TOP DRIVE

Varco Technical Education Center Montrose Scotland

AC TOP DRIVE Introduction Major Components.

Sections Section 1 - General Information Section 2 – Specifications Section 3 - Lubrication and Maintenance Section 4 - Installation, Commissioning and Decommissioning Section 5 - Guide Beams and Carriage Section 6 - Motor Housing, Transmission Section 7 - PH-50 Pipehandler Section 8 - Hydraulic System Section 9 - Varco Driller's Console Section 10 - System Interconnect Section 11 - Siemens Step 7 PLC Section 12 - Basics of AC Motors Section 13 - Basics of AC Drives Section 14 - Seimens 70 Series Drive Chassis AC to AC Section 15 - Parameter Listing Section 16 - Encoder Troubleshooting Instructions Section 17 - Simovis Version 5

Motor Cooling System

Counterbalance System

Hydraulic Disc Brakes (2)

Gooseneck (S-Pipe)

AC Drilling Motors (2) Transmission/ Motor Housing

Electrical System

Hydraulic System

Rotating Link Adapter

Guide Beam and Carriage

PH-50 Pipehandler

Rear

Left Side

Right Side

Front

A brief history of Top Drives Since the advent rotary drilling in the early 1900s, drilling technology has made steady and, in some cases, spectacular progress. In a little over 100 years, well depths have gone from the 70-foot depth of Drake's Well to over 40,000 feet at the rig on Kola Peninsula east of Finland. To accomplish this, advances were necessary in rig design, equipment, bits, materials and drilling techniques. Varco International, Inc., is proud of its part in advancing the technology of drilling. In 1982 they introduced the industry's first top drive drilling system. By replacing the traditional rotary drive and kelly with an advanced system that rotates the drill string and handles entire 93-ft. stands of pipe, Varco was able to reduce drilling time by up to 25% while increasing the overall capability and efficiency of the drilling operation. As a result, Varco Top Drive Drilling Systems have now become the new performance standard for the drilling industry. And Varco continues to extend the threshold of Top drive technology with the introduction of a complete line of AC top drive systems.

A new threshold in AC technology For years the backbone of oil industry power has been the 1000 hp DC traction motor adapted from locomotives. They are used extensively to power a variety drilling operations including drawworks, rotary tables and mud pumps. DC traction motors area rugged, dependable, readily available source of high torque electric power. These characteristics made them the ideal choice for the conversion of drilling equipment from direct drive diesel to electric power. In developing its Top Drive systems, Varco first turned to these DC motors to power its new technology. And while they were appropriate for some applications, it became evident that smaller, more compact motors were needed for today's performance requirements. There was a need for an efficient, highperformance alternative to traditional DC systems. As part of Varco’s ongoing development effort, various AC motors and

drives were reviewed in an effort to satisfy the specific requirements of drilling applications. Varco design engineers determined that rapid developments in adjustable frequency technology made AC drives and motors a better solution for certain applications traditionally served by DC systems. These modern AC motor/control combinations are uniquely suited for the requirements of the drilling industry. By optimising various components, rugged, reliable AC drives and motors now can produce superior power density for a given frame size. The result - compact, efficient power plants that extend the performance envelope of drilling operations.

A performance paradigm By utilising highly efficient AC motors with the latest variable frequency drives, Varco has defined a new category of performance top drive systems. These new AC drives can stall at full torque for extended periods of time, provide significantly higher intermittent torque and offer more precise control at all speeds. An additional benefit of the advanced AC technology of Varco top drives is constant, useable horsepower over a greater range of speed and torque. This means that you can run faster with more torque - an ideal condition for maximising the potential of diamond and polycrystalline diamond compact (PDC) bits. In the competitive world of drilling and production, Varco has developed technology that is defining a new performance paradigm. Their AC top drive systems combine increased performance, reduced maintenance, lower power consumption, and flexible drive parameters into an unbeatable combination over a wide variety of applications.

Varco’s Top Drive Drilling Systems development

Portable Top Drive Comparison

Specifications Comparison

Working Height-Ft Weight-Lbs.

IDS-1

TDS-9S

(DC SHUNT)

(AC)

(AC)

(AC)

23.0

17.8

16.0

18.0

30,700

24,000

18,000

28,000

Cont. Torque. 34,900 Ft-Lbs. @155 RPM

TDS-10S TDS-11S

32,500 20,000 38,000 @114 RPM @89 RPM @114 RPM

Horse Pwr.

1,000

700

350

800

Rated Ton.

500

400

250

500

TDS-9SA TORQUE SPEED

TDS-10SA TORQUE/SPEED

TDS-11SA TORQUE SPEED

TDS Training Manual

TOP DRIVE COMPONENTS

Typical TDS-9/11SA

AC Electrical

TDS Training Manual

TDS-9SA/TDS-11SA PLAN VIEW

AC Electrical

TDS Training Manual

POWER TRAIN CUTAWAY

AC Electrical

TDS Training Manual

TRANSMISSION/MOTOR HOUSING AND SWIVEL ASSEMBLY

AC Electrical

TDS Training Manual

Transmission/Motor Housing (Main Body) and Swivel Assembly

The transmission/motor housing and swivel assembly transfers the power produced by AC drilling motors to the drill string. Inside the transmission/motor housing main body is a single-speed double-reduction spur gear system that provides a 10.5:1 ratio from the motors to the main shaft. The main thrust bearing located inside the motor housing supports drilling loads, while the load stem, which bypasses the thrust bearing and provides support for the rotating link adapter and pipe handler, carries the tripping loads. The main body of the motor housing provides a sealed oil lubrication reservoir for the transmission gears and bearings. Bearings and gears are force fed by an oil pump that is integral with the main body. A low speed hydraulic motor drives the oil pump. The filtered lubrication oil constantly circulates through the main thrust bearing, take-up bearing, lower radial and compound gear bearings and over the gear meshes. An industry standard wash pipe packing box assembly is located between the main shaft/swivel stem and the S-pipe weldment. The bonnet supports the S-pipe weldment. The forged alloy steel bail swings forward for attaching to standard rotary drilling hooks. The bail is fitted with bronze bushings that are grease lubricated.

AC Electrical

TDS Training Manual

MOTOR COOLING SYSTEM

The motor cooling system on the AC TDS is a local intake pressure blower type. It consists of two 5 HP AC motors integrally mounted on top of each AC drilling motor. Air is drawn in from the combination brake cover/air intake and delivered through rigid ducting to an opening in the top of each motor. The cooling air then passes through the inside of the open-frame type AC drilling motors and exits out of two louver openings near the bottom of the motors.

AC Electrical

TDS Training Manual

HYDRAULIC CONTROL SYSTEM

AC Electrical

TDS Training Manual

HYDRAULIC SYSTEM

AC Electrical

TDS Training Manual

The hydraulic control system is a completely self-contained, onboard system. A 10horsepower, 1800 RPM, AC motor, drives two hydraulic pumps and powers the hydraulic system. A fixed displacement pump drives the Lube oil system motor. A variable displacement pump provides hydraulic power for the AC motor brakes, powered rotating head, remote actuated IBOP, pipe backup clamp cylinder link tilt and counterbalance system. The hydraulic manifold attaches to the main body and contains solenoid, pressure and flow control valves. A sealed stainless steel reservoir supplies hydraulic oil, eliminating the need for draining and refilling during normal rig moves. The reservoir is mounted between the two AC drilling motors and is equipped with strainers and oil level sight gauges. Three hydro-pneumatic accumulators are located on the main body. The counterbalance system uses the largest accumulator. The medium size accumulator unloads the variable displacement pump and the smallest accumulator activates the delay circuit on the IBOP actuator.

AC Electrical

TDS Training Manual

AC DRILLING MOTOR BRAKES

A modified U-face attaches the motors to the main body. This mounting method allows installation of the motors without shimming or special alignment. Each motor has double-ended shafts with a drive pinion mounted on the lower end and disc brake rotor mounted on the upper end. Two hydraulic calliper disc brakes mounted to the top end of each motor, hold torque in the drill string and assist in positioning during directional work. An electrical solenoid valve remotely operates the hydraulic calliper disc brakes. The AC drilling motors are an open-frame type, meaning that the cooling air passes through the inside of the motion The drilling motors, manufactured specifically for top drive applications, have internal temperature sensors, vacuum varnish impregnated windings, high capacity bearings, and tapered output shafts to improve serviceability of the pinion gear and brake hubs.

AC Electrical

TDS Training Manual

Powered Rotating link

The powered rotating link adapter located at the top of the pipe handler is a slip ring assembly. It allows the hydraulic lines to remain connected as the pipe handler rotates with the drill stem components while tripping out or positioning the link tilt. The rotating link adapter also provides an attachment for the link tilt, pipe backup clamp cylinder and remote IBOP actuator assembly. Grooves in the rotating link adapter align with radial holes in the load stem, allowing hydraulic fluid to flow between the rotating link adapter and the load stem as they rotate. The radial passages at the upper end of the load stem intersect with each hose attachment that runs to the hydraulic manifold. The radial passages in the lower end of the load stem intersect sealed grooves in the rotating link adapter that, in turn, connect with hose attachments that run to all the actuators on the pipe handler. The rotating link adapter can be powered in either direction by a hydraulic drive motor. A pinion gear on the hydraulic drive motor engages a ring gear attached to the top of the rotating link adapter. An electric solenoid valve operates the rotating link adapter hydraulic motor.

AC Electrical

TDS Training Manual

PH-50 PIPEHANDLER

AC Electrical

TDS Training Manual

TWO WAY LINK TILT (PH-50)

The two way link-tilt cylinder assemblies consist of the cylinder rods pinned to the rotating link adapter and the cylinder bodies pinned to the links through a set of clamps. Pressurising the cylinder assemblies by operating the switch on the driller's console extends the drill pipe elevator to the mouse hole or the drill down position. A float position allows the links to return to well centre, the latch on the cylinder assembly limits the travel of the elevator to the derrick man position. Releasing the larch by pulling a cable allows the elevator to travel to the mousehole position AC Electrical

TDS Training Manual

INTERNAL BLOWOUT PREVENTION

AC Electrical

TDS Training Manual

Internal Blowout Prevention The two Internal Blowout Prevention (IBOP) control valves contained in the pipehandler are ball type, full size. internal opening safety valves. These two valves a hex drive remotely operated upper valve, and a manually operated lower valve. form the ;well control system. Both valves have 6-5/8" regular RH connections and 15.000 psi pressure ratings. The remotely controlled upper IBOP valve is opened and closed by a yoke and a hydraulic cylinder that is controlled from the driller's console using an electric solenoid valve. A clam shell housing rotates with the valve body and moves up and down to drive a small crank arm on each side of the valve stem. The housing is actuated by a cylinder through a non-rotating actuator ring. The hydraulic cylinder is attached to the torque arrestor frame. The lower valve is the same type as the upper except it must be manually opened and closed with a wrench. Both valves remain in the string at all times and are readily available by connecting the Top Drive to the drill string. The lower valve can be broken-out from the upper valve using tongs after swinging the torque arrestor frame out of the way. The torque arrestor frame can be pulled away from the drill string after opening the front gate on the clamp cylinder body and removing the stabiliser half. After breaking-out the lower valve, the Top Drive can be hoisted away, allowing room to install the appropriate subs arid valves for well control operations. After removing the lower valve from the upper valve on the Top Drive using conventional fig tongs, the lower valve remains connected to the drill string for well control purposes. A crossover sub is included with the system to allow connection of the drill stem to the lower valve. A drill pipe elevator hangs from a pair of conventional links that attach the link adapter. Actuating the link tilt swings the elevator out to facilitate picking up pipe.

AC Electrical

TDS Training Manuak

TORQUE BACK-UP CLAMP

The torque hack-up clamp is supported by a torque arrestor frame that hangs from the rotating link adapter. The backup clamp is located below the lower shoulder of the saver sub and consists of a pair of gripping jaws with die inserts and 10" diameter clamping cylinder for gripping the box end of the tool joint when connected to the saver sub. The backup clamp body is attached to the torque arrestor frame in such a way that it can float up or down to allow for thread engagement and counter backup torque while making and breaking connections. When the clamp mode is activated, a shot pin mechanism automatically engages the rotating ring to prevent the link adapter from rotating while breaking out the connection.

AC Electrical

TDS Training Manual

COUNTERBALANCE SYSTEM

The counterbalance system includes two hydraulic cylinders connected between the bail and the hook. When the system is activated, the two cylinders support most of the weight of the Top Drive. This system protects root joint threads by taking much of the weight off the drill pipe while making or breaking connections. A new feature for the TDS-9S is called STAND JUMP. It consists of a switch at the driller's console allowing you to change the mode of operation of the counterbalance cylinders from DRILL, which is a standard counterbalance condition, to STAND JUMP. The STAND JUMP feature allows the cylinders to lift the weight of the top drive off the drill string while breaking out a connection, this eases the stress on the threads and avoids damage. The cylinders lift the swivel bail off its resting point on the hook. The two hydraulic cylinders are connected to a hydro-pneumatic accumulator located on the main body. A manual valve can extend the cylinders to assist during rig-up. The accumulator is charged with hydraulic fluid and maintained at a predetermined pressure setting by the counterbalance circuit in the hydraulic control manifold, located on the main body. The hydraulic manifold controls all hydraulic power to the Top Drive.

AC Electrical

TDS Training Manual

Electrical Interface

The electrical interface shown above is the standard layout for the TDS – 9/11S, there are main parts of this schematic, the Varco Top Drive, the Varco Driller’s Console, the Control House or Skid and the Service Loops/Connecting cables. The Top Drive consists of the two AC Drilling motors, Encoder Feedback, Solenoids Valves and Pressure and Temperature Switches. The Varco Driller’s Console consists of the switches and Potentiometers to Control the Top Drive System as well as Alarm Indicators and Horn, to indicate a Fault condition to the Driller. The Control House or Skid consists the Variable Frequency Drive which powers the AC Drilling Motors on the Top Drive, Varco control Panel which controls all the functions and Alarms on the Top Drive. The Service Loops are all electrical, these are the cabling system, which gives all the power to the Top Drive, as well as giving Alarm condition status back to the Control Panel.

AC Electrical

Preface Manual conventions This Preface contains the conventions used throughout this manual. Avoid injury to personnel and/or equipment damage by reading this manual and related documents before operating, inspecting, or servicing the equipment. Notes, cautions, and warnings The following examples explain the symbols for notes, cautions, and warnings. Please pay close attention to these important advisories.

Note

i

Provides additional information on procedures involving little or no risk of injury to personnel or equipment damage.

Caution

!

Alerts the reader to procedures involving a risk of equipment damage.

Warning

Warns the reader of procedures involving a definite risk of injury to rig personnel.

Product Bulletins The Product Bulletin tab, if included in your manual, defines a section of the manual in which you can store Product and Safety bulletins that may be issued by Varco.

Overall equipment safety requirements Varco drilling equipment is installed and operated in a controlled drilling rig environment that involves hazardous operations and situations.

i

To avoid injury to personnel or equipment damage, carefully observe the following safety requirements.

Personnel training All personnel installing, operating, repairing, or maintaining equipment, or those in the vicinity of this equipment, should be trained in rig safety, tool operation, and maintenance as applicable. This measure helps ensure the safety of everyone exposed to the equipment for whatever purpose.

i

During installation, operation, maintenance, or repair of this equipment, personnel should wear protective equipment. Contact the Varco Service Department to arrange for training for equipment operation and maintenance.

Systems safety practices The equipment covered by this manual may require or contain one or more utilities such as electrical, hydraulic, pneumatic, and cooling water.

i

Before installing or performing maintenance or repairs on the equipment, read the following instructions to avoid endangering exposed persons or damaging equipment. ❏ Isolate all energy sources before beginning work. ❏ Avoid performing maintenance and repairs while the equipment is in operation. ❏ Wear proper protective equipment during the installation, maintenance, or repair of this equipment.

Electrical systems and components

All electrical wiring, junction boxes, sensors, glands, and related equipment are designed for the specific application, environment and particular zone where the equipment is intended to be used. ❏ Before beginning work on this equipment, familiarize yourself with the electrical schematics, as well as the equipment power and voltage requirements. ❏ When performing installation, maintenance, or repairs on the equipment, isolate all power. Lock out switches and tag them to prevent injury. ❏ Prior to disconnecting wires, verify that all wires and terminals are properly labeled to ensure proper reconnection. Hydraulic systems and components

Hydraulic systems and components are designed for specific use in the drilling industry. The hydraulic pressure for this equipment can be as high as 3,000 psi. ❏ Before beginning work on any portion of the hydraulic system, familiarize yourself with the hydraulic and electrical schematics. ❏ Isolate, lock out, and tag the hydraulic and electrical power and controls. ❏ Take precautions when bleeding down residual system pressure, using bleed valves or equivalent techniques.

n

Hydraulic fluids can be extremely hot and under high pressure. ❏ Properly discharge all system accumulators. ❏ Collect all residual hydraulic fluid in a container to prevent rig or environmental contamination. ❏ Take precautions to prevent hydraulic oil from leaking into other open electrical or mechanical components, such as junction boxes.

Pneumatic systems and components

Pneumatic systems and components are designed for specific use in the drilling industry. The pneumatic pressure for this equipment can be as high as 150 psi. ❏ Prior to beginning work on any portion of the pneumatic system, familiarize yourself with the pneumatic and electrical schematics. ❏ Isolate, lock out, and tag the pneumatic and electrical power and controls. ❏ Take precautions when bleeding down residual system pressure using bleed valves or equivalent techniques. ❏ Properly discharge all system accumulators. Water cooling systems and components

Water cooling systems and components are designed for specific use in the drilling industry. The water can reach temperatures high enough to cause scalding. ❏ Prior to beginning work on any portion of the cooling system familiarize yourself with the plumbing and electrical schematics. ❏ Isolate, lock out, and tag the cooling water and electrical power and controls. ❏ Take precautions when bleeding down residual system pressure using bleed valves or equivalent techniques. ❏ Collect all residual cooling water in a container to prevent rig or environmental contamination if necessary. ❏ Take precautions to prevent cooling water from leaking into other open electrical or mechanical components such as junction boxes.

General safety Equipment motion hazards

Some of the Varco equipment travels either horizontally, vertically on rails, or both.

i

i

Avoid placing objects in or near the path of motion for this equipment. Such interference could cause personnel to be trapped or crushed by equipment.

Keep the working envelope/zone of the equipment free from personnel.

When replacing components

❏ During disassembly and reassembly of any equipment, verify all components such as cables, hoses, etc. are tagged and labeled to ensure reinstalling the components correctly. ❏ Replace failed or damaged components with Varco certified parts. Failure to do so could result in a hazard, equipment damage, or personal injury. During routine maintenance

Equipment must be maintained on a regular basis. See the body of the service manual for maintenance recommendations.

i

Failure to conduct regular maintenance can result in a hazard, equipment damage, or injury to personnel.

Visibility of equipment operation

Clear, unobstructed visibility of all equipment functions is critical to safe operation. Do not block or impair the equipment operator’s field of view. In cases where this is not possible, the customer must install video cameras to ensure adequate visibility. Proper use of equipment

Varco equipment is designed for specific functions and applications and should be used only for the intended purpose.

i

Do not hoist personnel using this equipment. Contact the Varco service center for questions regarding equipment operation, maintenance, hazards, and designed function.

TDS Training Manual


AC TOP DRIVE Section 1

General Information

AC Electrical

General Information

How to use this manual ...................................... 1-2 Identification numbers ....................................... 1-3

1

Lifting points ....................................................... 1-4 Safety wiring ....................................................... 1-5 Torque values ..................................................... 1-6

2

Basic useage ...................................................... 1-7 Drilling ahead with singles ............................................. 1-7 Drilling ahead with triples............................................... 1-8 Backreaming ................................................................. 1-9

3

TDS-9/11SA consumables ..................................... 1-10

4

5

6

7

8

9

TDS-11SA

General Information

How to use this manual 1

This manual is divided into 9 sections. The first page of each section is marked with a black tab that lines up with the thumb index tabs for each section and the back cover. You can quickly find each section without looking through a full table of contents. Use the symbols printed at the top corner of each page as a quick reference system. Each section uses a different symbol. Where applicable, each section includes: 1. A table of contents, or an illustrated view index showing: • Major assemblies, systems or operations • Page references to descriptions in text 2. Disassembly / assembly information and tools 3. Inspection information 4. Testing / troubleshooting information 5. Repair information 6. Adjustment information 7. Torque values

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 may manual contain warnings about proceedures which could damage equipment, make it unsafe, or cause PERSONAL INJURY. 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.

1-2

Varco Systems

General Information

Identification numbers 1 Encoder Instruction Label Located on the side of the brake housing

AC Motor Identification Label Located on the side of each AC motor

Warning Labels Located on the side of each AC motor

i

Trace code identifies the configuration of your equipment

SALES ORDER NO. ASSY NO. TRACE CODE DATE OF MANUFACTURE

REV

Top Drive Identification Plate Located on the front of the motor housing

Warning Label Located on the side of the bonnet

TDS-11SA

1-3

General Information

Lifting points 27,000 lb (12300 kg) TDS-11SA

1

Lifting Point For lowering/hoisting the Top Drive to/from the skid

! Bail Lock Must be installed before lowering/hoisting the Top Drive to/from the skid Lifting Points For the skid with Top Drive attached

i For information on Center of gravity see pages 2-2 and 2-3

30,000 lb (13600 kg) TDS-11SA on the skid

Lifting Points For the skid with Top Drive attached

!

1-4

Locking pins Must be in place prior to moving the skid with Top Drive attached

!

Locking pins Must be in place prior to moving the skid with Top Drive attached

Varco Systems

General Information

Safety wiring 1

3

TDS-11SA

2

4

1

5

1-5

General Information

Torque values (Unless otherwise specified) 1

Diameter

Threads per inch

Bolts Lubricated with Light Machine Oil

Bolts Lubricated with Anti-seize Compound

Grade 5

Grade 5

Min. Torque (ft lb)

Max. Torque (ft lb)

Clamp Force (lb)

Min. Torque (ft lb)

Max. Torque (ft lb)

Clamp Force (lb)

Coarse Thread Series, UNC 1/4

20

7.6

8.4

2020

5.7

6.3

2020

5/16

18

16

18

3340

12.1

13.4

3340

3/8

16

29

32

4940

21.4

23.6

4490

7/16

14

48

53

6800

36

39

6800

1/2

13

71

79

9050

53

59

9050

9/16

12

105

116

11600

78

87

11600

5/8

11

143

158

14400

107

118

14400

3/4

10

247

273

21300

185

205

21300

7/8

9

409

452

29400

306

339

29400

1

8

608

672

38600

456

504

38600

1 1/8

7

760

840

42300

570

630

42300

1 1/4

7

1064

1176

53800

798

882

53800

1 3/8

6

1387

1533

64100

1040

1150

64100

1 1/2

6

1843

2037

78000

1382

1528

78000

Fine Thread Series, UNF 1/4

28

9.5

10.5

2320

7.1

7.9

2320

5/16

24

18

20

3700

13.5

15.0

3700

3/8

24

33

37

5600

25

28

5600

7/16

20

52

58

7550

39

43

7550

1/2

20

86

95

10700

64

71

10700

9/16

18

114

126

12950

86

95

12950

5/8

18

162

179

16300

121

134

16300

3/4

16

285

315

23800

214

236

23800

7/8

14

447

494

32400

335

370

32400

1

14

665

735

42200

499

551

42200

1 1/8

12

836

924

47500

627

693

47500

1 1/4

12

1178

1302

59600

884

977

59600

1 3/8

12

1596

1764

73000

1197

1323

73000

1 1/2

12

2090

2310

87700

1568

1733

87700

T.S. = 120,000 psi to 1" dia. Proof Strength = 85,000 psi T.S. = 105,000 psi 1 1/8" to 1 1/2" dia. Proof Strength = 74,000 psi

1-6

Varco Systems

General Information

Basic useage Drilling ahead with singles 1 Step 1 Set slips on string Stop circulation Close IBOP Breakout connection using pipehandler and drilling motor (in reverse)

Step 2

Step 3

Step 4

Tilt links to mousehole

Pickup single with elevator

Latch drill pipe elevator around single

Release link tilt Stab bottom of single onto string

Step 5

Lower block to stab motor into top of single

Pull slips

Spin in motor and single

Start circulation

Makeup both connections with motor in torque mode

Open IBOP

Begin drilling

Makeup

Open IBOP Link Tilt Close IBOP Stab

TDS-11SA

Makeup

1-7

General Information

Basic useage Drilling ahead with triples 1

Step 1

Step 2

Set slips on string

Raise block

Stop circulation

Tilt link tilt to derrickman

Breakout connection using pipehandler and drilling motor (in reverse)

Step 3 Pickup stand with elevator Stab bottom of stand onto string

Step 4

Step 5

Lower block to stab motor into top of stand

Pull slips

Spin in motor and stand

Begin drilling

Start circulation

Makeup both connections with motor

Makeup

Link Tilt

Start Circulation

Stop Circulation Stab

1-8

Makeup

Varco Systems

General Information

Basic useage Backreaming Step 1 Hoist while circulating and rotating When 3-rd connection surfaces, stop rotation and circulation

Step 2 Set slips on string Breakout connection using pipehandler and drilling motor (reverse)

Step 3 Hoist free stand with elevator

Step 4 Setback stand using link tilt

1

Lower block, stab motor into string Spin in motor and makeup connection with motor

Breakout and spinout stand at floor

Breakout

Step 5

Start circulation, pull slips, hoist and rotate

Hoist

Setback

Hoist and Rotate Breakout

TDS-11SA

1-9

General Information

TDS-9/11SA consumables 1

Consumables

Quantity

Part Number

Page Ref.

Tong Dies

4

16781

See page 7-14

Stabilizer, Front

1

118368

See page 7-15

Stabilizer, Rear

1

118367

See page 7-15

Flippers, Stabbing Guide

2

76442

See page 7-15

Wash Pipe

1

123289

See page 6-11

Wash Pipe (Tungsten Coated)

1

123289-TC

See page 6-11

Wash Pipe Packing Kit, 3" Standard (Use with Wash Pipe 123289 or 123289-TC)

1

123290-PK

See page 6-11

Wash Pipe Packing Kit, 3" High Pressure (Use with Wash Pipe 123289-TC only)

1

123290-PK-1

See page 6-11

Hydraulic Oil Filter

1

114416-1

See page 4-30

Gear Oil Filter

1

111013-1

See page 4-32


Wash Pipe

Gear Oil Filter

Stabilizers

Tong Dies

Stabbing Guide

1-10

Varco Systems

TDS Training Manual



Specifications

AC Electrical

Specifications

Specifications

Size specifications ............................................. 2-2 1

General specifications ....................................... 2-4 Typical mast interface ....................................... 2-5

22

3

4

5

6

7

8

9

TDS-11SA TDS-11SA

2-1

Specifications

Size specifications Bail 120 in. (3.05 m)

18.5 in. (.47 m)

Bail 88 in. (2.24 m)

2

214.0 in. (5.43 m)

233.0 in. (5.82 m)

To Center of Gravity 112 in. (2.85 m)

To Center of Gravity 28 in. (.71 m)

56 in. (1.42 m) 62 in. (1.58 m)

2-2

To Center of Gravity 37 in. (.94 m)

72 in. (1.83 m)

= 30,000 lb = 13600 kg

Varco Systems

Specifications

Size specifications

Rear 33.7 in. (856 mm)

2

33.8 in. (859 mm) 30.0 in. (762 mm) Setback (Standard)

22.8 in. (579 mm)

C L Well 21.1 in. (53 mm) 22.1 in. (561 mm)

31.0 in. (787 mm) 32.6 in. (828 mm) 26.0 in. (660 mm)

36.9 in. (937 mm)

C L Well

Front

TDS-11SA

2-3

Specifications

General specifications Components

Items

Description

Top Drive

2

Weight Stack-up Height Power Requirements Horsepower Output torque (continuous) Tool torque (intermittent @ stall) Maximum Speed @ full power Hoisting capacity Load Path

27,000 lb 17.8 ft 700 KVA @ 575-600 VAC, 50/60 Hz 800 hp 37,500 ft lb (800 hp) 55,000 ft lb 228 rpm 500 ton Single

Sizes

3-1/2 in. to 5 in. (4 in. to 6-5/8 in. OD tool joint)

Type

PH-50 (55,000 ft lb torque)

Type

Reliance AC-575 VAC (2 x 400 hp)

Type

IDM Yaskowa Drive (800 hp, 575 VAC) or Siemens (800 hp, 600 VAC)

Type

Hydraulic caliper disc brakes

Type Power Speed

Local intake pressure blower (2) 5 hp AC motors 3,600 rpm

Type

Single speed, double reduction helical gear system 10.5:1 (4.38:1 optional)

Drill Pipe Pipe Handler Drilling Motor Variable Frequency Drive

Motor Braking Motor Cooling System

Gearcase

Gear ratio Gearcase Lubrication Type Reservoir capacity Full internal flow Oil Type

Pressure feed 15 gal

Power Flow Reservoir capacity Oil Type

10 hp, AC motor (1) 6 gpm, (1) 4 gpm 25 gal Mineral based hydraulic oil

Size Type Weight Input requirement

125.4 in. x 84.0 in., 91.2 in. height (Siemens) 140.0 in. x 90.0 in., 91.0 in. height (IDM) 9,500 lb 600 VAC(50/60 Hz), or 750 VDC, or 690 VDC(50/60 Hz)

EP Grade

Hydraulic System

Electrical House

2-4

Varco Systems

Specifications

Typical mast interface Existing Traveling Equipment 500-ton Hook/Block Combo-Typ.

* Dimensions are Subject to Verification ** Standard TDS ConfigurationTwo IBOP’s with 108 in. Elevator Links

TDS-11SA Varco Portable Top Drive System

Crown Clearance 13.5 ft. (4.1 m)**

Block Top

Stroked-Typ. 13.5 ft. (4.1 m)*

2

Bail Rest Sectional Guide Beam

TDS Work Height 18.0 ft. (5.4 m)** Tool Joint

Derrick Termination at ~73 ft. (24.4 m) Level* Mud Hose 75 ft. (22.9 m)* Connected to Standpipe at 73 ft. (22.3 m) Level

Drill Stand Made-up at 4 ft. (1,2 m) Level 93 ft. (28.3 m)

Service Loop

Varco Driller’s Control

Control Cable with Connectors 150 ft. (45.7 m)

Unitized Variable Frequency Inverter & Varco Control Panel Local Power Supply Diesel/Alternator Set/AC Buss

AC Cables

TDS-11SA

7.0 ft. (2.1 m)-Minimum

2 Custom Spanners On A-Frames or Mast Side Panels (by Customer)

10.0 ft. (3 m)-Minimum*

Portable Torque Reaction Beam “U”- Bolted to Spanners - (by Customer)

Clear Working Height 142 ft. (43.3 m)

C L Beam Service Loop Tool Joint 4.0 ft. (1.2 m) Drill Floor

AC Power and Control Cables

2-5

TDS Training Manual



Lubrication and Maintenance

AC Electrical

Lubrication and Maintenance

Transmission ...................................................... 3-2 Selecting the proper gearbox oil .................................... 3-2

1

Lubrication schedule ..................................................... 3-2 Recommended gear oils ............................................... 3-3 Gearbox lubrication ............................................ 3-4 Hydraulic system ................................................ 3-5 Precautions ................................................................... 3-5

2

Lubrication schedule ..................................................... 3-5 Recommended hydraulic fluid ....................................... 3-6 Hydraulic lubrication ...................................................... 3-7

3

Motors ................................................................. 3-8 Lubrication schedule ..................................................... 3-8 Recommended motor grease ........................................ 3-8 Motor lubrication ............................................................ 3-9

4

General purpose lubrication ............................... 3-10 Lubrication schedule ..................................................... 3-10 Recommended lubricants .............................................. 3-11

5

General lubrication ........................................................ 3-12

6

7

8

9

TDS-11SA

Lubrication

Transmission Selecting the proper gearbox oil TDS transmissions operate under a combination of heavy and shock loads. Under these conditions oil tends to extrude out of the gear mesh. Keeping an effective film of oil on the gear mesh requires oil with an AGMA “extra pressure” rating (EP), and a minimum viscosity of 100 SUS at internal operating temperature. Varco Top Drives also operate under a wide variety of ambient temperatures. Select lubrication for the TDS based on the minimum ambient temperature (surrounding air) to be expected before the next oil change. Under all but the most severe operating conditions, Varco recommends changing the oil every six months. Introducing an oil viscosity greater than required by the ambient temperature can:

3

❏ Damage the gearbox due to reduced oil flow ❏ Damage the oil pump because of excessive load

Lubrication schedule Description Replace the Gearbox Oil Following Intial Break-in

Frequency Following first month of operation

Replace the Gearbox Oil and Perform an Oil Analysis Oil viscosity should be adjusted based on expected ambient conditions for next six months

1 x every 6 Months

Replace the Gearbox Oil Filter (P/N 111013)

1 x every 3 Months

Remove, clean and replace the Magnetic Drain Plug

1 x every Year

The first oil change should be performed after the first month of operation since new units often contain metal contaminates and contaminates caused by initial break-in.

3-2

Varco Systems

Lubrication

Transmission Recommended gear oils Ambient Temperature Range -6˚ to 16˚ C

7˚ to 30˚ C

Above 21˚ C

(20˚ to 60˚ F)

(45˚ to 85˚ F)

(Above 70˚ F)

Alpha LS-68

Alpha LS-150

Alpha LS-320

Manufacturer Castrol

NL Gear 68

NL Gear 150

NL Gear 320

Exxon

Spartan EP68

Spartan EP150

Spartan EP320

Gulf

EP Lube HD68

EP Lube HD150

EP Lube HD320

Mobil

MobilGear 626

MobilGear 629

MobilGear 632

Chevron

Omala 68

Omala 150

Omala 320

Statoil

Loadway EP68

Loadway EP150

Loadway EP320

Texaco

Meropa 68

Meropa 150

Meropa 320

Total

Carter EP 68

Carter EP 150

Carter EP 320

Union

Extra Duty NL2EP

Extra Duty NL4EP

Extra Duty NL6EP

2EP

4EP

6EP

68

150

320

Shell

3

Viscosity Index AGMA ISO Viscosity Grade

!

i

Oils of insufficient viscosity can damage gears by allowing metal to metal contact.

For minimum temperatures below 20°F, the TDS must be warmed up by rotating at a very light load (less than 200 Amps) and at very slow speeds (less than 50 rpm) until the oil temperature climbs above 20°F. If drilling conditions dictate oil temperatures below 20°F, consult Varco service center. If the oil temperature rises above 200°F, Varco recommends shutting down or reducing drilling loads to stabilize the oil temperature below 200°F If drilling conditions dictate oil temperatures above 200°F, consult Varco service center.

TDS-11SA

3-3

Lubrication

Gearbox lubrication

Gearbox Oil “Drain”

3 Cork Ball (Level Indicator)

Sight Glass

i Gear Oil Sight Gauge Check with Top Drive “OFF”

i Gearbox Oil Fill Clean area before removing plug, then use a 1 3/8 inch, 12 point socket to remove plug

“Pop-up” Dirt Alarm

Procedure

Gear Oil Filter

Yearly Magnetic Drain Plug Remove and clean contamination

3-4

Check oil level, prior to adding oil (do not mistake the tan colored foam for the dark brown oil) Ensure that the unit is turned OFF The area must be wiped clean prior to adding gearbox oil Recheck oil level and replace the plug after adding oil Run the unit and recheck the oil level (not foam level), after the unit has been running and the transmission oil is warm

Varco Systems

Lubrication

Hydraulic system Precautions Release all hydraulic oil pressure by bleeding accumulators before disconnecting hydraulic lines. Turn the counterbalance valve to shutdown mode to bleed the hydraulic system. Hydraulic oil under pressure can penetrate skin and cause serious injury.

Before opening the hydraulic system, thoroughly clean work area, and maintain system cleanliness by promptly capping all disconnected lines. Dirt is extremely harmful to hydraulic system components and can cause equipment failure and subsequent injury to personnel.

!

!

Use care when handling components to prevent nicking close tolerance finishes.

Use care to prevent contamination from entering the hydraulic system during maintenance activities.

Lubrication schedule Description Perform Hydraulic System Oil Analysis Replace the Hydraulic Fluid Replace the Hydraulic System Filter (P/N 114416-1)

TDS-11SA

Frequency 1 x every 6 Months 1 x Year, or Earlier Based on Oil Analysis 1 x every 3 Months

3-5

3

Lubrication

Hydraulic system Recommended hydraulic fluid Oil Temperature Range -15˚ to 75˚ C

-10˚ to 85˚ C

(5˚ to 167˚ F)

(14˚ to 185˚ F)

Hyspin AWS-32

Hyspin AWS-46

AW Hyd oil 32

AW Hyd oil 46

Nuto H32

Nuto H46

Manufacturer Castrol Chevron Exxon

Harmony 32AW

Harmony 46AW

Mobil

DTE 24

DTE 25

Shell

Tellus 32

Tellus 46

Statoil

Hydraway HMA 32

Hydraway HMA 46

Texaco

Gulf

3

Rando oil HD32

Rando oil HD46

Total

Azolla ZS 32

Azolla ZS 46

Union

Unax AW32

Unax AW46

32

46

Viscosity Index ISO Viscosity Grade

3-6

Varco Systems

Lubrication

Hydraulic system Hydraulic lubrication Procedure The area must be clean prior to adding hydraulic fluid Remove dust plug from the male quick disconnect at the TDS-11SA hydraulic oil fill Remove dust plug from the female quick disconnect on the lubrication kit and connect it to the male fitting Pump fluid until the level reaches the middle of the sight glass as shown After adding fluid, replace the dust plugs

Cork Ball (Level Indicator)

3 Red “Pop-up” Dirt Alarm

Sight Glass Hydraulic Oil Sight Gauge


Hydraulic Oil Fill Male Quick Disconnect Dust Plug

Hydraulic Oil Fill

Female Quick Disconnect

Hydraulic Lubrication Kit 55 gal Drum Varco P/N 92643 Hydraulic Oil Drain

TDS-11SA

3-7

Lubrication

Motors Varco recommends that lubrication of all AC motors should be done by the rig electrician.

Lubrication schedule Description

3

No. of Points

Frequency

Type

Lubricate the AC Drilling Motor

4

1 x every 3 Months

Motor Grease

Lubricate the Blower Motor

4

1 x every 3 Months

Motor Grease

Lubricate the Hydraulic Pump Motor

2

1 x every 3 Months

Motor Grease

Recommended motor grease Motor Grease

Manufacturer Chevron

3-8

Black Pearl EP2 (Do Not Substitute)

Varco Systems

Lubrication

Motors Motor lubrication

i Apply motor grease to designated grease fittings with hand grease gun

3 Months AC Blower Motor (2) 3 pumps (2 grease fittings each motor)

Grease Fittings Grease Fitting 1/8 inch Varco P/N 53201

! Pipe Plug 1/8 inch (remove and reinstall after lubricating)

3

As Viewed From Below

3 Months AC Drilling Motor (2) 5 pumps (2 grease fittings each motor)

3 Months Hydraulic Pump AC Motor 3 pumps (2 grease fittings)

Procedure Remove the lubrication point plug Install a grease fitting Grease with a hand pump only Re-install the plug

TDS-11SA

3-9

Lubrication

General purpose lubrication

!

!

3

The lubrication intervals described in this manual are based on lubricant supplier recommendations. Severe conditions such as extreme loads or temperature, corrosive atmosphere, etc., may require more frequent lubrication.

Worn bushings, binding parts, rust accumulations, and other abnormal conditions indicate more frequent lubrication is necessary. Be careful not to over lubricate parts. For example, too much grease forced into a fitting can pop out a bearing seal. Over lubrication can also affect safety since over lubricated parts can drip, creating a potential slipping hazard for personnel.

Lubrication schedule Description

No. of Points

Frequency

Type

Washpipe Assembly

1

Daily

General Purpose Grease

Upper Bonnet Seal

1

Weekly


Bail Pins

2

Weekly


Rotating Link Adapter Gear

–

Weekly


Rotating Link Adapter

2

Weekly


IBOP Actuator Yoke, Cylinder Pins

5

Daily


IBOP Actuator Cranks

2

Daily


Upper IBOP Valve

1

Weekly


Stabilizer Bushing

4

Daily


Clamp Cylinder Gate

2

Daily


Carriage Assembly

8

Weekly


Torque Arrestor at Clamp Cylinder

4

Weekly


Wireline Adapter

2

Weekly


Elevator Link Eyes

4

Weekly

Pipe Dope

3-10

Varco Systems

Lubrication

General purpose lubrication Recommended lubricants Ambient Temperature Range Below -20˚ C

Above -20˚ C

(Below -4˚ F)

(Above -4˚ F)

N/R

MP Grease

Avi-Motive W

Avi-Motive

Manufacturer Castrol Chevron

Lidok EP1

Lidok EP2

Gulf Crown EP31

Gulf Crown EP32

Mobil

Mobilux EP1

Mobilux EP2

Shell

Alvania EP1

Alvania EP2

Statoil

Uniway EP1N

Uniway EP2N

Texaco

Multifak EP1

Multifak EP2

Total

Multis EP1

Multis EP2

Union

Unoba EP1

Unoba EP2

1

2

Exxon Gulf

3

Viscosity Index NGLI

TDS-11SA

3-11

Lubrication

General purpose lubrication General lubrication

i Apply general purpose grease to designated grease fittings with grease gun. Use a brush when greasing other parts.

3

Daily Wash Pipe Assembly Apply one pump at beginning of tour

Weekly

Weekly

Bail Pins (2) Two pumps each side

Upper Bonnet Seal One pump Use Hand Pump Only

Weekly Rotating Link Adapter Gear

3-12

Weekly Rotating Link Adapter Three pumps each

Varco Systems

Lubrication


i Apply general purpose grease to designated grease fittings with grease gun. Use a brush when greasing other parts.

Daily

3

IBOP Actuator Cylinder Pins One pump each (if equipped)

Daily IBOP Actuator Yoke One pump (if equipped)

Daily IBOP Actuator Yoke One pump each side

Daily

Weekly

IBOP Actuator Cranks One pump each side

Upper IBOP Valve Remove 1/4" NPT plug, install grease fitting Apply ten pumps

Weekly Torque Arrestor Tubes

!

Replace plug before operating

Daily Clamp Cylinder Gate One pump each side

Daily Stabilizer Bushing One pump each

Weekly Elevator Link Eyes (4)

Pipe Dope

Daily Stabilizer Bushing One pump each side

TDS-11SA

3-13

Lubrication


i Apply general purpose grease to designated grease fittings with grease gun

3

Weekly Rollers One pump each (if equipped)

Weekly Rollers One pump each (if equipped)

3-14

Varco Systems

Lubrication


i Apply general purpose grease to designated grease fittings with grease gun

3

Weekly Wireline Adapter One pump each

TDS-11SA

3-15

TDS Training Manual



Installation, Commissioning and Decommissioning

AC Electrical

Installation, Commissioning and Decommissioning Illustrated index ................................................. 4-3 Preinstallation .................................................... 4-4 Preparation .................................................................... 4-4

1

Installing the crown padeye and hang-off link ............... 4-5 Locating the control house ............................................ 4-6 Installing power cables .................................................. 4-7 Earthing the control house (land rigs) ............................ 4-8

2

Checklist ........................................................................ 4-9 Installation .......................................................... 4-10 Moving the TDS-11SA to the drill floor .......................... 4-10

3

Removing the TDS-11SA from the skid ......................... 4-11 Disengaging the lower carriage latch ............................ 4-12 Moving guide beam sections ......................................... 4-13 Present and hook the first guide beam section ............. 4-14

4

Hoist the first guide beam section ................................. 4-15 Stab and pin the first guide beam section ..................... 4-16 Completing guide beam installation............................... 4-17 Hanging the guide beam ............................................... 4-18

5

Installing the main tieback ............................................. 4-19 Installing the intermediate restraints .............................. 4-20 Disengaging the upper carriage latch ............................ 4-21 Installing derrick termination .......................................... 4-22

6

Installing the service loop to the derrick ........................ 4-23 Installing the driller’s console......................................... 4-24 Installing the driller’s console cabling ............................ 4-25 Motor rotation checkout procedure ................................ 4-26

7

Installing the pipe elevator and links.............................. 4-27 Installing the counterbalance ......................................... 4-28 Commissioning ................................................... 4-29 Checkout procedure ...................................................... 4-29

8

Hydraulic system checkout procedure........................... 4-30 Electrical system checkout procedure ........................... 4-31 Mechanical checkout procedure .................................... 4-32 Adjusting the link tilt ....................................................... 4-33 Removing and installing the saver sub .......................... 4-34 TDS-11SA

9



Decommissioning ............................................... 4-35 Securing the TDS-9/11SA for rig-down ............................ 4-35

1

Removing and storing the electrical cables and service loops .......................................................... 4-36 Setting the latches and locking the bail ......................... 4-37 Disconnecting the guide beam ...................................... 4-38

2

Unpinning each guide beam section ............................. 4-39 Lowering each guide beam section ............................... 4-40 Returning the TDS-9/11SA to the skid ............................. 4-41 Removing the TDS-9/11SA from the drill floor ................. 4-42

3

Long term storage procedures ...................................... 4-43

44

5

6

7

8

9

4-2

Varco Varco Systems Systems


Illustrated index Crown Padeye and Hang-off Link Page 4-5

Counterbalance Page 4-27

Guide Beam Page 4-13

Rotary Hose

Derrick Termination Page 4-22

4

Intermediate Restraints Page 4-20

Service Loop Page 4-23

Varco Driller’s Console (VDC) Page 4-24 Control Cable with Connectors Page 4-25

Main Tieback Page 4-19

Unitized Variable Frequency Inverter and Varco Control Panel (House) Page 4-6 Local Power Supply Diesel/Alternator Set/AC Bus AC Cables Page 4-7 AC Power and Control Cables Page 4-7

TDS-11SA

4-3


Preinstallation Preparation The TDS-11SA interfaces with the rig’s hoisting system and electrical power system. Derrick and electrical system modifications are required when installing the TDS-11SA on existing rigs. For derricks that handle triples, the required top drive travel is about 100 ft. compared to about 75 ft. when using a Kelly. It is generally necessary to replace the regular rotary hose (which is normally 60 ft. long) with a 75 ft. hose, and extend the standpipe height to approximately 73 ft. Although many rig floor layouts are possible, installing the guide beam on the drawworks side of the derrick, or mast, and opposite the V-door is an ideal arrangement for handling tubulars from the Vdoor. The location of the electrical loop and mud hose is an important installation consideration for pipe setback purposes, to ensure proper clearance and to help prevent wear to the service loop and mud hose. Other important installation considerations include the location of:

4

❏ The casing stabbing board ❏ Floor and derrick accessories ❏ Drawworks fastline ❏ Guide beam hang-off bracket ❏ Torque reaction beam ❏ Mud stand pipe extension ❏ Varco drillers console location ❏ Variable frequency inverter/Varco control panel location Derrick height is a critical interface requirement. Handling a 93 ft. stand typically requires 97 ft., resulting in an overall height from the floor to the top of the traveling block of at least 126 ft. Derrick Clear Working Height

Derrick Crown Clearance

152 ft.

25 ft.

147 ft.

20 ft.

142 ft.

15 ft.

136 ft.

9 ft.

Each rig has different crown clearance for efficient tripping. Installing the TDS-11SA with existing traveling equipment may require an adapter–further reducing crown clearance.

4-4

Varco Systems


Preinstallation Installing the crown padeye and hang-off link Recommended installations Dimension

Description

36.8 inches

Standard height configuration (adjustable)

33.8 inches

Varco’s IDS Top Drive requirements

30.0 inches

Original setback for TDS-9S/11S

Crown

Crown Padeye Weld according to table above

4 Shackle

See Table

Hang-off Link

C L Well

TDS-11SA

4-5


Preinstallation Locating the control house

Drawworks

Recommended Area for Control House Location

C L Well

4

V-Door Ramp TDS-11SA

Varco Driller’s Console

9,500 lb (4300 kg) Control House

C L Well

Control House

Recommendations 91 in. (2310 mm)

Position the control house off-driller’s side or behind the drawworks Position as close to derrick plate as possible to minimize cable lengths Ensure a safe distance from direct sources of heat (i.e. diesel engines, general exhausts)

140 in. (3560 mm)

90 in. (2290 mm)

Location of the control house must ensure accessibility from all sides Do not expose the control house to H2S

4-6

Varco Systems


Preinstallation Installing power cables COM POS ITE

CON NEC TOR

AUX . PO WE RC ON NEC TOR

Ground Lug to Top Drive

SER IAL CON NEC TOR

Plug Panel

UI NC OM ING 575 VA C V IN CO MIN G5 75V AC WI NC OM ING 575 VA C

Incoming Power Cables 575VAC to main circuit breaker (3 Places)

4

UO UT GO ING 575 VA C VO UT GO ING 575 VA C WO UT GO ING 575 VA C

Outgoing Power Cables to Top Drive (3 or 6 Places)

Varco Control House

Rain Cover Plug Panel

Procedure Clean all connector contacts Connect the power cables with the isolation circuit breaker turned OFF Connect cables in accordance with the electrical schematic provided in the Technical Drawings book Lockwire all connector nuts Earth the control house with the Varco Ground Rod Kit (See page 4-8)

TDS-11SA

4-7


Preinstallation Earthing the control house (land rigs)

Copper Plated Steel Rod Cable Clamp

Cable Lug Copper Wire 10 ft

4

The control house must be properly grounded to prevent injury to personnel

Procedure Insert the grounding rod into the soil (the rod must be in contact with ground water) Connect the rod to the control house (connection must be clean)

i

Ground Rod Kit P/N 116004

Grounding Points Located at opposite corners of the house floor

For offshore installations the control house must be grounded to the ground point on the rig structure

4-8

Varco Systems


Preinstallation Checklist The following assumes that all pre-installation planning and rig-up is complete prior to installation of the guide beam assembly and TDS-11SA. This includes: ❏ Make sure the derrick/mast is vertical, with the block over the center of the rotary table. ❏ Derrick/mast modifications are completed (if required) and the guide bean support bracket and torque reaction beam are installed and inspected to conform to Varco specifications as detailed in FIP00003. ❏ The service loop bracket is installed in the derrick/mast. ❏ The control panel and frequency drive are installed. ❏ Rigging of tong lines, etc. is inspected to ensure that they will not foul with the TDS-11SA.

4

❏ The hook or adaptor becket is installed. The hook should open toward the drawworks.

TDS-11SA

4-9


Installation Moving the TDS-9/11SA to the drill floor Procedure Ensure the safety of all personnel Locate the Top Drive at the bottom of the V-Door ramp Ensure that the bail lock assembly is installed Attach a lifting sling to the bail Attach backup lines to the skid Hoist the Top Drive and skid to the drill floor

! The Bail Lock Assembly must be installed Tube (P/N 113498) U-Bolt (P/N 113497) 2x 3/4" nuts

4 TDS-11SA on Skid

Lifting Block Hoist using the drawwork

Lifting Sling Attached to bail for hoisting

Lifting Sling

! Be sure that the Top Drive is pinned to the skid prior to hoisting it to the drill floor

3 TDS-11SA In position prior to lifting from skid

Drill Floor

2

30,000 lb (13600 kg) TDS-11SA on Skid Backup Line V-Door Ramp

1

4-10

Varco Systems


Installation Removing the TDS-9/11SA from the skid

! The Bail Lock Assembly must be installed. Remove only after installation is complete.

27,000 lb (12300 kg) TDS-11SA

View of Carriage from Rear

4 Pin

1 Latches Both sides engaged for hoisting

TDS-11SA

Pin

3

2

Hoist the TDS-11SA from the skid using the drawwork

Drill Floor

Procedure Ensure the Top Drive does not contact the rig

TDS-11SA

Lock Pin Remove prior to hoisting from skid

Ensure that both carriage latches are engaged for hoisting from the skid Ensure that the bail lock assembly is installed Engage the hook with the bail Remove the lock pin Hoist the Top Drive from the skid

4-11


Installation Disengaging the lower carriage latch

Guide Beam Top Section

Carriage

Guide Beam Wings

2

4

TDS-11SA Lifted from the skid 27,000 lb (12300 kg)

! After hoisting the TDS-11SA from the skid, disengage the Lower Carriage Latch and pin it as shown.

