Manual No, 185-5585 2 NATIONAL OILWELL VARCO INSTRUCTION, OPERATION AND SERVICE MANUAL FOR MODEL 20254 BRAKE CONTROL WITH BATTERY BACK-UP EQUIPMENT FURNISHED BY National Oilwell Varco 500 INDUSTRIAL BLVD. SUGAR LAND TEXAS 77478-2898 TELEPHONE: (281) 240-6111 FAX: (281) 274-0426N@Y warionat omwewt vARco TABLE OF CONTENTS Page ‘SECTION 1 INTRODUCTION AND DESCRIPTION 14 SCOPE OF MANUAL 14 1.2. GENERAL DESCRIPTION 14 SECTION 2 DESCRIPTION OF OPERATION 241 THEORY OF OPERATION 24 22 DRILL FLOOR COMPONENTS 24 2.2.1 Drillers Control (Drawing 55858) 24 2.2.2 Rig Floor Selector Switch (Drawing 55860) 22 23 SAFE AREA COMPONENTS 23 2.3.1 SCR Power Converter Model 20254 (Drawing 55850-2) 23 2.3.2 Auxiliary Printed Circuit Board 27 2.33 System Block Diagram 21 2.3.4 Intrinsic Safety 243 SECTION 3 SPECIFICATIONS 34 GENERAL 3 3.2 INPUT POWER REQUIREMENTS. 31 3.2.1. Brake Power Controller Input AC 34 3.3. INPUT SIGNAL REQUIREMENTS ot 34 BRAKE CONTROLLER OUTPUT POWER 34N@Y warionat onwett varco TABLE OF CONTENTS (Cont'd) Paragraph SECTION 4 INSTALLATION 44 GENERAL 4.2 HAZARDOUS AREA COMPONENTS 421 Driller's Control (Drawing #55858) 4.2.2 Rig Floor Selector Switch (Drawing #55860) 4.3 SAFE AREA COMPONENTS 431 General 43.2 Power Transformers 44 INITIAL SYSTEM POWER-UP 44.1 Test Equipment Required 442 Installation Checkout 443 Functional Test 4.5 HAZARDOUS AREA CONSIDERATIONS AND APPROVALS 45.1 General 45.2 Diiller’s Control (Drawing #55858) 453 Rig Floor Selector Switch (Drawing #55860) 46 APPROVALS SECTION § OPERATING INSTRUCTIONS 54 SCR POWER CONVERTER 6.4 SECTION 6 MAINTENANCE BRAKE AND CONTROL at at at 42 42 42 43 43 43 49 att an an 42 412 541 61(N@Y¥ wariowa owe. varco TABLE OF CONTENTS (Cont'd) Paragraph SECTION 7 PARTS AND SERVICE 7A GENERAL 72 PARTS AND SERVICE 73 RECOMMENDED SPARE PARTS, 734 SCR Assembly - 25KW Model 55850-2 7.3.2 Miscellaneous SECTION 8 DRAWINGS iti 7A 7-2 72N@Y mariowar omwewt varco 14 12 SECTION 4 INTRODUCTION AND DESCRIPTION SCOPE OF MANUAL This manual provides information pertaining to the installation, operation and maintenance of the following component parts of the Baylor Brake Control System: + SCR Power Controller + Intrinsic Safety Barrier * Hazardous Area Components The manual is divided into sections giving a narrative description of the theory of operation, function of controls, operating instructions, maintenance and service. Also recommended spare parts and supplies are listed along with schematics, block diagrams, and major assembly drawings. Operators are requested to read and thoroughly familiarize themselves with this manual before attempting to operate the equipment. GENERAL DESCRIPTION The Eddy Current Brake Control System (referred to in the balance of this Manual as CONTROL SYSTEM), provides a variable DC voltage and current input to an Eddy Current Brake. Braking control is accomplished through the movement of a single driller’s control handle. The movement of this control handle increases or decreases the level of the direct current excitation voltage input to the field coils of the Eddy Current Brake. The system is designed to operate any of the several BAYLOR Eddy Current Brakes, as well as other systems having like voltage and current requirements.24 22 2.24 N@V waviona. ouwext varco SECTION 2 DESCRIPTION OF OPERATION THEORY OF OPERATION The Baylor Brake Control System consist of a power conversion circuit and a circuit that processes, shapes and compares the driller’s control handle position input and the resulting current supplied to the Brake. Since the handle position is a function of the amount of braking effort the driller desires, and the output current determines the amount of Braking effort the Brake will supply, (within it's rated torque capability), the circuit continuously checks for any discrepancies in the Brake Control System, Due to the inductive nature of the eddy current brake, the rise time of brake current as a result of an instantaneous change in drillers input, may vary from approximately 3 seconds to 6 seconds. This variance in output current rise time is a function of the position of the Brake Control power selector switch. In the “DRILL” position when in the Current mode, approximately one half of the maximum current is supplied by the Brake Controller and in the “TRIP” position maximum current is supplied by the Brake Controller. When in the Voltage mode and in the “DRILL” Position, approximately one half of the maximum voltage is supplied by the Brake Controller and in the “TRIP” position, maximum voltage is supplied by the Brake Controller. The electronic circuit automatically modifies scale factors internally to match system operation when the power selector switch is in the “DRILL” position. The circuitry provides an adjustable window comparator for determination of proper brake controller operation. DRILL FLOOR COMPONENTS Driller's Control (Drawing 55858) The Driller's Control has been designed to give a maximum of trouble free operation in the rugged drill floor environment. It consists of a spring loaded handle which rotates a cam. These are the only moving parts in the Driller's Control assembly. A sensor (P/N 6575-95-0011) is positioned in the lower 2412.2.4 222 a NATIONAL OILWELL VARCO Driller's Control (Drawing 55858) (Cont'd) section of the assembly in such a manner that the cam surface is approximately 0.020" from the top surface of the sensors. As the cam is rotated, an increasing air gap is created between the cam and the sensor top. The sensor is able to measure this air gap change and convert it into an electrical analog. The electrical analog is a linear DC voltage that is directly proportional to the handle movement of the Driller’s Control and thus the amount of braking effort the Driller requires. The sensor electrical signal is connected to the Brake Controller through zener type barriers to establish intrinsic safety. The handle is arranged in such a manner that the output voltage is at maximum. when the Driller's Control is in the spring-returned “OFF” position. As the handle in case of a sensor failure is pulled on, the output voltage reduces. This is don or the Drillers Control cable has be cut/disconnected, the brake controller's output will be full on going to the brake. The typical voltage levels are from approximately -9.0 Vdc (“OFF” position) to 0.0 Vdc (“FULL ON”) Rig Floor Selector Switch (Drawing 55860) The Selector Switch divides the maximum braking capability into two ranges; “DRILL” and “TRIP”. “DRILL” is 50 percent of braking capability. When in the Current mode, it is 50 percent of the Brake's maximum rated current. When in the voltage mode, it is 50 percent of the Brake's maximum rated voltage. This selector ‘switch is connected through a zener type barrier to establish an intrinsic safe circuit. RIP” position provides more braking than “DRILL” position. 2223 2.3.4 (@Y navionat omwett varco SAFE AREA COMPONENTS SCR Power Converter Model 2025A (Drawing 55850-2) The SCR Power Converter is a three-phase, full wave silicon controlled rectifier bridge. It requires a nominal 240 volt three-phase 50/60 Hz input from the secondary of a delta connected transformer source. The transformer primary voltage must be specified at the time of purchase to match the rig power source. ‘The power converter is an SCR Bridge that requires properly timed gating or firing pulses. The firing pulses are generated in a firing circuit (P/N 55854) The Firing Circuit is connected to the SCR Power Controller through mult-conductor plugs and a terminal strip. These are listed as follows: wt - AC Current Input v2 - DC Voltage Sensing J - AC Voltage Sensing 4 - External Metering and Reset J5 - Activation of Throttle (2 Sets of Dry Contact) J6 - Firing PCB General Alarm SCR (2 Sets of Dry Contact) J101 = ~—_SCR Firing for A Phase SCR Module J201.- ~—_ SCR Firing for B Phase SCR Module J301.- ~—_—_SCR Firing for C Phase SCR Module J10 - Auxiliary Board Interconnection (Ribbon Cable) FTB1-1 - Common FTB1-2 - 33% Power Selection - N/A FTB1-3 - 67% Power Selection - N/A FTB1-4 - Drillers Control Signal Input FTB1-5 - 50% Power Selection (+15V drill, -15V trip) FTB1-6 - Open FIBI-7 - = -15Vde FTBI8 - = +15Vde FTB1-9 - Open FTB1-10- 415 VdeN@Y wariowa. omweut varco 2.3.1 SCR Power Converter Model 2025A (Drawing 55850-2) (Cont'd) The Firing Circuit P.C. Board will come to the customer already set-up and adjusted. A minor adjustment may be needed to match the Drillers Control the output ing Circuit Board, Perform the following set up instructions for the Firing Circuit P.C. Board: 1. Verify that all connectors are properly plugged in and TB1 fanning strip is connected to FTB1 2. Verify and/or set the following switches on the Firing Circuit PCB. S1 ~ REV position. $2 - to the LEFT (OFF). NOTE: See Schematic (DWG. #56041) for full explanation of this switch's function. $3 - VOLT position. $5 - to the LEFT (OFF). Both switches for 315 Vdc max. - to the RIGHT (ON) Both switches for 250 Vdc max position. This switch is to match the information on the Eddy Current Brake nameplate in the box indicated “Input Volts”. $6) - to the LEFT (OFF). All three switches. Ss7 - Select switch position based on Eddy Current Brake model. The correct position for this switch is indicated on Drawing 56041, Sheet 5 of 6 in Section 8 of this manual. \ S8 - Select switch position based on Eddy Current Brake model. The correct position for this switch is indicated on Drawing 56041, Sheet 4 of 6 in Section 8 of this manual. 24(NOV wariowas onweut varco 2.3.1 SCR Power Converter Model 2025 (Cont'd) 3. Adjust the “ZERO” and “SPAN” Potentiometer. A. With the Driller’s Control in the OFF position, adjust RG for +0.45 Vde at TP29 with respect to TP22 (GND). B. With the Drillers Control "FULL ON”, adjust RS for -8.00 Vde +/-0.50 Vdc at TP29 with St si respect to TP22 (GND). 4, Setup is now complete. The 2025 SCR Power Converter operates in either “VOLTAGE” or “CURRENT REGULATED” modes. The “VOLTAGE” mode allows the voltage to rise to the commanded set point, based on the brake’s maximum rated voltage. Switch S5 selects the brake's voltage to the brake’s maximum rated voltage. The “CURRENT” mode allows the voltage to rise to as much as 310 Vdc to force the current to the brake's maximum rated current and then the voltage decays to a level to maintain the commanded brake current. The Voltage/Current modes of operation will, if unchecked, force current through a Hot Brake, making it get even hotter and thus accelerate the breakdown of coil insulation. This is checked by a Brake Coil KW limiting circuit (See schematic Dwg. #58041 for proper setting). This circuit works to insure that the brake never dissipates more energy than it's coils can handle. This may result in the brake current being less than the full rated current. Also, operating at maximum rated Coil KW for extended periods of time can cause excessive heating if the Brake Rotor is turning less than 2 or 3 RPM's. This happens when the Driller's Control handle is moved to “FULL ON” and left there for prolonged periods of time to assist in drilling. There is additional circuitry which allows the Brake Control to operate in the “DRILL ASSIST” mode. After approximately two minutes at full current command, the maximum allowed power to the brake coils will be slowly reduced from 100% to 50% over a period of approximately 10 minutes. Note that 50% power to the Brake sill results in approximately 85% of full braking 25(N@Y warioma. onwet varco 2.3.1 SCR Power Converter Model 2025A (Drawing 55850-2) (Cont'd) Full Current command is restored by simply returning the Driller's Control handle to the "OFF" position and then back "ON". If a Brake Coil does fail and must be removed from the circuit until time permits a repair or replacement, Switch S2 (Applies to only Brakes that have all of the coils connected parallel, see Schematic Drawing 56041) allows for removal of one or two coils. The remaining coils will be properly current limited and controlled. The Brake should be overhauled as soon as possible if a coil has failed. OFF ON 4 Coils (Normal) S2-1 (X]} (1 Operational $22 (X] (1 3Coils Only = S2-4 od 0) Operational $2-2 Lal 2Coils Only S2-4 C1) (x) Operational $22 C1) (x) “OFF" is toggle to the left.N@Y wariomat omwett vaRco 23.4 2.3.2 ‘SCR Power Converter Model 2025A (Drawing 55850-2)(Cont'd) In summary, under normal conditions, the Control System would respond as follows: 1. Drillers Control handle "FULL ON" 2. Input to the Firing Circuit PC Board Terminal FTB-1-1 to FTB-1-4 should be approximately 0.5 Vdc at "FULL ON". 3. Gate pulses for power SCR's expanded fully into firing zone giving maximum output. The circuit approaches linearity, and linear output readings can be expected. (12. Diiller's Control 50% "ON" and gate pulses expanded halfway into the firing zone giving 50% output.) Aui ry Printed Circuit Board ‘The Auxiliary Printed Circuit Board attached to the door of the cabinet, provides two functions. It provides circuits to monitor and alarm under certain conditions and L.E.D.'s arranged in a mimic panel to show the status of various parts of the Brake Controller. (Reference Figure 2-1). The monitored conditions are as follows’ The indicating L.E.D.'s will be Green in the Normal or Non-Alarm Condition and will be Red in the Alarm Condition except as noted. 1. "PHASE ROTATION” The 240V, 3 Phase AC has the proper phase rotation (ABC). 2. “DRILLITRIP" Power Select Switch The Drill Floor Power Selector Switch is in a reduced range position. (L.E.D. is Yellow when in the “DRILL” position.)N@Y warionat onweit varco 2.3.2 Auxiliary Printed Circuit Board (Cont'd) 3. “DRILL ASSIST” L.E.D. indicates the SCR Bridge has “TIMED OUT” and gone into the Drill Assist mode of operation. (L.E.D. is Yellow when activated.) 4. “STANDBY CP” Normal The 120V Single Phase AC Power provides backup power to the monitor circuits but cannot provide DC power to the Brake. 5. “MAIN CP” Normal The 240V, 3 Phase AC power is available. This power must be present in order for the SCR Bridge to provide DC power to the Brake. 6. “POWER QUALITY” The Input AC Power is satisfactory. 