Escolar Documentos
Profissional Documentos
Cultura Documentos
Electric Manual
Model DQ70BSC
Serial No
06032
Preface
The design, manufacture and service of this product are based on the following quality
assurance system:
GB/T19001:2000 idt ISO9001:2000 Quality Management System-- Requirements
API Spec Q1 Specification for Quality Programs for the Petroleum and Natural Gas Industry
This manual contains information relating to Top Drive operation, service and maintenance.
The technical information of this product is included respectively in the following documents:
<Operation Manual>
<Electric Manual>
<Hydraulic Manual>
< Installation and Trouble Shooting Manual>
<Maintenance Manual>
<Electric House Manual>
<HSE Manual>
<Data Backup and Recovery Manual>
<Electric Drawing>
<Mechanical Drawing>
<Hydraulic Drawing>
With individualized design provided for the Top Drive based on the service operating
condition and special requirements of the customers, the technical document for this product
may not be suitable for the other products of the same type. Product type and No. shall be
checked when the technical document is used.
For information not covered by the accompanying documents and other problems arising
from the installation, operation and maintenance, contact the manufacturer if necessary:
BPM
Ads:
Postcode:
100083
Tel:
( 010) 62097381
Fax:
( 010) 62097613
E-mail:
Bpm.zhaojing@vip.163.com
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Contents
1.
Summary ....................................................................................................................1
2.
3.
3.1.
Basic specification......................................................................................................4
3.2.
Motor specification.....................................................................................................4
3.3.
Drilling parameter.......................................................................................................4
4.
4.1.
4.3.
PLC/MCC ................................................................................................................12
4.5.
4.6.
4.7.
4.8.
4.9.
5.1.
5.4.
5.5.
Brake........................................................................................................................31
5.6.
Make-up/break-out operation....................................................................................36
5.9.
E. Stop......................................................................................................................43
6.1.
6.2.
6.3.
GSM kit....................................................................................................................52
7.
7.1.
7.2.
7.3.
Power system............................................................................................................55
7.4.
7.5.
7.6.
Control status............................................................................................................58
7.7.
Auxiliary system.......................................................................................................59
7.8.
7.9.
Alarm logging...........................................................................................................62
8.1.
8.2.
8.3.
8.4.
8.5.1 Rectifier....................................................................................................................79
8.5.2 Inverter.....................................................................................................................81
8.6.
8.7.
Trouble shooting.......................................................................................................84
9.
9.1.
9.2.
9.3.
Electric Manual
1. Summary
Top Drive Drilling Equipment (short for Top Drive), it is a new-type petroleum drilling
equipment which replaces rotary table. Its a high-tech product which is integrated with
machinery, electric and hydraulic system. It is a very important work for trouble shooting,
operating and maintaining the electric system.
The electric system of BPM Top Drive which is installed, operated and maintained, that need
one personnel who have certain qualifications or have enough experience. It is the customers
obligation to train above-mentioned capacitates personnel.
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Electric Manual
2. Safety notice
This manual uses the following warning sign
Notes:
Caution:
Warning:
The following safety notices are very important for correct install, operate, maintain of Top
Drive, all the operators must read it carefully and understand it:
a) Do not work with power on, include: dont open safeguard with high voltage; dont
repair or dismantle any electrical device with power on, dont plug in/out each cable
connector with power on.
b) Dont open the junction box or Driller Console under having flammable gas
environment.
c) Do not try to change the DC fuse between DC bus and Inverter when Rectifier is
working or DC voltage is above safety range (DC 24V), It is dangerous for human
safety and electrical equipment!
d) If need maintain Rectifier, motor or Inverter, please turn main switch (3WL) to right
side (lock position), in order to prevent faulty operation.
e) The insulation of Inverter and Rectifier cant be checked by high-resistor meter or
else the high test voltage will damage the equipment.
f)
Driller Consoles protection air must keep pressure when power on! When air lost,
filling gas as quickly as possible and shut down the control power of Driller Console!
Forbid unprofessional person change any parameter of each Rectifier and Inverter,
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Electric Manual
When temperature is more than 40, and humidity percent is higher than 95% or
dew exists, dont start drivers or switch on control power before starting air
conditioning to lower down the temperature and decrease wet.
k) When system main power shut down by accident for more than half an hour, before
restart the system, must make sure that there is no dew in Electric House.
l)
Under the moist environment, when electric house temperature is lower than the
outside, forbid long time opening the electric house door, otherwise may produce dew
on the electric equipments!
In this manual, the words with indicates that it is an operating parts
of the electric system.
As for the installation, trouble shooting, operation and maintenance of
Top Drives electric system, the operator should read the manual before
operating. For continuous improvement and changing, you must check
the product serial number printed in the cover of this manual to ensure
that the product confirming to the technical manuals.
