SCR DRIVE SYSTEM

REVISION HISTORY
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REVISION HISTORY PAGE SCR DRIVE SYSTEM TECHNICAL MANUAL

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SCR DRIVE SYSTEM
SYSTEM INFORMATION
DESCRIPTION
The SCR Drive System provides electrical
power conversion and control for the DC
motors on a drilling rig. The system
regulates AC power from engine-generator
sets and delivers continuously variable DC
power to traction motors which are coupled
to functions such as Drawworks, Rotary
Table, Top Drive, Cement Pumps and Mud
Pumps (see Figure 1-1).
A typical drive system consists of the
following units:
• Generator Units for control of engine-
generator sets.
• SCR Units for AC to DC rectification for
traction motor power and control.
• Transformer Feeder Unit - AC feeder
breakers to feed step-down
transformers that deliver low voltage
power for AC auxiliaries such as motor
blowers, water pumping, lighting and
living accommodations.
• DW Dynamic Brake - electrical
resistance or regenerative brake for
Drawworks motors.
• Field Supply Unit for DC field supply to
shunt wound, separately excited DC
traction motors.
• Driller's Console for control of all drilling
functions from the drill floor.
• Mud Pump/Cement Pump Console for
local control of the pumps during
maintenance.
• Motor Control Center containing starters
for AC auxiliary motors and feeder
breakers for lighting panels and smaller
distribution transformers.
SCR DRIVE SYSTEM TECHNICAL MANUAL
24 HOUR SERVICE
1-1
SPECIFICATIONS
The drive system conforms to IEEE-45
standards for electrical switchgear. For
offshore systems, certification can be
obtained from American Bureau of Shipping
(ABS), United States Coast Guard (USCG),
and Det Norske Veritas. See Table 1-1 for
system specifications.
Table 1-1. System Specifications
ELECTRICAL
AC Input Three phase, 60 Hz, 600 VAC
Prime Power Usable KW depends on
horsepower of prime mover.
Engine Governor 0.5 Hz steady-state regulation
with one Second response time
at 5% load unbalance of rated
load
Generator Voltage Regulator
±3% regulation one second
response time with ±10% load
unbalance of rated KVAR's
DC Output Zero to 750 VDC at zero through
maximum current
Current Rating (Continuous Duty)
SCR bridge output is usually
zero to 1,800 ADC (this can vary
depending on model).
MECHANICAL
Temperature Range -22°F to 105°F
(-30°C to 40°C)
Cubicle Construction Fabricated from 12 gauge
cold-rolled steel with welded
construction and expanded
metal ventilation openings.
The cubicle bus is solid
copper with a 0.0005 Inch
(0.0013 cM) electroplating of
silver.
Console Construction Fabricated from 12-gauge
#304 stainless steel plate
with welded construction.
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SPECIFICATIONS (CONCLUDED)

Figure 1-1. SCR Drive System

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FUNCTIONAL DESCRIPTION 3. Adjust the VOLTAGE ADJUST

Figure 1-2 shows a typical one-line
diagram. Observe that power from the
engine-generator sets is collected on a
common AC bus.
AC to DC rectification occurs in SCR
bridges. The output of the SCR bridge is
applied to the DC traction motors via
contactors. Contactor logic is set at the
Control Console being used. Note that
circuit breakers isolate each generator set
and SCR Unit from the Main AC Bus.
control knob so the VOLTS meter
indicates 600 Volts.
4. Charge the circuit breaker (if
necessary), by pushing the
CHARGE pushbutton for electrically
charged circuit breakers, or by
cranking the circuit breaker handle
for manually charged breakers.
5. Close the circuit breaker by pushing
the illuminated PUSH TO CLOSE
pushbutton on the appropriate
generator cubicle door.
6. Turn the SYNC switch to the OFF
position.

OPERATING PROCEDURE
FOR GENERATOR SYSTEM SYNCHRONIZING GENERATORS
MODELS 1201 THROUGH 1650
TO BRING AN ADDITIONAL
During the following procedures, GENERATOR ON LINE
refer to Figures 1-3 through 1-6.
1. (Models 1200, 1201, 1500) Turn the
STARTING AN ENGINE SYNCHRONIZING switch (Item 9 on
Figure 1-3, Item 11 on Figure 1-4) to
1. Place the ENGINE CONTROL SYNC.
switch to IDLE. OR
2. Start the engine and run it at idle 1. (Model 1400) Turn the
speed until it is warmed up. SYNCRONIZING switch (Item 15 on
Figure 1-5) to the number of
3. Place the ENGINE CONTROL
generator about to be brought on
switch to RUN.
line.
OR
1. (Model 1600) turn the
BRINGING THE FIRST SYNCHRONIZING SWITCH (Item
GENERATOR ON LINE 20 on Figure 1-6) to AUTO.
2. Position the VOLTS ADJUST knob
1. Turn the SYNC switch to the number (Item 13 on Figure 1-3 and 1-4, Item
of generator about to be brought on 10 on Figure 1-5, Item 17 on Figure
line. The PUSH TO CLOSE 1-6) so the AC VOLTMETER (Item 5
pushbutton on the appropriate on Figures 1-3 and 1-4, Item 18 on
generator cubicle door should Figure 1-5, Item 7 on Figure 1-6)
illuminate. indicates 600 Volts.
2. Set the SPEED ADJUST control
knob so the FREQUENCY meter
indicates 60 Hz.

