Beruflich Dokumente
Kultur Dokumente
DEI Plus
M ining Systems
DEPTH
TARGET
43.7 123
65.2
ROP
PIPE
10:45
21:50
The information in this manual is subject to change without notice and Thunderbird Mining Systems cannot be held liable for any errors that may appear in it. No information in the manual may be reproduced without the prior written permission of Thunderbird Mining Systems.
DRILLING EFFICIENCY INDICATOR and DEI and DEI Plus are trademarks of Thunderbird Mining Systems.
2001-2011 Thunderbird Mining Systems 2635 - 151st Place N.E. Redmond, WA 98052-5562 U.S.A. (425) 869-2727 FAX: (425) 869-2735 www.tbirdpac.com Part Number 0150-025-001 This manual was written and illustrated by Ellen Theisen, Port Ludlow, Washington.
Circle or complete the part number for the DEI Plus components on this drill and record the serial numbers of all major components. DEI Plus System Component DEI Plus Mounting system Air pressure switch Optical shaft encoder Encoder mounting kit Encoder drive kit (optional) Cables: DC input power Air switch signal Encoder sensor 7070-191-_______ 7070-189-_______ 7060-190-_______ ______ = Enter the cable length in feet (for example, 025 = 25 feet). Part Number 6523-109-001 9001-105-109 3700-_______-001 4500630 6041-018-001 6041-018-002 9001-_______-_______ Serial Number ___________________ Not applicable. ___________________ ___________________ Not applicable.
Contents
Using This Manual Chapter 1 Introducing the DEI Plus
A Stand-Alone, Graphic Information Display
Current Hole Depth Target Depth Rate of Penetration Distance from Bottom Pipe-In-Hole (PIPE) Notification Drill Time Time to Complete Production Statistics
x 1
1
2 2 3 3 4 4 4 5
6 6
7 8 8 8 8 9
11
11 12 14 16 17
18 20
22 23
Connecting to the External Alarm Circuit Installing a Remote Zero Hole Depth Switch Verifying the Installation Calibrating the DEI Plus Switching Between Calibration Modes
25 27 28 28 36
39
39 40
40 42
45
46 51 52 54 56 59 61
63
63 65 66 67 68 70 73 75 77 79
vi
Illustrations
Diagnostics Menu Detailed System Status Menu System Status: Memory Test Screens System Status: Display Test Screens System Status: Bit Air Switch Status Screen System Status: Zero Hole Button Status Screen System Status: External Alarm Status Screen System Status: Encoder Status Screen Troubleshooting Screens General Info Menu General Info: Hardware General Info: Software
80 81 82 84 86 87 88 89 90 91 92 94
Chapter 4 Troubleshooting
Prerequisite Troubleshooting Information
The DEI Plus Air Pressure Switch Optical Shaft Encoder Chain and Sprocket Encoder Drives Torque Reel Encoder Drive Interconnecting Cables
97
97
99 99 100 100 101 101
Troubleshooting Procedures
Typical Symptoms Power Circuit Tests Air Circuit Tests Encoder Circuit Tests Re-Calibrate
102
102 103 105 109 113
115 117
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Illustrations
Figure 1. DEI Plus (Front) Figure 2. DEI Plus (Rear) Figure 3. Air Pressure Switch Figure 4. Optical Shaft Encoder Figure 5. DEI Plus System and Connections Figure 6. DEI Plus and RAM Mount Assembly Figure 7. DEI Plus Installed on RAM Mount Assembly Figure 8. Air Pressure Switch Connections Figure 9. Installing the Encoder Direct Sprocket Drive Method Figure 10. Installing the Encoder Indirect Sprocket Drive Method Figure 11. Installing the Split Sprocket Figure 12. Installing the Torque Reel (a) Figure 13. Installing the Torque Reel (b) Figure 14. Increasing and Decreasing Cable Tension Figure 15. Remote External Alarm Connections Figure 16. Remote Zero Hole Depth Switch Connections Figure 17. DEI Plus Power Button Figure 18. DEI Plus Control Elements Figure 19. Typical Installation on Hydrolic Machine Figure 20. DEI Plus Air Switch Cable Connector Figure 21. Air Pressure Switch Front Panel Figure 22. DEI Plus Encoder Cable Connector Figure 23. Cable to Optical Shaft Encoder Figure 24. 7070-189-xxx Cable Assembly DEI Plus to Air Pressure Switch 7 7 8 8 13 15 15 16 19 21 22 23 23 24 25 27 39 40 98 106 108 110 111 115
Figure 25. 7060-190-xxx Cable Assembly DEI Plus to Optical Shaft Encoder 115 Figure 26. 7070-191-xxx Cable Assembly DC Power to DEI Plus 115
viii
Illustrations
Figure 27. Mounting Template Air Pressure Switch Figure 28. Mounting Template RAM Mount Figure 29. Torque Reel Enclosure Sheet 1 Mounting Template Figure 30. Torque Reel Enclosure Sheet 2 Cable Exit Hole Reference
ix
This information gives the drilling and blasting personnel the ability to see beyond the drill collar and into the hole, allowing them to work more efficiently. In addition to the current drilling information, the DEI Plus provides details about the previous three holes and summary statistics about a production period, the current shift, and the three previous shifts. It also shows a graph of the rate of penetration at each depth reading for the current hole and for each of the three previous holes.
Target Depth
As each hole is started, the operator enters the target depth on a system management screen. Then, the target depth appears on the display beside the current hole depth as the operator drills, thus ensuring against over-drilling. The display of current hole information also shows a graphic representation of the target depth in relation to the current depth. For example, in the sample to the left, the current depth is indicated by the pointers at 43.7, and the target depth is indicated by the solid line at 65.2.
Rate of Penetration
The rate of penetration (ROP) value displayed on the DEI Plus shows constant information about the drilling speed, thus also helping the operator drill more efficiently. Knowing the ROP, the operator can make timely adjustments in the pulldown pressure, RPM, torque, or air pressure in order to optimize the drilling rate for the particular conditions. Increasing the overall drilling rate significantly increases the number of feet or meters drilled per hour. In coal mines, the ROP information is especially important. If the engineer has determined the approximate depth of the coal, the drill operator can watch for an increase in ROP at that depth and stop drilling when the drill bit is only a tenth of a foot (or meter) into the coal, instead of drilling into it far enough to identify the coal dust at the hole collar. This sample graph shows the difference in the rate of penetration at different hole depths. Engineers can use this detailed information to help them refine their conclusions about the strata layers.
With the press of a button on the front panel of the DEI Plus, the operator can change the display to show a graph of the ROP vs. the hole depth for the current hole and still monitor the current depth, ROP, and drill time. This sample shows how the graph appears on the display of the DEI Plus.
Drill Time
The DEI Plus tracks the time spent drilling on each hole. A status line on the DEI Plus display shows the status at all times, displaying Drilling during all drilling time and Non Drilling or Idle when drilling is not in progress. Drilling time is considered to be the time when the drill is moving downward plus any delays of less than 60 seconds.
Time to Complete
Once 5% of the target depth has been drilled, the DEI Plus calculates and displays the estimated time required to complete the hole. This information is on the display while drilling is in progress, giving the operator even more information to help prevent over-drilling.
