120electric manual

Top Drive Drilling Equipment

Electric Manual Model： DQ70BSC

Serial No： 06032

Preface

The design, manufacture and service of this product are based on the following quality assurance system:

GB/T19001:2000 idt ISO9001:2000 « Quality Management System-- Requirements»

API Spec Q1« Specification for Quality Programs for the Petroleum and Natural Gas Industry»

This manual contains information relating to Top Drive operation, service and maintenance. The technical information of this product is included respectively in the following documents: <Operation Manual>

< Installation and Trouble Shooting Manual>

With individualized design provided for the Top Drive based on the service operating condition and special requirements of the customers, the technical document for this product may not be suitable for the other products of the same type. Product type and No. shall be checked when the technical document is used.

For information not covered by the accompanying documents and other problems arising from the installation, operation and maintenance, contact the manufacturer if necessary:

BPM Beijing Petroleum Machinery Factory

Ads: No.41, Zhixin Road, Haidian District, Beijing P.R China

Postcode: 100083

Tel: ( 010) 62097381

Fax: ( 010) 62097613

E-mail: Bpm.zhaojing@vip.163.com

Contents

1. Summary ....................................................................................................................1

2. Safety notice ...............................................................................................................2

3. Main specification ......................................................................................................4

3.1. Basic specification......................................................................................................4

3.2. Motor specification.....................................................................................................4

3.3. Drilling parameter.......................................................................................................4

4. Electric control system................................................................................................5

4.1. The introduction of Top Drive.....................................................................................5

4.1.1. Top Drive assembly ....................................................................................................5

4.1.2. Top Drive structure.....................................................................................................6

4.1.3. Top Drive Communication..........................................................................................7

4.1.4. The curve of motor output torque and rotating speed...................................................7

4.2. Electric House ............................................................................................................8

4.3. AC variable frequency drive system............................................................................9

4.3.1. Rectifier cabinet..........................................................................................................9

4.3.2. Inverter cabinet ......................................................................................................... 11

4.4. PLC/MCC ................................................................................................................12

4.5. Local control box (LCB)...........................................................................................14

4.6. HPU Control Box .....................................................................................................15

4.7. Driller Console .........................................................................................................17

4.8. Auxiliary Control Box (Option) ................................................................................21

4.9. Main power cable .....................................................................................................22

4.10. Other cables..............................................................................................................23

4.10.1. LCB control cable.....................................................................................................23

4.10.2. HPU control cable ....................................................................................................23

4.10.3. Driller Console control cable ....................................................................................24

4.10.4. Auxiliary control box cable (option) .........................................................................24

4.10.5. Earth cable................................................................................................................24

5. Operating procedure .................................................................................................25

5.1. Start/stop electric control system...............................................................................25

5.1.1. Checking before start ................................................................................................25

5.1.2. Power on procedure ..................................................................................................25

5.1.3. Startup system ..........................................................................................................25

5.1.4. Stop system ..............................................................................................................26

5.2. Start/stop of hydraulic system (HPU)........................................................................27

5.2.1. HPU local control .....................................................................................................27

5.2.2. HPU remote control..................................................................................................27

5.2.3 Hydraulic system cooling..........................................................................................28

5.3. Main motor heating...................................................................................................29

5.4. Main motor’s cooling fan..........................................................................................30

5.5. Brake........................................................................................................................31

5.6. Drilling operation .....................................................................................................32

5.6.1. Drilling operation procedure .....................................................................................32

5.6.2. Reverse drilling under Drill Mode.............................................................................34

5.6.3. Speed control and torque control...............................................................................35

5.6.4. Stop drilling..............................................................................................................35

5.7. Make-up/break-out operation....................................................................................36

5.7.1. Make-up operation....................................................................................................37

5.7.2. Break-out operation ..................................................................................................38

5.7.3. Release reactive torque .............................................................................................39

5.8. Rotating head lock operation.....................................................................................40

5.9. Link operation ..........................................................................................................41

5.10. IBOP operation .........................................................................................................42

5.11. E. Stop......................................................................................................................43

5.12. Fault/Alarm ..............................................................................................................44

5.13. Encoder switch .........................................................................................................46

5.14. Running without encoder ..........................................................................................46

5.15. Local Control Box “Cable” operation .......................................................................47

5.15.1. Start “Cable” operation .............................................................................................47

5.15.2. Stop “Cable” operation .............................................................................................47

5.16. Driller Console emergency operation ........................................................................48

5.16.1. Start Em-operation....................................................................................................48

5.16.2. Stop Em-operation ....................................................................................................48

6. Remote communication and diagnostic (self-select part)...........................................49

6.1. Diagnostic setting .....................................................................................................49

6.2. SINAUT TIM4R module ..........................................................................................50

6.3. GSM kit....................................................................................................................52

7. Windows Control Center (WINCC) ..........................................................................53

7.1. Operation picture function ........................................................................................53

7.2. System help ..............................................................................................................54

7.3. Power system............................................................................................................55

7.4. Top Drive system......................................................................................................56

7.5. Network structure .....................................................................................................57

7.6. Control status............................................................................................................58

7.7. Auxiliary system.......................................................................................................59

7.8. Trend curve picture...................................................................................................60

7.9. Alarm logging...........................................................................................................62

7.10. System logon ............................................................................................................63

7.11. Setting function ........................................................................................................64

7.12. Exit system...............................................................................................................65

8. System software and hardware..................................................................................66

8.1. PLC system hardware ...............................................................................................66

8.2. Program download or upload ....................................................................................70

8.3. PROFIBUS network system .....................................................................................71

8.4. Distribute I/O station and communication module.....................................................72

8.4.1 ET200X distribute I/O station ...................................................................................72

8.4.2 ET200M distribute I/O station ..................................................................................74

8.4.3 Optical fiber connection module/ OLM.....................................................................75

8.4.4 REPEATER ..............................................................................................................77

8.5. Variable frequency drive system ...............................................................................79

8.5.1 Rectifier....................................................................................................................79

8.5.2 Inverter.....................................................................................................................81

8.6. Parameter upload and download for Rectifier and Inverter........................................83

8.7. Trouble shooting.......................................................................................................84

8.7.1 Air switch diagnosing ...............................................................................................84

8.7.2 Earth fault.................................................................................................................84

8.7.3 PLC fault checking ...................................................................................................84

8.7.4 Network checking.....................................................................................................85

8.7.5 Drive system.............................................................................................................85

8.8. System Power Down and Disconnection...................................................................86

9. Installation, troubleshooting and maintenance...........................................................87

9.1. Electric System Reinstallation...................................................................................87

9.2. Power on and Checking ............................................................................................88

9.3. Daily maintenance ....................................................................................................89

Drive cabinet initial state......................................................................................................90

PLC/MCC cabinet initial state..............................................................................................90

Driller Console initial state...................................................................................................90

Auxiliary Control Box initial state........................................................................................91

HPU Control Box initial state...............................................................................................91

BPM Top Drive Electric Manual

1. Summary

Top Drive Drilling Equipment (short for Top Drive), it is a new-type petroleum drilling

equipment which replaces rotary table. It’s a high-tech product which is integrated with

machinery, electric and hydraulic system. It is a very important work for trouble shooting, operating and maintaining the electric system.

The electric system of BPM Top Drive which is installed, operated and maintained, that need

one personnel who have certain qualifications or have enough experience. It is the customer’s obligation to train above-mentioned capacitates personnel.

2. Safety notice

This manual uses the following warning sign：

Notes:

This sign is used for additional notes for matters relating to bodily and equipment safety.

Caution:

This sign is used for prompting a condition that may lead to bodily or equipment damage.

Warning:

This sign is used for prompting a condition that will most likely lead to bodily or equipment damage.

The following safety notices are very important for correct install, operate, maintain of Top Drive, all the operators must read it carefully and understand it:

a) Do not work with power on, include: don’t open safeguard with high voltage; don’t repair or dismantle any electrical device with power on, don’t plug in/out each cable connector with power on.

b) Don’t open the junction box or Driller Console under having flammable gas environment.

c) Do not try to change the DC fuse between DC bus and Inverter when Rectifier is working or DC voltage is above safety range (DC 24V), It is dangerous for human safety and electrical equipment!

d) If need maintain Rectifier, motor or Inverter, please turn main switch (3WL) to right side (lock position), in order to prevent faulty operation.

e) The insulation of Inverter and Rectifier can’t be checked by high-resistor meter or else the high test voltage will damage the equipment.

f) Driller Console’s protection air must keep pressure when power on! When air lost, filling gas as quickly as possible and shut down the control power of Driller Console!

g) Each motor and control box should be correctly connected to PE connector in Electric House!

h) Forbid to bypass the safety interlock of Top Drive System. If necessary, recover bypass function of interlock as soon as possible after having solved the problem.

i) Forbid unprofessional person change any parameter of each Rectifier and Inverter,

otherwise may damage the mechanical or electrical equipment!

j) When temperature is more than 40 , and humidity℃ percent is higher than 95% or dew exists, don’t start drivers or switch on control power before starting air conditioning to lower down the temperature and decrease wet.

k) When system main power shut down by accident for more than half an hour, before restart the system, must make sure that there is no dew in Electric House.

l) Under the moist environment, when electric house temperature is lower than the outside, forbid long time opening the electric house door, otherwise may produce dew on the electric equipments!

In this manual, the words with 【】indicates that it is an operating parts of the electric system.

As for the installation, trouble shooting, operation and maintenance of Top Drive’s electric system, the operator should read the manual before operating. For continuous improvement and changing, you must check the product serial number printed in the cover of this manual to ensure that the product confirming to the technical manuals.

Unprofessional person not being specially trained can not do the work of installation, trouble shooting, operation and maintenance. It may damaged to the body or equipment. During operation, it is not permitted to repair and maintain.

3. Main specification

3.1. Basic specification

Supply voltage 600 V AC

Rated current 445 A × 2

Max. Current 770 A × 2

Ambient temperature －35 ℃ ～ +55 ℃

Altitude ≤1200 m

3.2. Motor specification

Rated power 400Hp ×2, S1

Rated rotating speed 1150 rpm

Max. Rotating speed 2400 rpm

3.3. Drilling parameter

Main shift of rotating speed 0～220 rpm

Working torque (S1) 50 kN.m（0 ~ 110 r/min）

Max. Torque（1min） 75 kN.m

4. Electric control system

4.1. The introduction of Top Drive

4.1.1. Top Drive assembly Top Drive drilling equipment is Power Converter, Pipe Handler Device, Electric drive and control system, Hydraulic system, Driller Console, Auxiliary Control Box, etc.

