Atlas Copco

Hole Navigation System

Training Manual

© Copyright 2014, Atlas Copco Rock Drills AB, Sweden Any unauthorized use or copying of the
contents or any part thereof is prohibited. This applies in particular to trademarks, model
denominations, part numbers and drawings

GPS Based Navigation System Training Manual, PMI NR: 9853 1289 01
1 DEFINITION OF THE SYSTEM.................................................................................3
1.1 NEW HARDWARE BROUGHT IN BY THE SYSTEM.................................................................. 3
1.2 NEW SENSORS BROUGHT IN THE SYSTEM.............................................................................. 5
1.3 PREPARATION FROM THE CUSTOMER...................................................................................... 7
2 GENERAL ABOUT HNS..............................................................................................8
2.1 WHAT IS GNSS........................................................................................................8
2.2 WHAT IS GPS...........................................................................................................8
2.3 GNSS AND OUR SYSTEM.............................................................................................................. 9
2.4 WHAT IS A COORDINATE SYSTEM.......................................................................................... 10
3 HNS USAGE.................................................................................................................13
3.1 WHAT IS ANMASK...............................................................................................13
3.2 DRILL PLAN IN LOCAL COORDINATES................................................................................... 15
3.3 ROC MANAGER / SURFACE MANAGER................................................................................ 16
3.4 PROBLEMS/ERRORS FOUND IN SATELLITE NAVIGATION SYSTEM................................20
4 ACTVIATION OF HNS..............................................................................................22
4.1 SETTINGS HNS.......................................................................................................22
4.2 SATELLITE SYMBOL..................................................................................................................... 22
5 START UP AND CALIBRATION.............................................................................23
5.1 STARTING UP THE SYSTEM........................................................................................................ 23
5.2 ACTION BEFORE CALIBRATION................................................................................................ 25
5.3 CALIBRATION OF THE SIGHT..................................................................................................... 26
5.4 CALIBRATION OF BOOM SWING............................................................................................... 26
5.5 CALIBRATION OF FEED TILT AND FEED TURN..................................................................... 26
5.6 CALIBRATION OF INCLINATION SENSOR (D175)....................................................27
5.7 HOW TO CALIBRATE BOOM LIFT AND BOOM EXTENSION............................................... 27
5.8 CALIBRATION OF BOOM LIFT AND BOOM EXTENSION FOR SMARTROC T35/T40. 28
5.9 CALIBRATION OF BOOM LIFT AND BOOM EXTENSION FOR SMARTROC T45........30
5.10 CALIBRATION OF BOOM LIFT FOR SMARTROC D65..............................................31
5.11 CALIBRATION OF FEED EXTENSION........................................................................................ 31
5.12 CHECKING AFTER CALIBRATION............................................................................................. 32
5.13 CALIBRATING THE COVERAGE AREA..................................................................................... 33
6 DRILL PLAN................................................................................................................35
6.1 LOAD DRILL PLAN........................................................................................................................ 35
6.2 SELECT HOLE................................................................................................................................. 36
6.3 QUALITY LOG................................................................................................................................ 38
7 TROUBLE SHOOTING..............................................................................................39
7.1 GPS QUALITY INDICATOR........................................................................................................ 39
7.2 HOLE NAVIGATION WARNING................................................................................................. 40
7.3 NO CONTACT WARNING............................................................................................................ 40
7.4 ANMASK WARNING................................................................................................................. 40
7.5 HYPERTERMINAL.......................................................................................................................... 41
8 DESCRIPTION OF ERROR......................................................................................43
8.1 BASE LINE ERROR........................................................................................................................ 43
8.2 BASE STATION COM ERROR..................................................................................................... 44
8.3 GPS SERIAL COM ERROR.......................................................................................................... 44
8.4 GPS SYSTEM ERROR................................................................................................................... 44
8.5 ANMASK SERIAL COM ERROR............................................................................................. 44

9 HOLE NAVIGATION STATUS INFORMATION..................................................45

1
10 ANMASK STATUS INFORMATION.......................................................................46

Appendix 1 – system structure

Appendix 2 – system layout
Appendix 3 – setting the node ID for sensors

2
1 Definition of the System
The hole navigation system, named in this context as the System, consists of the
following physical parts (hardware), apart from RCS:
- Base Station
- Moving Base Unit + Moving Base Antenna (receiver 1)
- Rover Unit + Rover Antenna (receiver 2)
- Radio Modem Unit + Radio Antenna
- Rig Inclinometer Sensor*
- Boom Swing Encoder Sensor
- Boom Lift Encoder Sensor*
- Boom Extension Encoder Sensor*
- Feed Extension Encoder Sensor*
- Feed Inclinometer Sensor
- Cradle Position Sensor
- Aim Device Angle Sensor
- ANMASK Display Unit
A detailed System structure can be found in Appendix 1.
*These are the extra sensors which come with the HNS system compared to a
standard SmartROC and are assembled and connected in the factory.

GPS Sensors and antennas

Assembled at a
fixed point
Radio
Base
1.1 New hardware brought in by the System
- One SPS 550 and one SPS851or two Leica MNS 1250
- Top GPS antenna at feed beam, from Trimble or Leica
- (Radio modem) could be used if customer has a mix between Trimble and
Leica at site
- Rear GPS antenna at rear of canopy, from Leica or Trimble
- Radio antenna at cabin roof
- USB converter box

3
1.1.1 Hardwear brought in by Trimble
For SPS X50:
- One SPS 85X
- One SPS 55X
- Two rugged Zephyr II antennas
- (Radio modem in Trimble moving base)

We have two receivers on the machine one called Moving Base or MBase. There are
today 4 versions of the same receiver available – SPS 850,851,852 and 855. They all
do the same thing and the only difference is the revisions.

The Moving base is connected to one satellite antenna mounted on the rear of the
canopy to the radio antenna on top of the cabin. Make sure the proper antenna is
mounted on the machine. There are one for 450Mhz radio and another one for 900
Mhz. The frequency can be found on a sticker on the base of the antenna.