Production Statistics
The control buttons on the front panel of the DEI Plus allow the operator to quickly display statistical information about previous holes, current and previous shifts, and any other specific time period. This is convenient for tracking the production per day. It may also be used to give valuable feedback when drill personnel are testing new bits or different drilling procedures. The DEI Pluss memory is backed up by a battery, so that the historical information is retained even if power to the DEI Plus or drill is turned off or lost. Historical information about previous holes includes: Depth Average rate of penetration Drilling time Information about shifts includes: Total holes started during the shift. Average depth of all holes drilled or partially drilled during the shift. Total depth drilled during the shift. Average time to drill a hole, in minutes and seconds. Total time drilling during the shift. Average ROP during the drilling.
Production information about a time period you define includes the same statistics as shift information, except for the total time.
M ining Systems
DEPTH
TARGET
43.7
ROP
65.2
123 21:50
PIPE
10:45
Encoder Drives
On some drills, the pulldown sprocket shaft does not rotate, or the encoder shaft cannot be coupled directly to the pulldown sprocket shaft. On these drills, the encoder shaft must be rotated indirectly by means of an intermediary sprocket rotated by the pulldown sprocket shaft or hub. This calls for a special encoder mounting kit. This mounting kit provides the parts necessary for installing the encoder on such drills. Some systems may require a torque reel or a custom installation.
Cables
Three cable assemblies are typically included with a DEI Plus system. DC input power cable to connect the DEI Plus to the 21 to 30 VCD power source.
Note: Cable lengths vary depending on the drill model and the locations where the components are installed:
Air switch signal cable to connect the air pressure switch to the DEI Plus. Encoder sensor cable to connect the optical shaft encoder to the DEI Plus.
11
IMPORTANT NOTE: If your drill uses varying lengths of drill stems, contact Thunderbird Mining Systems about installing a manual air switch. When the drill stems used on the drill are always the same length, that length is entered into the DEI Plus when it is calibrated. Then, when the optical shaft encoder detects movement that is approximately the same as the calibrated stem length, and the air pressure is off, the DEI Plus interprets this movement as the addition or removal of a drill stem and adjusts its hole depth calculations accordingly. However, when varying stem lengths are used, the drill stem length is declared to be zero during calibration, so the DEI Plus has no approximate length to compare to movement that occurs when the air is off. For this reason, the DEI Plus cannot distinguish between a temporary obstruction of the air pressure switch (which would appear as air pressure loss) and actual steel changes. This could result in false hole-depth readings. Therefore, when you use varying stem lengths, it is recommended that the air pressure switch be replaced by a manual switch, which must be closed by the operator before steel is changed and then opened again before drilling is resumed.
12
Operators Gauge
13
6. Pinch one end of the mounting arm to open the opposite end, and place the open end over the ball on the rectangular mounting plate. 7. Place the other end of the mounting arm over the ball on the rectangular plate attached to the DEI Plus. See Figure 7. 8. Position the DEI Plus at an angle that provides the operator the best view, and turn the mounting arm knob to secure the balls in this position.
14
M ining Systems
Mounting arm
M ining Systems
15
Mounting Holes
Operator's Gauge
To Dr Head
2. Determine where to mount the air pressure switch. It should be near the location where you plan to tie into the bailing air line. Mount it so that the connectors to the air switch signal cable and the air input line are on the bottom of the air pressure switch. It need not be visible during operation, but you must be able to access it in the future. 3. Using the template in Appendix B or the air pressure switch itself as a guide, mark the positions of the two holes you will use to mount the switch. 4. Drill 1/4-inch (6.4 mm) clearance holes for bolts at the two marked positions. 5. Bolt the air pressure switch to the mounting surface using the supplied bolts, washers, and nuts. 6. Tie into the bailing air line at the point you determined in Step 1. 7. Attach the socket end of the air switch signal cable (7070-189-xxx) to the 2-pin connector on the air pressure switch. 8. Route the cable away from moving equipment toward the DEI Plus. Use tie wraps to secure any excess cable. 9. Connect the other, 2-pin end of the air switch signal cable to the BIT AIR connector on the rear panel of the DEI Plus.
16
17
18
Flexible Coupling
Mounting Brackets
Hose Clamps
Figure 9. Installing the Encoder Direct Sprocket Drive Method Using the 6041-018-002 Kit
19
9. Slide the encoder bracket (with the encoder on it) as necessary until the chain is snug but not overtight, and secure the brackets. 10. Connect the 7-socket end of the encoder cable assembly (7060-190-xxx) to the port on the encoder. 11 Route the cable away from moving equipment. Use tie wraps to secure any excess cable. 12. Make the sure power to the DEI Plus is turned off. 13. Connect the 7-pin end of the encoder cable assembly to the ENCODER port on the rear panel of the DEI Plus.
Mounting Brackets
Encoder Cable 7060-190-xxx to Digital Display Module Pulldown Sprocket Shaft or Pin
21
22
23
24
BITAIR
C B A
RS232 RS232LEVEL
F E D C A B E D C F A B
7 8
ENCODER
Wire #1 Wire #2 Wire #1 Wire #2 Function Orange Red Blue Green Rate / Depth Alarm Pipe In Hole Ground
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Pin A is the signal input used for the detection of tramming. This input is designed to detect a switch closure to ground (pin B). A closed contact indicates the drill is tramming. Pin B is electrical ground, common with the power input ground. Pin C is the Pipe In Hole alarm relay contact. This is one side of a 2-amp relay contact; the other side of the contact is pin D. Pin D is the Pipe In Hole alarm relay contact (see pin C). Pin E is the Rate of Penetration or Depth alarm relay contact. This is one side of a 2-amp relay contact; the other side of the contact is pin F. These contacts are closed any time there is a Rate of Penetration or Depth alarm condition. Pin F is the Rate of Penetration or Depth alarm relay contact (see pin E). The relay contacts for the Pipe in Hole and Rate/Depth alarms have no internal connections to the DEI Plus, they are simply relay contacts that can be used to make or break an alarm circuit.
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C B
27
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3. With Configuration highlighted, press the Enter button to display the Configuration menu. 4. Move the highlight to Calibration and press the Enter button.
NOTE: The Parameters option is not functional on the standard DEI Plus. Selecting it displays a screen telling you the software must be upgraded in order to use the function.
5. When you choose Calibration, the Calibration Menu displays. Move the highlight to Perform Normal Calibration and press the Enter button to display the first calibration screen (see Sample Calibration Screen below).
Screen Title
Current Status
Current Time
6. Move the highlight to Yes and press the Enter button to display the screen where you enter your password.
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The password is six digits long. The default password is 1 2 3 4 5 6. Instructions for Changing the Password follow the instructions for Calibrating the DEI Plus. To enter the password: 1. For each digit in the password, press the DEI Plus button that corresponds to that digit. For example, to enter 1, press the Left Arrow button. An X appears on the screen for each digit you enter. 2. If the password is correct, the Calibration Screen 3 appears. Continue with Calibrating the DEI Plus. If the password is incorrect, the screen displays the following message: Incorrect password entered. Press [Enter] to try again Press the Enter button to return to the password screen. You are allowed an unlimited number of attempts. If you choose not to re-enter the password, press the Current Hole button, Data Entry button, System, or Help button to display the corresponding screen.
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In this step you record the initial position of the drill head by entering its distance from the drill deck. Use the Left and Right arrow buttons to move the pointer to the digit you want to change. Then use the Up arrow button to increase the value of the digit, or use the Down arrow button to decrease its value.
