6003527 Op's & Serv Manual May 13.pdf

Copyright © 2013 Boart Longyear. All rights reserved.

GLOBAL DRILLING PRODUCTS

PWM ROD HANDLER OPERATIONS AND SERVICE MANUAL May 2013

Table of Contents Chapter 1: Safety 1.1 Important Safety Information..................................................................... 3 1.1.1

Hazard Signal Indicators................................................................. 3

1.1.2

Safety Guidelines ........................................................................... 4

1.2 Cautions and Warnings.............................................................................. 6

Chapter 2: Introduction 2.1 General Information ................................................................................. 13 2.2 Prior to First Use....................................................................................... 13 2.3 Ordering and Returning Parts.................................................................. 14 2.3.1

Ordering Parts............................................................................... 14

2.3.2

Returning Parts............................................................................. 14

2.4 Limited Warranty....................................................................................... 15

Chapter 3: The Rod Handling Device 3.1 Introduction............................................................................................... 21 3.2 Rod Handler Parts Identification............................................................. 21 3.2.1

Rod Handler Mounts..................................................................... 23

3.2.2

Rod Handler Controls.................................................................... 23

3.2.2.1

Laser Safety Beam............................................................... 25

3.3 Control Panel Parts Identification........................................................... 25 3.4 Operating Status Indicator....................................................................... 30

Chapter 4: Rod Handler Set Up 4.1 Positioner Assembly Mounting............................................................... 33 4.1.1

Mounting Procedure...................................................................... 33

4.2 Pre Start Checks....................................................................................... 35 iii Copyright © 2007, 2011, 2013 Boart Longyear. All rights reserved. Boart Longyear is constantly striving to improve its products and must therefore reserve the right to change designs, materials, specifications, and price without notice.

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4.2.1

Lubrication checks......................................................................... 36

4.3 Hydraulic Connections............................................................................. 36 4.4 Electrical Connections............................................................................. 38 4.5 Control Panel Valve and Gauge Identification....................................... 42 4.6 Arm Horizontal Sensor (Inclinometer) Set Up........................................ 43

Chapter 5: Rod Handler Start Up 5.1 Pre-Checks and Warnings........................................................................ 47 5.1.1 Tools.............................................................................................. 47 5.2 Start Up Procedure................................................................................... 47 5.2.1.1

Valve Settings....................................................................... 48

5.3 Checking the Functions........................................................................... 49 5.3.1

Horizontal PLC Function............................................................... 49

5.3.2

Load/Unload PLC Function........................................................... 49

5.3.3

Traverse Cylinder Functions......................................................... 49

5.3.4

Slew and PLC Functions............................................................... 50

5.3.5

Gripper and PLC Functions........................................................... 50

5.3.6

Roller and PLC Functions............................................................. 51

5.3.7

Rod to Drill String Alignment......................................................... 52

5.3.8

Rod Feeding Sequence................................................................. 53

5.3.9

Rod Pulling Sequence................................................................... 54

Chapter 6: Rod Handler Operations 6.1 Rod Handler Parts..................................................................................... 59 6.1.1

Front and rear mounts................................................................... 59

6.1.2

Traverse Cylinder.......................................................................... 59

6.1.3

Carriage stop clamp...................................................................... 59

6.1.4

Slide rails....................................................................................... 60

6.1.5

Drill rod stop.................................................................................. 60

6.1.6

Slide blocks and bushes................................................................ 60

6.2 Carriage Slide Bush Replacement .......................................................... 60 6.2.1

Slide Bush Replacement Procedure............................................. 61

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6.3 Carriage Assembly.................................................................................... 62 6.3.1

Carriage Frame............................................................................. 62

6.3.2

Swing Arm with hose bulkhead..................................................... 63

6.3.3

Swing Arm mechanical stop.......................................................... 63

6.3.4

Swing Arm actuator and overcentre valve..................................... 63

6.3.5

Swing Arm Cushioning Adjustment............................................... 64

6.3.6

Head Tilt actuator and overcentre valve........................................ 64

6.3.7

Head Tilt actuator guard................................................................ 64

6.4 Valve Assembly......................................................................................... 65 6.4.1

Valve bank..................................................................................... 65

6.4.2

Solenoid control............................................................................. 66

6.5 Head Assembly......................................................................................... 66 6.6 Laser Perimeter Beam.............................................................................. 67 6.6.1

Reflector and stand....................................................................... 68

6.7 Rod Handling Operations......................................................................... 68 6.7.1

Adding a Rod before Rod Feeding................................................ 68

6.7.2

Removing a Rod after Rod Pulling................................................ 69

6.8 Rod Handler Servicing.............................................................................. 69 6.8.1

Laser Safety Beam........................................................................ 69

6.8.2

Serial number locations................................................................. 70

6.8.3

Servicing Notes............................................................................. 70

Chapter 7: Rod Handler Troubleshooting 7.1 Important Information............................................................................... 73 7.2 Troubleshooting Symptoms and Actions............................................... 74 7.3 Hydraulic Circuits..................................................................................... 77 7.3.1

Hydraulic Schematic Symbols....................................................... 77

7.3.2

Rod Handler Hydraulic Circuit....................................................... 79

7.4 Electrical Fault Finding Charts................................................................ 81 7.4.1 Introduction.................................................................................... 81 7.4.2

FAULT/BUTTON PRESSED indicator light................................... 82

7.4.3

Rod Pulling Mode.......................................................................... 82 v

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7.4.4

Rod Feeding Mode........................................................................ 84

7.5 I/O Modules................................................................................................ 85 7.5.1

I/O Module Connectors................................................................. 85

7.5.2

I/O Module Replacement............................................................... 86

7.6 PLC Circuit Diagrams............................................................................... 96

Chapter 8: Recommended Spare Parts Kit 8.1 12 Months Operation.............................................................................. 115 8.1.1

Rod Handler ............................................................................... 115

8.1.2

Carriage Assembly...................................................................... 115

8.1.3

Valve Assembly PWM................................................................. 115

8.1.4

Interconnecting Cable to Rod handler......................................... 116

8.1.5

Interconnecting Cable to LM Power Pack................................... 116

8.1.6

Laser Perimeter Beam................................................................ 116

8.1.7

Head Assembly........................................................................... 116

8.1.8

Guide Sets................................................................................... 116

8.1.9

Control Group Rod Handler......................................................... 117

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Table of Figures Chapter 1: Safety Figure 1–1: decals.

STOP WARNING — Stop and observe the surrounding warning ........................................................................................................ 6

Figure 1–2: PPE.

DO NOT CLIMB— No climbing activity to occur without appropriate ........................................................................................................ 6

Figure 1–3: BODY CRUSH HAZARD — Moving parts of the machine have the potential for crush injury......................................................................................... 7 Figure 1–4: MANUAL — Indicates to refer to this manual before proceeding with any activity...................................................................................................... 7 Figure 1–5: potential.

CRUSH HAZARD — This part of the machine has a rotating crush ........................................................................................................ 7

Figure 1–6: unguarded.

EXTEND/RETRACT — Component extends and retracts ........................................................................................................ 7

Figure 1–7: to touch.

HOT SURFACE — Surface adjacent to this warning can be too hot ........................................................................................................ 8

Figure 1–8:

PRESSURE VESSEL — This component is pressurised............... 8

Figure 1–9: machine.

HEARING PROTECTION — Must be worn when near this ........................................................................................................ 8

Figure 1–10: EYE PROTECTION — Must be worn when near this machine...... 8 Figure 1–11: HARD HAT — Must be worn when near this machine.................... 9 Figure 1–12: DIESEL FUEL — Diesel fuel connection site.................................. 9 Figure 1–13: LOADED SPRINGS — Warning that springs inside component are loaded and disassembly should be done with caution........................................... 9

Chapter 2: Introduction Chapter 3: The Rod Handling Device Figure 3–1:

Rod Handler components.............................................................. 22

Figure 3–2:

Rod Handler Parts Identification.................................................... 24

Figure 3–3:

Control Panel Parts Identification.................................................. 25 vii

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Figure 3–4:

Operating status indicator............................................................. 30

Chapter 4: Rod Handler Set Up Figure 4–1:

Positioner cradle............................................................................ 33

Figure 4–2:

Positioner assembly mounting procedure..................................... 35

Figure 4–3:

Lubrication points.......................................................................... 36

Figure 4–4:

Lower bulkhead on LM Power Pack (under hydraulic bulkhead).. 37

Figure 4–5:

View of underside of Control Panel............................................... 38

Figure 4–6:

Sensor Locations........................................................................... 39

Figure 4–7:

LM75/90 Control Panel Valves and Gauges................................. 42

Figure 4–8:

Arm Horizontal sensor................................................................... 43

Chapter 5: Rod Handler Start Up Figure 5–1:

Valve Locations............................................................................. 48

Chapter 6: Rod Handler Operations Figure 6–1:

Rod Handler Parts......................................................................... 59

Figure 6–2:

Slide Bush Replacement Tool....................................................... 60

Figure 6–3:

Slide Bearing components............................................................ 61

Figure 6–4:

Carriage Assembly........................................................................ 62

Figure 6–5:

Swing Arm adjustment.................................................................. 63

Figure 6–6:

Valve Assembly............................................................................. 65

Figure 6–7:

PVHC Actuator (p/n 5304275)....................................................... 66

Figure 6–8:

Head Assembly............................................................................. 66

Figure 6–9:

Laser Perimeter Beam Kit............................................................. 67

Chapter 7: Rod Handler Troubleshooting Figure 7–1:

Rod Handler Hydraulic Circuit....................................................... 80

Figure 7–2:

I/O Module connectors.................................................................. 85

Figure 7–3:

I/O Module rotary switch locations................................................ 86

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Chapter 8: Recommended Spare Parts Kit

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Contents

Chapter 1: Safety

1.1 Important Safety Information..................................................................... 3 1.1.1

Hazard Signal Indicators................................................................. 3

1.1.2

Safety Guidelines ........................................................................... 4

1.2 Cautions and Warnings.............................................................................. 6

1 Copyright © 2007, 2011, 2013 Boart Longyear. All rights reserved. Boart Longyear is constantly striving to improve its products and must therefore reserve the right to change designs, materials, specifications, and price without notice.

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Chapter 1: Safety

1.1 Important Safety Information 1.1.1

Hazard Signal Indicators Warning and Caution indicators are located throughout the manual at specific points of interest, and are intended to alert the reader to the existence and relative degree of a hazard. These notices are given to prevent personal injury, death and/or equipment damage. These indictors must be followed to reduce the possibility of personal injury, damage to the equipment, or improper service. Always heed these notices, and practice common sense when performing any maintenance or repair procedure.

This is the safety alert symbol. It is used to alert you to potential personal injury hazards. Obey all safety messages that follow this symbol to avoid possible injury and death.

“Danger” indicates an imminently hazardous situation which, if not avoided, could result in death.

“Warning” indicates a potentially hazardous situation which, if not avoided, could result in death or serious injury or property damage.

“Caution” indicates a potentially hazardous situation which, if not avoided, MAY result in minor or moderate injury and property damage. It may also be used to alert against unsafe practices.



Note: Notes are indicated to draw attention to detailed instructions. These notes are intended to give further important information regarding the machine and/or a step in a procedure. These notices are given to prevent personal injury, death and/or equipment damage. These indictors must be followed to reduce the 3 Copyright © 2007, 2011, 2013 Boart Longyear. All rights reserved. Boart Longyear is constantly striving to improve its products and must therefore reserve the right to change designs, materials, specifications, and price without notice.

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Chapter 1: Safety possibility of personal injury, damage to the equipment, or improper service. Always heed these notices, and practice common sense when performing any maintenance or repair procedure.

1.1.2

Safety Guidelines Familiarity and proper training are required for safe operation of this equipment. Failing to follow these instructions may result in serious injury or death. Read the operating instructions and familiarise yourself with the location and proper use of all controls. Safety is the most important element of any procedure. Preparation is essential to complete a procedure in a safe and efficient manner. ●● Keep clear of rotating equipment. Wear proper clothing. Loose or baggy clothing could become tangled in moving parts. ●● Be aware that sliding parts can create pinch points, and tilting parts can create crush points. ●● Never rotate the drill rods without the water swivel attached to the drill string. (Ensure that the hoisting cable is attached to water swivel bail.) ●● Keep guards installed and maintained in good working order. ●● Always keep the work area clean. ●● Avoid dangerous working environments. ●● Do not operate equipment while under the influence of drugs, alcohol, or medication. ●● Be aware of the operating zones and recommended areas for safe operation. Keep visitors a safe distance away from the work area. ●● Wear personal protective equipment such as a hard hat, safety glasses, and steel-toed work boots. ●● Prepare the required parts and materials. Gather the necessary parts and materials before beginning the procedure. ●● Prepare proper tools and equipment. Always use the correct tool for the job. Improper or homemade tools can cause injury or machine damage. ●● Use only Boart Longyear replacement parts. Failure to do so can cause severe damage to the machine or the operator, and may void your warranty. ●● ISOLATE all energy sources before servicing equipment. ●● Allow the machine to cool. Many components can get hot during operation. Be sure to allow enough time for components to cool before beginning service. ●● Use only qualified service technicians. Failure to do so could cause severe damage to the machine or the operator, and may void your warranty.

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Chapter 1: Safety

●● Never climb on top of the machine. ●● Ensure that the drill and accessories fully comply with applicable local safety and health regulations. ●● Do not exceed rated capacity of any piece of equipment. ●● Do not adjust the hydraulic system before consulting a Boart Longyear Technician. ●● Ensure that all commissioning checks and adjustments have been thoroughly carried out before operating the machine. ●● Never rotate the drill rods with a rod joint located behind or above the Chuck. ●● Do not change or alter the drill, its components, optional equipment, or accessories without prior approval from Boart Longyear. ●● Follow all procedures and safety warnings. Service procedures are written to be as safe and efficient as possible. Never take shortcuts, and never operate this machine when any person, including the operator, is under or in the operational envelope of the loading/ unloading process. ●● Be prepared for emergencies. Accidents can happen, even under the best conditions. Fire extinguishers and first aid kits should be well maintained and easily accessible. ●● Read and understand this Operations and Service Manual and all labels affixed to the machine. ●● Unauthorised alterations may void the warranty, render the equipment unsafe, or result in decreased performance. ●● Before operating any controls, be certain you know what function they control and the ramifications of that function. ●● Before operating any hoist, ensure that the rope is free and clear to travel. ●● When hoisting/lowering rods, make sure the hoisting cable is in complete tension before releasing the Chuck. ●● Do not use multiple part lines on the Main Hoist. ●● Ensure that all commissioning checks and adjustments have been thoroughly carried out before operating the machine. ●● Always wear a certified full-body harness with the shortest possible lanyard attached to a certified fall arrestor system while working on the platform. ●● Be aware of the travelling hoist plug at all times. ●● Be careful not to drop any tools when working on the platform. ●● Never exceed the rod rack derating weights. ●● Never attempt to loosen or remove any high-pressure hydraulic line without relieving the pressure beforehand. ●● Always be sure the machine is on a firm, level surface and will not tip, roll, slide, or fall while operating. 5 Copyright © 2007, 2011, 2013 Boart Longyear. All rights reserved. Boart Longyear is constantly striving to improve its products and must therefore reserve the right to change designs, materials, specifications, and price without notice.

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Chapter 1: Safety ●● Never start a unit in need of repair. ●● Keep the area behind the trailer clear of people while raising and lowering the mast! Never raise, lower, or turn the mast while unit is operating! ●● The trailer must be levelled before raising the tower. ●● Always replace the safety devices and guards after repairs and maintenance. ●● Always keep hands, feet, and loose clothing away from the moving parts on the generator and engine.

Note: For additional information on training or start-up, contact your local Boart Longyear representative.

1.2 Cautions and Warnings

Figure 1–1: STOP WARNING — Stop and observe the surrounding warning decals.

Figure 1–2: DO NOT CLIMB— No climbing activity to occur without appropriate PPE.

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Chapter 1: Safety

Figure 1–3: BODY CRUSH HAZARD — Moving parts of the machine have the potential for crush injury.

Figure 1–4: MANUAL — Indicates to refer to this manual before proceeding with any activity.

Figure 1–5: CRUSH HAZARD — This part of the machine has a rotating crush potential.

Figure 1–6: EXTEND/RETRACT — Component extends and retracts unguarded.

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Chapter 1: Safety

Figure 1–7: HOT SURFACE — Surface adjacent to this warning can be too hot to touch.

Figure 1–8: PRESSURE VESSEL — This component is pressurised.

Figure 1–9: HEARING PROTECTION — Must be worn when near this machine.

Figure 1–10: EYE PROTECTION — Must be worn when near this machine.

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Chapter 1: Safety

Figure 1–11: HARD HAT — Must be worn when near this machine.

Figure 1–12: DIESEL FUEL — Diesel fuel connection site.

Figure 1–13: LOADED SPRINGS — Warning that springs inside component are loaded and disassembly should be done with caution.

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Chapter 2: Introduction Contents 2.1 General Information ................................................................................. 13 2.2 Prior to First Use....................................................................................... 13 2.3 Ordering and Returning Parts.................................................................. 14 2.3.1

Ordering Parts............................................................................... 14

2.3.2

Returning Parts............................................................................. 14

2.4 Limited Warranty....................................................................................... 15

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Chapter 2: Introduction

2.1 General Information The purpose of this Operations and Service Manual is to furnish the operator with details on operating, maintaining and servicing the PWM Rod Handler. Read this Manual carefully before attempting to operate the PWM Rod Handler. Boart Longyear is backed by more than 100 years of experience in the design, manufacture, and operation of core drilling equipment. Many of the accepted industry practices in use today were pioneered by Boart Longyear. To obtain the utmost in performance and life of the equipment, it should be given regular care and operated in accordance with the instructions. Read this Manual carefully before attempting to operate the drill and keep this book handy at all times for reference when any question arises. IMPORTANT NOTE Do not start or operate the drill until you have read this Manual and understand its contents.

2.2 Prior to First Use After the arrival of your new Boart Longyear Rod Handler a quick inspection should be done: ●● Visually inspect the equipment for any loose hoses, fittings, or bolts, or any damage that may have occurred during shipping. ●● Take extreme caution when a loose hose or fitting has allowed oil to leak, as this will create a hazard. ●● Make sure that any oil leak has not drained the tank too low for proper operation. ●● Refer to the relevant chapters in this Manual for proper and safe movement of the drill rig. ●● Visually inspect all electrical connections. ●● Check oil levels and fill with recommended lubricants.

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2.3 Ordering and Returning Parts 2.3.1

Ordering Parts To help us expedite your order and assure correct replacement parts are supplied please specify the following when placing your order: 1. Name, model and Boart Longyear serial number of the product, subassembly or component for which the parts are ordered. 2. Boart Longyear part number and description of parts as shown in the Parts List. 3. Specify the quantity required for each line item. 4. Full shipping instructions: ○○ when required ○○ are partial shipments allowed ○○ method of shipment (e.g. Air Parcel Post, Air Freight, etc.) ○○ will purchaser be responsible for insurance ○○ prepaid or collect ○○ “ship to” address 5. Special instructions, if any. All parts are priced F.O.B., our factory, and separate charge will be made for transportation and export packing.

