Contents

1 Electric Control System Introduction ................................................................. 1 

2 AC Control Unit .................................................................................................... 2 
2.1 AC Control Unit ................................................................................................. 2 
2.1.1 Generator Circuit Breaker ................................................................................... 3 
2.1.2 Synchronous Device Circuit................................................................................ 4 
2.1.3 Outgoing Circuit of AC Control Module ............................................................ 6 
2.1.4 Power Limit Box ................................................................................................. 7 
2.1.4.1 Function of the Power Limit Box ....................................................................... 8 
2.1.4.2 Setting Limit Value............................................................................................. 8 
2.1.4.3 Limiting the Increasing Rate of Load................................................................. 8 
2.1.4.4 Power Limit ........................................................................................................ 9 
2.1.4.5 Limit of Underfrequency and Reverse Power .................................................... 9 
2.1.4.6 Display ............................................................................................................... 9 
2.1.4.7 Lamp Testing and Selecttion ............................................................................ 10 
2.1.5 Ground Fault Detection Circuit ......................................................................... 10 
2.2 AC Control Module............................................................................................ 12 
2.2.1 Frequency Regulator ......................................................................................... 12 
2.2.2 Master/Slave Control Circuit ............................................................................ 13 
2.2.3 Voltage Regulator .............................................................................................. 14 
2.2.4 Exciting Circuit ................................................................................................. 15 
2.2.5 Protection Circuit .............................................................................................. 15 
2.2.5.1 Overvoltage Protection..................................................................................... 15 
2.2.5.2 Underfrequency Protection .............................................................................. 16 
2.2.5.3 Overfrequency Protection ................................................................................ 16 
2.2.5.4 Reverse Power Protection ................................................................................ 16 
2.2.5.5 Idle Protection .................................................................................................. 16 
2.2.5.6 Feedback Pulse Loss Protection ....................................................................... 17 
2.3 AC Control Unit Technical Parameters .............................................................. 17 
2.3.1 Engine Speed Control Specifications ................................................................ 17 
2.3.2 AC Generator Voltage Control Specifications................................................... 18 
2.3.3 Parallel Running Specifications ........................................................................ 18 
2.3.4 Generator Protection Value (breaker trips if more than the protection value) ..... 19 
2.4 AC Control Unit Operation ................................................................................ 19 
2.4.1 Preparations before Starting .............................................................................. 19 
2.4.2 Starting the Engine ............................................................................................ 20 
2.4.3 On-Line Operation of Generator Set ................................................................. 23 
2.5 AC Control Unit Function Test .......................................................................... 25 
2.5.1 Preparations ....................................................................................................... 25 
2.5.2 Engine Actuator Test ......................................................................................... 25 
 2.5.3 Exciting Coil Resistance Test ............................................................................ 25 
2.5.4 AC Control Module Function Test .................................................................... 25 
2.5.4.1 Preparations ...................................................................................................... 25 
2.5.4.2 Check Power Supply ........................................................................................ 25 
2.5.4.3 Frequency Demodulation Test.......................................................................... 26 
2.5.4.4 Current Demodulator Output Test .................................................................... 26 
2.5.4.5 Voltage Regulator Test ..................................................................................... 26 
2.5.4.6 Speed Regulator Test ........................................................................................ 26 
2.5.5 Control Loop Test.............................................................................................. 27 
2.5.5.1 Generator Voltage Phase Sequence Test ........................................................... 27 
2.5.5.2 Module Board Six Phase Voltage Phase-Sequence Test................................... 27 
2.5.5.3 Voltage Regulator Test ..................................................................................... 28 
2.5.5.4 Engine Speed Regulation Test .......................................................................... 28 
2.5.6 Synchronous Circuit Test .................................................................................. 28 
2.5.7 Load Sharing Test.............................................................................................. 29 
2.5.7.1 Reactive Power Sharing Test ............................................................................ 29 
2.5.7.2 Active Power Sharing Test ............................................................................... 29 
2.5.8 Protection Function Test.................................................................................... 30 
2.5.8.1 No Pulse Trip and Stop Protection ................................................................... 30 
2.5.8.2 Reverse Power Trip Protection ......................................................................... 30 
2.6 AC Control Unit Troubleshooting Guide ......................................................... 30 
2.6.1 Generator Troubleshooting................................................................................ 30 
2.6.2 Engine Troubleshooting .................................................................................... 31 
2.6.3 AC Control Module Troubleshooting ............................................................... 32 
3 DC Control Unit .................................................................................................. 35 
3.1 DC Control System ............................................................................................ 35 
3.1.1 Thyristor Rectifier Bridge ................................................................................. 35 
3.1.2 Circuit Breaker .................................................................................................. 36 
3.1.3 Current Transformer .......................................................................................... 37 
3.1.4 RLC Filter Elements ......................................................................................... 37 
3.1.5 Pulse Transformer ............................................................................................. 37 
3.1.6 Voltage Feedback Board.................................................................................... 38 
3.1.7 Surge Suppression Circuit ................................................................................. 38 
3.1.8 DC Contactor .................................................................................................... 39 
3.1.9 DC Power Cable................................................................................................ 39 
3.2 DC Control Module............................................................................................ 40 
3.2.1 DC Regulator .................................................................................................... 40 
3.2.2 Foot Throttle Control ........................................................................................ 41 
3.2.3 Zero Throttle Interlock Protection ..................................................................... 42 
3.2.4 Current Limit Circuit......................................................................................... 42 
3.2.5 SCR Firing Circuit ............................................................................................ 42 
3.2.6 DC Control Module Panel ................................................................................. 43 
3.3 Belt Pulley Slip Protection Device ..................................................................... 44 
 3.4 Drawworks Dynamic Brake ............................................................................... 46 
3.5 DC Control Unit Operation ................................................................................ 48 
3.5.1 Deliver Electricity to SCR Cubicle ................................................................... 48 
3.5.2 Emergency Operation ........................................................................................ 49 
3.5.3 Surge Suppression ............................................................................................. 49 
3.5.4 Belt Pulley Slip Protection ................................................................................ 50 
3.5.5 Put SCR Cubicle off the Bus ............................................................................. 50 
3.6 DC Control Unit Function Test .......................................................................... 51 
3.6.1 DC Control System Specifications .................................................................... 51 
3.6.1.1 DC Control Cubicle Electric Parameters.......................................................... 51 
3.6.1.2 Forced Ventilation System Parameters ............................................................. 51 
3.6.2 SCR Bridge Rectification Test .......................................................................... 51 
3.6.2.1 Preparations ...................................................................................................... 51 
3.6.2.2 Module Power Supply Checking...................................................................... 52 
3.6.2.3 Contactor and Reference Test........................................................................... 52 
3.6.2.4 Firing Pulse Test ............................................................................................... 52 
3.6.2.5 SCR Rectifier Bridge Test ................................................................................ 53 
3.6.2.6 Rectifier Bridge Feedback Test ........................................................................ 53 
3.6.3 Dynamic Brake Test .......................................................................................... 53 
3.6.4 Troubleshooting SCR Components ................................................................... 54 
3.7 DC Control Unit Troubleshooting Guide ........................................................... 55 
3.7.1 SCR Unit Troubleshooting ................................................................................ 55 
3.7.2 DC Troubleshooting Guide ............................................................................... 56 
3.7.3 DWDB TROUBLESHOOTING GUIDE ......................................................... 61 
4 Driller’s console and PLC System .................................................................... 62 
4.1 Driller’s console ................................................................................................. 62 
4.1.1 Assignment Switch............................................................................................ 63 
4.1.2 BYPASS Selector Switch .................................................................................. 64 
4.1.3 Selector Switch.................................................................................................. 64 
4.1.4 Reference Hand Throttle Wheel and Current Limit Knob ................................ 65 
4.1.5 Meters................................................................................................................ 65 
4.1.6 Indicator Lights ................................................................................................. 65 
4.1.7 Pushbuttons ....................................................................................................... 65 
4.2 PLC System........................................................................................................ 66 
4.2.1 Description of system ........................................................................................ 66 
4.2.2 PLC Terminal Block Designation ..................................................................... 67 
4.2.3 PLC LED Indication ......................................................................................... 68 
4.2.4 PLC Troubleshooting ........................................................................................ 68 
4.3 Driller’s console Operation ................................................................................ 70 
4.3.1 Common Operation Procedure .......................................................................... 70 
4.3.2 Drawworks ........................................................................................................ 73 
4.3.3 Rotary Table Operation ..................................................................................... 74 
4.3.4 RT Current Limit ............................................................................................... 75 
 4.3.5 Mud Pump Operation ........................................................................................ 76 
4.4 Assignment Control ........................................................................................... 76 
4.4.1 DWA Motor Forward Rotation .......................................................................... 77 
4.4.2 DWA Motor Reverse Rotation .......................................................................... 77 
4.4.3 DWA and DWB Powered and Rotated at the Same Time ................................. 78 
4.4.4 DWS Forward Rotation..................................................................................... 78 
4.5 Speed Control ..................................................................................................... 78 
4.6 Blower Control and Alarm Devices ................................................................... 79 
4.7 Driller’s Console Function Test.......................................................................... 80 
4.8 Driller’s Console Maintenance and Troubleshooting Guide .............................. 80 
5 Power Supply System........................................................................................ 83 
5.1 Power Supply System ........................................................................................ 83 
6 AC MCC ............................................................................................................ 83 
6.1 MCC System ...................................................................................................... 83 
6.2 MCC Operation .................................................................................................. 84 
6.2.1 Start and Stop .................................................................................................... 84 
6.2.2 Protection .......................................................................................................... 85 
6.3 ECB .................................................................................................................... 85 
6.4 Travelling Wagon Anti-Collision System........................................................... 86 
6.4.1 Makeup and Function ........................................................................................ 86 
6.4.2 Operation of Travelling Block saver System .................................................... 86 
6.4.2.1 Measurement and Set of Total Height of Travelling Block .............................. 86 
6.4.2.2 Set Downward Slowdown Height and Downward Band-type Brake............... 87 
6.4.2.3 Set Upward Slowdown Height and Upward Band-typeBrake ......................... 87 
7 Installation and Maintenance of the Electric Control House .......................... 88 
7.1 Working Conditions in the Electric Control House .............................................. 88 
7.2 Installation ............................................................................................................ 88 
7.2.1 Installation Foundation........................................................................................ 88 
7.2.2 Installation ........................................................................................................... 89 
7.2.3 Wiring ................................................................................................................. 89 
7.3 Storage ................................................................................................................. 89 
8 Maintenance and Over-haul .............................................................................. 91 
8.1 Security Measures ................................................................................................ 91 
8.2 Maintenance ......................................................................................................... 91 
8.3 Check ................................................................................................................. 92 
8.3.1 Daily Check......................................................................................................... 92 
8.3.2 Weekly Check ..................................................................................................... 92 
8.3.3 Monthly Check .................................................................................................... 92 
8.4 Overhaul ............................................................................................................... 93 
8.4.1 Weekly Check ..................................................................................................... 93 
8.4.2 Quarterly Overhaul.............................................................................................. 93 
 1 Electric Control System Introduction

The electric drive system ZJ70 D consists of engine-generators unit (GEN cubicle), DC

control unit (SCR cubicle), driller’s console (DC), PLC control system, AC top drive and

MCC. The Distribution plan is shown as figure1-1.

DIESEL ENGNE DIESEL ENGNE DIESEL ENGNE DIESEL ENGNE DIESEL ENGNE

GEN1 GEN2 GEN3 GEN4 GEN5

AC AC AC AC AC
CONTROL CONTROL CONTROL CONTROL CONTROL
MODULE MODULE MODULE MODULE MODULE

CB1 CB2 CB3 CB4 CB5

600VAC 3PH 50HZ BUS

SCR1 SCR2 SCR3 SCR4 SCR5 FB1 FB2

DC DC DC DC DC AC TOP
PLC CONTROL CONTROL CONTROL CONTROL CONTROL
MODULE MODULE MODULE MODULE MODULE
XFMR1 600:400VAC
:Y 1250KVA
MCC SYSTEM

MP1 MP1 MP2 MP2 MP3 MP3

DWB/S DWA/RT RT DWA RT
DWB/S

Fiure 1-1 ZJ70D Distribution Plan of Electric Drive System

Except the driller’s console is set on the drilling floor and other devices above

mounted are installed in the eletrical control house.

AC control unit includes 5 GEN cubicles controlling the engine-generators. In a range

of the load change allowed, it intends to output 600V AC /50Hz. As the working state

requires, when all the generators or any more than two generators run online, the load can

be shared equally and transferred stably, suitable to the load characteristic of the drilling

rig and bear a surge of DC motors when they start to work.

DC control unit includes 5 SCR rectifier cubicles. Trough rectification, 600VAC is

turned into 0~750VDC voltage which can be regulated continuously. By PLC logical

control on DC contactors in each cubiclDC control unit changes over to different

assignments to drive mud pump (MP), drawworks(DW)，rotary table (RT) respectively.

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Motors of the drawworks and rotary table can rotate forward or reversely. RT current limit

can be regulated at will within a range of 50 to 1000ADC. Both the drawworks and mud

pump are driven by two motors. They are running with an equally shared load and at a

synchronous speed.

Through PLC, driller’s console makes the drillers do all kinds of operation during

drilling. Indicative lamps will tell the running state of the main equipments of the control

system.

Main functions of AC MCC are to control AC motors in such areas as drill floor of well

site, mud pump house, mud circulation tank area, oil tank area, air compressor house and

water tank area, and to supply lighting power to well site. The power supply of AC MCC

comes from a 600:400/230VAC 1250KVA dry-type transformer.

The auxiliary generator set configurated by the system through window and breaker

of auxiliary machine, the host machine and the auxiliary machine through interlock relation,

are put into MCC 400VAC bus.

Power distribution, output characteristic, control and protection function of electric

drive system meet requirements of 4000m~7000m working parameters, performances

and drilling technology. The system is explosionproof, quakeproof, dampproof and

fireproof.

Electric control system is installed in a house with skid base, and is connected with

cables of external equipment on one side and the side surface of the house. Connection

socket is reserved.

2 AC Control Unit

2.1 AC Control Unit

AC control system controls the engine-generators to make it give out a steady

output of 600 AC V 50Hz.

Each AC control system includes generator circuit breakers, synchronous devices,

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AC control modules, power limit circuit and ground detecting circuit. All of them are

installed in one cubicle (GEN Cubicle). Its structure is shown as figure 2-1.

2.1.1 Generator Circuit Breaker

The generator circuit breaker (MERILIN GERLIN MT20H1，65kA) energizes or

isolates the generator main bus and 600VAC bus. There is a magnetic tripping device

installed in the circuit breaker, which automatically trips when there is an overcurrent. Also

an undervoltage (UV) trip coil is in the circuit breaker which interlocks with the protective

circuit of AC module. When the circuit fails such as underfrequency, overfrequency,

overvoltage and reverse power, the protection circuit makes VU trip coil trip automatically

and the breaker trips, which protects the generator set and the load. Before operating the

circuit breaker, the long delay setting value and the instantaneous trip value must be

correctly set.

GEN
Circuit Breaker

AC Control MOD

Figure 2－1 GEN Cubicles

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 When the circuit breaker is open, the charge indicator indicates ‘OFF’. To close the

circuit breaker, firstly rotate the handle for several times until the charge indicator indicates

‘OK’, secondly press down the ‘PUSH TO CLOSE’ button on the panel of the cubicle, then

the circuit breaker will be energized. To disconnect the breaker, just press the ‘PUSH OFF’

button. Refer to figure 2-2.

Figure 2－2 GEN circuit breaker

2.1.2 Synchronous Device Circuit

The generator sync control circuit is shown as figure 017-002 (P07,P08,P09) ,In the

figures S01 is a sync selector switch. In the sync box, M1 is a frequency meter, M2 is a

sync meter, M3 is a voltmeter, L1and L2 are sync lamps.

M1 M3 M2 L1、L2
4
 Figure 2-3 Synchronous Box

The sync box connects the outside circuit by 4 lines among which 3 lines connect

with S01 and 1 line to 115VAC grounded neutral line.

The sync switch selects output of the generator ready to get online. For example,

when S01 is selected to GEN1, A10-B10, A04-B04, C10-D10, C04-D04 are closed. The

sync box will detect the voltage and the frequency of GEN1, showing them respectively on

meters, comparing them with the bus frequency (and phase), the sync meter and sync

lamp will show the synchronization state.

When a generator is already running online on AC bus, if you wish to bring another

generator to AC bus, before closing the generator circuit breaker, it is necessary to match

the voltage and the frequency of the generator to those of AC bus by the synchronous

device. When the sync switch on the panel is set on ‘OFF’, frequency meter and voltmeter

of the sync device will respectively show the frequency and the voltage of the common

bus. When the sync switch is set in the order number of generator ready online, then

frequency meter and the voltmeter will show the frequency and the voltage of generator

ready to get online. When the two voltages are identical, the sync meter and sync lamp on

the panel compare the frequency or the phase of the generator ready to get online with

that of the bus. If the frequencies or phases are different, the needle of the sync meter

rotates and the sync lamp keeps flickering. When both the signals are synchronized, the

needle of the sync meter points to 12o’clock, the sync lamp is off. When the signals of

both the generator ready to get online and the bus are delivered to the sync box, they are

also delivered to pins 01 and 04 of the sync relay RL 04. After synchronization, pin 07 and

pin 08 in RL04 are closed, the voltage of the generator ready to get online is delivered to

the sync lamp button LPB1, the lamp (figure 017-001. P06) is lit. At this moment, press

immediately the sync lamp button (‘PUSH TO CLOSE’), then the closing coil of the circuit

breaker is energized. Then close the circuit breaker and bring the generator to the bus.

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 2.1.3 Outgoing Circuit of AC Control Module

Figure 2－4 AC Module

AC control module is a core part of AC control system, the input signals of AC

control module are speed reference (SPD REF), voltage reference (VOLT REF), feedback

voltage 115 VAC of the transformer secondary(AC MODULE XFORMER), current

feedback signal of the current transformer (CT), speed feedback of the tachometer (TACH)

and feedback signals of the exciting current (Iex). The output signals of the AC control

module are speed adjusting signal of the engine (THROTTLE), pulse signal of voltage

adjusting (GATE) of the generator and driving signals of the KW meter and KVAR meter.

In figures 017-001 (P05) and 017-001 (P06), there shows AC module block

diagrams (AC MODULE) and each terminals (501-556).

115VAC is input on terminals 512 to 517 as voltage feedback signal. figures 017-001

(P05) but an input voltage of the module rectifier power. Terminals 510 and 511 are

connected to HOC circuit of the +12V accumulator, terminals 534 and 525 respectively

6
deliver the real current (IREAL) and the total current (ITOTAL) to the power limit box.

figure 017-003 (P11). Terminals 503, 507, 543, 544 are the master-slave control terminals

of the module. Terminals 504 and 505 deliver the voltage control pulse GATE A+ and

GATE A- to SCR control poles of the exciting circuit board (EXCITER PC). Terminals

533 and 545 deliver the engine speed control signal THROTTLE to the engine actuator.

Terminals 526 and 527 deliver the engine speed feedback signal to the module to adjust

speed. Terminal 536 is the ‘RUN/IDLE’ control terminal of the engine. When button PB01

is pushed to close, terminal 536 grounds, at ‘IDLE’ position; when PB01 is off, it is at ‘RUN’

position. Terminal 508 supplies +160VDC and gives +16VDC input to terminal 502 after a

voltage reduction by resistor. Only when the circuit breaker undervoltage trip coil (gen cb

uvr) gets 24VAC, the circuit breaker can be closed and keep closing. If any of various

failures happens in the generator, the normally open contacts between the module 528

and 529 will be open, the coil will be deenergized, and the circuit breaker will trip. Similarly,

if the ‘RUN’ button of the engine control switch is not set at ‘Push to Close’ position, or the

generator emergency off switch is pushed, the circuit breaker will also trip.

Terminals 519 to 524 input the current feedback signals of the current transformer.

