Atlas Copco Underground drill rigs

Diamec U4
Direct Hydraulic system.

Printed matter No: 6991 1449 01

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 Contents

Page

1. Power Unit 45E 3

2. Hydraulic system Diamec U4 (3719 0017 05) 4

3. Control panel for Diamec U4 (3719 0018 62) 4

4. Main valve (1V3 - 3719 0017 15) 6

5. (Drill control valve (1V6 – 3719 0018 05) 7

6. Logic valve (1V5 – 3719 0018 07) 8

7. Valve assembly for Diamec U4 (3719 0018 90) 9

8. Positioning valves (1V16 - 3719 001901) 10

9. Explanation of the Load sense system principle 11

10. Hydraulic diagrams 12

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Power Unit 45E

Electrical Motor (0M1) data:

ABB 45 kW High Efficiency 4 pole motor
50 Hz: 380-415V D, 1480 rpm
660-690V, 1000 Y, 1480 rpm
60Hz: 440V, 515V D, 1776 rpm
(Other voltages available on demand)

Hydraulic Main Pump (0P1) Data:

Bosch Rexroth GMBH A1OV 85cc
Automatic adjusted by actuators, maximum;
Pressure: 280 bar
Flow: 120 l/min @ 50 Hz, 145 l/min @ 60 Hz
Stand by setting: 22 bar
Hydraulic Service Pump (0P2) Data:
Bosch Rexroth GMBH A1OV 28cc
Automatic adjusted by actuators, maximum;
Pressure: 200 bar
Flow: 37 l/min @ 50 Hz, 45 l/min @ 60 Hz
Stand by setting: 22 bar

Cooler (0Z1)
On the Diamec U4, a water/oil cooler is mounted as standard. As an alternative, an Air/oil cooler can
be chosen instead. A hydraulic motor drives the Air/oil cooler.

Filters (0F1, 0F2)

There are two filters in the hydraulic system; they are Return filter (0F1, placed on the hydraulic tank)
Air filter (0F2, placed on the hydraulic tank). Recommended change interval on all filters is one year.
The rig is equipped with 10 micron filter inserts from factory in return filter, replace with original parts of
same quality only.

Hydraulic oil tank (TI)

The tank size is 70 liter of oil; it is equipped with a sight glass and thermometer. It is equipped with air
filters and has a combined temperature and level guard sticking down from the lid (0S1). On the front
side there is a drain box, this in order to get a controlled drain oil flow into the tank. The drain box is
filled with oil, before disconnecting any drain hose please empty the box with the connected hand
pump (0P3). The drain box also have a magnetic plug for indication and removal of metal particles in
the oil (0Z4).

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Hydraulic system Diamec U4 (3719 0017 05)
The Hydraulic system controlling Diamec U4 is divided in two places –
the control panel (3719 0018 62)
and the valve assembly (3719 0018 90, placed at the drill rig.

Control panel for Diamec U4 (3719 0018 62)

GRR Right rotation pressure gauge

GHB Holdback pressure on

rod string (kN kilo Newton’s)

GRPM RPM meter for rotation

head.(Option)
1V7 Control lever for manual
opening of rod holder. Locking
device to keep rod holder lever in
”rod holder closed” position.

1V3 Main valve:

1V3A Control lever for wire line

winch in and out.

1V3B Control lever for rotation

clockwise/counter clockwise.

1V3C Control lever for flush water

pump in high speed non drilling mode
(backward interlock).

Fine feed enable (forward

interlock).

1V3D Control lever for rod

handling
- Forward/backwards movement for
controlling fast travel, chuck and rod
holder

1V13 Control knob for wire

line free wheeling.

2V1 Control lever for flush pump in drilling mode.

1V6 Drill control valve:

6D Control knob for speed regulation for rotation head.

6F1 Control knob for hold back pressure on drill string.

6F2 Control knob or feed force pressure on drill string.

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 1V5 Logic Valve

WD Water pressure dump valve for relieving flush water pressure in the drill string

S3 Emergency stop button for tripping motor.

1V4 Control lever selection for rodrunning mode with 3 positions:

- rodrunning in (forward)
- drilling (center position)
- rodrunning out (backwards)

GWQ Flowmeter for flush pump water flow -liters per minute.

GP1 System pressure gauge for main hydraulic pump circuit (bar)

GWP Waterpressure at flushpump outlet (bar).

