TRUCORE CORE ORIENTATION KIT User Guide
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1 TRUCORE CORE ORIENTATION KIT User Guide
2 CONTENTS Chapter 1: Getting Started 02 Kit Contents 03 Speifiations 04 Handheld Features and Funtions 05 Tool Features 05 Modes of Operation 06 Initial Setup Chapter 2: Marking Core 10 Step-y-Step Chapter 3: Advaned Funtions 13 Chek Tool ID and Modes of Operation 13 Chek Tool Status on Handheld 14 TruCore Reset 15 Chek Tool Battery Life 16 Tool ID Override 16 Total Orientation Count 17 Chek Firmware Version 17 Single Tool Operation Chapter 5: Trouleshooting 18 Handheld Error Messages 21 Tool and Handheld Symptoms 24 Orientation Misalignments 25 Handheld Message Summary Chapter 5: Maintenane 26 Replaing the Battery 28 Reharging the Handheld 28 Cleaning the Tools 29 Caliration Chek Proedure 30 Spare Parts and Kit Seletion 31 TruCore Compatiility 32 Reommended Spares Chapter 6: Verifiation of Competeny 33 Delivering Verifiation of Competeny Training 33 Competeny Cheklist Quik Referene Guide P/N C SP
3 CHAPTER 1: GETTING STARTED TruCore is an easy to use, highly aurate ore orientation system featuring wireless ommuniation, a orrosion resistant steel ody and a field replaeale attery. The integrated housing omined with Boart Longyear parts redues the numer of joints and high wear on outer tue extension arrels. Its unique digital ore marking tehnology failitates the use of a single handheld ontroller to operate oth tools while wireless ommuniation eliminates the need for disassemly to retrieve results. Please review the omplete ontents of this User Guide prior to using TruCore Orientation tools. If additional training and support is required, please ontat a loal Boart Longyear representative. For more information, visit: Chapter 1: Getting Started 1
4 Copyright 2016 Boart Longyear. All rights reserved KIT CONTENTS ID ID Desription 1 Extension Barrel 2 2 x TruCore Tools 3 2 x Spare Batteries 4 Level Finder 5 Car Charger 6 O-ring Replaement Kit 7 User Guide and Certifiate of Conformane 8 2 x Inner Tue Adapters with Chek Valve Installed 9 Allen Key* 10 Handheld Charging Dok 11 TruCore Handheld Unit 12 Power Pak with Eletrial Cord *An Allen Key is not supplied with B size tools 2 Chapter 1: Getting Started
5 SPECIFICATIONS Chapter 1: Getting Started 3
6 HANDHELD FEATURES AND FUNCTIONS Infrared/optial ommuniation port Message display Up utton Down utton OK utton handheld Funtions Key Use Press and hold to power-up handheld Press to turn on a TruCore tool Press and hold to resume operation if handheld turns off (60s inative) Press to selet the displayed option Press to navigate through menu Press and hold to display whih TruCore tools are running Press to navigate through menu Press and hold to retrieve the TruCore ID and status. Refer to Chapter 3: Advaned Funtions. Press and hold oth uttons to enter Advaned Funtions 4 Chapter 1: Getting Started
7 TOOL FEATURES Inner tue adapter Chek valve ody and all Infrared/optial ommuniation port Integrated grease ap MODES OF OPERATION Sleep Mode Sleep mode allows a TruCore tool to extend attery life indefinitely (up to 10 years) when in storage. TruCore enters sleep mode if it remains in Standy Mode for 4 hours. TruCore is not ale to ommuniate with the handheld or perform any funtions in this mode. TruCore will automatially swith to Standy Mode from Sleep Mode if sujeted to any viration. To wake up TruCore from Sleep Mode, strongly shake the tool. Standy Mode In the standy mode, TruCore is ready to start running an orientation. TruCore automatially enters this mode when shaken in sleep mode, after a suessful orientation or after TruCore has een reset. It will automatially swith from Standy Mode to Sleep Mode if it remains in Standy Mode for more than 4 hours. Running Mode TruCore takes orientation measurements in the Running Mode. TruCore will enter this mode from Standy Mode when it is ommanded to turn on y the handheld. Orientation Mode In Orientation Mode, TruCore flashes its LEDs to indiate the orret ore orientation to the driller. TruCore enters this mode when ommanded y the handheld to FIND ORI. TruCore will return to standy mode one the orret orientation is onfirmed or the tool is reset. Chapter 1: Getting Started 5
8 INITIAL SETUP Step 1: Installing TruCore a d e f g Plae the inner tue assemly on a enh. Remove the inner tue ap y unthreading it from the spindle ushing on one end and the inner tue on the other. Thread the integrated grease ap side of tool onto spindle ushing of head assemly. Thread the inner tue adapter onto the tool (if not pre-assemled). Chek the inner tue adapter for the hek valve ody and all. If not present, loate the omponents and install. Thread the inner tue onto the inner tue adapter. Wait until setup is omplete efore sending inner tue assemly downhole. Inner tue assemly efore installation Tip: Order two extra inner tue adapters to prevent downtime when worn or damaged. Also, order other adapter sizes if you will e running other inner tue sizes e.g. BQTK and LTK60 adapters for a B size tool (See Chapter 3 Maintenane Spare Parts). Trouleshooting: If the inner tue adapter does not thread to the inner tue it is likely a different adapter was ordered than the one required y the inner tue. e.g. NQTK adapters for an NQ size tool (See Chapter 3 Maintenane Spare Parts). Trouleshooting: If you have diffiulty drilling or with ore washing after installation of TruCore, the hek valve may not e installed. Retrieve the inner tue assemly, hek for valve ody and all, and install as needed. 6 Chapter 1: Getting Started
