User Manual of ZJ70DBS Electrical Drive and Control System

ZJ70DBS Drilling Rig

Electrical Drive and Control System

User Manual

Sichuan Honghua Petroleum Equipment Co., Ltd.

July. 2012

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 User Manual of ZJ70DBS Electrical Drive and Control System

Preface

ZJ70DBS rig is manufactured by Sichuan Honghua Petroleum Equipment Co., Ltd.

according to SY/T 5609-1999 “The Types and Basic Parameters for Oil Drilling Rig”,
GB/T 3797-2005 “Electrical Control Equipment”, API RP505 “Classification of Locations
for Electrical Installations at Petroleum Facilities” and Relevant API specification. It is
able to meet with the requirements for oil & gas exploration and drilling development in
the middle or deep well.
This manual introduces system configuration, equipment operation, daily maintenance
and troubleshooting in details.
The system has the following features:
1) It is designed on the basis of advanced performance, safety, reliability, convenient
transportation and low-consumption running as per HSE requirements; the
performance and quality can reach up to the international advanced level.
2) The dynamic control system, AC output and all kinds of protect & interlock function
are designed to suit 7000m drilling condition.
3) Cables and wires are connected reliably, arranged properly and grounded steadily.
4) With proper method, the whole system is protected against explosion, vibration,
moisture and water to achieve safe operation
5) The system can be operated safely and reliably at an ambient temperature from
-18℃～+55℃
6) It is designed and manufactured as per relevant international standard
As the system is customized according to practical working condition and special
requirement, the technical document of the rig could not be fit for other same-type
products. Confirm the product type and number before using the documents.
As for the problems in installation, operation and maintenance which are not mentioned
herein, please contact with manufacturer:
GMT+8: 08:00—18:00 24 hours service phone(Chinese, English)

Tel: +86-028 8601 3554/8601 3546 Tel: +86-139 8192 9756

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 User Manual of ZJ70DBS Electrical Drive and Control System

Fax: +86-028 8601 3562 American area: +86-138 8225 2191

Service E-mail: [email protected] Middle East/African area: +86-138 8225

24 hours on-duty phone: (both Chinese and 2386

English languages) Southeast/south Asia area: +86-138 8225

Russia: +86-138 8225 1193 2396

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 User Manual of ZJ70DBS Electrical Drive and Control System

Contents

Chapter 1 System Configuration .................................................................................. 1

1. House Configuration and Internal Cabinets ........................................................ 2
1.1 VFD/MCC House ....................................................................................... 2
1.2 Driller’s Cabin ............................................................................................ 3
2. Generator System ............................................................................................... 5
2.1 System Introduction ...................................................................................... 5
2.2 System Configuration .................................................................................... 6
3. VFD System Configuration and Function ............................................................ 2
3.1 Rectifier unit (ABB)......................................................... 错误！未定义书签。
3.2 Invert Unit (ABB) .............................................................................................. 3
3.3 Brake Chopper (ABB) ................................................................................... 3
3.1 Rectifier unit ................................................................... 错误！未定义书签。
3.2 Invert Unit ....................................................................... 错误！未定义书签。
3.3 Brake Chopper ............................................................... 错误！未定义书签。
4. PLC System and Network Building ..................................................................... 4
5. Equipment Specification ...................................................................................... 8
5.1 Main Motor Specification ............................................................................... 8
5.2 Brake Resistor............................................................................................... 9
5.3 Main dynamic transformer ............................................................................. 9
5.4 Air Conditioner............................................................................................. 10
Chapter 2 Equipment Operation Instruction ............................................................. 11
1. Preparation of Electrification................................................................................ 14
1.1 Connection Inspection ............................................................................. 14
1.2 Insulation Test .......................................................................................... 14
1.3 Transformer and Connection Inspection .................................................. 14
1.4 Avoid Incorrect Connection of Different Voltage Level ............................. 15
1.5 Peripheral Circuit Inspection .................................................................... 15
2. Generator start/stop ............................................................................................ 16
2.1 Generator System Installing and Commissioning........................................ 16
2.2 Startup and Operation of Diesel Generators ............................................... 16
3. System power-on and equipment start-up ........................................................... 18

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 User Manual of ZJ70DBS Electrical Drive and Control System

3.1 Supply dynamic power, lighting power and controlling power ..................... 18
3.2 24VDC power supply operation................................................................... 19
3.3 power on individual unit orderly in VFD house ............................................ 20
3.4 check the rotation direction of blower inside the converter cabinet ............. 21
3.5 MCC house start-up and operation ............................................................. 21
3.6 startup and operation of driller’s cabin ........................................................ 22
3.7 check the running of motor blower and lube pump...................................... 22
4. Operation in Driller’s cabin .................................................................................. 23
4.1 Function and Operation of Apparatus on Driller’s Chair .............................. 23
4.2 Pressurization explosion-proof operation of driller’s cabin错误！未定义书签。
Chapter 3 Daily Service and Fault Treatment ............................................................ 25
1. Precautions ........................................................................................................ 25
2. Precautions of Hoisting, Transportation and Reinstallation ................................ 26
2.1 Hoisting and Transportation: ....................................................................... 26
2.2 Reinstallation:.............................................................................................. 26
3. Daily Maintenance and Storage .......................................................................... 27
3.1 Daily Maintenance....................................................................................... 27
3.2 Regular Inspection ...................................................................................... 29
3.3 Storage ........................................................................................................ 32
3.4 Maintenance ............................................................................................... 32
4. Trouble Shootings .............................................................................................. 33

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 User Manual of ZJ70DBS Electrical Drive and Control System

Chapter 1 System Configuration

The electrical system (hereinafter referred to as system) of ZJ70DBS rig mainly consists
of main diesel generator set, auxiliary diesel generator set, VFD/MCC house, driller’s
cabin, drawworks(DW) AC&VF motor(s), mud pump (MP) AC&VF motor(s), rotary table
(RT) AC&VF motor(s), auxiliary drive AC&VF motor, combined hydraulic pressure
unit(HPU), sensors, and pneumatic & hydraulic components.

The system is classified into three parts: power supply, power distribution and control.

Power is supplied from diesel generator set and provided for drilling operation.

Power distribution includes variable-frequency drive part and low-voltage distribution part.
The VF drive part is configured with cabinet-type rectifier unit, cabinet-type inverter unit
and braking chopper unit; and power supplied by DC bus bar. Low-voltage distribution
loops are mainly used with Schneider frame-type circuit breakers, molded case circuit
breakers, contactors, thermo-relays and squirrel-cage motors.

Figure 1.0 System one line diagram

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Control part is applied with Siemens S7-300 series PLC; with features of modulization,
non-fan, easy to arrange and powerful CPU, it’s suitable for oilfield environment. By
using PROFIBUS technology, CPU can fulfill high-speed and reliable transmission with
each station in PROFIBUS network. Siemens M377 touch screen applied with our
self-developed software provides a simple and easy operation to driller; real-time status
and parameter displaying on screen provide necessary information to driller for drilling
condition judgment, fault tracing and equipment maintenance. Meanwhile, this part has
the functions of Mis-operation protection and equipment self-test to prevent important
equipment from damage.

1. House Configuration and Internal Cabinets

The system is mainly composed of diesel generator house, VFD/MCC house, and
driller’s cabin.

1.1 VFD/MCC House

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Figure 1.1 VFD house layout

VFD house installed with:

◆ Gen. control unit
Function: control diesel generator sets in parallel/non-parallel operation, for
supplying 600V/50 Hz AC power to the whole system.
‹ Rectifier unit
Function: convert 600V AC power to 840V DC power, which into supply to inverter
unit.
‹ Inverter unit
Function: DW, MP and RT inverters supply frequency-adjustable power to
associated AC&VF motors for speed control.
‹ Dynamic Braking cabinet and matched braking resistors
Function: the dynamic braking control and energy consumption unit are applied to
consume feedback energy on DC bus from inverters.
◆ PLC cabinet
Function: the inside S7-300 controller are applied to collect digital and analog and
realize logical control by CPU; and the integrated industrial computer is installed
on cabinet door for drilling parameters displaying, record and inquiry.
◆ Aux. drive unit and braking resistor
Function: To supply frequency-adjustable AC power for aux. drive motor and
consume energy feedback generated during block lowering. This set is applicable
for providing constant WOB and ROP in drilling shallow formation.
◆ MCC cabinet
Function: to supply dynamic power to the blowers and lube pumps of DW, RT and
MP; as well as to control AC motors on drill floor, mud pump house, mud
circulating tank, fuel tank area, engine house and water tank areas.
‹ Switch cabinet
1#Switch cabinet: fitted with one 1250A air circuit breaker and one 800A breaker
to supply 600VAC power to dynamic transformerT1 primary and top drive system.

