Hohner CHM Series User manual

Hohner Automation Ltd. (UK)
Hohner Corporation (Canada)
CHM-xxx Series Geolograph / Air Line Retriever (Chameleon)
Operation and Maintenance Manual
WARNING
Please read this manual completely before installing and
using this device. Keep the manual in a safe location for
future reference. The Geolograph is a passive device used for
feedback. Not for positional safety.
This device conforms to the Machinery Directive (2006/42/EC)
and the ATEX directive (EN13463-1:2009 and EN13463-5:2011)
Zone 1, II 2 G c, Ex IIB T3/T4 Gb (Tamb = +1C to +40C)
In order to maximize the life cycle of our Geolograph, please follow the
recommended instructions for maintenance, operation and safety.
Thank you for purchasing the Geolograph / Air Line Retriever
General Product Use Criteria:
-Ensure the unit is either bolted or welded to a flat surface
and that the product is fully earthed.
-Ensure orientation of telescoping head is in line with the
direction of desired steel cable output
-Functionally rated at temperatures from -20C to + 60C
-Certified for use from +1C to +40C
-Use ONLY compressed air to drive device
-Ensure exposure to drilling fluids is minimized
-Cable is rated to 522 kilos breaking load
-If the cable does snap or break, an internal limiter is set to
minimise the speed.
-Ensure compliance with the ATEX directive and Zoning
requirements if used in a hazardous area
-Encoder certification varies upon model purchased, please
check the encoder certification separately.
-Lifetime of motor is about 20,000 hours (continuous use) at
200rpm.
Complete the following checklist prior to starting
installation in a hazardous area. All actions must
be completed in accordance with ATEX 100a.
-Read device label to ensure device is appropriately labelled
for intended zone use area
-Check site environment for potentially explosive substances
-Check ambient temperature of the site to make sure it’s
within the limits of the device operation
-Ensure the cable path outside the unit minimizes tangling
-Check that the cable paid out from device does not rub on
any surfaces outside the unit (minimize sparks)
-Check that internal parts are moving freely
-Check that the encoder certification and connections are
appropriate for the intended zone of use
-Keep electric equipment away from device as it uses strong
Nb magnets for the brake mechanism

Improper environment, installation and operation can result in injury and/or damage to property.
Qualified personnel must perform all work to assemble, install, operate, maintain and repair Geolograph
Qualified personnel must follow:
-These instructions and the warning and information labels on the Geolograph
-All other start up instructions, circuit diagrams
-The system and wiring specific legal regulations and requirements (typically EN 60079-14 and EN 60079-25)
-The current applicable national and regional specifications regarding explosion protection, safety and accident prevention
-Any work carried out should be done with appropriate safety wear at all times (gloves, hardhat, safety glasses, safety shoes)
CAUTION
The device uses a magnetic brake system. Please be careful when approaching the unit
with electronic devices.

Installation: (parts 1 through 12)
1) First ensure that the Geolograph is either bolted or
welded securely to the machine floor and securely
earthed in an area without vibration, avoiding corrosive
environments and its position is optimally located to
minimise any potential hazards (falling objects / moving
objects / personnel). For versions without FRL covers,
please ensure that the FRL is protected from potential
falling objects (via a suitable cover or similar).
DANGER
Ensure proper care is taken when
lifting and moving the device. Two
large handles at the sides are
provided. Two people are required.
2) Ensure the red shut off valve is closed.
3) Then ensure the regulator valve is closed by turning the
top in the minus direction till it stops. Also ensure oil
level is appropriate, see maintenance section 35
onwards.
4) Then attach your air inlet connector to the female inlet
port (1/2” is standard).
WARNING
Ensure the main air supply is off
before attaching the air inlet
connector.
5) The Encoder type and termination can change - refer to
encoder handbook provided in this manual packet for
detailed safety critical information. An appropriately
certified safety barrier will be required as the encoder
will be certified Intrinsically Safe (Ex ia).
For Junction Box Versions open the top cover (4x M12
hex bolts close the cover) and connect your cable to the
junction box of the unit by threading the cable in from
the side panel, and securely fasten to the Ex e terminals
available (refer to J.B. user manual included for details).
