Oilfield Technical Manual rN Zz 9 i a o 9 a 0 4 0 c Ie 2 5 10 4 = I 0 0 Q cINTRODUCTION This technical manual provides information to op- erate, service and troubleshoot the Ross Hill SCR Drive System. Use this manual as a study aid. Refer tothe SCR Schematics Job Book for diagrams specific to your rig. The first section in the manual, titled “SCR Drive System”, contains general information which applies to the drive system as a whole. The following sections have information that is specific to each unit such as “Generator Unit” or “SCR Unit”. The last section, titled “Unique Devices”, describes special components and applications. Ross Hill Controls welcomes comments concerning this manual. Please direct your correspondence to the following address: ‘Technical Publications Department Ross Hill Controls Corporation 1530 West Belt North Houston, Texas 77043 Table | is a list of abbreviations used throughout the manual. See figure 1 for the list of component symbols used in the illustrations. ALM Alarm ABS American Bureau of Shipping AWG — American Wire Gauge A Amperes c Capacitor CP Cement Pump CPC Cement Pump Console C/O Chain Oiler CB. Cireuit breaker K Contactor CT Current transformer °C Degrees Centigrade °F Degrees Fahrenheit DC _ Drillers Console DW —_Drawworks ERC Engine Room Console f Farads FL Field loss FYNR Full Voltage Nonreversing F Fuse FSD Full scale deflection GEN — Generator HED — Hall Effect Device HOA — Hand-Off-Auto HS Heat sink Hz Hertz (cycles per second) HP Horsepower TEEE Institute of Electrical & Electronics Engineers z Impedance K Kilo(10) KVA__ Kilovolt Amperes KW Kilowatts Lo Light M Meter MOV — Metal Oxide Varister m Milli (10) Be Micro (10) MCC Motor Control Center MS Motor Starter MP — Mud Pumps MPC — Mud Pump Console Table 1. Standard Abbreviations Sheet 1 of 2 RHCC SCR Drive System Technical Manual IntroductionNEC National Electrical Code NEMA. National Electrical Manufacturers Assoc. N Neutral a ‘Ohms of resistance ® Phase POT —Potentiometer PSI Pounds per square inch pf Power Factor PM Prime Mover PC Printed Circuit PROP Propulsion PB Push Button KVAR Reactive Kilovolt-Amperes REF Reference RL Relay RT _Rotary Table RTD _ Resistive Temperature Device R Resistor R/O Rod Oiler RHCC Ross Hill Controls Corporation Silicon Controlled Rectifier X"d_Sub-Transient Reactance orS Switch TB Terminal Block MCM_ Thousand Circular Mils XFMR orT — Transformer TH Thruster USCG United States Coast Guard VA Vac Vae WHC WIND Volt Amperes Volts Voltage (alternating current) Voltage (direct current) Wheelhouse Console Windlass ‘Table 1. Standard Abbreviations Sheet 2 of 2 RHCC SCR Drive System Technical Manual IntroductionElectrical Conductor Crossing of Conductors not Electrically Connected Crossing or Joining of Conductors Elec- tically Connected fe oe Two Conductor with Grounded Shield. W/R Indicates Conductor with Red Tracer. we +t Wiring Terminal Block q Printed Circuit Terminal Block Quick Dis-Connect Terminal (Fanning Strip) Ground or Chassis Resistor ; Variable Resistor (Potentiometer) > al F Capacitor Winding Magnetic Core Inductor Figure 1. Standard Symbols Sheet 1 of § RHCC SCR Drive System Technical Manual IntroductionDelta Connected Winding fe Wye Connected Winding ‘Transformer SIE Taps iE Auto Transformer, Adjustable Output by Adjustable Tap or Slide Wire, qe Current Transformer i Coit 3*0 Adjustable Output Transformer by Fixed Relay Coil © © Contacter Coil Motor Starter Coil © Contacts, Normally Open (“A” Contacts) a8 r Contacts, Normally Closed + SPDT Form “C* Contacts wey aPsy Three Position Selector used as an HOA oe | oh on Love yo dor cS Wafer or Banked Multi-Contact Switeh SREEABAE Tetetete Figure 1. Standard Symbols Sheet 2 of § RHC SCR Drive System Technical Manual IntroductionSPST as a Toggle — Push Button, Normally Open ae Push Button, Normally Closed ole Pressure Switch, Normally Closed ae Pressure Switch, Normally Open we Temperature Switch, Normally Closed o ‘Temperature Switch, Normally Open * Machine or Rotating Armature (Funda- ‘mental Symbol used in any of the Following Adaptations) O ‘One Line Presentation of AC Motor, 7% ‘One Line Presentation of Prime Mover car One Line Presentation of Generator, 2625 KVA, 2625 KvA © DC Motor Armature o> Separately Excited DC Shunt Motor aL a 2 Fi re DC Series Motor EO itemer Compound Wound Separately Excited DC Motor ean Se, rl ™M re One Line Presentation of Bolted in 3 Phase Circuit Breaker, or Single Pole Lighting Panel Circuit Breaker Figure 1. Standard Symbols Sheet 3 of 5 RHCC SCR Drive System Technical Manual IntroductionOne Line Presentation of Draw-out/Plug-in Convenience Power Outlet 3 Phase Circuit Breaker A p 3 Phase Circuit Breaker “UU ‘Alarm (Horn) Fuse, FI e so Diode a Thermal Overload 8 Silicon Controlled Rectifier a Zener Regulator Diode Incandescent Lamp a On @u ot NX a Florescent Lamp 400 ; : x - O-H ae Meters Figure |. Standard Symbols Sheet 4 of 5 RHCC SCR Drive System Technical Manual IntroductionFull Wave Three Phase Rectifier 400 oe ‘Auctioneering (Isolating) Configuration of Diodes tiv av tay tay ‘our av Metal Oxide Varister (MOV) y NPN Transistor, QI COLLECTOR youre PNP Transistor, QL ‘COLLECTOR a curren Operational Amplifier, Z1 Field Effect Transistor (FET) onan onan “1 1 source ounce None. Gaal, NAND Gate D- Light Emitting Diode (LED) ‘Thermister ® 4-0000-8 Figure 1, Standard Symbols Sheet 5 of § RHCC SCR Drive System Technical Manual Introductioneee SCR DRIVE SYSTEM ROSS HILL CONTROLS CORPORATIONSCR DRIVE SYSTEM Review Questions x -aAa |. Lamp on the Generator cubicle which indicates condition of Surge Suppressor Network is normal- ly —______ 2. Ground Detection circuit indicates ______ or _____ ground faults. 3. Voltage Adjust dial varies the generator voltage. The range is ______ to 640 volts 4, Surge Suppression filters spikes from the AC bus which might damage the 5. Speed Adjust knob is used to adjust the run frequency to ___ Hz. 6. Generator breaker is tripped automatically by four conditions, two of which are under} over- frequency and overvoltage. The remaining two conditions are_______and 7. To achieve KVAR sharing, the _____knob is varied to cause the generators to have equal amounts of reactive current 8. If the Synchroscope malfunctions, generators may be paralleled using the Sync lights. In this situation, the breaker should be closed when the Sync lights are 9. Each system should have only syne handle to prevent two generators from being placed on line at the same time. 10, When working on a SCR system or any electrical equipment, itis always a good policy to consider all circuits ____ unless known to be otherwise. 11, Assignment contactor logic and the DC voltage level are controlled from the 12. The SCR unit_____ the three phase AC supply to provide a continuously variable DC supply to the traction motors. 13. Assignment contactors break both ____ and ____ uses, 14. The AC voltage reaches 150 to 300 VAC, but will not increase to 600 VAC. The best way to get generator back on line would be to 15. Consider a rig which utilizes shunt motors. Drawworks is shut down because contactors do not close. The first thing you should check is I. Itis possible to operate all loads off of one engine with the Ross Hill system because: ‘A. All generators are applied to a common bus. B. All engines are slaved together. C. Traction motors can be assigned to different SCR cut D. Load Sharing.SCR DRIVE SYSTEM = Review Question: 2. Which circuit prevents the total DC load from exceeding the capactiy of the generators feeding the common bus? ‘A, Surge Suppressor Network B. Drawworks Dynamic Brake C. Power Limit Circuit D. Field Weakening circuits 3. SCR's are used to vary ‘A. Bridge voltage Surge Suppressor voltage . Exciter voltage D. Exciter and Bridge voltage of 4, Sprocket Slip circuit is used to protect, ‘A. Shunt motors B. Compound motors C, Series motors D. Series and shunt motors 5. When taking an engine off line, itis proper procedure to first ‘A. Check Synchroscope operation B. Rotate Engine Control switch to “idle” position. CC. Immediately shut off the engine D. Trip the Generator circuit breaker. 6. If a generator is tripped offline due to a reverse power condition, it will be necessary to turn off the Reverse Power indicator light by: ‘A. Placing the Engine Control switch in the “off” position. B. Charging the circuit breaker. CC. Adjusting the Voltage Control knob D, Pressing the Reverse Power Reset button on the Generator cubicle front panel. 7. The purpose of the Driller's Console is: A. Primary control of the DC functions. B. To allow the Driller to control all generators C. To indicate how many SCR's are being used. D. To synchronize Drawworks motors. 8, SCR cubicle blower intake filters should be cleaned at least . Once a month Once a week . Only when a blower fuse blows Each time air flow is completely restricted pop 098 HLL FONTROUS CORPORATION SSSCR DRIVE SYSTEM a Review Questions: 9. SCR breaker trips the bridge off line automatically under overcurrent, overtemperature, emer- geney off and A. When a DC ground fault occurs B. When SCR fuse blows C. When blower lights go out D. When Power Limit light comes on 10. To change direction of rotation of a DC traction motor, you must change direction of current through the A. Armature B. Field . Armature or Field D. Armature and Field 3|. OPERATION 1. Description The Ross Hill SCR Drive System provides electrical power conversion and control for the drilling rig. The system regulates AC power from engine-genera- tor sets and delivers continuously variable DC power to traction motors which are coupled to functions such as Drawworks. Rotary Table and Mud Pumps. See figure I-1. A typical drive system consists of the fol- lowing units: © Generator Unit for control of engine-generator sets. © SCR Unit for AC to DC rectification and traction ‘motor control. ‘© Transformer Feeder Unit - AC feeder to step-down transformers for AC auxiliaries such as motor blowers. ‘¢ DW Dynamic Brake - electrical resistance brake for Drawworks motors. Field Supply Unit for DC field supply to shunt wound, separately excited DC traction motors, ‘* Driller’s Console for control ofall drilling functions from the drill floor. © Mud Pump Console/Cement Pump Console for local control of the pumps during maintenance. ® Motor Control Center contains starters for AC auxiliaries A. Speci ‘The drive system conforms to IEEE-4S standards for clectrical switchgear. For offshore systems, certifica~ tion can be obtained from American Bureau of Ship- ping (ABS), United States Coast Guard (USCG), and Det Norske Veritas. See table I-I for system specifica- tions. ations B. Functional Description See figure I-2 for 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 bridge output is applied to DC traction motors via contactors. Contactor logic is set at the control console, Note that circuit breakers isolate cach generator set and SCR Unit from the AC bus. RHCC SCR Drive System Tech Electrical AC Input 600 Vac 60 Hz 30 Usable KW depends on horsepower of prime mover Prime Power: Engine Governor: 0.5 Hz steady-state regula tion, 1 see. response time, 45% load unbalance of rated load Generator Voltage 43% regulation. Regulator: 1 sec. response time £10% load unbalance of rated KVAR's DC Output 0 to 750 Vae at 0 through maximum current Current Rating Continuous Duty: SCR bridge output usually 0 10 1800 amps DC but could vary depending on unit’s model number Mechat ‘Temperature Range: -22°F to 140°F (30°C to 60°C) Cubicle Construction: Fabricated from 14-gauge cold-rolled steel with welded construction and expanded metal ventila- tion openings. Console Construction: Fabricated from 12-gauge No, 316 stainless steel plate with welded construction ‘Table I-1, System Specifications SCR Drive System12 2. Operating Procedure A.To Start An Engine (1). Put Engine Control switch to “Idle.” Q). Start engine and let it idle until warm, @). Put Engine Control switch to “Run.” B. To Bring The First Generator On Line (1). Turn Syne switch to number of generator about tobe brought on line. The “Push to Close" button should now be lit on that generator cubicle door. Q). Set Speed Adjust to 60 Hz, GQ). Set Voltage Adjust to 600 volts, (@). Crank breaker handle once to charge breaker. (5). Close breaker by pushing lit “Push to Close" bution on generator cubicle door. (6). Turn Syne switch to “Of” position. To Synchronize Generators (1). To bring an additional generator on line: (A). Turn Sync switch to number of generator about to be brought on line. (B). Set Voltage Adjust to 600 volts (C). Adjust speed until the synchronizing meter moves slowly clockwise (fast) and syne lights brighten and dim very slowly. (D). Crank breaker handle once to charge breaker. (E). Close circuit breaker when synchronizing ‘meter points straight up and syne lights go out RHCC SCR Drive System Technical Manual 1650/1400 MODEL SYSTEMS and “Push to Close” button is lighted. (F). Set Voltage Adjust for same reading on KVAR meter as other generators on line. (G). Turn Syne switch to “Of” position, 2). Remove generator from line and stop engine, (A). Open circuit breaker by pushing breaker “OfF” button, (B). Put Engine Control switch to “Idle.” (©). If Governor Control switch has an Off posi- tion, go to Off position only after engine has cooled down (D). If system equipped with pushbutton Gov- ernor Control switch, engine must be shut down at engine D. To Turn On An SCR Unit (1). Check Driller’s Console to insure assignment for this SCR is turned of. (2). Close the SCR circuit breaker by cranking handle E, Switch on Auxiliaries (1). Close the feeder breaker to feed AC supply to the distribution transformers and the MCC. (2). Close the circuit breakers corresponding to each of the blowers and auxiliaries. Set the HOA switch to “Auto”, if applicable. @). If the motors are shunt wound, switch on the appropriate field supplies. Field current to each motor should be approximately 50 amps. SCR Drive Systemwun nd wn 9 soatwe vos =}. vam ~O } an00n 2 + #--------- Re mr eanona seomnuay 2 anion eum 1 aMona Figure 1-2. Typical One Line Diagram SCR Drive System RHCC SCR Drive System Technical ManualF. Normal Operation (1). KVAR Sharing. Adjust the Volts Adjust knobs so that KVAR meters on all GEN units indicate the same value. (2). KW Sharing. A master-slave circuit automatically balances the KW's. This action results in an equal load ‘on all the engines. ‘The master generator has the lowest number among the ones on the bus. The remaining generators are slaves. For example, if GEN 1, GEN 2, and GEN 4 are on the bus, GEN 1 is the master. ‘The master-slave circuit also matches the slave unit frequencies to that of the master. The Speed Adjust knobs on the slave units are disabled, ‘The combination of KW and KVAR sharing should cause all generator ammeters to read an equal value 3). Power Distribution. Distribution of the total power is governed by the following equation: DC Power = Total Power - AC Power Bring additional generators on line to increase the Total Power. To increase the DC power, increase the Total Power. AC power is 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. Due to the common bus feature and the Power Limit circuit, it is possible to place as few generators on line as are necessary. For economy and efficiency, ‘match the total available power to the total load. G. Crisis Operation (1). Unit Malfunction. The GEN On Line and the SCR On lights will glow when the respective units are on the bus. The light goes out when that unit is tripped off the line, Ifa generator or a SCR unit becomes inopera- tive, continue the system operation on other units (2). Syne Malfunction. If the Synchroscope is inop- erative, use the Syne lights to parallel the genera- tors. If both the scope and the lights fail, use a multi- meter, ‘Switch the multimeter to read 600 Vac. Connect the meter across the circuit breaker from the top to the RHC SCR Drive System Technical Manual 1s bottom of any one phase. The voitage will swing from 0 to 600 Vac just as the lights flicker from bright to dim. Adjust the Speed Adjust knob until the swing slows. Close the circuit breaker when the voltage is minimum. (3). Transient AC Surge. The green Surge Suppression t will go out if a malfunction blows the incoming. line fuses. (4). Sprocket Slip. The Sprocket Slip light comes ‘on when MP assignment contactors are tripped due to a sprocket slip or chain failure of a mud pump mo- tor. After the chain drive has been repaired, push the Sprocket Slip Reset button to switch off the light and to allow the contactors to close. (). Ground Fault. The three Ground Detector lights and the %AC and %DC Ground meters flag ground faults. These are only indicators and the fault must bbe located and corrected. AC ground faults may occur anywhere along the AC power network: generator to AC bus cables, Feeder distribution to the AC motors, and the AC 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 needle will move as the faulty motor is speeded up or slowed down. H. Shut Down Instructions (1). Turn off the SCR unit by tripping the SCR circuit breaker. SCR On light will go off. (2). Remove the generator from the bus by tripping the Generator circuit breaker. The GEN On Line light will go off (3). Press the engine Idle button. Cool down the engine for a duration recommended by the manufacturer. (4). Shut down the fuel rack to stop the engine. 3. Capabilities Figure I-7 displays Current-vs-Voltage curve response of the SCR bridge. Figure 8 shows Speed-vs- ‘Torque curves for DC series and shunt motors. ‘SCR Drive SystemMODEL 1200, 1500 Generator On Line light 10 1 Engine Control switch ‘Synchronizing switch ‘Ammeter Select switch IL Voltmeter Select switch 12 Speed Adjust knob 13° Volts Adjust knob 14 % AC Ground Ammeter 15 % DC Ground Ammeter 16 Ground Fault Indicators 17 Ground Detector Test button 12 13 18 Power Limit light 19 Hertz (Frequency) meter 20 Synchroscope 21 Synchronizing lights Figure I-3. GEN Unit Controls and Indicators 1 GEN Cie Breaker 2 AC Kiowa mer 3 AC Kilovars tr 8 9 4 AC Ammeter 3 AC Votimter & Generate Ran ight $ s ° 0 RHCC SCR Drive System Technical Manual ‘SCR Drive SystemMODEL 1200, 1500 4 “7 Tem Description DC Voltmeter DC Ammeter Sprocket Slip Reset button SCR On light Sprocket Slip light Circuit Breaker Figure I-4, SCR Unit Controls and Indicators HOA Switch DC Ammeter (optional) Ammeter Select Switch (optional) Armature Current Unbalance Lights HOA Switch Circuit Breaker Flange Handle Note: Used only if rig is equipped with Shunt DC motors Figure 1-6. Figure I-5. MCC Controls and Indicators Field Supply Unit Controls and Indicators FA0008.4 FA.0000-4, HCC SCR Drive System Technical Manual ‘SCR Drive System18 MODEL 1201 Hem Description GEN Circuit Breaker AC Kilowatts meter ‘AC Ammeter AC Kilovars meter ‘AC Voltmeter Generator Run light, Generator On Line light ‘Ammeter select switch ‘Voltmeter select switch 10. Engine Control switch IL. Synchronizing switch 12 Speed Adjust knob 13. Volts Adjust knob 14, % AC Ground meter 15. % DC Ground meter 16. Ground Fault lights 17. Ground Test button © © 18 19. 