ECI II Troubleshooting

TROUBLESHOOTING
TESCO TRAINING
DEPARTMENT
ECI TOP DRIVE TRAINING
© 2013 Tesco Corporation. All rights reserved.

TROUBLESHOOTING
AT THE COMPLETION OF THIS SECTION YOU WILL BE

ABLE TO TROUBLESHOOT:
• INTERLOCKS
• MAIN POWER
• MD-500 DRIVE SYSTEM
• COOLING SYSTEM
• PLC CONTROLLER
© 2013 Tesco Corporation. All rights reserved. 2

TROUBLESHOOTING
INTERLOCKS
This following interlocks exist and should be considered
when operating, maintaining or troubleshooting the system.
Precharge:
• Coolant flow must be verified.
• The ENABLE switch must be in the OFF position.
• The ESD button must be pulled out.
• Control power must be present at each SCM.
• Cabinet humidity must be less than 90% RH.
• Communication must be verified between the SCM.
TROUBLESHOOTING
INTERLOCKS
MR-8

TROUBLESHOOTING
INTERLOCKS
Closing the Main Breakers:

• A minimum of approximately 700 VDC must be detected on
the Raw Bus before a Precharge OK signal is initiated,
allowing you to set the breakers.
• The brake resistor temperature must be below 158°F (70 C).
• The PQM RESET button must be pushed (if applicable).

TROUBLESHOOTING
INTERLOCKS DRW-98XXX113

TROUBLESHOOTING
INTERLOCKS
Enable, System Temperature, and Drive fault Reset:

• Top drive can be enabled only if the QUILL switch on the
driller’s panel is in the neutral position (no direction is
selected).
• The red SYSTEM TEMP warning light on the driller’s panel
will illuminate whenever the DRS system temperatures
reach “Warning” level.
• The DRS drive must be ‘disabled’ from the driller’s panel
before you can use the RESET button.

TROUBLESHOOTING

TROUBLESHOOTING
INTERLOCKS
Auxiliary Hydraulic Pump:

• The auxiliary pump automatically starts whenever the
GRABBER CLOSE or VALVE OPEN/CLOSE functions are used.
• Unless the ESD is activated, the auxiliary pump must always
be manually shut off.
• The low oil level switch in the hydraulic reservoir tank will
shut down the auxiliary pump in the event the oil level falls
below safe operating levels.

TROUBLESHOOTING

TROUBLESHOOTING
INTERLOCKS
Pipe Handler Unlock:

• The pipe handler cannot be unlocked unless the MODE
switch is set to CONN.
• QUILL direction switch is in the neutral position.
• There is less than 1,500 ft-lb torque and less than 5 rpm
speed at the quill.

TROUBLESHOOTING

TROUBLESHOOTING
INTERLOCKS
Pipe Handler Lock:

• The pipe handler cannot be locked unless the QUILL
REV/FWD switch is in the neutral position.
• Once the pipe handler is fully locked, the indicator light at
the driller’s panel will extinguish.
• If the pipe handler is locked when the GRABBER switch is set
to CLOSE, the pipe handler lock status is re-affirmed by the
PLC via feedback from a proximity switch located at the lock
cylinder.

TROUBLESHOOTING
INTERLOCKS

TROUBLESHOOTING
INTERLOCKS
Valve Open:
• When the VALVE switch is set to OPEN, the auxiliary pump
starts automatically and interlocks prevent quill rotation.
The valve-open circuit is programmed to operate on a 5-
second timer, which means the circuit remains energized for
5 seconds from the moment the switch is released. This is to
ensure full opening of the valve even if the switch is only
briefly selected.

TROUBLESHOOTING
INTERLOCKS
Valve Close:
• In drill-forward mode, interlocks prevent quill rotation until
the 5-second timed sequence is completed. Set SPEED
switch to INCR to re-start rotation.
• In drill-reverse mode, interlocks prevent quill rotation until
the 5-second timed sequence is completed. Set TORQUE
switch to INCR to re-start rotation.
• In connect mode, interlocks prevent quill rotation until the
5-second timed sequence is completed, after which the quill
will resume rotation at the pre-set speed.

TROUBLESHOOTING
INTERLOCKS

TROUBLESHOOTING
INTERLOCKS
Grabber Open:
• The GRABBER OPEN switch activates an 8-second operating
period timed from the moment the switch is released.
Grabber Close:
• The grabber will not close unless quill rotation is less than 5
rpm.

TROUBLESHOOTING
INTERLOCKS

TROUBLESHOOTING
INTERLOCKS
Mud Pump:
• Relay DR-1 is energized by the PLC whenever the VALVE
switch is set to CLOSE. One set of n/o contacts of DR-1 is
used to energize an air valve (mud pump) using Cord “D”
from the driller’s panel.
Drawwork:
• The PLC energizes relay DR-2, located within the driller’s
panel, whenever the grabber is closed. The contacts of this
relay are wired to the drawwork control circuits or air valve
and prevent the drawwork from being hoisted.

TROUBLESHOOTING

TROUBLESHOOTING
INTERLOCKS

TROUBLESHOOTING
DRS DRIVE PROTECTION
DRS Drive 'Disable' Conditions:

• Faults on the DRS drive system:
• Resolver malfunction.
• V-low or V-high beyond operational range (V-bus over-
voltage, or OV).
• Over-temperature (Pre-regulator, inverter, CCB, rotor,
stators)

TROUBLESHOOTING
DRS Drive 'Disable' Conditions:

• IGBT faults (pre-regulator or inverter).
• Loss of ground continuity wire.
• Loss of ‘Disable/Enable’ signal.
• Loss of communication between drive systems.
• Improper LabView setup.

TROUBLESHOOTING
Main DRS (MD500) Breaker(s) Trip Conditions:

The MB-2, MB-3, and MB-4 (ECI1350 only) breakers supply
power to the DRS Drives. Interlocks will cause all the breakers to
trip under the following conditions:
• DRS dynamic brake temperature exceeds 70°F.
• Drive overcurrent fault (>500 amps).
• Loss of supply service power.

