Untitled

Chapter 7: Maintaining the DCi System
Control systems
CR2032 69

CompactModule Metal
39
23
I/O module
227
digital and analogue 205
for R360 system
CAN out
CANopen interface
PWR DIA
8
2
77
52
Surface electrostatically
1
5
7
CAN in
coated (cathodic immersion)
10...32 V DC 6
5
5 LED M12 x1
Technical data 8 inputs (4 digital and 4 analogue/digital)

8 outputs (4 digital and 4 digital/PWM)
Housing Die-cast zinc housing with 8 outputs and terminal chamber

surface electrostatically coated (cathodic immersion), black
Dimensions (l x w x h) 227 x 77 x 39 mm (without cable gland)
Installation Screw connection by means of 3 M5 x l screws to DIN 912 or DIN 7984
Connections
Operating voltage and CAN bus 7-pole terminal strip with CAGE CLAMP ® connection technology
(2 x 2-pole / 1 x 3-pole) 0.08...4 mm2 (AWG 28...AWG 12), nominal current 20 A
Identical potentials can be linked using a jumper header
(GND and UB potentials linked upon delivery)
Cable entry via M16 cable gland
Inputs/Outputs 8 x M12 connector (socket), 5-pole
CANin/CANout 2 x M12 connector (plug/socket), 5-pole
Weight 1.35 kg
Inputs 8
can be configured as 4 digital, positive-switching (high side)
4 analogue, 0...10/32 V, 0/4...20 mA, ratiometric
or digital, positive-switching, with diagnostic capability
Sensor supply I max 400 mA
Outputs 8
can be configured as 4 digital, positive-switching (high side), with diagnostic capability
4 digital, positive-switching (high side), with diagnostic capability or PWM channel
switching current per output max. 2 A
total current max. 16 A
Operating voltage UB 10...32 V DC
Current consumption ≤ 60 mA (without external load at 24 V DC)
Operating temperature – 40...85 °C
Storage temperature – 40...85 °C
Protection IP 67
Interface CAN interface 2.0 B, ISO 11898
Baud rate 20 Kbits/s...1 Mbit/s (default setting 125 Kbits/s)
(adjustable using hex-code switches in the terminal chamber
or via the CANopen object directory)
\DATEN\100\DB-FORM—PZD/03/12/96
Communication profile CANopen, CiA DS 301 version 4, CiA DS 401 version 2.1
Node ID (default) hex 20 (= dec 32)
(adjustable using hex-code switches in the terminal chamber
or via the CANopen object directory)
Displays 1 LED green (PWR)
1 LED red (diagnosis, DIA)
16 LEDs yellow (status of the inputs / outputs)
ifm electronic gmbh • Friedrichstraße 1 • 45128 Essen We reserve the right to make technical alterations without prior notice. CR2032 / page 1 15.03.2006
239
Copyright © 2007, 2011, 2017 Boart Longyear. All rights reserved. 5307872
Boart Longyear is constantly striving to improve its products and must therefore reserve the right to change designs, materials, specifications, and price without notice.
Control systems
CR2032 Technical data
Connecting and operating elements

Jumper headers
CAGE CLAMP ® upon delivery:
connection clamps 3+4 / 5+6+7

Hex-coded
rotary switch

Hex-code switch coding

Switch Position Description
S1 0 1000 Kbits/s
•0•
Baud rate 1 800 Kbits/s E
2
•C•
•4•6
2 500 Kbits/s
3 250 Kbits/s •8•A
4 125 Kbits/s
5 100 Kbits/s
6 50 Kbits/s
7 20 Kbits/s
8...E not defined
F adjustment via object directory (default)
S2 0...7 high nibble, e.g. 20 hex (= 32 dec)
Node ID H F adjustment via object directory (default)
S3 0...E low nibble, e.g. 20 hex (= 32 dec)
Node ID L F adjustment via object directory (default)
Operating states (LEDs)

LED Status Description
PWR (green) OFF no supply voltage
ON module in stand-by mode
CANopen status: PREOPERATIONAL / PREPARED
outputs = OFF
2.0 Hz module active
CANopen status: OPERATIONAL
outputs are updated
DIA (red) OFF communication OK
ON communication disturbed
• node guard / heartbeat error
(if node guarding / heartbeat is activated)
• no synch objects
(if synch monitoring is activated)
IN (yellow) ON output switched
2.0 Hz diagnosis failure
OUT (yellow) ON binary output: output switched (ON)
analogue output: PWM preset value ≠ 0
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Control systems
CR2032 Characteristics of the inputs / outputs
Inputs ■ Digital inputs, with diagnostic capability

Channel 1, 3, 5, 7 (pin 4) Switch-on level 0.4...0.7 UB
Switch-off level 0.2...0.24 UB
Input resistance 3 kΩ
Input frequency max. 50 Hz
Channel 1, 3, 5, 7 (pin 2) ■ Analogue inputs
can be configured as ... voltage, current, ratiometric or digital positive-switching
Voltage inputs
Input voltage 0...10/32 V
Resolution 10 bits
Input resistance 50/30 kΩ
Input frequency 50 Hz
Accuracy ± 1 % FS
Current inputs
Input current 0/4...20 mA
Resolution 10 bits
Input resistance 400 Ω
Input frequency 50 Hz
Accuracy ± 1 % FS
Ratiometric inputs for potentiometric transducers (e.g. joystick)
Function ((UIN – ½UB) ÷ ½UB) x 1000 ‰
Value range 0...1000 ‰
Digital inputs, with diagnostic capability
Switch-on level 0.7 UB
Switch-off level 0.4 UB
Input resistance 30 kΩ
Input frequency max. 50 Hz
Outputs ■ Semiconductor outputs, with diagnostic capability (wire break and short circuit)
Channel 2, 4, 6, 8 (pin 4) short-circuit and overload protected
can be configured as ... Switching voltage 10...32 V DC
Switching current max. 2 A
Total current max. 8 A
■ PWM outputs
PWM frequency 20...250 Hz
Pulse duty factor 0...1000 ‰
Resolution 1‰
Switching current max. 2 A (referred to PWM value 1000 ‰.)
Channel 2, 4, 6, 8 (pin 2) ■ Semiconductor outputs, with diagnostic capability (wire break and short circuit)
can be configured as ... short-circuit and overload protected
Switching voltage 10...32 V DC
Switching current max. 2 A
Note also see wiring (following page)
Test standards and regulations
Climatic test Damp heat to EN 60068-2-30, test Db

(≤ 95% rel. humidity, non-condensing)
Salt mist test to EN 60068-2-52, test Kb, severity level 3
Protection test to EN 60529
Mechanical resistance Vibration to EN 60068-2-6, test Fc
Shock to EN 60068-2-27, test Ea
Bump to EN 60068-2-29, test Eb
Immunity to ISO 7637-2: 2004, pulses 2a, 3a, 3b, 4, severity level 4, function state A
to conducted interference to ISO 7637-2: 2004, pulse 1, 2b, severity level 4, function state C
to ISO 7637-2: 2004, pulse 5, severity level 1, function state A
Immunity to directive 2005/49/EC at 100 V/m (e1 type approval)
to interfering fields and DIN EN 61326 (CE)
Interference emission to directive 2005/49/EC (e1 type approval)
and DIN EN 61326 (CE)
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Control systems
CR2032 Wiring

Inputs Outputs
01

01
02 02
03 03
04 04
05 05
01

01
02 02
03 03
04 04
05 05
01

01
02 02
03 03
04 04
05 05
01

01
02 02
03 03
04 04
05 05
01 01
02

02
CAN IN 03 03 CAN OUT
04 04
05 05

01
05

07

02
06

04
03

CAN Interface / Supply

Abbreviations
CANH = CAN interface (high) PWM = output for pulse-width modulated signals
CANL = CAN interface (low) VBBC = operating voltage (via CANin/CANout plug)
GNDO = ground (output) VBBO = operating voltage (output)
GNDS = ground (module) VBBS = operating voltage (module)
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7.5 Wireline Hoist Sensor

This is a 4–20 mA device that varies its signal as a magnet rotates through 360 degrees
in front of the sensor. Each 4–20 mA cycle is equivalent to one revolution.
The direction of rotation is measured by signal movement:
●● An increasing signal indicates the cable is winding out.