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2#Switch cabinet: fitted with 1 2000A air circuit breaker to T1 secondary, 1.

◆ Lighting cabinet
Function: equipped with incoming switch NSX400, MCCB and ACB for supplying
power to lighting and small power equipments.
‹ High-power air conditioner
Function: single cold type is adopted to adjust the indoor temperature of VFD
house.
‹ Main dynamic transformer
Function: a. transformerT1 (600VAC/400VAC, 1250kVA) for supplying dynamic
and lighting power to the whole well-site.

1.2 Driller’s Cabin

Figure 1.2 Driller’s cabin layout

Cabin walls and console are all made of stainless steel; drilling operation integrates
electricity, pneumatics and hydraulics to realize centralized control and drilling
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parameter displaying. Electrical system includes PLC cabinet, electrical control

cabinet, touch screen, DW speed joystick and connecting cables. Via PLCs driller
can complete RT, DW and MP control on touch screen; as well as hydraulic and
pneumatic valves are controlled electrically. The control system has perfect
interlock-protection functions, such as, closed loop control applied for traveling
anti-collision; and it is designed for system power failure protection, RT torque limit,
drive E-stop and system E-stop etc.

◆ PLC cabinet
Function: as one of the logic control center of electrical drive system, it is
equipped with ET200 module, relevant I/O module, terminal block, diode PCB
and relays etc.
‹ Electrical control cabinet
Function: Fitted with switch power supply, circuit breaker, SITOP power supply,
contactor, relay, terminal block etc., to supply control power to driller’s cabin.
‹ Touch screen, DW speed joystick and disc brake handle
Function: via operating joystick, handle, touch screen and buttons, can realize
drilling control and operation; meanwhile, the drilling parameters will real-time
monitored by touch screen.
‹ Video system
Function: To monitor the whole wellsite in multiple channels & angles; and adjust
pan/tilt to zoom in/out images.
‹ Pressurization Ex-proof unit
The Electrical control cabinet, PLC cabinet, Driller chair arm are adopted with
pressurization explosion-proof which to meet explosion-proof requirements in
zone 2.

2. Generator System
2.1 System Introduction
The system is comprised of generator control cabinets, for supplying 600V/50 Hz AC
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power to drive system via single or parallel operation.

Main Technical Parameters:

¾ Diesel: Model: CAT3512B Capacity: 1714kVA

Rated RPM: 1500 r/min Rated voltage: 600VAC

Output power: 1200kW Rated frequency: 50Hz

Power factor: 0.7

Exciting current: 7.1A

Frequency stable accuracy: 2％

Voltage stable accuracy: 3％

Load share balance: <5%

Protection: over-voltage, under-voltage, over-frequency, under-frequency,

over current, reverse power, short circuit, and power limit.

2.2 System Configuration

2.2.1 Overview

Generator cabinets are used for generator sets paralleling operation, monitor and safety
protection.

2.2.2 Configuration units

‹ Speed Control Unit

Woodward 2301A-SC electronic speed controller, combined with actuator

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and tachometer head are formed to speed control system, into stabilize
diesel engine speed and generator frequency.
‹ Excitation control unit
Basler DECS-100 digital excitation control system is based on 16bit
high-performance microprocessor, designed to protect for
over-excitation/under-excitation, and control generator output voltage.
Meanwhile, it offers communication with PC for parameter upload and
download.
‹ Synchronizing unit
Woodward SPM-D11 is a synchronizing unit with integrated control functions
for power control and load sharing. Through the application of appropriate
logic to the discrete inputs, the following functions can be realized:
• Synchronization
• Synch-check
• Load/var sharing
• Over/under-voltage, over/under-frequency alarm signal output
‹ Electric instrument
It is used to measure phase voltage, line voltage, current, active power,
reactive power, apparent power, power factor and frequency, etc., based on
electromagnet shield theory and MCU; and via RS-485 interface
communicate digital with PLC.

3. VFD System Configuration and Function

This system is consisted of rectifier unit, inverter unit and braking unit, which adopts
6-pulse input and features high integration, compact design and easy installation.

3.1 Rectifier unit (HT)

This unit is composed of two rectifier sets; each set includes one control cabinet and
one power unit cabinet.

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 User Manual of ZJ70DBS Electrical Drive and Control System
3.1.1 Rectifier Control Cabinet
The cabinet is mainly equipped with main circuit breaker and control section.
z The main circuit breaker is adopted with Schneider MT frame type, which has
protect function for short circuit and overload, into make sure the rectifier
section normal running.
z The control section is taken S7-200PLC as logic control center, which
combined with analog modules to supply real-time monitoring to protect
rectifier system against fusing, overvoltage, over-current, over-temperature
and phase-lack, etc.
3.1.2 Power Unit Cabinet
This cabinet is fitted with input reactor and rectifier.
z The input reactor is used to inhibit the harmonic generated from non-linear
load, and then reduce the effect on upstream circuit and prevent excess
voltage and surge current impacting on drive system due to mis-operation.
z Rectifier module is the type of three-phase and Diode Bridge; and each
module is fitted with wheels for easy move and maintenance.

3.2 Invert Unit (ABB)

The invert units are applied to separately supplying power to DW motor, MP motor
and RT motor. And R8i inversion module has the features as follows:
‹ Bookshelf pattern, small volume and compact structure, easy to install
and maintain;
‹ Quick connection mode and bottom with wheel for simple access;
‹ Modules can be paralleled to satisfy different load requirement.
‹ Its redundant configuration is designed to keep normal running if any one
module has failure.

3.3 Brake Chopper (ABB)

The system has 2 brake chopper cabinets, which are combined with braking
resistors for consuming energy on DC bus feedback from all inverters.
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The braking hoppers are connected via optical fibers and one as master and others
as slavers. Once the voltage on DC bus exceeding 1127V is detected, the main
chopper will be put into operation and others will be activated.

4. PLC System and Network Building

The Siemens S7-300 series PLC is applied with PROFIBUS technology to fulfill DP
network connection:

Figure 4.1 System network

The system uses cold standby redundant system, which consists of 2 PLC control
systems: 1# channel and 2# channel. “Channel switch” button is located in driller’s
cabin, if one of the channels failed, the system will stop all drilling work and switch to
another channel to continue operation. Thus, network communication or module
fault will not affect the drilling process.