For Connector Versions, connect the mating connector
to the panel mount connector located on the side of the
geolograph and route cable as per the applicable Ex
wiring regulations (Typically BS EN 60079-14)
For Direct Cable Versions, route cable as per the
applicable Ex wiring regulations (Typically BS EN
60079-14)
Encoder has to be installed
following the encoder installation
document in accordance with
hazardous area re
g
ulations.
6) Open the top cover and remove the tape from the drum
to release the cable and thread through approx. 1m out
from the top of the telescope section. Close and secure
the cover with the 4 x M12 hex bolts.
7) Telescope height is fixed, though it can be rotated to
ensure cable exit is inline with travelling block.
8) Turn on the main air supply.
DANGER
Ensure the main air supply does
not exceed 7Bar. It must be clean
dry compressed air (-20C to +80C)*
*Air supply must be dry enough to
avoid ice formation below +2C
9) Open the shut off valve, and then gently and carefully
turn the regulator towards the + sign to allow minimal
pressure to the air motor. This is to ensure there is a
little tension in the cable before pulling the cable out to
attach to the target.
WARNING
Hold on to the end of the cable or
secure it so it does not get drawn
into the device.
10) Draw the cable out and securely attach to the travelling
block or desired point of fixation via pulley(s) to ensure
a straight as possible cable movement tracking the
block. It is imperative you keep the number of bends,
and obstacles to a minimum from the Geolograph to the
target.
11) Once you have ensured that the cable has cleared all
obstacles and does not get in the way of any walk paths
and personnel working areas, and is safely and securely
attached to the desired point of fixation you can adjust
the regulator to the desired BAR rating as per the graph
and table below. A rating of 4 BAR is recommended.
Three versions are available (Option B is standard)
Table 1 Option A Option B Option C
T Class T4 T3 T3
Functional Speed 1.8m/s 2.5m/s 3m/s
Brake S
p
ee
d
2.5m/s 2.5m/s u
p
to 5m/s
12) Device is now ready for use

DANGER
Ensure the rig is not doing any
operations and that the travelling
block is STATIONARY and others
are aware you are working
Do not continue until you are
certain the rig is no longer
operating, and that the rig manager
is aware of what you are doing.
Normal Usage: (parts 13 through 21)
13) The unit requires minimal to no supervision to operate
normally if installation is done correctly. Particularly
ensuring careful clearance of the cable outside the unit.
14) During operation the pneumatic motor will keep tension
on the cable and you will be able to monitor the distance
the travelling block moves up/down.
15) The drum has many cable layers, so each revolution will
have a slightly different linear length. Calibration is
required and is set up per end user systems.
16) The equivalent of this revolution distance to your
travelling block movement depends on the installation
and alignment of cable with the drilling mast.
iCalibration should be done to
ensure correct readings.
DANGER
Improper calibration can cause
incorrect readings relative to the
position of the travelling block,
resulting in possible injury.
17) The pressure gauge can be seen directly on the FRL. It
is good practice to check that the air pressure is at about
4 bar (52 psi) periodically
18) If you would like to use a different maximum speed on
your unit, please adjust the air pressure accordingly as
per the graphs and table shown on the previous page.
19) Also regularly check for any accumulation of dirt and
grime on the unit, if excessive, it is a good idea to keep
it relatively clean and to keep the telescope area clean of
any debris.
CAUTION
Cable moving at speed can cause
serious injury and / or death.
Ensure sufficient clearance
between it and other machinery and
personnel during normal
operations.
Ensure cable paying out from
device is well clear of any obstacles
and that bends, sharp objects or
turns via pulleys or other methods
are minimized.
20) The unit is designed to operate with minimal to no
maintenance, but we are aware that a drilling rig
environment differs between locations, as does the
environment around it. Therefore keeping it clean and
the cable clean helps with the life time. The unit is
designed to minimize tangling and damage inside the
unit, any damage to the cable outside will result in the
cable reeling in at a safe speed and causing no damage
to the internal mechanism.