●● A decreasing signal indicates the cable is winding in.
It is important that the signal direction is correct for the Speed Lock function to work
correctly.
If this sensor is not working, the hoist can still be operated, but the counter on the
Wireline screen and Speed Lock functions will not work and an error message will
appear at the bottom of the screen. Refer to the Diagnostics menu if required.
7.5.1 Replacing the Wireline Hoist Sensor and Magnet
Figure 7–4: Wireline Hoist Sensor Replacement
Note: Before replacing the Sensor or Magnet, check the electrical connections for
corrosion and continuity. Apply a small amount of non-conductive grease to any
connections when servicing. Do not apply too much grease as the connection may not
seat and connect electrically.
Tools required
●● 2.5mm hex key for Wireline Rotation Sensor and 9 pin bayonet type electrical
receptacle assembly mounting (if fitted).
●● 3mm hex key for Magnet and Wireline Rotation Sensor mounting.
●● 10mm A/F open ended spanner for grease nipple.
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●● 13mm A/F spanner or socket for Sensor Mount and Receptacle Bracket (if fitted).
●● 27 A/F open ended spanner for Magnet Mount.
●● Non-conductive grease p/n 602590 for electrical connections.
●● M12 Plastic caps and plugs for electrical connections.
●● Loctite 771 or equivalent anti-seize compound for fasteners.
●● RTV silicone sealant for sealing the internal hexagon on Socket Head Capscrews.
7.5.1.1 Removal Procedure

1. Turn off the power at the Power Pack Starter isolator switch using site specific
maintenance procedures.
2. Remove the M8x50 bolt (13 A/F) and P-clip retaining the Sensor electrical connector
and store them in a safe place.
3. Use a 2.5mm or 3mm hex key to remove the two M4x20 screws that keep the sensor
in place. The magnet will now be visible through the opening in the sensor mount.
4. Check the gap between the magnet face and Sensor mounting face is 1-4mm. If not,
rectify as this may be causing the issue.
5. Disconnect the short Sensor cable from the 9 pin Bayonet type Receptacle
Assembly, or from the Interconnecting cable (on older models).
Protect electrical connections from moisture and the environment using caps and
plugs.
6. Use a 3mm hex key to remove the two M4x20 screws securing the magnet in place.
The magnet can then be removed through the opening in the sensor mount.
7. Alternatively, the magnet can be accessed by removing the remaining three M8x50
bolts and the sensor mount.
7.5.1.2 Re-assembly
1. Use a 3mm hex key and M4x20 socket head screws to fit a new magnet through the
opening.
RTV silicone sealant can be used to seal off the hexagon counter-bores in the screw
heads to make removal easier at a future date.
(The 2mm diameter pin supplied with the magnet is not required.)
The magnet should be orientated onto the mount with the counter bored holes and
rectangular magnet facing outwards away from the hoist drum.
Remove any metal particles and grease from the magnet face after assembly.
2. Check the gap between the magnet face and the sensor mounting face is 1–4mm.
3. Use the M4x20 button head screws (provided with the sensor) to fit a new sensor
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with its label facing outwards. Do not over tighten as the mount is plastic. The cable
should be orientated away from the grease nipple access slot on the mount.
RTV silicone sealant can be used to seal off the hex internal sockets on the screws to
make removal easier at a future date if desired.
4. Using the M8x50 bolt and P-Clip, remount the sensor connector.
Use anti-seize compound on the fastener thread.

5. Reconnect the Wireline interconnecting cable and Receptacle Assembly (if
applicable) after applying a small amount of non-conductive grease (p/n 602590) to
the connection.
Do not use RTV silicone sealant on electrical connections.
Retain the caps and plugs for future use.

6. Turn on power to the rig. Do not reset the Emergency Stop system. An Emergency
Stop error message will remain on the screen, ignore this for now.
7. On the HMI screen, navigate to the PLC diagnostics via START UP > MAIN MENU
> DIAGNOSTIC > PLC. Note that HYDRAULICS OVERRIDE mode is not required to
check Wireline Sensor functionality.
8. On the PLC INPUTS – ST screen, check the displayed value of Input 33, it should be
between 4 and 20mA.
9. If the value is not between 4 and 20mA, check the wiring of the sensor is correct as
per the Boart Longyear circuit supplied in the manual. Rectify if necessary.
10. When safe to do so, place the hoist in Freewheel mode.
11. Rotate the drum by hand to spool cable out and check on the HMI screen that the mA
value displayed increases. If not, check the Sensor has been mounted correctly with
the label facing outwards.
12. Take the Hoist out of Freewheel mode.
13. Reset the Emergency Stop system using the EMERGENCY STOP RELAY RESET
pushbutton on the Starter and RESET FAULT/ALARM on the DCi Control Panel.
14. With the controls set to neutral, start the rig. The Hydraulics Override Active message
will disappear.
15. Navigate back to the MAIN MENU using the F5 function button on the HMI and select
OPERATIONS. The ROD HANDLING screen will be displayed.
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16. Select WIRELINE Mode, the Wireline Screen will appear.
Figure 7–5: Wireline Screen
Note: Proceed with caution if the Wireline cable is attached to In hole tools or could
get hung up on drill components.
17. While pressing the right pushbutton and ‘Deadman’ switch on the right Joystick,
move the right Joystick forward slowly and confirm the Wireline Position counter
increases in number and cable spools off the drum.
18. Press the COUNT RESET button on the HMI to zero the COUNTER when the In-hole
tools are in the appropriate position.
7.6 Water Pump Sensor

The Water Pump uses an Inductive Proximity Sensor to create a switching signal created
by a 4 lobe sleeve located on the Water Pump input shaft coupling.
One revolution of the input shaft results in 4 pulses on the inductive sensor. If this sensor
is not working, the water pump can still be used, but the flow will not be displayed on the
DCi OPERATIONS screens and Unattended Drilling functions will not work.
7.6.1 Replacing the Water Pump Sensor

Tools required
●● 2.5mm hex key for 9 pin bayonet type electrical receptacle assembly mounting (if
fitted).
●● 10mm A/F spanner or socket for Bell Housing Cover retaining bolts.
●● 17mm A/F spanner for Proximity Sensor retaining nut.
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●● 18mm spanner or socket for Hydraulic Motor mounting bolts.

●● M12 Plastic caps and plugs for electrical connections.
1–3mm
Figure 7–6: Water Pump Sensor Replacement

1. Remove the two M6 bolts (10 A/F), washers, and bell housing cover on the Water
Pump, and store them in a safe place.
2. Slowly rotate the Water Pump and stop when one of the lobes on the sensor sleeve
attached to the coupling lines up with the sensor. There should be an Amber indicator
light illuminated on the sensor when it is lined up with a lobe.
3. Stop the rig and turn off the electrical power at the Power Pack Starter isolator switch
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using site specific maintenance procedures.
4. Check the Sensor lines up properly with the sleeve attached to the shaft coupling, as
this may be the cause of the issue.
5. There should be a 1–3mm gap between the end of the sensor and the lobe. This also
could be the cause of the issue being experienced.
6. Disconnect the cable attached to the Water Pump Sensor.
Protect electrical connections from moisture and the environment using caps and
plugs if possible.
Male M12 plugs are available in packs of 10 (p/n 5305921).
Note: Before replacing the Sensor, check the electrical connections for corrosion and
continuity. Apply a small amount of non-conductive grease to any connections when
servicing. Do not apply too much grease as the connection may not seat and connect
electrically.
7. Loosen the Sensor retaining nut (17 A/F) and remove the sensor by unscrewing it
from the housing.
7.6.1.2 Re-assembly
1. Fit the new sensor by Fit a new sensor by screwing it into the bell housing. Keep the
front sensor face free of grease and anti-seize compound (if used).
2. Adjust the sensor so the gap between the sensor end and the top of one of the lobes
on the sensor sleeve is between 1–3 mm.
3. Tighten the sensor retaining nut (17 A/F). Only one Lock Nut is required.
4. Reconnect the Water Pump cables after applying a small amount of non-conductive
grease (p/n 602590) to the connection.

check Water Pump sensor functionality.
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Figure 7–7: PLC Inputs ST screen
7. On the PLC INPUTS – ST screen, check the indicator light for Input 24.
The indicator light should be Green when the sensor is lined up with a lobe. There
should also be an Amber light illuminated on the Water Pump sensor. Adjust the
sensor gap if necessary.
will disappear.
10. Navigate to the Rod Handling screen in Operations showing the four gauges.
11. Set the Water Pump Speed control to zero, then select the Water Pump REG
position.
12. Slowly increase the Water Pump speed and check that a flow is shown on the Water
Pressure gauge.
13. Fit the Cover, M6 bolts and washers back on the Bell Housing.
Use anti-seize compound on the bolt threads.
7.7 Rotation Unit Sensor Assembly

Fitted to the rear of the Rotation unit are two sensors:
●● Rotation Speed Sensor: This inductive proximity sensor measures a signal off
a four lobe Guide Bush retaining sleeve mounted to the Rotation Unit shaft. One
revolution of Rotation Unit results in 4 pulses on the inductive sensor. This sensor is
the same as that used on the Water Pump.
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If this sensor is not working, drilling can continue, but the Rotation Speed will not be
displayed on the Drill screen and Unattended Drilling functions will not work.
●● Rod End Sensor. This senses the rear of the rod string. It has a selective sensitivity
to different materials, hence it can differentiate between steel and aluminum of the
same or similar diameters. If this sensor is not working, drilling can continue but the
Auto Re-Chuck, Auto Feed, and Auto Pull functions will not work.
7.7.1 Replacing the Rotation Unit Speed Sensor
1–3mm
Figure 7–8: Rotation Unit Speed Sensor Replacement
Tools required
●● Two 17mm A/F spanners for sensor lock nuts.