Rema
Configuration Description Items Property
rks

Main station Channel qty. 2

VFD
PLC CPU model 6ES7;317-2EK14-0AB0
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Mode DP

Motor qty. 3

Power 1200KW

Lube pump 7.5KW

Liner wash pump 7.5KW

Mud pump
Charge pump 7.5KW

Travel switch
Adapter FIBER

Accessories
Motor qty. 2

Power 1000KW

Lube pump 7.5KW

Blower 15KW

Lube pressure
CONFIGURED WITH
Drawworks switch
Drive inverter
Air pressure
CONFIGURED WITH
switch
Travel switch
Adapter FIBER

Accessories
Motor qty. 1

Power 600KW

RT rated torque
Lube pump 7.5KW
Rotary
Blower 15KW
table
Lube pressure
CONFIGURED WITH
switch
Air pressure
CONFIGURED WITH
switch
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Adapter
Accessories
Motor qty. 1

Drive mode
Control mode
Top drive Control interface
Software
Adapter
Accessories
Qty. 1

Aux. drive Adapter DP

Accessories
Auxiliary Qty.
Controls
EM brake
Adapter
Accessories
Qty 2
Driller’s
Communication
cabin ET200
module
Qty
MCC Communication
module
Slave station Derrick Qty
lifting Communication
up/lowering module

Qty
Mud pump
Communication
console
module
Top drive Qty
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switchover Communication
module

Top drive Qty

control Communication
panel module
Qty. 1

Signal Communication
WB1850
collection Generator module
slave station Collection
module
Qty. 1

VFD IPC Language CHINESE;ENGLISH

Industrial Function DISPLAYING

computer Qty.
Toolpusher
Language
office IPC
Function
Qty. 2

Model 6AV6644-0AB01-2AX0
HMI HMI
Communication
DP
mode

Station configuration of DP network:

‹ Master station: CPU-317
‹ Slave station:
a. DW inverter Slave station
b. RT inverter Slave station
c. MP inverter Slave station
d. Industrial computer in VFD house
e. Aux. drive inverter slave station
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f. ET200 Slave station in driller’s cabin

g. 1# touch screen
h. 2# touch screen

5. Equipment Specification
5.1 Main Motor Specification
‹ RT AC&VF Motor
QTY 1

Type
Rated Speed 661r/min
Rated Power 600kW
Rated Voltage: 600V
Rated Current 714A
Power Factor 0.86
Rated Efficiency 95%
Insulation class 200

‹ DW AC&VF Motor

QTY 2
Type
Rated Speed 800r/min
Rated Power 1000kW
Rated Voltage: 600V
Rated Current 1215A
Power Factor 0.87
Rated Efficiency 95%
Insulation class 200

‹ Mud Pump AC&VF Motor

QTY 3

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Type
Rated Speed 1000r/min
Rated Power 1200kW
Rated Voltage: 600V
Rated Current 1449A
Power Factor 0.88
Rated Efficiency 95%
Insulation class 200

‹ Aux. drive motor

QTY 1
Type 50Hz
Rated Speed
Rated Power 1480r/min
Rated Voltage: 45kW
Rated Current 400V
Power Factor 75A
Rated Efficiency 0.85
Protection degree IP56

5.2 Brake Resistor

‹ Brake Resistor
QTY: 1
Type YTDZ51S
Rated Power 100kW×8+25kW×1
Rated Resistance 2.3Ω×8+4Ω×1
Cooling Method Forced air cool

5.3 Main dynamic transformer

QTY 1

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Capacity 1250kVA
Input/output 600V/400V
Cooling natural air cooling

5.4 Air Conditioner

‹ Air Conditioner in VFD House
QTY 2
TWE250LDNBBXNXK/TTA250ADEN
Type
KN USA controlling
Power 65KW
input voltage 380V
Frequency 50Hz
Structure Split type

‹ Air Conditioner in Driller’s Cabin

QTY 1
Type BYTF-45FG
Rated Power 4.5kW
Input voltage 220V
Frequency 50Hz
Structure window type, Single-cool

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Chapter 2 Equipment Operation Instruction

Safety Notice

General
For users’ safety, prior to any operation, read through the safety notice carefully, or else,
there could be equipment damage (see converter, motor or other driving equipment) or
personal injury even death.
The utilization of caution and warning
The manual includes two kinds of safety notice: caution and warning.
Warning is to remind the users of adapting correct precautions to get free of accident
which could cause equipment damages or personal injury even death.
Caution is to remind the user of the special event/ situation, or instruction about a certain
subject.
Warning remarks:

Hazadous Voltage: there is high voltage which probably lead to equipment

damage or physical injury.

Common Warning: non-electricty factors which probably lead to physical injury

or equipment damages!

Static Release Warning: the static relase which probably lead to equipment
damages!

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Electricity safety precautions:

1) Establish regular check-up regulations for the electric equipment, especially for
movable electric equipment; if there is fault or something not in conformity with
relevant requirement, solve it at once.
2) Operate the electric equipment as per the rules strictly, e.g.: never change the 3-pin
plug into 2 pin plug as random; never insert the cable head into socket for
electrification.
3) Live operation is forbidden, especially at the hazardous area, e.g.: narrow area; the
area where there is conductors with voltage to ground over 250V. If needed, it is
suggested to take safety precautions, e.g.: standing on a rubber carpet or wearing
rubber shoes; wrap the conductors nearby or grounding point with tape, and charge
one specific person with ward-ship for that .
4) The utilization of Magneto-ohmmeter
a. Use 500V meter to test the electric equipment under 500V; the insulation value

should not be less than 2MΩ.

b. Use 1000V meter to test equipment from 500V to 1000V; the insulation value

should not be less than 2MΩ.

c. It’s forbidden to test the insulation resistance directly at inlet / outlet of rectifier or

inverter.
Electric equipment installation and maintenance
These warning are mainly for these persons who operate converters, motor
cables or motors. Ignorance of these regulations could cause physical injury even
death.
Only the certified electric engineer can be authorized to install or maintain
the driving unit.

z It is forbidden to install or maintain the driving unit, motor cables or motors with power
on. Wait for at least 5 minutes after power off till the intermediate circuit capacitance
has been released thoroughly. Then use multi-meter with impedance at least 1 MΩ
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to test the voltage between the terminal UDC+ and UDC-, for ensuring that the
discharging of driving unit has finished.
z Never allowed to operate the controlling cables with the driving unit or external
controlling circuit power on. Although the main power has been cut off, there might be
hazardous voltage inside from the external circuit.
z All insulation tests can only be carried out with the cables disconnected.
z Make sure of correct phase sequence when re-connecting the cables.

Caution:
z Nevertheless the motor is running or not, there will generate hazardous high voltage
once the input power is connected.
z There is hazardous high DC voltage at these braking controlling terminals (UDC+,
UDC-, R+, R-), generally over 500V.
z When relay output terminals RO-RO3 is connected to power supply 115V or 220V
(230V), there will generate hazardous voltage.

z With the power off, the blower of rectifier cabinet, converter cabinet and braking
cabinet will still run for a while, and some parts, such as the radiator of power
semiconductor will also stay at high temperature for a while too. Hence just pay
attention to safety.

z The control power of rectifier cabinet, converting cabinet and brake cabinet as well as
power supply of blower are all from outside. After the main breaker on the cabinet is
disconnected, there will still have voltage in the control part of the cabinet. Please
refer to the circuit drawing to check the circuits still with voltage. Overall, just make
sure that the cabinet has no electricity by measurement.

z Before inserting and pulling out the plug of outlet cabinet, make sure that the plug &
receptacle have no electricity.
Warning:
Some electronic components on the printing circuit board are sensitive to static

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discharge. Therefore it is advisable to wear the earth wrist strap during operation. Don't
touch the circuit board at will.

1. Preparation of Electrification

1.1 Connection Inspection

Check the connection of dynamic loop to ensure there is no short circuit, connection
failure or disconnection on motor cables and primary / secondary of transformer as well
as circuit breaker inlet/outlet. Additionally, ensure that there is no clearance of lug
connection.

1.2 Insulation Test

Test insulation of bus in VFD/MCC house, motor cables, primary and secondary of
transformer, inlet and outlet of main breaker, as well as ground connection.

How to use Magneto-ohmmeter:

a. Use 500V magneto-ohmmeter to test consumers below 500V and the tested insulation
value should at least be 2MΩ. Get it recorded.

b. use 1000V magneto-ohmmeter to test consumers from 500V to 1000V and the tested
insulation value should at least be 2MΩ. Get it recorded.

c. it is forbidden to test insulation of DC bus & inverter outlet. Only measure

phase-ground insulation of primary/secondary transformer, and before measuring,
switch off all fuses on relevant bus or equipment; meanwhile finish connection of the
generator cable. In addition, prior to insulation measurement between inverter and the
relevant motor, disconnect the cable from outlet cabinet.

1.3 Transformer and Connection Inspection

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Check transformer connection to ensure that neutral phase of transformer has been
grounded, and 3-phase-1-ground, 2-phase-1-ground or 1-phase-1-ground is strictly
forbidden, namely, it is forbidden to use earth as neutral cable. Beside, Ensure that
electrical potential between house and cabinets, cable tray and substructure, derrick and
substructure, tank and house, motor shell and motor base is even, and all ground
connection is reliable. Pay attention to the following factors:

a. Ground cable between houses≥16 mm2

b. Ground cable of ground stake≥35 mm22

c. Cross section of ground stake bronze bar ≥35 mm2 and at least 1.5m must be buried
beneath the ground surface.