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20600-09 Rev. A

Figure 1-2. Typical One Line Diagram

3. Adjust the SPEED ADJUST knob moves clockwise (the

(Item 12 on Figures 1-3 and 1-4,
Item 9 on Figure 1-5, Item 18 on
Figure 1-6) until the
SYNCROSCOPE needle (Item 20 on
Figures 1-3 and 1-4, Item 17 on
Figure 1-5, Item 22 on Figure 1-6)
engine/generator speed is faster
than desired) and the two
SYNCHRONIZING LIGHTS (Items
21 on Figure 1-3, Items 19 on
Figures 1-4 and 1-5, Items 23 on
Figure 1-6) brighten/dim.

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Item Description
1. GEN Circuit Breaker
2. AC Kilowatts Meter
3. AC Kilovars Meter
4. AC Ammeter
5. AC Voltmeter
6. Generator Run Light
7. Generator On Line Light
8. Engine Control Switch
9. Synchronizing Switch
10. Ammeter Select Switch
11. Voltmeter Select Switch
12. Speed Adjust Knob
13. Volts Adjust Knob
14. % AC Ground Ammeter
15. % DC Ground Ammeter
16. Ground Fault Indicator Lamps
17. Ground Detector Test Button
18. Power Limit Light
19. Hertz (Frequency) Meter
20. Synchroscope
21. Synchronizing Lights

Figure 1-3. Controls and Indicators for Models 1200 and 1500

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Item Description
1. GEN Circuit Breaker
2. AC Kilowatts Meter
3. AC Ammeter
4. AC Kilovars Meter
5. AC Voltmeter
6. Generator Run Light
7. Generator On Line Light
8. Ammeter Select Switch
9. Voltmeter Select Switch
10. Engine Control Switch
11. Synchronizing Switch
12. Speed Adjust Knob
13. Volts Adjust Knob
14. % AC Ground Ammeter
15. % DC Ground Ammeter
16. Ground Fault Indicator Lights
17. Ground Detector Test Push Button
18. Power Limit Light
19. Synchronizing Lights
20. Synchroscope
21. Hertz (Frequency) Meter

Figure 1-4. Controls and Indicators for Models 1201

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Item Description
1. GEN Circuit Breaker
2. AC Kilowatts Meter
3. Kilovars Meter
4. AC Ammeter
5. Engine Control Run/Off/Idle Switch
6. GEN Run Light
7. GEN On Line Light
8. Push to Close Lighted Pushbutton
9. Speed Adjust Knob
10. Volts Adjust Knob
11. % AC Ground Fault
12. % DC Ground Fault
13. Ground Fault Indicator Lights
14. Ground Detector Test Push Button
15. Generator Synchronization
Select Switch
16. Frequency (Hertz) Meter
17. Synchroscope
18. AC Voltmeter
19. Synchronizing Lights
20. Power Limit Light
21. Hour Meter

Figure 1-5. Controls and Indicators for Model 1400

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Item Description Item Description

1. AC Kilowatt Meter 13. Ammeter Select Switch
2. Temperature Meter 14. Engine Governor Switch
3. Kilovars Meter 15. Circuit Breaker Switch
4. AC Ammeter 16. Voltmeter Select Switch
5. % DC Ground Meter 17. Volts Adjust Knob
6. % AC Ground Meter 18. Speed Adjust Knob
7. AC Voltmeter 19. Temperature Select Switch
8. Generator Run Light 20. Synchronizing Switch
9. Circuit Breaker Push to Charge 21. Frequency (Hertz) Meter
Push Button 22. Synchroscope
10. Ground Fault Indicator Lights 23. Synchronizing Lights
11. Ground Detector Test Push Button 24. GEN Circuit Breaker
12 Circuit Breaker Indicator Lights