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●● M12 plastic caps and plugs.

●● Side cutters for small cable ties.
●● Small 5mm wide cable ties for retaining electrical cables.

1. Slowly rotate the Rotation Unit until one of the lobes on the Rotation Unit Guide Bush
retaining sleeve lines up with the sensor.
3. Check the Sensor lines up with the Guide Bush Retaining Sleave as this may be the
cause of the issue.
4. There should be a 1-3mm gap between the end of the sensor and the lobe. This also
could be the cause of the issue being experienced.
5. Cut cable tie retaining the sensor cable to the mounting bracket. Disconnect the
Rotation Speed sensor cable and protect the electrical connections from moisture
and the environment using caps and plugs if possible.
6. Loosen the sensor retaining nut (17 A/F) located on the pick-up end of the sensor
and remove the sensor from the underside of the bracket.
7.7.1.2 Re-assembly
1. Fit and adjust one nut (17 A/F) on the new sensor to the same relative position as the
remaining nut on the old sensor.
2. Slide the sensor through the bracket and fit the upper retaining nut.
The sensor should now be located close to its final position.

3. Adjust the sensor so the gap between the sensor end and the top of one of the lobes
on the Guide Bush retaining sleeve is 1–3 mm.
4. Reconnect the electrical cable after applying a small amount of nonconductive

grease (p/n 602590) to the connection.
Retain the caps and plugs if used.

check Rotation Speed sensor functionality.
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The indicator light should be Green when the sensor is lined up with a lobe. There
should also be an Amber light illuminated on the Rotation Speed sensor.
pushbutton on the Starter and RESET FAULT/ALARM pushbutton on the DCi Control
Panel.
will disappear.
10. Navigate to the Rod Handling screen in Operations showing the four gauges on the
HMI.
11. In Rod Handling mode and with no rod or rod string through the chuck, start rotation
using the left Joystick.
12. Looking at the screen, check that a value appears in the Rotation Speed field and
varies with a change in rotation speed.
A hand-held tachometer and reflective patch can be used to verify the speed if
necessary.
13. Stop the rig and cable tie any loose cables as necessary to the sensor mounting
bracket.
7.7.2 Replacing the Rod End Proximity Sensor
Figure 7–9: Rod End Proximity Sensor Replacement
Tools required
●● 4mm hex key for sensor retaining screws.

●● 8mm A/F spanner or socket for sensor retaining nuts.
●● Small flat blade screwdriver or scriber for plastic capscrew covers removal.
●● M12 plastic caps and plugs for electrical connections.
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●● Side cutters for small cable ties.
●● Small 5mm wide cable ties for retaining electrical cables.

1. Turn off the power at the Power Pack Starter isolator switch using site specific
2. Cut cable tie retaining the sensor cable to the mounting bracket. Disconnect the Rod
End proximity sensor cable from the sensor and remove it through the slot.
Protect the electrical connections from moisture and the environment using caps and
plugs if possible.
3. Remove the plastic caps covering the 4 capscrews using a small flat blade
screwdriver or scriber.
4. Use a 4mm hex key and 8mm spanner (or socket) to remove the four M5x35
capscrews, washers, and nuts securing the sensor. Store these items in a safe place.
7.7.2.2 Re-assembly
1. Use M5x35 capscrews, flat washers, and Nyloc nuts to fit a new Rod End proximity
sensor with the electrical connection facing towards the Rotation Unit.
Apply anti-seize compound to fastener threads.

2. Reconnect the Rod End sensor electrical cable after applying a small amount of non-
conductive grease (p/n 602590) to the connection and passing the cable through the
slot on the bracket.
Retain caps and plugs if used.

check Rod End sensor functionality.
The indicator light on the HMI screen should be Green when a piece of steel is
placed over the sensor.
6. There should be a Green light illuminated on the Rod End proximity sensor when the
power is switched on, and also an Amber light illuminated on the Rod End proximity
sensor when a steel object is placed over the sensor.
7. Fit the plastic caps supplied with the sensor over the four capscrews to help prevent
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corrosion issues. Alternatively, fill the four cavities with RTV silicone sealant.
will disappear.
7.8 Pilot Manifold Assembly

The existing PP1 – PP9, WL, WP and PPX pilot connections located on the front Power
Pack bulkhead now get their pilot supply from a Pilot Manifold assembly fitted with 10
pressure reducing valves located at the front of the Power Pack.
This change makes handling of the Control Panel a simpler task and moves hydraulic
hoses away from the Driller.
These 24V DC Reducing Valves have a control range of 0-30 bar and are fitted close
together to save on space. If any of these solenoids are not working, the drill can’t be
used.
The faulty component must be replaced or the standard LM pilot Control Panel fitted and
used instead of the DCi Control Panel.
7.8.1 Replacing a Pressure Reducing Valve on the Pilot

Manifold Assembly
2
1–Pilot Solenoids 2–27x30 A/F Tube Spanner 3–Pilot Manifold Block
Figure 7–10: Pilot Pressure Reducing Valves
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Tools required
●● 6mm hex key for Pilot Hydraulics Enclosure Front Cover retaining screws.
●● 10mm A/F combination spanner for Tube Spanner retaining clamp (early version).
●● 16mm A/F combination spanner for Power Pack side cover retaining bolts.
●● 17mm A/F combination spanner for Power Pack side cover retaining bolts
(alternative).
●● 18mm A/F combination spanner for Tube Spanner retaining nut.
●● 19mm A/F combination spanner for Tube Spanner retaining nut (alternative).
●● 27x30 A/F tube spanner — Pilot Hydraulics assembly. This fits over the pilot solenoid
valves which are positioned close to each other.
●● Short bar less than Ø16 or 12” shifter for use with tube spanner.
●● Rubber Grease for lubricating the cartridge seals.
●● Small container to catch any lost oil, and rags to clean up oil spills.
●● Side cutters for removing cable ties if necessary.
●● Small replacement cable ties for holding electrical cables (if required).
Note: Stored pressure may be present in the PP7 pilot circuit. This must be vented
before removal of any pilot solenoid valve.
2. Using a 6mm hex key, loosen the Button Head screws holding the Front Cover on the
DCi Enclosure located on the Power Pack, slide it upwards and off the key slots and
store in a safe place. There is no need to remove these screws to remove the cover.
3. If any pressure is present on the Pilot Pressure gauge located on the side of the
Power Pack, it must be vented before removing any valves.
4. Loosen the two M10 bolts (16 A/F or 17 A/F) and remove the panel covering the
plenum chamber and two gauges on the side of the Power Pack, and store in a safe
place.
5. Slowly open the drain valve located next to the 0.35L accumulator on the Power Pack
and bleed the pilot pressure until a value of zero is showing on the Pilot Pressure
gauge.
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6. Depress the retaining clip located on the end of the cable and disconnect the
electrical connector from the faulty pilot valve. Ensure the orange seal stays intact
on the connector. If no seal is present, the cable or solenoid could be faulty due to
corrosion.
7. Using the appropriate spanner, remove the clamp or M12 nut and washer retaining
the 27x30 tube spanner located in the Pilot Hydraulics assembly. Store any loose
parts in a safe place.
8. Use the 27mm A/F end of the tube spanner to remove the solenoid from the Pilot
manifold assembly.
7.8.1.2 Re-assembly
1. Smear a small amount of rubber grease or hydraulic oil on the Pressure Reducing
Valve seals.
2. Screw the new cartridge into the cavity using the 27mm A/F tube spanner, paying
attention so as not to damage the seals.
3. Ensure the orange coloured seal is fitted on the electrical connector and is not
damaged. If necessary, replace the seal or fit another cable with the same part
number.
4. Re-attach the electrical connector to the solenoid valve after applying a small amount
of non-conductive grease (p/n 602590) to the connection.
5. Clean up any oil that has leaked from the cavity.
6. Turn on power to the rig. Reset the Emergency Stop system using the EMERGENCY
STOP RELAY RESET pushbutton on the Starter and RESET FAULT/ALARM on the
DCi Control Panel. Do not start the rig.
7. On the HMI, navigate to the DIAGNOSTICS menu via START UP > MAIN MENU.
Press the HYDRAULICS OVERRIDE function button, Hydraulics Override Active
should flash on the bottom of the screen. Hydraulics Override needs to be active
to check solenoid functionality, and this function will only activate if the Emergency
Stop system has been reset. The ROTATION ON/OFF Green indicator light may also
flash.
8. On the HMI, navigate to DCi I/O Module diagnostics via DIAGNOSTIC menu > CAN
#2 NODES (DCi). Select DCi Node #23, #22 or #21 to test the appropriate solenoid.
9. To test the connectivity of the replaced solenoid, use the relevant check below.
Note: When valves or variable controls are in neutral or OFF position, no values will
be displayed on the I/O module screens. They may not be displayed if the wrong
mode is selected or the sequence of events has not been followed as explained
for each test. If no values are displayed when the joysticks are moved, check the
functionality of the joystick and deadman switches using diagnostic on CAN NODE
#1.
During testing, an input and feedback signal will be shown next to some of the
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function(s). If these values are different by more than 100mA, there is an issue in the
wiring or a component and a fault code will be displayed. This fault must be rectified.
●● PP1-PP2 for Rotation  DCi Node #21 – With Rod Handling Mode selected, move
the left joystick while pressing the ‘Deadman’ switch and both an input and output
value should appear next to the function being tested.
The two values shown should be within 100mA.
An Amber light should illuminate on the HMI screen next to PP1 or PP2 and also next
to I/O module #21 port 1 or 2.
●● PP3-PP4 for Feed  DCi Node #21 – With Rod Handling Mode selected, move the
right joystick while pressing the ‘Deadman’ switch and both an input and output value
should appear next to the function being tested.
An Amber light should illuminate on the HMI screen next to PP3 or PP4 and also next
to I/O module #21 port 3 or 4.
●● PP5 for Feed / Pull  DCi Node #23 – Note that this valve does not have current
monitoring; its functionality can be tested when the rig is started.
To test connectivity, select R/H on the Mode selector and FEED on the Rod Handling
Feed/Pull selector.
When the right joystick is moved forward while pressing the ‘Deadman’ switch, an
Amber light should illuminate on both the HMI screen next to PP5 and also next to
I/O module #23 port 4.
●● PP9 for Drilling  DCI Node #23 - Note that this valve does not have current
monitoring; its functionality will be tested when the rig is started.
To test connectivity, select DRILL on the Mode selector switch, and an Amber light
should illuminate on the HMI screen next to PP9 and also next to I/O module #23 port
2.
No mA value will be displayed on the HMI.

