TDS4STrouble Shooting Guide

2

All information contained in this manual is based upon the latest product information available at the time of

printing. We reserve the right to make changes at any time without notice. No part of this publication may be

reproduced, stored in retrieval systems, or transmitted in any form by any means, electronic, mechanical,

photocopying, recording or otherwise, without the prior written permission of Varco Systems. This includes text,

figures and tables.

This manual is divided into 8 sections. The first page of each section is marked with a black tab that lines up with

one of the thumb index tabs on this page and the back cover. You can quickly find the first page of each section

without looking through a full table of contents.

Detailed descriptions of standard workshop procedures, safety principles and service

operations are not included. Please note that this manual does contain warnings which could

cause PERSONAL INJURY, or could damage equipment or make it unsafe. Please understand

that these warnings cannot cover all conceivable ways in which service, whether or not

recommended by Varco Systems, might be done, or the possible hazardous consequences of

each conceivable way. Nor could Varco Systems investigate all such ways. Anyone using

service procedures or tools, whether or not recommended by Varco Systems, must be

thoroughly satisfied that neither personal safety nor equipment safety will be jeopardized.

Special Information

Diagramatic Symbols

Notes, Cautions and Warnings

Beginning or Endingof Sequence

TroubleshootingInstructions Driller’s Action

Question

PageReference

Introduction

REV -© 2001 Varco Systems All rights reserved

How to Use This Manual

!

i

!

(Note) Gives helpful information.

(Caution) Indicates a possibility of personal injury or equipmentdamage if instructions are not followed.

(Warning) Indicates a strong possibility of severe personalinjury or loss of life if instructions are not followed.

4

3

4

5

6

7

8

1

2

TDS-4S/4H Troubleshooting Guide

IBOPTroubleshooting

PipehandlerTroubleshooting

Counterbalance andMotor Alignment Cylinder

Troubleshooting

Drilling Motor Housing,Brake and Guide Dolly

Troubleshooting

General Information

Drill/Spin/TorqueTroubleshooting

Service Centers

Appendix

3

4

5

6

7

8

General Information

1

2


Varco Driller's Console (VDC)............................. 1-3

Varco Driller's Console (VDC) Description ......... 1-4

Special tools ....................................................... 1-9

Drilling Operational Problems ............................ 1-10

1-2

1

Varco

General Information

3

4

5

6

7

8

General Information

1

2

Varco

1-3

1


General Information

Varco Driller's Console (VDC)

G G GR

RA

A

RR

RR

R

R

C C

A

TOR

QU

ER

PM

DR

ILL

TAB

LE

0

RO

TAR

Y

BLO

WE

R L

OS

S(B

LOW

ER

CA

NC

EL)

SP

IN

TOR

QU

E

OV

ER

TE

MP

MA

X

DR

IVE

TOP

AIR

OIL

OV

ER

TE

MP

OIL

PU

MP

LO

SS

CU

RR

EN

T L

IMIT

MA

KE

-UP

"OF

F"-

FR

EE

RO

TAT

E"O

N"-

AU

TO S

TOP

SIL

EN

CE

C

HE

CK

ALA

RM

LA

MP

LOW

GE

AR

GE

AR

HIG

H

RIG

HT

LEF

T

RO

TAT

ING

HE

AD

FIE

LD A

MP

S

3040

57

OF

F

RE

TR

AC

T

PU

SH

& H

OLD

TOR

QU

E W

RE

NC

H

OP

EN

OF

FO

N

RB

SIB

OP

CLO

SE

HO

LDF

LOAT

LIN

K T

ILT

EX

TE

ND

AU

TOB

RA

KE

ON

IBO

PC

LOS

ED

ON

BR

AK

ES

TALL

TD

S

CR

OW

N C

LEA

RA

NC

E2

FE

ET

(F

LAS

HIN

G)

5 F

EE

T (

ST

EA

DY

)

CR

OW

N C

LEA

RA

NC

E10

FE

ET

EX

TE

ND

OF

FB

LOC

K

RE

TR

AC

T

STA

RT

/STO

PH

PU

#3

STA

RT

/STO

PH

PU

#2

DIS

AB

LET

DS

PR

ES

S L

OS

SV

DC

HP

U #

1S

TAR

T/S

TOP

OF

FO

N

RB

SD

EP

LOY

ED

AIR

ELE

VAT

OR A

RM

ED

TO

CLO

SE

OP

EN

Technical DrawingsTechnical DrawingsTechnical Drawings

1-4

1

Varco

General Information

Varco Driller's Console (VDC) Description


MAKE-UP CURRENT LIMIT

Type

Sets the current limit in the VFD when using the Top Drive to make connections. The torque canbe adjusted by turning the potentiometer to increase or decrease the torque.

FunctionName

Potentiometer

OIL PRESS LOSSIndicator flashes and horn sounds when an oil pressure loss in the gearcase lubrication system is detected.

Red indicator

VDC PRESS LOSSIndicator flashes and horn sounds when a loss of purge pressure in the VDC is detected.

Red indicator

DRILL MOTOR OVERTEMPIndicator flashes and horn sounds if there is an overtemperature condition in one or both of the AC drilling motors.

Red indicator

DRILL/SPIN/TORQUEThe switch is in the DRILL mode during normaldrilling. SPIN mode is fixed speed and current signal to the AC motors. TORQUE mode is a fixed speed with gradual rise in torque up to the make-up value set by the make-uppotentiometer when in FORWARD mode.When in REVERSE the torque value rises tomaximum until the connection is broken.

3-Position selector switch (with TORQUE position momentary)

BLOWER LOSSIndicator flashes and horn sounds if there is a failure in one or both of the air cooling motors.

Red indicator

ALARM SILENCE/LAMP CHECKWhen any alarm indicator light flashes and the horn sounds,press the switch to silence the horn. However, the fault indicator that caused the alarm to sound remains lit until the fault is cleared or reset. If the fault is not cleared within 5 minutes, the alarm horn sounds again. When this switch is pressed and held for 2 seconds, it lights all of the indicators on the VDC for a lamp check.

Pushbutton switch

HYDRAULIC POWER AUTO/ONWhen set to AUTO, turns on hydraulic pump when commanded by the PLC. When set to ON, turns on hydraulic pump regardless of operating mode.

2-Position switch

1-5

1


General Information



Type FunctionName

(PIPEHANDLER) ROTATE LEFT/RIGHTTurning the spring-operated switch to the leftmoves the drill pipe elevator to the left, and turning the switch to the right moves the drillpipe elevator to the right. The switch automatically returns to center (off) position when released.NOTE: This works only after the LINK TILTFLOAT switch is pressed.

3-Position momentary switchwith center off

(PIPEHANDLER) LINK TILT FLOATThe elevator links “float” to the center (neutral) position when pushbutton is pushed, thus thepipe handler can then be rotated.

Pushbutton switch

(PIPEHANDLER) TORQUE WRENCH PUSH & HOLDWhen pressed and held, rotates pipehandler to engage shot pin, which will engage pipe clamp.NOTE: Torque wrench cannot clamp with the brake on or throttle open.

Pushbutton switch

(PIPEHANDLER) LINK TILT DRILL/OFF/TILTWhen set to DRILL, link tilt cylinders are retracted to place the elevators in the drill downposition. When set to TILT, link tilt cylinders are extended to tilt the elevators derrickman or mousehole. When set to OFF, the elevators remain in its present position until LINK TILTFLOAT is pushed.

3-Position maintained switch

BRAKE ONIndicator illuminates when the brake solenoid valve is energized.

Red indicator

BRAKE OFF/AUTO/ONWhen set to ON, the brake solenoid is energized to set the brakes and light the BRAKE ON indicator. When set to AUTO, the brake is released when THROTTLE is advanced and is set when THROTTLE is turned off. When set to OFF, the brake is released. The brake will will energize if there is a drive fault with the VFD,regardless of switch position.

3-Position switch

1-6

1

Varco

General Information


IBOP CLOSED

Type

Illuminates when hydraulic pressure is applied to the cylinder that closes the IBOP valve.

FunctionName

Amber indicator

IBOP OPEN/CLOSE

OPEN position extends the actuator cylinder to open the IBOP valve. CLOSE position retracts the actuator cylinder to close the IBOP valve.

2-Position switch

DRILL TORQUE: 0 to MAX Continuous

Sets current limit in VFD during drilling operations. This sets the maximum allowable drill pipe torque. The torque is adjusted by setting the brake and adjusting the DRILL TORQUE potentiometer to increase or decrease the torque as indicated on the TORQUE meter.

Potentiometer

TORQUE: 0 to Full Scale

Displays drill pipe torque in ft lb. In drilling mode, torque is set by DRILL TORQUE potentiometer and in makeup mode, by MAKE-UP CURRENT LIMIT potentiometer.

Meter (0 - 10 VDC)

RPM: 0 to 250 rpm

DC Panel

Multi-Field

RBS

Displays drill pipe rotational speed in rpm. Rotational speed is controlled by the THROTTLE control.

Meter (0 - 10 VDC)

TD/RT switch

30/40/57 AMP switch

RBS (Deployed IND) switch

Turning the switch to the TD position selects the Top Drive control mode, and turning the switch to the RT position selects the Rotary Table control mode. The Top Drive and Rotary Table will never operates simultaneously. If a transfer panel is not used, this switch is not required.

This is a three position maintained switch for field Current selection. The three positions are 30A, 40A and 57A. These are used to control the active field current outputs and allow efficient control of SCR field supplies so that operating rnage of motor can be adjusted.

The RBS ON/OFF selector switch provides the control power to RBS solenoids, and the RBS deployedindicator light illuminates when the RBS is moved from the stored position. This will ware the driller if the RBS were to mistakenly come out of its sotred position and present a collision hazard.


1-7

1


General Information


TDS Z Purge

Type FunctionName

TDS pressure loss indicator

VDC Z Purge

VDC pressure loss indicator

TDS Expo PurgeTDS purge loss indicator

TDS Expo PurgeTDS purge proceeding indicator

TDS Expo Purge

TP/VDC Expo Purge

TDS purge complete indicator

TDCS purge loss indicator

HPU

Water Pump

Rotating Head

HPU switch

Water pump switch

Rotate left/right switch

Depress this illuminated pushbutton energizes the HPU motor starter and illuminates the indicator. Depress the switch a second time de-energizes the HPU motor starter and turns the indicator off.

Depress this illuminated pushbutton energizes the water pump motor starter and illuminates the indicator. Depress the switch a second time de- energizes the water pump motor starter and turns the indicator off.

Deleted, same as (pipehandler) Rotate Left/ Right 3-position selector switch spring return to center.

Indicator flashes and horn sounds when a loss of purge pressure in the Top Drive motor is detected.

Same as "VDC PRESS LOSS".

Indicator flashed and horn sounds when a loss of purge pressure in the TOP Drive motor is detected.

Indicator illuminates when pressure switch in the protection units monitor the pressure and provide an alarm signal in the event of purge pressure loss.

Indicator illuminates when switches in the purge control system monitor the correct purge air flow, purge pressure and preset purge time are reached.

Indicator flashes and horn sounds when either transfer Panel or VDC purge pressure loss in the Expo Purge Control System.


1-8

1

Varco

General Information



Crown Clearance

TDS Stall

Field Loss

Gear Indicator

Elevator Control

TDS Disable

Block

Crown clearance indicator

TDS stall indicator

Field loss indicator

High/low gear indicator

Open/close indicator

2- Position Maintain

3- Position Maintain

Amber indicator illuminates when Top Drive hits 10 feet target. Red indicator illuminates when Top Drive hits 5 feet target. At 2 feet red indicator flashes and horn sounds. Alarm acknowledge does not stop the indicator from flashing, but does silence the horn.

Type FunctionName

Indicator flashes and horn sounds if DC motor stalls, the controls will automatically slowly ramp down torque to prevent damage to the DC motor communicator bars and extend brush life. TDS stall indicator on steady means that overpower protection is active and will ramp speed to a save limit.

Indicator flashes and horn sounds if the Activefield Supply for Varco Top Drive and customersshunt wound Rotary Table motor is loss.

Clear indicator illuminates when the high gear proximity is detected. A separate clear indicator is provided for low gear. TDS-4 is equipped with two proximity switches to detect High/Low gear the Top Drive is in. This allows the controls to compute correct torque output for the torque meter.

When switch is in the open position, energize Elevator open solenoid. The elevator will be in the open position.

When set to "ON", disables the TDS Dolly Retract System and other functions on the TDS. This switch can be customized for a particular rig. i.e. With PRHA, Link Tilt function on PRHA remains operable. When set to "OFF", Enables the TDS Dolly Retract System and other TDS functions.

"EXTEND", Block Dolly and TDS Dolly Extend towell center. "RETRACT", Block Dolly and TDSDolly retract to full retracted position. "OFF", blockdolly and TDS dolly maintain present position.Note: When TDS DISABLE switch is set to "ON"only Block Dolly Extends and Retracts.

1-9

1


General Information

Special Tools

• Multimeter

• Small, Medium, and Large Flat Blade Screwdrivers

• Standard Mechanical Tools

• 0-10V, 4-20mA Signal Generator (for advanced troublehshooting)

• Clamp-On Amp Meter

Troubleshooting in Drill/Spin/Torque Modes

• Multimeter

• Standard Mechanical Tools

• Stauff (hydraulic) Test Kit (P/N 940315-1000)

• Nitrogen Fill and Gauge Kit (P/N 170001)

• Clamp-On Amp Meter

Troubleshooting the IBOP, Torque Wrench, Rotating Head, Link Tilt, Blower Motor and Brake


1-10

1

Varco

General Information

Drilling Operational Problems

DrillingOperational

Problem

Is it aSpin

Problem?

Yes

No

Yes

No

Yes

No

Is it aTorque

Problem?

Yes

No

Is it aLink TiltProblem

?

Yes

No

Is it aBrake

Problem?

Yes

No

Is it anIBOP

Problem?

Yes

No

Is it aTorqueWrenchProblem

?

Call Field Service

SeePage

3-3

Yes

No

Is it aRotating Head

Problem?

SeePage

6-24

Yes

No

Is it aRetract

Guide DollyProblem

?

SeePage

6-7

Yes

No

Is it anAlignmentCylinderProblem

?

SeePage

5-6

SeePage

2-22 See

Page

2-25

SeePage

2-24See

Page

2-26

Is it aDrill

Problem?

SeePage

2-20

SeePage

6-4See

Page

6-5

SeePage

4-14

SeePage

4-3

Is it aTransmission

Problem?

Yes

No

Yes

No

Is it aCounterbalnce

Problem?

Yes

No

No

Is it aCooling System

Problem?

SeePage

6-16

YesIs it aLube System

Problem?

SeePage

6-14

SeePage

6-10

SeePage

5-3


2-1

2



3

4

5

6

7

8


1

2


Initial Startup.......................................................... 2-3

Fault and Alarm Problems .................................... 2-4VDC/Lamp Test Fault .................................................... 2-5

Field Loss Fault or Alarm .............................................. 2-6

Assignment Fault ........................................................... 2-7

Incorrect Rotation/Torque Problems ................... 2-8Rotation Incorrect .......................................................... 2-9

Wrong Direction............................................................. 2-10

Drill Torque Incorrect ..................................................... 2-11

No Rotation Problems ........................................... 2-12No Rotation and No Torque .......................................... 2-13

No Rotation and Hi Torque ............................................ 2-14

Speed Control Problems....................................... 2-15Speed Control Problems (Drill Mode) ............................ 2-16

Speed Control Problems (Spin Mode) ........................... 2-17

Speed Control Problems (Torque Mode)....................... 2-18

Mode Problems...................................................... 2-19Drill Mode Problems ...................................................... 2-20

Spin Mode Problems ..................................................... 2-21

Torque Mode Problems ................................................ 2-22

Set to Spin/Torque/Spin Out Problems................ 2-23Set to Spin ..................................................................... 2-24

Set to Torque (Make-Up Connection)............................ 2-25

Spin Out Problem .......................................................... 2-26

2-2

2

Varco


3

4

5

6

7

8


1

2

Varco

2-3

2



Initial Startup

FunctionalChecklist

SeePage

2-5

SeePage

2-7

SeePages

2-24

SeePage

2-11

SeePage

2-9

No

Yes

Yes

Perform Lamp Test

IsLamp Test

Good?

ContinueOperations

Switch toDRILL Mode

No

Throttle OFF

Faultsor

Alarms?

No

Yes

• Ensure SCR is ON•Assign FORWARD

Check VDC Purge(see page 2-5)

Faultsor

Alarms?

No

ThrottleON

IsRotationCorrect

?

Yes

NoDid DrillTorque Set

Okay?

Yes

NoDoes SPINMode Work

?

Yes

SeePages

2-25NoDoes

TORQUEMode Work

?

Yes

Set DrillTorque Limit

Use the DRILL/SPIN/TORQUE selector switch

Turn clockwise from the fully counterclockwise position to enable the SCR and set the throttle reference

Check hand throttle and switch position

Set brake to AUTO



Turn throttle OFF Set the brake Turn throttle ON Increase torque limit (turn clockwise)

until desired torque is reached Turn throttle OFF Release the brake

Press lamp check button

All lamps should light upafter a 2 second delaywhen lamp check button is pressed

Turn fully counterclockwiseto disable the SCR and set the throttle reference at zero

Lube oil pump starts Blower starts Field comes on


2-4

2

Varco


Fault and Alarm Problems


Symptom Probable Cause Remedy

Lamp test failed.

VDC pressure loss alarm.

Over speed light "ON" SCR interface board.

One or more of the VDC lamps failed.

Pressure disrupted at VDC.

Pressure switch failure.

Incorrect PLC inputs.

VDC gasket seal failure.

Field loss.

Check lamp(s).

Check PLC output.

Check power supply.

Check pressure at VDC and adjust as necessary.

Check pressure switch. Repair or replace as necessary.

Check PLC inputs.

Check gasket seal. Repair or replace as necessary.

Confirm field enabled signal from PLC.

Check field supply loss contact drawing numbers for the rigs.

Check for input on the PLC module.

Check field supply wiring.

Check voltage.

Check field supply current (should match the VDC field amp setting).

Refer to field supply manual.

SeePage

2-5

SeePage

2-5

SeePage

2-6

2-5

2



VDC/Lamp Test Fault

Lamp Test Failed

One or more ofthese lamps failed:

• Oil Overtemp• Air Overtemp• Blower Loss• VDC Pressure Loss• HPU#1 Start/Stop• HPU#2 Start/Stop• HPU#3 Start/Stop• Auto Stop/Free Rotate• High Gear• Low Gear• TDS Stall• Crown Clearance (2)• RBS Deployed• IBOP Closed• Brake On

• Check Lamp• Check PLC Output• Check Power Supply

Check PLC input using applicable Interconnect Diagram and PLC Software

Check PLC output using applicable Interconnect Diagram and PLC Software

Input lights when contacts on switch closes Output lights when output is commanded

by PLC

VDC Pressure LossAlarm

No

DidYou Find

Cause andFix It

?

Call Field Service

ContinueOperations

Yes

No

DidYou Find

Cause andFix It

?

Call Field Service

ContinueOperations

Yes

• Check Air Pressure at VDC• Check Pressure Switch• Check PLC Inputs• Check VDC Gasket Seal


2-6

2

Varco


Field Loss Fault or Alarm

Over Speed Light ONSCR Interface Board

No

DidYou Find

Cause andFix It

?

Call Field Service

Call Field Service

ContinueOperations

ContinueOperations

Yes

No

DidYou Find

Cause andFix It

?

Yes

No

IsThereFieldLoss

?

Yes

• Confirm Field Enabled Signal from PLC• Check Field Supply Loss Contact Drawing Numbers for the Rigs• Check for Input on the PLC Module• Check Field Supply Wiring• Check Voltage• Check Field Supply Current (should match the VDC field amp setting)

Refer to Field SupplyManual


2-7

2



Assignment Fault


Fault or AlarmAfter Assignment

BlowerLossAlarm

?

No

Yes

Yes

No

FieldLoss

?

SeePage

6-20

OilPressure

Alarm?

No

YesSee

Page

6-14

SeePage

2-6

Call Field Service

SeePage

6-15

2-8

2

Varco


Incorrect Rotation/Torque Problems


No/minimal rotation and hi torque.

Speed control problems.

Turning in wrong direction.

Drill torque incorrect.

Brake is engaged.

Transmission locked.

SCR interface card failure.

SCR system failure.

Adverse well conditions.

FORWARD/REVERSE incorrectly selected.

FORWARD/REVERSE switch failure.

Incorrect input to PLC.

Incorrect input to SCR.

Throttle micro switch failure.

Torque amp curves incorrect.

Motor deteriorating.

Hall-effect device meter out of calibration.

Check if brake is engaged.

Check for locked transmission.

Check SCR interface card.

Check SCR system.

Check well conditions.

Throttle OFF, change direction assignment, throttle ON.

Verify FORWARD/REVERSE switch function.

Verify correct input to PLC.

Verify correct input to SCR.

Verify throttle micro switch operation.

Check torque amp curves.

Verify torque with Hall-effect device meter.

Calibrate meter. Verify torque.

SeePage

2-10


2-9

2



Rotation Incorrect

Rotationis not Correct

No

NoRotation

andNo Torque

?

Yes

No

No orMinimal

Rotation andHi Torque

?

Yes

No

SpeedControl

Problems?

Yes

No

WrongDirection

?

