Maintenance instructions 10. Electrical system, IEC 10. Electrical system, IEC Safety + Dangerous voltage. * Risk of serious personal injury + Make sure the system is de-energised before starting any maintenance work. The electrical system may only be serviced by an authorised electrician. General Safety standard The electrical system complies with current regulations. Applied directives and standards are specified in the document Safety, chapter Declaration Low-voltage circuit Low voltage refers to an alternating current with a voltage greater than 50 V and less than or equal to 1000 V. + Cable on reeling unit and collector + Electric cabinet + Blectrie motor(s) for hydraulic pump(s) + Operating circuits + Service outlet + Battery charger for carrier (also extra low voltage) + Indicator lamps on electric cabinet Extra low-voltage circuit Extra low-voltage refers to an alternating current with a voltage less than or equal to 50 V and direct current with a voltage less than or equal to 120 V. 198Maintenance instructions 40. Electrical system, IEC + Operating circuits + Guards in the system + Battery charger for carrier (also low voltage) + Lighting + Oil level switch Before starting Check, before starting, all high-current connections in the electric cabinet and the collector, as well asthe electric motors. Also, check that the plug is plugged in prop- erly. Cable marking ‘All the cables are marked with cable numbers corresponding to the wiring diagram. Replacement of components. Whenever changing a component, make sure the new component has the same Atlas, Copeo part number as the old one. Mark new components with the same marking as the ones they replace. 199Maintenance instructions 10. Electrical system, IEC Lighting Risks on bulb change Hot surfaces Can cause burns Dirt on bulb glass is burned in and shortens the life of the bulb Never touch the glass on a bulb with your, fingers Always use a clean cloth when fitting the bulb or hold the bulb at its base Wait until the bulb has cooled before changing it Xenon bulbs * High voltage + Can cause personal injury + The supply voltage to the xenon bulb must be switched off before changing the bulb or starting other work on the supply circuit. + Xenon bulbs should only be handled by authorised maintenance personnel. Electric cabinet, high-current Indicator lamps 200Maintenance instructions 40. Electrical system, IEC For information on the electric cabinet indicator lamps, see operator's instructions Electrical system Inside, Y/D start (400-690V) ao F25 aot 1F01 2F01 Figure: Electrical distribution cabinet A10, standard IEC U40 Battery charger POL Voltmeter, ammeter and timer KS1_ Ground fault relay (ire protection) K50_ Phase sequence switch QOL Main swited F25_ Ground fault breaker (personal protection) FOL Motor protection relay (one foreach hydraulic pump unit) 201Maintenance instructions 10. Electrical system, IEC Inside, direct start (1000V) Figure: Electrical distribution cabinet A10, direct start (1000V) U40 Battery charger POL Voltmeter and ammeter QOL Main switch KS1_ Ground fault relay (fre protection) F25. Ground fault breaker (personal protection) SIL Motor switch S12 Motor switch KS0_ Phase sequence switch FOL Motor protection relay (one foreach hydraulic pump unit) Voltmeter, ammeter and timer mono ofefob Yo VAL A2 ABT Figure: Combined voltmeter, ammeter and timer Meter (P01) is a combined voltmeter, ammeter and timer. The five buttons can be used to select what is displayed on the meter’s screen. The LEDs under the buttons indicate which buttons are activated. 202Maintenance instructions 40. Electrical system, IEC Press button (V) to check that the input voltage to the rig complies with the rated voltage specified on the rig's data plat. Press buttons (A1-A3) to display the current consumption of the hydraulic pump electric motors. The number of buttons that are functional varies from rig to rig depending on how many hydraulic pump units the rig has. When the rig is in opera- tion you can check that the electric motors are not overloaded by comparing the meter readings with the rated current specified on the motors’ data plates. Press button (T) to display the percussion’s operating hours. Which operating hours are shown on the display (for which hydraulic pump unit) depends on which button (AL-A3) is activated. + Al =Percussion hours. + A2=Electric motor hours (Boltec LD and MD). Electrical system protection Main switch Description The main switch (QO1) is on the 3-phase circuit in the electric cabinet. It has a knob for on and off. The main switch has as standard under-voltage protection, thermal overload protection and magnetic short-circuit protection. ‘The switch can be reset after being triggered by turning the knob to position 0 (OFF) and then back to position 1 (ON). 203Maintenance instructions 10, Electrical system, IEC Main switch dip switches ae Figure: Main switch QOL 11 Dip switches for setting overload protection Ui switches for setting overload duration 13_Dip switches for Setting short cicuit protection Overload protection The overload protection setting is dependent on the supply voltage and total electric motor output. ‘The setting is made with DIP switches (11) on the main switch. Next to the DIP switches is a mark indicating the different setting alternatives, Check the following, table to see what setting to use. The duration (t1) must be set to 12 seconds in all cases. ‘Table: Setting, main switch overload protection ‘Supply voltage Electric motor Setting [380-400 V 2x 55 KW (0.6 x 400 A 204Maintenance instructions 40. Electrical system, IEC [Supply voltage Electric motor ‘Setting 380-400 2x75 KW [0.8% 400A 440 [2x55 KW [0.5 x 400A 440 [2x75 KW 0.7 x 400A 500V 2x55 KW [05x 400A 500V 2x75 KW (0.6 x 400 [550 [2x55 KW [0.4 x 400A 550V [2x75 KW [0.5 x 400A 660-680 2x55 KW [04x 400A 660-680 2x75 KW [0.4% 400A 660-690 V [2x95 KW [0.6 x 400A 1000 V 2x55 KW [0.4 x 250A 1000 V 2x75 KW [0.5 x 250A 1000 V 2x95 KW (0.7 x 250A Short circuit protection The settings for the short-circuit protection depend on the method of starting. The setting is made with DIP switches (13) on the main switch. Next to the DIP switches is a mark indicating the different setting alternatives. For rigs with Y/D start or soft start, the short-circuit protection must be set to 4.5 x the switch’s rated current (In). For rigs with direct start, the short-circuit protection should be set to 10 x the switch’s rated current (In), Phase sequence switch The electrical system has a phase sequence switch (K50) to prevent the electric ‘motors from starting if the power supply has the wrong phase sequence. If there is a phase sequence problem, an indicator lamp on the electric cabinet will come on, see operator's instructions Electrical system. Ifthe phase sequence fault indicator lamp comes on, the following measures must be taken by a qualified electrician. 