USING SIMPSON TEST NETER INDEX (Aletoecheck) voltage): et ete : a B) To check continuity ..- 2. +--+. ee 2 THE MOTOR CONTROL CENTER. 2... dgoo9o6 +3 CHECKING ELECTRIC MOTORS... . e0ocdqpuGdG u MOTOR NAVE PLATE INFORMATION . 0 ao 6 AVPROBE ANP METER 2 2. oe 6qu5c00 ay FIGURING MOTOR HORSEPOWER 2... eo GE SCR TROUBLE SHOOTING. . 2... - eee “9 FIELD SUPPLY ON GE SYST... . eee CHANGING PARTS IN A GE SCR HOUSE . . eod0cod 212 ROSS HILL SCR TROUBLE SHOOTING. . . oe 13 CHANGING MODULES ON ROSS HILL SYSTAS 2.2... wee 13 IPS SYSTEMS 2 ee ee eee ee THE DRILLERS CONSOLE. 2 _ ee eee 15 (732) OC|MOTORS =e 16 GENERATORS ON OLDER GE SYSTVS 6. ee ee "7 EMINES 2 eee 19 ENGING PROGUMS te el ACTUATOR te 22 LACK OF POWER: A) Avot Valve ee 28 B) High Water Temperature Valve... 2 ee ee ee 25 C) Water lose Valvers te 26) TANIENVATOR| CONTROU WIRING) ee) ese ct} ee 28) FUSES pegudgcocgoW) CIRCUIT BREAKERS ©... ee ee 3) PLUGS AND RECEPTACLES .. 2... ee ee ee -31CIRCUIT BREAKER PAGE 1 TO CHECK VOLTAGE 1. PLUG BLACK LEAD INTO THE HOLE MARKED COMMON. 2. PLUG RED LEAD INTO THE HOLE MARKED "+" FOR CHECKING VOLTAGES FROM "0" TO "250" VOLTS. 3. PLUG RED LEAD INTO THE HOLE MARKED "500" FOR CHECKING VOLTAGES FROM "0" TO "500" voLTs. 4, PLUG RED LEAD INTO THE HOLE MARKED "1000" FOR CHECKING VOLTAGES FROM "0" TO "1000" VOLTS 5. TURN KNOB IN MIDOLE ‘TO SCALE HIGHER THAN THE VOLTAGE YOU ARE ‘TRYING TO READ, IF YOU DON'T KNOW WHAT VOLTAGE WILL BE, START ON THE 500 VOLT AND COME Dow 6.. TURN SELECTOR KNOB ON LEFT 10 "AC." 7.. TOUCH THE RED AND THE BLACK LEADS 10 POINTS YOU ARE CHECKING VOLTAGE. USE THE RED SCALE MARKED “AC" WITH THE BLACK NUMBERS ABOVE IT. EXAMPLE: ‘YOU ARE CHECKING FOR 480 VOLTS. SET METER UP AS DESCRIBED ABOVE. TURN SELECTOR SWITCH TO 500 VOLT SCALE. READ METER, ON SCALE YOU WOULD USE "0" 10 "50" NUMBERS AND ADD A "0". YOU WOULD READ 48 VOLTE AND WITH "0" ADDED YOU WOULD HAVE 480 VOLTS.PAGE 2 ‘TO CHECK CONTINUITY 1. PLUG BLACK LEAD INTO HOLE ‘MARKED COMMON. PLUG RED LEAD INTO THE HOLE MARKED "+" ‘TORN CENTER SELECTOR SWITCH TO R x 100 SCALE. ‘TURN SELBCIOR SWITCH ON LEFT TO "4DC" POSITION. TOUCH THE BLACK AND RED LEADS TOGETHER. THE METER WILL SWING FROM LEFT 10 RIGHT. WITH LEADS ‘TOGETHER, TURN THE ZERO OHMS 9B UNTIL THE POINTER 1S ON AT THE RIGHT OF OHM SCALE. YOU ARE NOW READY TO CHECK FOR cConrmurry. TO CHECK FUSE, SET METER UP AS + OUTLINED ABOVE. PULL THE FUSE OUT OF HOLDER TO TEST. TOUCH RED LEAD TO ONE END OF FUSE AND BLACK LEAD TO OTHER END.OF FUSE, IF METER READS OVER ‘TO "0" OR CLOSE 10 IT THE FUSE IS coop. IF YOU GET NO READING AT ALL THE FUSE IS "NO GOOD. 7. WHEN CHECKING MOTORS, USE THE R-x 100 SELECTION FOR MOTOR INTERNAL WIRING AND USE THE R x 10,000 SELECTION FOR CHECKING Groups. WHEN YOU ARE THROUGH WITH THE METER MAKE SURE ‘THE CENTER KNOB Is IN ANY SELECTION BUT THE "R" NUMBERS. THIS TURNS THE METER OFF TO KEEP FROM RUNNING DOWN THE BATTERY.PAGE 3 ‘THE MOTOR CONTROL CENTER (MCC) In the SCR houses, or the Power Rigs generator houses, there will be a MCC panel. Some have a RED light only, and some of them have both the RED and the GREEN lights. On panel with the RED light only, when it is "ON" that means the breaker is ON and the starter is "CLOSED" and power SCR house. leaving the On the panels with both the RED and GREEN lights, when the GREEN is ON, that's telling you the breaker is on but NO power is leaving the SCR house. When the RED light comes on and the GREEN light goes out, that's telling you the breaker is ON and the starter is closed and power is leaving the SCR house. If the motor will not run out on the tanks, wire line, trip tank, etc. The first ing you do is go inside and press the reset button "ONE" time. "DO NOT TOUGH THE BREAKER HANDLE." Go out and try the motor again, if it starts, that tells you the motor is being overloaded by something, bearings getting rough and trying to lock-up, mid weight too heavy for the size impeller you have. For some reason the motor is trying to do more work than it was designed to do. You push the reset “ONE” time and try motor if it runs keep an eye on it for the signs above. If it trips again, "00 NOT PRESS THE RESET AGAIN" until you have found the problem. If you press the reset button and the motor still will not run, you then turn the breaker off and then back on. You then go try your motor, if it comes on, the breaker is telling you that there was a short circuit between the SOR house and the inside of the motor. There may have been a short in the plug, receptacle, or cord or even the motor junction box. IF the breaker trips right back off, "DO NOT TRY AND RESET IT" again until you have found the problem. If the motor goes ahead and runs, just keep an eye on it for signs of problems. If it runs for a short while and trips again, DO NOT RESET it until the problem has been corrected.PAGE 4 CHECKING ELECTRIC MOTORS 1. Start at the starter in the motor control center. MAKE SURE BREAKER IS OFF. At the bottom of the starter locate Tl, 12, 3. You take your test meter