OP's & Serv Manual May 13 PDF

GLOBAL DRILLING PRODUCTS
Copyright © 2013 Boart Longyear. All rights reserved.
PWM ROD HANDLER

OPERATIONS AND SERVICE MANUAL
May 2013
Table of Contents
Chapter 1: Safety
1.1 Important Safety Information..................................................................... 3
1.1.1 Hazard Signal Indicators................................................................. 3
1.1.2 Safety Guidelines ........................................................................... 4
1.2 Cautions and Warnings.............................................................................. 6
Chapter 2: Introduction
2.1 General Information ................................................................................. 13
2.2 Prior to First Use....................................................................................... 13
2.3 Ordering and Returning Parts.................................................................. 14
2.3.1 Ordering Parts............................................................................... 14
2.3.2 Returning Parts............................................................................. 14
2.4 Limited Warranty....................................................................................... 15
Chapter 3: The Rod Handling Device

3.1 Introduction............................................................................................... 21
3.2 Rod Handler Parts Identification............................................................. 21
3.2.1 Rod Handler Mounts..................................................................... 23
3.2.2 Rod Handler Controls.................................................................... 23
3.2.2.1 Laser Safety Beam............................................................... 25
3.3 Control Panel Parts Identification........................................................... 25
3.4 Operating Status Indicator....................................................................... 30
Chapter 4: Rod Handler Set Up

4.1 Positioner Assembly Mounting............................................................... 33
4.1.1 Mounting Procedure...................................................................... 33
4.2 Pre Start Checks....................................................................................... 35
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Copyright © 2007, 2011, 2013 Boart Longyear. All rights reserved. 3547445
Boart Longyear is constantly striving to improve its products and must therefore reserve the right to change designs, materials, specifications, and price without notice.
Table of Contents
4.2.1 Lubrication checks......................................................................... 36

4.3 Hydraulic Connections............................................................................. 36
4.4 Electrical Connections............................................................................. 38
4.5 Control Panel Valve and Gauge Identification....................................... 42
4.6 Arm Horizontal Sensor (Inclinometer) Set Up........................................ 43
Chapter 5: Rod Handler Start Up

5.1 Pre-Checks and Warnings........................................................................ 47
5.1.1 Tools.............................................................................................. 47
5.2 Start Up Procedure................................................................................... 47
5.2.1.1 Valve Settings....................................................................... 48
5.3 Checking the Functions........................................................................... 49
5.3.1 Horizontal PLC Function............................................................... 49
5.3.2 Load/Unload PLC Function........................................................... 49
5.3.3 Traverse Cylinder Functions......................................................... 49
5.3.4 Slew and PLC Functions............................................................... 50
5.3.5 Gripper and PLC Functions........................................................... 50
5.3.6 Roller and PLC Functions............................................................. 51
5.3.7 Rod to Drill String Alignment......................................................... 52
5.3.8 Rod Feeding Sequence................................................................. 53
5.3.9 Rod Pulling Sequence................................................................... 54
Chapter 6: Rod Handler Operations

6.1 Rod Handler Parts..................................................................................... 59
6.1.1 Front and rear mounts................................................................... 59
6.1.2 Traverse Cylinder.......................................................................... 59
6.1.3 Carriage stop clamp...................................................................... 59
6.1.4 Slide rails....................................................................................... 60
6.1.5 Drill rod stop.................................................................................. 60
6.1.6 Slide blocks and bushes................................................................ 60
6.2 Carriage Slide Bush Replacement .......................................................... 60
6.2.1 Slide Bush Replacement Procedure............................................. 61
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Table of Contents
6.3 Carriage Assembly.................................................................................... 62

6.3.1 Carriage Frame............................................................................. 62
6.3.2 Swing Arm with hose bulkhead..................................................... 63
6.3.3 Swing Arm mechanical stop.......................................................... 63
6.3.4 Swing Arm actuator and overcentre valve..................................... 63
6.3.5 Swing Arm Cushioning Adjustment............................................... 64
6.3.6 Head Tilt actuator and overcentre valve........................................ 64
6.3.7 Head Tilt actuator guard................................................................ 64
6.4 Valve Assembly......................................................................................... 65
6.4.1 Valve bank..................................................................................... 65
6.4.2 Solenoid control............................................................................. 66
6.5 Head Assembly......................................................................................... 66
6.6 Laser Perimeter Beam.............................................................................. 67
6.6.1 Reflector and stand....................................................................... 68
6.7 Rod Handling Operations......................................................................... 68
6.7.1 Adding a Rod before Rod Feeding................................................ 68
6.7.2 Removing a Rod after Rod Pulling................................................ 69
6.8 Rod Handler Servicing.............................................................................. 69
6.8.1 Laser Safety Beam........................................................................ 69
6.8.2 Serial number locations................................................................. 70
6.8.3 Servicing Notes............................................................................. 70
Chapter 7: Rod Handler Troubleshooting

7.1 Important Information............................................................................... 73
7.2 Troubleshooting Symptoms and Actions............................................... 74
7.3 Hydraulic Circuits..................................................................................... 77
7.3.1 Hydraulic Schematic Symbols....................................................... 77
7.3.2 Rod Handler Hydraulic Circuit....................................................... 79
7.4 Electrical Fault Finding Charts................................................................ 81
7.4.1 Introduction.................................................................................... 81
7.4.2 FAULT/BUTTON PRESSED indicator light................................... 82
7.4.3 Rod Pulling Mode.......................................................................... 82
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Table of Contents
7.4.4 Rod Feeding Mode........................................................................ 84

7.5 I/O Modules................................................................................................ 85
7.5.1 I/O Module Connectors................................................................. 85
7.5.2 I/O Module Replacement............................................................... 86
7.6 PLC Circuit Diagrams............................................................................... 96
Chapter 8: Recommended Spare Parts Kit

8.1 12 Months Operation.............................................................................. 115
8.1.1 Rod Handler ............................................................................... 115
8.1.2 Carriage Assembly...................................................................... 115
8.1.3 Valve Assembly PWM................................................................. 115
8.1.4 Interconnecting Cable to Rod handler......................................... 116
8.1.5 Interconnecting Cable to LM Power Pack................................... 116
8.1.6 Laser Perimeter Beam................................................................ 116
8.1.7 Head Assembly........................................................................... 116
8.1.8 Guide Sets................................................................................... 116
8.1.9 Control Group Rod Handler......................................................... 117
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Table of Contents
Table of Figures
Chapter 1: Safety
Figure 1–1: STOP WARNING — Stop and observe the surrounding warning
decals. ........................................................................................................ 6
Figure 1–2: DO NOT CLIMB— No climbing activity to occur without appropriate
PPE. ........................................................................................................ 6
Figure 1–3: BODY CRUSH HAZARD — Moving parts of the machine have the
potential for crush injury......................................................................................... 7
Figure 1–4: MANUAL — Indicates to refer to this manual before proceeding
with any activity...................................................................................................... 7
Figure 1–5: CRUSH HAZARD — This part of the machine has a rotating crush
potential. ........................................................................................................ 7
Figure 1–6: EXTEND/RETRACT — Component extends and retracts
unguarded. ........................................................................................................ 7
Figure 1–7: HOT SURFACE — Surface adjacent to this warning can be too hot
to touch. ........................................................................................................ 8
Figure 1–8: PRESSURE VESSEL — This component is pressurised............... 8
Figure 1–9: HEARING PROTECTION — Must be worn when near this
machine. ........................................................................................................ 8
Figure 1–10: EYE PROTECTION — Must be worn when near this machine...... 8
Figure 1–11: HARD HAT — Must be worn when near this machine.................... 9
Figure 1–12: DIESEL FUEL — Diesel fuel connection site.................................. 9
Figure 1–13: LOADED SPRINGS — Warning that springs inside component are
loaded and disassembly should be done with caution........................................... 9

Figure 3–1: Rod Handler components.............................................................. 22
Figure 3–2: Rod Handler Parts Identification.................................................... 24
Figure 3–3: Control Panel Parts Identification.................................................. 25
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Table of Contents
Figure 3–4: Operating status indicator............................................................. 30

Figure 4–1: Positioner cradle............................................................................ 33
Figure 4–2: Positioner assembly mounting procedure..................................... 35
Figure 4–3: Lubrication points.......................................................................... 36
Figure 4–4: Lower bulkhead on LM Power Pack (under hydraulic bulkhead).. 37
Figure 4–5: View of underside of Control Panel............................................... 38
Figure 4–6: Sensor Locations........................................................................... 39
Figure 4–7: LM75/90 Control Panel Valves and Gauges................................. 42
Figure 4–8: Arm Horizontal sensor................................................................... 43

Figure 5–1: Valve Locations............................................................................. 48

Figure 6–1: Rod Handler Parts......................................................................... 59
Figure 6–2: Slide Bush Replacement Tool....................................................... 60
Figure 6–3: Slide Bearing components............................................................ 61
Figure 6–4: Carriage Assembly........................................................................ 62
Figure 6–5: Swing Arm adjustment.................................................................. 63
Figure 6–6: Valve Assembly............................................................................. 65
Figure 6–7: PVHC Actuator (p/n 5304275)....................................................... 66
Figure 6–8: Head Assembly............................................................................. 66
Figure 6–9: Laser Perimeter Beam Kit............................................................. 67

Figure 7–1: Rod Handler Hydraulic Circuit....................................................... 80
Figure 7–2: I/O Module connectors.................................................................. 85
Figure 7–3: I/O Module rotary switch locations................................................ 86
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Table of Contents
ix
Table of Contents
THIS PAGE INTENTIONALLY LEFT BLANK
x
Chapter 1: Safety
Contents
1.1 Important Safety Information..................................................................... 3
1.1.1 Hazard Signal Indicators................................................................. 3
1.1.2 Safety Guidelines ........................................................................... 4
1.2 Cautions and Warnings.............................................................................. 6
1
Chapter 1: Safety
2
Chapter 1: Safety
1.1 Important Safety Information
1.1.1 Hazard Signal Indicators

Warning and Caution indicators are located throughout the manual at
specific points of interest, and are intended to alert the reader to the
existence and relative degree of a hazard. These notices are given
to prevent personal injury, death and/or equipment damage. These
indictors must be followed to reduce the possibility of personal injury,
damage to the equipment, or improper service. Always heed these
notices, and practice common sense when performing any maintenance
or repair procedure.
This is the safety alert symbol. It is used to alert you to potential personal
injury hazards. Obey all safety messages that follow this symbol to avoid
possible injury and death.
“Danger” indicates an imminently hazardous situation which, if not

avoided, could result in death.
“Warning” indicates a potentially hazardous situation which, if not

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

avoided, MAY result in minor or moderate injury and property damage. It
may also be used to alert against unsafe practices.
Note: Notes are indicated to draw attention to detailed instructions.

These notes are intended to give further important information regarding
the machine and/or a step in a procedure.
These notices are given to prevent personal injury, death and/or

equipment damage. These indictors must be followed to reduce the
3
Chapter 1: Safety
possibility of personal injury, damage to the equipment, or improper
service. Always heed these notices, and practice common sense when
performing any maintenance or repair procedure.
1.1.2 Safety Guidelines

Familiarity and proper training are required for safe operation of this
equipment. Failing to follow these instructions may result in serious
injury or death. Read the operating instructions and familiarise yourself
with the location and proper use of all controls.
Safety is the most important element of any procedure. Preparation is

essential to complete a procedure in a safe and efficient manner.
●● Keep clear of rotating equipment. Wear proper clothing. Loose or

baggy clothing could become tangled in moving parts.
●● Be aware that sliding parts can create pinch points, and tilting parts
can create crush points.
●● Never rotate the drill rods without the water swivel attached to the
drill string. (Ensure that the hoisting cable is attached to water
swivel bail.)
●● Keep guards installed and maintained in good working order.
●● Always keep the work area clean.
●● Avoid dangerous working environments.
●● Do not operate equipment while under the influence of drugs,
alcohol, or medication.
●● Be aware of the operating zones and recommended areas for safe
operation. Keep visitors a safe distance away from the work area.
●● Wear personal protective equipment such as a hard hat, safety
glasses, and steel-toed work boots.
●● Prepare the required parts and materials. Gather the necessary
parts and materials before beginning the procedure.
●● Prepare proper tools and equipment. Always use the correct tool for
the job. Improper or homemade tools can cause injury or machine
damage.
●● Use only Boart Longyear replacement parts. Failure to do so can
cause severe damage to the machine or the operator, and may
void your warranty.
●● ISOLATE all energy sources before servicing equipment.
●● Allow the machine to cool. Many components can get hot during
operation. Be sure to allow enough time for components to cool
before beginning service.
●● Use only qualified service technicians. Failure to do so could cause
severe damage to the machine or the operator, and may void your
warranty.
4
Chapter 1: Safety
●● Never climb on top of the machine.

