s11 axera 5 electric system

AXERA 5 MAIN SWITCHGEAR ELECTRIC SYSTEM

(22)

SANDVIK TAMROCK SECOMA S.A.S.19 avenue De Lattre-de-Tassigny - ZIB.P. 46 - 69881 MEYZIEU CedexTel : (33) 472 45 22 00 Fax : (33) 478 31 79 80

MAINTENANCE MANUAL

(22) 21-04-2004 GP-PC-FLAXERA 5 MAIN SWITCHGEAR ELECTRIC SYSTEM


1 PRELIMINARY REMARKS 3

1/1 GENERAL MAINTENANCE SAFETY 3

1/2 ELECTRIC MAINTENANCE SAFETY 5

1/3 ABOUT THIS BOOKLET 5

2 GENERAL 6

3 MAIN COMPONENTS OF THE MSE SYSTEM 7

3/1 MAIN SWITCHGEAR (MP) 7

3/1/1 ADJUSTMENT 7

3/1/2 SWITCHES 9

3/1/3 GAUGES 10

3/1/4 ADJUSTMENT OF CIRCUIT BREAKER 10

3/1/5 TRANSFORMERS 11

3/1/6 CONTACTORS, RELAYS 12

3/2 MULTITIMER UNIT (MTU) 14

3/2/1 INPUTS AND OUTPUTS FOR MTU 15

3/3 EXTERNAL SENSORS 16

4 OPERATION 17

4/1 STARTING AND STOPPING OF POWERPACK 17

4/1/1 AUTOMATIC STARTING OF COMPRESSOR AND WATER PUMPS 17

4/1/2 STARTING OF COMPRESSOR AND WATER PUMPS WHEN POWERPACK IS RUNNING 18

5 MAINTENANCE 19

6 TROUBLESHOOTING 20

6/1 POWERPACK DOES NOT START OR STOPS 20

6/2 POWERPACK STARTS, BUT STOPS AFTER A WHILE 20

6/3 POWERPACK MAIN CONTACTOR CLAPPING 20

6/4 WORKING LIGHTS DO NOT WORK 20

6/5 220-240 V 1-PHASE SOCKET OUTLET DOES NOT WORK (OPTIONAL) 20

6/6 OIL FILLING PUMP DOES NOT WORK (OPTIONAL) 21

7 PERIODIC MAINTENANCE TABLE - AXERA D05 MSE ELECTRIC SYSTEM 22

(22)21-04-2004 GP-PC-FL AXERA 5 MAIN SWITCHGEAR ELECTRIC SYSTEM


1 PRELIMINARY REMARKS

1/1 GENERAL MAINTENANCE SAFETY

The informations contained in this manual must be studied and thoroughly assimilated before undertaking any maintenance work on the equipment

WARNING: Operation, maintenance and adjustments are only allowed to persons with specific training in operation and maintenance of the equipment. Read the operating and maintenance instructions before using or servicing the equipment.

WARNING: Before starting any maintenance operation ensure that the machine is in a safe location with good safety, ventilation and lighting conditions. Ensure that lifting equipments and pedestals are compatible with elements’ weight. Follow all the safety instructions and ware safety protections as gloves, goggle, helmet, safety boots, ear protectors.

WARNING: Before any operation stabilize and fix steadily all the elements on suitable pedestals. Stop the power packs, switch the general power breaker. Place a tag or a board to warn other members of the personnel that maintenance work on the machine is in progress.

WARNING: Pressurized oil jets could cause severe injuries. Before any operation on hydraulic circuit, STOP the power packs and release remaining pressure in components by operating hydraulic control levers several times. Always release the static pressure in cylinders before disassemble them.NEVER WORK ON AN OPERATING CIRCUIT.

WARNING: While tests are in progress, do not allow any other member of the personnel to stand in the area surrounding the machine. Stay at the control station to be able to stop the movement and switch off the power pack.

WARNING: Maintenance, adjustment and repairs are restricted to qualified personnel with special training for the particular equipment. Always read the instructions carefully before starting any maintenance work.

CAUTION: Always use suitable tools and work in a clean place when dismantling and assembling hydraulic components. After removing cylinders the hydraulic inlet/outlet ports must be plugged to prevent dirt and air intrusion during operation.

