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    Baylor 1

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    Cesar Gamboa

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    © All Rights Reserved
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    ‘Manual No. 165-56380 BAYLOR INSTRUCTION OPERATION AND SERVICE MANUAL FOR MODEL. 56380 « BATTERY CHARGER AND SWITCHOVER UNIT EQUIPMENT FURNISHED BY BAYLOR COMPANY 500 INDUSTRIAL BLVD. SUGAR LAND, TEXAS 77478-2898 PHONE (281) 240-6111 FAX (281) 274-0426 6/98 REVISED BAYLOR NOTICE This document is and contains confidential and trade secret information of the Baylor Company. This Document is loaned for limited purposes only, and remains the property of the Baylor Company. It is to be returned upon request and in all events upon completion of the purpose of the loan. Neither it nor the information it contains may be reproduced, used, or disclosed to persons not having a need to know consistent with the purpose of the loan, without written consent of Baylor Company. ADDRESS COMMENTS TO: BAYLOR COMPANY 500 INDUSTRIAL BLVD. SUGAR LAND, TEXAS 77478-2898 TELEPHONE: (281) 240-6111 FAX: (281) 274-0426 PRINTED INU.S.A. SECTION 1 INTRODUCTION AND DESCRIPTION SCOPE OF MANUAL GENERAL DESCRIPTION SECTION 2 PRESCRIPTION OF OPERATION MAJOR COMPONENTS 2.1.1 BATTERY SWITCHOVER PANEL - P/N 56406 2.1.2 BATTERY CHARGER PANEL (P/N 56032) 2.1.2.1 ALARM CIRCUITS 2.1.2.2 CHARGING PROCEDURE 2.1.2.3 BATTERY CHECKS 2.1.3 DRILL FLOOR EMERGENCY STOP STATION (P/N 53564) SECTION 3 SPECIFICATIONS GENERAL BATTERY CHARGER AND SWITCHOVER UNIT DRILL FLOOR EMERGENCY STOP STATION GENERAL BATTERY CHARGER AND SWITCHOVER UNIT 4.3 4.2.1 MAIN POWER FREQUENCY SELECTION DRILL FLOOR EMERGENCY STOP STATION SECTION 5. OPERATING INSTRUCTIONS OPERATING PROCEDURE 5.1.1 Reset Procedures SECTION 6 MAINTENANCE BATTERY SWITCHOVER PANEL BATTERY CHARGER PANEL 6.2.1 | CURRENT LIMIT CHECK 6.2.2 FLOAT VOLTAGE CHECK 6.2.3 EQUALIZE VOLTAGE CHECK 6.2.4 ALARM CHECKS 6.2.4.1 FIRING BOARD POWER ALARM CHECK 6.2.4.2 HIGH, LOW AND RECTIFIER FAILURE ALARM CHECK 6.2.4.3 GROUND DETECTION ALARM CHECK SECTION 7 PARTS AND SERVICE GENERAL PARTS AND SERVICE RECOMMENDED SPARE PARTS - BATTERY SWITCHOVER PANEL RECOMMENDED SPARE PARTS - BATTERY CHARGER PANEL RECOMMENDED SPARE PARTS - EMERGENCY STOP STATION ii 6-2 6-2 6-2 6-3 6-4 6-4 BAYLOR 1.2 SECTION 1. INTRODUCTION AND DESCRIPTION SCOPE OF MANUAL This manual provides information regarding the installation, operation, troubleshooting and maintenance of the BAYLOR Model 56360 Battery Charger and Switchover Unit. This manual is divided into sections giving a narrative description of the theory of operation, function of controls, operating instructions, maintenance and service, a parts and supplies list, applicable schematics, flow diagrams, and major assembly drawings. Operators are requested to read and thoroughly familiarize themselves with this manual before attempting to operate the equipment. GENERAL DESCRIPTION The Baylor Battery Switchover Unit provides a simple and safe method of interfacing a Brake Control System with a bank of rechargeable batteries and a battery charger used as a source of backup DC power to the Eddy Current Brake. The 56032 Battery Charger is designed to charge the battery bank used for emergency backup power supply to an Eddy Current Brake. The charger consists of a main power transformer, an SCR bridge, a firing board, alarm circuits, and a display panel integrated together in a steel enclosure manufactured to NEMA 12 standards. The system is designed to operate on 50/60 Hz single phase 120/240 Volts AC. Two power ranges are available on the transformer output. Low power range is for charging battery banks of 240 Volts DC or less. The high power 1-1 BAYLOR 1.2 GENERAL DESCRIPTION (Cont! d) range is for charging battery banks of 240 to 325 Volts DC. In all cases voltage output is controlled by the firing board. In addition, the firing board also limits the output current to 5 amps. The alarm circuits installed in the Battery Charger detect high voltage output, low voltage output, SCR failure, firing board loss of power, and DC power output grounded. The Battery Charger contains a second transformer which provides control voltage to the firing board, alarm circuits, and indicator lights on the display panel. An indicator light is provided on the display panel for each of the above mentioned alarm conditions. In addition, the display panel contains voltage = output'_— control potentiometers for float and