Carlson Quarryman Pro User manual

Quarryman Pro manual H-5915-8503-03-A June 2018
Quarryman Pro
ruggedised laser scanner
user manual

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Contents
1Customer information.............................................................................................................................................................................5
1.1 Dear customer .............................................................................................................................................................................5
1.2 User manual ................................................................................................................................................................................5
2Introduction............................................................................................................................................................................................6
2.1 System overview..........................................................................................................................................................................6
2.2 Blast design package...................................................................................................................................................................6
3Laser safety...........................................................................................................................................................................................8
3.1 Quarryman Pro laser module with red dot pointer ........................................................................................................................8
4Equipment description .........................................................................................................................................................................10
4.1 The Quarryman Pro...................................................................................................................................................................10
4.2 Control Display Unit (CDU) ........................................................................................................................................................11
4.3 Laser module.............................................................................................................................................................................13
4.4 Telescope..................................................................................................................................................................................14
4.5 Yoke ..........................................................................................................................................................................................14
4.6 Carrying handle with GPS mount...............................................................................................................................................15
4.7 Tribrach .....................................................................................................................................................................................16
4.8 Battery pack...............................................................................................................................................................................17
4.9 Alternative power connections ...................................................................................................................................................19
4.10 USB drives.................................................................................................................................................................................20
4.11 Tripod ........................................................................................................................................................................................22
4.12 Transit case...............................................................................................................................................................................22
4.13 Carlson USB drive .....................................................................................................................................................................23
4.14 Quarryman Viewer software.......................................................................................................................................................24
5Maintenance and care of the Quarryman Pro.......................................................................................................................................25
5.1 General......................................................................................................................................................................................25
5.2 In Use........................................................................................................................................................................................25
5.3 Cleaning the Quarryman Pro......................................................................................................................................................25
5.4 Storage and transportation.........................................................................................................................................................26
6Using the Quarryman Pro ....................................................................................................................................................................27
6.1 Data files....................................................................................................................................................................................27
6.2 Startup.......................................................................................................................................................................................27
6.3 Main menu.................................................................................................................................................................................30
6.4 Point and shoot mode................................................................................................................................................................31

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6.5 FastScan mode..........................................................................................................................................................................33
6.6 AutoFix mode.............................................................................................................................................................................36
6.7 Saved settings...........................................................................................................................................................................36
6.8 Date and time settings ...............................................................................................................................................................37
7Operational guidelines .........................................................................................................................................................................39
7.1 System limitations......................................................................................................................................................................39
7.2 Instrument heights and target heights ........................................................................................................................................39
7.3 Notes on FastScan options........................................................................................................................................................41
7.4 Last-hit mode.............................................................................................................................................................................45
8Typical operating sequence.................................................................................................................................................................46
8.1 Positioning the Quarryman Pro..................................................................................................................................................46
8.2 Setting up the Quarryman Pro....................................................................................................................................................46
8.3 Switching on and starting the survey..........................................................................................................................................47
8.4 Resection observations..............................................................................................................................................................47
8.5 Toe and crest observations........................................................................................................................................................48
8.6 Shooting the hole markers.........................................................................................................................................................48
8.7 Scanning the face......................................................................................................................................................................48
8.8 Scanning....................................................................................................................................................................................49
8.9 Completing the survey ...............................................................................................................................................................49
9Quarryman Pro troubleshootingguide ..................................................................................................................................................50
9.1 Diagnosis of some common issues............................................................................................................................................50
9.2 Other faults................................................................................................................................................................................52
10 Quarryman Pro Specifications..............................................................................................................................................................53
11 Product information..............................................................................................................................................................................55

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1 Customer information
1.1 Dear customer
The Quarryman Pro system is designed to be easy to operate. However, we would ask you to take the time to
carefully work through these operating instructions before using the instrument and to keep the manual with the
instrument at all times.
If your system requires servicing or calibration, or if there are questions arising beyond the scope of this manual,
contact Carlson or your local Carlson representative. Visit our website – www.carlsonsw.com – for contact details.
To ensure best service, please make a note of your equipment’s serial number, which can be found on the upper
surface of the yoke of the instrument.
1.2 User manual
It is important that you read this manual carefully before using the instrument.
There are two manuals available with the Quarryman Pro system:
1. This Quarryman Pro hardware manual, provided on the supplied USB drive;
2. A Quarryman Viewer software manual, provided on the supplied USB drive.
This hardware manual describes the Quarryman Pro and all accessories supplied with a standard system.
Section 8 gives a brief overview of a typical operation. Some troubleshooting tips are offered in section 9, which
address some of the most common problems and questions that arise from users of the Quarryman Pro.
This manual has been compiled with care. However, should you discover any errors, we would be grateful if you
could contact Carlson directly.
Reproduction in whole or in part, including utilisation in machines capable of reproduction or retrieval, without the
express written permission of Carlson is prohibited. Reverse engineering is also prohibited.
The information in this document is subject to change without notice.