Yes

ContinueOperations

SeePage

2-13

SeePage

2-14

SeePage

2-10

• Check if Brake is Engaged• Check for Locked Transmission

• Check SCR Interface II Card• Check Stump/ Cyclops Card• Check Speed/ Torque II Card• Check SCR System• Consider Well Conditions

NoDidYou Find

Cause andFix It

?

ContinueOperations

Yes

SeePage

2-16

NoDidYou Find

Cause andFix It

?

ContinueOperations

Yes


2-10

2

Varco


Wrong Direction

WrongDirection

Throttle OFF,Change Direction

Assignment,Throttle ON

• Verify FORWARD/ REVERSE Switch Function• Verify Correct Input to PLC• Verify Correct Input to SCR• Was Throttle Turned OFF Before Direction Change Selected• Verify Throttle Micro Switch Operation• Verify Assignment Contactor Position

ContinueOperations

ContinueOperations

Yes

No

DidYou Find

Cause andFix It

?

Yes

No GoingCorrect

Direction?

Yes

NoIs

FORWARD/REVERSECorrectlySelected

?

Call Field Service


2-11

2



Drill Torque Incorrect


Drill TorqueIncorrect

No

YesDrill

TorqueLow/High or

Erratic?

Switch toDRILL Mode

Verify Torque withClamp-On Amp

MeterCreate Torque

Amp Curves Diagram


SeePage

2-20

SeePage

8-55

ContinueOperations

Yes

No

DidYou Find

Cause andFix It

?

Call Field Service

2-12

2

Varco


No Rotation Problems


Not Rotating in spin mode.

Throttle and current limit signals not present.

SCR not enabled.

Brake indicator is ON.

No downhole torque.

Voltage at throttle potentiometer failure.

Enable signal at throttle (microswitch) failure.

Throttle volts at card rack failure.

Cabling for short or open circuits failure.

SCR control console operation failure.

SCR interface card failure.

SCR failure.

Brake is ON.

Wiring is incorrect.

PLC in puts and outputs not functioning properly.

Brake stuck ON.

Motor incorrectly wired.

SCR assignment and retest failure.

SCR failure.

Verify voltage at throttle potentiometer.

Verify enable signal at throttle (microswitch).

Verify throttle volts at card rack.

Check cabling for short or open circuits.

Check SCR control console operation.

Check SCR interface card.

Check SCR.

Cycle brake ON to OFF.

Check wiring.

Check PLC inputs and outputs.

Check if brake is stuck ON.

Check motor wiring.

Change SCR assignment and retest.

Check SCR.


2-13

2



No Rotation and No Torque

No Rotationand No Torque

No

Yes

Yes

Make Sure DrillTorque Limit isNOT at zero andThrottle is ON

Verify InitialStartup

(see page 2-3)

Doesit Rotate

?

Try to Operatein SPIN Mode

No

Yes

• Check SCR

• Check SCR Control Console Operation• Check SCR Interface Card

AreThrottle

and CurrentLimit Signals

Present?

NoDid it

Rotate inSPINMode

?

NoIs

SCREnabled

?

• Verify Voltage at Throttle Potentiometer• Verify Enable Signal at Throttle (microswitch)• Verify Throttle Volts at Card Rack• Check Cabling for Short or Open Circuits

No

DidYou Find

Cause andFix It

?

Call Field Service

No

DidYou Find

Cause andFix It

?

SCR Problem,Troubleshoot SCR

ContinueOperations

Yes

ContinueOperations

Yes

ContinueOperations

Yes

Put back intoDRILL mode


2-14

2

Varco


No Rotation and Hi Torque


No or Minimal Rotationand Hi Torque

No

Yes Cycle BrakeON to OFF

(Reset)

Checkif BrakeIndicator

is ON

No

Yes • Consider Drilling Program• Consider Reducing Torque

• Check Wiring• Check PLC Inputs and Outputs

IsThere

DownholeTorque

?

• Brake Stuck ON• Motor Incorrectly Wired• Change SCR Assignment and Retest• Check SCR

ContinueOperations

Yes

No

DidYou Find

Cause andFix It

?

Call Field Service

ContinueOperations

Yes

No

DidYou Find

Cause andFix It

?

2-15

2



Speed Control Problems



Top Drive not spinning.

or RPM's incorrect or

Erractic speed problems.

Top Drive not rotating.

Drill torque incorrect.

SCR interface II card failure.

SCR DC module failure.

Spin current limit failure.

Potentiometer on card rack failure.

Speed signal output at card rack failure.

Cabling circuit failure.

Field loss.

SCR Interface failure.

SCR DC module failure.

Speed signal at card rack failure.

SCR interface failure.

Make-up current limit failure.

Field loss.

Check SCR interface II card.

Check SCR DC module.

Confirm spin current limit.

Check spin speed potentiometer on card rack.

Check speed signal output at card rack.

Check cabling for short or open circuits.

Check field supply.

Check SCR interface.

Check SCR DC module.

Check speed signal at card rack.

Check SCR interface.

Check make-up current limit.

Check field supply.

2-16

2

Varco


Speed Control Problems (Drill Mode)

Speed ControlProblems in DRILL Mode

• Assign SCR• Select DRILL Mode• Select FORWARD• Set Drill Current Limit to 50%• Set Throttle to 25%• Confirm Brake in OFF or AUTO Position

• Check Throttle Potentiometer• Check Throttle Signal• Check SCR Interface II Card• Check SCR DC Module• Check Field Supply• Consider Mechanical Restrictions• Consider Well Conditions

No

Yes

Does theTop Drive

Rotate?

No

YesGoingtooFast

?

YesGoingtoo

Slow?

No

No Yes

WasCurrent

LimitReached

?

No

YesErraticSpeed

Problems?

ContinueOperations

Yes

No

DidYou Find

Cause andFix It

?

Call Field Service

ContinueOperations

SeePage

2-9


2-17

2



Speed Control Problems (Spin Mode)

Speed ControlProblems in SPIN Mode

• Throttle OFF• Select FORWARD or REVERSE• Select SPIN Mode

• Check SCR Interface II Card• Check SCR DC Module• Confirm Spin Current Limit• Check Spin Speed Potentiometer on Card Rack• Check Speed Signal Output at Card Rack• Check Cabling for Short or Open Circuits• Check Field Supply

No

Yes

Does theTop Drive

Spin?

No

Yes

AreRPM'sCorrect

(~30 RPM's)?

No

YesErraticSpeed

Problems?

ContinueOperations

Yes

No

DidYou Find

Cause andFix It

?

Call Field Service

ContinueOperations


2-18

2

Varco


Speed Control Problems (Torque Mode)

Speed ControlProblems in TORQUE Mode

• Throttle OFF• Select FORWARD• Select TORQUE Mode

No

Yes

Does theTop Drive

Rotate?

No

Yes

AreRPM's Correct(~50 RPM's in

High Gear)?

No

YesErraticSpeed

Problems?

ContinueOperations

• Check SCR Interface II Card• Check SCR DC Module• Confirm Spin Current Limit• Check Spin Speed Potentiometer on Card Rack• Check Speed Signal Output at Card Rack• Check Cabling for Short or Open Circuits• Check Field Supply

Yes

No

DidYou Find

Cause andFix It

?

Call Field Service

ContinueOperations


2-19

2



Mode Problems



No rotaion in Drill mode.

Required drill torque limit not achieved.

No rotaion in Spin mode.

Required torque limit not achieved.

Brake not set.

Throttle not open.

Drill torque limit potentiometer not functioning.

Voltage at drill torque limit potentiometer failure.

Voltage signal at card rack failure.

Cabling and wiring incorrect.

PC/PLC incorrect and signal failure.

Field loss.

SCR interface II card failure.

Stump cyclops board failure.

SCR failure.

Mechanical restrictions

Incorrect gear setting.

Drill string problem

Brake not set.

Throttle not off.

Spin mode not selected.

Voltage at make-up current limit potentiometer failure.

Voltage signal at card rack failure.

Cabilng and wiring incorrect.

VDC PLC input failure.

TDS PLC output to card rack failure.

Set brake.

Open throttle.

Turn up drill torque limit potentiometer.

Verify voltage at drill torque limit potentiometer.

Verify voltage signal at card rack.

Check cabling and wiring.

Connect PC/PLC and verify signals.

Check field supply.

Check SCR interface II card.

Check stump cyclops board.

Check SCR.

Consider Mechanical Restrictions.

Confirm proper gear setting.

Disconnect drill string and repeat these checks.

Set brake.

Throttle OFF.

Select SPIN mode.

Verify voltage at make-up currnet limit potentiometer.

Verify voltage signal at card rack.

Check cabling and wiring.

Verify VDC PLC input.

Verify TDS PLC output to card rack.

2-20

2

Varco


Drill Mode Problems


!

DRILL Mode Problem

• Set Brake• Open Throttle• Turn Up Drill Torque Limit Potentiometer

• Check Field Supply• Check SCR Interface II Card• Check Stump Cyclops Board• Check SCR• Consider Mechanical Restrictions• Confirm Proper Gear Setting• Disconnect Drill String and Repeat These Checks

• Verify Voltage at Drill Torque Limit Potentiometer• Verify Voltage Signal at Card Rack• Check Cabling and Wiring• Connect PC/PLC and Verify Signals

ContinueOperations

ContinueOperations

Yes

No

No

DidYou Find

Cause andFix It

?

Yes

AchieveRequired

Drill TorqueLimit

?

No

Yes

IsThere

Rotation?

Call Field Service

ContinueOperations

Yes

No

DidYou Find

Cause andFix It

?

SeePage

2-13

No

YesSpeedControlProblem

?

SeePage

2-16

SeePage

2-14

No torque

Hi torque

Never apply power to stalled motor for more than 7 seconds.

2-21

2



Spin Mode Problems


SPIN Mode Problem

• Set Brake• Throttle OFF• Select SPIN Mode

See SCR InterfaceBoard Documentation

ContinueOperations

Yes

No

No

DidYou Find

Cause andFix It

?

Yes

AchieveRequired

Spin TorqueLimit

(~300 Amps)?

Call Field Service

• Release Brake

ContinueOperations

No

Yes

IsThere

Rotation?

SeePage

2-13

No

YesSpeedControlProblem

?

SeePage

2-17

SeePage

2-14

No torque

Hi torque

2-22

2

Varco


Torque Mode Problems

!

TORQUE ModeProblem

• Set Brake• Throttle OFF• Set Make-Up Current Limit to 20%• Select TORQUE Mode

• Verify Voltage at Make-Up Current Limit Potentiometer• Verify Voltage Signal at Card Rack• Check Cabling and Wiring• Verify VDC PLC Input• Verify TDS PLC Output to Card Rack

ContinueOperations

Yes

No

NoDid

You FindCause and

Fix It?

Yes

NoIs

ThereRotation and

Torque?

Yes

AchieveRequiredTorqueLimit

?

Call Field Service

ContinueOperations

Yes

No

DidYou Find

Cause andFix It

?

See SCR Interface IICard Documentation

SeePage

2-13

SeePage

2-18

Release brake

No

Yes

AchieveRequiredTorqueSpeed

?

Never apply power to stalled motor for more than 7 seconds.


2-23

2



Set to Spin/Torque/Spin Out Problems



Tool not spinning out. Turn throttle OFF.

Select reverse.

Brake connection with torque wrench.

Select spin mode.

2-24

2

Varco


Set to Spin

Yes

Yes

NoIs

RPMCorrect

?

No

DidYou Find

Cause andFix It

?

Call Field Service

No

Turn theForward/Reverse

Switch toFORWARD

• Check Counterbalance• Check Saver Sub

- Thread Damage- Selection

• Consider Operational Issues• Consider Alignment Issues

Set To SPIN Mode

Throttle to OFF

Unit SpinsForward

?

Check SCRInterface II Card

ContinueOperations

ContinueOperations

Yes

Yes

No

No

StallsOut at SPIN

CurrentLimit

?

Yes

DidConnectionShoulder Up

Correctly?

SeePage

2-14

SeePage

2-21


2-25

2



Set to Torque (Make-Up Connection)

Set to TORQUE Mode

ContinueOperations

No

Yes

SelectSPIN Mode

SelectTORQUE Mode

SpinIn and

ConnectionShouldersProperly

?

No

Yes

TorqueRamps

Up?

No

Yes

Make-UpCorrect

?

Make Up:• Select FORWARD• Throttle OFF• Set Make-Up Current Limit Potentiometer at 20%

Torque Up:• Increase Make-Up Potentiometer to Appropriate Torque

First stand only

SelectDRILL Mode

ReleaseTorque to

SPIN Mode

SeePage

2-24

SeePage

2-22

Check SCRInterface II Card

No

DidYou Find

Cause andFix It

?

Call Field Service

Yes


2-26

2

Varco


Spin Out Problem

ContinueOperations

Spin Out Problem

• Throttle OFF• Select Reverse• Break Connection with Torque Wrench

SelectSPIN Mode

Return toDrill Mode

Return toDrill Mode

RepeatProcedure as

Necessary

NoIsTool

Spinning?

Yes

Yes

No

DidYou Find

Cause andFix It

?

ContinueOperations

Yes

SeePage

2-24 Spin Mode Problem

SeePage

4-3 Torque Wrench Problems


3


IBOPTroubleshooting

3-1

3

4

5

6

7

8

IBOPTroubleshooting

1

2


IBOP Problem ........................................................ 3-3

3

Varco

IBOPTroubleshooting

3-2

3

4

5

6

7

8

IBOPTroubleshooting

1

2

Varco

3


IBOPTroubleshooting

3-3

IBOP Problem

IBOPProblem

ContinueOperations

No

Yes

Isthe IBOP

Fully Closing?

No

Yes

Isthe IBOP

Fully Opening?

No

YesIs

the IBOPValve

Leaking?

No

Yes

ClosedLight ON

When Switchin ClosedPosition

?

• Perform Lamp Test• Check PLC• Check Wiring• Check Pressure Switch

NoYes IsShell/Valve

Closing?

• Manually Close Valve• Check Mechanical• Check Solenoid• Check Air Pressure• Check Back Pressure on Open Side• Check Air Isolation Valves on Pipehandler

• Check Mud Pressure• Manually Open Valve• Check Mechanical• Check Solenoid• Check Air Pressure• Check Back Pressure on Closed Side• Check Air Isolation Valves on Pipehandler

Closed = Up Open = Down

DidYou Find

Cause andFix It

?

Call Field Service

ReplaceValve

ContinueOperations

Yes

Yes

No

No

DoesValve

OperateManually

?


3

Varco

IBOPTroubleshooting

3-4

4



4-1

3

4

5

6

7

8


1

2


Torque Wrench Problems ................................... 4-3Torque Wrench Does Not Cycle at All ........................... 4-5

Torque Wrench Does Not Cycle Properly ..................... 4-6

Torque Wrench Slips ..................................................... 4-7

Die Retainer and Bolts Damaged While Breaking Out .. 4-8

Torque Wrench Does Not Lift ........................................ 4-9

Torque Wrench Does Not Release................................ 4-10

Saver Sub Breaks Out Instead of Tool Joint ................. 4-11

Tong Dies Break or Drill Pipe Becomes Scored ............ 4-12

Link Tilt Problems............................................... 4-13Link Tilt Not Functioning Properly.................................. 4-14

4

Varco


4-24-2

3

4

5

6

7

8


1

2

Varco

4



4-3

Torque Wrench Problems


Tool does not cycle at all.

Tool does not cycle properly.

Torque wrench slips.

Die retainer and die retainer bolts damaged while breaking out.

Torque wrench does not lift.

Air solenoid valve out of adjustment.

Pilot operated valve on counterbalance manifold out of adjustment.

Hydraulic quick disconnects improperly connected.

Needle valve in counterbalance manifold is open.

Hydraulic supply is disrupted.

Air solenoid valve out of adjustment.

Pilot operated valve on counterbalance manifold out of adjustment.

Hydraulic quick disconnects improperly connected.

Needle valve in counterbalance manifold is open.

Defective cartridge valve or PRV valve.

Improper component or component installation.

Hydraulic filter requires replacement.

Tong dies worn or damaged.

Connection is over-torqued.

Saver sub incorrect length.

Incorrect orientation of die retainer and carrier.

Incorrect spacers.

Improper saver sub length or machining.

Oil bypass in pipehandler hydraulic components.

Readjust the valve per procedure.


Check quick disconnects to ensure proper connections and flowing in both directions.

Close needle valve (always with HPU running).

Check supply and repair as needed.



Check quick disconnects to ensure proper connections and flowing in both directions.

Close needle valve (always with HPU running).

Inspect valves for damaged seals or stuck spools. Replace as necessary.

Replace valve cartridges with correct type.

When changing the Make/Break valve, make sure the valve is properly oriented when installed.

Check and replace hydraulic filter as needed.

Check tong dies and replace as necessary.

Break the connection with a higher torque tool and re-make the connection to the proper torque.

Check saver sub length and correct as necessary.

Check orientation and correct as necessary.

Check for proper spacers and correct as necessary.

Check saver sub length. Sub should have proper chamfer on both shoulders.

Listen for oil bypassing in pipehandler cylinders or manifold. Locate and repair bypass as necessary.

SeePage

4-5

SeePage

4-6

SeePage

4-7

SeePage

4-8See

Page

4-9

i


4

Varco


4-4

Torque Wrench Problems


Tool goes up, clamps, and cycles, but remains clamped on pipe when switch is released.

Saver sub or lower IBOP breaks out instead of tool joint.

Tong dies break or drill pipe becomes scored.

Air pilot valve on counterbalance manifold stuck or inoperative.

Pilot valve dirty.

Improperly connected quick disconnects.

Hydraulic valve not shifting.

Saver sub not made up properly.

Threads worn or damaged.

Valves in manifold out of adjustment.

Tong dies worn.

Connection overtorqued.

Remove air supply line to verify air supply when solenoid valve is activated.

If air supply is available, remove end cap on pilot valve, clean and lubricate.

If air pilot valve is operable, hook both pipehandler hoses together and verify flow in both directions by activating switch with hydraulics on.

If there is flow in only one direction, check quick disconnects.

If quick disconnects are properly connected, check hydraulic pilot valve for stuck spool.

Repair or replace.

Make up saver sub per procedure described in the IBOP Service Manual, increase previous torque makeup 10% to maximum torque recommended in the IBOP Service Manual (for original Varco OEM subs).

Replace as necessary.

Readjust per procedure.

Replace tong dies.

If saver sub is made up to recommended torque and continues to break out instead of drill pipe connection, break out using rig tongs.

If saver sub or drill pipe will not break out using pipehandler, remove pipehandler and break out with rig tongs at floor.

SeePage

4-10

SeePage

4-11

SeePage

4-12


4



4-5

Torque Wrench Does Not Cycle at All

No

Is AirSolenoid

Valve Out ofAdjustment

?

No

IsPilot

Operated Hydraulic Valve

Out ofAdjustment

?

No

Yes

Yes

Yes

AreHydraulic

Quick Disconnects

ImproperlyConnected

?

Torque Wrench DoesNot Cycle At All

Call Field Service

No

DidYou Find

Cause andFix It

?

ContinueOperations

Yes

• Readjust Valve per Procedure


• Check QDs to Ensure Proper Connections and Flowing in Both Directions

No

YesIs

NeedleValveOpen

?

No

IsHydraulic

SupplyDisrupted

?

Yes • Check and Repair as Needed

• Inspect Needle Valve in Counterbalance Manifold• Close Needle Valve (always with HPU running)


4

Varco


4-6

Torque Wrench Does Not Cycle Properly

No

Is AirSolenoid

Valve Out ofAdjustment

?

No

IsPilot

Operated Hydraulic Valve

Out ofAdjustment

?

No

Yes

Yes

Yes

AreHydraulic

Quick Disconnects

ImproperlyConnected

?

Torque Wrench DoesNot Cycle Properly

Call Field Service

NoDid

You FindCause and

Fix It?

ContinueOperations

ContinueOperations

Yes

No

DidYou Find

Cause andFix It

?

Yes



• Check QDs to Ensure Proper Connections and Flowing in Both Directions

No

YesIs

NeedleValveOpen

?

No

IsCartridge

or PRV ValveDefective

?

Yes • Inspect Valves for Damaged Seals or Stuck Spools• Replace as Necessary

No

AreProper

ComponentsInstalledCorrectly

?

Yes • Replace Valve Cartridge with Correct Type

• Inspect Needle Valve in Counterbalance Manifold• Close Needle Valve (always with HPU running)

• Perform Complete Torque Wrench Adjustment Procedure• Check Mechanical Condition of Torque Wrench• Check Hydraulic Filter

See TDS-4S Service Manual SM00620, Maintenance & Troubleshooting Chapter 3,

Pages 4-49 thru 4-51.

When changing the Make/Break valve, make sure the valve is properly oriented when installed.

i


4



4-7

Torque Wrench Slips

No

AreTong DiesWorn or

Damaged?

No

IsConnection

Over-Torqued?

No

Yes

Yes

Yes

IsSaver SubIncorrectLength

?

Torque WrenchSlips

• Check Tong Dies and Replace as Necessary

• Break the Connection with a Higher Torque Tool and Re-Make the Connection to the Proper Torque

• Check Saver Sub Length and Correct as Necessary

• Check Orientation and Correct as Necessary

No

YesIs Die

Retainerand CarrierOrientationIncorrect

?

No

AreSpacersIncorrect

?

Yes • Check for Proper Spacers and Correct as Necessary

Call Field ServiceCall Field Service

DidYou Find

Cause andFix It

?