Pin

1 Upper Latch Engaged

Lower Latch Disengaged

As viewed from rear of Carriage

TDS-11SA In position to disengage lower latch

Pin

3 Drill Floor

Skid Remove from drill floor after hoisting the TDS-11SA 3,000 lb (1360 kg)

Procedure Ensure that the lower carriage latch is disengaged Ensure that the upper carriage latch is engaged Hoist the Top Drive Ensure the Top Drive or the guide beam does not contact the rig Remove the skid from the drill floor

4-12

Varco Systems


Installation Moving guide beam sections

Procedure Locate the guide beam sections near the V-Door Attach lifting slings to the lifting eyes of the first guide beam section to be hoisted Hoist the guide beam section to the drill floor

2,100 lb (950 kg) 20 ft. Guide Beam Section

4

Sling Ensure the Top Drive does not contact the rig

TDS-11SA

Guide Beam Section

3

2

Guide Beam Section Hoist to the drill floor

Lifting Eyes Attach slings for hoisting

Drill Floor

1 Guide Beam Sections Prior to Installation

TDS-11SA

4-13


Installation Present and hook the first guide beam section Guide Beam Top Section

1

2

Present

Match

Grease the bores on both joint halves Guide Surface Radius locks joint from unhooking at 8° rotation Hook Pin

Grease the bores on both joint halves

4 3

4

Engage

Hook

Ensure the Top Drive does not contact the rig

Present and Hook the first guide beam section

Guide Beam Section Hooked Drill Floor

4-14

Hook Pin In fully engaged position

Hook Pin Saddle

Procedure Locate the guide beam to be hooked under the top guide beam section Grease the bores on both joint halves Align the guide surface with the hook pin as shown Lower the top guide beam to match and engage the hook pin to the hook pin saddle Hoist the top guide beam to fully engage the hook pin Manually stabilize the back end of the guide beam

Varco Systems


Installation Hoist the first guide beam section

Guide Beam Top Section Hoist

Hook Pin

First Guide Beam Section Initially hoisted by the hook pin

4

Bar and Radius Locates pin bores for easy insertion of pins Hoist Using the drawwork

Ensure the Top Drive does not contact the rig Drill Floor

TDS-11SA

4-15


Installation Stab and pin the first guide beam section


1 Stab the guide beam joints together

Lynch Pin

2 Joint Pin Install after stabbing

4

4

3

Secure with the lynch pin

Retainer Pin Apply grease and insert

Stab and Pin the guide beam joint

Block as Required Drill Floor

4-16


Procedure Lower the guide beam to drill floor and stab the guide beam joints together Block the guide beam in a vertical position if required Install the joint pin Grease and install the retainer pin Secure the retainer pin with the lynch pin as shown

Varco Systems


Installation Completing guide beam installation


4

Repeat previous steps until Guide Beam Installation is complete

Procedure

Drill Floor

TDS-11SA

Move the next guide beam section to the drill floor Present the end of the guide beam to be hooked Ensure that the bores on both joint halves have been greased Engage the hook pin saddle around the hook pin Hoist the guide beam with the drawwork Lower the guide beam to the drill floor and stab the guide beam joints together Install the joint pin Install the retainer pin Secure the pins with the lynch pin

4-17


Installation Hanging the guide beam

i

Crown Pin the Guide Beam to the hang-off link Ensure the Top Drive does not contact the rig

Note: Use these pin positions if crown padeye installation is based on: 36.8 in. (935 mm) Standard adjustable height configuration

Crown Padeye

33.8 in. (859 mm) Varco’s IDS Top Drive requirements

! Ensure that the Shackle is pinned and the cotter pin is in place

30.0 in. (762 mm) Original TDS-9S/11S or if plate extension (36.8 in.) needs to be cut off due to interference.

Hang-off Link

4 Pin

Safety Pin


C L

C L


Well

Procedure Drill Floor

Floor Clearance

+.5 ft 7 ft. -0 ft +150 mm (2100 mm -0 mm )

4-18

Using the drawwork, hoist the top guide beam to the hang-off link Ensure that the shackle is pinned and it’s cotter pin is in place Pin the guide beam to the hang-off link in the appropriate position Check for 7 ft clearance from bottom of guide beam to the drill floor Secure the pin to the hang-off link with the nut and safety pin

Varco Systems


Installation Installing the main tieback Procedure Guide Beam Bottom Section

Check for Top Drive mainshaft alignment over well center Install the main spreader beam at the appropriate distance from well center Install the tieback plate and tieback link Check for Top Drive mainshaft alignment over well center Torque and lock wire all bolts Tieback Link Guide Beam Assembled

Tieback Plate

4 Main Spreader Beam

Apply Anti-seize Compound Typical Auxiliary Spreader Beam

Main Tieback and Spreader Beam Install after guide beam is assembled Mast Leg Drill Floor

Recommended Installations See Table

TDS-11SA

Dimension

Description

36.8 inches

Standard height configuration (adjustable)

C L

33.8 inches

Varco’s IDS Top Drive requirements

Well

30.0 inches

Original setback for TDS-9S/11S

4-19


Installation Installing the intermediate restraints Apply Anti-seize Compound Typical

Intermediate Tieback Plate 2 Places

Girt

Padeye 2 places if greater than 3 inches from girt

3 inches

4 105 Feet

i Padeye 1 place if less than 3 inches from girt

Double nut Space between girt and guide beam

Pin and Cotter Pin Guide Beam Assembled 55 Feet

Procedure

Drill Floor

4-20

Intermediate tiebacks are installed on girts closest to 55 feet and 105 feet above the drill floor Weld two padeyes to the guide beam if the space between the girt and the guide beam is greater than 3 inches Weld a single centered padeye if the space between the girt and the guide beam is less than 3 inches Install intermediate tieback plates as required Torque and lock wire all bolts Secure all pins with cotter pins

Varco Systems


Installation Disengaging the upper carriage latch Guide Beam Top Section

2

Carriage

Remove the Bail Lock Assembly Guide Beam Wings

3

!

Slowly lower the TDS-11SA

After hanging the guide beam, installing the tiebacks, and prior to lowering the Top Drive, disengage the Upper Carriage Latch and pin it as shown.

Pin

1 Upper Latch Disengaged

Lower Latch Disengaged

As viewed from rear of Carriage Pin

Procedure

Drill Floor

Bail Lock Assembly Remove

TDS-11SA

Ensure that the lower carriage latch is disengaged Ensure that the upper carriage latch is disengaged Remove the bail lock assembly Ensure the mast is clear of all obstructions and slowly run the Top Drive down the guide beam

4-21

4


Installation Installing derrick termination Hoist Line Attachment Point

Derrick/ Mast Leg

Derrick Leg Plate Hoist Line Attachment Points

Service Loop Brackets

4 Mount the Derrick Termination Plate as recommended

83 ft from drill floor

Recommendations Mount on the side of the derrick adjacent to the service loop brackets on the TDS-11SA Mount as far as practical from well center, to maintain a 36 inch minimum bend radius

Drill Floor

!

Maintaining a larger radius increases loop life and reduces damage due to “pinching” Location must ensure that the loops do not catch under the guide beam during operations and provide clearance for tong lines, the stabbing board, tugger lines, etc

4-22

Varco Systems


Installation Installing the service loop to the derrick Hoist

Derrick Termination Plate

1,000 lb (450 kg) Each Service Loop

Sling

4

! Avoid damage to the service loops by using care when dragging it near sharp edges and allow room for passing under the V-door

TDS Service Loop

Lifting Eyes Do not remove Derrick Service Loop

!

Recommendations

Avoid damage to the service loops by maintaining a 36 inch minimum bend radius Service Loop and Storage Tub 3,600 lb (1600 kg)

TDS-11SA

Do not unpack the service loops until they are ready to hang Use a sling attached to the lifting eyes to hoist each service loop Use the swivel at the tugger line attachment to allow each service loop to uncoil without twisting

4-23


Installation

Drawworks

Installing the driller’s console

TDS-11SA

V-Door Ramp

4

Recommended Area for Varco Driller’s Console Location

!

UE RQ TO

P IBO

Customers who choose to use control systems that are not manufactured by Varco should be aware that Varco systems are specifically designed with operational interlocks and safety devices to prevent possible injury to personnel and damage to the system. Other control systems must meet Varco requirements outlined in the QA 00098 document. Varco highly recommends the use of its system, as it is specifically made for use with the TDS-11SA.

E AK BR

Y NC GE ER OP EM ST

ER DL AN EH PIP

Recommendations

Pigtail Cable Connect to control house

4-24

Mount within easy reach and in plain view of the driller while the drawworks brake and clutches are being operated Location must ensure that the gauges are easily seen by the driller during drilling operations Location must be visible and readable at night

Varco Systems


Installation Installing the driller’s console cabling COM POS ITE

CON NEC TOR

AUX . PO WE RC ON NEC TOR

SER IAL CON NEC TOR

Profibus Serial Link to Driller’s Console

UI NC OM ING 575 VA C V IN CO MIN G5 75V AC

Plug Panel WI NC OM ING 575 VA C

4

UO UT GO ING 575 VA C VO UT GO ING 575 VA C WO UT GO ING 575 VA C

Varco Control House

Rain Cover Plug Panel

Recommendations Ensure that the Varco Driller’s Console is properly located Connect the power cables with the isolation circuit breaker turned OFF Connect cables in accordance with the electrical schematic provided in the Technical Drawings book Tighten connector nuts Lockwire connector nuts to prevent loosening

TDS-11SA

4-25


Installation Motor rotation checkout procedure Direction of Rotation Counterclockwise

Procedure Direction of Rotation Clockwise

Assign the Top Drive and inverter by selecting FORWARD or REVERSE on the driller’s console Check the rotation direction of the cooling and oil pump motors Rotate the drill stem using the THROTTLE on the driller’s console and observe proper operation Cooling Motors 2 Places

4 TO

RQ

UE

RQ

TO X

MA

OP

IB P IBOSED O CL

Y NC GE ER OP M T E S

UE

RQ

0

ILL

TO

DR D

SE

P LO IBO C

F

OF

N PE

O

IVE DRULT FA

AR

RW

FO

X

MA

SE

R

VE

RE

0

Throttle

Direction of Rotation Counterclockwise

Forward/Reverse Control Varco Driller’s Console TO

IB

BR

PIP

EH

AN

DL

AK

E

RQ

UE

Oil Pump Motor

OP

Y NC

GE ER OP EM ST

ER

Drill Stem Direction of Rotation

Reverse

Forward

4-26

Varco Systems


Installation Installing the pipe elevator and links Catch Link Bolt

Rear

Motor Guard

Catch Link Pin

600-2,400 lb (270-1100 kg) Elevator Link

AT

LO

ER T F DLK TIL ANLIN

EH PIAPTE IGHT

T RO

Catch Link

R

FT

LE

4

ILT KT LT LINOFF TI

H NC LL RELD DRI E WHO QUH & R TOPUS

Front Pipehandler Rotate Switch Link Tilt


Link UE RQ TO

OP IB E AK BR

Y NC

GE ER OP EM ST

ER DL AN EH PIP

Clevis Pin

Procedure Using the Varco Driller’s Console, rotate the pipehandler 90˚ (positioning the catch link under the front of the motor guard) Lubricate the elevator link eyes with pipe dope Hoist the elevator link onto the rotating link adapter (the small link eye at the bottom) Secure the catch link with the pin and bolt Secure the elevator link to the link tilt Rotate the pipehandler 180˚ and install the other elevator link Install the pipe elevator in accordance with the pipe elevator manual

TDS-11SA

4-27


Installation Installing the counterbalance Procedure Refer to Setting up the circuits in the Hydraulic section of this manual for initial system set up Install the pear links to the ears on the hook Turn on the Top Drive power Rotate the counterbalance mode valve from the RUN position to the RIG-UP position When the cylinders reach the end of stroke, slide the cylinder clevis over the pear link and install the cylinder clevis pin After securing the counterbalance cylinder to the pear link, rotate the counterbalance mode valve to the RUN position Adjust PCC clockwise to raise the pressure at test port CB until the bail just begins to lift off of the block Reduce the pressure slowly (25 psi) to allow pressure to stabilize

4

Hook

Pear Link 2 Places

Cylinder Clevis 2 Places

Cylinder Clevis Pin 2 Places Counterbalance Cylinder 2 Places (8.5 inch stroke)

Rig-up/Run/ Shutdown Valve Shown in RIG-UP position (switch to RUN after the counterbalance is installed)

Bail

RIG-UP

SHUTDOWN

RUN

CO

UN

NC

EM

P

ALA

-U

RB

IG

TE

R

4-28

S

H

U

N

T

U

D

R

O

W

N

COUNTERBALANCE MODE

OD

E

Hydraulic Manifold

Varco Systems


Commissioning Checkout procedure Initial Rig-Up Pre-charge all accumulators (See the Hydraulics System section of this manual) Adjust the hydraulic system Bleed the air from the hydraulic system Constantly monitor the hydraulic fluid level, and never allow the level to fall below the middle of the sight glass (system power OFF)


Checkout Procedure Lubricate all grease points (See Lubrication) Check for loose or missing connectors Lockwire all connector nuts Check for interference along entire mast Remove exhaust covers from AC drilling motors Check blower inlets and outlets for blockage Set the air conditioner to 75˚F (27˚C) Turn on the main breaker


4

Air Inlet Between motor and brake housing, 2 Places

TOP DRIVE

INS T WH ALL UN EN ST IT IS OR ED

VARCO

Exhaust Cover 4 Places

Exhaust Outlet Through louvers at bottom of AC drilling motors, 6 Places

TDS-11SA

4-29


Commissioning Hydraulic system checkout procedure Checking hydraulic fluid level


Red “Pop-up” Dirt Alarm Sight Glass

4

Hydraulic Oil Sight Gauge Hydraulic Oil Filter

Procedure Ensure that the pipehandler clamp cylinder is unclamped, the counterbalance cylinders are connected to the hook, the bail is resting in the hook, and the system power is OFF Check to see that the hydrulic fluid level is at the middle of the sight glass If the fluid is low, add hydraulic fluid (see the Lubrication and Maintenance section of this manual Check the red “pop-up” alarm on the hydraulic filter for contamination Replace the filter (P/N 114416-1) if the indicator has popped up Use care to prevent contamination from entering the hydraulic system during maintenance activities

4-30

Varco Systems


Commissioning Electrical system checkout procedure

Emergency Stop

Latch 9 Places

M

RP

TO

RQ

UE

UE

RQ

TO MA

P IBOOP

Y NC GE ER OP EM ST

IB SED O CL

E AK BRRAKE

B N O

ER

DL

AN

H IPE

P RO

PR

S OILLOS S ES

P -U IT KE LIM MAENT RR CU OR OT P L M EM X RIL RT MA DOVE

LE

TE RIG

KT

ILT

FL

OA

T

P LO IBO C

E E AK AK BR TO BRON AU

FT

ILT

KT LINOFF

T

ILT

O

DR

SE OF

N PE IVE DRULT FA

RE

VE

RS

F

FO

RW

AR

ILL

TO

RQ

UE

4

Torque Meter

D MA

E

X

0

F OF

CH EN ILL WR LD DR UE HO RQ H & TOPUS

0

R YD MP H LA ECK U TO A M CH AR AL NCE ILE

AU

LIC

R WE PO N O

/

S

SP DR

TA

LIN HT

0

RPM Meter

X

IN

TO

RQ

BL UE

OW

E

O RL

SS

ILL

Procedure All personnel must stand clear All personnel operating the Top Drive should be trained in rig safety and tool operation Operate each control on the Varco driller’s console (See Varco FIP00003) Check for alarm conditions and resolve any alarms at this time (See Varco FIP00003) Check all connectors for tightness and lockwire Check operation of meters Check operation of emergency stop Check the latches on the driller’s console for tightness

Pigtail Cable Connected to control house

TDS-11SA

4-31


Commissioning Mechanical checkout procedure Checking gearbox oil level Procedure With the drive motors and hydraulic system off, check to see that the oil level (identified by a floating cork ball) is at the middle of the glass located on the lube pump adapter plate mounted on the side of the gearbox Always check the oil level, not foam level (oil is dark brown, foam is tan) after the unit has been running and the transmission oil is warm If the oil level is low, add gear oil (see the Lubrication and Maintenance section of this manual Check the red “pop-up” alarm on the gear oil filter for contamination Replace the filter (P/N 111013-1) if the indicator has popped up

4 Cork Ball (Level Indicator)

Sight Glass

i

i

Gear Oil Sight Gauge Check with Top Drive “OFF”

Gearbox Oil Fill Clean area before removing plug, then use a 1 3/8 inch, 12 point socket to remove plug

“Pop-up” Dirt Alarm

Gear Oil Filter

4-32

Varco Systems


Commissioning Adjusting the link tilt

i

See the PH-50 Pipehandler section of this manual for inspection and disassembly/ assembly details

Jam Nut Adjust the derrickman position with the adjusting screw and lock in position with the jam nut Link Tilt Crank Assembly

Pin

4 26 inches (660 mm) Typical

Clamp

i Mousehole Position Cable Pull “up” or “down” to set mousehole position

3-4 inches (76-102 mm)

i Link Mousehole Position Derrickman’s Position Link clamps should be adjusted so that the elevator does not hit the diving board in this position

TDS-11SA

Drill Down Position Bottom of elevator should be above the bottom of the stabbing guide

Elevator Well Center Float Position

4-33


Commissioning Removing and installing the saver sub Torque values for drill stem components Component

I.D.

Connection

O. D.

Torque

Mainshaft to Upper IBOP Valve

3 in.

6 5/8 API Reg.

7 3/4 in.

52,000 ft-lb

Upper IBOP Valve to Lower IBOP Valve

3 in.

6 5/8 API Reg.

7 3/8 in.

48,000 ft-lb

Lower IBOP Valve to Saver Sub

3 in.

6 5/8 API Reg.

7 3/8 in.

46,000 ft-lb

Crossover Sub to Lower IBOP Valve

3 in.

6 5/8 API Reg.

7 3/8 in.

46,000 ft-lb

Crossover Sub

Tugger Line

Cylinder Pins Remove Torque Arrestor

4

V A R C O P H 5

Upper IBOP

i See the Technical Drawing Package for configuration details

0

IBOP Crank and Shell Remove CO

R VA

Lower IBOP

Swing Clear

Short Saver Sub For use with lower IBOP

4-34

Long Saver Sub For use without lower IBOP

Gate Pin Remove one

i Use Tongs for torquing the components together

Varco Systems


Decommissioning Securing the TDS-9/11SA for rig-down Procedure Lower the Top Drive to the drill floor Remove the mud hose, drill pipe elevator and links Power may be needed to turn rotating head into position for removing the links Locate the RIG-UP/RUN/SHUTDOWN valve on the hydraulic manifold With the hydraulic power ON select the “RIG-UP” position and remove the extended counterbalance cylinders from the hook ears Select the “SHUTDOWN” position and turn off the Top Drive Isolate and lock out ALL power to the Varco control house

4

O

W

N

Hydraulic Manifold

RU

S

H

U

T

D

N

-U

IG

R P

E C N LA BA R TE N U O C E D O M

TDS-11SA Lower to the drill floor

Rig-up/Run/ Shutdown Valve Rotate from RIG-UP to SHUTDOWN for Top Drive rig-down

RIG-UP

SHUTDOWN

RUN

Drill Floor

COUNTERBALANCE MODE

TDS-11SA

4-35


Decommissioning Removing and storing the electrical cables and service loops Lower

Derrick Termination Plate

1,000 lb (450 kg) Each Service Loop

Sling

4

! Avoid damage to the service loops by using care when dragging it near sharp edges and allow room for passing under the V-door

Derrick Service Loop

TDS Service Loop Lifting Eyes Do not remove

Procedure

! Avoid damage to the service loops by maintaining a 36 inch minimum bend radius Service Loop and Storage Tub 3,600 lb (1600 kg)

4-36

Position the service loop tubs for convenient loading of the service loops Disconnect the derrick service loop from the derrick termination plate and the control house Disconnect jumper cables (if installed) Cap all connectors and lower the derrick service loop into a service loop tub Use a sling attached to the lifting eyes to lower each service loop and a swivel at the tugger line attachment to allow each service loop to coil without twisting Disconnect the Top Drive service loop and repeat the above procedure Remove the service loop tubs from the area Remove the derrick termination plate if necessary

Varco Systems


Decommissioning Setting the latches and locking the bail

TDS-11SA Hoist to the crown

View of Carriage from Rear

Counterbalance Cylinders Disconnect from the hook 2 Places

Exhaust Cover 4 Places

!

VARCO

TOP DRIVE

INS TA WH LL UN EN ST IT IS OR ED

The Bail Lock Assembly must be installed

Pin

Latches Both sides engaged

Pin


TDS-11SA

Install the bail lock assembly It is NOT necessary to drain gear oil or hydraulic fluid for rig down Disconnect the counterbalance cylinders from the hook Install exhaust covers Hoist the Top Drive to the crown Engage the upper and lower carriage latches as shown

4-37

4


Decommissioning Disconnecting the guide beam Crown TDS-11SA Disconnect from the hang-off link Crown Padeye Do not remove Shackle Intermediate Tiebacks Disconnect from the guide beam

Hang-off Link

4 Bolt Pin

Safety Pin


Procedure

Drill Floor

4-38

Main Tieback Disconnect from the guide beam

Ensure that the bail lock assembly is installed and that both carriage latches are engaged (See page 4-37, Setting the latches and locking the bail) Disconnect the guide beam from the main tieback and intermediate tiebacks Hoist the Top Drive and guide beam to take the load off the hang-off link Remove the guide beam from the hang-off link Replace the pin, bolt and safety pin on the guide beam top section as shown Remove the hang-off link if necessary

Varco Systems


Decommissioning Unpinning each guide beam section


3 Guide Beam Hoist Lynch Pin Remove

2 Hook Pin Retainer Pin Remove

Joint Pin Remove

1 Guide Beam Lower to the drill floor

Drill Floor

TDS-11SA

Block as Required

Procedure Lower the guide beam to drill floor Block the guide beam in a vertical position if required Slightly compress the guide beam Remove the retainer pin, lynch pin and joint pin at the joint between the two lower guide beam sections Hoist the guide beam to open the joint

4-39

4


Decommissioning Lowering each guide beam section Procedure Ensure the Top Drive does not contact the rig

2 Guide Beam Lower to the drill floor

Using a tugger or crane, pull the lower guide beam section to a horizontal position Do not allow the angle at the guide beam joint to become less than 90 degrees Lower the guide beam to the drill floor Attach lifting slings to the lifting eyes of the lower guide beam section to be removed Unhook the lower guide beam section and remove from the drill floor Repeat the previous steps for each of the remaining guide beam sections until only the upper section remains

2,100 lb (950 kg) Guide Beam Section

Sling

4

Guide Beam Section

3 Lifting Eyes Attach slings, and unhook the guide beam section

Lower Guide Beam Section Horizontal position must remain greater than 90˚

1 Drill Floor Tugger

4-40

Varco Systems


Decommissioning Returning the TDS-9/11SA to the skid Pin Hook onto the top of the skid

27,000 lb (12300 kg) TDS-11SA

2 TDS-11SA Lowered onto skid

4


3 Lock Pin Install after lowering TDS-11SA onto the skid

Skid


1 3,000 lb (1360 kg) Skid

TDS-11SA

Ensure that the bail lock is installed Hoist the storage skid to the drill floor Using the drawwork, lower the TDS-11SA onto the skid Ensure that all carriage latches remain engaged Hook the TDS-11SA at the top of the skid and pin it at the bottom of the skid Install pin retainers

4-41


Decommissioning Removing the TDS-9/11SA from the drill floor Procedure Ensure that the bail lock assembly is installed Using the drawwork, lower the TDS-11SA and skid down the V-door ramp or from the drill floor using a crane

Sling

! The Bail Lock Assembly must be installed

4 Lifting Block Lower using the drawwork

Lifting Sling

Drill Floor

TDS-11SA with Skid 30,000 lb (13600 kg)

Lower the TDS-11SA on the Skid from the drill floor

Backup Line

4-42

Varco Systems


Decommissioning Long term storage procedures TDS-11SA Long Term Storage Procedures For indoor storage, cover the TDS-11SA in its shipping and handling skid. A cargo container is appropriate for outdoor storage. Avoid wide variations in temperature and high humidity. The preferred environment is clean and dry at 60˚-80˚F ambient. All exposed unpainted metal surfaces are coated with a rust preventive prior to shipment; however, check these surfaces periodically to be sure that no corrosion is taking place. The recommended rust preventive (slushing compound) for bare metal surfaces is Kendall Grade 5 (GE-D6C6A1) or equivalent. Cover all openings to prevent water or dust from entering. Leave enough space around the drilling motors for ventilation. Do not use silica gel or a dehydrating agent. During storage, rotate the motors and gear train periodically to distribute lubricant. Perform this at three month intervals if stored indoors, and at one month intervals if stored outdoors. For long term storage recommendations dealing with the AC drilling motors, see the motor manufacturer’s manual.

Returning the TDS-11SA to Service After Storage

4

Remove all rust preventive and any corrosion that may have taken place, taking special care with load carrying components. Repaint the tool if necessary. Follow the return to service procedures in the AC drilling motor manufacturer’s manual. Check for water and remove if any is found. Change the hydraulic fluid and gearbox oil. Lubricate the cooling and oil pump motors. Lubricate the tool with general purpose grease. Megger all connectors.

TDS-11SA

4-43

Guide Beams and Carriage

Inspecting the crown padeye and hang-off link 5-2 Inspecting the top section of the guide beam ... 5-3

1

Inspecting the guide beam joints....................... 5-4 Inspecting the main tieback .............................. 5-5 Inspecting the intermediate restraints .............. 5-6

2

Inspecting the carriage ...................................... 5-7

3

4

5

6

7

8

9

TDS-11SA

TDS Training Manual




AC Electrical


Inspecting the crown padeye and hang-off link Crown

Yearly Crown Padeye

2.1" (52 mm) minimum

Monthly Crown Padeye Visually inspect weld for cracks

Monthly Cotter Pin Replace if missing

Shackle 2.0" (50 mm) minimum

Monthly

5

Shackle Inspect and replace if worn 1.5" (37 mm) minimum

Monthly Hang-off Link Bores Inspect and repair if worn Hang-off Link Bores

5-2

Varco Systems


Inspecting the top section of the guide beam Crown

2.1" (52 mm) minimum 1.5" (37 mm) minimum

Bolt Assembly

Hang-off Link Bores

Monthly Safety Pin Replace if missing

Monthly Hang-off Link Bores Inspect and repair if worn


TDS-11SA

5-3

5


Inspecting the guide beam joints

! Verify that the joint pins, retainer pins and lynch pins are in place and secure. Replace any missing or damaged pins.

Secure

Daily Lynch Pin

5

Weekly Joint Pin

Yearly Typical Guide Beam Joint

Daily Retainer Pin

Monthly Inspect welds for cracks

5-4

Varco Systems


Inspecting the main tieback Guide Beam Bottom Section

Daily Check that the tool is aligned directly over well center Main Spreader Beam

Tieback Link

Tieback Plate

Yearly Typical all welds

5 Weekly Typical all welds and connections Inspect clamped connections for tightness and double nuts. Inspect welds for cracks. Auxiliary Spreader Beam

Mast Leg

See General Information for torque values See Installation for assembly/disassembly

TDS-11SA

5-5


Inspecting the intermediate restraints Daily Check that the tool is aligned directly over well center

Weekly Check for tightness of cotter pins, and double nuts. If there are signs of shifting, verify alignment.

Weekly

5

Pin and Cotter Pin Verify that all pins are in place. Replace any missing or damaged pins.

Mast Girt

Yearly Typical all welds Guide Beam

See General Information for torque values See Installation for assembly/disassembly

5-6

Varco Systems


Inspecting the carriage

Weekly Typical all rollers Inspect for uneven wear, damage and looseness. Replace as required.

5

Daily Typical all detent pins Verify that pins are in place and secure

See General Information for torque values

TDS-11SA

5-7

TDS Training Manual



Motor Housing, Transmission

AC Electrical

Motor Housing, Transmission

Illustrated index ................................................. 6-2 Inspection schedules ......................................... 6-3

1

Inspecting the internal lubrication flow (monthly) ............................................................. 6-4 Adjusting the encoder ........................................ 6-5

2

Gearbox lube pump assembly ............................ 6-7 Disassembly/assembly .................................................. 6-7 Inspection (yearly) ......................................................... 6-8 Gear backlash ..................................................... 6-9 Inspection (yearly) ......................................................... 6-9

3

Bail and main body ............................................. 6-10 S-pipe .................................................................. 6-11 Upper mainshaft liner ......................................... 6-12

4

Washpipe assembly ............................................ 6-13 Assembly ....................................................................... 6-13 Inspection ...................................................................... 6-14

5

Upper bonnet seals (yearly) ............................... 6-16 Mainshaft ............................................................ 6-17 Inspection ...................................................................... 6-17 Inspecting mainshaft end play (yearly) .......................... 6-18

6

Blower motor assemblies (monthly) .................. 6-19 Motor brakes (monthly) ...................................... 6-20 AC drilling motors (weekly) ................................ 6-21

7

Transmission disassembly/assembly ................. 6-22 Nondestructive Examination (NDE) ................... 6-23 Visual inspection ........................................................... 6-23 Magnetic Particle Inspection (MPI) ................................ 6-24

8

Ultrasonic Inspection ..................................................... 6-25 Safety valve inspection procedures (IBOP) ................... 6-25 9

TDS-11SA

Motor Housing and Transmission

Illustrated index

AC Motor Blower Assembly (2) Page 6-19

AC Motor Brakes (2) Page 6-20

6

Bail Page 6-10

S-Pipe Page 6-11

AC Drilling Motors (2) Page 6-21

Washpipe Assembly Page 6-13

Gearbox Lubrication Pump Assembly Page 6-7

Gearbox Assembly Page 6-4, 6-7

For AC motor and transmission lubrication see Page 3-2 thru 3-12

6-2

Varco Systems


Inspection schedules Daily

Page Number

Check for missing lockwire and cotter pins Check for loose or broken parts and leaks Check for damaged hoses and fittings Check the wash pipe assembly for leaks

See page 6-14

Check fluid levels and filter condition

See page 3-4

Weekly Check the AC motor louvers for damage

See page 6-19

Check the AC motor screens for contamination

See page 6-19

Monthly Check the flow of oil throughout the main body while the lube pump is running

See page 6-4

Check the S-pipe for pitting, corrosion, or erosion

See page 6-11

Check the upper mainshaft liner for erosion caused by leaking wash pipe packing

See page 6-18

Check the upper bearing retainer o-ring, bearing isolator, and oil seal for wear

See page 6-18

Check the blower motor assemblies for loose bolts

See page 6-19

Check brake pads for wear

See page 6-20

Yearly Check the gearbox lubrication pump assembly for wear or damage

See page 6-7

Check the gear teeth for pitting and corrosive wear

See page 6-8

Check for primary and secondary gear set backlash

See page 6-9

Check the mainshaft for axial movement

See page 6-18

Check bail, bushings and bail pins for wear

See page 6-10

Check the radial grooves on the stem and the load collar for wear

See page 6-17

6

Megger motors

5 Years Magnetic particle inspection (MPI)

TDS-11SA

See page 6-24

6-3


Inspecting the internal lubrication flow (monthly) Procedure Remove the 3 in. pipe plugs from the main body and check the flow of oil coming from the four spray nozzles (two in the body, two in cover) while the lube pump is operating Check that oil is running out of the upper gear drain holes in each compound gear set (indicates upper orifice is not blocked) and that oil is running through the spillway running from the thrust bearing (indicates orifice is not blocked)

Pipe Plug

Pipe Plugs

Monthly Upper Compound Gear Drain Hole Check flow

Monthly Body Spray Nozzles Cover spray nozzles not shown

6

Monthly Spillway Check flow

Pipe Plug Remove using a 2 inch, 12 point socket Main Body

6-4

Varco Systems


Adjusting the encoder Use the following procedure to adjust the encoder belt tension: 1. Remove the access covers 2. Disconnect all of the electrical connectors from the encoder. 3. Remove the lockwire and loosen the four sled hold-down screws. 4. Let the sled to move freely, allowing the belt tension spring to apply the proper tension to the belt.

!

Do not tension the belt by hand.

5. Carefully tighten the sled hold-down screws and torque them to 7 ft lb. 6. Lockwire the sled hold-down screws. 7. Reconnect the encoder electrical connections. 8. Replace both access covers and tighten the access cover screws to 15 ft lb and lockwire them.

6

TDS-11SA

6-5


Adjusting the encoder

Belt Tension Spring

Sled Hold-down Screws 4 Places

View from Side

Encoder Belt

Sled

View from Top (Blower Motor removed for clarity)

6

Electrical Connector Sled Encoder Belt

Encoder

Belt Tension Spring

6-6

Sled Hold-down Screws 4 Places

Varco Systems


Gearbox lube pump assembly Disassembly/assembly Disassemble the gearbox lubrication pump assembly and inspect the pump assembly components yearly for wear and damage as follows: 1. Drain the gearbox oil and disconnect the hydraulic lines from the pump assembly 2. Remove the pump assembly by removing the eight lockwired capscrews that attach the pump adapter plate to the main body 3. Disassemble the spline adapter, pump, and housing using the pump vendor service instruction HS15 (located in the Vendor Documentation Package) 4. Inspect the pump assembly components, replacing any parts that are worn or damaged. Pay particular attention to the spline between the pump and motor, the gears, and the motor and pump sideplates. 5. Assemble the lubrication pump assembly in the reverse order of disassembly

i

Follow the pump vendor service instruction HS15 (located in the Vendor Documentation Package) when assembling the lubrication pump components, and torque all fasteners in accordance with DS00008, located in the Supplemental Materials book.

6

i

When reinstalling the pump assembly into the main body, inspect the O-ring for damage and replace the O-ring if any flat spots, nicks, or other damage is found.

6. Install the pump assembly into the main body. Torque the fasteners in accordance with DS00008, and reconnect the hydraulic and electrical connections.

TDS-11SA

6-7


Gearbox lube pump assembly Inspection (yearly) End Cover Thrust Plate 2 Places

Yearly Gearbox Lubrication Pump Assembly Check parts for wear or damage

Ring Seal

Body Seal 2 Places Gear Housing

Roller Bearing 4 Places

Gear Set

Pump Adapter Plate Capscrew 10 Places

6 Hydraulic Motor Low-Speed/High-Torque

O-ring

Main Body

Procedure Drain the gearbox oil and disconnect the hydraulic lines from the pump assembly Remove the pump assembly by removing the ten lockwired capscrews that attach the pump adapter plate to the main body Disassemble using the drawings in the Technical Drawing Package as well as the pump vender service instruction Inspect and relace any parts that are worn or damaged

6-8

Varco Systems


Gear backlash Inspection (yearly)

A

6 Months Gear Teeth Check for wear, pitting, and gear set backlash

B

Solid Wire Solder

A

B

Dim. A + Dim. B = Backlash

Procedure

i

Inspect the pump adapter plate at the same time the gear backlash is checked

6 Drain the gearbox oil Remove the access cover and the pump adapter plate to check primary and secondary gear set backlash Run a piece of solid wire solder through the primary and secondary gear meshes and measure the thickness of the two flat spots made by the gear teeth surfaces with a micrometer. If the primary gear mesh backlash exceeds .030 in. or the secondary gear mesh backlash exceeds .040 in., excessive gear wear or bearing failure is indicated.

i

TDS-11SA

Check the gear teeth for pitting or corrosive wear at the same time the gear set backlash is checked

6-9


Bail and main body Inspection Wear allowances Component

Replace when

Bushing

Inner diameter is less than 4.450 in.

Bail Pin

Outer diameter is less than 4.125 in.

Bail

Yearly

Bushing 2 Places

Yearly

Main Body Cover

5 Years

6

Main Body

5 Years

Bail Pin 2 Places

Yearly

6-10

Varco Systems


S-pipe Inspection Procedure Unscrew the two nuts that hold the S-pipe in place along with the six bolts that secure the clamp to remove and inspect the S-pipe Clean the bore of the S-pipe and inspect for visible signs of pitting, corrosion, or erosion

i

Wing Nut

Seal Ring Plug

Use a flashlight and mirror to visually inspect the bore of the S-pipe. A Bore-o-Scope is best for inspection, if available.

Monthly Pressure test to rated working pressure

Remove and perform an ultrasonic inspection on the S-pipe if visual inspection indicates erosion or corrosion Check condition of the seals Apply pipe dope to the threads before re-installing

Monthly S-Pipe Check for visible signs of pitting, corrosion, or erosion (pitting or corrosion should be no deeper than 0.125 inch)

Clamp

Bolts

Seal Ring

Right-hand (inside of guard) configuration shown. Your S-pipe configuration may vary.

TDS-11SA

Wing Nut

6-11

6


Upper mainshaft liner Inspection Procedure Remove the wash pipe assembly Check the upper mainshaft liner for erosion caused by leaking wash pipe packing and replace the liner if erosion is found

i

The 3.875 in. OD polypack seal must also be replaced whenever the upper stem liner is replaced Grease the polypack seal and clean the mainshaft bore before re-installing Make sure the O-ring of the seal is facing down when the seal is installed on the liner

Wash Pipe Assembly

Monthly Upper Mainshaft Liner Replace if erosion is found during inspection

Polypack Seal

6 Polypack Seal Replace OD polypack seal when the upper mainshaft liner is replaced Main Shaft

Upper Mainshaft Liner

6-12

Varco Systems


Washpipe assembly Assembly 1. With the packing box upside down, assemble the packing seals and spacers into the packing box using care to line up the upper spacer slot with the dowel pin. 2. Hand pack all seals with multipurpose lithium-based or high temperature moly-based grease using care not to grease the outside diameter of the spacers. 3. Install the socket head dog nose screw, ensuring that the screw nose is fully engaged in the groove of the lower spacer. 4. Install the grease fitting and turn the packing box upright. 5. Install the wash pipe into the packing box assembly (slotted end up). 6. Install the wash pipe nut onto the wash pipe. 7. Grease the packing seal and install into the holding ring using care not to grease the outside diameter of the holding ring. 8. Install the packing seal and holding ring over the slotted end of the wash pipe. 9. Install the snap ring. 10. Install the upper and lower o-rings using grease to hold them in place. 11. Compress the assembly to the length of the wash pipe.

6

Disassemble the washpipe packing in the reverse order of the above procedure. Refer to the Washpipe Assembly Guide, P/N 128844.

TDS-11SA

6-13


Washpipe assembly Inspection

! The wash pipe nut and the packing box have left-handed threads

Slide the wash pipe nut and the packing box together for installation

Dowel Pin

Hand pack all seals with multipurpose lithium-based or high temperature moly-based grease completely filling the void

6 Ensure that the nose of the socket head dog nose screw is fully engaged in the groove of the lower spacer

Special Tools

3" Bore Wash Pipe Wrench 30150084

Recommended for proper tightening of the wash pipe nut and packing box

6-14

Varco Systems


Washpipe assembly Inspection O-Ring Snap Ring

Holding Ring

Daily

Packing Seal 5 per set

Wash Pipe Assembly Inspect for leaks

Wash Pipe Nut

Upper Spacer

Middle Spacer

Wash Pipe

Middle Spacer

Packing Assembly Box

6

Straight Ext. Grease Fitting

Lower Spacer

Socket Head Dog Nose Screw

O-Ring

Procedure Visually inspect the wash pipe assembly for leaks Replace any worn or damaged parts Apply pipe dope to the threads before installing in the Top Drive

TDS-11SA

6-15


Upper bonnet seals (yearly) Inspection Procedure Remove the bearing shield, the bearing retainer cap screws, and the bearing retainer Inspect the bearing isolator, the oil seal, and the retainer o-ring for wear Replace any worn or damaged parts

i

Align the shims so that the bearing lube tube bore is not blocked

Bearing Retainer Cap Screw 6 Places

Bearing Shield

Bearing Retainer

Lube Tube Oil Seal Bearing Shield

Bearing Isolator

Bearing Retainer Cap Screw 6 Places Bearing Retainer

Retainer O-Ring

Lube Tube O-Ring 2 Places

Yearly Retainer O-Ring

Yearly Bearing Isolator

6 Yearly Oil Seal

Lube Tube

Shims Hand pack the void with grease

6-16

Varco Systems


Mainshaft Inspection Wear allowances Component

Replace when

Stem Grooves

Groove width exceeds 0.650 in.

Load Collar Grooves

Groove width exceeds 0.620 in.

Stem

5 Years

Radial Grooves Inspect for groove wear and pitting 0.650 max

Yearly

Split Load Collar

5 Years

Radial Grooves Inspect for groove wear and pitting

Yearly

0.620 max

Retainer Ring

TDS-11SA

6-17

6


Mainshaft Inspecting mainshaft end play (yearly)

Dial Indicator Bearing Retainer Cap Screw 6 Places

Mainshaft Check for axial movement

Yearly Shims Bearing Retainer

Procedure

6

Remove the washpipe packing Check the mainshaft axial movement by applying an upward force to the mainshaft and measuring the amount of axial movement with a dial indicator If axial shaft movement is not .001 in. to .002 in., remove the bearing retainer and adjust the number of shims under the bearing retainer as required to allow .001 in. to .002 in. of axial shaft movement (end play) with the bearing retainer capscrews tightened to 250-270 ft lb

6-18

Varco Systems


Blower motor assemblies (monthly) Inspection Drip Shield

Bolts 4 Places, lock wire in pairs

Motor Fan Cover

Motor Fan

Bolts 4 Places, lock wire in pairs

Bolts 6 Places

Top Bearing Housing

Monthly Check for loose bolts

6 Procedure Check bolts for tightness Tighten as needed Check motor cables for damage Megger motors yearly

TDS-11SA

6-19


Motor brakes (monthly) Inspection Procedure Remove the brake housing covers to access the drilling motor brakes Inspect the brake pads for wear, and replace the pads if worn below the allowable lining wear limit given by the manufacturer If the brake pads are wearing unevenly, adjust the pads by adjusting the bolts on the brake calipers Inspect the brake hydraulic lines for leaks

Never check for hydraulic leaks with your hands. Oil under pressure escaping from a hole can be nearly invisible and can penetrate skin causing serious injury. Always check for leaks with a piece of wood or cardboard.

Caliper Mounting Bolts

6

Calipers and Pads Check pads for wear

Monthly

Brake Disc

Steel Plate 0.09 in. Min.

Adjust

Caliper Mounting Bracket

6-20

Brake Pads

Equal Gap

Varco Systems


AC drilling motors (weekly) Inspection Procedure Check for missing or damaged louvers Check screens for contamination Check motor leads for damage Check for missing lockwire Megger motors yearly

Weekly Motor Leads Check for damage

6 Weekly Louvers Check for damage

Weekly Screen Check for contamination

TDS-11SA

6-21


Transmission disassembly/assembly Stem Sleeve Taper Roller Bearing

Main Body Cover Cap Screw Upper Spray Nozzles

Dowel Pin

Upper Compound Roller Bearing

Lock Washer

Dowel Pin

Bull Gear

Internal Retaining Ring Upper Stem Liner

Compound Gear Internal Retaining Ring Spacer Ring

Poly Pack Seal Oil Gallery O-Ring

Lower Compound Roller Bearing Bearing Lock Washer Main Shaft Stem

Internal Locknut Retainer Main Body O-Ring

Tapered Roller Thrust Bearing

6 Main Body

Main Shaft Sleeve

Lower Main Bearing

Main Lower Roller Bearing

Wear Sleeve Lube Plate Oil Assembly

Lock Washer

Bearing Retainer

Cap Screw

6-22

Varco Systems


Nondestructive Examination (NDE) Yearly (or after approximately 3,000 operating hours), perform a Nondestructive Examination (NDE) of all critical load path items.

NDE inspection includes visual examination, dye penetrant examination, magnetic particle inspection, ultrasonic inspection, xray examination, and other methods of nondestructive testing for metallurgical integrity.

Visual inspection Use calipers on a regular basis to measure the amount of wear on the elevator link eyes. Compare the measurements with the Wear Chart to determine the current strength of the elevator links. The capacity of the links equals the capacity of the weakest link.

6

TDS-11SA

6-23


Nondestructive Examination (NDE) Magnetic Particle Inspection (MPI) Once a year, or every 3,000 operating hours, Varco recommends performing a Magnetic Particle Inspection (MPI) of the exposed surfaces of all load carrying components to reveal any fatigue or crack indications. Any indications found are a potential cause for replacing the suspect component. Round bottom pits and erosion are acceptable as long as the defect is less than 1/16 in. deep. Larger defects or any crack indications are cause for replacing the suspect component. After approximately five years, or 15,000 operating hours, depending on the severity of operating conditions, Varco recommends performing a MPI of all load carrying components over their entire surface (including internal bores) to reveal any fatigue or crack indications. Any indications found are a potential cause for replacing the suspect component. Round bottom pits and erosion are acceptable as long as the defect is less than 1/16 in. deep. Larger defects or any crack indications are cause for replacing the suspect component. The load carrying components are:

6

❏

Mainshaft (lower portion)

❏

Bail

❏

Landing collar (yearly)

❏

Upper and lower IBOP

❏

Link adapter

❏

Saver, crossover, and spacer subs

❏

Power subs

❏

Power swivels

❏

Elevator links

Details on MPI procedures are in the following publications:

6-24

I.A.D.C.

Drilling Manual, 9th Edition

ASTM A-275

Std. Method for Magnetic Particle Inspection of Steel Forgings

ASTM E-709

Std. Recommended Practice for Magnetic Particle Inspection

Varco Systems


Nondestructive Examination (NDE) Ultrasonic Inspection In addition to the MPI, Varco also recommends performing an Ultrasonic Inspection of the above components to detect any erosion of the inside diameter. Any erosion reduces the loadcarrying capability of the part. Any subsurface irregularity can also compromise a component’s integrity.

Details on Ultrasonic Inspection procedures are in the publication: ASTM A-388 Std. Practice for Ultrasonic Examination of Heavy Steel Forgings.

Safety valve inspection procedures (IBOP) Upper and lower IBOP valves, because of their internal grooves and shoulders, are particularly susceptible to corrosion fatigue cracking. These internal diameter changes act as stress risers for bending and tensile loads. It is especially important to properly inspect the IBOP valves on a frequent basis. Read and use the IBOP valve inspection procedures described in the IBOP Service Manual (SM00611).

6

TDS-11SA

6-25

TDS Training Manual



PH50 Pipehandler

AC Electrical

PH-50 Pipehandler

PH-50 Pipehandler

PH-50 Pipehandler illustrated index .................. 7-2 Inspection schedule ........................................... 7-3

1

Precautions ......................................................... 7-4 Elevator links ...................................................... 7-5 Disassembly/assembly .................................................. 7-5 Inspection ...................................................................... 7-6

2

Link tilt ................................................................ 7-8 Disassembly/assembly .................................................. 7-8 Inspection ...................................................................... 7-9 3

Torque wrench assembly ................................... 7-10 Clamp cylinder body disassembly/assembly ................. 7-10 Inspecting the clamp cylinder body ............................... 7-14 Inspecting the stabilizer ................................................. 7-15

4

Inspecting the IBOP actuator cylinder and yoke ............ 7-17 Well control system ............................................ 7-19 Tool joint locks disassembly/assembly .......................... 7-19 Inspecting the tool joint locks......................................... 7-20

5

Inspecting the IBOP valves and saver subs .................. 7-21 Shot pin assembly .............................................. 7-22 Disassembly/assembly .................................................. 7-22 Inspection ...................................................................... 7-23

6

Rotating link adapter/load stem ......................... 7-24 Removing the pipehandler and link tilt from the top drive (while in mast) ............................................................... 7-24 Disassembling the link tilt assembly .............................. 7-24

77

Assembling the link adapter .......................................... 7-26 Assembling the link adapter to the top drive (while in mast) ............................................................... 7-27 Wireline adapter ................................................. 7-28 Inspection ...................................................................... 7-28

8

Nondestructive Examination (NDE) ................... 7-29 Visual inspection ........................................................... 7-29 Magnetic Particle Inspection (MPI) ................................ 7-30

9

Ultrasonic Inspection ..................................................... 7-31 Safety valve inspection procedures (IBOP) ................... 7-31 TDS-11SA TDS-11SA

7-1

PH-50 Pipehandler

PH-50 Pipehandler illustrated index

Rotating Link Adapter Page 7-25

Link Tilt Page 7-9

IBOP Actuator Yoke and Cylinder Page 7-19

Stabilizer Page 7-16 Well Control System Page 7-20 Clamp Cylinder Body Page 7-11

7 Stabbing Guide Page 7-14

For pipehandler lubrication see Page 3-13

7-2

Drill Pipe Elevator and Elevator Links Page 7-6

Varco Systems

PH-50 Pipehandler

Inspection schedule Each Use

Page Reference

Check wireline adapter sheaves for excessive wear or damage

See page 7-30

Daily Check for missing lockwire and cotter pins Check for loose or broken parts and leaks Check for damaged hoses and fittings Check clamp cylinder gate pins and retainer bolts

See page 7-11

Check tong dies for wear

See page 7-14

Check upper and lower IBOP valves for proper operation

See page 7-21

Weekly Check link tilt clamps for position and tightness

See page 7-9

Check stabbing guide and flippers for damage and wear

See page 7-11

Check front and rear stabilizers for wear

See page 7-16

Check IBOP actuator cylinder for leaks, tighten fittings

See page 7-17

Check IBOP actuator rollers for wear or excessive play

See page 7-19

Check tool joint locks for loose bolts

See page 7-20

Check upper and lower (if equipped) IBOPs for damage

See page 7-22

Monthly Check elevator link eyes for wear

See page 7-8

Check link tilt bushings for wear

See page 7-9

Check link tilt actuator cylinder clevis pins for wear

See page 7-19

Check IBOP actuator yoke for wear or excessive play

See page 7-19

Check shot pin assembly for wear or damage

See page 7-23

7 Yearly Check piston ring for pitting and chipping

See page 7-25

Check stem for pitting, grooves and chipping

See page 7-25

Replace GLYD rings, o-rings and bushings on rotating link adapter

See page 7-25

5 Years MPI Inspection

TDS-11SA

See page 7-31

7-3

PH-50 Pipehandler

Precautions To avoid serious injury or death, read and understand the following warnings before performing inspection and maintenance procedures:

Properly lockout the main power source before performing lubrication, inspection, or replacement procedures, unless specifically noted in this manual.

Wear protective glasses to prevent eye injuries from fluids under pressure, as well as other hazards.

Do not attempt any adjustments while the machine is moving.

Use caution when draining lubricant. It can be hot.

Never check for hydraulic leaks with your hands. Oil under pressure escaping from a hole can be nearly invisible and can penetrate skin causing serious injury. Always check for leaks with a piece of wood or cardboard and always wear protective eyewear when working on hydraulic components.

Always discharge the three hydro pneumatic accumulators before performing repairs on the hydraulic system.

7 Do not attempt repairs you do not understand.

Read and understand all safety precautions and warnings before performing maintenance procedures.

7-4

Varco Systems

PH-50 Pipehandler

Elevator links Disassembly/assembly 1. Disconnect and remove the drill pipe elevator from the elevator links. 2. Using the Varco Driller’s Console (VDC), rotate the pipehandler 90° to position one of the elevator links directly below the front of the motor guard. 3. Remove the catch link bolt from the catch link. 4. Remove the clevis pin from the link, which connects the link tilt to the elevator link. 5. Using the sling, hoist the elevator link away from the pipehandler. 6. Rotate the pipehandler 180°, repeat the procedure to remove the other elevator link.

