TDS4STrouble Shooting Guide

Introduction
How to Use This Manual

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.
Diagramatic Symbols
Beginning or Ending of Sequence Question Troubleshooting Instructions Drillers Action Page Reference
Notes, Cautions and Warnings
i
!
(Note)
Gives helpful information.
(Caution)
Indicates a possibility of personal injury or equipment damage if instructions are not followed.
(Warning) Indicates a strong possibility of severe personal injury or loss of life if instructions are not followed.
Special Information
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.
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. REV 2001 Varco Systems All rights reserved
General Information
Drill/Spin/Torque Troubleshooting
IBOP Troubleshooting
Pipehandler Troubleshooting
Counterbalance and Motor Alignment Cylinder Troubleshooting
Drilling Motor Housing, Brake and Guide Dolly Troubleshooting
Service Centers
Appendix
4 TDS-4S/4H Troubleshooting Guide
General Information
Varco Driller's Console (VDC) ............................. 1-3 Varco Driller's Console (VDC) Description ......... 1-4 Special tools ....................................................... 1-9 Drilling Operational Problems ............................ 1-10
TDS-4S/4H Troubleshooting Guide
General Information
General Information
1-2
Varco
Varco Driller's Console (VDC)

MAKE-UP CURRENT LIMIT OIL OVERTEMP OIL PUMP LOSS HPU #1 START/STOP LEFT RIGHT 30 57 FIELD AMPS 40 VDC PRESS LOSS ROTATING HEAD TDS STALL RBS DEPLOYED IBOP CLOSED BRAKE ON
R
0 AIR OVERTEMP OFF ON TOP DRIVE ROTARY TABLE TDS DISABLE HPU #2 START/STOP "ON"-AUTO STOP "OFF"-FREE ROTATE MAX HIGH GEAR
R
CROWN CLEARANCE 2 FEET (FLASHING) 5 FEET (STEADY) OFF
A
RBS ON OPEN
A
IBOP OFF CLOSE
R
BRAKE AUTO ON
R
SPIN BLOWER LOSS (BLOWER CANCEL) BLOCK OFF HPU #3 START/STOP EXTEND RETRACT TORQUE ALARM LAMP SILENCE CHECK
G R
C
LOW GEAR
R
CROWN CLEARANCE 10 FEET OPEN AIR ELEVATOR TORQUE WRENCH PUSH & HOLD ARMED TO CLOSE LINK TILT FLOAT HOLD RETRACT EXTEND
RPM R G
TORQUE
DRILL
General Information
Technical Drawings
1-3
General Information
Varco Driller's Console (VDC) Description

Name Type Function
MAKE-UP CURRENT LIMIT Potentiometer Sets the current limit in the VFD when using the Top Drive to make connections. The torque can be adjusted by turning the potentiometer to increase or decrease the torque.
OIL PRESS LOSS Red indicator Indicator flashes and horn sounds when an oil pressure loss in the gearcase lubrication system is detected.
VDC PRESS LOSS Red indicator Indicator flashes and horn sounds when a loss of purge pressure in the VDC is detected.
DRILL MOTOR OVERTEMP Red indicator Indicator flashes and horn sounds if there is an overtemperature condition in one or both of the AC drilling motors.
DRILL/SPIN/TORQUE 3-Position selector switch (with TORQUE position momentary) The switch is in the DRILL mode during normal drilling. 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-up potentiometer when in FORWARD mode. When in REVERSE the torque value rises to maximum until the connection is broken.
BLOWER LOSS Red indicator Indicator flashes and horn sounds if there is a failure in one or both of the air cooling motors.
ALARM SILENCE/LAMP CHECK Pushbutton switch
When 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. When set to AUTO, turns on hydraulic pump when commanded by the PLC. When set to ON, turns on hydraulic pump regardless of operating mode.
HYDRAULIC POWER AUTO/ON 2-Position switch
Technical Drawings
1-4
Varco
General Information

Name Type Function
(PIPEHANDLER) ROTATE LEFT/RIGHT 3-Position momentary switch with center off
1
Turning the spring-operated switch to the left moves the drill pipe elevator to the left, and turning the switch to the right moves the drill pipe elevator to the right. The switch automatically returns to center (off) position when released. NOTE: This works only after the LINK TILT FLOAT switch is pressed.
(PIPEHANDLER) LINK TILT FLOAT Pushbutton switch
The elevator links float to the center (neutral) position when pushbutton is pushed, thus the pipe handler can then be rotated.
(PIPEHANDLER) TORQUE WRENCH PUSH & HOLD Pushbutton switch
When 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.
(PIPEHANDLER) LINK TILT DRILL/OFF/TILT 3-Position maintained switch
When set to DRILL, link tilt cylinders are retracted to place the elevators in the drill down position. 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 TILT FLOAT is pushed.
BRAKE ON Red indicator Indicator illuminates when the brake solenoid valve is energized.
BRAKE OFF/AUTO/ON 3-Position switch When 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.
Technical Drawings
1-5
General Information

Name Type Function
IBOP CLOSED Amber indicator IBOP OPEN/CLOSE 2-Position switch OPEN position extends the actuator cylinder to open the IBOP valve. CLOSE position retracts the actuator cylinder to close the IBOP valve. Illuminates when hydraulic pressure is applied to the cylinder that closes the IBOP valve.
DRILL TORQUE: 0 to MAX Continuous Potentiometer
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. 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.
TORQUE: 0 to Full Scale Meter (0 - 10 VDC)
RPM: 0 to 250 rpm Meter (0 - 10 VDC) Displays drill pipe rotational speed in rpm. Rotational speed is controlled by the THROTTLE control. 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.
DC Panel TD/RT switch
Multi-Field 30/40/57 AMP switch 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.
RBS RBS (Deployed IND) switch
Technical Drawings
1-6
Varco
General Information

Name
HPU HPU 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.
Type
Function
Water Pump Water pump switch Depress this illuminated pushbutton energizes the water pump motor starter and illuminates the indicator. Depress the switch a second time deenergizes the water pump motor starter and turns the indicator off.
Rotating Head Rotate left/right switch Deleted, same as (pipehandler) Rotate Left/ Right 3-position selector switch spring return to center.
TDS Z Purge TDS pressure loss indicator Indicator flashes and horn sounds when a loss of purge pressure in the Top Drive motor is detected.
VDC Z Purge VDC pressure loss indicator TDS Expo Purge TDS purge loss indicator 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. Same as "VDC PRESS LOSS".
TDS Expo Purge TDS purge proceeding indicator
TDS Expo Purge TDS purge complete indicator Indicator illuminates when switches in the purge control system monitor the correct purge air flow, purge pressure and preset purge time are reached.
TP/VDC Expo Purge TDCS purge loss indicator Indicator flashes and horn sounds when either transfer Panel or VDC purge pressure loss in the Expo Purge Control System.
Technical Drawings
1-7
General Information

Name Type Function
1
Crown Clearance Crown clearance indicator 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.
TDS Stall TDS stall indicator 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.
Field Loss Field loss indicator Indicator flashes and horn sounds if the Active field Supply for Varco Top Drive and customers shunt wound Rotary Table motor is loss.
Gear Indicator High/low gear indicator 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.
Elevator Control Open/close indicator 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 to well center. "RETRACT", Block Dolly and TDS Dolly retract to full retracted position. "OFF", block dolly and TDS dolly maintain present position. Note: When TDS DISABLE switch is set to "ON" only Block Dolly Extends and Retracts.
TDS Disable 2- Position Maintain
Block 3- Position Maintain
Technical Drawings
1-8
Varco
General Information
Special Tools
Troubleshooting in Drill/Spin/Torque Modes
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 the IBOP, Torque Wrench, Rotating Head, Link Tilt, Blower Motor and Brake
Multimeter Standard Mechanical Tools Stauff (hydraulic) Test Kit (P/N 940315-1000) Nitrogen Fill and Gauge Kit (P/N 170001) Clamp-On Amp Meter
Technical Drawings
1-9
General Information
Drilling Operational Problems

1
Drilling Operational Problem
Is it a Drill Problem ? No
Yes
See Page
2-20
Is it a Torque Wrench Problem ? No
Yes
See Page
4-3
Is it a Spin Problem ? No
Yes
See Page
2-24
See Page
Is it a Link Tilt Problem ? No
Yes
See Page
4-14
Is it a Counterbalnce Problem ? No
Yes
See Page
5-3
2-26
Yes See Page
Is it a Torque Problem ? No
2-22
See Page
Is it a Brake Problem ? No
Yes
See Page
6-4
See Page
Is it a Transmission Problem ? No
Yes
See Page
6-10
2-25
Yes See Page
6-5
Is it a Retract Guide Dolly Problem ? No Yes See Page Is it a Yes Cooling System Problem ? No See Page
Is it an IBOP Problem ? No
3-3
6-7
6-16
Is it a Rotating Head Problem ? No
Yes
See Page
6-24
Is it an Alignment Cylinder Problem ? No
Yes
See Page
5-6
Is it a Lube System Problem ? No
Yes
See Page
6-14
Call Field Service
Technical Drawings
1-10
Varco
Drill/Spin/Torque Troubleshooting Drill/Spin/Torque Troubleshooting
Initial Startup.......................................................... 2-3 Fault and Alarm Problems .................................... 2-4 VDC/Lamp Test Fault .................................................... 2-5 Field Loss Fault or Alarm .............................................. 2-6 Assignment Fault ........................................................... 2-7 Incorrect Rotation/Torque Problems ................... 2-8 Rotation Incorrect .......................................................... 2-9 Wrong Direction ............................................................. 2-10 Drill Torque Incorrect ..................................................... 2-11 No Rotation Problems ........................................... 2-12 No Rotation and No Torque .......................................... 2-13 No Rotation and Hi Torque ............................................ 2-14 Speed Control Problems ....................................... 2-15 Speed Control Problems (Drill Mode) ............................ 2-16 Speed Control Problems (Spin Mode) ........................... 2-17 Speed Control Problems (Torque Mode)....................... 2-18 Mode Problems ...................................................... 2-19 Drill Mode Problems ...................................................... 2-20 Spin Mode Problems ..................................................... 2-21 Torque Mode Problems ................................................ 2-22 Set to Spin/Torque/Spin Out Problems................ 2-23 Set to Spin ..................................................................... 2-24 Set to Torque (Make-Up Connection)............................ 2-25 Spin Out Problem .......................................................... 2-26
2-1
Drill/Spin/Torque Troubleshooting Drill/Spin/Torque
Troubleshooting
2-2
Varco
Initial Startup
Functional Checklist s Turn clockwise from the fully counterclockwise position to enable the SCR and set the throttle reference
Switch to DRILL Mode
s Use the DRILL/SPIN/TORQUE selector switch
Throttle ON
2
s Press lamp check button s All lamps should light up after a 2 second delay when lamp check button is pressed Is Rotation Correct ?
No
Perform Lamp Test
See Page
2-9
s Check hand throttle and switch position s Turn throttle OFF s Set the brake s Turn throttle ON s Increase torque limit (turn clockwise) until desired torque is reached s Turn throttle OFF s Release the brake
Yes
Is Lamp Test Good?
No
See Page
2-5
Set Drill Torque Limit
Yes s Turn fully counterclockwise to disable the SCR and set the throttle reference at zero
Throttle OFF
Did Drill Torque Set Okay?
No
See Page
2-11
s Set brake to AUTO
Yes Faults or Alarms ? No s Lube oil pump starts s Blower starts s Field comes on
Yes
Check VDC Purge (see page 2-5) Does SPIN Mode Work ?
No
See Pages
2-24
Yes
Ensure SCR is ON Assign FORWARD
Does TORQUE Mode Work ? Faults or Alarms ? No Yes See Page Yes
No
See Pages
2-25
2-7
Continue Operations
Technical Drawings
2-3
Fault and Alarm Problems

Symptom
Lamp test failed.
See Page
Probable Cause
One or more of the VDC lamps failed.
Remedy
Check lamp(s). Check PLC output. Check power supply.
2-5
2
VDC pressure loss alarm.
See Page
Pressure disrupted at VDC. Pressure switch failure. Incorrect PLC inputs. VDC gasket seal failure.
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.
2-5
Over speed light "ON" SCR interface board.

See Page
Field loss.
2-6
Technical Drawings
2-4
Varco
VDC/Lamp Test Fault

Lamp Test Failed VDC Pressure Loss Alarm
One or more of these 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 Air Pressure at VDC Check Pressure Switch Check PLC Inputs Check VDC Gasket Seal
Check Lamp Check PLC Output Check Power Supply
s Check PLC input using applicable Interconnect Diagram and PLC Software s Check PLC output using applicable Interconnect Diagram and PLC Software s Input lights when contacts on switch closes s Output lights when output is commanded by PLC
Did You Find Cause and Fix It ? No
Yes
Continue Operations
Yes
Continue Operations
Call Field Service
Call Field Service
Technical Drawings
2-5
Field Loss Fault or Alarm
Over Speed Light ON SCR Interface Board
2
Is There Field Loss ? No 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)
Call Field Service Did You Find Cause and Fix It ? No Yes Continue Operations
Refer to Field Supply Manual
Yes
Continue Operations
Call Field Service
Technical Drawings
2-6
Varco
Assignment Fault
Fault or Alarm After Assignment
2
Blower Loss Alarm ? No See Page
Yes
6-20
Oil Pressure Alarm ? No
Yes
See Page
See Page
6-14
6-15
Field Loss ?
Yes
See Page
2-6
No
Call Field Service
Technical Drawings
2-7
Incorrect Rotation/Torque Problems

Symptom
No/minimal rotation and hi torque. Speed control problems.
Probable Cause
Brake is engaged. Transmission locked. SCR interface card failure. SCR system failure. Adverse well conditions.
Remedy
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.
2
Turning in wrong direction.
See Page
FORWARD/REVERSE incorrectly selected. FORWARD/REVERSE switch failure. Incorrect input to PLC. Incorrect input to SCR. Throttle micro switch failure.
2-10
Drill torque incorrect.
Torque amp curves incorrect. Motor deteriorating. Hall-effect device meter out of calibration.
Technical Drawings
2-8
Varco
Rotation Incorrect
Rotation is not Correct
2
No Rotation and No Torque ? No Yes See Page
2-13
No or Minimal Rotation and Hi Torque ? No
Yes
Check if Brake is Engaged Check for Locked Transmission
Did You Find Cause and Fix It ? Yes
No
See Page
2-14
Continue Operations
Speed Control Problems ? No
Yes
Check SCR Interface II Card Check Stump/ Cyclops Card Check Speed/ Torque II Card Check SCR System Consider Well Conditions
No
See Page
2-16
Wrong Direction ?
Yes
See Page
Continue Operations
2-10
No
Continue Operations
Technical Drawings
2-9
Wrong Direction
Wrong Direction
2
Is FORWARD/ REVERSE Correctly Selected ?
No
Throttle OFF, Change Direction Assignment, Throttle ON
Yes
No
Going Correct Direction ?
Yes
Continue Operations 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
Yes
Continue Operations
Call Field Service
Technical Drawings
2-10
Varco
Drill Torque Incorrect
Drill Torque Incorrect
Switch to DRILL Mode
Drill Torque Low/High or Erratic ? No
Yes
See Page
2-20
Verify Torque with Clamp-On Amp Meter
See Page
8-55
Create Torque Amp Curves Diagram
Yes
Continue Operations
Call Field Service
Technical Drawings
2-11
No Rotation Problems
Symptom
Not Rotating in spin mode.
Probable Cause
Voltage at throttle potentiometer failure. Enable signal at throttle (microswitch) failure.
Remedy
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.
Throttle volts at card rack failure. Cabling for short or open circuits failure. Throttle and current limit signals not present. SCR control console operation failure.
SCR interface card failure. SCR not enabled. Brake indicator is ON. SCR failure. Brake is ON. Wiring is incorrect. PLC in puts and outputs not functioning properly. No downhole torque. Brake stuck ON. Motor incorrectly wired. SCR assignment and retest failure. SCR failure.
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.
Technical Drawings
2-12
Varco
No Rotation and No Torque
No Rotation and No Torque Are Throttle and Current Limit Signals Present ? Yes
No
Verify Initial Startup (see page 2-3)
Check SCR Control Console Operation Check SCR Interface Card
Make Sure Drill Torque Limit is NOT at zero and Throttle is ON
Is SCR Enabled ?
No Check SCR
Yes Does it Rotate ? Yes Did You Find Cause and Fix It ? No Try to Operate in SPIN Mode SCR Problem, Troubleshoot SCR Yes
No
Continue Operations
Continue Operations
Did it Rotate in SPIN Mode ? Yes
No
s Put back into DRILL mode Did You Find Cause and Fix It ? No
Verify Voltage at Throttle Potentiometer Verify Enable Signal at Throttle (microswitch) Verify Throttle Volts at Card Rack Check Cabling for Short or Open Circuits
Yes
Continue Operations
Call Field Service

