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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
Varcos 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.

Varcos 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 Drillers
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 Drillers 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

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.

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.

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.

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.

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.

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.

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 operators 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.

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

Varco Technical Education Center


Montrose Scotland

AC TOP DRIVE
Section 1

General Information

AC Electrical

General Information

How to use this manual ...................................... 1-2


Identification numbers ....................................... 1-3

Lifting points ....................................................... 1-4


Safety wiring ....................................................... 1-5
Torque values ..................................................... 1-6

Basic useage ...................................................... 1-7


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

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

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

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

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

TDS-11SA

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

409

452

29400

306

339

29400

608

672

38600

456

504

38600

1 1/8

760

840

42300

570

630

42300

1 1/4

1064

1176

53800

798

882

53800

1 3/8

1387

1533

64100

1040

1150

64100

1 1/2

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

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

 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

16781

See page 7-14

Stabilizer, Front

118368

See page 7-15

Stabilizer, Rear

118367

See page 7-15

Flippers, Stabbing Guide

76442

See page 7-15

Wash Pipe

123289

See page 6-11

Wash Pipe (Tungsten Coated)

123289-TC

See page 6-11

Wash Pipe Packing Kit, 3" Standard


(Use with Wash Pipe 123289 or 123289-TC)

123290-PK

See page 6-11

Wash Pipe Packing Kit, 3" High Pressure


(Use with Wash Pipe 123289-TC only)

123290-PK-1

See page 6-11

Hydraulic Oil Filter

114416-1

See page 4-30

Gear Oil Filter

111013-1

See page 4-32

Hydraulic Oil Filter

Wash Pipe

Gear Oil Filter

Stabilizers

Tong Dies

Stabbing Guide

1-10

Varco Systems

TDS Training Manual

Varco Technical Education Center


Montrose Scotland

AC TOP DRIVE
Section 2

Specifications

AC Electrical

Specifications

Specifications

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


1

General specifications ....................................... 2-4


Typical mast interface ....................................... 2-5

22

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)

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)

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

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 IBOPs 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)*

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 Drillers 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

Varco Technical Education Center


Montrose Scotland

AC TOP DRIVE
Section 3

Lubrication and Maintenance

AC Electrical

Lubrication and
Maintenance

Transmission ...................................................... 3-2


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

Lubrication schedule ..................................................... 3-2


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

Lubrication schedule ..................................................... 3-5


Recommended hydraulic fluid ....................................... 3-6
Hydraulic lubrication ...................................................... 3-7

Motors ................................................................. 3-8


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

General purpose lubrication ............................... 3-10


Lubrication schedule ..................................................... 3-10
Recommended lubricants .............................................. 3-11

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

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:

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

Viscosity Index
AGMA
ISO Viscosity Grade

Oils of insufficient viscosity can damage gears by allowing


metal to metal contact.

For minimum temperatures below 20F, 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 20F. If drilling conditions dictate oil temperatures below 20F,
consult Varco service center.
If the oil temperature rises above 200F, Varco recommends shutting
down or reducing drilling loads to stabilize the oil temperature below
200F If drilling conditions dictate oil temperatures above 200F,
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

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

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 Filter

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

No. of Points

Frequency

Type

Lubricate the AC Drilling Motor

1 x every 3 Months

Motor Grease

Lubricate the Blower Motor

1 x every 3 Months

Motor Grease

Lubricate the Hydraulic Pump Motor

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)

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

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

Daily

General Purpose Grease

Upper Bonnet Seal

Weekly

General Purpose Grease

Bail Pins

Weekly

General Purpose Grease

Rotating Link Adapter Gear

Weekly

General Purpose Grease

Rotating Link Adapter

Weekly

General Purpose Grease

IBOP Actuator Yoke, Cylinder Pins

Daily

General Purpose Grease

IBOP Actuator Cranks

Daily

General Purpose Grease

Upper IBOP Valve

Weekly

General Purpose Grease

Stabilizer Bushing

Daily

General Purpose Grease

Clamp Cylinder Gate

Daily

General Purpose Grease

Carriage Assembly

Weekly

General Purpose Grease

Torque Arrestor at Clamp Cylinder

Weekly

General Purpose Grease

Wireline Adapter

Weekly

General Purpose Grease

Elevator Link Eyes

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

Exxon
Gulf

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.

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

General purpose lubrication


General lubrication

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

Daily

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

General purpose lubrication


General lubrication

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

Weekly
Rollers
One pump each
(if equipped)

Weekly
Rollers
One pump each
(if equipped)

3-14

Varco Systems

Lubrication

General purpose lubrication


General lubrication

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

Weekly
Wireline Adapter
One pump each

TDS-11SA

3-15

TDS Training Manual

Varco Technical Education Center


Montrose Scotland

AC TOP DRIVE
Section 4

Installation, Commissioning and


Decommissioning

AC Electrical

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

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

Checklist ........................................................................ 4-9


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

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

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

Installing the main tieback ............................................. 4-19


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

Installing the service loop to the derrick ........................ 4-23


Installing the drillers console......................................... 4-24
Installing the drillers console cabling ............................ 4-25
Motor rotation checkout procedure ................................ 4-26

Installing the pipe elevator and links.............................. 4-27


Installing the counterbalance ......................................... 4-28
Commissioning ................................................... 4-29
Checkout procedure ...................................................... 4-29

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

Installation, Commissioning
and Decommissioning

Installation, Commissioning
and Decommissioning

Decommissioning ............................................... 4-35


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

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

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

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

44

4-2

Varco
Varco Systems
Systems

Installation, Commissioning
and Decommissioning

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

Intermediate
Restraints
Page 4-20

Service Loop
Page 4-23

Varco
Drillers 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

Installation, Commissioning
and Decommissioning

Preinstallation
Preparation
The TDS-11SA interfaces with the rigs 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:

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 adapterfurther reducing crown clearance.