Terminal 547 inputs speed reference signal and 551 inputs voltage reference signal.

In Figure 017-001 (PO5, P06), RL01 is an emergent off relay to control

normally-close contacts between 533 and 545. When the contact is closed, the engine

throttle is colsed too.L02 is GEN RUN lamp, L03 is GEN ON LINE lamp.LPB1 is a PUSH

TO CLOSE lamp. M10 is HOUR METER. GEN CB PTC is circuit breaker closing coil.

Figure 2-4 shows AC module outlooking.

2.1.4 Power Limit Box

Figure 2－5 is adiagrm of power limit box. Figure 017-003（P10）is a connection

diagram between the box and Siemens Driver and T11. Figure 017-003 （ P11 ） is

connection diagram between IREAL and ITOTAL of GEN AC modules to power limit box.

From these, the module which outputs the highest phase in each generator

represents IREAL(KW) and ITOTAL.

7
 2.1.4.1 Function of the Power Limit Box

(1) When real power (KW) or total current (ITOTAL) of the generator achieves its

setting values, limiting DC motor load to avoid the shutdown of the engine or the tripping

of the generator circuit breaker.

(2) When the load increases suddenly, making the load of the generator increase

gradually to protect the generator set.

(3) If there is an underfrequency, limiting the DC motor load.

2.1.4.2 Setting Limit Value

In the box, Z2 and Z3 respectively form the limit settings circuit of ITOTAL and KW,

the setting value is decided by the state of 4 switches. When all of the 4 switches are

closed, the setting value is 80% of the generator rated signal. When all of the four

switches are off, it is 110%. By changing the state of switch, the smallest change of setting

(2%) is available (80%, 82%, 84%......108%, 110%).

2－5 Power Limit Box

2.1.4.3 Limiting the Increasing Rate of Load

After the limit value is set, if the setting value is not reached, the drillers may at will

8
increase the hand throttle reference and the power of DC motor. As the generator can not

instantaneously reach the full power, it must take a few seconds to reach the full power,

but the load power often changes promptly, therefore, the power limit circuit has been

designed for a power increasing circuit with a given increase rate, which is composed of

Z10 and Z8. (see power limit schematic diagram)

2.1.4.4 Power Limit

When the hand throttle reference is increased, but the stroke of mud pump or speed

of the rotary table is not increased, this shows the drilling rig reaches the power limit value,

namely, a further increase of the hand throttle reference can not make the

engine-generators provide more power. If drilling operation is good at present, it is

unnecessary to bring another generator online. In fact, it is best to keep the generator

running nearly at the maximum power of the generator. It is good for maintaining the

engine generator and saving fuel. It is not harmful to any other equipment to keep the

power limit lamp on.

If the drilling operation needs more power, you must bring another generator online.

2.1.4.5 Limit of Underfrequency and Reverse Power

Because of a load increase and other reasons, the AC power frequency decreases to

42Hz or below. Z7 outputs power limit signal.

2.1.4.6 Display

When an underfrequency signal occurs, LED1 will shine, when KW achieves 95% of

its limit setting value, LED2 will shine; when ITOTAL achieves 95% of its limit setting,

LED3 will shine.If a power reverse occurs, LED4 will shine ,Any of the above 4 LEDS

shining will display the relay RL02 to pick up and make the power limit lamps on the

cubicle panel and on the driller’s console shall be illuminated.

9
 2.1.4.7 Lamp Testing and Selecttion

Z4 forms shaker , Z4 and pushbutton S1 together test if the 4 shining diodes above

mentioned are all right, When S1 is pressed down, the light flickers, it shows the shining

diode works normally.

When S6 is put on ‘NORMAL’ position, the power limit function is valid. When S6 is

put on ‘EMERG’, the power limit function is invalid. But 4 shining diodes flicker. When

dealing with emergent commission in the field, then rotate the selector switch to ‘EMERG’.

2.1.5 Ground Fault Detection Circuit

The ground fault detection circuit detects and displays ground faults or leakage faults

of AC and DC bus and show them. The circuit is installed in the SCR1 control cubicle. It

includes 3 lamps: L1, L2, L3, an AC ground meter M08 and a DC ground meter M09. As

Refer to 2-6.

2-6 Lndicating Lamp of Ground Fault Test

If there is no ground fault, all of the 3 lamps illuminate with equivalent brightness, the

ground meter will show ‘zero’. In any of AC 3 phases, a ground fault or leakage fault

occurs, the brightness of the 3 lamps will be different because the potential at the load

center point moves, the phase in which the dimmer lamp lies will be one in which there is

a ground fault. The ground fault meter M08 will indicate severity of the failure with a black

needle. The red needle of M08 is set at a certain angle. When AC ground fault is enough

severe, the black needle and the red one which is manually set coincide. At the moment,

the normally open contacts of M08 is closed to make the relay RL10 pick up, its normally

open contacts is closed. The PLC makes the ground fault lamp (‘GND FLT’) on driller’s

10
console shine for alarming.

2-7 AC Ground Detetcion Meters M08

2-7 DC Ground Detetcion Meters M09

If there is no ground fault in the DC system, the back needle of M09 is at the center

position. If there is a ground fault at the positive pole bus, the black needle deflects to the

right; if there is a ground fault at the negative pole bus, the black needle deflects to the left.

If the DC ground fault reaches enough severity, the black needle coincides with one of the

two red needles. Similarly, this makes the ‘GND FLT’ lamp on driller’s console shine for

alarming. See diagram 017-004 (P12)

11
 Whether an AC ground fault or a DC ground fault occurs, you must find out the cause

of the fault and remove it to avoid severe accidents.

2.2 AC Control Module

The AC Control module includes 3 parts: a frequency regulator, a voltage regulator

and a protective circuit. See AC unit schematic diagram.

2.2.1 Frequency Regulator

The frequency regulator controls the engine speed to stabilize it at 1200r/min, so as to

ensure that the generator voltage frequency stabilizes at 60Hz. It is double closed-loop

control circuit. The outer loop is the speed adjusting circuit and the inner loop is the

current adjusting circuit.

Output of the frequency regulator (terminals 533 and 545 of the AC module) is

connected to the coil of the engine actuator to control the valve of the engine fuel pipe.

The aperture of the valve is in a positive proportion to the intensity of current which passes

through the coil, and the opening of the valve has a positive correlation to the output

power of the engine.

The speed control loop which is formed from Z8 is a regulator PI. It synthesizes all the

signals such as speed reference, speed feedback and active current feedback, after the

signals are regulated by PI, they serve as a reference signal of the current regulator (inner

loop).

The speed reference signal is given by the speed adjusting knob on the control cubicle

panel by the operator. The knob is connected with the potentiometer which is connected

to terminal 547. It may get the signal of 0 to +11V. The corresponding generator

frequencies are 56Hz to 64Hz.

The speed feedback signals consist of the engine speed feedback and the generator

voltage frequency feedback :

The engine speed signal (reflecting generator voltage frequency) is given from a

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speed transducer. The speed transducer is an electromagnetic transducing unit, installed

on the edge of the engine fly wheel. The fly wheel rotates for every tooth, the unit will send

out a pulse and deliver it to the terminals 526(-) and 527(+) of the pulse pick up circuit of

the speed regulator.

The generator voltage frequency feedback signal is given by the frequency

demodulation circuit. The frequency demodulation circuit is the frequency/voltage (F/V)

converting circuit, it consists of 26 diodes and a resistance capacity network.

The speed feedback signal which is input into the speed regulator is only one of the

two signals above-mentioned. It is selected by an electronic switch circuit: when the

generator’s speed is lower than the idle speed, it selects the speed feedback signal from

the speed transducer and deliver the signals to Z5-3; when the generator’s speed is

higher than the idle speed, Z5-3 receives TP5 frequency feedback signal.

The current control loop consists of Z9 and PI part formed from the other relevant

components. Its input signals are the speed command from speed regulator and real

current feedback signal IREAL. Its output signal is magnified by the power magnifier

formed from Q4, and then passes through terminals 533 and 545 to the actuator installed

in the engine, thus changing the aperture of the value of the engine throttle.

2.2.2 Master/Slave Control Circuit

The master/slave control circuit distributes proportionately the active power to all the

engine/generator sets which provide power to the electric mains. A master/slave control

switch between the reference of the current regulator circuit and output of the frequency

regulator circuit is set in every generator online to make the references of the current

regulator of all the generators the same.

The master/slave control circuit is designed according to the following principle. In all

the generators online, the generators whose order number is the smallest is a master and

all the other generators are slaves. For example, when #1 generators is online, it is just a

master and all the other generators are slave. If #1 generators is not online, but #2

generators is online, then #2 generators is just a master and all the other generators are
13
slave and so on. In designing circuit, the frequency regulator circuit output of the master

generators is always used as an input signal of the current regulator circuit of all the

generators online.

When a generator is a master, the reference of its current regulator circuit is just the

frequency regulator circuit output of the generators and it is also used as a reference input

of the current regulator circuits of all the other slave generators. When a generator is a

salve, its frequency regulator circuit can not be used as the reference input of the

generators current regulator circuit, the reference can be given only by the frequency

regulator circuit of the master generators.

2.2.3 Voltage Regulator

It consists of two firing circuits and a double-loop control circuit. The outer loop of the

control circuit is a voltage regulator circuit and the inner loop is an exciting current

regulator circuit. When the load changes, the voltage regulator can automatically regulate

the generator exciting current to keep the generator 600V output stable.

The firing circuit is composed of Z10, Q203, Z11 and Q303. It provides dephasing

firing pulses to the SCR of half-control bridge of the exciting circuit board. Two firing

circuits are the same and only their firing phases are opposite. The sync voltage of the

firing circuit comes from the T10 secondary and its firing reference signal is given by the

exciting current regulator circuit.

The exciting regulator circuit is formed from PI part composed of Z2, the reference

signal at the input terminal comes from Z1 output. Its current feedback signal Iex+

(terminal 556) comes from terminals “+” of R5, R6 and R7 in the exciting circuits. The

exciting regulator circuit output is used as the control signal of the firing circuit.

The voltage regulator circuit consists of Z1 and so on. It is PI part. The circuit

provides current reference signal for the exciting current regulator circuit.

14
 2.2.4 Exciting Circuit

Refer to 017-001（P05）. Generator voltage is reduced via T08 (600/115V) and

delievered to EXCITER PC.In this PC11, there are two rectifer circuits,one of which is

formed by DB1 and DB2,the other is formed by SCR1,SCR2 and DB2 .The rest voltage of

generator is rectified and added to exciting coil via DB1and DB2. When the exciting

voltage is increased, the generator voltage is increased too. When the generator voltage

is abundant enough to supply power to AC module, K1 picks up and its 3 normally-opened

contacts open, SCR1 and SCR2 takes place of DB1 to rectify and control. At this moment,

DB1 only supply power to K1. Exciting PC supplies exciting current to generator via

terminals 01 and 10. Voltage signals of resistors R05, R06 and R07 are taken as current

feedback signals and delivered to terminal 556 of AC MODULE.

2.2.5 Protection Circuit

The protection system has several parts such as undervoltage, overvoltage,

underfrequency, overfrequency, reverse power, idle speed, and feedback pulse loss and

so on among which the undervoltage protection is set up by the circuit breaker itself. For

other protections they have their respective electronic circuits,. When a failure occurs, the

undervoltage trip coil of the generator circuit breaker will be cut off by the relay and the

generator will break away from the bus.

2.2.5.1 Overvoltage Protection

Voltage feedback signals are applied to voltage distributing circuits formed by R90 and

R96, normally Q6 is cut off. When generator voltage rises, there is a stable voltage circuit

between -39V power supply and ground whose value doesn’t change, there is only +160V

voltage rising. When generator voltage rises to about 700V, Q6 is energized, Q3 is cut off.

Relay K2 is power off and the circuit breaker trips.

15
 2.2.5.2 Underfrequency Protection

When frequency is normal, Z7 inputs the negative potential and outputs positive

potential, D24 cuts off. When the frequency exceeds the rated 54Hz, the input potential of

Z7 is slightly over than 0 and the output potential changes to the negative potential. D24 is

energized and Q3 is cut off. Circuit breaker of the generator trips.

At the same time, Z7 also delivers negative potential to R17 in voltage regulator circuit.

This negative potential makes generator exciting current automatically reduce and voltage

drop. When it is at the idle speed, voltage doesn’t exceed 350V.

2.2.5.3 Overfrequency Protection

When frequency is normal, -3V potential is input at the same phase terminal of Z14,

while -4.8V at the opposite one. As positive potential is output, D67 is cut off. When

frequency exceeds 66Hz, inputs at the same phase terminal inputs is lower than -4.8V,

Z14 output is turned to negative potential, D67 is flowned, Q3 is cut off, K2 is power off

and generator circuit breaker trips.

2.2.5.4 Reverse Power Protection

When a reverse power occurs on generator, its line current is opposite to the line

current of normal power supply, current demodulation circuit outputs active power, a

negative potential, which makes opposite terminal of Z6 change to negative potential. As

Z6 forms integral part to make reverse power reach 7%, after 8~10s delay, Z6 output rises

to positive potential, Q1 is saturated to energize, D26 is flowed, Q3 is cut off and the

breaker trips.

2.2.5.5 Idle Protection

When the engine is at idle state, the collector of Q2, outputs -14V potential, making

D67 flowned via D25, Q3 is cut off, K2 is power off and the circuit breaker trips.

16
 2.2.5.6 Feedback Pulse Loss Protection

When feedback pulse inputs normally, output signal from terminal AUX17 in pulse

detection circuit makes the potential of terminal 9 of pulse loss protection +16V, D169 is

cut off. If pulse is lost, the potential of 9 is -16V, after 100ms delay, K2 is open, and the

circuit breaker is cut off. Thus it can prevent the engine from an overspeed operation

under the situation of no speed negative feedback.

2.3 AC Control Unit Technical Parameters

2.3.1 Engine Speed Control Specifications

(1) Steady Frequency Adjustment Rate δf (%):0 to 5% (adjustable)

δf =(f1-f2)/f×100%

Here f is the rated frequency (Hz)

f1 is the steady frequency after the load has gradually changed, it is the maximum

of all the values (Hz).

f2 is the frequency at the rated load (Hz)

(2) Instantaneous Frequency Adjustment Rate δf s(%):+5%

δf s=(fs-f3)/f×100%

Here f is the rated frequency (Hz)

f3 is the steady frequency before the load has suddenly changed (Hz).

fs is the frequency at a moment when the load is suddenly changing, it is the

maximum or minimum of all the values(Hz).

(3) Frequency Fluctuation Rate δf b (%):0.5%

δf b=(fbmax-fbmin)/ (fbmax+fbmin) ×100%

Here fbmax, fbmin are maximum and minimum of the frequency in the same

observation time (Hz).

(4) Frequency Stable Time: 3 seconds

It is the required time from a time when the frequency has suddenly changed to a

17
 time when the frequency begins to be steady within the fluctuation range of frequency.

2.3.2 AC Generator Voltage Control Specifications

(1) Steady Voltage Adjustment Rate δu (%):±2.5%

δu = (U1-U)/U ×100%

Here U is the set up voltage at no-load (V);

U1 is the steady voltage after the load has gradually changed. It is the maximum or

minimum of all the reading (V);

U and U1 are the average values of the 3-phase line voltages.

(2) Instantaneous Voltage Adjustment Rate δu s: +20%

δu s=(Us-U)/U×100%

Here U is the set up voltage at no-load (V);

U and Us are the average value of the 3-phase line voltages.

δu s is the average value in three experiments.

(3) Voltage Fluctuation Rate δub (%):0.5%

δub=(ubmax-ubmin)/ (ubmax+ubmin) ×100%

Here ubmax and ubmin are the maximum and minimum of the voltages in the

same observation time (V).

(4) Voltage Restoring Time: 1.5 seconds

It is the required time from a moment when the voltage has suddenly changed to a

time when it restores for the first time to the voltage which is different from the set up

voltage at no-load by +3%.

2.3.3 Parallel Running Specifications

(1) Parallel Base Point: the output power of each generator set online should be

adjusted to 75% of the rated power, and the power factor, voltage and frequency

should be adjusted to the rated ones.

During the following test course, the speed and voltage must not be adjusted again.

18
 (2) Load Method: On the condition of the rated power factor, load should be changed

at following percentage of the total power and in following order: 75%→100%→

75%→50%→20%→50%→75% at least the generator should run for 5 minutes at each

level of the load.

(3) Active Power Distribution difference δp (%)≤+5%

δp=(p1-p2)/ 2p×100%

here P is the rated active power of generator set (kW);

P1 and P2 are the active power outputs respectively from one of two generator

sets in a certain working condition (kW).

(4)Reactive Power distribution difference δq (%)≤+10%

δq=(Q1-Q2)/ 2Q×100%

here Q is the rated reactive power of the generator set (kVAR)

Q1 and Q2 are the reactive power outputs respectively from one of two generator

sets in a certain working condition (kVAR).

2.3.4 Generator Protection Value (breaker trips if more than the protection value)

(1) Overcurrent: it is set up according to the rated current of the generator set.

(2) Overvoltage: about 700V, delay time 100ms

(3) Undervoltage: about 530V, delay time 100ms

(4) Overfrequency: 56Hz .

(5) Underfrequency: 42Hz .

(6) Reverse Power: -7%

2.4 AC Control Unit Operation

2.4.1 Preparations before Starting

The starting of the generator set needs a close coordination of electrician and

machinist. Before starting, the machinist firstly checks the oil, gas, water and all the

relevant parts according to the starting rules of the engine and then the electrician checks
19
in the following order:

(1) Be sure that the circuit breaker of the generator is at ‘OFF’ position.

(2) Press down the ‘IDLE’ button of the engine control button.

(1) (2)

(3) Speed adjusting knob and voltage adjusting knob should be in the middle position.

(4) Set the synchronizing switch in the position of ‘ready on line’ generator.

(5) Reset the overspeed trip mechanism of the engine.

(6) Check the voltage of the starting accumulator. It should be not less than +10VDC

Only when the above checks are correct, the engine-generators set can be started.

(5)

2.4.2 Starting the Engine

When the preparations are completed, machinist and technician operate according to
20
the following procedures:

(1) Machinist open the valve of air compressor, operates pneumatic button. Under the

control of AC control module, the speed of the engine will automatically increase to an‘idle

value’.

(2) Keep the engine running at an idle speed suggested by the engine manufacturer,

now ‘RUN’ light of the generator is gleaming.

(3) Press down ‘RUN’ on the engine control button, now the speed of the engine will

increase to the rated value. The ‘RUN’ light of the generator becomes bright.

(3)
(4) Turn the ‘VOLTS ADJUST’ knob, observe the reading on the voltmeter on the sync
box or the GEN cubicle. Make the voltage of the generator at 600V, then lock up the knob.

(4)
21
 (5) Turn the ‘SPEED ADJUST’ knob, observe the reading on the frequency meter or

the sync box, make the generator frequency at 50Hz/60Hz, then lock up the knob.

(5)

(6) Charge the generator circuit breaker.

(6)

(7) Bring the first generator on line. Press down ‘PUSH TO CLOSE’ button, now

‘ONLINE’ light of the generator becomes bright, showing the generator set is supplying

power to AC bus.

22
 (7)

2.4.3 On-Line Operation of Generator Set

When the drilling state needs to increase power, starting the second, third (or forth)

generators and bring them online. Refer to the following online operations:

(1) Set the sync switch at the position of the generator set ready to get online.

(2) Starting the generator set according to the rules mentioned in paragraph 2.4.2 to

(6).

(3) Observe the sync meter and sync light on the sync box. Slightly turn the ‘SPEED

ADJUST’ knob of the generator ready to get online. Let the needle of the sync meter

slowly turn clockwise, the change of the brightness of the sync light will be slowing down

23
accordingly. When the needle of the sync meter points upright (coinciding with the upright

line), all the sync lights are out. (At the same time, the light on the ‘PUSH TO CLOSE’

button of the generators ready to get online is lit). Press the ‘PUSH TO CLOSE’ button of

the generators, the ‘ON LINE’ light is lit, showing that the generators has been online with

the AC bus，namely running synchronously with on-line generators.