7

TDS-11SA

7-5

PH-50 Pipehandler

Elevator links Inspection Recess in Motor Guard

Rear 2 Lift and remove Link Tilt

Upper Catch Link

Catch Link Pin

950 lb (431 kg) Elevator Link

Front

26" (635mm) Typical

P

LE RO IPE FT T AT HA ND E

L

RIG LI ER HT NK TIL TF LO AT

Link

TO RQ PU UE SH WR & H EN OL CH D

DR LINK ILL O TI FF LT TIL T

Pipehandler Rotate Switch

Weekly

1

7

Link Clamps Inspect for position and tightness

Clevis Pin

Rotate PIP

EH

AN

DL

ER BR AK E IBO P

EM ER G ST EN OP CY

TO


RQ

UE

Monthly

TO

RQ

UE

RP

M

7-6

Elevator Link Eyes Inspect for wear (see table)

Varco Systems

PH-50 Pipehandler

Elevator links Inspection (Varco links only) Wear Chart - Forged Links Upper Eye Dimension (C)

Lower Eye Dimension (A)

Capacity (per set) in Tons

5 inches

2 3/4 inches

350

4 13/16 inches

2 9/16 inches

300

4 5/8 inches

2 3/8 inches

225

7 7/16 inches

2 3/16 inches

175

C

Upper Eye (Hook)

C

B = 3 1/2 in., 350-Ton

B

B = 4 1/2 in., 500-Ton 6 inches

3 1/2 inches

500

5 3/4 inches

3 1/4 inches

420

5 1/2 inches

3 inches

325

5 1/4 inches

2 3/4 inches

250

7 1/2 inches

7 1/2 inches

350

7 1/4 inches

7 1/4 inches

300

7 inches

7 inches

225

6 3/4 inches

7 3/4 inches

175

B

B = 6 1/4 in., 750-Ton

To determine the strength of worn links, measure (with calipers) the amount of eye wear and compare the measurements with the above Wear Chart to find the current capacity. The capacity of the set of links is determined by the weakest link.

A

Lower Eye (Elevator)

A

7

TDS-11SA

7-7

PH-50 Pipehandler

Link tilt Disassembly/assembly 1. Shutdown the power and bleed the system (turn the valve on the bottom of the gearcase to the SHUT DOWN position). 2. Disconnect the hydraulic lines from the link tilt cylinders and cap all connections. 3. Unpin and remove the link tilt cylinders. 4. Unpin and remove the link tilt crank.

i

Use the recommended spanner wrench to remove the rod gland seal.

7

7-8

Varco Systems

PH-50 Pipehandler

Link tilt Inspection

Pins Inspect for wear replace as needed

Monthly

Monthly Bushings Inspect for wear replace as needed

Monthly Link Tilt Actuator Cylinders Inspect the hydraulic connections for leaks

Link Tilt

Monthly Bushings Inspect for wear replace as needed

7

Wear allowances Component

Replace when

Pins

Wear exceeds .06 in. on diameter

Bushings

Metal backing is visible through the lining End cap of the metal backing exceeds .04 in. wear

i

TDS-11SA

Bushings should be pressed in using the mating pin as an installation mandrel.

7-9

PH-50 Pipehandler

Torque wrench assembly Clamp cylinder body disassembly/assembly 1.

Shutdown power and bleed the system (turn the valve on the bottom of the gearcase to the SHUT DOWN position).

2. Disconnect the hydraulic lines on the clamp cylinder body and cap all connections. 3. Support the clamp cylinder body. 4. Remove the two hex-head capscrews and lockwashers that hold the end cap in place. 5. Remove the end cap, spring spacer, spring sleeve, and spring. 6. Slowly lower the clamp cylinder body off the torque wrench frame and move it to a suitable work area. 7. Remove the 16 hex-head screws and lockwashers that hold the wear bushings on the clamp cylinder body. 8. Remove the four wear bushings, and replace the wear bushings as necessary. 9. Remove the two hinge pin retainer hex-head screws. 10. Swing out the two hinge pin retainers. 11. Remove the two hinge pins. 12. Remove the gate, front jaw, front stabilizer, and front stabbing guide. 13. Remove the two socket-head capscrews and hi-collar washers from the front jaw. 14. Remove the front jaw from the gate.

7

15. Repeat steps 11 and 12 for the rear jaw. 16. Push the cylinder head in enough to relieve the load on the cylinder head ring. Remove the cylinder head ring. Use care in this operation.

7-10

Varco Systems

PH-50 Pipehandler

Torque wrench assembly 17. Slowly pull out the cylinder head using the threaded holes. Remove and discard the piston seal. 18. Carefully push the piston out of the body. Remove and discard the piston seal. 19. Remove the wiper rod and rod seal from the body. Discard the seals. 20. Clean the piston, cylinder head, and the body. Clean and lightly lubricate the new seals and seal surfaces prior to reassembly.

i

Use recommended spanner wrench to remove the rod gland seal.

Assembly is performed in reverse order of disassembly.

7

TDS-11SA

7-11

PH-50 Pipehandler

Torque wrench assembly

Hydraulic Manifold

RIG-UP

SHUTDOWN

RUN

COUNTERBALANCE MODE

Rig-up/Run/ Shutdown Valve Shown in SHUTDOWN position (Shown with link tilt removed)

Torque Arrestor

Spring

Spring Spacer Spring Shims Adjust to ensure the torque wrench clamps fully onto the saver sub

7

Support clamp cylinder body before removing end cap.

End Cap

Clamp Cylinder Body

7-12

Varco Systems

PH-50 Pipehandler

Torque wrench assembly Manifold

Rear Stabilizer Front Stabilizer Hinge Pin Retainer

Spring Hex Head Screws

Cylinder Head Ring

Clamp Cylinder Body Body Seals

Cylinder Head

Jaw Assembly

Piston Seals

Tong Dies Piston Gate

Wear Bushing Socket Head Cap Screws Hinge Pin Front Stabbing Guide

Rear Stabbing Guide

7

Stabilizer

Spring

TDS-11SA

Retaining Plate

7-13

PH-50 Pipehandler

Torque wrench assembly Inspecting the clamp cylinder body

Tugger Line

V A R C O P H 5

0

Front and Rear Stabilizers Inspect for wear

Weekly

Tong Dies Inspect for excessive wear

CO

R VA

Daily Stabbing Guide Inspect for damage

Weekly

7 Clamp Cylinder Gate (Shown open)

Weekly Flippers Inspect for damage and excessive wear Swing Clear


Replace when

Stabilizer

Wear exceeds 1/8 in.

Flippers

Wear exceeds 1/8 in.

7-14

Varco Systems

PH-50 Pipehandler

Torque wrench assembly Inspecting the stabilizer Remove the two bolts (with slotted nuts and cotter pins) that hold the front stabilizer. Check the springs for damage and replace if needed. Pack spring cavities with grease and reassemble. Be sure all safety wire, cotter pins, and capscrews are tight, and tighten or replace as necessary.

7

TDS-11SA

7-15

PH-50 Pipehandler

Torque wrench assembly Inspecting the stabilizer

Stabilizer Springs Check for damage, replace as necessary.

Monthly

Monthly Stabilizers Inspect for wear. Replace if wear exceeds 1/8 in.

Cotter Pin

7

7-16

Varco Systems

PH-50 Pipehandler

Torque wrench assembly Inspecting the IBOP actuator cylinder and yoke

Weekly IBOP Actuator Cylinder Check for leaks, tighten fittings

Daily Hoses Replace if worn or damaged

Monthly Pins and Bushings Check for wear or excessive play

Monthly Weekly

IBOP Actuator Yoke Check pins and bushings for wear or excessive play

IBOP Actuator Yoke Check cam followers for wear or excessive play

For IBOP Actuator Yoke lubrication see Page 3-13


Replace when

Pins

Wear exceeds .03 in. on diameter

Bushings

Metal backing is visible through the lining End cap of the metal backing exceeds .04 in. wear

i

Bushings should be pressed in using the mating pin as an installation mandrel.

TDS-11SA

7-17

7

PH-50 Pipehandler

Torque wrench assembly Inspecting the IBOP actuator cylinder and yoke Disassembling the IBOP actuator cylinder and yoke 1. Shutdown the power and bleed the system (turn the valve on the bottom of the gearcase to the SHUT DOWN position). 2. Remove one gate hinge pin, open the gate, and pull back the torque wrench assembly. 3. Disconnect the hydraulic lines from the IBOP actuator cylinder and cap all connections. 4. Unpin and remove the IBOP actuator cylinder and yoke. 5. Replace the hydraulic lines as necessary. 6. Check for cylinder leaks.

7

7-18

Varco Systems

PH-50 Pipehandler

Well control system Tool joint locks disassembly/assembly

!

Do not reuse locking screws.

1. Lubricate the locking screw threads, screw head bearing area, and the tapers of the inner rings with molybdenum disulfide grease, such as Molykote Gn paste. 2. Make sure the save sub, IBOPs, and main shaft are free of “high spots”, such as tong marks. If high spots exist, remove with file or light grinding. 3. Slide the tool joint lock over the main shaft, IBOP valves, and saver sub. 4. Clean the IBOP valves, main shaft, and saver sub surfaces thoroughly. Make sure these surfaces are smooth and free of grease, oil, and pipe dope. 5. Locate the tool joint lock symmetrically at each joint.

!

Never tighten locking screws before the tool joint lock is at the correct location, otherwise it will not slide freely.

6. Take any three or four locking screws equally spaced and tighten them to establish parallel or perpendicular position of the tool joint lock collars relative to the main shaft, IBOP valves, and saver sub respectively. This properly seats the collars on the taper of the inner ring and aligns the collars. 7. Using a torque wrench, tighten all locking screws gradually in either a clockwise or counterclockwise sequence (not in a diametrically opposite sequence). Continue tightening all of the screws until they reach 185±5 ft lb.

7

8. Make sure no screw turns any more. The gap between the tool joint collars should be as equal as possible all the way around. 9. Safety wire all screws.

TDS-11SA

7-19

PH-50 Pipehandler

Well control system Inspecting the tool joint locks Tool Joint Lock to be Equally Spaced on Upper IBOP and Main Stem Joint Connection

1.4"

Tool Joint Shoulder

1.4"

Remove O-Ring and Look through this Space and Split on Inner Ring

Tapered Inner Ring Tool Joint Lock to be Offset on Upper and Lower IBOP Joint Connection Tool Joint 1.0" Shoulder

I.D. Groove First Line Up this Point with the Tool Joint Shoulder. Then Move Inner Ring Down 3/8" with the Outer Assembly. Replace O-Ring

Daily

7

1.4"

Tool Joint Shoulder

1.4"

Tool Joint Locks Inspect for loose bolts. Repair or replace if necessary. Torque to 185±5 ft lb.

Tool Joint Lock to be Equally Spaced on Lower IBOP and Saver Sub Joint Connection

Removing the Tool Joint Locks Gradually release the locking screws all the way around. Initially release each screw about a quarter of a turn, avoid tilting and jamming the collars. Do not remove the screws completely at this time, otherwise the collars may spring off. Remove any rust formed or dirt collected adjacent to the tool joint lock. Once the screws are loose, remove the tool joint lock from the saver sub, IBOP valves, and main shaft.

7-20

Varco Systems

PH-50 Pipehandler

Well control system Inspecting the IBOP valves and saver subs Wear allowances Component

Replace when

Saver Sub

Threads have been recut to a minimum shoulder-to-shoulder length of 5 in.

i

See the IBOP Service Manual for IBOP disassembly/assembly and servicing information.

Weekly

Daily

Upper IBOP (Remote) Inspect for damage

Valve Check for proper operation and pressure test for leaks

Weekly IBOP Crank (Remote) Inspect for damage

Weekly

Daily

Lower IBOP (Manual) (Optional) Inspect for damage

Valve Check for proper operation and pressure test for leaks

7

5 Years Upper and Lower IBOP

TDS-11SA

7-21

PH-50 Pipehandler

Shot pin assembly Disassembly/assembly 1. Disconnect the hydraulic and electrical lines. 2. Remove the capscrews that attach the shot pin assembly to the main body. 3. Remove the capscrew and lockwasher holding the shot pin cover in place 4. Remove the shot pin components as shown in the illustration on Page 7-24 (end cap, o-rings, rod seal assembly, shot pin) 5. Inspect the shot pin bearing and press the bearing out of the shot pin mounting bracket if the bearing is scored or damaged. 6. Remove the capscrew and lockwasher that hold the pinion gear in place, and remove the gear. 7. Remove the capscrews and lockwashers that hold the hydraulic motor in place and remove the motor. Inspect the disassemble parts and replace any worn or damaged parts. Assemble the shot pin in the reverse order of disassembly.

7

7-22

Varco Systems

PH-50 Pipehandler

Shot pin assembly Inspection Shot Pin Assembly

Shot Pin Base

Dowel Pin

Shot Pin Remove burrs

Rod Seal Assembly

Hydraulic Motor

Rod Seal Assembly Dual Port Manifold

Shot Pin Sleeve O-ring

Shot Pin Bushing

Shot Pin Cap

7

Shot Pin Cover


Replace when

Shot Pin

Outer diameter is less than 1.375 in.

Shot Pin Sleeve

Inner diameter is greater than 1.510 in.

Shot Pin Bushing

Inner diameter is greater than 1.475 in.

TDS-11SA

Pinion Gear

7-23

PH-50 Pipehandler

Rotating link adapter/load stem Removing the pipehandler and link tilt from the top drive (while in mast) 1. Drain the oil from the gearbox. 2. Disconnect and cap all tubing, remove the shot pin assembly and the landing collar. 3. Build a support over well center to support the weight of the link adapter. 4. Lower the top drive to the support built in Step 3. 5. Remove the bolts that attach the load stem to the main body. 6. Raise the top drive slowly to separate the link adapter from the main body. 7. Move the link adapter assembly to a clean, safe work area. 8. Orient the assembly with the stem flange up and block the entire assembly so that it is secure in this position.

Disassembling the link tilt assembly 1. Attach a 3-point sling to the stem and pull the stem out of the link adapter. 2. Turn the stem over and place it on its flange.

!

Protect the internal surfaces of the rotating link adapter and the surfaces of the drive stem when separating the two components. When removing the rotating link adapter from the stem, carefully tap with a mallet. There can be misalignment between the two bores when raising the drive stem and gear assembly.

7

i

The piston ring is assembled with a light press fit. Provide a support under the gear so that it does not drop when it breaks loose. 3. Remove and discard all rotary seals, O-rings, thrust ring, and the wear bushings from inside the rotating link adapter and gear inside dimension. 4. Remove and discard the stem flange O-rings and stem bore shaft seals.

7-24

Varco Systems

PH-50 Pipehandler

Rotating link adapter/load stem Inspecting the rotating link adapter Rotary GLYD Ring Remove, discard and replace

Yearly Rotary Link Adaptor O-Ring Remove, discard and replace

Yearly Thrust Ring Remove, discard and replace

Retainer Ring

Yearly

Turcite Bushing Remove, discard and replace

O-Ring

Yearly

Rotary GLYD Ring Wiper Seal

Yearly Piston Ring Inspect for pitting and chipped plating (Heat to 175-200° F to install)

Rotating Link Adapter Gear


Replace when

Thrust Ring

Thickness is less than 0.105 in.

Turcite Bushing

Thickness is less than 0.112 in.

Yearly Stem Inspect for pitting, grooves and chipped plating

Stem O-Ring Remove, discard and replace

Index Mark Indicates front of stem

Yearly

Level Work Surface

TDS-11SA

7-25

7

PH-50 Pipehandler

Rotating link adapter/load stem Assembling the link adapter 1. Orient the stem so the drive stem flange is down on a suitably protected surface. 2. Install the gear with its rotating seal and wiper in place. 3. Install the O-ring for the piston ring. 4. Install the piston ring by tapping on it lightly with a mallet to press it into place (Heat to 220-250°) 5. Install the retainer ring. 6. Install all of the rotary seals on the rotating link adapter, and an O-ring on the top surface. 7. Install the two wear bushings and the thrust ring in the rotating link adapter. 8. Rest the rotating link adapter on its bottom surface. 9. Clean and then lubricate (with hydraulic oil) the sealing surface of the stem and the inside diameter of the rotating link adapter. 10. Attach three lifting slings symmetrically through the holes on the top of the stem flange and slowly lower the assembly into the rotating link adapter body. Hammering with a large plastic mallet is an aid when assembing the stem to the link adapter.

i

Make sure the seals do not twist in the grooves.

11. Install the gear onto the link adapter and install the bolts.

7

12. Pressure test each port at 1,000 psi and inspect for leaks at the adjacent ports. 13. Grease all lubrication points on the assembly. 14. Inspect the lower gearbox seal (located inside the stem flange), and replace as necessary.

7-26

Varco Systems

PH-50 Pipehandler

Rotating link adapter/load stem Assembling the link adapter to the top drive (while in mast) 1. Check the condition of the manshaft wear ring and replace if there is any evidence of grooving. 2. Place the rotating link adapter assembly back on the support built over well center, orienting the assembly so that the stem flange is up, and so that the idex mark faces forward. 3. Carefully lower the top drive to engage the mainshaft in the stem bore and then the stem flange pilot diameter is in the main body bore. 4. Install the flange bolts. 5. Install the link tilt cylinders, pin, and secure in place. 6. Install the link tilt crank and pin, and secure in place. 7

Install all hose assemblies.

8. Install tubing. 9. Install the shot pin assembly. 10. Fill the gearcase with gear oil (see Lubrication). 11. Check and fill the hydraulic oil as necessary. 12. Turn on the top drive and perform all pipehandler functions several times, checking for proper function and any leaks. 13. Re-check the hydraulic oil level and fill as necessary.

!

Always install a new mainshaft seal and use care not to damage the seal or the case.

i

!

TDS-11SA

A light coating of grease applied to the O-ring helps in installing the rotating link adapter assembly into the main body.

Always install a new drive stem O-ring and use care not to damage the O-ring or the case.

7-27

7

PH-50 Pipehandler

Wireline adapter Inspection

i Inspect the condition of the sheaves before and after each use.

7

Each Use Sheaves Replace or repair damaged parts as necessary

7-28

Varco Systems

PH-50 Pipehandler

Nondestructive Examination (NDE) Yearly (or after approximately 3,000 operating hours), perform a Nondestructive Examination (NDE) of all critical load path items.

NDE inspection includes visual examination, dye penetrant examination, magnetic particle inspection, ultrasonic inspection, xray examination, and other methods of nondestructive testing for metallurgical integrity.

Visual inspection Use calipers on a regular basis to measure the amount of wear on the elevator link eyes. Compare the measurements with the Wear Chart to determine the current strength of the elevator links. The capacity of the links equals the capacity of the weakest link.

7

TDS-11SA

7-29

PH-50 Pipehandler

Nondestructive Examination (NDE) Magnetic Particle Inspection (MPI) Once a year, or every 3,000 operating hours, Varco recommends performing a Magnetic Particle Inspection (MPI) of the exposed surfaces of all load carrying components to reveal any fatigue or crack indications. Any indications found are a potential cause for replacing the suspect component. Round bottom pits and erosion are acceptable as long as the defect is less than 1/16 in. deep. Larger defects or any crack indications are cause for replacing the suspect component. After approximately five years, or 15,000 operating hours, depending on the severity of operating conditions, Varco recommends performing a MPI of all load carrying components over their entire surface (including internal bores) to reveal any fatigue or crack indications. Any indications found are a potential cause for replacing the suspect component. Round bottom pits and erosion are acceptable as long as the defect is less than 1/16 in. deep. Larger defects or any crack indications are cause for replacing the suspect component. The load carrying components are:

7

❏

Mainshaft (lower portion)

❏

Bail

❏

Landing collar (yearly)

❏

Upper and lower IBOP

❏

Link adapter

❏

Saver, crossover, and spacer subs

❏

Power subs

❏

Power swivels

❏

Elevator links

Details on MPI procedures are in the following publications:

7-30

I.A.D.C.

Drilling Manual, 9th Edition

ASTM A-275

Std. Method for Magnetic Particle Inspection of Steel Forgings

ASTM E-709

Std. Recommended Practice for Magnetic Particle Inspection

Varco Systems

PH-50 Pipehandler

Nondestructive Examination (NDE) Ultrasonic Inspection In addition to the MPI, Varco also recommends performing an Ultrasonic Inspection of the above components to detect any erosion of the inside diameter. Any erosion reduces the loadcarrying capability of the part. Any subsurface irregularity can also compromise a component’s integrity.

Details on Ultrasonic Inspection procedures are in the publication: ASTM A-388 Std. Practice for Ultrasonic Examination of Heavy Steel Forgings.

Safety valve inspection procedures (IBOP) Upper and lower IBOP valves, because of their internal grooves and shoulders, are particularly susceptible to corrosion fatigue cracking. These internal diameter changes act as stress risers for bending and tensile loads. It is especially important to properly inspect the IBOP valves on a frequent basis. Read and use the IBOP valve inspection procedures described in the IBOP Service Manual (SM00611).

7

TDS-11SA

7-31

TDS Training Manual



Hydraulic System

AC Electrical

Hydraulic System

Hydraulic system ................................................ 8-2 Illustrated index ................................................. 8-3

1

Hydraulic system diagram.................................. 8-4 Inspection ........................................................... Precautions ................................................................... Maintenance schedule .................................................. Hydraulic fluid level and filter ......................................... Adding the hydraulic fluid .............................................. Draining the hydraulic fluid ............................................ Hydraulic reservoir bladder (yearly) ............................... Heat exchanger ............................................................. Using the hydraulic system test ports ............................ Precharging the accumulators ....................................... IBOP timing circuit ......................................................... IBOP and oil pressure switch ........................................

8-5 8-5 8-7 8-8 8-9 8-10 8-11 8-12 8-13 8-14 8-15 8-16

Setting up the circuits ........................................ Hydraulic pumps and unloading circuit .......................... Fixed displacement (lube) and variable displacement pumps ............................................................................ Counterbalance circuit and stand-jump circuit ............... AC motor brake circuit ................................................... Shot pin circuit ............................................................... Link tilt cylinder circuit.................................................... Rotating link adapter hydraulic motor relief circuit .........

8-17 8-17

3

4

5 8-18 8-22 8-26 8-27 8-29 8-30

Troubleshooting .................................................. 8-31 HPU and reservoir bladder ............................................ 8-31 Counterbalance and stand jump.................................... 8-33 Stand jump testing ......................................................... 8-34 Counterbalance and stand jump schematic diagram .... 8-36 Troubleshooting the brakes ........................................... 8-37 Shot pin cylinder and clamp cylinder ............................. 8-39 Link tilt cylinders ............................................................ 8-41 Gearbox lubrication hydraulic system ............................ 8-43 Rotating link adapter motor schematic diagram ............ 8-46 IBOP actuator schematic diagram ................................. 8-47 Hydraulic schematic symbols ............................ 8-48 TDS-11SA

2

6

7

8

9

Hydraulic System

Hydraulic system The hydraulic control system is a completely self-contained, onboard system. A 10-horse power, 1800 rpm, AC motor, drives two hydraulic pumps and powers the hydraulic system. A fixed displacement pump drives the lube oil system motor. A variable displacement pump provides hydraulic power for the AC motor brakes, powered rotating head, remote actuated IBOP, pipe backup clamp cylinder, link tilt, and counterbalance system. Three hydropneumatic accumulators are located on the main body. The hydraulic manifold attaches to the main body and contains solenoid, pressure and flow control valves. A sealed stainless steel reservoir supplies hydraulic oil, eliminating the need for draining and refilling during normal rig moves. The reservoir is mounted between the AC drilling motors and is equipped with strainers and an oil level sight gauge.

8

8-2

Varco Systems

Hydraulic System

Illustrated index Specifications

Hydraulic Oil Filter Page 8-8

Pump Motor

10 hp, 1,800 rpm, AC motor

Reservoir Capacity

25 gal

Counterbalance Manifold Page 8-22

Counterbalance Accumulator Page 8-14

Main Hydraulic Manifold Page 8-13

Upper IBOP TimeDelay Accumulator Page 8-15 Hydraulic Oil Fill Page 8-9

Link Tilt Manifold Page 8-29

Oil Pressure Switch Page 8-16

Link Tilt Cylinders Page 8-29

System Accumulator Page 8-14 IBOP Pressure Switch Page 8-16 Upper IBOP Actuator Cylinder Page 8-15

Front

Counterbalance Cylinders Page 8-22 Hydraulic Oil Reservoir Page 8-11 Rotating Head Motor and Shot Pin Assembly Page 8-27

Rear

Front

10 HP AC Motor and Pump Assembly Page 8-17

Rear

8

TDS-11SA

8-3

Hydraulic System

Hydraulic system diagram Drilling Motor Brake

Upper IBOP Actuator Cylinder

Link Tilt Cylinders

Pipehandler Clamp Cylinder

Link Tilt Manifold

Counterbalance Accumulator

Rotating Head (Elevator Positioner)

Shot Pin Cylinder

Counterbalance Cylinders

Rotating Link Adapter Lift

Rotating Head Motor

Gearbox Lube Oil Distribution

Counterbalance Manifold

Main Hydraulic Manifold

Low Speed Hydraulic Motor Upper IBOP Time-Delay Accumulator

System Accumulator

Lube Oil Pump

Gearbox Sump

M 10 HP A.C. Motor

8

8-4

Variable Displacement Pump

Fixed Displacement Pump (Mtr. Lube)

Hydraulic Reservoir

Varco Systems

Hydraulic System

Inspection Precautions To avoid serious injury or death, read and understand the following warnings before performing inspection and maintenance procedures:

Properly lockout the main power source before performing lubrication, inspection, or replacement procedures, unless specifically noted in this manual.

Wear protective glasses to prevent eye injuries from fluids under pressure, as well as other hazards.

Do not attempt any adjustments while the machine is moving.

Use caution when draining lubricant. It can be hot.

Never check for hydraulic leaks with your hands. Oil under pressure escaping from a hole can be nearly invisible and can penetrate skin causing serious injury. Always check for leaks with a piece of wood or cardboard and always wear protective eyewear when working on hydraulic components.

Always discharge the three hydro pneumatic accumulators before performing repairs on the hydraulic system.

Do not attempt repairs you do not understand.

8 Read and understand all safety precautions and warnings before performing maintenance procedures.

TDS-11SA

8-5

Hydraulic System

Inspection Release all hydraulic oil pressure by bleeding accumulators before disconnecting hydraulic lines. Turn the counterbalance valve to shutdown mode to bleed the hydraulic system. Hydraulic oil under pressure can penetrate skin and cause serious injury.

Before opening the hydraulic system, thoroughly clean work area, and maintain system cleanliness by promptly capping all disconnected lines. Dirt is extremely harmful to hydraulic system components and can cause equipment failure and subsequent injury to personnel.

!

Use care when handling components to prevent nicking close tolerance finishes.

Hydraulic fluid escaping under pressure can penetrate the skin causing serious injury. Avoid injury by discharging the three accumulators and relieving pressure before disconnecting hydraulic lines. Always search for hydraulic leaks with a piece of cardboard or wood-not with your bare hands. Get immediate medical attention for hydraulic fluid injuries. Fluid injected into the skin must be surgically removed within a few hours or gangrene may result. Do not tighten hydraulic fittings while they are under pressure. Inspect the hydraulic system daily for leaks at fittings, damaged hose covers, kinked or crushed hoses, hard or stiff hoses, and damaged or corroded fittings. In addition, during the inspection, tighten or replace any leaking port connections, and clean any dirt buildup from hydraulic components.

8 Replace worn or damaged hydraulic system components immediately. Inspect the hydraulic fluid level in the hydraulic reservoir located between the AC drilling motors daily. Inspect the hydraulic filter located on the upper left AC drilling motor daily.

8-6

Varco Systems

Hydraulic System

Inspection Maintenance schedule Hydraulic system oil lubrication schedule Description

Frequency

Replace hydraulic system filter (P/N 114416-1)

1 x every 3 months

Perform hydraulic system oil analysis

1 x every 6 months

Replace hydraulic fluid

1 x every year, or earlier based on oil analysis

Inspect hydraulic reservior bladder

1 x every year

Replace hydraulic reservior bladder

1 x every 2 years

Daily inspections Description Check the condition of the hydraulic filter indicator Check hydraulic fluid levels Check for hydraulic fluid leaks Check the condition of hydraulic hoses

Recommended hydraulic lubricants Oil Temperature Range -15˚ to 75˚ C

-10˚ to 85˚ C

(5˚ to 167˚ F)

(14˚ to 185˚ F)

Hyspin AWS-32

Hyspin AWS-46

AW Hyd oil 32

AW Hyd oil 46

Nuto H32

Nuto H46

Harmony 32AW

Harmony 46AW

Manufacturer Castrol Chevron Exxon Gulf Mobil

DTE 24

DTE 25

Shell

Tellus 32

Tellus 46

Statoil

Hydraway HMA 32

Hydraway HMA 46

Texaco

Rando oil HD32

Rando oil HD46

Total

Azolla ZS 32

Azolla ZS 46

Union

Unax AW32

Unax AW46

8 Viscosity Index ISO Viscosity Grade

TDS-11SA

32

46

8-7

Hydraulic System

Inspection Hydraulic fluid level and filter


Daily Red “Pop-up” Dirt Alarm



Procedure

8

Check the red “pop-up” alarm on the hydraulic filter daily Replace the filter (Varco P/N 114416)if the indicator has popped up or as recommended Use care to prevent contamination from entering the hydraulic system during maintenance activities

8-8

Varco Systems

Hydraulic System

Inspection Adding the hydraulic fluid Specifications Reservoir Capacity

25 gal

Procedure Turn the TDS-11SA off Ensure that the area is clean prior to adding hydraulic fluid Remove dust plug from the male quick disconnect at the TDS-11SA hydraulic oil fill Remove dust plug from the female quick disconnect on the lubrication kit Connect the two fittings and pump fluid until the level reaches the middle of the sight glass as showm See Lube Schedule for specifications After adding fluid, replace the dust plugs



Hydraulic Oil Fill Male Quick Disconnect

Hydraulic Oil Fill

Female Quick Disconnect

Hydraulic Lubrication Kit 55 gal Drum Varco P/N 92643

TDS-11SA

8

8-9

Hydraulic System

Inspection Draining the hydraulic fluid

Precautions Hydraulic fluid may be hot Use care when opening the valve Avoid spills Holds 25 gallons

Valve Handle

Pump Inlet/Drain Adapter 10 HP AC Pump Motor

Procedure

8

Isolate power to the pump motor Ensure that the valve is closed Remove the plug and attach a hose Open the valve and drain the fluid Close the valve and remove the hose Replace the plug

8-10

Fixed Displacement Pump Variable Displacement Pump

Varco Systems

Hydraulic System

Inspection Hydraulic reservoir bladder (yearly)

Reservoir Breather

Hydraulic Oil Reservoir Between AC Drilling Motors Reservoir Cover

Apply gasket sealing compound to prevent leaks

Yearly Reservoir Bladder Varco P/N 110191-501 Check for wear and damage Gasket Varco P/N 110132

Front Apply gasket sealing compound to prevent leaks

Rear

Hydraulic Oil Reservoir

Procedure Drain hydraulic fluid and clean area before inspecting the reservoir bladder Remove the 10 cap screws and lock washers from the cover Remove cover with bladder attached Check yearly for wear or damage Replace the bladder every two years Replace the bladder if fluid escapes the reservoir breather when the Top Drive is on its back

TDS-11SA

8-11

8

Hydraulic System

Inspection Heat exchanger

Blower and Brake Covers

Monthly Oil Heat Exchanger Remove any dirt and inspect for leaks, corrosion, and cleanliness

Drill Motor Assembly Left side

8

8-12

Varco Systems

Hydraulic System

Inspection Using the hydraulic system test ports

Stand Jump SV9 L4

PV

Brake SV1

Clamp/ Shot Pin SV5

P1 IBOP SV4

PF

Float Link SV8 Tilt SV6

* B8

G5

A4 CB

* SA * P

* T1

C4 SV2 Rotating Link Adapter Z1

B9 B1

A6 C5 B5

8

B6

* These test ports are on sides or bottom of manifold.

As Viewed From Below

TDS-11SA

8-13

Hydraulic System

Inspection Precharging the accumulators

i

Port

Accumulator

Setting

System Accumulator

(125-cubic inch displacement) 800 psi precharge

SA



CB

Time-Delay Accumulator


C4

Bleed the accumulator if the pressure is higher, or add nitrogen if the pressure is lower than specified above.

Procedure Disconnect the hydraulic lines to the accumulators and drain them of all hydraulic fluid. With the hydraulic system shut down, and the counterbalance mode valve in the “shut down” position, test the hydraulic pressure at CB, SA and C4 on the hydraulic manifold, mounted to the transmission housing. Verify that all three points measure 0 psi.

i

Note that there is a time delay in pressure decay on port C4.


Upper IBOP Time- Delay Accumulator

Test the precharge pressure on the following three nitrogen filled accumulators, using part number 114446-1.

Varco Part Number 114446-1

Hydraulic Manifold (Reference)

System Accumulator

Front

Rear

8

8-14

Varco Systems

Hydraulic System

Inspection IBOP timing circuit IBOP Actuator Cylinder 2.500" Dia. Bore X 4.00" Stroke 1.750" Dia. Rod Open

Test Point Typical

Close

Hydraulic Cylinder CR LODC

30 PSI CXCD

2


1

T-13A

1

Logic Cartridge

30 Cubic Inches 800 PSI Precharge

2

3 50 PSI CP

VR

T-11A

Gas Charged Accumulator

A4

B4

A4

B4

-6

-6

IBOP Close Solenoid (Solenoid Valve 4) Double Solenoid Valve

-6

-6

(Small)

IBOP Close

Cable ID Number

A

B

P

T

b

SV4

A4

B4

-6

-6

-6

C04

C4

Manifold Assembly

.055ø D03

500 PSI

CV4

Flow Control Valve

D4 1

T-11A 3

T-11A

2

1

.010ø 2

8

3

PC4

System Pressure

TDS-11SA

Tank

8-15

Hydraulic System

Inspection IBOP and oil pressure switch Hoses Inspect for wear or damage. Replace yearly or as required.

Yearly

IBOP Pressure Switch Configuration

Oil Pressure Switch Configuration

Pressure Adjusting Screw

Yearly

Switch Pressure Settings Component

Setting

IBOP Pressure Switch

Factory preset at 102.0 BAR (1500 psi) rising +0 Factory preset at 18.0 -1.0 psi decreasing

Wires Inspect for wear or lose connections.

8 Oil Pressure Switch

8-16

Varco Systems

Hydraulic System

Setting up the circuits Hydraulic pumps and unloading circuit There are two pumps – a fixed displacement pump runs the transmission lubrication system and a variable displacement pump provides hydraulic flow to the hydraulic system.

Guide Beam

Pump/Motor

Pump Pressure Compensator Adjustment Point

8 Variable Displacement Pump

TDS-11SA

Fixed Displacement Pump

10 HP AC Pump Motor

8-17

Hydraulic System

Setting up the circuits Fixed displacement (lube) and variable displacement pumps 1. Jog-start the electric motor to make sure the direction of rotation is correct (clockwise when looking into pump shaft/ electric motor fan). Correct as required. 2. Start the electric motor and allow both hydraulic pumps to circulate oil. Listen for unusual noises that would indicate cavitation; check for leaks. 3. Locate the tube connecting manifold port PF to the lubrication motor. Disconnect the tube at the manifold end, cap the tube and plug the PF port using steel fittings. 4. Set the relief valve RV1 for the variable displacement pump to a minimum setting, fully counterclockwise, which allows the hydraulic system to operate without building up pressure. 5. Set the relief valve RV2 to minimum pressure, fully counterclockwise.

i

Make sure the variable displacement pump case is filled with clean hydraulic oil.

6. Connect a gauge to test point PF. Increase the pressure by adjusting relief valve RV2 clockwise until the pressure increases to 400 psi at test point PF. Set the jam nut on RV2. A steel cap is installed over the adjustment screw to discourage unauthorized adjustment.

i

While adjusting valves, verify a linear relationship between turning the adjustment screw and observing the pressure change.

7. Turn off the electric motor. Reconnect the tube between manifold port PF and the lubrication motor.

8

8. Connect an ammeter to the electric motor. Note the full-load amps on the motor nameplate. 9. Restart the hydraulic system electric motor. 10. Set the counterbalance mode valve to the RUN position. 11. Adjust UV1, fully clockwise, to maximum pressure.

8-18

Varco Systems

Hydraulic System

Setting up the circuits Fixed displacement (lube) and variable displacement pumps 12. Connect a gauge to test point PV. Note the ammeter reading while RV1 is at minimum setting. 13. Raise the setting of relief valve RV1 from 0 psi to 1,500 psi at a steady rate. During the pressure rise, observe the ammeter. The motor current should rise to a maximum value at 800 psi, then drop off and begin to rise again. The point where the current drops is the pump pressure compensator setpoint. 14. Adjust relief valve RV1 to its minimum setting. If maximum motor current does not occur at 800 psi, adjust the pump pressure compensator as required. 15. Adjust relief valve RV1 again from 0 psi to 1,500 psi, and back to 0 psi to verify maximum motor current at 800 psi. 16. Connect a gauge to test point SA, and leave the gauge on PV. 17. Adjust relief valve RV1 to 2,200 psi and secure the jam nut. 18. Install steel cap over the adjustment screw to discourage unauthorized adjustment. 19. Adjust unloading valve UV1 counterclockwise until the pressure at PV drops off, then an additional two turns counterclockwise. The pressure cycles like a sawtooth wave. Pressure at PV

3000

Pressure at SA

2000 Pressure 1700 (psi)

1000 800

8

150 0

10

20

30

40

50

60

Approximate Time (seconds)

TDS-11SA

8-19

Hydraulic System

Setting up the circuits Fixed displacement (lube) and variable displacement pumps 20. Observe the unloaded pressure at PV (about 0 psi) while SA reads about 2,000 psi. The pressure at SA decays until UV1 reloads. After reloading, the pressure rapidly rises to the unload pressure. 21. Observe several unload-reload cycles to determine the unload pressure. 22. Adjust the setting of UV1 as required to a 2,000 psi unload pressure.

!

Perform the adjustment with reasonable speed. The process takes no longer than two minutes. Taking longer increases the temperature of the hydraulic fluid.

23. Observe the cycle of loading and unloading of the relief valve. To verify the setting of UV1, note the difference in pump noise level between the loaded and unloaded condition.

RV1

RV2 CB6

CV5

CA6

CV4

A2

LB6

B2

CDR

CV1

PC1

LC5

LA6

RV2

RV1

PCC

T1

T1 C5

B1

B2

A2

Manifold Side View

Manifold Bottom View

B6

A6

Z1

DR

TF B5

B5

B4

C5

B9 TR T1

SV5 SV2

B4 E6

G6

E5

SV1

B1

SV9

CV2 PV

P5 C4

B8

PF RIG-UP

MV SHUTDOWN

PV DF

P/N 0181

PF RUN

SV4

COUNTERB NCE MODE

G5

8

PF

8-20

Varco Systems

Hydraulic System

Setting up the circuits Fixed displacement (lube) and variable displacement pumps

Manifold Assembly UV1 2200 PSI

T-10A RV2

2

3

T-11A

1 Z1 1

400 PSI

2 RV1

PV

PF

800 PSIG

Pump-Motor Assembly B 1.00 IN^ 3/REV. L

1.10 IN^ 3/REV. MAX. .50 IN^ 3/REV. MIN.

S

L1

8

TDS-11SA

8-21

Hydraulic System

Setting up the circuits Counterbalance circuit and stand-jump circuit 1. For the counterbalance circuit there are three adjustments: ❏

Relief valve (on counterbalance cylinder)

❏

PCC – operator set

❏

SJR – operator set

2. To set the relief valve, make sure the pumps are operating. 3. Adjust pressure reducing valve PCC to the maximum setting, fully clockwise. 4. Connect a gauge to test port CB. 5. Adjust the cylinder-mounted relief valve to mid-scale to lower the pressure setting. 6. Increase the pressure clockwise using a 5/32 in. Allen wrench and 9/16 in. open-end wrench. 7. Observe the relationship of turning the relief valve adjustment clockwise to pressure increase. 8. When the relief valve reaches system pressure, turn the setting one full turn clockwise beyond the setting and set the jam nut. 9. Install a steel cover over the valve. 10. Adjust PCC to 1,200 psi. 11. Measure pressure at test port CB. 12. Prepare the hardware to attach the cylinder pear links to the hook. 13. Rotate the counterbalance mode valve from the RUN position to RIG-UP position. This causes the counterbalance cylinders to slowly extend.

8

!

Cylinders stroke to the end of stroke with the mode valve in the RUN position.

8-22

Varco Systems

Hydraulic System

Setting up the circuits Counterbalance circuit and stand-jump circuit 14. Once cylinders reach end of stroke, attach hardware to the pear links on the hook. 15. Rotate the counterbalance mode valve back to the RUN position. 16. Adjust PCC counterclockwise to raise the pressure at test port CB until the rail just begins to lift off of the hook. 17. Reduce the pressure slowly (25 psi) to allow the pressure to stabilize. 18. Rotate the counterbalance mode valve to the SHUTDOWN position to bleed down counterbalance cylinders and system accumulator before shipping or performing maintenance. 19. Adjust pressure reducing valve PCC counterclockwise until the bail rests on the hook. Note the pressure at CB. 20. Reduce PCC an additional 25 psi. The pressure at CB is about 1,600 psi. 21. Connect a gauge to test point B9. Activate the STAND JUMP mode on the drilling console. Adjust relief valve SJR until the bail lifts off the hook. The gauge at B9 should read about 190 psi. 22. Switch back to DRILL counterbalance mode and observe the pressure at test point CB. 23. Switch back to STAND JUMP mode and observe the pressure CB increase by 190 psi.

8

TDS-11SA

8-23

Hydraulic System

Setting up the circuits Counterbalance circuit and stand-jump circuit PCC CB6

CV5

CA6

CV4

A2

LB6

B2

CDR

CV1

PC1

LC5

LA6

RV2

RV1

PCC

T1

T1 C5

B1

B2

A2

Manifold Side View

B6

A6

Z1

DR

P

Manifold Bottom View TF

B5

B5

B4

C5

Manifold End View

B9

SA

CTR

TR T1

SV5 SV2

B4 E6

G6

E5

SV1

B1

SV9

CV2 PV

C4 PF

UV1

RIG-UP

MV

1 XC

SHUTDOWN

PV

P/N 0181

PF COUNTERB NCE MODE

SV4

RUN

G5

DF

SA

CB

P5

B8

CB

8

8-24

Varco Systems

Hydraulic System

Setting up the circuits Counterbalance circuit and stand-jump circuit Pressure Relief Valve

2500 PSI T-3A

-4 OR1

ZC

2 CP

OR2

.075ø

1

CP

-12

CP

-12

.075ø

75 PSI 1 2

75 PSI 1 2

T-13A

T-13A

CV1

Counterbalance Cylinders 4.000" Dia. Bore X 8.50" Stroke 2.000" Dia. Rod

-12

CV2 T

-12 .010ø

T


Normally-Open Logic Cartridge Metering

T


-16

5 PSI

-6

90 PSI

XC

Prefill Valve

25mm

Cable ID Number

.047ø

Stand Jump

Counterbalance Mode Rig-up

Stand Jump Solenoid (Solenoid Valve 9)

2 Position Valve

Shut-down Run A

B

A

B

P

T

b C09

3 Position Valve with Detent

T

D03

-6

P

MV

.055ø

CB

Manifold Assembly

SV9 D03

XC CV3 75 PSI T-21A

CB

Test Port B9

B9

1 4 3

CDF 4 PSI DF

2

2 T-10A

1

System Accumulator

SA

TDS-11SA

2 2

TF

4

PCC T-21A

DF


1

1600 PSI

T-13A

T-5A 30 PSI

1

Pressure Relief Valve

1 SJR 2

190 PSI

3

8

System Pressure CTF

To Tank

8-25

Hydraulic System

Setting up the circuits AC motor brake circuit The AC drilling motor brakes are spring released and hydraulic pressure applied at 1,400 psi. The pressure reducing valve regulates the pressure to 1,400 psi. The solenoid valve operates to apply pressure, setting the brakes, or stop pressure to release the brakes. To test the system, turn the auto brakes switch on the driller’s console to the ON position. Attach a pressure gauge to B1 in the manifold. The pressure reading should be 1,400 psi. If the reading is not 1,400 psi, adjust the pressure control reducing valve PC 1 to 1,400. Turn the auto brakes switch to the OFF position. The pressure reading should be very low. If the pressure is high, the solenoid valve might be sticking. RV2 CB6

CV5

CA6

CV4

A2

LB6

B2

CDR

CV1

PC1

LC5

LA6

RV2

RV1

PCC

T1

T1 C5

B1

B2

A2

Manifold Side View

Manifold Bottom View

B6

A6

Z1

DR

TF B5

B5

B4

C5

B9 TR T1

SV5 SV2

B4 E6

G6

E5

SV1

B1

SV9

CV2 PV

P5 C4

B8

PF RIG-UP

PV

MV SHUTDOWN

DF

P/N 0181

PF COUNTERB NCE MODE

SV4

RUN

G5

B1

8

8-26

Varco Systems

Hydraulic System

Setting up the circuits Shot pin circuit 1. Set the adjustable relief valve near the body of the cylinder. The shot pin often misses the hole in the rotating gear. The force the shot pin exerts is limited until the pin engages a hole.

i

The electrical system jogs the rotating head until the pin engages a hole.

2. To limit the amount of force, you set the valve by operating solenoid valve SV5 manually, forcing the pin to stop on the face of the gear. 3. When the pin stalls out, measure the pressure at B5. Set the relief valve pressure to 200 psi. 4. Tighten the jam nut on the relief valve. 5. At rest, the SV5 valve is de-energized. 6. Test the pressure at C5. Adjust reducing valve AR5 to 500 psi. Hydraulic Drive Motor SV5

C5 Link Adapter Rotation Gear

Hydraulic Manifold

(As Viewed from Below)

Shot Pin

8

(Simplified for Clarity)

TDS-11SA

8-27

Hydraulic System

Setting up the circuits Rotating Link Adapter Drive Motor and Shot Pin Assembly

10 HP AC Motor and Pump Assembly


Hydraulic Drive Motor

Motor Relief Valve Rotating Link Adapter

B5

Shot Pin Relief Valve

A B Motor Relief Valve

C5 Link Adapter Rotation Gear

A5

Shot Pin

8

8-28

Varco Systems

Hydraulic System

Setting up the circuits Link tilt cylinder circuit 1. There is nothing to adjust on the manifold for the link tilt circuit. 2. Adjust the four load holding valves in pairs – the upper pair and lower pair. Adjust all four counterbalance valves fully clockwise, then one turn counterclockwise.

i

If the valves are not adjusted correctly, link tilt operation is not synchronized.

3. The correct pressure setting is 1,500 psi. The procedure is the same for all four valves. Adjust the valves one at a time. 4. There is a test point on each loading manifold. 5. From the driller’s console, move the link tilt to go to the mousehole position. 6. The cylinder goes to full extension and the pressure at the test port TP is 2,000 psi. 7. Command the link tilt to the OFF position and observe the pressure delay at TP. This delayed pressure is the setpoint of the counterbalance valve. 8. Raise the valve setpoint by turning the adjusting screw 1/4 turn counterclockwise. 9. Repeat steps 6 and 7 until the decayed pressure is 1,500 psi.

i

!

This is an iterative process. Continue to set the driller’s console control to the mousehole position and OFF, taking present and decayed pressure readings.

Turning the counterbalance valve counterclockwise increases the pressure.

8

10. Repeat the procedure above for the other cylinder at the mousehole position. 11. Command the link tilt to the DRILL position and repeat the procedure above to set both counterbalance valves on the DRILL side.

TDS-11SA

8-29

Hydraulic System

Setting up the circuits Rotating link adapter hydraulic motor relief circuit 1. Set the relief valves mounted on rotation motor. 2. Operate the clamp. The shot pin must go through the hole, which locks up the gear. 3. Turn the manual override on the SV2-rotation circuit to drive the head in the counterclockwise direction. Test the pressure at A and adjust the relief valve to 1,600 psi. 4. Turn the manual override on the SV2-rotation circuit to drive the rotating head in the clockwise direction and test the pressure at B. Adjust the relief valve to 1,600 psi.

Hydraulic Drive Motor

Relief Valves

Manifold Link Adapter Rotation Gear Test Points


8

8-30

Varco Systems

Hydraulic System

Troubleshooting HPU and reservoir bladder Problem

Probable cause

Remedy

Hydraulic system overheating

Relief valves RV1 and RV2 out of adjustment.

Test pressures and adjust relief valves.

Unloading valve is not working.

Test and adjust UV1 or replace unloading valve.

Counterbalance mode valve left in shut down position too long and pressure bleeds down.

Check system pressure.

No precharge in system accumulator.

Charge system accumulator.

System pressure is down.

Test pumps and motors. Test relief valve pressures. Adjust as required. Check for leaks, loose fittings, loose cylinders, worn hoses, fluid levels and seals.

Piston pump is not working.

Replace the piston pump.

Flexible coupling is damaged.

Replace the flexible coupling.

Lubrication pump is not working.

Replace the lubrication pump.

Pressure at UV1 is too low.

Adjust pressure at UV1.

Pumps are rotating in the wrong direction.

Inspect hydraulic connections and correct rotation.

Suction valve closed.

Open suction valve.

Low oil level in reservoir.

Fill hydraulic reservoir.

Hydraulic components do not operate.

8

TDS-11SA

8-31

Hydraulic System

Troubleshooting HPU and reservoir bladder schematic diagram

PV

PF

TR

DR

Manifold Assembly Hydraulic Fill Disconnect

System Pressure 6µm

50 PSID

Prefill Valve -12

Pressure Compensator Control

T

Filter with Bypass Valve

T -16

800 PSIG -6 XC B 1.00 In^ 3/Rev. L 1.10 In^ 3/Rev. Max. .50 In^ 3/Rev. Min.

M 10 HP 1800 RPM S

Variable Displacement Pump

L1

Filter (Strainer)

4 PSI Vent

Fixed Displacement Pump

Reservoir Assembly

8

8-32

Varco Systems

Hydraulic System

Troubleshooting Counterbalance and stand jump The accumulator, with precharge pressure of 900 psi, along with check valve CV3, maintains a hydraulic pressure. Refer to the vendor documentation material located in the Vendor Documentation Package, for the gas charging procedure for the accumulator. A three-position manually operated valve controls counterbalance operation for rig-up, run, and shut down modes. In the rig-up mode, system pressure is applied to XC and the prefill valve, causing both cylinders to extend. When the cylinders extend, you make up the mechanical connection to the bail. In the run mode, for counterbalance operation, approximately 1,600 psi is needed at the counterbalance cylinders to lift the TDS-11SA off the hook. The optional stand jump feature is controlled by solenoid valve SV9. With the counterbalance in the run mode and the stand jump switch on, additional pressure of approximately 300 psi is applied to over the normal counterbalance pressure to lift the TDS-11SA and drill string off the hook. In the shutdown mode, the hydraulic system bleeds down the system accumulator and the counterbalance accumulator pressure.

Counterbalance testing For the counterbalance operation, a lift of approximately 30,000 lb is achieved with a pressure of 1600 psi at CB. Perform the following steps to adjust the force: 1. Set the counterbalance mode valve on the bottom of the manifold to the RUN mode. Set the pressure control valve PCC to the minimum setting (fully counterclockwise). 2. Test the pressure at port B9. There should be a 0 psi reading. 3. Test the pressure at port CB. Observe the position of the top drive on the hook. 4. Adjust the pressure at pressure control valve PCC clockwise, observing pressure at CB, until the top drive just lifts off the hook. Back off the pressure 25 psi, as the top drive rests on the hook.

TDS-11SA

8

8-33

Hydraulic System

Troubleshooting Stand jump testing For the optional stand jump feature, a lift of about 33,000 lb is achieved with a pressure of approximately 1800 psi at CB. The additional 300 psi pressure over the normal counterbalance pressure is provided by energizing the stand jump solenoid valve SV9. Perform the following steps to adjust the pressure: 1. Set the counterbalance mode switch to RUN and engage the stand jump switch. Test the pressure at port CB and B9. Adjust relief valve SJR fully counterclockwise to the minimum setting. 2. Slowly increase the pressure at CB by adjusting relief valve SJR clockwise until the bail lifts off the hook with a stand of pipe in the elevator.

i

Adjust relief valve SJR slowly to allow pressure at CB to stabilize.

8

8-34

Varco Systems

Hydraulic System

Troubleshooting Problem

Probable cause

Remedy

Counterbalance does not function.

Cylinder damaged. Seal leaks.

Inspect cylinder and repair or replace seal.

No hydraulic pressure.

Test pressure and ajust pressure reducing valve.

Solenoid valve SV9 is not operating.

Test electrical and hydraulic operation. Replace or repair as applicable.

PCC is not operating.

Replace the valve.

Relief valve is not operating.

Replace the valve.

Precharge on the accumulator is low.

Charge the accumulator.

Cylinder damaged. Seal leaks.

Inspect cylinder and repair or replace seal.

No hydraulic pressure.

Test pressure and adjust pressure reducing valve.

Solenoid valve SV9 is not operating.