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2 Introduction
2.1 System overview
The Quarryman Pro is a field instrument which combines reflectorless laser ‘point and shoot’ measurement
technology with high-speed automatic scanning. The unit can be used for conventional total station survey methods
as well as 3D laser scanning. Complete scenes and objects in view at ranges of up to 750 m can be surveyed.
The instrument employs the ‘time-of-flight’ laser measurement technique to measure ranges to rock faces and other
objects without the need to place reflectors on the target. This allows accurate measurements to be made of
inaccessible points such as quarry faces and stockpiles.
Versions of the Quarryman have been used in the field for over 30 years. This experience has ensured that the
instrument has been developed very specifically for its intended applications. It is designed to be very simple to use
and is capable of operating in the harshest environments.
Selective use of the FastScan feature enables single or multiple high-definition scans to take place, highlighting
rock features and anomalies.
The Quarryman Pro will observe 250 points per second, or up to 900,000 points per hour.
Quarryman Viewer software is supplied with the Quarryman Pro. This can be used to process the survey, and then
to edit, view and export the data. Many third-party packages will also take in data directly from the Quarryman Pro
for specialist profiling and volumetric applications.
2.2 Blast design package
Carlson is able to provide a complete ‘blast design’ package to help quarry operators optimize their fragmentation
Figure 1 The Quarryman Pro

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operations.
The Quarryman Pro produces a detailed scan of the rock face to be blasted. The proposed positions of the borehole
collars can also be positioned by the Quarryman or, alternatively, a Carlson GPS system can be used for this
purpose.
Blast design software can then be used to design the blast by adjusting the proposed hole positions and parameters.
The resulting blast design can then be delivered to the driller to guide their drilling operations. Once drilling is
complete the Boretrak – Carlson’s borehole-deviation survey system – is used to audit the drilling by providing a
survey of the deviation of each hole.
Final burden calculations and hole reports can then be made in the blast design software, enabling the quarry
operators to plan the loading of their holes and the pattern of the blast.
Using a blast design system in this way has been proven to help quarry operators significantly improve the safety
and efficiency of their fragmentation processes.

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3 Laser safety
The Quarryman Pro is supplied with two internal laser modules: the laser range finder, and a targeting red dot laser
pointer. Refer to the relevant section below for eye safety classification and recommendations.
3.1 Quarryman Pro laser module with red dot pointer
The Quarryman Pro instrument is classified as a Class 2 laser product and fully complies with the British and
European standards BS EN 60825-1:2014. The following mandatory labels are permanently fixed, legible and
clearly visible upon the top base of the yoke, facing the user during operation, maintenance and service:
The optical specification of the embedded laser modules are described as follows:
Infrared laser module
Type InGaAs laser diode
Wavelength (typ) 905 nm
Operation Pulsed
Max energy per pulse 675 µJ
Pulse length (typ) 16 ns
Pulse frequency 2 kHz
Visible laser module
Type InGaAsP laser diode
Wavelength (typ) 650 nm
Operation Continuous wave (CW)
Maximum power < 0.6 mW
WARNING: invisible and visiblelaser radiation.Do not stare into the beamor direct it into the eyes of others.
Do not view directly with optical instruments, e.g. binoculars, theodolite or telescope.
CAUTION: use of controls or adjustments or performance of procedures other that those specified herein
may result in hazardous radiation exposure.
WARNING: opening the protective housing may result in exposure to Class
3B radiation.
The laser safety labels are located either on the underside of the laser module or on the right-hand side of the laser
yoke facing the user.