TROUBLESHOOTING
Main DRS (MD500) Breaker(s) Trip Conditions:

• Either Emergency Shut Down circuit activated (de-energizing
of UV trip coil).
• Loss of coolant flow.
• Loss of control power due to wiring or device failure.
• Any sensed voltage spike or voltage variation above or
below operational limits (If equipped with PQM).

TROUBLESHOOTING
DRS DRIVE INTERLOCKS
Resolver Failure
Resolver failure can include failure of any of the following:
• Resolver.
• Resolver circuitry within the CCB.
• Resolver signal cables.
• Resolver isolation board (Resolver Protection Package).

TROUBLESHOOTING
MAIN POWER
• Transient Voltage Surge Suppressor (TVSS)

• Main Distribution Power
• Top Drive Power Problems

TROUBLESHOOTING
TVSS
• The TVSS is expendable and is designed to protect

downstream electrical equipment, specifically
TESCO’s variable frequency drives.
• Always confirm that all diagnostic LED’s are ON
(lit).
• Extinguish and OFF lights are symptom of TVSS
fault.

TROUBLESHOOTING
TVSS DRW-98581107

TROUBLESHOOTING
MAIN DISTRIBUTION POWER

DRW-98581104
• No Power to Power Module Building (Main interface

breaker will not close).
1. Ensure that the rig power lock-out button in the customer MCC
building is not active.
2. Ensure ESD on TESCO power module building is not activated.
3. Check the ESD interface cable between customer MCC and TESCO
building.
4. Check the 600 V and 120 V control fuses (F1, F2, and F3).
5. If none of these preliminary checks reveals a problem, the
problem may be a faulty ESD cable, faulty main interface breaker
under-voltage trip coil or a faulty main interface breaker.
TROUBLESHOOTING

TROUBLESHOOTING

DRW-98581104
000.00 000.00
600.00
000.00 000.00
120.00

TROUBLESHOOTING

DRW-98581104
• Main Interface Breaker trips after closing.

1. Check ground fault meters and indicator lights. Use the following
points to interpret the ground fault meters and indicator lights in
the rig SCR building (if applicable).
 If the ground fault meters display zero, and all the indicator
lights are dim, this indicates that no ground fault exists (normal
status).
 If meters register anything but zero, or if one or more indicator
lights are brightly lit, then a ground fault exists.

TROUBLESHOOTING

DRW-98581104
• Main Interface Breaker trips persistently.

1. Check for under-voltage, over-voltage, under-frequency and over-
frequency tripping for top drives that incorporate a TESCO Main
Service ESD Interface package.
 Confirm that the generator meters are indicating 600V.
 If the system incorporates a TESCO main service ESD
interface cabinet, see next table.

TROUBLESHOOTING

DRW-98581104
TESCO Main Service ESD Interface Troubleshooting

Matrix

TROUBLESHOOTING
DRW-98XXX113
TOP DRIVE POWER PROBLEMS 98XXX202
98XXX204
• No Power to the Top Drive (DRS Drive Breakers Will

Not Close).
1. Unit Does Not Precharge to 830 VDC on All Drives.
2. Only One Drive will not Precharge to 830 VDC.
3. Unit Precharges to 830 VDC on All Drives, but the DRS Drive
Breakers Will Still Not Set.
4. Unit Precharges to 830 VDC on All Drives and Only One DRS Drive
Breaker Will Not Set.
5. Unit Precharges to 830 VDC on All Drives, All Breakers Set, But
After Two Minutes all Drive Breakers Trip.

TROUBLESHOOTING
1. Unit Does Not Precharge to 830 VDC on All DRW-98XXX113

98XXX202
Drives. 98XXX204
No Turn the Yes Turn the

Confirm switch is in Is the PRECH light switch to Is the CONTROL switch to
Start PRECH position (L5) ON CONTROL light (L6) ON PRECH A
position position
Yes No
Ensure:
- 120 VAC is present in all SCM’s. Check the “blown fuse”
- SCM’s switches are in ON position. indication light (F3).
-All Precharge interlock relays (MR-5, MR-6)
are receiving 120 VAC to pin 8 & 7, and NO
contacts 5 & 3 are closing.
Yes
Is the fuse
Replace the fuse
indicator light ON
No
Check:
- 120 VAC is present before
and after fuse.
- If the light bulb is funtional.

TROUBLESHOOTING

98XXX202
Drives. 98XXX204

TROUBLESHOOTING

98XXX202
Drives. 98XXX204
Confirm Driller’s panel is disable.
No Yes Check for an over-temperature
Is the PRECH light ON Check for loss of cooling flow, and confirm:
Is the light for the condition of the dynamic brakes.
A and the Raw Bus meter - Cooling pumps are operational.
relay ON Confirm this by checking diagnostic
B
climbed to ≈ 830 VDC - The rate of flow for motor and drive.
lights on PLC.
Check ON indicator light on flow relay MR-8.
No
Yes
Confirm Flow switches work properly.

End Check diagnostic light (A6) on PLC.
Any or both flow switches might be

No malfunctioning. Therefore, confirm:
Is the A6 light for - 24 VDC at terminal PSP1. If not power
input card ON is present, check the “blown fuse”
indication light F4, if ON replace the
fuse.
Yes
Yes Confirm:
- The corresponding brake over-temperature
Is either B2or B3 - 24 VDC at pins 10&2 on MR-8.
B light OFF
thermostat is malfunctioning, or
- NO contacts 1&3 are closing.
- Brake is over-heating
- Replace relay if necessary.
No
Yes
Is it 24 VDC
Confirm that the High Humidity present on MR-8
interlock (SSR-9) is not engaged.
No
Check:
- Output card light A9 on PLC.
- Loos termination.
- Card and terminal block are properly
seated.
- Replace output card if necessary.
TROUBLESHOOTING

98XXX202
Drives. 98XXX204
MR-5
MR-10
MR-8
MR-7
MR-9

TROUBLESHOOTING

98XXX202
Drives. 98XXX204
If none of the preliminary checks reveals a problem, confirm the following

components; refer to TESCO drawings 98xxx113 and 98xxx204:
a. Cooling Flow Relay (MR-8 for an ECI900). Confirm relay operation.
b. Brake T-Stat Interlock Relay (MR-10 for an ECI900). Confirm relay
operation.
c. Off/Control/Precharge switch, located on the drive cabinet door in
the power module building. Confirm switch operation.
d. Enable & High Humidity Interlock Relay (SSR-9 for an ECI900). Confirm
relay operation.
e. Precharge Timer Relay (MR-7 for an ECI900). Confirm relay operation.