1.4 Avoid Incorrect Connection of Different Voltage Level

Inspect it for misconnection by using Multi-meter and ensure that there is no short circuit
or misconnection for cables at different voltage, especially for low-voltage connection
between AC600V and DC24V, and connection between DC24V and AC220V, otherwise,
there could be electrical apparatus damages or personnel injury even death.

1.5 Peripheral Circuit Inspection

Inspect peripheral environment. Ensure that each terminals of cable are connected
correctly, and the cable is aligned orderly in right cable tray. Remove irrelevant cables
from the field.

In addition, keep the houses clean and ensure indoor temperature and humidity fit for
equipment operation. Check the connection of screws and wires in the cabinets and
ensure no foreign materials inside. Before electrification, ensure all load switches are in
“off “status. Close all the cabinet doors and other doors with dangerous voltage. Connect
to control power first, and then carry out further operation and control.

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2. Generator start/stop

2.1 Generator System Installing and Commissioning

2.1.1. Working Condition

Air-conditioners are mounted in the VFD house and Driller’s cabin to keep indoor
temperature around +27℃.

Placed at an altitude within 1000m, the equipment can reach the rated output. If the
altitude exceeds 1000m, the output current will decrease with the correction coefficient
as 8% reduction per 1000m increment.

There should not be excessive acid, alkali and salt, as well corrosive or explosive gases
in surroundings.

With the ambient temperature stable at 20℃, the relative humidity should not be over
90％.

2.1.2. Settings of Generator’s Breakers

Breakers setting
Rated Short
Ics
name current current type In A Ir tr Isd tsd Ii
kA
A kA
Q1~Q4 1650 31.89 MT20N2 2000 50 0.9 1 3 Off0.1 8

2.2 Startup and Operation of Diesel Generators

2.2.1 Preparation for Start-up

It is a cooperation work between electrician and diesel mechanic. First, the mechanics
check oil, gas, water and each relevant part according to the specification of diesel
engine and then electrician conducts checkup according to the following rules:

1) Make sure that UPS voltage in generator cabinet over 22V.

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2) Turn the generator main switch to the “off” position.

3) Test the resistance of GEN. controlling cable and the resistance to ground by using
multi-meter (the signal line cannot be grounded). Actuator resistance: around 30 ohm;
speed sensor resistance: Around 90 ohms; exciting wiring resistance is up to the wiring
connection: around 12 ohms if serial-connected; around 4 ohm if parallel connected (test
F+, F-).

4) Make sure that the programs DECS100, S7-200 and SPM-D11 have been down
loaded (Generally, the program is down-loaded before rig delivery, yet it is needed to pay
attention during module replacement.

5) Check 2301-sc parameter setting

a. RATED SPEED: turn the rated rpm potentiometer to minimum position (turn
anti-clockwise to the end)

b. RESET: turn to the middle position;

c. GAIN: turn to the middle position;

d. RAMP TIME: turn to the maximum (turn clockwise to the end)

e. LOW IDLE SPEED: turn to the maximum (turn clockwise to the end)

f. ACTUATOR COMENSATION: turn to “2” within the range from 0~10 for diesel, steam
turbine or oil-charge turbine.

g. START FUEL LIMIT: turn to the maximum (turn to the end clockwise)

With all above confirmed, start the GEN. set.

2.2.2 Startup

With the preparation ready, the diesel mechanic and electrician operate as the following
procedures.

1) First turn the generator mode switch to “IDLE”; second the diesel mechanic opens the
compressed air valve and press start button. Then the diesel engine speeds up to idle
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 User Manual of ZJ70DBS Electrical Drive and Control System

speed automatically.

2) After the diesel engine idles for a while, the electrician turns the “running mode switch”
to “rated” position and then the diesel engine speeds up to rated value.

3) Turn the “running mode switch” to the “run” position and then the generator starts
generating electricity, with “running” indicator illuminated; the voltage reading should be
around 600V and the frequency should be around 50HZ.

4) Turn the generator mode switch to “load” position; with bus power off, the breaker
engages on directly; with bus power on, the breaker engages on automatically after the
generator has been confirmed synchronizing. The GEN. set will get soft loading
automatically till the balance achievement between the active power and reactive power.

2.2.3 Generator shutdown

There is normal stop and emergency stop. The latter is taken as forced method for
emergent situation with all power supplies cut off, while the former is carried out by the
following steps:

A. Turn the generator switch to run”, and then the generator will reduce load
automatically. When the load is reduced to 5～10％ of the rated value, the main
breaker switches off automatically to get the unit off line.

B. Turn the “running mode switch to “rated” to de-excite the generator.

C. Turn the “running mode switch to “idle” to decelerate the generator.

D. After running for a certain period under idle mode, turn the “running mode switch to
“stop”.

3. System power-on and equipment start-up

3.1 Supply dynamic power, lighting power and controlling power

3.1.1 Dynamic power on.

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Note: main GEN. and AUX. GEN. cannot supply the system with dynamic power at the
same time as their corresponding breakers have been interlocked,

z Main generator power supplying: after the generator cabinet outputs AC600V power,
the red power indicator of transformer T1 inlet breaker on switch cabinet door gets
illuminated. For the first time, it’s needed to store the energy manually. After there
appears the remark which indicates the energy storage has been finished, press the
engage-on button, and then the green indicator gets illuminated too, indicating that
primary and secondary of power transformer T1 has been powered on; as for
supplying dynamic power to the system, just engage on the outlet breaker of T1 as
the above steps.

z AUX. generator power supplying: start AUX. GEN and engage on its inlet breaker to
supply dynamic power to the system.

3.1.2 Lighting equipment or small-power equipment power-on:

Switch on their power breaker manually, and then the inlet terminals of individual
controlling circuit and lighting circuit get electrified.

After system electrification, only professional electric engineer or technician is

allowed to open the cabinet door.

Use specific key to open the cabinet. It’s forbidden to make the cabinet withstand

human weight.

3.2 24VDC power supply operation

1) Switch on the UPS power breaker.

2) Press start-up button of UPS to supply lighting device and small-power equipment
with continuous power when UPS stops audio alarming.

3) Switch on ‘SITOP’ power breaker to output 24VDC power.

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4) Switch on the corresponding DC24v power breaker for supplying 24VDC.

3.3 To Power on individual unit orderly in VFD house

DSU unit operation (HT)

Preparation for DSU start-up

1) Ensure the correct connection inside the cabinet;

2) Ensure that the instrument has been properly installed as required;

3) Screws at interface between the components has been fixed tightly;

4) The equipment has been grounded reliably;

5) Install the safety guard properly;

6) The cabinet has been closed;

7) Local E-stop and drive E-stop have been engaged on;

Follow the steps to start rectifier cabinet:

1) Switch on the controlling circuit and the power indicator (white) gets illuminated. At
this time, PLC system starts working;

2) Check E-stop button is released or not;

3) Press SB1 to start rectifier cabinet. With the yellow indicator shining, the rectifier
starts pre-charging automatically and the output DC voltage steps up;

4) With conditions fulfilled, the main breaker switches on automatically and the running
indicators (green) shine.

5) After 1 second, the breaker switch-on circuit powers off, and another one second later,
the pre-charging circuit automatically switches off, followed by indicator darkening.

6) The rectifier starts to run normally.

Note: with the pre-charging period finished, the main breaker still does not close, and
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2S later the pre-charging circuit switches off automatically, meanwhile the relay
resets. In this situation, inspect the breaker for any damages, perhaps it is fault about
relay engaging-on operation.

7) Check whether rotation direction of blower inside the inverter cabinet is in conformity
with the arrow on the enclosure. If not, switch the blower off power and change any
two phases into each other in the three-phase power cable.

