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Drilling Efficiency Indicator

DEI Plus

Installation and Operations Guide

M ining Systems

DEPTH

TARGET

43.7 123

65.2

ROP

PIPE
10:45

21:50

The information in this manual is subject to change without notice and Thunderbird Mining Systems cannot be held liable for any errors that may appear in it. No information in the manual may be reproduced without the prior written permission of Thunderbird Mining Systems.

DRILLING EFFICIENCY INDICATOR and DEI and DEI Plus are trademarks of Thunderbird Mining Systems.

2001-2011 Thunderbird Mining Systems 2635 - 151st Place N.E. Redmond, WA 98052-5562 U.S.A. (425) 869-2727 FAX: (425) 869-2735 www.tbirdpac.com Part Number 0150-025-001 This manual was written and illustrated by Ellen Theisen, Port Ludlow, Washington.

Complete this System Configuration Information Now


Mine Drill ID __________________________________ Manufacturer Model Manufacturers Serial Number ________________________________ ________________________________ ________________________________

Circle or complete the part number for the DEI Plus components on this drill and record the serial numbers of all major components. DEI Plus System Component DEI Plus Mounting system Air pressure switch Optical shaft encoder Encoder mounting kit Encoder drive kit (optional) Cables: DC input power Air switch signal Encoder sensor 7070-191-_______ 7070-189-_______ 7060-190-_______ ______ = Enter the cable length in feet (for example, 025 = 25 feet). Part Number 6523-109-001 9001-105-109 3700-_______-001 4500630 6041-018-001 6041-018-002 9001-_______-_______ Serial Number ___________________ Not applicable. ___________________ ___________________ Not applicable.

Not applicable. Not applicable.

Contents
Using This Manual Chapter 1 Introducing the DEI Plus
A Stand-Alone, Graphic Information Display
Current Hole Depth Target Depth Rate of Penetration Distance from Bottom Pipe-In-Hole (PIPE) Notification Drill Time Time to Complete Production Statistics

x 1
1
2 2 3 3 4 4 4 5

System Management Features Components of the DEI Plus System


DEI Plus Display Module Air Pressure Switch Optical Shaft Encoder Encoder Mounting Kit Encoder Drives Cables

6 6
7 8 8 8 8 9

Chapter 2 Installing the DEI Plus


Unpacking the Components Laying Out and Tracking the Components Installing the DEI Plus Display Module Installing the Air Pressure Switch Installing the Optical Shaft Encoder
Direct Sprocket Drive Indirect Sprocket Drive

11
11 12 14 16 17
18 20

DEI Plus Installation and Operations Guide

Indirect Split Sprocket Drive Indirect Torque Reel

22 23

Connecting to the External Alarm Circuit Installing a Remote Zero Hole Depth Switch Verifying the Installation Calibrating the DEI Plus Switching Between Calibration Modes

25 27 28 28 36

Chapter 3 Operating the DEI Plus


Turning the DEI Plus On and Off DEI Plus Control Elements
Graphical Display Control Buttons

39
39 40
40 42

Reference to Statistics Screens


Statistics Current Hole Navigating Through Statistics Screens Production Statistics Reset Production Statistics ROP Graphic Screens Statistics: Previous Holes Shift Screens

45
46 51 52 54 56 59 61

Reference to System Screens


System Menu Navigating Through System Screens Brightness Screen Target Depth Screen Set Time Screen Shift Times Screens Alarms Screen Graphic Scaling Screen Configuration Menu Mast Level

63
63 65 66 67 68 70 73 75 77 79

vi

Illustrations

Diagnostics Menu Detailed System Status Menu System Status: Memory Test Screens System Status: Display Test Screens System Status: Bit Air Switch Status Screen System Status: Zero Hole Button Status Screen System Status: External Alarm Status Screen System Status: Encoder Status Screen Troubleshooting Screens General Info Menu General Info: Hardware General Info: Software

80 81 82 84 86 87 88 89 90 91 92 94

Chapter 4 Troubleshooting
Prerequisite Troubleshooting Information
The DEI Plus Air Pressure Switch Optical Shaft Encoder Chain and Sprocket Encoder Drives Torque Reel Encoder Drive Interconnecting Cables

97
97
99 99 100 100 101 101

Troubleshooting Procedures
Typical Symptoms Power Circuit Tests Air Circuit Tests Encoder Circuit Tests Re-Calibrate

102
102 103 105 109 113

Appendix A Cable Pinouts Appendix B Mounting Templates

115 117

vii

Illustrations
Figure 1. DEI Plus (Front) Figure 2. DEI Plus (Rear) Figure 3. Air Pressure Switch Figure 4. Optical Shaft Encoder Figure 5. DEI Plus System and Connections Figure 6. DEI Plus and RAM Mount Assembly Figure 7. DEI Plus Installed on RAM Mount Assembly Figure 8. Air Pressure Switch Connections Figure 9. Installing the Encoder Direct Sprocket Drive Method Figure 10. Installing the Encoder Indirect Sprocket Drive Method Figure 11. Installing the Split Sprocket Figure 12. Installing the Torque Reel (a) Figure 13. Installing the Torque Reel (b) Figure 14. Increasing and Decreasing Cable Tension Figure 15. Remote External Alarm Connections Figure 16. Remote Zero Hole Depth Switch Connections Figure 17. DEI Plus Power Button Figure 18. DEI Plus Control Elements Figure 19. Typical Installation on Hydrolic Machine Figure 20. DEI Plus Air Switch Cable Connector Figure 21. Air Pressure Switch Front Panel Figure 22. DEI Plus Encoder Cable Connector Figure 23. Cable to Optical Shaft Encoder Figure 24. 7070-189-xxx Cable Assembly DEI Plus to Air Pressure Switch 7 7 8 8 13 15 15 16 19 21 22 23 23 24 25 27 39 40 98 106 108 110 111 115

Figure 25. 7060-190-xxx Cable Assembly DEI Plus to Optical Shaft Encoder 115 Figure 26. 7070-191-xxx Cable Assembly DC Power to DEI Plus 115

viii

Illustrations

Figure 27. Mounting Template Air Pressure Switch Figure 28. Mounting Template RAM Mount Figure 29. Torque Reel Enclosure Sheet 1 Mounting Template Figure 30. Torque Reel Enclosure Sheet 2 Cable Exit Hole Reference

118 119 120 121

ix

Using This Manual


This manual describes Thunderbird Mining Systems DEI Plus (Drilling Efficiency Indicator), gives instructions for installing and operating it, and includes a troubleshooting guide to help you solve problems that may occur. It should be noted that a printed copy of this manual will accompany the shipment of a DEI Plus stand-alone system.

Chapter 1 Introducing the DEI Plus


The DEI Plus is an instrument that is installed on the drills in a mining, water well, quarry, exploration, or construction operation. It helps the drill operator know, at every moment, what is occurring in the drill hole by providing information that is not normally available. The DEI Plus is the second generation of Drilling Efficiency Indicators. Earlier DEI instruments have been installed on nearly all makes and models of drills. Today they are operating on hundreds of drills in mines throughout the world. Whether installed in a coal, metal, quarry, or other operation, the DEI has proven that it will increase productivity by reducing overall drilling costs and improving the blasting efficiency. The DEI Plus provides all the capabilities of its predecessors, PLUS: Even more information about the current drilling operation, instantaneously, on a much larger and easier-to-read display. Drilling statistics about the previous three holes, the current shift, the three previous shifts, and a production period you define. Features that allow you to set up the system, check the status of system elements, and do troubleshooting procedures. For example, the DEI Plus leads you through the calibration procedure in a sequence of interactive screens. The rest of this chapter gives you an overview of the information and system management features available on the DEI Plus.

A Stand-Alone, Graphic Information Display


On its single graphic display, the DEI Plus provides the following information about the current drilling operation, allowing the operator to monitor the drilling as it occurs: Current hole depth Target hole depth Rate of penetration, while the drill is moving downward Distance from the bottom of the hole, while the drill bit is lifted On-screen alarm flashing PIPE when there is a pipe-in-hole condition Drilling time so far on this hole Estimated time to complete the hole Graphic depiction of the current depth in relation to the target depth

DEI Plus Installation and Operations Guide

This information gives the drilling and blasting personnel the ability to see beyond the drill collar and into the hole, allowing them to work more efficiently. In addition to the current drilling information, the DEI Plus provides details about the previous three holes and summary statistics about a production period, the current shift, and the three previous shifts. It also shows a graph of the rate of penetration at each depth reading for the current hole and for each of the three previous holes.

Current Hole Depth


The depth display on the DEI Plus constantly shows the exact depth of the hole that is being drilled, to the nearest tenth of a meter or foot (according to your calibration). This information helps the drill operator drill to the precise depth specified on the drilling plan, without stopping to measure the hole. The DEI Plus even tracks the hole depth in multiple-pass drilling as pieces of pipe are added. This precision saves time and cuts costs by: Eliminating over-drilling, which can be costly in time, in wear on bits, and in the effort required to backfill the blasthole so the drilling plan can be met. Ensuring that the floor is level after blasting, so the mine does not have to bear the cost of either leveling it or reducing the life of its loading and hauling equipment by having them operate on a rough floor. Ensuring that the hole depth is precise in the critical and difficult task of angle drilling.

Target Depth
As each hole is started, the operator enters the target depth on a system management screen. Then, the target depth appears on the display beside the current hole depth as the operator drills, thus ensuring against over-drilling. The display of current hole information also shows a graphic representation of the target depth in relation to the current depth. For example, in the sample to the left, the current depth is indicated by the pointers at 43.7, and the target depth is indicated by the solid line at 65.2.

Chapter 1 Introducing the DEI Plus

Rate of Penetration
The rate of penetration (ROP) value displayed on the DEI Plus shows constant information about the drilling speed, thus also helping the operator drill more efficiently. Knowing the ROP, the operator can make timely adjustments in the pulldown pressure, RPM, torque, or air pressure in order to optimize the drilling rate for the particular conditions. Increasing the overall drilling rate significantly increases the number of feet or meters drilled per hour. In coal mines, the ROP information is especially important. If the engineer has determined the approximate depth of the coal, the drill operator can watch for an increase in ROP at that depth and stop drilling when the drill bit is only a tenth of a foot (or meter) into the coal, instead of drilling into it far enough to identify the coal dust at the hole collar. This sample graph shows the difference in the rate of penetration at different hole depths. Engineers can use this detailed information to help them refine their conclusions about the strata layers.

With the press of a button on the front panel of the DEI Plus, the operator can change the display to show a graph of the ROP vs. the hole depth for the current hole and still monitor the current depth, ROP, and drill time. This sample shows how the graph appears on the display of the DEI Plus.

Distance from Bottom


When the operator lifts the drill bit off the bottom of the hole, the ROP display will change to a display of the distance from the bottom. When drilling is resumed, this information helps the operator avoid slamming the bit into the hole bottom and possibly damaging the drill bit and steel. When the bit reaches the bottom of the hole and drilling is resumed, the ROP display once again shows the drilling rate of penetration.

DEI Plus Installation and Operations Guide

Pipe-In-Hole (PIPE) Notification


The DEI Plus provides functionality to help you prevent damage to equipment often caused by retracting the jacks or moving the drill when pipe is still in the hole. When you calibrate the DEI Plus, you specify the distance you want the bit to clear the ground for the pipe to be considered fully out of the hole, that is, how far above the ground you want the bit to be before the jacks are retracted so the drill can be moved. This distance is the PIH (pipe-in-hole) offset. Then, during operation, the information screen for the current hole flashes the word PIPE whenever there is a pipe-in-hole condition, that is, whenever there is any chance the operator might think the bit is out of the hole. The Pipe-In-Hole alert occurs whenever the following three conditions are met: Drilling air is turned off. Drill feed direction is reversed relative to the normal drilling direction (as indicated by encoder data). The distance from bottom value is greater than 85% of the hole depth. PIPE remains flashing until the DEI Plus reports that the distance from the bottom of the hole equals the hole depth plus the PIH offset, that is, the bit is above the ground by a distance equal to the PIH offset.

Drill Time
The DEI Plus tracks the time spent drilling on each hole. A status line on the DEI Plus display shows the status at all times, displaying Drilling during all drilling time and Non Drilling or Idle when drilling is not in progress. Drilling time is considered to be the time when the drill is moving downward plus any delays of less than 60 seconds.

Time to Complete
Once 5% of the target depth has been drilled, the DEI Plus calculates and displays the estimated time required to complete the hole. This information is on the display while drilling is in progress, giving the operator even more information to help prevent over-drilling.

Chapter 1 Introducing the DEI Plus

Production Statistics
The control buttons on the front panel of the DEI Plus allow the operator to quickly display statistical information about previous holes, current and previous shifts, and any other specific time period. This is convenient for tracking the production per day. It may also be used to give valuable feedback when drill personnel are testing new bits or different drilling procedures. The DEI Pluss memory is backed up by a battery, so that the historical information is retained even if power to the DEI Plus or drill is turned off or lost. Historical information about previous holes includes: Depth Average rate of penetration Drilling time Information about shifts includes: Total holes started during the shift. Average depth of all holes drilled or partially drilled during the shift. Total depth drilled during the shift. Average time to drill a hole, in minutes and seconds. Total time drilling during the shift. Average ROP during the drilling.

Production information about a time period you define includes the same statistics as shift information, except for the total time.

DEI Plus Installation and Operations Guide

System Management Features


The DEI Plus provides over 30 different screens that allow you to set up and manage your DEI Plus system. For example: Set up operating parameters, such as the target depth, shift times, alarm conditions. View the status of system elements, such as the external alarms state, the condition of the memory, the DEI Plus software version. Calibrate the DEI Plus by following a sequence of interactive screens. Perform diagnostics, such as troubleshooting procedures and testing system components.