2.3.2

Returning Parts 1. Before returning parts or products to Boart Longyear, please obtain formal authorisation, a Returned Memo Advice (RMA) number, and “ship-to” address (back to Boart Longyear facility) from your Boart Longyear Customer Service Centre or representative. 2. You will also need to submit a letter: ○○ detailing the reason for requesting the return, ○○ indicating the action desired. ○○ specifying the quantity and Boart Longyear part numbers of the product(s) concerned. Where applicable, the MODEL and SERIAL NUMBER are necessary for proper and full identification. ○○ citing the RMA number (if already assigned).

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3. When returning parts or products, the purchaser is responsible for prepaying any transportation, insurance, and/or delivery charges to a place designated by Boart Longyear. 4. DO NOT ship parts until authorization and shipping instructions are received. 5. All parts returned must be prepaid.

2.4 Limited Warranty a. Consumables. Boart Longyear warrants for a period of one (1) year after the date of shipment of the consumable products manufactured by it, or the performance of related services, under the Contract, that such consumable products are free from defects in materials and workmanship and such services are performed in a professional and workmanlike manner; provided, however, with respect to consumable products purchased through an authorized Boart Longyear distributor, the warranty period shall commence on the date of purchase by the end-user. b. Capital Equipment. Boart Longyear warrants that the capital equipment manufactured by it is free from defects in materials and workmanship for a period equal to the lesser of (i) one (1) year after the date of shipment, or (ii) the initial 1,000 operating hours. Boart Longyear warrants for a period of six (6) months after the performance of related services that such services are performed in a professional and workmanlike manner. c. General Terms. Boart Longyear further warrants that, to the extent applicable, as of the date of shipment or performance, all goods manufactured by it and services performed shall conform to the written specifications agreed between the parties. THIS IS BOART LONGYEAR’S ONLY WARRANTY. BOART LONGYEAR MAKES NO OTHER WARRANTY, INCLUDING WITHOUT LIMITATION, ANY WARRANTY OF

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Chapter 2: Introduction d. MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE. As a condition to Boart Longyear’s warranty obligations, the purchaser must: (i) contact Boart Longyear and request authorization to return any goods claimed to be defective promptly upon Purchaser’s discovery of the alleged defect, (ii) upon receipt of an approved authorization code from Boart Longyear, return any goods claimed to be defective under the foregoing warranty, at Purchaser’s expense, to the facility designated by Boart Longyear, and (iii) with respect to consumable products purchased through an authorized Boart Longyear distributor, the party making the warranty claim must also deliver to Boart Longyear reasonable evidence of the date of purchase. Boart Longyear shall perform its examination of the goods so returned by Purchaser and shall report the results of its examination to Purchaser within thirty (30) days following its receipt of such goods from Purchaser, or, if longer time is required to complete such examination, within such time as would be required through the exercise of reasonable diligence. As a further condition to Boart Longyear’s obligations hereunder for breach of warranty, Purchaser shall offer its reasonable cooperation and assist Boart Longyear in the course of Boart Longyear’s review of any warranty claim. If requested by Purchaser, Boart Longyear will promptly repair or replace, at Boart Longyear’s expense, goods that are confirmed to be non-conforming as a result of Boart Longyear’s examination and according to Boart Longyear’s warranty as set forth herein. All removal and installation of goods shall be at Purchaser’s expense; provided, however, Boart Longyear will reimburse the Customer for an amount equal to the reasonable expenses incurred by the Customer and attributable to the removal and shipment of any defective goods. Boart Longyear reserves the right to reimburse Purchaser for an amount equal to the purchase price of any defective goods in lieu of providing repaired or replacement goods. Anything contained herein to the contrary notwithstanding, in no event shall Boart Longyear be liable for breach of warranty or otherwise in any manner whatsoever for: (i) normal wear and tear; (ii) corrosion, abrasion or erosion; (iii) any goods, components, parts, software or services which, following delivery or performance by Boart Longyear, has been subjected to accident, abuse, misapplication, modification, improper repair, alteration, improper installation or maintenance, neglect, or excessive operating conditions; (iv) defects resulting from Purchaser’s specifications or designs or those of its contractors or subcontractors other than Boart Longyear; (v) defects associated with consumable parts or materials, the lifetime of which is shorter than the warranty period set forth in this Section; (vi) defects associated with Purchaser’s specifications or designs or those of its contractors or subcontractors other than Boart Longyear; (vii) 16 Copyright © 2007, 2011, 2013 Boart Longyear. All rights reserved. Boart Longyear is constantly striving to improve its products and must therefore reserve the right to change designs, materials, specifications, and price without notice.

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defects resulting from the manufacture, distribution, promotion or sale of Purchaser’s own products; or (viii) accessories of any kind used by the Purchaser which are not manufactured by or approved by Boart Longyear. e. Sourced Goods. If the defective parts or components are not manufactured by Boart Longyear, the guarantee of the manufacturer of those defective parts or components is accepted by the Purchaser and is the only guarantee given to the Purchaser in respect of the defective parts or components. Boart Longyear agrees to assign to the Purchaser on request made by the Purchaser the benefit of any warranty or entitlement to the defective parts or components that the manufacturer has granted to Boart Longyear under any contract or by implication or operation of law to the extent that the benefit of any warranty or entitlement is assignable. Boart Longyear Global Headquarters 10808 South River Front Parkway Suite 600 South Jordan, Utah 84095 United States of America [email protected] Tel: +1 801-972-6430 Fax: +1 801-977-3374

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Chapter 3: The Rod Handling Device Contents 3.1 Introduction............................................................................................... 21 3.2 Rod Handler Parts Identification............................................................. 21 3.2.1

Rod Handler Mounts..................................................................... 23

3.2.2

Rod Handler Controls.................................................................... 23

3.2.2.1

Laser Safety Beam............................................................... 25

3.3 Control Panel Parts Identification........................................................... 25 3.4 Operating Status Indicator....................................................................... 30

Tables Table 3–1:

Operating Status Indicator Table................................................... 30

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3.1 Introduction The PWM Rod Handler is a device that fits on the side of the Feed Frame and is hydraulically driven. Its purpose is to retrieve or add rods to the drill string from a safe position along the side of the Feed Frame, regardless of the working angle, reducing the manual handling of drill rods. The physical effort and associated injuries encountered using conventional manual handling are significantly reduced by automating the rod handling process. A 5-bank directional control valve controls the device via an electrical Control Panel. The device is semi-automated, i.e. a PLC monitors functions via sensors and only allows certain moves to be made if the right conditions are met. The PWM Rod Handler uses Pulse Width Modulation signals to control the operational hydraulics.

Note: A standard LM Rod Handler (p/n 3000318) can be upgraded to the PWM version by installing a retrofit kit (p/n 5304593).

3.2 Rod Handler Parts Identification The PWM Rod Handler can be mounted on 700 and 1300 Series Feed Frames fitted with 20 mm thick bottom runners by using the relevant mounting kit. It is compatible with LM Power Packs fitted with an optional hydraulic kit, and it can also be used on LM drills fitted with the DCi Control System. Hydraulic hoses connect the Power Pack and the Rod Handler. Each hose has different sized ends. ●● Load Sense hose — 7/16” JIC ●● Roller Motor Drain hose — 9/16” JIC ●● Main Pump Pressure hose — 3/4” JIC ●● Tank return hose — 1-1/16”JIC. When the Rod Handler is retro-fitted to a standard LM drill a separate Control Panel is used. If a DCi Control System is fitted, a single Control Panel can be used to control both the Rod Handler and the LM drill. A 10 pin 24V DC electrical cable (p/n 89182) connects the Starter assembly on the LM Power Pack to the Power Pack socket on the underside of the Rod Handler Control Panel.

21 Copyright © 2007, 2011, 2013 Boart Longyear. All rights reserved. Boart Longyear is constantly striving to improve its products and must therefore reserve the right to change designs, materials, specifications, and price without notice.

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Chapter 3: The Rod Handling Device For early model LM starters fitted with a 6 pin connector and a Stop/ Start pendant, it will be necessary to update the starter with a kit (p/n 5305286), and a remote pendant (p/n 3003488) which includes an Emergency Stop switch.

3

8

2 4 5 6 7 1 9

9

1– Rod Handler — PWM

2– Feed Frame

3– Power Pack

4–Control Panel — PWM

5– Hydraulic hoses

6– Laser cable

7–7-core Electrical cable

8–24V DC Electrical cable

9– Laser Perimeter Beam components

Figure 3–1: Rod Handler components A 7-core electrical cable connects the Rod Handler Control Panel to the Rod Handler Carriage. This cable supplies power to the DCV solenoids and sensors. A Laser Perimeter Beam protects the operators from the equipment without hindering access. It uses cable p/n 89182, and the Rod Handler joysticks deactivate when the beam is triggered. The PWM Rod Handler can handle BQ, NQ, HQ and PQ size rods and outer tubes. Its other capabilities include:

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Chapter 3: The Rod Handling Device

●● Angle range: –90° to 0° is the standard program setting for the PWM Rod Handler. A setting sequence can be changed so that it can also be used between 0° and +90° (See “22. GRIPPER OPEN (Up Hole Mode” in Section 3.3). A work platform may be necessary on up holes, due to the mounting location of the Rod Handler off the front of the Feed Frame. This will depend on the site set up and the hole angle being drilled. If power is lost to the drill, the PLC reverts back to the down hole program. ●● Average time to load / unload on a steep down hole including rod tripping on 1300 Feed Frame with HQ rods: 36–40 seconds each. (This is with a 2-man operation.) ●● Shallow angle holes: Less time is taken per trip as the Head Tilt and Traverse functions do not need to be used as much.

3.2.1

Rod Handler Mounts The Rod Handler mounts off the side of the Feed Frame chassis using front and rear mounting brackets: ●● A wider than standard face plate (p/n 3001445) is supplied as part of the mounting kit to attach the rig to the face. ●● Slide rails (2 standard HQ rods) fit between the front and rear mounts. These are used to support the Carriage assembly, and allow it to slide along the side of the Feed Frame. ●● A traverse cylinder is used to move the Carriage along the slide rails.

3.2.2

Rod Handler Controls A solenoid operated Directional Control Valve assembly is attached to the Carriage. This DCV is used to control all the hydraulic motion of the device. The DCV has pressure test points fitted to each section and requires a supply of oil from the Power Pack. A Swing Arm is also mounted off the Carriage assembly to position the rods in behind the Rotation Unit. It is moved by the swing arm rotary actuator. The Swing Arm supports the Head assembly, and can tilt through 90 degrees down, or 90 degrees up, depending on the set up. This tilt function is moved by the tilt actuator. A support arm, i.e. part of the head assembly, supports the rod being handled. 23

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Chapter 3: The Rod Handling Device Guide plates to suit individual rod sizes are fitted to the front and rear guide assemblies to help line up the rod being handled with the rod string. The rod is held in the head assembly by a pair of grippers that house some rollers to rotate the rod to aid the making and breaking of thread joints.

3

5 4 6

1

7

2 9

8

10 11

12 1– Carriage assembly

2– Swing Arm

3– Rear Mount

4– Traverse Cylinder

5– Slide Rails

6– Valve assembly

7– Rear Guide assembly

8– Support Arm

9– Rollers and Grippers

10– Head assembly

11– Front Guide assembly

12– Front Mount

Figure 3–2: Rod Handler Parts Identification The Rod Handler is operated from a control panel separate from the Drill Control Panel. 24 Copyright © 2007, 2011, 2013 Boart Longyear. All rights reserved. Boart Longyear is constantly striving to improve its products and must therefore reserve the right to change designs, materials, specifications, and price without notice.

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Chapter 3: The Rod Handling Device

A cable links the Power Pack and the Rod Handler Control Panel.

3.2.2.1

Laser Safety Beam A Laser Safety Beam is used to protect the operators from the equipment without hindering access. The Rod Handler controls are deactivated when the beam is triggered.

3.3 Control Panel Parts Identification

17

3

4

5

6

9

10

11

12

14 15

7

8

13

16

2 19

21

19

18

22

21

20

1

23

Figure 3–3: Control Panel Parts Identification 25 Copyright © 2007, 2011, 2013 Boart Longyear. All rights reserved. Boart Longyear is constantly striving to improve its products and must therefore reserve the right to change designs, materials, specifications, and price without notice.

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Chapter 3: The Rod Handling Device 1. PWM Rod Handler EMERGENCY STOP Push the switch down to activate the Emergency Stop; pull it up to reset. This switch stops ALL controls, and if a pilot is connected it will also drop out the Main Breaker. 2. PWM Rod Handler PULL ON / PUSH OFF Push the switch down to disable joysticks, pull it up to activate them. If the Rod Handler ON / OFF button is pulled up, power becomes available to the DCV solenoids and to the light mounted on the Rod Handler Carriage. The JOYSTICKS ACTIVE light on the Control Panel also illuminates. This On/Off button is also used to reset a fault when a fault code appears on the system fault light. To reset, push the button down, pull it up to reactivate. The lights at the top of the Control Panel are arranged in two sections: ○○ SYSTEM lights show conditions that the Handler and PLC require to operate. ○○ SENSOR lights indicate a signal is being received from the relevant sensor as in input to the PLC, and outputs from the PLC illuminate these individual lights. 3. POWER light This Red light indicates power is reaching Control Panel from the source (i.e. the Power Pack). This light gets its power from the 24V supply. 4. JOYSTICKS ACTIVE light This Green light indicates the Pull ON / Push OFF button has been pulled up and the joysticks are active. This light gets its power from main supply after going through a relay.

Note: Be aware of this situation at all times, especially when fault finding. The following twelve lights get their power from outputs on the PLC, and will only illuminate if the PLC is receiving a signal from the relevant sensor. 5. LOAD / UNLOAD light This light illuminates when the Swing Arm is out and the Head is horizontal. It indicates that both the required inputs have been registered at the PLC, allowing the grippers to open or close for loading or unloading rods safely. 6. CLAMP CLOSED light This light indicates the CLAMP OPEN/CLOSE button has been pressed to close the grippers. 26 Copyright © 2007, 2011, 2013 Boart Longyear. All rights reserved. Boart Longyear is constantly striving to improve its products and must therefore reserve the right to change designs, materials, specifications, and price without notice.

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Chapter 3: The Rod Handling Device

7. PERIMETER CLEAR light This light indicates the status of the latching perimeter clear signal within the controller. The light will be ON when the perimeter beam is in the ‘healthy’ state. The joysticks will not function when this light is OFF. 8. FAULT / BUTTON PRESSED light This light is a visual indication that any of the piezo switches located on top of the two joysticks have been pressed. It is also used to fault find the electrical circuits using a flash code sequence (for more information refer to Chapter 7 of this Manual). 9. ARM OUT light This light indicates the Swing Arm is in the LOAD / UNLOAD position along the side of the Feed Frame — one of two conditions that must be met before the PLC will allow the grippers to open in the LOAD/UNLOAD area. 10. HORIZONTAL light This light indicates the Head assembly is horizontal (as monitored by the Arm Horizontal sensor mounted on the tilt switch bracket) — the second of two conditions that must be met before the PLC will allow the grippers to open in the LOAD/UNLOAD area. 11. ROD FRONT light This light indicates a rod has been sensed loaded forward of the grippers in the Head assembly. 12. ROD REAR light This light indicates a rod has been sensed loaded rearward of the grippers in the Head assembly. 13. ARM IN light This light indicates the Swing Arm is in the MAKE/BREAK position behind the Rotation Unit — one of two conditions that must be met before the grippers will open in the MAKE / BREAK area. 14. SLEW light This light indicates the Head is near to parallel with the Feed Frame. The Swing arm will only operate if the slew sensor is activated and this light is illuminated. This has been incorporated as an additional safety feature when working on on steep holes. 15. GRIPPER PRESSURE light This light indicates the grippers have closed and the pressure switch is activated when the preset pressure has been achieved.

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Chapter 3: The Rod Handling Device 16. ARM CLEAR light This light indicates the Swing Arm is in the Arm Clear zone, away from the drill feed frame. This zone begins when the Swing Arm is approximately vertical (45 degrees away from the drill) and continues through to the Arm Out position. This condition must be active to enable Drill Control Panel hydraulic pilot pressure via the Pilot Dump function. 17. STROBE light

High voltage shock hazard! — Wait 6 minutes after removing power from the light before removing dome to replace the strobe.

This light indicates the laser beam has been broken, or the bridging plug is not fitted. The joysticks will not function when it is flashing. 18. LEFT joystick When in operation; ○○ Move left to lower the front guide assembly, right to raise the front guide assembly when the Swing Arm is in LOAD/UNLOAD position. ○○ Move up to rotate the rollers to make a rod joint at the rod string and down to undo (break) the rod joint. Note the rollers are used to clear the pin thread from the box thread at a faster rate than the Breakout Device. ○○ The Carriage light flashes when the left joystick is moved in any direction away from the neutral position. 19. JOINT OK buttons Both piezo buttons on the left joystick act as “Joint OK” switches when they are depressed. When Rod Feeding, press either Joint OK button when the joint is made up to allow the grippers to open and Swing Arm to come out. The FAULT / BUTTON PRESSED light will illuminate when either button is pressed. When Rod Pulling, press either Joint OK button when the grippers are closed and the joint is fully undone and clear of rod string to allow the Swing Arm to come out. The FAULT / BUTTON PRESSED light will illuminate when either button is pressed. 20. RIGHT joystick When in operation: ○○ Move left to traverse the carriage assembly towards the front (i.e. Rod Holder end) of the Feed Frame, and right to traverse the carriage assembly towards the rear (i.e. sheave end) of the Feed Frame. 28 Copyright © 2007, 2011, 2013 Boart Longyear. All rights reserved. Boart Longyear is constantly striving to improve its products and must therefore reserve the right to change designs, materials, specifications, and price without notice.

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Chapter 3: The Rod Handling Device

○○ Move up to move the Swing Arm in behind the Rotation Unit, down to move the Swing Arm out from behind the Rotation Unit. ○○ The Carriage light flashes when the right joystick is moved in any direction away from the neutral position. 21. CLAMP OPEN/CLOSE buttons Both piezo buttons on the right joystick also act as a switches when pressed. They open and close the Grippers. The FAULT / BUTTON PRESSED light will illuminate when either button is pressed. 22. PRESS WHEN LOAD/UNLOAD AREA IS CLEAR button

For personnel safety, the operator should always check the work area is clear before pressing this button to reactivate the joysticks.

This button reactivates the joysticks after the laser beam has been broken, as indicated by the Flashing Amber strobe light on the Control Panel. 23. ROD PULLING / ROD FEEDING selector This switch selects the mode of operation. It provides an input to the PLC program, which in turn will only allow certain gripper functions to occur, depending on the mode selected: ○○ ROD FEEDING must be selected when rods are being added to the rod string, ○○ ROD PULLING must be selected when removing rods from the string.

Note: A Rotation Unit breakout device is still required to break the joint when pulling rods.

GRIPPER OPEN (Up Hole Mode)

Note: This control mechanism is not shown on the illustration. This facility overrides the horizontal safety switch to allow the grippers to open when in a Vertical Up position. To activate: ●● Switch the Rod Handler ON/OFF selector to OFF, and touch either of the left hand piezo buttons five (5) times. ●● Switch the Rod Handler ON/OFF selector to ON, and the grippers will now open. ●● The horizontal light will flash continually in this mode. Deactivation is the reverse of the above procedure. 29 Copyright © 2007, 2011, 2013 Boart Longyear. All rights reserved. Boart Longyear is constantly striving to improve its products and must therefore reserve the right to change designs, materials, specifications, and price without notice.