and set the center knob on Rx 100. Tum the selector switch on the left to the DCt position, then touch the meter leads together and the meter should give you a reading. Adjust this reading to "0" by using the adjustment knob in the upper right hand 2. Next take the meter leads and check from Tl to 12, Tl to 73, and 72 to 13. Don't worry about what the reading is, all you're worried about is that they are all equal. BS Teansreemen 21 F folsi rea el i] S. | fs HH }O}x2 jol4 oe lo} s S| ~. [ists [sl : el Felt [olin : a t5| a2 aA ‘ a =PAGE 5 4. I£ you make checks 2 and 3 on preceding page and get a bad reading, next go to the plug and check it for burnt or bad connections. the plug and with the meter on the same settings, check from BLACK to WHITE, BLACK to RED, and WHITE to RED. These readings should all be equal. Next check each BLACK, WHITE and RED wire to the GREEN or ground wire. There should be no reading at all to ground. If you still get a bad reading go to the motor junction.box. Leave the plug disconnected from SCR house or generator house. Open the cover of the motor and most problems will be found in the junction box where a wire has bumt off or a hole has been rubbed in ‘the tape around the connections. If there is no problem visually, disconnect the BLACK, WHITE and RED wires and separate each one. 5. To the cord take your meter and check, with the meter on the RX100 and DC+ setting, BLACK to WHITE, BLACK to RED, WHITE to RED, you should get no reading at all. Next check BLACK to GREEN, RED to GREEN, WHITE ‘to GREEN. You should get no reading at all on the meter. If you get @ ‘reading on any wire going to each other in the cord there is a bad spot in the power cord, 6. I€ the cord checks out, your next check is the 3 leads that your cord was connected to, Let's say "1" is connected to BLACK, "2" is connected to WHITE and "3" is connected to RED. You check 1 to 2, 1 to 3, and 2 to 3, your readings should all be equal. Next check 1, 2, & 3 to the case of the motor. There should be no reading, if the motor fails either of these tests, the motor will have to be replaced.PAGE 6 MOTOR NAME PLATE INFORMATION FRAME | TYPE INS CLASS Ie: 284T Pp 8 28736C348 _ HP RPM vorts | ames | wz] se: 251765 | 4230/460 | 64/32,| 60 | 1.0 DESIGN B cope F | PHASE 3 Low wrt vouTs aaa wove 22, Nore 4, Aeb| TRA WHEN GETTING INFORMATION OFF OF MOTOR TO CALL FOR A REPLACEMENT, YOU NEED TO KNOW: A.) HORSE POWER B.) FRAME C.) RPM D.) VOLTAGE- WHETHER IT IS A 230/460, A 460 or a 575 VOLT MOTOR. NOTE 1: THIS IS A DUAL VOLTAGE MOTOR, IT CAN BE WIRED UP FOR ETTHER 230 OR 460 VOLTS. ‘NOTE : THIS IS THE AMPERAGE THE MOTOR WILL PULL AT THE TWO DIFFERENT VOLTAGES. AT 230 VOLTS THE MOTOR WILL PULL 64 AMPS. AT 460 VOLT THE MOTOR WILL PULL 32 AMPS. NOME 3: ‘THIS IS THE WIRING CONNECTIONS TO WIRE THE MOTOR FOR 230 VOLTS. YOU WOULD CONNECT 4-5~6 LEADS TOGETHER AND TAPE. CONNECT 7-1 ‘TO BLACK WIRE, 8-2 TO WHITE WIRE AND 9-3 TO THE RED WIRE, THEN ‘TAPE YOUR LEADS. NOTE4: ‘THIS 1S THE WIRING CONNECTIONS 10 WIRE THE MOTOR FOR 460 VOLTS. YOU CONNECT 4-7 AND TAPE, 5-8 AND TAPE, 6-9 AND TAPE. CONNECT 1-BLACK, 2-WHITE AND 3 TO RED, THEN TAPE YOUR LEADS.Page 7 AMPROBE AMP METER S To check amperage on the motor: 1) check motor nameplate amperage 2) connect ampmeter ground (one wire only) at the starter in the SCR house. Example: around wire T1, then check T2, then check wire connected to T3, All three readings should be fairly equal and not over nameplate rating. ‘The "red" scale numbers are for voltage measurement. ‘The ‘black" scale numbers are for amperage measurement.Page g MOTOR. EPS a Name Plate Horsepower Unknown Horse Power Name Plate Amperage Amperage shown on meter Example 1: A 2Shp motor pulls 34 amps at full 25 horsepower. You take an ampmeter and check the motor, it pulls 27 amps at present time. How much horsepower are you using out of this motor at present time? Name Plate Horsepower ‘Unknown Horse Power Name Plate Amperage Amperage shown on meter 25 HP x (unknown horsepower) 34 amps 27 amps - (25)(27) —— =x (25 bp) x (27 amps) = (34 amps) x (x) 4 : GIS = 34x (675) x 1/34 = (84x) x (1/34) 675 675/34 = x — =x 92 = x 34 2 =x So, your motor is pulling 19.2 hp with 27 amps. Example2: AC ) WO) ee ——=C BD B 2) BOE — =A D 3) (AM) = BEPAGE 9 GE SOR TROUBLE SHOOTING If the SCR cannot be assigned, first look at the drillers console lights. You have a SOR on light for each SCR. If the light is on the SCR should be ready to go. If not go down to the SCR house and check out the SCR. On the door of SCR's in the SOR house you have two meters, DC amp and DC volts, and two lights, blower loss and suppression. The blower loss light tells you the SCR cooling blower located in the bottam of the cabinet is not running. Shut the SCR switch off and crank it 3 times and put it back on the line. If you still have the blower loss light on, call the office and let us know. If the suppression light is on, the SCR has shut it's self down. Suppression is a shut down system