(4) Afterwards, observe KW meter and KVAR meter on the control cubicle of each

generator set. KW readings of all the generator sets should be identical. KVAR readings of

each generator may be different from others. Then turn the ‘VOLT ADJUST’ knob of the

generator set which has a higher KVAR value to reduce its value and be the same with

that of the other generator sets.

(5) Afterwards, turn the sync switch to the ‘OFF’ position. Now both the readings of

the voltmeter and the frequency meter on the sync box are the values of the AC bus.

(6) In running on line, the relationship between all the engines is a master-slave. The

engine whose order number is the smallest is the master, the others are slaves. The

slaves are controlled by the masters and synchronized with the master. Only the ‘SPEED

ADJUST’ knob of the master control cubicle is effective (The controlling of the ‘VOLT

ADJUST’ knob of each generator set is independent, having no master-slave relation).

(7) To turn any generator set off the AC bus, just press the ‘OFF’ button of the circuit

breaker.

24
 2.5 AC Control Unit Function Test

2.5.1 Preparations

Shut down the engine, turn off all the fuses of the generator unit.

2.5.2 Engine Actuator Test

Cut off the connecting lines on the terminal block at both the positive (TB11-1) and the

negative (TB11-2) ends of the speed regulator and measure the resistance between the

two connecting lines, the resistance value should be within 30 to 36Ω, measure the

resistance between each line and the earth which should be ∞, then connect them again.

2.5.3 Exciting Coil Resistance Test

Cut off the lead wires on the terminal block at both the positive (PC11-01) and the

negative (PC11-10) ends of exciter. Measure the resistance between the two lead wires,

the resistance value should be within 3 to 20Ω (depending on the model of generator),

measure the resistance between the lead wire and the earth. It should be ∞, and then

connect them again.

2.5.4 AC Control Module Function Test

2.5.4.1 Preparations

(1) Check the module connecting line, get rid of misconnection and looseness.

(2) Put the generator into working, the generator ‘RUN’ lamp and the power supply

lamp on the module panel are lit.

2.5.4.2 Check Power Supply

Measure the voltage of the following terminals.

25
 Terminal number 508 507 502 503 546 AUX 24

Voltage value +160V -160V +16V -16V +11V -11V

2.5.4.3 Frequency Demodulation Test

Check the waveform at the test point TP5, refer to figure 2-8.

2.5.4.4 Current Demodulator Output Test

When the generator has no current output, both the potentials at the terminals AUX

5(TP26) and AUX6 (TP17) of the current demodulator are 0.

2.5.4.5 Voltage Regulator Test

When at running speed, turn the voltage regulating knob to the middle, the voltage at

terminal TP12 is about -92VDC, the voltage of reference at the module (terminal 551)

should be +4 to + 6VDC, the firing pulse waveform at GATE A+(terminal 504) is shown as

figure 2-9.

2-8 Output Waveform 2-9 Firing Pulse Waveform

2.5.4.6 Speed Regulator Test

Turn the ‘SPEED ADJUST’ knob to the middle, the module speed reference (terminal

547) should be +4 to +6VDC, at this moment, the speed of the engine-generators must be

within the normal range.

26
 2.5.5 Control Loop Test

2.5.5.1 Generator Voltage Phase Sequence Test

Set the engine control switch at ‘IDLE’, start the engine and make its speed about 2/3

of the rated speed, then check the generator phase sequence with an oscilloscope, the

waveform as figure 2-10 shows should be obtained, namely B phase waveform lags

behind A phase waveform by 120 o, and C phase waveform lags behind B phase

waveform by 120o.

2－10

2.5.5.2 Module Board Six Phase Voltage Phase-Sequence Test

Refer to the wiring diagram as figure 017-001 (P05) shows, close the fuses F30,

F31, F32, F33, F34 and F35, check six phases’ voltages at terminals 512 to 517 of AC

module, every corresponding potential of six terminals (terminals 512 to 517) is 115V, in

which VAB (terminal 512) is of opposite phase to VBA (terminal 513), VBC (terminal 514)

is of opposite phase to VCB (terminal 515) and VCA (terminal 516) is of opposite phase to

VAC (terminal 517).

27
 2.5.5.3 Voltage Regulator Test

Cut off the connection lines at control poles A+ (terminal 504) and A- (terminal 505) of

SCR, close the fuses F39 and F40, and watch the generator voltmeter. Along with

continuous pick-up and drop-out of the build-up relay in the exciting circuit board PC11,

the voltage will periodically rise and drop. When the generator voltage rises to over

200VAC, the voltages from terminals 512 to 517 also rise and drop periodically.

If the abovementioned results are obtained, it illustrates that it works normally.

Connect the connection lines at control poles A+ and A- of SCR. Make voltage at 300～

450VAC.

2.5.5.4 Engine Speed Regulation Test

Set the ‘SPEED ADJUST’ knob in the place which is near 50%, set the engine control

switch to ‘IDLE’, start the engine. After 15 minutes’ preheat, turn the engine control switch

to ‘RUN’, now the generator voltage and frequency should be rising. Then turn slowly the

‘SPEED ADJUST’ knob and ‘VOLT ADJUST’ knob to make the generator voltage rise to

600V, 50Hz, then pull the engine switch to ‘IDLE’, at this moment the generator voltage

and frequency should reduce to the value which corresponds to ‘IDLE’, then return the

control switch to ‘RUN’. The generator will be steady at 60Hz 600V after two over

regulations.

2.5.6 Synchronous Circuit Test

(1) Bring a generator online.

(2) Test the second generator and make it at 600V 48Hz.

(3) Pull the sync selector switch to the generator ready to get online order number

position. Watch the sync meter and sync lamp: the needle of the sync meter will rotate

counterclockwise, the sync lamp will flicker. Connect a voltmeter with a range of 600V

across the generator phase A and the bus phase A and watch the voltmeter reading.

When the reading is the smallest, the needle of the sync meter is upright and the sync
28
lamp will be off.

(4) Regulate the generator frequency to 50Hz, the sync meter needle will rotate

slowly, the brightness of the sync lamp will change slowly. When the sync meter needle is

upright, the sync lamp will go out and the button lamp LPB1 will be lit, then close the

circuit breaker of the second generator.

Note: Before testing the sync meter and sync lamp, don’t close another generator

circuit breaker.

2.5.7 Load Sharing Test

At least two generators in parallel run on the bus, the load sharing test can be done.

2.5.7.1 Reactive Power Sharing Test

Turn the ‘VOLT ADJUST’ knobs of all the generators to make the KVAR meters of all

the generators online indicate the same and at the minimum value (permissible error

+10%).

2.5.7.2 Active Power Sharing Test

Bring all the generators online and share AC bus connect a load about 60%.

Watch ‘master/slave’ control relationship. The speed regulator of the master generator

controls the speeds of all the generators on line, namely, the generator #1 controls all the

generators on line. If the generator #1 is off line, the generator #2 will control all the other

generators on line. When both the generators #1 and #2 are off line, the generator #3 will

control all the other generators on line.

Watch the KW meters of all the generators online, the reading of each meter should be

the same. (Permissible error +10%).

29
 2.5.8 Protection Function Test

2.5.8.1 No Pulse Trip and Stop Protection

This test is suitable only for the circuit with a pulse speed transducer installed.

(1) Bring a normally running generator online, the ‘GEN ON LINE’ lamp is on.

(2) Cut off the speed transducer signal to the terminal 526 of the AC module, at this

moment, the circuit breaker trips, the engine stops and generator ‘ON LINE’ lamp goes

out.

Do the above test on every generator.

2.5.8.2 Reverse Power Trip Protection

(1) Bring a generator online

(2) Short circuit the terminals 533 and 545 (regulator output end) of the AC module to

cause reverse power. The generator circuit breaker will trip within 8-10s.

(3) After the breaker trips, remove the jumper across terminals 533 and 544, now the

engine return to a normal running speed.

Test all the other generators with the same method.

There is a test switch and a test meter on the panel of AC control module. The test

switch can quickly check the working signal of the system. The switch position and the

surface of the test meter are marked with colors. For example, when the test switch is set

in the yellow ‘Breaker Trip Voltage’ position, the meter needle will be inclined to the yellow

area. It shows that the system is normal.

2.6 AC Control Unit Troubleshooting Guide

2.6.1 Generator Troubleshooting

Symptom/probable cause Action

1. AC volts absent or
<150VAC 1.1 If the generator bus has no
30
 Engine speed is too low voltage, raise the speed to RUN setting
Generator residual magnetism when starting
voltage insufficient 1.2 Measure the magnetism voltage
across exciter field+ (PC11-01) and exciter
field – (PC11-10). It must be at least 1 VDC
during starting. Check the generator residual
magnetism voltage at full speed, It should be 15
to 20VAC. If both of the above conditions do not
exist, the generator residual magnetism is
Diode in the generator rotating insufficient, charge the exciter field.
rectifier is short-circuit or cut off 1.3 Check the rectifier diode in the
generator rotor.
Exciter fuses are blown or the
exciter field supply circuit is defective 1.4 Check the exciter field fuses and exciter
power supply.
2. AC voltage reaches 2.1 Repair or replace the exciter printed
150-200V but does not increase to circuit board.
600VAC
Defective exciter printed 2.2 Replace the AC control module.
circuit board
Defective AC control module

2.6.2 Engine Troubleshooting

Symptom / probable cause Action

1. Engine doesn’t run
Engine overspeed lever is not 1.1 Reset the lever.
reset
The actuator has no voltage 1.2 Measure resistance between
signal. The possible cause is: leads to generator
the throttle actuator are open, throttle+ (TB11-1) and generator throttle-
short-circuited or grounded (TB11-2). It should read 30 to 36Ω
1.3 Measure current to the throttle
The AC control module is not actuator,
supplying current to the actuator it should be 30 to 60mA, when the engine
is running at no-load speed, if there is no or
No signal from the engine pulse low current, replace the AC control module.
transducer (if used ) 1.4 When the engine is at crankshaft
speed,
the voltage of pulse transducer circuit is
not less than 2VAC.
2. Engine Running Problems 2.1 The engine may oscillate for a
Engine speed oscillates up and short
31
 down at a steady rate speed time during cold starting. It’s normal. If it
continues to oscillate, the AC control module
may be malfunctioning, regulate R58 which
Engine speed changes irregularly. may effectively eliminate the faults or replace
with spare parts.
Engine speed cannot be raised to 2.2 Check for any intermittence of
60Hz, probably the AC control voltage control
from transformers doesn’t reach that of the circuit connections. If the AC module has
AC control module faults, replace it.
Engine speed cannot be 2.3 Check for the failure point
adjusted between T10
and the AC control module and repair it. If
EG-B-3P actuator is used, speed adjustment
Engine speed and power sharing knob shall be ensured to set in maximum.
Problems 2.4 Speed adjust rheostat has
faults. Repair
Generator circuit breaker does not or replace it.
automatically trip for reverse power, 2.5 AC control module is defective,
underfrequency, overfrequency or no pulse check
faults. the actuator current.
2.6 AC control module is defective,
replace it. Or circuit breaker UV trip
device is faulty, find the faults and repair or
replace as required.

2.6.3 AC Control Module Troubleshooting

Symptom/probable cause Action

1. Power Supply 1. Check if the grounding voltage on pins

Transformer 512~517 is normal. The voltage at each point should
1.1 The generator voltage is over all be 115VAC. Abnormal voltage of any point will
high cause the overvoltage of the generator.
Check the fuses F33, F34, F35, replace the
fused. If the faults repeat, replace the AC control
module.
2. DC power supply 2.1 Measure the voltage at the following AC
The KVAR and KW meter control module pins:
needles oscillate against their Pin voltage
zero stop pin. 501 0VAC(the point is ground)
502 +16(+/-0.15)VDC
503 –16(+/-0.15)VDC

32
 546 +11(+/-0.15)VDC
These voltages should be present whenever
the generator voltage >250VAC. The cause is that
connection between pin 501 and the ground is
loose.
Generator voltage reaches 2.2Measure the voltage at the following AC
600VAC control module pins when The generator voltage is
but DC power supply is not 600VAC
working correctly Pin voltage
502 +16(+/-0.15)VDC
503 -16(+/-0.15)VDC
507 -160(+/-20)VDC
508 +160(+/-20)VDC
If voltages are incorrect, probably the power
supply rectifier section in module has faults,
repair/replace it.
3. A low reading at pin 551 of the AC control
3.Generator voltage reference module will cause this problem. Ensure that the
Unable to adjust generator ‘VOLT ADJUST’ knob is set at half rotation. Measure
voltage the voltage at pin 551. It should read +6VAC when
the generator output is 600VAC. The adjustment
range for the generator voltage reference is zero to
+11 VDC. If the voltage at pin 551 is incorrect,
repair/replace the voltage adjust potentiometer as
required.
4. Engine speed reference AC 4. Absence of a signal at pin 547 of the AC
circuit breaker trips owing to a low control module will cause this problem. Set the
engine speed or (underfrequency). speed reference to 50Hz and measure the voltage
at pin 547. It should be +6 VDC. The adjustment
range for the engine speed reference is zero to 11
VDC. If the voltage at pin 547 is abnormal,
repair/replace the speed adjust potentiometer.
5. Circuit breaker trips 5. Measure the voltage between pins 528 and
Circuit breaker has tripped 529(UV trip).The voltage should be 0V. If the voltage
is +24VAC, the trip relay in the AC control module
has not picked up and the circuit breaker has
tripped.
6. Throttle Output 6. Measure the current from either pin 533 or
Engine will only run when throttle 545 when the engine is running at no load speed,
is held by hand the reading should be 30 to 60mA. If the engine is
running at speed with full load, the reading should
be 180 to 200mA. Check the resistance between
two output leads when regulator is cut off. If the

33
 actuator resistance is 30~36Ω, this shows that the
faults are in AC modules, then replace it.
7. Exciter SCR control pulse 7. Using an oscilloscope to check for the state
The Generator voltage oscillates of firing pulses at AC control module pins 504 and
between 10 VAC and 300VAC as the 505. If the firing pulses are abnormal, replace the
build-up relay opens and closes AC control module
8. Exciter current feedback 8. Use an oscilloscope to check the voltage
Generator voltage out of waveform between pin 556 of the AC control module
regulation and ground, compare this waveform with that of a
known good generator.
9. AC current feedback 9. Measure the voltage between the following
There is a load imbalance AC
between the online generators. control module pins with an oscilloscope: 519 to
520, 521 to 522 and 523 to 524. The voltage should
be zero at no load, +2.4 VDC at full load. If the
voltage between any of these AC control module
pins is abnormal, find the faults and repair/replace it.
10. Master/Slave circuit 10. Start an engine-generators and allow it to
A large KW load imbalance operate until it is at normal temperature. Adjust the
between the engines. This is frequency to 50Hz. Disconnect the generator circuit
probably caused by improper breaker and then measure the actuator current at
actuator current adjustment. (There pin 533 or 545 of the AC control module by using a
are a few other reasons for a large multi-meter (set on the 100mA scale). Actuator
KW load imbalance: a defective KW current must be within 30 to 60mA. If it is not within
meter, a defective AC Control that range, adjust until it is. Perform this with all of
module, a bad actuator or an engine the engine-generators. Ensure that all of them have
problem). an actuator current that falls within a 10mA range
between smallest and largest. All actuators’ currents
must fall within 30 to 60 mA.

34
 3 DC Control Unit

3.1 DC Control System

DC control unit controls SCR components, rectifies 3 phase AC power supply to

provide continuously variable DC power to DC motors as figure 3-1 shows. The rectifying

unit is a 3 phase full control rectifier bridge formed from 6 SCR components, and the

bridge is seperated from AC electric mains by circuit breakers. The output of the bridge is

delivered to DC motors through the assignment contactor.

Every DC control unit includes thyristor rectifier bridge, surge suppression circuit,

contactor control circuit, DC control module, belt pulley slip protection circuit and so on.

The DC control unit is installed in a cubicle called SCR cubicle. Its structure is shown as

figure 3-2.

AC AC

SCR SCR

DC
Figure 3－1 DC System Diagram

3.1.1 Thyristor Rectifier Bridge

The 3 phase AC power comes from the AC bus provides to SCR bridge through the

circuit breaker, see figures 021-000 (P48), 021-000 (P49),every phase of AC power

connects two thyristors. Namely, phase A connects with A+ and A-SCR, phase B connects
35
with B+ and B-SCR, phase C connects with C+ and C-SCR. A+, B+ and C+SCR supply

power to DC+bus and A-, B- and C-SCR supply power to DC-bus. Under the control of the

firing pulse added to the gate and cathode of the thyristor, the DC voltage coming from the

rectifier bridge is variable within the range of 0 to 750V.

DC
CONTROL SCR

SCR

DC
CONTACTOR

Figure 3－2 SCR Cubicle

3.1.2 Circuit Breaker

SCR circuit breaker(MT20H1 65kA) mainly insulates the SCR rectifier bridge from

the main AC bus. Besides, two pair auxiliary contacts are installed in the circuit breaker.

One normally-open contact closes ‘SCR ON’ (SCR cubicle is energized) and ‘SSP ON’

(surge suppression circuit normal), the other normally-open contact delivers -14V power

signal to PLC.

The circuit breaker has a UV trip coil, terminal D1 of the coil is connected to terminal

T16-04, and D2 is connected to T16-03 , figure 021-000 (P48) and 021-000 (P49).

These normally closed contacts can cut off power of trip coil in any of the following

36
emergence states.

(1) If the fuse that protects the tube is blown, that the rod is pressed by the plunger of

the fuse makes the 12 microswitches such as FNSC+, FNSB+ which are connected in

series with the UV trip coil off.

(2) There are two thermosensitive cells TEMP 1 and TEMP 2. They are installed

respectively in the heat sinks of A+SCR and A-SCR. When the tube juncture temperature

exceeds 125℃ (the temp. of heat sink exceeds 91℃), the normally closed contacts of the

thermosensitive cells will be off.

(3) When in an emergency stop, the emergency stop button PB01 on the driller’s

console will be off (figure 021-001 P49，P53), so as to disconnect the UV trip coil power.

3.1.3 Current Transformer

There are three current transformers CT1, CT2 and CT3 on the SCR AC side, they

are used to measure the currents flowing into SCR. After rectification, the currents flowing

from the current transformer are added to terminal 131 of the DC module as current

feedback signals through PC01-5 and drive the DC ammeter on the DC controller panel to

show the intensity of output current from the rectifier bridge, see figure 021-000 (P48).

3.1.4 RLC Filter Elements

The chokes on AC side of all the phases and RC branch circuit across the thyristor

form RLC filter circuit. The circuit restrains the rising rate (du/dt) of the voltage in ‘OFF’

state and the rising rate (di/dt) of the current in ‘ON’ state of SCR so as to avoid SCR

being misfired or damaged by partial overheat.

3.1.5 Pulse Transformer

The pulse transformer transmits and varies the thyristor firing pulse. It varies the firing

circuit pulse changing from +15V to -15V to a gate pulse changing from 0V to +10V as

figure 3-3 shows. The pulse transformer also insulates firing circuit from the main circuit

37
 so as to ensure safety of the firing circuit and matches the impendence.

A+ CONTROL
CONTROL ELECTRODE
ELECTRO
DE CATHODE

TRANSFORMER
INPUT VOLTAGE

TRANSFORMER
OUTPUT VOLTAGE

Figure 3－3 Firing Pluse of Pulse Transformer

3.1.6 Voltage Feedback Board

On PC02 board there are 24 resistors connected (R1 to R24) in series. Connect two

ends (PC02-02 and PC02-15) across the DC bus (figure021-000-2), draw out two lines

from PC02-08 and PC02-10 to 101 and 102 figure 021-000 (P48) of DC module as

voltage feedback signals VBR (+) and VBR (-) which are used in the DC regulating circuit.