Components of the DEI Plus System


The DEI Plus system is made up of several components. The components for each drill vary somewhat depending on what is needed to make the system work on that specific drill. The components include: DEI Plus display module Display mounting system Air pressure switch Optical shaft encoder Encoder mounting kit (direct or indirect) Encoder drives (if necessary) Cables

Chapter 1 Introducing the DEI Plus

DEI Plus Display Module


This is the main module of the system. It is mounted on the drill rig in a location that is easily visible to the operator during operation of the drill. This unit receives the signals produced by the optical shaft encoder to calculate and display the current hole depth, current rate of penetration, distance from bottom, and other production statistics. The rear panel of the DEI Plus (Figure 2) contains the connectors for connecting it up to a DC power source, the air pressure switch, the optical shaft encoder, the remote zero hole button, and external alarms. Some of the DEI Plus design features include: Housing is machined aluminum (6.17 H x 7.31 W by 3.11 D), water-tight to NEMA 4 standards. Accepts power input from 21 to 30 VDC. Operating temperatures from -40 C to +80 C. Polycarbonate display window with anti-glare coating and viewing angle greater than 160. 512KB or 1MB battery-backed SRAM for storing system settings and logged data such as historical production information. Real Time Clock/Calendar (RTC) with second resolution, programmed for leap years, and accurate to within one minute per month. Lithium battery to provide a minimum of 5 years of non-volatile memory and RTC operation. 2KB of EPROM for fail save boot code

M ining Systems

DEPTH

TARGET

43.7
ROP

65.2

123 21:50

PIPE
10:45

Figure 1. DEI Plus (Front)

Figure 2. DEI Plus (Rear)

DEI Plus Installation and Operations Guide

Air Pressure Switch


The air pressure switch indicates the presence or absence of bailing air pressure to the DEI Plus, allowing it to determine whether or not the drill stem column is connected to the rotary head. This helps the DEI Plus determine when a drill stem is being added or removed. When air is on in the drill stem column and the drill head is moved up from the bottom of the hole, the DEI Plus displays the distance moved as the distance from the bottom. When air is not on, the DEI Plus interprets long distances of movement away from the bottom as adding new steel for multiplepass drilling. When drilling resumes, the DEI Plus accounts for the length of the new pipe in its calculations of the hole depth. The standard air pressure switch is for machines with up to 150 psi of bailing air. Air pressure switches are available for high-pressure drill rigs.

Figure 3. Air Pressure Switch

Optical Shaft Encoder


The optical shaft encoder is connected to the pulldown system, either directly or indirectly, so that it can sense the movement of the drill bit. As the drill bit moves, the encoder sends signals to the DEI Plus to indicate the amount and direction of the movement. It is from these signals that the DEI Plus computes the hole depth and rate of penetration. Figure 4. Optical Shaft Encoder

Encoder Mounting Kit


The mounting kit includes the brackets and coupling necessary for securing the encoder to the drill. The content of the kit varies depending on the way in which the encoder will be mounted.

Encoder Drives
On some drills, the pulldown sprocket shaft does not rotate, or the encoder shaft cannot be coupled directly to the pulldown sprocket shaft. On these drills, the encoder shaft must be rotated indirectly by means of an intermediary sprocket rotated by the pulldown sprocket shaft or hub. This calls for a special encoder mounting kit. This mounting kit provides the parts necessary for installing the encoder on such drills. Some systems may require a torque reel or a custom installation.

Chapter 1 Introducing the DEI Plus

Cables
Three cable assemblies are typically included with a DEI Plus system. DC input power cable to connect the DEI Plus to the 21 to 30 VCD power source.
Note: Cable lengths vary depending on the drill model and the locations where the components are installed:

Air switch signal cable to connect the air pressure switch to the DEI Plus. Encoder sensor cable to connect the optical shaft encoder to the DEI Plus.

Chapter 2 Installing the DEI Plus


Unpacking the Components
Before you begin the installation, make sure you have all the components you need for your system. The table that follows lists the most commonly used of components used for DEI Plus installation and gives their part numbers and the conditions under which you need each one. Component DEI Plus Display mounting system Air pressure switch (See note in Laying Out and Tracking the Components) Optical shaft encoder Encoder mounting kit Encoder drive kit 9001-097-002 9001-097-003 9001-116-001 9001-116-002 9001-117-001 9001-117-002 9001-117-003 9001-117-004 9001-117-005 9001-117-00X 9001-119-002 Cables: DC input power Air switch signal Encoder sensor 7070-191-xxx 7070-189-xxx 7060-190-xxx For systems connecting to a 21 to 30 VDC power source. For all systems. For all systems. Part Number 6523-109-001 9001-105-109 3700-030-001 3700-031-001 3700-032-001 3700-033-001 4500630 6041-018-001 6041-018-002 Standard, 12 - 150 psi. Optional, 20 - 350 psi. Optional, 50 - 450 psi. Optional, 60 - 650 psi. 40-pulse, standard, for most drills. For indirect connection to the pulldown system. For direct connection to the pulldown system. For indirect connection to pulldown system: ANSI 40 sprocket drive. ANSI 35 sprocket drive. ANSI 35 6.32 split sprocket drive. ANSI 35 5.002 ID sprocket drive. ANSI 40 5.50 split sprocket drive. ANSI 40 4.88 split sprocket drive. ANSI 40 5.125 split sprocket drive. ANSI 40 6.50 split sprocket drive. ANSI 40 5.25 split sprocket drive. ANSI 40 split sprocket drive (special order only). Torque reel drive. Conditions for Use Unit required on all systems.

xxx = Cable length in feet (for example, 025 = 25 feet).

11

DEI Plus Installation and Operations Guide

Laying Out and Tracking the Components


Before you begin installing the DEI Plus on the drill, use this procedure to avoid time-consuming errors during installation and to simplify the re-ordering of parts in the future. Refer to Figure 5. 1. Lay out all the components on the ground, a work table, or the bed of a truck. 2. Temporarily connect the cables to their respective ports. Determine where each component will be installed, and measure all the cables to make sure they are the lengths you require. Do not connect power to the system at this time. 3. Complete the system configuration information in the front of this manual.

IMPORTANT NOTE: If your drill uses varying lengths of drill stems, contact Thunderbird Mining Systems about installing a manual air switch. When the drill stems used on the drill are always the same length, that length is entered into the DEI Plus when it is calibrated. Then, when the optical shaft encoder detects movement that is approximately the same as the calibrated stem length, and the air pressure is off, the DEI Plus interprets this movement as the addition or removal of a drill stem and adjusts its hole depth calculations accordingly. However, when varying stem lengths are used, the drill stem length is declared to be zero during calibration, so the DEI Plus has no approximate length to compare to movement that occurs when the air is off. For this reason, the DEI Plus cannot distinguish between a temporary obstruction of the air pressure switch (which would appear as air pressure loss) and actual steel changes. This could result in false hole-depth readings. Therefore, when you use varying stem lengths, it is recommended that the air pressure switch be replaced by a manual switch, which must be closed by the operator before steel is changed and then opened again before drilling is resumed.

12

Chapter 2 Installing the DEI Plus

DEI Plus - Rear (6523-109-001)

External Alarm Cable Assembly (7070-180-xxx)

To Customer-supplied External Alarm

Encoder Cable Assembly (7060-190-xxx)

Air Switch Signal Cable (7070-189-xxx)

Air Pressure Switch (3700-03X-001)

Optical Shaft Encoder (4500630)

Operators Gauge

DC Power Cable (7070-191-xxx) To Check Valve

To Drill Head Bailing Air Line

To 21-30 VDC Power Source

Figure 5. DEI Plus System and Connections

13

DEI Plus Installation and Operations Guide

Installing the DEI Plus Display Module


To install the DEI Plus display module: 1. Locate a position in the cab that gives the operator a convenient view of the unit. Note: Before you mount the unit, be sure to determine how the cables will be routed to it. 2. Using the template in Appendix B or the mounting base plate itself as a guide, mark the positions of only four of the twenty four available mountingbracket holes on the mounting surface. 3. Drill 1/4-inch (6.4mm) clearance holes for bolts at the marked positions. 4. Secure one of the rectangular mounting plates with ball to the mounting surface with the supplied sets of mounting bolts (10-32 by 1-inch), washers, and nuts (four sets supplied). 5. Secure the other rectangular mounting plate with ball to the bottom surface of the DEI Plus with the four supplied bolts (10-32 by 5/8-inch) and lock washers. See Figure 6.
Caution: Do not use bolts over 5/8-inch long.

6. Pinch one end of the mounting arm to open the opposite end, and place the open end over the ball on the rectangular mounting plate. 7. Place the other end of the mounting arm over the ball on the rectangular plate attached to the DEI Plus. See Figure 7. 8. Position the DEI Plus at an angle that provides the operator the best view, and turn the mounting arm knob to secure the balls in this position.

14

Chapter 2 Installing the DEI Plus

M ining Systems

Figure 6. DEI Plus and RAM Mount Assembly

Rectangular mounting plate

Mounting arm

Rectangular mounting plate

M ining Systems

Figure 7. DEI Plus Installed on RAM Mount Assembly

15

DEI Plus Installation and Operations Guide

Installing the Air Pressure Switch


You should not need to adjust the air pressure switch since it was pre-set by Thunderbird Mining Systems. To install it: 1. Determine where you will tie into the bailing air line. The air pressure switch must be installed on the bailing air line between the drill head and the check valve. It can be done in any of the following ways: Install a tee at the operators gauge (see Figure 8). Or, drill and tap a 1/4-inch NPT hole. Or, install a tee with reducers to 1/4-inch NPT. The tee must have an ID equal to the air line.

DEI Plus (Rear)


Figure 8. Air Pressure Switch Connections

Air Pressure Switch

Mounting Holes

Air Switch Signal Cable (7070-189-xxx)

Operator's Gauge

Bailing Air Line To Compressor Check Valve

Tee with sam ID as air lin

To Dr Head

2. Determine where to mount the air pressure switch. It should be near the location where you plan to tie into the bailing air line. Mount it so that the connectors to the air switch signal cable and the air input line are on the bottom of the air pressure switch. It need not be visible during operation, but you must be able to access it in the future. 3. Using the template in Appendix B or the air pressure switch itself as a guide, mark the positions of the two holes you will use to mount the switch. 4. Drill 1/4-inch (6.4 mm) clearance holes for bolts at the two marked positions. 5. Bolt the air pressure switch to the mounting surface using the supplied bolts, washers, and nuts. 6. Tie into the bailing air line at the point you determined in Step 1. 7. Attach the socket end of the air switch signal cable (7070-189-xxx) to the 2-pin connector on the air pressure switch. 8. Route the cable away from moving equipment toward the DEI Plus. Use tie wraps to secure any excess cable. 9. Connect the other, 2-pin end of the air switch signal cable to the BIT AIR connector on the rear panel of the DEI Plus.

16

Chapter 2 Installing the DEI Plus

Installing the Optical Shaft Encoder


The design of the drills pulldown system determines the way the optical shaft encoder must be mounted. There are four general methods of installation. The instructions for these methods are given in this section. Direct Drive The encoder is flexibly coupled to the pulldown sprocket shaft and senses its rotation directly. Use this direct method of installation if both these conditions are true: The pulldown sprocket shaft rotates in proportion to the movement of the drill bit. The end of the pulldown sprocket shaft is accessible for attaching a shaft adapter. Indirect Drive and Indirect Split Sprocket Drive The encoder is attached to an intermediary sprocket that is rotated by the movement of the pulldown sprocket. The encoder senses the rotation of the pulldown sprocket indirectly through the rotation of the intermediary sprocket. Use one of these indirect methods of installation if both these conditions are true: There is at least 10 inches (25 cm.) of clearance above or below the pulldown sprocket. The pulldown sprocket shaft or hub is less than 6.5 inches (16.5 cm.) in diameter. Use the Indirect Sprocket Drive method if you can access the end of the pulldown sprocket shaft or hub to slide the instrumentation sprocket over it. Use the Indirect Split Sprocket Drive method if you cannot access the end of the pulldown sprocket shaft or hub. Indirect Torque Reel The encoder is enclosed within the torque reel box. The box is mounted at the top of the mast, and its tension cable is connected to the drill head or carriage. As the drill head moves up and down, the encoder inside the torque reel senses the movement of the drill head indirectly through the winding or unwinding of the tension cable. If your drill does not satisfy the conditions for any of these methods, contact your DEI Plus distributor.

17

DEI Plus Installation and Operations Guide

Direct Sprocket Drive


To install the encoder using the direct sprocket drive method (refer to Figure 9): 1. Locate the pulldown sprocket shaft most suitable for mounting the encoder, where the encoder will be best protected from physical damage. 2. Tack weld the shaft adapter to the center of the pulldown sprocket shaft. 3. Weld or bolt the encoder bracket in a position that supports the encoder in the alignment described in Step 5. Important: Do not weld the bracket after the encoder is attached. 4. Secure the encoder to the encoder mounting bracket or brackets, using the hardware provided. Use one or both brackets as required to position the encoder as described in Step 5. 5. Position the encoder so that the shaft adapter and the encoder are 3 to 5 inches (7 - 13 cm.) apart and closely aligned along the centerline axis of the pulldown sprocket shaft (1/16-inch runout maximum). 6. Connect the shaft adapter to the encoder by means of the flexible coupling and hose clamps provided. NOTE: Periodically during operation, check that the hose clamps are tight. 7. Connect the 7-socket end of the encoder cable assembly (7060-190-xxx) to the cable port on the encoder. 8. Route the cable away from moving equipment, making sure there is sufficient allowance for lowering the mast. Use tie wraps to secure any excess cable. 9. Make the sure power to the DEI Plus is turned off. 10. Connect the 7-pin end of the encoder cable assembly (7060-190-xxx) to the ENCODER port on the rear panel of the DEI Plus.