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In this step, you move the drill head as high as possible. The DEI Plus counts the encoder pulses that correspond to the distance the head moves from the first recorded position.
Now you record the second position, again by entering the distance of the drill head from the drill deck. Use the Left and Right arrow buttons to move the pointer to the digit you want to change. Then use the Up arrow button to increase the value of the digit, or use the Down arrow button to decrease its value. The DEI Plus calculates the distance moved as the difference between the first measurement and this measurement. If this value is not correct, press the System button to return to System Menu. Then begin the calibration procedure again. All the values you already entered are saved and appear on the calibration screens, so you can simply change them as required.
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This is the length of pipe in the rack, not the first pipe with bits, sub, stabilizers, and other components. NOTE: In cases where the drill stems in the pipe rack or carousel vary in length by 0.5 feet (15 cm) or more, set the length to 0.00. If the hole depth reading is inaccurate during hole reaming or cleaning or during excessive on-and-off cycling of the bailing air, contact Thunderbird Mining Systems. You may need to install a manual air switch. This offset is the distance the bit must be raised above the collar of the hole for the DEI Plus to consider the pipe out of the hole and turn off the PIPE (pipe-inhole) notification. A normal value for this offset is the distance between the bottom of the bit and the ground when the drill is on the level and the jacks and power head are fully retracted. You can adjust this value to increase or decrease the sensitivity of the PIPE alarm function. The PIPE notification turns off only when drilling resumes or after the distance from the bottom of the hole is equal to the hole depth plus this offset.
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If the bit air cable is disconnected, reconnect it at this point in the process.
If you do not want to save the calibration settings, press the System button to return to the System Menu.
NOTE: If the drill head drifts or moves during the calibration, you must repeat the calibration.
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7. After you enter the incorrect password, the screen displays the following message: Incorrect password entered. Press [Enter] to try again 8. Press the Zero Hole button to display a second Incorrect password screen. This screen is the same as the first, except that it also has small triangular highlights in the top left and bottom right corners. 9. Press the Zero Hole button again to continue the process. Or, press the Enter button to cancel out and return to screen where you enter the current password. 10. If you continue, a screen appears on which you enter the new password. Use the process described in Entering Your Password to enter six digits for the new password.
11. Once you enter the sixth digit, the screen displays this message confirming that your new password is now in effect: New password stored. Press [Enter] to continue. 12. Press Enter to return to the screen where you enter your new password to begin the calibration process.
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2. Use the Left, Up, Down, and Right arrow buttons on the DEI Plus to move the highlight to Configuration. 3. With Configuration highlighted, press the Enter button to display the Configuration menu. 4. Move the highlight to Calibration and press the Enter button. 5. When you choose Calibration, the DEI Plus displays the Calibration Menu. Move the highlight to Multi-Pass <=> Single-Pass Drilling and press the Enter button.
If the length of a second drill pipe was defined during calibration on Calibration Screen 9:
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6.
The confirmation screen appears. Highlight Yes, and press the Enter button to complete the switch.
7.
The Switch Complete screen appears. Press the Enter button to return to the Calibration Menu.
If a second pipe length was not defined during calibration : 6. This screen appears. To cancel the switch, highlight No and press Enter to return to the Calibration menu. To continue the switch, highlight Yes and press the Enter button to go to Calibration Screen 9, where you can enter a second pipe length. Once you complete and save the new calibration, start again at Step 1 of this process to switch to multipass drilling.
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M ining Systems
DEIPLUS
Press the POWER button on the front of the DEI Plus. The graphical screen becomes illuminated and the logo screen appears. To turn it off: Press the POWER button. The screen becomes blank.
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M ining Systems
Statistics
DEPTH TARGET
43.7 123
65.2
ROP
PIPE
10:45
21:50
Power
Left Up
Down Right
Graphical Display
The display area of the DEI Plus is your window into the operation of the system. It shows statistics about your current and previous drilling operations, help information, and alarm warnings. This area also displays system screens you can use to check and change the setup of the system and perform troubleshooting procedures. Refer ahead to Reference to Statistics Screens and Reference to System Screens for illustrations and explanations of the screens.
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The bottom line of most screens is the status line. For example:
Screen Title
The number of holes started during the current shift. This value increases by one each time the Zero Hole button is pressed if any depth has been recorded since the last Zero Hole button press. This value is reset to zero after a shift change. Indicator that shows whether the air pressure switch is on or off. The drill status, which is one of the following:
Drilling: Any time the pipe is making downward drilling progress in the hole. Note that a drilling delay of up to 60 seconds is counted as drilling. A longer delay causes the status to change to Non drilling. Non drilling: Any time the drill pipe is in the hole and not
Air Status
The system time in hours and minutes, as on a 24-hour clock. You can reset the time on the Set Time system screen.
NOTE: The battery inside the DEI Plus maintains the system clock even when the DEI Plus is not connected to a power source.
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Control Buttons
You use the control buttons below and to the right of the display to request the information or instructions you want to view and to enter new setup information into the DEI Plus.
Button Meaning Statistics Function
Press this button to access the statistics screens showing information about the current drilling operation and historical statistics. The default statistics screen appears, for example:
You can use the Left, Up, Down, and Right arrow buttons to move to other statistics screens. For complete details on displaying and reading the statistics screens, refer ahead to Statistics Screens.
Data
This button has no function in the basic DEI Plus system, and pressing it displays the following screen.
Contact Thunderbird Mining Systems about installing upgraded software that allows management personnel
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Button
Meaning
Function
to monitor and create reports summarizing drilling, the productivity of equipment, and other aspects of the operation.
System
From this screen, you can access the system screens on which you can view and change the system setup. For complete details on using the system screens, refer ahead to System Screens.
Help
Press this button to display help information about the screen currently displayed. For example, if you press the Help button when the default statistics screen is displayed, the following help information appears.
A down arrow at the bottom of a help screen indicates this is the first page of a multi-page help screen. Press the Down arrow on the DEI Plus to move to the next page.
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Button
Meaning
Function
Both arrows at the bottom of a help screen indicate that this is a middle page in a multipage help screen. Press the Up arrow on the DEI Plus to move back to the previous page, or press the Down arrow to move to the next page. An up arrow indicates that this is the last page in the multi-page help screen.
Enter
Use this button to make selections on certain screens. The specific use varies from screen to screen. Instructions for using this button are included with the instructions for all screens to which it applies. Use these buttons to navigate on certain screens and to navigate between certain screens. For example, when the System Menu screen is displayed, use the appropriate one of these keys to move to the screen you want to view; then press the Enter key to display the selected screen. Instructions for using these buttons are included with the instructions for all screens to which they apply. Whenever you start a new hole, press this button. If any depth has been recorded since the last time the button was pressed, the DEI Plus does the following: Increases the hole count by one, and zeros the hole depth so all new drilling applies to the new hole. Moves the readings for previous holes to the appropriate historical screens.
44
When you press the Statistics button on the DEI Plus, the display shows the default statistics screen which gives statistics for the current hole, that is, the hole currently being drilled (or most recently drilled). Once this screen is displayed, you can use the arrow buttons to display other statistics screens. This section explains each of the statistics screens, tells how to display each one, and details the function of each navigation control button on each screen. Refer ahead to Navigating Through Statistics Screens for a summary diagram showing all statistics screen and how to navigate from one to another.