Unprofessional person not being specially trained can not do the work
of installation, trouble shooting, operation and maintenance. It may
damaged to the body or equipment. During operation, it is not permitted
to repair and maintain.
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Electric Manual
3. Main specification
3.1. Basic specification
Supply voltage
600 V AC
Rated current
445 A 2
Max. Current
770 A 2
Ambient temperature
35 +55
Altitude
1200 m
400Hp 2, S1
1150 rpm
2400 rpm
0220 rpm
Max. Torque1min
75 kN.m
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4.
Electric Manual
Top Drive
Driller Console
Electric house
Auxiliary
control cable
Main power
cable
HPU
The electric control system mainly includes AC variable frequency drive system and
PLC/MCC system, and mainly consists of drive cabinet, PLC cabinet, Driller Console,
Auxiliary Control Box, Local Control Box, HPU Control Box, main power cable, auxiliary
control cable, etc. The Drive is SIEMENS SIMOVORT MASTERDRIVERS 6SE70 serial
product, with the variable frequency speed regulation system, drive two 400 hp AC variable
frequency motors, which could work together (master/slave) or separately. The whole system
possesses perfect diagnosing and protecting function, could realize all operations of Top
Drive.
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Whether the temperature is too high or too low will lead to system damage.
A suitable temperature and humidity inside is very important for Top Drives
safe running. High humidity will lead to elements defective insulation and
short circuit, also damage the equipment.
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Electric Manual
Aux.Current
Input Voltage
Control
Earth Fault
Power On
DC Current
DC Voltage
E.Stop
Main Air Switch
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Voltage Select
a)
Electric Manual
Meter
Input current: show the current value of 600V main power supply.
Aux. current: show the current value of auxiliary power supply.
Input voltage: show the voltage value of every phase of main power.
DC current: show the output current value of the Rectifier.
DC voltage: show the output value of the Rectifier.
b) Indicator light
Control power: this indicate light will on if control power (220V) is power on.
Earth fault: if system insulation faults, the light will on.
Power on: when main air switch in Power cabinet is closed, this indicator light will on.
c)
Button
If Top Drive was just shut down, during a period of time, the Rectifier cabinet will
discharge high voltage large capacitance. So, at this time, it is forbidden to open
Rectifier cabinet door.
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Electric Manual
Encoder Select
a)
Output Voltage
E.Stop
Meter
Output current: show the output current value of Inverter.
Output voltage: show the output voltage value of Inverter.
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4.4. PLC/MCC
PLC/MCC includes PLC and AC/DC power distribution system.
a)
Meter
Manual switch
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System StartWhen system was power on, this switch could realize systems start; start
Rectifier and main air switch, etc.
Control ModeSelect the control mode..:By pass, Profibus. Or Cable. Mode.
IBOP DisableWith this switch,the IBOP couldnt close except Well Control.
This switch is used to insure right operation of IBOP and safe of work at
unusual task.
Do not disable IBOP at usual drilling task to insure it can be close when it is
needed.
Encoder FaultWith this switch, system could run without encoder if the two encoders
were fault.
Motor HeaterWith this switch, motor heater could work independently without PLC.
When motor is running, heater is forbidden to run by PLC logical.
ResetIt has reset and silence function.
E. StopBe used to stop system promptly. All E.Stop in electric system are interlocked.
d) Industry PC
There is one Industry PC in PLC cabinet, and its self-contained display screen, mouse, and
keyboard are all in the electric house. This Industry PC is used to monitor and debug Top
Drive system.
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4.6.
Electric Manual
Hydraulic Control system is in HPU Box. It controls two hydraulic pumps (one use and one
backup) and one hydraulic oil cooling fan. The two pumps could be started locally or
remotely by Driller Console, but the local control has the priority. There is motor protector in
front of hydraulic pump motor, through setting protective current, which could realize protect
motors overload, current leakage, etc.
HPU Control Box panel:
Power On
Pump A
Cooling Fan
a)
Power
Pump Select
Pump B
HPU Pump
Indicator light
Power on: when 380V power supply is ready, this indicator light will on.
Pump A: When pump A is selected, this indicator light will on.
Pump B: When pump B selected, this indicator light will on.
b) Manual switch
Pump Select:Select pump A or pump B.
HPU Pump:Be used to control hydraulic pump locally. Turn to on means local start HPU
pump; turn to off means stop running HPU pump; turn to auto means Driller Console will
control the HPU Pump remotely.
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Electric Manual
Cooling Fan: Be used to control cooling pump. Turn to on means local start cooling fan;
turn to off means stop running cooling fan; turn to auto means PLC will remote control the
cooling fan.
