60-11

Printed in U.S.A. June 17, 1999

Manufacturers of Precision Instruments

INSTALLATION AND OPERATION WITH

ILLUSTRATED PARTS LIST

DAQ - Permanent LocationTOTAL SYSTEM 4

P/N 220425-100 & -101220492-008 & -009

Part Number 60-11

Revision A

Manual 60-11 contains 100 pages, divided as follows:

Cover. . . . . . . . . . . . . . . . . . . . . . . . . June 17, 1999Warranty/ Safety . . . . . . . . . . . . . . . . June 17, 1999TOC. . . . . . . . . . . . . . . . . . . . . . . . . . June 17, 1999LOF. . . . . . . . . . . . . . . . . . . . . . . . . . June 17, 1999LOT. . . . . . . . . . . . . . . . . . . . . . . . . . June 17, 1999Chapter 1. . . . . . . . . . . . . . . . . . . . . . June 17, 1999Chapter 2. . . . . . . . . . . . . . . . . . . . . . June 17, 1999Chapter 3. . . . . . . . . . . . . . . . . . . . . . June 17, 1999Chapter 4. . . . . . . . . . . . . . . . . . . . . . June 17, 1999Chapter 5. . . . . . . . . . . . . . . . . . . . . . June 17, 1999

All product, brand, or trade names used in this publication are the trademarks or registered trademarks of their respective owners.

Information in this manual is subject to change without notice.

Table of Contents

CHAPTER 1INTRODUCTION

1-1 PURPOSE OF MANUAL...................................................................................................................1-11-2 SCOPE OF MANUAL........................................................................................................................1-11-3 INTENDED AUDIENCE.....................................................................................................................1-11-4 PERSONNEL QUALIFICATIONS.....................................................................................................1-11-5 NOTES, CAUTIONS, AND WARNINGS.........................................................................................1-21-6 RELATED DOCUMENTS..................................................................................................................1-2

CHAPTER 2 DESCRIPTION

2-1 INTRODUCTION ...............................................................................................................................2-12-2 TOTAL/DAQ INTERFACE ................................................................................................................2-12-3 T-POT NETWORK ............................................................................................................................2-12-4 DATA ACQUISITION UNIT...............................................................................................................2-2

2-4-1 PERMANENT LOCATION DAQ CONFIGURATIONS ............................................................2-42-4-2 CalConf Software ....................................................................................................................2-42-4-3 Prom Set Selections for DAQ Boards .....................................................................................2-52-4-4 Digital Board (P/N 219493) .....................................................................................................2-52-4-5 Field Termination Board (P/N 219509)....................................................................................2-72-4-6 Analog I/O Board (P/N 219506) ..............................................................................................2-72-4-7 Analog I/O Board (P/N 220442-001) .......................................................................................2-72-4-8 Spectrum InterFace Board - SIF (P/N 221034-002)................................................................2-72-4-9 Electronic Depth Measurement System Board (P/N 219770-001) ..........................................2-82-4-10 Intrinsically Safe Modem (P/N 219916)...................................................................................2-82-4-11 Power Supplies (P/N 220251-Series)......................................................................................2-82-4-12 Battery Pack (P/N 219908 - optional) ......................................................................................2-8

2-5 SENSORS .........................................................................................................................................2-82-6 SPECIFICATIONS.............................................................................................................................2-9

CHAPTER 3INSTALLATION

3-1 INTRODUCTION ...............................................................................................................................3-13-2 HAZARDOUS AREA LOCATIONS ..................................................................................................3-13-3 SPECIAL TOOLS AND EQUIPMENT...............................................................................................3-23-4 UNPACKING AND INSPECTION .....................................................................................................3-33-5 HARDWARE INSTALLATION ..........................................................................................................3-3

3-5-1 Mounting the Enclosure...........................................................................................................3-33-5-2 Grounding................................................................................................................................3-43-5-3 Connecting Primary AC Power................................................................................................3-53-5-4 Digital Board Mode and Reset Switch Settings.......................................................................3-63-5-5 EDMS Board Mode Switch Settings........................................................................................3-83-5-6 "Super" SIF (Spectrum InterFace) Board ................................................................................3-8

3-6 SENSOR INSTALLATION ..............................................................................................................3-113-6-1 General Practices..................................................................................................................3-11

3-6-1-1 Electrical Interference .................................................................................................3-113-6-1-2 Sensor Shielded Cable Splicing..................................................................................3-11

June 17, 1999 Table of Contents -1M/D Totco

Table of Contents DAQ - System 4 Manual 60-11

3-6-1-3 Connecting Two Devices With Shielded Cable...........................................................3-133-6-1-4 Field Termination Board Sensor Connection Blocks...................................................3-13

3-6-2 Hook Load Sensor(s) Installation ..........................................................................................3-143-6-2-1 Deadline Anchor Application.......................................................................................3-143-6-2-2 Wireline Deflection Sensor (P/N TCE-Series).............................................................3-16

3-6-3 Pressure Sensor(s) Installation .............................................................................................3-193-6-4 Pressure Transducer Assembly (P/N H12288A-Series) .......................................................3-203-6-5 Pressure Transducer Assembly (P/N H12353A-Series) .......................................................3-21

3-6-5-1 H12354A Pressure Transducer (220425 Application).................................................3-213-6-5-2 H12354A Pressure Transducer (220492 Application).................................................3-22

3-6-6 Pressure Transducer Assembly (P/N 220631-Series) ..........................................................3-223-6-7 Pressure Transducer Assembly (P/N 220756-Series) ..........................................................3-23

3-6-7-1 220282 Pressure Transducer (220425 Application)....................................................3-243-6-7-2 220282 Pressure Transducer (220492 Application)....................................................3-243-6-7-3 940233-006 Pressure Transducer (220425 Application) ............................................3-253-6-7-4 940233-006 Pressure Transducer (220492 Application) ............................................3-253-6-7-5 220017 Pressure Transducer (220425 Application)....................................................3-26

3-6-8 Rotary Torque Installation .....................................................................................................3-273-6-8-1 218041-002 Current Transducer (220492 Application)...............................................3-28

3-6-9 Rotary Table RPM Installation...............................................................................................3-293-6-10 SPM Sensor(s) Installations ..................................................................................................3-30

3-6-10-1 232389 Proximity Sensor (220425 Application) ..........................................................3-313-6-10-2 232389 Proximity Sensor (220492 Application) ..........................................................3-313-6-10-3 H11094A-01 Proximity Sensor (220425 Application).................................................3-323-6-10-4 H11094A-01 Proximity Sensor (220492 Application)..................................................3-323-6-10-5 H11092A Proximity Sensor (220425 Application) .......................................................3-333-6-10-6 H11092A Proximity Sensor (220492 Application) .......................................................3-33

3-6-11 Top Drive Sensors.................................................................................................................3-343-6-11-1 Top Drive Torque Input (220425 Application) .............................................................3-343-6-11-2 Top Drive RPM Input (220425 Application).................................................................3-343-6-11-3 Top Drive Torque & RPM Input (220425/220492 Application)....................................3-35

3-6-12 Flow Sensor Installation ........................................................................................................3-363-6-12-1 MFTX4A Flow Sensor (220425 Application) ...............................................................3-383-6-12-2 MFTX4A Flow Sensor (220492 Application) ...............................................................3-38

3-6-13 Pit Level Sensor(s) Installations ............................................................................................3-393-6-13-1 262622-Series Reed Switch Probes (220425 Application) .........................................3-403-6-13-2 262622-Series Reed Switch Probes (220492 Application) .........................................3-403-6-13-3 221576 Ultra-Sonic Probes (220425 Application) .......................................................3-413-6-13-4 221576 Ultra-Sonic Probes (220492 Application) .......................................................3-41

3-6-14 Temperature/Density Sensor(s) Installations ........................................................................3-423-6-14-1 220005-Series Temperature/Density Probes (220425 Application)............................3-43

3-6-15 EDMS Depth Sensor(s) Installations.....................................................................................3-443-6-15-1 H12321A-Series Encoder (220425 Application) .........................................................3-443-6-15-2 219062 Encoder (220492 Application)........................................................................3-44

3-6-16 Calibration Switch Box Installation ........................................................................................3-453-6-16-1 219255-001 Cal Switch Box (220425 Application)......................................................3-453-6-16-2 219255-001 Cal Switch Box (220492 Application)......................................................3-45

3-6-17 Digital Outputs.......................................................................................................................3-463-7 CONNECTING T-POT.....................................................................................................................3-463-8 INITIAL POWER UP........................................................................................................................3-46

Table of Contents -2 June 17, 1999M/D Totco

DAQ - System 4 Table of ContentsManual 60-11

CHAPTER 4MAINTENANCE

4-1 INTRODUCTION ...............................................................................................................................4-14-2 RECOMMENDED INSPECTIONS ....................................................................................................4-14-3 TROUBLESHOOTING ......................................................................................................................4-1

4-3-1 General Checks.......................................................................................................................4-14-3-2 Fault Isolation Table ................................................................................................................4-1

4-4 DAQ MAINTENANCE PROGRAM ...................................................................................................4-34-5 SENSOR PROBLEMS ......................................................................................................................4-34-6 REPLACING E-PROM’S............................................................................................................. ......4-3

4-6-1 Digital Board E-PROMS ..........................................................................................................4-44-6-2 SIF Board E-PROM.................................................................................................................4-54-6-3 EDMS Board E-PROM ............................................................................................................4-5

4-7 POWER SUPPLY & WIRING HARNESS CHECKOUT PROCEDURE............................................4-64-8 EDMS BATTERY TEST ........................................................................................................... .........4-7

CHAPTER 5ILLUSTRATED PARTS BREAKDOWN

5-1 INTRODUCTION ...............................................................................................................................5-15-2 PARTS LIST.................................................................................................................. ....................5-1

5-2-1 Find Number............................................................................................................................5-15-2-2 Part Number ............................................................................................................................5-15-2-3 Description ..............................................................................................................................5-15-2-4 Units Per Assembly .................................................................................................................5-1

5-3 ABBREVIATIONS ............................................................................................................... ..............5-2

June 17, 1999 Table of Contents -3M/D Totco

Table of Contents DAQ - System 4 Manual 60-11

Table of Contents -4 June 17, 1999M/D Totco

List of Figures
CHAPTER 2
DESCRIPTIONFigure 2-1. Typical TOTAL/DAQ Interface Diagram ..........................................................................2-1Figure 2-2. DAQ (Data Acquisition Unit) ............................................................................................2-2Figure 2-3. DAQ (P/N 220492-Series) Functional Block Diagram .....................................................2-3Figure 2-4. DAQ (P/N 220425-Series) Functional Block Diagram .....................................................2-3Figure 2-5. DAQ Major Components .................................................................................................2-6

CHAPTER 3 INSTALLATION

Figure 3-1. Hazardous Area Block Diagram - 220425-Series DAQ...................................................3-1Figure 3-2. Hazardous Area Block Diagram - 220492-Series DAQ...................................................3-2Figure 3-3. DAQ Sensor Cable Installation Screwdriver ....................................................................3-2Figure 3-4. Installation Dimensions - Permanent Location DAQ........................................................3-3Figure 3-5. DAQ Ground, Power, and Signal Connectors .................................................................3-4Figure 3-6. AC Primary Power Connections ......................................................................................3-5Figure 3-7. Digital Board Mode and Reset Switches .........................................................................3-7Figure 3-8. EDMS Board Mode Switch Settings ................................................................................3-8Figure 3-9. Spectrum InterFace (SIF)Board Jumper Locations .........................................................3-8Figure 3-10. Recommended Method of Splicing Cable .....................................................................3-12Figure 3-11. Field Termination Board Sensor Connections...............................................................3-13Figure 3-12. Typical Hook Load Installation(S) ..................................................................................3-14Figure 3-13. TCE Transducer Installation ..........................................................................................3-16Figure 3-14. TCE System Assembly ..................................................................................................3-17Figure 3-15. Wiring Diagram - Wireline Deflection Sensor P/N TCE-Series......................................3-18Figure 3-16. Wireline Deflection Sensor Wiring (P/N TCE-Series) ....................................................3-18Figure 3-17. Pump Pressure Transducer Installation.........................................................................3-20Figure 3-18. H12288A Pressure Transducer Assembly.....................................................................3-20Figure 3-19. H12353A-Series Pressure Transducer Assembly .........................................................3-21Figure 3-20. Wiring Diagram - H12354A Transducer in H12288A or H12353A Assembly ................3-21Figure 3-21. Wiring Diagram - H12354A Transducer in H12288A or H12353A Assembly ................3-22Figure 3-22. 220631 Pressure Transducer Assembly........................................................................3-22Figure 3-23. 220756-Series Pressure Transducer Assembly ............................................................3-23Figure 3-24. Wiring Diagram - 220282 Transducer in 220631 or 220756 Assembly .........................3-24Figure 3-25. Wiring Diagram - 220282 Transducer in 220631 or 220756 Assembly .........................3-24Figure 3-26. Wiring Diagram - 940233-006 Transducer in 220631 or 220756 Assembly..................3-25Figure 3-27. Wiring Diagram - 940233-006 Transducer in 220631 or 220756 Assembly..................3-25Figure 3-28. Electronic Pressure Transducer Installation ..................................................................3-26Figure 3-29. Wiring Diagram - 220017-Series Pressure Transducer.................................................3-26Figure 3-30. Rotary Torque Sensor ...................................................................................................3-27Figure 3-31. Wiring Diagram - Rotary Torque Sensor P/N 218041-002 ............................................3-28Figure 3-32. RPM Proximity Installation.............................................................................................3-29Figure 3-33. Proximity Target Installation ..........................................................................................3-29Figure 3-34. Proximity Bracket Installation ........................................................................................3-30Figure 3-35. Wiring Diagram - Proximity Sensor P/N 232389............................................................3-31