20. Synchroscope 21. Hertz (Frequency) meter Figure I-3. GEN Unit Controls and Indicators RHCC SCR Drive System Technical Manual ‘SCR Drive SystemMODEL 1201 1 tem Description 1. DC Voltmeter 2 DC Ammeter 3. SCR On light 4 Sprocket Slip Reset button 5. Sprocket Slip light 6 Circuit Breaker Figure I-4, SCR Unit Controls and Indicators HOA Switeh DC Ammeter (optional) Ammeter Select Switch (optional) Armature Current Unbalance Lights HOA Switch Circuit Breaker Flange Handle Note: Used only if rig is equipped with Shunt DC motors. Figure 1-6. Figure I-5. MCC Controls and Indicators Field Supply Unit Controls and Indicators FA.0000- A006. RHC SCR Drive System Technical Manual SCR Drive System1410 MODEL 1600 Tem Description Item Description 1 AC Kilowatt meter 13 Ammeter select switch 2 Temperature meter 14 Engine Governor switch 3 Kilovars meter 15 Circuit Breaker switeh 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 switeh 8 Generator Run light 20 Synchronizing switch 9 Circuit Breaker Push to Charge button 21 Frequency (Hertz) meter 10 Ground Fault indicators 22 Synchroscope Il Ground Detector Test button 23 Synchronizing lights 12 Circuit Breaker indicators 24 — GEN Circuit Breaker Figure I-3. GEN Unit Controls and Indicators RHCC SCR Drive System Technical Manual SCR Drive SystemMODEL 1600 Mu Item Description DC voltmeter DC ammeter SCR On lamp Sprocket Slip Reset button Sprocket Slip light SCR Circuit Breaker Figure I-4. SCR Unit Controls and Indicators HOA Switch DC Ammeter (optional) Ammeter Select Switch (optional) Armature Current Unbalance Lights HOA Switch Circuit Breaker Flange Handle Note: Used only if rig is equipped with Shunt DC motors Figure 1-6. igure I-5. MCC Controls and Indicators Field Supply Unit Controls and Indicators FA.0000-A FA0004.4 RHCC SCR Drive System Technical Manual SCR Drive System12 MODEL 1400 Item Deseription | GEN Circuit Breaker AC Kilowatts meter 3. Killovars meter 4 AC Ammeter 5 Engine Run/Idle switches 6 GEN On Line light 7 GEN Run light 8 Push to Close 9 Speed Adjust knob 10 Volts Adjust knob 11% AC Ground ammeter 12% DC Ground ammeter 13 Ground Fault indicators 14 Ground Detector Test button 15 Synchronizing select switch 16 Frequency (Hertz) meter 17 Synchroscope 18 AC Voltmeter 19 Syne lights 20 Power Limit light Figure I-3. GEN Unit Controls and Indicators RHCC SCR Drive System Technical Manual ‘SCR Drive SystemMODEL 1400 ra 1 2 DC voltmeter 3 SCR On lamp 4 DCammeter 5 6 7 Description SCR circuit breaker Sprocket Slip lamp Power Limit lamp Sprocket Slip Reset button Figure I-4, SCR Unit Controls and Indicators HOA Switch Circuit Breaker Flange Handle DC Ammeter (optional) 1 2. Ammeter Select Switch (optional) 3. Armature Current Unbalance Lights 4, HOA Switch Note: Used only if rig is equipped with ‘Shunt DC motors. Figure 1-6. Figure I-5. MCC Controls and Indicators Field Supply Unit Controls and Indicators FA.0000-4, FA9004. RHC SCR Drive System Technical Manual SCR Drive System14 co e +5 | [1 | 1 ' es Ee LL cag | T | y{—t ele 1 1 T t + 1 1 200409600800 000 OO 14G0 1600 1890 2000 AwPS. sc-0012-A Figure I-7. SCR Bridge Current-vs-Voltage Curve ‘TORQUE FT-LBx Series 000 Shune = T . +t Lo FIELO CURRENT= 80.8 A 1 7 are roams ‘SPEED IN RPM x00 AT 750 A, EMD-D79 Motor B. GE-752 Motor pure 18, speed-eTorque Care e HCC SCR Drive System Technical Manual SCR Drive Systemwr Ul, MAINTENANCE This chapter contains information to assure proper operation of the system through periodic functional tests and preventive maintenance. If the system fails to perform as indicated in the func tional test instructions, consult the troubleshooting lines listed in Chapter II. 4. Receiving & Handling ‘The SCR switchgear is normally installed in a truck- load size house. See figure I-l. The house is a self-contained, structural steel building mounted on oilfield skids. Cabling to external devices such as generators, motors and control consoles is termi- nated at weatherproof plug panels If the house is not ordered, the equipment should be handled with care to prevent excessive mechanical shock, and protected from possible damage due to moisture and dirt during rig-up. See figure 1-2 for cubicle lifting procedure. 2. Installation See figure 11-3 for a typical layout of switchgear in a SCR house. Figure II-4 is an elevation drawing, IE SCR house is not ordered, refer to the following instructions, Figure Il-1. Typical SCR House PLUG PANEL RHCC SCR Drive System Technical Manual ‘SCR Drive System2 A. Cubick (1). Preliminary Considerations (A). 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. (B). Ventilation and Ducting. The room air must be changed twice per minute when the cubicles are en- closed in a room. Ducting in the front and rear of the room should force the air to flow the full length of room, (C). 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. (D). 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. (2). Location Lift the cubicle with a crane into the general instal lation area. Use four lifting points per cubicle. Refe. to figure II-2 for the lifting procedure. Use hydraulic hand trolleys (Rol-A-Lift or equiva- lent) 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. (A). Slide the trolley fork all the way underneath the cubicle. (B). Jack up the cubicle approximately 6 in. (15 em) above the floor. (C). Push the cubicle carefully into the location, jack down, and remove the fork. (3). Mounting (A). Butt the cubicles tightly side to side. (B). Bolt the cubicles together at the top and bottom using % in. by 1% in. bolts. (©). Install the AC bus splices to connect the bus together from cubicle to cubicle. RHCC SCR Drive System Technical Manual (4). Cable Installation Refer to the cabling diagrams in the SCR job book. Cables between the cubicles are furnished by the customer, All power terminations are made through the top of, the cubicles. A minimum 18 in, (46 cm) clearance is required for the cable tray. The terminations are silver-plated copper stubs with ‘one 4 in, diameter bolt hole. The customer should furnish one hole, plated copper, crimp-type lugs. Screw type pressure connectors should not be used. B. Control Consoles ‘The Driller’s Console is mounted on top of the Draw- works pneumatic control console. The Pilot House and the Engine Room consoles are welded to the floor in the respective rooms. The Mud Pump and Cement Pump consoles are provided with two stubs each with a 4 in, diameter bolt hole, for wall instal- lation. Refer to the respective console sections 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. 3. Testing This section contains information to test the proper functioning of the SCR Drive System. Perform the test daily. If the system fails to satisfy any part of the test, refer to the Troubleshooting section to lo- cate the malfunction. Safety Precautions If carelessly handled, the SCR Drive System can in- flict grave injury. Safety precautions must be ob- served at all times to prevent electric shock. (1). Team Work Maintenance work should preferably be performed by a team of two electricians. This assures help in an. emergency situation. (2). Personal Wear Do not wear metallic watch straps, rings, or bracelets, (8). Live Circuits Consider all circuits to be energized unless known to be dead. SCR Drive System13 \eeaare Figure 11-2. Cubicle Lifting Procedure ‘SCR Drive System RHCC SCR Drive System Technical Manual14 2a Figure 11-3. SCR House Layout RHCC SCR Drive System Technical Manual FRONT ACCESS SCR Drive SystemDOUBLE ACCESS | 4 | | els | § 4 aif i § : | [rasa | RHCC SCR Drive System Technical Manual Figure II-3 SCR House Layout 1s SCR Drive System16 MODEL 1200-1500 | : BE ' Hf ' i L al Figure II-4 SCR Drive System Cubicle Elevation RHC SCR Drive System Technical Manual SCR Drive SystemMODEL 1600 ™ Figure Il-4 SCR Drive System Cubicle Elevation Details RHCC SCR Drive System Technical Manual SCR Drive SystemLad MODEL 1400 0000 po 200 Pe eal | gnu) o. eo a: ete | A ‘ Bod] # a Figure IL-4 SCR Drive System Cubicle Elevation Details RHCC SCR Drive System Technical Manual SCR Drive System(4). 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, (6). Fuses, Close a fuse by pushing on the plastic cover, Do not place a finger underneath the cover. (8). Fire Remove power to the unit under fire, Read the label con the fire extinguisher to be sure it can put out an electrical fire, Water may be used instead B. 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. @). Check Ground Detector indicators. All three lamps should glow a dim orange. The Ground Fault Percentage meters should read close to 0. @). Check field current supply of all shunt motors. @). 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 both A and B motors of mud pumps ‘and drawworks are sharing the load by watching the SCR volt and ammeters. (), Ensure that all SCR blowers are running. (8). Check waveshape of SCR Amps at test pins ‘on the DC Control Module. See the SCR Unit section for further details. C. Monthly Test Perform the Engine Overspeed and Reverse Power Functional tests. Refer to Generator Unit section for instructions 4. Servicing Servicing consists of cleaning the system components and replacing those which have become defective or worn out. Periodic servicing will make the Ross Hill SCR Drive System more reliable and last longer. A reliable system is less likely to suffer sudden failures oF deteriorate below the performance specifications, ‘The system components are vulnerable to three fac- tors: inferior quality, harsh operation and severe ‘environment. A. Quality Efforts to eliminate this source of failure are made RHC SCR Drive System Technical Manual 119 at Ross Hill Controls manufacturing and testing facility. The system is rigorously tested through every phase of operation. The clectronic modules are placed in ovens at 165°F (75°C) for 168 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, B. Harsh Operation ‘The drive system should be operated within its ca- pabilities. 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. C. Environment (1), Heat Components can fail suddenly due to overheating. Even though the drive system is rated between -22°F (-30°C) through 122°F (50°C), the system operation is more reliable at normal temperature. Components age faster at temperature extremes, The six blowers in each SCR cubicle dissipate 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 assemblies frequently for indications of overheating such as charring or burned insulation due to loose connections. Replace the damaged com- ponents even though they may not have failed com- pletely. (2). Vibration ‘The drive system units do not generate vibrations. However, vibrations from rotating machinery such fas the generator set_cause mechanical stress which can loosen connections and crack insulation. (3). 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. (4). Molsture Moisture aggravates problems caused by dust. The contaminants cake on the components and con- ductivity is increased. Further, corrosion can occur. Servicing consists of three operations: cleaning, inspection, and replacement. D. Cleaning le and component surfaces with Wipe clean the cut SCR Drive System140 a lint-free cloth moistened with a mild cleaning sol- vent. Be sure to leave the surfaces dry. Caution Turn off the system before cleaning, Test the clean- ing solvent on a small surface to make sure it does not damage the plastic parts or insulation, or remove paint. E. Inspection ‘Check the system components for indications of ‘overheating and corrosion. Replace the damaged components even though they may not have failed completely. Inspect the cables and wires for broken cor burned insulation. Tighten all loose connections. Check the switches, knobs, and buttons for easy movement between the positions. Caution Careless inspection itself can cause malfunctions. Do not tug cables and wire harnesses, shake the electronic assemblies or fiddle with the knobs. Em- ploy visual inspection as far as possible. RHCC SCR Drive System Technical Manual ‘The servicing period depends on the operating con- ditions. Adhere to the following schedule during the initial period and adjust it according to need. F. Weekly Servicing (1). Clean all cubicle and air conditioning filters. @). Check Driller’s Console and Foot Throttle for air pressure. If there is moisture inside the compartments, the drier in the air line may be clogged. @). Check assignment contactors. Inspect the coils for signs of overheating such as discoloration or charred insulation. Check contacts for cor rosion or pitting. (4). Clean tachometer pickup plugs. Do not screw pick up in oo far. Flywheel will damagecoil upon starting diese. G. Quarterly Servicing ‘Clean and inspect the system components as it cated in the previous section. Tighten the bus bar bolts. SCR Drive SystemIll. TROUBLESHOOTING ‘This chapter provides information to isolate a mal- functioning unit of the SCR Drive System. Troubleshooting consists of first looking at the broad possibilities of failure, and then breaking down, the likely possibility into successively smaller trouble- spots. This consists of examining the whole system as itis situated between the generators and the loads, and then narrowing the search to a cubicle or console, then to an internal assembly, and finally to a com- ponent. The malfunction can be quickly located by seeking out signs of trouble, such as extreme read: ings 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, 1. Malfunction Analysis Troubleshooting is easier and faster if the nature of the malfunction is pinned down. Sometimes, the faulty behaviour of the system may be caused by operator error, For example, the Driller may forget to turn on the lockout switch, open the throttle, and assume that the SCR unit is defective. ‘The faulty behaviour of a motor or generator may be blamed on the SCR system. Make sure the fault is not outside the system before making extensive te~ pairs such as replacing a SCR cell. Ifthe malfunction occurs off and on, it may be useful to keep a log of the system parameters with a strip chart recorder. 2. Analysis of Front Panel Indicators Many malfunctions can be located by analyzing the ‘meters and lights on the front panel. 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 in- formation. 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. RHCC SCR Drive System Technical Manual 3. 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 U1 ‘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 sus- ppected units. Then examine the inputs to the faulty unit. If one of the inputs is incorrect, trace that in- put to its originating unit. If, however, the inputs are correct, troubleshoot the unit. Isolate the fault to 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 are correct, then the cell itself is defective. ORLLER'S a ‘CONSOLE oo : 1 oc circurr ELECTRONIC rae, BREAKER ca GATE FIRING ‘Ac SUPPLY SCR BRIDGE. 0-780 voc SUPPLY CONTROL Figure ITF, A System Block Diagram 188-0000-8 SCR Drive Systemm2 4, Signal Tracing ‘The defective unit can be easily located by tracing signals associated with the malfunction. Refer to figure III-2, The motor can be operated ‘on any one of the two power lines. 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 switch- ing 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 tied (0- ether in series. If the 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 the power supply is present, then obviously, the motor is de- fective. We need not probe further. If the power supply is absent, 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. Similarly, the signal tracing should be continued all the way back to the Generator until the defective component is located. In extremely long series cir- cuits, it is convenient to divide the circuit in half. Begin the probe in the middle and trace the signal toward the side on which it is absent. 5, Special Tools and Equipment The following instruments are needed to trouble- shoot the SCR Drive System, A. Multimeter A Triplett Model 630 APLK Weston Model 622 or equivalent is recommended to measure voltage and resistance values. The meter should be insulated, and, be rugged enough to withstand drilling rig conditions. DC/AC Volts: 0 through 1000 in several ranges Accuracy: 3 percent of full scale. om through 10 M ohms in several ranges. ‘Accuracy: 2 percent of are length, B. AC/DC Clamp-On Ammeter The meter is used to safely measure high currents. Columbia 1000A is recommended. C. Oscilloscope ‘Tektronix Model 305 is recommended. The scope should have at least a 3 in, diagonal viewing screen, and two channels for comparing two signals. The scope is used to check the SCR gate pulses and ripple on various DC voltages. & - a + ~~ LO RHCC SCR Drive System Technical Manual ‘SCR Drive SystemIV. REMOVAL & REPAIR 1. Cubicle A. Removal If a cubicle is damaged beyond repair, follow the removal instructions listed below: (1), Disconnect power cables from the bus stubs lo- ‘cated at the top of the cubicle. (2). Remove bus links which connect the AC bus from cubicle to cubicle. (3). Remove the 3" x 14" bolts which join the cubicles at the top and bottom. (@). Slide the fork of a hydraulic hand trolley under- neath the cubicle and jack it up approximately 6" above the floor. (8). Pull out the cubicle carefully, taking care not to bump the adjoining cubicles. B. Repair Repair of the SCR Drive System normally consists of repairing an assembly within a system unit. A sys- tem unit is not replaced unless it is damaged beyond repair. When a unit is replaced, perform its functional test before operating the system. Refer to the respec- tive unit manual for test instructions. 2. Control Module Ifa control module is malfunctioning, replace it with the spare module and return the faulty module to RHCC. See figure IV-1 for removal and assembly instructions. a eit LE the cover. ‘module to the cubicle wall. Zao T7 Unscrew Deutsch fastener at top and swing open 3. Unserew the four Deutsch fasteners which hold the Figure IV-1. Module Removal & Assembly “et 2. Release the wiring harness by removing each wire from the terminal board by loosening the retaining serew. 