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Only qualified and trained persons should be assigned to operate the Quarryman Pro. When not in use, the laser
should be stored in a location where unauthorized personnel cannot gain access.
We recommend that the instrument is not directly pointed at people’s eyes, especially if they are using optical
instruments. Do not unnecessarily look into the transmitter lens of the Quarryman Pro laser scanner.
Eye protection, designed to provide adequate protection against specific laser wavelengths (905 nm typically),
should be used in all hazard areas. Any exceptions should only be undertaken with the approval of the laser safety
officer. All laser protective eyewear shall be clearly labelled with information adequate to ensure proper choice with
the particular laser. For the Quarryman Pro instrument, the recommended CE marked laser eyewear shall be
marked as “R 905 L1”as specified to EN 207, or equivalent. Note that protection shall be afforded to infrared laser
radiation, and not the visible laser radiation. The visible laser is however Class 2 when operated by itself and as
such is safe to use without eyewear (unless deliberately stared at).

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4 Equipment description
The sections below describe each individual element of a standard Quarryman Pro system.
4.1 The Quarryman Pro
The Quarryman Pro instrument incorporates a laser module held between two pivots within a yoke. The laser
module houses the optical and electronic components that allow distance measurements to be recorded to
reflectorless targets up to 750 m from the instrument. The laser module rotates vertically within the yoke.
The yoke itself contains the vertical motor which drives the movement of the laser modulebetween the pillars of the
yoke. It also houses the vertical encoder which measures the angle through which the laser is rotated.
The horizontal housing contains the horizontal motor which drives the rotational movement of the yoke. It also
houses the horizontal encoder which measures the angle through which the yoke is rotated.
The combination of the two axes of rotation gives the Quarryman Pro a view that encompasses 360° horizontal and
135° vertical rotations. The yoke itself prevents the laser from viewing a 90° sector of the vertical rotational axis
looking down to the ground beneath the instrument.
Laser module
Telescope
System ‘power
on’ indicator light
Levelling bubble
Yoke
USB port
Horizontal
housing
Tribrach
Power
connector
Carrying handle
with GPS mount
Figure 2 Component parts of the Quarryman Pro

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Both motors are protected with clutches. This means that if the unit is rotated by hand or prevented
from moving by an obstruction, the motors will not be damaged. It is advisable, however, to minimise
any manual movement of the unit and to keep the instrument away from potential obstructions so the
motors may turn freely. Nevertheless, the possibility of finger or clothing entrapment exists. Users
should not obstruct the operation of the motors or allow clothing to come into contact with the device.
4.2 Control Display Unit (CDU)
The CDU allows you to control the Quarryman Pro: to input data and commands and to view the operation and
status of the unit. The CDU is integrated into the yoke. It incorporates a keypad and screen.
NOTE: The memoryin the CDU is protected by a small coin battery, which in normal use should last 10 years before
requiring replacement. The battery ensures that the time and date areretained. If this battery needs replacing, this
must be carried out by an engineer at a Carlson-approved service centre.
The 3.5 inch screen is sun-readable, and has a 320 × 240 resolution display.
The keypad has 17 buttons, some of which have a dual use or can be used in conjunction with other buttons in a
sequence of button presses.
All multi-button combinations result in feedback (e.g. a dialog box or change of screen) to confirm the appropriate
action has been taken, so the buttons should be pressed until the feedback is registered.
4.2.1 Primary button functions
Speed up / speed down
Fire
Function
Scroll
Figure 3 Control Display Unit (CDU)

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Enter
Home
Numerals
4.2.2 Secondary button functions
Power on
FastScan pause / resume
FastScan abort
Motorised movement - left
Motorised movement - right
Motorised movement – up
Motorised movement - down
4.2.3 Battery selection
To use a lead acid battery
hold for 5 seconds during power up
Toggle between lead acid /
lithium ion batteries
+
from the main menu

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4.2.4 Data entry
Confirm values and continue
Move the cursor to the left
Move the cursor upwards
Move the cursor forwards
4.2.5 Quick-start quide
A sticker showing the most common buttons required during a survey is displayed on the flat of the yoke.
4.3 Laser module
The Quarryman Pro laser has a 750 m reflectorless range.
The minimum calibrated range of the laser is 10 m.
The two 50 mm lenses within the laser module are the transmitting and receiving optics. It is through these optics
that the infrared measuring laser is fired, and its reflected light is then received back into the instrument.
A third, smaller window protects the visible red dot pointer laser which can be turned on to assist aiming the
Quarryman Pro in low light conditions.
The laser module incorporates a rifle-style telescope that is used for aiming the laser.
Figure 4 Quickstart guide

