DCR20

Pneumatic System
Compressor control circuits
 Contents

Summary ..................................................................................................................................1
Schematics ...............................................................................................................................2
Location of compressor equipment ..........................................................................................4
Starting switch on, Aid in engine starting operation ..................................................................8
After starting engine, Starting unload operation .......................................................................9
Starting unload operation .......................................................................................................10
Start compressing ..................................................................................................................13
Low pressure unload operation ..............................................................................................14
Low air flushing ......................................................................................................................15
High air flushing .....................................................................................................................16
Stopping engine .....................................................................................................................17

1
‫ع‬Summary

The double stage screw compressor for Down-the-hole drills operates multistage controls from starting
to rated operation. Fig.1 shows the relation between time and the pressure change in each stage.
There are four stages as follows:

1. Aid in engine starting operation

The compressor does not perform compression approx. ten seconds after the engine starts, it
reduces the load to the engine when starting.

2. Starting unload operation

Operates at 0.39-0.49MPa for 80 seconds after the engine starts so that it does not give sudden load
to the engine. The engine will stop automatically when pressure does not reach 0.32MPa.

3. Low pressure unload operation

By operating at a pressure of about half of the rated pressure, it reduces the engine power when
compressed air is not in use.

4. Rated operation
Operates at a rated pressure (2.4MPa). Compressed air is in use at all times in this condition.

2.4
2.5

2.0
Pressure (MPa)

1.5 1.35

1.0 High air flushing ON

0.39-0.49
0.5

When engine stops

0.32 or less

Engine start 10 80 Time (sec)

1 2 3 4
Controls
T2
TE 䊶 UT Timer

Fig.1

1
 ‫ع‬Schematics

Ǿ
MANIFOLD (B)

Ǿ

 


51..%
Ǿ



2562 MANIFOLD (D)

 
51.7. 51.7. Ǿ

/2C /2C

 Ǿ Ǿ


 MANIFOLD (A)
To AIR VALVE 

25#. /2C /2C

Ǿ

5.58
Ǿ

MANIFOLD (C)


 
Ǿ
9#:



Ǿ %
% %
%
. 
%
%

% 
RECEIVER TANK
COMPRESSOR 







Fig.2

2
 Mini-compressor  Oil check valve

 Unloader regulator  Oil control valve

 Low pressure regulator  Strainer

 High pressure regulator  Oil separator

 Vacuum relief valve  Silencer

 Auto-relief valve

 Pressure switch AL

 Pressure switch TP

 Solenoid valve SV

 Solenoid valve LC

 Solenoid valve UL1‫ޔ‬UL2

 Pressure control valve

 Safety valve

 Differential pressure gauge

 By-pass valve

 Oil cooler

 Drain cock

 Oil filter

3
 ‫ع‬Location of compressor equipment

Fig.3

 Compressor Ass’ y  Receiver Tank Ass’ y  Mini-compressor Ass’ y

4
 




Fig.4 Compressor Ass’ y Fig.5 Mini-compressor Ass’ y

 


Refer to Manifold (D)


Refer to Manifold (A)㨯(B)

 Mini-compressor

 Unloader regulator

 Auto-relief valve

 Pressure switch AL

 Solenoid valve SV

 Pressure control valve

Fig.6 Receiver Tank Ass’ y
 Safety valve

 Oil separator

5
 6

DETAIL - Manifold (D)

8 11

10

14 DETAIL - Manifold (A)･(B)

Fig.7 Manifold

3 High pressure regulator 8 Pressure switch TP

4 Low pressure regulator 10 Solenoid valve LC

5 Vacuum relief valve 11 Solenoid valve UL1、UL2

6 Auto-relief valve 14 Differential pressure gauge

6
 





 

Fig.8 Oil piping group

 By-pass valve  Oil check valve

 Oil cooler  Oil control valve

 Oil filter

7
 ‫ع‬Starting switch on, Aid in engine starting operation

4-50 4-51 4-52 4-53

SOLENOID VALVE SV PS-AL Contacts close
at 0.5MPa
P3
PRESSURE SWITCH

R25

R25 PS T2
-AL
MINI-COMPRESSOR
S0L-SV
Ǿ
Z01 Z03

MANIFOLD (C)
Z02

Ǿ
M R25
CLOSED UNLOADER REGULATOR
SOL
-SV
Ǿ %
NC
% %
%

Pressure Switch for

Unloader Close
.