When the bridge voltage is 750V, the voltage across VBR (+) and VBR (-) is 46.9V.

Besides, draw voltage from PC02-07 and PC02-11 to drive the DC voltage meter (VM) on

the panel, and draw voltage signal from PC02-06 and deliver to PLC.

See figure 021-000 (P48)..

3.1.7 Surge Suppression Circuit

With closing or cut off of a circuit or other causes, a surge voltage may occur, resulting

38
in an overvoltage at the SCR input end which may damage the SCR elements. To clean

up it, build up a surge suppression circuit with three piezo-resistors MOV1, MOV2 and

MOV3 connected in delta circuit as well as fuses F41,F42 and F43 with microswitches

according to figure 021-000 (P49)..

If surge suppression circuit runs normally, the surge suppression ON (SSP ON) lamp

L04 on the panel is lit. If a fuse of any circuits is blown, the mechanism of the fuse will cut

off the lamp switch, and the lamp will go out. When finding the indicator off, try to find the

causes of faults as soon as possible and repair it. Otherwise, SCR components will lose

overvoltage protection function.

3.1.8 DC Contactor

DC contactor closes the DC power supply output from SCR rectifier and DC motors of

every function. The closing and cutting off of DC contactor is controlled by assignment

switch and PLC on driller’s console. Under different working status, one SCR can drive 2

or more motors of different function by closing and off of DC contactors. Normally, the coil

voltage of DC contactor is 74VDC, and the contacts current of contactors used in DW and

RT is 1250A. The contacts current of contactors used in MP can reach 1800A. Single pole

contactor can only make motors rotate in fixed direction, while double pole contactor can

make motors rotate in various directions.

The assignment contactor needs DC 74V power to pick up. The positive pole of coil is

connected with +60V power supply, and the negative pole of coil is connected to -14V

power supply through a series of control contacts, so as to ensure that the motor can be

electrified after all related conditions are met. If any one contact is disconnected in this

loop, the contactor will be cut off, and the motor will stop ruuning.

3.1.9 DC Power Cable

The control cable connection of the DC power system is shown as figures 006-000

(P22), the power connection between all the SCR cubicles is shown as figures

39
007-000(P23), the mud pump power connection is shown as figure 006-000 (P20), and

the drawworks power connection is shown as figure 006-000 (P21). The power

connection between SCR cubicle and the DC motor is shown as figure 008-000(P24).

In the DC power system, on/off of the assignment contactor is controlled by the

assignment switch on driller’s console, the intensity of DC voltage output of the rectifier

bridge is adjusted by the speed reference knob on driller’s console. In the control unit of

the DC power system, the DC control module is installed to adjust the voltage and the

current within the presetting limit.

All the SCR rectifier bridges are identical. If one of them stops working, the other

rectifier units will continue to energize the motor via changing over of assignment

contactors. Similarly, the elements of the DC control module and the rectifier bridge are

interchangeable.

3.2 DC Control Module

The DC control module includes a DC regulator, SCR firing circuits, a drawworks

dynamic brake control circuit and a zero interlock protection circuit. See DC control

module circuit dIagram.

3.2.1 DC Regulator

The DC regulator is a control circuit that automatically regulates the motor speed and

torque according to the command of driller’s console. The regulator outputs the SCR firing

signal. Its input signals are speed reference, speed feedback and current feedback. The

regulator includes two control loops: one is a speed outer loop and the other is a current

(torque) inner loop. The speed reference signal coming from driller’s console is added to

the speed feedback signal, after regulation by Z7, a current reference signal is formed,

then it is added to the current feedback signal, after current regulation by Z8, a firing

reference signal is formed.

The speed reference signal is regulated in driller’s console. In driller’s console, a

40
speed reference hand throttle wheel which is connected to the potentiometer is installed。

When the hand throttle is rotated clockwise from ‘OFF’ to the ‘MAXIMUM’ position,

the speed reference of DC control module varies from zero to -8.2V.

The speed reference is enabled by an enabling circuit. Take MP1 for an example:

when MP1 has not been assigned, point ①in the circuit is +5V, D48 cuts off, the speed

reference signal from pins 125 or 126 will be invalid. When MP1 has been assigned, pin

124 is -14V, point ① is -13V, D2 cuts off, potential at point ② is controlled by the

reference signal at pin 125 and becomes negative (0 to -8.2V).

The speed feedback signal is an analog signal of the motor speed. In series motor, the

speed is a function of proportion of the armature voltage to field flux, therefore the speed

feedback signal ‘N’ is obtained in divider Z703 by the voltage feedback signal (output of

Z701) input from point ③ divided by the flux signal (figure 200D116-4) input from point

⑥. Flux is the function of armature current, Z702 forms current/flux inverter, the armature

current signal from pin AUX CB18 is simulated by Z702 to convert from current to flux.

Z702 includes four feedback branch circuits. The corresponding branch circuit is on

according to intensity of the current signal, the ON order is R725, D703, D704 and D705.

The more the ON branches are, the smaller the magnifying times of Z702 is. Thus the

functional relation of output signal from Z702 and current signal is similar to iron core

magnetization curve. Deliver the flux signal to pin ⑥ of the divider, speed feedback

signal “N” of the series motor will be got at pins① and ④of the divider and they are

delivered to the feedback branches of each speed regulator through terminal AUXCB15.

The current feedback signal comes from the current transformer on the AC side of the

SCR rectifier bridge figure 021-000 (P48).After it is rectified in PC01(power supply board),

through pin PC01-05 the current feedback signal is delivered to pin 131 of the DC module,

then goes into the current regulator Z8-2.

3.2.2 Foot Throttle Control

The foot throttle control is used only in the drawworks. To raise the efficiency, the foot

throttle control makes the drawworks motor run more quickly. Its reference signal is input
41
through pin 114, crossing the hand throttle reference signal, thus the bigger reference

signal is applied directly to Z7. When the driller steps on the foot throttle, the voltage and

current of the drawworks motor will rise quickly, so the motor speed rises quickly.
From the hand throttle wheel speed reference and foot throttle speed reference on
driller’s console, a higher (more negative) control command is selected and delivered to
Z7-3 of speed regulator through D59 and D18. When the driller starts lifting, first slightly
rotate the hand throttle to make the drawworks at a pulling cathead speed. Then the driller
steps on the foot throttle, the foot throttle will replace the hand throttle, thus the drawworks
rises quickly. When driller steps off the foot throttle, the foot throttle reference goes to zero,
the hand throttle will be in control again, the motor speed returns to the pulling cathead
speed.

3.2.3 Zero Throttle Interlock Protection

In DC module, Z7-06 and Q7-08 form the zero throttle interlock protection part which
is used to avoid the motor starting suddenly under high voltage. If the enabling circuit
signal switches to -14V while the corresponding speed reference signal is higher (more
negative), the zero throttle interlock disables the speed reference signal. Thus, the driller
must set the throttle to zero before switching the assignment, only after the assignment
switch switches to a working state, the corresponding hand wheel is rotated clockwise
from zero, and the speed reference control will be effective.

3.2.4 Current Limit Circuit

The current limit branch circuit avoids overcurrent and overlarge torque caused by
over high speed reference signal, which causes the drilling tools, DW or MP to be
damaged. It produces a negative current with a -10V voltage through a selective resistor
(e.g. R57, R73 etc), see point ② in figure200D116-2. When the potential of reference
signal is lower than that of this terminal, the counter offset state of diodes D47, D14, D7
and D59 will be cut off to stop reference signal, thus limiting the current of each DC motor.
When it needs a low current limit value, select a high resistance resistor.
The power limit signal avoids overload of the engine-generators caused by DC motor
overload. It comes from the power limit box pin 12 in the control cubicle of the generator. It
is input from pin 115.

3.2.5 SCR Firing Circuit

The firing circuit generates firing pulse for the SCR bridge. There are six identical
firing circuits in DC control module which fire six thyristors respectively. The nine
waveform diagrams on the upper of the drawing indicate the voltage waveforms at nine
different positions in B+ firing circuit.
42
 In the firing circuit, two narrow pulses with a space of 60º are produced in a period to
fire a thyristor gate. It’s shown as figure⑨ of which the first is a main pulse and the
second is a backup pulse. 3 phase SCR full-control bridge is demanded to continuously
deliver 2 narrow pulses in one period to fire 2 corresponding thyristors respectively. The
phase relation between firing pulses is decided by the phase relation of 6 phase AC
voltage. The ON sequence of the six tubes is A+B-, A+C-, B+C-, B+A-, C+A-, C+B-, A+B-.
The switching sequence is A+—C-—B+—A-—C+—B-. The phase sequence of the six
phase synchronous voltages must accord with the switching sequence of the six tubes.

3.2.6 DC Control Module Panel

-33-
Figure 3-4 DC Control Module Panel
In control module two printed circuits board are mounted, many electronic circuits
relevant to the SCR rectification and control are installed in it, all the PC board and the
other relevant elements are packed in a module box made of steel.
(1) Power on lamp
(2) Test voltmeter
(3) Test selector switch
(4) Manual voltage knob
(5) Manual voltage switch
(6) Zero throttle interlock lamp
(7) Overcurrent lamp
(8) SCR voltage test end
(9) SCR current test end
43
 When DC control module is energized, the lamps are lit.
The test selector switch ‘TEST’ and the test voltmeter check quickly the enabling
(CONT) signal and speed reference (REF) signal from driller’s console. Test voltmeter is
marked with color. When the selector switch is set in a certain REF position, the needle of
test voltage meter should be in blue area; when the selector switch is set in a certain
CONT position, the needle of the test voltmeter should be in the yellow area.
If the rectification control test of SCR bridge is needed, set the manual voltage switch
in ON position (pull it up) and rotate clockwise the ‘MANUAL VOLTAGE’ knob, meanwhile
monitor the rectification voltage of SCR bridge which should increase along with the
clockwise rotation of manual control knob. At this moment, all the assignment contactors
are off, SCR cubicle does not provide power to the DC motor.
Monitor the rectifier bridge voltage at the voltage test point (SCR VOLTS) on the
module panel, when the bridge voltage is 750V, voltage at the test point is 46.9VDC
(16/1).
Monitor the rectifier bridge current at the current test point (SCR AMPS) on the
module panel. When the bridge output is 1000A, voltage at the test point is 2.66VDC
(current/voltage=376/1).
The ZERO THROTTLE INTERLOCK lamp indicates the running state of the module
circuit, namely the restrain state for SCR bridge firing reference. When the lamp is on, the
bridge voltage is 0V.
The lamp will shine in the following two conditions:
(1) SCR unit is energized but is not assigned to any DC motor.
(2) Before the hand throttle on driller’s console returns to zero, SCR unit has been
assigned to a DC motor.
When the RT current or DW current is higher than 1500A, the firing pulse will be
locked, the output voltage of SCR bridge is zero and the overcurrent lamp and zero
throttle interlock lamp will illuminate on the module panel. At this moment, you should
check the cause of overload and current limit circuit. Then let the speed reference knob on
driller’s console return to zero, restart the motor.

3.3 Belt Pulley Slip Protection Device

When two series motors are supplied by one SCR cubicle and drive the mud pump in
parallel, due to a malfunction of loose belt pulley or broken belt, one or two motors may
run at an overspeed because of no load. The function of belt pulley slip protection device
is to measure the current of the series motor. When the current is overlow and the speed
exceeds the speed limit value, it cuts off the assignment contactors and the power supply
of the two motors. Meanwhile the belt pulley slip light on the control panel is lit.
Figure 3-5 is a typical power supply circuit for mud pump. Two motors MP1A and
MP1B run in parallel, which are energized by SCR1 or SCR2. The current of each motor is
measured by Hall Effect device HED1 and HED2. The HEDs are mounted in the air gap of
the soft magnet iron core, and a thick conductor (namely the motor’s main circuit) ,which
is flown with tested current, passes through the iron core, and produces magnetic flux in
44
the core. It is shown as figure 3-6(a). The HED also has four connection terminals as
figure 3-6(b) shows. Input 160mA control current between two terminals (this time the
voltage between these two terminals is 0.7V). The output voltage VH between another two
terminals is in positive proportion with the magnetic sense intensity B, namely in positive
proportion with tested current as figure 3-7 shows. Therefore, the intensity of VH reflects
the motor current value. See schematic diagram of pulley slip protection device.
Deliver the both VH signals of HED1 and HED2 respectively to the input ends of the
belt pulley slip protection circuit as figure 010-003(P30) shows, namely points①, ② and
points③, ④. Magnified at ends Z1 and Z2, both the output signals pass through the “OR”
gate which formed from diodes D1 and D10 will be delivered to terminal Z4-2 via D2 and
R35. The voltage feedback signals from PC06 are input to points 5 and 6 of slip protection
circuit and are also delivered to Z4-2 after being magnified by Z3. For both the motors are
supplied by one SCR cubicle, they bear the same voltage. When the mud pump running
at high speed works normally, Z4-2 get two signals of opposite polarity, namely, a higher
positive current feedback signal and a lower negative voltage feedback signal. Z4-6
outputs a negative potential, Q1 is on, K1 picks up to close PC05-16 and PC05-19 and to
close PC05-17 and PC05-18 in the mud pump enabling circuit. The mud pump will work
correctly.
If the mud pump runs at a high speed under a higher voltage, and the belt pulleys of
one or two motors slip to make Z1 or Z2 output potential fall, the efficiency of current
feedback signal on Z4-2 is smaller than voltage feedback signal, thus causing Z4-6 to
output positive potential, Q1 cuts off, K1 releases for power cut and the mud pump
enabling circuit is off. The mud pump motor will stop running for power cut. If the mud
pump runs at a slow speed under a low voltage, even if the belt pulley slips, for the voltage
feedback signal is small, it will also make Z4-6 output a negative potential. The mud pump
will remain running. This state will not cause overspeed of the motor.
When the mud pump stops running for belt pulley slipping, the normally closed
contacts of K1 will close to turn on the BELT PULLEY SLIP lamp on the cubicle panel. The
lamp may be put out by pressing PULLEY SLIP RESET button.

Figure 3－5 Mud Pump Power Supply Circuit Diagram

45
 Figure 3－6(a) Physical Quantity Relations in Hall Effects
Figure 3－6(b) Connection Terminals in Hall Effects
0.5

0.4

VH 0.3
(VOLTS)

0.2

0.1

0 100 200 300 400 500 600 700 800 900 1000
AMPS
Figure 3-7 Character Curve of Hall Effects

3.4 Drawworks Dynamic Brake

For the sake of raising efficiency in a lifting operation, stepping on the foot throttle will
make the drawworks run more quickly. When the traveling block rises to the second floor
platform, in order to slow down the motor speed quickly, the dynamic brake is used to
quickly reduce the motor speed to the cathead speed with the hand throttle controlling
Usually it needs 30 to 40 seconds for the drawworkds to drop from the full speed to the
cathead speed, the speed dropping time will be 12 to 18 seconds with the dynamic brake.
It will need 3 seconds from stepping off the foot throttle to the automatic starting of the
dynamic brake.
The basic principle of the dynamic brake is to transform the electromagnetic torque
into a resistance torque. The torque direction is opposite to the rotation direction of the
armature, thus the motor speed will quickly drop or stop running. At this time, the motor
absorbs mechanic energy of rotator, then turns it into electric energy and further changes
it into heat energy and be consumed, so it’s named DW dynamic brake. Figure 3-8 is a
46
drawworks dynamic brake schematic diagram。
when the motor DWA in braking state, SCR bridge does not output voltage. After
rectification, the secondary winding voltage of the transformer T02 is fed to the series coil
to produce magnetic field. The rotating DWA by inertia makes armature current pass
through contactors K1 and K2, then through grid-form braking resistor which is 0.48Ω and
can bear 300A continuous current. The current produces braking torque.
In the drawworks dynamic brake circuit as figure 011-003(P36) shows, as long as the
overtemperature switch OT is closed, 120VAC power from T01 will make the brake
contactor K02 DWDB pick up and on, cause the relay MS01 of the brake magnetic field
circuit to close, then apply a 600VAC power to the transformer T2 through resistors R01,
R02 and R03, T2 gets smaller voltage, and after rectification DWA gets a weak magnetic
field.
When starting the dynamic brake, since the foot throttle is released, the potential of
module terminal 114 is zero, the speed feedback potential of the motor runs at a high
speed is higher than the speed reference (terminal 117)potential, then the potential ①,
namely the firing reference signal at Y end in figure200D116-2 is about -5V, the potential
at the end ② namely CB116 is the enabling circuit potential of the drawworks, and it is
-14 V when the system drives drawworks. At this time, the emitting junction of Q702 is
reversely biased and cuts off to make Z704 input high potential and output negative
potential, Q703 is saturant conducting and its collector potential is near zero volts. It is fed
to the base of Q708 through D719, R760 and D730, and Q708 is saturate conducting,
then the reference potential of the firing circuit falls under -2V, the firing pulse disappears
and the SCR is locked.

Figure 3－8 Dynamic Brake Diagram

47
 At the same time, Q705starts conducting, relay K701 is energized and the contacts
close so the ends 127 and 138 are turned on. Since the contactors K01 and K06 in the
SCR cubicle has been closed when the drawworks is assigned, relay MS02 is energized
and the contacts closed and make R01, R02 and R03 short-circuit, the magnetic field
current of the drawworks motor DWA is in braking current state (about 200A).
When K701 picks up, Q705 collector potential falls, Z705 outputs high potential,
Q706 starts conducting, relay K702 is energized and the contacts close to make the ends
138 and 135 close and connect 120VAC power to D726, D727, R758 and D728. After
rectification, a +0.7V potential passes through D729 to lock SCR, and when braking has
been over, start conducting of SCR delays to avoid SCR bridge on and supply power
before the braking contactor K01 is cut off.
Closing K701 will connect 120VAC power to contactor K01 and relay RL01 to let them
combined conducting with K02, namely normally open contacts K01 and K02 close to
connect a resistor with low resistance (0.48Ω/300A) and high power to the two sides of the
motor armature to begin dynamic brake. When Q706 is on, about -11V potential signal of
the collector is fed to the output end of the I/Φ converter Z702, to replace the magnetic
flux transformed from the current feedback. Thus ensure that the speed feedback signal
remains and dynamic brake goes on normally for there is no current feedback signal in
braking course.
When the motor speed reduces to the cathead speed of hand throttle reference, the
potential rises to -3V~+0.5 to make Q702 on and the braking condition doesn’t exit again.
Then the DW motor runs at cathead speed under control of the hand throttle reference.
Only DWA has reverse rotation and dynamic braking functions, and DWB only has
forward rotation (lifting) function.

3.5 DC Control Unit Operation

3.5.1 Deliver Electricity to SCR Cubicle

The circuit breaker of one or several SCR cubicles may be closed as the drilling state
requires. Now the DC control unit is in operation and it runs according to the command of
driller’s console. Operate the SCR cubicle in the following order:
(1) Close the circuit breaker of the SCR cubicle.
(2) The “SCR ON” light of the SCR cubicle is lit, showing that the SCR unit is
connected to the AC bus.
(3) Monitor the parameters on the door of the SCR cubicle. The DC voltmeter shows
an approximate speed value of the DC motor. The DC ammeter shows an approximate
torque value of the motor.

48
 (1) (2)

(3)

3.5.2 Emergency Operation

If a malfunction such as SCR overheat occurs, the SCR circuit breaker will open
automatically to remove the SCR unit off the bus. To continue drilling operations, assign
the DC motor to the backup SCR unit.

3.5.3 Surge Suppression

There is a green surge suppression indicator on every SCR cubicle door, showing
whether instantaneous AC surge suppression state is normal or not. A surge suppression
circuit protects the SCR rectifiers from damage by current surges in the AC supply. The
green surge suppression indicator is on when the circuit is functioning normally. If the
indicator goes off, its fuses are probably blown. The system may be operated when
indicator is not on, however this should be brought to attention of the electrical
maintenance department and it should be serviced as soon as possible to avoid SCR from
damage.

