GDI PREVENTIVE MAINTENANCE INSTRUCTION Date: 15/04/10 Rev: 0

Maximo Ref. MPM-867-01-12 SFI Code 867-01

Equip.
SCR System
Description
Manufacturer Xi’an Equip. Location SCR Room

Model DDF-50D

MAINTENANCE SPECIFICATIONS

Frequency 6 Monthly Estimated Duration 4 Hours

Criticality 5 Area Authority Chief Electrician

Class Structure 2801 Failure Code EDSC

Craft Chief Electrician No. of Craft 1

SAFETY NOTES

• Complete required Permit-To-Work (PTW).

• Lockout / Tag-out Permit required.
• Review / Complete Job-Safety-Analysis (JSA).
• Inform Area authority if work is carried out on critical equipment for ongoing
operation.
• Do not wear jewellery when working around rotating machinery.
• Wear all proper safety equipment.

JOB PLAN INSTRUCTION

Check DC-SCR-system bay bridges for dirt accumulations. If excessively dirty blow out bay with
nitrogen(See figure 1). If dirt cannot be removed to an acceptable level then disassemble
1. bridge and clean all components (stagger procedure so work can be done with no down time).
Note; Unless bays are isolated from the 600-volt buss or you use insulated blankets, the bays
cannot be pulled out without shutting down the 600-volt buss.
Check firewall dividers (gasket insulators) for dirt build-up and for signs of overheating. Clean as
2.
required.
3. Check and tighten all buss connections in bay if found loose.

4. Check to ensure all terminal board, PLC, and circuit card connections are secure.
Tighten all connections to the dynamic braking resistor, if applicable, and inspect contact faces
5.
for pitting, excessive wear and any signs of overheating.
Inspect all remaining SCR Bay DC motor contactor faces for pitting, excessive wear and any
6.
signs of overheating.
7. Check trigger fuse microswitch for proper position. (See figure 2)
Function test to assure proper operation of the DC-SCR-system bays after completed inspection.
8.
(See figure 3)
Function test to assure proper operation of the AC-SCR-system bays after completed inspection.
9.
(See figure 4)

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 GDI PREVENTIVE MAINTENANCE INSTRUCTION Date: 15/04/10 Rev: 0

Maximo Ref. MPM-867-01-12 SFI Code 867-01

Equip.
SCR System
Description
Manufacturer Xi’an Equip. Location SCR Room

Model DDF-50D

FIGURES/DRAWINGS

Figure 1 example Mod 1500 generator/SCR cubicle

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 GDI PREVENTIVE MAINTENANCE INSTRUCTION Date: 15/04/10 Rev: 0

Maximo Ref. MPM-867-01-12 SFI Code 867-01

Equip.
SCR System
Description
Manufacturer Xi’an Equip. Location SCR Room

Model DDF-50D

Figure 2 trigger fuse micro switch

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 GDI PREVENTIVE MAINTENANCE INSTRUCTION Date: 15/04/10 Rev: 0

Maximo Ref. MPM-867-01-12 SFI Code 867-01

Equip.
SCR System
Description
Manufacturer Xi’an Equip. Location SCR Room

Model DDF-50D

Figure 3 example of function test for Ross Hill SCRs and SCR Bridges

Note; Ensure that SCR Unit to be tested will not be assigned from the Driller's Console.

• There are two separate tests: one for SCRs and one for SCR Bridges.

• Perform the appropriate test(s) after repairing or replacing any of the unit assemblies.

• If the unit under test fails to perform as indicated, refer to troubleshooting.

See Figure above for a front panel view of the DC Control Module.

The POWER ON LIGHT (Item 1 on Figure above) illuminates when power is applied to the DC
Control Module.

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 GDI PREVENTIVE MAINTENANCE INSTRUCTION Date: 15/04/10 Rev: 0

Maximo Ref. MPM-867-01-12 SFI Code 867-01

Equip.
SCR System
Description
Manufacturer Xi’an Equip. Location SCR Room

Model DDF-50D

The TEST SELECT SWITCH (Item 3 on Figure above) permits the operator to check the Contactor
(CONT) and Throttle Reference (REF) signals received from the SCR Control Cubicle. The TEST
SELECT SWITCH and TEST VOLTMETER (Item 2 on Figure above) are color coded. For example, if
the TEST SELECT SWITCH is set to one of the yellow CONT positions, the TEST VOLTMETER
needle will deflect to the yellow band to indicate a normal condition.