Figure 1-6. Controls and Indicators for Model 1600

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4. Crank the handle of the GEN
CIRCUIT BREAKER (Item 1 on
Figures 1-3, 1-4, and 1-5, Item 24 on
Figure 1-6) once to charge the GEN
CIRCUIT BREAKER.
5. Close the GEN CIRCUIT BREAKER
when the needle of the
SYNCROSCOPE points straight up,
the SYNCHRONIZING LIGHTS go
out, and the PUSH TO CLOSE
pushbutton on the GEN CIRCUIT
BREAKER is illuminated.
6. Position the VOLTAGE ADJUST
knob so the KVAR meter gives the
same reading as the other
generator(s) on line.
7. Turn the SYNCHRONIZING
SWITCH to the OFF position.
2. Charge the circuit breaker (if
necessary), by pushing the
CHARGE pushbutton (for
electrically-charged circuit breakers)
(refer to Figures 1-3 through 1-6) or
by cranking the circuit breaker
handle (for manually-charged circuit
breakers). Some systems have
molded-case circuit breakers. These
do not require charging.
3. Close the SCR circuit breaker by
pushing the PUSH TO CLOSE
pushbutton (this may be mounted
remotely or directly on the circuit
breaker). Crank the circuit breaker
handle once to close molded-case
circuit breakers.

REMOVE GENERATOR FROM SWITCH ON AUXILIARIES

LINE AND STOP ENGINE 1. Close the feeder circuit breaker to
feed AC supply to the distribution
1. Open the circuit breaker by pushing transformers and the MCC.
the circuit breaker OFF pushbutton.
2. Close the circuit breakers
2. Place the ENGINE CONTROL corresponding to each of the blowers
switch in the IDLE position. and auxiliaries. Set the
3. If the GOVERNOR CONTROL HAND/OFF/AUTO switch to AUTO
switch has an OFF position, go to (if applicable).
the OFF position only after engine 3. If the motors are shunt wound,
has cooled down. switch on the appropriate field power
4. If system equipped with a supplies. Each motor's field current
GOVERNOR CONTROL pushbutton should be ≈50 Amps (or per the
switch, the engine must be shut motor nameplate rating).
down at the engine.

TURNING ON AN SCR UNIT NORMAL OPERATION

1. Check the Driller's Console to insure KVAR SHARING

assignment for this SCR is turned off Adjust the VOLTS ADJUST knobs so all
(the 12 o'clock position de-assigns generator units KVAR meters are the
all SCRs). same.

KW SHARING
A master/slave circuit automatically
balances the Kilowatts (Horsepower)
among all on-line engines (the load is
shared equally).