9 Step 2: Installing the Extension Barrel a d Trip rods to retrieve outer tue assemly as neessary. Unthread reaming shell from outer tue. Install extension arrel etween outer tue and reaming shell. Optionally: remove outer tue from adapter oupling and reaming shell. Install extended length TruCore outer tue (no extension required). Slide inner tue assemly into outer tue assemly to verify that the inner tue lathes. If inner tue does not lath hek and make sure either the extension arrel or extended length outer tue was installed not oth. Wait until setup is omplete efore tripping assemlies and rods downhole. TruCore Tool Inner tue assemly after installation Tip: Order extra extension arrels or extended length outer tues to prevent downtime if one is damaged. (See Chapter 3 Maintenane Spare Parts). Trouleshooting: If the extension arrel or extended length outer tue does not thread to the adapter oupling or reaming shell, it is likely a different outer tue or extension was ordered than the one required y the system eing used. e.g. BQTK or LTK60 (See Chapter 3 Maintenane - Spare Parts). Chapter 1: Getting Started 7
10 Step 3: Initializing Handheld and Tools When the handheld first ommuniates with a TruCore tool, the first tool hosen is designated and loked in as the Blue Tool. When the handheld then ommuniates with the seond tool, it is designated and loked as the Green Tool. The three devies eome a system loked to work only with eahother. a Press and hold utton of handheld to wake it up. The handheld will display, PLEASE HOLD and then TURN ON TOOL. Note: If the utton is pressed too quikly, the handheld will not display a message. d e f g h i While the handheld displays, TURN ON TOOL, press again to plae the tool in running mode. The handheld will display POINT TO TOOL. Aim infrared port on handheld diretly at infrared port on the tool so that they are at right angles and almost touhing. One ommuniation is estalished, the handheld will display, BLUE RUNNING indiating the tool is in Running Mode and ready to use. The ore arrel assemly may now e sent down the hole to egin drilling. Mark the ore using the proedure outlined in Chapter 2: Marking Core. Press and hold utton of handheld to wake it up. The handheld will display, PLEASE HOLD and then TURN ON GREEN. While the handheld displays, TURN ON GREEN, press again to plae the seond tool in running mode. The handheld will display POINT TO TOOL. Aim infrared port on handheld diretly at infrared port on the seond tool so that they are at right angles and almost touhing. One ommuniation is estalished, the handheld will display, GREEN RUNNING indiating the seond tool is in Running Mode and ready to use. The seond ore arrel assemly may now e sent down the hole to ontinue drilling diretly following the retrieval of the first ore arrel assemly from the hole Proeed to Chapter 2: Marking Core Trouleshooting: If only one tool is working or availale skip step Instead proeed to Chapter 2: Marking Core. f Tip: Ensure that tools are kept at least 2 meters away from eah other in order to avoid interferene with infrared ommuniations. Interferene may ause prolems identifying and traking tools; i.e. oth tools are identified as Blue. 8 Chapter 1: Getting Started
11 Tip: If the handheld displays LOW TOOL BATTERY the tool has approximately 2 weeks of power left. Chek to make sure at least two spare atteries are on site and if not order immediately. Order additional spare atteries as soon as spares are installed in the tool. Trouleshooting: If the handheld displays REPLACE TOOL BATTERY, the tool has less than a week of power remaining and may stop operating at any time. Replae the attery as soon as possile. Warning: Only use TruCore atteries in sealed plasti and keep two spare atteries on-hand at all times. The seal should only e roken immediately efore installation, or attery life will not e aurately measured and ould result in lost data. Any unsealed atteries should e onsidered used and disposed of properly. Trouleshooting: If the message RECHARGE HANDHELD is displayed instead of TURN ON, the handheld attery is down to 33% of apaity or approximately two days of use. Use the supplied harging ase to reharge the handheld. Note: The handheld attery is not field replaeale. Removing the tamper proof srews and opening the ase will void the warranty and the renter will e harged for its replaement if damaged. Trouleshooting: If the handheld does not ommuniate with the tool, then the tool is in Sleep Mode. Shake the tool to swith it into Standy mode. The LED will flash rapidly for a short period of time upon entering Standy Mode. Chapter 1: Getting Started 9
12 CHAPTER 2: MARKING CORE STEP-BY-STEP The TruCore marking proedure is roken down to 5 simple steps: Eletronially marking the ore down hole using the handheld. Retrieving the ore per standard operating proedure. Orienting the TruCore tool on surfae and physially transferring the loation to the ore sample. Confirming the ore orientation using the handheld. Re-initializing the TruCore tool. Step 1: Mark Core a If the handheld has turned off, press to turn it ak on. The handheld should display, MARK BLUE or MARK GREEN depending on what tool is urrently eing marked. The tool status (i.e. GREEN RUNNING, or BLUE RUNNING) will e displayed momentarily efore hanging to MARK BLUE or MARK GREEN. Before reaking ore, press and handheld will display, KEEP STABLE WAIT. Keep rig still as prompted y display. Trouleshooting: If only one tool is working or availale after seleting MARK BLUE skip TURN ON GREEN if displayed y pressing until FIND BLUEORI is displayed then ontinue to Step Chapter 2: Marking Core