The other receiver is called Rover and it is a Trimble. There are today at least 5
versions of the same receiver available – SPS 550,551,552,552H, and 555.

The Rover is attached to the satellite antenna mounted on the top of the feed.

We also have a Base Station if it is bought in with the machine which might be

a
Trimble SPS 850,851,852 or 855. It is the same type of receiver as the Moving Base
but they are NOT interchangeable. There are software differences in the receivers.
The system requires a Base station for the precision, and won’t work without. It is
possible to transform the machine mounted receiver to a base station with an option
code from Sitech for a fee.

The base station is connected to a satellite antenna and a radio antenna. The base
station receiver itself can be placed inside a shelter but the antennas must be on the
outside, the satellite antenna must have free view of the sky in 360 degrees. Make
sure that the proper radio antenna for your customers’ purpose is used. There is a
variety of radio antenna available.

There could be a situation where the customer already has a base station installed on
a construction site or in a mine site. It could happen in some occasions that the
internal radio modem in the Trimble Moving Base cannot read the signal from the
base station, i.e. if they use a Top Con brand base station. In that case it is possible to
mount an external modem (Satel) to the Moving Base and then access the base
station. Always check with the site surveyor department about the type of base
station situation.

1.1.2 Hardwear brought in by Leica

- Two MNS 1250
- Two GPS antennas
- Radio modem

4
1.2 New sensors brought in the System
- Sensor for rig inclination
- Sensor for boom lift movement
- Sensor for boom extension movement (N/A for SmartROC D65)
- Sensor for feed extension movement

On all of our RCS machines there already are a boom swing sensor and a feed
inclination sensor. These are used by the HNS as well. The four extra sensors
mentioned above are extra sensors which are mounted on the machine when HNS is
installed.

A rig inclination sensor is mounted on the boom pillar console.

A boom lift sensor, mounted on the outside of the boom on single boom machines
and on the inside on folding boom machines.
On machines with folding boom there is a boom extension sensor mounted in the
joint between the booms.
The last sensor is the feed extension sensor mounted on top of the feed holder
bracket.

1.2.1 Purpose of the sensors

The purpose of the sensors is to make the machine able to keep track if there appears
a problem with the satellite receivers. We can check so the receivers are OK with the
help of the sensors and what is called a link model.

1.2.2 Link model

A link model is something we have in the RCS software (see Fig.1). It is a way of
telling the machine the distance between the satellite antennas. We also use the link
model to tell the system where the drill bit is in reference to the feed antenna.

There are 10 links going from the rear antenna to the top antenna on the feed telling
the X, Y and Z distances. There are also 4 links available together with length
encoder, telling the X, Y and Z distances from the feed antenna to the drill bit.

On SmartROC T35-45, if the starter rod is 12” but replaced with a 14”, the distance
is changed and L11 needs adjustment. That is why the starter rod length is settable in
the RCS, so no manual adjustment of the link model is necessary just because of rod
length change. However, in the case of SmartROC D65 and former SmartRig
D7C/D9C/F9C, the distance of L11 needs to be adjusted manually if the starter rod
were to be changed.

5
Fig. 1: link model

The 10 links together with the sensors gives the machine the information it needs to
be able to calculate a baseline (the distance between the two rig mounted antennas in
a straight line measured by the GPS receivers), the calculated baseline is then
compared with the range (see Fig. 2). The range being the same distance but
calculated from the position received on the satellite antennas. If the difference is
greater than 10 cm, the warning for “Base line error” pops up in the RCS display in
the cabin.

The problem is most often due to the poor calibration of the sensors. The calibration
of the sensors has to be done with precision. A digital level is required. The digital
level itself being calibrated correctly, read manual of digital level on how to
calibrate. Refer to chapter 5 for instructions on sensor calibrations.

Fig. 2: Hole Navigation Status Information menu

6
1.3 Preparation from the customer
The sensors are provide and mounted from our side but the customer still needs to
acquire certain components for the System to work. Before proceeding with any
work, make sure the customer has done the following:
- The customer must buy hardware mentioned in paragraph 1.1 locally.
- The customer must have a base station with radio coverage in the
attended drilling area.
- The customer must have a local coordinate system to download into the
receivers, which is normally created and done by the Trimble or Leica
representative.
- The customer must have a computer that can handle PMCIAA/USB if they
are to use ROC Manager/Surface Manager.
- The customer must have a computer that handles Windows XP and above in
order to handle ROC Manager/Surface Manager.

7
2 General about HNS
The hole navigation system, i.e. the System (referred in the context below), consists
of a number of parts that work together in order to obtain full accuracy at the position
of the drill bit by using the Global Navigation Satellite System (often shortened to
GNSS) and a correcting Base Station.

If any part of the System does not work as it should then full accuracy is not
obtained. RCS monitors System status and indicates this in different ways, which are
described later in the chapters.

The System, together with the guidance of the GNSS navigation tools, shows to the
operator where the holes are to be drilled. The operator still needs to tram and find
the holes manually. The system also has a very useful function that provides the
possibility to document exactly where the holes are drilled. This is needed on some
markets due to government reasons.

2.1 What is GNSS

There are currently three types of GNSS:
- GPS: Most commonly known, developed by the US air force.
- GLONASS: Developed and run by Russia.
- Galileo: Europe’s new system, not in operation yet.

The System at the rig can handle both the GPS and GLONASS systems. Make sure
that the Trimble/Leica dealer activates both systems. We need them both.

2.2 What is GPS

GPS has become an indispensable tool for navigation, map making and land
surveying since its initial launch in 1978. There are today more than two dozen GPS
satellites in Medium Earth orbit. These satellites transmit signals to the GNSS
receivers allowing their location, speed and direction to be determined.