TROUBLESHOOTING
2. Only one drive will Not Precharge to 830 VDC.
a. Ensure that 120 VAC control power is present to the corresponding

drive's SCM. Confirm that the corresponding SCM On/Off switch is in
the “On” position.
b. If the SCM switch is in the “On” position and the SCM has 120 VAC
control power present, confirm that its corresponding Precharge
Interlock relay is functioning. Confirm there is 120 VAC present to
Precharge Interlock Relay pins 8&7 and that normally open contact
5&3 is closing. Replace relay if necessary.
c. Confirm the corresponding drive’s Precharge Circuit; DRS Drawing
Number 060-904715. Confirm each item:
• Precharge Transformer T1
• Rectifier U4
• Current Limiting resistors R1 and R2
TROUBLESHOOTING
2. Only one drive will Not Precharge to 830 VDC. DRW-60-904715

TROUBLESHOOTING
2. Only one drive will Not Precharge to 830 VDC.

TROUBLESHOOTING
3. Unit Precharges to 830 VDC on all drives, but the

DRS Drive breakers will still not set.
This mostly refer to a breaker trip active:

a. Confirm that the ESD button on the driller’s panel is not pushed in.
b. If your unit is equipped with a PQM, check if the unit is preventing
the DRS breakers from setting due to an over-voltage or under-
voltage condition.
• Check the PQM indicator lights (if present) for faults.
• If any fault lights are illuminated (Main OV, Main UV, OV Trip, CB
Trip), then contact a qualified TESCO representative.

TROUBLESHOOTING
4. Unit Precharges to 830 VDC on all drives and only DRW-98XXX113

one DRS Drive breaker will not set. 98XXX114
Start
Confirm SSR light

is illuminated
Check:
- Confirm 120 VAC in terminals A1 and A2 of the No
relay, if so, confirm that NO contact 11-14 is Yes Reconfirm the drive
closing, if not replace the relay. Is the light ON is Precharged. Raw
- If NO contact is closing, the breaker might have Bus ≈ 830 VDC
a faulty UV trip coil or the breaker itself is faulty.
- Check for loose connection.
Is 120 VAC Yes

present on SSR Read this meter 0 Go back to case of
terminals and the other 830 study # 2
VDC
No
No
Check:
- Drive’s HVCB (lose connections).
- Confirm HVCB CB Interlock relay
(U1) is closing (Term J4, pins 1 and 4).

TROUBLESHOOTING
4. Unit Precharges to 830 VDC on all drives and only

one DRS Drive breaker will not set.

TROUBLESHOOTING
5. Unit precharges to 830 VDC on all drives, all breakers set, DRW-98XXX113
but after two minutes all drive breakers trip. 98XXX114
If the auxiliary contacts of all breakers do not make contact when the
corresponding breaker is closed, after approximately two minutes the
precharge timer relay will time-out and all breakers will trip through the
ESD Interlock Relay.
a. Confirm that all breakers’ auxiliary contacts (set 2) are closing.
b. If all auxiliary contacts are closing, confirm blocking Diode D1, which
is mounted on MPP terminal strip.

TROUBLESHOOTING
5. Unit precharges to 830 VDC on all drives, all breakers set, DRW-98XXX113
but after two minutes all drive breakers trip. 98XXX114

TROUBLESHOOTING
TOP DRIVE POWER PROBLEMS DRW-98XXX113

98XXX114
• The DRS Drive breakers trip persistently.

1. Loose termination in the under-voltage Trip Coil circuit. Check all
connections.
2. ESD Interlock circuit; a loose connection to the driller’s panel ESD
switch or intermittent break in the driller’s panel to power module
building interface cable (cable B) will cause the DRS drive breakers
to trip.
3. QM (if applicable).
4. Weak under-voltage trip coil in one DRS drive breaker.
5. Loss of cooling flow.

TROUBLESHOOTING

98XXX114
• The DRS Drive breakers trip persistently.

6. Dynamic brake thermostats.
7. UPS malfunctioning, check diagnostic lights on UPS.
8. Faulty SSR Interlock Relay (SSR-1 for drive-A, SSR-2 for
drive-B).
9. Faulty High Voltage Control Board.

TROUBLESHOOTING

98XXX114
• DRS Drive Breakers Trip on an Over-Current

Condition.
TESCO’s top drives are powered by AC motors fed from variable

frequency drives. Variable frequency drives are current limiting, so it is
not likely to trip out the main DRS drive breaker from an over-current
condition unless there is a dead short in the rectifier portion of the
drive.

TROUBLESHOOTING
DRS DRIVE SYSTEM
• Tracking
• Top drive will not enable
• Top drive will not rotate
• Top drive disables during rotation
• One DRS drive is unstable
• Top drive increases to and/or remains at rated speed
• Power connector problems
• Top drive function problems
• Expanded DRS troubleshooting procedures
TROUBLESHOOTING
TRACKING
Tracking refers to the situation that occurs when values

on the Vbus meter increase past acceptable parameters.
• Full Track: A full track occurs when the Vbus meter
displays a value of approximately 830 VDC.
• Half Track: A half track occurs when the Vbus meter
displays a value of approximately 200-400 VDC.
• Minor Track: A minor track occurs when the Vbus
meter displays a value less than 200 VDC and greater
than 50 VDC.
TROUBLESHOOTING
TRACKING

TROUBLESHOOTING
TRACKING
Half Tracking

TROUBLESHOOTING
TRACKING
Full Tracking

TROUBLESHOOTING
TRACKING
Conditions:
- Trip the drive breakers.
- System in precharge mode. What to do..?
- Ensure breakers are NOT set.
- Drive is disabled.
Start - Drive breakers ARE NOT set, or
- Disconnect the service loop from power
module.
- Drive breakers ARE set. Voltage WAS NOT
- Precharge the system. Check for tracking.
present before the breakers were set.
The problem is confirmed by:

- Vbus meter indicates more than 50 VDC when
the drive is disabled. If the tracking previously
- Drive will not enable if Vbus is greater than occurred ONLY when
200 VDC. breakers were set, then turn
the breakers ON
Yes
Fault might be in the
Vbus still track?
drive
No
Inspect Service loop

and PA44 motors

TROUBLESHOOTING
TRACKING
Probable Causes and Recommended Actions
Symptom Probable cause (s) Recommended Action(s)

Isolate and inspect the service loop.
Service loop ground fault Megger test the service loop between phases and to ground.
Record values.
Isolate and inspect the PA44 motor.
PA44 motor ground fault Megger test PA44 motor between phases and to ground.
Record values.
Full Track
Buck section IGBT failed Lock out the power and confirm IGBT with a Multimeter.
shorted
Buck choke shorted to Lock out the power and confirm buck chokes with a
Multimeter.
ground Meter buck chokes in reference to ground.

TROUBLESHOOTING
TRACKING
Probable Causes and Recommended Actions

Isolate and inspect the service loop.
Megger test the service loop between phases and to
Service loop ground fault ground.
Record values.
Isolate and inspect the PA44 motor.
PA44 motor ground fault Megger test PA44 motor between phases and to ground.
Half Track Record values.
or Buck choke shorted to Lock out the power and confirm buck chokes with a
Multimeter.
Minor Track ground Meter buck chokes in reference to ground.
Buck section IGBT not

being forced into the ‘off’ Check for a faulty buck IGBT gate driver board. or a faulty
position (-5 to -8 VDC gate IGBT (see test points).
signal to IGBT)
TROUBLESHOOTING
TRACKING
Buck Gate Driver board Test points (715-106374)

TROUBLESHOOTING
TRACKING
Test points IGBT 1: TP6 (gate), TP10 (emitter)
Test points

TROUBLESHOOTING
TRACKING
Buck Gate Driver board Test points (101164-X)

TROUBLESHOOTING
TRACKING
Test points IGBT 1: TP1(gate), TP2 (emitter)

TROUBLESHOOTING
TOP DRIVE WILL NOT ENABLE
This refer to the following:

• The top drive will not enable.
• The READY light on the driller’s panel will not
illuminate, or illuminates for approximately one
second, then extinguishes.
• The MODULE ‘ON’ light on the driller’s panel remains
illuminated.

TROUBLESHOOTING
Check:
- Quill direction switch is in neutral.
Start - Module ON light is illuminated.
- Lab View for any fault.
Disable the top drive, push and hold the No

Is the READY Replace the bulb
RESET push-button for three seconds, and
light illuminated and try again
then re-enable the top drive.
Yes
Restart the laptop

and LabView.

TROUBLESHOOTING
Ready light
Module light
TROUBLESHOOTING

If the problem persist, also check:
Probable cause (s) Recommended Action(s)

LabView indicates ONE of the following faults:
• Confirm LabView configuration.
• Confirm that no other programs are running on the laptop.
1. Loss of Communication between LabView and • For computer lock-ups, restart the computer and LabView
one or more System Control Modules. program.
• Check for a faulty Smart Switch.
• Check for faulty interface cabling.
2. Loss of Communication between one or more

• Confirm that the Housekeeping board RS485 Network
System Control Modules. This is indicated by a Jumper (terminating resistor) is in the correct position.
3005 and/or a 3003 code in the Operator Panel • Check for a faulty J9 Communication Cable. Check connector
ends and meter cable. Replace if necessary.
window under Resolver Output Counts for each
• Check for a faulty Housekeeping board.
motor screen.
• Check for a faulty buck gate drive board.
3. Pre-Reg fault. • Check for a faulty Buck IGBT / Flex circuit. Pre-reg IGBT
modules should be replaced as a set of 3.

TROUBLESHOOTING

TROUBLESHOOTING

TROUBLESHOOTING

TROUBLESHOOTING
Probable cause (s) Recommended Action(s)

• Confirm if there is a code other than 0 or 80 under “Resolver
Resolver output code indicates a fault code other
output counts” in the Operator Panel Window for each motor.
than 0 or 80. • Check the Resolver Code Output table.
The cause of this fault is typically a loose or broken connection.
System Control Module status lights indicate that • Check for a loose connection in the top drive junction box
ground sense wire (TDT-19A).
the system has a Motor Ground Fault.
• Check for a loose Sensor cable “T” pyle end connection or
• The Motor Ground Fault light on the side of the damaged cable.
System Control Module is lit (illuminated). • Check for a loose connection in Power Module building
ground sense terminal block (MPT-33).
• Note: Confirm ALL drives.
• Check for a loose ground sense connection at High Voltage
• A Motor Ground Fault is also referred to as a Control board. Ensure green wire on connector J5 is
DRS Ground Continuity Fault. terminated and tight.
• Check for a faulty High Voltage Control board.
• Check for a faulty ENABLE switch at the driller’s panel.
Master Motor (Drive-A) System Control Module is
• Check for faulty Dynamic Brake temperature sensors. Note
not receiving an enable signal from the PLC. that the main DRS drive breakers will trip.
Run each drive individually from LabView as per TESCO's
If none of the above checks isolate the problem, standard commissioning procedure (not greater than 10rpm).
run each drive (motor) separately from LabView This will confirm if the problem is isolated to a single drive or
an external input signal problem.
TROUBLESHOOTING
TOP DRIVE WILL NOT ROTATE

• The top drive remains enable but will not rotate.
• The READY light on the driller’s panel remains
illuminates.
• The MODULE ‘ON’ light on the driller’s panel remains
illuminated.

