Enviando - 1866228934 PDF

Varco Technical Education Center
Montrose Scotland
AC TOP DRIVE
Introduction
Major Components.
Sections
Section 1 - General Information
Section 2 – Specifications
Section 3 - Lubrication and Maintenance
Section 4 - Installation, Commissioning and Decommissioning
Section 5 - Guide Beams and Carriage
Section 6 - Motor Housing, Transmission
Section 7 - PH-50 Pipehandler
Section 8 - Hydraulic System
Section 9 - Varco Driller's Console
Section 10 - System Interconnect
Section 11 - Siemens Step 7 PLC
Section 12 - Basics of AC Motors
Section 13 - Basics of AC Drives
Section 14 - Seimens 70 Series Drive Chassis AC to AC
Section 15 - Parameter Listing
Section 16 - Encoder Troubleshooting Instructions
Section 17 - Simovis Version 5
Motor Cooling Counterbalance
System System
Hydraulic Disc Gooseneck

Brakes (2) (S-Pipe)
AC Drilling
Motors (2)
Transmission/
Motor Housing
Electrical
System
Hydraulic
System
Rotating Link
Adapter
Guide Beam
and Carriage
PH-50
Pipehandler
Rear Right Side
Left Side Front

A brief history of Top Drives
Since the advent rotary drilling in the early 1900s, drilling
technology has made steady and, in some cases, spectacular
progress. In a little over 100 years, well depths have gone from
the 70-foot depth of Drake's Well to over 40,000 feet at the rig
on Kola Peninsula east of Finland. To accomplish this,
advances were necessary in rig design, equipment, bits,
materials and drilling techniques.
Varco International, Inc., is proud of its part in advancing the
technology of drilling. In 1982 they introduced the industry's
first top drive drilling system. By replacing the traditional rotary
drive and kelly with an advanced system that rotates the drill
string and handles entire 93-ft. stands of pipe, Varco was able
to reduce drilling time by up to 25% while increasing the overall
capability and efficiency of the drilling operation.
As a result, Varco Top Drive Drilling Systems have now
become the new performance standard for the drilling industry.
And Varco continues to extend the threshold of Top drive
technology with the introduction of a complete line of AC top
drive systems.
A new threshold in AC technology

For years the backbone of oil industry power has been the
1000 hp DC traction motor adapted from locomotives. They are
used extensively to power a variety drilling operations including
drawworks, rotary tables and mud pumps. DC traction motors
area rugged, dependable, readily available source of high
torque electric power. These characteristics made them the
ideal choice for the conversion of drilling equipment from direct
drive diesel to electric power.
In developing its Top Drive systems, Varco first turned to these
DC motors to power its new technology. And while they were
appropriate for some applications, it became evident that
smaller, more compact motors were needed for today's perfor-
mance requirements. There was a need for an efficient, high-
performance alternative to traditional DC systems. As part of
Varco’s ongoing development effort, various AC motors and
drives were reviewed in an effort to satisfy the specific require-
ments of drilling applications. Varco design engineers deter-
mined that rapid developments in adjustable frequency
technology made AC drives and motors a better solution for
certain applications traditionally served by DC systems. These
modern AC motor/control combinations are uniquely suited for
the requirements of the drilling industry. By optimising various
components, rugged, reliable AC drives and motors now can
produce superior power density for a given frame size. The
result - compact, efficient power plants that extend the
performance envelope of drilling operations.
A performance paradigm
By utilising highly efficient AC motors with the latest variable
frequency drives, Varco has defined a new category of
performance top drive systems. These new AC drives can stall
at full torque for extended periods of time, provide significantly
higher intermittent torque and offer more precise control at all
speeds. An additional benefit of the advanced AC technology
of Varco top drives is constant, useable horsepower over a
greater range of speed and torque. This means that you can
run faster with more torque - an ideal condition for maximising
the potential of diamond and polycrystalline diamond compact
(PDC) bits. In the competitive world of drilling and production,
Varco has developed technology that is defining a new
performance paradigm. Their AC top drive systems combine
increased performance, reduced maintenance, lower power
consumption, and flexible drive parameters into an unbeatable
combination over a wide variety of applications.
Varco’s Top Drive Drilling Systems development
Portable Top Drive
Comparison
Specifications Comparison
IDS-1 TDS-9S TDS-10S TDS-11S
(DC SHUNT) (AC) (AC) (AC)
Working
Height-Ft 23.0 17.8 16.0 18.0
Weight-Lbs. 30,700 24,000 18,000 28,000
Cont. Torque. 34,900 32,500 20,000 38,000

Ft-Lbs. @155 RPM @114 RPM @89 RPM @114 RPM
Horse Pwr. 1,000 700 350 800
Rated Ton. 500 400 250 500

TDS-9SA TORQUE SPEED
TDS-10SA TORQUE/SPEED
TDS-11SA TORQUE SPEED
TDS Training Manual
TOP DRIVE COMPONENTS
Typical TDS-9/11SA
AC Electrical
TDS Training Manual
TDS-9SA/TDS-11SA PLAN VIEW
AC Electrical
TDS Training Manual
POWER TRAIN CUTAWAY
AC Electrical
TDS Training Manual
TRANSMISSION/MOTOR HOUSING
AND SWIVEL ASSEMBLY
AC Electrical
TDS Training Manual
Transmission/Motor Housing (Main Body) and

Swivel Assembly
The transmission/motor housing and swivel assembly transfers the power produced
by AC drilling motors to the drill string. Inside the transmission/motor housing main
body is a single-speed double-reduction spur gear system that provides a 10.5:1
ratio from the motors to the main shaft. The main thrust bearing located inside the
motor housing supports drilling loads, while the load stem, which bypasses the
thrust bearing and provides support for the rotating link adapter and pipe handler,
carries the tripping loads. The main body of the motor housing provides a sealed oil
lubrication reservoir for the transmission gears and bearings. Bearings and gears
are force fed by an oil pump that is integral with the main body. A low speed
hydraulic motor drives the oil pump. The filtered lubrication oil constantly circulates
through the main thrust bearing, take-up bearing, lower radial and compound gear
bearings and over the gear meshes. An industry standard wash pipe packing box
assembly is located between the main shaft/swivel stem and the S-pipe weldment.
The bonnet supports the S-pipe weldment. The forged alloy steel bail swings
forward for attaching to standard rotary drilling hooks. The bail is fitted with bronze
bushings that are grease lubricated.
AC Electrical
TDS Training Manual
MOTOR COOLING SYSTEM
The motor cooling system on the AC TDS is a local intake pressure blower
type. It consists of two 5 HP AC motors integrally mounted on top of each AC
drilling motor. Air is drawn in from the combination brake cover/air intake and
delivered through rigid ducting to an opening in the top of each motor. The
cooling air then passes through the inside of the open-frame type AC drilling
motors and exits out of two louver openings near the bottom of the motors.
AC Electrical
TDS Training Manual
HYDRAULIC CONTROL SYSTEM
AC Electrical
TDS Training Manual
HYDRAULIC SYSTEM
AC Electrical
TDS Training Manual
The hydraulic control system is a completely self-contained, onboard system. A 10-

horsepower, 1800 RPM, AC motor, drives two hydraulic pumps and powers the
hydraulic system. A fixed displacement pump drives the Lube oil system motor. A
variable displacement pump provides hydraulic power for the AC motor brakes,
powered rotating head, remote actuated IBOP, pipe backup clamp cylinder link tilt
and counterbalance system.
The hydraulic manifold attaches to the main body and contains solenoid, pressure
and flow control valves.
A sealed stainless steel reservoir supplies hydraulic oil, eliminating the need for
draining and refilling during normal rig moves. The reservoir is mounted between the
two AC drilling motors and is equipped with strainers and oil level sight gauges.
Three hydro-pneumatic accumulators are located on the main body. The

counterbalance system uses the largest accumulator. The medium size accumulator
unloads the variable displacement pump and the smallest accumulator activates the
delay circuit on the IBOP actuator.
AC Electrical
TDS Training Manual
AC DRILLING MOTOR BRAKES
A modified U-face attaches the motors to the main body. This mounting
method allows installation of the motors without shimming or special
alignment. Each motor has double-ended shafts with a drive pinion mounted
on the lower end and disc brake rotor mounted on the upper end. Two
hydraulic calliper disc brakes mounted to the top end of each motor, hold
torque in the drill string and assist in positioning during directional work. An
electrical solenoid valve remotely operates the hydraulic calliper disc brakes.
The AC drilling motors are an open-frame type, meaning that the cooling air
passes through the inside of the motion The drilling motors, manufactured
specifically for top drive applications, have internal temperature sensors,
vacuum varnish impregnated windings, high capacity bearings, and tapered
output shafts to improve serviceability of the pinion gear and brake hubs.
AC Electrical
TDS Training Manual
Powered Rotating link
The powered rotating link adapter located at the top of the pipe handler is a slip ring
assembly. It allows the hydraulic lines to remain connected as the pipe handler
rotates with the drill stem components while tripping out or positioning the link tilt.
The rotating link adapter also provides an attachment for the link tilt, pipe backup
clamp cylinder and remote IBOP actuator assembly. Grooves in the rotating link
adapter align with radial holes in the load stem, allowing hydraulic fluid to flow
between the rotating link adapter and the load stem as they rotate. The radial
passages at the upper end of the load stem intersect with each hose attachment that
runs to the hydraulic manifold. The radial passages in the lower end of the load
stem intersect sealed grooves in the rotating link adapter that, in turn, connect with
hose attachments that run to all the actuators on the pipe handler. The rotating link
adapter can be powered in either direction by a hydraulic drive motor. A pinion gear
on the hydraulic drive motor engages a ring gear attached to the top of the rotating
link adapter. An electric solenoid valve operates the rotating link adapter hydraulic
motor.
AC Electrical
TDS Training Manual
PH-50 PIPEHANDLER
AC Electrical
TDS Training Manual
TWO WAY LINK TILT (PH-50)
The two way link-tilt cylinder assemblies consist of the cylinder

rods pinned to the rotating link adapter and the cylinder bodies
pinned to the links through a set of clamps. Pressurising the
cylinder assemblies by operating the switch on the driller's
console extends the drill pipe elevator to the mouse hole or the
drill down position. A float position allows the links to return to
well centre, the latch on the cylinder assembly limits the travel
of the elevator to the derrick man position. Releasing the larch
by pulling a cable allows the elevator to travel to the mousehole
position
AC Electrical
TDS Training Manual
INTERNAL BLOWOUT PREVENTION
AC Electrical
TDS Training Manual
Internal Blowout Prevention

The two Internal Blowout Prevention (IBOP) control valves contained in the
pipehandler are ball type, full size. internal opening safety valves. These two valves
a hex drive remotely operated upper valve, and a manually operated lower valve.
form the ;well control system. Both valves have 6-5/8" regular RH connections and
15.000 psi pressure ratings. The remotely controlled upper IBOP valve is opened
and closed by a yoke and a hydraulic cylinder that is controlled from the driller's
console using an electric solenoid valve. A clam shell housing rotates with the valve
body and moves up and down to drive a small crank arm on each side of the valve
stem. The housing is actuated by a cylinder through a non-rotating actuator ring.
The hydraulic cylinder is attached to the torque arrestor frame. The lower valve is
the same type as the upper except it must be manually opened and closed with a
wrench. Both valves remain in the string at all times and are readily available by
connecting the Top Drive to the drill string. The lower valve can be broken-out from
the upper valve using tongs after swinging the torque arrestor frame out of the way.
The torque arrestor frame can be pulled away from the drill string after opening the
front gate on the clamp cylinder body and removing the stabiliser half. After
breaking-out the lower valve, the Top Drive can be hoisted away, allowing room to
install the appropriate subs arid valves for well control operations. After removing
the lower valve from the upper valve on the Top Drive using conventional fig tongs,
the lower valve remains connected to the drill string for well control purposes. A
crossover sub is included with the system to allow connection of the drill stem to the
lower valve. A drill pipe elevator hangs from a pair of conventional links that attach
the link adapter. Actuating the link tilt swings the elevator out to facilitate picking up
pipe.
AC Electrical
TDS Training Manuak
TORQUE BACK-UP CLAMP
The torque hack-up clamp is supported by a torque arrestor frame that hangs from
the rotating link adapter. The backup clamp is located below the lower shoulder of
the saver sub and consists of a pair of gripping jaws with die inserts and 10"
diameter clamping cylinder for gripping the box end of the tool joint when connected
to the saver sub. The backup clamp body is attached to the torque arrestor frame in
such a way that it can float up or down to allow for thread engagement and counter
backup torque while making and breaking connections.
When the clamp mode is activated, a shot pin mechanism automatically engages
the rotating ring to prevent the link adapter from rotating while breaking out the
connection.
AC Electrical
TDS Training Manual
COUNTERBALANCE SYSTEM
The counterbalance system includes two hydraulic cylinders connected between

the bail and the hook. When the system is activated, the two cylinders support
most of the weight of the Top Drive. This system protects root joint threads by
taking much of the weight off the drill pipe while making or breaking connections.
A new feature for the TDS-9S is called STAND JUMP. It consists of a switch at
the driller's console allowing you to change the mode of operation of the
counterbalance cylinders from DRILL, which is a standard counterbalance
condition, to STAND JUMP. The STAND JUMP feature allows the cylinders to lift
the weight of the top drive off the drill string while breaking out a connection, this
eases the stress on the threads and avoids damage. The cylinders lift the swivel
bail off its resting point on the hook. The two hydraulic cylinders are connected
to a hydro-pneumatic accumulator located on the main body. A manual valve
can extend the cylinders to assist during rig-up. The accumulator is charged with
hydraulic fluid and maintained at a predetermined pressure setting by the
counterbalance circuit in the hydraulic control manifold, located on the main
body. The hydraulic manifold controls all hydraulic power to the Top Drive.
AC Electrical
TDS Training Manual
Electrical Interface
The electrical interface shown above is the standard layout for the TDS – 9/11S,
there are main parts of this schematic, the Varco Top Drive, the Varco Driller’s
Console, the Control House or Skid and the Service Loops/Connecting cables.
The Top Drive consists of the two AC Drilling motors, Encoder Feedback, Solenoids
Valves and Pressure and Temperature Switches.
The Varco Driller’s Console consists of the switches and Potentiometers to Control
the Top Drive System as well as Alarm Indicators and Horn, to indicate a Fault
condition to the Driller.
The Control House or Skid consists the Variable Frequency Drive which powers the
AC Drilling Motors on the Top Drive, Varco control Panel which controls all the
functions and Alarms on the Top Drive.
The Service Loops are all electrical, these are the cabling system, which gives all
the power to the Top Drive, as well as giving Alarm condition status back to the
Control Panel.
AC Electrical
Preface
Manual conventions
This Preface contains the conventions used throughout this manual.
Avoid injury to personnel and/or equipment damage by reading this
manual and related documents before operating, inspecting, or servicing
the equipment.
Notes, cautions, and warnings
The following examples explain the symbols for notes, cautions, and
warnings. Please pay close attention to these important advisories.
Note
i Provides additional information on procedures involving little or no risk of

injury to personnel or equipment damage.
Caution
! Alerts the reader to procedures involving a risk of equipment damage.
Warning
Warns the reader of procedures involving a definite risk of injury to

rig personnel.
Product Bulletins
The Product Bulletin tab, if included in your manual, defines a section of
the manual in which you can store Product and Safety bulletins that may
be issued by Varco.
Overall equipment safety requirements
Varco drilling equipment is installed and operated in a controlled drilling
rig environment that involves hazardous operations and situations.
i To avoid injury to personnel or equipment damage, carefully observe the

following safety requirements.
Personnel training
All personnel installing, operating, repairing, or maintaining equipment,
or those in the vicinity of this equipment, should be trained in rig safety,
tool operation, and maintenance as applicable. This measure helps
ensure the safety of everyone exposed to the equipment for whatever
purpose.
i During installation, operation, maintenance, or repair of this equipment,

personnel should wear protective equipment.
Contact the Varco Service Department to arrange for training for

equipment operation and maintenance.
Systems safety practices

The equipment covered by this manual may require or contain one or
more utilities such as electrical, hydraulic, pneumatic, and cooling water.
i Before installing or performing maintenance or repairs on the equipment,

read the following instructions to avoid endangering exposed persons or
damaging equipment.
❏ Isolate all energy sources before beginning work.
❏ Avoid performing maintenance and repairs while the equipment is in

operation.
❏ Wear proper protective equipment during the installation,

maintenance, or repair of this equipment.
Electrical systems and components
All electrical wiring, junction boxes, sensors, glands, and related
equipment are designed for the specific application, environment and
particular zone where the equipment is intended to be used.
❏ Before beginning work on this equipment, familiarize yourself with

the electrical schematics, as well as the equipment power and
voltage requirements.
❏ When performing installation, maintenance, or repairs on the

equipment, isolate all power. Lock out switches and tag them to
prevent injury.
❏ Prior to disconnecting wires, verify that all wires and terminals are
properly labeled to ensure proper reconnection.
Hydraulic systems and components
Hydraulic systems and components are designed for specific use in the
drilling industry. The hydraulic pressure for this equipment can be as high
as 3,000 psi.
❏ Before beginning work on any portion of the hydraulic system,

familiarize yourself with the hydraulic and electrical schematics.
❏ Isolate, lock out, and tag the hydraulic and electrical power and
controls.
❏ Take precautions when bleeding down residual system pressure,

using bleed valves or equivalent techniques.
n Hydraulic fluids can be extremely hot and under high pressure.
❏ Properly discharge all system accumulators.

❏ Collect all residual hydraulic fluid in a container to prevent rig or
environmental contamination.
❏ Take precautions to prevent hydraulic oil from leaking into other open
electrical or mechanical components, such as junction boxes.
Pneumatic systems and components
Pneumatic systems and components are designed for specific use in the
drilling industry. The pneumatic pressure for this equipment can be as
high as 150 psi.
❏ Prior to beginning work on any portion of the pneumatic system,

familiarize yourself with the pneumatic and electrical schematics.
❏ Isolate, lock out, and tag the pneumatic and electrical power and
controls.
❏ Take precautions when bleeding down residual system pressure

❏ Properly discharge all system accumulators.

Water cooling systems and components
Water cooling systems and components are designed for specific use in
the drilling industry. The water can reach temperatures high enough to
cause scalding.
❏ Prior to beginning work on any portion of the cooling system

familiarize yourself with the plumbing and electrical schematics.
❏ Isolate, lock out, and tag the cooling water and electrical power and
controls.
❏ Take precautions when bleeding down residual system pressure

❏ Collect all residual cooling water in a container to prevent rig or
environmental contamination if necessary.
❏ Take precautions to prevent cooling water from leaking into other

open electrical or mechanical components such as junction boxes.
General safety
Equipment motion hazards
Some of the Varco equipment travels either horizontally, vertically on
rails, or both.
i Avoid placing objects in or near the path of motion for this equipment.
Such interference could cause personnel to be trapped or crushed by
equipment.
i Keep the working envelope/zone of the equipment free from personnel.
When replacing components

❏ During disassembly and reassembly of any equipment, verify all
components such as cables, hoses, etc. are tagged and labeled to
ensure reinstalling the components correctly.
❏ Replace failed or damaged components with Varco certified parts.

Failure to do so could result in a hazard, equipment damage, or
personal injury.
During routine maintenance
Equipment must be maintained on a regular basis. See the body of the
service manual for maintenance recommendations.
i Failure to conduct regular maintenance can result in a hazard,

equipment damage, or injury to personnel.
Visibility of equipment operation

Clear, unobstructed visibility of all equipment functions is critical to safe
operation. Do not block or impair the equipment operator’s field of view.
In cases where this is not possible, the customer must install video
cameras to ensure adequate visibility.
Proper use of equipment

Varco equipment is designed for specific functions and applications and
should be used only for the intended purpose.
i Do not hoist personnel using this equipment.
Contact the Varco service center for questions regarding equipment

operation, maintenance, hazards, and designed function.
TDS Training Manual

Montrose Scotland
AC TOP DRIVE
Section 1
General Information
AC Electrical
General Information
How to use this manual ...................................... 1-2

Identification numbers ....................................... 1-3 1
Lifting points ....................................................... 1-4
Safety wiring ....................................................... 1-5
Torque values ..................................................... 1-6 2
Basic useage ...................................................... 1-7
Drilling ahead with singles ............................................. 1-7
Drilling ahead with triples............................................... 1-8
Backreaming ................................................................. 1-9 3
TDS-9/11SA consumables ..................................... 1-10
TDS-11SA
General Information
How to use this manual

This manual is divided into 9 sections. The first page of each section is marked with a black tab that lines up
with the thumb index tabs for each section and the back cover. You can quickly find each section without looking
1 through a full table of contents. Use the symbols printed at the top corner of each page as a quick reference system.
Each section uses a different symbol.
Where applicable, each section includes:

1. A table of contents, or an illustrated view index showing:
• Major assemblies, systems or operations
• Page references to descriptions in text
2. Disassembly / assembly information and tools
3. Inspection information
4. Testing / troubleshooting information
5. Repair information
6. Adjustment information
7. Torque values
Notes, Cautions and Warnings
i (Note) Gives helpful information.
(Caution) Indicates a possibility of personal injury or equipment damage if instructions

! are not followed.
(Warning) Indicates a strong possibility of severe personal injury or loss of life if

instructions are not followed.
Special Information
Detailed descriptions of standard workshop procedures, safety principles and service operations are not included.
! Please note that this may manual contain warnings about proceedures which could damage equipment, make it
unsafe, or cause PERSONAL INJURY. Please understand that these warnings cannot cover all conceivable ways in
which service (whether or not recommended by Varco Systems) might be done, or the possible hazardous
consequences of each conceivable way. Nor could Varco Systems investigate all such ways. Anyone using service
procedures or tools, whether or not recommended by Varco Systems, must be thoroughly satisfied that neither
personal safety nor equipment safety will be jeopardized.
All information contained in this manual is based upon the latest product information available at the time of printing. We reserve the right to make
changes at any time without notice. No part of this publication may be reproduced, stored in retrieval systems, or transmitted in any form by any
means, electronic, mechanical, photocopying, recording or otherwise, without the prior written permission of Varco Systems. This includes text,
figures and tables.
1-2 Varco Systems

General Information
Identification numbers
1
Encoder
Instruction Label
Located on the side
i Trace code identifies the
configuration of your equipment
of the brake housing
AC Motor
Identification Label SALES ORDER NO.
Located on the side ASSY NO. REV
of each AC motor TRACE CODE
DATE OF MANUFACTURE
Top Drive
Identification Plate
Located on the front
Warning Labels of the motor housing
Located on the side
of each AC motor
Warning Label
Located on the
side of the bonnet
TDS-11SA 1-3
General Information
Lifting points
27,000 lb
(12300 kg)
1 TDS-11SA
Lifting Point
For lowering/hoisting the
Top Drive to/from the skid
!
Bail Lock
Must be installed before
lowering/hoisting the
Top Drive to/from the skid
Lifting Points
For the skid with
Top Drive attached
i
For information on
Center of gravity
see pages 2-2 and 2-3
30,000 lb
(13600 kg)
TDS-11SA on the skid
Lifting Points
For the skid with
Top Drive attached
! Locking pins
Must be in place ! Locking pins
Must be in place
prior to moving the skid prior to moving the skid
with Top Drive attached with Top Drive attached
1-4 Varco Systems

General Information
Safety wiring
1 2
1
3 4 5
TDS-11SA 1-5
General Information
Torque values
(Unless otherwise specified)
1 Bolts Lubricated with Bolts Lubricated with

Light Machine Oil Anti-seize Compound
Grade 5 Grade 5
Min. Max. Clamp Min. Max. Clamp

Threads Torque Torque Force Torque Torque Force
Diameter per inch (ft lb) (ft lb) (lb) (ft lb) (ft lb) (lb)
Coarse Thread Series, UNC

1/4 20 7.6 8.4 2020 5.7 6.3 2020
5/16 18 16 18 3340 12.1 13.4 3340
3/8 16 29 32 4940 21.4 23.6 4490
7/16 14 48 53 6800 36 39 6800
1/2 13 71 79 9050 53 59 9050
9/16 12 105 116 11600 78 87 11600
5/8 11 143 158 14400 107 118 14400
3/4 10 247 273 21300 185 205 21300
7/8 9 409 452 29400 306 339 29400
1 8 608 672 38600 456 504 38600
1 1/8 7 760 840 42300 570 630 42300
1 1/4 7 1064 1176 53800 798 882 53800
1 3/8 6 1387 1533 64100 1040 1150 64100
1 1/2 6 1843 2037 78000 1382 1528 78000
Fine Thread Series, UNF

1/4 28 9.5 10.5 2320 7.1 7.9 2320
5/16 24 18 20 3700 13.5 15.0 3700
3/8 24 33 37 5600 25 28 5600
7/16 20 52 58 7550 39 43 7550
1/2 20 86 95 10700 64 71 10700
9/16 18 114 126 12950 86 95 12950
5/8 18 162 179 16300 121 134 16300
3/4 16 285 315 23800 214 236 23800
7/8 14 447 494 32400 335 370 32400
1 14 665 735 42200 499 551 42200
1 1/8 12 836 924 47500 627 693 47500
1 1/4 12 1178 1302 59600 884 977 59600
1 3/8 12 1596 1764 73000 1197 1323 73000
1 1/2 12 2090 2310 87700 1568 1733 87700
T.S. = 120,000 psi to 1" dia. Proof Strength = 85,000 psi

T.S. = 105,000 psi 1 1/8" to 1 1/2" dia. Proof Strength = 74,000 psi
1-6 Varco Systems

General Information
Basic useage
Drilling ahead with singles
1
Step 1 Step 2 Step 3 Step 4 Step 5

Set slips on string Tilt links to Pickup single Lower block to Pull slips
mousehole with elevator stab motor into
Stop circulation top of single Open IBOP
Latch drill pipe Release link tilt
Close IBOP elevator around Spin in motor Start circulation
single Stab bottom of and single
Breakout connection single onto string Begin drilling
using pipehandler Makeup both
and drilling motor connections
(in reverse) with motor in
torque mode
Makeup
Open
IBOP
Link Tilt
Close IBOP
Stab Makeup
TDS-11SA 1-7
General Information
Basic useage
Drilling ahead with triples
1
Set slips on string Raise block Pickup stand Lower block to Pull slips
with elevator stab motor into
Stop circulation Tilt link tilt to top of stand Start circulation
derrickman Stab bottom of
Breakout connection stand onto string Spin in motor Begin drilling
using pipehandler and stand
and drilling motor
(in reverse) Makeup both
connections
with motor
Link Tilt Makeup
Start
Circulation
Stop
Circulation
Stab Makeup
1-8 Varco Systems

General Information
Basic useage
Backreaming
1
Hoist while Set slips on string Hoist free stand Setback stand Lower block, stab
circulating and with elevator using link tilt motor into string
rotating Breakout
connection using Spin in motor
When 3-rd pipehandler and and makeup
connection drilling motor connection with
surfaces, stop (reverse) motor
rotation and
circulation Breakout and Start circulation,
spinout stand pull slips, hoist
at floor and rotate
Breakout Hoist Setback
Hoist and
Rotate
Breakout
TDS-11SA 1-9
General Information
TDS-9/11SA consumables
Consumables Quantity Part Number Page Ref.
1 Tong Dies 4 16781 See page 7-14
Stabilizer, Front 1 118368 See page 7-15

Stabilizer, Rear 1 118367 See page 7-15
Flippers, Stabbing Guide 2 76442 See page 7-15
Wash Pipe 1 123289 See page 6-11
Wash Pipe (Tungsten Coated) 1 123289-TC See page 6-11

Wash Pipe Packing Kit, 3" Standard 1 123290-PK See page 6-11
(Use with Wash Pipe 123289 or 123289-TC)
Wash Pipe Packing Kit, 3" High Pressure 1 123290-PK-1 See page 6-11
(Use with Wash Pipe 123289-TC only)
Hydraulic Oil Filter 1 114416-1 See page 4-30
Gear Oil Filter 1 111013-1 See page 4-32
Hydraulic Oil Filter Wash Pipe
Gear Oil Filter
Stabilizers
Tong Dies
Stabbing Guide
1-10 Varco Systems

TDS Training Manual

Montrose Scotland
AC TOP DRIVE
Section 2
Specifications
AC Electrical
Specifications
Specifications
Size specifications ............................................. 2-2

General specifications ....................................... 2-4 1
Typical mast interface ....................................... 2-5
22
TDS-11SA
TDS-11SA 2-1
Specifications
Size specifications
Bail
120 in.
(3.05 m)
18.5 in. (.47 m)
Bail
88 in.
(2.24 m)
2
214.0 in. 233.0 in.