June 17, 1999 List of Figures-1M/D Totco

List of Figures DAQ - System 4 Manual 60-11

Figure 3-36. Wiring Diagram - Proximity Sensor P/N 232389............................................................3-31Figure 3-37. Wiring Diagram - Proximity Sensor P/N H11094A-01 ...................................................3-32Figure 3-38. Proximity Sensor Wiring (P/N H11094A-01)..................................................................3-32Figure 3-39. Proximity Sensor Wiring (P/N H11092A) .......................................................................3-33Figure 3-40. Wiring Diagram - Top Drive Torque Input......................................................................3-34Figure 3-41. Wiring Diagram - Top Drive RPM Signal .......................................................................3-34Figure 3-42. Mud Flow Sensor Installation: P/N MFTX4A-5 ..............................................................3-35Figure 3-43. Mud Flow Sensor Calibration ........................................................................................3-36Figure 3-44. Wiring Diagram -P/N MFTX4A-5 ...................................................................................3-37Figure 3-45. Mud Flow Sensor Wiring (P/N MFTX4A-5)....................................................................3-37Figure 3-46. Reed Switch Probe Installation......................................................................................3-38Figure 3-47. Wiring Diagram - Reed Switch Probe P/N 262622........................................................3-39Figure 3-48. Wiring Diagram - Reed Switch Pit Level Probe .............................................................3-39Figure 3-49. Wiring Diagram - Ultra-Sonic Probe P/N 221576 ..........................................................3-40Figure 3-50. Wiring Diagram - Ultra-Sonic Probe P/N 221576 ..........................................................3-40Figure 3-51. Mud Density Sensor Installation ....................................................................................3-41Figure 3-52. Wiring Diagram - Temperature/Density Probe...............................................................3-42Figure 3-53. Wiring Diagram - Encoder P/N H12321A-Series ...........................................................3-43Figure 3-54. Encoder (P/N 219062) Wiring........................................................................................3-43Figure 3-55. Wiring Diagram - Calibration Switch Box P/N 219255-001............................................3-44Figure 3-56. Calibration Switch Box connection to DAQ....................................................................3-44Figure 3-57. Digital Ouput Wiring.......................................................................................................3-45

CHAPTER 4 MAINTENANCE

Figure 4-1. Digital Board E-PROM Locations ....................................................................................4-4Figure 4-2. SIF Board E-PROM Location ..........................................................................................4-5Figure 4-3. EDMS E-PROM Location ................................................................................................4-5Figure 4-4. DC Power Distribution Wiring Diagram (220425 & 220492-Series) ................................4-8Figure 4-5. DAQ DC Power Distribtution............................................................................................4-9Figure 4-6. AC Power Distribution Wiring (Power Supplies 220251-005 & -006) ............................4-10

CHAPTER 5 ILLUSTRATED PARTS BREAKDOWN

Figure 5-1. Permanent Location DAQ (P/N 220492-KIT & 220425-KIT) ...........................................5-3

List of Figures-2 June 17, 1999M/D Totco

List of Tables
CHAPTER 1
INTRODUCTION

CHAPTER 2 DESCRIPTION

Table 2-1. Permanent Location DAQ’s (without software) Part Numbers.........................................2-4

Table 2-2. CalConf Software Part Numbers .....................................................................................2-4

Table 2-3. DAQ Prom Sets ...............................................................................................................2-5

Table 2-4. Power Supply Selection...................................................................................................2-8

Table 2-5. DAQ Specifications..........................................................................................................2-9

Table 2-6. Hazardous Location Certification...................................................................................2-10


Table 3-1. SIF Board Jumpers..........................................................................................................3-9

Table 3-2. JP3 - SIF Device ID Jumper Settings ..............................................................................3-9

Table 3-3. JP4 - Communication Baud Rate Jumper Settings .......................................................3-10

Table 3-4. JP5 - Relay Power Jumper Settings..............................................................................3-10

Table 3-5. JP6 - Display Power ......................................................................................................3-10

Table 3-6. Weight Indicator Load Data ...........................................................................................3-15


Table 4-1. Fault Isolation Table ........................................................................................................4-2

Table 4-2. DAQ DC Connections......................................................................................................4-9


Table 5-1. Parts List Abbreviations...................................................................................................5-2

Table 5-2. PERMANENT LOCATION DAQ - (INTERNAL BARRIERS W/ SIF) .............................5-12

Table 5-3. PERMANENT LOCATION DAQ - (INTERNAL BARRIERS W/ SIF & EDMS) ..............5-12

Table 5-4. 220492-KIT....................................................................................................................5-13

Table 5-5. PERMANENT LOCATION DAQ - (BARRIERLESS W/ SIF) .........................................5-16

Table 5-6. PERMANENT LOCATION DAQ - (BARRIERLESS W/ SIF & EDMS) ..........................5-17

Table 5-7. 220425-KIT....................................................................................................................5-18

June 17, 1999 List of Tables-1M/D Totco

List of Tables DAQ - System 4 Manual 60-11

List of Tables-2 June 17, 1999M/D TOTCO

trated ion of

CHAPTER 1INTRODUCTION

1-1 PURPOSE OF MANUAL

The purpose of this manual is to provide descriptions of the equipment, installation, maintenance, and parts information for the M/D Totco Data Acquisition Unit (DAQ) and related Sensors which form a part of the M/D Totco TOTAL™ system.

1-2 SCOPE OF MANUAL

This manual contains technical descriptions, installation, maintenance instructions, and illusparts breakdown for use in maintaining and servicing the DAQ and sensors. A brief descripteach chapter is as follows:

• Chapter Two - Describes each component of the DAQ and overall system speci-fications.

• Chapter Three - Verification of shipping container contents, installation of the DAQ hardware, and interface connections.

• Chapter Four - Provides procedures for maintaining the DAQ, isolating system malfunctions, and removal and replacement of parts and special testing.

• Chapter Five - Provides illustrated parts breakdown for each component of the DAQ.

1-3 INTENDED AUDIENCE

This manual is intended for use by field engineering, maintenance, operation, and repair personnel.

1-4 PERSONNEL QUALIFICATIONS

Installation and repair of the DAQ hardware should be accomplished only by personnel fullyqualified and trained to perform the procedures described in this manual.

June 17, 1999 Page 1-1M/D Totco

CHAPTER 1 DAQ - System 4INTRODUCTION Manual 60-11

1-5 NOTES, CAUTIONS, AND WARNINGS

Notes and two types of precautionary information are included in M/D Totco manuals, where applicable, to aid in operation, protection of equipment, and safety to personnel. Also refer to the precautionary notice at the beginning of this manual. Ensure that all personnel who intend to per-form any of the procedures in this manual have read this notice. Examples and explanations for each precautionary notice in this manual are as follows:

1-6 RELATED DOCUMENTS

M/D Totco documents related to the use of this manual are listed in Table 1-1.

NOTE

Used where special information may aid in understanding contents or pro-cedures contained in this manual.

CAUTION

Used where malfunction of equipment or damage to equipment may causeinterruption of service.

WARNING

Used where malfunction of equipment or damage to equipment could resultin serious or fatal injury to personnel or major property loss.

Table 1: Related Documents

Title Document Number

Configuration and Calibration, System 4 Manual 60-41

Visulogger XC Graphics Display, System 4 Manual 60-42

DATAWATCH, System 4 Manual 60-43

MUDWATCH, System 4 Manual 60-30

SPECTRUM Display Manual 60-21

Installation Control Drawing 219569

Page 1-2 June 17, 1999M/D Totco

CHAPTER 2DESCRIPTION

2-1 INTRODUCTION

This chapter provides descriptions of the data acquisition unit (DAQ) and sensor devices. Also included are specifications that describe the physical characteristics of the DAQ.

2-2 TOTAL/DAQ INTERFACE

The DAQ provides central processing and control of the TOTAL system. An example of the DAQ connected to components of a typical TOTAL system is shown in Figure 2-1. The amount of sys-tem component connections can vary according to customer requirements.

2-3 T-POT NETWORK

The T-POT network, shown in Figure 2-1, is a time-division, multiplexed, single-wire, frequency- shift-keying (FSK) communications media used by the TOTAL system. It operates similar to most other communications networks and uses a unique protocol developed specifically for the tasks associated with the TOTAL instrumentation system. Each device connected to the network has an assigned identification number to ensure that data records are routed to the appropriate device.

Figure 2-1. Typical TOTAL/DAQ Interface Diagram


CHAPTER 2 DAQ - System 4DESCRIPTION Manual 60-11

only cation he

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ultiple pter 2-4,

2-4 DATA ACQUISITION UNIT

Data Acquisition Units (DAQ’s) are available in two configurations, Standard (P/N 219567-Series) and Permanent Location DAQ’s (P/N 220492-XXX and 220425-XXX). This manual addresses Permanent Location DAQ’s, sometimes referred to as FAT DAQ’s. Permanent LoDAQ’s require installation of CALCONF software and the various prom sets as required by tspecific application.

The DAQ, shown in Figure 2-2, is enclosed in a heavy-gauge, stainless-steel case. The DAQitors up to 23 analog and 14 digital sensor channels, processes the incoming data from thesnels, and provides continuously updated information to devices connected to the communicT-POT network.

The functional areas of the DAQ are shown in Figure 2-3. DAQ's can also be cascaded in mconfigurations, with one designated as master and the additional DAQ's as slaves (see ChaThree - Installation). The DAQ consists of the following major assemblies, as shown in Figureand are described later in this chapter.

• Digital (processor) Board• SIF/Communications Board• Field Termination Board• Analog (sensor) I/O Board • Electronic Depth Measurement System (EDMS) Board (optional) • Intrinsically Safe Modem• Power Supplies (two)• Battery Pack (optional with EDMS)

Figure 2-2. DAQ (Data Acquisition Unit)


DAQ - System 4 CHAPTER 2Manual 60-11 DESCRIPTION

Figure 2-3. DAQ (P/N 220492-Series) Functional Block Diagram

Figure 2-4. DAQ (P/N 220425-Series) Functional Block Diagram



mod-priate elect 2-3.

ich UD-

2-4-1 PERMANENT LOCATION DAQ CONFIGURATIONS

Permanent Location DAQ’s are available in four versions, refer to Table 2-1. The 220492 els contain internal barriers, while the 220425 models are barrierless. To select the approPermanent Location DAQ, first choose the basic DAQ part number in Table 2-1, second sthe CALCONF software in Table 2-2, and third select the required chips as listed in Table

2-4-2 CalConf Software

Listed in Table 2-2 are the Part Numbers and Descriptions for the CALCONF software whmust be loaded into all DAQ’s. For example, if the DAQ will be used as part of a English MWATCH system, then 221457-02XXX should be selected.