How it works?
A GPS receiver calculates its position by measuring the distance between itself and
1 three or more GPS satellites. Measuring the time delay between transmission and
“Global Positioning System.” New World Encyclopedia. Web. 22 Jan. 2014.
reception of each GPS radio signal gives the distance to each satellite, since the
<http://www.newworldencyclopedia.org/entry/Global_Positioning_System>.
signal travels at a known speed. The signals also carry information about the
satellites' location. By determining the position of, and distance to, at least three
satellites, the receiver can compute its position using trilateration, or the
determination of a distance from three points. Receivers typically do not have
perfectly accurate clocks and therefore track one or more additional satellites to
correct the receiver's clock error.1

8
 In order to pinpoint a location, triangulation method (where angle measurement is
also taken into consideration) is used and is a really simple way to determine where
the satellite antennas are. We can use the same way of calculating to find a cell
phone or a radio transmitter. To find the position we need 3 satellites but for altitude
we need at least 4 satellites.

2.3 GNSS and our system

In our solution we offer an accuracy of less than 10 centimeters (4 in). In order to
achieve this high accuracy, we need to correct the bit positions with the aid of a local
base station which has a fixed GPS location. This is when the radio modem unit and
the radio antenna come into the picture.

We always use local coordinates with our system. The local coordinate system is
made locally by Trimble/Leica or the customer, and it is of course linked to the
world coordinate system WSG84.

2.3.1 Why base station

The base station is placed within the coordinate system and serves as a reference
position for the rig to correct its positions, also known as RTK (real time kinematic)
fix. The base station is comprised basically of a GPS receiver and a radio unit,
however the base station has to be placed on a fixed location without being moved
around during the entire operation.

2.3.2 How does a base station work?

The base station should be placed somewhere within 2000m of the machine, in good
conditions without too much obstacles such as buildings, trees, mountains blocking
the signal. The maximum range is 2400m.

The working principle is that during operation, the base station is sending out RTK
data to the radio modem on the rig in order to correct the bit’s position by adjusting
the carrier phase frequency sent from the satellites. In order words, by knowing the
carrier phase offset, the GPS positions of the drill bits can be corrected against the
reference coordinates of the base station no matter how the rig is moved.

9
2.4 What is a Coordinate system
Coordinate system is a very important term in the world of positioning measurement.
To choose the right coordinate system is crucial for achieving the right measurement
results.

You may picture the coordinate system as a grid, we put this grid over the earth, then
we flatten it out because we do not need nor want a curved grid. We do not want to
take the earth’s curve into consideration when we build a house or make a ditch, or a
pipe burial.

Source: Bram.us Homepage.

http://www.bram.us/2012/03/14/convert-lambert72-to-wgs84/

In principle there are two types of coordinate system:

- Local coordinate system
- Known coordinate system

2.4.1 Local coordinate system

The local coordinate system made locally by Trimble/Leica or the customer. This
coordinate system provides us a platform where we can build our drill plan for the
job site.

This is a crucial step in the whole working picture. If this coordinate system is
not calibrated correctly, it will not give the correct positions of the holes when
this coordinate system is plotted onto the world coordinate system.

It is of crucial importance that the local coordinate system is measured with adequate
amount of reference points (at least 5). A common mistake is that the local site is
measured with scarce number of points close to each other, which gives poor
precision of the site which drilling is to take place. This will pose a potential issue
when plotting in the site into the known coordinate system.

1
2.4.2 Known coordinate system
There are several well-recognized coordinate system, but the system which we work
with is the international coordinate system which all GPS receivers use –WGS84.

2.4.3 Altitude
What iscalculation
WGS84?
The
Theillustration belowSystem
World Geodetic shows the height
1984 relation
(WGS84) of adatum
is the measurement
used by point. The GPS
the Global
receivers measure
Positioning only
System the height
(GPS). to theisWGS84
The datum definedellipsoid, to recalculate
and maintained the ellipsoid
by the United
height to the actual orthometric height, a geoid model is needed in order
States National Geospatial-Intelligence Agency (NGA). Coordinates computed to provide
this
frominformation.
GPS receivers are likely to be provided in terms of the WGS84 datum and the
heights in terms of the WGS84 ellipsoid.2

Source: The University of Oklahoma Homepage.

http://principles.ou.edu/earth_figure_gravity/geoid/

On most commercial GPS receivers the height displayed is the calculated

orthometric height based on the data in the receiver’s firmware (geoid model). A
commonly used geoid model in Sweden is called RH2000.

2
“World Geodetic System 1984 (WGS84)” Land Information New Zealand. Web. 24 Jan.
2014. < http://www.linz.govt.nz/geodetic/datums-projections-heights/geodetic-
datums/world-geodetic-system-1984>.

11
2.4.4 Local coordinate system vs WGS84
In the figure below we can see the division of SWEREF 99, a known coordinate
system which confronts with the WGS84 system. The local coordinate system
provided by the customer or Trimble/Leica is seen as the “patch”. The more
reference points the surveyor takes the better precision it will be for the “patch” to
be fitted onto the known coordinate system. However it is recommended to take at
least 5 reference points to ensure a good precision.

The whole idea behind identifying the “patch” is to make sure that the local
coordinate system provided by the customer or Trimble/Leica will confront with
the known coordinate system with as little precision deviations as possible. The
“patch”, in most cases, also contains much more detailed information than what is
covered in SWEREF 99.

The “patch”

The positioning of this “patch” also plays an important role when it comes creating a
drill plan. Once the local coordinates has been entered into the System, this is the
“map” which our System will work with. All the holes we have planned will then fall
onto this local coordinate system (see paragraph 3.3.2 for more details).

If the local coordinate system has got the wrong positions or wrong tilt (also known
as an incline plane) which does not confront with the WGS84 system, which could
be caused by a number of factors, all the holes that will be drilled will also all have
the same deviations. This is a common mistake we have seen throughout the years
where the planned holes are not drilled as desired.