ContinueOperations

No

Yes


4

Varco


4-8

Die Retainer/Bolts Damaged While Breaking Out

No

IsLength or

Machining ofSaver SubImproper

?

Yes

Die Retainer and BoltsDamaged While Breaking Out

• Check Saver Sub Length• Sub Should Have Proper Chamfer on Both Shoulders


DidYou Find

Cause andFix It

?

ContinueOperations

No

Yes


4



4-9

Torque Wrench Does Not Lift

No

Is OilBypassing

in HydraulicComponents

?

Yes

Torque WrenchDoes Not Lift

• Listen for Oil Bypassing in Pipehandler Cylinders or Manifold• Locate and Repair Bypass as Necessary


DidYou Find

Cause andFix It

?

ContinueOperations

No

Yes


4

Varco


4-10

Torque Wrench Does Not Release

No

Isthe Air

Pilot Valve onCounterbalance

Manifold Stuck orInoperative

?

Yes

Torque Wrench ClampDoes Not Release

Call Field Service

Call Field Service

DidYou Find

Cause andFix It

?

ContinueOperations

No

Yes

Tool goes up, clamps and cycles, but remains clamped on pipe when switch is released.

• Remove Air Supply Line to Verify Air Supply When Solenoid Valve is Activated

No

Is thePilot Valve

Dirty?

Yes • If Air Supply is Available, Remove End Cap On Pilot Valve, Clean and Lubricate

No

AreQuick

DisconnectsImproperlyConnected

?

Yes

• If Air Pilot Valve is Operable, Hook Both Pipehandler Hoses Together and Verify Flow in Both Directions by Activating Switch With Hydraulics On• If There is Flow in Only One Direction, Check Quick Disconnects• If Quick Disconnects are Properly Connected, Check Hydraulic Pilot Valve for Stuck Spool

No

Is theHydraulicValve NotShifting

?

Yes• Repair or Replace


4



4-11

Saver Sub Breaks Out Instead of Tool Joint

No

Is theSaver SubMade Up

Improperly?

Yes

No

AreThreadsWorn or

Damaged?

Yes

Saver Sub Breaks OutInstead of Tool Joint

Call Field Service

Call Field Service

DidYou Find

Cause andFix It

?

ContinueOperations

No

Yes

Saver sub or the IBOP breaks out instead of the tool joint.

• Make Up Saver Sub per Procedure Described in the IBOP Service Manual, Increase Previous Torque Makeup 10% to Maximum Torque Recommended in the IBOP Service Manual (for Original Varco OEM Subs)

• Replace as Necessary


4

Varco


4-12

Tong Dies Break or Drill Pipe Becomes Scored

No

AreValves in

Manifold Out ofAdjustment

?

Yes

Tong Dies Break orScore the Drill Pipe

Call Field Service

Call Field Service

DidYou Find

Cause andFix It

?

ContinueOperations

No

Yes

• Readjust per Procedure

No

AreTong Dies

Worn?

Yes• Replace Tong Dies

No

IsConnectionOvertorqued

?

Yes

• If Saver Sub is Made Up to Recommended Torque and Continues to Break Out Instead of Drill Pipe Connection, Break Out Using Rig Tongs• If Saver Sub or Drill Pipe Will Not Break Out Using Pipehandler, Remove Pipehandler and Break Out With Rig Tongs at Floor


4



4-13

Link Tilt Problems


Link tilt does not extend, float, retract and/or hold.

Mechanical problem.

Incorrect PLC input.

Solenoid problem.

Pressure incorrect.

Check mechanical operation of link tilt.

Check PLC for correct inputs.

Check mechanical operation of solenoid.

Check pressure and adjust as necessary.

SeePage

4-14


4

Varco


4-14

Link Tilt Not Functioning Properly

No

Yes

DoesLink TiltExtend

?

• Check Mechanical• Check PLC Input• Check Solenoid• Check Pressure

No

Yes

DoesLink Tilt

Float?

No

Yes

DoesLink TiltRetract

?

No

Yes

DoesLink Tilt

Hold?

Link Tilt NotFunctioning Properly

ContinueOperations

No

DidYou Find

Cause andFix It

?

Call Field Service

ContinueOperations

Yes


5


Counterbalance and MotorAlignment Cylinder Troubleshooting

5-1

3

4

5

6

7

8


Troubleshooting

1

2


Counterbalance System Problems ..................... 5-3Counterbalance System Problem (HPU On) ................. 5-4

Counterbalance System Problem (HPU Off) ................. 5-5

Motor Alignment Cylinder Problems .................. 5-6Alignment Cylinder Fails to Move Motor Housing.......... 5-7

System Does Not Hold Pressure ................................... 5-8

Saver Sub Not Aligning with Drill Pipe........................... 5-9

Excessive Motor Movement .......................................... 5-10

5

Varco


5-2

3

4

5

6

7

8


Troubleshooting

1

2

Varco

5



5-3

Counterbalance System Problems

Needle valve is not closed.

Cylinder rod seals leak.

Fittings or hoses leak.

Dirty or defective PRV valve.

Accumulator leaking or not charged.

Dirty or stuck check valve.

Counterbalance control valve (if equipped)in rig down position (unique to parkingsystems).

Pressure setting too high.

Possible problem with system hydrauliccomponents.

Loss of nitrogen precharge in accumulatorslocated in motor dolly upright frame.


Turn on HPU. Check needle valve. Seeadjustment procedure and verify systempressure.

Replace seals.

Tighten or replace as required.

See adjustment procedure. Clean or replace.

Precharge, service or replace.

Clean or replace.

Return valve to drilling position.

Adjust per adjustment procedure.

Check the Counterbalance System Problem(HPU On) section of this book.

Recharge accumulators as per the procedurein the Counterbalance section of this book.

System does not holdpressure (HPU On)

Cylinder rods remainretracted (closed).

Counterbalance systemworks erratically ordoes not work at all(HPU Off).

When activating or reactivating the counterbalance system, never start an empty systemwith the needle valve closed. Always start the Hydraulic Power Unit (HPU) first, run for 3-5minutes, then slowly close needle valve with HPU running. If an empty system is startedup with needle valve closed there is a good potential for damaging counterbalancecylinder seals.

!

SeePage

5-4

SeePage

5-5


5

Varco


5-4

Counterbalance System Problem (HPU On)

ContinueOperations

CounterbalanceProblem (HPU On)

No

Is theNeedle Valve

Open?

Yes

Yes

No

AreCylinder

Rod SealsLeaking

?

• Turn On HPU• Check Needle Valve• See Adjustment Procedure• Verify System Pressure

Replace Seals

Yes

No

AreAny Fittings

or HosesLeaking

?

Tighten or Replaceas Required

Adjust perAdjustmentProcedure

No

Is thePRV Valve

Dirty orDefective

?

Yes

No

DidYou Find

Cause andFix It

?

Yes

Yes

No

Is theCheck Valve

Dirty orStuck

?

See AdjustmentProcedure and

Clean or Replace

Clean or Replace

Yes

No

Is theHydrualic

Return LineClear

?

• Check Quick Disconnects• Check Valve Alignment

Yes

No

Return Valve toDrilling Position

IsCounterbalance

Control Valvein Rig Down

Position?

Yes

No

No

CylinderRods

RemainRetracted

?

Is thePressure

Setting tooHigh

?

Yes


Pressure related problems


5



5-5

Counterbalance System Problem (HPU Off)

ContinueOperations

CounterbalanceProblem (HPU Off)

• Turn HPU Off• Check System Hydraulic Components• Check for Loss of Nitrogen Precharge in Accumulators Located in Motor Dolly Upright Frame

No

Problemwith

SystemHydraulics

?

Yes

NoDid

You FindCause and

Fix It?

Yes

Call Field Service

Counterbalance system works erratically or does not work at all

SeePage

5-4

No

Loss ofPrecharge in

Accumulators?

Yes RechargeAccumulators

as per Procedure


5

Varco


5-6

Motor Alignment Cylinder Problems


Alignment cylinder fails to move motor housing at trunnion pivot points with recommended pressure setting.

System does not hold pressure.

Saver sub on TDS does not align with drill pipe.

Excessive motor movement.

Transmission trunnion pins will not pivot in dolly support brackets, from lack of lubrication.

Needle valve is not closed.

Cylinder rod seals leak.

Fittings or hoses leak.

Dirty or defective PRV valve.

Alignment cylinder pressure too high or too low.

Alignment cylinder rod adjustment too long or too short.

Rails not properly aligned with centerline of well.

Alignment cylinder fluid flow not adequately throttled.

Free trunnion pins as needed and lubricate area regularly.

See the adjustment procedure.

Replace seals.

Tighten or replace as required.

Clean or replace.

See the adjustment procedure.

See the adjustmentz procedure.

Check to make sure that rotary is in center of floor and then check alignment of rails in relation to rotary.

See the adjustment procedure. Normal adjustment is 1 1/2 turn from full closed position on flow control valves. If there is excessive movement close to 3/4 turn from full closed position.

SeePage

5-8

SeePage

5-9

SeePage

5-7

SeePage

5-10


5



5-7

Alignment Cylinder Fails to Move Motor Housing

ContinueOperations

Alignment Cylinder Failsto Move Motor Housing

NoAre theTrunnion Pins

Lubricated?

Yes

Free Trunnion Pins asNeeded and Lubricate

Area Regularly

NoDid

You FindCause and

Fix It?

Yes

Call Field Service

Alignment cylinder fails to move motor housing at trunnion pivot points with recommended pressure setting


5

Varco


5-8

System Does Not Hold Pressure

ContinueOperations

System Does NotHold Pressure

No

Is theNeedle Valve

Open?

Yes

Yes

No

AreCylinder

Rod SealsLeaking

?


Check Needle Valve

Replace Seals

Yes

No

AreAny Fittings

or HosesLeaking

?

Tighten or Replaceas Required

No

Is thePRV Valve

Dirty orDefective

?

Yes

NoIs the

PRV ValveDirty or

Defective?

Yes

NoDid

You FindCause and

Fix It?

Yes


Clean or Replace

Call Field Service


5



5-9

Saver Sub Not Aligning with Drill Pipe

ContinueOperations

Saver Sub Does NotAlign with Drill Pipe

NoIs the

AlignmentCylinderPressure

OK?

Yes

Yes

NoIs

CylinderRod Adjusted

too Longor Short

?

If too High or Low,See Adjustment

Procedure

Adjust Accordingto Procedure

Yes

No

AreRails

Alignedwith Well

Centerline?

• Check to Make Sure that Rotary is in Center of Floor• Check Alignment of Rails in Relation to Rotary

NoDid

You FindCause and

Fix It?

Yes

Call Field Service


5

Varco


5-10

Excessive Motor Movement

ContinueOperations

ExcessiveMotor Movement

Check to Make Surethat Alignment

Cylinder Fluid Flow isAdequately Throttled

Yes

NoIs

Fluid FlowAdequatelyThrottled

?

See AdjustmentProcedure

NoDid

You FindCause and

Fix It?

Yes

Call Field Service

Normal adjustment is 1 1/2 turns from full closed position on flow control valves. If there is excessive movement close to 3/4 turn from full closed position.


6


Drilling Motor Housing, Brake andGuide Dolly Troubleshooting

6-1

3

4

5

6

7

8


Troubleshooting

1

2


Motor Air Brake Problems .................................. 6-3Motor Air Brake Problems ............................................. 6-4

Motor Air Brake Does Not Hold ..................................... 6-5

Motor Air Brake Does Not Release ............................... 6-6

Guide Dolly Problems ......................................... 6-7Retract Control Problem ................................................ 6-8

Guide Dolly Retracts too Slow or too Fast ..................... 6-9

Transmission Problems ...................................... 6-10Oil Leaking from Lower Gear Case Seal ....................... 6-11

Oil Leaking from Shaft Housing Breather ...................... 6-12

Gearbox Temperature Excessive .................................. 6-13

Oil Pump Problems ............................................. 6-14OIL OVERTEMP/OIL PUMP LOSS Alarm .................... 6-15

Cooling Blower Problems ................................... 6-16Mechanical Noise in Cooling Blower ............................. 6-17

Cooling Blower Runs Intermittently ............................... 6-18

Excessive Air Loss in Blower Motor Shaft Area ............ 6-19

BLOWER LOSS Alarm .................................................. 6-20

AIR OVERTEMP Alarm Stays On ................................. 6-21

AIR OVERTEMP Alarm Stays On ................................. 6-22

Rotating Head Problems..................................... 6-23Rotating Head Problems ............................................... 6-24

6

Varco


6-2

3

4

5

6

7

8


Troubleshooting

1

2

Varco

6



6-3

Motor Air Brake Problems


Brake does not hold.

Brake does not release.

Insufficient air supply.

Solenoid valve not shifting.

Brake drum contaminated with grease or pads worn or burnt.

Solenoid valve sticking.

Quick exhaust valve not functioning properly.

Check air supply pressure 90 psi minimum required.

Check electrical continuity.

Check lubricator on air supply.

Check mechanical operation of solenoid valve.

Inspect and replace if necessary.

Lubricate, repair with repair kit or replace valve.

Check air supply lubricator.

Clean or replace.

SeePage

6-5

SeePage

6-6


6

Varco


6-4

Motor Air Brake Problem

Yes

Yes

Yes

No

BrakeReleasing

?

Yes

No NoBrakeLightOn?

BrakeSlipping

<30,000 ft-lb?

NoBrakeReset

?

• Check Mechanical• Check Air Pressure• Perform Lamp Test• Check PLC• Ensure Air Dischage Outlets are Clear• See Page 6-6

• Check PLC• Check Wiring

Set Brake ON,then OFF

• Check Air Pressure• Check for Air Leaks• Check Pads• See Page 6-5

Yes

NoBrakeFunctioning

Correctly?

• Check PLC• Check Wiring• Check Mechanical• Check Hydraulic• See Page 6-5

BrakeProblem

No

DidYou Find

Cause andFix It

?

Call Field Service

ContinueOperations

Yes


6



6-5

Motor Air Brake Does Not Hold

ContinueOperations

Brake DoesNot Hold

NoDid

You FindCause and

Fix It?

Yes

Call Field Service

NoIs ThereSufficientAir Supply

?

Yes

Check Air Supply,90 psi Minimum

Required

NoIs theBrake Drum

Okay?

NoIs the

SolenoidValve

Shifting?

Yes

Yes

• Check Electrical Continuity• Check Lubricator on Air Supply• Check Mechanical Operation of Solenoid Valve

• Check Drum for Grease• Check for Worn or Burnt Shoes• Replace if Necessary


6

Varco


6-6

Motor Air Brake Does Not Release

ContinueOperations

Brake DoesNot Release

NoDid

You FindCause and

Fix It?

Yes

Call Field Service

NoIs the

SolenoidValveOkay

?

Yes

• Check the Valve for Sticking• Lubricate, Repair or Replace• Check Air Supply Lubricator

NoIs theQuick

Exhaust ValveOkay

?

Yes

Clean or Replace


6



6-7

Guide Dolly Problems


Only one guide dolly is operating.

Both guide dollies do not extend/ retract.

Guide dollies are not synchronized.

Guide dollies are not operating properly.

Guide Dolly retracts too slow or too fast.

Solenoid valve not operating properly.

Directional control valve not operating properly.

Retract manifold not setup properly.

Improperly connected quick disconnects.

Hose restrictions or improper connections.

Flow control valve out of adjustment.

Flow restrictor valve out of adjustment.

Flow controls on retract manifold out of adjustment.

Pressure relief valve out of adjustment.

Accumulator leaking or not charged.

Fast speed proximity switch and solenoid not operating properly.

Flow control valves on guide dolly not operating properly.

Flow control valves on the guide dolly are not properly set.

Manually operate the solenoid valve.

Check mechanical latch (dogs), cylinders, hydraulic pressure, quick disconnects, hoses, plumbing and retract manifold setup.

Manually operate the directional control valve.

Check mechanical latch (dogs), cylinders, hydraulic pressure, quick disconnects, hoses, plumbing and retract manifold setup.

Check retract manifold setup.

Check quick disconnects.

Check hose restrictions/connections.

Confirm flow control valve adjustment.

Confirm restrictor valve adjustment.

Check flow controls on retract manifold.

Check pressure relief valve.

Verify accumulator precharge, service or replace.

Check fast speed proximity switch and solenoid.

Check flow control valves on guide dolly.

Set the flow controls to attain desired retract speed.

SeePage

6-8

SeePage

6-8

SeePage

6-8

SeePage

6-8

SeePage

6-9


6

Varco


6-8

Retract Control Problem

ContinueOperations

ContinueOperations

Retract/ControlProblems

No

DidYou Find

Cause andFix It

?

Yes

Call Field Service

NoDo

BothDolliesExtend/Retract

?

Yes

No

IsOnly the

Block DollyOperating

?

Yes

No

DoBoth

DolliesExtend/Retract

?

Yes

• Check Mechanical Latch (Dogs)• Check Cylinders• Check Hydraulic Pressure• Check Quick Disconnect Connectors• Check Hoses and Plumbing• Check Retract Manifold Setup (page 13 of Hyd. Setup)• Confirm Flow Control Valve Adjustment• Confirm Flow Restrictor Valve Adjustment

• Manually Operate the Directional Control Valve

• Confirm TDS Disable Solenoid Operation/ Switch Position

NoAre

DolliesSynchronized

?

Yes

• Confirm Solenoids• Consider ZMS Interlock• Check PLC Inputs/Outputs• Check VDC Switch

• Check Retract Manifold Setup (page 13 of Hyd. Setup)• Check Quick Disconnect Connectors• Check Hose Connections/ Restriction

NoAre

DolliesOperatingProperly

?

Yes

• Check Flow Controls on Retract Manifold• Check Pressure Relief Valve• Verify Accumulator Precharge• Check Fast Speed Proximity Switch and Solenoid• Check Flow Control Valves On Dolly


6



6-9

Guide Dolly Retracts too Slow or too Fast

ContinueOperations

Guide Dolly RetractsToo Slow or Too Fast

NoNoDid

You FindCause and

Fix It?

Yes

ContinueOperations

DidYou Find

Cause andFix It

?

Yes

Call Field Service

No

No

AreFlow

Control Valveson DollyProperly

Set?

Yes

IsFast-Speed

CircuitOperative

?

Yes

Set the Flow Controlsto Attain Desired

Retract Speed

Check for Correct Operation of: • Fast-Speed Proximity Sensor and Targets • PLC Input • PLC Output • Wiring • Precharge Accumulator Pressure

Refer to Retract Guide Dolly Control Manual


6

Varco


6-10

Transmission Problems


Oil leaking from lower seal.

Oil leaking from shaft housing breather.

Gearbox temperature is excessive.

Lower gear case seals are dry or damaged.

Oil level too high.

Incorrect lubricant used.

Oil is foaming.

Oil level too low or too high.


Clogged oil filter.

Clogged or dirty heat exchangers on unit equipped with such.

Apply grease to seal. Grease fitting daily.

If problem persists replace gearcase seals and bearing.

Adjust oil level per recommended specification.

Check recommended lubricants chart and replace as needed.

Replace oil.

Adjust oil level to recommended level in sight glass.

Check recommended lubricants chart and replace as needed.

Remove filter from oil pump. Check discharge or pressure hoses at outlets to confirm circulation.

Check heat exchangers for air flow or water flow to ensure adequate heat transfer and dissipation.

SeePage

6-11

SeePage

6-12

SeePage

6-13


6



6-11

Oil Leaking from Lower Gear Case Seal

ContinueOperations

Oil Leaking fromLower Gear Case Seal

NoDid

You FindCause and

Fix It?

Yes

Call Field Service

No

AreSealsDry or

Damaged?

Yes• Apply Grease to Seals, Grease Fitting Daily• If Problem Persists Replace Gearcase Seals and Bearing


6

Varco


6-12

Oil Leaking from Shaft Housing Breather

ContinueOperations

Oil Leaking fromShaft Housing Breather

NoDid

You FindCause and

Fix It?

Yes

Call Field Service

No

Is OilLevel too

High?

Yes • Adjust Oil Level per Recommended Specification

No

IsIncorrectLubricant

Used?

Yes • Check Recommended Lubricants Chart and Replace as Needed

No

IsOil

Foaming?

Yes• Replace Oil


6



6-13

Gearbox Temperature Excessive

ContinueOperations

GearboxTemp Excessive

NoDid

You FindCause and

Fix It?

Yes

Call Field Service

No

IsOil Level

too Low ortoo High

?

Yes • Adjust Oil Level to Recommended Level in Sight Glass

No

IsIncorrectLubricant

Used?

Yes • Check Recommended Lubricants Chart and Replace as Needed

No

Is theOil FilterClogged

?

Yes

• Remove Filter from Oil Pump, and Check Discharge or Pressure Hoses at Outlets to Confirm Circulation

• Check Heat Exchangers for Air Flow or Water Flow to Ensure Adequate Heat Transfer and Dissipation

No

Are HeatExchangersClogged (ifequipped)

?

Yes


6

Varco


6-14

Oil Pump Problems


OIL OVERTEMP/OIL PUMP LOSSalarm is on.

No oil pressure while pump is running.

Starter is tripped.

Starter is not energized.

Motor is not running.

Incorrect motor rotation.

Oil pump cavitating-evidence of air bubbles in discharge lines.

Defective or improperly adjusted pressure switch.

Failure of oil pump drive coupling.

Faulty or worn oil pump.


Check oil pressure.

Check temperature and pressure switch.