The electric control system mainly includes AC variable frequency drive system and PLC/MCC system, and mainly consists of drive cabinet, PLC cabinet, Driller Console, Auxiliary Control Box, Local Control Box, HPU Control Box, main power cable, auxiliary control cable, etc. The Drive is SIEMENS SIMOVORT MASTERDRIVERS 6SE70 serial product, with the variable frequency speed regulation system, drive two 400 hp AC variable frequency motors, which could work together (master/slave) or separately. The whole system possesses perfect diagnosing and protecting function, could realize all operations of Top Drive.

Electric house Main power

Auxiliary control cable

Local control box

Auxiliary control box

Top Drive

Driller Console

4.1.2. Top Drive structure The generator sends 600V 50/60Hz power to the Electric House, pass main air switch (3WL) and line reactor connect to Rectifier unit. The output DC bus voltage is 810V. The DC Voltage is ready for inverter working.. Meanwhile, passing air switch, 600V power was transformed to AC 380V by auxiliary transformer as an auxiliary power go into the PLC/MCC. Then, the PLC/MCC could provide triphase 380V power for main motors’ fans, HPU pump, electric house air conditionings, etc. provide 220V control power for heater, Relay in cabinet, Rectifier cabinet and Inverter cabinet. H-type system adopts one-to-one drive mode, this kind of system has two Rectifiers and two Inverters. The structure of H-type has good dependability, and two sets of Rectifier/Inverter could work as two independent system. Under one motor’s work condition, Top Drive’s Max.Torque and Work Torque is half of two motors’. Main structure:

To make sure electrical system work normally, we recommend using separate generator to supply power for Top Drive system.

4.1.3. Top Drive Communication

There are two kinds of control and communication methods between PLC system and control stations: ①Cable connect; ②Profibus cable connect.

As for cable connect, PLC communicates with control stations by cable directly. The station contains HPU and Local Control Box.

As for Profibus cable connect, PLC communicates with control stations and drive systems by PROFIBUS-DP. PLC connects with other stations by SIEMENS PROFIBUS communication cable. PLC is Siemens SIMATIC S7-300 serial: CPU is 315-2DP. Driller Console station adopts ET200M I/O.

H-type network drawing:

4.1.4. The curve of motor output torque and rotating speed See Fig1: when the【Drilling Torque】setting is 35 kN.m, the red color curve shows the relation between the output torque and rotating speed.

Torque continuous kN.m

4.2. Electric House

The electric house, with AC variable frequency drive cabinet and PLC/MCC cabinet installed inside For detail information, please refer to <Electric House Manual>.

Whether the temperature is too high or too low will lead to system damage.

A suitable temperature and humidity inside is very important for Top Drive’s safe running. High humidity will lead to elements defective insulation and short circuit, also damage the equipment.

4.3. AC variable frequency drive system

AC variable frequency drive system, includes Rectifier cabinet, Inverter cabinet and relevant control circuit, it could provide power for AC frequency motor of Top Drive.

4.3.1. Rectifier cabinet The Rectifier cabinet is made up of Power In part and Rectifier part. Power In cabinet includes main air switch, transformer, insulation meter, line reactor, voltage meter, current meter, etc. It provides power for Rectifier cabinet and PLC/MCC cabinet. Rectifier cabinet includes Rectifier, current meter, voltage meter, etc. When main air switch is power on, the rectifier unit will work to transfer 600V power comes from Power In cabinet to 810V for DC bus.

Aux.Current

Input Voltage

Control Power On Earth Fault Voltage Select

E.Stop

DC Voltage

DC Current

Main Air Switch

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a) Meter

‘Input current’: show the current value of 600V main power supply. ‘Aux. current’: show the current value of auxiliary power supply. ‘Input voltage’: show the voltage value of every phase of main power.

‘DC current’: show the output current value of the Rectifier.

‘DC voltage’: show the output value of the Rectifier.

b) Indicator light

‘Control power’: this indicate light will on if control power (220V) is power on. ‘Earth fault’: if system insulation faults, the light will on. ‘Power on’: when main air switch in Power cabinet is closed, this indicator light will on.

c) Button

【Voltage Select】: show the three-phase voltage of Power In power supply.

【E. Stop】: be used to emergency stop of Top Drive System(normally closed).

All 【E.Stop】buttons are interlocked, press one of 【E.Stop】will Stop the system.

If Top Drive was just shut down, during a period of time, the Rectifier cabinet will discharge high voltage large capacitance. So, at this time, it is forbidden to open Rectifier cabinet door.

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4.3.2. Inverter cabinet

Inverter cabinet is made up of Inverter, output reactor, brake unit, etc.

a) Meter

‘Output current’: show the output current value of Inverter. ‘Output voltage’: show the output voltage value of Inverter.

b) Switch and button

【Encoder Select】: used to switch encoder.

【E.Stop】: used to stop system promptly (normally closed)

Output Current Output Voltage

E.Stop Encoder Select

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4.4. PLC/MCC

PLC/MCC includes PLC and AC/DC power distribution system.

a) Meter

‘Make Up Counter’: show make up counter times.

‘Cumulative running time’: show Top Drive main motor’s cumulative running time.

b) Indicator light

‘System ready’: When【System Start】switch is on, but system doesn’t ready, this indicator light will Flash, When main air switch is on, and system is ready, the indicator light will on constantly.

Heat’: When main motor heater is running, the indicator light will on.

‘Fault’: When system has alarm, this indicator light will flash. If fault happens, the indicator

light will on constantly. When error reset, it’s off.

‘Encoder fault’: When system is running without encoder, the indicator light will on.

c) Manual switch

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【System Start】：When system was power on, this switch could realize system’s start; start Rectifier and main air switch, etc.

【Control Mode】：Select the control mode..:By pass, Profibus. Or Cable. Mode.

【IBOP Disable】：With this switch,the IBOP couldn’t close except ‘Well Control’.

This switch is used to insure right operation of IBOP and safe of work at unusual task.

Do not disable IBOP at usual drilling task to insure it can be close when it is needed.

【Encoder Fault】：With this switch, system could run without encoder if the two encoders were fault.

【Motor Heater】：With this switch, motor heater could work independently without PLC. When motor is running, heater is forbidden to run by PLC logical. 【Reset】：It has reset and silence function. 【E. Stop】：Be used to stop system promptly. All E.Stop in electric system are interlocked.

d) Industry PC

There is one Industry PC in PLC cabinet, and its self-contained display screen, mouse, and keyboard are all in the electric house. This Industry PC is used to monitor and debug Top Drive system.

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4.5. Local control box (LCB)

The Local Control Box (LCB) is fixed on main body of Top Drive. It provides AC and DC power for main motor’s cooling fan, motor heater, magnet valve, etc. Also it could read the signal from main motor, temperature sensor, gear box (for instance: oil temperature), etc. The LCB adopts ET200X module, which have high-grade protection IP65; with self-diagnostic function, which could be used in harsh environment. Insides this box there is a heater, which makes LCB could work in low temperature; LCB adopts optical fiber to communicating with CPU in PLC/MCC cabinet. The fiber has good anti-interference ability; Control cables from LCB are all shielding and have good anti-interference ability, so they could be reliable to control accurately.

Local Control Box

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4.6. HPU Control Box

Hydraulic Control system is in HPU Box. It controls two hydraulic pumps (one use and one backup) and one hydraulic oil cooling fan. The two pumps could be started locally or remotely by Driller Console, but the local control has the priority. There is motor protector in front of hydraulic pump motor, through setting protective current, which could realize protect motor’s overload, current leakage, etc.

HPU Control Box panel:

a) Indicator light

‘Power on’: when 380V power supply is ready, this indicator light will on. ‘Pump A’: When pump A is selected, this indicator light will on. ‘Pump B’: When pump B selected, this indicator light will on.

b) Manual switch

【Pump Select】:Select pump A or pump B. 【HPU Pump】:Be used to control hydraulic pump locally. Turn to ‘on’ means local start HPU pump; turn to ‘off’ means stop running HPU pump; turn to ‘auto’ means Driller Console will control the HPU Pump remotely.

Power Power On Pump A Pump B

Cooling Fan Pump Select HPU Pump

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【Cooling Fan】: Be used to control cooling pump. Turn to ‘on’ means local start cooling fan; turn to ‘off’ means stop running cooling fan; turn to ‘auto’ means PLC will remote control the cooling fan. 【Power】switch: Be used to control HPU Control Box’s 380V power supply. Turn to ‘on’ means HPU Control Box is power on; turn to ‘off’ means HPU substaition is power off. When power is off, coil in terminal line, Q52, S4, K1 still have electric power, and ET200X also has electric power.

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4.7. Driller Console

The Driller Console has all basic functions that drilling demands; it adopts ET200M module, and could realize speed setting, torque setting, operation mode and all auxiliary operations. Driller Console has three alarm/fault indicator lights, which could notice different kinds of alarm/faults through different kinds of combinations. The Driller Console is explosion proof ExpniaIIT4; it could work only when shielding gas pressure is ready. On side face, there is a gas supply element for control the Driller Console’s power by achieve a certain pressure inside.

The preset pressure of air supply element pressure reducing valve is0.015MPa. Timely inspect and remove the accumulated water in wate/air filter is necessary.

Incorrectly preset the pressure of pressure reducing valve, may result in Driller Console Box’s pressure too high, and finally damage the elements in it or even hurt the operator.

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No Indicator light Type Function

1 ‘Pump Running’ Green indicator light

If hydraulic pump runs normally, it will on. If pressure lower than normal value, it will flash. If communication is interrupted or hydraulic pump stop running, it will off.

2 ‘Locking’ Red indicator light

This indicator light (2HZ) will become flash quickly when the switch is in lock. This indicator light will become on after finish locking operation.

3 ‘IBOP ‘ Red indicator light If the indicator light is on, it means IBOP is closed. If the indicator light is off, it means IBOP is opened.

4 ‘Brake’ Red indicator light It lights when brake is working.

5 ‘Ready’ Green indicator light

This indicator light will flash when Driller Console is

power on but system not ready. When system start and

everything is ready, it will on constantly.

‘Fault/Alarm’ Red indicator light

Through combination, these three light are used to

indicate alarms and faults. For detail information,

please refer to Fault/alarm section of Chapter 5.12.

