Maintenance Group Affected:

Electricians

Helmerich & Payne International Drilling Co.

Document Number: HP208-0008

AC Module and Generator Control

Troubleshooting Guide
Note:

While conducting these tests, all safety precautions and company policies must be
observed.

Revision: 01
Effective: 5-Mar-09

PAPER COPIES ARE UNCONTROLLED.

THE CONTROLLED VERSION OF THIS DOCUMENT CAN BE
FOUND ON THE HELMERICH & PAYNE IDC INTRANET.

Owner: RAMS Group

Author: Van Lee

AC Module Field Guide

Document Number HP206-0008
The following troubleshooting steps should be carried out before replacing AC module
Problem
Engine Will Not
Start

Possible Cause
Fuel Shut Off To Engine.

Magnetic Pickup
(Tach Sensor)

HOC Batteries

Remedy
Inquire with motorman to be sure
that the fuel lines are lined and
the filters are in good condition.

While engine is turning over,

check to see if the red LED light is
coming on at the front of the AC
Module. At pins 526 and 527 use
VOM to measure Vac across the
two wires. There should be a
minimum of 1 Vac for the engine
to start. With engine off, lift one
of the terminals and measure
resistance between the two wires.
The measurement should read
between 140 - 150 ohms. If the
measurement is above or below
the recommended readings,
adjust the tach sensor to meet the
setting.

If the LED indicator light does not

turn on while cranking the
engine, it is possible that the HOC
batteries are bad. Check the
output of the HOC batteries on the
AC Module using terminals 510
and 511. Terminal 510 should
read +12Vdc and terminal 511
should read -12Vdc in reference
to ground. (Terminal 501 on
module.) Check Vdc across the
terminals and the reading should
be no less than 24 Vdc. If less than
24Vdc, then replace or recharge
the batteries. If the voltage drops
while cranking the engine, then
replace the batteries.

Details

See Image 1.0

See images 1.1 and 1.2

See images 1.3 and 1.4

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AC Module Field Guide

Document Number HP206-0008

Engine Will Not

Start

Load Sharing

Throttle Circuit

Gauges

Throttle Signal

The throttle signal comes into the

AC Module at terminals 533 and
545. With one of the terminals
lifted, use VOM to measure
resistance between the two wires.
The meter reading should be
between 32-35 ohms. If the
circuit is open or shorted, check
throttle cable for knicks and cuts,
then repair the circuit.

See images 1.5 and 1.6

Check all gauges on individual

generator bays when offline to be
sure that the zero span is correct.
Use the screw head on the face of
the gauge to calibrate to zero.
Any tapping or touching the
gauge face will throw off the
readings. Do not adjust the
gauges when the generator is
online. This will produce false
readings.

See image 2.0

With the generators online, use

VOM to measure the Vdc output
of each AC Module. Measure on
terminals 533 and 545. When
load sharing properly, the
readings should be about the
same. If not, then with the
engines off, place the leads in line
with terminal 533.(Loosen
terminal 533 and place red meter
lead to terminal 533 and place
black lead on wire.) Start the
engine and leave in the run
position. DO NOT CLOSE
BREAKER AT THIS TIME. The
measures readings should fall
between 30-60ma. If the readings
are off, then follow the next steps.

See images 2.1 and 2.2

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AC Module Field Guide

Document Number HP206-0008
Load Sharing Cont.

PWM Module

Actuator

The PWM Module is located in the

engine control panel. The module
should be din rail mounted to keep
it from excessive engine heat.
(Refer to document HP201-0107
in the e-library.) Make sure the
module is in good condition and
not damaged in any way. When
checking resistance through the
cable, the readings should be
within 32-35 ohms. If not, check
the output of the resistor and
inductor. The resistor should read
19-20 ohms while the inductor
should read 5-7 ohms. If the
values are off, then replace the bad
component. If the inductor and the
resistor check good and the
throttle resistance is off, then
replace the PWM Module.

See Images 2.3-2.7

If the milliamp range is out of spec

(30-60ma) then the linkage needs
to be adjusted to bring the reading
into the required range. Set the
linkage to acquire a reading of 4045ma. Check all other actuators
for the correct milliamp range.

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AC Module Field Guide

Document Number HP206-0008
AC Module

AC Module Regulator
Transformer

Throttle Signal Output

Stop the engine to be tested before

taking measurements. Connect a
VOM to pins 1 and 2 of T-10(AC
Module regulator transformer).
This is the connection that will be
measuring 600 Vac. Set the meter
to measure frequency. Start the
engine and set it to RUN when
warmed up. Observe the VOM and
adjust the speed pot so it reads 60
HZ. Set the VOM to read Vac.
Observe the VOM and adjust the
voltage pot so it reads 600 Vac.
Compare these setting with the
hertz and volt meter on the sync
panel. Stop engine and remove
leads. If the measurements do not
line up with the sync panel, then
the AC module maybe bad.
Switch VOM to measure milliamps.
With engine off, remove the wire
from pin 533 on module. Attach
black lead to the wire and the red
lead to the terminal. Start the
engine and put it in RUN. DO NOT
CLOSE THE BREAKER AT THIS
TIME. When the engine is at 60HZ
and 600 volts, record the reading
on the meter. The reading should
fall between 30 and 60ma. If
outside the range either adjust the
linkage if using an actuator, or
after following this guide with
troubleshooting resistors and
inductor, replace the PWM Module.