●● Ensure that the drill and accessories fully comply with applicable
local safety and health regulations.
●● Do not exceed rated capacity of any piece of equipment.
●● Do not adjust the hydraulic system before consulting a Boart
Longyear Technician.
●● Ensure that all commissioning checks and adjustments have been
thoroughly carried out before operating the machine.
●● Never rotate the drill rods with a rod joint located behind or above
the Chuck.
●● Do not change or alter the drill, its components, optional equipment,
or accessories without prior approval from Boart Longyear.
●● Follow all procedures and safety warnings. Service procedures are
written to be as safe and efficient as possible. Never take shortcuts,
and never operate this machine when any person, including the
operator, is under or in the operational envelope of the loading/
unloading process.
●● Be prepared for emergencies. Accidents can happen, even under
the best conditions. Fire extinguishers and first aid kits should be
well maintained and easily accessible.
●● Read and understand this Operations and Service Manual and all
labels affixed to the machine.
●● Unauthorised alterations may void the warranty, render the
equipment unsafe, or result in decreased performance.
●● Before operating any controls, be certain you know what function
they control and the ramifications of that function.
●● Before operating any hoist, ensure that the rope is free and clear to
travel.
●● When hoisting/lowering rods, make sure the hoisting cable is in
complete tension before releasing the Chuck.
●● Do not use multiple part lines on the Main Hoist.
●● Ensure that all commissioning checks and adjustments have been
thoroughly carried out before operating the machine.
●● Always wear a certified full-body harness with the shortest possible
lanyard attached to a certified fall arrestor system while working on
the platform.
●● Be aware of the travelling hoist plug at all times.
●● Be careful not to drop any tools when working on the platform.
●● Never exceed the rod rack derating weights.
●● Never attempt to loosen or remove any high-pressure hydraulic line
without relieving the pressure beforehand.
●● Always be sure the machine is on a firm, level surface and will not
tip, roll, slide, or fall while operating.
5
Chapter 1: Safety
●● Never start a unit in need of repair.
●● Keep the area behind the trailer clear of people while raising and
lowering the mast! Never raise, lower, or turn the mast while unit is
operating!
●● The trailer must be levelled before raising the tower.
●● Always replace the safety devices and guards after repairs and
maintenance.
●● Always keep hands, feet, and loose clothing away from the moving
parts on the generator and engine.
Note: For additional information on training or start-up, contact your

local Boart Longyear representative.
1.2 Cautions and Warnings
Figure 1–1: STOP WARNING — Stop and observe the

surrounding warning decals.
Figure 1–2: DO NOT CLIMB— No climbing activity to occur

without appropriate PPE.
6
Chapter 1: Safety
Figure 1–3: BODY CRUSH HAZARD — Moving parts of the

machine have the potential for crush injury.
Figure 1–4: MANUAL — Indicates to refer to this manual before

proceeding with any activity.
Figure 1–5: CRUSH HAZARD — This part of the machine has a

rotating crush potential.
Figure 1–6: EXTEND/RETRACT — Component extends and

retracts unguarded.
7
Chapter 1: Safety
Figure 1–7: HOT SURFACE — Surface adjacent to this warning

can be too hot to touch.
Figure 1–8: PRESSURE VESSEL — This component is

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

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

machine.
8
Chapter 1: Safety
Figure 1–11: HARD HAT — Must be worn when near this machine.
Figure 1–12: DIESEL FUEL — Diesel fuel connection site.
Figure 1–13: LOADED SPRINGS — Warning that springs inside

component are loaded and disassembly should be done with
caution.
9
Chapter 1: Safety
10
Contents
2.1 General Information ................................................................................. 13
2.2 Prior to First Use....................................................................................... 13
2.3 Ordering and Returning Parts.................................................................. 14
2.3.1 Ordering Parts............................................................................... 14
2.3.2 Returning Parts............................................................................. 14
2.4 Limited Warranty....................................................................................... 15
11
12
2.1 General Information

The purpose of this Operations and Service Manual is to furnish the
operator with details on operating, maintaining and servicing the PWM
Rod Handler.
Read this Manual carefully before attempting to operate the PWM

Rod Handler.
Boart Longyear is backed by more than 100 years of experience in the

design, manufacture, and operation of core drilling equipment. Many of
the accepted industry practices in use today were pioneered by Boart
Longyear.
To obtain the utmost in performance and life of the equipment, it should

be given regular care and operated in accordance with the instructions.
Read this Manual carefully before attempting to operate the drill and
keep this book handy at all times for reference when any question
arises.
IMPORTANT NOTE
Do not start or operate the drill until you have read this Manual and
understand its contents.
2.2 Prior to First Use

After the arrival of your new Boart Longyear Rod Handler a quick
inspection should be done:
●● Visually inspect the equipment for any loose hoses, fittings, or

bolts, or any damage that may have occurred during shipping.
●● Take extreme caution when a loose hose or fitting has allowed oil
to leak, as this will create a hazard.
●● Make sure that any oil leak has not drained the tank too low for
proper operation.
●● Refer to the relevant chapters in this Manual for proper and safe
movement of the drill rig.
●● Visually inspect all electrical connections.
●● Check oil levels and fill with recommended lubricants.
13
2.3 Ordering and Returning Parts
2.3.1 Ordering Parts

To help us expedite your order and assure correct replacement parts
are supplied please specify the following when placing your order:
1. Name, model and Boart Longyear serial number of the product,

subassembly or component for which the parts are ordered.
2. Boart Longyear part number and description of parts as shown in

the Parts List.
3. Specify the quantity required for each line item.
4. Full shipping instructions:
○○ when required
○○ are partial shipments allowed
○○ method of shipment (e.g. Air Parcel Post, Air Freight, etc.)
○○ will purchaser be responsible for insurance
○○ prepaid or collect
○○ “ship to” address
5. Special instructions, if any.
All parts are priced F.O.B., our factory, and separate charge will be
made for transportation and export packing.
2.3.2 Returning Parts

1. Before returning parts or products to Boart Longyear, please obtain
formal authorisation, a Returned Memo Advice (RMA) number, and
“ship-to” address (back to Boart Longyear facility) from your Boart
Longyear Customer Service Centre or representative.
2. You will also need to submit a letter:
○○ detailing the reason for requesting the return,

○○ indicating the action desired.
○○ specifying the quantity and Boart Longyear part numbers of
the product(s) concerned. Where applicable, the MODEL
and SERIAL NUMBER are necessary for proper and full
identification.
○○ citing the RMA number (if already assigned).
14
3. When returning parts or products, the purchaser is responsible for
prepaying any transportation, insurance, and/or delivery charges to
a place designated by Boart Longyear.
4. DO NOT ship parts until authorization and shipping instructions are

received.
5. All parts returned must be prepaid.
2.4 Limited Warranty

a. Consumables. Boart Longyear warrants for a period of one (1)
year after the date of shipment of the consumable products
manufactured by it, or the performance of related services,
under the Contract, that such consumable products are free
from defects in materials and workmanship and such services
are performed in a professional and workmanlike manner;
provided, however, with respect to consumable products
purchased through an authorized Boart Longyear distributor,
the warranty period shall commence on the date of purchase by
the end-user.
b. Capital Equipment. Boart Longyear warrants that the capital

equipment manufactured by it is free from defects in materials
and workmanship for a period equal to the lesser of (i) one (1)
year after the date of shipment, or (ii) the initial 1,000 operating
hours. Boart Longyear warrants for a period of six (6) months
after the performance of related services that such services are
performed in a professional and workmanlike manner.
c. General Terms. Boart Longyear further warrants that, to the

extent applicable, as of the date of shipment or performance, all
goods manufactured by it and services performed shall conform
to the written specifications agreed between the parties.
THIS IS BOART LONGYEAR’S ONLY WARRANTY. BOART
LONGYEAR MAKES NO OTHER WARRANTY, INCLUDING
WITHOUT LIMITATION, ANY WARRANTY OF
15
d. MERCHANTABILITY OR FITNESS FOR A PARTICULAR
PURPOSE.
As a condition to Boart Longyear’s warranty obligations, the

purchaser must:
(i) contact Boart Longyear and request authorization to return any
goods claimed to be defective promptly upon Purchaser’s discovery
of the alleged defect,
(ii) upon receipt of an approved authorization code from Boart
Longyear, return any goods claimed to be defective under
the foregoing warranty, at Purchaser’s expense, to the facility
designated by Boart Longyear, and
(iii) with respect to consumable products purchased through
an authorized Boart Longyear distributor, the party making the
warranty claim must also deliver to Boart Longyear reasonable
evidence of the date of purchase. Boart Longyear shall perform its
examination of the goods so returned by Purchaser and shall report
the results of its examination to Purchaser within thirty (30) days
following its receipt of such goods from Purchaser, or, if longer
time is required to complete such examination, within such time as
would be required through the exercise of reasonable diligence.
As a further condition to Boart Longyear’s obligations hereunder
for breach of warranty, Purchaser shall offer its reasonable
cooperation and assist Boart Longyear in the course of Boart
Longyear’s review of any warranty claim.
If requested by Purchaser, Boart Longyear will promptly repair or
replace, at Boart Longyear’s expense, goods that are confirmed
to be non-conforming as a result of Boart Longyear’s examination
and according to Boart Longyear’s warranty as set forth herein. All
removal and installation of goods shall be at Purchaser’s expense;
provided, however, Boart Longyear will reimburse the Customer
for an amount equal to the reasonable expenses incurred by the
Customer and attributable to the removal and shipment of any
defective goods.
Boart Longyear reserves the right to reimburse Purchaser for an
amount equal to the purchase price of any defective goods in lieu
of providing repaired or replacement goods. Anything contained
herein to the contrary notwithstanding, in no event shall Boart
Longyear be liable for breach of warranty or otherwise in any
manner whatsoever for:
(i) normal wear and tear; (ii) corrosion, abrasion or erosion; (iii) any
goods, components, parts, software or services which, following
delivery or performance by Boart Longyear, has been subjected
to accident, abuse, misapplication, modification, improper
repair, alteration, improper installation or maintenance, neglect,
or excessive operating conditions; (iv) defects resulting from
Purchaser’s specifications or designs or those of its contractors or
subcontractors other than Boart Longyear; (v) defects associated
with consumable parts or materials, the lifetime of which is shorter
than the warranty period set forth in this Section; (vi) defects
associated with Purchaser’s specifications or designs or those of
its contractors or subcontractors other than Boart Longyear; (vii)
16
defects resulting from the manufacture, distribution, promotion or
sale of Purchaser’s own products; or (viii) accessories of any kind
used by the Purchaser which are not manufactured by or approved
by Boart Longyear.
e. Sourced Goods. If the defective parts or components are
not manufactured by Boart Longyear, the guarantee of the
manufacturer of those defective parts or components is
accepted by the Purchaser and is the only guarantee given to
the Purchaser in respect of the defective parts or components.
Boart Longyear agrees to assign to the Purchaser on
request made by the Purchaser the benefit of any warranty
or entitlement to the defective parts or components that the
manufacturer has granted to Boart Longyear under any contract
or by implication or operation of law to the extent that the benefit
of any warranty or entitlement is assignable.
Boart Longyear
Global Headquarters
10808 South River Front Parkway
Suite 600
South Jordan, Utah 84095
United States of America
Info@boartlongyear.com
Tel: +1 801-972-6430
Fax: +1 801-977-3374
17
18
Contents
3.1 Introduction............................................................................................... 21
3.2 Rod Handler Parts Identification............................................................. 21
3.2.1 Rod Handler Mounts..................................................................... 23
3.2.2 Rod Handler Controls.................................................................... 23
3.2.2.1 Laser Safety Beam............................................................... 25
3.3 Control Panel Parts Identification........................................................... 25
3.4 Operating Status Indicator....................................................................... 30
Tables
Table 3–1: Operating Status Indicator Table................................................... 30
19
20
3.1 Introduction
The PWM Rod Handler is a device that fits on the side of the Feed
Frame and is hydraulically driven. Its purpose is to retrieve or add rods
to the drill string from a safe position along the side of the Feed Frame,
regardless of the working angle, reducing the manual handling of drill
rods.
The physical effort and associated injuries encountered using

conventional manual handling are significantly reduced by automating
the rod handling process.
A 5-bank directional control valve controls the device via an electrical

Control Panel. The device is semi-automated, i.e. a PLC monitors
functions via sensors and only allows certain moves to be made if the
right conditions are met.
The PWM Rod Handler uses Pulse Width Modulation signals to control
the operational hydraulics.
Note: A standard LM Rod Handler (p/n 3000318) can be upgraded to

the PWM version by installing a retrofit kit (p/n 5304593).
3.2 Rod Handler Parts Identification

The PWM Rod Handler can be mounted on 700 and 1300 Series Feed
Frames fitted with 20 mm thick bottom runners by using the relevant
mounting kit. It is compatible with LM Power Packs fitted with an
optional hydraulic kit, and it can also be used on LM drills fitted with the
DCi Control System.
Hydraulic hoses connect the Power Pack and the Rod Handler. Each
hose has different sized ends.
●● Load Sense hose — 7/16” JIC

●● Roller Motor Drain hose — 9/16” JIC
●● Main Pump Pressure hose — 3/4” JIC
●● Tank return hose — 1-1/16”JIC.
When the Rod Handler is retro-fitted to a standard LM drill a separate

Control Panel is used.
If a DCi Control System is fitted, a single Control Panel can be used to

control both the Rod Handler and the LM drill.
A 10 pin 24V DC electrical cable (p/n 89182) connects the Starter

assembly on the LM Power Pack to the Power Pack socket on the
underside of the Rod Handler Control Panel.
21
For early model LM starters fitted with a 6 pin connector and a Stop/
Start pendant, it will be necessary to update the starter with a kit (p/n
5305286), and a remote pendant (p/n 3003488) which includes an
Emergency Stop switch.
3 8
5
6
1– Rod Handler — PWM 2– Feed Frame 3– Power Pack 4–Control Panel — PWM
5– Hydraulic hoses 6– Laser cable 7–7-core Electrical cable 8–24V DC Electrical cable
9– Laser Perimeter Beam components
Figure 3–1: Rod Handler components
A 7-core electrical cable connects the Rod Handler Control Panel to the
Rod Handler Carriage. This cable supplies power to the DCV solenoids
and sensors.
A Laser Perimeter Beam protects the operators from the equipment

without hindering access. It uses cable p/n 89182, and the Rod Handler
joysticks deactivate when the beam is triggered.
The PWM Rod Handler can handle BQ, NQ, HQ and PQ size rods and
outer tubes. Its other capabilities include:
22
●● Angle range: –90° to 0° is the standard program setting for the
PWM Rod Handler. A setting sequence can be changed so that it
can also be used between 0° and +90° (See “22. GRIPPER OPEN
(Up Hole Mode” in Section 3.3).
A work platform may be necessary on up holes, due to the
mounting location of the Rod Handler off the front of the Feed
Frame. This will depend on the site set up and the hole angle being
drilled.
If power is lost to the drill, the PLC reverts back to the down hole
program.
●● Average time to load / unload on a steep down hole including rod
tripping on 1300 Feed Frame with HQ rods: 36–40 seconds each.
(This is with a 2-man operation.)
●● Shallow angle holes: Less time is taken per trip as the Head Tilt
and Traverse functions do not need to be used as much.
3.2.1 Rod Handler Mounts

