Encoder Troubleshooting Encoder Troubleshooting .. Introduction Encoder Circuits .. Encoder Output Voltages Siemens Digital Tachometer Interface (DTI) Board .. 7-4 Typical signal measurements with a DMM (Top Drive not running) .. Troubleshooting... Indications of encoder circuit problems Disconnecting and Bypassing the DTI Board (Siemens drive). Encoder troubleshooting instruction IDM... AC Top Drive Troubleshooting Guide 7-1Encoder Introduc! Troubleshooting What is an encoder? ‘An encoder outputs a digital signal. The signal output is a series of pulses. The maximum and minimum voltage of the pulses is always the same, however the frequency varies with the shaft speed. As the shatt speed increases, the output frequency increases. As the shaft speed decreases, the output frequency decreases. Equipment connected to the encoder (an AC drive or PLC, for example) determines the shaft speed by counting the number of pulses over a brief period of ime. The pulse counting and speed calculation repeats it self continuously Why is an encoder needed? The AC top drives uses a digital encoder. The encoder feedback is not required most for driling o2erations, but is required when making or breaking pipe connections. The torque delivered by the top drive when making or breaking connections must be smooth and well regulated. An encoder is needed for this. Varco SystemsEncoder Circuits Encoder Output Voltages Enecder signals measured single endedly with an Oscilloscope [A+ 12 COM], [A- to COM}, [B+ to COM] and [B- to COM av w -J_l +15 LI ov - “vy o --LJ_ AC Top Drive Troubleshooting Guide v- tts 7-3Siemens Digital Tachometer Interface (DTI) Board “The +15VDC for the encoder is generated on the DTI board from the +24VDC supply from the inverter. Itis completely isolated from the +15VDC supply coming from the inverter to connector X03, od 7-4 Varco Systems s2avoe The +24VDC power supply ‘comes from the inverter. e Itis used to generate the 2AVDC RET iccintnr + 1SVNC sunny Inverter terminal block +15VDC RET, Digital Tachometer Interface The +15VDC power supply at X403 comes from the inverter. tis isolate from the rest of the DTI board and is only used to power the ‘Aand B outputs for the inverter.Encoder Circuits Typical signal measurements with a DMM (top drive not running) Several measurements can be made with a DMM (Digital MultiMeter). The measurements sive a good indication if the circuit is functioning correctly I is sometimes necessary to use an oscilloscope. The chart below shows possible measurements taken at the encoder connections of the DT! board when the top drive is stopped. The measurements depend on the position of the ‘encoder disk when it stops rotating. A B xa023 _x402.5, ggg AC Top Drive Troubleshooting Guide 7-5Troubleshooting Indications of encoder circuit problems 7-6 ‘The most frequent indication that there is something wrong with the encoder circuit is when the top drive is started and the drille’s console meters show zero (or near zero) RPM and the torque ramps up to limit. Other indications of encoder problems are fault messages on the drive that refer to encoder fault codas. If the encoder circuit does not fail completely, itis possible to observe intermittent erratic behavior of the top drive. This is indicated by rapid changes in RPM and/ or torque. Failures of the encoder circuit are usually simple, but can sometimes be difficult to find. Failures can include, but are not limited to, any one or more of the following: short or open circuits in the cabling between the inverter and the encoder broken solder connections in the cable plugs . . wet or loose connectors loose terminal block connections in the drive . noise induced due to improper cable routing (i.¢, running the encoder leads too close to higher voltage control circuits or blower motor cables) noise induced due to improper grounding of the shields simple electronic component failure power supply failure top drive runs properly for awhile, then it registers all torque but no speed: + intermittent short causing loss of pulses (the encoders short circuit protection shuts off the outputs until it cools off) Varco SystemsTroubleshooting connecting and Bypassing the DTI Board (Siemens drive) Depending on the problems with the circuit, it may be necessary to disconnect the DTI board and connect the encoder directly to the drive's encoder input terminal blocks. The encoder can be connected one of four ways. The way itis connected depends on what the problem with the circuit is. Before disconnecting the DTI board, make sure you have identified and marked the wires. Choose an appropriate circuit for the circumstances. If the drive does not turn and torque is Up when you put it back into olosed loop, the A and B leads may be backwards. Reverse the connections and try it again. Rotation is relative — it doesn't matter which is A and which is B, as long as the combination used works. +15VDC RET Inverter terminal block +15vbe Use the A+ and B+ signals if there is a problem with A- or 8 s1svoe RET Use :he A- and B- signals if there is a problem with A+ or B+. AC Top Drive Troubleshooting Guide 7-7Encoder troubleshooting instruction The encoder provides rotational position information to the Variable Frequency Drive (VFD) (On most of the top drives in the field, the encoder signal comes into the Varco interface terminal strip in the drive. The +15 VDC for the encoder is provided from the drive and goes out on pin 37 (common) and pin 38 +15 VDC. Most top drives use a differential input signal. The Sicnens drive uses an optional digital tachometer interface board to convert this differential signal (A+, A- and B+, B-) to a single-ended signal A+ and B+. The A+ signal is pin 40 and the A- signal is 41. The B+ signal is 43 and the B- signal is 44. Refer to the schemates. The waveforms for the respective signals are illustrated on page 7-9. The symptom of an encoder failure is that the drive when assigned and throttle given, refuses 10 rotate or rotates very slowly (torque gauge reads High). A failure indication on the drive is rarely seen, or it may trip out due to overcurrent. If you suspect the encoder, change the drive from speed control to frequency control per the procedure... the top drive starts rotating, itis an encoder problem. If t does not verify the changeover trom speed control to frequency control, try again. If it still does not turn, look at the inputs to the drive and not the encoder. (On the Siemens 70, use Encoder By-Pass Kit, Varco PIN 125580.) Check the signals with a voltmeter first — with the drive stopped). There should be approximately 15V between pin 38 and 37 (+15V and Common). If there is not, disconnect the encoder cable at the front of the house to see if itis shorted out. There should be approximately 12V or greater between (A+ and A-) and between (B+ and B-).If there is not and a scope is available, check the individual signals to see which one(s) are missing. This requires running the top drive in frequency mode. Varco SystemsEncoder troubleshooting instruction - a8 o TLE rsisv oJ l ov It you are missing a signal, on the Siemens drive, the signals can be rewired so that they do not pass through the DTI CCA to keep running. A+ and B+ are good, disconnect the At and B+ from the DTI CGA at X403. Then jump A+ to the A+ wire disconnected from X403-3 and B+ to the B+ wire disconnected from X403-3 and likewise with B- to Bs @ Miswired motors may look like an encoder problem. AC Top Drive Troubleshooting Guide 7-9Encoder troubleshooting instruction © Pin 32 or 12 ‘on Control Board 10 Encoder Input 1. Check for 12 VDC at TBX pins 45 and 46 for proper polarity. If they are okay, proceed to step 2, Due to same wiring variances of the IDM, these pins may also be pins 38 and 37. Make sure to identity the correct pins. 2. Go to OPEN LOOP and make sure the too! is spinning in the proper direction. If itis spinning in the proper direction, proceed to step 3, Miswired motors may look like an encoder problem: 3. Check the test points indicated in the chart (below) for waveforms of proper shape (low noise) and polarity as shown on page 7-9. Common #2 Asi a 4 From 2 ig Encoder B PGX Card TeX Varco Systems