Check PLC for correct input.

Check motor rotation.

Check oil level.

Check oil filter.

Check plumbing.

Meggar blower motor/cables.

Check PLC, wiring and output.

Check electrical components to ensure power is available to motor. Repair or replace as needed.

Verify proper rotation and correct if necessary.

Check all connections to ensure there are no air leaks on suction side of oil pump. Repair as needed.

Check switch operation. Repair or replace as needed.

Inspect, repair or replace as needed.

If unable to make oil pump work after checking all of the above, repair or replace as needed.

Check recommended lubricants chart to make sure proper viscosity of oil is used. Replace as needed.

SeePage

6-15


6



6-15

OIL OVERTEMP/OIL PUMP LOSS Alarm

Oil Overtemp/ OilPump Loss Alarm is ON

Yes

NoDid

Oil PumpCome

On?

• Check Oil Pressure• Check Temperature and Pressure Switch• Check PLC Input• Check Motor Rotation• Check Oil Level• Check Oil Filter• Check Plumbing

Yes

NoStarterTripped

?

Yes

NoStarterEnergized

?

• Check Connectors and Cable

No

DidYou Find

Cause andFix It

?

Call Field Service

ContinueOperations

Yes

• Check PLC• Check Wiring• Check Output

Yes

No

StarterTripped

?

• Reset Starter

• Meggar Blower Motor/Cables

ContinueOperations


6

Varco


6-16

Cooling Blower Problems


Mechanical noise in cooling blower.

Cooling blower runs intermittently.

Excessive air loss in blower motor shaft area.

BLOWER LOSS alarm is on.

AIR OVERTEMP alarm stays on with blower running.

Loose impeller.

Faulty motor bearings.

Physical damage.

Faulty or loose wiring.

Faulty motor starter.

Faulty motor.

Worn or defective seal or wear sleeve.

Loose or vibrating blower motor, wearing seals excessively.

Blower is not on.

Differential or purge pressure switches are faulty.

Starter is tripped.

Starter not energized.

Incorrect blower rotation.

Dirty or clogged spark arrestors (local or remote cooling systems).

Clogged water or air passages in water cooled exchangers (closed loop cooling).

Continuous drilling Amps over recommended levels.

Motor being stalled for over recommended periods of time.

Faulty temperature switch or probe.

Improper cooling water flow or incoming water temp too high (closed loop cooling).

Restricted air flow (local or remote cooling).

Reinstall impeller, hub and locktite screws.

Repair or replace as needed.

Inspect and repair or replace as needed.

Locate and repair as needed.


Meggar and check winding resistance.

Replace as needed.

Correct blower mounting problem or faulty motor bearing and replace blower shaft seals.

Check differential and purge pressure switches.

Check motor rotation.

Confirm air flow.

Check differential and purge pressure switches.

Meggar motor/cables.

Check PLC, wiring and output.

Verify blower rotation. Correct as needed.

Remove spark arrestors from motor and clean screens if screens are damaged with holes. Replace as needed.

Remove exchangers and clean passages as needed.

Check service manual for continuous Amp motor rating and adjust drilling program accordingly.

DC motor should never be stalled for more than 5 seconds with over 300 Amps applied.

Serious damage could occur to the motor if this is done.


Do not readjust or raise heat range setting.

See the Installation and Commissioning book for recommended or required flow rates and water temp.

Check and clean spark arrestors as needed.

Check air intake on blower to ensure there are

SeePage

6-17

SeePage

6-19

SeePage

6-20

SeePage

6-21

SeePage

6-18

i

!


6



6-17

Mechanical Noise in Cooling Blower

Mechanical Noisein Blower

No

Isthe Impeller

Loose?

Yes • Reinstall Impeller, Hub and Locktite Screws

No

Arethe MotorBearings

Faulty?

Yes • Repair or Replace as Needed

No

DidYou Find

Cause andFix It

?

Call Field Service

ContinueOperations

Yes


6

Varco


6-18

Cooling Blower Runs Intermittently

Blower RunsIntermittently

No

IsWiring

Loose orFaulty

?

Yes • Locate and Repair as Needed

No

Isthe Motor

StarterFaulty

?

Yes • Check for Dirt or Trash Between Starter Coil• Repair or Replace as Needed

No

DidYou Find

Cause andFix It

?

Call Field Service

ContinueOperations

Yes


6



6-19

Excessive Air Loss in Blower Motor Shaft Area

Excessive Air Lossin Blower Motor Shaft

No

Is Sealor Wear Sleeve

Defectiveor Worn

?

Yes• Replace as Needed

No

IsBlower

Motor Loose orVibrating

?

Yes• Correct Blower Mounting Problem or Faulty Motor Bearing and Replace Blower Shaft Seals

No

DidYou Find

Cause andFix It

?

Call Field Service

ContinueOperations

Yes


6

Varco


6-20

BLOWER LOSS Alarm

Blower LossAlarm

Yes

NoDidBlower

Come On?

• Check Differential and Purge Pressure Switches• Check Blower Motor Rotation• Confirm Air Flow

Yes

NoStarterTripped

?

Yes

No

StarterTripped

?

• Reset Starter

• Meggar Blower Motor/Cables

Yes

NoStarterEnergized

?

• Check Connections and Cable

No

DidYou Find

Cause andFix It

?

Call Field Service

ContinueOperations

ContinueOperations

Yes

• Check PLC• Check Wiring• Check Output


6



6-21

AIR OVERTEMP Alarm Stays On

Air OvertempAlarm Stays On

Has theDrill Motor

BeenRunning

?

Yes

No

OvertempAlarm

?

Yes

No NoDid

You FindCause and

Fix It?

ContinueOperations

Yes

• Check Top Drive Current Load• Check Blower• Check Blower Starters• Check Blower Rotation and Screens• Check Air Flow

• Check Wiring• Check PLC Inputs• Check Temperature Switch

Wait 15 Minuteswith Throttle OFF

and Blower Running

SeePage

6-22

SeePage

6-22


6

Varco


6-22

AIR OVERTEMP Alarm Stays On

i

!

Air OvertempAlarm Stays On

AIR OVERTEMP alarm stays on with blower running

Closed loop cooling.

Closed loop cooling.

Serious damage could occur to the motor if this is done

Do not readjust or raise heat range setting

No

IsBlower

RotationIncorrect

?

Yes• Verify Blower Rotation• Correct as Needed

No

AreSpark

ArrestorsDirty orClogged

?

Yes

• Remove Spark Arrestors from Motor and Clean Screens if Screens are Damaged with Holes• Replace as Needed

No

Airor Water

Passages inExchangers

Clogged?

Yes• Remove and Clean Passages as Needed

• Check Service Manual for Continuous Amp Motor Rating and Adjust Drilling Program Accordingly

No

ContinuousDrilling

Amps OverRecommended

Levels?

Yes

ContinueOperations

NoDid

You FindCause and

Fix It?

Yes

Call Field Service

No

MotorStalled Over

RecommendedTime

?

Yes • DC Motor Should Never Be Stalled for More than 5 Seconds with Over 300 Amps Applied

No

IsTemperature

Switch or ProbeFaulty

?

Yes• Repair or Replace as Needed

No

IsCooling

Water FlowImproper or

too High?

Yes

• See the Installation and Commissioning Book for Recommended or Required Flow Rates and Water Temp

• Check and Clean Spark Arrestors as Needed• Check Air Intake on Blower to Ensure There are No Restrictions• Verify Proper Blower Rotation

No

IsAir Flow

Restricted?

Yes


6



6-23

Rotating Head Problems


Rotating head not turning freely.

Rotating head seals are leaking.

Link tilt switch not in FLOAT position.

AUTO STOP light is ON.

Hydraulic supply at motor manifold is disrupted.

Cartridge valves and orifice at motor manifold not operating properly.

Solenoids not operating properly.

Directional control valve not operating properly.

Motor and/or gears dirty or defective.

Incorrect PLC input/output.

Bearings not lubricated.

Seals deteriorating.

Ensure link tilt switch is in FLOAT position.

Ensure AUTO STOP light is OFF.

Check hydraulic supply at motor manifold.

Check cartridge valves and orifice at motor manifold.

Check solenoids, readjust per procedure.

Check directional control valve, readjust per procedure.

Check motor and gears for contamination or deterioration.

Check PLC for correct input/output.

Lubricate bearings.

Repair or replace rotating head seals.

Consider using spare ports.

SeePage

6-24

SeePage

6-24


6

Varco


6-24

Rotating Head Problem

No

Yes

IsRotating

Head TurningFreely

?

• Ensure Link Tilt Switch In FLOAT• Ensure AUTO STOP Light is OFF• Check Hydraulic Supply at Motor Manifold• Check Cartridge Valves and Orifice at Motor Manifold• Check Solenoids• Check Directional Control Valve• Check Motor and Gears• Check PLC Input/Output• Lubricate Bearings

Rotating HeadProblem

No

YesAre

RotatingHead Seals

Leaking?

• Consider Using Spare Ports• Repair or Replace Rotating Head Seals

No

DidYou Find

Cause andFix It

?

Call Field Service

ContinueOperations

ContinueOperations

Yes


7


Service Centers

7-1

3

4

5

6

7

8

Service Centers

1

2


Varco Service Centers .......................................... 7-3

7

Varco

Service Centers

7-2

3

4

5

6

7

8

Service Centers

1

2

Varco

7


Service Centers

7-3

Varco Service Centers

United States of America

United Kindom

Contact: Support Help DeskTelephone: (713) 856-4128

Fax: (713) 849-6189

Contact: Service ManagerOffice: (713) 937-5500

Contact: Service ManagerOffice: (337) 364-4583

Fax: (337) 365-2545

Contact: Service ManagerOffice: (011) 44-1674-677-222

Fax: (011) 44-1674-677-379

Varco 12950 West Little York RoadHouston, TX 77041P.O. Box 1473Houston, TX 77251USA

Varco 8404 West Hwy. 90New Iberia, LA 70560USA

Varco (U.K.) Ltd. Forties RoadMontrose, Angus DD10 9ETScotland

Contact: Service ManagerOffice: (61) 893-363-988

Fax: (61) 893-363-987

Contact: Service ManagerOffice: 971-2-5552668

Fax: 971-2-5540012

Varco 1378 SaleVictoria, 3850Australia

Varco Al Mansoori ServicesP.O. Box 27011Abu DhabiUnited Arab Emirates

Australia

United Arab Emirates

7

Varco

Service Centers

7-4

Varco Service Centers

Contact: Regional Service ManagerMobile: (65) 97313441

Contact: Offshore SupervisorOffice: (65) 265-5066

Fax: (65) 265-7485Mobile:(65) 98314736

Contact: Workshop ManagerMobile: (65) 96320997

Varco No. 8, Sixth Lok Yang RoadJurong TownSingapore 628106

Singapore

Contact: Service ManagerMobile: (86) 1393008965

Contact: Service ManagerOffice: (86) 106-495-3025Mobile: (86) 1391224037

Varco ServiceChina

India

Brazil

Contact: Service ManagerOffice: (91) 36-155-1621

Varco Service

Office: 55-24-27-730600Fax: 55-24-27-730600

Varco do Brasil Ltda.Estrada São José Imboassica,sn-ImboassicaMacaéRio de Janeiro 27902-000

8


Appendix

8-1

3

4

5

6

7

8

Appendix

1

2


Checks ................................................................ 8-3

Vendor Documentation....................................... 8-4

Technical Drawings ............................................ 8-5

SCR Interface II Test Procedure ........................ 8-6

Speed/Torque II Test Procedure ........................ 8-14

Stump/Cyclops Test Procedure .......................... 8-22

Users Guide Stump ............................................. 8-32

Adjusting the Torque Wrench............................. 8-39

Adjusting the Counterbalance System .............. 8-42

Adjusting the Motor Alignment Cylinder System8-44

Adjusting the Saftey Valve Actuator.................. 8-50

TDS-4 Shunt Motor 22.5A Field .......................... 8-52

TDS-4 AMP/Torque Charts .................................. 8-54

2 Position, 4 way spring offset ............................................ 8-57

3 Position, 4 way (spring cntrd), float center ...................... 8-59

3 Pos., 4 way (sprng cntrd), solenoid contrlld, float center . 8-62

Load Holding Valves ........................................... 8-64

Counterbalanced, pilot assisted ......................................... 8-64

Relief valve, pilot operated ................................................. 8-67

Check valve, pilot operated ................................................ 8-69

Pressure Control Valves..................................................... 8-71

Pressure reducing valve, pilot operated ............................. 8-71

Auxillary Valves .................................................. 8-73

Check valve, pilot to close .................................................. 8-73

Check valve ........................................................................ 8-75

8

Varco

Appendix

8-2

3

4

5

6

7

8

Appendix

1

2

Varco

Flow Valves.......................................................... 8-76

Orifice.................................................................................... 8-75

Flow Control valve adjustable ............................................... 8-78

Output actuators.................................................. 8-80

Hydraulic cylinder, double acting .......................................... 8-80

Hydraulic motors ................................................................... 8-82

8


Appendix

8-3

Checks

Check PLC input using applicable Interconnect Diagram and PLC Software

Check PLC output using applicable Interconnect Diagram and PLC Software

Input lights when contacts on switch closes

Output lights when output is commanded by PLC

Verify PLC communication lights in VDC and Top Drive control cabinet

Check Wiring

Check PLC

Check wiring continuity

Check wiring for shorts to ground

Check for loose terminals

Check Solenoid

Is solenoid energizing (check for voltage) or noise

Check solenoid by activating mechanically

Check Relays

Light on relay lights when energized

Check continuity across contracts

Check continuity across contracts


Check actuation mechanism


Check Switches

Verify closure of main DC contactors

Check field supply (see TPC Vendor Document on page 8-4)

Check SCR

Verify correct throttle signal voltage

Verify correct torque/current limit signal voltage


8

Varco

Appendix

8-4

Vender Documentation


Document Name VDR #

Tech-Power Field Supply Manual VDR00011

GE752 Motor Instruction Book VDR00023

PLC Direct DL205 User Manual VDR00051

PLC Direct DL405 User Manual VDR00052

8


Appendix

8-5

Technical DrawingsThe drawings in this section are standard electrical drawings. They arefor reference only. For rig specific drawings, refer to your TechnicalDrawings Package.

System Schematic

System Schematic


8

Varco

Appendix

8-6

SCR Interface II Test Procedure

PRINTED CIRCUIT BOARD TEST PROCEDURE

Board Name: SCR Interface, Version II

Assembly Number: 92450

Schematic: 92452

Product: TDCS

PURPOSE: This test procedure provides a guideline to verify proper operation of the above board and is the basis for

completed PCB assembly acceptance.

This document is divided into the following sections:

I. SUMMARY OF BOARD FUNCTIONS

A brief summary of the functions of this board and its application

II. EQUIPMENT REQUIREMENTS

This section contains a list of the minimal equipment requirements to successfully test and verify proper

assembly of this board. The use of additional test equipment and/or fixtures is at the discretion of the tester

so long as the accuracy constraints are met.

III. INITIAL SETUP

Preliminary setup and board alignment procedures required prior to board testing

IV. TEST PROCEDURE

The actual procedure for testing the PCB assembly

V. FINAL ACCEPTANCE

Remaining functions required to prepare PCB assembly for final acceptance


8


Appendix

8-7


The SCR Interface II board provides an interface between the Varco Driller’s Console (VDC), the Programmable

Logic Controller (PLC), and the customer’s SCR system. The board is designed to be inserted into a Varco Control

System card rack with either a CR1/CR2 or CR1/CR3 configuration.

Basic features include:

• Control of SCR Throttle Signal

• Control of SCR Current Limit Signal

• Automatic ramp up and down of Current Signal for Torque control

• Ramp down control of Throttle Signal (power limit)

• Ramp down control of SCR Current (stall protection)

• Water detect sensor interface

• Overspeed Throttle Shutdown

Inputs:

Signal Type Qty Voltage

Speed Reference Analog 2 0 to ±30V (Max)

Current Limit Reference Analog 2 0 to ±30V (Max)

VDC Makeup Signal Analog 2 0 to ±30V (Max)

Water Sensor Analog 2 0 to -12V

Throttle Up Digital 1 0 to 24V

Throttle Down Digital 1 0 to 24V

Current Up Digital 1 0 to 24V

Current Down Digital 1 0 to 24V

Torque Ramp Up Digital 1 0 to 24V

Overspeed Digital 1 0 to 24V

Outputs:

Signal Qty Voltage

SCR Speed Control 2 0 to ±30V

SCR Current Signal 2 0 to ±30V

Modified Current Limit 2 0 to ±30VTop of Ramp 1 0 to +24V *Bottom of Ramp 1 0 to +24V ** Open collector transistor—pulled up externally to +24V when active (top or bottom of ramp)


8

Varco

Appendix

8-8

Indicators Installed on Board Assembly:

Function Indicator

Power Limit Red LEDThrottle Signal Position Bar graphIncrement Throttle Up Bar graphIncrement Throttle Down Bar graphStall Ramp Down Red LEDCurrent Signal Position Bar graphIncrement Current Up Bar graphIncrement Current Down Bar graphTorque Ramp Up Command Green LEDTorque/Spin Current Signal Position Bar graphTop of Ramp Green LEDBottom of Ramp Green LEDWater Detect #1 Red LEDWater Detect #2 Red LEDTorque Mode Green LEDSpin Mode Green LEDOverspeed Condition Red LEDRotary Table Mode Red LED


The following is required to test this assembly:

Equipment Range/Accuracy

Oscilloscope Bandwidth to at least 20MHzDVM 4 1/2 Digits, 0.1% accuracyVariable DC power supply 0 to 24VDCPotentiometer 1K, 1W Single Turn (quantity 2)Potentiometer 10K, 1W Single Turn (quantity 2)Fixed Resistor 1K, 1/4W, 2%

All test equipment must bear appropriate calibration identification in the form of a sticker or tag including dateof calibration, name of calibration facility, initials of individual performing calibration, serial number ofequipment, and the due date for next calibration.

Additionally, drawing 92452 is required to identify the location of all signal points referenced in this procedure.


8


Appendix

8-9

III. INITIAL SETUP

1. Apply power as required and place the board in Drill Mode.

2. Attach a 1K potentiometer to Throttle Excitation F/S (clockwise end) and Throttle Excitation Return,connecting the wiper to Speed Reference #1. This emulates the Driller’s Throttle control.

3. Attach a 1K potentiometer to Current Excitation F/S (clockwise end) and VDC Makeup Return, connectingthe wiper to VDC Makeup Signal. This emulates the VDC Makeup Current (torque) control.

4. Attach a 1K fixed resistor from Modified Drill Current Limit Excitation #1 to Current Excitation Return.

5. Attach a 10K potentiometer to Water Sensor #1 (+) and (-) so that the resistance between these two pointscan be varied from zero to 10K Ohms. Similarly, connect a second 10K potentiometer between WaterSensor #2 (+) and (-).

6. Verify the status of the following LED indicators:

Function Color Status

Power Limit Red OFFStall Ramp Down Red OFFRotary Table Mode Red OFFWater Detect #1 Red OFFWater Detect #2 Red OFFBottom of Ramp Green ONTop of Ramp Green OFFOverspeed Red OFFTorque Green OFFSpin Green OFFTorque Ramp Up Green OFF

Note: It is imperative that the board is in this state when power is first applied and that no action is performedto attain these states.


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IV. TEST PROCEDURE

Note: Unless otherwise specified, all measurements must be within 2% of stated values. Reference drawing 92452

for location of all signal points.

1. SCR Speed Signal

1.1. Drill Mode

Connect variable power supply between Throttle Excitation F/S and Throttle Excitation Return (this is the same

location as a 1K potentiometer is connected) and set the voltage to +20.0VDC. Vary the setting of the

potentiometer and verify the same value is measured at the SCR Speed Signal Output #1 as measured at

Speed Reference #1 (reference measurements to Throttle Excitation Return).

1.2. Power Limit

Verify Power Limit indicator (DS1) is OFF. It is imperative that the board is in this state when power is first applied

and that no action is performed to bring the Power Limit to the OFF state.

Briefly connect Throttle Down and Throttle Up Commands to analog ground for each step below. Note the

following sequence occurs with each transition of the command and that only one segment changes per

command transition:

—Bar Graph Indicators (DSP4)— (DS1) SCR #1

Command Inc Throt LED Throttle Ramp Power Limit Speed Signal

(None) OFF Segment #1 (Top) OFF 20.0V

Throttle Down Down (pulse) Segment #2 ON 19.4V








Throttle Up Up (pulse) Segment #7 ON 16.6V






Throttle Up Up (pulse) Segment #1 (Top) OFF 20.0V

Throttle Up Up (pulse) Segment #1 OFF 20.0V

1.3. Spin Mode

Assign Spin Mode (see 92452 sheet 3 for location of mode assignment pins—all commands are active low, i.e.,

connecting a signal to analog ground activates the associated mode). Verify Spin LED is ON. Adjust Spin

Speed potentiometer from zero to full clockwise position. Verify SCR Speed Signal #1 varies from zero to

7.87Volts (±0.5V).


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Appendix

8-11

1.4. Torque Mode

Assign Torque Mode. Verify Torque LED is ON. Adjust Torque Speed potentiometer from zero to full clockwise

position. Verify SCR Speed Signal #1 varies from zero to 20V.

1.5. Overspeed Condition

Leave the Torque Speed potentiometer in full clockwise position. While remaining in Torque Mode, assign

Overspeed and verify SCR Speed Signal #1 becomes zero volts.