4-4

Varco Systems

Installation, Commissioning
and Decommissioning

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

Description

36.8 inches

Standard height configuration (adjustable)

33.8 inches

Varcos 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

Installation, Commissioning
and Decommissioning

Preinstallation
Locating the control house

Drawworks

Recommended Area for


Control House Location

C
L
Well

V-Door
Ramp
TDS-11SA

Varco
Drillers
Console

9,500 lb
(4300 kg)
Control House

C
L
Well

Control
House

Recommendations
91 in.
(2310 mm)

 Position the control house off-drillers 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

Installation, Commissioning
and Decommissioning

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)

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

Installation, Commissioning
and Decommissioning

Preinstallation
Earthing the control house (land rigs)

Copper Plated
Steel Rod
Cable Clamp

Cable Lug
Copper Wire
10 ft

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)

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

Installation, Commissioning
and Decommissioning

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.

The hook or adaptor becket is installed. The hook should open


toward the drawworks.

TDS-11SA

4-9

Installation, Commissioning
and Decommissioning

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

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

4-10

Varco Systems

Installation, Commissioning
and Decommissioning

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

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, Commissioning
and Decommissioning

Installation
Disengaging the lower carriage latch

Guide Beam
Top Section

Carriage

Guide Beam
Wings

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, Commissioning
and Decommissioning

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

Sling
Ensure the
Top Drive does
not contact
the rig

TDS-11SA

Guide Beam
Section

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, Commissioning
and Decommissioning

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

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

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, Commissioning
and Decommissioning

Installation
Hoist the first guide beam section

Guide Beam
Top Section
Hoist

Hook Pin

First Guide
Beam Section
Initially hoisted
by the hook pin

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, Commissioning
and Decommissioning

Installation
Stab and pin the first guide beam section

Guide Beam
Top Section

1
Stab
the guide beam
joints together

Lynch Pin

2
Joint Pin
Install after stabbing

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

Ensure the
Top Drive does
not contact
the rig

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, Commissioning
and Decommissioning

Installation
Completing guide beam installation

Ensure the
Top Drive does
not contact
the rig

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, Commissioning
and Decommissioning

Installation
Hanging the guide beam

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)
Varcos 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

Guide Beam
Top Section

C
L

C
L

Guide Beam
Top Section

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 its
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, Commissioning
and Decommissioning

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

Varcos IDS Top Drive requirements

Well

30.0 inches

Original setback for TDS-9S/11S

4-19

Installation, Commissioning
and Decommissioning

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, Commissioning
and Decommissioning

Installation
Disengaging the upper carriage latch
Guide Beam
Top Section

Carriage

Remove the
Bail Lock
Assembly
Guide Beam
Wings

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

Installation, Commissioning
and Decommissioning

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, Commissioning
and Decommissioning

Installation
Installing the service loop to the derrick
Hoist

Derrick
Termination Plate

1,000 lb
(450 kg)
Each
Service Loop

Sling

!
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, Commissioning
and Decommissioning

Installation

Drawworks

Installing the drillers console

TDS-11SA

V-Door
Ramp

Recommended Area
for Varco Drillers
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, Commissioning
and Decommissioning

Installation
Installing the drillers console cabling
COM
POS
ITE

CON
NEC
TOR

AUX
. PO
WE
RC
ON
NEC
TOR

SER
IAL
CON
NEC
TOR

Profibus Serial Link


to Drillers Console

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

Plug Panel
WI
NC
OM
ING
575
VA
C

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 Drillers 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, Commissioning
and Decommissioning

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 drillers console
 Check the rotation direction of the cooling and oil
pump motors
 Rotate the drill stem using the THROTTLE on the
drillers 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

ILL

TO

DR
D

SE

P LO
IBO C

OF

N
PE

IVE
DRULT
FA

AR

RW

FO

MA

SE

VE

RE

Throttle

Direction
of Rotation
Counterclockwise

Forward/Reverse
Control
Varco
Drillers
Console
TO

IB

BR

PIP

EH

AN

DL

AK

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, Commissioning
and Decommissioning

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

FT

LE

ILT
KT
LT
LINOFF TI

H
NC
LL
RELD DRI
E WHO
QUH &
R
TOPUS

Front
Pipehandler
Rotate Switch
Link Tilt

Varco
Drillers
Console

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 Drillers 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, Commissioning
and Decommissioning

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

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

ALA

-U

RB

IG

TE

4-28

COUNTERBALANCE MODE

OD

Hydraulic
Manifold

Varco Systems

Installation, Commissioning
and Decommissioning

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)

Cork Ball
(Level Indicator)

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 75F (27C)
 Turn on the main breaker

Sight
Glass
Hydraulic
Oil Sight
Gauge

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

Installation, Commissioning
and Decommissioning

Commissioning
Hydraulic system checkout procedure
Checking hydraulic fluid level

Cork Ball
(Level Indicator)

Red
Pop-up
Dirt Alarm
Sight
Glass

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

Installation, Commissioning
and Decommissioning

Commissioning
Electrical system checkout procedure

Emergency Stop

Latch
9 Places

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

P LO
IBO C

E
E
AK
AK
BR TO BRON
AU

FT

ILT

KT
LINOFF

ILT

DR

SE
OF

N
PE
IVE
DRULT
FA

RE

VE

RS

FO

RW

AR

ILL

TO

RQ

UE

Torque Meter

D
MA

F
OF

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

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

AU

LIC

R
WE
PO N
O

SP
DR

TA

LIN
HT

RPM Meter

IN

TO

RQ

BL
UE

OW

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 drillers 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 drillers console for
tightness

Pigtail Cable
Connected to
control house

TDS-11SA

4-31

Installation, Commissioning
and Decommissioning

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

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

Installation, Commissioning
and Decommissioning

Commissioning
Adjusting the link tilt

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
Derrickmans 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

Installation, Commissioning
and Decommissioning

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

V
A
R
C
O
P
H
5

Upper IBOP

i
See the Technical
Drawing Package for
configuration details

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

Installation, Commissioning
and Decommissioning

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

Hydraulic
Manifold

RU

-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

Installation, Commissioning
and Decommissioning

Decommissioning
Removing and storing the electrical cables
and service loops
Lower

Derrick
Termination Plate

1,000 lb
(450 kg)
Each
Service Loop

Sling

!
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

Installation, Commissioning
and Decommissioning

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

Procedure
Drill
Floor

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

Installation, Commissioning
and Decommissioning

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

Guide Beam
Top Section

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

Installation, Commissioning
and Decommissioning

Decommissioning
Unpinning each guide beam section

Ensure the
Top Drive
does not
contact
the rig

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

Installation, Commissioning
and Decommissioning

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

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

Installation, Commissioning
and Decommissioning

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

Ensure the
Top Drive
does not
contact
the rig

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

Skid

Procedure
Drill
Floor

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

Installation, Commissioning
and Decommissioning

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

Installation, Commissioning
and Decommissioning

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 60-80F 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 manufacturers manual.