13 Step 2: Retrieve Core a d Retrieve inner tue assemly per standard operating proedure. Plae inner tue assemly on enh. Initialize the tool urrently not in use per Step 3: Initializing the tools and handheld from the previous hapter. Send the most reently initialized tool down the hole and resume drilling. Proeed to Step 3 to orient the ore in the retrieved inner tue assemly. Step 3: Orienting the Core a Return to the enh with the Inner Tue Assemly just retrieved. If the handheld has turned off, press to turn it ak on. The handheld should display, FIND BLUEORI or FIND GREENORI (depending on what tool is urrently eing oriented. Press and the handheld should now display, POINT TO TOOL. d e f g h Aim the infrared port on handheld diretly at infrared port on the tool suh that they are at right angles and almost touhing. One ommuniation is estalished, the handheld will display, ORIENT SAMPLE and the LED on the tool will egin to pulse. Rotate the inner tue assemly to orient the ore. The rate of pulsation will inrease as the measured orientation is approahed. When the orret orientation is reahed the LED will turn red. One the LED has turned red, ensure the inner tue is held in position and mark the downside of the ore sample using a red wax penil and the inluded Level. Tip: If operating in diret sunlight, asting a shadow over the LED may improve visiility. Trouleshooting: The pulsing LED will turn off after 60 seonds if the orret orientation is not reahed or after eing left stationary for 10 seonds to save power. To restart the pulsing LED, press on the handheld and point to the tool. Chapter 2: Marking Core 11
14 Step 4: Confirming the Orientation a One the orret orientation is reahed, the LED turns red and the ore has een marked, the orientation is ready to e onfirmed. Press and the handheld should now display, POINT TO TOOL. d e Aim infrared port on the handheld diretly at the infrared port on the tool suh that they are at right angles and almost touhing. One ommuniation is estalished, the handheld will display, ORI PASS If the handheld displays, ORI FAIL RETRY, then return to Step 3, Rotate the inner tue assemly and repeat proess. Tip: This step annot e ompleted until the handheld displays ORI PASS. Tip: If restarting the pulsing LED and the tue assemly is already in the orret orientation, this will prompt an ORI PASS and immediately ausing the LED to turn off again sending the tool to standy mode. Step 5: Remove Core and Re-initialize tool a d e f g Unthread inner tue and remove ore sample per standard operating proedure. One ore is removed re-attah the inner tue to the adapter. Press and hold utton of handheld to turn it on. The handheld will display, TURN ON BLUE or TURN ON GREEN. Press again to plae the tool in running mode. The handheld will display POINT TO TOOL. Aim infrared port on the handheld diretly at the infrared port on the tool suh that they are at right angles and almost touhing. One ommuniation is estalished, the handheld will display, BLUE RUNNING or GREEN RUNNING and indiating the tool is ready to use again. Repeat Steps 1 through 5 alternating every run etween oth lue and green TruCore tools. 12 Chapter 3: Advaned Funtions
15 CHAPTER 3: ADVANCED FUNCTIONS CHECK TOOL ID AND MODES OF OPERATION a Press and hold and the handheld should display, POINT TO TOOL. Aim infrared port on handheld diretly at infrared port on the tool of interest so that they are at right angles and almost touhing. The TruCore ID and its status will e indiated y the olour and pulsation of the LED aording to the following tale: LED RED BLUE GREEN BLUE GREEN Pattern ID Mode of Operation Single Pulses 8 x Single Pulses 8 x Single Pulses 3 x Triple Pulses 3 x Triple Pulses No ID Blue Tool Green Tool Blue Tool Green Tool Reset or new; Standy Standy Mode Standy Mode Running Mode Running Mode CHECK TOOL STATUS ON HANDHELD Press and hold following messages: and the handheld should display one of the Message BLUE RUNNING GREEN RUNNING BOTH RUNNING NO TOOLS RUNNING Ation Desription Notifiation that only the Blue Tool is in Running Mode. Notifiation that only the Green Tool is in Running Mode. Notifiation that oth tools are in Running Mode. Indiation that there are no tools urrently in Running Mode. Chapter 3: Advaned Funtions 13
