INSTRUCTION BOOK ELECTROMAGNETIC BRAKE RECTIFIER FE-1400 TYPE RFE 250/63-460-INDONESIA

TABLE OF CONTENTS

1 DESTINATION

The rectifier with continuous adjustable voltage of the <RFE 250/63-460-60Hz.> type is conceived to supply the electromagnetic brake of the FE-1400 type within drilling facilities.

The rectifier ensures on output a continuous constant voltage and the limitation of the maximum current by load.

2 OPERATING CONDITIONS

2.1 Environment requirements

The equipment is meant to operate within areas with tropical and humid climate TH in accordance with STAS 6535-83 and in the operating category 3 in accordance with STAS 6692-83.

2.2 Operating environment conditions

2.3 Transport conditions

2.4 Storing conditions

3 DESCRIPTION OF THE PRODUCT

3.1 APPLICATION SPHERE

The rectifier of the <RFE 250/63-460> type is meant to supply with continuous adjustable voltage the electromagnetic brake of the FE-1400 type within drilling facilities.

3.2 STRUCTURE OF THE EQUIPMENT

The equipment is accomplished as a sub-assembly with the sizes 850x640x185 mm whereon is mounted the three-phase rectifier with thyristor modules and electric devices for the low voltage commutation and electric contact connectors.

The equipment is mounted on the left side in the DBR cabinet composing the container SDACRN INDONESIA.

The constructive structure of the equipment is shown in drawing no. 376-2.0.

The distribution of the rectifier power module and of the electric devices for low voltage commutation is performed from the upper left side of the sub-assembly, as follows:

4 MARKING AND SYMBOLIZATION

4.1 The symbolization of the product that is the subject matter of this Instruction Book is RFE 250/63-460 and it is performed through a combination of letters and figures with the following meaning:

R - rectifier

FE - electromagnetic brake

X/Y-Z - U_CC./I_CC.-U_alim

4.2 The marking of the product comprises:

- the short name of the product;

- the symbolization according to point 4.1;

5 TECHNICAL FEATURES. PERFORMANCES

5.1 CONSTRUCTIVE TECHNICAL FEATURES

5.1.1 SHAPE AND SIZES

The shape and sizes are compliant with image 1.

5.1.2 NORMAL PROTECTION DEGREE

The normal protection degree of the product is IP23 according to STAS 5325-79

5.1.3 MASS

The total maximum mass of the product is of ~ . kg ± ..%

5.1.4 FUNCTIONAL TECHNICAL FEATURES

The product is accomplished in accordance with:

the general electric scheme

the sequential command scheme

the electric connection scheme.

Electric features:

the continuous rated output adjustable voltage: 10.250V_CC

the maximum continuous output current: 63A_CC

5.2 PERFORMANCES

The rectifier meant to supply with continuous adjustable voltage the electromagnetic brake of the FE-1400 type ensures:

the 2-step supply with continuous adjustable voltage

the limitation of the maximum current rectified by load

protection against short-circuit

preparation, command and start-up, protections and signals.

5.2.1 Electric features of the supply network

5.2.2 Technical features of the rectifier <U3>

5.2.1 Protection commands

5.3.1 Commands

The <preparation> operations in order to set under voltage the rectifier are the following:

supply with 3N/PE AC 460 Vef. by closing <Q1>

supply with stabilized sources from <U1-MF-03> by closing <Q5>

imposing controller supply <U7> by closing <Q4>

supply of electric sequential command diagram by closing <Q2> and <Q3>

pushing the button on the <ON> position from the safety supervision block within the three-polar separator SF. F1, F2, F3.

After performing these preparing operations, the command <start-up> of the rectifier, respectively of the supply of the electromagnetic brake is issued.

The <start> operation of the rectifier is accomplished by:

the start command of the sofstarters at the water cooling pumps 1 or 2 electromagnetic brake on the chief driller's console <KPR1.8-9>, <KPR2.8-9>

actuation of the rectifier command voltage imposing controller <U7> and the closing of the contact or <U7.13-14> from the preparation circuit on the chief driller's console.