1
3 HNS usage
The System can be used in two ways:
1. Drilling without drill plan in local coordinates with 3rd party system, e.g.
ANMASK (Road constructions)
2. Drilling with drill plan in local coordinates (Quarries, mines)

3.1 What is ANMASK

ANMASK is an aid commonly used in Norway and also in Sweden for major road
construction projects. ANMASK is developed by MESTA A/S in Norway, with
Vägverket Produktion in Sweden as a partner. Currently ANMASK is used in most
of the major road construction projects in Norway, and in Sweden too.

In the case of ANMASK, the drill rig’s control system communicates with
ANMASK so that the control system continuously advises of the drill bit’s position
in the XYZ axis, and ANMASK replies with the current hole depth and applicable
angles for current drill bit position. There are number codes shown at the bottom
edge of the drill rig display to help the operator ascertain the rig's current position on
the road profile. Consequently, no drill plan handling is used but the operator still
marks the holes in the rock manually, and then drills according to that pattern. The
major advantage is the very high degree of accuracy that is achieved since the drill
rig always knows the precise hole depth at each point, which leads to level hole
bottoms and accordingly higher quality mining.

When using ANMASK an extra screen is used, it is assembled on top of the RCS
screen. Information about the road model and different settings for ANMASK is
done in this screen with a keyboard by the customer. We only monitor the
information from ANMASK into the RCS screen. For use of ANMASK the
ANMASK must be tapped in menu F2 settings 2.

By knowing the codes (see dotted area below) in the ANMASK system presented in
menu F4 the operator can see where on the road model he/she is.

13
 Codes

For information about the codes refer to ANMASK instruction (only in Norwegian).

1
3.2 Drill plan in local coordinates
When drilling in quarries the extra computer where ANMASK is normally run is not
in place. Instead the drill plan handling in the rig is used to assist with accurate
navigation. As mentioned earlier, the drill plan which will be implemented into the
System, is dependent on the local coordinate system. The drill plan itself is made in
the local coordinate system in a software outside the rig, e.g. Roc Manager. The drill
plan must be supplied in the IREDES format as this format is the only one the drill
rig recognizes and can interpret.

Once the drill plan is transferred to the rig, the operator selects a hole in the drill
plan, and a three-part interface assists the operator to navigate to the predetermined
position in the rock. In this case there is no need at all for any marking of the rock by
the operator, which means that time is saved, and there is also the opportunity to drill
more holes in this way during one shift.

In addition, in both cases (ANMASK or drill plan handling) a very good

parallelity between the holes is achieved because of the very precise injection
angle that is set for each hole.

Figure: ROC Manager 3.0

15
3.3 ROC Manager / Surface Manager
3.3.1 Purpose of both software
Both software are stand-alone PC based tool for the following purposes:
- Planning and making of drill patterns (ROC Manager only)
- Drill pattern conversions (Surface Manager only)
- Presentation of drilling data such as:
 Hole deviation compared to planned holes
 MWD (Measuring While Drilling) data
 Performance results
- Reports
- Advanced MWD analysis (option)

We have the possibility of using two different programs for handling of data from
our machines, one is called ROC manager and it is the first program that is used for
making drill plans. We have had some variations on the program but the latest is
called 3.0.

There is also a program called Surface Manager, a name which we have had on ROC
Manager for some time but was never officially released.

The two programs should not be mixed up since ROC Manager is more used on the
entrepreneur side and maybe mostly used on those who want to make a rectangular
drill plan. Whereas Surface Manager is more used on mine industries, with new
functions such as server functionalities, new layout for showing turn-outs, what the
machine is doing during the time. It is not possible to create drill plans in Surface
Manager, but the program itself has an in-built conversion program which allows the
user to take for example a CSV file and convert it to a IREDES.xml file which can
be read in our machine. In order words, Surface Manager can be regarded more as of
a statistical program for planning.

Figure: Surface Manager

1
3.3.2 How Roc Manager works
Once the drill plan is created and transferred to the rig via USB (refer to detailed
instructions in chapter 6.1), the operator will need to select a hole in the drill plan to
start the navigation in order to guide the rig to the correct drilling location.
Remember that the drill plan is created on a flat surface, so ground unevenness needs
to be compensated through system calculations.

It is important to remember that we are always drilling

against elevation, not desired hole depth/length. This is
simply due to the fact that in order to reach an even
hole bottom, holes will need to be drilled at different
length due to varying terrain.

When the local coordinate system is made, the

surveyor measures points or monuments where a
known coordinate system is then attached. The drill
plan which we create in ROC Manager/Surface
Manager is done on a flat plane, and it will be “laid
out” flat onto the local coordinate system. However,
the drill plan that needs to be laid out has to have a
reference hole on the local coordinate system in order
to locate the drill plan level in relation to the terrain
(see Fig. 2). This is done by entering the precise
positions of a reference hole in ROC Fig. 1: Setting the reference hole
Manager/Surface Manager when creating the drill in ROC Manager 3.0
plan (see Fig. 1).

planned holes done through ROC Manager actual holes to be drilled / hole start point extra distance to be drilled above drill pl

reference hole sets the drill plan level

drill plan level

terrain

hole bottom
Fig. 2: Planned holes vs. actual holes

The rig during operation will have to be moved to different elevations on this local
coordinate, having to be placed either above or below the drill plan level.

17
Once the reference hole is defined, the position
of a second hole also needs to be defined in
order to determine the blasting direction of the
site. This is done by entering the position of the
second hole and also choosing a left/right hand
system (see figure right).

The target height we have entered in ROC

Manager is the absolute height that the bottom
of the holes should be on. With the help of
GPS position readings, the System will
calculate exactly how much more or less in
distance, the rig needs to be drill using the drill
plan level reference. If drilling is to be at an
angle, the System will also calculate the angle
projection of the hole hence guiding the
operator to position the feed/boom to the
correct positions. Figure: Setting the blast direction
in Surface Manager 3.0

Coverage area

Hole bottom

Calculated hole start

Drill bit

Figure: HNS fine navigation menu seen from the rig

1
Once the rig is positioned within the coverage area, the Feed Alignment Menu
further guides the operator to re-position the boom/feeder to the calculated hole start
position.