Technical Drawings
2-13
No Rotation and Hi Torque

No or Minimal Rotation and Hi Torque
Check if Brake Indicator is ON No
Yes
Cycle Brake ON to OFF (Reset)
Yes
Continue Operations
Check Wiring Check PLC Inputs and Outputs
Is There Downhole Torque ? No
Yes
Consider Drilling Program Consider Reducing Torque
Brake Stuck ON Motor Incorrectly Wired Change SCR Assignment and Retest Check SCR
Yes
Continue Operations
Call Field Service
Technical Drawings
2-14
Varco
Speed Control Problems

Symptom
Top Drive not spinning. or RPM's incorrect or Erractic speed problems.
Probable Cause
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.
Remedy
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.
Top Drive not rotating.
SCR Interface failure. SCR DC module failure. Speed signal at card rack failure.
Drill torque incorrect.
SCR interface failure. Make-up current limit failure. Field loss.
Technical Drawings
2-15
Speed Control Problems (Drill Mode)

Speed Control Problems 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
Does the Top Drive Rotate ? Yes
No
See Page
2-9
Going too Fast ? No
Yes
Going too Slow ? No
Yes
Was Current Limit Reached ? Yes
No
Erratic Speed Problems ? No
Yes
Check Throttle Potentiometer Check Throttle Signal Check SCR Interface II Card Check SCR DC Module Check Field Supply Consider Mechanical Restrictions Consider Well Conditions
Yes
Continue Operations
Continue Operations
Call Field Service

Technical Drawings
2-16
Varco
Speed Control Problems (Spin Mode)

Speed Control Problems in SPIN Mode
Throttle OFF Select FORWARD or REVERSE Select SPIN Mode
Does the Top Drive Spin ? Yes
No
Are RPM's Correct (~30 RPM's) ? Yes
No
Yes
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
Continue Operations
Continue Operations
Call Field Service
Technical Drawings
2-17
Speed Control Problems (Torque Mode)

Speed Control Problems in TORQUE Mode
Throttle OFF Select FORWARD Select TORQUE Mode
Does the Top Drive Rotate ? Yes
No
Are RPM's Correct (~50 RPM's in High Gear) ? Yes
No
Yes
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
Continue Operations
Continue Operations
Call Field Service
Technical Drawings
2-18
Varco
Mode Problems
Symptom
No rotaion in Drill mode.
Probable Cause
Brake not set. Throttle not open. Drill torque limit potentiometer not functioning.
Remedy
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.
Required drill torque limit not achieved.
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
No rotaion in Spin mode.
Brake not set. Throttle not off. Spin mode not selected.
Required torque limit not achieved.
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.
Technical Drawings
2-19
Drill Mode Problems

DRILL Mode Problem
Is There Rotation ?
No
See Page
s No torque
2-13
See Page s Hi torque
Yes
2-14
Set Brake Open Throttle Turn Up Drill Torque Limit Potentiometer
!
Never apply power to stalled motor for more than 7 seconds.
Verify Voltage at Drill Torque Limit Potentiometer Verify Voltage Signal at Card Rack Check Cabling and Wiring Connect PC/PLC and Verify Signals
Achieve Required Drill Torque Limit ? Yes
No
Yes
Continue Operations
Speed Control Problem ? No
Yes
See Page
2-16
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
Continue Operations Did You Find Cause and Fix It ? No Yes Continue Operations
Call Field Service
Technical Drawings
2-20
Varco
Spin Mode Problems

SPIN Mode Problem
Is There Rotation ?
No
See Page
s No torque
2-13
See Page s Hi torque
Yes
2-14
Set Brake Throttle OFF Select SPIN Mode
Achieve Required Spin Torque Limit (~300 Amps) ? Yes
No
See SCR Interface Board Documentation
Release Brake
Yes
Continue Operations
Speed Control Problem ? No
Yes
See Page
2-17
Call Field Service
Continue Operations
Technical Drawings
2-21
Torque Mode Problems
TORQUE Mode Problem
Set Brake Throttle OFF Set Make-Up Current Limit to 20% Select TORQUE Mode
!
Never apply power to stalled motor for more than 7 seconds.
Achieve Required Torque Limit ? Yes
No
s Release brake
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
Yes
Continue Operations
See SCR Interface II Card Documentation
Is There Rotation and Torque ? Yes
No
See Page
2-13
Achieve Required Torque Speed ? Yes
No
See Page
2-18
No Call Field Service
Did You Find Cause and Fix It ?
Yes
Continue Operations
Technical Drawings
2-22
Varco
Set to Spin/Torque/Spin Out Problems

Symptom
Tool not spinning out.
Probable Cause
Remedy
Turn throttle OFF. Select reverse. Brake connection with torque wrench. Select spin mode.
Technical Drawings
2-23
Set to Spin
Set To SPIN Mode
Throttle to OFF
Turn the Forward/Reverse Switch to FORWARD
Unit Spins Forward ?
No
See Page
2-14
Yes
Is RPM Correct ?
No
See Page
2-21
Yes
Stalls Out at SPIN Current Limit ? Yes
No
Check SCR Interface II Card
Yes
Continue Operations
Did Connection Shoulder Up Correctly ? Yes
No
Check Counterbalance Check Saver Sub - Thread Damage - Selection Consider Operational Issues Consider Alignment Issues
Call Field Service
Continue Operations
Technical Drawings
2-24
Varco
Set to Torque (Make-Up Connection)
Set to TORQUE Mode
Make Up: Select FORWARD Throttle OFF Set Make-Up Current Limit Potentiometer at 20%
s First stand only
Select SPIN Mode
Spin In and Connection Shoulders Properly ? Yes
No
See Page
Torque Up: Increase Make-Up Potentiometer to Appropriate Torque
2-24
Make-Up Correct ? No
Check SCR Interface II Card
Select TORQUE Mode Yes
Torque Ramps Up ? Yes
No
See Page
Release Torque to SPIN Mode
Yes
2-22
Select DRILL Mode
Call Field Service
Continue Operations
Technical Drawings
2-25
Spin Out Problem
Spin Out Problem
Throttle OFF Select Reverse Break Connection with Torque Wrench
Select SPIN Mode
Is Tool Spinning ?
No Return to Drill Mode
Repeat Procedure as Necessary
Yes
Return to Drill Mode Yes
Yes
Continue Operations
Continue Operations See Page s Spin Mode Problem
2-24
See Page s Torque Wrench Problems
4-3
Technical Drawings
2-26
Varco
IBOP
IBOP Troubleshooting Troubleshooting
IBOP Problem ........................................................ 3-3 1
33
TDS-4S/4H Troubleshooting Guide TDS-4S/4H Troubleshooting Guide
3-1
33
3-2
Varco Varco
IBOP Problem
IBOP Problem
Is the IBOP Fully Closing ? Yes
No
Closed Light ON When Switch in Closed Position ?
No
Perform Lamp Test Check PLC Check Wiring Check Pressure Switch
Yes
Yes
Is Shell/Valve Closing ?
No
s Closed = Up s Open = Down
Manually Close Valve Check Mechanical Check Solenoid Check Air Pressure Check Back Pressure on Open Side Check Air Isolation Valves on Pipehandler
Is the IBOP Fully Opening ? Yes
No
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 Does Valve Operate Manually ?
No
Is the IBOP Valve Leaking ? No
Yes
Replace Valve
Yes
Did You Find Cause and Fix It ? Continue Operations No
Yes
Continue Operations
Call Field Service
Technical Drawings
3-3
3-4
Varco
Pipehandler Troubleshooting Pipehandler Troubleshooting
Torque Wrench Problems ................................... 4-3 Torque 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............................................... 4-13 Link Tilt Not Functioning Properly.................................. 4-14
4-1
Pipehandler Troubleshooting Pipehandler
Troubleshooting
4-2
Varco
Torque Wrench Problems

Symptom
Tool does not cycle at all.
See Page
Probable Cause
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.
Remedy
Readjust the valve per procedure. 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. Readjust the valve per procedure. Readjust the valve per procedure. 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.
4-5
Tool does not cycle properly.
Air solenoid valve out of adjustment. Pilot operated valve on counterbalance manifold out of adjustment.
See Page
4-6
Hydraulic quick disconnects improperly connected. Needle valve in counterbalance manifold is open. Defective cartridge valve or PRV valve. Improper component or component installation.
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.
Hydraulic filter requires replacement. Torque wrench slips.

See Page
Tong dies worn or damaged. Connection is over-torqued.
4-7
Saver sub incorrect length. Incorrect orientation of die retainer and carrier. Incorrect spacers. Die retainer and die retainer bolts damaged while breaking out. Torque wrench does not lift. Improper saver sub length or machining. Oil bypass in pipehandler hydraulic components.
See Page
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.
4-8
See Page
4-9
Technical Drawings
4-3
Torque Wrench Problems

Symptom
Tool goes up, clamps, and cycles, but remains clamped on pipe when switch is released.
See Page
Probable Cause
Air pilot valve on counterbalance manifold stuck or inoperative. Pilot valve dirty. Improperly connected quick disconnects.
Remedy
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.
4-10
Hydraulic valve not shifting.
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.
Saver sub or lower IBOP breaks out instead of tool joint.

See Page
Saver sub not made up properly.
4-11
Tong dies break or drill pipe becomes scored.
See Page
Threads worn or damaged. Valves in manifold out of adjustment. Tong dies worn. Connection overtorqued.
4-12
Technical Drawings
4-4
Varco
Torque Wrench Does Not Cycle at All

Torque Wrench Does Not Cycle At All
Is Air Solenoid Valve Out of Adjustment ? No
Yes
Readjust Valve per Procedure
Is Pilot Yes Operated Hydraulic Valve Out of Adjustment ? No
Is Needle Valve Open ? No
Yes
Inspect Needle Valve in Counterbalance Manifold Close Needle Valve (always with HPU running)
Are Hydraulic Yes Quick Disconnects Improperly Connected ? No
Check QDs to Ensure Proper Connections and Flowing in Both Directions
Is Hydraulic Supply Disrupted ? No
Yes
Check and Repair as Needed
Continue Operations
Yes
Call Field Service
Technical Drawings
4-5
Torque Wrench Does Not Cycle Properly

Torque Wrench Does Not Cycle Properly
Is Air Solenoid Valve Out of Adjustment ? No
Yes
Is Cartridge or PRV Valve Defective ? No
Yes
Inspect Valves for Damaged Seals or Stuck Spools Replace as Necessary
Is Pilot Yes Operated Hydraulic Valve Out of Adjustment ? No
Are Proper Components Installed Correctly ? No
Yes
Replace Valve Cartridge with Correct Type
When changing the Make/Break valve, make sure the valve is properly oriented when installed.
Are Hydraulic Yes Quick Disconnects Improperly Connected ? No
Continue Operations Check QDs to Ensure Proper Connections and Flowing in Both Directions
Is Needle Valve Open ? No
Yes
Inspect Needle Valve in Counterbalance Manifold Close Needle Valve (always with HPU running)
No
Perform Complete Torque Wrench Adjustment Procedure Check Mechanical Condition of Torque Wrench Check Hydraulic Filter s See TDS-4S Service Manual SM00620, Maintenance & Troubleshooting Chapter 3, Pages 4-49 thru 4-51. Did You Find Cause and Fix It ? No
Continue Operations
Yes
Call Field Service

Technical Drawings
4-6
Varco
Torque Wrench Slips

Torque Wrench Slips
Are Tong Dies Worn or Damaged ? No
Yes
Check Tong Dies and Replace as Necessary
Is Yes Connection Over-Torqued ?
Break the Connection with a Higher Torque Tool and Re-Make the Connection to the Proper Torque
No
Is Saver Sub Incorrect Length ? No
Yes
Check Saver Sub Length and Correct as Necessary
Is Die Retainer and Carrier Orientation Incorrect ? No
Yes Check Orientation and Correct as Necessary
Are Spacers Incorrect ? No
Yes
Check for Proper Spacers and Correct as Necessary
Yes
Continue Operations
Call Field Service
Call Field Service

Technical Drawings
4-7
Die Retainer/Bolts Damaged While Breaking Out
Die Retainer and Bolts Damaged While Breaking Out
Is Length or Machining of Saver Sub Improper ? No
Yes
Check Saver Sub Length Sub Should Have Proper Chamfer on Both Shoulders
Yes
Continue Operations
Call Field Service
Call Field Service
Technical Drawings
4-8
Varco
Torque Wrench Does Not Lift
Torque Wrench Does Not Lift
Is Oil Bypassing in Hydraulic Components ? No
Yes
Listen for Oil Bypassing in Pipehandler Cylinders or Manifold Locate and Repair Bypass as Necessary
Yes
Continue Operations
Call Field Service
Call Field Service
Technical Drawings
4-9
Torque Wrench Does Not Release

s Tool goes up, clamps and cycles, but remains clamped on pipe when switch is released.
Torque Wrench Clamp Does Not Release
Is the Air Pilot Valve on Yes Counterbalance Manifold Stuck or Inoperative ? No
Remove Air Supply Line to Verify Air Supply When Solenoid Valve is Activated
Is the Pilot Valve Dirty ? No
Yes
If Air Supply is Available, Remove End Cap On Pilot Valve, Clean and Lubricate
Are Quick Disconnects Improperly Connected ? No
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
Is the Hydraulic Valve Not Shifting ? No
Yes Repair or Replace
Call Field Service
Yes
Continue Operations
Call Field Service
Technical Drawings
4-10
Varco
Saver Sub Breaks Out Instead of Tool Joint
Saver Sub Breaks Out Instead of Tool Joint
s Saver sub or the IBOP breaks out instead of the tool joint.
Is the Saver Sub Made Up Improperly ? No
Yes
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)
Are Threads Worn or Damaged ? No
Yes Replace as Necessary
Call Field Service Did You Find Cause and Fix It ? No Yes Continue Operations
Call Field Service
Technical Drawings
4-11
Tong Dies Break or Drill Pipe Becomes Scored
Tong Dies Break or Score the Drill Pipe
Are Yes Valves in Manifold Out of Adjustment ? No
Readjust per Procedure
Are Tong Dies Worn ? No
Yes Replace Tong Dies
Is Connection Overtorqued ?
Yes
No
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
Call Field Service
Yes
Continue Operations
Call Field Service
Technical Drawings
4-12
Varco
Link Tilt Problems

Symptom
Link tilt does not extend, float, retract and/or hold.
See Page
Probable Cause
Mechanical problem. Incorrect PLC input. Solenoid problem. Pressure incorrect.
Remedy
Check mechanical operation of link tilt. Check PLC for correct inputs. Check mechanical operation of solenoid. Check pressure and adjust as necessary.
4-14
Technical Drawings
4-13
Link Tilt Not Functioning Properly

Link Tilt Not Functioning Properly
Does Link Tilt Extend ?
No
Yes
Does Link Tilt Float ?
No
Yes
Does Link Tilt Retract ?
No
Yes
Does Link Tilt Hold ?
No
Check Mechanical Check PLC Input Check Solenoid Check Pressure
Yes
Continue Operations
Yes
Continue Operations
Call Field Service
Technical Drawings
4-14
Varco
Counterbalance Counterbalance and and Motor Alignment Cylinder Troubleshooting Motor Alignment Cylinder Troubleshooting
Counterbalance System Problems ..................... 5-3 Counterbalance System Problem (HPU On) ................. 5-4 Counterbalance System Problem (HPU Off) ................. 5-5 Motor Alignment Cylinder Problems .................. 5-6 Alignment 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
5-1
Counterbalance and Motor Counterbalance Alignment Cylinder Troubleshooting
and Motor Alignment Cylinder Troubleshooting
5-2
Varco
Counterbalance System Problems