4, During installation of the new module, be sure to match up wire number to the pin number. RHCC SCR Drive System Technical Manual CR Drive SystemSCR DRIVE SYSTEM 10. IL 12, 13, 14, 15, AC pe 540, 40 SCR Pucks Cy Reverse Power Overcurrent Voltage Adjust Knob Out One Energized Drillers Console Reetifies DC+ De ‘Swap AC module Field current Review Answers. 10. Alll Generators are Applied to a Common Bus. Power Limit Exciter and Bridge Voltage Series Motors ‘Trip the Generator Circuit Breaker . Pushing Reverse Power Reset Button on Front of Gen. Cubicle The Primary Control for the DC Functions Once a Month 3. When SCR Fuses Fail Armature or FieldSCR UNIT AOS HILL CONTROLS CORPORATION SmSCR UNIT 10. nL. 14, 15. ‘Review Questions: =A- ‘The three phase, full wave SCR bridge contains ___ SCR’. ‘An SCR is controlled through firing pulses applied to the gate to deliver a variable Oto. ‘Vde to the traction motor. SCR circuit breaker is tripped by overcurrent, overtemperature, ________and ‘when the ______ on the Driller’s Console is pressed, |. Firing circuits in the DC module are enabled when the module received the proper. and —___ inputs. For test purposes, the SCR bridge can be phased up by setting the manual voltage switch to on and rotating the ________ knob on the DC module front panel. . Overtemperature switch opens if the SCR heatsink temperature exceeds ___ degrees. . SCR turns on when the anode junction is more positive than the cathode only ifthe gate is through a current pulse. Each SCR receives two pulses during a cycle. The first pulseis called the main pulse and the second pulse is called the _____ pulse. 1. Each SCR requires two pulses each cycle to ensure operation during discontinuous current. DC Module has ____ firing circuits that generate these pulses. Ross Hill system restricts the firing angle between 10 degrees to ___ degrees. Surge Suppression circuit clamps on the AC bus which can damage the SCR bridge. . Ground Detection circuit lights glow dimly during ________ operation. ‘When replacing an SCR, itis important to tighten both bolts of the clamp an___amount and to the "value. In order to phase up an SCR bridge assigned to run traction motors on a mud pump, the DC module must receive the appropriate ________ and __vollages that cor- respond to the motor being turned on. The DC regulator requires _______ and ____ feedback to provide control of the traction motor. 1SCR UNIT a Review Questions: —Be 1. Surge Suppression network, across the SCR, filters spikes from the AC bus which might cause the SCR to A. Overheat B. Misfire C. Turn off D. Vibrate 2. The Ross Hill system utilizes __ SCR firing cireuits A6 B. 12 C8 D. 16 3. When the bridge output current is 1000 amps, current feedback voltage to the DC module will be: A. 46.8 Vde B. -14 Vac C. 2.67 Vde D. II Vac 4. A460 V is wired to one side of each contactor in the SCR cubicle. To close the contactors a control signal is necessary. A. +4 B-I4V c. 0 D.-24V ‘5, Firing pulses come out of the DC control module on pin ______ through pin A. 154 through 134 B. 137 through 160 C. 139 through 150 D, 124 through 125 6. Firing order of the SCR’s in a bridge is A.C, Ct, As, At, Be BY B. B+, C-, At, B, Cr, Ae C. At, As, BY, Be, Cr, C- D. By At, Cs Be, As, C+ 7. Its possible to check for the appropriate throttle voltage and pull in assignment contactors with- out applying power to motors by ‘A, Jumpering auxiliary contacts of the SCR breaker B. Energizing the bus CC. Closing the safety fuses D. Switching the manual voltage switch to on ness bt FONTROUE CORPORATION SSSCR UNIT Review Questions: 8. SCR On light on the front of the SCR cubicle will turn on when A. Traction motors are running B. Driller pushes the Emergency Off button C. Trigger fuse on an SCR enclosure is blown D. SCR breaker is closed 9, Bridge voltage is processed in the Voltage Feedback card to develop Voltage Feedback signal. It is then sent ot the DC module to A, Develop Speed feedback B. Act as Speed reference C. Develop firing pulses D. Drive the ammeter on the SCR cubicle 10, Lamp on the Surge Suppression network is normally A. Off B. On to indicate normal operation C. On to indicate a blown fuse D, Flashes when surges are being suppressed. 11, If all three lamps on the Ground Detection circuit glow brightly, itis an indication of A. Normal condition B. AC bus ground on A phase C. DC ground fault D. Malfunction of the ground fault circuit 12, Sprocket Slip circuit is necessary when two series motors drive the mud pump froma single SCR bridge because An unloaded series motor will overspeed Broken chain would force one motor to maintain the full load Slipping sprocket wastes mud Two blowers are utilized poe nos mit Connon CORRORATION!1, OPERATION ‘The SCR Unit rectifies the three-phase AC supply to provide a continuously variable DC supply to the traction motors. The SCR bridge, which performs the rectification, is isolated by a circuit breaker from the ‘AC bus. The bridge output is assigned to one of the motors via contactors. The contactors are closed in pairs (DC + and DC —). See figure I-1 ‘The contactor logic and the DC voltage level are controlled from the Driller’s Console. Electronic circuits in the DC control module regulate the volt- age and current within preset limits. al. If one unit is down, another is usually available to maintain power to the motor. Similarly, the electronic DC Modules and SCR cells of the bridge are interchangeable. 1. Specifications (1). Electrical See figure 1-2. (2). Mechanical Specifications (A). Cubicle, The assemblies are mounted within the cubicle, on the side and door panels and a slide pan located below the blowers. (B). Controls and Indicators. These are mounted on the cubicle and on the electronic DC module front panels. (©). DC Module. Many of the electronic circuits associated with SCR rectification and control are as- sembled on a single printed circuit (PC) card. The SRT ‘scr 2 “ys | 4 7 aus ‘80R BRIDGE. = i Figure 1. | SCR Unit One Line Diagram 4OF motor 2-0000-4 RHCC SCR Drive System Technical Manual SCR Unit,(A), Three Phase AC Input 1. Voltage: 600 Vac 2. Frequency: 60 Hz (B) DC Output per SCR Unit 2.Current: 0 to current limit valve Amps continuous at stall through maximum volts. 3. Current Limits: Different limits are selected to allow maximum horsepower and torque to be obtained from Rig Equipment without exceed- ing Manufacturers ratings. Refer to label on top of each DC control module to verify current limit settings. (©) Circuit Breaker ‘The circuit breaker has an overcurrent mag- netic trip circuit. It also has an undervoltage (UV) or shunt trip circuit which is triggered for fuse failure and SCR overtemperature. 1. Current Rating. These values available on system one line print 2. Overtemperature Rating. The overtemp- erature switch, associated with each SCR, is set at 165°F (74°C), RHCC SCR Drive System Technical Manual card and associated components are housed in a mod- ule constructed from 12-gauge cold-rolled steel. The module has its own heat sink, ize: 4 in, W by 12 in, D by 12 in, H (10 em W by 30 em D by 30 cm H) Weight: 21 Ib (9.5 kg) (D) Forced-Ventilation System The ventilation system consists of two or six air blowers located below the SCR bridge. 1. Air Flow Rating. 400 cubic meters per minute through each SCR cell. 2. Each bridge may require Three motors or a single motor to power the blowers. Each motor turns two blowers connected at either end of its shaft. Voltage: 600 Vac single phase Current: Approximately 1.0 Amp Speed: (RPM 3. Intake Air Filter Rating, Filters are located on the front and back below the bridge. They consist of ex- panded aluminum gauze enclosed in a metal frame. They have an MBS (Master Bureau of Standards) rating of 12 to 15 percent, which is sufficient to trap ‘common dust particles. w. The SCR is mounted within a set of enclosures de- signed to provide insulation and heat transfer, and to dampen mechanical vibration. The entire assem- bly is called the SCR enclosure. ICR Enclosure ‘The innermost assembly consists of the SCR enclosed oon either side by aluminum heatsinks. A two-bolt clamp is tightened to press the heatsinks into the SCR, Pressure exerted on the SCR is indicated by a gauge located on the top side of the enclosure, SCR Unitmm ll, MAINTENANCE This Chapter contains specific functional tests to assure proper operation of the SCR unit. # Perform the tests after repairing or replacing any Of the unit assemblies. © If the unit fails to perform as indicated, refer to the troubleshooting index in Chapter III to locate the malfunction, Refer to Chapter III Troubleshooting for explana- tion of the various SCR unit circuits, and Chapter IV Removal and Repair for identification of the com- ponents. See figure Il-1 for a front panel view of the DC Control Module. The Test Select switch enables a quick check of the Contactor (CONT) and Throttle Reference (REF) signals received from the control console. The switch and Test meter are color coded. For example, if the select switeh is set to one of the yellow CONT positions, the Test meter needle will deflect to the yellow band to indicate a normal condition. The SCR bridge can be phased up for testing by setting the Manual Voltage switch to “on” and rotating the knob clockwise. In he “on” position, the switch opens all assignment contactors so that power is not applied to the DC traction motors. Bridge voltage can be monitored at the SCR Volts test pins. The ratio is 15:1 such that the test pins will be at 50 Vde when bridge voltage is 750 Vdc. SCR Amps test pins should register 2.66 Vde per 1000 amps bridge current. The Zero Throttle Interlock light indicates opera- tional status of a circuit in the module which sup- presses the Firing Reference for the SCR bridge. ‘When the light is on, bridge voltage will be 0. The light is on under two condtions listed betow 1, SCR Unit is on but not assigned to any of the DC functions, 2. SCR Unit is assigned to a function before the throttles are set to 0. The light goes off when the throttles are set to 0 and assigned contactors pull in. RHCC SCR Drive System Technical Manual Item Description Power On light Test Voltmeter Test Select switch Manual Voltage knob Manual Voltage switch Zero Throttle Interlock SCR Volts test pins R Amps test pins Figure 1-1. DC Module Controls and Indicators SCR Unit2 ACTION RESULT I. Preliminary 1, Ensure that SCR Unit to be tested will not be assigned from the Driller’s Console. 2. Energize the AC bus, if required. 3, Close the SCR circuit breaker. SCR Bridge Check 1. On the DC Module, set the spring-loaded Manual Volts switch to “on”. 2. Rotate the Manual Volts knob slowly clock- wise to “Max.” and back down to “Min.” IIL. Contactor and Throttle Check |. Trip the SCR breaker. 2. Jumper the auxiliary contact of the breaker (TB8-4,5). 3. Set the Driller’s Console assignment switch to various positions. 4, Remove aux. contact jumper when all CONT and REF signals are checked out. A. SCR On light will glow. B. Blowers under the SCR bridge will switch on, C.On DC Control Module, Power On and Zero Throttle Interlock lights will glow. Observe the front panel DC voltmeter. The voltage will climb smoothly to 750 Vde as the knob is rotated clockwise, and return to 0 as the knob is rotated coun- terclockwise. This will allow us to close the assignment contactors without applying power to the motors. In each position, check contactor (CONT) and Throt- lle Reference (REF) signals from Driller’s Console. Ex: Suppose RT is assigned to the SCR Unit in 1 o'clock position. Then RT CONT (pin 129) and RT REF | (pin 130) can be checked Table I-1. SCR Unit Test RHCC SCR Drive System Technical Manual SCR UnitACTION 13 RESULT I, Module Power Supply Check Energize he AC bus, if necessary. IL, Firing Pulse Check 1. Ensure that SCR Unit under test will not be assigned at the Driller’s Console. 2, Open the SCR circuit breaker. 3, Set the spring-loaded Manual Volts switch to On" and turn the Manual Volts knob a ‘4 turn, 4, After completing the test close SCR breaker. Be sure Manual Volts switch is off, Confirm following voltages at DC Module. Voltage Location 12 Vae Pins 103-108 +14V Pin 153 =14V Pin 154 SCR On light will glow and blowers will switch on. Check firing pulses to each of the 6 SCR’s with an oscilloscope. Example: Place the ground lead on K terminal of the Firing Pulse transformer and Probe on the G terminal, See figure II-1 for a typical waveform, SVD, 2mS/DW. Figure II-1. SCR Firing Pulse ‘Table RHCC SCR Drive System Technical Manual 2. SCR Bridge Test Sheet 1 of 2 SCR UnitACTION RESULT IIL, Feedback Check Check ripple of the Voltage Feedback signal across SCR Volts test pins on front of DC Module. See figure II-2 for the waveform. The waveform provides an indication of firing of the SCR's, Note that there are six peaks. Each SCR contri butes a peak. Goop BAD BAD Figure II-2. Voltage Feedback ‘Table 11-2. SCR Bridge Test Sheet 2 of 2 RHCC SCR Drive System Technical Mai SCR UnitIs ACTION RESULT |. Isolate Faulty SCR 1, This is accomplished by comparing the Cur- rent Feedback ripple and SCR firing pulses on a dual trace oscilloscope while the SCR Unit is driving a load. 2. During each 60 Hz cycle, there are six peaks in the ripple. Each of the six SCR’s in the bridge contributes a peak. If one of the SCR’s does not fire, a peak will be missing. If the SCR misfires, one of the peaks will be distorted. 3. To idemtify the faulty SCR, compare firing pulses (pins 140, 142, 144, 146, 148 and 150) to each of the six SCR’s with the current feedback ripple (pin 131) Firing pulse which is in syne with the missing or distorted peak is the one going to the faulty SCR. See figure 11-4 See figure II-3 for the Current Feedback wave- form (pin 131) or at SCR Amps on front of DC Module. 02vIDW, Oat -3 [rom frm SCR MISFIRING SCR NOT FIRING ‘SA.0007 Figure II-3. Current Feedback SVD Figure II-4, Current Feedback- Firing Pulse Comparison ‘Table 11-3. SCR Test Sheet 1 of 2 RHCC SCR Drive System Technical Manual SCR UnitACTION RESULT SCR Resistance Test 1, Trip the SCR circuit breaker. 2. Switch Multimeter polarity to “+7 and the seale to “R x 10,000”. 3. Test the meter by joining the “+ ”” and“ leads. 4, Disconnect the SCR Gate (G) and Cathode (K) leads. The SCR does not have to be re- moved from the heatsink. 5. Measure resistance across the SCR by touch: ing one lead to the AC bus bar and the other lead to the DC bus bar. 6. Measure resistance across the SCR in the reverse direction, interchanging the leads. 7. If the SCR is not installed in heatsink, lacks pressure, it will not be possible to make resistance test. ‘The meter needle will swing to indicate 0 ohms. It should be in the Meg ohms. The SCR is leaking if the resistance is less. You will see the charging, action of snubber capacitor that is across SCR Let meter stabilize before taking final reading, Again, the resistance should be in the Meg ohms Table 11-3. SCR Test Sheet 2 of 2 RHCC SCR Drive System Technical Manual SCR Unit1 Il. TROUBLESHOOTING ‘Troubleshooting consists of locating a malfunction- ing component in the SCR Unit. The troubleshooting index in the back of this chapter provides specific instructions, The following Theory of Operation Provides an explanation of the various circuits in the unit, 1. Theory of Operation See figure IlI-2 for the SCR Unit schematic diagram Gireuits in the unit can be grouped as follows: A. SCR Bridge B. Surge Suppression Circuit C. Ground Detection Circuit D. Contactor Control Logic E. DC Module F. Sprocket Slip Circuit A. SCR Bridge See sheet 1 of figure 111-2. A 30 AC supply from the bus is applied to the SCR bridge through a circuit breaker. Each AC phase is connected to two SCR’s. ‘One SCR feeds positive AC portion to the DC (+) bus and the other SCR feeds the negative AC portion to the DC (~) bus. For example, @A is connected to A+ and A~ SCR’s. A+ SCR feeds the DC (+) bus while the A— SCR feeds the DC (—) bus. DC (+) and DC (-) buses are connected to traction motors via assignment contactors. The SCR’s are switched on and off to vary the DC level through firing pulses applied across the “Gate” and “Cathode” terminals of each SCR. The firing pulses are generated in the DC Control Module. See sheet 2 of figure III-2 and figure I-1 Refer to Unique Devices section for a general de- scription of an SCR. Circuit Breaker. The breaker is equipped with a set of auxiliary contacts. A normally open contact is interlocked with the front panel “SCR On” light. Another normally open contact is a part of the Assignment Contactor logic. The breaker also has a UV Trip coil. The breaker is tripped automatically if 28 Vde power supply to the coil is interrupted. Positive terminal of the coil is permanently connected to a +14 Vde power supply. ‘The negative terminal is connected to a ~14 Vde RHCC SCR Drive System Technical Manual supply through various normally closed switches which signal the following hazardous conditions. + SCR Overtemperature. There are two temperature sensors. Sensor TI is mounted on the DC (+) bus and T2 is mounted on the DC (~) bus. The sensor contact is designed 10 open when the SCR junction temperature exceeds 220°F (125°C). ‘© Blown SCR Fuse. Fuse protection for the SCR consists of two 600 amp fuses mounted in parallel. The UV Trip circuit is wired through trigger fuse microswitches of all the SCR’s, A trigger fuse is connected across each Main fuse assembly. If a main fuse blows, excess current flows through the trigger fuse, blowing it as well. The trig- ger fuse has a long plunger which is set close to the microswitch arm. When the fuse blows, the plunger pushes into the arm, causing the microswitch contact to open, * Emergency Off. The UV Trip circuit is also inter- locked with the normally closed “Emergency Off" button on the Driller’s Console. Current Feedback. Three Current Transformers (CT1, CT2 and CT3) are used to sense current flowing into the SCR bridge. On PCI board, the CT signals are rectified and the resulting DC output divided through a resistor circuit. One signal is used to drive the front panel DC ammeter. The other signal is applied to the DC Control Module as SCR Amps (Pin 131), SCR Amps signal is 2.66 V per 1000 amps out of the SCR bridge. RLC Filter. A ferrite core is used for each SCR along, with an RC circuit connected across the SCR, forms. an RLC filter. The filter is designed to reduce rate of change of voltage (dV/dt) through the SCR. The line reactors also reduce current change rate (dl/dt) Excessive dV /dt or dl/dt can cause the SCR to misfire and burn out. Firing Pulse. A Pulse transformer is used to invert and double the SCR firing pulse supplied by the DC Control Module. The current pulse rises in less than 20 n Sec. to approximately 1 amp to “hard fire” the SCR. It then descends to a 0.5 amp “*backporch” to force more and more of the SCR to turn on through a regenerative process. See figure III-1 SCR Unitm2 1A Scneuaric «GRAM ~~ o rhe | ke A+ are 2 a ‘ care pa As care ‘ ——s| « catwooe are Fe LJ 8 aare vouce cweury tov ov -v Vi 1 Cleearevournce Ft +m \ 1°“ ourron AL ! te oy “8 } r Vaal \ 1 | \ Vy it il it 1 \ 1 oot \ \ | tt gee pt pt i, | Gatene | | i 1 yt Aan * I ! 