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Chapter 2 Installing the DEI Plus

Pulldown Sprocket Pulldown Shaft Sprocket Shaft Adapter

Optical Shaft Encoder

Flexible Coupling

Mounting Brackets
Hose Clamps

Tack weld to mast or frame

Encoder Cable 7060-190-xxx to Digital Display Module

Figure 9. Installing the Encoder Direct Sprocket Drive Method Using the 6041-018-002 Kit

19

DEI Plus Installation and Operations Guide

Indirect Sprocket Drive


Installing the encoder using this method requires an encoder mounting kit (6041018-001) and an encoder drive kit (9001-097-00x). You can purchase these parts from your DEI Plus distributor . This installation may also require machine shop facilities. To install the encoder using the indirect sprocket drive method (see Figure 10): 1. Measure the diameter of the pulldown sprocket hub. 2. Obtain the 48-tooth instrumentation sprocket from the mounting kit, and machine the inside diameter of the hole to 0.005 inch greater than the hub diameter measured in Step 1. NOTE: If there is not enough clearance beside the pulldown sprocket and above or below it to use the 48-tooth instrumentation sprocket, or if there is not enough clearance for the ANSI 40 roller chain, you can use a 72-tooth sprocket in this step, a 24-tooth sprocket in Step 6, and an ANSI 35 chain in Step 8. However, Thunderbird Mining Systems strongly recommends using the ANSI 40, since it is stronger and alignment problems are more likely to occur with the ANSI 35. 3. Slide the 48-tooth sprocket over the hub of the pulldown sprocket, making sure it is perpendicular to the hub and that there is clearance between the chains. Then tack-weld the sprocket onto the hub. 4. Weld the encoder bracket to the mast in a position that supports the encoder in the alignment described in Step 7. Make sure your bracket set up allows you to slide the encoder toward or away from the pulldown sprocket, so that you can tighten the roller chain (Step 9). Important: Do not weld the bracket after the encoder is attached. 5. Secure the encoder to the encoder mounting bracket or brackets, using the hardware provided. Use one or both brackets as required to position the encoder, as described in Step 7. 6. Slide the supplied 16-tooth instrumentation sprocket onto the encoder shaft and tighten the set screw to secure it in place. 7. Position the encoder above or below the pulldown sprocket and on the mast so that the two instrumentation sprockets are precisely aligned and not more than 10 inches (25 cm.) apart. Note: The preferred method is below the pull-down sprocket since it minimizes the load on the encoder shaft. IMPORTANT: The alignment of the two sprockets is critical. Misalignment might cause the chain to come off or break, or, more importantly, it might damage the encoder. 8. Using the ANSI 40 roller chain, connect the two instrumentation sprockets. Remove links as necessary to tighten the chain. 20

Chapter 2 Installing the DEI Plus

9. Slide the encoder bracket (with the encoder on it) as necessary until the chain is snug but not overtight, and secure the brackets. 10. Connect the 7-socket end of the encoder cable assembly (7060-190-xxx) to the port on the encoder. 11 Route the cable away from moving equipment. Use tie wraps to secure any excess cable. 12. Make the sure power to the DEI Plus is turned off. 13. Connect the 7-pin end of the encoder cable assembly to the ENCODER port on the rear panel of the DEI Plus.

Optical Shaft Encoder

16-Tooth Instrumentation Sprocket ANSI 40 Roller Chain

48-Tooth Instrumentation Sprocket

Mounting Brackets

Tack weld to mast frame

Encoder Cable 7060-190-xxx to Digital Display Module Pulldown Sprocket Shaft or Pin

Pulldown Pulldown Sprocket Sprocket Hub

Figure 10. Installing the Encoder Indirect Sprocket Drive Method

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DEI Plus Installation and Operations Guide

Indirect Split Sprocket Drive


Installing the encoder with this method requires an encoder mounting kit (6041018-001) with a split sprocket drive (9001-117-00x). Several sizes of sprockets are available from your DEI Plus distributor. Make sure the one you have has an internal diameter the same as the diameter of the pulldown sprocket shaft. To install the encoder using the indirect split sprocket drive method (refer to Figure 11): 1. Assemble the sprocket onto the shaft using the supplied hardware and sprocket assembly plates. Finger-tighten the nuts to allow for play. Shim the gap between the sprocket halves as necessary to obtain the correct tooth orientation. 2. Shim the sprocket against the tube shaft as necessary to ensure that it is concentric with the shaft (within 0.015 inch), perpendicular to it, and far enough away from the pulldown sprocket so there is clearance between the chains. 3. Secure the split sprocket to the shaft by welding a minimum of three places on each side of the sprocket. 4. Finish the installation by following steps 4 through 12 of the instructions for the Indirect Sprocket Drive method (refer to Figure 10).

Figure 11. Installing the Split Sprocket

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Chapter 2 Installing the DEI Plus

Indirect Torque Reel


If you ordered a torque reel drive kit with the DEI Plus, the encoder is already installed in the box. Because of the great variation in drill design, Thunderbird Mining Systems does not supply the brackets to attach the torque reel to the mast or to attach the cable to the drill head or carriage. To install the torque reel and encoder (refer to Figures 12 and 13, and to Figures 29 and 30 in Appendix B): 1. Determine the design of the brackets you need and fabricate them. Design the bracket so that you can weld it to the mast and then bolt the torque reel box to it using the four mounting holes on the box. The box must be directly above the drill head so the tension cable coming out of the box can be connected to the drill head and aligned so it is parallel to the movement of the drill head. 2. Determine the maximum length of cable that must extend from the torque reel. Pull out that amount plus about 4.5 feet (1.5 meters). The tension should be tight enough that no more cable can be pulled out. To adjust the tension, refer to the following subsections. 3. Mount the torque reel box at the top of the mast so that the tension cable exits the bottom of the box and is directly above the drill head. Make sure the cable moves perpendicular to the bottom of the box to minimize wear on the cable. 4. Attach the end of the tension cable to the drill head. A common method of doing this is to weld an eye bolt to the drill head and then use cable clamps to attach the cable to the eye bolt. Make sure the cable is precisely parallel to the movement of the drill head. Important: Make sure there is sufficient cable before you lower the drill head.

Figure 12. Installing the Torque Reel (a)

Figure 13. Installing the Torque Reel (b)

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DEI Plus Installation and Operations Guide

Increasing the Tension on the Tension Cable


If the cable from the torque reel to the drill head is not taut enough to move the pulley inside the torque reel box, use the following instructions to increase it: 1. Lift off the clamps that hold the lid on the torque reel box (refer back to Figure 13), and remove the lid. 2. Use a wrench to rotate the mainspring shaft counter-clockwise until the tension is correct. Do not over-tighten the tension (see Figure 14). 3. Increasing the tension decreases the length of the cable, so verify the length before you move the drill head.

Decreasing the Tension on the Tension Cable


If the cable from the torque reel to the drill head is too tight, the torque reel will not allow enough cable to be released. Use the following instructions to decrease the tension on the cable: 1. Lift off the clamps that hold the lid on the torque reel box (refer back to Figure 13), and remove the lid. 2. Reach behind the torque reel and carefully press the tension lock spring on the bottom of the reel. Do not press it too hard or too long, or too much tension will be released. Then check the tension again. If it is still too tight, briefly press the spring again. If you decrease it too much, use the previous procedure to increase it.

Figure 14. Increasing and Decreasing Cable Tension

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Chapter 2 Installing the DEI Plus

Connecting to the External Alarm Circuit


You can connect components on your drill to the external alarm circuit, so that their operation is controlled by the rate of penetration (ROP) and hole depth alarms set up on the Alarms system screen of the DEI Plus. For example, you could set up a light or an audible alarm to signal when the hole depth reaches a specified distance or the ROP reaches a specified rate. The port on the back panel of the DEI Plus provides access to an internal relay which has two isolated contact sets. Each set contains a normally closed and a normally open circuit. Each relay contact provides a 2-Amp maximum current capability. These normal positions occur when the alarms are off and the DEI Plus power is off. 1. Connect the 6-pin end of the external alarm cable to the ALARM/TRAM port on the rear panel of the DEI Plus. 2. Connect your remote components according to the instructions in Figure 15.
DEI Plus (Rear) 6523-109-001 POWER
A B

BITAIR
C B A

ALARM/ ZEROHOLE TRAM


F E C B A D C A B

DEI Plus External Alarm Relay 9001-120-101


7070-180-010 7: N. C. (Normally Closed) contacts open when 6: N.O. (Normally Open) in an alarm condition contacts close when Non-Polarized in an alarm condition 8: Input Comm Connect to 24 VDC Deadman Switch circuit

RS232 RS232LEVEL
F E D C A B E D C F A B

7 8

6 Splice into circuit

ENCODER
Wire #1 Wire #2 Wire #1 Wire #2 Function Orange Red Blue Green Rate / Depth Alarm Pipe In Hole Ground

Figure 15. Remote External Alarm Connections

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DEI Plus Installation and Operations Guide

Description for the Alarm Output / Tram Input Connector


This description provides complete information for the cable wiring. MS Connector A (black) B (white) C (red) D (green) E (orange) F (blue) Function Tram Input Ground PIH Alarm Relay Contact Common PIH Alarm Relay Contact Norm. Open ROP/Depth Alarm Relay Contact Common RPO/Depth Alarm Relay Contact Norm. Open

Pin A is the signal input used for the detection of tramming. This input is designed to detect a switch closure to ground (pin B). A closed contact indicates the drill is tramming. Pin B is electrical ground, common with the power input ground. Pin C is the Pipe In Hole alarm relay contact. This is one side of a 2-amp relay contact; the other side of the contact is pin D. Pin D is the Pipe In Hole alarm relay contact (see pin C). Pin E is the Rate of Penetration or Depth alarm relay contact. This is one side of a 2-amp relay contact; the other side of the contact is pin F. These contacts are closed any time there is a Rate of Penetration or Depth alarm condition. Pin F is the Rate of Penetration or Depth alarm relay contact (see pin E). The relay contacts for the Pipe in Hole and Rate/Depth alarms have no internal connections to the DEI Plus, they are simply relay contacts that can be used to make or break an alarm circuit.

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Chapter 2 Installing the DEI Plus

Installing a Remote Zero Hole Depth Switch


You can install a remote access switch for resetting the hole depth to zero. This is in addition to the reset button on the front of the DEI Plus. The port on the DEI Plus provides a parallel connection to the front panel ZERO HOLE DEPTH switch. The connector has a 5 VDC pull-up on the A pin, with an internal ground on the C pin. The contact is normally open. Closing the connection resets the hole depth. 1. Connect the 3-pin end of the remote control cable (available from Thunderbird Mining Systems) to the ZERO HOLE port on the rear panel of the DEI Plus. 2. Connect your remote switch (available from Thunderbird Mining Systems) according to the instructions in Figure 16. Connect to any open and unused contacts. Warning: Do not apply power or an external ground to the ZERO HOLE contacts. Doing so will damage the DEI Plus and void the warranty.

C B

Cable Assembly 7070-292-xxx

Improper connections will damage the DEI

C Blk A Red Normally open Momentary closed

Figure 16. Remote Zero Hole Depth Switch Connections

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DEI Plus Installation and Operations Guide

Verifying the Installation


In order to avoid damage to the DEI Plus components, it is very important to ensure that the DEI Plus is installed correctly before you calibrate it. Follow these instructions. 1. Tighten all nuts and bolts. 2. Check all electrical connections and make sure the MS connectors are tight. 3. Check the routing of the cables to make sure they are away from moving equipment, and make sure all excess (loose) cable is secured. 4. Make sure cables are long enough to allow for the mast to be lowered. Note: As you check the installation, make sure you have accurately completed the System Configuration Information sheet in the front of the manual.

Calibrating the DEI Plus


Calibration is necessary to suit the DEI Plus to the particular drill rig on which it is installed. Normally, it is only necessary when the DEI Plus is first installed on the drill (or moved from a different drill). However, if the DEI Plus detects a calibration failure during operation, it flashes a warning screen on the display, and you must re-calibrate before you continue. During calibration, the DEI Plus counts the number of pulses sent from the optical encoder as the drill head moves the distance you specify. So, it equates that number of pulses to that distance. For example, if the DEI Plus counts 2000 pulses, and you record the distance moved as 20, the DEI Plus operates on a scale of 2000 pulses to 20 units of distance. The units of measure you use during calibration (meters or feet) are the units used throughout operation. When you calibrate the DEI Plus, you specify only the numerical value of the distance the drill head moves, not the units. So, if you calibrate using feet, the DEI Plus operates in feet and feet per hour. If you calibrate using meters, the DEI Plus operates in meters and meters per hour. The Calibration screens lead you through the calibration procedure. BEFORE YOU BEGIN CALIBRATION: Make sure the DEI Plus is completely and correctly installed. To begin: 1. Press the System button to display the System Menu. 2. Use the Left, Up, Down, and Right arrow buttons on the DEI Plus to move the highlight to Configuration.

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Chapter 2 Installing the DEI Plus

3. With Configuration highlighted, press the Enter button to display the Configuration menu. 4. Move the highlight to Calibration and press the Enter button.
NOTE: The Parameters option is not functional on the standard DEI Plus. Selecting it displays a screen telling you the software must be upgraded in order to use the function.

5. When you choose Calibration, the Calibration Menu displays. Move the highlight to Perform Normal Calibration and press the Enter button to display the first calibration screen (see Sample Calibration Screen below).

Sample Calibration Screen

Screen Title

Procedural Instructions for the Calibration Process

Current Hole Number and Air Status

Current Status

Current Time

6. Move the highlight to Yes and press the Enter button to display the screen where you enter your password.

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DEI Plus Installation and Operations Guide

Entering your Password


When you choose to perform a normal calibration, you are asked for your password. The illustration below shows the screen and the DEI Plus buttons below and to the right of the screen. Each button corresponds to a digit from 1 through 0.
Current Hole Data Entry System Help Enter

The password is six digits long. The default password is 1 2 3 4 5 6. Instructions for Changing the Password follow the instructions for Calibrating the DEI Plus. To enter the password: 1. For each digit in the password, press the DEI Plus button that corresponds to that digit. For example, to enter 1, press the Left Arrow button. An X appears on the screen for each digit you enter. 2. If the password is correct, the Calibration Screen 3 appears. Continue with Calibrating the DEI Plus. If the password is incorrect, the screen displays the following message: Incorrect password entered. Press [Enter] to try again Press the Enter button to return to the password screen. You are allowed an unlimited number of attempts. If you choose not to re-enter the password, press the Current Hole button, Data Entry button, System, or Help button to display the corresponding screen.

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Chapter 2 Installing the DEI Plus

Calibrating the DEI Plus


Once you enter the correct password, Steps 3 through 12 are given on the screens. The screens are reproduced below with notes to the right of some screens. Steps 3 through 8 lead you through a method of accurately measuring the distance the drill head moves from one position (entered in Step 5) to another (enter in Step 7). This process allows the DEI Plus to set up the ratio of encoder pulses to units of distance. These instructions assume the drill is in the field. However, it is not necessary to use a drilled hole. In this step, you position the drill head as low as possible to ensure that the distance used for calibration is 18 feet (6 meters) or more. The greater the distance the more accurate the calibration will be.

In this step you record the initial position of the drill head by entering its distance from the drill deck. Use the Left and Right arrow buttons to move the pointer to the digit you want to change. Then use the Up arrow button to increase the value of the digit, or use the Down arrow button to decrease its value.

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DEI Plus Installation and Operations Guide

In this step, you move the drill head as high as possible. The DEI Plus counts the encoder pulses that correspond to the distance the head moves from the first recorded position.