●● WP1 for Water Pump  DCi Node 22 – Select REG on the Water Pump selector.
When the Water Pump Speed variable control is rotated, the two values shown on
the HMI screen next to WP1 should vary too but remain within 100mA of each other.
An Amber light will illuminate on the HMI next to WP1 and also next to I/O Module
#22 port 3.
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Figure 7–11: Node #22 Screen
●● PPX for Torque control  DCi Node #22 – In DRILL mode, select Water Pump REG
and press Rotation ON/OFF so the pushbutton light illuminates. When the Torque
(PPX) variable control is rotated, the two values shown on I/O module #22 port 5
should vary too but remain within 100mA of each other.
An Amber light will illuminate on the HMI next to PPX and also next to I/O Module
#22 port 5.
●● WL1-WL2 for Wireline  DCi Node #22 – Select W/L with the mode switch.
Move the right joystick while pressing the ‘Deadman’ switch and top right pushbutton.
Both an input and feedback value should appear next to the function being tested.
An Amber light should illuminate on the HMI screen next to WL1 or WL2 and also
next to I/O module #22 port 1 or 2.
10. Shut the PP7 pilot vent valve located next to the accumulator.
Note: If the seals on the reducing valve are are damaged during installation, a pilot
pressure may get through to a valve causing unplanned movement. A seal kit is
available for these valves.
will disappear. No unplanned movements should occur.
If any function operates on start up, shutdown immediately and rectify. Check for
leaks.
12. Check that 35–45 bar is present on the Pilot Pressure gauge on the Power Pack.
13. Select DRILL mode and ensure the Rod Holder opens and the Chuck closes. Return
to R/H mode.
14. The pilot circuit that has been open to atmosphere may need to be bled as per
normal LM bleeding procedures.
15. Fit the panel back onto the plenum side of the Power Pack with the M10 fasteners
provided.
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16. Fit the 27x30mm A/F tube spanner back into the clamp or onto the retaining bolt
provided in the DCi Pilot Hydraulics assembly.
17. Fit the Front panel back on the Pilot Hydraulics assembly.
18. Dispose of any hydraulic oil and oily rags in the appropriate manner.
7.9 Fine Feed Manifold Assembly

The existing FC1–FC4, RH1 and RH2 connections located on the front Power Pack
bulkhead now get their oil supply from a Fine Feed Manifold assembly fitted with a series
of valves located in the DCi Hydraulics Enclosure. This makes handling of the Control
Panel a simpler task and moves high pressure hydraulic hoses away from the Driller.
There have also been four pressure transducers incorporated into this manifold to allow
measurement of Water, Circuit, Feed A and Feed B pressures.
The rig should not be used if the Fine Feed Pressure, Fine Feed Flow and Rod Holder
Isolate valves are not operating correctly. The pressure transducers give feedback to the
driller in all modes; hence the drill should not be used if any of these four sensors is not
functioning.
7.9.1 Solenoid Replacement

The 24V DC solenoids used on the three control valves located on the Fine Feed
manifold are all replaceable without changing out the complete valve. There are two
solenoid types used, one type on the Fine Feed Flow and Fine Feed Pressure valves,
used as proportional valves, and the other type on the Rod Holder Isolator valve which is
an On / Off type application.
If any of these solenoids is not working, the drill can’t be used. The faulty component
needs to be replaced or the standard LM pilot control panel fitted and used instead of the
DCi panel.
259
7.9.2 Replacing the Fine Feed Flow and Fine Feed

Pressure 24V DC Solenoids
1 2
1–Fine Feed Flow Solenoid 2–Fine Feed Pressure Solenoid
Figure 7–12: Fine Feed Solenoids
Tools required
●● 6mm hex key for removal of the Front Cover on the Pilot Hydraulics Assembly.
●● 27mm A/F 12 point socket and matching ratchet handle for removal of plastic
solenoid retaining nut. This socket is only required if the solenoid retaining nut is
difficult to remove by hand. A short extension bar would also minimize the chance of
damaging cables if available.

1. Stop the rig and turn off the Power at the Power Pack Starter isolator switch using
site specific maintenance procedures.
2. Loosen the Button Head screws holding the Front Cover on the DCi Enclosure
located on the Power Pack, slide it upwards and off the key slots and store in a safe
place. There is no need to remove these screws to remove the cover.
3. Depress the retaining clip and disconnect the cable from the solenoid.
4. Remove the plastic nut retaining the solenoid onto the cartridge spindle by hand if
possible.
If stubborn, use a 27mm 12 point socket to remove the nut.
(Using a tool like multi-grips to remove the nut runs the risk of damaging the retaining
nut.)
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Be careful to retain the two O-ring seals that sit in both the plastic nut and at the base
of the spindle, and store in a safe place.
7.9.2.2 Re-assembly
1. Place the new 24V DC solenoid over the valve spindle, ensuring there is an O-ring
fitted at the base of the spindle and inside the nut.
The electrical connection should be orientated to the 12 o’clock position and facing
outwards. Hand tighten the solenoid retaining nut.
2. Re-attach electrical connector to the solenoid after applying a small amount of non-
conductive grease (p/n 602590) to the connection.
should flash on the bottom of the screen. Hydraulics Override needs to be active to
check solenoid functionality, and this function will only activate if the Emergency Stop
system has been reset. The Hydraulics STOP/START pushbutton also needs to be in
the mid position. The ROTATION ON/OFF Green indicator light may also flash.
5. On the HMI, navigate to DCi I/O Module diagnostics via DIAGNOSTIC menu >
CAN #2 - NODES (DCi). Then navigate to DCi Node #21 to show the FFF and FFP
solenoid valve functions.
To test the connectivity of the replaced solenoid, use the relevant check below.
be displayed on the I/O module screens.
During testing, an input and feedback signal will be shown next to these functions.
If these values are different by more than 100mA, there is an issue in the wiring or a
component and a fault code will be displayed. This fault must be rectified.
●● Fine Feed Pressure control > DCi Node #21 – Select DRILL on the Mode Selector
switch, two values should appear next to FINE FEED PRESSURE (FFP) on the HMI
screen I/O module #21 port 5 when the variable control is away from neutral.
When the Fine Feed Pressure (FFP) variable control is rotated, the two values shown
should also vary, but remain within 100mA of each other.
An Amber light will illuminate on the HMI screen next to FINE FEED PRESSURE
(FFP) and also next to I/O module #21 port 5 when the FINE FEED PRESSURE
variable control is away from neutral.
●● Fine Feed Flow control > DCi Node #21 – Select DRILL on the Mode selector switch.
Move the right Joystick forward while pressing the deadman switch.
On the HMI, a mA value will be present next to Fast Feed (PP3), there will also be
values shown next to Fine Feed Pressure and Fine Feed Flow when the controls are
261
rotated away from the zero position.
When the Fine Feed Flow (FFF) variable control is rotated, the two values shown on
I/O module #21 port 7 should also vary, but remain within 100mA of each other.
An Amber light will illuminate on the HMI screen next to FINE FEED FLOW (FFF)
and also next to I/O module #21 port 7 when the FINE FEED FLOW variable control
is away from neutral.
6. Return all controls to the neutral position and start the rig. Select DRILL mode.
7. Operate the Fine Feed controls and verify functionality is correct.
8. Fit the Front Cover back on to the Pilot Hydraulics assembly and tighten the retaining
screws.
7.9.3 Replacing the 24V DC Fine Feed Flow and Fine