Table 2-1. Permanent Location DAQ’s (without software) Part Numbers

Part Number Description

220492-008 Permanent Location, Internal barriers, SIF board, no software

220492-009 Permanent Location, Internal Barriers, SIF board, EDMS board, no software

220425-100 Permanent Location, Barrierless, SIF board, no software

220425-101 Permanent Location, Barrierless, SIF board, EDMS board, no software

Table 2-2. CalConf Software Part Numbers

Part Number Application

221457-01XXX TOTAL System (English)

221457-02XXX MUDWATCH System (English)

221457-04XXX DRILLWATCH System (English)

221457-05XXX SPECTRUM System (English)

221457-11XXX TOTAL System (Metric)

221457-12XXX MUDWATCH System (Metric)

221457-14XXX DRILLWATCH System (Metric)

221457-05XXX SPECTRUM System (Metric)

XXX = The version number. i.e. 4.38



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2-4-3 Prom Set Selections for DAQ Boards

Listed in Table 2-3 are the Part Numbers and Descriptions for the Prom Sets which must be installed on the various referenced boards as required by DAQ’s application.

2-4-4 Digital Board (P/N 219493)

The digital board interfaces with the calibration/configuration PC and connects to the analog I/O board 64-pin connector through the DAQ chassis. The board also provides a pback connector for the communications board and the EDMS board option. The board coand communicates with all other boards contained within the DAQ. The digital board contboth the DAQ main and analog processors, associated PROMS and RAM memory, modetion and reset switches, LED's, and a watchdog timer with associated LED indicator.

The applications and analog processors control the overall operation of the DAQ based oware programs contained in their associated PROMS. Both use RAM memory for the tempstorage of data during operation. DIP switches are used to select master and slave DAQ'more than one DAQ is used in the system, select debug mode, dump processor error couconfigure EDMS, and erase the EE PROM to set the DAQ back to a default configurationChapter Three - Installation for switch settings).

Also included are push-button switches for manually resetting the applications or analog psor. Two of the three LED's indicate that each processor and the communications (applicaprocessor) functions of the board are operating. The third LED indicates that the watchdogis operating normal. The watchdog timer monitors digital board activity and if no activity issensed for a period of 60 milliseconds, the system automatically reboots. This clears posprocessor hang-ups or malfunctions without the operator opening the DAQ cover to pressual reset switches.

Table 2-3. DAQ Prom Sets

Part Number Prom Set Application

221378-002XXX Digital Board

220206-001XXX EDMS Board

221459-304XXX SIF (super) Board

221377-001XXX Analog Board

XXX = The version number. i.e. 4.38



Figure 2-5. DAQ Major Components



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2-4-5 Field Termination Board (P/N 219509)

The field termination board provides connections for all incoming rig sensors monitored, and output deviecs driven by the DAQ.

The field termination board provides 23 analog inputs, 14 digital I/O connections, six power outputs, and electronic depth measurement connections.The board is located above and con-nects to the analog I/O board through two 96-pin connectors.

2-4-6 Analog I/O Board (P/N 219506)

The analog I/O board (P/N 219506) is part of the 220492-Series DAQ’s. It is located belowfield termination board and connects to it through two 96-pin connectors and the DAQ chadigital board 64-pin connector. The I/O board contains the following:

• Analog Multiplexer • Digital I/O• EDMS Interface• Power Barriers • A/D Conversion Electronics

The analog board converts all analog sensor inputs to digital words suitable for input to thital board for processing. Digital and EDMS inputs are also conditioned on the analog boarprovided as connections to the digital board. All signals are routed through the intrinsic sabarriers before conditioning.

2-4-7 Analog I/O Board (P/N 220442-001)

The analog I/O board (P/N 220442-001) is part of the 220425-Series DAQ’s. It is located bthe field termination board and connects to it through two 96-pin connectors and the DAQsis digital board 64-pin connector. The I/O board contains the following:

• Analog Multiplexer • Digital I/O• EDMS Interface• A/D Conversion Electronics

The analog board converts all analog sensor inputs to digital words suitable for input to thital board for processing. Digital and EDMS inputs are also conditioned on the analog boarprovided as connections to the digital board.

2-4-8 Spectrum InterFace Board - SIF (P/N 221034-002)

SIF is an acronym which stands for Spectrum InterFace. Physically the SIF is an interface boarused to convert data within the DAQ into SPECTRUM protocol and transmit this informatiovarious SPECTRUM type displays.



2-4-9 Electronic Depth Measurement System Board (P/N 219770-001)

The electronic depth measurement system (EDMS) board is an option for use when an EDMS system is installed on the rig and connected to the DAQ field termination board. The board pro-cesses positioning information from the drawworks encoder to provide block height information at all times during drilling operations.

2-4-10 Intrinsically Safe Modem (P/N 219916)

The modem provides an interface for data to be transmitted to devices connected to the T-POT communications network. The modem is attached to the interior of the DAQ chassis and provides a BNC connector that is accessible from the outside of the DAQ.

2-4-11 Power Supplies (P/N 220251-Series)

The two 40 watt, dual output power supplies provide +5, +28, +15, and -15 VDC levels required to power the DAQ circuit board and external power output voltages. The voltages are initially supplied to the digital board then distributed within the DAQ. The supplies are fused for over-load protection.

To select the correct power supply for your DAQ configuration, refer to Table 2-4

2-4-12 Battery Pack (P/N 219908 - optional)

The battery pack is included if the EDMS feature is incorporated in the DAQ. The battery pack provides 12 volts DC to operate the EDMS board and prevent the loss of block height data in the event of a power failure.

2-5 SENSORS

The DAQ interfaces with many different sensors located throughout the drilling rig depending upon the requirements of that rig. The most common sensors are listed, but not limited to the following:

Table 2-4. Power Supply Selection

Power Supply P/N Description Application Applicable DAQ(s)

220251-005 +15V, -15V,+5V DAQ w/ SIF Board 220425-100, -101220492-008, -009

220251-006 28V, 50W DAQ w/ SIF Board 220425-100, -101220492-008, -009

• Hydraulic to Electric Transducers• Mud Temperature Sensors• Hydraulic to Current Transducers• Pump Stroke Sensors• Mud Flow Sensors • Depth Switch Sensors

• Encoders• Ultrasonic Sensors• Mud Pit Level Sensors• Proximity Switch Sensors• Mud Density Sensors• RPM Sensors



2-6 SPECIFICATIONS

The overall specifications for the DAQ are listed in Table 2-1.

Table 2-5. DAQ Specifications

Parameter Requirements/Limits

Electrical:

Primary Power 90 to 250 VAC, No modification required. (Y Power)

Grd to Neutral VAC 1 Volt max

Frequency 47 to 90 Hz.

Current Requirements 2.0 amperes maximum.

Primary Power Fuse Time delay fuse, FLM, 2.0 amperes.

Environment:

Ambient Operating Temperature

-20 C to +60 C.

Ambient Storage Temperature

-30’C to+85 C.

Internal Humidity 5% to 90% Non-condensing.

Mechanical:

Enclosure Stainless Steel, NEMA 4X (IP 65).

Dimensions (Pm Lc DAQ) 21.5 H x 19.0 W x 13.0 D (546 mm x 482 mm x 330.2 mm)

Mounting Brackets 20.0 H x 13.8 W (508 mm x 351 mm).

Mounting Hole 0.40 (10.2 mm) diameter.

Door Clearance Area 21.5 H x 48 W (546 mm x 122 mm) @ 90 arc.

Weight 57 lb. (126 kg).

Sensors:

Analog Channels 23 analog input channels per DAQ unit. Up to four DAQ’s tied together allow up to 52 total input channels.

Analog Voltage 0 to 10 volts maximum in two ranges; 0 to 5 volts and 0 to 10 volts.

Analog Current 0 to 20 mA max (typically 4-20mA)

Analog Accuracy To 0.5% full scale.

Digital Channels 14 digital I/O channels available. Up to four DAQ’s tied together allow up to 56 total channels.



Digital Inputs Maximum frequency - 100 Hz (6000 pulses/minute). Minimum pulse width - 7 mSec.

Digital Standard Input Sensors

Proximity sensors - 2 or 3 wire, (4 wire - can be used by utilizing two input channels.) Contact closure - Closed= 500 ohms or less, Open= 10K ohms or greater.

Digital Outputs Maximum frequency - 110 Hz. Output jitter - <0.5%.

Digital Output (Analog) Pulse width modulation - 0 to 100% duty cycle, 0 to 10 volt output. Maximum frequency response of driven device - 40 Hz. Simulated analog output voltage range - 0 to 10 volts. This signal can drive analog chart recorders and meters having a frequency response of less than 40 Hz.

Digital Output (Alarm) User defined high and low set point.0 and 10 volt Ievels. Normally high and normally low signal levels available.

Digital Output (Discreet) User defined trip point.User defined hysteresis.0 and 10 volt Ievels.Normally high and normally low signal levels available.

Table 2-6. Hazardous Location Certification

Systems Containing DAQ Part Numbers 220492-008 and -009

Systems Containing DAQ Part Numbers 220425-100 and -101

DAQAssembly

May be installed in a Class I, Division 2, Groups C and D or IEC 79-10 Zone 2, Groups IIB hazardous location when installed in accordance with drawing 219569.

May be installed in a Class I, Division 2, Groups C and D or IEC 79-10 Zone 2, Groups IIB hazardous location when installed in accordance with drawing 219569.

DAQ SensorConnections

The DAQ provides intrinsically safe con-nections to the specific sensors identified in drawing 219569

The DAQ must be connected to sensors through external barriers as indicated herein.

Sensors

The specific sensors identified in drawing 219569, may be installed in a Class I, Division 1, Groups C and D or IEC 79-10 Zone 0, Group IIB hazardous location when installed in accordance with drawing 219569.

The sensors are individually certified intrinsically safe and may be installed in a Class I, Division 1, 2, Groups C and D or IEC 79-10 Zone 0, 1, 2, Group IIB hazard-ous location as indicated herein.

T-POTCommunicationNetwork Cable

The T-POT Communications network cable may be routed through a Class I, Division 1, Groups C and D or IEC 79-10 Zone 0, Group IIB hazardous location when installed in accordance with drawing 219569.

The T-POT Communications network cable may be routed through a Class I, Division 1, Groups C and D or IEC 79-10 Zone 0, Group IIB hazardous location when installed in accordance with drawing 219569.

Table 2-5. DAQ Specifications

Parameter Requirements/Limits



3-1 INTRODUCTION

This chapter describes the procedures for installing the data acquisition unit (DAQ), grounding, AC primary power, connecting the rig sensors, and T-POT network.

3-2 HAZARDOUS AREA LOCATIONS

The DAQ incorporates safety features for installation in hazardous locations. Specific components varies between International Installations and N. American Installations. A block diagram repre-senting component placement in International Installations is shown in Figure 3-1. North Ameri-can component placement is shown in Figure 3-2.

Before beginning installation, the installer should have a working knowledge of intrinsic safety techniques and be thoroughly familiar with the code requirements of the installation location. This includes installing intrinsically safe equipment and the most common methods of installation, mounting locations, and hazardous area classifications for all areas of the installation site.

Figure 3-1. Hazardous Area Block Diagram - 220425-Series DAQ

WARNING

The DAQ is designed to comply with the intrinsic safety requirements ofUL913 and IEC79-11. Incorrect installation may invalidate systemcertification and may result in an explosion or fire hazard. For detailedinstallation requirements for hazardous locations, reference drawing219569 and local electrical code (in the U.S.- NFPA70 National ElectricalCode.)


CHAPTER 3 DAQ - System 4INSTALLATION Manual 60-11

Figure 3-2. Hazardous Area Block Diagram - 220492-Series DAQ

3-3 SPECIAL TOOLS AND EQUIPMENT

A special screwdriver is required for connecting the sensor cabling to the DAQ field termination board. The screwdriver shown in Figure 3-3 is contained in a special holder located on the inside of the DAQ.

• Screwdriver, P/N 999701-005.

Figure 3-3. DAQ Sensor Cable Installation Screwdriver


DAQ - System 4 CHAPTER 3Manual 60-11 INSTALLATION

nd and OT

hole to a he ft side uate

3-4 UNPACKING AND INSPECTION

Unpack the DAQ and components from the shipping container(s) and perform the following:

• Carefully compare all items shipped with the packing list and examine for dam-aged or missing components.

• Notify the shipping agency and M/D Totco immediately if parts are damaged or missing.