Test electrical and hydraulic operation. Replace or repair as applicable.

PCC is not operating.

Replace the valve.

Relief valve is not operating.

Replace the valve.

Precharge on the accumulator is low.

Charge the accumulator.

Stand jump does not function.

8

TDS-11SA

8-35

Hydraulic System

Troubleshooting Counterbalance and stand jump schematic diagram Pressure Relief Valve

2500 PSI T-3A

-4 OR1

ZC

2 CP

OR2

.075ø

1

CP

-12

CP

-12

.075ø

75 PSI 1 2

75 PSI 1 2

T-13A

T-13A

CV1

Counterbalance Cylinders 4.000" Dia. Bore X 8.50" Stroke 2.000" Dia. Rod

-12

CV2 T

-12 T

.010ø

T


Normally-Open Logic Cartridge Metering


-16

5 PSI

-6

90 PSI

XC

Prefill Valve

25mm

Cable ID Number

.047ø

Stand Jump

Counterbalance Mode Rig-up

Stand Jump Solenoid (Solenoid Valve 9)

2 Position Valve

Shut-down Run A

B

A

B

P

T

b C09

3 Position Valve with Detent

T

D03

-6

P

MV

.055ø

CB

Manifold Assembly

SV9 D03

XC CV3 75 PSI T-21A

CB

Test Port B9

B9

1 4 3

CDF 4 PSI DF

2

2 T-10A

1

8

System Accumulator

SA

8-36

2 2

TF

4

PCC T-21A

DF


1

1600 PSI

T-13A

T-5A 30 PSI

1

Pressure Relief Valve

1 SJR 2

190 PSI

3

System Pressure CTF

To Tank

Varco Systems

Hydraulic System

Troubleshooting Troubleshooting the brakes Problem

Probable cause

Remedy

Brake does not release.

Directional valve is stuck.

Test the valve and replace if necessary.

Brake releases but still drags.

Check valve is blocked or tube is pinched.

Replace the check valve or tube as required.

Mechanical problems with brakes.

Repair brake mechanism.

Hydraulic oil on brake pads.

Check for hydraulic leaks and repair.

Pressure is not 1,400 psi or does not rise crisply to 1,400 psi.

Reducing valve is plugged or needs to be adjusted or replaced.

Directional valve is stuck (check pressure at B1).

Replace valve or check electrical signal.

Hydraulic oil is contaminated.

Replace hydraulic oil.

Pressured reducing valve is faulty.

Replace valve.

Brakes do not engage or slip.

Delay in brakes actuating after console switch is turned on.

8

TDS-11SA

8-37

Hydraulic System

Brake circuit schematic diagram Brake Calipers

2 Position Solenoid Valve Brakes On

Cable ID Number

A

B

P

T

b

-4

C01

B1

SV1

.071ø

Manifold Assembly

D03

Non-Adjustable Orifice P1

Test Point

1400 PSI PC1

Reducing Valve

8

1

T-11A

2

System Pressure

8-38

3

Tank

Drain

Varco Systems

Hydraulic System

Troubleshooting Shot pin cylinder and clamp cylinder Problem

Probable cause

Remedy

Shot pin does not engage.

Solenoid valve is not operating or relief valve is not adjusted.

Check electrical actuation and test pressure. Adjust as required.

Abnormal pressure change at B5 and C5 indicates valve problem.

Replace directional control valve.

Normal pressure change indicates plumbing or shot pin cylinder are faulty.

Repair plumbing or shot pin cylinder.

Shot pin applies excessive force to rotating head gear.

Relief valve is not operating or out of adjustment.

Test pressures and adjust as required.

Clamp cylinder does not actuate.

No pressure or reduced pressure at the cylinder. Test pressures and adjust and repair as required.

i

Shot pin engages but clamp cylinder does not activate.

Cylinder is damaged.

Inspect cylinder and repair or replace.

To provide high pressure to the clamp circuit, pressure at C5 must be 2,000 psi and G5 must be less than 100 psi. If this condition is met, pressure at CP should increase from less than 100 psi to higher than 2,000 psi. If not, check the plumbing, rotating link adapter, and clamp cylinder.

Repair plumbing, rotating head, or clamp cylinder.

While clamping, pressure at CR should be 2.7 times the pressure at CP. When the dies contact the pipe, pressure at CR should be less than 100 psi. If the pressure does not fade, check valve CNEC for contamination.

Clean or repair CNEC valve.

Control valve not operating.

Check pressure at C5. Replace valve CV5 if required or the regenerate manifold.

8

TDS-11SA

8-39

Hydraulic System

Troubleshooting Shot pin cylinder and clamp cylinder schematic diagram Clamp Cylinder 10.000" Dia. Bore X 2.0" Stroke 8.000" Dia. Rod

Hydraulic Cylinder Cavity Plug

CP

CR

1

Pilot-to-Close Check Valve

2

3 T-2A

CKEB

30 PSID 2 1 CNEC

Shot-Pin Cylinder

3

2.000" Dia. Bore X 2.31" Stroke 1.500" Dia. Rod

Relief Valve

T-2A

1 T-5A

COFA .047ø

2

Shot Pin Cylinder

400 PSI

2

30 PSID

2

2x .094ø

VR

VP 1

2 Position Solenoid Valve 5 Clamp/Shot Pin

Non-Adjustable Flow Control

Cable ID Number

A

B

P

T

b

A5

.159ø

SV5 D03

E5

G5

E5

G5

-8

G5

.039ø

B5

.031ø

C5

AR5 2

3

Pressure Reducing Valve

2

1 LC5

1

T-11A

.031ø

50 PSI 3

Logic Cartridge

Rotating Link Adapter Assembly

-6

-6

C05

E5

-8

Clamp

-8

-8

T-10A B5 C5

.031ø

500 PSI

T-11A

3

2

T-21A CV5

Externally-Drained Pilot-to-Open Valve

1

4 75 PSI P5

Drain

1

8

3

T-11A

System Pressure

PC5

2

Tank

Drain System Pressure Tank T1

8-40

T1

D5

Manifold Assembly

Varco Systems

Hydraulic System

Troubleshooting Link tilt cylinders Problem

Probable cause

Remedy

Drill pipe elevator does not reach mouse hole/ derrickman position.

Link clamp incorrectly adjusted.

Readjust

Links drift when valve is released.

Pressure at B8 does not decay to less than 100 psi.

Replace the pilot to open check valve.

Pilot to open check valve is stuck open or contaminated.

Replace the pilot to open check valve.

Faulty cylinder seal.

Replace the seal.

Load holding relief valves are out of adjustment, stuck open, or contaminated.

Adjust or replace the load holding relief valve.

Drill pipe elevator does not float back to center position.

Use manual override. If the link tilts, the problem is electrical. If the links do not tilt, the problem is hydraulic.

Test the solenoid and connectors. Test the hydraulic system.

Link tilt does not tilt.

Solenoid valve is not shifting.

Check electrical continuity.

Links do not move together.

Load holding valves are out of adjustment.

Adjust the pressure for all four valves to 1,500 psi.

8

TDS-11SA

8-41

Hydraulic System

Troubleshooting Link tilt cylinders schematic diagram Link Tilt Cylinder 3.250" Dia. Bore X 10.3" Stroke 1.380" Dia. Rod

Mousehole Drill Down

C1

C1

1500 PSI

CV1 T-11A 1

X1

C2

CV2 T-11A 3

1

X2

3 2

2

2

C2

T-11A CB2

1

3

2

C2

1500 PSI

T-11A CB1

1

3

C1

V1

V2

H

J

Link Tilt "Tilt" Solenoid (Solenoid Valve 6)

Link Tilt "Drill Down" Solenoid (Solenoid Valve 6)

B

P

T

SV8

Logic Cartridge

D03

B8

LA6 T-11A 1 50 PSI 2

8

3 A6

A

B

C07 Drill Down P

T

b

-8

A

-6

b C08

Link Tilt

E6 .031ø

.071ø

1

SV6

D03 .031ø

75 PSI

.031ø B6

3

3

2

4

.031ø

Logic Cartridge

a C06 M'hole

-8

Link-Tilt Float

X -8

X -8

G6

-8 X

-8

J

Rotating Link Adapter Assembly

Link Tilt "Float" Solenoid (Solenoid Valve 8)

CA6 T-21A .031ø

G6

T-11A 1

50 PSI 2 LB6

.071ø 4

2

3

1 CB6 75 PSI T-21A

Pressure Tank

Manifold Assembly X

D1

X

A8

8-42

H

-8 X

E6

G6

-8

B8

-8

E6

Cable ID Number

-8

-8 G6

X

-8

-8

E6

X

-6 B8

X

-6 B8

V2

V1

FL

Varco Systems

Hydraulic System

Troubleshooting Gearbox lubrication hydraulic system Problem

Probable cause

Remedy

Oil leaking from lower seal. Worn oil seals.

Replace seals.

Oil leaking from upper bearing retainer.

Worn oil seals.

Replace seals.

Gearbox oil temperature (less than 230˚F).

Oil level too low or too high.

Adjust oil level to middle of sight glass.

Incorrect lubricant used.

Check recommended lubricants chart and replace as needed.

Damaged gears or bearings.

Repair or replace as needed.

Oil level is too low. Oil overheated.

Add oil.

Oil pressure switch is out of adjustment.

Adjust per page 8-16.

Gear spray nozzle missing.

Replace spray nozzle.

Excessive oil viscosity.

Lower oil viscosity.

Faulty motor. Intermittent operation.

Replace motor.

Oil pump hydraulic motor failure.

Replace motor.

Broken lube pump adapter plate spline.

Replace adapter plate spline.

Faulty fixed displacement pump.

Check pressure at PF. Replace pump if pressure is low.

Low hydraulic fluid in reservoir.

Add hydraulic fluid.

Suction valve closed on fixed displacement pump.

Open suction valve.

Missing inspection plugs.

Replace inspection plugs.

Upper gearbox seals worn.

Replace seals.

Water in oil.

Replace oil.

Excessively viscous oil. Cold oil.

Lower oil viscosity.

Worn gears or damaged bearings.

Replace gears or bearings.

Damaged oil pump.

Replace oil pump.

Foreign particles blocking orifice or nozzle.

Clean orifice or nozzle.

Oil pump loss alarm is on.

Water/mud in oil.

Excessive foaming.

Metal in oil.

Restricted oil flow.

TDS-11SA

8

8-43

Hydraulic System

Troubleshooting Gearbox lubrication hydraulic system schematic diagram Pressure Switch S04

Spray Nozzles (4)

Orifices (6)

18 PSI Decreasing -16 1.0 GPM Ea.

1.5 GPM Ea.

Upper Compound Gear

Lower Compound Gear

.205ø

.062ø

Upper Mainshaft Bearing

.047ø .047ø

.059ø .059ø

Lower Radial/Main Thrust Bearings

Upper Compound Bearing

L4

Lower Compound Bearing

Lube-Oil Filter Lube Pump

60µm

5.10 In.^ 3/Rev. L1 -16

Lube-Oil Pump -10 A

-10

Tank

B

3.0 In.^ 3/Rev. Lube Pump Motor

Hydraulic Motor

Hydraulic Heat Exchanger

Tank

T-10A RV2

2

1

400 PSI

Manifold

PF

1.00 IN^ 3/REV.

8 Part of Pump Motor Assembly

8-44

Reservoir Assembly

Varco Systems

Hydraulic System

Troubleshooting Problem

Probable cause

Remedy

Tool does not rotate.

Direct control valve or relief valve is sticking.

Inspect, repair or replace the valve.

When you override a directional valve, you bypass the safety interlock and top drive components move, possibly causing serious injury or death.

Tool does not return to home position.

Links are not synchronized.

Solenoid valve is not electrically operating.

Check electrical connections and valve functions.

Motor is worn out or gear teeth are broken.

Replace the motor.

Shot pin is engaged.

Adjust the relief valve.

Mechanical interference.

Inspect and repair.

Directional valve does not shift.

Test pressure left and right. Replace the valve.

Fixed valve orifice is plugged.

Clear orifice or replace the valve.

Hydraulic lines are damaged.

Replace hydraulic lines.

Valve is sticking or relief valve is out of adjustment.

Test pressures and inspect valves. Adjust the relief valve as required.

Sensor is broken.

Replace sensor.

If the motor will drive normally, but not drive to the home position, the cause could be the control system.

Checkout control system.

Counterbalance valves are out of adjustment.

Adjust valves together-pressure is the same for all four valves.

8

TDS-11SA

8-45

Hydraulic System

Troubleshooting Rotating link adapter motor schematic diagram Rotating Head Motor

A

B

Fixed Displacement Motor 2

1

T-10A

Pressure Relief Valves

1600 PSI

1600 PSI

T-10A

2

1

A

B

Rotate Left Solenoid

Rotate Right Solenoid

Rotating Head

Cable ID Number

A

Cable ID Number

B

b

a

C03

C02 P

T

-6

Right

-6

Left

A2

8

SV2 .071ø

Non-Adjustable Orifice

8-46

B2

D03

Pressure

Tank

Manifold Assembly

3 Position Solenoid Valve

Varco Systems

Hydraulic System

Troubleshooting IBOP actuator schematic diagram IBOP Actuator Cylinder 2.500" Dia. Bore X 4.00" Stroke 1.750" Dia. Rod Open

Test Point Typical

Close

Hydraulic Cylinder CR LODC

30 PSI CXCD

2


1

T-13A

1

Logic Cartridge


2

3 50 PSI CP

VR

T-11A

Gas Charged Accumulator

A4

B4

A4

B4

-6

-6

IBOP Close Solenoid (Solenoid Valve 4) Double Solenoid Valve

-6

-6

(Small)

IBOP Close

Cable ID Number

A

B

P

T

b

SV4

A4

B4

-6

-6

-6

C04

C4

Manifold Assembly

.055ø D03

500 PSI

CV4

Flow Control Valve

D4 1

T-11A 3

T-11A

2

1

.010ø 2

8

3

PC4

System Pressure

TDS-11SA

Tank

8-47

Hydraulic System

Hydraulic schematic symbols The following hydraulic troubleshooting section provides a schematic diagram and description for each TDS-11SA hydraulic circuit. Following each schematic is a group of troubleshooting charts to help you quickly locate and correct hydraulic system problems. When performing hydraulic troubleshooting, be aware that: ❏ The electrical control system can be bypassed for troubleshooting by manually overriding the solenoid valve for each operational system.

Alert all personnel near the top drive before overriding a solenoid valve. When you override a solenoid valve, you bypass the safety interlock and top drive components will move possibly causing serious injury or death. ❏ Test points shown in the hydraulic schematic with a box (e.g., A4) can be found on the manifold under the main body. There are also test points on the rotating link adapter motor. ❏ The system is preadjusted. Hydraulic problems are usually related to faulty valves, contamination, or other damage to the system rather than misadjustments. Changes to adjustments should be made only after all other possible causes have been eliminated.

8

8-48

Varco Systems

Hydraulic System

Hydraulic schematic symbols Description

Symbol

Schematic Reference

2 Position 4 Way Valves (Single Solenoid) Solenoid Operated Valves

SV1, SV4, SV5, SV8, SV9 33-1

3 Position 4 Way Valves (Double Solenoid)

SV2, SV6 33-2

Manual Valve (Rotary)

MV

3 Position 4 Way Valve 33-3

Fixed Displacement 33-4

Pumps Variable Displacement

33-5

RV2, A2R, B2R, SJR

Standard Valve 33-6

Pressure Relief Valves

Ventable Relief Valve

RV1 33-7

UV1

Differential Unloading Valve 33-8

Pressure Reducing Valve

PC1, PC4 33-9

PCC

Pressure Reducing/Relieving Valve

8

33-10

Chack Valve 33-11

TDS-11SA

CDF, CTF, CV2, CTR, CDR, CXCD Prefill valve assembly CV1, CV2

8-49

Hydraulic System


Symbol

Schematic Reference CKCB (Link Tilt)

Pilot-To-Open Check Valves

33-12

CA6, CB6, CV3, CV4 (Clamp Body)

Pilot-To-Close 33-13

1 3

PC5

Cavity Plug 2 33-14

Internal Plug 33-15

CV1

Non Adjustable Flow Control Valves 33-16

Non Adjustable Orifice

Diameter in inches 33-17

CBCA (Link Tilt Circuit)

3 Port (Internal Drain) Counterbalance Valves

33-18

4 Port (External Drain)

CWCK (Link Tilt Circuit) 33-19

Standard Cartridge Logic Cartridge

LA6, LB6, LC5, LODC 33-20

With Metering

8

See Prefill Assembly 33-21

Quick Disconnect Coupling 33-22

8-50

Varco Systems

Hydraulic System


Symbol

Schematic Reference See Lube Oil Circuit

Non Bypass Filter 33-23

Filter with Bypass

See Return Circuit 33-24

Manual Shutoff Valve 33-25

Lube Oil Circuit

Thermostat 33-26

Pressure Switch

Lube Oil Circuit 33-27

Hydraulic Circuit (Inside Brake Housing)

Heat Exchanger 33-28

Pressure Compensator Control

Part of the Pump 33-29

Hydro-Pneumatic Accumulator 33-30

Hydraulic Motor (Bi-Directional) 33-31

Hydraulic Cylinder 33-32

8

Tank (Reservoir) 33-33

Test Point 33-34

TDS-11SA

8-51

TDS Training Manual




AC Electrical


VARCO DRILLERS CONSOLE (VDC)

The VDC is made from 300-series stainless steel, it uses full size oil tight switches and indicators and is designed for zone one hazardous areas with its EEx de (ia) rating without requiring to be purged. The Varco supplied Driller’s console is equipped with the following items to directly interface with the AC frequency drives: Throttle The throttle uses a design similar to a standard throttle control supplied with SCR Systems. The handle includes integral stops to prevent damage Torque Limit The torque limit it potentiometer is very similar to the designs used on SCR Systems. The maximum torque output of the drive is limited to the continuous torque rating of the drive and motors. Make-Up Limit Potentiometer The make-up potentiometer controls the makeup torque when the top drive is used to makeup connections using the drilling motor. This control allows the top drive to operate at the intermittent rating. AC TDS Training Manual


VDC CONTROLS

1. DRIVE FAULT Red indicator light flashes and horn sounds when a drive (VFI) fault is detected. 2. BLOWER LOSS Red indicator light flashes and horn sounds if there is a failure in one or both of the air cooling motors. 3. BRAKE ON Red indicator illuminates when the brake solenoid valve is energised. The indicator flashes in case of a faulty make-up connection. 4. DRILL MOTOR OVER-TEMPERATURE Red indicator flashes and horn sounds if there is an over- temperature condition in one or both of the AC drilling motors. AC TDS Training Manual


5. IBOP CLOSED Amber indicator light illuminates when there is hydraulic pressure to the cylinder that closes the IBOP valve. 6. OIL PRESSURE LOSS Red indicator flashes when there is an oil pressure loss in the gear case lubrication system. 7. ALARM SILENCE/LAMP CHECK When any alarm indicator light flashes and the horn sounds, press the switch to silence the horn, the alarm light stays on until the fault is rectified, if the fault is not rectified in 5 minutes, the alarm repeats. The switch is also a lamp check for all lights on the VDC, the switch must be pushed and held for two seconds to obtain a lamp check. 8. BRAKE SWITCH There is three brake switch positions, OFF, AUTO and ON, turning the switch to the ON position turns the brake on and lights the brake indicator. In the AUTO position, the brake automatically turns on when the throttle is turned off. Turning the brake to the OFF position turns the brake off. The brake will operate if there is a drive fault with the VFI. 9. DRILL CURRENT LIMIT POTENTIOMETER The potentiometer sets the current limit in the VFI during drilling operations, this sets the torque for normal drilling operations in the drill position. 10. DRILL PIPE ELEVATOR SWITCH There are three switch positions, OFF, LEFT and RIGHT, 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. NOTE: - This works only after the link tilt float switch is pressed. 11. DRILL/SPIN/TORQUE SWITCH There are three switch positions, DRILL, SPIN and TORQUE, the switch is in the DRILL mode during normal drilling, SPIN mode is a fixed speed and current signal to the AC motors and TORQUE mode is a fixed speed with gradual rise in torque up to the make-up value set by the makeup potentiometer when in Forward mode, when in Reverse the Torque value rises to maximum until the connection is broken. 12. EMERGENCY STOP CIRCUIT The Emergency Stop switch is hard wired to the VFI, pressing the button deselects the VFI and will cause the Top Drive rotation cost to a stop regardless of throttle position. NOTE: - All other auxiliary functions remain ON.

13. IBOP SWITCH The IBOP switch activates the upper IBOP valve, turning the switch to the left retracts the IBOP actuator cylinder to close the valve, turning the switch to the right extends the cylinder to open the valve. AC TDS Training Manual


14. LINK TILT FLOAT The elevator links “float” to the centre (NEURAL) position when the pushbutton is pushed, thus the drill pipe elevator can then be rotated. 15. LINK TILT SWITCH This activates the link tilt cylinders, the centre position is OFF, turning the switch to the left extends the cylinders, turning the switch to the right retracts the cylinders. This is a maintained switch that holds the position of the cylinder when returned to the OFF position. 16. MAKE UP CURRENT LIMIT POTENTIOMETER This potentiometer sets the current limit in the VFI when using the Top Drive to make connections, the Torque can be adjusted by turning the potentiometer to increase or decrease the Torque. 17. OFF/FORWARD/REVERSE SWITCH There are three switch positions, OFF, FORWRD and REVERSE, the OFF position is used to deselect the VFI, FORWARD and REVERSE are used when drilling or making/breaking connections. The switch acts as the drive assignment. 18. TORQUE WRENCH SWITCH Pushing this button engages the pipe clamp and shot pin lock. NOTE: - Wrench cannot clamp with the brake on or throttle open.

19. RPM METER Displays the RPM of the drill pipe. 20. TORQUE METER Displays the drill pipe Torque in Ft/Lbs. 21. STAND-JUMP SWITCH Energises the stand-jump solenoid, this causes drill pipe connection to separate from the saver-sub as it unscrews. 22. THROTTLE Controls the speed of the AC Drilling motors when in drill mode, by sending a reference signal to the VFI. 23. TORQUE RELEASE When the Top Drive is drilling ahead and stalled out, pressing the Torque Release switch will slowly unwind the Torque out of the drill string in a controlled manner. 24. HYDRAULIC POWER AUTO/ON When switched to ON, the Top Drive Hydraulics can still be operated with the Forward/Reverse switch in the OFF position. When in the AUTO position the hydraulics are operated by the assignment of the Top Drive Forward/Reverse. Thus when the Top Drive rotation of the main shaft is not required, the hydraulics can still be operated.

AC TDS Training Manual

TDS Training Manual



System Interconnect

AC Electrical

TDS Training Manual



Siemens Step 7 PLC

AC Electrical

PLC Introduction Programmable Logic Controllers (PLCs), also referred to as programmable controllers, are in the computer family. They are used in commercial and industrial applications. A PLC monitors inputs, makes decisions based on its program, and controls outputs to automate a process or machine. This course is meant to supply you with basic information on the functions and configurations of PLCs.

PLCs consist of input modules, a Central Processing Unit (CPU), and output modules. An input accepts a variety of digital or analogue signals from various field devices (sensors) and converts them into a logic signal that can be used by the CPU. The CPU makes decisions and executes control instructions based on program instructions in memory. Output modules convert control instructions from the CPU into a digital or analogue signal that can be used to control various field devices (actuators). A programming device is used to input the desired instructions. These instructions determine what the PLC will do for a specific input. An operator interface device allows process information to be displayed and new control parameters to be entered. Prior to PLCs, many of these control tasks were solved with contactor or relay controls. This is often referred to as hard-wired control. Circuit diagrams had to be designed, electrical components specified and installed, and wiring lists created. Electricians would then wire the components necessary to perform a specific task. If an error was made the wires had to be reconnected correctly. A change in function or system expansion required extensive component changes and rewiring. The same, as well as more complex tasks, can be done with a PLC. Wiring between devices and relay contacts is done in the PLC program. Hard-wiring, though still required to connect field devices, is less intensive. Modifying the application and correcting errors are easier to handle. It is easier to create and change a program in a PLC than it is to wire and rewire a circuit. PLC Advantages • Smaller physical size than hard-wire solutions • Easier and faster to make changes • PLCs have integrated diagnostics and override functions • Diagnostics are centrally available • Applications can be immediately documented

Siemens Step 7 PLC

Various Varco control systems uses the Siemens Step 7 300 series PLC (AR4000, TDS-4S, Electronic Driller). The complete system consists of the 315-DP CPU, with local Inputs and Outputs, and remote Inputs and Outputs through the PROFIBUS DP network. What is PROFIBUS ? PROFIBUS is a serial fieldbus used primarily as the communication system for exchange and information between automation systems and distributed field devices. Thousands of successful applications have provided impressive proof that use of fieldbus technology can save up to 40% in costs for cabling, commissioning and maintenance as opposed to conventional technology. Only two wires are used to transmit all relevant information (i.e. input and output data, parameters, diagnostic data, programs and operating power for field devices). In the past, incompatible vendorspecific fieldbuses were frequently used, virtually all systems in design today are open standard systems, the user is no longer tied to individual vendors and is able to select the best and most economical product from a wide variety of products. PROFIBUS specifies the technical and functional characteristics of a serial fieldbus system with which decentralised digital controllers can be networked together from the field level to the cell level, Profibus distinguishes between master and devices and slave devices.

Siemens Step 7 PLC Programming The Siemens Step 7 PLC has three main methods of programming, these are LAD (Ladder Logic), STL (Statement List) and FBD (Function Block Diagram). The software for the AC Top drive is written mainly in Ladder Logic with a small part written in Statement List (For the communication with the Siemens 70 Series Drive), none of the program was written in Function Block Diagram.

Ladder Logic Diagram The left vertical line of a Ladder Logic Diagram (above), represents the power or energised conductor. The output element or instruction represents the neutral or return path of the circuit. The right vertical line, which represents the return path on a hard-wired control line diagram, is omitted. Ladder logic diagrams are read from leftto-right, top-to-bottom. Rungs are sometimes referred to as networks. A network may have several control elements, but only one output coil.

Statement List A statement is an instruction for the PLC. A Statement List (STL) (above), provides another view of a set of instructions. A comparison between the statement list shown below, and the ladder logic shown above, reveals a similar structure. The operation, what is to be done, is shown on the left. The operand, the item to be operated on by the operation, is shown on the right.

Understanding Ladder Logic

Diagram 1

Diagram 2

Diagram 3

Diagram 4

Diagram 5

Central Processing Unit 315-2 DP

Varco P/N = 122627-03 Mode Selector RUN-P Run program mode The CPU scans the user program, the key cannot be taken out in this position. Programs can be read of out and loaded into the CPU with a programming device. RUN Run mode. The CPU scans the user program, the key can be removed in this position to prevent anyone changing the operating mode. Programs in the CPU can be read out with a programming device, but the program in the load memory cannot be changed. STOP Stop mode. The CPU does not scan the user program, the key can be removed to prevent anyone changing the operating mode. Programs can be read of out and loaded into the CPU with a programming device. MRES Reset CPU memory Momentary contact position of the mode selector switch for resetting the CPU memory when a special sequence is carried out.

Status and Fault LED’s SF (red) System error fault Lights up in the event of: - (a) Hardware faults, (b) Firmware errors, (c) Programming errors, (d) Parameter assignment errors, (e) Arithmetic errors, (f) Timer errors, (g) Defective memory card, (h) Battery failure or no back-up on POWER ON, (i) I/O fault error. Note:- You must use a programming device and read out the contents of the diagnostic buffer to determine the exact nature of the error/fault. BATF (red) Battery fault Lights up if the battery defective, not inserted or discharged. 5VDC (green) 5 VDC supply for CPU Lights up if the internal 5 VDC supply is OK. RUN (green) Run mode. Flashes at a CPU restart for at least three seconds, during the CPU re-start the STOP LED also lights up, when the STOP LED goes off and the RUN LED is on constant, the outputs are enabled. STOP (yellow) Stop mode. Lights up when the CPU is not scanning the user program. Flashes at one-second intervals when the CPU requests a memory re-set. Display Elements for PROFIBUS LED’S SF DP BUSF Description Off

Off

Configuration data OK, all configured slaves are addressable.

On

On

Bus Hardware fault, DP interface fault

Possible Remedies:- Check the bus cable for short or interruption, evaluate the diagnostic data, reconfigure or correct the configuring data. On

Flashes

Station failure or at least one of the configured slaves cannot be addressed.

Possible Remedies:- Check to make sure that the bus cable is connected correctly to the CPU or that the bus is not interrupted. Wait until the CPU has completed its power up, if the LED does not stop flashing, check the DP slaves or evaluate the diagnostic data for the DP slaves. On

Off

Missing or incorrect configuring data.

Possible Remedies:- Evaluate the diagnostic data, reconfigure or correct the configuring data.

Step 7 CPU315-DP Back-up battery

Varco P/N = 122627-26

The Back-up battery for the CPU315-DP should only be replaced with the Power On, to prevent the loss of data from the internal user memory, and to keep the clock of the CPU running. Siemens recommend that the Back-Up battery be replaced at yearly intervals. When not in use the Back-Up batteries should be stored in a cool dry place, and can be stored for five years.

Flash EPROM Memory Card

Installing the Memory card into the CPU. Varco P/N – 122627-24 The purpose of the Memory Card is to store the user program, this will then be retained when the CPU is powered down, even if a back-up battery has not been installed. With the 315 - 2DP CPU, the Memory Card can be written to directly when installed as above in the CPU. The following procedure should be used for writing to the Flash Card when inserted in the CPU :-

1. 2. 3. 4. 5.

Power down the CPU and insert the Flash card. Power up the CPU. Delete the CPU using the key switch. In the OFFLINE mode, download all the Blocks and System Data to the RAM. Once all Blocks and Data are loaded, do a compare ONLINE and OFFLINE, this should show that there are no differences (except for DB’s). 6. Still in the OFFLINE mode, do a Save RAM to ROM. This should then display the message that this has been carried out satisfactory.

CPU Memory Reset The CPU memory must be reset before a transfer of a complete user program to the CPU, or if the CPU requests a MRES with its STOP LED flashing at one second intervals, possible reasons for this are as follows:-

1. Wrong memory card has been plugged into the CPU. 2. RAM error in CPU. 3. Working memory too small, that is not all blocks of the user program on a memory card could be loaded. 4. Attempt to load blocks with errors, for example if a wrong command has been programmed. With the 315-2 DP CPU and 5V FEPROM plugged in, the CPU requests a memory reset.

Resetting the CPU Memory using the Mode Selector. To reset the CPU using the Mode selector the following procedure should be carried out:-

1. Turn the key to the STOP position 2. Turn the key to the MRES position and hold it in this position for about three seconds, until the STOP LED lights up again. 3. Within three seconds, you must turn the key back to the MRES position and hold it in this position until the STOP LED flashes, when the CPU has completed the reset, the STOP LED stops flashing and remains lit. The CPU has then performed the Reset.

PS 307 Power Supply Module (5A)

Varco P/N = 122627-01 The PS 307 power supply module has an output voltage of 24 VDC with an output current of 5 Amp, this is short circuit and open circuit proof.

Basic Circuit Diagram

Relay Output module SM 322

Module front view and block diagram of relay outputs

Varco P/N = 122627-18 The relay output module has 8 output points, isolated in groups of two. There are two Relay Outputs in the PLC rack (Slot 4 and 5), Slot 4 is used for all the 24 VDC solenoids on the Top Drive (Brakes On, IBOP Closed, Torque Wrench, etc.). Slot 5 is used for the Motor Starters for the Hydraulic Pump and the Right and Left Blower motors, it is also used for the Encoder By-Pass Indicator. If fitted to the Top Drive it would also control the Stand Jump and Elevator Open/Close solenoids.

Digital Input Module SM 321

Module front view and block diagram of digital inputs

Varco P/N = 122627-09

The digital inputs module has 16 input points, isolated in groups of 16. The rated input voltage is 24 VDC, they Inputs are used for the Over-temperatue and Pressure Switches on the Top Drive, the Encoder By-Pass switch is also inputted to this module.

Bartec Distributed I/O system

The Bartec Distributed I/O System

The field bus on which the Bartec Modex System is based on a version of PROFIBUS known as PROFIBUS DP (DP = Decentralised Periphery or Distributed I/0), this is designed for minimum reaction times in communication with the distributed inputs and outputs. The Modex System comes from MODular EXplosion and consists of an EEx d flameproof enclosure and EEx e connecting terminals. The analogue modules used with the Varco Driller’s Console also have intrinsically safe circuits EEx ia.



Bartec Profibus Analogue Output

Varco P/N = 140244-2 The Bartec Profibus Analogue output module has eight intrinsically safe direct analogue outputs of 4-20mA. Two of these outputs are used as 4-20mA signals to supply the Electro Flow RPM and Torque gauges on the Varco Driller’s Console, the other two can be used for the customer logging equipment. LED Indicators ON BF SF UB2 OUTPUT

When 24 VDC power applied, the LED will glow Yellow, no LED will mean a power problem. (Bus Fault) Normally it is off. If there is a bus problem/communication failure it will glow Red. (System Failure) Comes on when there is either a short or open circuit on one of the Outputs. Separate supply voltage to terminal U+/U-, glows green when voltage applied, will turn off when no voltage applied. 8 x Double LED (1-8). Yellow – Output satisfactory, Red – Open/Short Circuit.



Bartec Modex Potentiometer Input

Varco P/N = 140968-4 The Bartec Profibus Potentiometer Input module, has a supply voltage of 24 VDC with four analogue inputs, three of these inputs are used for the Throttle, Drill Torque Limit and Make Up Torque Limit potentiometers on the Varco Driller’s Console. The fourth input is an unused spare, which could be used if there was a problem with any of the other inputs, with software and cabling changes inside the VDC. LED Indicators ON BF SF OUTPUT

When 24 VDC power applied, the LED will glow Yellow, no LED will mean a power problem. (Bus Fault) Normally it is off. If there is a bus problem/communication failure it will glow Red. (System Failure) Comes on when there is either a short or open circuit on one of the Inputs. 4 x Double LED (1-4). Yellow – Input active, Red – Open/Short Circuit.



Bartec Modex Digital Input Modual

Varco P/N = 140968-2

There are two Bartec Profibus Digital Inputs modules in the Varco Driller’s Console, they have a supply voltage of 24 VDC, with 16 EEx e digital inputs. The Inputs are received from all the switch functions in the Varco Driller’s Console (Brake, IBOP, Forward/Reverse, etc.).

LED Indicators ON BF SF INPUT

When 24 VDC power applied, the LED will glow Yellow, no LED will mean a power problem. (Bus Fault) Normally it is off. If there is a bus problem/communication failure it will glow Red. N/A 16 x Double LED (1-16). Yellow On – Input High (1) (+10V to +30V), Yellow Off – Input Low (0) (-30V to +5V).



Bartec Modex Digital Output Module

Varco P/N = 140244

The Bartec Profibus Digital Output module has a supply voltage of 24 VDC, it has 16 outputs of 24 V DC. The Outputs go to all the Indicators and the Horn in the Varco Driller’s console (Drive Fault, Brake On, IBOP Closed, Horn, etc.) LED Indicators

ON BF SF OUTPUT

When 24 VDC power applied, the LED will glow Yellow, no LED will mean a power problem. (Bus Fault) Normally it is off. If there is a bus problem/communication failure it will glow Red. (System Failure) Comes on when there is either a short or open circuit on one of the Outputs. 16 x Double LED (1-16). Yellow – Output active, Red – Open/Short Circuit.


AC Top Drive Step 7 PLC Program Structure

The Step 7 program for the AC Top Drive is structured as above, the program is split into Functions (FC), which are initially called from the Organisation Block (OB). There are two Program Block types, they are User Blocks and System Blocks. User Blocks are the areas provided for managing the program code and the data for the program. Based on the requirement of the process, the program can be structured with the various options for user blocks, some of these blocks can be executed cyclically, while others can be executed only when needed. User blocks are also referred as Program blocks. System Blocks are pre-defined function or function blocks integrated in the operating system on the CPU, these blocks do not occupy any additional space in the user memory. System blocks are called from the user program level, these blocks have the same interface ,same design and the same number in the entire system. The User Blocks types that are used are Organisation block, Functions and Data blocks. Organisational Blocks (OB) form the interface between the S7 CPU and the user program, the program for the AC Top drive is stored in various blocks and uses OB1 to call these blocks when needed.

Functions (FC) are logic operation blocks to which no memory area is assigned, an FC does not need an instance data block, temporary variables are stored in the local stack until the Function is concluded, and are lost when the FC finishes executing. Data Blocks (DB) are permanently assigned areas in which data or information is stored that another function collected, they are read/write areas that can be loaded in the CPU as part of the program. The System Block that is used in the program is the System Functions (SFC). A System Function is a pre-programmed, debugged function that is integrated in the S7 CPU, some of these tasks supported by these blocks are setting parameters for modules, data communication, copying functions etc. SFC’s can be called from the program without being loaded as part of the program, and do not have to be assigned to a data block.

When the program is structured into Blocks, it must be accessed by calling one block from another. As seen in the diagram above, when the program calls the second block, the called block then executes all of its instructions, once the called block has completed execution of its instructions, the calling block resumes the execution of its program at the network following the Call instruction.

Choosing The Correct Operating mode Step 7 allows you to examine, modify and write to programs in three different ways, these ways are Direct, Offline and Online.

DIRECT This mode is ideal for maintenance, in this mode you can directly monitor programs without referencing to a project (no program loaded into Step 7). The project can be can be modified or simply monitored to gather information about the system.

OFFLINE Offline mode is best suited to offline programming, i.e. when the CPU is not present or when the programming unit is not connected to the CPU. In this mode, blocks can be written and then transferred (downloaded) to the CPU, downloading is obviously only possible if the MPI cable is connected to the system. The program can also be monitored, providing the program in the programming unit is the same as the one in the CPU.

ONLINE Online mode is the suited to programming with the programming unit connected to the CPU, if the MPI cable is not present, the link will be automatically aborted. Programming changes will however only take place when the appropriate ICON has been selected. To avoid differences between the program on the disk and the program in the CPU (time stamp conflict), it is essential to STORE TO DISK first and then DOWNLOAD to the CPU. Monitoring in this state is easier as you are looking at what is at present in the CPU.

When working with Step 7, it is essential that only one of these modes is selected at any one time, Step 7 will not allow to have blocks open in the Offline and online modes together, one of the modes will have to be closed down before continuing.

TDS Training Manual



Basics of AC Motors

AC Electrical

Basics of AC Motors

AC MOTOR BENEFITS


Basics of AC Motors

AC EXTRA PERFORMANCE


Basics of AC Motors

AC MOTORS •

Operate on the principle of induced magnetic field from an alternating electric current.

•

Magnetic field induced in STATOR rotates around STATOR frame, which in turn induces current in stationary ROTOR.

•

ROTOR current induces a magnetic field on ROTOR, this field tries to align itself with rotating magnetic field on STATOR.

•

The result of this attempted alignment is TORQUE at the ROTOR shaft, the magnitude of this TORQUE depends how much SLIP occurs between the rotating magnetic field on the STATOR and the ROTOR magnetic field.


Basics of AC Motors

AC MOTOR CONSTRUCTION •

•

Used in industrial applications

Three phase 550/575 VAC in TDS applications


Basics of AC Motors

ROTOR CONSTRUCTION Squirrel Cage Most Common Rotor consists of Stack of Steel Laminations with evenly spaced conductor bars.

• Current flows through the Rotor bars and around the End ring. • Current flow produces Magnetic Fields around each Rotor bar. • Rotor becomes an Electromagnet with alternating North and South poles. • Magnetic Fields of Rotor interact with Magnetic Fields of Stator. • Current and Magnetic Fields of Stator and Rotor constantly changing. • As Stator Magnetic Field rotates, Rotor and Shaft follow. AC TDS Training Manual

Basics of AC Motors

STATOR CONSTRUCTION The stator of the induction motor is a hollow cylinder made up from silicon iron laminations with the winding housed in slots in the inner surface. Like the D.C. motor field, it can have any number of pole pairs and each pole can be produced by any number of concentric coils. The drawing below shows a motor with only two poles two coils per phase (i.e. 4 slots per pole per phase). Note that only one pole per phase is shown for clarity.


Basics of AC Motors

ROTATING MAGNET FIELD •

•

• •

Rotating Magnetic Field produced in Motor Stator windings. Number of Poles is depending by how many times a phase winding appears. TDS-9, 10 and 11, 4 Pole (2 pole pairs). TDS-8, 6 Pole (3 pole pairs).

2- Pole Stator Windings.


Basics of AC Motors

Rotating Magnet •

•

• •

•

No direct electrical connection between Stator and Rotor. To visualise how a Rotor works, substitute a Magnet for the Squirrel cage Rotor. Magnet Field interacts with rotating Stator Field. North Pole of Stator attracts South Pole of Magnet. Magnet follows rotating Magnetic fields.


Basics of AC Motors

ROTATING MAGNETIC FIELD

• •

Evaluate the Field at 60° intervals After six intervals the field rotates 360°.


Basics of AC Motors

Synchronous Speed • Speed of Rotating Magnet Field Refereed to as Synchronous Speed (Ns). • Equal to 120 Times the Frequency (F) Divided by the Number of Poles.

Slip • Relative Difference between Speed of Rotor and Rotating Magnetic Field. • Necessary to Produce Torque. • Dependent on Load.


Basics of AC Motors

Electrical components of an AC Motor • • • • • • • • •

Vs = Line Voltage applied to Stator power leads. Rs = Stator Resistance. Ls = Stator leakage inductance. Is = Stator current. E = Air gap or magnetising voltage. Lm = Magnetising inductance. Im = Magnetising current. Rr = Rotor leakage inductance. Iw = Working or Torque producing current.


Basics of AC Motors

Working Current • Current that Flows in the Rotor Circuit and produces Torque. • Function of the Load. • An Increase in Load Causes the Rotor Circuit to Work Harder, Increasing Working Current (Iw). • A Decrease in Load, Decreases the Work of the Rotor Circuit does Decreasing Working Current (Iw).

Stator Current • Full-Load Ampere rating on the Motor Nameplate. • Current that flows in the Stator Circuit. • Can be measured on the Supply Line and is also referred to as Line Current.


Basics of AC Motors

HORSEPOWER AND KILOWATTS •

•

AC Drives and Motors manufactured in United States measured in HP (Horsepower). AC Drives and Motors manufactured in Europe, generally rated in KW (Kilowatts). KW = 0.746 * HP HP = 1.341 * KW

DRILLING MOTORS •

•

• • • •

Glass served installation on all new and reworked motors to increase voltage rating. Snubbers added to reduce voltage from Siemens and IDM IGBT drives. TDS-8 = 1 * 1150 HP motor. TDS-9 = 2 * 350 HP motors (700 HP). TDS-10 = 1 * 350 HP motor. TDS-11 = 2 * 400 HP motors (800 HP).


Basics of AC Motors

MOTOR NAMEPLATE •

Installation Class

•

Established by NEMA. Ambient temperature is standardised at 40° C or 104° F. Combination of ambient temperature and allowed temperature rise equals maximum winding temperature.

• •

•

NEMA Design

•

National Electrical Manufacturers Association (NEMA) established standards for motor construction and performance.

•

Efficiency

•

Indication of how much input electrical energy is converted to output mechanical energy.

•

Voltage Connection and Amps

• •

The Reliance motor is specified for 550 Volts. Maximum full load current of 331 Amps.

•

Base Speed

• •

Nameplate speed, given in RPM, where motor develops rated Horsepower at rated Voltage and Frequency. Reliance motor is 1155 RPM.

•

Maximum Speed

•

Maximum rated speed of the motor, torque is reduced. Reliance motor is 2400 RPM.

•

Reliance motor used on TDS-9 + 10. (TDS-11, 575 V & 366 A) AC TDS Training Manual

TDS Training Manual



Basics of AC Drives

AC Electrical

Basics of AC Drives

AC Drives u

Speed of an AC Motor can be Controlled Using Electronic Drive Equipment. – – – –

Variable or Adjustable Speed Drives. Commonly known as AC Drives Also referred to as Inverters. Although the Inverter is only one part of the AC Drive.

Vector Control u u u u u u

Control Torque and Speed Continuously through Zero Speed. Can hold motor stationary against an applied torque. Requires Tach feedback to work best. Speed control reaction time <=20ms. Torque control reaction time <=10ms. Current Limit, 150% motor rated current for One minute.


Basics of AC Drives

Power in an AC Circuit True Power • Consumed and used to do Useful Work. • Measured in Watts (W).

Reactive Power • Not Consumed. • Measured in Volt-Amps Reactive (VAR). Apparent Power • Vector Sum of True Power and Reactive Power. • Measured in Volt-Amps (VA).

Reactive vs. True Power


Basics of AC Drives

Power Factor u Ratio of True Power to Apparent Power u Purely Resistive Circuit – Current and Voltage in Phase and There is No Angle Displacement – Cosine of Zero is 1 – PF = 1

Three-Phase Power • Produced by Three Voltages Sources. - Each Phase offset by 120 Electrical Degrees. • Used where a Large Quantity of Power is Required. - Commercial and Industrial Applications.

Three Phase Power Formula


Basics of AC Drives

Pulse Width Modulation (PWM)

• Provide more Sinusoidal Current Output. • More Efficient, Higher levels of Performance.


Basics of AC Drives

PWM Converter and DC Link • Fixed Diode Bridge Rectifier - Rectified DC Value Approximately 1.35 Times Line to Line Voltage. - The Choke (L1) and Capacitors (C1) smooth the DC Link Voltage.


Basics of AC Drives

PWM Logic and Inverter Section • Output Voltage and Frequency Controlled by Control Logic and Inverter Section. • Inverter Section Consists of Switching Devices. - Depending on Drive, Thyristors, Bipolar Transistors, MOSFETS, GTO’s or IGBT’s can be used.


Basics of AC Drives

IGBT’s • Insulated Gate Bipolar Transistor. - Provides High switching speed required by PWM’s. - Capable of switching ON and OFF Several Thousand Times a Second. - Turn ON in Less than 400 Nanoseconds. - Turn OFF in 500 nanoseconds.


Basics of AC Drives

Developing a Basic AC Output


Basics of AC Drives

Generating a PWM Output


Basics of AC Drives

PWM Voltage and Current Output


Basics of AC Drives

Four Quadrant Operation • The dynamics of the Top Drive, require Four Quadrant Operation. • When equipped with a Breaking Resistor the AC Drive is capable of producing Four Quadrant Operation. • Torque will always act to cause synchronous speed. • If synchronous speed is reduced, negative Torque is developed in the Motor. • The Motor acts like a generator, converting mechanical power into electrical power, which is returned to the AC Drive.


Basics of AC Drives

Breaking Resistor • Electrical energy is returned to the AC Drive by the Motor can cause the DC Link to become excessively high when added to existing supply voltage. • The Breaking Resistor is added and removed from the circuit by an IGBT, when requested. • The Resistor placed across the DC Link, dissipates excessive energy. • Thus returning the Dc Link to a save voltage. • This process allows the motor to act like a brake, slowing the connected load quickly.


TDS Training Manual



Siemens 70 Series Drive Chassis AC to AC

AC Electrical

Description Range of application The frequency converter is a power electronics component for feeding three-phase drives in the output range from 37 kW to 400 kW. The unit can be operated from a three-phase system with a frequency of 50/60 Hz and a voltage in the range of the values entered on the rating plate (380...480 / 500...600 / 660...690 V). The three-phase current from the system is rectified, smoothed and fed onto the capacitor DC link. The inverter enables a variable output frequency between 0 Hz and a maximum of 600 Hz to be generated from the DC current with the pulse width modulation method (PWM). The internal DC 24 V voltage is supplied through an integral power supply unit. The unit is controlled by the internal closed-loop electronics, the functions are provided by the unit software. Operator control is via the PMU operator control panel, the user-friendly OP1S operator control panel, the terminal strip or via the serial interfaces of the bus system. For this purpose, the unit is provided with a number of interfaces and six slots for the use of optional boards. Pulse encoders and analog tachometers can be used as encoders on the motor.

Terminal strip

Optional boards

PMU

Control electronics

Serial interface

Pre-charging DC link U1/L1

U2/T1

V1/L2

V2/T2

Motor connecW2/T3 tion

W1/L3 Rectifier

Inverter

C / L+ D/LPE1

PE2

Fans, volumetric flow, opening crosssections

MLFB

Fan

Opening cross-section in the roof section at the top (also possible at the front and/or at the side)

6SE70xx-xEJ60 6SE70xx-xFJ60 6SE70xx-xGJ60

6SE7037-0EK60

2 x RH28M

2 x RH28M

Minimum volumetric flow [m3/s]

0.46

0.6

Min. opening cross-section in the cabinet doors [m2] Type of protection IP00 to IP42

0.26

0.26

Min. opening cross-section in the top cover [m2] Type of protection < IP20

0.26

0.26

Min. opening cross-section in the roof section [m2] Type of protection IP22 to IP42

0.26

0.26

Direct partition between the fan box and the cabinet frame from all 4 sides

Cabinet frame

Partition to adjacent cabinets on the left, on the right and at the rear

Opening crosssections in the doors (maybe with filters situated behind them)

Installing the optional boards WARNING

The boards may only be replaced by qualified personnel. It is not permitted to withdraw or insert the boards under voltage.

Slots

A maximum of six slots are available in the electronics box of the unit for installing optional boards. The slots are designated with the letters A to G. Slot B is not provided in the electronics box. It is used in units of the Compact PLUS type of construction. If you wish to use slots D to G, you will additionally require the following: ♦ Bus expansion LBA (Local Bus Adapter), which is used for mounting the CU board and up to two adaption boards, and ♦ An adaption board (ADB - Adaption Board) on which up to two optional boards can be mounted. The slots are situated at the following positions: ♦ Slot A

CU board

Position: top

♦ Slot C

CU board

Position: bottom

♦ Slot D

Adaption board at mounting position 2

Position: top

♦ Slot E


Position: bottom

♦ Slot F


Position: top

♦ Slot G


Position: bottom

Mounting position 1 Mounting position 3

Mounting position 2

NOTE

Mounting position 2 can be used for technology boards (T100, T300, TSY). Mounting positions 2 and 3 can also be used for communication boards SCB1 and SCB2.

WARNING

The unit has hazardous voltage levels up to 5 minutes after it has been powered down due to the DC link capacitors. The unit must not be opened until at least after this delay time.

CAUTION

The optional boards contain components which could be damaged by electrostatic discharge. These components can be very easily destroyed if not handled with caution. You must observe the ECB cautionary measures when handling these boards.

Disconnecting the unit from the supply

Disconnect the unit from the incoming power supply (AC or DC supply) and de-energize the unit. Remove the 24 V voltage supply for the electronics. Open the front panel.

Preparing installation

Remove the CU board or the adaption board from the electronics box as follows: ♦ Disconnect the connecting cables to the CU board or to the optional boards. ♦ Undo the two fixing screws on the handles above and below the CU board or the adaption board. ♦ Pull the CU board or the adaption board out of the electronics box using the handles. ♦ Place the CU board or the adaption board on a grounded working surface.

Installing the optional board

Insert the optional board from the right onto the 64-pole system connector on the CU board or on the adaption board. The view shows the installed state. Screw the optional board tight at the fixing points in the front section of the optional board using the two screws attached.

Re-installing the unit Re-install the CU board or the adaption board in the electronics box as follows:

♦ Insert the CU board into mounting position 1 and the adaption board into mounting position 2 or 3. NOTE

Mounting position 3 cannot be used until at least one adaption board has been installed at mounting position 2. Boards should first be installed in mounting position 2, before mounting position 3 is used. ♦ Secure the CU board/adaption board at the handles with the fixing screws. Re-connect the previously removed connections. Check that all the connecting cables and the shield sit properly and are in the correct position.

Connecting-up WARNING

SIMOVERT MASTERDRIVES units are operated at high voltages. The equipment must be in a no-voltage condition (disconnected from the supply) before any work is carried out! Only professionally trained, qualified personnel must work on or with the units. Death, severe bodily injury or significant property damage could occur if these warning instructions are not observed. Hazardous voltages are still present in the unit up to 5 minutes after it has been powered down due to the DC link capacitors. Thus, the appropriate delay time must be observed before working on the unit or on the DC link terminals. The power terminals and control terminals can still be live even when the motor is stationary. When working on an opened unit, it should be observed that live components (at hazardous voltage levels) can be touched (shock hazard). The user is responsible that all the units are installed and connected-up according to recognized regulations in that particular country as well as other regionally valid regulations. Cable dimensioning, fusing, grounding, shutdown, isolation and overcurrent protection should be particularly observed.