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Sample Screen
A sample screen is shown and explained below. Graphic Display of Current Depth and Target Depth Screen Title
Display Details
NOTE: If the distance recorded in the calibration procedure was measured in feet, all readings on the DEI Plus are in feet. If the calibration was done in meters, all readings are in meters.
DEPTH
Current Hole Depth. The display shows the actual depth of the hole presently being drilled, in meters or feet (to the nearest tenth). Values range from 0.0 to 999.9.
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ROP
Rate of Penetration. While the pipe is making downward progress (the status is Drilling), the display shows the actual rate of drill penetration in meters or feet per hour. Whenever the drill bit is raised from the bottom of the hole, the label changes to read Distance From Bottom, and the display shows the distance the drill bit is raised from the hole bottom (in meters or feet). This helps the operator avoid slamming the bit into the hole bottom and possibly damaging the drill bit and steel. When the bit air is turned off, the displayed Distance From Bottom value freezes, showing the value when the air was turned off. When the drill bit is returned to the hole bottom and drilling is resumed, the label returns to ROP, and the display reverts to showing the rate.
DRILLING TIME
The length of time, in minutes and seconds, spent drilling on the current hole. That is, the time when downward progress is being made, including delay periods of less than 60 seconds. (Status in the status line says Drilling.) The target depth for the current hole, in meters or feet (to the nearest tenth). Note: You can change the target depth on the Target Depth system screen.
TARGET
PIPE
When the drill is moving downward, this area is blank. When the ROP display is showing the Distance From Bottom, and there is a Pipe-In-Hole condition, the word PIPE flashes in this area of the display to alert the operator to the condition. This features helps you prevent damage to equipment often caused by retracting the jacks or moving the drill when pipe is still in the hole. The Pipe-In-Hole alert occurs whenever the following three conditions are met: Drilling air is turned off. Drill feed direction is reversed relative to the normal drilling direction (as indicated by encoder data). The distance from bottom value is greater than 85% of the hole depth.
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TIME TO COMPLETE
The estimated time remaining to finish drilling the current hole is based on the distance remaining and the current rate of penetration. The value is calculated as the difference between the target depth and the current depth, divided by the current ROP. This value is displayed after 5% of the hole has been drilled. Right and left arrows on the graph show the current depth. A dark line shows the target depth. Note: You can change the minimum and maximum values on the scale through the Graphic Scaling system screen.
Graphic Display
Button Usage
Enter Left Up Down Right
No function on this screen. Displays the Shift Screen: Current Shift. Displays the Production Screen. Displays the Statistics Screen: 1st Previous Hole. Displays the ROP Graphics Screen: Current Hole.
Alarm Screens
When any of three possible alarm conditions occur, the DEI Plus interrupts the current display by flashing a screen with appropriate alarm information until the alarm condition no longer exists. Since these alarm conditions are detected during drilling, normally it is the Statistics: Current Hole screen that is interrupted.
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The three alarm conditions are: ROP is too high. If the ROP exceeds the rate set up on the Alarms screen (discussed in Reference to System Screens), and the ROP alarm is enabled, the DEI Plus flashes a warning screen on the display, telling you the ROP has reached or exceeded your specified maximum. Once the alarm condition is corrected, the screen is removed from the display. For example:
Hole is too deep. If the drilling reaches the depth set up on the Alarms screen, and the depth alarm is enabled, the DEI Plus flashes a warning screen telling you the depth has reached or exceeded your specified distance. Once the alarm condition is corrected, the screen is removed from the display. For example:
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Calibration has failed. If the DEI Plus detects a calibration failure during drilling, it flashes a warning screen on the display, and you must re-calibrate before you continue, or your data will be unreliable. The warning is shown below.
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The following subsections explain these screens: Production Statistics Reset Production Statistics ROP Graphic Screens Statistics: Previous Holes Shift Screens
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Production Statistics
Use the Production Statistics screen to track the cumulative statistics during some period, such as a shift or a day. The screen displays combined statistical data for all holes drilled since the last time the values were reset to zero through the Reset Production Statistics screen. To display this screen: 1. Press the Statistics button to display the default statistics screen Statistics: Current Hole. 2. Press the Up arrow button. Note: Press the Down arrow button to return to the default statistics screen.
Sample Screen
A sample screen is shown and explained below. Screen Title
Display Details
TOTAL HOLES AVERAGE DEPTH
Number of holes started during the production period. Average depth of all holes partially or completely drilled during the production period, in meters or feet (to the nearest tenth). Average time spent drilling on each hole. The total depth drilled during the production period, in meters or feet (to the nearest tenth). The average rate of penetration per hour during the production period.
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Button Usage
Enter Left Up Down Right
Displays the Reset Production Statistics screen. No function. No function. Displays the Statistics: Current Hole screen. No function.
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Sample Screen
A sample screen is shown and explained below.
Screen Title
Current Status
Current Time
Display Details
YES
Highlight this box and press the Enter button to reset all the production values to zero and return to the reset Production Statistics screen. Highlight this box and press the Enter button to return to the Production Screen without resetting the production values to zero.
NO
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Button Usage
Enter
Executes your selection and returns to the Reset Production Statistics screen. Moves the highlight to the YES box. No function. No function. Moves the highlight to the NO box.
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Sample Screen
A sample screen for the Current Hole is shown and explained below. ROP vs. Depth Graph Screen Title
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Display Details
DEPTH
Current Hole Depth. The display shows the actual depth of the hole presently being drilled, in meters or feet (to the nearest tenth). Values range from 0.0 to 999.9. Rate of Penetration. While the pipe is making downward progress (the status is Drilling), the display shows the actual rate of drill penetration in meters or feet per hour. Whenever the drill bit is raised from the bottom of the hole, the label changes to read Distance From Bottom, and the display shows the distance the drill bit is raised from the hole bottom (in meters or feet). This helps the operator avoid slamming the bit into the hole bottom and possibly damaging the drill bit and steel. When the bit air is turned off, the displayed Distance From Bottom value freezes, showing the value when the air was turned off. When the drill bit is returned to the hole bottom and drilling is resumed, the label returns to ROP, and the display reverts to showing the rate.
ROP
DRILLING TIME
The length of time, in minutes and seconds, spent drilling on the current hole. That is, the time when downward progress is being made, including delay periods of less than 60 seconds. (Status in the status line says Drilling.)
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ROP Graphic
Shows the rate of penetration (on the X axis) plotted against the depth (on the Y axis). For example, the sample screen shows that when the hole depth was approximately 35 feet (or meters), the ROP was approximately 114 feet (or meters) per hour.
Note: You can change the minimum and maximum values on either scale through the Graphic Scaling system screen.
Button Usage
Enter Left Up Down Right
No function. Displays the Statistics screen for the current hole. No function. Displays the Statistics screen for the previous hole. No function.
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Sample Screen
A sample screen is shown and explained below. ROP vs. Depth Graph Screen Title Shows the Hole Number Statistics for the Hole
Display Details
DEPTH
Hole Depth. The display shows the final depth of the hole, in meters or feet (to the nearest tenth). Values range from 0.0 to 999.9.
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Average Rate of Penetration. The length of time, in minutes and seconds, spent drilling on the indicated hole. Drilling time is the time when downward progress was being made, including delay periods of less than 60 seconds. (Status in the status line says Drilling.) Shows the rate of penetration (on the X axis) plotted against the depth (on the Y axis). For example, the sample screen shows that when the hole depth was approximately 35 feet (or meters), the ROP was approximately 114 feet (or meters) per hour.
