POWER FACTOR CORRECTOR

REVISION HISTORY
Rev. Description ERO/ECN #
A Initial Release - 041400
B Change Figure 10-23 to make callouts larger. C23347
C Correct Figure callouts in text and Figure Numbers in Figure Titles. Add Footer to C24123
Revision History Page.
D Make text and formatting corrections. C24394
E Remove references to Ansaldo Ross Hill on pages 10-1, 10-14, 10-20, 10-21, and 10- C24670
22.
F Update figures. C25849
G Add photo numbers. C26042
H Add model number to footer. C28454
J Convert to Word 97 format. C28671
K Minor formatting changes. C28926
L Add Table of Contents codes. Correct Level 5 and Level 6 styles and errors. C29124
M Revisions per Dave Carnahan; content corrections, including Figure 10-15. C29775
N Update Revision History page. C30031

REVISION HISTORY PAGE SCR DRIVE SYSTEM TECHNICAL MANUAL

20605-85 Rev. N 24 HOUR SERVICE (713) 467-2523
 10-1

POWER FACTOR CORRECTOR

3. When power is supplied by a
INTRODUCTION commercial utility, an improved load
power will allow the customer to
Great increases in the number of SCR
avoid low PF penalties which may be
controlled motors and the need for reducing
imposed by the utility company.
operating cost of these motors have
created a demand for the Power Factor
4. Sometimes commercial power lines
Corrector.
experience large variations in
voltage as low PF loads are applied.
What is Power Factor (PF)? A characteristic
A Power Factor Corrector (PFC) can
inherent to all electric motors requires the
eliminate this problem.
motor to return a portion of the input power
back to the source. When a motor is driven
What type of equipment is required for
by an SCR drive, PF is a result of the delay
correcting the PF?
technique used by the SCR to drive a DC
motor at a variable speed. In this case, the
Two types of equipment are used for PFC:
input PF of the SCR drive is about equal to
the percentage of full speed of the DC
1. Capacitor banks.
motor.
2. Synchronous motors.
Another way to express PF is with a ratio.
The TOTAL POWER being supplied to a
Each method will work, but each has
motor is called APPARENT POWER. The
several drawbacks and limitations.
AMOUNT OF POWER REQUIRED TO
DRIVE THE MOTOR'S LOAD is called
The capacitor bank has been the most
TRUE POWER. PF is the ratio of true
practical for existing applications where the
power to apparent power.
PF is relatively constant. Although the
synchronous motor will correct a large
True Power (KW)
PF = variation in PF, it has slow response, high
Apparent Power (KVA) maintenance cost and has a greater initial
cost.
If TRUE POWER equals APPARENT
POWER, PF is "one", the ideal situation. The PFC is a solid state system that
provides continuous PF correction and
Why improve the PF? faster response than a synchronous motor
system. Plus, the PFC is combined with a
1. Operating without correcting the PF harmonic suppression system designed to
may result in overloaded cables, improve voltage quality and current
transformers, sluggish motor waveforms on the main AC power bus.
operation, and increased power
costs.

2. When the electrical power is

supplied by engine/generator sets,
an improved PF may allow an engine
to be taken off-line.

SCR DRIVE SYSTEM TECHNICAL MANUAL POWER FACTOR CORRECTOR - MODEL 1600
24 HOUR SERVICE (713) 467-2523 20605-85 Rev. N
10-2

BASIC PFC ELECTRICAL

HIGH POWER
SYSTEM DESCRIPTION
ANODE
The PFC maintains a near unity power
factor by using the capacitors in the input
tuned filters or traps. When the inductive
load is light, the capacitors in the tuned
filters create a substantial leading power
factor. If this is the case, the control module CATHODE
turns on SCRs to allow current flow from
the SCR bridge into a large inductive load. LOW POWER
It is possible to determine the amount of 20602-10 Rev. A

KVAR correction by interpreting meter
readings. In order to become familiar with
overall system operation, it is necessary to
be acquainted with simple rectifier and
(SCR) thyristor operation.
THE RECTIFIER (DIODE)
The rectifier (diode) functions to change AC
electric current to DC electric current. It only
allows current to flow in one direction. It is
represented by the symbol, as shown in
Figure 10-1, and is available for both low
and high power applications. Examples of
several diodes are shown in Figure 10-2.
Figure 10-2. Low and High Power Diodes
RECTIFIER OPERATION WITH A
BATTERY
Electric current flow is permitted when the
diode is connected so that the arrow
symbol points from positive to negative of
the electrical source. Figure 10-3 illustrates
this by allowing DC current to flow from the
battery to turn on the lamp.
POWER FLOW

BATTERY LAMP ON

20602-11 Rev. A

Figure 10-3. Diode Allowing Current

ANODE CATHODE Flow in Electrical Circuit

20602-09 Rev. A

Figure 10-1. Diode Symbol

POWER FACTOR CORRECTOR - MODEL 1600 SCR DRIVE SYSTEM TECHNICAL MANUAL
20605-85 Rev. N 24 HOUR SERVICE (713) 467-2523
 10-3

If the diode is reversed, no battery current
can flow through the lamp (refer to Figure
10-4). This shows the diode's electrical
characteristic: it allows current flow in one
direction and blocks it in the other direction.
NO POWER FLOW
+ AC to DC is very inefficient and develops a
BATTERY LAMP OFF
20602-12 Rev. A
Figure 10-4. Diode Blocking Current
Flow in Electrical Circuit
The simple battery-diode circuits discussed
illustrate diode characteristics, but do not
demonstrate one of the diode's most useful
functions, that of rectification. Rectification
can be shown by placing a diode in series
with a lamp plugged into a normal 110 VAC
wall outlet. The diode allows current to pass
only when AC voltage is positive. Figure 10-
5 illustrates the conversion of AC to DC
power.
The utilization of a single diode to convert
poor quality DC called pulsating DC. The
DC efficiency and quality can be
substantially improved by a diode bridge
rectifier.
Figure 10-6 illustrates the bridge rectifier. It
is easy to see the reason for improvement:
all three AC input voltage pulses can
produce an output. On the other hand, a
single diode has no output when the input
AC is negative.

CURRENT FLOW DIODE RECTIFIER PULSATING DC

1 2 3
+ 1 3

+ + 110 VAC
LAMP
WALL
PLUG

NO CURRENT FLOW

20602-13 Rev. A

Figure 10-5. Half Wave Diode Rectifier

110 VAC DIODES +

1 2 3 1 2 3

+ +
LAMP

AC INPUT DC OUTPUT

20602-21 Rev. A

Figure 10-6. Full Wave Diode Rectifier

SCR DRIVE SYSTEM TECHNICAL MANUAL POWER FACTOR CORRECTOR - MODEL 1600
24 HOUR SERVICE (713) 467-2523 20605-85 Rev. N
10-4

RECTIFIER OPERATION WITH A The operating principle of an SCR can be

BATTERY (CONCLUDED) best understood by thinking of the electric
current as a fluid. The SCR can then be
A diode rectifier can also be made using a
represented as equivalent to a check valve
gate or control wire. Figure 10-7 shows the
followed by a needle valve (see Figure 10-
electrical symbol and physical appearance
8).
of this component, a SILICON
CONTROLLED RECTIFIER (SCR). The
SCR has been used for AC to DC
conversion in a wide range of products
since the 1950s.