3.4 check the rotation direction of blower inside the converter cabinet

Only when DC bus was electrified, can cooling fan of inverter module starts running.
Therefore, on the condition that DC bus bar is not electrified, it’s suggested to check the
rotary direction of these blowers (blower in brake cabinet and the blower of brake
resistors) first. When the blower in brake cabinet is working, the cooling air blows upward;
when two resistor blowers are running, they both rotate at the same direction, with the
wind blowing to resistor.

With respect to rotary direction of the blowers in inverter cabinet, they can be
checked respectively after rectifier units are electrified, and the wind direction should
accord with arrow on the blower shell.

3.5 MCC house start-up and operation

MCC feed circuit and motor control circuit installed at drawer-pattern cabinet is
comprised of breakers, contactors, thermo-relay, button and indicator etc, in
convenience for service and operation. Each cabinet is configured with grounding
protector; each control unit protected by fuse can achieve service-lock function and can
be disconnected from main circuit at the same time.

Start-up and running

When corresponding bus bar has been electrified in MCC house, red indicator on MCC
drawer will shine, which indicates inlet terminal of drawer is at electrified status and the
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drawer can be switched on. After switching breaker on, the green running light shines,
which means this drawer has been powered on.

Some of the drawers which adopt voltage-loss protection will trip off automatically when
voltage-loss occurs. Before next switch-on operation, it is needed to switch off the
relevant breaker and reset the tripped drawer. Then, further switch-on can be carried out.

There should be no excessive acid, alkali and salt, corrosive gases and explosive
gases in the surrounding

Before MCC bus is electrified, switch off MCC drawer breaker to get free of overload.
With any mistake in start-up period, there might be equipment damages or personnel
injury even death.

3.6 startup and operation of driller’s cabin

Driller’s cabin is the control center of the whole drilling system. The breaker for “driller’s
cabin power supply” must be switched on at first.

Press green “switch-on” button to close contactor in power control cabinet automatically.
Then driller’s cabin is connected to the main power.

The electric control cabinet mainly supplies control power to driller’s cabin. First open the
cabinet, second manually close corresponding breakers and start UPS at the same time,
and then 220VAC(120V)AC/24VDC/24VAC/12VDC control power supplies in driller’s
cabin are all switched on, and PLC indicator shines, followed by HMI starting up slowly.

3.7 check the running of motor blower and lube pump

First make sure that breakers or drawers for cooling blowers of mud pump, RT, and
cooling oil pumps of DW gearbox, MP as well as the liner wash pump have been
switched on. Second manually turn “test” button to “test” position (the button is to start
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the intermediate relay which control the above circuit). At this moment, the
corresponding motors start running, and indicator on the intermediate relay coil used for
receiving the corresponding air pressure signal and operation signal of the blower shines.
If the motor does not run or if the motor runs without the indicator shining or the lockout
button activates without intermediate relay coil indicator shinning, troubleshoot it at once.

3.8 system network communication checkup

Turn the two CPUs in the PLC cabinet to “RUN” position, and supply power to IPC on the
cabinet door and to all inverter units at the same time. Switch on the power breaker in
lighting cabinet and power on slave station module ET200 and two touch screens
MP377. At this time, there is one workable communication channel between driller’s
cabin and PLC cabinet. Refer to the following description for the normal status detail:

1). There should be no red indicator shining on ET200M and CPU as well as their
selected channel and module, while the other green status indicators are shining.

2). Three status indicators of NPBA-12 in the PLC cabinet should be all green;

3). The data displayed on the touch screen on synthetic cabinet door in VFD house and
that on MP377 touch screen is zero or shown by a concrete values, not shown as “###”.

With the above three items fulfilled, the communication is proved to be normal.
Otherwise, troubleshoot the soonest possible to ensure correct communication.

When set or operate some important electrical apparatuses, such as rectifier unit,
inverting modules, some controlling modules in generator cabinets, PLC module, air
conditioner, and video system etc., just refer to the relevant document.

4. Operation in Driller’s cabin

4.1 Function and Operation of Apparatus on Driller’s Chair

The driller’s chair is configured with buttons for system E-stop, drive E-stop, DW joystick,
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brake joystick, E-brake and park-brake. The system E-stop button is used to stop all the
generator units under emergency. When press this button, the whole system will be cut
off power supply. The drive E-stop button is used to switch drive section off power supply,
namely, directly disconnect inlet terminals of the two rectifier units, and in this way the
DW, RT, and mud pumps cannot be actuated.

Channel switchover function: when the network is faulty or the communication is not
normal, switch to the other backup network.

DW joystick adjusts the speed of the DW motor A or B to realize the hoisting, lowering
and suspending of the whole movable system. The joystick can perform self-reset and
self-zero lock function. At free mode, it is automatically locked at middle position (zero).
Operation method: hold the joystick with the left hand and press the lock button, and
then the joystick can be moved upward or backward. When the joystick is off the zero
position, the operator gets free of it and then it automatically returns to the zero and gets
locked.

At zero position, the joystick sends a zero-speed signal to DW. At this time, if the DW
motor is running, the traveling block will stay at suspending mode.

When the joystick gets to other position by being pulled forward or pushed backward, the
DW motors will rotate clockwise or anticlockwise so as to control the travelling system
moving upward or downward at the required speed. During the period, with the joystick
to the limit position, it will send maximum speed signal to rotate the DW motors and then
traveling system can be hoisted and lowered at maximum speed.

Note：

1) Make sure that all doors of electrical control cabinets are closed; before opening the
cabinet and console, ensure all power has been turned off.
2) Keep surface clean and dry. It’s forbidden to store debris inside.
3) It’s required to check and clean regularly; avoid any collisions.
4) Only the professionals are authorized to inspect or maintain.
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Abide by the regulations on the manual, otherwise, there will be equipment

damages or personnel injury even death.

Chapter 3 Daily Service and Fault Treatment

1. Precautions

1) Firstly, ask a special person to be responsible for the whole electric-control system;
only the personnel with corresponding qualification certificate can get access to VFD
house; all the operations must conform to the corresponding regulations.
2) The air conditioner in VFD house should be in the automatic operation status all the
time; keep indoor temperature about +25℃, and indoor humidity generally not beyond
85%; keep the house clean, and no smoking indoor. When the indoor humidity exceeds
85%, adopt proper measures immediately; otherwise, it may cause damage to some
equipment.
3). When the system is running, do not open or close the door frequently; otherwise, the
heat which comes from outside forms into condensate because of the low temperature
indoor, as a result equipment could be damaged.
4). It’s forbidden to switch off the conversion cabinets during running period.
5) Don’t operate channel switching too frequently; otherwise there would be damages on
the relevant equipment. Channel switching can only be performed when necessary, and
prior to operation, halt all equipment through the touch screen (switch-on/off not
necessary).
6). In order to avoid the danger from residual voltage, it’s only allowed to open the
cabinet for inspection till 5-minute discharging after it shuts down. Before handling
sensitive electrical apparatus, operator must discharge static of his own.
7) The blowers of drawworks motors, mud pump motors and liner wash pump, cooling oil
pump are interlocked. Therefore, when the motors are enabled, their blowers will work;
when the DW is enabled, the cooling oil pump will work too. Make sure that the signal
indicator on the MCC drawer is correct, or else, the motor cannot be started up. Usually,
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turn the switches on drawers to “on” position, and select “auto” control mode. For
maintenance, please switch off power supply circuit.
8). Do Not open the cabinet door with system running, otherwise, it could result to
influence upon the cooling-air circulation and to personnel injury or even death because
of high voltage inside and personnel carelessness in operation.

9). As for the drawers with HOA (Hand-Off-Auto) control, the contactor inside will be
directly closed with the knob turned to “H” position for power on after the breaker
engages on. Therefore, when start a motor by using the HOA control, make sure there is
no persons close to the motors and all the cables are connected correctly and reliably.