Feed Pressure Control Valves
2
3 4
2–27/30 A/F Tube Spanner 3–Fine Feed Flow Solenoid

4–Fine Feed Pressure Solenoid
Figure 7–13: Fine Feed Solenoids
Tools required
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●● 27x30 A/F tube spanner — Pilot Hydraulics assembly. This tool fits over the solenoid
valves which are positioned close to each other.
●● Short bar less than Ø16 or 12” shifter for use with tube spanner.
●● Small cable ties for holding electrical cables out of the way when changing the
Solenoid Valve(s).
Note: Feed pressure can be retained in the Feed circuit even when the rig is
switched off. This can be seen on the Feed Pressure and Holdback Pressure gauges
on the HMI if power is available.
1. The Feed Frame should be in a horizontal position when changing these valves.
If that is not possible, the Rotation Unit should not be holding the rod string and the
carriage should be positioned at the lower end of feed travel so it can’t fall when
either valve is removed.
This set-up also minimizes the risk of any air entering the system.
2. Place the DCi controls in neutral and stop the rig.
3. One of the OPERATIONS screens needs to be displayed to check for residual

pressure in the Fine Feed circuit. If necessary, navigate to a relevant screen via
the Main Menu and select OPERATIONS. If there is pressure greater than 1-2 bar
showing on either the FEED PRESSURE or HOLDBACK PRESSURE gauges, this
pressure needs to be released. If you are confident there is no residual pressure
present, go to step 8.
4. If pressure is present or you are unsure, navigate to the DIAGNOSTICS menu via
the MAIN MENU. Press the HYDRAULICS OVERRIDE function button, Hydraulics
Override Active should flash on the bottom of the screen. Hydraulics Override needs
to be active to vent any residual pressure in the Fine Feed circuit when the rig
hydraulics are not running. The ROTATION ON/OFF Green indicator light may also
flash.
5. Navigate back to the MAIN MENU, select OPERATIONS and a Rod Handling screen
will appear showing four gauges.
6. While pressing the Deadman switch on the Right joystick, move it back and forth to
vent the trapped pressure. The pressure should drop to 1-2 bar on both the FEED
and HOLDBACK gauges. If the PP7 pilot pressure has dropped off too much, the
pressure may not fully dissipate from the Fine Feed circuit, see further details below.
Removing the MFA or MFB test hoses at the manifold end with pressure in feed circuit
could result in an oil injection type injury.
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7. If using the Feed joystick did not successfully remove residual pressure, crack the
Feed A and Feed B hoses in a convenient place to vent any stored pressure, keeping
in mind the note in step 1.
If power is not available, a 0–400 bar pressure gauge can be placed in the Feed A
and Feed B test points located next to the Power Pack bulkhead to verify pressure
has been released. The MFA and/or MFB 2mm test hoses to the Fine Feed manifold
must first be disconnected at the test point end to do this.
8. Turn off the Power at the Power Pack Starter isolator switch using site specific
place. There is no need to remove these screws to remove the cover. If residual
pressure is still present in the Fine Feed circuit, remove the side cover from the Pilot
Hydraulics assembly adjacent the Gauge Selector.
10. Using the appropriate spanner, remove the clamp or M12 nut and washer retaining
the 27x30 tube spanner located in the Pilot Hydraulics assembly. Store any loose
parts in a safe place.
For the following steps keep the loose electrical connection away from any possible
source of oil contamination.
12. Remove the plastic nut retaining the solenoid onto the cartridge spindle.
If stubborn, use a 27mm 12 point socket to remove the nut.
(Using something like multi-grips to remove the nut runs the risk of damaging the
retaining nut.)
13. Use the 30mm tube spanner to remove the cartridge from the manifold.
7.9.3.1 Re-assembly
2. Smear a small amount of rubber grease on the cartridge valve seals.
3. Screw the new valve cartridge into the cavity using the 30mm tube spanner, paying
The recommended tightening torque is 50Nm.

4. Place the new solenoid over the valve spindle, ensuring there is an O-ring fitted at
the base of the spindle.
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The electrical connection should be orientated to 12 o’clock position and facing

outwards, then hand tighten the solenoid retaining nut.
check solenoid functionality. This function will only activate if the Emergency Stop
system has been reset and the HYDRAULICS STOP/START pushbutton is in the mid
position. The ROTATION ON/OFF Green indicator light may also flash.
9. On the HMI, navigate to DCi I/O Module diagnostics via DIAGNOSTIC menu >
CAN #2 - NODES (DCi). Then navigate to DCi Node #21 to show the FFF and FFP
solenoid valve functions.
To test the connectivity of the replaced solenoid, use the relevant check below.
be displayed on the I/O module screens.
During testing, an input and feedback signal will be shown next to these functions.
If these values are different by more than 100mA, there is an issue in the wiring or a
component and a fault code will be displayed. This fault must be rectified.
●● Fine Feed Pressure control > DCi Node #21 – Select DRILL on the Mode Selector
switch, two values should appear next to FINE FEED PRESSURE (FFP) on the HMI
screen I/O module #21 port 5 when the variable control is away from neutral.
When the Fine Feed Pressure (FFP) variable control is rotated, the two values shown
should vary too but remain within 100mA of each other.
An Amber light will illuminate on the HMI screen next to FINE FEED PRESSURE
(FFP) and also next to I/O module #21 port 5 when the FINE FEED PRESSURE
variable control is away from neutral.
●● Fine Feed Flow control > DCi Node #21 – Select DRILL on the Mode selector switch.
Move the right Joystick forward while pressing the deadman switch.
●● On the HMI, a mA value will be present next to Fast Feed (PP3), there will also be
values shown next to Fine Feed Pressure and Fine Feed Flow when the controls are
rotated away from the zero position.
When the Fine Feed Flow (FFF) variable control is rotated, the two values shown on
I/O module #21 port 7 should vary too but remain within 100mA of each other.
An Amber light will illuminate on the HMI screen next to FINE FEED FLOW (FFF)
and also next to I/O module #21 port 7 when the FINE FEED FLOW variable control
is away from neutral.
10. Return all controls to the neutral position and start the rig. Select DRILL mode.
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11. Operate the Fine Feed controls and verify functionality is correct.
12. Fit the 27x30 A/F tube spanner back into the clamp or onto the retaining bolt provided
in the DCi Pilot Hydraulics assembly.
13. Fit the Front and Side Covers back on the Pilot Hydraulics assembly and tighten the
retaining screws.
7.9.4 Replacing the Rod Holder 24V DC Solenoid

Located on the Fine Feed Manifold Assembly
5–Rod Holder Solenoid Valve
Figure 7–14: Rod Holder Solenoid
Tools required
●● 27x30 A/F tube spanner located in the Pilot Hydraulics assembly. This tool is a loose
fit on the solenoid retaining nut but is ok to use by hand.
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If the valve cartridge is functioning correctly and regardless of mode selected, the
Rod Holder will close if not already closed. The pressure in the Rod Holder hoses
vent to tank when the rig is turned off.
If stubborn, use the 27mm end of the tube spanner or a 27mm 12 A/F socket and
remove by hand.
nut.)
Be careful to retain the O-ring seal that sit in a groove on the outer end of the
solenoid. There is also one at the base of the spindle.
Store loose items in a safe place.
7.9.4.2 Re-assembly
1. Place the new 24V DC solenoid over the valve spindle, ensuring the O-ring fitted at
the base of the spindle is seated correctly and the exposed end of the solenoid has a
recess groove showing.
The electrical connection should be orientated to 12 o’clock position.
Fit the outer O-ring over the valve spindle and into the solenoid recess.
2. Fit and hand tighten the solenoid retaining nut. The small step in the nut should be
facing towards the solenoid.
check the solenoid functionality and will only activate if the Emergency Stop system
has been reset and the HYDRAULICS STOP/START button is in the mid position.
The ROTATION ON/OFF Green indicator light may also flash.
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#2 - NODES (DCi). DCi Node #23 should appear which includes the Rod Holder I/O
port 6.
Note: This valve does not have current monitoring. Its functionality will need to be
tested when the rig is running and when safe to do so.
7. To test connectivity without the Rod Holder opening, select R/H on the mode switch,
then ISOLATED on the Rod Holder selector switch. A message will appear asking to
press the RESET FAULT / ALARM pushbutton to confirm isolate action.
Once pressed, an Amber light should illuminate on both the HMI screen next to
Rod Holder Solenoid port 6 and also on I/O module #23 port 6. No mA value will be
displayed on the HMI.
8. A ROD HOLDER ISOLATED! message should also flash on the screen.
9. Reset the ROD HOLDER switch back to AUTO, and the warning message will
disappear.
The following check can only be done if there is no rod weight being supported by the Rod
Holder; otherwise uncontrolled rod string movement will occur.
10. Start the rig, select DRILL on the Mode switch.
11. Select ISOLATED on the Rod Holder selector switch.
A message will appear asking to press the RESET FAULT / ALARM pushbutton to
confirm isolate action.
Once pressed, an Amber light should illuminate on both the HMI screen next to Rod
Holder Solenoid port 6 and also on I/O module #23 port 6.
No mA value will be displayed.
The Rod holder should open as per normal.