No Meter Type Function

9 ‘Torque’ Meter Show actual output torque of head shaft with unit being

10 ‘Speed’ Meter Show actual output speed of head shaft with unit being

r/min.

No Switch Type Function

11 【HPU】

Run/Stop three-position switch

Turn to ‘run’, pump will run.

Turn to ‘stop’, pump will stop running.

Turn to ‘auto’，pump will run according to pressure.

12 【E. Stop】 mushroom button If press this button, drive unit will stop running, after a

short time, main air switch will be open.

13 【Locking Pin】

unlock/lock two-position switch

Turn to ‘lock’ means lock the rotating head.

Turn to ‘unlock’ means unlock the rotating head.

‘Locking’indicator light could show the status of

rotating head.【Link Rotation】is invalid if already

operate 【Lock Pin】.

14 【Link Rotation】 three-position switch Spring reset key, turn back to middle position

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ccw/stop/cw automatically. This switch is used to operate rotating head: ccw/stop/cw

15 【Clamp】 three-position switch Turn this switch to “clamp”, Backup Tong will keep clamp, it will reset when loose.

16 【Auxiliary】 two-position switch If this switch is on, the C-Box on monkey board could operate the Pipe Handler Device. Otherwise not.

17 【Link Center】 Black button Press this button, the elevator link will on float.

18 【Link Incline】

Rear/stop/Front three-position switch

Spring reset key, turn back to middle position automatically. The switch is used to realize the elevator rear/front operation.

19 【Air Cooling】

On/Off/Auto three-position switch

This switch is used to control main motor’s cooling fan. Turn to ‘auto’, air cooling fan will be controlled by procedure in PLC. Turn to ‘on’, cooling fan will start. Turn to ‘off’, it will stop.

20 【IBOP】

Open/Close two-position switch

Combination with the mud pump switch on signal.

On ‘open’ position, means open the IBOP valve gate.

On ‘close’ position, means close IBOP valve gate.

21 【Motor】

A/A＋B/B three-position switch

Select motor’s work mode of Top Drive.

Turn to ‘A’, motor A will work.

Turn to ‘B’, motor B will work.

Turn to ‘A+B’, two motors will work simultaneously.

22 【Brake】

off /Auto/ On three-position switch

‘on’ means brake is working; ‘off’ means brake is

open; and ‘auto’ means brake will work according to

PLC program.

23 【Operation】

Drill/Spin/Torque three-position switch

Be used to choose the operation mode: drill, spin or

torque. ‘Drill’ in zero position is the (initial state).

24 【Reset/Silence】 black button

When alarm, press this button will stop the sound.

After resolving system faults, press this button again

will reset the alarm or fault. Keep on press it for three

seconds will test all indicator lights.

25 【Direction】

Ccw/Stop/Cw three-position switch

Be used to choose the motor’s direction. ‘Stop’ position

is the initial state.

26 【Makeup Torque】 potentiometer

Be used to set a max torque for make up operation.

Under two motors’ working condition, full range torque

is 50kN.m; and under one motor’s working condition,

full range torque is 25kN.m. If set value is higher than

25kN.m, system’s output torque will keep on 25kN.m.

27 【Drilling Torque】 potentiometer Be used to set a max torque for drilling operation.

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Under two motors’ working condition, full range torque

is 50kN.m; and under one motor’s working condition,

full range torque is 25kN.m. If set value is higher than

25kN.m, system’s output torque will keep on 25kN.m.

28 【Throttle】 Potentiometer

Be used to set drilling rotation speed.

Speed range is 110rpm or 220rpm. Different rated

speed could be realized by【Speed Range】switch on

Wincc system.

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4.8. Auxiliary Control Box (Option)

The Auxiliary Control Box, connects to electric house by cable, which is explosion proof, and used for operating elevator link rotating device and incline device on monkey board. If Driller Console 【Auxiliary】is ‘on’, Auxiliary Control Box will be valid, and Driller Console’s same operation will be invalid. The Auxiliary Control Box is shown as below:

a) Indicator light:

Enable indicator: when Driller Console’s【Auxiliary】switch is ‘on’, the indicator will on, this means Auxiliary Control Box will be enable.

b) Manual switch:

【Link Incline】switch: Be used for link incline operation.

【Link Rotation】switch: Be used for link rotating operation.

【Link Center】pushbutton: Press this button, the elevator link will on float (center).

Link Center

Link Rotation Link Incline

Enable

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4.9. Main power cable

The main power cables are used to connect the Inverter with Top Drive’s two main motors. For installing and connecting easily, the cable has three parts:

a) Ground cable (option): 38m, from electric house to the bottom of derrick.

b) Derrick cable: 38m, from the derrick bottom to supporter nearby monkey board.

c) Traveling cable: 30m, from the supporter to main motor.

Quick connectors are used among three-cables, between main power cable and main motor, also between main power cable and main control cabinet. This is very convenient for install on local well site. They are shown as below:

Plesse insure the cable connection is dependable, and avoid entrance of rain.

To avoid connector loosing or even destroying, timely check and maintain all cables and their plugs/connectors is very importance because of bad environment and complex drill condition on well site (check and maintain period should be not more than five days).

Top Drive Electric house

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4.10. Other cables

4.10.1. LCB control cable LCB control cable is multi-core cable, with quick connectors and very convenient for install on well site. LCB cable includes two sections:

a) A: 12-core power cable, provide 380V and 220V power for air cooling fan and heater.

b) B: 67-core shielded cable, used to transfer LCB 24V DC control power supply, manual signal, and main motor encoder signal.

Plesse insure the cable connection is dependable, and avoid entrance of rain.

4.10.2. HPU control cable The main power (380V) of HPU Control Box is from PLC/MCC cabinet, it connect with electric house by use of quick connector which could be connected easily. HPU Control Box control cable includes control signals (digital signals) cable and analog sensor (analog signals) cable, its two sides use plugs.

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4.10.3. Driller Console control cable There are four control cables for Driller Console, and cables’ two sides all use plugs:

a) X1: it sends manual signal of Driller Console to PLC/MCC cabinet, used for emergency operation.

b) X101: provides 24V control power for Driller Console, send signals of well control and emergency stop.

c) X102: shielded cable, used for output signal of Top Drive speed / torque (4-20mA current).

d) X200: the festoon cable of Profibus communication, the ability of anti-interference is very strong.

4.10.4. Auxiliary control box cable (option) Auxiliary control box cable is one piece of cable, used to connect Auxiliary Control Box with Electric House.

4.10.5. Earth cable The electric system adopts two earth cables (each 5m) with two earth bars (1.8m) for protection. Note: earth bar resistance must be less than 4 ohm, fix in deep earth and it is necessary to water it timely to keep wet. Galvanized earth bar shows as below:

Timely measure earthing resistance with megger, makes sure that earthing is well.

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5. Operating procedure

5.1. Start/stop electric control system

5.1.1. Checking before start

Before starting electric system, should check the following items:

a) Check the mechanical and hydraulic system first. Make sure that they are ready.

b) Check all operation cabinets and meters of electric system and Driller Console; ensure they are in initial status. (Refer to appendix 1).

c) The indicators on Driller Console could be tested by press the button of 【Reset/Silence】for three seconds.

5.1.2. Power on procedure

Ordinal close each degree’s power switches, check line voltage, auxiliary voltage transformer, control voltage transformer’s output voltage, and SITOP output power.

Make sure that all switches have been power on (except main air switch Q1,Q2), and the power supply is in good condition.

5.1.3. Startup system

Turn【System Start】switch on PLC/MCC cabinet to ‘on’, the ‘system ready’ indicator light will flash, and then the Rectifier begins to run, after a short time, the corresponding Rectifier cabinet’s main air switch will power on. 600V power supplied to Rectifier, Inverter will run when Driller Console gives an enable signal, and then Top Drive is ready.

When electric system is ready, at the same time the ‘system ready’ and ‘ready’ indicator light on Driller Console will on constantly. Enable signal from Driller Console will startup the Inverter.

The operation of ‘system start’ will invalid if the system is not in initial status!

When system is running, operating 【System Start】switch on PLC/MCC cabinet will cause fault stop.

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5.1.4. Stop system

Stop electric system:

a) Turn 【Throttle】handle of Driller Console to zero, and turn【Direction】 switch to the ‘Stop’ position. Inverter will stop and Top Drive will stop running.

b) Turn【System Start】switch to ‘off’. The main air switch will disconnect when Rectifier accept system stop signal, then, the system will stop running.

The power only can be shut off after the main air switch was opened.

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5.2. Start/stop of hydraulic system (HPU)

5.2.1. HPU local control

Start HPU locally:

a) Operating the【Pump Select】switch on HPU to ‘A’ or ‘B’.

b) Turn HPU Control Box 【Power】to ‘on’.

c) When ‘Power On’ indicator light is on, turn 【HPU Pump】to ‘on’, the selected pump will run, and ‘Pump A Running’ or ‘Pump B Running’ indicator light will on. When communication is well, 【Pump Running】on Driller Console will on.

Stop HPU locally:

a) Turn the 【HPU Pump】switch to ‘off’, the pump will stop running, and indicator light will off.

b) If HPU pump keep stop for a long time, operator should turn 【Power】on HPU Control Box to ‘off’.

Compared with remote operation by Driller Console, local operation on HPUhas priority. When checking or repairing, it is important to disconnect power supply to ensure personnel and equipment safety.

When HPU pump on local control mode, 【E_Stop】operation cann’t stop the HPU pump.

5.2.2. HPU remote control When communication is well, Driller Console remote control HPU procedure:

a) Turn HPU Control Box 【Power】to on.

b) Use HPU panel to select pump A or B.

c) Turn 【HPU Pump】 to ‘auto’, set HPU pump to remote control.

d) Turn 【HPU】 on Driller Console to ‘run’, could start the selected pump. Turn【HPU】on Driller Console to ‘stop’, could stop the selected pump. If turn to “auto”, the pump will run automatically when pressure is lower than 14Mpa, while pump will stop automatically when pressure is higher than 16Mpa.

e) If HPU keep stop for a long time, operator should turn HPU Control Box 【Power】to ‘off’.

When HPU pump on remote control mode, 【E_Stop】operation will stop the HPU pump. If need pump running, control the pump locally.

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5.2.3 Hydraulic system cooling

HPU Cooling Fan has two control modes: Auto and Manual. Operate 【Cooling Fan】 could realize switch its modes.