21) Cleaning the cable as it comes in and out is not required,
though a good wipe with a thick cloth while using
gloves is good practice once a week. Do this by gently
applying a ‘damp’ cloth to the cable (right by the
telescope) while the cable is paying in or out. Be sure to
wear safety gloves and glasses during this operation. It
is advised that restricted access is in place in normal
operation (especially to the top telescope section, where
the cable enters the geolograph via two pulleys).
CAUTION
Take extra precautions when
applying the damp cloth to the cable
during operation as the cable can
have sharp or worn edges and to
avoid an
y
potential static char
g
es.
Failure Mode: (parts 22 through 31)
22) If during operation the cable snaps or brakes, the cable
will automatically reel into the device at a maximum
controlled speed as per table 1 (when set at 4Bar). This
is a safe speed which will minimize the damage and
injury to machines and personnel while it reels in.
23) Most of the failures will be a result of the cable
snapping or getting damaged outside of the unit.
Therefore it is important to have a clear path for the
cable to track the target.
24) If the cable does snap, the drum will continue to turn
until the air shutoff valve is turned off.
CAUTION
It is recommended to wait for the
cable to fully reel back in before
approaching the Geolograph in
such a case, and only then shutting
the air off at the main supply or the
manual shut off valve.
25) Once the drum comes to a complete stop, ensure the
manual valve is truly set to OFF. Turn the regulator in
the direction of the minus sign to fully shut off the air to
the unit. Now the air is ‘twice’ shut off from the device,
and it’s now safe to open the device.
26) Open the device by removing the 4x M12 hex bolts on
corners of the device. Keep them in a safe place.
DANGER
Ensure wear and tear to the cable is
minimized as any fraying or kinks
might cause the cable to snap and
possibly cause damage to the unit
itself and injuries to others. It is
important to monitor the condition
of the cable regularly and replace it
if necessar
y
.

27) Once opened, turn the drum by hand until you find the
loose end of cable. ****if the cable is tangled go to
troubleshoot section****
28) Thread this cable through the pulley bars as per the
following diagrams. Ensure the correct sequence is
used. The drum reels in clock wise in this diagram.
i
The diagram above shows the
orientation of the cable relative to
the drum and telescope.
Regardless of the type, ensure the
cable is threaded between the
pulle
y
s and pulle
y
bars.
DANGER
The sequence to lay the cable has
to be followed exactly as shown.
As the anti-tangle mechanism is
dependent on it. Also ensure the
cable is threaded through between
the pulleys and pulley bars. This is
imperative for the safe functionality
of the unit.
The Geolograph comes with
100/75m of cable. Ensure enough
cable is left after breakage to
continue safe usa
g
e of device.
iThe below diagrams shows the
threading of the cable between the
pulley and the pulley bars
29) Once the cable has been re-threaded, pull it through the
telescope and reattach the cover using the 4x M12
screws.
30) Go to step (2) in the installation manual and follow
instructions.
Encoder Issues: (parts 31 through 36)
31) If the encoder is giving faulty signals or no signals at all,
the quickest solution is to attach a new encoder to the
unit.
32) First ensure that the air supply or shut off valve is
switched off before commencing any work, and that the
encoder is fully disconnected from the barrier (de-
energised).
33) Open the top cover, then junction box (if fitted) and
undo the encoder wires coming from the encoder cable.
Then remove the junction box to get access to the
encoder mounting screws.
34) Refer to the ‘spare encoder’ part number engraved by
the top plate of the Geolograph and contact us with the
information provided for a replacement.
35) Then remove the encoder, which also removes the shaft
holding the pulley. Undo the three encoder pins on the
motor side of the frame. The encoder should now slide
out. To replace a new encoder, follow the steps in
reverse ensuring the pulley is tightly fastened to the
encoder shaft and that the pulley is located centrally and
directly underneath the periscope.
36) Rewire the encoder to the junction box and close the
junction box and then close the top cover.
DANGER
Ensure that both the main air
supply and/or shut off valve are
switched off and that the encoder is
de-energised before commencing
an
y
work.

