CMS Training

Sandvik Blasthole Drill
Air Systems - Low Pressure

CMS – compressor management system
Sandvik Rotary Drill Division

Alachua Facility
March 2012
Sandvik Mining and Construction

Description
 Compressor oil lubrication and air

control components are local to the
compressor or receiver tank
 CMS component locations

(identified in green) will vary
depending on machine model
 Auxiliary air options for drilling and

non-drilling features are positioned
at various areas on the machine
deck

Applicable Engine Displacements
 C15 series 15.2 L 403 kw (540)
 C18 series 18.1 L 522 Kw (700)
 C27 series 27 L 597 kw (800)
 C27 series 27 L 652 kw (875)
 C27 series 27 L 708 kw (949)
 C32 series 32 L 838 kw (1123)
Machine model D25KS D245KS D45KS D50KS D55SP D75KS DR460 D90KS
Engine rate C15-475hp C15-475hp C16-475hp C15-540hp C27-800hp C27-800hp C27-875hp C32-1125hp
FUEL Full load lt/hr 91 91 91 104 154 154 168 216
FUEL 65% load lt/hr 59 59 59 68 100 100 109 141

Applicable Engine Displacements
 QSK19 series 19 L (567 kw (760)
 QSK23 series 23 L 708 kw (949)
 QST30 series 30 L 746 kw (1000)
 QSK45 series 45 L 895 kw (1200)

Rotary Screw Compressor
 Applicable Compressor Volumes

 Standard air cubic meter/scfm
− 25.5 m³/min – 6.9 bar (900 scfm – 100 psi)
− 29. 7 m³/min – 6.9 bar (1050 scfm – 100 psi)
− 34. 7 m³/min – 6.9 bar (1225 scfm – 100 psi)
− 36.8 m³/min – 6.9 bar (1300 scfm – 100 psi)
− 45.3 m³/min – 6.9 bar (1600 scfm – 100 psi)
− 56.6 m³/min – 6.9 bar (2000 scfm – 100 psi)
− 73.6 m³/min – 5.5 bar (2600 scfm – 80 psi)
− 85 m³/min – 5.5 bar (3000 scfm – 80 psi)

Rotary Drill Bits
Carbide button roller bit

Soft rock Hard rock
Overburden
Bit Cooling - Flushing - UHV
> 5000 FPM
< 10000 FPM
Annulus Area

Uphole Velocity Numbers
45.3 m³/min (1600 cfm) – 194 mm, 7.625 in drill pipe
UHV 6500 7500 8500 9500 10500 12500 14500 16500 18500
Bit D²
9 7/8 in
250 mm
9.25 in
235 mm
9 in
228 mm
8 5/8 in
219 mm

Compressor
DR420 with CMS
 29.7 m³/min (1050 cfm) compressor

mounted to engine and frame (top picture)
mounted to engine and frame (bottom
picture)
 All hoses connected for lubrication and
electric cables for control systems
 Butterfly inlet valve secured with gasket
seals to compressor inlet
 Manufacture identification plates stamped
to discharge housing
DR440 with CMS

Compressor D90KS with CMS

mounted to engine and frame (top picture)
mounted to engine and frame (bottom
picture)
 All hoses connected for lubrication and
electric cables for control systems
 Butterfly inlet valve secured with gasket
seals to compressor inlet
 Manufacture identification plates stamped
to discharge housing
D75KS with CMS

COMMON PARTS
already on machine

Safety Relief Valve
 Low pressure compressor applications:

 ASME certified relief valve
− Sandvik p/n 003501-003
− Pressure preset for 140 psi (9.7 bar)
− Temperature rated - 60° to + 406° F (- 51° to +
208° C)
 Replace valve if it is
− Repeated exposure to over pressure
− Over heated or subjected to fire
− Leaks air/oil to atmosphere
Atmospheric
 Adjusting this valve voids safety vent
standards and machine warranty
Air/Oil

Bearing Manifold
COP compressor oil pressure
 The bearing distribution manifold is last point for

oil injection
 Compressor oil in bearing manifold is distributed
to compressor housings for bearing and rotor
lubrication
 Minimum bearing pressure 1 bar (15 psi)
 Transducer will shut down machine with a loss of
oil pressure
 29.7 m³/min (1050 cfm) compressor mounted to
engine and frame (top picture)
 45.3 m³/min (1600 cfm) compressor mounted to
engine and frame (bottom picture)