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Chapter 3: The Rod Handling Device If power is lost or the E-Stop system is activated, the system reverts back to Down Hole mode.

3.4 Operating Status Indicator

Figure 3–4: Operating status indicator Fitted to the Carriage assembly is a multicolour light that indicates the following operating conditions: LED

Indication

Status

Description

Not Illuminated

Disabled

The Rod Handler is DISABLED and INACTIVE. The Red ‘STOP’ mushroom head pushbutton is depressed.

Steady Yellow

Idle

The Rod Handler is ENABLED but INACTIVE. The Grippers may be actuated Open or Closed.

Flashing Yellow

Active

The Rod Handler is ENABLED and ACTIVE. Motion of the Arm, Tilt, Roll or Traverse is in progress. Any joystick is actuated from the Neutral position.

Steady Red

Fault

There is an active FAULT condition. Only partial functionality may be available. The specific fault will be indicated using a numeric ‘flash code’ on the ‘ERROR’ red panel LED. Rectify the fault condition, then depress and release the Red ‘STOP’ pushbutton to cancel the fault indication. Refer to section 7.4 for details.

Table 3–1: Operating Status Indicator Table

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Contents

Chapter 4: Rod Handler Set Up

4.1 Positioner Assembly Mounting............................................................... 33 4.1.1

Mounting Procedure...................................................................... 33

4.2 Pre Start Checks....................................................................................... 35 4.2.1

Lubrication checks......................................................................... 36

4.3 Hydraulic Connections............................................................................. 36 4.4 Electrical Connections............................................................................. 38 4.5 Control Panel Valve and Gauge Identification....................................... 42 4.6 Arm Horizontal Sensor (Inclinometer) Set Up........................................ 43

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Chapter 4: Rod Handler Set Up

THIS PAGE INTENTIONALLY LEFT BLANK

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Chapter 4: Rod Handler Set Up

4.1 Positioner Assembly Mounting Before fitting a PWM Rod Handler to an existing drill, it may be necessary to shorten the cradle pivot bars, and fit a Power Pack hydraulics kit. The standard Rod Handler mounting kits suit Feed Frame chassis with 20mm thick bottom runners. (Earlier Feed Frames had 12mm thick runners, so this should be checked before proceeding any further.) The Rod Handler Mounting Kits for the 700 and 1300 Series Feed Frames are the same, with the exception of the rear mounting bracket.

Only attempt to fit the Rod Handler to the Feed Frame in a horizontal position. The Feed Frame should also be fitted to a Positioner for stability.

4.1.1

Mounting Procedure 1. Shorten the pivot bars on the cradle to clear Rod Handler carriage slide rails. (Refer to Figure 4-1 below.) This can be done using a circular saw or oxyacetylene kit in a safe place.

Shorten pivot bars if necessary Positioner cradle

Figure 4–1: Positioner cradle 2. The front mount for the Rod Handler fits between the front plate of the Feed Frame and the face plate. (Refer to Figure 4-2, overleaf).) 3. The rear mount attaches to the Feed Frame chassis bottom slide rails with two clamp plates. Set this up so the distance between the

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Chapter 4: Rod Handler Set Up mounting surfaces on the front and rear mounting plates is approx. 3040 mm. Leave the bracket slightly loose so it can be positioned when the handler is being mounted. 4. The front slide adaptor subs can be fitted on rear side of front mounting plate so the 1300 Feed Frame can slide along the cradle a little further. If required, do this before fitting the Rod Handler to the mounting plates. 5. Using the two lift points on the carriage (as shown in Figure 4-2), the Rod Handler should hang near to vertical once lifted clear of the transport pallet. Lift it into position and attach to the front mount. Fit the large square washers on the side of the mount with the slots. Slide the rear bracket back until it touches the Rod Handler and bolt together. Fit the large square washers and spring washers under the bolt heads. Tighten all mounting bolts, keeping in mind the line up of the Rod Handler with the drill string is to be done once the rig is powered up. 6. Fit the face plate. It is wider than the standard face plate so an air leg can be used to bolt the rig to the ground. 7. The Feed Frame and Rod Handler can now be positioned over the hole. Note the swing clearance that is required to operate the Rod Handler. 8. Rock bolt the positioner to the ground. Once the positioner is set up over the drill hole, the front hole in the positioner base next to the Rod Handler mount is hard to get to. Use alternatives if necessary. 9. If possible, set up the Control Panel in a safe position near the front corner of the Feed Frame to enable clear visibility of the Rod String, the Rod Handler, and the Driller’s Assistant at all times.

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Chapter 4: Rod Handler Set Up

10. Run the cables and hoses away from walk areas. If possible, place them under boards without restricting their movement. Rear clamps

Rear mount

Lift points

Face plate

Front mount

Figure 4–2: Positioner assembly mounting procedure

4.2 Pre Start Checks All Rod Handlers have been fully tested before they leave the factory. The following additional checks are intended to: ●● assist in setting up the Rod Handler, and ●● ensure the factory settings of the hydraulic components are correct, and that all hoses are properly connected and purged. Importantly, they also enable operators to become familiar with the operation of this equipment.

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Chapter 4: Rod Handler Set Up

4.2.1

Lubrication checks

Traverse Cylinder Trunnions (behind carriage)

Carriage Slide Blocks

Swing Arm Bearing

Head Pivot Shaft

Gripper Cylinder Trunnions

Figure 4–3: Lubrication points Before proceeding any further, check all of the following components have been greased: ●● Carriage Slide Block nipples (4) ●● Swing Arm bearing (1) ●● Traverse Cylinder Trunnions (2 — behind carriage) ●● Gripper Cylinder Trunnions (4 — underside of head) ●● Head Pivot Shaft nipple (1).

4.3 Hydraulic Connections Connect the Interconnecting Tank, Drain, Load Sense and Pressure hoses to the lower bulkhead on the Power Pack (located under the hydraulic reservoir) as described below: ●● LOAD SENSE — 1/4” hose with 7/16” JIC hose ends runs from the LS port on the Rod Handler valve bank to the LS port on the lower bulkhead on the Power Pack. ●● DRAIN — 3/8” hose with 9/16” JIC hose ends runs from the bulkhead fitting on the Rod Handler bottom valve mounting plate to the Drain Manifold on the Power Pack. 36 Copyright © 2007, 2011, 2013 Boart Longyear. All rights reserved. Boart Longyear is constantly striving to improve its products and must therefore reserve the right to change designs, materials, specifications, and price without notice.

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Chapter 4: Rod Handler Set Up

●● PRESSURE — 1/2” hose with 3/4” JIC hose ends runs from the P port on the Rod Handler DCV to the P port on the lower bulkhead on the Power Pack. ●● TANK — 3/4” hose with 1-1/16” JIC hose ends runs from the T port on the Rod Handler DCV to the T port on the lower bulkhead on the Power Pack. Each hose has different size fitings so they cannot be mixed up.

Figure 4–4: Lower bulkhead on LM Power Pack (under hydraulic bulkhead)

The hydraulic pump used to power this device must be a load sensing type.

37 Copyright © 2007, 2011, 2013 Boart Longyear. All rights reserved. Boart Longyear is constantly striving to improve its products and must therefore reserve the right to change designs, materials, specifications, and price without notice.

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Chapter 4: Rod Handler Set Up

4.4 Electrical Connections

1

2

3

4

Figure 4–5: View of underside of Control Panel Referring to the above photo: ●● Connect the Laser Perimeter Beam or dummy plug to the SAFETY BEAM socket (1) on the underside of the Control Panel (X24). One or the other must be fitted. ●● Connect the Rod Handler 7 pin electrical CAN cable to the CAN BUS socket (2) on the underside of the Control Panel (X23). ●● Connect a 24V DC electrical supply from the Power Pack to the POWER PACK socket (3) on the underside of the Control Panel (X22). ●● Connect a Start/Stop pendant or dummy plug to the START/STOP socket (4) on the underside of the Control Panel (X21). Do not start the Rig Hydraulics until the following checks have been made. 1. The POWER light indicates power is reaching the Control Panel from the source. Check that it illuminates when the electrical power is switched on. Some sensor lights at the top of the Control Panel may also illuminate, depending on whether objects are in the pick-up range of the sensors. This is normal. 2. Rod Handler PULL ON / PUSH OFF button ○○ Pull out to activate the 24V supply to the two joysticks, DCV solenoids, and JOYSTICKS ACTIVE light.

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Chapter 4: Rod Handler Set Up

○○ Push in to disable the 24V supply to the joysticks, DCV solenoids, and JOYSTICKS ACTIVE light. Arm In sensor (top) Arm Out sensor (bottom – hidden)

Arm Clear sensor

Gripper Pressure sensor (rear of valve – hidden) Slew sensor

Arm Horizontal sensor

Rod Rear sensor

Rod Front sensor

Figure 4–6: Sensor Locations ○○ When the button is pulled up (i.e. ON), check the: ■■ JOYSTICKS ACTIVE light illuminates. ■■ Light on the Carriage terminal box illuminates. ■■ Green lights on the Directional Control Valve solenoids (4) illuminate with no rod loaded. ○○ When the button is pushed in (i.e. OFF), check the: ■■ JOYSTICKS ACTIVE light turns off. ■■ Light on the Carriage terminal box turns off. ■■ Green lights on the Directional Control Valve solenoids (4) turn off. 3. ROD FRONT light: Indicates a rod has been sensed loaded forward of the grippers in the Head assembly. ○○ Green POWER light on the ROD FRONT sensor is illuminated. ○○ Amber SENSING light on the ROD FRONT sensor illuminates when a metal object is placed over the square sensing area. ○○ ROD FRONT light on the Control Panel comes on when a metal object is placed over the square sensing area. 4. ROD REAR light: Indicates a rod has been sensed loaded rearward of the grippers in the Head assembly. ○○ Green POWER light on the ROD REAR sensor is illuminated. 39 Copyright © 2007, 2011, 2013 Boart Longyear. All rights reserved. Boart Longyear is constantly striving to improve its products and must therefore reserve the right to change designs, materials, specifications, and price without notice.

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Chapter 4: Rod Handler Set Up ○○ Amber SENSING light on the ROD REAR sensor illuminates when a metal object is placed over the square sensing area. ○○ ROD REAR light on the Control Panel comes on when a metal object placed over the square sensing area. 5. ARM IN light: Indicates the Swing Arm is in the MAKE/BREAK position behind the Rotation Unit — one of two conditions that must be met before the grippers will open in the MAKE/BREAK area. ○○ Amber Light on the ARM IN sensor illuminates when a metal object is placed over the sensing area. ○○ ARM IN light on the Control Panel comes on when a metal object is placed over the sensing area. 6. ARM OUT light: Indicates the Swing Arm is in the LOAD/UNLOAD position alongside the Feed Frame — one of two conditions that must be met before the grippers will open in the LOAD/UNLOAD area. ○○ Amber Light on the ARM OUT sensor illuminates when a metal object is placed over the sensing area. ○○ ARM OUT light on the Control Panel comes on when a metal object is placed over the sensing area. 7. SLEW light: Indicates the Head assembly is near to parallel with the Feed Frame — a condition that must be met before the Swing Arm is allowed to move in or out. ○○ Amber Light on the SLEW sensor illuminates when a metal object is placed over the sensing area. ○○ SLEW light on the Control Panel comes on when a metal object is placed over the sensing area. ○○ Pull up the Rod Handler ON / OFF button, with the hydraulics still off. 8. LEFT JOYSTICK: When in operation, move left to lower the front guide assembly, or move right to raise the front guide assembly when Swing Arm is in the LOAD/UNLOAD position. ○○ Move up to join the rod (make) to the drill string, or move down to undo (break) the rod joint. ○○ Carriage light flashes when the left joystick is moved left, right, up and down.

A Rotation Unit breakout device is still required to break the joint when pulling rods.

9. RIGHT JOYSTICK: Move left to traverse the carriage assembly towards the front of the Feed Frame, or move right to traverse the carriage assembly towards the rear of the Feed Frame. 40 Copyright © 2007, 2011, 2013 Boart Longyear. All rights reserved. Boart Longyear is constantly striving to improve its products and must therefore reserve the right to change designs, materials, specifications, and price without notice.

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Chapter 4: Rod Handler Set Up

○○ Move up to move the Swing Arm in behind the Rotation Unit, or down to move the Swing Arm out from behind the Rotation Unit ○○ Carriage light flashes when the right joystick is moved left, right, up and down. 10. PRESS WHEN LOAD/UNLOAD AREA IS CLEAR button: Is used to reactivate the joysticks after the laser beam has been broken, as indicated by the flashing Amber strobe light on the Control Panel.

For personnel safety, the operator should check the work area is clear before pressing this button to reactivate the Joysticks.

○○ Check the Strobe works by breaking the beam or removing the dummy plug. ○○ Check the Red light on the Laser illuminates when the beam is broken (if applicable). ○○ Check the strobe stops flashing by pressing the PRESS WHEN LOAD/UNLOAD AREA IS CLEAR button. The dummy plug will need to be refitted. ○○ Push in the Rod Handler ON / OFF button. The JOYSTICKS ACTIVE light will turn off. ○○ Ensure the controls on the hydraulic power source are in Neutral. 11. Check the oil level in the Power Unit reservoir is full. 12. Turn the cooling water supply on to give a flow of 20–30 LPM.

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Chapter 4: Rod Handler Set Up

4.5 Control Panel Valve and Gauge Identification Circuit Pressure

Hold Back Pressure P2 Feed Pressure P1

Water Pressure

Drilling (UP) Rod Handling (DOWN) Rod Feeding (UP) Rod Pulling (DOWN) Rod Holder Isolator Valve

Water Pump

Wireline Hoist

Feed Pressure Fine Feed

Rotation Speed Control (V16)

Feed Forward/Reverse

Rotation Forward/Reverse

Figure 4–7: LM75/90 Control Panel Valves and Gauges If attached to a LM75/90 Drill, check the following on the Drill Control Panel: ●● Rotation and Feed control levers must be in Neutral. ●● Drilling/Rod Handling selector lever must be in ROD HANDLING, i.e. pulled towards the operator. ●● Wireline Hoist control lever must be in Neutral. ●● Water Pump speed control (if fitted) must be fully wound out (i.e. anti-clockwise) to the zero speed position and the selector lever in the centre off position. ●● Rotation speed control (V16) must be fully wound out (i.e. anticlockwise) to the low speed position. ●● Rod Feeding/Pulling control lever can be in either position.

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Chapter 4: Rod Handler Set Up

4.6 Arm Horizontal Sensor (Inclinometer) Set Up T2 T1

Out1 Out2

Power

Figure 4–8: Arm Horizontal sensor For the Swing Arm to be in the LOAD/UNLOAD area alongside the Feed Frame and for the grippers to be opened during Rod Handling, the HORIZONTAL light on the Control Panel must be illuminated. This indicates the Head Assembly is positioned within +/- 5 degrees of horizontal. Therefore, after replacing any of the Head assembly components, it may be necessary to set the inclinometer to again consistently recognise the Arm Horizontal position. To do this it is necessary to “teach” the inclinometer to recognise the 5 degree deflection limit (for both clockwise and anti-clockwise rotation when viewed from the front of the Head Assembly): 1. Position the Head Assembly horizontally alongside the Feed Frame. 2. Press button T1 on the Arm Horizontal sensor and hold for more than 2 seconds. The Green Power LED and Yellow Out 2 LED should not illuminate, and the Yellow Out 1 LED flashes. 3. Raise the end of the Head Assembly front guide assembly approx. 85 mm (equivalent to 5 degrees of clockwise rotation).

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Chapter 4: Rod Handler Set Up

Figure 4–9: 4. Briefly press T1 and the Yellow Out 1 LED will illuminate for 1.5 seconds, confirming the clockwise switching point has been taught. 5. Lower the end of the Head Assembly front guard assembly approx. 170 mm, i.e. 85 mm to return to its original position and then lower it a further 85 mm (equivalent to 5 degress of anti-clockwise rotation). 6. Briefly press T1 once more and the Yellow Out 1 LED again illuminates, confirming the anti-clockwise switching point has been taught. 7. Return the Head Assembly to the horizontal position and the HORIZONTAL light should illuminate, confirming the “teach” session has been successful.

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Chapter 5: Rod Handler Start Up Contents 5.1 Pre-Checks and Warnings........................................................................ 47 5.1.1 Tools.............................................................................................. 47 5.2 Start Up Procedure................................................................................... 47 5.2.1.1

Valve Settings....................................................................... 48

5.3 Checking the Functions........................................................................... 49 5.3.1

Horizontal PLC Function............................................................... 49

5.3.2

Load/Unload PLC Function........................................................... 49

5.3.3

Traverse Cylinder Functions......................................................... 49

5.3.4

Slew and PLC Functions............................................................... 50

5.3.5

Gripper and PLC Functions........................................................... 50

5.3.6

Roller and PLC Functions............................................................. 51

5.3.7

Rod to Drill String Alignment......................................................... 52

5.3.8

Rod Feeding Sequence................................................................. 53

5.3.9

Rod Pulling Sequence................................................................... 54

Tables Table 5–1:

Valve Settings............................................................................... 48

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Chapter 5: Rod Handler Start Up

5.1 Pre-Checks and Warnings

For personal safety, turn the Rod Handler OFF using switch on the Control Panel, or by turning OFF the Power Pack when making adjustments.

All speeds and times quoted below are for the Rod Handler when it is powered by drill hydraulics.

5.1.1

Tools The following tools are required: ●● 400 bar Gauge with test point connection. ●● 3mm and 6mm Hex keys ●● 10mm spanner. ●● Stop watch, tachometer and patch.

5.2 Start Up Procedure 1. Start the Power Unit. 2. Check for oil leaks and rectify if necessary. 3. Check the valve pressure settings. Use a 400 bar Gauge with test point connection, a 6 mm Allen key for setting pressures, and the handle supplied with the valve. Pressures can be set by dead heading actuators, or plugging hose ends.

Extreme care is required when operating the valve manually.

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Chapter 5: Rod Handler Start Up 4. Switch On / pull up the Rod Handler ON / OFF button. The Main Pump will be heard loading up a little. If any functions move other than the grippers opening or closing, TURN OFF Rod Handler immediately and rectify the problem. Solenoids

V5 V4 V3 V2 V1

LS Port (on side)

LS B Test Points LS A Test Points Spool Stop Adjustment

LS B Setting Screw

Lever Action A

Pressure Port

Tank Port

LS A Setting Screw

Main Relief

B

Figure 5–1: Valve Locations

5.2.1.1

Valve Settings Function ROLLERS

Section V5

GRIPPERS

V4

HEAD TILT

V3

SWING ARM TRAVERSE

V2 V1

Relief Valve

Action

Setting (bar)

LSA5

Break

200

LSB5

Make

200

LSA4

Close

120

LSB4

Open

60

LSA3

Front Up

140

LSB3

Front Down

140

LSA2

Arm Out

140

LSB2

Arm In

140

LSA1

Extend

120

LSB1

Retract

210

Table 5–1: Valve Settings

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Chapter 5: Rod Handler Start Up

5.3 Checking the Functions 5.3.1

Horizontal PLC Function HORIZ. light: Indicates the Head assembly is horizontal — one of the two conditions that have to be met before the grippers will open in the LOAD/UNLOAD area.

