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SCR UNIT
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SCR DRIVE TRAINING SYSTEM
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OPERATION AND MAINTENANCE MANUAL
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SCR Drive System Operation and Maintenance SCR Unit
TABLE OF CONTENTS
1. OPERATION ...........................................................................................................................3
1.1 SPECIFICATIONS...........................................................................................................3
1.1.1 Electrical ..............................................................................................................3
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1.1.2 Mechanical...........................................................................................................3
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1.1.3 Forced-Ventilation System...................................................................................4
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1.1.4 SCR Enclosure ....................................................................................................4
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1.1.5 Circuit Breaker .....................................................................................................4
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1.1.6 Overtemperature Rating. .....................................................................................4
2. MAINTENANCE ......................................................................................................................5
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3. TROUBLESHOOTING ..........................................................................................................11
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3.1 SCR LOGIC INDICATOR ..............................................................................................11
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3.2 THEORY OF OPERATION............................................................................................11
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3.2.1 SCR Bridge ........................................................................................................11
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3.2.2 Circuit Breaker. ..................................................................................................11
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3.2.3 Current Feedback ..............................................................................................13
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3.2.4
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RLC Filter...........................................................................................................13
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3.2.5 Firing Pulse ........................................................................................................13

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3.2.6 Voltage Feedback ..............................................................................................13

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3.2.7 Regulator Power Supply ....................................................................................13

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3.2.8 Surge Suppression Circuit .................................................................................13

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3.2.9 DC Ground Fault Detection Circuit ....................................................................14

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3.2.10 Contactor Control Logic .....................................................................................14

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3.2.11 DC Module .........................................................................................................15

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3.2.12 DC Regulator .....................................................................................................16

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3.2.13 SCR Firing Circuit ..............................................................................................18

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4. DC MODULE OVERVIEW.....................................................................................................32
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4.1 BASIC FUNCTIONS ......................................................................................................32

4.2 DC MODULE POWER SUPPLY ...................................................................................33
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4.3 MODULE INPUT CIRCUITS..........................................................................................33

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4.4 TYPICAL ASSIGNMENT ...............................................................................................33

4.5 FIRING CIRCUITS ........................................................................................................36
4.6 POWER LIMIT ...............................................................................................................38
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4.7 MOTOR SPEED REGULATION....................................................................................38

4.8 MANUAL BRIDGE PHASE UP TESTING .....................................................................38
4.9 SPEED CALCULATOR CIRCUIT..................................................................................38
5. DC SLIDE ..............................................................................................................................40
5.2 SCR CURRENT FEEDBACK ........................................................................................40
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5.3 METERING CALIBRATION...........................................................................................40
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5.4 +60VDC CONTACTOR SUPPLY ..................................................................................41
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6. REPLACEMENT AND REPAIR.............................................................................................42
6.1 SCR REPLACEMENT ...................................................................................................42
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6.1.1 SCR Clamp Tightening Procedure.....................................................................46
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6.2 BLOWER REPLACEMENT ...........................................................................................48
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1. OPERATION
The SCR Unit rectifies the three-phase AC supply to provide a continuously variable DC
supply to the traction motors. The SCR bridge, which performs the rectification, is isolated
by a circuit breaker from the AC bus. The bridge output is assigned to one of the motors
via contactors. The contactors are closed in pairs (DC + and DC-).
The contactor logic and the DC voltage level are controlled from the Operator’s Console.
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Electronic circuits in the DC control module regulate the voltage and current within preset
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limits.
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All SCR Units are typically identical. If one unit is down, another is usually available to
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maintain power to the motor. Similarly, the electronic DC Modules and SCR cells of the
bridge are interchangeable.
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1.1 SPECIFICATIONS
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1.1.1 Electrical
Three Phase AC Input:
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Voltage: 600 VAC tr
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Frequency: 50 Hz
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DC Output per SCR Unit
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Voltage: 0-1.25 x the rated AC supply voltage
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Current: 0-to current limit DC Amps continuous at stall through maximum volts.
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Different limits are selected to allow maximum horsepower and torque to be obtained from
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the Equipment without exceeding Manufacturers ratings. Refer to label on top of each DC
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control module to verify current limit settings.

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1.1.2 Mechanical
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a) Cubicle
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The assemblies are mounted within the cubicle, on the side and door panels and a
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slide pan located below the blowers.

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b) DC Module
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Many of the electronic circuits associated with SCR rectification and control are
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assembled on a single printed circuit (PC) card. The card and associated components
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are housed in a module constructed from 12-gauge cold-rolled steel. The module has
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its own heat sink.

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Size: 100mm W x 300mm D x 300mm H

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Weight: 9.5 kg
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1.1.3 Forced-Ventilation System

The ventilation system consists of one or two forced air blowers located below the SCR
bridge.
a) Air Flow Rating. 1500 linear feet per minute through each SCR cell.
b) Each bridge requires a motor to power the blowers. Each motor turns two blowers
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connected at either end of its shaft. Newest designs require only one fan per cell
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assembly.
Voltage: 600 VAC single phase, 3 phase, or 240/120 VAC single phase
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Current: Approximately 1.0 Amp at 600 volt or 3 amp at 120 VAC
Speed: 1800 RPM
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c) Electrostatic Filters are located on the front or back below the bridge. They consist of
expanded aluminum gauze enclosed in a metal frame. They have an MBS (Master
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Bureau of Standards) rating of 12 to 15 percent, which is sufficient to trap common
dust particles.
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Note: Filters are used when required.
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1.1.4 SCR Enclosure
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The SCR is mounted within a set of enclosures designed to provide insulation and heat
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transfer, and to dampen mechanical vibration. The entire assembly is called the SCR
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enclosure or cubicle.
The innermost assembly consists of the SCR enclosed on either side by aluminum
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heatsinks. A two-bolt clamp is tightened to press the heatsinks into the SCR. Pressure
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exerted on the SCR is indicated by a gauge located on the top side of the enclosure.
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1.1.5 Circuit Breaker

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The circuit breaker has an overcurrent magnetic trip circuit. It also has an undervoltage
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(UV) or shunt trip circuit which is triggered for fuse failure and SCR overtemperature.
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1.1.6 Overtemperature Rating.

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The overtemperature switch mounted on each SCR stack is set at 74C and located at the
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furthest heat sink point from the airflow source.

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2. MAINTENANCE
This section contains specific functional tests to assure proper operation of the SCR unit.
Perform the tests after repairing or replacing any of the unit assemblies.
If the unit fails to perform as indicated, refer to the troubleshooting index in Section III to
locate the malfunction.
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Refer to Section III Troubleshooting for explanation of the various SCR unit circuits, and
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Section IV Removal and Repair for identification of the components.
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The DC Module test select switch (Fig II-1) enables a quick check of the contactor
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(CONT) and throttle reference (REF) signals received from the control console. The
switch and test meter are colour coded. For example, if the select switch is set to one of
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the yellow CONT positions, the test meter needle will deflect to the yellow band to indicate
a normal condition.
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Fig 2.1: DC Module Front Panel

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The SCR bridge can be phased up for testing by setting the manual voltage switch to ON
and rotating the knob clockwise. In the ON position, the switch opens all assignment
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contactors so that power is not applied to the DC traction motors.

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CAUTION
NEVER SWITCH THE DC MODULE TEST SWITCH TO THE ON POSITION IF
THE SCR IS ASSIGNED AND RUNNING A DC TRACTION MOTOR.
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The SCR bridge voltage can be monitored at the SCR volts test pins on the DC module.
The ratio is 15:1 such that the test pins will be at 50 VDC when bridge voltage is 750
VDC. SCR Amps test pins should register 2.66 VDC per 1000 amps bridge current.
The zero throttle interlock light indicates operational status of a circuit in the module that
sup-presses the firing reference for the SCR bridge. When the light is on, the bridge
voltage will be 0V. The light is on under two conditions listed below:
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SCR Unit is on but not assigned to any of the DC functions.
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SCR Unit is assigned to a function before the throttles are set to 0.
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The light goes off when the throttles are set to 0 and assigned contactors pull in.
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ACTION RESULT
1. Preliminary
a) Ensure that SCR Unit to be a) SCR On light will glow.
tested will not be assigned from b) Blowers under the SCR bridge will
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the Control Console. switch on.
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b) Energise the AC bus, if required. c) On DC Control Module, Power On and
c) Close the SCR circuit breaker. Zero Throttle Interlock lights will glow.
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2. SCR Bridge Check
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a) On the DC Module, set the Observe the front panel DC voltmeter. The
spring-loaded Manual Volts voltage will climb smoothly to 750 VDC as
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switch to “on”. the knob is rotated clockwise, and return to
b) Rotate the Manual Volts knob 0 as the knob is rotated counterclockwise.
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slowly clockwise to “Max.” and
back down to “Min.”
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3. Contactor and Throttle Check
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a) Trip the SCR breaker. This will allow us to close the assignment
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b) Jumper the auxiliary contact of contactors without applying power to the
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the breaker motors.
c) Set the Control Console In each position, check contactor (CONT)
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assignment switch to various and Throttle Reference (REF) signals from
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positions. Control Console.

d) Remove aux. contact jumper Example:
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when all CONT and REF signals Suppose RT is assigned to the SCR Unit in
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are checked out. 1 o’clock position. Then RT CONT (pin 129)

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and RT REF 1 (pin 130) can be checked.

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4. Module Power Supply Check

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Energise the AC bus. Confirm following voltages at DC Module.

Voltage Location
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12 VAC Pins 103-108

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+14 VDC Pin 153

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-14 VDC Pin 154

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5. Firing Pulse Check

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a) Ensure that SCR Unit under test SCR On light will glow and blowers will
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will not be assigned at the switch on.

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Driller’s Console.
Check firing pulses to each of the 6 SCRs
b) Open the SCR circuit breaker.
with an oscilloscope.
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c) Set the spring-loaded Manual

Volts switch to “On” and turn the Example:
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Manual Volts knob a ½ turn. Place the ground lead on K terminal of the
d) 4. After completing the test Firing Pulse transformer and Probe on the G
close SCR breaker. Be sure terminal.
Manual Volts switch is off.
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ACTION RESULT
6. Feedback Check
Check ripple of the Voltage Feedback The feedback waveform provides an
signal across SCR Volts test pins on indication of firing on the SCRs.
front of DC Module.
Note that there are six peaks. Each SCR
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contributes a peak.
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Bridge Voltage Feedback
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50VDC from 101(+) to 102(-)
for 800V across SCR
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2ms per division
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Bad
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ACTION RESULT
7. Isolate Faulty SCR
a) This is accomplished by
comparing the Current Feedback
ripple and SCR firing pulses on a
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dual trace oscilloscope while the
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SCR Unit is driving a load.
b) During each 60Hz cycle, there
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are six peaks in the ripple. Each
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of the six SCRs in the bridge
contributes a peak.
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c) If one of the SCRs does not fire, Good
a peak will be missing. If the
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SCR misfires, one of the peaks
will be distorted.
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d) To identify the faulty SCR,
compare firing pulses (pins 140,
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142, 144, 146, 148 and 150) to
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each of the six SCRs with the
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current feedback ripple (pin 131).
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e) Firing pulse which is in sync with
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the missing or distorted peak is Bad - misfiring SCR - check gate pulses
the one going to the faulty SCR.
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Bad - SCR firing out of sync

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ACTION RESULT
8. SCR Resistance Test
a) Trip the SCR circuit breaker.
b) Switch Multimeter polarity to “+”
and the scale to “R x 10,000”.
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c) Test the meter by joining the “+” The meter needle will swing to indicate 0
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and “-” leads. ohms.
d) Disconnect the SCR Gate (G)
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and Cathode (K) leads. The SCR
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does not have to be removed
from the heatsink.
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e) Measure resistance across the It should be in the Meg ohms. The SCR is
SCR by touching one lead to the leaking if the resistance is less. You will see
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AC bus bar and the other lead to the charging action of snubber capacitor that
the DC bus bar. is across SCR. Let meter stabilise before
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f) Measure resistance across the Again, the resistance should be in the Meg
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SCR in the reverse direction, ohms.
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interchanging the leads.
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g) If the SCR is not installed in
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heatsink, lacks pressure, it will
not be possible to make
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resistance test.
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3. TROUBLESHOOTING
Troubleshooting consists of locating a malfunctioning component in the SCR Unit. The
troubleshooting index in the back of this section provides specific instructions. The Theory
of Operation section provides an explanation of the various circuits in the unit.
3.1 SCR LOGIC INDICATOR
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ZEEFAX SCR systems are fitted with
SCR logic indicators as standard. These
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provide a mimic diagram of the SCR
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control and assignment logic which helps
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rapidly identify the cause of any problem.
The top section contains LEDs which
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indicate the status of the blower, SCR
fuses and temperature switches.
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The lower section shows the logic
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sequence from the DC module CONT
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signal (pin 114), through the circuit
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breaker, returning to the DC module via
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the assignment contactors and auxiliary
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interlocks.
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Fig 3.1: SCR Logic Indicator
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The SCR logic indicator is the first point
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of call when troubleshooting and SCR.
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3.2
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THEORY OF OPERATION
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3.2.1 SCR Bridge

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A 3Ø AC supply from the bus is applied to the SCR bridge through a circuit breaker. Each
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AC phase is connected to two SCRs. One SCR feeds positive AC portion to the DC (+)
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bus and the other SCR feeds the negative AC portion to the DC (-) bus. For example, ØA
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is connected to A+ and A- SCRs. A + SCR feeds the DC (+) bus while the A- SCR feeds
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the DC (-) bus.

DC (+) and DC (-) buses are connected to loads via assignment contactors. The SCRs
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are switched on and off to vary the DC level through firing pulses applied across the
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GATE (G) and CATHODE (K) terminals of each SCR. The firing pulses are generated in
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the DC Control Module.

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Refer to unique devices section for a general description of an SCR.

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3.2.2 Circuit Breaker.

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The breaker is equipped with a set of auxiliary contacts. A normally open contact is
interlocked with the front panel SCR ON light. Another normally open contact is a part of
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the Assignment Contactor logic.

The breaker also has an undervoltage (UV) trip coil. The breaker is tripped automatically if
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the power supply to the coil is interrupted. Positive terminal of the coil is permanently
connected to a +14Vdc power supply. The negative terminals is connected to a -14Vdc
supply through various normally closed switches which signal the following hazardous
conditions.
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a) SCR Overtemperature. There are two temperature sensors. Sensor TS11 is mounted
on the DC (+) bus and TS21 is mounted on the DC (-) bus. The sensor contact is
designed to open when the SCR junction temperature exceeds 220°F (125°C).
b) Blown SCR Fuse. Fuse protection for the SCR consists of high speed indicating
silicon fuses. The UV Trip circuit is wired through trigger fuse microswitches of all the
SCRs.
A trigger fuse is connected across each Main fuse assembly. If a main fuse blows, the
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micro-switch trigger activates. The trigger fuse has a long plunger which is set close to
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the micro-switch arm. When the fuse blows, the plunger pushes into the arm, causing
the micro-switch contact to open.
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c) Emergency Off. The UV Trip circuit is also interlocked with normally closed
EMERGENCY OFF button on the Driller’s Console.
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3.2.3 Current Feedback

Three current transformers are used to sense current flowing into the SCR bridge. On the
PC1 Drillers Slide PCB, the CT signals are rectified and the resulting DC output divided
through a resistor circuit. One signal is used to drive the front panel DC ammeter. The
other signal is applied to the DC Control Module as SCR Amps (Pin 131). SCR Amps
signal is 2.66 V per 1000 amps out of the SCR bridge.
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3.2.4 RLC Filter
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A ferrite core is used for each SCR along with the RC circuit connected across the SCR,
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to form an LRC filter. The filter is designed to reduce rate of change of voltage (dV/dt)
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through the SCR. Excessive dV/dt or dI/dt can cause the SCR to misfire and burn out.
3.2.5 Firing Pulse
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A pulse transformer is used to invert and double the SCR firing pulse supplied by the DC
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control module. The current pulse rises in less than 20 n Sec. to approximately 1 amp to
“hard fire” the SCR. It then descends to a 0.5 amp “backporch” to force more and more of
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the SCR to turn on through a regenerative process.
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3.2.6 Voltage Feedback
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The DC (+) and DC (-) buses are connected through a resistor divider network on PC2
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(Voltage Feedback PCB) to develop a 1:15 analogue of the SCR bridge volts. Signals
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from the bus are dropped through a set of 3.9 kΩ resistors used to drive the front panel
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SCR Voltmeter. The other is a differential signal Vbr+ - Vbr- which is applied to the DC
Control Module (pins 101-102) for use in the DC regulator circuit. When the bridge voltage
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is 750 VDC, voltage across Vbr+ - Vbr- is 50 VDC.
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3.2.7 Regulator Power Supply

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Transformer T5 supplies 46 VAC, 3Ø to PC1 board where it is rectified on PC1 to +60V

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for the contactor power supply. When added to the -14VDC contactor supply output from
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the DC module 74VDC is available for energising the coils of the main DC contactors.
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The star winding of transformer T4 supplies six 12VAC phase voltages to the module
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(Vca, Vcb, Vab, Vba, Vbc and VAC - pins 103 through 108). These signals are used to
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synchronise firing pulses for the six SCRs and derive the +14VDC power supplies.
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3.2.8 Surge Suppression Circuit

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This is a circuit which filters transient spikes on the AC bus. Loss of the circuit does not
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disable the drive system but does increase the likelihood of increased electrical noise on
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the main AC bus.

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Old Style
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The line input is fused and then rectified through a diode bridge. DC output from the
bridge charges a capacitor bank to 1000 VDC. A 25Ω , 225W resistor limits the charging
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current to 35A. About 30ms after power is turned on, relay K1 energises to short out the
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resistor. It takes 30ms. for K1 contacts to close.

Excess charge caused by a spike is discharged through the resistor bank. When power is
turned off, the capacitors are also discharged through the resistor bank.
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CAUTION
THE CAPACITOR DISCHARGE TAKES 10 SECONDS. DO NOT TOUCH ANY
PART OF THE CIRCUIT DURING THIS PERIOD.
The front panel surge suppressor light is normally on. It will go out if any of the line fuses
are blown. The line fuses are linked via trigger fuses to a microswitch (FS1) whose
normally closed contacts are in series with the surge suppressor light circuit. When a line
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fuse blows, the corresponding trigger fuse blows, causing its plunger to trip the
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microswitch.
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New Style
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The new style surge suppression circuits utilises Metal Oxide Varistors ( MOVs) instead of
an RC circuit. MOVs are much faster acting, and clip voltage spikes above a rated level by
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absorbing their energy.
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3.2.9 DC Ground Fault Detection Circuit
The circuit consists of three lights connected on one side to a phase of the AC bus and
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grounded on the other. A series-connected meter indicates percentage of the fault.
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The lights glow dimly during normal operation. A DC ground fault completes the circuit
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through all the bus phases, so that all the three lights glow brightly. A positive or negative
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reading on the %DC ground fault meter indicates a ground on one of the DC buses.
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CAUTION
THE CIRCUIT IS ONLY AN INDICATOR. THE GROUND FAULT MUST BE
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QUICKLY LOCATED AND CORRECTED.
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3.2.10 Contactor Control Logic

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The bridge output is assigned to one of several DC motors by closing the appropriate
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contactors. The contactor logic is set through the Drillers Console assignment switch.
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Single pole contactors are used to assign motors which turn in only one direction. For
reversing motors, the outputs of the single pole contactors are applied to the armature of
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the motor via a double pole contactor. This contactor reverses the armature lead polarity
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to reverse the motor.

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The power contactor coils require a 74VDC power supply to energise. The positive
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terminal of all coils is hardwired to a +60VDC power supply. A -14VDC supply is applied
to the negative terminals of the coils via a series of contacts to ensure that all conditions
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are satisfactory to power the assigned motor. If any one of the contacts in this control logic
opens, the power contactors trip and the SCR bridge is phased down.
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Refer to schematics S402-001 and S402-002. Note that the RT can be assigned to SCR2
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in either the 11 o’clock or 1 o’clock assignment switch positions.

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SCR2 bridge is connected to the RT motor through single pole contactors K3 and K4 and
reversing contactor K5.
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Now observe K3, K4 and K5 coil connections in the schematic. Note that the positive
terminals of all the coils are connected to + 60VDC
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Next, trace the -14VDC control signal. The -14VDC power supply in the DC Module is first
passed through the manual volts switch internally, and that is normally closed. It is opened
for test purposes to phase up the SCR bridge without applying power to the traction
motors.
The signal emerges from the module as CONT PS at pin 134. It is routed through a
normally open auxiliary contact of the SCR2 circuit breaker. The contact closes when the
breaker is closed, thereby assuring that the SCR2 unit is turned on.
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Next, the control signal is sent to the Driller’s Console where it turns on the SCR2 ON
light.
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The signal is also connected to one side of the assignment switch. It emerges on the other
side at the 11 o’clock contact when the assignment switch is set to the 11 o’clock position
or the 1 o’clock position.
d L
Next, the signal passes through the REV-OFF-FWD control switch to select forward or
ve ec
PY
reverse operation. Coil of contactor K5 is energised accordingly. The RT assignment has
only one reversing contactor (K5) , so K5 has to be energised when RT is assigned to
er el
others SCRs as well.
O
tr
The control signal continues through auxiliary contacts from K5 ensure K5 has energised,
T C
and is passed through an auxiliary relay contact. This contact ensures that all the auxiliary
re n
motors associated with this assignment have started (e.g. blowers, lubrication pumps).
A R
ts Co
Note that there is a bypass contact from K4. This means that once the assignment has
M O
s
completed initially, failure of one of the auxiliary motors will not cause the drive to shut
down. However, the failure of one of these units will cause an alarm which must be
1
R CE
investigated immediately before damage to the motor or connected equipment occurs.
rig 01
CAUTION
FO U
DO NOT ALLOW AUXILIARY ALARM CONDITIONS TO PERSIST FOR

ll 2
h
MORE THAN A FEW MINUTES WITHOUT INVESTIGATION WITH THE

Y D
©
DRIVE RUNNING. THE DRIVE ONLY CONTINUE TO BE USED TO ENSURE

N O
SAFE SHUTDOWN.
ht
A PR
Further, the control signal is routed through all the normally closed auxiliary contacts of
power contactors in the SCR2 unit other than K3, K4 and K5. This assures that the bridge
A
ig
output is not connected to two motors at one time.

IN E
yr
Next, K3 and K4 coils are energised. To ensure that their contacts have closed as a
R
result, the control signal is passed through their normally open auxiliary contacts.
op
Finally, the signal is returned to the DC Modules as RT CONT (Pin 129). In the module,
the reference for the SCR firing circuits is disabled as long as all CONT signals (RT
O
C
CONT, MP1 CONT, etc.) are not -14VDC.

N
The schematic also highlights the RT reference and current limit control signals which
originate in the Driller’s Console.
O
3.2.11 DC Module
D
The DC Module contains electronic circuits for the SCR Unit. These can be grouped into
three assemblies.
a) DC Regulator
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b) SCR Firing Circuits

c) DW Dynamic Brake
Refer to the Dynamic Brake section for information on the brake circuit.
A functional block diagram of the DC module is shown on Fig 3.2:
d
i te
im
d L
ve ec
PY
er el
O
tr
T C
re n
A R
ts Co
M O
s
1
R CE
rig 01
FO U
ll 2
h
Y D
Fig 3.2: DC Module Block Diagram

©
N O
3.2.12 DC Regulator
ht
A PR
The regulator is a feedback control circuit which automatically matches the motor speed
and torque to the throttle command from the Control Console.
A
ig
The regulator output is a firing reference (TP7) to the SCR firing circuits. Inputs to the
IN E
yr
circuit consist primarily of the speed reference, speed feedback and current feedback. The
R
regulator consists of two control loops, an outer voltage (speed) and an inner current
op
(torque) loop. A speed reference from the control console is compared with the speed
T
feedback signal to derive a current command which, in turn, is compared with the current
O
feedback signal to derive the firing reference.

C
Speed Reference
This signal originates in the control consoles. The consoles are equipped with handwheels
O
which the operator rotates clockwise to control the traction motors. Each handwheel is
linked to a rheostat which outputs a 0 to -8.2VDC speed reference signal representing
D
zero to maximum throttle.

The regulator may receive the speed reference from more than one location. For example,
the MP1 reference may come from either the Driller’s Console or the Mud Pump Console.
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Speed Feedback
This is an analogue of the motor speed. It is 0 to +5VDC for maximum speed. The signal
is designated ‘N’ because the letter is a symbol for speed in conventional motor speed
equations.
In a shunt motor, the speed is directly proportional to the armature voltage. Therefore, the
differential voltage feedback signals (Vbr+ - Vbr-) are simply compared in op amp Z701 to
d
derive the single level ‘N’.
te
In a series motor, however, the speed is a function of the armature voltage divided by the
magnetic flux. The flux, in turn, is a function of the armature current. Therefore, ‘N’ for
i
im
series motors is derived by dividing the Voltage Feedback signal with the shaped Current
Feedback signal in Z703.
d L
Current Feedback
ve ec
PY
This is an analogue of the motor torque, since torque is directly proportional to the
armature current. It is derived from the rectified output from the three current transformers
measuring the 3-phase AC input to the SCR bridge.
er el
O
DC Foot Throttle Operation
tr
T C
A Foot Throttle is provided for the Drawworks for quick response from the SCR bridge
re n
during tripping. The DW Foot Throttle reference (pin 114) is applied directly to the current
A R
ts Co
regulator summing the junction, skipping the speed feedback junction. Therefore, it acts
M O
s
as a current command. When the Driller presses the foot throttle, current to the
Drawworks motors rises quickly and the voltage follows.
1
R CE
The DW speed reference from the Driller’s Console hand wheel (pin 117) and the DW foot
rig 01
throttle reference are auctioneered through D10 and D59 to select the higher (more
negative) throttle command. When the driller begins a tripping operation, he first sets the
FO U
ll 2
h
Drawworks to cathead speed by slightly cranking the hand throttle. This enables the foot
Y D
throttle via a microswitch on the hand throttle. When the driller presses the foot throttle to
©
lift a heavy load, the foot throttle reference quickly supersedes the DW speed reference.
N O
The foot throttle reference goes to zero when the driller removes his foot from the throttle.
ht
A PR
As a result, the DW speed reference takes over, and the motor speed and torque return to
cathead values.
A
ig
IN E
Slaving Circuits
yr
This circuit achieves load sharing between two motors which are parallel-connected to
drive a common shaft but are powered by separate SCR units. Such an arrangement is
op
normally utilised for Drawworks.

O
Load sharing is accomplished by applying the same current command to regulators of

C
both SCR units. A diode or FET auctioneering circuit is used to select the higher (more
N
negative) current command.

O
Several safety interlock and limiting circuits are tied into the regulator.
D
Contactor Interlock
In the OFF mode, the speed reference signal is disabled by a hardwired positive current
flow (+14VDC / 2.7kΩ). This positive flow is cancelled when the corresponding CONT
signal switches from +5VDC to -14VDC.
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Zero Throttle Interlock

This circuit protects the SCR bridge and the traction motor from sudden starts. It disables
the firing reference if the CONT signal switches to -14VDC while the corresponding speed
reference is also high (negative). Consequently, the operator has to set the throttle to zero
before switching the assignment.
Current Limit
d
This signal prevents the Speed Reference signal from demanding excess current. It is
te
simply a negative current flow produced by applying a -10VDC across a selected resistor.
To lower the Current Limit, the negative current flow is decreased by selecting a resistor
i
im
with higher value. If the current limit desired is 1000 amps, R sel is approximately 390 kΩ.
Speed Limit
d L
This signal prevents the speed reference from demanding excess speed. It is particularly
ve ec
PY
useful for series motors. In shunt motors, an adequate field current prevents
overspeeding.
er el
Power Limit
O
tr
This signal prevents the current command from demanding excessive power, and thereby
T C
overload the engines. It is excessive at about 85% to 90% to the engine-generator
re n
capacity on line. The power limit signal is derived by processing the current feedback, KW
A R
ts Co
feedback and KVAR feedback from generators on line. See the Generator section for
M O
s
further information.
Manual Operation
1
R CE
rig 01
During testing, it is often convenient to phase up the SCR bridge without applying power
to the motor. A manual operation circuit makes this feasible.
FO U
ll 2
h
When the manual volts switch (S1) is set to ON, the -14VDC CONT Power Supply to the
Y D
assignment contactor logic is disconnected and the manual volts rheostat is inserted into
©
the regulator circuit. Now the bridge can be phased up by rotating the manual volts knob
N O
clockwise. Power is not applied to the traction motors since the assignment contactors
ht
A PR
remain open.
A
ig
IN E
CAUTION
yr
NEVER SWITCH THE DC MODULE TEST SWITCH TO THE ON POSITION IF

op
THE SCR IS ASSIGNED AND RUNNING A DC TRACTION MOTOR.

T
3.2.13 SCR Firing Circuit

O
C
These circuits generate firing pulses for the SCR bridge.

N
There are six identical firing circuits, one for each SCR. A Firing Pulse waveform is shown
O
in Fig 3.3. The waveform actually consists of two pulses, a main pulse followed by a
backup pulse. The back up pulse is essential for re-firing the SCR at low DC output when
D
the current is discontinuous. The time difference between the main and backup pulses is
constant.
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d
i te
im
Fig 3.3: SCR Firing Pulses
The main pulse is synchronised with one of the 6-phase signals from the AC bus (Vab,
d L
Vbc, etc.) and Firing Reference from the DC Regulator. The backup pulse is synchronised
with a main pulse signal from one of the remaining firing circuits.
ve ec
PY
SCR Operation
er el
O
An SCR turns on when it is forward biased, and secondly, when its gate terminal is “fired”
with a current pulse. If the gate is fired as soon as the SCR is forward biased, the SCR
tr
T C
acts as an ordinary diode. The firing is delayed to vary the DC output. In the SCR firing
re n
circuit described above, the 6-phase reference indicates when the SCR is forward biased,
A R
ts Co
and the firing reference indicates when the SCR should be fired to achieve the desired DC
M O
output level. For a general description of an SCR.
s
Diode Bridge
1
R CE
See Fig 3.4. The diodes turn on and off automatically as the bias changes. This process is
rig 01
called commutation.
FO U
ll 2
The waveform shows the commutation process through a single cycle. The 360° cycle is
h
Y D
divided into 30° sections. Observe that between 30°-150° diode A+ is more positively
©
biased than either B+ or C+. Similarly, diode C- is more negatively biased than either A- or
N O
B- during 90° to 210°. Refer to the table for the commutation sequence.
ht
A PR
Note that each diode is on for 120°. At any one time, two diodes are on. One feeds the
positive AC portion to the DC (+) bus and the other feeds negative portion to the DC (-)
A
ig
bus.
IN E
yr
R
op
T
O
C
N
O
D
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d
i te
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d L
ve ec
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er el
O
tr
T C
re n
A R
ts Co
M O
s
1
R CE
rig 01
FO U
ll 2
h
DEGREES TURNS TURNS

Y D
ON OFF
©
30 A+ C+
N O
90 C- B-
ht
A PR
150 B+ A+
210 A- C-
A
ig
270 C+ B+
IN E
360 B- A-
yr
Fig 3.4: Diode Commutation

op
T
O
C
N
O
D
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SCR Bridge
In a SCR bridge, the commutation does not occur automatically. It must be forced through
firing pulses.
Observe that in Fig 3.4 diode A+ is positively biased between 30° and 150°. Similarly, the
SCRs are biased for forward flow for 120° during each cycle. Thus the SCR can be fired
anytime between 0° to 120°. This is defined as a firing angle (α) range.
d
When the firing angle α = 0°, the SCRs are fired as soon as they are forward biased and
te
the bridge output is maximum
i
im
d L
ve ec
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er el
O
tr
T C
re n
A R
ts Co
M O
s
1
R CE
rig 01
FO U
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h
Y D
©
N O
ht
A PR
A
ig
IN E
yr
R
op
Fig 3.5: SCR Firing Angles

T
In figure 3.5 the bridge output is also shown for firing angles α = 30°, 60° and 90°. The
O
C
firing angle is restricted between 120° to 10°. This corresponds to a speed reference of 0
N
to -8.2VDC, firing reference of 0.5 to -2.5VDC and bridge voltage of 0 to 750VDC at no

load.
O
D
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3.2.14 Sprocket Slip Circuit

This circuit provides overspeed protection for two series motors that are driven in parallel
from a single SCR bridge. Such an arrangement is normally used for Mud Pumps.
If either one of the motors exceeds a preset speed limit, due to a malfunction in the chain
drive, the circuit cuts off power to both motors by tripping the assignment contactors. It
also turns on the front panel sprocket slip light.
d
te
Overspeed protection for shunt motors is achieved through a field loss relay. A shunt
motor cannot overspeed unless its field is removed or significantly weakened. The field
i
loss relay, located in the field supply, monitors the field current. It opens to trip the
im
assignment contactors of the motor if the current is below 35% of the rated value.
Overspeed protection for series motors is normally provided through the overspeed circuit
d L
in the DC Module. The circuit compares the voltage feedback signal from the motor with
ve ec
PY
the current feedback signal. It phases back the current command if the V/I ratio exceeds a
preset level. Recall that in an overspeeding motor, voltage is high and the current is low.
er el
O
tr
T C
re n
A R
ts Co
M O
s
1
R CE
rig 01
FO U
ll 2
h
Y D
©
N O
ht
A PR
A
ig
IN E
yr
R
op
Fig 3.6: Parallel Motors

O
C
The overspeed circuit functions effectively for all configurations of series motors except
N
where two motors are driven in parallel from a single SCR bridge. Refer to figure 3.6.
Suppose MOTOR A breaks its chain drive. The unloaded motor will overspeed. It will draw
O
the full voltage, but little current. Most of the current will flow into MOTOR B. The
overspeed circuit will not detect the overspeed because the current feedback signal
D
indicates the total current drawn by the two motors.

The Sprocket Slip circuit measures the DC current drawn by each motor through Hall
Effect Devices (HEDs) and compares them to the armature voltage to detect overspeed.
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Refer to Fig 3.7 for the installation diagram of the HEDs. An HED, mounted on the DC
cable, measures current to the MPA motor. HED 2 measures current to the MPB motor.
d
i te
im
d L
ve ec
PY
er el
O
tr
T C
re n
A R
ts Co
M O
s
1
R CE
rig 01
FO U
ll 2
h
Fig 3.7: Sprocket Slip Connections

Y D
©
Refer to the schedule diagram of the Sprocket Slip card, figure 3.8. Differential voltage
N O
signals from HED1 and HED2 are compared on Op Amps Z1 and Z2 to obtain I1A and I1B
ht
respectively. The currents are auctioneered via D1 and D10 to select the current with the
A PR
lower value. (Since the motors have equal armature voltage, the motor with the lower
A
ig
current has the higher speed.)

IN E
The lower current signal is summed in op amp Z4 against the voltage feedback current
yr
from op amp Z3. Output Z4-6 is amplified via Q1 and applied to the coil of relay K1. K1 is
op
energised during normal operation and de-energised under fault conditions.

T
Normally open contacts from K1 are mounted in the assignment logic of both mud pump
O
C
motor assignments. The contacts open to trip the main assignment contactors, thereby
cutting off power to the motors.
N
A normally closed contact of K1 closes to turn on the front panel Sprocket Slip light. The
O
light can be switched off by pushing the integral reset button. The button re-energises the
coil of K1.
D
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d
i te
im
d L
ve ec
PY
er el
O
tr
T C
re n
A R
ts Co
M O
s
1
R CE
rig 01
FO U
ll 2
h
Y D
©
N O
Fig 3.8: Sprocket Slip Circuit

ht
A PR
A
ig
Sprocket Slip Test Procedure

IN E
yr
Perform the following tests to verify correct operation of the Sprocket Slip circuit.
R
a) Verify that the mud pumps are in a satisfactory condition to run.

op
b) Jumper pins 16-19 and 17-18 on the sprocket slip card. Electrically disconnect and run
motors slowly one at a time to verify proper rotation. Verify that the voltage feedback
O
C
to the sprocket slip PC board is present while motors are running, and that the voltage
N
at pin 6 of the sprocket slip PC board is positive with respect to pin 5. After the rotation
of each motor has been verified as correct, reconnect both motors. Remove jumpers
O
from pins 16-19 and 17-18 of the sprocket slip PC.

D
c) Have rig personnel bring up the mud pump throttle slowly. The SCR bridge voltage
must exceed 200VDC in order for sprocket slip to occur. If one of the HED outputs are
reversed, a sprocket slip condition will be occur, the mud pump will shut down and the
sprocket slip light will illuminate.
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d) Reset the mud pump by turning the hand throttle to zero and push the sprocket slip
reset to turn out light.
e) Run the pump again slowly. Monitor the voltages at the cathode of D1 and the
cathode of D10. Verify that the DC level at D1 and D10 is approx. +1V/100 amps in
the mud pump armature. If lower or negative polarity, it may indicate that HED wiring
is incorrect. Bring mud pump up slowly and observe voltage change at cathode of D1
and D10. If one is going negative, reverse the HED input to the sprocket slip card, or
d
reverse lead at HED if possible.
te
f) After proper voltage feedback polarity and HED polarity have been established, run
the mud pump up to greater than 250 VDC on motors. Remove one of the HED inputs
i
im
to the sprocket slip PC and verify that pump stops and sprocket slip is indicated.
Repeat for other HED. Perform test on all SCRs that can be assigned to the mud
pump.
d L
ve ec
PY
er el
O
tr
T C
re n
A R
ts Co
M O
s
1
R CE
rig 01
FO U
ll 2
h
Y D
©
N O
ht
A PR
A
ig
IN E
yr
R
op
T
O
C
N
O
D
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Table 3.1: SCR Unit Troubleshooting (1)
PROBLEM ACTION
1. SCR Circuit Breaker Trips
Emergency stop. All SCR breakers trip. Driller may have pressed the Emergency
d
Stop button on the Driller’s Console. To
te
resume operation, close the breakers.
SCR/ Fuse Failure a) If an SCR fails, some fuses are also
i
im
blown. Check fuse trip indicators or
trigger fuses.
b) Test which SCR fuses are blown.
d L
c) Replace all blown fuses and defective
SCRs.
ve ec
PY
er el
Overcurrent trip. Close the breaker to resume operation.
O
SCR Overtemperature
tr a) Overtemperature switches will reset
T C
after SCR junction temperature drops
re n
below 74°C. Close the breaker to
A R
ts Co
resume operation.
M O
s
b) Make sure SCR blowers are running. If
not, check fuses.
1
R CE
Field loss If the motors are shunt-type, ensure that
rig 01
field current is approximately 50 amps.

FO U
ll 2
h
2. SCR Bridge Inoperative

Y D
©
Zero throttle interlock Check Zero Throttle LED on DC module. To

N O
resume operation set throttle at control

console to zero.
ht
A PR
A
ig
Throttle signal not reaching the module. Check for Speed Reference signal from the
control console at the DC module.
IN E
yr
Contactor logic defective. Check for -14VDC motor CONT signal at the
module. If absent, trace the control signal.
op
See Contactor Control Logic section for

more information.
O
C
DC module defective. a) Check SCR firing pulses.

b) If pulses are absent, check module
O
power supplies. If these are present,

replace the module.
D
SCR misfiring Check current feedback ripple.
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PROBLEM ACTION
3. Motor Speed Does Not Regulate
No feedback signals to the module Check V br+ (pin 101) - Vbr- (pin 102) and
SCR Amps (pin 131) signals.
In case of mud pumps slaving, slave signal Check Slave inputs (pin 133 or 136)
d
may be absent.
te
Defective DC regulator Replace the module.
i
im
4. Insufficient Power- DW, MP Check ammeters of SCR units driving two
Mud Pump of Drawworks motors. One of
d L
them may read low, indicating that only one
motor is running.
ve ec
PY
er el
O
tr
T C
re n
A R
ts Co
M O
s
1
R CE
rig 01
FO U
ll 2
h
Y D
©
N O
ht
A PR
A
ig
IN E
yr
R
op
T
O
C
N
O
D
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PARAMETER PIN VOLTAGE TROUBLESHOOTING

1. Power Supply 103-108 12 VAC to Ground If absent, the + 14Vdc supplies will
AC Voltages be low. As a result, one or more
d
SCRs may not file. Check safety
te
fuses.
i
im
2. Power Supply 155 Ground All must be present for normal
DC Voltages 154 -14+1 VDC operation. Check safety fuses if
153 +14+1 VDC absent.
d L
ve ec
PY
3. Bridge Voltage 101 & 102 The Voltage across the If absent, hand throttles on the
Feedback pins is 50VDC when the Driller’s Console will be extremely
er el
O
Signal bridge voltage is 750 sensitive.
(Vbr+ & Vbr-) VDC. Polarity: 101 is
tr
T C
positive for series
re n
motors, negative for
A R
ts Co
shunt motors.
M O
4. Current 131 2.67VDC when bridge If absent, the motors will oscillate,
s
Feedback current is 1000 Amps. and may blow SCR Fuses.
Signal (I
1
R CE
feedback)
rig 01
5. Contactor 116 (DW) -14 VDC When SCR breaker is closed, and
FO U
ll 2
h
Signal DW assignment selected on Driller’s

Y D
Console.
©
N O
ht
A PR
6. Hand Throttle 117 (DW) 0 to -8.2VDC for zero Refer to the following pages for
Reference through maximum information regarding other
A
ig
throttle. functions.
IN E
yr
R
op
T
O
C
N
O
D
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PIN NAME FUNCTION SCR CB BREAKER NORMAL TROUBLESHOOTING
OPEN CLOSED, DC RUNNING
CONTACT-
ORS OPEN
101 Vbr+ SCR Bridge Voltage 0V 0V for SCR Bridge off. Measure voltage across
Feedback, positive lead 1/15 of Bridge output voltage. pins 101 and 102. If
d
Vbr- SCR Bridge Voltage Polarity: 101 is positive for absent, hand throttle on
102 Feedback, negative lead. series motors. 101 is negative Driller’s Console will be
te
for shunt motors. extremely sensitive.
103 Vca Power Supply AC Voltages 12 VAC If absent or low, check F1,
i
im
104 Vcb F2 and F3. TB4-10 should
105 Vab read 0 ohms to ground.
106 Vba
d L
107 Vbc
108 VAC
ve ec
PY
109 Spare
CP Ref 2 Hand throttle ref. from CP 0 to -8.2VDC for zero through maximum If absent, trace signal from
Console for Cement Pump throttle. CP Console hand throttle
er el
rheostat.
O
PROP DB Propulsion Dynamic Brake
phase back signal.
tr
T C
112 CP Cont Cement Pump contactor 24 VDC Coil: -14VDC Signal is present only on
re n
signal. +8 VDC when CP SCR units driving CP.
A R
ts Co
74 VDC Coil: contactor

+60VDC closes.
M O
s
113 CP Ref 1 Hand throttle ref from 0 to -8.2VDC If absent, trace signal from
Cement Pump Console for for - through the Cement Pump Console
1
R CE
Cement Pump maximum hand throttle rheostat for
throttle CP.
rig 01
112 CP Cont Cement Pump contactor 24 VDC Coil: -14VDC Signal is present only on
signal. +8 VDC when CP SCR units driving CP.
FO U
ll 2
h
74 VDC Coil: contactor

Y D
+60VDC closes.
©
113 CP Ref 1 Hand throttle ref from 0 to -8.2VDC If absent, trace signal
N O
Cement Pump Console for for - through from the Cement Pump
Cement Pump maximum Console hand throttle
ht
A PR
throttle rheostat for CP.

114 DW Ft Th Throttle reference from the 0V for off. 0V to -8.2V for zero through If absent, trace signal to
A
ig
Foot Throttle used to drive maximum throttle. the Foot Throttle rheostat.
IN E
Drawworks.
yr
115 DC Pwr System Power limit input. -8.2V for system generators at no load, Troubleshoot the Power
R
Lim close to 0V at full load. Limit card which is located

in GEN I cubicle.
op
116 DW Cont DW Contactor signal Same as pin 112 -14VDC Signal present only on
must be SCR units driving DW.
O
C
present to
drive DW.
N
117 DW Spd Reference from the 0V for off. 0 to -8.2VDC for zero through If absent, trace signal to
Ref Drawworks hand throttle on maximum throttle. the DW hand throttle
O
Driller’s Console. rheostat.

Note: Propulsion Console
D
assignment switch must

be set to Drilling.
118 P Ref Reference from the As Above If absent, trace signal to
ERC Propulsion hand throttle on Prop hand throttle on the
the Engine Room Console. Engine Room Console.
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CONTACT-
ORS OPEN
119 P Ref Ref from the Propulsion As Above if absent, trace signal to
WHC hand throttle on the Wheel Prop hand throttle on the
House Console. Wheel House Console.
120 P Cont Propulsion contactor signal Same as pin 112 -14VDC signal present only on
d
must be SCR units driving
present to thrusters.
te
drive
propulsion
i
thrusters.
im
121 MP2 Cont Mud Pump #2 contactor Same as pin 112 -14VDC Signal present only on
signal when MP2 SCR units driving MP2.
assignment
d L
contactors
in this SCR
ve ec
PY
unit close.
122 MP Ref Mud Pump # 2 hand throttle Same as Pin 117 if absent, trace signal to
er el
DC reference from the Driller’s the MP2 rheostat on the
O
Console tr Driller’s Console.
123 MP2 Ref Mud Pump #2 hand throttle Same as Pin 117 if absent, trace signal to
T C
MPC reference from the Mud the MP2 rheostat on the
re n
Pump Console. Mud Pump Console
A R
124 MPI Cont Mud Pump #1 contactor Same as Pin 112 -14VDC Signal present only on
ts Co
signal. when MP1 SCR units driving MP1.
M O
s
assignment
contactors
in this SCR
1
R CE unit close.
rig 01
125 MP1 Ref Mud Pump # 1 hand throttle Same as Pin 117 If absent, trace signal to
DC reference from the Driller’s the MP1 rheostat on the
FO U
Console. Driller’s Console.

ll 2
h
Note: Propulsion Console

Y D
assignment switch must

©
be set to Drilling.
N O
126 MP1 Ref Mud Pump #1 hand throttle Same as Pin 117 if absent, trace signal to
ht
A PR
MPC reference from the Mud the MP1 rheostat on the

Pump Console. Mud Pump Console
A
ig
127 DB Field Dynamic Brake Logic signal. Same as Pin 112 +14VDC for Present only on units
DB driving DW.
IN E
contactor
yr
open. -
R
14VDC
op
when it is
T
closed.
O
128 RT 1 Lim Rotary Table current limit 0 to -8.2VDC for 50A to maximum If absent, trace signal to 1
C
signal from the Driller’s current limit Limit rheostat.

N
Console.
129 RT Cont Rotary Table contactor +14VDC -14VDC Present only in units
signal Linked to DW Cont if when RT which drive RT
O
RT driven by a DW motor. contactors

in this SCR
D
unit close.
130 RT Ref Rotary Table hand throttle Same as Pin 117 If absent, trace signal to
reference from Driller’s RT rheostat.
Console.
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CONTACT-
ORS OPEN
131 1 fdbck Armature current feedback 0V + 2.67 V for 1000 Amps out if absent, motor will
from SCR bridge CTs. of the bridge. oscillate, bridge fuse may
blow.
132 RT Ref 2 Same as Pin 117 if absent, trace signal to
d
RT rheostats.
133 MP1 Slv MP1 slaving signal to 0V +5.0 V for 1,000 Amps when
te
assure load sharing driving a MP1 motor.
between two MP1 motors.
i
134 Cont PS Assignment contactor logic 0V if Manual Switch on DC Module front
im
control signal. panel is set to On. Otherwise, -14VDC.
135 DB CONT Dynamic Brake Logic signal.
d L
136 MP2 Slv MP2 slaving signal to Same as pin 133
assure load sharing
between two MP2 motors.
ve ec
PY
137 Do Not
Use
er el
138 DBø Dynamic Brake Logic signal.
O
139 A + Gate A + SCR Firing Pulse
tr 0V with Refer toFig 3.3 Monitor the pulse across
140 A + Cath Manual Gate (139) and Cath (140)
T C
SW off. pins.
re n
141 A - Gate A - SCR Firing Pulse As Above
A R
142 A - Cath
ts Co
143 B + Gate B + SCR Firing Pulse As Above
M O
s
144 B + Cath
145 B - Gate B - SCR Firing Pulse As Above
1
146 B - Cath
R CE
147 C + Gate C + SCR Firing Pulse As Above
rig 01
148 C + Cath
149 C - Gate C - SCR Firing Pulse As Above
FO U
ll 2
150 C - Cath
h
Y D
151 Spare
©
152 Spare
N O
153 +14 V A DC power supply + 14VDC If absent, check safety

154 -14 V - 14VDC fuses.
ht
A PR
155 GND Ground, Chassis 0V 0 V to chassis frame.

156 Do Not
A
ig
Use
IN E
yr
R
op
T
O
C
N
O
D
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4. DC MODULE OVERVIEW
4.1 BASIC FUNCTIONS
The basic function of the DC module is to control the DC motor, whether series wound or
separately excited shunt wound style motor. The ZEEFAX DC control module has the built
in ability to operate multiple, selectable assignments. To perform this properly the DC
d
module must have a means of selecting different current limits for different assignments.
The module must also provide for speed regulation of the motor and also motor
te
overspeed protection (speed catching). The ZEEFAX system will also use the DC
i
modules to carry out the power limiting function of the SCR power assemblies.
im
The hand throttle, foot throttle, or computer generated speed input to the DC module is a
speed reference. The particular input reference effective in controlling the module output
d L
is determined by a contactor (assignment) input. The contactor assignment -14 volts goes
through a resistor to +14 volts. With no -14 volt contactor input, the +14 volt through the
ve ec
PY
resistor turns on a diode to turn off a gate, therefore blocking the speed reference input.
When the proper assignment is made, and -14 volts is applied to the contactor input at the
er el
O
module, the diode is biased off, thus allowing the speed reference input to be compared to
the speed feedback (“N”). When running shunt motors the module will utilise a reduced
tr
T C
value of voltage feedback, as speed feedback (“N”). The formula :
re n
A R
SP = VA
ts Co
∅(FIELD)
M O
s
1
expresses the speed of a DC motor as armature volts divided by the flux of the field. Since
R CE
field current is held constant, ∅(flux) is constant and speed is basically armature voltage.
rig 01
“N” feedback must be positive so that the input to the differential amplifier must have the
FO U
correct polarity input to produce a positive “N”. If the voltage feedback is reversed, this
ll 2
h
would cause the shunt motor to go quickly to a very high speed, limited only by the load
Y D
©
and current feedback.

N O
When controlling series motors, the basic speed equation still applies, but the field current
ht
A PR
does not remain a constant and the value of ∅(flux) changes. Therefore, to determine the
speed of a series motor, armature voltage must be divided by a voltage representing field
A
ig
flux. Z702 creates the voltage for field flux from the current feedback. The polarity of the
IN E
voltage feedback is reversed (from that of shunt motors) so that the output of AD532 will
yr
be positive.
op
The voltage at test point TP8 is the current command. The more negative TP 8 goes the
T
more current will be delivered from the SCR bridge. A current limit is provided on each
O
module assignment inputs to prevent excess current (torque) from being obtained. The
C
current command signal (input to Z8) is compared is compared to the current feedback to
N
produce the firing reference for the firing circuits.

O
D
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4.2 DC MODULE POWER SUPPLY

The DC module obtains it’s power from the AC bus through safety fuses. The safety fuses
are mounted as close to the bus as we can safely mount them to eliminate long, unfused,
wiring runs to the bus. Power is supplied to the primary of the DC regulator transformer
through 6/10A fuses. 6 phases are produced in the secondary of the regulator transformer
that are 12VAC with reference to ground. The transformer also has 3 separate secondary
d
windings rated at 120VAC for use in the peripheral auxiliary systems such as the throttle
te
circuits and contactor logic supply.
The 6 phases are applied to diode bridges DB1, DB2, and DB3 to create the + & - 14 volt
i
im
power supply. Notice that the + & - 14 volt s is not zener regulated as the zeners (D723 &
D724) in the supply are 18 volts.
d L
4.3 MODULE INPUT CIRCUITS
ve ec
PY
The DC module has 6 different types of input functions available. They are all basically the
same with minor differences. To develop the operational concept, one input will be
examined then minor differences will be discussed.
er el
O
4.4 TYPICAL ASSIGNMENT
tr
T C
Pin 124 on the module (MP1 INPUT) will be positive 8-10 volts coming out of the module
re n
when the contactors are not assigned. R11 brings the positive voltage to pin 124, the MP1
A R
ts Co
contactor input, and also puts a strong positive at the junction of the D2 cathode and R53.
M O
s
When the module is assigned (-14 volts applied to pin 124) the reference input will cause
junction D2 and R53 to go negative, this is a request for current. The amount of current
1
R CE
that will be applied depends upon the load on the motor because R53 brings in the
rig 01
positive “N” feedback to sum with the negative going speed reference.
R47 and R56 (select) connect to the +10 volt supply. This pulls positive on the speed
FO U
ll 2
h
comparison junction putting a positive offset at the junction which forces the reference to
Y D
go -1 volt before a current command is obtained. This positive offset is called the dead
©
band, requiring that the operator rotate the throttle 15 to 20 degrees before the bridge
N O
begins to phase up. The smaller the value of this resistor the more voltage from the
ht
A PR
throttle is required to phase the SCR up. The current limit setting will affect the dead band.
The dead band allows the bridge to phase down and stop the motor even if the throttle
A
ig
voltage does not drop completely to zero.

IN E
yr
Reference ZEEFAX DC Regulator Schematic MP1 input. Assume that D48 is not in the
R
circuit. Voltage at R34 (D48 cathode) can be calculated by the following (assume ½ volt
op
drop for D48).

T
I R34 = 9.5 = 9.5

O
C
562K + 22K 584K

N
I R34 = 16.27 x 10-6

O
E R34 = 22 x 103 x 16.27 x 1010-6

D
E R34 = -0.37V
Cathode of D47 is -0.5V more negative than cathode of D48
D47 cathode -0.357 + (-0.5) = -0.857V
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The current limit resistors R802 and R57 at -10V hold the cathode of D47 at the maximum
negative voltage of about -1Volt. A -1Volt at the cathode of D47 would be -.5Volt at pin 3
of Z7. Z7 has a gain of 11 from the non-inverting input.
Gain Z7 = R33 + R32 or 10 + 100 = 11
R33 10
d
Therefore output of Z7 is approximately -0.5 x 11 = -5.5V. This is -5.0 at TP8 due to the
te
diode drop of D20.
To find the trim for R802, (resistor R57). TP8 equals -4.088V for 800 amps. Output of Z7
i
im
is:
-4.088 + (-0.5V) = -4.588V. Input to Z7 is -4.588V/11 = -0.417V (E R34).
d L
E R34 / R34 = I R34 -0.417 / 22K = 1.895 x 10-5 amps.
ve ec
PY
At the current limit D47 is reversed biased and this current is also the same value through
R57 and R802. The voltage across R57 and R802 = 10V - (4.08 + 0.5V)/11 +0.4V. The
er el
parallel combination of R57 and R802 is 485K ohms for a mud pump current limit of 800
O
amps.
tr
T C
NOTE : Pin 131 (current feedback) is 2.67 volts per 1000 amps
re n
A R
The output of Z7 is applied to pin 2 of Z8 via R25 (178K) + R39 (22.1K) or 200K ohm so
ts Co
that the current command is reduced by twice the feedback. This is the feature for two
M O
s
motor pump applications. In this case TP8 is 2 x (2.55/1000A) or 5.10V/1000A.
1
R CE
TP8 value is -5.1V/1000A
rig 01
Z7 pin 6 value is -(5.1V/1000A + 0.5V)

FO U
Z7 pin 3 value is -(5.1V/1000A + 0.5V)11

ll 2
h
Y D
D48 value is -(5.1V/1000A)11 + 0.4V

©
N O
Op amp Z7 has a small offset on the inverting input pin 2 established by R58, a 2.2meg
resistor to a -10V. The output of Z7 is the current command to the firing circuit network.
ht
A PR
This is a voltage of -5.10/1000A at TP8. Pin 6 of Z7 is a diode drop more negative than
A
ig
TP8.
IN E
The current command at TP8 is compared to the current feedback at the input to Z8,
yr
creating the firing reference at the output of Z8 pin 6. The negative current command of
5.1V/1000A is applied to pin 2 of Z8 through R25 and R39 (200K). Current feedback, a
op
positive 2.66V/1000A, is coming into Z8 pin 2 via R37, a 100K resistor. When Z8 has an
output of 0.5V, the limit or maximum, is established by D21. This corresponds to the
O
C
maximum bridge output.

N
Z8’s negative limit is set by voltage the voltage divider R76, R77 and diode D72. Setting
the junction of R76 and R77 at -.5V will allow R76 to drop 14.5V at Z8’s maximum
O
negative output.
D
I R76 = 14.5V = 0.9063ma.

16K
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I R77 = 0.9063
E R77 = 0.9063 x 10-3 x 4.7 x 103 = 4.25V
The maximum negative output of Z8 is approximately, E R77 = -4.25V + (-0.5V), present
at junction of R76 and R77, therefore the output of Z8 voltage, pin 6 TP9, is -4.75V.
Notice the module has an input for mud pumps for both the main console and remote
console. Also notice that the input resistor for the remote console is 47K while the input for
d
the main console is only 22K. This is to limit the speed from the remote console by ½ of
te
that from the main operators console. This is due to the fact that the remote console is
only for maintenance purposes.
i
im
The rotary table (top drive) has 2 inputs. The second input is available for third mud pump
operation or top drive.
d L
RT input pull down to negative 10 volts is used but two others, R35 and R23, go to pin
ve ec
PY
128. This input can also be pulled negative by voltage coming from the operators console
(variable 0 to -8.2V). Since both sets of resistors go to a negative power supply, they are
in parallel by varying amounts depending on the position of the current limit pot on the
er el
O
operators console. This current limit varies from 50 to 1200 amps and lets the operator
tr
adjust the torque of the motor.
T C
re n
The propulsion input pin 111, during regeneration of the bridge, allows us to set a current
A R
limit of 500A maximum, or what ever R66 is adjusted to. The braking control signal input
ts Co
goes through R66 to set the limit. Notice R19 to “N” feedback is omitted, it can be
M O
s
reconnected if this assignment is to be utilised for some other function besides propulsion.
Speed feedback is not required as the prop does not come out of the water.
1
R CE
rig 01
The foot throttle input is terminal 114. The foot throttle pot is typically a 200 ohm, 90
degree type, not a 300 degree as typically used. The throttle uses -8.2V source, so pin
FO U
114 normal input range is the same as the other speed reference inputs, 0 to -8.2V. Since
ll 2
h
foot throttle usage is actually more like that of a switch, full off or full on, the input circuit
Y D
©
resistor, diode and capacitor arrangement on op amp Z9 (C5, C6, R52) creates a ramp for
N O
increasing the load. R51(300K) with D55 allows for current to decrease faster, but still not
ht
an immediate shut down of the current.

A PR
This allows the drawworks load to function without a severe application of torque. It also
A
ig
allows smaller or older engines to pick up the load slower and helps to prevent
IN E
overshooting when the load is suddenly dropped.

yr
Before the output of Z8 is fed to the firing circuits, there is a signal that interrupts the
op
command for lack of assignment enable signal and, also, zero throttle confirmation after
T
the assignment is made. Diode D42, D43, D44, D45, D46 and D73 go to the contactor
O
C
inputs. If the contactors are not assigned, the 2.7K resistors to +14V will establish +8 to
+10 volts at the cathode of the diodes. This will turn off the diodes so that +10V on the
N
end of R43 will bring the base of Q1 to a positive level, thus Q1 turns on. This allows -10V
on emitter of Q1 to go to the collector where through D56 it can pull off the firing reference
O
and keep the bridge from phasing on. Q1 is used as a switch and can be called the firing
D
inhibit transistor.
Q1 is on when the module is not assigned, or has been assigned but a throttle reference
was detected before the assignment was confirmed(zero throttle interlock). If the throttle
input for the assignment is -0- and the assignment is made, the contactor input is pulled to
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-14V which will eliminate the effect of +10V through R43 that is keeping Q1 turned on.
Now Q1 can turn off, thus removing the -10V pull down voltage from the firing reference,
however, C13 (5uF) must be discharged to remove the -10V effect on the firing reference.
The output of Z8 may now control the firing reference (TP7).
On the output of Z8 there is another diode arrangement of D38, D39 and D58 (D58 is
omitted unless regenerative braking is utilised). When the bridge is first phased up in
manual mode, notice the voltmeter goes negative. This indicates the SCRs will accept
d
current that goes opposite to normal current output. SCRs will allow current flow from the
te
motor back into the main bus for regenerative braking. When regenerative braking is
used, we cannot stop firing the SCR bridge. This motor current is inductive current, so it
i
im
cannot be stopped abruptly. The voltage swings way up due to Ldi/dt, if the current flow
were to stop. D58, D38 and D39 and resistors keep TP7 voltage from going below the
firing ramp regardless of what Z8 output does. The reference is held about -1.8V during
d L
regen. D58 should be removed if regeneration is NOT used. If it is in and resistor R82 is
ve ec
PY
not selected, it will keep the firing reference from coming up properly. One easy way to tell
if the SCR bay is regenerative is that the volt meter will be center scaled with both + and -
scales.
er el
O
4.5 FIRING CIRCUITS
tr
T C
Firing circuits start with a capacitor to ground and a resistor to -10V. The + and -14V
re n
supply in the module is not zener regulated. 18 volt zeners are used which act as
A R
ts Co
crowbars to keep spikes from damaging the op amps. Op amps will take 18 volts.
M O
s
Refer to B+ firing circuit, for the following.
1
R CE
Voltage on C302 is setting at +0.5V. Input AC, sync, is filtered slightly by C301 and R301
rig 01
to get the noise out of it. AC is then applied to diode D301. When AC is positive D301 is
biased off and the charge on C302 has not changed. When AC goes negative it will now
FO U
pull down on 22K resistor R303, removing the effect of +10V through D303, since it is now
ll 2
h
biased off. C302 will now charge towards -10V to create a ramp. Due to the RC time C302
Y D
©
will only charge to about -2.3V during the negative half cycle of sync.
N O
Time = RC
ht
A PR
0.47 x 10-6
A
ig
42.2 x 103
IN E
yr
19.83 x 10-6 second (1 RC)

R
So in 19.83ms the charge on C302 may reach 63% but the time of one ½ cycle is
op
16.6666/2 or 8.33ms. We have less than ½ of 1 RC time constant for charging C302 (42%
of 1 RC). Not using log ratio to determine the exact charge on C302, we have
O
C
8.33ms/19.83ms = 0.42 of 1 RC. 1 RC = 63% of 10V which is 6.3V. Assuming we would

N
charge to 42% of 6.3V, C302 would reach 6.3 x 0.42 = approximately 2.65V.
The firing angle is determined by the firing reference moving up and down the firing ramp.
O
Whenever ramp pin 3 is above pin 2, Z3’s output will be positive. As firing ramp crosses
D
the reference, pin 3 can swing the output of Z3 in the negative direction. When ever the
ramp is less negative than the reference, Z3’s output will be positive.
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Z3 will generate a variable width square wave, but instead of applying this pulse directly to
the firing transistor, it goes through a resistor diode arrangement and capacitor C303 that
is tied through R308 to +13V.
The output of C303 is clamped above 0V by 2 diodes, D312 and D313. The output of Z3
is a nice square wave but C303 will cause a pulse to be developed. D307 will bypass
R312 (4.7K) to pulse harder during negative output of Z3 then when Z3’s output goes
positive, the capacitor almost sees a short circuit when diode D307 is on, but sees 4.7K
d
ohms when D307 is off. Why is this done? The output is clamped at +1V. When Z3’s
te
output swings back positive, the charge on C303 is dumped into diodes D312 and D313 to
0V. So the op amp would be facing a short circuit (when it goes positive) not during
i
im
negative. Early op amps would be damaged by this but new op amps can take it. This is
still left in for the extra protection since the circuit can swing from +13V to -13V, over a
25V swing.
d L
Since we are only concerned with the negative transition of Z3, the circuit provides a
ve ec
PY
negative transition that moves up and down.
As the firing reference gets down near the bottom of the ramp, firing pulses would become
er el
O
very narrow. This can be damaging to large SCR devices. They need at least a 50
tr
microsecond pulse in order to turn on the entire device. If the SCR is not turned
T C
completely on all current must pass through a small area, damaging the SCR. In order to
re n
ensure a negative output that is always long enough, D302 goes back to the input to
A R
ts Co
ensure the output of Z3 is held negative for at least 300 microseconds. This causes a
M O
s
glitch on the initial ramp and negative comes back to pin 3 (positive feedback) preventing
sliver pulses.
1
R CE
The negative signal from the output of Z3 goes to the base of PNP transistor Q301. The
rig 01
negative input will turn on Q301. This will drop -14V towards 0V, which is in the positive
direction, causing Q302 to conduct into the pulse transformer.
FO U
ll 2
h
A back up pulse is used so that the SCRs can commutate. Remember when we deliver
Y D
©
current to an inductive load we do not want to break the current flow at any time during the
N O
conduction cycle.
ht
A PR
The SCR on the + side sends a back up pulse to the SCR on the - side. The SCR on the -
side sends a back up pulse on the + side. The firing cycle is A+ to B-, B+ to C-, C+ to A-,
A
ig
C- to A+, B- to C+ and A- to B+.

IN E
yr
The main firing pulse into Q301 is followed up 60° later by a back up pulse. Either the
R
main or the back up can pulse Q301. The main pulse will be around 300 microseconds
op
with the back up pulse around 200 microseconds in duration. The back up pulse comes in
T
through diode D306, this shortens the time it turns on Q301 due to the diode drop. The
O
C
time differential is not a problem since the SCRs only need 50 microseconds to turn on for
full surface area conduction. D310 across the pulse transformer is a suppression diode,
N
needed since the transformer can put out a large inductive pulse when Q302 turns off.
The suppression diode protects the transistor from damage.
O
The pulse transformer is mounted as close as possible to the SCR device. Wiring from the
D
DC module to the pulse transformer is via twisted shielded pair wire. The shield must be
grounded at the source end (module). The step down pulse transformer matches the
impedance of the SCR to the module. It needs gate current to fire the SCR. A 33 ohm
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resistor is used to keep the transformer from ringing and the resistance should not go
below 27 ohms.
4.6 POWER LIMIT
The power limit signal comes into pin 115 of the DC module. This signal originates from
the power limit circuit external to the DC module which is connected to the individual AC
modules and calculates the load in KW and KVA from the engine / generator sets that are
d
on line.
te
At TP8 in the DC module we have a negative current command. The SCR bay in use
delivering the most current will be cut back as the power limit signal goes positive. This
i
im
pulls TP8 less and less negative in proportion to the incoming power limit signal being
applied to pin 115 of the DC module, thus limiting the maximum phase angle of the
negative current command signal to the firing circuits.
d L
4.7 MOTOR SPEED REGULATION
ve ec
PY
Higher than normal RPM (ie: cement pump) is accomplished by bringing in a negative 14V
from the contactor line to offset “N” feedback. Normal RPM high limit is 1300. This
er el
O
adaptation allows for RPMs as high as 2200.
tr
T C
Diode D13 is installed when the module is controlling a series motor for drilling and a
re n
shunt motor for propulsion. The module will calculate overspeed and attempt to shut down
A R
the shunt motor as the module thinks it is a series motor. D13 brings in a negative to
ts Co
offset “N” when propulsion contactors are pulled in. A shunt motor will not overspeed with
M O
s
a field so we do not need “N” for motor speed catching.
1
4.8
R CE
MANUAL BRIDGE PHASE UP TESTING
rig 01
Signal firing reference comes from Z9. You may want to fire the SCR bridge manually to
verify if the bridge operates properly. When you lift the manual phase switch, it interrupts
FO U
ll 2
h
the -14V source for the contactor line at pin 134. This is a safety feature in the manual
Y D
phase up mode so that you cannot directly operate the motor from the manual phase up
©
pot.
N O
ht
TP7 firing ramp range is from -2.5V to +0.5V. Voltage divider network will give the manual
A PR
pot -5V to 0V giving the bridge phase up from 0 to approximately 900V. Why is this more
A
ig
than 750V? Since the bridge has no load, capacitors in the snubber circuit network build
IN E
the voltage to near peak of the AC input.

yr
4.9 SPEED CALCULATOR CIRCUIT

op
AD532 is a multiplier chip that can be used as a divider. Z702 can be a plain inverting
T
amplifier but current feedback is brought in from the board with a gain of 10 (240/24). As
O
the output reaches a point determined by R721 and R722 the diodes D703, D704 and
C
D705 turn on as their cathodes reach -0.5V. This parallels the 240K feedback resistor
N
reducing the gain of Z702.

O
The motor torque curve is approximated in the circuit in a three point curve. When Z703
turns on it hits the first break in the curve. When Z704 turns on it hits the second break in
D
the curve. The second break circuit approximates the flux curve of the motor from IA
feedback. The gain of Z702 is 10 until the first break point is reached. The output of Z702
is about -5V at the first break.
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If the bridge phases down there is no If, but there is some residual, but no Ia. So Ø = 0
and Vbridge / 0 = ∞ but the output of the divider is not stable. There will be some Vbridge
because the motor is spinning and residual flux causes voltage in the armature.
So the offset provided by R716 gives about 50A to allow AD532 to create an answer (“N”)
from the residual flux (∅). NOTE : The offset adjusted by R716 should be -1.7V + or -
0.3V. This offset may be increased, but should not go above -2.3V.
d
For series motors we put in two positive signals into the divider chip and we get -X / 10Y
te
out. The chip takes the answer, divides it by 10 and inverts it. Since we need A + N we put
in negative flux because the chip is an inverting multiplier it will always give you -XY / 10,
i
(always invert and divide by 10).
im
The answer is divided by 10 to keep the output within the power supply range.
d L
When shunt motors are used “N” must be + so pin 101 of the module is tied to - side of
the bridge so that “N” will come out +. Changing the value of R713 to a larger value
ve ec
PY
should have no effect on AD532 but it will increase the time it takes for (∅) flux to build up
due to the increased RC.
er el
O
The output of the speed calculation circuit is input to the gate suppression network to
tr
T C
provide a safety protection against the possibility of motor overspeed, particularly with
regard to series motor operation. The output is also utilised with the initiation and control
re n
A R
of the motor braking circuit, when used.
ts Co
M O
s
1
R CE
rig 01
FO U
ll 2
h
Y D
©
N O
ht
A PR
A
ig
IN E
yr
R
op
T
O
C
N
O
D
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Project 116/07
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Page 39 of 49
5. DC SLIDE
The DC Slide PCB (PC1) collects together a number of circuits which historically were
mounted on a slide-out panel on the SCR (hence the name). It is mounted inside the
cubicle door, just above the DC Module. The principle circuits are described in the
following sections.
d
i te
im
d L
ve ec
PY
er el
O
tr
T C
re n
A R
ts Co
M O
s
1
R CE
rig 01
FO U
ll 2
h
Y D
©
N O
ht
A PR
Fig 5.1: DC Slide PCB

A
ig
5.2 SCR CURRENT FEEDBACK

IN E
The output from the 3 current transformers (T1-T3) are connected to pins 1-3 of the DC
yr
Slide PCB. A 3-phase diode bridge rectifies these signals. The output of the diode bridge
is connected to two 1 ohm burden resistors to provide a DC voltage which is proportional
op
to the SCR current. This signal provides the SCR current feedback to the DC module, and
drives the current meter on the SCR cubicle door, and any other current metering
O
C
associated with the SCR (e.g. Rotary Table current on the drillers console when
N
assigned).
5.3 METERING CALIBRATION
O
The SCR current feedback signal is passed through independent calibration resistors to
D
provide meter drive outputs on pins 6, 7 and 8 of the PCB. One of the meter drives is
allocated to driving the meter on the SCR cubicle door. The others are usually used for
remote indications, e.g. the Rotary Table current meter on the drillers console (when
assigned).
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Project 116/07
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Page 40 of 49
5.4 +60VDC CONTACTOR SUPPLY

The three secondary voltages from the contactor supply transformer are connected to pins
16,17 and 18 of the PCB. These are then rectified by a 3-phase diode bridge to produce
60VDC which, when referenced to the -14VDC CONT supply from the DC module,
provides a total of 74VDC to drive the main DC contactors.
d
i te
im
d L
ve ec
PY
er el
O
tr
T C
re n
A R
ts Co
M O
s
1
R CE
rig 01
FO U
ll 2
h
Y D
©
N O
ht
A PR
A
ig
IN E
yr
R
op
T
O
C
N
O
D
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Project 116/07
Revision 1
Page 41 of 49
6. REPLACEMENT AND REPAIR

Please read ahead to section 6.1.2 (SCR Clamp Tightening Procedure) before attempting
to replace an SCR. The tightening procedure is a vital part of the process and must be
followed exactly.
6.1 SCR REPLACEMENT
d
1 Trip the SCR circuit breaker and remove the DC
te
Module safety fuses
CAUTION
i
im
LIVE VOLTAGES MAY BE PRESENT ON
SOME TERMINALS EVEN WITH THE
CIRCUIT BREAKER OPEN AND THE
d L
DC MODULE SAFETY FUSES
REMOVED. SOME CIRCUITS, E.G.
ve ec
PY
SPROCKET SLIP MUST REMAIN
ENERGISED FOR CONTINUED RIG
er el
O
OPERATION. EXERCISE EXTREME
CAUTION.
tr
T C
2 Remove the insulated panels covering the SCR
re n
stacks and identify the SCR to be replaced.
A R
ts Co
Positive SCRs are on the left, negative on the right.
M O
The topmost SCR is A, and the lowest is C.
s
Therefore the top-left SCR is A+.
1
R CE
rig 01
FO U
ll 2
h
Y D
©
N O
3 Remove the black insulating caps covering the

ht
A PR
SCR clamp bolts.

Tip: pinch the bolt cover between forefinger and
A
ig
thumb to help remove it.

IN E
yr
R
op
T
O
C
N
O
D
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Project 116/07
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Page 42 of 49
5 Disconnect the bolt fixing the heatsink stab to the

SCR fuse.
It may be necessary to unbolt the fuse completely
to facilitate easy removal of the SCR heatsink.
d
i te
im
4 Disconnect the snubber resistor wires so that front
heatsink is free for removal.
d L
ve ec
PY
er el
O
tr
T C
re n
A R
ts Co
5 Remove the heatsink clamp bolts
M O
s
1
R CE
rig 01
FO U
ll 2
h
Y D
©
N O
ht
A PR
6 Slide off the SCR heatsink to reveal the SCR puck

A
ig
suspended in it’s Nomex positioning card. Make a

IN E
yr
note of the orientation of the SCR by observing the

R
position of the cathode. The cathode is the face

op
with a larger flange, and this also has one of the

T
small, coloured, firing circuit control wires

O
connected to it.
C
N
O
D
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Project 116/07
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Page 43 of 49
7 Make a note of the positions of the coloured, firing

circuit control wires from the SCR to terminal block
on the side component panel, paying particular
attention to the cathode wire. The colour coding of
the new SCR device may be different, so make
sure you can identify the cathode connection
irrespective of wire colour.
d
Disconnect the wires, taking care not to lose or
te
misplace the 33R resistor connected across the
terminals.
i
Carefully feed the wires through the panel and
im
remove the SCR from the heatsink.
8 Place the new device in the locating card and fit to
d L
the heatsink assembly, taking care that the
cathode of the device is correctly orientated. In this
ve ec
PY
photograph the cathode is facing the rear heatsink.
On the opposite stack it will be facing the forward
er el
O
tr heatsink.
T C
re n
A R
ts Co
M O
s
9 Feed the gate and cathode wires through the

1
R CE
component panel and re-connect to the terminal
rig 01
block ensuring that the gate and cathode wires are

FO U
connected in the correct positions.

ll 2
h
Make sure the 33R resistor is re-fitted and is

Y D
securely connected.
©
N O
ht
A PR
A
ig
IN E
yr
10 Slide the front heatsink back on to the assembly

op
and fit the clamping bolts. Tighten the bolts until

T
they are FINGER-TIGHT ONLY, then refer to the

O
instructions below for final tightening.

C
CAUTION
IT IS ESSENTIAL THAT THE CLAMP
O
BOLTS ARE TIGHTENED TO THE

CORRECT LEVEL. THE SCR DEVICE
D
MUST BE UNDER THE CORRECT

PRESSURE TO OPERATE, BUT
EXCESSIVE PRESSURE MAY DAMAGE
IT OR DISTORT THE HEATSINKS.
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Project 116/07
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Page 44 of 49
12 Re-fit the SCR fuse ensuring the connections are

firm.
d
i te
im
13 Reconnect the snubber resistor
d L
ve ec
PY
er el
O
tr
T C
re n
A R
ts Co
14 Re-fit the black insulated bolt covers.
M O
s
1
R CE
rig 01
FO U
ll 2
h
Y D
©
N O
ht
A PR
A
ig
15 Re-fit the insulated covers to the SCR stack

assemblies and test the SCR bridge.
IN E
yr
R
op
T
O
C
N
O
D
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Project 116/07
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Page 45 of 49
6.1.1 SCR Clamp Tightening Procedure

By virtue of their design, this range of clamps can only be used in multiple sets,
and each assembled for the same load for any clamping arrangement that they
may be used. It is also imperative that the disc spring washers are lubricated with
a suitable load bearing grease prior to assembly and that they are so arranged as
specified for any given load requirement. The loading of any limb assembly must
d
be followed as shown below in table 6.1.
te
With the C-Clamp correctly assembled, fit to limb with a suitably long screw or bolt
i
with a thread as specified in the table. Tighten with fingers only - NO LEVERAGE
im
TOOLS - until the screws/bolts of all the C-Clamps are as tight as is feasible. If
the bolt head cannot be reached, the use of a socket may be used. Ensure that
d L
the heatsink to semiconductor surfaces are fully seated and parallel.
ve ec
PY
Using a suitable wrench, tighten the clamp assemblies progressively in sequence
with one quarter of a turn each until the maximum turns shown in the table is
er el
O
attained. It is important that the clamps are loaded in small stages together so as
tr
to be able to load the semiconductor evenly. Semiconductor to heatsink contact
T C
will be severely impaired if this operation is not performed with enough due care
re n
and attention.
A R
ts Co
M O
s
1
R CE
rig 01
FO U
ll 2
h
Y D
©
N O
ht
A PR
A
ig
IN E
yr
R
op
T
O
C
N
O
D
Fig 6.1: Heatsink Clamp Assembly
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Project 116/07
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Page 46 of 49
Part Number Load per Number Thread Size

C-Clamp of Turns
C-CLAMP/B/2 2 kN 1 M6
C-CLAMP/B/3 3 kN ¾ M6
C-CLAMP/B/4 4 kN ½ M6
d
C-CLAMP/B/5 5 kN ½ M6
te
C-CLAMP/A/3.25 3.25 kN 2 M8
C-CLAMP/A/6.5 6.5 kN 1¼ M8
i
C-CLAMP/A/10 10 kN 1 M8
im
C-CLAMP/A/13.5 13.5 kN 5/8 M8
C-CLAMP/A/17.5 17.5 kN 5/8 M8
d L
C-CLAMP/A/20 20Kn ¾ M8
ve ec
PY
C-CLAMP/A/25 25 kN 1/3 M8
Table 6.1: SCR Clamp Loading
er el
O
The clamp used on this system is C-CLAMP/A/13.5
tr
T C
re n
A R
ts Co
M O
s
1
R CE
rig 01
FO U
ll 2
h
Y D
©
N O
ht
A PR
A
ig
IN E
yr
R
op
T
O
C
N
O
D
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Project 116/07
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Page 47 of 49
6.2 BLOWER REPLACEMENT

1 Trip the SCR circuit breaker and remove the DC Module
safety fuses
CAUTION
LIVE VOLTAGES MAY BE PRESENT ON SOME
d
TERMINALS EVEN WITH THE CIRCUIT
te
BREAKER OPEN AND THE DC MODULE
SAFETY FUSES REMOVED. SOME CIRCUITS,
i
E.G. SPROCKET SLIP MUST REMAIN
im
ENERGISED FOR CONTINUED RIG OPERATION.
EXERCISE EXTREME CAUTION.
d L
2 The blower assembly is located immediately below the SCR
ve ec
PY
stacks. Disconnect the wires connecting the blower to the
terminal block.
er el
O
tr
T C
re n
A R
ts Co
M O
s
1
R CE
3 Slide out the blower assembly. Either replace the blower on
rig 01
the mounting frame, or slide in a complete spare assembly.

FO U
Make a note of the blower full load current (FLC).

ll 2
h
Y D
©
N O
ht
A PR
A
ig
IN E
yr
4 Reconnect the blower connecting wires. Test the blower for

op
correct direction of rotation by either (a) checking that the

T
blower motor current is at least 75% of FLC with and AC

O
clamp meter, or (b) checking the amount of airflow through

C
the SCR stacks.

N
CAUTION
O
WHEN CHECKING THE AIR FLOW THROUGH

D
THE SCR STACKS TAKE GREAT CARE NOT TO

TOUCH OR DROP OBJECTS INTO THE STACK
ASSEMBLY.
Document SCR Unit

Project 116/07
Revision 1
Page 48 of 49

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C

3.2.2 Circuit Breaker. ..................................................................................................11

3.2.5 Firing Pulse ........................................................................................................13

3.2.6 Voltage Feedback ..............................................................................................13

3.2.7 Regulator Power Supply ....................................................................................13

3.2.8 Surge Suppression Circuit .................................................................................13

3.2.9 DC Ground Fault Detection Circuit ....................................................................14

3.2.10 Contactor Control Logic .....................................................................................14

3.2.11 DC Module .........................................................................................................15

3.2.12 DC Regulator .....................................................................................................16

3.2.13 SCR Firing Circuit ..............................................................................................18

4.1 BASIC FUNCTIONS ......................................................................................................32

4.3 MODULE INPUT CIRCUITS..........................................................................................33

4.4 TYPICAL ASSIGNMENT ...............................................................................................33

Document SCR Unit

4.7 MOTOR SPEED REGULATION....................................................................................38

Document SCR Unit

control module to verify current limit settings.

slide pan located below the blowers.

its own heat sink.

Size: 100mm W x 300mm D x 300mm H

Document SCR Unit

1.1.3 Forced-Ventilation System

1.1.5 Circuit Breaker

1.1.6 Overtemperature Rating.

furthest heat sink point from the airflow source.

Document SCR Unit

Fig 2.1: DC Module Front Panel

contactors so that power is not applied to the DC traction motors.

Document SCR Unit

Document SCR Unit

b) Jumper the auxiliary contact of contactors without applying power to the

positions. Control Console.

are checked out. 1 o’clock position. Then RT CONT (pin 129)

and RT REF 1 (pin 130) can be checked.

4. Module Power Supply Check

Energise the AC bus. Confirm following voltages at DC Module.

12 VAC Pins 103-108

+14 VDC Pin 153

-14 VDC Pin 154

5. Firing Pulse Check

will not be assigned at the switch on.

c) Set the spring-loaded Manual

Document SCR Unit

Document SCR Unit

current feedback ripple (pin 131).

Bad - SCR firing out of sync

Document SCR Unit

interchanging the leads.

Document SCR Unit

Fig 3.1: SCR Logic Indicator

3.2.1 SCR Bridge

the DC (-) bus.

the DC Control Module.

Refer to unique devices section for a general description of an SCR.

3.2.2 Circuit Breaker.

the Assignment Contactor logic.

Document SCR Unit

Document SCR Unit

3.2.3 Current Feedback

3.2.7 Regulator Power Supply

Transformer T5 supplies 46 VAC, 3Ø to PC1 board where it is rectified on PC1 to +60V

3.2.8 Surge Suppression Circuit