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KW SHARING (CONCLUDED)
The master generator is the lowest-
numbered unit connected to the Main AC
Bus. The remaining generators are slaved
to the master. For example, if Generator 1,
2, and 4 are connected to the Main AC Bus,
Generator 1 is the master.
In systems using Auto Share (Auto Sync)
AC Control Modules, master/slave floats.
No AC Control Module can be the
dedicated master in an Auto Share system.
The magnetic coupling that exists between
paralleled generators insures that all engine
generator sets connected to the Main AC
Bus at the same time will run at the same
speed. The SPEED ADJUST knob on the
master generator has total control of the
Main AC Bus frequency. The slave units
SPEED ADJUST controls are disabled.
The combination of KW (Real Power) and
KVAR (Reactive Power) sharing between
engine generator sets should cause all
generator AMMETERS to read about the
same value. Any imbalance in the readings
of the various KVAR meters can be
adjusted by using the VOLTAGE ADJUST
knob of the generator that has the lowest
KVAR meter reading.
POWER DISTRIBUTION
Distribution of the total power is governed
by the following equation:
DCPower Demand = Power Used (Total - AC)
Bring additional generators on line to
increase the total power available. To
increase the total DC power available,
increase the total power by putting more
generators on line. AC power is usually a
small fraction of the DC power. To increase
power for a specific DC function, it also
helps to reduce the power consumed by the
other DC functions.
SCR DRIVE SYSTEM
20605-45 Rev K 24 HOUR SERVICE
Due to the Main AC Bus feature and the
Power Limit circuit, it is possible to connect
as few generators to the Main AC Bus as
are necessary to do the work. For
economy and efficiency, match the total
available power to the total load.
CRISIS OPERATION
UNIT MALFUNCTION
The GEN ON LINE and SCR ON lights will
illuminate when the respective units are
connected to the Main AC Bus. The lights
go out when that unit is tripped off-line
(disconnected from the Main AC Bus). If a
generator\SCR unit becomes inoperative,
continue the system operation on other
units.
SYNC MALFUNCTION
If the SYNCHROSCOPE is inoperative, use
the SYNC lights to parallel the generators.
If both the SYNCHROSCOPE and the
SYNC lights fail, use a Multimeter.
Switch the Multimeter to a 600 VAC scale.
Connect it across the generator circuit
breaker from the top to the bottom of any
one phase. The voltage will swing from
minimum to 600 VAC just as the SYNC
lights should change from dim to bright.
Adjust the SPEED ADJUST knob for the
oncoming generator until the swing slows.
Close the circuit breaker when the
Multimeter voltage reading is minimum.
TRANSIENT AC SURGE
The green SURGE SUPPRESSION light
will extinguish if a problem blows the Surge
Suppression Circuit incoming line fuses.
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SPROCKET SLIP
The SPROCKET SLIP light illuminates
when Mud Pump assignment contactors
trip. This is caused by a sprocket slip, chain
failure, or belt slippage on a dual motor
mud pump. After the chain drive is
repaired, push the SPROCKET SLIP
RESET button to extinguish the
SPROCKET SLIP light and to allow the
contactors to close.
GROUND FAULT
The three GROUND DETECTOR lights and
the % AC GROUND and % DC GROUND
meters indicate ground faults.
These are only indicators and the
fault must be located and
corrected.
AC ground faults can occur anywhere along
the AC power network (generator to AC bus
cables, feeder distribution to the AC motors,
and the generator control bus in the cubicle
itself). The GROUND DETECTOR lights
will isolate the fault to one of the phases,
and the % AC GROUND meter will indicate
the degree of the fault.
DC ground faults may occur anywhere
along the DC network from the DC (+) and
DC (-) buses in the SCR cubicles to the
motor cables. Isolate the fault to one motor
by observing the % DC GROUND meter.
The % DC GROUND meter needle will
fluctuate as the faulty motor speed is
changed.
SCR DRIVE SYSTEM TECHNICAL MANUAL
24 HOUR SERVICE
1-11
SHUT DOWN INSTRUCTIONS
1. Turn off the SCR unit by tripping the
SCR circuit breaker. The SCR ON
light will extinguish.
2. Disconnect the generator from the
Main AC Bus by tripping the
Generator circuit breaker. The GEN
ON LINE light will extinguish.
3. Push the engine IDLE pushbutton.
Cool the engine per the engine
manufacturer.
4. After the engine cool-down period is
over, turn the Generator Control
cubicle OFF/IDLE/RUN switch to
OFF to stop the engine. Shut down
the fuel rack if there is no OFF
button.
CAPABILITIES
Figure 1-7 shows an SCR bridge Current
versus Voltage response curve. Figure 1-8
shows DC series and shunt motors Speed
versus Torque curves. These are for a
specific brand and model motor. Other
brands and models will be different.
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20600-91 Rev. A

Figure 1-7. SCR Bridge Current versus Voltage Curve

20600-92 Rev. A

Figure 1-8. Speed versus Torque Curve

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FS-201-01

Figure 1-9. Typical SCR House

If the house is not ordered, the equipment

MAINTENANCE should be handled with care to prevent
excessive mechanical shock, and protected
This chapter contains information to assure
from possible damage due to moisture and
proper operation of the system through
dirt during rig-up. See Figures 1-11 and
periodic functional tests and preventive
1-12 for cubicle lifting procedure.
maintenance.

If the system fails to perform as indicated in

the functional test instructions, consult the
troubleshooting guidelines listed in this
manual.

RECEIVING & HANDLING

SCR switchgear is normally installed in a

truckload-sized house (see Figure 1-9), a
self-contained, structural steel building
mounted on skids. Cabling to external
devices such as generators, motors and
control consoles is terminated at FS-050-11

weatherproof plug panels (see Figure 1-10). Figure 1-10. Plug Panel of One SCR
House

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Figure 1-11. Cubicle Lifting Procedure

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Figure 1-12. Cubicle Lifting Procedure

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INSTALLATION If an SCR house was not ordered, refer to

the following instructions for installation of
See Figure 1-13 for a typical SCR the SCR Cubicles. Figure 1-14 shows a
switchgear layout in a house. typical SCR Drive Cubicle lineup.

Figure 1-13. SCR House Layout

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Figure 1-14. SCR Drive System Typical Cubicle Lineup