5.3.2

Load/Unload PLC Function LOAD/UNLOAD light: Illuminates when it is safe to load or unload rods from the device, i.e. to open or close the grippers without dropping a rod. The Head assembly must be HORIZONTAL and the Swing Arm in the OUT position for this light (condition) to illuminate. Using the left joystick, carefully place the Head assembly into a HORIZONTAL position in the LOAD /UNLOAD area at the side of the Feed Frame, then check: ●● ARM OUT light is On. ●● HORIZ. light comes On. ●● LOAD/UNLOAD light comes On. When viewed from operator side of Feed Frame check: ●● Head rotates anticlockwise when the Left Joystick is moved left. ●● Head rotates clockwise when the Left Joystick is moved right. ●● HORIZ. light goes off when the Head is tilted 10 – 12 degrees in both directions from horizontal. Rectify if necessary. Return the Head assembly to a horizontal position.

5.3.3

Traverse Cylinder Functions ●● Ensure the Interconnecting Hose Group does not foul on equipment during full travel of the Carriage. ●● Move the Right Joystick to the right and check the Carriage moves towards the rear of the Feed Frame. ●● Check the hydraulic hoses at the rear of valve bank and to the traverse cylinder do not foul on the rear mounting bracket.

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Chapter 5: Rod Handler Start Up ●● Move the Right Joystick to the left and check the Carriage moves towards the front of the Feed Frame. ●● Traverse the Carriage back and forth and check the cushioning works at both ends. ●● Traverse the carriage back and check the travel time is 5.5 – 6 seconds. ●● Traverse carriage the forward and check the travel time is 3.5 – 4 seconds.

5.3.4

Slew and PLC Functions SLEW light: Indicates that the Head assembly is near to parallel with the Feed Frame. The Head assembly needs to be parallel with the Feed Frame so the Swing Arm can not be accidentally operated on steep holes instead of the Traverse function, and the Head swings to the side striking an assistant or the operator. 1. Tilt the Head assembly until it is near to parallel with the Feed Frame and the SLEW light illuminates. 2. Select ROD FEEDING and move the Swing Arm in part way. 3. Tilt the Head assembly until the SLEW light turns off. 4. Check the Swing Arm function cannot be operated in both directions with either ROD FEEDING or ROD PULLING selected. 5. Tilt the Head assembly until the SLEW light illuminates. 6. Select ROD PULLING and move the Swing Arm to the OUT position and tilt the Head assembly until the Head is horizontal.

5.3.5

Gripper and PLC Functions GRIPPER PRESSURE light: Indicates the grippers have closed and the pressure switch is activated. CLAMP CLOSED light: Indicates the CLAMP OPEN/CLOSE button has been pressed to close the grippers and the gripper pressure switch is activated. CLAMP OPEN/CLOSE button: A toggle button on top of the right joystick used to open and close the grippers.

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Chapter 5: Rod Handler Start Up

1. Place an appropriately-sized drill rod in the rod guides fitted to the Head. The pin thread should be located mid way between the front two guides. Check the ROD FRONT and REAR lights come on. 2. With Grippers open, check the Traverse, Roll, Tilt and Swing Arm functions don’t work. 3. Press the toggle button to close the grippers. The grippers close. 4. Check the GRIPPER PRESSURE and CLAMP CLOSED lights come on. 5. With a pressure gauge connected to LSA4, check the clamp closes and the light goes off. Reset LSA4 to 120 bar and check both lights come back on. 6. Tilt the Head assembly until the HORIZ. light turns off. 7. Press the toggle button to open the grippers. The grippers stay closed. 8. Tilt the Head assembly until the SLEW light come on. 9. Select ROD FEEDING and rotate the swing arm until the ARM OUT light turns off. 10. Press the toggle button to open the grippers. The grippers stay closed. 11. Select ROD PULLING, and return the Swing Arm to the ARM OUT position.

5.3.6

Roller and PLC Functions Place a reflective patch for the tachometer on the side of one of the driven rollers. ●● Roller rotates clockwise at 280 – 300 rpm. ●● Roller rotates anti-clockwise at 380 – 400 rpm. With a rod mounted in the Rod Handler head assembly and the grippers closed, test the following in a horizontal position ●● Rod rolls forward (makes) when the Left Joystick is pushed forward. ●● Rod rolls back (breaks) when the Left Joystick is pulled back. ●● Rod stops when the rod ends pass over both the FRONT and REAR ROD proximity switches.

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Chapter 5: Rod Handler Start Up ●● Rod will only roll away from the grippers once it reaches the proximity switches. Return the rod back to a position with the pin thread mid way between the front two guides.

5.3.7

Rod to Drill String Alignment OPERATION switch: Used to select either ROD PULLING or ROD FEEDING. JOINT OK button: The top right hand piezo button on the Left Joystick. When ROD FEEDING, press for half a second when the joint is made up to allow the grippers to open and the Swing Arm to come out. When ROD PULLING, press for half a second when the grippers are closed and the joint fully undone and clear of the rod string to allow the Swing Arm to come out. 1. Move the Rotation Unit fully forward and place short drill rod through the Rod Holder so that 150 – 200 mm protrudes out the rear of the Rotation Unit. 2. Select ROD FEEDING. Move the Rod Handler carriage to rear of the Feed Frame and tilt the Head to make it parallel with Feed Frame. The SLEW light will illuminate. 3. Move the Right Joystick forward to move the Swing Arm and the Head assembly in behind the Rotation Unit, with the the front guide clearing the rear of the drill string. 4. Adjust the Rod Handler at the front and rear mounts so that: ○○ Front guide lines up with the drill string. ○○ Rod in the Handler lines up with the rear rod support roller. ○○ Drill rod sits centrally over the support roller. ○○ Swing Arm mechanical stop may also need to be adjusted. ○○ Head Tilt mechanical stop may also need to be adjusted. 5. Packers can be fitted under the support roller if necessary, but still allow clearance for water swivel. 6. Select ROD PULLING, and press the JOINT OK button. 7. Using Right Joystick, move the Swing Arm, Head and rod back out to the side.

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5.3.8

Chapter 5: Rod Handler Start Up

Rod Feeding Sequence 1. With Head assembly horizontal, place a rod in the guides and close the grippers. 2. Switch the Rod Pulling / Rod Feding selector to ROD FEEDING and move the Rod Handler Carriage to rear of the Feed Frame and tilt the Head to make it parallel with the Feed Frame. 3. The SLEW light illuminates when the Head assembly is near to parallel with the Feed Frame. 4. Move the Right Joystick forward to move the Swing Arm and Head assembly in behind the Rotation Unit with the front guide locating on rear of the drill string. 5. The Swing Arm moves in when the Right Joystick is pushed forward. 6. The Swing Arm actuator cushioning works near end of travel. 7. The Swing Arm travel in time is 3.5 – 4 seconds. 8. Check the ARM IN light comes on when the line up is complete. 9. The Swing Arm does not come out when the Right Joystick is pulled back. 10. Roll a rod forward and ensure the thread makes up. 11. Press the toggle button to open the grippers. The grippers stay closed. 12. Press the JOINT OK button for half a second. 13. The Swing Arm does not come out when the Right Joystick is pulled back. 14. Press the toggle button to open the grippers. The grippers open. 15. The Swing Arm moves out when the Right Joystick is pulled back. 16. Move the Swing Arm back out to the side until the ARM OUT light on the Control Panel comes on. 17. The Swing Arm does not move in when the right joystick is pushed forward.

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Chapter 5: Rod Handler Start Up

5.3.9

Rod Pulling Sequence 1. Switch the Rod Pulling / Rod Feeding selector to ROD PULLING and close the grippers. The Swing Arm does not move in when Right Joystick is pushed forward. 2. Open the grippers then move the Rod Handler Carriage to the rear of the Feed Frame and tilt the Head to make it parallel with the Feed Frame. 3. The SLEW light will illuminate when the Head assembly is near to parallel with the Feed Frame. 4. Move the Right Joystick forward to move the Swing Arm and Head assembly through 90 degrees (half the swing travel) and stop. 5. Rotate the Head assembly back and forth using the Tilt function. The Head assembly tilt time is 2.5 – 3 seconds each way through 90 degrees. 6. Tilt the Head until the mechanical stop is reached, and continue to take the Swing Arm and Head assembly in behind the Rotation Unit with the front guide locating on the rear of the drill string. 7. Press the toggle button to close the grippers. The grippers close. 8. Check the GRIPPER PRESSURE OK and CLAMP CLOSED lights come on. 9. Roll the rod back and ensure the thread breaks fully. 10. The Swing Arm does not come out when the Right Joystick is pulled back. 11. Press the JOINT OK button for half a second. 12. The Swing Arm moves out when the Right Joystick is pulled back. 13. Move the Swing Arm back out to the side until the ARM OUT light comes on. 14. The Swing Arm actuator cushioning works near the end of travel. 15. The Swing Arm travel out time is 3.5 – 4 sconds. 16. The Swing Arm does not move in when the Right Joystick is pushed forward. 17. Open the Grippers and remove the drill rod. 18. Turn off the Rod Handler at the Control Panel and check for oil leaks.

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Chapter 5: Rod Handler Start Up

19. Turn Off the Power Pack and cooling water. The Rod handler is now ready for operation.

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Chapter 6: Rod Handler Operations Contents 6.1 Rod Handler Parts..................................................................................... 59 6.1.1

Front and rear mounts................................................................... 59

6.1.2

Traverse Cylinder.......................................................................... 59

6.1.3

Carriage stop clamp...................................................................... 59

6.1.4

Slide rails....................................................................................... 60

6.1.5

Drill rod stop.................................................................................. 60

6.1.6

Slide blocks and bushes................................................................ 60

6.2 Carriage Slide Bush Replacement .......................................................... 60 6.2.1

Slide Bush Replacement Procedure............................................. 61

6.3 Carriage Assembly.................................................................................... 62 6.3.1

Carriage Frame............................................................................. 62

6.3.2

Swing Arm with hose bulkhead..................................................... 63

6.3.3

Swing Arm mechanical stop.......................................................... 63

6.3.4

Swing Arm actuator and overcentre valve..................................... 63

6.3.5

Swing Arm Cushioning Adjustment............................................... 64

6.3.6

Head Tilt actuator and overcentre valve........................................ 64

6.3.7

Head Tilt actuator guard................................................................ 64

6.4 Valve Assembly......................................................................................... 65 6.4.1

Valve bank..................................................................................... 65

6.4.2

Solenoid control............................................................................. 66

6.5 Head Assembly......................................................................................... 66 6.6 Laser Perimeter Beam.............................................................................. 67 6.6.1

Reflector and stand....................................................................... 68

6.7 Rod Handling Operations......................................................................... 68 6.7.1

Adding a Rod before Rod Feeding................................................ 68

6.7.2

Removing a Rod after Rod Pulling................................................ 69

6.8 Rod Handler Servicing.............................................................................. 69 6.8.1

Laser Safety Beam........................................................................ 69 57

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6.8.2

Serial number locations................................................................. 70

6.8.3

Servicing Notes............................................................................. 70

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Chapter 6: Rod Handler Operations

6.1 Rod Handler Parts

Front Mount Carriage Stop Clamp Slide Blocks and Bushes Slide Rails Traverse Cylinder

Drill Rod Stop

Rear Mount

Overcentre Valve

Head Assembly

Carriage Assembly

Figure 6–1: Rod Handler Parts The Rod Handler consists of the following parts:

6.1.1

Front and rear mounts The mounts are used to bolt the Rod Handler assembly to the mounting kit fitted to the Feed Frame.

6.1.2

Traverse Cylinder The traverse cylinder moves the Carriage and Head assemblies along the side of the Feed Frame. It attaches to the front mount and is fitted with an overcentre valve, used in the event of a hydraulic hose failure.

6.1.3

Carriage stop clamp The carriage stop clamp is used when replacing the traverse cylinder if the Rod Handler and Feed Frame are set up on an angle hole, and can’t be placed into a horizontal position. 59

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Chapter 6: Rod Handler Operations

6.1.4

Slide rails The slide rails are a couple of HQ drill rods, which attach to the front and rear mounts via adaptor subs.

6.1.5

Drill rod stop The drill rod stop is fitted and used if the power fails and the Head assembly is on an angle. It stops the potentially dangerous situation of a drill rod sliding out of the grippers when the power is likely to be off for an extended period of time.

6.1.6

Slide blocks and bushes The slide blocks attach to the back of the carriage and are used to support and guide the Carriage along the side of the Feed Frame. The fitted bushes are replaceable.

Figure 6–2: Slide Bush Replacement Tool

6.2 Carriage Slide Bush Replacement To replace the slide bearings, the above tool (or similar) must be made. Only one half is used, and it can be made of brass or steel. 60 Copyright © 2007, 2011, 2013 Boart Longyear. All rights reserved. Boart Longyear is constantly striving to improve its products and must therefore reserve the right to change designs, materials, specifications, and price without notice.

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Chapter 6: Rod Handler Operations

The flange helps to extract the tool from the slide block once the old bearing is pushed out. This operation should be performed with the Rod Handler in a horizontal position. The bushes are split in two for ease of removal and fitment. Replace one split bush at a time, and don’t mix up the bush halves — they are machined as pairs.

Keeper plate Slide block Slide bearing

Figure 6–3: Slide Bearing components

6.2.1

Slide Bush Replacement Procedure 1. Turn OFF the Rod Handler and Power Pack. 2. Remove the keeper plates (4) from each side of one block. 3. Knock out one half of a bush at a time, using the tool described above. Take care not to damage the sliding surface. 4. Liberally coat the new bush with lubricating oil and place one half of a bush at a time into the block using the tool. The oil will help with installation, and extend the life of the bush. It may be easier to replace half of the bush with the Swing Arm out and the other half with the Swing Arm in, i.e. by transferring the weight off each bearing section. 5. Replace the keeper plates, and use an anti-seize compound on the bolts. 6. Repeat this procedure for the other three blocks. 7. Lubricate each block with a general purpose grease using the nipples provided.

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Chapter 6: Rod Handler Operations

6.3 Carriage Assembly

Head Tilt Actuator

Head Actuator shaft

Swing Arm mechanical stop

Swing Arm

Carriage Frame Copper sealing washers (2) Swing Arm Actuator Actuator guard

Valve assembly

Figure 6–4: Carriage Assembly The Carriage assembly includes the following components:

6.3.1

Carriage Frame The Carriage frame attaches to the carriage slide blocks and traverse cylinder. The Swing Arm, Valve and Head assemblies mount off this frame.

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6.3.2

Chapter 6: Rod Handler Operations

Swing Arm with hose bulkhead The Swing Arm is a structure used to support the Head and Head Tilt actuator. It incorporates a bulkhead for the hydraulic hoses that go to the Head assembly. A lug is welded to this frame for the ARM IN proximity sensor to pick up on.

6.3.3

Swing Arm mechanical stop This mechanical stop is used to limit the travel inwards and align the rod held in the Head assembly with the rod string.

6.3.4

Swing Arm actuator and overcentre valve The Actuator mounts off an adaptor plate fitted to the frame. It rotates through 180° to move the Swing Arm in behind the Rotation Unit from its Home position at the side of the Feed Frame,and is fitted with cushioning at both ends of its travel. The actuator is fitted with an overcentre valve that mounts onto the actuator with two banjo bolts, and has copper sealing washers sandwiched between the two items.

Swing Arm Out

Swing Arm In

Figure 6–5: Swing Arm adjustment

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Chapter 6: Rod Handler Operations

6.3.5

Swing Arm Cushioning Adjustment A 10mm A/F spanner is required to adjust the actuator cushioning. Loosen the locknut, and turn screw clockwise to increase cushioning, then re-tighten the locknut.

Do not wind the screw out more than 13mm from the Actuator body, otherwise the screw will separate from the body and loss of control of the Actuator will occur. High pressure oil could also be ejected from the cavity, causing possible injury and mechanical damage.

6.3.6

Head Tilt actuator and overcentre valve This actuator mounts off the Swing Arm and is used to rotate the Head assembly. It is capable of rotating through 180°, but is limited to rotating 90° by a mechanical stop fitted on the Head Frame. The Head assembly only needs to rotate through 90° to cover all down holes. By moving the mechanical stop on the Head Frame, the Head is able to rotate through another 90° to cover all up holes. This actuator is not fitted with cushioning. An overcentre valve is fitted to this actuator also, and it uses the same cartridges as used on the Swing Arm overcentre valve.

6.3.7

Head Tilt actuator guard This guard stops carriage hoses getting tangled up and also incorporates a pick up for the ARM OUT sensor. The Rod Handler will not function with this guard removed.

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Chapter 6: Rod Handler Operations

6.4 Valve Assembly Solenoids

V5 V4 V3 V2 V1

LS B Test Points

LS Port (on side)

LS A Test Points

Pressure Port

Tank Port

Spool Stop Adjustment LS B Setting Screw

Lever Action A

LS A Setting Screw

Main Relief

B

Figure 6–6: Valve Assembly The above diagrams show the main components in the valve assembly.

6.4.1

Valve bank ●● Pressure test points for Load Sense relief valves. ●● Pressure switch for sensing gripper pressure. ●● Handle for manual operation.

Use the handle with extreme care, and only if the Rod Handler Control Panel is switched OFF.

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SPARE PARTS: 5304378 SEALKIT, PVHC Chapter 6: Rod Handler Operations

6.4.2

Solenoid control

5304274 VALVE, PROPORTION SOLENOID 24V

5304275 PVHC ELECTRICAL ACTUATOR Figure 6–7: PVHC Actuator (p/n 5304275)

●● The Rod Handler uses Pulse Width Modulation (PWM) current controlled solenoids. ●● The current range for normal operation is 0–750mA. ●● There is a pair of coils per valve section. Refer to the label plate for details of individual connections. If power is lost, turn the Rod Handler OFF so the Power Pack doesn’t start under hydraulic load.

6.5 Head Assembly Drill Rod Stop Roller Motor Head Tilt Stop Support Tube

Guide Mounts

Gripper

Gripper Cylinder

Guides

Figure 6–8: Head Assembly The above diagram shows the Head assembly components ●● Head frame support tube 66 Copyright © 2007, 2011, 2013 Boart Longyear. All rights reserved. Boart Longyear is constantly striving to improve its products and must therefore reserve the right to change designs, materials, specifications, and price without notice.

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Chapter 6: Rod Handler Operations

●● Head Tilt mechanical stop ●● Grippers — both are the same type with an angle built in for rolling the rods back and forth. ●● Gripper pivot bushes. ●● Gripper Cylinder with overcentre valve — the same cartridge as is used on the actuator overcentre ●● Head tilt stop block. Swap sides depending on whether drilling up or down the hole. Limits the tilt to 90 degrees to get the Head parallel with the Feed Frame and rod string. ●● Guide mounts. ●● Guides — BQ, NQ, HQ and PQ sizes with outer tube handling provision. ●● Notches are used to indicate the side used when handling rods, and also as a wear indicator.

6.6 Laser Perimeter Beam The Laser Perimeter Beam Kit (p/n 3002693) protects drill operators without hindering their access to the equipment. It uses a Class 2 laser. The light emitted from this device is safe to look at but is not recommended. If the laser beam is interrupted the Joystick controls to the Rod Handler will be disabled. This will be indicated by the flashing strobe. The Joystick controls to the Rod Handler can be re-enabled using the AREA IS CLEAR button.

Note: Before pressing the AREA IS CLEAR button ensure no one is in the machine work area.