Returning the TDS-11SA to Service After Storage

 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 manufacturers 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

Inspecting the guide beam joints....................... 5-4


Inspecting the main tieback .............................. 5-5
Inspecting the intermediate restraints .............. 5-6

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

TDS-11SA

TDS Training Manual

Varco Technical Education Center


Montrose Scotland

AC TOP DRIVE
Section 5

Guide Beams and Carriage

AC Electrical

Guide Beams
and Carriage

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

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

Guide Beams
and Carriage

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

Guide Beam
Top Section

TDS-11SA

5-3

Guide Beams
and Carriage

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

Weekly
Joint Pin

Yearly
Typical Guide
Beam Joint

Daily
Retainer Pin

Monthly
Inspect welds
for cracks

5-4

Varco Systems

Guide Beams
and Carriage

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

Guide Beams
and Carriage

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

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

Guide Beams
and Carriage

Inspecting the carriage

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

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

Varco Technical Education Center


Montrose Scotland

AC TOP DRIVE
Section 6

Motor Housing, Transmission

AC Electrical

Motor Housing,
Transmission

Illustrated index ................................................. 6-2


Inspection schedules ......................................... 6-3

Inspecting the internal lubrication flow


(monthly) ............................................................. 6-4
Adjusting the encoder ........................................ 6-5

Gearbox lube pump assembly ............................ 6-7


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

Bail and main body ............................................. 6-10


S-pipe .................................................................. 6-11
Upper mainshaft liner ......................................... 6-12

Washpipe assembly ............................................ 6-13


Assembly ....................................................................... 6-13
Inspection ...................................................................... 6-14

Upper bonnet seals (yearly) ............................... 6-16


Mainshaft ............................................................ 6-17
Inspection ...................................................................... 6-17
Inspecting mainshaft end play (yearly) .......................... 6-18

Blower motor assemblies (monthly) .................. 6-19


Motor brakes (monthly) ...................................... 6-20
AC drilling motors (weekly) ................................ 6-21

Transmission disassembly/assembly ................. 6-22


Nondestructive Examination (NDE) ................... 6-23
Visual inspection ........................................................... 6-23
Magnetic Particle Inspection (MPI) ................................ 6-24

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

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

Motor Housing
and Transmission

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

Megger motors

5 Years
Magnetic particle inspection (MPI)

TDS-11SA

See page 6-24

6-3

Motor Housing
and Transmission

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

Monthly
Spillway
Check flow

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

6-4

Varco Systems

Motor Housing
and Transmission

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.

TDS-11SA

6-5

Motor Housing
and Transmission

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)

Electrical
Connector
Sled
Encoder Belt

Encoder

Belt Tension
Spring

6-6

Sled
Hold-down
Screws
4 Places

Varco Systems

Motor Housing
and Transmission

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

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.

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

Motor Housing
and Transmission

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

Motor Housing
and Transmission

Gear backlash
Inspection (yearly)

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

Solid Wire Solder

Dim. A + Dim. B = Backlash

Procedure

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.

TDS-11SA

Check the gear teeth for pitting or corrosive


wear at the same time the gear set backlash
is checked

6-9

Motor Housing
and Transmission

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

Main Body

5 Years

Bail Pin
2 Places

Yearly

6-10

Varco Systems

Motor Housing
and Transmission

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

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

Motor Housing
and Transmission

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

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

Motor Housing
and Transmission

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.

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

Motor Housing
and Transmission

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

Motor Housing
and Transmission

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

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

Motor Housing
and Transmission

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

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

Motor Housing
and Transmission

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

Motor Housing
and Transmission

Mainshaft
Inspecting mainshaft end play (yearly)

Dial
Indicator
Bearing Retainer
Cap Screw
6 Places

Mainshaft
Check for
axial movement

Yearly
Shims
Bearing
Retainer

Procedure

 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

Motor Housing
and Transmission

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 Housing
and Transmission

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

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

Motor Housing
and Transmission

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

Motor Housing
and Transmission

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

Motor Housing
and Transmission

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.

TDS-11SA

6-23

Motor Housing
and Transmission

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:

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

Motor Housing
and Transmission

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 components 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).

TDS-11SA

6-25

TDS Training Manual

Varco Technical Education Center


Montrose Scotland

AC TOP DRIVE
Section 7

PH50 Pipehandler

AC Electrical

PH-50 Pipehandler

PH-50 Pipehandler

PH-50 Pipehandler illustrated index .................. 7-2


Inspection schedule ........................................... 7-3

Precautions ......................................................... 7-4


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

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

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

Inspecting the IBOP valves and saver subs .................. 7-21


Shot pin assembly .............................................. 7-22
Disassembly/assembly .................................................. 7-22
Inspection ...................................................................... 7-23

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

Nondestructive Examination (NDE) ................... 7-29


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

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 Drillers 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.

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

LE RO IPE
FT T
AT HA
ND
E

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

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

Varco
Drillers Console

RQ

UE

Monthly

TO

RQ

UE

RP

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

Upper
Eye
(Hook)

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

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 = 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.

Lower
Eye
(Elevator)

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.

Use the recommended spanner wrench to remove the rod gland


seal.

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

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

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.

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.

Use recommended spanner wrench to remove the rod gland seal.

Assembly is performed in reverse order of disassembly.

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

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

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

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

Wear allowances
Component

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.

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

7-16

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

Wear allowances
Component

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

Bushings should be pressed in using the mating pin


as an installation mandrel.

TDS-11SA

7-17

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.