in the SCR controls. If the Power surges, or a 752 motor tries to arc inside itself the system will shut down to protect it's self. You reset the systen by simply turning the SCR off then right back on. If the SCR will not reset and start working properly, open the door and check all the lights located on the 3 printed circuit cards, and the indicating light located on the power supply, they should ‘all be on. First check the light and the switch located on the power supply. The power supply is located on the back of the swing out door behind the DC volt and DC anp meters. There is a yellow indicating light and an black switch located right to the right of the light. If the light is out the switch should be tripped. Reset the switch slowly and the yellow light should come back on. Feo . wy ex Los" ow") Ry . lo a “ | } 3 Second, check the two lights located on the NOWA card. The two lights are located at the top of the card. The first light is YELLOW and labeled IMOK. It's telling you that the card has checked itself out and telling you I AW OK!. Right below the IMOK light is a RED SUID light. When this light is on the SR is on but no power is leaving the cabinet. If the RED light is out while the YELLOW INDK light is on this means the SCR is coverting power and the DC power is leaving the SCR cabinet. On the NFCB card, located directly behing the NOWA card, there are two YELLOW lights located at the bottan of the card. Both YELLOW lights should be on at all times.PAGE 10 fhe high voltage board is located at the back, right hand side of the SCR cabinet. This card has 12 lights located on it. It has 6 AMBER LIGHES, which tell you all six fuses are good going to the ScR cell Gfacks. These lights are stacked up and down on the card. “anytime the SCR is.on, all Six AMBER LIGMS should be on. Directly in front of the six AMBER LIGHTS are six RED LIGMS. .The six RED lights tell you when the SCR cells are firing. So whenever the SCR is on and Rover is leaving the cabinet turning a Da's or mud pump mtor all-eix RED LIGHTS should be on. If the SCR. is on but no work is being done, you will look. at this card and only see six AMBER LIGHS-on. fay ws ten totter oember weers Eo ote HAE he 1 * het There “is a small switch located on each one. Tt: usually ‘takes at jeast 2 of the. switches to -be on. to supply enough. power for fall pW xe ear ne ie sce Saxe otePAGE 11 ‘THE FIELD SUPPLY ON GE SYSTEM The field supply is located behind a set of double doors with a round OFF - ON switch located in the right hand door. On most of the Rigs it's located on the opposite side of the panel as the SCR's are. To open the doors on the field supply with the breaker on you have to use a screw driver and turn the release lever which locks the door any time the breaker is on. To operate the release lever you turn the small screw located inside of the ring and slowly pull doors open. Inside the cabinet you will see all kinds of contacts. The labels are as follows: NPIAF = Mud pump 1 "A" motor MPIBF = Mud pump 1 "B" motor forward direction NP2AF = Mud pump 2 "A" motor forward direction \Me2BF = Mud pump 2 “B" motor forward direction DWAE forward DWAR reverse DuBF forward direction DWBR reverse direc! DACF forward direction NPIAR. loss relay NPIBFL loss relay MP2AFL loss relay MP2BFL loss relay Draw works "A" field loss relay OWBFL = Draw works "B" field loss relay DNCFL = Draw works "C" field loss realy When calling in these are some of the different contacts I'II have you looking at.PAGE 12 CHANGING PARTS IN A GE SCR HOUSE Before any changes are made in the SCR cabinet, make sure that the SCR switch is "OFF". 1) Power supply located in SCR panel: A) Mark wires connected to terminal board located on tight hand side of module. . i B) Disconnect the plug from the side of the module. Notice which receptacle it came out of so you can place it in the same place on the new module. ‘This plug has a little lock on the side that you have to release to be able to unplug it. - C) Loosen four (4) screws-holding module to door and remove. D) Re-install new module and reconnect all wiring and plugs. 2) Changing out the NOWA or NFCB cards: A) Remove cards by lifting the gray tabs out from card. This will unseat the card and you can then pull the card straight out. B) Remove daughter board from card. Be sure and notice if the plastic guides have locks on them or not. If they have the locks and you try to remove the small card, you could damage it. Take this daughter board and install it onto the new card. ©) Install new card into proper slot while holding the gray tabs pointing out. When card goes in against the back of housing, fold the gray tabs down against the card. This will seat it. 3.) Motor Control Starter & Breaker Draw-outs: A) Fist check for any external wiring coming in from the side, not going through the terminal board. B) Unlock two (2) locking screws at the top left and the top right corners of the draw-out. Next, open the long door that runs from