Figure 6–9: Laser Perimeter Beam Kit 67 Copyright © 2007, 2011, 2013 Boart Longyear. All rights reserved. Boart Longyear is constantly striving to improve its products and must therefore reserve the right to change designs, materials, specifications, and price without notice.

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Chapter 6: Rod Handler Operations

6.6.1

Reflector and stand Unlike a PIR beam, this device needs a signal back to operate. The lasers will not work if less than a metre away from the reflector, and they have a range of up to approximately 30m.

6.7 Rod Handling Operations 6.7.1

Adding a Rod before Rod Feeding 1. Ensure the Mode selector is in ROD HANDLING. 2. With Head assembly horizontal, place a rod in the guides and close the grippers. Ensure no operator is near the Rod Handler jaws, then press CLAMP OPEN/CLOSE, followed by Joint OK. 3. Switch the Rod Pulling / Rod Feeding selector to ROD FEEDING and move the Rod Handler Carriage to rear of the Feed Frame and tilt the Head to make it parallel with the Feed Frame. 4. The SLEW sensor light illuminates when the Head assembly is near to parallel with the Feed Frame. 5. Move the Right Joystick forward to move the Swing Arm and Head assembly in behind the Rotation Unit with the front guide locating on rear of the drill string.

Note: Swing Arm actuator cushioning works near end of travel. 6. Check the ARM IN sensor light comes on when the line up is complete.

Note: The Swing Arm does not come out when the Right Joystick is pulled back. 7. Roll a rod forward and ensure the thread makes up. 8. Press the JOINT OK button (i.e. either of the push buttons on the Left Joystick) for half a second. 9. Press the CLAMP OPEN/CLOSEe button to open the grippers. The grippers open. 10. The Swing Arm will move out when the Right Joystick is pulled back. Move the Swing Arm back out to the side until the ARM OUT sensor light comes on.

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Chapter 6: Rod Handler Operations



Note: The Swing Arm does not move in when the right joystick is pushed forward.

6.7.2

Removing a Rod after Rod Pulling 1. Ensure the Mode selector is in ROD HANDLING. 2. Switch the Rod Pulling / Rod Feeding selector to ROD PULLING. 3. Open the grippers then move the Rod Handler Carriage to the rear of the Feed Frame and tilt the Head to make it parallel with the Feed Frame. 4. The SLEW light will illuminate when the Head assembly is near to parallel with the Feed Frame. 5. Move the Right Joystick forward to move the Swing Arm and Head assembly through 90 degrees (half the swing travel) and stop. 6. Tilt the Head until the mechanical stop is reached, and continue to take the Swing Arm and Head assembly in behind the Rotation Unit with the front guide locating on the rear of the drill string. 7. Press the toggle button to close the grippers. The grippers close. 8. Check the GRIPPER PRESSURE OK and CLAMP CLOSED lights come on. 9. Roll the rod back and ensure the thread breaks fully. 10. Press the JOINT OK button (i.e. either of the push buttons on the Left Joystick) for half a second. 11. The Swing Arm moves out when the Right Joystick is pulled back. Move the Swing Arm back out to the side until the ARM OUT light comes on.

Note: Swing Arm actuator cushioning works near the end of travel. 12. Open the Grippers and remove the drill rod.

6.8 Rod Handler Servicing 6.8.1

Laser Safety Beam The sensor unit used on the Laser Safety Beam is a sealed electrical device. No maintenance can be performed on the internals of the unit. 69

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Chapter 6: Rod Handler Operations Periodic cleaning of the external lenses on the laser unit and reflector is required. This will ensure the beam is reflected successfully and correct operation of the Laser Safety Beam is maintained. To test the operation of the laser and reflector system, check the following: ●● The green light on the front, top corner of the laser unit is on. This indicates that the power supply to the unit is connected. ●● Check the yellow light on the front, top corner is on. This indicates the beam is being reflected successfully ●● Break the beam using your hand, the yellow light will turn off. Remove hand to restore the reflected beam, the yellow light will turn on.

6.8.2

6.8.3

Serial number locations Rod Handler:

LMRH number on Carriage

Traverse Cylinder:

BH and number near rear port.

Gripper Cylinder:

BH and number near rear port.

Control Panel:

Inside panel assembly

Servicing Notes ●● Bush bearings: All nylon, which should be lubricated with oil when replacing to increase life expectancy. ●● Carriage slide blocks (4). ●● Head pivot shaft (1). ●● Gripper pivots (4) ●● Gripper thrust washers (3) ●● Head Support shaft bushes (2) ●● Head flex bushes (2). Standard sway bar bushes. ●● Swing Arm rotary actuator removal. ●● Prop swing arm with timber and slings. ●● Head tilt rotary actuator removal. ●● Washer stops head from falling off.

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Chapter 7: Rod Handler Troubleshooting Contents 7.1 Important Information............................................................................... 73 7.2 Troubleshooting Symptoms and Actions............................................... 74 7.3 Hydraulic Circuits..................................................................................... 77 7.3.1

Hydraulic Schematic Symbols....................................................... 77

7.3.2

Rod Handler Hydraulic Circuit....................................................... 79

7.4 Electrical Fault Finding Charts................................................................ 81 7.4.1 Introduction.................................................................................... 81 7.4.2

FAULT/BUTTON PRESSED indicator light................................... 82

7.4.3

Rod Pulling Mode.......................................................................... 82

7.4.4

Rod Feeding Mode........................................................................ 84

7.5 I/O Modules................................................................................................ 85 7.5.1

I/O Module Connectors................................................................. 85

7.5.2

I/O Module Replacement............................................................... 86

7.6 PLC Circuit Diagrams............................................................................... 96

Tables Table 7–1:

Field Module switch settings......................................................... 87

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Chapter 7: Rod Handler Troubleshooting

THIS PAGE INTENTIONALLY LEFT BLANK

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Chapter 7: Rod Handler Troubleshooting

7.1 Important Information Please check each section carefully, as what may appear to be a hydraulics fault at the valve, may in fact be a Control Panel electrical fault or vice versa. If you experience any problems not mentioned on this list, please contact your nearest Boart Longyear office for advice. When the drill hydraulics are running, hydraulic pressure is supplied to the Rod Handler DCV pressure port, regardless of whether the Rod Handler joysticks are active or not. The lights on the Control Panel have been included to make fault finding an easier task. The sensor lights on the right hand side of the Control Panel will only illuminate if a 24V DC signal gets to the particular PLC input from each of the sensors, then the PLC sends a 24V DC output to the relevant light. This is important to note when fault finding. Please note which lights illuminate when a fault occurs. This will help you and us, should you require outside assistance. This way, we can quickly eliminate possible causes, and minimise down time. Two charts are included which show what lights should be on at each part of the rod handling sequence. This is for both rod feeding and rod pulling. All sensors with the exception of the pressure switch, have a light on them which illuminates when they are sensing an object in their range. Note also, that all sensors with the exception of the pressure switch, work even when the hydraulics to the machine are switched off. This means most electrical faults can be traced safely without the machine running. All of the hydraulic control valve sections are controlled via I/O module inputs and outputs, which have LEDs to indicate their status. These LEDs are normally yellow when the input or output is activated, and this will help with fault finding. In the event of an electrical failure to the Rod Handler and it is necessary to move it to a safe position, a handle is supplied attached to the valve assembly for emergency manual operation. It is important to note that the handle will not operate the spools when electrical power is still available at the solenoids.

Use this “Emergency Manual Operations” handle with extreme caution.

During manual operation the PLC no longer has control of the safety functions. Understand what each valve section is used for, 73 Copyright © 2007, 2011, 2013 Boart Longyear. All rights reserved. Boart Longyear is constantly striving to improve its products and must therefore reserve the right to change designs, materials, specifications, and price without notice.

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Chapter 7: Rod Handler Troubleshooting and proceed with extreme caution, as a wrong move could mean injury or death.

7.2 Troubleshooting Symptoms and Actions

Symptom Action

POWER light off or flickers when cable connected to Power Pack 1

All lights on Control Panel are off.

Check power available from source.

Check for damage to supply cable between Drill and Handler Control Panel.

Check for continuity, and for a 24V DC supply with a multimeter between pin A and C on supply cable.

Replace the cable if necessary. 2 Broken POWER light. If other lights are illuminated on the Control Panel, check the light wiring inside the Control Panel and replace the light if necessary.

Laser strobe light flashes when Pull ON / Push OFF switch is pulled up. Laser beam has been activated, laser cable damaged, or bridging plug not fitted if laser is not connected. NOTE: The PLC monitors sensors and laser beam when power is available at the Rod Handler Control Panel, even when Pull ON / Push OFF switch is in the OFF position. PLC won’t allow Joysticks to be activated until AREA IS CLEAR button is pressed. Ensure no one is in the machine work area before pressing AREA IS CLEAR Button.

Joystick(s) won’t work. 1

No power to joysticks.

If POWER light is OFF, check power supply.

If POWER light is ON, check PULL ON, PUSH OFF BUTTON is up and JOYSTICKS ACTIVE light is illuminated. 2 Safety beam activated. Strobe light flashing. Check reflector is in line with laser beam (Red light goes out on laser and Input 1 on PLC turns on when set up and aligned). Ensure no one is in the machine work area before pressing AREA IS CLEAR Button. If strobe continues to flash, check if Input 1 on PLC is on. If not, check laser cable for damage and replace if necessary. 3

Safety beam activated. Strobe light not flashing due to

Check reflector is in line with laser beam (Red light goes out on laser and Input 1 on PLC turns on

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Chapter 7: Rod Handler Troubleshooting

broken strobe. when set up and aligned). Ensure no one is in the machine work area before pressing AREA IS CLEAR Button. Output 9 on PLC illuminates when strobe is flashing.

Symptom Action

Refer to PLC diagram. Replace broken strobe if necessary. High voltage shock hazard. When replacing strobe, wait 6 minutes after removing power before removing dome. 4

Strobe light flashing. No laser beam fitted.

Check bridging plug fitted to rear of Control Panel.

Fit if necessary and press LOAD/ UNLOAD AREA IS CLEAR button if no personnel are in work zone. Without a Laser Beam in place, personnel can walk into path of device, causing injury or death. 5 Strobe light flashes when Laser is Check the laser transmitter is not too close to lined up OK. reflector — it should be at least 1 metre away. Ensure no one is in the machine work area before pressing AREA IS CLEAR Button. Check the AREA IS CLEAR Button provides a reset signal. Input 12 on the PLC is activated when the button is pressed. 6 POWER light is on, Rod is loaded Check grippers are closed if a rod is loaded and into Arm, but Arm will not move. both ROD FRONT and ROD REAR lights are illuminated. Handler will not function if a rod is loaded, and the grippers are open. If trying to move the arm in or out, check that the Rod Feeding / Rod Pulling switch is in the correct position for the operation being performed. Also check that the Head assembly is parallel with the Feed Frame and the SLEW light is ON. If the SLEW light is OFF, the PLC is stopping the operation from being performed for safety reasons. 7

POWER light is on but sensor lights on the front of the Control Panel are off. Circuit breaker(s) tripped.

Check circuit breakers inside Control Panel and rectify problem if tripped. Refer to circuit diagrams.

8 Wiring or DCV solenoid fault. With the joysticks active, check that the indication LEDs on the I/O modules are Orange for those inputs or outputs that should be activated. Ensure that the Power indication LEDs on the I/O modules are flashing Green, indicating that the module is powered correctly. Ensure that Red Diagnostics LEDs on the I/O

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Chapter 7: Rod Handler Troubleshooting modules are Off. Check the continuity of cables for any broken or faulty connections. Replace or repair as necessary. Symptom Action

Function(s) slow to operate. Check for corrosion on connectors, valve plug top or at wiring junctions. Operate the joystick and check the signal wire voltage from the joystick varies between 0V and 24V when the joystick is moved to it’s extremes. With the joysticks inactive and the drill hydraulics off, use the lever supplied and operate the relevant valve section and check for a sticking spool.

Grippers won’t open or close 1 Drilling Assistant trying to load or unload Check Head Assembly is horizontal and Swing rods at the side of the Feed Frame. Arm is fully out. ARM OUT and HORIZ. lights should be illuminated on the Control Panel.

PLC will only allow grippers to open or close when these two conditions are met for safety reasons. Selecting Uphole Mode will allow the Grippers to be opened when the Arm is not horizontal. Check also that the plug tops on the valve section V4 is not loose. Check that the appropriate output is being activated on the I/O module. (Node 3 output 2 or 4.) The status indicator for outputs is the upper yellow LED, and for inputs it is the lower yellow LED. Check for corrosion on the connections at the plug top or any wiring junctions.

2 Trying to add or take rods from the drill Check the Swing Arm is fully in and the ARM IN light string when the Handler head is behind is illuminated. The Joint O.K. button must be pressed the Drill Rotation Unit. before the Open command is given to enable the PLC to open the grippers. The PLC will only allow the grippers to open or close when these two conditions are met in this position for safety reasons. Check the Rod Feeding / Rod Pulling switch is set correctly for the mode of operation also. Check that the plug tops on valve section V4 is not loose. Check for corrosion on the connections at the plug top or at junction boxes if necessary. 3

Rod loaded and Rod Front and Rear lights Open Control Panel and check Input 9 on the PLC is illuminated. Broken wire or faulty button activated when the Gripper Open / Close button in either Gripper Open / Close or Joint O.K. is pressed.

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Chapter 7: Rod Handler Troubleshooting

circuit. Check Input 4 on the PLC is activated when the Joint O.K. button is pressed. Check wiring and switches as necessary.

7.3 Hydraulic Circuits 7.3.1

Hydraulic Schematic Symbols The following component symbols are used on the Rod Handler circuit diagrams.

Hydraulic Pump, Fixed Capacity, Uni-Directional

Hydraulic Pump, Fixed Capacity, Bi-Directional

Hydraulic Pump, Variable Capacity, Bi-Directional Hydraulic Motor, Fixed Capacity, Non-Reversible Hydraulic Motor, Variable Capacity, Reversible Hydraulic Motor, Fixed Capacity, Reversible Electric Motor Cylinder, Double-Acting Pilot Control Unit Directional Control Valve 4/2 Lever Actuation, with Detent Directional Control Valve 4/2 Hydraulic Pilot Actuation, Spring Return Throttling DCV 5/2 Hydraulic Pilot Actuation, SpringCentred Non-Return Valve Non-Return Valve, Spring Loaded

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Chapter 7: Rod Handler Troubleshooting

Flow Control Valve, Variable Restriction Flow Control Valve, Variable Restriction Pressure Compensated Main Pressure Relief Valve

Pressure Relief Valve

Unloading Valve, External Drain, Directly Operated

Sequence Valve, External Drain, Directly Operated

Pressure Regulator

Pressure Regulator with Relief Port

Pressure Reducing Valve

Pressure Reducing Valve, with Free Flow Check Pressure Reducing Valve, Direct Operating Spool with Check Counterbalance Valve with Integral Check Counterbalance Valve with Integral Check, Pilot Operated Pilot Operated Dual Counterbalance Valve DCV 4/3 Valve, Pilot Operated Shuttle Valve Throttle Valve Throttle Valve, Variable Restriction Shut-Off Valve

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Chapter 7: Rod Handler Troubleshooting

Proximity Sensor

Electrical Solenoid Control Working Line, Return Line, Feed Line Pilot Control Line Drain or Bleed Line Flexible Hose Quick-Acting Coupling – connected with mechanically opened Non-Return Valve Accumulator Filter Water Trap, Manual Control Filter with Condensate Trap, Manual Control Heat Exchanger, Water Cooled Manual Control Pressure Switch Push Button Control Lever Control Direct Acting Control by Application of Pressure Indirect Control, Pilot Actuated by Application of Pressure Pressure Gauge 5 Position Rotary Gauge Selector

7.3.2

Rod Handler Hydraulic Circuit The Rod Holder hydraulic circuit appears overleaf.

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Chapter 7: Rod Handler Troubleshooting

Figure 7–1: Rod Handler Hydraulic Circuit 80 Copyright © 2007, 2011, 2013 Boart Longyear. All rights reserved. Boart Longyear is constantly striving to improve its products and must therefore reserve the right to change designs, materials, specifications, and price without notice.

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Chapter 7: Rod Handler Troubleshooting

7.4 Electrical Fault Finding Charts 7.4.1

Introduction All faults or error conditions on the Rod Handler are detailed by means of a unique numeric identifier (ID). A complete list of possible faults is detailed in the Table on the next page. All active faults are annunciated using a ‘flash code’ on the ‘Fault/Error’ LED Lamp, centre-left of the Rod Handler control panel. The flash code sequence is as follows: 1. The first, most significant digit (tens) is indicated using a fast flash of 0.5 sec ON/OFF (1 HZ). The count of the number of successive flashes represents the value of the digit. 2. A 1 sec delay where the LED lamp will remain OFF 3. The second, least significant digit (units) is indicated using a fast flash of 0.5 sec ON/OFF (1 HZ). The count of the number of successive flashes represents the value of the digit. 4. The sequence is followed by a 2 sec delay, where the LED lamp will remain OFF. The two digits indicated by the sequence, combined, represent the numeric ID of the active fault in the range 11-99. For convenience and ease of presentation, only specific codes detailed in the following table will be provided. The above sequence will be repeated for all active faults in numerical order. When all active faults have been annunciated, the entire process will be repeated indefinitely. To acknowledge the active faults, it will be necessary to rectify the respective faults, and reset the annunciation process by actuating the Rod Handler ON/OFF maintained mushroom-head pushbutton.

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Chapter 7: Rod Handler Troubleshooting

7.4.2

FAULT/BUTTON PRESSED indicator light The FAULT /BUTTON PRESSED light on the Control Panel assists with fault finding by displaying unique flash code sequences to identify specific faults. A summary of flash codes, names, and their corresponding fault descriptions appears below.

Listed overleaf are additional electrical fault finding charts to be used when the rod handler is operating in Rod Pulling and Rod Feeding modes. The PLC unit used with the Rod Handler requires inputs from sensors for certain functions to occur. Control Panel lights illuminate when the relevant sensor sends a signal to the PLC.

7.4.3

Rod Pulling Mode In the following table it is assumed that the Rod Handler is set up on an angle, and to the side of the Feed Frame at the start of the Pulling sequence, with the hydraulics operational.