(5.43 m) (5.82 m)
To Center
of Gravity
112 in.
(2.85 m)
To Center To Center
of Gravity of Gravity
28 in. 37 in.
(.71 m) 56 in. (.94 m)
(1.42 m)
62 in. = 30,000 lb
(1.58 m) 72 in. (1.83 m) = 13600 kg
2-2 Varco Systems

Specifications
Size specifications
Rear
33.7 in. (856 mm)
33.8 in.
(859 mm)
30.0 in.
(762 mm) 22.8 in.
Setback (579 mm)
(Standard)
C
L
Well
21.1 in.
(53 mm)
22.1 in.
(561 mm)
31.0 in. (787 mm)

32.6 in. (828 mm)
26.0 in. (660 mm) 36.9 in. (937 mm)
C
L
Well
Front
TDS-11SA 2-3
Specifications
General specifications
Components Items Description
Top Drive
Weight 27,000 lb
Stack-up Height 17.8 ft
Power Requirements 700 KVA @ 575-600 VAC, 50/60 Hz
Horsepower 800 hp
2 Output torque (continuous) 37,500 ft lb (800 hp)
Tool torque (intermittent @ stall) 55,000 ft lb
Maximum Speed @ full power 228 rpm
Hoisting capacity 500 ton
Load Path Single
Drill Pipe
Sizes 3-1/2 in. to 5 in. (4 in. to 6-5/8 in. OD tool joint)
Pipe Handler
Type PH-50 (55,000 ft lb torque)
Drilling Motor
Type Reliance AC-575 VAC (2 x 400 hp)
Variable Frequency Drive
Type IDM Yaskowa Drive (800 hp, 575 VAC) or
Siemens (800 hp, 600 VAC)
Motor Braking
Type Hydraulic caliper disc brakes
Motor Cooling System
Type Local intake pressure blower
Power (2) 5 hp AC motors
Speed 3,600 rpm
Gearcase
Type Single speed, double reduction helical gear
system
Gear ratio 10.5:1 (4.38:1 optional)
Gearcase Lubrication
Type Pressure feed
Reservoir capacity 15 gal
Full internal flow
Oil Type EP Grade
Hydraulic System
Power 10 hp, AC motor
Flow (1) 6 gpm, (1) 4 gpm
Reservoir capacity 25 gal
Oil Type Mineral based hydraulic oil
Electrical House
Size 125.4 in. x 84.0 in., 91.2 in. height (Siemens)
Type 140.0 in. x 90.0 in., 91.0 in. height (IDM)
Weight 9,500 lb
Input requirement 600 VAC(50/60 Hz), or 750 VDC,
or 690 VDC(50/60 Hz)
2-4 Varco Systems

Specifications
Typical mast interface

Existing
* Dimensions are Subject Traveling Equipment
to Verification Crown
500-ton Hook/Block Combo-Typ.
** Standard TDS Configuration- Clearance
Two IBOP’s with 108 in.
Elevator Links
13.5 ft. (4.1 m)**
Block Top
TDS-11SA
Varco Portable
Top Drive System Stroked-Typ.
13.5 ft. (4.1 m)* 2
Bail Rest
Sectional Guide Beam TDS Work Height

18.0 ft. (5.4 m)**
Tool Joint
Derrick Termination
at ~73 ft. (24.4 m) Level*
Mud Hose
75 ft. (22.9 m)* Drill Stand
Connected to Standpipe Made-up at
at 73 ft. (22.3 m) Level 4 ft. (1,2 m)
Level
93 ft. (28.3 m)
Service Loop
Portable Torque Reaction Beam

“U”- Bolted to Spanners - (by Customer) Clear
Working
Height
10.0 ft. (3 m)-Minimum*

142 ft.
7.0 ft. (2.1 m)-Minimum

2 Custom Spanners
(43.3 m)
On A-Frames or Mast Side Panels (by Customer)
Varco Driller’s Control
Control Cable with Connectors

150 ft. (45.7 m)
C
L
Beam
Unitized Variable Frequency Service Loop
Inverter & Varco Control Panel Tool Joint
4.0 ft. (1.2 m)
Local Power Supply Drill Floor
Diesel/Alternator Set/AC Buss
AC Power and
AC Cables Control Cables
TDS-11SA 2-5
TDS Training Manual

Montrose Scotland
AC TOP DRIVE
Section 3
Lubrication and Maintenance
AC Electrical
Lubrication and
Maintenance
Transmission ...................................................... 3-2

Selecting the proper gearbox oil .................................... 3-2 1
Lubrication schedule ..................................................... 3-2
Recommended gear oils ............................................... 3-3
Gearbox lubrication ............................................ 3-4

2
Hydraulic system ................................................ 3-5
Precautions ................................................................... 3-5
Recommended hydraulic fluid ....................................... 3-6
3
Hydraulic lubrication ...................................................... 3-7
Motors ................................................................. 3-8

Recommended motor grease ........................................ 3-8
4
Motor lubrication ............................................................ 3-9
General purpose lubrication ............................... 3-10

Recommended lubricants .............................................. 3-11 5
General lubrication ........................................................ 3-12
TDS-11SA
Lubrication
Transmission
Selecting the proper gearbox oil
TDS transmissions operate under a combination of heavy and
shock loads. Under these conditions oil tends to extrude out of the
gear mesh. Keeping an effective film of oil on the gear mesh
requires oil with an AGMA “extra pressure” rating (EP), and a
minimum viscosity of 100 SUS at internal operating temperature.
Varco Top Drives also operate under a wide variety of ambient

temperatures. Select lubrication for the TDS based on the minimum
ambient temperature (surrounding air) to be expected before the
next oil change. Under all but the most severe operating
conditions, Varco recommends changing the oil every six months.
Introducing an oil viscosity greater than required by the ambient
3 temperature can:
❏ Damage the gearbox due to reduced oil flow

❏ Damage the oil pump because of excessive load
Lubrication schedule
Description Frequency
Replace the Gearbox Oil Following Intial Break-in Following first month of operation
Replace the Gearbox Oil and Perform an Oil Analysis 1 x every 6 Months
Oil viscosity should be adjusted based on expected ambient conditions for next six months
Replace the Gearbox Oil Filter (P/N 111013) 1 x every 3 Months
Remove, clean and replace the Magnetic Drain Plug 1 x every Year
The first oil change should be performed after the first month of
operation since new units often contain metal contaminates and
contaminates caused by initial break-in.
3-2 Varco Systems

Lubrication
Transmission
Recommended gear oils
Ambient Temperature Range
-6˚ to 16˚ C 7˚ to 30˚ C Above 21˚ C
(20˚ to 60˚ F) (45˚ to 85˚ F) (Above 70˚ F)
Manufacturer
Castrol Alpha LS-68 Alpha LS-150 Alpha LS-320
Chevron NL Gear 68 NL Gear 150 NL Gear 320
Exxon Spartan EP68 Spartan EP150 Spartan EP320
Gulf EP Lube HD68 EP Lube HD150 EP Lube HD320
Mobil MobilGear 626 MobilGear 629 MobilGear 632
Shell Omala 68 Omala 150 Omala 320
Statoil Loadway EP68 Loadway EP150 Loadway EP320 3
Texaco Meropa 68 Meropa 150 Meropa 320
Total Carter EP 68 Carter EP 150 Carter EP 320
Union Extra Duty NL2EP Extra Duty NL4EP Extra Duty NL6EP
Viscosity Index
AGMA 2EP 4EP 6EP
ISO Viscosity Grade 68 150 320
! Oils of insufficient viscosity can damage gears by allowing

metal to metal contact.
i For minimum temperatures below 20°F, the TDS must be warmed

up by rotating at a very light load (less than 200 Amps) and at very
slow speeds (less than 50 rpm) until the oil temperature climbs
above 20°F. If drilling conditions dictate oil temperatures below 20°F,
consult Varco service center.
If the oil temperature rises above 200°F, Varco recommends shutting

down or reducing drilling loads to stabilize the oil temperature below
200°F If drilling conditions dictate oil temperatures above 200°F,
consult Varco service center.
TDS-11SA 3-3
Lubrication
Gearbox lubrication
Gearbox Oil
“Drain”
3
Cork Ball
(Level Sight
Indicator) Glass
i i
Gear Oil
Sight Gauge Gearbox Oil Fill
Check with Top Drive Clean area before removing plug,
“OFF” then use a 1 3/8 inch, 12 point
socket to remove plug
“Pop-up”
Dirt Alarm
Procedure
Check oil level, prior to adding oil
(do not mistake the tan colored
foam for the dark brown oil)
Ensure that the unit is turned OFF
The area must be wiped clean
Gear Oil Filter prior to adding gearbox oil
Recheck oil level and replace the
plug after adding oil
Yearly Run the unit and recheck the oil
level (not foam level), after the unit
Magnetic Drain Plug has been running and the
Remove and clean contamination transmission oil is warm
3-4 Varco Systems

Lubrication
Hydraulic system
Precautions
Release all hydraulic oil pressure by bleeding

accumulators before disconnecting hydraulic lines.
Turn the counterbalance valve to shutdown mode to
bleed the hydraulic system. Hydraulic oil under
pressure can penetrate skin and cause serious injury.
Before opening the hydraulic system, thoroughly clean

work area, and maintain system cleanliness by
promptly capping all disconnected lines. Dirt is 3
extremely harmful to hydraulic system components
and can cause equipment failure and subsequent injury
to personnel.
! Use care when handling components to prevent nicking close

tolerance finishes.
! Use care to prevent contamination from entering the hydraulic

system during maintenance activities.
Perform Hydraulic System Oil Analysis 1 x every 6 Months

Replace the Hydraulic Fluid 1 x Year, or Earlier Based on Oil Analysis
Replace the Hydraulic System Filter (P/N 114416-1) 1 x every 3 Months
TDS-11SA 3-5
Lubrication
Hydraulic system
Recommended hydraulic fluid
Oil Temperature Range
-15˚ to 75˚ C -10˚ to 85˚ C
(5˚ to 167˚ F) (14˚ to 185˚ F)
Manufacturer
Castrol Hyspin AWS-32 Hyspin AWS-46
Chevron AW Hyd oil 32 AW Hyd oil 46
Exxon Nuto H32 Nuto H46
Gulf Harmony 32AW Harmony 46AW
Mobil DTE 24 DTE 25
Shell Tellus 32 Tellus 46
3 Statoil Hydraway HMA 32 Hydraway HMA 46
Texaco Rando oil HD32 Rando oil HD46
Total Azolla ZS 32 Azolla ZS 46
Union Unax AW32 Unax AW46
Viscosity Index
ISO Viscosity Grade 32 46
3-6 Varco Systems

Lubrication
Hydraulic system
Hydraulic lubrication
Procedure
The area must be clean prior to adding hydraulic fluid
Remove dust plug from the male quick disconnect at
the TDS-11SA hydraulic oil fill
Remove dust plug from the female quick disconnect
on the lubrication kit and connect it to the male fitting
Pump fluid until the level reaches the middle of the
sight glass as shown
Cork Ball
After adding fluid, replace the dust plugs (Level Indicator)
3
Red
“Pop-up”
Dirt Alarm Sight
Glass
Hydraulic
Oil Sight
Hydraulic Gauge
Oil Filter
Hydraulic Oil Fill

Male Quick Disconnect
Dust Plug
Hydraulic
Oil Fill
Female
Quick
Disconnect
Hydraulic
Lubrication Kit
55 gal Drum
Varco P/N 92643
Hydraulic
Oil Drain
TDS-11SA 3-7
Lubrication
Motors
Varco recommends that lubrication of all AC motors

should be done by the rig electrician.
Description No. of Points Frequency Type
Lubricate the AC Drilling Motor 4 1 x every 3 Months Motor Grease

Lubricate the Blower Motor 4 1 x every 3 Months Motor Grease
Lubricate the Hydraulic Pump Motor 2 1 x every 3 Months Motor Grease
3 Recommended motor grease

Motor Grease
Manufacturer
Chevron Black Pearl EP2 (Do Not Substitute)
3-8 Varco Systems

Lubrication
Motors
Motor lubrication
i Grease Fittings
Apply motor grease
to designated Grease
grease fittings Fitting
with hand grease gun 1/8 inch
Varco P/N
53201
3 Months
!
Pipe Plug 3
AC Blower 1/8 inch
Motor (2) (remove and
3 pumps reinstall after
(2 grease fittings lubricating)
each motor)
As Viewed From Below
3 Months
AC Drilling
Motor (2)
5 pumps
(2 grease fittings
each motor) 3 Months
Hydraulic Pump AC Motor
3 pumps
(2 grease fittings)
Procedure
Remove the lubrication point plug

Install a grease fitting
Grease with a hand pump only
Re-install the plug
TDS-11SA 3-9
Lubrication
General purpose lubrication
! The lubrication intervals described in this manual are based

on lubricant supplier recommendations. Severe conditions
such as extreme loads or temperature, corrosive atmosphere,
etc., may require more frequent lubrication.
! Worn bushings, binding parts, rust accumulations, and other

abnormal conditions indicate more frequent lubrication is
necessary. Be careful not to over lubricate parts. For example,
too much grease forced into a fitting can pop out a bearing
3 seal. Over lubrication can also affect safety since over
lubricated parts can drip, creating a potential slipping hazard
for personnel.
Description No. of Points Frequency Type
Washpipe Assembly 1 Daily General Purpose Grease
Upper Bonnet Seal 1 Weekly General Purpose Grease
Bail Pins 2 Weekly General Purpose Grease
Rotating Link Adapter Gear – Weekly General Purpose Grease
Rotating Link Adapter 2 Weekly General Purpose Grease
IBOP Actuator Yoke, Cylinder Pins 5 Daily General Purpose Grease
IBOP Actuator Cranks 2 Daily General Purpose Grease
Upper IBOP Valve 1 Weekly General Purpose Grease
Stabilizer Bushing 4 Daily General Purpose Grease
Clamp Cylinder Gate 2 Daily General Purpose Grease
Carriage Assembly 8 Weekly General Purpose Grease
Torque Arrestor at Clamp Cylinder 4 Weekly General Purpose Grease
Wireline Adapter 2 Weekly General Purpose Grease
Elevator Link Eyes 4 Weekly Pipe Dope
3-10 Varco Systems

Lubrication

Recommended lubricants
Ambient Temperature Range
Below -20˚ C Above -20˚ C
(Below -4˚ F) (Above -4˚ F)
Manufacturer
Castrol N/R MP Grease
Chevron Avi-Motive W Avi-Motive
Exxon Lidok EP1 Lidok EP2
Gulf Gulf Crown EP31 Gulf Crown EP32
Mobil Mobilux EP1 Mobilux EP2
Shell Alvania EP1 Alvania EP2
Statoil Uniway EP1N Uniway EP2N 3
Texaco Multifak EP1 Multifak EP2
Total Multis EP1 Multis EP2
Union Unoba EP1 Unoba EP2
Viscosity Index
NGLI 1 2
TDS-11SA 3-11
Lubrication

General lubrication
i
Apply general purpose
grease to designated
grease fittings with
grease gun. Use a brush
when greasing other parts.
Daily
Wash Pipe
Assembly
Apply one pump
at beginning of tour
Weekly Weekly
Bail Pins (2) Upper Bonnet Seal
Two pumps each side One pump
Use Hand Pump Only
Weekly
Weekly
Rotating Link
Rotating Link Adapter
Adapter Gear
Three pumps each
3-12 Varco Systems

Lubrication

General lubrication
i
Apply general purpose grease
to designated grease fittings
with grease gun. Use a brush
when greasing other parts.
Daily
IBOP 3
Actuator
Cylinder Pins
One pump each (if equipped)
Daily
IBOP Actuator Yoke
One pump (if equipped)
Daily
IBOP Actuator Yoke
One pump each side
Daily Weekly
IBOP Actuator Cranks Upper IBOP Valve
One pump each side Remove 1/4" NPT plug,
install grease fitting
Apply ten pumps
Weekly Replace
Torque
Arrestor Tubes ! plug before
operating
Daily
Clamp Cylinder Gate
One pump each side Daily
Stabilizer Bushing
One pump each
Weekly
Elevator Link Eyes
(4)
Daily
Pipe Dope
Stabilizer Bushing
One pump each side
TDS-11SA 3-13
Lubrication

General lubrication
i
with grease gun
Weekly
Rollers
One pump each
(if equipped)
Weekly
Rollers
One pump each
(if equipped)
3-14 Varco Systems

Lubrication

General lubrication
i
with grease gun
Weekly
Wireline Adapter
One pump each
TDS-11SA 3-15
TDS Training Manual

Montrose Scotland
AC TOP DRIVE
Section 4
Installation, Commissioning and

Decommissioning
AC Electrical
Installation, Commissioning
and Decommissioning
Illustrated index ................................................. 4-3

Preinstallation .................................................... 4-4
1
Preparation .................................................................... 4-4
Installing the crown padeye and hang-off link ............... 4-5
Locating the control house ............................................ 4-6
Installing power cables .................................................. 4-7
2
Earthing the control house (land rigs) ............................ 4-8
Checklist ........................................................................ 4-9
Installation .......................................................... 4-10

Moving the TDS-11SA to the drill floor .......................... 4-10 3
Removing the TDS-11SA from the skid ......................... 4-11
Disengaging the lower carriage latch ............................ 4-12
Moving guide beam sections ......................................... 4-13
Present and hook the first guide beam section ............. 4-14 4
Hoist the first guide beam section ................................. 4-15
Stab and pin the first guide beam section ..................... 4-16
Completing guide beam installation............................... 4-17
Hanging the guide beam ............................................... 4-18 5
Installing the main tieback ............................................. 4-19
Installing the intermediate restraints .............................. 4-20
Disengaging the upper carriage latch ............................ 4-21
Installing derrick termination .......................................... 4-22 6
Installing the service loop to the derrick ........................ 4-23
Installing the driller’s console......................................... 4-24
Installing the driller’s console cabling ............................ 4-25
Motor rotation checkout procedure ................................ 4-26 7
Installing the pipe elevator and links.............................. 4-27
Installing the counterbalance ......................................... 4-28
Commissioning ................................................... 4-29

8
Checkout procedure ...................................................... 4-29
Hydraulic system checkout procedure........................... 4-30
Electrical system checkout procedure ........................... 4-31
Mechanical checkout procedure .................................... 4-32
9
Adjusting the link tilt ....................................................... 4-33
Removing and installing the saver sub .......................... 4-34
TDS-11SA
and Decommissioning
and Decommissioning
Decommissioning ............................................... 4-35

1 Securing the TDS-9/11SA for rig-down ............................ 4-35
Removing and storing the electrical cables
and service loops .......................................................... 4-36
Setting the latches and locking the bail ......................... 4-37
2 Disconnecting the guide beam ...................................... 4-38
Unpinning each guide beam section ............................. 4-39
Lowering each guide beam section ............................... 4-40
Returning the TDS-9/11SA to the skid ............................. 4-41
3 Removing the TDS-9/11SA from the drill floor ................. 4-42
Long term storage procedures ...................................... 4-43
44
4-2 Varco
Varco Systems
Systems
and Decommissioning
Illustrated index
Crown Padeye and

Hang-off Link
Page 4-5
Counterbalance
Page 4-27
Rotary Hose
Guide Beam Derrick

Page 4-13 Termination
Page 4-22
Service Loop
Page 4-23
Intermediate
Restraints
Page 4-20
Varco
Driller’s Console
(VDC)
Page 4-24
Control Cable
with Connectors
Page 4-25 Main Tieback
Page 4-19
Unitized Variable
Frequency Inverter and
Varco Control Panel (House)
Page 4-6
Local Power Supply

Diesel/Alternator Set/AC Bus
AC Cables
Page 4-7
AC Power and
Control Cables
Page 4-7
TDS-11SA 4-3
and Decommissioning
Preinstallation
Preparation
The TDS-11SA interfaces with the rig’s hoisting system and
electrical power system. Derrick and electrical system modifications
are required when installing the TDS-11SA on existing rigs.
For derricks that handle triples, the required top drive travel is
about 100 ft. compared to about 75 ft. when using a Kelly. It is
generally necessary to replace the regular rotary hose (which is
normally 60 ft. long) with a 75 ft. hose, and extend the standpipe
height to approximately 73 ft.
Although many rig floor layouts are possible, installing the guide
beam on the drawworks side of the derrick, or mast, and opposite
the V-door is an ideal arrangement for handling tubulars from the V-
door.
The location of the electrical loop and mud hose is an important

installation consideration for pipe setback purposes, to ensure
proper clearance and to help prevent wear to the service loop and
4 mud hose. Other important installation considerations include the
location of:
❏ The casing stabbing board
❏ Floor and derrick accessories
❏ Drawworks fastline
❏ Guide beam hang-off bracket
❏ Torque reaction beam
❏ Mud stand pipe extension
❏ Varco drillers console location
❏ Variable frequency inverter/Varco control panel location
Derrick height is a critical interface requirement. Handling a

93 ft. stand typically requires 97 ft., resulting in an overall height
from the floor to the top of the traveling block of at least 126 ft.
Derrick Clear Working Height Derrick Crown Clearance

152 ft. 25 ft.
147 ft. 20 ft.
142 ft. 15 ft.
136 ft. 9 ft.
Each rig has different crown clearance for efficient tripping.

Installing the TDS-11SA with existing traveling equipment may
require an adapter–further reducing crown clearance.
4-4 Varco Systems

and Decommissioning
Preinstallation
Installing the crown padeye and hang-off link
Recommended installations
Dimension Description
36.8 inches Standard height configuration (adjustable)

33.8 inches Varco’s IDS Top Drive requirements
30.0 inches Original setback for TDS-9S/11S
Crown
Crown Padeye
Weld according
to table above
See Table
Shackle
Hang-off Link
C
L
Well
TDS-11SA 4-5
and Decommissioning
Preinstallation
Locating the control house
Recommended Area for

Control House Location
Drawworks
V-Door
Ramp
4 C
L
Well
TDS-11SA
Varco
Driller’s
9,500 lb Console
(4300 kg)
Control House
C
L
Well
Control
House
Recommendations
Position the control house off-driller’s side or
91 in. behind the drawworks
(2310 mm)
Position as close to derrick plate as possible
to minimize cable lengths
Ensure a safe distance from direct sources of
heat (i.e. diesel engines, general exhausts)
140 in. 90 in. Location of the control house must ensure
(3560 mm) (2290 mm) accessibility from all sides
Do not expose the control house to H2S
4-6 Varco Systems

and Decommissioning
Preinstallation
Installing power cables
COM
POS
ITE
CON
NEC
TOR
AUX
. PO
WE
RC
ON
NEC
TOR
SER
IAL
Ground Lug CON
NEC
TOR
to Top Drive
Plug Panel
UI
NC
OM
ING
575
VA
C
V IN
CO
MIN
G5
75V
AC
WI
NC
OM
Incoming Power Cables
ING
575
VA
575VAC to main circuit breaker
C
(3 Places)
UO
4
UT
GO
ING
575
VA
C
VO
UT
GO
ING
575
VA
Outgoing Power Cables
C
WO to Top Drive
UT
GO
ING
575
(3 or 6 Places)
VA
C
Varco
Rain Cover Control House
Plug Panel
Procedure
Clean all connector contacts
Connect the power cables with the isolation
circuit breaker turned OFF
Connect cables in accordance with the
electrical schematic provided in the Technical
Drawings book
Lockwire all connector nuts
Earth the control house with the Varco
Ground Rod Kit (See page 4-8)
TDS-11SA 4-7
and Decommissioning
Preinstallation
Earthing the control house (land rigs)
Copper Plated
Steel Rod
Cable Clamp
Cable Lug
Copper Wire
10 ft
The control house must

be properly grounded to
prevent injury to personnel
Procedure
Insert the grounding rod into the soil (the rod
Ground Rod Kit
must be in contact with ground water) Grounding Points
P/N 116004
Connect the rod to the control house Located at opposite
(connection must be clean) corners of the house floor
For offshore installations the control house
i must be grounded to the ground point on the
rig structure
4-8 Varco Systems

and Decommissioning
Preinstallation
Checklist
The following assumes that all pre-installation planning and rig-up
is complete prior to installation of the guide beam assembly and
TDS-11SA. This includes:
❏ Make sure the derrick/mast is vertical, with the block over the
center of the rotary table.
❏ Derrick/mast modifications are completed (if required) and the

guide bean support bracket and torque reaction beam are
installed and inspected to conform to Varco specifications as
detailed in FIP00003.
❏ The service loop bracket is installed in the derrick/mast.
❏ The control panel and frequency drive are installed.
❏ Rigging of tong lines, etc. is inspected to ensure that they will

not foul with the TDS-11SA.
❏ The hook or adaptor becket is installed. The hook should open 4

toward the drawworks.
TDS-11SA 4-9
and Decommissioning
Installation
Moving the TDS-9/11SA to the drill floor
Procedure
Ensure the safety of all personnel
Locate the Top Drive at the bottom of the
V-Door ramp
Ensure that the bail lock assembly is installed
Attach a lifting sling to the bail
Attach backup lines to the skid
Hoist the Top Drive and skid to the drill floor
!
The Bail Lock Assembly
must be installed
Tube (P/N 113498)
U-Bolt (P/N 113497)
2x 3/4" nuts
TDS-11SA
Lifting on Skid
Block
Hoist using Lifting Sling
the drawwork Attached to bail
for hoisting
Lifting
Sling
!
Be sure that the Top Drive
is pinned to the skid prior
to hoisting it to the drill floor
3 Drill 2 30,000 lb
Floor (13600 kg)
TDS-11SA TDS-11SA on Skid
In position
prior to lifting Backup Line
from skid V-Door Ramp
1
4-10 Varco Systems

and Decommissioning
Installation
Removing the TDS-9/11SA from the skid
! 27,000 lb
The Bail Lock Assembly (12300 kg)
must be installed. Remove only TDS-11SA
after installation is complete.
View of
Carriage
from Rear
4
Pin
1
Latches
Both sides
engaged TDS-11SA
for hoisting
Pin
3
2
Hoist the
TDS-11SA Lock Pin
from the skid Remove prior to
using the drawwork hoisting from skid
Drill Procedure
Floor
Ensure that both carriage latches are
Ensure the Top Drive engaged for hoisting from the skid
does not contact the rig Ensure that the bail lock assembly is installed
Engage the hook with the bail
Remove the lock pin
Hoist the Top Drive from the skid
TDS-11SA 4-11
and Decommissioning
Installation
Disengaging the lower carriage latch
Guide Beam
Top Section
Carriage
Guide Beam
Wings
2
4
TDS-11SA
Lifted from
the skid
!
27,000 lb After hoisting the TDS-11SA
(12300 kg) from the skid, disengage the
Lower Carriage Latch
and pin it as shown.
Pin
1
Upper
Latch
Engaged
Lower
As viewed from Latch
rear of Carriage Disengaged
TDS-11SA
In position
to disengage Pin
lower latch
3
Drill
Floor Skid Procedure
Remove from drill floor
Ensure that the lower carriage latch is disengaged
after hoisting the TDS-11SA
3,000 lb (1360 kg) Ensure that the upper carriage latch is engaged
Hoist the Top Drive
Ensure the Top Drive or the guide beam
does not contact the rig
Remove the skid from the drill floor
4-12 Varco Systems

and Decommissioning
Installation
Moving guide beam sections
Procedure
Locate the guide beam sections near the
V-Door
Attach lifting slings to the lifting eyes of the
first guide beam section to be hoisted
Hoist the guide beam section to the drill floor
2,100 lb
(950 kg)
20 ft. Guide Beam Section
Sling
Ensure the
Top Drive does
not contact
the rig
TDS-11SA
Guide Beam
Section
3 2
Guide Beam Section Lifting Eyes
Hoist to the drill floor Attach slings
for hoisting
Drill
Floor
1
Guide Beam Sections
Prior to Installation
TDS-11SA 4-13
and Decommissioning
Installation
Present and hook the first guide beam section
Guide Beam
Top Section
1 2
Present Match
Grease
the bores on
both joint halves
Guide
Surface
Radius locks joint

from unhooking
at 8° rotation
Hook Pin Grease

the bores on
both joint halves
4
3 4
Engage Hook
Ensure the
Top Drive does
not contact Hook Pin
the rig In fully engaged
position
Present
and Hook
the first guide
beam section Hook Pin
Saddle
Procedure
Guide Beam
Section Locate the guide beam to be hooked
Hooked under the top guide beam section
Drill Grease the bores on both joint halves
Floor Align the guide surface with the hook pin as
shown
Lower the top guide beam to match and
engage the hook pin to the hook pin saddle
Hoist the top guide beam to fully engage the
hook pin
Manually stabilize the back end of
the guide beam
4-14 Varco Systems

and Decommissioning
Installation
Hoist the first guide beam section
Guide Beam
Top Section
Hoist
Hook Pin
First Guide
Beam Section 4
Initially hoisted
by the hook pin
Bar and Radius

Locates pin bores for
easy insertion of pins
Hoist
Using the
drawwork
Ensure the
Top Drive does
not contact
the rig
Drill
Floor
TDS-11SA 4-15
and Decommissioning
Installation
Stab and pin the first guide beam section
Guide Beam 1
Top Section Stab
the guide beam
joints together
Lynch Pin
2
Joint Pin
4 Install after stabbing
4 3
Secure Retainer Pin
with the Apply grease
lynch pin and insert
Stab
and Pin
the guide
beam joint
Block as Procedure
Ensure the
Required
Top Drive does
Drill Lower the guide beam to drill floor and stab
not contact
Floor the guide beam joints together
the rig
Block the guide beam in a vertical position if
required
Install the joint pin
Grease and install the retainer pin
Secure the retainer pin with the lynch pin as
shown
4-16 Varco Systems

and Decommissioning
Installation
Completing guide beam installation
Ensure the
Top Drive does
not contact
the rig
Repeat previous steps until

Guide Beam Installation
is complete
Procedure
Move the next guide beam section to the drill floor
Present the end of the guide beam to be hooked
Ensure that the bores on both joint halves have
been greased
Drill Engage the hook pin saddle around the hook pin
Floor Hoist the guide beam with the drawwork
Lower the guide beam to the drill floor and stab
the guide beam joints together
Install the joint pin
Install the retainer pin
Secure the pins with the lynch pin
TDS-11SA 4-17
and Decommissioning
Installation
Hanging the guide beam
Crown i Note:
Use these pin positions if
Pin the crown padeye installation
Guide Beam is based on:
to the hang-off
link
Ensure the 36.8 in.
Top Drive (935 mm)
does not Standard adjustable
Crown Padeye height configuration
contact
the rig
33.8 in.
! (859 mm)
Varco’s IDS Top Drive
Ensure that requirements
the Shackle is
pinned and the 30.0 in.
cotter pin is in place (762 mm)
Original TDS-9S/11S or
Hang-off Link if plate extension (36.8 in.)
needs to be cut off due
to interference.
4
Pin
Safety Pin
C
L C
L
Guide Beam
Guide Beam Well
Top Section
Top Section
Procedure
Using the drawwork, hoist the top guide beam
Drill to the hang-off link
Floor Floor Clearance Ensure that the shackle is pinned and it’s
cotter pin is in place
Pin the guide beam to the hang-off link in the
+.5 ft appropriate position
7 ft. -0 ft
+150 mm Check for 7 ft clearance from bottom of guide
(2100 mm -0 mm ) beam to the drill floor
Secure the pin to the hang-off link with the nut
and safety pin
4-18 Varco Systems

and Decommissioning
Installation
Installing the main tieback
Procedure
Check for Top Drive mainshaft alignment over Guide Beam
well center Bottom Section
Install the main spreader beam at the
appropriate distance from well center
Install the tieback plate and tieback link
Check for Top Drive mainshaft alignment over
well center
Torque and lock wire all bolts
Tieback Link
Guide
Beam
Assembled
Tieback
Plate
4
Main
Spreader
Beam
Apply Anti-seize
Compound
Typical
Auxiliary
Spreader Beam
Main Tieback and

Spreader Beam
Install after guide
beam is assembled
Mast Leg
Drill
Floor
Recommended Installations
See Table Dimension Description
36.8 inches Standard height configuration (adjustable)

C
L 33.8 inches Varco’s IDS Top Drive requirements
Well 30.0 inches Original setback for TDS-9S/11S
TDS-11SA 4-19
and Decommissioning
Installation
Installing the intermediate restraints
Apply Anti-seize
Compound
Typical
Intermediate
Tieback Plate
2 Places
Girt Padeye
2 places if greater than
3 inches from girt
3 inches
4
105
Feet
i
Double nut Padeye
1 place if less than
3 inches from girt
Space between girt
and guide beam
Pin and
Cotter Pin
Guide Beam
Assembled
55
Feet
Procedure
Intermediate tiebacks are installed on girts
closest to 55 feet and 105 feet above the drill
floor
Weld two padeyes to the guide beam if the
Drill space between the girt and the guide beam is
Floor greater than 3 inches
Weld a single centered padeye if the space
between the girt and the guide beam is less
than 3 inches
Install intermediate tieback plates as required
Torque and lock wire all bolts
Secure all pins with cotter pins
4-20 Varco Systems

and Decommissioning
Installation
Disengaging the upper carriage latch
Guide Beam
Top Section
2 Carriage
Remove the
Bail Lock
Assembly
Guide Beam
Wings
3 !
Slowly After hanging the guide beam,
lower the installing the tiebacks, and prior
TDS-11SA to lowering the Top Drive, 4
disengage the Upper Carriage
Latch and pin it as shown.
Pin
1
Upper
Latch
Disengaged
Lower
Latch
Disengaged
As viewed from
rear of Carriage
Pin
Drill Procedure
Floor Ensure that the lower carriage latch is
disengaged
Ensure that the upper carriage latch is
disengaged
Remove the bail lock assembly
Bail Lock Assembly Ensure the mast is clear of all obstructions and
Remove slowly run the Top Drive down the guide beam
TDS-11SA 4-21
and Decommissioning
Installation
Installing derrick termination
Hoist Line Derrick/
Attachment Point Mast Leg
Derrick
Leg Plate
Hoist Line Service Loop
Attachment Brackets
Points
4
Mount the
Derrick
Termination
Plate
as recommended
83 ft
from drill floor
Recommendations
Mount on the side of the derrick adjacent to the
service loop brackets on the TDS-11SA
Drill Mount as far as practical from well center, to

Floor maintain a 36 inch minimum bend radius
! Maintaining a larger radius increases loop life and

reduces damage due to “pinching”
Location must ensure that the loops do not
catch under the guide beam during operations
and provide clearance for tong lines, the
stabbing board, tugger lines, etc
4-22 Varco Systems

and Decommissioning
Installation
Installing the service loop to the derrick
Hoist
Derrick
Termination Plate
1,000 lb
(450 kg)
Each
Service Loop
Sling
!
Avoid damage to
the service loops
by using care when
dragging it near TDS
sharp edges and Service Loop
allow room for
passing under the
V-door
Lifting Eyes
Do not remove
Derrick
Service Loop
! Recommendations
Avoid damage to the
service loops by maintaining a Do not unpack the service loops until they are
36 inch minimum ready to hang
bend radius Use a sling attached to the lifting eyes to hoist
each service loop
Service Loop Use the swivel at the tugger line attachment to
and Storage Tub allow each service loop to uncoil without
3,600 lb twisting
(1600 kg)
TDS-11SA 4-23
and Decommissioning
Installation
Installing the driller’s console
Drawworks
V-Door
TDS-11SA Ramp
Recommended Area
for Varco Driller’s
Console Location
!
UE
RQ
TO
P
IBO
Y
NC
Customers who choose to use control BR
AK
E
EM ST
GE
ER OP
systems that are not manufactured by Varco PIP

