Part Number 30-03

INSTALLATION, OPERATION AND MAINTENANCE

RPM/SPM TACHOMETER
GENERATOR SYSTEM

Manufacturers of Precision Instruments

Printed in U.S.A. August 15, 1981

 INSTRUCTION MANUAL 30-03
LIST OF EFFECTIVE PAGES

Total number of pages in this publication is 30 consisting of the following:

PAGE ISSUE
NO. DATE

Cover . . . . ...... .15 August 1981

A...... ...... .15 August 1981
i thru iv . . ...... .15 August 1981
l-l thru 1-4 ...... .15 August 1981
2-l thru 2-10 ...... .15 August 1981
3-1 thru 3-7 ...... .15 August 1981
3-8 Blank . . ...... .15 August 1981
4-l . . . . . ...... ~15 August 1981
4-2 Blank . . ...... 015 August 1981

Q1981, by TOTCO, All Rights Reserved

 IMPORTANT
SAFETY NOTICE

Proper service and repair is important to the safe, reliable operation of all M/D TOTCO equipment. The service
procedures recommended by M/D TOTCO and described in the technical manuals are recommended
methods of performing service operations. Some of these service operations require the use of tools specially
designed for the purpose. The special tools should be used when and as recommended. lt is important to
note that some warnings against the use of specific service methods that can damage the equipment or
render it unsafe are stated in the manuals. lt is also important to understand these warnings are not exclusive.
M/D TOTCO could not possibly know, evaluate and advise the service people of all conceivable ways in
which service might be done or of possible hazardous consequences of each way. Accordingly, anyone who
uses service procedures or tools which are not recommended by M/D TOTCO must first satisfy themselves
thoroughly that neither personnel safety or equipment safety will be jeopardized by the method selected.

July 27,1992 Page A

M/D TOTCO
LIMITED
PRODUCT WARRANTY

THE FOLLOWING WARRANTY IS EXCLUSIVE AND IN UEU OFALLOTHER WARRANTIES, WHETHER

EXPRESS, IMPUED OR STATUTORY, INCLUDING, BUT NOT BY WAY OF LlMITATlON, ANY
WARRANTY OF MERCHANTABIUTY OR FlTNESS FOR ANY PARTlCULAR PURPOSE. M/D TOTCO
warrants to each original retail purchaser (“Purchaser’) of new products manufactured by M/D TOTCO that
such productsare, at the time Ofd8liV8rytO the Purchaser, free of material and workmanship defects, provided
that no warranty is made with respect to: Any product which has been repalred or altered In such a way,
In M/D TOTCO’s judgment, as to affect the product adversely. (b) Any product which has, in M/D TOTCO’s
judgment, been subject to negligence, accident or improper Storage. (c) Any product which has not been
operated and maintained in accordance with normal practice and with the r8commendations of M/D TOTCO.
(d) All items made by others are supplied by M/D TOTCO on special order. The items covered in (d) above
are not manufactured by M/D TOTCO and any claims should be submitted directly to the manufacturer
thereof. M/D TOTCO’s obligation under this warranty is limited to repairing or, at its option, replacing, during
normal business hours at any authorized service facility of M/D TOTCO, any products which in its judgment
proved not to be as warranted within the applicable warranty period. All costs of transportation of products
claimed not to b8 as warranted and of repaired or replacement products to or from such service facility shall
be borne by the Purchaser. M/D TOTCO may require the return of any part claimed not to be as warranted
to one of its facilities as designated by M/D TOTCO, transportation prepaid by the Purchaser, to establish a
claim Under this warranty. The cost of labor for installing a repaired or replacement part shall b8 born8 by
the Purchaser. Replacement parts provided Under the terms of this warranty are warranted for the remainder
of the warranty period of the product upon which installed to the same extent as if such parts were original
components thereof. The warranty p8riods for various products are: (a) Hydraulics and Mechanical
equipment: one (1) year from date of installation or 15 months from date of Shipment from M/D TOTCO,
whichever occursfirst. (b) All Elastomer Diaphragms: six (8) months from date ofshipmentfrom M/D TOTCO.
(c) Electronic Equipment: six (8) months from date of shipment from M/D TOTCO.