ANODE GATE

CATHODE

SCR SYMBOL

20602-23 Rev. A
ANODE
Figure 10-8. Mechanical Analogy of SCR
SCR OPERATION WITH 110 VAC

The SCR (Thyristor) is controlled by the

GATE
CATHODE gate or control wire. If a positive voltage is
SILICON CONTROLLED RECTIFIER connected to the SCR gate (see Figure 10-
(SCR)
9) by switch S1, the SCR will act as a
20602-22 Rev. A normal rectifier and pass the positive
Figure 10-7. SCR Electrical Symbol and portions of the AC input cycles.
Appearance
A control signal is applied to the SCR gate If switch S1 is open, disconnecting the
terminal to adjust current from zero to full battery, the SCR does not allow current
flow. (power) to pass in either direction, No
power can reach the lamp (load).
FIRING PULSE
S1
THYRISTOR +
SILICON CONTROLLED RECTIFIER OR SCR BATTERY

+ +
LAMP
S 1 CLOSED
WALL PLUG (Lamp On)

S 1 OPEN
INPUT VOLTS (Lamp Off)
20602-24 Rev. A

Figure 10-9. SCR Operating as a Diode Rectifier

POWER FACTOR CORRECTOR - MODEL 1600 SCR DRIVE SYSTEM TECHNICAL MANUAL
20605-85 Rev. N 24 HOUR SERVICE (713) 467-2523
 10-5

By controlling the opening and closing of
switch S1, the amount of power reaching
the lamp can be smoothly and continuously
controlled. Thus, the SCR, or thyristor, is a
device which allows us to smoothly vary the
amount of electrical power to the load. To
obtain a better understanding of how SCRs
can vary the amount of power to the load,
we will again use the SCR circuit where the
gate is connected to a positive voltage by
switch S1.
In Figure 10-10, if firing switch S1 is closed
at time 1 on Waveform A, near the
beginning of each positive-going half cycle,
the output is similar to the output with a
single diode in the circuit.
60 HZ
+ +
AC INPUT 0 injected into the gate. Hence, in contrast to
TO SCR
NEAR
MAXIMUM A current, called the FIRING PULSE.
OUTPUT
If the firing switch closes at time 2 on
waveform B, about half of the input voltage
will be delivered to the output. If the SCR is
not turned on until time 3 on Waveform C,
only a small portion of the input voltage
passes to the output.
Finally, if the SCR never turns on (Figure
10-10 Waveform D), zero power is
delivered to the lamp. Therefore, the lamp
is off.
In summary, the SCR has a characteristic
similar to that of a diode. That is, current
can flow through the device in only one
direction. The SCR blocks the current flow
in the opposite direction and can support a
substantial voltage. The most significant
characteristic of an SCR, differing it from a
diode, is that the SCR forward current is
initiated by a relatively small current
a diode rectifier, the SCR can block the
current flow in both directions. However, the
SCR conducts current in the forward
direction when turned on by the proper gate

PFC SPECIFICATIONS AND

FEATURES
APPROX.
ONE HALF B
OUTPUT DESCRIPTION

The PFC consists of harmonic filter traps

NEAR
MINIMUM C tuned to the fifth and seventh harmonic
OUTPUT frequencies. These traps act as a passive
PFC. PF control is obtained using a
standard SCR bridge with an inductor for a
ZERO load.
OUTPUT D
LAMP OFF
SPECIFICATIONS
20602-25 Rev. A

Figure 10-10. SCR Being Turned On for
Various Power Outputs
The drive system meets IEEE-45 standards
for electrical switchgear. Offshore system
certification can be obtained from American
Bureau of Shipping (ABS), United States
Coast Guard (USCG), and Det Norske
Veritas.

SCR DRIVE SYSTEM TECHNICAL MANUAL POWER FACTOR CORRECTOR - MODEL 1600
24 HOUR SERVICE (713) 467-2523 20605-85 Rev. N
10-6

SPECIFICATIONS (CONCLUDED) MECHANICAL SPECIFICATIONS

The following is a list of typical power factor Temperature: -22°F to 140°F.

specifications. The specifications for your (-30°C to 60°C).
specific application may vary.
Weight: ≈4,000 pounds.
ELECTRICAL SPECIFICATIONS Cooling Forced Air: 4,500 CFM.

Electrical specifications are given Cubicle

for circuit operation at an ambient Construction: Fabricated from 14-
temperature of 40°C. gauge cold rolled steel
with welded
AC Input: 600 VAC construction and
60 Hz expanded metal
3 Phase ventilation openings.

Capacity: 1,600 KVAR

PFC SYSTEM BLOCK
Current Rating: SCR Bridge Output is DIAGRAM
(Continuous Duty) usually zero to 2,000
ADC. However, this
1. The input circuit breaker (refer to
may vary, depending
Figure 10-11) provides isolation and
on unit model number
protection for the PFC. This breaker
and amount of PF
can be tripped by an emergency
required.
shutdown switch or by PFC circuit
protection devices.

COOLING SYSTEM
INPUT
BREAKER

3Ø INPUT SCR
TRAPS BRIDGE INDUCTIVE
AC
5th & 7th AC-DC LOAD
BUS
HARMONIC RECTIFIER

1 2 3 4
PFC
CONTROL
MODULE

6
20602-26 Rev. A

Figure 10-11. PFC System Block Diagram

POWER FACTOR CORRECTOR - MODEL 1600 SCR DRIVE SYSTEM TECHNICAL MANUAL
20605-85 Rev. N 24 HOUR SERVICE (713) 467-2523
 10-7

2. Filters consisting of resonant traps

provide power filtering to maintain
sinusoidal voltage and current
waveforms on the bus. Capacitors in
these filters provide power factor
correction equal to the sum of the
KVAR rating of their capacitors.
3. A standard three-phase SCR bridge.
4. The inductive load for the SCR
bridge provides a means to allow the
PFC to offset the effects of large
capacitors in the harmonic traps.
5. The input filter and SCR cubicles are
air-cooled by blowers mounted in the
cubicles.
6. The electronic control module
provides the electronic circuitry
required to monitor and maintain
automatic PFC up to the rating of the
PFC.
OPERATIONAL DESCRIPTION
OF THE SCR BRIDGE
The PFC rectifier unit (refer to Figure 10-
12) incorporates six SCRs (thyristors)
connected in a full-wave three-phase bridge
rectifier configuration.
To understand rectifier unit operation,
consider the operation of this circuit if all six
devices were simple diodes. Each diode
would conduct current when it became
forward-biased by the AC input voltage.
Since the circuit input is a set of three-
phase sine waves, for one-third of the time
(electrically 120°) the A phase voltage is the
most positive of the three input phases. B
phase then becomes the most positive for
120°, then the C phase for 120°.

A B C A
PHASE PHASE PHASE PHASE
VOLTAGE VOLTAGE VOLTAGE VOLTAGE

(+)
120 o
AC INPUT POWER A+ B+ C+
A PHASE C PHASE
A PHASE MOST MOST
DC POSITIVE POSITIVE
B PHASE OUTPUT
C PHASE POWER
C PHASE A PHASE B PHASE
MOST MOST MOST
A- B- C- NEGATIVE NEGATIVE NEGATIVE