equalizing operations, as well as panel meters for displaying the voltage and current output of the Battery Charger. A circuit breaker is also mounted in the display panel to provide short circuit protection to the AC input circuits of the Battery Charger. It also functions as the on/off switch. The battery disconnect switch is a heavy duty, two pole, circuit breaker used to manually disconnect the battery bank from the battery transfer unit. The fuse in the battery circuit is sized to protect the battery cables and limit available battery fault current. The disconnect switch is rated for 250 volts DC at 125 amperes. An auxiliary switch is installed to be connected to the battery transfer logic circuitry. 1-2 BAYLOR GENERAL DESCRIPTION (Cont! d) If the switchover panel (DWG 56406) is revision “C” or higher, the following applies. A shunt trip is installed in the battery disconnect, which can be remotely shunt tripped using a contact closure that is rated for 120 vac. It is only used for emergency total shutdown condition. Also included is a timed shunt trip, which senses the battery supply monitor relay (CR1)and the de-energization of C1. When CR1 is energized and C1 is de-energized, the timer (TDR2) starts timing out. The timer has a range that can be adjusted up to 10 minutes. Once timed at the timer’s set point, it shunt trips the battery disconnect. This will prevent the batteries from draining down to a nonrecoverable recharging condition. The recommended set point on the timer is 5 minutes, which should provide adequate time to bring the drawworks load to a stop and set the drill pipe into the slips. As soon as conditions permit, the system can be reset using the reset procedure in Section 5.1.1. BAYLOR SECTION 2 DESCRIPTION OF OPERATION MAJOR COMPONENTS AND THEIR THEORY OF OPERATION BATTERY SWITCHOVER PANEL The 56406 Battery Switchover Panel has been designed to give a maximum of trouble-free operation in the rugged drilling rig environment with a minimum of maintenance required. A magnetic DC contactor is used to connect a bank of rechargeable batteries to the Eddy Current Brake when either one of the following occu: 1. Loss of AC power to the primary Brake Control unit. 2. Upon energizing the Drill Floor Emergency Stop Button, by the Driller. Input AC power to the primary Brake Control unit is monitored by providing an input at fuses F3, F4 and FS from the Brake Control unit 186/240 volt AC power input. Loss of power is sensed by relays MR1, MR2 and MR3. Upon loss of power MR1, MR2 or MR3 is de-energized which allows its contacts 1 and 7 to open, in turn de-energizing normally closed contactor Cl. When contactor Cl closes full battery voltage is applied to the brake and the "BACK UP IN USE" lamps are illuminated on the Unit’s front door and on the Drill Floor Emergency Stop Station. Depressing the Emergency Stop Pushbutton at the Driller's position on the rig floor accomplishes the same function by breaking the path of coil voltage to the contactor C1. BAYLOR 2.1.2 BATTERY SWITCHOVER PANEL (Cont'd) The reader will note, upon examination of the logic and wiring diagrams, that the positive output of the primary SCR unit and the positive terminal of the battery bank are always connected to the positive brake terminal thru steering diodes which isolate the primary Brake Control unit from the battery bank. Upon closure of the DC contactor Cl, the battery bank is effectively in parallel with the primary Brake Control. Therefore regardless of the output voltage level of the primary Brake Control unit the highest voltage present at the point of connection of the steering diode cathode terminals will be present at the brake after the DC contactor closes. After an operation of the transfer unit the system is reset by opening the battery disconnect switch. Disconnecting battery voltage from the unit is sensed by Battery Supply Monitor Relay CR-1, When battery voltage is removed, CR-1 is de-energized which starts the time delay relay TDRI cycle. TDR1 should be set to provide a time delay while the brake field is collapsed thru the free wheeling diode and contactor Cl which is still in the closed position. Upon completion of the time delay, contactor ci is energized (opened) and the "CLOSE DISCONNECT" lamp will be illuminated. Upon closure of the battery disconnect switch, Ri-1 will be energized, which in turn extinguishes the "CLOSE DISCONNECT" lamp and illuminates the "SYSTEM READY" lamp. The system is now ready for use. An isolation transformer is provided in the battery transfer unit to accept a the customer furnished, stable, source of 120/240 VAC power to operate system logic. Be sure and select the correct voltage during installation as an improper voltage setting may damage components. 