Turn to ‘on’ means manually startup the cooling fan.

Turn to ‘off’ means manually stop the cooling fan.

Turn to ‘auto’ means the cooling pump will be controlled by oil temperature logic in PLC program.

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5.3. Main motor heating

When main motors are not running, switch 【Motor Heater】of PLC/MCC cabinet to ‘on’ could startup the heater of two main motors. The ‘Heat’ on PLC/MCC will show the status of motor heater.

In PLC logic, heater and motor’s running are interlocked. Namely when main motors are running, heater is forbidden to work; if start main motor when heater is working, the heater will stop automatically.

If it has been rained for a long time outside or Top Drive has not been worked for a long time, it is necessary to start heaters to enhance motor’s insulation before starting motors. So that two motors could work safely.

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5.4. Main motor’s cooling fan

Two air cooling fans are installed on the top of main motors.

The ‘on’ position of 【Air Cooling】on Driller Console could startup the air cooling fan directly. If 【Air Cooling】switch is on ‘off’ position, after delay time, the main motor’s cooling fan will stop. But when motors are running, no matter which position of【Air Cooling】, the air cooling fan will not stop.

When 【Air Cooling】switch is on ‘auto’ position, before Top Drive start running, system preset main motor’s corresponding cooling fan will start.

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5.5. Brake

The brake function could only be used under Drill Mode. When receive brake signal, the 【Brake】 indicator light will on constantly. When receive stop brake signal, the ‘Brake’ indicator light will off.

Turn【Break】 switch to ‘On’ before motors running, motors will output torque equal to the scale of 【Drilling Torque】, but no speed.

If motors are running, turn 【Break】switch to ‘On’, motors will reduce its speed. When the speed is suitable, brake will work to stop the motor.

When 【Break】is on ‘auto’, Top Drive main motor will startup, and brake will release automatically after a practical torque is founded. When stopping system, brake will work and hold on brake state after speed lower down to a suitable range; If system work mode will change from Drill Mode to Spin Mode, and motor brake will open automatically.

When【Brake】is ‘off’, Top Drive could be started, when stopping system; main motor will decrease its speed and keep on zero speed, brake will not work.

When 【Break】 switch is on ‘Off’ position, Top Drive could start or run normally, but when system stops, brake will not work automatically.

When fault happens and system stops emergently, system will reduce its speed quickly. When speed is suitable, brake will work to keep on brake status.

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5.6. Drilling operation

5.6.1. Drilling operation procedure

Check the system before operating, follow chapter 5.1 to startup system correctly. Make sure that system is in following status:

Name Button or Switch Status

Driller Console 【Brake】 ‘Auto’

Driller Console 【HPU】 ‘Run’

Driller Console 【Locking】 ‘Unlock’

Driller Console 【Link Rotation】 Center position

Driller Console 【Link Incline】 Center position

Driller Console 【IBOP】 ‘Open’

Driller Console 【Auxiliary】 ‘Off’

Driller Console 【Air Cooling】 ‘On’or ‘Auto’

Driller Console 【Operation】 ‘Drill’

Driller Console 【Direction】 ‘Stop’

Driller Console 【Makeup Torque】 Zero position

Driller Console 【Drilling Torque】 Zero position

Driller Console 【Throttle】 Zero position

Driller Console 【Clamp】 Center position

HPU Control Box 【Power】 ‘ON’

HPU Control Box 【ON OFF AUTO】 ‘AUTO’

HPU Control Box 【Cooling Fan】 ‘AUTO’

Follow below items:

a) Make sure that HPU pump runs normally, when communication is well, ‘Pump Running’ indicator light on Driller Console will on constantly.

b) Set speed range on the Wincc system.

c) Operating the 【Motor】 switch to select motors (motor A or motor B or motor A+B).

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d) Slowly turn 【Drilling Torque】switch to a need torque.

e) Operating the 【Direction】 switch to select ‘cw’ position.

f) Turn 【Throttle】slowly away from zero position, the main motor will rotate clockwise with the speed given by 【Throttle】.

Only system is not working and【Throttle】is on ‘zero’ position, 【Operation】switch is valid. Otherwise, 【Operation】switch is invalid.

Only system is not working and【Throttle】is on ‘zero’ position, 【Direction】switch is valid. Otherwise, 【Direction】switch is invalid.

Only system is not working,【Direction】is on ‘stop’ position, and【Throttle】is on ‘zero’ position, the【Motor】switch is valid. Otherwise, 【Motor】switch is invalid.

If the operation of 【Motor】or 【Operation】has a mistake, the system will give a three seconds sound alarm but no light alarm; After system returning to normal, this sound will disappear.

【Throttle】, 【Drilling torque】and【Makeup torque】handle back to zero position, means set these switches to left end (throttle no input data).

When startup main motors, for safety, the preset【Drilling Torque】value shouldn’t be very high. After the main shaft begin to rotate, operator could increase 【Drilling Torque】value at this time.

Before startup the main motor, make sure that 【Brake】 is in right status and 【Drilling Torque】value is right.

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5.6.2. Reverse drilling under Drill Mode

In normal condition, it is not permitted to do drilling ccw. But in order to solve some complex working conditions, Top Drive has the function of drilling ccw, which needs to do some setting in the Wincc system.

Check the system before this operation, follow chapter 5.1 to startup system correctly. Make sure that system is in following status:

Follow below items:

a) Make sure that HPU pump runs normally, when communication is well, ‘Pump Running’ indicator light on Driller Console will on constantly.

b) Set speed range in the Wincc system. After logon, operate 【DRILLING_CCW SETTING】button could realize drill ccw under Drill Mode. If successful, this button will become red color.

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c) Operating the 【Motor】 switch to select motors (motor A or motor B or motor A+B).

d) Slowly turn 【Drilling Torque】switch to a need torque.

e) Turn 【Direction】switch to ‘ccw’ when 【Throttle】is on zero position and system is not running.

f) Turn【 Throttle】 slowly away from zero position, the main motor will rotate counterclockwise with the speed given by 【Throttle】.

g) Logout Ccw Mode on Wincc after finishing ccw drill operation.

When drilling ccw under Drill Mode, pay more attention to drilling torque’s preset value, in order to avoid drill pipe back out and accident.

5.6.3. Speed control and torque control

During drilling, when actual torque gets to【Drilling Torque】preset value, the main shaft will stop drilling (speed is zero), and system will keep this torque. When drill torque decereases, system will rotates as preset speed.

During drilling, when system detects motor temperature is alarming, system will auto limit main shaft’s output: speed ≤60rpm. For safe, at this time, stop to cooling the main motor and troubleshooting equipments is necessary. If keep on running the motor when its temperature is over high, this may burn the insulation layer. Therefore, except special needs, stop the mian motor in time.

During drilling, when system detects that the flow rate switch of gearbox lubrication oil is alarming, system will auto limit main shaft’s output: speed ≤60rpm. For safe, at this time, stop the main motor and troubleshooting equipments is necessary. If flow rate switch of gearbox lubrication oil begins to alarm, this means the lubrication is insufficient to meet the high-speed of rotating. At this time, keep on running system will lead to mechanical damage. Therefore, except special needs, stop the mian motor in time.

5.6.4. Stop drilling

Under Drill Mode, turn 【Throttle】 to zero position and 【Direction】switch to ‘Stop’ position, Top Drive will stop running normally. If break is on ‘auto’ position, the brake will work when the speed is suitable.

When system is running under Drill Mode, if incorrect operate【Direction】switch away from ‘Cw’ position, or incorrect operate the【Brake】switch, or some electric faults occur, the system will decrease the speed and finally stoprunning.

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5.7. Make-up/break-out operation

Check the system before this operation, follow chapter 5.1 to startup system correctly. Make sure that system is in following status:

Driller Console 【Motor】 ‘A+B’

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5.7.1. Make-up operation

1） Make-up with stand

a) Make sure that HPU is in good condition. When communication is well, ‘Pump Running’ indicator light will on.

b) Turn 【Makeup Torque】to a preset value.

c) Select【Direction】switch to ‘Cw’ position and 【Operation】switch to ‘Spin’ . At this time system will work clockwise under Spin Mode, with fixed speed and torque.

d) When system keep 15% of rated torque and direction of rotation keep clockwise, turn【Operation】switch to ‘Torque’, the make-up operation will be finished automatically with the preset torque of【Makeup Torque】.

2） Make-up with single

b) Turn 【Makeup Torque】to a preset value.

c) Turn【Locking Pin】on Driller Console to ‘Lock’ to do locking operation. When the locking indicator light become on, means locking operation has finished. Clamp operation should be done after finishing the clocking operation.

d) Turn 【Direction】switch to ‘CW’ position,【Operation】to ‘Spin’ will realize clockwise Spin Mode. System will clockwise spin with fixed speed and torque.

e) After finishing spin, ensure rotating head is locked, then turn【Clamp】to ‘lock’ by left hand, and turn【Operation】to ‘Torque’ at the same time, system will switch to Make-up Mode. After a short time, system will Make-up with value given by【Makeup Torque】.

f) When torque reach to preset value, left hand release the【Clamp】, right hand turn【Operation】switch to ‘Drill’, this finish the make-up operation.

g) Turn【Locking Pin】 switch to ‘Unlock’ position to let the locking pin out. If the locking indicator is off, means ‘unlock’ operation has finished.

Before operating clamp, confirm that the rotating head locking operation has completed, namely, has already detected the locking pin insert ready signal, the ‘Locking’ indicator light will become on.

Before Make-up operation, pay attention to ‘Torque’ meter, make sure that the actual Make-up torque reaches to the preset value given by【Makeup Torque】.

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5.7.2. Break-out operation

b) Turn【Locking Pin】on Driller Console to ‘Lock’ to do locking operation. When the locking indicator light become on, means locking operation has finished. Clamp operation should be done after finishing the clocking operation.

c) Turn 【Direction】switch to ‘ccw’.

Before operating clamp, confirm that the rotating head locking operation has completed, namely, has already detected locking pin insert ready signal, the ‘Locking’ indicator light become on.

d) Turn 【Clamp】 to ‘lock’, and turn【Operation】to ‘torque’. Backup Tong will close firstly, after a short time system will counterclockwise rotates with a speed not more than Max torque value 75kN.m. When speed is faster than value of spin speed, the system will stop automatically. Left hand release the【Clamp】, right hand away from 【Operation】switch, then finish the break-out operation.

