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© Copyright 2000, Atlas Copco Rock Drills AB, Örebro, Sweden.

Any unauthorized use or copying of the contents or any part
thereof is prohibited. This applies in particular to trademarks,
model denominations, part numbers and drawings.

1R
System description
Swellex pump HSP A51

March 1999

Atlas Copco Rock Drills AB R&D

Summary
This system description covers the hydraulically powered Swellex pump HSP A51. It describes the
most interesting technical components on the pump unit and is the basis for the documents with which
the customer/user comes into contact with in the field. Consequently, this document is for internal use
only.
Note that the information contained in this document may be revised by Atlas Copco Rock Drills AB
R&D without reservation.
Contents
1 Introduction ____________________________________________________________1
2 Service data ____________________________________________________________1
2.1 Notes on Service Data ______________________________________________________ 2
3 Applying the bolt ________________________________________________________3
3.1 Pump unit function ________________________________________________________ 4
3.2 Swelling the bolt __________________________________________________________ 4
3.2.1 Swelling development, completion pressure 300 bar___________________________________ 5
3.2.2 Swelling development, completion pressure 240 bar___________________________________ 5
4 Component description and function ________________________________________6
4.1 Hydraulic system__________________________________________________________ 7
4.1.1 Hydraulic motor with hydraulic block ______________________________________________ 7
4.2 Water system _____________________________________________________________ 8
4.2.1 Safety valve __________________________________________________________________ 9
4.2.2 Pressure regulator _____________________________________________________________ 9
4.2.3 Water filter__________________________________________________________________ 11
4.2.4 Water pump _________________________________________________________________ 12
4.2.5 Overflow valve ______________________________________________________________ 13
4.2.6 Oil recommended by pump unit supplier and pump manufacturer. _______________________ 15
4.2.7 Capacitive sensor -water monitor ________________________________________________ 18
4.2.8 Pressure monitor _____________________________________________________________ 19
4.3 Electrical system _________________________________________________________ 21
4.3.1 AP1 function ________________________________________________________________ 22
4.3.2 System function when swelling, pressure monitor switches. ____________________________ 23
4.4 Mechanics ______________________________________________________________ 24
List of figures
Figure 1 Functional diagram of the pump unit ___________________________________________________ 1
Figure 2 Service data. ______________________________________________________________________ 1
Figure 3 Applying the bolt from the charging basket, -Boomer.______________________________________ 3
Figure 4 Principle for applying the bolt, hand-held. ______________________________________________ 3
Figure 5 Cross-section of bolt inserted in rock hole, unswelled and swelled respectively.__________________ 4
Figure 6 Unswelled and swelled bolt. __________________________________________________________ 4
Figure 7 Swelling Standard Swellex 2400 mm to 300 bar, delay 0.0 sec._______________________________ 5
Figure 8 Swelling Standard Swellex 2400 mm to 240 bar, delay 1.4 sec._______________________________ 6
Figure 9 Pump unit complete with connecting hoses (on rear) and control box. _________________________ 6
Figure 10 Hydraulic diagram for pump unit. ____________________________________________________ 7
Figure 11 Hydraulic motor with hydraulic block. Connections also on reverse side. _____________________ 7
Figure 12 Water diagram for pump unit. _______________________________________________________ 8
Figure 13 Data sheet for water reducing valve. __________________________________________________ 9
Figure 14 Exploded view of reducing valve. ____________________________________________________ 10
Figure 15 Water filter, illustration with cross-section showing gasket and filter insert. __________________ 11
Figure 16 Dismantling the filter holder from the pump unit, view from left. ___________________________ 11
Figure 17 Exploded view of water pump. ______________________________________________________ 12
Figure 18 Material data pump A51. __________________________________________________________ 12
Figure 19 Overflow valve with connections. ____________________________________________________ 13
Figure 20 Approval for running pump for 1.5s, outlet pressure 320 bar.______________________________ 14
Figure 21 Capacitive sensor KN5101. ________________________________________________________ 18
Figure 22 Setting the capacitive sensor. _______________________________________________________ 18
Figure 23 Pressure monitor PN7020. _________________________________________________________ 19
Figure 24 Setting the pressure monitor. _______________________________________________________ 20
Figure 25 Electrical system principle diagram. _________________________________________________ 21
Figure 26 Circuit diagram. _________________________________________________________________ 21
Figure 27 Supply / signal, connection blocks RSM-24.____________________________________________ 22
Figure 28 Functional diagram of pressure monitor switches for rising and falling pressure respectively. ____ 23
Figure 29 Cover for pump unit HSp A51. ______________________________________________________ 24
Figure 30 Box for mounting pump unit components, HSP A51. _____________________________________ 24
1 Introduction
Thank you for your interest in the Swellex pump HSP A51. This description will provide an overview of
the functions and choice of components for the hydraulic Swellex pump.