3-5 HARDWARE INSTALLATION

Hardware installation consists of installing the hardware components, connecting earth grouprimary power, routing, installing, and connecting the sensor cables, and connecting the T-Pnetwork to the DAQ.

3-5-1 Mounting the Enclosure

Install the DAQ using the four mounting holes located on rear door of the enclosure. The locations and dimensions are shown in Figure 3-4. The enclosure may be bolted directly rigid structure or bolted to mounting brackets then clamped securely to a rigid structure. Tenclosure requires a clearance of approximately 35 inches (76.2 cm) in front and on the leto allow the door and case to swing fully open. Clearance below the DAQ should be adeqfor service loops that allow opening of the case to access the rear compartment.

Figure 3-4. Installation Dimensions - Permanent Location DAQ



3-5-2 Grounding

Connect the ground conductor, P/N 230017, from the DAQ to earth ground as follows:

1. Connect one end to DAQ ground lug shown in Figure 3-5.

2. Connect other end to a one-half inch ground clamp. Keep wire length between DAQ and ground connection to an absolute minimum.

3. Drive a one-half inch, eight foot, copper clad ground rod full length into ground.

4. Connect clamp end of ground wire to exposed end of ground wire. If a ground rod is not practical, connect clamp end to an approved earth ground.

Figure 3-5. DAQ Ground, Power, and Signal Connectors

CAUTION

Ensure that all ground connections are free of oil and paint. All connectionsmust have a secure contact made with a compression connector. Do notsolder connections.



3-5-3 Connecting Primary AC Power

Connect the AC primary power cable, P/N 219531-002, from the rig power source to the DAQ enclosure as follows:

Ensure that ground wire is properly installed before connecting AC primary power cable.

1. Open back cover door on Std DAQ or front cover on Fat DAQ.

2. Ensure that DAQ ON/OFF switch is set to OFF position.

3. Route end of AC power cable with terminals through DAQ enclosure cable gland shown in Figure 3-6.

4. Observe wire color coding and connect terminals to terminal block and ground lug as shown in Figure 3-6.

5. Tighten cable gland nut until cable is secured.

6. Connect other end of AC cable to rig power source.

7. Roll and tie excess cable away from rig traffic and working space.

Figure 3-6. AC Primary Power Connections



r the and

fea-

nected h as

itches ter" use

3-5-4 Digital Board Mode and Reset Switch Settings

The digital board modes are set using switch SW2, positions 1 through 8 as shown in Figure 3-7. The board also contains two momentary switches (SW1 and SW4) used for manu-ally resetting the main and analog processors respectively. Switch SW3 is not used at this time.

The configuration values contained in the main processor EPROM are cleared upon boot-up after SW2-8, is set to the “OFF” position and then turned ON after power is applied or aftereset button is toggled. This deletes all configuration data stored in configuration memoryshould not be used except as a last resort when problems exist.

The debug switch (SW2-4), when set to the “OFF” position, enables access to the debug tures only with a PC connected to the calibration/configuration port.

Switch SW2-5 set to “OFF” position causes a dump of processor error counts to a PC conto the calibration/configuration port. The PC must be using a communication program suc"PROCOMM II".

Switch positions SW2-1 and 2 allow up to four different DAQ’s to be connected, each withunique ID code. If only one DAQ is used, it must be designated as a "master" with both swset to the "ON" position. If more than one DAQ is connected, one must be set to the "masposition and the remainder set to different "slave" positions. The following rules apply to theof multiple DAQ configurations:

• All slave DAQ’s in the system must be configured as "devices" in the T-POT configuration of the master DAQ.

• All DAQ’s must be individually configured and calibrated.Slave DAQ’s have to be configured only for the channels assigned for it to handle and it’s digital and analog outputs.

• Any channel configured on a slave DAQ must also have that same logical channel configured on the master DAQ.

• Slave DAQ’s only talk on the network when asked by the master DAQ. The only information a slave sends over the network are the current val-ues for it’s configured channels.

• All slave DAQ’s are asked to send their calculated current values each time the master DAQ broadcasts the system current values to the network.

• A master DAQ may output digital/analog values for any channel in the system.

• A slave may only output digital/analog values for a channel in it’s own configuration.



Figure 3-7. Digital Board Mode and Reset Switches



3-5-5 EDMS Board Mode Switch Settings

The eight-position switch (DCW1) shown in Figure 3-8 is currently not used.

Figure 3-8. EDMS Board Mode Switch Settings

3-5-6 "Super" SIF (Spectrum InterFace) Board

The Spectrum I/F (Super SIF) board, P/N 221034-002, is shown in Figure 3-9. Jumper settings are listed in Table 3-1.

Figure 3-9. Spectrum InterFace (SIF)Board Jumper Locations

JP1JP2

JP3JP4

JP5

JP6



Table 3-2. JP3 - SIF Device ID Jumper Settings

Table 3-1. SIF Board Jumpers

Jumper Default Jumper Setting General Description

JP1 Not Applicable Not currently used.

JP2 Installed between pins 15 and 16 for 42.8K baud

Used to select the T-POT network baud rate (default = 42.8K).

JP3 Not installed Used to select the SIF device ID. (refer to Table 3-2)

JP4 Installed between pins 1 and 2

Used to select the SIF processor speed

JP5 Installed between pins 1 and 2 for 24V relay power.

Used to select relay power: 24V for IS sys-tems and 12V for non-IS systems

JP6 Installed between pins 2 and 3 for 16V display power.

Used to select display power: 16V for IS sys-tems and 10V for non-IS systems.

SIF 3-4 5-6 7-8 13-14*

0 X

1 X X

2 X X

3 X X X

4 X X

5 X X X

6 X X X

7 X X X X

*13-14 used as a Speed Jumper



Table 3-3. JP4 - Communication Baud Rate Jumper Settings

BAUD 1-2 3-4

9600

31K X

42.8K X

125K X X

Table 3-4. JP5 - Relay Power Jumper Settings

1-2 2-3

+12V X

+24V X

Table 3-5. JP6 - Display Power

1-2 2-3

+10V X

+16V X



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3-6 SENSOR INSTALLATION

The paragraphs that follow describe the suggested channel assignments, provide a list of DAQ termination board channel assignments, describe sensor groups, and sensor installation on a rig. Instructions for rigging up the applicable sensors and sensor cables are discussed separately for each channel.

3-6-1 General Practices

The following general practices should be observed when running signals cables between the sensors and the DAQ termination board:

• Cables must be routed so that they are out of walkways and not exposed to sharp corners that could wear through the insulation.

• Signal cable runs should be planned to avoid wet areas and close proximity to power cables.

• Nylon tie wraps should be used to dress, secure, and support the cables.• Special care must be taken to protect splices from moisture or excessive stra

3-6-1-1 Electrical Interference

When signal cables must be run in cable trays or otherwise located next to electrical pocables, noise is often inducted into the cables. This type of electrical disturbance may cerratic values to appear on one or more channels. Therefore, the use of shielded cablesrequired to eliminate the induced noise in lieu of the non-shielded cables that are typicaused on most land rigs.

3-6-1-2 Sensor Shielded Cable Splicing

Splicing of a sensor cable must usually be accomplished in the field. Figure 3-1 shows recommended method of using butt splices to join two pieces of shielded cable or a lenshielded cable and a shielded cable pigtail assembly.

NOTE

The sensors described in this manual represent a cross section of sensorsinstalled in a drilling rig. If a sensor is not shown in this manual, pleasecontact M/D Totco Engineering Field Service for suggestions and/oradditional installation instructions.

WARNING

Plan each rig up so that splices are not located in a hazardous area.



STEP 1. CUT EACH CABLE AND STRIP OUTER INSULATIONBACL 4 INCHES FROM BOTH ENDS.

STEP 2. CUT EACH CONDUCTOR TO STAGGERED LENGTHSAS SHOWN IN EXAMPLE "A".

STEP 3. STRIP 0.25 INCH (6.4MM) OF INSULATION FROM ENDOF EACH CONDUCTOR.

STEP 4. JOIN MATCHING CONDUCTORS (BLACK TO BLACK,WHITE TO WHITE, ETC) WITH CRIMPED BUTT SPLICES.

STEP 5. WRAP SPLICED AREA WITH MASTIC TAPE (APPROX 7 INCHES)AS SHOWN IN EXAMPLE "B".

STEP 6. WRAP SEALED AREA SECURELY WITH BLACK ELECTRICALTAPE AS SHOWN IN EXAMPLE "C".

Figure 3-1. Recommended Method of Splicing Cable

When joining two pieces of cable, always cut the individual conductors as shown in Figure 3-1. The butt splices must be staggered along the length of the cable splice. Observe color code when cutting and splicing conductors. Use a crimping tool and apply enough pressure on each butt splice connector to ensure a good compression connection between the conductor and the connector. Always seal and protect each splice with a strip of mastic tape that extends up the cable about one inch past both sides of the splice. Wrap the mastic tape securely with black electrical tape.



3-6-1-3 Connecting Two Devices With Shielded Cable

When shielded cable is used to connect two devices, the shield is usually connected to ground at just one end of the cable. If the shield is connected to ground at both ends of the cable, a path is formed for ground loops that may cause additional interference. As a rule, the shield in a cable that runs between the DAQ field termination board and a sensor should be connected to ground only at the DAQ field termination board end of the cable. When using butt splice connectors to fabricate a length of shielded cable, the cable shield should only be spliced to the shield in the pigtail that connects to the DAQ field termination board. At the other end of the cable, the shield should be cut off even with the cable insulation and not connected to any other shield or device.

3-6-1-4 Field Termination Board Sensor Connection Blocks

All analog and digital channel sensor wiring is connected to the DAQ Field termination board shown in Figure 3-1. The board contains termination blocks for 23 analog inputs, 14 digital programmable inputs and outputs, six digital power outputs, and EDMS connections. Also, located on the analog I/O board, below the termination board, are 24 analog sensor switches used to select either voltage or current source inputs for the corresponding 23 analog chan-nels. Switch position 24, as counting from the top, is not functional.

Figure 3-1. Field Termination Board Sensor Connections



3-6-2 Hook Load Sensor(s) Installation

Hook Load is typically sensed is one of two ways, either a sensor in the deadline anchor or a deflection sensor attached to a static section of the wire rope. The most common method is the sensor located in the deadline anchor. Refer to Section 3-6-2-1 for information regarding a dead-line anchor installation. Refer to Section 3-6-2-2 for information regarding a deflection sensor installation.

Figure 3-2. Typical Hook Load Installation(S)

3-6-2-1 Deadline Anchor Application

Connecting the Hook Load channel requires breaking into the hydraulic line that runs from the load cell on the deadline anchor to the weight indicator or the drilling recorder located on the rig floor. Since the driller relies on the weight indicator for Hook Load (and in some cases, the same hydraulic system may be used to run the automatic driller), any loss of hydraulic fluid or leaks caused during transducer installation would be extremely serious. Therefore, care must be taken to avoid loss of hydraulic fluid, introducing air into the system, or causing leaks by damaging any hydraulic lines or fittings.

The transducer assembly used for the Hook Load channel must be chosen to match the weight indicator system used on each rig. If transducers are used that measure over a fixed pressure range, either a 0-1000 psig transducer or a 0-2000 psig transducer matches most existing weight indicators. Table 3-6 lists a summary of maximum deadline load, load cell output, and matching M/D Totco transducers. The same information can be used when selecting a trans-ducer assembly from a different manufacture.



Before disconnecting the hydraulic line to insert a tee, always advise the driller, the tool pusher, and company man that a hydraulic connection is about to be made in the weight indi-cator system. Please note that some drilling contractors may not allow tie-ins to the load cell hydraulic system. In that case, a deadline diaphragm or TCE transducer must be used. When a hydraulic connection to a load cell is permitted, the transducer assembly should be connected into the line when Hook Load is as small as possible (hydraulic pressure is also low). The driller should be asked to put the drill string on the slips while the transducer connection is made. After the connection is completed, the driller should be advised so normal operations can resume.

The signal cable must not interfere with the movement of either the dead line or the anchor. Always check for leaks in the hydraulic system after the transducer assembly is installed.

Table 3-6. Weight Indicator Load Data

Type of Weight Indicator

Maximum Deadline Load

(lbs.)