1 1 casos | ! 1 AL —asceronen bel wsEe k—— se | Figure IL-1. Firing Pulse sc-0085-0 RHCC SCR Drive System Technical Manual SCR Unit113 DOUBLE ACCESS (1200, 1500, 1600) ona EP = —— ao mifece ove aa ev woe OF SCR Unit Figure 111-2. SCR Unit Schematic Diagram Sheet 1 of 2 RHCC SCR Drive System Technical Manualtd DOUBLE ACCESS (1200, 1500, 1600) ee Can Ca Figure HII-2. SCR Unit Schematic Diagram Sheet 2 of 2 RHCC SCR Drive System Technical Manual SCR UnitUKs MODEL 1400 Figure 111-2. SCR Unit Schematic Diagram Sheet 1 of 2 RHCC SCR Drive System Technical Manual SCR Unitae MODEL 1400 & Figure II1-2. SCR Unit Schematic Diagram Sheet 2 of 2 RHCC SCR Drive System Technical Manual SCR UnitVoltage Feedback. The DC (+) and DC (.) buses are tapped to develop a I:15 analog of the SCR bridge volts. Signals from the bus are dropped through a set of 3.9 kM resistors used to drive the front panel SCR Voltmeter. The other is a differential signal Vbr+ = Vor- which is applied to the DC Control Module (Pins 101-102) for use in the DC Regulator circuit. When the bridge voltage is 750 Ve, voltage aeross Vbr+ - Vbr- is 50 Va Regulator Power Supply. See sheet 2 of figure III-2. ‘Transformer TS supplies 46 Vac, 36 to PCI board where it is rectified to 60 V for contactor power supply. Italso supplies power for the front panel “SCR On” lamp. Star winding of transformer T4 supplies six 12 V phase voltages to the module (Vea, Vcb, Vab, Vba, Vbe and Vac — pins 103 through 108). These signals are used to synchronize firing pulses for the six SCR’S and derive #14V power supplies. B. Surge Suppression Circuit This is a RC circuit which filters transient spikes fon the AC bus. Loss of the circuit does not disable the drive system but does increase the likelihood of damage to the SCR cells, See figure I1I-4 The line input is fused and then rectified through 4 diode bridge. DC output from the bridge charges a capacitor bank to 1000 Vdc. A 250 , 225W resistor limits the charging current to 35A. About 30 mSec. after power is turned on, relay KI energizes to short out the resistor. It takes 30 mSec. for KI contacts to close, Excess charge caused by a spike is discharged through the resistor bank. When power is turned off, the capacitors are also discharged through the resistor bank. Warning The capacitor discharge takes 10 seconds. Do not touch any part of the cireuit during this period. The front panel Surge Suppressor light is normally on, It will go out if any of the line fuses are blown, The line fuses are linked via trigger fuses (F4, FS, and F6) to microswitches (S1, $2 and $3) whose normally closed contacts are in series with the Surge Suppressor light circuit. When a line fuse blows, RHCC SCR Drive System Technical Manual M7 the corresponding trigger fuse blows, causing its plunger to trip the microswitch. C. DC Ground Detection Circuit Refer to the schematic diagram, figure 111-3. The circuit consists of three lights connected on one side toa phase of the AC bus and grounded on the other. A series-connected meter indicates percentage of the fault The lights glow dimly during normal operation. A DC ground fault completes the circuit through all the bus phases, so that all the three lights glow brightly. A positive reading on the %DC Ground meter indicates a ground on one of the DC buses. Caution ‘The circuit is only an indicator. The ground fault must be quickly located and corrected. Refer to the GEN Unit section for details on the AC Ground Detection circuit. D. Contactor Control Logic ‘The bridge output is assigned to one of several trac- tion motors by closing the appropriate contactors The contactor logic is set through the Driller's Con- sole assignment switeh, Single pole contactors are used to assign motors which turn in only one direction. For reversing motors, the outputs of the single pole contactors are applied to the armature of the motor via a double pole contactor. This contactor reverses the armature leads to reverse the motor. ‘The power contactor coils require a 74 Vde power supply to energize. The positive terminal of all coils is hardwired to a #60 V power supply. A -14 V supply is applied to the negative terminals of the coils via a series of contacts to ensure that all conditions are satisfactory to power the assigned motor. If any fone of the contacts in this control logic opens, the power contactors trip and the SCR bridge is phased down, ce figure III-S for a typical control logic schematic diagram. The figure highlights the control signal route when the Rotary Table is assigned to SCR 3 at the Driller’s Console assignment switch, and the RT “FWD-REV” switch is se to "REV", SCR UniU8 See assignment switch configuration at the top right corner of the schematic. Note that RT can be run on either SCR 2, SCR 3, or SCR 4. ‘See RT motor connections at bottom left corner of the schematic. SCR 3 bridge is connected to the RT motor through single pole contactors KI and K6 and reversing contactor KS. Now observe K1, KS and K6 coil connections in the ‘middle of the schematic. Note that positive terminals, of all the coils are connected to + 60V. Next, trace the ~14V control signal. The —14V power supply in the DC Module is first passed through the Manual Volts switch that is normally closed. It is opened for test purposes to phase up the SCR bridge without applying power to the trac- tion motors. ‘The signal emerges from the module as CONT PS at pin 134, It is routed through a normally open auxiliary contact of the SCR 3 circuit breaker. The contact closes when the breaker is closed, thereby assuring that the SCR Unit is turned on. Next, the control signal is sent to the Driller’s Con- sole where it turns on the SCR 3 On light. The signal is also connected to one side of the assign- ‘ment switch. It emerges on the other side at the 3 o'clock contact since the assignment switch is set to the 3 o'clock position, Next, the signal passes through “REV” contact of the RT lockout switch. Consequently, col of contactor KS is energized. Further, the control signal is routed through all the normally closed auxiliary contacts of power contactors in the SCR 3 Unit other than KI, KS and K6. This assures that the bridge output is not connected to two motors at one time. Next, K1 and K6 coils are energized. To ensure that their contacts have closed as a result, the control signal is passed through their normally open auxiliary contacts. Finally, the signal is returned to the DC Module as, RT CONT (Pin 129). In the module, reference for the SCR firing circuits is disabled as long as all CONT signals (RT CONT, MPI CONT, etc.) are not ~14 V. The schematic also highlights the RT reference and Current Limit signals which originate in the Driller’s, Console. ea 1 0¢ GROUNO METER oe Nexa ardeesw aden Bu vont ssw ee tac oRouNo were oun oETECTOR ‘Test Push euTToN RHCC SCR Drive System Technical Manual ire IHI-3. Ground Detection Circuit Schematic Diagram1-9 2-80-05, 89°%9'€9 swoxiovevo iy rat oa zo Swonrovays) ¥O¥ kaa] beatae uv s3sng wa0one ‘390m 30010 vos. [es}h— sna 43 zt ene NY Aces ee -4, Surge Suppression Schematic Diagram Figure SCR Unit RHCC SCR Drive System Technical ManualM10 Figure IILS. Typical Rotary Table Control! Schematic RHCC SCR Drive System Technical Manual SCR UnitE. DC Module ‘The DC Module contains electronic circuits for the SCR Unit These can be grouped into three assemblies, (1). DC Regulator Q). SCR Firing Circuits @). DW Dynamic Brake Refer to the Dynamic Brake section for information on the brake circuit. See figure II1-6 for the module diagrams. Sheet 1 shows the block diagram and pin designations. (1), DC Regulator The regulator is a feedback control circuit which automatically matches the motor speed and torque to the throttle command from the Control Console. The regulator circuit is primarily on sheet 2 of figure IIL-6. Refer to the Unique Devices section for a gen- eral description of the feedback control circuit. ‘The regulator output is a Firing Reference (TP7) to the SCR firing circuits. Inputs to the circuit consist primarily of the Speed Reference, Speed Feedback and Current Feedback. The regulator consists of ‘wo control loops, an outer Voltage (Speed) and an inner Current (Torque) loop. Speed Reference ftom the Control Console is summed with the Speed Feed- back signal to derive a Current Command which, in turn, is summed with the Current Feedback signal to derive the Firing Reference. Speed Reference. This signal originates in the Con- trol Consoles. The consoles are equipped with hand- wheels which the operator rotates clockwise to control the traction motors. Each handwhee is linked to a rheostat which outputs a 0 to —8 V Speed Reference signal for 0 to maximum throttle. ‘The regulator may receive the Speed Reference from more than one location. For example, the DW reference may come from either the Driller’s Console or the Foot Throttle. Speed Feedback. This is an analog of the motor speed. It is 0 to +5 V for maximum speed. The signal is designated ‘N’ because the letter is a symbol for speed in conventional motor speed equations, Ina shunt motor, the speed is directly proportional to the armature voltage. Therefore, the differential voltage feedback signals (Vbr+ ~ Vbr-~) are simply compared in Op Amp Z701 to derive the single level ‘NY. See sheet 4 of figure IL-6, RHC SCR Drive System Technical Manual nr Ina series motor, however, the speed is a function of the armature voltage divided by the magnetic flux. The flux, in turn, is a function of the armature current. Therefore, ‘N’ for series motors is derived by dividing the Voltage Feedback signal with the shaped Current Feedback signal in 2703. Current Feedback. This is an analog of the motor torque, since torque is directly proportional to the armature current. It is derived by tapping the 38 AC input to the SCR bridge. DC Foot Throttle Operation. A Foot Throttle is provided for the Drawworks for quick response from the SCR bridge during tripping. See sheet 2 of figure IL-6. DW Foot Throttle reference (pin 114) is applied directly to the Current Limit summing the Junction, skipping the Speed Feedback junction, ‘Therefore, it acts as a Current Command. When the Driller presses the Foot Throttle, current to the Drawworks motors rises quickly and the voltage follows. DW Speed Reference from the Driller's Console hand wheel (pin 117) and the DW Foot Throttle Reference are auctioneered through D10 and DS9 to select the higher (more negative) throttle command, When the Driller begins a tripping operation, he first sets the Drawworks to cathead speed by slightly cranking the hand throttle. At this time, the Speed Reference and Foot Throttle are enabled. When the Driller presses the Foot Throttle to lift a heavy load, the Foot Throttle Referencequickly supersedes the DW Speed Reference, The Foot Throttle Reference goes to 0 when the Driller removes his foot from the throttle. As a result, the DW Speed Reference is enabled, and the motor speed and torque return to cathead values. Slaving Cireuits. This circuit achieves load sharing between two motors which are parallel-connected to ve a common shaft but are powered by separate SCR units. Such an arrangement is normally utilized for mud pumps. Load sharing is accomplished by applying the same Current Command to regulators of both SCR units. A diode or FET auctioneering circuit is used to select the higher (more negative) current command. Several safety interlock and limiting circuits are tied into the regulator. Contactor Interlock. In the “off” mode, the Speed Reference signal is disabled by a hardwired positive current flow (+14 V/2.7 kf1).This positive flow is cancelled when the corresponding CONT signal switches from +5 V to —14 V. SCR Unitmez Zero Throttle Interlock. This circuit protects the SCR bridge and the traction motor from sudden starts. It disables the Firing Reference if the CONT signal switches to —14V while the corresponding Speed Reference is also high (negative). Conse: quently, the Driller has to set the throttle to 0 before switching the assignment. Current Limit. This signal prevents the Speed Refer- ence signal from demanding excess current, It is ply a negative current flow produced by applying a =10 V across a selected resistor. To lower the Current Limit, the negative current flow is decreased by selecting a resistor with higher value. If the cur- rent limit desired is 1000 amps, R sel is approximately 390 ka. ‘Speed Limit. This signal prevents the Speed Reference from demanding excess speed. It is particularly use- ful for series motors. In shunt motors, an adequate field current prevents overspeeding. Power Limit. This signal prevents the Current Com- ‘mand from demanding excessive power, and thereby overload the engines. It is effective at about 85% to 90% to the engine-generator capacity on line. The Power Limit signal is derived by processing the Current Feedback, KW Feedback and KVAR Feed- back from all generators on line. See the Generator Unit section for further information. Manual Operation. During testing, it is often con- venient to phase up the SCR bridge without applying power to the motor, A Manual Operation circuit makes this feasible. When the Manual Volts switch (S1) is set to “on”, the -14V CONT Power Supply to the assignment contactor logic is disconnected and the Manual Volts rheostat is inserted into the regulator circuit. Now, the bridge can be phased up by rotating the Manual Volts knob clockwise. Power is not applied to the traction motors since the assignment contactors remain open, (2) SCR Firing Circuit These circuits generate firing pulses for the SCR bridge. The circuits are shown on sheet 3 of figure M16. ‘There are six identical firing circuits, one for each SCR. A Firing Pulse waveform is shown at position 9. The waveform actually consists of two pulses, a main pulse followed by a backup pulse. The backup pulse is essential for refiring the SCR at low DC ‘output when the current is discontinuous. The time RHCC SCR Drive System Technical Manuat difference between the main and backup pulses is constant. ‘The main pulse is synchronized with one of the 60 signals from the AC bus (Vab, Vbe, etc.) and Firing Reference from the DC Regulator. The backup pulse is synchronized with a main pulse signal from one of the remaining firing circuits. ‘SCR Operation. An SCR turns on when it is forward biased, and secondly, when its Gate terminal is “fired” with a current pulse. If the gate is fired as soon as the SCR is forward biased, the SCR acts as an ordinary diode. The firing is delayed to vary the DC ‘output. In the SCR firing circuit described above, the 60 reference indicates when the SCR is forward biased, and the Firing Reference indicates when the SCR should be fired to achieve the desired DC out- put level. For a general description of an SCR, refer to the Unique Devices section. Diode Bridge. See schematic A in figure III-7. The diodes turn on and off automatically as the bias changes. This process is called commutation. ‘The waveform shows the commutation process through a single 60 Hz cycle. The 360° cycle is divided into 30° sections. Observe that between 30° to 150°, diode A+ is more positively biased than either BY or Ct, Similarly, diode C- is more negatively biased than either A- or B- during 90° to 210°, See table III-1 for the commutation sequence. DEGREES TURNS ON TURNS OFF 30 A+ c+ 90 c- B- 150 B+ At 210 A- c- 270 c+ B+ 360 B- AR Table 111-1. Diode Commutation Note that each diode is on for 120°, At any one time, two diodes are on. One feeds the positive AC portion to the DC (+) bus and the other feeds nega- tive portion to the DC (—) bus. SCR Bridge. See schematics B, C and D of figure IIL7, In a SCR bridge, the commutation does not occur automatically. It must be forced through firing pulses. Observe that SCR A+ is positively biased between 30° and 150°. Similarly, the SCR’s are biased for Forward flow for 120° during each cycle. Thus the SCR Unitm3 9.40 1-AMS 9-6600-05 S30v UU ¥-Eq!0-05 DO sina awn HIM ousnon q3345 3AVH END ZW {51NO TOWLNOD LNSWAND S¥H IM LON i 1 I yovaoaay 03345 1 i ‘OSL / AOE ~ 4 109 ond wouvia3y A woivrnoay 3oaiwe 405, ' ' 1 [ 4 swomonomen ob , ; ' i 18 D0V0001 7ASSE | a1ndow 90 SCR Unit Figure III-6. DC Regulator Schematic Diagram Sheet 1 of 6 RHCC SCR Drive System Technical ManuslM4 Figure 1-6 DC Regulator Schematic Diagram Sheet 2 of 6 RHCC SCR Drive System Technical Manual SCR UnitMI-AS Figure I11-6 DC Regulator Schematic Diagram Sheet 3 of 6 RHCC SCR Drive System Technical Manual SCR Unit16 Figure 111-6, DC Regulator Schematic Diagram Sheet 4 of 6 RHCC SCR Drive System Technical Manual SCR UnitM17 Figure Il1-6. DC Regulator Schematic Diagram Sheet 5 of 6 RHCC SCR Drive System Technical Manual SCR Unit8 Figure IL-6, DC Regulator Schematic Diagram Sheet 6 of 6 RHCC SCR Drive System Technical Manual SCR Unitm9 == bed 4 v8 008 r2 081 om 98 2A 908 nt om 21 29 Kes Lx. NAN N on 08 008 942 ou e209 6 AVA beer rel Figure III-7. SCR Bridge Oper SCR Unit RHCC SCR Drive System Technical Manualm1 SCR can be fired anytime between 0° to 120°. This is defined as a firing angle (a) range. When the firing angle a = 0°, the SCR’s are fired as soon as they are forward biased. See schematic B. The bridge output is maximum. In schematic C, = 60°, and in schematic D, a = 105°. The bridge remains off if « is 120°. In the Ross Hill system, the firing angle is restricted between 120° to 10°. This corresponds to a Speed Reference of 0 to —8V, Firing Reference of 0.5 to ~2.5V and bridge voltage of 00 750Vde at no load, F. Sprocket Slip Circuit This circuit provides overspeed protection for two series motors that are driven in parallel from a single SCR bridge. Such an arrangement is normally used for Mud Pumps. If either one of the motors exceeds a preset speed limit, due to a malfunction in the chain drive, the circuit