12. The ROD HOLDER ISOLATED! message should flash on the screen.
13. Set the Mode switch to R/H, and the Rod Holder should stay open.
If not, the solenoid may have been fitted the wrong way around.
14. Reset the ROD HOLDER switch back to AUTO and ensure the Rod Holder shuts and
the warning message disappears.
15. If used, fit the 27x30 A/F tube spanner back into the clamp or onto the retaining bolt
retaining screws.
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7.9.5 Replacing the 24V DC Rod Holder Isolator Valve

Located on the Fine Feed Manifold Assembly
6
5–Rod Holder Solenoid Valve 6–30/36 A/F Tube Spanner
Figure 7–15: Rod Holder Solenoid
Tools required
●● 27x30 tube spanner located in the Pilot Hydraulics assembly. This tool is a loose fit
on the solenoid retaining nut but is ok to use by hand.
●● 30x36 tube spanner located in the Pilot Hydraulics assembly. This tool is for the valve
cartridge.
269

If the valve cartridge is functioning correctly and regardless of mode selected, the
Rod Holder will close if not already closed. The pressure in the Rod Holder hoses
vent to tank when the rig is turned off.
If the valve is stuck in the closed position, pressurised oil may be trapped between the
Solenoid valve and the Rod Holder. This would be indicated by the Rod Holder staying
open when the power is switched off. The Rod Holder hose would need to be carefully
loosened to release the trapped pressure before removing the valve cartridge.
For the following steps, keep the loose electrical connection away from any possible
source of oil contamination.
If stubborn, use the 27mm end of the tube spanner or a 27mm 12 A/F socket and
remove by hand.
nut.)
Be careful to retain the O-ring seal that sit in a groove on the outer end of the
Store loose items in a safe place.
Note: If the Rod Holder is located higher than the Pilot Hydraulics Module, the head
of oil may drain out through the open cavity.
5. Use the 36mm tube spanner to remove the cartridge from the manifold.
If this spanner is not available, the Gauge and MWP pressure transducers must be
removed to gain access for an adjustable spanner to be used.
7.9.5.2 Re-assembly
Be careful to retain the O-ring seal that sits in a groove on the outer end of the
Store in a safe place.

270
2. Smear a small amount of rubber grease on the cartridge valve seals.
3. Use the 36mm tube spanner to screw the new valve cartridge into the cavity, paying
The recommended tightening torque is 80Nm.

4. Place the new 24V DC solenoid over the valve spindle, ensuring the O-ring fitted at
the base of the spindle is seated correctly and the exposed end of the solenoid has a
recess groove showing.
The electrical connection should be orientated to 12 o’clock position.
Fit the outer O-ring over the valve spindle and into the solenoid recess.
5. Fit and hand tighten the solenoid retaining nut. The step in the nut should be facing
towards the solenoid.
6. Reattach the electrical connector to the solenoid after applying a small amount of
non-conductive grease (p/n 602590) to the connection.
8. Ensure any hoses that may have been loosened off to vent residual pressure have
been re-tightened.
#2 - NODES (DCi). DCi Node #23 should appear which includes the Rod Holder I/O
port 6.
Note: This valve does not have current monitoring. Its functionality will need to be
tested when the rig is running and when safe to do so.
12. To test connectivity without the Rod Holder opening, select R/H on the mode switch,
then ISOLATED on the Rod Holder selector switch.
Once pressed, an Amber light should illuminate on both the HMI screen next to Rod
Holder Solenoid port 6 and also on I/O module #23 port 6.
No mA value will be displayed on the HMI.

13. A ROD HOLDER ISOLATED! message should also flash on the screen.
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14. Reset the ROD HOLDER switch back to AUTO, and the warning message will
disappear.
The following check can only be done if there is no rod weight being supported by the Rod
Holder; otherwise uncontrolled rod string movement will occur.
15. Start the rig, select DRILL on the Mode switch.
16. Select ISOLATED on the Rod Holder selector switch.
Once pressed, an Amber light should illuminate on both the HMI screen next to
Rod Holder Solenoid port 6 and also on I/O module #23 port 6. No mA value will be
displayed.
The Rod holder should open as per normal.

17. The ROD HOLDER ISOLATED! message should flash on the screen.
18. Set the Mode switch to R/H, and the Rod Holder should stay open.
If not, the solenoid may have been fitted the wrong way around.
19. Reset the ROD HOLDER switch back to AUTO and ensure the Rod Holder shuts and
the warning message disappears.
20. Clean up any oil spills.
21. If used, fit the tube spanners back into the clamps or onto the retaining bolts provided
22. Fit the Front Cover back on the Pilot Hydraulics assembly and tighten the retaining
screws.
7.9.6 Replacing the Feed A (MFA) and Feed B (MFB)

Transducers
These two transducers are used to monitor the Feed and Holdback pressure generated
on both sides of the Feed cylinder. They are connected to the Feed A and Feed B ports
via 2mm test hoses.
272
7 8
2–27x30 A/F Tube Spanner 7–MFB Pressure Transducer

8–MFA Pressure Transducer
Figure 7–16: Fine Feed Manifold Pressure Transducers
Tools required
●● 11/16” A/F open ended spanner for hydraulic adaptor.
●● 27x30 tube spanner located in the Pilot Hydraulics assembly for the transducer body.
●● Rubber Grease for lubricating the hydraulic adaptor seal.
Note: Feed pressure can be retained in the Feed circuit even when the rig is switched
off. This can be seen on the Feed Pressure and Holdback Pressure gauges on the HMI if
power is available and the transducers are working correctly.
273
1. The Feed Frame should be in a horizontal position when changing these valves.
If that is not possible, the Rotation Unit should not be holding the rod string and the
carriage should be positioned at the lower end of feed travel so it can’t fall when
either sensor is removed.
This set-up also minimizes the risk of any air entering the system.
2. Place the DCi controls in neutral and stop the rig.
3. One of the OPERATIONS screens needs to be displayed to check for residual