Maximum Load Cell Output

(psig)

Suggested Transducer

M/D Totco "G" (or equivalent)

30,000 970 1000 PSIG

M/D Totco "FS"(or equivalent)

40,000 1408 1500 PSIG

M/D Totco "D"(or equivalent)

50,000 816 1000 PSIG

M/D Totco "E"(or equivalent)

75,000 816 1000 PSIG

M/D Totco "EB"(or equivalent)

100,000 1088 1000 PSIG

M/D Totco 120 and HERCULES 122A

120,000 1304 1500 PSIG

M/D Totco 120 and HERCULES 150

120,000 1440 1500 PSIG

M/D Totco 150 and HERCULES 150

150,000 1800 2000 PSIG



3-6-2-2 Wireline Deflection Sensor (P/N TCE-Series)

Figure 3-1. TCE Transducer Installation

Install the TCE Line Tension Transducer as follows:

1. Find an acceptable site to install the TCE, keeping in mind the following:

a. The best place to install the device is close to the anchor; this reduces cable sway and vibration.The shortest distance from the anchor to the TCE is 3 feet (0.914 m).

b. Reduce cable-routing effort by considering the location of the data-acquisition unit to which the TCE is attached.

c. Because it is not a hydraulic device, the elevation of the TCE relative to other devices is not important.

2. Make sure that the crank retaining screw (Figure 3-2) is in place and tight.

3. Loosen the yoke (Figure 3-2) by rotating the crank counterclockwise.

4. Rotate the crank until there is enough gap to allow installation.

5. Open the clamp by lowering the clamping mechanism and rotating it 180 degrees.

6. This allows the installation of the wire rope.

7. Close the clamp by rotating 180 degrees.

8. Make sure that the holes in the clamping block line up with the guide posts.

NOTE

To simplify installation, perform these steps when the wire line is notunder load.



9. Tighten the clamp by rotating the crank clockwise one full turn after the wire rope contacts the transducer body.

10.When installing signal cable, PIN A is (-) signal and PIN C is (+) source. Secure the cable near the sensor, providing strain relief and preventing accelerated cable wear.

11.Attach RF ground lead (minimum 1 inch ground braid) to one of the four socket head cap screws next to the signal connector.

Figure 3-2. TCE System Assembly

NOTE

The ground wire must be attached to the steel structure and as shortas possible- 25 feet maximum.

Crank

Body

Clamping

Yoke

Signal OutputConnector

End

Deflector

WireRope

Shoe

Retaining

Screw

3.20

4.00

4.56

RF GroundAttachmentPoint



Figure 3-3. Wiring Diagram - Wireline Deflection Sensor P/N TCE-Series

Figure 3-4. Wireline Deflection Sensor Wiring (P/N TCE-Series)



3-6-3 Pressure Sensor(s) Installation

The following installation procedure describes how to install a mud pump pressure diaphragm. If the rig already has a mud pump pressure diaphragm mounted on a standpipe, a 0-5000 psig transducer may be connected into the existing diaphragm of the recorder hydraulic line. The connection may be at either the diaphragm or recorder end as shown in Figure 3-5. The recorder end should be used to avoid damage from standpipe shock.

1. Connect diaphragm to hydraulic hand pump. Add hydraulic fluid while holding out-put valve open until all air is bled from line and diaphragm.

2. Release valve and continue pumping while observing bottom of diaphragm. Pump-ing should continue until diaphragm is almost totally collapsed. Do not overpres-sure diaphragm.

3. Connect diaphragm to standpipe.

4. Connect 0-5000 psig transducer to diaphragm and open valve. Since pressures of 3000 psig or higher are possible, disconnecting or connecting transducer should only be done when pump is off and pressure is near or at zero.

5. After diaphragm and transducer are installed, connect signal cable from transducer to DAQ.

6. Recheck all hydraulic and electrical connections for security and ensure that instal-lation does not interfere with normal rig operations.

NOTE

Prior to connecting transducer to hydraulic line, connect transducer to ahydraulic hand pump and fill with hydraulic fluid. Ensure no air is trappedinside transducer.

WARNING

Ensure that driller is aware of pending standpipe break and have drillerclose valve to point of connection to prevent escape of drilling mud.



Figure 3-5. Pump Pressure Transducer Installation

3-6-4 Pressure Transducer Assembly (P/N H12288A-Series)

The Pressure Ttansducer Assembly (P/N H12288A-Series) contains up to four pressure trans-ducers used to convert hydraulic pressure input to a 4-20mA output.Tbe H12288A only houses the H12354A transducer. The pressure range for the H12354A transducer varies from 15 PSI to 10,000 PSI.Hook Load typically utilizes a 0-1000 PSI transducer, Tong Torque 0-3,000 PSI, and Pump Pressure a 0-5000 PSI transducer.

Figure 3-6. H12288A Pressure Transducer Assembly

HYDRAULICINPUT

ELECTRICALOUTPUT



3-6-5 Pressure Transducer Assembly (P/N H12353A-Series)

The Pressure Transducer Assembly (P/N H12353A-Series) contains one or two pressure trans-ducers used to convert hydraulic pressure input to a 4-20mA output.The H12353A is used to house the H12354A transducer. The pressure range for the H12354A transducer varies from 15 PSI to 10,000 PSI. Hook Load typically utilizes a 0-1000 PSI transducer, Tong Torque 0-3,000 PSI, and Pump Pressure a 0-5000 PSI transducer.

.

Figure 3-7. H12353A-Series Pressure Transducer Assembly

3-6-5-1 H12354A Pressure Transducer (220425 Application)

The pressure range for the H12354A transducer varies from 15 PSI to 10,000 PSI. The H12354A transducer is housed in the H12353A (2 transducer) assembly or the H12288A (4 transducer) assembly.

Figure 3-1. Wiring Diagram - H12354A Transducer in H12288A or H12353A Assembly

HYDRAULIC INPUT

ELECTRICALOUTPUT



3-6-5-2 H12354A Pressure Transducer (220492 Application)

Figure 3-1. Wiring Diagram - H12354A Transducer in H12288A or H12353A Assembly

3-6-6 Pressure Transducer Assembly (P/N 220631-Series)

The Pressure Transducer Assembly (P/N 220631-Series) contains up to four pressure transduc-ers used to convert hydraulic pressure input to a 4-20mA output.

The 220631 houses the 220282-Series transducer and the 940233-006 transducer. The pressure range for the 220282 transducer varies from 100 PSI to 5,000 PSI. The 940233-006 transducer is rated at 10,000 PSI. Hook Load typically utilizes a 0-1000 PSI transducer, Tong Torque 0-3,000 PSI, and Pump Pressure a 0-5000 PSI transducer.

Figure 3-2. 220631 Pressure Transducer Assembly

HYDRAULICINPUT

ELECTRICALOUTPUT



3-6-7 Pressure Transducer Assembly (P/N 220756-Series)

The Pressure Transducer Assembly (P/N 220756-Series) contains one or two pressure transduc-ers used to convert hydraulic pressure input to a 4-20mA output.

The 220756 houses the 220282-Series transducer and the 940233-006 transducer. The pressure range for the 220282 transducer varies from 100 PSI to 5,000 PSI. The 940233-006 transducer is rated at 10,000 PSI. Hook Load typically utilizes a 0-1000 PSI transducer, Tong Torque 0-3,000 PSI, and Pump Pressure a 0-5000 PSI transducer.

Figure 3-3. 220756-Series Pressure Transducer Assembly

HYDRAULIC INPUT

ELECTRICALOUTPUT



3-6-7-1 220282 Pressure Transducer (220425 Application)

The Pressure Transducer, 220282-Series, is located in the Pressure Transducer Assembly, 220756-Series or 220631-Series. The 220631 houses one or two transducers and the 220756 houses up to four.

The 220282 Pressure transducer is available in six pressure ranges from 100 to 5,000 PSI. Refer to Figure 3-1 and Figure 3-1 for wiring information.

Figure 3-1. Wiring Diagram - 220282 Transducer in 220631 or 220756 Assembly


Figure 3-1. Wiring Diagram - 220282 Transducer in 220631 or 220756 Assembly



3-6-7-3 940233-006 Pressure Transducer (220425 Application)

The 940233-006 transducer is rated at 10,000 PSI. The 940233-006 is only used in high pres-sure applications, such as pump pressure or annulus pressure. The 940233-006 transducer is housed in the 220756 (2 transducer) assembly or the 220631 (4 transducer) assembly.

Figure 3-1. Wiring Diagram - 940233-006 Transducer in 220631 or 220756 Assembly

3-6-7-4 940233-006 Pressure Transducer (220492 Application)

Figure 3-1. Wiring Diagram - 940233-006 Transducer in 220631 or 220756 Assembly




The 220017-Series pressure transducer is available in 14 different models with pressure ranges from 6,000 PSI to 20,000 PSI. The 220017 transducer is available in standard and H2S models. A 1502 wing nut is an integral part of the 220017 transducer, allowing the transducer to be attached directly to the standpipe. The safe over-pressure range of the sensor is 1.5 times the rated pressure. The burst pressure is 2.5 times the rated pressure.

Figure 3-1. Electronic Pressure Transducer Installation

Figure 3-2. Wiring Diagram - 220017-Series Pressure Transducer



3-6-8 Rotary Torque Installation

A current transducer is available for use as an electrical rotary torque sensor. When clamped around the correct DC motor leads, the split core transducer senses the amount of current used by the motor. The amount of current used varies in direct proportion to the amount of torque developed by the motor at any given time. The following procedure describes how to rig an electrical rotary torque channel using a current transducer.

Figure 3-3. Rotary Torque Sensor

1. Install transducer by clamping two sections around positive motor lead with red dots pointing toward most positive segment current source of cable (not toward drive motor). Use electrical tape to prevent transducer from sliding along cable.

NOTE

The Electric Drive Current Transducer Sensor can only be installed withDAQ’s which contain internal barriers.

WARNING

Use extreme caution when handling power cables and connectors. Powercables in electric drive motor circuits carry dangerously high voltages.When possible, shut off power before handling cables.



2. After installing transducer, run rotary torque signal cable from transducer to DAQ. Route cable away from walkway and sharp corners where excessive wear to cable insulation could occur. Avoid wet locations if possible and tie cable runs with plas-tic tie wraps.

3. Connect cables between transducer and DAQ as shown in Figure 3-6-11.

4. Recheck all electrical connections for security and ensure that installation does not interfere with normal rig operations.

3-6-8-1 218041-002 Current Transducer (220492 Application)

Figure 3-1. Wiring Diagram - Rotary Torque Sensor P/N 218041-002

NOTE

Do not install transducer on any cable carrying current used for reversingmotor direction as transducer only senses current flow in one direction.

NOTE

The transducer window hole is designed to fit a cable with a diameter upto two inches (50.8 mm). The transducer body red dots indicate positivepolarity and must face the most positive segment of the cable.



3-6-9 Rotary Table RPM Installation

Proximity or non-contacting sensor applications are similar to dry contact switches except that they detect ferrous targets. These sensors, shown in Figure 3-4, operate with an established elec-tromagnetic field around their head. The field is disturbed when a ferrous metallic object (target) passes through it and the sensor detects this disturbance and generates a pulse. Two-Wire Prox-imity sensors act like a variable resistor with two value (low and high) positions dependent whether the target is present.

The rotary RPM sensor responds when ferrous metal is in close proximity to it when metal enters the sensing area, the circuit current drops and produces a pulse. For this installation, a tar-get is attached to an exposed bolt located on the coupling located between the transmission and the rotary table. The coupling rotates a known number of times for each rotation of the rotary table. The sensor is installed so that the target passes within the sensing range of the probe when the rotary table is turning.

Figure 3-2. RPM Proximity Installation

Install the rotary RPM sensor as follows:

1. Remove the rig floor cover which covers the motor and transmission drive for the rotary table.

2. Attach a 1" to 2" metal target to one of the exposed bolts on the coupling between the transmission and the rotary table. Refer to Figure 3-3.

Figure 3-3. Proximity Target Installation



3. Secure a bracket to the rig sub-floor and attach the sensor. Make sure to locate the bracket so that the sensor when attached will intersect the coupling target. Using the adjustment nuts on the sensor, adjust the sensor so that the sensing end passes within 3/16 to 3/8 inch of the target. Probe must be moved as close as possible to ensure accurate RPM counts. Refer to Figure 3-4.

Figure 3-4. Proximity Bracket Installation

4. Run signal cable and connect to rotary sensor and DAQ as shown for your specific application, International or N American.

5. Recheck all mechanical and electrical connections for security and ensure that installation does not interfere with normal rig operations. Replace the rig floor cover.