the top to the bottom of the panel. C) Tum bottom center jacking screw cbunter-clockwise. Draw-out will come out and release, D) Check the size of the starter or the breaker of the new part to the size of the old one. You must put the same size starter or breaker in the old slot. E) Insert the new draw-out and tm the bottom jacking screw clock-wise to Seat the drav-out, Turn the two locking screws, top left and top right, to locking position. Re-connect any wiring needed. Always check the heaters in the old starter and install them in the new one if need be.PAGE 13 ROSS HILL SCR TROUBLE SHOOTING On the Ross Hill system if you have a DWA motor that won't run in the 1:00 position you would find another position that would put DNA in another SCR. EXAVPLE: At the 1:00 position DWA was in SCR 1, in the 3:00 position DNA is in SCR 2. This will tell you if your problem is in the DC motor itself, or the SCR. Next try another selection in the suspected SCR and see if it will run that . You have now took the first step of trouble shooting. The more information you can give me when you call, will make it that much faster to find the problem or give me some idea what the repair man needs to bring with them so they get it fixed on the first trip. CHANGING MODULES ON ROSS HILL SYSTEMS When changing a module, either an AC or DC, you need to make sure they match what you already have on your system. You do this by comparing the information labels on each module. AC NODULE CHANGE OUT: First shut down engine then pull all 3 fuses, F30, F31, F32, located about shoulder high on left hand wall of cabinet. You then need to tape the following leads for safety, 0 you don't shut the Rig down. They are 544, 543, 542, 5&1, 549, 539, 537, 510, 511, 538. Next loosen all screws that have @ wire on ‘them,’ on the module and remove the wiring harness. Loosen 2 thurb screws at the top of module and the 2 at the bottom of the module. Remove the module and install new one. Connect all untaped wires. CAREFULLY! reconnect the wires you have taped back to their proper terminal. Plug 3 power fuses back in and start engine and test module. DC MODULE CHANGE OUT: First make sure SCR breaker is OFF. Next pull fuses F20, F21, F22. Loosen the terminals with wires connected and remove wiring harness. Loosen 2 thutb screws at the top of the module and the 2 at the bottom of the module. Remove the old module and install the new one. Reconnect the wiring harness. Re-instal! all the fuses and turn breaker on. Test unit on all selections it operates. On all modules that you think are bad you need to take a piece of Paper and put all the information on the label on this paper. Also include the RIG, SCR number it was on, DATE, and a little description of what the module was doing. Then send it to Victoria yard for repair.PAGE 18 IPS SYSTEM To change one of the generator control! modules out on the IPS system you first shut the engine dow. Next turn the circuit breaker OFF on the back of the module. It is usually a double pole white handled breaker. You will then loosen the set screw on the front of the module you want to change out, the generator control, voltage regulator, or metering module. Pull the old one out and re-install new one. Turn circuit breaker back on and test run module. If this card change out did not help the problem any, re-install the old card back and try changing out one of the other two cards. If one of the cards changed out solves the problem, tag it with RIG number, engine nunber, the date and what kind of problem you were having with the module. To change out the OC drive control module, you shut off SCR switch or breaker and loosen thutb screw and pull out card. Re: new card and test SCR in all selections possible in that SCR. If the new module repairs problem mark it like the other modules and send to Victoria for repair. installPAGE 15 ‘THE DRILLERS CONSOLE The drillers console has a row of indicating lights located along the top. These lights are there to tell you what's going on and to help in trouble shooting SCR problems. You have generator lights, which tell you which generators are on the line. You have SCR lights which tells you whether your SCR's are ON or OFF. There are lights indicating whether your blowers on the DC motor are on or not. Some Rigs also have lights for rod oilers on the mud pumps and also for super charger operation. So as you can see just by looking at the lights on the drillers console you can pretty well tell what's going on around the Rig "ELECTRICALLY." The selector switch on the drillers console does all the motor selection for you. On the GE system when you assign a motor, say WA motor for example, the first thing that happens is the blower comes on. The blower has to come on before any of the contactors or relay start closing putting the motor on the line. If the blower doesn't come on, the sequence stops there and nothing else happens until the blower problem is repaired. On the Ross Hill system you will