS...........................................................................................................................................11 6.1 Low hydraulic oil level, engine shut down....................................................................................................................11 6.2 High hydraulic oil temperature ......................................................................................................................................11 6.3 High compressor temperature........................................................................................................................................11

Page 1 of 11

40

2008-10-21 PLC Programme, ROC L7 (Bosal cabin)

Function

Signal from/position

1. GENERAL FUNCTIONS 1.1 Power supply S139/Ignition ON Fuse F13-F23/ON X1/100 •

Input/s tatus

Output

+ 24V - ground connection

+24V

Valve/relay

K11

When ignition key S139 is in position I, ignition ON, relay K11 is activated to allow power supply to fuse F13, F15-F22. Fuse F14 and F23 are powered directly aside from the K11 relay.

1.2 Engine cranking S130/Tramming pos.

D552-CH2/3/ON

S180/Compressor load E-stops S132A, S132B not activated S139/Engine start 1.3 Start Conditions for diesel engine B366/Compressor temp. B362/Hydraulic oil temp. B143/Hydraulic oil level

D552-CH9/OFF

X11-13/ON X17-1/ON X18-8/OFF

Y121A Y121B Y210 OFF

X10-8/ON D550-CH3/ON

X11-4/ON

K5A

X16-7 (