OPERATING

MANUAL

Electronic Ex Torque Gauge ExTG

field test version

Keep this manual for future reference!

Issue/rev. date: April 2004

 Publisher: Weatherford Oil Tool GmbH
Hainhäuser Weg 150
D -30855 Langenhagen
( +49 (0)511-7702-0
FAX +49 (0)511-7702-187
WEATHERFORD OPERATING MANUAL
TERMS AND CONDITIONS OF USE

A. The materials contained in this Weatherford Operating Manual are protected by copyright,
trademark and other forms of proprietary rights. Nothing contained herein shall be
construed as conferring any license or right to use or practice any copyright, trademark,
patent or other forms of proprietary rights. This Operating Manual may not be copied or
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converted to any mechanical, electronic or machine readable form, in whole or in part,

without Weatherford’s consent.
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B. This Operating Manual is not intended to address every issue that may arise in the course
of operations of the device described therein or the planning of same. Each well and each
job are unique and have numerous variables. Experience and other specialized training
can complement the materials used in this Operating Manual.

C. Weatherford makes no representation as to the accuracy or completeness of the materials

in this Operating Manual. All materials are provided “AS IS” WITHOUT WARRANTY OF
ANY KIND WHATSOEVER, EITHER EXPRESS OR IMPLIED, INCLUDING BUT NOT
LIMITED TO, THE IMPLIED WARRANTIES OF MERCHANTABILITY, FITNESS FOR A
PARTICULAR PURPOSE OR NON-INFRINGEMENT. Weatherford expressly disclaims all
responsibility for the consequences, direct, indirect, consequential or otherwise, of any
errors or omissions in the materials.

D. This information is confidential and proprietary property of Weatherford. Do not disclose to

unauthorized parties. Do not use except as permitted by Weatherford. Copyright 2004
Weatherford. All rights reserved.

p/n: 561

06 April 2004 BL

Page 2 of 27 Rev. April 2004 Operating Manual

CONTENTS PAGE
1 Safety................................ ................................ ................................ ................................ ...4

2 Transportation and Installation ................................ ................................ .......................... 4

3 General description ................................ ................................ ................................ ............5

3.1 GENERAL DESCRIPTION ................................ ................................ ....................... 5
3.2 SYSTEM COMPONENTS ................................ ................................ ........................ 6
3.2.1 ExTG Panel ...................................................................................................................6
3.2.2 AC Power supply...........................................................................................................6

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3.2.3 Compact Flash Card Position .........................................................................................7

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3.3 TECHNICAL DATA................................ ................................ ................................ ...8

4 operation ................................ ................................ ................................ ............................. 9

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4.1 DUMP TORQUE................................ ................................ ................................ .......9
4.2 CARD ................................ ................................ ................................ ....................... 9
4.3 FILE ANALYSIS ................................ ................................ ................................ .......9
4.4 POWER UP AND MAIN MENU ................................ ................................ .............. 10
4.5 MAIN MENU................................ ................................ ................................ ........... 11
4.5.1 The Main Menu looks like this: ...................................................................................11
4.5.2 File ..............................................................................................................................12
4.6 INTERFACE CHECK................................ ................................ .............................. 14
4.6.1 Calibrate F4 .................................................................................................................14
4.7 ACQUIRING ................................ ................................ ................................ ........... 15
4.7.1 Save.............................................................................................................................17
4.8 SETUP ................................ ................................ ................................ ................... 20
4.9 HARDWARE ................................ ................................ ................................ .......... 21
4.10 PROGRAM INFO ................................ ................................ ................................ ...22

5 Appendix ................................ ................................ ................................ ........................... 24

5.1 CIRCUIT DIAGRAM EXTG ................................ ................................ ..................... 24
5.2 LOAD CELL CABLE ................................ ................................ ............................... 26
5.3 DUMP VALVE CABLE................................ ................................ ............................ 27

Operating Manual Rev. April 2004 Page 3 of 27

 1 SAFETY

This device is a working sample for testing purpose only

Don’t use it in hazardous areas.

2 TRANSPORTATION AND INSTALLATION

Will be available at a later date
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Page 4 of 27 Rev. April 2004 Operating Manual

3 GENERAL DESCRIPTION

3.1 GENERAL DESCRIPTION

The ExTG is designed exclusively for recording torque values occurring during make-up (or

break-out) of casing and tubing operation of hydraulically operated Weatherford tongs as well as

for controlling the tong dump valve and thus the maximum torque

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ExTG Panel

AC Power
Supply

Operating Manual Rev. April 2004 Page 5 of 27

 3.2 SYSTEM COMPONENTS

3.2.1 ExTG Panel

Back wall of the ExTG shows the connection position.