ROP Graphic
Note: You can change the minimum and maximum values on either scale through the Graphic Scaling system screen.
Button Usage
Enter Left Up
No function. No function. On screens for 2nd previous and 3rd previous holes, this button displays the Statistics for a more recently drilled hole. On screens for 1st and 2nd previous holes, this button displays the Statistics for a previous hole. On the screen for the 3rd previous hole, it has no function. On the Statistics: Current Hole screen only, displays the ROP Graphic Screen
Down
Right
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Shift Screens
There are four shift screens. Each one screen displays cumulative statistical data for all holes worked on during the selected shift current shift or one of the three previous shifts. Starting and ending times for shifts are set up on the Shift Times system screens. To display one of the shift screens: 1. Press the Statistics button to display the default statistics screen Statistics: Current Hole. 2. Press the Left arrow button to display the shift screen for the current shift. 3. Press the Left arrow button to display the screen for a different shift (once for the previous shift, twice for the 2nd previous, or three times for the 3rd previous shift). You can move through the four shift screens by pressing the Right arrow button to move to a screen for a more recent shift and by pressing the Left arrow button to move to a screen for a previous shift.
Sample Screen
A sample screen for the current shift is shown and explained below.
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Display Details
TOTAL HOLES TOTAL TIME AVERAGE ROP
Number of holes started during the shift. Total drilling time on holes finished during the shift. The average rate of penetration during the drilling of all holes worked on during the shift. The total depth drilled during the shift, in meters or feet (to the nearest tenth). Average depth of all holes worked on during the shift, in meters or feet (to the nearest tenth). Average drilling time per hole worked on during the shift.
TOTAL DEPTH
AVERAGE DEPTH
AVERAGE TIME
Button Usage
Enter Left
No function. Displays the Shift screen for a previous shift. No function on the Shift screen for the 3rd previous shift. No function. No function. Displays the Shift screen for a later shift. On the Shift screen for the current shift only, displays the Statistics: Current Hole screen.
Up Down Right
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When you press the System button on the DEI Plus, the display shows the System Menu screen, through which you access all other system screens. This section explains each of the system screens and tells how to display and use each one. Refer ahead to Navigating Through System Screens for a summary diagram showing all system screen and how to navigate to each one.
System Menu
The System Menu provides an entry into the other system screens. Note that the Diagnostics and General Info items display additional menus from which you choose. From any screen, press the System button to display this screen. The most recently used option is highlighted when the menu appears. IMPORTANT: The drill must be idle or not drilling before you use many of the system screens. In general, use the system screens only when you are not drilling. The screen is shown and explained below.
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Screen Title
1. Use the arrow buttons (Left, Up, Down, Right) to move the highlight to the item you want to select. 2. Press the Enter button.
Button Usage
Enter
Selects the highlighted option, and displays the appropriate screen. Moves the highlight to the left column. Moves the highlight up one row. Moves the highlight down one row. Moves the highlight to the right column.
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Detailed System Status Menu Memory Test Screens Display Test Screens Bit Air Switch Screen Memory Alarm Status Screen Encoder Status Screen
General Info Menu Parts Screens Version Number Screen Hardware Software
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Brightness Screen
You may need to adjust the brightness of the DEI Plus display area to optimize your view of the screens as the level of light in the environment changes. Use Brightness screen to adjust the brightness level of the display. To display this screen: 1. Press the System button to display the System Menu. 2. Use the arrow buttons (Left, Up, Down, Right) to move the highlight to Brightness. Then press the Enter button.
Sample Screen
Screen Title
The current brightness level. 100% is the highest. 15% is the lowest.
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Button Usage
Enter Left Up Down Right
Applies the selected brightness level. No function. Increases the brightness level setting. Decreases the brightness level setting. No function.
Sample Screen
Screen Title
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Button Usage
Enter
Changes the target depth to the value in the New Target Depth box. Moves the pointer left one digit. Increases the value of the selected digit by one. Decreases the value of the selected digit by one. Moves the pointer right one digit.
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Once the local time is set in the DEI Plus, the battery backup allows the clock to keep the correct time even when the DEI Plus is not connected to a power source. However, you will need to change the local time when you start or end Daylight Savings time, or if you move the DEI Plus to a new time zone, or if you notice that it has become slightly off precision. The new time setting appears on all the screens as soon as you apply the change. To display this screen: 1. Press the System button to display the System Menu. 2. Use the arrow buttons (Left, Up, Down, Right) to move the highlight to Set Time. Then press the Enter button.
Sample Screen
Screen Title
When the screen first appears, the current time appears in both boxes. Note that the time is always presented as on a 24-hour clock (hour:minute). You can change only the value in the New Time box. To change the system time of the DEI Plus: 1. Use the Left and Right arrow buttons to move the pointer in the New Time box to the hour or minute digit you want to change. (The seconds setting is not adjustable; it is set to 00 when you apply the new setting.) 2. Use the Up or Down arrow buttons to increase or decrease (respectively) the value of the selected digit. If the value is 9, pressing Up changes it to 0. If the value is 0 pressing Down changes it to 9. 3. Repeat steps 1 and 2 until the correct time appears in the box.
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4. Press Enter to apply the new setting. A confirmation screen appears for 3 seconds, then the System Menu reappears.
Button Usage
Enter
Changes the current time to the value in the New Time box. Moves the pointer left one digit. Increases the value of the selected digit by one. Decreases the value of the selected digit by one. Moves the pointer right one digit.
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Sample Screen
Screen Title
Start and end times for the shift indicated in the title (hour: minute)
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6. Press Enter to apply the new setting for Shift 2. If the combined lengths of the first and second shifts is less than 24 hours, the Shift 3 Time screen appears. Continue with step 7. If their combined length is 24 hours, the DEI Plus recognizes that you have only two shifts, and the confirmation screen appears. Go to step 8. 7. The Shift 3 Time screen is an information screen only. The DEI Plus sets the third shift to be the remaining time (in a day) not allocated for either of the other two shifts. (That means the start time of the third shift is set as the end time of the second shift, and the end time of the third shift is set as the start time of the first shift.) You cannot change these settings. If the settings are correct, press the Enter button to display the confirmation screen. 8. The confirmation screen shows the start and end times of all your shifts. If you have defined fewer than 3 shifts, the times for the undefined shift (or shifts) says NONE. If the times are correct, highlight Yes and press the Enter button to return to the system menu. If not, highlight No and press the Enter button to return to the Shift 1 Time screen so you can begin again. An example screen is shown below:
Button Usage
Enter Left
Apply the new shift times and move to the next screen. Moves the pointer left one digit; or, if the pointer is at the leftmost digit in the End box, moves the pointer to the rightmost digit in the Start box. Increases the value of the selected digit by one. Decreases the value of the selected digit by one.
Up Down
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Right
Moves the pointer right one digit; or, if the pointer is at the rightmost digit in the Start box, moves the pointer to the leftmost digit in the End box.