cuts off power to both motors by tripping the assignment contactors. It also turns on the front panel Sprocket Slip light. In the Ross Hill system, overspeed protection for shunt motors is achieved through a Field Loss relay. Recall that a shunt motor cannot overspeed unless its field is removed. The Field Loss relay, located in the Driller’s Console, monitors the field current. It opens to trip the assignment contactors of the motor if the current is below 35M of the rated value. Overspeed protection for series motors is normally provided through the Overspeed circuit in the DC Module. The circuit compares the voltage feedback signal from the motor with the current feedback signal. It phases back the current command if the VII ratio exceeds a preset level. Recall that in an overspeeding motor, voltage is high and the current is tow, ‘The Overspeed circuit functions effectively for all configurations of series motors except where two motors are driven in parallel from a single SCR bridge. Refer to figure III-8, Suppose MP 1A breaks its chain drive, The unloaded motor will overspeed. It will draw the full voltage, but little current. Most of the current will flow into MP 1B, The Speed Catching circuit will not detect the overspeed be- cause the Current Feedback signal indicates the to- tal current drawn by the two motors. ry go we scr erioce Figure Li VOLTAGE FeEoeAcK (CURRENT FEEDBACK. -8. A Typical Mud Pump Drive System sc-o03e RHC SCR Drive System Technical Manual SCR Unit‘The Sprocket Slip circuit measures the DC current drawn by each motor through Hall Effect Devices (HED) and compares them to the voltage to detect, overspeed. See the Unique Devices section for a gen- eral description of the HED. Refer to figure III-9 for the installation diagram of the HED’s. HED 1, mounted on the DC (—) cable, measures current to the MP 1A motor. HED 2, mounted on the DC (+) cable, measures current to the MP 1B motor. Refer to the schematic diagram of the Sprocket Slip card, figure 111-10. Differential voltage signals from HED 1 and HED 2 are compared on Op Amps Zi and Z2 to obtain Ia, and Iyp respectively. The cur- rents are auctioneered via D1 and D2 to select the ‘current with the lower value. (Since the motors have equal armature voltage, the motor with the lower current has the higher speed.) The lower current signal is summed in Op Amp Z4 against the voltage feedback current from Op Amp mat Z3. Output Z4-6 is amplified via QI and applied to coils KIA and KIB of relay K1. The V/I ratio at which Z4 energizes K1 is set by selecting R28. When K1 energizes, its normally closed contact KIA, ‘opens to deenergize K2. K2 is the Sprocket Slip relay. K2 normally’ closed contacts are mounted in the assignment logic of both mud pump motors. The contacts open to trip the main assignment contactors, thereby cutting off power to the motors. Normally open contact KIB closes to turn on the front panel Sprocket Slip light, The switched off by pushing the adjacent Reset button. The button deenergizes coil KIB. 2. Troubleshooting Index See tables 1-2 through I1I-4 oc ect ve 14) oc neo CO CO neoz MY} pe rane we in RHCC SCR Drive System Technical Manual Figure 111-9, HED Installation 8¢-0030-8, SCR Unit1-22 Figure 111-10. Sprocket Slip Schematic Diagram RHCC SCR Drive System Technical Manual SCR Unit111-23 PROBLEM ACTION 1. SCR Circuit Breaker Trips 1, Emergency stop AILSCR breakers trip. 2, SCR/Fuse Failure 3. Overcurrent trip 4. SCR Overtemperature 5. Field loss TL. SCR Bridge Inoperative 1. Zero throttle interlock 2. Throttle signal not reaching the module 3. Contactor logic defective 4. DC module defective 5. SCR misfiring Driller may have pressed the Emergency Stop button on the Driller’s Console. To resume ‘operation, close the breakers. ‘A. If an SCR fails, some fuses are also blown, Check fuse trip indicators or trigger fuses. B. Test SCR’s whose fuses are blown. See Table IL-3. SCR Test for instructions. Replace all blown fuses and defective SCR’s, Close the breaker to resume operation. ‘A. Overtemperature switches will reset after SCR junction temperature drops below 165°F (74°C). Close the breaker to resume operation, B, Make sure SCR blowers are running. If not, check fuses. If the motors are shunt-type, ensure that field current is approximately 50 amps. Check Zero Throttle LED on DC module. To resume operation, set throttle at control con- sole to 0. Check for Speed Reference signal from the control console at the DC module. Check for -14 V motor CONT signal at the mod- ule. If absent, trace the control signal. See section D, Contactor Control Logic on page ILS for information. ‘A, Check SCR firing pulses. B. If pulses are absent, check module power supplies. If these are present, replace the module. Check Current Feedback ripple. See Table IL-3. SCR Test for instructions. Table III-2. SCR Unit Troubleshooting Index Sheet 1 of 2 RHCC SCR Drive System Technical Manual SCR Unitmm24 PROBLEM ACTION IIL, Motor Speed does not regulate 1. No feedback signals to the module 2. In case of mud pumps slaving, Slave signal may be absent 3. Defective DC regulator 1V. Insufficient Power - DW, MP. Check V br+ (pin 101) - Vbr- (pin 102) and SCR Amps (pin 131) signals. Check Slave inputs (pin 133 or 136) Replace the module. Check ammeters of SCR units driving the two Mud Pump or Drawworks motors. One of them ‘may read low, indicating that only one motor is running. Table II1-2. SCR Unit Troubleshooting Index Sheet 2 of 2 RHCC SCR Drive System Technical Manual SCR Unith-2s seusigpa among PUN von wma oon 903208 010 (nanan eouutsse ig Ue pou oa HOS are waa (ruisspe009 5 enn en emis op wate +> ay og is apg wag 294 2 tesa "> (mn pot oan) soon 820) « trois repo 25 sys sg ants ons one wet 28 Yo 20 une 299 med Boe zor von me a 1arP0 vomno monte as oe erotonanontesorasnseren crocs _ ono ab ering ts coe ene — feta a Son ao peronen 2 seroma os 0 SNLOORSTTEnOWE sovEIOn aaeniw wa ices DC Module Troubleshooting Table Sheet 1 of 4 ‘Table 1-3. SCR Unit RHCC SCR Drive System Technical Manual111-26 asm 95 0 Son woos es nner ‘ONILOOHSaTENOW ‘RINNE WON faasorawanwaua | S220 NPIVANE HOS DC Module Troubleshooting Table Sheet 2 of 4 Table 111-3. RHCC SCR Drive System Technical Manual SCR UnitM27 setae ug ama] ‘onnnuwwauon | N8d08¥OIGvING2D | Naso uRHWaUa HOR NoW.oNn awn wa DC Module Troubleshooting Table Sheet 3 of 4 ‘Table I-3. SCR Unit RHCC SCR Drive System Technical Manual11-28 — ‘6 ont) WED pug) 2D aH aH en senson, | HHH nae mina tn ws ov ‘SNILOONSITENOUL nN un | 320 suOLOvINGD OG T Wago WanvauE HOS NouoNna awn | ws SUINNEY TYRRION | ass URNYAUE Sheet 4 of 4 DC Module Troubleshooting Table Table TII-3. SCR Unit RHC SCR Drive System Technical ManualDOUBLE ACCESS (1200, 1500, 1600) _1v. REMOVAL & REPAIR See figure IV-I for a view of the assemblies in the SCR cubicle. 1. SCR Cell See figure IV-2. To remove an SCR cell, simply disconnect the in- coming wires to the terminal board on the compo- nent plate, and remove the bus stubs from the bus bars. Each stub is attached to the bus bar with two % in. bolts. ‘The trigger fuse lead on the spare SCR cell is left unhooked. If it is to be a + cell (located at the front of the cubicle), connect the lead to the left stub, which is attached to the DC (+) bus bar. Ifit is to be fa cell (located at the rear of the cubicle), connect lead to the right stub, which is attached to the DC (9 bus bar. In other words, the wire should always be attached to the SCR cell bus bar that supports the fuse. 2. SCR To replace an SCR, observe the removal/assembly procedure listed in figure 1V-3. RHCC SCR Drive System Technical Manual Wa Update the SCR Serial Record Table. The table is pasted on one side of the SCR cell. See table IV-1 SOR SERIAL RECORD Ss Table IV-1. SCR Serial Record Table SCR UnitDOUBLE ACCESS 2 SoA cinouIT ‘BREAKER sane He wu san SCR Unit Figure IV-1. GEN/SCR Cubicle RHC SCR Drive System Technical Manual0 L ams N39 anus sg dusig sorstsay MSS WST uonduasog sonpede9 get 1 souusoysuea] 98nd wondussoq, weFRONT & REAR ACCESS Wa 1. Trip the circuit breaker before touching any part of the SCR enclosure, 2. Tools needed: screwdriver, 7/16" boxend 3. Discharge the capacitor by short circuiting the wrench, and a 14" wrench terminals with screwdriver. 4, Replace the trigger fuse if its plunger has tripped 5. Disconnect wires leading into the enclosure the microswitch, at the terminal board. 6. Remove the SCR enclosure by loosening the 7. Remove the fuse assembly, if necessary, using bolts which attach it to bus bars a hex wrench, Figure 1V-3. SCR Removal Sheet 1 of 2 RHCC SCR Drive System Technical Manual SCR UnitFRONT & REAR ACCESS oo) \ a \ 8, Remove 14” bolts in back of the enclosure, and 9. Disconnect capacitor and trigger fuse leads disconnect Gate (G), Cathode (K) leads and extract, and lift out the Glastic box. them through the hole in the Glastic box. 10. Loosen the two-bolt clamp by unscrewing the 11, Separate the heatsink sections and lift out the 4%" bolts and lift out the SCR. SCR ¢ © Lene 12, Replace the SCR and assemble in reverse order 13. Tighten both bolts ofthe clamp equally uni ofremoval.Besureto braid the Gand K lads ofthe the pressure gauge shows recommended vale, new SCR. Figure IV-3. SCR Removal Sheet 2 of 2 RHCC SCR Drive System Technical Manual SCR UnitFRONT ACCESS (1400) IV. REMOVAL & REPAIR ‘See figure IV-1 for a view of the assemblies in the SCR cubicle. 1. SCR Cell See figure IV-2 for an assembly drawing. 2. SCR To replace an SCR refer to figure IV-2 and observe the removal/ assembly procedure listed in figure IV-3. Update the SCR Serial Record Table. The table is pasted on one side of the SCR enclosure. See table IV-1 RHCC SCR Drive System Technical Manual SCR SERIAL RECORD 1-6 Ss ‘Table IV-1. SCR Serial Record Table SCR Unitwr FRONT ACCESS CIRCUIT BREAKER: SCA BRIDGE oc CONTROL MODULE’ ‘SCR BLOWERS Figure IV-1. SCR Cubicle RHCC SCR Drive System Technical Manual SCR UnitFRONT ACCESS (1400) 8 Figure IV-2. SCR Cell Mechanical View RHCC SCR Drive System Technical Manual SCR UnitLad FRONT ACCESS 1. Trip the circuit breaker before touching any part of the SCR enclosure. 2. Tools needed: Screwdriver, 7/16" boxend 3, Remove fuse assembly to access the SCR assembly. wrench, 14" wrench, Disconnect leads to the Trip Indicator, if applicable. roms reouso 4, Place a sheet of paper underneath the bottom 5. Disconnect the appropriate Gate (G) and enclosure to prevent any nuts or washers from Cathode (K) leads and pull them out through the falling into the blower outlet. stuffing tube. ‘Figure IV-3. SCR Removal Sheet 1 of 3 RHCC SCR Drive System Technical Manual SCR UnitFRONT ACCESS 1-10 6, Pull out the clip lead which connects the re- 7. Using the 7/16” boxend wrench, disconnect sistor to the heatsink. the bus from the heatsink. 8, Using the !4" wrench, remove the bolts which 9. Carefully slide out the front heatsink and SCR clamp the SCR between the heatsinks. assembly, Figure IV-3. SCR Removal Sheet 2 of 3 RHCC SCR Drive System Technical Manual SCR UnitWal FRONT ACCESS 10. Note that the SCR is held in place by a Glastic 11. Loosen the two nylon screws to remove Glastic card. card. 12, Lift out the defective SCR. Perform SCR 13, Tighten both bolts of the clamp. The pressure assembly in reverse order of removal, Be sure ‘gauge should read 2500 Ib, to braid the G and K leads in order to reduce elec- tronic noise caused by the firing pulses. Figure IV-3. SCR Removal Sheet 3 of 3 RHCC SCR Drive System Technical Manual SCR UnitSCR UNIT a eriew 1.6 2. 750 Vde 3. Main SCR Fuse Failure Emergency Off Button 4. Contactor Logic Throttle 5. Manual Voltage 6. 165 Degrees F 7. Fired 8, Backup 13. Equal, Recommended 14, Contactor, Reference 15. Voltage, Current 10. 12, Misfire AC “av 139 through 150 B- At C- Bt A-C+ Sumpering the Auxiliary Contacts of the SCR Breaker ‘The SCR Breaker is Closed Develop Speed Feedback (On to Indicate a Blown Fuse DC Ground Fault An Unloaded Series Motor will OverspeedGENERATOR UNIT ROSS HILL CONTROLS CORPORATION:GENERATOR UNIT ena et e nae 1 AC regltor provides KW and sharing etneen enero 2. AC relator consis of te engine governor and 4. Governors re wed to adjust the tte evel for sarng 4, Voltage Regulator provides two functions: supply ______— adjustment and sharing. 5, Volts Adjust dials are adjusted to achieve same reading on all the ___ meters. 6. Exciter field is ______ volts during idle and a maximum of _______ volts during run. 7. Residual voltage is __ to ___ Ve. 8. The Exciter current feedback to the AC module is _____ volt per ___ amp of Exciter current. 9. Exciter SCR gates should receive firing pulses that come from the AC module pins ____and 10, Speed feedback may be developed by usinga magnetic pick up device or through a___ circuit in the AC module. 1. In order to function properly, the AC regulator must receive _____ from the load and engine, A, Protection B. Feedback C. Ground Detection D. Warning Lights 2, Throttle and Exciter outputs are fed to the actuator and exciter via A. TB7 BIBI C. TBS D. TB4 3, Protection circuits in the AC regulator work through the —_____ in the generator breaker. AA. Shunt rp coi e B. Magoetic tip unit . Vari-Syne relay D. UV Trip coi N 1review Questions: 10. GENERATOR UNIT During start up, the residual voltage in the generator is rectified through diode and fully applied to the exciter. A. Bridge 2 B. Bridge C. Controlled SCR’s D. Bridge 1 & 2 Voltage Reference potentiometer on the front panel controls the voltage input to pin on the AC regulator, A. S51 B. 547 cc. 533 D. 504 Voltage available for both voltage and speed references is adjustable from ____to- A. 0t0-16 Vde B. 0 to #16 Vde C. O10 +11 Vde D. Oto-I1 Vde Frequency range of the Speed Adjust dial is limited between _____ Hz to ___ Hz. A. 48 to 80 Hz B. 5410 70 Hz C. 30 to 60 Hz D. 45 to 75 Hz Master Slave circuit is connected such that the master generator is always A. Generator with the greatest load B. Generator with the lightest load C. The lowest numbered generator on line D. Highest numbered generator on line Ifa generator is a slave, it receives its throttle signal from the master generator via pin on the AC module. AL S88 B. 547 c. 943 D. SSI If the Tach signal is lost, Protection circuit in the AC module wilt A. Trip the Generator breaker and shut down the governor B. Trip the Generator breaker and increase the governor output C. Overspeed the engine D. Run the Exciter to full output1, OPERATION 1. Description The Generator Unit controls the engine-generator set, to develop aconstant AC supply. The output of several ‘generators are fed toa common AC bus. See figure I-1. Each Generator Unit has an electronic engine gover- nor, a voltage regulator and a circuit breaker. The cir- cuit breaker is interlocked with a Protection circuit which automatically trips the breaker for malfunc- tions such as overcurrent, overvoltage, under/over- frequency and reverse power. Inaddition, a Synchron- ization Panel is provided with each system to match individual generator frequency and voltage to the bus frequency and voltage. a} wore scruxron ==} wore scTusroR i ! ENGINE 1 i ENGINE 2 i i ' t ' I ! ' 1-3} reup excites 1 pal reo wearer it GENERATOR | 1 | GENERATOR 2 tt iy ra Vy | tot ty it toy 4 vt 14 ry 1 bo | ! \ ; i L--4 L--d ¢ LJ 4 ¢ ‘Ac BUS y x AC BUS GEN UNIT! GEN UNIT 2 <— rower <= Coto Figure 1-1. Generator Unit Functional Diagram : ‘SC-0084-8 RHCC SCR Drive System Technical Manual GEN Unit12 2. Specifications A. Electrical (1). 39 AC Supply (A). Voltage: 600 Vac (B). Frequency: 60 Hz, (2). GEN Circuit Breaker ‘The circuit breaker is preset to trip under the follow- ing conditions: Amperes required to trip depends on generator KVA rating. (A). Overcurrent: (B). Overvoltage: Approximately I.3 times normal bus voltage, 100 mSec. delay. (C). Overfrequency: 64 Hz (D). Underfrequency: 56 Hz (B). Reverse Power: -7% (8). Engine Governor (A). Regulation: 0.5 Hz, steady state (B). Response Time: | sec. (O). Load Unbalance: + 5% of rated load, + 10% no load to full load, if one engines cold RHCC SCR Drive System Technical Manual (4). GEN Voltage Regulator (A). Regulation: + 34 maximum (B). Response Time: I sec (©). Load Unbalance: + 10%, no load to full load of rated KVAR's (D). Exciter Power: 100 Vdc. 8 amps maximum KVA’s are distributed among generators by reactive droop compensation. B. Mechanical The assemblies are mounted in a cubicle constructed from I2-gauge, cold rolled steel. Dimensions vary from model to model. A typical cubicle is 90°H x36"D x 24"W. The weight is approximately 2,000 Ibs. Many of the electronic circuits associated with genera~ tor control are housed in the AC Control Module. The ‘module is constructed from 12-gauge, cold rolled steel, and has its own heatsink. Size: 12°H x 12°D x 4"H ‘Weight: 25 Ibs. GEN Unitll. MAINTENANCE ‘This chapter contains testing and servicing informa tion to assure proper operation of the Generator Unit. Refer to chapter III Troubleshooting for explanation of the various GEN Unit circuits and chapter IV Re- ‘moval and Repair for identification of the assemblies. 1. Testing Perform the following functional tests after repairing. or replacing any of the unit assemblies. In addition, the Reverse Power and Engine Overspeed tests listed in table II-3 should be performed once a month. Caution Serious damage to the engine can result if Reverse Power and Engine Overspeed functions do not func~ tion properly. Generator Unit Functional Test AC Module Functional Test Protection Circuit Functional Test Table I1-4, Actuator Calibration See figure II-1 for a front panel view of the AC Mod- tule, The Test switch enables a quick check of the vital signals. The switch positions and the Test meter face are color coded. For example, if the Test switch is set to the yellow “Breaker Trip Voltage” position, the Test ‘meter needle will deflect to the yellow band to indicate normal condition. 