The Rod Handler mounts off the side of the Feed Frame chassis using
front and rear mounting brackets:
●● A wider than standard face plate (p/n 3001445) is supplied as part

of the mounting kit to attach the rig to the face.
●● Slide rails (2 standard HQ rods) fit between the front and rear
mounts. These are used to support the Carriage assembly, and
allow it to slide along the side of the Feed Frame.
●● A traverse cylinder is used to move the Carriage along the slide
rails.
3.2.2 Rod Handler Controls

A solenoid operated Directional Control Valve assembly is attached to
the Carriage. This DCV is used to control all the hydraulic motion of the
device. The DCV has pressure test points fitted to each section and
requires a supply of oil from the Power Pack.
A Swing Arm is also mounted off the Carriage assembly to position the
rods in behind the Rotation Unit. It is moved by the swing arm rotary
actuator.
The Swing Arm supports the Head assembly, and can tilt through 90
degrees down, or 90 degrees up, depending on the set up. This tilt
function is moved by the tilt actuator.
A support arm, i.e. part of the head assembly, supports the rod being
handled.
23
Guide plates to suit individual rod sizes are fitted to the front and rear
guide assemblies to help line up the rod being handled with the rod
string.
The rod is held in the head assembly by a pair of grippers that house
some rollers to rotate the rod to aid the making and breaking of thread
joints.
6
1
2 7
8
9
10
11
12
1– Carriage assembly 2– Swing Arm 3– Rear Mount

4– Traverse Cylinder 5– Slide Rails 6– Valve assembly
7– Rear Guide assembly 8– Support Arm 9– Rollers and Grippers
10– Head assembly 11– Front Guide assembly 12– Front Mount
Figure 3–2: Rod Handler Parts Identification
The Rod Handler is operated from a control panel separate from the Drill
Control Panel.
24
A cable links the Power Pack and the Rod Handler Control Panel.
3.2.2.1 Laser Safety Beam

A Laser Safety Beam is used to protect the operators from the
equipment without hindering access.
The Rod Handler controls are deactivated when the beam is triggered.
3.3 Control Panel Parts Identification
17
3 4 5 6 9 10 11 12
14
15
7 8 13 16
2
19 19 21 21
18 20
1
22 23
Figure 3–3: Control Panel Parts Identification
25
1. PWM Rod Handler EMERGENCY STOP
Push the switch down to activate the Emergency Stop; pull it up to

reset.
This switch stops ALL controls, and if a pilot is connected it will also
drop out the Main Breaker.
2. PWM Rod Handler PULL ON / PUSH OFF
Push the switch down to disable joysticks, pull it up to activate

them.
If the Rod Handler ON / OFF button is pulled up, power becomes
available to the DCV solenoids and to the light mounted on the Rod
Handler Carriage. The JOYSTICKS ACTIVE light on the Control
Panel also illuminates.
This On/Off button is also used to reset a fault when a fault code
appears on the system fault light. To reset, push the button down,
pull it up to reactivate.
The lights at the top of the Control Panel are arranged in two
sections:
○○ SYSTEM lights show conditions that the Handler and PLC
require to operate.
○○ SENSOR lights indicate a signal is being received from the
relevant sensor as in input to the PLC, and outputs from the PLC
illuminate these individual lights.
3. POWER light
This Red light indicates power is reaching Control Panel from the
source (i.e. the Power Pack). This light gets its power from the 24V
supply.
4. JOYSTICKS ACTIVE light
This Green light indicates the Pull ON / Push OFF button has been
pulled up and the joysticks are active. This light gets its power from
main supply after going through a relay.
Note: Be aware of this situation at all times, especially when fault

finding.
The following twelve lights get their power from outputs on the PLC,
and will only illuminate if the PLC is receiving a signal from the
relevant sensor.
5. LOAD / UNLOAD light
This light illuminates when the Swing Arm is out and the Head
is horizontal. It indicates that both the required inputs have been
registered at the PLC, allowing the grippers to open or close for
loading or unloading rods safely.
6. CLAMP CLOSED light
This light indicates the CLAMP OPEN/CLOSE button has been

pressed to close the grippers.
26
7. PERIMETER CLEAR light
This light indicates the status of the latching perimeter clear signal
within the controller. The light will be ON when the perimeter beam
is in the ‘healthy’ state. The joysticks will not function when this light
is OFF.
8. FAULT / BUTTON PRESSED light
This light is a visual indication that any of the piezo switches

located on top of the two joysticks have been pressed. It is also
used to fault find the electrical circuits using a flash code sequence
(for more information refer to Chapter 7 of this Manual).
9. ARM OUT light
This light indicates the Swing Arm is in the LOAD / UNLOAD

position along the side of the Feed Frame — one of two conditions
that must be met before the PLC will allow the grippers to open in
the LOAD/UNLOAD area.
10. HORIZONTAL light
This light indicates the Head assembly is horizontal (as monitored

by the Arm Horizontal sensor mounted on the tilt switch bracket) —
the second of two conditions that must be met before the PLC will
allow the grippers to open in the LOAD/UNLOAD area.
11. ROD FRONT light
This light indicates a rod has been sensed loaded forward of the
grippers in the Head assembly.
12. ROD REAR light
This light indicates a rod has been sensed loaded rearward of the
grippers in the Head assembly.
13. ARM IN light
This light indicates the Swing Arm is in the MAKE/BREAK position

behind the Rotation Unit — one of two conditions that must be met
before the grippers will open in the MAKE / BREAK area.
14. SLEW light
This light indicates the Head is near to parallel with the Feed
Frame. The Swing arm will only operate if the slew sensor is
activated and this light is illuminated. This has been incorporated
as an additional safety feature when working on on steep holes.
15. GRIPPER PRESSURE light
This light indicates the grippers have closed and the pressure
switch is activated when the preset pressure has been achieved.
27
16. ARM CLEAR light
This light indicates the Swing Arm is in the Arm Clear zone, away
from the drill feed frame. This zone begins when the Swing Arm
is approximately vertical (45 degrees away from the drill) and
continues through to the Arm Out position. This condition must be
active to enable Drill Control Panel hydraulic pilot pressure via the
Pilot Dump function.
17. STROBE light
High voltage shock hazard! — Wait 6 minutes after removing power

from the light before removing dome to replace the strobe.
This light indicates the laser beam has been broken, or the bridging
plug is not fitted. The joysticks will not function when it is flashing.
18. LEFT joystick
When in operation;
○○ Move left to lower the front guide assembly, right to raise the
front guide assembly when the Swing Arm is in LOAD/UNLOAD
position.
○○ Move up to rotate the rollers to make a rod joint at the rod string
and down to undo (break) the rod joint. Note the rollers are used
to clear the pin thread from the box thread at a faster rate than
the Breakout Device.
○○ The Carriage light flashes when the left joystick is moved in any
direction away from the neutral position.
19. JOINT OK buttons
Both piezo buttons on the left joystick act as “Joint OK” switches
when they are depressed.
When Rod Feeding, press either Joint OK button when the joint is
made up to allow the grippers to open and Swing Arm to come out.
The FAULT / BUTTON PRESSED light will illuminate when either
button is pressed.
When Rod Pulling, press either Joint OK button when the grippers
are closed and the joint is fully undone and clear of rod string
to allow the Swing Arm to come out. The FAULT / BUTTON
PRESSED light will illuminate when either button is pressed.
20. RIGHT joystick
When in operation:
○○ Move left to traverse the carriage assembly towards the front
(i.e. Rod Holder end) of the Feed Frame, and right to traverse
the carriage assembly towards the rear (i.e. sheave end) of the
Feed Frame.
28
○○ Move up to move the Swing Arm in behind the Rotation Unit,
down to move the Swing Arm out from behind the Rotation Unit.
○○ The Carriage light flashes when the right joystick is moved in any
direction away from the neutral position.
21. CLAMP OPEN/CLOSE buttons
Both piezo buttons on the right joystick also act as a switches when
pressed. They open and close the Grippers. The FAULT / BUTTON
PRESSED light will illuminate when either button is pressed.
22. PRESS WHEN LOAD/UNLOAD AREA IS CLEAR button
For personnel safety, the operator should always check the work
area is clear before pressing this button to reactivate the joysticks.
This button reactivates the joysticks after the laser beam has been
broken, as indicated by the Flashing Amber strobe light on the
Control Panel.
23. ROD PULLING / ROD FEEDING selector
This switch selects the mode of operation. It provides an input

to the PLC program, which in turn will only allow certain gripper
functions to occur, depending on the mode selected:
○○ ROD FEEDING must be selected when rods are being added to
the rod string,
○○ ROD PULLING must be selected when removing rods from the
string.
Note: A Rotation Unit breakout device is still required to break the

joint when pulling rods.
GRIPPER OPEN (Up Hole Mode)
Note: This control mechanism is not shown on the illustration.
This facility overrides the horizontal safety switch to allow the grippers to
open when in a Vertical Up position.
To activate:
●● Switch the Rod Handler ON/OFF selector to OFF, and touch either
of the left hand piezo buttons five (5) times.
●● Switch the Rod Handler ON/OFF selector to ON, and the grippers
will now open.
●● The horizontal light will flash continually in this mode.
Deactivation is the reverse of the above procedure.
29
If power is lost or the E-Stop system is activated, the system reverts
back to Down Hole mode.
3.4 Operating Status Indicator
Figure 3–4: Operating status indicator
Fitted to the Carriage assembly is a multicolour light that indicates the

following operating conditions:
LED Indication Status Description

Not Disabled The Rod Handler is DISABLED and
Illuminated INACTIVE.
The Red ‘STOP’ mushroom head
pushbutton is depressed.
Steady Idle The Rod Handler is ENABLED but
Yellow INACTIVE.
The Grippers may be actuated Open or
Closed.
Flashing Active The Rod Handler is ENABLED and
Yellow ACTIVE.
Motion of the Arm, Tilt, Roll or Traverse
is in progress.
Any joystick is actuated from the Neutral
position.
Steady Red Fault There is an active FAULT condition.
Only partial functionality may be
available.
The specific fault will be indicated using
a numeric ‘flash code’ on the ‘ERROR’
red panel LED.
Rectify the fault condition, then depress
and release the Red ‘STOP’ pushbutton
to cancel the fault indication.
Refer to section 7.4 for details.
Table 3–1: Operating Status Indicator Table
30
Contents
4.1 Positioner Assembly Mounting............................................................... 33
4.1.1 Mounting Procedure...................................................................... 33
4.2 Pre Start Checks....................................................................................... 35
4.2.1 Lubrication checks......................................................................... 36
4.3 Hydraulic Connections............................................................................. 36
4.4 Electrical Connections............................................................................. 38
4.5 Control Panel Valve and Gauge Identification....................................... 42
4.6 Arm Horizontal Sensor (Inclinometer) Set Up........................................ 43
31
32
4.1 Positioner Assembly Mounting

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

1. Shorten the pivot bars on the cradle to clear Rod Handler carriage
slide rails. (Refer to Figure 4-1 below.) This can be done using a
circular saw or oxyacetylene kit in a safe place.
Shorten pivot bars if necessary
Positioner cradle
Figure 4–1: Positioner cradle
2. The front mount for the Rod Handler fits between the front plate of
the Feed Frame and the face plate. (Refer to Figure 4-2, overleaf).)
3. The rear mount attaches to the Feed Frame chassis bottom slide
rails with two clamp plates. Set this up so the distance between the
33
mounting surfaces on the front and rear mounting plates is approx.
3040 mm.
Leave the bracket slightly loose so it can be positioned when the

handler is being mounted.
4. The front slide adaptor subs can be fitted on rear side of front
mounting plate so the 1300 Feed Frame can slide along the cradle
a little further.
If required, do this before fitting the Rod Handler to the mounting

plates.
5. Using the two lift points on the carriage (as shown in Figure 4-2),
the Rod Handler should hang near to vertical once lifted clear of the
transport pallet. Lift it into position and attach to the front mount.
Fit the large square washers on the side of the mount with the slots.
Slide the rear bracket back until it touches the Rod Handler and
bolt together. Fit the large square washers and spring washers
under the bolt heads.
Tighten all mounting bolts, keeping in mind the line up of the Rod
Handler with the drill string is to be done once the rig is powered
up.
6. Fit the face plate. It is wider than the standard face plate so an air
leg can be used to bolt the rig to the ground.
7. The Feed Frame and Rod Handler can now be positioned over the
hole. Note the swing clearance that is required to operate the Rod
Handler.
8. Rock bolt the positioner to the ground. Once the positioner is set up
over the drill hole, the front hole in the positioner base next to the
Rod Handler mount is hard to get to. Use alternatives if necessary.
9. If possible, set up the Control Panel in a safe position near the

front corner of the Feed Frame to enable clear visibility of the Rod
String, the Rod Handler, and the Driller’s Assistant at all times.
34
10. Run the cables and hoses away from walk areas. If possible, place
them under boards without restricting their movement.
Rear clamps
Rear mount
Lift points
Face plate
Front mount
Figure 4–2: Positioner assembly mounting procedure
4.2 Pre Start Checks