The <start> operation has as an effect:

the energizing of the contactor <K1> transformer couple <T1> and the setting of the rectifier supplying the electromagnetic brake under voltage.

The <start> operation of the rectifier is not accomplished if:

the preparation operations are not fulfilled

there are stopping conditions rendered by the rectifier <U3>

the contact <U7.13-14> from the imposing controller has not been shut down

the button from the position <ON> from the fuse supervision block in the three-polar separator SF.F1, F2, F3 has not been pushed

The <start> operation of the rectifier is accomplished by:

the command to stop the softstarters of the water cooling pumps brake <KPR.1>, <KPR.2>

non-actuated imposing controller

the burnt super-fast fuses noticed on the fuse supervision block set in the three-polar separator SF.F1, F2, F3.

The <start> operation of the rectifier has as an effect:

the absence of continuous output voltage.

5.3.2 Protections

The protection of the semiconductor elements and of the load shall be performed by a collective protection with the super-fast fuses F1, F2, F3 displayed on the input of the rectifier.

The rectifier also ensures an implemented electronic software protection that blocks the impulses on the thyristors composing the rectifier in case of a short-circuit on the load.

5.4 Alarms, operational states and signaling

The equipment ensures the optical and acoustical signaling for the following functional states:

three-phased transformer under voltage;

the presence of sequential command voltage;

burnt super-fast fuses;

Through its implemented software system, the rectifier is able to sequentially track and communicate by displaying in real time on the operator panel <U6.PO-02> the operational states that occurred during the operation of the equipment, such as:

short-circuit on the load

absence of current measure reaction

absence of voltage measure reaction

burnt super-fast fuses

blocked impulses

absence of supply stage

5.5 The display of electric parameters

Electric measured parameters are displayed on the operator panel <U6.PO-02> and they are expressed in units of physical sizes.

The displayed electric parameters are the following:

prescribed voltage <Up>

limitation current <Ilimita/Ip>

output voltage <Ufrana/Us>

load current

Up = 250

Ilimita = 63

Ufrana = 250

Isarcina = 45

6. MOUNTING INSTRUCTIONS

6.1 Location and fixing

The equipment shall be placed both in storing and in operating on horizontal surfaces and it is meant to operate in covered rooms.

The place where the equipment shall be placed should be void of corrosive agents and have a ventilation system that should not allow the exceeding of the maximum temperature specified in the operating conditions.

6.2 The execution of electric contacts

The execution of electric contacts shall be performed in accordance with:

the general electric scheme

the electric sequential control scheme

the equipment connection scheme

the connection scheme to the chief driller's console.

On executing the electric connections, the following shall be observed:

the observance of the direct succession of the phases R, S, T according to the notes from the general electric scheme

the observance of the polarities of the output terminals of rectifier B9XpL1/F1(+), B9XpL2/F2(-) with the polarities of the electromagnetic brake.

The execution of the electric input-output connections from the equipment to the outside shall be performed according to the following table:

7 INSTRUCTIONS FOR SETTING INTO FUNCTION

7.1 The documentation necessary for setting into function

ATTENTION!

The setting into function shall be performed by qualified personnel that should hold a training chart for labor protection according to the applicable norms and that should have experience in the field of power converters.

The documentation necessary for the setting into function:

the general electric scheme (pl 1/1) shown in the chapter Appendixes

the electric sequential control scheme (pl ½) shown in the chapter Appendixes

the equipment connection scheme shown in the chapter Appendixes

the connection scheme of the driller's console shown in the chapter Appendixes

the specification of the electric device shown in the chapter Appendixes

The operations of checking and setting into function shall be performed in two main phases/stages:

the checking of the electric equipment without load

the checking of the electric equipment with load

7.2 Measuring devices necessary for the setting into function

Oscilloscope with two memory spots

measurement field 1mV-500V

minimum time base 10 MHz

Digital multi-meter

minimum input resistance: 1 MΩ

3 ½ or 4 digits

Measurement field: 0.1-1000 V, 10 Ω-10 MΩ

D.C. voltmeter

measurement field 0-400 Vc.c.

precision class: 1.5

D.C. ammeter equipped with magnetic measuring shunt for load current

measurement field 0-100 Ac.c

precision class: 1.5

A.C. voltmeter for the network voltage

measurement field 0-1000 Vc.a

precision class: 1.5

8 MAINTENANCE AND REPAIR INSTRUCTIONS

8.1 Instructions and revisions

The purpose of maintenance is to keep the equipment in proper operating condition.