THREE PHASE AC INPUT VOLTAGES

20602-27 Rev. A

Figure 10-12. SCR Rectifier Bridge and Phase Waveforms

SCR DRIVE SYSTEM TECHNICAL MANUAL POWER FACTOR CORRECTOR - MODEL 1600
24 HOUR SERVICE (713) 467-2523 20605-85 Rev. N
10-8
OPERATIONAL DESCRIPTION OF THE
SCR BRIDGE (CONCLUDED)
The entire cycle then repeats. If the devices
were diodes, the A phase would conduct for
120° through the A+ device to the output
terminal. In similar fashion, B phase would
then conduct through B+, and C phase
would conduct through C+.
Halfway through each positive half-cycle,
the most positive portion is reached. During
this time, the A+ device would conduct with
the B- device because the B- cathode is the
most negative, until this point is reached. At
this time, C phase begins a 120° interval
where it is the most negative. This is
followed by an interval of 120° where A
phase is the most negative. Then, B phase
again will be more negative for 120°,
repeating the cycle. The positive portion of
the three phases go through the 120°
conduction period in a slightly different
sequence. The conduction order is
illustrated by Table 10-1. This listing of the
conduction order shows that the three-
phase bridge requires conduction from a
positive and negative device at the same
time. Failure to keep either device turned
on results in the bridge turning off. At each
crossover point, one diode turns off as
another device turns on (COMMUTATION).
Table 10-1. Diodes Conduction Time
with Input of Continuous DC Current
DIODES ELECTRICAL
CONDUCTING DEGREES
A+ and B-
60°
A+ and C- 60°
B+ and C- 60°
B+ and A- 60°
C+ and A- 60°
C+ and B- 60°
TOTAL 360°
POWER FACTOR CORRECTOR - MODEL 1600
20605-85 Rev. N 24 HOUR SERVICE
In Table 10-1, the DC output of the full-
wave three-phase bridge rectifier is the
resulting difference between the most
positive and the most negative AC voltages
applied to the input terminals.
From study of Figure 10-12 and Table 10-1
it is possible to derive a five point summary
of the primary characteristics of the three-
phase bridge.
1. The DC Output Voltage follows the
variation in the AC voltage
amplitude. This DC Output Voltage
ripple occurs at six times the input
power frequency.
2. Each device conducts for 120°
electrical.
3. At any time, two devices are
conducting, one on the positive side,
and one on the negative side.
4. Every 60° electrical, conduction
transfers from one device to another
device within the bridge.
5. The output current can flow in only
one direction because the bridge is
made up of devices which only
permit current flow in one direction.
If the diodes in the three-phase bridge were
replaced by thyristors (SCRs), the DC
output of the bridge would be the same as
diodes, providing the firing signals occur at
the earliest time the SCR could start
conduction.
PFC MODULE
The PFC Module controls the three-phase
thyristor (SCR) bridge. The primary
functions provided by the module for
rectifier control are:
SCR DRIVE SYSTEM TECHNICAL MANUAL
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1. Create a set of six separate firing
signals for the power thyristors.
2. Synchronize the firing pulses to the
AC input frequency.
3. Sequence the firing signals so the
proper order is maintained.
4. Shift the gate firing signals to the
proper angle so the resulting
inductive current is sufficient to
cancel all excess leading KVARs
produced by the PFC capacitors.
5. Develops the signal required to drive
the PFC metering.
THEORY OF POWER FACTOR
CORRECTION
If the PFC is not connected by its circuit
breaker to the three-phase line (refer to
Figure 10-13), the overall load of the Power
Control House causes a lagging power
factor while the motors are driven. The
amount of inductive KVARs from this
overall load can vary depending upon the
number of driven motors, the motor speeds,
the motor loads, etc.
If these inductive KVARs were constant, a
three-phase capacitor bank could be
chosen and connected to the line. This
would cause overall power factor to be near
unity when power remained at a constant
value. If there was a method to vary the
capacitances of the capacitors to
compensate for the variations of the
inductive KVARs of the rest of the load, the
overall power factor could be maintained at
a constant value near unity.
However, this is not practical. A solution is
to use the PFC. The PFC is equipped with
three phase capacitors that will cancel
some or all of the lagging KVAR created by
AC motors and SCR powered DC motors.
The total KVAR represented by the
capacitors of the PFC produce leading
SCR DRIVE SYSTEM TECHNICAL MANUAL
24 HOUR SERVICE
10-9
KVAR that will compensate or cancel the
lagging KVAR produced by the electrical
equipment. However, if the rig is not drilling,
the KVAR created will not be large enough
to equal all the KVAR of the capacitors in
the PFC, and excess leading KVAR will
remain.
To cancel the leading KVAR produced by
the capacitors in the PFC, the SCR bridge
of the PFC will be turned on to supply
current into a large load inductor. The
current flow into the inductor produces
lagging KVAR which cancels the excess
leading KVAR. This will enable the rig's
power utilization to operate at or near a
unity power factor up to the rating of the
PFC.
Installing larger mud pumps and adding
electrical loads increases the KVAR
demand on the drilling rig. Because of the
increased KVAR demand many drilling
companies will be forced to upgrade the
rig's power package in order to handle the
additional power requirements. If the rig's
engines have adequate horsepower but the
rig is required to run an additional generator
to handle the increased KVAR demand, the
most cost-effective solution to this problem
is the addition of a PFC. The PFC will
supply the additional KVAR up to the rating
of the PFC installed. This is the equivalent
to adding an additional generator without
the expenses associated with purchasing
and operating a prime mover.
A leading/lagging power factor always
causes the line currents to be higher than
they would be if the power factor were
unity. The higher line currents cause power
and energy losses in the system supplying
the currents. Utility companies will not
permit a drilling rig to be connected to their
power grid unless the rig is equipped with a
PFC to remove the harmonics and correct
the power factor.
POWER FACTOR CORRECTOR - MODEL 1600
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10-10
THEORY OF POWER FACTOR
CORRECTION (CONTINUED)
In addition, the PFC greatly improves
current and voltage waveforms supplied to
the Power Control House. Without the PFC,
there would be greater waveform distortion
due to SCR bridge operation in the
equipment, be it a DC or AC drive. This
distortion would not affect the performance
of any equipment driven by SCR
equipment. However, it can affect the
performances of other equipment
elsewhere.
Part of the PFC consists of a circuit
composed of inductors and capacitors
connected as series resonant traps for the
5th and 7th harmonic frequencies. The
expanded PFC one-line diagram shown in
Figure 10-14 expands Figure 10-13 to
better illustrate PFC functional concepts.
The traps shown inside the dotted PFC box
in Figure 10-14 serve two purposes:
Figure 10-13. PFC One Line Drawing
POWER FACTOR CORRECTOR - MODEL 1600
20605-85 Rev. N 24 HOUR SERVICE
1. Serving as harmonic suppression
filters to improve the quality of the
AC bus or distribution system
voltage and current waveforms.
2. These filter capacitors also serve as
the correcting KVARs in the PFC.
They provide a total value of KVAR
correction up to the rating of the
PFC.
The remaining part of the PFC is the SCR
bridge with its inductive load. It now
becomes an active device able to regulate
the power factor to unity within the limits of
its corrective capacity (refer to Figure 10-
15).
20602-28 Rev. A
SCR DRIVE SYSTEM TECHNICAL MANUAL
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 10-11

20602-29 Rev. A

Figure 10-14. Expanded PFC One Line Drawing

SCR DRIVE SYSTEM TECHNICAL MANUAL POWER FACTOR CORRECTOR - MODEL 1600
24 HOUR SERVICE (713) 467-2523 20605-85 Rev. N
10-12

THEORY OF POWER FACTOR

CORRECTION (CONCLUDED)