Page B July 27,1992

M/D TOTCO
INSTRUCTION MANUAL 30-03
 INSTRUCTION MANUAL 30-03
SI UNIT AND METRIC CONVERSION FACTORS

ATMOSPHERES (atm) (standard sea level pressure)

x 101.325 = Kilopascals (kPa) absolute
x 29.92 = Inches of mercury (in Hg) at O°C

KILOPASCALS (kPa)
x 0.001 = Pascals (Pa)
x 0.001 = Newtons per square metre (N/m2)

POUNDS PER SQUARE INCH GAUGE (PSLG)

= Pounds-force/square inch (lbf/in2)
x 6.895 = Kilopascals (kPa)
x 0.0703 = Kilograms per sq cm (Kg/cm2)

BARRELS, PETROLUEM (bbl)

x 0.1590 = Cubic metres (m3)
x 42 = U.S. gallons (U.S. gal) oil

BARRELS PER INCH, PETROLEUM (bbl/in)

x 0.626 = Cubic metres per centimeter (m3/cm)

INCHES (in.)
x 2.540 = Centimetres (cm)

SQUARE FEET (ft2)

x 0.0929 = Square metres (m2)

DEGREES FAHRENHEIT (OF)

(OF-32) x 5/9 = OC

DEGREES CENTIGRADE ('C)

('C x 9/5) + 32 = OF

POUNDS-FORCE (lbf av.)

x 4.448 = Newtons (N)
x 0.4448 = Decanewtons (daN)
x 0.4536 = Kilograms (Kg)

POUNDS MASS PER U.S. GALLON (lb/gal)

x 119.826 = Kilograms per cubic metre (kg/m3)

ii
 INSTRUCTION MANUAL 30-03
TABLE OF CONTENTS

Section Title Page

PURPOSE AND DESCRIPTION ...................... l-l

l-l Introduction ....................... l-l
l-3 Purpose .......................... l-l
l-5 Description ........................ l-l
l-6 .General......................... l-l
l-7 . Tachometer Generator .................. l-l
l-8 . Indicating Meter .................... l-l
l-9 . Electrical Cable Assembly ................ l-l
l-10 Operation ......................... l-l
l-11 .General......................... l-l
II INSTALLATION AND ADJUSTMENT .................... 2-l
2-l Installation ....................... 2-l
2-2 .General... ...................... 2-l
2-3 . Tachometer Generator .................. 2-l
2-4 . RPM Tachometer Generator ................ 2-l
2-5 . SPM Tachometer-Generator ................ 2-l
2-6 . Electrical Cable .................... 2-8
2-7 . Indicating Meter .................... 2-9
2-8 . RPM Start-Up Procedures ................. 2-9
2-9 . SPM Start-Up Procedures ................. 2-9
2-10 RPM/SPM Meter Modification ................ 2-10
III PERIODIC INSPECTION, FIELD MAINTENANCE AND SHOP MAINTENANCE .... 3-l
3-l General Information .................... 3-l
3-3 Periodic Inspection .................... 3-l
3-4 .General......................... 3-l
3-5 Field Maintenance ..................... 3-l
3-6 .General... ...................... 3-l
3-7 . Component Removal and Replacement ............ 3-2
3-8 Shop Maintenance ..................... 3-2
3-9 .General......................... 3-2
3-10 . Tachometer Generator .................. 3-2
3-11 . Cable, Electrical .................... 3-2
3-12 . RPM/SPM Bra&et-Mount Meter ............... 3-2
3-13 . RPM/SPM Panel-Mount Meter ................ 3-3
3-14 . Rectifier Assembly ................... 3-3
3-16 . RPM/SPM Meter Calibration ................ 3-6
IV TROUBLESHOOTING .......................... 4-l
4-l General .......................... 4-l

LIST OF ILLUSTRATIONS

Figure Title Page

l-l Typical RPM/SPM Tachometer Generator System . . . . . . . . . . . . l-2

2-l Installation Dimension, RPM/SPM Meter . . . . . . . . . . . . . . . 2-2
2-2 Dust Proof (Type AR) Tachometer Generator with Pulley . . . - . . . 2-3
Drive, Installation Dimension
2-3 Dust Proof (Type AR) Tachometer Generator Pulley Drive . . . . . l 2-3
with Rotary Swivel, Installation Dimensions

iii
 INSTRUCTION MANUAL 30-03
LIST OF ILLUSTRATIONS (Cont’d)