7. “THROTTLE SIGNAL MISMATCH” The commanded current is below the acceptable window of acceptability. This will turn the SCR to full “ON” and provide contact closure to activate any backup brake supply. 8. “OVERCURRENT” L.E.D. indicates current to the Brake is under or over the set limit. 9. “OVER KILOWATT” L.E.D. indicates the Kilowatt output to the Brake is under or over the set limit 10. “SCR FAILURE” The six (6) SCR's in the Bridge are each monitored for proper gating control,N@Y maviowa. onwewt varco 2.3.2. Auxiliary Printed Circuit Board (Cont'd) 11. "DC CABLE GROUNDED” L.E.D. indicates a ground condition on the (+) DC Power conductor. L.E.D. indicates a ground condition on the (-) DC Power Conductor. 12. “AC PHASE GROUND” One of the 3 phases of the AC input power is grounded. 13. “OPEN COIL FUSE” LED. indicates one or more of the fuses in F-1, F-2, F-3 and F-4 has blown or is open. 14. “BATTERY BACKUP” (Optional) Battery Backup is in use. 15. “BAR GRAPH DISPLAY” Display of relative magnitude of commanded braking current. 16. “BAR GRAPH DISPLAY” Display of relative magnitude of commanded braking current.(N@Y warionat omwett varco AD Phase ROTATION 8 ‘sTaNoey Oo A BB hk @ [AUXILIARY EDDY. JCURRENT BRAKE | (~) BATTERY BACKUP (©ptional) col. FUSE: Figure 2-1 System Status and Mimic Display Panel 2-10N@Y wariomat onwet varco 3, System Block Diagram The System overall block diagram is shown in Figure 2-2. The control signal paths are marked by arrows showing also the direction of information flow. The Driller's Control command signal is the input to the firing board on TB1-4 with respect to TB1-1 (Common). This will be a negative DC voltage. The signal is then scaled to be +.0 Vdc to -7.5 Vde representing a 0 to 80 Amps DC current command with a 10% deadband at the start. With Switch S1 in the "REVERSE" position, the voltage changes from Driller’s Control "OFF" to "FULL ON", even though the Driller’s Control commanded voltage will be declining from its maximum to its minimum. The current command is then processed through the command reduction circuitry, where the signal is reduced to 50% of its input value, if the Drill Floor Power Selector is in the “DRILL” position. This “CURRENT COMMAND" is the input to the current regulating loop. The current feedback is sensed from the AC current transformers. The AC current signals are then rectified and summed to create an analog signal that represents the DC current flowing to the Brake. This signal is scaled 1 volt for 10 Amps of DC current and is the feedback for the current regulating loop. The output of the loop is called the “CONTROL VOLTAGE” and ranges from about ~4 Vde to about +7 Vde. This produces an output from the SCR Bridge that ranges from -240 Vdc to +310 Volts. This range allows the current excitation to the brake to be changed as rapidly as possible to follow the current command from the Driller’s Control 24N@Y wariomat onweit varco 234 Intrinsic Safety The Zener type barriers used with the Brake Control are energy limiting devices to limit the available energy to a level that cannot ignite the hazardous atmospheres likely to be present at the device being protected. Therefore the circuits on the drill floor are classified as intrinsically safe. Device spacing is used to ensure that protected wiring is segregated from non- protected wiring and from protected wiring of different potential. The panel layout and wiring is designed to comply with the recommended practices set forth in the ISA RP 12.6 publication. The assembly is designed to act as an interface between safe area equipment and the equipment located in hazardous locations.N@Y wariomat omwewt varco wexbeya Yoota yynoxFD z-z gUNOTE v indy a PAPA: 2th Oe ¥ epen, id 1 aos ‘Adkng soM0g use saat sa pan nai A 00104 Ov 9160) e185 uw dou és J | Buyuonpuo: 7 wee reubis: scoss eset tna ano | 940 Lopes Li—emas oa | Ba 200104 00 seu “um ob [ine NO. 212(N@Y waviowat omwett vARCO 34 3.2 3.24 33 3.4 SECTIONS SPECIFICATIONS GENERAL The Brake Controller is designed to meet the special requirements of an offshore drilling rig service. The material and workmanship will satisfy the service demands ‘of normal drilling operations. The System is rated for 50°C maximum ambient temperature in a NEMA Type 4 (IP42 rating) enclosure. All drill floor control circuits are designed to satisfy the requirements of intrinsically safe classification as set forth in ISA-RP 12.6 and NEPA 493 INPUT POWER REQUIREMENTS, Brake Power Controller Input AC Input AC Power required: (Reference TABLE 3-1.) Note: See ABS Table 4/5.2 for proper cable sizing, INPUT SIGNAL REQUIREMENTS, There is no external input signals required that are not generated by Sensors and Transducers supplied with the Brake Control. BRAKE CONTROLLER OUTPUT POWER DC voltage to the Brake is adjustable to match Brake nameplate requirements. (Reference TABLE 3-2.) 34175050 240 750 [scroawa| 120 7s [sorta [905 [ecrio AWG AWG ‘3650 240 eo [scraawe] 120 ws facria | 810 [ecrto AWG AWG 7656 2a0 30 [acraawal 120 Te [sorta [280 [oro AWG awa 550 a0 a [acreawe] 720 ie [seria | 288 _[aorio Awa AWG 7040 220 a |screawa| 120 76 [sorta | 250 [acrio AWG AWG ose 280 eo [screawe] 120 7 [eerie | 250 [acre Awe AWG 250 240 0 |scveawa] 120 is facia | 310 [4676 AWG AW Boa2 280 0 [serena] 120 ie [sorta | 250 [acre AWG AWG 3550 280 wo [screawa] 120 1s [eorta | 254 [acre AWG AWG yeRDIS0 | 240 30 [screawe| 120 7s [sorte | 810 acre Awe. Awe ‘anpiao | 120 ao [acreawG| NA Wa Wa | 185 [2Cre awa TAI | 120 so [screawe] WA WR Wa [90 [2076 AWG TABLE 3-1 Supply Voltage, Circuit Breaker and Cable Size for Brakes 32NOY watioma: owweit vanco9 DC Voltage and Current for Brakes 33 rane | BRAKE] COWS | open con move. | °° PER | DER COIL CONNECTIONS VOLTS | BRAKE PARALLEL |SER/PAR | SERIES 75050 325 a 302 # 9650 | 310 4 199 # 7638 | 250 4 185 # 8350 | 258 a 202 ¥ 7040 250 4 195 # 6082 | 250 4 208 7 5250 | 310 4 246 7 5032 | 250 4 233 # 3550 | 264.) 4 m6 ; TORDI90 | 310 2 D7 : 9RD130 155, - aa7 # 7RDIE0 | 90 2 207 # TABLE 3-2(N@ mavionat onwett varco 4A 42 424 SECTION 4 INSTALLATION GENERAL. The 2025A Brake Controller System has two components mounted in the hazardous area and a Brake Controller enclosure mounted in the safe area, All initial installation and startup should be performed by a qualified technician. All components mounted in the hazardous area are either designed for use in such areas or protected by devices that render them intrinsically safe. Interconnecting cables must be of size and type to comply with standards and practices in effect. Total cable inductance and capacitance must not exceed values published by certifying groups for intrinsic safety at voltages used. HAZARDOUS AREA COMPONENTS Driller's Control (Drawing #55858) Install the Driller’s Control so a downward movement of the handle advances the control toward the “FULL ON” position. The return spring will bring the handle back to the “OFF” position when the driller releases the handle. This arrangement ‘seems most natural to drillers since it gives the Control System the same direction and sense as the drawworks mechanical friction brake lever. The Rig Floor Selector Switch is designed to be mounted in sight of and easily accessible by the Driller. aX@Y warionat omweLt vARco 42.2 Rig Floor Selector Switch (Drawing #55860) The enclosure is water-tight, and the device inside is rendered intrinsically safe by means of a zener barrier in the circuit. The zener barrier is located in the Brake Controller #55850-2 cabinet. Use caution while working on the Intrinsically Safe Circuits since shorting the cables may destroy the Zener Barriers and render the System inoperative. 4.3 SAFE AREA COMPONENTS 43.1 General The Brake Controller Cabinet should be mounted in a space for ease of maintenance and economy of cable runs. The Controller can be mounted in any convenient non-hazardous location. Usual practice is to mount the Controller System at the nearest convenient safe location to the drill floor, since this minimizes cable inductance and capacitance considerations in the intrinsically safe wiring, and may allow shorter runs for less cable expense. After completion of initial installation of the System, Proceed to Section 6 of this manual and make measurements required to establish a record for this Brake and Monitor System. 42(N@Y¥ wariowat omwett vaRco 43.2 44 444 44.2 Power Transformer The Power Transformer provided is to be wired in a 3 phase delta-delta bank to feed the SCR Brake Power Controller. Mount the transformer in any convenient location. Once the installation is accomplished, frequent access to the transformer should not be required, INITIAL SYSTEM POWER-UP After all system components are properly installed and all cables are connected using wiring information supplied in this manual, proceed as follows to confirm that all components and circuits are within acceptable tolerances. These tests are intended as a basis for acceptance in terms of operational performance as measured at selected test points. Test Equipment Required 1. Digital Multimeter with: 0-300 Volt, 0-20 Volt and 0-1 Amp range Ammeter: 0-100 Amp range Ohmmeter or continuity meter Oscilloscope Two (2) Decade Resistance boxes OPRon Installation Checkout 4.4.2.1 "No Power" Checks For the Model 2025 control system, the following resistance measurements should be made and recorded at the time of installation, without any power applied to the unit. Use a VOM or digital meter for the measurements. (Not a megger!) 43NOY wariowat onweit varco 4.4.2.4 "No Power" Checks (Cont'd) Measuring Resistance Point to Ground Transformer Pri A Phase Transformer Pri B Phase Transformer Pri C Phase Transformer SecA Phase Transformer Sec B Phase Transformer Sec C Phase Brake + DC leads Brake - DC leads Firing board 781-4 Firing board TB1-1 4.4.2.2 "Powered" Checks (No current commanded) Before energizing the control, check that the power supply jumpers on the firing board are correct for the supplied voltage (240 Vac or 120 Vac). Upon energizing the control, there should be some L.£.D.'s turned "ON" in the top left corner of the firing board. If they are not, then turn "OFF" the control and investigate power integrity. All measurements are made with respect to TP22, electronics common, which should also be connected to ground. Proceed with Expected Value Inf, Inf. Inf. 3.3K 3.3K 3.3K 500K *% 500K 30K 0 Ohms. the following power checks as measured with a VOM or digital meter: 44(NOY wariowa. onwet. vanco 4.4.2.2 “Powered” Checks (No current commanded) (Cont'd) POWERED STATIC MEASUREMENTS Measuring Measured Expected Point Value to TP22 Value TP6 - Electronics +15 4154.15 Vde TP7 - Electronics -15 154.15 Vde 240 Vac A Phase 135 Vac / 240 Vac B Phase 135 Vac / 240 Vac C Phase 135 Vac TP2 (A Phase scaled) _ 3.20 Vac TP3 (B Phase scaled) 3.20 Vac TP4 (C Phase scaled) 3.20 Vac TP14 (Vin) 9.50 Vde TP8 - Cb firing ramp approx 5 Vac TP9 - Bc firing ramp approx 5 Vac TP10 - Ba firing ramp. approx § Vac TP11 - Ab firing ramp approx 5 VacN@¥ wavioma. omwett varco 44.2.2 “Powered” Checks (No current commanded) (Cont'd) TP12- Ca firing ramp TP13 - Ac firing ramp Firing Board TB1-4 4.4.2.3 "Powered" Checks - Current commanded Make sure the controls are calibrated as indicated in Section 2.3.1 and then the approx 5 Vac approx 4 Vac approx -9 Vde following checks can be made as the control is varied from full "OFF" to full "ON". Please note these reading are based upon a nominal full output, and with no power reduction ("TRIP mode): Measured Point Firing Board TB1-4 ‘TP1 - Current Command ‘TP29 - DC Signal TPS - Control Voltage TP15 - A Phase Current ‘TP16 - B Phase Current TP17 - C Phase Current TP21 - Current Feedback Measured Variance Variance 46 to Expected -9.00 to -0.50 Vde +0.45 to -8.00 Vde 40.45 to -8.00 Vde -6.00 to +5.00 Vde 0 to 2.50 Vac Oto 2.50 Vac 0 to 2.50 Vac 0 to 8.00 VdeN@Y mariowa. omwent vanco ae 4.4.2.3 "Powered" Checks - Current commanded (Cont'd) TP24 - Vout to 0107.5 Vde TP23 - Coil KW to 0 to 6.0 Vde 4.4.2.4 "Auxiliary Board" Checkout One of the main functions of the Auxiliary board is to monitor the circuit operation of the rest of the controls. 44.2.4.1 Overall If the Auxiliary Board is operating correctly, the L.E.D. side of the Auxiliary Board will have all L.E.D.'s showing in Green. There are 2 L.£.D.'s that should not be "ON" at this time. They are identified as No. 2 and 3 in Figure 2-1. They are single color (Yellow) L.E.D.’s. They will turn "ON" as their function is activated. If any of the bicolor L.E.D.’s (identified as being frosted Grey or White) are not tumed "ON" at all, the board is defective. Replace with the spare board. 4,4.2.4.2 Control Power If either of the control power L.E..'s are Red, verify proper operation of the plus and minus 15 volt power supplies. Make sure the fuse on the PC board is good. 4.4.2.4.3 Input Quality If the input voltage drops too low or loses a phase this L.E.D. will turn from Green to Red. If so, check TP14 - Vin for about 2.40 Vdc for an input of 240 Vac. An excessive amount of AC ripple would indicate a possible phase loss. Determine which by measuring TP's 2, 3, 4 looking for any irregularity. 4.4.2.4.4 AC Ground If any of the input voltages are reduced as the result of a ground, the respective L.ED. tums from Green to Red. Measure test points 2, 3, 4 to make sure and then measure the phase voltages A, B, and C to insure there is a ground. Then tum off power and clear the ground. Note that disconnecting R1, R2, and R3 47N@Y wariowat omweut varco 4,4.2.4.4 AC Ground (Cont'd) from ground inside the 2040 SCR enclosure and disconnecting J3 from the firing board should result in the input terminals being almost infinite resistance above ground. 4.4.2.45 SCR Misfiring This alarm works by camnarin~ “= current going through the individual SCR's to INELEE PRODUCTOS, taurus R's. Once set, the alarm turns the L.E.D. from ntil it again sees the proper level of current in lugging J5 on the Auxiliary PCB. Rena: (errs pe bine wae EX-200°S Fecha de Venta: ag of the electronics of 125% of brake coil 2 20 second time interval. It is intended to Resetting can be done with the ad, reset switch. If the L.E.D. continually ‘ol signal Neen Da inn ate Spat cae tenemos Tana pee SEs moh chem ray home cmc ee tag bisicas nocesatias Come ‘repuestos ¥ 7 hy ee ico 2 Pere laccse eat) 07009 onics senses a current level 150% that of conds. Such will usually result if an SCR ransient suppressor shorts, of two input ‘ectifier cubicle. wren Brea M5 ef, Ege cal oe _sewo-Exe.