Mini-compressor

Unloader Close
%
%

%
Fig.10
COMPRESSOR

Fig.9

1. When the starting switch is turned to the ON position, the solenoid valve SV will be energized(closed).
The mini-compressor(MC) starts operating and supplies compressed air to the unloader regulator.
When the pressure reaches 0.15MPa, the pressure overcomes spring tension of the unloader regulator,
the piston in the unloader regulator moves to close the butterfly valve (Fig.9).

2. When the pressure reaches 0.5MPa, the pressure switch AL will be turned on and make its contact
close, causing the relay R25 (4-51) to be energized. With the relay R25 is energized, relay contacts
(4-50) break current to the MC and MC stops operating. Once the relay R25 is energized, it is ‘latched’
on by closing own contacts (4-52) (Fig.10).

8
‫ع‬After starting engine, Starting unload operation

1-14 1-15 1-18 1-19

P2
1. When the engine started, the alternator
4-53
starts generating. The relay ENR0 (1-14) will
P1 P3 be energized, causing relay contacts (1-18)
Contacts open
after 5-10sec.
to close. As a result, the relay ENR1, timer
T2
ENR0 TE and T2 will be energized.

4-55
Z03
2. The solenoid valve SV keeps operating until
set time of the timer T2(5-10sec.) goes on,
203
keeps the butterfly valve closed(Fig.9). As a
TPL
result, compressor maintains unload
POS
207 R condition, the engine can be started up
G 249
smoothly.
ENR0 ENR1 TE T2
SOL
-SV 3. When set time of the timer T2 has passed,
NC the timer contacts (4-53) open, the solenoid
Set: 5-10sec.
valve SV stops operating(open).
Engine Running Signal
Engine Starting Signal

Low Pressure Signal

Unloader Close
Unload Cut-off
Alternator

Fig.11

Solenoid valve
SV goes off

25#. 4. W h e n t h e s o l e n o i d v a l v e S V s t o p s
operating,compressed air flows to the
air-end.

MINI-COMPRESSOR 5. The unloader regulator slowly opens the

5.58
butterfly valve because pressure slightly
Ǿ decreases by the orifices.When the butterfly
valve opened, the compressor starts
compressing.

Ǿ
UNLOADER REGULATOR
OPEN
ORIFICE

Ǿ

COMPRESSOR

CHECK VALVE

Fig.12

9
 ‫ع‬Starting unload operation
While compressing
AUTO-RELIEF Ǿ
MANIFOLD (B)
VALVE (1)
Ǿ

VACUUM RELIEF
VALVE
Ǿ
51..%
AUTO-RELIEF
VALVE (2)
2562 MANIFOLD (D)

51.7. 51.7. Ǿ /2C /2C

Ǿ Ǿ

Solenoid valves
UL1/UL2 on
MANIFOLD (A)
To AIR VALVE

25#.
/2C /2C
Ǿ

5.58
Ǿ

MANIFOLD (C)

Ǿ UNLOADER

9#:
CLOSED
REGULATOR

Ǿ %
%
%
%

.

%
%

%
RECEIVER TANK
COMPRESSOR

OIL CHECK VALVE

Fig.13

1. When the compressor starts compressing, discharge pressure works the auto-relief valves (1),(2) to
close. Also it works the oil check valve to open and supplies compressor oil to the air-end.

2. Compressued air is applied to the pilot chamber (C6) of the vaccum relief valve, the valve closes the
passage from the receiver tank to the air-end (C4).

3. As the solenoid valves UL1,UL2 have been energized since the key switch was turned on,
compressed air flows to the unloader regulator through the solenoid valve SV.

10
Maintain 0.39-0.49MPa

AUTO-RELIEF Ǿ
MANIFOLD (B)
VALVE (1)
Ǿ

VACUUM RELIEF
VALVE
Ǿ
51..%
AUTO-RELIEF
VALVE (2)
2562 MANIFOLD (D)

51.7. 51.7. Ǿ /2C /2C

Ǿ Ǿ

Solenoid valves
UL1/UL2 on
MANIFOLD (A)
To AIR VALVE

25#.
/2C /2C
Ǿ

5.58
Ǿ

MANIFOLD (C)

Ǿ UNLOADER

9#:
CLOSED
REGULATOR

Ǿ %
%
%
%

.

%
%

%
RECEIVER TANK
COMPRESSOR

OIL CHECK VALVE

Fig.14

1. As pressure increases, the unloader regulator throttles intake air volume by closing the butterfly valve.
When the pressure increased to 0.39-0.49MPa, the butterfly valve closes and the compressor stops
compression.

2. When the butterfly valve closed, air-end is in negative. As a result, the pilot chamber (C6) of the
vacuum relief valve is in negative, receiver tank pressure opens the vacuum relief valve. When the
vacuum valve opened, supplies a part of compressed air to the air-end.

11
 1-14 1-15 1-18 1-19 1-21 1-72
P2
4. When the receiver tank pressure reaches
P1
0.32MPa, the pressure switch PS-TP (1-72)
ENR1
will be turned on and make its contacts
ENR0 TPL
close.The relay TPL will be energized,
causing relay contacts (1-19) to open. This
4-55 cuts current flow to the timer TE, the
250
compressor maintains a condition of Fig. 14
203 210 for 70 seconds.
TPL
POS Contacts close
207 R at 0.32MPa
G

PS
ENR0 ENR1 TE T2 UT -TP

NC Set: 80sec.
Engine Running Signal
Engine Starting Signal

Compressor Starting
Low Pressure Signal

Pressure Switch for

Receiver Tank
Unload Cut-off
Alternator

Fig.15

PC1
1-19 1-72 1-39
5. If receiver tank pressure does not reach
P2 0.32MPa, the pressure switch contact (1-72)
remains open and the contacts of the relay
TPL (1-19) remains closed, current keeps
flowing to the timer TE.
TPL

(TQO'04 6. If set time of the timer TE has passed

250 (80sec.),the timer contacts (1-39) will close,
1 31 32
causing current from engine ECM to flow to
27 E.C.M ground. This lets the engine shuts off.
219
TPL
Contacts Contacts close
remain open after 80sec.

PS
TE -TP TE

Set: 80sec.
Engine Shut-off Signal
Low Pressure Signal

Pressure Switch for

Receiver Tank

Fig.16

12
‫ع‬Start compressing

1-21 3-27 3-28

P7 1. When set time of the timer UT (1-21) has passed

Contacts open (80sec.), timer contacts (3-27,28) will open. This
P2
after 80sec.
cuts the current flow to the solenoid valve
UL1,UL2 coils and the solenoid valves stop
ENR1 UT UT
operating (Fig.17).

720 720 2. W h e n t h e s o l e n o i d v a l v e s U L 1 , U L 2 s t o p
operating(closed), compressed air applied to the
210 unloader regulator flows to the air-end through
the orifices (Fig.18).

3. The butterfly valve slowly opens by the spring

force of the unloader regulator, the compressor
UT starts compressing. When the compressor starts
SOL SOL compressing, pressure in the C6 port is in
-UL1 -UL2
positive, the vacuum relief valve will close.
NC
Air Pressure Change-over

Set: 80sec.
Compressor Starting

Fig.17

AUTO-RELIEF
VALVE (1)
VACUUM RELIEF
VALVE
Ǿ
AUTO-RELIEF
VALVE (2)

2562
51.7. Ǿ

51.7.