Now you record the second position, again by entering the distance of the drill head from the drill deck. Use the Left and Right arrow buttons to move the pointer to the digit you want to change. Then use the Up arrow button to increase the value of the digit, or use the Down arrow button to decrease its value. The DEI Plus calculates the distance moved as the difference between the first measurement and this measurement. If this value is not correct, press the System button to return to System Menu. Then begin the calibration procedure again. All the values you already entered are saved and appear on the calibration screens, so you can simply change them as required.

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Chapter 2 Installing the DEI Plus

This is the length of pipe in the rack, not the first pipe with bits, sub, stabilizers, and other components. NOTE: In cases where the drill stems in the pipe rack or carousel vary in length by 0.5 feet (15 cm) or more, set the length to 0.00. If the hole depth reading is inaccurate during hole reaming or cleaning or during excessive on-and-off cycling of the bailing air, contact Thunderbird Mining Systems. You may need to install a manual air switch. This offset is the distance the bit must be raised above the collar of the hole for the DEI Plus to consider the pipe out of the hole and turn off the PIPE (pipe-inhole) notification. A normal value for this offset is the distance between the bottom of the bit and the ground when the drill is on the level and the jacks and power head are fully retracted. You can adjust this value to increase or decrease the sensitivity of the PIPE alarm function. The PIPE notification turns off only when drilling resumes or after the distance from the bottom of the hole is equal to the hole depth plus this offset.

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DEI Plus Installation and Operations Guide

If the bit air cable is disconnected, reconnect it at this point in the process.

If you do not want to save the calibration settings, press the System button to return to the System Menu.

NOTE: If the drill head drifts or moves during the calibration, you must repeat the calibration.

Changing the Password


To change the calibration password, you begin by entering an incorrect password for the calibration process. Detailed instructions follow: 1. Press the System button to display the System Menu. 2. Move the highlight to Configuration and press the Enter button to display the Configuration menu. 3. Move the highlight to Calibration and press Enter to display the Calibration Menu. 4. Move the highlight to Perform Normal Calibration and press Enter to display the first calibration screen. 5. Highlight Yes (to calibrate) and press Enter to display the screen where you enter the password. 6. Enter a six-digit incorrect password. If necessary, refer back to Entering your Password for instructions.

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Chapter 2 Installing the DEI Plus

7. After you enter the incorrect password, the screen displays the following message: Incorrect password entered. Press [Enter] to try again 8. Press the Zero Hole button to display a second Incorrect password screen. This screen is the same as the first, except that it also has small triangular highlights in the top left and bottom right corners. 9. Press the Zero Hole button again to continue the process. Or, press the Enter button to cancel out and return to screen where you enter the current password. 10. If you continue, a screen appears on which you enter the new password. Use the process described in Entering Your Password to enter six digits for the new password.

11. Once you enter the sixth digit, the screen displays this message confirming that your new password is now in effect: New password stored. Press [Enter] to continue. 12. Press Enter to return to the screen where you enter your new password to begin the calibration process.

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DEI Plus Installation and Operations Guide

Switching Between Calibration Modes


Use the following instructions to switch between calibration modes when the same drill is used to drill single-pass holes and multi-pass holes.

To switch from single-pass to multi-pass drilling:


1. Press the System button to display the System Menu.

2. Use the Left, Up, Down, and Right arrow buttons on the DEI Plus to move the highlight to Configuration. 3. With Configuration highlighted, press the Enter button to display the Configuration menu. 4. Move the highlight to Calibration and press the Enter button. 5. When you choose Calibration, the DEI Plus displays the Calibration Menu. Move the highlight to Multi-Pass <=> Single-Pass Drilling and press the Enter button.

If the length of a second drill pipe was defined during calibration on Calibration Screen 9:

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Chapter 2 Installing the DEI Plus

6.

The confirmation screen appears. Highlight Yes, and press the Enter button to complete the switch.

7.

The Switch Complete screen appears. Press the Enter button to return to the Calibration Menu.

If a second pipe length was not defined during calibration : 6. This screen appears. To cancel the switch, highlight No and press Enter to return to the Calibration menu. To continue the switch, highlight Yes and press the Enter button to go to Calibration Screen 9, where you can enter a second pipe length. Once you complete and save the new calibration, start again at Step 1 of this process to switch to multipass drilling.

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DEI Plus Installation and Operations Guide

To switch from multi-pass to single-pass drilling:


1. Press the System button to display the System Menu. 2. Use the Left, Up, Down, and Right arrow buttons on the DEI Plus to move the highlight to Configuration. 3. With Configuration highlighted, press the Enter button to display the Configuration menu. 4. Move the highlight to Calibration and press the Enter button to display the Calibration Menu.. 5. Move the highlight to Multi-Pass <=> Single-Pass Drilling and press the Enter button. 6. The confirmation screen appears. Highlight Yes, and press the Enter button to complete the switch.

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Chapter 3 Operating the DEI Plus

Chapter 3 Operating the DEI Plus


This section explains how to operate the DEI Plus and how to read and use the graphical screens. NOTE: If the distance recorded in the calibration procedure was measured in feet, all readings on the DEI Plus are in feet or feet per hour. If the calibration was done in meters, all readings are in meters or meters per hour.

Turning the DEI Plus On and Off


When the DEI Plus is on, the graphical screen is illuminated. When it is off, the screen is blank. To turn the DEI Plus on:
M ining Systems

M ining Systems

DEIPLUS

Press the POWER button on the front of the DEI Plus. The graphical screen becomes illuminated and the logo screen appears. To turn it off: Press the POWER button. The screen becomes blank.

Figure 17. DEI Plus Power Button

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DEI Plus Installation and Operations Guide

DEI Plus Control Elements


This section explains the function of each element on the front of the DEI Plus. The elements include the graphical display, ten control buttons, and the power button.

M ining Systems

Statistics
DEPTH TARGET

43.7 123

65.2

Data System Help Enter

ROP

PIPE
10:45

21:50

Power

Left Up

Down Right

Zero Hole Depth

Figure 18. DEI Plus Control Elements

Graphical Display
The display area of the DEI Plus is your window into the operation of the system. It shows statistics about your current and previous drilling operations, help information, and alarm warnings. This area also displays system screens you can use to check and change the setup of the system and perform troubleshooting procedures. Refer ahead to Reference to Statistics Screens and Reference to System Screens for illustrations and explanations of the screens.

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Chapter 3 Operating the DEI Plus

The bottom line of most screens is the status line. For example:

Screen Title

Specific Screen Content

Status Line Current Hole Air Number Status


Current Hole Number

Current Drill Status

Current Time (24-hour clock)

The number of holes started during the current shift. This value increases by one each time the Zero Hole button is pressed if any depth has been recorded since the last Zero Hole button press. This value is reset to zero after a shift change. Indicator that shows whether the air pressure switch is on or off. The drill status, which is one of the following:
Drilling: Any time the pipe is making downward drilling progress in the hole. Note that a drilling delay of up to 60 seconds is counted as drilling. A longer delay causes the status to change to Non drilling. Non drilling: Any time the drill pipe is in the hole and not

Air Status

Current Drill Status

making downward progress for a period longer than 60 seconds.


Idle: Any time the drill pipe is out of the hole. Current Time

The system time in hours and minutes, as on a 24-hour clock. You can reset the time on the Set Time system screen.
NOTE: The battery inside the DEI Plus maintains the system clock even when the DEI Plus is not connected to a power source.

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DEI Plus Installation and Operations Guide

Control Buttons
You use the control buttons below and to the right of the display to request the information or instructions you want to view and to enter new setup information into the DEI Plus.
Button Meaning Statistics Function

Press this button to access the statistics screens showing information about the current drilling operation and historical statistics. The default statistics screen appears, for example:

You can use the Left, Up, Down, and Right arrow buttons to move to other statistics screens. For complete details on displaying and reading the statistics screens, refer ahead to Statistics Screens.
Data

This button has no function in the basic DEI Plus system, and pressing it displays the following screen.

Contact Thunderbird Mining Systems about installing upgraded software that allows management personnel

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Chapter 3 Operating the DEI Plus

Button

Meaning

Function

to monitor and create reports summarizing drilling, the productivity of equipment, and other aspects of the operation.
System

Press this button to display the System Menu screen.

From this screen, you can access the system screens on which you can view and change the system setup. For complete details on using the system screens, refer ahead to System Screens.
Help

Press this button to display help information about the screen currently displayed. For example, if you press the Help button when the default statistics screen is displayed, the following help information appears.

A down arrow at the bottom of a help screen indicates this is the first page of a multi-page help screen. Press the Down arrow on the DEI Plus to move to the next page.

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DEI Plus Installation and Operations Guide

Button

Meaning

Function

Both arrows at the bottom of a help screen indicate that this is a middle page in a multipage help screen. Press the Up arrow on the DEI Plus to move back to the previous page, or press the Down arrow to move to the next page. An up arrow indicates that this is the last page in the multi-page help screen.
Enter

Use this button to make selections on certain screens. The specific use varies from screen to screen. Instructions for using this button are included with the instructions for all screens to which it applies. Use these buttons to navigate on certain screens and to navigate between certain screens. For example, when the System Menu screen is displayed, use the appropriate one of these keys to move to the screen you want to view; then press the Enter key to display the selected screen. Instructions for using these buttons are included with the instructions for all screens to which they apply. Whenever you start a new hole, press this button. If any depth has been recorded since the last time the button was pressed, the DEI Plus does the following: Increases the hole count by one, and zeros the hole depth so all new drilling applies to the new hole. Moves the readings for previous holes to the appropriate historical screens.

Left Up Down Right Zero Hole Depth

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Chapter 3 Operating the DEI Plus

Reference to Statistics Screens


Statistics screens provide information about the drilling operation. Continually updated details about the current hole allow the operator to know, at every moment, what is occurring in the hole the current depth, target depth, rate of penetration, the distance from the bottom when the bit is raised, whether or not the pipe is still in the hole, the time spent drilling the hole, and the time required to complete the hole. Historical statistics (that is, production during a given period, statistics about previous holes and previous shifts) provide supervisors with a summary of drilling data.

When you press the Statistics button on the DEI Plus, the display shows the default statistics screen which gives statistics for the current hole, that is, the hole currently being drilled (or most recently drilled). Once this screen is displayed, you can use the arrow buttons to display other statistics screens. This section explains each of the statistics screens, tells how to display each one, and details the function of each navigation control button on each screen. Refer ahead to Navigating Through Statistics Screens for a summary diagram showing all statistics screen and how to navigate from one to another.

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DEI Plus Installation and Operations Guide

Statistics Current Hole


The Statistics Current Hole screen shows details about the hole currently being drilled. It allows you to monitor the drilling as it occurs. To display this screen, from any screen, press the Statistics button.

Sample Screen
A sample screen is shown and explained below. Graphic Display of Current Depth and Target Depth Screen Title

Statistics for Current Hole

Current Hole Air Number Status

Current Drill Status

Current Time (24-hour clock)

Display Details
NOTE: If the distance recorded in the calibration procedure was measured in feet, all readings on the DEI Plus are in feet. If the calibration was done in meters, all readings are in meters.
DEPTH

Current Hole Depth. The display shows the actual depth of the hole presently being drilled, in meters or feet (to the nearest tenth). Values range from 0.0 to 999.9.

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Chapter 3 Operating the DEI Plus

ROP

Rate of Penetration. While the pipe is making downward progress (the status is Drilling), the display shows the actual rate of drill penetration in meters or feet per hour. Whenever the drill bit is raised from the bottom of the hole, the label changes to read Distance From Bottom, and the display shows the distance the drill bit is raised from the hole bottom (in meters or feet). This helps the operator avoid slamming the bit into the hole bottom and possibly damaging the drill bit and steel. When the bit air is turned off, the displayed Distance From Bottom value freezes, showing the value when the air was turned off. When the drill bit is returned to the hole bottom and drilling is resumed, the label returns to ROP, and the display reverts to showing the rate.

DRILLING TIME

The length of time, in minutes and seconds, spent drilling on the current hole. That is, the time when downward progress is being made, including delay periods of less than 60 seconds. (Status in the status line says Drilling.) The target depth for the current hole, in meters or feet (to the nearest tenth). Note: You can change the target depth on the Target Depth system screen.

TARGET

PIPE

When the drill is moving downward, this area is blank. When the ROP display is showing the Distance From Bottom, and there is a Pipe-In-Hole condition, the word PIPE flashes in this area of the display to alert the operator to the condition. This features helps you prevent damage to equipment often caused by retracting the jacks or moving the drill when pipe is still in the hole. The Pipe-In-Hole alert occurs whenever the following three conditions are met: Drilling air is turned off. Drill feed direction is reversed relative to the normal drilling direction (as indicated by encoder data). The distance from bottom value is greater than 85% of the hole depth.

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DEI Plus Installation and Operations Guide

TIME TO COMPLETE

The estimated time remaining to finish drilling the current hole is based on the distance remaining and the current rate of penetration. The value is calculated as the difference between the target depth and the current depth, divided by the current ROP. This value is displayed after 5% of the hole has been drilled. Right and left arrows on the graph show the current depth. A dark line shows the target depth. Note: You can change the minimum and maximum values on the scale through the Graphic Scaling system screen.

Graphic Display

Button Usage
Enter Left Up Down Right

No function on this screen. Displays the Shift Screen: Current Shift. Displays the Production Screen. Displays the Statistics Screen: 1st Previous Hole. Displays the ROP Graphics Screen: Current Hole.

Alarm Screens
When any of three possible alarm conditions occur, the DEI Plus interrupts the current display by flashing a screen with appropriate alarm information until the alarm condition no longer exists. Since these alarm conditions are detected during drilling, normally it is the Statistics: Current Hole screen that is interrupted.

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Chapter 3 Operating the DEI Plus

The three alarm conditions are: ROP is too high. If the ROP exceeds the rate set up on the Alarms screen (discussed in Reference to System Screens), and the ROP alarm is enabled, the DEI Plus flashes a warning screen on the display, telling you the ROP has reached or exceeded your specified maximum. Once the alarm condition is corrected, the screen is removed from the display. For example:

Hole is too deep. If the drilling reaches the depth set up on the Alarms screen, and the depth alarm is enabled, the DEI Plus flashes a warning screen telling you the depth has reached or exceeded your specified distance. Once the alarm condition is corrected, the screen is removed from the display. For example:

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DEI Plus Installation and Operations Guide

Calibration has failed. If the DEI Plus detects a calibration failure during drilling, it flashes a warning screen on the display, and you must re-calibrate before you continue, or your data will be unreliable. The warning is shown below.