2-2 BAYLOR 2.1.2 BATTERY CHARGER PANEL - P/N 56032 The 56032 Battery Charger provides a means for charging the battery bank used as emergency backup power for a Baylor Eddy Current Brake. The voltage output of the Battery Charger is adjustable to match the voltage requirements for charging the battery bank. The voltage level is adjusted by moving the float or equalizing voltage controls on the display panel. Float voltage is defined as the voltage level required to maintain the charge of the battery bank. Equalizing voltage is defined as the voltage level necessary to recharge all of the cells in a battery bank to the same volts per cell. A battery bank that has been discharged to a level of 60% to 708 of the rated voltage per cell can be recharged in the equalize mode for 6 hours maximum. This will insure the full charging of all cells in the battery bank. The Battery Bank must be maintained on float charge and should be fully recharged within 24 hours after any discharge. output current is limited to 5 Amps. in either the float or equalize operation. Do not attempt to recharge a battery with an open circuit voltage less than 1.0 volt per cell. Hydration shorts may be present, causing the battery to be non-recoverable. 2.1.2.1 ALARM CIRCUITS Alarm circuits are integrated into the Battery Charger. These alarm circuits detect high voltage output, low voltage output, SCR failure, firing board power failure, and DC output grounded. Alarm conditions are indicated by lights on the display panel. In addition, a dry set of contacts are available for interfacing the general alarm into a customer supplied alarm annunciation system or brake monitor. 2-3 BAYLOR 2.1.2.2 CHARGING PROCEDURE If the battery bank has been engaged to power the Eddy Current Brake, or a new battery bank is being charged for the first time, the following charging procedure should be followed: 1) 2) 3) Carry out the reset procedure for the battery switchover system. Make sure that the battery bank is disconnected from the Eddy Current Brake. With the float/equalize timer switch in the float position read the current and voltage as displayed on the ammeter and voltmeter mounted on the display panel. If the Battery Charger voltage is near the float voltage setting ( Reference SECTION 6 "MAINTENANCE") and the current is less than 2 Amp., leave the Float/Equalize timer switch on the "Float" position. If the ammeter on the display panel indicates that the current is greater than 2 Amp., turn the Float/Equalize timer knob for 6 hour equalize charge. The voltage level indicated by the voltmeter on the display panel should rise and the current, as indicated on the ammeter mounted on the display panel, should increase. If the battery charger is current limited there will not be any increase in voltage or current. After the 6 hour charge time the battery charger voltage will switch back to the "Float" WARNING ! The “Equalize” setting of the Battery Charger is not intended for long term use. If the Battery Charger is left in the “Equalize” setting for a period of time greater than 6 hours, damage to the cells of the battery bank could result. _—————— 2-4 condition. BAYLOR 2.1.2.2 CHARGING PROCEDURE (Cont’d) 4) If the battery bank is not quite fully charged, the Battery Charger will continue to trickle charge the battery bank on the "Float" setting. 2.1.2.3 BATTERY CHECKS Periodic checks of the ammeter and voltmeter on the display panel of the Battery Charger should be performed to insure that the unit is functioning properly. Most battery manufacturers recommend periodic checks of the "Float" voltage of a battery bank on a volts per cell basis. If one battery in the battery bank exhibits “Bloat" voltage readings that are low, it may be necessary to charge the bank at “Equalize" voltage for a period of time to insure that all cells are fully charge. When performing this operation, be sure and follow the battery manufacturers recommendations. (See SECTION 9.) DRILL FLOOR EMERGENCY STOP STATION P/N 53564 The Drill Floor Emergency Stop Station provides the Driller with a means of manually activating the Model 56380 Battery Switchover Unit in emergency situations or for test purposes. The Drill Floor Emergency Stop Station consists of a mushroom head pushbutton and a red lamp installed in an enclosure certified for use in a Class 1, Division 1, Group c & D hazardous area. 2-5 DRILL FLOOR EMERGENCY STOP STATION (Cont/d) When the Driller firmly depresses the large mushroom operator on the pushbutton, the battery switchover unit is activated connecting full battery potential to the Eddy Current Brake Magnet Coils. The red "BACKUP IN USE" is illuminated when the battery switchover unit is activated. GENERAL The Model 56380 is designed and manufactured to meet the special requirements of land and offshore drilling rig service. BATTERY CHARGER AND SHITCHOVER UNIT Battery Bank Voltage (Max.). . . . Battery Rating . 