Figure Title Page

2-4 Dust Proof (Type AB) Tachometer Generator with Flexible . . . . . . 2-4
Coupling Drive, Installation Dimensions
2-5 Explosion Proof (Type E) Tachometer Generator with Pulley . . . . . 2-4
Drive, Installation Dimension
2-6 Explosion Proof (Type E) Tachometer Generator with Rotary l . . . . 2-5
Swivel, Installation Dimension
2-7 Explosion Proof (Type E) Tachometer Generator with Flexible . . . . 2-5
Coupling Drive, Installation Dimensions
2-8 Counter Shaft Adapter Drive for RPM Installation. . . . l . . . . . 2-6
2-9 Flexible Coupling Drive for RPM Installation . . . . . . . . . . . 2-6
2-10 Rotorseal Adapter Installation for RPM or SPM . . . . . . . . . . . 2-7
2-11 Main Pump Shaft Drive for SPM Installation . . . . . . l . . . . . 2-7
2-12 Pulley Drive for SPM Installation * * . * * . . . a . . l . l . . . 2-8
3-l Electrical Cable * * * * * *
l l . . . . . . . . . . .
l . . . . . 3-3
3-2 Bracket-Mount Meter . . . . . . . . . . . . . . . . . . . . . . . . 3-4
3-3 Panel Mount Meter . . . . . . . . . . . . . . . . . . . . . . . . . 3-5
3-4 Rectifier Assembly . . . . . . . . . . . . . . . . . . . . . . . . 3-6
3-5 Rectifier Board Modification with Bridge . . . . . . . . . . . . . 3-7
3-6 Rectifier Board Modification with Bridge . . . . . . . . . . . . . 3-7

LIST OF TABLES

Table Title Page

l-l Leading Particulars ....................... l-3

3-l Periodic Inspection Requirments .................. 3-l
4-l Troubleshooting Table ....................... 4-l

RELATED PUBLICATIONS
Publication
Number Title

30-02 RPM/SPM Tachometer Generator System (Illustrated Parts Breakdown)

RELATED TOOLS AND TEST EQUIPMENT

Part Number Description

935706-001 Digital Voltmeter

999719-001 Soldering Gun, 25 watts

APPROVED EXPENDABLE ITEMS LIST

Part Number Description

993205-002 Solder
991202-045 Silicone

iv
 INSTRUCTION MANUAL 30-03
SECTION I
PURPOSE AND DESCRIPTION

l-l INTRODUCTION

l-2 This manual contains installation, operation and maintenance instructions

for the RPM and SPM Indicating Systems manufactured by TOTCO Instrument
Sales. Information given in this manual is sufficient for skilled maintenance
technicians with a basic knowledge of electronics to install and satisfactorily
accomplish all operating and maintenance tasks. Unless otherwise specified, the
instructions contained in this manual apply to both the TOTCO RPM and SPM Indicating
Systems.

l-3 PURPOSE

l-4 The TOTCO RPM indicating system is designed to indicate the rotary table
speed in revolutions per minute. (RPM). The TOTCO SPM indicating system
is designed to indicate the mud pump strokes per minute (SPM).

l-5 DESCRIPTION

l-6 GENERAL. The RPM/SPM indicating system (See Figure l-l) consists of a
tachometer generator, indicating meter (either RPM or SPM) and inter-
connecting electrical cable. Two models of the tachometer generator are available:
an explosion-proof model and one for general purpose areas. See Table l-l for
leading particulars.

l-7 TACHOMETERGENERATOR. Both models of the tachometer generator are self-

contained, alternating current generators, maximum output 1OV ac at 150 mA.
The Type E is an explosion-proof while Type AB is for general purpose. The
explosion-proof model (Type E) is rated for use in areas designated as NEC Class 1,
Division 1, Group D or Class 2, Division 1, Group F and G. The general purpose
model (Type AB) is for use in non-hazardous areas and is rated dust resistant.

l-8 INDICATING METER. The indicating meter is a milliampere meter using a

six-inch dial, which is calibrated for RPM or SPM and whose pointer has
250' travel. The indicating meter incorporates a 50K ohm, lo-turn potentiometer
and a bridge rectifier. The potentiometer is used to regulate or control the amount
of ac potential to the rectifier. The rectifier converts the ac potential to a dc
potential and applies that potential to the meter movement assembly which deflects
the pointer an amount directly proportional to the applied potential.

l-9 ELECTRICAL CABLE ASSEMBLY. The cable assembly is shielded with a 3-pin
female connector on each end, in lengths of 25, 100, 150, or 200 feet. The
cable has three conductors and a ground.

l-10 OPERATION

l-11 GENERAL. Both systems are designed for oil field operation. Tachometer-
generators are small, units which require no outside power nor
batteries and have no brushes or contacts that create sparks or result in wear.
The generator can be rotated in either direction.