Maintenance: (parts 37 through 48)
37) OIL LEVEL: Check to see if the oil level in the
lubricator is sufficient before use. The reservoir should
be at least half full. Do not adjust the feed drop rate for
the oil that is pre-set at the factory for ideal conditions.
38) If oil needs refilling, shut down the device (refer to
section 57-59). Then use any mineral oil available
suitable for pneumatic filters to refill the right side
canister and empty out the left side.
39) CLEANING: To clean the cable and inside the unit,
first shut down the device (refer to section 57-59). Then
open the unit (refer to instruction 25-26).
40) You may spray clean water all over the insides of the
unit to remove any excess grime, keeping caution to not
get excessive water into the air exhaust of the air motor.
Externally you can use a ‘damp’ cloth to remove any
dirt or deposits on the FRL and side panels.
i
All items are IP rated inside the
device, be careful to not get water
in to the muffler of the air motor.
The sliding shafts do NOT need oil,
cleanin
g
with water is ideal.
41) NEW CABLE: to add a new reel of cable, first shut
down the device (refer to section 57-59). Then open the
unit (refer to instruction 25-26 and 45).
42) Thread the end of the new cable through the telescope
and through the pulleys (refer to section 27-28).
43) Once it’s all the way through, thread the end through the
hole in the diameter of the drum for it to come out again.
At this point tie or make a loop wide and strong enough
so that it does not come back out.
44) Close the device, and refer to section (6-12 and 45).
45) NEW DRUM: Open the ‘DRUM ACCESS’ panel be
undoing the 4x M10 bolts and removing the ‘R’ clips,
Keep these in a safe place. Take the old drum out and
add a new drum and re-thread the cable as per
instruction (27). Replace the ‘DRUM ACCESS’ panel.
46) COUPLING: The coupling is designed to be
maintenance free, though it is recommended to check it
periodically for wear and tear, replace or contact Hohner
if any significant wear/play is present.
47) BUSHINGS and BEARINGS: The Geolograph uses
two different types of bushings (composite material) and
one bearing (Stainless steel). Please contact Hohner if
for replacements. The bushings and flange bearings are
maintenance free and self-lubricating. The telescope
bearing is maintenance free and is not self-lubricating,
though due to the nature of the application no extra
lubrication is required. The lifetime of the parts are
detailed in the table below:
Paramete
r
Pulley Bush JSM-1622-20
10N 20C 220 rpm 24hr/75% Min 3.4 years
10N 40C 350 r
p
m 24hr/100% Min 1.8
y
ears
Paramete
r
Flange Bearing EFOM-20
19N 20C 220 rpm 24hr/75% Min 3.0 years
19N 40C 350 rpm 24hr/100% Min 1.0 years
Paramete
r
Telesc. Bearin
g
CRFSPN19T
100N 20C 1 rpm 24hr/75% Min 12 years
100N 40C 2 rpm 24hr/100% Min 8 years
48) PNEUMATICS AND MOTOR: The geolograph uses an
ATEX rated Motor and FRL. It is recommended that the muffler
and motor is checked regularly as follows:
1. Remove the sound absorber. 2. Clean the felt filter.
3. Check the air compressor. 4. Listen for changes in the sound of
the motor. If motor sounds smooth, you are finished. If motor
does not sound like it running smoothly, contact Hohner for
further instructions or replacement parts.
49) PERISCOPE: Alternate the cable tension between the
periscope pulleys evenly. After each day rotate the periscope 180
degrees to ensure an even wear and tear of the periscope.

Shutdown: (parts 50 through 56)
50) Reel in as much cable as possible while the end is still
attached to the travelling block
DANGER
Ensure the rig is not doing any
operations and that the travelling
block is STATIONARY and others
are aware you are working.
Do not continue until you are
certain the rig is no longer
operating, and that the rig manager
is aware of what you are doing.
51) Reduce the air pressure going to the motor to zero,
turning the regulator towards the minus sign till it stops.
Also close the manual valve.
52) Unhook the cable from the travelling block and bring it
down to the rig floor and lay it neatly away from
personnel and machinery. Make a large loop at the end
of the cable and hook the loop onto the telescope.