Powerswitch: Be used to control HPU Control Boxs 380V power supply. Turn to on
means HPU Control Box is power on; turn to off means HPU substaition is power off. When
power is off, coil in terminal line, Q52, S4, K1 still have electric power, and ET200X also has
electric power.
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No
Indicator light
Electric Manual
Type
Function
If hydraulic pump runs normally, it will on.
Pump Running
Locking
IBOP
Brake
Ready
Green indicator light power on but system not ready. When system start and
everything is ready, it will on constantly.
6
7
Red indicator light indicate alarms and faults. For detail information,
please refer to Fault/alarm section of Chapter 5.12.
No
Meter
Type
Torque
Meter
10
Speed
Meter
No
Switch
Type
HPU
11
12
Run/Stop
E. Stop
Function
Show actual output torque of head shaft with unit being
kN.m.
Show actual output speed of head shaft with unit being
r/min.
Function
Turn to run, pump will run.
13
Locking Pin
unlock/lock
two-position switch
14
Link Rotation
Electric Manual
ccw/stop/cw
head: ccw/stop/cw
15
Clamp
three-position switch
16
Auxiliary
two-position switch
17
Link Center
Black button
18
Link Incline
Rear/stop/Front
19
Air Cooling
On/Off/Auto
three-position switch
IBOP
20
Open/Close
Motor
21
A/AB/B
three-position switch
Brake
22
off /Auto/ On
Operation
23
Drill/Spin/Torque
three-position switch
24
Reset/Silence
black button
Direction
25
Ccw/Stop/Cw
three-position switch
26
Makeup Torque
potentiometer
27
Drilling Torque
potentiometer
Electric Manual
Throttle
Potentiometer
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Enable
Link Center
Link Incline
a)
Link Rotation
Indicator light:
Enable indicator: when Driller ConsolesAuxiliaryswitch is on, the indicator will on, this
means Auxiliary Control Box will be enable.
b) Manual switch:
Link Inclineswitch: Be used for link incline operation.
Link Rotationswitch: Be used for link rotating operation.
Link Centerpushbutton: Press this button, the elevator link will on float (center).
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Electric Manual
Ground cable (option): 38m, from electric house to the bottom of derrick.
b) Derrick cable: 38m, from the derrick bottom to supporter nearby monkey board.
c)
Quick connectors are used among three-cables, between main power cable and main motor,
also between main power cable and main control cabinet. This is very convenient for install
on local well site. They are shown as below:
Electric house
Top Drive
Plesse insure the cable connection is dependable, and avoid entrance of rain.
To avoid connector loosing or even destroying, timely check and maintain all
cables and their plugs/connectors is very importance because of bad
environment and complex drill condition on well site (check and maintain
period should be not more than five days).
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Electric Manual
A: 12-core power cable, provide 380V and 220V power for air cooling fan and heater.
b) B: 67-core shielded cable, used to transfer LCB 24V DC control power supply, manual
signal, and main motor encoder signal.
Plesse insure the cable connection is dependable, and avoid entrance of rain.
To avoid connector loosing or even destroying, timely check and maintain all
cables and their plugs/connectors is very importance because of bad
environment and complex drill condition on well site (check and maintain
period should be not more than five days).
4.10.2. HPU control cable
The main power (380V) of HPU Control Box is from PLC/MCC cabinet, it connect with
electric house by use of quick connector which could be connected easily. HPU Control Box
control cable includes control signals (digital signals) cable and analog sensor (analog signals)
cable, its two sides use plugs.
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Electric Manual
X1: it sends manual signal of Driller Console to PLC/MCC cabinet, used for emergency
operation.
b) X101: provides 24V control power for Driller Console, send signals of well control and
emergency stop.
c)
X102: shielded cable, used for output signal of Top Drive speed / torque (4-20mA
current).
Timely measure earthing resistance with megger, makes sure that earthing is
well.
To avoid connector loosing or even destroying, timely check and maintain all
cables and their plugs/connectors is very importance because of bad
environment and complex drill condition on well site (check and maintain
period should be not more than five days).
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Electric Manual
5. Operating procedure
5.1. Start/stop electric control system
5.1.1. Checking before start
Before starting electric system, should check the following items:
a)
Check the mechanical and hydraulic system first. Make sure that they are ready.
b) Check all operation cabinets and meters of electric system and Driller Console; ensure
they are in initial status. (Refer to appendix 1).
c)
The indicators on Driller Console could be tested by press the button of Reset/Silence
for three seconds.
The operation of system start will invalid if the system is not in initial status!
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Electric Manual
b) TurnSystem Startswitch to off. The main air switch will disconnect when Rectifier
accept system stop signal, then, the system will stop running.
The power only can be shut off after the main air switch was opened.