Rotary Screw Compressor
 Oil flooded
 Male and female rotors
 Radial bearings front and rear
 Inlet housing
 Sealed shaft
 Stator housing
 Discharge housing
 Radial and thrust bearings rear

Oil Cooling
thermal manifold & filter assembly
2 ea 82° C (184° F) thermal valves

2 ea 3.5 bar (50 psi) Delta P check valves

Cold Oil Circulation

Oil Cooler
 AKG High ambient cooler
 Rated -42° C to +54° C (-45° to130° F)
 Cooler specs:
− Operating pressure = system pressure
− Maximum burst pressure = 55 bar (800 psi)
 Differential pressure from in to out will
vary according to oil flow
 Typical delta P:
− 0.3 – 1 bar (5 – 15 psi)
− 1 – 2.4 bar (15 – 35 psi)
− 2.4 – 3.4 bar (35 – 50 psi)
Typical delta T:
− Approximate -6° to +4° C (20° – 40° F)
Variables:
− Oil temperature
− Oil viscosity
− Thermostat position

Hot Oil
Circulation
 Example:
 Oil temp into compressor
− 82 C (180 F)
 Oil temp at compressor outlet
− 104 C (220 F)
 delta T inside compressor for oil
injection is based on compression
cycle:
− +4 C (40 F)

Compressor Switches
shutdown
Compressor oil pressure switches COP
Air temperature sender ATS

Remove MPV spring
factory applications without MPV
 CMS manages receiver tank pressure via

software recognition
 For field installations remove minimum
pressure valve spring, leave the piston and
o-ring seal
DANGER
− Valve body end cap is under pressure by
spring force use caution when unthreading
 Factory installations will use a 90° elbow

in place of a minimum pressure valve

CMS PARTS
additional parts for cms installation

CMS
parts
 Air inlet piping
 Hose clamps
 Gasket
 Butterfly inlet valve
 Gasket
 Linear actuator mounting
 Linkage
 Linear actuator
 Transducer
 Cable harness

CMS
parts
 VIT vacuum inlet transducer

 RAP receiver air pressure transducer
 WAP working air pressure transducer
 Transducers: two terminal device that

require thread ground
− Do not use thread sealant or teflon tape to
seal threads
− Copper coat - anti-seize compound is
conductive
− Swantek Graphtek 600 anti-seize

CMS
parts
 Solenoid EPSV
 Solenoid OSVP
 Shutdown switches COP and CAT
 Cable harness

CMS Oil stop valve without pilot: closed for
shutdown modes stopping oil
parts
Oil stop valve with pilot: opens for run

modes passing oil
CMS
parts
 Discharge check valve plate opens with

oil flow to allow air/oil mixture
circulation
 Spring holds plate closed without oil
flow
 Gaskets seal both end surfaces
 Seal both gasket surfaces with Loctite
515
 Equal bolt torques 190 Nm (140 ft lbs)

CMS
parts
 EPIV evacuation pump isolation valve threaded to
the discharge check valve adapter
 Pilot pressure hose from EPSV evacuation pump
solenoid valve
 Drain hose return to compressor inlet

CMS
parts
 Evacuation compressor
 Hydraulic motor
 Junction box
− Control module CM
− Circuit breaker CB
− Linear actuator current control LACC
 Cables
 Hoses hydraulic and pneumatic
 Installation instructions

Compressor inlet
linear actuator
 Features:
 24 VDC permanent magnetic motor
 Reinforced glass fiber piston rod
 Built in non adjustable limit switches
 Ambient temperature – 20° + 40° C
 0 – 90° degree butterfly plate position
Motor
Feed back pot
 Do not force butterfly inlet open with

actuator rod attached to linkage

LACC
linear actuator current controller
 Adjustments required for new circuit

boards
 DIP switch positions
− 4 Off
− 3 Off
− 2 Off
− 1 Off
 Trim pot positions
− Accel ramp: CCW
− Decel ramp: CCW
− Current limit: CW
 Control logic pin
− POS position

CMS
evacuation compressor
 Evac compressor is used to:

− Evacuate air from main compressor stator
housing during unload conditions
− Manages main compressor bearing oil
pressure during unload conditions by
maintaining receiver air pressure
 CCW rotation as noted from shaft end
 Is a highly modified compressor from a
Commando 120
31
CMS
Lube oil isolation valve (LOIV) cooling oil control
 2 way normal closed poppet valve

CMS
Lube oil isolation valve (LOIV) cooling oil control
 Pilot pressure: LOIV pilot to be hydraulic

pressure
− With engine running LOIV is piloted open
− When engine is stopped LOIV is spring closed