WARNING: The operator must always wear required personal protection, such as safety helmet, protective overall, safety boots, hearing protectors, safety goggles etc.

WARNING: Danger of high pressure oil jets.High pressure oil jets can cause serious personal injuries.Release the pressure in the hydraulic circuits before opening caps or connections.(Accumulator, Cylinder and Hydraulic circuit)

Remember: SAFETY FIRST!Always observe the warnings accompanied by the following symbols.

WARNING

!

WARNING

WARNING

WARNING

WARNING

CAUTION

WARNING



WARNING: Danger of hot surface.Hot surface can cause serious injuries.Components rod, shank or hydraulic component can be hot and beforestarting a maintenance work, please let them cool off. The operator must have adequate wears as gloves.

WARNING: Crushing hazard : do not stay in dangerous area, for instance: centralarticulation, front chassis and rear chassis.

WARNING

!

SAFETY

Do not attempt any such repairs or adjustments that you do not fullyunderstand.

ABOUT THE SAFETY OF REPAIRS

Certain workstages require the use of the feed mechanism during the repair.Make sure then that:

- no danger is caused to anybody.- the machine can be immediately stopped when necessary.- the powerpack is stopped again before the repair-work is continued.

Before starting any repair-work move away from the area where you have justdrilled.

Use proper tools.

Always wear protective clothing, eye protection, earmuffs, safety footwear, andother safety equipment required by the work.

Always follow the marked safety instructions, andobserve caution while working.

The following safety instructions are general rules.

Keep tools and drillingequipment clean.

!

!

!

!

!!!



1/2 ELECTRIC MAINTENANCE SAFETY

CAUTION: Electric devices will stay in safe working condition if they arerepaired and serviced by a qualified electrician.

CAUTION: Repairs on electric devices is only allowed to personswho are notonly qualified but also authorized to do the work.

CAUTION: Check the condition of all electric devices and wires regularly.

CAUTION: Remember to close all electric switchgear doors properly afterrepairs or adjustments.

WARNING: If you suspect a fault in any electric device, cut off the voltage atthemain switch, and call in an electricianwho is specialized in theelectric systems of the equipment you are using.

WARNING: Make sure that the voltage cannot be accidentally switched onwhen you are working on the equipment.

WARNING: Even when you are working on dead equipment, use goodinsulated tools. This is a simple method to improve your ownsafety.

WARNING: Take the operation of the safety devices seriously. If a safetydevice prevents the operation of a device, call in an electrician atonce to determine the fault.

1/3 ABOUT THIS BOOKLET

The present manual is destined for the use of personnel in charge of carrying out, servicing and maintenance operations on Jumbos.

It contains maintenance operations schedule and operating methods concerning the main

elements of the AXERA 5 MAIN SWITCHGEAR ELECTRIC SYSTEM .

Note that servicing and maintenance operations must be carried out by personnel with the

required qualifications, technical knowledge, and proper training on the machine.

CAUTION

CAUTION

CAUTION

CAUTION

!

!

!

!



2 GENERAL

The main switchgear electric system consists of the main switchgear (MP), and the devices,

sensors, and the control and the indicator light panel connected to it. The electric control of the

hydraulic system is dealt with in separate instruction manuals.

In the electric circuits of the electric motors, the cabin heater, and the socket outlets the voltage is

over 100 VAC. The sensors, the switches,the working lights, the indicator lights, and the electric

control of hydraulics use reduced voltage (24 VDC).

Tamrock manufactures the electric system of the rig to conform to the standard EN 791.

The power supply must be dimensioned to guarantee trouble free operation at full power and

when electric motors are started. The power supply transformer or the generator, and the power

supply cable must be rated to meet the rig's power requirements.

The rig is designed to operate in a supply network that meets the requirements in 4.3.1 of the

standard EN 6020461. The power requirement, the frequency, and the operating voltage are

given on the panel at the main switch. The fluctuation of the rated voltage must not exceed + or -

10% at the main switchgear, whether idling or operating at full power.

Tamrock defines the maximum voltage drop in the power supply cable to below 3%.

The main switchgear electric system is made to the protection class IP55, which means

enclosures that are jets of water and dust tight.