3-6-10 SPM Sensor(s) Installations

Proximity or non-contacting sensor applications are similar to dry contact switches except that they detect ferrous targets. These sensors, shown in Figure 3-4, operate with an established elec-tromagnetic field around their head. The field is disturbed when a ferrous metallic object (target) passes through it and the sensor detects this disturbance and generates a pulse. Two-Wire Prox-imity sensors act like a variable resistor with two value (low and high) positions dependent whether the target is present.

NOTE

Sensor cable must not be run next to or near rig power cables. This couldcause the system to pickup erroneous signals and cause problems with therotary RPM channel.



3-6-10-1 232389 Proximity Sensor (220425 Application)

Figure 3-1. Wiring Diagram - Proximity Sensor P/N 232389

3-6-10-2 232389 Proximity Sensor (220492 Application)

Figure 3-1. Wiring Diagram - Proximity Sensor P/N 232389



3-6-10-3 H11094A-01 Proximity Sensor (220425 Application)

Figure 3-1. Wiring Diagram - Proximity Sensor P/N H11094A-01

3-6-10-4 H11094A-01 Proximity Sensor (220492 Application)

Figure 3-1. Proximity Sensor Wiring (P/N H11094A-01)



3-6-10-5 H11092A Proximity Sensor (220425 Application)

Figure 3-1. Proximity Sensor Wiring (P/N H11092A)

3-6-10-6 H11092A Proximity Sensor (220492 Application)



3-6-11 Top Drive Sensors

Two types of signals, Torque and RPM, are monitored via the Top Drive control panel. They can be individually monitored as shown in Figure 3-1 and Figure 3-1 or monitored together as shown in Figure 3-1.

3-6-11-1 Top Drive Torque Input (220425 Application)

Figure 3-1. Wiring Diagram - Top Drive Torque Input

3-6-11-2 Top Drive RPM Input (220425 Application)

Figure 3-1. Wiring Diagram - Top Drive RPM Signal



3-6-11-3 Top Drive Torque & RPM Input (220425/220492 Application)

Figure 3-1. Wiring Diagram - Top Drive RPM & Torque Combined



3-6-12 Flow Sensor Installation

Voltage sensors are the most common sensor and are typically used where cable lengths are short and noise immunity and isolation are not a concern. Applications of voltage sensors are as follows:

• DC voltage outputs from other electronic equipment.• Potentiometer type sensors.

Follow the steps below to install and calibrate this mud flow sensor.

1. Select a location on the flow line for installing the mud flow sensor. This location must meet the following criteria:

• slopes down toward shaker pit• is accessible for servicing• is above spill-over level of shale shaker• is away from bends in the flow line

2. Cut a 9.25" x 2.50" (235 mm x 63.5 mm) hole lengthwise in return flow line (Figure 3-2) and weld sensor base squarely onto flow line. Be sure base containing three holes is upstream from other end.

Figure 3-2. Mud Flow Sensor Installation: P/N MFTX4A-5

NOTE

If a base mounted to the flow line from a previous rig-up meets the aboverequirements, it can be used. Otherwise, proceed to Step 2.

WARNING

Be sure area is free of explosive vapors before using welding torch.



3. Determine flow line diameter and select appropriate paddle size.

4. Measure from top of flow flange to bottom of flow line to determine where on sen-sor to mount paddle; then attach using furnished screws. Ensure locking nuts for screws are on downstream side of paddle arm. Place paddle through hole in pipe, with concave side facing upstream.

5. Ensure that when no mud is flowing and paddle is in down position, there is a 0.25 - 0.75-inch gap (6.3 - 19 mm) between paddle and base of pipe and there is no block-age (cement/cuttings) when sensor is mounted in its base; adjust paddle using holes in paddle arm, if necessary.

6. Ensure base has sufficiently cooled from welding; then position neoprene gasket on face of base.

7. Rotate flow sensor approximately 90o to place paddle through opening; then rotate it back to align body with base and bolt to base.

8. Remove potentiometer housing cover (Figure 3-3). Set sensor zero point by holding paddle in down position. Loosen two screws and slide potentiometer assembly until 150-250 ohms is present between terminals 1 and 2 on TB1. Tighten screws.

9. Connect sensor cable to TB1 and then either directly to DAQ (Figure 3-1). Replace cover.

Figure 3-3. Mud Flow Sensor Calibration



3-6-12-1 MFTX4A Flow Sensor (220425 Application)

Figure 3-1. Wiring Diagram -P/N MFTX4A-5

3-6-12-2 MFTX4A Flow Sensor (220492 Application)

Figure 3-1. Mud Flow Sensor Wiring (P/N MFTX4A-5)



3-6-13 Pit Level Sensor(s) Installations

Voltage sensors are the most common sensor and are typically used where cable lengths are short and noise immunity and isolation are not a concern.

Ensure that mud pit level probes selected for each installation are the correct length. If mud probes do not already have floats in place, loosen set screws in each retaining collar and remove collars from end of each probe. Place a float on each probe and replace the collars. Align the top of the retaining collar to one of the lines etched around the lower part of each probe. The line nearest the bottom of the probe is used with an eight inch spherical float. Install the mud probe(s) as follows:

1. Install mud pit level probes in areas with a minimum of mud turbulence. Tighten mounting clamp, shown in Figure 3-2, on tank edge or on cross member over tank.

2. Adjust extension bracket over tank. Place probe assembly in tank and hold in verti-cal position. Before attaching, move probe assembly in a circular pattern to ensure nothing hampers float movement as mud level changes.

3. Place probe in clamp, then tighten clamp bolts.

4. Run cables and connect mud volume channels as shown in Figure 3-1 or Figure 3-1. Tie wrap cables along run for neatness and to reduce possibility of cable damage.

5. Recheck all electrical connections for security and ensure that installation does not interfere with normal rig operations.

Figure 3-2. Reed Switch Probe Installation

WARNING

Do not let the mud pit level probes come in contact with the mud pitagitators. Severe equipment damage could result.



3-6-13-1 262622-Series Reed Switch Probes (220425 Application)

Figure 3-1. Wiring Diagram - Reed Switch Probe P/N 262622

3-6-13-2 262622-Series Reed Switch Probes (220492 Application)

Figure 3-1. Wiring Diagram - Reed Switch Pit Level Probe



3-6-13-3 221576 Ultra-Sonic Probes (220425 Application)

Figure 3-1. Wiring Diagram - Ultra-Sonic Probe P/N 221576

3-6-13-4 221576 Ultra-Sonic Probes (220492 Application)

Figure 3-1. Wiring Diagram - Ultra-Sonic Probe P/N 221576



be ut the rovide asure f the

3-6-14 Temperature/Density Sensor(s) Installations

The mud density channel receives information from either 1 or 2 mud density sensors, depend-ing on the customer’s requirements. For example, a two probe system consists of one promeasuring the weight of the mud-in and another measuring the mud weight out. The outprange from any one sensor to the DAQ is 4-20 mA. For installation, one probe mounts in suction pit and the other mounts in the possum belly. C-clamps and adjustable brackets pmounting stability as shown in Figure 3-2. The mud weight probe may be assembled to memud weight at several depths. The end section of the probes must be under the surface omud. Install and connect the probes as follows:

1. Install mud-out probe in possum belly away from mud return inlet and in least tur-bulent area of pit.

2. Mount probe so that top of baffle is at least 1-inch below surface of mud during nor-mal drilling conditions.

3. Install mud-in probe in suction pit so that top of baffle is at least 12 inches under surface of mud. Set to depth that allows for variations in mud levels during normal conditions. Place probe in least turbulent area of pit.

4. Run cables and connect sensor probes to DAQ as shown in Figure 3-1.

Figure 3-2. Mud Density Sensor Installation

CAUTION

Do not put probe in slug pit, and avoid area where new mud is pumped intosuction pit. Newly mixed mud may foul probes.



3-6-14-1 220005-Series Temperature/Density Probes (220425 Application)

Figure 3-1. Wiring Diagram - Temperature/Density Probe



3-6-15 EDMS Depth Sensor(s) Installations

3-6-15-1 H12321A-Series Encoder (220425 Application)

Figure 3-1. Wiring Diagram - Encoder P/N H12321A-Series

3-6-15-2 219062 Encoder (220492 Application)

Figure 3-1. Encoder (P/N 219062) Wiring



3-6-16 Calibration Switch Box Installation

3-6-16-1 219255-001 Cal Switch Box (220425 Application)

Figure 3-1. Wiring Diagram - Calibration Switch Box P/N 219255-001

3-6-16-2 219255-001 Cal Switch Box (220492 Application)

Figure 3-1. Calibration Switch Box connection to DAQ



3-6-17 Digital Outputs

Digital output examples from the DAQ are shown in Figure 3-2. The output is either a pulsed output from 0-10 VDC or a steady DC level to drive, a solenoid or relay.

Figure 3-2. Digital Ouput Wiring

3-7 CONNECTING T-POT

The T-POT network connects to the DAQ BNC connector at the location shown in Figure 3-5.

3-8 INITIAL POWER UP

After all DAQ ground connections, power connections, sensors, and T-POT connector are con-nected, apply primary power to the DAQ as follows:

1. Open DAQ rear cover door (Front cover on Fat DAQ).

2. Set power ON/OFF switch to ON position.

3. Perform system calibration/configuration procedure (refer to Chapter One under Related Documents).


M’s,

nt fail-e com-

prob-ling, po-ted


4-1 INTRODUCTION

This chapter contains procedures for inspecting, troubleshooting, replacing the DAQ EPROEDMS battery, and general interface cabling information for the DAQ. Refer to Chapter Five(Illustrated Parts Breakdown) for parts lists and illustrations depicting component locations, assembly, and disassembly.

4-2 RECOMMENDED INSPECTIONS

The following items should be checked periodically or each time the unit is opened.

1. Check all component mounting bolts for looseness. Tighten as required.

2. Check enclosure for moisture ingression. Correct as necessary.

4-3 TROUBLESHOOTING

The paragraphs that follow provide general troubleshooting checks and a table for isolating specific problems.

4-3-1 General Checks

Field experience has proven that minor repairs can correct 90% of all electronic equipmeures, avoiding the replacement of major assemblies. The following steps should always bpleted prior to performing more extensive repairs.

1. Verify primary power is supplied to the unit and is specified power for the unit being serviced (see Chapter Two and Chapter Three).

2. Check for loose, crushed, frayed, cut, or otherwise damaged cables.

3. Check wiring connections for loose or broken leads.

4. Verify all components are properly interconnected and properly seated in their mat-ing connector or socket.(see Chapter Three)

4-3-2 Fault Isolation Table

Table 4-1 lists specific malfunctions, probable causes, and corrective actions for isolatinglems within the DAQ. Refer to Figures 4-1 through 4-5 as required for interface wiring, caband component locations. Note that after replacement of any circuit board or related comnents, a recalibration of the system must be performed. Refer to Chapter One under RelaManuals.


CHAPTER 4 DAQ - System 4MAINTENANCE Manual 60-11

Table 4-1. Fault Isolation Table

Problem Probable Cause Corrective Action

System inoperative. 1. No power to system. Check and correct power source.

2. Blown fuse. Replace fuse.

3. Defective power supply. Perform power supply checkout proce-dure, paragraph 4-7.

Digital board analog LED off.

Analog processor malfunc-tion or digital board failure.

Press main processor reset. If problem still exists, set SW2,switch 8 to off posi-tion, then press both processor reset switches SW1 and SW4. Set switch 8 to on position. If problem still exists, replace digital board, P/N 219493.

Digital board watch dog timer. LED off or blinking.

Main processor malfunction or digital board failure.

Press main processor reset. If problem still exists, set SW2, switch 8 to off posi-tion, then press both processor reset switches SW1 and SW4. Set switch 8 to on position. If problem still exists, replace digital board, P/N 219493.

Digital board main proces-sor communications LED off.

Main processor malfunction or digital board malfunction.

Cycle power. If problem still exists, press main processor reset. If problem still exists, set SW2, switch 8 to off posi-tion, then press both processor reset switches SW1 and SW4. Set switch 8 to on position. If problem still exists, replace comm board, P/N 219484. If problem still exists, replace digital board, P/N 219493.

All three digital board LEDs off.

Power problem or digital board malfunction.