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Electric Manual
When Power On indicator light is on, turn HPU Pumpto on, the selected pump will
run, and Pump A Running or Pump B Running indicator light will on. When
communication is well, Pump Runningon Driller Console will on.
Turn the HPU Pumpswitch to off, the pump will stop running, and indicator light
will off.
b) If HPU pump keep stop for a long time, operator should turn Poweron HPU Control
Box to off.
Compared with remote operation by Driller Console, local operation on HPU
has priority. When checking or repairing, it is important to disconnect power
supply to ensure personnel and equipment safety.
When HPU pump on local control mode, E_Stopoperation cannt stop the
HPU pump.
5.2.2. HPU remote control
When communication is well, Driller Console remote control HPU procedure:
a)
d) Turn HPU on Driller Console to run, could start the selected pump. TurnHPU
on Driller Console to stop, could stop the selected pump. If turn to auto, the pump
will run automatically when pressure is lower than 14Mpa, while pump will stop
automatically when pressure is higher than 16Mpa.
e)
If HPU keep stop for a long time, operator should turn HPU Control Box Powerto
off.
When HPU pump on remote control mode, E_Stopoperation will stop the
HPU pump. If need pump running, control the pump locally.
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5.5. Brake
The brake function could only be used under Drill Mode. When receive brake signal, the
Brake indicator light will on constantly. When receive stop brake signal, the Brake
indicator light will off.
TurnBreak switch to On before motors running, motors will output torque equal to the
scale of Drilling Torque, but no speed.
If motors are running, turn Breakswitch to On, motors will reduce its speed. When the
speed is suitable, brake will work to stop the motor.
When Breakis on auto, Top Drive main motor will startup, and brake will release
automatically after a practical torque is founded. When stopping system, brake will work and
hold on brake state after speed lower down to a suitable range; If system work mode will
change from Drill Mode to Spin Mode, and motor brake will open automatically.
WhenBrakeis off, Top Drive could be started, when stopping system; main motor will
decrease its speed and keep on zero speed, brake will not work.
When Break switch is on Off position, Top Drive could start or run
normally, but when system stops, brake will not work automatically.
When fault happens and system stops emergently, system will reduce its
speed quickly. When speed is suitable, brake will work to keep on brake status.
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Electric Manual
Button or Switch
Status
Driller Console
Brake
Auto
Driller Console
HPU
Run
Driller Console
Locking
Unlock
Driller Console
Link Rotation
Center position
Driller Console
Link Incline
Center position
Driller Console
IBOP
Open
Driller Console
Auxiliary
Off
Driller Console
Air Cooling
Onor Auto
Driller Console
Operation
Drill
Driller Console
Direction
Stop
Driller Console
Makeup Torque
Zero position
Driller Console
Drilling Torque
Zero position
Driller Console
Throttle
Zero position
Driller Console
Clamp
Center position
Power
ON
ON OFF AUTO
AUTO
Cooling Fan
AUTO
Make sure that HPU pump runs normally, when communication is well, Pump Running
indicator light on Driller Console will on constantly.
Operating the Motor switch to select motors (motor A or motor B or motor A+B).
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Electric Manual
f)
Turn Throttleslowly away from zero position, the main motor will rotate clockwise
with the speed given by Throttle.
Only system is not working andThrottleis on zero position, Operation
switch is valid. Otherwise, Operationswitch is invalid.
Only system is not working andThrottleis on zero position, Direction
switch is valid. Otherwise, Directionswitch is invalid.
Only system is not working,Directionis on stop position, andThrottle
is on zero position, theMotorswitch is valid. Otherwise, Motorswitch
is invalid.
If the operation of Motoror Operationhas a mistake, the system will
give a three seconds sound alarm but no light alarm; After system returning to
normal, this sound will disappear.
Throttle, Drilling torqueandMakeup torquehandle back to zero
position, means set these switches to left end (throttle no input data).
When startup main motors, for safety, the presetDrilling Torquevalue
shouldnt be very high. After the main shaft begin to rotate, operator could
increase Drilling Torquevalue at this time.
Before startup the main motor, make sure that Brake is in right status and
Drilling Torquevalue is right.
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Electric Manual
Button or Switch
Status
Driller Console
Brake
Auto
Driller Console
HPU
Run
Driller Console
Locking
Unlock
Driller Console
Link Rotation
Center position
Driller Console
Link Incline
Center position
Driller Console
IBOP
Open
Driller Console
Auxiliary
Off
Driller Console
Air Cooling
Onor Auto
Driller Console
Operation
Drill
Driller Console
Direction
Stop
Driller Console
Makeup Torque
Driller Console
Drilling Torque
Zero position
Driller Console
Throttle
Zero position
Driller Console
Clamp
Center position
Power
ON
ON OFF AUTO
AUTO
Cooling Fan
AUTO
Zero position
Make sure that HPU pump runs normally, when communication is well, Pump Running
indicator light on Driller Console will on constantly.
b) Set speed range in the Wincc system. After logon, operate DRILLING_CCW
SETTINGbutton could realize drill ccw under Drill Mode. If successful, this button will
become red color.