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Chapter 3 Operating the DEI Plus

Navigating Through Statistics Screens


The following diagram shows all the available statistics screens. Note that the default screen is highlighted in black. It is the screen that appears whenever you press the Statistics button on the DEI Plus. On the diagram, the arrows between screens indicate the DEI Plus control buttons you use to move from one screen to another. For example, if the Statistics: Current Hole screen is currently on the display, press the Left arrow button to display the Current Shift screen; then press the Right arrow button to return to the Statistics: Current Hole screen. If the Production Statistics screen is on the display, press the Enter key to display the Reset Production Statistics screen.

The following subsections explain these screens: Production Statistics Reset Production Statistics ROP Graphic Screens Statistics: Previous Holes Shift Screens

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DEI Plus Installation and Operations Guide

Production Statistics
Use the Production Statistics screen to track the cumulative statistics during some period, such as a shift or a day. The screen displays combined statistical data for all holes drilled since the last time the values were reset to zero through the Reset Production Statistics screen. To display this screen: 1. Press the Statistics button to display the default statistics screen Statistics: Current Hole. 2. Press the Up arrow button. Note: Press the Down arrow button to return to the default statistics screen.

Sample Screen
A sample screen is shown and explained below. Screen Title

Statistics for Recent Holes

Current Hole Air Number Status

Current Drill Status

Current Time (24-hour clock)

Display Details
TOTAL HOLES AVERAGE DEPTH

Number of holes started during the production period. Average depth of all holes partially or completely drilled during the production period, in meters or feet (to the nearest tenth). Average time spent drilling on each hole. The total depth drilled during the production period, in meters or feet (to the nearest tenth). The average rate of penetration per hour during the production period.

AVERAGE TIME TOTAL DEPTH AVERAGE ROP

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Chapter 3 Operating the DEI Plus

Button Usage
Enter Left Up Down Right

Displays the Reset Production Statistics screen. No function. No function. Displays the Statistics: Current Hole screen. No function.

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DEI Plus Installation and Operations Guide

Reset Production Statistics


Use this screen to reset the cumulative production values to zero so you can begin tracking production anew on the Production Statistics screen. To display this screen: 1. Press the Statistics button to display the default statistics screen Statistics: Current Hole. 2. Press the Up arrow button to display the Production Statistics screen. 3. Press the Enter button.

Sample Screen
A sample screen is shown and explained below.

Screen Title

User entry area

Current Hole Number

Current Status

Current Time

Display Details
YES

Highlight this box and press the Enter button to reset all the production values to zero and return to the reset Production Statistics screen. Highlight this box and press the Enter button to return to the Production Screen without resetting the production values to zero.

NO

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Chapter 3 Operating the DEI Plus

Button Usage
Enter

Executes your selection and returns to the Reset Production Statistics screen. Moves the highlight to the YES box. No function. No function. Moves the highlight to the NO box.

Left Up Down Right

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DEI Plus Installation and Operations Guide

ROP Graphic Screens


The ROP Graphic Screen displays depth, ROP, and drill time for the hole currently being drilled. It also graphically displays the ROP in relationship to the depth. To display this screen: 1. Press the Statistics button to display the default statistics screen Statistics: Current Hole. 2. Press the Right arrow button. You can move through the three Statistics screens for previous holes by pressing the Down arrow one, two, three times. Then use the Up arrow button to move back to a more recent hole. NOTE: From the ROP Graphics screen, press the Left arrow button to return to the Statistics: Current Hole screen.

Sample Screen
A sample screen for the Current Hole is shown and explained below. ROP vs. Depth Graph Screen Title

Statistics for the Hole

Current Hole Air Number Status

Current Drill Status

Current Time (24-hour clock)

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Display Details
DEPTH

Current Hole Depth. The display shows the actual depth of the hole presently being drilled, in meters or feet (to the nearest tenth). Values range from 0.0 to 999.9. Rate of Penetration. While the pipe is making downward progress (the status is Drilling), the display shows the actual rate of drill penetration in meters or feet per hour. Whenever the drill bit is raised from the bottom of the hole, the label changes to read Distance From Bottom, and the display shows the distance the drill bit is raised from the hole bottom (in meters or feet). This helps the operator avoid slamming the bit into the hole bottom and possibly damaging the drill bit and steel. When the bit air is turned off, the displayed Distance From Bottom value freezes, showing the value when the air was turned off. When the drill bit is returned to the hole bottom and drilling is resumed, the label returns to ROP, and the display reverts to showing the rate.

ROP

DRILLING TIME

The length of time, in minutes and seconds, spent drilling on the current hole. That is, the time when downward progress is being made, including delay periods of less than 60 seconds. (Status in the status line says Drilling.)

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ROP Graphic

Shows the rate of penetration (on the X axis) plotted against the depth (on the Y axis). For example, the sample screen shows that when the hole depth was approximately 35 feet (or meters), the ROP was approximately 114 feet (or meters) per hour.

Note: You can change the minimum and maximum values on either scale through the Graphic Scaling system screen.

Button Usage
Enter Left Up Down Right

No function. Displays the Statistics screen for the current hole. No function. Displays the Statistics screen for the previous hole. No function.

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Statistics: Previous Holes


Three different screens show the statistics for the three holes drilled immediately previous to the current hole. You can access these screens from either the default statistics screen (Statistics: Current Hole) or the ROP Graphic screen. To display this screen: 1. Press the Statistics button to display the default statistics screen Statistics: Current Hole. 2. Press the Right arrow button to display the ROP Graphic screen. 3. Press the Down arrow button to display the statistics screen for the hole of interest (once for the 1st previous hole screen, twice for the 2nd previous hole screen, or three times for the 3rd previous hole screen). You can move through the three statistics screens by pressing the Up arrow button to move to a screen for a more recent hole and by pressing the Down arrow button to move to a screen for a previous hole.

Sample Screen
A sample screen is shown and explained below. ROP vs. Depth Graph Screen Title Shows the Hole Number Statistics for the Hole

Current Hole Air Number Status

Current Drill Status

Current Time (24-hour clock)

Display Details
DEPTH

Hole Depth. The display shows the final depth of the hole, in meters or feet (to the nearest tenth). Values range from 0.0 to 999.9.

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AVERAGE ROP DRILLING TIME

Average Rate of Penetration. The length of time, in minutes and seconds, spent drilling on the indicated hole. Drilling time is the time when downward progress was being made, including delay periods of less than 60 seconds. (Status in the status line says Drilling.) Shows the rate of penetration (on the X axis) plotted against the depth (on the Y axis). For example, the sample screen shows that when the hole depth was approximately 35 feet (or meters), the ROP was approximately 114 feet (or meters) per hour.

ROP Graphic

Note: You can change the minimum and maximum values on either scale through the Graphic Scaling system screen.

Button Usage
Enter Left Up

No function. No function. On screens for 2nd previous and 3rd previous holes, this button displays the Statistics for a more recently drilled hole. On screens for 1st and 2nd previous holes, this button displays the Statistics for a previous hole. On the screen for the 3rd previous hole, it has no function. On the Statistics: Current Hole screen only, displays the ROP Graphic Screen

Down

Right

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Shift Screens
There are four shift screens. Each one screen displays cumulative statistical data for all holes worked on during the selected shift current shift or one of the three previous shifts. Starting and ending times for shifts are set up on the Shift Times system screens. To display one of the shift screens: 1. Press the Statistics button to display the default statistics screen Statistics: Current Hole. 2. Press the Left arrow button to display the shift screen for the current shift. 3. Press the Left arrow button to display the screen for a different shift (once for the previous shift, twice for the 2nd previous, or three times for the 3rd previous shift). You can move through the four shift screens by pressing the Right arrow button to move to a screen for a more recent shift and by pressing the Left arrow button to move to a screen for a previous shift.

Sample Screen
A sample screen for the current shift is shown and explained below.

Screen Title (indicates the shift)

Statistics for the Indicated Shift

Current Hole Air Number Status

Current Drill Status

Current Time (24-hour clock)

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Display Details
TOTAL HOLES TOTAL TIME AVERAGE ROP

Number of holes started during the shift. Total drilling time on holes finished during the shift. The average rate of penetration during the drilling of all holes worked on during the shift. The total depth drilled during the shift, in meters or feet (to the nearest tenth). Average depth of all holes worked on during the shift, in meters or feet (to the nearest tenth). Average drilling time per hole worked on during the shift.

TOTAL DEPTH

AVERAGE DEPTH

AVERAGE TIME

Button Usage
Enter Left

No function. Displays the Shift screen for a previous shift. No function on the Shift screen for the 3rd previous shift. No function. No function. Displays the Shift screen for a later shift. On the Shift screen for the current shift only, displays the Statistics: Current Hole screen.

Up Down Right

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Reference to System Screens


System screens allow you to set up and manage your DEI Plus system. For example: Set up operating parameters, such as the target depth, shift times, alarm conditions. View the status of system elements, such as the external alarms state, the condition of the memory, the DEI Plus software version. Calibrate the DEI Plus by following a sequence of interactive screens. Perform diagnostics, such as troubleshooting procedures and testing system components.

When you press the System button on the DEI Plus, the display shows the System Menu screen, through which you access all other system screens. This section explains each of the system screens and tells how to display and use each one. Refer ahead to Navigating Through System Screens for a summary diagram showing all system screen and how to navigate to each one.

System Menu
The System Menu provides an entry into the other system screens. Note that the Diagnostics and General Info items display additional menus from which you choose. From any screen, press the System button to display this screen. The most recently used option is highlighted when the menu appears. IMPORTANT: The drill must be idle or not drilling before you use many of the system screens. In general, use the system screens only when you are not drilling. The screen is shown and explained below.

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Screen Title

Options to Display System Screens

Current Hole Air Number Status To select an item on the menu:

Current Drill Status

Current Time (24-hour clock)

1. Use the arrow buttons (Left, Up, Down, Right) to move the highlight to the item you want to select. 2. Press the Enter button.

Button Usage
Enter

Selects the highlighted option, and displays the appropriate screen. Moves the highlight to the left column. Moves the highlight up one row. Moves the highlight down one row. Moves the highlight to the right column.

Left Up Down Right

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Navigating Through System Screens


The following diagram shows all the available system screens and how to get to each of them from the System Menu. Note that the screens containing additional menus are highlighted with black title bars. On the diagram, the arrows between screens indicate the item to highlight on the menu before you press the Enter button to display the corresponding screen. For example, on the System Menu, highlight Brightness and press the Enter button to display the Brightness Screen. The following subsections explain each of the menus and screens shown in the diagram.
System Menu Brightness Screen Target Depth Screen Set Time Screen Shift Times Screens Alarms Screen Shift Times Alarms Mast Level Diagnostics General Info Brightness Graphic Scaling Configuration Menu Calibration Parameters Calibration Screens

Diagnostics Menu Detailed System Status Troubleshooting

Detailed System Status Menu Memory Test Screens Display Test Screens Bit Air Switch Screen Memory Alarm Status Screen Encoder Status Screen

General Info Menu Parts Screens Version Number Screen Hardware Software

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Brightness Screen
You may need to adjust the brightness of the DEI Plus display area to optimize your view of the screens as the level of light in the environment changes. Use Brightness screen to adjust the brightness level of the display. To display this screen: 1. Press the System button to display the System Menu. 2. Use the arrow buttons (Left, Up, Down, Right) to move the highlight to Brightness. Then press the Enter button.

Sample Screen

Screen Title

The current brightness level. 100% is the highest. 15% is the lowest.

Current Hole Air Number Status

Current Drill Status

Current Time (24-hour clock)

Using the Screen


To change the brightness of the display: 1. Press the Up arrow button to increase the brightness. Or, press the Down arrow to decrease the brightness. As the percentage on the screen changes, the brightness level of the display changes accordingly. 2. When the display is the brightness you want, press the Enter button. A confirmation screen appears for 3 seconds, then the System Menu reappears.

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Button Usage
Enter Left Up Down Right

Applies the selected brightness level. No function. Increases the brightness level setting. Decreases the brightness level setting. No function.

Target Depth Screen


Whenever you start a new hole with a new target depth, use this screen to specify the target depth for the current hole. The new target depth will appear on the Statistics: Current Hole screen next time that screen is displayed. To display this screen: 1. Press the System button to display the System Menu. 2. Use the arrow buttons (Left, Up, Down, Right) to move the highlight to Target Depth. Then press the Enter button.

Sample Screen

Screen Title

The current target depth and your new setting.

Current Hole Air Number Status

Current Drill Status

Current Time (24-hour clock)

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Using the Screen


When the screen first appears, the current target depth appears in both boxes. You can change only the value in the New Target Depth box. To change the target depth for the current hole: 1. Use the Left and Right arrow buttons to move the pointer in the New Target Depth box to the digit you want to change. 2. Use the Up or Down arrow buttons to increase or decrease (respectively) the value of the selected digit. If the value is 9, pressing Up changes it to a blank. Pressing Up again changes it to a 1. If the value is 0 pressing Down changes it to a blank. Pressing Down again changes it to a 1. To add a digit to the left of the leftmost digit, move the pointer to the blank space and use the buttons to select the value for the space. The maximum depth you can set is 999.9. 3. Repeat steps 1 and 2 until the correct target depth appears in the box. 4. Press Enter to apply the new setting. A confirmation screen appears for 3 seconds, then the System Menu reappears.

Button Usage
Enter

Changes the target depth to the value in the New Target Depth box. Moves the pointer left one digit. Increases the value of the selected digit by one. Decreases the value of the selected digit by one. Moves the pointer right one digit.

Left Up Down Right

Set Time Screen


The DEI Plus comes with an internal real-time clock and calendar (RTC). This clock invisibly attaches the GMT (Greenwich Mean Time) time to all data records. However, when the DEI Plus displays the time on the screens, it converts the time to local time according to the 24-hour clock time set by the operator on this system screen.

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Once the local time is set in the DEI Plus, the battery backup allows the clock to keep the correct time even when the DEI Plus is not connected to a power source. However, you will need to change the local time when you start or end Daylight Savings time, or if you move the DEI Plus to a new time zone, or if you notice that it has become slightly off precision. The new time setting appears on all the screens as soon as you apply the change. To display this screen: 1. Press the System button to display the System Menu. 2. Use the arrow buttons (Left, Up, Down, Right) to move the highlight to Set Time. Then press the Enter button.