All Rod Handlers have been fully tested before they leave the factory.
The following additional checks are intended to:
●● assist in setting up the Rod Handler, and

●● ensure the factory settings of the hydraulic components are correct,
and that all hoses are properly connected and purged.
Importantly, they also enable operators to become familiar with the

operation of this equipment.
35
4.2.1 Lubrication checks
Traverse Cylinder
Trunnions (behind
carriage)
Carriage Slide
Blocks Head Pivot Shaft
Swing Arm Gripper Cylinder

Bearing Trunnions
Figure 4–3: Lubrication points
Before proceeding any further, check all of the following components

have been greased:
●● Carriage Slide Block nipples (4)

●● Swing Arm bearing (1)
●● Traverse Cylinder Trunnions (2 — behind carriage)
●● Gripper Cylinder Trunnions (4 — underside of head)
●● Head Pivot Shaft nipple (1).
4.3 Hydraulic Connections

Connect the Interconnecting Tank, Drain, Load Sense and Pressure
hoses to the lower bulkhead on the Power Pack (located under the
hydraulic reservoir) as described below:
●● LOAD SENSE — 1/4” hose with 7/16” JIC hose ends runs from the
LS port on the Rod Handler valve bank to the LS port on the lower
bulkhead on the Power Pack.
●● DRAIN — 3/8” hose with 9/16” JIC hose ends runs from the
bulkhead fitting on the Rod Handler bottom valve mounting plate to
the Drain Manifold on the Power Pack.
36
●● PRESSURE — 1/2” hose with 3/4” JIC hose ends runs from the
P port on the Rod Handler DCV to the P port on the lower bulkhead
on the Power Pack.
●● TANK — 3/4” hose with 1-1/16” JIC hose ends runs from the T port
on the Rod Handler DCV to the T port on the lower bulkhead on the
Power Pack.
Each hose has different size fitings so they cannot be mixed up.
Figure 4–4: Lower bulkhead on LM Power Pack (under hydraulic

bulkhead)
The hydraulic pump used to power this device must be a load sensing
type.
37
4.4 Electrical Connections
1 2 3 4
Figure 4–5: View of underside of Control Panel
Referring to the above photo:
●● Connect the Laser Perimeter Beam or dummy plug to the SAFETY

BEAM socket (1) on the underside of the Control Panel (X24). One
or the other must be fitted.
●● Connect the Rod Handler 7 pin electrical CAN cable to the CAN
BUS socket (2) on the underside of the Control Panel (X23).
●● Connect a 24V DC electrical supply from the Power Pack to the
POWER PACK socket (3) on the underside of the Control Panel
(X22).
●● Connect a Start/Stop pendant or dummy plug to the START/STOP
socket (4) on the underside of the Control Panel (X21).
Do not start the Rig Hydraulics until the following checks have
been made.
1. The POWER light indicates power is reaching the Control Panel

from the source. Check that it illuminates when the electrical power
is switched on.
Some sensor lights at the top of the Control Panel may also
illuminate, depending on whether objects are in the pick-up range
of the sensors. This is normal.
2. Rod Handler PULL ON / PUSH OFF button
○○ Pull out to activate the 24V supply to the two joysticks, DCV
solenoids, and JOYSTICKS ACTIVE light.
38
○○ Push in to disable the 24V supply to the joysticks, DCV
solenoids, and JOYSTICKS ACTIVE light.
Arm Clear sensor

Arm In sensor
(top)
Arm Out sensor
(bottom – hidden)
Gripper Pressure
sensor
(rear of valve – hidden)
Slew sensor
Arm Horizontal sensor
Rod Rear sensor
Rod Front sensor
Figure 4–6: Sensor Locations
○○ When the button is pulled up (i.e. ON), check the:

■■ JOYSTICKS ACTIVE light illuminates.
■■ Light on the Carriage terminal box illuminates.
■■ Green lights on the Directional Control Valve solenoids (4)
illuminate with no rod loaded.
○○ When the button is pushed in (i.e. OFF), check the:
■■ JOYSTICKS ACTIVE light turns off.
■■ Light on the Carriage terminal box turns off.
■■ Green lights on the Directional Control Valve solenoids (4)
turn off.
3. ROD FRONT light: Indicates a rod has been sensed loaded forward
of the grippers in the Head assembly.
○○ Green POWER light on the ROD FRONT sensor is illuminated.

○○ Amber SENSING light on the ROD FRONT sensor illuminates
when a metal object is placed over the square sensing area.
○○ ROD FRONT light on the Control Panel comes on when a metal
object is placed over the square sensing area.
4. ROD REAR light: Indicates a rod has been sensed loaded rearward
of the grippers in the Head assembly.
○○ Green POWER light on the ROD REAR sensor is illuminated.

39
○○ Amber SENSING light on the ROD REAR sensor illuminates
when a metal object is placed over the square sensing area.
○○ ROD REAR light on the Control Panel comes on when a metal
object placed over the square sensing area.
5. ARM IN light: Indicates the Swing Arm is in the MAKE/BREAK
position behind the Rotation Unit — one of two conditions that must
be met before the grippers will open in the MAKE/BREAK area.
○○ Amber Light on the ARM IN sensor illuminates when a metal

object is placed over the sensing area.
○○ ARM IN light on the Control Panel comes on when a metal object
is placed over the sensing area.
6. ARM OUT light: Indicates the Swing Arm is in the LOAD/UNLOAD
position alongside the Feed Frame — one of two conditions that
must be met before the grippers will open in the LOAD/UNLOAD
area.
○○ Amber Light on the ARM OUT sensor illuminates when a metal

○○ ARM OUT light on the Control Panel comes on when a metal
7. SLEW light: Indicates the Head assembly is near to parallel with
the Feed Frame — a condition that must be met before the Swing
Arm is allowed to move in or out.
○○ Amber Light on the SLEW sensor illuminates when a metal

○○ SLEW light on the Control Panel comes on when a metal object
is placed over the sensing area.
○○ Pull up the Rod Handler ON / OFF button, with the hydraulics still
off.
8. LEFT JOYSTICK: When in operation, move left to lower the front
guide assembly, or move right to raise the front guide assembly
when Swing Arm is in the LOAD/UNLOAD position.
○○ Move up to join the rod (make) to the drill string, or move down
to undo (break) the rod joint.
○○ Carriage light flashes when the left joystick is moved left, right,
up and down.
A Rotation Unit breakout device is still required to break the joint

when pulling rods.
9. RIGHT JOYSTICK: Move left to traverse the carriage assembly

towards the front of the Feed Frame, or move right to traverse the
carriage assembly towards the rear of the Feed Frame.
40
○○ Move up to move the Swing Arm in behind the Rotation Unit, or
down to move the Swing Arm out from behind the Rotation Unit
○○ Carriage light flashes when the right joystick is moved left, right,
up and down.
10. PRESS WHEN LOAD/UNLOAD AREA IS CLEAR button: Is used
to reactivate the joysticks after the laser beam has been broken, as
indicated by the flashing Amber strobe light on the Control Panel.
For personnel safety, the operator should check the work area is
clear before pressing this button to reactivate the Joysticks.
○○ Check the Strobe works by breaking the beam or removing the

dummy plug.
○○ Check the Red light on the Laser illuminates when the beam is
broken (if applicable).
○○ Check the strobe stops flashing by pressing the PRESS WHEN
LOAD/UNLOAD AREA IS CLEAR button. The dummy plug will
need to be refitted.
○○ Push in the Rod Handler ON / OFF button. The JOYSTICKS
ACTIVE light will turn off.
○○ Ensure the controls on the hydraulic power source are in Neutral.
11. Check the oil level in the Power Unit reservoir is full.
12. Turn the cooling water supply on to give a flow of 20–30 LPM.
41
4.5 Control Panel Valve and Gauge Identification
Circuit Pressure Hold Back Pressure P2
Water Pressure Feed Pressure P1
Drilling (UP)
Rod Handling
(DOWN)
Rod Feeding (UP)

Rod Pulling
(DOWN)
Rod Holder Rotation Speed

Feed Pressure
Isolator Valve Control (V16)
Water Fine Feed
Pump
Wireline Hoist Feed Forward/Reverse
Rotation Forward/Reverse
Figure 4–7: LM75/90 Control Panel Valves and Gauges
If attached to a LM75/90 Drill, check the following on the Drill Control

Panel:
●● Rotation and Feed control levers must be in Neutral.

●● Drilling/Rod Handling selector lever must be in ROD HANDLING,
i.e. pulled towards the operator.
●● Wireline Hoist control lever must be in Neutral.
●● Water Pump speed control (if fitted) must be fully wound out (i.e.
anti-clockwise) to the zero speed position and the selector lever in
the centre off position.
●● Rotation speed control (V16) must be fully wound out (i.e. anti-
clockwise) to the low speed position.
●● Rod Feeding/Pulling control lever can be in either position.
42
4.6 Arm Horizontal Sensor (Inclinometer) Set Up
T2 T1
Out1 Out2 Power
Figure 4–8: Arm Horizontal sensor
For the Swing Arm to be in the LOAD/UNLOAD area alongside the

Feed Frame and for the grippers to be opened during Rod Handling,
the HORIZONTAL light on the Control Panel must be illuminated. This
indicates the Head Assembly is positioned within +/- 5 degrees of
horizontal.
Therefore, after replacing any of the Head assembly components, it may

be necessary to set the inclinometer to again consistently recognise
the Arm Horizontal position. To do this it is necessary to “teach”
the inclinometer to recognise the 5 degree deflection limit (for both
clockwise and anti-clockwise rotation when viewed from the front of the
Head Assembly):
1. Position the Head Assembly horizontally alongside the Feed

Frame.
2. Press button T1 on the Arm Horizontal sensor and hold for more
than 2 seconds. The Green Power LED and Yellow Out 2 LED
should not illuminate, and the Yellow Out 1 LED flashes.
3. Raise the end of the Head Assembly front guide assembly approx.
85 mm (equivalent to 5 degrees of clockwise rotation).
43
Figure 4–9:
4. Briefly press T1 and the Yellow Out 1 LED will illuminate for 1.5
seconds, confirming the clockwise switching point has been taught.
5. Lower the end of the Head Assembly front guard assembly approx.
170 mm, i.e. 85 mm to return to its original position and then
lower it a further 85 mm (equivalent to 5 degress of anti-clockwise
rotation).
6. Briefly press T1 once more and the Yellow Out 1 LED again
illuminates, confirming the anti-clockwise switching point has been
taught.
7. Return the Head Assembly to the horizontal position and the

HORIZONTAL light should illuminate, confirming the “teach”
session has been successful.
44
Contents
5.1 Pre-Checks and Warnings........................................................................ 47
5.1.1 Tools.............................................................................................. 47
5.2 Start Up Procedure................................................................................... 47
5.2.1.1 Valve Settings....................................................................... 48
5.3 Checking the Functions........................................................................... 49
5.3.1 Horizontal PLC Function............................................................... 49
5.3.2 Load/Unload PLC Function........................................................... 49
5.3.3 Traverse Cylinder Functions......................................................... 49
5.3.4 Slew and PLC Functions............................................................... 50
5.3.5 Gripper and PLC Functions........................................................... 50
5.3.6 Roller and PLC Functions............................................................. 51
5.3.7 Rod to Drill String Alignment......................................................... 52
5.3.8 Rod Feeding Sequence................................................................. 53
5.3.9 Rod Pulling Sequence................................................................... 54
Tables
Table 5–1: Valve Settings............................................................................... 48
45
46
5.1 Pre-Checks and Warnings
For personal safety, turn the Rod Handler OFF using switch on
the Control Panel, or by turning OFF the Power Pack when making
adjustments.
All speeds and times quoted below are for the Rod Handler when it is
powered by drill hydraulics.
5.1.1 Tools
The following tools are required:
●● 400 bar Gauge with test point connection.

●● 3mm and 6mm Hex keys
●● 10mm spanner.
●● Stop watch, tachometer and patch.
5.2 Start Up Procedure

1. Start the Power Unit.
2. Check for oil leaks and rectify if necessary.
3. Check the valve pressure settings.
Use a 400 bar Gauge with test point connection, a 6 mm Allen

key for setting pressures, and the handle supplied with the valve.
Pressures can be set by dead heading actuators, or plugging hose
ends.
Extreme care is required when operating the valve manually.
47
4. Switch On / pull up the Rod Handler ON / OFF button.
The Main Pump will be heard loading up a little.

If any functions move other than the grippers opening or
closing, TURN OFF Rod Handler immediately and rectify the
problem.
Solenoids
V5
V4
V3
V2
V1
LS B Test Points LS Port (on side)
LS A Test Points Tank Port Pressure Port

Spool Stop Adjustment LS A Setting Screw
LS B Setting Screw
Lever Action
Main Relief
A B
Figure 5–1: Valve Locations
5.2.1.1 Valve Settings

Function Section Relief Valve Action Setting
(bar)
ROLLERS V5 LSA5 Break 200
LSB5 Make 200
GRIPPERS V4 LSA4 Close 120
LSB4 Open 60
HEAD TILT V3 LSA3 Front Up 140
LSB3 Front Down 140
SWING ARM V2 LSA2 Arm Out 140
LSB2 Arm In 140
TRAVERSE V1 LSA1 Extend 120
LSB1 Retract 210
Table 5–1: Valve Settings
48
5.3 Checking the Functions
5.3.1 Horizontal PLC Function

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

LOAD/UNLOAD light: Illuminates when it is safe to load or unload rods
from the device, i.e. to open or close the grippers without dropping a
rod.
The Head assembly must be HORIZONTAL and the Swing Arm in the
OUT position for this light (condition) to illuminate.
Using the left joystick, carefully place the Head assembly into a
HORIZONTAL position in the LOAD /UNLOAD area at the side of the
Feed Frame, then check:
●● ARM OUT light is On.