The Swellex pump HSP A51 is intended for swelling all types of Swellex bolts. The pump is a modular
compact design and is mounted principally on mobile mining equipment. When fitted, the pump is
connected to the existing power systems such as the hydraulic and electric systems. Water is taken
from an external source.

2
5
3
4

Figure 1 Functional diagram of the pump unit

1) Water IN
2) Hydraulic energy
3) Electric energy
4) Pump unit Swellex HSP A51
5) Water OUT

2 Service data
The pump unit can be regarded as a booster pump that raises the pressure of the incoming water up
to the preset level required for swelling Swellex bolts in rock. The pump data is given below.

Service data: HSP A51

Hydraulic pressure 190-230 bar
Hydraulic flow, without load 20 l/min
Water flow 10.2 l/min, Pout=1 bar
Boost ratio 1:75
Max. water pressure IN Pin=14 bar
Max. water pressure OUT Pout=320 bar, 1.5 sec.
Voltage 24V, max 28V DC
Current consumption max 1A
LxBxH 660x300x300 mm
Weight 48kg
CE marked Yes
Noise level, in service XX dB
Figure 2 Service data.

1
2.1 Notes on Service Data
• Test assignment PPM no. 97303 shows that hydraulic pressure 190 bar to pump unit gives 300 bar
in bolt with a margin of 10 bar. 230 bar max. pressure for hydraulic valves, block and motor.
• The hydraulic flow through the pump will vary due to the flow regulator. When the resistance on the
water side increases, the hydraulic flow will also increase slightly. The regulator is factory set to 20
l/min and "sealed" with Loctite 270 according to the purchase drawing.
• Max. water pressure IN same as Atlas Copco rock drilling rig standard, 14 bar.
• Supplier approves pump load of 320 bar for 1.5 sec. The time 1.4s is a delay on the pressure
monitor that turns off the Swellex pump (1.5 sec is not practical to set on the monitor). In other
words, the pump will pump water through the overflow during this time. The overflow must not be
set higher than 320 bar.
• The pump unit is connected to a stabilised 24V supply when fitting to Atlas Copco drilling rigs.
• Overall current consumption including hydraulic valve and sensor.

2
3 Applying the bolt
HSP A51 is for use principally on Atlas Copco BOOMER rigs and BOLTEC but the unit can even be
sold separately for fitting on trucks with scissor bed or similar. With a Boomer rig, the bolts are applied
manually in a pre-bored hole. For Boltec, the bolts are applied mechanically using a Bolt unit that drills
holes and applies bolts. The same pump unit is used but on Boltec, the pump is controlled by the rig
control system. Boltec also has a bolt chuck that clamps the bolt to prevent it from falling from the
chuck if reversing is required while inserting the bolt into the hole.

Figure 3 Applying the bolt from the charging basket, -Boomer.

Figure 4 Principle for applying the bolt, hand-held.

3
3.1 Pump unit function
Below is a description of how the Swellex pump works when applying bolts.

1. The pump unit is set correctly, i.e.

• Water is connected from the rig / mine, max. 14 bar.
• The pump unit has been connected to the rig / machine hydraulic system, 190 - 230 bar, and
electric system, 24V stabilised supply.
2. Mount bolt into chuck and place in rock hole.
3. Activate pump.
4. If water present, capacitive sensor active, and if pressure in outlet hose, measured via pressure
sensor, within criteria for the pressure sensor to send start signal to unit, the valve in the hydraulic
block on the motor will become active and hydraulic oil will flow through the motor that drives the
water pump.
5. The bolt will fill with water. When it is filled, it starts to swell and becomes permanently deformed.
6. Once the bolt has reached the rock, it will stop deforming and the water pressure will rise to the set
completion pressure. When the pressure monitor criteria have been fulfilled, it will signal the
hydraulic valve to close and the pump stops. A certain drop in pressure, approx. 10 bar, may occur
as the pump is turned off.

3.2 Swelling the bolt

Bolt swelling is based on plastic deformation. Once a substance has passed its yield point, which is its
limit for elastic / non-permanent deformation, the substance will start to become fluid and attempt to
attain a state of equilibrium. See 3.2.1 below. The bolt is first filled with water. The pressure increases
and the yield point is passed. The material in the bolt starts to become fluid and is permanently
deformed. Once the bolt has reached the rock, the pressure rapidly rises to the set value and the
pressure monitor cuts out. The usual setting is 300 bar but depending on the type of bolt and the rock,
some bolts require only 240 bar for full expansion, see development of pressure below.

Figure 5 Cross-section of bolt inserted in rock hole, unswelled and swelled respectively.

Figure 6 Unswelled and swelled bolt.

4
3.2.1 Swelling development, completion pressure 300 bar
The graph below illustrates the swelling development of a Swellex bolt. The hydraulic flow through the
hydraulic motor is almost constant thanks to the flow regulator. As described above, the bolt is first
filled with water and then it starts to expand. As the bolt reaches the rock, the water pressure in the bolt
will rise. Once the water pressure in the bolt has reached the preset value on the pressure monitor, the
pump unit will be shut off by the hydraulic valve ceasing to send oil to the motor.
Note that the completion pressure for bolt swelling at 300 bar below, where the shut-off delay setting
on the pressure monitor is 0.0 sec. When this is set to 1.4s (factory setting), the completion pressure
will be 300-310 bar. Using the graph, it was decided to add a shut-off delay.

Figure 7 Swelling Standard Swellex 2400 mm to 300 bar, delay 0.0 sec.
A) Water pressure
B) Hydraulic flow

3.2.2 Swelling development, completion pressure 240 bar

To swell a bolt to a pressure lower than the one factory set on the Swellex pump, both the pressure
monitor and the overflow setting must be lowered to ensure the correct pressure is attained. Note that
only the end of the swelling development is shown in the graph below.

1. Raise the pressure monitor setting to 350 bar.

2. Start the pump.
3. Lower the overflow setting by unscrewing the lock nut securing the spring / reducing the spring
pressure until a pressure is attained that corresponds to the sum of the desired pressure and the
pump pulse width, i.e. 20 bar. E.g. 240 bar + 20 bar = 260 bar. Read the pressure monitor.
4. Lower the pressure monitor setting to 240 bar.

5
 A

Figure 8 Swelling Standard Swellex 2400 mm to 240 bar, delay 1.4 sec.
A) Water pressure
B) Hydraulic flow

4 Component description and function

The technically most interesting components fitted to the pump unit are described below. The pump
unit is constructed in a box with removable cover for easy servicing. All the components are therefore
mounted inside the box. The sides are open. The box is painted grey. Part number for HSP A51: 9106
1480 00. Key for illustration below, pos. 1: Pressure sensor, 2: Hydraulic motor, 3: Water filter, 4:
Electric box.

Figure 9 Pump unit complete with connecting hoses (on rear) and control box.

6
4.1 Hydraulic system
The unit's hydraulic system consists only of the hydraulic motor and its mounted hydraulic block. The
block has connections for the booster function, P2A, P2B, - these are not used for the Swellex pump
application. P1A, or P1B, is connected to the rig's hydraulic system, which is a constant pressure,
closed centre, system with pressure 190 - 230 bar. The block contains a cartridge type flow regulator.
This is adjusted to 20 l/min when there is no load on the motor. The flow regulator adjusting screw,
hexagon socket, is locked with Loctite grade 270 after factory adjustment, see also 4.1.1.

Figure 10 Hydraulic diagram for pump unit.

A) Hydraulic motor
B) Electrically controlled on/off hydraulic valve
C) Constant flow regulator

4.1.1 Hydraulic motor with hydraulic block

The gear-driven hydraulic motor has a displacement of 15cc. The aluminium block is mounted on the
end of the motor. The block has an integrated pressure-compensated flow regulator and hydraulic
valve. The hydraulic valve is a 3/2 valve with ON/OFF function, 24V, 15W.

A
D

B
C

Figure 11 Hydraulic motor with hydraulic block. Connections also on reverse side.
A) Block with connections
B) Flow regulator
C) Electrically controlled hydraulic valve
D) Hydraulic motor

7
4.2 Water system
The water pressure is reduced to 4 bar with the reducing valve. Read the pressure on the pressure
gauge. If the pressure reducing valve is functioning properly, the pressure will increase to 8 bar as the
safety valve opens. Water will run from the box when the valve opens as a visual warning that the input
pressure to the pump unit is too high and there is risk that the filter and pump can be damaged. The
water is filtered in the filter. B251 is a capacitive sensor that detects whether there is any water in the
hose between the filter and the pump. The pressure monitor B192 is mounted after the pump on the
output line. When the pressure monitor detects a water pressure higher than its setting, the pump will
be turned off.

Figure 12 Water diagram for pump unit.

8
4.2.1 Safety valve
The safety valve opens at a factory set pressure, 8 bar, which is sealed with steel wire and lead. The
valve with ¼” male threaded connection is approx. 8 cm long and has a key ring fastened to the valve
shaft. The ring is pulled to test the valve function. This will compress the preloaded spring and the
valve will open. Water will exit radially through three holes. The valve is mounted inside the pump unit
cover.
4.2.2 Pressure regulator
The pressure regulator maintains the set pressure of 4 bar. The pressure is read on the pressure
gauge. The valve is necessary as the filter and pump can only withstand an intake pressure of 8 bar
and 10 bar respectively. The water pressure in mines is often higher than this and our rigs generally
have a capacity of 14 bar as standard. The difference in pressure between the reduced pressure and
the safety valve opening pressure, approx. 4 bar, is necessary due to the development of the flow
when the pump is started and stopped. If the difference is too little, the safety valve can open when the
pump is turned off. The reducing valve is joined to the filter. The pressure gauge is directed to left
when viewing the pump from the front.

Figure 13 Data sheet for water reducing valve.

9
Figure 14 Exploded view of reducing valve.

10
4.2.3 Water filter
The water filter is mounted after the reducing valve on the on the incoming water. The filter insert is
easy to change by unscrewing the filter canister and removing it from the pump unit box. The filter
insert is 30µm. On top of the filter holder is a red button used to ventilate the system up to the filter
when depressed. Note that it is easiest to ventilate the entire system by opening the valve to the
Swellex chuck and "draining" the pump unit. Max. pressure for filter unit 8 bar. Depending on the water
quality, the filter should be dismantled and checked regularly. If the filter is completely clogged and no
water is reaching the pump, the pump will be stopped by the water monitor, see 4.2.7.

Figure 15 Water filter, illustration with cross-section showing gasket and filter insert.
1) Ventilation
2) Filter insert

Figure 16 Dismantling the filter holder from the pump unit, view from left.

11
4.2.4 Water pump
The water pump, A51/10-250, is an axial plunger pump. It comprises five ceramic plungers running in
their bores parallel to the rotation axle. The plungers are resting against an inclined disc that rotates
with the input shaft. The plungers' return movement is by spring pressure. According to the data sheet,
the pump delivers 10.2 l/min at 1450 rpm and 1 bar pressure. This is approved for pumping 320 bar for
1.5 sec., see below.
Depending on the load, the pump delivers pressure pulses due to a discontinuous flow of water. These
pressure pulses are up to 20 bar for 8 ms depending on the motor speed and number of plungers.
The oil level in the pump housing must be checked regularly. For oil grade see 4.2.6.

Figure 17 Exploded view of water pump.

Pump materials A51/10-250

Valve housing Special brass
All ceramic, gera part
Plungers hardened stainless steel
Valves Stainless steel
Nitrile with reinforced
Sleeves fabric
Support rings Teflon with graphite
Bearings Axial ball bearings
Spring Corrosion proof
Swash plate Aluminium

Figure 18 Material data pump A51.

12
4.2.5 Overflow valve
The overflow valve is mounted directly on the pump unit. If the pump attains a high pressure, the valve
will open and lead the water back to the water intake on the pump. Adjustment is carried out with the
lock nut outside the spring. A blue spring is factory fitted. The plugged outlet closest to the spring on
the right-hand side is for connecting e.g. a pressure gauge. Practical tests have shown that the valve is
strongly damped and opens at 305 bar, being fully open at 320 bar. The valve is not completely closed
until the pressure drops to 270 bar. If the pump starts with a closed outlet, e.g. closed water valve -
BOLTEC, the water pressure will increase rapidly and make the overflow valve open too far. The
pressure will then drop as the water is drained, water will be circulated through the valve at a lower
pressure than the pressure monitor is set to and the pump will not be shut off. This is because the
pressure monitor has a preset shut-off delay of 1.4s, see 4.2.8.

Figure 19 Overflow valve with connections.

A) Pressure setting, max pressure
B) Pressure gauge outlet, plugged
C) Water out, when overflow valve is open (to rear of illustration)
D) Water out to Swellex chuck
E) Water in from pump

4.2.5.1 Setting the overflow valve

The opening pressure, when the entire flow passes the valve, should be set to the sum of 20 bar and
the pressure required for swelling the bolt. E.g. required swelling pressure 300 bar, -> overflow setting
300 + 20 = 320 bar. Required swelling pressure 240 bar, -> overflow setting 240 + 20 = 260 bar. The
20 bar that must be added to the swelling pressure corresponds to the pressure pulses from the pump,
peak - valley.
See also: Test report for PPM 97303. Note that absolute max pressure setting is 320 bar.

13
Figure 20 Approval for running pump for 1.5s, outlet pressure 320 bar.

14
4.2.6 Oil recommended by pump unit supplier and pump manufacturer.
The pump unit is delivered with Statoil Mereta ISO VG 68.

Figure 21 Oil recommended by ALTO Sverige AB, pump unit supplier.

15
Figure 22 Oil recommended by SPECK, pump manufacturer.

16
Figure 23 Specification AVIA GEAR VSG 68.

17
4.2.7 Capacitive sensor -water monitor
The capacitive sensor is used as a water monitor. It is mounted on the water hose to the water filter
and detects the differences in media in front of it. If the hose is not filled with water, the monitor will
remain inactive and the pump cannot be started. Calibrate as described below. It also ensures against
incorrect connection on site as the air hose and water hose may have the same connections. A
pressure monitor on the incoming water would not have been able to determine whether it was
compressed air or water in the hose. A functional test can be carried out by turning off the water to the
pump unit and activating the pump. The pump will then stop after a time delay (integrated in AP1) of a
few seconds. This delay is necessary as the pump would stop directly if there were the slightest
amount of air in the hose to the pump when starting.

Figure 21 Capacitive sensor KN5101.

Figure 22 Setting the capacitive sensor.

18
4.2.8 Pressure monitor
The pressure monitor has two switches integrated in the unit. They are set separately as
described below.

4.2.8.1 Explanation to pressure monitor settings

The pressure monitor has a number of possible settings. However, the monitor has a basic setting of
300 bar on delivery from the pump unit manufacturer for swelling bolts. When swelling bolts at a lower
pressure, the operator must change the SP2 variable to the desired pressure (even the overflow
opening pressure, see 4.2.3.1). The user or service personnel can disregard the other variables as
long as they are at their standard settings. Both switches therefore have an adjustable hysteresis, SP1
and rP1 or SP2 and rP2 respectively. The pump always starts when one switch is active. In other
words, if rP2=100, the pump will start at 100 bar, pressure drop, since switch 2 is then inactive. If rP2 is
set to below rP1, then the pump will start at the value of rP1 since switch 1 then becomes inactive
before switch 2. See 4.3.2.

• SP1 = 56. Specifies the pressure at which switch 1 is active, upper LED on display lights up.
• rP1 = 52. Specifies the pressure at which switch 1 is inactive, upper LED on display goes out.
• dS1 = 0. Specifies the time that the pressure reading should exceed SP1 for switch 1 to be active.
• dr1 = 0. Specifies the time that the pressure reading should be below rP1 for switch 1 to be
inactive.
• OU1 = Hno. Specifies whether switch 1 should be making, (Hno -normally open), or breaking, (Hnc
-normally closed).
• daP = 60. Sampling rate, time between pressure readings.
• SP2 = 300. Specifies the pressure at which switch 2 is active, lower LED on display lights up.
• rP2 = 52. Specifies the pressure at which switch 2 is inactive, upper LED on display goes out.
• dS2 = 1.4 Specifies the time that the pressure reading should exceed SP2 for switch 2 to be active.
• dr2 = 0. Specifies the time that the pressure reading should be below rP1 for switch 2 to be
inactive.
• OU2 = Hno. Specifies whether switch 2 should be making, (Hno -normally open), or breaking, (Hnc
-normally closed).
• daP = 60. Sampling rate, time between pressure readings.

As the pump delivers a pulsing pressure, the completion pressure, when the pump has been shut off,
will be above the set pressure depending on the delay of dS2. The pump pulses are 15-20 bar and if
switch 2 is to be active, all the sampled values must be above SP2, which means that the 1.4 seconds
begins to be counted as soon as a reading is below SP2. Due to the pulsations, the mean pressure will
be >10 bar above SP2.

Figure 23 Pressure monitor PN7020.

19
4.2.8.2 Setting the pressure monitor

Figure 24 Setting the pressure monitor.

20
4.3 Electrical system
The electrical system comprises an electric box, cable to hydraulic valve Y531, pressure monitor B192
and water monitor B251. When the Start button on the control box is pressed in and the green lamp in
the button lights up, the pump unit will be active and operate according to the criteria from the pressure
monitor. If the valve in the Swellex arm is closed or the valves in the Boltec water system are closed,
the pump will build up pressure until it is shut off according to the pressure monitor criteria. The PLC
controls the pump via A61:2 in the Boltec application, where the pump starts differently depending on
where the bolt tool is on the feeder; flushing, clamping, swelling.

Figure 25 Electrical system principle diagram.

Figure 26 Circuit diagram.

21
4.3.1 AP1 function
The brain in the HSP A51 is the AP1, which is mounted in the electric box. AP1 contains a circuit board
that controls different processes depending on the signal its connection blocks have, etc. The following
specifies what the connection blocks are connected to and the expected readings.

Block 1. 24V DC supply to pushbuttons.

Block 2. 24V DC- supply to LED.
Block 3. 24V DC+ supply to LED.
Block 4. 24V DC supply to thermocontact.
Block 5. 24V DC signal (24V DC = thermocontact OK).
Block 6. 24V AC contactor.
Block 7. 0V contactor.
Block 8. Incoming supply 0V AC/DC.
Block 9. Incoming supply 24V AC/DC.
Block 10. 24V DC signal (24V DC = water present).
Block 11. Supply to flow monitor +24V DC.
Block 12. Supply to flow monitor -24V DC.
Block 13. 24V DC signal (24V DC = pressure monitor 300 bar), switch 2.
Block 14. 24V DC signal (24V DC = pressure monitor 50 bar), switch 1.
Block 15. Supply to pressure monitor -24V DC.
Block 16. Supply to pressure monitor +24V DC.
Block 17. 24V DC signal, stop button.
Block 18. 24V DC signal, start button.
Figure 27 Supply / signal, connection blocks RSM-24.

22
4.3.2 System function when swelling, pressure monitor switches.
The graph below shows the activity of the different switches. Factory settings. The graph presents a
rising pressure and a falling pressure. When the bolt is swelled, the pump will stop at the set pressure.
The pressure is maintained until the Swellex chuck is activated - if an unswelled bolt or not bolt at all is
connected to the Swellex bolt. If there is a water leak between the pump and the bolt, the pressure will
drop and the pump start, irrespective of whether the water valve is activated!

Pressure
1

D
B

C
2

Figure 28 Functional diagram of pressure monitor switches for rising and falling pressure
respectively.
1) Pump stop
2) Pump start
A) SP2 fulfilled - Switch 2 active
B) SP1 fulfilled - Switch 1 active
C) rP1 and rP2 fulfilled - Switch 1 and 2 inactive
D) Pressure monitor with display, buttons and LEDs for switches

23
4.4 Mechanics
The box with cover and attachments for sensors, etc., are manufactured in sheet steel. Primed and
painted in grey. The cover is fitted with an attachment for an eccentric lock for rapid and easy access
to the pump for servicing.

Figure 29 Cover for pump unit HSp A51.

The sturdy centre plate acts as a stay and attachment for the pump unit complete with hydraulic motor.
Pre-drilled holes for fitting electric box, filter, etc.

Figure 30 Box for mounting pump unit components, HSP A51.

24