l-l
 INSTRUCTION MANUAL 30-03

A. RPMlSPM METER RPMlSPM METER

(BRACKET MOUNT) (FRONT VIEW)

(TYPE E) EXPLOSION PROOF

TACHOMETER GENERATOR
TO A OR B

_--------- -I
r- &TOAORB . TO A OR B

SWIVEL

I
I
1 2

I
\
3

C. DUS:PROOF (TYPE AB) D. DUST PROOF (TYPE AB) E. DUST PROOF (TYPE ABl
TACHOMETER GENERATOR TACHOMETER GENERATOR TACHOMETER GENERATOR
WITH V-BELT AND PULLEY DRIVE WITH WITH FLEXIBLE COUPLING
PULLEY DRIVE ROTARY SWIVEL DRIVE
26-681-3

FIGURE l-l. TYPICAL RPM/SPM TACHOMETERGENERATOR SYSTEM

l-2
 INSTRUCTION MANUAL 30-03

LEGEND FOR FIGURE l-1

A. RPM/SPM METER (BRACKET MOUNT) B. RPM/SPM METER (PANEL MOUNT)

1. Washer 1. Nut
2. Screw 2. Screw
3. Electrical Connector 3. Electrical Connector
4. Potentiometer 4. Seal
5. Meter 5. Potentiometer
6. Meter

C. TYPE AB TACHOMETER-GENERATORWITH D. TYPE AB TACHOMETER-GENERATORWITH

V-BELT AND PULLEY DRIVE PULLEY AND ROTARY SWIVEL DRIVE
1. Electrical Cable 1. Electrical Cable
2. V-Belt 2. V-Belt
3. Pulley 3. Pulley (Two required)
4. Nut 4. Nut
5. Screw 5. Screw
6. Bolt 6. Bolt
7. Base 7. Base
8. Generator 8. Generator

E. TYPE AB TACHOMETER-GENERATORWITH FLEXIBLE DRIVE

1. Electrical Cable 5. Screw
2. Flexible Coupling 6. Bolt
3. Adapters 7. Base
4. Nut 8. Generator

TABLE l-l. LEADING PARTICULARS

System Electrical
Tachometer-Generator Maximum output 1OV ac, 150 mA ac
Type E Explosion-proof
Type m General purpose, rated dust proof
Indicating Meter Milliampere meter
6-inch dial
2500 pointer travel

Dial Calibrated RPM or SPM

Cable Three conductor and ground
Operating Temperature -50' to +150°F (-45O to +65'C)

l-3
 INSTRUCTION MANUAL 30-03

l-12 Once the RPM/SPM indicating system is installed, any rotation of the tachometer-
generator shaft produces a small electrical potential (voltage). The ampli-
tude of this electrical potential is directly proportioned to the speed of the
tachometer-generator. The potential (voltage) produced by the tachometer-generator
is applied to the indicating meter through the electrical cable. The indicating
meter (milliampere meter), receives the ac potential and applies it in series with
a 50K ohm potentiometer to a full-wave bridge rectifier. The output of the rectifier
is applied to the meter movement resulting in pointer deflection.

l-13 When the tachometer generator is installed to rotate in direct ratio to

the rotary table, the indicating meter will read revolutions per minute
(RPM): when installed to rotate in direct ratio to the mud pump pinion shaft, the
indicating meter will read pump strokes per minute (SPM).

l-4
 INSTRUCTION MANUAL 30-03
SECTION II
INSTALLATION AND ADJUSTMENT

2-l INSTALLATION

2-2 GENERAL. This section contains procedures for installing the RPM/SPM in-
dicating system. Components of the RPM/SPM indicating system have been
field tested for hot and cold extremes (-50° to +150°F). The components are
shipped individually or as a complete system, and simple installation procedures
are all that is necessary to complete an interconnected system (See Figure l-l).
Installation dimensions are shown in Figures 2-1, 2-2, 2-3, 2-4, 2-5, 2-6 and 2-7.

2-3 TACHOMETER-GENERATOR. To install the tachometer-generator, perform a

rig survey to determine the following: type of drive that will be used;
where the rotary output will be taken from; location of the tachometer-generator;
and the type (AB or E). Locate the tachometer-generator in a well-protected area.

2-4 RPM TACHOMETER-GENERATOR. Install the RPM tachometer-generator to be driven

from one of the following:

a. Rotary clutch with V-belt (Rotary Swivel)

b. Counter shaft with V-belt

C. Direct drive (Flexible Coupling)

Typical installations are shown in Figures 2-8, 2-9 and 2-10.