●● HORIZ. light comes On.
●● LOAD/UNLOAD light comes On.
When viewed from operator side of Feed Frame check:
●● Head rotates anticlockwise when the Left Joystick is moved left.

●● Head rotates clockwise when the Left Joystick is moved right.
●● HORIZ. light goes off when the Head is tilted 10 – 12 degrees in
both directions from horizontal. Rectify if necessary.
Return the Head assembly to a horizontal position.
5.3.3 Traverse Cylinder Functions

●● Ensure the Interconnecting Hose Group does not foul on equipment
during full travel of the Carriage.
●● Move the Right Joystick to the right and check the Carriage moves
towards the rear of the Feed Frame.
●● Check the hydraulic hoses at the rear of valve bank and to the
traverse cylinder do not foul on the rear mounting bracket.
49
●● Move the Right Joystick to the left and check the Carriage moves
towards the front of the Feed Frame.
●● Traverse the Carriage back and forth and check the cushioning
works at both ends.
●● Traverse the carriage back and check the travel time is
5.5 – 6 seconds.
●● Traverse carriage the forward and check the travel time is
3.5 – 4 seconds.
5.3.4 Slew and PLC Functions

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

directions with either ROD FEEDING or ROD PULLING selected.
5. Tilt the Head assembly until the SLEW light illuminates.
6. Select ROD PULLING and move the Swing Arm to the OUT
position and tilt the Head assembly until the Head is horizontal.
5.3.5 Gripper and PLC Functions

GRIPPER PRESSURE light: Indicates the grippers have closed and the
pressure switch is activated.
CLAMP CLOSED light: Indicates the CLAMP OPEN/CLOSE button has

been pressed to close the grippers and the gripper pressure switch is
activated.
CLAMP OPEN/CLOSE button: A toggle button on top of the right

joystick used to open and close the grippers.
50
1. Place an appropriately-sized drill rod in the rod guides fitted to the
Head. The pin thread should be located mid way between the front
two guides.
Check the ROD FRONT and REAR lights come on.

2. With Grippers open, check the Traverse, Roll, Tilt and Swing Arm
functions don’t work.
3. Press the toggle button to close the grippers. The grippers close.
4. Check the GRIPPER PRESSURE and CLAMP CLOSED lights

come on.
5. With a pressure gauge connected to LSA4, check the clamp closes

and the light goes off.
Reset LSA4 to 120 bar and check both lights come back on.
6. Tilt the Head assembly until the HORIZ. light turns off.
7. Press the toggle button to open the grippers. The grippers stay
closed.
8. Tilt the Head assembly until the SLEW light come on.
9. Select ROD FEEDING and rotate the swing arm until the ARM
OUT light turns off.
closed.
11. Select ROD PULLING, and return the Swing Arm to the ARM OUT
position.
5.3.6 Roller and PLC Functions

Place a reflective patch for the tachometer on the side of one of the
driven rollers.
●● Roller rotates clockwise at 280 – 300 rpm.

●● Roller rotates anti-clockwise at 380 – 400 rpm.
With a rod mounted in the Rod Handler head assembly and the grippers
closed, test the following in a horizontal position
●● Rod rolls forward (makes) when the Left Joystick is pushed

forward.
●● Rod rolls back (breaks) when the Left Joystick is pulled back.
●● Rod stops when the rod ends pass over both the FRONT and
REAR ROD proximity switches.
51
●● Rod will only roll away from the grippers once it reaches the
proximity switches.
Return the rod back to a position with the pin thread mid way between
the front two guides.
5.3.7 Rod to Drill String Alignment

OPERATION switch: Used to select either ROD PULLING or ROD
FEEDING.
JOINT OK button: The top right hand piezo button on the Left Joystick.
When ROD FEEDING, press for half a second when the joint is made
up to allow the grippers to open and the Swing Arm to come out.
When ROD PULLING, press for half a second when the grippers are
closed and the joint fully undone and clear of the rod string to allow the
Swing Arm to come out.
1. Move the Rotation Unit fully forward and place short drill rod
through the Rod Holder so that 150 – 200 mm protrudes out the
rear of the Rotation Unit.
2. Select ROD FEEDING. Move the Rod Handler carriage to rear

of the Feed Frame and tilt the Head to make it parallel with Feed
Frame. The SLEW light will illuminate.
3. Move the Right Joystick forward to move the Swing Arm and the
Head assembly in behind the Rotation Unit, with the the front guide
clearing the rear of the drill string.
4. Adjust the Rod Handler at the front and rear mounts so that:
○○ Front guide lines up with the drill string.

○○ Rod in the Handler lines up with the rear rod support roller.
○○ Drill rod sits centrally over the support roller.
○○ Swing Arm mechanical stop may also need to be adjusted.
○○ Head Tilt mechanical stop may also need to be adjusted.
5. Packers can be fitted under the support roller if necessary, but still
allow clearance for water swivel.
6. Select ROD PULLING, and press the JOINT OK button.
7. Using Right Joystick, move the Swing Arm, Head and rod back out
to the side.
52
5.3.8 Rod Feeding Sequence

1. With Head assembly horizontal, place a rod in the guides and close
the grippers.
2. Switch the Rod Pulling / Rod Feding selector to ROD FEEDING

and move the Rod Handler Carriage to rear of the Feed Frame and
tilt the Head to make it parallel with the Feed Frame.
3. The SLEW light illuminates when the Head assembly is near to

parallel with the Feed Frame.
4. Move the Right Joystick forward to move the Swing Arm and Head
assembly in behind the Rotation Unit with the front guide locating
on rear of the drill string.
5. The Swing Arm moves in when the Right Joystick is pushed

forward.
6. The Swing Arm actuator cushioning works near end of travel.
7. The Swing Arm travel in time is 3.5 – 4 seconds.
8. Check the ARM IN light comes on when the line up is complete.
9. The Swing Arm does not come out when the Right Joystick is
pulled back.
10. Roll a rod forward and ensure the thread makes up.
closed.
12. Press the JOINT OK button for half a second.
pulled back.
14. Press the toggle button to open the grippers. The grippers open.
15. The Swing Arm moves out when the Right Joystick is pulled back.
16. Move the Swing Arm back out to the side until the ARM OUT light
on the Control Panel comes on.
17. The Swing Arm does not move in when the right joystick is pushed
forward.
53
5.3.9 Rod Pulling Sequence

1. Switch the Rod Pulling / Rod Feeding selector to ROD PULLING
and close the grippers.
The Swing Arm does not move in when Right Joystick is pushed
forward.
2. Open the grippers then move the Rod Handler Carriage to the rear
of the Feed Frame and tilt the Head to make it parallel with the
Feed Frame.
3. The SLEW light will illuminate when the Head assembly is near to
assembly through 90 degrees (half the swing travel) and stop.
5. Rotate the Head assembly back and forth using the Tilt function.
The Head assembly tilt time is 2.5 – 3 seconds each way through
90 degrees.
6. Tilt the Head until the mechanical stop is reached, and continue to
take the Swing Arm and Head assembly in behind the Rotation Unit
with the front guide locating on the rear of the drill string.
8. Check the GRIPPER PRESSURE OK and CLAMP CLOSED lights

come on.
9. Roll the rod back and ensure the thread breaks fully.
pulled back.
11. Press the JOINT OK button for half a second.
13. Move the Swing Arm back out to the side until the ARM OUT light
comes on.
14. The Swing Arm actuator cushioning works near the end of travel.
15. The Swing Arm travel out time is 3.5 – 4 sconds.
16. The Swing Arm does not move in when the Right Joystick is
pushed forward.
17. Open the Grippers and remove the drill rod.
18. Turn off the Rod Handler at the Control Panel and check for oil
leaks.
54
19. Turn Off the Power Pack and cooling water.
The Rod handler is now ready for operation.
55
56
Contents
6.1 Rod Handler Parts..................................................................................... 59
6.1.1 Front and rear mounts................................................................... 59
6.1.2 Traverse Cylinder.......................................................................... 59
6.1.3 Carriage stop clamp...................................................................... 59
6.1.4 Slide rails....................................................................................... 60
6.1.5 Drill rod stop.................................................................................. 60
6.1.6 Slide blocks and bushes................................................................ 60
6.2 Carriage Slide Bush Replacement .......................................................... 60
6.2.1 Slide Bush Replacement Procedure............................................. 61
6.3 Carriage Assembly.................................................................................... 62
6.3.1 Carriage Frame............................................................................. 62
6.3.2 Swing Arm with hose bulkhead..................................................... 63
6.3.3 Swing Arm mechanical stop.......................................................... 63
6.3.4 Swing Arm actuator and overcentre valve..................................... 63
6.3.5 Swing Arm Cushioning Adjustment............................................... 64
6.3.6 Head Tilt actuator and overcentre valve........................................ 64
6.3.7 Head Tilt actuator guard................................................................ 64
6.4 Valve Assembly......................................................................................... 65
6.4.1 Valve bank..................................................................................... 65
6.4.2 Solenoid control............................................................................. 66
6.5 Head Assembly......................................................................................... 66
6.6 Laser Perimeter Beam.............................................................................. 67
6.6.1 Reflector and stand....................................................................... 68
6.7 Rod Handling Operations......................................................................... 68
6.7.1 Adding a Rod before Rod Feeding................................................ 68
6.7.2 Removing a Rod after Rod Pulling................................................ 69
6.8 Rod Handler Servicing.............................................................................. 69
6.8.1 Laser Safety Beam........................................................................ 69
57
6.8.2 Serial number locations................................................................. 70

6.8.3 Servicing Notes............................................................................. 70
58
6.1 Rod Handler Parts
Front Mount
Carriage Stop Clamp
Slide Blocks and Bushes
Slide Rails
Drill Rod Stop Traverse Cylinder

Rear Mount
Overcentre Valve
Head Assembly Carriage Assembly
Figure 6–1: Rod Handler Parts
The Rod Handler consists of the following parts:
6.1.1 Front and rear mounts

The mounts are used to bolt the Rod Handler assembly to the mounting
kit fitted to the Feed Frame.
6.1.2 Traverse Cylinder

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

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

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

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

The slide blocks attach to the back of the carriage and are used to
support and guide the Carriage along the side of the Feed Frame. The
fitted bushes are replaceable.
Figure 6–2: Slide Bush Replacement Tool
6.2 Carriage Slide Bush Replacement

To replace the slide bearings, the above tool (or similar) must be made.
Only one half is used, and it can be made of brass or steel.
60
The flange helps to extract the tool from the slide block once the old
bearing is pushed out.
This operation should be performed with the Rod Handler in a horizontal

position. The bushes are split in two for ease of removal and fitment.
Replace one split bush at a time, and don’t mix up the bush halves —
they are machined as pairs.
Keeper plate
Slide block
Slide bearing
Figure 6–3: Slide Bearing components
6.2.1 Slide Bush Replacement Procedure

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

nipples provided.
61
6.3 Carriage Assembly
Head Tilt Actuator
Head Actuator shaft

Swing Arm
mechanical
stop
Swing Arm
Carriage Frame
Copper sealing
washers (2)
Swing Arm
Actuator
Actuator guard
Valve
assembly
Figure 6–4: Carriage Assembly
The Carriage assembly includes the following components:
6.3.1 Carriage Frame

The Carriage frame attaches to the carriage slide blocks and traverse
cylinder. The Swing Arm, Valve and Head assemblies mount off this
frame.
62
6.3.2 Swing Arm with hose bulkhead

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

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

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

the actuator with two banjo bolts, and has copper sealing washers
sandwiched between the two items.
Swing Arm Out Swing Arm In
Figure 6–5: Swing Arm adjustment
63
6.3.5 Swing Arm Cushioning Adjustment

A 10mm A/F spanner is required to adjust the actuator cushioning.
Loosen the locknut, and turn screw clockwise to increase cushioning,

then re-tighten the locknut.
Do not wind the screw out more than 13mm from the Actuator body,
otherwise the screw will separate from the body and loss of control of the
Actuator will occur.
High pressure oil could also be ejected from the cavity, causing possible
injury and mechanical damage.
6.3.6 Head Tilt actuator and overcentre valve

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

this actuator also, and it uses the same cartridges as used on the Swing
Arm overcentre valve.
6.3.7 Head Tilt actuator guard

This guard stops carriage hoses getting tangled up and also
incorporates a pick up for the ARM OUT sensor. The Rod Handler will
not function with this guard removed.
64
6.4 Valve Assembly
Solenoids
V5
V4
V3
V2
V1
LS B Test Points LS Port (on side)
LS A Test Points Tank Port Pressure Port

Spool Stop Adjustment LS A Setting Screw
LS B Setting Screw
Lever Action
Main Relief
A B
Figure 6–6: Valve Assembly
The above diagrams show the main components in the valve assembly.
6.4.1 Valve bank

●● Pressure test points for Load Sense relief valves.
●● Pressure switch for sensing gripper pressure.
●● Handle for manual operation.
Use the handle with extreme care, and only if the Rod Handler Control
Panel is switched OFF.
65
SPARE PARTS:
5304378 SEALKIT, PVHC
6.4.2 Solenoid control
5304274 VALVE, PROPORTION

SOLENOID 24V
5304275 PVHC ELECTRICAL ACTUATOR

Figure 6–7: PVHC Actuator (p/n 5304275)
●● The Rod Handler uses Pulse Width Modulation (PWM) current

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

Roller Motor
Head Tilt Stop
Support Tube
Guide Mounts
Gripper
Gripper Cylinder Guides
Figure 6–8: Head Assembly
The above diagram shows the Head assembly components
●● Head frame support tube