Customer case:
Cement industry
 AutoPOS together with Hole Navigation System.
 Saving up to 30% in explosives.
 40% less secondary crushing.
This customer is saving a lot of time and money by using
our SmartROC advanced features!

19
3.4 Problems/errors found in satellite navigation system
One common problem on site with new machines is how the existing system is set
up, or calibrated. The coordinate system in use is something that requires calibration
to the site and in many cases elevation problems were found so the issue is not in the
machine, but many times due to the calibration of the site.

When calibrating a site the surveyor measures points or monuments where the
coordinate system is then attached (see Fig. 1). If these are not surveyed properly
they will get what is called an incline plane (see Fig. 2), meaning that the system
will drop of the longer you get from the origin of the systems points.

Fig. 1: Correct surveying when the Fig. 2: Wrong surveying when the coordinate
coordinate system is attached system is attached causing an incline plane

And if the holes planned in the ROC Manager are plotted onto a wrongly calibrated
local coordinate system (see Fig. 3), the System will believe that the rig is situated at
a higher position (point A) or a lower position (point B) than the actual correct
positions (see blue points). These misconceptions will cause the rig to drill more (at
point A) or less (at point B) compared to a correct plotting, thus resulting in a tilted
hole bottom compared to the original plan.

A
planned holes done through ROC Manager
actual hole start positions in a correct local coordinate system hole start positions in a

reference hole sets the drill plan level

drill plan level

B
terrain

hole bottom
Fig. 3: Correct local coordinate system vs wrong local coordinate system

Receivers found outside the chosen coordinate system will get the result of no
position in the machine. Every value seen in the Hole Navigation Status field can
show OK but the bit position is not (Trimble). The Leica receivers are showing no

2
coordinates what so ever in the same case. Check what coordinate system is in the
receivers and what system the site uses. If it is one man one machine that does not
have to take anybody else into consideration, use a system that covers the area he is
using. The Swedish systems RT90 or SWEREF 99, covers the country but is
available in different zones.

The receivers cannot hold the entire geoid for the whole country but for instance a
RT90 2,5 gon west will work all over the place but the accuracy will not be good
enough.

21
4 Actviation of HNS
4.1 Settings HNS
On a rig equipped with HNS the HNS system is activated from the start. It can then
be deactivated/activated in the Rig Options menu.

Figure: Settings with Hole Navigation selected

The following settings apply so that drill plan handling shall work:
 Use Drillplan Must be selected for drill plan handling to work.
 Local coord. drillplan Must be selected to enable drilling in a local coordinate
system. This is the most common system we drill in.
 Auto hole selection If this is selected the system will suggest a new hole for
the operator when the drill bit is within “auto hole radius”. It is confirmed by the
operator with Reset button on the right-hand lever for the suggested hole to be
selected. This function minimises keystrokes in the drill plan menu.
 Auto hole radius When the drill bit is within the selected distance from a
hole the system suggests the hole as next. Must be confirmed by the operator
with Reset button on the right-hand lever.
4.2 Satellite symbol
The satellite symbol shows the status of the satellite contact.
 Grey: System not OK, a second warning is probably also shown in the status bar.
 Yellow: System OK, but inadequate contact with satellite. This means that
full accuracy will not be attained.
 Green: System OK.

2
5 Start up and Calibration
5.1 Starting up the system
5.1.1 Switching on the ignition/RCS system
 Check that the fuse for the HNS system is not tripped, e.g. F27 for SmartROC
T35/T40/T45/C50.
 Switch on the ignition
 Switch on the RCS system (in earlier SmartRig models, the RCS system has to be
started separately using a button on the power board)
 Check that the radio modem is energized.
 Check that all CAN sensors are energized and that the CAN communication
is running, i.e. no sensors should be marked red in the menu.

Figure: CAN module menu

23
  Check that the GPS serial communication is working (the status should change
from Failure to OK in the menu below.

Figure: Hole Navigation Status Information menu

5.1.2 Switching off the ignition/RCS system

 Switch off the ignition
 Switch off the RCS system (in earlier SmartRig models, the RCS system has
to be switched off separately using a button on the power board)
 Check that the radio modem and GPS communication are shut down

2
5.2 Action before calibration
5.2.1 Checking the angle area for boom lift
 Check the angle area for boom lift by positioning boom lift to its end
positions and reading the boom lift value in the Calibration menu. (see Fig. 1)
 Check that the raw value for boom lift does not pass 0 (zero) in the angle area.
 Check that the angle value decreases when the boom is raised.
 If the raw value 0 (zero) is within the angle area for boom lift then the sensor’s
axis must be turned 180° (a half turn).

Sensor value Raw value Calibrate Offset

Fig. 1: Calibration menu at AC level

5.2.2 Checking the angle area for boom extension

 Check the angle area for boom extension by positioning boom extension to its
end positions and reading the boom extension value in the Calibration menu. (see
Fig. 1)
 Check that the raw value for boom extension does not pass 0 (zero) in the
angle area.
 Check that the angle value decreases when the boom is extended.
 If the raw value 0 (zero) is within the angle area for boom extension then the
sensor’s axis must be turned 180° (a half turn).

25
5.3 Calibration of the sight
 Place a set square against the inside of the windscreen as per below.
 Turn the sight straight forward in the rig’s direction so that the sight’s cage is
in line with the set square.
 Calibrate the sight to 0.0° by pressing the calibrate button for the sight in the
Calibration menu.

windscreen

5.4 Calibration of boom swing

 For Volvo cabin:
Set the boom swing straight forward in the longitudinal direction of the
rig (measure with a roll-up measuring tape between boom swing and cab
until parallelity is achieved).
 For Bosal cabin:
Use the boom pillar to make sure the alignment is right. Use the digital spirit
level put it against the pillar and measure towards the boom making sure it
is straight.
 Calibrate boom swing to 0 (zero) by pressing the calibrate button for boom
swing in the Calibration menu.