2. Servicing Servicing consists of oil change and calibration of the throttle actuator terminal shaft rotation. A. Oil Change ‘The Woodward EG-3P Actuator receives oil from the ‘engine oil supply, so regular engine oil change is suf- ficient, Woodward EG-B 10P/13P Actuator has its own oil supply. The oil should be changed every 6 months un- der favorable operating conditions. The oil sump ca- pacity is 14 quarts. Refer to the following instructions. (A). To drain the oil, unscrew the Drain Cock located in the lower left-hand corner of the front panel. (B). To flush the actuator, add 114 quarts of diesel fuel ‘or Kerosene through the Oil Cup located on the top. Run the engine up and down by switching the Engine Control switch between “Idle” and “Run”. After afew minutes, shut the engine and drain the fuel. Repeat the flushing until the fuel out of the Drain Cock is clean, (©). Drain all the fuel and screw in the Drain Cock. Fill the actuator with 1% quarts of recommended lub- ricating oil. Woodward recommends Mobil 1 RHCC SCR Drive System Technical Manual Caution If the oil in the EGB series actuators is not changed regularly, the acuator will become clogged with gum and fail B. Terminal Shaft Calibration Calibrate actuators of all the engines if KW load shar- ing at full load exceeds 10 percent. Refer to table I-4. Figure 1 AC Module Controls and Indicators GEN Unit12 ACTION RESULT |. Preliminary 1. Open all the Generator unit fuses. UL Throttle Check 1. Disconnect Throttle (+(TB1I-1) and Throttle (xTB11-2) 2. Reconnect the throttle leads M Exciter Check 1, Disconnect the Exciter (+) (TBI-7) and Ex- citer (-) (TBI1-8). 2. Reconnect the Exciter leads. IV. Control Circuit Test 1, Set the Engine Control Switch to “Idle”, 2, Start the engine and run it at approximately half speed (30 Hz line frequency). Measure the resistance between the leads to the Throttle to check for open or short circuit con- ditions. The resistance should be 30 0 Measure the resistance between the leads to the Exciter to check for open or short circuit con- ditions. The resistance should be 3 to 500 depending on model of generator utilized. Using the oscilloscope, check the phase rotation at the generator stabs. Refer to figure II-I forthe phase rotation sequence. Phase B Table U1-1. GEN Unit Functional Test Sheet 1 of 3 RHCC SCR Drive System Technical Manual GEN Unit3 ACTION RESULT ), F31, F32, F35, F36 and F37. F35, F36 and F37 will be fuses numbered F33, F34 & F35 in Mode! 1400-1650. A. Voltage Regulator Test (J). Disconnect wires Gate A+ (Pin 504) and Gate A- (Pin 505). Q).Close the Exciter fuses. Exciter fuse numbers depend on model of system. Check your gener ator control schematic. Exciter fuses for 1400 system are F39 & F40, (3). If the result indicated above holds true, re- connect the Gate A+ and Gate A- wires. (4). Set the Volts Adjust dial to 50% range. B. Engine Governor Test (1), Examine the throttle actuator. Phase C SA.0033-4, -1 Phase Rotation Figure ‘Check the phase rotation at the AC Module pins 512 through 517. These are six phase voltages. ‘Vab (pin 512) should have a waveform which is inverse of Vba (pin 513). The inverse relation- ship also exists between Vbc (pin 514) and Veb (pin $15), and Vea (pin 516) and Vac (pin 517) Observe the generator voltmeter. The voltage should rise to 200 Vac or above, and fallcyclical- ly as K1, the build-up relay, picks up and drops out. Signals at pins 512 through 517 should also rise and drop. If the actuator is Woodward EG-B 10P or 13P, confirm that the controls are set as listed below: ‘Speed Droop knob to “0”. Load Limit knob to “Maximum Fu ‘Speed knob to “Maximum’. Woodward EG-3P has no variable controls. Table RHCC SCR Drive System Technical Manual GEN Unit Functional Test GEN Unit4 ACTION RESULT @). Set the Speed Adjust dial to somewhat less than 50% range. (3). After 15 minutes of warm-up, turn the En- ‘gine Control Switch to “Run”, (4). Fine tune the Voltage Adjust and Speed Ad- just knobs to achieve 600 Vac at 60 Hz. (8). Switch the engine back to “Idle” (6). Switch the engine back to “Run”. V. Synchronization Circult Test 1, Place one generator on the bus. Caution Do not close the breaker of another generator until the Synchroscope and the Sync lights have been checked out. 58 He. that it slowly syncs in and out. 4. Close the circuit breaker when syne occurs. VI. Load Distribution Test This test must be performed with at least two ‘generators on line. A. KVAR Sharing Test (1). Using the Volts Adjust dial, balance the KVAR's. B. KW Sharing Test (J), Place all the system generators on line. 2. Proceed to the next generator, and following the steps indicated in the previous sections of the test, adjust its controls to develop 600 Vac at 3. Adjust the generator frequency to 60 Hz, so The generator voltage and frequency should The generator voltage and frequency should slow to “Idle” values. ‘The generator frequency should stabilize at 60 He within two overshoots, Observe the Synchroscope and Sync lights. The scope pointer will rotate counterclockwise. The lights will alternately dim and brighten. Connect an AC voltmeter, switched to read 600 Vac, between the generator stab QA and busstab QA. Observe that when the meter reads mini- mum volts, Synchroscope is vertical, and the ‘Syne lights are off ‘The circuit breaker will trip out if syne has not been achieved. ‘The KVAR meters of all generators will read the same value. Observe that only the master generator Speed Adjust dial controls the speed of all the engines con the line. Verify that: GEN 1 controls all others. With GEN | off the bus, GEN 2 controls all others With GEN | and GEN 2 off the bus, GEN 3 con- trols all others and so on. Table 1-1. GEN Unit Functional Test Sheet 3 of 3 RHCC SCR Drive System Technical Manual GEN UIs ACTION RESULT Q). Connect a dummy load, such as a tank of salt water, to the AC feeder stabs. 1, Preliminary 1. Inspect the module wiring harness connec~ tions. 2. Turn on the Generator unit , Power Supply Check Ill, Frequency Demodulator Test WV. Current Demodulator Test Observe that KW meters ofall the generators on the bus have the same reading. Look for incorrect or loose connections. ‘The Generator Run light and the module front panel Power On light will glow. Measure the voltages listed below: Voltage Location +160 Vac -160 Vac +16 Vae -16 Vae 11 Vde Pin 546 . DC control voltages are fed to the Driller’s Console from each SCR cubicle via A. TB6 B.TB7 c. TBI D. TBS a DY wwMCC, DW DYNAMIC BRAKE, FIELD SUPPLY, CONTROL CONSOLES Review Questions. 10. |. Throttle references are developed in the Driller’s Console by ‘A, Separate power supply that develops 8.2 Vde B. Battery pack of 8.2 Vde C. The -i4 Vde supply from each SCR cubicle and a 8.2 V Zener diode D. The 60 Vdc contactor power supply and a 8.2 V Zener diode Alarm in the Driller’s Console will sound when the air pressurization is lost or ‘A. When a blower is not switched on and the throttle is up B. When a blower is not switched off and the throttle is off C. Blower On lamp does not light D. A fuse blows in the console Mud Pump Console is used for ‘A, Maintenance operational checks B. Routine pump operation C. Backup unit for the Driller’s Console D. Anytime mud pumps are to be run at 14 or full speed 7. SCR On lights on the Driller’s Console utilize 428 Vae 115 Vac +14 Vde and -14 Vde -14 Vde pap Relays KI, K2 and K3, located on PCI in the Driller’s Console, are used to A. Drop out DW B motor when L. W is in reverse B. Allow the Driller to reverse RT . Connect foot throttle to the proper SCR cubicle D, Connect RT ammeter to the proper SCR cubicle Holding circuit or contacts for the blower motor starters in the MCC are located in the - Driller’s Console MCC relay panel Traction motor Blower motor por> SCR differs from a conventional diode in that ‘A. It operates on only DC voltage B. It conducts only when the anode is negatively biased C. The gate allows control of the rectification D. No difference. SCR is just another name for a diode. 2 ROSS HILL CONTROL CORPORATION SSMCC, DW DYNAMIC BRAKE, FIELD SUPPLY, CONTROL CONSOLES a Review Answers 10, -A- Transformer Feeder unit Hand 10 15 DWA . Active Field Supply 1. Increase pe Hand Throttle Lockout Switch A Shunt Motor without a Field Supply will overspeed . Hall Effect Device TBS .. The -14 Vde Supply from each SCR and a 8.2V Zener Diode ‘A Blower is not Switched on and the ‘Throttle is up. Maintenance Operational Checks +14 Vde and -14 Vde Connect the RT Current Meter to Proper SCR Cubicle MCC Relay Pane! The Gate Allows us to Control Rectification.MODEL 425 iM |, OPERATION 1. Description ‘The Driller’s Console is the primary control for the rig DC functions. Installed on the drill floor near the Drawworks, it contains an Assignment switch to ap- ply power to various combinations of functions suit- able for tripping or drilling. In addition, the console houses a lockout switch and throttle for each function. Lights on the panel indicate the on-line status of the generators, SCR units, and auxiliary AC devices such as blowers, chain oilers, ete A. Specifications (1). Electrical (A). Input ‘The console does not require an independent power supply. It receives the following voltages from the other SCR Drive System units. 1, 115 Vac from the Generator Syne section 2. £ 14 Vde from each SCR Unit 3. - 14 Vde Contactor Power Supply used to develop Contactor control signals associated with each trac- tion motor. (B). Output 1.0 to -8 Vdc throttle reference signals back to the SCR Units for each DC function. 2. -14 Vde contactor control signal for each traction motor. 3,-8.2 Vde supply for the DW Foot Throttle rheostat. (2). Mechanica! (A). Console. The console is fabricated from 12-gauge No. 316 stainless steel plate. The control knobs and levers are also stainless steel. The meters and lights are mounted behind reinforced glass. The assembly is watertight. Size: 18 in, Hx 36 in, W x 12in, D (46 em H x 92 em W x 31 em D) Weight: 130 Ib. (60 kg). RHCC SCR Drive System Technical Manual (B). DW Foot Throttle. The foot throttle is fabrica- ted from No. 303 stainless steel plate. The pedal is corrugated to provide a skid-proof footing. The assembly is watertight. Size: 12.75 in, H x 12.75 in. W x 11 in. D maximum, (32 em H x 32. em W x 28 em D) Weight: 30 Ib. (14 ke), Both the console and the foot throttle are pressurized. The customer should provide a dry air bleed at 75 to 150 psi. 2. Indicators and Controls Figure I-1 shows the various types of indicators and controls on a typical console. ‘The GEN and SCR lights (3 and 4) glow when the corresponding units are on line. The Assignment switch (1) positions are arranged as the hours on a clock, with the vertical 12 o'clock position being “off”. Positions on the left side (8 through I1) are designed for tripping and those on the right side (I through 4) are intended for drilling, although the Driller is free to choose whichever he needs at any time. For each of these positions, num- ber in the blocks refers to the SCR units. The function it drives is listed below the number. In Drilling positions, DWA and DWB motors are connected in series (DWS) to provide full lifting capability but only half the hoisting speed. In Tripping positions, the motors are connected in parallel for full hoisting speed. ‘The Blower lights (5) are associated with auxiliary AC devices of the corresponding DC functions. For example, the DW blower light glows when all auxiliary devices of both the Drawworks motors such as blowers and chain oilers are switched on. There is a Lockout switch (8 and 10) for each DC function. Once the Lockout switch is turned fon, the corresponding Hand Throttle wheel (12) is rotated clockwise to turn the function from 0 to maximum speed. Diiller’s ConsoleL ‘The Drawworks Foot Throttle pedal (13) is depressed to operate the Drawworks once the DW Hand Throttle is rotated out of the “off” position. The RT ammeter (7) indicates current drawn by the Rotary Table motor. This is an indication of developed torque. The RT Limit knob (11) is rotated clockwise to increase the torque limit on the Rotary ‘Table motor from 0 to 10. MODEL 425 The Power Limit meter (2) indicates percentage of power consumed by the load of the total power capability of the generators and SCR’s on line. The Power Limit light (6) glows when the generators and SCR’s on line are running at their maximum capability. ‘The Emergency Off button (9) is pressed 10 dis- connect power to all DC functions in case of an emergency. Ttem Description 1 Assignment switch 2. Power Limit meter 3. GEN Status lights 4, SCR Status lights s. Blower Status lights 6. Power Limit light 1, Rotary Table Ammeter 8. On-Off Lockout switch 9, Emergency Off button 10. I. 2. 13. RT Limit knob Hand Throttle handwheel Drawworks Foot Throttle Forward-Off-Reverse Lockout switch ure I-1, Driller’s Console Indicators and Controls, 1 RHCC SCR Drive System Technical Manual Driller’s ConsoleMODEL 425 3. Operating Instructions A. General (1). Set the Assignment Switch to Off and rotate all the Hand Throttles to Off as a safety precaution. (2). Ifa shunt motor is to be run, make sure the field supply is On. (8). Check the GEN status lights to make sure there are sufficient generators on line to meet the load re- quirement, (4). Check the SCR status lights to make sure the SCR units to be used are on line. (5). Make sure the SCR units to be used have been assigned to “Drilling” at the Engine Room Console, if applicable. (6). Set the Assignment Switch to the position de- sired (7). Set the appropriate Lockout Switch to On, Fwd, or Rev, as applicable. (8). Rotate the desired Hand Throttle clockwise. Just beyond the Off position, you should sense the click of a miero-switch closing. (8). The corresponding Blower light will come on. Caution Do not proceed further ifthe light remains unlit. Turn off the throttle and-troubleshoot the system. (10). Advance the Throttle to achieve the desired speed. (14), The Power Limit meter will indicate percentage of power consumed out of the total available from the generators and SCR’s on line. Power Limit light will glow when the power consumption is at 95%. In the interest of fuel economy, operate the rig near 90 to 95% as long as all functions are operating at desired speeds. Power Limit can be raised by bringing additional generators on line. If all generators available are on line and the Power Limit light comes on, all the equipment will still run, though at reduced speed. Speed reduction is performed automatically RHCC SCR Drive System Technical Manual B by a Power Limit circuit to prevent overloading of the engine-generators, (12). When changing direction of Drawworks or Rotary Table from forward to reverse, or vice versa, first turn the Hand Throttle all the way counterclockwise to “off”. Let the motor come to a complete stop before switching the Lockout Switch to the opposite direction. Otherwise, damage may result to the SCR unit as well as the Drawworks or Rotary Table. B. Drawworks (1). Achieve cathead speed by observing the general instructions listed in section A. (2). For a speedy tripping operation, press the Foot Throttle Caution ‘The Foot Throttle remains inoperative until the DW hand throttle is moved out of the Off position. (3). After the tripping operation, slow the Drawworks to the hand throttle setting by simply releasing the foot pedal. Caution ‘The Drawworks Dynamic Brake is automatically ap- plied if the Foot Throttle is released for more than two seconds. The brake may not set if the hand throttle setting (cathead speed) is very high. C. Rotary Tabl (1). Observe the general instructions listed in sec~ tion A to turn on the Rotary Table. (2). Observe the RT ammeter periodically to check the current drawn by the motor. The torque limit is not exceeded even if the pipe torques up and forces the Rotary Table to stall. Driller’s Console4 (8). If the Rotary Table stalls but more torque is re- quired, the torque limit can be raised by rotating the RT Limit Knob clockwise. Caution If the Rotary Table torques up and stalls, slowly turn the Hand Throttle counterclockwise to “ofl”. If you suddenly switch off the RT Lockout switch or quickly turn down the throttle, a backlash may result. D. Mud Pump (1), Observe the general instructions listed in see- tion A to turn on the Mud Pumps. RHCC SCR Drive System Technical Manual MODEL 425 Note If your rig has a Mud Pump Console, be sure to turn on its Lockout switches. (2). For maintenance activity, such as installing a new chain, the pumps can be operated from the Mud Pump Console. The Lockout switch on the Driller’s Console must be switched on before the Mud Pump Console is operational. The above instructions are also applicable to oper- ation of the cement pump from the Cement Pump Console, Driller's Consoleil. MAINTENANCE Refer to the SCR Drive System section for general information regarding shipping and storage. This chapter will provide installation, testing and servic- ing instructions specific to the Driller’s Console. 1, Installation A. Console ‘The console is normally mounted on top of the pneu- matic Drawworks console. Cables are brought in via connectors or stuffing tubes located underneath the console. Sec figure Il-I. The pneumatic console has square holes in its top panel for cable entry. Place the console on top of the pneumatic console and weld it around the edges. An alternate method ‘would be to bolt it down. The bolts must have wash- crs to achieve an airtight seal, To Dw FOOT THROTTLE eee ‘To ROTARY TORQUE INDICATOR Figure IL-1. Drller’s Console Cable Entry B. DW Foot Throttle The Foot Throttle is flush mounted at a convenient location on the drill floor underneath the Driller's Console. The cable from the Driller's Console and the dry air tube should be strung below the floor. See figure 11-2. Cutout a 9.75 in. (25 cm) square section and drill four 0.562 in, (1.5 em) clearance holes as indicated. Insert % in. bolts in the pedal place holes and insert the lower assembly into the cutout. Screw in the nut from underneath. RHCC SCR Drive System Technical Manual 2. Testing Perform the functional test after repairing or re- placing any of the console assemblies. If the unit fails to perform as indicated, refer to the trouble- shooting tables in chapter III to locate the malfune- tion. To test the console, simply observe the operating in- structions to run the motors in each Assignment switch position. Make sure the Blower lights turn on as indicated and the motor performance follows the throttle command. IF itis not feasible to run the motors, observe the in- structions listed in table 1-1 3. Servicing Refer to the SCR Drive System section for general servicing instructions. A. Console (1). Examine the internal assemblies periodically for signs of corrosion. This is possible if the front panel door is not properly sealed or if the air bleed is bringing in a large quantity of moisture. Make sure the heater is functioning properly (2). Rotate the hand wheels and the switches and examine the switch and rheostat assemblies behind the door panel. Check the switch contacts and rheo- stat wiper arms carefully. Test the rheostat linkage for tightness. B. DW Foot Throttle The foot throttle should be serviced every three months under normal conditions. (1). Remove the foot throttle and open the rear dust cover. Refer to figure I1I-7 for a mechanical view of the foot throttle, (2). Check and re-tighten the set screws. (8). Check that the rheostat wiper does not rub the wires entering the foot throttle. (4). Grease the bearing surfaces. (5). Reassemble carefully to ensure that the box is watertight. Diiller's Consolem2 veo veo pew err Cee teneeoy 78 cuTouT___ "hour (4 Reg) 1 { — 40, Oa | Bee eee 4-4 § q | 5 | § | | ; 6 4 538 = - amore cel | Recoudeimes eros a seed UNLESS OTHERWISE SPECIFIED DIMENSIONS ARE IN INCHES AND TOLERANCES ARE Xe $10 x= 020 XXX= #008 FRACTIONS + ANGULAR 2) Figure 11-2, DW Foot Throttle Mounting Diagram 8¢-0015-A RHCC SCR Drive System Technical Manual Driller’s Console13 ACTION RESULT 1. Set the console Assignment switch to the 12 o'clock “Off” position. 