16 TRUCORE RESET A reset must e performed any time a tool or handheld is replaed. The system reset an also e used to reover from a malfuntion or system hang up (no response). When a TruCore tool is reset it goes ak to fatory settings and swithes to Standy Mode. Any pending orientation data is lost after a reset. a Press and hold to turn on the handheld. The handheld will display, PLEASE HOLD and then whihever message it was last on. Press and hold oth uttons and simultaneously to enter Advaned Funtions. The handheld should now display, RESET TOOL. Press again to plae handheld in reset mode. The handheld will display HOLD OK BUTTON. d Press and hold and the handheld should now display, POINT TO TOOL. e f g Aim infrared port on the handheld diretly at infrared port on the tool of interest suh that they are at right angles and almost touhing. One ommuniation is estalished, the handheld will display RESET COMPLETE, however the first tool is not ready for use until the seond tool is also reset. Repeat steps through f f for the seond tool. Tip: One a handheld is reset it an still e used to mark a running tool, ut the advaned funtion MARK ANY must e used (see Chapter 3: Advaned Funtions, tool ID Override). One orientation is omplete the system will need to e reset per the aove proedure in order to return to normal operation. Warning: Mixing or swapping equipment with other kits or resetting either tool independently will ause the handheld to not reognize the tool as part of the system. When further ommuniations are attempted a WRONG HANDHELD or WRONG TOOL may e displayed. Resolve this issue first y trying a different handheld or tool efore performing a system reset. Warning: If one tool is reset during normal operation while the other tool is in Running Mode, the handheld will no longer have the option to the orientation. Use the MARK ANY feature in Advaned Funtions (Chapter 3 Advaned Features, Advaned Funtions). One seleted, the MARK ORI option will eome availale and the orientation of the running TruCore tool an e ompleted. A system reset must e performed efore resuming normal operation. 14 Chapter 3: Advaned Funtions
17 CHECK TOOL BATTERY LIFE a Press and hold to turn on the handheld. The handheld will display, PLEASE HOLD and then whihever message it was last on. Press and hold oth uttons and simultaneously to enter Advaned Funtions. The handheld should now display, RESET TOOL. Press to sroll through advaned funtions until the sreen reads TOOL % BATTERY d Press to selet this option. e Aim the handheld at the tool to display attery life as a perentage. Warning: The LOW TOOL BATTERY message indiated less than 10% attery life is remaining (approximately two weeks of operation). Change the attery to avoid any potential data loss and rig downtime. Warning: The REPLACE TOOL BATTERY message the tool has less than a week of power remaining and may stop operating at any time. Replae the attery as soon as possile. Warning: Only use TruCore atteries in sealed plasti and keep two spare atteries on-hand at all times. The seal should only e roken immediately efore installation, or attery life will not e aurately measured and ould result in lost data. Any unsealed atteries should e onsidered used and disposed of properly. Chapter 3 Advaned Features 15
18 TOOL ID OVERRIDE (MARK ANY) The ID of the tools an e overridden to allow an orientation to e found under the following irumstanes: If one tool is reset during normal operation while the other tool is in Running Mode. If a new handheld is introdued due to a dead attery. Handheld is missing or non-operational after turning on TruCore tool(s). To aess the tool ID override funtionality, the following proedure should e followed: a Press and hold to turn on the handheld. The handheld will display, PLEASE HOLD and then whihever message it was last on. Press and hold oth uttons and simultaneously to enter Advaned Funtions. The handheld should now display, RESET TOOL. Press to sroll through advaned funtions until the sreen reads MARK ANY d Press to selet this option and ontinue marking the ore. e Upon ompleting the orientation, perform a System Reset using the new handheld to re-estalish the link etween the tools. TOTAL ORIENTATION COUNT The total numer of times the message ORI PASS is displayed an e aessed through the advaned funtion proedure: a Press and hold to turn on the handheld. The handheld will display, PLEASE HOLD and then whihever message it was last on. Press and hold oth uttons and simultaneously to enter Advaned Funtions. The handheld should now display, RESET TOOL. Press to sroll through advaned funtions until the sreen reads YYYY PASSES where YYYY represents the numer of passes reorded. d Press to toggle the numer of passes display message. 16 Chapter 3: Advaned Funtions
19 CHECK FIRMWARE VERSION The hek firmware version funtion is an internal audit feature uilt into the tools to provide a visual onfirmation that the tools have een updated to the latest release. It is for Boart Longyear referene and trouleshooting purposes only. To aess the funtion, use the following proedure: a Press and hold to turn on the handheld. The handheld will display, PLEASE HOLD and then whihever message it was last on. Press and hold oth uttons and simultaneously to enter Advaned Funtions. The handheld should now display, RESET TOOL. Press to sroll through advaned funtions until the sreen reads VERSION: YYYB where YYYB represents the tools firmware version. d Press to toggle the version display message. SINGLE TOOL OPERATION Single tool operation may e required in ases where there is only one tool availale (lost, roken et.). There are two options for single tool operation: 1 2 Use the same tool for every run y swapping it etween eah innertue assemly. Mark orientation every seond run. In oth of the aove situations, the following workflow hanges are required: a d When prompted y the handheld to TURN ON BLUE/GREEN, press to sroll through the options. Keep srolling until desired option appears. Press to TURN ON TOOL. Deploy the tool per proedure in hapter 2. Upon ompletion of drilling the run, MARK BLUE/GREEN per proedure in hapter 2. When prompted y the handheld to TURN ON BLUE/GREEN, press to sroll until FIND BLUE/GREEN ORI appears. e Press to onfirm and repeat the proess. Warning: Do not mark ore orientation every seond run without formal lient onsent. Inomplete or missing ore orientation data ould have signifiant onsequenes in the downstream ore orientation proess. Chapter 3: Advaned Funtions 17