7-18

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 1855 ft lb.

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

1.4"

Tool Joint
Shoulder

1.4"

Tool Joint
Locks
Inspect for loose bolts.
Repair or replace if necessary.
Torque to 1855 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.

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

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.

7-22

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

Shot Pin
Cover

Wear allowances
Component

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.

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

Wear allowances
Component

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

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.

Make sure the seals do not twist in the grooves.

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

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.

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

PH-50 Pipehandler

Wireline adapter
Inspection

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

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.

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:

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 components 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).

TDS-11SA

7-31

TDS Training Manual

Varco Technical Education Center


Montrose Scotland

AC TOP DRIVE
Section 8

Hydraulic System

AC Electrical

Hydraulic System

Hydraulic system ................................................ 8-2


Illustrated index ................................................. 8-3

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

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

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.

8-2

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

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

8-4

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

Cork Ball
(Level Indicator)

Daily
Red
Pop-up
Dirt Alarm

Sight
Glass
Hydraulic
Oil Sight
Gauge

Hydraulic
Oil Filter

Procedure

 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

Cork Ball
(Level Indicator)

Sight
Glass
Hydraulic
Oil Sight
Gauge

Hydraulic Oil Fill


Male Quick Disconnect

Hydraulic
Oil Fill

Female
Quick
Disconnect

Hydraulic
Lubrication Kit
55 gal Drum
Varco P/N 92643

TDS-11SA

8-9

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

 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

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

8-12

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

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

Port

Accumulator

Setting

System Accumulator

(125-cubic inch displacement) 800 psi precharge

SA

Counterbalance Accumulator

(728-cubic inch displacement) 900 psi precharge

CB

Time-Delay Accumulator

(30-cubic inch displacement) 800 psi precharge

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.

Note that there is a time delay in pressure


decay on port C4.

Counterbalance
Accumulator

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

8-14

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

Time-Delay
Accumulator

T-13A

Logic Cartridge

30 Cubic Inches
800 PSI Precharge

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

SV4

A4

B4

-6

-6

-6

C04

C4

Manifold Assembly

.055
D03

500 PSI

CV4

Flow Control
Valve

D4
1

T-11A
3

T-11A

.010
2

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.

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.

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. 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

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

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

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.

L1

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.

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.

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

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

8-24

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

.075

CP

-12

CP

-12

.075

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
.010

Counterbalance
Accumulator

Normally-Open
Logic Cartridge
Metering

728 Cubic Inches


900 PSI Precharge

-16

5 PSI

-6

90 PSI

XC

Prefill
Valve

25mm

Cable ID
Number

.047

Stand
Jump

Counterbalance Mode
Rig-up

Stand Jump Solenoid


(Solenoid Valve 9)

2 Position
Valve

Shut-down
Run
A

b
C09

3 Position
Valve with
Detent

D03

-6

MV

.055

CB

Manifold Assembly

SV9
D03

XC
CV3
75 PSI
T-21A

CB

Test
Port
B9

B9

1
4
3

CDF
4 PSI
DF

2
T-10A

System
Accumulator

SA

TDS-11SA

2
2

TF

PCC
T-21A

DF

126 Cubic Inches


800 PSI Precharge

1600 PSI

T-13A

T-5A
30 PSI

Pressure
Relief
Valve

1
SJR
2

190 PSI

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 drillers
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

8-26

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.

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

(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

(Simplified for Clarity)

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

8-28

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.

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 drillers 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.

This is an iterative process. Continue to set the drillers console


control to the mousehole position and OFF, taking present and
decayed pressure readings.

Turning the counterbalance valve counterclockwise increases


the pressure.

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

(Simplified for Clarity)

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.

TDS-11SA

8-31

Hydraulic System

Troubleshooting
HPU and reservoir bladder schematic diagram

PV

PF

TR

DR

Manifold Assembly
Hydraulic Fill
Disconnect

System
Pressure
6m

50 PSID

Prefill Valve
-12

Pressure
Compensator
Control

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

8-32

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

8-33

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.

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

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.

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

.075

CP

-12

CP

-12

.075

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

.010

Counterbalance
Accumulator

Normally-Open
Logic Cartridge
Metering

728 Cubic Inches


900 PSI Precharge

-16

5 PSI

-6

90 PSI

XC

Prefill
Valve

25mm

Cable ID
Number

.047

Stand
Jump

Counterbalance Mode
Rig-up

Stand Jump Solenoid


(Solenoid Valve 9)

2 Position
Valve

Shut-down
Run
A

b
C09

3 Position
Valve with
Detent

D03

-6

MV

.055

CB

Manifold Assembly

SV9
D03

XC
CV3
75 PSI
T-21A

CB

Test
Port
B9

B9

1
4
3

CDF
4 PSI
DF

2
T-10A

System
Accumulator

SA

8-36

2
2

TF

PCC
T-21A

DF

126 Cubic Inches


800 PSI Precharge

1600 PSI

T-13A

T-5A
30 PSI

Pressure
Relief
Valve

1
SJR
2

190 PSI

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.

TDS-11SA

8-37

Hydraulic System

Brake circuit schematic diagram


Brake Calipers

2 Position
Solenoid Valve
Brakes On

Cable ID
Number

-4

C01

B1

SV1

.071

Manifold Assembly

D03

Non-Adjustable
Orifice
P1

Test Point

1400 PSI
PC1

Reducing
Valve

T-11A

System
Pressure

8-38

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.

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.

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

Pilot-to-Close
Check Valve

3
T-2A

CKEB

30 PSID
2
1
CNEC

Shot-Pin Cylinder

2.000" Dia. Bore X 2.31" Stroke


1.500" Dia. Rod

Relief Valve

T-2A

1 T-5A

COFA
.047

Shot Pin
Cylinder

400 PSI

30 PSID

2x .094

VR

VP
1

2 Position
Solenoid
Valve 5
Clamp/Shot Pin

Non-Adjustable
Flow Control

Cable ID
Number

A5

.159

SV5
D03

E5

G5

E5

G5

-8

G5

.039

B5

.031

C5

AR5
2

Pressure
Reducing
Valve

1
LC5

T-11A

.031

50 PSI
3

Logic
Cartridge

Rotating Link
Adapter Assembly

-6

-6

C05

E5

-8

Clamp

-8

-8

T-10A
B5 C5

.031

500 PSI

T-11A

T-21A
CV5

Externally-Drained
Pilot-to-Open
Valve

4 75 PSI
P5

Drain

T-11A

System Pressure

PC5

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.