Alarms Screen
The DEI Plus provides two automatic alarms to notify you of problem conditions. You specify the criteria for each alarm, and whether or not you want to use the alarm. If you enable an alarm and the alarm condition occurs, the DEI Plus flashes the appropriate alarm screen on the display until the alarm condition is corrected. Since these alarm conditions are detected during drilling, it is the Statistics: Current Hole screen that is interrupted. You can also connect an external alarm to the back of the DEI Plus (rightmost connector on the top row). The external alarm, too, is triggered when the conditions specified on this screen occur. The two alarms are: ROP alarm. You specify the maximum rate of penetration. Then, if the ROP exceeds that rate, the DEI Plus flashes a warning screen on the display, telling you the ROP has reached or exceeded your specified maximum. Depth alarm. You specify the maximum depth for the hole. Then, if the drilling reaches that depth, the DEI Plus flashes a warning screen telling you the depth has reached or exceeded your specified distance.
Use the Alarms screen to view or change the criteria for the ROP and Depth alarms and to enable or disable either alarm. To display the Alarms screen: 1. Press the System button to display the System Menu. 2. Use the arrow buttons (Left, Up, Down, Right) to move the highlight to Alarms. Then press the Enter button.
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Sample Screen
Screen Title
Button Usage
Enter Left Up
Apply the new settings and return to the System Menu. Moves the pointer left one elementdigit or state setting. For values, increases the value of the selected digit by one. For on/off states, alternates between ON and OFF.
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Down
For values, decreases the value of the selected digit by one. For on/off states, alternates between ON and OFF. Moves the pointer right one elementdigit or state setting.
Right
To display this screen: 1. Press the System button to display the System Menu. 2. Use the arrow buttons (Left, Up, Down, Right) to move the highlight to Graphic Scaling. Then press the Enter button.
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Sample Screen
NOTE: The values on this sample define the axes to be as they are shown in the sample illustrations of the Statistics: Current Hole screen and the ROP Graphic screen in earlier sections of the manual.
Screen Title
Scale Settings
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Button Usage
Enter Left Up Down Right
Apply the new settings and return to the System Menu. Moves the pointer left one digit or box. Increases the value of the selected digit by one. Decreases the value of the selected digit by one. Moves the pointer right one digit or box.
Configuration Menu
This screen provides three options for viewing and changing the system configuration. Use the Calibration option to calibrate the DEI Plus. The Parameters option is provided for future enhancements. Use the Mast Adjustment option to calibrate the mast level zero position. To display the Configuration Menu: 1. Press the System button to display the System Menu. 2. Use the arrow buttons (Left, Up, Down, Right) to move the highlight to Configuration. Then press the Enter button.
Screen
Screen Title
Configuration Options
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Calibration Screens
For illustrations of the screens and complete instructions for displaying and using them, refer to Calibrating the DEI Plus in Chapter 2.
Parameters Screen
The current version of the DEI Plus does not support the Parameters option. If you select this item, the following screen appears for 3 seconds. Then the System Menu reappears.
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If you select this option without having an inclinometer installed, the following screen appears for 3 seconds. Then the System Menu reappears.
Mast Level
If you have an inclinometer installed, display this screen to view the mast angle and level, starting from the point indicated as zero through the Mast Adjustment screen.
If you select this option without having an inclinometer installed, the following message appears for 3 seconds. Inclinometer is not installed. Then the System Menu reappears.
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Diagnostics Menu
This screen provides two options for viewing and entering diagnostics information. Use the diagnostics screens in conjunction with the troubleshooting instructions in the manual. To display the Diagnostics Menu: 1. Press the System button to display the System Menu. 2. Use the arrow buttons (Left, Up, Down, Right) to move the highlight to Diagnostics. Then press the Enter button.
Screen
Screen Title
Diagnostic Options
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To display the Detailed System Status Menu: 1. Press the System button to display the System Menu. 2. Use the arrow buttons (Left, Up, Down, Right) to move the highlight to Detailed System Status. Then press the Enter button.
Screen
Screen Title
Status Options
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If the memory test fails, return the DEI Plus to Thunderbird Mining Systems for repair. To display the Memory Test screen: 1. Press the System button to display the System Menu. 2. Use the arrow buttons (Left, Up, Down, Right) to move the highlight to Diagnostics. Then press the Enter button to display the Diagnostics menu. 3. Use the Up and Down arrow buttons to move the highlight to Detailed System Status. Then press the Enter button to display the Detailed System Status menu. 4. Use the arrow buttons to move the highlight to Memory. Then press the Enter button. NOTE: To return to the Detailed System Status menu, highlight No and press the Enter button. To return to the System Menu, press the System button.
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Initial Screen
Screen Title
Options
4. To return to the Detailed System Status menu, press the Enter button. Or, to return to the System Menu, press the System button.
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Initial Screen
Screen Title
Options
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2. Press Enter to display a test pattern screen, which consists of alternating light and dark pixels in a checkerboard pattern. Any display anomalies should be easily visible on this screen. After 7 seconds, the test pattern screen is removed and the Detailed System Status menu reappears. While this screen is displayed, no control buttons are functional. The following two illustrations show test pattern screens. The first shows what the screen looks like when the display is working properly.
The second sample indicates a problem with the display. If your display shows a problem, contact Thunderbird Mining Systems for information on how to return the unit for repair.
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Sample Screen
Screen Title
Status Indicators
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Sample Screen
Screen Title
Status Indicators
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2. Press the Zero Hole control button on the front of the DEI Plus. Make sure the Zero Hole Button ON box is highlighted while you are pressing the button. 3. Release the button. Make sure the Zero Hole Button OFF box becomes highlighted again. 4. If the boxes do not become highlighted as expected, contact Thunderbird Mining Systems. To check the operation of the remote Zero Hole switch (if you have connected a remote switch to the back of the DEI Plus): 1. When the screen first appears, make sure the Zero Hole Switch OFF box is highlighted. 2. Press the remote Zero Hole control switch. Make sure the Zero Hole Switch ON box is highlighted while you are pressing the switch. 3. Release the switch. Make sure the Zero Hole Switch OFF box becomes highlighted again. 4. If the boxes do not become highlighted as expected, check your remote switch connections and repeat the test. If the result of the test remains the same, contact Thunderbird Mining Systems to order a switch replacement.
Sample Screen
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Screen Title
Status Indicators
If the ON box is highlighted, the external alarm is activated (the alarm condition exists). If the OFF box is highlighted, the alarm is not activated.
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Sample Screen
Screen Title
Status Indicators
Troubleshooting Screens
The troubleshooting screens list possible symptoms of problems, and they indicate the area where the problem is. Use these screens in conjunction with the troubleshooting procedures in the next section. To display the Troubleshooting screens: 1. Press the System button to display the System Menu. 2. Use the arrow buttons (Left, Up, Down, Right) to move the highlight to Diagnostics. Then press the Enter button to display the Diagnostics menu. 3. Use the Up and Down arrow buttons to move the highlight to Troubleshooting. Then press the Enter button. NOTE: To return to the Detailed System Status menu, press the Enter button. To return to the System Menu, press the System button. For your convenience the screens are reproduced in the section Typical Symptoms in Chapter 4.
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Screen
Screen Title
Information Options
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92
Screen 3
Screen 4
Screen 5
Screen 6
Screen 7
Screen 8
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Screen 9
94
Sample Screen
Screen Title
Software Information
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Chapter 4 Troubleshooting
Prerequisite Troubleshooting Information
By design, the DEI Plus system is composed of various modules that may be disconnected and re-connected very easily. A thorough knowledge of basic system operation and "what parts do what" will help you make a quick and accurate diagnosis of your problem, thus saving you time and frustration. Before you begin any troubleshooting activities, read this section carefully to gain a clear understanding of the systems general operation and its various components. Use the diagram in Figure 19 as a reference as you read the information and follow the procedures. Then proceed to the next section, Troubleshooting Procedures, and attempt to isolate the problem.