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c)
Electric Manual
Operating the Motor switch to select motors (motor A or motor B or motor A+B).
Turn Directionswitch to ccw when Throttleis on zero position and system is not
running.
f)
Turn Throttle slowly away from zero position, the main motor will rotate
counterclockwise with the speed given by Throttle.
Electric Manual
Button or Switch
Status
Driller Console
Motor
A+B
Driller Console
Brake
Auto
Driller Console
HPU
Run
Driller Console
Locking
Unlock
Driller Console
Link Rotation
Center position
Driller Console
Link Incline
Center position
Driller Console
IBOP
Open
Driller Console
Auxiliary
Off
Driller Console
Air Cooling
Onor Auto
Driller Console
Operation
Drill
Driller Console
Direction
Stop
Driller Console
Makeup Torque
Zero position
Driller Console
Drilling Torque
Zero position
Driller Console
Throttle
Zero position
Driller Console
Clamp
Center position
Power
ON
ON OFF AUTO
AUTO
Cooling Fan
AUTO
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Electric Manual
a)
Make sure that HPU is in good condition. When communication is well, Pump Running
indicator light will on.
d) When system keep 15% of rated torque and direction of rotation keep clockwise, turn
Operationswitch to Torque, the make-up operation will be finished automatically
with the preset torque ofMakeup Torque.
2
a)
Make sure that HPU is in good condition. When communication is well, Pump Running
indicator light will on.
After finishing spin, ensure rotating head is locked, then turnClampto lock by left
hand, and turnOperationto Torque at the same time, system will switch to Make-up
Mode. After a short time, system will Make-up with value given byMakeup Torque.
Before operating clamp, confirm that the rotating head locking operation has
completed, namely, has already detected the locking pin insert ready signal, the
Locking indicator light will become on.
Before Make-up operation, pay attention to Torque meter, make sure that the actual
Make-up torque reaches to the preset value given byMakeup Torque.
f)
When torque reach to preset value, left hand release theClamp, right hand turn
Operationswitch to Drill, this finish the make-up operation.
g) TurnLocking Pin switch to Unlock position to let the locking pin out. If the locking
indicator is off, means unlock operation has finished.
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Electric Manual
Make sure that HPU is in good condition. When communication is well, Pump Running
indicator light will on.
d) Turn Clamp to lock, and turnOperationto torque. Backup Tong will close firstly,
after a short time system will counterclockwise rotates with a speed not more than Max
torque value 75kN.m. When speed is faster than value of spin speed, the system will stop
automatically. Left hand release theClamp, right hand away from Operationswitch,
then finish the break-out operation.
When Top Drive under Torque Mode, release Clampswitch or releaseOperation
switch, PLC system will stop the drive unit.
e)
f)
When drill pipe tool joint loosen completely, turnDirectionswitch to stop and
Operationswitch to drill, system will stop running.
g) Turn Locking Pin switch to unlock position to do the unlock operation. When the
indicator is off, means unlock operation has finished.
When the drive is running under Spin Mode, if incorrectly operateDirection or
electric faults happens, the system will stop running.
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Electric Manual
To avoid drill pipe thread off happens during the release reactive torque operation,
all operations should strictly follow the routine procedure. To avoid the accident,
the ccw rotate speed should be strictly controlled during release reactive torque
operation.
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5.10.IBOP operation
When system stops running, IBOPcould control IBOPs movement.
Turn urn IBOPto off, if system has received mud pump running signal, the IBOP
indicator light will flicker, the sound will on (silence button is useless).Operator could turn
IBOPto on (the switch in on),IBOP keep on opening. Operator also could close the mud
pump: after closing it, the IBOP will off, the indicator light will on. If Operator does nothing,
IBOP will off delay 10 seconds, and then the indicator light will on, and the sound will off.
During well testing etc., turn PLC/MCC cabinets IBOP Disableto Disable for protect
cable in the well, the operating procedure shown as follow:
a) Turn IBOP to Open ,open the IBOP.
b) Turn PLC/MCC cabinetsIBOP Disableto Disable.
c) The well testing finished, turnIBOP Disableto Enable, IBOP could be controlled by
Driller Consoles IBOP.
During well testing etc., turn PLC/MCC cabinets IBOP Disableto Disable
for protect cable in the well.
After well testing finished, please turn PLC/MCCs IBOP Disableto Enable
for IBOP control reliability, it could be controlled by Driller ConsolesIBOP.