EH
AN
DL
ER
should be aware that Varco systems are

specifically designed with operational
interlocks and safety devices to prevent
possible injury to personnel and damage to
the system. Other control systems must
meet Varco requirements outlined in the QA
00098 document. Varco highly recommends
the use of its system, as it is specifically
made for use with the TDS-11SA.
Recommendations
Mount within easy reach and in plain view of the
driller while the drawworks brake and clutches
are being operated
Pigtail Cable Location must ensure that the gauges are easily
Connect to seen by the driller during drilling operations
control house Location must be visible and readable at night
4-24 Varco Systems

and Decommissioning
Installation
Installing the driller’s console cabling
COM
POS
ITE
CON
NEC
TOR
AUX
. PO
WE
RC
ON
NEC
TOR
SER
IAL Profibus Serial Link
CON
NEC
TOR to Driller’s Console
UI
NC
OM
ING
575
VA
C
V IN
CO
MIN
G5
75V
AC
Plug Panel
WI
NC
OM
ING
575
VA
C
UO
4
UT
GO
ING
575
VA
C
VO
UT
GO
ING
575
VA
C
WO
UT
GO
ING
575
VA
C
Varco
Rain Cover Control House
Plug Panel
Recommendations
Ensure that the Varco Driller’s Console is
properly located
Connect the power cables with the isolation
circuit breaker turned OFF
Connect cables in accordance with the
electrical schematic provided in the Technical
Drawings book
Tighten connector nuts
Lockwire connector nuts to prevent loosening
TDS-11SA 4-25
and Decommissioning
Installation
Motor rotation checkout procedure
Direction
of Rotation
Counterclockwise
Procedure
Assign the Top Drive and inverter by selecting Direction
FORWARD or REVERSE on the driller’s console of Rotation
Clockwise
Check the rotation direction of the cooling and oil
pump motors
Rotate the drill stem using the THROTTLE on the
driller’s console and observe proper operation
Cooling Motors
2 Places
UE
RQ
TO
RQ
TO
X
MA
IB POP
IBOSED Y
CL
O NC
GE
MER OP RQ
UE
E ST 0 TO
ILL
DR
D
SE AR
P LO RW
IBO C OF
F
FO
X
N MA
OPE SE
R
VE
IVE RE 0
DRULT
FA Throttle Direction
of Rotation
Counterclockwise
Forward/Reverse
Control
Varco
Driller’s
Oil Pump
Console
TO
RQ
UE
Motor
OP
IB
Y
NC
E GE
AK ER OP
BR EM ST
ER
DL
AN
EH
PIP
Drill Stem
Direction Reverse
of Rotation
Forward
4-26 Varco Systems

and Decommissioning
Installation
Installing the pipe elevator and links
Catch
Link Bolt
Rear
Motor
Guard
Catch Link 600-2,400 lb

Pin (270-1100 kg)
Elevator Link
AT
LO
ER T F
DLK TIL
ANLIN
EH Catch
PIAPTE IGHT
T R
RO Link 4
FT
LE
ILT
KT LT
LINOFF TI
H
NC LL
RELD DRI
E WHO
R QUH &
TOPUS
Front
Pipehandler
Rotate Switch
Link Tilt
Varco
Driller’s
Console Link
UE
RQ
TO
OP
IB
Y
NC
E GE
AK ER OP
BR EM ST
ER
DL
AN
EH
PIP
Clevis
Pin
Procedure
Using the Varco Driller’s Console, rotate the
pipehandler 90˚ (positioning the catch link under
the front of the motor guard)
Lubricate the elevator link eyes with pipe dope
Hoist the elevator link onto the rotating link adapter
(the small link eye at the bottom)
Secure the catch link with the pin and bolt
Secure the elevator link to the link tilt
Rotate the pipehandler 180˚ and install the other
elevator link
Install the pipe elevator in accordance with the pipe
elevator manual
TDS-11SA 4-27
and Decommissioning
Installation
Installing the counterbalance
Procedure
Refer to Setting up the circuits in the
Hydraulic section of this manual for initial
system set up Hook
Install the pear links to the ears on the hook
Turn on the Top Drive power
Rotate the counterbalance mode valve from Pear Link
the RUN position to the RIG-UP position 2 Places
When the cylinders reach the end of stroke,
slide the cylinder clevis over the pear link
and install the cylinder clevis pin
Cylinder
After securing the counterbalance cylinder to Clevis
the pear link, rotate the counterbalance 2 Places
mode valve to the RUN position
Adjust PCC clockwise to raise the pressure
at test port CB until the bail just begins to lift
off of the block
Reduce the pressure slowly (25 psi) to allow
pressure to stabilize
4 Cylinder
Clevis Pin
2 Places
Rig-up/Run/ Counterbalance
Shutdown Valve Cylinder
Shown in RIG-UP 2 Places
position (switch to RUN (8.5 inch stroke)
after the counterbalance
is installed) Bail
RUN
SHUTDOWN
RIG-UP
COUNTERBALANCE MODE
N
W
O
R
D
U
T
N
U
H
S
CO
UN
TE
RB
Hydraulic
R
IG
ALA
-U
NC
P
EM
OD
E
Manifold
4-28 Varco Systems

and Decommissioning
Commissioning
Checkout procedure
Initial Rig-Up
Pre-charge all accumulators (See the
Hydraulics System section of this manual)
Adjust the hydraulic system
Bleed the air from the hydraulic system Cork Ball
(Level Indicator)
Constantly monitor the hydraulic fluid level, and
never allow the level to fall below the middle of
the sight glass (system power OFF)
Checkout Procedure
Lubricate all grease points (See Lubrication)
Check for loose or missing connectors Sight
Glass
Lockwire all connector nuts
Check for interference along entire mast Hydraulic
Remove exhaust covers from AC drilling motors Oil Sight
Gauge
Check blower inlets and outlets for blockage
Set the air conditioner to 75˚F (27˚C)
4
Turn on the main breaker
Air Inlet
Between motor
and brake housing,
2 Places
Exhaust Cover
4 Places
TOP DRIVE
INS
T
WH ALL
UN EN
ST IT IS
VARCO
OR
ED
Exhaust Outlet
Through louvers at
bottom of AC drilling motors,
6 Places
TDS-11SA 4-29
and Decommissioning
Commissioning
Hydraulic system checkout procedure
Checking hydraulic fluid level
Cork Ball
(Level Indicator)
Red
“Pop-up”
Dirt Alarm
Sight
Glass
4 Hydraulic
Oil Sight
Gauge
Hydraulic
Oil Filter
Procedure
Ensure that the pipehandler clamp cylinder is
unclamped, the counterbalance cylinders are
connected to the hook, the bail is resting in the
hook, and the system power is OFF
Check to see that the hydrulic fluid level is at
the middle of the sight glass
If the fluid is low, add hydraulic fluid (see the
Lubrication and Maintenance section of this
manual
Check the red “pop-up” alarm on the hydraulic
filter for contamination
Replace the filter (P/N 114416-1) if the
indicator has popped up
Use care to prevent contamination from
entering the hydraulic system during
maintenance activities
4-30 Varco Systems

and Decommissioning
Commissioning
Electrical system checkout procedure
Emergency Stop
Latch
9 Places
M
RP
UE
RQ
TO
UE
RQ RPM Meter
TO
X
MA
P
IBOOP
IB SED Y
CL
O NC
GE
AK
E ER OP RQ
UE
BRRAKE EM ST 0
ILL
TO
ER OA
T
B N
O
P LO
SE AR
D
DR
Torque Meter 4
FL RW
DL ILT IBO C OF
F
FO
H AN KT MA
X
N
P IPE LIN
O PE
RS
E
HT E E VE
TE RIG AK AK IVE RE 0
TA BR TO BRON DRULT
RO AU FA
FT F
S LE ILT OF
OILLOS
S KT ILT
ES LINOFF T
PR
P CH
-U IT EN ILL
KE LIM WR LD DR
MAENT UE HO
RR RQ H &
CU TOPUS
OR
OT P R
L M EM WE
X RIL RT PO N
MA DOVE LIC O
R AU
YD
MP H
0 LA ECK U TO
A
AR
M CH /
AL NCE
S ILE
O SS
E RL
OW
BL
UE
RQ
SP
IN TO
ILL
DR
Procedure
All personnel must stand clear
All personnel operating the Top Drive should be
trained in rig safety and tool operation
Operate each control on the Varco driller’s console
(See Varco FIP00003)
Check for alarm conditions and resolve any alarms
at this time (See Varco FIP00003)
Check all connectors for tightness and lockwire
Check operation of meters
Check operation of emergency stop
Check the latches on the driller’s console for
tightness
Pigtail Cable
Connected to
control house
TDS-11SA 4-31
and Decommissioning
Commissioning
Mechanical checkout procedure
Checking gearbox oil level
Procedure
With the drive motors and hydraulic
system off, check to see that the oil level
(identified by a floating cork ball) is at the
middle of the glass located on the lube
pump adapter plate mounted on the side
of the gearbox
Always check the oil level, not foam level
(oil is dark brown, foam is tan) after the
unit has been running and the
transmission oil is warm
If the oil level is low, add gear oil (see the
Lubrication and Maintenance section of
this manual
Check the red “pop-up” alarm on the gear
oil filter for contamination
Replace the filter (P/N 111013-1) if the
4 indicator has popped up
Cork Ball
(Level Sight
Indicator) Glass
i i
Gear Oil Gearbox Oil Fill
Sight Gauge Clean area before removing plug,
Check with Top Drive then use a 1 3/8 inch, 12 point
“OFF” socket to remove plug
“Pop-up”
Dirt Alarm
Gear Oil Filter
4-32 Varco Systems

and Decommissioning
Commissioning
Adjusting the link tilt
i See the PH-50 Pipehandler

section of this manual for
Jam Nut inspection and disassembly/
Adjust the derrickman position assembly details
with the adjusting screw and
lock in position with the jam nut
Link Tilt
Crank
Assembly
Pin
4
26 inches
(660 mm)
Typical
Clamp
i
Mousehole
Position Cable 3-4 inches
Pull “up” or “down” (76-102 mm)
to set mousehole
position
i
Drill Down
Position
Bottom of elevator
should be above
Link the bottom of the
Mousehole stabbing guide
Position
Derrickman’s Position
Link clamps should be adjusted
so that the elevator does not Elevator
hit the diving board in this position Well Center
Float Position
TDS-11SA 4-33
and Decommissioning
Commissioning
Removing and installing the saver sub
Torque values for drill stem components
Component I.D. Connection O. D. Torque
Mainshaft to Upper IBOP Valve 3 in. 6 5/8 API Reg. 7 3/4 in. 52,000 ft-lb
Upper IBOP Valve to Lower IBOP Valve 3 in. 6 5/8 API Reg. 7 3/8 in. 48,000 ft-lb
Lower IBOP Valve to Saver Sub 3 in. 6 5/8 API Reg. 7 3/8 in. 46,000 ft-lb
Crossover Sub to Lower IBOP Valve 3 in. 6 5/8 API Reg. 7 3/8 in. 46,000 ft-lb
Crossover Sub
Tugger
Cylinder Pins Line
Remove
Torque
4 Arrestor
V
A
R
C
O
P
H
Upper IBOP 5
0
i IBOP Crank
See the Technical and Shell
Drawing Package for Remove
configuration details
RCO
VA
Lower IBOP
Gate Pin
Swing Remove one
Clear
Short Saver Sub

For use with
Long Saver Sub
For use without
i
lower IBOP lower IBOP Use Tongs for torquing
the components together
4-34 Varco Systems

and Decommissioning
Decommissioning
Securing the TDS-9/11SA for rig-down
Procedure
Lower the Top Drive to the drill floor
Remove the mud hose, drill pipe elevator
and links
Power may be needed to turn rotating head
into position for removing the links
Locate the RIG-UP/RUN/SHUTDOWN valve
on the hydraulic manifold
With the hydraulic power ON select the
“RIG-UP” position and remove the extended
counterbalance cylinders from the hook ears
Select the “SHUTDOWN” position and turn
off the Top Drive
Isolate and lock out ALL power to the Varco
control house
Hydraulic
Manifold
N
RU
W
O
N
D
T
U
H
S
C
O
U
N
R
TE
IG
R
BA
-U
LA
P
N
C
E
M
O
D
E
Rig-up/Run/
TDS-11SA Shutdown Valve
Lower to the Rotate from RIG-UP to
drill floor SHUTDOWN for Top Drive rig-down
RUN
Drill
SHUTDOWN
Floor
RIG-UP
COUNTERBALANCE MODE
TDS-11SA 4-35
and Decommissioning
Decommissioning
Removing and storing the electrical cables
and service loops
Derrick Lower
Termination Plate
1,000 lb
(450 kg)
Each
Service Loop
Sling
Derrick
! Service Loop
Avoid damage to
the service loops
by using care when
dragging it near TDS
sharp edges and Service Loop
allow room for
passing under the Lifting Eyes
V-door Do not remove
Procedure
Position the service loop tubs for convenient
loading of the service loops
Disconnect the derrick service loop from the
derrick termination plate and the control house
Disconnect jumper cables (if installed)
! Cap all connectors and lower the derrick service
loop into a service loop tub
Avoid damage to the
service loops by maintaining a Use a sling attached to the lifting eyes to lower
36 inch minimum each service loop and a swivel at the tugger line
bend radius attachment to allow each service loop to coil
without twisting
Disconnect the Top Drive service loop and repeat
Service Loop
the above procedure
and Storage Tub
3,600 lb Remove the service loop tubs from the area
(1600 kg) Remove the derrick termination plate if necessary
4-36 Varco Systems

and Decommissioning
Decommissioning
Setting the latches and locking the bail
View of
Counterbalance
TDS-11SA Carriage
Cylinders
Hoist to from Rear
Disconnect
the crown from the hook
2 Places
Exhaust
Cover
4 Places
!
TOP DRIVE
INS
TA
WH LL
UN EN
ST IT IS
VARCO
OR
ED
The Bail Lock

Assembly
must be installed
4
Pin
Latches
Both sides
engaged
Pin
Procedure
Install the bail lock assembly
Drill
Floor It is NOT necessary to drain gear oil or
hydraulic fluid for rig down
Disconnect the counterbalance cylinders
from the hook
Install exhaust covers
Hoist the Top Drive to the crown
Engage the upper and lower carriage
latches as shown
TDS-11SA 4-37
and Decommissioning
Decommissioning
Disconnecting the guide beam
Crown
TDS-11SA
Disconnect
from the
hang-off link
Crown Padeye
Do not remove
Shackle
Intermediate
Tiebacks
Disconnect
from the Hang-off Link
guide beam
Bolt
Pin
Safety Pin Guide Beam

Top Section
Procedure
Main Tieback and that both carriage latches are engaged
Disconnect (See page 4-37, Setting the latches and locking
from the the bail)
Drill guide beam Disconnect the guide beam from the main
Floor tieback and intermediate tiebacks
Hoist the Top Drive and guide beam to take the
load off the hang-off link
Remove the guide beam from the hang-off link
Replace the pin, bolt and safety pin on the
guide beam top section as shown
Remove the hang-off link if necessary
4-38 Varco Systems

and Decommissioning
Decommissioning
Unpinning each guide beam section
Ensure the
Top Drive
does not
contact
the rig
3
Guide
Beam
Hoist
Lynch Pin
Remove
2
Hook Pin 4
Retainer Pin
Remove
Joint Pin
Remove
1
Guide Beam
Lower to
the drill floor
Block as Procedure
Required
Drill Lower the guide beam to drill floor
Floor Block the guide beam in a vertical position if
required
Slightly compress the guide beam
Remove the retainer pin, lynch pin and joint
pin at the joint between the two lower guide
beam sections
Hoist the guide beam to open the joint
TDS-11SA 4-39
and Decommissioning
Decommissioning
Lowering each guide beam section
Procedure
Using a tugger or crane, pull the lower guide
Ensure the beam section to a horizontal position
Top Drive Do not allow the angle at the guide beam
does not joint to become less than 90 degrees 2,100 lb
contact (950 kg)
the rig Lower the guide beam to the drill floor Guide Beam
Attach lifting slings to the lifting eyes of the Section
lower guide beam section to be removed
2 Unhook the lower guide beam section and
Guide remove from the drill floor
Beam Repeat the previous steps for each of the
Lower to remaining guide beam sections until only the
the drill floor upper section remains
Sling
4
Guide Beam
Section
3
Lifting Eyes
Attach slings,
and unhook the
Lower Guide guide beam section
Beam Section
Horizontal position
must remain
greater than 90˚
1
Drill
Floor
Tugger
4-40 Varco Systems

and Decommissioning
Decommissioning
Returning the TDS-9/11SA to the skid
Pin 27,000 lb
Hook onto the (12300 kg)
top of the skid TDS-11SA
2
TDS-11SA Ensure the 4
Lowered Top Drive
onto skid does not
contact
the rig
3
Lock Pin
Install after lowering
TDS-11SA onto the skid
Skid
Procedure
Drill Ensure that the bail lock is installed
Floor Hoist the storage skid to the drill floor
1 Using the drawwork, lower the TDS-11SA onto
3,000 lb the skid
(1360 kg) Ensure that all carriage latches remain engaged
Skid
Hook the TDS-11SA at the top of the skid and
pin it at the bottom of the skid
Install pin retainers
TDS-11SA 4-41
and Decommissioning
Decommissioning
Removing the TDS-9/11SA from the drill floor
Procedure
Using the drawwork, lower the TDS-11SA and Sling
skid down the V-door ramp or from the drill floor
using a crane
!
The Bail Lock
Assembly
must be installed
4
Lifting
Block
Lower using
the drawwork
Lifting TDS-11SA
Sling with Skid
30,000 lb
(13600 kg)
Lower the
TDS-11SA on the Skid
Drill from the drill floor
Floor
Backup Line
4-42 Varco Systems

and Decommissioning
Decommissioning
Long term storage procedures
TDS-11SA Long Term Storage Procedures
For indoor storage, cover the TDS-11SA in its shipping and handling skid. A cargo
container is appropriate for outdoor storage.
Avoid wide variations in temperature and high humidity. The preferred environment is
clean and dry at 60˚-80˚F ambient.
All exposed unpainted metal surfaces are coated with a rust preventive prior to
shipment; however, check these surfaces periodically to be sure that no corrosion is
taking place. The recommended rust preventive (slushing compound) for bare metal
surfaces is Kendall Grade 5 (GE-D6C6A1) or equivalent.
Cover all openings to prevent water or dust from entering. Leave enough space
around the drilling motors for ventilation. Do not use silica gel or a dehydrating agent.
During storage, rotate the motors and gear train periodically to distribute lubricant.
Perform this at three month intervals if stored indoors, and at one month intervals if
stored outdoors.
For long term storage recommendations dealing with the AC drilling motors, see the
motor manufacturer’s manual.
Returning the TDS-11SA to Service After Storage 4

Remove all rust preventive and any corrosion that may have taken place, taking
special care with load carrying components.
Repaint the tool if necessary.
Follow the return to service procedures in the AC drilling motor manufacturer’s manual.
Check for water and remove if any is found.
Change the hydraulic fluid and gearbox oil.
Lubricate the cooling and oil pump motors.
Lubricate the tool with general purpose grease.
Megger all connectors.
TDS-11SA 4-43
Guide Beams and Carriage
Inspecting the crown padeye and hang-off link 5-2

Inspecting the top section of the guide beam ... 5-3 1
Inspecting the guide beam joints....................... 5-4
Inspecting the main tieback .............................. 5-5
Inspecting the intermediate restraints .............. 5-6 2
Inspecting the carriage ...................................... 5-7
TDS-11SA
TDS Training Manual

Montrose Scotland
AC TOP DRIVE
Section 5
Guide Beams and Carriage
AC Electrical
Guide Beams
and Carriage
Inspecting the crown padeye and hang-off link

Crown
Yearly
2.1"
Crown Padeye (52 mm)
minimum
Monthly
Crown Padeye
Visually inspect weld for cracks
Monthly Shackle
Cotter Pin 2.0"

Replace if missing (50 mm)
minimum
Monthly
5 Shackle
Inspect and replace if worn
1.5"
(37 mm)
minimum
Monthly
Hang-off Link Bores
Inspect and repair if worn
Hang-off Link Bores
5-2 Varco Systems

Guide Beams
and Carriage
Inspecting the top section of the guide beam

Crown
2.1"
(52 mm)
minimum
1.5"
(37 mm)
minimum
5
Bolt Assembly Hang-off Link Bores
Monthly
Safety Pin
Replace if missing Monthly
Hang-off Link Bores
Inspect and repair if worn
Guide Beam
Top Section
TDS-11SA 5-3
Guide Beams
and Carriage
Inspecting the guide beam joints
!
Verify that the joint pins,
retainer pins and lynch pins are
in place and secure. Replace
any missing or damaged pins.
Secure
Daily
Lynch Pin
Weekly
Joint Pin
Yearly
Typical Guide
Beam Joint
Daily
Retainer Pin
Monthly
Inspect welds
for cracks
5-4 Varco Systems

Guide Beams
and Carriage
Inspecting the main tieback

Guide Beam
Daily Bottom Section
Check that the tool is aligned
directly over well center
Main
Spreader Beam
Tieback
Tieback Plate Link
Yearly
Typical all welds
5
Weekly
Typical all welds
and connections
Inspect clamped connections
for tightness and double nuts.
Inspect welds for cracks.
Auxiliary Spreader Beam
Mast Leg
See General Information

for torque values
See Installation
for assembly/disassembly
TDS-11SA 5-5
Guide Beams
and Carriage
Inspecting the intermediate restraints

Daily
Check that the tool
is aligned directly
over well center
Weekly
Check for
tightness of
cotter pins, and double
nuts. If there are signs of
shifting, verify alignment.
Weekly
5 Pin and Cotter Pin
Verify that all pins are
in place. Replace any
missing or damaged pins.
Mast Girt
Yearly
Typical all welds
Guide Beam

for torque values
See Installation
for assembly/disassembly
5-6 Varco Systems

Guide Beams
and Carriage
Inspecting the carriage
Weekly
Typical
all rollers
Inspect for uneven
wear, damage and
looseness.
Replace
as required.
Daily
Typical all
detent pins
Verify that pins
are in place
and secure

for torque values
TDS-11SA 5-7
TDS Training Manual

Montrose Scotland
AC TOP DRIVE
Section 6
Motor Housing, Transmission
AC Electrical
Motor Housing,
Transmission
Illustrated index ................................................. 6-2

Inspection schedules ......................................... 6-3 1
Inspecting the internal lubrication flow
(monthly) ............................................................. 6-4
Adjusting the encoder ........................................ 6-5
2
Gearbox lube pump assembly ............................ 6-7
Disassembly/assembly .................................................. 6-7
Inspection (yearly) ......................................................... 6-8
Gear backlash ..................................................... 6-9 3

Inspection (yearly) ......................................................... 6-9
Bail and main body ............................................. 6-10

S-pipe .................................................................. 6-11
4
Upper mainshaft liner ......................................... 6-12
Washpipe assembly ............................................ 6-13
Assembly ....................................................................... 6-13
Inspection ...................................................................... 6-14 5
Upper bonnet seals (yearly) ............................... 6-16
Mainshaft ............................................................ 6-17
Inspection ...................................................................... 6-17
Inspecting mainshaft end play (yearly) .......................... 6-18 6
Blower motor assemblies (monthly) .................. 6-19

Motor brakes (monthly) ...................................... 6-20
AC drilling motors (weekly) ................................ 6-21 7
Transmission disassembly/assembly ................. 6-22
Nondestructive Examination (NDE) ................... 6-23
Visual inspection ........................................................... 6-23
8
Magnetic Particle Inspection (MPI) ................................ 6-24
Ultrasonic Inspection ..................................................... 6-25
Safety valve inspection procedures (IBOP) ................... 6-25
TDS-11SA
Motor Housing
and Transmission
Illustrated index
AC Motor
Bail
Blower
Page 6-10
Assembly (2)
Page 6-19
S-Pipe
Page 6-11
AC Motor
Brakes (2)
Page 6-20
AC Drilling Washpipe
Motors (2) Assembly
Page 6-21 Page 6-13
Gearbox
6 Lubrication
Gearbox
Assembly
Pump Assembly
Page 6-4, 6-7
Page 6-7
For AC motor and

transmission lubrication
see Page 3-2 thru 3-12
6-2 Varco Systems

Motor Housing
and Transmission
Inspection schedules
Daily Page Number
Check for missing lockwire and cotter pins
Check for loose or broken parts and leaks
Check for damaged hoses and fittings
Check the wash pipe assembly for leaks See page 6-14
Check fluid levels and filter condition See page 3-4
Weekly
Check the AC motor louvers for damage See page 6-19
Check the AC motor screens for contamination See page 6-19
Monthly
Check the flow of oil throughout the main body while the lube pump is running See page 6-4
Check the S-pipe for pitting, corrosion, or erosion See page 6-11
Check the upper mainshaft liner for erosion caused by leaking wash pipe packing See page 6-18
Check the upper bearing retainer o-ring, bearing isolator, and oil seal for wear See page 6-18
Check the blower motor assemblies for loose bolts See page 6-19
Check brake pads for wear See page 6-20
Yearly
Check the gearbox lubrication pump assembly for wear or damage See page 6-7
Check the gear teeth for pitting and corrosive wear See page 6-8
Check for primary and secondary gear set backlash See page 6-9
Check the mainshaft for axial movement See page 6-18
6
Check bail, bushings and bail pins for wear See page 6-10
Check the radial grooves on the stem and the load collar for wear See page 6-17
Megger motors
5 Years
Magnetic particle inspection (MPI) See page 6-24
TDS-11SA 6-3
Motor Housing
and Transmission
Inspecting the internal lubrication flow

(monthly)
Procedure
Remove the 3 in. pipe plugs from the main
body and check the flow of oil coming from
the four spray nozzles (two in the body, two in
cover) while the lube pump is operating
Check that oil is running out of the upper gear
drain holes in each compound gear set
(indicates upper orifice is not blocked) and
that oil is running through the spillway running
from the thrust bearing (indicates orifice is not
blocked)
Pipe Plug
Pipe Plugs
Monthly
Upper
Compound
Gear Drain Hole
Check flow
Monthly
Body Spray
6 Nozzles
Cover spray Monthly
nozzles not shown
Spillway
Check flow
Pipe Plug
Remove using a
2 inch, 12 point socket
Main Body
6-4 Varco Systems

Motor Housing
and Transmission
Adjusting the encoder

Use the following procedure to adjust the encoder belt tension:
1. Remove the access covers
2. Disconnect all of the electrical connectors from the encoder.
3. Remove the lockwire and loosen the four sled hold-down

screws.
4. Let the sled to move freely, allowing the belt tension spring to
apply the proper tension to the belt.
! Do not tension the belt by hand.
5. Carefully tighten the sled hold-down screws and torque them to

7 ft lb.
6. Lockwire the sled hold-down screws.
7. Reconnect the encoder electrical connections.
8. Replace both access covers and tighten the access cover

screws to 15 ft lb and lockwire them.
TDS-11SA 6-5
Motor Housing
and Transmission
Adjusting the encoder
Sled
Hold-down
Screws
Belt Tension
4 Places
Spring
View from Side
Encoder Belt Sled
View from Top

(Blower Motor
removed for clarity)
6 Electrical
Connector
Sled
Encoder Belt
Encoder
Sled
Belt Tension Hold-down
Spring Screws
4 Places
6-6 Varco Systems

Motor Housing
and Transmission
Gearbox lube pump assembly

Disassembly/assembly
Disassemble the gearbox lubrication pump assembly and inspect
the pump assembly components yearly for wear and damage as
follows:
1. Drain the gearbox oil and disconnect the hydraulic lines from
the pump assembly
2. Remove the pump assembly by removing the eight lockwired

capscrews that attach the pump adapter plate to the main
body
3. Disassemble the spline adapter, pump, and housing using the

pump vendor service instruction HS15 (located in the Vendor
Documentation Package)
4. Inspect the pump assembly components, replacing any parts

that are worn or damaged. Pay particular attention to the
spline between the pump and motor, the gears, and the motor
and pump sideplates.
5. Assemble the lubrication pump assembly in the reverse order

of disassembly
i Follow the pump vendor service instruction HS15 (located in the

Vendor Documentation Package) when assembling the lubrication
pump components, and torque all fasteners in accordance with
DS00008, located in the Supplemental Materials book.
i When reinstalling the pump assembly into the main body, inspect
the O-ring for damage and replace the O-ring if any flat spots,
nicks, or other damage is found.
6. Install the pump assembly into the main body. Torque the
fasteners in accordance with DS00008, and reconnect the
hydraulic and electrical connections.
TDS-11SA 6-7
Motor Housing
and Transmission
Gearbox lube pump assembly

Inspection (yearly)
End Cover
Thrust Plate
Yearly 2 Places
Ring Seal
Gearbox Lubrication
Body Seal
Pump Assembly
2 Places
Check parts for wear or damage
Gear
Housing
Gear Set
Roller Bearing
4 Places
Pump
Adapter Plate
Capscrew
10 Places
6
Hydraulic Motor
Low-Speed/High-Torque
O-ring Main Body
Procedure
Drain the gearbox oil and disconnect the
hydraulic lines from the pump assembly
Remove the pump assembly by removing the
ten lockwired capscrews that attach the pump
adapter plate to the main body
Disassemble using the drawings in the
Technical Drawing Package as well as the
pump vender service instruction
Inspect and relace any parts that are worn or
damaged
6-8 Varco Systems

Motor Housing
and Transmission
Gear backlash
Inspection (yearly)
A 6 Months
Gear Teeth
Check for wear, pitting,
and gear set backlash
B Solid Wire Solder
A B
Dim. A + Dim. B = Backlash
Procedure
Inspect the pump adapter plate at the same
i time the gear backlash is checked
6
Drain the gearbox oil
Remove the access cover and the pump
adapter plate to check primary and secondary
gear set backlash
Run a piece of solid wire solder through the
primary and secondary gear meshes and
measure the thickness of the two flat spots
made by the gear teeth surfaces with a
micrometer. If the primary gear mesh backlash
exceeds .030 in. or the secondary gear mesh
backlash exceeds .040 in., excessive gear
wear or bearing failure is indicated.
i Check the gear teeth for pitting or corrosive

wear at the same time the gear set backlash
is checked
TDS-11SA 6-9
Motor Housing
and Transmission
Bail and main body

Inspection
Wear allowances
Component Replace when
Bushing Inner diameter is less than 4.450 in.

Bail Pin Outer diameter is less than 4.125 in.
Bail
Yearly
Bushing
2 Places
Yearly
Main Body Cover

5 Years
Main Body
5 Years
Bail Pin
2 Places
Yearly
6-10 Varco Systems

Motor Housing
and Transmission
S-pipe
Inspection
Procedure
Unscrew the two nuts that hold the S-pipe in Wing Nut
place along with the six bolts that secure the
clamp to remove and inspect the S-pipe
Clean the bore of the S-pipe and inspect for Seal Ring
visible signs of pitting, corrosion, or erosion
Plug
Use a flashlight and mirror to visually inspect the Monthly
i bore of the S-pipe. A Bore-o-Scope is best for
inspection, if available. Pressure test to
rated working pressure
Remove and perform an ultrasonic inspection
on the S-pipe if visual inspection indicates
erosion or corrosion
Monthly
Check condition of the seals
Apply pipe dope to the threads before S-Pipe
re-installing Check for
visible signs of pitting,
corrosion, or erosion
(pitting or corrosion
should be no deeper
than 0.125 inch)
Clamp
6
Bolts
Seal Ring
Right-hand (inside of guard)

Wing Nut
configuration shown. Your S-pipe
configuration may vary.
TDS-11SA 6-11
Motor Housing
and Transmission
Upper mainshaft liner

Inspection
Procedure
Remove the wash pipe assembly
Check the upper mainshaft liner for erosion
caused by leaking wash pipe packing and
replace the liner if erosion is found
The 3.875 in. OD polypack seal must also be
i replaced whenever the upper stem liner is
replaced
Grease the polypack seal and clean the
mainshaft bore before re-installing
Make sure the O-ring of the seal is facing
down when the seal is installed on the liner Wash Pipe
Assembly
Monthly
Upper
Mainshaft Liner
Replace if erosion
is found during
inspection
Polypack
Seal
6
Polypack Seal
Replace OD polypack
seal when the upper
mainshaft liner is replaced
Main
Shaft
Upper
Mainshaft Liner
6-12 Varco Systems

Motor Housing
and Transmission
Washpipe assembly
Assembly
1. With the packing box upside down, assemble the packing
seals and spacers into the packing box using care to line up
the upper spacer slot with the dowel pin.
2. Hand pack all seals with multipurpose lithium-based or high

temperature moly-based grease using care not to grease the
outside diameter of the spacers.
3. Install the socket head dog nose screw, ensuring that the
screw nose is fully engaged in the groove of the lower spacer.
4. Install the grease fitting and turn the packing box upright.
5. Install the wash pipe into the packing box assembly (slotted
end up).
6. Install the wash pipe nut onto the wash pipe.
7. Grease the packing seal and install into the holding ring using
care not to grease the outside diameter of the holding ring.
8. Install the packing seal and holding ring over the slotted end
of the wash pipe.
9. Install the snap ring.
10. Install the upper and lower o-rings using grease to hold them
in place.
11. Compress the assembly to the length of the wash pipe.