The SCR Bridge can be phased up for testing by setting the MANUAL VOLTAGE
SWITCH (Item 5 on Figure above) to ON and rotating the MANUAL VOLTAGE KNOB (Item 4 on
Figure above) clockwise. In the ON position, the MANUAL VOLTAGE SWITCH opens all of the
assignment contactors so that power is not applied to the DC traction motor.

Bridge voltage can be monitored at the SCR VOLTS TEST PINS (Item 7 on Figure above). The
voltage ratio is 16:1, such that the SCR VOLTS TEST PINS (Item 7 on Figure above) will represent
a bridge voltage of 750 VDC when the SCR VOLTS TEST PINS register 46.8 VDC.

An indication of Bridge current can be monitored at the SCR AMPS TEST PINS (Item 8 on Figure
above). The current/voltage ratio is 376:1, such that the SCR AMPS
TEST PINS represent 1,000 Amps of bridge current for each 2.66 VDC present on the SCR AMPS
TEST PINS.

The ZERO THROTTLE INTERLOCK LIGHT (Item 6 on Figure above) indicates the operational
status of the module circuit which suppresses the SCR Bridge Firing Reference. When the ZERO
THROTTLE INTERLOCK LIGHT is illuminated, the bridge voltage will be ZERO. It is illuminated
under the two following conditions:

1. SCR Unit is ON but not assigned to any of the DC functions.

2. SCR Unit is assigned to a function before the throttles are set to ZERO.

The light is not illuminated when the throttles are set to ZERO and assigned contactors PULL IN.

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 GDI PREVENTIVE MAINTENANCE INSTRUCTION Date: 15/04/10 Rev: 0

Maximo Ref. MPM-867-01-12 SFI Code 867-01

Equip.
SCR System
Description
Manufacturer Xi’an Equip. Location SCR Room

Model DDF-50D

SCR Unit Test

SCR unit test (concluded)

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 GDI PREVENTIVE MAINTENANCE INSTRUCTION Date: 15/04/10 Rev: 0

Maximo Ref. MPM-867-01-12 SFI Code 867-01

Equip.
SCR System
Description
Manufacturer Xi’an Equip. Location SCR Room

Model DDF-50D

SCR Bridge test

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 GDI PREVENTIVE MAINTENANCE INSTRUCTION Date: 15/04/10 Rev: 0

Maximo Ref. MPM-867-01-12 SFI Code 867-01

Equip.
SCR System
Description
Manufacturer Xi’an Equip. Location SCR Room

Model DDF-50D

SCR Bridge test (concluded)

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 GDI PREVENTIVE MAINTENANCE INSTRUCTION Date: 15/04/10 Rev: 0

Maximo Ref. MPM-867-01-12 SFI Code 867-01

Equip.
SCR System
Description
Manufacturer Xi’an Equip. Location SCR Room

Model DDF-50D

SCR test

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 GDI PREVENTIVE MAINTENANCE INSTRUCTION Date: 15/04/10 Rev: 0

Maximo Ref. MPM-867-01-12 SFI Code 867-01

Equip.
SCR System
Description
Manufacturer Xi’an Equip. Location SCR Room

Model DDF-50D

SCR test (concluded)

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 GDI PREVENTIVE MAINTENANCE INSTRUCTION Date: 15/04/10 Rev: 0

Maximo Ref. MPM-867-01-12 SFI Code 867-01

Equip.
SCR System
Description
Manufacturer Xi’an Equip. Location SCR Room

Model DDF-50D

Figure 4 example of function test to assure proper operation of the AC-SCR-system

Perform the functional tests given in Tables 2-2 through 2-6 after repairing/replacing any assembly.
Perform the Reverse Power Trip and Engine Mechanical Overspeed tests listed in Table 2-4 once a
month.