2... sos ss +. 288 volt De see es 40 amp, at 20 min. to 1.75 V.P.c. Brake Control Voltage Sense . ... . . 186/240 volt AC, 3 phase, 50/60 Hz Customer Furnished Supply Feeder . . . 120/240 volt ac, (Battery Charge Panel 20A/10A) 1 phase, (Battery Switchover Panel 10A/5A) 50/60 Hz DC Contactor Rating»... ..... 2... 110 amp DC DC Contactor Coil Volts .......... . 120 volt AC Max. Charger Current ...............5 amp Battery Charger Float Voltage .... . . . 270-272.4 vde Battery Charger Equalize Voltage . . . . . 280-282.4 vde Enclosure Type... 2... 2. ....... . NEMA12 Cable Entry... ......... 2... Top or Bottom DRILL FLOOR EMERGENCY STOP STATION Emergency Stop Pushbutton . . .. 1N.0., 1 N.C. Contact rated at 6 amp, 120 volt AC "BACKUP IN USE" Lamp... . ... . . 120 volt AC, RED Enclosure... 2... 2... Cast aluminum 3-1 SECTION 4 INSTALLATION GENERAL The Battery Charger and Switchover system has two components that require installation: * Battery Charger and Switchover unit * Drill Floor Emergency Stop Station Baylor Drawings 56409, and 56008 detail SCHEMATICS for the system. Also, see SECTION 8 for customer cable detail connections. BATTERY CHARGER AND SWITCHOVER UNIT The Battery Charger and Switchover Unit should be installed in an upright position against a wall or bulkhead using the two mounting channels provided. There should not be any restriction to air flow at the top or bottom and the cabinet should be mounted as far away as possible from any heat producing sources. The cabinet should be installed in @ clean, dry, non-hazardous atmosphere such as the air conditioned SCR house or switchboard room. THE BATTERY CHARGER AND SWITCHOVER UNIT SHOULD NOT BE INSTALLED IN A HAZARDOUS AREA SUCH AS THE DRILL FLOOR Provisions are made for top or bottom cable entry into the enclosure. 4-1 BAYLOR 4.2.1 MAIN POWER FREQUENCY SELECTION If the AC power to the Battery Charger is 50 Hz, insure that the jumper at JU8 is in the 50 Hz position on the firing board. This is accomplished by installing a jumper between points 1 and 2 of JU8. For 60 Hz power the jumper at JU8 should be in the 60 Hz position of the firing board. This is accomplished by installing a jumper between points 2 and 3 of gus. DRILL FLOOR EMERGENCY STOP STATION The Drill Floor Hmergency Stop Station should be installed on the Drill Floor within easy sight and reach of the Driller. Two mounting ears for 1/4 inch bolts are provided at the rear of the enclosure. Mount the enclosure to allow cable entry from the bottom. Always use cable glands or fittings appropriate for hazardous area. 4-2 W ka FP SECTION 5 OPERATING INSTRUCTIONS OPERATING PROCEDURE The Baylor Model 56380 Battery Charger and Switchover Unit provides a means of interfacing a bank of rechargeable batteries, that are used to backup the primary Brake Control System, in the event of an AC power loss or in an emergency. In normal operations the Eddy Current Auxiliary Drawworks Brake is powered by the primary Brake Control unit. The "SYSTEM READY" lamp on the Battery Charger and Switchover Unit front door should be illuminated and the Battery Disconnect Switch should be closed. The battery bank should be charged and ready for use. In the event of a loss of power to the primary Brake Control unit, contactor Cl in the Battery Charger and Switchover Unit will close automatically, connecting the Battery Bank voltage to the Eddy Current Brake magnet coils. At this time the "BACKUP IN USE" lamps, located on the Battery Charger and Switchover Unit front door and on the Emergency Stop Station, will be illuminated. On BRAKE MONITOR SYSTEMS only (Models 1025, 1040, 2025, or 2040) there is a throttle mismatch relay (R3 or K3) if an error is detected, it will open a set of contacts on R3 that breaks the circuit to the coil of Contactor (C1). Contactor (Cl), on the battery switchover panel will de- energized. This connects the battery bank potential to the Eddy Current Brake. Also, at this time the “BACKUP IN USE” lamps, located on the Battery Charger/Switchover Unit and Emergency Stop Station, will be illuminated. : BAYLOR : 5.1 5.1.1 OPERATING PROCEDURE (Cont/d) After the drawworks load has been brought to a stop and the drill pipe is set in the slips, the following reset procedure should be accomplished: RESET PROCEDURE 1. Return AC power to the primary Brake Control unit. 2. Open the battery disconnect switch. 