20 CHAPTER 4: TROUBLESHOOTING HANDHELD ERROR MESSAGES Symptom Handheld Message ERROR 01: WRONG HANDHELD Cause: 1. A different handheld from the one originally used to ommuniate with the TruCore tool is eing used. 2. The handheld has een reset sine the TruCore tool was turned on. Solution: 1. Use the orret handheld. 2. If not availale follow system reset proedure (Chapter 3 Advaned Funtions, TruCore Reset). Prevention: 1. Keep handheld with mathing tools. 2. When performing a system reset, follow proedure. (Chapter 3 Advaned Funtions, TruCore Reset). Symptom Handheld Message ERROR 02: WRONG TOOL Cause: The handheld is attempting to ommuniate with TruCore tool that does not math the message prompt or sequene (i.e. Blue or Green Tool). Solution: Selet the same funtion and point to the other TruCore tool. Prevention: Point to orret tool initially. Symptom Handheld Message ERROR 03: SURVEY TIMEOUT - ORI MARK LOST! Cause: The MARK BLUE or MARK GREEN ommand was initiated on the handheld eyond the maximum survey time of 6.5 hours. The orientation diretly preeding the appearane of this error will not e availale. Solution: Do not reset the tool. The orientation of the previous run has een lost. Proeed to the next run y following the handheld prompt: POINT TO TOOL. 18 Chapter 4: Trouleshooting
21 Prevention: Ensure ore is marked within 6.5 hours from the time the tool is initiated on surfae (i.e. TURN ON TOOL). Warning: The orientation of the run diretly preeding ERROR 03: SURVEY TIMEOUT error is null and void. Symptom Handheld Message ERROR 04: INCOMPATIBLE VERSION Cause: 1. The TruCore tool and handheld are not ompatile. 2. The handheld has een reset sine the TruCore tool was turned on. Solution: Return the omplete TruCore Kit to Boart Longyear for replaement. Prevention: N/A Symptom Handheld Message ERROR 05: ORIENTATION TIMEOUT Cause: An attempt to orient the ore was made eyond the maximum orientation limit of 10.5 hours. Solution: Press OK and proeed to the next run as usual. The orientation of the run diretly preeding this error is not availale. Prevention: Ensure the ore is oriented within 10.5 hours from the time the tool has een initiated. Symptom Handheld Message ERROR 06: SERVICE REQUIRED Cause: The tool has een used eyond it s expeted servie interval. Solution: Return the omplete TruCore Kit to Boart Longyear for replaement. Prevention: N/A Chapter 4: Trouleshooting 19
22 Symptom Handheld Message ERROR 07: COMMUNICATION ERROR Cause: 1. The Communiation Window on the TruCore tool is dirty or ostruted 2. The handheld is not aimed at the Communiation Window on the TruCore tool properly. 3. An internal sensor has failed. Solution: 1. Clean the Communiation Window of any visile dirt and deris y following the TruCore tool maintenane guidelines (see Chapter 4: Maintenane). 2. Aim infrared port on the handheld diretly at infrared port on the tool of interest suh that they are at right angles and almost touhing. 3. Return the omplete TruCore Kit to Boart Longyear for replaement. Prevention: 1. Keep the Communiation Window free from dirt and deris y following the reommended tool maintenane guidelines (see Chapter 4: Maintenane). 2. Ensure the infrared port on the handheld is aimed diretly at infrared port on the tool of interest suh that they are at right angles and almost touhing. Symptom Handheld Message ERROR 08: HANDHELD FAILURE Cause: An internal eletroni error is preventing normal operation. Solution: 1. Return the handheld to Boart Longyear for immediate replaement. 2. Temporarily use a handheld from a spare kit if availale. Prevention: None. 20 Chapter 4: Trouleshooting
23 TOOL AND HANDHELD SYMPTOMS Symptom Both TruCore tools are flashing Blue Causes: 1. Inorret reset proedure was performed. One tool was reset and turned on, efore the other tool was reset. 2. A tool was turned on in lose proximity to the other tool. 3. New or just reset TruCore tool; Blue Tool started and stopped then seond tool started. Solution: Reset handheld and TruCore tools (refer to Chapter 3 Advaned Funtions, TruCore Reset for orret proedure). Prevention: 1. When performing a system reset, oth TruCore tools must e reset efore setting either one to Running Mode. 2. When turning on a TruCore tool, the other tool should e least 2 meters away. Symptom Handheld is missing or non-operational after turning on TruCore tool(s). Cause: N/A Solution: Use a new handheld and the MARK ANY? funtion to mark ore. After orientation is onfirmed, reset handheld and TruCore tools. (Chapter 3 Advaned Funtions, TruCore Reset). Prevention: 1. Keep handheld with orresponding TruCore tools and use reasonale are in handling. 2. Do not let handheld attery to eome fully disharged. Chapter 4: Trouleshooting 21