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4.4 Telescope
The sighting telescope is mounted on the laser module. The telescope is designed to be used with a separation
between the eye and the eyepiece. This allows much easier operation of the system when operating over prolonged
periods.
The magnification is ×1.5 – 4. This is adjustable using the central zoom ring. The focus ring is on the end of the
telescope and can be adjusted to sharpen the image.
The telescope is aligned to be coincident with the laser beam at the unit’s maximum operating range. This means
that there is effectively a vertical offset between the centre of the cross hairs and the scanning laser of up to 60 mm
for near-field targets. This offset will generally only be noticeable at very short ranges.
WARNING: do not look through the telescope while using the laser pointer.
4.5 Yoke
The laser module is mounted between the pillars of the yoke. The yoke itself is mounted on the horizontal housing.
Encoders in the yoke and horizontal housing provide vertical and horizontal angular measurements respectively.
Angles are measured to one hundredth of a degree.
When mounted in the yoke, the laser has movement through −55° (below horizontal) to +90° (above horizontal) in
the vertical. The handle will restrict ranging at upper vertical angles but can be removed if required with a 6 mm hex
key.
Motorised movement of the yoke – and the laser module held within it – is controlled via the keypad. There are four
direction buttons on the right-hand side of the display: 2 = up, 4 = left, 6 = right, 8 = down. On pressing each button,
the motor will operate at the speed that has been set with the SPEED UP / SPEED DOWN buttons on the left of the
keypad. The speed buttons can be used at the same time that the unit is being moved. The default speed is the
slowest possible speed which is most commonly used for fine aiming.
Clutches also allow the system to be moved manually. Large movements of the laser module should be carried out
manually, whilst finer aiming can be achieved more precisely with the motorised controls.
Transmitting
optics
Red dot
pointer
Receiving
optics
Telescope
Figure 5 Quarryman Pro laser module

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A level bubble is installed on the crossbar of the yoke to allow accurate levelling of the Quarryman Pro. This can be
achieved by varying the length of the tripod legs, and then by adjusting the foot-screws on the tribrach.
4.6 Carrying handle with GPS mount
While the Quarryman Pro is out of its transit case, use the carrying handle to transport the instrument around a site.
If necessary, use a 6 mm hex key to remove the carrying handle. This will allow the laser an unrestricted view
vertically upwards. This may be required if, for example, you are scanning an underground chamber and require a
complete view of the roof above the instrument.
The carrying handle incorporates a 5/8 inch thread. This can be used when you need to establishthe position of the
Quarryman unit using a GPS system. Use the supplied 5/8 inch male-to-male adaptor to mount a GPS antenna to
the handle.
The vertical distance from the embossed cross on the side panel to the top of the handle is 141 mm.
The height of the knurled centre of the 5/8 inch male-to-male adaptor is 8 mm.
Thus, when mounting a GPS antenna on the handle using the 5/8 inch male-to-male adaptor supplied, there will be
a total vertical offset of 149 mm from the embossed cross on the side panel to the base of the GPS antenna.
Figure 6 Carrying handle
Figure 7 5/8 in male to male adaptor loose and on handle

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4.7 Tribrach
The yoke is mounted in a tribrach. The three mounting feet in the base of the yoke unit fit into the corresponding
holes in the tribrach and a latch holds the Quarryman Pro in place. The tribrach allows the system to be mounted
on a tripod with standard 5/8 inch thread. Use the tribrach’s foot-screws to level the instrument, with reference to
the levelling bubble on the yoke.
A circular bubble on the tribrach can be used for rough levelling of the tripod and tribrach beforethe Quarryman Pro
itself is attached. However, always use the bubble on the yoke of the Quarryman Pro for accurate levelling of the
instrument before starting a survey.
The tribrach incorporates an optical plummet which is required if the Quarryman Pro needs to be set up over a fixed
survey station.
Figure 8 Dimensions from embossed cross on side panel to GPS mount point
Offset to top of
carrying handle:
141 mm
Offset to top of knurled
centre of 5/8 inch
male-to-male adaptor:
149 mm
Figure 9 Tribrach