2. Precautions of Hoisting, Transportation and Reinstallation

2.1 Hoisting and Transportation:

1) Before hoisting, look over the position and type of hoisting stake and hole.
2) Choose proper tool and method accordingly.
3) Crane numbers must be taken into account according to house weight and crane
capacity.
4) Structure and thickness of rope must be adequate for hoisting.
5) Choose appropriate vehicle according to the weight and length of the house.
6) be aware of the height limitation; use rope or strap to fix the house onto the vehicle to
avoid movement of the house during transporting.
7) While being transported, all the doors (for house and cabinet) must be locked well to
avoid any damage

2.2 Reinstallation:

1) Protect the cables while unloading from being damaged by hard or sharp materials
etc.
2) As the cable is transported with the cable tray, it should be coiled in the cable tray

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firmly to avoid damage during transportation.

3) Protect plugs and sockets; when disassemble the plug, rotate it properly in correct
direction to protect threads and contacting components inside. When putting away the
cables, do not drag the cables by holding the plugs, or else, the plug could be torn off or
the cable could be disconnected. In addition, strap each plugs to prevent water or foreign
materials from entering the plugs.
4) Pack precise instruments, such as touch screen with a special-purpose box. They
should be packed with soft cushion materials like foam to avoid damage during
transportation.
5) The components and parts (including the air conditioner, transformer, braking resistor,
etc.) in VFD house must be fixed reliably before moving and all cabinet doors must be
closed without exception.

6) When the equipments arrives at the installation site, check whether the equipment is
damped or damaged.

7) When plugs and cables are being reinstalled, ensure them de-energized and
conductivity and insulation should also be inspected, which should be firmly installed
according to the tag name.

8) Ground stake installation should follow the standard.

9) Open the cabinet for ventilation when necessary, for example, the blower door of
generator house, both sides’ doors of braking resistor.

3. Daily Maintenance and Storage

The electric equipment should be checked and maintained regularly to ensure the
normal operation of the system and prolong the service life.

3.1 Daily Maintenance

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1）Regular inspection in running process of rectifier cabinet:

· Whether the indicator is normal.
· Whether the ammeter and voltmeter are normal.
· Whether abnormal smells or noises in the cabinet
· Whether the cooling blower is running normally

Replacement of rectifying system devices must be conducted according to

relevant installation & maintenance manual by qualified electrician.

2）Visual inspection in running process of the converting cabinet and VF motor:

· Whether the ambient environment is suitable as required.
· Whether the data displayed on CDP312 panel of conversion cabinet is correct.
· Whether abnormal smells or noises are found
· Whether the blower is working normally
· Whether the motor has abnormal startup
· Whether high temperature, noise or abnormal smells of the motor are found.

Apparatus replacement of inverting system must be conducted according

to relevant installation & maintenance manual by qualified electrician.

3）Inspection of the braking cabinet:

· Whether ambient environment is favorable.
· Whether abnormal smells or noises are found.
· Whether the blower is working normally
Replacement of apparatus of braking system must be conducted by
qualified electrician according to relevant installation & maintenance
manual.
4）Inspection on MCC cabinet during the running process of MCC cabinet:
· Whether the indicator on the drawer is normal.

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· Whether the ammeter reading of the drawer is normal.

· Whether abnormal smells or noises are found
5）Inspection on transformer during running process:
· Whether abnormal vibrations or noises are found.
· Whether there is abnormal smells, like burnt odor
· Whether there is discolor or deformation because of partial overheat
6) Inspection on generator in running process:
· Whether generator parameters are normal.
· Whether load distribution of the generators are balanced.
· Whether any alarm information is found on generator panel.
· Whether abnormal smells or noises are found.
· Whether blower normal.
7) Inspection of air compressor:
· Whether instruments are normal.
· Whether the air compressor can discharge high-pressure air automatically or not
· Whether pipe line and valves are in proper position.
8) Inspection on solid control system and HPU motors:
· Whether abnormal startup of the motors is found.
· Whether high temperature, noise or abnormal smells are found.
· Whether current and voltage of the drawers are abnormal.
9) Inspection on PLC system:
· Whether the indicator of PLC module is abnormal.
· Whether noise or abnormal smells are found while PLC is working.
· Whether any physical damage of PLC module is found.

3.2 Regular Inspection

When a regular check is required, first shutdown system and cut off the power, second
open the cabinets for checkup. However the inspection on rectifier cabinets and

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converter cabinet can only be carried out at least 5 minutes later after power off because
they are still with dangerous voltage.
1） Ambience
Ensure that the ambient environment is favorable.
Check the temperature, humidity, vibration and air (whether there is dust, gas, oil mist,
dew, etc) by instrument.
Confirm there is foreign object or hazardous material around by visual check.
2) Control Circuit
Check whether the control circuit is connected firmly; inspect the terminal connections
for looseness, burnt smells, discolored, cracks, distortion and rust.
3) Cooling system
Inspect the cooling fan for abnormal noise, abnormal vibration and bolts looseness, as
well as overheat discoloration; check if there is any block stuff or foreign material in vent
and radiator.
4) Main Loops
z Bus bar: inspect bolts for looseness, and insulation for distortion, cracks, damages or
discoloration due to overheating as well as dust.
z Conductors and cables: inspect conductor for discoloration and deformation; inspect
the cover for damages, cracks or discoloration.
z Check whether the terminal supports are broken.
z Inspect the filter capacitors for leakage, discoloration, cracks or shell swelled; check
whether the valves are obviously swelled. Measure the static capacitance as
required by static capacitance instrument.
z Inspect the resistance for strange smell because of overheating; inspect the
insulators for cracks or disconnection.
z Inspect the contactor and relays for vibration sounds or cold solder joint.
z Refer to the operation instructions of motors to checkup and maintain the motors.
5） MCC Drawer
z Inspect the component and wire grooves for dust and contaminants.

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z Check connection between the main bus bar and vertical bus bar and tighten when
needed; Check and tighten the other terminal connections too.
z Inspect the wires for insulation damaged or bad connections. Pull out the plug &
receptacle assembly to check the installation.
z As the breakers are switched off/on frequently, especially after short-circuit, the
contact terminal is easily burned out and covered with carbon stuff which increases
contact resistance. Just maintain and lockout as per the breaker manual.
6) Main Transformer
Abnormal Possible Cause Eliminating
Phenomenon
Dirty windings harsh environment Blow with dry air or clean with a duster or cloth.
and bad Don’t scratch the wire insulation or use solvent
maintenance like gasoline, etc.
Windings Partial overheat or solve with manufacturer
cracking, natural ageing
discoloration
Winding Produce abnormal Find out the reason and take
flashover with voltage or be measurement.
carbon tracking affected by
abnormal voltage
Rustiness of Aging of antirust Repair with specified coating as air-tight and
iron core materials, harmful water-proof treatment to reduce the indoor
gas, rain, or humidity.
condensation.
Discoloration of Overload. Loose Reduce the load and tighten the bolts, polish
outlet bolts or poor contact and galvanize the contact surface
connections surfaces
due to overheat

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3.3 Storage

1) The VFD house and driller’s cabin usually used outdoor can be stored outside for a
short time, generally at temperature ranging from -2℃ to +55℃, with equipment
performance in good condition.
2). If the equipment will not be used for long (e.g.: half one year), they should be stored
indoors. Do not expose them to the sun and rain; inspect the equipment regularly for
humidity, condensate and mould; with any phenomena as above, dehumidify with heater
and fan.
3) No matter long-term or short time storage, make sure of clean environment and clean
it with dust collector periodically.