Mains connection

DC link connection PE1 / GND

PMU X300

X108 X101 Mount.pos. 1 (CUVC) X102 X103 Optional board in slot C Mounting position 3 Mounting position 2 Aux. contactor, external DC24 V supply X9

Shield connection for control cables

Terminals for setting the fan voltage Motor connection PE2 / GND

NOTE

Due to the 230 V fan a transformer is integrated into the converters. The terminals on the primary side of the transformer must be connected corresponding to the rated input voltage.

Protective conductor connection

The protective conductor has to be connected both on the line side and on the motor side. It has to be dimensioned according to the power connections.

DC link connection

The "braking unit" and "dv/dt filter" options can be connected up to the DC link terminals C/L+ and D/L-. These terminals are not suitable for connecting up other inverter units (e.g. DC units). This connection is not suitable for connecting up a rectifier or rectifier/feedback unit. With the M65 option, it is possible to move the DC link terminals to the bottom of the unit. .

NOTE Type K

Due to the 230 V fan a transformer is integrated into the converters. The terminals on the primary side have to be reconnected according to the rated input voltage, if necessary. If this is not done, the fuses F3, F4 or F101, F102 may blow.

CUVC Control connections Standard connections

In the basic version, the unit has the following control connections on the CUVC: ♦ Serial interface (RS232 / RS485) for PC or OP1S ♦ A serial interface (USS bus, RS485) ♦ A control terminal strip for connecting up a HTL unipolar pulse enocder and a motor temperature sensor (PTC / KTY84) ♦ Two control terminal strips with digital and analog inputs and outputs.

X108 S1 S2 S3/3,4 S3/1,2 X101

X102

X103

S4/4,5,6 S4/1,2,3

X101

Controller P24V

2

M24

Slot A

Microcontroller

Slot C Slot D Slot E Slot F

3 In 4

Bidirectional digital inputsand outputs Iout ≤ 20 mA

Out In

Out In

5 6

4 bidirectional digital inputs/outputs 7

5V

Digital inputs Ri = 3,4 kΩ

5V

In

24V 9

10

Serial interface 2 USS (RS485)

9 8 7 6 5 4 3 2 1

5V

In

24V

Inputs

11

Out In In

24V 8

RS485P RS485N

X300

Out In

24V

Outputs

PMU

Out In

Out/In 5V

Slot G

RS485N RS232 TxD P5V

Out

UART

BOOT RS485P RS232 RxD n.c.

Aux. power supply 150 mA

1

BOOT

12 Reference potential RS485

S2 +5V

X102 Switch for USS bus connection Reference voltage P10 V / N10 V I ≤ 5 mA

13 14

P10 AUX ≥1

N10 AUX

S1

15

A

S3 Analog input 1 (non-floating)

D

+5V Switch for USS bus connection

AI 1

1 2 11 bit + sign U: Rin = 60 kΩ I: Rin = 250 Ω (Close S3)

In

16

X103

17 S3

Analog input 2 (non-floating)

Tacho M

A

In

D

Track A

AI 2

3 4 18

AO 1 D

19 20

M D

21

A

Analog output 2

X101 – Control terminal strip

M

1 2

AO 2

22

3

A

Analog output 1 10 bit + sign U: I ≤ 5 mA I: R ≤ 500 Ω

S4

S4 6

4 5

-10...+10 V 0...+20 mA

A S I C

Track B Zero pulse Control

Tacho P15 -10...+10 V 0...+20 mA

Mot. temp BS Mot.temp

23 24 25

Pulse encoder I≤190 mA

26 27 28 29 Motor temperature 30 sensor KTY84 or PTC thermistor

The following connections are provided on the control terminal strip: ♦ 4 optionally parameterizable digital inputs and outputs ♦ 3 digital inputs ♦ 24 V aux. voltage supply (max. 150 mA) for the inputs and outputs ♦ 1 serial interface SCom2 (USS / RS485)

Terminal

Designation

Significance

Range

1

P24 AUX

Aux. voltage supply

DC 24 V / 150 mA

2

M24 AUX

Reference potential

0V

3

DIO1

Digital input/output 1

24 V, 10 mA / 20 mA

4

DIO2


24 V, 10 mA / 20 mA

5

DIO3


24 V, 10 mA / 20 mA

6

DIO4


24 V, 10 mA / 20 mA

7

DI5

Digital input 5

24 V, 10 mA

8

DI6

Digital input 6

24 V, 10 mA

9

DI7

Digital input 7

24 V, 10 mA

10

RS485 P

USS bus connection SCom2

RS485

11

RS485 N

USS bus connection SCom2

RS485

12

M RS485

Reference potential RS485

Connectable cross-section: 1.5 mm² (AWG 16) Terminal 1 is at the top when installed.

X102 – Control terminal strip

The following connections are provided on the control terminal strip: ♦ 10 V aux. voltage (max. 5 mA) for the supply of an external potentiometer ♦ 2 analog inputs, can be used as current or voltage input ♦ 2 analog outputs, can be used as current or voltage output Terminal

Designation

Significance

Range

13

P10 V

+10 V supply for ext. potentiometer

+10 V ±1.3 %, Imax = 5 mA

14

N10 V

-10 V supply for ext. potentiometer

-10 V ±1.3 %, Imax = 5 mA

15

AI1+

Analog input 1 +

11 bit + sign

16

M AI1

Ground, analog input 1

Voltage:

17

AI2+

Analog input 2 +

± 10 V / Ri = 60 kΩ

18

M AI2

Ground, analog input 2

Current: Rin = 250 Ω

19

AO1

Analog output 1

10 bit + sign

20

M AO1

Ground, analog output 1

Voltage:

21

AO2

Analog output 2

± 10 V / Imax = 5 mA

22

M AO2

Ground, analog output 2

Current: 0...20 mA R ≥ 500 Ω


X103 – Pulse encoder connection

The connection for a pulse encoder (HTL unipolar) is provided on the control terminal strip. Terminal

Designation

Significance

Range

23

- VSS

Ground for power supply

24

Track A

Connection for track A

HTL unipolar

25

Track B

Connection for track B

HTL unipolar

26

Zero pulse

Connection for zero pulse

HTL unipolar

27

CTRL

Connection for control track

HTL unipolar

28

+ VSS

Power supply pulse encoder

15 V Imax = 190 mA

29

- Temp

Minus (-) connection KTY84/PTC

KTY84: 0...200 °C

30

+ Temp

Plus (+) connection KTY84/PTC

PTC: RPTC therm ≤ 1.5 kΩ


X300 - Serial interface

Either an OP1S or a PC can be connected up via the 9-pole Sub D socket. Pin

5

9

1

Name

Significance

Range

1

n.c.

Not connected

2

RS232 RxD

Receive data via RS232

RS232

3

RS485 P

Data via RS485

RS485

4

Boot

Control signal for software update

Digital signal, low active

5

M5V

Reference potential to P5V

0V

6

P5V

5 V aux. voltage supply

+5 V, Imax = 200 mA

7

RS232 TxD

Transmit data via RS232

RS232

8

RS485 N

Data via RS485

RS485

9

n.c.

Not connected

6

Switch settings

Switch

S1

Significance

SCom1 (X300): Bus terminating resistor

•

open

•

Resistor open

•

closed

•

Resistor closed

•

open

SCom2 (X101/10,11): Bus terminating resistor

•

closed

•

Resistor open

•

Resistor closed

S2

S3 (1,2)

AI1: Changeover current/voltage input

•

open

•

Voltage input

•

closed

•

Current input

S3 (3,4)

AI2: Changeover current/voltage input

•

open

•

Voltage input

•

closed

•

Current input

S4 (1,2,3)

AO1: Changeover current/voltage output

•

Jumper 1, 3

•

Voltage output

•

Jumper 2, 3

•

Current output

S4 (4,5,6)

AO2: Changeover current/voltage output

•

Jumper 4, 6

•

Voltage output

•

Jumper 5, 6

•

Current output

Parameter input via the PMU The PMU parameterizing unit enables parameterization, operator control and visualization of the converters and inverters directly on the unit itself. It is an integral part of the basic units. It has a four-digit seven-segment display and several keys. The PMU is used with preference for parameterizing simple applications requiring a small number of set parameters, and for quick parameterization. Key

Significance

Function •

For energizing the drive (enabling motor activation).

•

If there is a fault: For returning to fault display

OFF key

•

For de-energizing the drive by means of OFF1, OFF2 or OFF3 (P554 to 560) depending on parameterization.

Reversing key

•

For reversing the direction of rotation of the drive. The function must be enabled by P571 and P572

Toggle key

•

For switching between parameter number, parameter index and parameter value in the sequence indicated (command becomes effective when the key is released).

•

If fault display is active: For acknowledging the fault

ON key

Raise key

Lower key

Hold toggle key and depress raise key

Hold toggle key and depress lower key

For increasing the displayed value: •

Short press = single-step increase

•

Long press = rapid increase

For lowering the displayed value: •

Short press = single-step decrease

•

Long press = rapid decrease

•

If parameter number level is active: For jumping back and forth between the last selected parameter number and the operating display (r000)

•

If fault display is active: For switching over to parameter number level

•

If parameter value level is active: For shifting the displayed value one digit to the right if parameter value cannot be displayed with 4 figures (left-hand figure flashes if there are any further invisible figures to the left)

•

If parameter number level is active: For jumping directly to the operating display (r000)

•

If parameter value level is active: For shifting the displayed value one digit to the left if parameter value cannot be displayed with 4 figures (right-hand figure flashes if there are any further invisible figures to the right)

Raise key

Seven-segment display for: Drive statuses Alarms and faults

Reversing key ON key

Parameter numbers

Toggle key OFF key

Parameter indices

Lower key X300

Toggle key (P key)

Parameter values

As the PMU only has a four-digit seven-segment display, the 3 descriptive elements of a parameter ♦ Parameter number, ♦ Parameter index (if parameter is indexed) and ♦ Parameter value cannot be displayed at the same time. For this reason, you have to switch between the individual descriptive elements by depressing the toggle key. After the desired level has been selected, adjustment can be made using the raise key or the lower key. With the toggle key, you can change over: •

from the parameter number to the parameter index

•

from the parameter index to the parameter value

•

from the parameter value to the parameter number

Parameter number P

P

Parameter value

Parameter index P

If the parameter is not indexed, you can jump directly to the parameter value.

NOTE

If you change the value of a parameter, this change generally becomes effective immediately. It is only in the case of acknowledgement parameters (marked in the parameter list by an asterisk ‘ * ’) that the change does not become effective until you change over from the parameter value to the parameter number. Parameter changes made using the PMU are always safely stored in the EEPROM (protected in case of power failure) once the toggle key has been depressed.

Example

The following example shows the individual operator control steps to be carried out on the PMU for a parameter reset to factory setting.

Set P053 to 0002 and grant parameter access for PMU ∇

P053

Ì

Î

0000

Ì

∇

Ì P Î

Î

0001

Ì P Î 0002

Select P060 ∇

Ì

Î

P053

P060

Set P060 to 0002 and select "Fixed settings" menu

P060

Ì

∇

Ì P Î

Î

1

Ì P Î 2

P060

Select P970

Î

∇

P060

Ì

∇

Ì

Î

P366

P970

Set P970 to 0000 and start parameter reset

P970

Ì 1

∇

Ì P Î

Î

Ì P Î 0

°005

P053

Parameter input via the OP1S General The operator control panel (OP1S) is an optional input/output device which can be used for parameterizing and starting up the units. Plaintext displays greatly facilitate parameterization. The OP1S has a non-volatile memory and can permanently store complete sets of parameters. It can therefore be used for archiving sets of parameters, but first the parameter sets must be read out (upread) from the units. Stored parameter sets can also be transferred (downloaded) to other units. The OP1S and the unit to be operated communicate with each other via a serial interface (RS485) using the USS protocol. During communication, the OP1S assumes the function of the master whereas the connected units function as slaves. The OP1S can be operated at baud rates of 9.6 kBd and 19.2 kBd, and is capable of communicating with up to 32 slaves (addresses 0 to 31). It can therefore be used in a point-to-point link (e.g. during initial parameterization) or within a bus configuration. The plain-text displays can be shown in one of five different languages (German, English, Spanish, French, Italian). The language is chosen by selecting the relevant parameter for the slave in question. Order numbers

Components

Order Number

OP1S

6SE7090-0XX84-2FK0

Connecting cable 3 m

6SX7010-0AB03

Connecting cable 5 m

6SX7010-0AB05

Adapter for installation in cabinet door incl. 5 m cable

6SX7010-0AA00

8.2 A 25 V 00 # 100.000 min-1 * 100.000 min-1 Run LED red LED green

LCD (4 lines x 16 characters)

9-pole SUB-D connector on rear of unit

Fault Run

Reversing key ON key

I

OFF key

O

Jog key

Jog

Raise key Lower key

P

Key for toggling between control levels 7

8

9

4

5

6

1

2

3

0

+/-

Reset

0 to 9: number keys

Reset key Sign key

OP1S connections

Pin

Designation

Significance

RS485 P

Data via RS485 interface

Range

1 2 1

5

3 4

6

5

N5V

Ground

6

P5V

5 V aux. voltage supply

RS485 N

Data via RS485 interface

9

7 8 9

Reference potential

±5%, 200 mA

Connecting The OP1S can be connected to the units in the following ways: ♦ Connection via 3 m or 5 m cable (e.g. as a hand-held input device for start-up) ♦ Connection via cable and adapter for installation in a cabinet door ♦ Plugging into MASTERDRIVES Compact units (for point-to-point linking or bus configuration) SIEMENS 100.0A 380.0V zz #-300.000Hz *-300.000Hz Betrieb Fault Run

I O

USS via RS485

P

USS-Bus Jog

7 4

8

9

5

6

1

2

3

0

+/-

Reset

X300

OP1S

Connecting cable

9 8 7 6

5 4 3

5 4 3

2 1

2 1

9 8 7 6

OP1S side:

Unit side:

9-pole SUB D socket

9-pole SUB D connector

Plugging into units of the Compact and chassis type

Carefully penetrate the pre-punched holes for the fixing screws in the front panel of the Compact units. Plug the OP1S onto the Sub D socket X300 and screw it tight using the two screws (M5 x 10, accessory pack) from the inside of the front panel.

Run-up After the power supply for the unit connected to the OP1S has been turned on or after the OP1S has been plugged into a unit which is operating, there is a run-up phase. NOTE

The OP1S must not be plugged into the Sub D socket if the SCom1 interface parallel to the socket is already being used elsewhere, e.g. bus operation with SIMATIC as the master.

NOTE

In the as-delivered state or after a reset of the parameters to the factory setting with the unit’s own control panel, a point-to-point link can be adopted with the OP1S without any further preparatory measures. When a bus system is started up with the OP1S, the slaves must first be configured individually. The plugs of the bus cable must be removed for this purpose (see section "Bus operation"). During the run-up phase, the text "Search slave" is shown in the first line of the display, followed by "Slave found" and the found slave number as well as the set baud rate. Slave found Adress: [00] Baudrate: [6]

Example of a display after the run-up phase (6 corresponds to 9.6 kBd)

After approximately 4 s, the display changes to SIEMENS MASTERDRIVES VC 6SE7016-1EA61 SW:V3.0 OP:V2T20

Example of what is displayed after a slave address has been found

After a further 2 s, there is a changeover to the operating display. If it is not possible to start communicating with the slave, an error message “Error: Configuration not ok” appears. About 2 s later, a request is made for new configuration. New config? #yes no

Error message displayed when communication is not possible

Operator control Operator control elements Key

O Jog

P

Significance ON key

•

For energizing the drive (enabling motor activation). The function must be enabled by P554.

OFF key

•

For de-energizing the drive by means of OFF1, OFF2 or OFF3. The function must be enabled by P554 to P560.

Jog key

•

For jogging with jog setpoint 1 (only effective when the unit is in the "Ready to start" state). This function must be enabled by P568.

Reversing key

•

For reversing the direction of rotation of the drive. This function must be enabled by P571 and P572.

Toggle key

•

For selecting menu levels and switching between parameter number, parameter index and parameter value in the sequence indicated. The current level is displayed by the position of the cursor on the LCD display (the command comes into effect when the key is released).

•

For conducting a numerical input.

•

For leaving menu levels

•

If fault display is active: For acknowledging the fault. This function must be enabled by P565.

Reset key

Reset

Raise key

Lower key

+/0

to

9

Function

For increasing the displayed value •

Short press = single-step increase

•

Long press = rapid increase

•

If motorized potentiometer is active, this is for raising the setpoint. This function must be enabled by P573.

For lowering the displayed value: •

Short press = single-step decrease

•

Long press = rapid decrease

•

If motorized potentiometer is active, this is for lowering the setpoint. This function must be enabled by P574.

Sign key

•

For changing the sign so that negative values can be entered

Number keys

•

Numerical input

Operating display After run-up of the OP1S, the following operating display appears: 0.0A 0V 00 # 0.00 min-1 * 0.00 min-1 Ready.

Example of an operating display in the "Ready" status

st

The values shown in the operating display (except for slave number, 1 line on the far right) can be specified by means of parameterization: st

1 line, left (P0049.001)

in the example "Output current"

st

1 line, right (P0049.002) nd

in the example "DC link voltage"

2 line actual value (P0049.003) rd

3 line setpoint (P0049.004) th

4 line (P0049.005)

in the example "Actual speed" (only a visualization parameter) in the example "Speed setpoint" in the example "Operating state"

In the operating display, the actual value is indicated with "#" and the setpoint with "*". In addition to the operating display on the display unit, the operating state is indicated by the red and green LEDs as follows:

red LED green LED

Flashing

Continuous

Alarm

Fault

Ready for ON

Operation

Basic menu When the "P" key is pressed, a changeover is made from the operating display to the basic menu.

Ì P Î 0.0 A 0 V 00 VectorControl # 0.00 min-1 *Menu Selection * 0.00 min-1 OP: Upread Ready. OP: Download

Display of the basic menu

The basic menu is the same for all units. The following selections can be made: ♦ Menu selection ♦ OP: Upread ♦ OP: Download ♦ Delete data ♦ Change slave ♦ Config. slave ♦ Slave ID As not all the lines can be shown at the same time, it is possible to scroll the display as required with the "Lower" and "Raise keys.

Ì ∇ Î VectorControl *Menu Selection OP: Upread OP: Download

Ì ∇ Î

VectorControl *Menu Selection #OP: Upread OP: Download

Ì ∇ Î

VectorControl *Menu Selection OP: Upread #OP: Download

Ì ∇ Î

VectorControl OP: Upread OP: Download #Delete data

VectorControl OP: Download Delete data #Change slave

and so on

Example of switching from one line to the next

The currently active function is indicated by the "*" symbol and the selected function by the "#” symbol. After the "P" key has been pressed, the relevant symbol jumps to the selected function. The "Reset" key is for returning to the operating display.

Slave ID With the "Slave ID" function, the user can request information about the connected slave. The slave ID consists, for example, of the following lines: MASTERDRIVES VC 6SE7016-1EA61 2.2 kW V3.0 15.02.1998 Starting from the basic menu, the "Slave ID" function is selected with "Raise" or "Lower" and activated with "P". As all the lines cannot be shown at the same time, it is possible to scroll the display as required with the "Lower" and "Raise" keys. In addition, the slave number is shown at the top on the right-hand side.

Ì P Î VectorControl Change slave Config. slave #Slave ID

Ì ∇ Î

Ì ∇ Î

Ì ∇ Î

VectorControl 00 VectorControl 00 VectorControl 00 VectorControl 00 Slave ID Slave ID Slave ID Slave ID MASTERDRIVES VC 6SE7016-1EA61 6SE7016-1EA61 2.2 kW

Example of a slave ID

and so on

Menu selection The actual parameterization and start-up of the connected slave is performed by means of the "Menu selection" function. Starting from the basic menu, the "Menu selection" function is selected with "Lower" or "Raise". By pressing "P", the unit-specific sub-menu is displayed with the following choices: ♦ User Param. ♦ Param Menu.. ♦ FixedSet... ♦ Quick Param... ♦ Board Conf. ♦ Drive Set ♦ Download ♦ UpR/fr.Access ♦ Power Def. Two or more dots after these items mean that there is a further submenu level. If "Parameter menu.." is selected, access is possible to all parameters via correspondingly structured sub-menus. If "UpR/fr. Access" is selected, direct access is gained to the parameter level. 7x

Ì ∇ Î

Ì P Î VectorControl *Menu selection Upread Download

Menüauswahl *User Param. Param Menu.. FixedSet...

Ì ∇ Î

Menu selection Drive Set. Download #UpR/fr.Access

r001 Drive Status

9

Ready

Example: Selecting the parameter level by means of UpR/fr.access

2x

Ì P Î Menu selection *User Param. #Param Menu.. FixedSet...

Ì ∇ Î

Parameter Menu *Gen. Param. Terminals Communication

Ì P Î

Param Menu *Gen. Param. Terminals #Communication

Example: Selecting a parameter via sub-menus

Ì P Î

Communication P700.001 *SST1/SST2 0 Field bus conn. SCom Bus Addrese SIMOLINK Ser. Interf.1

A parameter number can be selected from the parameter level directly with the numerical keys or with "Raise"/"Lower". The parameter number is shown as a three-figure quantity. In the event of four-figure parameter numbers, the first figure (1, 2 or 3) is not displayed. A distinction is made with the letters (P, H, U etc.).

Ì 0 Î r001 Drive Status

Ì 4 Î

9 r000

Ì 9 Î

r004

r049.001 4 OP OperDisp 1. line, on left

Ready

Example: Direct input of the parameter number with the numerical keypad

Î

Ì

∇

∇

Ì r001 Drive Status

9 r002

Î

Ì

r004

∇

Parameter display and parameter correction

Î

r006

0 min-1 0.0 A 0 V Actual speed Output Amps DC Bus Volts

Ready.

Example: Correcting the parameter number by means of "Raise"

If the parameter is found not to exist when the number is entered, a message "No PNU" appears. A non-existent parameter number can be skipped by selecting "Raise" or "Lower". How the parameters are shown on the display depends on the type of parameter. There are, for example, parameters with and without an index, with and without an index text and with and without a selection text. Example: Parameter with index and index text P704.001 0 ms SCom Tlg OFF Ser.Interf.1

1st line: Parameter number, parameter index 2nd line:

Parameter value with unit

3rd line:

Parameter name

4th line:Index text

Example: Parameter with index, index text and selection text P701.001 6 SCom Baud rate Ser Interf.1 9600 Baud

1st line: Parameter number, parameter index, parameter value 2nd line:

Parameter name

3rd line:

Index text

4th line:Selection text Example: Parameter without index, with selection text, binary value P053 0006Hex Parameter Access 0000000000000110 ComBoard: No

1st line: Parameter number, parameter value, hexadecimal parameter value 2nd line:

Parameter name

3rd line:

Parameter value, binary

4th line:Selection text Transition between the parameter number, parameter index and parameter value levels is made with "P". Parameter number → "P" → Parameter index → "P" → Parameter value If there is no parameter index, this level is skipped. The parameter index and the parameter value can be corrected directly with the "Raise"/"Lower" keys. An exception to this are parameter values shown in binary form. In this case, the individual bits are selected with "Raise"/"Lower" and corrected with the numerical keys (0 or 1). If the index number is entered by means of the numerical keys, the value is not accepted until "P" is pressed. If the "Raise" or "Lower" keys are used to correct the number, the value comes into effect immediately. The acceptance of an entered parameter value and return to the parameter number does not take place until "P" is pressed. The level selected in each case (parameter number, parameter index, parameter value) is marked with the cursor. If an incorrect parameter value is entered, the old value can be obtained by pressing "Reset". The "Reset" key can also be used to go one level lower. Parameter value → "Reset" → Parameter index → "Reset" → Para.No.

Parameters which can be changed are shown in upper-case letters and visualization parameters which cannot be changed are shown in lowercase letters. If a parameter can only be changed under special conditions or if an incorrect value has been entered with the numerical keys, an appropriate message follows, e.g.: ♦ "Value not perm."

Incorrect value entered

♦ "Value <> min/max" Value too large or too small ♦ "P53/P927?"No parameter access ♦ "Operating status?" Value can only be changed in the "Drive setting" status, for example With "Reset", the message is deleted and the old value is re-instated. NOTE

Parameter changes are always stored with power-failure protection in the EEPROM of the unit connected to the OP1S. Example of parameter correction

Ì P Î P605 Brake control

Correction of parameter value

Accept and return

∇

Selection of parameter value

Ì P Î

Ì

0 P605 Brake control

without brake

Î


without brake


Brake w/o chkbk

Brake w/o chkbk



Accept and return

Ì P Î

Ì 5 Î

Ì P Î

P600

0 ms MCont mssg time

Selection of parameter index

Ì P Î P049.001




Accept and return

Ì P Î

Ì 4 Î

Ì P Î

Ì

P049.001

Î P049.002

P049.002

4 OP OperDisp 1st line, left

Ì P Î

P049.002

6 OP OperDisp 1st line, right

6 OP OperDisp 1st line, right

OP OperDisp 1st line, ???

Selection of bit

Correction of bit

Accept and return

Ì 0 Î

Ì P Î

Ì

Î

P049.002 4

∇

Selection of parameter index


Correction of parameter index

4 OP OperDisp 1st line, left

P600

P600


∇

P600

1

P053 0006Hex P053 0006Hex P053 0006Hex P053 0006Hex P053 0004Hex Parameter Access Parameter Access Parameter Access Parameter Access Parameter Access 0000000000000110 0000000000000110 0000000000000110 0000000000000100 0000000000000110 ComBoard: No BaseKeypad: Yes BaseKeyp: No ComBoard: No BaseKeyp: No

4 OP OperDisp 1st line, ???

A fault or alarm message is indicated by the red LED. In the event of a fault, the red LED lights up and stays on. A fault message appears in the 3rd and 4th line of the operating display.

Ì

∇

Fault and alarm messages

Î

0.0 A 0 V 00 0.0 A 0 V 00 # 0.00 min-1 # 0.00 min-1 F065: SCom Tlg 1T 3h 2" Fault 1/1 Fault 1/1

Example of a fault display

The fault number and the respective text are shown in the 3rd line. Up to 8 fault messages can be stored but only the first fault to occur is shown on the display. Several subsequent faults are shown in the 4th line, e.g. with 1/3 (first of three). Information on all faults can be obtained from the fault memory. With "Raise"/"Lower", the associated operating hours are shown when a fault is waiting to be remedied. After the cause of a fault has been removed, the fault is acknowledged with "Reset" inside the operating display (the "Reset" key must be appropriately parameterized. See section "Issuing commands via the OP1S"). By pressing "P" and "Lower" at the same time, it is possible to skip back directly to the operating display from the parameter level. When there is an alarm, the red LED flashes. A warning appears in the 4th line of the operating display. 8.2 A 520 V 00 # 100.00 min-1 * 100.00 min-1 -33:Overspeed

Example of an alarm display

The alarm number and the respective text is shown in the 4th line. There can be several alarms at the same time but only the first alarm to occur is shown on the display. Several alarms are shown in the 4th line before the alarm number with an "+” instead of "-”. Information on all alarms can be obtained with the alarm parameters r953 to r969. An alarm cannot be acknowledged. As soon as the cause no longer exists, the alarm/display disappears automatically.

Parameters Parameters are the intervention points for adapting function blocks to an application, for interconnecting function blocks via connectors and binectors and for visualizing internal signals. The various parameters are differentiated according to their function as follows: ♦ Function parameters (can be read and written) ♦ BICO parameters (can be read and written) ♦ Visualization parameters (can only be read). Each parameter is clearly designated.The parameter designation comprises the parameter name and the parameter number, and enables every parameter to be clearly identified. In addition to the parameter name and the parameter number, many parameters also have a parameter index. With the aid of this index, it is possible to store several values for one parameter under one parameter number. The function diagrams indicate the factory setting for every BICO parameter and every function parameter. They further indicate the value ranges for the changeable function parameters. Parameter numbers on the PMU

The parameter numbers shown on the parameterizing unit (PMU) which is directly mounted on the unit consist of a letter and a three-digit number. The following applies for the letters: ♦ Upper-case letters (P, U, H and L) represent the BICO parameters and function parameters which can be changed ♦ Lower-case letters (r, n, d and c) represent the visualization parameters which cannot be changed. The three-digit number covers the value range from 000 to 999; but not all values are used.

Parameter numbers on the OP1S

The OP1S operator control panel enables parameters to be selected directly by their parameter numbers. As the OP1S only has a numerical keypad, the parameter number must be replaced by a figure when input. The following replace mode is applicable: ♦ "P"xxx and "r"xxx are replaced by "0"xxx ♦ "H"xxx and "d"xxx are replaced by "1"xxx ♦ "U"xxx and "n"xxx are replaced by "2"xxx ♦ "L"xxx and "c"xxx are replaced by "3"xxx Examples: Select r004 on OP1S: Select P050 on OP1S: Select U123 on OP1S: Select L411 on OP1S

Input 0004 Input 0050 Input 2123 Input 3411

Function parameters The response of a function block is determined by function parameters. Typical examples of function parameters are: ♦ Normalization of an input signal ♦ Acceleration or deceleration times in the ramp-function generator ♦ Proportional gain (Kp) and integral time (Tn) in the speed controller. Function parameters can be indexed. The significance of the parameter values stored in the various indices depends on the definition of the respective parameter. A special group is formed by the function parameters which are part of the so-called function data sets. Parameter name DT1 Element T1 0.0 ... 10.0 ms P249.F (0.0)

Parameter number Parameter index

Function data sets (Setpoint data sets)

Value range

Factory setting

Special function parameters are put together in function data sets. These parameters are marked in the function diagrams with the parameter index .F. The parameters concerned are indexed four-fold, which means that one parameter value can be stored under each parameter index, i.e. a total of four parameter values can be stored. The active function data set determines which value is currently being used. If function data set 1 is active, the parameter value stored in parameter index 1 is used. If function data set 2 is active, the parameter value stored in parameter index 2 is used, etc. Example: P462.1 = 0.50 P462.2 = 1.00 P462.3 = 3.00 P462.4 = 8.00 A total of 4 values are stored under parameter P462 (Accel Time). If function data set 1 is active, the acceleration time is 0.50 secs. If function data set 2 is active, the acceleration time is 1.00 secs. If function data set 3 is active, the acceleration time is 3.00 secs and if function data set 4 is active, the acceleration time is 8.00 secs. The individual function data sets are selected by means of control word bits 16 and 17 in control word 2 (P576.B and P577.B). Changeover is possible at any time. The active function data sets are displayed via the visualization parameter r013 (Active FuncDSet).

NOTE

Changeover of all the indexed parameters of the function data sets between parameter indices 1, 2, 3 and 4 is always effected jointly.

Motor parameters

The motor parameters enable the converter to the be adapted to the connected motor and enable the open-loop and closed-loop control structure to be adapted. Typical examples for motor parameters are: ♦ Rated motor data from the rating plate ♦ Specification of the connected tachometer ♦ Current and output limits Motor parameters are indexed 4-fold. Parameter number Parameter index Maximum current 0.1 ... 6553.5 A P128.M (~)

Factory setting Parameter name Value range

MIN

Motor data sets

Selected function parameters are put together in motor data sets. These parameters are marked in the function diagrams with the parameter index .M The parameters concerned are indexed four-fold, which means that one parameter value can be stored under each parameter index of these parameters, i.e. a total of four parameters can be stored. The active motor data block (MDS) determines which value is currently being used. If MDS1 is active, the parameter value stored in parameter index 1 is used, if MDS2 is active, the parameter value stored in parameter index 2 is used, etc Example: P100.1 = 4 P100.2 = 3 P100.3 = 1 P100.4 = 1 A totoal of 4 values are stored under parameter P100 (Control Mode). If motor data set 1 is active, the drive operates in speed control with a tachometer. If the motor data set 2 is active, the drive operates in frequency control without a tachometer. If motor data set 3 and 4 are active, the drive operates in v/f control. Individual motor data sets are selected via control word bits 18 and 19 in control word 2 (P578.B and P579.B). Changeover is only possible in the powered-down state.

NOTE

All indexed parameters of the motor data sets are always changed over jointly between parameter indices 1, 2, 3 and 4.

BICO parameters

With BICO parameters, you can determine the sources of the input signals of a function block. This means that you can use BICO parameters to define the connectors and binectors from which a function block reads in its input signals. In this manner, you can "softwire" the function blocks stored in the units to meet your requirements. This is referred to as the BICO system. For every BICO parameter, the type of input signals (connector or binector) which you can connect to the inputs is specified. BICO parameters have the following identification: ♦ B Binector parameter for connecting binectors ♦ K Connector parameter for connecting connectors with word length (16 bit) ♦ KK Connector parameter for conneting connectors with double-word length (32 bit) Reciprocal "softwiring" of binectors and connectors is not permitted. However, you can always connect connector with word length and double-word length to the connector parameters. BICO parameters are available in two forms; they can either be ♦ non-indexed, or ♦ double-indexed.

BICO data sets (Basic/reserve data sets)

Selected BICO parameters are put together in BICO data sets. These parameters are marked in the function diagrams with the parameter index .B. The parameters concerned are double-indexed, which means that one parameter value can be stored under each parameter index of these parameters, i.e. a total of two parameter values can be stored. The active BICO data set determines which value is currently being used. If BICO data set 1 is active, the parameter value stored in parameter index 1 is used. If BICO data set 2 is active, the parameter value stored in parameter index 2 is used. Example: P554.1 = 10 P554.2 = 2100 A total of 2 values are stored under parameter P554 (Src ON/OFF1). If BICO data set 1 is active, the ON command comes from digital input 1 of the basic unit. If BICO data set 2 is active, the ON command comes from bit 0 of the first data word received by serial interface 1. Individual BICO data sets are selected by means of control word bit 30 in control word 2 (P590. The active BICO data set is displayed via visualization parameter r012 (Active BICO DS).

NOTE

All indexed BICO parameters are always switched jointly between parameter index 1 and 2.

Parameter name

Parameter name Src Torq (set)

Src DigOut1 Parameter number

P651.B (0) B

Parameter index / factory setting

Parameter number

P260.B (0) K

Parameter index / factory setting

Connectable connector type (K or KK)

Connectable binector

Connectors with word lengths of 16 bit and 32 bit

Visualization parameters

Visualization parameters are used for visualizing internal quantities (e.g. applicable output current). These parameters are only displayed and cannot be changed by you. To distinguish them from the other parameters, they are designated with a lower-case letter (r, n, d and c) in the parameter number. Parameter number r006 DC Bus Volts Parameter name

Visualization parameters

Connecting up function blocks (BICO system) BICO system is the term used to descrbe the method of creating connections between function blocks. This is performed with the aid of binectors and connectors. The name BICO system is derived from these two terms. A connection between two function blocks consists of a connector or binector on the one side, and a BICO parameter on the other side. The connection is always made from the point of view of the input of a function block. You must always assign an output to an input. Assigment is made by entering in a BICO parameter the number of the connector or the binector from which the required input signals are read in. You are allowed to enter the same connector and binector numbers several times in different BICO parameters and thus use output signals of one function block as input signals for several other function blocks. Example: In the following figure, connector K0152 is connected to connector parameter P228. For this purpose, you must assign the number of connector K0152 as the value to the connector parameter P228 , i.e. in this case 152.

Parameter list Vector Control Parameter

Description

Data

Read/write

r001 Drive Status

Visualization parameter for the current status of the converter or inverter. The converter status is, for example, determined by the control commands for the internal sequence control (see control word 1 and 2 r550,r551) and by menu selection P060.

Dec.Plc.: 0 Unit: Indices: Type: O2

Menus: - Parameter menu + General parameters + Motor/encoder + Encoder data + Control/gating unit + Position Control + Diagnostics + Trace + Technology + Synchronism + Positioning + Setting up/MDI - Fix

Dec.Plc.: 3 Unit: Hz Indices: Type: I4

Menus: - Parameter menu + General parameters - Upread/free access

Dec.Plc.: 1 Unit: V Indices: Type: I2


Dec.Plc.: 1 Unit: A Indices: Type: I4


Dec.Plc.: 1 Unit: % Indices: Type: I2


1

0 = Power section definition 1 = Initialization of converter or inverter 2 = Hardware initialization 3 = Drive system initialization 4 = Board configuration 5 = Drive setting 6 = Selection of several drive test functions 7 = Störung 8 = Start inhibt 9 = Ready for ON 10 = Precharging of Dc link bus 11 =Ready for operation 12 = Ground fault test 13 = "Flying restart" is active 14 = Operation 15 = OFF1 is active 16 = OFF3 is active 17 = "DC braking" is active 18 = Motor data identification at standstill is active 19 = Optimization of speed controller 20 = "Synchronization" active 21 = Download r002 Rot Freq

Visualization parameter for the speed actual value in Hz (multiplied by the pole pair number P109 of the drive)

2

Display quantity for the PMU parameterizing unit and the OP (see P049). In function diagram: 350.7, 351.7, 352.7

r003 Output Volts

Visualization parameter for the output voltage of the converter or inverter (fundamental rms)

3

In function plan: 285.3, 286.3

r004 Output Amps

Visualization parameter for the output current of the converter or inverter (fundamental rms)

4

In function diagram: 285.7, 286.7

r005 Output Power

Visualization parameter for the ouput active power. The display value is normalized to the reference power which is derived from the product of reference frequency P352 and referencetorque P354.

5

In function diagram: 285.7, 286.7

Parameter

Description

Data

Read/write

r006 DC Bus Volts

Visualization parameter for DC link voltage.

Dec.Plc.: 0 Unit: V Indices: Type: I2


Dec.Plc.: 1 Unit: % Indices: Type: I2


Dec.Plc.: 0 Unit: % Indices: Type: O2

Menus: - Parameter menu - Upread/free access

Dec.Plc.: 0 Unit: °C Indices: Type: I2

Menus: - Parameter menu + General parameters + Functions - Upread/free access

Dec.Plc.: 0 Unit: % Indices: Type: O2



Menus: - Parameter menu + General parameters - Drive setting - Upread/free access

6

Displayed quantity for the PMU parameterizing unit and the OP (r049). In function diagram: 285.3, 286.7

r007 Motor Torque

Visualization parameter for torque referred to the reference torque (P354).

7

Precondition: P100 = 3, 4, 5 (vector control types) In function diagram: 285.7

r008 Motor Utilizat.

Visualization parameter for thermal motor utilization (calculated value).

8

Precondition: P383 >= 100 s ATTENTION. For an overload protection of the motor which is derived from this parameter, sufficient cooling of the motor must be ensured.

r009 Motor Temperat. 9

Visualization parameter for the current motor temperature. A correct display is only possible if the motor temperature is measured with a KTY84 temperature sensor or BICO parameter P385 is softwired to a connector which provides the temperature signal in the normalization 1°=40 Hex. Precondition: P360 > 1 or P361 > 1 or P310 = 2 and P361 > 1 In function diagram: 280.3

r010 Drive Utilizat.

Visualization parameter for the current thermal utilization of the converter or inverter.

10

The utilization is determined byan i2t calculation of the output current. A value of 100 % is achieved in continuous operation with the rated current. If a 100 % utilization is exceeded, an alarm message (A024) is tripped and the output current is reduced to 89 % of the rated current..

r011 act. MotDataSet

Visualization parameter for the currently active motor data sets.

11

1 = Data set 1 2 = Data set 2 3 = Data set 3 4 = Data set 4 A motor data set is selected with control word bits 18 and 19. The relevant BICO parameters for linking the control word bits are P578 and P579. In function diagram: 20.5

Parameter

Description

Data

Read/write

r012 Active BICO DSet

Visualization parameter for the currently active BICO data set.

12

1 = Data set 1 2 = Data set 2





Dec.Plc.: 1 Unit: 1/min Indices: Type: I4


Dec.Plc.: 1 Unit: 1/min Indices: Type: I4


Index1: 0 Unit: Indices: 5 Type: L2, C

Menus: - Parameter menu + General parameters - Upread/free access changeable in: - Ready - Run

Dec.Plc.: 1 Unit: % Indices: 5 Type: I4


BICO parameter for selecting binectors which are to be shown in visualization parameter r031. The binector numbers entered in the respective index are displayed in the same index of parameter r031.

Index1: 0 Unit: Indices: 5 Type: L2, B


Visualization parameter for displaying the binectors given in P030. The binectors displayed in the respective index have been selected in the same index of parameter P030.

Dec.Plc.: 0 Unit: Indices: 5 Type: O2


A BICO data set is selected with control word bit 30. The relevant BICO parameter for linking the control word bit is P590. In function diagram: 20.5 r013 Active FuncDSet

Visualization parameter for the currently active function data set.

13

1 =Data set 1 2 = Data set 2 3 = Data set 3 4 = Data set 4 A function data set is selected with control word bits 16 and 17. The relevant BICO parameters for linking the control word bits are P576 and P577. In function diagram: 20.5

r014 Setp Speed

Visualization parameter for the speed setpoint at the speed controller input or at the frequency input of the v/f control.

14 In function diagram: 360.4, 361.4, 362.4, 363.4 r015 n(act) 15 P028* SrcDispPowerConn 28

Visualization parameter for the speed actual value. In function diagram: 350.7, 351.7, 352.7 BICO parameter for selecting connectors which contain a power and are to be displayed in visualization parameter r029 in (%). The connector numbers entered in the respective index are displayed in the same index of parameter r029. In function diagram: 30.7

r029 DispPowerConn 29

Visualization parameter for displaying connectors given in P028 in (%). The connectors displayed in the respective index have been selected in the same index of parameter P028. Normalization is determined in P352 and P354. In function diagram: 30.8

P030* Src Disp Binec 30

r031 Display Binector 31

Parameter

Description

Data

Read/write

P032* Src Disp Conn

BICO parameter for selecting connectors which are to be displayed in visualization parameter r033 in [%]. The connector numbers shown in the respective index are displayed in the same index of parameter r033.

Index1: 0 Unit: Indices: 5 Type: L2, CC


Visualization parameter for displaying the connectors given in P032. The connnectors displayed in the respective index have been selected in the same index of parameter P032. A connector value of 4000 H or 4000 0000 H is shown at 100 %.



BICO parameter for selecting connectors which contain a voltage and are to be displayed in visualization parameter r035 in [V]. The connector numbers entered in the respective index are displayed in the same index of parameter r035.



Visualization parameter for displaying connectors given in P034 in [V]. The connectors displayed in the respective index have been selected in the same index of parameter P034. The normalization is specified in P351. The following method of calculation must be used: r035 = P351 xConnector Value in [%]/100%.

Dec.Plc.: 1 Unit: V Indices: 5 Type: I4


BICO parameter for selecting connectors which contain a current and are to be displayed in visualization parameter r037 in [A]. The connector numbers entered in the respective index are displayed in the same index of parameter r037.



Visualization parameter for the display of connectors given in P036 in [A]. The connectors displayed in the respective index have been selected in the same index of parameter P036. The normalization is specified in P350. The following method of calculation must be used: r037 = P350 xConnector Value in [%]/100%.

Dec.Plc.: 2 Unit: A Indices: 5 Type: I4


BICO parameter for selecting connectors which contain a torque and are to be displayed in visualization parameter r039 in (%). The connector numbers entered in the respective index are displayed in the same index of parameter r039.







32

r033 Display Conn 33 P034* SrcDispVoltsConn 34

r035 Disp Volts Conn 35

P036* SrcDispAmpsConn 36

r037 Disp Amps Conn 37

P038* Src DispTorqConn 38

In function diagram: 30.4 r039 Disp Torq Conn 39

Visualization parameter for the display of connectors given in P038 in (%). The connectors displayed in the respective index have been selected in the same index of parameter P038. Normalization is determined in P354. In function diagram: 30.5

P040* SrcDisp SpdConn 40

BICO parameter for selecting connectors which contain a torque and are to be displayed in visualization parameter r041 in [1/min]. The connector numbers entered in the respective index are displayed in the same index of parameter r041.

Parameter

Description

Data

Read/write

r041 Disp Speed Conn

Visualization parameter for the display of connectors given in P040 in [1/min]. The connectors displayed in the respective index have been selected in the same index of parameter P040. The normalization is specified in P353. The following method of calculation must be used: r041 = P353 xConnector Value in [%]/100%.

Dec.Plc.: 1 Unit: 1/min Indices: 5 Type: I4


BICO parameter for selecting connectors which contain a frequency and are to be displayed in visualization parameter r043 in [Hz]. The connector numbers entered in the respective index are displayed in the same index of parameter r043.



Visualization parameter for the display of connectors given in P042 in [Hz]. The connectors displayed in the respective index have been selected in the same index of parameter P042. The normalization is specified in P352. The following method of calculation must be used: r043 = P352 x Connector Value in [%]/100%.

Dec.Plc.: 3 Unit: Hz Indices: 5 Type: I4


BICO parameter for selecting connectors which are to displayed in visualization parameter r045 as an integral decimal number preceded by a plus or minus sign. The connector numbers entered in the respective index are displayed in the same index of parameter r045.



Visualization parameter for the display of connectors given in P044 as an integral whole decimal number. The connectors displayed in the respective index have been selected in the same index of parameter P044.

Dec.Plc.: 0 Unit: Indices: 5 Type: I4


BICO parameter for selecting connectors which are to be displayed in visualization parameter r046 as an integral value (hexadecimal). The connector numbers entered in the respective index are displayed in the same index of parameter r046.



Visualization parameter for the display of connectors given in P045 as a hexadecimal number. If word connectors have been selected in P046, then Indices 1 to 5 = Value of the connector Indices 6 to 10 = 0 If double word connectors have been selected in P046, then: Indices 1 to 5 = Upper 16 bits of the connector Indices 6 to 10 = Corresponding lower 16 bits of the connector

Dec.Plc.: 0 Unit: Indices: 10 Type: L2


Init: 2 Min: 0 Max: 3999 Unit: Indices: Type: O2


41

P042* SrcDispFreqConn 42

r043 Disp Freq Conn 43

P044* SrcDisp DecConn 44

r045 Disp DecConn 45 P046* SrcDisp HexConn 46

r047 Disp Hex Conn 47

Example: KK0091 = 1234 5678 P046.1= 91 r047.1 = 1234 r047.6 = 5678 P048* PMU OperDisp 48

Function parameter for selecting parameter whose value is to be shown in the operating display of the PMU.

Parameter

Description

Data

Read/write

P049* OP OperDisp

Function parameter for selecting parameters whose values are to be shown in the operating display of the optional OP1S user-friendly operator control panel.

Index1: 4 Min: 0 Max: 3999 Unit: Indices: 5 Type: O2




Init: 6 Min: 0 Max: 65535 Unit: Indices: Type: V2

Menus: all Menus changeable in: all states

49 Index 1: 1st line left Index 2: 1st line right Index 3: 2nd line (actual value), only visualization parameters Index 4: 3rd line (setpoint), only function parameters Index 5: 4th line P050* Language

Function parameter for setting the language in which texts are to be displayed on the optional OP1S user- friendly operator control panel.

50 0 = German 1 = English 2 = Spanish 3 = French 4 = Italian P053* Parameter Access

Function parameter for releasing interfaces for parameterization.

53

0 = None 1 = Cbx communication board 2 = PMU operator control panel 4 = Serial interface (SST/SST1), also OP1S and PC 8 = SCB serial input/output modules 16 = Txxx technology board 32 = Serial interface 2 (SCom2) Each interface has a code number. When the number or the sum of different numbers assigned to the interfaces is/are entered, the interface(s) is/are released for use as a parameterizing interface. Example: The factory-setting value 6 is the sum of 2 and 4. This means that parameterization is allowed via the PMU and serial interface 1 and thus for the OP1S as well. The parameter can always be written from any interface. This also applies if this interface has not been released for parameterization purposes.

Parameter

Description

Data

Read/write

P060* Menu Select

Function parameter for selecting the current menu.


Menus: all Menus changeable in: all states


Menus: - Parameter menu + General parameters - Drive setting - Upread/free access changeable in: - Drive setting

Dec.Plc.: 1 Unit: Indices: 8 Type: O2

Menus: - Parameter menu + General parameters - Fixed settings - Quick parameterization - Board configuration - Drive setting - Download - Upread/free access - Power section definition

60

0 = User parameter (selection of the visible parameters in P360) 1 = Parameter menu 2 = Fixed settings (also contains factory settings) 3 = Quick parameterization (changes to "Drive Setting" state) 4 = Board configuration (changes to "Board Configuration" state) 5 = Drive setting (changes to "Drive Setting" state) 6 = Download (changes to "Download" state) 7 = Upread/Free access 8 = Power section definition (changes to "Power section definition" state) If it is not possible to change to another state due to the currently valid state, the corresponding menu cannot be selected either. Example: "Operating" state, change to "Download" not possible. "Ready for switching on" state, change to "Download" not possible. With parameters P358 Key and P359 Lock, menus can be locked with the exception of the menus "User parameters" and "Fixed settings".

P068* Output Filter 68

Function parameter for entering the output filter. Parameter values 0 = without output filter 1 = with sinusoidal output filter 2 = with dv/dt output filter The parameter value 1 limits the depth of modulation to the range of space vector modulation (see also P342 and r345, maximum depth of modulation). The pulse frequency P340 is adapted to the envisaged sinusoidal filter after leaving the drive setting (see P060 = 5). Notes: · For n/f/Torque control and for temperature adaption (P386 > 0), the sinusoidal filter for the converter is taken into account. . ·The parameter value 2 limits the adjustable pulse frequency P340 to 3 kHz. In function diagram: 430.3, 390.7, 405.6

r069 SW Version

Visualization parameter for displaying the software versions of the basic board as well as the optional boards in slots A to G

69 Index 1: Software version of basic board Index 2: Software version of optional board Slot A Index 3: Software version of optional board Slot B Index 4: Software version of optional board Slot C Index 5: Software version of optional board Slot D Index 6: Software version of optional board Slot E Index 7: Software version of optional board Slot F Index 8: Software version of optional board Slot G The slots D-G are not available in type COMPACT PLUS. For optional boards which contain no software, (e.g. SBR, SLB), the parameter value in the respective index is always 0.0.

Parameter

Description

Data

Read/write

P070* Order No. 6SE70.

Function parameter for entering the order numbers of converter or inverter modules. These numbers tell the control board which power section it works with.


Menus: - Parameter menu + General parameters - Upread/free access - Power section definition changeable in: - Power section definition

Init: ~ Min: 90 Max: 1320 Unit: V Indices: Type: O2

Menus: - Parameter menu + General parameters - Quick parameterization - Drive setting - Upread/free access changeable in: - Drive setting

72

Parameter for displaying the rated current of the converter or inverter. The rated current is the current which can be output continuously. It must be identical to the current indicated on the rating plate of the converter.

Init: ~ Min: 4,5 Max: 6540,0 Unit: A Indices: Type: O4

Menus: - Parameter menu + General parameters - Drive setting - Upread/free access - Power section definition changeable in: - Power section definition

P073 Rtd Drive Power

Parameter for displaying the rated power of the converter or inverter.

Init: ~ Min: 0,3 Max: 6400,0 Unit: kW Indices: Type: O2

Menus: - Parameter menu + General parameters - Upread/free access - Power section definition changeable in: - Power section definition

Function parameter for the motor magnetizing reactance (saturated) along the rotor axis (d axis) , referred to the rated motor impedance.

Index1: 150,0 Min: 1,0 Max: 999,0 Unit: % Indices: 4 Type: O2

Menus: - Parameter menu + Motor/encoder + Motor data - Upread/free access changeable in: - Ready - Run

Function parameter for the motor magnetizing reactance (saturated) transverse to the rotor axis (q axis), referred to the rated motor impedance.



Function parameter for motor leakage reactance of the damper winding along the rotor axis (d axis), referred to the rated motor impedance.



70 For parameter values, see annex "Compendium".

P071 Line Volts

Function parameter for entering the line voltage of the converter or inverter.

71

Converter (AC/AC): rms value of the line AC voltage Inverter (DC/AC): input direct voltage The value is for calculating the rated DC link voltage as a basis for the voltage limits of the Vd(max) and Vd(min) [KIB) controller (e.g. undervoltage failure limit).