When Top Drive under Torque Mode, release 【Clamp】switch or release【Operation】switch, PLC system will stop the drive unit.

e) Turn【Operation】switch to ‘spin’, then the system will switch to counterclockwise Spin Mode with fixed speed and torque.

f) When drill pipe tool joint loosen completely, turn【Direction】switch to ‘stop’ and 【Operation】switch to ‘drill’, system will stop running.

g) Turn 【Locking Pin】 switch to ‘unlock’ position to do the unlock operation. When the indicator is off, means ‘unlock’ operation has finished.

When the drive is running under Spin Mode, if incorrectly operate【Direction】 or electric faults happens, the system will stop running.

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5.7.3. Release reactive torque

When the load torque is larger than preset torque, drill pipe may be jammed and could not drill; two methods are recommended shown as below to release the reactive torque.

Releasing torque reverse:

a) Keep the ‘Throttle’ handle and the brake switch position, ensure the master motor can output torque continually. Decrease the setting value of ‘Drilling Torque’ handle. It makes the master motor’s output torque down slowly. The drill reverses slowly until the ‘Drilling Torque’ handle to Zero; The reverse velocity of drill is down to Zero.

b) Keep the value of ‘Drilling Torque’ handle and the ‘Throttle’ handle goes back to ‘ZERO’ position when the drill torque is limited. The system brakes down when the motor stop to output. ‘Operation Mode’ and ‘Direction’ switches hold their status. The drill starts to reverse slowly after releasing the brake switch. Based on the reverse velocity, the operator will apply the brake in suitable situation to ensure the drill’s interface can not be thrown off. Repeated the above process until the drill’s reverse velocity cuts down to Zero.

The using of method 2 is decided by the ability and status of the brake. And it is also influenced by the experience for the drilling operator. So we recommend you to use the method 1 for releasing reverse torque. Only when the drive device can not work, we can adopt the method 2.

To avoid drill pipe thread off happens during the release reactive torque operation, all operations should strictly follow the routine procedure. To avoid the accident, the ccw rotate speed should be strictly controlled during release reactive torque operation.

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5.8. Rotating head lock operation

After starting the HPU, operate【Locking Pin】switch of Driller Console could realize lock and unlock of rotating head. Before operating the clamp, operator should operate【Locking Pin】switch to complete rotating head lock operation firstly. Turn【Locking】switch to ‘lock’ position, the rotating head will rotate with a small increments and the locking pin will act. After locked, the ‘Locking’ indicator light will on, means lock operation has completed. If the indicator light does not on, turn 【Locking Pin】switch to ‘unlock’, do lock operation again.

【Locking Pin】and 【Link Rotation】switches are interlocked.

In order to keep equipment and personal safe, after finishing rotating head lock operation, then operator could operate clamp.

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5.9. Link operation

After starting the hydraulic system, when making sure that the rotating head locking device has unlocked, turn【Link Rotation】switch could control the elevator link clockwise or counterclockwise rotation.

Driller Console’s 【Link Incline】switch could realize the control of elevator link front/rear.

【Link Rotation】 and 【Link Incline】can not operate at the same time.

Press【Links Center】button could operate the elevator link back to center position. Pay

attention to avoid colliding drill string when operating.

Before the link rotation operation, make sure that the lock pin has unlocked; otherwise link rotation operation is invalid.

If the master computer system has set the interlock between ‘link rotation’ and ‘link incline’, after finishing link incline operation, press 【Link Center】,then a few time’s later the link rotation operation will be valid.

【Locking Pin】and 【Link Rotation】are interlocked. When operating link rotation operation, locking pin operation is invalid; when operation locking pin operation, the link rotation operation is invalid.

When Driller Console’s【Auxiliary】switch is ‘on’ and the Auxiliary Control Box indicator lights is on, operate the switch on Auxiliary Control Box could realize the same function mentioned above. Auxiliary Control Box and Driller Console are interlocked.

Max. Load weight of tilt oil cylinder is 2ton, when hoisting overweight things such as drill collar, make sure that elevator link is in floating status, namely tilt oil cylinder runs without strength.

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5.10. IBOP operation

When system stops running, 【IBOP】could control IBOP’s movement.

Turn urn 【IBOP】to ‘off’, if system has received mud pump running signal, the IBOP indicator light will flicker, the sound will on (silence button is useless).Operator could turn 【IBOP】to on (the switch in on),IBOP keep on opening. Operator also could close the mud pump: after closing it, the IBOP will off, the indicator light will on. If Operator does nothing, IBOP will off delay 10 seconds, and then the indicator light will on, and the sound will off.

During well testing etc., turn PLC/MCC cabinet’s 【IBOP Disable】to ‘Disable’ for protect cable in the well, the operating procedure shown as follow:

a) Turn 【IBOP】 to ‘Open’ ,open the IBOP.

b) Turn PLC/MCC cabinet’s【IBOP Disable】to ‘Disable’.

c) The well testing finished, turn【IBOP Disable】to ‘Enable’, IBOP could be controlled by Driller Console’s 【IBOP】.

During well testing etc., turn PLC/MCC cabinet’s 【IBOP Disable】to ‘Disable’ for protect cable in the well.

After well testing finished, please turn PLC/MCC’s 【IBOP Disable】to ‘Enable’ for IBOP control reliability, it could be controlled by Driller Console’s 【IBOP】.

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5.11. E. Stop

When urgent condition taking place, operator could press any of【E. Stop】switch, then, all equipments of Top Drive will stop quickly（if HPU. Pump on remote contorl mode）.

After press【E. Stop】, it is forbidden to do any further operations, except that operator has finished below procedures:

a) Turn【Throttle】handle back to zero position; turn【Direction】to ‘stop’; turn【Operation】to ‘Drill’.

b) Turn PLC/MCC cabinet’s【System Start】to ‘off’.

c) Solve the emergency, and make sure that there is no fault or alarm in system.

d) Reset 【E. Stop】.

e) Press【Reset/Silence】to silence the alarm, then press this button again to reset and rescind emergency status.

f) Turn 【System Start】to ‘on’, restart the system.

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5.12. Fault/Alarm

The error can be divided into 4 types:

a) System fault: The drive system faults, the system will stop quickly.

b) Communicating fault: either of PROFIBUS substation communication is interrupted, (under ‘cable’ mode, it will not give alarm when Top Drive Local substation communication is interrupted), the system will stop quickly.

c) Electric fault : Such as main air switch, auxiliary power supply, I/O power supply, Ⅰ

Driller Console power supply, E-stop, etc. the system will stop quickly.

d) Electric fault : Such as UPS power supply, Ⅱ HPU power supply, etc. the system will normal stop automatically.

There are three ‘Fault/Alarm’ indicator lights on Driller Console, which could notice different kinds of alarm/faults through different kinds of combinations.

H1 H2 H3

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H1 H2 H3 Alarm type Top Drive description

off other alarms off

flash encoder loss alarm

off air pressure loss alarm flash flash

main motors overtemperature off other communication faults

off flash communication fault of Inverter off communication fault of Rectifier.

on flash

Communication fault

communication fault of Local Control Box (LCB) off other equipment faults

off flash Rectifier fault off Inverter fault

System fault

braking unit over temperature off other electric faults

off flash auxiliary power fault off emergency stop

flash flash

on Electric fault

air cooling power fault

When fault or alarm happens, sound will on.

After system stop running, operator should turn【Throttle】handle back to zero position,【Direction】to ‘stop’,【Operation】to ‘Drill’, and turn【System Start】on PLC/MCC cabinet to ‘off’.

After fault or alarm happens, press【Reset/Silence】to stop sound, but ‘Fault/Alarm’ indicator lights will keep on its status. At this time, operator could search for alarm record in the Wincc system. After solving the fault, press【Reset/Silence】again to reset the system and extinguish ‘Fault/Alarm’ indicator lights.

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5.13. Encoder switch

If the encoder of main motor was damaged, the Wincc system will give record of alarm. At this time, switch【Encoder Select】switch could realize system work with the other encoder.

a) Turn【Throttle】to the zero position, turn【Direction】switch to ‘stop’ position, turn【Operation】switch to ‘drill’, and turn the【System Start】to ‘off’.

b) Turn 【ENCODER SELECT】on Inverter 1 cabinet.

c) Turn 【System Start】on PLC cabinet to ‘on’, Top Drive enter into ready state.

At this time, change the encoder or solve the problem immediately.

Use the corresponding encoder for the stability,when running in single motor.

Switch 【Encoder Select】timely, not more than two weeks, this kind of alternately run of encoder could enhance system’s reliability.

5.14. Running without encoder

If the encoder of two motors were damaged, switch【Encoder Fault】switch to ‘fault’ could realize system running without encoder.

a) Turn【Throttle】to the zero position, turn【Direction】switch to ‘stop’ position, turn【Operation】switch to ‘drill’, and turn the【System Start】to ‘off’.

b) Turn PLC’s 【Encoder Fault】to ‘fault’. This time, ‘Without Encoder’ indicator light will power on.

c) Turn 【System Start】on PLC cabinet to ‘on’, Top Drive enter into ready state.

At this time, change the encoder or solve the problem immediately.

System running without encoder, the control definition for torque was reduced;Please change the encoder for system’s credibility.

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5.15. Local Control Box “Cable” operation

5.15.1. Start “Cable” operation

In case of PROFIBUS optic fiber of Top Drive system was interrupted, the system can be switched to the “Cable” operating mode.

a) Turn【System Start】to “off”, and reset all switches of Driller Console to initial position. (Refer to appendix 1)

b) Turn 【Control Mode】switch on PLC/MCC cabinet to “Cable”, and 【System Start】switch to “on”, switch system to “Cable” operation mode.

c) PLC system control signal is sent to Top Drive substation through multicore cable. Other operations are same with that drill in the normal condition, but only can not collect the reducing gear box temperature and oil pressure signals. At this time, main motor could work, and Top Drive also could work, but the operator should settle the problem as soon as possible.

When stop the electric system (include CPU restart), operator must turn 【Control Mode】switch on PLC/MCC cabinet to “Profibus” mode.

5.15.2. Stop “Cable” operation

a) After the communication of LCB has recovered, reset all switches on Driller Console to the initial position (refer to appendix 1), then, turn 【System Start】 to “off”, and turn 【Control Mode】to “Profibus.”.

b) Press the 【Reset/Silence】button when system has no alarm or fault. After that the electric system will switch back to normal communication mode.