2, Jumper the auxiliary contact of a SCR circuit breaker. 3. Set the Assignment switch to a specific function driven by the SCR unit utilized. (For example, MP1) 4. Rotate the appropriate throttle (MP1). Note Make certain the function being tested is not driven by another SCR unit, '5. Repeat steps 2 through 4 for the remaining fune- tions driven by the SCR unit. 6. Set the Assignment switch to Drawworks. Operate the foot throttle. 7. Remove the jumper across the circuit breaker auxiliary contact, Caution Be sure to remove the jumper. Otherwise, power may be inadvertently applied to the motor. 1. The -14 Vde Cont logic signal is applied to the Driller’s Console. 2. This enables the assignment contactors to be pulled in without applying power from the SCR bridge. 3. The -14 Vde Cont logic signal returns to the DC Module (MP 1 Cont at pin 124), Monitor the throttle reference at the DC Module. (MP 1 Ref at pin 125), It should be 0 V for off and vary from0 V to-8 V for0 through maximum throttle. 1. Refer to figure III-2 for a list of the wiring between the Driller’s Console and the DC Module. 1. Observe that the foot throttle reference (DW Ft Th at pin 114) also varies from 0 to -8 Vde corres- ponding to the throttle position. Table H- RHCC SCR Drive System Technical Manual Driller’s Console Functional Test Driller’s ConsoleMt I. TROUBLESHOOTING Refer to the troubleshooting table in the back of this chapter for specific instructions. The following ‘Theory of Operation section provides an explanation of the various circuits in the console. 1. Theory of Operation A. Console (1), Mechanical To comply with an ABS rule, the electrical assem- blies are isolated from the local atmosphere by maintaining positive pressure within the console. This is done to prevent an electrical spark from ig- niting what could be explosive gas on the drill floor. The customer is required to supply dry air at 75 to 150 psi via a connector located underneath the con- sole. An Air Pressure Sensor triggers an alarm in the console if the positive pressure is lost. The console is also watertight. A 225 W heater is installed within the console as a precaution against corrosion due to salt and moisture. (2). Electrical ‘The following description is referenced to a drive system with three generators and four SCR units. Refer to the diagrams in this section as a study aid. The SCR Schematics manual has the diagrams ap- propriate to your rig. Figure III-1 indicates the assignment program and the corresponding wiring. The console receives the -14 Vde contactor and throttle power supply signals from each SCR unit. It returns to them the appro- priate throttle and contactor signals. Figure IIJ-2 indicates the wiring for SCR 2. Note that SCR 2 can operate the RT, DW and MPI. Contactor and throttle lines for only these functions are wired. ‘The AC Section provides a 115 Vac power supply and control signals which turn on the GEN status lights. The MCC provides control signals which turn on the Blower status lights. Figure 111-3 highlights the circuits which are en- ‘abled when the Assignment switch is set to the 11 o'clock position to run MP I on SCR 2. GEN 1 is on line. Further, MP I lockout switch is set to On and the MP I hand throttle is rotated clockwise ASSIGNMENT TRIPPING 2 DRILLING T 373 ),, T7273 wer | ows |ows | nr Lows | wer | wpe TT 27S] Hho. acl2 le. ows | wei| nr |owa wer | at lows peters comeate T2314 9. 3 owe |owa| er [wee ar rel_1e2 193 Tee Tes T868_T89 bw Foor, THROTTLE, a6 786 78 78) Tar scr | scr 2 scr 3 sor 4 ‘AC SECTION mec Figure I1I-1, Driller’s Console Wiring Diagram ec-o0r7-A RHCC SCR Drive System Technical Manual Driller’s Console12 ‘The console circuits may be functionally grouped as following: (A). Assignment Logic (B). Throttle Logic (C). Blower Light Logic {D). Horn Logic (E). Power Limit Light (F). DW/RT Chain Drive (A). Assignment Logic. Refer to figure 111-2. As- signment logic enables a -14 Vde signal which orig. inates in the DC Module at pin 154. It is returned to the SCR unit to close the appropriate assignment contactors and to unlock the SCR firing circuits ‘The signal is first passed through the normally closed Manual Volts switch. The switch is turned ‘on for testing purposes to phase up the SCR bridge without running a motor. The signal emerges at pin 134 as Cont PS. It is now passed through the normally open auxiliary contacts ‘of the circuit breaker. The signal is enabled when the breaker is closed to feed AC power to the bridge. Cont PS is applied to the Driller’s Console via TB6. Refer to figure III-2. Cont PS from SCR 2 is applied to all the Assignment switch contacts for the func: tions run on SCR 2. Cont PS also turns on the #28 Vde SCR 2 status light, ‘The other terminal of the light is connected to +14 Vde from SCR 2. ‘The Assignment switch consists of 8 wafers: A through H. Refer to figure IIl-4, There are 12 term- inals on each wafer. They are numbered | through 12, and are positioned as the hours on a clock. A contact is made across the adjacent wafers: A-B, C-D, E-F and G-H. When the Driller selects the 2 o'clock position, contacts A2-B2, C2-D2, E2-F2 and G2-H2 are closed. In figure 111-3, the Assignment switch has one roller when the Assignment switch is placed in the 11 o'clock position, -14V comes to E11 from TB3-2 In figure 111-3, the -14 Vde control signal emerges on the FI side of the Assignment switch as MPI Cont. When the MP I Lockout switch S2 is closed, Mp 1 Cont is applied to the MP I assignment contactor coils. Further ahead, MP 1 Cont goes to the DC Module in SCR 2 to unlock the SCR firing circuits. RHCC SCR Drive System Technical Manual (B). Throttle Logic. The throttle hand whee! is linked toa rheostat which outputs a 0 to -8 Vde signal cor- responding to 0 through maximum throttle. ‘The -8 Vde supply for the rheostat is developed on PCI from -14 Vde supply from each SCR unit. Re- fer to figure III-5 for the schematic diagram of PCI. ‘The -14 Vac input is dropped through 82.12 resistors and applied to 8.2 V Zener diodes. Recall that the voltage across a Zener diode is constant even though the incoming voltage may vary. The regulated -8.2 V is applied to the hand throttle, foot throttle and RT I Limit rheostats. In figure 111-3, the throttle reference from the front RT rheostat is sent to SCR 2as RT Ref 2 via TB2-11. The rear RT rheostat sends its reference to SCR 3. ‘The rheostats for each function are mounted in tan- dem such that the throttle hand wheel rotates their wipers by the same degree. Further, the reference signal from each rheostat is applied to all the SCR units, This assures that there will be little change in the motor performance, if for example, the Dril- ler switches the Rotary Table from SCR 2 to SCR 3. ‘A micro-switch is inked to each throttle hand wheel, ‘The switch contacts are closed when the wheel is rotated just beyond the Off position. The switches control the logic for the blower light and the other auxiliary functions. Refer to the following section for further information, (C). Blower Lights Logie. There is one blower light associated with each DC function. The light glows when all the associated AC functions are switched on, Refer to figure III-6. Observe that the MP1 Blower light cannot turn on until the MP 1A Blower, MP IB Blower, the MP | Rod Oiler, MP 1 Chain Oiler and the MP | Charging Pump are switched on. ‘The lights operate off the 115 Vac from the Generator Syne section, The relays which switch on the AC functions are located in the MCC, Relay R3 is ener- gized when the MPI micro SW isclosed. The normally ‘open contacts:close to switch on power to the AC functions listed in the previous paragraph. Similarly MP 2 logic is enabled by the MP 2 micro SW. The Drawworks and Rotary Table blowers are en- abled by their respective Lockout switches. Driller’s Console13 + > ans Figure 111-2, Driller's Console - SCR 2 Wiring Diagram RHCC SCR Drive System Technical Manual Driller’s ConsoleM4 een ion sv Le scr 2 ON ‘SWITCH SCHEDULE. ‘no. FUNCTIONS | CONTACTS'PoS |No. Functions ‘SL ASSIGNMENT (2 ROLLERS) 2 STAGE 5 58 MPI WicRO ‘82 MPI OFF-ON Sstage [2 ce uee a tL AIR PRESSURE SWITCH Be BLOWER FAILURE ALARM CONSOLE HTR. Ison 228W is vars Been on 784 To FEEDER CUB. Figure III-3. Driller’s Console Schematic Diagram ‘Shunt Motor System sc-oo4e-8 RHCC SCR Drive System Technical Manual Dailler’s Consolems Sect waa > sg ito | | Lgl inesfe L : ae ote L_ a _ I Figure IIL3. Drillers Console Schematic Diagram Sheet 2 of 2 Driller’s Console RHCC SCR Drive System Technical Manualms The blower runs for 2 to $ seconds before the Driller can raise the throttle to start the traction motor. This is done to comply with an ABS rule which re- quires a drill floor motor to be purged of existing air before operation, (D). Alarm Logic, The alarm will sound if either the positive pressurization within the console is lost or the blower is not switched on, Refer to figure 111-6. The normally open air pressure switch closes to trigger the alarm if the pressure drops below 75 psi. The alarm is also triggered if the normally closed blower contact does not open when the corresponding hand throttle SW is closed. (E). Power Limit Light. The light glows to indicate that the generators on line are close to power limit. Contactor K1 on the Power Limit board closes to feed 115 Vac to the light. Refer to the Power Limit theory of operation in the GEN Unit section, (F). DW/RT Interlock. On some rigs, the motor is used to drive either the Drawworks or the Rotary Table through a chain drive. A gear box is used to shift the chain drive between the two functions. In the Dril- ler's Console, a relay interlock circuit is used to insure that the Drawworks contactor is open when the Ro- tary Table is running, and vice versa. Refer to the Driller’s Console schematic diagram in the job book. The interlock circuit consists of a RT relay ‘whose coil is connected to the power supply througha normally open contact of the RT hand throttle micro- switch. A normally closed contact of the RT relay is part of the DW Cont. logic. Thus the interlock circuit normally enables the DW Cont. and disables the RT Cont. The situation is reversed when the Driller rotates the RT hand throttle clockwise. The micro-switch closes and, in turn, energizes the RT relay. Conse- quently, the DW Cont. signal is disabled and the RT Cont, signal is enabled. RHCC SCR Drive System Technical Manual Figure I1I-4. Assignment Switch Rear View FAOO13.A,1-7 o Figure III-8, PC1 Schematic Diagram RHCC SCR Drive System Technical Manual Driller’s Console18 H—)— |_| HHH EHH L 14 }44 2 f 4H Figure 111-6. Driller’s Console AC Cireuits Dailler’s Console RHCC SCR Drive System Technical Manualm9 B. DW Foot Throttle (1). Mechanical Refer to figure I1I-7 for the front and side views of to a counterweight so that it returns to the top posi- the foot throttle. The pedal is linked through a spring tion when released. PEDAL- COUNTERWENGHT: RY AiR S-CONDUCTOR CABLE BLEED FROM DRILLER'S ‘CONSOLE. RlGHT SIDE ViEW 7 ut q B Si 110 Max. oT zo | TOLERANCES ARE xe 0 REAR VIEW + Figure 111-7. DW Foot Throttle Mechanical View se-0016-4 RHCC SCR Drive System Technical Manual Driller's Console(2). Electrical ‘The incoming -8.2 Vde signal is enabled when the DW [SW is closed. Therefore, the foot throttle is ‘operational only after the Drawworks hand throt- tle is set beyond the Off position. Refer to figure III-8 for the schematic diagram of the foot throttle. The foot pedal arm is linked to the theostat wiper arm. The resulting DW Ft Th signal varies from 0 to-8 Vde for 0 through maximum throttle, —--=-------- ---p---------— rei = } | : i 4 I ° IT t | RED | ow-usw | | { 184 1 | | ! | | | | (sor 4) ow FT TH | 10 2 | + wat : ye I | | ee i | | rouno | 20 3 ! ! | T Toren | | | | —— men's commons ff ow Foor rimorrie | ‘S-coNDUCTOR CABLE Figure 111-8. DW Foot Throttle Schematie Diagram s¢-000-4 2. Troubleshooting Index Refer to table [11-1 RHCC SCR Drive System Technical Manual Driers Consolevay pus ty Sma yun ayy “aemssyio “param fideo aoig a pur area iday 9g enw Ou LIEIP 24), "¢ ‘uysng iessoays ay to pasn aq snus ymuwey “uy uu 34. "aH0HHN 3 pur wmatoe ie Uo pa 3g snus oNIIOs 2uosge 6 ondasp 241 u yeu ayn SOE 08005 (61 18 2A ZF J aouEstd 10) POU P29 YOS20 Jo 9g 9 ve (euNs souazap aN 7990 T rnueyy sEwaNDS 00) put 3A woo 1010u 284 $11 242 20834“ OS 28 Hi swesERIP aneUayoe uniiasue5 28, ey} so) pa2ig ae ip 24) 9949 "1 trays 30 yeus mer U2H0H8 20) 249 2PA jojueysou H wiajgosd WE YDS A IAS 0 ae ma ae. sssge suo sonewouss 2S 240 w wresBeIp snewayps 208409 §qIUC) 3H 0} 2)py ‘3Ho} wowultes sieudoidde 249 YS 24) 208 "pos eadoudae 2401 "¢ sdwy 0g srewrrosdde speos ssiowue ws.un> Brau aun pur "up 81 Addins poy 241 TUS ¥>OUD *Z “8 sve 94199049 4 saynys sony 24) J0 940 Uo Smatne 18 2007 2 ‘uyuns pases s904 01 se 40 "uo poyouns u9q 10u s0H eMOIg UL“ ‘pazunssaid J9fuo| 8 8 2}0SU09 244 “L "uo 1 9ye1q sau 24 SYOMMELC IT'S mp0 aq ayy Auyoras rou suis aqno puRy 343. «dn payed aney 104 Kou so}seIUe> IMUBESY “¢ 0% eu quauno pyay 24) “2dGv-wunys 248 eo1ow jE "yo 94 Sow sun YS "N39 “4 su0% 10u s20p smo. 104 +E spunos won -e uns 300 1M 10 "1 NONLOV ‘asnvo a1evEoud WOLAWAS: ‘Table IL-1. Driller’s Console Troubleshooting Table RHCC SCR Drive System Technical Manual Dailler's ConsoleIV. REMOVAL & REPAIR 1. Console To access the console assemblies, open the front panel door by unlocking the latches. See figure IV-1 for idemtification of the assemblies. Caution Before removing the cables, mark each with the corresponding TB number 2. DW Foot Throttle Release the four 14-32 bolts located in the corners of the pedal place and lift out the assembly. To ac- ‘cess the rheostat, remove the rear dust cover by re- leasing the four corner screws. Refer to figure IV-2 for the parts list, Figure IV-1. Driller’s Console Assemblies RHCC SCR Drive System Technical Manual L B. COMPARTMENT VIEW aev2 6000-08 vere main Ir yal! Figure IV-2. DW Foot Throttle Assembly Drillers Console RHCC SCR Drive System Technical Manual1v3 3. CSA Compliance with CSA Approval/Listing of Model 425 Driller’s Console for use in Class I, Division 11, Groups C & D Hazardous Atmosphere Locations. Caution: A. Air Purge Alarm System Multi-Pote connectors are for installation only. The Air Purge Alarm System must be modified to Do not disconnect unless area is known to be comply with NFPA-496 Rules for Type Z Purging as. non-hazardous, and al circuits are de-energized. interpreted by CSA, Changes required are as follows: (1), Delete Alarm Silence toggle switch, or supply selfresetting (CSA. Approved) Alarm Silence switch, _ (2). Delete existing Supply Line pressure switch, B. Implementation (3). Increase orifice diameter to 0.161 inch (#20 Drill (1). Implement for all Driller’s Consoles shipped to Bit) to provide 5.0 SCFM flow at 50 psi. inada or for eventual Canadian use. (4). Install Dwyer differential pressure swith (P/N (2). Implement for all Driller’s Consoles shipped (0403-0081-00) complete with connection to after 4/15/80, atmosphere (3). Do not retrofit unless required by regulatory (5). Add cautionary nameplate in both English and bodies. French, (4). Implementation at any location other than Ross (6). IfPYLE-NATIONAL connectors are installed on Hill Controls Corporation plant, 1530 West Belt console, add cautionary nameplate in both English North, Houston, Texas 77043, violates CSA and French as follows: Agreements, RHCC SCR Drive System Technical Manual Driller’s ConsoleMUD PUMP/CEMENT PUMP CONSOLE ROSS HILL CONTROLS CORPORATION =————e1, OPERATION 1. Description ‘The console enables control of the pumps for main- tenance operations such as changing liner sizes, The following description is referenced to the Mud Pumps. The same applies to Cement Pumps. The console is not intended for routine operation of the pumps. The throttle range is restricted to half the range available from the Driller’s Console. Fur- ther, the rod oiler, chain oiler, and charging pump are not automatically switched on, 2. Specifications A. Electrical The console has dual control circuits, one for MPI and another for MP2. Each circuit receives the fol- Towing voltages from the SCR units assignable to Mud Pumps: (1). +14V to turn on a Power On light (2). -14V contactor contro! logic Each circuit outputs the following voltages to the same SCR units (1). -14V contactor control logic (2). 0 to -BV throttle reference ‘The MCC provides 115 Vac, 19 to power a strip heat- ef and a courtesy outlet. B. Mechanical The console is fabricated from 12 gauge st steel. The assembly is watertight. Size: 18 in. L by 10 in. H by 10 in. D (46 cm L by 26 em H by 26 cm D) Weight: 30 Ib (14 kg) 3. Operating Instructions Figure I-1 identifies the controls and indicators. ‘The console has a dual set of controls, one for MPI and another for MP2. During normal operation of ‘the pumps from the Driller’s Console, the lockout ‘switches should remain switched on, Padlock at- tachments are available to prevent tampering. The Power On light glows when the pump is assigned. To operate a pump from the Mud Pump Console for maintenance activity, observe instructions listed below: ‘A. Set the MPI (MP2) lockout switch and the cor- responding throttle to Off. B. At the Driller’s Console, first set the MPI (MP2) throttle to Off. Set the assignment switch to MPI (MP2) and turn On the corresponding lockout switch. ©. At the Mud Pump Console, the MP1 (MP2) Power On light will glow. D. Set the MP1 (MP2) lockout switch to On and ‘crank the throttle to achieve the desired speed. E. To resume normal operation from the Driller’s Console, turn the throttle handwheel to Off. Do not turn off the lockout switch. Turning off the switch prevents operation of the pump from either the Mud Pump Console or the Driller’s Console. Lockour switch => THROTTLE HANDWHEEL. Figure I-1. Controls and Indicators, POWER ON LIGHT RHCC SCR Drive System Technical Manual ‘Mud Pump ConsoleIl. MAINTENANCE Refer to the SCR Drive System section for general 2. Testing instructions regarding shipping, storage and servicing. Test the console afer repaiting or replacing any : n ° 1. Installatio of its active components. A functional test simply Four stabs are welded to the back panel of the con- consists of operating the console according to the tole to falitate wall mounting instructions istd in the previous secon RHCC SCR Drive System Technical Manual ‘Mud Pump ConsoleIll. TROUBLESHOOTING 1. Theory of Operation Figure III-1 shows the console assembly. Schematic diagram is figure II1-2 and figure III-3 shows the con- trol logic. The logic diagram highlights.the circuit activated when MPI is driven from the Mud Pump Console on SCR 2. The 0 to -8V MPI Reference (MP2 Reference) is applied to DC Module pin 126 (pin 123) of all the SCR units assignable to MP1 (MP2). A speed com- mand is created from this reference by passing it through a 47 KO resistor. This contrasts with a 22 K® resistor used for reference from the Driller’s Console. As result, throttle range from the Mud Pump Console is approximately half the range from the Driller’s Console. 