pressure in Feed Pressure and Holdback Pressure gauges and Feed circuit.
If necessary, navigate to a relevant screen via the Main Menu and select
OPERATIONS. If there is pressure greater than 1-2 bar showing on either the
FEED PRESSURE or HOLDBACK PRESSURE gauges, this pressure needs to be
released. If you are confident there is no residual pressure present, go to step 8.
4. If pressure is present or you are unsure, navigate to the DIAGNOSTICS menu via
the MAIN MENU. Press the HYDRAULICS OVERRIDE function button, Hydraulics
Override Active should flash on the bottom of the screen. Hydraulics Override needs
to be active to vent any residual pressure trapped in the Feed circuit when the rig
hydraulics are not running. The ROTATION ON/OFF Green indicator light may also
flash.
5. Navigate back to the MAIN MENU, select OPERATIONS and a Rod Handling screen
will appear showing four gauges.
6. While pressing the Deadman switch on the Right joystick, move it back and forth to
vent the trapped pressure. The pressure should drop to 1-2 bar on both the FEED
and HOLDBACK gauges. If the PP7 pilot pressure has dropped off too much, the
pressure may not fully dissipate from the Fine Feed circuit, see further details below.
Removing the MFA or MFB test hoses at the manifold end with pressure in feed circuit
could result in an oil injection type injury.
7. If using the Feed joystick did not successfully remove residual pressure or a
transducer has failed, crack the Feed A and Feed B hoses in a convenient place to
vent any stored pressure, keeping in mind the note in step 1.
place. There is no need to remove these screws to remove the cover. If residual
pressure is still present in the Fine Feed circuit, remove the side cover from the Pilot
Hydraulics assembly adjacent the Gauge Selector.
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10. If using the Feed joystick did not successfully remove residual pressure, crack the
Feed A and Feed B hoses in a convenient place to vent any stored pressure, keeping
in mind the note in step 1.
11. Disconnect the electrical cable from the MFA or MFB sensor as required.
In the next step, keep the loose electrical connection away from any possible source
of oil contamination.
12. A slot has been provided in the Pilot Hydraulics assembly framework to allow access
from the bottom with an open end spanner.
Use the 11/16” or 3/4” spanner to remove the sensor and M/F adaptor from the
manifold. A straight adaptor should remain in the Fine Feed manifold.
13. Using the appropriate spanner, remove the 27x30 tube spanner from the support
clamp, and store loose parts in a safe place.
14. Remove the sensor from the attached hydraulic M/F adaptor using the 3/4” and
30mm end of the tube spanner, or an adjustable spanner.
7.9.6.2 Re-assembly
1. Check the hydraulic M/F adaptor removed from the sensor in step 14 above is in
good condition, otherwise replace.
2. Attach the hydraulic M/F adaptor onto the replacement sensor. Use a small amount
of Rubber grease or similar on the adaptor seal.
3. Attach the sensor and M/F adaptor onto the straight adaptor that remained in the
Fine Feed manifold.
4. Reattach the electrical connector to the MFA or MFB sensor after applying a small
amount of non-conductive grease (p/n 602590) to the electrical connection.
been re-tightened.
8. On the HMI, navigate to an OPERATIONS screen that shows the Feed and Holdback
Pressure gauges.
9. With controls in neutral and R/H mode selected, start the rig and check for leaks.
275
10. If a rod string is through the Chuck and Rod Holder (and it is safe to do so), select
PULL mode.
Using the Feed joystick to run the Chuck to the front of the Feed Frame over the rod
string and let the pressure build.
The Feed gauge should increase to the maximum Feed circuit pressure and the
Holdback gauge should drop to a low value, depending on tank back pressure.
Do not let the Chuck pass over the rear of a rod string otherwise a rod drop may occur.
11. If a rod string is through the Chuck and Rod Holder (and it is safe to do so), select
FEED mode.
Run the Chuck to the rear of the Feed Frame over the rod string and let pressure
build.
The Holdback pressure gauge should increase to the maximum Feed circuit
pressure.
12. If no pressure is showing on the Feed or Holdback Pressure gauge, navigate to Main
Menu  Diagnostic Menu  CAN #2 – NODES (DCi). DCi Node #23 should appear
which includes the Feed Pressure Sensor ‘MFA’, I/O port 1 and Holdback Pressure
Sensor ‘MFB’, I/O port 3.
13. There should be a 4–20mA value showing next to port 1 and 3 when the electrical
connections to both these transducers is healthy. 4mA should be expected when the
gauge is reading 0 bar, and the value will go higher as pressure increases.
retaining screws.
276
7.9.7 Replacing the GAUGE Transducer

2
2–27x30 A/F Tube Spanner 9–GAUGE Pressure Transducer
Figure 7–17: GAUGE Pressure Transducer
Tools required
●● 27x30 tube spanner located in the Pilot Hydraulics assembly for the transducer body.

1. Stop the rig then place the HYDRAULICS STOP/START switch in the mid position.
2. An OPERATIONS screen needs to be displayed to check for residual pressure in

Circuit Pressure gauge.
3. Ensure that PT2 is selected and check there is no pressure showing on the Gauge
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Pressure [Rotation] gauge.
The Rotation circuit is normally fitted with an open centre control spool so it does not
retain pressure when not operating or the rig is switched off. If there is any concern there
may be trapped pressure, crack the Rotation A or Rotation B hose in a convenient place to
check and vent pressure.
6. Disconnect the electrical cable from the Gauge sensor.
of oil contamination.
manifold. A straight adaptor should remain in the Fine Feed manifold.
7.9.7.2 Re-assembly
1. Check the hydraulic M/F adaptor removed from the sensor in step 9 above is in good
condition, otherwise replace.
Fine Feed manifold.
4. Reattach the electrical connector to the Gauge sensor after applying a small amount
of non-conductive grease (p/n 602590) to the electrical connection.
been re-tightened.
278
8. With controls in neutral and R/H mode selected, navigate to the OPERATIONS
screen which will show the four pressure gauges.
9. Start the rig and check for leaks.
10. Move the Rotation joystick forward. If a rod is loaded, the rotation circuit pressure
should build when the Chuck closes and tries to turn the rod with the Rod Holder still
closed.
11. If no pressure is showing on the Gauge Pressure (Rotation) gauge, navigate to Main
Menu  Diagnostic Menu  CAN #2 – NODES (DCi). DCi Node #23 should appear
which includes the Gauge Pressure Sensor ‘Gauge’, I/O port 5.
12. With pressure in the Rotation circuit, there should be a 4–20mA value showing next
to port 5 when the electrical connections to the Gauge transducer is healthy. 4mA
should be expected when the gauge is reading 0 bar, and the value will go higher as
pressure increases.
retaining screws.
7.9.8 Replacing the Water Pressure Transducer
Figure 7–18: Water Pressure Transducer
Tools required
279
●● 27x30 tube spanner located in the Pilot Hydraulics assembly for the IFM transducer
body.
●● 27mm A/F open ended spanner for the Hydac transducer body (early versions).

1. Stop the rig then place the HYDRAULICS STOP/START switch in the mid position.
Bleed off any pressure retained in the water pressure line using water pressure circuit
valves or by cracking a hose connection.
2. An OPERATIONS screen can be displayed to check for residual pressure in Water
Pressure gauge.
5. Disconnect the electrical cable from the Water Pressure Transducer (MWP).
of water contamination.
manifold. A straight adaptor should remain in the Fine Feed manifold. On earlier
versions, a 27mm open ended spanner.
On earlier DCi Units, a 27mm open ended spanner is required to remove the sensor.
280
7.9.8.2 Re-assembly
1. Check the hydraulic M/F adaptor removed from the sensor in step 8 above is in good
condition, otherwise replace.
Fine Feed manifold.
4. Reattach the electrical connector to the Gauge sensor after applying a small amount
of non-conductive grease (p/n 602590) to the electrical connection.
been re-tightened.
10. Ensure the Water Pump Speed variable control is in the OFF position, then select
REG on the Water Pump selector.
11. Increase the Water Pump Speed variable control to get a pressure registering in the
system.
12. If no pressure is showing on the Water Pressure gauge, navigate to Main Menu 
Diagnostic Menu  CAN #2 – NODES (DCi). DCi Node #23 should appear which
includes the Water Pressure Sensor ‘MWP’, I/O port 7.
13. With pressure in the water circuit, there should be a 4–20mA value showing next to
port 7 when the electrical connections to the Water Pressure transducer is healthy.
4mA should be expected when the gauge is reading 0 bar, and the value will go
higher as pressure increases.
15. Fit the Front Cover back on the Pilot Hydraulics assembly and tighten the retaining
screws.
281
7.10 Reduced Load Sense Pressure Assembly

Located in the LM hydraulic module is a Reduced Load Sense Pressure assembly that
limits load sense pressure in the forward Rotation circuit when making threads. The Feed
circuit will also have reduced load sense pressure when re-chucking and using the Soft
Touch function.
The manifold incorporates a shuttle valve that is used to send the Rotation or Feed load
sense signals (whichever is higher) to the pressure reducing valve.
The shuttle valve is accessed by removing the adaptor fitted in the top RMB port on the
manifold. A 6mm hex key is required to do this.
It should be noted that the solenoid-operated Pressure Reducing Valve allows the
highest load sense pressure when the current supplied is 0 Amps, and load sense
pressure reduces with an increase in current to the solenoid. The maximum current is
800mA. This is the opposite of normal practice, but increases the life expectancy of the
solenoid as it is not energized when drilling.
If this solenoid valve fails electrically, the drill will still work but load sense pressure will
be the maximum available in the circuit when there should be reduced pressure.
Two variants of the Pressure Reducing valve have been used. On early model valves,
the solenoid is held in place by 4 socket head capscrews. On later versions, the solenoid
is held in place by a single plastic nut. In both cases, the electrical connection stays the
same.
7.10.1 Replacing the Shuttle Valve in the LS Pressure

Reducing Manifold
Figure 7–19: LS Pressure Reducing Manifold Shuttle Valve
282
Tools required
●● 16mm A/F combination spanner for side cover and manifold M10 retaining bolts.
●● 17mm A/F combination spanner for side cover and manifold M10 retaining bolts.
●● 5/8” A/F combination spanner for hydraulic adaptor.
●● 9/16” JIC (#6) cap x 3
●● 9/16” JIC (#6) plug x 3
●● Rubber Grease for lubricating the shuttle valve and adaptor seal.