When stop the electric system (include CPU restart), operator must turn 【Control Mode】switch on PLC/MCC cabinet to “Profibus” mode.

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5.16. Driller Console emergency operation

5.16.1. Start Em-operation

When the CPU can’t work due to some faults, emergency operation should be adopted. But please replace a new CPU as soon as possible.

a) Turn【System Start】to “off”, and reset all switches of Driller Console to original position. (Refer to appendix 1)

b) Turn 【ON OFF AUTO】switch on HPU to “on”.

c) Turn 【Control Mode】switch on PLC/MCC cabinet to “Bypass”, switch system to manual emergency operation mode.

d) Turn 【Air Cooling】to “on” to start main motor’s cooling fan.

e) Turn 【System Start】switch to “on”, drive unit will ready.

f) After ensuring the cooling fan has started, turn 【Direction】to “cw” or “ccw”.. The main shaft will rotate clockwise or counterclockwise with a fix speed.

Under this mode, operator should manually operate Brake, HPU pump, HPU cooling fan, “auto” is invalid.

5.16.2. Stop Em-operation

a) After system has recovered from faults, turn【Direction】switch to “stop”, system will stop running.

b) Turn all switches of Driller Console back to original position first, then turn 【System

Start】to “off”, turn【Control Mode】to “Profibus” at last.

c) Press Driller Console 【Reset/Silence】, Top Drive will run in normal status.

Under manual operation mode, it is possible to do some simple magnet valve operation. But under this mode, although main shaft could rotate, Top Drive could run only with the rotating speed and torque preset by system.

Under manual operation mode, system work without CPU. So that all the interlocks, alarms and protections in programme can not be realized.

Under manual operation mode, all the interlocks are invalid, so the operator should be more carefully, avoid damaging equipment or any person.

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6. Remote communication and diagnostic (self-select part)

Top Drive is equipped with a remote diagnostic system. It adopts Siemens SINAUT ST7, not only can send alarm and fault messages but also can send the runtime data to other computer with GSM network. SINAUT ST7 is based on SIMATIC S7 serial controller (like S7-300, S7-400 PLC), and the PC control center based on WINCC. Its hardware contains SINAUT TIM4R module and GSM kit.

6.1. Diagnostic setting

After logon, press【Setting】button in the WINCC control system and then the ‘setting’ picture will be shown as below. In ‘SMS MOBIL No.’, operator could set the mobile number for receive alarm or fault message. The method is: ‘blank + mobile number’, then press ‘CHANGE’ for saves. This function is very convenient for maintaining on well site.

Diagnosis setting

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6.2. SINAUT TIM4R module

SINAUT TIM module, has 1MB data memory with the main function of communication control, is the focus part of SINAUT ST7. See below picture:

TIM4R has MPI port. It is suitable for integration into the SIMATIC S7-300, and can also be connected to one or more SIMATIC S7-300/ 400 or ST7cc via MPI. It also has two WAN interfaces, provided by modem in TIM, or outlay MD connected by RS232 port, and third party modem.

TIM 4R module indicate LED No. Inscription Relevant

TIM interface Type of

WAN driver Description

1 SF All - Group error Indicates missing or incorrect settings as well as RAM errors.

2 TXD Internal modem

interface

Dedicated line

Transmit Data LED is continuously on and goes out during transmission of messages (TXD).

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LED No.

Inscription Relevant TIM interface

Type of WAN driver

Description

Dial-up network

Transmit Data No connection made: LED is out. Connection made: LED is continuously on and goes out during transmission of messages (TXD).

3 RXD Internal modem

interface

Dedicated line

Receive Data The LED is on as long as the data carrier level (DCD) is detected and goes out during reception of messages (RXD).

Dial-up network

Receive Data Goes on with an incoming call (RI), stays on after that as long as the data carrier level (DCD) is detected and goes out during reception of messages (RXD).

4 MPI / K MPI / K bus (partyline) -

Data flow via MPI / partyline The display status changes every time a message is sent or received via MPI / partyline.

5 TIM-BUS TIM-BUS - (presently not used)

6 DCF77 DCF77 radio clock -

Status of the DCF77 clock (when present) The LED is on as long as the time of day is clear and blinks for every second.

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6.3. GSM kit

GSM net transmit data by use of MC45 GSM kit. MC45, it connects with TIM by RS232 serial port, has the same function with SINAUT MD modem. The MC45 GSM kit includes: MC45 wireless modem, cable (connect MC45 and 24V DC), GSM aerial and aerial cable. See picture below:

MC45 GSM kit

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7. Windows Control Center (WINCC)

7.1. Operation picture function

Each function operation can be done on operation picture. Four separate areas show different information.

² Toolbar: in this area, there is a picture exchange button.

² Display area: main area for monitoring and operation.

² Alarm area: display latest alarm/fault.

² Status area: display current picture name and system time.

Click each function soft-button can change to related picture. The WINCC has the pictures as below:

² ‘SYSTEM HELP’ picture

² ‘POWER SYSTEM’ picture

² ‘NETWORK STRUCTURE’ picture

² ‘TOPDRIVE SYSTEM’ picture

² ‘CONTROL STATUS’ picture

² ‘AUXILIARY SYSTEM’ picture

² ‘ALARM LOGGING’ picture

² ‘SYSTEM TREND’ picture

² ‘STSTEM SET’ picture

² ‘SYSTEM LOGON’ picture

² ‘SYSTEM EXIT’ picture

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7.2. System help

Clicking ‘HELP’ button could open system help picture.and help document

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7.3. Power system

Clicking ‘POWER’ button could open power structure picture. The picture could show the status of all electric switches and loops. The green color of each circuit breaker shows close status. The green line shows that the loop has power on. The picture could help to check status and fault of power system.

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7.4. Top Drive system

Clicking ‘DRIVER’ button could open driver status picture. The picture shows all data and status of Top Drive system. The picture could help operator to know system status well.The ‘INPUT MODIFY’ button in the picture is for setting each handle’s zero position on Driller Console. If changing the handle (or its resistor) or the zero position is not correct, the value must be reset. The ‘INPUT MODIFY’ button will disappear when drive is running. To reset the value, you must move the handle to its zero position first, click ‘0’ button; then move the handle to its 100% position, click ‘100%’button. After finishing the operation, the handle must go back to ‘zero’ position.

Click ‘Speed Range’ could change system’s rotating speed range. ‘Normal’ is ‘0~110r/min’, and ‘Full Range’ is ‘0~220r/min’. The original position is ‘Normal’.

Speed Range

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7.5. Network structure

Clicking ‘NETWORK’ button could open network topology picture. The picture shows PROFIBUS structure and each station of TopDrive system. The picture could help operator to know all information of network system. If one station communicate to CPU was interrupted, a red ‘cross’ will show on the correspondent station.

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7.6. Control status

Clicking ‘CW/SW’ button could open control status picture. The picture shows equipment’s control word and status word. Operator could know other equipments’ status by watching right bottom list.

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7.7. Auxiliary system

Clicking ‘AUXILIARY’ button could open auxiliary system picture. The picture shows auxiliary system operations and status information of all parts of Top Drive’s, but only except Top Drive’s main control system.

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7.8. Trend curve picture

Clicking ‘TREND’ button could open trend curve picture. The trend is divided into: ² System trend ² Current trend ² Voltage trend ² Torque trend ² Frequency trend ² Trend for NO.1 Rectifier ² Trend for NO.2 Rectifier ² Trend for NO.1 Inverter ² Trend for NO.2 Inverter ² Trend for decelerator ² Driller Console operation record ² Fault and alarm record

Clicking right bottom window of the picture could open select menu and select the above trends, every trend has same arrangement:

² Title bar: display the title of the current trend

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² Toolbar: operation button ² Trend display area: display trend curve ² Status bar: show the status of the trend curve (historical data or real time data)

Button explanation:

Set and define the current display window to be the first window.

Set and define the current display window to be the last window.

Set and define the current display window forward a window.

Set and define the current display window backward a window.

(One trend window shows one time segment that the time axis defined.)

Clicking the button, one vertical line will display on trend window, and a data sheet

will jump out on the bottom of the window to show the actual value that the trend

curve is on. The data sheet shows the trend name, tag name, recorder file name,

actual value of tag and its recording time. The vertical line can be moved and the

value on data sheet will change according to the position on time axis. Clicking the

button again, the function will terminate.

Zoom in area can be selected after clicking the button. The time step in the selected

area will be zoomed in and the trend curve will show subtly in the area. Clicking the

button again, the function will terminate.

There are two ways to define the time range of trend curve, clicking the button can

select the ways:

1） Absolute time range: filling the begin time and date in ‘From Data time’

and filling the end time and date in ‘Till date time’.

2） Till now, how long it has been. Select from the defined time cycle.

Previous trend curve

Next trend curve

Clicking the button can switch the status of trend between ‘stop’ and ‘updating’.

When click ‘STOP’ with left key, the button will become to ‘GO’, the displayed

curve will be ‘static’, till click ‘GO’ by left key (‘GO’ will become to ‘STOP’), then

curve will be back to ‘dynamic’.

Note: after click this button, then the button will be usable.

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7.9. Alarm logging

Clicking ‘ALARM’ button could open alarm logging picture. The fault/alarm is separated into three classes: ALARM, FAULT (electric fault2), and FAILURE (equipment fault, communication fault, and electric fault1). Alarm including: Number, Date, Time, Type, Status, Message text, Help text. Colors define:

² Fault/alarm coming: red ² After confirming all fault/alarm, the color will become black ² After solving the fault/alarm, the color will become blue.

The button on toolbar could confirm the fault/alarm.

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7.10. System logon

Clicking ‘LOGON’ button could open logon window; Clicking ‘KEYBOARD’ button could open soft-keyboard of windows. The logon is successful after inputting the user name and its password correctly. Some special operation (for example: handle range setting, analog alarm value setting, bypass setting, back to windows,etc.) needs the logon operation. After finishing the operation, clicking ‘LOGOFF’ button to exit logon status and cancel the operating authorization.

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7.11. Setting function

Clicking ‘SETTING’ button could open the setting window after logon. The system parameter could be modified on this window. Operator could bypass the system fault and alarm through items on below picture, also could set procedure interlock if need. Red color words are fault and alarm, cancel ‘√’ means bypass. White color words are procedure interlocks, ‘√’ means enforce this item’s interlock.