Maintenance operations are executed after longer technological breaks or on pre-established dates (revisions).

Maintenance and revisions are executed by electricians on duty appointed for such purpose, who should know the structure and operating of the equipment, as well as the labor protection norms.

8.1.1 Current maintenance comprises:

- checking the proper condition of the insulation at power and control cables

- checking weather the bolts and the connection elements are fastened

- checking the physical condition of the equipment (of the mechanical wear and tear)

- checking the accurate signaling of the signaling lamps

- checking the accuracy of the indications of electric parameters on the operator panel.

8.1.2 The revision comprises:

- execution of all operations/check-ups from the current maintenance;

- checking the connection and interruption devices;

- removing the set dust by cleaning the entire equipment with low pressure air jet

- removing all deteriorations or failures that have been eventually assessed.

8.2 Repair

The repair shall be performed only by the specialized electric maintenance personnel or by a SERVICE team.

All necessary protection measures stipulated in the normative documents shall be taken in order to execute the repair works.

For an as good as possible repair of the equipment, it is advisable to hold an evidence of all occurring failures, of their causes, how the failure was assessed and what the remedy method was.

Failures are generally assessed by:

optical indication with signaling lamps

display of errors and alarms on the operator panel

non-accomplishment of preparation and start-up operations.

ATTENTION!

No improvisation or modification of the electric circuits is allowed without the approval of the manufacturing company S.C. ICPE ACTEL-S.A.

The replacement of a commutation and protection equipment shall be performed only with a device or a part of the same type and with the same technical features.

9 DESCRIPTION OF THE OPERATING MODE

9.1 Theoretical electric scheme

The electric equipment destined to supply the electromagnetic brake FE-1400 is accomplished in accordance with:

the general electric scheme

the electric sequential control scheme

the electric connection scheme

the specification of the electric device.

9.1.1 Supply of equipment

The equipment <RFE 250/63-460-60Hz.> is supplied at the terminals of the three-polar switch <Q1> with alternative voltage 3x460Vef + N, 60 Hz and the sequential commands shall be supplied by a mono-phase corroborated voltage transformer <T2>.

The equipment is controlled by control and signaling devices, operator panel, controller imposing voltage/current to the rectifier <U7>, mounted on the door of the cabinet and on the console of the chief driller.

9.2 Description of the operating of the equipment

The setting into function of the equipment comprises the following stages:

9.2.1 Preparation

Preparation has as an effect the supply of the secondary circuits of the rectifier and of the sequential commands.

Preparation shall be accomplished by manually actuating the commutation devices mounted on the sub-assembly from the cabinet and on the chief driller's console according to the electric schemes shown in appendix 1.

The supply of the three-phase rectifier with thyristors <U3> shall be performed by manually actuating the switch <Q1>, energizing the contactor <K1> that sets under voltage the three-phase transformer lowering the voltage <T1> conditioned by:

setting in the softstarters for the water cooling pumps at the electromagnetic brake <KPR.1 8-9> or <KPR2. 8-9>.

the actuation of the rectifier command imposing controller <U7>

the signal to stop the rectifier given by the control and numerical regulation device <U2.J7.1-2>

and actuating the three-polar separator <SF> with the super-fast fuses F1, F2, F3.

The supply of the mono-phase transformer <T4> in place within the control and regulation unit displayed on plate <U1-MF-01> with actual phase voltage <U_RO> by connector X1.1, X1.2, by actuating the automatic switch <Q5> and obtaining one of the secondary windings of the synchronization voltage

The supply of the controller for imposing the command voltage/current / prescribed to the rectifier <U7> by actuating the automatic switch <Q4>.

The supply of the sequential control circuit by actuating the automatic switch <Q2>, the setting under voltage the voltage lowering mono-phase transformer <T2> and actuating the switch <Q3>.