-Tums Red when the electronics senses the brake control is putting out less than one half the current it should be putting out at that moment. This activates a relay that is used to enable the Battery Back Up unit, if one is installed. It will in any event, activate the alarm relay. 48N@Y mationa omwe1t varco 4.4.2.4.10 Power Select and Drill Assist Power Select L.E.D. will tum "ON", Yellow, when the brake control is in a reduced "power selected" mode. When the driller selects "DRILL", this L.E.D. will turn "ON". The Drill Assist L.E.D. will turn "ON" Yellow after a period of approximately 2 minutes. ike 4.4.2.4.41 Battery Back Up This L.E.D. will tum Red when J4 on the Auxiliary PCB is unplugged 44.3 Functional Test Turn on the main circuit breaker that supplies 240 Volts, 3 Phase AC to the SCR Brake Control. Measure the power supply output at TP6 (Test Point 6) with respect to common TP22. The voltage should be +15.00 (+/-0.18 Vdc). Record reading TP6___-Vde Place the Power Selector Switch on the "TRIP" position. Confirm that the Driller's, Control is working by measuring a varying voltage at FTB4-4 with respect to FTB1-1. This voltage should vary from "OFF" equal to -9 (+/-1.0 Vdc) to -.50 (+/- 0.5 Vdc) at full "ON" with switch $1 in the "REVERSE" position. Record: Control "OFF" ——Vde Control "FULL ON" __ Vde Ghange Switch S3 on the Firing Circuit Board to “VOLT™. Slowly increase the Driller's Control while measuring the DC output voltage at the input to the eddy current brake. At maximum Driller's Control movement, the meter indication should be $20 + 5 volts DC. Connect the oscilloscope at the same place and view the rectified wave shapes of the DC output as the Driller's Control slowly increased. The oscilloscope trace should be uniform and its level of magnitude should change smoothly as the voltage increases. Measure the voltage at TP24 with respect to TP22. It should be proportional to the DC output voltage in the 49N@¥ naviowas omwent vanco 4.4.3 Functional Test (Cont'd) ratio of 1.0 Volt to 32.4 Volts. Measure the voltage at TP28 with respect to TP22. It should remain at 0.0 + 0.2 Vde as the output voltage goes from minimum to maximum signifying there are no DC Cable or Brake Coil grounds. Check the voltage at TP21 with respect to TP22. It is related to the DC current being supplied to the Brake and is scaled as 1.0 Volt per 10.0 Amps DC. Move the Drill Floor Power Selector Switch to the "DRILL" position and check that the maximum Driller's Control input produces approximately 50% of the current measured in the previous step. "DRILL" Position _Vde __ Ade “TRIP” Position ___Vde __ Ade With the Drill Floor Power Selector Switch in the "TRIP" position hold the Driller's ~ Control full "ON". After approximately 2 minutes the Yellow "DRILL ASSIST” L.E.D. on the mimic panel will turn on and the DC voltage to the Brake will start to ramp down. After approximately 10 minutes the voltage will level off at approximately 50% of the maximum or starting value. Releasing the Driller's Control handle will return it to zero or the "OFF" position. This will reset the Ramp Circuit and the next time the Control is moved to maximum the output will also go to maximum. To check an "OVER KILOWATT™ indication, you must simulate the condition by temporarily connecting a decade resistance box, set to 250K ohms of resistance, between TP30 and TP31 on the Firing Circuit Board. Slowly increase the current using the Driller's Control and verify that the "OVER POWER" L.E.D. on the Firing Circuit Board and "OVER KILOWATT" LE.D. on the Mimic Panel turns “ON” (Red). This simulates an abnormally high kilowatt requirement (approximately 125% of normal). Disconnect the Decade Box and push the reset button on the Firing Board. The "OVER KILOWATT" L.E.D. should reset to Green, 4-10N@Y maviona. onwe1t vanco 44.3 45 4.54 45.2 Functional Test (Cont'd) To check an “OVER CURRENT" limit condition, you must simulate the condition by temporarily connecting a decade resistance box between TP21 and TP32 located on the Firing Circuit Board. Set the decade box to 20k ohms of resistance. Slowly increase the Driller's Control. When the Firing Circuit "OVER CURRENT" L.E.D. tums Red, the current limit (150% of normal current) has been reached. Disconnect the Decade Resistance Box and push the reset button on the Firing Circuit Board. The "OVER CURRENT" L.E.D. should reset to Green, The system should be in operating condition. A final check of the Mimic Panel to see that all of the L.E.D.’s are Green will confirm that the system operational. HAZARDOUS AREA CONSIDERATIONS AND APPROVALS: General Brake Control System components intended for installation in hazardous areas are rendered intrinsically safe by virtue of being connected to the safe area portion of the System through approved zener barriers which are physically located in the Intrinsic Safety Barrier Assembly. Interconnecting cables must be of size and type to comply with regulations, standards and practices in effect for the particular installation. Total cable inductance and capacitance must not exceed values published by certifying groups for intrinsic safety at voltages used. Caution should be used while working on equipment, as shorting of interconnect cables could destroy zener barrier devices and render portions of the system inoperative. Driller's Control (Drawing #55858) The Baylor Driller's Control is rendered intrinsically safe by means of operating through a zener type barrier installed in the SCR Assembly (Drawing #55850-2). an(N@Y wariowa. ouweut vaRco 4.5.3 Rig Floor Selector Switch (Drawing #55860) The Rig Floor Selector Switch is rendered intrinsically safe by means of operating through a zener type barrier installed in the SCR Assembly (Drawing #55850-2). 4.6 APPROVALS * Factory Mutual OV2HO.AX * Underwriters Laboratories E152169 * Canadian Standards Association LR 7661-3 * PTB Certificate of Conformity NR.EX-83/2053X, (See the following pages) 412oT tobe cisibuted outside the FACTORY MUTUAL SYSTEM, except by CLIENT. MODEL SB x9 3x0 M rOUKK SAFETY BARRIERS FoR HAZARDOUS LOCATIONS FROM ABB CEAG Lus Cobh NEVER WEC 47 6930 EBERBACH CERIANY J.T, ov2H0.ax (3610) February 12, 1992 Ss Factory Mutual Research 115% Sonon-Frovicence Tusnaike 2.0. Box 3162 ioe Mateecnutests 02082Factory Mutual Research 1151 Beston Providence Turpike P.O, Box 9102 Norwooe, Massaehusotts 02062 J.T, OV2HO.AX February 12, 1992 (3610) MODEL SB_X9_XXO M 200K SAFETY BARRIERS FOR HAZARDOUS LocATIONS ROK ABB CEAG Lus Gabh ‘NEVER VEC 47 6930 EBERBACH ‘GERMANY 1 mropuerion 1.1, ABB CEAG Lue Gmbh requested examination of the apparatus Listed in Section 1.2 to be in compliance with the applicable roquirenents of the following standards: moe Class No. Jasue Date Intrinsically Safe Apparatus and 3610 october 1988 Associated Apparatus for Use in Class I, I1, and IIT, Division 1 Hazardous (Classified) Locations Note: Faccors appliod to voltege or current rather than energy. Electrical Equipment for Use In 3600 March 1989 Hazardous (Classified) Locations General Requirements Electrical and Electronic 3810 March 1989 Test, Measuring, and Process Control Equipment 1.2 The following was evaluated as having intrinsically safe 6 for Class 1) applicable Groups A, 8, ordence with entity requirements and ABB CEAC Lus Gnbh Control Drawing No. GHG 11-4-3507/3 hazardous locetions and vill appear in the Approval Guide as follows:FACTORY MUTUAL RESEARCH CORPORATION JOB IDENTIFICATION OV2HO.AX 11 1G - CHG 11-4-3507/3- Entity Shunt Diode Barrier Assembly. Modele SB 19 XX M XOX Max. Entity Parameters: Standard D.C. Barrier, Single Channel Model Vos ‘Iss_(oa) Sa (uF) Lato) SB 19 140 4 0710 10 200 3.2 98 SB 19 040 K 0710 10 200 312 98 SB 19 140 0715 as 150 78 iz SB 19 040 M 0715 15 150 :78 uz SB 19 140 0722 22 150 126 172 SB 19 040 0722 22 150 126 1172 $B 19 140 X 0728 28 93 4 48 SB 19 040 M 0728 28 93 14 48 Standard A.C. Barrier, Single channel Model Yoo vd ‘sc_(mad Sa (uF), Lato) SB 19 240 4 0710 10 200 3.21 98 SB 19 240 M0728 28 93 ers 4.38 Dual Chennel A.C. Barrier, With Separate Ground Returns Each Channel Model, Yoo ov Ise (oA) a (uF Sewer) SB 59 240 4 0751 1 100 1000 3.8 SB 59 240 4 0760 10 200 3.2 -38 SB 59 240 M 0761, 9 100 4.89 3.8 SE 59 240 M 0766 12 2 1164 238 SB 59 240 x 0765 a5 150 78 1.72 SB 59 240 X 0766 2 30 1.64 3.87 SB 59 240 M 0772 22 a 226 7.02 SB 59 240 M 0778 28 a 14 16.58 Dual Channel D.C. Barrier, With Separace Ground Returns Each Channe! Voc Isc (Ai a (uF) La (ot SB 59 160 M 0764 2 2 1.64 238 SB 59 140 4 0767 a5 150 “78 1.72 Page 2FACTORY MUTUAL RESEARCH CORPORATION JOB IDENTIFICATION OV2HO.AK Dual Channel D.C, Barrier, With Separate Ground Returns Bach Channel Moo 0) Isc) Ga_(ub) aod $B 59 160M 0768 = 22 a7 26 1.79 SB 59140077928 3 fe 4138 5B 5904040779 28 93 na 438 pual Channel D.C. Barrier, With Diode Return, Separate Supply Barrier Each Channel Moe) Issa) SatuFD Lett) 5B 59 440M 0786-28 0 23 5.5 dual hennel D.C. Barrier, With Diode Return, Separate Supply Barrier Terminal 23 co Gnd. ‘Terminal 13 to Gnd. Voc/Isc Cat Voc/tee ca La Wy Gu Ga Ova on GH SB 59 440 M0787 26/0 ado 28/93 we 4.38 $B 59 440 M1787 28/0 as 38 28/33 ne a8 Duel Channel D.C. Barrier ‘Terning] 13 co 23 (We 6 10 yew) ie ima ca (ue SB 59 440 M0787 29.75 93 “2 SB 59 440 M1787 «29.75 3 fae Dual Channel D.C. Barrier, With Separate Returns Terminal 23 to Gnd. ‘Terminal 13 to Gnd. Voo/tse la Voe/tee ca Ls cuey/eay GaP) Gah vaei/ena) GF. da SB 59140 M0788 28/93, we 4.38 10/200 3.21 98 SB 59 140 M0796 26/87 uv 4.98, 20/52 36 1a.ie SB 59 040 M0796 26/87 uv 4138 z 3B us Page 3FACTORY MOTUAL RESEARCH CORPORATION JOB IDENTIFICATION 0V2HO.AX 11 DESGRIPTION 2.1, Each SB X9 XXO M KOK Series Barrier consists of # printed ctreult board encapsulated in a plastic enclosure. The barrier assenbly is « protective asseably which passes an electrical signal but linics the transfer of energy to the hazardous location. TTI EXAMINATION AND TESTS 3.1 Representative samples of Model SB X9 XXO M XXX Barriers were examined and tested by Factory Mutual Research Corporation (FMRC) to determine the acceptability for use in the specified hazardous location. The examination included circuit analysis, couponent tests and temperature measureuents as well as @ review of the manufacturer’ s docunontation and the unit’s physical construction. All vere satisfactory and are sunnarized in the following sections. All data is on file at FMRC along with other documents and correspondence applicable to this program. 3.2 Entity Concept - Under “Entity” requirements, the concept allows interconnection of intrinsically safe apparatus to associated apparatus, not specifically examined in such combination. The criteria for intereonnection 1 that the voltage (Vmax) and current (Imax) which intrinsically safe apparatus can receive and remain intrinsically safe, considering faults, must be equal to or greater than the voltage (Voc) er (Vt) and current (Isc) or (It) levels which can be delivered by the associated apparatus, considering faults and applicable factors. In addition, the maximum unprotected capacitance (Ci) and inductance (Li) of the intrinsically eafe apparatus, including interconnecting wiring, must be equel or less than the cepacitance (Ca) ené inductance (La) which can be safely connected to the associated apparatus, If these criceria are met then the conbination may be connected. Asso rinsically Safe Apparatus Evalu: + The following evaluations and tests verified Model SB X9 XY0 M X0GX Barriers for connection to Clase 1, IZ and IIT, Division 1, Groups A, B, C, D, E, F and G Hazardous Locations. 3.3.1 Critical Component Evaluction - The following components are considered eritiesl to the operation of the barriers; Barrier “Model Component. Vendor Deserints SB 19 140 M0710 Resistor RI Draloric 0207S 3.32 ohm, .6W, 1% Resistor R2 Draloric 0611S 68.1 ohm, iv, ‘1x Fuse Si Uickann 19201 50 nA, medina Diode VL,V6 Motorola 1N5346B 9,1, SW, 5% SB 1S 040M 0710 Resistor AL Drsloric 02075 3.32 ohm, .6¥, 1 Resistor RZ Dralorte 0411s, 68.1 ohm, iW, 12 Fuse Si Wieknann 19201 50 mA, medium Diode Vi,vé Motorola 1N53468 9,1, SW, 5% Page 4SB SB SB 3B 33 SB sB as 1 1 19 1s 19 19 1 240 M0710 140 M0715 040 0715 140 M0722 oo 4 0722 140 M0728 040 ¥ 0728 260 M0728 FACTORY MUTUAL RESEARCH CORPORATION JOB IDENTIFICATION OV2HO.AK Resistor RL Resistor R2 Fuse Si Diode vi,v2, v6,v7 Resistor RL Resistor RZ Resistor R2° Fuse Si Diode V1,¥6, Resistor RL Resistor 22 Resistor 22” Fuse Si Diode V1,¥6, Resistor RL Resistor 22 Resistor 22’ Fuse Si Diode V1.¥6, Diode V2,V7 Resistor RI Resistor R2 Resistor 22" Fuse Si Diode V1,¥6, Diode ¥2.V7 Resistor RI Resistor 2 Resistor RZ’ Fuse Si Diode V1,V6, Diode V2,V7 Resistor Rl Resistor R2 Resistor 2" Fuse Si Diode V1,V6, Diode V2,07 Resistor Rl Resietor R2 Resistor RZ” Fuse Si Dralerte Dralorie Wiemann Motorola Dralorie Dealeric Dralorie Wieknann Motorola Draleric Dralorie Dralorie Wickman Motorola Draloric Draloric Draloric Wickasnn Motorola Motorola Draloric Dralorie Dralorie Wicknenn Moterela Motorola Draloric Draloric Dralorie Wickman Motorola Motorola Draloric Draloric Draloric Wickman Notorela Motorole Draloric Drslorie Dreloric Wicknann 02075 owns 19201 1NS345B 207s oun oats 19201 1N53518 02078 oars outs 19201 N53515 0207s oaiis outis 19201 1553455 1N53498 0207s oats oa1is 19201 13455 1NS3498 o207s cutis oes isz01. 