P072 Rtd Drive Amps

73

P075 X (magnet,d)tot 75

P076 X (magnet,q)tot. 76

P077 X (sigma,d) damp 77

Automatic parameterization (P115=1) should be executed after the parameter value is changed. Precondition: P095 = 12 (synchronous motor)

Parameter

Description

Data

Read/write

P078 X (sigma,q) damp

Function parameter for motor leakage reactance of the damper winding transverse to the rotor axis (q axis) referred to the rated motor impedance.















78 Automatic parameterization (P115=1) should be executed after the parameter value is changed. Precondition: P095 = 12 (synchronous motor) P079 R (damping,d)

Function parameter for motor resistance of damper winding along the rotor axis (d axis), referred to the rated motor impedance.

79 Automatic parameterization (P115=1) should be executed after the parameter value is changed. Precondition: P095 = 12 (synchronous motor) P080 R (damping,q)

Function parameter for the motor resistance of the damper winding transverse to the rotor axis (q axis), referred to the rated motor impedance.

80 Automatic parameterization (P115=1) has to be executed after the parameter value is changed. Precondition: P095 = 12 (synchronous motor) P081 Iexc(0)/Iexc(n)

Function parameter for the ratio between no-load and rated excitation current.

81

The parameter corresponds to the transmission factor between the rotating-field system of the current model and the direct-current system of the excitation current control. Precondition: P095 = 12 (synchronous motor)

P082 Psi(sat.char.,1) 82

Function parameter for entering the first (lowest) flux value of the saturation characteristic, referred to the rated rotor flux (rated EMF) of the motor. The value belongs to the first excitation current value P083. Precondition: P095 = 12 (synchronous motor)

P083 Iexc(sat.char,1)

Function parameter for entering the first (lowest) current excitation value of the saturation characteristic, referred to the no-load excitation current of the motor.

83 The value belongs to the first flux value P082. Precondition: P095 = 12 (synchronous motor) P084 Psi(sat.char.,2) 84

Function parameter for entering the second flux value of the saturation characteristic, referred to the rated rotor flux (rated EMF) of the motor. The value belongs to the second excitation current value P085. Precondition: P095 = 12 (synchronous motor)

Parameter

Description

Data

Read/write

P085 Iexc(sat.char,2)

Function parameter for entering the second current excitation value of the saturation characteristic, referred to the no-load excitation current of the motor.







Index1: 0,00 Min: 0,00 Max: 655,35 Unit: Nm/A Indices: 4 Type: O2

Menus: - Parameter menu + Motor/encoder + Motor data - Drive setting - Upread/free access changeable in: - Drive setting

85 The value belongs to the second flux value P084. Precondition: P095 = 12 (synchronous motor) P086 Psi(sat.char.,3) 86

Function parameter for entering the third (highest) flux value of the saturation characteristic, referred to the rated rotor flux (rated EMF) of the motor. The value belongs to the third excitation current value P087. A value of 100 % corresponds to an induced terminal voltage amounting to the rated motor voltage (in no-load at synchronous speed). Precondition: P095 = 12 (synchronous motor)

P087 Iexc(sat.char,3) 87

Function parameter for entering the third (highest) excitation current value of the saturation characteristic, referred to the no-load excitation current of the motor. The value belongs to the third flux value P086. A value of 100 % corresponds to the rating plate value of the excitation current which produces a terminal voltage amounting to the rated motor voltage in no-load at synchronous speed. Precondition: P095 = 12 (synchronous motor)

P088 kT(n) 88

Function parameter for entering the torque constant (kTn (100 Kelvin)). The value corresponds to the current/motor torque proportionality constants. Precondition: P095 = 13 (synchronous motor, permanently excited)

Parameter

Description

Data

Read/write

P095* Type of Motor

Function parameter for changing between international (IEC) and US (NEMA) motor data parameterization. If NEMA is selected, the efficiency and the rated motor output instead of the power factor cos(PHI) are displayed during motor parameterization.





Index1: ~ Min: 100 Max: 2000 Unit: V Indices: 4 Type: O2


95

Parameter values: 10: IEC induction motor 11: NEMA induction motor 12: Synchronous motor (externally excited) 13 Synchronous perm. Note: Selection of a synchronous motor (12, 13) is only considered for certain special applications. P95 can also be at "0" (factory settging) during operation of permanently-excited synchronous motors. In both cases, the following functions are disabled: Synchronizing (P582), Flying restart (P583, P525, P526), Automatic restart (P373), DC braking (P395), Motor identification (P115=2,3,4,6), Control mode (P100=0,1,2,3 for P95=12), Control mode (P100=0,2,4,5 for P095=13). Synchronizing (P582) is used for P095=12 for resetting to the initial position if P172 is not connected. P100* Control Mode

Function parameter for selecting the open/closed loop control mode

100

Parameter values: 0: v/f contol with superposed speed control (only for P095 = 10, 11) 1: v/f control (only for P095 = 10, 11, 13) 2: v/f control for textile applications; allows no frequency corrections (e.g. by the current limitation controller) (only for P095 = 10, 11) 3: Frequency control (without tachometer) (only for P095 = 10, 11, 13) 4: Speed control (only for P095 = 10, 11, 12) 5: Torque control (only for P095 = 10, 11, 12) In function diagram: 14

P101* Mot Rtd Volts 101

Function parameter for entering the rated motor voltage. The rating plate value of the voltage for the current kind of connection (star/delta) and for line duty has to be entered. Note: Input for Siemosyn motors is the rated voltage at rated motor frequency. For P95=13 (motor type =sync.perm.), the motor rated voltage is only used as a normalization quantity for the rated motor impedance to which all resistances and reactances are referred (e.g. P075). in function diagram: 405.3

Parameter

Description

Data

Read/write

P102* Motor Rtd Amps

Function parameter for entering the rated motor current for the connected synchronous or induction motor. The rating plate value for the current kind of connection (star/delta) has to be entered.

Index1: ~ Min: 0,6 Max: 6553,5 Unit: A Indices: 4 Type: O4


Index1: ~ Min: 0,0 Max: 95,0 Unit: % Indices: 4 Type: O2

Menus: - Parameter menu + Motor/encoder + Motor data - Drive setting - Upread/free access changeable in: - Drive setting - Ready

Index1: ~ Min: 0,500 Max: 1,000 Unit: Indices: 4 Type: O2


Index1: ~ Min: 0,1 Max: 2000,0 Unit: hp Indices: 4 Type: O2


Index1: ~ Min: 50,0 Max: 99,9 Unit: % Indices: 4 Type: O2


102

Permissible values: 0.125 * P072 <= P102 < 1.36 * P072

P103* Motor Magn Amps 103

Function parameter for entering the motor magnetizing current referred to the rated motor current. The correct input improves the calculation of motor parameters in automatic parameterization (P115=1). The value is determined during motor data identification (P115=2,3) and during the no-load test (P115=4). Synchronous motor (P95=12): Reactive current component at the motor rating point. Note: The value always has to be set to 0.0% so that the rated motor current is contributed completely to torque generation. Precondition: P095 = 10,11,12 (Motor type = Induc.IEC, Induc.NEMA, synchronous motor)

P104* MotPwrFactor

Function parameter for entering hte power factor for the connected induction motor. The rating plate value has to be entered.

104 Precondition: P95 = 10,12 (motor type: induc.IEC, synchronous motor)

P105* Motor Rtd Power

Function parameter for entering the rated motor power in Hp (rating plate value).

105

Precondition: P095 = 11 (motor type: NEMA induction motor)

P106* Motor Rtd Effic.

Function parameter for entering the rated motor efficiency (rating plate value).

106

Precondition: P095 = 11 (motor type: NEMA induction motor)

Menu levels

The parameter menus have several menu levels. The first level contains the main menus. These are effective for all sources of parameter inputs (PMU, OP1S, SIMOVIS, field bus interfaces). The main menus are selected in parameter P60 Menu Selection. Examples: P060 = 0 "User parameters" menu selected P060 = 1 "Parameter menu" selected ... P060 = 8 "Power section definition" menu selected Menu levels 2 and 3 enable the parameter set to be more extensively structured. They are used for parameterizing the units with the OP1S operator control panel.

Main menus P060

Menu

Description

0

User parameters

•

Freely configurable menu

1

Parameter menu

•

Contains complete parameter set

•

More extensive structure of the functions achieved by using an OP1S operator control panel

2

Fixed settings

•

Used to perform a parameter reset to a factory or user setting

3

Quick parameterization

•

Used for quick parameterization with parameter modules

•

When selected, the unit switches to status 5 "Drive setting"

•

Used for configuring the optional boards

•

When selected, the unit switches to status 4 "Board configuration"

•

Used for detailed parameterization of important motor, encoder and control data

•

When selected, the unit switches to status 5 "Drive setting"

•

Used to download parameters from an OP1S, a PC or an automation unit

•

When selected, the unit switches to status 21 "Download"

•

Contains the complete parameter set and is used for free access to all parameters without being restricted by further menus

•

Enables all parameters to be upread by an OP1S, PC or automation unit

•

Used to define the power section (only necessary for units of the Compact and chassis type)

•

When selected, the unit switches to status 0 "Power section definition"

4

5

6

7

8

Board configuration

Drive setting

Download

Upread/free access

Power section definition

Parameter reset to factory setting The factory setting is the defined initial state of all parameters of a unit. The units are delivered with this setting. You can restore this initial state at any time by resetting the parameters to the factory setting, thus canceling all parameter changes made since the unit was delivered. The parameters for defining the power section and for releasing the technology options and the operating hours counter and fault memory are not changed by a parameter reset to factory setting. Parameter number

Parameter name

P070

Order No. 6SE70..

P072

Rtd Drive Amps

P073

Rtd Drive Power

P366

Select FactSet

Parameters which are not changed by the factory setting

NOTE

Parameter factory settings which are dependent on converter or motor parameters are marked with ’(~)’ in the block diagrams.

P053 = 6

P060 = 2

P366 = ?

P970 = 0 Unit carries out parameter reset and then leaves the "Fixed settings" menu

Grant parameter access 6: Parameter changes permitted via PMU and serial interface SCom1 (OP1S and PC) Select "Fixed settings" menu

Select desired factory setting 0: Standard 1: Standard with OP1S 2: Cabinet unit with OP1S (BICO1) or terminal strip (BICO2) 3: Cabinet unit with PMU (BICO1) or terminal strip (BICO2) 4: Cabinet unit with NAMUR terminal strip (SCI) Note: This parameter was correctly set prior to delivery of the unit and only needs to be changed in exceptional cases. Start parameter reset 0: Parameter reset 1: No parameter change

PROFIBUS Product description of the CBP communications board The CBP communications board (Communications board PROFIBUS) is for linking SIMOVERT MASTERDRIVES to higher-level automation systems via PROFIBUS-DP.

Fastening screw System connector LED (green) LED (yellow) LED (red) 9-pole Sub-D connection X448 Fastening screw

Technical data

The communications board has three LEDs (green, yellow, red) for providing information on the current operating status. Voltage is supplied from the basic unit through the system’s plug-in connector. The CBP has a 9-pole SUB D socket (X448) which is provided for connecting it up to the PROFIBUS system in accordance with the PROFIBUS standard. All connections of this RS485 interface are shortcircuit-proof and floating. The CBP supports baud rates of 9.6 kBaud to 12 MBaud and is also suitable for connecting fiber-optic cable by means of optical link plugs (OLPs).

Functionality

♦ Useful data is exchanged with the master according to the "PROFIBUS profile for variable-speed drives", PROFIDRIVE. ♦ Acyclical communications channel for transferring parameter values up to a length of 101 words with a SIMATIC S7-CPU ♦ Acyclical communications channel for linking the PC-based SIMOVIS start-up and service tool ♦ Automatic adoption of the useful data structure defined in the master ♦ Supporting of diagnostic alarms in conjunction with a SIMATIC S7

♦ Monitoring of the bus interface ♦ Supporting of SYNC-type PROFIBUS control commands for synchronized data transfer from the master to several slaves ♦ Supporting of FREEZE-type PROFIBUS control commands for synchronized data transfer from several slaves to the master ♦ Extremely simple parameterization of the CBP via the PMU of the basic unit.

Description of the CBP’s functions on the PROFIBUS-DP Definition

The PROFIBUS-DP is an international and open standard field bus as specified in field bus standard EN 50170 Part 2. Its specification as an international standard guarantees its openness and its independence from any particular manufacturer. The PROFIBUS-DP enables very fast, time-critical transfer of data on the field level. With the PROFIBUS, a distinction is made between masters and slaves. ♦ Masters determine data traffic on the bus and are also designated in the literature as active nodes. There are two classes of master: • DP-Master Class 1 (DPM1): These are central stations (e.g. SIMATIC S5, S7 and SIMADYN D) which exchange information with the slaves in defined communications cycles. • DP-Master Class 2 (DPM2): Units of this type are programming units, planning units or control and monitoring units which are used for configuring, starting up or monitoring systems in operation. ♦ Slaves (e.g. CBP, CB15 etc.) can only acknowledge the messages they receive or transfer messages to a master when the latter requests a slave to do so. Slaves are also designated as passive nodes.

Protocol architecture

The protocol architecture of the PROFIBUS-DP is oriented to the OSI (Open System Interconnection) reference model in accordance with the international standard, ISO 7498, and uses layers 1 and 2 as well as the user interface.

Transmission equipment

When transmission equipment is being selected, criteria such as high transmission speed and simple, inexpensive wiring and cabling is of primary importance. PROFIBUS supports transmission according to RS485 and also transmission by means of fiber-optic cable.

The transmission speed can be selected between 9.6 kBaud and 12 MBaud. The same speed is specified for all units on the bus when the system is started up for the first time. Bus-access procedure

The PROFIBUS works according to the token-passing procedure, i.e. the masters become token holders for a defined time window in a logical ring. Within this time window, the master can communicate with other masters. Alternatively, it can communicate with slaves by using a lower-level master-slave procedure. The PROFIBUS-DP mainly uses the master-slave method and data is usually exchanged with the drives cyclically.

Data exchange via PROFIBUS

This enables very rapid data exchange between the higher-level systems (e.g. SIMATIC, SIMADYN D, PC/PGs) and the drives. Access to the drives is always made according to the master-slaves method. The drives are always the slaves and each slave is clearly defined by its address. Higher-level computer "Master"

MASTERDRIVES

"Slave"

Other "Slave"

CBP Other nodes

PROFIBUS interface (PROFIBUS cable)

The cyclical communications functions are determined by the PROFIBUS-DP basic functions in accordance with EN 50170. For purposes of parameterization, diagnosis and alarm-handling during cyclical data exchange with intelligent drives, acyclical extended communications functions are also used which are defined in PROFIBUS Guideline No. 2.081 (German) or 2.082 (English). The following illustration contains an overview of the communications functions which are enabled with the CBP.

CBP slots in Compact and chassis-type units with the CUs of function classes FC (CU1), VC (CU2) or SC (CU3)

Electronics box Adaption board

+1.B1 +1.B3 +1.B2

Optional board CBP

The adaption board with optional board can be mounted in the electronics box in 1.B2 and/or 1.B3.

On the adaption board (MRPD 6SE7090-0XX84-0KA0), only one CBP can be mounted in slot X 198, i.e. at the BOTTOM. If the CBP is mounted with adaption board, the LBA (Local Bus Adaptor, LBA, MRPD 6SE7090-0XX84-4HA0) must first be mounted. NOTE

If only one optional board is used, it must always be inserted in slot +1.B2 (on the RIGHT) in the electronics box. If, in addition to the CBP, a technology board (T100 / T300 or T400) is inserted in the electronics box. it must be inserted in slot +1.B2. In this case, the CBP is inserted in slot +1.B3.

Connecting up the CBP to the PROFIBUS Assignment of plug-in connector X448 Connecting up

9

5

The CBP optional board has a 9-pin Sub-D socket (X448) which is provided for connecting the CBP to the PROFIBUS system. The connections are short-circuit proof and floating. Pin

Designation

Significance

1

SHIELD

Ground connection

Area

2

-

Not connected

3

RxD/TxD-P

Receive/transmit data P (B/B´)

RS485

4

CNTR-P

Control signal

TTL

5

DGND

PROFIBUS data reference potential (C/C´)

6

VP

Power supply Plus

7

-

Not connected

8

RxD/TxD-N

Receive/transmit data N (A/A´)

9

-

Not connected

6 1

5 V ± 10 % RS485

Bus connectors

You need bus connectors in order to connect the PROFIBUS to a CBP. There are different types of bus connector with degree of protection IP 20. Their different uses are shown in the table below.

Order No.

6ES7 972-0BA10-0XA0

6ES7 972-0BA20-0XA0

6ES7 972-0BB10-0XA0

6ES7 972-0BB20-0XA0

Appearance

PG socket

0BA10: no 0BB10: yes

0BA20: no 0BB20: yes

Max. baud rate

12 MBaud

12 MBaud

Can be connected as required

Can be connected as required

Vertical

Swivel-type: slanting / vertical

Terminating resistor Outgoing cable Interfaces •

PROFIBUS nodes

•

9-pole Sub-D socket

•

9-pole Sub-D socket

•

PROFIBUS cable

•

4 terminal blocks for wires up to 1.5 mm2

•

4 terminal blocks for wires up to 1.5 mm2

Connectable diameter of PROFIBUS cable

8 ± 0.5 mm

8 ± 0.5 mm

Recommended for •

IM 308-B

•

IM 308-C

•

S5-95U

•

S7-300

•

S7-400

•

M7-300

•

M7-400

•

CBP

n n n n n

n

n n n

n

Installing the bus cable

Bus cable connection for first and last nodes on the bus1

1

Bus termination

Bus cable connection for other nodes on the bus

The bus cable can be connected either on the left or on the right!

Each bus segment must be fitted with a resistor network, the bus termination, at each end. If the recommended bus connectors can be used, the bus termination can be connected or disconnected by means of switches. Terminating resistor connected

on off

Terminating resistor not connected

on off

If these bus connectors are not used, the user must ensure installation of a bus termination network at the first and last bus station in accordance with the following illustration. VP (PIN 6) 390 Ohm Data line

RxD/TxD-P (PIN 3) 220 Ohm

Data line

RxD/TxD-N (PIN 8) 390 Ohm DGND (PIN 5)

!

WARNING

A bus segment must always be terminated at both ends with a matching resistor. This is not the case, for example, if the last slave with bus connector is not live. Because the bus connector obtains its voltage from the station, the matching resistor has no effect. Make sure that the stations at which the matching resistor is connected is always supplied with voltage.

Pulling out the bus connector

Connection example

You can pull out the bus connector with looped-through bus cable from the PROFIBUS-DP interface at any time without interrupting data transfer on the bus. First bus node

Other bus nodes

Bus termination

From preceding bus node

Last bus node

Bus termination

To next bus node

Diagnosis and troubleshooting NOTE

With regard to basic parameterization, please note the differences to the types of unit with the older function classes FC (CU1), VC (CU2) and SC (CU3). These differences are described below. In order to make these differences clear, the parameter numbers and other deviations are either printed in dark grey or have a dark-grey background.

Evaluating the possibilities of hardware diagnosis LED displays

The three LED displays are located on the front of the CBP. These are as follows: • CBP operating (red) • Data exchange with the basic unit (yellow) • Transfer of useful data via the PROFIBUS (green) Diagnostic LEDs give the user rapid information on the status of the CBP at any particular instant. More detailed diagnostic information can be read out directly from the diagnostics memory of the CBP by means of a diagnostic parameter.

NOTE

During normal operation, all three LEDs repeatedly light up at the same time and for the same length of time (flashing)! If an LED is continuously on or off, this indicates an exceptional condition (parameterization phase or fault)!

LED

Status

Red

Flashing

CBP operating; voltage supply on

Yellow

Flashing

Fault-free data exchange with the basic unit

Green

Flashing

Fault-free useful data transfer via the PROFIBUS

LED

Status

Red

Flashing

Yellow

Flashing

Green

Off

Diagnostic information

Diagnostic information No transfer of useful data via the PROFIBUS-DP due to e.g. EMC interference, bus connector pulled out, polarity reversal of connections, node number not supplied with useful data by the master.

LED

Status

Diagnostic information

Red

Off/On

Voltage supply for CBP cut off; replace CBP or basic unit

Yellow

Off/On

Data exchange with the basic unit not possible; replace CBP or basic unit

Green

Off/On

Transfer of useful data via PROFIBUS not possible; PROFIBUS cable not connected or defective

In the following, all exceptional operating conditions are listed which are displayed as such by the CBP. LED

Status

Red

Flashing

Yellow

Off

Green

On

Red

On

Yellow

Off

Green

Flashing

Red

Flashing

Yellow

On

Green

Off

Red

Flashing

Yellow

On

Green

On

Diagnostic information CBP is waiting for the basic unit to begin initialization

CBP is waiting for the basic unit to complete initialization

Checksum error in flash EPROM of the CBP (Download firmware again or replace CBP) Error in RAM test of the CBP Replace CBP (external RAM, DPRAM or SPC3-RAM defective)

Fault and alarm display If faults in PROFIBUS communication with the CBP occur, corresponding faults or alarms are also displayed on the PMU or on the OP of the basic unit. Alarm number

Alarms

A 081

Meaning The identification-byte combinations which are sent in the configuration telegram by the DP master do not tally with the permitted combinations of identification bytes (see Table 8.2-12). Effect: No connection is established with the PROFIBUS-DP master; re-configuration is necessary

A 082

A valid PPO type cannot be found in the configuration telegram from the DP master. Effect: No connection is established with the PROFIBUS-DP master; re-configuration is necessary

A 083

No useful data or invalid useful data (e.g. complete control word STW1 = 0) are received by the DP master. Effect: The process data are not passed on to the DPR. If parameter P722 (P695) is not equal to zero, this leads to fault trip F082 (see chapter "Process data monitoring".

A 084

Telegram traffic between the DP master and the CBP has been interrupted (e.g. broken cable, bus connector pulled out or DP master switched off). Effect: If parameter P722 (P695) is not equal to zero, this leads to fault trip F 082 (see chapter "Process data monitoring".

A 085

Error in the DPS manager software of the CBP. Effect: If this error occurs, the heartbeat-counter for the basic unit is no longer incremented. The consequence is fault trip F 081.

NOTE

The alarm A 082 can even be displayed on the basic unit the first time the CBP is started as long as telegrams are not being exchanged with a DP master, e.g. because the bus cable has not yet been connected.

F ault dis plays

F ault number F 080

Meaning F ault in the dual-port A RM R emedial meas ure: C B P probablydefec tive, i.e. replac e CB P

F 081

F ault in monitoring of the heartbeat-c ounter. T he heartbeat-c ounter is no longer being inc remented due to an internal fault c aus ed by the CB P . C B P is not c orrec tlyplugged in or is defec tiv e R emedial meas ure: C hec k for c orrec t ins tallation; if nec es s,ary replac e CBP

F 082

T elegram failure in the dual-portAM R (DP R ) T he telegram-failure w a tc hdog time s et bymeans of parameter P 722 (P 695) has exp ired. (s ee c hapter " P roc es s data monitoring" . B us is interrupted or all us eful data are trans ferred with 0 (s ee als o A 083). R emedial meas ure: : C hec k bus c able inc l. c onnec tor plug; in the P D mas ter, as s ign av lues not equal to ero z to c ontrol word S TW 1

Faults and Alarms Faults

General information regarding faults For each fault, the following information is available: Parameter r947 Fault number r949 Fault value r951 Fault list P952 Number of faults r782 Fault time If a fault message is not reset before the electronic supply voltage is switched off, then the fault message will be present again when the electronic supply is switched on again. The unit cannot be operated without resetting the fault message. (Exception: Automatic restart has been selected, see P373).

Fault number F001

F002

Fault

Counter-measure

Main contactor checkback

P591 Src Contactor Msg

If a main contactor checkback is configured, no checkback takes place within the time set in P600 after the power-up command.

Parameter value must be in conformance with the connection of the main contactor checkback.

In the case of externally excited synchronous motors (P095 = 12), there is no checkback for the excitation current unit.

Check the checkback loop of the main contactor (or the checkback of the excitation current unit in the case of synchronous motors).

Pre-charging

Check the supply voltage,

When pre-charging, the minimum DC link voltage (P071 Line Volts 1.34) of 80 % has not been reached.

Compare with P071 Line Volts (compare P071 with the DC link voltage on DC units).

The maximum pre-charging time of 3 seconds has been exceeded.

Check the rectifier/regenerative unit on DC units. The rectifier/regenerative unit must be switched on before the inverter is switched on.

Fault number F006

Fault

Counter-measure

Line voltage

I DC voltage I range

208 V - 230 V

I 280 V – 310 V I appr. 410 V

380 V - 460 V

I 510 V – 620 V I appr. 820 V

Check the supply voltage or input DC voltage. Converter is operating in regenerative mode without rectifier possibility. If the converter supply voltage is at the upper tolerance limit and it is operating at full load, F006 can also be caused by a line phase failure.

500 V - 575 V

I 675 V – 780 V I appr. 1020 V

Possibly:

660 V - 690 V

I 890 V – 930 V I appr. 1220 V

•

Increase P464 Decel Time,

•

Activate P515 DC Bus Volts Reg (check P071 beforehand)

•

Reduce P526 Fly Search Speed.

•

Reduce P259 Max Regen Power (only for P100 = 3, 4 or 5)

DC link overvoltage Shutdown has occurred due to excessive DC link voltage. I Shutdown I threshold

For parallel-connected converters (BF L) r949 = 1: Overvoltage in the DC link of the master r949 = 2: Overvoltage in the DC link of the slave. F008

Check: DC link undervoltage The lower limit value of 76 % of the DC link • Input DC voltage voltage (P071 Line Volts), or of 61 % when • DC link kinetic buffering has been enabled, has been fallen short of. Undervoltage in the DC link in 'normal' operation (i.e. no SIMULATION). Undervoltage in the DC link with active kinetic buffering and speed less than 10 % of the rated motor speed. It was a 'brief power failure' which was not detected until system recovery (auto restart flag).

F011

Overcurrent

Check

Overcurrent shutdown has occurred.

•

the converter output for short-circuit or ground fault

•

the load for an overload condition

•

whether motor and converter are correctly matched

•

whether the dynamic requirements are too high.

The shutdown threshold has been exceeded.

F012

I too low During excitation of the induction motor, the current did not rise above 12.5 % of the setpoint magnetizing current for no-load operation.

Only for closed loop n/f/T control (P100 = 3, 4 or 5) If no motor is connected, go into the simulation mode P372. Check current detection, check power section.

Fault number F015

Fault

Counter-measure

Motor stall Motor has stalled or is locked:

•

Reduce load

•

Release brake

•

if the static load is too high

•

Increase current limits

•

if the acceleration or deceleration time is too fast or if load change is too fast and too great,

•

Increase P805 PullOut/BlckTime

•

Increase P792 response threshold for set/actual deviation

•

•

due to incorrect parameterization of the pulse encoder pulse number P151 or of the analog tachometer scaling P138.

Only for f/n/T control (P100 = 3, 4, 5)

due to disturbed speed signals (tachometer shield not connected)

Only n/T control or v/f control with speed controller: (P100 = 0, 4, 5)

The fault is only generated after the time set in P805. The binector B0156 is set, in the status word 2 r553 Bit28. To detect whether the drive is locked, see P792 (Perm Deviation) and P794. With n/f control, this fault is tripped if the torque limits have been reached (B0234).

•

•

Check tachometer cable breal

•

Check pulse encoder pulse number

•

Check analog tachometer scaling

•

Connect shield of tachometer cable on motor side and converter side

•

Reduce smoothing of speed pre-control P216 (only n/T control)

Only frequency control: (P100 = 3)

With speed control (P100 = 4) and master • drive (see P587), the fault can also point to an interruption in the encoder cable. This • case has the same significance as if the drive is locked. • With v/f control, the I(max) controller has to be activated (P331). The monitor does not operate with v/f textile applications (P100 = 2).

By reaching the maximum frequency in the case of synchronous motors (P095 = 12,13)

Slow down acceleration time (see also P467-ProtRampGen Gain) Increase current in the lower frequency range (P278, P279, P280) Switch in speed controller pre-control (P471>0)

•

Set EMF controller more dynamically (P315) to max. approx. 2

•

Increase changeover frequency for the EMF model (P313)

•

Replace by speed control with pulse encoder

Motor has stalled or is locked: •

Increase torque limits or torque setpoint

In the case of overmodulated n/f controller:

As a result of missing or excessively high excitation current in the case of externally excited synchronous motors (P095 = 12): (flux is too small or too great).

•

When the maximum frequency (including control reserves) (B0254) has been reached on synchronous motors, the fault is generated immediately. If the deviations in the rotor flux are too great, first of all, the converter current is switched to zero, the excitation current is reduced and, after some time, the fault message is tripped at the level of the double damping time constant (2*r124.1). During this wait time, the status word bit is set already B0156 (r553.28)

Only for synchronous motor: (P095 = 12)

Track speed setpoint with the speed actual value so that the set/actual deviation is always less than that set in P792.

•

Check current limits of the excitation unit.

•

Check excitation current setpoint and actual value (incl. wiring)

•

Check voltage limits of the excitation unit during dynamic current changes.

•

Check drive system for resonance oscillations.

Fault number

Fault

Counter-measure

F017

SAFE OFF in operation

Check whether the switch for SAFE OFF (X009/5-6) is open (only for devices with Order No....-11, ...-21,...-31).

F018

F set fly The found set-frequency could not be implemented because the additional setpoint is too high.

Check additional setpoint.

F019

Motor not found Motor has not been found (during flying restart without tachometer).

Power up after coasting. Possibly increase P525 Fly Search Amps.

F020

Motor temperature

Check the motor (load, ventilation, etc.). The actual motor temperature can be read in r009. Check P381 Mot Tmp Fault

The motor temperature limit value has been exceeded. r949 = 1 Limit value of motor temperature exceeded r949 = 2 Short-circuit in the cable to the motor temperature sensor or sensor defective

Power up after coasting. Release both directions of rotation.

Check the KTY84 input at connector X103:29,30 for short-circuit.

r949 = 3 wire break in the cable to the motor temperature sensor or sensor defective F021

Motor I2t

Check: P383 Mot Tmp T1

Parameterizable limit value of the I2t monitoring for the motor has been exceeded. F023

Inverter temperature The limit value of the inverter temperature has been exceeded. r949 = 1: Limit value of inverter temperature has been exceeded.

Measure the air intake and ambient temperature. Please observe the reduction curves at >40 ºC. Check: •

r949 = 2: Sensor 1: Wire break of sensor cable or sensor defective

Whether the fan -E1 is connected and is rotating in the correct direction.

•

r949 = 18: Sensor 2: Wire break of sensor cable or sensor defective

That the air entry and discharge openings are not restricted.

•

Temperature sensor at -X30

r949 = 34: Sensor 3: Wire break of sensor cable or sensor defective r949 = 50: Sensor 4: Wire break of sensor cable or sensor defective F025

UCE Ph. L1

Check:

There has been an UCE shutdown in phase L1.

•

Phase L1 for short-circuit or ground fault (-X2:U2 – including motor).

•

That CU is correctly inserted.

•

That the switch for ‘SAFE OFF’ (X9/5-6) is open (only for units with Order No. ...-11, ...-21,...-31).

Fault number F026

F027

Fault

Counter-measure

UCE Ph. L2

Check:


•

Phase L2 for short-circuit or ground fault (-X2:V2 – including motor).

•


•


UCE Ph. L3

Check :


•

Phase L3 for short-circuit or ground fault (-X2:W2 – including motor).

•


•


F028

Supply phase The frequency and the amplitude of the DC link ripple indicate a single-phase power failure.

Check the supply voltage.

F029

Meas. value sensing

Fault in measured value sensing.

A fault has occurred in the measured value sensing system;

Fault in power section (valve cannot block)

F035

F036

•

(r949 = 1) Offset adjustment not possible in phase L1

•

(r949 = 2) Offset adjustment not possible in phase L3

•

(r949 = 3) Offset adjustment not possible in phases L1 and L3

•

(r949=65) Autom. Adjustment of the analog inputs is not possible

Fault on CU

Ext. fault 1

Check:

Parameterizable external fault input 1 has been activated

•

whether there is an external fault

•

whether the cable to the appropriate digital input has been interrupted

•

P575 Src No ExtFault1

Ext. fault 2

Check:

Parameterizable external fault input 2 has been activated

•

Whether there is an external fault

•

Whether the cable to the appropriate digital input has been interrupted

•

P586 Src No ExtFault2

Fault number F037

Fault Analog input

Counter-measure Check the connection to •

Analog input 1 -X102:15, 16.

•

Analog input 2 -X102: 17, 18.

Check parameters •

P632 CU AnaIn Conf

•

P634 CU AnaIn Smooth

•

P631 CU AnaIn Offset

F038

Voltage OFF during parameter storage During a parameter task, a voltage failure occurred on the board.

Re-enter the parameter. The number of the parameter concerned can be seen in fault value r949.

F040

AS internal Incorrect operating status

Replace CU (-A10)

F041

EEPROM fault A fault has occurred when storing the values in the EEPROM.

Replace CU (-A10)

F042

Calculating time Calculating time problems

Reduce the calculating time load: •

Increase P357 Sampling Time

•

Calculate individual blocks in a slower sampling time

Observe r829 CalcTimeHdroom. F044

BICO Manager

F045

Opt. Board HW A hardware fault has occurred when accessing an optional board.

Replace CU

Par. Task

Power the unit down and up again.

F046

Check connection of the board subrack to the boards Replace CU (-A10).

F047

Internal calculating time The calculating time in the gating unit computer is not sufficient.

Replace CU (-A10). For synchronous motors (P095 = 12): Pulse frequency is set too high (P340 > 2kHz).

F048

Internal pulse frequency

Change P340 Pulse Frequency.

F049

SW Version

Use uniform firmware

The firmware versions on the CU have a different firmware release. F050

TSY Init.

Check:

Error when initializing the TSY board

•

Whether the TSY is correctly inserted

Fault number F051

Fault

Counter-measure

Speed encoder

Check the parameters:

Digital tachometer or analog tachometer sensing are faulty.

•

P130 Src SpdActV

•

P151

•

P138 AnalogTachScale

•

P109 Motor #PolePairs

The product of P109 and P138 must be smaller than 19200. Check or replace tachometer. Check connection to tachometer. Replace CU F052

n-Cntr. Input The fault input on the TSY has been active.

Cancel tachometer with control track P130 Src Spd ActV Replace TSY. Check the tachometer connection at the TSY. Several versions are possible, depending on the type of tachometer.

F053

Tachometer dn/dt The permissible change value of the speed encoder signal P215 dn(act,perm) has been doubly exceeded.

Check tachometer cables for interruptions. Check earthing of tachometer shield. •

The shield must be connected both at the motor and the converter side.

•

The encoder cable must not be interrupted.

•

The encoder cable must not be laid together with the power cables.

•

Only recommended encoders should be used.

•

In the case of a signal fault, the DT1 board may have to be used.

If necessary, change P215 F054

Sensor board initialization fault

Fault value r949 1: Board code incorrect 2: TSY not compatible 20: TSY board double

F056

SIMOLINK telegram failure

Check:

F058

Parameter error during parameter task

•

Fiber-optic cable ring

•

Whether an SLB in the ring is without voltage

•

Whether an SLB in the ring is faulty

•

Check P741 (SLB Tlg OFF)

No counter-measure

Fault number

Fault

Counter-measure

F059

Parameter error after factory setting/initialization

The number of the inconsistent parameter is indicated in fault value r949. Correct this parameter (ALL indices) and power down and power up the voltage again. Depending on circumstances, several parameters may be concerned, i.e. repeat the procedure.

F060

MLFB is missing This is set if the MLFB = 0 after exiting INITIALIZATION (0.0 kW). MLFB = order number.

After acknowledgement, in INITIALIZATION enter a suitable MLFB in parameter P070 MLFB (6SE70..). (Only possible with the corresponding access stages to both access parameters).

F061

Incorrect parameterization A parameter entered during drive setting (e.g. P107 Mot Rtd Freq, P108 Mot Rtd Speed, P340 Pulse Frequency) is not in a permissible range (depending on control type)

Acknowledge the fault and change the corresponding parameter value. The missing parameter is indicated in r949 as a fault value.

Fault number F062

Fault Multi-parallel circuit Fault in connection with the multi-parallel circuit or board ImP1 has been detected.

Counter-measure r949 = 10: Communications card does not reply. When writing the control word, BUSY is not active if CSOUT is inactive. Communications card is probably not inserted. r949 = 11,12: Timeout during BUSY during initialization. BUSY does not become active within 1 sec. r949 = 15: Timeout during BUSY during normal communication. BUSY does not become active within 1 sec. r949 = 18: Timeout when reading out the fault information from the ImPIs. Within one second after activation of FAULT no fault cause can be supplied by the ImP1. r949 = 20+i: HW conflict. This is set if bit HWCONF is set in status word of slave i. (Fault in the configuration of the multi-parallel circuit) r949 = 30+i: HW version of ImPI is not compatible. The relevant slave number is contained in i. r949 = 40: Number of slaves does not tally with the setpoint number of slaves of the unit. r949 = 50+i: Inconsistency in the number of slaves. The number of slaves notified by the ImPI is not in conformance with the number of status words or with the setpoint number of slaves of the MLFB. Counter-measure:

F065

•

Check ImPI or communications card and replace, if necessary.

•

Check configuration of multi-parallel circuit.

•

Check parameterization.

•

Replace CU.

•

Replace ImPI.

SCom Telegram

r949 = 1 SCom1

No telegram was received at an SCom interface (SCom/USS protocol) within the telegram failure time.

r949 = 2 SCom2 •

Check the connection CU -X100:1 to 5 and check the connection PMU -X300.

•

Check ”Scom/SCB TLG OFF” P704.01 (SCom1) and P704.02 (SCom2)

•

Replace CU (-A10).

Fault number F070

Fault

Counter-measure

SCB Init.

r949 = 1: Board code incorrect

Error during initialization of the SCB

r949 = 2: SCB board not compatible r949 = 5: Initialization data error •

Check parameter SCB Protocol P696 parameter and Scom/SCB Baud Rate P701.03

r949 = 6: Timeout during initalization r949 = 7: SCB board double r949 = 10: Error in configuration channel F072

EB initialization error

r949 = 2: 1. EB1 not compatible r949 = 3: 2. EB1 not compatible r949 = 4: 1. EB2 not compatible r949 = 5: 2. EB2 not compatible r949 = 21: There are three EB1 boards r949 = 22: There are three EB2 boards

F073

AnaIn1 SL1 4 mA at analog input 1, slave1 fallen short of

Check the connection between the signal source and the SCl1 (Slave 1) -X428:4, 5.

F074


Check the connection between the signal source and the SCI1 (Slave 2) -X428:7, 8.

F075


Check the connection between the signal source and the SCI1 (Slave 3) -X428:10, 11.

F076


Check the connection between the signal source and the SCI1 (Slave1) -X428:4, 5.

F077


Check connection between signal source and SCI1 (Slave 2) -X428:7,8.

F078


Check connection between signal source and SCI1 (Slave 3) -X428:10, 11.

F079

SCB Telegram

•

No telegram has been received by the SCB (USS, Peer-to-Peer, SCI) within the telegram failure time.

•

Check P704.03”SCom/SCB TLG OFF”.

•

Replace SCB1(2).

•

Replace CU (-A10).

Check connection of SCB1(2).

Fault number F080

Fault TB/CB Init. Error during initialization of the board at the DPR interface

Counter-measure r949 = 1: TB/CB not inserted or TB/CB board code incorrect r949 = 2 TB not compatible r949 = 3: CB not compatible r949 = 5: Error in initialization data Check that the T300 / CB board is inserted correctly r949 = 6: Timeout during initialization r949 = 7: TB/CB board double r949 = 10: Error in configuration channel Check the CB initialization parameter:

F081

F082

F087

Opt. Board Heartb TB, CB or SCB no longer processes the monitoring counter

•

P918 CB Bus Address

•

P711 to P721 CB parameters 1 to 11

r949 = 0: TB/CB Heartbeat counter r949 = 1: SCB Heartbeat counter •

Replace SCB, TB or CB

•

Check connection between subrack and optional boards

TB/CB Tlg

r949 = 1: TB/CB

No new process data have been received by the TB or the CB within the telegram failure time.

r949 = 2: 2. CB

SIMOLINK initialization fault

•

Check the connections of the CB/TB.

•

Check P722 ”CB/TB TLG OFF”.

•

Replace CB or TB.

•

Replace CU

•

Replace SLB

F090

Power down and power up again. If it reMId Param. An error occurred when attempting to change occurs, replace the CU. a parameter from the standstill measurement or the rotating measurement (Mot ID).

F091

MId Time The rotating measurement takes longer than programmed in a measured status. Possible causes: •

Load torque too high

•

Load torque not uniform

•

Ramp-function generator disabled

Eliminate the cause and re-start the measurement (power up the converter again). If it re-occurs, replace the CU.

Fault number F095

Fault

Counter-measure

•

Permissible phase sequence

•

Maximum frequency,

There must be a 10% frequency range which lies above 1.1 times the changeover frequency and below 0.9 times the start of field-weakening frequency. Possible counter-measures;

•

Minimum speed,

•

Permit both phase sequences

•

Changeover frequency between V and I model,

•

Increase maximum frequency

•

Reduce minimum speed,

•

Start of field-weakening frequency,

•

•

Frequency suppression bandwidth

Reduce changeover frequency between the V and I model.

MId n(set) Due to entries for

It was not possible to determine a permissible • frequency range for the rotating measurement. F096

MId abort The rotating measurement was aborted due to inadmissible external intervention.

Reduce or remove the frequency suppression bandwidth.

The fault value in r949 defines the type of intervention: 4

Setpoint inhibit

5

Changeover, setpoint channel

8

Unexpected change in the converter status

12 Motor data set changeover (for function selection "Compl. Mot ID”) 13 Changeover to slave drive 14 Motor data set changeover to data set with v/f_charac 15 Controller inhibit is set 16 Ramp-function generator is disabled 17 Selection "Tacho test" for F controller 18 Ramp-function generator stopped inate cause F097

MId measured value The measured values for the nominal rampup time when optimizing the controller deviate too greatly. Cause: very unsteady load torque

If necessary, increase the torque limit values to 100 percent

Fault number F098

Fault MId Tachof The rotating measurement has detected a fault in the speed actual value signal. The fault value defines the type of fault. The fault message may have been erroneously generated if the drive speed is externally forced (e.g. completely locked drive generates the "no signal" message)

Counter-measure The fault value in r949 defines the type of intervention 4

No speed signal present

5

Sign of the signal is incorrect

6

A track signal is missing

7

Incorrect gain

8

Incorrect pulse number

Checking the measurement cables. Checking the parameters

F100

GRND Init

•

P130 Src Speed ActV

•

P151 Encoder Pulse #

The cause of the fault can be read out from r376 "GrdFltTestResult".

During the ground fault test, a current not equal to zero has been measured, or an UCE Check the converter output for short-circuit or ground fault or overcurrent monitoring has responded, although no valve has yet been triggered. (-X2:U2, V2, W2 – including motor). Check that the CU is inserted correctly. Sizes 1 and 2: •

Check the transistor modules on the PEU board -A23 for short-circuit.

Size 3 and 4: • F101

GRND UCE During the ground fault test, the UCE monitoring has responded in a phase in which no valve has been triggered.

Check the transistor modules -A100, -A200, -A300 for short-circuit

Check valves in the power section for shortcircuit, and on converters with fiber-optic gating, check the gating unit wiring and the UCE checkbacks for correct assignment. r376 can be interrogated to indicate which UCE monitoring has responded.

F102

The fault value can be read out from r949. During the ground fault test, a current flows in The digit of the xth position indicates the a phase in which no valve has been triggered valve where the fault occurred at power-up or the UCE monitoring has responded in the x = 1 = V+ x = 2 = Vx = 3 =U+ phase in which the valve has been triggered. x = 4 = U- x = 5 = W+ x = 6 =WGRND Phase

The figure of the xth digit indicates the phase in which I 0 and thus a valve must be defective (always conductive). x = 1 = Phase 1 (U) x = 3 = Phase 3 (W) x = 4 = Phase 1 (U) or 3 (W)

Examine phase for defective valves (always conductive).

Fault number F103

Fault

Counter-measure

There is a ground fault or a fault in the power section.

Read out fault value from r949. The digit of the xth position indicates the valve where the fault occurred at power-up.

Ground fault

During the ground fault test, a current flows from the phase in which a valve has been triggered, the overcurrent comparator has responded, or a UCE monitoring has responded in a phase in which a valve has been triggered.

x = 1 = V+ x = 2 = Vx = 4 = U- x = 5 = W+

x = 3 =U+ x = 6 =W-

Check the motor including the feeder cable for short-circuit. If no ground fault is present, check the power section for defective valves (always conductive). The digit of the xth position indicates the phase in which I 0 and therefore a valve must be defective (always conductive). 1 = Current in phase 1 (U) 2 = UCE in phase 2 (V) 1) 3 = Current in phase 3 (W) 4 = Only overcurrent occurred

The speed of the motor shaft during the ground fault test should be less than 10 % of the nominal speed! 1) A ground fault or a defective valve (aways conductive) is present in phase V or the switch for ‘SAFE OFF’ (X9/5-6) is open (only for units with Order No. ...-11, ...21,...-31). F107

MId I = 0 A fault has occurred during the test pulse measurement.

Read out fault value from r949. The figures of the grey shaded areas indicate which fault has occurred. xx = 01: Both current actual values remain 0 xx = 02: Motor-converter cable phase U interrupted xx = 03: Motor-converter phase V interrupted xx = 04: Motor-converter phase W interrupted xx = 05: Current actual value I1 remains 0 xx = 06: Current actual value I3 remains 0 xx = 07: Valve U+ does not trigger xx = 08: Valve U- does not trigger xx = 09: Valve V+ does not trigger xx = 10: Valve V- does not trigger xx = 11: Valve W+ does not trigger xx = 12: Valve W- does not trigger xx = 13: Sign I1 incorrect xx = 14: Sign I3 incorrect xx = 15: Sign I1 and I3 incorrect xx = 16: I1 confused with I3 xx = 17: I1 confused with I3 and both currents have an incorrect sign

The digit of the grey shaded area indicates where the fault has occurred.

Fault number

Fault

Counter-measure x = 0 = Single converter x = 1 = Inverter 1 x = 2 = Inverter 2 x = 3 = Inverters 1 and 2

Check that all 3 motor feeder cables and the motor windings do not have any interruption. Check the connection between the current converter and the electronics and check the current converter itself. Check the correct input of the rating plate data for the motor data set valid during the measurement. F108

MId Unsym During the DC measurement, the measurement results for the individual phases differ significantly. The fault value indicates which quantity(ies) is (are) concerned and in which phase the greatest deviation occurred.

Read out fault value from r949. The digit of the xth position indicates; Transverse voltage too high x = 1 = phase R; x = 2=phase S; x = 3 = phase T Dev. stator resistance (1, 2, 3 as above) Dev. rotor resistance (1, 2, 3 as above) Dev. dead-time compensation (1, 2, 3 as above) Deviation valve voltage (1, 2, 3 as above)

The motor, power section or actual-value sensing are significantly non-symmetrical. F109

F110

MId R(L) The rotor resistance determined during DC measurement deviates too significantly from the value which was calculated by the automatic parameterization from the rated slip.

•

Incorrect input of rated speed or rated frequency

•

Pole pair number incorrect

MId di/dt During test pulse measurement, the current has increased significantly faster than was expected. Thus for the 1st test pulse, an overcurrent condition occurred within the first half of the minimum switch-on time.

•

There may be a short-circuit between two converter outputs.

•

The motor rating plate data have not been correctly parameterized.

•

The motor leakage is too low.

F111

Fault e_Func A fault has occurred while calculating the equalization function.

F112

Unsym l_sigma The individual leakage test results deviate too significantly.

Fault number

Fault

F114

MId OFF The converter has automatically aborted the automatic measurement as the time limit was exceeded up to converter power-up, or due to an OFF command during the measurement; the selection in P115 Function Select is reset.

For P115 Function Select = 2 restart "Motor data identification at standstill". The ON command must be provided within 20 s after the alarm message A078 = standstill measurement appears.

F115

KF internal

Power-down the converter and electronics and power-up again.

F148

Fault 1 Function blocks

Check cause of fault, see function diagram 710

F149



F150



F151


Check cause of fult, see function diagram 710

F243

Link int. Faults in internal linking. One of the two linked partners does not reply.

Replace CU (-A10).

F244

ParaLink int.

Release comparison of MWH software and CU software regarding the transfer parameters.

Fault in the internal parameter linking

Counter-measure

Withdraw the OFF command, and restart the measurement.

Replace CU (-A10). F255

Fault in the EEPROM

Switch off the unit and power it up again. If it occurs again, replace the CU.

Alarms

Alarm number

The alarm message is periodically displayed on the PMU by A = alarm/ alarm message and a 3-digit number. An alarm cannot be acknowledged. It is automatically deleted once the cause has been eliminated. Several alarms can be present. The alarms are then displayed one after the other. When the converter is operated with the OP1S operator control panel, the alarm is indicated in the lowest operating display line. The red LED additionally flashes (refer to the OP1S operating instructions). Param. No.

Cause

Counter-measure

Bit No.

A001

r953 0

A002

A014

r953 13

A015

r953 14

Calculating time

•

Observe r829 CalcTimeHdroom

The CUVC board calculating time utilization is too high

•

Increase P357 Sampling Time or

•

Reduce P340 Pulse Frequency.

SIMOLINK start alarm

Check •

the fiber-optic cable ring

•

whether there is an SLB without voltage in the ring

•

whether there is a faulty SLB in the ring

•

P741 (SLB Tlg OFF)

Simulation active alarm

•

Set P372 to 0

The DC link voltage is not equal to 0 when the simulation mode is selected. (P372 = 1)

•

Reduce DC link voltage (disconnect the converter from the supply)

External alarm 1

Check Parameterizable external alarm input • Whether the cable to the corresponding 1 has been activated digital input is interrupted. •

A016

r953 15

External alarm 2

Check Parameterizable external alarm input • Whether the cable to the corresponding 2 has been activated digital input is interrupted. •

A017

r954 0

A020

r954 3

Parameter P588 Src No Ext Warn1

Parameter P589 Src No Ext Warn2

SAFE OFF alarm active

Close switch X9 5-6 and thus release the The switch for blocking the inverter inverter pulses. pulses (X9 terminal 5-6) has been opened (only for units with Order No. ...-11, ...-21,...-31).

Overcurrent An overcurrent condition has occurred.

Check the driven load for an overload condition. •

Are the motor and the converter matched?

•

Have the dynamic performance requirements been exceeded?

Alarm number

Param. No.

Cause

Counter-measure

Bit No.

A021

r954 4

A022

r954 5

Overvoltage An overvoltage condition has occurred.

Check the supply voltage. The converter regenerates without regeneration possibility.

Inverter temperature

•

The threshold for initiating an alarm has been fallen short of.

Observe r833 Drive Tmp. Measure intake air or ambient temperature. Observe reduction curves at >40 ºC .

Check:

A023

r954 6

A024

r954 7

A025

r954 8

A029

r954 12

A033

r955 0

A034

r955 1

A035

r955

Motor temperature

•

Whether the fan -E1 is connected and is rotating in the correct direction.

•

The air intake and discharge openings for blockage.

•

The temperature sensor at -X30.

The parameterizable threshold for initiating an alarm has been exceeded.

Check the motor (load, ventilation, etc.). The current temperature can be read in r009 Motor Tmp. Check the KTY84 input at connector X103:29,30 for short-circuit.

Motor movement

Lock the motor

The motor has moved during motor data identification in first start-up.

I2t Inv. If the instantaneous load condition is maintained, then the inverter will be thermally overloaded.

I2t motor The parameterized limit value for the I2t monitoring of the motor has been exceeded.

Overspeed Bit 3 in r553 status word 2 of the setpoint channel. The speed actual value has exceeded the value of maximum speed plus the set hysteresis.

Motor load cycle exceeded! Check the parameters: P382 Motor Cooling P383 Mot Tmp T1 P384 Mot Load Limits Motor load cycle is exceeded! Check the parameters: P382 Motor Cooling P383 Mot Tmp T1 P384 Mot Load Limits P804 Overspeed Hyst plus P452 n/f(max, FWD Spd) or P453 n/f(max,REV Spd) has been exceeded. Increase the parameter for the maximum frequencies or reduce the regenerative load.