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ROD

PUSH OFF

O

O

O

O

O

O

O

O

O

O

O

O

O

O

O

O

SELECT ROD PULLING

CHECK HEAD HORIZONTAL

CHECK ARM IS OUT

CHECK GRIPPERS OPEN

TRAVERSE BACK

TILT HEAD TO PARALLEL

SWING ARM IN

CLOSE GRIPPERS

UNSCREW JOINT

PRESS JOINT OK (0.5 SEC)

SWING ARM OUT

TILT HEAD TO HORIZONTAL

TRAVERSE FORWARD

OPEN GRIPPERS

UNLOAD ROD

REPEAT CYCLE

FEEDING

O Indicates the Function is used or Light is Illuminated

O

O

CHECK LASER STATUS

DEACTIVATE JOYSTICKS

O

O

PULL ON

ACTIVATE JOYSTICKS

POWER CONNECTED

MODE

PULLING

PULLING O

O

O

O

O

O

O

O

O

O

O

O

O

O

O

O

O

CENTRE O

O

O

O

O

O

O

O

O

O

O

O

O

O

O

O

BREAK O

DOWN O

O

O

JOINT OK

MAKE X Indicates tha Light Flashes

O

O

UP

CENTRE O

O

O

O

O

O

O

O

O

O

O

O

O

O

O

ARM IN O

RIGHT JOYSTICK

O

O

ARM OUT

POSITION OF CONTROLS

O

FORWARD

LEFT JOYSTICK

O

REVERSE

OPERATION

CLAMP O

O

O

AREA IS CLEAR O

POWER O

O

O

O

O

O

O

O

O

O

O

O

O

O

O

O

O

O

O

O

JOYSTICKS ACTIVE O

O

O

O

O

O

O

O

O

O

O

O

O

O

O

O

O

O

LOAD / UNLOAD O

O

O

O

O

O

O

O

O

ARM OUT O

O

O

O

O

O

HORIZONTAL O

O

O

O

O

O

O

O

O

O

O

LIGHTS

INDICATION

O

O

O

O

O

O

O

O

O

O

ROD FRONT

HANDLER

O

O

O

O

O

O

O

O

ROD REAR

OPERATION

ARM IN O

O

O

O

O

O

O

O

SLEW O

O

O

O

GRIPPER PRESSURE O

O

O

O

O

O

LIGHT ON CARRIAGE O

O

O

X

X

X

O

X

O

X

X

X

O

X

X

O

O

O

DCV LIGHTS O

O

O

O

O

O

O

O

O

O

O

O

O

O

O

O

O

Chapter 7: Rod Handler Troubleshooting

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83

FAULT CODE (NEW)

CLAMPS CLOSED

PUSH OFF

O

O

O

O

O

O

O

O

O

O

O

O

O

O

O

CHECK HEAD HORIZONTAL

CHECK ARM IS OUT

CHECK GRIPPERS OPEN

LOAD ROD

CLOSE GRIPPERS

TRAVERSE BACKWARD

TILT HEAD TO PARALLEL

SWING ARM IN

MAKE UP JOINT

PRESS JOINT OK (0.5 SEC)

OPEN GRIPPERS

SWING ARM OUT

TILT HEAD TO HORIZONTAL

TRAVERSE FORWARD

REPEAT CYCLE

O

O

O

O

O

O

O

O

O

O

O

O

O

O

O

O

O

FEEDING

O Indicates the Function is used or Light is Illuminated

O

O

SELECT ROD FEEDING

DEACTIVATE JOYSTICKS

O

CHECK LASER STATUS

PULL ON

O

O

CENTRE

O

O

O

O

O

O

O

O

O

O

O

O

O

O

O

MAKE

O

DOWN O

O

O

JOINT OK

BREAK

X Indicates tha Light Flashes

O

O

O

O

O

O

O

O

O

O

O

O

O

O

O

O

CENTRE

PULLING

ARM IN O

O

O

O

O

CLAMP O

O

O

AREA IS CLEAR O

POWER O

O

O

O

O

O

O

O

O

O

O

O

O

O

O

O

O

O

O

O

JOYSTICKS ACTIVE O

O

O

O

O

O

O

O

O

O

O

O

O

O

O

O

O

O

LOAD / UNLOAD O

O

O

O

O

O

O

O

O

CLAMPS CLOSED O

O

O

O

O

O

ARM OUT O

O

O

O

O

O

O

O

O

O

O

HORIZONTAL O

O

O

O

O

O

O

O

O

O

LIGHTS

INDICATION

O

O

O

O

O

O

O

O

O

O

O

O

O

O

O

O

ARM IN O

O

O

O

SLEW O

O

O

O

O

O

GRIPPER PRESSURE O

O

O

O

O

O

LIGHT ON CARRIAGE O

X

X

X

O

O

X

X

X

X

O

O

O

X

X

O

O

O

DCV LIGHTS O

O

O

O

O

O

O

O

O

O

O

O

O

O

O

O

O

7.4.4

ACTIVATE JOYSTICKS

POWER CONNECTED

MODE

ROD

FEEDING

UP

RIGHT JOYSTICK

ARM OUT

POSITION OF CONTROLS

FORWARD

LEFT JOYSTICK

REVERSE

OPERATION

ROD FRONT

HANDLER

ROD REAR

OPERATION

Chapter 7: Rod Handler Troubleshooting

Rod Feeding Mode In the following table it is assumed that the Rod Handler is set up on an angle, and to the side of the Feed Frame at the start of the Feeding sequence, with the hydraulics operational.

84

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FAULT CODE (NEW)



Chapter 7: Rod Handler Troubleshooting

7.5 I/O Modules 7.5.1

I/O Module Connectors Located inside the valve compartment on the Carriage assembly are three I/O Modules that receive control signals from various sensors on the Rod Handler.

Figure 7–2: I/O Module connectors

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Chapter 7: Rod Handler Troubleshooting

7.5.2

I/O Module Replacement Field Modules Node 2 Node 3

Node 2

S1 S2 S3

Valve assembly

Field Module Node 4

Node 3

Node 4

S1 S2 S3

S1 S2 S3

Figure 7–3: I/O Module rotary switch locations To replace a faulty I/O module: 1. Turn OFF the Rod Handler and Power Pack. 2. Undo the hex head bolts and remore the cover panel that is protecting the faulty module, then disconnect the jumper cables from the module. 3. Remove the 3 capscrews securing the module to the compartment wall, then remove the 2 capscrews securing the protective cover across the bottom section of the module to expose the jumper switches and rotary switches.

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Chapter 7: Rod Handler Troubleshooting

4. Check the rotary switch setings for the new/replacement I/O module are the same as in the following table. Use a small screwdriver to adjust the settings if necessary. Node/Setting

S1

S2

S3

Node 2 (CR2032)

4

0

2

4

0

3

4

0

4

Node 3 (CR2032)

Node 4 (CR2031)

Table 7–1: Field Module switch settings Once the switch settings have been checked/adjusted the replacement I/O module can be installed: 5. Replace the protective cover over the jumper switches and rotary switches across the bottom of the module, then secure the module to the compartment wall. 6. Reconnect the jumper cables to the I/O module, and replace the external cover. The following 8 pages contain technical data sheets for the two I/O Modules used in the PWM Rod Handler: ●● CR2031 (4 pages), and ●● CR2032 (4 pages). (This information has been supplied by ifm electronic gmbm, the manufacturer of the I/O modules. It may be useful for field electricians.)

87 Copyright © 2007, 2011, 2013 Boart Longyear. All rights reserved. Boart Longyear is constantly striving to improve its products and must therefore reserve the right to change designs, materials, specifications, and price without notice.

3547445

Chapter 7: Rod Handler Troubleshooting

Control systems

CR2031 Output module digital and analogue for R360 system

Technical data

Housing Dimensions (l x w x h) Installation Connections Operating voltage and CAN bus

Outputs CANin/CANout Weight Outputs can be configured as

4

2

3

1

52

6 5

CAN in

8

77 9

7

LED M12 x1

6

8 digital / PWM outputs with integrated current measurement Die-cast zinc housing with 8 outputs and terminal chamber surface electrostatically coated (cathodic immersion), black 227 x 77 x 39 mm (without cable gland) Screw connection by means of 3 M5 x l screws to DIN 912 or DIN 7984 7-pole terminal strip with CAGE CLAMP ® connection technology (2 x 2-pole / 1 x 3-pole) 0.08...4 mm2 (AWG 28...AWG 12), nominal current 20 A Identical potentials can be linked using a jumper header (GND and UB potentials linked upon delivery) Cable entry via M16 cable gland 8 x M12 connector (socket), 5-pole 2 x M12 connector (plug/socket), 5-pole 1.2 kg 8 digital, positive-switching (high side) PWM channel, or current-controlled channel

switching current per output

max. 4 A

total current

max. 16 A

Operating voltage UB

10...32 V DC

Current consumption

≤ 50 mA (without external load at 24 V DC)

Operating temperature

– 40...85 °C

Storage temperature

– 40...85 °C

Protection

IP 67

Interface

CAN interface 2.0 B, ISO 11898

Baud rate

20 Kbits/s...1 Mbit/s (default setting 125 Kbits/s) (adjustable using hex-code switch in the terminal chamber or via the CANopen object directory)

Communication profile

CANopen, CiA DS 301 version 4, CiA DS 401 version 2.1

Node ID (default)

\DATEN\100\DB-FORM—PZD/03/12/96

5

Indication

ifm electronic gmbh • Friedrichstraße 1 • 45128 Essen

5

10...32 V DC

PWR DIA

CAN out

227 205

CANopen interface Surface electrostatically coated (cathodic immersion)



39 23

CompactModule Metal

69

hex 20 (= dec 32) (adjustable using 2 hex-code switches in the terminal chamber or via the CANopen object directory) 1 LED green (PWR) 1 LED red (diagnosis, DIA) 8 LEDs yellow (status of the outputs)

We reserve the right to make technical alterations without prior notice.

CR2031 / page 1

15.03.2006

88 Copyright © 2007, 2011, 2013 Boart Longyear. All rights reserved. Boart Longyear is constantly striving to improve its products and must therefore reserve the right to change designs, materials, specifications, and price without notice.

3547445



Chapter 7: Rod Handler Troubleshooting

Control systems CR2031

Technical data

Connecting and operating elements 1

2

4

3

2

1

3

4

5

5

1

2

CAN in

CAN out PWR DIA

Jumper headers upon delivery: 3+4 / 5+6+7

CAGE CLAMP ® connection clamps 1 2

3 4

5 6 7

CAN

GND

+VBB

S1

S3

Description

0 1 2 3 4 5 6 7 8...E F

1000 Kbits/s 800 Kbits/s 500 Kbits/s 250 Kbits/s 125 Kbits/s 100 Kbits/s 50 Kbits/s 20 Kbits/s not defined adjustment via object directory (default)

S2 Node ID H

0...7 F

high nibble, e.g. 20 hex (= 32 dec) adjustment via object directory (default)

S3 Node ID L

0...E F

low nibble, e.g. 20 hex (= 32 dec) adjustment via object directory (default)

LED

Status

PWR (green)

OFF ON

E

•0•

•C•

S1 Baud rate

•4•6

Position

2

Switch

•8•A

Hex-code switch coding

S2

Hex-coded rotary switch

Operating states (LEDs)

\DATEN\100\DB-FORM—PZD/03/12/96

2.0 Hz

ifm electronic gmbh • Friedrichstraße 1 • 45128 Essen

Description no supply voltage module in stand-by mode CANopen status: PREOPERATIONAL / PREPARED outputs = OFF module active CANopen status: OPERATIONAL outputs are updated

DIA (red)

OFF ON

communication OK communication disturbed • node guard / heartbeat error (if node guarding / heartbeat is activated) • no synch objects (if synch monitoring is activated)

OUT (yellow)

ON

binary output: output switched (ON) analogue output: PWM preset value ≠ 0 current preset value > 20

We reserve the right to make technical alterations without prior notice.

CR2031 / page 2

15.03.2006

89 Copyright © 2007, 2011, 2013 Boart Longyear. All rights reserved. Boart Longyear is constantly striving to improve its products and must therefore reserve the right to change designs, materials, specifications, and price without notice.

3547445

Chapter 7: Rod Handler Troubleshooting

Control systems CR2031

Characteristics of the outputs

Digital outputs

8 semiconductor outputs; short-circuit and overload protected Switching voltage 10...32 V DC Switching current max. 4 A Total current max. 16 A The current measurement of 2 channels each can be selected by means of the wire connections. The following channels are combined: 1+2, 3+4, 5+6, 7+8

PWM outputs

With the configuration (1+2, 3+4, 5+6, 7+8). PWM frequency Pulse duty factor Resolution Switching current Total current

as "PWM output" two outputs each are combined

With the configuration (1+2, 3+4, 5+6, 7+8). PWM frequency Control range Control resolution Setting resolution Control characteristics Accuracy Switching current Load resistance

as "current-controlled output" two outputs each are combined

Current outputs

20...250 Hz 50...1000 ‰ 1‰ max. 4 A max. 16 A

20...250 Hz 20...1000 mA / 80...4000 mA 1 mA / 4 mA (see control parameters) 1 mA can be set via the object directory (see control parameters) ± 2% FS max. 4 A min. 12 / 3 Ω (at UB = 12 V DC) min. 24 / 6 Ω (at UB = 24 V DC)

Control parameters

By indicating the max. load current [mA] for each output pair the respective control or value range (1000 or 4000 mA) is automatically selected. In addition the P/I behaviour of the current controller can be parameterised for each output pair.

Free-wheel diode is integrated!

To avoid errors in the measuring result, no external free-wheel diode must be connected in parallel with the load in the "current-controlled output" operating mode.

\DATEN\100\DB-FORM—PZD/03/12/96

Test standards and regulations Climatic test

Damp heat to EN 60068-2-30, test Db (≤ 95% rel. humidity, non-condensing) Salt mist test to EN 60068-2-52, test Kb, severity level 3 Protection test to EN 60529

Mechanical resistance

Vibration to EN 60068-2-6, test Fc Shock to EN 60068-2-27, test Ea Bump to EN 60068-2-29, test Eb

Immunity to conducted interference

to ISO 7637-2, pulses 2, 3a, 3b, 4, severity level 4, function state A to ISO 7637-2, pulse 5, severity level 1, function state A to ISO 7637-2, pulse 1, severity level 4, function state C

Immunity to interfering fields

to directive 95/54/EC at 100 V/m (e1 type approval) and DIN EN 61000-6-2 (CE)

Interference emission

to directive 95/54/EC (e1 type approval) and DIN EN 61000-6-3 (CE)

ifm electronic gmbh • Friedrichstraße 1 • 45128 Essen

We reserve the right to make technical alterations without prior notice.

CR2031 / page 3

15.03.2006

90 Copyright © 2007, 2011, 2013 Boart Longyear. All rights reserved. Boart Longyear is constantly striving to improve its products and must therefore reserve the right to change designs, materials, specifications, and price without notice.

3547445



Chapter 7: Rod Handler Troubleshooting

Control systems

Outputs






  

­ 



01 02 03 04 05

  

­ 



01 02 03 04 05

  

­ 



01 02 03 04 05



      

































  

­ 



01 02 03 04 05



  

­ 



01 02 03 04 05



  

­ 



01 02 03 04 05



  

­ 



01 02 03 04 05



01 02 03 04 05

CAN OUT



      

01  02 

CAN IN

01 02 03 04 05

Outputs



05   06  

07   



  

­ 



03 

04 



01 02 03 04 05



Wiring



CR2031



CAN Interface / Supply Abbreviations CANH = CANL = GNDO = GNDS =

CAN interface (high) CAN interface (low) ground (output) ground (module)

ifm electronic gmbh • Friedrichstraße 1 • 45128 Essen

PWM VBBC VBBO VBBS

= = = =

output for pulse-width modulated signals operating voltage (via CANin/CANout plug) operating voltage (output) operating voltage (module)

We reserve the right to make technical alterations without prior notice.

CR2031 / page 4

15.03.2006

91 Copyright © 2007, 2011, 2013 Boart Longyear. All rights reserved. Boart Longyear is constantly striving to improve its products and must therefore reserve the right to change designs, materials, specifications, and price without notice.

3547445

Chapter 7: Rod Handler Troubleshooting

Control systems

CR2032 I/O module digital and analogue for R360 system

Technical data

Housing Dimensions (l x w x h) Installation Connections Operating voltage and CAN bus

Inputs/Outputs CANin/CANout Weight Inputs can be configured as

Sensor supply I max Outputs

\DATEN\100\DB-FORM—PZD/03/12/96

can be configured as

4

2

3

1

LED M12 x1

52

6 5

CAN in

8 7

77 9 5

6

8 inputs (4 digital and 4 analogue/digital) 8 outputs (4 digital and 4 digital/PWM) Die-cast zinc housing with 8 outputs and terminal chamber surface electrostatically coated (cathodic immersion), black 227 x 77 x 39 mm (without cable gland) Screw connection by means of 3 M5 x l screws to DIN 912 or DIN 7984 7-pole terminal strip with CAGE CLAMP ® connection technology (2 x 2-pole / 1 x 3-pole) 0.08...4 mm2 (AWG 28...AWG 12), nominal current 20 A Identical potentials can be linked using a jumper header (GND and UB potentials linked upon delivery) Cable entry via M16 cable gland 8 x M12 connector (socket), 5-pole 2 x M12 connector (plug/socket), 5-pole 1.35 kg 8 4 digital, positive-switching (high side) 4 analogue, 0...10/32 V, 0/4...20 mA, ratiometric or digital, positive-switching, with diagnostic capability 400 mA 8 4 digital, positive-switching (high side), with diagnostic capability 4 digital, positive-switching (high side), with diagnostic capability or PWM channel

switching current per output

max. 2 A

total current

max. 16 A

Operating voltage UB

10...32 V DC

Current consumption

≤ 60 mA (without external load at 24 V DC)

Operating temperature

– 40...85 °C

Storage temperature

– 40...85 °C

Protection

IP 67

Interface

CAN interface 2.0 B, ISO 11898

Baud rate

20 Kbits/s...1 Mbit/s (default setting 125 Kbits/s) (adjustable using hex-code switches in the terminal chamber or via the CANopen object directory)

Communication profile Node ID (default)

Displays

ifm electronic gmbh • Friedrichstraße 1 • 45128 Essen

5

10...32 V DC

PWR DIA

CAN out

227 205

CANopen interface Surface electrostatically coated (cathodic immersion)



39 23

CompactModule Metal

69

CANopen, CiA DS 301 version 4, CiA DS 401 version 2.1 hex 20 (= dec 32) (adjustable using hex-code switches in the terminal chamber or via the CANopen object directory) 1 LED green (PWR) 1 LED red (diagnosis, DIA) 16 LEDs yellow (status of the inputs / outputs) We reserve the right to make technical alterations without prior notice.

CR2032 / page 1

15.03.2006

92 Copyright © 2007, 2011, 2013 Boart Longyear. All rights reserved. Boart Longyear is constantly striving to improve its products and must therefore reserve the right to change designs, materials, specifications, and price without notice.

3547445



Chapter 7: Rod Handler Troubleshooting

Control systems CR2032

Technical data

Connecting and operating elements



























   

Jumper headers upon delivery: 3+4 / 5+6+7

CAGE CLAMP ® connection clamps  

 

  











Description

0 1 2 3 4 5 6 7 8...E F

1000 Kbits/s 800 Kbits/s 500 Kbits/s 250 Kbits/s 125 Kbits/s 100 Kbits/s 50 Kbits/s 20 Kbits/s not defined adjustment via object directory (default)

S2 Node ID H

0...7 F

high nibble, e.g. 20 hex (= 32 dec) adjustment via object directory (default)

S3 Node ID L

0...E F

low nibble, e.g. 20 hex (= 32 dec) adjustment via object directory (default)

LED

Status

PWR (green)

OFF ON

E

•0•

•C•

S1 Baud rate

•4•6

Position

2

Switch

•8•A

Hex-code switch coding



Hex-coded rotary switch

Operating states (LEDs)

\DATEN\100\DB-FORM—PZD/03/12/96

2.0 Hz

ifm electronic gmbh • Friedrichstraße 1 • 45128 Essen

DIA (red)

OFF ON

IN (yellow)

ON 2.0 Hz

OUT (yellow)

ON

Description no supply voltage module in stand-by mode CANopen status: PREOPERATIONAL / PREPARED outputs = OFF module active CANopen status: OPERATIONAL outputs are updated communication OK communication disturbed • node guard / heartbeat error (if node guarding / heartbeat is activated) • no synch objects (if synch monitoring is activated) output switched diagnosis failure binary output: output switched (ON) analogue output: PWM preset value ≠ 0

We reserve the right to make technical alterations without prior notice.