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

X2

3
2

C2

T-11A
CB2

C2

1500 PSI

T-11A
CB1

C1

V1

V2

Link Tilt
"Tilt" Solenoid
(Solenoid Valve 6)

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

SV8

Logic
Cartridge

D03

B8

LA6 T-11A
1
50 PSI 2

3
A6

C07
Drill Down P

-8

-6

b
C08

Link Tilt

E6 .031

.071

SV6

D03 .031

75 PSI

.031
B6

.031

Logic
Cartridge

a
C06
M'hole

-8

Link-Tilt Float

X -8

X -8

G6

-8 X

-8

Rotating Link
Adapter Assembly

Link Tilt
"Float" Solenoid
(Solenoid Valve 8)

CA6
T-21A
.031

G6

T-11A
1

50 PSI 2
LB6

.071
4

1
CB6 75 PSI
T-21A

Pressure
Tank

Manifold Assembly
X

D1

A8

8-42

-8 X

E6

G6

-8

B8

-8

E6

Cable ID
Number

-8

-8
G6

-8

-8

E6

-6
B8

-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 230F).

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

8-43

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

.205

.062

Upper
Mainshaft
Bearing

.047 .047

.059 .059

Lower
Radial/Main
Thrust
Bearings

Upper
Compound
Bearing

L4

Lower
Compound
Bearing

Lube-Oil
Filter
Lube Pump

60m

5.10 In.^ 3/Rev.


L1 -16

Lube-Oil Pump
-10
A

-10

Tank

3.0 In.^ 3/Rev.


Lube Pump Motor

Hydraulic
Motor

Hydraulic
Heat Exchanger

Tank

T-10A
RV2

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.

TDS-11SA

8-45

Hydraulic System

Troubleshooting
Rotating link adapter motor schematic diagram
Rotating Head Motor

Fixed
Displacement
Motor
2

T-10A

Pressure
Relief Valves

1600 PSI

1600 PSI

T-10A

Rotate Left
Solenoid

Rotate Right
Solenoid

Rotating Head

Cable ID
Number

Cable ID
Number

C03

C02
P

-6

Right

-6

Left

A2

SV2
.071

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

Time-Delay
Accumulator

T-13A

Logic Cartridge

30 Cubic Inches
800 PSI Precharge

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

SV4

A4

B4

-6

-6

-6

C04

C4

Manifold Assembly

.055
D03

500 PSI

CV4

Flow Control
Valve

D4
1

T-11A
3

T-11A

.010
2

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.

8-48

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

33-10

Chack Valve
33-11

TDS-11SA

CDF, CTF, CV2, CTR,


CDR, CXCD
Prefill valve assembly
CV1, CV2

8-49

Hydraulic System

Hydraulic schematic symbols


Description

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

See Prefill Assembly


33-21

Quick Disconnect Coupling


33-22

8-50

Varco Systems

Hydraulic System

Hydraulic schematic symbols


Description

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

Tank (Reservoir)
33-33

Test Point
33-34

TDS-11SA

8-51

TDS Training Manual

Varco Technical Education Center


Montrose Scotland

AC TOP DRIVE
Section 9

Varco Drillers Console

AC Electrical

Varco Drillers Console

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 Drillers 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

Varco Drillers Console

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

Varco Drillers Console

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

Varco Drillers Console

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

Varco Technical Education Center


Montrose Scotland

AC TOP DRIVE
Section 10

System Interconnect

AC Electrical

TDS Training Manual

Varco Technical Education Center


Montrose Scotland

AC TOP DRIVE
Section 11

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 LEDs


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 LEDS
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 DBs).
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 Drillers Console also have intrinsically safe
circuits EEx ia.

AC TDS Training Manual

Bartec Distributed I/O system

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 Drillers 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.

AC TDS Training Manual

Bartec Distributed I/O system

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 Drillers 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.

AC TDS Training Manual

Bartec Distributed I/O system

Bartec Modex Digital Input Modual

Varco P/N = 140968-2

There are two Bartec Profibus Digital Inputs modules in the Varco Drillers 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 Drillers 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).

AC TDS Training Manual

Bartec Distributed I/O system

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
Drillers 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 TDS Training Manual

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. SFCs 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

Varco Technical Education Center


Montrose Scotland

AC TOP DRIVE
Section 12

Basics of AC Motors

AC Electrical

Basics of AC Motors

AC MOTOR BENEFITS

AC TDS Training Manual

Basics of AC Motors

AC EXTRA PERFORMANCE

AC TDS Training Manual

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.

AC TDS Training Manual

Basics of AC Motors

AC MOTOR CONSTRUCTION

Used in industrial applications

Three phase 550/575 VAC in TDS applications

AC TDS Training Manual

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.

AC TDS Training Manual

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.

AC TDS Training Manual

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.

AC TDS Training Manual

Basics of AC Motors

ROTATING MAGNETIC FIELD

Evaluate the Field at 60 intervals


After six intervals the field rotates 360.

AC TDS Training Manual

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.

AC TDS Training Manual

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.

AC TDS Training Manual

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.

AC TDS Training Manual

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).

AC TDS Training Manual

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

Varco Technical Education Center


Montrose Scotland

AC TOP DRIVE
Section 13

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.

AC TDS Training Manual

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

AC TDS Training Manual

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

AC TDS Training Manual

Basics of AC Drives

Pulse Width Modulation (PWM)

Provide more Sinusoidal Current Output.


More Efficient, Higher levels of Performance.

AC TDS Training Manual

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.

AC TDS Training Manual

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,
GTOs or IGBTs can be used.