9.2.2 Start-up

The start-up of the equipment shall be commenced by actuating the imposing controller from the chief driller's console and energizing the contactor coil <K₁> from circuit 2 table 2/2.

By shutting down CND <KPR1.8-9> or <KPR2. 8-9> from circuit 2, the contacts <SF.13-14>, <U2J7.1-2> is energized the contactor <K1> and is supplied the three-phase transformer <T1> and so is obtained at the output of the rectifier the continuous variable voltage to which corresponds an optimal braking coupling in the technological process.

The setting under voltage of transformer <T1> is signaled by the lighting up of a green lamp <H1>,

9.2.3 Stop

The stopping of the equipment shall be commenced by the stopping of the softstarter water cooling pumps of the brake or the imposing controller on the position zero and the de-excitation of contactor <K1> and the removing from under voltage of the three-phase transformer <T1> and of the rectifier supplying the electromagnetic brake.

The stopping of the equipment by de-exciting the contactor <K1> is also commenced further to an intentional stop of the rectifier given from the operator panel or further to a breakdown stop caused by internal or external failures given from the command, control and regulation plate <U2-DCGRN-02> by changing the state of the relay from such plate from state CNI into state CND <U2.J7.1-2> or the burning of the super-fast fuses.

9.2.4 Description of the automatic regulation scheme

The adopted automatic regulation scheme is of the convergence type.

The automatic regulation scheme ensures the command impulses supplied through the impulse transformers on the gates of the thyristor modules - thyristor that compose the rectifier <U3> from the command, control and numeric regulation plate <U2-DCGRN-03> that enables the regulation of the continuous voltage at the output of the rectifier and the limitation of the current by load.

The command, control and regulation unit <U2-DCGRN-03> is accomplished by hardware with the micro-controller DSP on 16 bytes whereby the load parameters are programmable through an operator panel <U6-PO-02>.

The command to spark the thyristors composing the rectifier with thyristors <U3> shall be performed by the command of the angle for the sparking of thyristors "α" versus the synchronization voltage of the network, having as a scope the regulation of the average value of the redressed voltage, impulses that are obtained in the command device on the numeric grid from plate <U2-DCGRN-03> and applied to the thyristors through the impulse transformers T11, T12, T13, T14, T15, T16 displayed on the power plate <U1-MF-03>.

The load parameters are memorized in the memory of the EEPROM type comprising the full set of parameters in order to actuate the electromagnetic brake.

The impulses for the sparking of the thyristors composing the three-phase rectifier are generated from the command, control and numeric regulation plate <U2-DCRN-03>,

The real load voltage information is taken over from the voltage transducer TT-LEM-LV meant to transmit with galvanic separation the voltage measured at the output of the rectifier with thyristors and to deliver on output the unified signal in continuous voltage in a certain division report (0:±10V) and it is a reaction signal for the voltage regulator and for the protection circuit.

The real information on the load current is taken over through the current transducer TC-LEM-LA destined to transmit with galvanic separation the current measured at the output of the rectifier with thyristors and deliver on output the unified signal in continuous voltage (0:±10V) and it is a reaction signal for the current regulator and for the protection circuit.

The two transducers are displayed on the plate <U1-MF-03> from the rectifier with thyristors.

The voltage regulator and the current regulator implemented on plate <U2-DCGRN-03> are of numerical type and they have a proportion-integral feature PI and they are meant to deliver the command signal to the command device on the grid receiving on entry the imposed value signal, respectively the measured value of the voltage and of the input current of the rectifier with thyristors.

10 MEASURES OF LABOR PROTECTION AND PREVENTION OF FIRES DURING OPERATING

All measures of labor safety and protection technique specific to the low voltage electric equipment shall be observed.

All provisions on the prevention of fires shall be observed.

No checking, mounting or repair shall be performed, unless the equipment is removed from under voltage.

ATTENTION!

The absence of voltage in the connector rows at the input in equipment 1X, L1, L2, L3 shall be checked with a measuring device, after the low voltage switch supplying the equipment is disconnected.