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Ross Hill and Hill Graham AC, DC and FR Module Testing

AC and DC Module Testing

AC Module Testing

AC Simulator
AC Simulator

Our unique, variable frequency simulator allows us to fully simulate all AC Module functions for rapid and fault-finding and accurate calibration. Because we use a simulator rather than a full-size, working generator we are able to emulate extreme and unusual conditions without risk of damage to the module or other equipment. Our objective is to test the module, not equipment connected to it!

Using our simulator we can simulate the following essential functions:

  • Overfrequency - with the AC Module running on demodulator or pulse-pick-up speed feedback
  • Underfrequency
  • Loss of Pulse Pick-Up
  • Overvoltage
  • Undervoltage
  • Reverse power
  • Hands-Off-Starting (HOC)
  • Speed Regulation
  • KW Load Sharing (Master/Slave)
  • KVAR Load Sharing (KVAR Droop)
  • Exciter Firing
  • KW and KVAR Demodulators and Instrumentation
  • Diagnostic Functions (Front Panel Meter and Switch)

Each AC Module undergoes a rigorous set tests and is awarded a test certificate which details results of tests and records key measurements. A detailed description of faults found and their possible consequences is included wehere applicable.

DC Module Testing

Hill Graham Controls incorporated a large number of variations to the standard Ross Hill DC Module. Using our DC Simulator we are able to test and repair these modified versions safely and accurately as well as testing and repairing standard units from Ross Hill Controls. In many cases we are able to implement these modifications to new or old modules. This is particularly useful where spares and replacements are required. Modifications include:

DC Simulator
DC Simulator
  • DW Regenerative Braking - replaces the Dynamic Brake with a regenerative version (needs external mods to retrofit)
  • RT Regulator - more accurate speed regulation for Top Drives
  • DC Regulator Auxiliary II - exploits the full power range of the DC Motor within commutation limits by current limit profiling
  • Stall Protection - safely shuts down a motor when stalled for too long
  • Power Swivel Protection- protective functions for Top Drives
  • DWDB Retrofit - improves Dynamic Brake performance, especially for Series Motors
  • DW Override - higher current limit for tight hole emergencies

Using our DC Simulator we are able to perform the following test and calibration sequences safely and accurately:

  • Speed Regulation
  • Current Limits and Dead Bands
  • Firing Circuits
  • Zero Throttle Interlock (ZTI)
  • Overcurrent Protection
  • Dynamic Braking
  • Slave Circuits
  • Power Limit
  • Diagnostic Functions (Front Panel Meter and Switch)

Each DC Module undergoes a rigorous set tests and is awarded a test certificate which details results of tests and records key measurements. A detailed description of faults found and their possible consequences is included where applicable.

FR Module Testing

FR Simulator
FR Simulator

Our unique Field Regulator Simulator allows us to quickly, comprehensively and accurately test Hill Graham Field Regulator Modules. The module was produced in two basic configuratios: Single Field for applications such as Rotary table, Top Drive or single motor Mud Pumps or Drawworks, and Dual Field for dual motor Mud Pumps and Drawworks. We test the following:

  • Field Current Regulation
  • Field Current Settings and Selection
  • Field Weakening
  • External Field Trim
  • Firing Circuits
  • Field Loss Protection
  • Overcurrent Protection
  • Mud Pump Load Balancing
  • Unbalance Protection
  • Annunciators
  • Metering

Each FR Module undergoes a rigorous set tests and is awarded a test certificate which details results of tests and records key measurements. A detailed description of faults found and their possible consequences is included wehere applicable.

AutoSync AC Module Testing

In the early 1980's Ross Hill developed the ACII Module, also called the AutoSync Module. The AautoSync Module was an ambitious attempt to incorporate more features and functionality into the AC Module, which included building the Exciter PCB into the module, improved load sharing, more comprehensive fault annunciation and metering, and synchronisation to the main bus.

This means that the AutoSync Module is considerably more complex than the standard AC Module and consequently difficult to troubleshoot and repair.

We use our standard AC Simulator with an adapter interface to conduct a comprehensive set of tests and calibrations to return your AutoSync Modules to full health, including:

AutoSync Adapter
AutoSync Adapter
  • Overfrequency
  • Underfrequency
  • Loss of Pulse Pick-Up
  • Overvoltage
  • Undervoltage
  • Reverse Power
  • Hands-Off-Starting (HOC)
  • Speed Regulation
  • KW Load Sharing
  • KVAR Load Sharing
  • Exciter Build-Up
  • Exciter Regulation
  • KW and KVAR Demodulators and Instrumentation
  • Synchronising

Each AutoSync Module undergoes a rigorous set tests and is awarded a test certificate which details results of tests and records key measurements. A detailed description of faults found and their possible consequences is included where applicable.

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