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CUBICLES
PRELIMINARY CONSIDERATIONS
Door Clearance
The SCR room must be large enough to
allow the doors to be opened 90 degrees.
The doors cover the full height of the
cubicles. The height of the room must have
clearance for the cable tray, piping, and
ducting.
Ventilation and Ducting
The room air must be changed twice per
minute when the cubicles are enclosed in a
room. Ducting in the front and rear of the
room should force the air to flow the full
length of room.
Heat Loss
Heat loss for a SCR system housed in a
room fully insulated on walls, floor and
ceiling, and containing no distribution
transformers, is approximately 2.5 tons for
each 1,000 HP of DC load.
Vibration Pads
If the cubicles are mounted in a high
vibration area, such as the region close to
the engine skid, the cubicles should be
mounted on vibration insulating pads. The
vibration frequency should be within 30 Hz,
and the amplitude should not exceed 0.02
cM. Korfund spring-type vibration isolators
are recommended.
Location
Lift the cubicle with a crane into the general
installation area. Use four lifting points per
cubicle. Refer to Figures 1-11 and 1-12 for
the lifting procedure.
SCR DRIVE SYSTEM
20605-45 Rev K 24 HOUR SERVICE
Use hydraulic hand trolleys (Rol-A-Lift or
equivalent) to move the cubicles into the
exact location. Two trolleys may be
required for wide cubicles such as the
Motor Control Center. Cover the vertical
rest beams of the trolleys with carpeting to
protect the finish of the cubicle panels.
Slide the trolley horizontal forks all the way
underneath the cubicle.
Jack up the cubicle approximately 6" (15
cm) above the floor.
Push the cubicle carefully into the location,
jack down, and remove the trolley
horizontal forks.
Mounting
Butt the sides of the cubicles tightly
together.
Bolt the cubicles together at the top and
bottom using 3/8" bolts.
Install the AC bus splices to connect the
bus together from cubicle to cubicle.
Cable Installation
Refer to the cabling diagrams in the SCR
job book. Cables between the cubicles are
furnished by the customer unless the SCR
drive system is installed in a Power Control
Building.
All power terminations are made through
the cubicle top unless otherwise designed.
If the SCR system is supplied inside a
Power Control Building, power and control
cable terminations are at one end of the
building.
The terminations are copper stubs with an
one inch diameter bolt hole. The customer
should furnish plated-copper, crimp-type
lugs. Avoid screw-type pressure
connectors.
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If multiple single conductor cables are used Team Work

to feed the system, transposing of the
cables must be considered to ensure
current sharing between conductors.
Control Consoles
Maintenance work should preferably be
performed by a team of two electricians.
This assures help in an emergency
situation.

The Driller's Console is typically mounted Personal Wear

on top of the Drawworks pneumatic control
console. The Mud Pump and Cement Pump
consoles are provided with tabs. Each tab
has a bolt hole for wall installation. Refer to
the respective console drawings for detailed
installation instructions.
Control cable terminations are made from
the bottom with plug-in-type Pyle National
connectors or screw-type terminal blocks
fed through stuffing tubes.
TESTING
This section contains information to test the
proper functioning of the SCR Drive
System. Perform the test daily. If the
system fails any part of the test, use the
Troubleshooting section to locate the
malfunction.
SAFETY PRECAUTIONS
IF CARELESSLY HANDLED,
THE SCR DRIVE SYSTEM CAN
INFLICT GRAVE INJURY.
SAFETY PRECAUTIONS MUST
BE OBSERVED AT ALL TIMES TO
PREVENT ELECTRIC SHOCK.
Do not wear metallic watch straps, rings, or
bracelets.
Live Circuit
Consider all circuits to be energized unless
known to be dead.
Tools
All electric tools should be grounded.
Handles on the tools should be insulated.
Do not leave tools in the cubicles after the
work is completed.
Fuses
Close a fuse by pushing on the plastic
cover. Do not place a finger underneath
the cover.
Fire
Remove power to the unit under fire. Read
the label on the fire extinguisher to be sure
it can put out an electrical fire. Water may
be used, but be very certain that all
power is removed including the power
on the main bus.