3.4 Maintenance

1) The bolt-fixed part could be loosened due to vibration and the terminals will lose
conductivity, so the bolt must be checked regularly.
2) Cables must be checked often since vibration may produce friction between the
insulation layer and other components; as a result, there will be electric accident.
3) Dust is easily to absorb moisture. With too much dust accumulated on the bus bars,
there will result to creepage between the bus bar and the support members (ground
connection); with too much dust accumulated between pins of connector, there will
result in false signal connection; with too much dust accumulated on radiator in the
cabinet, there will be influence upon the effect of heat emission, and finally lead to
damages on electric and electronic apparatus. Therefore, cleaning work must be
carried out regularly.
4) Generally protective circuit doesn’t work; it only works when there is accident.
Hence, check it regularly to ensure of normal status.
5). AC motors, as rotary equipment, is one of the key equipments of electric drive
system, hence there is a mass of maintenance work.
First check and clean the air filter of the motor regularly to prevent dust from blocking
the air circulation, so as to get free of overheating. It is recommended that the
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motor should be checked after 500 running hours. Refer to the relevant
maintenance guide provided by motor manufacturer for further maintenance.
Based on above instruction, maintenance procedure can be carried out as follow:
Daily Check of Crew Shift:
(1) Whether that switch and indicator works normal or not
(2) Whether the fuses are in good condition.
(3) Whether the blowers and the air conditioner are running properly
(4) Whether generator load distribution is even.
Monthly Check:
(1) Whether the bolts of all terminals are loose.
(2) Whether cables are broken.
(3) Whether protective electrical apparatus is in a good condition.
(4) Whether there is anything abnormal on the connections.
(5) Whether the relays work normally.
(6) Remove the dust from the cabinet.
Carry on thorough checkup carefully every year with power off. Inspect bolts for
looseness; check protection circuit, relays and transformer. Lubricate rotating parts;
replace lighting fixture; remove dust in the house, etc. Refer to operation
instructions of generator and motor for detailed procedures.

4. Trouble Shootings

When the rectification and inversion units are faulty，please refer to User Manual for
detailed resolutions. If the problems can’t be solved, please directly contact the local
ABB technical support. Common malfunctions and treatments are as follows:

HT rectifier cabinet

Rectifier cabinet Faults

Failure Cause Solution
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1. rectifier fan non-running Close control loop switch,

and check fan power circuit
2. TD400C panel displays Correctly set EM231
abnormally (110000 for 0-20mA; 101000
for 0-10V). Measure
detection module with
multimeter for within normal
range (0-20mA or 0-10V);
replace if necessary.
3. Pre-charge indicator Check whether TD400C
(yellow) not display after panel displays fault alarm,
pressing down startup and solve it according to the
Cannot be buttonSB1 instruction and press F8 to
switched on reset.
4. Fault lamp on panel Press F7 on TD400C for
displays in red alarm information
5. DC voltage is lower after Replace DC voltage
pre-charging completed measuring module, heck
(lower than 0.865 time of diode within module for
rated voltage) normal with multimeter
(normal voltage drop should
be 0.3V)
6.Local E-stop or Drive E-stop Pull up the button
button being pressed down
7.the contactor in pre-charge Replace it
circuit damaged

Inverter Faults

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Failure Cause Solution

COMM MODULE Profibus communication Inspect the connection of Profibus
Fault code: failure has been found adapter module.
7510 from receiving terminals
of the Profibus module or In the control system that uses ABB
communication channel Advance upper computer, inspect the
CH0 (Programmable CH0 optical fiber (or Nxxx type Profibus
module fault, please adapter) between RMIO board and
refer parameter 70.04). upper computer system. Replace with
new optical fiber.

Inspect Profibus cable grounding status.

Inspect node address. Inspect the status

of Profibus adapter. Refer the
corresponding Profibus adapter manual.

If Profibus adapter has been turned on,

please check the parameter settings in
the parameter group 51. Inspect
connection between the Profibus and
the adapter.

Check the correctness of bus controller

configuration and communication.
DC OVERVOLT 1. Main circuit static Inspect correctness of brake wave
Fault code: charge or transient chopper function. Check correctness of
3210 overpressure. brake mode during speed reducing
2. Brake wave chopper process if regeneration brake system is

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or brake resistance applied.

fault (if they are used
in the system). Inspect DC voltage of the medium DC
3. If there is no brake circuit and the rated power of inverter.
wave chopper or
regeneration brake Replace NINT-xx circuit board (the
system used in the voltage measurement circuit at fault)
system, fault might
be caused by too
short of a speed
reducing time.
4. Internal fault of
inversion unit.
DC Medium DC voltage too Inspect power source and fuse breaker
UNDERVOLT low. It might be caused of the inverter.
Fault code: by phase failure of the
3220 rectification bridge. Inspect the appropriateness of the
feedback current connected to DC
switch module, if MultiDrive HW and DC
switch optional parts are used in the
system.
EARTH FAULT Unbalanced load at the Inspect motor.
Fault code: input side of the main
2330 circuit. Possible causes Inspect motor cable.
are motor fault, motor
cable fault or internal Inspect if there is power factor
faults. (programmable compensation capacitor or surge
module fault, refer absorption apparatus used in the motor
parameter 30.20). cable.

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Non-parallel inverter
R10…R12i trip level
setting too sensitive.
Check parameter 30.25.
ENCODER A<>B Pulse encoder 1 phase Exchange phase A and phase B
Fault code: sequence error: phase A connection of the pulse encoder.
7302 is connected to phase B
terminal or vice versa.
ENCODER ERR Speed measurement 1 Inspect settings of parameter group 50.
Fault code: fault. Possible causes
7301 are loose connection of Inspect pulse encoder and the
cables, communication connection of phase A and B of it. When
over-time or too much motor rotates, parameter 1.03 SPEED
difference between the MEASURED 1 and internal actual signal
internal speed and the 1.02 MOTOR SPEED must be the
actually measured same. If different, exchange connection
speed. of phase A and B of the pulse encoder.

Inspect installation and connection

between RMIO and the optional circuit
boards RDCU and DDCS.

Inspect the connection of optical fiber

between RMIO board and RTAC pulse
encoder module.

Inspect the correctness of grounding of

the apparatus.

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Inspect existence of strong disturbance

source.
INT CONFIG The quantity of ACS800 Inspect the status of inverter modules
Fault code: R8i inverter modules not found by the system. Refer
5410 found by the system parameter 8.22 INT CONFIG WORD.
does not tally with the
initial configuration. Inspect the connection of optical fiber
between APBU and R8i inverter
modules.

When the Reduced Run function is still

effective, isolate the faulty inverter
module in the main circuit and input the
quantity of existing inverter modules in
the system into parameter 16.10 INT
CONFIG USER. Restart drive unit.
Refer chapter of Reduced Run Function.
INV DISABLED During operation, DC Before start, please turn on the DC
Fault code: switch turns on, or when switch between input DC inlet terminal
3200 DC switch turns on, start of the inverter and the common DC bus.
command has already The status of DC switch of each parallel
been given. inverter module can be seen in
This trouble-shooting parameter 8.20 INV ENABLED WORD.
function is applicable to
ACS800 R8i module If there is no DC switch in the
provided with AFSC-0x configuration of drive unit hardware,
knife-melting control unit. please stop this function through
parameter 98.12 FUSE SWITCH CNTR.

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OVERCURRENT Over current. If the drive unit trips during the fast start
Fault code: process check if the parameter 21.01
2310 START FUNCTION has been set as
AUTO. (The other modes do not support
Fast Start).

Inspect motor load.

Inspect speedup time.

Inspect motor and motor cable

(including phase sequence).

Inspect pulse encoder and its wire

connection.

Inspect if there is power factor

compensation capacitor or surge
absorption apparatus used in the motor
cable.

Inspect rated motor parameter in the

parameter group 99 to ensure
correctness of motor type.
SHORT CIRC Short circuit. Over Inspect resistance of power source
Fault code: current output. board.
2340
If fault is found on power source board,
please replace the board, NINT board,

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NGDR board or the complete inverter

phase module.

Inspect that during operation, the

accident start preventing circuit is not
disconnected.
1. No control power or Inspect and ensure that control power
power supply or power supply has been connected
with the blower plug.
Blowers in the
2. Blower damaged Replace the blower
inversion cabinet
3. Circuit breaker of Switch on the breaker.
do not work.
blower control power in
the inversion cabinet has
not been switched on.
Blowers in the 1. Blower de-energized. Switch on blower breaker in the switch
chopper cabinet cabinet.
do not work 2. Blower control circuit Switch on all the circuit breakers in the
breaker in the chopper chopper cabinet.
cabinet not switched on.
3. Blower damaged Replace the blower
1. Not energized Switch on the circuit breaker
controlling the blower in switch cabinet
Blower in brake 2. Blower damaged Replace the blower
resistor cabinet 3. The intermediate relay Replace intermediate relay coil.
do not work coil controlling the blower
in the auto-bit cabinet
damaged
Inverter failed to 1. Inverter has not been Switch on ‘OESL’ isolating switch on
start energized the door of inversion cabinet.