5.5 Calibration of feed tilt and feed turn

 Set the feeder in vertical position (see Figure right)
by positioning the feed tilt and feed turn to vertical
position 0° using the electronic spirit level.
 Calibrate feed turn and feed tilt to 0 (zero) by
pressing the calibration buttons for feed turn and
feed tilt respectively in the Calibration menu.

2
5.6 Calibration of inclination sensor (D175)
 Position the rig on a level surface.
 Make sure that the boom system is positioned in the rig’s longitudinal direction
(boom swing in center position) and that the sight is aligned straight forward
(i.e. the sensor value for boom swing and sight should show 0° in the Calibration
menu).
 Use track oscillation with open track oscillation lock and the boom system to
adjust the rig horizontally.
 Chassis, side inclination should be: 0° ± 1.5°
 Chassis, tilt inclination should be: 0° ± 0.15°
 Lock track oscillation.
 To calibrate, press the calibration button in the Calibration menu.

5.7 How to calibrate boom lift and boom extension

 Go toNote:
menu System/Sensors/Positioning. (see Figure below)
 Manual
Theoffset needed:
following Enterfor
applies thesubsequent
measured value/calculated
calibration: calibration value (see
point5.8Boom
& 5.9)swing
for boom
must not be moved from its zero position. in the offset
lift (only for T45) and boom extension
box.  The sight must not be moved from its zero position.
 Activate the button for calibration.
 Rig inclination must be horizontal (zero).
 Check that the current sensor value is the same as the value entered into the offset
box.

Sensor valueRaw value CalibrateOffset

Figure: Calibration menu

During the calibration of other sensors (apart from boom lift on T45 and boom
extension), there is no need for the offset value to be entered, but instead the
sensor is calibrated automatically to a value of zero when the calibration button
for each respective sensor is activated.

27
5 Calibration of boom lift and
extension for SmartROC T35/T40

 Prior
Align theto electronic
carryingspiritout
levelany
on
the inner boom in accordance
calibration work, make sure the with
Fig. 1. (Note:
electronic Makelevel
spirit sure that
is the
itself
spirit level is set in degrees)
 Set the inner boom in horizontal
position and maneuver the inner Fig. 1
boom to the position where the
spirit level shows 0 (zero) degrees.
 Calibrate boom lift to 0 (zero)
degrees in accordance with
Point Error! Reference source
not found..

 Align the electronic spirit level on

the outer boom in accordance with
Fig. 2 – outer boom fully
extended.
 Read the inclination of the outer
Fig. 2
boom in degrees.
 Measured value:
 Calibrate boom extend to the
measured value by entering the measured value as offset, in accordance with
Point Error! Reference source not found..

For example, if the measured value is 21.4°, enter the value, then push the Offset
button.

2
Figure: Boom extension calibrated

2
5 Calibration of boom lift and
extension for SmartROC T45

 Prior
Align theto electronic
carryingspirit
outlevelany
on
calibration work,
the inner boom make sure with
in accordance the
electronic
Fig.1. (Note:spirit
Makelevel is the
sure that itself
spirit level is set in degrees).
 Read the inclination of the Fig. 1
inner boom in degrees.
 Measured value:
Note! This angle is a negative angle,
which must be calibrated in with a
minus sign in front of the measured
value!
 Calibrate boom lift to the measured
value by entering the measured
value as offset, but with the minus
sign in front in accordance with
Point Error! Reference source not
found.. Fig. 2

 Align the electronic spirit level on the outer boom in accordance with Fig. 2 –
outer boom fully extended.
 Read the inclination of the outer boom in degrees.
 Measured value:
 Calculate the calibration value for boom extension:
Calibration value = boom extension measurement value + boom lift sensor value
(without minus sign)
Calibration value = + =
 Calibrate boom extension to the calculated value by entering the calculation
result as offset, in accordance with Point Error! Reference source not found..

3
5.10 Calibration of boom lift for SmartROC D65

 Prior
Align theto electronic
carryingspirit
outlevelany
on
the front part
calibration of themake
work, boomsure
(see the
yellow line)spirit
electronic in accordance
level iswith
itself
Fig.
1. (Note: Make sure that the spirit
level is set in degrees)
 Set the boom in horizontal position Fig. 1
and maneuver the boom to the
position where the spirit level
shows 0 (zero) degrees.
 Calibrate boom lift to 0 (zero)
degrees in accordance with Point Error! Reference source not found..

5.11 Calibration of feed extension

 Fully retract feed extension cylinder
(see Fig. 2).
 Calibrate feed extension to 0 (zero)
in this position by pressing the
calibrate button for feed extension in
the Calibration menu.

Fig. 2

3
5.12 Checking after calibration
 Go into the menu “Hole Navigation Status Information”.
 Check that the values for Range and Calc Baseline correspond with each other
(see Fig. 2). The value may differ by ± 10 cm.

Fig. 2: Hole Navigation Status Information menu

3
5.13 Calibrating the coverage area
 Check that the rig is still in horizontal position (the inclination sensor should
show 0 (zero) in menu “Hole Navigation Status Information”, and that the track
oscillation is locked.
 Activate drilling position.

Note! The following applies for subsequent calibration points in this chapter.

 The feeder must be in vertical position

 Feed extension must be in position 0 (zero position) (see Point 5.10)

 Position the boom system max. left and as far forward as possible (Fig.1).

 Go into the menu “Calibration coverage area” and press box 1 (Fig.7).

 Position the boom system straight forward and as far forward as possible (Fig. 2).

 Press box 2 in the Calibration menu (Fig. 7).

 Position the boom system max. right and as far forward as possible (Fig. 3).