Load Cell

Dump Valve

AC power
supply
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3.2.2 AC Power supply

Back wall of the AC power supply shows the connection position.

Power cable
Power cable connector ExTG
to AC Power side
Supply

Power
cable to
ExTG

Page 6 of 27 Rev. April 2004 Operating Manual

3.2.3 Compact Flash Card Position

Compact
Flash Card

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Compact
Flash Card

Operating Manual Rev. April 2004 Page 7 of 27

 3.3 TECHNICAL DATA

Preliminary

AC Power Supply PN5614955

Dimensions:

Protection class: min. IP40

Storage temperature:

Ambient temperature: -25°C < Ta > +55°C

Weight:

Approval: ATEX type approval in progress

{ 2 II G EEx [ia] IIB }

Electrical Data:
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Supply Voltage: 110V-120V / 220V-230V AC 50-60Hz

Power Consumption: 80W

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ExTG Panel PN5614950

Dimensions: (width x height x depth)

Protection class: IP65

Storage temperature:

Ambient temperature: -25°C < Ta > +60°C

Weight:

Approval: ATEX type approval in progress

Electrical Data:

Supply Voltage: use AC Power Supply PN564955 only

Dump Valve output: max. 5V 50mA

Load Cell: 4 – 20mA, max. 13V at full load

Page 8 of 27 Rev. April 2004 Operating Manual

4 OPERATION

4.1 DUMP TORQUE

There are different DUMP TORQUE values.

On the ACQUIRING page and in the MAKE mode the DUMP TORQUE is like in the SETUP adjusted.

SAFETY DUMP

On the ACQUIRING page and in the BREAK mode the SAFETY DUMP TORQUE is like the end of the
measurement range from the Load Cell. The end of the measurement range from the Load Cell don`t
need to be setup. This value is reached if 20mA are measured.
On the INTERFACE CHECK page the SAFETY DUMP TORQUE is like the end of the measurement
range from the Load Cell.
On every other page the SAFETY DUMP TORQUE is 10% from the DUMP TORQUE

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4.2 CARD

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The first use of a new Compact Flash Memory Cards you have to format the card (Format FAT 16).
This must be done by a personal computer (later also by ExTG)

If the card is stuck in the ExTG the ExTG generates a directory structure at the card ( \wford\extg )

! Do not remove the card during read or write operation!

It is allowed to remove or stuck the card under power.
27 files can be administrated on one card.

4.3 FILE ANALYSIS

The different files can be evaluated using MS Excel.

Plug the card to a personal computer using an adapter card for Compact Flash.
You will need Excel to access the files.
-Open a file on the card.
-Choose all file format.
-Choose the file you want to evaluate ( file termination .xtg ).
-Choose the separate button and press next.
-Choose separating character comma and press finish.
-Excel creates the list with data from the file.

Operating Manual Rev. April 2004 Page 9 of 27

 4.4 POWER UP AND MAIN MENU

After power up the LCD backlight is illuminated. First the system information and the Weatherford Oil
Tool GmbH address are displayed.
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Press F5(START) to enter the Main Menu.

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Page 10 of 27 Rev. April 2004 Operating Manual

4.5 MAIN MENU

4.5.1 The Main Menu looks like this:

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Use the UP and DOWN keys(M1,M2) to select a Menu option, the active Menu choice will be
highlighted, press GOTO(F5) to select. With F1 you can restart the CAN bus.

Operating Manual Rev. April 2004 Page 11 of 27

 4.5.2 File
You see the directory of all files, if you press F4.

By a later version here the data of each made up connection are displayed: joint no. and type, time,
date, final torque, comment 1. Then you can select a joint by the UP/DOWN-keys (M1,M2) and edit it
by F5. Then connection no. , comment, joint no. and type can be changed.
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4.5.2.1 New F3

Create a new file. Use not more than 8 digits for the name.
Use the UP/DOWN-keys (M1, M2) to select a character, use the +CURS (F4) to skip to the next
digit.
ESC (F1) cancel and back either to the file page or the dir page.
ENTER (F5) save the new file and back either to the file page or the dir page.

Page 12 of 27 Rev. April 2004 Operating Manual

4.5.2.2 Dir F4

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All the files on the card will be shown.
The activatetd file is highligted.
Use UP/DOWN-keys (M1, M2) to select a file.
DELETE (F4) to delete the selected file.

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NEW (F3) see 4.5.2.1
BACK (F1) back to FILE page.