NOTE

Tachometer-generator shaft may be driven

clockwise or counterclockwise.

2-5 SPM TACHOMETER-GENERATOR. Install the SPM tachometer-generator to be

driven from one of the following:

a. Main pump shaft (V-belt)

b. Pump oiler belt (Pulley drive)

C. Pump clutch (Pulley drive with rotary swivel)

Typical installations are shown in Figures 2-10, 2-11 and 2-12.

NOTE

Tachometer-generator shaft may be driven

clockwise or counterclockwise.

2-l
 INSTRUCTION MANUAL 30-03

FIGURE 2-l. INSTALLATION DIMENSION, RPM/SPM METER

2-2
 INSTRUCTION MANUAL 30-03

318-16 x 21N.
LAT HEAD BOLT
ADJUSTABLE
2.28 TO 3.93

26-661-5 MOUNTING SURFACE

SUPPLIED BY CUSTOMER

FIGURE 2-2. DUST PROOF (TYPE AB) TACHOMETER-GENERATOR

WITH PULLEY DRIVE, INSTALLATION DIMENSION

ROTARY SWIVEL

TYPE “A” BELT, 8 FOOT LONG

1243.8 cm)

318-16 x 2 FLAT HEAD BOLT

ADJUSTABLE
2.28 TO 3.93

1.50
.8 cm)
MOUNTING SURFACE
SUPPLIED BY CUSTOMER

FIGURE 2-3. DUST PROOF (TYPE AB) TACHOMETER-GENERATORPULLEY DRIVE

WITH ROTARY SWIVEL, INSTALLATION DIMENSIONS
2-3
 INSTRUCTION MANUAL 30-03

ADJUSTABLE
2.28 TO 3.93
(5.8-10.0 cm)

6.50

MOUNTING SURFACE
SUPPLIED BY CUSTOMER
26-661~7
(15.9 cm)

FIGURE 2-4. DUST PROOF (TYPE AB) TACHOMETER-GENERATORWITH

FLEXIBLE COUPLING DRIVE, INSTALLATION DIMENSIONS

114-20 UNC x 1 .O LG
TYPE “A” BELT OP. l/4-20(4 PLACES)
8 FOOT LONG

GROUNDING

3.33 TO 4.92
(8.5-12.5 cm1

SECTION A-A-

MOUNTING SURFACE
UPPLIED BY CUSTOMER

3/8-l 6 x 2 IN. FLAT HEAD BOLT

(3 1.4 cm)

FIGURE 2-5. EXPLOSION PROOF (-TYPE E) TACHOMETER-GENERATOR

WITH PULLEY DRIVE, INSTALLATION DIMENSION
2-4
 INSTRUCTION MANUAL 30-03

ROTARY SWIVEL
3/8-16 x 21N.
FLAT HEAD BOLT

SECTION A-A

3.50 DIA

ADJUSTABLE
3.33 TO 4.92
(8.5-l 2.5 cm)
MOUNTING SUR
SUPPLIED BY CUS

FIGURE 2-6. EXPLOSION PROOF (TYPE E) TACHOMETER-GENERATORPULLEY DRIVE

WITH ROTARY SWIVEL, INSTALLATION DIMENSIONS

114-20 UNC x 1 .O LG
OP, l/4-20(4 PLACES)

3.33 TO 4.92
(8.5-l 2.5 cm)

SECTION A-A-

MOUNTING SURFACE
UPPLIED BY CUSTOMER

3/8-l 6x2 IN. FLAT HEAD BOLT

26.6W10

FIGURE 2-7. EXPLOSION PROOF (.TYPE E) TACHOMETER-GENERATORWITH

FLEXIBLE COUPLING DRIVE, INSTALLATION DIMENSIONS
2-5
 INSTRUCTION MANUAL 3043

-A
CENTERED ON
SUB SHAFT SHAFT
COUPLING
ADAPTER
CAUTION
/

c
v
WELD CAREFULLY TO PRE-
VENT DAMAGING RIG
SHAFT BEARINGS. II

PULLEY
& SHAFT
SECTION A-A
\ WELD
(SEE CAUTION)