 Press box 3 in the Calibration menu (Fig. 7).

 Position the boom system max. right and as close to the rig as possible (Fig. 4).

 Press box 4 in the Calibration menu (Fig. 7).

 Position the boom system straight forward and as close to the rig as possible
(Fig. 5).

 Press box 5 in the Calibration menu (Fig. 7).

 Position the boom system max. left and as close to the rig as possible (Fig. 6).

 Press box 6 in the Calibration menu (Fig. 7).

Now the boom system’s coverage area can be seen on the screen. This area is used in
the fine navigation menu for viewing which holes can be reached from the current
position.

3
Fig. 1:boom out max left Fig. 2: boom out middle position

Fig. 3: boom out max right Fig. 4: boom in max right

Fig. 5: boom in middle position Fig. 6: boom in max left

Fig. 7

3
6 Drill plan
6.1 Load drill plan
A USB memory stick with the drill plan produced in ROC Manager/Surface
Manager (SM) is inserted into the rig’s USB socket on the right-hand post by the
display. Drill plans are downloaded from the Drillplan menu or from the Data
menu.

Figure: Drill plan menu

 From the Angle Indication menu, select Drillplan. Go to Load drillplan,

confirm with Enter.
 Select drill plan and confirm with Enter. When Load Ok is shown on the display
 screen, acknowledge this with the ESC key three times.

Menu information:
 DrillPlan Name : Name of drill plan
 DrillPlan Id : Drill plan’s ID.
 Blast Direction : The injection direction selected in SM.
 HoleName : Number of hole.
 Status : Shows whether the hole is undrilled, drilled manually or in Auto mode.
 Drillbit diameter : Diameter of hole from start coordinate to final plane.
 Hole length : The depth of the hole. (Selected in SM)
 Hole spacing : The distance between holes. (Selected in SM)
 Burden : Distance between rows in the drill plan. (Selected in SM)
 Hole angle : The angle of the hole. (Selected in SM)
 Side angle : The side angle of the hole. (Selected in SM)

3
6.2 Select hole

Figure: Drillplan menu

Go to the Drillplan menu. Choose the first hole to drill by selecting the hole and
pressing Enter.

Set the feeder angles and make sure that the bars are green with the semi-
autopositioning button in combination with the boom levers. The drill bit then has
the correct coordinates.

Return to the Angle Indication menu and the selected angles from SM are presented
together with bars on the side with drill bit location in relation to the selected
coordinates for the hole in question.

3
Figure: Menu Angle Indication

Reset the depth meter on rock contact. Now hole length is presented for the selected
final plan in the local coordinate system. Start drilling. The rig will stop drilling
when the correct final plan is attained.

After drilling a hole the next is selected manually or automatically. Repeat as above.

When the drill plan has been drilled everything must be saved for retrieval in the
event of changes to the original. To save, select Save drillplan in the Data menu and
confirm with Enter.

3
6.3 Quality log
In addition, save a quality log for retrieval with all facts on the completed drill plan.

Figure: Data menu

 Select Save quality log

 Remove the USB memory stick and import the information into SM in
accordance with the instructions for SM.

3
7 Trouble shooting
7.1 GPS Quality Indicator
The GPS Quality Indicator symbol is permanently located in the information box in
the F4 direct menu. The GPS Quality Indicator indicates the degree of accuracy that
the System has and that the System is intact. The GPS Quality Indicator is shown in
three different colours, green, yellow and grey (background colour). The meaning of
the colours is as follows:
Green symbol
System intact, full accuracy.

Yellow symbol
System intact, not full accuracy.
This is probably due to external circumstances, e.g. poor satellite coverage, poor
satellite geometry (high DOP value)

What
Grey is DOP?
symbol
DOP (Dilution
System not intact.of Precision) is a quality indicator for the GPS signal, if we
Inhave our satellites
this state in a cluster
an information for instance
warning will alsowe
be will get giving
present a high DOP value,
a reason for the state.
but we want them to be scattered across the sky for more precise
positioning.
DOP values will differ and we see values up to 5 with no problems,

3
7.2 Hole Navigation Warning
The Hole Navigation Warning symbol is a yellow warning that is shown in the status
box in the event of an error in the System. When the error arises, a message box is
shown on the screen with an error text. This error text is also entered into the event
log. The cause of the error can be deduced using this information and the information
in the Hole Navigation Status Information menu. The error could be one of the
following:
- Base Line Error
- Base Station Com Error
- GPS Serial Com Error
- GPS System Error

7.3 No Contact Warning

The No Contact Warning symbol is a yellow warning that is shown in the status box
when CAN communication with a module in RCS has stopped working. This is
checked by activating the Module Info menu where more detailed information is
received as to which module has an error indication. The following errors that affect
the System are indicated with No Contact Warning:
- Rig Inclinometer Sensor Com Error
- Boom Swing Encoder Sensor Com Error
- Boom Lift Encoder Sensor Com Error
- Boom Extension Encoder Sensor Com Error
- Feed Inclinometer Sensor Com Error
- Cradle Position Sensor Com Error (only applies to ROC F9C)

7.4 ANMASK Warning

The ANMASK Warning symbol is a yellow warning that is shown in the status box
in the event of an error related to ANMASK. The cause of the error can be deduced
using the ANMASK Status Information menu. The error could be one of the
following:
- ANMASK Serial Com Error

4
7.5 Hyperterminal
The Hyperterminal software is a way of looking at the traffic from the receiver
outside our own (RCS) system. It allows us to connect to the receiver trough the
serial COM port and read the info sent over the COM port.

Windows 7 does not have Hyperterminal installed from start but you can find and
download the software on this page:

http://h0w2.blogspot.se/2011/09/how-to-enable-hyper-terminal-in-windows.html

We can use it to verify and see what side of the system is malfunctioning, Trimble or
RCS side.