2. SCR Current Signal

2.1. Drill Mode

Connect a power supply to Current Limit Reference #1 and assign Drill Mode. Vary the voltage from zero to

20VDC and verify the voltage at SCR Current Signal #1 and #2 is the same as the value at the Current Limit

Reference Input.

2.2. Stall Protection

Verify Stall Ramp Down indicator (DS2) is OFF. It is imperative that the board is in this state when power is first

applied and that no action is performed to bring the Stall Ramp Down to the OFF state. Briefly connect Current

Down and Current Up Commands to analog ground and remove as indicated below. Note the following

sequence occurs with each transition of the command and that only one segment changes per command

transition:

—Bar Graph Indicators (DSP1)— (DS2) SCR #1

Command Inc Curr LED Throttle Ramp Stall Ramp Down Current Signal

(None) OFF Segment #1 (Top) OFF 20.0VCurrent Down Down (pulse) Segment #2 ON 17.5V

Current Down Down (pulse) Segment #3 ON 15.0V







Current Up Up (pulse) Segment #7 ON 5.0V

Current Up Up (pulse) Segment #6 ON 7.5V

Current Up Up (pulse) Segment #5 ON 10.0VCurrent Up Up (pulse) Segment #4 ON 12.5VCurrent Up Up (pulse) Segment #3 ON 15.0VCurrent Up Up (pulse) Segment #2 ON 17.5VCurrent Up Up (pulse) Segment #1 (Top) OFF 20.0VCurrent Up Up (pulse) Segment #1 OFF 20.0V


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Appendix

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2.3. SpinAssign Spin Mode. Apply 20VDC between Current Excitation F/S and Current Excitation Return. Set Spin

Current potentiometer to full counter-clockwise position. Verify the value at SCR Current Signal #1remains less than 100mV as the position of the VDC Current Limit potentiometer is rotated from zero tofull clockwise rotation.

Adjust Spin Current potentiometer to full clockwise rotation. Vary VDC Current Limit potentiometer from fullcounter-clockwise to full clockwise rotation. Verify the voltage at SCR Current Signal #1 increases from6.67Volts to 9.1Volts (±4%).

2.4. Torque Mode Ramp UpAssign Torque Mode and adjust Spin Current to full counter-clockwise position. Connect an oscilloscope

to SCR Current Signal #1 output (referenced to Current Exc Rtn). Assign Torque Ramp Up and verifyTorque Ramp Up indicator (DS11) is ON, Bottom of Ramp indicator (DS6) goes OFF, and segments ofDSP2 and DSP3 increment from Bottom of Ramp to Top of Ramp as marked PCB silk-screen.

Verify that the complete ramp up time is four seconds, that no steps are missing as the voltage steps from0V to 20Volts as monitored on the oscilloscope, and that Top of Ramp indicator (DS7) is ON.

2.5. Torque Mode Ramp DownRemove the Torque Ramp Up Command and verify that the segments on displays DSP2 and DSP3

increment down from Top of Ramp to Bottom of Ramp.

Verify that the complete ramp down time is two seconds and that no steps are missing as the voltage stepsfrom 20Volts to 0V as monitored on the oscilloscope.

2.6. OverspeedReturn to Torque Ramp Up Mode and verify voltage at SCR Current Signal #1 is 20Volts. Assign Overspeed

command and verify voltage drops to less than 100mV. Note that Overspeed indicator DS is ON.

Remove Overspeed condition and verify SCR Current Signal #1 is 20VDC. Assign Spin command and verifyoutput voltage drops to less than 100mV, as above.

3. Modified Drill Current Limit

3.1. TDS ModeRotate TD Current Limit from full counter-clockwise to full clockwise positions and verify the voltage at

Modified Drill Current Limit Excitation varies from 10Volts to 20Volts.

3.2. Rotary Table ModeAssign Rotary Table Mode. Rotate RT Current Limit from full counter-clockwise to full clockwise positions

and verify the voltage at Modified Drill Current Limit Excitation varies from 10Volts to 20Volts.

4. Water Detection

4.1. Water Sensor #1Vary the value of the potentiometer at the Water Sensor #1 input from 10K toward zero. Verify that Water

Detect #1 LED (DS5) goes ON when resistance is 4K Ohms (±500 Ω). Technical DrawingsTechnical DrawingsTechnical Drawings

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Appendix

8-13

4.2. Water Sensor #2Vary the value of the potentiometer at the Water Sensor #2 input from 10K toward zero. Verify that Water

Detect #2 LED (DS4) goes ON when resistance is approximately 4K Ohms (±500 Ω).

V. FINAL ACCEPTANCE

1. Verify board has been properly conformal coated.2. Verify board assembly is in accordance with IPC-610-A (latest revision), Class 3.3. Verify torque on all hardware.

After successful completion of this procedure, PCB assembly is to be:

• Serialized• Dated• Stamped indicating individual performing test• Properly bagged and boxed


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Speed/Torque II Test Procedure


Board Name: Speed/Torque Interface II


Schematic: 92962

Product: TDCS

PURPOSE: This test procedure provides a guideline to verify proper operation of the above board and is the basis

for completed PCB assembly acceptance.



A brief summary of the functions of this board and its application.


A list of the minimal equipment requirements to successfully test and verify proper assembly of this board.

The use of additional test equipment and/or fixtures are at the discretion of the tester so long as the

accuracy constraints are met.

III. INITIAL SETUP

Preliminary setup and board alignment procedures required prior to board testing.

IV. TEST PROCEDURE

The actual procedure for testing the PCB assembly.

V. FINAL ACCEPTANCE

Remaining functions required to prepare PCB assembly for final acceptance.


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Appendix

8-15


The Speed/Torque II board provides an interface between the Varco Driller’s Console (VDC), the Programmable

Logic Controller (PLC), and the customer’s SCR system. The board is designed to be inserted into a Varco control

system rack with either a CR1/CR2 or CR1/CR3 configuration.


• RPM measurement

• TDS direction indication

• Armature Current correction for plus and minus polarities

• Galvanically isolated -10V to +10V output for tach feedback signal

Inputs:

Signal Qty Voltage

Magnetic pickup* 1 4-30V p-p

Proximity sensor 2 24V pulse

Reverse Command from PLC 1 0V or open

Rotary Table Tach Signal 1 -10VDC to +10VDC

Armature Current sensor 2 -5VDC to +5VDC

Rotary Table Command from PLC 1 0V or open

Gear Ratio (for TDS-4 only) 1 0V or open

* (For older systems without TDS direction indication)

Outputs:

Signal Qty Voltage

TDS RPM 2 0-10VDC

TDS RPM 3 4 to 20mA

TDS Armature Current 2 0-10VDC

TDS Armature Current 3 4 to 20mA

Reverse (open for reverse) 1 Dry Contact

Reverse (close for reverse) 1 Dry Contact

Tachometer Signal 1 -10VDC to +10VDC

Reverse Signal (to PLC) 1 0V or 24VDC

Board Identifier 1 0V

Indicators installed on board assembly:

Function Indicator

TDS Reverse Red LED

Proximity Sensor “A”/Mag PU signal Green LED

Proximity Sensor “B” signal Green LED

RPM display (0 to 250 RPM) Bar graph

Armature Current (0 to 1500 AMPS) Bar graph

TDS Type selected Seven-segment display

TDS4 High Gear Selected Decimal point on aboveTechnical DrawingsTechnical DrawingsTechnical Drawings

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Oscilloscope Bandwidth to at least 20MHz

DVM 4 1/2 Digits, 0.1% accuracy

Variable DC power supply 0 to 24VDC

Function generator Variable Duty Cycle to 1kHz

Frequency Counter Accuracy at least ±1Hz

All test equipment must bear appropriate calibration identification in the form of a sticker or tag including date of

calibration, name of calibration facility, initials of individual performing calibration, serial number of equipment, and

the due date for next calibration.

Additionally, drawing 92962 is required to identify the location of all signal points referenced in this procedure.

III. INITIAL SETUP

1. Place SW1 in CALIBRATE position; set SW2A and SW2B to OPEN positions.

2. Connect frequency counter between TP1 and GND.

3. Set SW3 to position 3.

4. Adjust R21 so that the frequency measured at TP1 is as indicated on chart located on schematic drawing

92962, ±2 Hertz.

5. Similarly, adjust R22 - R25, changing SW3 and Gear Ratio as appropriate.

6. Place SW1 in OPERATE position.

7. Input a square wave of 24V amplitude and 33% duty cycle at P1-C26 with return at P1-C13 (frequency to

be ±1%).

8. Adjust R31 - R35 to achieve 10VDC (±0.1VDC) at P1-B19 using SW3 to select TDS type.


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IV. TEST PROCEDURE

Note: Unless otherwise specified, all measurements must be within 2% of stated values. Reference drawing 92962

for location of all signal points.

1. RPM Function

1.1. Magnetic PickupFor the following, input a 8V p-p sine wave as indicated at P1-C12 with return at P1-C13 andmeasure the output at P1-B19 (referenced to analog ground):

Input TDS Type Output

140Hz 3 2.5V

280Hz 3 5.0V

420Hz 3 7.5V

560Hz 3 10.0V

1.2. Proximity Sensor “A”For the following, input a 24V p-p square wave with a 33% duty cycle as indicated at P1-C26 withreturn at P1-C13 and measure the output at P1-B19 (referenced to analog ground). Use SW3 andGear Ratio input to establish TDS Type.

Verify that TDS indicator DSP3 corresponds with TDS type selected. (Jumper P1-C13 to P1-C2 forthe remainder of this test procedure)

Input TDS Type DSP3 Output

150Hz 3 3 2.68V150Hz 4L 4 1.80V150Hz 4H 4. 2.81V Note: DSP3 decimal point is ON150Hz 5 5 1.95V150Hz 6 6 2.68V300Hz 3 3 5.36V300Hz 4L 4 3.59V300Hz 4H 4. 5.63V300Hz 5 5 3.90V300Hz 6 6 5.36V500Hz 3 3 8.93V500Hz 4L 4 5.99V500Hz 4H 4. 9.38V500Hz 5 5 6.49V500Hz 6 6 8.93V560Hz 3 3 10.0V835Hz 4L 4 10.0V533Hz 4H 4. 10.0V770Hz 5 5 10.0V560Hz 6 6 10.0V


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1.3. Proximity Sensor “B” (normal mode)Using 24VDC to simulate proximity sensors, perform the following sequence and note the state ofthe red REVERSE indicator (DS3) and the green status indicators (DS1 and DS2):

——Prox Sensor Inputs—— Indicator“A” DS1 “B” DS2 DS30V OFF 0V OFF OFF or ON0V OFF 24V ON OFF24V ON 24V ON OFF24V ON 0V OFF OFF24V ON 24V ON ON0V OFF 24V ON ON0V OFF 0V OFF ON0V OFF 24V ON OFF

1.4. Proximity Sensor “B” (inverted mode)Continue with SW2A and SW2B in the CLOSE position:

——Prox Sensor Inputs—— Indicator“A” DS1 “B” DS2 DS324V ON 24V ON OFF or ON24V ON 0V OFF OFF0V OFF 0V OFF OFF0V OFF 24V ON OFF0V OFF 0V OFF ON24V ON 0V OFF ON24V ON 24V ON ON24V ON 0V OFF OFF

1.5. RPM Output Circuit VerificationSelect TDS Type 3 and input the following frequencies as in Step 1.2 and verify the RPM outputs as

well as the number of segments lit on bar graph display (DSP1). Bar graph indication must be ±1 bar:Input 0-10V #1 0-10V #2 4-20mA #1 4-20mA #2 4-20mA #3 DSP1

0Hz 0.0V 0.0V 4mA 4mA 4mA 0

112Hz 2.0V 2.0V 7.2mA 7.2mA 7.2mA 3

280Hz 5.0V 5.0V 12mA 12mA 12mA 7

420Hz 7.5V 7.5V 16mA 16mA 16mA 10

560Hz 10.0V 10.0V 20mA 20mA 20mA 10

1.6. Board IdentifierVerify resistance from P1-A19 to Analog Ground is less than 1 Ohm.

1.7 TDS Direction IndicationCheck Reverse input and output operation by connecting P1-A14 to Analog Ground and verifyingresponses:

Reverse Cmnd DS3 P2-C4 to P2-B4 P2-C4 to P2-A4 Reverse SignalJumper ON ON > 20M Ohms < 0.5 Ohms < 2VDCOpen OFF < 0.5 Ohms > 20M Ohms > 20VDC


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Appendix

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2. Armature Current

2.1. Armature Current Sensor #1Select TDS Type 3 and place SW4A - SW4D in the OPEN position. Input the following voltages atP1-C15 and verify proper values at the indicated TDS Armature Current outputs and bar graphdisplay, DSP2. Outputs must be ±3% and DSP2 value must be ±1 bar:

Input 0-10V #1 0-10V #2 4-20mA #1 4-20mA #2 4-20mA #3 DSP2

-5.0V 10.0V 10.0V 20.0mA 20.0mA 20.0mA 10-4.0V 8.0V 8.0V 16.8mA 16.8mA 16.8mA 8-2.5V 5.0V 5.0V 12.0mA 12.0mA 12.0mA 5-1.0V 2.0V 2.0V 7.2mA 7.2mA 7.2mA 20.0V 0.0V 0.0V 4.0mA 4.0mA 4.0mA 01.0V 2.0V 2.0V 7.2mA 7.2mA 7.2mA 22.5V 5.0V 5.0V 12.0mA 12.0mA 12.0mA 54.0V 8.0V 8.0V 16.8mA 16.8mA 16.8mA 85.0V 10.0V 10.0V 20.0mA 20.0mA 20.0mA 10

2.2. Armature Current Sensor #2Select TDS Type 6. Input the following voltages at P1-C15 and P1-A9 verify proper values at the i

ndicated TDS Armature Current output and bar graph display, DSP2 (bar graph value must be ±1 bar):

Input#1 Input#2 0-10V #1 DSP2

-2.0V -5.0V 7.0V 10-2.0V -2.0V 4.0V 8-2.0V 0.0V 2.0V 4-2.0V 2.0V 4.0V 8-2.0V 5.0V 7.0V 10

0.0V -5.0V 5.0V 100.0V -2.0V 2.0V 40.0V 0.0V 0.0V 00.0V 2.0V 2.0V 40.0V 5.0V 5.0V 10




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2.3. Reduced Gain ModeSelect TDS Type 6 and place SW4A - SW4D in the CLOSE position. Input the following voltages and verify

proper values at the indicated TDS Armature Current output:

Current#1 Current#2 0-10V #1

0.0V -4.0V 2.0V-2.0V -2.0V 2.0V-2.0V 0.0V 1.0V-2.0V 2.0V 2.0V4.0V 2.0V 3.0V4.0V -4.0V 4.0V

Place SW4A - SW4D in the OPEN position and continue:

2.0V 2.0V 4.0V-2.0V -2.0V 4.0V

3. Galvanically Isolated Tach Feedback Signal and Calibration Mode

3.1. Rotary Table ModeSelect TDS Type 3 and Rotary Table Mode (reference P1-C18). Apply the following voltages to theRotary Table Tach Signal inputs and measure the subsequent Tach Output signal (P1-A24 and P1-A25). Make certain that both voltage source and DVM are completely isolated from PCB powersupply return:

Input OutputDSP3

-5V -5V 00V 0V 05V 5V 0

3.2. TDS ModeSelect TDS mode (i.e., not Rotary Table Mode). Apply the following signals at Proximity Sensor “A” input and verify proper voltages at Tach Output (P1-A24 and P1-A25) in both forward and reverseconditions. Ouput must be ±3%:

Input Direction DSP3 Output

140Hz Forward 3 2.5V280Hz Forward 3 5.0V420Hz Forward 3 7.5V560Hz Forward 3 10.0V

140Hz Reverse 3 -2.5V280Hz Reverse 3 -5.0V420Hz Reverse 3 -7.5V560Hz Reverse 3 -10.0V


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Appendix

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3.3. Ground Isolation Verification.With all power removed from PCB assembly, measure the resistance between U20, pin 2 and U20pin 32. This resistance must be greater than 20M Ohms.

3.4. Calibration ModeSelect Calibration mode. Switch TDS mode as noted and verify the following values and thecorresponding number of segments lit on bar graph displays:

TDS RPM 0-10V #1 DSP1 Arm Cur 0-10V #1 DSP2

3 10.0V 10 5.0V 54L 10.0V 10 5.0V 54H 10.0V 10 5.0V 55 10.0V 10 5.0V 56 10.0V 10 5.0V 10

V. FINAL ACCEPTANCE

1. Verify all DIP switches are in the OPEN or OFF state.

2. Verify board has been properly conformal coated.

3. Verify board assembly is in accordance with IPC-610-A (latest revision), Class 3.

4. Verify torque on all hardware.




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Stump/Cyclops Test Procedure


Board Name: STUMP/CYCLOPS Version II


Schematic: 96142

Product: TDCS

PURPOSE: This test procedure provides a guideline to verify proper operation of the above board and is the basis for

completed PCB assembly acceptance.



A brief summary of the functions of this board and its application


This section contains a list of the minimal equipment requirements to successfully test and verify proper

assembly of this board. The use of additional test equipment and/or fixtures is at the discretion of the tester

so long as the accuracy constraints are met.

III. INITIAL SETUP

Preliminary setup and board alignment procedures required prior to board testing

IV. TEST PROCEDURE

The actual procedure for testing the PCB assembly

V. FINAL ACCEPTANCE

Remaining functions required to prepare PCB assembly for final acceptance


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Appendix

8-23


The STUMP/CYCLOPS Version II board performs two major functions, either individually or simultaneously, namely,

1) Calculation of Pipe RPM and Torque, and 2) Calculation of Percent of Pipe Yield. When used for Pipe Yield

Calculations, a display panel (P/N 88808) is additionally required; when used for RPM/Torque only applications, a

configuration board (P/N 89740) is required. Under no circumstances are the Display Panel and Configuration Board

connected at the same time.

The board is designed to be inserted into a Varco Control System card rack with either a CR1/CR2 or CR1/CR3

configuration or, alternately, in a standalone rack (P/N 91756) for applications without a Varco Transfer Panel.


• Calculation of Pipe RPM based on Armature Voltage and Armature Current Values

• Calculation of Pipe Torque

• Calculation of Percent of Pipe Yield based on Torque, Internal Pressure, and Pipe Tension

• Output of Armature Current

• Display of Field Current Value

• Onboard Display of Armature Voltage, Armature Current, and Pipe RPM

• Self-Test and Diagnostic Capability

For a detailed functional description of STUMP/CYCLOPS hardware and software, reference the followingdocuments:

Document Description Number

User’s Guide: STUMP 92908

User’s Guide: CYCLOPS 92692

STUMP/CYCLOPS Software Listing 96729


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Inputs:

Signal Type Qty Voltage Sensor Input Range

Armature Voltage Analog 1 0 to ±2.5V 0 to ±1000VDC

Armature Current Analog 2 0 to ±5V 0 to ±1500ADC

Hook Load Analog 1 4 to 20mA 0 to F/S PSI

Mud Pressure Analog 1 4 to 20mA 0 to 5000PSI

Field Current Analog 1 4 to 12 to 20mA -75 to 0 to +75ADC

Field Current Select Digital 2 0 or floating 30A, 40A, 57A, User

Gear Ratio=High Digital 1 0 or floating 0=High Gear

Rotary Table Mode Digital 1 0 or floating 0=Rotary Table Mode

Gear Ratio Unknown Digital 1 0 or floating 0=Gear Ratio Unknown

Serial Data Input (Programming Port) Digital 1 RS232 N/A

Serial Data Input (Display Port) Digital 1 RS485 N/A

RPM=Speed Board Digital 1 0 or floating 0=Speed Board RPM

Outputs:

Signal Qty Voltage Engineering Value

Pipe RPM 2 0 to 10V 0 to 350 RPM

Pipe RPM 3 4 to 20mA 0 to 350 RPM

Armature Current 2 0 to 10V 0 to 1500ADC

Armature Current 3 4 to 20mA 0 to 1500ADC

Pipe Torque 1 0 to 10V 0 to 55,000 FT-LB

Pipe Torque 2 4 to 20mA 0 to 55,000 FT-LB

Percent Yield 1 0 to 10V 0 to 120 Percent

Percent Yield 1 4 to 20mA 0 to 120 Percent

Percent Yield Alarm 1 Dry Contact OPEN=Alarm

Percent Yield Alarm 1 Dry Contact CLOSED=AlarmSerial Data Output (Programming Port) 1 RS232 N/ASerial Data Output (Printer Port) 1 RS232 N/ASerial Data Output (Display Port) 1 RS485 N/A

Indicators Installed on Board Assembly:

Function Indicator

Armature Voltage Bar Graph

Armature Current Bar graph

RPM Bar graph

TDS Type/Gear Ratio Seven-Segment Display

Motor Type/Field Current Dot-Matrix Display

Data Out Red LED

A/D Conversion ON Red LED


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Appendix

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DVM4_ Digits, 0.1% accuracy

Current Meter 4_ Digits; 0.1% accuracy

Variable DC Power Supply 0 to ±5VDC (Qty 3)

Variable DC Current Supply 4 to 20mA (Qty 3)

ASCII Terminal (RS232) 9600 Baud

Serial Printer (RS232) 4800 Baud

Display Panel (P/N 88808) N/A

Configuration Board (P/N 89740) N/A

All test equipment must bear appropriate calibration identification in the form of a sticker or tag including date of

calibration, name of calibration facility, initials of individual performing calibration, serial number of equipment, and

the due date for next calibration.