TROUBLESHOOTING

Check PLC interlocks:
• Top drive is placed in neutral for more than five
minutes in drill mode, the drill-FWD speed command
is set to zero.
• Mud saver VALVE switch is set to OPEN or CLOSE
during top drive rotation, the PLC will disable rotation
in all modes (drill, connect and pipe handler).
• If PLC detects an unwind mode, it will prevent the
operator from selecting reverse quill direction or
disabling the drive until the delivered torque is within
2,000 ft-lb of the set torque.
TROUBLESHOOTING
Mud saver
interlock
relay

TROUBLESHOOTING

Other Probable Causes and Recommended Actions

• Lock the Pipe-Handler.
The pipe handler is unlocked while the top
• Check for a faulty Pipe-Handler lock
drive is in drill mode or connect mode. proximity switch.
Drive setup parameters are set to zero torque

Check the drive setup parameters.
or speed.
Top drive will Faulty Resolver or resolver circuit.
not rotate • The top drive will not rotate, however the
driller's panel indicates that the motors are
• Check for incorrectly connected motor leads.
producing torque. • Check for faulty resolver or resolver wiring.
• The drive will torque up to torque limit
setting, assuming that there are no down hole
conditions causing the drive to torque up.

TROUBLESHOOTING

TROUBLESHOOTING


• Check for a faulty Pipe-Handler proximity switch.
• Check the drive parameters to see if they are set
to zero.
Master Motor (Drive-A) System Control • Check for a faulty FWD/REV QUILL direction
Module is not receiving a speed or torque switch.
• Check for a faulty SPEED or TORQUE DECR/INCR
Top drive will signal from the PLC.
switch on the driller’s panel.
not rotate • Check for loose connections, especially at the
driller’s panel.
If none of the above checks isolate the Run each drive individually from LabView (not
greater than 10rpm).
problem, run each drive (motor) This will confirm if the problem is isolated to a
separately from LabView. single drive or an external input signal problem.

TROUBLESHOOTING

Housekeeping
Interface Board

TROUBLESHOOTING


Top drive will Faulty nano sensor in the corresponding
not rotate, and inverter module.
the DRS drive in Note: On a multi-motor drive this may
the power also be seen as the top drive rotates; • Check for a faulty nano sensor and replace if
necessary.
module building however the drive with the faulty nano is • Check for faulty nano sensor cabling. Repair or
makes a chirping making the chirping sound. This may replace faulty wiring.
noise that also be accompanied with an erratic
sounds like a Vbus and intermittent dumping to the
brake.
bird.

TROUBLESHOOTING

TROUBLESHOOTING
TOP DRIVE DISABLES DURING ROTATION

• The top drive rotates normally, then stops.
• On the driller's panel, the READY light extinguishes,
and the MODULE ‘ON” light remains lit, or
• The top drive rotates normally, then stops.
• On the driller’s panel, the READY light remains lit, and
the MODULE ‘ON’ remains lit.

TROUBLESHOOTING

LabView indicates one of the following faults
• Confirm Housekeeping board RS485 Network
1. Loss of Communication between one or
Jumper (terminating resistor) is in the correct
Top drive more System Control Modules. position.
disables during This is indicated by a 3005 and/or 3003 code • Check for a faulty J9 Communication Cable.
Check connector ends and meter cable.
rotation. in the Operator Panel Window under Resolver
Replace if necessary.
• READY light Output counts” for each motor screen. • Check for a faulty Housekeeping board.
on the driller’s • Check for a faulty buck gate driver board.
panel • Check for a faulty Buck IGBT / Flex circuit.
2. Pre-reg Fault. Pre-reg IGBT modules should be replaced as a
extinguishes. set of 3.
• MODULE
• Check for a faulty Inverter Gate Driver Board.
‘ON’ light • Check for a faulty Inverter IGBT / Flex circuit.
remains lit. 3. Inverter IGBT (J) Fault. Inverter IGBT modules should be replaced as a
set of 4 for the corresponding phase which is
indicating an IGBT failure.

TROUBLESHOOTING

A quill speed of 9999rpm and a resolver output
code of 3200 indicates a broken or loose wire on
the Sine or Cosine of the corresponding resolver.
Always confirm the reference as well. Confirm
Top drive resolver resistance values with an ohmmeter and
isolate the loose or broken wire.
disables during Although a loose or broken wire can be anywhere
4. Loss of resolver feedback signal, indicated
rotation. typical locations are as follows:
in LabView by a quill speed reading of 9999 • Top Drive Junction box
• READY light
and a Resolver Output Count of 3200. • Loose Sensor cable “T” pyle end connection.
on the driller’s • Damaged Sensor cable “T”.
panel • Faulty or damaged resolver pigtail cable.
extinguishes. • Faulty resolver protection package, loose
connection or stripped terminal.
• MODULE • Faulty resolver. Internal winding brake or pin
‘ON’ light connection in resolver.
remains lit. 5.Over-temperature shut down. Check cooling system.
• Check for a loose Sensor cable “T” pyle end

6.Multiple temperature sensor failures on
connection.
the same motor or drive. • Check for a damaged Sensor cable “T”.

TROUBLESHOOTING

• Confirm there is a code other than 0 or 80 under
“Resolver output counts” in the Operator Panel
7. Resolver output code indicates a fault
Window for each motor.
Top drive code other than 0 or 80. • Check the Resolver Code Output Table, see Table
disables during 6-2 on page 95 and Table 6-3 on page 96.
rotation. • CCB Over-voltage trip setting (VR1) is set too low.
• READY light Confirm trip setting is set to 4.15V (870 VDC).
• Check for electrical noise; confirm the following:
on the driller’s • Rig grounds rods are correctly installed.
panel • Top drive and power module ground is connected.
extinguishes. • Check for a drive internal or external ground fault.
8. Vbus Over-voltage shutdown. • Check for a faulty Resolver feedback circuit.
• MODULE Perform the following checks:
‘ON’ light • Motor leads are improperly connected
remains lit. • Noisy resolver signal
• Faulty resolver or resolver wiring: confirm
resolver resistance values, confirm motor timing
• Check for a faulty High Voltage Control Board.