6
Disassemble the washpipe packing in the reverse order of the
above procedure. Refer to the Washpipe Assembly Guide, P/N
128844.
TDS-11SA 6-13
Motor Housing
and Transmission
Washpipe assembly
Inspection
!
The wash pipe nut and
the packing box have
left-handed threads
Dowel Slide the

Pin wash pipe nut
and the packing box
together for installation
Hand pack all seals

with multipurpose
lithium-based or
high temperature
moly-based grease
completely filling
the void
6
Ensure that the nose of the
socket head dog nose screw
is fully engaged in the groove of
the lower spacer
Special Tools
3" Bore
Wash Pipe Wrench
30150084
Recommended for proper

tightening of the wash pipe
nut and packing box
6-14 Varco Systems

Motor Housing
and Transmission
Washpipe assembly
Inspection
O-Ring
Snap Ring
Holding Ring
Upper Spacer
Packing Seal
Daily 5 per set
Wash Pipe
Assembly Wash Pipe
Inspect for leaks Nut
Middle Spacer
Wash Pipe
Middle Spacer
Packing
Assembly Box 6
Straight Ext. Lower Spacer

Grease Fitting
Socket Head
Dog Nose Screw
O-Ring
Procedure
Visually inspect the wash pipe assembly for leaks
Replace any worn or damaged parts
Apply pipe dope to the threads before installing in
the Top Drive
TDS-11SA 6-15
Motor Housing
and Transmission
Upper bonnet seals (yearly)

Inspection
Procedure
Remove the bearing shield, the bearing retainer Bearing
cap screws, and the bearing retainer Retainer
Inspect the bearing isolator, the oil seal, and the Cap Screw
retainer o-ring for wear 6 Places
Replace any worn or damaged parts
i Align the shims so that the bearing lube

tube bore is not blocked
Bearing
Shield
Bearing
Retainer
Lube Tube
Bearing
Oil Isolator Bearing
Seal Retainer Lube Tube O-Ring
Cap Screw 2 Places
Bearing 6 Places
Shield
Bearing
Retainer
Retainer Yearly
O-Ring Retainer O-Ring
Yearly
Bearing Isolator
6
Yearly
Lube Tube Oil Seal
Shims
Hand pack the

void with grease
6-16 Varco Systems

Motor Housing
and Transmission
Mainshaft
Inspection
Wear allowances
Stem Grooves Groove width exceeds 0.650 in.

Load Collar Groove width exceeds 0.620 in.
Grooves
Stem
5 Years
Split Load Collar

Radial Grooves
Inspect for groove wear 5 Years
and pitting
0.650 Yearly
max Radial Grooves
Inspect for groove wear
and pitting
Yearly 6
0.620
max
Retainer Ring
TDS-11SA 6-17
Motor Housing
and Transmission
Mainshaft
Inspecting mainshaft end play (yearly)
Dial
Indicator
Mainshaft Bearing Retainer

Check for Cap Screw
axial movement 6 Places
Yearly
Shims
Bearing
Retainer
Procedure
6 Remove the washpipe packing
Check the mainshaft axial movement by
applying an upward force to the mainshaft and
measuring the amount of axial movement with a
dial indicator
If axial shaft movement is not .001 in. to .002 in.,
remove the bearing retainer and adjust the
number of shims under the bearing retainer as
required to allow .001 in. to .002 in. of axial
shaft movement (end play) with the bearing
retainer capscrews tightened to 250-270 ft lb
6-18 Varco Systems

Motor Housing
and Transmission
Blower motor assemblies (monthly)

Inspection
Bolts
Drip Shield 4 Places,
lock wire
in pairs
Motor
Fan Cover
Bolts
4 Places,
lock wire
in pairs
Motor Fan
Bolts
6 Places
Top Bearing
Housing
Monthly
Check for
loose bolts
Procedure
Check bolts for tightness
Tighten as needed
Check motor cables for damage
Megger motors yearly
TDS-11SA 6-19
Motor Housing
and Transmission
Motor brakes (monthly)

Inspection
Procedure
Remove the brake housing covers to access
the drilling motor brakes
Inspect the brake pads for wear, and replace
the pads if worn below the allowable lining wear
limit given by the manufacturer
If the brake pads are wearing unevenly,
adjust the pads by adjusting the bolts on the Calipers and Pads
brake calipers Check pads for wear
Inspect the brake hydraulic lines for leaks Monthly
Never check for hydraulic leaks

with your hands. Oil under Brake Disc
pressure escaping from a hole
can be nearly invisible and can
penetrate skin causing serious
injury. Always check for leaks
with a piece of wood or
cardboard.
Caliper
Mounting Steel
6 Bolts Plate
0.09 in.
Min.
Adjust
Caliper Brake Equal

Mounting Pads Gap
Bracket
6-20 Varco Systems

Motor Housing
and Transmission
AC drilling motors (weekly)

Inspection
Procedure
Check for missing or damaged louvers
Check screens for contamination
Check motor leads for damage
Check for missing lockwire
Megger motors yearly
Weekly
Motor Leads
Check for damage
Weekly
Louvers
Check for damage
Weekly
Screen
Check for contamination
TDS-11SA 6-21
Motor Housing
and Transmission
Transmission disassembly/assembly
Stem Sleeve
Taper Roller
Main Body Cover Bearing
Cap Screw Dowel Pin

Upper Spray Nozzles
Dowel Lock
Pin Washer
Upper Compound Bull Gear
Roller Bearing
Internal
Retaining Ring
Upper Stem
Compound Gear Liner
Internal
Retaining Ring Poly Pack
Seal
Oil
Spacer Ring Gallery
O-Ring
Lower Compound
Roller Bearing
Bearing Lock Washer

Main Shaft
Stem
Internal
Locknut Retainer
Main Body O-Ring
Tapered Roller
6 Thrust Bearing
Main Body
Main Shaft
Sleeve
Lower Main Main Lower

Bearing Roller Bearing
Wear Sleeve
Lube Plate
Oil Assembly Bearing
Lock Washer Retainer
Cap Screw
6-22 Varco Systems

Motor Housing
and Transmission
Nondestructive Examination (NDE)

Yearly (or after approximately 3,000 operating hours), perform a
Nondestructive Examination (NDE) of all critical load path items.
NDE inspection includes visual examination, dye penetrant
examination, magnetic particle inspection, ultrasonic inspection, x-
ray examination, and other methods of nondestructive testing for
metallurgical integrity.
Visual inspection
Use calipers on a regular basis to measure the amount of wear on
the elevator link eyes. Compare the measurements with the Wear
Chart to determine the current strength of the elevator links. The
capacity of the links equals the capacity of the weakest link.
TDS-11SA 6-23
Motor Housing
and Transmission

Magnetic Particle Inspection (MPI)
Once a year, or every 3,000 operating hours, Varco recommends
performing a Magnetic Particle Inspection (MPI) of the exposed
surfaces of all load carrying components to reveal any fatigue or
crack indications. Any indications found are a potential cause for
replacing the suspect component. Round bottom pits and erosion
are acceptable as long as the defect is less than 1/16 in. deep.
Larger defects or any crack indications are cause for replacing the
suspect component.
After approximately five years, or 15,000 operating hours,

depending on the severity of operating conditions, Varco
recommends performing a MPI of all load carrying components over
their entire surface (including internal bores) to reveal any fatigue or
suspect component. The load carrying components are:
❏ Mainshaft (lower portion)
❏ Bail
❏ Landing collar (yearly)
❏ Upper and lower IBOP
❏ Link adapter
❏ Saver, crossover, and spacer subs

6
❏ Power subs
❏ Power swivels
❏ Elevator links
Details on MPI procedures are in the following publications:
I.A.D.C. Drilling Manual, 9th Edition
ASTM A-275 Std. Method for Magnetic Particle Inspection of

Steel Forgings
ASTM E-709 Std. Recommended Practice for Magnetic Particle

Inspection
6-24 Varco Systems

Motor Housing
and Transmission

Ultrasonic Inspection
In addition to the MPI, Varco also recommends performing an
Ultrasonic Inspection of the above components to detect any
erosion of the inside diameter. Any erosion reduces the load-
carrying capability of the part. Any subsurface irregularity can also
compromise a component’s integrity.
Details on Ultrasonic Inspection procedures are in the
publication:
ASTM A-388 Std. Practice for Ultrasonic Examination of Heavy
Steel Forgings.
Safety valve inspection procedures (IBOP)

Upper and lower IBOP valves, because of their internal grooves and
shoulders, are particularly susceptible to corrosion fatigue cracking.
These internal diameter changes act as stress risers for bending
and tensile loads. It is especially important to properly inspect the
IBOP valves on a frequent basis. Read and use the IBOP valve
inspection procedures described in the IBOP Service Manual
(SM00611).
TDS-11SA 6-25
TDS Training Manual

Montrose Scotland
AC TOP DRIVE
Section 7
PH50 Pipehandler
AC Electrical
PH-50 Pipehandler
PH-50 Pipehandler
PH-50 Pipehandler illustrated index .................. 7-2

Inspection schedule ........................................... 7-3 1
Precautions ......................................................... 7-4
Elevator links ...................................................... 7-5
Inspection ...................................................................... 7-6 2
Link tilt ................................................................ 7-8
Inspection ...................................................................... 7-9
Torque wrench assembly ................................... 7-10 3
Clamp cylinder body disassembly/assembly ................. 7-10
Inspecting the clamp cylinder body ............................... 7-14
Inspecting the stabilizer ................................................. 7-15
Inspecting the IBOP actuator cylinder and yoke ............ 7-17 4
Well control system ............................................ 7-19

Tool joint locks disassembly/assembly .......................... 7-19
Inspecting the tool joint locks......................................... 7-20
5
Inspecting the IBOP valves and saver subs .................. 7-21
Shot pin assembly .............................................. 7-22
Inspection ...................................................................... 7-23
6
Rotating link adapter/load stem ......................... 7-24
Removing the pipehandler and link tilt from the top drive
(while in mast) ............................................................... 7-24
Disassembling the link tilt assembly .............................. 7-24
77
Assembling the link adapter .......................................... 7-26
Assembling the link adapter to the top drive
(while in mast) ............................................................... 7-27
Wireline adapter ................................................. 7-28
8
Inspection ...................................................................... 7-28
Nondestructive Examination (NDE) ................... 7-29
Visual inspection ........................................................... 7-29
Magnetic Particle Inspection (MPI) ................................ 7-30
9
Ultrasonic Inspection ..................................................... 7-31
Safety valve inspection procedures (IBOP) ................... 7-31
TDS-11SA
TDS-11SA 7-1
PH-50 Pipehandler
PH-50 Pipehandler illustrated index
Rotating Link
Adapter
Page 7-25
Link Tilt
Page 7-9
IBOP Actuator
Yoke and Cylinder
Page 7-19
Stabilizer
Page 7-16
Well Control System

Page 7-20
Clamp Cylinder
Body
Page 7-11
7
Stabbing Guide
Page 7-14
Drill Pipe Elevator

For pipehandler lubrication and Elevator Links
see Page 3-13 Page 7-6
7-2 Varco Systems

PH-50 Pipehandler
Inspection schedule
Each Use Page Reference
Check wireline adapter sheaves for excessive wear or damage See page 7-30
Daily
Check for missing lockwire and cotter pins
Check for loose or broken parts and leaks
Check for damaged hoses and fittings
Check clamp cylinder gate pins and retainer bolts See page 7-11
Check tong dies for wear See page 7-14
Check upper and lower IBOP valves for proper operation See page 7-21
Weekly
Check link tilt clamps for position and tightness See page 7-9
Check stabbing guide and flippers for damage and wear See page 7-11
Check front and rear stabilizers for wear See page 7-16
Check IBOP actuator cylinder for leaks, tighten fittings See page 7-17
Check IBOP actuator rollers for wear or excessive play See page 7-19
Check tool joint locks for loose bolts See page 7-20
Check upper and lower (if equipped) IBOPs for damage See page 7-22
Monthly
Check elevator link eyes for wear See page 7-8
Check link tilt bushings for wear See page 7-9
Check link tilt actuator cylinder clevis pins for wear See page 7-19
Check IBOP actuator yoke for wear or excessive play See page 7-19
Check shot pin assembly for wear or damage See page 7-23
7
Yearly
Check piston ring for pitting and chipping See page 7-25
Check stem for pitting, grooves and chipping See page 7-25
Replace GLYD rings, o-rings and bushings on rotating link adapter See page 7-25
5 Years
MPI Inspection See page 7-31
TDS-11SA 7-3
PH-50 Pipehandler
Precautions
To avoid serious injury or death, read and understand the following
warnings before performing inspection and maintenance
procedures:
Properly lockout the main power source before

performing lubrication, inspection, or replacement
procedures, unless specifically noted in this manual.
Wear protective glasses to prevent eye injuries from

fluids under pressure, as well as other hazards.
Do not attempt any adjustments while the machine is

moving.
Use caution when draining lubricant. It can be hot.
Never check for hydraulic leaks with your hands. Oil

under pressure escaping from a hole can be nearly
invisible and can penetrate skin causing serious injury.
Always check for leaks with a piece of wood or
cardboard and always wear protective eyewear when
working on hydraulic components.
Always discharge the three hydro pneumatic

accumulators before performing repairs on the
hydraulic system.
7
Do not attempt repairs you do not understand.
Read and understand all safety precautions and

warnings before performing maintenance procedures.
7-4 Varco Systems

PH-50 Pipehandler
Elevator links
1. Disconnect and remove the drill pipe elevator from the
elevator links.
2. Using the Varco Driller’s Console (VDC), rotate the

pipehandler 90° to position one of the elevator links directly
below the front of the motor guard.
3. Remove the catch link bolt from the catch link.
4. Remove the clevis pin from the link, which connects the link tilt
to the elevator link.
5. Using the sling, hoist the elevator link away from the
pipehandler.
6. Rotate the pipehandler 180°, repeat the procedure to remove

the other elevator link.
TDS-11SA 7-5
PH-50 Pipehandler
Elevator links
Inspection
Recess in
Motor Guard
Rear
2
Lift and
remove
Link Tilt
Catch Link Pin Upper

Catch Link 950 lb
(431 kg)
Elevator Link
Front
26"
(635mm)
P
LE RO IPE
FT T
AT HA
Typical
E ND
L
RIG LI ER
HT NK
TIL
TF
LO
AT
TO
RQ
PU UE
Link
SH WR
& H EN
OL CH
D
DR LINK
ILL O TI
FF LT
TIL
T
Pipehandler
Rotate Switch
Weekly Clevis
Pin
Link Clamps
Inspect for position
1 and tightness
7
Rotate
PIP
EH
AN
DL
ER
BR
AK
E
IBO
P
EM
ER TO
G
ST EN RQ
UE
OP CY
Varco TO
RQ
Monthly
UE
Driller’s Console Elevator Link Eyes

RP
M
Inspect for wear (see table)
7-6 Varco Systems

PH-50 Pipehandler
Elevator links
Inspection (Varco links only)
Wear Chart - Forged Links
Upper C
Upper Eye Lower Eye Capacity (per set) C
Eye
Dimension (C) Dimension (A) in Tons (Hook)
B = 3 1/2 in., 350-Ton
5 inches 2 3/4 inches 350
4 13/16 inches 2 9/16 inches 300

4 5/8 inches 2 3/8 inches 225
7 7/16 inches 2 3/16 inches 175
B = 4 1/2 in., 500-Ton B
6 inches 3 1/2 inches 500

5 1/2 inches 3 inches 325
B
B = 6 1/4 in., 750-Ton

A
7 inches 7 inches 225
Lower
To determine the strength of worn links, measure (with calipers) Eye
the amount of eye wear and compare the measurements (Elevator)
with the above Wear Chart to find the current capacity.
The capacity of the set of links is determined by the weakest link.
A
TDS-11SA 7-7
PH-50 Pipehandler
Link tilt
1. Shutdown the power and bleed the system (turn the valve on
the bottom of the gearcase to the SHUT DOWN position).
2. Disconnect the hydraulic lines from the link tilt cylinders and
cap all connections.
3. Unpin and remove the link tilt cylinders.
4. Unpin and remove the link tilt crank.
i Use the recommended spanner wrench to remove the rod gland

seal.
7-8 Varco Systems

PH-50 Pipehandler
Link tilt
Inspection
Pins
Inspect for wear
replace as needed
Monthly
Monthly
Bushings
Inspect for wear
replace as needed
Monthly
Link Tilt
Actuator Cylinders
Inspect the hydraulic
connections for leaks
Link Tilt
Monthly
Bushings
Inspect for wear
replace as needed
7
Wear allowances
Pins Wear exceeds .06 in. on diameter
Bushings Metal backing is visible through the lining
End cap of the metal backing exceeds .04 in. wear
Bushings should be pressed in using the mating pin

i as an installation mandrel.
TDS-11SA 7-9
PH-50 Pipehandler
Torque wrench assembly

Clamp cylinder body disassembly/assembly
1. Shutdown power and bleed the system (turn the valve on the
bottom of the gearcase to the SHUT DOWN position).
2. Disconnect the hydraulic lines on the clamp cylinder body and

cap all connections.
3. Support the clamp cylinder body.
4. Remove the two hex-head capscrews and lockwashers that

hold the end cap in place.
5. Remove the end cap, spring spacer, spring sleeve, and spring.
6. Slowly lower the clamp cylinder body off the torque wrench
frame and move it to a suitable work area.
7. Remove the 16 hex-head screws and lockwashers that hold

the wear bushings on the clamp cylinder body.
8. Remove the four wear bushings, and replace the wear

bushings as necessary.
9. Remove the two hinge pin retainer hex-head screws.
10. Swing out the two hinge pin retainers.
11. Remove the two hinge pins.
12. Remove the gate, front jaw, front stabilizer, and front stabbing
guide.
13. Remove the two socket-head capscrews and hi-collar washers

from the front jaw.
14. Remove the front jaw from the gate.

7 15. Repeat steps 11 and 12 for the rear jaw.
16. Push the cylinder head in enough to relieve the load on the
cylinder head ring. Remove the cylinder head ring. Use care in
this operation.
7-10 Varco Systems

PH-50 Pipehandler

17. Slowly pull out the cylinder head using the threaded holes.
Remove and discard the piston seal.
18. Carefully push the piston out of the body. Remove and discard
the piston seal.
19. Remove the wiper rod and rod seal from the body. Discard the
seals.
20. Clean the piston, cylinder head, and the body. Clean and lightly
lubricate the new seals and seal surfaces prior to reassembly.
i Use recommended spanner wrench to remove the rod gland seal.
Assembly is performed in reverse order of disassembly.
TDS-11SA 7-11
PH-50 Pipehandler
RUN
SHUTDOWN
RIG-UP
Hydraulic
COUNTERBALANCE MODE
Manifold
Rig-up/Run/
Shutdown Valve
Shown in SHUTDOWN
position
(Shown with
link tilt removed)
Torque Arrestor
Spring
Spring Spacer
Spring Shims
Adjust to ensure
the torque wrench
clamps fully onto
the saver sub Support clamp
cylinder body
before removing
7 end cap.
End Cap
Clamp Cylinder
Body
7-12 Varco Systems

PH-50 Pipehandler

Manifold
Rear Stabilizer
Front Stabilizer
Hinge Pin Spring
Retainer
Cylinder Head Ring Hex Head
Screws
Clamp Cylinder
Body
Body Seals
Cylinder Head
Piston Seals Jaw Assembly

Tong Dies
Piston
Gate
Wear Bushing
Socket Head
Cap Screws
Hinge Pin
Rear Stabbing Guide Front Stabbing Guide
Stabilizer
Retaining Plate
Spring
TDS-11SA 7-13
PH-50 Pipehandler

Inspecting the clamp cylinder body
Tugger
Line
V
A
R
C
O
P
H
5
0
Front and Rear

Stabilizers
Inspect for wear
Weekly
Tong Dies
Inspect for
RCO
excessive wear
VA
Daily
Stabbing Guide
Inspect for damage
7 Weekly
Clamp
Cylinder Gate
(Shown open) Weekly
Flippers
Inspect for damage
and excessive wear
Swing Clear
Wear allowances
Stabilizer Wear exceeds 1/8 in.

Flippers Wear exceeds 1/8 in.
7-14 Varco Systems

PH-50 Pipehandler

Inspecting the stabilizer
Remove the two bolts (with slotted nuts and cotter pins) that hold
the front stabilizer. Check the springs for damage and replace if
needed. Pack spring cavities with grease and reassemble. Be sure
all safety wire, cotter pins, and capscrews are tight, and tighten or
replace as necessary.
TDS-11SA 7-15
PH-50 Pipehandler

Inspecting the stabilizer
Stabilizer Springs Monthly

Check for damage,
replace as necessary. Stabilizers
Inspect for wear.
Monthly Replace if wear exceeds
1/8 in.
Cotter Pin
7-16 Varco Systems

PH-50 Pipehandler

Inspecting the IBOP actuator cylinder and yoke
Weekly
IBOP
Actuator Cylinder
Check for leaks,
Daily tighten fittings
Hoses
Replace if worn Monthly
or damaged
Pins and Bushings
Check for wear
or excessive play
Monthly
IBOP Weekly
Actuator Yoke IBOP
Check pins and Actuator Yoke
bushings for wear Check cam followers for wear
or excessive play or excessive play
For IBOP Actuator Yoke lubrication

see Page 3-13 7
Wear allowances
Pins Wear exceeds .03 in. on diameter

Bushings Metal backing is visible through the lining
End cap of the metal backing exceeds .04 in. wear
Bushings should be pressed in using the mating pin

i as an installation mandrel.
TDS-11SA 7-17
PH-50 Pipehandler

Inspecting the IBOP actuator cylinder and yoke
Disassembling the IBOP actuator cylinder and
yoke
1. Shutdown the power and bleed the system (turn the valve on the
bottom of the gearcase to the SHUT DOWN position).
2. Remove one gate hinge pin, open the gate, and pull back the
torque wrench assembly.
3. Disconnect the hydraulic lines from the IBOP actuator cylinder

and cap all connections.
4. Unpin and remove the IBOP actuator cylinder and yoke.
5. Replace the hydraulic lines as necessary.
6. Check for cylinder leaks.
7-18 Varco Systems

PH-50 Pipehandler
Well control system

Tool joint locks disassembly/assembly
! Do not reuse locking screws.
1. Lubricate the locking screw threads, screw head bearing area,

and the tapers of the inner rings with molybdenum disulfide
grease, such as Molykote Gn paste.
2. Make sure the save sub, IBOPs, and main shaft are free of
“high spots”, such as tong marks. If high spots exist, remove
with file or light grinding.
3. Slide the tool joint lock over the main shaft, IBOP valves, and
saver sub.
4. Clean the IBOP valves, main shaft, and saver sub surfaces
thoroughly. Make sure these surfaces are smooth and free of
grease, oil, and pipe dope.
5. Locate the tool joint lock symmetrically at each joint.
! Never tighten locking screws before the tool joint lock is at the
correct location, otherwise it will not slide freely.
6. Take any three or four locking screws equally spaced and

tighten them to establish parallel or perpendicular position of
the tool joint lock collars relative to the main shaft, IBOP
valves, and saver sub respectively. This properly seats the
collars on the taper of the inner ring and aligns the collars.
7. Using a torque wrench, tighten all locking screws gradually in

either a clockwise or counterclockwise sequence (not in a
7
diametrically opposite sequence). Continue tightening all of
the screws until they reach 185±5 ft lb.
8. Make sure no screw turns any more. The gap between the tool
joint collars should be as equal as possible all the way around.
9. Safety wire all screws.
TDS-11SA 7-19
PH-50 Pipehandler
Well control system

Inspecting the tool joint locks
Tool Joint Lock to be Equally
Spaced on Upper IBOP and
Main Stem Joint Connection
1.4" Tool Joint

Shoulder
1.4"
Remove O-Ring Tapered

and Look through Inner Ring
this Space and
Split on Inner Ring
Tool Joint Lock to
be Offset on Upper
and Lower IBOP
Joint Connection
Tool Joint
1.0" Shoulder
I.D. Groove
First Line Up this Point with the
Tool Joint Shoulder. Then Move
Inner Ring Down 3/8" with the
Outer Assembly. Replace O-Ring
Daily
Tool Joint
Locks
7 1.4" Tool Joint Inspect for loose bolts.
Shoulder Repair or replace if necessary.
Torque to 185±5 ft lb.
1.4"
Tool Joint Lock to be Equally
Spaced on Lower IBOP and
Saver Sub Joint Connection
Removing the Tool Joint Locks

Gradually release the locking screws all the way around. Initially release each screw
about a quarter of a turn, avoid tilting and jamming the collars. Do not remove the
screws completely at this time, otherwise the collars may spring off.
Remove any rust formed or dirt collected adjacent to the tool joint lock. Once the screws
are loose, remove the tool joint lock from the saver sub, IBOP valves, and main shaft.
7-20 Varco Systems

PH-50 Pipehandler
Well control system

Inspecting the IBOP valves and saver subs
Wear allowances
Saver Sub Threads have been recut to a minimum

shoulder-to-shoulder length of 5 in.
i See the IBOP Service Manual for IBOP

disassembly/assembly and servicing
information.
Weekly Daily
Upper IBOP Valve
(Remote) Check for
Inspect for damage proper operation
and pressure test
for leaks
Weekly
IBOP Crank
(Remote)
Inspect for damage
Weekly Daily 7
Lower IBOP Valve
(Manual) Check for
(Optional) proper operation
Inspect for damage and pressure test
for leaks
5 Years
Upper and Lower IBOP
TDS-11SA 7-21
PH-50 Pipehandler
Shot pin assembly

1. Disconnect the hydraulic and electrical lines.
2. Remove the capscrews that attach the shot pin assembly to

the main body.
3. Remove the capscrew and lockwasher holding the shot pin

cover in place
4. Remove the shot pin components as shown in the illustration

on Page 7-24 (end cap, o-rings, rod seal assembly, shot pin)
5. Inspect the shot pin bearing and press the bearing out of the
shot pin mounting bracket if the bearing is scored or
damaged.
6. Remove the capscrew and lockwasher that hold the pinion

gear in place, and remove the gear.
7. Remove the capscrews and lockwashers that hold the

hydraulic motor in place and remove the motor.
Inspect the disassemble parts and replace any worn or damaged

parts. Assemble the shot pin in the reverse order of disassembly.
7-22 Varco Systems

PH-50 Pipehandler
Shot pin assembly

Inspection
Shot Pin
Assembly
Shot Pin Base
Dowel Pin
Rod Seal
Hydraulic
Assembly
Shot Pin Motor
Remove burrs
Rod Seal
Assembly
Dual Port
Shot Pin Manifold
Sleeve
O-ring
Shot Pin Bushing
Shot Pin Cap

Pinion Gear 7
Shot Pin
Cover
Wear allowances
Shot Pin Outer diameter is less than 1.375 in.