53) Open the manual valve on the device and gradually
increase air pressure until the cable starts slowly reeling
in. Stay by the unit while it is slowly reeling in.
DANGER
Ensure the pressure to pneumatic
motor is low enough to keep a
steady slow reeling in speed from
the Geolograph.
CAUTION
Moving cable during this process,
please be careful and wear safety
gloves and glasses. Keep hands
near the shut off valve in case of
emer
g
enc
y
.
54) Let it reel all the way in until the cable tightens around
the telescope, thus stopping the movement.
55) Put some tape across the drum and cable to secure it.
56) Turn the air fully off at the regulator and shut-off valve
and then disconnect air hose.
DANGER
Do not disconnect the air inlet
connector as the line might still be
pressurized. Ensure it is no longer
pressurized before doing so.
Emergency Shut Down
57) Turn off the manual air valve on the unit
58) Turn off the main air supply to the unit.
59) Not necessarily in this sequence, but ensure the air
supply is shut off as quickly and safely as possible.
General Technical Data
1) Weight: <50kg
2) Max linear cable speed: See Table 1
3) Material of structure and all side panels: Aluminum
4) Material of main shaft: Stainless Steel
5) Material of main drum: Aluminum
6) Material of sliding shafts: Stainless Steel 316
7) Material of pulleys and related parts: Stainless Steel 316
8) Dimensions L x W x H: 400 x 465 x 315 mm
9) Dimensions Imperial: 15.7” x 18.4” x 12.5”
10) Recommended Air Supply: Between 4 and 7 bar max
11) Lubrication: Gulf Harmony 53, Shell Tellus 33 or equiv
12) Cable is 7x19 core 3.0mm cable with 552 kg break load
Troubleshooting
1) Drum is not turning:
a. Ensure air is on to the device
b. Ensure manual valve is open
c. Ensure regulator set to 4 bar
2) Encoder is not giving signals:
d. Ensure encoder is connected
e. Ensure voltage to encoder is at the correct level
3) Cable is not reeling in
f. Ensure air to motor is on
g. Ensure no obstructions to cable
h. Ensure unit is clean
4) Cable is tangled
i. Shut the unit off (steps 57 to 59)
j. Open the unit (step 26), but keep in mind the
cable is still coming out through the telescope,
so be careful.
k. By hand try to dislodge the cable from
wherever it tangled, it might take some manual
work in turning the drum by hand back and
forth to dislodge the cable. No clear cut
method, it’s time consuming and you have to
be patient. Additionally see section 45 to allow
easier access.
l. Once the cable has been untangled and the
cable has been fully pulled out, gently reel it
back in by following steps 8-9).
m. The device is now ready.
CAUTION
If the unit is well worn, the cable
might have frayed edges, please
use safety gloves to dislodge cable
and replace if necessary.
DANGER
Ensure the rig is not doing any
operations and that the travelling
block is STATIONARY and others
are aware you are working.
Do not continue until you are
certain the rig is no longer
operating, and that the rig manager
is aware of what you are doing.