Additionally, documents 92692, 96142, and 92972 are required to identify the location of all signal points referenced

in this procedure and to determine proper board functions.

III. INITIAL SETUP

1. Place all DIP switches in the OFF or OPEN positions.

2. Install Configuration Board into P4 and set switches as follows (Display Panel is not connected):

SW1 (TDS Type) to position 3

SW2 Motor Type) to position 1

3. Apply power and verify Vref (TP9) is +5.000 (±2%).

4. Verify the status of the following indicators:

Indicator Location Status

Dot-Matrix Display J1 Message: “VARCO CYCLOPS SELF-TEST PASSED…”Followed by: “TDS3” then “GE S”

A/D On DS1 FlashingData Out DS2 OFFSeven-Segment DSP1 “3”

Failure of the above indicates possible EEPROM programming error.

5. Disconnect power and remove Configuration Board.6. Connect an RS232 terminal and printer to P4 (reference drawing 96142 to determine proper wiring). Note

that the connection at P4 is wired as a “Y” with both terminal and printer serial lines connected to the sameconnector. Set the terminal baud rate to 9600 and the printer to 4800. Apply power.


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Appendix

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7. Switch SW2F to the DOWN or CLOSE position and type CTRL-C at the terminal. A “READY” prompt shouldbe displayed. Type “LIST# <space> 1-10 <ENTER>” and verify program lines 1 through 10 are printed.Handshaking is not supported on the printer post. If large portions of program listing are requested, extranull characters are required after each line is printed. To accomplish this, type “NULL <space>100<ENTER>” at the READY Prompt.

8. Disconnect power and remove connector at P4. Connect Display Panel TB1 to STUMP/CYCLOPS BoardP1 (reference schematics 92972 and 96142 for pin number details). Place SW2F in the UP or OPENposition.

9. Apply power and verify the indicators display the same states as in Step 4 (with the exception of DS2 nowflashing periodically) and the Display Panel shows the information detailed in document 92962.

IV. TEST PROCEDURE

Note: Unless otherwise specified, all measurements must be within 2% of stated values. Reference drawing96142 for location of all signal points.

1. Analog Inputs

1.1. Armature VoltageApply 2.000V to Armature Voltage Input. From the Display Panel, select SENSOR INPUTS as outlined in

section 5.3 of the CYCLOPS User’s Guide, 92962. Verify that the Input Voltage displayed is 2V. Reversethe input voltage and verify the display again reads 2V.

1.2. Armature Current #1Apply 4.000V to the Armature Current #1 Input. From the Display Panel, select Armature Current #1 and

verify the Input Voltage displayed is 4V. Reverse the input voltage and verify the display again reads 4V.

1.3. Mud PressureApply 16.0mA to the Mud Pressure Input. From the Display Panel, select Mud Pressure and verify the input

voltage displayed is 4V.

1.4. Hook LoadApply 16.0mA to the Hook Load Input. From the Display Panel, select Hook Load and verify the input voltage

displayed is 4V.

1.5. SpareApply 16.0mA to the Spare Input. From the Display Panel, select Spare and verify the input voltage displayed

is 4V.


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1.6 Field CurrentApply 16.0mA to the Field Current Input. From the Display Panel, select Field Current and verify the input

voltage displayed is 4V.

1.7 Armature Current #2Apply 4.000V to the Armature Current #2 Input. From the Display Panel, select Armature Current #2 andverify the Input Voltage displayed is 4V. Reverse the input voltage and verify the display again reads 4V.

1.8 RPMAssign RPM=Mag Pickup/Proximity Sensor Mode and verify RPM 0 to 10V #2 Output is 0V. Apply 5.00Vto RPM 0 to 10V Output #2. (Although a voltage is being applied to the RPM Output connector, no conflictexists as long as RPM=Mag Pickup/Proximity Sensor is selected.) From the Display Panel, select Speed/Torque RPM and verify the voltage displayed is 2.5V. Remove voltage from RPM Output and return RPMMode to Normal.

2. Digital Inputs

2.1. Rotary Table Mode Select Rotary Table Mode and verify DSP1 displays “0”. Return to TDS Mode.

2.2. Field SelectAssign Field Select #1 and verify front panel dot-matrix display (88220) shows “30A”. Open Field Select #1.

Assign Field Select #2 and verify dot-matrix display shows “40A”.

Assign Field Select #1 (leaving Field Select #2 assigned) and verify dot-matrix display shows “57A”.

Open both Field Select #1 and #2 and verify dot-matrix display shows “GE S”.

2.3. Gear Ratio Select Select Gear Ratio=High and verify decimal point of DSP1 is ON. Open Gear Ratio Select.

2.4. Gear Ratio Unknown This input is not used at this time. Skip to Step 2.5.

2.5. Calibrate Mode Select Calibration Mode. Verify the following outputs shown in the first column under “Normal”:


8

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Appendix

8-28

——————————Value—————————-

Output Normal RPM=Prox Sensors

RPM 0 to 10V #1 5V 0V

RPM 0 to 10V #2 5V 0V

RPM 4to 20mA #1 12mA 0V

RPM 4 to 20mA #2 12mA 0V

RPM 4 to 20mA #3 12mA 0V

Armature Current 0 to 10V #1 5V 0V

Armature Current 0 to 10V #2 5V 0V

Armature Current 4 to 20mA #1 12mA 0V



Pipe Torque 0 to 10V 10V 10V

Pipe Torque 4 to 20mA #1 20mA 20mA

Pipe Torque 4 to 20mA #2 20mA 20mA

Percent Yield 0 to 10V 10V 10V

Percent Yield 4 to 20mA 20mA 20mA

2.6. RPM=Mag Pickup/Proximity Sensors

Select RPM=Mag Pickup/Proximity Sensors and verify the outputs are as shown in the second column inStep 2.5, above marked “RPM=Prox Sensors”.

Return to Operate Mode


8


Appendix

8-29

3. Analog Outputs

3.1. RPM

Verify Motor Type is GE Series and TDS Type is set to 3. Apply 1.250V to Armature Voltage Input and 1.000V

to Armature Current #1 Input. Verify RPM Output #1 is 6.03V. Reverse polarity of Armature Voltage Input and

verify RPM Output remains at 6.03V. Similarly, reverse Armature Current Input (with Armature Voltage Input

reversed) and verify RPM Output remains at 6.03V.

3.2. Armature Current

Apply 2.500V to Armature Current Input #1 and verify Armature Current Output is 5.00V. Reverse input voltage

and verify Armature Current Output remains at 5.00V.

From the LCD Panel, select TDS Type 6 (see 92692 for instructions). Apply 2.500V at Armature Current Input

#2 and verify Armature Current Output is 6.0V.. Reverse input and verify Armature Current Output remains at

6.0V.

3.3. Pipe Torque

From the LCD Panel, select 40A Shunt Motor and TDS Type 3. Apply 1.250V to Armature Voltage Input and

4.667V to Armature Current Input #1. Verify Torque 0 to 10V Output is 4.90V

3.4. Percent Yield

Apply the following signals at the indicated inputs:

Input Value

Armature Voltage 1.000V

Armature Current #1 1.000V

Mud Pressure 12.0mA

Hook Load 6.0mA

From the LCD Panel, perform Hook Load Sensor Calibration as outlined in document 92962, using Total Weight

of 45,000 pounds. Continue and select the following:

From the LCD Panel, select Pipe Data and enter the following:

Pipe Grade: G

Pipe Diameter/Tool Joint Connector Type: 4.5”/NC50(IF)

Filter Constant: 1

Units for Tension: Pounds

Change Hook Load Input to 8.0mA. Verify display indicates “Percent Yield: 17.0” (±1%) and the Percent Yield 0to 10V Output is 1.42V. Also verify the weight/foot (LB/FT) is shown as 25.10.


8

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Appendix

8-30

4. Analog Displays

4.1. Armature Voltage

Make certain board is set for GE Series Motor and TDS Type 3. Apply 1.250V to Armature Voltage Inputand verify associated front panel bar graph shows four or five segments lit.

4.2. Armature Current

Apply 2.500V to Armature Current Input and verify associated bar graph display shows four or fivesegments lit.

4.3. RPM

Apply 2.500V to Armature Voltage Input and 1.000V to Armature Current #1 Input. Verify RPM bar graphdisplay shows seven or eight segments lit.

5. General Operation

5.1. Percent Yield Alarm

With LCD Panel showing 17% Yield as in Step 3.4, choose Yield Alarm Option (see 92692 for details).Select “Yield Alarm Setpoint” of 10%. Verify Percent Yield Alarm contacts change state as indicated below(return to 100% and measure again):

Output Resistance

Setpoint Open=Alarm Close=Alarm

100% <1Ω >20MΩ

10% >20MΩ <1Ω

100% <1Ω >20MΩ

5.2. Seven-Segment DisplayFrom the LCD Panel, Select TDS Types 3, 4, 5, and 6. Verify Seven-Segment display follows TDS Typeselected. Return to TDS Type 4.

5.3. Dot-Matrix DisplayFrom the LCD Panel, select each motor type and verify Dot-Matrix display follows motor type selected. Leaveboards set for 40A Shunt motor. Enter Calibration Mode and verify display alternates between “CAL” and“MODE”. Return to Operate Mode.

5.4. Battery Backup OperationRemove power and wait 10 seconds. Apply power and verify seven-segment display shows TDS Type 4 andthe dot-matrix display shows 40A shunt motor. The LCD should display the pipe parameters entered in Step3.4.

From The LCD Panel, select TDS Type 3 and 57A Shunt motor.


8


Appendix

8-31

V. FINAL ACCEPTANCE

1. Verify board has been properly conformal coated.

2. Verify board assembly is in accordance with IPC-610-A (latest revision), Class 3.

3. Verify torque on all hardware.

4. Verify all DIP Switches are in OFF or OPEN positions.

5. Verify Operate/Calibrate Switch is in the OPERATE position.

6. Verify EEPROM is labeled in accordance with Drawing 96729 and reflects current revision.




8

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Appendix

8-32

Users Guide StumpSPEED TORQUE UNIT MICRO-PROCESSOR(STUMP)

1.0 GENERAL DESCRIPTION 3

2.0 FUNCTIONAL DESCRIPTION 3

3.0 TECHNICAL DESCRIPTION 3

3.1 Sensor Inputs 3

3.2 STUMP Calculations 3

3.2.1 RPM 3

3.2.2 Pipe Torque 4

4.0 INITIAL CALIBRATION AND SET UP 4

4.1 Meter Calibration 4

4.2 TDS/Motor Type Selection 5

5.0 OPERATION 6

6.0 HARDWARE FUNCTIONS 6

6.1 Power Up Sequence 6

6.2 Test Modes 6

6.3 DIP Switch Summary 7

6.4 Digital Inputs 8

APPENDIX A

Field EPROM/EEPROM Installation 9

APPENDIX B

EPROM/EEPROM Software Version History 10


8


Appendix

8-33

1.0 GENERAL DESCRIPTION

The STUMP provides a drilling operator RPM, Armature Current and Torque signals to drive.

2.0 FUNCTIONAL DESCRIPTION

The STUMP Systems consists of a processor board located in a safe area that receives inputs from two sensors,namely Armature Voltage and Motor Current and Calculates RPM and Torque. Outputs are provided for RPM,Armature Current and Torque in the form of both 0-10VDC and 4-20 mA signals.

3.0 TECHNICAL DESCRIPTION

Information is acquired from the two aforementioned sensors and processed with table information pertinent tothe type of motor in use. From these values, RPM and Torque are calculated.

3.1Sensor Inputs

The following sensors are input to the STUMP:

Sensor Input Signal Range Sensor OutputArmature Voltage -1000 VDC to + 1000 VDC -2.5V to + 2.5VArmature Current -1500 ADC to + 1500 ADC -5V to + 5V

3.2 STUMP Calculations

3.2.1 RPM

The STUMP processor digitizes the two analog signals and calculates RPM using the followingequations:

RPM = ((V - I* K) + B) / (I*M + B) / (G * R) (for series motors)RPM = (V * M + B) / (G * R) (for shunt motors)

Where: V = Armature VoltageI = Armature CurrentK = Constant for particular motor typeM = Motor curve slope for given current rangeB = Motor curve intercept for given current rangeG = TDS Gear RatioR = TDS-4 High/Low gear offset


8

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Appendix

8-34

The values for M and B are adjusted based on Armature Current and are calculated for each of 15 equal divisions from0 to 1500 ADC.

3.2.2 Pipe Torque

Pipe torque is calculated as follows:

T =(I * M + B) / (G * R)

Where: I = Armature CurrentM = Slope for given motor type and Armature current rangeB = Intercept for given motor typeG = TDS Type Gear Ratio

R = Offset for High/Low gear (TDS-4 only)

4.0 INITIAL CALIBRATION AND SET UP

The calibration and set-up sequence is performed only upon initial set-up or in the event of meter replacement.

4.1 Meter Calibration

With switch S1 in the CALIBRATE position, all analog voltage and current outputs are at preset values.For Torque this is +10VDC for voltage outputs and 20mA for current loop outputs. For RPM and ArmatureCurrent this value is +5VDC for Voltage outputs and 12mA for current loop outputs.

WARNING: Do not arbitrarily use the calibration feature while the TDS is in operation as this sends ahigh value RPM signal to the control system that can be interpreted as an overspeed condition, thusshutting down the TDS.

Set panel meters as follows using the adjustment knob on the rear of each meter:

Meter ValueRPM 175 RPMCurrent 750 ADCTorque 55,000 ft-lb (or equivalent)

If a torque meter is not part of the system, torque values are obtained from the current meter face plate.Note that auxiliary equipment connected the STUMP system (i.e. strip chart recorders) can be similarlycalibrated.

Make certain that the front panel switch is returned to the “OPERATE” position prior to using the TDS.


8


Appendix

8-35

4.2 TDS/Motor Type Selection

A configuration module (P/N 89740) is installed on STUMP board and is set using two rotary switches.

TDS Type Selection - Set “TDS TYPE” switch (SW1) to select the TDSType in use:

Function Position

IDS 1TDS-3 3TDS-4 4TDS-5 5TDS-6 6

Motor Type Selection - Set “MOTOR TYPE” switch (SW2) to select the MotorType in use:

Function Position

EMD Series 0GE Series 115A Shunt 230A Shunt 340A Shunt 450.5A Shunt 557A Shunt 660A Shunt 7

5.0 OPERATION

After initial setup, the STUMP requires no further adjustment or maintenance.

6.0 HARDWARE FUNCTIONS

6.1 Power Up Sequence

Upon application of power or reset via SW2-7, the system determines the validity of battery backed-upparameters. If these values remain stored, the front panel do-matrix display will scroll the followingmessage:

VARCO CYCLOPS SELF-TEST PASSED...

If the battery backed-up memory is lost, the STUMP will still function properly if the configuration moduleis in place.

The dot-matrix display on the STUMP will briefly indicate the TDS type followed by the motor type in use.In the event an optional field current sensor is connected, the dot-matrix display will alternately show typeand the actual field current.


8

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Appendix

8-36

6.2 Test Modes

The STUMP performs two basic test modes.

WARNING: NEVER ENTER VOLTAGE DISPLAY MODE WHILE DRILLING

Voltage Display Mode - With SW2-4 CLOSED, the onboard dot-matrix display will indicate the voltageat the input channel selected by SW2-1 to SW2-3 (all open for channel 0 through all closed for channel7). This voltage will simultaneously appear at all analog outputs.

Engineering Unit Display Mode - With SW2-4 OPEN and SW2-3 CLOSED, the onboard display willindicate the engineering unit value of an analog output as selected by SW2-1 and SW2-2 (both open forchannel 0 through both closed for channel 3). This test mode does not affect the operation of the STUMPand can be entered with power applied.

6.3 DIP Switch Summary

The following describes the function of the DIP switch, SW2, and the onboard dot-matrixdisplay (0 = Open; C = Closed; X = Either Open or Closed):

Switch (SW2) Function Display Display Range

1 2 3 4 5 6 7 Voltage Display Mode

O O O C O O O Armature Voltage Sensor Ch 0 Volts 0.00 to 2.50VO O C C O O O Armature Current Sensor Ch 1 Volts 0.00 to 5.00VO C O C O O O Mud Pressure Sensor Ch 2 Volts 0.00 to 5.00V(**)O C C C O O O Hook Load Sensor Ch 3 Volts 0.00 to 5.00V(**)C O O C O O O Spare Input Ch 4 Volts 0.00 to 5.00VC O C C O O O Field Current Ch 5 Volts 0.00 to 5.00VC C O C O O O Armature Current (Reverse) Ch 6 Volts 0.00 to -5.00VC C C C O O O Armature Voltage (Reverse) Ch 7 Volts 0.00 to -2.50V

Eng. Unit Display Mode

O O C O O O O Calculated RPM RPM 0 to 350(RPM)O C C O O O O Measured Current Armature Current 0 to 1500(AMPS)C O C O O O O Calculated Yield Percent Yield 0 to 9999(Percent) (**)C C C O O O O Calculated Torque Torque 0 to 55.0(ft-lbs x 1000)

Other Functions

X X X X X X C Reset processor BlankX X X X X C O Disable Watchdog Timer Motor TypeX X X X C O O* Use 32K of RAM Motor TypeO O O O O O O Normal Operation Motor Type

*For factory test only - erases the contents of battery backed-up RAM**Not used in STUMP Mode


8


Appendix

8-37

6.4 Digital Inputs

Three digital inputs are provided on the STUMP backplane connector. These are used to providedynamic changes to the operating program and are enabled by grouping the following pins with a contactclosure in the indicated terminal:

Terminal Function

CR1-15 Select TDS field current=30.0ACR1-16 Ground

CR1-17 Select TDS field current=40.0ACR1-18 Ground

Both grounded: Field current=57.0ABoth floating: Use operator selected field current

CR1-13 Select high range gear ratio for RPM/Torque calculations (TDS4 only)CR1-14 Ground


8

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Appendix

8-38

APPENDIX A:

Field EPROM Installation;

This Appendix describes the installation of new EPROM Programs. Note that EPROM’s must be replaced with the sameversion or higher and both EPROM’s must be of the same version - they are replaced as a set, never individually.

To change the program, perform the following:

1. Remove EPROM’s from 88230 board locations U27 and U28.

2. Install new EPROM’s observing proper orientation (notch on plastic EPROM carrier corresponds to the whitemarking on the board).

Location EPROM Part No.

U27 89454-1U28 89454-2

3. Verify operation of new program and discard removed EPROM’s.

Field EEPROM Installation (Stump Board P/N 96140)

1. Remove EEPROM from 96140 board location U20.

2. Install new EEPROM (p/N 96729) observing proper orientation (notch on plastic EEPROM carrier correspondsto the white marking on the board).

3. Verify operation of new program.

APPENDIX B:EPROM Software Version History

Version Effective Date EnhancementV1.0 26 Feb 89 Initial VersionV1.1 24 Apr 89 Added field current inputV2.0 26 Jun 89 Added 40A shunt motor and configuration boardV2.1 09 Feb 90 Added % yield alarm outputV2.2 16 Apr 90 Added Hook Load auto calibrate/removed configuration headerV2.3 18 Jun 90 Moved Torque output to interrupt routineV2.4 01 Mar 90 No field loss check if Armature Current <29A; RPM Calibrate mode is

now 175 RPM (5VDC)

EEPROM Software Version History

Rev Effective Date Enhancement- 25 Nov 91 Initial VersionA 29 May 92 Added IDS to TDS Type List

Added 3 1/2" Grade E to Pipe TableRevision letter shown on front display at startup

B 09 Jun 92 Added 6 5/8" Grade E and 5" Grade C120 to Pipe TableC 01 Mar 93 Added 70A Shunt SettingD 20 Jul 93 Added TDS6 Torque Output Technical DrawingsTechnical DrawingsTechnical Drawings

8


Appendix

8-39

Adjusting the torque wrenchUse the following procedure to adjust the pipehandler torque wrench:

e The pipehandler torque wrench is properly adjusted and tested in thefactory before it is shipped. Perform the adjustment procedure afterperforming maintenance on the torque wrench or if the torque wrenchdoes not function correctly.

1. Connect a pup joint or joint of drill pipe to the saver sub and makeuphand tight. Be sure to use the correct thread compound when makingup.

z When adjusting torque wrench manifold needle valves, loosen thelocknut around the valve stem and use a 5/32 in. hex wrench to adjustthe valve. After obtaining desired setting tighten locknut around valvestem.

i

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8

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Appendix

8-40

2. With the HPU off, screw the RECYCLE, CLAMP, and TORQUEsequence valves on the torque wrench manifold fully in (Figure 4-18).

3. Fully back out the Pressure Reducing Valve (PRV), then screw in oneturn.

4. Turn the LIFT/LOWER flow control valve fully in, and then back it outthree turns.

5. Turn on the HPU.

6. If the torque cylinders are in their full clockwise position, set theMake/Break valve to MAKE. If they are in their full counterclockwiseposition, set Make/Break valve to BREAK. Note that torque cylindersshould not move if the recycle sequence valve is fully in.

7. Slowly back out the RECYCLE sequence valve until torque cylindersjust start to move, then screw out an additionalfull turn.