AC TDS Training Manual

Basics of AC Drives

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

AC TDS Training Manual

Basics of AC Drives

Developing a Basic AC Output

AC TDS Training Manual

Basics of AC Drives

Generating a PWM Output

AC TDS Training Manual

Basics of AC Drives

PWM Voltage and Current Output

AC TDS Training Manual

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.

AC TDS Training Manual

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.

AC TDS Training Manual

TDS Training Manual

Varco Technical Education Center


Montrose Scotland

AC TOP DRIVE
Section 14

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

Adaption board at mounting position 2

Position: bottom

Slot F

Adaption board at mounting position 3

Position: top

Slot G

Adaption board at mounting position 3

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

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 k

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

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

S3
Analog input 1
(non-floating)

+5V
Switch for USS bus connection

AI 1

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

In

16

X103

17
S3

Analog input 2
(non-floating)

Tacho M

In

Track A

AI 2

3 4
18

AO 1
D

19
20

M
D

21

Analog output 2

X101 Control
terminal strip

1
2

AO 2

22

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

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
I190 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

P24 AUX

Aux. voltage supply

DC 24 V / 150 mA

M24 AUX

Reference potential

0V

DIO1

Digital input/output 1

24 V, 10 mA / 20 mA

DIO2

Digital input/output 2

24 V, 10 mA / 20 mA

DIO3

Digital input/output 3

24 V, 10 mA / 20 mA

DIO4

Digital input/output 4

24 V, 10 mA / 20 mA

DI5

Digital input 5

24 V, 10 mA

DI6

Digital input 6

24 V, 10 mA

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 mm (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 k

18

M AI2

Ground, analog input 2

Current: Rin = 250

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

Connectable cross-section: 1.5 mm (AWG 16)


Terminal 13 is at the top when installed.

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 k

Connectable cross-section: 1.5 mm (AWG 16)


Terminal 23 is at the top when installed.

X300 - Serial
interface

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


socket.
Pin

Name

Significance

Range

n.c.

Not connected

RS232 RxD

Receive data via RS232

RS232

RS485 P

Data via RS485

RS485

Boot

Control signal for software


update

Digital signal, low


active

M5V

Reference potential to P5V

0V

P5V

5 V aux. voltage supply

+5 V, Imax = 200 mA

RS232 TxD

Transmit data via RS232

RS232

RS485 N

Data via RS485

RS485

n.c.

Not connected

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

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

0000

0001

P
0002

Select P060

P053

P060

Set P060 to 0002 and select "Fixed settings" menu

P060

P
2

P060

Select P970

P060

P366

P970

Set P970 to 0000 and start parameter reset

P970

P
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

OFF key

Jog key

Jog

Raise key
Lower key

Key for toggling between control levels


7

+/-

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

3
4

N5V

Ground

P5V

5 V aux. voltage supply

RS485 N

Data via RS485 interface

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

USS-Bus
Jog

7
4

+/-

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 units 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

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

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.

P
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.


VectorControl
*Menu Selection
OP: Upread
OP: Download

VectorControl
*Menu Selection
#OP: Upread
OP: Download

VectorControl
*Menu Selection
OP: Upread
#OP: Download

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.

P
VectorControl
Change slave
Config. slave
#Slave ID

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

P
VectorControl
*Menu selection
Upread
Download

Menauswahl
*User Param.
Param Menu..
FixedSet...

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

r001
Drive Status

Ready

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

2x

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

Parameter Menu
*Gen. Param.
Terminals
Communication

Param Menu
*Gen. Param.
Terminals
#Communication

Example: Selecting a parameter via sub-menus

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.).

0
r001
Drive Status

9 r000

r004

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

Ready

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

r001
Drive Status

9 r002

r004

Parameter display
and parameter
correction

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

P
P605
Brake control

Correction of
parameter value

Accept and
return

Selection of
parameter value

0 P605
Brake control

without brake

0 P605
Brake control

without brake

1 P605
Brake control

Brake w/o chkbk

Brake w/o chkbk

Selection of
parameter value

Correction of
parameter value

Accept and
return

P600

0 ms
MCont mssg time

Selection of
parameter index

P
P049.001

5 ms
MCont mssg time

Selection of
parameter value

Correction of
parameter value

Accept and
return

P049.001

P049.002

P049.002

4
OP OperDisp
1st line, left

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

P049.002
4

Selection of
parameter index

5 ms
MCont mssg time

Correction of
parameter index

4
OP OperDisp
1st line, left

P600

P600

0 ms
MCont mssg time

P600

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.

Fault and alarm


messages

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

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

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

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

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

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

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 = Strung
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)

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)

In function plan:
285.3, 286.3

r004
Output Amps

Visualization parameter for the output current of the


converter or inverter (fundamental rms)

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.

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

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

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

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

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
- Upread/free access

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

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

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).

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

r008
Motor Utilizat.

Visualization parameter for thermal motor utilization


(calculated value).

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.: 0
Unit: Indices: Type: O2

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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 %.

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

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

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.

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

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

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

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

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.

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

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

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

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

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.

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

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

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

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

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

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

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.

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

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

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

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

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.

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

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

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

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

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.

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

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

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

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

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

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

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

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

Init: 0
Min: 0
Max: 4
Unit: Indices: Type: O2

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

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.

Init: 1
Min: 0
Max: 8
Unit: Indices: Type: O2

Menus:
all Menus
changeable in:
all states

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

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.

Init: 0
Min: 0
Max: 254
Unit: Indices: Type: O2

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.

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 motor leakage reactance of the


damper winding along the rotor axis (d axis), referred to
the rated motor impedance.

Index1: 9,00
Min: 0,10
Max: 49,99
Unit: %
Indices: 4
Type: O2

Menus:
- Parameter menu
+ Motor/encoder
+ Motor data
- Upread/free access
changeable in:
- Ready
- Run

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.