get an alarm but the motor will go ahead and run. 1f you assign a motor to #1 SCR and it won't work try it on one of the other SCR's. This way you find if it's the motor or the SCR causing the problem. On the hand throttle on the drillers console there are micro-switches located on the back side. These switches are used to tell the SCR when the throttle is in the off position and also tells the super charger when to care on, on the mid punp throttles. The foot throttle, on GE and IPS Rigs have 5 switches that operate according to how far the peddle is depressed. The first switch to operate tells the SR whether the foot throttle is in the OFF position and not stuck part way down. If you assign an SCR to DW's motor and the foot throttle is stuck part way down you won't be able to roll the DW's until you get the foot throttle to come all the way up to the OFF position. This is a safety to keep someone from leaving the throttle on when they shut the SOR off, then when he turns the SCR back on the motors jump up to the speed the throttle was left at. On the GE systems you have 3 pressure switches located inside the drillers console panel. They are "HIGH DRUM", "LOW RUM" AND "ROTARY." These switches are connected to the clutches on drillers control panel. If none of the 3 clutches are activated you are in what's called "CAT HEAD" limit. This means you will only be able to get about 750 amps out of the DW's motors. With HICH or LOW drum clutches engaged you will be able to get 1800 amps out of each DW's motor. When the Rotary clutch is engaged, your power available goes from.0 to 900 amps depending on where you have your rotary torque setting at.6a Page 16 . ° 752 DC MoToRS On your 752 motors there are lock-out switches. Anytime, a man ig working on a DC motor the lock-out pin should be inatalled to keeo Someone from turning the motor on while he is. working. Also driller df you assign a motor and nothing happens, the first thing to check ig to See if someone forgot to pull the lock-out pin out. ‘Inside the 752 GE motors are 12 brushes. They are located in 4 brush holders with 3. brushes mounted in each brush-holder. ‘These brushes Reed ‘to be checked regularly to make Sure they are free to move in the: brush “holder. Sometimes ‘they stick and as the brush weats dow it $kS farther and farther away from the commutator causing arcing and finally-no contact: at all. The brush holdets are located in the Aas “3200, and 9:00 position. - mn lees \N Sant Cf> Ic eee! Bath a is —4] Wes Beak wnkee The brush holders located at. the 12:00 and 3:00 position can be serviced through the.top inspection opening. The holders at the 6:00 and (9:00 positions can be serviced through the botton inspection $pening. When working in the lover part of 752 DC motor, through the ‘lower inspection plate, -you need to be careful to watch out for the eRe Sogeater located on bottom of motor. ‘This heater is on-anytine. the 752 motor is not assigned and it gets very hot. So! ven checking lower brushes watch out for the heater.PAGE 17 GENERATORS ON OLDER GE SYSTEMS: At sometime your going to have no voltage showing on the meters when you go to start up an engine to put on line. The first thing to check is that the voltage selector knob, located to the left of the engine control switch is not in the "OFF" position. It should be in the "A to BY, "A to C", or "B to CY selection points. You have checked and the voltage ‘switch is in the proper position, you now check that your engine selection switch is in the right position. ! say this because on the older RIGS you have ENGINE SHUT DOAN, IDLE, RUN-NO-LOAD, VR-GN and LOAD positions. On the Rewer Rigs you have ENGINE SHUT DOWN, IDLE, RUN-NO-LOAD and LOAD positions. On the newer rigs they, meaning GE, have combined VR-ON and RUN-NO-LOAD positions. So when you go from IDLE to the RUN-NO-LOAD Position your engine speeds up to 1200 RPM's plus your voltage regulator is turned on, and you should have voltage build up at this time. 0K, you've checked the selector switch positions on both the voltage selector and engine control switches and both are in the Rroper positions, and there is still no voltage build up. You now open the engine contro! cabinet and look inside. On the RIGS with all the engine controls in the sane cabinet, 196, 10% there will be three switches from about chest high up. They will be located beside the reverse power trip module, Figure #1. fr ge agente (RE Rg te. i PRE z ap |r _ (@hawas @ = 2. 