CMS
hydraulic supply 460 1
1. Vane pump
2. Pump control manifold
3. Hydraulic motor

CMS
hydraulic schematic 45/75/460/90

Hydraulic pump
T6C pump specs
 3.7 cm/rev (2.26 cu in):

− Continuous pressure rated up to 241 bar
(3500 psi)
− Static seals ‘orings’ are nitrile material
 Temperature range:
− -40 C (-40 F) to 82 C (180 F)
 Case:
− Shall not exceed 50% of theoretical flow

Hydraulic motor
motor specs
 3 cm/rev (1.83 cu in):

− Continuous pressure rated up to 420 bar
(6090 psi)
− Static seals ‘orings’ are nitrile material
 Temperature range:
− -40 C (-40 F) to 80 C (176 F)
 Case pressure:
− 0.7 – 2 bar (10 – 30 psi)

CMS
hydraulic supply 420/440
1. Load sense piston pump

2. 2 section directional control valve
3. Hydraulic motor 1

CMS hydraulic
schematic 420

CMS
 Evacuation compressor driven by Amega

coupling and Parker hydraulic motor.
 Expected speed 4300 - 5000 rpm and not to
exceed 5000 rpm

COMPRESSOR CONTROL

CMS
Compressor Management System
 The aim of CMS is to unload the compressor as much as possible when the compressor is
off-load (not drilling) to reduce parasitic load and thus reduce fuel consumption and
throttle the compressor when on-load (drilling) assisting drilling parameters.
 Expected benefits from installing CMS are as follows:
1. Reduced load factors resulting in reduced fuel consumption.
2. Extended life of the engine due to reduced load and lower fuel consumption.
(engine life is measured by total fuel consumed at a certain average load)
3. Extend life of the compressor due to lower average load.
4. Software regulation system vs mechanical regulators.
5. Software calibration of compressor regulation to meet air requirements.
6. Extend service intervals. (longer engine oil life)
7. Reduced load at start-up. (easy starting extending battery and starter life)
8. Reduced load at shut-down. (lower load on turbo chargers)

CMS
Compressor Management System
CMS is one piece of Sandvik Automation Modules CMS
EPEC 2024 module EPEC 2040 HMI
CAN

CMS
less waste (air & fuel consumption)
 CMS concept: manage air consumption to reduce load on engine, which

reduces fuel burn and COx and NOx emissions reducing carbon footprint
left on the environment
 Start-up functionality
− Smart algorithm minimizes start-up compressor load
 When NOT drilling
− Creates vacuum in main compressor
− Allows cool shut-down
 When drilling
− Delivers precise air volume to flushing needs

SRBV – Energized
ULV - Energized
ff)
ir O e
(A h Idl
Hig
SRBV – De-energized
Accessory and
ULV - Energized
Drilling air
usage
g
illin
Dr
SRBV – Energized
ULV - Energized
n)
ir O e
(A h Idl
Hig
SRBV – Energized
ULV – De-Energized
ff)
ir O e
(A h Idl
Hig
SRBV – Energized
ULV - Energized
Accessory
SRBV – Energized
usage
ULV - Energized
e
SRBV – Energized Idl
w g
ULV - dEnergized Lo nnin
Ru
SRBV – Energized
ULV - Energized
ing
rm
Wa
SRBV – Energized
ULV – De-Energized
rpm
99
11
0–
15
SRBV – Energized
ULV - Energized
g
ki n
an
Valve State Change

Cr
SRBV – De-Energized
ULV - Energized
Offload Pressure Set-Point
Air Pressure
High Pressure Set Point
Min Pressure Set-point

HP: 12.4 Bar / 180 PSI
LP: 6.9 Bar / 100 PSI
LP: 3.1 Bar / 45 PSI
Atmospheric Pressure
HP: 24.1 / 350 PSI

LP: 2.75 Bar
HP: 11 Bar
Air system schematic - CMS

CMS
how does it work?
 The Compressor Management System (CMS) has a number of modes of

operation:
1. Start-up At start CMS software holds the inlet butterfly closed to allow
the engine to crank, start and accelerate to low idle
2. Off-load When the compressor is off-load, the CMS software regulates
receiver pressure and evacuates the main compressor.
3. On-Load When the compressor is on-load, the CMS software throttles
the volume of the compressor.
4. Shut-down The CMS software unloads the compressor from the engine
to allow for cooler engine shut-down.