49
 3.5.4 Belt Pulley Slip Protection

Every SCR cubicle may be assigned to drive the mud pump. The belt slippage of the
mud pump will cause the overspeed of the DC motor. The belt slip states will be shown by
the slip indicator on the SCR cubicle.
When the mud pump is running normally, the ‘PULLEY SLIP’ indicator will be off. If
there is a breakdown such as belt pulley slippage on the mud pump, the motor will stop
and the ‘PULLEY SLIP’ indicator will be on. Sometimes the indicator will be on because
the hand throttle is rotated too quickly. The system is equipped with a mud pump
‘LOCK-OUT/ PULLEY SLIP RESET’ button, if the mud pump is working regularly, but the
indicator is still on, put the indicator out by pressing the ‘RESET’ button and hold it for 3
seconds to reset it .
In servicing the mud pump, the ‘RESET’ button is used to cut off the power of the
driving motor of the mud pump, lock up the button with a padlock, the mud pump will not
work.

3.5.5 Put SCR Cubicle off the Bus

Just pressing down the ‘OFF’ button of any SCR cubicle circuit breaker will make the
SCR cubicle off the AC bus. You must pay attention to that before the off operation, that all
the load of the cubicle should be removed.

50
 3.6 DC Control Unit Function Test

3.6.1 DC Control System Specifications

3.6.1.1 DC Control Cubicle Electric Parameters

Input AC voltage: 600VAC

Output DC voltage: 0 to 750V continuously variable
Output current: 0 to current limit value continuously variable the rated current is
2000A.
Current limit: In order to get the drilling rig the greatest power and torque but not to
exceed the ratings provided by the manufacturer, an appropriate current limit value should
be selected. Refer to the reference value on the top of every DC control module,
respectively set up the current limit value of each DC motor. Regulating R23 and R73 can
respectively set up the maximum and minimum current limit value of RT. Regulating R57,
R54 and R75 can respectively set up the current limit value of MP 1#, MP2# and DW.

3.6.1.2 Forced Ventilation System Parameters

The ventilation system consists of the blowers installed under the SCR bridge.
(1) Ventilation: 1500m3/h through each SCR component.
(2) Ventilation motor: a motor is installed under every rectifier bridge, the motor drives
two fans connected to the both ends of the motor shaft.
The motor parameters: 3PH 600VAC 50Hz 3 phase
Air–in filter: the filter is installed in the front and back of the place below the SCR
bridge, made up of drawn aluminum gauze. The venting quality is 12% to 15%.

3.6.2 SCR Bridge Rectification Test

3.6.2.1 Preparations

(1) Ensure there is no assignment from driller’s console in SCR unit, then test to
assure the safety.
(2) Remove the connecting line at pin 134 of the DC control module to cut off the
contactor.
(3) AC bus should be electrified.
(4) Close the SCR circuit breaker.
Results: SCR ‘ON’ lamp will be lit, the blower under the SCR bridge is on, the
POWER ‘ON’ indicator on the DC control module will be lit, the zero throttle interlock lamp
will be lit. (If the assignment contactor closes, the reference hand throttle returns to 0, the

51
zero throttle interlock lamp will go out).

3.6.2.2 Module Power Supply Checking

Electrify the AC bus, check the following potential on the DC control module.
Position Terminal 103 to108 Terminal 153 Terminal 154
voltage 12VAC +14V -14V

3.6.2.3 Contactor and Reference Test

(1) Cut off the SCR circuit breaker, ensure the safety
(2) Connect the line to pin 134 of the DC control module again to be ready for closing
the contactor.
(3) Connect a line across the auxiliary contacts (TB08-03 and TB08-04) of the circuit
breaker to PLC. Thus the motor is off when the contactor is closed.
(4) Set the assignment switch of driller’s console in various positions and check the
contactor (CONT) signal and reference signal (REF) coming from driller’s console.
For example, when the assignment switch is set in 4 o`clock, the rotary table (RT) is
assigned to cubicle SCR4, the RT contactor (CONT) signal (terminal 129) and RT
reference signal (terminal 130) should be checked.
(5) When the check is over, remove the line across TB08-03 and TB08-04.

3.6.2.4 Firing Pulse Test

(1) Cut off the SCR circuit breaker

(2) Pull up the manual voltage switch of the DC control module.
(3) Rotate the manual voltage knob and check the pulses applied to 6 SCR
components with an oscilloscope. Connect the oscilloscope ground wire to the cathode
pin K of the SCR component, connect the oscilloscope probe to pin G, watch the typical
waveform of figure 3-9.

52
 Figure 3-9 SCR Firing Pulse

3.6.2.5 SCR Rectifier Bridge Test

(1) Close the SCR circuit breaker

(2) Pull up the manual voltage switch of the DC control module.
(3) Slowly rotate clockwise the manual voltage knob of the DC control module to the
Maximum (MAX). Watch the voltmeter on the panel, the reading should steadily rise to
800V. If rotating the knob counterclockwise to the minimum (MIN), the voltmeter reading
will steadily fall to 0.

Figure 3-10 SCR Output Wave Figure 3-11 SCR Output Wave
of Rectifier Bridge Voltage of Rectifier Bridge Voltage Troubles

3.6.2.6 Rectifier Bridge Feedback Test

Check the voltage feedback signal with an oscilloscope across the two voltage test
points (SCR VOLTS) on the DC control module board. The waveform shown as
Figure3-10, it has six peaks, one for each SCR component. Figure 3-11 displays the faults
of voltage output waveform of the bridge. The waveform of the upper part shows correct,
the middle part shows there is a misfired tube, the below shows there is an unfired tube.

3.6.3 Dynamic Brake Test

(1) When the braking does not begin, contactor K02 is energized and picks up,
voltage at pin 138 of the DC control module is 120VAC, and voltages at pins 135 and 127
are 0V. It shows the relays K701 and K702 in DC modules don’t pick up.
(2) When the drawworks is assigned, and the auxiliary switch of the drawworks
blower (DW BLO RL) is closed, relay MS01 will be energized and picks up, T02 outputs a

53
weak exciting current to the exciting coil.
(3) When the foot throttle is released for over 3 seconds, the drawworks dynamic
brake relay K701 is energized and picks up, MS02 picks up to short-circuit resistors R01,
R02 and R03 to let the exciting coil get full exciting current. At the same time terminals
135 and 138 of the DC control module close, 120VAC voltage measured at terminal 135. It
will energize contactor K01 and relay RL01 and make them pick up, and then the
resistance box is connected to both end of DWA motor armature.
(4) When stepping on the foot throttle, voltages at terminals 135 and 127 return to 0,
K01 and RL01 is off and cuts off the resistance box, MS02 is off, the exciting coil gets
weak magnetic current again. After 1.5 seconds, K01 and RL01 is released for power cut.

3.6.4 Troubleshooting SCR Components

In order to find broken components, compare the current feedback waveform with the
SCR firing pulse waveform by a double-line oscilloscope when the SCR runs with a load.
A probe of the oscilloscope is connected to terminal 131 on module or the current test
point (SCR AMPS) on the module panel , the other probe is connected to
TP1,TP2,TP3,TP4,TP5 and TP6 of the module, the firing pulse signal at A+, A-, B+,B-, C+
and C- SCR can be measured respectively. Compare the current feedback waveform at
the current test point with the SCR firing pulse waveform on the oscilloscope screen.
There are six peaks in single period, one for each SCR component. If a certain component
is unfired, its waveform will disappear. If the component is misfired, its waveform will be
distorted. The waveform diagram is shown as figure 3-12. All the firing pulses figure 3-13
synchronized with no waveform or distorted waveforms represent the pulses of faulty
components. For example, the firing pulse dropping edge of B-component synchronizes
with distorted peak. It shows B- component is misfired.
Use the following methods to measure the resistance across the poles of the SCR to
judge whether the component is good or bad.
(1) Cut off the SCR circuit breaker.
(2) Cut off the connecting line across the gate G and cathode K of SCR but the SCR
component need not to be removed from the heat sink.
(3) Connect a test line of the multi-meter to the AC bus, the other to the DC bus, then
measure the resistance between A-K of the SCR component. And then exchange the test
lines to measure the reverse resistance of the SCR.
(4) Measure the forward and reverse resistance between G-K of the SCR
components.
The measuring result should be that the resistance between A-K of the SCR >10kΩ. If
the
resistance is smaller than 10kΩ, SCR has leakage of electricity. The resistance
between
G-K of the SCR should be within 9-16Ω.The overlarge or oversmall will both make the
tube work abnormally. Absorber capacitors are connected at both ends of the SCR
component, so in measuring there will be the charging of the capacitor, reading the
54
 data should be after the needle is stable.

Figure 3－12 SCR Bridge Current Wave

Figure 3－13 SCR Components Troubleshooting

3.7 DC Control Unit Troubleshooting Guide

3.7.1 SCR Unit Troubleshooting

Symptom/probable cause Action

1 SCR Circuit breaker trips 1.1 Driller may have pressed the
EMERGENCY STOP pushbutton on driller’s
1.1 Emergency stop and all SCR console. To resume operation, close the circuit
breakers trip breakers.
1.2 If a SCR fails, some fuses are also
1.2 SCR fuse failure blown. Check fuse trip indicators. Check

55
 corresponding SCR components whose fuses
are blown. Replace all blown fuses and defective
SCR components.
1.3 Overcurrent trip 1.3 Close the circuit breaker to resume
operation.
1.4 SCR overtemperature 1.4 The overtemperature switch will reset
after temperature of the SCR junction drops
below 88℃. Close the circuit breaker to resume
operation. Ensure the SCR blower is running
normally. If not, check fuses and blower motor’s
RESET pushbutton.
2 SCR Bridge inoperative 2.1 Check zero throttle interlock indicator on
2.1 Zero throttle interlock DC control module. It shows the zero interlock
occur when the lamp lit. To resume operation,
2.2 Speed reference signal not set the THROTTLE command to ZERO before
reaching the DC control module assignment.
2.2 Check the speed reference signal from
the driller’s console at the DC control module.
2.3 Contactor circuit defective 2.3 Check -14V motor CONT signal at the
DC module. If it is absent, trace the control signal
in corresponding CONT circuit.
2.4 DC control module defective 2.4 Check SCR firing pulses. If they are
absent, check the DC control module power. If
the power is normal, replace the DC control
module.
3 Motor speed does not regulate 3.1 Check the signals of Vbr+ (terminal 101)
3.1 No feedback signals to the DC and Vbr-(terminal 102) and SCR Amps(terminal
control module 131) signals.
3.2 Defective DC regulator 3.2 Replace the DC control module
4. Insufficient power-DW, MP 4.1 Check the ammeters of each motor. If
4.1 only one motor is running one of the ammeter readings is lower, it indicates
that this motor is not running.
5. Motor runs hot and 5.1 Check current feedback waveform. If
noisy(sounds as if Bearings are bad) there is distortion, check faulty SCR components
5.1 SCR misfiring or not firing and their firing pulses. If the latter is defective,
replace the DC control module.

3.7.2 DC Troubleshooting Guide

Problem/Indication Explanation/Action
1. Power supply AC voltage 1.1 Measure the voltage at DC control
1.1 One or more SCR components module terminals 103 to 108, it should be
not firing 12VAC. If the voltage is abnormal, the 14VDC
56
 supply voltages will be low. As a result one or
more of the SCR components may not fire.
Check the fuses and connections to verify the
ground connections. Also probably it’s electronic
components destroyed.
2. Power supply DC voltage 2.1 Measure the voltage at each of the
2.1 DC voltages are abnormal following DC control module terminals. If any is
absent, check the fuses and connections.
Terminal 153 +14VDC
Terminal 154 -14VDC
Terminal 155 0 VDC (ground)
3. Bridge voltage feedback signal 3.1 Measure the voltage between pins 101
(VBR+ and VBR-) and 102 of the DC control module. It should be
3.1 System not operating normally +46.9VDC when the bridge voltage is +750VDC.
For series motors, terminal 101 is +. This voltage
must be present for normal operation. If it is
absent, check the voltage feedback card,
calibration voltmeter and connections.
4.Current feedback signal (IFDBCK) 4.1 Check for presence of IFDBCK at pin
4.1 Motor overspeed/overtorque 131 of the DC control module. It should be
and SCR fuses may blow. +2.66VDC when bridge current is 1000Amps.
5 Hand throttle reference 5.1 Monitor the corresponding reference
5.1 Hand throttle reference is voltage of the DC control module while moving
abnormal the hand throttle. The voltage should vary from
zero VDC to -8VDC.
6 Drawworks 6.1 Monitor the voltage at terminal 114 (DW
6.1 Foot throttle reference signal of FT TH) of the DC control module while moving
drawworks has faults. the foot throttle from the upper to the lower. The
voltage should vary between zero (MINIMUM)
and -8 VDC (MAXIMUM). If the voltage signal is
absent, trace the signal to the foot throttle
potentiometer.
6.2 Drawworks contactor signal not 6.2 Monitor the voltage at terminal 116 (DW
present. CONT) of the DC control module. The voltage
should be +10VDC when the SCR circuit
breaker is open. In normal running, it will be
-14VDC when the Drawworks contactor
closes.(This signal will only present on the SCR
units driving the Drawworks).
6.3 Drawworks speed reference 6.3 Monitor the voltage at terminal 117 (DW
signal not present SPD REF) of the DC control module while the
hand throttle vary from zero to MAX. This
voltage should vary between zero and -8VDC. If

57
 the voltage is absent, trace the signal from the
HAND THROTTLE potentiometer.(This signal
will only be present on the SCR units driving the
drawworks)
7 Drillers Console 7.1 When SCR circuit breaker is closed and
7.1 Contactor signal is abnormal DW is selected on driller’s console, the voltage
at terminal 116 (DW) of the DC control module
should be -14VDC.
7.2 With the SCR bridge on, measure the
7.2 Hand Throttle reference on voltage across terminals 101 and 102 of the DC
Drillers Console is extremely sensitive control module. The voltage should be 1/16 of
the voltage on the SCR bridge. When the
voltage of SCR bridge is +750VDC, the voltage
between terminals 101 and 102 should be
+46.9VDC. Polarity of terminal 101 is + for series
motors. Absence of the voltage will cause this
problem.
7.3 Mud Pump not pumping 7.3 Monitor the contactor signal voltage at
terminals 121 (MP2 CONT) and pin124 (MP1
CONT) of the DC control module. The voltage at
each terminal should be +10VDC with the SCR
circuit breaker open. -14VDC with the SCR
circuit breaker closed and the MP assignment
contactors in this SCR unit closed. This voltage
must be present in order to drive the mud pump
(The voltages are only present on SCR units
driving the Mud Pumps)
7.4 MP1 Hand Throttle Reference 7.4 Monitor the voltage at terminals 125
signal not present (MP 1 REF DC) and 126(MP1 REF MPC) of the
DC control module while moving the reference
throttle of MP1 hand throttle from MIN. to MAX.
The voltage at each terminal should vary
between zero and -8VDC.If the voltage at either
of the terminals is absent, trace the signal to the
MP1 potentiometer on driller’s console.
7.5 MP2 Hand Throttle Reference 7.5 Monitor voltage at terminals 122(MP 2
signal not present REF DC) and 123(MP 2 REF MPC) of the DC
control module while moving MP2 reference
hand throttle from Min. to Max. The voltage at
each of the pins should vary between zero and
-8 VDC. If the voltage at either of the pins is
absent, trace the signal to the MP2
potentiometer on driller’s console.

58
 8 One or more of the SCR 8.1 Check for the voltages at terminals 103
components not firing (VCA), 104 (VCB), 105(VAB), 106(VBA),
8.1 The waveform of one or more 107(VBC) and 108(VAC) of the DC control
phases of 6 phase voltages is abnormal module. It should be +12VDC. If absent or low,
check the fuses and ground connections.
9 DC power limit 9.1 Monitor the voltage at terminal 115 (DC
9.1 DC power limit not working PWR LIM) of the DC control module. The
voltage should be -4VDC when the system
generators with no load, -0.3VDC when the
generators are at full load. If voltage is missing
or incorrect, check and repair the power limit
box.
10 Rotary table 10.1 Monitor the voltage at terminal 128 (RT
10.1 Rotary table current limit signal LIM) of the DC control module while rotating
missing driller’s console CURRENT LIMIT potentiomter.
It should be between zero VDC (50Amps) to
-8VDC (maximum current limit). If the voltage is
absent, trace the signal to the current limit
potentiometer.
10.2 Rotary table CONT signal 10.2 Monitor the voltage at terminal 129(RT
missing CONT) of the DC control module. It should be
+10VDC with the SCR circuit breaker open or
closed but the DC contactors open. In normal
operation, the voltage will be -14 VDC when the
rotary table contactors closed.(RT CONT will
only be present in SCR units which are driving
the rotary table)
10.3 Rotary table hand throttle 10.3 Monitor the voltage at terminals
reference signal missing 130(RT REF) and 132(RT REF2) of the DC
control module while rotating driller’s console
hand throttle. It should be somewhere between
zero VDC to -8VDC. If either/both voltage is
absent, trace the signal to the Rotary Table
reference potentiometer.
11 SCR bridge CT Armature 11.1 Monitor the voltage at terminal
Current feedback 131(IFDBCK) of the DC control module. It should
11.1 Motor speed control not be zero VDC with the SCR circuit breaker open
possible or closed but the DC contactors open. In normal
operation, the voltage will be +2.66 VDC when
output of the bridge is 1000Amps. If the signal is
missing, motor speed control is not possible.
12 Assignment contactor 12.1 Monitor the voltage at terminal 134 of
12.1 Assignment contactor logic the DC control module. If the MANUAL switch of

59
control signal missing the DC control module is not engaged, the
voltage at terminal 134 should be -14VDC. If pull
up the MANUAL SWITCH, the voltage should be
zero V.
.13 DC power supply 13.1 Monitor the voltage at terminal 153
13.1 DC power supply voltage (+14VDC) and 154(-14VDC) of the DC control
missing module. If either or both voltages are missing,
check fuses F01, F02 and F03.

14 SCR Firing pulse Note: The correct way to connect the

oscilloscope is to connect the oscilloscope
ground lead to the CATH pole of the DC control
module and the oscilloscope probe lead to the
GATE pole of the DC control module.
14.1 A+SCR Firing Pulse 14.1 Monitor the firing pulse signal at
terminals 139 (A+GATE) and 140(A+CATH).
14.2 A-SCR Firing Pulse 14.2 Monitor the firing pulse signal at
terminals 141(A-GATE) and 142(A-CATH)
14.3 B+SCR Firing Pulse 14.3 Monitor the firing pulse signal at
terminals 143(B+GATE) and 144(B+CATH)
14.4 B-SCR Firing Pulse 14.4 Monitor the firing pulse signal at
terminals 145 (B-GATE) and 146 (B-CATH)
14.5 C+SCR Firing Pulse 14.5 Monitor the firing pulse signal at
terminals 147(C+GATE) and 148(C+CATH)
14.6 C-SCR Firing Pulse 14.6 Monitor the firing pulse signal at
terminals 149 (C-GATE) and 150 (C-CATH).

60
 3.7.3 DWDB TROUBLESHOOTING GUIDE

Problem Cause and Action

1. Brake Remains On 1. 1When the foot throttle is depressed, K701
1.1 Control circuit malfunction of the DC module is off; K702 is off after 1.5
seconds so as to weaken the motor magnetic
field before the DWDB contactor K01 is off to
avoid the arc burning K01 contacts. Besides,
when DW is in brake, SCR bridge which drives
DWA and DWB should be shut off, or replace the
DC control module.
1.2 Overtemperature switch OT 1.2 When SCR bridge outputs voltage, if the
is not open braking is going on, the current will keep flowing
through the braking resistor. If the current is
larger, overtemperature relay OT will be open,
K02 is off, if not, check OT.
2. Brake Does Not WORK
2.1 Operational error 2.1 If the drawworks speed hand throttle is
set at ahigh speed, brake will not work, rotate the
hand throttle to the position whose angle is
2.2 Temperature of gride-form smaller than “10 point ”clock.
Braking resistor is higher than 300℃ 2.2 Temperature relay switch should de
closed. Or temporally stop dynamic brake to cool
down grid-form braking resistor.
2.3 Loss of power supply 2.3 Check 120VAC voltage between
TB04-1 and TB05-1. Check fuses F03, F04 and
F05.
2.4 Loss of magnetism 2.4 When drawworks works, MS01 should
pick up, magnetic current is small(50A).
2.5 Control circuit malfunction 2.5 When brake does not work, K02 should
be energized and picked up, the voltage at
terminal 138 assigned to the drawworks should
be 120VAC. When the foot throttle is released for
more than 3 seconds, the DW brake magnetic
field(DC control module terminal 127) is
connected to 120VAC, MS02 is energized and
picks up, the exciting coil current is at full
value(about 200A). The DC control module
terminal 135 is connected to 120VAC, K01 and
RL01 will be energized and pick up.