CR2032 / page 2

15.03.2006

93 Copyright © 2007, 2011, 2013 Boart Longyear. All rights reserved. Boart Longyear is constantly striving to improve its products and must therefore reserve the right to change designs, materials, specifications, and price without notice.

3547445

Chapter 7: Rod Handler Troubleshooting

Control systems CR2032

Characteristics of the inputs / outputs

Inputs Channel 1, 3, 5, 7 (pin 4)

■ Digital inputs, with diagnostic capability Switch-on level 0.4...0.7 UB Switch-off level 0.2...0.24 UB Input resistance 3 kΩ Input frequency max. 50 Hz

Channel 1, 3, 5, 7 (pin 2) can be configured as ...

■ Analogue inputs voltage, current, ratiometric or digital positive-switching Voltage inputs Input voltage Resolution Input resistance Input frequency Accuracy

0...10/32 V 10 bits 50/30 kΩ 50 Hz ± 1 % FS

Current inputs Input current Resolution Input resistance Input frequency Accuracy

0/4...20 mA 10 bits 400 Ω 50 Hz ± 1 % FS

Ratiometric inputs for potentiometric transducers (e.g. joystick) Function ((UIN – ½UB) ÷ ½UB) x 1000 ‰ Value range 0...1000 ‰ Digital inputs, with diagnostic capability Switch-on level 0.7 UB Switch-off level 0.4 UB Input resistance 30 kΩ Input frequency max. 50 Hz Outputs Channel 2, 4, 6, 8 (pin 4) can be configured as ...

■ Semiconductor outputs, with diagnostic capability (wire break and short circuit) short-circuit and overload protected Switching voltage 10...32 V DC Switching current max. 2 A Total current max. 8 A ■ PWM outputs PWM frequency Pulse duty factor Resolution Switching current Total current

20...250 Hz 0...1000 ‰ 1‰ max. 2 A (referred to PWM value 1000 ‰.) max. 8 A

Channel 2, 4, 6, 8 (pin 2) can be configured as ...

■ Semiconductor outputs, with diagnostic capability (wire break and short circuit) short-circuit and overload protected Switching voltage 10...32 V DC Switching current max. 2 A Total current max. 8 A

Note

also see wiring (following page)

\DATEN\100\DB-FORM—PZD/03/12/96

Test standards and regulations Climatic test

Damp heat to EN 60068-2-30, test Db (≤ 95% rel. humidity, non-condensing) Salt mist test to EN 60068-2-52, test Kb, severity level 3 Protection test to EN 60529

Mechanical resistance

Vibration to EN 60068-2-6, test Fc Shock to EN 60068-2-27, test Ea Bump to EN 60068-2-29, test Eb

Immunity to conducted interference

to ISO 7637-2: 2004, pulses 2a, 3a, 3b, 4, severity level 4, function state A to ISO 7637-2: 2004, pulse 1, 2b, severity level 4, function state C to ISO 7637-2: 2004, pulse 5, severity level 1, function state A

Immunity to interfering fields

to directive 2005/49/EC at 100 V/m (e1 type approval) and DIN EN 61326 (CE)

Interference emission

to directive 2005/49/EC (e1 type approval) and DIN EN 61326 (CE)

ifm electronic gmbh • Friedrichstraße 1 • 45128 Essen

We reserve the right to make technical alterations without prior notice.

CR2032 / page 3

15.03.2006

94 Copyright © 2007, 2011, 2013 Boart Longyear. All rights reserved. Boart Longyear is constantly striving to improve its products and must therefore reserve the right to change designs, materials, specifications, and price without notice.

3547445



Chapter 7: Rod Handler Troubleshooting

Control systems

Inputs









CAN IN

01 02 03 04 05



   

01 02 03 04 05



   

01 02 03 04 05



   

01 02 03 04 05



   

01 02 03 04 05

  

        

   

Wiring

     

CR2032

Outputs



































   

01 02 03 04 05





   

01 02 03 04 05





   

01 02 03 04 05





   

01 02 03 04 05



01 02 03 04 05

CAN OUT

  

        

05   06   07  

03    04   

01   02  

 ­€‚




CAN Interface / Supply Abbreviations CANH = CANL = GNDO = GNDS =

CAN interface (high) CAN interface (low) ground (output) ground (module)

ifm electronic gmbh • Friedrichstraße 1 • 45128 Essen

PWM VBBC VBBO VBBS

= = = =

output for pulse-width modulated signals operating voltage (via CANin/CANout plug) operating voltage (output) operating voltage (module)

We reserve the right to make technical alterations without prior notice.

CR2032 / page 4

15.03.2006

95 Copyright © 2007, 2011, 2013 Boart Longyear. All rights reserved. Boart Longyear is constantly striving to improve its products and must therefore reserve the right to change designs, materials, specifications, and price without notice.

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Chapter 7: Rod Handler Troubleshooting

7.6 PLC Circuit Diagrams The remaining pages in this chapter contain copies of the PLC circuits.

96 Copyright © 2007, 2011, 2013 Boart Longyear. All rights reserved. Boart Longyear is constantly striving to improve its products and must therefore reserve the right to change designs, materials, specifications, and price without notice.

3547445

Copyright © 2007, 2011, 2013 Boart Longyear. All rights reserved. Boart Longyear is constantly striving to improve its products and must therefore reserve the right to change designs, materials, specifications, and price without notice.

DATE

10 MAY 12

ISSUE

A

USED ON

EO No.

123491

REFER ECN

RELEASED FOR / REVISION

ISSUE

DATE

EO No.

RELEASED FOR / REVISION

DO NOT SCALE UNLESS OTHERWISE SPECIFIED: ALL DIMENSIONS IN MILLIMETRES OR MICROMETRES PERMISSIBLE TOLERANCES ON DIMENSIONS:

3547445

SCALE

MATERIAL

WT.

Boart Longyear Pty Ltd, Mitchell Park, South Australia.

THE DESIGNS, CONSTRUCTIONS, ARRANGEMENTS, DISCLOSURES, AND DEVICES SHOWN OR DEFINED IN THE PROPOSAL, DRAWINGS, OR SKETCHES BEARING THIS LEGEND, ARE THE PROPERTY OF LONGYEAR AND ARE SUBMITTED IN CONFIDENCE WITH THE UNDERSTANDING THAT SUCH DESIGNS, CONSTRUCTIONS, ARRANGEMENTS, DISCLOSURES, AND DEVICES SHALL NOT BE UTILIZED IN WHOLE OR IN PART BY ANY PERSON, FIRM, OR CORPORATION WITHOUT THE PRIOR WRITTEN PERMISSION OF THE LONGYEAR COMPANY.

ITEM

MAT'L

F.ALEITE

DWN

DWG. NO.

SHEET

DWG. SIZE 1

OF

UG-ROD HADLER CAN -PWM EXTERNAL CONNECTION 3.06.2011

DATE

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EO No.

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Copyright © 2007, 2011, 2013 Boart Longyear. All rights reserved. Boart Longyear is constantly striving to improve its products and must therefore reserve the right to change designs, materials, specifications, and price without notice. SCALE

MATERIAL

WT.

Boart Longyear Pty Ltd, Mitchell Park, South Australia.

THE DESIGNS, CONSTRUCTIONS, ARRANGEMENTS, DISCLOSURES, AND DEVICES SHOWN OR DEFINED IN THE PROPOSAL, DRAWINGS, OR SKETCHES BEARING THIS LEGEND, ARE THE PROPERTY OF LONGYEAR AND ARE SUBMITTED IN CONFIDENCE WITH THE UNDERSTANDING THAT SUCH DESIGNS, CONSTRUCTIONS, ARRANGEMENTS, DISCLOSURES, AND DEVICES SHALL NOT BE UTILIZED IN WHOLE OR IN PART BY ANY PERSON, FIRM, OR CORPORATION WITHOUT THE PRIOR WRITTEN PERMISSION OF THE LONGYEAR COMPANY.

ITEM

DWN

DATE

DESCRIPTION

F.ALEITE

3.06.2011

DWG. NO.

SHEET

DWG. SIZE 2

OF

UG-ROD HADLER CAN -PWM POWER SUPPLY

MAT'L

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DATE

10 MAY 12

ISSUE

A

USED ON

EO No.

123491

REFER ECN

RELEASED FOR / REVISION

ISSUE

DATE

EO No.

RELEASED FOR / REVISION

S0304

LEFT HAND JOYSTICK

DO NOT SCALE UNLESS OTHERWISE SPECIFIED: ALL DIMENSIONS IN MILLIMETRES OR MICROMETRES PERMISSIBLE TOLERANCES ON DIMENSIONS:

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POTENTIOMETER

MAT'L

F.ALEITE

DWN

DWG. NO.

SHEET

DWG. SIZE 3

OF

UG-ROD HADLER CAN -PWM LH JOYSTICK 3.06.2011

DATE

DESCRIPTION

POTENTIOMETER

Boart Longyear Pty Ltd, Mitchell Park, South Australia.

THE DESIGNS, CONSTRUCTIONS, ARRANGEMENTS, DISCLOSURES, AND DEVICES SHOWN OR DEFINED IN THE PROPOSAL, DRAWINGS, OR SKETCHES BEARING THIS LEGEND, ARE THE PROPERTY OF LONGYEAR AND ARE SUBMITTED IN CONFIDENCE WITH THE UNDERSTANDING THAT SUCH DESIGNS, CONSTRUCTIONS, ARRANGEMENTS, DISCLOSURES, AND DEVICES SHALL NOT BE UTILIZED IN WHOLE OR IN PART BY ANY PERSON, FIRM, OR CORPORATION WITHOUT THE PRIOR WRITTEN PERMISSION OF THE LONGYEAR COMPANY.

ITEM

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S0404

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RIGHT HAND JOYSTICK

Copyright © 2007, 2011, 2013 Boart Longyear. All rights reserved. Boart Longyear is constantly striving to improve its products and must therefore reserve the right to change designs, materials, specifications, and price without notice. SCALE

MATERIAL

WT.

Boart Longyear Pty Ltd, Mitchell Park, South Australia.

THE DESIGNS, CONSTRUCTIONS, ARRANGEMENTS, DISCLOSURES, AND DEVICES SHOWN OR DEFINED IN THE PROPOSAL, DRAWINGS, OR SKETCHES BEARING THIS LEGEND, ARE THE PROPERTY OF LONGYEAR AND ARE SUBMITTED IN CONFIDENCE WITH THE UNDERSTANDING THAT SUCH DESIGNS, CONSTRUCTIONS, ARRANGEMENTS, DISCLOSURES, AND DEVICES SHALL NOT BE UTILIZED IN WHOLE OR IN PART BY ANY PERSON, FIRM, OR CORPORATION WITHOUT THE PRIOR WRITTEN PERMISSION OF THE LONGYEAR COMPANY.

ITEM

DWN

DATE

DESCRIPTION

F.ALEITE

3.06.2011

DWG. NO.

SHEET

DWG. SIZE 4

OF

UG-ROD HADLER CAN -PWM RH JOYSTICK

MAT'L

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DATE

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ISSUE

A

USED ON

EO No.

123491

REFER ECN

RELEASED FOR / REVISION

ISSUE

DATE

EO No.

RELEASED FOR / REVISION

UNLESS OTHERWISE SPECIFIED: ALL DIMENSIONS IN MILLIMETRES OR MICROMETRES PERMISSIBLE TOLERANCES ON DIMENSIONS:

DO NOT SCALE

PLC SYSTEM ARRANGEMENT

ROD HANDLER CONTROL SYSTEM

3547445

SCALE

MATERIAL

WT.

Boart Longyear Pty Ltd, Mitchell Park, South Australia.

THE DESIGNS, CONSTRUCTIONS, ARRANGEMENTS, DISCLOSURES, AND DEVICES SHOWN OR DEFINED IN THE PROPOSAL, DRAWINGS, OR SKETCHES BEARING THIS LEGEND, ARE THE PROPERTY OF LONGYEAR AND ARE SUBMITTED IN CONFIDENCE WITH THE UNDERSTANDING THAT SUCH DESIGNS, CONSTRUCTIONS, ARRANGEMENTS, DISCLOSURES, AND DEVICES SHALL NOT BE UTILIZED IN WHOLE OR IN PART BY ANY PERSON, FIRM, OR CORPORATION WITHOUT THE PRIOR WRITTEN PERMISSION OF THE LONGYEAR COMPANY.

ITEM

MAT'L

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2

1

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4

3

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CAN in

6

5

ISSUE

DATE

EO No.

CAN in

4

2

3

1

PWR DIA

6

5

RELEASED FOR / REVISION

CAN out

A

A

A

A

GRIPPERS B

GRIPPERS A

UNLESS OTHERWISE SPECIFIED: ALL DIMENSIONS IN MILLIMETRES OR MICROMETRES PERMISSIBLE TOLERANCES ON DIMENSIONS:

DO NOT SCALE

TRAVERSE FORWARD

ARM IN

TILT DOWN

ROLL MAKE

ROD HANDLER CANBUS - PWM CONTROL SYSTEM

Copyright © 2007, 2011, 2013 Boart Longyear. All rights reserved. Boart Longyear is constantly striving to improve its products and must therefore reserve the right to change designs, materials, specifications, and price without notice. PWR DIA

SCALE

MATERIAL

CAN in

2

4

3

1

6

8

5

7

WT.

CAN out

Boart Longyear Pty Ltd, Mitchell Park, South Australia.

THE DESIGNS, CONSTRUCTIONS, ARRANGEMENTS, DISCLOSURES, AND DEVICES SHOWN OR DEFINED IN THE PROPOSAL, DRAWINGS, OR SKETCHES BEARING THIS LEGEND, ARE THE PROPERTY OF LONGYEAR AND ARE SUBMITTED IN CONFIDENCE WITH THE UNDERSTANDING THAT SUCH DESIGNS, CONSTRUCTIONS, ARRANGEMENTS, DISCLOSURES, AND DEVICES SHALL NOT BE UTILIZED IN WHOLE OR IN PART BY ANY PERSON, FIRM, OR CORPORATION WITHOUT THE PRIOR WRITTEN PERMISSION OF THE LONGYEAR COMPANY.

ITEM

DWN

DATE

DESCRIPTION

F.ALEITE

3.06.2011

DWG. NO.

SHEET

DWG. SIZE

REQ'D

6

OF

17

A1

TRAVERSE REVERSE

ARM OUT

TILT UP

ROLL BRAKE

UG-ROD HADLER CAN -PWM I/O CONNECTION

B

B

B

B

MAT'L

Chapter 7: Rod Handler Troubleshooting

102

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DATE

10 MAY 12

ISSUE

A

USED ON

EO No.

123491

REFER ECN

RELEASED FOR / REVISION

ISSUE

DATE

EO No.

RELEASED FOR / REVISION

DO NOT SCALE UNLESS OTHERWISE SPECIFIED: ALL DIMENSIONS IN MILLIMETRES OR MICROMETRES PERMISSIBLE TOLERANCES ON DIMENSIONS:

3547445

SCALE

MATERIAL

WT.

Boart Longyear Pty Ltd, Mitchell Park, South Australia.

THE DESIGNS, CONSTRUCTIONS, ARRANGEMENTS, DISCLOSURES, AND DEVICES SHOWN OR DEFINED IN THE PROPOSAL, DRAWINGS, OR SKETCHES BEARING THIS LEGEND, ARE THE PROPERTY OF LONGYEAR AND ARE SUBMITTED IN CONFIDENCE WITH THE UNDERSTANDING THAT SUCH DESIGNS, CONSTRUCTIONS, ARRANGEMENTS, DISCLOSURES, AND DEVICES SHALL NOT BE UTILIZED IN WHOLE OR IN PART BY ANY PERSON, FIRM, OR CORPORATION WITHOUT THE PRIOR WRITTEN PERMISSION OF THE LONGYEAR COMPANY.

ITEM

MAT'L

3.06.2011 F.ALEITE

DATE DWN

DWG. NO.

SHEET

DWG. SIZE 7

OF

17

A1

REQ'D

UG-ROD HADLER CAN -PWM OPERATOR INTERFACE CONNECTION

DESCRIPTION

Chapter 7: Rod Handler Troubleshooting

103

DATE

10 MAY 12

ISSUE

A

USED ON

EO No.

123491

REFER ECN

RELEASED FOR / REVISION

ISSUE

DATE

EO No.

RELEASED FOR / REVISION

DO NOT SCALE UNLESS OTHERWISE SPECIFIED: ALL DIMENSIONS IN MILLIMETRES OR MICROMETRES PERMISSIBLE TOLERANCES ON DIMENSIONS:

Copyright © 2007, 2011, 2013 Boart Longyear. All rights reserved. Boart Longyear is constantly striving to improve its products and must therefore reserve the right to change designs, materials, specifications, and price without notice. SCALE

MATERIAL

WT.

Boart Longyear Pty Ltd, Mitchell Park, South Australia.

THE DESIGNS, CONSTRUCTIONS, ARRANGEMENTS, DISCLOSURES, AND DEVICES SHOWN OR DEFINED IN THE PROPOSAL, DRAWINGS, OR SKETCHES BEARING THIS LEGEND, ARE THE PROPERTY OF LONGYEAR AND ARE SUBMITTED IN CONFIDENCE WITH THE UNDERSTANDING THAT SUCH DESIGNS, CONSTRUCTIONS, ARRANGEMENTS, DISCLOSURES, AND DEVICES SHALL NOT BE UTILIZED IN WHOLE OR IN PART BY ANY PERSON, FIRM, OR CORPORATION WITHOUT THE PRIOR WRITTEN PERMISSION OF THE LONGYEAR COMPANY.

ITEM

DWN

DATE

MAT'L

F.ALEITE

3.06.2011

DWG. NO.

SHEET

DWG. SIZE 8

OF

17

A1

REQ'D

UG-ROD HANDLER CAN-PWM OPERATORS INTERFACE CONNECTION

DESCRIPTION

Chapter 7: Rod Handler Troubleshooting

104

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DATE

10 MAY 12

ISSUE

A

USED ON

EO No.

123491

REFER ECN

RELEASED FOR / REVISION

ISSUE

DATE

EO No.

RELEASED FOR / REVISION

DO NOT SCALE UNLESS OTHERWISE SPECIFIED: ALL DIMENSIONS IN MILLIMETRES OR MICROMETRES PERMISSIBLE TOLERANCES ON DIMENSIONS:

3547445

SCALE

MATERIAL

WT.

Boart Longyear Pty Ltd, Mitchell Park, South Australia.

THE DESIGNS, CONSTRUCTIONS, ARRANGEMENTS, DISCLOSURES, AND DEVICES SHOWN OR DEFINED IN THE PROPOSAL, DRAWINGS, OR SKETCHES BEARING THIS LEGEND, ARE THE PROPERTY OF LONGYEAR AND ARE SUBMITTED IN CONFIDENCE WITH THE UNDERSTANDING THAT SUCH DESIGNS, CONSTRUCTIONS, ARRANGEMENTS, DISCLOSURES, AND DEVICES SHALL NOT BE UTILIZED IN WHOLE OR IN PART BY ANY PERSON, FIRM, OR CORPORATION WITHOUT THE PRIOR WRITTEN PERMISSION OF THE LONGYEAR COMPANY.