153458 1N5355B 0207s oats outs 19201 ns3458 1N53553 207s oats osiis 19201 3.32 ohm, .6W, 12 68.1 ohm, iv, 1x 50 mA, medium 8.7, SW, 5% 3.32 ohm, .6W, 4% 71.5 ohm, iW, 1% 73.2 ohm, 1, 18 100 ma, medium av, SY, SE 3.32 chm, .6¥, 1% 71.5 chm, iw, ‘1x 73.2 cha, 1W, 12 100 ma, medium lav, Su, 5% 3.32 ohm, .6¥, 1¢ 82.5 ohm, IW, ‘1x 84.5 ohm, 1W, 1% 50 mA, nediua 8.7V, sw, 5% 12v, ‘sw, 5% 3.32 ohn, .6¥, 18 82.5 ohm, iW, ‘15 4,5 ohm, 1M, 1x 50 ma, medium 8.7, 58, 5% 12V, "3, 5H 3.32 ohm, .6W, 1% 158 ohm, "1W, it 162 ohm, 1W, 1% 30 mA, medium 8.7, 5¥, 5% iv, "SW, “5 3.32 ohm, .6W, 1% 158 ohe, 1, Le 162 ohm, 1W, 1t 50 mA, medium 8.7¥, su, 5% i8v, 58, 5% 3,32 ohm, .6W, 15 158 chm, IW, ix 162 cha, 1W, 1% 50 mA, mediumSB SB SB sB SB se 39 59 39 260 M 0751 240M 0760 260 M 0761 140 4 0764 240 # 0764 240 M 0765 240 M0766 FACTORY MUTUAL RESEARCH CORPORATION JOB IDENTIFICATION OV2HO..Ax Diodes V1,V2, V6,V7 Diodes V3,¥4, ve,v9 Resistor RL,RI’ Resistor R2 Resistor R2’ Fuse Si Fuse si” Diode ¥1,¥2,V3, ¥4,¥6,¥8,¥9 Resistor R1,RI’ Resistor R2,R3 Fuse Si,si’ Diodes V1.Vv2, v3,¥6,¥7,08 Resistor R1,R1° Resistor R2,R2” Fuse S151 Diodes ¥i,v2,v3 V4,V6,07, 98,09 Resistor R1,RI Resistor R2,R3 Fuse 81,81" Diodes V1,V3, v6,v8 Resistor R1,RI’ stor _R2,R2" Diodes ¥1,V3,¥4, ¥6,V7,¥8, 09 Resistor R1,RI’ Resistor R2,83 Fuse 81,8!" Diodes V1,V2,¥3, ¥6,¥7,V8 Resietor RL,RI” Resistor R2,R2’ Pure S£,5i" Diodes V1,V2,V3 ¥6,V7,V8,v9 Motorola Motorola Drslorie Draloric Draloric Wiekmann Whelmann, 1534s, 1N5355B 207s 02078 02075 19201 19201 Telefunken 194005 Dralorie Draloric Wickman Motorola Dralorie Dralorie tekmann Motorola Draloric Dealorie Wieknann Motorole Dralorie Dralorie Wiekmann , Motorola Draloric Dralorie Wickaann Motorole Dealeric Draloric Wickman Motorola Page 6 02075 unis 19201 1N53453 207s outs 19201 ror) oz07s 02075 19201 ANs4aB 02075 02075 19201 153473 0207s oes 19201 153508 2075 ous 19201 ans3a7B 8.7¥, Su, SE iev, Su, 5% 3.32 ohm, .6u, 1x 14.3 ohm, -6W, 1x 16.3 ohm, 16W, 1% 260 ma, nediun 160 ma, medium FIV 100v, 1 3.32 ohm, .6W, 1% 68.1 ohm, iv, 1x 50'mA, nediua 8.79, 5Y, SE 3.32 oha, .6¥, 1x 133 ohm, 1, 12 100 mk, ‘medium 7.5v, Sy, Se 3,32 ohm, .6¥, 1 1050 ohm, .6¥, 1% 50 mA, medium liv, 5H, 35% 3.32 ohm, .6W, 18 1050 ohm, \6W, 1% 50 ma, medium tov, Sw, 5% 3.32 ohm, .6¥, 12 118 che, "aw, ix 50 mA, medium 13v, 5H, 5% 3.32 ohm, .6¥, 12 155 che, IW, it 50 mA, meciom lov, 3u, 5%‘SB 59 140 M 0767 SB 59 140 M 0768 SB 59 140 0772 3B 59 240 M 0778 SB 59 140 4 0779 SB 59 040 M0779 SB 59 440 M 0786 FACTORY MUTUAL RESEARCH CORPORATION JOB IDENTIFICATION OV2H0.AX Resistor RL,RI’ Resistor R2,R3 Resistor R2" ,R3’ Fuse Si,Si” Diodes V1,V3, V6VE Resistor RL,Rl’ Resistor R2,R3 Resistor R2" ,R3) Fuse 1,51 Draloric Dreloric Dreloric Wickaenn Motorola Dealorie Drsloric braloric Wickaenn Diodes V1,V3,V6,V8 Notorola Diodes V2,V4,07,V9 Motorola Resistor RL,RY’ Resistor R2,R3 Fuse Si,st” Dreloric Draloric Wickman Diodes V1,V3,Vé, Motorola 7,¥8,¥2 Resistor RL,EL’ Resisror R2,R3 Fuse 31,51 praloric Draloric Uickeann Diodes V1,V2,V3, Motorola V6,V7,V8 Restator R1,RL’ Resistor R2,K3 braloric Dralerie Rosistor 22’,R3 Dralerie Fure §1,51” Diodes V1,V3, v6,ve Diodes V2,V4,V7 Resistor RI.RL’ Resistor R2,R3 Wleknann Motorola 1¥9 Motorola Draloric Dralerie Resistor 22’ ,R3 Draloric Fuse $1.81" Diodes V1,V3, v6,v6 Wickman Motorola Diodes V2,V4,V7,V9 Motorola Resistor RI,RI’ Resistor R2,83, Fuse S1,Si" Diodes 1,3, W6,¥8 Draleric Draleric Wiekmann Motorola, Diodes ¥2,V4,V7,V9 Motorola Telefunken 1M&00S Diodes V1i,ViI" va,vi2" Page 7 02075 ouiis oulis 19201 1N53518, 02075 ou1is outs 19201 1853458 1153498 02075 owns 19201 1N53578 207s outs 19201 1N53608, 02075 ou2is ouiis 19201 ANs3458 1Ns3598 2078 owas owls 19201 153458 1N5355B 0207s 02075 19201 ANs3455 153555 3.32 cha, 6, 1% 7.5 ohm, in, "12 73.2 ohe, 1W, 1% 100 mA, medium Lav, 5u, 5x 3.32 ohe, 64, 1¢ 82.5 ohm, iw, 1% 86.2 ohm, 1M) 1% 50 mA, medium 8.7V, Sv, 5% aay, su, 's. 3.32 ohm, 6H, 1% 316 ohm, 1, 1x 50 mA, medium 2ov, Su, 5x 3.32 ohm, .6W, 1X 634 ohm, 1, ix 50 mk, nediom 25v, 3W, 5% 3.32 ohm, .6u, 1x 158 ohm, 1, 1x 162 ohm, 1W, 12 50 ma, medium 8.70, 54, 5x sv, 5¥, 5% 3.32 ohm, 6, 1% 158 ohm, 1H, ix 162 ohm, 10, 12 50 mA, medium 8.7, 5¥, 5% av, 5¥, 5% 3.32 ohm, .6W, 1 LA.7 ohm, 16W, 1x bo'ma, neaiun’ 8.7, sv, 5x 1B, SW, Sx PIV'100v, 19,SB 59 440 M 0787 5B 59 440 M1787 SB 59 440 m 0788 SB 59 140 M 0796 SB 59 040 % 0796 FACTORY MUTUAL RESEARCH CORPORATION JOB IDENTIFICATION OV2HO.Ax Resistor RL,RI’ Resistor B2 Resistor RI Resistor B3 Fuse Si, si” Diodes V1,¥3, v6,ve Diodes V2,V4,V7 Diodes vii, viz Restetor R1,RI’ Resistor R2 Diodes V2,V4,V7 Diodes Vii, viz Resistor R1,RI’ Resistor K3 Resistor Ri’ Resistor R2 Fuse $4.51" Diodes Vi,v6, Diodes ¥3,v8 Diodes Ya,v9 Resistor R1,RI’ Resistor 22 Resistor RZ” Resistor 23 Resistor R3" Fuse S1,s1° Diodes V1,V6, Diodes V3,V8 Diodes vé,v9 Resistor RL,RI’ Resictor R2 Resistor R2’ Resistor R3 Resistor RS” Fuse $1,9i/ Diodes Vi,V6, Dralorte 02078 Dralorie 0411s Draloric 04118 Dralorie 02075 Wicknenn 19201 Motorola 1NS3455 19 Motorola 1N5355B Telefunken 1N6005 Dralorie 02078 Draloric 04115 Draleric 04115, Dralerie 02075 Wicknann 19201 Motorola 1N5345B 1U9 Motorole 1NS355B ITT sp 103 A Draloric 02075 Draloric 0411s Draloric 04115, Dralerie 02075 Wiekasnn 19201 Motorola 1N53468, Motorola 1N53452 Motorola 1N5355B Draleric 02078 Draloric 04118 Draloric 04118, Dralorie o4lls Draloric 04115, Wickmann 19201 Motorola 1NS356B Motorola 1NS345B Motorola 1N5353B Draleric 0207s Dralorie o4118 Draloric O411s Drelorie 0411s Dralorte o4lls Wicknann 19201 Motorola 1N53563 Page 8 3.32 ohm, .6w, 1x 158 ohm, ‘iW, ix 162 oba, IW, 1x 14.7 ohm, .6¥, 12 50 mA, mediua 8.7V, Su, 5x sv, su, 32 PIV' 1007, 1¥ 3.32 ohm, .6W, 1x 158 ohm, ‘18, ix 162 ohm, 1W, 1% 14.7 ohm, .6¥, 1f 50 mA, medium 8.7, su, 5x lev, su, sz PIV'40v, .4W 3.32 ohm, .6y, 1 158 ohm, 1, ix 162 ohm, 1W, 1x 68.1 ob, .6H, 1x 50 mA, medium 9.1, "su, sx 8.7, su, 5x ev, ‘ow, "sx 3.32 ohe, .6u, 1x 203 obm, 1, ix 210 ohm, tw, 12 158 ohm, IW, it 162 ohm, 1W, 5% 50 mA, neditm 1ov, Sy, 5x 8.7V, SW, 3x Lev, ‘su, sz 3.32 ohm, .6W, 1x 205 ohm, Li, 1x 210 ohm, 1W, 1% 158 ohm, Iw) Iz 162 ohm) Lv) Se 50 BA, edie iov, Sy, 5x 8.70, 5%, 5a 16, '5¥, 5x.FACTORY MUTUAL RESEARCH CORPORATION JOB IDENTIFICATION OV2HO.AX 3.3.2 Quen Ciccult Voltage - To determine the maximun zener diode voltage paraneters, the formula method vas used. Wormal Voc = Vz - tol. Fault Yoo = Vz + tol. Normal or Favl: Ise = Voo/R - tol. 3.3.3 Output Pareneters - The resultant parameters, appearing below, axe used for open circuit voltage, vith the minimum resistance of th output resistors used to determine the short eireult current, The following are the theoretical hazardous location parameters vhich could be produced under normal, one and two fault conditions, For some applications ABB requested to use greater Voc/Ise paraneters vhich is acceptable Standard D.C. Single Channel vith Ground Return Zener Safety Barrier one fault evo fault Mosiel ind ‘Waa Srouns SB 19 140 H 0710 86/128 s.s/1ar 95/141 ABODEFG 5B 19 040 0710 6/128.6 9. 5/141 915/161 ABCDEFC SB 19 140M 0715 13.393, 34.7/103 14.7/103 ABODEFG SB 19 040 M 0715 1313/93 147/103 14.7/103-ABCDEFC SB 19 140 ¥ 0722 wins 2. 7/3h 217/131 ABCDEFG SB 19 040 H 0722 wis AST 217/131 ABCDEFC SB 19 140 M 0728 25/80 25/88.4 28/88.4 ABCDEFC SB 19 040 M 0728 25/80 28/86.4 28/88.4 ABCDEFG Standard A.C. Single Chennel with Ground Return Zener Safety Berrier noraal ° ewe faule Model ab wens ees Grows 88 19 240 0710 8.6/128 roses 1o/i4s——ABCDEEG 5B 19 240 0728 25/80 27.8/88 27.8/88 —-ABCDEG Stonderd A.C. Dual Chennel vith Seperate Returns Zener Safety Betrier normal one fault two fault Moga), ma Wena vas Sroupe 8B 59 240 M0751 9763.6 9/63.6 9/63.6 ABODEFG SB 59 240M 0760, eins losis ioyi4s —ARODEFC 5B 39 240 4 0761 87h 8.76/67 8.76/67 -ABCDEFG SB 59 240 H 0764 10.4/10 Wat 1i4/l —ABODERG SB 59 240M 0765, 13.2/11314.5/124.5 14.5/126.5 ABCDEFG s3 #2 200 x 0 302/63.6 115/69.8 31a765.8 Bc: 5B 59 240 M0972 20/63.6 21.9770 21.9/70 ABODEFC 88 59 240 4 0778 266/38 27.1/83.3 —-27.1/43.3ABGDEFG Page 9FACTORY MUTUAL RESEARCH CORPORATION JOB IDENTIFICATION OV2HO.AK Standard D.C, Dusl Channel with Separate Returns Zener Safety Barrier pornal one fault two fault Yodel ia Wns Wma Groups, SB 59 140 H 0764 10.4/10 11,6/11.211,6/11.2__ABCDEFG SB 59 140 M 0767 13.3/93 14:7/102.6 —1417/102.6 ABCDEFG SB 59 140 M 0768 19.6719 2.7/1.5 217713115 aBcoErE SB 59 040 W079, 25/80 28/88.5 28/88.5 ° ABCDEFG SB 59 140 M 0779 25/80 28/88.5 28/88.5 ABCDERG Dual Channel D.C. Barrier, With Diode Return, Separate Supply Berrter Terminal 23 to Gnd. Terminal 13 to Gnd. Groups ABCDEFG Croups ABCDEFG Normal one Fault tvo fault Normal one Fault. two fault Wek Wma waa Wins mk ‘Wns SB 59 4u0 M0786 25/0 28/0 26/0 25/0 28/0 28/0 SB 59 440 M0787 26/0 28/0 28/0 25/80 © 28/86 28/86 SB 59 440 M1787 26/0 28/0 28/0 25/80 28786 28/86 Standard D.C. Dual Channel Terminal 13 to 23, ve & Ie Zener Safety Barrier nornel one fault two fault Model aa aa Waa Grouns SB 59 440M 0787 20/83.6 29.75/88.7 28.75/88.7 ABCDEG SB 59 400 M 1787 28/8316 29.75/88. 29.75/88.7 ABCDEFG Dual Channel D.C. Barrier, With Separate Returns Terminal 23 to Gnd. Terminal 13 to Gnd. ‘Groups ABCDEFG Groupe ABCDEFG Noraal one Fault tvo fault Normal one Fault two fault Wak Wak vos Was Wn vend SB 59 140M 0788 25.6/80 28/88.5 28/88.58.64/128 9.6/161 96/141 SB 59 140 M0796 23.5/7%6 26/82 26/82 1e/as—20/48.6 2048.6 SB 59 040 M0796 23.5/74 26/82 26/82 16/ae 20/4816 -20/48.6 These output current an¢ voltage levels were determined to be incapable of {gnition by comparison to figure Bl of FMRC Standard 3610, for @ Group A,B atmosphere Page 10FACTORY MUTUAL RESEARCH CORPORATION JOB IDENTIFICATION OV2HO.AX 3.3.4 02078, .6W, IX and Oélis, Iv, 12 their power rating under fault conditions Test - Analysis revealed chat resistors eal film operate at wore than 2/3 of Six samples of each were subjected to the maximum fault voltage (29.75 Vde). The results ere not more than 10% of ite nominal value. 3.3.5 the thermal conductivity of the encapsulate material (Ruta 436 and Rutapox Hardener SL 50) increased the power tisfactory in that the resistance did not decrease by more than 33% and + It was verified that Cast Resin EA ation of the resistors (P/M 0411S, 1,09, 1 and P/N 0207S, .6¥, 1X) from 6 W to 1.0 © and 1.0 W to 1.83 ¥, which te satisfactory. 3.3.6 Diode rating. 2 + Under normal and fault conditions the voltage limiting zener diodes operate at less than 2/3 of their power 3.3.7 Resistor Fover Rating - Under nornal, conditions the current Limiting output resistors operate at less than 2/3 of their pover ratings, 3.3.8 Shunt Diods shorted to ground + The primary circuit fuses (50mA, 100mA and 160mA Wicknan medium fuses) were analyzed to determine if they were adequate in protecting rener diodes. Due to the characteristics (as determined by Wicknan data sheet) of the fuse 19201 used in the barrier assemblies, testing vas conducted as follows. assonblies vere tested at currents of 100mA, 200mA and 320mA (200% of their current ratings). The tests were conducted with each output open and ‘The tests vere conducted until the diodes and/or resistors reached thermal equilibrium. The reeult there was no diode failure that vould render the barrier ineffective, nor any damage to the printed circuit hoard. Samples of the barrier tisfactory in that 3.3.9 Allowable Capacitance and Inductance - Analysis revealed the total seri inductance (La) and Shunt capacitance (Ca) that can be connected to the barrier output terminals must be restricted co the following values for the single channel barriers Model 3B SB 8B 3B SB SB SB SB SB SB 19 140 M0710, 19 040 m 0710, 19 240 M o710 19 1e0 m 0715, 19 040 m 0715 39 140 m 0722 19 040 4 9722 19 140 M 0728 19 040 M0728 19 240 x 0726 croups ASB ‘BE 3.21/ 3.21/ 3.217, jap 78/1. 26/1 ay 14/4. s4/s. 98 198 298 7 n 72 38 38 38 Page 11 Groups C&E ‘MEZaH 9.64/4.03, 9.6474.03 9.64/4.03 213/656 2.3/6.96 78/6.36 43/17.28 143/17.28 243/17-28 C 2 2: 2 sroups D,F&G ‘EZ 5.6/7 .46 5.6/7.46 5.6/7.46 23.22 :2/13.22 t0a3.22FACTORY MUTUAL RESEARCH CORPORATION JOB IDENTIFICATION OV2HO.AX The following is the total Series inductance (La) and shunt capacitance (Ca) that can be connected to each channel of = dual channel barrier, Model Groups ASB Groups C&E Groups D,FSC E/ait EA EZ SB 59 240 N 0751 1000/3.8, 1009/15, 1000/29.6 SB 59 240 M 0760 3.2/.98 9.6/4. 25/746 SB 59 240 M 0762 4973.8 16s 39/29 3B 59 140 M 0764 116/238, 49/868 13/1000 SB 59 240 M 0764 116/238 4l97eue 13/1000 8B 59 240 M 0765 -78/1.72 21376.96 6.2/13 SB 59 260 M 0766 i.6/5.87 419723 13/46.19 5B 39 140M 0767 78/1.72 2:376.96 6.2/13.22 SB 59 140 M 0768 1287179 -78/7.23 213.77 $B 59 240 M072, £26/7.02 £78/27.38 2/5542 SB 59 240 M 0778 [16/1658 143 /63.27 1.1/133 ‘SB 59 140 M 079 114/438 43/17.28 1.1/34.23 SB 59 040 K 0779 [16/638 243/17 28 11/3423 SB 59 400 M 0786 feys.5 139/21 10/43 The following is the total Series inductance (La) and Shunt capacitance (Ca) thet can be connected to terminal 23 to ground and terainal 13 to ground of « dual channel barrier. Terminal 23 co Gnd Terminal 13 to Gnd Geps AGB Gxps CAE Grps D,F&G Grps ASB Grps CAE Grps D,F&G MEA = uE/e uP /ait SEAg — uF/a uE/ai SB 59 440 M0787 .14/5.5 43/21 1.1 /43 -16/4.38 .43/17.28 .1/34.23 SB 59 440M 1787 14/55 143/21 1.14/43 16/4.8143/17.28 11/34.23 SB 59 140 M0788 14 /4.38 .43/17.28.1.1/34.23 3.27.98 9.6/4. 35/7,48 SB 59 140 M0796 11774198 ‘si/16.61 1.32/39 34/ie.a6 1758.16 2.7/113 SB 59 040 M 0796 17/4198 |s1/16.61 1.3/39 3414.14 1754.16 2.77113 Terminal 13 to 23. Model Groups Ass Groups D,FS¢ ‘Eat E/al 9B 59 440 M 0787 12/6.38 99/34 3B 59 440 M 1787 12/438 dl Page 12FACTORY MUTUAL RESEARCH CORPORATION JOB IDENTIFICATION OV2HO.AX 3.3.10 Greepage and 2 + Analysis revealed that conponents which affect intrinsic safety meet the minimum requirement of 3.3 am (13 in.) for creepage and 6.0 nm (.24 in.) for clearance, for a confornally coated printed circuit board, which is subject to 250 V, Field wiring tersinals for intrinsically safe circuits and nonintrinsically safe circuits are separated ‘by more than the minimum requirezent of 50 mm (2 in.) 3.4 Enclosure Evaluation - The equipment enclosure vas not examined as part of the Approval but vas considered to comply with the requirements of this section. Reference paragraph 7.3 of Nanufacturer’s Responsibilities for additional information to that listed below. 