Ex
p
loded Full Product View and General Bill of Materials

Use the number and description here for re-ordering parts and for spare parts
(only use genuine Hohner parts for replacements)
(depending on what needs replacing, we will send detailed instructions upon request)
1: M12 closing screws 4x To close cove
r
2: Optional cover for FRL 1x from drawing # Covers
–
sheet 1 of 2
3: Telescope assembly 1x from drawing # Telescope Parts
4: Filter/Lubricator/Re
g
ulato
r
/Switch 1/2” kit 1x Nor
g
ren BL64-401
5: Telescope Support 1x SealMaster CRFS-PN19T
6: Customer Connection 1x Either Cable Gland or Connector specified by Custome
r
7: Front Cove
r
1x from drawing # Aluminium Side Plates - sheet 6 of 6
8: Top cove
r
1x from drawing # Aluminium Side Plates - sheet 3 of 6
9: Grommet 1x Grommet to protect Air Line Tube (variable sizes)
10: Air Line Tube 1x section of
p
art number PPU128BL
K
11: Junction Box 1x IP20 rated box (example PL612 Box with M20 cable gland exits)
12: Air Moto
r
1x Air motor GAST 6AMNRV22A
13: Frame 1x set of profiles, see drawing # Profile drawings for KJN
14: Handles 2x Handles for lifting device and 1x (or 2x) handles on drum cove
r
15: Air Line Swivels 2x 90 degree swivels for connecting tubing to motor and FLR P/N 101471248
16: Junction Box Mount 1x from drawin
g
# Aluminium Side Plates - sheet 5 of 6
17: Inside Mechanism Plates 1x from drawing # Aluminium Side Plates - sheets 1 of 6 and 5 of 6
18: Encoder Spacers 3x from drawing # Main Drum Parts - sheet 2 of 5
19: Encode
r
1x Encoder as per customer specification from drawing # System Installation
20: Large Pulley and shaft 1x Main shaft and 1x Large Pulley
21: Coupling 1x Coupling to join motor to main shaft
22 Aluminium disc brake 1x from drawin
g
# Main Drum Parts - sheet 4 of 5
23: Magnet Holde
r
2x from drawing # Main Drum Parts - sheet 5 of 5
24: Magnets for disc brake 2/3 sets of two EP383 Nd magnets for brake mechanism
25: Inside Base Plate 1x from drawing # Aluminium Side Plates - sheet 2 of 6
26: Sliding shafts 4x from drawing # Sliding Shaft Mechanism - sheet 2 of 3
27: Flange Bearing Bushes 3x (or 4x) from Igus EFOM-20
28: Drum Shaft for Geolo
g
ra
p
h 1x from drawin
g
# Main Drum Parts - sheet 3 of 5
29: Pulleys 4x from drawing # Sliding Shaft Mechanism - sheet 3 of 3
30: Bottom Base Plate 1x from drawing # Aluminium Side Plates - sheet 4 of 6
31: Drum Parts 1x from drawing # Main Drum Parts - sheet 1 of 5
32: Pulley guides 10x from drawing # Sliding Shaft Mechanism - sheet 1 of 3
33: External closing plate 1x from drawing # Aluminium Side Plates - sheet 5 of 6
34: Cover for o
p
tional external bearin
g
1x from drawin
g
# Covers - sheet 2 of 2
35: ‘R’ pin clip 4x ‘R’ pin clips to keep bolts from coming off once unit is closed

Certification Requirements, Instructions and ‘X’ Conditions
1) As the encoder type and termination can change, please refer to the installation drawing shipped with
the product (part number specific) for all safety parameters and wiring requirements / specifications. A
suitably certified safety barrier / isolator will also be required as the encoder is intrinsically safe (Ex ia).
2) The fitted encoder is fully isolated, and does not require any special earthing requirements, however it is
recommended to earth the cable screen for EMC purposes at one point only (generally in the safe zone),
and a facility will be available for junction box and connector versions.
3) The equipment may include some areas of non-conducting materials and may generate an ignition-
capable level of electrostatic charges under certain extreme conditions. The user should ensure that the
equipment may not come in contact with fast moving laden air/gas or non-conductive fluids (such as
high-pressure steam) which might cause a build-up of electrostatic charges on non-conducting surfaces.
Steps must also be taken to ensure the equipotential bonding is maintained. Additionally, cleaning of
these areas on the equipment should be done only with a damp cloth.
4) Ensure the Air Regulator Filter (FRL) is protected from any potential impact in final installation if not
already fitted with the Hohner optional guard (part number specific).
5) To avoid electrostatic charging, steps must be taken to ensure that equipotential bonding is maintained
(the chassis is appropriately earthed).
6) Only use clean compressed air with a maximum pressure of 7 Bar.
7) For junction box versions ensure that the lid is fully tightened down after the cable has been fitted.
8) The material composition of the geolograph is predominantly aluminium (anodised and/or powder
coated as standard). The end user should assess its suitability for the area that it is installed.
9) For spares and repairs only use approved parts stated in either this manual or included Motor / FRL
manual. Contact Hohner for further information.