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5.11.E. Stop
When urgent condition taking place, operator could press any ofE. Stopswitch, then, all
equipments of Top Drive will stop quicklyif HPU. Pump on remote contorl mode.
After pressE. Stop, it is forbidden to do any further operations, except that operator has
finished below procedures:
a)
Solve the emergency, and make sure that there is no fault or alarm in system.
d) Reset E. Stop.
e)
PressReset/Silenceto silence the alarm, then press this button again to reset and rescind
emergency status.
f)
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Electric Manual
5.12.Fault/Alarm
The error can be divided into 4 types:
a)
System fault: The drive system faults, the system will stop quickly.
Electric fault : Such as main air switch, auxiliary power supply, I/O power supply,
Driller Console power supply, E-stop, etc. the system will stop quickly.
d) Electric fault : Such as UPS power supply, HPU power supply, etc. the system will
normal stop automatically.
There are three Fault/Alarm indicator lights on Driller Console, which could notice different
kinds of alarm/faults through different kinds of combinations.
H1
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H2
H3
H1
H2
off
flash
flash
off
on
flash
off
on
flash
off
flash
H3
Electric Manual
Alarm type
off
other alarms
flash
off
Alarm
flash
off
flash
off
Communication fault
flash
off
flash
off
Rectifier fault
System fault
Inverter fault
flash
off
flash
off
Electric fault
emergency stop
flash
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Electric Manual
5.13.Encoder switch
If the encoder of main motor was damaged, the Wincc system will give record of alarm. At
this time, switchEncoder Selectswitch could realize system work with the other encoder.
a)
Turn System Starton PLC cabinet to on, Top Drive enter into ready state.
b) Turn PLCs Encoder Faultto fault. This time, Without Encoder indicator light will
power on.
c)
Turn System Starton PLC cabinet to on, Top Drive enter into ready state.
System running without encoder, the control definition for torque was reduced;
Please change the encoder for systems credibility.
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Electric Manual
TurnSystem Startto off, and reset all switches of Driller Console to initial position.
(Refer to appendix 1)
PLC system control signal is sent to Top Drive substation through multicore cable. Other
operations are same with that drill in the normal condition, but only can not collect the
reducing gear box temperature and oil pressure signals. At this time, main motor could
work, and Top Drive also could work, but the operator should settle the problem as soon
as possible.
When stop the electric system (include CPU restart), operator must turn
Control Modeswitch on PLC/MCC cabinet to Profibus mode.
After the communication of LCB has recovered, reset all switches on Driller Console to
the initial position (refer to appendix 1), then, turn System Start to off, and turn
Control Modeto Profibus..
b) Press the Reset/Silencebutton when system has no alarm or fault. After that
electric system will switch back to normal communication mode.
the
When stop the electric system (include CPU restart), operator must turn
Control Modeswitch on PLC/MCC cabinet to Profibus mode.
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TurnSystem Startto off, and reset all switches of Driller Console to original position.
(Refer to appendix 1)
f)
After ensuring the cooling fan has started, turn Directionto cw or ccw.. The main
shaft will rotate clockwise or counterclockwise with a fix speed.
Under this mode, operator should manually operate Brake, HPU pump, HPU
cooling fan, auto is invalid.
After system has recovered from faults, turnDirectionswitch to stop, system will stop
running.
b) Turn all switches of Driller Console back to original position first, then turn System
Startto off, turnControl Modeto Profibus at last.
c)
Press Driller Console Reset/Silence, Top Drive will run in normal status.
Under manual operation mode, it is possible to do some simple magnet valve
operation. But under this mode, although main shaft could rotate, Top Drive
could run only with the rotating speed and torque preset by system.
Under manual operation mode, system work without CPU. So that all the
interlocks, alarms and protections in programme can not be realized.
Under manual operation mode, all the interlocks are invalid, so the operator
should be more carefully, avoid damaging equipment or any person.
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Diagnosis setting
Diagnosis setting
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TIM4R has MPI port. It is suitable for integration into the SIMATIC S7-300, and can also be
connected to one or more SIMATIC S7-300/ 400 or ST7cc via MPI. It also has two WAN
interfaces, provided by modem in TIM, or outlay MD connected by RS232 port, and third
party modem.
TIM 4R module indicate
LED
Relevant
Type of
Inscription
No.
TIM interface WAN driver
Description
Group error
SF
All
TXD
Internal
modem
interface
Dedicated
line
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Transmit Data
LED is continuously on and goes out
during transmission of messages (TXD).
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LED
Relevant
Type of
Inscription
No.
TIM interface WAN driver
Description
Transmit Data
Dial-up
network
RXD
Internal
modem
interface
No connection made:
LED is out.