3. After approximately one minute the "CLOSE DISCONNECT" lamp, on the Battery Charger and Switchover Unit, will be illuminated. 4. Close the battery disconnect switch and note that the “SYSTEM READY" lamp has been illuminated. 5. The system is now ready for use. |THE SYSTEM SHOULD BE RESET AS SOON AS SAFE. In the event of a drill floor emergency, the Battery Charger and Switchover Unit can be operated, upon demand, by depressing the emergency stop push-button, located on the drill floor emergency stop station. As soon as conditions permit the system can be reset following the above reset procedure. 5-2 BAYLOR 6.1 SECTION 6 MAINTENANCE BATTERY SWITCHOVER PANEL The Battery Switchover Unit should not require any maintenance other than a periodic inspection for loose terminals and broken or damaged wires. ANY INSPECTION OTHER THAN OPERATIONAL | CHECKS SHOULD BE PERFORMED WITH POWER] REMOVED. On a routine basis the entire system should be tested, to assure correct operation, using the following procedure. 1. Remove AC Power from the primary Brake Control Unit by opening the circuit breaker on the transformer primary. 2. Note that system transfers to battery power. 3. Reset system following procedure in Section 5.1. 4. Operate Emergency Stop Pushbutton on the Drill Floor Emergency Stop Station. 5. Note that system transfers to battery power. 6. Reset system following procedure in Section 5.1. BAYLOR ABOVE TEST SHOULD BE PERFORMED DURING LOGGING OR OTHER OPERATIONS NOT REQUIRING USE OF THE EDDY CURRENT BRAKE, AS ESTING WILL PARTIALLY DISCHARGE BATTERY BANK. ALWAYS NOTIFY DRILLER THAT TESTING IS IN PROGRESS. 6.2 BATTERY CHARGER PANEL The 56032 Battery Charger is simple in design and does not require regular maintenance. It is recommended that the current limit and alarm settings be checked every six months. 6.2.1 CURRENT LIMIT CHECK Step 1 Make sure that the battery bank and AC input power are properly connected to the battery charger. Step 2 The current limit can only be set if the battery it charger is delivering its maximum rate of charge. Adjust potentiometer R11 (counter clockwise lowers the current limit)on the VRCLIP-1 board to limit the maximum current to 5 Amp. 6.2.2 FLOAT VOLTAGE CHECK The float voltage setting can be checked by placing the Float/Equalize timer switch in the "Float" position and reading the voltage from the voltmeter mounted on the display panel. Since most Baylor Brakes utilize either a 240 Volt DC or a 325 Volt DC battery banks, "Float" voltage settings, for these two common battery bank voltage levels, are listed below: BATTERY BANK | FLOAT VOLTAGE VOLTS Dc VOLTS DC @ 75° 325 365 240 272 6-2 BAYLOR 6.2.2 6.2.3 FLOAT VOLTAGE CHECK (Cont'd) If the ambient temperature is not 75°F consult the Battery’s Field Service Manual for recommended float voltage setting, See DWG. #BTD-177. If the "Float" voltage setting is not correct, adjust the "Float" potentiometer mounted on the display panel until the correct voltage is displayed on the voltmeter mounted on the display panel. EQUALIZE VOLTAGE CHECK The "Equalize" voltage setting can be checked by moving the Float/Equalize timer switch off of the "Float" position. This will switch to the "Equalize" position. Read the voltage from the voltmeter mounted on the display panel. Since most Baylor Brakes utilize either a 240 volt DC or a 325 volt DC battery banks, "Equalize" voltage settings for these two common battery bank voltage levels are listed below: -—— eae BATTERY BANK | EQUALIZE VOLTAGE voLTs pc VOLTS DC @ 75°F If the “Equalize" voltage setting is not correct, adjust the "Equalize" potentiometer mounted on the display panel until the correct voltage is displayed on the voltmeter mounted on the display panel. 6-3 The following alarm checks, must be performed with the DC output to the battery charger disconnected from the battery bank. This can be accomplished by removing the two knife switch blocks that are located on the rear wall on the center right side. Caution must be taken because there is still 200 to 290 Volt DC level on both sides of the knife switch blocks while performing these checkouts. 