66
●● Head Tilt mechanical stop
●● Grippers — both are the same type with an angle built in for rolling
the rods back and forth.
●● Gripper pivot bushes.
●● Gripper Cylinder with overcentre valve — the same cartridge as is
used on the actuator overcentre
●● Head tilt stop block. Swap sides depending on whether drilling
up or down the hole. Limits the tilt to 90 degrees to get the Head
parallel with the Feed Frame and rod string.
●● Guide mounts.
●● Guides — BQ, NQ, HQ and PQ sizes with outer tube handling
provision.
●● Notches are used to indicate the side used when handling rods,
and also as a wear indicator.
6.6 Laser Perimeter Beam

The Laser Perimeter Beam Kit (p/n 3002693) protects drill operators
without hindering their access to the equipment. It uses a Class 2 laser.
The light emitted from this device is safe to look at but is not
recommended.
If the laser beam is interrupted the Joystick controls to the Rod Handler
will be disabled. This will be indicated by the flashing strobe.
The Joystick controls to the Rod Handler can be re-enabled using the
AREA IS CLEAR button.
Note: Before pressing the AREA IS CLEAR button ensure no one is in

the machine work area.
Figure 6–9: Laser Perimeter Beam Kit

67
6.6.1 Reflector and stand

Unlike a PIR beam, this device needs a signal back to operate.
The lasers will not work if less than a metre away from the reflector, and
they have a range of up to approximately 30m.
6.7 Rod Handling Operations
6.7.1 Adding a Rod before Rod Feeding

1. Ensure the Mode selector is in ROD HANDLING.
2. With Head assembly horizontal, place a rod in the guides and close
the grippers. Ensure no operator is near the Rod Handler jaws,
then press CLAMP OPEN/CLOSE, followed by Joint OK.
3. Switch the Rod Pulling / Rod Feeding selector to ROD FEEDING

and move the Rod Handler Carriage to rear of the Feed Frame and
tilt the Head to make it parallel with the Feed Frame.
4. The SLEW sensor light illuminates when the Head assembly is

near to parallel with the Feed Frame.
assembly in behind the Rotation Unit with the front guide locating
on rear of the drill string.
Note: Swing Arm actuator cushioning works near end of travel.
6. Check the ARM IN sensor light comes on when the line up is

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

The grippers open.
10. The Swing Arm will move out when the Right Joystick is pulled
back.
Move the Swing Arm back out to the side until the ARM OUT
sensor light comes on.
68
Note: The Swing Arm does not move in when the right joystick is
pushed forward.
6.7.2 Removing a Rod after Rod Pulling

1. Ensure the Mode selector is in ROD HANDLING.
2. Switch the Rod Pulling / Rod Feeding selector to ROD PULLING.
3. Open the grippers then move the Rod Handler Carriage to the rear
of the Feed Frame and tilt the Head to make it parallel with the
Feed Frame.
4. The SLEW light will illuminate when the Head assembly is near to
assembly through 90 degrees (half the swing travel) and stop.
6. Tilt the Head until the mechanical stop is reached, and continue to
take the Swing Arm and Head assembly in behind the Rotation Unit
with the front guide locating on the rear of the drill string.
8. Check the GRIPPER PRESSURE OK and CLAMP CLOSED lights

come on.
9. Roll the rod back and ensure the thread breaks fully.
10. Press the JOINT OK button (i.e. either of the push buttons on the
Left Joystick) for half a second.
Move the Swing Arm back out to the side until the ARM OUT light
comes on.
Note: Swing Arm actuator cushioning works near the end of travel.
12. Open the Grippers and remove the drill rod.
6.8 Rod Handler Servicing
6.8.1 Laser Safety Beam

The sensor unit used on the Laser Safety Beam is a sealed electrical
device. No maintenance can be performed on the internals of the unit.
69
Periodic cleaning of the external lenses on the laser unit and reflector is
required. This will ensure the beam is reflected successfully and correct
operation of the Laser Safety Beam is maintained.
To test the operation of the laser and reflector system, check the
following:
●● The green light on the front, top corner of the laser unit is on. This
indicates that the power supply to the unit is connected.
●● Check the yellow light on the front, top corner is on. This indicates
the beam is being reflected successfully
●● Break the beam using your hand, the yellow light will turn off.
Remove hand to restore the reflected beam, the yellow light will
turn on.
6.8.2 Serial number locations

Rod Handler: LMRH number on Carriage
Traverse Cylinder: BH and number near rear port.
Gripper Cylinder: BH and number near rear port.
Control Panel: Inside panel assembly
6.8.3 Servicing Notes

●● Bush bearings: All nylon, which should be lubricated with oil when
replacing to increase life expectancy.
●● Carriage slide blocks (4).
●● Head pivot shaft (1).
●● Gripper pivots (4)
●● Gripper thrust washers (3)
●● Head Support shaft bushes (2)
●● Head flex bushes (2). Standard sway bar bushes.
●● Swing Arm rotary actuator removal.
●● Prop swing arm with timber and slings.
●● Head tilt rotary actuator removal.
●● Washer stops head from falling off.
70
Chapter 7: Rod Handler
Troubleshooting
Contents
7.1 Important Information............................................................................... 73
7.2 Troubleshooting Symptoms and Actions............................................... 74
7.3 Hydraulic Circuits..................................................................................... 77
7.3.1 Hydraulic Schematic Symbols....................................................... 77
7.3.2 Rod Handler Hydraulic Circuit....................................................... 79
7.4 Electrical Fault Finding Charts................................................................ 81
7.4.1 Introduction.................................................................................... 81
7.4.2 FAULT/BUTTON PRESSED indicator light................................... 82
7.4.3 Rod Pulling Mode.......................................................................... 82
7.4.4 Rod Feeding Mode........................................................................ 84
7.5 I/O Modules................................................................................................ 85
7.5.1 I/O Module Connectors................................................................. 85
7.5.2 I/O Module Replacement............................................................... 86
7.6 PLC Circuit Diagrams............................................................................... 96
Tables
Table 7–1: Field Module switch settings......................................................... 87
71
72
7.1 Important Information

Please check each section carefully, as what may appear to be a
hydraulics fault at the valve, may in fact be a Control Panel electrical
fault or vice versa.
If you experience any problems not mentioned on this list, please

contact your nearest Boart Longyear office for advice.
When the drill hydraulics are running, hydraulic pressure is supplied

to the Rod Handler DCV pressure port, regardless of whether the Rod
Handler joysticks are active or not.
The lights on the Control Panel have been included to make fault finding
an easier task. The sensor lights on the right hand side of the Control
Panel will only illuminate if a 24V DC signal gets to the particular PLC
input from each of the sensors, then the PLC sends a 24V DC output to
the relevant light. This is important to note when fault finding.
Please note which lights illuminate when a fault occurs. This will help
you and us, should you require outside assistance. This way, we can
quickly eliminate possible causes, and minimise down time.
Two charts are included which show what lights should be on at each
part of the rod handling sequence. This is for both rod feeding and rod
pulling.
All sensors with the exception of the pressure switch, have a light on
them which illuminates when they are sensing an object in their range.
Note also, that all sensors with the exception of the pressure switch,
work even when the hydraulics to the machine are switched off. This
means most electrical faults can be traced safely without the machine
running.
All of the hydraulic control valve sections are controlled via I/O module
inputs and outputs, which have LEDs to indicate their status. These
LEDs are normally yellow when the input or output is activated, and this
will help with fault finding.
In the event of an electrical failure to the Rod Handler and it is

necessary to move it to a safe position, a handle is supplied attached to
the valve assembly for emergency manual operation. It is important to
note that the handle will not operate the spools when electrical power is
still available at the solenoids.
Use this “Emergency Manual Operations” handle with extreme caution.
During manual operation the PLC no longer has control of the

safety functions. Understand what each valve section is used for,
73
and proceed with extreme caution, as a wrong move could mean
injury or death.
7.2 Troubleshooting Symptoms and Actions

Symptom Action
POWER light off or flickers when cable connected to Power Pack

1 All lights on Control Panel are off. Check power available from source.
Check for damage to supply cable between Drill
and Handler Control Panel.
Check for continuity, and for a 24V DC supply with a
multimeter between pin A and C on supply cable.
Replace the cable if necessary.
2 Broken POWER light. If other lights are illuminated on the Control Panel,
check the light wiring inside the Control Panel and
replace the light if necessary.
Laser strobe light flashes when Pull ON / Push OFF switch is pulled up.
Laser beam has been activated, laser cable
damaged, or bridging plug not fitted if laser is not
connected.
NOTE: The PLC monitors sensors and laser beam
when power is available at the Rod Handler Control
Panel, even when Pull ON / Push OFF switch is in
the OFF position.
PLC won’t allow Joysticks to be activated until AREA
IS CLEAR button is pressed. Ensure no one is in the
machine work area before pressing AREA IS CLEAR
Button.
Joystick(s) won’t work.

1 No power to joysticks. If POWER light is OFF, check power supply.
If POWER light is ON, check PULL ON, PUSH OFF
BUTTON is up and JOYSTICKS ACTIVE light is
illuminated.
2 Safety beam activated. Strobe light flashing. Check reflector is in line with laser beam (Red light
goes out on laser and Input 1 on PLC turns on
when set up and aligned). Ensure no one is in the
Button.
If strobe continues to flash, check if Input 1 on PLC
is on. If not, check laser cable for damage and
replace if necessary.
3 Safety beam activated. Check reflector is in line with laser beam (Red light
Strobe light not flashing due to goes out on laser and Input 1 on PLC turns on
74
broken strobe. when set up and aligned). Ensure no one is in the
Button.
Output 9 on PLC illuminates when strobe is flashing.
Symptom Action
Refer to PLC diagram.

Replace broken strobe if necessary.
High voltage shock hazard. When replacing

strobe, wait 6 minutes after removing power
before removing dome.
4 Strobe light flashing. No laser beam fitted. Check bridging plug fitted to rear of Control Panel.
Fit if necessary and press LOAD/ UNLOAD
AREA IS CLEAR button if no personnel are in work
zone.
Without a Laser Beam in place, personnel can
walk into path of device, causing injury or
death.
5 Strobe light flashes when Laser is Check the laser transmitter is not too close to
lined up OK. reflector — it should be at least 1 metre away.
Ensure no one is in the machine work area before
pressing AREA IS CLEAR Button.
Check the AREA IS CLEAR Button provides a reset

signal. Input 12 on the PLC is activated when the
button is pressed.
6 POWER light is on, Rod is loaded Check grippers are closed if a rod is loaded and
into Arm, but Arm will not move. both ROD FRONT and ROD REAR lights are
illuminated.
Handler will not function if a rod is loaded, and the
grippers are open.
If trying to move the arm in or out, check that the Rod
Feeding / Rod Pulling switch is in the correct position
for the operation being performed. Also check that
the Head assembly is parallel with the Feed Frame
and the SLEW light is ON.
If the SLEW light is OFF, the PLC is stopping the
operation from being performed for safety reasons.
7 POWER light is on but sensor lights Check circuit breakers inside Control Panel and
on the front of the Control Panel are off. rectify problem if tripped. Refer to circuit diagrams.
Circuit breaker(s) tripped.
8 Wiring or DCV solenoid fault. With the joysticks active, check that the indication
LEDs on the I/O modules are Orange for those inputs
or outputs that should be activated.
Ensure that the Power indication LEDs on the I/O
modules are flashing Green, indicating that the
module is powered correctly.
Ensure that Red Diagnostics LEDs on the I/O
75
modules are Off.
Check the continuity of cables for any broken or faulty
connections.
Replace or repair as necessary.
Symptom Action
Function(s) slow to operate. Check for corrosion on connectors, valve plug

top or at wiring junctions.
Operate the joystick and check the signal wire voltage
from the joystick varies between 0V and 24V when
the joystick is moved to it’s extremes.
With the joysticks inactive and the drill hydraulics off,
use the lever supplied and operate the relevant valve
section and check for a sticking spool.
Grippers won’t open or close

1 Drilling Assistant trying to load or unload Check Head Assembly is horizontal and Swing
rods at the side of the Feed Frame. Arm is fully out. ARM OUT and HORIZ. lights
should be illuminated on the Control Panel.
PLC will only allow grippers to open or close when

these two conditions are met for safety reasons.
Selecting Uphole Mode will allow the Grippers to

be opened when the Arm is not horizontal.
Check also that the plug tops on the valve section V4
is not loose.
Check that the appropriate output is being activated
on the I/O module. (Node 3 output 2 or 4.) The status
indicator for outputs is the upper yellow LED, and for
inputs it is the lower yellow LED.
Check for corrosion on the connections at the plug
top or any wiring junctions.
2 Trying to add or take rods from the drill Check the Swing Arm is fully in and the ARM IN light
string when the Handler head is behind is illuminated. The Joint O.K. button must be pressed
the Drill Rotation Unit. before the Open command is given to enable the PLC
to open the grippers.
The PLC will only allow the grippers to open or close
when these two conditions are met in this position for
safety reasons.
Check the Rod Feeding / Rod Pulling switch is set
correctly for the mode of operation also.
Check that the plug tops on valve section V4 is not
loose.
Check for corrosion on the connections at the plug top
or at junction boxes if necessary.
3 Rod loaded and Rod Front and Rear lights Open Control Panel and check Input 9 on the PLC is
illuminated. Broken wire or faulty button activated when the Gripper Open / Close button
in either Gripper Open / Close or Joint O.K. is pressed.
76
circuit. Check Input 4 on the PLC is activated when the Joint
O.K. button is pressed.
Check wiring and switches as necessary.
7.3 Hydraulic Circuits
7.3.1 Hydraulic Schematic Symbols