Setpoint/actual value deviation Check: Bit 8 in r552 status word 1 of setpoint • Whether an excessive torque channel. The difference between requirement is present. frequency setpoint/actual value is Whether the motor has been • greater than the parameterizable dimensioned too small. value and the control monitoring time has elapsed. Increase values P792 Perm Deviation Frq/ set/actual DevSpeed and P794 Deviation Time

Wire break

Check whether cable(s) to the

Alarm number

Param. No.

Cause

Counter-measure

Bit No. The clockwise and/or the counterclockwise rotating field is not enabled, or a wire breakage is present in the terminal wiring (both control word bits are zero)

corresponding digital input(s), P572 Src REV Speed/ P571 Src FWD Speed is (are) interrupted or released.

A036

Brake checkback "Brake still closed”

Check the brake checkback (see FD 470)

A037

Brake checkback "Brake still open"

Check brake checkback (see FP 470)

Vdmax controller inhibit

Check:

The line voltage is too high or the drive line voltage (P071) is incorrectly parameterized. The Vdmax controller is disabled despite parameter access (P515), as otherwise the motor would accelerate immediately in operation to the maximum frequency.

•

Line voltage

•

P071 Line Volts

Motor stall/lock

Check:

Motor is stalled or locked.

•

Whether the drive is locked.

The alarm cannot be influenced by P805 ” PullOut/BlckTime”, but by P794 ”Deviation Time”.

•

Whether the encoder cable is interrupted during speed control and whether the shield is connected.

•

Whether the drive has stalled.

•

For synchronous motors (P095=12): excitation current injection

2

A041

r955 8

A042

r955 9

A043

r955 10

n-act jump The permissible change value of the speed encoder signal (P215) has been exceeded. Additionally for synchronous motors (P095=12): The motor rotates with more than 2 % of the rated speed at the time of inverter release. The inverter status "Ready for operation" is not exited.

A044

r955 11

I too low Only for synchronous motors

Check the tachometer cables for interruptions. Check the earthing of the tachometer shield. •

The shield must be connected both on the motor and on the converter side.

•

The encoder cable must not be interrupted.

•

The encoder cable must not be laid with the power cables.

•

Only the recommended encoders should be used.

•

If there is a signal fault, use the DTI board if necessary.

•

If necessary, change P215

•

Additionally for synchronous motors (P095=12): Do not grant inverter release until the motor is at standstill.

Only for synchronous motors P095 = 12 Check:

Alarm number

Param. No.

Cause

Counter-measure

Bit No. (P095=12) in operation: The difference smoothed with P159 between excitation current setpoint and actual value (r160 - r156 ) deviates from zero by more than 25 % of the rated magnetizing current.

A045

r955 12

A049

r956 0

A050

r956 1

A051

r956 2

A052

r956 3

A053

r956 4

A057

r956 8

DC braking activated

•

Whether the current limitation of the excitation current control is too small.

•

Whether the dynamic performance of the excitation current injection is too low.

•

Whether the excitation current injection function is operating,

•

Whether the wiring of excitation current actual-value P155 is correct,

•

Whether the wiring of excitation current setpoint r160 is correct,

•

Whether there is a wire breakage between MASTERDRIVES and the excitation device.

•

Whether the voltage limitation is too low for dynamic excitation current control.

•

Whether the analog output for r160 takes place without isolating amplifiers (despite cable length > 4m).

•

Increase frequency at which DC braking begins.

The DC braking function has been activated and the motor frequency is still above the frequency at which DC braking begins (P398).

No slave

P690 SCI AnaIn Conf

At ser. I/O (SCB1 with SCI1/2) no slave is connected or fiber-optic cable is interrupted or slaves are without voltage.

•

Check slave.

•

Check cable.

Slave incorrect

Check P690 SCI AnaIn Conf

At ser. I/O the slaves required according to a parameterized configuration are not present (slave number or slave type).

Peer Bdrate In a peer-to-peer connection, a baud rate has been selected which is too high or too different.

Adjust the baud rate in conjunction with the SCB boards P701 SCom/SCB Baud Rate

Peer PcD L

Reduce number of words In a peer-to-peer connection, a PcD P703 SCom PcD #. length has been set which is too high (>5).

Peer Lng f. In a peer-to-peer connection, the PcD length of transmitter and receiver do not match.

TB Param Occurs when a TB is logged on and

Adjust the word length for transmitter and receiver P703 SCom/SCB PcD # Replace TB configuration (software).

Alarm number

Param. No.

Cause

Counter-measure

Bit No. present, but parameter tasks from the PMU, SCom1 or SCom2 are not answered by the TB within 6 seconds.

A061

Alarm 1 function blocks

Check cause of alarm (see FP 710)

A062



A063



A064



Auto restart active

Caution!

The auto restart option (P373) restarts the drive. A possibly parameterized power-up delay time (P374) expires if flying restart is not selected. During pre-charging of the DC link, there is no time monitoring i.e. with an external electronics power supply, it is also switched-in again.

Personnel could be in danger when the drive automatically restarts. Check whether the auto restart function is really required!

fsyn > fmax

Check:

The measured target frequency of the external converter (or supply) is greater than the parameterized maximum frequency of the synchronizing converter.

•

P452 n/f(max, FWD Spd)/ P453 n/f(max,REV Spd) are correct and

•

Correct motor data set P578 Src MotDSet Bit0 are selected.

fsyn < fmin

Check:

The measured target frequency of the external converter (or supply) is less than the minimum frequency required for synchronizing.

•

r533 Sync Target Freq

•

Synchronising cable

fsyn<>fsoll

Adjust total setpoint (main and additional setpoints) to the target frequency displayed in visualization parameter r533.

A065

r957 0

A066

r957 1

A067

r957 2

A068

r957 3

A069

r957 4

A070

r957 5

The setpoint frequency of the synchronizing converter deviates too significantly from the measured target frequency of the external converter (or supply). The permissible deviation can be set in P529.

RGen active

Wait until acceleration has been completed. Synchronizing is not started as long Check whether: as the ramp-function generator in the • P462 Accel Time synchronizing converter setpoint channel is active. This alarm is only • P463 Accel Time Unit has been output if synchronizing is selected. correctly set.

Sync. Error This alarm is output if the phase difference goes outside the synchronizing window (P 391) after successful synchronization.

The alarm can only be deleted after synchronization has been exited.

Alarm number

Param. No.

Cause

Counter-measure

Bit No.

A071

r957 6

A076

r957 11

A077

r957 12

A078

r957 13

A079

r957 14

A080

r957 15

A081.. A096 A097.. A112 A113.. A128

r958 1...15 r959 1...15 r960 1...15

TSY missing

Insert the TSY board in the subrack.

An attempt was made to start synchronization with either the synchronizing board not inserted or not parameterized.

t-comp lim The determined compensation time was limited to the value range of 0.5µs - 1.5µs.

r-g limit The measured resistance was limited to the maximum value of 49 %.

The converter output and the motor output are too different. Check motor data entries P095 to P109. Converter output and motor output are too different. Check motor data entries P095 to P109.

Stands. Meas

If the standstill measurement can be The standstill measurement is executed without any danger: executed when the converter is • Power up the converter powered-up. With this measurement, the motor can align itself in any direction of rotation.

MId Inv Stop

P561 Src InvRelease – Release the inverter

The rotating measurement has been aborted or cannot commence because an inverter stop command is present.

or re-start the measurement by powering-up the converter.

MotId:Dr.M.

If the rotating measurement can be When the converter is powered-up, executed without any danger: the rotating measurement • Power-up the converter automatically accelerates the drive. The drive can then only be externally controlled in a very restricted fashion.

CB alarm See user manual for CB board

TB alarm 1 See user manual for TB board

TB alarm 2 See user manual for TB board

Fatal errors (FF)

Fatal errors are serious hardware or software errors which no longer permit normal operation of the unit. They only appear on the PMU in the form "FF". The software is re-booted by actuating any key on the PMU.

FFxx

Error message

FF01

Time slot overflow A non-removable time sector overflow was identified in the higher priority time sectors.

•

Increase sampling time (P357) or reduce pulse frequency (P340)

•

Replace CU

Access error, optional board Fatal errors occurred when accessing external optional boards (CB, TB, SCB, TSY ..)

•

Replace CU

•

Replace LBA

•

Replace optional board

Stack overflow Overflow of the stack.

•

Increase sampling time (P357) or reduce pulse frequency (P340)

•

Replace CU

Other fatal errors

•

Replace CU

E

Fatal hardware errors

•

Replace CU

EEEE

Fatal firmware errors

•

Replace CU

•

Re-load firmware

FF03

FF06

FFxx

Power-down the converter and power-up again. Call the service personnel if a fatal error message is displayed again

Maintenance and Repair WARNING

SIMOVERT MASTERDRIVES units are operated at high voltages. All work carried out on or with the equipment must conform to all the national electrical codes (VBG 4 in Germany). Maintenance and service work may only be executed by qualified personnel. Only spare parts authorized by the manufacturer may be used. The prescribed maintenance intervals and also the instructions for repair and replacement must be complied with. Hazardous voltages are still present in the drive units up to 5 minutes after the converter has been powered down due to the DC link capacitors. Thus, the unit or the DC link terminals must not be worked on until at least after this delay time. The power terminals and control terminals can still be at hazardous voltage levels even when the motor is stationary. If it is absolutely necessary that the drive converter be worked on when powered-up: ♦ Never touch any live parts. ♦ Only use the appropriate measuring and test equipment and protective clothing. ♦ Always stand on an ungrounded, isolated and ESD-compatible pad. If these warnings are not observed, this can result in death, severe bodily injury or significant material damage.

Replacing the Fan T he fan is des igned for an operating time of L 10 ³ 35 000 hours at an ambient temperature of T u = 40 °C . It s hould be replaced in good time to maintain the availability of the unit.

Torx M8x12

Torx M8x12

F an

F an hous ing

T he fan as s embly cons is ts of: ¨

the fan hous ing

¨

a fan.

T he fan as s embly is ins talled at the top of the chas s is . ¨

W ithdraw connector X 20.

¨

Undo the two M8 s crews of the fan as s embly.

¨

P ull out the fan as s embly towards the front (if neces s ary, tilt it s lightly downwards at the front) and lay it down s afely.

CAUTION

The fan assembly weighs up to 38 kg, depending on its design.

♦ Undo the cable fastenings and fan connections. ♦ Take the fan support plate out of the fan assembly and remove the fan from the support plate. ♦ Install the new fan assembly in the reverse sequence. Prior to start-up, check that the fan can run freely and check for correct direction of air flow. The air must be blown upwards out of the unit. The direction of rotation is counter-clockwise when seen from above.

Replacing the fan fuse The fuses are in a fuse holder which is mounted on a DIN rail in the bottom of the unit. The fuse holder has to be opened to replace the fuses.

Replacing the fan transformer fuse -F3, -F4 : Fuses -F3, -F4 The fuses are in a fuse holder which is arranged below the fan in front of the air baffle plate. To replace the fuses, the fuse holder has to be opened.

Replacing the fan transformer

♦ Mark the connecting cables on the transformer and disconnect them. ♦ Undo the screw connections at the bottom on the transformer plate and remove the transformer. Secure the transformer against falling down! ♦ Install the new transformer in the reverse sequence.

The starting capacitor is situated • inside the fan housing (, -C110). ♦ Withdraw the plug connections on the starting capacitor. ♦ Unscrew the starting capacitor. ♦ Install the new starting capacitor in reverse sequence (4.5 Nm).

Replacing the capacitor battery The unit is an assembly which consists of the DC link capacitors, the capacitor support and the DC link bus module.

The capacitor battery consists of three modules. Each module has a capacitor support and a DC link bus module. ♦ Withdraw the plug connections. ♦ Detach the mechanical fastening (four screws: two on the left, two on the right). Swing the capacitor battery out as far as it will go, slightly raise the unit and pull it forwards out of the converter. CAUTION

The capacitor battery weighs up to 15 kg, depending on the converter output!

Replacing the SML and the SMU SML: Snubber Module Lower SMU: Snubber Module Upper ♦ Remove the capacitor battery. ♦ Undo the fixing screws (4 x M8, 8 - 10 Nm or 4 x M6, 2.5 - 5 Nm, 1 x M4, max 1.8 Nm). ♦ Remove the modules. Install the new modules in the reverse sequence.

Removing and installing the module busbars Removal

♦ Remove the capacitor battery. ♦ Undo the screws of the module busbars. M8 power connections M6 fastening on spacers M4 circuit. ♦ Take out the insulation of the SMU / SML. ♦ Lift out the module busbars.

Installation NOTE

The spacing between the plus busbar and the minus busbar must be at least 4 mm. In order to install the module busbars, you must therefore use a template, e.g. a 4 mm thick piece of plastic. ♦ Place the module busbars and SMU/SML insulation on spacer bolts and fix in place (M6). ♦ Place the template instead of the DC link bus module in the module busbars. ♦ Locate the SMU and SML and tighten the modular connections (M8, 8 - 10 Nm, M6, 2.5 - 5 Nm). ♦ Screw the nuts tight on the spacer bolts (6 Nm). ♦ Connect the circuit resistors (M4, 1.8 Nm). ♦ Tighten the power connections (M8, 13 Nm). ♦ Remove the template from the module busbars. Template 4 mm

Module screw connection −

Module screw connection +

4

Replacing the balancing resistor The balancing resistor is situated in the rear installation level on the heat sink between the inverter modules, i.e. behind the capacitor battery and the module busbars. ♦ Remove the capacitor battery. ♦ Remove the module busbars and the IGD module. ♦ Undo the fixing screws and take out the balancing resistor. ♦ Install the new component in reverse sequence. ♦ The balancing resistor is tightened with 1.8 Nm. Coat the base plate evenly and thinly with a thermo-lubricant, paying attention to correct contact assignment.

Replacing the IVI Board ♦ Unscrew the two screws of the electronics slide-in unit and pull it out to its endstops. ♦ Disconnect the ground cable of the electronics slide-in unit. ♦ Remove all boards from the electronics box and place them on a suitable surface which cannot be statically charged. ♦ Unscrew the two fixing screws of the electronics box. ♦ Push the electronics box out of its interlock and take it out towards the front. ♦ Pull out the ABO Adaption Board. ♦ Disconnect the fiber-optic cables. ♦ Unscrew the IVI board and take it out. ♦ Install the new IVI in the reverse sequence.

Replacing the VDU and the VDU resistor VDU: Voltage-Dividing Unit The VDU and the VDU resistor are only found on converters with higher supply voltages. The VDU bracket is an integral component of the electronics slide-in unit. VDU

♦ Detach the plug-in connections. ♦ Undo the fixing screw ♦ Take out the VDU. ♦ Install the new VDU in the reverse sequence.

VDU resistor

♦ Unscrew the cable fasteners. ♦ Detach the plug-in connections. ♦ Take out the VDU resistor. ♦ Install the new VDU resistor in the reverse sequence.

Replacing the PSU2

¨

R emove the V DU and the V DU res is tor (if pres ent).

¨

R emove the V DU retainer plate.

¨

Detach the plug-in connections on the P S U.

¨

Undo the s crews (s ix T orx M4 s crews ) on the P S U.

¨

T ake out the P S U.

¨

Ins tall the new P S U in the revers e s equence.

R eplacing the IG D

NOT E

T he s pacing between the plus bus bar and the minus bus bar mus t be at leas t 4 mm. In order to ins tall the module bus bars , you mus t therefore us e a template, e.g. a 4 mm thick piece of plas tic. ¨

T he IG D board is s ituated behind the module bus bars .

¨

T ake out the capacitor battery.

¨

T ake out the S ML and S MU modules .

¨

R emove the module bus bars .

¨

R emove the nine fiber-optic cables at the top of the IG D.

¨

W ithdraw the P 15 feeder cable.

¨

Undo the fixing s crews and remove the IG D board.

¨

Ins tall the new IG D in the revers e s equence. Make s ure when doing s o that you pus h in the fiber-optic cables up to the ends top.

Replacing the TDB TDB: Thyristor Drive Board The TDB is arranged in front of the thyristor modules. These are situated in the rectifier section between the fan assembly and the inverter. ♦ Remove the cover (undo screws, then first of all detach the righthand snap hook, and then the left-hand snap hook) ♦ Withdraw connectors X246, X11, X12 and X13. ♦ Disconnect the PUD and NUD connections of the pre-charging resistors R1 and R2 (M4, Torx). ♦ Disconnect the connections to phases U, V, W . ♦ Disconnect the NUD1, NUD2, NUD3 connections. ♦ Remove the TDB board. ♦ Install the new TDB in the reverse sequence. See figure under section "Replacing the thyristor modules"

Replacing the IGBT module Replacement is carried out as in the case of the IGD board, with the following additions: ♦ Remove the fixing screws of the faulty IGBT module and take it out. ♦ Install a new IGBT module, paying attention to the following: • Coat the contact surfaces thinly and evenly with a thermolubricant. • Tighten the fixing screws of the IGBT module with 5 Nm, observing the sequence of tightening. ♦ Modules with the same type designation e.g. FZxxxxRYYKF4 must be installed in every phase 1

4

3

2

3

C

E

6

1

2

5

4

Screw on IGBT module: 1. Hand-tighten (~ 0.5 Nm) Sequence 1 - 2 - 3 - 4 - 5 - 6 2. Tighten with 5 Nm (Order No. 6SE7031-8EF60: 2.5 - 3.5 Nm) Sequence 1 - 2 - 3 - 4 - 5 - 6

Replacing the thyristor modules (V1 to V3, ) Replacement as in the case of the TDB, with the following additions: ♦ Disconnect the supply cables C+ D− of the option terminals ♦ Disconnect the connection of the C and D bars between the rectifier and the inverter. ♦ Disconnect the connections U, V, W of the modules. ♦ Disconnect the connections between modules and C(+) bar. ♦ Remove the connecting bar C(+). ♦ Disconnect the connections between modules and D(−) bar. ♦ Remove the connecting bar D(−). ♦ Undo the module fixing screws (M6, Torx). ♦ Remove the module (weight approx. 500 g). ♦ Clean the contact surface. ♦ Coat the new modules thinly and evenly with a thermo-lubricant and mount them. Tightening torque of the fixing screws: 6 Nm ± 15 %. ♦ Further installation is performed in the reverse sequence. Tightening torque of the electrical connections (C and D): 12 Nm (+ 5 %, − 10 %).

Replacing the PMU ♦ Remove the ground cable on the side panel. ♦ Carefully press the snap catches on the adapter section together, remove the PMU with adapter section from the electronics box. ♦ Withdraw connector X108 on the CUx board. ♦ Carefully lift forward the PMU out of the adapter section using a screwdriver. ♦ Install the new PMU in the reverse sequence.

Adapter section PMU

E-box

Snap catches

Replacing the pre-charging resistors (R1 - R4, ) These are situated on the right next to the TDB board in the rectifier section. ♦ Remove the cover (undo screws, then detach first the right-hand snap catch and then the left-hand snap catch). ♦ Disconnect the PUD and the NUD connections of the pre-charging resistors R1 - R4 (M4, Torx). ♦ Detach the pre-charging resistors and take them out. ♦ Install the new pre-charging resistor with torque of 20 Nm ± 10 %. CAUTION

Do NOT tilt the pre-charging resistor!

♦ Mount the fastenings and the connections in the reverse sequence. See figure under section "Replacing the thyristor modules"

Replacing the circuit resistor ♦ Take out the capacitor battery. ♦ Take out the SML and SMU modules. ♦ Remove the module busbars. ♦ Undo the fixing screws (2 x M5, torque: max. 1.8 Nm) and take out the circuit resistor. ♦ The new resistor must be thinly and uniformly rolled in a thermolubricant. ♦ Max. torque of the electrical connections: 1.8 Nm. ♦ Install the new circuit in the reverse sequence.

Forming If a unit has been non-operational for more than one year, the DC link capacitors have to be newly formed. If this is not carried out, the unit can be damaged when the line voltage is powered up. If the unit was started-up within one year after having been manufactured, the DC link capacitors do not have to be re-formed. The date of manufacture of the unit can be read from the serial number. How the serial number is made up

(Example: A-J60147512345) Digit

Example

Significance

1 and 2

A-

Place of manufacture

3

H

1996

J

1997

K

1998

4

1 to 9

January to September

O

October

N

November

D

December

5 to 14

Not relevant for forming

The following applies for the above example: Manufacture took place in June 1997. During forming, the DC link of the unit is connected up via a rectifier, a smoothing capacitor and a resistor. As a result, the DC link capacitors receive a defined voltage and a limited current, and the internal conditions necessary for the function of the DC link capacitors are restored.

3AC

A

C

R

C / L+

D / L-

Forming

Disconnect

Motorconnection

Pre-charging

U1/L1

U2/T1

V1/L2

V2/T2

W1/L3

W2/T3

DC link PE1

Rectifier

Inverter PE2

Components for the forming circuit (suggestion)

Types E to G: Vrated

A

R

C

3AC 380 V to 480 V

SKD 62 / 16

330 Ω / 150 W

22 nF / 1600 V

3AC 500 V to 600 V

3 x SKKD 81 / 22

470 Ω / 200 W

22 nF / 1600 V

3AC 660 V to 690 V

3 x SKKD 81 / 22

470 Ω / 100 W

22 nF / 1600 V

A

R

C

3AC 380 V to 480 V

SKD 62 / 16

100 Ω / 500 W

22 nF / 1600 V

3AC 500 V to 600 V

3 x SKKD 81 / 22

150 Ω / 500 W

22 nF / 1600 V

3AC 660 V to 690 V

3 x SKKD 81 / 22

150 Ω / 500 W

22 nF / 1600 V

Type K: Vrated

Procedure

♦ Before you form the unit, all mains connections must be disconnected. ♦ Connect the required components in accordance with the circuit example. ♦ Energize the forming circuit. The duration of forming depends on the idle time of the converter. 6

Forming time in hours

5 4 3 2

Off-circuit idle time in years

1

1

2

3

4

5

TDS Training Manual



Parameter Listings

AC Electrical

TDS-9S

SIEMENS SERIES 70 DRIVE (WITH CUVC CONTROL) LISTING OF INVERTER PARAMETERS

VIEW PAR. NO.

IND.

PARAMETER DESC.

VALUE(Units)

YES P050 YES P053 YES P060 2 P068 P070 P071 P072 P073 P075 P075 P076 P076 P095 P095 P100 P100 P101 P101 YES P102 YES P102 P103 P103 P104 P104 YES P105 YES P105 P106 P106 P107 P107 P108 P108 P109 P109 YES P113 YES P113 YES P115 3 P116 P116 P120 P120 P121 P121 P122 P122 P127 P127 YES P128 YES P128 P130 P130

0 1 2 1 2 1 2 1 2 1 2 1 2 1 2 1 2 1 2 1 2 1 2 1 2 1 2 1 2 1 2 1 2 1 2 1 2 1 2 1 2 1 2

Language Parameter Access Menu Select Output Filter Order No. 6SE70 Line Volts Rated Drive Amps Rated Drive Power X (magnet,d)tot X (magnet,d)tot X (magnet,q)tot X (magnet,q)tot Type of Motor Type of Motor Control Mode Control Mode Motor Rated Volts Motor Rated Volts Motor Rated Current Motor Rated Current Motor Magn Current Motor Magn Current Motor Power Factor Motor Power Factor Motor Rated Power Motor Rated Power Motor Rated Efficiency Motor Rated Efficiency Motor Rated Frequency Motor Rated Frequency Motor Rated Speed Motor Rated Speed Motor #Pole Pairs Motor #Pole Pairs Motor Rated Torque Motor Rated Torque Calc Motor Model Start-Up Time Start-Up Time Main Reactance Main Reactance Stator Resistance Stator Resistance Total Leakage React Total Leakage React RotResistTmpFact RotResistTmpFact Imax Imax Select Motor Encoder Select Motor Encoder

1 6 0 0 38-6U.6. 780V 860.0A 630.0 kW 150.0% 150.0% 150.0% 150.0% 11 11 4 3 550V 550V 662.0A 662.0A 0 0 0.87 0.87 700.0 Hp 700.0 Hp 92.0% 92.0% 39.2 Hz 39.2 Hz 1155 1/min 1155 1/min 2 2 4203.0 Nm 4203.0 Nm 0 0.18 s typ 0.20 s typ 380.5 typ 391.0 typ 3.24% typ 3.35% typ 25.61% typ 25.80% typ 82.8% typ 84.4% typ 1169.5 A 1169.5 A 11 10

TDS-9S SIEMENS DRIVE PARAMETERS (CUVC)

COMMENTS

Language (1=English) Access for Parameters Parameter Menu (7 = Free Access) No Output filter MLFB: Drive Size 128 Rated Drive Voltage Rated Drive Current Rated Drive Power (Default) (Default) (Default) (Default) NEMA Induction Motor NEMA Induction Motor Speed Regulation Frequency Regulation Motor Nameplate Motor Nameplate Motor Nameplate Motor Nameplate Typ = 22.1% Typ = 22.5% Motor Nameplate Motor Nameplate Motor Nameplate Motor Nameplate Motor Nameplate Motor Nameplate Motor Nameplate Motor Nameplate Motor Nameplate Motor Nameplate Motor Nameplate Motor Nameplate Calculated From Motor Nameplate Calculated From Motor Nameplate Auto Tune (P115=2, 4, 5) Auto Tuned Auto Tuned (Auto tuned) (Auto tuned) (Auto tuned) (Auto tuned) (Auto tuned) (Auto tuned) Resistance Temp Factor (Auto tuned) Resistance Temp Factor (Auto tuned) Maximum current setpoint (1.5 x P102) Maximum current setpoint (1.5 x P102) 11 = Encoder 10 = No encoder

23/03/2001 10:56

126743 REV.SHEET 2 OF 14

VIEW PAR. NO.

P151 P151 YES P215 YES P215 P216 P216 P221 P221 P222 P222 P223 P223 P233 P233 P234 P234 P235 P235 P236 P236 P240 P240 YES P259 YES P259 P273 P273 P274 P274 P283 P283 P284 P284 P287 P287 P291 P291 YES P295 YES P295 P303 P303 P305 P305 P313 P313 P314 P314 P315 P315 P316 P316 P338 P338 P338 P338

IND.

PARAMETER DESC.

VALUE(Units)

1 2 1 2 1 2 1 2 1 2 1 2 1 2 1 2 1 2 1 2 1 2 1 2 1 2 1 2 1 2 1 2 1 2 1 2 1 2 1 2 1 2 1 2 1 2 1 2 1 2 1 2 3 4

Encoder Pulse # Encoder Pulse # Max dn/dt Max dn/dt Smooth n/f (FWD) Smooth n/f (FWD) Smooth n/f (Set) Smooth n/f (Set) Source of n/f (act) Source of n/f (act) Smooth n/f (act) Smooth n/f (act) n/f Reg. Adapt.1 n/f Reg. Adapt.1 n/f Reg. Adapt.2 n/f Reg. Adapt.2 n/f-reg. Gain 1 n/f-reg. Gain 1 n/f-reg. Gain 2 n/f-reg. Gain 2 n/f Reg. Time n/f Reg. Time Max Regen Power Max Regen Power Smooth Isq (set) Smooth Isq (set) Isq (set) grad. Isq (set) grad. Current Reg Gain Current Reg Gain Current Reg Time Current Reg Time SmoothDCBusVolts SmoothDCBusVolts Fsetp Flux (set) Fsetp Flux (set) Efficiency Optim Efficiency Optim Smooth Flux (Set) Smooth Flux (Set) FieldWeakRegTime FieldWeakRegTime f(cEMF Mod) f(cEMF Mod) f(cEMF->AMP-mod) f(cEMF->AMP-mod) cEMF Reg Gain cEMF Reg Gain cEMF Reg Time cEMF Reg Time Common Mode Comp Common Mode Comp Common Mode Comp Common Mode Comp

1024 1024 8.10 Hz 8.10 Hz 0.0 ms typ 4.8 ms typ 4 ms 4 ms 0 0 4 ms typ 0 ms typ 0.0% 0.0% 100.0% 100.0% 2.6 typ 1.7 typ 2.6 typ 1.7 typ 134 ms typ 230 ms typ -30.0% -30.0% 7 ms typ 7 ms typ 2648.0 A typ 2648.0 A typ 0.324 typ 0.327 typ 6.4 ms typ 6.4 ms typ 9 9 100.0% 100.0% 50.0% 50.0% 20 ms typ 15 ms typ 150 ms 150 ms 3.92 Hz typ 3.92 Hz typ 50.0% 50.0% 0.162 typ 0.324 typ 50.0 ms typ 50.0 ms typ 3.00 us 3.00 us 3.00 us 3.00 us


COMMENTS

Number of encoder pulses Number of encoder pulses Speed Error Allowed Speed Error Allowed Smoothing Value for Speed Reg (Auto tuned) Smoothing Value for Speed Reg (Auto tuned) (Default) (Default) (Default) (Default) (Auto tuned) (Auto tuned) (Default) (Default) (Default) (Default) Porport Gain of Speed Regulator (Auto tuned) Porport Gain of Speed Regulator (Auto tuned) Porport Gain of Speed Regulator (Auto tuned) Porport Gain of Speed Regulator (Auto tuned) Integral time of speed controller (Auto tuned) Integral time of speed controller (Auto tuned) Maximum allowed regenerative power. Maximum allowed regenerative power. Torque smoothing time constant (Auto tuned) Torque smoothing time constant (Auto tuned) Rise limitation for Isq setpoint (Auto tuned) Rise limitation for Isq setpoint (Auto tuned) Gain of the PI current controller (Auto tuned) Gain of the PI current controller (Auto tuned) Adjust. time of the PI controller (Auto tuned) Adjust. time of the PI controller (Auto tuned) DC link bus V smoothing time const (Default) DC link bus V smoothing time const (Default) Flux setpoint from rated rotor flux (Default) Flux setpoint from rated rotor flux (Default) Better Control at Reduced Load Better Control at Reduced Load Flux setpt smoothing time const (Auto tuned) Flux setpt smoothing time const (Auto tuned) Field weakening time for PI contoller (Default) Field weakening time for PI contoller (Default) Frequency of switch for models (Auto tuned) Frequency of switch for models (Auto tuned) Frequency of switch for models (Default) Frequency of switch for models (Default) PI for counter EMF model (Auto tuned) PI for counter EMF model (Auto tuned) Integral time for counter EMF (Auto tuned) Integral time for counter EMF (Auto tuned) Edge pulse modulator compensate (Default) Edge pulse modulator compensate (Default) Edge pulse modulator compensate (Default) Edge pulse modulator compensate (Default)

23/03/2001 10:56


VIEW PAR. NO.

P338 P338 P339 P339 P340 P340 P342 P342 P344 P344 P347 P347 P348 P349 YES P350 P351 P352 P353 YES P354 P357 YES P360 P360 P360 P360 P360 P360 P360 P360 P360 P360 P360 P360 P360 P360 P360 P360 P360 P360 P360 P360 P360 P360 P360 P360 P360 P360 P360 P360 P360 P360 P360 P360 P360 P360

IND.

PARAMETER DESC.

VALUE(Units)

5 6 1 2 1 2 1 2 1 2 1 2 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34

Common Mode Comp Common Mode Comp ModSystemRelease ModSystemRelease Pulse Frequency Pulse Frequency Max ModulatDepth Max ModulatDepth ModDepth Headroom ModDepth Headroom ON VoltsCompens. ON VoltsCompens. Dead Time Comp T(DeadtimeComp.) Ref Amps Ref Volts Ref Frequency Ref Speed Ref torque Sampling time Select User Parameter Select User Parameter Select User Parameter Select User Parameter Select User Parameter Select User Parameter Select User Parameter Select User Parameter Select User Parameter Select User Parameter Select User Parameter Select User Parameter Select User Parameter Select User Parameter Select User Parameter Select User Parameter Select User Parameter Select User Parameter Select User Parameter Select User Parameter Select User Parameter Select User Parameter Select User Parameter Select User Parameter Select User Parameter Select User Parameter Select User Parameter Select User Parameter Select User Parameter Select User Parameter Select User Parameter Select User Parameter Select User Parameter Select User Parameter

3.00 us 3.00 us 0 0 2.5 kHz 2.5 kHz 96.0% 96.0% 0.0% 0.0% 1.1 V typ 1.1 V typ 0 2.50us 662.0 A 550 V 81.50 Hz 2400 1/min 4203.00Nm 1.2 ms P060 P053 P358 r001 r002 r003 r004 r005 r006 r007 r008 r011 r012 r013 r014 r015 P050 P102 P105 P113 P115 P128 P215 P259 P295 P350 P354 P401 r419 P492 r496 r497 P498 r502


COMMENTS

Edge pulse modulator compensate (Default) Edge pulse modulator compensate (Default) Freq system type to release P338 (Default) Freq system type to release P338 (Default) Drive Carrier Frequency (Default) Drive Carrier Frequency (Default) Max modulation depth of modulator (Default) Max modulation depth of modulator (Default) Modulator headroom depth (Default) Modulator headroom depth (Default) IGBT voltage diff compensation (Auto tuned) IGBT voltage diff compensation (Auto tuned) Select deadtime Comp,0=off (Auto tuned) Gate unit intrlock compens time (Auto tuned) Set to P102 (Motor Rated Current) Set to P101 (Motor Rated Voltage) Motor Nameplate Motor Nameplate Set to P113 (Motor Rated Torque) Base Sampling Time Always select P060 (Menu Access) Always select P053 (Parameter access) Always select P358 (Key unlock parameter) Select Drive Status. Select Rotational Frequency Select Output Volts Select Output Amps Select Output Power Select DC Bus Volts Select Motor Torque Select Motor Utilization Select Active Motor Data Set Select Active BICO Data Set Select Active Function Data Set Select Set Point Speed Select Speed Actual Input Select Language Select Motor Rated Amps Select Motor Rated Power Select Motor Rated Torque Select Motor Calculation (Auto Tune) Select Imax Select max. dn/dt Select Max Regen Power Select Efficiency Optim Select Reference Amps Select Reference Torque Select Fixed Setpoint 1 Select # of Active Fault Setpoints Select FixTorque 1 Set Select Fix Torque 1 Select Actual Upper Torque Limit Select FixTorq 2 Set Select Fix Torque 2

23/03/2001 10:56


VIEW PAR. NO.

IND.

PARAMETER DESC.

VALUE(Units)

P360 P360 P360 P360 P360 P360 P360 P360 P360 P360 P360 P360 P360 P360 P360 P360 P360 P360 P360 P360 P361 P366 P368 P370 P375 P382 P382 P383 P383 P401 P401 P401 P421 P422 P423 P425 P426 P427 P428 P429 P430 P433 P433 P434 P434 P434 P443 P443 P444 P444 P444 P445 P445 P445

35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 1 2 1 2 1 2 3 1 2 1 2 3 1 2 1 2 3 1 2 3

Select User Parameter Select User Parameter Select User Parameter Select User Parameter Select User Parameter Select User Parameter Select User Parameter Select User Parameter Select User Parameter Select User Parameter Select User Parameter Select User Parameter Select User Parameter Select User Parameter Select User Parameter Select User Parameter Select User Parameter Select User Parameter Select User Parameter Select User Parameter OP1s Backlight Select FactSet Select Setp Src Quick Param Ground Flt Test Motor Cooling Motor Cooling Mot ThermT-Const Mot ThermT-Const Fixed Setpoint 1 Fixed Setpoint 1 Fixed Setpoint 1 MOP (max) MOP (min) Src MOP inv. Conf MOP StartValue MOP Src Set MOP Src SetV MOP Src Auto SetP Src Manual/Auto Src AddSetpoint1 Src AddSetpoint1 Scale Add Setpoint Scale Add Setpoint Scale Add Setpoint Src MainSetpoint Src MainSetpoint Scale Main Setp Scale Main Setp Scale Main Setp Base Setpoint Base Setpoint Base Setpoint

r550 r551 r552 r553 P590 P602 P640 P643 P644 r782 r783 r784 r785 r786 r787 r825 r947 r949 P971 U002 0 1 1 0 0 1 1 1800 s 1800 s 0.00% 10.00% 5.00% 100.0% 0.0% 2111 0110 0.0% 0 0 0 0 41 0 100.00% 100.00% 100.00% 3002 58 100.00% 100.00% 100.00% 0.0% 0.0% 0.0%


COMMENTS

Select Control Word 1 Select Control Word 2 Select Status Word 1 Select Status Word 2 Select Src BICO Dset Select Excitation time Select Src Analog Out Select CU AnalogOutGain Select CU- AnalogOutOff Select Last 8 Fault Trip Times Select n/f actual (r218) at time of last trip Select n/f actual/second at time of last trip Select actual torque current at time of trip Select actual converter out V at time of trip Select Control Status at time of trip Select Operating Hours (Inverter Pulsing) Select Last 8 Faults Select Last 8 Fault Values Select EEPROM Saving Select Fixed Setpt 18 (Meter Torque Scaling) 0= Always On Select Factory Setting (Default) Analog Input & Terminal Strip (Default) P370=1 Will Factory DEFAULT Parameters!!!! Blocked (Default) 1 = Forced Vent 1 = Forced Vent Max Time Allowed in Stall = 30 min. Max Time Allowed in Stall = 30 min. Additional Drill Speed Spin Speed Set to 10% of Rated Speed Torque Speed Set to 5% of Rated Speed Upper Limit of OP1S (Default) Lower Limit of OP1S (Default) BICO for Direction Change on OP1S Configuration of MOP MOP Starting Value BICO Source for MOP Use (Default) BICO Source for MOP Set Value (Default) BICO Source for MOP Auto Setpt (Default) BICO Source for Manual/Auto Switching BICO to Set Spin, Torque, and Speed BICO to Set Spin, Torque, and Speed Gain for Additional Setpoint 1 (Default) Gain for Additional Setpoint 1 (Default) Gain for Additional Setpoint 1 (Default) BICO for Main Setpoint BICO for Main Setpoint Scaling factor for Main Setpoint (Default) Scaling factor for Main Setpoint (Default) Scaling factor for Main Setpoint (Default) Basic Setpoint (Added to Main Setpoint)(Def) Basic Setpoint (Added to Main Setpoint)(Def) Basic Setpoint (Added to Main Setpoint)(Def)

23/03/2001 10:56


VIEW PAR. NO.

IND.

PARAMETER DESC.

VALUE(Units)


1 2 3 1 2 3 1 2 3 1 2 3 1 2 3 1 2 3 1 2 3 1 2 1 2 3 1 2 3 1 2 3 1 2 1 2 3 1 2 1 2 3 1 2 3 1 2 1 2

Jog Setp 1 Jog Setp 2 n/f(max, FWD Spd) n/f(max, FWD Spd) n/f(max, FWD Spd) n/f(max,REV Spd) n/f(max,REV Spd) n/f(max,REV Spd) Min setp Min setp Min setp Accel. Time Accel. Time Accel. Time Accel. Time Unit Accel. Time Unit Accel. Time Unit Decel. Time Decel. Time Decel. Time Decel. Time Unit Decel. Time Unit Decel. Time Unit Decel. Time OFF3 Decel. Time OFF3 ProtRampGen Gain ProtRampGen Gain ProtRampGen Gain Rgen Round Type Ramp StartSmooth Ramp StartSmooth Ramp StartSmooth Ramp End Smooth Ramp End Smooth Ramp End Smooth Scale Torq (PRE) Scale Torq (PRE) Ramp Limitation RampGen Act Hyst FixTorque 1 Set FixTorque 1 Set FixTorque 1 Set Src Fixtorque 1 Src Fixtorque 1 FixTorque 1 Gain FixTorque 1 Gain FixTorque 1 Gain FixTorque 2 Set FixTorque 2 Set FixTorque 2 Set Src FixTorque 2 Src FixTorque 2 Scale TorqLim2 Scale TorqLim2

10.00% 20.00% 100.0% 100.0% 100.0% -50.00% -50.00% -50.00% 0.0% 0.0% 0.0% 5.0 5.0 5.0 0 0 0 2 2 2 0 0 0 2.0 s 0.0 s 2.9 typ 1.0 typ 1.0 typ 0 0.50 s 0.50 s 0.50 s 0.50 s 0.50 s 0.50 s 100.0% 100.0% 0.0% 1.0% 100.0% 10.0% 150.0% 3003 170 100.00% 100.00% 100.00% -100.00% -10.00% -200.00% 3005 171 100.00% 100.00%


COMMENTS

Jogging Setpoint 1 (Default) Jogging Setpoint 2 (Default) Max Setpoint for CW (Forward) Rotating Field Max Setpoint for CW (Forward) Rotating Field Max Setpoint for CW (Forward) Rotating Field Max Setpoint for CCW(Reverse) Rotating Field Max Setpoint for CCW(Reverse) Rotating Field Max Setpoint for CCW(Reverse) Rotating Field Minimum Setpoint of the Drive (Default) Minimum Setpoint of the Drive (Default) Minimum Setpoint of the Drive (Default) Acceleration Time (P463) From 0 to 100% Acceleration Time (P463) From 0 to 100% Acceleration Time (P463) From 0 to 100% 0 = Seconds 0 = Seconds 0 = Seconds Deceleration Time (P465) From 100 to 0% Deceleration Time (P465) From 100 to 0% Deceleration Time (P465) From 100 to 0% 0 = Seconds 0 = Seconds 0 = Seconds Keypad "quickstop" from 100% to standstill Keypad "quickstop" from 100% to standstill Acceleration Time (P462) Gain Factor(Auto Tn) Acceleration Time (P462) Gain Factor Acceleration Time (P462) Gain Factor Mode for Ramp Function Rounding (Default) Initial Rounding Up Time for Ramp Func (Def) Initial Rounding Up Time for Ramp Func (Def) Initial Rounding Up Time for Ramp Func (Def) Final Rounding Up Time for Ramp Func (Def) Final Rounding Up Time for Ramp Func (Def) Final Rounding Up Time for Ramp Func (Def) Gain of the n/f controller precontrol (Default) Gain of the n/f controller precontrol (Default) "0.0" Deactivates Ramp-Func Tracking (Def) Hysteresis for "Rmp-Func Gen Active" msg. Forward Maximum Drill Torque Forward Spin Torque Maximum Make-up Torque (Forward) BICO Source for Upper Torque Limitation BICO Source for Upper Torque Limitation Scaling Factor for Upper Torque Limitation Scaling Factor for Upper Torque Limitation Scaling Factor for Upper Torque Limitation Reverse Maximum Drill Torque Reverse Spin Torque Maximum Breakout Torque (Reverse) BICO Source for Lower Torque Limit BICO Source for Lower Torque Limit Scaling Factor for Lower Torque Limit (Def) Scaling Factor for Lower Torque Limit (Def)

23/03/2001 10:56


VIEW PAR. NO.

IND.

PARAMETER DESC.

VALUE(Units)


3 1 2 1 2 1 2 1 2 1 2 1 2 1 2 1 2 1 2 1 2 1 2 1 2 1 2 1 2 1 2 1 2 1 2 1 2 1 2 1 2 1 2 1 2 1 2 1 2 1 2 1 2 1

Scale TorqLim2 SIMO Sound SIMO Sound n/f RegDyn (set) n/f RegDyn (set) n/f RegDyn (act) n/f RegDyn (act) Src ON/OFF1 Src ON/OFF1 Src1 OFF2 (Coast) Src1 OFF2 (Coast) Src2 OFF2 (Coast) Src2 OFF2 (Coast) Src3 OFF2 (Coast) Src3 OFF2 (Coast) Src1 OFF3 (Qstop) Src1 OFF3 (Qstop) Src2 OFF3 (Qstop) Src2 OFF3 (Qstop) Src3 OFF3 (Qstop) Src3 OFF3 (Qstop) Src InvRelease Src InvRelease Src RampGen Rel Src RampGen Rel Src RampGen Stop Src RampGen Stop Src Setp Release Src Setp Release Src1 Fault Reset Src1 Fault Reset Src2 Fault Reset Src2 Fault Reset Src3 Fault Reset Src3 Fault Reset Src Jog Bit0 Src Jog Bit0 Src Jog Bit1 Src Jog Bit1 Src FWD Speed Src FWD Speed Src REV Speed Src REV Speed Src MOP UP Src MOP UP Src MOP Down Src MOP Down Src No ExtFault1 Src No ExtFault1 Src FuncDSet Bit0 Src FuncDSet Bit0 Src FuncDSet Bit1 Src FuncDSet Bit1 Src MotSSet Bit0

100.00% 1 1 50% 50% 50% typ 49% typ 3100 2100 22 22 1 1 1 1 2102 2102 1 1 1 1 1 1 1 1 1 1 1 1 18 18 3107 0 2107 2107 3108 2108 0 0 3111 2111 3112 2112 2113 2113 2114 2114 20 20 3400 0 3401 0 3402


COMMENTS

Scaling Factor for Lower Torque Limit (Def) Adjusts Noise Spectrum of Machine Adjusts Noise Spectrum of Machine Dynamic Response of n Control Circuit (Def) Dynamic Response of n Control Circuit (Def) P536 Adjustment After P115=5 (Auto Tuned) P536 Adjustment After P115=5 (Auto Tuned) Drive ON/OFF Command,P590=0 (PLC Cntrl) Drive ON/OFF Command,P590=1 (OP1S Ctrl) Drive OFF Command From E-STOP (Coast) Drive OFF Command From E-STOP (Coast) 2nd BICO Source for OFF (Coast Stop)(Def) 2nd BICO Source for OFF (Coast Stop)(Def) 3rd BICO Source for OFF (Coast Stop)(Def) 3rd BICO Source for OFF (Coast Stop)(Def) Drive OFF Command From OP1S (Qck Stop) Drive OFF Command From OP1S (Qck Stop) 2nd BICO Source for OFF (Quick Stop)(Def) 2nd BICO Source for OFF (Quick Stop)(Def) 3rd BICO Source for OFF (Quick Stop)(Def) 3rd BICO Source for OFF (Quick Stop)(Def) BICO Source for Releasing Inverter (Def) BICO Source for Releasing Inverter (Def) BICO Source for Releasing Ramp Gen (Def) BICO Source for Releasing Ramp Gen (Def) BICO Source for Starting Ramp Gen (Def) BICO Source for Starting Ramp Gen (Def) BICO for Releasing Setpoint (cw1,bit 1)(Def) BICO for Releasing Setpoint (cw1,bit 1)(Def) Digital In 5 (Not used) Digital In 5 (Not used) AutoReset Drive From PLC Reset Drive From OP1S Keypad Reset Drive From OP1S Keypad Reset Drive From OP1S Keypad Jog from Bit 8, Control Word 1 Jog from OP1S Keypad BICO Src to Jog ( Sets Bit 9, cw1)(Not Used) BICO Src to Jog ( Sets Bit 9, cw1)(Not Used) BICO Source to Command Fwd Rotation(PLC) BICO Source to Command Fwd Rot (Keypad) BICO Source to Command Rev Rotation (PLC) BICO Source to Command Rev Rot (Keypad) BICO Source to Increase MOP (Not Used) BICO Source to Increase MOP (Keypad) BICO Source to Decrease MOP (Not Used) BICO Source to Decrease MOP (Keypad) BICO Source for External Fault 1 BICO Source for External Fault 1 BICO Src for Func Data Set (cw2,bit16) BICO Src for Func Data Set (cw2,bit16)(Def) BICO Src for Func Data Set (cw2,bit17) BICO Src for Func Data Set (cw2,bit17)(Def) BICO Src for Motor Data Set (cw2,bit 18)

23/03/2001 10:56


VIEW PAR. NO.

IND.

PARAMETER DESC.

VALUE(Units)

P578 P579 P579 P590 P602 P602 P603 P603 P640 P640 P643 P643 P644 P644 P652 P652 P722 P722 P734 P734 P734 P734 P734 P734 P952 P970 P971 U001 U001 U001 U002 U002 U002 U107 U107 U108 U108 U117 U118 U119 U120 U121 U122 U950 U950 U950 U951 U951 U952

2 1 2 1 2 1 2 1 2 1 2 1 2 1 2 1 2 1 2 3 4 5 6 1 2 3 1 2 3 1 2 1 2 031 032 075 004 059 047

Src MotSSet Bit0 Src MotSSet Bit1 Src MotSSet Bit1 Src BICO Dset Excitation Time Excitation Time De-MagnetizeTime De-MagnetizeTime Src AnaOut Src AnaOut CU AnalogOutGain CU AnalogOutGain CU--AnalogOutOFF CU--AnalogOutOFF Src DigOut2 Src DigOut2 CB/TB TlgOFF CB/TB TlgOFF SrcCB/TBTrnsData SrcCB/TBTrnsData SrcCB/TBTrnsData SrcCB/TBTrnsData SrcCB/TBTrnsData SrcCB/TBTrnsData # of Faults Factory Setting EEPROM Saving FixSetp 17 FixSetp 17 FixSetp 17 fixSetp 18 fixSetp 18 fixSetp 18 Src Conn Mult1 Src Conn Mult1 Src Conn Mult2 Src Conn Mult2 Src ConnAbsV1 Mode ConnAbsV1 SmoothConAbsV1 Src ConnAbsV2 Mode ConnAbsV2 SmoothConAbsV2 Sampling Times1 Sampling Times1 Sampling Times1 Sampling Times2 Sampling Times2 Sampling Times3

3402 0 0 0 0.20 s 0.20 s 3.00 s 3.00 s 148 24 10.00 V 10.00 V 0.00 V 0.00 V 122 122 10 ms 10 ms 32 467 33 468 170 250 7 1 0 95.00% 95.00% 95.00% 54.50% 54.50% 54.50% 491 401 492 402 148 1 0 ms 24 1 0 ms 2 2 2 2 2 2


COMMENTS

BICO Src for Motor Data Set (cw2,bit 18) BICO Src for Motor Data Set (cw2,bit 19)(Def) BICO Src for Motor Data Set (cw2,bit 19)(Def) Set PLC or OP1S Control (0=PLC) Wait Time Before Releasing Frequency Wait Time Before Releasing Frequency Time to DE-excite Motor (Auto Tuned) Time to DE-excite Motor (Auto Tuned) BICO for Analog 1 Out (Speed) BICO for Analog 1 Out (Torque) Porportional Gain for Analog Outputs (Def) Porportional Gain for Analog Outputs (Def) Offset Voltage for P643 Analog Outs (Def) Offset Voltage for P643 Analog Outs (Def) Undervoltage Fault (Status Word 1, Bit 11) Undervoltage Fault (Status Word 1, Bit 11) Fault if No Communication for 10 ms (Def) Fault if No Communication for 10 ms (Def) Status Word 1(To PLC) Speed to Meter (To PLC) Status Word 2 (To PLC) Torque to Meter (To PLC) Spin Torque (To PLC) Fault Number (To PLC) Number of Stored Fault Trips P970=0 Will Factory DEFAULT Parameters!!!! Save Parameters(Ram To EEPROM)(P971=1) RPM Scaling (For VDC Meter) RPM Scaling (For VDC Meter) RPM Scaling (For VDC Meter) Torque Scaling (For VDC Meter) Torque Scaling (For VDC Meter) Torque Scaling (For VDC Meter) Multipliers for RPM Meter Multipliers for RPM Meter Multipliers for Torque Meter Multipliers for Torque Meter BICO Source for 1st Abs Value Generator Mode Sel for Ist Abs Value Gen (1=| Signal |) Smoothing Time Const for 1st Abs Val Gen BICO Source for 2nd Abs Value Generator Mode Sel for 2nd Abs Value Gen (1=| Signal |) Smoothing Time Const for 2nd Abs Val Gen Sampling time Sampling time Sampling time Sampling time Sampling time Sampling time

23/03/2001 10:56


TDS-9S

PAR. NO.

P050 P051 P052 P053 P054 P071 P074 P075 P076 P077 P090 P091 P140 P141 P144 P160 P310 P311 P312 P313 P314 P315 P316 P317 P318 P319 P320 P329 P353 P354 P366 P368 P408 P409 P486 P517 P518 P554 P555 P556 P557 P561 P565 P566 P567 P568 P569 P571 P575 P578

SIEMENS SERIES 70 DRIVE LISTING OF RECTIFIER PARAMETERS IND.

0 0 0 0 0 0 0 0 0 0 0 0 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 0 0 0 0 1 0 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1

PARAMETER DESC.