Operating Manual Rev. April 2004 Page 13 of 27

 4.6 INTERFACE CHECK

The actual torque is displayed in units and in digits. In this mode no automatic dump is done only a
safety dump. (see Dump Torque 4.1) There are keys to toggle the dump valve (F5), to zero the load
cell (F3) to calibrate the load cell (F4) and to restart the CAN bus (F2).
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4.6.1 Calibrate F4

First the last actual torque from the interface check page is displayed. Now you can adjust the known
correct torque using +CURS/-CURS (F2/F4) to choose a digit and UP/DOWN (M1/M2) to change this
digit. The correction is possible at ±20% from the measured value.

Page 14 of 27 Rev. April 2004 Operating Manual

 Press ENTER to confirm the adjusted value or ESC to abort and go back to the INTERFACE CHECK
page.

4.7 ACQUIRING

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Press the MAIN-key (F1), if you want to exit to main menu (only activated when Dump signal off). Press
F5 to go to safety Dump mode (see Dump Torque). Press F4 to restart.
!Press LC->0 and the Torque value is zero. Do this only if the Load Cell is without load !
F2 you can choose between a MAKE or BREAK connection.
Make at the button F2 means you can change to a MAKE connection.
Break at the button F2 means you can change to a BREAK connection.

Operating Manual Rev. April 2004 Page 15 of 27

 After reaching 25% of the adjusted torque the key SAVE is activated and Safety key disappears.
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The dates shown above the bargraph are the actual torque (left) and the peak torque (right).

Page 16 of 27 Rev. April 2004 Operating Manual

4.7.1 Save

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If the dump torque is reached the MAIN (F1) button is deleted.
You have to select new or save.
If you select “SAVE”, a menu is displayed, where you can choose between accept, reject, breakout,
pup joints, tool, re-torque and function test. Here you can also decide yourself for two prefixed
comments, that are stored with the data, and change the connection no and joint no.

Operating Manual Rev. April 2004 Page 17 of 27

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The Final Torque, Date and Time are not selectable.

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With UP/DOWN you can choose between:

Connection No
Joint No
Joint Type
Comment 1
Comment 2

ACCEPT F3 Joint Type will be set to Accept, dataset will be saved a the end of the file and jump
back to the ACQUIRING page.
REJECT F4 Joint Type will be set to Reject, dataset will be saved a the end of the file and jump
back to the ACQUIRING page.
SAVE F1 block will be saved at the end of he file and jump back to the ACQUIRING page.

Jumping back to the ACQUIRING page the Connection No. is automatically incremented.
The Joint No. is automatically incremented if the Joint Type is Accept or Pup Joint.

With ENTER you can select an item.

Page 18 of 27 Rev. April 2004 Operating Manual

 Connection No or Joint No

If an item is selected, a cursor will appear and highlight the smallest digit.
Use the +CURS/-CURS keys (F2,F4) to move the cursor, the UP/DOWN keys (M1,M2) to scroll a

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digit.
With ENTER (F5) you confirm the input.

Comment: E
The comment 1 and 2 consist of 3 pages.
With SAVE (F1) the chosen comment will be taken over.

Operating Manual Rev. April 2004 Page 19 of 27

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4.8 SETUP

Use the UP/DOWN keys (M1,M2) to select a Menu option, the active Menu choice will be highlighted,
press F5 (ENTER) to select.

Page 20 of 27 Rev. April 2004 Operating Manual

 If an item is selected, a cursor will appear and highlight the smallest digit. Use the +CURS/-CURS keys
(F2,F4) to move the cursor, the UP/DOWN keys (M1,M2) to scroll a digit or the unit and the CLR
key(F3) to set the minimum value. Press ESC(F1) to restore the old value or ENTER(F5) to save the

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new value.
The load cell range can also be represented in [N]. For the tong arm length and the dump torque as well
metric units can be chosen.

4.9 HARDWARE

Operating Manual Rev. April 2004 Page 21 of 27

 Here you can toggle the backlight and adjust the contrast of the LCD display.
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4.10 PROGRAM INFO

The system information and the Weatherford Oil Tool GmbH address are displayed.

Page 22 of 27 Rev. April 2004 Operating Manual

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Operating Manual Rev. April 2004 Page 23 of 27

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5
0 1 2 3 4 5 6 7 8 9

5.1

Page 24 of 27
APPENDIX

L N
Load J3 J2 J1

100 W
IPS_BW4

IPS IPS IPS IPS

CIRCUIT DIAGRAM EXTG

Line
L N
Vout1 Vout2 Vout3 Vout4
9V 9V 9V 9V
IS IS IS IS
J7 J6 J9 J8 J11 J10 J13 J12