1 dhe maz] se Nees, a fe eo oe alec fl gS 2. PSE] eS euyiae ea Ficuke eTPAGE 18 On the newer Rigs the ones with a separate cabinet for each generator the circuit breaker for the voltage regulator is located in the engine control cabinet about knee high. It's located right beside the voltage regulator itself, Figure #2. If this breaker switch is in the up or on position, you need to call and talk to the office. Your problem will have to be checked out by an electrician. If however, the switch is in the down or off position you would first turn the engine control switch to the IDLE position. Next flip the circuit breaker on. Now turn the engine control witch to VR-ON or RUN-NO-LOAD whichever your RIG -has. At this time you should see your generator build up to 600 volts on volt meter. If you still don't get voltage on volt meter shut the engine down and call the office.Page 19 ENGINES Qn the engines you have a number of safety shut downs. Most of the shutdowns work by dumping the oil pressures and then a low off Pressure sensor shuts down the engine. There is the water loss Valve, which shuts the’ engine dom if you lose all of your vater in the radiator. There is the HIG! water temp valve that shuts the engine: down: if the water inthe engine gets over 210*F. ‘There is the }mote valves which shuts the engine dom if one or the other ait intake flaps close and the other one doesn't close. ‘The engine vill ee $e, ghedd and run with one flapper closed but you won't be able to get full power out and will cause major problems in the engine if -left'to - run in this condition. If any one of these shutdowns are activated ---=— “it opens a:valve and dumps the oil pressure back into the blocker © the engine The low oil pressure sensor sees this pressure drop and You also have two types of overspeed shut-downs. “on the never engines there is a Bydro-mechanigal shut down. Standing at the back . of the ‘engine, it's located on the front right hand side, about knee. 7 high of the engine. “The shut down has a red, pull to Kill knob handle on it. It also works off low ofl pressure. . The otiter type overspeed shut down is a BARBER COLMAN style. Tr works off the mag pick-up which counts the teeth on the flywheel. If : the flywheel gets to turning too fast, the Barber Colman will shut the flapper valves on the air intakes. and push the fuel rack closed, shutting down the engine. ‘The Barber Colman has two components » the first is, the air closing system, usually located on the back of the engine. “It has a plate with a-valve assenbly and a push to kill knob mounted on it. The other component is the electrical part.’ It's pocated in the engine control cabinet in the SCR house. ‘If your tig, has all three engine controls in one cabinet, all three ‘Barbe! « Celmans will be mounted in there. EXAMPLE: Rigs 88, 104, 196. on the, Tigs that have a separate cabinet for each engine control you will have the overspeed mounted in there. It is a swall green bow with two black, rubber coated push buttons located on it.Page 20 Xf the Barber Colman has tripped and shuts the engitie dom: you will have air blowing out of. 3/8" pipe plug that has a-hole drilled in § it. This. plug will either be located on the valve plate mounted. on ‘the engine or mounted on one of the.flapper valves located on’ either side of. the engine... If air is:bloving. out of this plug the only: way IMPORTANT NOTE: Anytime. the flapper ‘valves, either-one or both have’ “shut for any reason you have to bleed the AMOTE valve. Do this by --=~— loosing the vacuum line that comes from both intake manifolds to the’ AWONT valve. “All you have to do is loosen it part of the way and then retighten it.” I£ you don't bleed the system when’ you ‘rest the engine, you won't be able. to get full power out.ofit. --. a5 / :PAGE 21 ENGINE PROBLEMS Engine Starting Problem on GE Systems and some Ross Hilts. Tf you have a problem starting the engine, it is real easy to determine whether it is the engine or the SCR house causing the problem. While the engine is being turned over by the starter, look up into the "V" of the engine at the actuator arm: i A) Ifthe arm goes up while the engine is cranking, the problem is in the engine. - B) Ifthe arm doesn't move while the engine is cranking, the problem is i the SCR house. : Load Sharing Problems When you have a load sharing problem, the first thing we need to do is check the rated Freed adjustment pots and see if they are adjusted propetly. Next check the oll nad feat filters, either by looking at the gauge or the records Ef you don't find the problem with these checks, you have to determine whether it is something in the engine or if the problem is in the controls in the SCR house, Actuator We'll stat by checking the actuator, One check will be to easily jiggle the plug where the Nites go into the actuator and the wire connections right above the actuator ood ccc ifit affects the engines operations at all. -Sometimes I'11 have you ACTUATOR check the actuator for me. One check will be to easily jiggle the plug where the wires go into the actuator and the wire connections right above the actuator and sce if it affects the engines operations at all. Other times I'll have you check’ the actuator arn travel. “You will agree that when the engine is running and the fuel rack is wide open or in the full up position, what: will happen? ‘The engine should overspeed. To do the following test, you need a straight edge and a ruler. 