WARNING: Water must never be sprayed directly at the electric boxes or cabinets ofthe rig!

MSE MAIN SWITCHGEAR

SUPPLY

CARRIER OPERATOR

DRILLING

CONTROL

SYSTEM

MO

TO

RS

LIG

HT

ING

SE

NS

OR

S

IND

ICA

TO

RS

GA

UG

ES

!



3 MAIN COMPONENTS OF THE MSE SYSTEM

The main switchgear electric system consists of the main switchgear (MP), and the devices, sensors,and the control and the indicator light panel connected to it.

3/1 MAIN SWITCHGEAR (MP)

• Contains the main switch, the motor controls, and the power supply system for the electric

devices.

3/1/1 ADJUSTMENTCAUTION: Reset the protective switches to position I only when the main switch is in the 0 position, if the rig is connected to the power supply network.

Motor protector switches, circuit breakers.

Adjustments of protector switch for powerpack motor.

CAUTION



1F100 Motor protector switch of the powerpack with thermal and magnetic triggering. The set

value (A) of the triggering current for the thermal switch is 1x the nominal current given on the

motor's type plate.

The triggering current of the magnetic switch is constant. The protective switch must be reset by

turning the control handle first to position 0 and then to position 1.

F230 Water booster pump's motor protector switch with fixed magnetic triggering and adjustable

thermal triggering. The set value of the thermal triggering current is equal to the nominal current

given on the motor's type plate.

F240 Compressor's motor protector switch with fixed magnetic triggering and adjustable thermal

triggering. The set value of the thermal triggering current is equal to the nominal current given on

the motor's type plate.

A



F250 Transformer protector switch of outlet socket and cabin heater transformer. (Optional)

F290 Protector switch with fixed magnetic triggering and adjustable thermal triggering for power

supply transformer of 3-phase service socket outlet or its transformer or the circuit breaker for

external pump supply. (Optional)

F295,296 Motor protector switch of oil cooler fan with fixed magnetic triggering and adjustable

thermal triggering for boom. The set value of the thermal triggering current is equal to the nominal

current given on the motor's type plate. (Optional)

F310 Transformer protector switch of control.

F320 Transformer protector switch of internal 24 V control voltage of main switchgear cabinet.

3/1/2 SWITCHES

Q100 Main switch; cuts off power supply.

WARNING: Without pilot-system it does not cut off the voltage at the cable reel and the slip rings, nor the battery voltage of the carrier.

It can be locked in the 0 position.The main switch also cuts the pilot conductor that monitors the

supply cable and the protective conductor. The pilot conductor is an optional device. When the

main switch is turned into the 1 position (ON), the switchgear cabinet door is locked.

!



3/1/3 GAUGES1P100 Rock drill percussion hourmeter.

1P101 Powerpack hourmeter. (Optional)

P400 Compressor hourmeter.

P410 Supply voltage meter.

3/1/4 ADJUSTMENT OF CIRCUIT BREAKERF251 Fault current circuit breaker for cabin heater and sockets. (Optional)

F253 Circuit breaker cabin heater. (Optional)

F291 Fault current circuit breaker for 3-phase socket. (Optional)

F311 Fault current circuit breaker for internal 220 V control voltage in main switchgear.

F450 Circuit breaker for internal 24V control voltage in main switchgear.

F451.1 Circuit breakers for drilling control system.

F452.1 Circuit breakers for working lights.

F452.3 (Optional)

F453.1 Circuit breakers for cabin (Optional).

F453.4

F454.1 Circuit breakers for hydraulic oil filling pump, Multitimer unit, carrier and instruments.

F454.5

F455.1 Circuit breakers for air conditionner. (Optional)

F455.2 Circuit breakers for Diesel EMR. (Optional)



3/1/5 TRANSFORMERS

T250 4500 VA power supply transformer for 1-phase 220-240 V service socket outlet and cabin

heater. The transformer is equipped with an overheating protector (150°C) that cuts off the socket

outlet load. The protector resets automatically when the transformer has cooled down sufficiently.