TROUBLESHOOTING

Not in LabView
Typically this is a result of a loose or broken
connection.
Motor Ground Fault. • Check for a loose connection in top drive
Top drive
The System Control Module status lights junction box ground sense wire (TDT-19A).
disables during • Check for a loose Sensor cable “T” pyle end
indicates that the system has a Motor
rotation. connection or damaged cable.
Ground Fault. • Check for a loose connection in Power Module
• READY light
Note: Confirm ALL drives. building ground sense terminal block (MPT-33).
on the driller’s • Check for a loose ground sense connection at
A Motor Ground Fault is also referred to as a
panel High Voltage Control board. Ensure green wire
DRS Ground Continuity Fault. on connector J5 is terminated and tight.
extinguishes.
• Check for a faulty High Voltage Control board.
• MODULE
• Check for a faulty ENABLE switch at the
‘ON’ light Master Motor (Drive-A) System Control driller's panel. Confirm in EClog.
remains lit. Module is not receiving an ENABLE signal • Check for faulty Dynamic Brake temperature
sensors. Note that the DRS drive breakers will
from the PLC.
trip.

TROUBLESHOOTING

• Service loop ground fault:
- Isolate and inspect the service loop.
- Megger test the service loop between phases and
to ground.
Top drive - Record values.
• PA44 motor ground fault:
disables during
- Isolate and inspect the PA44 motor.
rotation. - Megger test the PA44 motor between phases and
• READY light to ground.
- Record values.
on the driller’s Drive(s) has an internal or external ground
• Buck choke shorted to ground:
panel fault. - Lock out power and confirm buck chokes with
extinguishes. multimeter.
- Meter buck chokes in reference to ground.
• MODULE
• Check Vbus to ground with multimeter. This is
‘ON’ light confirmed with the Buck choke test above. A good
remains lit. reading indicates O.L.
• The Rig Ground Fault Detection System can be
checked to confirm internal or external DRS drive
ground faults. Refer to “General Information” on
page 6.

TROUBLESHOOTING

Faulty Resolver Circuit.
Typically a faulty resolver circuit will be
seen as either a Resolver Output count • Check for improperly connected motor leads.
code of 3200 or a Vbus Over-voltage • Refer to the EC log on all drives.
Top drive shutdown. However, there are situations • Check for a faulty resolver or resolver wiring.
disables during where a noisy or faulty resolver can cause • Check for a noisy resolver signal.
rotation. a shutdown with no shutdown codes other
• READY light than a 3001 Immediate Shutdown Alarm.
on the driller’s
• Exchange PA44 motor leads, resolver wiring and
panel resolver dip switch settings between the faulting
extinguishes. drive and another working drive. Record both dip
• MODULE If none of the above checks isolates the switch settings before starting. Typically, this is a
item causing the faulting motor/drive to simple wire for wire swap on the resolver circuit as
‘ON’ light Motor-A Sine and Cosine signals are usually
remains lit. disable the top drive, exchange the faulting reversed on the field side of the resolver protection
drive’s PA44 motor with a drive that is not packages. Use caution with drives that do not
indicating the fault. follow the standard. See drawing 98xxx120. This
will confirm if the problem is drive related or PA44
motor related (motor, cabling or resolver).
• Contact TESCO Technical Support.
TROUBLESHOOTING
Symptom Probable cause (s) Recommended

Action(s)
Top drive
disables during • Run each drive individually
from LabView or the driller’s
rotation. panel as per TESCO’s standard
• READY light on If none of the above checks isolates the problem to a commissioning procedures.
the driller’s panel specific drive/motor, run each drive (motor) separately. This will isolate the problem to
a specific drive/motor.
extinguishes. • Contact TESCO Technical
• MODULE ‘ON’ Support.
light remains lit.

TROUBLESHOOTING
Symptom Probable cause (s) Recommended

Action(s)
The Pipe handler lock proximity switch is loose and the
signal indicating that the Pipe Handler is locked is lost
while trying to operate the top drive in drill mode or
connect mode. Note the Pipe Handler “CAUTION” light
will illuminate or flash and the top drive stops rotating
• READY light on as the commanded speed and torque signal is set to
the driller's panel zero because the PLC thinks that the Pipe handler is
remains lit. unlocked.
• MODULE ‘ON’ NOTE: this can also be seen as an intermittent loss of
light the Pipe Handler Lock signal. One must be careful as in
remains lit. this case the Pipe handler “Caution” light will not be
illuminated or flashing as it would have only slightly
flickered when the signal was lost. Always check the
Pipe Handler proximity switch to confirm that it is
positioned correctly, is tightly secured and is not
damaged.
TROUBLESHOOTING
TOP DRIVE INCREASES TO AND/OR REMAINS AT

RATED SPEED
Start
Typically, a faulty resolver circuit will be
seen as either a Resolver Output count
of 3200, indicating a loss of the resolver
feedback signal or a V-bus over-voltage
shutdown.
Check the resolver resistance

values with a multimeter.
Values are: Yes Yes

Scope the resolver signal to Check for faulty
Ref: 100 ohms Is the amplitude 3 V
confirm the amplitude of the resolver or resolver
Sin: 115 ohms peak?
waveform cabling.
Cos: 115 ohms
No
No
Replace Resolver

TROUBLESHOOTING
TOP DRIVE INCREASES TO AND/OR
REMAINS AT RATED SPEED

TROUBLESHOOTING
TOP DRIVE INCREASES TO AND/OR
REMAINS AT RATED SPEED
Check also the following:

• Check if motor leads are improperly plugged in at the
power module building plug board or at the top drive.
• Confirm motor timing. Confirm timing of all phases to
ensure motor leads are properly connected.
• Check for a noisy resolver signal when troubleshooting
“Top Drive Disables During Rotation” only

TROUBLESHOOTING
For timing:
Test points on
CCB: TP-54/JP-29

TROUBLESHOOTING
For noisy: Resolver: + Sin

Approx. 6 V pk-pk, 2.5 kHz

TROUBLESHOOTING
For noisy: Resolver: + Cos


TROUBLESHOOTING
For noisy: Resolver: + Iref


TROUBLESHOOTING
Noisy:

TROUBLESHOOTING
CONNECT FORWARD/REVERSE
PreReg or Inverter Temperatures.

• Temperature greater than 27°C will prevent the drive
from achieving full connect capability.
• It will operate at approximately 84% capacity.
• Allow the drive to cool down.