20602-30 Rev. D

Figure 10-15. Detailed One Line Expansion of Dotted PFC Box in Figure 10-14

POWER FACTOR CORRECTOR - MODEL 1600 SCR DRIVE SYSTEM TECHNICAL MANUAL
20605-85 Rev. N 24 HOUR SERVICE (713) 467-2523

The SCR bridge allows the equivalent of a
variable inductance. This varying value
equivalent is obtained by automatic
variation of the SCR firing times. The SCRs
turn on to compensate for capacitors in the
traps. If no load is on the AC bus, the full
amount of trap capacitor KVARs must be
canceled by an inductive current. In this
situation, the SCRs turn on to produce a
maximum current through the load inductor.
Therefore, producing maximum inductive
KVARs to offset the effects of the
capacitors to bring the power factor to unity.
As the motors start, this represents an
inductive load. The amount of inductive
KVARs required from the PFCs SCR bridge
and inductive load is reduced and the
amount of current supplied by the PFCs
SCR bridge is reduced. As the motor load
increases to the PFC rating, the SCRs in
the PFC bridge are not fired. This shuts off
the SCR current, bringing the PFC
inductance to zero. At this point, all
additional KVARs of reactive current must
be provided by the generators or hi-line
source.
AUTOMATIC PFC
The Electronic Control Module contains
circuitry necessary to regulate SCR bridge
current to produce the necessary inductive
VARs. This offsets excess capacitive VARs
whenever the motor load is below the PFC
rating. A thorough study of Figures 10-13
through 10-15 (including inputs and
outputs) will give an understanding of the
necessary requirements for PFC proper
operation. This will aid the development of
troubleshooting strategies.
KVAR DEMODULATION
System KVARs must be accurately
determined for the PFC to regulate the
power factor. The Electronic Control
Module utilizes a five channel KVAR
calculator, permitting total KVARs to be
SCR DRIVE SYSTEM TECHNICAL MANUAL
24 HOUR SERVICE
10-13
determined for more than one source. This
is accomplished in a multiplier circuit by
figuring the product of the A phase current
and a voltage (VCB) that leads A phase
current by 90 degrees.
Each source of A phase current is
monitored by a CT (refer to Figures 10-14
and 10-15). The current signal or signals
are summed at the input of inverting buffer
Z1. The gain of Z1 is adjusted to produce
an output of +2 VDC from KVAR calculator
Z2 when the system is supplying a leading
1,000 KVARs.
Consider the following example: (Refer to
the PFC Module Schematic 7424-00, Sheet
5 of 8.)
If the load is 600 KVARs and the PFC
Rating is 1,600 KVARs, there are 1,000
Excessive Capacitive KVARs (1,600 - 600).
The current is monitored with a 4,000:5
(800:1) CT. If the CT load is one Ω, there
will be 1,000 Amps of reactive current. This,
in turn, will output 1.25 Volts RMS to the
input of Z1.
The gain of Z1 is 0.32, thus giving an input
to X2 of Z2 of 0.40 Volts RMS (1.25 x 0.32).
VCB (the product of the A phase current
and a voltage) that leads A phase current
by 90 degrees) is 5.0 Volts RMS. It is input
into Y1 of Z2 (the KVAR calculator). Y1 is
multiplied by the Cosine, in this case, of
180° (-1.0), thus giving a value of -5.0 Volts
RMS.
In the PFC, the X1 and Y2 outputs are set
at a value of Zero. Z2's output (transfer
function) VOUT is equal to the product of the
value of Y1 minus Y2 and X1 minus X2.
Therefore the first quantity (Y1 minus Y2) is
(-5.0 Volts RMS minus Zero), the value of
Y1. The second quantity (X1 minus X2) is
(Zero minus 0.40 Volts RMS).
The output of Z2 is therefore (-5.0 Volts
RMS x -0.40 Volts RMS) +2.0 Volts. The
output of Z2 provides the signal for the PFC
KVAR Meter and the input to Z3.
POWER FACTOR CORRECTOR - MODEL 1600
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10-14
THE KVAR COMMAND
Z2's (the KVAR calculator) output is input to
the inverting input of Z3. Z3's negative
output is the KVAR Command. It has a
limited swing of from +0.5 VDC at Zero
KVARs to about –4.6 VDC for maximum
KVARs (maximum bridge current). This limit
can be reduced to almost zero by the
KVAR MIN/MAX (Current Limit)
potentiometer located on the front of the
PFC Cubicle.
The KVAR command is routed to Z8 where
it is compared to bridge current feedback at
a +2.66 VDC per 1,000 Amps DC. The
output of Z8 is the firing reference fed to all
cosine firing circuits in the PFC Control
Module.
VOLTAGE CLAMP
Bridge voltage feedback is developed by
three diodes: D16, D17, and D18. They
form a three-phase, half-wave rectifier for
voltage feedback. The voltage feedback
signal may have some filtering before being
applied to Z4 and Z5. Both of these op
amps invert the positive voltage feedback
signal. Z4 is a buffer used to drive the
voltmeter so the clamp volts setting can be
verified. Z5 has limits on its output, from
+0.5 VDC (no effect on PFC operation) to
about -5.0 VDC (to turn on the SCR bridge
to provide a measure of overvoltage
protection).
It is possible that the system can become
overcorrected. If this happens, it can cause
an unacceptable voltage rise. In this event,
the voltage clamp circuit overrides the
KVAR command phasing up the SCR
bridge, thus removing some of the
overcorrection from the system. The point
that Z5 will begin to affect the KVAR
command is adjustable. We suggest that
the clamp voltage be set 10% above
operating voltage.
POWER FACTOR CORRECTOR - MODEL 1600
20605-85 Rev. N 24 HOUR SERVICE
SCR BRIDGE OUTPUT
The SCR bridge operates at zero output
voltage, representing a purely inductive
load. The rectifier load inductor is sized so
that when, operating at its maximum
current, the inductive resistance fully offsets
capacitive reactance from the harmonic
filter traps.
TYPICAL PFC CUBICLE
Figure 10-16 shows the physical layout of a
typical PFC Cubicle.
DESCRIPTION OF PFC CUBICLE
CONTROLS AND INDICATORS
The following devices are located on the
front door of the PFC Cubicle:
DC AMMETER (Item 4) - This meter
displays the amount of the DC current (Zero
- 2,000 ADC) supplied by the SCR bridge.
KVAR METER (Item 8) - This meter
displays the total KVARs (2,000 - Zero -
2,000) supplied to the Power Control House
or system including the amount supplied to
the PFC.
VOLTAGE ADJUST Potentiometer (Item
16) - This control sets the level at which the
line-voltage will be clamped. For a typical
system, the voltage is 600 (+/- 10%) VAC.
AC VOLTMETER (Item 22) - This meter
displays either the line-voltage or the
voltage at which the line-voltage will be
clamped (Zero to 1,000 VAC).
POWER AVAILABLE Lamp (Item 56) - A
green lamp which illuminates to indicate
closing of the customer's feeder circuit
breaker.
SCR DRIVE SYSTEM TECHNICAL MANUAL
(713) 467-2523
 10-15

6261-001-01 Rev. B

Figure 10-16. Typical PFC Cubicle Lineup

SCR DRIVE SYSTEM TECHNICAL MANUAL POWER FACTOR CORRECTOR - MODEL 1600
24 HOUR SERVICE (713) 467-2523 20605-85 Rev. N
10-16
DESCRIPTION OF PFC BRIDGE
CONTROLS AND INDICATORS
(CONCLUDED)
POWER ON Lamp (Item 57) - A red lamp
which illuminates to indicate closing of the
PFC MAIN CIRCUIT BREAKER (Item 63).
CB2 CLOSED Lamp (Item 58) - A red lamp
which illuminates to indicate that the 5th
trap circuit breaker is closed.
CB3 CLOSED Lamp (Item 59) - A red lamp
which illuminates to indicate that the 7th
trap circuit breaker is closed.
It is possible to connect a three-
phase capacitor on the line which
will cause an undesirable rise of line-
voltage. To prevent this from occurring
in the PFC, clamping is provided. The
PFC will not allow the line voltage to rise
above the clamp-voltage level even
though the DC current from the SCR
bridge must rise above the preset limit
to prevent this. The DC current can be
limited to a preset value to allow the
KVARs supplied to the Power Control
House to be capacitive and not zero.
CURRENT LIMIT ADJUST Potentiometer
(Item 60) - This control sets the KVAR
value at which the DC current supplied by
the SCR bridge is to be limited. To minimize
losses in the PFC and allow the KVAR's
supplied to the Power Control House to be
capacitive while the motors are inoperative,
you may want to limit the DC current. After
proper adjustment is made, further
adjustments should not be necessary. The
DC current may rise above the preset limit if
it is necessary to prevent the voltage from
rising above the clamp-voltage value.
EMERGENCY OFF Pushbutton (Item 61) -
When this switch is depressed, the PFC is
removed from the incoming power source
and all circuit breakers are opened.
POWER FACTOR CORRECTOR - MODEL 1600
20605-85 Rev. N 24 HOUR SERVICE
VOLTMETER SELECT Switch (Item 62) -
This switch allows selection between line
voltage and the voltage at which the line
voltage will be clamped.
PFC MAIN CIRCUIT BREAKER (Item 63) -
An electrically-controlled circuit breaker
which supplies 600 VAC three phase main
input power to the PFC.
5TH TRAP CIRCUIT BREAKER (Item 64) -
An electrically-controlled circuit breaker
which supplies power to the 5th trap.
7TH TRAP CIRCUIT BREAKER (Item 65) -
An electrically-controlled circuit breaker
which supplies power to the 7th trap.
PFC OPERATING
INSTRUCTIONS
On the PFC, there are two
potentiometers which qualified
personnel can use for making
adjustments. When proper adjustments
have been made, the PFC will reduce the
KVARs supplied by high line or
generator sets to near zero. Thus, within
the limitations of the PFC, (the KVAR
rating) the KVARs will automatically be
kept near zero as the load changes.
DO NOT TURN THE VOLTAGE
ADJUST (ITEM 16) OR KVAR
ADJUST (ITEM 60)
POTENTIOMETERS, IF THESE
CONTROLS HAVE BEEN PROPERLY
ADJUSTED. FURTHER ADJUSTMENTS
WILL REDUCE THE ABILITY OF THE
PFC TO MAKE CORRECTIONS.
SCR DRIVE SYSTEM TECHNICAL MANUAL
(713) 467-2523