Sample Screen

Screen Title

Current time (hour: minute) and your new setting.

Current Hole Air Number Status

Current Drill Status

Current Time (24-hour clock)

When the screen first appears, the current time appears in both boxes. Note that the time is always presented as on a 24-hour clock (hour:minute). You can change only the value in the New Time box. To change the system time of the DEI Plus: 1. Use the Left and Right arrow buttons to move the pointer in the New Time box to the hour or minute digit you want to change. (The seconds setting is not adjustable; it is set to 00 when you apply the new setting.) 2. Use the Up or Down arrow buttons to increase or decrease (respectively) the value of the selected digit. If the value is 9, pressing Up changes it to 0. If the value is 0 pressing Down changes it to 9. 3. Repeat steps 1 and 2 until the correct time appears in the box.

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4. Press Enter to apply the new setting. A confirmation screen appears for 3 seconds, then the System Menu reappears.

Button Usage
Enter

Changes the current time to the value in the New Time box. Moves the pointer left one digit. Increases the value of the selected digit by one. Decreases the value of the selected digit by one. Moves the pointer right one digit.

Left Up Down Right

Shift Times Screens


Statistics are tracked by shifts and displayed on the shift statistics screens. So, it is important for the shift periods to be set correctly in the DEI Plus. Use this series of three screens to view or change the start and end times for up to three shifts (Shifts 1, 2, and 3). To display the first of these screens: 1. Press the System button to display the System Menu. 2. Use the arrow buttons (Left, Up, Down, Right) to move the highlight to Shift Times. Then press the Enter button.

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Sample Screen

Screen Title

Start and end times for the shift indicated in the title (hour: minute)

Current Hole Air Number Status

Current Drill Status

Current Time (24-hour clock)

Using the Screen


When the screen first appears, the current start and end times for Shift 1 appear in the boxes. Note that time is always presented as on a 24-hour clock (hour:minute:). To change the defined shift periods: 1. On the Shift 1 Time screen, use the Left and Right arrow buttons to move the pointer to the digit you want to change. NOTE: To move from the rightmost digit in the Start box to the leftmost digit in the End box, press Right, and to move back press Left. 2. Use the Up or Down arrow buttons to increase or decrease (respectively) the value of the selected digit. 3. Repeat steps 1 and 2 until the correct start and end times for the first shift appear in the boxes. 4. Press Enter to apply the new setting for Shift 1. If the length of the first shift is less than 24 hours, the Shift 2 Time screen appears. Continue with step 5. If the length of the first shift is 24 hours, the DEI Plus recognizes that you have only one shift, and the confirmation screen appears. Go to step 8. 5. Use the instructions in steps 1 and 2 to change the end time of the second shift, if necessary. The time you specified for the end of Shift 1 is the start time of Shift 2. You cannot change it.

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6. Press Enter to apply the new setting for Shift 2. If the combined lengths of the first and second shifts is less than 24 hours, the Shift 3 Time screen appears. Continue with step 7. If their combined length is 24 hours, the DEI Plus recognizes that you have only two shifts, and the confirmation screen appears. Go to step 8. 7. The Shift 3 Time screen is an information screen only. The DEI Plus sets the third shift to be the remaining time (in a day) not allocated for either of the other two shifts. (That means the start time of the third shift is set as the end time of the second shift, and the end time of the third shift is set as the start time of the first shift.) You cannot change these settings. If the settings are correct, press the Enter button to display the confirmation screen. 8. The confirmation screen shows the start and end times of all your shifts. If you have defined fewer than 3 shifts, the times for the undefined shift (or shifts) says NONE. If the times are correct, highlight Yes and press the Enter button to return to the system menu. If not, highlight No and press the Enter button to return to the Shift 1 Time screen so you can begin again. An example screen is shown below:

Button Usage
Enter Left

Apply the new shift times and move to the next screen. Moves the pointer left one digit; or, if the pointer is at the leftmost digit in the End box, moves the pointer to the rightmost digit in the Start box. Increases the value of the selected digit by one. Decreases the value of the selected digit by one.

Up Down

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Right

Moves the pointer right one digit; or, if the pointer is at the rightmost digit in the Start box, moves the pointer to the leftmost digit in the End box.

Alarms Screen
The DEI Plus provides two automatic alarms to notify you of problem conditions. You specify the criteria for each alarm, and whether or not you want to use the alarm. If you enable an alarm and the alarm condition occurs, the DEI Plus flashes the appropriate alarm screen on the display until the alarm condition is corrected. Since these alarm conditions are detected during drilling, it is the Statistics: Current Hole screen that is interrupted. You can also connect an external alarm to the back of the DEI Plus (rightmost connector on the top row). The external alarm, too, is triggered when the conditions specified on this screen occur. The two alarms are: ROP alarm. You specify the maximum rate of penetration. Then, if the ROP exceeds that rate, the DEI Plus flashes a warning screen on the display, telling you the ROP has reached or exceeded your specified maximum. Depth alarm. You specify the maximum depth for the hole. Then, if the drilling reaches that depth, the DEI Plus flashes a warning screen telling you the depth has reached or exceeded your specified distance.

Use the Alarms screen to view or change the criteria for the ROP and Depth alarms and to enable or disable either alarm. To display the Alarms screen: 1. Press the System button to display the System Menu. 2. Use the arrow buttons (Left, Up, Down, Right) to move the highlight to Alarms. Then press the Enter button.

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Sample Screen

Screen Title

Alarm criteria and state

Current Hole Air Number Status

Current Drill Status

Current Time (24-hour clock)

Using the Screen


When the screen first appears, the current criteria and state is displayed for both alarms. To change the alarm criteria or the state: 1. Use the Left and Right arrow buttons to move the pointer to the element you want to change either the maximum ROP rate or hole depth or the on/off state of one of the alarms. 2. Use the Up or Down arrow buttons to increase or decrease (respectively) the value of the selected digit or to alternate the state between ON and OFF. 3. Repeat steps 1 and 2 until both the values and states on the screen are as you currently require. 4. Press Enter to apply the new settings. A confirmation screen appears for 3 seconds, then the System Menu reappears.

Button Usage
Enter Left Up

Apply the new settings and return to the System Menu. Moves the pointer left one elementdigit or state setting. For values, increases the value of the selected digit by one. For on/off states, alternates between ON and OFF.

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Down

For values, decreases the value of the selected digit by one. For on/off states, alternates between ON and OFF. Moves the pointer right one elementdigit or state setting.

Right

Graphic Scaling Screen


The Statistics: Current Hole screen displays a graph of the hole depth and target depth. The ROP Graphic screen and the statistics screens for previous holes display a graph of the ROP at each depth, for the relevant hole. Use the Graphic Scaling screen to define the scale for those graphs by adjusting the minimum and maximum Depth and ROP values to use on the scales.
Note: You can adjust the graphic scaling only at the start of a new hole.

To display this screen: 1. Press the System button to display the System Menu. 2. Use the arrow buttons (Left, Up, Down, Right) to move the highlight to Graphic Scaling. Then press the Enter button.

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Sample Screen
NOTE: The values on this sample define the axes to be as they are shown in the sample illustrations of the Statistics: Current Hole screen and the ROP Graphic screen in earlier sections of the manual.

Screen Title

Scale Settings

Current Hole Air Number Status

Current Drill Status

Current Time (24-hour clock)

Using the Screen


When the screen first appears, the current scale settings are displayed for both graph axes. To change the scale settings: 1. Use the Left and Right arrow buttons to move the pointer to the digit you want to change or to a different scaling parameter. 2. Use the Up or Down arrow buttons to increase or decrease (respectively) the value of the selected digit. 3. Repeat steps 1 and 2 until all the values on the screen are as you want. 4. Press Enter to apply the new settings. A confirmation screen appears for 3 seconds, then the System Menu reappears.

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Button Usage
Enter Left Up Down Right

Apply the new settings and return to the System Menu. Moves the pointer left one digit or box. Increases the value of the selected digit by one. Decreases the value of the selected digit by one. Moves the pointer right one digit or box.

Configuration Menu
This screen provides three options for viewing and changing the system configuration. Use the Calibration option to calibrate the DEI Plus. The Parameters option is provided for future enhancements. Use the Mast Adjustment option to calibrate the mast level zero position. To display the Configuration Menu: 1. Press the System button to display the System Menu. 2. Use the arrow buttons (Left, Up, Down, Right) to move the highlight to Configuration. Then press the Enter button.

Screen
Screen Title

Configuration Options

Current Hole Air Number Status

Current Drill Status

Current Time (24-hour clock)

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Calibration Screens
For illustrations of the screens and complete instructions for displaying and using them, refer to Calibrating the DEI Plus in Chapter 2.

Parameters Screen
The current version of the DEI Plus does not support the Parameters option. If you select this item, the following screen appears for 3 seconds. Then the System Menu reappears.

Mast Adjustment Screen


If you have an inclinometer installed, this option allows you to set the zero position for the inclinometer. 1. 2. Set the drill to the position you want to use as the zero starting point for mast level. Display the screen, and press the Zero Hole button to set the zero position for the inclinometer.

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If you select this option without having an inclinometer installed, the following screen appears for 3 seconds. Then the System Menu reappears.

Mast Level
If you have an inclinometer installed, display this screen to view the mast angle and level, starting from the point indicated as zero through the Mast Adjustment screen.

If you select this option without having an inclinometer installed, the following message appears for 3 seconds. Inclinometer is not installed. Then the System Menu reappears.

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Diagnostics Menu
This screen provides two options for viewing and entering diagnostics information. Use the diagnostics screens in conjunction with the troubleshooting instructions in the manual. To display the Diagnostics Menu: 1. Press the System button to display the System Menu. 2. Use the arrow buttons (Left, Up, Down, Right) to move the highlight to Diagnostics. Then press the Enter button.

Screen

Screen Title

Diagnostic Options

Current Hole Air Number Status

Current Drill Status

Current Time (24-hour clock)

Using the Screen


Use the Up or Down arrow buttons to highlight the option you want. Then press the Enter button. The two options are: Detailed System Status. When you select this option, the Detailed System Status submenu appears, allowing you to display any of six types of status information. Troubleshooting. When you select this option, the DEI Plus displays a series of three screens on which you locate the symptom you are having. The most likely problem area is noted beside each symptom. For complete troubleshooting instructions, refer to Chapter 4.

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Detailed System Status Menu


This submenu provides six options for viewing status information about the DEI Plus components: Results of a memory test. Results of a display test. Status of the bit air switch. Operation of the Zero Hole button. Status of the external alarm. Status of the encoder.

To display the Detailed System Status Menu: 1. Press the System button to display the System Menu. 2. Use the arrow buttons (Left, Up, Down, Right) to move the highlight to Detailed System Status. Then press the Enter button.

Screen

Screen Title

Status Options

Current Hole Air Number Status

Current Drill Status

Current Time (24-hour clock)

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System Status: Memory Test Screens


The DEI Plus contains 1 MB of SRAM in which system settings and historical production information are stored. Since the power required for the memory (SRAM) is backed up by a lithium battery, your data and settings are safe as long as the battery is operating. However, the memory could fail if the battery needs to be replaced. Test the memory under any of the following conditions: The calibration fails, and re-calibrating does not correct the failure. Data displayed on the screen is incorrect.

If the memory test fails, return the DEI Plus to Thunderbird Mining Systems for repair. To display the Memory Test screen: 1. Press the System button to display the System Menu. 2. Use the arrow buttons (Left, Up, Down, Right) to move the highlight to Diagnostics. Then press the Enter button to display the Diagnostics menu. 3. Use the Up and Down arrow buttons to move the highlight to Detailed System Status. Then press the Enter button to display the Detailed System Status menu. 4. Use the arrow buttons to move the highlight to Memory. Then press the Enter button. NOTE: To return to the Detailed System Status menu, highlight No and press the Enter button. To return to the System Menu, press the System button.

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Initial Screen

Screen Title

Options

Current Hole Air Number Status

Current Drill Status

Current Time (24-hour clock)

Using the Screen


To run the memory test: 1. If necessary, on the Memory Test screen, use the Left arrow to highlight Yes. 2. Press Enter to begin the test. While the test is in progress, a new screen appears asking you to Please Wait. While this screen is displayed, no control buttons are functional. 3. After the test is complete, a different screen appears, indicating the results of the test. For example, if the memory test is successful, the screen looks like this:

4. To return to the Detailed System Status menu, press the Enter button. Or, to return to the System Menu, press the System button.

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System Status: Display Test Screens


If segments are missing in the display, or if the display appears wrong in some other way, run the display test. To display the Display Test screen: 1. Press the System button to display the System Menu. 2. Use the arrow buttons (Left, Up, Down, Right) to move the highlight to Diagnostics. Then press the Enter button to display the Diagnostics menu. 3. Use the Up and Down arrow buttons to move the highlight to Detailed System Status. Then press the Enter button to display the Detailed System Status menu. 4. Use the arrow buttons to move the highlight to Display. Then press the Enter button. NOTE: To return to the Detailed System Status menu, highlight No and press the Enter button. To return to the System Menu, press the System button.

Initial Screen

Screen Title

Options

Current Hole Air Number Status

Current Drill Status

Current Time (24-hour clock)

Using the Screen


To run the display test: 1. If necessary, on the Display Test screen, use the Left arrow to highlight Yes.

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2. Press Enter to display a test pattern screen, which consists of alternating light and dark pixels in a checkerboard pattern. Any display anomalies should be easily visible on this screen. After 7 seconds, the test pattern screen is removed and the Detailed System Status menu reappears. While this screen is displayed, no control buttons are functional. The following two illustrations show test pattern screens. The first shows what the screen looks like when the display is working properly.

The second sample indicates a problem with the display. If your display shows a problem, contact Thunderbird Mining Systems for information on how to return the unit for repair.

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System Status: Bit Air Switch Status Screen


This screen shows the state of the bit airon or off. You use it in conjunction with the troubleshooting procedures. For details refer to Air Circuit Tests in Chapter 4. To display the Bit Air Switch status screen: 1. Press the System button to display the System Menu. 2. Use the arrow buttons (Left, Up, Down, Right) to move the highlight to Diagnostics. Then press the Enter button to display the Diagnostics menu. 3. Use the Up and Down arrow buttons to move the highlight to Detailed System Status. Then press the Enter button to display the Detailed System Status menu. 4. Use the arrow buttons to move the highlight to Bit Air Switch. Then press the Enter button. NOTE: To return to the Detailed System Status menu, press the Enter button. To return to the System Menu, press the System button.