ITEM

MAT'L

3.06.2011 F.ALEITE

DWN

DWG. NO.

SHEET

DWG. SIZE 9

OF

UG- ROD HANDLER CAN-PWM I/O CONNECTION DATE

DESCRIPTION

17

A1

REQ'D

Chapter 7: Rod Handler Troubleshooting

105

DATE

10 MAY 12

ISSUE

A

USED ON

EO No.

123491

CAN in

6

4

2

5

3

1

CAN out

REFER ECN

RELEASED FOR / REVISION

PWR DIA

8

7

ISSUE

DATE

EO No.

RELEASED FOR / REVISION

DO NOT SCALE UNLESS OTHERWISE SPECIFIED: ALL DIMENSIONS IN MILLIMETRES OR MICROMETRES PERMISSIBLE TOLERANCES ON DIMENSIONS:

Copyright © 2007, 2011, 2013 Boart Longyear. All rights reserved. Boart Longyear is constantly striving to improve its products and must therefore reserve the right to change designs, materials, specifications, and price without notice. SCALE

MATERIAL

WT.

Boart Longyear Pty Ltd, Mitchell Park, South Australia.

THE DESIGNS, CONSTRUCTIONS, ARRANGEMENTS, DISCLOSURES, AND DEVICES SHOWN OR DEFINED IN THE PROPOSAL, DRAWINGS, OR SKETCHES BEARING THIS LEGEND, ARE THE PROPERTY OF LONGYEAR AND ARE SUBMITTED IN CONFIDENCE WITH THE UNDERSTANDING THAT SUCH DESIGNS, CONSTRUCTIONS, ARRANGEMENTS, DISCLOSURES, AND DEVICES SHALL NOT BE UTILIZED IN WHOLE OR IN PART BY ANY PERSON, FIRM, OR CORPORATION WITHOUT THE PRIOR WRITTEN PERMISSION OF THE LONGYEAR COMPANY.

ITEM

DWN

DATE

DESCRIPTION

F.ALEITE

3.06.2011

DWG. NO.

SHEET

10

DWG. SIZE OF

UG-ROD HANDLER CAN-PWM NODE 2

MAT'L

17

A1

REQ'D

Chapter 7: Rod Handler Troubleshooting

106

3547445

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DATE

10 MAY 12

ISSUE

A

USED ON

EO No.

123491

REFER ECN

RELEASED FOR / REVISION

ISSUE

DATE

EO No.

RELEASED FOR / REVISION

DO NOT SCALE UNLESS OTHERWISE SPECIFIED: ALL DIMENSIONS IN MILLIMETRES OR MICROMETRES PERMISSIBLE TOLERANCES ON DIMENSIONS:

3547445

SCALE

MATERIAL

WT.

Boart Longyear Pty Ltd, Mitchell Park, South Australia.

THE DESIGNS, CONSTRUCTIONS, ARRANGEMENTS, DISCLOSURES, AND DEVICES SHOWN OR DEFINED IN THE PROPOSAL, DRAWINGS, OR SKETCHES BEARING THIS LEGEND, ARE THE PROPERTY OF LONGYEAR AND ARE SUBMITTED IN CONFIDENCE WITH THE UNDERSTANDING THAT SUCH DESIGNS, CONSTRUCTIONS, ARRANGEMENTS, DISCLOSURES, AND DEVICES SHALL NOT BE UTILIZED IN WHOLE OR IN PART BY ANY PERSON, FIRM, OR CORPORATION WITHOUT THE PRIOR WRITTEN PERMISSION OF THE LONGYEAR COMPANY.

ITEM

MAT'L

3.06.2011 F.ALEITE

DWN

DWG. NO.

SHEET

11

DWG. SIZE OF

UG- ROD HANDLER CAN-PWM I/O CONNECTION DATE

DESCRIPTION

17

A1

REQ'D

Chapter 7: Rod Handler Troubleshooting

107

DATE

10 MAY 12

ISSUE

A

USED ON

EO No.

123491

CAN in

6

4

2

5

3

1

CAN out

REFER ECN

RELEASED FOR / REVISION

PWR DIA

8

7

ISSUE

DATE

EO No.

RELEASED FOR / REVISION

DO NOT SCALE UNLESS OTHERWISE SPECIFIED: ALL DIMENSIONS IN MILLIMETRES OR MICROMETRES PERMISSIBLE TOLERANCES ON DIMENSIONS:

Copyright © 2007, 2011, 2013 Boart Longyear. All rights reserved. Boart Longyear is constantly striving to improve its products and must therefore reserve the right to change designs, materials, specifications, and price without notice. SCALE

MATERIAL

WT.

Boart Longyear Pty Ltd, Mitchell Park, South Australia.

THE DESIGNS, CONSTRUCTIONS, ARRANGEMENTS, DISCLOSURES, AND DEVICES SHOWN OR DEFINED IN THE PROPOSAL, DRAWINGS, OR SKETCHES BEARING THIS LEGEND, ARE THE PROPERTY OF LONGYEAR AND ARE SUBMITTED IN CONFIDENCE WITH THE UNDERSTANDING THAT SUCH DESIGNS, CONSTRUCTIONS, ARRANGEMENTS, DISCLOSURES, AND DEVICES SHALL NOT BE UTILIZED IN WHOLE OR IN PART BY ANY PERSON, FIRM, OR CORPORATION WITHOUT THE PRIOR WRITTEN PERMISSION OF THE LONGYEAR COMPANY.

ITEM

MAT'L

3.06.2011 F.ALEITE

DWN

DWG. NO.

SHEET

12

DWG. SIZE OF

UG-ROD HANDLER CAN-PWM NODE 3 DATE

DESCRIPTION

17

A1

REQ'D

Chapter 7: Rod Handler Troubleshooting

108

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DATE

10 MAY 12

ISSUE

A

USED ON

EO No.

123491

Y1319

Y1314

Y1309

Y1303

REFER ECN

RELEASED FOR / REVISION

ISSUE

DATE

EO No.

ARM OUT (V2A)

ARM IN (V2B)

RELEASED FOR / REVISION

DO NOT SCALE UNLESS OTHERWISE SPECIFIED: ALL DIMENSIONS IN MILLIMETRES OR MICROMETRES PERMISSIBLE TOLERANCES ON DIMENSIONS:

3547445

MATERIAL

SCALE

WT.

Boart Longyear Pty Ltd, Mitchell Park, South Australia.

THE DESIGNS, CONSTRUCTIONS, ARRANGEMENTS, DISCLOSURES, AND DEVICES SHOWN OR DEFINED IN THE PROPOSAL, DRAWINGS, OR SKETCHES BEARING THIS LEGEND, ARE THE PROPERTY OF LONGYEAR AND ARE SUBMITTED IN CONFIDENCE WITH THE UNDERSTANDING THAT SUCH DESIGNS, CONSTRUCTIONS, ARRANGEMENTS, DISCLOSURES, AND DEVICES SHALL NOT BE UTILIZED IN WHOLE OR IN PART BY ANY PERSON, FIRM, OR CORPORATION WITHOUT THE PRIOR WRITTEN PERMISSION OF THE LONGYEAR COMPANY.

Y1341

MAT'L

3.06.2011 F.ALEITE

DATE DWN

DWG. NO.

SHEET

13

DWG. SIZE OF

UG-ROD HADLER CAN -PWM I/O CONNECTION - PWM VALVES

ROLL BREAK (V5A)

(V5B)

ROLL MAKE

(V3A)

Y1337

TILT UP

(V3B)

TILT DOWN

(V1A)

Y1332

Y1327

DESCRIPTION

TRAVERSE REVERSE

TRAVERSE FORWARD (V1B)

ITEM

17

A1

REQ'D

Chapter 7: Rod Handler Troubleshooting

109

DATE

10 MAY 12

ISSUE

A

USED ON

EO No.

123491

CAN in

6

4

2

5

3

1

CAN out

REFER ECN

RELEASED FOR / REVISION

PWR DIA

8

7

ISSUE

DATE

EO No.

RELEASED FOR / REVISION

DO NOT SCALE UNLESS OTHERWISE SPECIFIED: ALL DIMENSIONS IN MILLIMETRES OR MICROMETRES PERMISSIBLE TOLERANCES ON DIMENSIONS:

Copyright © 2007, 2011, 2013 Boart Longyear. All rights reserved. Boart Longyear is constantly striving to improve its products and must therefore reserve the right to change designs, materials, specifications, and price without notice. SCALE

MATERIAL

WT.

Boart Longyear Pty Ltd, Mitchell Park, South Australia.

THE DESIGNS, CONSTRUCTIONS, ARRANGEMENTS, DISCLOSURES, AND DEVICES SHOWN OR DEFINED IN THE PROPOSAL, DRAWINGS, OR SKETCHES BEARING THIS LEGEND, ARE THE PROPERTY OF LONGYEAR AND ARE SUBMITTED IN CONFIDENCE WITH THE UNDERSTANDING THAT SUCH DESIGNS, CONSTRUCTIONS, ARRANGEMENTS, DISCLOSURES, AND DEVICES SHALL NOT BE UTILIZED IN WHOLE OR IN PART BY ANY PERSON, FIRM, OR CORPORATION WITHOUT THE PRIOR WRITTEN PERMISSION OF THE LONGYEAR COMPANY.

ITEM

DWN

DATE

DESCRIPTION

F.ALEITE

3.06.2011

DWG. NO.

SHEET

14

DWG. SIZE OF

UG-RODHANDLER CAN-PWM PWM VALVES - MODULE

MAT'L

17

A1

REQ'D

Chapter 7: Rod Handler Troubleshooting

110

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DATE

10 MAY 12

ISSUE

A

USED ON

EO No.

123491

CABLE 15 15m

REFER ECN

RELEASED FOR / REVISION

(1) (2) (3) (4) (5) (6) (7) (8) (9) (10) (11) (GN)

ISSUE

DATE

(1) (2) (3) (4) (5) (6) (7) (8) (9) (10) (11) (GN)

EO No.

RELEASED FOR / REVISION

DO NOT SCALE UNLESS OTHERWISE SPECIFIED: ALL DIMENSIONS IN MILLIMETRES OR MICROMETRES PERMISSIBLE TOLERANCES ON DIMENSIONS:

3547445

SCALE

MATERIAL

WT.

Boart Longyear Pty Ltd, Mitchell Park, South Australia.

THE DESIGNS, CONSTRUCTIONS, ARRANGEMENTS, DISCLOSURES, AND DEVICES SHOWN OR DEFINED IN THE PROPOSAL, DRAWINGS, OR SKETCHES BEARING THIS LEGEND, ARE THE PROPERTY OF LONGYEAR AND ARE SUBMITTED IN CONFIDENCE WITH THE UNDERSTANDING THAT SUCH DESIGNS, CONSTRUCTIONS, ARRANGEMENTS, DISCLOSURES, AND DEVICES SHALL NOT BE UTILIZED IN WHOLE OR IN PART BY ANY PERSON, FIRM, OR CORPORATION WITHOUT THE PRIOR WRITTEN PERMISSION OF THE LONGYEAR COMPANY.

ITEM

MAT'L

3.06.2011 F.ALEITE

DWN

DWG. NO.

SHEET

15

DWG. SIZE OF

UG-ROD HANDLER CAN-PWM CABLE 15 DATE

DESCRIPTION

17

A1

REQ'D

Chapter 7: Rod Handler Troubleshooting

111

DATE

10 MAY 12

ISSUE

A

USED ON

123491

EO No.

X24

X22

REFER ECN

RELEASED FOR / REVISION

X23

ISSUE

X21

DATE

EO No.

DOWN

LOAD / UNLOAD

CLAMP

JOINT OK

UP

ROD HOLDER PULL ON / PUSH OFF

ROD PULLING

CLAMP OPEN / CLOSE

FORWARD

REVERSE

UNLESS OTHERWISE SPECIFIED: ALL DIMENSIONS IN MILLIMETRES OR MICROMETRES PERMISSIBLE TOLERANCES ON DIMENSIONS:

DO NOT SCALE

OPERATION

ROD REAR

ROD FEEDING

ARM OUT

GRIPPER SLEW

PRESSURE

ARM IN

PRESSED

FRONT.

ROD

SENSORS HORIZ.

FAULT / BUTTON

CLOSED

RELEASED FOR / REVISION

PRESS WHEN LOAD / UNLOAD AREA IS CLEAR

BREAK (ANTI CLOCKWISE)

ACTIVE

ON

SYSTEM JOYSTICK

POWER

Copyright © 2007, 2011, 2013 Boart Longyear. All rights reserved. Boart Longyear is constantly striving to improve its products and must therefore reserve the right to change designs, materials, specifications, and price without notice. SCALE

MATERIAL

WT.

Boart Longyear Pty Ltd, Mitchell Park, South Australia.

THE DESIGNS, CONSTRUCTIONS, ARRANGEMENTS, DISCLOSURES, AND DEVICES SHOWN OR DEFINED IN THE PROPOSAL, DRAWINGS, OR SKETCHES BEARING THIS LEGEND, ARE THE PROPERTY OF LONGYEAR AND ARE SUBMITTED IN CONFIDENCE WITH THE UNDERSTANDING THAT SUCH DESIGNS, CONSTRUCTIONS, ARRANGEMENTS, DISCLOSURES, AND DEVICES SHALL NOT BE UTILIZED IN WHOLE OR IN PART BY ANY PERSON, FIRM, OR CORPORATION WITHOUT THE PRIOR WRITTEN PERMISSION OF THE LONGYEAR COMPANY.

ITEM

DWN

DATE

DESCRIPTION

F.ALEITE

3.06.2011

DWG. NO.

SHEET

16

DWG. SIZE OF

UG-ROD HADLER CAN -PWM LAYOUT

MAT'L

17

A1

REQ'D

Chapter 7: Rod Handler Troubleshooting

112

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Chapter 8: Recommended Spare Parts Kit Contents 8.1 12 Months Operation.............................................................................. 115 8.1.1

Rod Handler ............................................................................... 115

8.1.2

Carriage Assembly...................................................................... 115

8.1.3

Valve Assembly PWM................................................................. 115

8.1.4

Interconnecting Cable to Rod handler......................................... 116

8.1.5

Interconnecting Cable to LM Power Pack................................... 116

8.1.6

Laser Perimeter Beam................................................................ 116

8.1.7

Head Assembly........................................................................... 116

8.1.8

Guide Sets................................................................................... 116

8.1.9

Control Group Rod Handler......................................................... 117

113 Copyright © 2007, 2011, 2013 Boart Longyear. All rights reserved. Boart Longyear is constantly striving to improve its products and must therefore reserve the right to change designs, materials, specifications, and price without notice.

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Chapter 8: Recommended Spare Parts Kit

THIS PAGE INTENTIONALLY LEFT BLANK

114 Copyright © 2007, 2011, 2013 Boart Longyear. All rights reserved. Boart Longyear is constantly striving to improve its products and must therefore reserve the right to change designs, materials, specifications, and price without notice.

3547445



Chapter 8: Recommended Spare Parts Kit

Description

Part No.

Qty

8.1 12 Months Operation 8.1.1

Rod Handler

Complete Assembly

5304600

SLIDE BEARING

3001401

SEAL KIT TRAVERSE CYLINDER

6003643 1

NIPPLE GREASE M6 45 DEGREES

84630

4

NIPPLE GREASE M6 90 DEGREES

87171

2

8.1.2

4

Carriage Assembly

Complete

5303830

BEARING SELF ALIGNING

602494

1

BUSH HEAD SHAFT PIVOT

3001860

1

WASHER SEALING 3/8” BSPP COPPER

3000539

2

WASHER SEALING 3/8” BSPP

94715

2

IO MODULE CAN CR2032 - INPUT

5302493

1

IO MODULE CAN CR2031 - OUTPUT

5301966

1

CABLE 21 SOLENOID VALVE

5304190

2

CABLE 22 SOLENOID VALVE

5304191

2

SENSOR PROXIMITY M12

3069645

3

CABLE M12 JUMPER 1300MM

5304193

3

INDICATOR LIGHT 5 PIN CONNECTOR

3070220

1

8.1.3

Valve Assembly PWM

Complete

5304270

TEST POINT 1/4” BSPP

88738

2

SWITCH PRESSURE

5303958

1

SEAL KIT PVHC VALVE ASSY

5304378

1

ELECTRICAL ACTUATOR PVHC

5304275

2

115 Copyright © 2007, 2011, 2013 Boart Longyear. All rights reserved. Boart Longyear is constantly striving to improve its products and must therefore reserve the right to change designs, materials, specifications, and price without notice.

3547445

Chapter 8: Recommended Spare Parts Kit

8.1.4

Interconnecting Cable to Rod handler

CABLE ASSEMBLY 7-PIN

8.1.5

1

Interconnecting Cable to LM Power Pack

CABLE ASSEMBLY 10-PIN

8.1.6

5304196

89182

1

Laser Perimeter Beam

Complete Assembly

3002693

CABLE INTERCONNECTING

89182

1

KNOB HAND

602334

1

SAFETY BEAM LASER

3002694

1

8.1.7

Head Assembly

Complete

3000320

BUSH SUPPORT TUBE PIVOT

3001451

2

BUSH GRIPPER PIVOT

3000324

4

WASHER GRIPPER PIVOT

3001346

3

BEARING BALL 30 ID x 72 OD x 19 W

62617

4

BEARING BALL 30 ID x 62 OD x 16 W

30949

4

INDUCTIVE SENSOR – ROD END

3070221

2

SENSOR PROXIMITY M12

3069645

1

SENSOR INCLINATION SINGLE AXIS

5304186

1

CABLE M12 JUMPER 4000MM

5304192

4

RING RETAINING

101805

6

ROLLER

3001348 4

CAP ROD ROLLER BEARING

602743

2

SEAL KIT GRIPPERCYLINDER

6003643

1

CARTRIDGE O/C VALVE

5301608

1

3001703

1

8.1.8

Guide Sets

GUIDE SET BQ — BQ OUTER TUBE

116 Copyright © 2007, 2011, 2013 Boart Longyear. All rights reserved. Boart Longyear is constantly striving to improve its products and must therefore reserve the right to change designs, materials, specifications, and price without notice.

3547445



Chapter 8: Recommended Spare Parts Kit

GUIDE SET NQ — NQ OUTER TUBE

3001354

1

GUIDE SET HQ — HQ OUTER TUBE

3001355

1

GUIDE SET PQ — PQ OUTER TUBE

3001353

1

8.1.9

Control Group Rod Handler

Complete

5303840

JOYSTICK DUAL AXIS

3070198

1

L.E.D. 10mm GREEN

3069198

1

L.E.D. 10mm RED

3069199

1

SWITCH TOGGLE 2-POSITION FEED/PULL

3069202

1

SWITCH PUSH BUTTON - RESET

3069201

1

RECEPTACLE X22 LOOM - POWERPACK

5304932

1

CAP X22 – POWERPACK RECEPTACLE

3069206

1

RECEPTACLE X23 LOOM – ROD HANDLER

5304933

1

CAP X23 – ROD HANDLER RECEPTACLE

5304467

1

PLUG BRIDGING 10 PIN - LASER

3001689

1

LIGHT STROBE AMBER

3070199

1

117 Copyright © 2007, 2011, 2013 Boart Longyear. All rights reserved. Boart Longyear is constantly striving to improve its products and must therefore reserve the right to change designs, materials, specifications, and price without notice.

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Chapter 8: Recommended Spare Parts Kit

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3547445

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