1. Kill the engine. +2, Measure from the. top of accuator to the top of the-aim vith: ara held up as‘ far as it will go. 3. start ‘the engine and put.it on the line. _ Flue *L Me By HAND By doing this simple test you will be able to tell if itt: ‘the Now 4. Now measure the same point from the top of the accuator to top tuner chee seers Bim AEWGISE pumine Treat 'S your engine giving you the problem ot the SCR house controls causing it. For EXAMPLE: Say #1 engine is pulling 500 KW and #2 is only pulling 200 KW. You would first check the distance between the arm and the engine shut down using check thé fuel and air-filters on #2. Next top of the actuator with figure #1 above on #2 engine. You will now Put the engine back on line and measure the distance between the straight edge and arm, Figure #2, on #2 engine. Now, lets see what we got. The #2 engine is only pulling 200K while the fl engine is pulling 500. We measured the distance on figure #1 and lets say we got 2". When we started the engine and put it back Rete dine using Figure #2 ve still got 2". that's that tell you? Renber the fuel rack according to the measurement is at the full up Be-on the floor wide open. Now think, if the engine throttle is wide pen what should be overspeeding but 200 KW happening? - Right, the engine should be is all it will put out.Page 23 So, as you can see, it’s easy to tell if it's the engine or SCR house causing a load sharing problem. ~ LACK OF POWER ‘The engine won't share the load and using the procedure ’above shows that the problem is in the engine, not the SCR house. When trouble-shooting, you are trying to get the most information you can with the fewest amount of checks you have to make. Sometimes the problem is one of the external safeties on the engine. One is the Amot. Valve, another is the High Water Temperature Valve, and another is the Water Loss Valve. he Amot< Valve z ~ The Amot - valve is mounted on the engine to detect if one of the air intake flappers closes and the other side doesn’t. You all know that the engine will continue to Tun with one flapper closed. If this condition continues for a very long time the engine can be damaged. The Amot: valve detects this condition and shuts the engine down or slows it down enough that the driller will have a power problem. (SEE NEXT PAGE) ‘The way the Amot works: With both of the turbos working, you have a positive Pressure on both intake manifolds "A" & "B". Valves "C" & “D" are one way check valves. ‘They will only allow air to flow back into the manifold, not from the manifold out. At this time, intake flapper valves "F" & "G* are open and the two turbos are boosting the intake air pressure up to, say for example, 10 Ibs.- At this time, the air at the Amot «valve "HT" is in dead air, no pressure and no vacuum. Let's say air intake valve "F" closes for some reason and valve "G" gets hung up and doesn’t close. What happens? With valve "F* closed, the engine is still running but it can’t get.any air on this side. It causes manifold "A" to go into a vacuum. Looking at check valve °C’, it will allow a vacuum to be drawn through the valve and line all the way around to valve "D". ‘The vacuum in this line will also be on Valve "H. This vacuum will pull a diaphragm down that is connected to a valve. When the diaphragm goes down, the valve is opened allowing oil to flow through it. This oil flow will drop the pressure of the oiling system of the engine and the low oil Pressure controls will shut the engine down or slow it down.PAGE 24 NABORS SHUTDOWN SYSTEM FOR ONE AIR INTAKE SHUTOFF. VALVE CLOSED_ * AMOT HODEL 4047 LOW PRESSURE VALVE (5 PSI FALLING PRESSURE) RIGHT INTAKE =, MANIFOLD, ‘BlPage 25 You come into the engine house’and find the engine “munning* with oné flapper closed and the other one opened. "NEVER" open the flapper valve with the engine running. Shut the engine down. ‘The engine is dead and one or both flappers are closed. ‘The first thing you need to do is to break the line loose somewhere between valves “C’, "D', and "A". ‘As you can see, there is a vacimm trapped between the two check valves, and if you don't bleed it off when you restart the engine, you are going to have a problem. Fither it won't start or it won’t run up to full power. ‘ Next, open the flapper valves and look around the engine for a sign of why the flapper valves closed. Restart the engine with someone on the kill switch in case something happens and you need to shut down the engine. * High Water Temperature Valve . : If the engine water temperature gets over a set temperature, the valve will open, dropping the system oil pressure, and the low oil pressure controls of the engine will shut it down. High Coolaur Temp. + Shut Dows valve. peseom | DUMP : LINE Water Yacke-t . At times, we have had this valve stick, particularly open. When this happens, it usually causes the rod that closes the fuel rack for low oil pressure to extend part way Out. It doesn't push the rack far enough to shut the engine down, but what you will