(Optional)

T290 Transformer for external pump earth leakage relay. (Optional)

T310 Control voltage transformer. Control voltage: 400 VA, 220-240 V

T490 Transformer for external pump control circuit. (Optional)

A410 Battery charger. Charges the carrier's batteries when the rig is connected to the supply

network and the main switch is on. The charger is equipped with charging automatics to prevent

overcharging.

A420 Power transformer. The power source of the rig's 24 VDC circuit.Output 1000 VA.



3/1/6 CONTACTORS, RELAYS

KM1 Delta contactor of powerpack motor.

KM2 Starter contactor of powerpack motor.

KM3 Star contactor of powerpack motor.

1K101 Auxiliary starter relay for powerpack.

1K112 Thermistor relay for temperature control of powerpack electric motor.

K77 Emergency stop relay.

K78 Emergency stop auxiliary relay.



K230 Starter contactor of water booster pump.

K240 Starter contactor of compressor.

K260 Contactor for air conditioning compressor. (Optional)

K290 Contactor for external pump. (Optional)

K291 Auxiliary relay for external pump. (Optional)

K295 Starter contactor of oil cooler fan. (Optional)

K320 Phase sequence control relay.

K395 Relay of oil cooler fan. (Optional)

K400 Connecting contactor for lighting.

K401 (Optional)

K424 Auxiliary relay for monitoring functions.

K425 Battery feed connector relay.

K430 Contactor for 1-phase socket outlet. Cuts off power supply to socket if transformer is

overloaded. (Optional)

K442 Thermistor relay of compressor temperature monitoring. (Australian models / Hydrovane

compressor)

K445 Drilling stop auxiliary relay. (Power optional)

K461 Auxiliary relay for air conditioning compressor. (Optional)

K471 Auxiliary relay for supply net ON.

K480 Pilot interlock relay. (Optional)

K481 External pump auxiliary relay. (Optional)

K491 Starting relay for External pump. (Optional)

K492 Earthing wire continuity control relay. (Australian models)

K493 Blinking relay for earthing failure. (Australian models)



3/2 MULTITIMER UNIT (MTU)

1. Adjustment of delay for water pressure monitoring.

2. Adjustment of delay for air pressure monitoring.

Water pump and drilling functions stop after set delay if water pressure drops below 2.8 bar.

Drilling functions stop after set delay if output pressure from compressor drops below 2.8 bar.

Under the cover of the timer unit (A100) you will find the two adjusting screws that are used for

setting the delays for the water pump and the compressor.

By turning the adjusting screw clockwise you can increase the delay, and by turning the

screw anti-clockwise you decrease the delay.

The factory settings for the delays are: 4 seconds for water pressure and 10 seconds for

air pressure.

A100

10CH 11CH

0CH 1CH

1

2



3/2/1 INPUTS AND OUTPUTS FOR MTU

IN 0 CH. (Channel)

OUT 10 CH. (Channel)

IN 1 CH. (Channel)

I/O Symbol Description Normal state*0 S422 Water pressure control 01 S421 SAir pressure control 02 S420 Hydraulic oil level control 13 S501 Water pump automatic use 14 S501 Water pump manual use (start) 05 S502 Compressor automatic use 16 S502 Compressor manual use (start) 07 S505 Pressure switch reset 18 S507 Double booster pump use (option) 09 HP_RUN Hydraulic pump running 1

10 Overload Water pump / compressor overload 111 Oil_hot Hydraulic oil hot 0

COM 0VDC 0

I/O Symbol Description Normal state*012 H601 Water pressure low 03 H609 Air pressure low 04 H602 Oil level low 05 Drill_stop Drilling stop 06 K424 Main control relay 17 Control 24 VDC control supply 1

COM +24 VDC 1COM +24 VDC 1COM +24 VDC 1COM +24 VDC 1

I/O Symbol Description Normal state*0 SH520 Pressure switch by pass (Power) 012 KVL KVL oil level low 034 S428 Water pump control 1



OUT 11 CH. (Channel)

* In the table, normal state means a state where the powerpack, water pump, and compressor

are on and no faults are active.

When the input or output is 0, the voltage is 0 volts. When the input or output is 1, the voltage is

24 VDC.

CAUTION: The output leds of the multi-channel timer relay indicate the status of the program, i.e. in order to ensure the state of the output, it must be measured directly from the connector.