3.4.1 Accessibilicy - The enclosure so thet its’ circuits ere ac accessible vhen a.) the IEC articulate accessibility probe applied in every possible position to the exterior or exposed surfaces, including the bottom, or b.) the TEC rigid accessibility probe applied with ‘the a paximun force of 30.0 newtons (6.75 lbs force) in every possible position to the exterior oF exposed surfaces, including the bottom, touches the part. For rack or panel mounted equipment, the IEC probes shall be applied only to the exterior or exposed surfaces rensining after installation. 3.4.2 Protection Fron Fire - If the enclosure fe non-metallic, it shall have the proper flensabilicy rating. rier Assembly must be mounted in the ssible by a tool only. A part is 3.4.3 Grounding - A metallic enclosure must have @ protective grounding terminal and be marked as such, All accessible conductive parts mst be bonded to the protective grounding cerainal. 3.4.4 General Construction - The equipment enclosure or parts of the enclosure required to be in place to comply with the requirenente for protection from electric shock, spread of fire, personal injury, protection of internal parts and wiring and external cord and cable assembly strain relief shall comply with the following tests for mechanical strength. 3.4.4.1 Impace Tests - The equipment shall be held firmly against a rigid support and shall be subjected to sets of three blows from a spring-operated impact hamer. The hammer shall be applied to any externa] part that vhen broken is likely to expose live parts. A window of an indicating device shall vithstand an impact of 0.085 newton-meter (0.753 1b force-inch) from @ hollow steel impact ephere 50.8 m= (2.0 in.) in dieneter and an approximate mass of 113.4 g (4.0 02). 3.4.4.2 Preceure Tests - A force of 90 newtons (20 pounds) shall be applied from 4 metal rod 12.7 mm (0.5 in,) in diameter, the end of which is rounded. The force shall be applied for one minute to any point overs sure except che botton. The bottom shall sustain a force of 65.0 newtons (15.0 pounds)FACTORY MUTUAL RESEARCH CORFORATION JOB IDENTIFICATION OV2HO.AX 3.4.4.3 Tip Stability Test - Equipment having a weight of 11.0 ks (24.0 Ib) or gore shall not tip over vhen placed at the center of an Amelined plane that makes an angle of 10 degrees vith the horizoneal and then turned co the position (with ell doors, drawers and other openable and sliding parts in the least steble position) ost likely to cause tip-over 3.4.4.4 Sharp Edges - An accessible edge, projection or corner of an enclosure, opening, frame, guard, handle, or the like shall be smooth and vell rounded and shall not cause a cut-type injury during normal use of the equipaent, 1V MARKING Marking meets requirenents as illustrated in the attachments. vo RBtaRKs 5.1 Manufacturer’ s instructions supplied with the protective assemblies 22 well as the system installation instructions and the National Electric Code must be followed when installing this equipment. 5,2 Control room equipment connected to associated apparatus should not use or generate more than the maximum voltage specified for the barrier. 5.3 Tampering or replacement with nonfactory components may adversely affect the safe use of the systen 5.4 The resistance between the shunt diode barrier ground and earch ground must be less than 1.0 ohn. see ANSI/ISA RP12.6, “Inctallation of 5.5 For guidance on installation, lazardous (Classified) Locations, Intringieslly Safe Inetrument Systen for w TLITIES. 04 Fury The manufacturing site at Eberbach, Germany vas examined with regard to facilities ané quality control procedures ‘and results were satisfactory in that the level of performance vhich produced the item vhich vas tested was mainteined. VI MANUEACTURERS RESPONSIBILITIES 7.1 The documentation listed in section IX ie applicable to this Approval and ts on file at FMRC. No changes of any nature shall be made unless notice of the proposed change hes been given and written authorization obtained fron FMRC. The Approved Product - Revision Report, FMRC Form 797 shall be forwarded to FMRC as notice of propesed changes Page 14FACTORY MUTUAL RESEARCH CORPORATION JOB IDENTIFICATION OVZHO.AX 7.2 The manufacture shall inform the end user of the details of the equipment enclosure requirements, Further enclosure requirements details aay be found in ANSI/ISA $82.01, $82.02 and $82.03 Standards. 7.3. The manufacturer shell supply a copy of the Factory Mutual Research Corporation controlled installation draving number GHC 11-4-3507 vith every barrier shipped. VIII GoNcLUSTON ‘The apparatus described in Section 1.2 meets FARC requirements. Approval is effective when the Approvel Agreenent is signed and received by FURC. EXAMINATION AND TESTS BY: Paul M. Finn ATTACHMENTS : Control Drawing GHG 1-4-3507 Label GHC 110 71 55 ORIGINAL TEST DATA: Test Novebook No. 91-251 WRITTEN BY: REVIEWED BY: Paul H. Firm, Engineer Thristoptler D. Goache, Project Engines? Instrumentation Section Instrumentacion Section Approvals Divicion Approvals Division TX ROGUMENTATION ‘The following docusentation is applicable to this Approval ané is on file at PARC. Rocument No. Revision qisle o710 o710 Stendard Zener Barrier SB 19 140 Standard Zener Barrier SB 19 040 M Standard Zener Barrier SB 19 240 M 0710 Standard Zener Barrier $B 19 140 M 0715 Standard Zener Barrier SB 19 040 M 0715 x ™ 4 ™ « GHGLI1914040710-US 3/25/91 KG ic. c "6. 26. 1G) Standard Zener Barrier SB 19 140 u 0722 2c. 2c i c GHGLI19040N0710-US_ 3/23/91 GHGLIL9240MO710-US 3/25/91 GHCI119140M0715-US 3/25/91 GHG111904040715-Us 3/25/91 GHOLIL9140M0722-US 3/25/91 11190400722-US 3/25/91 GHCLIIS1U0MO728-US 3/25/91 GHGLIL9040N0728-Us 3/25/91 GHGI1L9240N0728-Us 3725/91 GHCLISS24GHO7SI-US 3725/91 Standard Zener Barrier SB 19 040 M 0722 Standerd Zener Barrier SB 19 140 M 0728 Standard Zener Barrier $8 19 040 M 0728 Standard Zener Barrier SB 19 240 M 0728 joe A.C. Zener Barrier SB 55 240 M 0751 Page 15FACTORY MUTUAL RESEARCH CORPORATION JOB IDENTIFICATION OV2HO.Ax Docuzent No. Revision Mele (0H011592400760-US 3/25/91 Double A.C. Zener Barrier $B 59 240 4 0760 GHCL159240H0761-US 3/25/91 Double A.G. Zener Barrier SB 59 240 M 0761 (GHGI159140H0764-Us 3/25/31 Double D.C. Zener Barrier SB 59 140 H 0764 GHCL1S9240H0764-US 3/25/91 Double A.C. Zener Barrier SB 59 240 M 0764 Hoi159240N0765-US 3/25/91 Double A.C. Zener 0765, GHC1159240H0766-US 3/25/91 Double A.C. Zener M0766, GHCL159140N0767-US 3/25/91 Double D.C. Zener ¥ 0767 GHGLIS9140NO76E-US 3/25/91 Double D.C. Zener M0768 GHGLIS9240M0772-US 3/25/91 ‘Double A.C. Zener Barrier SB 59 260 M 0772 GHCL139240K0778-US 3/25/31 Double A.C. Zener Barrier 3B 59 240 M 0778 GHe1159140N0779-US 3/25/91 Double D.C. Zener Barrier SB 59 140 4 0779 GHG1159040H0779-US 3/25/91 Double D.C. Zener B 0778 GHCLIS9440NO7B6-US 3/25/91 Double D.C. Zener 0786 GuG1159440N0787-US 3/25/91 Double D.C. Zener Barrier SB 59 440 H 0787 cuci1s9q40M1787-Us 3/25/91 Double D.G. Zener Barrier SB 59 460 M 1787 GHGIL59140M0788-US 37/25/91 Double D.C. Zener Barrier SB 59 140 M 0788 (GHGL159140K0796-US 3/25/91 Double D.C. Zener Barrier SB 59 140 M 0796 (GHELI59040KO796-US 3/25/21 Double D.C. Zener Barrier SB 59 O40 4 0796 Guel1-3-40souSA A Universal Double Barrier Printed Circuit Board GuGI1-3-4052USA 9/20/89 «Double Evaluation Barrrier Printed Circuit Bd Ge 11-4-3507 I Control Drawing Safety Barrier cue 110 71 55 fl Label Page 16GHG 110 0881 P 1 - ABB Label 1 (Side) : (See 316" x 1-1/4) ABB CEAG GLASS |, 1 SAFETY BARRIER GROUPS — coEFG oo y : APPROVED ‘ABB CEAG. Made Neuer Weg 47, 6930 Eberbach, Germany Germany Insalation Dwg. GHG11~4-3507 Rev.2 Label 2 (Top): (size ; 241/16" x 3/8*) HAZ. AREA SAFETY BARRIER SAFE SIDE | NO. GRD 13 23 214i 9,00 ar Pe double layer adhesive foil with acnlic adhesive Boviom ler white 0.05 mm thick insripton stamped on op layer transparent, 0.012 mm thick, stuck to botiom layer. Drawing cannot be akered without prior consent of ‘approval agencies. pare: MAA 25, 1981 SION Anon Hein! GHG 110 71 55 Peles | LABELoll GHG 110 0881 P 3 - ABB (See: 3-1/16" x 1-1/4") ABB CEAG CLASS |, Il, Ill DV t SAFETY BARRIER Bnours — cDEFG <> v : APPROVED: ie v be = ma o - 1 a mit ‘ABB CEAG Neuer Weg 47, 6890 Eberbach, Germany in Germany Installation Dwg. GHG11-4~3507 Rev. 2 Label 2 (Top) : (Size : 2-1/16" x 3/87) HAZ. AREA SAFETY BARRIER SAFE SIDE | NO. GRD 13 23 aaa 9,0 ° | 1 iG CU Beckground : ig Part No. “—— Background + red Prat Black Print black Pe double layer adhesive foil with acrylic adhesive Botiom layer white 0.05 mm thick ingeripon stamped on, Drewing cannot be akered ‘Top layer transparent, 0.012 mm thick, suck to bottom layer. | without prior consent of eporoval agencies. GHG 110 71 55 pare: MAR 25, 1991 SGN: Anton HelncilGHG 110 0881 P 4 - ABB 31/16" x 1-1/6") ABB CEAG iAss 1, n,m SAFETY BARRIER Gnours cere & woooy — ee Yoo = me s e ‘ABB CEAG Made in Germany Neuer Weg 47, 6830 Eberbach, Germany Installation Dwg. GHG11-4-3507 Rev, 2 Label 2 (Top) 1/16" x 3/8") HAZ. AREA SAFE SIDE | NO. SAFETY BARRIER GRD 13 23 a 0,00 gO | Background + light blue Priat black Pe double layer adhesive foil with acrylic adhesive Botiom layer white 0.05 mm thick, inscription stamped on Drawing cannot be altered ‘Top layer transparent, 0.012 mm thick, stuck to botiom layer. | without prior consent of approval agencies. = eels] | pare. MAR 25, 1991 SIGN. : Anton HeinillPart No. GHG 110 0881 P 6 - ABB 1 (Side) : (Size : 3-1/16" x 1-1/4") ABB CEAG Class 40, a SAFETY BARRIER hours cpera & Ce APPROVED ENTITY PARAMETERS Yoo = v Isg = mA Gos uF io mH ‘ABB CEAG Made in Germany Neuer Weg 47, 6930 Eberbach, Germany Insiallation Dwg. GHG11~4-3507 Rev.2 Label 2 (Top) : (size : 2-1/16" x 3/8") HAZ. AREA SAFETY BARRIER SAFE SIDE | NO. GRD - + +: o,00 ae Background + light biue Background + red Print: black Print + black Fe double layer adhesive foil with acrylic adhesive Bottom layer white 0.03 mm thick, inscription stamped on, Drawing cannot be atered ‘Top layer transparent, 0.012 mm thick, stuck to bottom layer. | without prior consent of approval agencies. pare: MAR 25, 1891 Di SIGN: Anton Heinsill GHG 5 A v8 RAWING NO, 110 71 5: :Label 1 (Side) (Size : 3-1/16" x 1-1/4") ABB CEAG CLASS |, 1, UI bv SAFETY BARRIER GROUPS CDEFG y, v

mH ABB CEAG Made ia Ger Neuer Weg 47, 6950 Eberbach, Germany Installation Dwg. GHG11~4-3507 Rev. 2 Label 2 (Top): (ste: 21/16" x 3/87) HAZ. AREA SAFE SIDE | NO. SAFETY BARRIER GRD ~ ~ to 0,00 1 Background : light blue Print # black Backsround : red Print + Black Fe double layer adhesive foil wih acrylic adhesive Bottom ler white 0.05 mm thick, insription stamped on. Drawing cannot be akered Top layer Wansparent, 0.012 mm thick, stuck to botiom layer. | without prior consert of Preval agercies, pate; MAR 25, 1991 SIGN: Aron Heinsil DRAWING. NO, GHG 110 71 55GHG 110 0881 P 10 - ABB (Sze + 31/16" x Layer) Label 1 (Side) = ABB CEAG CLASS 1, I, II Neuer Weg 47, 6590 Eberbach, Germany Label 2 (Top) : (Sie : 2-1/16" x 3/8") Backgrouad + ight blue Cat No, Print + black Print Pe double layer adhesive foil with acrylic adhesive Bottom layer white 0.05 mm thick, inseription stamped op. ‘Top layer ‘ransparent, 0.012 mm thick, stuck to bottom layer. pare» MAR 25, 1991 SION Anton Hein LABEL i Ovi SAFETY BARRIER GROUPS CDEFG Ww y

"NY 7 APPROVED ENTITY PARAMETERS Yoo = ¥ ee ma Cy oF ty mH ABB CEAG Made in Germany Neuer Weg 47, 6930 Eberbach, Germany Installation Dwg. GHG11-4~-3507 Rev. 2 Label 2 (Top): (Sue: 251/16" x 3/8 HAZ, AREA SAFE SIDE | NO. SAFETY BARRIER GRO 13 23 an 0,00 I ; Sg Bacigromd : Heke te — Pan No. U— pucrground ? ved Pritt black Print black Pe double Iver adhesive fil with sent adbesv Boom ayer white 6.09 mim thick lasipfos stmped on. [Drawing cannot be altered Top lnyer transparent 0.012 mm tic, sik 19 botom layer. | whoUt prior Consent Of approval agenct pate MAR 25, 1991 DRAWING NO. SIGN : Anton Heinsill GHG 110 71 55 i. aD ED aNtSINGLE CHANNEL SAFETY BARRIER NON-HAZARDOUS SIDE | (white) Safety barrier bise) with Entity parameters Voc! sc: Carta ) (ue) } Notes 1) Single Intrinsic Safety Bat Vee © Vinax amd ors ae aod ee a an HP t+ teas aad 2) Simple apparatus is a device which will not generate or store more than 1.2 V, 0.1 A, 25 mW or 20 uJ. Examples are : Switches, TC's, RTD's, LED's. 3) lateinsically Safety Barrier busbar conncetion to the earth ground must be less than (1) 2. 4) Electrical apparatus conaccted to the int for generate voltages greater than 250 V. 5) Installation should be in accor: ANSI/ISA RP12.6. Drawing cannot be eltered without Prior consent of approval agencies CONTROL DRAWING ‘SAFETY BARRIERS. ABB SSEABROWN SOVER [mous ta 4-ssor [st a | HAZARDOUS SIDE Intrinsically safe approved apparatus with Entiy Parameters — 5 ot sically safe system should not use unce with the NEC ANSI/NFPA 70 and ‘Anton Helnskit ian 25, 1992 |= Double Channel SAFETY BARRIER | Mazarvous swe inal sae approves paris wh Ea Pare ¥, NON-HAZARDOUS SIDE ———i Channel 1 23 te) (ae ‘ SAFETY BARRIER 2 with Entity parameters Yoc!¥ o/c, elise Ltt 411 chamel2 3 om ‘Spe Apparnve (wore Drawing cannot be altered without prior consent of approval ageraies channel 2 : Vee £ no a 3 te 2) Simple apparatus is a device wh will not generate or store more than 1.2 V, 0.14, 25 mW or 0 uJ. Examples are : Switches, TC's, RTD's LED's. 3) latrinsically Safety Barrier busbar conncction to the earth ground must be less than (1) 2. 4) Electrical apparatus connected to the intrinsically safe system should not use or Benerate voltages greater than 250 V. 5) Installation should be in accordance with NEC ANSI/NFPA 70 and ANSI/ISA RPI2.6, CONTROL DRAWING ‘SAFETY BARRIERS GHG 11. 