Shot Pin Sleeve Inner diameter is greater than 1.510 in.
Shot Pin Bushing Inner diameter is greater than 1.475 in.
TDS-11SA 7-23
PH-50 Pipehandler
Rotating link adapter/load stem

Removing the pipehandler and link tilt from the top drive
(while in mast)
1. Drain the oil from the gearbox.
2. Disconnect and cap all tubing, remove the shot pin assembly
and the landing collar.
3. Build a support over well center to support the weight of the

link adapter.
4. Lower the top drive to the support built in Step 3.
5. Remove the bolts that attach the load stem to the main body.
6. Raise the top drive slowly to separate the link adapter from
the main body.
7. Move the link adapter assembly to a clean, safe work area.
8. Orient the assembly with the stem flange up and block the
entire assembly so that it is secure in this position.
Disassembling the link tilt assembly
1. Attach a 3-point sling to the stem and pull the stem out of the
link adapter.
2. Turn the stem over and place it on its flange.
! Protect the internal surfaces of the rotating link adapter and

the surfaces of the drive stem when separating the two
components. When removing the rotating link adapter from the
stem, carefully tap with a mallet. There can be misalignment
between the two bores when raising the drive stem and gear
assembly.
7
i The piston ring is assembled with a light press fit. Provide a

support under the gear so that it does not drop when it breaks
loose.
3. Remove and discard all rotary seals, O-rings, thrust ring, and
the wear bushings from inside the rotating link adapter and
gear inside dimension.
4. Remove and discard the stem flange O-rings and stem bore
shaft seals.
7-24 Varco Systems

PH-50 Pipehandler

Inspecting the rotating link adapter
Rotary GLYD Ring

Remove, discard and replace
Yearly
Rotary Link Adaptor

O-Ring
Remove, discard
and replace
Yearly
Thrust Ring
Retainer Ring Remove, discard and replace
Yearly
Turcite Bushing
Remove, discard and replace
O-Ring
Yearly
Rotary GLYD Ring
Wiper Seal
Yearly
Piston Ring
Inspect for pitting
Rotating Link and chipped plating
Adapter Gear (Heat to 175-200° F
to install)
Wear allowances
Component Replace when Yearly
Thrust Ring Thickness is less than 0.105 in. Stem

Inspect for pitting,
Turcite Thickness is less than 0.112 in. grooves and chipped plating 7
Bushing
Index Mark Stem O-Ring

Indicates front of stem Remove, discard and replace
Yearly
Level Work Surface
TDS-11SA 7-25
PH-50 Pipehandler

Assembling the link adapter
1. Orient the stem so the drive stem flange is down on a suitably
protected surface.
2. Install the gear with its rotating seal and wiper in place.
3. Install the O-ring for the piston ring.
4. Install the piston ring by tapping on it lightly with a mallet to

press it into place (Heat to 220-250°)
5. Install the retainer ring.
6. Install all of the rotary seals on the rotating link adapter, and
an O-ring on the top surface.
7. Install the two wear bushings and the thrust ring in the rotating
link adapter.
8. Rest the rotating link adapter on its bottom surface.
9. Clean and then lubricate (with hydraulic oil) the sealing

surface of the stem and the inside diameter of the rotating link
adapter.
10. Attach three lifting slings symmetrically through the holes on

the top of the stem flange and slowly lower the assembly into
the rotating link adapter body. Hammering with a large plastic
mallet is an aid when assembing the stem to the link adapter.
i Make sure the seals do not twist in the grooves.
11. Install the gear onto the link adapter and install the bolts.
12. Pressure test each port at 1,000 psi and inspect for leaks at
7
the adjacent ports.
13. Grease all lubrication points on the assembly.
14. Inspect the lower gearbox seal (located inside the stem
flange), and replace as necessary.
7-26 Varco Systems

PH-50 Pipehandler

Assembling the link adapter to the top drive (while in
mast)
1. Check the condition of the manshaft wear ring and replace if
there is any evidence of grooving.
2. Place the rotating link adapter assembly back on the support

built over well center, orienting the assembly so that the stem
flange is up, and so that the idex mark faces forward.
3. Carefully lower the top drive to engage the mainshaft in the

stem bore and then the stem flange pilot diameter is in the main
body bore.
4. Install the flange bolts.
5. Install the link tilt cylinders, pin, and secure in place.
6. Install the link tilt crank and pin, and secure in place.
7 Install all hose assemblies.
8. Install tubing.
9. Install the shot pin assembly.
10. Fill the gearcase with gear oil (see Lubrication).
11. Check and fill the hydraulic oil as necessary.
12. Turn on the top drive and perform all pipehandler functions
several times, checking for proper function and any leaks.
13. Re-check the hydraulic oil level and fill as necessary.
! Always install a new mainshaft seal and use care not to

damage the seal or the case. 7
i A light coating of grease applied to the O-ring helps in installing the

rotating link adapter assembly into the main body.
! Always install a new drive stem O-ring and use care not to
damage the O-ring or the case.
TDS-11SA 7-27
PH-50 Pipehandler
Wireline adapter
Inspection
i
Inspect the condition of the
sheaves before and after each use.
Each Use
Sheaves
Replace or repair damaged
parts as necessary
7-28 Varco Systems

PH-50 Pipehandler

Yearly (or after approximately 3,000 operating hours), perform a
Nondestructive Examination (NDE) of all critical load path items.
NDE inspection includes visual examination, dye penetrant
examination, magnetic particle inspection, ultrasonic inspection, x-
ray examination, and other methods of nondestructive testing for
metallurgical integrity.
Visual inspection
Use calipers on a regular basis to measure the amount of wear on
the elevator link eyes. Compare the measurements with the Wear
Chart to determine the current strength of the elevator links. The
capacity of the links equals the capacity of the weakest link.
TDS-11SA 7-29
PH-50 Pipehandler

Magnetic Particle Inspection (MPI)
Once a year, or every 3,000 operating hours, Varco recommends
performing a Magnetic Particle Inspection (MPI) of the exposed
surfaces of all load carrying components to reveal any fatigue or
suspect component.
After approximately five years, or 15,000 operating hours,

depending on the severity of operating conditions, Varco
recommends performing a MPI of all load carrying components over
their entire surface (including internal bores) to reveal any fatigue or
suspect component. The load carrying components are:
❏ Mainshaft (lower portion)
❏ Bail
❏ Landing collar (yearly)
❏ Upper and lower IBOP
❏ Link adapter
❏ Saver, crossover, and spacer subs
❏ Power subs
❏ Power swivels
❏ Elevator links
7
Details on MPI procedures are in the following publications:
I.A.D.C. Drilling Manual, 9th Edition
ASTM A-275 Std. Method for Magnetic Particle Inspection of

Steel Forgings
ASTM E-709 Std. Recommended Practice for Magnetic Particle

Inspection
7-30 Varco Systems

PH-50 Pipehandler

Ultrasonic Inspection
In addition to the MPI, Varco also recommends performing an
Ultrasonic Inspection of the above components to detect any
erosion of the inside diameter. Any erosion reduces the load-
carrying capability of the part. Any subsurface irregularity can also
compromise a component’s integrity.
Details on Ultrasonic Inspection procedures are in the
publication:
ASTM A-388 Std. Practice for Ultrasonic Examination of Heavy
Steel Forgings.
Safety valve inspection procedures (IBOP)

Upper and lower IBOP valves, because of their internal grooves and
shoulders, are particularly susceptible to corrosion fatigue cracking.
These internal diameter changes act as stress risers for bending
and tensile loads. It is especially important to properly inspect the
IBOP valves on a frequent basis. Read and use the IBOP valve
inspection procedures described in the IBOP Service Manual
(SM00611).
TDS-11SA 7-31
TDS Training Manual

Montrose Scotland
AC TOP DRIVE
Section 8
Hydraulic System
AC Electrical
Hydraulic System
Hydraulic system ................................................ 8-2

Illustrated index ................................................. 8-3 1
Hydraulic system diagram.................................. 8-4
Inspection ........................................................... 8-5
Precautions ................................................................... 8-5
Maintenance schedule .................................................. 8-7 2
Hydraulic fluid level and filter ......................................... 8-8
Adding the hydraulic fluid .............................................. 8-9
Draining the hydraulic fluid ............................................ 8-10
Hydraulic reservoir bladder (yearly) ............................... 8-11 3
Heat exchanger ............................................................. 8-12
Using the hydraulic system test ports ............................ 8-13
Precharging the accumulators ....................................... 8-14
IBOP timing circuit ......................................................... 8-15 4
IBOP and oil pressure switch ........................................ 8-16
Setting up the circuits ........................................ 8-17
Hydraulic pumps and unloading circuit .......................... 8-17
Fixed displacement (lube) and variable displacement 5
pumps ............................................................................ 8-18
Counterbalance circuit and stand-jump circuit ............... 8-22
AC motor brake circuit ................................................... 8-26
Shot pin circuit ............................................................... 8-27 6
Link tilt cylinder circuit.................................................... 8-29
Rotating link adapter hydraulic motor relief circuit ......... 8-30
Troubleshooting .................................................. 8-31
HPU and reservoir bladder ............................................ 8-31 7
Counterbalance and stand jump.................................... 8-33
Stand jump testing ......................................................... 8-34
Counterbalance and stand jump schematic diagram .... 8-36
Troubleshooting the brakes ........................................... 8-37
8
Shot pin cylinder and clamp cylinder ............................. 8-39
Link tilt cylinders ............................................................ 8-41
Gearbox lubrication hydraulic system ............................ 8-43
Rotating link adapter motor schematic diagram ............ 8-46
9
IBOP actuator schematic diagram ................................. 8-47
Hydraulic schematic symbols ............................ 8-48
TDS-11SA
Hydraulic System
Hydraulic system
The hydraulic control system is a completely self-contained,
onboard system. A 10-horse power, 1800 rpm, AC motor, drives
two hydraulic pumps and powers the hydraulic system. A fixed
displacement pump drives the lube oil system motor. A variable
displacement pump provides hydraulic power for the AC motor
brakes, powered rotating head, remote actuated IBOP, pipe backup
clamp cylinder, link tilt, and counterbalance system. Three hydro-
pneumatic accumulators are located on the main body.
The hydraulic manifold attaches to the main body and contains

solenoid, pressure and flow control valves.
A sealed stainless steel reservoir supplies hydraulic oil, eliminating

the need for draining and refilling during normal rig moves. The
reservoir is mounted between the AC drilling motors and is
equipped with strainers and an oil level sight gauge.
8-2 Varco Systems

Hydraulic System
Illustrated index
Specifications
Pump Motor 10 hp, 1,800 rpm, AC motor

Reservoir Capacity 25 gal
Hydraulic Oil Filter

Page 8-8 Counterbalance
Manifold
Page 8-22
Counterbalance
Accumulator
Page 8-14 Main Hydraulic
Manifold
Upper IBOP Time- Page 8-13
Delay Accumulator
Page 8-15
Link Tilt
Hydraulic Oil Fill Manifold
Page 8-9 Page 8-29
Oil Pressure Link Tilt

Switch Cylinders
Page 8-16 Page 8-29 Counterbalance
Cylinders
System Page 8-22
Accumulator
Page 8-14
Hydraulic Oil
IBOP Pressure Reservoir
Switch Front Page 8-11
Page 8-16
Rotating Head
Upper IBOP Motor and
Actuator Cylinder Rear
Shot Pin
Page 8-15 Assembly
Page 8-27
10 HP AC
Motor and
Front Pump Assembly
Page 8-17
Rear
8
TDS-11SA 8-3
Hydraulic System
Hydraulic system diagram

Drilling Upper IBOP Link Tilt Pipehandler
Motor Brake Actuator Cylinder Cylinders Clamp Cylinder
Link Tilt
Counterbalance Manifold
Accumulator
Rotating Head
(Elevator Positioner)
Counterbalance Shot Pin Rotating

Cylinders Cylinder Link Adapter
Lift
Rotating
Head Gearbox Lube
Motor Oil Distribution
Counterbalance
Manifold
Main Hydraulic Manifold
Low Speed Lube Oil

Hydraulic Pump
Motor
Upper IBOP System

Time-Delay Accumulator Gearbox Sump
Accumulator
M
Variable Fixed
10 HP A.C. Displacement Displacement
Motor Pump Pump (Mtr. Lube) Hydraulic
8
Reservoir
8-4 Varco Systems

Hydraulic System
Inspection
Precautions
To avoid serious injury or death, read and understand the following
warnings before performing inspection and maintenance
procedures:
Properly lockout the main power source before

performing lubrication, inspection, or replacement
procedures, unless specifically noted in this manual.
Wear protective glasses to prevent eye injuries from

fluids under pressure, as well as other hazards.
Do not attempt any adjustments while the machine is

moving.
Use caution when draining lubricant. It can be hot.
Never check for hydraulic leaks with your hands. Oil

under pressure escaping from a hole can be nearly
invisible and can penetrate skin causing serious injury.
Always check for leaks with a piece of wood or
cardboard and always wear protective eyewear when
working on hydraulic components.
Always discharge the three hydro pneumatic

accumulators before performing repairs on the
hydraulic system.
Do not attempt repairs you do not understand.
8
Read and understand all safety precautions and
warnings before performing maintenance procedures.
TDS-11SA 8-5
Hydraulic System
Inspection
Release all hydraulic oil pressure by bleeding

accumulators before disconnecting hydraulic lines.
Turn the counterbalance valve to shutdown mode to
bleed the hydraulic system. Hydraulic oil under
pressure can penetrate skin and cause serious injury.
Before opening the hydraulic system, thoroughly clean

work area, and maintain system cleanliness by
promptly capping all disconnected lines. Dirt is
extremely harmful to hydraulic system components
and can cause equipment failure and subsequent
injury to personnel.
! Use care when handling components to prevent nicking close

tolerance finishes.
Hydraulic fluid escaping under pressure can penetrate

the skin causing serious injury. Avoid injury by
discharging the three accumulators and relieving
pressure before disconnecting hydraulic lines. Always
search for hydraulic leaks with a piece of cardboard
or wood-not with your bare hands. Get immediate
medical attention for hydraulic fluid injuries. Fluid
injected into the skin must be surgically removed
within a few hours or gangrene may result. Do not
tighten hydraulic fittings while they are under
pressure.
Inspect the hydraulic system daily for leaks at fittings, damaged

hose covers, kinked or crushed hoses, hard or stiff hoses, and
damaged or corroded fittings. In addition, during the inspection,
tighten or replace any leaking port connections, and clean any dirt
buildup from hydraulic components.
8
Replace worn or damaged hydraulic system
components immediately.
Inspect the hydraulic fluid level in the hydraulic reservoir located

between the AC drilling motors daily. Inspect the hydraulic filter
located on the upper left AC drilling motor daily.
8-6 Varco Systems

Hydraulic System
Inspection
Maintenance schedule
Hydraulic system oil lubrication schedule
Replace hydraulic system filter (P/N 114416-1) 1 x every 3 months
Perform hydraulic system oil analysis 1 x every 6 months
Replace hydraulic fluid 1 x every year, or earlier based on oil analysis
Inspect hydraulic reservior bladder 1 x every year
Replace hydraulic reservior bladder 1 x every 2 years
Daily inspections
Description
Check the condition of the hydraulic filter indicator
Check hydraulic fluid levels
Check for hydraulic fluid leaks
Check the condition of hydraulic hoses
Recommended hydraulic lubricants

Oil Temperature Range
-15˚ to 75˚ C -10˚ to 85˚ C
(5˚ to 167˚ F) (14˚ to 185˚ F)
Manufacturer
Castrol Hyspin AWS-32 Hyspin AWS-46
Chevron AW Hyd oil 32 AW Hyd oil 46
Exxon Nuto H32 Nuto H46
Gulf Harmony 32AW Harmony 46AW
Mobil DTE 24 DTE 25
Shell Tellus 32 Tellus 46
Statoil Hydraway HMA 32 Hydraway HMA 46
Texaco Rando oil HD32 Rando oil HD46
Total Azolla ZS 32 Azolla ZS 46
Union Unax AW32 Unax AW46
8
Viscosity Index
ISO Viscosity Grade 32 46
TDS-11SA 8-7
Hydraulic System
Inspection
Hydraulic fluid level and filter
Cork Ball
(Level Indicator)
Daily
Red
“Pop-up” Sight
Dirt Alarm Glass
Hydraulic
Oil Sight
Gauge
Hydraulic
Oil Filter
Procedure
Check the red “pop-up” alarm on the hydraulic
filter daily
Replace the filter (Varco P/N 114416)if the
indicator has popped up or as recommended
8
Use care to prevent contamination from
entering the hydraulic system during
maintenance activities
8-8 Varco Systems

Hydraulic System
Inspection
Adding the hydraulic fluid
Specifications
Reservoir Capacity 25 gal
Procedure
Cork Ball
Turn the TDS-11SA off (Level Indicator)
Ensure that the area is clean prior to adding
hydraulic fluid
Remove dust plug from the male quick
disconnect at the TDS-11SA hydraulic oil fill
Remove dust plug from the female quick
disconnect on the lubrication kit
Connect the two fittings and pump fluid until
the level reaches the middle of the sight Sight
glass as showm Glass
See Lube Schedule for specifications
Hydraulic
After adding fluid, replace the dust plugs Oil Sight
Gauge
Hydraulic Oil Fill

Male Quick Disconnect
Hydraulic
Oil Fill
Female
Quick
Disconnect
Hydraulic
Lubrication Kit 8
55 gal Drum
Varco P/N 92643
TDS-11SA 8-9
Hydraulic System
Inspection
Draining the hydraulic fluid
Precautions
Hydraulic fluid may be hot
Use care when opening the valve
Avoid spills
Holds 25 gallons
Pump
Valve
Inlet/Drain
Handle
Adapter
10 HP AC
Pump Motor
Procedure
Isolate power to the pump motor Fixed
Ensure that the valve is closed Displacement
Pump
Remove the plug and attach a hose
Open the valve and drain the fluid
Close the valve and remove the hose Variable
8 Displacement
Replace the plug Pump
8-10 Varco Systems

Hydraulic System
Inspection
Hydraulic reservoir bladder (yearly)
Hydraulic Oil
Reservoir
Between AC
Drilling Motors
Reservoir
Breather Reservoir
Cover
Apply gasket sealing

compound to prevent leaks
Yearly
Reservoir Bladder
Varco P/N 110191-501
Check for wear and damage
Gasket
Varco P/N 110132
Front
Apply gasket sealing
compound to prevent leaks
Rear
Hydraulic Oil
Reservoir
Procedure
Drain hydraulic fluid and clean area before
inspecting the reservoir bladder
Remove the 10 cap screws and lock
washers from the cover 8
Remove cover with bladder attached
Check yearly for wear or damage
Replace the bladder every two years
Replace the bladder if fluid escapes the
reservoir breather when the Top Drive is on
its back
TDS-11SA 8-11
Hydraulic System
Inspection
Heat exchanger
Blower and
Brake Covers
Monthly
Oil Heat
Exchanger
Remove any dirt
and inspect for leaks,
corrosion, and cleanliness
Drill Motor
Assembly
Left side
8-12 Varco Systems

Hydraulic System
Inspection
Using the hydraulic system test ports
Stand Jump Brake Clamp/

SV9 SV1 P1 Shot Pin Float
Link
IBOP SV5 SV8 Tilt
L4 PV PF * B8
SV4 SV6
A4 G5
CB
* SA
* P
* T1
C4
A6
SV2
C5
Rotating B6 8
Link B5
Adapter
B9 * These test ports are on sides
Z1 B1 or bottom of manifold.
As Viewed From Below
TDS-11SA 8-13
Hydraulic System
Inspection
Precharging the accumulators
Accumulator Setting Port
System Accumulator (125-cubic inch displacement) 800 psi precharge SA

Counterbalance Accumulator (728-cubic inch displacement) 900 psi precharge CB
Time-Delay Accumulator (30-cubic inch displacement) 800 psi precharge C4
Bleed the accumulator if the pressure is higher, or add

i nitrogen if the pressure is lower than specified above.
Procedure
Counterbalance
Disconnect the hydraulic lines to the
Accumulator
accumulators and drain them of all hydraulic
fluid.
With the hydraulic system shut down, and
the counterbalance mode valve in the “shut
down” position, test the hydraulic pressure at
CB, SA and C4 on the hydraulic manifold,
mounted to the transmission housing. Verify
that all three points measure 0 psi.
Upper IBOP
i Note that there is a time delay in pressure
decay on port C4.
Time- Delay
Accumulator
Test the precharge pressure on the following
three nitrogen filled accumulators, using part
number 114446-1.
Hydraulic
System Manifold
Varco Part Number
Accumulator (Reference)
114446-1
Front
Rear
8-14 Varco Systems

Hydraulic System
Inspection
IBOP timing circuit
IBOP Actuator Cylinder
2.500" Dia. Bore X 4.00" Stroke
1.750" Dia. Rod
Open Test Point Typical

Close
Hydraulic Cylinder
CR
LODC 30 PSI
2 CXCD 1 Time-Delay
1
T-13A Accumulator
30 Cubic Inches
Logic Cartridge 800 PSI Precharge
3 2
50 PSI
CP T-11A VR
Gas Charged
Accumulator
(Small)
-6
-6
A4 B4
A4 B4
IBOP Close Solenoid

-6
-6
(Solenoid Valve 4)
Double Solenoid Valve IBOP Close
Cable ID
Number A B
b
C04
P T
-6
-6
-6
A4 SV4 B4 C4 Manifold Assembly

.055ø
D03
500 PSI CV4

D4 Flow Control
1 T-11A Valve
3 1 2
T-11A
.010ø
2 3 8
PC4
System
Tank
Pressure
TDS-11SA 8-15
Hydraulic System
Inspection
IBOP and oil pressure switch
Hoses
Inspect for wear
or damage.
Replace yearly
or as required.
Yearly
IBOP Pressure Switch Oil Pressure Switch

Configuration Configuration
Pressure
Adjusting Screw
Yearly
Wires
Inspect for wear
Switch Pressure Settings or lose connections.
Component Setting
8
IBOP Pressure Switch Factory preset at 102.0 BAR (1500 psi) rising
+0
Oil Pressure Switch Factory preset at 18.0 -1.0 psi decreasing
8-16 Varco Systems

Hydraulic System
Setting up the circuits

Hydraulic pumps and unloading circuit
There are two pumps – a fixed displacement pump runs the
transmission lubrication system and a variable displacement pump
provides hydraulic flow to the hydraulic system.
Guide Beam Pump/Motor
Pump Pressure
Compensator
Adjustment Point
8
Variable Fixed 10 HP AC
Displacement Displacement Pump Motor
Pump Pump
TDS-11SA 8-17
Hydraulic System

Fixed displacement (lube) and variable displacement
pumps
1. Jog-start the electric motor to make sure the direction of
rotation is correct (clockwise when looking into pump shaft/
electric motor fan). Correct as required.
2. Start the electric motor and allow both hydraulic pumps to

circulate oil. Listen for unusual noises that would indicate
cavitation; check for leaks.
3. Locate the tube connecting manifold port PF to the lubrication

motor. Disconnect the tube at the manifold end, cap the tube
and plug the PF port using steel fittings.
4. Set the relief valve RV1 for the variable displacement pump to
a minimum setting, fully counterclockwise, which allows the
hydraulic system to operate without building up pressure.
5. Set the relief valve RV2 to minimum pressure, fully

counterclockwise.
i Make sure the variable displacement pump case is filled with clean
hydraulic oil.
6. Connect a gauge to test point PF. Increase the pressure by

adjusting relief valve RV2 clockwise until the pressure
increases to 400 psi at test point PF. Set the jam nut on RV2.
A steel cap is installed over the adjustment screw to
discourage unauthorized adjustment.
i While adjusting valves, verify a linear relationship between turning

the adjustment screw and observing the pressure change.
7. Turn off the electric motor. Reconnect the tube between

manifold port PF and the lubrication motor.
8. Connect an ammeter to the electric motor. Note the full-load

8
amps on the motor nameplate.
9. Restart the hydraulic system electric motor.
10. Set the counterbalance mode valve to the RUN position.
11. Adjust UV1, fully clockwise, to maximum pressure.
8-18 Varco Systems

Hydraulic System

pumps
12. Connect a gauge to test point PV. Note the ammeter reading
while RV1 is at minimum setting.
13. Raise the setting of relief valve RV1 from 0 psi to 1,500 psi at a
steady rate. During the pressure rise, observe the ammeter. The
motor current should rise to a maximum value at 800 psi, then
drop off and begin to rise again. The point where the current
drops is the pump pressure compensator setpoint.
14. Adjust relief valve RV1 to its minimum setting. If maximum motor
current does not occur at 800 psi, adjust the pump pressure
compensator as required.
15. Adjust relief valve RV1 again from 0 psi to 1,500 psi, and back
to 0 psi to verify maximum motor current at 800 psi.
16. Connect a gauge to test point SA, and leave the gauge on PV.
17. Adjust relief valve RV1 to 2,200 psi and secure the jam nut.
18. Install steel cap over the adjustment screw to discourage

unauthorized adjustment.
19. Adjust unloading valve UV1 counterclockwise until the pressure

at PV drops off, then an additional two turns counterclockwise.
The pressure cycles like a sawtooth wave.
3000 Pressure at PV
Pressure at SA
2000
Pressure 1700
(psi)
1000
800 8
150
0 10 20 30 40 50 60
Approximate Time
(seconds)
TDS-11SA 8-19
Hydraulic System

pumps
20. Observe the unloaded pressure at PV (about 0 psi) while SA
reads about 2,000 psi. The pressure at SA decays until UV1
reloads. After reloading, the pressure rapidly rises to the unload
pressure.
21. Observe several unload-reload cycles to determine the unload

pressure.
22. Adjust the setting of UV1 as required to a 2,000 psi unload

pressure.
! Perform the adjustment with reasonable speed. The process

takes no longer than two minutes. Taking longer increases the
temperature of the hydraulic fluid.
23. Observe the cycle of loading and unloading of the relief valve.
To verify the setting of UV1, note the difference in pump noise
level between the loaded and unloaded condition.
RV2 RV1
CB6 CA6 CV5
CV4
A2
B2 CDR CV1
PC1 RV1
LC5 RV2 PCC
LB6 LA6 T1
T1
B1
C5 A2 B2
Manifold
Side View
Manifold
Bottom View B6 A6 DR Z1
TF
B5 B4
B5 C5 B9
TR
T1
SV5
B1
B4 SV2 SV1 SV9 CV2
G6 E6 E5 PV
P5
C4
B8
PF
RIG-UP
G5 SV4 PF
8
COUNTERB NCE MODE
RUN
P/N 0181
PV MV
SHUTDOWN
DF
PF
8-20 Varco Systems

Hydraulic System

pumps
Manifold Assembly
UV1
2200 PSI
2 T-10A
RV2
3
T-11A
1
Z1
1 2 400 PSI
RV1
PV PF
800 PSIG
Pump-Motor
Assembly
B
1.00 IN^ 3/REV.

L
1.10 IN^ 3/REV. MAX.

.50 IN^ 3/REV. MIN.
L1
S
TDS-11SA 8-21
Hydraulic System

Counterbalance circuit and stand-jump circuit
1. For the counterbalance circuit there are three adjustments:
❏ Relief valve (on counterbalance cylinder)
❏ PCC – operator set
❏ SJR – operator set
2. To set the relief valve, make sure the pumps are operating.
3. Adjust pressure reducing valve PCC to the maximum setting,

fully clockwise.
4. Connect a gauge to test port CB.
5. Adjust the cylinder-mounted relief valve to mid-scale to lower

the pressure setting.
6. Increase the pressure clockwise using a 5/32 in. Allen wrench

and 9/16 in. open-end wrench.
7. Observe the relationship of turning the relief valve adjustment

clockwise to pressure increase.
8. When the relief valve reaches system pressure, turn the

setting one full turn clockwise beyond the setting and set the
jam nut.
9. Install a steel cover over the valve.
10. Adjust PCC to 1,200 psi.
11. Measure pressure at test port CB.
12. Prepare the hardware to attach the cylinder pear links to the
hook.
13. Rotate the counterbalance mode valve from the RUN position
to RIG-UP position. This causes the counterbalance cylinders
to slowly extend.
8
! Cylinders stroke to the end of stroke with the mode valve in
the RUN position.
8-22 Varco Systems

Hydraulic System

14. Once cylinders reach end of stroke, attach hardware to the pear
links on the hook.
15. Rotate the counterbalance mode valve back to the RUN

position.
16. Adjust PCC counterclockwise to raise the pressure at test port

CB until the rail just begins to lift off of the hook.
17. Reduce the pressure slowly (25 psi) to allow the pressure to
stabilize.
18. Rotate the counterbalance mode valve to the SHUTDOWN

position to bleed down counterbalance cylinders and system
accumulator before shipping or performing maintenance.
19. Adjust pressure reducing valve PCC counterclockwise until the

bail rests on the hook. Note the pressure at CB.
20. Reduce PCC an additional 25 psi. The pressure at CB is about

1,600 psi.
21. Connect a gauge to test point B9. Activate the STAND JUMP
mode on the drilling console. Adjust relief valve SJR until the
bail lifts off the hook. The gauge at B9 should read about 190
psi.
22. Switch back to DRILL counterbalance mode and observe the

pressure at test point CB.
23. Switch back to STAND JUMP mode and observe the pressure
CB increase by 190 psi.
TDS-11SA 8-23
Hydraulic System

PCC
CB6 CA6 CV5
CV4
A2
B2 CDR CV1
PC1 RV1
LC5 RV2 PCC
LB6 LA6 T1
T1
B1
C5 A2 B2
Manifold
Side View
Manifold
Manifold
P
TF
B5
End View
B5 C5 B4
B9
CTR
SA
TR
T1
SV5
B1
B4 SV2 SV1 SV9 CV2
G6 E6 E5 PV
P5
CB
SA
C4
B8
PF
UV1
RIG-UP
G5 SV4 PF
COUNTERB NCE MODE
1
RUN
P/N 0181
XC
PV MV
SHUTDOWN
DF
CB
8-24 Varco Systems

Hydraulic System

Pressure 2500 PSI
Relief Valve T-3A 1
-4 2
ZC CP
OR1 OR2
CP -12
.075ø .075ø
75 PSI 75 PSI
1 2 1 2 CP -12 Counterbalance Cylinders
T-13A T-13A 2.000" Dia. Rod
CV1 CV2 -12
T
-12 Counterbalance
Normally-Open Accumulator
T
.010ø Logic Cartridge 728 Cubic Inches
Metering 900 PSI Precharge
T -16
5 PSI
-6
XC 90 PSI
25mm
Prefill Cable ID Stand Jump Solenoid
Valve Number (Solenoid Valve 9)
.047ø
Counterbalance Mode Stand

Jump 2 Position
Rig-up Shut-down Valve
Run
A B A B
b
C09
P T P T
-6
3 Position D03 MV .055ø CB SV9 Manifold Assembly

Valve with D03
XC
Detent
CV3 Test
B9
75 PSI 1 Port
T-21A 4 B9
CB
3
CDF 2 Pressure
4 PSI 1 Relief
T-10A
DF 2 1 1 Valve
1600 PSI
SJR
PCC 4
T-13A 2 190 PSI
T-21A
System DF 2 3
Accumulator
126 Cubic Inches
800 PSI Precharge 2 1
TF
System Pressure 8
T-5A CTF
30 PSI
SA To Tank
TDS-11SA 8-25
Hydraulic System

AC motor brake circuit
The AC drilling motor brakes are spring released and hydraulic
pressure applied at 1,400 psi. The pressure reducing valve
regulates the pressure to 1,400 psi. The solenoid valve operates to
apply pressure, setting the brakes, or stop pressure to release the
brakes.
To test the system, turn the auto brakes switch on the driller’s
console to the ON position. Attach a pressure gauge to B1 in the
manifold. The pressure reading should be 1,400 psi. If the reading
is not 1,400 psi, adjust the pressure control reducing valve PC 1 to
1,400. Turn the auto brakes switch to the OFF position. The
pressure reading should be very low. If the pressure is high, the
solenoid valve might be sticking.
RV2
CB6 CA6 CV5
CV4
A2
B2 CDR CV1
PC1 RV1
LC5 RV2 PCC
LB6 LA6 T1
T1
B1
C5 A2 B2
Manifold
Side View
Manifold
TF
B5 B4
B5 C5 B9
TR
T1
SV5
B1
B4 SV2 SV1 SV9 CV2
G6 E6 E5 PV
P5
C4
B8
PF
RIG-UP
G5 SV4 PF
COUNTERB NCE MODE
RUN
P/N 0181
PV MV
SHUTDOWN
DF
B1
8-26 Varco Systems

Hydraulic System

Shot pin circuit
1. Set the adjustable relief valve near the body of the cylinder.
The shot pin often misses the hole in the rotating gear. The
force the shot pin exerts is limited until the pin engages a
hole.
i The electrical system jogs the rotating head until the pin engages a
hole.
2. To limit the amount of force, you set the valve by operating

solenoid valve SV5 manually, forcing the pin to stop on the
face of the gear.
3. When the pin stalls out, measure the pressure at B5. Set the
relief valve pressure to 200 psi.
4. Tighten the jam nut on the relief valve.
5. At rest, the SV5 valve is de-energized.
6. Test the pressure at C5. Adjust reducing valve AR5 to 500 psi.
Hydraulic
Drive Motor
SV5
C5
Link Adapter
Rotation Gear
Hydraulic Manifold
Shot Pin
(As Viewed from Below)
(Simplified for Clarity) 8
TDS-11SA 8-27
Hydraulic System
Rotating Link Adapter

Drive Motor and
Shot Pin Assembly
10 HP AC Motor
and Pump Assembly
(Simplified for Clarity) Hydraulic

Drive Motor
Motor
A
Relief Valve
B
Rotating Motor
Link Shot Pin Relief Valve
B5
Adapter Relief Valve
C5
Link Adapter
A5
Rotation Gear
Shot Pin
8-28 Varco Systems

Hydraulic System

Link tilt cylinder circuit
1. There is nothing to adjust on the manifold for the link tilt
circuit.
2. Adjust the four load holding valves in pairs – the upper pair
and lower pair. Adjust all four counterbalance valves fully
clockwise, then one turn counterclockwise.
i If the valves are not adjusted correctly, link tilt operation is not
synchronized.
3. The correct pressure setting is 1,500 psi. The procedure is the

same for all four valves. Adjust the valves one at a time.
4. There is a test point on each loading manifold.
5. From the driller’s console, move the link tilt to go to the

mousehole position.
6. The cylinder goes to full extension and the pressure at the test
port TP is 2,000 psi.
7. Command the link tilt to the OFF position and observe the
pressure delay at TP. This delayed pressure is the setpoint of
the counterbalance valve.
8. Raise the valve setpoint by turning the adjusting screw 1/4

turn counterclockwise.
9. Repeat steps 6 and 7 until the decayed pressure is 1,500 psi.
i This is an iterative process. Continue to set the driller’s console

control to the mousehole position and OFF, taking present and
decayed pressure readings.
! Turning the counterbalance valve counterclockwise increases

the pressure.
8
10. Repeat the procedure above for the other cylinder at the
mousehole position.
11. Command the link tilt to the DRILL position and repeat the
procedure above to set both counterbalance valves on the
DRILL side.
TDS-11SA 8-29
Hydraulic System

Rotating link adapter hydraulic motor relief circuit
1. Set the relief valves mounted on rotation motor.
2. Operate the clamp. The shot pin must go through the hole,
which locks up the gear.
3. Turn the manual override on the SV2-rotation circuit to drive the

head in the counterclockwise direction. Test the pressure at A
and adjust the relief valve to 1,600 psi.
4. Turn the manual override on the SV2-rotation circuit to drive the

rotating head in the clockwise direction and test the pressure at
B. Adjust the relief valve to 1,600 psi.
Hydraulic
Drive Motor Relief
Valves
Manifold
Link Adapter
Rotation Gear
Test
Points
(Simplified for Clarity)
8-30 Varco Systems

Hydraulic System
Troubleshooting
HPU and reservoir bladder
Problem Probable cause Remedy
Hydraulic system Relief valves RV1 and RV2 out of adjustment. Test pressures and adjust relief valves.
overheating
Unloading valve is not working. Test and adjust UV1 or replace unloading valve.
Counterbalance mode valve left in shut down Check system pressure.

position too long and pressure bleeds down.
No precharge in system accumulator. Charge system accumulator.
Hydraulic components System pressure is down. Test pumps and motors. Test relief valve
do not operate. pressures. Adjust as required. Check for leaks,
loose fittings, loose cylinders, worn hoses,
fluid levels and seals.
Piston pump is not working. Replace the piston pump.
Flexible coupling is damaged. Replace the flexible coupling.
Lubrication pump is not working. Replace the lubrication pump.
Pressure at UV1 is too low. Adjust pressure at UV1.
Pumps are rotating in the wrong direction. Inspect hydraulic connections and
correct rotation.
Suction valve closed. Open suction valve.
Low oil level in reservoir. Fill hydraulic reservoir.
TDS-11SA 8-31
Hydraulic System
Troubleshooting
HPU and reservoir bladder schematic diagram
PV PF TR DR Manifold Assembly
Hydraulic Fill
Disconnect
System
Pressure
6µm
50 PSID
Prefill Valve
Pressure -12
Compensator T
Filter with
Control Bypass
T -16
800 PSIG Valve
-6
XC
B
1.00 In^ 3/Rev.
L
1.10 In^ 3/Rev. Max.