6.2.4.1 Firing Board Power Alarm Check Place Circuit Breaker (CB1) in the “OFF” Position and remove fuse F2. After the fuse has been removed from the fuse holder, turn Circuit Breaker (CB1) to the “on” position. The firing board alarm light should activate, as well as the low voltage, general alarm and rectifier failure alarm lights. Place Circuit Breaker (CB1) in the “OFF” position and replace fuse F2. Turn Circuit Breaker (CB1) on. The firing board alarm light should not activate. 6.2.4.2 High, Low, and Rectifier Failure Alarm Check Insure that the Float/Equalize timer on the display panel is in the “Float” position. Use the “Float” potentiometer to adjust the output voltage of the Battery Charger to the levels listed below. For accurate readout of the Battery Charger output voltage, it is recommended that a voltmeter be connected to the output of the Battery Charger. This can be accomplished by inserting the red voltmeter lead in the red positive test point on the display panel and the black voltmeter lead into the black negative test point on the display panel. The various alarms should activate at the alarm “ON” voltage and deactivate at the “OFF” voltage for 6-4 BAYLOR 6.2.4.2 High, Low, and Rectifier Failure Alarm Check (Cont! d) each alarm listed below. If incorrect operation is observed, adjust the appropriate potentiometer on the 56038 alarm board as listed below. CAUTION Use care in making adjustments since surrounding components are at a high voltage and can cause electrical shock. Settings are listed for 240 and 325 Volt DC battery banks. 240 VOLT BATTERY BANK (ALL READINGS ARE VOLTS DC) ALARM ALARM ON ALARM OFF ADJUST POT ON VOLTAGE VOLTAGE PCBH56038 HIGH DC VoLTS 288 286 Re LOW Dc VOLTS 235 237 RO RECTIFIER FAIL 215 217 R1O 325 VOLT BATTERY BANK (ALL READINGS ARE VOLTS DC) ALARM ALARM ON ALARM OFF ADJUST POT ON VOLTAGE VOLTAGE PCBH56038 HIGH DC VOLTS 382 380 RE LOW DC VOLTS 295 297 RO RECTIFIER FAIL 275 277 R10 BAYLOFfrF 6.2.4.2 HIGH,LOW,AND RECTIFIER FAILURE ALARM CHECK (Cont'd) To test the rectifier failure alarm, adjust the "Floats poténtiometer to drop the voltage below the “Low pc volte" alarm set point, The "Low DC Volte" alarm will come on at the "Low DC Volts" alarm set point reading. The "Low DC Volts" alarm will stay "ON" until the "Float" potentiometer is adjusted to a point that raises the Battery Charger output voltage above the "Low DC Volts" alarm "OFF" voltage setting. The activation of any alarm will cause the general alarm to activate. Before continuing, readjust the "Float" potentiometer on the display panel so that the output of the Battery Charger is at the correct "Float" voltage per SECTION 6.2.2. 6.2.4.3 GROUND DETECTION ALARM Attach a jumper between groumd and TB9-2, the negative side of the Battery Charger output. The ground alarm and the general alarm should activate. If the ground alarm does not activate, adjust potentiometer R19 on the 56036 ground detection board until an alarm is given. CAUTION Use care in making adjustments since surrounding components are at a high voltage and can cause electrical shock. Remove the grounding jumper and the ground alarm should go away. No grounding alarm should be given. It may be necessary to fine tune the ground detection point by adjusting potentiometer R19 on the 56036 ground detection board to insure that the ground alarm activates and deactivates as it should. 6-6 BAYLOR 6.2.4.3 GROUND DETECTION ALARM (Cont‘d) Repeat the procedure for the positive side of the Battery Charger output using TB9-1 as the grounding point and potentiometer R14 on the ground detection board for adjustment. It should take approximately one minute to activate the positive ground alarm. Use care in making adjustments since surrounding components are at a high voltage and can cause electrical shock. Da SECTION 7 RARIS AND SERVICE 7.1 GENERAL The recommended spare parts and supplies for the Control System are provided in the following tables. 