4 - 3507NON-HAZARDOUS SIDE | INTERCONNECTED CHANNELS ON DOUBLE BARRIER HAZARDOUS SIDE £24 23t —+ invrinsictiy (nite) Safety barrier (biue) safe approved with Entity parameters | apparatus with Voc Isc: Car ba Entity Parameters pi Ve lt By p> FP. Vmax, imax Ci. Li (white) (Wve) f 1 yy | Simple Apparatus | | vy, sod 4 and I cs Cteads amd u a I leads 2) Simple apparatus is a device which will not generate or store more than 1.2 V, 0.1 A, 25 mW or 20 uJ. Examples are : Switches, ‘TC's, RTD's, LED's, Fe A 3) Intrinsically Safety Barrier busbar connection to the earth ground must be less than (1) @- 4) Electrical apparatus connected to the intrinsically safe system should not use or generate voltages greater than 250 V. 5) Installation should be in accordance with the NEC ANSI/NFPA 70 and ANSI/ISA RP12.6, Drawing cannot be altered without Prior consent of approval agencies CONTROL DRAWING ‘SAFETY BARRIERS [reong season [3 [oa | A ASEABROWN SOVER! Jan 25, 1992Entity Parameters : $33 satiarie dy Teumaine | vos | so | Grow [srw | Sonn (blue) v)_ | (ma) w AB GE |0,FG wv fe]. ase | ame | 20s nan TERMINAL No. | Voc | ‘gg | ¥y Group | Group | Group blue) 4v)_| (mad |v) AB CE [DFG fall ame aon | ace [oe Biseawis iy Tamme | Yoo | me | Grow | Grup] Gow owe | eo | cap | oe |Sioe a = Lo [- ia wel fia oe 19 wom o72 a i ie oanarce is, oc] se | . (blue) ow _| mw | wm Ae | ce [DRG Siiuauare ayy TERMINAL No. | Vog | Isc | Yr Group | Group | Group (biue) Low | ma | Ww) ae | Oe ee {+ a | 3 | - 498 | 1728 | 9428 | ABB | ‘CONTROL DRAWING. ‘SAFETY BARRIERS GHG 11-4 “Jen 25, 19928B 19 240M 0728 ° by uf) (oto TERMMAL Ne. | Yoo | ‘sc | Yr | tr | Group ] Group | Group | Group | Group | Group aa | ee | on | ew | AP | Ge [Oe | AB | Ce |DRe nae zs [ss | - | - | om | os | tu | aoe | 1720] onze ‘SB 59 240 M 0751 cy La uh (ot Terminate] Voc | ‘sc | Yr | tr | Group | Group | Group | Group | Group | Group ay |i | | ow | AB | OE (DG) AB | CE [DRG 1a, exo + | sw | - “aon | so000| sooo] eso | reas | 2oee 25, GN + | ao | = | = | to000} tooo} tooo} 380 | 1605] 2563 ‘SB 59 240 M 0760 cy ba wh ot TeAMINALNG. | Yoo | 'sc | %7 | 4 | Grow | Group | Group | Growp | Group | croup peal Lem | wm fo | Ae | oF [Dra] AB | ce [ore 13, GAD 10 | 20 | - az | oes | asso] ase | aa | ras Ee to | am | > | = | az | see | 250s] ose | ae | Fas $B 59 240 M 0761 cy ba wn co enwmat No. | Yoo | isc | Yr | tr | Group | Group | Group | Group | Group | croup oho) [Lim | oy fw | AB | Ce [OFG| AB | GE IDFG 73, exo © [sm] - | - | se | sase| aera] aco | sso] anes 28, GND 8 | io |: |: | deo | tase] sore] 320 | i505] 206 op 50 140 M 0764 oe res uf) (ni) TERMINAL He. | Vog | Vz | ty | Group | Group | Group | Group | Group | Group (bive) w | w |ow| 48] CE |DnG] AB | ce loFG 13, ND we } 2 | - | - | use | 492 | var2| 20025| eaao| 000 23, GND 1 12 : -__| 164 | 492 | 1912] 298.25] 8489] 1000 ‘CONTROL DRAWING SAFETY BARRIERS eten ieee [met [es [Pian 2s. 1992 | {SEA BROWN SOFERL GHG 11-4 - 3507emma te | Yoo | tse] vs ] [ecw [Group [oom em Jereup [ecw tones We | aS A | ty | SS? | Sse [Sete | [ere [sree savewe non =] ea leas] ase sl ease eee [#8] 2 {2 |: [38 ]48 | oe] ze] see] me 050 240 w ores c i “a oo Terma. ] Voo | | | w [emu [eur [arom | Gap [ere [ome oe Lee | oe | tty [Ome | Cos? [ere | Sax" | Cre ame woo |i | so] - [- | om |ass| ea | az] eo | am Et eee [ ‘SB 59 240 M 0766 cy a Pe oats Tenmmatve. | Yoo | 6 | | & Jenn |eow oon [eww Taroom [arom toon ae eS | ak | ata {ome | Cem | Sete | Sew | reer | sroun seo | 2 [8 |: |: fis fse] eel ee] asl es ‘SB 59 140 M 0767 ca be sh on Terunacne. | vo] be | |W |eom lew oom | eam oem Tomw (be) avy _{ ima) | wv) | ima | AB | CE LOFG] AB | CE DFG begote Hiei iat i ove | 2s [os | 12 | es | BB be co wou ares a os Teme | Yoo | ee an | as (won| aoe (bive) Ww) | im | Ww [DFG AB CE |D,Fe 23, GND 22 147 . 2.09 179 | 723 1377 ae GHG 14-4 - 9507 CONTROL DRAWING ‘SAFETY BARRIERS [Ps Pe 5 [len 25. 1092 |‘SB 59 240 M 0772 cy ba uP ot) TERMINAL No. | Yoo | Isc | Yr | tr |Sr0up | Group | croup | Group | Group | Group prs > lien | wm lim | A® | CE [DFG] AB | Ce |oFe 13, z |r | - | - | 026 | are | 200 | roe | 2750] ssaz 23, z [7 | > |: | 026 | aze | 200 | 702 | 2738) 5642 ‘8B 59 240M 0778 Oe a uF) nit) TERMINAL No. | Yoo | 'sc | Yr | tr | Group | Group | Group | Group | Group | Group (blue) 4v)_| (ma) |v) im) | A8 | GE |DFG) AB CE |DFG 19, GND ze [a | - | - [am | ose | sx | se80| car] ram 22, GND ze [a | > |: [av | aa | iia | tes8| cea | tac ‘$B 69 140 M 0779 Ca la 88 59 040 M 0779, aa a TERMINAL No. | Yoo | isc | Yr | tr | Group | Group | Group | Group | Group ] Group (blue) Ww) | (im) | wm (ma) | AB | GE [OFG) AB CE [DFG 12, GND ze fos | - | - | ar | css | a4 | 408 | 1726] o420 23, GNO ze | os |: | = [arm | oss | tre | 420 | i720] onze ‘SB 59 440 M 0786 cy ba i) on TERMINAL NO. | Voc | sc ] Vr | tr | Group | Group | Group | Group | Group | Group (ued @ low | [ow] 8 | CE |DRG| AB | CE [DFG 13, GND wz fo [- |- [aw] os] | ss | a | a 23, GND z io 2 fog | age | vo [ss | a | a3 re 440 M 0787 o ie $8 59 440 M1 a ia TeRMINALNO. | Voc | Isc | vr | tr | Group [Group | Group | Group | Group | croup Ate) w law | wm |ow | AB | CE [ore] AB | Ce [DFG 18, XO we foo | - | - | ar | o4a | ssa | ag0 | i726] onze 20, XD ze | | aw | oa | to | ss | ar | as 13,29 | - | 2ors| 90 | arf | oar | ose | 420 | 1720] o4z0 CONTROL DRAWING SAFETY BARRIERS GHG 11 - 4 - 3507 ‘lan 25, 1992SB 59 140 M 0768 ce ta uA (td TERMINAL No. | Voc | Isc ] Yr | ty | Group | croup | Group | Group | Group Tay ow | ow | w | mm | AB | CE lore] AB | CE DRG 13,0 10 | 20 | - 221 | see | 2569] a96 | 403 | 746 25, GND zs {| - | - | ar | oa | isa | 490 | i720] a4co ‘$B 59 140 M 0796 Oy ly 3B 59 040 M 0796 un ae TERMINAL No. | Voc | Ise | Vz | 4 .| Group | Group Group | Group (ive) w | mw | w | wm | 48 | CE CE |DEG 13, GO zo | st | ase [sor sate | r1318 23, G40 z |e |: |: | av | os rest | 3000 GHG 14-4 - 3507 CONTROL DRAWING ‘SAFETY BARRIERS. [me Tes | “Jan 25, 199290 Pegs Terme ons. Snzc08e ona ta om ‘cima es @ Underwriters Laboratories inc.» Teme SUL 22 1983 File No. BLS2169 Eroject fo. 524810629 tee H CROUSE-EINDS ELECTRICAL CONSTRUCTION we 13222 (ob EQUIEMENE, FOR USE IN the felloving =e! resulting fron the investigation under the above iesed (see attached Addendum or below for page numbers}: nex cages and illustrations for Follow-up Service Procedure. ised pages end ilivatations in place of material of "EE should be filee in ite proper nunecicel order. Please Like ies Jal and report any inaccuracies to DAVID HORENSTEIN the above project number. Please review ext. UNDERWRITERS LABORATORIES INC. #4300 ESSEN 1, FED CEA, ‘nto eanaton (reat bt ley a nid ety senceFile £152169 Vol. 1 Sec. 1 Pagel Issued: 6-8-93 and Report Revised: 7-20-93 DESCRIPTION PRODUCT COVER! Associated Apparatus, Nonhazardous Locations. *safety barriers, Cat. Nos. SB 59 240 M 0760, SB 59 240 M 0760, SB 59 440 M1787, SB 19 240 M 0728, SB 59 140 M 0779, SB 49 430 M 2427, SB 59 240 M 0778, SB 39 230 M 0201, SB 59 040 M 0796, SB 59 240 M 0761, SB 39 230 M 8301, SB 49 130 M 1350, $B 49 130 M 1351, SB 19 140 M 2410, SB 49 140 M 2410, SB 19 140 M 1250, SB 49 140 M 1250, Sa 19 140 M 2420, SB 49 140 M 2420, SB 19 140 M 0715, SB 19 140 M 0728, SB 59 140 M 0767, SB 59 140 M 0796 provided intrinsically safe circuits for use in hazardous locations Class I, Groups A, 3, C, D; Class IT, Groups E, F, G; Class ITI when installed in-accordance with Drawing No. GE GENERAL, These barriers are required to be connected to a grounding bus. It is expected that the barriers will be wired by persons familiar with intrinsically safe systems. The output circuits of each barrier are intrinsically safe for the specified hazardous locations when installed in accordance with Drawing No. GHG11-4-3507. ENTITY CIRCUIT PARAMETERS/INSTALLATION INSTRUCTIONS Refer to ILL, 1 for entity parameters and installation instructions. A sample of each drawing should be provided with the safety barrier and should be as shown in ILL. 1. SPACINGS: * Barrier Cat, Nos. S# 59 240 M 0760, $B 59 240 M 0761 *sp 39 230 M6301 - A through air and over surface spacing of 0.02 in. (0-5 mm) is provided at the following locations: A. The circuit board traces, solder pads and component leads connected between the fuse and the current limiting resistor are separated from all circuits except ground.UNDERWRITERS LASORATORIES INC. kh ADDENDUM 70 TRANSMITTAL LETTER File 152169 Project 93NK10623 Revised 7-20-93 Report Date _vol. Sec. Revised or New Material 6-8-93 1 2 Revised Pages 1, 2, 5+ 6) 71 Revised ILL. 1 (Pgs, 4-10) New Pages 6A, 8, New 2, New ILLS. 13 thru 25€ 0 =e Mr. V. Buter ReZer to LR 77661-3 ABB Ceag Sicherhetstechnike Gabi January 14, 1993 Neuer Weg 47 D-6930 Eberbach, Germany Subject: Safecy Fuse sdous Loca! Gentlemen: Ve have pleasure in informing you that the subject equipment complies with che Usplicable csa requirenents. This equipment is therefore eligible to bear the Gib Merk in accordance with instructions contained in previous correspondence. ‘A copy of our Corcificacion Record is enclosed for your files. ena Hazardous Locations Group eis) 747-4271 (16) 747-6178 WE Me. P. Babiarz Crouse-Binds Wolf & 7th N. Sc. 2.0. Box 4999 Syzacuse, HY 15221 Canadian Standards Association, 178 Rexdale Slvd. Resdsle (Toronto) Ontario, Canada MOW IRS “Telephone: (416) 747-1000 Telefon ($16) 737-189Canadian Standards Association CERTIFICATION ‘Association canadienne de normalisation RECORI D aE EE Tame BAGH Tat Dean SIDSLEM by Canadian Standards Anociation 19 feoresent the products Urea [t's Tae Samay ance and go avi the CSA Mark = @ +” 10 that products scoring to the terms an conditions si tie GEA Servien Agreement. WU@R 077661K0000 January 16, 1993 CLASS 2258 03 (Re-examination Service) ABB CEAG 77661 Sicherhetstechnik GubE Neuer Weg 47 +6930 Eberbach, Germany PROCESS CONTROL EQUIPMENT - Intrinsically Safe and Non~Incendive Systens ~ For Hazardous Locations = chase T, Groups A, B, C and Dj Clase IT, Groups E, F and G; Class T2T: = shunt diode safety barriers iascalled per aanufecturer's drawing Gugl-4-3507 ABB Crouse-Hinds Bart No Bare No YMax (Volts) RMin (Ohms) Notes GHG 111 91 30 $B 19 130 34 47 ¥ 2403 ¥ 2403 GHG 111 91 40 SB 19 140 1s 100 0715 MOTs Gg 111 91 40 sp 19 140 28 300 ¥ 0728 0728 GHC 111 91 40 $B 19 140 as 38.7 1250 1250 Gag 111 91 40 §B 19 140 28 186 Groups 0-6 M2410 M2410 Gac 111 91 40 sB 19 140 28 aL Groups C-G 2420 2420 Gag 113 92 30 SB 39 230 53 29.7 Each of 2 0201 0201 Channels Cac 114 91 30 $B 49 130 11.66/11.66 466/67 Double Channel 1350 4 1350 GuG 114 9130 SB 49 130 11.66 466 Each of 2 41351 4 1351 Channels uc 114 91 40 SB 49 140 as 38.7 Each of 2 4 1250 1250 Channels CHC 114 91 40 SB 49 140 28/28 196/186 Groups C-¢ 2610 M2410 GHG 116 91 40 SB 49 140 28/28 a31/131 Groups 0-¢ 2620 ¥ 2420 GRC 114 94 30 SB 49 430 26.25/26.25 252/Diede Double Channel M2427 4 2627 (Cont!)= Canzgien Standards Association CERTIFICATION ‘Association canadienne de normalisation RECORD AnaTY Rana bag ha bee aahoraed by Canadian Siandarcs Amociaion to repre the produce tated wis record af °CSA Certified” and 10 affix Bie GSA Mark - @ ~~ to Hew produc according to the tenn: and conditions 07766120000 January 14, 1993 CLASS 2258 03 (Re~exanination Service) Page 2 GEG 115 90 40 sz 59 040 20/26 390/300 Double Channel ¥ 0796 0796 GEG 115 91 40 $B 59 160 15 1000 Each of 2 0767 0767 Channels Gc 115 91 40 $B 59 140 28 300 Each of 2 «079 0779 Channels Gag 115 91 40 $B 59 140 20/26 390/300 Double Chennel 0796 ¥ 0796 Gag 115 92 40 28 600 Each of 2 078 Channels GEG 115 94 40 28 Diode Each of 2 40786 Channels CHG 115 94 40 28/28 300/Diode Double Channel x 1787 at GG 11s 92 40 10 30 Bach of 2 0760, Channels GHG 115 92 40 9 90 Each of 2 x 0761 Chamnels Gag 111 92 40 28 300 40728 ¥ 0728 Note: The above products are Certified, as components, for installation in non-hazardous area within « suitable enclosure. The final coubination is Subject to Acceptance by Locsl inspection authority having jurisdiction.Physikalisch-Technische Bundesanstalt CERTIFICATE OF CONFORMITY PTB Nr. ex- 83/2053 X hie certisieate is ‘sued for the electrical apparatus Zener barrier type GHG 111 9.3. Vue menufactured and subaitted for cextifieation-by Brown, Boveri & Cie AG D-6900 Heidelberg This clectcical apparatus and any acceptable vaziation thereto is specified in the Annex to tnée Centisicat ‘the Physikaliech—Technische Bundesanstalt (PTS), approved certification body in Zecordance with Article 14 of the Council Directive of tho Suropean Communities GE 16 December 1975 (76/117/E20), contizas that the apparatus has been found to Cosply with the harmonized Ruropean Standards Electrical apparatus for votentially explosive atmos! SX SO 014-1977 / WOE O171 Part 1/5.78 General Requirements EN-50 020-1977/VDE 0171 Part 7/5.78 Intrinsic safety "i" after having successfully net the examination and test requirenents which exe Seconded in @ confidential Test. Report. ‘The apparatus earking chal inelude the foitewing cote (Bx 4b) Ie or (HEx ib) ITB the nanufacturer has the responsibility to ensure chat che apparatus bearing the Earking confors to the specification laid dovn in the Annex to this Certifi- Ecce aad has satisfied the prescribed routine verifications and tests. ‘This apparacus may be marked with the Distinctive Comunity Hark shown above and Specified in Annex IZ to the Council Directive of € February 1979 (79/196/ZEC) . For and en behalf of PTB Braunschweig, 15.6.1983 (Dr.