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DAILY TEST
Perform the following checks to assure the
proper functioning of the drive system.
1. Check lights and meters on cubicles
and control consoles.
2. Check Ground Detector indicators.
All three lamps should glow a dim
orange. The Ground Fault
Percentage meters should read
close to Zero.
3. Check field current supply of all
shunt motors.
4. Ensure that KW's and KVAR's are
shared between all the generators
on line.
5. During tripping, listen for switching
action of the DW Dynamic Brake
contactor.
6. Ensure that all SCR blowers are
running.
MONTHLY TEST
Perform the "Mechanical Overspeed Trip"
and "Reverse Power Trip" Functional tests,
located in Table 2-4 (see Section 2).
1. Check waveshape of SCR Amps at
the test pins on the DC Control
Module. See the SCR Unit section
for further details.
2. Inspect the cooling inlet filters and
clean/replace as necessary.
When working in conditions of low
humidity, wipe off meter lenses
with a damp cloth or use anti-static
spray.
SERVICING
Servicing consists of cleaning the system
components and replacing those which
have become defective or worn out.
Periodic servicing will make the SCR Drive
SCR DRIVE SYSTEM
20605-45 Rev K 24 HOUR SERVICE
System more reliable and last longer. A
reliable system is less likely to suffer
sudden failures or deteriorate below the
performance specifications.
The system components are vulnerable to
three factors: inferior quality, harsh
operation and severe environment.
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 96 hours to simulate
numerous hours of operation at normal
temperature. Thus, components which are
likely to fail during the first hours of
operation are replaced before shipment.
HARSH OPERATION
The drive system should be operated within
its capabilities. Operation above the ratings
subjects the system to severe strains. The
controls should be handled with care. A
harsh switching action can generate a
damaging transient overload.
ENVIRONMENT
HEAT
Components can fail suddenly due to
overheating. Even though the drive system
is rated between -22°F (-30°C) through
104°F (40°C), the system operation is more
reliable at normal temperatures.
Components age faster at temperature
extremes.
The blowers in each SCR cubicle remove
the heat from the electrical assemblies. As
a further precaution, vital units such as the
SCR bridges and electronic modules have
heat sinks for faster cooling. Inspect the
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assemblies frequently for indications of
overheating such as charring or burned
insulation due to loose connections.
Replace the damaged components even
thought they may not have failed
completely.
VIBRATION
The drive system units do not generate
vibrations. However, vibrations from
rotating machinery such as the generator
set cause mechanical stress which can
loosen connections and crack insulation.
DUST
Dust is attracted to high voltage switchgear
surfaces because of the static electricity
charge. As a result, circuit discontinuities,
or even shorts can occur.
MOISTURE
Moisture aggravates problems caused by
dust. The contaminants cake on the
components and conductivity is increased.
Further, corrosion can occur.
Servicing consists of three operations:
cleaning, inspection, and replacement.
CLEANING
Wipe clean the 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 MAIN POWER
TO THE SYSTEM BEFORE
CLEANING. TEST THE
CLEANING SOLVENT ON A
SMALL SURFACE TO MAKE SURE IT
DOES NOT DAMAGE THE PLASTIC
PARTS OR INSULATION, OR REMOVE
PAINT.
SCR DRIVE SYSTEM TECHNICAL MANUAL
24 HOUR SERVICE
1-21
INSPECTION
Check all components for overheating and
corrosion. Replace damaged components
even if not completely failed. Inspect
cables and wires for broken or burned
insulation. Tighten all connections and
check switches, knobs, and buttons for
easy movement.
CARELESS INSPECTION
ITSELF CAN CAUSE
MALFUNCTIONS. DO NOT TUG
CABLES AND WIRE
HARNESSES, SHAKE THE ELECTRONIC
ASSEMBLIES OR FIDDLE WITH THE
KNOBS. EMPLOY VISUAL INSPECTION
AS FAR AS POSSIBLE.
Operating conditions dictate the servicing
period. Adhere to the following schedule
during the initial period and adjust it
according to need.
CONNECTIONS
Experience has shown that many problems
with electrical equipment are the result of
loose connections. Periodic checks for
tightness can be helpful.
WEEKLY SERVICING
1. Clean all cubicle and air conditioning
filters.
2. Check Driller's console and Foot
Throttle for air pressure. If there is
moisture inside the compartments,
the dryer in the air line may be
clogged.
3. Check assignment contactors.
Inspect the coils for signs of
overheating such as discoloration or
charred insulation. Check contacts
for corrosion or pitting. Inspect the
freewheeling diodes; also inspect
auctioneering diodes in the system.
SCR DRIVE SYSTEM
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1-22
ENVIRONMENT (CONCLUDED)
4. Clean tachometer pickup plugs. Do
not screw pick up in too far. Flywheel
will damage coil upon starting diesel.
5. Check AC leakage for every SCR
bridge.
QUARTERLY SERVICING
Clean and inspect the system components
as indicated in Weekly Servicing. In
addition, tighten the bus bar bolts.
STORING AN SCR DRIVE SYSTEM
1. Disconnect HOC batteries at the
battery terminals.
2. It is important to keep the SCR
house interior dry while stacked.
Install covers on all external
connectors on the plug panels. Place
corrosion inhibitors in consoles and
cabinets.
3. Seal any openings to keep varmints
out.
4. Lift the brushes on traction motors.
5. Apply power to generator and
traction motor heaters if possible.
Heaters in electrical equipment
areas are helpful.
6. Cover traction motor blower
openings.
REMOVING AN SCR DRIVE FROM
STORAGE AND PLACING IT IN SERVICE
1. Inspect bus bars for debris. Inspect
and clean throughout cubicles,
consoles, MCC cans and underneath
the main and switchgear line-ups.
2. Physically rotate the SCR blowers.
3. Manually operate all motor starters
and contactors before powering up.
4. Open and inspect all modules.
SCR DRIVE SYSTEM
20605-45 Rev K 24 HOUR SERVICE
5. Open and inspect all generator and
traction motor covers.
6. Open all fuses in the system and
high-resistance check the main three
phase bus bars before applying
power.
7. Remove covers and inspect SCR
bridges. Clean as necessary.
8. Reconnect HOC batteries. If good,
they will fully recharge within 24
hours.
9. Clean all potentiometer windings
(speed adjust, voltage adjust, hand
throttles, foot throttle).
10. Tighten all bus bar bolts and screw
connections.
11. Manually phase-up each SCR bridge
as soon as possible.
12. Inspect all power resisters for cracks.
13. Check AC leakage on all SCR
bridges.
14. Check knob settings on EGB-10P or
13P actuators.
15. Check resistance of all magnetic
pickup circuits and all actuator
circuits.
16. Check compatibility of all modules.
17. Check outputs of hand and foot
throttles.
18. Check current and voltage feedback
for all SCR bridges.
19. Perform emergency-off and reverse
power trip tests for all engines.
20. Verify sync circuits with a VOM.
21. If equipment has been idle for more
than one year, all electrolytic
capacitors should be replaced.
SCR DRIVE SYSTEM TECHNICAL MANUAL
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TROUBLESHOOTING ANALYSIS OF FRONT PANEL