see is that the engine will run fine up to a point and then it won't pick up any more of the load. The engine will act like it just hits a stopping point. If you think this could be your problem, all you have to do is break the down stream oil line loose from the valve, the one that goes to the middle of the "V". This line should be dry and no oil should be leaking through the valve. If the engine is not hot and oil is leaking through the valve, the valve is bad and needs to be changed out.Page 26 ter Loss Valve < The valve works on ounces of head pressure, If the water level getstbelow a given point, the spring overrides the head pressure valve and the valve opens the oil line Pressure side to the dump side, dropping the oil pressure and shutting down the engine, 7 : : “Ware Loss _ 5 ode . + Value .. pe NT : 2: . a ae : (CooLanr . 4 MANIFOLD Allot of the time, these three valves, the Amot ;, the Water Loss, and the High Water ‘Temperature, are all connected by the same pressure line and all three are connected to the same dump line. When they are connected this way, you can just break loose the line where they all come together. Ifit’s dry, none of the valves are the problem. IE there is oil in this line, start tracking back to find out which safety valve is causing the problem. (SEE NEXT PAGE)SIT Aldgns SUNSSBUd WO » 49078 BRIDNS & . Ao 7 L3yove wary: “BAIA dW3L oy MBLWM HOI L BATA SSO1 YL [See 3NIT dwna: * p . 3NN ByNss3ud ABNOVE UBLvAPee 2g Allenveror Cowreow, WiringPage Fuses Tes M cigs You have sone saftey fuses in the electrical circuits. pee fuses are in there and are a specific size fore Treason. If on then chee nel YUE Fed & green lights don't cone ony ‘cheek che bulbs. Spm check your fuses. If the fuse you take out ie’at amp fuse put @ lamp or smaller back in it. Fae AEs, Your air compressor blovs a control fuse. You take out the fuse and replace it. Now when you turn the power back on it blovs Rut fuse right out. So, Joe Blow says: pul cmthns and another, ec van 8 bigger fuse in it. You keep doing this ante something in the panel starts ‘smoking. OK, now the probier started out with a Start nick in the wie going from the panel te the Lights in the Goer op plittle bit of tape would have repaired the problem and put Changed oat ek jo Line." However, when the fuses” fuse kept. being Changed out it finally shorted out the control transformers. You now ghen he has to order the part which cost $150.07 re takes 7 days to See _Part, then another service call to install, a £2 you can see, then nar, fond 8 Problem, try changing fuses ONE tina, /it Se blows , then ‘call for help. A phone call is © lot cheaper than a service sa je nite Won't be able to fix it all the time ome the Phone’ but so far we've been déing pretty good! FUSE SIZES FOR’ MOTOR CONTROL CENTER 1) Nema size 1 ~ 6/10 AMP 2) Nema size 2- + AMP 3) Nema size 3 ~ 1-6/10 AMP 4) Nema size 4 - 2-1/2.AMP 1 *Replace the fuses one time, if it blows again you have to trace down the problem. 29PAGE 30 CIRCUIT BREAKERS ‘There are three types of Circuit Breakers, single pole, double pole, and three pole. The number of poles is telling you how many HOT wires are comming out of the breaker. EXAMPLE: 110 SINGLE POLE ‘VOLT 110 VOLT BREAKER DOUBLE POLE 7 208/220 VOLT BREAKER The purpose of a circuit breaker is to protect the wiring from the breaker to the receptacle. If a breaker trips reset it "ONE TIME", if it trips again "DO NOT* reset it until you have found ‘the problem. "DO NOT" install a bigger breaker in ones place that keeps tripping, you are just asking for a bigger problem than you started out with. Find the problem, you can change breaker with one the same size but not bigger.PAGE 31 PLUGS and RECEPTACLES Appleton plugs and receptacles are used to provide connections for 3-phase power to motors (usually 480 VAC and 600 VAC) and to provide connections to switches and pushbuttons for controls (usually 120 VAC). On these plugs and receptacles, you will see a "CAT" nurber. This number indicates how many pins are insulated and able to conduct "hot" and if a pin is grounded. 1. EXAVPLE: ACP3034 ACP - Appleton Company Plug 30 - 30 Amps maximum 3. - Hot pins available 4 - Total pins available 2. EXAVPLE: AcP3084 ACP - Appleton Company Plug 30 - 30 Amps maximum - Number of pins isolated from ground. - Total pins available EXAPLE: ACRGO3 ACR 60 Appleton Receptacle 60 Arps maximum 3-3 pins available to conduct power 4 - 4 pins total available, and fourth is groundedPAGE 32 Note below that the ground pin (and its receptacle tube) is longer. If you try to plug a Swire, 4-pole plug into a 3-wire, 4-pole receptacle, the ground pin will "bottom-out" before the other pins have made up, causing a bad connection that will get hot and perhaps cause equipment damage and a hazard to personnel. (Hot Pin and Receptacle) =—- C—meeEe (Ground Strap) —s7 (Ground Stray (Ground Strap) (Ground Pin and Receptacle) ACR3034 REC ACP3034 Plug (ome) (Ground Stray ACR3034 REC sa ACP 8044 Pug