BREAK MAKE

PRVTORQUECLAMPRECYCLE

LIFT LOWER

PSI

Ft.Lbs. x1000

0

1020

30

4050 60

70

8090

1000

500

1000 1500

2000

2500®

Make/BreakValve

Torque WrenchManifold

TorqueSequence

Valve

ClampSequence

Valve

RecycleSequence

Valve

HydraulicPressureReturn

HydraulicPressure

Inlet

Lift/LowerFlow Control

Valve

Torque Gauge0 - 2500 PSI

Figure 4-18. Torque wrench control manifold


8


Appendix

8-41

8. Move the Make/Break valve to BREAK. Set the PRVto 750 psi.

9. Switch the lever between MAKE and BREAK to adjust the RECYCLEsequence valve until full rotation in each direction takes six to eightseconds. Tighten the locknut around the RECYCLE sequence valveadjustment screw.

10. Set the Make/Break valve to MAKE.

11. Depress and hold the torque wrench operating button on the VDC.The torque wrench should lift and the clamp jaws should remainretracted.

12. Slowly back out the CLAMP sequence valve until the clamp jaws justbegin to clamp onto the tool joint. Screw out an additional half turn.Lock the CLAMP sequence valve adjustment screw in position bytightening the locknut.

13. Back out the TORQUE sequence valve until the torque cylinders justbegin to stroke, then back out an additional half turn. Tighten thelocknut around the TORQUE sequence valve adjustment screw.

14. Release the torque wrench operating button on the VDC. The torquewrench should start to unclamp and drop, then the torque cylindersshould recycle.

15. If the torque cylinders recycle before the clamp cylinders retract,screw in the RECYCLE sequence valve until the torque cylinders donot move before clamp cylinders have fully retracted. Tighten theRECYCLE sequence valve adjustment screw locknut.

16. Cycle the torque wrench as many times as required to makeup theconnection.

17. Set the Make/Break valve to BREAK.

18. Verify that the torque wrench correctly breaks out the drill pipe fromthe saver sub, without breaking out the saver sub or lower IBOP.

19. The torque wrench is ready for operation.


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Appendix

8-42

Adjusting the counterbalance system

Leave the HPU on during the entire adjustment procedure, anddisconnect the TDS from the drill string near the bottom of the rails, butwell off the stops.

1. Remove the caps and loosen the lock nuts on the needle valve andPRV located on the counterbalance manifold (Figure 4-19). It is notnecessary to remove the front guard for access to the manifold. Asmall amount of oil will leak around the adjusting stems afterremoving the caps.

2. Open the needle valve and let the stem circulate for two minutes.Crack both upper cylinder fittings and bleed air from system. Tightenthe fittings. Close the needle valve.

3. Using a hex wrench, screw in the PRV until the cylinder retracts,raising the TDS.

4. Slowly back out the PRV. The pressure decreases and the cylinderrods begin extending. When the integrated swivel bail contacts thehook, note the pressure on the gauge. Allow the pressure todecrease an additional 25 psi and tighten the locknut. Replace thecaps on the valve adjustment stem.


8


Appendix

8-43

Upper Motor FrameCrossmember

Pressure ReducingValve

PressureGauge

Needle Valve(on opposite side)

Figure 4-19. Counterbalance manifold


8

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Appendix

8-44

Adjusting the motor alignment cylinder system

Once the alignment cylinder is installed, use the following procedure toproperly adjust the motor alignment before operating TDS systems thathave a separate alignment cylinder accumulator and valve manifold.

1. With the HPU turned off, bleed down the alignment cylinderaccumulator by opening the needle valve located at the alignmentcylinder valve manifold (Figures 4-20 and 4-21).

2. Remove the split shipping brace from the motor alignment cylinder(Figure 4-22).

3. Turn on the HPU and allow the system to circulate for approximatelytwo minutes.

4. Close the needle valve.

5. Open the two flow control valves located at the alignment cylindersupply return lines 1-1/2 turns off their seats.


8


Appendix

8-45

Alignment CylinderLug (ref)

Pressure ReducingValve

Needle Valve

Motor Frame (ref)

AlignmentCylinderManifold

Accumulator

BracketGas Valve

Figure 4-20. Typical motor alignment cylinder valve manifold


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Appendix

8-46

Pressure Reducing Valve(PRV)

Directional Control Valve(Operation Switch)

Prefill Valve Assembly

Needle Valve

Motor Frame (ref)

Alignment CylinderValve Manifold

Accumulator

Bracket

Gas Valve

Figure 4-21. Motor alignment cylinder valve manifold


8


Appendix

8-47

Motor AlignmentCylinder

MotorFrame Dolly (Ref)

ShippingBrace

Figure 4-22. Motor alignment cylinder


8

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Appendix

8-48

The pressure setting is adjusted by screwing the PRV in or out with a hexwrench (Figure 4-19). Screwing in the valve increases pressure andmoves the saver sub toward the rails. Backing out the PRV reducespressure and moves the saver sub away from the rails (see additionalnotes at the end of this procedure).

6. Verify the correct pressure setting using the following procedure:

a. With the HPU on, back down the pressure using the PRV untilthe saver sub begins to pivot away from the rails. Record thispressure.

b. Slowly increase the pressure until the saver sub no longer movescloser to the rails as pressure increases. At this time, the cylindershould be in a “dead band” area.

c. Slowly increase the pressure until the saver sub begins to movetoward the rails again. Record the pressure reading when thisoccurs.

d. To determine the correct pressure setting, add the average pressurereadings from steps a and c above and divide by two. The resultingpressure “dead band” provides equal pre-load in each direction –both toward and away from the rails.

e. Record the pressure setting for future reference.

7. Set a joint of drill pipe in the slips.

8. Bring the top drive down as if stabbing the saver sub into the box.The pin and the box should be in alignment so that the OD of the pinclears the shoulder of the box. If adjustment is necessary, use thefollowing procedure:

a. Measure how far and in what direction (toward or away from therails) the pin must move to line up with drill pipe box.

b. Turn off the HPU and bleed down the alignment cylinderaccumulator. This allows the motor alignment cylinder to relaxand the motor to rotate on its trunnions, until the swivel contactsthe motor frame.

c. Loosen the lock tab and jam nut on the cylinder clevis.

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8


Appendix

8-49

d. Use a wrench on the cylinder rod flats to screw the rod into or outof the clevis, in the same direction the saver sub pin is to bemoved. A 1/4 in. of pin movement results from a 3/4 turn of therod. The alignment cylinder rod extension should be 2 3/8 ± 1/8in. gland to rod threads when the system is properly aligned.

e. Secure the jam nut and lock tab.

f. The nominal position of the two flow control valves is 1-1/2 turns off their seats. Should heavy drill pipe vibration beencountered, first attempt to control it with non-rotatingstabilizers in the casing close to the surface. If motor movementbecomes excessive due to continued vibration (more than 1/2 in.of cylinder stroke), the flow control valves may be closed to 3/4turn off their seats.

g. Tighten the lock nuts and replace the caps on all valve stems.

z If the alignment cylinder is removed for service, install the alignmentcylinder replacement brace to support the motor housing assembly whilecontinuing to operate the TDS. After reinstalling the alignment cylinder,use the three bleed holes (located along top of cylinder barrel) to removeair trapped in the cylinder.

Rail spacing and setback from the centerline of the well must be heldwithin recommended tolerances in order to maintain vertical alignment ofthe TDS.

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Appendix

8-50

Adjusting the safety valve actuator

Proper safety valve actuator installation and adjustment is essential toassure proper action of the mechanism and to minimize mechanicalcomponent wear. The actuator shell installs over the upper IBOP safetyvalve. Changing the position of the two threaded eye bolts that suspendthe safety valve actuator air cylinders on the PH-85, PH-60d and singlecrank PH-60 (Figure 13) adjusts the safety valve actuator. Adjust the PH-85, PH-60d and single crank PH-60 actuator shell as follows:

1. After removing the crank assemblies, make sure the actuator shelleasily moves up and down over the upper IBOP.

z There is only one crank on upper IBOPs for the PH-60 pipehandler.There are also three roller assemblies.

2. With the IBOP valve at mid-stroke, reinstall the crank assemblies.

3. Torque the 3/8 in. retaining bolts to 30-35 ft lb, lock tab.

4. Using a hex wrench, manually shift the IBOP valve through the crankassemblies and check for signs of binding. Make sure the shelltravels freely throughout its full range of travel. If binding exists,troubleshoot to eliminate any problems before returning to service.

5. Actuate the control switch on the driller’s console to the open thesafety valve. The cylinders should retract and the actuator ringshould be down.

6. For the PH-85, PH-60d and single crank PH-60 only, measure thedistance between the cylinder rod end and the cylinder gland oneach actuating cylinder (Figure 13). If that distance is not 1 inch,adjust the cylinder rod locknuts until it measures exactly 1 inch.

7. Actuate the valve to make sure it opens and closes fully.

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Appendix

8-51

OPEN

CLOSE

Upper IBOP Valve Actuator Shell

Crank Assembly(shown with valve OPEN,

note Crank Assembly position.)

Upper IBOP

ActuatorArm

Torque Tube

Lower IBOP

Saver Sub

Landing Collar

Link Adapter

Upper IBOP ValveActuator Air Cylinders (2)

Drive Stem

Eye Bolts (2)

Cylinder Adjustment

Bolts (4)

Rod End

CylinderGland

Cylinder inOPEN Position

*IMPORTANT

*1 in.

Figure 13. Adjusting the safety valve actuator system for the PH-85,PH-60d and single crank PH-60


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Appendix

8-52

TDS-4 Shunt Motor 22.5A FieldGraph Graph Graph

Current Mtr Torque Hi Gear Lo Gear200 477 3678 2350250 750 5784 3696300 928 7156 4573350 1200 9254 5913400 1400 10796 6899450 1554 11984 7657500 1760 13572 8673550 1948 15022 9599600 2120 16348 10447650 2286 17628 11264700 2416 18631 11905750 2564 19772 12634800 2695 20782 13280850 2803 21615 13812900 2915 22479 14364950 3011 23219 148371000 3085 23790 152021050 3158 24353 155611100 3227 24885 159011150 3270 25217 161131200 3319 25594 163551250 3371 25995 166111300 3406 26265 167831350 3427 26427 168871400 3450 26605 170001450 3459 26674 170451500 3459 26674 170451550 3471 26767 17104


8


Appendix

8-53

High Gear 5.080Low Gear 7.950Efficiency 0.975

Slope22.5A_ST 4.235 0 to 500AIntercept22.5A_ST -329.536 0 to 500ASlope22.5A_ST 2.650 501 to 1000AIntercept22.5A_ST 521.864 501 to 1000ASlope22.5A_ST 0.753 1000 TO MAXIntercept22.5A_ST 2388.273 1000 TO MAX

NOTE: When in 22.5A Field the Armature current shouldbe limited to 769A.


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Appendix

8-54

0

500

1000

1500

2000

2500

3000

3500

4000

22.5A Field Current Limit = 769A

Mo

tor T

orq

ue

Current

TDS-4 Motor Torque vs Current @ 22.5A Field


8


Appendix

8-55

0

5000

10000

15000

20000

25000

30000

GraphHiGear

Drill Torque

Cu

rrent

22

.5A

Field C

urren

t Lim

it = 7

69

A

TDS-4

Drill To

rqu

e vs. Cu

rrent @

22

.5A

Field


8

Varco

Appendix

8-56

8


Appendix

8-57

Directional valves

Directional control valve, solenoid operated, 2-position, 4-way(spring offset)

The two position, solenoid operated, four-way directional controlvalve directs hydraulic fluid to one of two possible flow paths. Thepresence or absence of electrical current in the single solenoidcoil determines the flow path selection. This valve is a low flowvalve and is used to supply hydraulic fluid to small actuators, or itmay be used as a pilot operator for larger valves.

Theory of operation

The valve has a spool that slides into a machined bore in thevalve housing. The housing has a number of ports to which thepressure, the tank, and two working lines for the actuator areconnected. Internally, the ports are connected to cast ormachined passages in the valve housing which terminate at themachined bore where the spool is located. The axial movementof the spool in the bore determines which ports are connected.

The spool is held in one of the valve’s two positions by a spring.In this position, the P (pressure) port is connected to the Aworking port and the B working port is connected to the T (tank)port. A solenoid is located at the end of the spool opposite thespring. If the coil is energized, the solenoid armature moves thespool through a push pin.

When the solenoid coil is energized, enough force is generatedto overcome the spring and the spool shifts in the housing. In thisposition, the P port is connected to the B working port and the Aworking port is connected to the T port. When the solenoid coil isdeenergized, the spring returns the spool to its original position.

A manual override button is located on the end of the solenoidhousing. Pressing this button performs the same function as thesolenoid coil by manually shifting the spool against the spring.This valve is a manifold-mounted valve in that the ports are alllocated on the valve mounting surface and are equipped with O-ring face seals. This valve is identified on hydraulic schematicdrawings using the following symbol:

aA B

P TTechnical DrawingsTechnical DrawingsTechnical Drawings

8

Varco

Appendix

8-58

Diagnostic procedure

A problem with this component is usually related to impropershifting of the spool. This could mean that the spool doesn’t shiftwhen the solenoid is energized, that the spring doesn’t return orhold the spool offset when the solenoid is deenergized, or thatthe spool does not shift fully in one or both directions. The mostlikely cause of a stuck spool is particulate contamination of thehydraulic fluid.

The other type of potential failure is an O-ring failure at themounting surface, but the external leakage of hydraulic fluidmakes this easy to detect. This procedure assumes that there isno electrical problem (i.e., the coil is drawing the proper amountof current when energized).

Perform the following steps to isolate a faulty valve:

1. Verify that supply pressure (usually 2,500 psi) is available atthe pressure port of the valve by connecting a test gauge tothe appropriate test point. If the required pressure is notpresent, the valve is probably not the problem. Check forproblems upstream of the supply port.

2. The valve can be actuated either electrically or by using themanual override button on the solenoid housing. If the manualoverride button is used, the coil should be in the deenergizedstate. If no change of state is present, the spool is most likelystuck in one position. See step d, below, to correct the problem.

3. Repairing a stuck spool: Try to free the spool by pressing onthe manual override button or with a light tapping on the bodyof the valve. It may help to turn off the HPU (or press the killswitch on the operator’s console) while doing this.

If this doesn’t free the spool, remove the valve to expose thespool through its ports. Clean the area around the valve beforeremoving it to prevent contamination of the exposed sealingsurfaces and passageways.

Attempt to free the spool using a screwdriver in between the glandsof the spool. Do not pry on the outside diameter of the spool.Lubricate the inside of the valve with a light mineral-based oil.

If the spool appears to move freely when the manual overridebutton is pressed, lubricate the inside of the valve with a lightmineral-based oil and remount the valve.If the spool cannot be freed or the problem reoccurs, replace thevalve.


8


Appendix

8-59

Directional control valve, solenoid operated, 3-position,4-way (spring centered), float center

The three-position, solenoid operated, four-way, directional control valvedirects hydraulic fluid to one of three possible flow paths. The presenceor absence of electrical current in the two solenoid coils determines theflow path selection. This valve is a low flow valve and is used to supplyhydraulic fluid to small actuators, or it may be used as pilot operator forlarger valves.

Theory of operation

The valve has a spool that slides into a machined bore in the valvehousing. The housing has a number of ports to which the pressure, thetank, and two working lines for the actuator are connected. Internally, theports are connected to cast or machined passages in the valve housingwhich terminate at the machined bore where the spool is located. Theaxial movement of the spool in the bore determines which ports areconnected.

The spool is held in the valve’s center position by springs. In thisposition, the P port is blocked and both the A working port and the Bworking port are connected to the T port. Solenoids are located at eitherend of the spool. If one of the coils is energized, the solenoid armaturemoves the spool through a push pin.

When the A solenoid coil is energized, enough force is generated toovercome the spring and the spool shifts in the housing. In this position,the P port is connected to the B working port and the A working port isconnected to the T port. When the A solenoid coil is deenergized, thespring returns the spool to its center position.

When the B solenoid coil is energized, enough force is generated toovercome the spring and the spool shifts in the housing. In this position,the P port is connected to the A working port and the B working port isconnected to the T port. When the B solenoid coil is deenergized, thespring returns the spool to its center position.

A manual override button is located on the end of each solenoid housing.Pressing this button performs the same function as the solenoid coil bymanually shifting the spool against the spring.


8

Varco

Appendix

8-60

This valve is a manifold-mounted valve in that the ports are alllocated on the valve mounting surface and are equipped with O-ring face seals. This valve is identified on hydraulic schematicdrawings using the following symbol:

a bA B

P T


A problem with this component is usually related to impropershifting of the spool. This could mean that the spool doesn’t shiftwhen one of the solenoids is energized, that the spring doesn’treturn or hold the spool centered when the solenoids aredeenergized, or that the spool does not shift fully in one or bothdirections.

The most likely cause of a stuck spool is particulatecontamination of the hydraulic fluid. The other type of potentialfailure is an O-ring failure at the mounting surface, but theexternal leakage of hydraulic fluid makes this easy to detect. Thisprocedure assumes that there is no electrical problem (i.e., thecoils are drawing the proper amount of current when energized).


1. Verify that supply pressure (usually 2,500 psi) is available atthe pressure port of the valve by connecting a test gauge tothe appropriate test point. If the required pressure is notpresent, the valve is probably not the problem–check forproblems upstream of the supply port.

2. Using a test gauge on the test points for the A and B workingports, verify that a change in state occurs on the workingports when the valve is cycled. You can actuate the valveeither electrically or use the manual override buttons on thesolenoid housings. If you use the manual override button,both coils should be in the deenergized state. With a normallyoperating valve, the pressure at a working port shouldalternate between a relatively low value and a much highervalue when the valve is cycled between either A or B andcenter. If no change of state is present, the spool is mostlikely stuck in one position. See step 4 below to correct theproblem.


8


Appendix

8-61

3. Using a test gauge on the test points for the A and B workingports, verify that the pressure at each working port equalizeswith the supply pressure measured in step 1 when one of thecoils is energized. It may be necessary to wait for an actuatorto move to its end of stroke before the pressure can stabilize.If the pressure does not stabilize, the valve is probably notthe problem and there may be an internal leak somewheredownstream of the valve.

4. Repairing a stuck spool: Try to free the spool by pressing onthe manual override button or with a light tapping on the bodyof the valve. It may help to turn off the HPU (or press the killswitch on the operator’s console) while doing this.

If this doesn’t free the spool, remove the valve to expose thespool through its ports. Clean the area around the valve beforeremoving it to prevent contamination of the exposed sealingsurfaces and passageways.

Attempt to free the spool using a screwdriver in between thelands of the spool (do not pry on the outside diameter of thespool). Lubricate the inside of the valve with a light mineral-basedoil.

If the spool appears to move freely when the manual overridebutton is pressed, lubricate the inside of the valve with a lightmineral-based oil and remount the valve. If the spool cannot befreed or the problem reoccurs, replace the valve.


8

Varco

Appendix

8-62

Directional control valve, pilot operated, 3-position,4-way (spring centered), solenoid controlled, float center

The three-position, pilot operated, solenoid controlled, four-waydirectional control valve directs hydraulic fluid between one ofthree flow paths. The presence or absence of sufficient hydraulicpressure acting on the two pilot pistons determines the selectionof flow path. This valve is normally used to handle medium tolarge flows and is controlled by a small, solenoid operated, four-way pilot valve.

Theory of operation

This valve is composed of a pilot operated main valve with asolenoid operated pilot valve directly coupled, hydraulically andmechanically, to the main valve. The pilot valve takes its pressuresupply and directs its return flow through the main valve. In a likemanner, the two working ports (A and B) of the pilot valve areconnected to the pilot pistons of the main valve through internalpassages in the main valve. The main valve has provisions toallow the supply pressure for the pilot valve to come from anexternal source (the x port). An internal plug is used to isolate thepressure supply of the main valve in this case. A similar port (they port) exists for external pilot drain (return).

The theory of operation of the solenoid operated pilot valve isdescribed in Diagnostic Procedure D-1. The theory of operationof the pilot operated main valve is described in DiagnosticProcedure D-2. The valve is shown below in a typical circuit.


8


Appendix

8-63

A B

P T

3 Position, Pilot-Operated Directional Control Valve,Solenoid-Controlled, 4 Way (Spring Centered),

Float Center, Typical Circuit

a

x y

bA B

P T

x yA B

P T

Pilot-Operated Valve,4 Way (Spring Centered), Float Center

When the two valves are directly coupled as shown above, the simplifiedsymbol shown below is usually on schematic drawings.


8

Varco

Appendix

8-64

Load holding valves

Counterbalance valve, pilot assisted

The counterbalance valve with pilot assist is designed foroverrunning load control and hydraulic load locking. In use, itrestricts flow out of a hydraulic cylinder or motor to preventcavitation, which would occur if the load caused the actuator tomove faster than the supply coming from the pump. Thecounterbalance valve locks the loaded actuator in place if thehydraulic line to the actuator breaks and it provides reliefprotection if the actuator is driven by an external force.

Theory of operation

Circuits using counterbalance valves use a directional controlvalve that connects the working ports A and B to the tank in thecenter position. This type of directional valve allows the bestcontrol and positioning of the load and provides an unrestrictedpath to the tank for any oil displaced when the counterbalancevalves act as reliefs. As illustrated in the counterbalance valvesymbol below, counterbalance valves respond to pressure fromtwo different sources. These are the pressure induced by the loadacting on the cylinder or motor and the pressure at the pilotassist port. The forces generated by pressure at these two portsopen the valve when the sum of the two forces is high enough toovercome the major bias spring (valve pressure setting). Thereverse free flow check valve permits a free flow of fluid towardthe actuator in the reverse direction of operation. Thecounterbalance valve is shown below schematically and in atypical circuit.