INDICATORS
OVERVIEW
Many malfunctions can be located by
Troubleshooting allows the isolation of a analyzing the meters and lights on the front
malfunctioning SCR Drive System unit. panel.

It consists of first looking at the broad
possibilities of failure, and then breaking
down the likely possibility into successively
smaller trouble spots.
Examine the whole system as it is situated
between the generators and the loads.
Then narrow the search to a cubicle or
console, then to an internal assembly, and
finally to a component. The malfunction
can be quickly located by seeking out signs
of trouble, such as extreme readings on the
meters, tripped circuit breakers, and
smoking components.
A step-by-step troubleshooting approach
should consist of the following items:
malfunction analysis, analysis of front panel
indicators, systems analysis, and signal
tracing.
Warning lights on the cubicle panels flag
ground faults, AC surge, sprocket slip, and
reverse power conditions. Operational
lights indicate whether a SCR or a
Generator is on the bus. Even voltmeters
and ammeters provide valuable
troubleshooting information. For example,
a stalled motor is indicated by high current,
and low voltage. Low current and high
voltage is an indication of an unloaded
motor.
SYSTEMS ANALYSIS
Think of the system as being made up of
interrelated blocks or units. Ignore the
contents of the unit, and simply consider
the inputs and outputs. Refer to Figure 1-
15.
DRILLER'S GENERATOR
CONSOLE

MALFUNCTION ANALYSIS

Troubleshooting is easier and faster if the DC

ELECTRONIC
CIRCUIT
BREAKER
nature of the malfunction is pinned down. MODULE

Sometimes, the faulty behavior of the

system may be caused by operator error. GATE FIRING
AC SUPPLY
For example, the Driller may forget to turn PULSES

SCR BRIDGE
on the lockout switch, open the throttle, and
assume that the SCR unit is defective. 0 - 750 VDC SUPPLY

POWER
The faulty behavior of a motor or generator CONTROL

may be blamed on the SCR system. Make 20601-07 Rev. A

sure the fault is not outside the system Figure 1-15. System Block Diagram
before making extensive repairs such as
replacing a SCR cell.

If the malfunction occurs off and on, it may

be useful to keep a log of the system
parameters with a strip chart recorder.

SCR DRIVE SYSTEM TECHNICAL MANUAL SCR DRIVE SYSTEM

24 HOUR SERVICE (713) 467-2523 20605-45 Rev K
1-24
SYSTEMS ANALYSIS (CONCLUDED)
A malfunctioning unit does not provide the
correct outputs. The fault may be due to
incorrect inputs. If not, some of the
assemblies within the unit may be
defective.
To troubleshoot, the system, first isolate the
faulty unit by examining the outputs of the
suspected units. Then examine the inputs
to the faulty unit. If one of the inputs is
incorrect, trace the signal from the incorrect
input to its source unit. If, however, the
inputs are correct and the outputs are
incorrect, troubleshoot the defective unit.
Isolate the fault to any one of the unit
assemblies by a similar system analysis.
Inputs to many of the SCR Drive System
units are of two forms: power and control.
For example, a SCR cell must receive the
AC supply and the control firing pulse at the
gate. If both the inputs to the SCR cell are
correct and the output of the SCR cell is
incorrect, the cell is defective.
The defective unit can be easily located by
tracing signals associated with the
malfunction.
GENERATOR 1 CIRCUIT SCR 1 CONTACTOR
BREAKER
GENERATOR 2 CIRCUIT SCR 2 CONTACTOR
BREAKER
20601-08 Rev. A
Figure 1-16. A Parallel Circuit
SCR DRIVE SYSTEM
20605-45 Rev K 24 HOUR SERVICE
The motor can be operated on any one of
the two power lines (refer to Figure 1-16). If
it fails to run, the fault can be in the motor,
the assignment switch, or the power lines.
The power line can be checked out by
simply switching the motor to one of the
other lines. If the motor runs, then
obviously, the first power line is defective.
Each power line is made up of components
in series. If the power line circuit is
defective, all the components and the wiring
must be suspected. The defective
component can be located by tracing the
power supply from the motor back to the
generator.
Begin the signal tracing at the motor. If
power is present at the motor and the motor
is not running, the motor is defective.
If power is absent at the motor, check for its
presence on both sides of the contactor. If
power exists on the SCR side, but not on
the motor side, the contactor is open.
Signal tracing should continue back toward
the Generator until the defective component
is located. In extremely long series circuits,
it may be convenient to divide the circuit in
half. Begin the probe in the middle. If the
signal is missing, trace back toward the
generator until the signal is regained. If the
signal is present, trace away from the
generator until the signal is lost.
MOTOR
SCR DRIVE SYSTEM TECHNICAL MANUAL
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 1-25