Symptom
System does not hold pressure (HPU On)
See Page
Probable Cause
Needle valve is not closed.
Remedy
Turn on HPU. Check needle valve. See adjustment procedure and verify system pressure. 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.
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 parking systems).
5-4
Cylinder rods remain retracted (closed). Counterbalance system works erratically or does not work at all (HPU Off).
See Page
Pressure setting too high. Possible problem with system hydraulic components. Loss of nitrogen precharge in accumulators located in motor dolly upright frame.
Adjust per adjustment procedure. Check the Counterbalance System Problem (HPU On) section of this book. Recharge accumulators as per the procedure in the Counterbalance section of this book.
5-5
When activating or reactivating the counterbalance system, never start an empty system with the needle valve closed. Always start the Hydraulic Power Unit (HPU) first, run for 3-5 minutes, then slowly close needle valve with HPU running. If an empty system is started up with needle valve closed there is a good potential for damaging counterbalance cylinder seals.
Technical Drawings
5-3
Counterbalance System Problem (HPU On)

Counterbalance Problem (HPU On) s Pressure related problems
Is the Needle Valve Open ? No
Yes
Turn On HPU Check Needle Valve See Adjustment Procedure Verify System Pressure
Is the PRV Valve Dirty or Defective ? No
Yes
See Adjustment Procedure and Clean or Replace
Are Cylinder Rod Seals Leaking ? No
Yes Replace Seals
Is the Check Valve Dirty or Stuck ? No
Yes Clean or Replace
Are Any Fittings or Hoses Leaking ? No
Yes
Tighten or Replace as Required
Is Counterbalance Yes Control Valve in Rig Down Position ? No
Return Valve to Drilling Position
Cylinder Rods Remain Retracted ? Yes
No
Is the Hydrualic Return Line Clear ? No
Yes
Check Quick Disconnects Check Valve Alignment
Is the Pressure Setting too High ? No
Yes
Adjust per Adjustment Procedure
Yes
Continue Operations
Call Field Service
Call Field Service
Technical Drawings
5-4
Varco
Counterbalance System Problem (HPU Off)

s Counterbalance system works erratically or does not work at all
Counterbalance Problem (HPU Off)
Turn HPU Off Check System Hydraulic Components Check for Loss of Nitrogen Precharge in Accumulators Located in Motor Dolly Upright Frame
Problem with System Hydraulics ? No
Yes
See Page
5-4
Loss of Yes Precharge in Accumulators ?
Recharge Accumulators as per Procedure
No No Did You Find Cause and Fix It ? Yes
Call Field Service
Continue Operations
Technical Drawings
5-5
Motor Alignment Cylinder Problems

Symptom
Alignment cylinder fails to move motor housing at trunnion pivot points with recommended pressure setting. System does not hold pressure.
See Page
Probable Cause
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.
See Page
Remedy
Free trunnion pins as needed and lubricate area regularly.
5-7
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.
5-8
Saver sub on TDS does not align with drill pipe.
See Page
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.
5-9
Excessive motor movement.
See Page
5-10
Technical Drawings
5-6
Varco
Alignment Cylinder Fails to Move Motor Housing

s Alignment cylinder fails to move motor housing at trunnion pivot points with recommended pressure setting
Alignment Cylinder Fails to Move Motor Housing
Are the Trunnion Pins Lubricated ?
No
Free Trunnion Pins as Needed and Lubricate Area Regularly
Yes No Did You Find Cause and Fix It ? Yes
Call Field Service
Continue Operations
Technical Drawings
5-7
System Does Not Hold Pressure

System Does Not Hold Pressure
Is the Needle Valve Open ? No
Yes
See Adjustment Procedure and Check Needle Valve
Are Cylinder Rod Seals Leaking ? No
Yes Replace Seals
Are Any Fittings or Hoses Leaking ? No
Yes
Tighten or Replace as Required
Is the PRV Valve Dirty or Defective ? No
Yes
See Adjustment Procedure and Clean or Replace
Is the PRV Valve Dirty or Defective ? Yes
No No
Call Field Service

Technical Drawings
Continue Operations
5-8
Varco
Saver Sub Not Aligning with Drill Pipe
Saver Sub Does Not Align with Drill Pipe
Is the Alignment Cylinder Pressure OK ? Yes
No
If too High or Low, See Adjustment Procedure
Is Cylinder Rod Adjusted too Long or Short ? Yes
No
Adjust According to Procedure
Are Rails Aligned with Well Centerline ? Yes
No
Check to Make Sure that Rotary is in Center of Floor Check Alignment of Rails in Relation to Rotary
No
Call Field Service
Continue Operations
Technical Drawings
5-9
Excessive Motor Movement

Excessive Motor Movement
Check to Make Sure that Alignment Cylinder Fluid Flow is Adequately Throttled
Is Fluid Flow Adequately Throttled ? Yes
No
See Adjustment Procedure
s 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.
No
5
Call Field Service
Continue Operations
Technical Drawings
5-10
Varco
DrillingDrilling Motor Housing, Brake and Motor Housing, Guide Dolly Troubleshooting Brake and Guide Dolly Troubleshooting
Motor Air Brake Problems .................................. 6-3 Motor Air Brake Problems ............................................. 6-4 Motor Air Brake Does Not Hold ..................................... 6-5 Motor Air Brake Does Not Release ............................... 6-6 Guide Dolly Problems ......................................... 6-7 Retract Control Problem ................................................ 6-8 Guide Dolly Retracts too Slow or too Fast ..................... 6-9 Transmission Problems ...................................... 6-10 Oil Leaking from Lower Gear Case Seal ....................... 6-11 Oil Leaking from Shaft Housing Breather ...................... 6-12 Gearbox Temperature Excessive .................................. 6-13 Oil Pump Problems ............................................. 6-14 OIL OVERTEMP/OIL PUMP LOSS Alarm .................... 6-15 Cooling Blower Problems ................................... 6-16 Mechanical 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..................................... 6-23 Rotating Head Problems ............................................... 6-24
6-1
Drilling Motor Housing, Brake and Drilling Motor Housing, Guide Dolly Troubleshooting
Brake and Guide Dolly Troubleshooting
6-2
Varco
Motor Air Brake Problems

Symptom
Brake does not hold.
See Page
Probable Cause
Insufficient air supply. Solenoid valve not shifting.
Remedy
Check air supply pressure 90 psi minimum required. Check electrical continuity. Check lubricator on air supply. Check mechanical operation of solenoid valve.
6-5
Brake drum contaminated with grease or pads worn or burnt. Brake does not release.
See Page
Inspect and replace if necessary. Lubricate, repair with repair kit or replace valve. Check air supply lubricator.
Solenoid valve sticking.
6-6
Quick exhaust valve not functioning properly.
Clean or replace.
Technical Drawings
6-3
Motor Air Brake Problem

Brake Problem
Brake Releasing ?
No
Brake Light On ? Yes
No
Check Mechanical Check Air Pressure Perform Lamp Test Check PLC Ensure Air Dischage Outlets are Clear See Page 6-6
Yes
Set Brake ON, then OFF
Yes
Brake Reset ?
No
Check PLC Check Wiring
Brake Slipping <30,000 ft-lb ?
Yes
Check Air Pressure Check for Air Leaks Check Pads See Page 6-5
No
Brake Functioning Correctly ? Yes
No
Check PLC Check Wiring Check Mechanical Check Hydraulic See Page 6-5
Continue Operations
Yes
Call Field Service

Technical Drawings
6-4
Varco
Motor Air Brake Does Not Hold
Brake Does Not Hold
Is There Sufficient Air Supply ? Yes
No
Check Air Supply, 90 psi Minimum Required
Is the Solenoid Valve Shifting ? Yes
No
Check Electrical Continuity Check Lubricator on Air Supply Check Mechanical Operation of Solenoid Valve
Is the Brake Drum Okay ? Yes
No
Check Drum for Grease Check for Worn or Burnt Shoes Replace if Necessary
6
No Did You Find Cause and Fix It ? Yes
Call Field Service
Continue Operations
Technical Drawings
6-5
Motor Air Brake Does Not Release
Brake Does Not Release
Is the Solenoid Valve Okay ? Yes
No
Check the Valve for Sticking Lubricate, Repair or Replace Check Air Supply Lubricator
Is the Quick Exhaust Valve Okay ? Yes
No Clean or Replace
No
Call Field Service
Continue Operations
Technical Drawings
6-6
Varco
Guide Dolly Problems

Symptom
Only one guide dolly is operating. See
Page
Probable Cause
Solenoid valve not operating properly.
Remedy
Manually operate the solenoid valve. Check mechanical latch (dogs), cylinders, hydraulic pressure, quick disconnects, hoses, plumbing and retract manifold setup.
6-8
Both guide dollies do not extend/ retract.
See Page
Directional control valve not operating properly.
Manually operate the directional control valve. Check mechanical latch (dogs), cylinders, hydraulic pressure, quick disconnects, hoses, plumbing and retract manifold setup.
6-8
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.
Guide dollies are not synchronized.

See Page
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.
6-8
Guide dollies are not operating properly.

See Page
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.
6-8
Guide Dolly retracts too slow or too fast.

See Page
Flow control valves on the guide dolly are not properly set.
6-9
Technical Drawings
6-7
Retract Control Problem

Retract/Control Problems
Is Only the Block Dolly Operating ? No
Yes
Confirm TDS Disable Solenoid Operation/ Switch Position
Do Both Dollies Extend/ Retract ? Yes
No
Manually Operate the Directional Control Valve
Do Both Dollies Extend/ Retract ? Yes
No
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
Confirm Solenoids Consider ZMS Interlock Check PLC Inputs/Outputs Check VDC Switch
Are Dollies Synchronized ?
No
Check Retract Manifold Setup (page 13 of Hyd. Setup) Check Quick Disconnect Connectors Check Hose Connections/ Restriction Did You Find Cause and Fix It ? No Continue Operations Yes
Yes
Are Dollies Operating Properly ? Yes
No
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
Call Field Service
Continue Operations
Technical Drawings
6-8
Varco
Guide Dolly Retracts too Slow or too Fast
Guide Dolly Retracts Too Slow or Too Fast
Are Flow Control Valves on Dolly Properly Set ? Yes
No
Set the Flow Controls to Attain Desired Retract Speed
s Refer to Retract Guide Dolly Control Manual
Check for Correct Operation of: Fast-Speed Proximity Sensor and Targets PLC Input PLC Output Wiring Precharge Accumulator Pressure
No
Is Fast-Speed Circuit Operative ? Yes
No
Continue Operations Did You Find Cause and Fix It ? No Yes Continue Operations
Call Field Service
Technical Drawings
6-9
Transmission Problems
Symptom
Oil leaking from lower seal.
See Page
Probable Cause
Lower gear case seals are dry or damaged.
Remedy
Apply grease to seal. Grease fitting daily. If problem persists replace gearcase seals and bearing.
6-11
Oil leaking from shaft housing breather.
See Page
Oil level too high. Incorrect lubricant used. Oil is foaming. Oil level too low or too high. Incorrect lubricant used. Clogged oil filter.
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.
6-12
Gearbox temperature is excessive.
See Page
6-13
Clogged or dirty heat exchangers on unit equipped with such.
Technical Drawings
6-10
Varco
Oil Leaking from Lower Gear Case Seal
Oil Leaking from Lower Gear Case Seal
Are Seals Dry or Damaged ? No
Yes
Apply Grease to Seals, Grease Fitting Daily If Problem Persists Replace Gearcase Seals and Bearing
No
Call Field Service
Continue Operations
Technical Drawings
6-11
Oil Leaking from Shaft Housing Breather
Oil Leaking from Shaft Housing Breather
Is Oil Level too High ? No
Yes
Adjust Oil Level per Recommended Specification
Is Incorrect Lubricant Used ? No
Yes
Check Recommended Lubricants Chart and Replace as Needed
Is Oil Foaming ? No
Yes Replace Oil
6
No
Call Field Service
Continue Operations
Technical Drawings
6-12
Varco
Gearbox Temperature Excessive
Gearbox Temp Excessive
Is Oil Level too Low or too High ? No
Yes
Adjust Oil Level to Recommended Level in Sight Glass
Is Incorrect Lubricant Used ? No
Yes
Check Recommended Lubricants Chart and Replace as Needed
Is the Oil Filter Clogged ? No
Yes
Remove Filter from Oil Pump, and Check Discharge or Pressure Hoses at Outlets to Confirm Circulation
6
Are Heat Exchangers Clogged (if equipped) ? No Did You Find Cause and Fix It ? Yes Yes Check Heat Exchangers for Air Flow or Water Flow to Ensure Adequate Heat Transfer and Dissipation
No
Call Field Service
Continue Operations
Technical Drawings
6-13
Oil Pump Problems

Symptom
OIL OVERTEMP/ OIL PUMP LOSS alarm is on.
See Page
Probable Cause
No oil pressure while pump is running.
Remedy
Check oil pressure. Check temperature and pressure switch. Check PLC for correct input. Check motor rotation. Check oil level. Check oil filter. Check plumbing.
6-15
Starter is tripped. Starter is not energized. Motor is not running.
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.
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. Incorrect lubricant used.
Technical Drawings
6-14
Varco
OIL OVERTEMP/OIL PUMP LOSS Alarm

Oil Overtemp/ Oil Pump Loss Alarm is ON
Did Oil Pump Come On ? Yes
No
Starter Tripped ?
No
Starter Energized ?
No
Check PLC Check Wiring Check Output
Yes
Yes
Check Oil Pressure Check Temperature and Pressure Switch Check PLC Input Check Motor Rotation Check Oil Level Check Oil Filter Check Plumbing
Reset Starter
Check Connectors and Cable
Yes
Continue Operations
Starter Tripped ?
Yes
Call Field Service Continue Operations
No
Meggar Blower Motor/Cables
Technical Drawings
6-15
Cooling Blower Problems

Symptom
Mechanical noise in cooling blower. See
Page
Probable Cause
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.
Remedy
Reinstall impeller, hub and locktite screws. Repair or replace as needed. Inspect and repair or replace as needed. Locate and repair as needed. Repair or replace 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.
6-17
Cooling blower runs intermittently. See
Page
6-18
Excessive air loss in blower motor shaft area.
See Page
6-19
See Page
BLOWER LOSS alarm is on.
6-20
Differential or purge pressure switches are faulty. Starter is tripped. Starter not energized. AIR OVERTEMP alarm stays on with blower running. 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.
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.
See Page
6-21
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. Repair or replace as needed. Do not readjust or raise heat range setting.
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).
Technical Drawings
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
6-16
Varco
Mechanical Noise in Cooling Blower

Mechanical Noise in Blower
Is the Impeller Loose ?
Yes
Reinstall Impeller, Hub and Locktite Screws
No
Are the Motor Bearings Faulty ? No
Yes
Repair or Replace as Needed
Yes
Continue Operations
6
Call Field Service
Technical Drawings
6-17
Cooling Blower Runs Intermittently

Blower Runs Intermittently
Is Wiring Loose or Faulty ? No
Yes
Locate and Repair as Needed
Is the Motor Starter Faulty ? No
Yes
Check for Dirt or Trash Between Starter Coil Repair or Replace as Needed
Yes
Continue Operations
6
Call Field Service
Technical Drawings
6-18
Varco
Excessive Air Loss in Blower Motor Shaft Area
Excessive Air Loss in Blower Motor Shaft
Is Seal Yes or Wear Sleeve Defective or Worn ? No
Replace as Needed
Is Yes Blower Motor Loose or Vibrating ? No
Correct Blower Mounting Problem or Faulty Motor Bearing and Replace Blower Shaft Seals
Yes
Continue Operations
6
Call Field Service
Technical Drawings
6-19
BLOWER LOSS Alarm

Blower Loss Alarm
Did Blower Come On ? Yes
No
Starter Tripped ?
No
Starter Energized ?
No
Check PLC Check Wiring Check Output
Yes
Yes
Check Differential and Purge Pressure Switches Check Blower Motor Rotation Confirm Air Flow
Reset Starter
Check Connections and Cable
Yes
Continue Operations
Starter Tripped ?
Yes
Call Field Service Continue Operations
No
Meggar Blower Motor/Cables
Technical Drawings
6-20
Varco
AIR OVERTEMP Alarm Stays On
Air Overtemp Alarm Stays On
Has the Drill Motor Been Running ? Yes
No
Check Wiring Check PLC Inputs Check Temperature Switch
Wait 15 Minutes with Throttle OFF and Blower Running
Overtemp Alarm ?
No
Check Top Drive Current Load Check Blower Check Blower Starters Check Blower Rotation and Screens Check Air Flow
No
See Page
6-22
Yes
See Page
Continue Operations
6-22
Technical Drawings
6-21
AIR OVERTEMP Alarm Stays On

Air Overtemp Alarm Stays On s AIR OVERTEMP alarm stays on with blower running
Is Blower Rotation Incorrect ? No
Yes
Verify Blower Rotation Correct as Needed
Motor Stalled Over Yes Recommended Time ? No
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
Are Spark Arrestors Dirty or Clogged ? No
Yes
Remove Spark Arrestors from Motor and Clean Screens if Screens are Damaged with Holes Replace as Needed
Is Temperature Yes Switch or Probe Faulty ? No
Repair or Replace as Needed
Do not readjust or raise heat range setting
Air or Water Yes Passages in Exchangers Clogged ? s Closed No
Remove and Clean Passages as Needed
Is Cooling Yes Water Flow Improper or too High ? s Closed No
See the Installation and Commissioning Book for Recommended or Required Flow Rates and Water Temp
loop cooling.
loop cooling.
Check and Clean Spark Arrestors as Needed Check Air Intake on Blower to Ensure There are No Restrictions Verify Proper Blower Rotation
Continuous Drilling Yes Amps Over Recommended Levels ? No
Check Service Manual for Continuous Amp Motor Rating and Adjust Drilling Program Accordingly
Is Air Flow Restricted ? No
Yes
No
Call Field Service
Continue Operations
Technical Drawings
6-22
Varco
Rotating Head Problems

Symptom
Rotating head not turning freely.
See Page
Probable Cause
Link tilt switch not in FLOAT position. AUTO STOP light is ON.
Remedy
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.
6-24
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.
Rotating head seals are leaking.