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7070-189-xxx
ZEROHOLE
C B A
ALARM/ TRAM
F E D C A B
1 4
NPT
RS232 RS232LEVEL
F E D C A B E D C F A B
21-30 VDC
ENCODER
7070-180-xxx
ANSI 40 48-tooth 3180045
ANSI 40 16-tooth ANSI 40 Chain 4105-006-002 Alternate: ANSI 40 Sprocket Drive Kit 9001-097-002
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Chapter 4 Troubleshooting
It is important to mount the DEI Plus in a location where it does not get too hot to touch. Since the unit uses only 15 VDC of the power it receives, the more input power, the more heat that must be dissipated. The DEI Plus will get quite warm if 30 VDC is supplied and the DEI Plus is mounted with the sun shining on it. If the power supplied to the DEI Plus is greater than 30 VDC, it may be damaged and must be returned to Thunderbird Mining Systems for repair.
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The switch is provided with a signal of approximately 4.5 VDC from the DEI Plus. When the switch is open (air is detected) the DEI Plus keeps the line at a 4.5 VDC potential. When the switch is closed (air pressure is lost), the DEI Plus sets the line to ground or earth potential. The state of the switch indicates to the DEI Plus the state of the drilling: Open. Informs the DEI Plus that drilling is in process or about to begin. The DEI Plus uses this information, along with information from the encoder, to make internal decisions regarding the hole depth and ROP. Closed. Informs the DEI Plus that drilling has ceased and perhaps steel is being added or removed. If the drill feed direction is then reversed relative to normal drilling mode (as indicated by the encoder data) Distance From Bottom data is calculated and displayed on the DEI Plus screen. When the Distance From Bottom value is greater than 85% of the hole depth, the PIPE message flashes on the screen and Distance From Bottom is blanked out. Based on what happens next, it determines whether steel is being added or removed and adjusts its calculations accordingly.
If an incorrect value is entered for PIPE length and the drill is being used for multi-pass drilling, then you can expect the hole depths to be inaccurate, since each time steel is added the DEI Plus will add too much depth.
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Chapter 4 Troubleshooting
Most problems with chains and sprockets are due to poor alignment of the chain and sprockets or incorrect tension on the chain. It is critical that the chain be aligned properly with the sprockets. If it is not, the chain might come off or break, or the encoder might be damaged. If the chain is too loose, it will keep jumping off. If it is too tight, it will damage the bearings in the encoder, and you will have to replace the encoder. It is recommended that you use stainless steel chain (which is the type provided by Thunderbird Mining Systems). Although it is more expensive than other types of chains, it is stronger, has much less stretch, and does not seize from rust.
Interconnecting Cables
Military-grade connectors are used for connecting all the cables in the system except the connection made to the power source on the drill. All the teflon-type (red) cables have their connectors filled with a semi-rigid sealing epoxy, while the connectors of other cables are sealed with an RTV type electronic grade silicon or the semi-rigid sealing epoxy. Due to this construction, if the cables operate properly when installed, they can be expected to continue working indefinitely, assuming no physical damage occurs.
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Troubleshooting Procedures
1. Make sure that all DEI Plus cable connections are tight. 2. Make sure there is a good connection to the drills power source. 3. Review the Troubleshooting system screens to see if your symptom is listed in one of them (refer ahead to Typical Symptoms). If your symptom is listed, follow the procedure in the troubleshooting section for the circuit indicated on the screen.
Typical Symptoms
Troubleshooting system screens on the DEI Plus list symptoms of possible problems, and they indicate the circuit where the problem may likely be corrected. For your convenience, the screens are reproduced in this section. To display the screens: 1. Press the System button to display the System Menu. 2. Use the arrow buttons (Left, Up, Down, and Right)to highlight Diagnostics. Then press the Enter button to display the Diagnostics menu. 3. Use the arrow buttons to highlight Troubleshooting. Then press the Enter button. NOTE: To return to the Detailed System Status menu, press the Enter button. To return to the System Menu, press the System button.
Screens
Press the Down arrow button on the DEI Plus to move to the next troubleshooting screen.
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Chapter 4 Troubleshooting
Press the Down arrow button on the DEI Plus to move to the next troubleshooting screen, or press the Up button to return to the previous one.
Press the Up arrow button on the DEI Plus to return to the previous troubleshooting screen.
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Before you begin the following checklist: 1. Disconnect the air pressure switch cable from the DEI Plus. If the problem changes, go to Air Circuit Tests. 2. Disconnect the encoder cable from the DEI Plus. If the problem changes, go to Encoder Circuit Tests. Problems with the DEI Plus are normally in the power circuit and are generally due to one of the following. Go through this checklist in order. 1. Check the wiring. There may be loose or improper wiring, either in the positive or the ground (earth). Most often it is a poor ground that does not allow proper current draw or injects a large amount of noise. The greater distance any electronic equipment is from the original source, the greater the differential in ground potential and the greater the chance of generated noise interfering with electronic equipment. When in doubt, move the DEI Pluss input ground (where the DEI Plus power cable connects to the power source) as close to the original power source as possible. Do not assume that since the operator console lights work, the electronics will. 2. Check the power source. If you suspect that power input is inadequate, begin checking voltages at the power source, working your way toward the DEI Plus. All voltage readings should be 21 30 VDC. If you suspect that power input is excessive, check the voltage levels to the DEI Plus, starting at the DEI Pluss power cable and working backward toward the source. All voltage readings should be 21 30 VDC. If the DEI Plus display is blank, but the Power button is pushed in (to the ON position),the DEI Plus may be receiving excessive power. The drills batteries may be low or damaged, causing the alternator to overcompensate and output too much power. If the display flashes on and off, the drills alternator diodes may have failed, allowing half-wave rectified voltage into the electrical system. This may not yet have caused damage, but it will eventually damage the DEI Plus. 3. If the DEI Plus is too hot to touch and it is mounted where the sun shines on it, you may need to move it out of direct sunlight. 4. There may be a case short in the DEI Plus. Unbolt the unit from its mounting bracket, isolate it from ground (earth). If it cools off, there is a case short. Return it to Thunderbird for repair. If none of these suggestions solves your problem, contact Thunderbird Mining Systems for service.
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Chapter 4 Troubleshooting
Note: Instead of the air pressure switch, some installations use a mechanical switch on the console, or a set of contacts on the drills AIR ON/OFF switch.
Diagnostic Information
Failures in the air circuit are generally due to one of the following, listed in order of probability: a. Incorrect value entered for the standard pipe length in Step 9 of the calibration procedure. b. Lack of pressure to the air pressure switch due to a clogged or frozen air feed line. c. Disconnected or loose cable connections, perhaps occurring during recent repairs to machinery. d. Incorrect air pressure connection. If the air pressure switch is connected to the main (compressor) air rather than the working (bit) air, there will be incorrect pressure to the switch. e. Incorrect adjustment of the switch. The air pressure switch is preset at the factory, but adjustment may be necessary. Refer to Air Circuit Tests, Switch Adjustment. for adjustment instructions.