The following component symbols are used on the Rod Handler circuit
diagrams.
Hydraulic Pump, Fixed Capacity, Uni-Directional
Hydraulic Pump, Fixed Capacity, Bi-Directional
Hydraulic Pump, Variable Capacity, Bi-Directional
Hydraulic Motor, Fixed Capacity, Non-Reversible
Hydraulic Motor, Variable Capacity, Reversible
Hydraulic Motor, Fixed Capacity, Reversible
Electric Motor
Cylinder, Double-Acting
Pilot Control Unit
Directional Control Valve 4/2 Lever Actuation, with

Detent
Directional Control Valve 4/2 Hydraulic Pilot Actuation,
Spring Return
Throttling DCV 5/2 Hydraulic Pilot Actuation, Spring-
Centred
Non-Return Valve
Non-Return Valve, Spring Loaded
77
Flow Control Valve, Variable Restriction
Flow Control Valve, Variable Restriction Pressure

Compensated
Main Pressure Relief Valve
Pressure Relief Valve
Unloading Valve, External Drain, Directly Operated
Sequence Valve, External Drain, Directly Operated
Pressure Regulator
Pressure Regulator with Relief Port
Pressure Reducing Valve
Pressure Reducing Valve, with Free Flow Check
Pressure Reducing Valve, Direct Operating Spool with

Check
Counterbalance Valve with Integral Check
Counterbalance Valve with Integral Check, Pilot

Operated
Pilot Operated Dual Counterbalance Valve
DCV 4/3 Valve, Pilot Operated
Shuttle Valve
Throttle Valve
Throttle Valve, Variable Restriction
Shut-Off Valve
78
Proximity Sensor
Electrical Solenoid Control
Working Line, Return Line, Feed Line

Pilot Control Line
Drain or Bleed Line
Flexible Hose
Quick-Acting Coupling – connected with mechanically
opened Non-Return Valve
Accumulator
Filter
Water Trap, Manual Control
Filter with Condensate Trap, Manual Control
Heat Exchanger, Water Cooled
Manual Control
Pressure Switch
Push Button Control
Lever Control
Direct Acting Control by Application of Pressure

Indirect Control, Pilot Actuated by Application of
Pressure
Pressure Gauge
5 Position Rotary Gauge Selector
7.3.2 Rod Handler Hydraulic Circuit

The Rod Holder hydraulic circuit appears overleaf.
79
Figure 7–1: Rod Handler Hydraulic Circuit
80
7.4 Electrical Fault Finding Charts
7.4.1 Introduction
All faults or error conditions on the Rod Handler are detailed by means
of a unique numeric identifier (ID).
A complete list of possible faults is detailed in the Table on the next

page.
All active faults are annunciated using a ‘flash code’ on the ‘Fault/Error’
LED Lamp, centre-left of the Rod Handler control panel.
The flash code sequence is as follows:
1. The first, most significant digit (tens) is indicated using a fast flash
of 0.5 sec ON/OFF (1 HZ).
The count of the number of successive flashes represents the

value of the digit.
2. A 1 sec delay where the LED lamp will remain OFF
3. The second, least significant digit (units) is indicated using a fast

flash of 0.5 sec ON/OFF (1 HZ).
The count of the number of successive flashes represents the

value of the digit.
4. The sequence is followed by a 2 sec delay, where the LED lamp
will remain OFF.
The two digits indicated by the sequence, combined, represent the

numeric ID of the active fault in the range 11-99.
For convenience and ease of presentation, only specific codes detailed

in the following table will be provided.
The above sequence will be repeated for all active faults in numerical
order.
When all active faults have been annunciated, the entire process will be
repeated indefinitely.
To acknowledge the active faults, it will be necessary to rectify the

respective faults, and reset the annunciation process by actuating the
Rod Handler ON/OFF maintained mushroom-head pushbutton.
81
7.4.2 FAULT/BUTTON PRESSED indicator light

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

when the rod handler is operating in Rod Pulling and Rod Feeding
modes.
The PLC unit used with the Rod Handler requires inputs from sensors
for certain functions to occur. Control Panel lights illuminate when the
relevant sensor sends a signal to the PLC.
7.4.3 Rod Pulling Mode

In the following table it is assumed that the Rod Handler is set up on
an angle, and to the side of the Feed Frame at the start of the Pulling
sequence, with the hydraulics operational.
82
OPERATION POSITION OF CONTROLS INDICATION
HANDLER OPERATION LEFT JOYSTICK RIGHT JOYSTICK LIGHTS
UP
MAKE
SLEW
DOWN
BREAK
CLAMP
ARM IN
ARM IN
POWER
CENTRE
CENTRE
PULLING
PULL ON
ROD
FEEDING
JOINT OK
ARM OUT
ARM OUT
REVERSE
PUSH OFF
FORWARD
ROD REAR
ROD FRONT
DCV LIGHTS
HORIZONTAL
PULLING
AREA IS CLEAR
LOAD / UNLOAD
MODE
CLAMPS CLOSED
JOYSTICKS ACTIVE
FAULT CODE (NEW)
LIGHT ON CARRIAGE
GRIPPER PRESSURE
POWER CONNECTED O O O O
ACTIVATE JOYSTICKS O O O O O O O
CHECK LASER STATUS O O O O O O O O
SELECT ROD PULLING O O O O O O O O
CHECK HEAD HORIZONTAL O O O O O O O O X O
Copyright © 2007, 2011, 2013 Boart Longyear. All rights reserved.

CHECK ARM IS OUT O O O O O O O O O X O
CHECK GRIPPERS OPEN O O O O O O O O O O O O

TRAVERSE BACK O O O O O O O O O X O
TILT HEAD TO PARALLEL O O O O O O O O X O
SWING ARM IN O O O O O O O O O O X O
CLOSE GRIPPERS O O O O O O O O O O O O O O
UNSCREW JOINT O O O O O O O O O O O X O
PRESS JOINT OK (0.5 SEC) O O O O O O O O O O O O O O
SWING ARM OUT O O O O O O O O O O O X O
TILT HEAD TO HORIZONTAL O O O O O O O O O O O O X O
TRAVERSE FORWARD O O O O O O O O O O O O X O
OPEN GRIPPERS O O O O O O O O O O O O O
UNLOAD ROD O O O O O O O O O O O
REPEAT CYCLE O O O O O O O O O O O
DEACTIVATE JOYSTICKS O O O O O O O O
O Indicates the Function is used or Light is Illuminated X Indicates tha Light Flashes
3547445
83
OPERATION POSITION OF CONTROLS INDICATION
84
HANDLER OPERATION LEFT JOYSTICK RIGHT JOYSTICK LIGHTS
UP
MAKE
SLEW
DOWN
BREAK
CLAMP
ARM IN
ARM IN
POWER
CENTRE
CENTRE
PULLING
PULL ON
ROD
FEEDING
JOINT OK
ARM OUT
ARM OUT
REVERSE
PUSH OFF
FORWARD
ROD REAR
ROD FRONT
DCV LIGHTS
HORIZONTAL
FEEDING
AREA IS CLEAR
LOAD / UNLOAD
MODE
CLAMPS CLOSED
7.4.4
JOYSTICKS ACTIVE
FAULT CODE (NEW)
LIGHT ON CARRIAGE
GRIPPER PRESSURE
POWER CONNECTED O O O O
ACTIVATE JOYSTICKS O O O O O O O
CHECK LASER STATUS O O O O O O O O
SELECT ROD FEEDING O O O O O O O O
CHECK HEAD HORIZONTAL O O O O O O O O X O
CHECK ARM IS OUT O O O O O O O O O X O
CHECK GRIPPERS OPEN O O O O O O O O O O O O

LOAD ROD O O O O O O O O O O O O
CLOSE GRIPPERS O O O O O O O O O O O O O O O O
TRAVERSE BACKWARD O O O O O O O O O O O O O X O
Rod Feeding Mode
TILT HEAD TO PARALLEL O O O O O O O O O O O O X O
SWING ARM IN O O O O O O O O O O O O X O
MAKE UP JOINT O O O O O O O O O O O O X O
PRESS JOINT OK (0.5 SEC) O O O O O O O O O O O O O O O
OPEN GRIPPERS O O O O O O O O O O O O O
SWING ARM OUT O O O O O O O O X O
TILT HEAD TO HORIZONTAL O O O O O O O O O X O

sequence, with the hydraulics operational.
TRAVERSE FORWARD O O O O O O O O O X O
REPEAT CYCLE O O O O O O O O O
DEACTIVATE JOYSTICKS O O O O O O O O
O Indicates the Function is used or Light is Illuminated X Indicates tha Light Flashes
In the following table it is assumed that the Rod Handler is set up on
an angle, and to the side of the Feed Frame at the start of the Feeding
3547445
7.5 I/O Modules
7.5.1 I/O Module Connectors

Located inside the valve compartment on the Carriage assembly are
three I/O Modules that receive control signals from various sensors on
the Rod Handler.
Figure 7–2: I/O Module connectors
85
7.5.2 I/O Module Replacement
Field Modules Valve Field Module

Node 2 Node 3 assembly Node 4
Node 2 Node 3 Node 4
S1 S2 S3 S1 S2 S3 S1 S2 S3
Figure 7–3: I/O Module rotary switch locations
To replace a faulty I/O module:
1. Turn OFF the Rod Handler and Power Pack.
2. Undo the hex head bolts and remore the cover panel that is
protecting the faulty module, then disconnect the jumper cables
from the module.
3. Remove the 3 capscrews securing the module to the compartment

wall, then remove the 2 capscrews securing the protective cover
across the bottom section of the module to expose the jumper
switches and rotary switches.
86
4. Check the rotary switch setings for the new/replacement I/O
module are the same as in the following table. Use a small
screwdriver to adjust the settings if necessary.
Node/Setting S1 S2 S3
Node 2 (CR2032)
4 0 2
Node 3 (CR2032)
4 0 3
Node 4 (CR2031)
4 0 4
Table 7–1: Field Module switch settings
Once the switch settings have been checked/adjusted the replacement

I/O module can be installed:
5. Replace the protective cover over the jumper switches and rotary
switches across the bottom of the module, then secure the module
to the compartment wall.
6. Reconnect the jumper cables to the I/O module, and replace the
external cover.
The following 8 pages contain technical data sheets for the two I/O
Modules used in the PWM Rod Handler:
●● CR2031 (4 pages), and

●● CR2032 (4 pages).
(This information has been supplied by ifm electronic gmbm,
the manufacturer of the I/O modules. It may be useful for field
electricians.)
87
Control systems
CR2031 69

CompactModule Metal
39
23
Output module 227
digital and analogue 205
for R360 system
CAN out
CANopen interface
PWR DIA
8
2
77
52
Surface electrostatically
9
1
5
7
CAN in
coated (cathodic immersion)
10...32 V DC 6
5
5 LED M12 x1
Technical data 8 digital / PWM outputs

with integrated current measurement
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
Outputs 8 x M12 connector (socket), 5-pole
CANin/CANout 2 x M12 connector (plug/socket), 5-pole
Weight 1.2 kg
Outputs 8
can be configured as digital, positive-switching (high side)
PWM channel,
or current-controlled channel
switching current per output max. 4 A
total current max. 16 A
Operating voltage UB 10...32 V DC
Current consumption ≤ 50 mA (without external load at 24 V DC)
Operating temperature – 40...85 °C
Storage temperature – 40...85 °C
Protection IP 67
Interface CAN interface 2.0 B, ISO 11898
Baud rate 20 Kbits/s...1 Mbit/s (default setting 125 Kbits/s)
(adjustable using hex-code switch in the terminal chamber
or via the CANopen object directory)
Communication profile CANopen, CiA DS 301 version 4, CiA DS 401 version 2.1
Node ID (default) hex 20 (= dec 32)
(adjustable using 2 hex-code switches in the terminal chamber
Indication 1 LED green (PWR)
\DATEN\100\DB-FORM—PZD/03/12/96
1 LED red (diagnosis, DIA)

8 LEDs yellow (status of the outputs)
ifm electronic gmbh • Friedrichstraße 1 • 45128 Essen We reserve the right to make technical alterations without prior notice. CR2031 / page 1 15.03.2006
88
Control systems
CR2031 Technical data
Connecting and operating elements

1 2
5
4 3 1 2
2 1
5
CAN in CAN out
3 4
PWR DIA
Jumper headers
CAGE CLAMP ® upon delivery:
connection clamps 3+4 / 5+6+7
1 2 3 4 5 6 7
Hex-coded
rotary switch
CAN GND +VBB
S1 S2 S3
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)
OUT (yellow) ON binary output: output switched (ON)
analogue output: PWM preset value ≠ 0
current preset value > 20
89
Control systems
CR2031 Characteristics of the outputs
Digital outputs 8 semiconductor outputs; short-circuit and overload protected

Switching voltage 10...32 V DC
Switching current max. 4 A
Total current max. 16 A
The current measurement of 2 channels each can be selected by means of the wire
connections. The following channels are combined: 1+2, 3+4, 5+6, 7+8
PWM outputs With the configuration as "PWM output" two outputs each are combined
(1+2, 3+4, 5+6, 7+8).
PWM frequency 20...250 Hz
Pulse duty factor 50...1000 ‰
Resolution 1‰
Current outputs With the configuration as "current-controlled output" two outputs each are combined
(1+2, 3+4, 5+6, 7+8).
Control range 20...1000 mA / 80...4000 mA
Control resolution 1 mA / 4 mA (see control parameters)
Setting resolution 1 mA
Control characteristics can be set via the object directory (see control parameters)
Accuracy ± 2% FS
Load resistance min. 12 / 3 Ω (at UB = 12 V DC)
min. 24 / 6 Ω (at UB = 24 V DC)
Control parameters By indicating the max. load current [mA] for each output pair the respective control
or value range (1000 or 4000 mA) is automatically selected.
In addition the P/I behaviour of the current controller can be parameterised for each
output pair.
Free-wheel diode is integrated! To avoid errors in the measuring result, no external free-wheel diode must be
connected in parallel with the load in the "current-controlled output" operating mode.
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, pulses 2, 3a, 3b, 4, severity level 4, function state A
to conducted interference to ISO 7637-2, pulse 5, severity level 1, function state A
to ISO 7637-2, pulse 1, severity level 4, function state C
Immunity to directive 95/54/EC at 100 V/m (e1 type approval)
to interfering fields and DIN EN 61000-6-2 (CE)
Interference emission to directive 95/54/EC (e1 type approval)
and DIN EN 61000-6-3 (CE)
90
Control systems
CR2031 Wiring