Solenoid valves
25#. UL1/UL2 goes off

/2C
5.58 Ǿ
Ǿ

UNLOADER
REGULATOR
OPEN
ORIFICE
Ǿ %

% %
%
.

%
%

%

RECEIVER TANK
COMPRESSOR

Fig.18

13
 ‫ع‬Low pressure unload condition

Ǿ
MANIFOLD (B)
Ǿ

VACUUM RELIEF
VALVE
Ǿ
51..%

2562 MANIFOLD (D) LOW PRESSURE

REGULATOR
51.7. 51.7. Ǿ /2C
/2C
Ǿ Ǿ

PRESSURE MANIFOLD (A)

To AIR VALVE
CONTROL
25#. VALVE

/2C /2C
Ǿ

5.58
Ǿ

MANIFOLD (C)

Ǿ

9#:
UNLOADER
CLOSED
REGULATOR

Ǿ %
%
%
%

.

%
%

%
RECEIVER TANK
COMPRESSOR

Fig.19

1. When the compressor starts compressing, receiver tank pressure will increase and open the pressure
control valve (0.98MPa). As a result, compressed air flows to the air valve. If the air valve opens at this
point, compressed air flows to the DTH hammer and the hammer starts operating.

2. When the receiver tank pressure increases further, it opens the low pressure regulator (1.35MPa). As
the solenoid valves LC has been energized since the key switch was turned on, compressed air flows
to the unloader regulator through the solenoid valve SV, the unloader regulator throttles intake air
volume by closing the butterfly valve. As a result, the receiver tank maintains pressure at 1.35MPa.

3. When the butterfly valve closed, air-end is in negative, causing the vacuum relief valve to open, and
supplies a part of compressed air to the air-end.

14
‫ع‬Low air flushing
Ǿ
MANIFOLD (B)

Ǿ
From port C7

From port C6 AUTO-RELIEF

VALVE (1)
VACUUM
RELIEF To port C4 51..%
VALVE Ǿ

2562 LOW
PRESSURE
MANIFOLD (D) REGULATOR
Ǿ /2C /2C
51.7. 51.7.
Ǿ Ǿ

MANIFOLD (A)
To D.T.H hammer PRESSURE
CONTROL
‫ޓ‬ VALVE
Solenoid valve
A1 goes on /2C

/2C
From Hyd. line Ǿ
P.M.V port SP1

51.#

AIR VALVE

9#:
Ǿ
UNLOADER
OPEN REGULATOR

Ǿ %
% %
%
. To pilot chamber of
vacuum relief valve

%
%
RECEIVER TANK
%

To Auto-relief COMPRESSOR
valve (1)

Fig.20

1. When the flushing & dust collector lever switch is in low air flushing position, the solenoid valve A1 will
be energized. Pressure oil from hydraulic circuits works the air valve to open and supplies
compressed air to the D.T.H hammer.

2. Once the air valve opened, the low pressure regulator will close because the receiver tank pressure
drops instantly. As a result, compressed air applied to the unloader regulator flows to the air-end.

3. The butterfly valve slowly opens by the spring force of the unloader regulator, the compressor starts
compressing. The receiver tank pressure will increase again, and keeps compressing until it maintains
set pressure of the low pressure regulator (1.35MPa).