1. PFC Power must be available from the
customer's main power source. If power
is present, the amber POWER
AVAILABLE Lamp (Item 56) will
illuminate.
2. Close the PFC MAIN CIRCUIT
BREAKER (Item 63). When this circuit
breaker is closed, the red POWER ON
Lamp (Item 57) will illuminate.
3. To bring the PFC into operation, close
the 5TH AND 7TH TRAP CIRCUIT
BREAKERS (Items 64 and 65) by
moving the circuit breaker handle UP. If
either of the circuit breakers have
tripped, pull the circuit breaker handle
DOWN (this resets the circuit breaker)
before attempting to move the circuit
breaker handle UP. The red 5TH TRAP
CIRCUIT BREAKER CLOSED Lamp
(Item 58) will illuminate when the 7TH
TRAP CIRCUIT BREAKER (Item 64) is
closed. The red 7TH TRAP CIRCUIT
BREAKER CLOSED (Item 59) lamp will
illuminate when the 7TH TRAP
CIRCUIT BREAKER (Item 65) is
closed.
4. Comparison of the PFC Cubicle KVAR
METER (Item 8) and the AC
KILOWATT METER (Item 7) readings
will indicate if the PFC is functioning
correctly. Meter readings will vary based
on KVAR rating of the PFC. Table 10-2
shows figures for a PFC with a rating of
1,600 KVARs.
Table 10-2. Meter Readings Based on 1,600 KVAR Rated PFC
KVARs Required Generator/Distribution
KVAR Meter(s) Reading
<1,600 Below Zero (negative)
1,600 Zero
>1,600 +2 at 500 KVARs
SCR DRIVE SYSTEM TECHNICAL MANUAL
24 HOUR SERVICE
10-17
The AC KILOWATT METER is
normally located on the
SCR/GEN 1 Cubicle front panel. Refer to
Drawing XXXX-001-00 in your drawing
package (XXXX is your job number).
5. Since Table 10-1's readings are not
from your system, some variation may
not indicate a problem in the operation
of your PFC. If there is a question
regarding your PFC's performance,
notify your maintenance or engineering
department.
6. Do not change (rotate) the settings of
the VOLTAGE ADJUST (Item 16) or
KVAR ADJUST (Item 60)
potentiometers unless instructed to do
so by qualified personnel. Changing
these will harm the PFC, but may
reduce the capabilities of the PFC to
correct the power factor.
PFC INSTALLATION
This section contains information needed to
insure proper installation of the PFC.
CUBICLE INSTALLATION
PRELIMINARY CONSIDERATIONS
Door Clearance
The control room must be large enough to
allow the cubicle doors to be opened 110º
outward. The doors cover the full height of
the cubicles. The room height must have
clearance for the cable tray, piping, and
ducting.
PFC KVAR Meter PFC DC Ammeter
Reading
Leading (+) Zero to 1,950
Zero Zero
-1,000 Zero
POWER FACTOR CORRECTOR - MODEL 1600
(713) 467-2523 20605-85 Rev. N
10-18

Ventilation And Ducting
When the cubicles are enclosed in a room,
the room air must be changed twice per
minute. Ducting in the front and rear of the
room should force the air to flow the full
room length.
angle between any cable and the plane
of the top of the PFC Cubicle is ≈ 60°.
The estimated total weight of a
PFC Cubicle is 4,000 pounds,
height is 90", width is 96", and depth is
48".

Heat Loss 2. Use hydraulic hand trolleys (Rol-A-Lift or

equivalent) to move the PFC Cubicle
Heat loss from a PFC housed in a room into the exact location.
with fully insulated walls, floor, and ceiling,
and containing no distribution transformers, 3. Cover the vertical forks of the trolleys
is approximately 2.5 tons for each 1,000 with carpeting to protect the PFC
amps of DC output from the SCR bridges. Cubicle panel finish.
4. Slide the trolley's forks all the way
HANDLING PFC CUBICLES beneath the PFC Cubicle.

With a crane, lift the PFC Cubicle to the
general installation area. Use four lifting
points per cubicle (refer to Figure 10-17).
5. Jack up the PFC Cubicle ≈ 6" (15 cM)
above the floor.
6. Carefully push the PFC Cubicle into
location, then lower and remove the
trolley's forks.

Alternative methods for moving the system

45 in.
are to set it on wheeled carts or to roll it on
APPROX.
pieces of pipe.
CLEVIS 60°
APPROX.
Equipment can be moved over a smooth
floor using pipe rollers. The bottom of each
cubicle is a smooth, flat surface to ease
rolling. However, pipes must extend beyond
the edge of each cubicle so that the
equipment weight is transferred to the pipe
by the perimeter structure of each cubicle.
END VIEW (TYPICAL)

20602-31 Rev. A Keep the distance between pieces of pipe

Figure 10-17. Shackles with Clevis at least 12" (30 cM).

1. Lift the PFC Cubicle as one unit by DO NOT DROP THE PFC
lifting from the top. For this purpose, two CUBICLE. ALTHOUGH IT IS
lifting angles are bolted to the top of the VERY RUGGED, AND HAS
PFC Cubicle. (These angles can be BEEN FIELD PROVEN IN
removed after the PFC Cubicles are in THOUSANDS OF INSTALLATIONS, IT IS
place). The lifting angles are designed NOT WARRANTED AGAINST
so that a shackle pin with a 1" diameter MISHANDLING DAMAGE.
can be used for lifting (refer to Figure
10-17). Arrange the cables so that the

POWER FACTOR CORRECTOR - MODEL 1600 SCR DRIVE SYSTEM TECHNICAL MANUAL
20605-85 Rev. N 24 HOUR SERVICE (713) 467-2523
 10-19

POWER CABLE RUNS

DO THIS
If the power utilized requires multiple A B C
conductors per phase, observe the
following guidelines:

1. Ensure that the cables share current

equally.
2. Minimize magnetic losses which can
cause heating in nearby steel.
3. Run power cables in groups of three,
each group consisting of one A, B, &
C phase to ensure current sharing.
20602-32 Rev. A
4. Make cables for each identical in Figure 10-18. Incorrect Cable Run
length to ensure current sharing.
5. When passing through a hole in steel
plate or through a steel ring (or NOT THIS
conduit), always pass through equal
numbers of each phase. This avoids A B C
eddy currents or magnetic heating.
6. When necessary to run multiple
cables per phase, side-by-side,
interchange the cable positions or
separate them widely. Otherwise, the
center cable carries little current and
the outside cables become
overloaded. Figures 10-18 through
10-20 shows examples of cable 20602-33 Rev. A

runs. Figure 10-19. Correct Cable Run

7. Failure to follow these guidelines,
OR THIS
even for short runs, can easily result
in burning insulation or red hot steel. A B C

STORAGE

Store the PFC Cubicle, which is

constructed for indoor use, in a covered
warehouse. Heat it while in storage to keep
the air temperature in the PFC Cubicle
above the Dew Point (the temperature at
which water vapor begins to condense).
This is very important if the air is laden with
salt or other chemicals. 20602-34 Rev. A

Figure 10-20. Correct Cable Run

Place a 200 to 600 Watt space heater in the
PFC Cubicle bottom. If space heaters
cannot be used, use three 100 watt light
bulbs.
SCR DRIVE SYSTEM TECHNICAL MANUAL POWER FACTOR CORRECTOR - MODEL 1600
24 HOUR SERVICE (713) 467-2523 20605-85 Rev. N
10-20

PFC MAINTENANCE AND DAILY CHECKS

STARTUP TESTS
SAFETY PRECAUTIONS
If carelessly handled, the PFC can inflict
grave injury. Observe safety precautions at
all times to prevent electric shock.
TEAM WORK
Maintenance work should preferably be
performed by a team of two electricians,
assuring help in an emergency.
PERSONAL WEAR
Do not wear metallic watch straps, rings, or
bracelets.
LIVE CIRCUITS
Consider all circuits to be energized unless
known to be dead.
TOOLS
Ground all electrical tools. Insulate all tool
handles. Do not leave tools in cubicles after
the work is complete.
FUSES
Close a fuse by pushing on the plastic
cover. Do not place a finger underneath the
cover.
FIRE
Remove power to the unit on fire. Read the
label on the fire extinguisher to be sure it
can put out an electrical fire. Water may be
used instead.
Perform the following checks to assure
proper functioning of the PFC.
1. Check lights and meters on the PFC
Cubicle.
2. Ensure that all cubicle blowers are
running.
WEEKLY TEST
Check the SCR Amps Test Pins
waveshape located on the front of the PFC
Control Module. See
TROUBLESHOOTING in this section for
details.
STARTUP INSTRUCTIONS
All startup tests must be performed by or
under the supervision of one of our field
engineers or a person trained by us.
The equipment is fully tested at the plant
and should be fully operational upon
installation. However, it is recommended
that a careful verification test procedure be
completed before applying full power to the
system.
STARTUP TESTS
Perform the following tests:
VISUAL INSPECTION TEST
Remove bolt-on covers and examine all
equipment for damage, loose connections,
and foreign material. Check all electrical
connections for tightness. Verify all fuse
and breaker values.