M .50 In^ 3/Rev. Min.
10 HP
1800 RPM 4 PSI
L1 Filter Vent
S
(Strainer)
Variable Fixed
Displacement Displacement
Pump Pump
Reservoir Assembly
8-32 Varco Systems

Hydraulic System
Troubleshooting
Counterbalance and stand jump
The accumulator, with precharge pressure of 900 psi, along with
check valve CV3, maintains a hydraulic pressure. Refer to the
vendor documentation material located in the Vendor
Documentation Package, for the gas charging procedure for the
accumulator.
A three-position manually operated valve controls counterbalance

operation for rig-up, run, and shut down modes. In the rig-up mode,
system pressure is applied to XC and the prefill valve, causing both
cylinders to extend. When the cylinders extend, you make up the
mechanical connection to the bail. In the run mode, for
counterbalance operation, approximately 1,600 psi is needed at the
counterbalance cylinders to lift the TDS-11SA off the hook.
The optional stand jump feature is controlled by solenoid valve

SV9. With the counterbalance in the run mode and the stand jump
switch on, additional pressure of approximately 300 psi is applied
to over the normal counterbalance pressure to lift the TDS-11SA
and drill string off the hook.
In the shutdown mode, the hydraulic system bleeds down the

system accumulator and the counterbalance accumulator pressure.
Counterbalance testing
For the counterbalance operation, a lift of approximately 30,000 lb
is achieved with a pressure of 1600 psi at CB. Perform the
following steps to adjust the force:
1. Set the counterbalance mode valve on the bottom of the

manifold to the RUN mode. Set the pressure control valve
PCC to the minimum setting (fully counterclockwise).
2. Test the pressure at port B9. There should be a 0 psi reading.
3. Test the pressure at port CB. Observe the position of the top
drive on the hook.
4. Adjust the pressure at pressure control valve PCC clockwise,

observing pressure at CB, until the top drive just lifts off the
hook. Back off the pressure 25 psi, as the top drive rests on
the hook. 8
TDS-11SA 8-33
Hydraulic System
Troubleshooting
Stand jump testing
For the optional stand jump feature, a lift of about 33,000 lb is
achieved with a pressure of approximately 1800 psi at CB. The
additional 300 psi pressure over the normal counterbalance
pressure is provided by energizing the stand jump solenoid valve
SV9. Perform the following steps to adjust the pressure:
1. Set the counterbalance mode switch to RUN and engage the

stand jump switch. Test the pressure at port CB and B9. Adjust
relief valve SJR fully counterclockwise to the minimum setting.
2. Slowly increase the pressure at CB by adjusting relief valve SJR

clockwise until the bail lifts off the hook with a stand of pipe in
the elevator.
i Adjust relief valve SJR slowly to allow pressure at CB to stabilize.
8-34 Varco Systems

Hydraulic System
Troubleshooting
Counterbalance does not Cylinder damaged. Seal leaks. Inspect cylinder and repair or replace seal.
function.
No hydraulic pressure. Test pressure and ajust pressure reducing valve.
Solenoid valve SV9 is not operating. Test electrical and hydraulic operation.
Replace or repair as applicable.
PCC is not operating. Replace the valve.
Relief valve is not operating. Replace the valve.
Precharge on the accumulator is low. Charge the accumulator.

Stand jump does not
function. Cylinder damaged. Seal leaks. Inspect cylinder and repair or replace seal.
No hydraulic pressure. Test pressure and adjust pressure

reducing valve.
Solenoid valve SV9 is not operating. Test electrical and hydraulic operation.
Replace or repair as applicable.
PCC is not operating. Replace the valve.
Relief valve is not operating. Replace the valve.
Precharge on the accumulator is low. Charge the accumulator.
TDS-11SA 8-35
Hydraulic System
Troubleshooting
Counterbalance and stand jump schematic diagram
Pressure 2500 PSI

Relief Valve T-3A 1
-4 2
ZC CP
OR1 OR2
CP -12
.075ø .075ø
75 PSI 75 PSI
1 2 1 2 CP -12 Counterbalance Cylinders
T-13A T-13A 2.000" Dia. Rod
CV1 CV2 -12
T
-12 Counterbalance
Normally-Open Accumulator
T
.010ø Logic Cartridge 728 Cubic Inches
Metering 900 PSI Precharge
T -16
5 PSI
-6
XC 90 PSI
25mm
Prefill Cable ID Stand Jump Solenoid
Valve Number (Solenoid Valve 9)
.047ø
Counterbalance Mode Stand

Jump 2 Position
Rig-up Shut-down Valve
Run
A B A B
b
C09
P T P T
-6
3 Position D03 MV .055ø CB SV9 Manifold Assembly

Valve with D03
XC
Detent
CV3 Test
B9
75 PSI 1 Port
T-21A 4 B9
CB
3
CDF 2 Pressure
4 PSI 1 Relief
T-10A
DF 2 1 1 Valve
1600 PSI
SJR
PCC 4
T-13A 2 190 PSI
T-21A
System DF 2 3
8 Accumulator
126 Cubic Inches
800 PSI Precharge 2 1
System Pressure
TF CTF
T-5A
30 PSI
SA To Tank
8-36 Varco Systems

Hydraulic System
Troubleshooting
Troubleshooting the brakes
Brake does not release. Directional valve is stuck. Test the valve and replace if necessary.
Brake releases but still drags. Check valve is blocked or tube is pinched. Replace the check valve or tube as required.
Mechanical problems with brakes. Repair brake mechanism.
Brakes do not engage or slip. Hydraulic oil on brake pads. Check for hydraulic leaks and repair.
Pressure is not 1,400 psi or does not rise Reducing valve is plugged or needs to be
crisply to 1,400 psi. adjusted or replaced.
Directional valve is stuck Replace valve or check electrical signal.

(check pressure at B1).
Delay in brakes actuating Hydraulic oil is contaminated. Replace hydraulic oil.

after console switch is
turned on. Pressured reducing valve is faulty. Replace valve.
TDS-11SA 8-37
Hydraulic System
Brake circuit schematic diagram

Brake Calipers
2 Position
Solenoid Valve
Brakes On
Cable ID
Number
A B
b
C01
P T -4
SV1 B1 Manifold Assembly

.071ø
D03
Non-Adjustable
Orifice
P1
Test Point
1400 PSI
PC1 1 T-11A
Reducing 2 3
8 Valve
System Tank Drain

Pressure
8-38 Varco Systems

Hydraulic System
Troubleshooting
Shot pin cylinder and clamp cylinder
Shot pin does not engage. Solenoid valve is not operating or relief valve Check electrical actuation and test pressure.
is not adjusted. Adjust as required.
Abnormal pressure change at B5 and C5 Replace directional control valve.

indicates valve problem.
Normal pressure change indicates plumbing Repair plumbing or shot pin cylinder.
or shot pin cylinder are faulty.
Shot pin applies Relief valve is not operating or Test pressures and adjust as required.
excessive force to out of adjustment.
rotating head gear.
Clamp cylinder does No pressure or reduced pressure at the cylinder. Test pressures and adjust and repair as required.
not actuate.
Cylinder is damaged. Inspect cylinder and repair or replace.
To provide high pressure to the clamp circuit, Repair plumbing, rotating head, or clamp cylinder.
i pressure at C5 must be 2,000 psi and G5 must
be less than 100 psi. If this condition is met,
pressure at CP should increase from less than
100 psi to higher than 2,000 psi. If not, check
the plumbing, rotating link adapter, and
clamp cylinder.
While clamping, pressure at CR should be Clean or repair CNEC valve.

2.7 times the pressure at CP. When the dies
contact the pipe, pressure at CR should be
less than 100 psi. If the pressure does not
fade, check valve CNEC for contamination.
Shot pin engages Control valve not operating. Check pressure at C5. Replace valve CV5
but clamp cylinder if required or the regenerate manifold.
does not activate.
TDS-11SA 8-39
Hydraulic System
Troubleshooting
Shot pin cylinder and clamp cylinder schematic diagram
Clamp Cylinder
8.000" Dia. Rod
Hydraulic Cylinder
Cavity Plug CP CR
1 3
Pilot-to-Close CKEB
T-2A
Check Valve 2
30 PSID
2 1
CNEC
Shot-Pin Cylinder 3 T-2A
2.000" Dia. Bore X 2.31" Stroke 1 T-5A
Relief Valve 1.500" Dia. Rod COFA
.047ø
2 400 PSI 2 30 PSID
Shot Pin
Cylinder 2x .094ø 2
VP VR
1
2 Position
T-10A Non-Adjustable
Solenoid
B5 C5 Flow Control
Valve 5
Clamp/Shot Pin
-8
-8
Clamp
E5 G5
Cable ID Rotating Link

A B
Number b E5 G5 Adapter Assembly
C05
-8
-8
P T
-6
-6
A5 SV5 .039ø B5 C5 E5 G5
D03
Pressure
.159ø .031ø T-11A 1
50 PSI .031ø Reducing
3 AR5 Valve
3
1 2
LC5 2
Logic .031ø 500 PSI
T-11A
Cartridge
Externally-Drained
Pilot-to-Open
3 2 Valve
T-21A
4 75 PSI
CV5 1
P5
Drain 1
T-11A 3
System Pressure
PC5 2
8 Tank Drain
System Pressure
Tank
T1 T1 D5 Manifold Assembly
8-40 Varco Systems

Hydraulic System
Troubleshooting
Link tilt cylinders
Drill pipe elevator does Link clamp incorrectly adjusted. Readjust

not reach mouse hole/
derrickman position.
Links drift when Pressure at B8 does not decay to Replace the pilot to open check valve.
valve is released. less than 100 psi.
Pilot to open check valve is stuck open Replace the pilot to open check valve.
or contaminated.
Faulty cylinder seal. Replace the seal.
Load holding relief valves are out of Adjust or replace the load holding relief valve.
adjustment, stuck open, or contaminated.
Drill pipe elevator Use manual override. If the link tilts, the Test the solenoid and connectors.
does not float back problem is electrical. If the links do not tilt, Test the hydraulic system.
to center position. the problem is hydraulic.
Link tilt does not tilt. Solenoid valve is not shifting. Check electrical continuity.
Links do not move Load holding valves are out of adjustment. Adjust the pressure for all four valves
together. to 1,500 psi.
TDS-11SA 8-41
Hydraulic System
Troubleshooting
Link tilt cylinders schematic diagram
Link Tilt Cylinder

1.380" Dia. Rod
Mousehole
Drill Down
C1 C1 C1 X1 C2 C2 C2
1500 PSI T-11A 1500 PSI T-11A

CV1
T-11A 1 CB1 1 CB2
1 CV2 1 X2
3 3 T-11A 3 3
2 2 2 2
V1 V2
V1 V2
FL
-6
-6
-8
-8
-8
-8
X -8
X -8
X
X
B8 B8 E6 E6 G6 G6 H J
B8 E6 G6 H J
-8 X
-8 X
-8
-8
Rotating Link -8
Adapter Assembly
Link Tilt Link Tilt Link Tilt

"Float" Solenoid "Drill Down" Solenoid "Tilt" Solenoid
(Solenoid Valve 8) (Solenoid Valve 6) (Solenoid Valve 6)
Link-Tilt Float Link Tilt

Cable ID
A B A B Logic
Number b b a Cartridge
C08 C07 C06
P T Drill Down P T M'hole
-6
-8
-8
SV8 D03 B8 E6 .031ø .031ø SV6 D03 .031ø G6

Logic
Cartridge LA6 T-11A .071ø
.031ø
75 PSI B6
1 2
50 PSI 2 3 T-11A
4 3
CA6 1
8 3 1 T-21A
.071ø
.031ø 50 PSI 2
A6
LB6 2
4 3
1
Pressure
CB6 75 PSI
Tank T-21A
A8 D1 Manifold Assembly
X
8-42 Varco Systems

Hydraulic System
Troubleshooting
Gearbox lubrication hydraulic system
Oil leaking from lower seal. Worn oil seals. Replace seals.
Oil leaking from upper Worn oil seals. Replace seals.

bearing retainer.
Gearbox oil temperature Oil level too low or too high. Adjust oil level to middle of sight glass.
(less than 230˚F).
Incorrect lubricant used. Check recommended lubricants chart
and replace as needed.
Damaged gears or bearings. Repair or replace as needed.
Oil pump loss alarm is on. Oil level is too low. Oil overheated. Add oil.
Oil pressure switch is out of adjustment. Adjust per page 8-16.
Gear spray nozzle missing. Replace spray nozzle.
Excessive oil viscosity. Lower oil viscosity.
Faulty motor. Intermittent operation. Replace motor.
Oil pump hydraulic motor failure. Replace motor.
Broken lube pump adapter plate spline. Replace adapter plate spline.
Faulty fixed displacement pump. Check pressure at PF.

Replace pump if pressure is low.
Low hydraulic fluid in reservoir. Add hydraulic fluid.
Suction valve closed on fixed displacement pump. Open suction valve.
Water/mud in oil. Missing inspection plugs. Replace inspection plugs.
Upper gearbox seals worn. Replace seals.
Excessive foaming. Water in oil. Replace oil.
Excessively viscous oil. Cold oil. Lower oil viscosity.

8
Metal in oil. Worn gears or damaged bearings. Replace gears or bearings.
Damaged oil pump. Replace oil pump.
Restricted oil flow. Foreign particles blocking orifice or nozzle. Clean orifice or nozzle.
TDS-11SA 8-43
Hydraulic System
Troubleshooting
Gearbox lubrication hydraulic system schematic
diagram
Pressure Spray
Switch Nozzles (4) Orifices (6)
S04 18 PSI
Decreasing
-16
1.0 1.5 .062ø .205ø .059ø .059ø .047ø .047ø L4
GPM GPM
Ea. Ea.
Upper Lower Upper Lower Upper Lower
Compound Compound Mainshaft Radial/Main Compound Compound
Gear Gear Bearing Thrust Bearing Bearing
Bearings
Lube-Oil
Filter
Lube Pump 5.10 In.^ 3/Rev. 60µm
L1 -16
Lube-Oil Pump
-10
A B
Tank
-10
3.0 In.^ 3/Rev.
Lube Pump Motor
Hydraulic Hydraulic
Motor Heat Exchanger
Tank
2 T-10A
RV2
400 PSI
Manifold PF
1.00 IN^ 3/REV.

8
Part of
Pump Motor
Assembly Reservoir
Assembly
8-44 Varco Systems

Hydraulic System
Troubleshooting
Tool does not rotate. Direct control valve or relief valve is sticking. Inspect, repair or replace the valve.
When you override a directional valve, you

bypass the safety interlock and top drive
components move, possibly causing serious
injury or death.
Solenoid valve is not electrically operating. Check electrical connections and valve functions.
Motor is worn out or gear teeth are broken. Replace the motor.
Shot pin is engaged. Adjust the relief valve.
Mechanical interference. Inspect and repair.
Directional valve does not shift. Test pressure left and right. Replace the valve.
Fixed valve orifice is plugged. Clear orifice or replace the valve.
Hydraulic lines are damaged. Replace hydraulic lines.
Tool does not return Valve is sticking or relief valve is Test pressures and inspect valves.
to home position. out of adjustment. Adjust the relief valve as required.
Sensor is broken. Replace sensor.
If the motor will drive normally, but not drive Checkout control system.
to the home position, the cause could be
the control system.
Links are not Counterbalance valves are out of adjustment. Adjust valves together-pressure is the same
synchronized. for all four valves.
TDS-11SA 8-45
Hydraulic System
Troubleshooting
Rotating link adapter motor schematic diagram
Rotating Head Motor
A B
Fixed
Displacement
Motor
1 2
Pressure
Relief Valves
T-10A 1600 PSI
1600 PSI T-10A
2 1
A B
Rotate Left Rotating Head Rotate Right

Solenoid Solenoid
Cable ID A B Cable ID
Number Number
b a
C03 C02
Left P T Right
-6
-6
A2 SV2 B2 Manifold
Assembly
8 .071ø D03
Non-Adjustable Pressure Tank 3 Position

Orifice Solenoid Valve
8-46 Varco Systems

Hydraulic System
Troubleshooting
IBOP actuator schematic diagram
IBOP Actuator Cylinder
1.750" Dia. Rod
Open Test Point Typical

Close
Hydraulic Cylinder
CR
LODC 30 PSI
2 CXCD 1 Time-Delay
1
T-13A Accumulator
30 Cubic Inches
Logic Cartridge 800 PSI Precharge
3 2
50 PSI
CP T-11A VR
Gas Charged
Accumulator
(Small)
-6
-6
A4 B4
A4 B4
IBOP Close Solenoid

-6
-6
(Solenoid Valve 4)
Double Solenoid Valve IBOP Close
Cable ID
Number A B
b
C04
P T
-6
-6
-6
A4 SV4 B4 C4 Manifold Assembly

.055ø
D03
500 PSI CV4

D4 Flow Control
1 T-11A Valve
3 1 2
T-11A
.010ø
2 3 8
PC4
System
Tank
Pressure
TDS-11SA 8-47
Hydraulic System
Hydraulic schematic symbols

The following hydraulic troubleshooting section provides a
schematic diagram and description for each TDS-11SA hydraulic
circuit. Following each schematic is a group of troubleshooting
charts to help you quickly locate and correct hydraulic system
problems.
When performing hydraulic troubleshooting, be aware that:
❏ The electrical control system can be bypassed for

troubleshooting by manually overriding the solenoid valve for
each operational system.
Alert all personnel near the top drive before overriding

a solenoid valve. When you override a solenoid valve,
you bypass the safety interlock and top drive
components will move possibly causing serious injury
or death.
❏ Test points shown in the hydraulic schematic with a box (e.g.,

A4) can be found on the manifold under the main body. There
are also test points on the rotating link adapter motor.
❏ The system is preadjusted. Hydraulic problems are usually

related to faulty valves, contamination, or other damage to the
system rather than misadjustments. Changes to adjustments
should be made only after all other possible causes have been
eliminated.
8-48 Varco Systems

Hydraulic System

Description Symbol Schematic Reference
2 Position 4 Way Valves

SV1, SV4, SV5, SV8, SV9
(Single Solenoid)
Solenoid
33-1
Operated
Valves
3 Position 4 Way Valves
(Double Solenoid) SV2, SV6
33-2
Manual
Valve 3 Position 4 Way Valve MV
(Rotary)
33-3
Fixed Displacement
33-4
Pumps
Variable Displacement
33-5
Standard Valve RV2, A2R, B2R, SJR
33-6
Pressure
Relief Ventable Relief Valve RV1
Valves
33-7
Differential Unloading Valve UV1
33-8
Pressure Reducing Valve PC1, PC4
33-9
Pressure Reducing/Relieving Valve PCC
33-10
8
CDF, CTF, CV2, CTR,
Chack Valve CDR, CXCD
Prefill valve assembly
33-11
CV1, CV2
TDS-11SA 8-49
Hydraulic System

Pilot-To-Open CKCB (Link Tilt)

Check 33-12
Valves
CA6, CB6, CV3, CV4
Pilot-To-Close
(Clamp Body)
33-13
1
3
Cavity Plug PC5
2
33-14
Internal Plug
33-15
Non Adjustable Flow Control Valves CV1
33-16
Non Adjustable Orifice Diameter in inches
33-17
3 Port (Internal Drain) CBCA (Link Tilt Circuit)

Counter-
33-18
balance
Valves
4 Port (External Drain) CWCK (Link Tilt Circuit)
33-19
Standard Cartridge LA6, LB6, LC5, LODC
Logic 33-20
Cartridge
With Metering See Prefill Assembly
8 33-21
Quick Disconnect Coupling
33-22
8-50 Varco Systems

Hydraulic System

Non Bypass Filter See Lube Oil Circuit
33-23
Filter with Bypass See Return Circuit
33-24
Manual Shutoff Valve
33-25
Thermostat Lube Oil Circuit
33-26
Pressure Switch Lube Oil Circuit
33-27
Heat Exchanger Hydraulic Circuit

(Inside Brake Housing)
33-28
Pressure Compensator Control Part of the Pump
33-29
Hydro-Pneumatic Accumulator
33-30
Hydraulic Motor (Bi-Directional)
33-31
Hydraulic Cylinder
33-32
Tank (Reservoir) 8
33-33
Test Point
33-34
TDS-11SA 8-51
TDS Training Manual

Montrose Scotland
AC TOP DRIVE
Section 9
Varco Driller’s Console
AC Electrical
VARCO DRILLERS CONSOLE (VDC)
The VDC is made from 300-series stainless steel, it uses full size oil tight
switches and indicators and is designed for zone one hazardous areas with
its EEx de (ia) rating without requiring to be purged.
The Varco supplied Driller’s console is equipped with the following items to
directly interface with the AC frequency drives: -
Throttle
The throttle uses a design similar to a standard throttle control supplied with
SCR Systems. The handle includes integral stops to prevent damage
Torque Limit
The torque limit it potentiometer is very similar to the designs used on SCR
Systems. The maximum torque output of the drive is limited to the continuous
torque rating of the drive and motors.
Make-Up Limit Potentiometer

The make-up potentiometer controls the makeup torque when the top drive is
used to makeup connections using the drilling motor. This control allows the
top drive to operate at the intermittent rating.
AC TDS Training Manual

VDC CONTROLS
1. DRIVE FAULT
Red indicator light flashes and horn sounds when a drive (VFI) fault is
detected.
2. BLOWER LOSS
Red indicator light flashes and horn sounds if there is a failure in one or
both of the air cooling motors.
3. BRAKE ON
Red indicator illuminates when the brake solenoid valve is
energised. The indicator flashes in case of a faulty make-up
connection.
4. DRILL MOTOR OVER-TEMPERATURE
Red indicator flashes and horn sounds if there is an over- temperature
condition in one or both of the AC drilling motors.
5. IBOP CLOSED
Amber indicator light illuminates when there is hydraulic pressure to the
cylinder that closes the IBOP valve.
6. OIL PRESSURE LOSS
Red indicator flashes when there is an oil pressure loss in the gear case
lubrication system.
7. ALARM SILENCE/LAMP CHECK
When any alarm indicator light flashes and the horn sounds, press the
switch to silence the horn, the alarm light stays on until the fault is rectified,
if the fault is not rectified in 5 minutes, the alarm repeats. The switch is
also a lamp check for all lights on the VDC, the switch must be pushed and
held for two seconds to obtain a lamp check.
8. BRAKE SWITCH
There is three brake switch positions, OFF, AUTO and ON, turning the
switch to the ON position turns the brake on and lights the brake indicator.
In the AUTO position, the brake automatically turns on when the throttle is
turned off. Turning the brake to the OFF position turns the brake off. The
brake will operate if there is a drive fault with the VFI.
9. DRILL CURRENT LIMIT POTENTIOMETER
The potentiometer sets the current limit in the VFI during drilling
operations, this sets the torque for normal drilling operations in the drill
position.
10. DRILL PIPE ELEVATOR SWITCH
There are three switch positions, OFF, LEFT and RIGHT, turning the
spring operated switch to the left moves the drill pipe elevator to the left,
and turning the switch to the right moves the drill pipe elevator to the right.
NOTE: - This works only after the link tilt float switch is pressed.
11. DRILL/SPIN/TORQUE SWITCH
There are three switch positions, DRILL, SPIN and TORQUE, the
switch is in the DRILL mode during normal drilling, SPIN mode is a fixed
speed and current signal to the AC motors and TORQUE mode is a fixed
speed with gradual rise in torque up to the make-up value set by the make-
up potentiometer when in Forward mode, when in Reverse the Torque
value rises to maximum until the connection is broken.
12. EMERGENCY STOP CIRCUIT
The Emergency Stop switch is hard wired to the VFI, pressing the button
deselects the VFI and will cause the Top Drive rotation cost to a stop
regardless of throttle position.
NOTE: - All other auxiliary functions remain ON.
13. IBOP SWITCH
The IBOP switch activates the upper IBOP valve, turning the switch to the
left retracts the IBOP actuator cylinder to close the valve, turning the
switch to the right extends the cylinder to open the valve.

14. LINK TILT FLOAT

The elevator links “float” to the centre (NEURAL) position when the
pushbutton is pushed, thus the drill pipe elevator can then be rotated.
15. LINK TILT SWITCH
This activates the link tilt cylinders, the centre position is OFF, turning the
switch to the left extends the cylinders, turning the switch to the right
retracts the cylinders. This is a maintained switch that holds the position of
the cylinder when returned to the OFF position.
16. MAKE UP CURRENT LIMIT POTENTIOMETER
This potentiometer sets the current limit in the VFI when using the Top
Drive to make connections, the Torque can be adjusted by turning the
potentiometer to increase or decrease the Torque.
17. OFF/FORWARD/REVERSE SWITCH
There are three switch positions, OFF, FORWRD and REVERSE, the OFF
position is used to deselect the VFI, FORWARD and REVERSE are used
when drilling or making/breaking connections. The switch acts as the
drive assignment.
18. TORQUE WRENCH SWITCH
Pushing this button engages the pipe clamp and shot pin lock.
NOTE: - Wrench cannot clamp with the brake on or throttle open.
19. RPM METER
Displays the RPM of the drill pipe.
20. TORQUE METER
Displays the drill pipe Torque in Ft/Lbs.
21. STAND-JUMP SWITCH
Energises the stand-jump solenoid, this causes drill pipe connection to
separate from the saver-sub as it unscrews.
22. THROTTLE
Controls the speed of the AC Drilling motors when in drill mode, by
sending a reference signal to the VFI.
23. TORQUE RELEASE
When the Top Drive is drilling ahead and stalled out, pressing the Torque
Release switch will slowly unwind the Torque out of the drill string in a
controlled manner.
24. HYDRAULIC POWER AUTO/ON
When switched to ON, the Top Drive Hydraulics can still be operated with
the Forward/Reverse switch in the OFF position. When in the AUTO
position the hydraulics are operated by the assignment of the Top Drive
Forward/Reverse. Thus when the Top Drive rotation of the main shaft is
not required, the hydraulics can still be operated.

TDS Training Manual

Montrose Scotland
AC TOP DRIVE
Section 10
System Interconnect
AC Electrical
TDS Training Manual

Montrose Scotland
AC TOP DRIVE
Section 11
Siemens Step 7 PLC
AC Electrical
PLC Introduction
Programmable Logic Controllers (PLCs), also referred to as programmable controllers,
are in the computer family. They are used in commercial and industrial applications. A
PLC monitors inputs, makes decisions based on its program, and controls outputs to
automate a process or machine. This course is meant to supply you with basic
information on the functions and configurations of PLCs.
PLCs consist of input modules, a Central Processing Unit (CPU), and output modules.
An input accepts a variety of digital or analogue signals from various field devices
(sensors) and converts them into a logic signal that can be used by the CPU. The CPU
makes decisions and executes control instructions based on program instructions in
memory. Output modules convert control instructions from the CPU into a digital or
analogue signal that can be used to control various field devices (actuators). A
programming device is used to input the desired instructions. These instructions
determine what the PLC will do for a specific input. An operator interface device allows
process information to be displayed and new control parameters to be entered.
Prior to PLCs, many of these control tasks were solved with contactor or relay controls.
This is often referred to as hard-wired control. Circuit diagrams had to be designed,
electrical components specified and installed, and wiring lists created. Electricians
would then wire the components necessary to perform a specific task. If an error was
made the wires had to be reconnected correctly. A change in function or system
expansion required extensive component changes and rewiring.
The same, as well as more complex tasks, can be done with a PLC. Wiring between
devices and relay contacts is done in the PLC program. Hard-wiring, though still
required to connect field devices, is less intensive. Modifying the application and
correcting errors are easier to handle. It is easier to create and change a program in a
PLC than it is to wire and rewire a circuit.
PLC Advantages
• Smaller physical size than hard-wire solutions
• Easier and faster to make changes
• PLCs have integrated diagnostics and override functions
• Diagnostics are centrally available
• Applications can be immediately documented
Siemens Step 7 PLC
Various Varco control systems uses the Siemens Step 7 300 series PLC (AR4000,
TDS-4S, Electronic Driller). The complete system consists of the 315-DP CPU, with
local Inputs and Outputs, and remote Inputs and Outputs through the PROFIBUS DP
network.
What is PROFIBUS ?
PROFIBUS is a serial fieldbus used primarily as the communication system for

exchange and information between automation systems and distributed field devices.
Thousands of successful applications have provided impressive proof that use of
fieldbus technology can save up to 40% in costs for cabling, commissioning and
maintenance as opposed to conventional technology. Only two wires are used to
transmit all relevant information (i.e. input and output data, parameters, diagnostic data,
programs and operating power for field devices). In the past, incompatible vendor-
specific fieldbuses were frequently used, virtually all systems in design today are open
standard systems, the user is no longer tied to individual vendors and is able to select
the best and most economical product from a wide variety of products.
PROFIBUS specifies the technical and functional characteristics of a serial fieldbus
system with which decentralised digital controllers can be networked together from the
field level to the cell level, Profibus distinguishes between master and devices and slave
devices.
Siemens Step 7 PLC Programming
The Siemens Step 7 PLC has three main methods of programming, these are LAD
(Ladder Logic), STL (Statement List) and FBD (Function Block Diagram). The
software for the AC Top drive is written mainly in Ladder Logic with a small part
written in Statement List (For the communication with the Siemens 70 Series Drive),
none of the program was written in Function Block Diagram.
Ladder Logic Diagram

The left vertical line of a Ladder Logic Diagram (above), represents the power or
energised conductor. The output element or instruction represents the neutral or
return path of the circuit. The right vertical line, which represents the return path on a
hard-wired control line diagram, is omitted. Ladder logic diagrams are read from left-
to-right, top-to-bottom. Rungs are sometimes referred to as networks. A network may
have several control elements, but only one output coil.
Statement List
A statement is an instruction for the PLC. A Statement List (STL) (above), provides
another view of a set of instructions. A comparison between the statement list shown
below, and the ladder logic shown above, reveals a similar structure. The operation,
what is to be done, is shown on the left. The operand, the item to be operated on by
the operation, is shown on the right.
Understanding Ladder Logic
Diagram 1
Diagram 2
Diagram 3
Diagram 4
Diagram 5
Central Processing Unit 315-2 DP
Varco P/N = 122627-03
Mode Selector
RUN-P Run program mode
The CPU scans the user program, the key cannot be taken out in this position. Programs can be
read of out and loaded into the CPU with a programming device.
RUN Run mode.

The CPU scans the user program, the key can be removed in this position to prevent anyone
changing the operating mode. Programs in the CPU can be read out with a programming device,
but the program in the load memory cannot be changed.
STOP Stop mode.

The CPU does not scan the user program, the key can be removed to prevent anyone changing
the operating mode. Programs can be read of out and loaded into the CPU with a programming
device.
MRES Reset CPU memory

Momentary contact position of the mode selector switch for resetting the CPU memory when a
special sequence is carried out.
Status and Fault LED’s
SF (red) System error fault
Lights up in the event of: - (a) Hardware faults, (b) Firmware errors, (c) Programming errors, (d)
Parameter assignment errors, (e) Arithmetic errors, (f) Timer errors, (g) Defective memory card,
(h) Battery failure or no back-up on POWER ON, (i) I/O fault error.
Note:- You must use a programming device and read out the contents of the diagnostic
buffer to determine the exact nature of the error/fault.
BATF (red) Battery fault

Lights up if the battery defective, not inserted or discharged.
5VDC (green) 5 VDC supply for CPU

Lights up if the internal 5 VDC supply is OK.
RUN (green) Run mode.