TROUBLESHOOTING
CONNECT FORWARD/REVERSE
PreReg or Inverter Temperatures.

TROUBLESHOOTING
CONNECT OR DRILL MODE FORWARD/REVERSE
Pipe Handler Lock.

• You will not be able to operate the connect/drill
forward or reverse functions if the PIPE HANDLER
switch is in the UNLOCK position.
• This is a safety feature.

TROUBLESHOOTING

TROUBLESHOOTING
Drive Setup Parameters.

• If the drive setup parameters are set to zero, you are
commanding zero torque or zero speed, and the
drive will not rotate.

TROUBLESHOOTING
PLC Interlocks.
• PLC will disable rotation If the mudsaver VALVE
switch is set to OPEN or CLOSE.

TROUBLESHOOTING
Mud saver
interlock
relay

TROUBLESHOOTING
BREAKOUT
• Same as for connect-forward/reverse with the

exception of the pipe handler-lock interlock.
• The drive must be in connect-reverse mode before
you can use the breakout function.
• PLC logic varies for each unit.

TROUBLESHOOTING
PIPE HANDLER ROTATE
Pipe Handler Lock.

• You will not be able to operate the pipe handler
rotate function if the PIPE HANDLER switch is in the
LOCK position. This is a safety feature.
• The PIPE HANDLER switch must be in the UNLOCK to
enable the rotation.
• The PIPE HANDLER ROTATE button must be pressed
for the pipe handler function to operate.

TROUBLESHOOTING
PIPE HANDLER ROTATE

TROUBLESHOOTING
TOP DRIVE MOTORS OVERHEATING
Cooling System Components.

• Top drive cooling pump/motor (7 gpm per PA44
motor).
• UCARTHERM coolant (50/50 mixture).
• Filter.
• Modine fan.
• Flow meter and flow switch.

TROUBLESHOOTING
Cooling System Components

TROUBLESHOOTING
TOP DRIVE MOTORS OVERHEATING

TROUBLESHOOTING
TOP DRIVE MOTORS OVERHEATING DRW-98XXX107

98XXX108
Start
Check the following:

No - Faulty thermostat.
Is the cooling fan - Faulty motor starter.
turning ON when glycol - Starter overload circuit tripped.
exceeds 90°F (32°C) - Cooling fan breaker or short in the in the motor circuit.
- Faulty switch.
- Lost of phase.
Yes
Check the Top Drive

cooling pump

No - Confirm pump switch is in ON position.
- Faulty motor starter.
Is the cooling pump
- Starter overload circuit tripped.
rotating ?
- Cooling pump breaker or short in the in the motor circuit.
Yes - Faulty switch.
© 2013 Tesco Corporation. All rights reserved. - Lost of phase. 113
TROUBLESHOOTING
POWER MODULE BUILDING TEMPERATURE

AND HUMIDITY
System Components.
• Heat pump, controlled by:
 electronic thermostat.
 heat pump humidistat.
• Building heater, controlled by electronic thermostat.
• Dehumidifier.
• System monitoring (MODULE ON light on driller’s panel
flashes)
TROUBLESHOOTING

AND HUMIDITY

TROUBLESHOOTING

AND HUMIDITY DRW-98XXX202

TROUBLESHOOTING


TROUBLESHOOTING


TROUBLESHOOTING
Start
Power module
Module ON light Relative Humidity
ambient
flashing (1/10 a level is greater than
temperature is
second) 80-90%
greater than 68°F
Yes Yes
Yes Close the door or
Is the power module Is the power module Is the power module
Close the door check sensor and
building door open building door open building door open
circuit.
No No No
- Turn ON the dehumidifier

Yes
- Confirm breaker CB2 is turned ON
Check for faulty Heat pump cut out or
Dehumidifier is OFF - Set the following parameters:
sensor and circuit. is turned OFF
Fan speed = HIGH
Humidity level = 30 – 50%
No
- Confirm heat pump breaker is in the ON position. Yes
- Confirm heat pump ON/OFF switch is in the ON position.
Yes - Heat pump shut down on low head pressure.
Heat pump cut out or - Confirm chiller is operational.
is turned OFF - Faulty humidistat.
- Faulty electronic thermostat.
- Heat pump fan not operating.
- Heat pump compressor failure.
- Check heat pump diagnostic lights.
TROUBLESHOOTING
HEAT PUMP TROUBLESHOOTING
Heat Cool
Symptom Probable cause (s) ing ing
Correction
main power off X X check fuses
No response to any defective control transformer X X replace
thermostat Setting. broken or loose connection X X repair
defective thermostat X X replace
Unit short cycles thermostat or sensor improperly located X X relocate
defective compressor overload X X replace
defective compressor contactor X X replace
supply voltage too low X X correct

Blower runs, but compressor
defective compressor capacitor X X replace
does not
defective windings X X replace
check
limit switches open X X cause/replace
or repair
TROUBLESHOOTING
Contactors
Compressor
Blower motor
Control Tx

TROUBLESHOOTING

Heat Cool
Correction
dirty filter X X replace/clean
blower RPM too low X X correct
loss of conditioned air due to leaks in ductwork X X repair leaks
introduction of excessively hot return-air X correct
introduction of excessively cold return-air X correct
low on refrigerant charge X X locate leak, repair and recharge
Insufficient restricted thermal expansion valve X X replace
capacity defective reversing valve X X correct
thermostat improperly located X X relocate
unit undersized X X recalculate heat gains/losses
inadequate water flow X X increase GPM
scaling in heat exchanger X X clean or replace
water too hot X decrease temperature
water too cold X increase temperature

TROUBLESHOOTING
Fill connections Air filter

TROUBLESHOOTING

Heat Cool
Correction
inadequate GPM X increase water flow to unit
water too hot X decrease temperature
High pressure inadequate air flow X check, clean, blower the coil
switch open dirty filter X clean/replace
overcharged with refrigerant X X decrease charge
defective pressure switch X X check or replace
trash in heat exchanger X back flush
low water flow X increase GPM
overcharge of refrigerant X X decrease charge

High head
non-condensable in system X X evacuate and recharge by weigh
pressure
water too hot X X decrease temperature
dirty filter X clean/replace
inadequate air flow X check, clean, blower the coil