Compressor loading at start up 1

Compressor loading at start up 2

CMS bearing lubrication
 Lubricate:
− Radial bearings front and rear Butterfly closed
− Radial and thrust bearings rear

− COP switch protection
− CAT switch protection
 Compression cycle depleted

− Oil injection
− Stator housing

CMS on compressor unloaded

CMS off compressor loaded

CMS on compressor unloaded

Compressor Blowdown Valve
CBV
 Compressor blowdown valve

− Open to vent air during start up 0 150 rpm
− Continues to vent air up to 1200 rpm
− Closes to allow tank air pressure to raise
− Closes during drilling cycle
− Opens to vent air when air pressure becomes
greater than 4.5/4.8 bar (65/70 psi)
− Closes to allow tank air pressure to raise when air
pressure drops below 4.5 bar (65 psi)
− Opens to vent air when air pressure becomes
greater than 6.9 bar (100 psi)

Flushing Air
DR460
 Flushing air on/off – Drill mode
− 1 push left full flushing on
− 1 push right full flushing off
Service valve -flushing

Flushing Air
DR420/440
 Flushing air on/off – Drill mode
− 1 push on half flushing
− 2 push on full flushing
− 1 push off ends flushing
5 4 Flushing air on
7
3
6
Flushing air off
 Drill screen represents flushing

on/off mode
5 4 Flushing air on
Flushing Air 7 6
Flushing air off
3
DR420/440 hydraulic/electric
Flushing valve manifold

Receiver Air Pressure is Influenced By
bit orifices – AA – back pressure – drill cutting - ground water - water injection
Annulus Area
Water Injection
Back Pressure
Bit nozzle size

TROUBLESHOOTING CMS

Troubleshooting CMS: Components
Compressor Blowdown Valve (CBV)

Controls the pressure in the air receiver tank in various operational modes:
• Open at start-up.
• Closed for normal air receiver tanks regulation.
• Open when receiver tank exceeds the maximum pressure.
• Open at shut-down to depressurize the receiver tank.
• The CBV is electrically controlled by the PLC.

Inlet Butterfly (IBV)

Controls air entering the compressor from full volume to no air.
• Closed when the compressor is unloading, linear actuator extended and opened
when the compressor is loading, linear actuator retracted.
• The inlet butterfly is electrically controlled via the PLC, with a LACC or DC motor
driver and a linear actuator.

Discharge Check Valve (DCV)

Isolates the compressor from the receiver when the compressor is unloading.
• Closed when the compressor is unloading.
• Open when the compressor is loading.
Oil Stop Valve (OSV)

Controls the cooling oil flow.
• Closed when the compressor is unloading and open when the compressor is
loading.
• The oil stop valve is pneumatically controlled by the compressor discharge
pressure via a pilot signal switched by the PLC from between the compressor and
the discharge check valve.
Safety Relief Valve (SRV)

Used to regulate the absolute maximum receiver pressure (opens to dump air to
atmosphere, prevents air system component damage) should the control system
fail.
Evacuation Pump (EP) compressor

Evacuates the main compressor and maintains receiver tank pressure when the main
compressor is unloading.
• The CMS directional control valve is electrically controlled by the PLC to
enable the hydraulic motor and evacuation pump.
Evacuation Pump Isolation Valve (EPIV)

Controls the air supply into the evacuation pump.
• Closed when the main compressor is loading and open when the main
• The EPIV is pilot controlled from receiver tank pressure via EPSV.
Evacuation Pump Solenoid Valve (EPSV)

Controls the EPIV.
• Closed when the main compressor is loading and open when the main
• The EPSV is electrically controlled by the PLC.
Evacuation Pump Relief Valve (EPRV)

Controls the operation of the Evacuation pump drive motor.
• The EPRV is open when the compressor is unloading and closed when the
compressor is loading.
• The EPRV is electrically controlled by the PLC to relieve to fully open when
energised.
Oil Stop Pilot Valve (OSPV)

Controls the pilot signal to the oil stop valve.
• When the flushing air is switched off, the OSPV is energised. This will
evacuate the pilot air signal that opens the oil stop valve to the inlet of the
compressor. This is used to stop the flow of cooling oil into the compressor
stator housing so that the evacuation compressor can evacuate the discharge
of the main compressor without having to also evacuate the cooling oil flow.
• The OSPV is electrically controlled by the PLC.