7.2 PARTS AND SERVICE Parts and service are available from the factory: BAYLOR COMPANY 500 Industrial Blvd. Sugar Land, Texas 77478-2898 Telephone: (281) 240-6111 Fax: (281) 274-0426 Or from the following Baylor Service Centers: BAYLOR COMPANY LTD. ABB SERVICES AS Unit 13 Robert Leonard ctr. Torneroseveien 4, Howemoss Drive, Kirkhill P.O. Box 173 Industrial Estate N-4033 FORUS Dyce, Aberdeen Norway Scotland Telephon 44 1224 773555 Telephone: 47 51 678022 Telefax: 44 1224 773445 Telefax: 47 51 678683 WATT & AKKERMANS PTE. LTD. No.2, Pioneer Sector 3, Jurong, Singapore 2262 Telephone: 65 861 4444 Telefax: 65 861 2054 71 : BAYLOR 7.3 RECOMMENDED SPARE PARTS - BATTERY SWITCHOVER PANEL QUANTITY OR HOHE He hee PART NUMBER 6525~40-0056 6525~42-0022 6425-70-0038 6425-05-0007 6425~-05-0016 6500~18-0001 6525-25-0152 6525~-25-0134 6525~25-0129 6425-05-0096 6450-95-0088 6450-75-0181 DESCRIPTION Contactor, 2 Pole (C1) Auxiliary Contact Kit (C1) Time Delay Relay (TDR1) Relay, 3 PDT, (MR1, MR2, MR3) Relay, 4PDT, (RL1) Diode (Di, thru D7) Fuse, 125 amp (F-B) Fuse, 2amp 250 volt (F1) Fuse, lamp 250 volt (F2, F3, Relay, DPDT (CRI) Resistor, 12K 5W (R1) Resistor, 1.2K (RA,RB, RC) 7.4 RECOMMENDED SPARE PARTS ~ BATTERY CHARGER PANEL QUANTITY 10 10 1 1 i 10 1 7.5 RECOMMENDED SPARE PARTS - EMERGENCY QUANTITY 1 1 PART NUMBER 6525-25-0134 6525-25-0064 6725-12-0009 56038 56036 6375-10-0053 6500~33-0049 PART NUMBER 6525-67-0015 6375~29-0008 7-2 DESCRIPTION Fuse, 2A Fuse, 5A, 600V Firing Board Alarm Board Ground Board Lamp, Display Module, Dual SCR STOP STATION DESCRIPTION Pushbutton, Explosion Proof Lamp, Red, Explosion Proof DESCRIPTION Outline and Dimensions ... . Cable Diagram Model 48999 Brake Customer Connect Diagram . . . Cable Diagram, 2025A ..... Cable Diagram, PWM... 1. Cable Diagram, 1025...... Interconnect System Diagram, Brake Controller Wiring Diagram, Customer Interconnections Assembly, Brake Power Backup/Switchover . Bill of Material... . Assembly, Panel Battery Switcho' Bill of Material... . . Wiring Diagram, Battery Backup/Switchover Logic Diagram, Battery Backup/Switchover Assembly, Panel Battery Charger System Bill of Material... . ver 8-1 54968 56954 56955 55789 56435, 56496 56484 56404 56380 56380 56406 56406 56408 56409 56032 56032 BAYLOR DESCRIPTION DRAWING NUMBER Assembly, Status Panel Unitzed system... ........ 56318 Bill of Material... 2.1... ........ B/W 56318 Wiring Diagram, Status Panel United System... . 2... 56377 Assembly, Heat Sink... . 6... eee 86084 Schematic, Battery Charger... 1... ........ . 56008 Wiring Diagram, Battery Charger Panel fee ee ee ww . 56006 ASSEMBLY AND SCHEMATIC, GROUND DETECTION PCB tote ew we . 56036 ASSEMBLY AND SCHEMATIC, ALARM CONDITION PCB . soe ee ee - 56038 Assembly, Emergency Stop Control ............ . 53564 Bill of Material»... 2... LL... Bs 53564 8-2 \ DRL FLOOR. \ OrALERS coNTRAL SAEE AREA ' SOR BRAKE CONTROL we, 70 | sees 9 aac 1 es 490/240 VOL, TOR, SP, 59/6082 { ' BATTERY TRANSFER unt i soe se ASST 156320, | EMERGENCY STOP AL DUNGEONS AE OMS WSS Ong SonED oae/oup seoouren tie i a ee paar anes i FE S| SEVERE Sean wena meee ure tear Seaman eeacnemesremane fale alee ge / = <2 & =| [ | snpee | == oe = sree SAFE AREA DRILL FL005 AC INPUT POWER ‘SCR ASSEMBLY sees wa sm 9 72 le i : = s— dea oO ae ORMLERS CONTROL “ASSEMBLY ogy aes ‘Sn POWER SELECTOR SWITCH ASSEMBLY i LODY CURRENT BRAKE NOTE: aa _ “ee O- wo re eS fe @ = IrewuLy MRED aie rf eects a : | reaper 3 = z exeree eet amraneemem remem | [ees 1 Savas, gg ate ane Fastouh ave Pha sil 6 |” a3 doors Thala PART No. DRUL FLOOR 4 CONDUCTOR No.4. 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Ne HU cia a Oeanar eleea| 11/32 DA. MIG Eee | —312—e| [Pe [us "ASSEWBLY- & OUTUINE ee ie site EMERGENCY STOP CONTROL i | Sor wo | ‘uel 172 1B 53564 at ot [O | en een eee rate care REDRAWN TO CAD | Reeiatnanracractartta tua een emurarRE roe FRI, JUN ZU, 199/ Bib UF marRKuAL PAGE NO: teet AS OF 6/20/87 CLASS CODE GROUP: + UNCIASSTFrED GLASS CODE: 3030 DT-ELECTRICAL COMPONENTS Daw foo ux. LDS chol97 53564 OPCODE: 1 REV: C —ASSY, EMERGENCY STOP STATION ABPVL, OL? | eat nppuL. L464, toate Sethe” ¢, SRM Ae loch ECO NO? ECN#C ene DATE OF LAST ECO: 5/01/97 ; R pays © a7eM gry PeR yrexD EP DEFAULT OFF REFERENCE EFFECTIV OBSOLETE TTY SET SEQ DESIGNATOR DATE DATE, 1120-08-0082 ENCE, ELEC 3.62 X 12.62 X 5.62 4 4 4,000 1,000 EAP mM = 1,000 0 90/00/00 98/33/99 6525-57-0035 2/8,‘ MUSHROOM HEAD RED 1NO/NC 1 2 1,000 1,000 EAP uy 21000 0 oo 90700700 99/99/93 6375-23-0008, EiGitt, PILOT RED 110 EXP 1 3 1,000 1/000 EAP HIN 1.000 9 00/00/00 99/99/99, ~ §3506-1 HAMEPEATE, BACKUP IN USE a % £1000 1000 EA P YN © 1.000 0 oo. 90/00/00 99/99/99 53506-2 MAMBPLATS, EMER STOP 1 5 1000 L100 EAP YN 000 00 00/00/00 99/99/99 ION _9 veh INFORMATION 9.1 Enerpro Firing Circuit Pip 9.2 Batteries 9-1 Single Phase Four SCR Firing/Regulator Circuit Board Part Number FCRO4100 Features ‘Syrimatrical Digital Gate Delay Generator for balanced phase control. ‘Custom CMOS LSI gate array for lower parts count, higher reliably. “Soft Start & Soft Stop circuit. “Feedback Error