TROUBLESHOOTING

Compressor
control module
Overflow
High pressure switch
Low pressure switcht
switch
Freeze
protection
switch
TROUBLESHOOTING

Heat Cool
Correction
undercharged X X locate leak, repair and recharge
restricted thermal expansion valve X X repair/replace

Low suction
inadequate air flow X check, clean, blower the coil
pressure
inadequate GPM X increase GPM
inadequate GPM X increase GPM
water too cold X increase temperature
inadequate air flow X increase CFM

Low pressure
switch OPEN
undercharged with refrigerant X X increase charge
defective pressure switch X X replace
heat transfer fluid too cold X raise water temperature

TROUBLESHOOTING

TROUBLESHOOTING
PLC TROUBLESHOOTING
Considerations:
• Stand clear of controlled equipment when power is applied.
• Never reach into a machine to operate a switch since
unexpected motion could occur, causing injury.
• Remove all electrical power at the Main Power Disconnect
to ensure total power removal.
• Always remove power before inserting or removing
modules, or before connecting I/O cabling.

TROUBLESHOOTING
PLC TROUBLESHOOTING
PROFICY

TROUBLESHOOTING
PLC TROUBLESHOOTING DRW-98XXX111
Fuse for 24
VDC to PLC

TROUBLESHOOTING
PLC TROUBLESHOOTING

TROUBLESHOOTING
PLC TROUBLESHOOTING DRW-98XXX201
Fuse to PLC

TROUBLESHOOTING
PLC TROUBLESHOOTING

TROUBLESHOOTING
PLC TROUBLESHOOTING
PROFICY
PROFICY
PROFICY

TROUBLESHOOTING
PLC TROUBLESHOOTING

TROUBLESHOOTING
PLC TROUBLESHOOTING

TROUBLESHOOTING
PLC TROUBLESHOOTING
PROFICY

TROUBLESHOOTING
PLC TROUBLESHOOTING
PROFICY

TROUBLESHOOTING
PLC TROUBLESHOOTING
PROFICY
PROFICY
PROFICY
PROFICY

TROUBLESHOOTING
PLC TROUBLESHOOTING
PROFICY
PROFICY

TROUBLESHOOTING
PLC TROUBLESHOOTING
PROFICY

TROUBLESHOOTING
QUESTIONS

ECI II Troubleshooting

Diunggah oleh

Informasi Dokumen

Judul Asli

Hak Cipta

Format Tersedia

Bagikan dokumen Ini

Bagikan atau Tanam Dokumen

Opsi Berbagi

Apakah menurut Anda dokumen ini bermanfaat?

Apakah konten ini tidak pantas?

Hak Cipta:

Format Tersedia

ECI II Troubleshooting

Diunggah oleh

Hak Cipta:

Format Tersedia

TROUBLESHOOTING

ECI TOP DRIVE TRAINING

© 2013 Tesco Corporation. All rights reserved.

AT THE COMPLETION OF THIS SECTION YOU WILL BE

© 2013 Tesco Corporation. All rights reserved. 2

© 2013 Tesco Corporation. All rights reserved. 4

Closing the Main Breakers:

© 2013 Tesco Corporation. All rights reserved. 5

© 2013 Tesco Corporation. All rights reserved. 6

Enable, System Temperature, and Drive fault Reset:

© 2013 Tesco Corporation. All rights reserved. 7

© 2013 Tesco Corporation. All rights reserved. 8

Auxiliary Hydraulic Pump:

© 2013 Tesco Corporation. All rights reserved. 9

© 2013 Tesco Corporation. All rights reserved. 10

Pipe Handler Unlock:

© 2013 Tesco Corporation. All rights reserved. 11

© 2013 Tesco Corporation. All rights reserved. 12

Pipe Handler Lock:

© 2013 Tesco Corporation. All rights reserved. 13

© 2013 Tesco Corporation. All rights reserved. 14

© 2013 Tesco Corporation. All rights reserved. 15

© 2013 Tesco Corporation. All rights reserved. 16

© 2013 Tesco Corporation. All rights reserved. 17

© 2013 Tesco Corporation. All rights reserved. 18

© 2013 Tesco Corporation. All rights reserved. 19

© 2013 Tesco Corporation. All rights reserved. 20

© 2013 Tesco Corporation. All rights reserved. 21

© 2013 Tesco Corporation. All rights reserved. 22

DRS DRIVE PROTECTION

DRS Drive 'Disable' Conditions:

© 2013 Tesco Corporation. All rights reserved. 23

DRS DRIVE PROTECTION

DRS Drive 'Disable' Conditions:

© 2013 Tesco Corporation. All rights reserved. 24

DRS DRIVE PROTECTION

Main DRS (MD500) Breaker(s) Trip Conditions:

© 2013 Tesco Corporation. All rights reserved. 25

DRS DRIVE PROTECTION

Main DRS (MD500) Breaker(s) Trip Conditions:

© 2013 Tesco Corporation. All rights reserved. 26

DRS DRIVE INTERLOCKS

© 2013 Tesco Corporation. All rights reserved. 27

• Transient Voltage Surge Suppressor (TVSS)

© 2013 Tesco Corporation. All rights reserved. 28

• The TVSS is expendable and is designed to protect

© 2013 Tesco Corporation. All rights reserved. 29

© 2013 Tesco Corporation. All rights reserved. 30

MAIN DISTRIBUTION POWER

• No Power to Power Module Building (Main interface

MAIN DISTRIBUTION POWER

© 2013 Tesco Corporation. All rights reserved. 32

MAIN DISTRIBUTION POWER

© 2013 Tesco Corporation. All rights reserved. 33

MAIN DISTRIBUTION POWER

• Main Interface Breaker trips after closing.

© 2013 Tesco Corporation. All rights reserved. 34

MAIN DISTRIBUTION POWER

• Main Interface Breaker trips persistently.

© 2013 Tesco Corporation. All rights reserved. 35

MAIN DISTRIBUTION POWER

TESCO Main Service ESD Interface Troubleshooting

© 2013 Tesco Corporation. All rights reserved. 36