ROCK DRILL TRAINING

HYDRASTAR 200
 Hydrastar 200

1. General presentation

2. Working principle

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 General Presentation

Application

The Hydrastar 200 is designed for rock bolting in hard

rock with Sandvik bolters.
It’s also suitable for tunneling and mine devellopment
drilling with Sandvik Narrow vein mining jumbos.

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 General Presentation

Main Characteristics

The compact design of the Hydrastar 200 hydraulic percussive

rock drill, when mounted on the TU-C bolting heads, provides to
Sandvik bolters a excellent ability to install bolts wherever it is
need to, even in real uneven conditions.
The power level perfectly fitted to the application enables an
outstanding lifetime to the drilling tools.
Biodegradable oils can be used both in hydraulic and in shank
lubrication to reduce risk of environment.

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 General Presentation
1. Pressure accumulator
2. Rotation mecanism
3. Percussion mecanism
4. Flushing head

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 General Presentation

Main Specifications

Hole diameter: Bolting 27  45 mm

Drifting 35  41 mm

Power class: 10 kW

Percussion rate: 40 - 65 Hz (according to percussion pressure)

Operating pressure:
Percussion 140 - 200 bar
Rotation (max) 210 bar

Rotation motor type: OMS 125

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 General Presentation

Rock Tools

Drill steels

Bolting H25 - H28 drifter rods

H22 - H25 integral rods
Drifting H25 - H28 drifter rods

Shanks

Bolting Female R25-R28-R32

Drifting Male R32-R38

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 General Presentation

Main Dimension

Length: 765 mm
Profile height: 152 mm
Width: 297 mm
Weight: 95 kg

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 General Presentation

Rotation Mecanism

Motor Orbit: OMS 125

Torque (at 210 bar): 420 Nm
Rotation speed: 0...300 rpm
Flow (at max speed): 40 l/min

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 General Presentation

Percussion Mecanism

Operating pressure: 140 - 200 bar

Percussion power: 6 - 10 kW
Percussion rate: 40 - 65 Hz
Flow: 60 l/min

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 General Presentation

Accumulator

Accumulator: gas Nitrogen N2

Inflating pressure: 55 bar
Filling valve: Vg8 DIN 7756

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 General Presentation

Flushing

Max pressure (air/water): 15 bar

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 General Presentation

Shank Lubrication

Air flow (at 6 bar):250 l/min

Pressure: 2.5 bar
Oil consumption: 100 g/h

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 General Presentation

Oil Recommendations

Oil operating temperature: +40...+65° C

Oil Type:
Shell Tellus S68 (Ambient temperature between 0 °C and +30 °C)
Shell Tellus S100 (Ambient temperature above +30 °C)

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 Working Principle

Hydraulic law

Liquid transmit applied pressure in all directions and act with equal force
on all equal areas and at right angles to them.

Force = Pressure x Area

Force: daN, pressure: bar, Area: cm²

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 Working Principle

Hydraulic law

F1 s1

F2 s2

p
s1>s2
p x s1 = F1 p x s2 = F2
F1>F2
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 Working Principle

Hydraulic law

p1 p2

s1 s2

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 Working Principle

From the drilling regulation block, the percussion pressure is always directed to the front chamber of the percussion
mecanism, the shuttle valve and the accumulator.
The shuttle valve allows the rear chamber to be alternatively pressurized by the percussion flow then connected to the
return line.

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 Working Principle

The piston reaches the impact point, the pressure within the pilot channel can be release to the return due to the groove of
the piston.
The pressure is applied now only ot the smallest pilot chamber of the shuttle valve. This will move in the position shown
allowing the rear chamber of the piston to be connected to the return.
THE PISTON WILL START THE REVERSE MOTION
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 Working Principle

When the piston reaches the rear position, the high pressure from front chamber flows into the pilot channel.
Both pilot chambers of the shuttle valve are now pressurized. But as the pilot chamber is the largest, the valve will move in
the position shown.
The rear chamber of the piston is pressurized. The rear chamber is larger than the front one.
THE PISTON STARTS TO MOVE FORWARD
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 Working Principle

Purpose of the accumulator

The accumulator store energy during the reverse motion.

This energy will be supplied to the percussion mecanism at the end of the
forward motion to achieve the highest speed at the impact point.
While the drifter is working, the percussion flow needed varies according
to the position of the piston . The accumulator absorbs the flow surges.
By keeping the accumulator in good working order, you prevent the hoses
vibrations and poor drilling performance.

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 Working Principle

Shuttle valve principle

From the pressure inlet groove, the pressure hole allows oil to flow to each
ends of the shuttle valve. The high pressure is therefor always applied on both
sides of the spool on diameter D1 and D2.
The pilot area is alternatively pressurized then connected to the return. When
it is pressurized the whole diameter D3 is pressurized (area D1 + the ring area
of the pilot area).

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 Working Principle

The motion of the valve can be explained by this chart:

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 Working Principle

Impact point

Rear chamber

Front chamber

Pressure is applied on both (rear and front) chambers of the piston. The piston is moving forward, closed to the end of
travel, the accumulator suppies energy to keep increasing the speed.

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 Working Principle

Impact point

Rear chamber

Front chamber

At the impact point, the pilot channel pressure is realised to return due to the piston central groove. The shuttle valve will
move as shown by the arrow. When the shuttle valve will shift over, the rear chamber will be connected to the return.
THE PISTON WILL START TO REVERSE
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 Working Principle

Reverse position

The front chamber is only pressurized. The rear chamber is vented to the return. During this motion, the accumulator is fully
charged. In rear position the front groove of the piston allows high pressure to flows into the pilot channel. The pilot area of
the shuttle valve is then pressurized. The valve will move according to th arrow.
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 Working Principle

Reverse position

When the shuttle valve will shift over th rear chamber will be pressurized.
THE PISTON WILL START FORWARD MOTION

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 Working Principle

Detail of the pilot channel

As show on this drawing, when moving in reverse, the front piston groove allow H.P. oil to flow into the pilot channel

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 Working Principle

Drawing A : Long stoke

The piston moved in reverse, the pilot channel is pressurized when the piston reaches the
position shown. The piston move to its maximun rear position.

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 Working Principle

Drawing B : medium stoke

The screw 2 has been removed. The pilot channel is pressurized sooner. The piston stroke is
reduced (lower impact energy / Higher frequency).

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 Working Principle

Drawing C : short stoke

The screw 1 has been removed. The pilot channel is now pressurized at the shortest stroke
of the piston. Note: installing or not the screw 2 has no influence.

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 Working Principle

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 Working Principle

Rotation mecanism

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 Working Principle

Rotation mecanism

The rotation mecanism consist of an hydraulic motor which runs the driver
gear. The driver gear is coupled to the main gear which runs the shank
adaptor throught the bronze driver.
All moving parts are lubricated by the hydraulic oil. The drain flow from the
hydraulic motor is directed to the rotation housing. A calibrated jet is
connected to the rotation return line R. This increases the drain flow for better
cooling efficiency.
NEVER CONNECT THE INLET PRESSURE TO THE ROTATION PORT R.
The driver gear is guided by two bronze bushings.
The two bushings which guide the maingear are made by steel with a deposit
of bronze. One lip seal is installed on each bushing.

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