-Ing- Schedsdat) (signature) Oberregierungsrat ‘Feat certificates without signature and official stamp are not vali No alteration may be made co copies of this cest certificate. Extracts or changes may be sade only with the permission of the Physikalésch~ echnische Bundesanstalt, Bundesailee 100, Postfach 3345, D-3300 sraunschweis.ANNEX to Certificate of Conformity PIB No. Ex-83/2053 x ‘The Zener barrier is @ passive network and limits the voltege end current of a non-intrinsically safe circuit (input circuit) Yo such @ degree that the limited output circuit complies with the regulations VDE 0171 for the type of protection “intrinsic safety" Type code: He Ht aa Mamufeeturer's code Apparatus code Current-voltage limiter ype of assembly 9 = outside potentially explosive atmosphere Type and polarity 0 = safety barrier, negative 1 = safety barrier, positive 2 = safety barrier for alternating potential 3 = evaluation barrier, negetive 4 = evaluation barrier; positive 5 = supply barrier, negative = supply barrier, positive Design 3 Limitation 0 = by chmic resistance 1 = by ohmic resistance and can be balanced Variants Wo-load voltage and short circuit current Page 1/6Page 2 to Annex to BBC Certificate of Conformity Fett | Sep ko. Be-03/2083 2 Electricel date Input circuit .... = 250 V (safe limit value) (terminals: Un‘ and’ "j Un rated operating voltage output circuit, ..... in_type of protection "intrinsic safety" (Serminals: "i" end’") (Bex ib) I or (EBx ib) IIB Max. values: voltage . Uy current aie Ty Max. perm, capacitance . Ca cle Mex. pern, inductance See the following tables for the respective max. values for short-eireult current and no-load voltage Ho-Load voltege and capacitance and Short-cireult current and inductance The dener barrier is installed outside the potentially explosive gas atmosphere. ‘The non-intrinsically safe input circuit and the intringically eae output Circuit are galvanically connected. Page 2/6BC Page 3 to Annex to Gertificate of Conforsity PIB Wo. Ex-83/2053 X Table 4 vz () Ty (ma) uy (v) Ty (ma) ue rB qe 1B 16.5 500 500 29 90 260 7 460 500 29.4 86 255 175 420 500 30 80 240 16 400 500 30.8 16 230 18.5 360 500 3 6 221 19 350 500 32 70 a3 19.5 330, 500 uM 6 190 20 310 500, 35 65 180 20.5 280 500 36 62 170 a 270 500 37 59 163 21.5 250 430 38 56 153 22 235 460 32.8 53 148 22.5 220 420 40 50 140 23 205 410 42.6 45 125 23.5 190 405 5 40 115 24 160 390 48 38 109 24.5 165 315 48 37 100 25 150 353 50 35 95 25.7 140 140 32 3 88 26 135 327 35 30 60 26.3 130 320 58 27 23 ar 120 300 50 25 70 28 110 280 62 23 61 28.5 100 270 6 20 81 Page 3/6B Boge 4 to Annex to Certificate of Conformity ee PIB Wo, 2x-83/2053 X Table 2 Ty (mA) La (ait) Tg (mA) Ta (ait) qe mm qr0 me 390 0.5 60 8 32 380 0.8 ST 9 36 370 0.7 55 10 39 360 0.8 50 12 a 340 0.9 45 14.5 58 320 ff 40 18.5, 70 300 12 35 24 96 280 1d 32 30 110 270 1s 30 34 130 260 1.6 28 38 150 250 4.7 25 49 190 240 2 23 38 220 220 2.3 a 10 260 200 0.5 3 20 76 230 180 0.6 3.5 19 8s 320 170 0.8 4 18.5 30 340 160 1 ay 18 95 360 150 W3 & 17.8 100, 370 140 15 5.4 16 120 450 130 7 6.3 5 140 520 120 2 8 13 180 700 110 2.5 3.5 R 220 800 100 3 2 ” 260 4000 90 365 14 10 310 1200 86 4 5 9 400 1500 80 45 8 8 500 2000 76 5 20 7 660 2500 70 6 25 6 300 3500 65 7 2 5 1400 5000 62 co) 30 4 3000, 8000 61 78 3 365 any any Page 4/6Fage 5 to Annex to BBC Certificate of Conformity Pee PIB Wo. Ex-83/2053 X Ug (VY) Ga (nF) u, (v) ca (n? or uP) me 1B xe IB 65 8 80 17.8 270 1100 60 10 93 17.7 280 1100 5 12 105 11.4 300 1150 50 15 it 7 310 1200 46 19 145 16 380 1400 42.6 23 165 15.5 420 1600 40 2 185 8 460 1900 38.8 29 192 14.5 520 2200 35 39 230 14 600 2600 32 50 270 13.5 660 3000 31 34 280 13 750 3600 30 39 300 12.8 200 3900 23 60 320 2 1 5 uP 28.9 65 320 11.6 at 6 28 70 340 " 1 15 26.3 80 370 10.5 1.55 10 26 90 380 10 1.8 3 25 100 410 9.5 2.2 16 24 110 440 9 2.7 22 23 130 470 8.2 4 38 22 145 520 79 45 42 2 160 570 15 5.5 5 20 190 630 12 6.4 55 19.9 200 640 7 5 60 19 220 750 6. 13 62 18.3 250 300 6.5 10 4 18 260 1000 6 3B 85 5.9 4 90 5 any Interpolation to pbtain intermediate values for I, or Uz is not permitted; the next lowest value for Le or Ca must be selected.Page 6 to Annex to Certificate of Conformity PIB No. Ex-83/2053 X co wo a | i Special conditions 1, Only apparatus, where volteges of not more than 250 V occur during operatién, nay be connected to the non-intrinsically safe side of the Zener barrier. ‘The protective carth terminal of the Zener barrier iv to be connected to the respective protective earth terminals inside the potentially explosive gas etmosphere via a potential equalization conductor in order to achieve potential equalization. ‘The Zener barrier must be protected by an enclosure, which guarantees 2 minimum degree of protection of IP 20 according to IEC Publication 144. 4. The Zener barrier is to be installed outside the potentially explosive gas atmosphere. signed on: Test documentatio: pages 14.02.63 Description of apparatus SK-No. 3061 1 pages 14.02.83 Annex to description Drawing No. GHG sheet 14.028 1 Ge 1 Sheet CHG 1 Sheet cus. 1 sheet Ee 1 sheet GHG i sheet cue 4 sheet Go 11-3-3192 1 sheet GHG 1-3-3187 1 sheet GHG 11-3-3198 i sheet GHG 1-3-3183 1 sheet For and on behalf of PIB Braunschweig. 15.6. 1983 (Signature) (DrewIng. Schebsdat) Goerregierungerat Page 6/6BI Translation SUPPLEMENT 2 to Certificate of Conformity PTB No. Bx-83/2053 x Brown, Boveri & Cie AG of Messrs. D-6800 Heidelberg in future the Zener barrier, type GHG 111 9.3. V...., may also be manufactured under the type code GHG 111.913. Rl... the "Electrical Data" and the special conditions remain unchanged. For and on behalf of Pra Braunschweig, 09.04.1991 (signature) Dr.-Ing. Schebsdat Regierungsdirektor page 1/1 (EEx ib] TIC or [EEx ib] I7B | ___——_N@Y wariowat onwet varco 54 SECTION § OPERATING INSTRUCTIONS SCR POWER CONVERTER The Eddy Current Brake, controled by this Control System, provides an actual braking effect controlled as required, rather than a speed regulation which is limited to a certain pre-selected degree of braking effect. ‘The Power Selector allows the operator to select the proper range of braking effect for his drilling conditions. The Selector divides the Control System's maximum braking capability into two ranges: "DRILL" and "TRIP". ‘The mechanical friction brake lever on most drawworks is located at the driller's right hand. It is usually convenient for the driller to transfer his left hand from the drum clutch controls to the eddy current brake control since these two controls are normally operated alternately during tripping cycles. The operator should have complete control, with his left hand, of the braking effect from zero to fully applied, while his right hand is on the mechanical friction brake lever. As the Driller's Control is advanced toward "FULL ON", the voltage excitation to the brake magnet coils increases toward a maximum. The Control System thus provides the driller with controlled braking that is easily varied during any rotation of the drawworks. By modulating the Driller’s Control, the maximum safe controlled speed of descent of each stand of pipe into the hole is assured. 54N@Y wavionat omweLt VARCO 5.4 SCR POWER CONVERTER (Cont'd) In the "TRIP" position of the Selector Switch, a small variation of the Driller's Control effects a large change in descent speed. This control effect is reduced in the Drill Selector Switch position. For instance, with a light load on the drawworks, operating in the “DRILL” Selector Switch position, gives the operator better speed control, For typical operation proceed as follows: 1. Select the desired Selector Switch position for the drawworks load conditions. 2. Pick the pipe up off the slips and start the downward travel into the hole with the Drille’s Control left slightly "ON" until the load accelerates. 3. Keep the rate of descent under control by moving the control handle in the "FULL ON" direction to decrease pipe speed or if the descent speed is too slow, by moving the control handle in the "OFF" direction Since the load conditions may vary the amount of braking required, even during the downward travel of one stand of pipe, it is normal for the driller to advance the control handle toward “FULL ON” and return it towards “OFF” position several times during the downward descent of a stand of drill pipe to maintain a uniform safe speed of descent. 4. As the stand nears the end of its downward travel and the elevator approaches the rotary table, advance the Driller's Control toward "FULL ON" to decelerate the pipe. The mechanical brake is then used to hold the load under complete control until the slips are set. 5-2N@Y waviomat onwent varco 54 ‘SCR POWER CONVERTER (Cont'd) By keeping the load under control with the BAYLOR Eddy Current Brake Control System, the driller is able to go into the hole with optimum safe speed and with minimum wear of the mechanical friction brake system on the drawworks.N@Y wariomat onwent varco SECTION 6 MAINTENANCE 6.4 BRAKE AND CONTROL, The Control System should not require any maintenance other than a periodic inspection for loose terminals or broken or damaged wires. Any inspection or preventive maintenance other than operational checks should be performed with power removed. For the BAYLOR Brake Control System, one set of resistance measurements (Table 6.1), and the following operational voltage checks should be made and recorded at time of installation: Power Input Phase A to B 22240 Vac) Power Input Phase A to C = 2%" (240 Vac) Power Input Phase B to C = ____ (240 Vac) Terminal TB10-1 to TB10-2 = 1°71 (120 Vac) With the Brake Power Selector Switc! Control at "FULL ON", the DC voltage to the Brake should be recorded: each of the two positions and the Driller's “DRILL” Positions: Vde “TRIP” Positions: Vde Max Driller’s Control input (FTB1-4 to FTB1-1): Vde 6-1N@Y warioma. ouwett varco 6.1 BRAKE AND CONTROL (Cont'd) Because the output DC voltage is a function of the AC input voltage, some variance will be noted for AC voltages other than 240 Vac. The above listed measurements should be made on a periodic basis and at any time abnormal Brake operation is suspected. Any difference in the measurements will be clues to use in the trouble shooting of the Control System. 6-2N@Y wariowat onweLt vARco BRAKE MODEL NUMBER: BRAKE SERIAL NUMBER: START DATE: NOTE: Measurements should be made at the brake junction box with the coil leads disconnected from the terminals. DATE COIL RESISTANCE RESISTANCE TO GRD. COMMENTS: (OHMS) (MEG. OHM) Fi-F2 | F3-F4] Fo-F6 | F7-F8 |F1 |F4 [FS |FS —___— TABLE 6.1 6-3N@Y mariowat onwe1t vaRco SECTION 7 PARTS AND SERVICE 7A GENERAL ‘The recommended spare parts and supplies for the Control System are provided in the following tables. 7.2. PARTS AND SERVICE Parts and service are available from the factory: NATIONAL OILWELL VARCO 500 Industrial Blvd. Sugar Land, Texas 77478-2898 Telephone: (281) 240-6111 Fax: (281) 274-0426 Factory Sales and Services personnel may also be directly contacted at the following e-mail address: Baylorsales-service@nov.com Factory Engineering personnel may also be directly contacted at the following e-mail address: Baylorengr@nov.com For a list of worldwide National Oilwell Varco locations and Service Centers go to www.nov.com and click “Contact Us” TA(N@¥ wariowa. onwett varco 7.3 RECOMMENDED SPARE PARTS 7.3.1 SCR Assembly - 25 KW, Model 55850-2 QUANTITY PART NUMBER DESCRIPTION 7 55854 Firing Circuit P.C. Board 1 55856-2 Auxiliary, P.C. Board 3 6500-13-0003 ‘Semi Pak SCR Assembly 3 55088 DviDt Network Assembly i) 6425-05-0152 Relay, 2PDT, 1.0K ohm Coil 8 6525-25-0208 Fuse, 25 Amp 2 6525-25-0211 Fuse, 1/2 Amp (Firing Ckt. P.C.B.) 2 6525-25-0205 Fuse, 750ma Amp (Auxiliary P.C.B.) 1 6425-06-0004 Zener Barrier (CH) 10 6375-10-0058 Lamp, Pilot Light 7.3.2. Miscellaneous [ QUANTITY PART NUMBER DESCRIPTION 1 6575-95-0011 Drilier’s Control Sensor 1 6525-75-1052 Operator, 2 Position 7 6525-51-0002 Contact, Normally Close 72N@Y wariona. omwett varco SECTION 8 DRAWINGS Description Outline and Mounting, 2025 Brake Control System Assembly, 2025A Brake Control .....s.csssscessenenee Bill of Material. Assembly, Panel, Inside Back SCR Mounting....... Bill of Material Assembly, Heatsink 2025. Bill of Material Assembly, Panel, Right Side 2026A......... Bill of Material Wiring Diagram Cable Diagram, Brake Control Interconnection System Diagram, 20265A........ ‘Schematic, PCB SCR Firing 2025 ‘Schematic, PCB Firing Auxiliary Outline & Mounting, 55858 Driller's Control Drawing Number .. 56280 5850-2 .«.BIM 55850-2 56018 B/M 56018 56022 B/M 56022 56024 BIM 56024 ns 56043 55846 56353 56041 55856-2 56165N@Y wavioma. omwett vaRco DRAWINGS (Cont'd) Description Drawing Number Assembly, Model 55858 Driller’s Control....... 55858 Bill of Material B/M 55858 Wiring Diagram, Driller’s Control... 55859 Outline & Mounting, Power Selector Switch...... 56483 Assembly, Rig Floor Selector Switch.. 55860 B/M 55860 Bill of Material 8-20 ve on fs uy i ca oei) 3m (79) TH (4) AES fe 8 eal 4 om 5 Oe erin S J ia 7191] be esteaeaenate| © @ & Lect —-] 5.00[127) 6.25(1 59) > #49] ——$§$4 ss BI | sate} oan —-| oxs3) —_—_—.| ae 7 aPPRO. WEGHE: 53 Us [2.5 KG ALL OMINSIOS JRE WINCHES UNLESS OTERMISE SPEDRED Pl OD aorenro) , 1,200.2 MORTAGRS BAYLOR COMPANY orsrasutton: exc Hous oer ter tase site oF warenene Pace WO: el as oF 0720/96 cxass cove sour: 1 wweeasszeze0 ‘ SERSS GB0E. "S00 Snake coneonens om ; Y cme, Masses edlep ssose ovcones 4 REV: A ASSY, OWE SEL SHITOH/ORELE eT RPPUL, vein. swum awe. LAL, !0l08(46 MODEL RELEASE 4. 5COG6e co Nos EcMA ‘i [sise Ente ce Inst" eco: 10/20/96 8 ons oO rren ory pen vex —_—EP_verauur OFF REFERENCE eFrEcTIV oasoLeTE PART MUNBER oascazerzoH Saw TRS" SEhvmar GAGA on sc OF UANNITY Set seq DEStonNTOR "DATE DATE sesso JUNCTION BOX, HD PRE SEL SY 4 © «£4,000 2.00 AM ono 0000/00 99/99/98 deaee Jeera eteetCkaten ome see 8 «Lion dceop eT H tM tlop BO Govooven 99/8973 Sea sss SPERAON SEE; KNOD 2POGNTNAN «<3 Llaoo 4000 EXP Mw tape OO sh 80700700 39/99/08 Sere ese PEAR eee ceo emoeL | 0 troop dono ERP YN i000 OO Swi 0veos00 93/39/99 SeEs-52 0002 CONT em gros Zon D000 i = $s hlaoo dlaoo EF yw trope 00 Ta So7eoree 99/38788 Seasi Sanesiate, oRteL/TREP + Liben too eR ww iieoo 8 soscoreo 99/29/38 H8So6-0000 bitsy sario 9/0 55 ¢ $ beoo coo eke males 8 coseoseo 95/39/98 Bokegcones anes eacaa x 472 88 & 3 Noeo Eooe EX fot Sloe 88 S0vc0/00 99729793 itvesence Eeeenence socueinnexon Se os | M8la eos ear ww Sto f Gogm Greaves 99799793 WaSeeeaee) a 1.1, 200,2.NDATABAS NATIONAL OFLWELL LP (SUGAR TAKD) DISTRIBUTION: BELINDA ~ Tau, OCT a1, 2004 BILL OF MATERIAL PAGE No: tera ‘AS OF 10/21/04 CLASS cope GROUP: 1 UNCLASSIFIED GLASS CODE: 1000 BRAKE: COMPONETS ow 5850-2 OPCODE: 1 REV: F —ASSY, BRAKE CONT MDL 2025A-2 apn. 4 few Zifoer/o4_, FINAL APPvL. iF HoDEL: 20254-2 WELEASE of Beo NO: ECNHE. Wsjoe Date OF LAST Eco: 10/21/04 k pays © rem ory Pek YIELD EP DEFAULT OFF REFERENCE EFFECTIV PART NUMBER DESCRIETION P RY NO. ASOENBLY FACTR UM SC QF QUANTITY SET SEQ DESIGNATOR DATE 55052 ASSY, BOX ORK CONT 2025WINDOY 0B 1 «1-000 1.000 BAM YN 1.000 9 0 00/00/00 6375-29-0009 trent, Prior RED’ 35vDc {8 2 1000 11000 EAP YN 1.000 9 80700700, 6375 29-0010 LIGHT, Plot Gen Seve 18 3 11000 11000 EAP YN 1.000 9 o 00/00/00 Soo2s PR, LEXAN COVER SCR D-CONTR 1 @ Leno tooo EAH YN 1.000 9 09/00/00 36029 COVER, LEXAN SCR BRK CONTROL, 1 $ 11000 1000 EAP YN 11000 0 oO 09/00/00 6023 GASKET, LEXAN COVER SCR/BRK & Ilen0 1000 EAP YN 1000 «8 80700700 56499 PANEL. MIMIC FIRING SCR BRK CN 19 7 1.000 1.000 EAB YN 1.000 9 0 2713/93 Soo22 AQOY, HEATSTNK. 