Operator could set Reverse Drill Mode in this procedure. Press ‘DRILLING_CCW SETTING’, when this button turns to red color means success. After finishing certain operation, operator should switch back to normal mode, because reverse mode is easy to breakout.

Without special conditions, it is strictly forbidden to shield fault alarm or unlock procedure interlock.

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7.12. Exit system

Click ‘EXIT’ button on main picture toolbar, enter the picture of ‘exit windows’, and please operate according to the notes of the picture.

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8. System software and hardware

8.1. PLC system hardware

The PLC system of Top Drive is SIMATIC S7-300 series PLC, and the CPU is 315-2DP. It also includes Digital Input, Analog Input, Digital Output, and Analog Output module. The hardware is as below:

PS CPU

CPU Power Supply and CPU 315-2DP

The power supply module has power input AC 220V and output DC 24V; the output power is connected to CPU power terminal. If power supply module‘s switch turn to ‘ON’ and power indicator light (green light) become on, this means the power module works well.

The CPU module has indicator lights to show the status:

SF System fault On (red) Hardware or software is not correct or damaged

BUSF Bus fault On/flash (red) Network system fault or station lose DC5V Internal power supply On (green) Power supply for CPU is OK FRCE Force output On (green) When force output by programmer RUN CPU run On (green) CPU in run status STOP CPU stop On /flash (yellow) CPU in stop status

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CPU work mode switch has three positions:

Up Run + program CPU running and can online programming

Middle Stop CPU stop

Down Clear memory Clear internal RAM

When turn【Mode Switch】from stop to run, the run indicator light will flash until CPU has detected that all hardwares and softwares has been ready, the indicator light then will on contently (green). Otherwise, CPU will keep on stop mode.

The software of Top Drive has the function that even one or several distribute I/O stations are lost or fault, the CPU still could keep on ‘RUN’ mode, but the ‘BUSF’ indicator light will flash and ‘SF’ indicator light will on.

The program of internal RAM can be cleared by pressing【Mode Switch】to the down position, the ‘STOP’ indicator light will flash slowly; Releasing【Mode Switch】and press again, the ‘STOP’ light will fast flash, then releasing the【Mode Switch】again, the clean operation will be finished after the ‘STOP’ indicator light stops flashing.

After clearing the program of CPU internal memory and turning the【Mode Switch】to ‘RUN’ position, the CPU will load program from memory card, and run it again. Programmer only can clear the program in the memory card.

Before clearing the program of memory card, ensure already back up theprogram!

When CPU power off happens, the memory card in the front of CPU is for

program protection. This memory card could only be inserted or pulled out

after CPU power is off!

CPU memory card

There are three kinds of I/O modules in main PLC system: digital input module, digital output module and analog output module. The terminal figure can be found on the back of each module terminal cover. Each module has its front connector, and when changing the module, the connector can be pulled out from the module.

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Front connector of module

Each I/O modules and CPU are installed on back rail. When pulling out the module, one screw

must be loosed on the bottom of the module. For detail of installation of S7-300 PLC, Please see the manual of SIEMENS S7-300 hardware installation. (In optical disk, name ‘OEM’)

Module installation

Each digital input module and output module has indicator light for each channel, the green light means the channel is in logic ‘1’ status.

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Digital module and address

There is only one analog output module on the main PLC system, the module has been set to 0-10V output, if the hardware configure is not correct or losing DC 24V power supply, the red ‘SF’ indicator light will on.

Analog output module

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8.2. Program download or upload

PLC program can be downloaded to CPU or uploaded from CPU to programmer.

Two ways can be taken to recover program when changing CPU or CPU lose the program: One is that insert the memory card into new CPU when power is off, after power on again, the program stored in memory card will loaded to CPU automatically. Another way is that download program by programmer on online function. For detail, Please see the manual of STEP7 program language. Programmer on online function also could upload PLC program, and then store them in hard disk or soft disk.

Only professional engineer have right to do the operation of upload and download.

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8.3. PROFIBUS network system

The network system of Top Drive is PROFIBUS-DP; all distribute I/O stations, and variable frequency drive systems are connected to CPU by PROFIBUS. All bus cables from CPU to each station are two twist-wire shielded cables except for the cable from CPU to Local Control Box. The communication from CPU to Local Control Box is optical cable. The OLM is used to change optical signal of PROFIBUS to electric signal. PROFIBUS cable connect with each station by use of PROFIBUS connectors, terminal resistor switch must be set to ‘ON’ position when the station is on physical top or end of PROFIBUS except ET200X station (ET200X doesn’t need PROFIBUS connector.).

PROFIBUS connector and terminal resistor setting

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8.4. Distribute I/O station and communication module

Top Drive electric system has two distribute I/O stations, while ET200X is used in Local Control Box, and ET200M is used in Driller Console. Following chapters shows the detail instructions.

8.4.1 ET200X distribute I/O station

Top Drive system has two distribute I/O stations, Local Control Box uses ET200X I/O module. The ET200X is high protection module, it includes base module, digital input module, digital output module, analog input module, and analog output module.

The ET200X base module includes two power connectors and one PROFIBUS connector, the top one is control power supply plug, the middle one is PROFIBUS bus connector, the bottom one is I/O channel power supply plug. The base module also has eight digital input channels.

PROFIBUS address setting

ET200X remote I/O station

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The base module has two DIP-switches under the three connectors, one is for PROFIBUS station address setting, and another is for PROFIBUS terminal resistor setting. The terminal switch must be set to ‘ON’ position on every last station of PROFIBUS physical structure.

PROFIBUS terminal resistor setting

Top Drive electric system’s Local Control Box address is 24, it’s ‘4’, ‘5’ should be set to ‘ON’, the rest are on lower position. Local Control Box’s terminal resistances should be set to ‘ON’. There are indicator lights on base module to show the status.

SF System fault On (red) Hardware configure or software is not correct or damage

BF Bus fault On/flash (red) Communication error with CPU ON Internal power supply On (green) Power supply for control is OK DC24V I/O power supply On (green) Power supply for I/O is OK

All ET200X digital I/O modules have indicator lights for each I/O channel, the indicator light will be green when it is in ‘1’ status.

The ET200X module could only be changed when power is off!

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8.4.2 ET200M distribute I/O station

Top Drive Driller Console is ET200M distribute I/O station.ET200M adopts high density module. Its max transmit speed is 12Mbit/s, and expanded module could fit S7-300PLC I/O module. This distribute I/O station contains ET200M interface module IM153, digital input module, digital output module, analog signal input module and analog signal output module.

IM 153 base module schematic map：

IM 153 interface DI/DO and AI/AO module

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ET200M status indication：

SF System fault on（red） Hardware or software failure or damaged

BF Bus line fault On/flash (red) Communication with CPU fails, or Slave station address wrong.

ACT Out of use yellow Out of use in IM153-1 ON DC 24Vpower supply on（green） DC 24Vpower supply is good

In Top Drive electric system, Driller Console distribute I/O station address is 14, so set ‘2’, ‘4’, ‘8’ to ‘ON’, while the rest are set to the other side. Terminal resistance of Profibus connector should be set to ‘ON’.

8.4.3 Optical fiber connection module/ OLM

PROFIBUS optical fiber connection module (OLM）has three channels: Two optical fiber interfaces and one electric interface. OLM is DC 24V. OLM module has three indicator lights. Yellow shows communication is in good condition. Two optical fibers connected to OLM must cross connection, namely first OLM output terminal connect with second OLM input terminal.

PROFIBUS optical fiber connection module OLM

RS485 joint

Run indicator

DC 24Vpower supply

Optical fiber connect terminal

Code switch

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OLM indicator light：

System OLM power supply

Light (green) means power supply is in good status

CH1 Electric interface indicate

Light(yellow) means electric circuit regular

Optical fiber interface indicate

Light(yellow) means CH2/CH3 optical fiber

communication regular

OLM DIP switch location:

It is strictly forbidden to dial the code switch of OLM without permit.

Compatibility

Out. Power CH3

Out. Power CH2

Mode CH3

Mode CH2

Mode CH1

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8.4.4 REPEATER

PROFIBUS RS 485 REPEATER, is used to connect two PROFIBUS or MPI bus segment of max 32 stations. It can increase station and transmit distance, could realize electric isolate bus. There are three indicators lights show its running status:

DC 24V power supply terminal Segment 1

Segment 2 RS 485 （ProfiBus

DP）Segment 1

PROFIBUS REPEATER

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REPEATER function is below：

Terminal for connecting the power supply of RS 485

repeater(pin ‘M5.2’ is the reference ground if you

want to measure the voltage between terminals ‘A2’

and ‘B2’)

② Shield clamp for strain relief and ground the LAN

cable of bus segment 1 or bus segment 2

③ Terminal for the LAN cable of bus segment 1

④ Teminating resistor for bus segment 1

⑤ DIP switch, used to connect or cutoff part 1 and 2

⑥ Teminating resistor for bus segment 2

⑦ Terminal for the LAN cable of bus segment 2

⑧ Catch for mounting and removing the RS 485

repeater on a standard rail

⑨ Interface for PG/PC on bus segment 1

⑩ 24V DC power supply indicate

⑪ Indicator for bus segment 1 ⑫ Indicator for bus segment 2

Terminating resistor , , and DIP switch , of PROFIBUS REPEATER used ④ ⑥ ⑤

by Top Drive, all should be set to ‘ON’ position.

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8.5. Variable frequency drive system

Top Drive driver system includes Rectifier and Inverter. Rectifier could change AC to DC. AC power supply is 600V50/60HZ, DC output is 810V.

Don’t touch any of DC bus or power unit until the DC voltage has down to safety area (24V)!

8.5.1 Rectifier

The Rectifier unit has the central controller board (CUR) and PROFIBUS interface board (CBP2). The CBP2 is inserted in ADB expanded board. When the control power of Rectifier has power on, the CUR will self check and show o009 on PMU screen. If it can’t show o009, the CUR is not in ready mode, operator could read the relevant manual of Rectifier (the status code or error message). If it has error happened, operator could press the ‘P’ key on PMU or press reset key on Driller Console to reset the fault message (this fault is not caused by hardware damage).

The communication board of Rectifier (CBP2) has three indicator lights, if the CPU is running and communication with CPU is OK, the three indicator lights will flash in same frequency.

. The Rectifier can only be disassembled or repaired by related expert!

CUR and PMU

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PROFIBUS base module (CBP2)

When CUR loses communication with CPU, it will stop and has fault message F082 on PMU. When resetting the fault by pressing the ‘P’ key on PMU, the fault message will become alarm message A082 and flash on PMU screen.