24 Symptom Handheld does not ommuniate with the TruCore tool. Cause: 1. The Communiation Window on the TruCore tool is dirty or ostruted 2. The TruCore tool has een stationary for more than four hours and entered sleep mode. 3. The handheld is not aimed at the Communiation Window on the TruCore tool properly. 4. An internal sensor has failed. Solution: 1. Clean the Communiation Window of any visile dirt and deris y following the TruCore tool Maintenane guidelines (see Chapter 4: Maintenane). 2. Shake the TruCore tool to swith it from sleep mode to standy mode. 3. Aim infrared port on the handheld diretly at infrared port on the tool of interest suh that they are at right angles and almost touhing. 4. Return the omplete TruCore Kit to Boart Longyear for replaement. Prevention: 1. Keep the Communiation Window free from dirt and deris y following the reommended tool Maintenane guidelines (see Chapter 4: Maintenane). 2. Ensure the infrared port on the handheld is aimed diretly at infrared port on the tool of interest suh that they are at right angles and almost touhing. Symptom The TruCore tool has dim LED lights. Cause: 1. The TruCore tool has a drained or damaged attery. 2. The Communiation Window on the TruCore tool is dirty or ostruted. Solution: 1. Install a new attery into the TruCore tool (see Chapter 4: Maintenane). 2. Clean the Communiation Window of any visile dirt and deris y following the TruCore tool maintenane guidelines (see Chapter 4: Maintenane). Prevention: 1. Replae the tool attery efore it eomes ritially low. 2. Keep the Communiation Window free from dirt and deris y following the reommended tool maintenane guidelines (see Chapter 4: Maintenane). 22 Chapter 4: Trouleshooting
25 Symptom TruCore tool light goes solid Red or Blue, even if rotated while in Orientation Mode. Cause: The TruCore tool has a drained or damaged attery. Solution: Install a new attery into the TruCore. Prevention: Replae the tool attery efore it eomes ritially low. Chapter 4: Trouleshooting 23
26 ORIENTATION MISALIGNMENTS Symptom Core mark does not line up with previous sample. Causes: 1. The tool was not initialized prior to sending down the hole. 2. The rig was not stale while marking the ore. 3. The ore lifter was worn allowing the sample to move in the lifter. 4. The Inner Tue Adapter was not tight ausing it to unthread during orientation. 5. The ground was not ompetent preventing an orientation from eing made. 6. Orientation mark lost In removal due to diffiulty removing the ore. Solution: 1. Initiate eah tool y following the steps outlined in Chapter 2: Marking Core. 2. Keep the rig stale when marking the ore (i.e. not spinning). 3. Replae ore lifter. 4. Tighten Inner Tue Adapters efore using the tool (see Chapter 1: Getting Started). 5. None. 6. When the ore is diffiult to remove from the lifter, ontinue the orientation mark along the ottom of the ore, efore striking the ore fae to free the sample. Prevention: 1. Ensure the tool has een initiated y following the steps outlined in Chapter 2: Marking Core. 2. Ensure the rig is stale when marking the ore y following the prompts on the handheld. 3. Inspet ore lifter ondition prior to eah run and replae as required. 4. Ensure Inner Tue Adapters are tight efore using the tool. 5. None. 6. Ensure the orientation mark is ontinued along the ore exterior if the mark is likely to e lost during the removal proess. 24 Chapter 4: Trouleshooting
27 HANDHELD MESSAGE SUMMARY Message TURN ON TOOL POINT TO TOOL BLUE RUNNING GREEN RUNNING BOTH RUNNING MARK BLUE MARK GREEN MARK ORI KEEP STABLE WAIT RE-MARK BLUE RE-MARK GREEN HOLD OK CANCEL TASK? RECHARGE HANDHELD TURN ON GREEN TURN ON BLUE FIND BLUEORI FIND GREENORI ORIENT SAMPLE ORI FAIL RETRY ORI PASS RETRY ORI RESET TOOL MARK ANY TOOL % BATTERY XXXX PASSES VERSION: 506B XXX% LOW TOOL BATTERY RESET COMPLETE WRONG TOOL CANCEL ORIENTATION? NO TOOLS RUNNING REPLACE TOOL BATTERY POWER OFF PLEASE HOLD OK BATTERY CHARGING BATTERY CHARGED Ation Desription Press OK utton to initialize first (lue) tool. Align handheld ommuniation window with tool window. Notifiation that only the Blue Tool is in Running Mode. Notifiation that only the Green Tool is in Running Mode. Notifiation that oth tools are running. Press OK utton to eletronially mark the ore down hole. Press OK utton to eletronially mark the ore down hole. Press OK utton to eletronially mark the ore down hole. Maintain Rig silene. Press OK utton to eletronially mark the ore down hole. Press OK utton to eletronially mark the ore down hole. Hold OK utton for 3 seonds to onfirm. Canel urrent marking operation. 33% of attery life remaining. Reharge handheld. Press OK to initiate Green Tool for running mode. Press OK to initiate Blue Tool for running mode. Press OK to egin tool orientation mode. Press OK to egin tool orientation mode. Rotate inner tue assemly until LEDs in the tool flash red. Attempt to orient sample failed. LEDs must e flashing red. Core sample was oriented orretly. Attempt to orient sample failed. LEDs must e flashing red. Press OK to enter reset proedure. Press OK to override urrent tool ID prompt. Press OK to display tool attery perentage remaining. Numer of orientation passes displayed. Current tool version displayed. Tool attery perentage remaining. Warning approx. 2 weeks of attery life remaining. Indiation of suessful tool reset. Indiation that the tool has not een paired with the handheld. Canel the last orientation and start a new one. Indiation that there are no tools urrently in Running Mode. Tool attery level ritial. Replae immediately. Notifiation the handheld is powering off Instrutions to hold the OK utton for 3 seonds Handheld attery is urrently harging Handheld attery is fully harged Chapter 4: Trouleshooting 25