 CMS function test

 12 screens
− Diagnose component network
input vs functionality
− Navigate with up/down arrows
− OK button to move to test screen
− Back button to return to last state


 Troubleshooting thru the GUI

 10 screens
− Canbus components

 EPEC module 2024

 Digital and analog inputs and digital outputs
 Two Can buses – can-lo & can-hi
 Operating temperature: I/O
− -40°C + 70°C input/output
 Overheat protection cabling
 Operating voltage range
− 10 – 30 vdc
 Over voltage max 70 vdc
− shutdown at 32 vdc
 Under voltage reset < 9.5 vdc
 Water and dust proof per IP65 and IP67
 Over load protection for outputs 8 pin bus
 Connectors 1, 2, 3 = I/O cabling
 Connector 4 + Bus

 BUS between nodes is a twisted pair cable 4 3

− Yellow – voltage supply (1) 5
− Brown – CAN low (2) 1 2
− Green- ground (3)
− White – CAN high (4) 3 4
Male end
− Wire shield (5) 5
 Minimum length 10 cm (4 inches) maximum 2 1
length 1000 meters (0.62 miles)
 Length of the bus depends on the used speed Female end
on the bus
 Higher speed more bauds per second = shorter
length cables
 Bus cabling is made with cables having M12
connectors on both ends

 To prevent contamination entry

it is recommended to apply
quality di-electric grease to the
M12 can cable ends

Termination Resisters
 CTR - Test termination resistance

 Bus termination by plug assembly
includes 2 each - 62 ohm resisters
− GUI graphical user interface (in cabin)
− CTR - Test termination CAN HI
120 Ω
CAN LO

 Transducers: two terminal device that

require thread ground
− Do not use thread sealant or teflon tape to
seal threads
− Copper coat - anti-seize compound is
conductive
− Swantek Graphtek 600 anti-seize
 VIT vacuum inlet transducer

 RAP receiver air pressure transducer
 WAP working air pressure transducer

Maintenance
 Dust control: Regulated air pressure

require 3.2 – 4 bar (50 – 60 psi)
 Thread grease: Regulated air pressure

require 3.2 – 4 bar (50 – 60 psi)
 Hydraulic tank pressurization:

Regulated air pressure require 0.3 –
0.5 bar (5 – 7 psi)

Maintenance
 Chain lube: SAE 30 – 50 wt chain oil

for lubricating both pulldown and
hoist chains
 Auto lube: NLG1 grease for pin and

bushing lubrication

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Sandvik Blasthole Drill

Air Systems - Low Pressure

Sandvik Rotary Drill Division

Sandvik Mining and Construction

 Compressor oil lubrication and air

 CMS component locations

 Auxiliary air options for drilling and

Sandvik Mining and Construction

 C18 series 18.1 L 522 Kw (700)

 C27 series 27 L 597 kw (800)

 C27 series 27 L 652 kw (875)

 C27 series 27 L 708 kw (949)

 C32 series 32 L 838 kw (1123)

Sandvik Mining and Construction

 QSK23 series 23 L 708 kw (949)

 QST30 series 30 L 746 kw (1000)

 QSK45 series 45 L 895 kw (1200)

Sandvik Mining and Construction

 Applicable Compressor Volumes

Sandvik Mining and Construction

Carbide button roller bit

Sandvik Mining and Construction

Sandvik Mining and Construction

 29.7 m³/min (1050 cfm) compressor

DR440 with CMS

 73.6 m³/min (2600 cfm) compressor

D75KS with CMS

Sandvik Mining and Construction

 Low pressure compressor applications:

Sandvik Mining and Construction

 The bearing distribution manifold is last point for

Sandvik Mining and Construction

Sandvik Mining and Construction

2 ea 82° C (184° F) thermal valves

Sandvik Mining and Construction

Sandvik Mining and Construction

Sandvik Mining and Construction

Sandvik Mining and Construction

Compressor oil pressure switches COP

Air temperature sender ATS

Sandvik Mining and Construction

 CMS manages receiver tank pressure via

 Factory installations will use a 90° elbow

Sandvik Mining and Construction

Sandvik Mining and Construction

Sandvik Mining and Construction

 VIT vacuum inlet transducer

 Transducers: two terminal device that

Sandvik Mining and Construction

Sandvik Mining and Construction

Oil stop valve with pilot: opens for run

 Discharge check valve plate opens with

Sandvik Mining and Construction

Sandvik Mining and Construction

Sandvik Mining and Construction

Feed back pot

 Do not force butterfly inlet open with

Sandvik Mining and Construction

 Adjustments required for new circuit

Sandvik Mining and Construction

 Evac compressor is used to:

 2 way normal closed poppet valve

Sandvik Mining and Construction