61
 4 Driller’s console and PLC System

4.1 Driller’s console

The driller’s console is abbreviated to DC. It is the main control unit for all the DC
driving functions, which can control such as MP, DW, RT and bit feed. It is installed on the
driller station near the drawworks. Its panel is shown as figure 001-04, and connections
between the driller’s console and all the control cubicles are shown as figure 4-1. The
following electric parts are mounted on the driller’s console.

PLC PANEL
TB10 TB20 TB08 A1，B1

Q P N C1

ECB CUBICLE

L Q P N C1
TB12 TB01 TB10 TB04 A1，B1

DRILLERS CONSOLE
TB09 TB03 TB05 TB06 TB07 TB08 TB21 TB22 TB23 TB24

DRAWWORKS PREVEVT BUMP PREVENT RT BREAK DW BREAK DRUM SHAFT BRAKE BRAKE BRAKE BRAKE
FOOT THROTTLE POINT BUMP VALVE SIGNAL SIGNAL ENCODER HANDLE CONTROL ALARM SPARE
VALVE

DRY AIR SUPPLY

Figure 4-1-a Connections between Driller’s console and SCR House

62
 指配开关
L01 L02 L03 L04 L05 L16 L22 ASSIGNMENTS SWITCH
RT AMP % POWER ECB AMP PB03 PB01
GEN1 GEN2 GEN3 GEN4 GEN5 PLC OK SCR T.H

MO1 MO2 MO3 L06 L07 L08 L09 L10 L24 L23 L25 GEN EMERG OFF SCR EMERG OFF
SCR1 SCR2 SCR3 SCR4 SCR5 ECB RUN ECB SPARE PB02 PLC BYPASS
FAULT
L11 L12 L15 L13 L14 L19 L20 L21 旁 路指配=2点种方向
BYPASS AS SIGNMENT=T WO C LOCK ALARM ILENCE S15
MP1 BLO MP3 BLO RT BLO POWER PURGE GROUND /TEST
MP2 BLO DW BLO LIMIT TEL：086 -029-84520 736 FAX：086 -029-84516 611

DW RT
MP1 MP2 MP3
TOUCH SCREEN OFF ON OFF ON OFF ON FWD
OFF
REV FWD
OFF
REV
ILIMIT

MP377(12 INCH) TH11,TH12

S02 S03 S04 S05 S06

MP1 MP2 MP3 DW RT

S08(TH1,2) S09(TH3,4) S10(TH5,6)
S11(TH7,8) (TH9,10)

Figure 4-1-b Connections between Driller’s console

4.1.1 Assignment Switch

On the driller’s console an Assignment Switch S1 (ASSIGNMENT SW)is installed.

The switch is used to form various power supply and control circuit to meet the
requirements of drilling technology such as drilling and tripping. Switching over of all the
DC motor contactors is completed by the assignment switch.
Assignment relations are shown as figure 022-001-1(P53). It is a two-layered
structure. There are 11 pins on each layer, arranged in numerical order from 1 to 11. The
positions are arranged as the hours on a clock. Every couple of contacts connect across
the relevant positions at each layer, namely A1-B1, A2-B2……A11-B11.The sequence
number to which every contact closes is identical with the hour number of the assignment
switch.
For example, when the switch is set at one o’clock, contacts A1-B1 will close, setting
at two o’clock will close A2-B2 and so on.
In the figure the name of each driven DC motor is marked in each block, SCR1 to
SCR5 marked on top of the block indicate the sequence number of each SCR unit, on one
side of the block the corresponding figures are marked according to hour positions of a
clock. At any moment, the assignment switch is only set at a single position to determine a
certain driving function.
For example, as for a system with five SCR cubicles, if the handle of the assignment
switch S1 is set at 1 o’clock, SCR#1 provides power to MP1, DWB/DWS motors, SCR#2
to MP1, DWA, RT motors, SCR #3 to DWB/DWS, RT, MP 2 motor, SCR#4 to MP2, MP3,
DWA motors; SCR#5 to RT, MP3 motors.
If the assignment switch is set at other positions, assignment will be different.
Therefore the driving system meets various technology requirements and is very flexible
to use. Besides, since all the SCR cubicles are completely identical, if any SCR unit is out
of order, just change over the assignment switch, another SCR unit will at once feed the
running motor.
63
 DWS in the Assignment Switch indicates that both Motors DWA and DWB which are
driven by a single cubicle are running in series to meet requirement of langer lift load, but
lifting speed reduces to 50%.

TRIPPING ASSIGNMENTS SWITCH DRILLING

SCR1 SCR2 SCR3 SCR4 SCR5 SCR1 SCR2 SCR3 SCR4 SCR5
OFF
MP1 DWA DWB MP3 RT DWS MP1 RT MP2 MP3
12
11 1
MP1 DWA DWB MP2 RT MP1 RT DWS MP2 MP3
10 2

DWB MP1 RT DWA MP3 9 3 MP1 DWA RT MP2 MP3

8 4
DWB RT MP2 DWA MP3 DWS MP1 MP2 MP3 RT
7 5

DWB DWA RT MP2 MP3 MP1 RT MP2 DWA MP3

Figure 4-1 -1 Assignment Switch

4.1.2 BYPASS Selector Switch

PLC (PROGRZMMED LOGIC CO-NTROL)–BYPASS selector switch S15 are also

installed. Turn the selector switch PLC-BYPASS S15 to ‘PLC’, if the function and the
communication of PLC are normal. All monitor and control are completed by PLC and
touch screen, display screen and IPC are in order. The signal of PLC can be transmitted
on the bus. The system has a perfect function of assignment, monitor, control and
protection. That is a way of normal operation. If the system or communication is out of
order, turn S15 to ‘BYPASS’ composed of relay, the control of electric control system can
be finished by ‘BYPASS’. This basic function of drilling can be done with only one working
status(2 CLOCK), and free assignment cannot be allowed. Indicating light and display
instrument on the drilling console are invalid. In addition, protection and, tripping and other
functions cannot be realized. That is an emergent operation. Drilling workers should take
the operation seriously and electric technology workers should remove the failure as soon
as possible.

4.1.3 Selector Switch

On the driller’s console ‘ON-OFF’ selector switch S02, S03 and S04 of the Mud Pumps
MP1, MP2 and MP3 are installed when they are at ‘ON’ position and the blowers of the
corresponding MP motors starts working. FWD-OFF- REV selector switch S05 and S06
of the drawworks (DW) and rotary table (RT) are mounted on the driller’s console. When
the S05 is set at ‘FWD’ or ‘REV’, the blowers of corresponding motors starts working.
When the S06 is set at ‘FWD’ or ‘REV’, the blowers of corresponding motors starts
working.
64
 4.1.4 Reference Hand Throttle Wheel and Current Limit Knob

At bottom of the driller’s console panel, there are three MP speed reference hand
throttle wheels. One is DW speed reference hand throttle wheel and the other one is RT
speed reference hand throttle wheel. Each reference hand throttle wheel controls
rheostats with the two-layered single shaft in front of and behind it. By turning these hand
throttles the drillers control SCR firing pulse phase and further control SCR bridge voltage
and the DC motor speed. The RT current limit knob (RT I LIMIT) sets the maximum
output current to RT motor.

4.1.5 Meters

A RT ammeter(M01) is mounted in the upper right corner of the driller’s console to

indicate the RT torque. The load percentage meter(M02) indicates the percentage of the
power consumed by all the loads out of the total active power by all on-line generators.
One brake current meter（M03）indicates the brake current. The other one touch screen
MP37 displays situations in drilling.

4.1.6 Indicator Lights

The indicator lights (red) L01, L02, L03 , L04 and L05 on the first row indicate the
running states of each generator, and the lights will be on if the generators get online; L16
displays PLC running state, the light is lit when PLC runs well. L22 indicator lights (yellow),
the lights is lit when SCR house has high temp.
The indicator (Green) Lights L06, L07, L08,L09 and L10 on the second row indicate
running states of all the SCR units, they are lit when SCR is energized; L24 displays
running state of brake cubicle; (yellow) L23 displays brake faults.
The (white) lights L11, L12 L13, L14 and L15 on the third row indicate running state of
all the DC motor blowers, they are on when the blower is running;
The (yellow) lights display respectively L19 and L20 and L21 respectively indicate: L19
Power Limit (when the load percentage meter indicates 95% and the lamp is on); L20
pressure failure (when the pressure is in fault, the lamp is on); Ground Failure L21(the
light is on when AC and DC bus have serious ground failures.
. Refer to diagram 022-000(P50).

4.1.7 Pushbuttons

When the PB01” SCR EMER OFF” button is pressed, all the SCR circuit breakers will
trip and SCR rectifier bridge power will be cut off. But the other motor power supply (e.g.
the power supply of blower AC motor) is still on. When the PB03 “AC EMER OFF” button
is pressed, all the engines will shut down. The PB02 “ALARM SILENCE/TEST” button is
65
to clear up the buzzer and check the indicator light.
Besides, PLC module, circuit breaker, a pressure sensor, a heater, a buzzer, a plug,
connecting terminal and other components are installed in the driller’s console. The heater
can remove the moist. When the humidity inside the driller’s console is too high, the
control switch will close, and the heater is energized, thus, keep dry to prevent
condensation inside the driller’s console and prevent the condensation. When driller’s
console is put into operation after stop for some time, heating and moist-removing should
be done first.
Pressure sensor is used to test the pressure difference between inside and outside of
the driller’s console. Inside the driller’s console positive air pressure must be kept to
prevent outside gases from entering into the driller’s console so as to avoid that electric
sparks may cause combustible gases around the wellhead to explode and burn. Under
the driller’s console a 75 to 150 Ibf /in² dry air pipeline should be laid. When positive air
pressure disappears, a pressure transducer will make the alarm sound and illuminate.

4.2 PLC System

PLC is PROGRAMMED LOGIC CONTROLLER. It is an electronic system device with

numerical operation. We use PLC system to reduce the amount of control cables between
the driller’s console and electric control house. Transmitting information is accomplished
by using serial communication between each PLC components as well as between the
driller’s console and the SCR House. We use optic cable between the driller’s console and
SCR House to avoid the interference of outside electromagnetic waves.
Also, we can use cable communication to display GEN and SCR other working
information on touch screen.

4.2.1 Description of system

The PLC system is made up of three or four PLC RACKS (refer to Table 4-1) using
S7-300 PLC made by SIEMENS. The CPU is a 315-2DP. Serial communication between
the driller’s console and the SCR House is performed by PROFIBUS-DP In addition to
providing a serial link for communication of commands between PLC locations, the PLC
logic also provides:
Table 4－1 PLC RACK
RACK LOCATION Description

SCR CR1 SCR House SCR House Central Rack-1:

PLC Cubicle 1 PLC power module PS307,
a 315-2 DP CPU,
six I/O modules,
1 optical cabe connection unit OLM
an IM 360 interface module,

66
 SCR ER1 SCR House SCR House Expansion Rack-1:
PLC Cubicle 1 PLC power module PS307
5 I/O modules,
1 touch screen MP377
an IM 361 interface module
DC RR1 Driller’s Console Driller’s console Remote Rack -1:
1 PLC power module PS307
1 touch screen MP377
1 optical cabe connection unit OLM
8 I/O modules
an IM 153 interface module

(1) All mud pump references are programmed according to the law of the gradual
change rather than the signal outputs of the analog potentiometers.
(2) Delaying close of the assignment contactor. After an assignment switch is set,
turn selector switch to ‘ON’ or ‘FWD’ or ‘REV’ position. This will make the auxiliary motors
run on. Once all motor starters are closed and there is no alarm. The Assignment
contactor will close after a delay of five seconds. A failure of the auxiliary motor will cause
an alarming. But the assignment will keep no change. Alarming can be canceled in two
ways:
a. Cancel of the assignment.
b. Restart the motor
Figures 015-000(P42), 015-000(P43) and 022-001 (P52) are connection diagrams of
the series communication among those PLC racks. All twisted PROFIBUS lines should be
wired with BELDEN cable #3079A (or equivalent) cable. The multiline bus extension
cables that connect the central racks and extension racks are made by SIEMENS (Part
number 6ES7368-3BB01-AA0).
The termination resistors are built into the connectors of each BELDEN cable.It
should be switched to “ON”when used (The switch is located on the side of the
connector).

4.2.2 PLC Terminal Block Designation

In PLC terminal block, a special terminal block symbol is used as follows:

(1) The specific rack location.
(2) The rack number in that location.
(3) The PLC’s slot position in that rack.
The terminals on each of I/O modules are very similar. PLC location is configured
in the software. It is thus independent of the order in which the I/O modules are installed.
Designation of each terminal must be unique. Rack numbers, slot numbers and terminal
numbers designated to each terminal must also be unique. The unique terminal block
designation number is constructed in the following manner:
Rack #/slot#-pin#
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 For example: If a certain PLC output end is located at rack 1 in slot 4 on pin 15 in the
electric control house, the terminal block designation should be: SCR CR 1/4-15.
Slot 2 in SCR CR1 contains a CPU. If there is no CPU, then there is no Slot 2. Slot 3
of SCR CR1 (SCR House PLC Rack 1) and SCR ER 1(SCR House PLC Expansion Rack
1) respectively contain an interface module.

4.2.3 PLC LED Indication

When a particular concrete I/O is closed or TRUE or ON, the LED on the I/O module
associated with that I/O will be illuminated. For input point, the corresponding LED is
illuminated if the correct voltage is added to the input point. For the output point, the
corresponding LED is illuminated if the PLC program commands the output end to close.
Figure 4-2 shows a typical output module block and terminal connection diagram
which show the association between pin numbers and LED location.
In figure 4-2, (pins 4,8,13 and 17 are common, pin 1 is +24VDC, pin 20 is zero
potential (grounds) that six pins are not connected to the LED, and eight pins are
connected to LED of digital output module, PIN 3 to LED 0, PIN 5 to LED 1, PIN 7 to
LED 2, PIN 9 to LED 3, PIN 12 to LED4, PIN 14 to LED 5, PIN 16 to LED 6,
PIN18 to LED7.

Figure 4－2 SM322 Module and its Terminals Diagram

4.2.4 PLC Troubleshooting

To aid troubleshooting, the drawings show the logic association with each concrete
output in equation form. If you want to understand the logic equation on the drawing, you
have to understand the meaning of PLC terminal designation. Each concrete output’s
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equations give the following information:
(1) All of the input terminal designations for that specific concrete output.
(2) Only the logic input condition must exist, can the particular output be obtained.
Figure 4-3 is an example of a PLC program shown in a ladder equation, the program
assigns DWA/RT motor’s forward rotation driven by SCR2. The ladder equation of the
PLC program states (starting at the left side and proceeding to the right):
(MODE 3 or MODE 7 or MODE11) .FWD.REV.SCR ON. (DW-
ASSIGN+DWA/RT-FWD-SCR2-ASSIGN). COMM LOSS ALARM = DWA/RT-FWD-SCR
2-ASSIGN.
Objects on the right of ladder can come true only when the all conditions on the
left of the ladder are satisfied.
In this equation, MODE 3, MODE7 and MODE 11 are set to true by the software which
monitors the position of the driller’s console assignment switch. If set to MODE 3 or
MODE7 or MODE 11, this part of the equation will be true.
FWD is set to true by the software based on the position of the driller’s console
FWD/OFF/REV lockout selector switch. If this switch is set to the FWD position, this part
of the equation will be true.
REV is an interlock used to prevent SCR 2 being assigned to power DWA/RT motor in
both the forward and the reverse direction at the same time. In this case, if the contact is
open (the motor is not being powered in the reverse direction by SCR 2), this part of the
equation will be true.
SCR2 ON is mapped to SCR ER1/4-3 figure 015-000 (P44). If SCR2 is turned on, this
part of the equation will be true.
DW-ASSIGN is true if the auxiliary devices are in operation. In this equation, it is OR
with DWA/RT-FWD-SCR 2-ASSIGN, Therefore for the overall equation to be true only
when the DWA/RT motor is initially set to run in forward direction, the auxiliary devices
must be operating. However, once the motor is running in the forward direction, the
auxiliary devices can be turned off and the motor will continue to be powered in the
forward direction.
COM LOSS ALARM is set to true (the contact is open) when the equipment has
detected a loss in communication. If the contact is closed (no communication loss has
been detected), this part of the equation will be true.
DWA/RT-FWD-SCR-2-ASSIGN is mapped on SCR ER 1/6-14. If the ladder equation
shown in figure 4-3 is true (all the conditions are met), the contact at SCR ER 1/6-14 will
close, SCR 2 will be assigned to power DWA/RT, and the DWA/RT motor will rotate in the
forward direction.
In this example, the output DWA -FWD-SCR 2-ASSIGN is fed to assignment contactor
and it is closed. If for some reason, this contactor is not closed, then this is a logical
troubleshooting procedure (Figure 4-3):

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 Figure 4－3 Ladder of DWA Forward Rotated By SCR2

(1) Check to see if the DWA/RT-FWD-SCR 2-ASSIGN contactor voltage is on its coil.
If voltage is present on the coil, then the contactor is bad and we should replace it. If
voltage is not present on the coil, then just proceed to step 2.
(2) Measure the voltage between pins 1 and pin 20 of module SM322. If voltage is
present, proceed to step 3. If voltage +24VDC is not present, there is an external wiring
problem.
(3) Monitor LED 5. If it is illuminated (True), pins 13 and 14 should be connected.
Measure a resistance reading between them. If the reading is not zero Ω, the module
needs to be replaced.
(4) If the resistance reading is zero Ω, check for a wiring problem.
(5) If LED 5 is still not illuminated (False), replace the out put module.

4.3 Driller’s console Operation

The Driller’s console controls all the drilling functions. It is mounted in the Driller’s
Romm。

4.3.1 Common Operation Procedure

(1) Set the assignment switch at 12 o’clock ‘OFF’ position, rotate all speed
reference hand throttles counterclockwise until the hand throttles reach at zero point.
(2) Check the GEN STATUS lamps to make sure there are enough generators
online to meet the load requirement. Meet the load requirement.
(3) Check SCR STATUS lamps to make sure that all the SCR units are online.
(4) Set the Assignment switch to the position desired .Switch positions are arranged
as the hours on a clock, with the vertical 12 o’clock ping is at off position The right position
is designed for the status of drilling and the left position is designed for the status of
tripping, drillers are free to select any position at any time.

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 There are the order numbers of every SCR cubicle above the block, e.g SCR 1 and
SCR2 etc to indicate different SCR cubicles, the drilling device driven by a SCR unit is
indicated in each block.
For instance, when the switch is set at 3 o’clock, SCR1 is assigned to MP1, SCR2 is
assigned to DWA, SCR3 is assigned to RT, SCR4 is assigned to MP2 and SCR5 is
assigned to MP3.