8


Appendix

8-65

Counterbalance Valve

Free-flowCheck Valve

Major BiasSpring Adjustment

Cylinder Port

Valve Port

Pilot AssistPort

Weight

CounterbalanceValve

Counterbalance Valve - Typical Circuit

P T


8

Varco

Appendix

8-66


This valve can fail in either the open or closed position. If it failswhile open, the load causes the actuator to drift over time. If theactuator is observed to be drifting, troubleshooting consists ofverifying that the valve has indeed failed in the open position andthat it is not open due to misadjustment or being piloted open.

If the valve fails while closed, movement of the actuator isimpaired in the protected direction (i.e., opposite the free flowdirection). Blocked flow across the check valve in the free flowdirection is unlikely because of the large forces available to movethe valve stem in this direction.


1. If the actuator holds its position when the direction controllingvalve is in neutral and the actuator is not at the end of itstravel, proceed to step 4.

2. Measure the pressure at the pilot assist port. With theactuator’s control valve in the center (neutral) position, thepilot pressure should be relatively low, usually less than 100psi. Higher pressures may allow the valve to open, so checkfor a failure in the part of the circuit related to the pilot assistport.

3. If the pilot pressure measured in step 2 is normal (less than100 psi), try increasing the valve pressure setting by turningthe adjusting screw counterclockwise. If the load continues todrift, contamination may be preventing the valve from closing.Remove the valve and replace it with a new one.

4. Activate the control valve in the direction that will causepressure to be applied to the pilot assist port. If the actuatordoes not move, measure the pressure at the pilot assist portwhile the control valve is actuated. With no load inducedpressure acting on the valve, 800 psi at the pilot assist portshould open the valve and allow the actuator to move. Higherload induced pressures reduces the required pilot pressureby approximately 30 psi for every 100 psi acting directly onthe valve’s cylinder port. If the required amount of pilotpressure is present and the actuator does not move, reducethe pressure setting by turning the adjusting screw clockwise.If this does not correct the problem, replace the valve.


8


Appendix

8-67

Relief valve, pilot operated

The pilot operated relief valve is used to smoothly andconsistently regulate maximum system pressure in a hydraulicsystem or subsystem over widely varying flow conditions.

Theory of operation

A pilot operated relief valve consists of two sections–the mainvalve and a pilot section. The main valve has the inlet and outletports, a spool with an orifice in the center, and a spool biasspring. The pilot section consists of a small capacity, direct actingrelief valve with a screw adjustment.

The pilot supply orifice in the piston end of the main spoolconnects the inlet of the valve to the bias spring cavity. The areasof the piston at the inlet and in the spring cavity are equal so thepressure/area forces on the main spool are in balance. If fluidentering through the pilot supply orifice cannot escape, the pistonis in hydraulic balance and the bias spring holds the spool in theclosed position, blocking the passage from inlet to return.

An adjustable pilot spring holds the small capacity, direct actingrelief valve in position. This pilot spring establishes the pressurelevel at which the inlet pilot flow is directed to a lower pressurelevel (return to tank). When pressure in the bias spring cavity ishigh enough to open the small relief, fluid flows from the cavity toreturn. This flow creates a pressure differential across the orifice.When this pressure differential is high enough to overcome theforce of the bias spring, the piston opens and creates a large flowpath from the inlet to return to tank. The relief valve schematic isshown below.

Inlet

Outlet(Tank)

Bias Spring(Adjustment)

Pilot-Operated Relief Valve


8

Varco

Appendix

8-68


A problem with this component can be that it relieves at too low apressure or that it does not relieve at all.

Perform the following steps to isolate a faulty component:

1. If the relief valve opens at a pressure below that which isexpected, measure the differential pressure across the valve(the difference in pressure between the valve’s inlet andoutlet ports) and compare it to the required setting. Increasethe valve setting as required. Turning the adjustment screwclockwise increases the setting of the valve. If the valve staysopen regardless of the setting and/or differential pressureacross the valve, it is probably stuck open and should bereplaced.

2. If the valve opens at too high a pressure or doesn’t open atall, measure the differential pressure across the valve (thedifference in pressure between the valve’s inlet and outletports) and compare it to the required setting. Decrease thevalve setting as required. Turning the adjustment screwcounterclockwise decreases the setting of the valve. Ifreducing the valve set point does not allow the valve to open,it may be stuck and should be replaced.


8


Appendix

8-69

Check valve, pilot operated

The pilot operated check valve positively locks a pressurizedload, but releases the load upon application of a pressure signalat the pilot port. This valve is normally used to lock an actuator inposition when the directional control valve is centered (neutral). Itis used in applications where overrunning load control and/or arelief function is not needed or is provided by other means.

Theory of operation

A pilot operated check valve consists of a valve body with inletand outlet ports and a poppet held against a seat by a spring.Directly opposite the check valve poppet are a plunger and aplunger piston that are biased by a light spring. Pilot pressure issensed at the plunger piston through the pilot port. The valveallows free flow from its inlet port to its outlet port. Fluid flowattempting to pass through the valve from the outlet port to theinlet port forces the poppet to its seat, blocking flow through thevalve. When enough pilot pressure is sensed at the plungerpiston, the plunger moves and unseats the check valve allowingfluid to pass. The ratio of the load pressure to the pilot pressurerequired to release the load is called the pilot ratio. Theschematic below shows a pilot operated check valve in a typicalcircuit.

Cylinder Port

Pilot-Operated Check Valve

Valve Port

Pilot Port


8

Varco

Appendix

8-70

Weight

Pilot-OperatedCheck Valve

Pilot-Operated Check Valve,Typical Circuit

P T


This valve is most likely to fail in the open position. That is, thevalve will not positively lock the pressurized load. If the valve failsclosed, in the free flow direction, severe contamination ordamage to the internal sliding surfaces probably exists. Performthe following steps to isolate a faulty component:

1. If the valve does not pass flow in the free flow direction,measure the pressure on both sides of the valve using testgauges. If the upstream pressure is significantly higher thanthe downstream pressure, the valve is probably stuck closedand should be replaced.

2. If the valve does not lock the pressurized load with thedirectional valve centered, measure the pressure at the pilotport. This pressure should be relatively low (usually less than100 psi). Higher pressures may allow the valve to open, socheck for a problem with the part of the circuit connected tothe pilot port.

3. If the pressurized load cannot be released, check thepressures at both the pilot port and the outlet port (the portconnected to the actuator). If the pilot pressure is greaterthan the actuator pressure divided by the pilot ratio (usually3:1), the valve should open. If it does not, replace the valve.


8


Appendix

8-71

Pressure control valves

Pressure reducing valve, pilot operated

The pilot operated pressure reducing valve is used to regulatemaximum system pressure in a hydraulic system or subsystem.

Theory of operation

A pilot operated pressure reducing valve consists of twosections–the main valve and a pilot section. The main valve hasthe inlet and outlet ports, a spool with an orifice in the center, anda spool bias spring. The pilot section consists of a small capacity,direct acting relief valve with a screw adjustment.

A pilot supply orifice in the piston end of the main spool connectsthe inlet of the valve to the bias spring cavity. The areas of thepiston at the inlet and in the spring cavity are equal so thepressure/area forces on the main spool are in balance. If fluidentering through the pilot supply orifice cannot escape, the pistonis in hydraulic balance and the bias spring holds the spool in theopen position, allowing full flow from inlet to return.

An adjustable pilot spring holds he small capacity, direct actingrelief valve in position. This pilot spring establishes the pressurelevel at which the inlet pilot flow is directed to a lower pressurelevel (return to tank). When pressure in the bias spring cavity ishigh enough to open the small relief, fluid flows from the cavity toreturn. This flow creates a pressure differential across the orifice.When this pressure differential is high enough to overcome theforce of the bias spring, the piston begins to close creating arestriction in the flow path. This restriction limits the flow from theinlet to the outlet to a value that maintains the selected reducedpressure in the outlet portion of the circuit.

Any pressure at the pilot drain port is additive to the pressuresetting of the valve. This characteristic can be used to implementremote control of the valve. The pressure reducing valve is shownbelow schematically.

Inlet

Outlet

Pilot-Operated Pressure Reducing Valve

Pilot Drain

Bias Spring(Adjustment)


8

Varco

Appendix

8-72


A problem with this component can be that it fails to close down,not providing the required pressure reduction.


1. If the outlet pressure is too high, try reducing the setting ofthe valve by turning the adjusting screw counterclockwisewhile observing the pressure at the outlet port. If this doesnot reduce the pressure to the desired level, measure thepressure at the pilot drain port. If this pressure is higher thanthe desired set point, a condition exists in the pilot draincircuit that prevents the pressure reducing valve from beingadjusted lower. Correct this problem and then readjust thevalve.

2. If the pilot drain pressure measured in step a. is below thedesired valve setting and the valve does not adjust lower, thespool may be stuck and the valve should be replaced.

This arrangement is shown on hydraulic schematic drawingsusing the following symbols:

W

Control Cover

Hydrostat Insert

Fixed Orifice (Proportional Valve)


8


Appendix

8-73

Auxiliary valves

Check valve, pilot to close

The pilot to close check valve allows flow in one direction onlybut will prevent flow in the free flow direction upon application ofsufficient pressure at the pilot port. This valve is normally used tolock an actuator in position when the directional control valve iscentered (neutral). It is used in applications where multiplefunctional modes are required–regenerative circuits, for instance.

Theory of operation

A pilot to close check valve consists of a valve body with inletand outlet ports and a poppet held against a seat by a spring.Opposite the check valve poppet is a pilot piston. The pilot pistonand the poppet are held apart by a light spring. Pilot pressure issensed at the pilot piston through the pilot port.

The valve allows free flow from its inlet port to its outlet port.Fluid flow attempting to pass through the valve from the outletport to the inlet port forces the poppet onto its seat, blocking flowthrough the valve. When enough pressure is present at the pilotpiston, the piston moves against the poppet preventing flow ineither direction. The ratio of the load pressure to the pilotpressure required to lock the load is called the pilot ratio.

This valve is identified on hydraulic schematic drawings using thefollowing symbol:

Inlet

OutletPilot Port

Check Valve, Pilot to Close


8

Varco

Appendix

8-74


This valve will most likely fail in the open position. That is, thevalve will allow flow in both directions. If the valve fails whenclosed, in the free flow direction, severe contamination ordamage to the internal sliding surfaces probably exists.


1. If the valve does not pass flow in the free flow direction,measure the pressure on both sides of the valve using testgauges. If the upstream pressure is significantly higher thanthe downstream pressure, the valve is probably stuck closedand should be replaced.

2. If the valve does not block flow from the outlet to the inlet,measure the pressure at the inlet and outlet ports of thevalve. If the pressure on the outlet is higher than at the inlet,remove the valve and check for damaged seals and replaceas necessary. If the seals are not damaged, the poppet isprobably stuck open because of contamination, and the valveshould be replaced.

3. This step should be carried out if the valve does not appearto block flow in the free flow direction when piloted closed.Measure the pressure at the pilot and inlet ports. If the pilotpressure is at least 1.8 times the inlet pressure, flow in thefree flow direction should be prevented. If it is not, remove thevalve and check for damaged seals and replace as required.If the seals are not damaged, the poppet is probably stuckopen because of contamination and the valve should bereplaced. Note that any pressure at the outlet port reducesthe required pilot ratio to values below 1.8.


8


Appendix

8-75

Check valve

The check valve allows flow in one direction only.

Theory of operation

A check valve consists of a valve body with inlet and outlet portsand a poppet held against a seat by a spring. The valve allowsfree flow from its inlet port to its outlet port when the differentialpressure between the inlet and outlet is greater than the“cracking pressure” of the valve. The cracking pressure isdetermined by the strength of the spring and the areas exposedto the differential pressure across the valve. Fluid flow attemptingto pass through the valve from the outlet port to the inlet portforces the poppet to its seat blocking flow through the valve. Thisvalve is identified on hydraulic schematic drawings using one ofthe following symbols:

Inlet

Outlet

Inlet

Outlet


This valve will most likely fail in the open position. That is, thevalve will permit flow in both directions. If the valve fails whenclosed, in the free flow direction, severe contamination ordamage to the internal sliding surfaces probably exists.


1. If the valve does not pass flow in the free flow direction,measure the pressure on both sides of the valve using testgauges. If the upstream pressure is higher than thedownstream pressure by an amount at least 50 psi greaterthan the cracking pressure, the valve is probably stuck closedand should be replaced.

2. If the valve does not block flow from the outlet to the inlet,measure the pressure at the inlet and outlet ports of thevalve. If the pressure on the outlet is higher than at the inlet,remove the valve, check for damaged seals and replace asnecessary. If the seals are not damaged, the poppet isprobably stuck open because of contamination and the valveshould be replaced.


8

Varco

Appendix

8-76

Flow valves

Orifice

Orifices are used in hydraulic circuits to provide a knownrestriction in a flow path.

Theory of operation

An orifice is a small opening in a fluid’s flow path. The flow rate ofa fluid through an orifice is affected by the diameter of the orifice,the pressure differential across the orifice, and the temperatureof the fluid. Common examples of fixed orifices used in hydraulicsare threaded plugs or check valves with a hole drilled throughtheir centers. This component is identified on hydraulic schematicdrawings using the following symbol:

Orifice


This component fails to perform if it becomes plugged either fullyor partially by contamination. If a circuit that includes an orifice isnot performing properly, remove and clean the orifice.

Flow control valve, pressure compensated, fixed orifice

This flow control valve uses a fixed orifice to control the flow ratein a circuit. The valve is pressure compensated to provideconstant regulated flow, regardless of load variations. The flowrate is factory set by means of a fixed orifice. This valve iscapable of reverse, noncompensated flow equal to the flowsetting (orifice size).

Theory of operation

This valve consists of a body with an inlet and outlet, acompensator spool with a fixed orifice and a spring. Flow mustpass through the orifice in the center of the compensator spooland then out the side of the spool through a series of holes thatare radially located. The valve body also has a series of radiallylocated holes in the area of the outlet port.


8


Appendix

8-77

The compensator spool senses both the incoming pressure andthe load pressure and moves to restrict the flow through the twosets of holes, maintaining a constant pressure drop across theorifice. This causes the valve to maintain a constant flow output,regardless of variations in the upstream or downstream pressure.Reverse flow from the outlet to the inlet causes the compensatorspool to move all the way to one side fully opening the two setsof holes to the outlet port. Thus, only the fixed orifice acts toregulate the flow and is, therefore, not pressure compensated.This component is identified on hydraulic schematic drawingsusing the following symbol:

Flow Control Valve,Pressure Compensated,

Fixed Orifice


This component fails to perform when the orifice becomesplugged or the compensator spool sticks because ofcontamination.


1. If the valve allows too much flow to pass, remove, check fordamaged seals, and replace as required. If the seals are notdamaged, the compensator spool may be stuck open bycontamination and the valve should be replaced.

2. If the valve does not allow enough flow to pass, the orificemay have become plugged. Remove the valve, check forcontamination, and clean it. If this does not solve theproblem, the compensator spool may be stuck closed bycontamination and the valve should be replaced.


8

Varco

Appendix

8-78

Flow control valve, adjustable, pressure compensated, fullreverse free flow

This flow control valve uses a variable orifice spool to control theflow rate in a circuit. The valve is pressure compensated toprovide constant regulated flow regardless of load variations. Theflow rate is adjustable by means of a threaded screw. This valveis capable of full reverse, noncompensated flow, regardless ofthe flow setting.

Theory of operation

This valve consists of a body with an inlet and outlet, acompensator spool with a fixed orifice, and a bias spring. It alsocontains a smaller spring to provide full reverse free flow. Flowmust pass through the orifice in the center of the compensatorspool and then out the side of the spool through a series of holesthat are radially located. The valve body also has a series ofradially located holes in the area of the outlet port. A second setof holes in the valve body in conjunction with an annular grooveon the outside of the compensator spool allows for full reversefree flow.

The compensator spool senses both the incoming pressure andthe load pressure and moves to restrict the flow through the twosets of holes maintaining a constant pressure drop across theorifice. This causes the valve to maintain a constant flow output,regardless of variations in the upstream or downstream pressure.The value of the bias spring adjustment controls the maximumcompensated flow through the valve. Reverse flow from the outletto the inlet causes the compensator spool to move against thesmall spring all the way to one side connecting the inlet to theoutlet through the second set of holes in the valve body inconjunction with the annular groove on the outside of thecompensator spool. This component is identified on hydraulicschematic drawings using the following symbol:

Inlet

Outlet


8


Appendix

8-79


This component fails to perform if the orifice becomes plugged orthe compensator spool sticks because of contamination.

Perform the following steps to check this component:

1. If the valve allows too much flow to pass in the controlleddirection, remove it and check for damaged seals and replaceas required. If the seals are not damaged, the compensatorspool or the check function may be stuck open bycontamination and the valve should be replaced.

2. If the valve does not allow enough flow to pass in thecontrolled direction, the orifice may have become plugged.Remove the valve, check for contamination, and clean it. Ifthis does not solve the problem, the compensator spool maybe stuck closed by contamination and should be replaced.


8

Varco

Appendix

8-80

Output actuators

Hydraulic cylinder, double acting

The hydraulic cylinder is a device that converts hydraulic energyinto straight line mechanical energy. A hydraulic cylinder can alsohold and lower a load against gravity forces with the addition ofsuitable hydraulic circuitry.

Theory of operation

A hydraulic cylinder consists of a cylinder body, a movable piston,and a piston rod attached to the piston. End caps are attached tothe cylinder body barrel by threads, tie rods or a weld. The endthrough which the rod extends is called the head end or rod endand the opposite end is called the cap end or blind end. Eachend cap has a port that allows fluid to enter and exit that end ofthe cylinder. As the cylinder rod moves in and out, it is guidedand supported by a removable bushing called a rod gland or rodbearing. The rod gland contains a piston rod wiper and a primaryseal. The piston is equipped with one or more primary seals and,in some cases, wears rings. Hydraulic cylinders are identified onhydraulic schematic drawings using the following symbols:

Single Rod Cylinder Double Rod Cylinder

Hydraulic Cylinders

Tandem Cylinder


A problem with this component is usually related to the cylindernot producing the required push or pull force. If the fault is withthe cylinder and not its related hydraulic circuitry, it is most likelycaused by internal or external leakage of the pressurized fluid.External leakage is easy to detect and is not dealt with here. Ifthe piston seals fail, fluid from the high pressure side of thepiston passes to the low pressure side, which is generallyconnected to tank through a directional valve. If this leak is largeenough, the hydraulic power unit is not able to maintain thepressure at the intended level. If the cylinder is supporting agravity load, internal leakage may allow the rod to extend orretract until end of stroke is reached. Trouble shooting an internalseal failure requires determining if the cylinder will hold pressureover time. Perform the following steps to check the cylinder:


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Appendix

8-81

1. If the cylinder is required to support a gravity load and is notholding its position, verify that the related load holding valvesare functioning properly. Use the diagnostic procedurespecified for that component.

2. Attach a test gauge to the appropriate test point in the line forthe cylinder in question. Actuate the appropriate directionalcontrol valve and observe the pressure as the cylinderstrokes. When the cylinder reaches the end of stroke, thereading should rise and stabilize at the supply pressurevalue. It may help to operate only a single pump and to usethe slowest speed available for the function. A faulty pistonseal may prevent the pressure from stabilizing. In addition, itmay be possible to hear the flow of the oil leaking across thepiston. If this is the case, replace the piston seals.


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Varco

Appendix

8-82

Hydraulic motors

The hydraulic motor is a device that converts hydraulic energyinto rotary mechanical energy.

Theory of operation

Hydraulic motors operate by causing an imbalance that results inthe rotation of a shaft. A geroler motor is a type of internal gearmotor with an inner drive gear and an outer drive gear with onemore tooth than the inner gear. The inner gear is attached to ashaft connected to the load. The outer gear in a geroler motorconsists of several rollers held in place by a slotted ring. Theimbalance in this type of motor is caused by the difference ingear area exposed to hydraulic pressure at the motor inlet. Theexposed area of the inner gear increases at the inlet. Fluidpressure acting on these unequally exposed teeth results in atorque at the motor shaft. Larger gears or higher pressurescreate higher torques at the output shaft. A cylindrical portingring directs fluid between the inlet and outlet ports and therotating group through passages in the motor housing. A casedrain is sometimes provided to protect the shaft seals fromdamage due to internal motor leakage. Hydraulic motors areidentified on hydraulic schematic drawings using the followingsymbol:

Case Drain


A problem with this component is usually related to a loss ofoutput torque due either to internal binding or to excessiveinternal leakage. Perform the following steps to check the motor:

1. If the motor fails to rotate freely when not under load orexcessive heat or noise is generated, internal damage hasoccurred, and the motor should be replaced.

2.To check for excessive internal leakage, operate the motor in astalled condition. Check the pressure at both the inlet andoutlet ports of the motor. The inlet pressure should be verynear the supply pressure for this circuit, normally 2500 psi.The pressure at the outlet port should be near that of thetank pressure, less than 100 psi. If this is not the case, orexcessive flow across the stalled rotor is evidenced by heator noise, replace the motor.


TDS4STrouble Shooting Guide

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