3/3 EXTERNAL SENSORS

S420 Oil level switch. Two switching points are provided: lower level for oil level alarm and upper

for oil filling pump.

S421 Pressure switch for shank lubrication and flushing air.

S422 Pressure switch for flushing and cooling water.

S424 Oil temperature switch and gauge. The temperature switches are incorporated in the

temperature gauge. Two switching points are provided: upper for oil temperature alarm and

stopping (75°C) and lower for bypassing oil filter monitoring (30°C).

S425 Pressure switch of hydraulic oil return filter.

S428 Pressure switch for water pump control. Water pump can start when S428 is actived (by

pushing the percussion joystick or water flushing joystick).

S441 Temperature switch for compressor's output air.

R441 Thermistor sensor of compressor motor. Australian models only.

1S180 Pressure switch for hydraulic oil pressure filter of powerpack.

1R112 Thermistor relay of powerpack motor (stator temperature 155°C).

I/O Symbol Description Normal state*0 K230 Water pump control 11 K240 Compressor control 12 K280 Double booster pump control (Optional) 03

COM +24 VDC 1

CAUTION



4 OPERATION

CAUTION: Read and observe the Tamrock Safety Instructions.

4/1 STARTING AND STOPPING OF POWERPACK

Make sure that the electric switchgear cabinet doors are closed.

Turn the main switch Q100 into position 1.

Make sure that all hydraulic control levers are in the neutral position.

Before and after starting the powerpack, check the voltage meter reading. The supply voltage

should be within the limits given by the manufacturer (+ or - 10%).

Stop the powerpack by turning the boom's start switch to the stop position, and back.

CAUTION: If the starter contactor of powerpack motor is clapping, do not continue starting attempts. The starter contactor may be damaged and may cause severe damage in the electric switchgear.

CAUTION: Do not use the Emergency Stop button for stopping under normalcircumstances. Do not stop the powerpack if a function is activated.

4/1/1 AUTOMATIC STARTING OF COMPRESSOR AND WATER PUMPSTurn the starting switches for the compressor (S502) and the water pump (S501) into position 1.

Start the powerpack motor by turning the boom's start switch to the start position, and back.

Water pump will start after pushing percussion joystick or water flushing joystick.

CAUTION

CAUTION

CAUTION



4/1/2 STARTING OF COMPRESSOR AND WATER PUMPS WHEN POWERPACK IS RUNNING

(When the starting switches for the compressor (S502) and the water pump (S501) are in

position O.)

Start the powerpack motor by turning the boom's start switch to the start position, and back.

Start the compressor by turning the switch S502 into position 1. Wait at least 1 second before

starting the next motor. Start the water booster pump, and wait at least 2 seconds before starting

the next motor. Any starting order of the above motors can be used.



5 MAINTENANCE

Each shift

• Check the operation of the emergency stop button(s).

• Make sure that the electric cabinet door is properly closed and that the plugs are properly

connected.

• Visually check the condition of the electric cables.

Once a month

• Check the electric boxes subjected to moisture, and dry them if necessary.

• Apply protective agent to the connections.

• Carefully check all cables for damage, cable mountings, and grommets for tightness.

• Check the operation of the fault current protector switch.

• Pull the power supply cable out and check it's condition.

• Check the water drainage holes are open.

• Check the seal bushings condition and tighteness.

Once a year

• Check the operation of the safety device sensors.

• Check the tightness of the motor terminals and other screw-mounting terminals in the main

switchgear and in the control system.

After a long period out of use

• Check the electric cabinets and boxes for condensate water. Wipe off any moisture.

• Check the insulation resistance at the supply cable end with the main switch in position I. Also

check the insulation of the electric motors.

• Check the contactors of the plug connectors for oxidation. Clean and protect with grease as

necessary.

In connection to repairsIf you have to replace components in the electric control system (24 V) or remove protective agent,

always apply protective agent to the connections when you have finished the repairs: protective

grease for plug-in connections, such as multi-pole connectors and valve connectors, and

protective coating for screw connections.

Protective grease ID-867 429 89

Protective coating ID-867 430 49



6 TROUBLESHOOTING

6/1 POWERPACK DOES NOT START OR STOPS

• Make sure that the main switch is on.