2. Troubleshooting Index See table 1 LockouT swiToH RHEOSTAT A, DOOR POWER ON LIGHT Po.CARD B. CABINET Figure III-1. Console Assembly RHCC SCR Drive System Technical Manual Mud Pump ConsoleDun ae puE 2fosu0D duh PAIN uy ve youdls apie 34h 40 20uaa1d 94) 10) MD "E wo s pris moor (ZAHN) 1A 2 pe 12s Aayeudoudde 51 yous WaKIUEISSE 30500. 521 ‘hua au) sunk abu yo SN) UO J2Mod 24D Lot arnpowy qr ay Auyoeer you soua1sas smo Ag 80°F sopenu0> tun ou s30p dum PW fore asnvo sTevEoud WOLAWAS ‘Table 111-1, Mud Pump Console Troubleshooting Index ‘Mud Pump Console HCC SCR Drive System Technical ManualFigure I1I-2, Mud Pump Console Schematic Diagram RHCC SCR Drive System Technical Manual ‘Mud Pump ConsoleFigure II-3. Mud Pump Control Logic RHCC SCR Drive System Technical Manual Mud Pump ConsoleTRANSFORMER FEEDER UNIT "cod f =e it Kh _ ROSS HILL CONTROLS CORPORATION|. OPERATION ‘The Feeder unit consists of circuit breakers which channel power from the common AC bus to the rig AC distribution network. Figure I-1 identifies the front panel controls. Figure I-2 is a one line diagram. A of each output line is monitored by an ammeter. APC card mounted at the back of each meter has a diode bridge circuit which rectifies the AC control signal to power a DC meter movement. Figure I-1. Feeder Unit Controls and Indicators Ac 8us 600¥, 60H, 38 Ac us “Tt 4 % a) 3000:8 cT's Figure 1-2. Feeder Unit One Line Diagram MOTOR CONTROL CENTER sc-o02i~a RHCC SCR Drive System Technical Manual ‘Transformer Feeder UnitMOTOR CONTROL CENTER SS F05s HILL CONTROLS CORPORATION =e1. OPERATION ‘The Motor Control Center (MCC) is a part of the RHCC SCR Drive System package. It provides cen- tralized control of the auxiliary AC functions from the SCR room. The MCC components are vendor items which are assembled by RHCC according to the customer's specifications. 1. Description Full Voltage Non-Reversing (FVNR) combination starters are used for blowers, rod and chain oilers, charging pumps, ete. Each starter unit has either a HOA switch or a Start-Stop pushbutton. Overload protection is achieved through thermal overload relays, and a circuit breaker provides short circuit protection, A circuit breaker is used for both pro- tection and control for non-rotating devices such as welding machines. 2. Specifications The MCC conforms to NEMA Class I, Type C guide- lines. A. Electrical Line input - 600V/480V/208V/120V, 60 Hz, 34 ‘The MCC bus is capable of carrying 600 Amps con- tinuous current and can withstand 42,000 Amps RMS symmetric fault current. Starter coil rating is 120 Vac. Starter size, CB rating and rating of the overload heater elements are based on the maximum horse- power rating of the motor. See figure I-2 for details. B. Mechanical The MCC consists of one vertical section or several sections bolted together. Each section has space for six size I starters mounted in 13 in. (33 cm) high modules, Section Size: 90 in, H by 20 in, W by 20 in. D (230 em H by SI em W by SI em D) RCC SCR Drive System Technical Manual 3. Operating Instructions Figure +I identifies the controls. The operating instructions are listed below. A. Start-up (1). Set all the MCC controls to Off as a safety precaution, (2). Make sure the front panel doors of all the starter units are smugly closed. The Disconnect handle is interlocked with the door latch, It will not set to On unless the door is closed (3). At the Transformer Feeder section, close the ap- propriate circuit breaker to energize the MCC bus. B. Normal Operation (1). To turn on a particular device, first close the corresponding circuit breaker by setting the Dis- connect handle to On, (2). If the device has remote operation capability set the HOA switch to Auto for operation from the control console. To operate the device locally, in case of malfunction or curing test, set the HOA switch to Hand. The device can be turned off locally by returning the HOA switch to the Off position, C. Reset Operation When power to a device is cut off at the MCC, set the corresponding HOA switch to Off or push in the Off button, as applicable (1). The circuit breaker provides short circuit pro- tection. To resume operation, simply close the break- er by setting the Disconnect handle to On, (2). A thermal relay provides overload protection. The relay cannot be reset until the heater element cools down: (3). Resume operation by following instructions listed in section B. Motor Control CenterCircuit Breaker Switch HOA Switch Thermal Relay Reset Button Figure I-1. MCC Unit Controls FA0036.8 RHCC SCR Drive System Technical Manual Motor Control Center480 Vac 1A 1B 1c 1D 28 )s07s ses Jreers ) 150s 1 ! 2 uly ae am a am é g 8 e we ° s B 2 8 2 8 3 8 ® : 8 8 a & & & & [toa HOA HOA HOA 7 HOA aN “NN CHAIN Motor AGITATOR CHARGING == MUD OILER BLOWER PUMP MIX PUMP Figure -2, MCC One-Line Diagram RHCC SCR Drive System Technical Manual Motor Control CenterIl, MAINTENANCE Refer to the SCR Drive System section for general instructions regarding installation, shipping and storage. 1. Servicing A. Deenergize the MCC by tripping the appropriate circuit breaker at the Transformer Feeder section. B. Remove accumulated dust and dirt in the modules land the wireways. ©. Inspect the main and vertical bus joints and tighten if necessary, If the MCC consists of several vertical sections, examine the splices between sec- tions for tightness. HCC SCR Drive System Techn D. Check all the wiring for damage to the insulation and tightness. Remove the plug-in modules and check the stab assemblies. 2. Testing Testing the MCC is elementary. To examine the unit components during operation, a defeater mechanism is provided to disable the interlock between the door latch and the circuit breaker disconnect handle. The defeater is a small screw which has to be loosened. Motor Control CenterIll, TROUBLESHOOTING e The following theory of operation provides an ex- units ofthe drive system. Figure IIL? isthe diagram planation of the various MCC cireuls. Figure I-l of astarter unit and Figure II-3 shows the assembly, shows the relationship between the MCC and other Ac ous BOOV, BOF, 3B ac sus + * ¢ TRANSFORMER | FEEDER UNIT ae aeov reov/208v REMOTE OPERATION Logic 1 \ 201208 mcc, LIGHTING DRILLER'S PANEL CONSOLE PUMP PUMP BLOWER OILER aoeeeeee Figure ILI, Motor Control One Line Diagram se-oott-a RHCC SCR Drive System Technical Manual Motor Control Center‘The remote control logic for auxiliary AC functions associated with the drilling traction motors is loca- ted in the Driller’s Console. For example, blowers for the traction motors (Drawworks, Rotary Table, ‘Mud Pump, etc) are activated through the corres- ponding lockout switch on the console. The remain- ing auxiliaries (rod oiler, chain oiler, etc) are nor- mally switched on by a microswitch interlocked with the corresponding hand throttle. The switch is closed when the hand throttle is rotated out of the Off position. Each starter relay has a set of auxiliary contacts. ‘When all the contacts for a particular function are RHCC SCR Drive System Technical Manus + 5| TL Deve sore Cpa Tas a wae neo 1 Figure 12 Motor Starter Schematic a i closed, its blower light on the console glows. For example, the MP! blower light glows when the auxiliary contacts of the MPIA and MPIB blowers, MPI rod oiler, MPI chain oiler and MP1 charging pumps are closed. A normally closed auxiliary contact of the blower starter relay is part of the blower loss logic. If the blower is selected to run but doesn’t start, the con- tact remains closed to switch on an alarm which is ‘mounted inside the Driller’s Console. ‘The Driller’s Console section provides additional troubleshooting information on the remote control logic. Motor Control CenterCircuit Breaker Disconnect Switch Heater Elements TBto ees Drillers Console Relays Figure IL-3. MCC Assembly RHCC SCR Drive System Technical Manual Motor Control CenterFIELD SUPPLY UNIT —n-oss HILL CONTROLS CORPORATION|. OPERATION 4, Description The unit develops DC field current for separately excited shunt-wound motors. The AC supply from the common bus is rectified in a diode bridge. There is an independent rectifier cireuit for each shunt DC function. ‘The field supply is interlocked with the motor assign- ment logic through a Field Loss relay. The relay pre- vents application of power to the motor if the field ccurrent is below a preset level. A. Specifications (1). Electrical ‘The input is 600 Vac, single phase tapped from the common AC bus. The output is 200 Vde at 50 Amps (2). Mechanical The circuits are mounted within a cubicle 90" (230 em) fabricated from 12 gauge stecl plate. Each cubicle is capable of housing up to 6 independent field supplies. Weight: Approximately 2000 Ib. (960 kg). 2. Indicators and Controls Figure I-1 provides a view of the front panel controls and indicators on a typical Field Supply Unit ‘The HOA switch (4) enables operation of the field supply manually or automatically. In the “Auto” mode, the field supply is interlocked with the corres ponding blower motor. The field supply is cut off if the blower is switched off. The Armature Current Unbalance light (3) glows if field currents to two motors driving a single function (e.g. Mud Pump) are not equal. The field supply current can be monitored on the DC ammeter (1) by selecting the appropriate motor at the ammeter select switeh (2) 3. Operating Instructions A, Ensure that Fused switches in the cubicle are closed. B. Set HOA switch of the desired field supply to “Auto” C. IF your Field Supply has a ammeter switch, rotate the Ammeter select switch to the appropriate position and observe the ammeter. The field current should be approximately 50 amps. If you do not have ammeter, open Field Supply cubicle door and. RHCC SCR Drive System Technical Manual verify the red lenses are lit indicating presence of field current. D. Ia function (eg. Mud Pump) is driven by uso ‘motors, ensure that field supply current to both motors is approximately equal Caution RHCC does not recommend operation of a motor when its blower is inoperative. 1. DC Ammeter (optional) 2. Ammeter Select Switch (optional) 3. Armature Current Unbalance Lights 4. HOA Switch Figure I-1. Field Supply Controls and Indicators Field Supply UnitIl. MAINTENANCE Refer to the SCR Drive System section for general instructions regarding installation, shipping, stor- age and servicing. Table II-1 is a list of instructions for testing the Field Supply Unit. Ifthe unit fails to perform as indicated, refer to the troubleshooting tables in chapter II] to locate the malfunction. ACTION RESULT General 1. With the Field Supply Unit off, examine the corresponding Field Loss (FL) relay. 2. Close the appropriate circuit breaker and place the corresponding HOA switch in the Hand position. Assign the motor from the control console and set its lockout switch in the On position. 3, Place the HOA switch in the Auto position. Ul, Active Field Supply 1. Follow instructions in section 1 IL, Fleld Weakening 1. Follow the above instructions with the Winch Console assignment switch in Reel-In Low position, 2. Switch the Winch Console assignment switch to Reel-In Hi 1. The relay coil should be deenergized. 1. The front panel ammeter should read approxi- mately 50 Amps or two small LEDs located on Field Supply pan will be it, If the motor blower is interlocked with the lock- out switch, the field supply unit does not turn on until the switeh is turned on, 1. During operation, field current to both A and B ‘motors should be approximately equal. If currents to ‘A and B motor armature differ by more than 200 Amps, armature current unbalance will shut down pump. To start pump reset button on Field Supply must be pushed. 1, The front panel ammeter should read approxi- mately 50 Amps. 2. The front panel ammeter should read approxi mately 40 Amps. ‘Table 11-1. Field Supply Functional Test RHC SCR Drive System Technical Manual Field Supply UnitIll. TROUBLESHOOTING 1. Theory of Operation The following description is referenced to typical field supplies. The SCR Schematic Manual has sche- matic diagrams appropriate for your rig Passive Field Supply Refer to figure IlI-3. This is the Field Supply sche- matic for a separately excited shunt-wound Rotary Table motor. The fused switch isolates the field supply circuits from A and $B of the 600 Vac com- mon bus. If the HOA switch is placed in the Hand mode, relay R3 is energized when the RT lockout switch on the Driller’s Console is closed. The normally open con- tacts of R3 close to apply AC power to the Diode Bridge via transformer T3. If the HOA switch is set to the Auto mode, the RT blower contact in the MCC. must also close before R3 is energized. ‘The DC output from the bridge is directly applied to the RT motor field winding. A Shunt is inserted in the DC (-) line to develop the control signal for the front panel ammeter. The 0 to 100A ammeter range corresponds toa S0mV FSD. The Field Loss relay is energized through a 50:1 CT in the AC input to the bridge. A normally open contact of the relay is inserted in the RT motor as- signment logic. If the AC supply to the field supply bridge is cut off, the relay is deenergized. The relay ‘contacts open to prevent application of power to the motor. Current to the bridge is limited to 80 Amps through a fast acting fuse. B. Active Field Supply This circuit is used to achieve load sharing between two shunt motors driven in parallel from a single SCR bridge. Such a drive is normally used for Mud Pumps. See figures 111-1 and Ill-4. Load sharing is achieved by matching the armature currents of the two motors. Recall that for a fixed load, the armature current for a shunt motor can be varied by varying the armature voltage or the field current. Since the two motors drive a common shaft in parallel, they run at the same speed and have the same armature voltage. Therefore, control is achieved by varying the field current. RHCC SCR Drive System Technical Manual Observe from figures III-1 and IlI-2 that the MPIA field current, derived from a diode bridge, is held fixed. MPIB field current is varied so as to match the armature currents. MPIB field supply is derived from a controlled bridge made up of two SCR's A regulator circuit periodically switches the SCR's ‘on and off to vary the bridge output. Refer to the Unique Devices section for a general description of the SCR device. Figure Il1-2 is the block diagram of the regulator circuit and figure III-S is the schematic diagram. The regulator has two firing circuits. These develop gate firing pulses for SCR’s | and 2, respectively. The pulses are synchronized with the AC input to the re- spective SCR. A firing reference from Op Amp Z6 determines when the SCR's are fired during the AC cycle, The reference is derived from an error signal ‘out of the summing junction which precedes Z6. ‘One of the three inputs to the summing junction is a DC analog of the MPIA field current. This is the pr ‘mary current command. It is developed by tapping the AC input to the MPIA diode bridge via CT 1 CT 1 output is rectified through DBI. The current ‘command is matched to the second input, a DC ana- log of MPIB field current. This feedback signal is de- veloped by tapping the AC input to the MPIB bridge via CT 2. CT 2 output is rectified through DB 2. The third input to the summing junction is from the Hall Effect Device (HED). It indicates the difference in armature current of the two motors. The signal compensates for the differences in tolerances of the two motors. If the motors were ideally matched, the armature currents would be equal when the field currents are matched. Refer to the Unique Devices section for a general description of the HED. C. Field Weakening Recall that the speed of a shunt moter is inversely related to the field strength. If the field current is re~ duced, the speed range is increased. In RCC systems, the field current is normally held constant and the armature voltage is varied to vary the speed. In this, special case, the field current can be set at one of two levels to achieve two speed ranges. This feature is called Field Weakening. Field Supply Unit4 Field Weakening is normally used for Windlass mo- tors. Refer to figure III-6 for the schematic diagram of a Windlass field supply. Observe that transformer 3, which feeds AC power to the diode bridge, has two taps on the secondary side. The 95 Vac tap is selected for the higher speed range. When the Windlass Console assignment switch (S1) ergized. The normally open contact of R10 closes to feed the 95 Vac supply to the bridge. Relay RII is energized when the assignment switch is set to Reel- In High. 2. Troubleshooting Index is set to Drive Out or Reel-In Low, relay R10 is en- See table III-1. Few surety v0 --}—fon) + |4 -- 4+—____ (on scr YY BRIDGE ™ Figure III-L. Active Field Supply Configuration ees sort neo Free or] cate 2 imine cxr eo (1 carn sor 2 ou oe RING xT 2| a Gye car arn yo we) —— FIELD LOSS rut RELAY r- Figure 111-2. Field Supply Regulator Block Diagram Ces Field Supply Unit HCC SCR Drive System Technical Manualpotas 88H upppay ua paxBious 2q pinows 1 (91) 9 pus 91) § su¥d Jd 3 aa 24001 seuss yur 991 40 ause1d 104 9994 °T 2suotajp duty got 24 pimow 4 C0" sta fang 20uaIa}9). 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