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4.8 Battery pack
The Quarryman Pro is supplied with a dedicated 14.4 V dc lithium-ion battery pack. The battery pack is rated to 6.8
Ah, and will allow continuous scanning operation for at least 3.5 hours before recharging. This time will reduce at
cold temperatures: 3 hours’ operation would be expected at -20° C.
The battery pack incorporates a bayonet connector with four pins.
This connector will accept the main Quarryman Pro power cable which runs directly from the instrument.
Push the connector on the power cable onto the battery connector and turn it clockwise to lock it in place. Turn the
connector anti-clockwise and pull to disconnect.
The other end of the power cable is a silver lemo connector. Match the red dot on this connector to the corresponding
red dot on the power connector on the side of the Quarryman Pro. Push the lemo connector into the Quarryman
Pro until it clicks securely in place.
Figure 10 Battery pack
Figure 11 Power cable

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The battery pack has a mounting bracket which allows it to be hooked onto a tripod.
A separate battery charger is supplied, which plugs directly into the mains and connects to the battery pack through
the 4-pin connector.
Only the supplied battery charger should be used to charge the Quarryman Pro battery. A fully discharged battery
requires around six hours to fully recharge from the mains supply. The battery charger is supplied with a selection
of plug types to fit mains sockets around the world. An LED on the charger will show a flashing green light while
charging and a solid green light when the battery is fully charged. A flashing red light is shown if the battery charger
develops a fault.
Figure 12 Quarryman Pro connected to the battery pack
Figure 13 Battery charger

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When the lithium-ion battery drops beneath 12.5 V dc, the Quarryman Pro will carry out a controlled shut-down due
to low power.
All batteries contain highly reactive, poisonous and corrosive chemicals, which are hazardous if
released due to physical damage. Should the battery or battery charger approach end-of-life, become
non-functional or damaged, stop using it and source a replacement unit from a Carlson-approved
source.
4.9 Alternative power connections
In addition to the lithium-ion battery pack, the Quarryman Pro may also be powered from a 12 V dc battery using
the blue cable supplied. This cable incorporates two crocodile clips which connect to the positive (red) and negative
(black) terminals of the battery. The minimum requirement for a lead acid battery is 12 V, 7 Ah, 84 Wh. Larger
batteries can also be used.
The Quarryman Pro will also run with an old-style lead acid battery (part number A-5914-0222). However, in this
case, the old power cable (part number A-5915-0200) and the old battery charger (part number A-5914-0223) must
be used in conjunction with the old battery, as the connectors on the new equipment are slightly different. The lemo
power connector on the Quarryman Pro itself has not changed.
Figure 15 Old-style lead acid battery pack
Figure 14 Crocodile clip DC cable (left) - attached to a 12 V battery (right)

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By default, the Quarryman Pro is connected to the standard lithium-ion battery supplied. If a lead acid battery is
used instead, whether with the blue crocodile clip cable or the main power cable, you will need to press the 5button
on the keypad for three seconds when powering the Quarryman Pro ON. Alternatively, from the main menu, press
the FUNCTION key and 5key together to toggle the battery selection between lead acid and lithium-ion.
It is necessary to carry out this procedure because of the different voltages and discharge profiles of lithium-ion and
lead acid batteries. If you do not identify the battery as lead acid, the Quarryman Pro will assume that it is connected
to a discharged lithium-ion battery. In this case, very soon after it is turned on, the Quarryman Pro will display a low
battery warning and carry out a controlled shut-down.
The battery type will be displayed on the start-up splash screen. It will also be displayed on the battery indicator in
the status bar as either Pb (lead acid) or Li (lithium-ion).
If a lead acid battery is being used at a voltage of less than 10.8 V dc, the Quarryman Pro will carry out a controlled
shut-down due to low power.
Any voltage source connected to the Quarryman Pro must be within the specified voltage range. This
includes car batteries as an acceptable stand-alone power source but does not include a car battery
connected to a powered vehicle, or a dc power generator.
4.10 USB drives
Three USB drives are supplied with the Quarryman Pro. During all operations with the Quarryman Pro, data is
stored in a USB drive inserted into the instrument.
The USB drives fit into the USB port on the side of the Quarryman Pro.
The USB port is sealed and waterproof. A rubber plug with lanyard is connected to the Quarryman Pro and can be
used to physically protect the USB drive when no USB drive is connected to the unit.
Figure 16 Charge indicators for lead acid & lithium-ion batteries
Figure 17 USB drive attached to the Quarryman Pro