POWER FACTOR CORRECTOR - MODEL 1600 SCR DRIVE SYSTEM TECHNICAL MANUAL
20605-85 Rev. N 24 HOUR SERVICE (713) 467-2523

CONNECTION TEST
All connections from the SCR to external
destinations should be checked for
continuity with an Ohmmeter by grounding
one end and reading resistance at the
other.
INSULATION RESISTANCE TEST
The main bus and each cubicle should be
tested for insulation resistance with a
minimum 500 VDC Megohmmeter. Tests
should be line to line and line to ground.
PHASE ROTATION TEST
Proper phase rotation must be verified at
the main bus and each drive module.
SNUBBER CONTINUITY TEST
Verify the each device's snubber continuity
with a VOM.
DC MODULE POWER SUPPLIES TEST
Check the following Pins for the indicated
voltage.
Pin 133: -10 VDC
Pin 124: +10 VDC
Pin 153: +14 VDC
Pin 154: -14 VDC
SCR FIRING PULSES TEST
Check the firing pulses at each SCR for
polarity, shape, amplitude, and 2.77 mS
time interval between main and backup
firing pulses.
SCR DRIVE SYSTEM TECHNICAL MANUAL
24 HOUR SERVICE
10-21
AIR FILTERS TEST
Verify that air filters are installed correctly.
BLOWER ROTATION TEST
Check that the blower is rotating in the
correct direction.
EMERGENCY OFF PUSHBUTTON TEST
Verify that it operates and does open the
main circuit breaker delivering power to the
PFC.
VOLTAGE CLAMP TEST
Before applying power, set the voltage
clamp adjustment to its full clockwise
position (750 VAC).
METER CALIBRATION AND CT
PHASING TEST
Verify meter calibration and CT phasing by
leaving the 5th trap and 7th trap circuit
breakers open. Put a single generator or hi-
line distribution on the main bus. The KVAR
meters on the generator or utility
distribution and the PFC should agree.
Repeat this test for each generator.
POWER FACTOR CORRECTOR - MODEL 1600
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10-22
SCR BRIDGE FUNCTIONAL TEST
Perform the following steps:
1. Close the 5th and 7th harmonic traps
circuit breakers.
2. Move the spring-loaded switch on
the front of the PFC Control Module
to ON (up). While holding it in this
position, move the MANUAL VOLTS
knob clockwise. The DC AMMETER
on the PFC will swing up to a
maximum reading (the exact reading
will depend on the PFC rating).
For example:
If the PFC is rated at 1,600 KVARS,
the DC amps will be 1.22 X 1,539 =
1,878 Amps. The actual reading may
be slightly higher because of circuit
efficiency. The above calculations
assume 100% PFC efficiency.
3. Set the VOLTAGE CLAMP to the
main bus voltage plus 10%. If the
main bus operates at 600 VAC, the
VOLTAGE CLAMP setting will be
660 VAC.
4. Set the KVAR MIN/MAX adjustment
knob to the full clockwise position.
PREVENTATIVE
MAINTENANCE
Preventative Maintenance consists of
cleaning the system components and
replacing those which become defective or
worn out. Periodic servicing makes the PFC
more reliable and longer lasting. A reliable
system is less likely to suffer sudden
failures or deteriorate below the
performance specifications.
POWER FACTOR CORRECTOR - MODEL 1600
20605-85 Rev. N 24 HOUR SERVICE
System components are vulnerable to three
factors: inferior quality, harsh operation,
and severe environment.
INFERIOR QUALITY
Efforts to eliminate this source of failure are
made at our manufacturing and testing
facility. The system is rigorously tested
through every phase of operation. The
electronic modules are placed in ovens at
165°F (75°C) for 168 hours to simulate
numerous hours of operation at normal
temperature. Therefore, components likely
to fail during the first hours of operation are
replaced before shipment.
HARSH OPERATION
Operate the PFC within its capabilities.
Operating above the ratings subjects the
system to severe strains. Handle the
controls with care. A harsh switching action
can generate a damaging transient
overload.
SEVERE ENVIRONMENT
There are several different conditions which
constitute a severe environment:
OVERHEATING
Components can fail suddenly due to
overheating. Even though the PFC system
is rated to perform between -22°F (-30°C)
and 122°F (50°C), it is more reliable at
normal temperatures.
HIGH TEMPERATURES
Components age faster at very high
temperatures. The blowers in the SCR
Bridge and Filter Cubicle dissipate the heat
from electronic assemblies. As a further
precaution, vital units such as the SCR
bridges and Electronic Control Modules
have heatsinks for faster cooling.
SCR DRIVE SYSTEM TECHNICAL MANUAL
(713) 467-2523

Inspect all assemblies on a frequent basis
for indications of overheating such as
charring or burned insulation due to loose
connections. Replace any damaged
components even though they may not
have failed completely.
VIBRATION
The PFC system units do not generate
vibrations. However, vibrations from
rotating machinery such as the generator
set(s) cause mechanical stress which can
loosen connections and crack insulation.
DUST
It is attracted to high voltage switchgear
surfaces because of static electricity
charge. As a result, circuit discontinuities,
or even short, can occur.
MOISTURE
This aggravates problems caused by dust.
The contaminants cake on the components
and conductivity is increased. Further,
corrosion can occur.
PREVENTATIVE MAINTENANCE
SERVICING
This consists of three operations: cleaning,
inspection, and replacement.
CLEANING
Wipe clean all cubicle and component
surfaces with a lint-free cloth moistened
with a mild cleaning solvent. Be sure to
leave the surfaces dry.
TURN OFF THE SYSTEM
BEFORE CLEANING. TEST THE
CLEANING SOLVENT ON A
SMALL SURFACE TO MAKE
SURE THAT IT DOES NOT DAMAGE
PLASTIC PARTS OR INSULATION, OR
REMOVE PAINT.
SCR DRIVE SYSTEM TECHNICAL MANUAL
24 HOUR SERVICE
10-23
INSPECTION
Check system components for indications
of overheating and corrosion. Replace
damaged components even though they
have not failed completely. Inspect the
cables and wires for broken and burned
insulation. Tighten all loose connections.
Check switches, knobs, and buttons for
easy movement between positions.
CARELESS INSPECTION CAN,
IN AND BY ITSELF, CAUSE
MALFUNCTIONS. DO NOT TUG
AT CABLES AND WIRE
HARNESSES, SHAKE THE ELECTRONIC
ASSEMBLIES OR FIDDLE WITH THE
KNOBS. EMPLOY NONTOUCHING
VISUAL INSPECTION AS MUCH AS
POSSIBLE.
The servicing period depends on the
system's operating conditions. Adhere to
the following schedule during the initial
period and adjust it according to need.
MONTHLY PREVENTATIVE (OR AS
NEEDED)
1. Inspect all cubicle air filters. Clean or
replace as required.
2. If the system is installed in an air
conditioned SCR or switchgear
room, inspect all air conditioning
system filters and replace if dirty.
3. Verify any air conditioning drains are
free of obstructions.
POWER FACTOR CORRECTOR - MODEL 1600
(713) 467-2523 20605-85 Rev. N
10-24
TROUBLESHOOTING
INTRODUCTION
This section provides information needed to
isolate a malfunctioning PFC.
Troubleshooting consists of:
1. Looking at the broad possibilities of
failure.
2. Then breaking down the most likely
possibility into successively smaller
troublespots. This consists of
examining the entire system as it is
situated. Next, the inspection is
narrowed to a faulty cubicle or
internal assembly. The search is
finally narrowed to a faulty
component. The malfunction can be
quickly located by seeking out signs
of trouble. Some of these signs are
extreme readings on meters, tripped
circuit breakers, or smoking
components.
A step-by-step approach to
troubleshooting should consist of:
1. Malfunction Analysis.
2. Front Panel Indicators
Analysis.
3. Systems Analysis.
4. Signal tracing.
MALFUNCTION ANALYSIS
Troubleshooting is easier and faster if the
nature of the malfunction is pinned down.
Sometimes, faulty behavior in the PFC may
be caused by operator error.
POWER FACTOR CORRECTOR - MODEL 1600
20605-85 Rev. N 24 HOUR SERVICE
Faulty performance of other equipment may
be blamed on the PFC. Be sure the fault is
not from outside the system before making
extensive repairs such as replacing an SCR
device.
If a malfunction occurs occasionally, it may
be necessary to keep a log of system
parameters with a strip chart recorder.
FRONT PANEL INDICATORS ANALYSIS
Many malfunctions can be located by
analyzing the meters and lights on the front
panel.
Operational lights indicate whether the PFC
is on-line. The voltmeters and ammeters
can provide valuable troubleshooting
information as well.
SYSTEMS ANALYSIS
It is easiest to understand the PFC by
thinking of it as being made up of
interrelated blocks or units. Ignore the
contents of any particular unit, and instead
consider its inputs and outputs.
A malfunctioning unit does not supply the
correct outputs. This fault may be due to
incorrect inputs. If not, some of the
assemblies within the unit may be
defective.
To troubleshoot the PFC, first isolate the
faulty unit by examining the PFC outputs.
Next, examine the inputs to the faulty unit. If
one of the inputs is wrong, trace that input
to its generating unit. If, however, the inputs
are correct, troubleshoot the unit. Isolate
the fault to one of the unit assemblies by a
similar system analysis.
SCR DRIVE SYSTEM TECHNICAL MANUAL
(713) 467-2523
 10-25

