‘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.