Verify power, fuse, and power supply operation (paragraph 4-7. If problem still exists, replace digital board, P/N 219493.

Erratic or no indication from sensor channel.

1. Analog board voltage/current switch.

Verify switch is in correct position for sensor type.

2. Sensor connections. Ensure that all sensor connections are secure.

3. Sensor. Refer to sensor manufactures instruc-tion manual.

4. Faulty Channel. Reconnect sensor to different sensor channel (con’t) channel. Recalibrate channel.

5. Analog Board. Check LED’s on digital board (see Fig-ure 4-1). If functioning, replace analog board, P/N 219506. If not functioning, go to next step.


DAQ - System 4 CHAPTER 4Manual 60-11 MAINTENANCE

There S

4-4 DAQ MAINTENANCE PROGRAM

The DAQ operating program can be monitored using the PROCOMM Plus program on a PC con-nected to the same DAQ serial port used by the calibration/configuration program.

(currently under development)

4-5 SENSOR PROBLEMS

Sensor problems are generally caused by improper installation, alignment, faulty cables or connec-tions, or the sensors themselves. If the problem is traced to a sensor, repair or replace the sensor.

4-6 REPLACING E-PROM’S

E-PROM’s may require replacement either as a result of failure or routine software updates.are three boards (Digital, SIF/Communications, and EDMS boards) which contain E-PROMwhich may require replacing. Refer to the following sections for details on replacing each E-PROM.



4-6-1 Digital Board E-PROMS

The E-PROM chips (U15 and U16) are located on the digital board as shown in Figure 4-1. These chips (U15 and U16) are refered to as the Main Program E-PROMS and may be replaced as described in the procedure below. The Analog Board E-PROM (U19) is also located on the Digital Board and is also shown in Figure 4-1. Replacement of this chip is identi-cal as U15 and U16. For replacement E-PROM part numbers, refer to Table 2-3.

1. Open rear cover door.

2. Set power ON/OFF switch to OFF.

3. Observe CAUTION, note direction of I.C. notch, and carefully remove chip from socket using an IC extractor tool (P/N T10078A).

4. Carefully install replacement chip. Make sure notch in chip is facing in same direc-tion as chip removed.

5. Close rear cover door.

6. Set power ON/OFF switch to ON.

7. Recalibrate system as described in configuration/calibration manual (see Chapter 1).

Figure 4-1. Digital Board E-PROM Locations

CAUTION

STATIC DISCHARGE CAN DAMAGE INTEGRATED CIRCUITS.Do not handle integrated circuits or component boards unless properlygrounded. Do not let clothing or plain plastic materials contact or come inclose proximity to these static sensitive devices.



4-6-2 SIF Board E-PROM

The E-PROM chip (U9) is located on the SIF board as shown in Figure 4-2. It may be replaced as described in Section 4-6-1. For replacement E-PROM part numbers, refer to Table 2-3.

Figure 4-2. SIF Board E-PROM Location

4-6-3 EDMS Board E-PROM

The E-PROM chip (U17) is located on the EDMS board as shown in Figure 4-3. It may be replaced as described in Section 4-6-1. For replacement E-PROM part numbers, refer to Table 2-3.

Figure 4-3. EDMS E-PROM Location

U9

E-PROM (U9)



4-7 POWER SUPPLY & WIRING HARNESS CHECKOUT PROCEDURE

The following procedure tests both power supply outputs and associated wiring. A schematic of the DC power distribution that includes interfaces, connector pins, signal names, and wire color coding is shown in Figure 4-2. Perform the procedure in the following sequence:

1. Refer to Figure 4-3 and remove four screws securing power supply on-off switch pro-tective cover. Remove cover and set aside.

2. Using digital voltmeter (DVM), measure voltages from power supply connectors to chassis ground as follows:

3. If any voltages are incorrect, replace associated power supply. If voltages are all cor-rect, measure for the following voltages:

4. For EDMS option, measure for the following voltages:

5. If any above voltages are not present, repair or replace wiring between power supply and associated connector.

Connector\Pins Volts DC Color

From (+) To (-)

P4 - J6 Gnd -15 Vdc Yellow

P4 - J2 Gnd +5 Vdc Red

P4 - J1 Gnd +15 Vdc Orange

P14 - J1 Gnd +28 Vdc Purple

Connector Pins Volts DC Color

From (+) To (-)

P8 - J1 Gnd +5 Vdc Red


P11 - J1 Gnd +28 Vdc Purple


P11 - J8 Gnd -15 Vdc Yellow

Connector Pins Volts DC Color

From (+) To (-)

P3 - J9 Gnd +28Vdc Purple




4-8 EDMS BATTERY TEST

Refer to Figures 4-2 and 4-3 and measure battery output voltage at the following test points:

Connector Pins Volts DC

From (+) To (-)

P3-J4 P3-J2 10.5 to 12.0 Vdc *

* If voltage reading is below 10.5 Vdc, replace battery.



Figure 4-4. DC Power Distribution Wiring Diagram (220425 & 220492-Series)



Figure 4-5. DAQ DC Power Distribtution

Table 4-2. DAQ DC Connections

Pin Description

P1 Battery Pack Connector (+)

P2 Battery Pack Connector (-)

P3 Connector to EDMS Board

P4 Power Supply Connector

P8 Connector to Digtial Board

P11 Connector to Digital Board

P14 Power Supply Connector

P3

P8

P2

P1

(EDMS)

BATTERY PACK - 12VDC(EDMS)

P11

P4

P14

POWERSUPPLY

POWERSUPPLY



Figure 4-6. AC Power Distribution Wiring (Power Supplies 220251-005 & -006)



5-1 INTRODUCTION

This chapter contains the illustrated parts breakdown and recommended spare pare parts list for use in maintaining the DAQ. The illustrated parts breakdown contains illustrations of major com-ponents and assemblies accompanied by parts lists keyed to index numbers on the illustrations. The main features of the illustrated parts breakdown are described below.

5-2 PARTS LIST

The four columns of the parts list are described in Paragraphs 5-2-1 through 5-2-4 below.

5-2-1 Find Number

This column lists the figure and index number of the component, assembly or part described.

5-2-2 Part Number

This column contains the M/D Totco part number.

5-2-3 Description

This column contains the name and description of each assembly, subassembly and part.

5-2-4 Units Per Assembly

This column lists the number of units required for one next higher assembly.


CHAPTER 5 DAQ - System 4ILLUSTRATED PARTS BREAKDOWN Manual 60-11

5-3 ABBREVIATIONS

Table 5-1 contains the standard abbreviations used in the parts lists.

Table 5-1. Parts List Abbreviations

Abbreviation Explanation Abbreviation Explanation

ap Attaching parts pcb Printed Circuit Board

assy Assembly pnhd Pan Head

awg American Wire Gauge pos Position

bdgh Binding Head pt Point

ext External rd Root Diameter

flhd Flat Head ref Reference

id Inside Diameter shld Shield

ins Inside slflkg Self Locking

is Intrinsically Safe sltd Slotted

lg Length sst Stainless Steel

m/f Male-Female thd Thread

od Outside Diameter unc Unified Coarse Thread


DAQ - System 4 CHAPTER 5Manual 60-11 ILLUSTRATED PARTS BREAKDOWN

Figure 5-1. Permanent Location DAQ (P/N 220492-KIT & 220425-KIT)




DAQ - System 4 CHAPTER 5
Manual 60-11 ILLUSTRATED PARTS BREAKDOWN

CHAPTER 5 DAQ - System 4
ILLUSTRATED PARTS BREAKDOWN Manual 60-11












Table 5-2. PERMANENT LOCATION DAQ - (INTERNAL BARRIERS W/ SIF)

FIND # PART NUMBER DESCRIPTION QTY

-- 220492-008 DAQ ASSY, BARRIER, W/ SIF --

1 220492-KIT DAQ, UL, SYS4, PERM LOC 1

2 220339-011 ID PLATE, DAQ 1

4 999241-008 SCREW, DRV, #2x.187, RDH 6

5 991206-026 SEALANT, RTV 3145 (DOW) NA

Table 5-3. PERMANENT LOCATION DAQ - (INTERNAL BARRIERS W/ SIF & EDMS)