The load sense circuit vents when the electric motor stops.
2. Return the HYDRAULICS STOP/START switch to the mid position.
3. Loosen the two M10 bolts (16 A/F or 17 A/F) and remove the panel that covers the
plenum chamber and the two gauges on the side of the Power Pack. Store in a safe
place.
4. Depress the retaining clip and disconnect the electrical cable from the Load Sense
Pressure Reducing valve.
Place the connector away from the manifold to minimize the risk of damage.
5. Remove the hose from the side Tank port in the LS manifold, then plug and cap the
hose and fitting.
6. Remove the hose from the top RMB port in the LS manifold, then plug and cap the
hose and fitting.
7. Loosen the 90° elbow in the RMB port on top of the LS manifold.
8. Remove the hose from the bottom FMB port in the LS manifold, then plug and cap
283
the hose and fitting.
9. Remove the two M10 (16 A/F or 17 A/F) bolts holding the Reduced LS Pressure
Manifold and store in a safe place. The manifold will drop down.
Take care not to damage the fitting that is holding the accumulator in place.
10. Remove the elbow from the top RMB port.
11. Place the manifold in a vice (if possible) then use a 6mm hex key and remove the
shuttle valve out through the top RMB port on the manifold.
7.10.1.2 Re-assembly
1. Place a small amount of rubber grease on the Shuttle Valve seals.
2. Screw the shuttle valve into the LS manifold through the RMB port.
The recommended seating torque is 15Nm.

3. Refit the 90° elbow into the RMB port on top of the LS manifold and orientate it to an
angle that is similar to when it was originally fitted.
4. Remount the manifold onto the mounting bracket using the two M10 fasteners.
5. Refit the hoses to the FMB, RMB and Tank ports on the manifold.
The RMB hose comes from the Rotation section on the M4 valve and fits to the top
port fitted with an elbow on the manifold.
The FMB hose should come from the separate shuttle valve located lower on the
framework, or from the Feed section on the M4 valve located in the Hydraulic Module
on the earlier DCi version.
6. Tighten all fittings.
7. Re-attach the electrical connector to the solenoid after applying a small amount of
non-conductive grease (p/n 602590) to the connection.
DCi Control Panel.
11. The functionality of the shuttle valve for reduced Rotation pressure can be checked
by doing an Auto Rod Feeding sequence with a rod joint positioned between the
Chuck and Rod Holder.
The rod joint should make up at a value that is 25-40% of full circuit pressure,
depending on the rod size selected in the SET UP menu.
284
12. The functionality of the shuttle valve for Unattended Drill Re-chuck pressure can be
checked by doing an Auto re-chuck sequence.
The reverse Feed pressure should be limited to the P37 parameter value when the
carriage reaches the end of reverse travel (P37 default value: 50%).
The Soft Touch forward Feed pressure should be limited to the P66 parameter value
when the carriage reaches the end of forward travel (P66 default value: 40%).
7.10.2 Replacing the LS Manifold Pressure Reducing

Valve Solenoid
Figure 7–20: LS Manifold Pressure Reducing Valve Solenoid
Tools required
●● 3mm hex key for Solenoid retaining screws (early version only).
●● 16mm A/F combination spanner for side cover M10 retaining bolts.
●● Rags to clean up minor oil spills.

285
two gauges and plenum chamber on the side of the Power Pack.. Store in a safe
place.
4. Depress the retaining clip and disconnect the electrical cable from the Load Sense
Pressure Reducing valve.
Place the connector away from the manifold to minimize the risk of damage.
5. There are two types of solenoids used on this valve.
●● Type 1 solenoid
a. Remove the plastic nut retaining the solenoid onto the cartridge spindle.
b. Be careful to retain the O-ring seal that sit in a groove in the plastic nut. There is
also one at the base of the spindle.
c. Store loose items in a safe place.
a. To remove the solenoid, remove the four M4x70 retaining screws using a 3mm
hex key. A small amount of oil may dribble out the end of the valve body.
b. Ensure the O-ring at the end of the valve stays attached to the valve body.
7.10.2.2 Re-assembly
1. There are two types of solenoids used on this valve.
●● Type 1 solenoid;
a. Place the new 24V DC solenoid over the valve spindle, ensuring the O-ring fitted
at the base of the spindle is seated correctly. Fit the outer O-ring over the valve
spindle.
b. Fit and hand tighten the solenoid retaining nut. The small step in the nut should
be facing towards the solenoid. The electrical connection should be facing any
direction away from the side panel.
Note: The square plate that the four solenoid screws attach to is free to rotate until
the screws are tightened up after solenoid fitment.
a. Clean any oil residue from the end of the valve body and ensure the O-ring is still
in place.
b. Fit the replacement solenoid with the four M4x70 screws.
c. The electrical connection should be facing any direction away from the side
panel.
286
#2 - NODES (DCi). Select Node #22 which includes the Pressure Control I/O module
port 7.
6. The functionality of the solenoid for reduced Load Sense pressure can be checked by
moving the left Rotation Joystick forward with the deadman button pushed.
Both an input and feedback value should appear next to port 7. The two values
shown should be within 100mA.
An Amber light will also illuminate next to port 7 on the HMI and I/O module #22 port
7.
7. If the solenoid works for this functionality, it will also work for the reduced Feed
pressure functions.
8. Return all controls to the neutral position and start the rig.
9. Operate the Rotation and Soft Touch Feed controls and verify functionality is correct.
10. Fit the 27x30 A/F tube spanner back into the clamp or onto the retaining bolt provided
11. Fit the Side Cover back on the Power Pack assembly and tighten the retaining
screws.
287
7.10.3 Replacing the LS Manifold Pressure Reducing

Valve
Figure 7–21: LS Manifold Pressure Reducing Valve Solenoid
Tools required
●● 3mm hex key for Solenoid retaining screws (early version only).
●● 27x30mm A/F tube spanner (p/n 5305758), provided in the DCi Pilot Hydraulics
assembly or a 30mm socket for removing cartridge.

two gauges and plenum chamber on the side of the Power Pack. Store in a safe
place.
288

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Chapter 7: Maintaining the DCi System

Technical data 8 inputs (4 digital and 4 analogue/digital)

Housing Die-cast zinc housing with 8 outputs and terminal chamber

CR2032 Technical data

Connecting and operating elements

Hex-code switch coding

Operating states (LEDs)

CR2032 Characteristics of the inputs / outputs

Inputs ■ Digital inputs, with diagnostic capability

Test standards and regulations

Climatic test Damp heat to EN 60068-2-30, test Db

CAN Interface / Supply

7.5 Wireline Hoist Sensor

The direction of rotation is measured by signal movement:

●● An increasing signal indicates the cable is winding out.

7.5.1 Replacing the Wireline Hoist Sensor and Magnet

Figure 7–4: Wireline Hoist Sensor Replacement

7.5.1.1 Removal Procedure

Use anti-seize compound on the fastener thread.

Do not use RTV silicone sealant on electrical connections.

Retain the caps and plugs for future use.

10. When safe to do so, place the hoist in Freewheel mode.

12. Take the Hoist out of Freewheel mode.

16. Select WIRELINE Mode, the Wireline Screen will appear.

Figure 7–5: Wireline Screen

7.6 Water Pump Sensor

7.6.1 Replacing the Water Pump Sensor

●● 18mm spanner or socket for Hydraulic Motor mounting bolts.

Figure 7–6: Water Pump Sensor Replacement

7.6.1.1 Removal Procedure

using site specific maintenance procedures.

6. Disconnect the cable attached to the Water Pump Sensor.

Male M12 plugs are available in packs of 10 (p/n 5305921).

Do not use RTV silicone sealant on electrical connections.

Figure 7–7: PLC Inputs ST screen

Use anti-seize compound on the bolt threads.

7.7 Rotation Unit Sensor Assembly

7.7.1 Replacing the Rotation Unit Speed Sensor

Figure 7–8: Rotation Unit Speed Sensor Replacement

●● Two 17mm A/F spanners for sensor lock nuts.

●● M12 plastic caps and plugs.

7.7.1.1 Removal Procedure

The sensor should now be located close to its final position.

4. Reconnect the electrical cable after applying a small amount of nonconductive

Do not use RTV silicone sealant on electrical connections.

Retain the caps and plugs if used.

7.7.2 Replacing the Rod End Proximity Sensor

Figure 7–9: Rod End Proximity Sensor Replacement

●● 4mm hex key for sensor retaining screws.

●● Loctite 771 or equivalent anti-seize compound for fasteners.

7.7.2.1 Removal Procedure

Apply anti-seize compound to fastener threads.

Do not use RTV silicone sealant on electrical connections.

Retain caps and plugs if used.

7.8 Pilot Manifold Assembly

7.8.1 Replacing a Pressure Reducing Valve on the Pilot

1–Pilot Solenoids 2–27x30 A/F Tube Spanner 3–Pilot Manifold Block

Figure 7–10: Pilot Pressure Reducing Valves

●● 18mm A/F combination spanner for Tube Spanner retaining nut.

●● Non-conductive grease p/n 602590 for electrical connections.

●● Rubber Grease for lubricating the cartridge seals.

●● Side cutters for removing cable ties if necessary.

7.8.1.1 Removal Procedure

5. Clean up any oil that has leaked from the cavity.