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 GDI PREVENTIVE MAINTENANCE INSTRUCTION Date: 15/04/10 Rev: 0

Maximo Ref. MPM-867-01-12 SFI Code 867-01

Equip.
SCR System
Description
Manufacturer Xi’an Equip. Location SCR Room

Model DDF-50D

Table 2-2 Engine/Generator Unit Functional Test

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 GDI PREVENTIVE MAINTENANCE INSTRUCTION Date: 15/04/10 Rev: 0

Maximo Ref. MPM-867-01-12 SFI Code 867-01

Equip.
SCR System
Description
Manufacturer Xi’an Equip. Location SCR Room

Model DDF-50D

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 GDI PREVENTIVE MAINTENANCE INSTRUCTION Date: 15/04/10 Rev: 0

Maximo Ref. MPM-867-01-12 SFI Code 867-01

Equip.
SCR System
Description
Manufacturer Xi’an Equip. Location SCR Room

Model DDF-50D

14
 GDI PREVENTIVE MAINTENANCE INSTRUCTION Date: 15/04/10 Rev: 0

Maximo Ref. MPM-867-01-12 SFI Code 867-01

Equip.
SCR System
Description
Manufacturer Xi’an Equip. Location SCR Room

Model DDF-50D

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 GDI PREVENTIVE MAINTENANCE INSTRUCTION Date: 15/04/10 Rev: 0

Maximo Ref. MPM-867-01-12 SFI Code 867-01

Equip.
SCR System
Description
Manufacturer Xi’an Equip. Location SCR Room

Model DDF-50D

16
 GDI PREVENTIVE MAINTENANCE INSTRUCTION Date: 15/04/10 Rev: 0

Maximo Ref. MPM-867-01-12 SFI Code 867-01

Equip.
SCR System
Description
Manufacturer Xi’an Equip. Location SCR Room

Model DDF-50D

17
 GDI PREVENTIVE MAINTENANCE INSTRUCTION Date: 15/04/10 Rev: 0

Maximo Ref. MPM-867-01-12 SFI Code 867-01

Equip.
SCR System
Description
Manufacturer Xi’an Equip. Location SCR Room

Model DDF-50D

Table 2-2 Engine/Generator Unit Functional Test (Concluded)

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 GDI PREVENTIVE MAINTENANCE INSTRUCTION Date: 15/04/10 Rev: 0

Maximo Ref. MPM-867-01-12 SFI Code 867-01

Equip.
SCR System
Description
Manufacturer Xi’an Equip. Location SCR Room

Model DDF-50D

Table 2-3. AC Control Module Functional Test

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 GDI PREVENTIVE MAINTENANCE INSTRUCTION Date: 15/04/10 Rev: 0

Maximo Ref. MPM-867-01-12 SFI Code 867-01

Equip.
SCR System
Description
Manufacturer Xi’an Equip. Location SCR Room

Model DDF-50D

20
 GDI PREVENTIVE MAINTENANCE INSTRUCTION Date: 15/04/10 Rev: 0

Maximo Ref. MPM-867-01-12 SFI Code 867-01

Equip.
SCR System
Description
Manufacturer Xi’an Equip. Location SCR Room

Model DDF-50D

Table 2-3. AC Control Module Functional Test (Concluded)

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 GDI PREVENTIVE MAINTENANCE INSTRUCTION Date: 15/04/10 Rev: 0

Maximo Ref. MPM-867-01-12 SFI Code 867-01

Equip.
SCR System
Description
Manufacturer Xi’an Equip. Location SCR Room

Model DDF-50D

Table 2-4. Protection Circuit Functional Test

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 GDI PREVENTIVE MAINTENANCE INSTRUCTION Date: 15/04/10 Rev: 0

Maximo Ref. MPM-867-01-12 SFI Code 867-01

Equip.
SCR System
Description
Manufacturer Xi’an Equip. Location SCR Room

Model DDF-50D

Table 2-6. Calibration Procedure for Woodward EG-B 10P Actuators Used on EMD
Engines

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