15
 ‫ع‬High air flushing
Ǿ
MANIFOLD (B)

Ǿ
From port C7

From port C6 AUTO-RELIEF Solenoid valve

VALVE (1) LC goes off
VACUUM
RELIEF
VALVE Ǿ
51..%

HIGH
2562
PRESSURE
MANIFOLD (D) REGULATOR

51.7. 51.7. Ǿ /2C /2C

Ǿ Ǿ

MANIFOLD (A)
To D.T.H hammer PRESSURE
CONTROL
‫ޓ‬ VALVE
Solenoid valve
A1 goes on /2C

/2C
From Hyd. line Ǿ
P.M.V port SP1

51.#

AIR VALVE

9#:
Ǿ
UNLOADER
OPEN REGULATOR

Ǿ %
% %
%
. To pilot chamber of
vacuum relief valve

%
%
RECEIVER TANK
%

To Auto-relief COMPRESSOR
valve (1) OIL
CONTROL
VALVE

Fig.21

1. When the flushing & dust collector lever switch is in high air flushing position, the solenoid valve LC
will be de-energized(closed). As a result, compressed air applied to the unloader regulator flows to the
air-end.

2. The butterfly valve slowly opens by the spring force of the unloader regulator, the compressor starts
compressing. The receiver tank pressure will increase again, and keeps compressing until it maintains
set pressure of the high pressure regulator (2.4MPa).

3. When the high pressure regulator opened, compressed air flows to the pilot chamber of the oil control
valve. The spool of the oil control valve throttles passage of oil and decreases volume of oilflow to the
air-end.

16
‫ع‬Stopping engine

AUTO-RELIEF Ǿ
MANIFOLD (B)
VALVE (1) CHECK VALVE
Ǿ

VACUUM
RELIEF
VALVE
Ǿ
51..%

2562 MANIFOLD (D)

51.7. 51.7. Ǿ /2C /2C

Ǿ Ǿ

PRESSURE MANIFOLD (A)

To Air valve
CONTROL
25#. VALVE

/2C /2C
Ǿ

5.58
Ǿ

MANIFOLD (C)

Ǿ

9#:
UNLOADER
CLOSED
REGULATOR

Ǿ %
%
%
%

.

%
%

%
RECEIVER TANK
COMPRESSOR

OIL CHECK
VALVE

Fig.22 Immediately engine stop

1. When stopped the engine, discharge pressure (C7) drops, causing the auto-relief valve (1) to open,
the receiver tank pressure is released to the atmosphere. A part of pressure flows to the check valve,
works the unloader regulator and makes the butterfly valve fully close. This prevents oil from blowing
back to the air cleaner. The auto-relief valve (2) remains closed because receiver tank pressure is
applied to the its pilot chamber.

2. Since there is no pressure at C7 port, the oil check valve closes and stops oil circulation.

17
 AUTO-RELIEF Ǿ
MANIFOLD (B)
VALVE (1)
Ǿ

VACUUM
RELIEF
VALVE
Ǿ
51..%

2562 MANIFOLD (D)

51.7. 51.7. Ǿ /2C /2C

Ǿ Ǿ

PRESSURE MANIFOLD (A)

To Air valve CONTROL
VALVE
25#.
/2C /2C
Ǿ

5.58
Ǿ

MANIFOLD (C)

Ǿ UNLOADER

9#:
CLOSED㸢OPEN
REGULATOR

Ǿ %
%
%
%

.

%
%

%

RECEIVER TANK
COMPRESSOR

Fig.23 Auto-relief valve (2) operated

3. As receiver tank pressure decrease, the pressure control valve closes. The auto-relief valve (2) will
open to release pressure in the piping by the differential pressure of the receiver tank pressure and
outlet pressure of the pressure control valve.

4. When the system pressure is completely released, the butterfly valve will fully open by the spring
force of the unloader regulator.

18
 Down-the-Hole Drill

DCR20
Pneumatic System
Compressor Control Circuits

Published：Oct. 2010
Revised ：Jul. 2011
Feb. 2012
May. 2012

Furukawa Rock Drill Co, Ltd.

All rights reserved
Address: 5- 3, 1-chome, Nihonbashimuromachi, Chuoku,
Tokyo, 103 - 0027, Japan.

Phone: 81-3-3231-6982
Fax: 81-3-3231-6993