GFD Feed force pressure on rodstring (kN kilo Newtons)

The adjustments on the hydraulics in the panel:

Nozzle 1V19 on Break port in valve 1V5 is an adjustable nozzle that will feed oil into the feed cylinder
to create thread compensation when breaking.
Nozzle (valve) 5E controls delay of chuck closing when breaking to get the dynamic effect.
Valve 5H sets the flow to the clockwise rotation and chuck oil, should be set to 90 -92 liters.
Flows and pressure according to description of valve 1V3 below

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Main valve (1V3) (3719 0017 15)

The main valve is a load sense valve with four work port sections. Starting from the inlet section, they
control: Wire line hoist, Drill motor, Water pump/Fine Feed and the Feed cylinder in Fast Feed mode

1V3A Wire line section: closed

center spool.
Settings: 75 l/min, pressure
limiting valve set at 180 bars

1V3B Drill motor section:

open center spool.
Settings: 92 l/min in B direction
(clock wise rotation), 50 l/min in
A direction (anti clockwise
rotation),

1V3C Water pump/Fine Feed

section: open center spool.
Settings: 5 l/min in B direction
(Fine Feed supply), 30 l/min in A
direction (Water pump supply),
Pressure limiting valve for water
pump supply set at 200 bars

1V3D Feed cylinder section:

open center spool.
Settings: 110 l/min in A and B
direction.

All four main valve sections are lever controlled from the control console.
In the inlet section there is a pressure relief valve set at 300 bars, to prevent pressure peaks in the
hydraulic system.

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Drill control valve (1V6) (3719 0018 05)

The drill control valve is a block with several valves included:

Valve 6F1 controls the hold back pressure from 10 to 315 bar. Located on top surface.

Valve 6F2 controls the bit force pressure from 10 to 315 bar. Located on top surface.

Valve 6B will select the highest pressure from the feed and holdback valves to feed into the main
valve to be forwarded to the pump regulator, creating the needed pressure. Located on back surface
in deep groove.

Valve 6D controls the displacement control pressure from 2 to 55 bar to the rotation motor. Located on
top surface.

Valve 6A1 and 6A2 helps isolating the volume around the cylinder – to prevent the feed cylinder to
drift when not pressurized. Located on back- (6A1) and front- (6A2) surface in shallow grooves.

Nozzle 6C1 and 6C2 sets the maximum speed used in fine feed movement of the cylinder. Located
on left surface under plugs.

Nozzle 6E delays displacement decrease of rotation motor, to overcome the stick-slip friction in
rotation unit. Located on front surface under plug.

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Logic valve (1V5) (3719 0018 07)

The logic valve is positioned inside the column of the control panel, it have several valves included:

Nozzle 1V19 on Break port in valve 1V5 is an adjustable nozzle that will feed oil into the feed cylinder
to create thread compensation when breaking.

Check valve 5C3 prevents holdback pressure to enter the logic valve and passes oil for thread
compensation in break mode to pass. Valve 5C3 is located inside Break port on top surface.

Valve 5E controls delay of chuck closing when breaking to get the dynamic effect. Valve 5E is located
on front surface.

Valve 5G nozzle give a time delay to let the chuck close before the rod holder opens in drilling mode.
It also prevents the Rod holder to open in Make/Break mode, and make sure the Rod holder closes
before chuck opens when rod running. Valve 5G is located inside Sync port on top surface.

Valve 5G check valve keeps the pressure in the rod holder from leaking out; the oil must drain
through commutator for safety reasons.

Check valve 5D1 and 5D2 prevents pressure in the chuck to leak out, and closes the chuck when
rotating, in make, in break and in drilling mode. Located on right surface (5D1) and left surface (5D2)
under plugs.

Shuttle valve 5B gives opening signal valve 5A1 to drain feed cylinder when there is a need for
thread compensation in make or break. The valve is located on back surface in deep groove.

Check valve 5C1 and 5C2 prevents control valve 1V4 signal to enter the logic valve and passes
drainage from feed cylinder in thread compensation in make or break mode. They also prevents
pressurized oil in Feed cylinder to drain of to tank. Valves are located on back surface (5C1) and
bottom surface (5C2) under plugs.

Pilot check valve 5A1 and 5A2 helps isolating the volume around the cylinder – to prevent the feed
cylinder to drift when not pressurized. In clockwise rotation, 5A1 and 5A2 will open, Valve 1V4 will
determine if feed cylinder is floating or not. In counter clockwise rotation, 5A1 will open. Valves are
located on the right surface.

Valve 5F reduces pressure for closing the hydraulic chuck, it is located on the right surface.

Valve 5H control the pressure compensating valve in the rotational section on the main valve (Valve
1V3I) to get the proper flow for clockwise rotation and chuck lubrication. 5H should be set so that 90 –
92 l/min leaves B port on section 1V3B; it is located on the right surface of valve block 1V5.