L01 L02 L03 L04 L05 L16 L22

GEN1 GEN2 GEN3 GEN4 GEN5 PLC OK SCR T.H

L06 L07 L08 L09 L10 L24 L23 L25

SCR1 SCR2 SCR3 SCR4 SCR5 ECB RUN ECB SPARE
FAULT
L11 L12 L15 L13 L14 L19 L20 L21
MP1 BLO MP3 BLO RT BLO POWER PURGE GROUND
MP2 BLO DW BLO LIMIT
(3)

TRIPPING ASSIGNMENTS SWITCH DRILLING

SCR1 SCR2 SCR3 SCR4 SCR5 SCR1 SCR2 SCR3 SCR4 SCR5
OFF
MP1 DWA DWB MP3 RT DWS MP1 RT MP2 MP3
12
11 1
MP1 DWA DWB MP2 RT MP1 RT DWS MP2 MP3
10 2

DWB MP1 RT DWA MP3 9 3 MP1 DWA RT MP2 MP3

8 4
DWB RT MP2 DWA MP3 DWS MP1 MP2 MP3 RT
7 5

DWB DWA RT MP2 MP3 MP1 RT MP2 DWA MP3

旁 路 指 配 =2点 钟 方 向
BYPASS ASSIGNMENT=TWO CLOCK

(4)

(5) Set the appropriate selector switches MP to ‘ON’, ‘FWD’ or ‘REV’, ‘DW’ or ‘RT’.
The relevant blower lamps should be switched on.

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 DW RT
MP1 MP2 MP3 OFF OFF ILIMIT
OFF ON OFF ON OFF ON FWD REV FWD REV

S02 S02 S03 S05 S06 TH11,TH12

MP1 MP2 MP3 DW RT

S08(TH1,2) S09(TH3,4) S09(TH5,6) S11(TH7,8) S12(TH9,10)

(5)
Attention:
if the indicator light that should be on is off, further operation should be stopped,
turn the speed reference to zero point and find the failure.
(6) Rotate the corresponding hand throttle wheel steadily to achieve desired speed.
You should sense the ‘click’ of a micro switch switching as the throttle is rotated to off
position. The micro switch turns on the foot throttle or auxiliary devices such as rod and
chain oiler.
Attention:
a.） If the throttle is first not in off position motor will not running when SCR is
assigned to a motor.
b. ） If motor blower is not turned on, there will be an alarming when the throttle is
advanced. The motor does not run without the blower. Alarming will also be sound if air
supply to the driller console is cut off.
(7) Whether to increase or cut off generator on AC bus can be decided by the
display of load percentage meter. For saving fuel, we should operate the rig at 90% to 95%
of general power of generators online at desired speed. The power limit lamp will be on
when power consumption is approximately 95%.
We can make the power limit have no effect by adding generator online. If all
generators are online and power limit light is still on, the power limit device will keep all
equipment running by speed-down the DC motor so as to prevent the engine generator
set from an over-load.

PB03 PB01
RT AMP ECB AMP

MO1 MO2 MO3 GEN EMERG OFF SCR EMERG OFF

PB02 PLC BYPASS

ALARM ILENCE/TEST S15

(7)
(8) Make sure to turn the throttle back to 0(counterclockwise) and the motor
completely stops before setting the selector switch to off or changing the assignment

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switch. This is the same as before changing the direction of drawworks or rotary table.

(8) (9)
(9) In case of emergency, press the ‘SCR EMER OFF’ button to make the SCR
cubicle circuit breaker tripped.

4.3.2 Drawworks

Switch and reference throttle of DW is located at the front of the driller’s console.
There is mounted a foot throttle at the front right of the chair.
Firstly, ‘Drawwork drum clutch’is spotted at ‘Speration’,‘DW reference throttle’is
at ‘Zero’,‘DW Control S05’is at ‘OFF’.Then, make assignment switch S01 at a required
position,which illustrates the work mode is decided. Next, ‘S05’is turned to ‘FWD’and
‘REV’.Now, DWA and DWB motor blowers start to work. Their running lamps ‘DW
Blower’are bright.If the system works well, the self-check has no problem and DC cubicles
starts to work. Rotate the throttle slowly, and its normally –opened contacts will be closed,
electrify electro-magnetic valve to release inertial brake.Make DW motor work at a
cathead speed.Put the ‘DW D drum clutch switch’ at ‘Close’, the you can hear air course
and drum clutch act. When the cluch is closed,motor will run at a cathead speed.
Reference throttle is avaible to rotate to adjust the speed.Release the foot throttle make
DWA have a dynamic brake. Motor will slow down quickly to a cat speed. Turn ‘DW Drum
Clucth’to ‘Seperation’to start disc brake.
When the DWS motors are running in series, two motors are supplied with power by
one SCR cubicle. At this moment the SCR cubicle provides the maximum twisted torque
but its speed is half of the rated speed.
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 (1) Make the motor achieve cathead speed.
(2) To accelerate the lifting speed of drawworks, press the ‘FOOT THROTTLE’
button.

(3)
Note: Foot throttle must be off until the drawworks hand throttle achieves to cathead
speed.
(3) To slow down the drawworks to a cathead speed after a prompt advance, step
off the foot throttle. DW dynamic brake is on effect automatically when foot throttle is
released for more than 3 seconds. If the rotating angle of the hand throttle which has a
cathead speed is more than 90°, the dynamic brake will lose its function.
Notice: The dynamic brake slows down the DW motors after the clutch is thrown out
and the motors are freely rotating. This function can’t be replaced neither by
electromagnetic eddy-current nor hydrodynamic brake.
Notice: Three work modes for DW, namely, Singal motor DWA, DWB; Double motors
DWA, DWB; Serial motors DWS; they are decided by assignments.
Notice: Reverse rotation and dynamic brake only occurs on DWA. Speed stopped up
motor is not allowed for DW.
Notice: Under PLC, When DW drive cubicle goes wrong, a disc brake probably begin
to work for safety. But drillers must carefully work because BYPASS has no such function.
Notice: Prohibit to put ‘DW drum clutch switch’and ‘Auto Bit Feed Clutch’at
‘Close’.Under a normal PLC, the system will refuse to excute the wrong operation. Under
a relay emergence,a wrong operation will cause ‘Speed Stopped Up motor’,which is not
allowed.

4.3.3 Rotary Table Operation

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 Make sure S12 at ‘Zero(inertial brake is unreleased)’,DC cubicle its assignment
switch is working now. Now turn S06 RT switch’to ‘Forward’or ‘Reverse’, RT blower should
work and its RT BLOWER lamp should be turned on. If the system works well and its self
check has no problem,RT DC cubicle is supposed to work. Now operate RT speed
reference throttle,its normally open contacts will be closed to drive electro-magnectic
valve,now release the inertial brake.The increasing reference will decide RT direction and
speed.
According to request, at any time, drillers can change the biggest torque limited value
of RT. The knob RT LIMIT of RT turque limit to the different positions can adjust the torque
limit within an arrangement of 0～100% rated value. To change the running direction of RT,
firstly, turn reference throttle ‘zero position’. Next, get S06 to the ‘reverse rotation’. At last,
rotate reference throttle RT.

4.3.4 RT Current Limit

(1) Turn on the rotary table.

(2) Set the rotary table torque limit knob to a high setting, namely at 8

(2)
(3) Triping in with a desired weight on the bit.
(4) Watch the rotary table ammeter and rotate the limit knob counterclockwise to
reduce the torque setting until the ammeter needle starts dropping.

(4)
(5) Rotate the limit knob clockwise slightly to set torque limit slightly above the
operating torque.
(6) Reset the torque limit if weight on the bit changes significantly.
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 Notice: Watch RT inertial brake. RT inertial brake is released whe RT DC cubicels
work. If there is a wrong operation, cause the locked rotor will be caused under a relay
emergent mode.
Notice: But torque limit value is not supposed to be too small, because a locked rotor
will be caused under a heavy load or an unstable coring speed.

4.3.5 Mud Pump Operation

Observe instructi0ns in section 4.3.1 to Turn on the mud pumps.

The mud pump console controls the pump when the mud pump is serviced. In normal
operation, firstly the console works to start the pump running at a lower speed, then the
driller’s console control it.
The work routine is as followings:
(1) To operate the MP1, firstly set the MP1’s throttle of the driller’s console
counterclockwise to zero, and then set the MP1 ON/OFF switch to ‘OFF’.
(2) Select the appropriate SCR cubicle assignment in the driller’s console, set the
MP1 ON/OFF switch to ‘ON’.
(3) Set the MP1 ‘ON/OFF’ switch S02 of the mud pump console to ‘ON’. Now the
blower starts and the power lamp is on.
(4) Rotate clockwise the MP1 hand wheel of the mud pump console to make the
MP1 run slowly, then set the hand wheel back to zero. Half of the maximum MP speed is
obtained if the speed throttle wheel on the MP console is used.
(5) Rotate the MP1 hand throttle of the driller’s console clockwise to make the pump
displacement capacity and pressure achieve a desired speed.
(6) Return the hand throttle slowly to zero when stopping the MP pump stops, turn
the S02 from ON to OFF.

(3) (4)

4.4 Assignment Control

In the driller’s console control circuit, contactors, relays, switches, electronic circuits
and PLC are combined together to control various functions of rig. Its control cable
connection diagram is shown as figure 005-000 (P18).
In DC system, the rated voltage of the main circuit DC contactor coil is 74VDC. The
positive terminals of all the contactor coils are connected to +60v power supply, the
negative terminals of the coils are connected to -14V power supply through some control
76
contacts and PLC. Only when the drillers operation meets the running conditions for the
drawworks, rotary table or mud pump, the assigned contactors can turn on the
corresponding SCR units and relevant DC motors. As an example, the description
following describes the DWA/RT assignment of SCR5 cubicles system.

4.4.1 DWA Motor Forward Rotation

Figures 011-001 is DWA assignment control circuit diagrams. In figure 011-01 (P32),
if the assignment switch S01 is set in five o’clock, SCR 4 unit will power DWA. -14V
power supply in SCR4 go through pin 154 is connected to the manual voltage switch of
the SCR DC control module. The switch is open only for SCR bridge rectifier test. When
the DWA motors are running, the switch is closed, SCR CB AUX is an auxiliary normally
open contact of the SCR circuit breaker, it will be closed when the breaker is closed. Then
-14V power signal can be passed through pin 06-02 of SCR 4 and applied to pin
ER 1/4-05 of PLC, PLC determines the channels of the output signal according to the
positions of all the switches on the driller’s console panel.
For example, when S01 is set at 5 o’clock, S02 and S03 and S04 at ‘OFF’, S05 at
‘DWA-FWD’, S6 at ‘OFF’, S15 at ‘PLC’, ER1/6-18 will supply +24VDC to pin 04 of
solid-state relay PC 18 under the PLC’s control. When PC18-04 receives +24VDC,PC
18-12 and PC 18-13 will be turned on, -14VDC signal is passed through pins X04-09
and PC04-02 of SCR 2 and connected to the negative terminal of the forward rotation
contactor coil K05 FWD. The positive terminal will connected to the +60V power supply of
SCR4, and the FWD rotation contactor energized and pick up. At the same time the
auxiliary normally-open contact of K05 FWD closed, -14VDC signal goes through the
lockout relay RL14 DWA I/O of SCR2 and normally-closed contactor K07 MP2 for
interlock protection of SCR4, and then is connected to the coil negative terminals of the
main contactors K01 DWA and K06 DWA. The coil positive terminal is connected to
+60VDC power supply. At this moment, the main circuit from SCR4 to DWA is turned on,
the auxiliary normally-open contacts of K-01 DWA and K-06 DWA are closed, The -
14VDC signal is carried to pin 116 (DW CONT) of the DC control module. The signal is
the contactor signal of the DWA. It unlocks the DW reference signal at pin 117, thus the
DWA motor will run forward.

4.4.2 DWA Motor Reverse Rotation

If S05 is set at REV and other switches are unchanged, ER 1/6-19 of PLC will carry
+24VDC to PC 18-6 to turn on PC 18-12 and PC 18-14, -14VDC signal is passed through
pins X04-10 and PC04-10 then connected to the negative terminal of the coil K05 REV
which is in the reverse rotate contactor. The positive terminal is connected to +60V power
supply of SCR4, the contactor for reverse rotation will be powered and pick up, at the
moment K05 REV auxiliary normally-open contact is closed. The other control logic is
identical with DWA in forward rotation. Then DWA motor can run reversely.

77
 4.4.3 DWA and DWB Powered and Rotated at the Same Time

If S01 is set at 7 o’clock, S02 and S03 and S04 are set at ‘OFF’, S5 at ‘FDW’, S06 set
at ‘OFF’,S15 at PLC, PLC will make -14VDC signal pass through PC 15-13 and PC
03-03 and carried to K05 DWB contactor of SCR 1. At the same time, PLC will make
-14VDC signal pass through PC16-13 and PC04-01 and carry the -14VDC to K05 FWD
contactor of SCR 2. At the moment the DWA motor and DWB motor are powered
respectively by SCR 1 and SCR2, the two motors are rotating forward.
In the drive system with three SCR units, When S01 is set in 11 o’clock, the above
conditions will be got.

4.4.4 DWS Forward Rotation

If S01 is set at one o’clock, PLC will make -14VDC signal pass through PC15-14 and
PC03-05 and go to K05 DWS contactor of SCR 1. At the same time, -14VDC signal is
passed through PC04-03 of SCR2 to make K05 FWD powered and pick up, now the DWA
motor and DWB motor are running forward in series and powered by SCR When lifting in
heavy load or at low speed, the working conditions will be used to double the lifting torque
and reduce the lifting speed by one half. Refer to figure 011-001(P34).
The main circuit trend of the DWS in running is as follows:
SCR1(+) → 1K1→DWBF→FF→DWBA1→A2→1K5(1 3) →DWAF→FF →2K5(3 1)
→DWAA2→A1→2K5(2 4) →1K5(2 4) →1K6→SCR1(-)
The mud pump control circuit is shown as figure 010-001(P25). Its control theory is
identical with the drawworks’.

4.5 Speed Control

As above-mentioned, each speed adjusting hand throttle wheel on the driller’s

console panel controls respectively the front rheostat or the back rheostat. Both ends of
the front rheostat are connected to +10V power supply. All the moving contacts of the front
rheostat feed 0 to +10VDC speed reference signal through RR 1/8 to the PLC. Then
under the PLC’s control, 0 to -8.2VDC variable voltages are output at the different
interfaces as the reference signals for the mud pump, drawworks and rotary table. Both
ends of the back rheostat are connected to -8.2VDC power supply. Through BYPASS
contact of S15, all the moving contacts of the back rheostat feed 0 -8.2V speed reference
signal and current limit signal directly to the relevant terminals of DC module.
The mud pump reference control circuit is shown as figure 010-002(P29).
The drawworks reference control circuit is shown as figure 011-002(P35).
The RT reference control circuit is shown as figure 012-002(P41).
On the all four hand throttles are installed micro switches, one for each hand throttle,
they are S8, S9, S10, S11, and S12. When the hand throttle is turned counterclockwise to
the end, some contacts of the micro switch are open, others are closed; when the hand
78
throttle begins to turn clockwise, the conditions of the micro switches are contrary. Those
micro switches control the ‘ON-OFF’ and interlock protection of all the lubricating pumps.
Under the driller’s console a DW FOOT THROTTLE is mounted, the driller’s stepping
on the foot throttle will lift the drill rod quickly. When stepping off the foot throttle, the foot
throttle will return to the highest position by the reaction of the spring. See from figure
022-001 (P55), only when the DW speed reference hand throttle is not set in ‘MIN’
position, the micro switch S11 will close to turn on +10VDC power supply, this moment the
foot throttle will be operated . Therefore, before using the foot throttle, the speed reference
hand throttle must first be turned to a place whose rotation angle is smaller than 90°
(cathead speed), then step on the foot throttle.
The foot throttle reference voltage after PLC’s handling is variable within the range of 0
to -8V. Under the condition of BYPASS, the foot throttle will directly output 0-8V reference
power.

4.6 Blower Control and Alarm Devices

A blower is mounted on each DC motor. Before the main motor runs, the blower motor
must run in advance.
The following description takes MP1 as an example to present the blower control
circuit. When S02 is set at ON position , 24VDC is fed to RR1/4-14 figure 022-001 (P53) of
the PLC, then the PLC carries 115VAC to the blower middle relay RL01-MP1 in the MCC
house of blower through CR1/9-01 and CR1/9-02 figure 015-000 (P46), RL01 auxiliary
contact will be closed, then the blower contactor KM will pick up through MCC-HOA
controller ( see the HOA control schematic diagram 041-005 P71 ). At the same time,
normally-open contacts of MP1A Blower and MP1B Blower in figure 041-009 (P75) and
041-009 (P76) are closed, and the blower will run. 115VAC is delivered to ER 1/5-07
interface of the PLC in diagram 015-000 (P47), then under the PLC’s control, 24VDC is
connected to the blower indicator lamp of the driller console through RR1/7-09 figure
022-001 (P54) to make it illuminate.
If the blower is switched on under the condition of assignment signal, RR1/7-19 output
cuts off the purge loss relay RL02 in diagram 022-001 (P54) to make the normally open
contact open figure 022-001 (P52).
If the blower is shut down under condition of assignment signals, RL02 will receive
24VDC and pick up, its normally-open contact will be closed to make the buzzer alarm.
When the positive pressure inside of the driller’s console falls to 751bf/in², the
normally-closed contact NC of the air pressure switch S14 will be closed and the
normally-open contact NO cuts off to make the normally-closed contact of RL01 close
because of power –cut and buzzer alarms, purge loss lamp L20 will illuminate.
To remove the sound alarming, press down the PB02 ‘ALARM SILENCE’ button on
the driller’s console, so RL03 is powered and picks up, the buzzer stops alarming. If the
communication device has broken down, the buzzer will send out a short alarm sound at
interval of every second. To test the indicator lamps, press the button for over 4 seconds,
all the lamps will illuminate. When the button is released, the lamps which originally are
79
illuminated will still illuminate and the lamps which originally are not illuminated still do not
illuminate.

4.7 Driller’s Console Function Test

(1) Cut off all the SCR circuit breakers to prevent the SCR bridge from having
voltage when the assignment switch is closed.
(2) Connect across the auxiliary contacts of the SCR1 circuit breaker, namely,
short-circuit the two contacts (TB08-03 and TB08-04) of SCR1 connected to PLC, then
the assignment contactor of SCR 1 will be closed for a successful functional test, at the
moment, the ‘SCR ON’ lamp on the driller’s console will illuminate.
(3) Select an object for functional test with the assignment switch. Turn the
assignment switch to 2 o’clock, then set the ‘ON-OFF’ switch of the MP1 at ‘ON’ position,
the MP1 will be powered by SCR1 and run. At this moment, the MP1 contactor of SCR 1
will pick up to make the MP 1 motor blower run. The auxiliary devices will (e.g. oil pump
and liner wash) also be running. Meanwhile, ‘MP 1 BLOWER ON’ lamp on the driller’s
console will illuminate.
(4) Turn the MP 1 hand throttle clockwise to the end and check the change of the
reference voltage at the MP 1 input end (pin 125) of the DC control module. When the
hand throttle is turned counterclockwise to the end, the voltage is zero volt. When the
hand throttle is turned clockwise to the end, the voltage will be -8.2VDC.
(5) Test the other SCR unit according to the above steps. After all the tests are over,
do not forget to remove the jumper for test between the two auxiliary contacts (TB08-03
and TB08-04) of SCR circuit breaker.
(6) Test the DW foot throttle of each SCR for its working state. Every time
short-circuit a pair of contacts (TB08-03 and TB08-04) of only one SCR unit. When
stepping on the foot throttle slowly, monitor the variation of the DW foot throttle reference
voltage at pin 114 of the DC control module: The voltage will be zero V as the pedal is not
pressed. When the pedal is pressed to the end, the voltage will be -8.2VDC.
(7) Remove the jumper between the auxiliary contacts of the SCR circuit breaker
and close the circuit breaker, prepare for the SCR running.