Flashes at a CPU restart for at least three seconds, during the CPU re-start the STOP LED also
lights up, when the STOP LED goes off and the RUN LED is on constant, the outputs are
enabled.
STOP (yellow) Stop mode.

Lights up when the CPU is not scanning the user program. Flashes at one-second intervals when
the CPU requests a memory re-set.
Display Elements for PROFIBUS LED’S

SF DP BUSF Description
Off Off Configuration data OK, all configured slaves are

addressable.
On On Bus Hardware fault, DP interface fault
Possible Remedies:- Check the bus cable for short or interruption, evaluate the
diagnostic data, reconfigure or correct the configuring data.
On Flashes Station failure or at least one of the configured slaves

cannot be addressed.
Possible Remedies:- Check to make sure that the bus cable is connected correctly
to the CPU or that the bus is not interrupted. Wait until the
CPU has completed its power up, if the LED does not stop
flashing, check the DP slaves or evaluate the diagnostic data
for the DP slaves.
On Off Missing or incorrect configuring data.
Possible Remedies:- Evaluate the diagnostic data, reconfigure or correct the configuring data.
Step 7 CPU315-DP Back-up battery
Varco P/N = 122627-26
The Back-up battery for the CPU315-DP should only be replaced with the Power On, to
prevent the loss of data from the internal user memory, and to keep the clock of the
CPU running.
Siemens recommend that the Back-Up battery be replaced at yearly intervals.
When not in use the Back-Up batteries should be stored in a cool dry place, and can be
stored for five years.
Flash EPROM Memory Card
Installing the Memory card into the CPU.
Varco P/N – 122627-24
The purpose of the Memory Card is to store the user program, this will then be retained
when the CPU is powered down, even if a back-up battery has not been installed. With
the 315 - 2DP CPU, the Memory Card can be written to directly when installed as above
in the CPU.
The following procedure should be used for writing to the Flash Card when inserted in
the CPU :-
1. Power down the CPU and insert the Flash card.

2. Power up the CPU.
3. Delete the CPU using the key switch.
4. In the OFFLINE mode, download all the Blocks and System Data to the RAM.
5. Once all Blocks and Data are loaded, do a compare ONLINE and OFFLINE,
this should show that there are no differences (except for DB’s).
6. Still in the OFFLINE mode, do a Save RAM to ROM.
This should then display the message that this has been carried out satisfactory.
CPU Memory Reset
The CPU memory must be reset before a transfer of a complete user program to the
CPU, or if the CPU requests a MRES with its STOP LED flashing at one second
intervals, possible reasons for this are as follows:-
1. Wrong memory card has been plugged into the CPU.
2. RAM error in CPU.
3. Working memory too small, that is not all blocks of the user program on a
memory card could be loaded.
4. Attempt to load blocks with errors, for example if a wrong command has been
programmed.
With the 315-2 DP CPU and 5V FEPROM plugged in, the CPU requests a memory
reset.
Resetting the CPU Memory using the Mode Selector.
To reset the CPU using the Mode selector the following procedure should be carried
out:-
1. Turn the key to the STOP position
2. Turn the key to the MRES position and hold it in this position for about three
seconds, until the STOP LED lights up again.
3. Within three seconds, you must turn the key back to the MRES position and
hold it in this position until the STOP LED flashes, when the CPU has
completed the reset, the STOP LED stops flashing and remains lit.
The CPU has then performed the Reset.

PS 307 Power Supply Module (5A)
Varco P/N = 122627-01
The PS 307 power supply module has an output voltage of 24 VDC with an output
current of 5 Amp, this is short circuit and open circuit proof.
Basic Circuit Diagram

Relay Output module SM 322
Module front view and block diagram of relay outputs
Varco P/N = 122627-18
The relay output module has 8 output points, isolated in groups of two. There are two
Relay Outputs in the PLC rack (Slot 4 and 5), Slot 4 is used for all the 24 VDC
solenoids on the Top Drive (Brakes On, IBOP Closed, Torque Wrench, etc.). Slot 5
is used for the Motor Starters for the Hydraulic Pump and the Right and Left Blower
motors, it is also used for the Encoder By-Pass Indicator. If fitted to the Top Drive it
would also control the Stand Jump and Elevator Open/Close solenoids.
Digital Input Module SM 321
Module front view and block diagram of digital inputs
Varco P/N = 122627-09
The digital inputs module has 16 input points, isolated in groups of 16. The rated
input voltage is 24 VDC, they Inputs are used for the Over-temperatue and Pressure
Switches on the Top Drive, the Encoder By-Pass switch is also inputted to this
module.
Bartec Distributed I/O system
The Bartec Distributed I/O System
The field bus on which the Bartec Modex System is based on a version of
PROFIBUS known as PROFIBUS DP (DP = Decentralised Periphery or Distributed
I/0), this is designed for minimum reaction times in communication with the
distributed inputs and outputs. The Modex System comes from MODular EXplosion
and consists of an EEx d flameproof enclosure and EEx e connecting terminals. The
analogue modules used with the Varco Driller’s Console also have intrinsically safe
circuits EEx ia.

Bartec Profibus Analogue Output
Varco P/N = 140244-2
The Bartec Profibus Analogue output module has eight intrinsically safe direct
analogue outputs of 4-20mA. Two of these outputs are used as 4-20mA signals to
supply the Electro Flow RPM and Torque gauges on the Varco Driller’s Console, the
other two can be used for the customer logging equipment.
LED Indicators
ON When 24 VDC power applied, the LED will glow Yellow, no LED will
mean a power problem.
BF (Bus Fault) Normally it is off. If there is a bus problem/communication
failure it will glow Red.
SF (System Failure) Comes on when there is either a short or open circuit
on one of the Outputs.
UB2 Separate supply voltage to terminal U+/U-, glows green when voltage
applied, will turn off when no voltage applied.
OUTPUT 8 x Double LED (1-8). Yellow – Output satisfactory, Red – Open/Short
Circuit.

Bartec Modex Potentiometer Input
Varco P/N = 140968-4
The Bartec Profibus Potentiometer Input module, has a supply voltage of 24 VDC
with four analogue inputs, three of these inputs are used for the Throttle, Drill Torque
Limit and Make Up Torque Limit potentiometers on the Varco Driller’s Console. The
fourth input is an unused spare, which could be used if there was a problem with any
of the other inputs, with software and cabling changes inside the VDC.
LED Indicators
on one of the Inputs.
OUTPUT 4 x Double LED (1-4). Yellow – Input active, Red – Open/Short Circuit.

Bartec Modex Digital Input Modual
Varco P/N = 140968-2
There are two Bartec Profibus Digital Inputs modules in the Varco Driller’s Console,
they have a supply voltage of 24 VDC, with 16 EEx e digital inputs. The Inputs are
received from all the switch functions in the Varco Driller’s Console (Brake, IBOP,
Forward/Reverse, etc.).
LED Indicators
SF N/A
INPUT 16 x Double LED (1-16). Yellow On – Input High (1) (+10V to +30V),
Yellow Off – Input Low (0) (-30V to +5V).

Bartec Modex Digital Output Module
Varco P/N = 140244
The Bartec Profibus Digital Output module has a supply voltage of 24 VDC, it has 16
outputs of 24 V DC. The Outputs go to all the Indicators and the Horn in the Varco
Driller’s console (Drive Fault, Brake On, IBOP Closed, Horn, etc.)
LED Indicators
on one of the Outputs.
OUTPUT 16 x Double LED (1-16). Yellow – Output active, Red – Open/Short
Circuit.

AC Top Drive Step 7 PLC Program Structure
The Step 7 program for the AC Top Drive is structured as above, the program is
split into Functions (FC), which are initially called from the Organisation Block (OB).
There are two Program Block types, they are User Blocks and System Blocks.
User Blocks are the areas provided for managing the program code and the data for
the program. Based on the requirement of the process, the program can be
structured with the various options for user blocks, some of these blocks can be
executed cyclically, while others can be executed only when needed. User blocks
are also referred as Program blocks.
System Blocks are pre-defined function or function blocks integrated in the

operating system on the CPU, these blocks do not occupy any additional space in
the user memory. System blocks are called from the user program level, these
blocks have the same interface ,same design and the same number in the entire
system.
The User Blocks types that are used are Organisation block, Functions and Data
blocks.
Organisational Blocks (OB) form the interface between the S7 CPU and the user
program, the program for the AC Top drive is stored in various blocks and uses OB1
to call these blocks when needed.
Functions (FC) are logic operation blocks to which no memory area is assigned, an
FC does not need an instance data block, temporary variables are stored in the local
stack until the Function is concluded, and are lost when the FC finishes executing.
Data Blocks (DB) are permanently assigned areas in which data or information is
stored that another function collected, they are read/write areas that can be loaded in
the CPU as part of the program.
The System Block that is used in the program is the System Functions (SFC).
A System Function is a pre-programmed, debugged function that is integrated in

the S7 CPU, some of these tasks supported by these blocks are setting parameters
for modules, data communication, copying functions etc. SFC’s can be called from
the program without being loaded as part of the program, and do not have to be
assigned to a data block.
When the program is structured into Blocks, it must be accessed by calling one block
from another. As seen in the diagram above, when the program calls the second
block, the called block then executes all of its instructions, once the called block has
completed execution of its instructions, the calling block resumes the execution of its
program at the network following the Call instruction.
Choosing The Correct Operating mode
Step 7 allows you to examine, modify and write to programs in three different ways,
these ways are Direct, Offline and Online.
DIRECT
This mode is ideal for maintenance, in this mode you can directly monitor programs without
referencing to a project (no program loaded into Step 7). The project can be can be modified or
simply monitored to gather information about the system.
OFFLINE
Offline mode is best suited to offline programming, i.e. when the CPU is not present or
when the programming unit is not connected to the CPU. In this mode, blocks can be
written and then transferred (downloaded) to the CPU, downloading is obviously only
possible if the MPI cable is connected to the system. The program can also be
monitored, providing the program in the programming unit is the same as the one in the
CPU.
ONLINE
Online mode is the suited to programming with the programming unit connected to the CPU, if
the MPI cable is not present, the link will be automatically aborted. Programming changes will
however only take place when the appropriate ICON has been selected. To avoid differences
between the program on the disk and the program in the CPU (time stamp conflict), it is essential
to STORE TO DISK first and then DOWNLOAD to the CPU. Monitoring in this state is easier
as you are looking at what is at present in the CPU.
When working with Step 7, it is essential that only one of these modes is selected at any
one time, Step 7 will not allow to have blocks open in the Offline and online modes
together, one of the modes will have to be closed down before continuing.
TDS Training Manual

Montrose Scotland
AC TOP DRIVE
Section 12
Basics of AC Motors
AC Electrical
Basics of AC Motors
AC MOTOR BENEFITS

Basics of AC Motors
AC EXTRA PERFORMANCE

Basics of AC Motors
AC MOTORS
• Operate on the principle of induced magnetic

field from an alternating electric current.
• Magnetic field induced in STATOR rotates
around STATOR frame, which in turn induces
current in stationary ROTOR.
• ROTOR current induces a magnetic field on

ROTOR, this field tries to align itself with
rotating magnetic field on STATOR.
• The result of this attempted alignment is

TORQUE at the ROTOR shaft, the magnitude
of this TORQUE depends how much SLIP
occurs between the rotating magnetic field on
the STATOR and the ROTOR magnetic field.

Basics of AC Motors
AC MOTOR CONSTRUCTION
• Used in industrial applications
• Three phase 550/575 VAC in TDS applications

Basics of AC Motors
ROTOR CONSTRUCTION
Squirrel Cage Most Common
Rotor consists of Stack of Steel Laminations with evenly

spaced conductor bars.
• Current flows through the Rotor bars and around the

End ring.
• Current flow produces Magnetic Fields around each
Rotor bar.
• Rotor becomes an Electromagnet with alternating
North and South poles.
• Magnetic Fields of Rotor interact with Magnetic Fields
of Stator.
• Current and Magnetic Fields of Stator and Rotor
constantly changing.
• As Stator Magnetic Field rotates, Rotor and Shaft
follow.

Basics of AC Motors
STATOR CONSTRUCTION
The stator of the induction motor is a hollow cylinder
made up from silicon iron laminations with the winding
housed in slots in the inner surface. Like the D.C. motor
field, it can have any number of pole pairs and each pole
can be produced by any number of concentric coils. The
drawing below shows a motor with only two poles two
coils per phase (i.e. 4 slots per pole per phase). Note that
only one pole per phase is shown for clarity.

Basics of AC Motors
ROTATING MAGNET FIELD
• Rotating Magnetic Field produced in Motor

Stator windings.
• Number of Poles is depending by how many
times a phase winding appears.
• TDS-9, 10 and 11, 4 Pole (2 pole pairs).
• TDS-8, 6 Pole (3 pole pairs).
2- Pole Stator Windings.

Basics of AC Motors
Rotating Magnet
• No direct electrical connection between Stator

and Rotor.
• To visualise how a Rotor works, substitute a
Magnet for the Squirrel cage Rotor.
• Magnet Field interacts with rotating Stator Field.
• North Pole of Stator attracts South Pole of
Magnet.
• Magnet follows rotating Magnetic fields.

Basics of AC Motors
ROTATING MAGNETIC FIELD
• Evaluate the Field at 60° intervals

• After six intervals the field rotates 360°.

Basics of AC Motors
Synchronous Speed
• Speed of Rotating Magnet Field Refereed to as Synchronous

Speed (Ns).
• Equal to 120 Times the Frequency (F) Divided by the
Number of Poles.
Slip
• Relative Difference between Speed of Rotor and Rotating

Magnetic Field.
• Necessary to Produce Torque.
• Dependent on Load.

Basics of AC Motors
Electrical components of an AC Motor
• Vs = Line Voltage applied to Stator power leads.

• Rs = Stator Resistance.
• Ls = Stator leakage inductance.
• Is = Stator current.
• E = Air gap or magnetising voltage.
• Lm = Magnetising inductance.
• Im = Magnetising current.
• Rr = Rotor leakage inductance.
• Iw = Working or Torque producing current.

Basics of AC Motors
Working Current
• Current that Flows in the Rotor Circuit and produces Torque.
• Function of the Load.
• An Increase in Load Causes the Rotor Circuit to Work Harder,
Increasing Working Current (Iw).
• A Decrease in Load, Decreases the Work of the Rotor Circuit does
Decreasing Working Current (Iw).
Stator Current
• Full-Load Ampere rating on the Motor Nameplate.
• Current that flows in the Stator Circuit.
• Can be measured on the Supply Line and is also referred to as Line
Current.

Basics of AC Motors
HORSEPOWER AND
KILOWATTS
• AC Drives and Motors manufactured in

United States measured in HP (Horsepower).
• AC Drives and Motors manufactured in
Europe, generally rated in KW (Kilowatts).
KW = 0.746 * HP
HP = 1.341 * KW
DRILLING MOTORS
• Glass served installation on all new and

reworked motors to increase voltage rating.
• Snubbers added to reduce voltage from
Siemens and IDM IGBT drives.
• TDS-8 = 1 * 1150 HP motor.
• TDS-9 = 2 * 350 HP motors (700 HP).
• TDS-10 = 1 * 350 HP motor.
• TDS-11 = 2 * 400 HP motors (800 HP).

Basics of AC Motors
MOTOR NAMEPLATE
• Installation Class
• Established by NEMA.
• Ambient temperature is standardised at 40° C or 104° F.
• Combination of ambient temperature and allowed temperature
rise equals maximum winding temperature.
• NEMA Design
• National Electrical Manufacturers Association (NEMA)
established standards for motor construction and
performance.
• Efficiency
• Indication of how much input electrical energy is converted to
output mechanical energy.
• Voltage Connection and Amps
• The Reliance motor is specified for 550 Volts.
• Maximum full load current of 331 Amps.
• Base Speed
• Nameplate speed, given in RPM, where motor develops rated
Horsepower at rated Voltage and Frequency.
• Reliance motor is 1155 RPM.
• Maximum Speed
• Maximum rated speed of the motor, torque is reduced.
• Reliance motor is 2400 RPM.
Reliance motor used on TDS-9 + 10. (TDS-11, 575 V & 366 A)

TDS Training Manual

Montrose Scotland
AC TOP DRIVE
Section 13
Basics of AC Drives
AC Electrical
Basics of AC Drives
AC Drives
u Speed of an AC Motor can be

Controlled Using Electronic Drive
Equipment.
– Variable or Adjustable Speed Drives.
– Commonly known as AC Drives
– Also referred to as Inverters.
– Although the Inverter is only one part of the
AC Drive.
Vector Control
u Control Torque and Speed

Continuously through Zero Speed.
u Can hold motor stationary against an
applied torque.
u Requires Tach feedback to work best.
u Speed control reaction time <=20ms.
u Torque control reaction time <=10ms.
u Current Limit, 150% motor rated
current for One minute.

Basics of AC Drives
Power in an AC Circuit
True Power
• Consumed and used to do Useful Work.
• Measured in Watts (W).
Reactive Power
• Not Consumed.
• Measured in Volt-Amps Reactive (VAR).
Apparent Power
• Vector Sum of True Power and Reactive Power.
• Measured in Volt-Amps (VA).
Reactive vs. True Power

Basics of AC Drives
Power Factor
u Ratio of True Power to Apparent Power
u Purely Resistive Circuit
– Current and Voltage in Phase and There is No
Angle Displacement
– Cosine of Zero is 1
– PF = 1
Three-Phase Power
• Produced by Three Voltages Sources.
- Each Phase offset by 120 Electrical Degrees.
• Used where a Large Quantity of Power is Required.
- Commercial and Industrial Applications.
Three Phase Power Formula

Basics of AC Drives
Pulse Width Modulation (PWM)
• Provide more Sinusoidal Current Output.
• More Efficient, Higher levels of Performance.

Basics of AC Drives
PWM Converter and DC Link
• Fixed Diode Bridge Rectifier

- Rectified DC Value Approximately 1.35 Times Line to
Line Voltage.
- The Choke (L1) and Capacitors (C1) smooth the DC Link
Voltage.

Basics of AC Drives
PWM Logic and Inverter Section

• Output Voltage and Frequency Controlled by Control Logic and
Inverter Section.
• Inverter Section Consists of Switching Devices.
- Depending on Drive, Thyristors, Bipolar Transistors, MOSFETS,
GTO’s or IGBT’s can be used.

Basics of AC Drives
IGBT’s
• Insulated Gate Bipolar Transistor.
- Provides High switching speed required by PWM’s.
- Capable of switching ON and OFF Several Thousand Times
a Second.
- Turn ON in Less than 400 Nanoseconds.
- Turn OFF in 500 nanoseconds.

Basics of AC Drives
Developing a Basic AC Output

Basics of AC Drives
Generating a PWM Output

Basics of AC Drives
PWM Voltage and Current Output

Basics of AC Drives
Four Quadrant Operation

• The dynamics of the Top Drive, require Four Quadrant
Operation.
• When equipped with a Breaking Resistor the AC Drive is
capable of producing Four Quadrant Operation.
• Torque will always act to cause synchronous speed.
• If synchronous speed is reduced, negative Torque is developed
in the Motor.
• The Motor acts like a generator, converting mechanical power
into electrical power, which is returned to the AC Drive.

Basics of AC Drives
Breaking Resistor
• Electrical energy is returned to the AC Drive by the Motor can
cause the DC Link to become excessively high when added to
existing supply voltage.
• The Breaking Resistor is added and removed from the circuit by
an IGBT, when requested.
• The Resistor placed across the DC Link, dissipates excessive
energy.
• Thus returning the Dc Link to a save voltage.
• This process allows the motor to act like a brake, slowing the
connected load quickly.

TDS Training Manual

Montrose Scotland
AC TOP DRIVE
Section 14
Siemens 70 Series Drive

Chassis AC to AC
AC Electrical
Description
Range of application The frequency converter is a power electronics component for feeding
three-phase drives in the output range from 37 kW to 400 kW.
The unit can be operated from a three-phase system with a frequency
of 50/60 Hz and a voltage in the range of the values entered on the
rating plate (380...480 / 500...600 / 660...690 V).
The three-phase current from the system is rectified, smoothed and fed
onto the capacitor DC link.
The inverter enables a variable output frequency between 0 Hz and a
maximum of 600 Hz to be generated from the DC current with the pulse
width modulation method (PWM).
The internal DC 24 V voltage is supplied through an integral power
supply unit.
The unit is controlled by the internal closed-loop electronics, the
functions are provided by the unit software.
Operator control is via the PMU operator control panel, the user-friendly
OP1S operator control panel, the terminal strip or via the serial
interfaces of the bus system. For this purpose, the unit is provided with
a number of interfaces and six slots for the use of optional boards.
Pulse encoders and analog tachometers can be used as encoders on
the motor.
Terminal strip
Optional PMU
boards
Control electronics Serial
interface
Pre-charging
DC link
U1/L1 U2/T1
V1/L2 V2/T2 Motor
connec-
W1/L3 W2/T3 tion
Rectifier Inverter
C / L+
D/L-
PE1 PE2
Fans, volumetric MLFB 6SE70xx-xEJ60 6SE7037-0EK60
flow, opening cross- 6SE70xx-xFJ60
sections 6SE70xx-xGJ60
Fan 2 x RH28M 2 x RH28M
Minimum volumetric flow [m3/s] 0.46 0.6
Min. opening cross-section in the
cabinet doors [m2] 0.26 0.26
Type of protection IP00 to IP42
top cover [m2] 0.26 0.26
Type of protection < IP20
roof section [m2] 0.26 0.26
Type of protection IP22 to IP42
Opening cross-section in Direct partition

the roof section at the top between the fan box
(also possible at the front and the cabinet frame
and/or at the side) from all 4 sides
Cabinet frame
Partition to adjacent
cabinets on the left,
on the right and at the
rear
Opening cross-
sections in the doors
(maybe with filters
situated behind them)
Installing the optional boards
WARNING The boards may only be replaced by qualified personnel.

It is not permitted to withdraw or insert the boards under voltage.
Slots A maximum of six slots are available in the electronics box of the unit
for installing optional boards. The slots are designated with the letters A
to G. Slot B is not provided in the electronics box. It is used in units of
the Compact PLUS type of construction.
If you wish to use slots D to G, you will additionally require the
following:
♦ Bus expansion LBA (Local Bus Adapter), which is used for mounting
the CU board and up to two adaption boards, and
♦ An adaption board (ADB - Adaption Board) on which up to two
optional boards can be mounted.
The slots are situated at the following positions:
♦ Slot A CU board Position: top
♦ Slot C CU board Position: bottom
♦ Slot D Adaption board at mounting position 2 Position: top
♦ Slot E Adaption board at mounting position 2 Position: bottom
♦ Slot F Adaption board at mounting position 3 Position: top
♦ Slot G Adaption board at mounting position 3 Position: bottom
Mounting
position 1
Mounting
position 3
Mounting
position 2
NOTE Mounting position 2 can be used for technology boards (T100, T300,
TSY).
Mounting positions 2 and 3 can also be used for communication boards
SCB1 and SCB2.
WARNING The unit has hazardous voltage levels up to 5 minutes after it has been
powered down due to the DC link capacitors. The unit must not be
opened until at least after this delay time.
CAUTION The optional boards contain components which could be damaged by

electrostatic discharge. These components can be very easily
destroyed if not handled with caution. You must observe the ECB
cautionary measures when handling these boards.
Disconnecting the Disconnect the unit from the incoming power supply (AC or DC supply)
unit from the supply and de-energize the unit. Remove the 24 V voltage supply for the
electronics.
Open the front panel.
Preparing Remove the CU board or the adaption board from the electronics box
installation as follows:
♦ Disconnect the connecting cables to the CU board or to the optional
boards.
♦ Undo the two fixing screws on the handles above and below the CU
board or the adaption board.
♦ Pull the CU board or the adaption board out of the electronics box
using the handles.
♦ Place the CU board or the adaption board on a grounded working
surface.
Installing the Insert the optional board from the right onto the 64-pole system
optional board connector on the CU board or on the adaption board. The view shows
the installed state.
Screw the optional board tight at the fixing points in the front section of
the optional board using the two screws attached.
Re-installing the unit Re-install the CU board or the adaption board in the electronics box as
follows:
♦ Insert the CU board into mounting position 1 and the adaption board
into mounting position 2 or 3.
NOTE Mounting position 3 cannot be used until at least one adaption board
has been installed at mounting position 2.
Boards should first be installed in mounting position 2, before mounting
position 3 is used.
♦ Secure the CU board/adaption board at the handles with the fixing
screws.
Re-connect the previously removed connections.
Check that all the connecting cables and the shield sit properly and are
in the correct position.
Connecting-up
WARNING SIMOVERT MASTERDRIVES units are operated at high voltages.

The equipment must be in a no-voltage condition (disconnected from
the supply) before any work is carried out!
Only professionally trained, qualified personnel must work on or with
the units.
Death, severe bodily injury or significant property damage could occur if
these warning instructions are not observed.
Hazardous voltages are still present in the unit up to 5 minutes after it
has been powered down due to the DC link capacitors. Thus, the
appropriate delay time must be observed before working on the unit or
on the DC link terminals.
The power terminals and control terminals can still be live even when
the motor is stationary.
When working on an opened unit, it should be observed that live
components (at hazardous voltage levels) can be touched (shock
hazard).
The user is responsible that all the units are installed and connected-up
according to recognized regulations in that particular country as well as
other regionally valid regulations. Cable dimensioning, fusing,
grounding, shutdown, isolation and overcurrent protection should be
particularly observed.
Mains connection DC link
connection
PE1 / GND
PMU
X300
X108
X101
Mount.pos. 1 (CUVC)
X102
X103
Optional board
in slot C
Mounting position 3
Mounting position 2
Aux. contactor, external
DC24 V supply X9
Shield connection
for control cables
Terminals for
setting the
fan voltage
Motor connection
PE2 / GND
NOTE Due to the 230 V fan a transformer is integrated into the converters.
The terminals on the primary side of the transformer must be connected
corresponding to the rated input voltage.
Protective The protective conductor has to be connected both on the line side and
conductor on the motor side. It has to be dimensioned according to the power
connection connections.
DC link connection The "braking unit" and "dv/dt filter" options can be connected up to the
DC link terminals C/L+ and D/L-. These terminals are not suitable for
connecting up other inverter units (e.g. DC units).
This connection is not suitable for connecting up a rectifier or
rectifier/feedback unit.
With the M65 option, it is possible to move the DC link terminals to the
bottom of the unit.
NOTE Type K Due to the 230 V fan a transformer is integrated into the converters.
The terminals on the primary side have to be reconnected according to
the rated input voltage, if necessary.
If this is not done, the fuses F3, F4 or F101, F102 may blow.
CUVC
Control connections
Standard In the basic version, the unit has the following control connections on
connections the CUVC:
♦ Serial interface (RS232 / RS485) for PC or OP1S
♦ A serial interface (USS bus, RS485)
♦ A control terminal strip for connecting up a HTL unipolar pulse
enocder and a motor temperature sensor (PTC / KTY84)
♦ Two control terminal strips with digital and analog inputs and
outputs.
X108
S1
S2
S3/3,4
S3/1,2
X101
X102
X103
S4/4,5,6
S4/1,2,3
X101 Controller Slot A
1 P24V Micro- Slot C
Aux. power controller Slot D
supply 2 M24
150 mA Slot E
3 Slot F
Out Slot G
Out In In
Out PMU X300
4 Out
Bidirectional Out/In
digital inputs- 5V In
In
and outputs 5 Out
Iout ≤ 20 mA 24V In
6 Out
In
4 bidirectional digital inputs/outputs
Outputs
7 5V
24V In
8 5V
Digital inputs 24V In
Ri = 3,4 kΩ 9 8 7 6 5 4 3 2 1
9 5V
BOOT
P5V
n.c.
RS485N
RS232 TxD
RS485P
RS232 RxD
24V In
Inputs
RS485P
10
Serial interface 2
USS (RS485) RS485N UART BOOT
11
12
Reference potential RS485
S2
+5V
X102 Switch for USS bus connection
Reference voltage P10 AUX
P10 V / N10 V 13
I ≤ 5 mA ≥1
N10 AUX
14
15
S1
S3 A
In
Analog input 1 D +5V
1 2 AI 1 Switch for USS bus connection
(non-floating)
11 bit + sign
16
U: Rin = 60 kΩ X103
I: Rin = 250 Ω
(Close S3) 17 Tacho M
S3 A 23
In
Analog input 2 D
Track A Pulse
(non-floating) 3 4 AI 2 24
encoder
18 A Track B I≤190 mA
S4 S 25
AO 1
1
D 3 -10...+10 V I Zero pulse
19 26
A 0...+20 mA
Analog output 1 2 C Control
20 M 27
10 bit + sign S4
U: I ≤ 5 mA AO 2 4 Tacho P15
6 -10...+10 V 28
I: R ≤ 500 Ω D
21 Mot. temp BS
A 0...+20 mA
Analog output 2 5 29 Motor
22 M temperature
Mot.temp
30 sensor
KTY84
or PTC
thermistor
X101 – Control The following connections are provided on the control terminal strip:
terminal strip ♦ 4 optionally parameterizable digital inputs and outputs
♦ 3 digital inputs
♦ 24 V aux. voltage supply (max. 150 mA) for the inputs and outputs
♦ 1 serial interface SCom2 (USS / RS485)
Terminal Designation Significance Range
1 P24 AUX Aux. voltage supply DC 24 V / 150 mA
2 M24 AUX Reference potential 0V
3 DIO1 Digital input/output 1 24 V, 10 mA / 20 mA
7 DI5 Digital input 5 24 V, 10 mA
10 RS485 P USS bus connection RS485
SCom2
11 RS485 N USS bus connection RS485
SCom2
12 M RS485 Reference potential RS485
Connectable cross-section: 1.5 mm² (AWG 16)
Terminal 1 is at the top when installed.
X102 – Control The following connections are provided on the control terminal strip:
terminal strip ♦ 10 V aux. voltage (max. 5 mA) for the supply of an external
potentiometer
♦ 2 analog inputs, can be used as current or voltage input
♦ 2 analog outputs, can be used as current or voltage output
13 P10 V +10 V supply for ext. +10 V ±1.3 %,
potentiometer Imax = 5 mA
14 N10 V -10 V supply for ext. -10 V ±1.3 %,
potentiometer Imax = 5 mA
15 AI1+ Analog input 1 + 11 bit + sign
16 M AI1 Ground, analog input 1 Voltage:
17 AI2+ Analog input 2 + ± 10 V / Ri = 60 kΩ
18 M AI2 Ground, analog input 2 Current: Rin = 250 Ω
19 AO1 Analog output 1 10 bit + sign
20 M AO1 Ground, analog output 1 Voltage:
21 AO2 Analog output 2 ± 10 V / Imax = 5 mA
22 M AO2 Ground, analog output 2 Current: 0...20 mA
R ≥ 500 Ω
X103 – Pulse The connection for a pulse encoder (HTL unipolar) is provided on the
encoder connection control terminal strip.
23 - VSS Ground for power supply
24 Track A Connection for track A HTL unipolar
25 Track B Connection for track B HTL unipolar
26 Zero pulse Connection for zero pulse HTL unipolar
27 CTRL Connection for control track HTL unipolar
28 + VSS Power supply pulse 15 V
encoder Imax = 190 mA
29 - Temp Minus (-) connection
KTY84/PTC KTY84: 0...200 °C
30 + Temp Plus (+) connection PTC: RPTC therm ≤
KTY84/PTC 1.5 kΩ
X300 - Serial Either an OP1S or a PC can be connected up via the 9-pole Sub D
interface socket.
Pin Name Significance Range
1 n.c. Not connected
5 1
2 RS232 RxD Receive data via RS232 RS232
3 RS485 P Data via RS485 RS485
4 Boot Control signal for software Digital signal, low
update active
9 6
5 M5V Reference potential to P5V 0V
6 P5V 5 V aux. voltage supply +5 V, Imax = 200 mA
7 RS232 TxD Transmit data via RS232 RS232
8 RS485 N Data via RS485 RS485
9 n.c. Not connected
Switch settings Switch Significance
S1 SCom1 (X300): Bus terminating resistor
• open • Resistor open
• closed • Resistor closed
S2 SCom2 (X101/10,11): Bus terminating
• open resistor
• closed • Resistor open
• Resistor closed
S3 (1,2) AI1: Changeover current/voltage input
• open • Voltage input
• closed • Current input
S3 (3,4) AI2: Changeover current/voltage input
• open • Voltage input
• closed • Current input
S4 (1,2,3) AO1: Changeover current/voltage output
• Jumper 1, 3 • Voltage output
• Jumper 2, 3 • Current output
S4 (4,5,6) AO2: Changeover current/voltage output
• Jumper 4, 6 • Voltage output
• Jumper 5, 6 • Current output
Parameter input via the PMU
The PMU parameterizing unit enables parameterization, operator
control and visualization of the converters and inverters directly on the
unit itself. It is an integral part of the basic units. It has a four-digit
seven-segment display and several keys.
The PMU is used with preference for parameterizing simple
applications requiring a small number of set parameters, and for quick
parameterization.
Key Significance Function