1, Tum off the main switch for the input cable and pull out the plug. 2. ‘Switch two of the phases in the consumer mains source. Settings Must be set for a delay of 10 seconds and a minimum of 180V. 205Maintenance instructions 10. Electrical system, IEC Figure: Phase sequence relay. setting values Ground fault equipment ‘The electrical system has an ground fault relay (K51) and an ground fault breaker 25) ‘The purpose of the ground fault relay (K51) is to protect the rig from fires in the main circuit. This switch is set by the supplier to 300 mA and 0.5 seconds. ‘The ground fault switch (F25) provides personal protection as when it trips the sup- ply to the transformer circuit for service outlet 230 V AC and to the battery charger (U40) is disconnected. This switch is set to 30 mA and max. 40 ms. The ground fault equipment should be tested regularly by a qualified electrician. ‘The ground fault equipment settings are checked prior to delivery and the equipment sealed. Motor protection Motor protection - Atlas Copco Electronic motor protection relay Note The following information applies to models GL 16, GL 40, GL 90 and GL 200. Appearance may vary between models. 206Maintenance instructions 40. Electrical system, IEC 1 2 4 GL 16 6 8 Sreserell , 5 igure: Electronic motor protection relay Indicator for motor protection in operating position Indicator for overcurrent and thermal overload Indicator for phase loss and phase error Indicator or overheating Reset button Setting rated current Setting the trp class Phase sequence monitoring Each hydraulic pump motor has an electronic motor protection relay (1FO1-4F01) that protects the motor against overheating (thermistor) and overcun Motor protection phase sequence monitoring (8) should be in the Off position. ‘The motor protection has a green LED (1) that indicates that the power supply is on and that the output relay is in operating position. If the motor protection is triggered, the LED goes out, The motor protection has three LEDs (2, 3 and 4) to indicate which type of fault has triggered the protection. LED (4) illuminates when the permitted motor temperature has been exceeded (over- heating). The electric motor stops in the event of overheating. LED (3) illuminates in the event of a phase loss or a phase error. The electric motor stops or cannot be started, 207Maintenance instructions 10. Electrical system, IEC LED (2) illuminates when the permitted motor current is exceeded (overcurrent), Motor protection then triggers because the motor is overloaded (thermal overload). If the protection has been triggered 1. Check which LED (2, 3 or 4) is on and ify the cause of the stoppage. a. LED (4) is on. Check that the electric motor is properly cooled or if it has been overloaded for a long time. b, LED (3) is on. Tum off the main power contactor for the input cable and pull out the plug from the wall socket. Then check the cables in the electric motor circuit and the electric motor. ¢. If LED (2) illuminates, it means that the motor current exceeds the set rated current and that the motor protection has been triggered. Check that the voltage is not less than the voltage for which the rig is designed. The voltage for which the rig is designed can be read on the data plate for the rig of the electric motor. If the voltage is correct, check the electric motor cir- cuit, see item b above. 2. Once the cause of the stoppage has been rectified, reset the motor protection with button (5). Setting rated current 208 The motor protection must be set to the rated current of the motor unless the motor has a service factor (SF) higher than 1.0. + Ifthe service factor is 1.15, the motor protection must be set to a value 15% higher than the rated current, + Ifthe service factor is 1.3, the motor protection must be set to a value 30% higher than the rated current. The rated current and service factor are specified on the motor’s data plate. The motor protection has a basic value of 4 A for GL 16, 15 A for GL 40, 40 A for GL 90 or 60 A for GL 200, that must be taken into consideration when setting. The value set for direct start must consequently be 4, 15, 40 or 60 A lower than the rated current for the motor, alternatively 4, 15, 40 or 60 AA lower than the rated current for the motor times the service factor (1.15 or 1.3). For Y/D start the value must be as above but times 0.58. rip class must be set to a value of 10 (7). Settings are made using DIP switches on the motor protection (6).Maintenance instructions 40. Electrical system, IEC Battery charger General The battery charger (U40) supplies the rig's 24 V-system and is fitted integrated into the electrical distribution cabinet (A10).. The supply voltage to the battery charger must be 240 V AC, 45-65 Hz. Figure: Battery charger (U40) When replacing a battery charger the correct charging voltage must be set. The charg- ing voltage is adjusted on screw (1) and must be set at 26.8V, Measure the set voltage between 2(+) and 3(-) using a voltmeter, Cable recommendations For recommendations regarding the power supply cable, see the chapter General. Diagnostics Before starting fault finding, check that: + all fuses are intact and tumed on. + the correct power supply is connected to the rig (see voltmeter). + all warning lamps on the electric cabinet are in working order (lamp test) 209