Index1: 9,00
Min: 0,10
Max: 49,99
Unit: %
Indices: 4
Type: O2

Menus:
- Parameter menu
+ Motor/encoder
+ Motor data
- Upread/free access
changeable in:
- Ready
- Run

Index1: 8,00
Min: 0,10
Max: 49,99
Unit: %
Indices: 4
Type: O2

Menus:
- Parameter menu
+ Motor/encoder
+ Motor data
- Upread/free access
changeable in:
- Ready
- Run

Index1: 8,00
Min: 0,10
Max: 49,99
Unit: %
Indices: 4
Type: O2

Menus:
- Parameter menu
+ Motor/encoder
+ Motor data
- Upread/free access
changeable in:
- Ready
- Run

Index1: 50,0
Min: 1,0
Max: 100,0
Unit: %
Indices: 4
Type: O2

Menus:
- Parameter menu
+ Motor/encoder
+ Motor data
- Upread/free access
changeable in:
- Ready
- Run

Index1: 60,0
Min: 10,0
Max: 200,0
Unit: %
Indices: 4
Type: O2

Menus:
- Parameter menu
+ Motor/encoder
+ Motor data
- Upread/free access
changeable in:
- Ready
- Run

Index1: 30,0
Min: 5,0
Max: 799,0
Unit: %
Indices: 4
Type: O2

Menus:
- Parameter menu
+ Motor/encoder
+ Motor data
- Upread/free access
changeable in:
- Ready
- Run

Index1: 80,0
Min: 10,0
Max: 200,0
Unit: %
Indices: 4
Type: O2

Menus:
- Parameter menu
+ Motor/encoder
+ Motor data
- Upread/free access
changeable in:
- Ready
- Run

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: 45,0
Min: 5,0
Max: 799,0
Unit: %
Indices: 4
Type: O2

Menus:
- Parameter menu
+ Motor/encoder
+ Motor data
- Upread/free access
changeable in:
- Ready
- Run

Index1: 90,0
Min: 10,0
Max: 200,0
Unit: %
Indices: 4
Type: O2

Menus:
- Parameter menu
+ Motor/encoder
+ Motor data
- Upread/free access
changeable in:
- Ready
- Run

Index1: 65,0
Min: 5,0
Max: 799,0
Unit: %
Indices: 4
Type: O2

Menus:
- Parameter menu
+ Motor/encoder
+ Motor data
- Upread/free access
changeable in:
- Ready
- Run

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: 10
Min: 0
Max: 13
Unit: Indices: 4
Type: O2

Menus:
- Parameter menu
+ Motor/encoder
+ Motor data
- Drive setting
- Upread/free access
changeable in:
- Drive setting

Index1: 1
Min: 0
Max: 5
Unit: Indices: 4
Type: O2

Menus:
- Parameter menu
+ Motor/encoder
+ Motor data
- Drive setting
- Upread/free access
changeable in:
- Drive setting

Index1: ~
Min: 100
Max: 2000
Unit: V
Indices: 4
Type: O2

Menus:
- Parameter menu
+ Motor/encoder
+ Motor data
- Drive setting
- Upread/free access
changeable in:
- Drive setting

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

Menus:
- Parameter menu
+ Motor/encoder
+ Motor data
- Drive setting
- Upread/free access
changeable in:
- Drive setting

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

Menus:
- Parameter menu
+ Motor/encoder
+ Motor data
- Drive setting
- Upread/free access
changeable in:
- Drive setting

Index1: ~
Min: 0,1
Max: 2000,0
Unit: hp
Indices: 4
Type: O2

Menus:
- Parameter menu
+ Motor/encoder
+ Motor data
- Drive setting
- Upread/free access
changeable in:
- Drive setting

Index1: ~
Min: 50,0
Max: 99,9
Unit: %
Indices: 4
Type: O2

Menus:
- Parameter menu
+ Motor/encoder
+ Motor data
- Drive setting
- Upread/free access
changeable in:
- Drive setting

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

User parameters

Freely configurable menu

Parameter menu

Contains complete parameter set

More extensive structure of the functions achieved by


using an OP1S operator control panel

Fixed settings

Used to perform a parameter reset to a factory or user


setting

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"

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 systems 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 CBPs 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

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

SHIELD

Ground connection

Area

Not connected

RxD/TxD-P

Receive/transmit data P (B/B)

RS485

CNTR-P

Control signal

TTL

DGND

PROFIBUS data reference potential


(C/C)

VP

Power supply Plus

Not connected

RxD/TxD-N

Receive/transmit data N (A/A)

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

Installing the bus


cable

Bus cable connection for first


and last nodes on the bus1

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 C.
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:

There has been an UCE shutdown in phase


L2.

Phase L2 for short-circuit or ground fault


(-X2:V2 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).

UCE Ph. L3

Check :

There has been an UCE shutdown in phase


L3.

Phase L3 for short-circuit or ground fault


(-X2:W2 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).

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

AnaIn2 SL1
4 mA at analog input 2, slave1 fallen short of

Check the connection between the signal


source and the SCI1 (Slave 2) -X428:7, 8.

F075

AnaIn3 SL1
4 mA at analog input 3, slave1 fallen short of

Check the connection between the signal


source and the SCI1 (Slave 3) -X428:10, 11.

F076

AnaIn1 SL2
4 mA at analog input 1, slave2 fallen short of

Check the connection between the signal


source and the SCI1 (Slave1) -X428:4, 5.

F077

AnaIn2 SL2
4 mA at analog input 2, slave2 fallen short of

Check connection between signal source and


SCI1 (Slave 2) -X428:7,8.

F078

AnaIn3 SL2
4 mA at analog input 3, slave2 fallen short of

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 P704.03SCom/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

Changeover, setpoint channel

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

Sign of the signal is incorrect

A track signal is missing

Incorrect gain

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

Fault 2 Function blocks

Check cause of fault,


see function diagram 710

F150

Fault 3 Function blocks

Check cause of fault,


see function diagram 710

F151

Fault 4 Function blocks

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 C .

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

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

Alarm 2 function blocks

Check cause of alarm (see FP 710)

A063

Alarm 3 function blocks

Check cause of alarm (see FP 710)

A064

Alarm 4 function blocks

Check cause of alarm (see FP 710)

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
0.5s - 1.5s.