Inputs to the PFC are in two forms: When RL10 is de-energized by any one of
these faults, CB1 cannot be closed, or will
1. Power. trip because 120 VAC will be missing from
2. Control. the left side of CB1's UVR coil.

For example: SPECIAL TOOLS AND

EQUIPMENT
An SCR device must receive the AC supply
and control firing pulse at the gate. If both The following items are needed to
inputs are correct, then the device itself is troubleshoot the PFC.
defective.
MULTIMETER
SIGNAL TRACING
A Triplett Model 630, APLK Weston Model
The defective unit can be easily located by 622, or equivalent is recommended to
tracing signals associated with the problem. measure voltage and resistance. It should
be insulated, and rugged enough to
Example: withstand drilling rig conditions.

During the following example, DC/AC Volts: Zero - 1,000 in several

refer to the drawings of the PFC in ranges.
the drawing package of this technical
manual. Accuracy: 3% of full scale.

The CONTROL POWER ON lamp will be Ohms: Zero - 10 MΩ in several

illuminated if CB1 can be closed. Input ranges.
circuit breaker CB1 can be closed if RL10 is
Accuracy: Two percent of arc length.
energized. RL10 will be de-energized by a
fault condition of: AC/DC CLAMP-ON AMMETER

1. An open microswitch on any pair of This meter is used to safely measure high
main SCR fuses is caused by that currents. The Columbia Model 1000A is
pair of fuses being blown. recommended, but is not usually required
for PFC troubleshooting.
2. One of the SCR bridge
overtemperature switches has
OSCILLOSCOPE
opened. The opening of this switch
at 190°F (88°C), may be caused by The Fluke Model 123 or 192 is
blower malfunction. recommended. The selected Oscilloscope
3. An overtemperature switch on the should have at least a three inch diagonal
Filter Cubicle load inductor is open. viewing screen, and two channels for
The overtemperature switch opens comparing signals. The Oscilloscope is
at 250°F (121°C). used to check SCR gate pulses and ripple
on various DC voltages.
4. The EMERGENCY STOP
pushbutton is operated.

SCR DRIVE SYSTEM TECHNICAL MANUAL POWER FACTOR CORRECTOR - MODEL 1600
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10-26

TROUBLESHOOTING GUIDE
Troubleshooting of the PFC can be
accomplished by use of Table 10-3. Refer
to Section 3 of this manual for SCR
troubleshooting.

Table 10-3. PFC Troubleshooting Guide

PROBLEM PROBABLE CAUSE

INPUT BREAKER 12 VAC power supply missing from Pins 103 through 108 of the PFC Control
WILL NOT Module. +14 VDC supplies may be low or absent. Check for the presence of
CLOSE the following problems and correct as required.
CONTROL POWER NOT ON Check fuses F1, F2, F3. Check R7, R8
and R9 for opens.
MAIN SCR FUSES BAD Verify that all main SCR fuses are good.
BRIDGE OVERTEMPERATURE There is one switch on each side of the
SWITCH OPEN vertical bridge at the top heatsink (TS8
and TS9)
FILTER CUBICLE Verify cubicle blower is running. Be sure
OVERTEMPERATURE SWITCH there are no obstructions to air flow into
IS OPEN the blower or through the Filter Cubicle.
PFC INPUT DC power supply voltages are missing or low. Check for the following voltages
CIRCUIT at the indicated pins.
BREAKER MAY PIN VOLTAGE
NOT CLOSE OR
122 -10 (± 1) VDC
PRODUCE
ADEQUATE 124 +10 (± 1) VDC
CORRECTION 153 +14 (± 1) VDC
154 -14 (± 1) VDC
155 Zero VDC (Ground)
All must be present for normal operation. If any are missing, check F1, F2, and
F3. If all fuses are good, and AC input is normal, PFC Control Module power
supply is defective. In this case, replace the PFC Control Module. Refer to the
PFC Control Module changing procedure later in this section.
PFC INPUT A pair of SCR fuses may have been blown by a defective SCR. Check across
BREAKER TRIPS. all SCRs for a short. If check does not reveal a shorted SCR, replace the SCR
UNIT HAS BEEN fuses and perform a check of the SCR current feedback waveform.
WORKING.
CUBICLE
TEMPERATURES
ARE NORMAL.
UNIT WILL NOT
GO BACK ON-
LINE.
PFC UNIT WILL Power Factor enable signal -14 VDC not getting to Pin 121 of the PFC Control
NOT PRODUCE Module. Refer to Sheet 1 of the PFC Control Schematic XXXX-031-02 in the
ANY PFC System Drawings.

POWER FACTOR CORRECTOR - MODEL 1600 SCR DRIVE SYSTEM TECHNICAL MANUAL
20605-85 Rev. N 24 HOUR SERVICE (713) 467-2523
 10-27

Table 10-3. PFC Troubleshooting Guide (Concluded)

PROBLEM PROBABLE CAUSE

ONE OR BOTH This can be caused by any of the following:
HARMONIC OVERTEMP SWITCH OPEN Refer to drawing XXXX-031-01 in the
FILTER TRAP System Drawings.
BREAKER(S)
TRIPPED. BLOWER(S) NOT RUNNING Check the blower fuses. Refer to Sheet 1
of Drawing XXXX-031-02 in the System
When re- Drawings, for fuse numbers. If replacing
ferring to a
specific drawing in
the fuses do not return the blower to
the System operation; replace the blower.
Drawing section of 200 KVAR CAPACITORS HAS A pressure switch on one of them has
this manual: XXXX HIGH INTERNAL PRESSURE opened due to internal pressure. It may be
in the referenced apparent which capacitor is defective by
drawing is your visual inspection. To identify the open
four-digit job
pressure switch, refer to Drawing XXXX-
number.
031-01 in the System Drawings. These
capacitors are located in the bottom of the
capacitor cubicle.
CAPACITORS CAN HOLD DANGEROUS CHARGES FOR A
LONG TIME. READ MANUFACTURER'S INSTRUCTIONS IN THE
UNIQUE DEVICES SECTION OF THIS MANUAL BEFORE
ATTEMPTING TO SERVICE THESE CAPACITORS.
PFC INPUT SCR Cubicle overtemperature. Check blower fuses. Refer to Sheet 1 of
POWER CIRCUIT Drawing XXXX-031-02 in the System Drawings, for fuse numbers.
BREAKER TRIPS
PROBLEM PROBABLE CAUSE
PFC PRODUCING MAXIMUM LAGGING Possible misadjusted clamp volts. Setting has been
KVARS lowered below the normal adjustment of 10% above
This creates an excessive KVAR load on normal operating voltage. Check clamp voltage
main AC source, affecting other equipment adjustment and correct as required. Defective PFC
by preventing it from running at maximum Control Module. Make power supply checks before
power or overloading the Distribution replacing.
System.
PFC BRIDGE AMPS ARE ZERO WITH Misadjusted KVAR MIN/MAX CONTROL. It has
LIGHT TO MEDIUM LOAD. GENERATOR been turned to its full CCW position. Readjust to full
KVARS READ BELOW ZERO. KVAR clockwise setting.
METER ON PFC READS + LEADING
KVARS.
There is an excessive amount of circuit
capacitance. PFC SCR Bridge cannot
introduce any inductive KVARS to cancel
excessive capacitance. If the load is running
above the PFC rating, no problem would be
indicated - meter readings would be normal.