28 CHAPTER 5: MAINTENANCE REPLACING THE TRUCORE TOOL BATTERY The TruCore tool is powered y a non-rehargeale lithium attery. When a tool is turned on to Running Mode, the tool attery power level is heked automatially. If the handheld displays LOW TOOL BATTERY the tool has approximately 2 weeks of power left. Chek to make sure at least two spare atteries are on site. If not, order immediately. The following proedure should e followed eah time a attery replaement is required. a Move the TruCore tool to a loation free of dust, water and dirt. Clean and dry tool. Remove inner tue adapter if still installed. d e Position the tool horizontally and open the attery ap using the supplied 14mm Allen key. Wipe the threads on oth the ap and the tool with a dry loth to remove any moisture from the threads. Carefully disonnet the drained attery from the attery onnetor and properly dispose of it. f Unpak the new attery from its plasti sealing and reonnet the onnetors. g One the new attery is onneted to the TruCore tool, it will flash rapidly in a single olor and power up. Gently insert the attery ak into the housing. h i j Replae the O-rings on the attery ap and apply the inluded grease. Re-install attery ap to 55 Nm (40 ft.ls). Re-install inner tue adapter. 26 Chapter 5: Maintenane
29 Battery O-rings Battery Connetors Battery Cap Inner Tue Adapter TruCore Exploded view Warning: When the handheld displays REPLACE TOOL BATTERY, the tool has less than a week of power remaining and may stop operating at any time. Replae the attery as soon as possile. Warning: Only use TruCore atteries in sealed plasti. The seal should only e roken immediately efore installation, or attery life will not e aurately measured and ould result in lost data. Any unsealed atteries should e onsidered used and disposed of properly. Warning: Failure to apply grease when hanging O-rings ould ause the eletronis to fail due to water damage. Chapter 5: Maintenane 27
30 RECHARGING THE HANDHELD The handheld is powered y a rehargeale attery that an e reharged on site using the supplied ase and either AC or DC harging ale. The handheld will display RECHARGE HANDHELD, when it drops to 33% of a full harge. It will display this message every time its turned on until reharged. a Ensure the appropriate harging ale is onneted to the ase and either a wall outlet or 12/24V ar outlet. Slide handheld on to harging ase. Hold the to display the message BATTERY CHARGING should display on the handheld. d The handheld will require four hours to fully harge if allowed to go ompletely flat or 30 minutes a shift will maintain its harge. The message BATTERY CHARGED will e displayed on the handheld when harging is omplete. Remove the handheld one harged. Warning: Only use the supplied power adapters. Other power adapters may not regulate orretly and damage the attery and or handheld. Warning: The handheld attery is not field replaeale. Removing the tamper proof srews and opening the ase will void the warranty and the renter will e harged for its replaement if damaged. CLEANING THE TOOLS 1 2 Both TruCore tools should e rinsed off with fresh water after every shift to limit the uild up of potentially orrosive sustanes. The ommuniation ports should e leaned regularly to keep them free from dirt and deris. Avoid using any sharp or arasive materials that ould potentially damage the ommuniation port. 28 Chapter 5: Maintenane
31 CALIBRATION CHECK PROCEDURE If a tool is suspeted of false or inorret orientation readings, the following aliration hek proedure an e used to verify funtionality: a Plae TruCore at the approximate dip angle of the hole as shown. Note: The angle should e less than 85 to ensure aurate results. The tool must e seured at this angle to prevent it from rolling. 85 or less Initialize the tool using the proedure outlined in Step 3: Initializing Handheld and Tools of the Initial Setup setion from Chapter 1 (see pg. 8). One the tool is turned on, use a paint pen or other visile marking medium to mark the ottom of the TruCore ody at whihever end is onvenient. This mark simulates the downhole position of the ore sample in the hole prior to ore reak. Paint pen mark d e f Ensure the tool remains stale at this position and perform a mark operation (see setion Chapter 2: Marking Core). Plae the tool on a horizontal surfae and perform Step 3: Orienting the Core from Chapter 2. The red LEDs should align the tool with the down side position previously marked in step of this proedure. Repeat steps a through e, with eah iteration marking the tool 90 from the previous attempt. Four suessive alignments of these marks will onfirm the tool is within the aliration limits and is fully funtional. Chapter 5: Maintenane 29
32 SPARE PARTS AND KIT SELECTION All parts required to get started are inluded in the TruCore Kit with the exeption of the PQ size option whih may need additional parts (see PQ Head Conversion Kit tale). The Kit Seletion tale elow ontains all the items initially supplied in eah Kit aording to the hosen size. Contat Boart Longyear to replae any lost, damaged or worn out parts as required. KIT SELECTION PART # DESCRIPTION KIT, BQ TRUCORE KIT, BQTK TRUCORE BQ BQTK QUANTITY NQ LTK KIT, LTK60 TRUCORE KIT, NQ TRUCORE KIT, NQTK TRUCORE NQTK HQ PQ* KIT, HQ TRUCORE ASM, SOLID SPINDLE PQ CONVERSION TOOL, TRUCORE B SIZE TOOL, TRUCORE N SIZE TOOL, TRUCORE H SIZE ADAPTER, BQ CHECK VALVE ADAPTER, BQTK CHECK VALVE ADAPTER, LTK60 CHECK VALVE ADAPTER, NQ TRUCORE CHECK VALVE ADAPTER, NQTK TRUCORE CHECK VALVE ADAPTER, HQ TRUCORE CHECK VALVE ADAPTER, PQ TRUCORE CHECK VALVE BALL, 22mm BALL, 3/4in BODY, BQ CHECK VALVE BODY, CHECK VALVE EXTN, BQ TRUCORE O/TUBE EXTN, BQTK TRUCORE O/TUBE EXTN, LTK60 TRUCORE O/TUBE EXTN, NQ O/TUBE TRUCORE EXTN, HQ O/TUBE TRUCORE EXTN, PQ TRUCORE O/TUBE 1 30 Chapter 5: Maintenane