See Page
Seals deteriorating.
6-24
Technical Drawings
6-23
Rotating Head Problem
Rotating Head Problem 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
Is Rotating Head Turning Freely ? Yes
No
Are Rotating Head Seals Leaking ? No
Yes
Consider Using Spare Ports Repair or Replace Rotating Head Seals
Yes
Continue Operations
Continue Operations
Call Field Service
Technical Drawings
6-24
Varco
Service Centers
Service Centers
Varco Service Centers .......................................... 7-3 1
7-1
Service Centers
Service Centers
7-2
Varco
Service Centers
Varco Service Centers
United States of America

Varco 12950 West Little York Road Houston, TX 77041 P.O. Box 1473 Houston, TX 77251 USA Contact: Support Help Desk Telephone: (713) 856-4128 Fax: (713) 849-6189 Contact: Service Manager Office: (713) 937-5500
Varco 8404 West Hwy. 90 New Iberia, LA 70560 USA
Contact: Service Manager Office: (337) 364-4583 Fax: (337) 365-2545
United Kindom
Varco (U.K.) Ltd. Forties Road Montrose, Angus DD10 9ET Scotland Contact: Service Manager Office: (011) 44-1674-677-222 Fax: (011) 44-1674-677-379
Australia
Varco 1378 Sale Victoria, 3850 Australia Contact: Service Manager Office: (61) 893-363-988 Fax: (61) 893-363-987
United Arab Emirates

Varco Al Mansoori Services P.O. Box 27011 Abu Dhabi United Arab Emirates Contact: Service Manager Office: 971-2-5552668 Fax: 971-2-5540012
7-3
Service Centers
Varco Service Centers

Singapore
Varco No. 8, Sixth Lok Yang Road Jurong Town Singapore 628106 Contact: Regional Service Manager Mobile: (65) 97313441 Contact: Offshore Supervisor Office: (65) 265-5066 Fax: (65) 265-7485 Mobile:(65) 98314736 Contact: Workshop Manager Mobile: (65) 96320997
China
Varco Service Contact: Service Manager Mobile: (86) 1393008965 Contact: Service Manager Office: (86) 106-495-3025 Mobile: (86) 1391224037
India
Varco Service Contact: Service Manager Office: (91) 36-155-1621
Brazil
Varco do Brasil Ltda. Estrada So Jos Imboassica, sn-Imboassica Maca Rio de Janeiro 27902-000
Office: 55-24-27-730600 Fax: 55-24-27-730600
7-4
Varco
Appendix
Appendix
Checks ................................................................ 8-3 Vendor Documentation ....................................... 8-4 Technical Drawings ............................................ 8-5 SCR Interface II Test Procedure ........................ 8-6 2 Speed/Torque II Test Procedure ........................ 8-14 Stump/Cyclops Test Procedure .......................... 8-22 Users Guide Stump ............................................. 8-32 3 Adjusting the Torque Wrench ............................. 8-39 Adjusting the Counterbalance System .............. 8-42 Adjusting the Motor Alignment Cylinder System 8-44 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 8 7 6 5 4 1
TDS-4S/4H Troubleshooting Guide TDS-4S/4H Troubleshooting Guide
8-1
Appendix
Appendix
1 Flow Valves .......................................................... 8-76 Orifice .................................................................................... 8-75 2 Flow Control valve adjustable ............................................... 8-78 Output actuators.................................................. 8-80 Hydraulic cylinder, double acting .......................................... 8-80 3 Hydraulic motors ................................................................... 8-82
8-2
Varco
Appendix
Checks
Check PLC 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 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 for loose terminals Check Switches Check continuity across contracts Check for loose terminals Check actuation mechanism
Check SCR Verify correct throttle signal voltage Verify correct torque/current limit signal voltage Verify closure of main DC contactors Check field supply (see TPC Vendor Document on page 8-4)
Technical Drawings
8-3
Appendix
Vender Documentation
Document Name Tech-Power Field Supply Manual GE752 Motor Instruction Book PLC Direct DL205 User Manual PLC Direct DL405 User Manual VDR # VDR00011 VDR00023 VDR00051 VDR00052
Technical Drawings
8-4
Varco
Appendix
Technical Drawings
The drawings in this section are standard electrical drawings. They are for reference only. For rig specific drawings, refer to your Technical Drawings Package. System Schematic System Schematic
Technical Drawings
8-5
Appendix
SCR Interface II Test Procedure

PRINTED CIRCUIT BOARD TEST PROCEDURE
Board Name:
Assembly Number: Schematic: Product:
SCR Interface, Version II 92450 92452 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
8
V.
FINAL ACCEPTANCE Remaining functions required to prepare PCB assembly for final acceptance
Technical Drawings
8-6
Varco
Appendix
I.
SUMMARY OF BOARD FUNCTIONS The SCR Interface II board provides an interface between the Varco Drillers Console (VDC), the Programmable Logic Controller (PLC), and the customers 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 Speed Reference Current Limit Reference VDC Makeup Signal Water Sensor Throttle Up Throttle Down Current Up Current Down Torque Ramp Up Overspeed Outputs: Signal SCR Speed Control SCR Current Signal Qty 2 2 Voltage 0 to 30V 0 to 30V Type Analog Analog Analog Analog Digital Digital Digital Digital Digital Digital Qty 2 2 2 2 1 1 1 1 1 1 Voltage 0 to 30V (Max) 0 to 30V (Max) 0 to 30V (Max) 0 to -12V 0 to 24V 0 to 24V 0 to 24V 0 to 24V 0 to 24V 0 to 24V
Modified Current Limit 2 0 to 30V Top of Ramp 1 0 to +24V * Bottom of Ramp 1 0 to +24V * * Open collector transistorpulled up externally to +24V when active (top or bottom of ramp)
Technical Drawings
8-7
Appendix
Indicators Installed on Board Assembly:
Function Power Limit Throttle Signal Position Increment Throttle Up Increment Throttle Down Stall Ramp Down Current Signal Position Increment Current Up Increment Current Down Torque Ramp Up Command Torque/Spin Current Signal Position Top of Ramp Bottom of Ramp Water Detect #1 Water Detect #2 Torque Mode Spin Mode Overspeed Condition Rotary Table Mode
Indicator Red LED Bar graph Bar graph Bar graph Red LED Bar graph Bar graph Bar graph Green LED Bar graph Green LED Green LED Red LED Red LED Green LED Green LED Red LED Red LED
II.
EQUIPMENT REQUIREMENTS The following is required to test this assembly:
Equipment Oscilloscope DVM Variable DC power supply Potentiometer Potentiometer Fixed Resistor
Range/Accuracy Bandwidth to at least 20MHz 4 1/2 Digits, 0.1% accuracy 0 to 24VDC 1K, 1W Single Turn (quantity 2) 10K, 1W Single Turn (quantity 2) 1K, 1/4W, 2%
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 92452 is required to identify the location of all signal points referenced in this procedure.
Technical Drawings
8-8
Varco
Appendix
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 Drillers Throttle control. 3. Attach a 1K potentiometer to Current Excitation F/S (clockwise end) and VDC Makeup Return, connecting the 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 points can be varied from zero to 10K Ohms. Similarly, connect a second 10K potentiometer between Water Sensor #2 (+) and (-).
6. Verify the status of the following LED indicators:
Function
Color
Status
Power Limit Stall Ramp Down Rotary Table Mode Water Detect #1 Water Detect #2 Bottom of Ramp Top of Ramp Overspeed Torque Spin Torque Ramp Up
Red Red Red Red Red Green Green Red Green Green Green
OFF OFF OFF OFF OFF ON OFF OFF OFF OFF OFF
Note: It is imperative that the board is in this state when power is first applied and that no action is performed to attain these states.
Technical Drawings
8-9
Appendix
IV.
TEST PROCEDURE
Technical Drawings
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) Command Inc Throt LED Throttle Ramp (DS1) Power Limit SCR #1 Speed Signal 20.0V 19.4V 18.9V 18.3V 17.7V 17.1V 16.6V 16.0V 16.0V 16.6V 17.1V 17.7V 18.3V 18.9V 19.4V 20.0V 20.0V
(None) OFF Throttle Down Down (pulse) Throttle Down Down (pulse) Throttle Down Down (pulse) Throttle Down Down (pulse) Throttle Down Down (pulse) Throttle Down Down (pulse) Throttle Down Down (pulse) Throttle Down Down (pulse) Throttle Up Up (pulse) Throttle Up Throttle Up Throttle Up Throttle Up Up (pulse) Up (pulse) Up (pulse) Up (pulse) Up (pulse) Up (pulse) Up (pulse)
Segment #1 (Top) OFF Segment #2 ON Segment #3 Segment #4 Segment #5 Segment #6 Segment #7 Segment #8 Segment #8 Segment #7 Segment #6 Segment #5 Segment #4 Segment #3 ON ON ON ON ON ON ON ON ON ON ON ON
Throttle Up Throttle Up Throttle Up
Segment #2 ON Segment #1 (Top) OFF Segment #1 OFF
1.3. Spin Mode Assign Spin Mode (see 92452 sheet 3 for location of mode assignment pinsall 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).
8-10
Varco
Appendix
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) Command Inc Curr LED Throttle Ramp (DS2) SCR #1
Stall Ramp Down Current Signal
(None) Current Down Current Down Current Down Current Down Current Down Current Down Current Down Current Down Current Up Current Up Current Up Current Up Current Up Current Up Current Up Current Up
OFF Down (pulse) Down (pulse) Down (pulse) Down (pulse) Down (pulse) Down (pulse) Down (pulse) Down (pulse) Up (pulse) Up (pulse) Up (pulse) Up (pulse) Up (pulse) Up (pulse) Up (pulse) Up (pulse)
Segment #1 (Top) Segment #2 Segment #3 Segment #4 Segment #5 Segment #6 Segment #7 Segment #8 Segment #8 Segment #7 Segment #6 Segment #5 Segment #4 Segment #3 Segment #2 Segment #1 (Top) Segment #1
OFF ON ON ON ON ON ON ON ON ON ON ON ON ON ON OFF OFF
20.0V 17.5V 15.0V 12.5V 10.0V 7.5V 5.0V 2.5V 2.5V 5.0V 7.5V 10.0V 12.5V 15.0V 17.5V 20.0V 20.0V
Technical Drawings
8-11
Appendix
2.3. Spin Assign 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 #1 remains less than 100mV as the position of the VDC Current Limit potentiometer is rotated from zero to full clockwise rotation. Adjust Spin Current potentiometer to full clockwise rotation. Vary VDC Current Limit potentiometer from full counter-clockwise to full clockwise rotation. Verify the voltage at SCR Current Signal #1 increases from 6.67Volts to 9.1Volts (4%). 2.4. Torque Mode Ramp Up Assign 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 verify Torque Ramp Up indicator (DS11) is ON, Bottom of Ramp indicator (DS6) goes OFF, and segments of DSP2 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 from 0V to 20Volts as monitored on the oscilloscope, and that Top of Ramp indicator (DS7) is ON. 2.5. Torque Mode Ramp Down Remove 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 steps from 20Volts to 0V as monitored on the oscilloscope. 2.6. Overspeed Return 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 verify output voltage drops to less than 100mV, as above. 3. Modified Drill Current Limit 3.1. TDS Mode Rotate 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 Mode Assign 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 #1 Vary 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 ). Technical Drawings
8-12
Varco
Appendix
4.2. Water Sensor #2 Vary 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 ).
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
Technical Drawings
8-13
Appendix
Speed/Torque II Test Procedure

Board Name:
Speed/Torque Interface II 92960 92962 TDCS
PURPOSE:
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 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.
Technical Drawings
8-14
Varco
Appendix
I.
SUMMARY OF BOARD FUNCTIONS
The Speed/Torque II board provides an interface between the Varco Drillers Console (VDC), the Programmable Logic Controller (PLC), and the customers SCR system. The board is designed to be inserted into a Varco control system rack with either a CR1/CR2 or CR1/CR3 configuration. Basic features include: Inputs: Signal Magnetic pickup* Qty 1 Voltage 4-30V p-p 0V or open -10VDC to +10VDC -5VDC to +5VDC 0V or open 0V or open RPM measurement TDS direction indication Armature Current correction for plus and minus polarities Galvanically isolated -10V to +10V output for tach feedback signal
Proximity sensor 2 24V pulse Reverse Command from PLC 1 Rotary Table Tach Signal Armature Current sensor Rotary Table Command from PLC Gear Ratio (for TDS-4 only) Outputs: Signal TDS RPM TDS RPM TDS Armature Current TDS Armature Current Reverse (open for reverse) Reverse (close for reverse) Tachometer Signal Reverse Signal (to PLC) Board Identifier Qty 2 3 2 3 1 1 1 1 1 1 2 1 1
* (For older systems without TDS direction indication)
Voltage 0-10VDC 4 to 20mA 0-10VDC 4 to 20mA Dry Contact Dry Contact -10VDC to +10VDC 0V or 24VDC 0V
Indicators installed on board assembly: Function TDS Reverse Proximity Sensor A/Mag PU signal Proximity Sensor B signal RPM display (0 to 250 RPM) Armature Current (0 to 1500 AMPS)
Technical Drawings
Indicator Red LED Green LED Green LED Bar graph Bar graph Seven-segment display Decimal point on above
TDS Type selected TDS4 High Gear Selected
8-15
Appendix
II.
EQUIPMENT REQUIREMENTS
The following is required to test this assembly: Equipment Oscilloscope DVM Variable DC power supply Function generator Frequency Counter Range/Accuracy Bandwidth to at least 20MHz 4 1/2 Digits, 0.1% accuracy 0 to 24VDC Variable Duty Cycle to 1kHz 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. 2. 3. 4. 5. 6. 7. 8. Place SW1 in CALIBRATE position; set SW2A and SW2B to OPEN positions. Connect frequency counter between TP1 and GND. Set SW3 to position 3. Adjust R21 so that the frequency measured at TP1 is as indicated on chart located on schematic drawing 92962, 2 Hertz. Similarly, adjust R22 - R25, changing SW3 and Gear Ratio as appropriate. Place SW1 in OPERATE position. Input a square wave of 24V amplitude and 33% duty cycle at P1-C26 with return at P1-C13 (frequency to be 1%). Adjust R31 - R35 to achieve 10VDC (0.1VDC) at P1-B19 using SW3 to select TDS type.
Technical Drawings
8-16
Varco
Appendix
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 Pickup For the following, input a 8V p-p sine wave as indicated at P1-C12 with return at P1-C13 and measure the output at P1-B19 (referenced to analog ground):
Input 140Hz 280Hz 420Hz 560Hz
TDS Type 3 3 3 3
Output 2.5V 5.0V 7.5V 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 with return at P1-C13 and measure the output at P1-B19 (referenced to analog ground). Use SW3 and Gear Ratio input to establish TDS Type. Verify that TDS indicator DSP3 corresponds with TDS type selected. (Jumper P1-C13 to P1-C2 for the remainder of this test procedure) Input 150Hz 150Hz 150Hz 150Hz 150Hz 300Hz 300Hz 300Hz 300Hz 300Hz 500Hz 500Hz 500Hz 500Hz 500Hz 560Hz 835Hz 533Hz 770Hz 560Hz TDS Type 3 4L 4H 5 6 3 4L 4H 5 6 3 4L 4H 5 6 3 4L 4H 5 6 DSP3 Output 3 4 4. 5 6 3 4 4. 5 6 3 4 4. 5 6 3 4 4. 5 6 2.68V 1.80V 2.81V Note: DSP3 decimal point is ON 1.95V 2.68V 5.36V 3.59V 5.63V 3.90V 5.36V 8.93V 5.99V 9.38V 6.49V 8.93V 10.0V 10.0V 10.0V 10.0V 10.0V
Technical Drawings
8-17
Appendix
1.3. Proximity Sensor B (normal mode) Using 24VDC to simulate proximity sensors, perform the following sequence and note the state of the red REVERSE indicator (DS3) and the green status indicators (DS1 and DS2): Prox Sensor Inputs A DS1 B 0V OFF 0V 0V OFF 24V 24V ON 24V 24V ON 0V 24V ON 24V 0V OFF 24V 0V OFF 0V 0V OFF 24V Indicator DS2 DS3 OFF OFF or ON ON OFF ON OFF OFF OFF ON ON ON ON OFF ON ON OFF
1.4. Proximity Sensor B (inverted mode) Continue with SW2A and SW2B in the CLOSE position: Prox Sensor Inputs A DS1 B 24V ON 24V 24V ON 0V 0V OFF 0V 0V OFF 24V 0V OFF 0V 24V ON 0V 24V ON 24V 24V ON 0V Indicator DS2 DS3 ON OFF or ON OFF OFF OFF OFF ON OFF OFF ON OFF ON ON ON OFF OFF
1.5. RPM Output Circuit Verification Select 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 112Hz 280Hz 420Hz 560Hz 0.0V 2.0V 5.0V 7.5V 10.0V 0.0V 2.0V 5.0V 7.5V 10.0V 4mA 7.2mA 12mA 16mA 20mA 4mA 7.2mA 12mA 16mA 20mA 4mA 7.2mA 12mA 16mA 20mA 0 3 7 10 10
1.6. Board Identifier Verify resistance from P1-A19 to Analog Ground is less than 1 Ohm. 1.7 TDS Direction Indication Check Reverse input and output operation by connecting P1-A14 to Analog Ground and verifying responses:
Reverse Cmnd Jumper ON Open

Technical Drawings
DS3 ON OFF
P2-C4 to P2-B4 > 20M Ohms < 0.5 Ohms
P2-C4 to P2-A4 < 0.5 Ohms > 20M Ohms
Reverse Signal < 2VDC > 20VDC
8-18
Varco
Appendix
2.
Armature Current 2.1. Armature Current Sensor #1 Select TDS Type 3 and place SW4A - SW4D in the OPEN position. Input the following voltages at P1-C15 and verify proper values at the indicated TDS Armature Current outputs and bar graph display, DSP2. Outputs must be 3% and DSP2 value must be 1 bar: Input -5.0V -4.0V -2.5V -1.0V 0.0V 1.0V 2.5V 4.0V 5.0V 0-10V #1 10.0V 8.0V 5.0V 2.0V 0.0V 2.0V 5.0V 8.0V 10.0V 0-10V #2 10.0V 8.0V 5.0V 2.0V 0.0V 2.0V 5.0V 8.0V 10.0V 4-20mA #1 20.0mA 16.8mA 12.0mA 7.2mA 4.0mA 7.2mA 12.0mA 16.8mA 20.0mA 4-20mA #2 20.0mA 16.8mA 12.0mA 7.2mA 4.0mA 7.2mA 12.0mA 16.8mA 20.0mA 4-20mA #3 DSP2 20.0mA 16.8mA 12.0mA 7.2mA 4.0mA 7.2mA 12.0mA 16.8mA 20.0mA 10 8 5 2 0 2 5 8 10
2.2. Armature Current Sensor #2 Select 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 -2.0V -2.0V -2.0V -2.0V -2.0V 0.0V 0.0V 0.0V 0.0V 0.0V 2.0V 2.0V 2.0V 2.0V 2.0V 4.0V 4.0V 4.0V 4.0V 4.0V Input#2 -5.0V -2.0V 0.0V 2.0V 5.0V -5.0V -2.0V 0.0V 2.0V 5.0V -5.0V -2.0V 0.0V 2.0V 5.0V -5.0V -2.0V 0.0V 2.0V 5.0V 0-10V #1 7.0V 4.0V 2.0V 4.0V 7.0V 5.0V 2.0V 0.0V 2.0V 5.0V 7.0V 4.0V 2.0V 4.0V 7.0V 9.0V 6.0V 4.0V 6.0V 9.0V DSP2 10 8 4 8 10 10 4 0 4 10 10 8 4 8 10 10 10 8 10 10
Technical Drawings
8-19
Appendix
2.3. Reduced Gain Mode Select 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 0.0V -2.0V -2.0V -2.0V 4.0V 4.0V Current#2 -4.0V -2.0V 0.0V 2.0V 2.0V -4.0V 0-10V #1 2.0V 2.0V 1.0V 2.0V 3.0V 4.0V
Place SW4A - SW4D in the OPEN position and continue: 2.0V -2.0V 3. 2.0V -2.0V 4.0V 4.0V
Galvanically Isolated Tach Feedback Signal and Calibration Mode
3.1. Rotary Table Mode Select TDS Type 3 and Rotary Table Mode (reference P1-C18). Apply the following voltages to the Rotary Table Tach Signal inputs and measure the subsequent Tach Output signal (P1-A24 and P1A25). Make certain that both voltage source and DVM are completely isolated from PCB power supply return: Input -5V 0V 5V Output DSP3 -5V 0V 5V 0 0 0
3.2. TDS Mode Select TDS mode (i.e., not Rotary Table Mode). Apply the following signals at Proximity Sensor A i nput and verify proper voltages at Tach Output (P1-A24 and P1-A25) in both forward and reverse conditions. Ouput must be 3%: Input 140Hz 280Hz 420Hz 560Hz 140Hz 280Hz 420Hz 560Hz
Technical Drawings
Direction Forward Forward Forward Forward Reverse Reverse Reverse Reverse
DSP3 Output 3 3 3 3 3 3 3 3 2.5V 5.0V 7.5V 10.0V -2.5V -5.0V -7.5V -10.0V
8-20
Varco
Appendix
3.3. Ground Isolation Verification. With all power removed from PCB assembly, measure the resistance between U20, pin 2 and U20 pin 32. This resistance must be greater than 20M Ohms. 3.4. Calibration Mode Select Calibration mode. Switch TDS mode as noted and verify the following values and the corresponding number of segments lit on bar graph displays: TDS 3 4L 4H 5 6 RPM 0-10V #1 10.0V 10.0V 10.0V 10.0V 10.0V DSP1 10 10 10 10 10 Arm Cur 0-10V #1 5.0V 5.0V 5.0V 5.0V 5.0V DSP2 5 5 5 5 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.
After successful completion of this procedure, PCB assembly is to be:
Serialized Dated Stamped indicating individual performing test Properly bagged and boxed
Technical Drawings
8-21
Appendix
Stump/Cyclops Test Procedure

Board Name:
STUMP/CYCLOPS Version II 96140 96142 TDCS
PURPOSE:
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
8
V.
FINAL ACCEPTANCE Remaining functions required to prepare PCB assembly for final acceptance
Technical Drawings
8-22
Varco
Appendix
I.
SUMMARY OF BOARD FUNCTIONS
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.
Basic features include:
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 following documents:
Document Description Users Guide: STUMP Users Guide: CYCLOPS STUMP/CYCLOPS Software Listing
Number 92908 92692 96729
Technical Drawings
8-23
Appendix
Inputs:
Signal Armature Voltage Armature Current Hook Load Mud Pressure Field Current Field Current Select Gear Ratio=High Rotary Table Mode Gear Ratio Unknown Serial Data Input (Programming Port) Serial Data Input (Display Port) RPM=Speed Board Type Analog Analog Analog Analog Analog Digital Digital Digital Digital Digital Digital Digital Qty 1 2 1 1 1 2 1 1 1 1 1 1 Voltage 0 to 2.5V 0 to 5V 4 to 20mA 4 to 20mA 4 to 12 to 20mA 0 or floating 0 or floating 0 or floating 0 or floating RS232 RS485 0 or floating Sensor Input Range 0 to 1000VDC 0 to 1500ADC 0 to F/S PSI 0 to 5000PSI -75 to 0 to +75ADC 30A, 40A, 57A, User 0=High Gear 0=Rotary Table Mode 0=Gear Ratio Unknown N/A N/A 0=Speed Board RPM
Outputs:
Signal Pipe RPM Pipe RPM Armature Current Armature Current Pipe Torque Pipe Torque Percent Yield Percent Yield Percent Yield Alarm Qty 2 3 2 3 1 2 1 1 1 Voltage 0 to 10V 4 to 20mA 0 to 10V 4 to 20mA 0 to 10V 4 to 20mA 0 to 10V 4 to 20mA Dry Contact Engineering Value 0 to 350 RPM 0 to 350 RPM 0 to 1500ADC 0 to 1500ADC 0 to 55,000 FT-LB 0 to 55,000 FT-LB 0 to 120 Percent 0 to 120 Percent OPEN=Alarm
Percent Yield Alarm Serial Data Output (Programming Port) Serial Data Output (Printer Port) Serial Data Output (Display Port) Indicators Installed on Board Assembly:
1 1 1 1
Dry Contact RS232 RS232 RS485
CLOSED=Alarm N/A N/A N/A
Function
Armature Voltage Armature Current RPM TDS Type/Gear Ratio Motor Type/Field Current Data Out A/D Conversion ON
Indicator
Bar Graph Bar graph Bar graph Seven-Segment Display Dot-Matrix Display Red LED Red LED
Technical Drawings
8-24
Varco
Appendix
II.
EQUIPMENT REQUIREMENTS The following is required to test this assembly: Equipment DVM4_ Digits, 0.1% accuracy Current Meter Variable DC Power Supply Variable DC Current Supply ASCII Terminal (RS232) Serial Printer (RS232) Display Panel (P/N 88808) 4_ Digits; 0.1% accuracy 0 to 5VDC (Qty 3) 4 to 20mA (Qty 3) 9600 Baud 4800 Baud N/A Range/Accuracy
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 Dot-Matrix Display A/D On Data Out Seven-Segment
Location J1 DS1 DS2 DSP1
Status Message: VARCO CYCLOPS SELF-TEST PASSED Followed by: TDS3 then GE S Flashing OFF 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 same connector. Set the terminal baud rate to 9600 and the printer to 4800. Apply power.
Technical Drawings
8-25
Appendix
7. Switch SW2F to the DOWN or CLOSE position and type CTRL-C at the terminal. A READY prompt should be 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, extra null 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 Board P1 (reference schematics 92972 and 96142 for pin number details). Place SW2F in the UP or OPEN position. 9. Apply power and verify the indicators display the same states as in Step 4 (with the exception of DS2 now flashing 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 drawing 96142 for location of all signal points.
1.
Analog Inputs 1.1. Armature Voltage Apply 2.000V to Armature Voltage Input. From the Display Panel, select SENSOR INPUTS as outlined in section 5.3 of the CYCLOPS Users Guide, 92962. Verify that the Input Voltage displayed is 2V. Reverse the input voltage and verify the display again reads 2V. 1.2. Armature Current #1 Apply 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 Pressure Apply 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 Load Apply 16.0mA to the Hook Load Input. From the Display Panel, select Hook Load and verify the input voltage displayed is 4V.
1.5. Spare Apply 16.0mA to the Spare Input. From the Display Panel, select Spare and verify the input voltage displayed is 4V.
Technical Drawings
8-26
Varco
Appendix
1.6 Field Current Apply 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 #2 Apply 4.000V to the Armature Current #2 Input. From the Display Panel, select Armature Current #2 and verify the Input Voltage displayed is 4V. Reverse the input voltage and verify the display again reads 4V. 1.8 RPM Assign RPM=Mag Pickup/Proximity Sensor Mode and verify RPM 0 to 10V #2 Output is 0V. Apply 5.00V to RPM 0 to 10V Output #2. (Although a voltage is being applied to the RPM Output connector, no conflict exists 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 RPM Mode 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 Select Assign 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:
Technical Drawings
8-27
Appendix
ValueOutput Normal RPM=Prox Sensors
RPM 0 to 10V #1 RPM 0 to 10V #2 RPM 4to 20mA #1 RPM 4 to 20mA #2 RPM 4 to 20mA #3 Armature Current 0 to 10V #1 Armature Current 0 to 10V #2 Armature Current 4 to 20mA #1 Armature Current 4 to 20mA #2 Armature Current 4 to 20mA #3 Pipe Torque 0 to 10V Pipe Torque 4 to 20mA #1 Pipe Torque 4 to 20mA #2 Percent Yield 0 to 10V Percent Yield 4 to 20mA
5V 5V 12mA 12mA 12mA 5V 5V 12mA 12mA 12mA 10V 20mA 20mA 10V 20mA
0V 0V 0V 0V 0V 0V 0V 0V 0V 0V 10V 20mA 20mA 10V 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 in Step 2.5, above marked RPM=Prox Sensors.
Return to Operate Mode
Technical Drawings
8-28
Varco
Appendix
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 Armature Voltage Armature Current #1 Mud Pressure Hook Load Value 1.000V 1.000V 12.0mA 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: Pipe Diameter/Tool Joint Connector Type: Filter Constant: Units for Tension: G 4.5/NC50(IF) 1 Pounds
Change Hook Load Input to 8.0mA. Verify display indicates Percent Yield: 17.0 (1%) and the Percent Yield 0 to 10V Output is 1.42V. Also verify the weight/foot (LB/FT) is shown as 25.10.
Technical Drawings
8-29
Appendix
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 Input and 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 five segments lit. 4.3. RPM Apply 2.500V to Armature Voltage Input and 1.000V to Armature Current #1 Input. Verify RPM bar graph display 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 100% 10% 100% Open=Alarm <1 >20M <1 Close=Alarm >20M <1 >20M
5.2. Seven-Segment Display From the LCD Panel, Select TDS Types 3, 4, 5, and 6. Verify Seven-Segment display follows TDS Type selected. Return to TDS Type 4. 5.3. Dot-Matrix Display From the LCD Panel, select each motor type and verify Dot-Matrix display follows motor type selected. Leave boards set for 40A Shunt motor. Enter Calibration Mode and verify display alternates between CAL and MODE. Return to Operate Mode. 5.4. Battery Backup Operation Remove power and wait 10 seconds. Apply power and verify seven-segment display shows TDS Type 4 and the dot-matrix display shows 40A shunt motor. The LCD should display the pipe parameters entered in Step 3.4.
From The LCD Panel, select TDS Type 3 and 57A Shunt motor.
Technical Drawings
8-30
Varco
Appendix
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.
After successful completion of this procedure, PCB assembly is to be:
Serialized Dated Stamped indicating individual performing test Properly bagged and boxed
Technical Drawings
8-31
Appendix
Users Guide Stump

SPEED TORQUE UNIT MICRO-PROCESSOR (STUMP) 1.0 GENERAL DESCRIPTION 3
2.0
FUNCTIONAL DESCRIPTION
3.0
TECHNICAL DESCRIPTION 3.1 3.2 3.2.1 3.2.2 Sensor Inputs STUMP Calculations RPM Pipe Torque
3 3 3 3 4
4.0
INITIAL CALIBRATION AND SET UP 4.1 4.2 Meter Calibration TDS/Motor Type Selection
4 4 5
5.0
OPERATION
6.0
HARDWARE FUNCTIONS 6.1 6.2 6.3 6.4 Power Up Sequence Test Modes DIP Switch Summary Digital Inputs
6 6 6 7 8
APPENDIX A Field EPROM/EEPROM Installation 9
APPENDIX B EPROM/EEPROM Software Version History 10
Technical Drawings
8-32
Varco
Appendix
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 to the 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 Armature Voltage Armature Current 3.2 STUMP Calculations 3.2.1 RPM The STUMP processor digitizes the two analog signals and calculates RPM using the following equations: RPM = ((V - I* K) + B) / (I*M + B) / (G * R) RPM = (V * M + B) / (G * R) Where: V = (for series motors) (for shunt motors) Input Signal Range -1000 VDC to + 1000 VDC -1500 ADC to + 1500 ADC Sensor Output -2.5V to + 2.5V -5V to + 5V
Armature Voltage I= Armature Current K= Constant for particular motor type M= Motor curve slope for given current range B= Motor curve intercept for given current range G= TDS Gear Ratio R= TDS-4 High/Low gear offset
Technical Drawings
8-33
Appendix
The values for M and B are adjusted based on Armature Current and are calculated for each of 15 equal divisions from 0 to 1500 ADC. 3.2.2 Pipe Torque Pipe torque is calculated as follows: T =(I * M + B) / (G * R) Where: I = M= B= G= R= Armature Current Slope for given motor type and Armature current range Intercept for given motor type TDS Type Gear Ratio 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 Armature Current 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 a high value RPM signal to the control system that can be interpreted as an overspeed condition, thus shutting down the TDS.
Set panel meters as follows using the adjustment knob on the rear of each meter: Meter RPM Current Torque Value 175 RPM 750 ADC 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 similarly calibrated. Make certain that the front panel switch is returned to the OPERATE position prior to using the TDS.
Technical Drawings
8-34
Varco
Appendix
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 TDS Type in use: Function IDS TDS-3 TDS-4 TDS-5 TDS-6 Position 1 3 4 5 6
Motor Type Selection - Set MOTOR TYPE switch (SW2) to select the Motor Type in use: Function EMD Series GE Series 15A Shunt 30A Shunt 40A Shunt 50.5A Shunt 57A Shunt 60A Shunt 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-up parameters. If these values remain stored, the front panel do-matrix display will scroll the following message: VARCO CYCLOPS SELF-TEST PASSED... If the battery backed-up memory is lost, the STUMP will still function properly if the configuration module is 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 type and the actual field current. Position 0 1 2 3 4 5 6 7
Technical Drawings
8-35
Appendix
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 voltage at the input channel selected by SW2-1 to SW2-3 (all open for channel 0 through all closed for channel 7). This voltage will simultaneously appear at all analog outputs. Engineering Unit Display Mode - With SW2-4 OPEN and SW2-3 CLOSED, the onboard display will indicate the engineering unit value of an analog output as selected by SW2-1 and SW2-2 (both open for channel 0 through both closed for channel 3). This test mode does not affect the operation of the STUMP and 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-matrix display (0 = Open; C = Closed; X = Either Open or Closed): Switch (SW2) 1234567 OOOCOOO OOCCOOO OCOCOOO OCCCOOO COOCOOO COCCOOO CCOCOOO CCCCOOO Function Voltage Display Mode Armature Voltage Sensor Armature Current Sensor Mud Pressure Sensor Hook Load Sensor Spare Input Field Current Armature Current (Reverse) Armature Voltage (Reverse) Eng. Unit Display Mode OOCOOOO OCCOOOO COCOOOO CCCOOOO Calculated RPM Measured Current Calculated Yield Calculated Torque RPM Armature Current Percent Yield Torque 0 to 350(RPM) 0 to 1500(AMPS) 0 to 9999(Percent) (**) 0 to 55.0(ft-lbs x 1000) Ch 0 Volts Ch 1 Volts Ch 2 Volts Ch 3 Volts Ch 4 Volts Ch 5 Volts Ch 6 Volts Ch 7 Volts 0.00 to 2.50V 0.00 to 5.00V 0.00 to 5.00V(**) 0.00 to 5.00V(**) 0.00 to 5.00V 0.00 to 5.00V 0.00 to -5.00V 0.00 to -2.50V Display Display Range
Other Functions XXXXXXC XXXXXCO X X X X C O O* OOOOOOO Reset processor Disable Watchdog Timer Use 32K of RAM Normal Operation Blank Motor Type Motor Type Motor Type
*For factory test only - erases the contents of battery backed-up RAM **Not used in STUMP Mode
Technical Drawings
8-36
Varco
Appendix
6.4
Digital Inputs Three digital inputs are provided on the STUMP backplane connector. These are used to provide dynamic changes to the operating program and are enabled by grouping the following pins with a contact closure in the indicated terminal: Terminal CR1-15 CR1-16 CR1-17 CR1-18 Function Select TDS field current=30.0A Ground Select TDS field current=40.0A Ground Both grounded: Field current=57.0A Both floating: Use operator selected field current CR1-13 CR1-14 Select high range gear ratio for RPM/Torque calculations (TDS4 only) Ground
Technical Drawings
8-37
Appendix
APPENDIX A: Field EPROM Installation; This Appendix describes the installation of new EPROM Programs. Note that EPROMs must be replaced with the same version or higher and both EPROMs must be of the same version - they are replaced as a set, never individually. To change the program, perform the following: 1. 2. Remove EPROMs from 88230 board locations U27 and U28. Install new EPROMs observing proper orientation (notch on plastic EPROM carrier corresponds to the white marking on the board). Location U27 U28 3. EPROM Part No. 89454-1 89454-2
Verify operation of new program and discard removed EPROMs.
Field EEPROM Installation (Stump Board P/N 96140) 1. 2. Remove EEPROM from 96140 board location U20. Install new EEPROM (p/N 96729) observing proper orientation (notch on plastic EEPROM carrier corresponds to the white marking on the board). Verify operation of new program.
3.
APPENDIX B: EPROM Software Version History Version V1.0 V1.1 V2.0 V2.1 V2.2 V2.3 V2.4 Effective Date 26 Feb 89 24 Apr 89 26 Jun 89 09 Feb 90 16 Apr 90 18 Jun 90 01 Mar 90 Enhancement Initial Version Added field current input Added 40A shunt motor and configuration board Added % yield alarm output Added Hook Load auto calibrate/removed configuration header Moved Torque output to interrupt routine No field loss check if Armature Current <29A; RPM Calibrate mode is now 175 RPM (5VDC)
EEPROM Software Version History
Rev A
Effective Date 25 Nov 91 29 May 92
B C D
09 Jun 92 01 Mar 93 20 Jul 93
Enhancement Initial Version Added IDS to TDS Type List Added 3 1/2" Grade E to Pipe Table Revision letter shown on front display at startup Added 6 5/8" Grade E and 5" Grade C120 to Pipe Table Added 70A Shunt Setting Technical Drawings Added TDS6 Torque Output
8-38
Varco
Appendix
Adjusting the torque wrench

Use the following procedure to adjust the pipehandler torque wrench: and tested in the ! e The pipehandleristorque wrench is properly adjustedprocedure after factory before it shipped. Perform the adjustment performing maintenance on the torque wrench or if the torque wrench does not function correctly. 1. Connect a pup joint or joint of drill pipe to the saver sub and makeup hand tight. Be sure to use the correct thread compound when making up.
z i
When adjusting torque wrench manifold needle valves, loosen the locknut around the valve stem and use a 5/32 in. hex wrench to adjust the valve. After obtaining desired setting tighten locknut around valve stem.
Technical Drawings
8-39
Appendix
2. With the HPU off, screw the RECYCLE, CLAMP, and TORQUE sequence valves on the torque wrench manifold fully in (Figure 4-18). 3. Fully back out the Pressure Reducing Valve (PRV), then screw in one turn. 4. Turn the LIFT/LOWER flow control valve fully in, and then back it out three turns. 5. Turn on the HPU. 6. If the torque cylinders are in their full clockwise position, set the Make/Break valve to MAKE. If they are in their full counterclockwise position, set Make/Break valve to BREAK. Note that torque cylinders should not move if the recycle sequence valve is fully in. 7. Slowly back out the RECYCLE sequence valve until torque cylinders just start to move, then screw out an additional full turn.
Make/Break Valve
Recycle Sequence Valve
Clamp Sequence Valve
Torque Sequence Valve
Torque Wrench Manifold
BREAK
Hydraulic Pressure Return RECYCLE Hydraulic Pressure Inlet Lift/Lower Flow Control Valve CLAMP TORQUE
MAKE
PRV
40
50
60
70
30
1000
1500
80
LIFT LOWER
20
500
2000
90
10
2500
10 0
PSI Ft.Lbs.
x1000
Torque Gauge 0 - 2500 PSI
Figure 4-18. Torque wrench control manifold
Technical Drawings
8-40
Varco
Appendix
8. Move the Make/Break valve to BREAK. Set the PRV to 750 psi. 9. Switch the lever between MAKE and BREAK to adjust the RECYCLE sequence valve until full rotation in each direction takes six to eight seconds. Tighten the locknut around the RECYCLE sequence valve adjustment 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 remain retracted. 12. Slowly back out the CLAMP sequence valve until the clamp jaws just begin to clamp onto the tool joint. Screw out an additional half turn. Lock the CLAMP sequence valve adjustment screw in position by tightening the locknut. 13. Back out the TORQUE sequence valve until the torque cylinders just begin to stroke, then back out an additional half turn. Tighten the locknut around the TORQUE sequence valve adjustment screw. 14. Release the torque wrench operating button on the VDC. The torque wrench should start to unclamp and drop, then the torque cylinders should recycle. 15. If the torque cylinders recycle before the clamp cylinders retract, screw in the RECYCLE sequence valve until the torque cylinders do not move before clamp cylinders have fully retracted. Tighten the RECYCLE sequence valve adjustment screw locknut. 16. Cycle the torque wrench as many times as required to makeup the connection. 17. Set the Make/Break valve to BREAK. 18. Verify that the torque wrench correctly breaks out the drill pipe from the saver sub, without breaking out the saver sub or lower IBOP. 19. The torque wrench is ready for operation.
Technical Drawings
8-41
Appendix
Adjusting the counterbalance system

Leave the HPU on during the entire adjustment procedure, and disconnect the TDS from the drill string near the bottom of the rails, but well off the stops. 1. Remove the caps and loosen the lock nuts on the needle valve and PRV located on the counterbalance manifold (Figure 4-19). It is not necessary to remove the front guard for access to the manifold. A small amount of oil will leak around the adjusting stems after removing 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. Tighten the 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 cylinder rods begin extending. When the integrated swivel bail contacts the hook, note the pressure on the gauge. Allow the pressure to decrease an additional 25 psi and tighten the locknut. Replace the caps on the valve adjustment stem.
Technical Drawings
8-42
Varco
Appendix
Needle Valve (on opposite side)
Upper Motor Frame Crossmember
Pressure Reducing Valve
Pressure Gauge
Figure 4-19. Counterbalance manifold
Technical Drawings
8-43
Appendix
Adjusting the motor alignment cylinder system

Once the alignment cylinder is installed, use the following procedure to properly adjust the motor alignment before operating TDS systems that have a separate alignment cylinder accumulator and valve manifold. 1. With the HPU turned off, bleed down the alignment cylinder accumulator by opening the needle valve located at the alignment cylinder 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 approximately two minutes. 4. Close the needle valve. 5. Open the two flow control valves located at the alignment cylinder supply return lines 1-1/2 turns off their seats.
Technical Drawings
8-44
Varco
Appendix
Alignment Cylinder Lug (ref) Pressure Reducing Valve
Needle Valve
Motor Frame (ref)
Alignment Cylinder Manifold Accumulator
Bracket Gas Valve
Figure 4-20. Typical motor alignment cylinder valve manifold
Technical Drawings
8-45
Appendix
Prefill Valve Assembly
Directional Control Valve (Operation Switch) Pressure Reducing Valve (PRV)
Needle Valve
Motor Frame (ref)
Alignment Cylinder Valve Manifold
Bracket Gas Valve Accumulator
Figure 4-21. Motor alignment cylinder valve manifold
Technical Drawings
8-46
Varco
Appendix
Motor Alignment Cylinder
Shipping Brace
Motor Frame Dolly (Ref)
Figure 4-22. Motor alignment cylinder
Technical Drawings
8-47
Appendix
The pressure setting is adjusted by screwing the PRV in or out with a hex wrench (Figure 4-19). Screwing in the valve increases pressure and moves the saver sub toward the rails. Backing out the PRV reduces pressure and moves the saver sub away from the rails (see additional notes 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 until the saver sub begins to pivot away from the rails. Record this pressure. b. Slowly increase the pressure until the saver sub no longer moves closer to the rails as pressure increases. At this time, the cylinder should be in a dead band area. c. Slowly increase the pressure until the saver sub begins to move toward the rails again. Record the pressure reading when this occurs. d. To determine the correct pressure setting, add the average pressure readings from steps a and c above and divide by two. The resulting pressure 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 pin clears the shoulder of the box. If adjustment is necessary, use the following procedure: a. Measure how far and in what direction (toward or away from the rails) the pin must move to line up with drill pipe box. b. Turn off the HPU and bleed down the alignment cylinder accumulator. This allows the motor alignment cylinder to relax and the motor to rotate on its trunnions, until the swivel contacts the motor frame.
c. Loosen the lock tab and jam nut on the cylinder clevis.
Technical Drawings
8-48
Varco
Appendix
d. Use a wrench on the cylinder rod flats to screw the rod into or out of the clevis, in the same direction the saver sub pin is to be moved. A 1/4 in. of pin movement results from a 3/4 turn of the rod. The alignment cylinder rod extension should be 2 3/8 1/8 in. 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 11/2 turns off their seats. Should heavy drill pipe vibration be encountered, first attempt to control it with non-rotating stabilizers in the casing close to the surface. If motor movement becomes excessive due to continued vibration (more than 1/2 in. of cylinder stroke), the flow control valves may be closed to 3/4 turn off their seats.
g. Tighten the lock nuts and replace the caps on all valve stems.
z i
If the alignment cylinder is removed for service, install the alignment cylinder replacement brace to support the motor housing assembly while continuing to operate the TDS. After reinstalling the alignment cylinder, use the three bleed holes (located along top of cylinder barrel) to remove air trapped in the cylinder. Rail spacing and setback from the centerline of the well must be held within recommended tolerances in order to maintain vertical alignment of the TDS.
Technical Drawings
8-49
Appendix
Adjusting the safety valve actuator

Proper safety valve actuator installation and adjustment is essential to assure proper action of the mechanism and to minimize mechanical component wear. The actuator shell installs over the upper IBOP safety valve. Changing the position of the two threaded eye bolts that suspend the safety valve actuator air cylinders on the PH-85, PH-60d and single crank PH-60 (Figure 13) adjusts the safety valve actuator. Adjust the PH85, PH-60d and single crank PH-60 actuator shell as follows: 1. After removing the crank assemblies, make sure the actuator shell easily moves up and down over the upper IBOP.
z i
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 crank assemblies and check for signs of binding. Make sure the shell travels 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 drillers console to the open the safety valve. The cylinders should retract and the actuator ring should be down. 6. For the PH-85, PH-60d and single crank PH-60 only, measure the distance between the cylinder rod end and the cylinder gland on each 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.
Technical Drawings
8-50
Varco
Appendix
Drive Stem Link Adapter
Cylinder Adjustment Bolts (4) Eye Bolts (2) Upper IBOP Valve Actuator Air Cylinders (2)
Landing Collar
Upper IBOP Valve Actuator Shell Crank Assembly (shown with valve OPEN, note Crank Assembly position.)
CLOSE OPEN
*1 in. Actuator Arm Upper IBOP
Cylinder Gland Cylinder in OPEN Position Rod End
Torque Tube Lower IBOP
*IMPORTANT
Saver Sub
8 Figure 13. Adjusting the safety valve actuator system for the PH-85, PH-60d and single crank PH-60
Technical Drawings
8-51
Appendix
TDS-4 Shunt Motor 22.5A Field