26-661-l 1

-A

FIGURE 2-8. COUNTER SHAFT ADAPTER DRIVE FOR RPM INSTALLATION

-A
FLEX. CPLG. SUB, WELD CENTERED ON
TO SHAFT SHAFT
(SEE CAUTION)

i I
/ I
GENERATOR
\

-4
--I, “I\ PINION
CAUTION SHAFT

WELD CAREFULLY TO PRE-

VENT DAMAGING RIG
SECTION A-A
SHAFT BEARINGS

26-661-12

FIGURE 2-9. FLEXIBLE COUPLING DRIVE FOR RPM INSTALLATION

2-6
 INSTRUCTION MANUAL 30-03

, PULLEY & SHAFT

CENTERED ON
WASHER SHAFT
\

SHAFT
/ SECTION A-A

V-BELT

A-

FIGURE 2-10. ROTORSEAL ADAPTER INSTALLATION FOR RPM OR SPM

TACHOMETER GENERATOR

26-66/-14

FIGURE 2-11. MAIN PLJMPSHAFT DRIVE FOR SPM INSTALLATION

2-7
 INSTRUCTION MANUAL 30-03

TIGHT SIDE

V-BELT TO
PINION SHAFT. I
GENERATOR
W/PULLEY

PISTON ROD
OILER PUMP

FIGURE 2-12. PULLEY DRIVE FOR SPM INSTALLATION

2-6 ELECTRICAL CABLE. Route the electrical cable through well-protected areas.
Avoid areas where moving machinery and rig personnel are working. Clamp
or tie cable clear of water, mud and walkways where it may sustain damage (See
Figure l-l).

WARNING

WHEN INSTALLING AN EXPLOSION PROOF (TYPE E)

TACHOMETER-GENERATOR,THE GENERATORAND ELEC-
TRICAL CABLE MUST BE IN COMPLIANCE WITH NEC
CLASS I, GROUP D, DIVISION 1, OR CLASS II,
GROUP F AND G, DIVISION 1.

a. Connect one end of electrical cable to tachometer-generator and route

cable to driller's console or weight indicator box.

b. Connect electrical cable to indicating meter.

2-8
 INSTRUCTION MANUAL 30-03

2-7 INDICATING METER. To install the indicating meter, determine type of

mounting (Bracket Mount/Panel Mount) and proceed as follows (See A or B,
Figure l-l):

a. Attach bracket to meter (A-5) using washer (1) and screw (2). Secure
meter and bracket into weight indicator box with hardware supplied.
Connect electrical connector (3).

b. Secure meter (B-6) into driller's console with screw (2) and nut (1).
Connect electrical connector (3). Mount potentiometer (5) and seal (4)
adjacent to meter (6) on driller's console.

2-8 RPM START-UP PROCEDURES. After installation and before any accurate
indication can be obtained, the RPM system must be adjusted. Proceed as
follows (See Figure 3-2 or 3-3):

a. Count the rotary table revolutions per minute.

b. Loosen stem locking nut on the potentiometer (17, Figure 3-2 or 18,
Figure 3-3).

CAUTION

TURN POTENTIOMETER STEM SLOWLY; DO NOT FORCE

IT. FORCING POTENTIOMETER STEM WILL CAUSE
EQUIPMENT DAMAGE.

C. Adjust potentiometer stem (while monitoring RPM meter) to obtain a

meter indication that corresponds to the number of revolutions counted
in step a.

d. Tighten stem locking nut on potentiometer (17, Figure 3-2 or 18, Figure
3-3).

2-9 SPM START-UP PROCEDURES. After installation and before any accurate
indication can be obtained, the SPM system must be adjusted. Proceed as
follows (See Figure 3-2 or 3-3):

a. Count the mud pump strokes per minute.

b. Loosen the potentiometer stem locking nut (17, Figure 3-2 or 18, Figure
3-3).
CAUTION

TURN POTENTIOMETER STEM SLOWLY; DO NOT FORCE

IT. FORCING POTENTIOMETER STEM WILL CAUSE
EQUIPMENT DAMAGE.

C. Adjust potentiometer stem (while monitoring SPM meter) to obtain a

meter indication that corresponds to the number of strokes counted
in step a.

d. Tighten stem locking nut (17, Figure 3-2 or 18, Figure 3-3).

2-9
 INSTRUCTION MANUAL 30-03

2-10 RPM/SPM METER MODIFICATION. The RPM/SPM meter contains a bridge rectifier
circuit for converting an ac signal to dc. When using this meter with a
dc signal source (input), this circuit must be bypassed. Proceed as follows (See
Figure 3-5 or 3-6):

a. Remove cannon plug from meter, use a multimeter (Refer to Related

Tools and Test Equipment) momentarily connect lead and between pins
A and C.

b. The RPM/SPM meter movement will deflect to the positive (show an

increase indication), reverse the multimeter leads on pins A and C,
again the RPM/SPM meter movement will deflect to the positive (show an increase
indication). This test signifies that the rectifier is functional. If during
the test, the RPM/SPM meter movement deflects less than zero (show a decrease in-
dication), the rectifier has been bypassed.