F1
1A

wh IPS1L-/4 2.1
X01 L1 N Pe
sl IPS1L+/4 2.1

bu IPS1L-/3 2.1

Rev. April 2004

pk IPS1L+/3 2.1

yl IPS1L-/2 2.1

gn IPS1L+/2 2.1

110-120 V or IPS1L-/1
L1 br 2.1
230-240 V N IPS1L+/1
rd 2.1
50-60Hz PE

draft
YEAR 04.03.04 =
DRN. PSt Power Supply +
CHK. ExTG Complete Page 1
LTR. ECN-No. APP'D. 4.37.0212 of 2

Operating Manual
 0 1 2 3 4 5 6 7 8 9

yl/bk

sl/bk

J
10 11 12
10 11 12
bk

Operating Manual
I
9
9
vi

H
8
8
8
1.7 IPS1L-/4 wh

G
7
7
7
ExTG

sl wh vi bk
1 .7 IPS 1L+/4 sl

F
6
6
6
1.7
IPS1L-/3 bu
panel

E
5
5
5
IPS1L+/3 pk

pk bu
1.7
20

20 pins
20 pins

D
4
4
4
IPS1L-/2 yl
1.7

C
3
3
3
IPS1L+/2 gn

gn yl
1.7

B
2
2
2
IPS1L-/1 br
1.7

-X7
-X8
MemCard

A
1
1
1
IPS1L+/1

rd br
1.7 rd

1
1
rd

-X2
-X6
2
2

25m
br

3
3
gn

4
4
yl

rechargable battery
-X10
11 pins

-X9
5
pk
1 2 4 3 11 10

6
bu -X5

7
sl
+ - + - + -

8
wh

Rev. April 2004

yl/gn
yl/bk sl
sl rd wh br

IPS backwall
PA
-X4 E D A B C LC -X3 A B C DV ExTG
draft
LC DV
yl gn wh br sl yl sl
gn/rd

A D E C B F D A B C
PA
load cell dump valve

YEAR 04.03.04 =
ExTG and its external
DRN. PSt +
CHK.
components ExTG Complete Page 2
LTR. ECN-No. APP'D. 4.370212 of 2

Page 25 of 27
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0 1 2 3 4 5 6 7 8 9

LC-cable JAMPro V1.X 5.2

RU-side LC-side

Page 26 of 27
connector angle 561-2258 connector, straight 561-2297

E RU-Side Signal Wire Color LC-Side A

A D F B
A green/red Shield green/red E
B white spare white C
B C E C
LOAD CELL CABLE

C brown Test brown B D

D green 4 -20 mA green D
E yellow 12 V+ yellow A
n.c. slate F

90 mm 561-0871 Helukabel 25 mm

2,5m 5x0,34 Supertronic-C-PuRö

1x Dustcap 561-2298
1x Dustcap 561-2276 1x 1,0 cm shrinking hose 2,4-1,2

Rev. April 2004

2x Skintop 561-2288 1x 4,5 cm shrinking hose 6,4-3,2 black
6x 1,0 cm shrinking hose 2,4-1,2 1x 4,5 cm shrinking hose 6,4-3,2 blue
1x 4,5 cm shrinking hose 6,4-3,2 black 1x 3,0 cm shrinking hose 12,4-4,8 blue
1x 4,5 cm shrinking hose 6,4-3,2 blue
1x 3,0 cm shrinking hose 9,5-4,5 blue

YEAR 21.03.03

DRN.
Part-No.: 5610901
PSt LC cable JAMPro V1.X
CHK. sheet 1
Rev.: - Drn.-No.: 3.37.0162
LTR. ECN-No. APP'D. from 1 Bl.

Operating Manual
 0 1 2 3 4 5 6 7 8 9

5.3
DV-cable JAMPro V1.X
RU side dump valve side

Operating Manual
connector angle 561-2257 connector angle 561-2296

A A yellow A slate A
C D
B shield D yellow
C slate B+C jumper
B C B
DUMP VALVE CABLE

7.5 m 5x0.34 Supertronic-C-PuRö

561-0871 Helukabel

1x Dustcap 561-2275 1x Dustcap 561-2298

1x Skintop 561-2288 1x Skintop 561-2288

4x 1,0 cm shrinking hose 2,4 -1,2 2x 1,0 cm shrinking hose 2,4-1,2

1x 4,5 cm shrinking hose 6,4-3,2 black 1x 4,5 cm shrinking hose 6,4-3,2 black

1x 4,5 cm shrinking hose 6,4-3,2 blue 1x 4,5 cm shrinking hose 6,4-3,2 blue

Rev. April 2004

YEAR 21.03.03

DRN.
Part-No.: 5610902
PSt DV cable JAMPro V1.X
CHK. sheet 1
Rev.: - Drn.-No.: 3.37.0163
LTR. ECN-No. APP'D. from 1 Bl.

Page 27 of 27
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