4.8 Driller’s Console Maintenance and Troubleshooting Guide

Check the components on the driller`s console regularly to find out whether it is
corroded. A bad-sealed panel or more vapor in the input air can lead to components
corroded. Rotate hand throttle and select switch, check the switch and potentiometer
which is behind the driller`s console panel, check carefully the switch contact and
potentiometer terminal arm.
Generally, maintain the foot throttle every three months.
Pick out the foot throttle and open the dust cap behind it, check and tighten the screw
to make sure that potentiometer of foot throttle can return to zero. Make sure that the
cursor of potentiometer doesn’t rub with the wire which is connected to the foot throttle.
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Then install and adjust carefully to make sure that the foot throttle is airproof.
Troubleshooting for driller’s console:

1.Motor 1.1 Generator or SCR 1.1 Check the

does not run. units may be off generator and SCR ON
lamp.

1.2Assignment 1.2 Looking for a

contactors may have not -14VDC contactor logic
picked up signal by tracing the
appropriate assignment
logic. The failure point is at
the point of missing signal.

1.3 The speed control 1.3 The hand throttle

signal is not sent to the DC reference signal should be
control module between zero and-1VDC at
‘OFF’ and up to -8.2VDC at
MAXIMUM throttle. Check
the signal at the selected
SCR unit TB. Trace the
direction in which the signal
is absent

1.4 Hand throttle is set 1.4 Either the DWB

to cathead speed, but the motor is leading the DWA
draw works is run under the motor or the driven module
dynamic brake. of DWA motor is defective.

2. Horn sounds. 2.1 The driller’s console 2.1 Check whether the
is no longer pressurized. dry air bleed is leakage.
2.2 The blower has not 2.2 Trace the 480VAC
switched on or fails to start MCC motor control circuit.
running.

3. Foot throttle 3.1 Potentiometer 3.1 Check the

does not work. failure. reference signal at pin 114
of the DC module which is
in the selected SCR unit.
Check for presence of the
+10VDC at DC control
module TB09-01 in the
driller’s console (bypass is

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 -8.2VDC). Trace the signal
in the direction that it is
absent
3.2 loose set of one 3.2 Screw down all
screw which is on shaft of screws inside the throttle,
double connect jam nut on the
potentiometer. potentiometer.
3.3 The foot throttle 3.3 The drain hole must
may be frozen be kept clear. The air supply
inlet must be kept
unblocked. If not, the foot
throttle unit may fill with
water and freeze.

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 5 Power Supply System

5.1 Power Supply System

Breaker(M16H1 65kA) under GEN1# cubicle in GEN1# provides 600V 3PH 50HZ
power to AC TOP; breaker (MT12H1 65kA) under GEN4# provides once terminal power
to the main transformer 600:400/230AC (1250KVA); after 600V main bus is electrified,
close the switch to make the main transformer to put into operation.

6 AC MCC

6.1 MCC System

MCC lies in the electric control house and includes1 feeder cubicle, 1 incoming cubicle,
8 MCC drawer cubicles, 1 distribution cubicle and 1 electromagnetic eddy-current brake
cubicle. The distribution of load in each unit is showed in the MCC ichnography (040-001)
(P58, P59).
A 2000A horizontal copper bar and a 1000A vertical one are adopted by main bus bar.
The cubicle can bear a short circuit current with 65kA. The protection class of cubicle is
IP40.
Breaker MT20N2(QF1) at the upper part of MCC incoming cubicle is the secondary
control switch of the main transformer, the interrupting capacity of the breaker is 50kA,
and it provides 400V normal working power for MCC.
Breaker MT08N2(QF2) at the lower part of incoming cubicle is the incoming switch of
auxiliary generator, the interrupting capacity of the breaker is 50kA, and it provides 400V
emergency power for MCC system electric equipment. Interlock function is set on
outgoing switch (QF1) of main transformer of incoming cubicle and incoming switch of
auxiliary generator.
See diagram 041-003 (P69).
MCC system also has the function of ground fault display.
Feeder cubicle panel and incoming cubicle panel are both installed with voltage
meters, ampere meters, current change-over switches and power indicators, which
display working states of 400VAC power supplies.
Both AC load distribution states controlled by cubicles and units are installed with loop
plates, and the interrupting capacity of each unit breaker is 36KA. Power voltage of feeder
unit is 400VAC, three-phase four-wire, 50Hz.
Each cubicle drawer is matched with single-line diagram 041-001 (P62-66), and letters
and numbers beside devices in single-line diagram show device style.

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 6.2 MCC Operation

The breaker (the host machine or auxiliary machine) of the incoming cubicle is closed
to supply power to MCC bus, 400VAC, 3PH 50HZ BUS.

6.2.1 Start and Stop

(1) For the sake of safety, set all the control switches of the MCC to ‘OFF’.

Figure 5-1 Open the Draw

(2) When the operation handle of drawer is in the open position, it can be moved
freely. When the operation handle of the drawer is in the close position, the drawer can not
be moved. Be sure that all the drawers of the starting unit can be pushed to the end.

Figrue 5-1 Close the Draw

(3) Supply power to MCC bus by closing the relative circuit breaker of the
transformer.
(4) Figure 041-005(P71) is the ‘HOA’ (HAND OFF AUTO) starter control schematic
for starting the blower. During a test, BAPASS or failure, just operate on the spot, put the
‘HOA’ switch in ‘H’ (HAND) position, the motor will start. Normally, the ‘HOA’ switch is put
in ‘A’ (AUTO) position. When S2, S3 or S4 in the driller’s console which control on-off of
the mud pump are closed; or S5 or S6 which controls the forward and the reverse
rotations of DW/RT is closed, the relay KA (diagram 041-009 (P75)) will pick up to set the
normally-open contact KM closed , which is in the control loop for the blower motor, the
motor will start. Meanwhile, HOA switch is set to “0” (off) position, and blower motor will be
cut off and stop running. When related DC motors lose assignment form assignment
switch, blower motors will stop running, and at the same time blower indicators on driller’s

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console are extinguished.
(5) Figure 041-006(P72) is a control schematic of 3WRC soft (3 WIRE REMOTE
CONTROL) starter. Press this REMOTE CONTROL button, contactor KM will pickup and
lock itself, motor starts working and indictor will be shinning.
(6) Figure 041-007(P73) is a control schematic for HOA and 3WRC. It is easy to
operate and has two ways to control for controlling filling pump, one of which is AUTO and
another is 3WRC. The close emergency stop button is also set for emergencies.

6.2.2 Protection

Model TM-D (namely NSX100F I=60A, NSX100F I=100A and NSX160F I=150A and
NSX250F I=200A in the one line diagram) circuit breakers in all the load circuits provide
short-circuit protection and overload protection.
But Model MA circuit breaker (namely NSX160F MA and NSX100F MA in the one line
diagram) provides only short-circuit protection. A contactor and a heating protection relay
must be added in the circuit to effectively protect motor starter, which is a secondary start
circuit.
The heat relay FR provides overload protection. When the motor is overloaded,
excessive current sets the heat relay acting to cut off the control circuit, the motor will stop
running for power cut, the relay can not be reset till the thermal elements cool down.
The control circuit itself has an undervoltage protection function. When the supply
voltage is too low or there is a power cut, the contactor will release for power out, the
motor will stop running, when power supply is restored, the operator must start the motor
again to set it running.

6.3 ECB

The power system of ECB is 400VAC 60Hz. ECB is powered by MCC6# P606and
equipped with Siemens 6RA70. It outputs 450VAC 50Hz and makes it to 0-320VDC, its
maximum current is 80A. It gives electri-magnetic torque to DW during a tripping progress.
A surge suppression system is equipped in ECB to avoid a stroke to 6RA70.
Input signal from ECB BRAKE HANDLE is 120VAC and output is 0-18VAC thus they
are lined to pins 1 and 3 on VB. Pins 6 and 9 outputs 4-20m A signals. Afterwards, signals
will be sent to （AI）X174-4、X174-5 in 6RA70 vai control cables Q. （AO）X175-16、
X175-17 delivers the output current to M03 on driller’s console, the current become
singlas for monitoring. X175-14, X175-15 and X175-16, X175-17 deliver the singals to
MO1,M02 on ECB door to have a voltage and current.
If the device runs in normal, pin X171-46 of DC controller (+24VDC) will output 24VDC
to pick up RL01 and illuminate running lamp L03 on cubicle door. Meanwhile, signal will be
sent to PLC, and ECB RUN lamp (L24) on DC will be lit through the bus.
If the device runs out of order, 6RA70 (DO) pin X171-48 will sent out 24VDC to pick
up RL02 and illuminate fault lamp L04. At the same time, signal will be sent to PLC, and
ECB FAULT lamp (L23) on DC will be illuminated through the bus. Besides, RL02 pickup
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will make the its normally close contacts 3 and 11 open, all this leads to electromagnetic
valve YV power off and start the air course brake device to protect device and operators.
The device has the function of water supply cutoff protection, when brake pressure
switch (water pressure switch) is in fault, RL03 will send signal to PLC to light ECB FAULT
(L23) on DC through the bus.

6.4 Travelling Wagon Anti-Collision System

6.4.1 Makeup and Function

This system is valid for preventing the collided accident from up and down.
The coder on the roller of DW is used to test the height position of the travelling block
automatically and compared it with the set value. In a normal condition of DW rolling rope,
PLC slows down automatically at the set slope no matter whether the drillers make a
deceleration or not, while the travelling block runs to a preset alarmed position of the
upper or under the derrick set pre-warm. PLC will give out an urgent instruction and make
the travelling block stop instantaneously activating with audible and visual alarm to make
sure the travelling block security when it runs to the dangerous height.
The system will memorize its position, it stores the position automatically when the
travelling block stops at any height to avoid a power shutdown suddenly. The travelling
block can work well without recalibration if the power restores.

6.4.2 Operation of Travelling Block saver System

Set an accurate total height of travelling block after turning to the anti-collided
interface of travelling block on the touch screen (click the “Traveling Block Anti-Collision”
button on the main interface). Its height is the basis to count other parameters including
the present travelling block height. Inaccurate total height will lead to more errors of
calculating other parameters.

6.4.2.1 Measurement and Set of Total Height of Travelling Block

Drop the travelling block to the surface (the lowest point) of driller`s console when
setting the total height of travelling block and press the ‘0 Meter Calibration Finished’
button, (instantaneously the ‘0 Meter Calibration Finished’ button changes to ‘0 Meter
Calibration Start’ button) and then repress it to restore, 5 seconds later (button displays
‘Zero Meter Calibration Finished’), and then hoist the travelling block to the highest
position before collided mechanically and press the ‘Highest Position Calibration Finished’
button (button changes to ‘the highest position calibration start’). 5 seconds later, repress
the button and restore it (button display ‘Highest Position Calibration Finished’). At this
moment, measure the distance from the surface of driller`s console to the highest position.
Namely, it is the total height value of travelling block .
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 6.4.2.2 Set Downward Slowdown Height and Downward Band-type Brake

Firstly drop the travelling block to a normal stop position when setting its downward
slowdown height. And adjust the downward slowdown point of travelling block to the value
that reduced the height of decades of cm. from the height of travelling block . Lift and drop
it repeatedly to test until making the downward slowdown height value suitable for the
actual operation.
After the downward slowdown point is set the proper value of downward band-type
brake height can be confirmed according to the inertia of dropping the travelling block .

6.4.2.3 Set Upward Slowdown Height and Upward Band-typeBrake

The way of setting upward slowdown height and upward band-type brake is just the
same as the above mentioned. It is essential to set the upward slowdown height and
upward band-type brake.
After the parameter of travelling block saver is set, press the anti-collision system
button ‘Anti Collision’ and keep it work all the time.
Note: Get the anti-collision system work when testing and setting the anti-collision
system (button shows ‘Anti Collision System Turned On’).
The travelling block saver system is put into use under an accidental condition, so it
doesn’t work neither at a normal lifting nor a dropping process. It also can’t be used to
stop the DW. If we want the lifting height higher than upward anti-collision height, or
dropping height lower than downward anti-collision height, it needs to shut up the system
temporarily.

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7 Installation and Maintenance of the Electric Control House

7.1 Working Conditions in the Electric Control House

The electric power control house with DDF motors is mounted with a air-
conditioner.Under the different air relative humidity and environmental temperature, its
running with no dew at the lowest temperature is shown as table 7-1.

Relative humidity should be less than or equal to 90% when the environmental
temperature is +20C.
In the district area under an elevation of 1000m, the equipment rated output can be
available. In the district area over 1000m, the output is reduced by 8% for every 1000m
higher.
There should be no excessive corrosive gases such as basic, acid and salt gases and
no explosive gases in the ambient environment of the equipment.

7.2 Installation

7.2.1 Installation Foundation

The dimension of electric control house are 13000(L) ×2900(W) ×3100(H) mm, the
weight of that is 28 tons (40D). A transformer and an air-conditioner are installed in the
rear of the house.
For the sake of a rational arrangement, the outgoing line terminals of the electric
control house face the driller’s station. On the side with a window from which outgoing line
runs are laid with all the engine/generator sets side by side.
The base of the electric control house consists of three bars of 28BI-steel with a width
of 124mm, they are centrally symmetrical with a 1125mm internal space between them.

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Before installing the house, a foundation should be laid with concrete over #150, at the
bottom of the foundation and in the protruding terrace are installed with Φ10 reinforcing
mattress of class II, with a space of 250mm between the mattresses. There are three
strips of protruding terraces shoulder mated with the other equipments. The height of the
terrace should be mated with the other equipments. The tolerance is 10mm. During laying
the equipment, if there is a gap between the foundation and the top surface of the terrace,
it should be stuffed with a steel plate.
There are significant ground marks on the skid base of house, steel bolts are installed
on the mark. Be sure to make a reliable connection between the ground pole (brass H62,
L1500mm, diameter 30mm) and the ground wire (multi-glue 50mm2, flexible cord), both
disposed by the manufacturer. The other end of ground line is screwed by nut to the steel
ground bolt of the house. The ground pole is vertically hammered into ground at least
1300mm. If the soil in the operational site is dry and loose, it should be irrigated with salty
water punctually and tamped. Make sure the ground resistance of ground devices does
not exceed 4Ω.

7.2.2 Installation

The frame of the electric control house is made of steel. The outer cover is made of
bended steel plates or buckled plates by welding. The inner cover is stuffed with thermal
insulation material and fitted up with fireproof plates. During hoisting the house, in order to
avoid squeezing the wall, two cranes should be used by running a rope through the
hangers at both ends of inside the house’s base. Additionally, a liner plate should be put at
the place where the steel rope contacts with the house wall for avoiding scratching the
house wall.

7.2.3 Wiring

The cables which go to various places in the well site are lined on the external lined
wall of house through the cable trail. According to the mark on the plug of every cable, the
cables are connected to the corresponding socket on the external lined wall. The other
end of cable is connected to the relevant electric equipment on the well site. Do not make
mistakes when inserting the plug of cable,and be careful.
After cable plug is set in the socket, power torque should be controlled within
100-120N.m. If the nut is screwed too loosely, it will make socket overheat, if too tightly, it
will be difficult to take off the nut.

7.3 Storage

The electric control house is designed as equipment in the open air. The reliability of
working in the open air and its safe storage has been considered. In general, it will not
damage the equipment to store it in the open air, as long as the door is locked up. When

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storing at the ambient with temperature between -20.C and +50C, if it will not be used in a
short time, the performance of the equipment will not be affected, the components and
devices will not go bad either.
If storing in a long time (e.g. more than half a year), the house should be stored
indoors in order to avoid being exposed to the sun and the rain, and check it regularly for
phenomena such as moisture, dew and mildew. If the above phenomena emerge, remove
them promptly. For example, a heater or a fan should be equipped temporarily to get rid of
moisture.
The storage place should be kept clean and dustless. Inside of house should be
cleared regularly with a dust-collector.

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 8 Maintenance and Over-haul

8.1 Security Measures

A serious shock damage will occur on both man and equipment before the devices
are not power off. So device must be checked or maintained when it is not alive.
If there is a lock switch in system, before operation we need to add a padlock when the
switch is turned off. This kind of switch is equipped on the panel door of SCR cubicle.
Some motors are equipped with the lock switch. For safety, check its function before using
them.

Cut off the power immediately when a fire occurs. Extinguisher is used to put out the
fire. If the equipment has no electric, we can use water to put out the fire.
Electrician and driller should be correspondingly qualified and they must experience
the systematic training before they use the equipment.
Additionally, handles of all tools should be insulated, some tool should be grounded.
Do not wear metal ring or bracket in case to a conductive connection with the
devices.

8.2 Maintenance

It is necessary for the house to be maintained regularly. As a result of connecting with

the engine house, the electric control house bears the vibration so some parts which are
tightened with screws may become loose, especially at the wiring terminals. The
looseness will cause the junctures to come off, and the components to fall apart and the
signals of the wiring terminals being lost. As a result, the system can not work. So the
tightened parts with screws should be checked regularly. Vibration may damage the
insulation layer of the conducting wire because it rubs against the components which
contact with conducting wire, so that an electric accident may be caused. In addition, dust
is easy to absorb moisture, much dust on the bus bars will make a leakage of electricity
between the bus and the supporting parts (ground wire in general). Much dust between
the contact pins on the socket will cause a signal crosstalk or short-circuit. Much dust on
the heat radiator of the thyristor will affect the radiation; finally it will damage the efficiency
of thyristor. Therefore, the dust at the above-mentioned places must be cleared regularly.
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 The DC motor is one of the key equipments which need a monthly maintaince in
electric drive. It should be maintained according to the relevant maintenance regulations
of the motor manufacturer. For example, regularly check and clear the air-filter of the
motor to avoid clogging of dust, which is harmful to the circulation of the cool air and
causes the motor overheat. That a regularly check the height of the carbon brush, its
pressure on the commutator and clear up the carbon dust among the commutator
segments is important for the normal running of the motor.

8.3 Check

8.3.1 Daily Check

(1) Check the indicator lamps of the cubicles and the driller’s console.
a. The relevant generator run lamp, generator on line lamp, and motor blower lamp
should be lit.
b. The surge suppression signal lamp should illuminate.
c. All three ground detector lamp should give out dull orange light.
When pressing the ground detection test button, three lamps should be all dull orange,
and the readings of the AC ground percentage meter and DC ground percentage meter
should be zero.
(2) Make sure that air-conditioner and all the blowers run.
(3) Make sure that active power (KW) and reactive power (KVAR) be shared out
equally by all the generators online, the reactive power may be shared out equally by
rotating the voltage regulating knob. If the active power sharing is fault, the actuator of the
engine needs servicing.
(4) In lifting and tripping, check the working state of DW dynamic brake contactor.
(5) Make sure that the heaters of the generator and motors work normally.

8.3.2 Weekly Check

On each module, there is a colorful test switch and meter. When the color of switch
position and meter indication keep the same, it demonstrates module signals work in a
normal range.

8.3.3 Monthly Check

(1) Check the waveform of the SCR current signal at the test point of the DC control
module, ensure that all the SCR components are fired normally.
(2) Test the functions of the engine for overspeed trip and reverse power trip.
(3) Test the functions of the protection circuit of the AC control unit.

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 8.4 Overhaul

Clear up all electric parts and replace broken components.

8.4.1 Weekly Check

(1) Check the SCR blower and air filter, clean them. Replace them if necessary.
(2) Clean the tacho-transducer plugs of the generator set if possible.
(3) Check the driller’s console and the DW foot throttle, ensure the air pressure
normal.
(4) Check the drier which goes to the inside air line hose of the driller’s console.
(5) Check all the outdoor sockets, junction boxes and switches so as to see if there is
corrosion or moisture.

8.4.2 Quarterly Overhaul

(1) Check the tightness of the terminal blocks, switches and sockets
(2) Check the contactor coils of the power supply for overheat and check if junctions
are rusting or corrosive.
(3)Wipe the surface of the cubicle with a cloth dipped in a low concentration cleaner.
Warning: Before cleaning, the power supply must be cut off. Before the driving
equipment is cut off, do not touch the bus bar and the feeder cable of the transformer.
(4) Check to see if all the cables wear and tear, crack and vibration friction.
(5) Check the emergency lighting device in the SCR house, ensure a normal function.

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