Language Access Level Function Select Parameter Access Display Light Line Volts Limit LowVoltage Rtd Amps Config. Pcircuit Factory Set type Board Position 2 Board Position 3 Rectifier Resistance Rectifier Inductance DC Bus Capacitance Motor Current Limit DC Current Reg Gain DC Current Reg Time DC Cur Reg CWord DC Volts Reg Gain DC Volts Reg Time DC Volts Reg CWord DC V-Reg +Limit DC V-Reg -Limit DC V(Set,red) DC V(Set,red)Hys Smooth Load Amps Pre Charge Time Thyristor Test Ground Flt Test Auto Restart Time DC Bus Volts Caps Forming Time Contactor Delay Src Current Setup DC Volts Dev Limit Deviation Time Src ON/OFF1 Src1 OFF2(coast) Src2 OFF2(coast) Src3 OFF2(coast) Src InvRelease Src1 Fault Reset Src2 Fault Reset Src3 Fault Reset Src Jog1 ON Src Jog2 ON Src Reduce DC V Src No ExtFault1 Src RDataSet Bit0


VALUE(Units)

1 3 0 6 0 575.0 V 61 1023 1 0 0 0 0.007 0.21 32.22 150 0.15 0.015 2111 8.8 3 0010 0.01 -1.00 95.00 6.00 5.00 500 0 2 2 6.1 10 0 0 2 0.1 1001 0001 0001 0001 1003 1004 0000H 2001 0000H 0000H 0001 0001 0000H

COMMENTS

Set DC Bus to 780V

Restart After Power Recovery

Used To Reduce DC Bus Via P318

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PAR. NO.


IND.

1 1 1 1 1 0 0 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 0 0 0 0 1 1 1 1 1 1 1 1 0 1 1 1 1 1 0 1 1 1 0 0 0 0 0

PARAMETER DESC.

Src RDataSet Bit1 Src No ExtFault2 Src Master/Slave Src No Ext Warn1 Src No Ext Warn2 Src Base/Reserve Src ContactorMsg Trg Bit Ready ON Trg Bit Ready Operator Trg Bit Oper Trg Bit Fault Trg Bit No OFF2 Trg Bit On blocked Trg Bit Warning Trg Regen Ready Trg Low Voltage Trg Low Voltage Trg Bit Contact Trg DC V reduced Trg Current Lim. Trg Bit Ext Flt1 Trg Bit Ext Flt2 Trg Bit Ext Warn Trg Bit i2tInv Trg Bit Flt Tmp Inv TrgBitWarTmpInv Trig Bit Charging CUR AnaOutActVal CUR AnaOut Gain CUR AnaOut Offset AnaOut Conf Curr SCI AnaLogInConf SCI AnaInSmooth SCI AnaLogInOffs SCI AnaOutActVal SCI AnaOut Gain SCI AnaOut Offs SCom1 Act Value SCom2 Act Value SCB Protocol SCom/SCB BusAddr SCom/SCB Baud SCom/SCB PCV SCOM/SCB # PrDat SCom/SCB TlgOFF SCom2 Protocol SCB Peer2PeerExt SCB Act Values CB/TB Act Values CB/TB Tlg Off Time CB Parameter 1 CB Parameter 2 CB Parameter 3 CB Parameter 4


VALUE(Units)

COMMENTS

0000H 0001H 0000H 0001H 0001H 0000H 0001H 0000H 0000H 0000H 1001 0 0 1002 0 0 0 0 0 0 0 0 0000H 0000H 0000H 0000H 0000H 37 10.00 0.00 0 0 2 0 0 10 0 968 968 0 0 6 127 2 0 ms 1 0 0 968 20ms 0 0 0 0

23/03/2001 10:56


PAR. NO.

P700 P701 P702 P703 P704 P705 P772 P773 P775 P776 P777 P778 P779 P780 P785 P788 P793 P799 P917 P918 P928 P971

IND.

0 0 0 0 0 0 1 1 1 1 1 1 0 1 0 1 0 0 0 0 0 0

PARAMETER DESC.

CB Parameter 5 CB Parameter 6 CB Parameter 7 CB Parameter 8 CB Parameter 9 CB Parameter 10 Thyr Voltg Corr Deadband Convert Min Gating Angle Max Gating Angle Max Gat Ang Ramp Line FrquFiltTime Phase Shift Corr Fault Masking I2T Control Word RAM Access Addr Line Voltg Delay Special Access Change Reports CB Bus Address Src Base/Reserve EEPROM Storing


VALUE(Units)

COMMENTS

0 0 0 0 0 0 0 0.01 0 150 20 200 0.8 0 1 0 0.03 4 0 3 0000H 0

23/03/2001 10:56


TDS-11S

SIEMENS SERIES 70 DRIVE (WITH CUVC CONTROL) LISTING OF INVERTER PARAMETERS

VIEW PAR. NO.

IND.

PARAMETER DESC.

VALUE(Units)

YES P050 YES P053 YES P060 2 P068 P070 P071 P072 P073 P075 P075 P076 P076 P095 P095 P100 P100 P101 P101 YES P102 YES P102 P103 P103 P104 P104 YES P105 YES P105 P106 P106 P107 P107 P108 P108 P109 P109 YES P113 YES P113 YES P115 3 P116 P116 P120 P120 P121 P121 P122 P122 P127 P127 YES P128 YES P128 P130 P130

0 1 2 1 2 1 2 1 2 1 2 1 2 1 2 1 2 1 2 1 2 1 2 1 2 1 2 1 2 1 2 1 2 1 2 1 2 1 2 1 2 1 2

Language Parameter Access Menu Select Output Filter Order No. 6SE70 Line Volts Rated Drive Amps Rated Drive Power X (magnet,d)tot X (magnet,d)tot X (magnet,q)tot X (magnet,q)tot Type of Motor Type of Motor Control Mode Control Mode Motor Rated Volts Motor Rated Volts Motor Rated Current Motor Rated Current Motor Magn Current Motor Magn Current Motor Power Factor Motor Power Factor Motor Rated Power Motor Rated Power Motor Rated Efficiency Motor Rated Efficiency Motor Rated Frequency Motor Rated Frequency Motor Rated Speed Motor Rated Speed Motor #Pole Pairs Motor #Pole Pairs Motor Rated Torque Motor Rated Torque Calc Motor Model Start-Up Time Start-Up Time Main Reactance Main Reactance Stator Resistance Stator Resistance Total Leakage React Total Leakage React RotResistTmpFact RotResistTmpFact Imax Imax Select Motor Encoder Select Motor Encoder

1 6 0 0 38-6U.6. 780V 860.0A 630.0 kW 150.0% 150.0% 150.0% 150.0% 11 11 4 3 575V 575V 732.0A 732.0A 0 0 0.87 0.87 800.0 Hp 800.0 Hp 92% 92% 39.2 Hz 39.2 Hz 1155 1/min 1155 1/min 2 2 4934.0 Nm 4934.0 Nm 0 0.20 s typ 0.21 s typ 380.9 typ 388.3 typ 3.43% typ 3.38% typ 31.15% typ 31.21% typ 80.7% typ 78.6% typ 1169.5 A 1169.5 A 11 10


COMMENTS

Language (1=English) Access for Parameters Parameter Menu (7 = Free Access) No Output filter MLFB: Drive Size 128 Rated Drive Voltage Rated Drive Current Rated Drive Power (Default) (Default) (Default) (Default) NEMA Induction Motor NEMA Induction Motor Speed Regulation Frequency Regulation Motor Nameplate Motor Nameplate Motor Nameplate Motor Nameplate Typ = 22.3% Typ = 22.3% Motor Nameplate Motor Nameplate Motor Nameplate Motor Nameplate Motor Nameplate Motor Nameplate Motor Nameplate Motor Nameplate Motor Nameplate Motor Nameplate Motor Nameplate Motor Nameplate Calculated From Motor Nameplate Calculated From Motor Nameplate Auto Tune (P115=2, 4, 5) Auto Tuned Auto Tuned (Auto tuned) (Auto tuned) (Auto tuned) (Auto tuned) (Auto tuned) (Auto tuned) Resistance Temp Factor (Auto tuned) Resistance Temp Factor (Auto tuned) Maximum current setpoint (1.5 x P102) Maximum current setpoint (1.5 x P102) 11 = Encoder 10 = No encoder

14/02/2001 16:29

124965 REV.B SHEET 2 OF 13

VIEW PAR. NO.

P151 P151 YES P215 YES P215 P216 P216 P221 P221 P222 P222 P223 P223 P233 P233 P234 P234 P235 P235 P236 P236 P240 P240 YES P259 YES P259 P273 P273 P274 P274 P283 P283 P284 P284 P287 P287 P291 P291 YES P295 YES P295 P303 P303 P305 P305 P313 P313 P314 P314 P315 P315 P316 P316 P338 P338 P338 P338

IND.

PARAMETER DESC.

VALUE(Units)

1 2 1 2 1 2 1 2 1 2 1 2 1 2 1 2 1 2 1 2 1 2 1 2 1 2 1 2 1 2 1 2 1 2 1 2 1 2 1 2 1 2 1 2 1 2 1 2 1 2 1 2 3 4

Encoder Pulse # Encoder Pulse # Max dn/dt Max dn/dt Smooth n/f (FWD) Smooth n/f (FWD) Smooth n/f (Set) Smooth n/f (Set) Source of n/f (act) Source of n/f (act) Smooth n/f (act) Smooth n/f (act) n/f Reg. Adapt.1 n/f Reg. Adapt.1 n/f Reg. Adapt.2 n/f Reg. Adapt.2 n/f-reg. Gain 1 n/f-reg. Gain 1 n/f-reg. Gain 2 n/f-reg. Gain 2 n/f Reg. Time n/f Reg. Time Max Regen Power Max Regen Power Smooth Isq (set) Smooth Isq (set) Isq (set) grad. Isq (set) grad. Current Reg Gain Current Reg Gain Current Reg Time Current Reg Time SmoothDCBusVolts SmoothDCBusVolts Fsetp Flux (set) Fsetp Flux (set) Efficiency Optim Efficiency Optim Smooth Flux (Set) Smooth Flux (Set) FieldWeakRegTime FieldWeakRegTime f(cEMF Mod) f(cEMF Mod) f(cEMF->AMP-mod) f(cEMF->AMP-mod) cEMF Reg Gain cEMF Reg Gain cEMF Reg Time cEMF Reg Time Common Mode Comp Common Mode Comp Common Mode Comp Common Mode Comp

1024 1024 8.10 Hz 8.10 Hz 0.0 ms typ 4.8 ms typ 4 ms 4 ms 0 0 4 ms typ 0 ms typ 0.0% 0.0% 100.0% 100.0% 2.9 typ 1.6 typ 2.9 typ 1.6 typ 134 ms typ 258 ms typ -30.0% -30.0% 7 ms typ 7 ms typ 2928.0 A typ 2928.0 A typ 0.395 typ 0.395 typ 6.4 ms typ 6.4 ms typ 9 9 100.0% 100.0% 50.0% 50.0% 20 ms typ 20 ms typ 150 ms 150 ms 3.93 Hz typ 3.93 Hz typ 50.0% 50.0% 0.156 typ 0.300 typ 52.0 ms typ 54.0 ms typ 3.00 us 3.00 us 3.00 us 3.00 us


COMMENTS

Number of encoder pulses Number of encoder pulses Speed Error Allowed Speed Error Allowed Smoothing Value for Speed Reg (Auto tuned) Smoothing Value for Speed Reg (Auto tuned) (Default) (Default) (Default) (Default) (Auto tuned) (Auto tuned) (Default) (Default) (Default) (Default) Porport Gain of Speed Regulator (Auto tuned) Porport Gain of Speed Regulator (Auto tuned) Porport Gain of Speed Regulator (Auto tuned) Porport Gain of Speed Regulator (Auto tuned) Integral time of speed controller (Auto tuned) Integral time of speed controller (Auto tuned) Maximum allowed regenerative power. Maximum allowed regenerative power. Torque smoothing time constant (Auto tuned) Torque smoothing time constant (Auto tuned) Rise limitation for Isq setpoint (Auto tuned) Rise limitation for Isq setpoint (Auto tuned) Gain of the PI current controller (Auto tuned) Gain of the PI current controller (Auto tuned) Adjust. time of the PI controller (Auto tuned) Adjust. time of the PI controller (Auto tuned) DC link bus V smoothing time const (Default) DC link bus V smoothing time const (Default) Flux setpoint from rated rotor flux (Default) Flux setpoint from rated rotor flux (Default) Better Control at Reduced Load Better Control at Reduced Load Flux setpt smoothing time const (Auto tuned) Flux setpt smoothing time const (Auto tuned) Field weakening time for PI contoller (Default) Field weakening time for PI contoller (Default) Frequency of switch for models (Auto tuned) Frequency of switch for models (Auto tuned) Frequency of switch for models (Default) Frequency of switch for models (Default) PI for counter EMF model (Auto tuned) PI for counter EMF model (Auto tuned) Integral time for counter EMF (Auto tuned) Integral time for counter EMF (Auto tuned) Edge pulse modulator compensate (Default) Edge pulse modulator compensate (Default) Edge pulse modulator compensate (Default) Edge pulse modulator compensate (Default)

14/02/2001 16:29


VIEW PAR. NO.

P338 P338 P339 P339 P340 P340 P342 P342 P344 P344 P347 P347 P348 P349 YES P350 P351 P352 P353 YES P354 P357 YES P360 P360 P360 P360 P360 P360 P360 P360 P360 P360 P360 P360 P360 P360 P360 P360 P360 P360 P360 P360 P360 P360 P360 P360 P360 P360 P360 P360 P360 P360 P360 P360 P360 P360

IND.

PARAMETER DESC.

VALUE(Units)

5 6 1 2 1 2 1 2 1 2 1 2 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34

Common Mode Comp Common Mode Comp ModSystemRelease ModSystemRelease Pulse Frequency Pulse Frequency Max ModulatDepth Max ModulatDepth ModDepth Headroom ModDepth Headroom ON VoltsCompens. ON VoltsCompens. Dead Time Comp T(DeadtimeComp.) Ref Amps Ref Volts Ref Frequency Ref Speed Ref torque Sampling time Select User Parameter Select User Parameter Select User Parameter Select User Parameter Select User Parameter Select User Parameter Select User Parameter Select User Parameter Select User Parameter Select User Parameter Select User Parameter Select User Parameter Select User Parameter Select User Parameter Select User Parameter Select User Parameter Select User Parameter Select User Parameter Select User Parameter Select User Parameter Select User Parameter Select User Parameter Select User Parameter Select User Parameter Select User Parameter Select User Parameter Select User Parameter Select User Parameter Select User Parameter Select User Parameter Select User Parameter Select User Parameter Select User Parameter Select User Parameter

3.00 us 3.00 us 0 0 2.5 kHz 2.5 kHz 96.0% 96.0% 0.0% 0.0% 1.1 V typ 1.1 V typ 0 2.55us 732.0 A 575 V 81.50 Hz 2400 1/min 4934.00Nm 1.2 ms P060 P053 P358 r001 r002 r003 r004 r005 r006 r007 r008 r011 r012 r013 r014 r015 P050 P102 P105 P113 P115 P128 P215 P259 P295 P350 P354 P401 r419 P492 r496 r497 P498 r502


COMMENTS

Edge pulse modulator compensate (Default) Edge pulse modulator compensate (Default) Freq system type to release P338 (Default) Freq system type to release P338 (Default) Drive Carrier Frequency (Default) Drive Carrier Frequency (Default) Max modulation depth of modulator (Default) Max modulation depth of modulator (Default) Modulator headroom depth (Default) Modulator headroom depth (Default) IGBT voltage diff compensation (Auto tuned) IGBT voltage diff compensation (Auto tuned) Select deadtime Comp,0=off (Auto tuned) Gate unit intrlock compens time (Auto tuned) Set to P102 (Motor Rated Current) Set to P101 (Motor Rated Voltage) Motor Nameplate Motor Nameplate Set to P113 (Motor Rated Torque) Base Sampling Time Always select P060 (Menu Access) Always select P053 (Parameter access) Always select P358 (Key unlock parameter) Select Drive Status. Select Rotational Frequency Select Output Volts Select Output Amps Select Output Power Select DC Bus Volts Select Motor Torque Select Motor Utilization Select Active Motor Data Set Select Active BICO Data Set Select Active Function Data Set Select Set Point Speed Select Speed Actual Input Select Language Select Motor Rated Amps Select Motor Rated Power Select Motor Rated Torque Select Motor Calculation (Auto Tune) Select Imax Select max. dn/dt Select Max Regen Power Select Efficiency Optim Select Reference Amps Select Reference Torque Select Fixed Setpoint 1 Select # of Active Fault Setpoints Select FixTorque 1 Set Select Fix Torque 1 Select Actual Upper Torque Limit Select FixTorq 2 Set Select Fix Torque 2

14/02/2001 16:29


VIEW PAR. NO.

IND.

PARAMETER DESC.

VALUE(Units)


35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 1 2 1 2 1 2 3 1 2 1 2 3 1 2 1 2 3 1 2 3

Select User Parameter Select User Parameter Select User Parameter Select User Parameter Select User Parameter Select User Parameter Select User Parameter Select User Parameter Select User Parameter Select User Parameter Select User Parameter Select User Parameter Select User Parameter Select User Parameter Select User Parameter Select User Parameter Select User Parameter Select User Parameter Select User Parameter Select User Parameter OP1s Backlight Select FactSet Select Setp Src Quick Param Ground Flt Test Motor Cooling Motor Cooling Mot ThermT-Const Mot ThermT-Const Fixed Setpoint 1 Fixed Setpoint 1 Fixed Setpoint 1 MOP (max) MOP (min) Src MOP inv. Conf MOP StartValue MOP Src Set MOP Src SetV MOP Src Auto SetP Src Manual/Auto Src AddSetpoint1 Src AddSetpoint1 Scale Add Setpoint Scale Add Setpoint Scale Add Setpoint Src MainSetpoint Src MainSetpoint Scale Main Setp Scale Main Setp Scale Main Setp Base Setpoint Base Setpoint Base Setpoint

r550 r551 r552 r553 P590 P602 P640 P643 P644 r782 r783 r784 r785 r786 r787 r825 r947 r949 P971 U002 0 1 1 0 0 1 1 1800 s 1800 s 0.00% 10.00% 5.00% 100.0% 0.0% 2111 0110 0.0% 0 0 0 0 41 0 100.00% 100.00% 100.00% 3002 58 100.00% 100.00% 100.00% 0.0% 0.0% 0.0%


COMMENTS

Select Control Word 1 Select Control Word 2 Select Status Word 1 Select Status Word 2 Select Src BICO Dset Select Excitation time Select Src Analog Out Select CU AnalogOutGain Select CU- AnalogOutOff Select Last 8 Fault Trip Times Select n/f actual (r218) at time of last trip Select n/f actual/second at time of last trip Select actual torque current at time of trip Select actual converter out V at time of trip Select Control Status at time of trip Select Operating Hours (Inverter Pulsing) Select Last 8 Faults Select Last 8 Fault Values Select EEPROM Saving Select Fixed Setpt 18 (Meter Torque Scaling) 0= Always On Select Factory Setting (Default) Analog Input & Terminal Strip (Default) P370=1 Will Factory DEFAULT Parameters!!!! Blocked (Default) 1 = Forced Vent 1 = Forced Vent Max Time Allowed in Stall = 30 min. Max Time Allowed in Stall = 30 min. Additional Drill Speed Spin Speed Set to 10% of Rated Speed Torque Speed Set to 5% of Rated Speed Upper Limit of OP1S (Default) Lower Limit of OP1S (Default) BICO for Direction Change on OP1S Configuration of MOP MOP Starting Value BICO Source for MOP Use (Default) BICO Source for MOP Set Value (Default) BICO Source for MOP Auto Setpt (Default) BICO Source for Manual/Auto Switching BICO to Set Spin, Torque, and Speed BICO to Set Spin, Torque, and Speed Gain for Additional Setpoint 1 (Default) Gain for Additional Setpoint 1 (Default) Gain for Additional Setpoint 1 (Default) BICO for Main Setpoint BICO for Main Setpoint Scaling factor for Main Setpoint (Default) Scaling factor for Main Setpoint (Default) Scaling factor for Main Setpoint (Default) Basic Setpoint (Added to Main Setpoint)(Def) Basic Setpoint (Added to Main Setpoint)(Def) Basic Setpoint (Added to Main Setpoint)(Def)

14/02/2001 16:29


VIEW PAR. NO.

IND.

PARAMETER DESC.

VALUE(Units)


1 2 3 1 2 3 1 2 3 1 2 3 1 2 3 1 2 3 1 2 3 1 2 1 2 3 1 2 3 1 2 3 1 2 1 2 3 1 2 1 2 3 1 2 3 1 2 1 2

Jog Setp 1 Jog Setp 2 n/f(max, FWD Spd) n/f(max, FWD Spd) n/f(max, FWD Spd) n/f(max,REV Spd) n/f(max,REV Spd) n/f(max,REV Spd) Min setp Min setp Min setp Accel. Time Accel. Time Accel. Time Accel. Time Unit Accel. Time Unit Accel. Time Unit Decel. Time Decel. Time Decel. Time Decel. Time Unit Decel. Time Unit Decel. Time Unit Decel. Time OFF3 Decel. Time OFF3 ProtRampGen Gain ProtRampGen Gain ProtRampGen Gain Rgen Round Type Ramp StartSmooth Ramp StartSmooth Ramp StartSmooth Ramp End Smooth Ramp End Smooth Ramp End Smooth Scale Torq (PRE) Scale Torq (PRE) Ramp Limitation RampGen Act Hyst FixTorque 1 Set FixTorque 1 Set FixTorque 1 Set Src Fixtorque 1 Src Fixtorque 1 FixTorque 1 Gain FixTorque 1 Gain FixTorque 1 Gain FixTorque 2 Set FixTorque 2 Set FixTorque 2 Set Src FixTorque 2 Src FixTorque 2 Scale TorqLim2 Scale TorqLim2

10.00% 20.00% 100.0% 100.0% 100.0% -50.00% -50.00% -50.00% 0.0% 0.0% 0.0% 5.0 5.0 5.0 0 0 0 2 2 2 0 0 0 2.0 s 0.0 s 2.9 typ 1.0 1.0 0 0.50 s 0.50 s 0.50 s 0.50 s 0.50 s 0.50 s 100.0% 100.0% 0.0% 1.0% 100.0% 10.0% 133.0% 3003 170 100.00% 100.00% 100.00% -100.00% -10.00% -200.00% 3005 171 100.00% 100.00%


COMMENTS

Jogging Setpoint 1 (Default) Jogging Setpoint 2 (Default) Max Setpoint for CW (Forward) Rotating Field Max Setpoint for CW (Forward) Rotating Field Max Setpoint for CW (Forward) Rotating Field Max Setpoint for CCW(Reverse) Rotating Field Max Setpoint for CCW(Reverse) Rotating Field Max Setpoint for CCW(Reverse) Rotating Field Minimum Setpoint of the Drive (Default) Minimum Setpoint of the Drive (Default) Minimum Setpoint of the Drive (Default) Acceleration Time (P463) From 0 to 100% Acceleration Time (P463) From 0 to 100% Acceleration Time (P463) From 0 to 100% 0 = Seconds 0 = Seconds 0 = Seconds Deceleration Time (P465) From 100 to 0% Deceleration Time (P465) From 100 to 0% Deceleration Time (P465) From 100 to 0% 0 = Seconds 0 = Seconds 0 = Seconds Keypad "quickstop" from 100% to standstill Keypad "quickstop" from 100% to standstill Acceleration Time (P462) Gain Factor(AutoTn) Acceleration Time (P462) Gain Factor (Def) Acceleration Time (P462) Gain Factor (Def) Mode for Ramp Function Rounding (Default) Initial Rounding Up Time for Ramp Func (Def) Initial Rounding Up Time for Ramp Func (Def) Initial Rounding Up Time for Ramp Func (Def) Final Rounding Up Time for Ramp Func (Def) Final Rounding Up Time for Ramp Func (Def) Final Rounding Up Time for Ramp Func (Def) Gain of the n/f controller precontrol (Default) Gain of the n/f controller precontrol (Default) "0.0" Deactivates Ramp-Func Tracking (Def) Hysteresis for "Rmp-Func Gen Active" msg. Forward Maximum Drill Torque Forward Spin Torque Maximum Make-up Torque (Forward) BICO Source for Upper Torque Limitation BICO Source for Upper Torque Limitation Scaling Factor for Upper Torque Limitation Scaling Factor for Upper Torque Limitation Scaling Factor for Upper Torque Limitation Reverse Maximum Drill Torque Reverse Spin Torque Maximum Breakout Torque (Reverse) BICO Source for Lower Torque Limit BICO Source for Lower Torque Limit Scaling Factor for Lower Torque Limit (Def) Scaling Factor for Lower Torque Limit (Def)

14/02/2001 16:29


VIEW PAR. NO.

IND.

PARAMETER DESC.

VALUE(Units)


3 1 2 1 2 1 2 1 2 1 2 1 2 1 2 1 2 1 2 1 2 1 2 1 2 1 2 1 2 1 2 1 2 1 2 1 2 1 2 1 2 1 2 1 2 1 2 1 2 1 2 1 2 1

Scale TorqLim2 SIMO Sound SIMO Sound n/f RegDyn (set) n/f RegDyn (set) n/f RegDyn (act) n/f RegDyn (act) Src ON/OFF1 Src ON/OFF1 Src1 OFF2 (Coast) Src1 OFF2 (Coast) Src2 OFF2 (Coast) Src2 OFF2 (Coast) Src3 OFF2 (Coast) Src3 OFF2 (Coast) Src1 OFF3 (Qstop) Src1 OFF3 (Qstop) Src2 OFF3 (Qstop) Src2 OFF3 (Qstop) Src3 OFF3 (Qstop) Src3 OFF3 (Qstop) Src InvRelease Src InvRelease Src RampGen Rel Src RampGen Rel Src RampGen Stop Src RampGen Stop Src Setp Release Src Setp Release Src1 Fault Reset Src1 Fault Reset Src2 Fault Reset Src2 Fault Reset Src3 Fault Reset Src3 Fault Reset Src Jog Bit0 Src Jog Bit0 Src Jog Bit1 Src Jog Bit1 Src FWD Speed Src FWD Speed Src REV Speed Src REV Speed Src MOP UP Src MOP UP Src MOP Down Src MOP Down Src No ExtFault1 Src No ExtFault1 Src FuncDSet Bit0 Src FuncDSet Bit0 Src FuncDSet Bit1 Src FuncDSet Bit1 Src MotSSet Bit0

100.00% 1 1 50% 50% 50% typ 49% typ 3100 2100 22 22 1 1 1 1 2102 2102 1 1 1 1 1 1 1 1 1 1 1 1 18 18 3107 0 2107 2107 3108 2108 0 0 3111 2111 3112 2112 2113 2113 2114 2114 20 20 3400 0 3401 0 3402


COMMENTS

Scaling Factor for Lower Torque Limit (Def) Adjusts Noise Spectrum of Machine Adjusts Noise Spectrum of Machine Dynamic Response of n Control Circuit (Def) Dynamic Response of n Control Circuit (Def) P536 Adjustment After P115=5 (Auto Tuned) P536 Adjustment After P115=5 (Auto Tuned) Drive ON/OFF Command,P590=0 (PLC Cntrl) Drive ON/OFF Command,P590=1 (OP1S Ctrl) Drive OFF Command From E-STOP (Coast) Drive OFF Command From E-STOP (Coast) 2nd BICO Source for OFF (Coast Stop)(Def) 2nd BICO Source for OFF (Coast Stop)(Def) 3rd BICO Source for OFF (Coast Stop)(Def) 3rd BICO Source for OFF (Coast Stop)(Def) Drive OFF Command From OP1S (Qck Stop) Drive OFF Command From OP1S (Qck Stop) 2nd BICO Source for OFF (Quick Stop)(Def) 2nd BICO Source for OFF (Quick Stop)(Def) 3rd BICO Source for OFF (Quick Stop)(Def) 3rd BICO Source for OFF (Quick Stop)(Def) BICO Source for Releasing Inverter (Def) BICO Source for Releasing Inverter (Def) BICO Source for Releasing Ramp Gen (Def) BICO Source for Releasing Ramp Gen (Def) BICO Source for Starting Ramp Gen (Def) BICO Source for Starting Ramp Gen (Def) BICO for Releasing Setpoint (cw1,bit 1)(Def) BICO for Releasing Setpoint (cw1,bit 1)(Def) Digital In 5 (Not used) Digital In 5 (Not used) AutoReset Drive From PLC Reset Drive From OP1S Keypad Reset Drive From OP1S Keypad Reset Drive From OP1S Keypad Jog from Bit 8, Control Word 1 Jog from OP1S Keypad BICO Src to Jog ( Sets Bit 9, cw1)(Not Used) BICO Src to Jog ( Sets Bit 9, cw1)(Not Used) BICO Source to Command Fwd Rotation(PLC) BICO Source to Command Fwd Rot (Keypad) BICO Source to Command Rev Rotation (PLC) BICO Source to Command Rev Rot (Keypad) BICO Source to Increase MOP (Not Used) BICO Source to Increase MOP (Keypad) BICO Source to Decrease MOP (Not Used) BICO Source to Decrease MOP (Keypad) BICO Source for External Fault 1 BICO Source for External Fault 1 BICO Src for Func Data Set (cw2,bit16) BICO Src for Func Data Set (cw2,bit16)(Def) BICO Src for Func Data Set (cw2,bit17) BICO Src for Func Data Set (cw2,bit17)(Def) BICO Src for Motor Data Set (cw2,bit 18)

14/02/2001 16:29


VIEW PAR. NO.

IND.

PARAMETER DESC.

VALUE(Units)

P578 P579 P579 P590 P602 P602 P603 P603 P640 P640 P643 P643 P644 P644 P652 P652 P722 P722 P734 P734 P734 P734 P734 P734 P952 P970 P971 U001 U001 U001 U002 U002 U002 U107 U107 U108 U108 U117 U118 U119 U120 U121 U122 U950 U950 U950 U951 U951 U952

2 1 2 1 2 1 2 1 2 1 2 1 2 1 2 1 2 1 2 3 4 5 6 1 2 3 1 2 3 1 2 1 2 031 032 075 004 059 047

Src MotSSet Bit0 Src MotSSet Bit1 Src MotSSet Bit1 Src BICO Dset Excitation Time Excitation Time De-MagnetizeTime De-MagnetizeTime Src AnaOut Src AnaOut CU AnalogOutGain CU AnalogOutGain CU--AnalogOutOFF CU--AnalogOutOFF Src DigOut2 Src DigOut2 CB/TB TlgOFF CB/TB TlgOFF SrcCB/TBTrnsData SrcCB/TBTrnsData SrcCB/TBTrnsData SrcCB/TBTrnsData SrcCB/TBTrnsData SrcCB/TBTrnsData # of Faults Factory Setting EEPROM Saving FixSetp 17 FixSetp 17 FixSetp 17 fixSetp 18 fixSetp 18 fixSetp 18 Src Conn Mult1 Src Conn Mult1 Src Conn Mult2 Src Conn Mult2 Src ConnAbsV1 Mode ConnAbsV1 SmoothConAbsV1 Src ConnAbsV2 Mode ConnAbsV2 SmoothConAbsV2 Sampling Times1 Sampling Times1 Sampling Times1 Sampling Times2 Sampling Times2 Sampling Times3

3402 0 0 0 0.20 s 0.20 s 3.00 s 3.00 s 148 24 10.00 V 10.00 V 0.00 V 0.00 V 122 122 10 ms 10 ms 32 467 33 468 170 250 7 1 0 95.00% 95.00% 95.00% 62.58% 62.58% 62.58% 491 401 492 402 148 1 0 ms 24 1 0 ms 2 2 2 2 2 2


COMMENTS

BICO Src for Motor Data Set (cw2,bit 18) BICO Src for Motor Data Set (cw2,bit 19)(Def) BICO Src for Motor Data Set (cw2,bit 19)(Def) Set PLC or OP1S Control (0=PLC) Wait Time Before Releasing Frequency Wait Time Before Releasing Frequency Time to DE-excite Motor (Auto Tuned) Time to DE-excite Motor (Auto Tuned) BICO for Analog 1 Out (Speed) BICO for Analog 1 Out (Torque) Porportional Gain for Analog Outputs (Def) Porportional Gain for Analog Outputs (Def) Offset Voltage for P643 Analog Outs (Def) Offset Voltage for P643 Analog Outs (Def) Undervoltage Fault (Status Word 1, Bit 11) Undervoltage Fault (Status Word 1, Bit 11) Fault if No Communication for 10 ms (Def) Fault if No Communication for 10 ms (Def) Status Word 1(To PLC) Speed to Meter (To PLC) Status Word 2 (To PLC) Torque to Meter (To PLC) Spin Torque (To PLC) Fault Number (To PLC) Number of Stored Fault Trips P970=0 Will Factory DEFAULT Parameters!!!! Save Parameters(Ram To EEPROM)(P971=1) RPM Scaling (For VDC Meter) RPM Scaling (For VDC Meter) RPM Scaling (For VDC Meter) Torque Scaling (For VDC Meter) Torque Scaling (For VDC Meter) Torque Scaling (For VDC Meter) Multipliers for RPM Meter Multipliers for RPM Meter Multipliers for Torque Meter Multipliers for Torque Meter BICO Source for 1st Abs Value Generator Mode Sel for Ist Abs Value Gen (1=| Signal |) Smoothing Time Const for 1st Abs Val Gen BICO Source for 2nd Abs Value Generator Mode Sel for 2nd Abs Value Gen (1=| Signal |) Smoothing Time Const for 2nd Abs Val Gen Sampling time Sampling time Sampling time Sampling time Sampling time Sampling time

14/02/2001 16:29


TDS-11S

PAR. NO.

P050 P051 P052 P053 P054 P071 P074 P075 P076 P077 P090 P091 P140 P141 P144 P160 P310 P311 P312 P313 P314 P315 P316 P317 P318 P319 P320 P329 P353 P354 P366 P368 P408 P409 P486 P517 P518 P554 P555 P556 P557 P561 P565 P566 P567 P568 P569 P571 P575 P578

SIEMENS SERIES 70 DRIVE LISTING OF RECTIFIER PARAMETERS IND.

0 0 0 0 0 0 0 0 0 0 0 0 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 0 0 0 0 1 0 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1

PARAMETER DESC.

Language Access Level Function Select Parameter Access Display Light Line Volts Limit LowVoltage Rtd Amps Config. Pcircuit Factory Set type Board Position 2 Board Position 3 Rectifier Resistance Rectifier Inductance DC Bus Capacitance Motor Current Limit DC Current Reg Gain DC Current Reg Time DC Cur Reg CWord DC Volts Reg Gain DC Volts Reg Time DC Volts Reg CWord DC V-Reg +Limit DC V-Reg -Limit DC V(Set,red) DC V(Set,red)Hys Smooth Load Amps Pre Charge Time Thyristor Test Ground Flt Test Auto Restart Time DC Bus Volts Caps Forming Time Contactor Delay Src Current Setup DC Volts Dev Limit Deviation Time Src ON/OFF1 Src1 OFF2(coast) Src2 OFF2(coast) Src3 OFF2(coast) Src InvRelease Src1 Fault Reset Src2 Fault Reset Src3 Fault Reset Src Jog1 ON Src Jog2 ON Src Reduce DC V Src No ExtFault1 Src RDataSet Bit0


VALUE(Units)

1 3 0 6 0 575.0 V 61 1023 1 0 0 0 0.007 0.21 32.22 150 0.15 0.015 2111 8.8 3 0010 0.01 -1.00 95.00 6.00 5.00 500 0 2 2 6.1 10 0 0 2 0.1 1001 0001 0001 0001 1003 1004 0000H 2001 0000H 0000H 0001 0001 0000H

COMMENTS

Set DC Bus to 780V

Restart After Power Recovery

Used To Reduce DC Bus Via P318

14/02/2001 16:29


PAR. NO.


IND.

1 1 1 1 1 0 0 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 0 0 0 0 1 1 1 1 1 1 1 1 0 1 1 1 1 1 0 1 1 1 0 0 0 0 0

PARAMETER DESC.

Src RDataSet Bit1 Src No ExtFault2 Src Master/Slave Src No Ext Warn1 Src No Ext Warn2 Src Base/Reserve Src ContactorMsg Trg Bit Ready ON Trg Bit Ready Operator Trg Bit Oper Trg Bit Fault Trg Bit No OFF2 Trg Bit On blocked Trg Bit Warning Trg Regen Ready Trg Low Voltage Trg Low Voltage Trg Bit Contact Trg DC V reduced Trg Current Lim. Trg Bit Ext Flt1 Trg Bit Ext Flt2 Trg Bit Ext Warn Trg Bit i2tInv Trg Bit Flt Tmp Inv TrgBitWarTmpInv Trig Bit Charging CUR AnaOutActVal CUR AnaOut Gain CUR AnaOut Offset AnaOut Conf Curr SCI AnaLogInConf SCI AnaInSmooth SCI AnaLogInOffs SCI AnaOutActVal SCI AnaOut Gain SCI AnaOut Offs SCom1 Act Value SCom2 Act Value SCB Protocol SCom/SCB BusAddr SCom/SCB Baud SCom/SCB PCV SCOM/SCB # PrDat SCom/SCB TlgOFF SCom2 Protocol SCB Peer2PeerExt SCB Act Values CB/TB Act Values CB/TB Tlg Off Time CB Parameter 1 CB Parameter 2 CB Parameter 3 CB Parameter 4


VALUE(Units)

COMMENTS

0000H 0001H 0000H 0001H 0001H 0000H 0001H 0000H 0000H 0000H 1001 0 0 1002 0 0 0 0 0 0 0 0 0000H 0000H 0000H 0000H 0000H 37 10.00 0.00 0 0 2 0 0 10 0 968 968 0 0 6 127 2 0 ms 1 0 0 968 20ms 0 0 0 0

14/02/2001 16:29


PAR. NO.

P700 P701 P702 P703 P704 P705 P772 P773 P775 P776 P777 P778 P779 P780 P785 P788 P793 P799 P917 P918 P928 P971

IND.

0 0 0 0 0 0 1 1 1 1 1 1 0 1 0 1 0 0 0 0 0 0

PARAMETER DESC.

CB Parameter 5 CB Parameter 6 CB Parameter 7 CB Parameter 8 CB Parameter 9 CB Parameter 10 Thyr Voltg Corr Deadband Convert Min Gating Angle Max Gating Angle Max Gat Ang Ramp Line FrquFiltTime Phase Shift Corr Fault Masking I2T Control Word RAM Access Addr Line Voltg Delay Special Access Change Reports CB Bus Address Src Base/Reserve EEPROM Storing


VALUE(Units)

COMMENTS

0 0 0 0 0 0 0 0.01 0 150 20 200 0.8 0 1 0 0.03 4 0 3 0000H 0

14/02/2001 16:29


TDS Training Manual



Encoder Troubleshooting

AC Electrical

Encoder Troubleshooting Instructions CUVC Card Version

The encoder is used to provide rotational position information to the Variable Frequency Drive (VFD). On the AC TDS systems, the encoder signal comes into the Varco Interface Terminal Strip (TB1 Drive on drawing) in the drive. The +I5VDC for the encoder is provided from the CUVC card and goes out on terminal 31 (Common) and terminal 32 (+15VDC). The AC Top Drives use a differential input signal and on the Siemens drive an optional Digital Tach. Interface board to convert this differential signal (A+,A- and B+,B-) to a single ended signal (A+ and B+). The (A+) signal comes into terminal 34, the (A-) signal is 35, the (B+) signal is 37 and the (B-) signal is 38. This can be verified on the schematics. The waveforms for the respective signals are shown above. The symptom of encoder failure is that the drive when assigned and throttle given will refuse to rotate or rotate very slowly, with high Torque showing on the Torque meter. You probably will not see a failure indication on the drive, or it may trip out due to over-current. If you suspect the encoder change the drive from speed control (n) to frequency control (f) by using the encoder bypass switch. If the AC TDS starts rotating you have an encoder problem. If it does not verify that you have performed the changeover from speed control to frequency control correctly by viewing the motor data set in the VFD (parameter r011, 1=n speed control, 2 =f frequency control) and then try again. If it still does not turn you should look at the inputs to the drive and not the encoder. The first check of the encoder should be measurement of the signals with a voltmeter this should be done with the drive stopped. There should be approximately 15V between

terminals 31 and 32 (+15DCV and Common) if there is not disconnect the encoder cable, to see if it is being shortened out. There should be approximately 15V between pins 34 and 35 (A+ and A-) and between terminals 37 and 38 (B+ and B-) if there is not and you have a scope check the individual signals to see which one or ones are missing this will require you to run the AC TDS in the frequency mode. If you are missing a signal remember that on the Siemens drive you can rewire the signals so that they do not pass through the DTI card to keep running. If (A+) and (B+) are both good disconnect the (A+) and (B+) signals from the DTI card at terminals X403 and X402. You can then connect (A+) to (A+) and (B+) to the (B+) wire straight across, be sure to do the same with both the (+15VDC) and both the (Common) signals as well. If you still can not get the top drive to turn and you have signals that are 90 degrees from each other (See A+ and B+ above) try reversing the (A+) and (B+) wires. Encoder Fuse There is a "fuse" in line with the (+15VDC), if too much current is drawn the fuse opens. This thermal fuse is self resetting after it cools. With a short on one of the outputs, the driver sources too much current “opening” the fuse. When power is removed the fuse will reset after a short period of time, and upon application of power the signals will come back. If it appears that you have no output from the encoder disconnect the encoder cable then reconnect after a few minutes. Cable Testing A common fault with the encoder is a broken or a shorted cable in the encoder loop, this can be checked by disconnecting the encoder cable at the Top Drive end and also at the Varco control house end, the cables should then be checked for continuity and also tested between cores for possible shorts. A common problem is that the Top drive will fault at the same place in the derrick this is good way of telling there is a problem with the service loop.

Waveforms

The above picture shows a scoped waveform from a rotating Top Drive, this is what would be expected to see when looking at both the (A+) and (B+) signals together with an oscilloscope. If the Top drive was drilling ahead when checking the signals you could expect to see the widths of the waveforms constantly changing, this would be because when the Top Drive experiences “down-hole Torque”, it would momentarily slow down (remember that the encoder sends out 1024 pulses per revolution of both the motor and encoder). What should be noted from these waveforms is that the small “spikes” at the edges of the waves are not a problem because the signal is a digital signal, only when the “spike” was in the middle of the waveform would there be a possibility that this would be a problem, but it would be expected that the DTI card would rectify that problem.

DTI Schematic

EEx Digital Encoder

Varco P/N = 122725 The Eex Digital Encoder used on the AC Top Drive, has a four channel output (A+,A-,B+,B-) with 90° Displacement at 1024 pulses per Revolution.

TDS Training Manual



Simovis Version 5

AC Electrical

Table of Contents Section 1 Section 2 Section 3 Section 4 Section 5 Section 6 Section 7 -

Introduction (page 3) Configuration of Control Card (page 4) UPREAD from the AC DRIVE to a PC (page 6) Viewing the UPREAD parameters (page 8) DOWNLOADING from a PC to the AC DRIVE (page 10) Examination (page 12) Examination Answers(page 13)

2

Section 1 - Introduction SIMOVIS Version – 5, is for use with the Siemens 70 Series Drive, by using the SIMOVIS PC program, you can UPREAD parameter sets from the units, store them on the hard disk or on floppy disks and transfer them back to the units by DOWNLOAD. You have the additional possibility of editing the parameters off-line and of creating parameter files especially for your application. These files do not have to contain the complete parameter scope. They can be limited to parameters, which are relevant for the particular application. This module is mainly aimed at the newer Vector Control Card the CUVC, but the same method is used for Upreading and Downloading parameters to a CU2 card, the communication differences are explained in Section 2. This section is split into four parts, they are Configuration of Control Card, UPREAD, View an UPREAD set and DOWNLOAD. Section 2 – Configuration of Control Card This part shows how to configure the type of control card that is inserted in the Siemens 70 Series drive. For this section we are using a CUVC card, but if the card that was to be configured the Section 3 – UPREAD a parameter set This part shows how to UPREAD a complete parameter set from the AC Drive to a PC. Section 4 – View an UPREAD parameter set. The second part of this section shows how to view an upread set of parameters once it has been upread from the AC Drive and stored to disk. Section 5 – DOWNLOAD a parameter set The third part of this section shows how to DOWNLOAD a complete parameter set into the AC Drive from a PC and how to check for errors.

3

Section 2 - Configuration of Control Card To get ONLINE with SIMOVIS, firstly ensure that the cable (RS 232) is inserted into the PMU and “Com Port 1” on the PC. Details on this cable can be found in the SIMOVIS “Readme” file. The Siemens Part Number for the cable is:- 6SX7005-0AB00

Above is the first window that is viewed when SIMOVIS is opened from the Desktop of your PC. To configure a Drive you click on the “Blue Cross”.

This brings up the “Add a drive” screen, to set up for the CUVC card with software version 3.1, click on the down arrows at “Drive type” and “SW-version”, and select the type and version as above, then click on “OK”. For this section we are using a CUVC card, but if the card that was to be configured was a CU2 card, this would be selected from the list and would be “MASTERDRIVES VC(CU2).

4

The Drive Type, Software, etc. is then displayed under Bus Address 0, other Drive types could be configured to different Bus Addresses, this would be done in “Add a Drive”. To communicate with the Drive, double click on the blue highlighted bar for the CUVC card.

This then communicates with the Drive and all the present value of the parameters are displayed down the right hand side of the screen, the top of the screen displaying “Online (EEPROM) identifies this. The Drive status is also displayed in the bottom left of the screen, in this case the drive shows a green “OK” which means there is no faults or alarms on the drive at present, but if there was a fault, it would then display a red “F” here. If you cannot get ONLINE, check the cable connection or the “Drive type” and then try again.

5

Section 3 - UPREAD from the AC DRIVE to a PC

To UPREAD all the parameters from the Drive, Select “Upread” then “Base unit all” from “File”, as shown above.

The program then automatically defaults to save the parameter set to the “Masterdives VC(CUVC)” folder in SIMOVIS, this can be changed to another folder on the hard drive (c) or to a floppy disk (a), by clicking on the down arrow next to “Masterdives VC(CUVC)” and then selecting the required option. It is best when saving to the hard drive (c), to save to the SIMOVIS default, as it will also automatically default to this when “DOWNLOAD” is selected. At this stage the parameter set that is to be Upread from the AC Drive requires a name, for this example “Test” is to be used, this should be written into the “File name” box. Once the folder has been chosen and the parameter set has been given a name, click on “Save” to start Upreading the parameter set.

6

When the “UPREAD” has started, the above dialog box will be displayed, this shows that SIMOVIS is Upreading the parameters and saving them as “TEST” (top of box), it also displays the amount of parameters to be upread (in this case 1030), how many have been upread (in this case 37), how many have been upread successfully (OK) and how many have not been upread successfully (E). This function can be aborted by clicking on “Cancel”.

If the upread has been completed successfully, this will be displayed by a dialog box as above, if there has been a problem, it will show a dialog box with the details of the problem parameters (this will be shown later in the DOWNLOAD section). To proceed, click on “OK”.

7

Section 4 - Viewing the UPREAD parameters

To view the Upread parameters, you have to change to the “OFFLINE” mode. To do this, select “Offline” from the “View”, as shown above.

This will then display either “File New” (factory parameter set), or “File Open” (Open a previously saved parameter set). Choose and click on “File Open” as above, because you want to open your previously saved parameter set (TEST).

8

The “Open parameter set” dialog box then appears; this is asking you what parameter set you require to open. The above dialog box shows three options, TDS11S(CUVC), Test or Train CUVC. To open the “Test” parameter set, click on “Test” as shown above, this is then shown in the “File name” box, finally click on “Open”, thus opening “Test”.

The parameter set “Test” is then viewed in the Offline mode as shown at the top of the screen as “offline (Test)” with all the parameters shown down the right hand side of the screen. The “Drive status” in the bottom left of the screen is now shown as a blue “O”, to signify that the drive is Offline. Note you do not have to be connected to the drive to view parameter sets in the Offline mode.

9

Section 5 - DOWNLOADING from PC to the AC DRIVE

To Download a parameter set from a PC to the Siemens 70 Series Drive, you have to be Online with the drive, and in the Online Status, this was previously shown in the Upread part. Once SIMOVIS is successfully Online with the Drive, select “Download” and then “Save (EEPROM)”, from “File” as shown above. It is best to save to EEPROM, as the parameters are permanently stored into the Drive.

The “Open parameter set” dialog box appears which again automatically defaults to “Masterdrives VC (CUVC)”, from this the previously saved program to be downloaded can be selected. Shown above is “Test” set to be Downloaded, to do this click on “Test”, this is then shown in the “File name” box, then click on “Open”, this opens the parameter set to be downloaded, and starts the downloading process.

10

The dialog box “Download” appears as above, this shows at the top of the box, the parameter set that is being downloaded, in this case “Test”. Also shown is the number of parameters that are to be Downloaded in this case 829, the number of parameters that have been downloaded in this case 15 and the number of parameters that have been successfully Downloaded (OK) or not successfully downloaded (E). This process can be aborted by clicking on “Cancel”. When the Download is in process the drive will automatically default to download status 21, this should be viewed on the PMU.

A dialog box will then be displayed explaining how many parameters have been written and refused, in the case above from 829 parameters, 828 were written successfully and 1 was refused, the parameters that were refused can be looked at by clicking on “Details”. If no parameters were refused only the “OK” box would be available.

If the “Details” box was selected in the previous dialog box, the “Error” dialog box will be displayed as above, with the parameters that SIMOVIS was not able to Write to the drive. In this case only one parameter was refused 368, this would have to be checked and then manually changed by either the PMU, OP1S or SIMOVIS. Clicking on “OK” returns you to the Online screen where all the parameters that have been downloaded can now be viewed.

11

Section 6 – Examination 1. What type of cable is used to communicate a PC to a Siemens 70 Series drive? ___________________________________________________________________ ___________________________________________________________________ 2. What two type of Siemens 70 Series Drive control cards has Varco used to control its AC Top Drives and Pipe Racking Systems? ___________________________________________________________________ ___________________________________________________________________ 3. What is the difference between UPREAD and DOWNLOAD when using SIMOVIS version 5? ___________________________________________________________________ ___________________________________________________________________

4. What type of files are used to store the parameter sets in SIMOVIS version 5? ___________________________________________________________________ ___________________________________________________________________ 5. If the Drive Status is shown as a Blue “O”, what does this mean? ___________________________________________________________________ ___________________________________________________________________ 6. If the Drive Status is shown as a Red “F”, what does this mean? ___________________________________________________________________ ___________________________________________________________________ 7. What is the difference between a “P” type parameter and an “r” type parameter? ___________________________________________________________________ ___________________________________________________________________ 8. Can Parameters be changed in the AC Drive through SIMOVIS when the PC is connected to the AC Drive? ___________________________________________________________________ ___________________________________________________________________

12

Section 7 – Examination Answers 1) What type of cable is used to communicate a PC to a Siemens 70 Series drive? An RS232 cable is used to communicate a PC to a Siemens 70 Series Drive. 2) What two type of Siemens 70 Series Drive control cards has Varco used to control its AC Top Drives and Pipe Racking Systems? Varco use either a CU2 or a CUVC card to control the Siemens 70 Series drives in their equipment. 3) What is the difference between UPREAD and DOWNLOAD when using SIMOVIS version 5? UPREAD is used to transfer parameters from the AC drive to a PC, DOWNLOAD is used to transfer parameters from a PC to the AC drive. 4) What type of files are used to store the parameter sets in SIMOVIS version 5? The File type that is used to store parameters in SIMOVIS version 5 is Download files (*.DNL). 5) If the Drive Status is shown as a Blue “O”, what does this mean? This signifies that the AC drive is OFFLINE from the PC and the parameter set displayed is from an internal file in the PC and not from the AC drive. 6) If the Drive Status is shown as a Red “F”, what does this mean? This signifies that the AC drive is ONLINE and communicating with the PC satisfactory, but there is a fault at present with the AC drive. 7) What is the difference between a “P” type parameter and an “r” type parameter? A “P” type parameter is an operator changeable parameter that can be changed to alter the control of the AC drive. An “r” type parameter is a read only parameter, this can only be viewed to gain information about the AC drive. 8) Can Parameters be changed in the AC Drive through SIMOVIS when the PC is connected to the AC Drive? Yes, parameters can be changed in the AC drive when the PC is connected and ONLINE, care should be taken NOT to change parameters unnecessarily.

13

TOP DRIVE

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