SPECIAL TOOLS AND AC/DC CLAMP-ON AMMETER

EQUIPMENT
This meter is used to safely measure high
The following instruments are needed to currents. The Columbia Model 1000A is
troubleshoot the SCR Drive System. recommended.

MULTIMETER OSCILLOSCOPE

The Simpson Model 250 (or equivalent) is
recommended to measure voltage and
resistance values. The meter should be
insulated, rugged and possess:
DC/AC Volts:Zero through 1,000 Volts in
several ranges.
Accuracy: 3% of full scale.
Ohms: Zero through 10 MΩ in
several ranges.
Accuracy: 2% of arc length.
The oscilloscope is used to check the SCR
gate pulses and ripple on various DC
voltages. The Tektronix Model 305 (or
equivalent) is recommended. The unit
chosen should have >3 Inch diagonal
viewing screen and two channels for
comparing two signals.

It is recommended that digital-

type meters not be used for
measurements in power circuits. It has
been found that, in some cases, reading
inaccuracies may be induced by digital-
type meter usage.

Digital multimeters may be used to

measure voltage and current signals in the
SCR drive but you should be aware that
some digital meters are overly sensitive to
the high electrical noise typical of that found
in any switching high power supply. Digital
meters that are not designed with proper
filtering and measuring techniques and can
give inaccurate readings.

SCR DRIVE SYSTEM TECHNICAL MANUAL SCR DRIVE SYSTEM

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1-26

REMOVAL & REPAIR

CUBICLE REMOVAL

If a cubicle is damaged beyond repair,

perform the following steps:

1. Disconnect power cables from the

bus stubs located at the top of the
cubicle.

2. Remove bus links which connect the

AC bus from cubicle to cubicle. FS-047-02
1. Unscrew the Deutsch fastener at the top
of the module and swing open the
3. Remove the bolts which join the cover.
cubicles at the top and bottom.

4. Slide the fork of a hydraulic hand

trolley underneath the cubicle and
jack it up approximately 6" above the
floor.

5. Pull out the cubicle carefully, taking

care not to bump the adjoining
cubicles.

CUBICLE REPAIR

Repair of the SCR Drive System normally FS-047-05

consists of repairing an assembly within a 2. Release the wiring harness by removing
system unit. A system unit is not replaced each wire from the terminal board.
unless it is damaged beyond repair. When
a unit is replaced, perform a functional test
on it before operating the system. Refer to
the respective unit manual for test
instructions.

AC CONTROL MODULE

If an AC Control Module is malfunctioning,

replace it with the spare AC Control Module
and return the faulty unit to us.

To remove and replace the AC Control

FS-066-03
Module perform the following steps. 3. Unscrew the four Deutsch fasteners
which hold the module to the cubicle
wall.

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 1-27

CUBICLE REPAIR (CONCLUDED)

FS-047-05
6. Reconnect the wiring harness by
FS-066-05
replacing each wire on the terminal
4. During new module installation, ensure board. Ensure that each wire is correctly
you match the wire number to pin placed and that the retaining screw is
number. tightened.

FS-066-03 FS-047-02
5. Reconnect the module to the cubicle 7. Swing the cover closed and fasten it in
wall with the four Deutsch fasteners. place with the Deutsch fastener on top.

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24 HOUR SERVICE (713) 467-2523 20605-45 Rev K
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SCR DRIVE SYSTEM SCR DRIVE SYSTEM TECHNICAL MANUAL

20605-45 Rev K 24 HOUR SERVICE (713) 467-2523