Amplifier for current or voltage regulation ‘Regulator Circuit intertace for optional “piggy-back" voltage regulation/current limit board. ‘New larger capacity on-board transformer with primary vottage: available up to 600 Vac. ‘Bipolar gating for 4-quadrant applications, ‘Auxiliary (slave) Fring Board output for gating parallel and 4- ‘quadrant SCR ciruits, Fully connectorized for easy maintenance. Applications “Heavy-duty two-sided .093 inch circult board with solder mask The FCRO4100 firing circuit/regulator supplies hard firing “picket % «Polyurethane conformal coating. ence" gate pulses for single phase AC/AC controller and AC/DC ‘converters. Common SCR phase control circuit configurations “Fully tested at rated voltage in customer's SCR circuit include: configuration. Single Way Converter 3 2-SCR with center- Soe transforme’) Gate Delay Angle Transfer Function ‘The gate delay angle in the open loop mode varies in negative Proportion to the contral signal input voltage as shown below. ‘The minimum and maximum delay angles, amin and amax , +2-Quadrant Bridge Converter are determined by the values of two resistors. Typical limits are 5° and 175°, max, “AC Controller (2 ant-parallel SCRs) Fin *4-Quadrant Bridge Converter (requires FCOAUX60 auxiliary firing board) 3 DELAY ANGLE, a ere 23 4 5 ‘CONTROL VOLTAGE (Vdc) Phase Delay Generator The variable gate delay angle cis produced it a phase-locked Joop (PLL) consisting of an XOR phase detector, low pass fier, ‘summing junction, volage-contriled oscWitor (VCO) and digi countdown chain, The VCO, countdtvin chaln, and phase detectors, as well as addtional bank select and inhibit circuitry, are contained in a custom 22-pin DIP CMOS gate array IC, Input Control Signal ‘The input control command signal is 0 to 5.0 Vac with an input impedance of 10.0 k©. An optional input shunt resistor can be installed to permit operation with a miliamp type control signal, 2.9.4 to 20 mAdc. Current and Voltage Regulation ‘The included error amplifier provides the option of either current Or voltage regulation. Current transformer feedback or an attenuated 0 to 1.0 Vée voltage feedback must he supplied. The FCRO4100 may also be used in the open-loop mode with no. feedback. AA regulator board interface connector is included for mounting Special purpose “piggy-back’ regulator circuits. Two such plug in boards now availabie.are the models. VRCL1P-1 and PTIR. ‘The VACLIP-1 provides vottage regulation with current ‘The PTIR-1 provides vottage and current regulation in addi a “polarity transition inhibit" circult foruse with 4-quadrant converters, Power-On Reset Circuitry is provided to inhibit gating until the on-board power ‘Supply voltage has stabilized. This circuit also inhibits SCR Gating during line voltage dropouts, Soft-Start & Soft-Stop ‘The Soft-Start circuit over-rides the gate delay angle command. ‘The Soft-Start circuit is activated by a contact opening. Gating ‘commences at the maximum delay angle limit. The delay angle ‘amps down to the commanded angle, ‘The Soft-Stop circuits activated by a contact closure. The delay ‘angle ramps up from the commanded delay angle to the ‘maximum delay angle limit before gating is inhibited. The soft- ‘start and soft-stop ramp rates are separately settable with timing resistors. Instantaneous Inhibit ‘A second inhibit function is provided which instantly enables or inhibits SCR gating. This function is actuated by a contact closure, Board Mounted Power Supply ‘A 24,VA transformer with a center-tapped 120/240 Vac or 240/480 Vac primary winding is standard. Other voltages are also avalable. The transformer output is rectified and filtered and sed otrectly for gate drive +30 V power and is also applied to a +12 V regulator for operation ofthe control electronics circuitry, ‘The 24 Vac output ofthe transformer is also used as the phase Felerence for the gate delay circuit, SCR Gate Drive Circuits Four isolated and 180° spaced hard-fring gate pulse outputs are Provided. Gate drive outputs are pulse transformer coupled, Gate Pulse Specification Burst width: 180-a Pulse width: 32.6 ps Pulse risetime: = § Ain 6 us Short circuit current: 2.0 A initial pulse BAsustaining pulses Open circuit voltage: 15 These voltage and current levels are nominal because they are ‘derived trom unregulated 24 Vac, Gate Delay Angle Specifications Frequency response: 3 6B atten, at 67 Hz 45° phase shift at 57 Hz Frequency sensitivity 2.6°el/Hz Temp. sensitivity: 32° el. for 0 °C

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