Current 200 250 300 350 400 450 500 550 600 650 700 750 800 850 900 950 1000 1050 1100 1150 1200 1250 1300 1350 1400 1450 1500 1550 Graph Mtr Torque 477 750 928 1200 1400 1554 1760 1948 2120 2286 2416 2564 2695 2803 2915 3011 3085 3158 3227 3270 3319 3371 3406 3427 3450 3459 3459 3471 Graph Hi Gear 3678 5784 7156 9254 10796 11984 13572 15022 16348 17628 18631 19772 20782 21615 22479 23219 23790 24353 24885 25217 25594 25995 26265 26427 26605 26674 26674 26767 Graph Lo Gear 2350 3696 4573 5913 6899 7657 8673 9599 10447 11264 11905 12634 13280 13812 14364 14837 15202 15561 15901 16113 16355 16611 16783 16887 17000 17045 17045 17104
Technical Drawings
8-52
Varco
Appendix
High Gear Low Gear Efficiency
5.080 7.950 0.975
Slope22.5A_ST Intercept22.5A_ST Slope22.5A_ST Intercept22.5A_ST Slope22.5A_ST Intercept22.5A_ST
4.235 -329.536 2.650 521.864 0.753 2388.273
0 to 500A 0 to 500A 501 to 1000A 501 to 1000A 1000 TO MAX 1000 TO MAX
NOTE: When in 22.5A Field the Armature current should be limited to 769A.
Technical Drawings
8-53
Appendix
TDS-4 Motor Torque vs Current @ 22.5A Field

4000
3500
3000
22.5A Field Current Limit = 769A
2500
Motor Torque
2000
1500
1000
500
8
0
Current
Technical Drawings
8-54
Varco
TDS-4 Drill Torque vs. Current @ 22.5A Field

30000
Appendix
25000
22.5A Field Current Limit = 769A
20000
Drill Torque
Graph Hi Gear
15000
10000
Technical Drawings
5000
Current
8-55
Appendix
8-56
Varco
Appendix
Directional valves
Directional control valve, solenoid operated, 2-position, 4-way (spring offset)
The two position, solenoid operated, four-way directional control valve directs hydraulic fluid to one of two possible flow paths. The presence or absence of electrical current in the single solenoid coil determines the flow path selection. This valve is a low flow valve and is used to supply hydraulic fluid to small actuators, or it may be used as a pilot operator for larger valves.
Theory of operation
The valve has a spool that slides into a machined bore in the valve housing. The housing has a number of ports to which the pressure, the tank, and two working lines for the actuator are connected. Internally, the ports are connected to cast or machined passages in the valve housing which terminate at the machined bore where the spool is located. The axial movement of the spool in the bore determines which ports are connected. The spool is held in one of the valves two positions by a spring. In this position, the P (pressure) port is connected to the A working port and the B working port is connected to the T (tank) port. A solenoid is located at the end of the spool opposite the spring. If the coil is energized, the solenoid armature moves the spool through a push pin. When the solenoid coil is energized, enough force is generated to overcome 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 is connected to the T port. When the solenoid coil is deenergized, the spring returns the spool to its original position. A manual override button is located on the end of the solenoid housing. Pressing this button performs the same function as the solenoid coil by manually shifting the spool against the spring. This valve is a manifold-mounted valve in that the ports are all located on the valve mounting surface and are equipped with Oring face seals. This valve is identified on hydraulic schematic drawings using the following symbol:
A a P T
Technical Drawings
8-57
Appendix
Diagnostic procedure
A problem with this component is usually related to improper shifting of the spool. This could mean that the spool doesnt shift when the solenoid is energized, that the spring doesnt return or hold the spool offset when the solenoid is deenergized, or that the spool does not shift fully in one or both directions. The most likely cause of a stuck spool is particulate contamination of the hydraulic fluid. The other type of potential failure is an O-ring failure at the mounting surface, but the external leakage of hydraulic fluid makes this easy to detect. This procedure assumes that there is no electrical problem (i.e., the coil is drawing the proper amount of current when energized). Perform the following steps to isolate a faulty valve: 1. Verify that supply pressure (usually 2,500 psi) is available at the pressure port of the valve by connecting a test gauge to the appropriate test point. If the required pressure is not present, the valve is probably not the problem. Check for problems upstream of the supply port. 2. The valve can be actuated either electrically or by using the manual override button on the solenoid housing. If the manual override button is used, the coil should be in the deenergized state. If no change of state is present, the spool is most likely stuck in one position. See step d, below, to correct the problem. 3. Repairing a stuck spool: Try to free the spool by pressing on the manual override button or with a light tapping on the body of the valve. It may help to turn off the HPU (or press the kill switch on the operators console) while doing this. If this doesnt free the spool, remove the valve to expose the spool through its ports. Clean the area around the valve before removing it to prevent contamination of the exposed sealing surfaces and passageways.
Attempt to free the spool using a screwdriver in between the glands of 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 override button is pressed, lubricate the inside of the valve with a light mineral-based oil and remount the valve. If the spool cannot be freed or the problem reoccurs, replace the valve.
Varco
Technical Drawings
8-58
Appendix
Directional control valve, solenoid operated, 3-position, 4-way (spring centered), float center
The three-position, solenoid operated, four-way, directional control valve directs hydraulic fluid to one of three possible flow paths. The presence or absence of electrical current in the two solenoid coils determines the flow path selection. This valve is a low flow valve and is used to supply hydraulic fluid to small actuators, or it may be used as pilot operator for larger valves.
Theory of operation
The valve has a spool that slides into a machined bore in the valve housing. The housing has a number of ports to which the pressure, the tank, and two working lines for the actuator are connected. Internally, the ports are connected to cast or machined passages in the valve housing which terminate at the machined bore where the spool is located. The axial movement of the spool in the bore determines which ports are connected. The spool is held in the valves center position by springs. In this position, the P port is blocked and both the A working port and the B working port are connected to the T port. Solenoids are located at either end of the spool. If one of the coils is energized, the solenoid armature moves the spool through a push pin. When the A solenoid coil is energized, enough force is generated to overcome 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 is connected to the T port. When the A solenoid coil is deenergized, the spring returns the spool to its center position. When the B solenoid coil is energized, enough force is generated to overcome 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 is connected to the T port. When the B solenoid coil is deenergized, the spring 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 by manually shifting the spool against the spring.
Technical Drawings
8-59
Appendix
This valve is a manifold-mounted valve in that the ports are all located on the valve mounting surface and are equipped with Oring face seals. This valve is identified on hydraulic schematic drawings using the following symbol:
A a P T B b
A problem with this component is usually related to improper shifting of the spool. This could mean that the spool doesnt shift when one of the solenoids is energized, that the spring doesnt return or hold the spool centered when the solenoids are deenergized, or that the spool does not shift fully in one or both directions. The most likely cause of a stuck spool is particulate contamination of the hydraulic fluid. The other type of potential failure is an O-ring failure at the mounting surface, but the external leakage of hydraulic fluid makes this easy to detect. This procedure assumes that there is no electrical problem (i.e., the coils are drawing the proper amount of current when energized). Perform the following steps to isolate a faulty valve: 1. Verify that supply pressure (usually 2,500 psi) is available at the pressure port of the valve by connecting a test gauge to the appropriate test point. If the required pressure is not present, the valve is probably not the problemcheck for problems upstream of the supply port. 2. Using a test gauge on the test points for the A and B working ports, verify that a change in state occurs on the working ports when the valve is cycled. You can actuate the valve either electrically or use the manual override buttons on the solenoid housings. If you use the manual override button, both coils should be in the deenergized state. With a normally operating valve, the pressure at a working port should alternate between a relatively low value and a much higher value when the valve is cycled between either A or B and center. If no change of state is present, the spool is most likely stuck in one position. See step 4 below to correct the problem.
Technical Drawings
8-60
Varco
Appendix
3. Using a test gauge on the test points for the A and B working ports, verify that the pressure at each working port equalizes with the supply pressure measured in step 1 when one of the coils is energized. It may be necessary to wait for an actuator to move to its end of stroke before the pressure can stabilize. If the pressure does not stabilize, the valve is probably not the problem and there may be an internal leak somewhere downstream of the valve. 4. Repairing a stuck spool: Try to free the spool by pressing on the manual override button or with a light tapping on the body of the valve. It may help to turn off the HPU (or press the kill switch on the operators console) while doing this. If this doesnt free the spool, remove the valve to expose the spool through its ports. Clean the area around the valve before removing it to prevent contamination of the exposed sealing surfaces and passageways. Attempt to free the spool using a screwdriver in between the lands of 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 override button is pressed, lubricate the inside of the valve with a light mineral-based oil and remount the valve. If the spool cannot be freed or the problem reoccurs, replace the valve.
Technical Drawings
8-61
Appendix
Directional control valve, pilot operated, 3-position, 4-way (spring centered), solenoid controlled, float center
The three-position, pilot operated, solenoid controlled, four-way directional control valve directs hydraulic fluid between one of three flow paths. The presence or absence of sufficient hydraulic pressure acting on the two pilot pistons determines the selection of flow path. This valve is normally used to handle medium to large flows and is controlled by a small, solenoid operated, fourway pilot valve.
Theory of operation
This valve is composed of a pilot operated main valve with a solenoid operated pilot valve directly coupled, hydraulically and mechanically, to the main valve. The pilot valve takes its pressure supply and directs its return flow through the main valve. In a like manner, the two working ports (A and B) of the pilot valve are connected to the pilot pistons of the main valve through internal passages in the main valve. The main valve has provisions to allow the supply pressure for the pilot valve to come from an external source (the x port). An internal plug is used to isolate the pressure supply of the main valve in this case. A similar port (the y port) exists for external pilot drain (return). The theory of operation of the solenoid operated pilot valve is described in Diagnostic Procedure D-1. The theory of operation of the pilot operated main valve is described in Diagnostic Procedure D-2. The valve is shown below in a typical circuit.
Technical Drawings
8-62
Varco
Appendix
A a x P
B b T y
3 Position, Pilot-Operated Directional Control Valve, Solenoid-Controlled, 4 Way (Spring Centered), Float Center, Typical Circuit
When the two valves are directly coupled as shown above, the simplified symbol shown below is usually on schematic drawings.
A x P
B y T
Pilot-Operated Valve, 4 Way (Spring Centered), Float Center
Technical Drawings
8-63
Appendix
Load holding valves

Counterbalance valve, pilot assisted
The counterbalance valve with pilot assist is designed for overrunning load control and hydraulic load locking. In use, it restricts flow out of a hydraulic cylinder or motor to prevent cavitation, which would occur if the load caused the actuator to move faster than the supply coming from the pump. The counterbalance valve locks the loaded actuator in place if the hydraulic line to the actuator breaks and it provides relief protection if the actuator is driven by an external force.
Theory of operation
Circuits using counterbalance valves use a directional control valve that connects the working ports A and B to the tank in the center position. This type of directional valve allows the best control and positioning of the load and provides an unrestricted path to the tank for any oil displaced when the counterbalance valves act as reliefs. As illustrated in the counterbalance valve symbol below, counterbalance valves respond to pressure from two different sources. These are the pressure induced by the load acting on the cylinder or motor and the pressure at the pilot assist port. The forces generated by pressure at these two ports open the valve when the sum of the two forces is high enough to overcome the major bias spring (valve pressure setting). The reverse free flow check valve permits a free flow of fluid toward the actuator in the reverse direction of operation. The counterbalance valve is shown below schematically and in a typical circuit.
Technical Drawings
8-64
Varco
Appendix
Major Bias Spring Adjustment
Cylinder Port Free-flow Check Valve
Pilot Assist Port
Valve Port Counterbalance Valve
Counterbalance Valve
Weight
Counterbalance Valve - Typical Circuit
Technical Drawings
8-65
Appendix
This valve can fail in either the open or closed position. If it fails while open, the load causes the actuator to drift over time. If the actuator is observed to be drifting, troubleshooting consists of verifying that the valve has indeed failed in the open position and that it is not open due to misadjustment or being piloted open. If the valve fails while closed, movement of the actuator is impaired in the protected direction (i.e., opposite the free flow direction). Blocked flow across the check valve in the free flow direction is unlikely because of the large forces available to move the valve stem in this direction. Perform the following steps to isolate a faulty valve: 1. If the actuator holds its position when the direction controlling valve is in neutral and the actuator is not at the end of its travel, proceed to step 4. 2. Measure the pressure at the pilot assist port. With the actuators control valve in the center (neutral) position, the pilot pressure should be relatively low, usually less than 100 psi. Higher pressures may allow the valve to open, so check for a failure in the part of the circuit related to the pilot assist port. 3. If the pilot pressure measured in step 2 is normal (less than 100 psi), try increasing the valve pressure setting by turning the adjusting screw counterclockwise. If the load continues to drift, 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 cause pressure to be applied to the pilot assist port. If the actuator does not move, measure the pressure at the pilot assist port while the control valve is actuated. With no load induced pressure acting on the valve, 800 psi at the pilot assist port should open the valve and allow the actuator to move. Higher load induced pressures reduces the required pilot pressure by approximately 30 psi for every 100 psi acting directly on the valves cylinder port. If the required amount of pilot pressure is present and the actuator does not move, reduce the pressure setting by turning the adjusting screw clockwise. If this does not correct the problem, replace the valve.
Technical Drawings
8-66
Varco
Appendix
Relief valve, pilot operated
The pilot operated relief valve is used to smoothly and consistently regulate maximum system pressure in a hydraulic system or subsystem over widely varying flow conditions.
Theory of operation
A pilot operated relief valve consists of two sectionsthe main valve and a pilot section. The main valve has the inlet and outlet ports, a spool with an orifice in the center, and a spool bias spring. The pilot section consists of a small capacity, direct acting relief valve with a screw adjustment. The pilot supply orifice in the piston end of the main spool connects the inlet of the valve to the bias spring cavity. The areas of the piston at the inlet and in the spring cavity are equal so the pressure/area forces on the main spool are in balance. If fluid entering through the pilot supply orifice cannot escape, the piston is in hydraulic balance and the bias spring holds the spool in the closed position, blocking the passage from inlet to return. An adjustable pilot spring holds the small capacity, direct acting relief valve in position. This pilot spring establishes the pressure level at which the inlet pilot flow is directed to a lower pressure level (return to tank). When pressure in the bias spring cavity is high enough to open the small relief, fluid flows from the cavity to return. This flow creates a pressure differential across the orifice. When this pressure differential is high enough to overcome the force of the bias spring, the piston opens and creates a large flow path from the inlet to return to tank. The relief valve schematic is shown below.
Inlet
Bias Spring (Adjustment) Outlet (Tank) Pilot-Operated Relief Valve
Technical Drawings
8-67
Appendix
A problem with this component can be that it relieves at too low a pressure 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 is expected, measure the differential pressure across the valve (the difference in pressure between the valves inlet and outlet ports) and compare it to the required setting. Increase the valve setting as required. Turning the adjustment screw clockwise increases the setting of the valve. If the valve stays open regardless of the setting and/or differential pressure across the valve, it is probably stuck open and should be replaced. 2. If the valve opens at too high a pressure or doesnt open at all, measure the differential pressure across the valve (the difference in pressure between the valves inlet and outlet ports) and compare it to the required setting. Decrease the valve setting as required. Turning the adjustment screw counterclockwise decreases the setting of the valve. If reducing the valve set point does not allow the valve to open, it may be stuck and should be replaced.
Technical Drawings
8-68
Varco
Appendix
Check valve, pilot operated
The pilot operated check valve positively locks a pressurized load, but releases the load upon application of a pressure signal at the pilot port. This valve is normally used to lock an actuator in position when the directional control valve is centered (neutral). It is used in applications where overrunning load control and/or a relief function is not needed or is provided by other means.
Theory of operation
A pilot operated check valve consists of a valve body with inlet and outlet ports and a poppet held against a seat by a spring. Directly opposite the check valve poppet are a plunger and a plunger piston that are biased by a light spring. Pilot pressure is sensed at the plunger 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 outlet port to the inlet port forces the poppet to its seat, blocking flow through the valve. When enough pilot pressure is sensed at the plunger piston, the plunger moves and unseats the check valve allowing fluid to pass. The ratio of the load pressure to the pilot pressure required to release the load is called the pilot ratio. The schematic below shows a pilot operated check valve in a typical circuit.
Cylinder Port
Pilot Port Valve Port Pilot-Operated Check Valve
Technical Drawings
8-69
Appendix
Pilot-Operated Check Valve
Weight
Pilot-Operated Check Valve, Typical Circuit
This valve is most likely to fail in the open position. That is, the valve will not positively lock the pressurized load. If the valve fails closed, in the free flow direction, severe contamination or damage to the internal sliding surfaces probably exists. Perform the 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 test gauges. If the upstream pressure is significantly higher than the downstream pressure, the valve is probably stuck closed and should be replaced. 2. If the valve does not lock the pressurized load with the directional valve centered, measure the pressure at the pilot port. This pressure should be relatively low (usually less than 100 psi). Higher pressures may allow the valve to open, so check for a problem with the part of the circuit connected to the pilot port.
3. If the pressurized load cannot be released, check the pressures at both the pilot port and the outlet port (the port connected to the actuator). If the pilot pressure is greater than the actuator pressure divided by the pilot ratio (usually 3:1), the valve should open. If it does not, replace the valve.
Technical Drawings
8-70
Varco
Appendix
Pressure control valves

