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Section 7

Operation R55 Booster

Table of Contents
7.1 Description of Main Panel ........................................................................................ 1
7.21 Operator Daily Checklist .................................................................................... 6
7.3 Pre-start checks ......................................................................................................... 7
7.4 Start-Up ....................................................................................................................... 9
7.5 Periodic Inspections ................................................................................................ 12
7.4 Shut-down................................................................................................................. 14
Operation - Booster Skid............................................................................................... 15
Compressor Functions .............................................................................................. 16

7.1 Description of Main Panel

Indicator Panel
See Figure 7.12 for
Details

Disconnect
Handle

Signal Cable Load/


Unload Function

Fig 7.11 Main Panel

Fig 7.12 Indicator Panel

7.2 Safety and Precautions


Warnings!
This is the warning or caution symbol. Read instructions carefully in manuals and
on safety decals.
1. Be completely familiar with operating and maintenance procedures before
inspecting, operating or servicing the drill or booster. You must read and
understand all procedures described in each manual.
2. Do not inspect or repair any components without properly shutting down
drill and booster.
3. Do not move drill, booster or any components if they are in potentially
unstable conditions or if visibly obscured in any way.
4. Check that all controls on drill and booster are in off positions before
connecting electrical power, mine air and water supply line.
5. Disconnect electric power source, mine air, booster line and water supply
before diagnosing or servicing drill or booster. Relieve pressures in
hydraulic and pneumatic systems prior to servicing.
6. Check that personnel are clear of drill before starting system. High pressure
leaks from hydraulic and pneumatic systems could result in injuries.
7. Keep safety and instruction decals clean. Replace them if they are not
clearly legible.
8. Any modifications to controls or operating procedures must be noted clearly
on equipment and all operators must be advised of changes.
9. Observe all safety procedures when operating and servicing the equipment.
10. Keep hands, clothing, rags and tools away from moving parts.
11. Keep shields and guards in place. Do not operate equipment with electrical
panel door open.
12. Tag drill and booster to prevent accidental start-up. Signs must be clearly
visible to alert of service in progress.
13. Repair any damaged components immediately.
14. High and medium voltage systems are to be serviced and diagnosed by
qualified electrical personnel only.
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15. Make sure that you are in a dry and safe position when working with
electrical circuits.
16. Secure all moving components with proper restraining devices before
removing or loosening any hydraulic components. This is to prevent
components from shifting when hydraulic components lose pressure.
17. Keep all non-essential personnel away from operators controls and
maintenance area while service work is in progress.
18. Wear protective gear when operating, diagnosing or servicing the
equipment.
19. Do not weld or grind near electrical wiring or supply lines.
20. Do not stand under mast at any time.
21. Do not reconnect or repair loose or damaged wiring with electrical power
connected to drill or booster.
22. Disconnect electrical power supply to drill and booster before washing.

Caution!
1. Follow all service procedures at recommended intervals.
2. Inspect all hoses, hose connection safety devices, fittings and supply lines
at frequent intervals for indication of wear or damage. Repair or replace
damaged components immediately.
3. Check all bolts, nuts and adjustments frequently for proper tension. Check
all fluids at recommended intervals.
4. Tag or mark hoses, wires or components to assist in reinstallation.
5. Cap or plug all hydraulic or pneumatic connections immediately after
removal.
6. Cap fluid ports to keep foreign material from entering components during
servicing.
7. Clean Grease fittings with clean cloth before greasing.

All maintenance programs should follow the recommended P.M. schedules as


found in the maintenance manuals for the equipment.
WARNING: This Booster unit must only be serviced by qualified personnel.
No attempt should be made to alter this unit in any manner without written
permission from Cubex. Any alterations may result in serious injury or
damage to the unit.
Whenever working on this unit, turn off the mine air supply and check that the
system has fully bled off before opening any connections. Compressed air has
tremendous contained energy, which is released when opened to atmosphere.
The potential to cause severe injury or damage is great if proper procedures are
not followed.

7.21 Operator Daily Checklist


R55 BOOSTER: OPERATOR DAILY CHECK LIST
Cubex Serial Number:

Date:

Operator Name:

Hours start of shift:

Foreman:

Hours end of shift:

Set Up Location:
NOTE: If any of the following checks are not YES DO NOT RUN UNIT
Pre-Start Inspection

YES

NO

Has the compressor been washed down in order to get optimum cooling capacity?
Has moisture been drained from air receiver and mine air filter?
Has air and hydraulic hoses and fittings been visually checked for leaks?
Has the oil level on booster compressor been checked (fill if required)?
Has belt tension on compressor been checked? Adjust tension so belt does not slip
Has lamp test button been pushed? All fault indicator lights should illuminate.
Has the complete machine been checked for loose bolts & nuts?
NOTE: On start-up the Booster is programmed to run on low pressure mode for 1 minute before
moving to high pressure mode. On shut-down the Booster is programmed to go to low pressure
mode for 1 minute before shutting down.
Operating Inspection
Do all the following checks and readings under full load and airflow.
YES