SCR DRIVE SYSTEM TECHNICAL MANUAL POWER FACTOR CORRECTOR - MODEL 1600
24 HOUR SERVICE (713) 467-2523 20605-85 Rev. N
10-28

RECOMMENDED SPARE
PARTS
To assure maximum performance and
reliability of the PFC, it is recommended
that the parts shown in Table 10-4 be kept
in your inventory.

Table 10-4. Recommended PFC Spare Parts

QUANTITY PART NUMBER DESCRIPTION

1 0000-7424-00 Module - PFC Reg. W/Six CT Inputs. 60 Hz.
6 0000-6954-26 Fuse - 315 Amps, 700 Volts, Capacitor.
10 0301-0010-00 Fuse - 2 Amps, 500 Volts, 10 KIC.
6 0000-6953-60 Fuse - 900 Amps, 1,300 Volts.
10 0301-0019-00 Fuse - 30 Amps, 600 VAC.
10 0301-0009-00 Fuse - 0.6 Amps, 500 Volts.
1 0510-0400-27 PC - Current Feedback, SCR.
1 0509-1900-02 PC - Burden Resistors, D2, D4, D6 omitted, R1 through
R3 change to 95.3 KΩ.
1 0100-0357-00 Pulse Transformer - 26T:14T, w/Black Epoxy Resin.
2 0000-6953-55 Capacitor - 200 KVAR, 660 Volts, Three Phase, 60 Hz.
1 0000-6931-24 Bridge Blower - Aerofoil, Type KG
1 0200-1076-62 Blower - Model G/1B, 600 Volts, Two HP. Three Phase.
3 0501-2616-18 1600 SCR - 1,800 Amps, 4" Package, Screen for 1,000
Volts/µSec.
2 0506-0001-00 Rheostat - 1 KΩ, Type H.
1 0000-6898-79 Relay - 120 VAC, 3 Pole Double Throw, 10 Amps.
1 0801-0117-02 Meter - Blank, DB40, Zero to One Milliamp Movement,
Logo Zero to Left, DC Ammeter Self Contained.
1 0801-0184-00 Meter - Blank, DB40, One Milliamp to Zero to One
Milliamp Movement.
3 0000-6827-99 Temperature Switch - Open on Rise to 325 (± 15)°F.
20 0405-0019-00 Lamp Bulb - 130 VAC.
2 0403-0008-01 Temperature Switch - Open on Rise to 190 (± 5)°F,
Close on Drop to 160 (± 7)°F.
2 0000-6954-27 Micro Switch - Blown Fuse
10 0301-0012-00 Fuse - 6 Amps, 500 Volts

POWER FACTOR CORRECTOR - MODEL 1600 SCR DRIVE SYSTEM TECHNICAL MANUAL
20605-85 Rev. N 24 HOUR SERVICE (713) 467-2523
 10-29

SCR CELL
PFC CUBICLE REPLACEMENT
Figure 10-22 is an exploded-view drawing
REMOVAL AND REPAIR of the SCR cell in the PFC Cubicle. To
replace the SCR, perform the procedure
Figure 10-21 shows a front view of the PFC which follows Figure 10-22.
Cubicle.

FS-200-10

Figure 10-21. Power Factor Control SCR Cubicle

SCR DRIVE SYSTEM TECHNICAL MANUAL POWER FACTOR CORRECTOR - MODEL 1600
24 HOUR SERVICE (713) 467-2523 20605-85 Rev. N
 10-30

20605-85 Rev. N
Item Description
1 AC Bus Bar
2 Fuse
3 Fuse Trip Indicator
4 Pressure Gauge
5 SCR
6 25 Ω , 55 W Resistor
7 DC Bus Bar
8 Overtemperature Switch
9 1 µ f Capacitor
10 Pulse Transformer
11 Heatsink

POWER FACTOR CORRECTOR - MODEL 1600

24 HOUR SERVICE
(713) 467-2523
Figure 10-22. Power Factor Corrector SCR Bridge Mechanical View
10197-33 Rev. A

SCR DRIVE SYSTEM TECHNICAL MANUAL

 10-31

PFC CUBICLE SCR REPLACEMENT

1. Trip the circuit breaker which

supplies power to the PFC Cubicle
SCR Bridge before touching any part
of the PFC Cubicle SCR Bridge.

FS-200-02

4. Place a sheet of paper beneath the

bottom of the SCR enclosures to
prevent nuts or washers from falling
into the blower outlet.

FS-201-03

2. Tools required: Stubby screwdriver,

3/8" nut driver, 9/16" and 3/4" box-
end wrenches, 9/16" and 3/4" socket,
rachet handle, 9" extension, and a
pair of small side-cutting pliers.

FS-200-03

5. On the fuse of the SCR to be

replaced, unplug the connector from
both the top and bottom microswitch
assembly.

FS-200-01

3. Remove both Glastic Bridge Covers

with the 3/8" nut driver. Each Glastic
Bridge Cover is secured with four
3/8" machine screws.

SCR DRIVE SYSTEM TECHNICAL MANUAL POWER FACTOR CORRECTOR - MODEL 1600
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10-32

PFC CUBICLE SCR REPLACEMENT

(CONCLUDED)

FS-200-05

8. Use the 3/8" nut driver to remove the

FS-200-02
capacitor wire connected to the rear
6. On the SCR to be replaced, use the of the SCR Heatsink Assembly.
3/4" box-end wrench to remove the
bolts holding the two fuses on the
SCR Heatsink Assembly, then
remove the top of the SCR Assembly
on the other side of the SCR Bridge.

FS-200-06

9. Disconnect the appropriate Gate (G)

and Cathode (K) leads and feed
them through the opening in the
Glastic Side Panel.
FS-200-04

7. Use the 9/16" socket and 9/16" box-

end wrench to remove the two bolts
from the center bus connection to
allow the bus cross piece to be
moved.

POWER FACTOR CORRECTOR - MODEL 1600 SCR DRIVE SYSTEM TECHNICAL MANUAL
20605-85 Rev. N 24 HOUR SERVICE (713) 467-2523

FS-200-07
10. Use the 9/16" socket and socket
extension to remove the Clamp Nuts.
Note that the Bus Bar has been
moved for removal of the SCR
Heatsink.
FS-200-08
11. The SCR is held in place by a Nylon
screw. The Nylon screw may be
loosened to allow removal of the
SCR.
If replacing the SCR on the other
side of the SCR Bridge, the
procedure is the same, but the SCR
will remain on the back Heatsink.
SCR DRIVE SYSTEM TECHNICAL MANUAL
24 HOUR SERVICE
10-33
FS-200-08
12. Note the position of the SCR Flange
before removing the SCR. Lift out
the defective SCR. Install the new
SCR ensuring it's orientation is the
same as the old one. Perform the
reassembly of the SCR in the
reverse order of removal. Be sure to
braid the G and K leads (this will
reduce the electronic noise caused
by the firing pulses). Ensure that
fingerprints, oil, and any other
smudges are kept off the SCR's
anode and cathode surfaces.
FS-200-09
13. To prevent cocking of the SCR
heatsink, alternately tighten the two
9/16" clamp nuts one turn until the
Gauge's bar is lined up with the
bottom notch (this is ≈ 600 lb. Force).
POWER FACTOR CORRECTOR - MODEL 1600
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10-34

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POWER FACTOR CORRECTOR - MODEL 1600 SCR DRIVE SYSTEM TECHNICAL MANUAL
20605-85 Rev. N 24 HOUR SERVICE (713) 467-2523