33 KIT SELECTION CONTINUED PART # DESCRIPTION QUANTITY PQ* HQ NQTK NQ LTK60 BQTK BQ HANDHELD, TRUCORE LEVEL, TRUCORE BATTERY, TRUCORE RECEPTACLE, HANDHELD CHARGER POWER PACK, HANDHELD CHARGER POWER CORD and COUNTRY ADAPTERS CAR ADAPTER, HANDHELD CHARGER ALLEN KEY, M USER GUIDE, TRUCORE CASE, TRUCORE B SIZE CASE, TRUCORE N SIZE CASE, TRUCORE H SIZE KIT, B SIZE O-RING REPLACEMENT KIT, N/H/P SIZE O-RING REPLACEMENT * PQ TruCore rentals require the onversion assemly part numer TRUCORE COMPATIBILITY The following tale outlines the ompatiility of Boart Longyear head assemlies with eah size of TruCore. Kit Size BQ BQTK LTK60 NQ NQTK HQ PQ Part Numer * Compatile Head Assemlies Inompatile Head Assemlies MKII MKII MKII MKII x x MKII MKII MKII MKII MKII MKII MKII* x x * PQ TruCore rentals require the onversion assemly part numer Chapter 5: Maintenane 31
34 RECOMMENDED SPARES The items presented in the tale elow are the reommended spares required for eah kit to ensure ontinuous operation. The part numers highlighted in orange are optional extended outer tues that may e sustituted for the extension tues initially supplied in eah kit to eliminate the extra joint in the drill string. It is reommended that at least two of eah item e kept on hand per kit. 32 RECOMMENDED SPARES PER KIT PART # DESCRIPTION QUANTITY PQ* HQ NQTK NQ LTK60 BQTK BQ O/TUBE, BQ 3M/10' TRUCORE EXTENDED O/TUBE, BQTK 3M/10' TRUCORE EXTENDED O/TUBE, LTK60 3M/10' TRUCORE EXTENDED O/TUBE, NQ 3M/10' TRUCORE EXTENDED O/TUBE, HQ 3M/10' TRUCORE EXTENDED O/TUBE, PQ 3M/10' TRUCORE EXTENDED EXTN, BQ TRUCORE O/TUBE EXTN, BQTK TRUCORE O/TUBE EXTN, LTK60 TRUCORE O/TUBE EXTN, NQ O/TUBE TRUCORE EXTN, HQ O/TUBE TRUCORE EXTN, PQ TRUCORE O/TUBE ADAPTER, BQ CHECK VALVE ADAPTER, BQTK CHECK VALVE ADAPTER, LTK60 CHECK VALVE ADAPTER, NQ TRUCORE CHECK VALVE ADAPTER, NQTK TRUCORE CHECK VALVE ADAPTER, HQ TRUCORE CHECK VALVE ADAPTER, PQ TRUCORE CHECK VALVE BALL, 22mm BALL, 3/4in BODY, BQ CHECK VALVE BODY, CHECK VALVE BATTERY, TRUCORE KIT, B SIZE O-RING REPLACEMENT KIT, N/H/P SIZE O-RING REPLACEMENT FITTING, HYD GREASE Chapter 5: Maintenane
35 CHAPTER 6: VERIFICATION OF COMPETENCY DELIVERING VERIFICATION OF COMPETENCY TRAINING Boart Longyear reommends an ongoing Verifiation of Competeny program e implemented at eah site to ensure all supervisors and drilling personnel are adequately trained in the operation of TruCore. The training session should inlude a omination of lass room lessons, a pratial assessment, a training session attendane sheet and ompeteny sign-off to e kept on file. COMPETENCY CHECKLIST In order to verify eah TruCore user is ale to use the tools orretly, Boart Longyear reommends the following skills e periodially assessed. By the end of the assessment session, the partiipant will e ale to suessfully operate and maintain a Boart Longyear TruCore Orientation tool. 1. Aility to identify all the tool and handheld features 2. Clear understanding of the Modes of Operation 3. Completing the Initial Setup Installing TruCore Installing the Extension Barrel Initializing Handheld and tools 4. Marking the Core Eletronially marking the ore down hole using the handheld. Retrieving the ore per standard operating proedure. Orienting the TruCore tool on surfae and physially transferring the loation to the ore sample. Confirming the ore orientation using the handheld. Re-initializing the TruCore tool. 5. Chek Tool ID and Modes of Operation 6. Chek Tool Status on handheld 7. TruCore Reset 8. Tool ID Override 9. Replaing the Battery 10. Reharging the Handheld 11. Cleaning the Tools Chapter 6: Verifiation of Competeny 33
36 QUICK REFERENCE GUIDE Funtion Keys Tool Assignment Legend Press Press Press to turn on handheld to view standard options to selet urrently displayed funtion First tool to e initialized eomes the Blue Tool. Seond tool to e initialized eomes the Green Tool Operation Sequene a Install TruCore tool onto Inner Tue Assemly One. Press to TURN ON TOOL on TruCore and assign Blue Tool status. d Send Inner Tue Assemly One downhole and egin drilling. Install seond TruCore tool onto Inner Tue Assemly Two. e f One drilling is omplete efore reaking ore, press Retrieve Inner Tue Assemly One after ore reak. to MARK BLUE. g Press to TURN ON GREEN TruCore tool. h Upon retrieving the Inner Tue Assemly One (Blue Tool), send down Inner Tue Assemly Two (Green Tool) and ontinue drilling. i Press to FIND BLUEORI to end Orientation Mode. j k Rotate inner tue until flashing LED hanges from Blue to Red. Keep Inner Tue Assemly stale one the orret orientation is found as indiated y the Red LED. Physially mark downside of ore and remove ore per normal proedure. l Press and point handheld at the Blue TruCore tool to onfirm. m Handheld must display ORI PASS, otherwise repeat steps j and to l n Reassemle Blue TruCore tool onto the Inner Tue Assemly. o Repeat steps e to n alternating etween Blue and Green for eah yle.
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