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2. ‘CDP-312’ on the Press ‘LOC/REM’ button of CDP-312,

auxiliary cabinet door is no ‘L’ displayed on the first line of the
under local control mode panel
3. Blower drawer is not Switch on drawer or corresponding
switched on, or it is control circuit breaker, and turn ‘HOA’
switched on but ‘HOA’ is to ‘AUTO’ position
not on ‘AUTO’ position
4. Blower plug is not Inspect the connection of the blower,
connected. and ensure reliable connection with
motor.
5. Blower maintenance Release the button
button is pressed down
6. The blower is running, 1. Inspect air blower rotation direction
but no pressure feedback 2. Inspect sensitivity of air pressure
signal is received detection switch
3. Inspect the connection between the
blower and outlet board
4. Inspect damage of corresponding
relay
7. Relevant status icon on 1. Press down fault reset button on the
the interface is red, which interface until it turns white.
indicates inverter fault 2. If it is still red after it has been
pressed down, find out the fault reason
of CDP-312 in VFD house, then
eliminate the fault according to
hardware manual.
NPBA-12 Faults
Fault Information Cause Counter Measure
Status indicator RAM detection failure Reset module

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MASTER is red,
MSG is red and Contact local ABB service
DDCS flashes representative
Status indicator ROM detection failure Reset module
MASTER
flashes, MSG is Contact local ABB service
red, DDCS is red representative

MASTER and DDCS link failure Inspect drive energizing status

MSG status
indication lights Inspect dust or cracks on optical fiber
are in the last
effective status. Ensure proper connection of connector
DDCS is red
Use new optical fiber

Contact local ABB service

representative
Status indication PROFIBUS Inspect PROFIBUS status of master
light MASTER is communication failure (no computer.
green, MSG is data exchange)
red and flashes,
DDCS is green
and flashes
Status indication PROFIBUS link failure Inspect PROFIBUS status of master
light MASTER is computer.
red and flashes,
MSG is red, Inspect PROFIBUS cable
DDCS is green

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and flashes
Note: Only common faults of inverter are listed as above. If any other fault occurs, refer
to “ABB firmware manual, system software 7.x”

Air Cooling System Faults

Failure Cause Solution
1. A/C de-energized. Switch on A/C control drawer.
2. Motor of A/C Replace motor.
compressor or outdoor
unit damaged.
3. Contactor of A/C Replace contactor
compressor or outdoor
A/C not work
motor damaged.
4 Control wire or power Reconnect control wire and power
supply cable loosed or supply cable.
disconnected.
5 Some unit may have Change cable phase sequence.
phase protection.
MCC Drawer Faults
Failure Cause Solution
Switch-on 1. AC 120V control power Switch on MCC control power circuit
indicator lamp of in MCC cabinet not breaker in the lighting box.
drawer off energized.
2. Fuse in the drawer Replace fuse.
burned.

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3. Circuit breaker 1. Check if cable between outlet

tripped. board and electrical apparatus had
short circuit or motor failed.
2. Increase setting value of over load
protection of the circuit breaker
1. Cable between outlet Connect control cable properly
board and start/Stop
controller not connected
2. Start/Stop controller Replace Start/Stop controller
Remote start damaged
failure after 3. Thermorelay tripped Reset thermorelay and increase
switch-on protection parameter.
4. Motor damaged or Replace motor, adjust the motor shaft
motor coupling damaged.
5. For drawer with ‘HOA’, Choose ‘AUTO’ of ‘HOA’.
‘AUTO’ not chosen.
Control System Faults
Failure Cause Solution
1. Memory card not Insert memory card to proper position
inserted to proper position after turning off power.
2. Unreliable connection Fasten the connection bolt. Replace
between CPU backboard backboard connector.
CPU no running
connector and module, or
or SF/BF fault
backboard connector
indication light
failed.
turned red
3. CPU switch is not on Turn the switch to running position.
running position.
4 Peripheral network Connect properly the peripheral
cable not connected. network cable.

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 User Manual of ZJ70DBS Electrical Drive and Control System

5. Peripheral network Eliminate all the unreliable connections

cable broken, connection of the peripheral network cable, and
point loosing or dropping ensure no connection problem.
off, two bared wires of plug
contacted with each other.
6. Network terminal Inspect all the DP network connectors.
resistance not connected Only the terminals of VFD monitoring
channel and transfer cabinet should be
at ‘ON’ position, the others should be
at ‘OFF’ position.
7. One of the substations Turn on substation power
has no power, causing BF
turning red.
8. Short-circuit of external Find out external power supply with
sensor power supply short circuit and eliminate the fault
9. One of the modules in Find out un-energized module and
the system not energized energize it.
1. Unreliable connection Fasten the screw connecting module
between backboard and conduction cabinet. Replace
connector and other backboard connector.
modules, or backboard
SF indication
connector failed.
light of AI module
2. Module damaged Replace the module (Attention: as
turned red
replacing the module, the signal
selection at the sideboard of the
module should be consistent with that
prior to replacement).

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SF light of Unreliable connection Fasten the screw connecting module

FM350-1 module between backboard and conduction cabinet. Replace
turned red. connector and other backboard connector.
modules, or backboard
connector failed.
‘CR’ and ‘DIR’ 1. Hook height reset Press hook height reset button till it
indication lights button not turned green. turns green.
on FM350-1 2. Hook height encoder Connect hook height encoder cable
module not on not properly connected. properly
when DW drum 3. A and B phase from Change A and B cable connection
operates. encoder to module is sequence
reversed.
4. Encoder input signal Change to same signal.
does not accord with
selection signal.
1. Unreliable connection Fasten bolt connecting module and
between backboard conduction cabinet. Replace
connector and other backboard connector.
modules, or backboard
ET200M Fault
connector failed.
2. ET200M address code Modification of ET200M address code
does not accord with is prohibited.
hardware configuration
MP377 Faults
Failure Cause Solution
1. MP377 not electrified Inspect DC24V power supply of
MP377 Black
MP377
screen
2. MP377 is damaged Replace MP377
MP377 touch MP377 is damaged or Replace MP377 or reinstall the drivers

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cannot be driver is missed.

operated
1. Sensor is not Connect the cable from outlet board to
connected sensors
2. Sensor calibration Set sensor calibration coefficient to 1.
coefficient is 0 in If it does not conform to actual value,
parameter setting. adjust the coefficient until it accords
Incorrect display
with actual value.
of sensor or no
3. QD connector Fill oil to the QD connector
display at all
connecting with sensor not
filled with oil
4.Sensor damaged Replace the sensor
5. Signal transmitter Replace signal transmitter
damaged
Drawworks low 1. Oil pump does not Start oil pump
oil pressure started
alarm 2. Oil pressure detection Repair oil pressure detection switch
switch failed
Signal is not correct, or Refer to “Incorrect display of sensor or
Pump pressure
pump pressure exceeds no display at all “; reduce mud pump
alarm
limit value stroke setting
Crown saver is enabled. 1. Inspect mechanical cause of
enabling the crown saver and
eliminate the problem.
Crown saver
2. Press down drum brake protection
alarm
non-release button
3. Press brake deflation button to
release the alarm.

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Actual load power 1. If there are still one or more

exceeds maximum power generators available, put it or them
provided by the generator online.
Power -limit
2. Reduce setting value or stop some
alarm
converters
3. Press the ‘Power Over Limit Reset’
button on parameter setting interface.
Incorrect signal; low oil 1. Refer to “Incorrect display of sensor
Low oil level level of HPU or no display at all“.
alarm 2. Add cooling oil to HPU
3. Inspect leakage on HPU
Incorrect connection; Refer to “Incorrect display of sensor or
Filter is blocked. no display at all“; clean or replace the
Filter block alarm
filter.
Cooling oil is too dirty Replace cooling oil
Incorrect signal; HPU oil 1. Refer to “Incorrect display of sensor
High oil temperature is too high or no display at all“
temperature 2. Start air cooling apparatus to reduce
alarm HPU temperature
3. Add new cooling oil to HPU

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