NO

Has the unit been checked for unusual noises from compressor and motor?
Has the unit been checked for water and air leaks?
Has pressure at which compressor normally unloads (360 psi, 24.8 bar) been
checked?
Has compressor oil been ensured to remain stable at 15 - 50 psi (1.3 - 3.5 bar)?
Low Mine Water Pressure Shut-down 25 psi (1.7 bar)
Compressor High Temperature Shut-down 375F
Compressor Low Oil Pressure Shut-down 10 psi (0.68 bar)
Low Mine Air Pressure Shut-down 60 psi (4.1 bar)
Mine Air Filter Differential Pressure Shut-down 10 psi (0.68 bar)

psi
F
psi
psi
psi

Operators comments and observations:

7.3 Pre-start checks


Fig 7.31 Side View

Mine Air Inlet

Secondary Filter
Auto-Drain

Pre-Filter
Manual Drain.

1. Drain Moisture from mine air pre-filter.


2. Check automatic drain for secondary filter.

3. Check oil level in the compressor(s) with provided dipstick(s). Refer to Figure
7.32

Modulating Water Valve

Dipstick

WARNING!
Do not remove discharge hose for
Modulating Water Valve. Water
discharged from this valve when activated
is scalding hot and may cause serious
injury.
Fig 7.32 Top View
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7.4 Start-Up
1. Make all necessary checks on drill (See operators manual for drill) and on
booster (See section 7.3 of this manual).
2. Close booster discharge and hook up to drill. Install the hose connection
safety device (adhere to site specific requirements). Refer to figures 7.41
and 7.42
Fig 7.41 Rear View

Compressor Water
Outlet and valve

Compressor Air Outlet


and valve

Fig 7.42 outlets


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3. Hook up mine air and water to the inlets. Install hose connection safety
devices (adhere to site specific requirements) Refer to section 7.3 figure
7.31 for Air inlet. Refer to figure 7.43 of this chapter for water inlet.
Fig 7.43 Water Inlet

Outlet for washing drill


Mine Water Inlet

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4. Open up mine air and water inlet valves to allow flow to booster.
5. Press Lamp Test button to verify that all lights are working on indicator
panel of booster. Refer to figure 7.44
6. Start compressor. Refer to figure 7.44
7. Open discharge valve on booster to allow flow to drill. Refer to figure 7.42
Fig 7.44 Indicator Panel

Compressor
Start Button

Lamp Test
Button

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7.5 Periodic Inspections


1. Check that the discharge and system pressures are maintained (See
figure 7.51).
Figure 7.51
Compressor
Pressure and
Temperature Gauges

Figure 7.51
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2. Check the pressure differential and restriction indicators. If there is a


pressure differential greater than 10psi (0.68 bar) or the indicators are
showing red the filters must be cleaned or replaced (see figure 7.52).
Figure 7.52
Inlet Filter Restriction
Indicators

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7.4 Shut-down
1. Close discharge Valve (See figure 7.42).
2. Push system stop buttons for each compressor on indicator panel (See
figure 7.44).

CAUTION
Do not use emergency stop button for routine
shutdown.
3. Close mine air supply once compressors have stopped.

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Operation - Booster Skid


CAUTION! If safety chain or cable is not properly secured, mine air supply
line could uncouple and whip, endangering personnel.

Turn on water supply before starting compressor


1. Make all necessary checks on drill and booster fluid levels.
2. Shift the drilling air controls to the OFF position.
3. Before starting drill, ensure compressor oil pressure is between 15-50 psi
(1.3-3.5 bar).
4. Shift the collaring air control to the ON position.
5. The drill is ready to collar a new hole at 80-100 psi (5.5-6.9 bar) mine air
pressure.
6. After collaring is complete, shift the drilling air switch to ON, this places the
booster to the UNLOAD mode.
7. The drill is now ready to drill with 350 psi (24.1 bar) air.
8. After drilling off each rod, turn the drilling air OFF, this shifts the booster to
the UNLOAD mode.
9. This will allow the compressor to run under a no load condition, with the
three-way valve positioned to take atmosphere air, which will keep heat
build-up to a minimum.
10. After adding the next rod, turn the air ON; this automatically shifts the
booster to LOAD position and increasing the air pressure to the hammer.
11. To shut down drill and booster at the end of a shift, turn drilling air OFF,
then drain air receiver tank of all air and condensation.
Note: For optimum running condition, while drilling, the booster should
never cycle (load-unload). The choke in the hammer should be sized to
achieve this condition.

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Compressor Functions
The booster compressor runs in two different modes LOAD and UNLOAD. In the
LOAD function the drill air switch should be in the ON position, which allows 90
psi (6.2 bar) mine air into the suction valves. This is for drilling or cleaning the
hole. The other function is UNLOAD, with the drill air switch in the ON position.
This is used for collaring a new hole.
WARNING! The booster is in the UNLOAD mode, 90 psi (6.2 bar) mine air
should not be applied for any long period of time, extended exposure will
cause heat build-up and premature failure of valves.
A second UNLOAD function is with the air OFF, allowing the booster to vent in
and out of the atmosphere air filter. This is for stand-by operation, when no
drilling is in progress.

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