Connection made:
LED is continuously on and goes out
during transmission of messages (TXD).
Receive Data
Dedicated
line
Dial-up
network
MPI / K
MPI / K bus
(partyline)
TIM-BUS
TIM-BUS
DCF77
DCF77 radio
clock
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Speed Range
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Clicking right bottom window of the picture could open select menu and select the above
trends, every trend has same arrangement:
Title bar: display the title of the current trend
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7.10.System logon
Clicking LOGON button could open logon window; Clicking KEYBOARD button could
open soft-keyboard of windows. The logon is successful after inputting the user name and its
password correctly. Some special operation (for example: handle range setting, analog alarm
value setting, bypass setting, back to windows,etc.) needs the logon operation. After finishing
the operation, clicking LOGOFF button to exit logon status and cancel the operating
authorization.
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7.11.Setting function
Clicking SETTING button could open the setting window after logon. The system
parameter could be modified on this window.
Operator could bypass the system fault and alarm through items on below picture, also could
set procedure interlock if need. Red color words are fault and alarm, cancel means
bypass. White color words are procedure interlocks, means enforce this items interlock.
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7.12.Exit system
Click EXIT button on main picture toolbar, enter the picture of exit windows, and please
operate according to the notes of the picture.
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PS
CPU
System fault
On (red)
BUSF
DC5V
FRCE
RUN
STOP
Bus fault
Internal power supply
Force output
CPU run
CPU stop
On/flash (red)
On (green)
On (green)
On (green)
On /flash (yellow)
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Run + program
Middle
Stop
CPU stop
Down
Clear memory
When turnMode Switchfrom stop to run, the run indicator light will flash until CPU has
detected that all hardwares and softwares has been ready, the indicator light then will on
contently (green). Otherwise, CPU will keep on stop mode.
The software of Top Drive has the function that even one or several distribute I/O stations are
lost or fault, the CPU still could keep on RUN mode, but the BUSF indicator light will
flash and SF indicator light will on.
The program of internal RAM can be cleared by pressingMode Switchto the down position,
the STOP indicator light will flash slowly; ReleasingMode Switchand press again, the
STOP light will fast flash, then releasing theMode Switchagain, the clean operation will
be finished after the STOP indicator light stops flashing.
After clearing the program of CPU internal memory and turning theMode Switchto RUN
position, the CPU will load program from memory card, and run it again. Programmer only
can clear the program in the memory card.
Before clearing the program of memory card, ensure already back up the
program!
When CPU power off happens, the memory card in the front of CPU is for
program protection. This memory card could only be inserted or pulled out
after CPU power is off!
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Module installation
Each digital input module and output module has indicator light for each channel, the green
light means the channel is in logic 1 status.
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The base module has two DIP-switches under the three connectors, one is for PROFIBUS
station address setting, and another is for PROFIBUS terminal resistor setting. The terminal
switch must be set to ON position on every last station of PROFIBUS physical structure.
Bus fault
ON
On/flash (red)
On (green)
All ET200X digital I/O modules have indicator lights for each I/O channel, the indicator light
will be green when it is in 1 status.
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IM
153
interface
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System fault
onred
BF
On/flash (red)
ACT
Out of use
yellow
ON
In Top Drive electric system, Driller Console distribute I/O station address is 14, so set 2,
4, 8 to ON, while the rest are set to the other side. Terminal resistance of Profibus
connector should be set to ON.
8.4.3 Optical fiber connection module/ OLM
PROFIBUS optical fiber connection module (OLMhas three channels: Two optical fiber
interfaces and one electric interface. OLM is DC 24V.
OLM module has three indicator lights. Yellow shows communication is in good condition.
Two optical fibers connected to OLM must cross connection, namely first OLM output
terminal connect with second OLM input terminal.
Code switch
DC 24Vpower supply
Run indicator
RS485 joint
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means
CH2/CH3
CH3
communication regular
OLM DIP switch location:
Compatibility
Out. Power CH3
Out. Power CH2
Mode CH3
Mode CH2
Mode CH1
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8.4.4 REPEATER
PROFIBUS RS 485 REPEATER, is used to connect two PROFIBUS or MPI bus segment of
max 32 stations. It can increase station and transmit distance, could realize electric isolate bus.
There are three indicators lights show its running status:
Segment 1
RS 485 ProfiBus
Segment 2
DPSegment 1
PROFIBUS REPEATER
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When CUR loses communication with CPU, it will stop and has fault message F082 on PMU.
When resetting the fault by pressing the P key on PMU, the fault message will become
alarm message A082 and flash on PMU screen.
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8.5.2 Inverter
Each Inverter has central controller CUVC, PROFIBUS communication board(CBP2) and
SIMOLINK board(SLB) in its electrical control box.