Sample Screen

Screen Title

Status Indicators

Current Hole Air Number Status

Current Drill Status

Current Time (24-hour clock)

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System Status: Zero Hole Button Status Screen


When you first install the DEI Plus, use this screen to check that the Zero Hole button is operating. If, during your operations, the total hole count is not incremented correctly, use this screen to check the operation of the button. To display the Zero Hole Button status screen: 1. Press the System button to display the System Menu. 2. Use the arrow buttons (Left, Up, Down, Right) to move the highlight to Diagnostics. Then press the Enter button to display the Diagnostics menu. 3. Use the Up and Down arrow buttons to move the highlight to Detailed System Status. Then press the Enter button to display the Detailed System Status menu. 4. Use the arrow buttons to move the highlight to Zero Hole Button. Then press the Enter button. NOTE: To return to the Detailed System Status menu, press the Enter button. To return to the System Menu, press the System button.

Sample Screen

Screen Title

Status Indicators

Current Hole Air Number Status

Current Drill Status

Current Time (24-hour clock)

Using the Screen


To check the operation of the Zero Hole button on the front of the DEI Plus: 1. When the screen first appears, make sure the Zero Hole Button OFF box is highlighted.

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2. Press the Zero Hole control button on the front of the DEI Plus. Make sure the Zero Hole Button ON box is highlighted while you are pressing the button. 3. Release the button. Make sure the Zero Hole Button OFF box becomes highlighted again. 4. If the boxes do not become highlighted as expected, contact Thunderbird Mining Systems. To check the operation of the remote Zero Hole switch (if you have connected a remote switch to the back of the DEI Plus): 1. When the screen first appears, make sure the Zero Hole Switch OFF box is highlighted. 2. Press the remote Zero Hole control switch. Make sure the Zero Hole Switch ON box is highlighted while you are pressing the switch. 3. Release the switch. Make sure the Zero Hole Switch OFF box becomes highlighted again. 4. If the boxes do not become highlighted as expected, check your remote switch connections and repeat the test. If the result of the test remains the same, contact Thunderbird Mining Systems to order a switch replacement.

System Status: External Alarm Status Screen


You can connect your own external alarm to the appropriate connector on the back of the DEI Plus (the rightmost connector on the top row). Use this screen to check whether the alarm is enabled or disabled. To display the External Alarm status screen: 1. Press the System button to display the System Menu. 2. Use the arrow buttons (Left, Up, Down, Right) to move the highlight to Diagnostics. Then press the Enter button to display the Diagnostics menu. 3. Use the Up and Down arrow buttons to move the highlight to Detailed System Status. Then press the Enter button to display the Detailed System Status menu. 4. Use the arrow buttons to move the highlight to External Alarm. Then press the Enter button. NOTE: To return to the Detailed System Status menu, press the Enter button. To return to the System Menu, press the System button.

Sample Screen

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Chapter 3 Operating the DEI Plus

Screen Title

Status Indicators

Current Hole Air Number Status

Current Drill Status

Current Time (24-hour clock)

If the ON box is highlighted, the external alarm is activated (the alarm condition exists). If the OFF box is highlighted, the alarm is not activated.

System Status: Encoder Status Screen


This screen indicates the various states of the quadrature encoder. You use it in conjunction with the troubleshooting procedures. For details refer to Encoder Circuit Tests in Chapter 4. To display the Encoder status screen: 1. Press the System button to display the System Menu. 2. Use the arrow buttons (Left, Up, Down, Right) to move the highlight to Diagnostics. Then press the Enter button to display the Diagnostics menu. 3. Use the Up and Down arrow buttons to move the highlight to Detailed System Status. Then press the Enter button to display the Detailed System Status menu. 4. Use the arrow buttons to move the highlight to Encoder. Then press the Enter button. NOTE: To return to the Detailed System Status menu, press the Enter button. To return to the System Menu, press the System button.

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Sample Screen

Screen Title

Status Indicators

Current Hole Air Number Status

Current Drill Status

Current Time (24-hour clock)

Troubleshooting Screens
The troubleshooting screens list possible symptoms of problems, and they indicate the area where the problem is. Use these screens in conjunction with the troubleshooting procedures in the next section. To display the Troubleshooting screens: 1. Press the System button to display the System Menu. 2. Use the arrow buttons (Left, Up, Down, Right) to move the highlight to Diagnostics. Then press the Enter button to display the Diagnostics menu. 3. Use the Up and Down arrow buttons to move the highlight to Troubleshooting. Then press the Enter button. NOTE: To return to the Detailed System Status menu, press the Enter button. To return to the System Menu, press the System button. For your convenience the screens are reproduced in the section Typical Symptoms in Chapter 4.

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Chapter 3 Operating the DEI Plus

General Info Menu


This screen provides two options for viewing information about the DEI Plus hardware and software. To display the General Info Menu: 1. Press the System button to display the System Menu. 2. Use the arrow buttons (Left, Up, Down, Right) to move the highlight to General Info. Then press the Enter button to display the General Info menu.

Screen

Screen Title

Information Options

Current Hole Air Number Status

Current Drill Status

Current Time (24-hour clock)

Using the Screen


Use the Up or Down arrow buttons to highlight the option you want. Then press the Enter button. The two options are: Hardware.. A series of screens listing hardware related to the DEI Plus system, and giving the part number of each item. Use these screens to identify spare or replacement parts you need to order. Software. A screen showing the software version currently in use on the DEI Plus.

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General Info: Hardware


These screens list the hardware components related to the DEI Plus and gives the part number for each. The screens are reproduced here for your convenience. To display the Hardware screens: 1. Press the System button to display the System Menu. 2. Use the arrow buttons (Left, Up, Down, Right) to move the highlight to General Info. Then press the Enter button to display the General Info menu. 3. Use the Up and Down arrow buttons to move the highlight to Hardware. Then press the Enter button to display the first screen. On each screen except the last one, use the Down arrow button to move to the next screen in sequence. On each screen except the first one, use the Up arrow button to return to the previous screen in sequence. NOTE: To return to the General Info menu, press the Enter button. To return to the System Menu, press the System button. Screen 1 Screen 2

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Screen 3

Screen 4

Screen 5

Screen 6

Screen 7

Screen 8

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Screen 9

General Info: Software


This screen shows the software version currently operating on your DEI Plus. Use this screen if a Thunderbird Mining Systems technician asks you for the version of software you are using. To display the Software Info screen: 1. Press the System button to display the System Menu. 2. Use the arrow buttons (Left, Up, Down, Right) to move the highlight to General Info. Then press the Enter button to display the General Info menu. 3. Use the Up and Down arrow buttons to move the highlight to Software. Then press the Enter button. NOTE: To return to the General Info menu, press the Enter button. To return to the System Menu, press the System button.

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Chapter 3 Operating the DEI Plus

Sample Screen

Screen Title

Software Information

Current Hole Air Number Status

Current Drill Status

Current Time (24-hour clock)

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Chapter 4 Troubleshooting
Prerequisite Troubleshooting Information
By design, the DEI Plus system is composed of various modules that may be disconnected and re-connected very easily. A thorough knowledge of basic system operation and "what parts do what" will help you make a quick and accurate diagnosis of your problem, thus saving you time and frustration. Before you begin any troubleshooting activities, read this section carefully to gain a clear understanding of the systems general operation and its various components. Use the diagram in Figure 19 as a reference as you read the information and follow the procedures. Then proceed to the next section, Troubleshooting Procedures, and attempt to isolate the problem.

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7070-189-xxx

Air Pressure Switch 3700-03x-001

To bit air POWER 7070-191-xxx


A B

DEI Plus (Rear) 6523-109-001 BITAIR


C B A

ZEROHOLE
C B A

ALARM/ TRAM
F E D C A B

1 4

NPT

RS232 RS232LEVEL
F E D C A B E D C F A B

21-30 VDC

ENCODER

7070-180-xxx
ANSI 40 48-tooth 3180045

7060-190-xxx To customer-supplied external alarm

ANSI 40 16-tooth ANSI 40 Chain 4105-006-002 Alternate: ANSI 40 Sprocket Drive Kit 9001-097-002

Optical Shaft Encoder 4500630

Figure 19. Typical Installation on Hydraulic Machine

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The DEI Plus


How it maintains drilling information
During drilling, the DEI Plus receives a set of complex pulses from the optical shaft encoder. During calibration X number of pulses were specified as equal to Y (feet or meters) in depth. Based on this equality, the DEI Plus uses the pulses it receives to determine the hole depth information. It uses the depth information along with an internal timer to determine the rate-of-penetration. In general operation, the DEI Plus tracks the number of pulses and their direction in order to determine where the bit is at any given moment. In addition, it uses information from an air pressure switch to determine whether the bit air is on or off. This information, along with the pulses and some internal algorithms, allows the DEI Plus to determine if an additional stem (pipe) is being added or removed. In this way, it accurately maintains the hole depth. The encoder pulses, along with a signal from the air pressure switch, allow the DEI Plus to track the bit position and speed. For all of this to work correctly it is imperative that the DEI Plus is accurately calibrated, the air pressure switch properly functioning and the encoder properly driven.

Its power requirements and usage


In normal operation, the DEI Plus is supplied with 21-30 VDC. Power is typically supplied through either the drills 21-30 VDC batteries or a DC power supply. This voltage is used to power the internal electronics as well as external modules: It supplies the optical shaft encoder with 5 VDC and receives a set of four pulses in return. It sends a signal of approximately 4.5 VDC to the air pressure switch.

It is important to mount the DEI Plus in a location where it does not get too hot to touch. Since the unit uses only 15 VDC of the power it receives, the more input power, the more heat that must be dissipated. The DEI Plus will get quite warm if 30 VDC is supplied and the DEI Plus is mounted with the sun shining on it. If the power supplied to the DEI Plus is greater than 30 VDC, it may be damaged and must be returned to Thunderbird Mining Systems for repair.

Air Pressure Switch


The air pressure switch is connected to the bailing air line or the working air gauge on the panel with a T. It should be adjusted to go on and off quickly. The DEI Plus uses the information from this switch to aid in deciding if a length of drill pipe is being added or removed.

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The switch is provided with a signal of approximately 4.5 VDC from the DEI Plus. When the switch is open (air is detected) the DEI Plus keeps the line at a 4.5 VDC potential. When the switch is closed (air pressure is lost), the DEI Plus sets the line to ground or earth potential. The state of the switch indicates to the DEI Plus the state of the drilling: Open. Informs the DEI Plus that drilling is in process or about to begin. The DEI Plus uses this information, along with information from the encoder, to make internal decisions regarding the hole depth and ROP. Closed. Informs the DEI Plus that drilling has ceased and perhaps steel is being added or removed. If the drill feed direction is then reversed relative to normal drilling mode (as indicated by the encoder data) Distance From Bottom data is calculated and displayed on the DEI Plus screen. When the Distance From Bottom value is greater than 85% of the hole depth, the PIPE message flashes on the screen and Distance From Bottom is blanked out. Based on what happens next, it determines whether steel is being added or removed and adjusts its calculations accordingly.

If an incorrect value is entered for PIPE length and the drill is being used for multi-pass drilling, then you can expect the hole depths to be inaccurate, since each time steel is added the DEI Plus will add too much depth.

Optical Shaft Encoder


The encoder is connected somewhere within the pulldown mechanism. It is provided with a 5VDC signal from the DEI Plus. Its purpose is to monitor the movement of the drill power head. When the drill power head is moved, the encoder shaft is rotated causing the encoder to produce some combination of 4 signals (quadrature with complements) relative to the linear movement of the power head. It sends these signals to the DEI Plus. These signals may be thought of as two signal pairs: A and A, B and B. At any given moment the DEI Plus is receiving two signals, one from each pair. You can observe the signals change on the Encoder system status screen. (Refer back to System Status: Encoder Status Screen.) The DEI Plus uses the information it receives from these signals to help it determine the distance, direction, and speed of the power head. This is translated into hole depth, distance from bottom, and ROP.

Chain and Sprocket Encoder Drives


Various combinations of chains and sprockets are used to drive the optical shaft encoder. Their purpose is to translate the linear motion of the power head into the rotary motion of the encoder shaft.

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Most problems with chains and sprockets are due to poor alignment of the chain and sprockets or incorrect tension on the chain. It is critical that the chain be aligned properly with the sprockets. If it is not, the chain might come off or break, or the encoder might be damaged. If the chain is too loose, it will keep jumping off. If it is too tight, it will damage the bearings in the encoder, and you will have to replace the encoder. It is recommended that you use stainless steel chain (which is the type provided by Thunderbird Mining Systems). Although it is more expensive than other types of chains, it is stronger, has much less stretch, and does not seize from rust.

Torque Reel Encoder Drive


Torque reels (spring tension take-up) are typically used on machines that have cylinder and/or cable pulldown systems. The torque reel is mounted inside an enclosure with the wire rope wrapping a sheave that is mounted to the encoder shaft. The wire rope exits the housing through a quad bi-lateral bearing set. The bearing is machined aluminum with stainless steel pins and teflon rollers. The main enclosure is mounted to the top of the mast and the end of the wire rope is attached to a wire rope leader, which drops down and attaches to the carriage, or perhaps the power head. Typically the carriage has a 1:2 ratio with the power head. So, attaching the leader to the carriage instead of the power head means less rope will be pulled from the reel as the head moves, thereby reducing wear and tear. It is critical for the wire rope to be perpendicular to the torque reel housing and for the tension and the extraction length of the rope to be set correctly before drilling begins. If you do not allow enough rope for the movement of the drill head or carriage, the unit will be damaged.

Interconnecting Cables
Military-grade connectors are used for connecting all the cables in the system except the connection made to the power source on the drill. All the teflon-type (red) cables have their connectors filled with a semi-rigid sealing epoxy, while the connectors of other cables are sealed with an RTV type electronic grade silicon or the semi-rigid sealing epoxy. Due to this construction, if the cables operate properly when installed, they can be expected to continue working indefinitely, assuming no physical damage occurs.

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Troubleshooting Procedures
1. Make sure that all DEI Plus cable connections are tight. 2. Make sure there is a good connection to the drills power source. 3. Review the Troubleshooting system screens to see if your symptom is listed in one of them (refer ahead to Typical Symptoms). If your symptom is listed, follow the procedure in the troubleshooting section for the circuit indicated on the screen.