Pressure reducing valve, pilot operated
The pilot operated pressure reducing valve is used to regulate maximum system pressure in a hydraulic system or subsystem.
Theory of operation
A pilot operated pressure reducing valve consists of two sectionsthe main valve and a pilot section. The main valve has the inlet and outlet ports, a spool with an orifice in the center, and a 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 connects the inlet of the valve to the bias spring cavity. The areas of the piston at the inlet and in the spring cavity are equal so the pressure/area forces on the main spool are in balance. If fluid entering through the pilot supply orifice cannot escape, the piston is in hydraulic balance and the bias spring holds the spool in the open position, allowing full flow from inlet to return. An adjustable pilot spring holds he small capacity, direct acting relief valve in position. This pilot spring establishes the pressure level at which the inlet pilot flow is directed to a lower pressure level (return to tank). When pressure in the bias spring cavity is high enough to open the small relief, fluid flows from the cavity to return. This flow creates a pressure differential across the orifice. When this pressure differential is high enough to overcome the force of the bias spring, the piston begins to close creating a restriction in the flow path. This restriction limits the flow from the inlet to the outlet to a value that maintains the selected reduced pressure in the outlet portion of the circuit. Any pressure at the pilot drain port is additive to the pressure setting of the valve. This characteristic can be used to implement remote control of the valve. The pressure reducing valve is shown below schematically.
Inlet Bias Spring (Adjustment) Pilot Drain Outlet Pilot-Operated Pressure Reducing Valve
Technical Drawings
8-71
Appendix
A problem with this component can be that it fails to close down, not providing the required pressure reduction. Perform the following steps to isolate a faulty component: 1. If the outlet pressure is too high, try reducing the setting of the valve by turning the adjusting screw counterclockwise while observing the pressure at the outlet port. If this does not reduce the pressure to the desired level, measure the pressure at the pilot drain port. If this pressure is higher than the desired set point, a condition exists in the pilot drain circuit that prevents the pressure reducing valve from being adjusted lower. Correct this problem and then readjust the valve. 2. If the pilot drain pressure measured in step a. is below the desired valve setting and the valve does not adjust lower, the spool may be stuck and the valve should be replaced. This arrangement is shown on hydraulic schematic drawings using the following symbols:
Hydrostat Insert
W
Fixed Orifice (Proportional Valve) Control Cover
8
Technical Drawings
8-72
Varco
Appendix
Auxiliary valves
Check valve, pilot to close
The pilot to close check valve allows flow in one direction only but will prevent flow in the free flow direction upon application of sufficient pressure at the pilot port. This valve is normally used to lock an actuator in position when the directional control valve is centered (neutral). It is used in applications where multiple functional modes are requiredregenerative circuits, for instance.
Theory of operation
A pilot to close check valve consists of a valve body with inlet and outlet ports and a poppet held against a seat by a spring. Opposite the check valve poppet is a pilot piston. The pilot piston and the poppet are held apart by a light spring. Pilot pressure is sensed 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 outlet port to the inlet port forces the poppet onto its seat, blocking flow through the valve. When enough pressure is present at the pilot piston, the piston moves against the poppet preventing flow in either direction. The ratio of the load pressure to the pilot pressure required to lock the load is called the pilot ratio. This valve is identified on hydraulic schematic drawings using the following symbol:
Outlet Pilot Port
Inlet
Check Valve, Pilot to Close
Technical Drawings
8-73
Appendix
This valve will most likely fail in the open position. That is, the valve will allow flow in both directions. If the valve fails when closed, in the free flow direction, severe contamination or damage to the internal sliding surfaces probably exists. Perform the 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 test gauges. If the upstream pressure is significantly higher than the downstream pressure, the valve is probably stuck closed and 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 the valve. If the pressure on the outlet is higher than at the inlet, remove the valve and check for damaged seals and replace as necessary. If the seals are not damaged, the poppet is probably stuck open because of contamination, and the valve should be replaced. 3. This step should be carried out if the valve does not appear to block flow in the free flow direction when piloted closed. Measure the pressure at the pilot and inlet ports. If the pilot pressure is at least 1.8 times the inlet pressure, flow in the free flow direction should be prevented. If it is not, remove the valve and check for damaged seals and replace as required. If the seals are not damaged, the poppet is probably stuck open because of contamination and the valve should be replaced. Note that any pressure at the outlet port reduces the required pilot ratio to values below 1.8.
Technical Drawings
8-74
Varco
Appendix
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 ports and a poppet held against a seat by a spring. The valve allows free flow from its inlet port to its outlet port when the differential pressure between the inlet and outlet is greater than the cracking pressure of the valve. The cracking pressure is determined by the strength of the spring and the areas exposed to the differential pressure across the valve. Fluid flow attempting to pass through the valve from the outlet port to the inlet port forces the poppet to its seat blocking flow through the valve. This valve is identified on hydraulic schematic drawings using one of the following symbols:
Outlet Outlet
Inlet
Inlet
This valve will most likely fail in the open position. That is, the valve will permit flow in both directions. If the valve fails when closed, in the free flow direction, severe contamination or damage to the internal sliding surfaces probably exists. Perform the 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 test gauges. If the upstream pressure is higher than the downstream pressure by an amount at least 50 psi greater than the cracking pressure, the valve is probably stuck closed and 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 the valve. If the pressure on the outlet is higher than at the inlet, remove the valve, check for damaged seals and replace as necessary. If the seals are not damaged, the poppet is probably stuck open because of contamination and the valve should be replaced.
Technical Drawings
8-75
Appendix
Flow valves
Orifice
Orifices are used in hydraulic circuits to provide a known restriction in a flow path.
Theory of operation
An orifice is a small opening in a fluids flow path. The flow rate of a fluid through an orifice is affected by the diameter of the orifice, the pressure differential across the orifice, and the temperature of the fluid. Common examples of fixed orifices used in hydraulics are threaded plugs or check valves with a hole drilled through their centers. This component is identified on hydraulic schematic drawings using the following symbol:
Orifice Diagnostic procedure
This component fails to perform if it becomes plugged either fully or partially by contamination. If a circuit that includes an orifice is not 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 rate in a circuit. The valve is pressure compensated to provide constant regulated flow, regardless of load variations. The flow rate is factory set by means of a fixed orifice. This valve is capable of reverse, noncompensated flow equal to the flow setting (orifice size).
Theory of operation
This valve consists of a body with an inlet and outlet, a compensator spool with a fixed orifice and a spring. Flow must pass through the orifice in the center of the compensator spool and then out the side of the spool through a series of holes that are radially located. The valve body also has a series of radially located holes in the area of the outlet port.
Technical Drawings
8-76
Varco
Appendix
The compensator spool senses both the incoming pressure and the load pressure and moves to restrict the flow through the two sets of holes, maintaining a constant pressure drop across the orifice. 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 compensator spool to move all the way to one side fully opening the two sets of holes to the outlet port. Thus, only the fixed orifice acts to regulate the flow and is, therefore, not pressure compensated. This component is identified on hydraulic schematic drawings using the following symbol:
Flow Control Valve, Pressure Compensated, Fixed Orifice
This component fails to perform when the orifice becomes plugged or the compensator spool sticks because of contamination. Perform the following steps to isolate a faulty component: 1. If the valve allows too much flow to pass, remove, check for damaged seals, and replace as required. If the seals are not damaged, the compensator spool may be stuck open by contamination and the valve should be replaced. 2. If the valve does not allow enough flow to pass, the orifice may have become plugged. Remove the valve, check for contamination, and clean it. If this does not solve the problem, the compensator spool may be stuck closed by contamination and the valve should be replaced.
Technical Drawings
8-77
Appendix
Flow control valve, adjustable, pressure compensated, full reverse free flow
This flow control valve uses a variable orifice spool to control the flow rate in a circuit. The valve is pressure compensated to provide constant regulated flow regardless of load variations. The flow rate is adjustable by means of a threaded screw. This valve is capable of full reverse, noncompensated flow, regardless of the flow setting.
Theory of operation
This valve consists of a body with an inlet and outlet, a compensator spool with a fixed orifice, and a bias spring. It also contains a smaller spring to provide full reverse free flow. Flow must pass through the orifice in the center of the compensator spool and then out the side of the spool through a series of holes that are radially located. The valve body also has a series of radially located holes in the area of the outlet port. A second set of holes in the valve body in conjunction with an annular groove on the outside of the compensator spool allows for full reverse free flow. The compensator spool senses both the incoming pressure and the load pressure and moves to restrict the flow through the two sets of holes maintaining a constant pressure drop across the orifice. 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 maximum compensated flow through the valve. Reverse flow from the outlet to the inlet causes the compensator spool to move against the small spring all the way to one side connecting the inlet to the outlet through the second set of holes in the valve body in conjunction with the annular groove on the outside of the compensator spool. This component is identified on hydraulic schematic drawings using the following symbol:
Outlet
8
Inlet
Technical Drawings
8-78
Varco
Appendix
This component fails to perform if the orifice becomes plugged or the 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 controlled direction, remove it and check for damaged seals and replace as required. If the seals are not damaged, the compensator spool or the check function may be stuck open by contamination and the valve should be replaced. 2. If the valve does not allow enough flow to pass in the controlled direction, the orifice may have become plugged. Remove the valve, check for contamination, and clean it. If this does not solve the problem, the compensator spool may be stuck closed by contamination and should be replaced.
Technical Drawings
8-79
Appendix
Output actuators
Hydraulic cylinder, double acting
The hydraulic cylinder is a device that converts hydraulic energy into straight line mechanical energy. A hydraulic cylinder can also hold and lower a load against gravity forces with the addition of suitable 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 to the cylinder body barrel by threads, tie rods or a weld. The end through which the rod extends is called the head end or rod end and the opposite end is called the cap end or blind end. Each end cap has a port that allows fluid to enter and exit that end of the cylinder. As the cylinder rod moves in and out, it is guided and supported by a removable bushing called a rod gland or rod bearing. The rod gland contains a piston rod wiper and a primary seal. The piston is equipped with one or more primary seals and, in some cases, wears rings. Hydraulic cylinders are identified on hydraulic schematic drawings using the following symbols:
Single Rod Cylinder
Double Rod Cylinder Hydraulic Cylinders
Tandem Cylinder
Technical Drawings
A problem with this component is usually related to the cylinder not producing the required push or pull force. If the fault is with the cylinder and not its related hydraulic circuitry, it is most likely caused by internal or external leakage of the pressurized fluid. External leakage is easy to detect and is not dealt with here. If the piston seals fail, fluid from the high pressure side of the piston passes to the low pressure side, which is generally connected to tank through a directional valve. If this leak is large enough, the hydraulic power unit is not able to maintain the pressure at the intended level. If the cylinder is supporting a gravity load, internal leakage may allow the rod to extend or retract until end of stroke is reached. Trouble shooting an internal seal failure requires determining if the cylinder will hold pressure over time. Perform the following steps to check the cylinder:
Varco
8-80
Appendix
1. If the cylinder is required to support a gravity load and is not holding its position, verify that the related load holding valves are functioning properly. Use the diagnostic procedure specified for that component. 2. Attach a test gauge to the appropriate test point in the line for the cylinder in question. Actuate the appropriate directional control valve and observe the pressure as the cylinder strokes. When the cylinder reaches the end of stroke, the reading should rise and stabilize at the supply pressure value. It may help to operate only a single pump and to use the slowest speed available for the function. A faulty piston seal may prevent the pressure from stabilizing. In addition, it may be possible to hear the flow of the oil leaking across the piston. If this is the case, replace the piston seals.
Technical Drawings
8-81
Appendix
Hydraulic motors
The hydraulic motor is a device that converts hydraulic energy into rotary mechanical energy.
Theory of operation
Hydraulic motors operate by causing an imbalance that results in the rotation of a shaft. A geroler motor is a type of internal gear motor with an inner drive gear and an outer drive gear with one more tooth than the inner gear. The inner gear is attached to a shaft connected to the load. The outer gear in a geroler motor consists of several rollers held in place by a slotted ring. The imbalance in this type of motor is caused by the difference in gear area exposed to hydraulic pressure at the motor inlet. The exposed area of the inner gear increases at the inlet. Fluid pressure acting on these unequally exposed teeth results in a torque at the motor shaft. Larger gears or higher pressures create higher torques at the output shaft. A cylindrical porting ring directs fluid between the inlet and outlet ports and the rotating group through passages in the motor housing. A case drain is sometimes provided to protect the shaft seals from damage due to internal motor leakage. Hydraulic motors are identified on hydraulic schematic drawings using the following symbol:
Case Drain
A problem with this component is usually related to a loss of output torque due either to internal binding or to excessive internal leakage. Perform the following steps to check the motor: 1. If the motor fails to rotate freely when not under load or excessive heat or noise is generated, internal damage has occurred, and the motor should be replaced.
Technical Drawings
2.To check for excessive internal leakage, operate the motor in a stalled condition. Check the pressure at both the inlet and outlet ports of the motor. The inlet pressure should be very near the supply pressure for this circuit, normally 2500 psi. The pressure at the outlet port should be near that of the tank pressure, less than 100 psi. If this is not the case, or excessive flow across the stalled rotor is evidenced by heat or noise, replace the motor.
Varco
8-82

TDS4STrouble Shooting Guide

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TDS4STrouble Shooting Guide

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Introduction

How to Use This Manual

Notes, Cautions and Warnings

Gives helpful information.

Counterbalance and Motor Alignment Cylinder Troubleshooting

Drilling Motor Housing, Brake and Guide Dolly Troubleshooting

4 TDS-4S/4H Troubleshooting Guide

TDS-4S/4H Troubleshooting Guide

Varco Driller's Console (VDC)

TDS-4S/4H Troubleshooting Guide

Varco Driller's Console (VDC) Description

ALARM SILENCE/LAMP CHECK Pushbutton switch

HYDRAULIC POWER AUTO/ON 2-Position switch

Varco Driller's Console (VDC) Description

(PIPEHANDLER) LINK TILT FLOAT Pushbutton switch

(PIPEHANDLER) TORQUE WRENCH PUSH & HOLD Pushbutton switch

(PIPEHANDLER) LINK TILT DRILL/OFF/TILT 3-Position maintained switch

TDS-4S/4H Troubleshooting Guide

Varco Driller's Console (VDC) Description

DRILL TORQUE: 0 to MAX Continuous Potentiometer

TORQUE: 0 to Full Scale Meter (0 - 10 VDC)

DC Panel TD/RT switch

RBS RBS (Deployed IND) switch

Varco Driller's Console (VDC) Description

TDS Expo Purge TDS purge proceeding indicator

TDS-4S/4H Troubleshooting Guide

Varco Driller's Console (VDC) Description

TDS Disable 2- Position Maintain

Block 3- Position Maintain

TDS-4S/4H Troubleshooting Guide

Drilling Operational Problems

Is it a Torque Wrench Problem ? No

Is it a Link Tilt Problem ? No

Is it a Rotating Head Problem ? No

Is it an Alignment Cylinder Problem ? No

Is it a Lube System Problem ? No

Call Field Service

Drill/Spin/Torque Troubleshooting Drill/Spin/Torque Troubleshooting

TDS-4S/4H Troubleshooting Guide

Drill/Spin/Torque Troubleshooting Drill/Spin/Torque

Switch to DRILL Mode

s Use the DRILL/SPIN/TORQUE selector switch

Perform Lamp Test

Is Lamp Test Good?

Set Drill Torque Limit

Did Drill Torque Set Okay?

Ensure SCR is ON Assign FORWARD

TDS-4S/4H Troubleshooting Guide

Fault and Alarm Problems

Over speed light "ON" SCR interface board.

VDC/Lamp Test Fault

Check Lamp Check PLC Output Check Power Supply

Did You Find Cause and Fix It ? No

Did You Find Cause and Fix It ? No

Call Field Service

Call Field Service

TDS-4S/4H Troubleshooting Guide

Field Loss Fault or Alarm

Over Speed Light ON SCR Interface Board

Refer to Field Supply Manual

Did You Find Cause and Fix It ? No

Call Field Service

Fault or Alarm After Assignment