Outputs 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)
91
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
9
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
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
Displays 1 LED green (PWR)
1 LED red (diagnosis, DIA)
16 LEDs yellow (status of the inputs / outputs)
92
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
93
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
■ PWM outputs
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
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)
94
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)
95
7.6 PLC Circuit Diagrams

The remaining pages in this chapter contain copies of the PLC circuits.
96
USED ON ITEM DESCRIPTION MAT'L REQ'D

THE DESIGNS, CONSTRUCTIONS, ARRANGEMENTS,
ISSUE DATE EO No. RELEASED FOR / REVISION ISSUE DATE EO No. RELEASED FOR / REVISION DO NOT SCALE DISCLOSURES, AND DEVICES SHOWN OR DEFINED MATERIAL
IN THE PROPOSAL, DRAWINGS, OR SKETCHES
UNLESS OTHERWISE SPECIFIED: BEARING THIS LEGEND, ARE THE PROPERTY OF
A 10 MAY 12 123491 REFER ECN LONGYEAR AND ARE SUBMITTED IN CONFIDENCE
ALL DIMENSIONS IN MILLIMETRES WITH THE UNDERSTANDING THAT SUCH DESIGNS,
UG-ROD HADLER CAN -PWM
OR MICROMETRES CONSTRUCTIONS, ARRANGEMENTS, DISCLOSURES,
PERMISSIBLE TOLERANCES ON AND DEVICES SHALL NOT BE UTILIZED IN WHOLE
EXTERNAL CONNECTION
OR IN PART BY ANY PERSON, FIRM, OR
DIMENSIONS: CORPORATION WITHOUT THE PRIOR WRITTEN
PERMISSION OF THE LONGYEAR COMPANY. SCALE WT. DATE 3.06.2011 DWG. SIZE A1
3547445
DWN F.ALEITE SHEET 1 OF 17
DWG. NO.
Boart Longyear Pty Ltd, Mitchell Park, South Australia.
97
98

ALL DIMENSIONS IN MILLIMETRES UG-ROD HADLER CAN -PWM
WITH THE UNDERSTANDING THAT SUCH DESIGNS,
POWER SUPPLY
DWG. NO.
3547445
LEFT HAND JOYSTICK
S0304

POTENTIOMETER
POTENTIOMETER
LH JOYSTICK
3547445
DWG. NO.
99
100
RIGHT HAND JOYSTICK
S0404


RH JOYSTICK
DWG. NO.
3547445
ROD HANDLER CONTROL SYSTEM

PLC SYSTEM ARRANGEMENT

PLC ARRANGEMENT
3547445
DWG. NO.
101
102
ROD HANDLER CANBUS - PWM CONTROL SYSTEM
A B
ROLL BRAKE
ROLL MAKE
A B
TILT DOWN TILT UP
5 6 7 8
A B
3 4 5 6
ARM IN ARM OUT
1 2 3 4
A B
TRAVERSE TRAVERSE
CAN in CAN out FORWARD 1 2
REVERSE
PWR DIA
CAN in CAN out
PWR DIA

5 6
GRIPPERS
A
3 4
GRIPPERS
1 2 B
CAN in CAN out
PWR DIA

I/O CONNECTION
DWG. NO.
3547445

OPERATOR INTERFACE CONNECTION
3547445
DWG. NO.
103
104

ALL DIMENSIONS IN MILLIMETRES UG-ROD HANDLER CAN-PWM
OPERATORS INTERFACE CONNECTION
DWG. NO.
3547445

UG- ROD HANDLER CAN-PWM
I/O CONNECTION
3547445
DWG. NO.
105
106
7 8
5 6
3 4
1 2

CAN in CAN out
PWR DIA

ALL DIMENSIONS IN MILLIMETRES UG-ROD HANDLER CAN-PWM
NODE 2
DWG. NO.
3547445

UG- ROD HANDLER CAN-PWM
I/O CONNECTION
3547445
DWG. NO.
107
108
7 8
5 6
3 4
1 2

CAN in CAN out
PWR DIA

UG-ROD HANDLER CAN-PWM
NODE 3
DWG. NO.
3547445
Y1303 Y1327
TRAVERSE
FORWARD TILT DOWN
(V1B) (V3B)
Y1309 Y1332

TRAVERSE
REVERSE TILT UP
(V1A) (V3A)

Y1314 Y1337
ROLL MAKE
ARM IN (V5B)
(V2B)
Y1319 Y1341
ARM OUT ROLL BREAK

(V2A)
(V5A)
I/O CONNECTION - PWM VALVES
3547445
DWG. NO.
109
110
7 8
5 6
3 4
1 2

CAN in CAN out
PWR DIA

ALL DIMENSIONS IN MILLIMETRES UG-RODHANDLER CAN-PWM
PWM VALVES - MODULE
DWG. NO.
3547445
(1) CABLE 15 (1)

(2) 15m (2)
(3) (3)
(4) (4)
(5) (5)
(6) (6)
(7) (7)
(8) (8)
(9) (9)
(10) (10)
(11) (11)
(GN) (GN)

UG-ROD HANDLER CAN-PWM
CABLE 15
3547445
DWG. NO.
111
112
SYSTEM SENSORS
POWER JOYSTICK LOAD / CLAMP ROD ROD

ON ACTIVE UNLOAD CLOSED HORIZ. FRONT. REAR
FAULT / BUTTON GRIPPER

PRESSED ARM IN SLEW PRESSURE
ROD HOLDER
PULL ON / PUSH OFF
DOWN UP
FORWARD REVERSE
CLAMP
JOINT OK OPEN / CLOSE
BREAK (ANTI CLOCKWISE)

ARM OUT
ROD PULLING ROD FEEDING

PRESS WHEN LOAD / UNLOAD OPERATION
AREA IS CLEAR
X24 X23 X22 X21

LAYOUT
DWG. NO.
3547445
Chapter 8: Recommended Spare
Parts Kit
Contents
8.1 12 Months Operation.............................................................................. 115
8.1.1 Rod Handler ............................................................................... 115
8.1.2 Carriage Assembly...................................................................... 115
8.1.3 Valve Assembly PWM................................................................. 115
8.1.4 Interconnecting Cable to Rod handler......................................... 116
8.1.5 Interconnecting Cable to LM Power Pack................................... 116
8.1.6 Laser Perimeter Beam................................................................ 116
8.1.7 Head Assembly........................................................................... 116
8.1.8 Guide Sets................................................................................... 116
8.1.9 Control Group Rod Handler......................................................... 117
113
114
Description Part No. Qty
8.1 12 Months Operation

8.1.1 Rod Handler
Complete Assembly 5304600
SLIDE BEARING 3001401 4

SEAL KIT TRAVERSE CYLINDER 6003643 1
NIPPLE GREASE M6 45 DEGREES 84630 4
NIPPLE GREASE M6 90 DEGREES 87171 2
8.1.2 Carriage Assembly
Complete 5303830
BEARING SELF ALIGNING 602494 1

BUSH HEAD SHAFT PIVOT 3001860 1
WASHER SEALING 3/8” BSPP COPPER 3000539 2
WASHER SEALING 3/8” BSPP 94715 2
IO MODULE CAN CR2032 - INPUT 5302493 1
IO MODULE CAN CR2031 - OUTPUT 5301966 1
CABLE 21 SOLENOID VALVE 5304190 2
CABLE 22 SOLENOID VALVE 5304191 2
SENSOR PROXIMITY M12 3069645 3
CABLE M12 JUMPER 1300MM 5304193 3
INDICATOR LIGHT 5 PIN CONNECTOR 3070220 1
8.1.3 Valve Assembly PWM
Complete 5304270
TEST POINT 1/4” BSPP 88738 2

SWITCH PRESSURE 5303958 1
SEAL KIT PVHC VALVE ASSY 5304378 1
ELECTRICAL ACTUATOR PVHC 5304275 2
115
8.1.4 Interconnecting Cable to Rod handler
CABLE ASSEMBLY 7-PIN 5304196 1
8.1.5 Interconnecting Cable to LM Power Pack
CABLE ASSEMBLY 10-PIN 89182 1
8.1.6 Laser Perimeter Beam
Complete Assembly 3002693

CABLE INTERCONNECTING 89182 1
KNOB HAND 602334 1
SAFETY BEAM LASER 3002694 1
8.1.7 Head Assembly
Complete 3000320
BUSH SUPPORT TUBE PIVOT 3001451 2

BUSH GRIPPER PIVOT 3000324 4
WASHER GRIPPER PIVOT 3001346 3
BEARING BALL 30 ID x 72 OD x 19 W 62617 4
BEARING BALL 30 ID x 62 OD x 16 W 30949 4
INDUCTIVE SENSOR – ROD END 3070221 2
SENSOR PROXIMITY M12 3069645 1
SENSOR INCLINATION SINGLE AXIS 5304186 1
CABLE M12 JUMPER 4000MM 5304192 4
RING RETAINING 101805 6
ROLLER 3001348 4
CAP ROD ROLLER BEARING 602743 2
SEAL KIT GRIPPERCYLINDER 6003643 1
CARTRIDGE O/C VALVE 5301608 1
8.1.8 Guide Sets
GUIDE SET BQ — BQ OUTER TUBE 3001703 1
116
GUIDE SET NQ — NQ OUTER TUBE 3001354 1
GUIDE SET HQ — HQ OUTER TUBE 3001355 1
GUIDE SET PQ — PQ OUTER TUBE 3001353 1
8.1.9 Control Group Rod Handler
Complete 5303840
JOYSTICK DUAL AXIS 3070198 1

L.E.D. 10mm GREEN 3069198 1
L.E.D. 10mm RED 3069199 1
SWITCH TOGGLE 2-POSITION FEED/PULL 3069202 1
SWITCH PUSH BUTTON - RESET 3069201 1
RECEPTACLE X22 LOOM - POWERPACK 5304932 1
CAP X22 – POWERPACK RECEPTACLE 3069206 1
RECEPTACLE X23 LOOM – ROD HANDLER 5304933 1
CAP X23 – ROD HANDLER RECEPTACLE 5304467 1
PLUG BRIDGING 10 PIN - LASER 3001689 1
LIGHT STROBE AMBER 3070199 1
117
118
www.boartlongyear.com
Copyright © 2012 Boart Longyear. All rights reserved.

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GLOBAL DRILLING PRODUCTS

Copyright © 2013 Boart Longyear. All rights reserved.

PWM ROD HANDLER

Chapter 3: The Rod Handling Device

Chapter 4: Rod Handler Set Up

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

Chapter 5: Rod Handler Start Up

Chapter 6: Rod Handler Operations

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

Chapter 7: Rod Handler Troubleshooting

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

Chapter 8: Recommended Spare Parts Kit

Chapter 3: The Rod Handling Device

Figure 3–4: Operating status indicator............................................................. 30

Chapter 4: Rod Handler Set Up

Chapter 5: Rod Handler Start Up

Chapter 6: Rod Handler Operations

Chapter 7: Rod Handler Troubleshooting

Chapter 8: Recommended Spare Parts Kit

THIS PAGE INTENTIONALLY LEFT BLANK

THIS PAGE INTENTIONALLY LEFT BLANK

1.1 Important Safety Information

1.1.1 Hazard Signal Indicators

“Danger” indicates an imminently hazardous situation which, if not

“Warning” indicates a potentially hazardous situation which, if not

“Caution” indicates a potentially hazardous situation which, if not

Note: Notes are indicated to draw attention to detailed instructions.

These notices are given to prevent personal injury, death and/or

1.1.2 Safety Guidelines

Safety is the most important element of any procedure. Preparation is

●● Keep clear of rotating equipment. Wear proper clothing. Loose or

●● Never climb on top of the machine.

Note: For additional information on training or start-up, contact your

1.2 Cautions and Warnings

Figure 1–1: STOP WARNING — Stop and observe the

Figure 1–2: DO NOT CLIMB— No climbing activity to occur

Figure 1–3: BODY CRUSH HAZARD — Moving parts of the

Figure 1–4: MANUAL — Indicates to refer to this manual before

Figure 1–5: CRUSH HAZARD — This part of the machine has a

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

Figure 1–7: HOT SURFACE — Surface adjacent to this warning

Figure 1–8: PRESSURE VESSEL — This component is

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

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

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

Figure 1–13: LOADED SPRINGS — Warning that springs inside

THIS PAGE INTENTIONALLY LEFT BLANK

THIS PAGE INTENTIONALLY LEFT BLANK

2.1 General Information

Read this Manual carefully before attempting to operate the PWM

Boart Longyear is backed by more than 100 years of experience in the

To obtain the utmost in performance and life of the equipment, it should

2.2 Prior to First Use

●● Visually inspect the equipment for any loose hoses, fittings, or

2.3 Ordering and Returning Parts

2.3.1 Ordering Parts

1. Name, model and Boart Longyear serial number of the product,

2. Boart Longyear part number and description of parts as shown in

3. Specify the quantity required for each line item.

4. Full shipping instructions:

5. Special instructions, if any.

2.3.2 Returning Parts

2. You will also need to submit a letter: