Eci MD-500

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Copyright 2011 Tesco Corporation

MD-500 DRIVE SYSTEM

MD-500

MD-500
 Supplies power for the Top Drive

motor(s).
 AC-AC converter. Controlling both

voltage and frequency.
 Operated using a System

Controller (CCB) for running Top
Drive motor(s) in a synchronous
mode.

MD-500 BLOCK DIAGRAM

MD-500 COOLING
 Liquid cooled.
 Each MD-500 requires 15gpm of cooling

flow.
 Cooling is interlocked with the drive

system through flow switches.
 “No Flow, No Go”

MD-500 COOLING

MD-500 COOLING

MD-500 COMPONENTS
Input Module
Buck Module
Choke (not shown)
Inverter Module

MD-500 POWER MODULE
0-780 VDC

COMMON NEGATIVE BUS
0-780 VDC

MD-500 COMPONENTS
Input Module

INPUT MODULE
 Three phase full wave bridge
rectifier.
 600 VAC input voltage is rectified

to 830 VDC.
 This voltage is automatically

present once it goes through the
bridge.
 This 830 VDC is called the “Raw

Bus” voltage.
INPUT MODULE
0-780 VDC

INPUT MODULE TOPOLOGY

POSITIVE OF RAW BUS
0-780 VDC

CAPACITOR BANK
 Located behind the Buck

module.
 Paralleled across the “Raw

Bus”.
 Reduces the ripple on the 830

VDC from the rectification
bridge.

0-780 VDC
Capacitor Bank
BUCK MODULE
Buck Module

BUCK MODULE
 Takes “Raw Bus” voltage and

varies it from 0-780VDC.
 This voltage makes up the “V

Bus” to feed the Inverter
module.
 Varying the voltage is possible

by the use of “IGBT’s” with an
associated blocking diode.

BUCK MODULE
0-780 VDC

BUCK MODULE TOPOLOGY

CHOKE MODULE
 Located behind the Input
Module.
 Large induction coils used to

oppose the change in current.
 Has individual input from the

Buck Module and star
connected output.
 Used in conjunction with a

capacitor bank to make an LC
filter for the V-Bus.
CHOKE MODULE

CHOKE MODULE TOPOLOGY
0-780 VDC

POSITIVE OF V-BUS
0-780 VDC

LC FILTER
 Located behind the Inverter
module.
 Paralleled across the “V-Bus”.
 Used in combination with Chokes

to create an LC filter.
 Capacitors = C : oppose a
change in Voltage
 Chokes = L : oppose a change in

Current
Choke Module
0-780 VDC
LC Filter
Capacitor Bank
INVERTER MODULE
Inverter Module

INVERTER MODULE
 Voltage supplied from the “V

Bus” is used to supply a
Trapezoidal (six step) waveform
to the PA-44 motor on the Top
Drive.
 Process possible by the use of

IGBT’s (insulated gate bi-polar
transistors).

IGBT INVERTER

INVERTER MODULE

INVERTER MODULE TOPOLOGY

COMPONENTS OF THE
MD-500

INPUT MODULE COMPONENTS
INPUT MODULE

POWER DIODES

POWER DIODES
 Three Phase Full Wave

Rectification Bridge.
 Total of three diode packs.
 Each pack consists of two back

to back diodes for a total of six
diodes.

POWER DIODES

POWER DIODES

POWER DIODES
2 3

DIODE

AC SINE WAVE
Positive VAC
0VAC
Negative VAC

SINGLE PHASE FULL
WAVE RECTIFICATION
24 VAC IN = VDC OUT

THREE PHASE FULL
WAVE RECTIFICATION
600 VAC IN = 810 VDC OUT

POWER DIODES
+VAC

POWER DIODES
-VAC

POWER DIODES
Positive of the Negative of the

Raw Bus Raw Bus

INPUT (AC)
Input = 600VAC
A phase
B phase
C phase

OUTPUT (DC)
Output = 830VDC
-VDC
+VDC

RAW BUS
Raw Bus = 830VDC

Neg.
Raw Bus
Pos.

PRE-CHARGE CCT.
Pre-charge cct.
 Charges the “Raw Bus” before main

breakers can be set.
 Prevents Inrush current to the

capacitor bank located under the
Buck module.

PRE-CHARGE CCT.

PRE-CHARGE CCT

PRE-CHARGE CCT

PRE-CHARGE CCT
50 VA Transformer
120:600VAC

PRE-CHARGE CCT

PRE-CHARGE CCT
Precharge
Relay

PRE-CHARGE CCT

HIGH VOLTAGE CONTROL
HVCB ( High Voltage Control Board)
 Monitors both the “Raw Bus” and the

“V Bus” for their respective voltages.
 Controls the brake cct. (dump cct.)

in over voltage conditions.

HVCB

HIGH VOLTAGE CONTROL

BRAKE CCT
Brake cct. (Dump cct.)
 Diverts all potential stored on the MD-

500 to a grid resistor in a shutdown or
unwind situation.
 The system also fires to the brake for

2 seconds after the system is disabled.

BRAKE CCT

BRAKE CIRCUIT ISSUES
The MD500 Drive will fire to the brakes under the following
conditions:
1) if the V-Bus exceeds 790 VDC

2) if the system is in unwind mode
3) if the motor exceeds 3000 RPM in FWD
4) if the motor exceeds 600 RPM in REV
5) for 2 seconds after being disabled
Where do the signals for points 2,3, &4 come from?

THE RESOLVER

BRAKE CCT

BRAKE CCT

BRAKE CCT

BRAKE CCT
INTELLIGENT POWER MODULE

BRAKE CCT
Braking IGBT
IPM Capacitor
Blocking diode

BRAKING RESISTORS
 Discharges the “V-Bus” when

the drillers panel is disabled
or during unwind.
 Paralleled across the “V-Bus”

for intermittent use only.

BUCK MODULE COMPONENTS
Buck Module

IGBT
(Insulated Gate Bi-polar Transistor)

IGBT
 High speed switching device.
 Has a switching frequency of

30KHz.
 30,000 times per second.
 +15VDC to turn on and –8 VDC

to force off.

IGBT
E
E C

IGBT

IGBT
830 VDC
15 VDC

IGBT
830VDC
-8 VDC

Buck Module
Buck Gate driver Board
 Receives a firing signal

from the System
controller to gate
IGBT’s.
 Varies voltage supplied
from “Raw Bus” to
feed “V Bus”.
Capacitor Bank
 Located behind the

Inverter module.
 Paralleled across the
“V-Bus”.
 Used in combination
with Chokes to create
an LC filter.

Capacitor Bank
Discharge Resistor

Discharge Resistor
 Slowly drains the

charge off the
capacitor bank
located on the “Raw
Bus”.
 Fully discharges
capacitors in about 5-
7min.

Buck Gate Driver
 Signal from system

controller comes as a
pulse. This pulse is used
to determine the firing
frequency supplied to the
IGBT’s.
 This is referred to as PWM
(Pulse Width Modulation).

Buck Gate Driver
Flex cct’s
 Signal from the Gate

Driver board is
transmitted via a flex
cct.
 15VDC is used to turn
the IGBT’s on and –
8VDC to force them
off.
Flex cct’s

Flex cct’s
Buck Module
Flex cct

Driver Board Test Points

TP1 : Gate
TP2 : Emitter
TP3 : Collector

1 amp soldered in fuses

for the protection of the
Gate Driver board.
Checking fuse can be
performed from the back
of the board with a multi-
meter.

TP29 : Emitter (+)

TP26 : Gate (-)

TP 26 & 29 : IGBT SET 1
TP 18 & 20 : IGBT SET 2
TP 6 & 10 : IGBT SET 3

Buck Gate Driver
Board
Buck Gate Driver Boards

can only be identified by
the serial number.

Buck Gate Driver
Board
The “-7” or “-4”

indicates this board is
for the Buck Module.
*A “-5” indicates a
Inverter Gate Driver
board.

MD-500 Components
Inverter Module

Flex cct’s
Inverter flex cct

Inverter
Q1 Q2
Q3 Q4

Inverter
Q1 Q2
Q3 Q4

Inverter

Inverter
Q1 Q2
Q3 Q4

Inverter

Output Waveform

Output Waveform
 Variable voltage waveform

produced by the MD-500.
 Waveform can be varied in
Amplitude (Volts) and width
(Hertz).
 Average similar to a
sinusoidal waveform.

System Control Module

( Commercial Control Board )
 System Control Module, or

SCM, is the interface between
the MD-500 and the outside
world.
 The speed and torque input
signals are a 0 – 10 VDC signal
coming from the PLC
 The SCM converts these speed
and torque signals to operate
the inverter.
Vicor power supply
 Supplies control power

for the SCM and the
MD-500.
 Input of 120VAC with
multiple outputs of
+15Vdc, -15Vdc, and
5Vdc

Vicor Power Supply

System Controller
Commercial control board
 Acts as the “brains” of

the system.
 Processes all the
torque and speed
commands given to
the Top Drive.

CCB
( Commercial Control Board )

Common for all test points JP-29

5 VDC Power on D1 TP-4

+15 VDC Power on TP-75 D40

-15 VDC Power on D41 TP-77

5 VDC Reset Signal TP-5 D3

System Run D2

Sin & Cos

Resolver Input
Cos TP-26
Sin TP-27

Resolver +Cos TP-26
Approx. 6 Vpk-pk, 2.5 kHz

Resolver +Sin TP-27
Approx. 6 Vpk-pk, 2.5 kHz

Resolver +Iref
TP-44
* Approx 13 Vpk-pk, 2.5 kHz waveform.


VR1 Trim pot

Over
Voltage
 By adjusting the small set
screw on the side of the
VR1 trim pot, we set the
level of voltage at which ADJUSTMENT SCREW
the unit will shutdown to

an OV, or OverVoltage,
fault.
 If the test point (TP45) is
checked while the TD is
rotating, it will shutdown
to an OV fault.
Over voltage Setting
TP-45 VR-1
* 4.15VDC = 820VDC on the V-Buss

S1 Timing Switch

Buck Controller Board
 Controls the IGBT firing of

the Buck Module
 Receives voltage
command from the CCB
and compares it with the
output of the “V-Bus”



D16 (red) – Pre-Reg. Fault
 A Pre-Reg fault is an
indication that a fault has
occurred somewhere in
the Buck Module.
 This would most likely be
one of three things :
1. Buck Module IGBT’s
2. Buck Module Flex Circuit
3. Buck Gate Driver Board

D15 (green) – Power on

D19 (green) – Pre-Reg. Enable

Housekeeping Board
Housekeeping Board
 Isolation board.
 Separates all incoming
and outgoing signals
from the CCB.

Housekeeping Board

System Interface

Housekeeping Board

Housekeeping Board

Housekeeping Board
Test Points

Housekeeping Board
TP1 & TP3 = Com

Housekeeping Board
TP2 = 15 VDC

Housekeeping Board
TP4 = 5 VDC

Housekeeping Board
TP5 = -15 VDC

Tracking

What is Tracking ?
 Tracking is a situation
where the V-Bus gauge
follows, or “tracks”, the
Raw Bus gauge to a
certain value or matches
the full Raw Bus Value
 If the gauge goes to
approximately 830 VDC, it
is called “Full tracking”.
 If the gauge stops HALF TRACKING
somewhere between 250

FULL TRACKING
and 500 VDC, it is called
“Half tracking”.
Tracking In The Real World

Tracking
 The most likely causes :

 Half tracking:
1. Service loop ground fault
2. PA44 motor ground fault
3. Buck Choke ground fault.
 Full Tracking:
1. Buck Module IGBT
2. Buck Module Flex Circuit
3. Buck Gate Driver Board

Eci MD-500

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Copyright 2011 Tesco Corporation

Copyright 2011 Tesco Corporation

Copyright 2011 Tesco Corporation

 Supplies power for the Top Drive

 AC-AC converter. Controlling both

 Operated using a System

Copyright 2011 Tesco Corporation

Copyright 2011 Tesco Corporation

 Each MD-500 requires 15gpm of cooling

 Cooling is interlocked with the drive

 “No Flow, No Go”

Copyright 2011 Tesco Corporation

Copyright 2011 Tesco Corporation

Copyright 2011 Tesco Corporation

Choke (not shown)

Copyright 2011 Tesco Corporation

Copyright 2011 Tesco Corporation

Copyright 2011 Tesco Corporation

Copyright 2011 Tesco Corporation

 600 VAC input voltage is rectified

 This voltage is automatically

 This 830 VDC is called the “Raw

Copyright 2011 Tesco Corporation

Copyright 2011 Tesco Corporation

Copyright 2011 Tesco Corporation

 Located behind the Buck

 Paralleled across the “Raw

 Reduces the ripple on the 830

Copyright 2011 Tesco Corporation

Copyright 2011 Tesco Corporation

 Takes “Raw Bus” voltage and

 This voltage makes up the “V

 Varying the voltage is possible

Copyright 2011 Tesco Corporation

Copyright 2011 Tesco Corporation

Copyright 2011 Tesco Corporation

 Large induction coils used to

 Has individual input from the

 Used in conjunction with a

Copyright 2011 Tesco Corporation

Copyright 2011 Tesco Corporation

Copyright 2011 Tesco Corporation

 Paralleled across the “V-Bus”.

 Used in combination with Chokes

 Chokes = L : oppose a change in

Copyright 2011 Tesco Corporation

 Voltage supplied from the “V

 Process possible by the use of

Copyright 2011 Tesco Corporation

Copyright 2011 Tesco Corporation

Copyright 2011 Tesco Corporation

Copyright 2011 Tesco Corporation

Copyright 2011 Tesco Corporation

Copyright 2011 Tesco Corporation

Copyright 2011 Tesco Corporation

 Three Phase Full Wave

 Total of three diode packs.

 Each pack consists of two back

Copyright 2011 Tesco Corporation

Copyright 2011 Tesco Corporation

Copyright 2011 Tesco Corporation

Copyright 2011 Tesco Corporation