Typical Symptoms
Troubleshooting system screens on the DEI Plus list symptoms of possible problems, and they indicate the circuit where the problem may likely be corrected. For your convenience, the screens are reproduced in this section. To display the screens: 1. Press the System button to display the System Menu. 2. Use the arrow buttons (Left, Up, Down, and Right)to highlight Diagnostics. Then press the Enter button to display the Diagnostics menu. 3. Use the arrow buttons to highlight Troubleshooting. Then press the Enter button. NOTE: To return to the Detailed System Status menu, press the Enter button. To return to the System Menu, press the System button.

Screens
Press the Down arrow button on the DEI Plus to move to the next troubleshooting screen.

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Press the Down arrow button on the DEI Plus to move to the next troubleshooting screen, or press the Up button to return to the previous one.

Press the Up arrow button on the DEI Plus to return to the previous troubleshooting screen.

Power Circuit Tests


Components
This circuit consists of: The DC power cable (7070-191-xxx) connecting the drills 21-30 VCD power source to the POWER connector on the rear panel of the DEI Plus.

Diagnostic Information and Procedure


If your symptom is Graphical display does not illuminate, make sure that you have pressed the Power button on the front panel of the DEI Plus. The button remains pushed in when the system is on. If the display still does not illuminate, follow the procedure below.

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Before you begin the following checklist: 1. Disconnect the air pressure switch cable from the DEI Plus. If the problem changes, go to Air Circuit Tests. 2. Disconnect the encoder cable from the DEI Plus. If the problem changes, go to Encoder Circuit Tests. Problems with the DEI Plus are normally in the power circuit and are generally due to one of the following. Go through this checklist in order. 1. Check the wiring. There may be loose or improper wiring, either in the positive or the ground (earth). Most often it is a poor ground that does not allow proper current draw or injects a large amount of noise. The greater distance any electronic equipment is from the original source, the greater the differential in ground potential and the greater the chance of generated noise interfering with electronic equipment. When in doubt, move the DEI Pluss input ground (where the DEI Plus power cable connects to the power source) as close to the original power source as possible. Do not assume that since the operator console lights work, the electronics will. 2. Check the power source. If you suspect that power input is inadequate, begin checking voltages at the power source, working your way toward the DEI Plus. All voltage readings should be 21 30 VDC. If you suspect that power input is excessive, check the voltage levels to the DEI Plus, starting at the DEI Pluss power cable and working backward toward the source. All voltage readings should be 21 30 VDC. If the DEI Plus display is blank, but the Power button is pushed in (to the ON position),the DEI Plus may be receiving excessive power. The drills batteries may be low or damaged, causing the alternator to overcompensate and output too much power. If the display flashes on and off, the drills alternator diodes may have failed, allowing half-wave rectified voltage into the electrical system. This may not yet have caused damage, but it will eventually damage the DEI Plus. 3. If the DEI Plus is too hot to touch and it is mounted where the sun shines on it, you may need to move it out of direct sunlight. 4. There may be a case short in the DEI Plus. Unbolt the unit from its mounting bracket, isolate it from ground (earth). If it cools off, there is a case short. Return it to Thunderbird for repair. If none of these suggestions solves your problem, contact Thunderbird Mining Systems for service.

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Chapter 4 Troubleshooting

Air Circuit Tests


Components
This circuit consists of: An air pressure switch (3700-03x-001), which is pre-adjusted at the factory. An electrical cable (7070-189-xxx) connecting the air pressure switch to the DEI Plus. An air pressure connection to the working or bit air, typically a T joint from the panel gauge to the air pressure switch.

Note: Instead of the air pressure switch, some installations use a mechanical switch on the console, or a set of contacts on the drills AIR ON/OFF switch.

Diagnostic Information
Failures in the air circuit are generally due to one of the following, listed in order of probability: a. Incorrect value entered for the standard pipe length in Step 9 of the calibration procedure. b. Lack of pressure to the air pressure switch due to a clogged or frozen air feed line. c. Disconnected or loose cable connections, perhaps occurring during recent repairs to machinery. d. Incorrect air pressure connection. If the air pressure switch is connected to the main (compressor) air rather than the working (bit) air, there will be incorrect pressure to the switch. e. Incorrect adjustment of the switch. The air pressure switch is preset at the factory, but adjustment may be necessary. Refer to Air Circuit Tests, Switch Adjustment. for adjustment instructions.

Diagnostic Procedure
Before you begin this procedure: 1. Make sure the power circuit is working properly. Most problems occur in the power circuit. 2. Disconnect the encoder cable from the DEI Plus. If the problem changes, go to Encoder Circuit Tests. 3. Display the Bit Air Switch system screen (for instructions, refer back to System Status: Bit Air Switch Status Screen in Chapter 3.)

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Then begin with Initial Check and follow all steps of the procedure in order, observing the status indicated on the Bit Air Switch status screen. Figure 20. DEI Plus Air Switch Cable Connector
DEI Plus Ground

C B
Not Used

~4.5 VDC
POWER
A B

BITAIR
C B A

ZEROHOLE
C B A

ALARM/ TRAM
F E D C A B

RS232 RS232LEVEL
F E D C A B E D C F A B

ENCODER

Initial Check
Action to take 1. 2. 3. 4. Turn the air pressure off. Turn the air pressure on. Turn the air pressure quickly on and off several times. Go to Re-Calibrate. If result is this, go to next step Status is OFF. Status is ON. Status changes between ON and OFF appropriately. If not, do this... Go to Bit Air Switch Cable Check. Go to Bit Air Switch Cable Check. Go to Switch and Line Check.

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Chapter 4 Troubleshooting

Bit Air Switch Cable Check


Action to take 1. Disconnect the air switch cable from the back of the DEI Plus. If result is this, go to next step Status is ON. If not, do this... Verify the power circuit again. If the problem continues, replace the DEI Plus. Status is OFF. Verify the power circuit again. If the problem continues, replace the DEI Plus. Status is ON. Replace the air switch cable.

2.

Use a piece of wire or a paper clip to jumper Pin A to Pin B of the AIR connector on the back of the DEI Plus. Re-connect the air switch cable to the DEI Plus, and disconnect it at the air pressure switch. Use a piece of wire or a paper clip to jumper the pins on the cable connector.

3.

4.

Status is ON.

Replace the air switch cable.

5.

Re-connect the cable to the air pressure switch. Then go to Switch and Line Check.

Switch and Line Check


Action to take 1. Disconnect the pressure line at the air pressure switch. Check the line to see if it is clogged. Turn the air pressure quickly on and off several times. If result is this, go to next step Line is not clogged. If not, do this... Clear the line, or replace it. Then connect the line at the air pressure switch and continue. Clean the switch and recheck. If the problem continues, do the Switch Adjustment, then recheck. If the problem continues, replace the switch. 3. Remove the four cover screws on the air pressure switch and check the internal connections. The connections are secure, unfrayed, and unbroken. Repair or replace the wires. If the problem continues, replace the switch.

2.

Switch quickly activates and deactivates.

4.

Re-connect the encoder cable to the DEI Plus. Repeat Initial Check. If the problem continues, go to Re-Calibrate.

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Switch Adjustment
The air pressure switch is adjusted at the factory and normally does not need to be re-adjusted. Use this procedure only if, when you perform the Air Circuit Tests, Diagnostic Procedures, the air switch does not activate and de-activate as the bailing air is turned on and off (Switch and Line Check, step 2). 1. Make sure the air pressure switch is installed correctly and connected to the DEI Plus. 2. Make sure the drill compressor is running. 3. Turn off the bailing air. 4. Loosen the locknut on the top of the air pressure switch. 5. Turn the adjustment screw until the front panel display on the air pressure switch reads 30% to 40% of working air pressure. For example, if the bit air pressure is 60 psi, the front panel display should be 20.

Figure 21. Air Pressure Switch Front Panel Note: The Operation Indicator can only be adjusted at the factory. 6. Watch the status boxes on the Bit Air Switch status screen of the DEI Plus as you cycle the bailing air on and off. Make sure the status changes between on and off quickly and corresponds to the on/off state of the bailing air. You should also hear and see the air pressure switch open and close as you cycle the bailing air. 7. If necessary, repeat steps 3 through 6 until step 6 is satisfied. 8. Tighten the locknut on the top of the air pressure switch. 9. Verify step 6.

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Encoder Circuit Tests


Components
This circuit consists of: An optical shaft encoder (4500630) An electrical cable (7060-190-xxx) connecting the DEI Plus to the encoder. In some instances there is an electrical extension cable (7060-195-xx) that extends the length of the 7060-190-xxx cable. It is typically installed from the DEI Plus to a position near the drill mast hinge pin. An encoder drive mechanism that is connected between the drills pulldown system and the encoder shaft.

Diagnostic Information
Failures in the encoder circuit are generally due to one of the following, listed in order of probability: a. Calibration was incorrect. If an incorrect value is entered at any point in calibration, or the power head drifts during the calibration, you can expect all displayed measurements to be incorrect. b. Smashed, cut, or otherwise damaged cabling causing complete or intermittent shorts and opens. Note: If two of either pair ( or ) of the status boxes on the Encoder Status screen are highlighted at any time, it is likely that there is a short in either the cable or the encoder itself. If none of the boxes are highlighted, it is likely that there is an open in the cable or the encoder. c. Encoder drive chain comes off, slips, or misses because there is too much or little tension on the chain. d. On a direct drive installation, the hose connecting the encoder to the hub may be broken or disconnected, or the cable clamps on the hose may be loose, allowing the hose to slip. e. Damaged encoder, either mechanically or electrically.

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Diagnostic Procedure
Before you begin this procedure: 1. Make sure the power circuit is working properly. Most problems occur in the power circuit. 2. Disconnect the air switch cable from the DEI Plus. If the problem changes, go to Air Circuit Tests. 3. Display the Encoder system screen (for instructions, refer back to System Status: Encoder Status Screen in Chapter 3.)

Then begin with Initial Check and follow all steps of the procedure in order, observing the status indicated on the Encoder status screen. Figure 22. DEI Plus Encoder Cable Connector

POWER
A B

BITAIR
C B A

ZEROHOLE
C B A

ALARM/ TRAM
F E D C A B

RS232 RS232LEVEL
F E D C A B E D C F A B

ENCODER

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Chapter 4 Troubleshooting

Initial Check
Action to take 1. Disconnect the encoder cable from the back of the DEI Plus. If result is this, go to next step No status lights are highlighted on the Encoder status screen. If not, do this... Verify the power circuit. If it is working properly, replace the DEI Plus.

2.

Using a piece of wire or a paper clip, jumper the encoder connector socket D to socket A.

Box

is highlighted.

Same: verify the power circuit. If it is working properly, replace the DEI Plus.

3.

Jumper socket D to socket B.

Box

is highlighted.

Same: verify the power circuit. If it is working properly, replace the DEI Plus.

4.

Jumper socket D to socket C.

Box

is highlighted.

Same: verify the power circuit. If it is working properly, replace the DEI Plus.

5.

Jumper socket D to socket E.

Box

is highlighted.

Same: verify the power circuit. If it is working properly, replace the DEI Plus.

6.

Re-connect the encoder cable to the back of the DEI Plus, and go to Encoder Cable Check.

Figure 23. Cable to Optical Shaft Encoder

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Encoder Cable Check


Action to take 1. Disconnect the encoder cable from the encoder. If result is this, go to next step No status lights are highlighted on the Encoder status screen. If not, do this... Replace the cable.

2.

Using a piece of wire or a paper clip, jumper the cable connector socket D to socket A.

Box

is highlighted.

Replace the cable.

3.

Jumper socket D to socket B.

Box

is highlighted.

Replace the cable.

4.

Jumper socket D to socket C.

Box

is highlighted.

Replace the cable.

5.

Jumper socket D to socket E.

Box

is highlighted.

Replace the cable.

6.

Go to Encoder Check.

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Encoder Check
Action to take 1. Re-connect the encoder cable to the encoder. Rotate the encoder shaft by hand. If result is this, go to next step Exactly one box from each pair ( or )is highlighted on the Encoder status screen. The shaft turns smoothly and quietly. If not, do this... Replace the encoder.

2.

Replace the encoder. Make sure the tension on the chain is not too tight. Replace the encoder.

3.

Continue rotating the encoder shaft by hand.

The highlighted boxes on the screen alternate exactly one box per pair being highlighted at any one time. The ROP/DISTANCE FROM BOTTOM display on the statistics screen is updated in units of one-tenth.

4.

Press the Statistics button on the DEI Plus. Then continue rotating the encoder shaft by hand. Go to Re-Calibrate.

Replace the encoder.

5.

Re-Calibrate
1. Most problems occur in the power circuit. Verify that it is working properly. 2. If the problem continues, re-calibrate the DEI Plus, making sure that you enter the correct pipe length in Step 9 and all other calibration values accurately. If you are unable to calibrate successfully, go to Encoder Circuit Tests. 3. If the problem continues, replace the DEI Plus. If the following occurs twice in succession, return the digital DEI Plus to Thunderbird Mining Systems for repair: When the DEI Plus is first turned on, the Calibration Failed warning screen flashes on the display.

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Appendix A Cable Pinouts


Figure 24. 7070-189-xxx Cable Assembly DEI Plus to Air Pressure Switch

Figure 25. 7060-190-xxx Cable Assembly DEI Plus to Optical Shaft Encoder

Figure 26. 7070-191-xxx Cable Assembly DC Power to DEI Plus

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Appendix B Mounting Templates


This appendix contains templates for mounting the: Air pressure switch Base plate of the RAM mount Torque reel enclosure and cable exit hole Each template includes the measurements of the holes and between holes, and the first two templates are drawn to scale.

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DEI Plus Installation and Operations Guide

Figure 27. Mounting Template Air Pressure Switch

118

Appendix B Mounting Templates

Figure 28. Mounting Template RAM Mount

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DEI Plus Installation and Operations Guide

10.0 (254 cm.)

12.0 (305 cm.)

14.0 (356 cm.) 14.75 (375 cm.)

7.68 (195 cm.) Torque reel cable exit hole (see next figure)

Figure 29. Torque Reel Enclosure Sheet 1 Mounting Template Note: Illustration Scale = 1:2.

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Appendix B Mounting Templates

Torque Reel Enclosure

7.68 (195 cm.)

Torque reel cable exit hole 1.30 (33 cm.)

Mounting flange

Figure 30. Torque Reel Enclosure Sheet 2 Cable Exit Hole Reference

121