• Check the indicator lights (Cf. 3.3).

• Water pump or compressor is running.

• If the voltage meter does not show any reading, check the protector switch F311.

• Check the circuit breaker F310 for the 220-240 V control voltage, and the fault current protector

switch F311.

• If the indicator light H617 is not lit, check the protective switch F320 of the 24 VDC feed

transformer, and the circuit breaker F450.

6/2 POWERPACK STARTS, BUT STOPS AFTER A WHILE

• Compressor air temperature rise above 115°C or compressor - or water pump motors are

overload. In this case all motors stops and indicator light H604 goes on. Fault goes off when

temperature is under 115°C andcompressor- and water pump circuit breakers are on.

• Hydraulic oil tank temperature rise above 75°C. After that power packs stops and indicator light

H610 goes on. Fault goes off when temperature is again under 75°C.

• Hydraulic oil level drops (over 3 seconds) below the minimum. Indicator light H602 goes on.

Press pressure switch reset button S505 (indicator light H602 goes off), after that powerpacks

can be restarted (if oil level is above the minimum oil level).

6/3 POWERPACK MAIN CONTACTOR CLAPPING

• Power supply network too weak. Check the supply voltage and the dimensioning of the supply

network, the cross-sectional area and length of the supply cable.

• Check the control voltage.

6/4 WORKING LIGHTS DO NOT WORK

Working light bulb burnt.

Lighting plug off.

Check the working lights circuit breaker F452.1, 452.2 and 452.3.

Check the protective switch F320 of the 24 VDC feed transformer, and the circuit breaker F450.

Control circuit fault.

6/5 220-240 V 1-PHASE SOCKET OUTLET DOES NOT WORK (OPTIONAL)

• Too great load.

• Check the protective switch F250 of the socket outlet transformer.



• Check the fault current protector circuit breaker F251.

• If the socket outlet transformer is overloaded (too hot), the thermal protector of the transformer

switches the socket load off. The protector resets automatically as the transformer cools down.

Check the reason for overheating.

• Control circuit fault.

6/6 OIL FILLING PUMP DOES NOT WORK (OPTIONAL)

• Oil tank full.

• Check circuit breaker F454.1.

• Check the control circuits and the wiring.



7 PERIODIC MAINTENANCE TABLE - AXERA 5 MAIN SWITCHGEAR ELECTRIC SYSTEM

❏ Check Adjust ▲ Replace

❍ Clean ● Lubricate/Apply protective agent

Protective grease ID-867 429 89 Protective coating ID-867 430 49

Serial number: Percussion hours (PH): Name:

Date: Signature:

PERIODS DONE.

Each shift Once a month

Once a year

After a long period out of used

AXERA 5 MAIN SWITCHGEAR ELECTRIC SYSTEM

YES NO

❏ ❏ ❏ ❏ Check the operation of the emergency stop button(s).

❏ ❏ ❏ ❏ Make sure that the electric cabinet door is properly closed and that the plugs are properly connected.

❏ ❏ ❏ ❏ Visually check the condition of the electric cables.

❏ ❏ ❏ Check the electric boxes subjected to moisture, and dry them if necssary.

❏ ❏ ❏ Carefuffy check all cables for damage, cable mountings, and grommets for tightness.

❏ ❏ ❏ Pull the power supply cable out and check it’s condition.

❏ ❏ ❏ Check the water drainage holes are open.

❏ ❏ ❏ Check the seal bushings condition and thightness.

❏ ❏ Check the operation of the safety device sensors.

❏ ❏ Check the tightness of the motor terminals and other screw-mounting terminals in the main switchgear and in the control system.

❏❍ Checks the electric cabinets and boxes for condensate water. Wipe off any moisture.

❏ Check the insulation resistance at the supply cable end with the main switch in position 1. Also check the insulation of the electric motors.

❏● Check the contactors of the plug connectors for oxidation. Clean and protect with grease as necessary.

● ● ● Apply protective agent to connections.

s11 axera 5 electric system

Documents

maintenance operation

maintenance work

electric maintenance

maintenance instructions

maintenance manualpage

main components

safety instructions

main switchgear mp