The CBP2 and SLB board are inserted on CUVC board directly. When control power of
CUVC has power on, the CUVC will self check and show o009 (or o008 OFF1 disable) on
the screen of PMU. If it couldnt show o009 (o008), the CUVC is not in ready mode, operator
could read relevant manual of Inverter (the status code or error message). If Inverter fault
happens, operator could press the P key on PMU or press reset key on Driller Console to
reset the fault message (this fault is not caused by hardware damage).
CUVC terminals
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The communication board of Inverter (CBP2) has three indicator lights. When CPU is
running and communication with CPU is OK, the three indicator lights will flash in a same
frequency.
The SIMOLINK is used for communication between two Inverters. It has three indicator
lights, if the communication is OK, the three indicator lights will flash in a same frequency.
The cables between two SIMOLINK modules are plastic fiber optical cable, the two optical
fibers must cross connection, namely the first input channel must connect to the second output
channel, and the first output channel must connect to the second input channel.
If communication of SIMOLINK has communication fault, the fault message F056 will
display on PMU screen. When resetting the fault by press the P key on PMU or reset key on
Driller Console, the fault message will become alarm message A002 and flash on PMU
screen.
When SIMOLINK has fault, the Inverter will stop automatically; after reset the fault, Inverter
will run again.
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Close monitor computer before disconnecting the main air switch, this could avoid
creating alarm record in system when disconnecting the main air switch.
d) Disconnect the main air switch firstly, then close PLC power supply, disconnect UPS at
last.
e)
f)
Below items must be operated if Top Drive electric system has powered off for a long time:
a)
Switch off each power supply from low level to high level. Make sure that all switches
are shut off finally.
Disconnect the cables which connect with electric house. Label those cables to prepare
for the next install.
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The electric house must be put on horizontal place, and away from the ground to avoid
water flow in from the bottom.
b) All cables should be connected with motor or local panel side first. All cable connectors
must be locked strictly to avoid water and loosing.
c)
Earth bar must be built (resistor <4) near the electric house and connected with the
main PE point of electric house.
d) The insulation of motors and cables must be checked before being connected with electric
house.
e)
All cables must be checked carefully to make sure correct connection before power on.
f)
Checking element parts and relevant supporters inside control cabinet to find any loose or
damage caused by transportation.
g) Switch off all air switches inside PLC/MCC cabinet. Generally, it is no need to open all
air switches inside Inverter and Rectifier cabinets.
h) Checking initial position of some mode select switches (refer to appendix 1).
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Operating the voltage select switch on Rectifier cabinet to check that each phase voltage
is in correct range (-15 to +10% of rated voltage 600V).
Switch on the light inside PLC/MCC cabinet and light of electric house.
f)
Checking power on status from monitor system, for detail, please see related chapter.
j)
Operating each button and switch manually to check each hydraulic valve and auxiliary
mechanical system of Top Drive.
After checking the system status on monitor system and make sure that no fault or alarm
happens, the system is ready for operation.
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For electric system, dust proof and damp proof are most important. Operator should pay
attention to keep it dry and clean, and do not work in high (temperature higher than 45)
or low (temperature lower than -13) temperature environment. If Top Drive doesnt
work for a long time, before restart, operator should clean the dust on element parts by
dust collector, and dry them by hairdryer. Check the insulation resistance value finally, be
1M at least, generally the value is over 5M.
b) Start cooling fan first, and then select direction before start main motors.
c)
While running, pay attention to the current meter value of all control cabinet in electric
house.
d) Every cable should connect firmly, screw thread could not loose, and the weld parts
should be firm too.
e)
Because the light shine and air oxidation, cable will aging. Operator should pay attention
to check whether it split, flake or not after using two years. Usually operator should
change the cables after using four years.
f)
Driller Console is EX type, operator should use air filter and water separator to keep air
dry and clean, and make sure that there are no flammable and explosive gases exist.
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Initial position
E.Stop
Loose
Note
Loose is initial position
Initial position
Note
Loose
Profibus
System Start
Off
Motor Heater
Off
E.Stop
Channel Select
Initial position
Note
E Stop
Loose
Brake
Auto
HPU
Stop
Locking
Unlock
Link Rotation
Center Position
Link Incline
Center Position
IBOP
Open
Auxiliary
Close
Air Cooling
Close
Clamp
Center position
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Motor
AB
Operation
Drill
Direction
Stop
Makeup Torque
Zero
Drilling Torque
Zero
Throttle
Zero
Initial position
Note
Link Rotation
Center position
Link Incline
Center position
Initial position
Power
OFF
Note
Switch off 380V power supply in HPU
Control Box
HPU
Stop
Cooling
Stop
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