1. Connect your receiver to a COM port on your computer using the dogleg
and a serial COM cable, NOT the Ethernet cable.
2. Turn receiver on
3. Open software Hyperterminal in XP Start-Accessories-Communication-
Hyperterminal

4
 4. Name the connection, the icon does not matter choose any of them

5. Choose the com port the receiver is connected to

6. Set the properties like the picture Bps: 38400 data bits: 8 parity: none stop
bits: 1 and flow control: none
7. Click apply and then OK

4
 This is the info from a 552 Rover receiver which is not connected to a sat
antenna. It shows coordinates, time date and height Yaw and Tilt

If the setup is OK you will get the info like this, showing what protocol in this
case PJK, you also get the data. In this case 0 because the receiver is on my desk
with no antennas attached. When operational you will get the values the receiver
is sending. The fact that you receive the data with the setting Bps 38400 also
called baud rate shows that the receiver is sending data with the correct speed. If
the baudrate is set wrong you will get no information.

You can also get the Hz by counting that we get 2 messages/second so that’s OK
to. This signal/message from both receivers is all we need for our HNS system.
NMEA PJK 2Hz.

8 Description of error
8.1 Base Line Error
This error occurs when the difference between the calculated Base Line value and the
Base Line value (distance to Rover Antenna) shown by the GPS is greater than ± 10
cm.
Possible Causes:
Sensor not calibrated
Sensor error
Different coordinate system in the receivers
Measurement error in link model

4
8.2 Base Station Com Error
This error occurs when the quality indicator for Moving Base shows 1. This means
that no information is received from the base station.
Possible Causes:
Error in Base Station (not energised, error in radio, settings error)
Error in Radio Antenna
Error in coaxial cable between Radio Antenna and Radio Modem Unit
Error in Radio Modem Unit
Error in voltage supply to Radio Modem Unit
Settings error in Radio Modem Unit (frequency, communication settings)
Error in serial cable between Radio Modem Unit and Moving Base Unit
Settings error in Moving Base Unit (protocol, communication settings, wrong port)

8.3 GPS Serial Com Error

This error occurs when the communication status is in error, i.e. when serial
communication between Moving Base Unit and RCS is not working.
Possible Causes:
Error in cable between Moving Base Unit and RCS (CCI module).
Error in voltage supply to Moving Base Unit.
Settings error in Moving Base Unit (protocol, communication settings, wrong port).
Settings error in RCS (protocol, communication settings, wrong port).

8.4 GPS System Error

This error occurs when the quality indicator for Moving Base Unit or Rover Unit
shows 0. This means that the GPS receivers cannot calculate any position.
Possible Causes:
Error in Rover Antenna.
Error in coaxial cable between Rover Antenna and Rover Unit.
Error in Moving Base Antenna.
Error in coaxial cable between Moving Base Antenna and Moving Base Unit.
Error in serial cable between Moving Base Unit and Rover Unit.

8.5 ANMASK Serial Com Error

This error occurs when the communication status is in error, i.e. when serial
communication between ANMASK Display Unit and RCS is not working.
Possible Causes:
Error in cable between ANMASK Display Unit and RCS (CCI module).
Settings error in ANMASK Display Unit (protocol, communication settings, wrong
port).
Settings error in RCS (protocol, communication settings, wrong port).

4
9 Hole Navigation Status Information
The Hole Navigation Status Information menu contains information on the System
and can be useful in fault finding. When the yellow Hole Navigation Warning
illuminates in the status box this menu should be activated in order to obtain more
detailed information on the cause.

Pos. Description
1 Current date that Moving Base and Rover send.
Format: mmddyy, month:day:year
2 Current UTC time that Moving Base and Rover send.
Format: hhmmss.cc, hours:minutes:.seconds:centiseconds
3 Number of satellites that Moving Base and Rover are in contact with.
4 DOP value for Moving Base and Rover
5 Quality indicator for Moving Base and Rover.
0-Fix Invalid; 1-Autonomous GPS; 2-RTK Float; 3-RTK Fix; 4-DGPS
6 Northerly coordinate in metres for Moving Base
7 Easterly coordinate in metres for Moving Base
8 Ellipsoidal height in metres for Moving Base
9 Side angle to Rover Antenna in degrees, positive clockwise, northerly direction is zero
10 Vertical angle to Rover Antenna in degrees, positive upwards, the horizontal plane is zero
11 Distance (Base Line) to Rover Antenna in metres.
12 Communication parameters and status for serial communication between CCI and Moving
Base.
13 Northerly coordinate in metres for Drill bit
14 Easterly coordinate in metres for Drill bit
15 Ellipsoidal height in metres for Drill bit
16 Rig compass direction in degrees, positive direction clockwise, northerly direction is zero.
17 Calculated Base Line (Distance) between Moving Base Antenna and Rover Antenna

4
10 ANMASK Status Information
The ANMASK Status Information menu contains information on ANMASK and can
be useful during fault finding. When the yellow ANMASK Warning illuminates in
the status box this menu should be activated in order to obtain more detailed
information on the cause.

Pos. Description
1 Communication parameters and status for serial communication between RCS and ANMASK
2 Northerly coordinate in metres for Moving Base
3 Easterly coordinate in metres for Moving Base
4 Ellipsoidal height in metres for Moving Base

4
Appendix 1 - system structure

Radio Antenna
Feeder Extend Sensor
Rig Inclinometer
Sensor Boom Lift Cradle Position
Sensor Sensor
Boom Extend Rover
Sensor Antenna

Base Station
Feeder
Radio Modem Inclinometer
Unit Sensor
Moving Base
Antenna

Moving Rov CCI ANMAS

Base er Modu K
Unit Unit le Displ
(RCS) ay
Unit

RS232 RS232 RS232

RS232

4
Appendix 2 - system layout

4
Appendix 3 – setting the node ID for sensors
 Detach the cover carefully on the sensor and set the DIP switches to the positions in accordance with below.
 Refit the cover and check that it seals firmly.

Last updated 18 March 2014