C. If meter is wired incorrect for signal source; remove meter to field

shop, then refer to paragraph 3-15 for correction.

2-10
 INSTRUCTION MANUAL 30-03
SECTION III
PERIODIC INSPECTION, FIELD MAINTENANCE AND SHOP MAINTENANCE

3-l GENERAL INFORMATION

3-2 RPM/SPM systems are built to give trouble-free service with a minimum of
maintenance and inspections. To keep the system in best operating condition,
periodic inspections must be carried out. Maintenance personnel must establish a
suitable inspection cycle based on usage and operating environment of the system.

3-3 PERIODIC INSPECTION

3-4 GENERAL. Carry out a general visual inspection of the entire RPM/SPM
system installation, checking for damage, wear and loose parts. Carefully
check V-belts, pulleys, flexible couplings, adapters and tachometer-generator. A
thorough inspection should be made at each rig-up. For periodic inspection re-
quirements, refer to Table 3-l.

3-5 FIELD MAINTENANCE

3-6 GENERAL. Field maintenance is limited to the removal and replacement of

RPM/SPM system components and system adjustment. Do not disassemble or
reassemble any component at field level maintenance. Any component/unit that is
defective, damaged, malfunctioning, or suspected of improper operation, must be
removed and replaced with a like item and the defective one sent to the TOTCO
field shop for complete overhaul, test and calibration.

TABLE 3-l. PERIODIC INSPECTION REQUIREMENTS

COMPONENT INTERVAL REMARKS

V-Belt Checked every 30 days. Frayed, loose or deter-

iorated.

Electrical Cord Checked every 30 days. Cut, crack, kinks,

residue buildup and
bare wires.

Electrical Connectors Checked every 30 days. Loose, wet and/or corrode1

Mounting Bracket Checked every 30 days. Loose bolts and adjust-

ment.

Meter Checked every 30 days. Residue buildup, conden-

Refer to Paragraph 2-8 sation and security.
or 2-9.

Tachometer-Generator Checked every 30 days. Residue buildup, align-

ment and security.

3-1
 INSTRUCTION MANUAL 30-03

3-7 COMPONENTREMOVAL AND REPLACEMENT. Loose, worn, defective or inoperative

components must be removed and replaced.

WARNING

ALL POWERMUST BE REMOVED FROM EQUIPMENT

PROVIDING MECHANICAL DRIVE TO TACHOMETER-
GENERATOR.

Follow index numbers assigned to illustration for component replacement.

3-8 SHOP MAINTENANCE

3-9 GENERAL. Unless overhaul of the RPM/SPM system components is to be carried

out, component disassembly should be only to the extent necessary for re-
placement of defective parts. Do not remove decals, nameplates, gaskets, and
parts bonded in place unless replacement is necessary. Parts that are swaged,
bonded, welded, riveted, peened, press-fitted, staked or soldered together as
assemblies, should not be separated; replace these items as subassemblies. Dis-
assembly of components is accomplished by following the order of index numbers
assigned to the exploded views.

3-10 TACHOMETER-GENERATOR. Do not attempt repair of tachometer generator;

return to vendor for all maintenance.

WARNING

DO NOT ATTEMPT REPAIR OF EXPLOSION PROOF

TACHOMETER-GENERATORELECTRICAL CABLE.

3-11 CABLE, ELECTRICAL. When electrical cable becomes defective, do not

splice: cut electric cord to length and fabricate new cable as shown
in Figure 3-l.

3-12 RPM/SPM BRACKET-MOUNT METER. Place the meter on clean work surface; to
disassemble, follow the order of index numbers assigned to Figure 3-2.
Reassemble the meter by following reverse order of assigned index numbers. Observe
the following:

a. Do not perform any maintenance on movement (5), replace with like

item.

b. When meter is used with dc tachometer-generator input, the rectifier

assembly must be bypassed. Refer to paragraph 3-15 for meter modi-
fication.

C. Encapsulate solder connection on potentiometer (17) and male connector

(19) with clear rubber silicone sealant (Refer to Approved Expendable
Items List).