See image 3.0 and 3.1

Record findings and

measurements in
RAMS service report to
be used to obtain an
RMA number.

See image 3.2

Record findings and

measurements in
RAMS service report to
be used to obtain an
RMA number.

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Effective Date: 5-Mar-09

AC Module Field Guide

Document Number HP206-0008
AC Module Cont.

Speed Feedback

AC Module Power Supply

After the throttle current signal is

within acceptable range, use VOM
to measure TP 19(Speed
Feedback) using terminal 501 as a
ground reference. TP 19 should
read between -2.5 at 60 HZ. If the
reading is off, then replace AC
Module.

See image 3.3

Record findings and
measurements in RAMS
service report to be used
to obtain an RMA
number.

When generator is running the

measure the following points in
reference to ground(501):
Terminal Pin 502 -

+16Vdc

Terminal Pin 503 -

-16Vdc

Terminal Pin 507 -

-160Vdc

Terminal Pin 508 -

+160Vdc

Terminal Pin 546 -

+11Vdc

Aux Board Pin 24 -

-11Vdc

Record findings and

measurements in RAMS
service report to be used
to obtain an RMA
number.

If the above voltages are not

present then replace the AC
Module.
Frequency Demodulator
Output

Using an oscilloscope, measure TP

5 on the AC Module for FDO
waveform. Compare to a known
working AC Module. If wave form
is wrong, then replace AC Module.

O-scope setting should be at

500mv with .5/V/DIV.

See Image 3.4

Record findings and
measurements in RAMS
service report to be used
to obtain an RMA
number.

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Revision: 01

Effective Date: 5-Mar-09

AC Module Field Guide

Document Number HP206-0008

Flashing the
Generator

Loss Of Field

Check all fuses in the generator

control cabinet. (Depending on
class of rig, the typical fuses that
blow will be F39 and F40.)

See Image 4.0

Remember: When dealing with

live circuits with high voltage, use
VOM to measure Vac across the
fuse. If voltage is measured, then
the fuses are bad.
Measure Vac across exciter field
on exciter card pin 2(+) and pin
10 (-). At full speed the residual
voltage should be between 15
20Vac. If this is not present, flash
the generator.

Flashing the Generator.

If the generator has just been

replaced, check to see if the
heater and exciter field cable are
terminated correctly. Pull off
back end of bell cover and inspect
diodes and MOV. Clean off diodes
and check them using a VOM.
(There is a diode setting on the
VOM.) Test all diodes and
compare. If the above checks out,
the generator needs to be flashed.
Using a 12Vdc battery(i.e. an HOC
battery), install jumpers on the
positive and negative leads of the
battery. While the engine is
running in idle, place the battery
leads on the exciter terminals
2(pos) and 10(neg) until the
voltage picks up at idle speed.
From there, the generator should
be ready to be set to full run
voltage. Adjust the speed and
voltage and put generator online.

See image 4.1

See Images 4.2 and 4.3

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AC Module Field Guide

Document Number HP206-0008

Example Images

Image 1.0

Image 1.1

Check Fuel Lines.

Image 1.2

Indicator Light

Image 1.3

Measure Tach Signal Resistance

HOC Batteries
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AC Module Field Guide

Document Number HP206-0008

Image 1.4

Image 1.5

Measuring between pins 501 and 510 for HOC

circuit.

Lift terminal 533 to measure resistance on

throttle circuit.

Image 1.6

Image 2.0

Measure resistance on throttle circuit.

Zero gauge face before bringing generator

online.
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Revision: 01

Effective Date: 5-Mar-09

AC Module Field Guide

Document Number HP206-0008
Image 2.1

Image 2.2

Measure Vdc across pins 533 and 545 to

compare load sharing.

With VOM set to read milliamps, measure pin

533 inline to view throttle signal current.

Image 2.3

Image 2.4

Engine control panel.

PWM module, resistor, and inductor.

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AC Module Field Guide

Document Number HP206-0008
Image 2.5

Image 2.6

Remove resistor.

Take measurement on the resistor.

Image 2.7

Image 3.0

Take measurement on the inductor.

Measure T-10 HZ output.

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AC Module Field Guide

Document Number HP206-0008

Image 3.1

Image 3.2

Measure T-10 Vac output.

Measure throttle output current.

Image 3.3

Image 3.4

Measure speed feedback on TP-19

TP-5 output waveform

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AC Module Field Guide

Document Number HP206-0008
Image 4.0

Image 4.1

Check Fuses F39 and F40

Flashing the Generator

Image 4.2

Exciter Board

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Revision: 01

Effective Date: 5-Mar-09