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<No>". 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

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 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
+

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

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

1996

1997

1998

1 to 9

January to September

October

November

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

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

3AC 380 V to 480 V

SKD 62 / 16

330 / 150 W

22 nF / 1600 V

3AC 500 V to 600 V

3 x SKKD 81 / 22

470 / 200 W

22 nF / 1600 V

3AC 660 V to 690 V

3 x SKKD 81 / 22

470 / 100 W

22 nF / 1600 V

3AC 380 V to 480 V

SKD 62 / 16

100 / 500 W

22 nF / 1600 V

3AC 500 V to 600 V

3 x SKKD 81 / 22

150 / 500 W

22 nF / 1600 V

3AC 660 V to 690 V

3 x SKKD 81 / 22

150 / 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

TDS Training Manual

Varco Technical Education Center


Montrose Scotland

AC TOP DRIVE
Section 15

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
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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

TDS-9S SIEMENS DRIVE PARAMETERS (CUVC)

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

126743 REV.SHEET 3 OF 14

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

TDS-9S SIEMENS DRIVE PARAMETERS (CUVC)

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

126743 REV.SHEET 4 OF 14

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%

TDS-9S SIEMENS DRIVE PARAMETERS (CUVC)

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

126743 REV.SHEET 5 OF 14

VIEW
PAR. NO.

IND.

PARAMETER DESC.

VALUE(Units)

P448
P449
P452
P452
P452
P453
P453
P453
P457
P457
P457
P462
P462
P462
P463
P463
P463
P464
P464
P464
P465
P465
P465
P466
P466
P467
P467
P467
P468
P469
P469
P469
P470
P470
P470
P471
P471
P475
P476
P492
P492
P492
P493
P493
P494
P494
P494
P498
P498
P498
P499
P499
P500
P500

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%

TDS-9S SIEMENS DRIVE PARAMETERS (CUVC)

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

126743 REV.SHEET 6 OF 14

VIEW
PAR. NO.

IND.

PARAMETER DESC.

VALUE(Units)

P500
P535
P535
P536
P536
P537
P537
P554
P554
P555
P555
P556
P556
P557
P557
P558
P558
P559
P559
P560
P560
P561
P561
P562
P562
P563
P563
P564
P564
P565
P565
P566
P566
P567
P567
P568
P568
P569
P569
P571
P571
P572
P572
P573
P573
P574
P574
P575
P575
P576
P576
P577
P577
P578

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

TDS-9S SIEMENS DRIVE PARAMETERS (CUVC)

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

126743 REV.SHEET 7 OF 14

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

TDS-9S SIEMENS DRIVE PARAMETERS (CUVC)

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

126743 REV.SHEET 8 OF 14

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

TDS-9S SIEMENS DRIVE PARAMETERS (CUVC)

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

23/03/2001
10:56

126743 REV.SHEET 10 OF 14

PAR. NO.

P579
P586
P587
P588
P589
P590
P591
P600
P601
P602
P603
P604
P606
P607
P608
P610
P611
P612
P613
P618
P619
P620
P621
P622
P623
P624
P631
P655
P656
P657
P658
P660
P661
P662
P664
P665
P666
P680
P681
P682
P683
P684
P685
P686
P687
P688
P689
P690
P694
P695
P696
P697
P698
P699

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

TDS-9S SIEMENS DRIVE PARAMETERS (CUVC)

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

126743 REV.SHEET 11 OF 14

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

TDS-9S SIEMENS DRIVE PARAMETERS (CUVC)

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

126743 REV.SHEET 12 OF 14

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

TDS-11S 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 = 22.3%
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

TDS-11S SIEMENS DRIVE PARAMETERS (CUVC)

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

124965 REV.B
SHEET 3 OF 13

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

TDS-11S SIEMENS DRIVE PARAMETERS (CUVC)

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

124965 REV.B
SHEET 4 OF 13

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%

TDS-11S SIEMENS DRIVE PARAMETERS (CUVC)

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

124965 REV.B
SHEET 5 OF 13

VIEW
PAR. NO.

IND.

PARAMETER DESC.

VALUE(Units)

P448
P449
P452
P452
P452
P453
P453
P453
P457
P457
P457
P462
P462
P462
P463
P463
P463
P464
P464
P464
P465
P465
P465
P466
P466
P467
P467
P467
P468
P469
P469
P469
P470
P470
P470
P471
P471
P475
P476
P492
P492
P492
P493
P493
P494
P494
P494
P498
P498
P498
P499
P499
P500
P500

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%

TDS-11S SIEMENS DRIVE PARAMETERS (CUVC)

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

124965 REV.B
SHEET 6 OF 13

VIEW
PAR. NO.

IND.

PARAMETER DESC.

VALUE(Units)

P500
P535
P535
P536
P536
P537
P537
P554
P554
P555
P555
P556
P556
P557
P557
P558
P558
P559
P559
P560
P560
P561
P561
P562
P562
P563
P563
P564
P564
P565
P565
P566
P566
P567
P567
P568
P568
P569
P569
P571
P571
P572
P572
P573
P573
P574
P574
P575
P575
P576
P576
P577
P577
P578

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

TDS-11S SIEMENS DRIVE PARAMETERS (CUVC)

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)

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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

TDS-11S SIEMENS DRIVE PARAMETERS (CUVC)

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

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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

TDS-11S SIEMENS DRIVE PARAMETERS (CUVC)

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.

P579
P586
P587
P588
P589
P590
P591
P600
P601
P602
P603
P604
P606
P607
P608
P610
P611
P612
P613
P618
P619
P620
P621
P622
P623
P624
P631
P655
P656
P657
P658
P660
P661
P662
P664
P665
P666
P680
P681
P682
P683
P684
P685
P686
P687
P688
P689
P690
P694
P695
P696
P697
P698
P699

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

TDS-11S SIEMENS DRIVE PARAMETERS (CUVC)

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

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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

TDS-11S SIEMENS DRIVE PARAMETERS (CUVC)

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

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TDS Training Manual

Varco Technical Education Center


Montrose Scotland

AC TOP DRIVE
Section 16

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

Varco Technical Education Center


Montrose Scotland

AC TOP DRIVE
Section 17

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)

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.

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).

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.

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.

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.

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).

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.

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?
___________________________________________________________________
___________________________________________________________________

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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.

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