3-2
 INSTRUCTION MANUAL 30-03

STRIP AND TIN

li

26-681-16
GREEN (GROUND)

FIGURE 3-l. ELECTRICAL CABLE

3-13 RPM/SPM PANEL MOUNT METER. Place the meter on clean work surface; to
disassemble, follow the order of index numbers assigned to Figure 3-3.
Reassemble the gauge by following reverse order of assigned index numbers. Ob-
serve the following:

a. Do not perform any maintenance on movement (5), replace with like

item.

b. When meter is used with dc tachometer generator input, the rectifier

assembly must be bypassed. Refer to paragraph 3-15 for meter
modification.

C.On purged meters, install seal (19, Figure 3-3), encapsulate solder
connections (7, 19, Figure 3-2) panel mount meter; (18, 20, Figure 3-3)
panel mount purged meter with clear silicone rubber sealant (Refer to Approved
Expendable Items List).

3-14 RECTIFIER ASSEMBLY. When performing maintenance on the rectifier assembly,

use standard soldering practice. To disassemble rectifier, follow the
order of index numbers assigned to Figure 3-4. To reassemble the rectifier,
follow the reverse order of assigned index numbers.

3-3
 INSTRUCTION MANUAL 30-03

FIGURE 3-2. BKAGKH'l'-MUUN'L ME'l'EK

 INSTRUCTION MANUAL 30-03

co
t-

FIGURE 3-3. PANEL BOUNT METER

3-5
 INSTRUCTION MANUAL 30--03

OLD BOARD; DIODE NEW BOARD; BRIDGE

26-651-I
1 RECTIFIER ASSEMBLY RECTIFIER ASSEMBLY

FIGURE 3-4. RECTIFIER ASSEMBLY

3-15 The RPM/SPM meter contains a bridge rectifier circuit for converting the
ac signal from the AC Tachometer-Generator to dc. When using this meter
with a DC Tachometer-Generator, this circuit must be bypassed. To bypass the
rectifier circuit, proceed as follows (See Figure 3-2 or 3-3):

a. Remove the meter face covering (1 thru 4).

b. Remove the meter movement assembly (5 thru S) from the housing.

C. Solder a jumper wire from position A to B (Figure 3-5 or 3-6) on the

rectifier board; then relocate meter movement black wire (-) to posi-
tion C.

d. Reassemble meter.

e. Identify meter as having been modified; if meter is used again with

ac signal source, modification must be removed.

3-16 RPM/SPM METER CALIBRATION. No in-shop calibration is required; for rig

adjustment and system startup procedures refer to paragraph 2-8 or 2-9.

3-6
 INSTRUCTION MANUAL 30-03

c--------- RpM/SpM METER---------l

I
I
I ,,,..,-,,~a ,.,,r,C- -AY fiU.1 ,XC,STOR RECTIFIER I
/ BOARD I

0
M-
O
-__ ___ bj 1 CANNON PLUG (VIEW FROM BACK)
i
I I CONNECTS TO RPM/SPM METER
i BRIDGE’
1 b BLACK WIRE 1

! RPM/SPM METER MOVEMENT

FIGURE 3-5. RECTIFIER BOARD MODIFICATION WITH BRIDGE

r---------.RpM/SpM METER---------
1
I
RECTIFIER BOARD

LUG (VIEW FROM BACK)

CONNECTS TO RPM/SPM METER

4K OHM RESISTOR

RPM/SPM METER MOVEMENT

FIGURE 3-6. RECTIFIER BOARD MODIFICATION WITH DIODES

3-7/3-s
 INSTRUCTION MANUAL 30-03
SECTION IV
TROUBLESHOOTING

4-l GENERAL

4-2 When the system is properly adjusted for the service which it is being
used, the reading on the indicating meter will be correct. An erroneous
reading can easily be verified by counting the pump strokes (SPM) or rotary table
revolutions (RPM). A list of probable causes for troubles is given in Table 4-l.

TABLE 4-l. TROUBLESHOOTING TABLE

TROUBLE PROBABLE CAUSE CORRECTIVE ACTION

Erratic meter reading. Slippage between drives and Tighten drive.

generator.
L

Poor electrical contact in Clean receptacle.

receptacle.

Internal meter damage. Replace meter.

Water in connector. Clean and dry

connector.
I
Meter indication low. Slippage between driver and Tighten drive.
generator,

Improperly adjusted. Readjust system.

Internal meter damage. Replace meter.

No indication on Generator drive unit loose or Repair or replace

inoperative. driver.

Loose electrical connections. Tighten connection.

Inoperative generator. Replace generator.

Internal meter damage. Replace meter.

4-l/4-2