-- 220492-009 DAQ ASSY, BARRIER, W/ SIF & EDMS --

1 220492-KIT DAQ, UL, SYS4, PERM LOC 1

4 999241-008 SCREW, DRV, #2x.187, RDH 6

5 219770-001 PCBA, E-DEPTH, TOTAL SYS 1

6 219908 BATTERY PACK ASSY, EDMS 1

7 999266-284 STANDOFF, M/F, #6-32X.44 2

8 999252-401 SCREW, #6-32x.37, BDGH 2

9 999216-026 WASHER, FLAT, .144x.27x. 4

18 991206-026 SEALANT, RTV 3145 (DOW) 1



Table 5-4. 220492-KIT


1 219506 PCBA, DAQ ANALOG BRD 1

2 219509 PCBA, DAQ FIELD TERM BR 1

3 219493-002 PCBA, DAQ DIG BRD, 512K 1

4 221034-002 PCB ASSY, SPECTRUM I/F 1

5 999252-401 SCREW, #6-32x.37, BDGH 15

7 999494-003 STANDOFF, F/F, #6-32X.5 2

10 J10480A-17 SEAL, HOLE, 1.00"CND 4

11 J10480A-16 SEAL, HOLE, O-T SWT 3

12 999216-026 WASHER, FLAT, .144x.27x. 21

14 219554-100 ENCLOSURE ASSY, DAQ, PER 1

15 232039 LUG, GROUNDING, 3/8-16 B 1

16 999449-164 SCREW, #10-32x.31, PNH 1

17 999269-004 WASHER, LOCK, EXT T, #10 6

18 999310-015 WASHER, FLAT, .380x.88x. 4

19 999411-016 WASHER, SHLDR, .375X.43 5

20 999411-017 WASHER, SHLDR, .375X.5X 1

21 999279-007 NUT, 3/8-16, HEX, SST, SLF 1

22 999321-008 WASHER, LOCK, HEL, 3/8 1

23 999397-503 NUT, 3/8-16X.337, MACH 1

24 950859-024 CAP, RCPT, MS-14S w/CHAIN 1

25 999449-038 SCREW, #4-40X.62, PNH, SL 4

26 999442-001 WASHER, SEAL, #6, .15x.25 4

27 970118-008 NUT RING, #4-40, MS-14 1

28 235386-002 GASKET, MS #14 BLKHD, CO 1

29 J857-3 NUT, LOCK, CND, 0.75" NPS 3

30 955706-007 CONN, CORD, .38-.50, 3/4" 3

31 999449-068 SCREW, #6-32x.38, PNH, SL 12

32 999494-011 STANDOFF, F/F, #6-32X.68 8

33 999291-010 WASHER, FLAT, #6, .138x.2 16



34 999951-143 STANDOFF, F/F, #6-32X1.4 9

35 219624-001 LABEL "GND" (DAQ ASSY) 2

36 935676-006 PROT, AC, I-201, 240V, 1AM 1

37 951330-008 BLK, FUSE, FLT BASE, DIR 1

38 951330-011 TERM STRP, END SECT 1

39 999449-080 SCREW, #6-32x.75, PNH, SL 8

40 219626 AC COVER ASSY, DAQ 1

41 999449-116 SCREW, #8-32x.37, PNH, SL 6

42 951330-009 CLMP, TUBLR, 22-10 WIRE 2

43 951330-010 TERM BLK, END SECT 1

44 999397-030 NUT, #10-32X.13, MACH, HE 2

45 999310-009 WASHER, FLAT, .220x.44x. 4

46 932312-401 SWITCH SELECTOR 800T-H 1

47 932312-410 SWITCH, CONTACT BLOCK 1

48 J10481A-01 HUB, CONDUIT, .50"NPT 1

49 955707-003 CONN, CORD,.30-.40,1/2" 1

50 947645-003 MOUNT, CABLE TIE, 3/4" S 6

51 947619-001 TIE WRAP 4"x.10" NATL 6

52 234641-038 LABEL "BARRIER GROUND" 1

53 219624-003 LABEL "CAL CONFIG" (DA 1

54 232398-007 LABEL "AC IN" 1

55 219623 CABLE ASSY, CAL CONFIG 1

56 219531-001 HARNESS, A.C. PWR SPLY 2

57 946617-001 WIRE, 600 V, TFL, 18 AWG, FT 2

58 950827-002 TERMINAL, SPADE #6 X #2 8

59 999445-004 WASHER, FLAT, #8, .174X.3 2

60 946617-010 WIRE, 600 V, TFL, 18 AWG, FT 2

61 999457-143 STANDOFF, F/F, #6-32X1.4 3

62 951330-012 TAPE, VNYL MRKG, F/TERM 1

63 951330-013 PLUG, NYLON HLDG, F/MRKG 1

Table 5-4. 220492-KIT




64 949956-004 CONN, TYPE C DIN, 96 CON 1

65 949956-003 CONN SHROUD, BKPLN, PINL 1

66 999449-034 SCREW, #4-40X.50, PNH, SL 2

67 999397-917 NUT, #4-40, MACH, HEX, SST 2

68 219645-101 CABLE ASSY, GRND, 5" 1

69 999701-005 SCREWDRVR, TYPE 2, f/236 1

70 991206-026 SEALANT, RTV 3145 (DOW) AR

71 999457-231 STANDOFF, F/F, #6-32X2.3 4

72 999449-072 SCREW, #6-32x.50, PNH, SL 4

73 999440-019 NUT, 3/8-24, STAMPED, HEX 2

74 999445-010 WASHER, FLAT, 3/8, .39X.6 2

75 999231-030 HANDLE, FOLDING 1

76 955706-006 CONN, CORD, .88-1.0, 1.0" 4

77 J857-4 NUT, LOCK, CND, 1.00" NPS 5

78 999485-098 STANDOFF, F/F, #6-32x.75 9

79 B1833-3 SEAL RING, CND, 1.0"NPT 5

80 B1833-2 SEAL RING, CND, .75" NPT 3

81 X10092A-001 LOCTITE #242 (50mL) AR

83 219916-001 T-POT BOX/ DAQ, TOTAL 1

84 999439-004 WASHER, SHLDR 1

85 999389-101 NUT, BNC 1

86 H10351A-043201 STAND-OFF, 6-32 M/F 1/4 4

87 999764-001 PROTEC.VINYL POCKET 1

88 999376-001 STANDOFF, M/F,#6-32x.25 8

89 999432-124 SCREW, #6-32x.25, BDGH 14

90 991202-018 SEALANT, RTV 3140, NON-C .3

91 950873-003 CAP-BNC, MALE W/CHAIN 1

92 219624-008 LABEL "WARNING:DO NOT 2

93 938203-021 FUSE, 3AMP, 250V, SLO-BLO 1

94 235318-084 LABEL "FUSE / 3 AMP 1

Table 5-4. 220492-KIT





96 J10481A-03 HUB, CONDUIT, 1.00" NPT 1

97 J1292-6 PLUG, SQ HD, 1" NPT POL 1

98 220251-005 PWR SPLY, MOD, 5V, 15V, -15V 1

99 220251-006 PWR SPLY, MOD, 28V, 50W 1

100 219962-004 CABLE ASSY, DC PWR, 1

101 955706-012 CONN, CORD, .50-.63, 1.0" 1

102 222322-001 GASKET, DOOR, TOTAL DAQ 2

103 220395 GLAND PLATE, BLANK, IDAQ 2

104 220397 GASKET, GLAND PLATE 2

105 220338 TIEBAR, REAR DOOR ASSY 1

106 A11424A-11 TRACK, MTG, 16.62" 3

107 G177-3HA WASHER, LOCK, SPR,#10 8

108 999449-174 SCREW, #10-32x.62, PNH 2

109 G180A-03143 WASHER, FLAT, #10 8

110 999449-166 SCREW, #10-32x.37, PNH 6

111 999397-043 NUT, #8-32X.13, MACH, HEX 32

112 G180A-02543 WASHER, FLAT, #, 8, .188X.5 32

113 G177-2HA WASHER, LOCK, SPR, #8, .16 32

Table 5-5. PERMANENT LOCATION DAQ - (BARRIERLESS W/ SIF)


-- 220425-100 DAQ, SYS 4, BARRIRLESS W/ SIF --

1 220425-KIT DAQ, SYS4, PERM LOC, SIF 1

4 999241-008 SCREW, DRV, #2x.187, RDH 6

991206-026 SEALANT, RTV 3145 (DOW) 5

Table 5-4. 220492-KIT




Table 5-6. PERMANENT LOCATION DAQ - (BARRIERLESS W/ SIF & EDMS)


-- 220425-101 DAQ, SYSTEM 4, BARRIERLESS W/ SIF, EDMS

--

1 220425-KIT DAQ, SYS4, PERM LOC, SIF 1

4 999241-008 SCREW, DRV, #2x.187,RDH 6

5 219770-001 PCBA, E-DEPTH, TOTAL SYSA 1

6 219908 BATTERY PACK ASSY, EDMS 1

7 999266-284 STANDOFF, M/F, #6-32X.44 2

8 999252-401 SCREW, #6-32x.37, BDGH 2

9 999216-026 WASHER, FLAT, .144x.27x. 4

10 927003-001 MODULE, DIGITAL I/O, GOR 2

NS 927003-002 MODULE, INOUT/OUTPUT, MT 1



Table 5-7. 220425-KIT


1 220442-001 PCBA, DAQ ANALOG 1

2 219509 PCBA, DAQ FIELD TERM 1

3 219493-002 PCBA, DAQ DIG BRD, 512K 1

4 221034-002 PCB ASSY, SPECTRUM I/F 1

5 999252-401 SCREW, #6-32x.37, BDGH 17

7 999494-003 STANDOFF, F/F, #6-32X.5/ 2

10 J10480A-17 SEAL, HOLE, 1.00" CND 4

11 J10480A-16 SEAL, HOLE, O-T SWT 3

12 999216-026 WASHER, FLAT, .144x.27x. 21

14 219554-100 ENCLOSURE ASSY, DAQ 1

15 232039 LUG, GROUNDING, 3/8-16 B 1

16 999449-164 SCREW, #10-32x.31, PNH 1

17 999269-004 WASHER, LOCK, EXT T, #10 6

18 999310-015 WASHER, FLAT, .380x.88x. 4

19 999411-016 WASHER, SHLDR, .375X.43 5

20 999411-017 WASHER, SHLDR, .375X.5X 1

21 999279-007 NUT, 3/8-16, HEX, SST, SLF 1

22 999321-008 WASHER, LOCK, HEL, 3/8 1

23 999397-503 NUT, 3/8-16X.337, MACH 1

24 950859-024 CAP, RCPT, MS-14S w/CHAIN 1

25 999449-038 SCREW, #4-40X.62, PNH, SL 4

26 999442-001 WASHER, SEAL, #6, .15x.25 4

27 970118-008 NUT RING, #4-40, MS-14 1

28 235386-002 GASKET, MS #14 BLKHD 1

29 J857-3 NUT, LOCK, CND, 0.75" NPS 3

30 955706-007 CONN, CORD, .38-.50, 3/4" 3

31 999449-068 SCREW, #6-32x.38, PNH, SL 12

32 999494-011 STANDOFF, F/F, #6-32X.68 8

33 999291-010 WASHER, FLAT, #6, .138x.2 16



34 999951-143 STANDOFF, F/F, #6-32X1.4 9

35 219624-001 LABEL "GND" (DAQ ASSY) 2

36 935676-006 PROT, AC, I-201, 240V, 1AM 1

37 951330-008 BLK, FUSE, FLT BASE, DIR 1

38 951330-011 TERM STRP, END SECT 1

39 999449-080 SCREW, #6-32x.75, PNH, SL 8

40 219626 AC COVER ASSY, DAQ 1

41 999449-116 SCREW, #8-32x.37, PNH, SL 6

42 951330-009 CLMP, TUBLR, 22-10 WIRE 2

43 951330-010 TERM BLK, END SECT 1

44 999397-030 NUT, #10-32X.13, MACH, HEX 2

45 999310-009 WASHER, FLAT, .220x.44x. 4

46 932312-401 SWITCH SELECTOR 800T-H 1

47 932312-410 SWITCH, CONTACT BLOCK 1

48 J10481A-01 HUB, CONDUIT, .50" NPT 1

49 955707-003 CONN, CORD, .30-.40, 1/2" 1

50 947645-003 MOUNT, CABLE TIE, 3/4" 6

51 947619-001 TIE WRAP 4"x.10" NATL 6

52 234641-038 LABEL "BARRIER GROUND" 1

53 219624-003 LABEL "CAL CONFIG" 1

54 232398-007 LABEL "AC IN" 1

55 219623 CABLE ASSY, CAL CONFIG 1


57 946617-001 WIRE, 600 V, TFL, 18 AWG, FT 2

58 950827-002 TERMINAL, SPADE #6 X #2 8

59 999445-004 WASHER, FLAT, #8, .174X.3 2

60 946617-010 WIRE, 600 V, TFL, 18 AWG, FT 2

61 999457-143 STANDOFF, F/F, #6-32X1.4 3

62 951330-012 TAPE, VNYL MRKG, F/TERM 1

63 951330-013 PLUG, NYLON HLDG, F/MRKG 1

Table 5-7. 220425-KIT




64 949956-004 CONN, TYPE C DIN, 96 CON 1

65 949956-003 CONN SHROUD, BKPLN, PINL 1

66 999449-034 SCREW, #4-40X.50, PNH, SL 2

67 999397-917 NUT, #4-40, MACH, HEX, SST 2

68 219645-101 CABLE ASSY, GRND, 5" 1

69 999701-005 SCREWDRVR, TYPE 2, f/236 1

70 991206-026 SEALANT, RTV 3145 (DOW) AR

71 999457-231 STANDOFF, F/F, #6-32X2.3 4

72 999449-072 SCREW, #6-32x.50, PNH, SL 4

73 999440-019 NUT, 3/8-24, STAMPED, HEX 2

74 999445-010 WASHER, FLAT, 3/8, .39X.6 2

75 999231-030 HANDLE, FOLDING 1

76 955706-006 CONN, CORD, .88-1.0, 1.0" 4

77 J857-4 NUT, LOCK, CND, 1.00" NPS 5

78 999485-098 STANDOFF, F/F, #6-32x.75 9

79 B1833-3 SEAL RING, CND, 1.0" NPT 5

80 B1833-2 SEAL RING, CND, .75" NPT 3

81 X10092A-001 LOCTITE #242 (50mL) AR

83 219916 T-POT BOX/ DAQ, TOTAL 1

84 999439-004 WASHER, SHLDR, .5/.562X 1

85 999389-101 NUT, BNC 1

86 H10351A-043201 STAND-OFF, 6-32 M/F 1/4 4

87 999764-001 PROTEC. VINYL POCKET 1

88 999376-001 STANDOFF, M/F, #6-32x.25 8

89 999432-124 SCREW, #6-32x.25, BDGH 14

90 991202-018 SEALANT, RTV 3140, NON-C .3

91 950873-003 CAP-BNC, MALE W/CHAIN 1

92 219624-008 LABEL "WARNING:DO NOT 2

93 938203-021 FUSE, 3AMP, 250V, SLO-BLO 1

94 235318-084 LABEL "FUSE / 3 AMP / 1

Table 5-7. 220425-KIT





96 J10481A-03 HUB, CONDUIT, 1.00" NPT 1

97 J1292-6 PLUG, SQ HD, 1"NPT POL 1

98 220251-005 PWR SPLY, MOD, 5V, 15V, -15V 1

99 220251-006 PWR SPLY, MOD, 28V, 50W 1

100 219962-004 CABLE ASSY, DC PWR, TOT 1

101 955706-012 CONN,CORD, .50-.63, 1.0" 1

102 222322-001 GASKET, DOOR, TOTAL DAQ 2

103 220395 GLAND PLATE, BLANK, IDAQ 2

104 220397 GASKET, GLAND PLATE 2

105 220338 TIEBAR, REAR DOOR ASSY 1

106 A11424A-11 TRACK, MTG, 16.62" 3

107 G177-3HA WASHER, LOCK, SPR, #10 8

108 999449-174 SCREW, #10-32x.62, PNH 2

109 G180A-03143 WASHER, FLAT, #10, .203X. 8

110 999449-166 SCREW, #10-32x.37, PNH 6

111 999397-043 NUT, #8-32X.13, MACH, HEX 32

112 G180A-02543 WASHER, FLAT, #8, .188X.5 32

113 G177-2HA WASHER, LOCK, SPR, #8,.16 32

Table 5-7. 220425-KIT