Diagnostic Procedure
Before you begin this procedure: 1. Make sure the power circuit is working properly. Most problems occur in the power circuit. 2. Disconnect the encoder cable from the DEI Plus. If the problem changes, go to Encoder Circuit Tests. 3. Display the Bit Air Switch system screen (for instructions, refer back to System Status: Bit Air Switch Status Screen in Chapter 3.)
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Then begin with Initial Check and follow all steps of the procedure in order, observing the status indicated on the Bit Air Switch status screen. Figure 20. DEI Plus Air Switch Cable Connector
DEI Plus Ground
C B
Not Used
~4.5 VDC
POWER
A B
BITAIR
C B A
ZEROHOLE
C B A
ALARM/ TRAM
F E D C A B
RS232 RS232LEVEL
F E D C A B E D C F A B
ENCODER
Initial Check
Action to take 1. 2. 3. 4. Turn the air pressure off. Turn the air pressure on. Turn the air pressure quickly on and off several times. Go to Re-Calibrate. If result is this, go to next step Status is OFF. Status is ON. Status changes between ON and OFF appropriately. If not, do this... Go to Bit Air Switch Cable Check. Go to Bit Air Switch Cable Check. Go to Switch and Line Check.
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Chapter 4 Troubleshooting
2.
Use a piece of wire or a paper clip to jumper Pin A to Pin B of the AIR connector on the back of the DEI Plus. Re-connect the air switch cable to the DEI Plus, and disconnect it at the air pressure switch. Use a piece of wire or a paper clip to jumper the pins on the cable connector.
3.
4.
Status is ON.
5.
Re-connect the cable to the air pressure switch. Then go to Switch and Line Check.
2.
4.
Re-connect the encoder cable to the DEI Plus. Repeat Initial Check. If the problem continues, go to Re-Calibrate.
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Switch Adjustment
The air pressure switch is adjusted at the factory and normally does not need to be re-adjusted. Use this procedure only if, when you perform the Air Circuit Tests, Diagnostic Procedures, the air switch does not activate and de-activate as the bailing air is turned on and off (Switch and Line Check, step 2). 1. Make sure the air pressure switch is installed correctly and connected to the DEI Plus. 2. Make sure the drill compressor is running. 3. Turn off the bailing air. 4. Loosen the locknut on the top of the air pressure switch. 5. Turn the adjustment screw until the front panel display on the air pressure switch reads 30% to 40% of working air pressure. For example, if the bit air pressure is 60 psi, the front panel display should be 20.
Figure 21. Air Pressure Switch Front Panel Note: The Operation Indicator can only be adjusted at the factory. 6. Watch the status boxes on the Bit Air Switch status screen of the DEI Plus as you cycle the bailing air on and off. Make sure the status changes between on and off quickly and corresponds to the on/off state of the bailing air. You should also hear and see the air pressure switch open and close as you cycle the bailing air. 7. If necessary, repeat steps 3 through 6 until step 6 is satisfied. 8. Tighten the locknut on the top of the air pressure switch. 9. Verify step 6.
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Chapter 4 Troubleshooting
Diagnostic Information
Failures in the encoder circuit are generally due to one of the following, listed in order of probability: a. Calibration was incorrect. If an incorrect value is entered at any point in calibration, or the power head drifts during the calibration, you can expect all displayed measurements to be incorrect. b. Smashed, cut, or otherwise damaged cabling causing complete or intermittent shorts and opens. Note: If two of either pair ( or ) of the status boxes on the Encoder Status screen are highlighted at any time, it is likely that there is a short in either the cable or the encoder itself. If none of the boxes are highlighted, it is likely that there is an open in the cable or the encoder. c. Encoder drive chain comes off, slips, or misses because there is too much or little tension on the chain. d. On a direct drive installation, the hose connecting the encoder to the hub may be broken or disconnected, or the cable clamps on the hose may be loose, allowing the hose to slip. e. Damaged encoder, either mechanically or electrically.
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Diagnostic Procedure
Before you begin this procedure: 1. Make sure the power circuit is working properly. Most problems occur in the power circuit. 2. Disconnect the air switch cable from the DEI Plus. If the problem changes, go to Air Circuit Tests. 3. Display the Encoder system screen (for instructions, refer back to System Status: Encoder Status Screen in Chapter 3.)
Then begin with Initial Check and follow all steps of the procedure in order, observing the status indicated on the Encoder status screen. Figure 22. DEI Plus Encoder Cable Connector
POWER
A B
BITAIR
C B A
ZEROHOLE
C B A
ALARM/ TRAM
F E D C A B
RS232 RS232LEVEL
F E D C A B E D C F A B
ENCODER
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Chapter 4 Troubleshooting
Initial Check
Action to take 1. Disconnect the encoder cable from the back of the DEI Plus. If result is this, go to next step No status lights are highlighted on the Encoder status screen. If not, do this... Verify the power circuit. If it is working properly, replace the DEI Plus.
2.
Using a piece of wire or a paper clip, jumper the encoder connector socket D to socket A.
Box
is highlighted.
Same: verify the power circuit. If it is working properly, replace the DEI Plus.
3.
Box
is highlighted.
Same: verify the power circuit. If it is working properly, replace the DEI Plus.
4.
Box
is highlighted.
Same: verify the power circuit. If it is working properly, replace the DEI Plus.
5.
Box
is highlighted.
Same: verify the power circuit. If it is working properly, replace the DEI Plus.
6.
Re-connect the encoder cable to the back of the DEI Plus, and go to Encoder Cable Check.
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2.
Using a piece of wire or a paper clip, jumper the cable connector socket D to socket A.
Box
is highlighted.
3.
Box
is highlighted.
4.
Box
is highlighted.
5.
Box
is highlighted.
6.
Go to Encoder Check.
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Chapter 4 Troubleshooting
Encoder Check
Action to take 1. Re-connect the encoder cable to the encoder. Rotate the encoder shaft by hand. If result is this, go to next step Exactly one box from each pair ( or )is highlighted on the Encoder status screen. The shaft turns smoothly and quietly. If not, do this... Replace the encoder.
2.
Replace the encoder. Make sure the tension on the chain is not too tight. Replace the encoder.
3.
The highlighted boxes on the screen alternate exactly one box per pair being highlighted at any one time. The ROP/DISTANCE FROM BOTTOM display on the statistics screen is updated in units of one-tenth.
4.
Press the Statistics button on the DEI Plus. Then continue rotating the encoder shaft by hand. Go to Re-Calibrate.
5.
Re-Calibrate
1. Most problems occur in the power circuit. Verify that it is working properly. 2. If the problem continues, re-calibrate the DEI Plus, making sure that you enter the correct pipe length in Step 9 and all other calibration values accurately. If you are unable to calibrate successfully, go to Encoder Circuit Tests. 3. If the problem continues, replace the DEI Plus. If the following occurs twice in succession, return the digital DEI Plus to Thunderbird Mining Systems for repair: When the DEI Plus is first turned on, the Calibration Failed warning screen flashes on the display.
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Figure 25. 7060-190-xxx Cable Assembly DEI Plus to Optical Shaft Encoder
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117
118
119
7.68 (195 cm.) Torque reel cable exit hole (see next figure)
Figure 29. Torque Reel Enclosure Sheet 1 Mounting Template Note: Illustration Scale = 1:2.
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Mounting flange
Figure 30. Torque Reel Enclosure Sheet 2 Cable Exit Hole Reference
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