2025 2D © & 1009 11000 AX YH 1.000 0 0700/00 56016 ASSY! PANEL INSIDE BACK Of 5 Llo00 11000 ERX yw 11000 0 60/00/00, 6175 -68-0168 SPACER, 1/420 X S/8L N/E HEX 1 10 2-000 1,000 BAP YN 2,000 0 0 80700700 $598 7-1 Bus BAR, 4/a-K 1X 21-1/26 1 111.000 1-000 EAM YN 1.000 0 O 80700700, 589873 BUS BAR, 1/8.K 1/2 Ke4i/i616 1 «12,-—=—«3.000 1.000 EAM YN 3.000 9 0 9700/00, Seo24 AS8Y, PANEL RIGHT SIDE dc 13 loo 1000 EX xX YN 1.000 9 9 1097/00/00 55080 ASEY) PANEL LEE SIDE 05 i4 11000 1000 EX xX YN 1.000 0 oO 05/00/00 asa NAMEPLATE, BAYLOR TR ts 1000 $2000 EAP YN 1.000 9 oO 0700/00 2009-10-0003 Pins, #032 4.3/8 316 68 i“ 46 21000 1000 EAP YN 2.000 9 00700700 10-04-3020 KAMESLATE, E1sC CONTROL ENCL 15 17 1.000 1-000 GAP YN 1000 0 0 0700/00 2411 06-0002 BIMS, “Bon32% 1/4 88 2” 16 41000 12000 EA YN 4.000 0 0 0700/00 5442-59 NAMETAG, POWER ON ta 19 te00 11000 EAN YX 31000 9 80700700, 54842-60 NAMETAG, ALARN/RESET {3 20 11000 L000 EAM YN 11000 0 80700700, 2805-06-0007 Rims, #i-0 41/4 PHILLAPS $8 1° aL 1000 EASY" 4.000 0 00/00/00 1420-25-0008, AUT, HEX 1/4=200NC PLD. {22 47/000 11000 EAP YK 47-000 9 80700700 3690-01-0007 Waser, PLAIN 1/1 ZINC PLID 1 23-50-00 1.000 EAP YN 50.000 0 0 80700790 1690-10-0008, TOEREAGHER EL SPR 1/4 CLT 1 «447-000 1.000 EA P YN 47.000 9 0 80700700 2412-05-05 Bins, Wi0e32'X"5/5,cAD PL. = 253-000 1,000 EAF YN 3.000 0 0 0700/00, 41690-01-0008 UnBHER, PLATIC #10. PLT 1 26 —13:000 1000 EA F YN 13.000 9 0 90/00/00 1690-11-0025 LOCKWASHER, INT 10 58 } a7 ~—:13:800 1000 EA F YN 13,000 9 o 0700/00, Yoao=25-0020 Soop einen 1/atz0 1-1/4 881 384.000 1.000 EAP YN 4.000 9 0700/00 1420-28-0007 NU, WEX"1/4-201NC. NYLON 1 29-8000 1.000 EA P YN o 6 0700/00 1690-08-0005 WASiiOR, NYLON 1/4 1 30. 4!000 1000 EAP YX 4.000 9 0 0700/00 3912-05-00 fines, io-32 x. 3/4 eur {32 10,000 1/000 EA Fs YX 10.000 9 12707792 ssa5o ASSY, PCB AUXILIARY BoaRD 1G 32 "1.00 1.000 EAX YW 1.000 00 00700700, 500~35-0033 Mterierer, SELENIUM SURGE SUPP 1 39 4.00 1.000 EAP xk 4.000 9 0 0700/00, 6690-35-0006 MIRE, RBN'34/CON W/CONN 36"LG 1 34—«1,000 1,000 BAP XN 11000 90 0700/00 82-51-0010 CONTACT, BLOCK NO 1-35-1000 1000 EAP YN 1,000 9 9704/94 @175-81-0050 CONNECTOR, PLUG 3PIN STR 1 38: t1eg0 1000 EAP YN 11000 9 8/04/94 f17s-st-00s1 CONNECTOR, PLUG 2PIN DUAL Rov 1 37 «41000 1.000 FA P YN 4.000 9 © sroaroa 6175-51-0052 CONNECTOR, PLUG 12PIN DUAL Row 1 382.000 1.000 EAP YN 2.000 9 5/0a7oa $175-72-0012 FIN CONNECTOR 24-18 AUG LOOSE 1 «:39—«25.000 1.000 EA P xX 5.000 0 0 5/04/98 s1997-2 TAG, INSTL & SET-UP PROCEDURE 0 401-000 1,000 EAM XN 1.000 0 0 3/26/99 s5aao DING, CABLING 20254 BC 6G 100 1.000 1000 FA Fs¥N 1.000 0 0 00/00/00 onsoLeTE DATE 99/99/99 39/99/99 99/99/99 99/39/99 99/99/99 99/99/99 99/99/99 99/99/95 99/99/99 99/99/99 99/99/99 39799799 99/99/99 99/99/39 99/99/99 99/99/99 99/99/98 99/99/99 99/99/99 99/99/99 99/99/93 99/99/99 39/99/99 99/99/95 99/99/95 99/99/98 99/99/98 99/99/95 99/99/95, 99/99/95 99/99/98 99/99/95 99/99/95 99/99/95 99/99/95 99/99/95 99/99/95 99/99/95 99/99/9¢ 99/99/95 99/99/95) ) LT,200,2.MDATABAS NATIONAL OTLWELL LP (SUGAR LAND) ‘ui, Ob 21, 2004 BILL OF MATERIAL PAGE NO: Bor2 ‘AS OF 10/21/04 CLASS Cong GROUP: 1 UNCLASSIFIED bao, bbe GLASS CODE: 1000 BRAKE COMPONENTS Den. Un. 8850-2 OPCODE: 1 REV: F —ASSY, BRAKE CONT MDL. 2029-2 nvev.. Lfiene auberof eran “Avove. open: 20251~7 WELRATE feo No: Bent W/sfea~ Date OF LABT Heo: 10/21/08 ‘ pays ony PER YIELD TP DEFAULT OFF REFERENCE FFFRCTIV onsoLETE PART. KUMDER Descer Prion ASSEMALY PACTR UM SC QF QUANTITY SET SEQ DESIGNATOR DATE DATE 36353 INTERCONN SYS DIAG, 2025A HC 0G 101 1,000 1.000 EA FS YW 1.000 0 Oo 0/00/00 99/99/99 56043 WIRING DIA, SCR BRK CONT 20254 0D 102 1.000 1.000 BA FS YN 1,000 OO (90/00/00 98/39/99 56280 0 & My BRAKE CONTROL ©. 103-1000 11000 EA FS YN 1.000 0 (00/00/00 99/99/99 155850-2 TEST PROCEDURE, 20254 0 101-1000 11000 GA RS YN 1000 00 (00/00/00 99/99/39 1477 TEST FORM, 20250 0 105~=—«ta0a 1000 EA FS YN 12000 0 0 (00/00/00 99/99/99AS OP 5/26/99, Halt soi OPcooE: © REV: E ASSY, PANEL SNSIDE BACK “Shy Il pa ; DATE OF LAST ECO: 5/26/99 ah[29 seoz9 PANEL, INSIDE BACK 43 4 4,000 1.000 EAM YN 1.000 0 o 00/00/00 99/99/99, 6526-91-o004 BLOCK, FUSE AP 600V, SOA W/SW 1 2 Llowo 100 EA PE ¥N © 3,000 0 60/00/00 99/99/99, 6825-25-0208 FUSE, 25 6.621CP 1 3 Alo0o 4000 EA PEN © #1000 00 iiv22/98 99/89/39, ssesa Hss¥, pes Sck FIRING BOARD 1D © ~—=«4.000 1.000 EAM YN 4,000 00 0700/00 93739738 6176-01-0197 ConnéeroR, PLUG 6 PIN 10-30RNG 1 S 71000 1000 EA Pc YN 71000 90/00/00 99/99/39 6475-01-0136 CONNECTOR, PLUG SPIN 20-30RNG. 1 & 1000 4000 EA Pe YN t.000 9 0700/00 98/38/33, 6475-01-0175 CONECTOR| RECPT 6PIN 5 7 tooo tlo00 ER Pe YN 11000 Do 190700700 $3/98/39, 57336 asst, Pes DRILL ASSIST INNIBIT OC 8 ~—=«1,000 1.000 EAM Yu 110009 5/26/99 93/38/39 6600-36-0077 EMR, CURR 54081 165°7 a 5 3000 t.000 EA PP YN © 310000 9700/00 33738799, 5725-12-0003 VARISTOR, MOV 2750 #027SHE2SO. 4 103.000 L100 EX PP YW 3.000 90 (90/00/00 99/38/98 6176 668-0178 SPACER, #6 LG X 3/1600 M/E 55 1 i: 1000 4/000 EAP YN = 0000 5/2678 98/38/99, 6425-06-0008 BARRIER, INTRINSIC SAFETY 765° 1 iz 41000 41009 ERP YN $1000 00 A/L77/98 99798798 2408-06-0003 BHMS, 6-32 X 3/8 85 4 £3 4[000 11000 EX Ps YN trove oo 5/26/93 99/99/99 az5-s9-o010 BUS, INTRINSIC SAFETY GRN 20S + £4 1/000 4.000 ERP YN t,000 00 b70878a 98799799 6476-31-0008 CHANNEL, RELAY MOUNT PLATED 0 {3 11000 dlooo Fr es YH 1/000 00 00/00/00 98/99/99 6476-25-0110 FANNING-STRIP, 10POS STR UH 2 i 41000 41000 EAP YN 1000 0 0700/00 9995/99 fe2s-01-0008 INSULATOR, STOP 1X1 600 = 17 71000 $000 ERP YN © 7.000 0 oo 109700/00 98/98/99, 2445-05-0008 BHMS, 1/4220 X 1/2 CAD 2b i 18 71000 4,000 BAF YN 7,000 9 Oo 99700700 99/99/99 4650-01-0007 ASHER, PLAIN 1/4 PL 4 13 141000 11000 EAB YN 11-000 0 0 99/00/03 93795/38 4690-10-0008 LOCKWASHER, HEL SPR 1/4 CADPL 1 20 tlo0e ek P YN 44,000 0 0 '90700/00 99/99/38 3615-05-0008 eKss, 474-20 X 1 CAD PL + 2 flo0e Ea P YN 4.000 00 0700/00 99/93/38 4420-25-o076 nur, Hex 1/4-20UNC 58 1 22 41000 $1000 ERP YN 4.000 9 99/00/00 99/99/98 1690-01-0033, WASHER, PLAIW M6 ss ° 23 8000 $1000 EA YN 4.000 00 3726/88 99/99/95, 2432-05-0008 BHMS, #20-2/K 1/2 CAD PL 1 271000 41000 EA F YW 7.000 9 Oo 00/00/00 95/99/38 £680-01-0006 WASHER, PLAIN #10 CAD PL 1 28 19,000 $1000 ER F YN 19.000 9 0 90/00/00 99/99/99 ies0-11-0005 TOCKWASHER, INT #10 cAD PL 1 264,900 41000 EA F YN 19,000 0 0 0/00/00 99793/38 2442-05-0005 BHMS, 20-52 % 5/8 CAD PL 1 25 121000 41000 BAF YN 12,000 09 0 00/00/00 93/99/98 2ait-05~0005, BEMS, "8-32 X 5/8 CAD PL i 2s "6.060 £000 EA YN 6.000 0 0 (90/00/00 93/99/99 1690-01-0008, WASHER, PLAT #e CAD PE 1 23.000 £1000 ER F YN 8.000 0 00/00/00 93/99/98 4680-11-0004 LOCKWASHER, INT #8 CAD PI a 508.000 41000 EA F YN 8,000 oo 00/00/00 99/99/39 s6001-3 RESTAGS, IDENTIFICATION O58 31 «3.000 11000 SF M YN 1.000 08 00/00/00 $9/99/39, se2i7 BUS BAR, COIL/FUSE INTERCONNEC 1A 321,000 1,000 EAM YN 1.000 0 0 90/00/00 93/39/99 36256 Reeve Resreton MOUNTING PEATE OR 23 1.000 1.000 BAK YN £1000 0 29/00/00 99/99/38 2Ast--08-0003 BHNS, 5-32 3/8 CAD PL 5 $4 21000 41000 EA F YN © 2.000 9 90/00/00 99/98/99, 6176-32-0008 LAMB, CHANNEL TERM BLOCK a 3521000 11000 EA P «YN 2,000 00 8/10/84 93/99/99Li,200,2,. }aBAS BAYLOR COMPANY JorstexeurioN: enct - THO, NOV" 1/1996 BILL OF MATERIAL PAGE Or AS oF 11707796 CLASS CODE GROUP: 1 UNCLASSIFTED EcASS Cove: 3000 SEECTRECAL COMPONENTS aw. i Lag Hilt on, 208 n/1[96 ssoza OpCoDe: 0 REV: D ASSY, HEATSINC 2025 aoove, atten Vilie | exuns, repre. LA bn ise movet: 2025,n,8, avense —L,seanace Seo No: echo ahitae DATE OF EAST ECO: 11/07/96 8 pays © rTM ory een wretD fe eravur OFF REFERENCE EFrecTIV oBsoLETE Pant wUNBER vesearprrow P nv “Wo ASSEMBLY FACTR UM Sc GF QUANTITY SEF SEQ DESIGNATOR DATE. DATE ssaee wearstnk, xacuzwius 20250 4 4,000 1.000 EAM YN 4.000 0 00/00/00 99/99/99 3300-19-0002 mooure, GUM. sem 90a ta00uRNS 3 3000 tio0 BA Be vw Seo 8 a scri-3.— gn/00700 99/99/99, Ss00-ie-0001 Drove, neveRsiie scobiisie 3 ton tooo ga Fw t.o00 8 o OM 12709799 99799798 Ssoe8 hast, pee ov/oT woo 2025 i 2 3000 tibbo ex WN 3000 © o ScRL-2 00700700 99799799 Sszse—2 Bus, ‘sen. contecrine t — Eooo too ex mm 2.000 88 $2fesr9s 93793798 2422-06-0005 Bung, nioce7 €5/8° 55 i 5 slope tone ex > tN as.000 88 arazrae 99/99/99 Uisoconooss ——wasiiény DEATW #10 Se : & t3lo00 too exe ow ivomn 88 Brazras 99/33/89 issocsi-o028 Tockwaswen, wr #19_ 56 : 3 ilove tle00 ERE YN 37,000 6 oo/oarao 39/99/38 1z0-28-0075 Nur, ex 16-220vP 8 {43 “Elon0 tooo exe eM t000 08 3728/98 99/99/89 dhia-oe-0008 Bun, siona2 «378 8S tif Eton tloe gap tw to00 8 12/0%799 99799799 Stzees Bus, ‘comizerzne i 12 Eaoo tooo exw oy fo00 88 8/22/34 99/39/89 sizseas-o0s2 SeBGrwany RING #6 X 10 NON-INt $2, -—«2,000 $1000 ENP YH 2,000 9 S/azrae 99799799 Sbaccscccoss WIRE ncAwe sis Cay ncstusoov 1 ikon long FP YW 1000 «9 B/2arae 95/99/99LI, 200,2-MOATABAS NATIONAL OTLWELL LP (SUGAR LAND) DISTRIBUTION: HOLLIE ~ WED, SEP" 34, 2005 BILL OF MATERIAL PAGE NO: TXB OF 9/24/05 CLASS CODE GROUP: 1 UNCLASSIFIED ad CLASS CODE: 3000 ELECTRICAL COMPONENTS: Dyn. cuK, OPCODE: 0 REV: E ASSY, PANEL RIGHT SIDE APPYL. if -of , PINAL 20250 RELEASE 2 BCNHE. sor DATE OF LAST ECO: 9/14/05 R pays IVEM gry PER YIELD EP DEFAULT OFF REFERENCE EFFECTIV OBSOLETE PART NUMEER DESCRIPTION tee ._ABBEMBLY FACTR ig SC OF QUANTITY SET SEQ DESIGNATOR DATE DATE 55983 PANEL, RIGHT SIDE 1B 1 1,0001.000 EAM YH 1.000 0 0 00/00/00 39/99/99 6176-20-c094 TERMINAL BLOCK, 1500 o 2 111000 1000 EA P YN 13,000 0 0 TBS~B7 00/00/00 99/99/99 6176-20- 0061 BLOCK, TERM 300V 50A STR UKGN 1 4 145000 1.000 EA PD YX 14,000 9 0 TBS-TB12_ 00/00/00 99/99/99 6176-21- 6033 COVER, END TERN BLOCK GRAY 0 S 41000 1.000 EA Py © 4.000 0 oo (00/00/00 39/99/99 6176-31 0008 CHANNEL, RELAY MOUNT PLATED 1. 6 30,000 1000 FT Fs YN 30.000 0 0 00/00/00 39/99/99 3175~77- 0007 SOCKET, “RELAY SPIN OCTAL SCREW 1 7 “zi000 1.000 BAP YN 2.000 0 oo (00/00/00 99/33/99, 6425-05-0152 RELAY, | 2PDT 1.0K OMS COIL 1 8 2.000 1.000 EAP YN 2.000 00 KA, K3 (00/00/00 99/99/99 2412-05-0003, BHINs, ‘10-32 X 3/8 CAD PL. a 3 10.000 1.000 EA Fs YX 10.000 0 oO 90/00/00 99/39/39 1690-11-0025, ‘LOCKWASHER, INT #10 55 a 106.000 1.000 EA YN 6.000 0 oo 00/00/00 99/99/99 2413-05-0003, BHMB, 8-32'x 3/0 PLT a 11 910001000 EAP YN 9.000 0 0 00/00/00 99/99/99 1690-01 0005, WASHER, PLATW #8 PLT a 32 90001-000 EAF YN 9.000 0 0 90/00/00 99/99/99 1690-10- 0004 LOCKWASHER, WEL SPR #8 PLT = 1 33 9.0001.000 EA Fs YN 9.000 00 90/00/00 99/99/99 ‘Sse001-2 TAGE, IDENTIFICATION OA 14 11000 17000 stm YN ©1000 0 oo 90/00/00 99/99/99 6276~32- 0002 CLAMP, CHANNEL UNIV #58 2 25 141000 1.000 EAP YN 14.000 0 0 7/3/93 99/99/99 6176-30- 0087 MARKER, STRIP 1-10 VERTICAL — 1 16 41000 1.000 FAP YN 4.000 00 00/00/00 99/38/99,NON-HAZAROOUS AREA HAZARDOUS AREA 1 bacfe we 70m 735 s30 100 |, 2 Hal ae eee aieeee re L a Tp omc ene F earrcer pice | 10 wm psa) HEHE) eo ee 1 (@rncm) — — 7 ‘ 5 NOIES: pew vee fen) cauoud Ne retocaly ea e Sie To wince tantid W'S or comeay SERRE RE TRIE one Shri kcicon cher Sauteceso0Us A964 nem ni tom?y i ete Br pi &, ! tae y Se | “Ub a a EE i au i i i i iti iif 3 , fs § \ | i : ‘ ‘ | HHI} Ea} ie i ce HL i 7 F 5 EU Ee Blow |i il ih a 8 Se Soi i He4" oyee/wYS4/31 — va 1 F sor aioe es 4 1 ste] 1 3/a (ais WS Me NES \ y SL yaa : Z >| 2 fhe) 2 a/c) | ad = : eal ee bas ' aves ae | svten Z 7 | i ve‘ey \ J J bi, 200.2.MDATABAS BAYLOR COMPANY DISTRIBUTION: ENGL - wed, JAN"29, 2003 BILL OF MATERIAL PAGE Wo: tae ‘AS OF 1729/03 CLASS CODE GROUP: 1 UNCLASSIFIED CLASS CODE: 1000 BRAKE COMPONENTS Dan wa bby "8 tos CHK. OM fooet SE La gomsrc feo tio eex¥e TESS BAPE OF EAST ECO: 1/24/09 R pays © ITEM gry PER YIELD EP DEFAULT OFF REFERENCE EFFECTIV OBSOLETE PART NUMBER DESCRIPTION P RV NO. ASSEMBLY FACTR UM Sc QP QUANTITY SET SEQ DESIGNATOR DATE DATE $6003 ‘CAM, 2025 DRILLERS CONTROL = 4 4 1,000 1.000 AP YN 1,000 9D 0700/00 99/99/99, 56002 PLATE, SENSOR NTC BRAKE MON 2 41000 4000 EAP YN 1.000 0 0 00/00/00 99/99/39 55008 HOUSING, SENSOR ERAKE MON a 3 t1000 11000 EAP YN 1.000 00 100700700 99/93/99 4705-53000 HOUSING, UPPER H-2-X VALVE 1 4 tle00 4.000 EXP YN 1.000 9 0 0700/00 93/39/99 10-03-5051 SHAFT, CAM is § 11000 4.000 GAP YN © 1.000 00 0700/00 $3739/99, 1705~$3~0002 ARBOR, Hi-2-K VALVE 4 6 11000 1.000 Ea PD YN 1.000 00 90/00/00 99/98/39 010-084-8026 SPRING, HANDLE RETURN a 3 tle00 11000 EAP YN 1.000 0 0 (00700/00 99/99/99 3705-53—0007 SLEEVE, H-2-X VALVE + % 41000 S000 EAP YN 1.000 90 6700/00 99/98/33, 4705-53-0003 MUT, CAP H-2-X VALVE 1 8 11000 $000 EAP YN 1.000 00 0700/00 99/99/99, 4435—5s—0021 KNOB, RED 3/0-24 BRASS INSERT + 10 tiene tleoa EAP YN © 1.000 0 0 0709/00 99/39/99, $705-53-0008 HANDLE, SHAFT H-2-X VALVE 4 ii tle t1000-EA P YN = 1.000 00 00709/00 99/99/99 3708-53—0006 HANDLE, YOKE H-2-_ VALVE 4 42 11000 41000 EAP YN 1,000 0 O 20700/00 99/99/99 3617-06—0005 SKSS, $/16-18 X 5/8 58 CUP 45 11000 1,000 EAP YN 1.000 0 oo (90/00/00 39/33/99 2409-06-0005 BHMS, 6-32 X 578 8S. 1 fe 41000 1.000 EA YN © 4,000 90 00/00/00 99/39/93 1420-25—0040 NUT, HEX 1/¢—2601F ss 1 is £1000 11000 EAP YN 2,000 9 00/00/00 99/99/98 41420-20077 NUT, HEX 5/26-16UNC 55 1 ie 2,000 4,000 EAP YN 2,000 00 00700700 39/93/99 40-04-5005 MAMETAG, DRILLERS CONTROL i247 tie00 4/000 EAP YN © 1,000 0 0 0700/00 99/39/93 6176-01-00 BLOCK, TERM 3P0S 15 300V 1 is 11000 41000 EA PE YN 1.000 0 (00700/00 99/33/99 6475-890062 TERMINAL, FORK 22-16 X #4 RED 1 49 61000 1,000 EAF yw © 6.000 0 (0700/00 93/39/93 2403-06-00 BHMS, 632 X 1/1 88 1 20 41000 1.000 EA F YN © 4.000 0 oO 100700700 98/93/33 2003-06—0008 FHMS, 6-32 K 1/2 5S 1 2t 41000 1000 EA F YN 4.000 0 0 0700/00 98/93/99 6575-95-01 SENSOR, VIBROWECS INA~061 ip 22 1,000 4,000 EAP YN 1,000 0 0 (00/00/00 99/99/99 3555-20-06 O-RING, 42470 X 1038 1 23 t1a00 1.000 EAP YN 1.000 00 90/00/00 98/33/39 5600s COVER, ‘seNSOR HOUSING 1 24 £1000 1000 EAP oN © 1.000 90 90/00/00 99/95/33 10-03-8016 PIN, STOP SPRING i225 11000 41000 EAP YN ©0000 18/04/94 99/93/99 4005-11 -0028 SEALANT, SILICONE PERNATEX 1 26 ‘x00 41000 Ea PWN 400 0 00/00/00 99/93/39 seis. ©-8'M, BRILLERS CONTROL 0 19011000 41000 ER Fs YN 4.000 0 (90/00/00 99/98/39 REFERENCE REFERENCE DOCUMENTATION 0B 993 boo t1o00 EA YN 000 «OO WIRING 00/00/00 38/99/99 DIAGRAM 4556590 Test PROCEDURE TPSS856 TEST FORM aaasaaex 34! COMPANY evs TOE USA ‘WIRING DIAGRAM, ated frei] MODEL 2025 DRILLERS CONTROL eo _ 35859 aoe ie Fut! B a 52142] Pane 35858 ey Re (0) ———_{ ‘yaw (sew) wane (com), ——] FROM SENSOR