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8.5.2 Inverter

Each Inverter has central controller CUVC, PROFIBUS communication board(CBP2) and SIMOLINK board(SLB) in its electrical control box.

The CBP2 and SLB board are inserted on CUVC board directly. When control power of CUVC has power on, the CUVC will self check and show o009 (or o008 OFF1 disable) on the screen of PMU. If it couldn’t show o009 (o008), the CUVC is not in ready mode, operator could read relevant manual of Inverter (the status code or error message). If Inverter fault happens, operator could press the ‘P’ key on PMU or press reset key on Driller Console to reset the fault message (this fault is not caused by hardware damage).

CUVC terminals

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The communication board of Inverter (CBP2) has three indicator lights. When CPU is running and communication with CPU is OK, the three indicator lights will flash in a same frequency.

The SIMOLINK is used for communication between two Inverters. It has three indicator lights, if the communication is OK, the three indicator lights will flash in a same frequency. The cables between two SIMOLINK modules are plastic fiber optical cable, the two optical fibers must cross connection, namely the first input channel must connect to the second output channel, and the first output channel must connect to the second input channel.

If communication of SIMOLINK has communication fault, the fault message F056 will display on PMU screen. When resetting the fault by press the ‘P’ key on PMU or reset key on Driller Console, the fault message will become alarm message A002 and flash on PMU screen.

When SIMOLINK has fault, the Inverter will stop automatically; after reset the fault, Inverter will run again.

SIMOLINK module (SLB)

The Inverter can only be disassembled or repaired by related expert!

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8.6. Parameter upload and download for Rectifier and Inverter

The parameter of Rectifier and Inverter can be downloaded or uploaded by the special software DRIVEMONITOR; the computer’s RS232 or RS485 interface can be connected to the SubD-connector of PMU, the baud rate of the communication is 38400 (the original set when leave factory). For detail information of DRIVEMONITOR, please see its manual (In optical disk, name ‘OEM’).

RS232 cable from computer to PMU D-connector

Only professional engineer have right to set Rectifier and Inverter parameter.

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8.7. Trouble shooting

Top Drive control system has a monitor computer. Operator could check the fault or alarm diagnosis on monitor screen if system can’t work correctly.

8.7.1 Air switch diagnosing

If air switch broken by accident, the diagnose mainly consists of over current, the connection cable or load equipment shorting cut to earth or phase shorting cut.

8.7.2 Earth fault

The top driver electrical system is IT system, it has isolation indication equipment in main power line. The equipment can examine the isolation of rectifier input side, main power cable and main transformer. If it gives an alarm, while main power is OK, the system can work continually, but you must check the power system’s isolation as quick as possible, because the alarm shows that the power system isolation resistor has reduced or one phase of power system is short cut to the earth.

The humidity or dirty of cable connector or isolation damage of power cable or transformer can cause the isolation resistor reducing.

It is dangerous to human safety when one phase is short circuit to earth!

8.7.3 PLC fault checking

Top Drive PLC program has the function that the CPU can still run even lose a distributed I/O station. But if CPU could not run, the CPU hardware or I/O module may be damaged.

Before checking the CPU, Please check its power supply first, the correct voltage is DC 24V. To check the CPU, operator should remove the memory card after power off first, and then power on the CPU and do memory clear operation. If CPU can run after this operation, this means CPU is OK. Otherwise the CPU hardware may be damaged already.

Programmer with STEP7 software could exam the I/O equipment; it has fully diagnostic function for fault checking. For detail please see STEP7 manual.

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8.7.4 Network checking

The network system of Top Drive is PROFIBUS-DP. If one or several stations are lost by accident, interface power supply of the station must be checked first. The correct voltage is DC24V. If the power supply is OK, operator could check the PROFIBUS cable to find whether it has broken or loosed bus connector. If power supply and cable connection are OK, the base module may be damaged already.

The network can also be diagnosed by STEP7 software.

To check the PROFIBUS cable by multimeter, operator must power off all stations’ power supply and pull out every bus connector.

8.7.5 Drive system

The drive system includes Rectifier and Inverter. The Rectifier and Inverter have PMU operation board to show the equipment status, fault, and alarm. The explanation can be found in Rectifier and Inverter manual, the fault could be reset by ‘P’ key on PMU or ‘RESET’ key on Driller Console (PROFIBUS communication is OK.) except hardware damage.

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8.8. System Power Down and Disconnection

a) Turn 【Operation】switch to ‘drill’, 【Direction】switch to ‘stop’, 【Throttle】handle back to zero position, and turn 【System Start】on PLC/MCC cabinet to ‘off’. Then, system will stop running.

b) Reset system back to original status. (see appendix 1)

c) Close monitor computer before disconnecting the main air switch, this could avoid creating alarm record in system when disconnecting the main air switch.

d) Disconnect the main air switch firstly, then close PLC power supply, disconnect UPS at last.

e) Power off HPU power supply.

f) Power off the auxiliary transformer in Rectifier cabinet.

Below items must be operated if Top Drive electric system has powered off for a long time:

a) Switch off each power supply from low level to high level. Make sure that all switches are shut off finally.

b) Switch off 600V main switch in power supply. (diesel motor)

c) Disconnect the cables which connect with electric house. Label those cables to prepare for the next install.

d) Disconnect motor and local panel’s cables.

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9. Installation, troubleshooting and maintenance

This manual has offered general request and precautions for electric system installation and troubleshooting, if you want to know more information, please refer to the <Installation and Trouble Shooting Manual>. After arriving at destination, please mount it according to the following items. Check all connecting, and then troubleshoot the electric system separately.

9.1. Electric System Reinstallation

a) The electric house must be put on horizontal place, and away from the ground to avoid water flow in from the bottom.

b) All cables should be connected with motor or local panel side first. All cable connectors must be locked strictly to avoid water and loosing.

c) Earth bar must be built (resistor <4Ω) near the electric house and connected with the main PE point of electric house.

d) The insulation of motors and cables must be checked before being connected with electric house.

e) All cables must be checked carefully to make sure correct connection before power on.

f) Checking element parts and relevant supporters inside control cabinet to find any loose or damage caused by transportation.

g) Switch off all air switches inside PLC/MCC cabinet. Generally, it is no need to open all air switches inside Inverter and Rectifier cabinets.

h) Checking initial position of some mode select switches (refer to appendix 1).

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9.2. Power on and Checking

After main 600V power has ready, and every cable from electric house to local equipment has been correctly connected, then operator could power on Top Drive electric system.

a) Operating the voltage select switch on Rectifier cabinet to check that each phase voltage is in correct range (-15 to +10% of rated voltage 600V).

b) Switch on the control power switch inside Rictifier cabinet.

c) Switch on the light inside PLC/MCC cabinet and light of electric house.

d) If in wet or high temperature environment, air conditioning must be switched on first to reduce humidity and temperature.

e) Power on each function block from high level to low level.

f) Checking power on status from monitor system, for detail, please see related chapter.

g) Switch on the【System Start】on PLC/MCC cabinet to start Rectifier, checking DC output voltage, the correct voltage is 810V.

h) Manually start cooling fan of main motor to check motor’s cooling fan, Rectifier cooling

fan and Inverter cooling fan.

i) Checking oil level of HPU and starting each pump manually.

j) Operating each button and switch manually to check each hydraulic valve and auxiliary mechanical system of Top Drive.

After checking the system status on monitor system and make sure that no fault or alarm happens, the system is ready for operation.

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9.3. Daily maintenance

a) For electric system, dust proof and damp proof are most important. Operator should pay attention to keep it dry and clean, and do not work in high (temperature higher than 45 ) ℃

or low (temperature lower than -13 )℃ temperature environment. If Top Drive doesn’t work for a long time, before restart, operator should clean the dust on element parts by dust collector, and dry them by hairdryer. Check the insulation resistance value finally, be 1MΩ at least, generally the value is over 5MΩ.

b) Start cooling fan first, and then select direction before start main motors.

c) While running, pay attention to the current meter value of all control cabinet in electric house.

d) Every cable should connect firmly, screw thread could not loose, and the weld parts should be firm too.

e) Because the light shine and air oxidation, cable will aging. Operator should pay attention to check whether it split, flake or not after using two years. Usually operator should change the cables after using four years.

f) Driller Console is ‘EX’ type, operator should use air filter and water separator to keep air dry and clean, and make sure that there are no flammable and explosive gases exist.

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Appendix 1: System initial state

Drive cabinet initial state

Before starting system, make sure that all switches and buttons of drive cabinet are in following initial state.

Button or Switch Initial position Note

【E.Stop】 Loose ‘Loose’ is initial position

PLC/MCC cabinet initial state

Before starting system, make sure that all switches and buttons of PLC/MCC cabinet are in following initial state.

【E.Stop】 Loose ‘Loose’ is initial position

【Channel Select】 Profibus ‘Profibus’ is initial position

【System Start】 Off On this position, system is stop

【Motor Heater】 Off Motor heating is in stop state

Driller Console initial state

Before starting system, make sure that all switches and buttons on Driller Console are in following initial state.

【E Stop】 Loose

【Brake】 Auto

【HPU】 Stop Hydraulic pump stop running

【Locking】 Unlock Lock pin is in unlock state

【Link Rotation】 Center Position Link rotation is not used

【Link Incline】 Center Position Link tilt is not used

【IBOP】 Open ‘open’ is initial position

【Auxiliary】 Close Auxiliary operation is forbidden

【Air Cooling】 Close In initial position, it is on ‘close’ position

【Clamp】 Center position

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【Motor】 ‘A＋B’

【Operation】 Drill

【Direction】 Stop

【Makeup Torque】 Zero

【Drilling Torque】 Zero

【Throttle】 Zero

【Throttle】, 【Drilling torque】and【Makeup torque】handle back to zero position, means set these switches to left end (throttle no input data).

Auxiliary Control Box initial state

Before starting system, make sure that all switches and buttons of Auxiliary Control Box are in following initial state.

【Link Rotation】 Center position Link rotation is not used

【Link Incline】 Center position Link tilt is not used

HPU Control Box initial state

Before starting system, should make sure that all switches or buttons of HPU Control Box are in following initial state.

【Power】 ‘OFF’ Switch off 380V power supply in HPU

Control Box

【HPU】 Stop Hydraulic pump is stop

【Cooling】 Stop Cooling fan is stop

120electric manual

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