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Valve assembly for Diamec U4 (3719 0018 49)
1V10 Shuttle valve for release of cylinder pressure when thread compensation needed
1V11 Sequence valve to create minimum pressure to guarantee open rod holder and closed
chuck when clock wise revolution of rotation unit, set to 110 bar.
1V8, 1V9 Counter balance valves creates a closed volume around the cylinder – to prevent the feed
cylinder to drift when not pressurized. They should be set to 280 bar.
1VRPM “Nozzle – check” valve to delay Rpm signal to decrease displacement on rotation unit
motor, extra valve for Cargill salt delivery to handle the 25 meter long hoses.

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Positioning valves (1V16) (3719 0019 01)

The skid version of the Diamec U4 is equipped with a positioner arm with two pivoting points.

Valve 1V16 is placed on the operator’s side at the side of the

positioner. It is a 3-valve section block with open center motor
spools. A pressure-limiting valve protects the cylinders from over
loading.

Section 16V1 is plugged; it may be used for customer unique

needs.

Section 16V2 is used for raising the feed frame. On the cylinder
a dual counter balance valve is placed to keep the cylinder
locked in position over time, and also prevent possible accidents
in case of a hose break or excessive force on the feed beam.

Section 16V3 is used for tilting the positioner arm. On the

cylinders a dual counter balance valves is placed to keep the
cylinder locked in position over time, and also prevent possible accidents in case of a hose break or
excessive force on the feed beam.

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Explanation of the Load sense system principle.
In a LS-system the pump is constantly trying to keep a
certain pressure drop over the LS-valve (and the hoses
and fittings). If the standby pressure is 22 bar, the
pressure drop over the valve (Δp) is approximately 19
bar.
The difference is caused by the internal control pressure
and leakage in the pump regulator. Whenever the size of
the passing over the valve is changed (spool is shifted
with lever), the pump reacts with a change in flow
(displacement change) to keep the pressure drop over
the valve constant. I.e. the flow regulation is really made
in the pump; the valve just controls the pump. The Load
sense signal runs from after the in-flow side of the valve
(before the actuator) - through the spool (black arrows
outside blue main flow arrows in spool - to the pump
regulator, see figure to the right. The shuttle valve in the
valve section feeds the highest pressure demand from
the connected load sense valves to the pump.
The upper regulating valve on the pump is the load-
sensing spool (compare figure below and to the right).
The spring adjustment determines the desired pressure
drop over the LS-valve. System pressure from the left
side of the spool balance the pressure in Load sense
hose plus the spring force. If the pressure drop
increases over the LS-valve (less throttle on the actuator
wanted), LS hose get less pressure, the load-sensing
spool shifts to the right and more pressure passes the
lower (pressure limiting) spool and changes the force
balance on the cradle holding the pistons in the pump.
The cradle then swivel in (less angle - less stroke of the
pistons), the displacement in the pump and flow from the
pump reduces until new balance is found and the
pressure drop over the LS-valve equals the spring
adjustment in the pump regulator again. The lower
adjustment on the pump regulator, the pressure limiting
spool, compares system pressure from the left with the
pre-set spring force from the right and relieves pressure
higher than wanted (280 bar in the Diamec U4 case).

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Hydraulic diagram Components used for wire line control

Main Pump supplies 1V3 – Main valve with pressure and flow. In the inlet section, valve 1V3E supplies
freewheeling valve - 1V13 - with 30 bar. 1V13 can to disconnect the motor ports of wire line motor –
1WL from the hydraulic pressure and flow with valve 1V14. 1:st Main valve section 1V3A controls wire
line motor, port B to lower the hoist and port A lo lift. Load sense function controls the pump.

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Hydraulic diagram Components used for flush water control

The water pump motor can be supplied with oil from either of the hydraulic pumps in the power unit.
When drilling, the main pump supplies oil to the rotation unit, chuck and rod holder and fine feed. To
avoid disturbances from oscillations in the water pump, the drill water is then supplied with flow and
pressure from the auxiliary pump - 0P2. From 0P2, the oil goes to 2V1 on the front of the control panel
- a variable, pressure compensated constant flow valve. After 2V1, pressure is fed back to 0P2 “X”
port, the load sense port. After the 2V1 valve, the oil passes check valve 2V2 (that protects 2V1 and
0P2 from back pressure) and drives the water pump motor at a constant speed, regardless of pressure
variations in the water system. Check valve 1V15 isolates the water pump motor from the open center
spool in main valve section 1V3C.

When flushing the drill hole or pumping in the over-shot or inner tube, additional oil from main pump -
0P1 - can be used to speed up the water pump. Main valve section 1V3C is used and controls the 0P1
pump. 1V3C is limited so that the two valves (2V1 and 1V3C) and pumps can be used in parallel
without over speeding the water pump.

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Hydraulic diagram Components used for drilling rotation

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Hydraulic diagram Components used for rod running into the hole

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Hydraulic diagram Components used for breaking a rod joint

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