ON key • For energizing the drive (enabling motor activation).
• If there is a fault: For returning to fault display
OFF key • For de-energizing the drive by means of OFF1, OFF2 or OFF3
(P554 to 560) depending on parameterization.
Reversing key • For reversing the direction of rotation of the drive.
The function must be enabled by P571 and P572
Toggle key • For switching between parameter number, parameter index
and parameter value in the sequence indicated (command
becomes effective when the key is released).
• If fault display is active: For acknowledging the fault
Raise key For increasing the displayed value:
• Short press = single-step increase
• Long press = rapid increase
Lower key For lowering the displayed value:
• Short press = single-step decrease
• Long press = rapid decrease
Hold toggle key • If parameter number level is active: For jumping back and forth
and depress raise between the last selected parameter number and the
key operating display (r000)
• If fault display is active: For switching over to parameter
number level
• If parameter value level is active: For shifting the displayed
value one digit to the right if parameter value cannot be
displayed with 4 figures (left-hand figure flashes if there are
any further invisible figures to the left)
Hold toggle key • If parameter number level is active: For jumping directly to the
and depress lower operating display (r000)
key • If parameter value level is active: For shifting the displayed
value one digit to the left if parameter value cannot be
displayed with 4 figures (right-hand figure flashes if there are
any further invisible figures to the right)
Raise key
Seven-segment display for:
Drive statuses
Reversing key Alarms and

faults
ON key
Toggle key Parameter numbers
OFF key
Parameter indices
Lower key
X300 Parameter values
Toggle key As the PMU only has a four-digit seven-segment display, the 3
(P key) descriptive elements of a parameter
♦ Parameter number,
♦ Parameter index (if parameter is indexed) and
♦ Parameter value
cannot be displayed at the same time. For this reason, you have to
switch between the individual descriptive elements by depressing the
toggle key. After the desired level has been selected, adjustment can
be made using the raise key or the lower key.
With the toggle key, you can change Parameter number
over:
• from the parameter number to the P
P
parameter index
• from the parameter index to the
parameter value Parameter Parameter
index value
• from the parameter value to the
parameter number P
If the parameter is not indexed, you
can jump directly to the parameter
value.
NOTE If you change the value of a parameter, this change generally becomes
effective immediately. It is only in the case of acknowledgement
parameters (marked in the parameter list by an asterisk ‘ * ’) that the
change does not become effective until you change over from the
parameter value to the parameter number.
Parameter changes made using the PMU are always safely stored in
the EEPROM (protected in case of power failure) once the toggle key
has been depressed.
Example The following example shows the individual operator control steps to be
carried out on the PMU for a parameter reset to factory setting.
Set P053 to 0002 and grant parameter access for PMU
∇ ∇
Ì P Î Ì Î Ì Î Ì P Î
P053 0000 0001 0002 P053
Select P060
∇
Ì Î
P053 P060
Set P060 to 0002 and select "Fixed settings" menu

∇
Ì P Î Ì Î Ì P Î
P060 1 2 P060
Select P970
∇ ∇
Ì Î Ì Î
P060 P366 P970
Set P970 to 0000 and start parameter reset

∇
P970 1 0 °005
Parameter input via the OP1S
General
The operator control panel (OP1S) is an optional input/output device

which can be used for parameterizing and starting up the units. Plain-
text displays greatly facilitate parameterization.
The OP1S has a non-volatile memory and can permanently store
complete sets of parameters. It can therefore be used for archiving sets
of parameters, but first the parameter sets must be read out (upread)
from the units. Stored parameter sets can also be transferred
(downloaded) to other units.
The OP1S and the unit to be operated communicate with each other via
a serial interface (RS485) using the USS protocol. During
communication, the OP1S assumes the function of the master whereas
the connected units function as slaves.
The OP1S can be operated at baud rates of 9.6 kBd and 19.2 kBd, and
is capable of communicating with up to 32 slaves (addresses 0 to 31). It
can therefore be used in a point-to-point link (e.g. during initial
parameterization) or within a bus configuration.
The plain-text displays can be shown in one of five different languages
(German, English, Spanish, French, Italian). The language is chosen by
selecting the relevant parameter for the slave in question.
Order numbers Components Order Number

OP1S 6SE7090-0XX84-2FK0
Connecting cable 3 m 6SX7010-0AB03
Connecting cable 5 m 6SX7010-0AB05
Adapter for installation in cabinet door incl. 5 m cable 6SX7010-0AA00
8.2 A 25 V 00
# 100.000 min-1 LCD (4 lines x 16 characters)
* 100.000 min-1
Run
9-pole SUB-D connector
LED red Fault on rear of unit
LED green Run
Reversing key
ON key I Raise key
OFF key O P Lower key

Key for toggling between control levels
Jog key Jog 7 8 9
4 5 6 0 to 9: number keys
1 2 3
0 +/- Reset Reset key

Sign key
OP1S connections Pin Designation Significance Range

1
2
1 5
3 RS485 P Data via RS485 interface
4
5 N5V Ground
6 9
6 P5V 5 V aux. voltage supply ±5%, 200 mA
7
8 RS485 N Data via RS485 interface
9 Reference potential
Connecting
The OP1S can be connected to the units in the following ways:

♦ Connection via 3 m or 5 m cable (e.g. as a hand-held input device
for start-up)
♦ Connection via cable and adapter for installation in a cabinet door
♦ Plugging into MASTERDRIVES Compact units (for point-to-point
linking or bus configuration)
SIEMENS
100.0A 380.0V zz
#-300.000Hz
*-300.000Hz
Betrieb
Fault
Run
O P
USS-Bus
USS via RS485
Jog 7 8 9
4 5 6
1 2 3
0 +/- Reset
X300
OP1S Connecting cable
5 5
9 9
4 4
8 8
3 3
7 7
2 2
6 6
1 1
OP1S side: Unit side:
9-pole SUB D socket 9-pole SUB D connector
Plugging into units Carefully penetrate the pre-punched holes for the fixing screws in the
of the Compact and front panel of the Compact units. Plug the OP1S onto the Sub D socket
chassis type X300 and screw it tight using the two screws (M5 x 10, accessory pack)
from the inside of the front panel.
Run-up
After the power supply for the unit connected to the OP1S has been
turned on or after the OP1S has been plugged into a unit which is
operating, there is a run-up phase.
NOTE The OP1S must not be plugged into the Sub D socket if the SCom1
interface parallel to the socket is already being used elsewhere,
e.g. bus operation with SIMATIC as the master.
NOTE In the as-delivered state or after a reset of the parameters to the factory
setting with the unit’s own control panel, a point-to-point link can be
adopted with the OP1S without any further preparatory measures.
When a bus system is started up with the OP1S, the slaves must first
be configured individually. The plugs of the bus cable must be removed
for this purpose (see section "Bus operation").
During the run-up phase, the text "Search slave" is shown in the first
line of the display, followed by "Slave found" and the found slave
number as well as the set baud rate.
Slave found
Adress: [00]
Baudrate: [6]
Example of a display after the run-up phase (6 corresponds to 9.6 kBd)
After approximately 4 s, the display changes to

SIEMENS
MASTERDRIVES VC
6SE7016-1EA61
SW:V3.0 OP:V2T20
Example of what is displayed after a slave address has been found
After a further 2 s, there is a changeover to the operating display. If it is

not possible to start communicating with the slave, an error message
“Error: Configuration not ok” appears. About 2 s later, a request is
made for new configuration.
New config?
#yes
no
Error message displayed when communication is not possible

Operator control
Operator control elements
Key Significance Function

ON key • For energizing the drive (enabling motor activation). The
function must be enabled by P554.
OFF key • For de-energizing the drive by means of OFF1, OFF2 or
O OFF3. The function must be enabled by P554 to P560.
Jog key • For jogging with jog setpoint 1 (only effective when the
Jog
unit is in the "Ready to start" state). This function must
be enabled by P568.
Reversing key • For reversing the direction of rotation of the drive. This
function must be enabled by P571 and P572.
Toggle key • For selecting menu levels and switching between

P parameter number, parameter index and parameter
value in the sequence indicated. The current level is
displayed by the position of the cursor on the LCD
display (the command comes into effect when the key is
released).
• For conducting a numerical input.
Reset key • For leaving menu levels
Reset
• If fault display is active: For acknowledging the fault. This
function must be enabled by P565.
Raise key For increasing the displayed value
• Short press = single-step increase
• Long press = rapid increase
• If motorized potentiometer is active, this is for raising the
setpoint. This function must be enabled by P573.
Lower key For lowering the displayed value:
• Short press = single-step decrease
• Long press = rapid decrease
• If motorized potentiometer is active, this is for lowering
the setpoint. This function must be enabled by P574.
Sign key • For changing the sign so that negative values can be
+/- entered
Number keys • Numerical input
0 to 9
Operating display
After run-up of the OP1S, the following operating display appears:

0.0A 0V 00
# 0.00 min-1
* 0.00 min-1
Ready.
Example of an operating display in the "Ready" status
st
The values shown in the operating display (except for slave number, 1
line on the far right) can be specified by means of parameterization:
st
1 line, left (P0049.001) in the example "Output current"
st
1 line, right (P0049.002) in the example "DC link voltage"
nd
2 line actual value (P0049.003) in the example "Actual speed"
(only a visualization parameter)
rd
3 line setpoint (P0049.004) in the example "Speed setpoint"
th
4 line (P0049.005) in the example "Operating state"
In the operating display, the actual value is indicated with "#" and the
setpoint with "*".
In addition to the operating display on the display unit, the operating
state is indicated by the red and green LEDs as follows:
Flashing Continuous
red LED Alarm Fault
green LED Ready for ON Operation

Basic menu
When the "P" key is pressed, a changeover is made from the operating
display to the basic menu.
Ì P Î
0.0 A 0 V 00 VectorControl
# 0.00 min-1 *Menu Selection
* 0.00 min-1 OP: Upread
Ready. OP: Download
Display of the basic menu
The basic menu is the same for all units. The following selections can
be made:
♦ Menu selection
♦ OP: Upread
♦ OP: Download
♦ Delete data
♦ Change slave
♦ Config. slave
♦ Slave ID
As not all the lines can be shown at the same time, it is possible to
scroll the display as required with the "Lower" and "Raise keys.
Ì ∇ Î Ì ∇ Î Ì ∇ Î Ì ∇ Î
VectorControl VectorControl VectorControl VectorControl VectorControl
*Menu Selection *Menu Selection *Menu Selection OP: Upread OP: Download and so on
OP: Upread #OP: Upread OP: Upread OP: Download Delete data
OP: Download OP: Download #OP: Download #Delete data #Change slave
Example of switching from one line to the next
The currently active function is indicated by the "*" symbol and the
selected function by the "#” symbol. After the "P" key has been
pressed, the relevant symbol jumps to the selected function. The
"Reset" key is for returning to the operating display.
Slave ID
With the "Slave ID" function, the user can request information about the
connected slave. The slave ID consists, for example, of the following
lines:
MASTERDRIVES VC
6SE7016-1EA61
2.2 kW
V3.0
15.02.1998
Starting from the basic menu, the "Slave ID" function is selected with
"Raise" or "Lower" and activated with "P". As all the lines cannot be
shown at the same time, it is possible to scroll the display as required
with the "Lower" and "Raise" keys. In addition, the slave number is
shown at the top on the right-hand side.
Ì P Î Ì ∇ Î Ì ∇ Î Ì ∇ Î
VectorControl VectorControl 00 VectorControl 00 VectorControl 00 VectorControl 00
Change slave Slave ID Slave ID Slave ID Slave ID
Config. slave MASTERDRIVES VC 6SE7016-1EA61 and so on
#Slave ID 6SE7016-1EA61 2.2 kW
Example of a slave ID
Menu selection
The actual parameterization and start-up of the connected slave is

performed by means of the "Menu selection" function. Starting from the
basic menu, the "Menu selection" function is selected with "Lower" or
"Raise". By pressing "P", the unit-specific sub-menu is displayed with
the following choices:
♦ User Param.
♦ Param Menu..
♦ FixedSet...
♦ Quick Param...
♦ Board Conf.
♦ Drive Set
♦ Download
♦ UpR/fr.Access
♦ Power Def.
Two or more dots after these items mean that there is a further sub-
menu level. If "Parameter menu.." is selected, access is possible to all
parameters via correspondingly structured sub-menus. If "UpR/fr.
Access" is selected, direct access is gained to the parameter level.
7x
Ì P Î Ì ∇ Î Ì ∇ Î
VectorControl Menüauswahl Menu selection r001 9
*Menu selection *User Param. Drive Set. Drive Status
Upread Param Menu.. Download
Download FixedSet... #UpR/fr.Access Ready
Example: Selecting the parameter level by means of UpR/fr.access
2x
Ì P Î Ì ∇ Î Ì P Î Ì P Î
Menu selection Parameter Menu Param Menu Communication P700.001
*User Param. *Gen. Param. *Gen. Param. *SST1/SST2 0
#Param Menu.. Terminals Terminals Field bus conn. SCom Bus Addrese
FixedSet... Communication #Communication SIMOLINK Ser. Interf.1
Example: Selecting a parameter via sub-menus

Parameter display A parameter number can be selected from the parameter level directly
and parameter with the numerical keys or with "Raise"/"Lower". The parameter number
correction is shown as a three-figure quantity. In the event of four-figure
parameter numbers, the first figure (1, 2 or 3) is not displayed. A
distinction is made with the letters (P, H, U etc.).
Ì 0 Î Ì 4 Î Ì 9 Î
r001 9 r000 r004 r049.001
Drive Status 4
OP OperDisp
Ready 1. line, on left
Example: Direct input of the parameter number with the numerical keypad
∇ ∇ ∇
Ì Î Ì Î Ì Î
r001 9 r002 r004 r006
Drive Status 0 min-1 0.0 A 0 V
Actual speed Output Amps DC Bus Volts
Ready.
Example: Correcting the parameter number by means of "Raise"
If the parameter is found not to exist when the number is entered, a

message "No PNU" appears. A non-existent parameter number can be
skipped by selecting "Raise" or "Lower".
How the parameters are shown on the display depends on the type of
parameter. There are, for example, parameters with and without an
index, with and without an index text and with and without a selection
text.
Example: Parameter with index and index text

P704.001
0 ms
SCom Tlg OFF
Ser.Interf.1
1st line: Parameter number, parameter index

2nd line: Parameter value with unit
3rd line: Parameter name
4th line:Index text
Example: Parameter with index, index text and selection text
P701.001 6
SCom Baud rate
Ser Interf.1
9600 Baud
1st line: Parameter number, parameter index, parameter value

2nd line: Parameter name
3rd line: Index text
4th line:Selection text
Example: Parameter without index, with selection text, binary

value
P053 0006Hex
Parameter Access
0000000000000110
ComBoard: No
1st line: Parameter number, parameter value, hexadecimal parameter

value
2nd line: Parameter name
3rd line: Parameter value, binary
4th line:Selection text
Transition between the parameter number, parameter index and

parameter value levels is made with "P".
Parameter number → "P" → Parameter index → "P" → Parameter
value
If there is no parameter index, this level is skipped. The parameter
index and the parameter value can be corrected directly with the
"Raise"/"Lower" keys. An exception to this are parameter values shown
in binary form. In this case, the individual bits are selected with
"Raise"/"Lower" and corrected with the numerical keys (0 or 1).
If the index number is entered by means of the numerical keys, the
value is not accepted until "P" is pressed. If the "Raise" or "Lower" keys
are used to correct the number, the value comes into effect
immediately. The acceptance of an entered parameter value and return
to the parameter number does not take place until "P" is pressed. The
level selected in each case (parameter number, parameter index,
parameter value) is marked with the cursor. If an incorrect parameter
value is entered, the old value can be obtained by pressing "Reset".
The "Reset" key can also be used to go one level lower.
Parameter value → "Reset" → Parameter index → "Reset" → Para.No.
Parameters which can be changed are shown in upper-case letters and
visualization parameters which cannot be changed are shown in lower-
case letters. If a parameter can only be changed under special
conditions or if an incorrect value has been entered with the numerical
keys, an appropriate message follows, e.g.:
♦ "Value not perm." Incorrect value entered
♦ "Value <> min/max" Value too large or too small
♦ "P53/P927?"No parameter access
♦ "Operating status?" Value can only be changed in the "Drive
setting" status, for example
With "Reset", the message is deleted and the old value is re-instated.
NOTE Parameter changes are always stored with power-failure protection in

the EEPROM of the unit connected to the OP1S.
Example of parameter correction

Selection of Correction of Accept and
parameter value parameter value return
∇
P605 0 P605 0 P605 1 P605 1
Brake control Brake control Brake control Brake control
without brake without brake Brake w/o chkbk Brake w/o chkbk
Selection of Correction of Accept and

parameter value parameter value return
Ì P Î Ì 5 Î Ì P Î
P600 P600 P600 P600
0 ms 0 ms 5 ms 5 ms
MCont mssg time MCont mssg time MCont mssg time MCont mssg time
Selection of Correction of Selection of Correction of Accept and

parameter index parameter index parameter value parameter value return
∇
Ì P Î Ì Î Ì P Î Ì 4 Î Ì P Î
P049.001 P049.001 P049.002 P049.002 P049.002 P049.002
4 4 6 6 4 4
OP OperDisp OP OperDisp OP OperDisp OP OperDisp OP OperDisp OP OperDisp
1st line, left 1st line, left 1st line, right 1st line, right 1st line, ??? 1st line, ???
Selection of Selection of Correction of bit Accept and

parameter index bit return
∇
Ì P Î Ì Î Ì 0 Î Ì P Î
P053 0006Hex P053 0006Hex P053 0006Hex P053 0006Hex P053 0004Hex
Parameter Access Parameter Access Parameter Access Parameter Access Parameter Access
0000000000000110 0000000000000110 0000000000000110 0000000000000100 0000000000000110
ComBoard: No ComBoard: No BaseKeypad: Yes BaseKeyp: No BaseKeyp: No
Fault and alarm A fault or alarm message is indicated by the red LED. In the event of a
messages fault, the red LED lights up and stays on. A fault message appears in
the 3rd and 4th line of the operating display.
∇
Ì Î
0.0 A 0 V 00 0.0 A 0 V 00
# 0.00 min-1 # 0.00 min-1
F065: SCom Tlg 1T 3h 2"
Fault 1/1 Fault 1/1
Example of a fault display
The fault number and the respective text are shown in the 3rd line. Up
to 8 fault messages can be stored but only the first fault to occur is
shown on the display. Several subsequent faults are shown in the 4th
line, e.g. with 1/3 (first of three). Information on all faults can be
obtained from the fault memory. With "Raise"/"Lower", the associated
operating hours are shown when a fault is waiting to be remedied.
After the cause of a fault has been removed, the fault is acknowledged
with "Reset" inside the operating display (the "Reset" key must be
appropriately parameterized. See section "Issuing commands via the
OP1S"). By pressing "P" and "Lower" at the same time, it is possible to
skip back directly to the operating display from the parameter level.
When there is an alarm, the red LED flashes. A warning appears in the
4th line of the operating display.
8.2 A 520 V 00
# 100.00 min-1
* 100.00 min-1
-33:Overspeed
Example of an alarm display
The alarm number and the respective text is shown in the 4th line.
There can be several alarms at the same time but only the first alarm to
occur is shown on the display. Several alarms are shown in the 4th line
before the alarm number with an "+” instead of "-”. Information on all
alarms can be obtained with the alarm parameters r953 to r969.
An alarm cannot be acknowledged. As soon as the cause no longer
exists, the alarm/display disappears automatically.
Parameters
Parameters are the intervention points for adapting function blocks to
an application, for interconnecting function blocks via connectors and
binectors and for visualizing internal signals.
The various parameters are differentiated according to their function as
follows:
♦ Function parameters (can be read and written)
♦ BICO parameters (can be read and written)
♦ Visualization parameters (can only be read).
Each parameter is clearly designated.The parameter designation
comprises the parameter name and the parameter number, and
enables every parameter to be clearly identified. In addition to the
parameter name and the parameter number, many parameters also
have a parameter index. With the aid of this index, it is possible to store
several values for one parameter under one parameter number.
The function diagrams indicate the factory setting for every BICO
parameter and every function parameter. They further indicate the
value ranges for the changeable function parameters.
Parameter numbers The parameter numbers shown on the parameterizing unit (PMU) which
on the PMU is directly mounted on the unit consist of a letter and a three-digit
number.
The following applies for the letters:
♦ Upper-case letters (P, U, H and L) represent the BICO parameters
and function parameters which can be changed
♦ Lower-case letters (r, n, d and c) represent the visualization
parameters which cannot be changed.
The three-digit number covers the value range from 000 to 999; but not
all values are used.
Parameter numbers The OP1S operator control panel enables parameters to be selected
on the OP1S directly by their parameter numbers. As the OP1S only has a numerical
keypad, the parameter number must be replaced by a figure when
input. The following replace mode is applicable:
♦ "P"xxx and "r"xxx are replaced by "0"xxx
♦ "H"xxx and "d"xxx are replaced by "1"xxx
♦ "U"xxx and "n"xxx are replaced by "2"xxx
♦ "L"xxx and "c"xxx are replaced by "3"xxx
Examples:
Select r004 on OP1S: Input 0004
Select P050 on OP1S: Input 0050
Select U123 on OP1S: Input 2123
Select L411 on OP1S Input 3411
Function parameters The response of a function block is determined by function parameters.
Typical examples of function parameters are:
♦ Normalization of an input signal
♦ Acceleration or deceleration times in the ramp-function generator
♦ Proportional gain (Kp) and integral time (Tn) in the speed controller.
Function parameters can be indexed. The significance of the parameter
values stored in the various indices depends on the definition of the
respective parameter. A special group is formed by the function
parameters which are part of the so-called function data sets.
Parameter name
DT1 Element T1
0.0 ... 10.0 ms Value range
P249.F (0.0)
Parameter number Parameter index Factory setting
Function data sets Special function parameters are put together in function data sets.
(Setpoint data sets) These parameters are marked in the function diagrams with the
parameter index .F.
The parameters concerned are indexed four-fold, which means that one
parameter value can be stored under each parameter index, i.e. a total
of four parameter values can be stored.
The active function data set determines which value is currently being
used. If function data set 1 is active, the parameter value stored in
parameter index 1 is used. If function data set 2 is active, the parameter
value stored in parameter index 2 is used, etc.
Example:
P462.1 = 0.50
P462.2 = 1.00
P462.3 = 3.00
P462.4 = 8.00
A total of 4 values are stored under parameter P462 (Accel Time). If
function data set 1 is active, the acceleration time is 0.50 secs. If
function data set 2 is active, the acceleration time is 1.00 secs. If
function data set 3 is active, the acceleration time is 3.00 secs and if
function data set 4 is active, the acceleration time is 8.00 secs.
The individual function data sets are selected by means of control word
bits 16 and 17 in control word 2 (P576.B and P577.B). Changeover is
possible at any time.
The active function data sets are displayed via the visualization
parameter r013 (Active FuncDSet).
NOTE Changeover of all the indexed parameters of the function data sets
between parameter indices 1, 2, 3 and 4 is always effected jointly.
Motor parameters The motor parameters enable the converter to the be adapted to the
connected motor and enable the open-loop and closed-loop control
structure to be adapted. Typical examples for motor parameters are:
♦ Rated motor data from the rating plate
♦ Specification of the connected tachometer
♦ Current and output limits
Motor parameters are indexed 4-fold.
Parameter number Parameter index Factory setting
Maximum current Parameter name

0.1 ... 6553.5 A Value range
P128.M (~)
MIN
Motor data sets Selected function parameters are put together in motor data sets.
These parameters are marked in the function diagrams with the
parameter index .M
The parameters concerned are indexed four-fold, which means that one
parameter value can be stored under each parameter index of these
parameters, i.e. a total of four parameters can be stored.
The active motor data block (MDS) determines which value is currently
being used. If MDS1 is active, the parameter value stored in parameter
index 1 is used, if MDS2 is active, the parameter value stored in
parameter index 2 is used, etc
Example:
P100.1 = 4
P100.2 = 3
P100.3 = 1
P100.4 = 1
A totoal of 4 values are stored under parameter P100 (Control Mode). If
motor data set 1 is active, the drive operates in speed control with a
tachometer. If the motor data set 2 is active, the drive operates in
frequency control without a tachometer. If motor data set 3 and 4 are
active, the drive operates in v/f control.
Individual motor data sets are selected via control word bits 18 and 19
in control word 2 (P578.B and P579.B).
Changeover is only possible in the powered-down state.
NOTE All indexed parameters of the motor data sets are always changed over
jointly between parameter indices 1, 2, 3 and 4.
BICO parameters With BICO parameters, you can determine the sources of the input
signals of a function block. This means that you can use BICO
parameters to define the connectors and binectors from which a
function block reads in its input signals. In this manner, you can "soft-
wire" the function blocks stored in the units to meet your requirements.
This is referred to as the BICO system.
For every BICO parameter, the type of input signals (connector or
binector) which you can connect to the inputs is specified. BICO
parameters have the following identification:
♦ B Binector parameter
for connecting binectors
♦ K Connector parameter
for connecting connectors with word length (16 bit)
♦ KK Connector parameter
for conneting connectors with double-word length (32 bit)
Reciprocal "softwiring" of binectors and connectors is not permitted.
However, you can always connect connector with word length and
double-word length to the connector parameters.
BICO parameters are available in two forms; they can either be
♦ non-indexed, or
♦ double-indexed.
BICO data sets Selected BICO parameters are put together in BICO data sets. These
(Basic/reserve data parameters are marked in the function diagrams with the parameter
sets) index .B.
The parameters concerned are double-indexed, which means that one
parameter value can be stored under each parameter index of these
parameters, i.e. a total of two parameter values can be stored.
The active BICO data set determines which value is currently being
used. If BICO data set 1 is active, the parameter value stored in
parameter index 1 is used. If BICO data set 2 is active, the parameter
value stored in parameter index 2 is used.
Example:
P554.1 = 10
P554.2 = 2100
A total of 2 values are stored under parameter P554 (Src ON/OFF1). If
BICO data set 1 is active, the ON command comes from digital input 1
of the basic unit. If BICO data set 2 is active, the ON command comes
from bit 0 of the first data word received by serial interface 1.
Individual BICO data sets are selected by means of control word bit 30
in control word 2 (P590.
The active BICO data set is displayed via visualization parameter r012
(Active BICO DS).
NOTE All indexed BICO parameters are always switched jointly between
parameter index 1 and 2.
Parameter name Parameter name
Src DigOut1 Src Torq (set)

Parameter index / Parameter index /
Parameter number P651.B (0) Parameter number P260.B (0)
factory setting factory setting
B K
Connectable binector Connectable connector type (K or KK)
Connectors with word lengths of 16 bit and 32 bit
Visualization Visualization parameters are used for visualizing internal quantities

parameters (e.g. applicable output current). These parameters are only displayed
and cannot be changed by you.
To distinguish them from the other parameters, they are designated
with a lower-case letter (r, n, d and c) in the parameter number.
Parameter number
r006
DC Bus Volts
Parameter name
Visualization parameters
Connecting up function blocks (BICO system)

BICO system is the term used to descrbe the method of creating
connections between function blocks. This is performed with the aid of
binectors and connectors. The name BICO system is derived from
these two terms.
A connection between two function blocks consists of a connector or
binector on the one side, and a BICO parameter on the other side. The
connection is always made from the point of view of the input of a
function block. You must always assign an output to an input.
Assigment is made by entering in a BICO parameter the number of the
connector or the binector from which the required input signals are read
in. You are allowed to enter the same connector and binector numbers
several times in different BICO parameters and thus use output signals
of one function block as input signals for several other function blocks.
Example:
In the following figure, connector K0152 is connected to connector
parameter P228. For this purpose, you must assign the number of
connector K0152 as the value to the connector parameter P228 , i.e. in
this case 152.
Parameter list Vector Control
Parameter Description Data Read/write
r001 Visualization parameter for the current status of the Dec.Plc.: 0 Menus:
Drive Status converter or inverter. The converter status is, for example, Unit: - - Parameter menu
determined by the control commands for the internal Indices: - + General parameters
1 sequence control (see control word 1 and 2 Type: O2 + Motor/encoder
r550,r551) and by menu selection P060. + Encoder data
+ Control/gating unit
0 = Power section definition + Position Control
1 = Initialization of converter or inverter + Diagnostics
2 = Hardware initialization + Trace
3 = Drive system initialization + Technology
4 = Board configuration + Synchronism
5 = Drive setting + Positioning
6 = Selection of several drive test functions + Setting up/MDI
7 = Störung - Fix
8 = Start inhibt
9 = Ready for ON
10 = Precharging of Dc link bus
11 =Ready for operation
12 = Ground fault test
13 = "Flying restart" is active
14 = Operation
15 = OFF1 is active
16 = OFF3 is active
17 = "DC braking" is active
18 = Motor data identification at standstill is active
19 = Optimization of speed controller
20 = "Synchronization" active
21 = Download
r002 Visualization parameter for the speed actual value in Hz Dec.Plc.: 3 Menus:
Rot Freq (multiplied by the pole pair number P109 of the drive) Unit: Hz - Parameter menu
Indices: - + General parameters
2 Display quantity for the PMU parameterizing unit and the Type: I4 - Upread/free access
OP
(see P049).
In function diagram:
350.7, 351.7, 352.7
r003 Visualization parameter for the output voltage of the Dec.Plc.: 1 Menus:
Output Volts converter or inverter (fundamental rms) Unit: V - Parameter menu
3 In function plan: Type: I2 - Upread/free access
285.3, 286.3
r004 Visualization parameter for the output current of the Dec.Plc.: 1 Menus:
Output Amps converter or inverter (fundamental rms) Unit: A - Parameter menu
4 In function diagram: Type: I4 - Upread/free access
285.7, 286.7
r005 Visualization parameter for the ouput active power. Dec.Plc.: 1 Menus:
Output Power The display value is normalized to the reference power Unit: % - Parameter menu
which is derived from the product of reference frequency Indices: - + General parameters
5 P352 and referencetorque P354. Type: I2 - Upread/free access
285.7, 286.7
r006 Visualization parameter for DC link voltage. Dec.Plc.: 0 Menus:

DC Bus Volts Unit: V - Parameter menu
Displayed quantity for the PMU parameterizing unit and Indices: - + General parameters
6 the OP (r049). Type: I2 - Upread/free access
285.3, 286.7
r007 Visualization parameter for torque referred to the Dec.Plc.: 1 Menus:

Motor Torque reference torque (P354). Unit: % - Parameter menu
7 Precondition: Type: I2 - Upread/free access
P100 = 3, 4, 5 (vector control types)
285.7
r008 Visualization parameter for thermal motor utilization Dec.Plc.: 0 Menus:

Motor Utilizat. (calculated value). Unit: % - Parameter menu
Indices: - - Upread/free access
8 Precondition: Type: O2
P383 >= 100 s
ATTENTION.
For an overload protection of the motor which is derived
from this parameter, sufficient cooling of the motor must
be ensured.
r009 Visualization parameter for the current motor temperature. Dec.Plc.: 0 Menus:
Motor Temperat. Unit: °C - Parameter menu
A correct display is only possible if the motor temperature Indices: - + General parameters
9 is measured with a KTY84 temperature sensor or BICO Type: I2 + Functions
parameter P385 is softwired to a connector which - Upread/free access
provides the temperature signal in the normalization
1°=40 Hex.
Precondition:
P360 > 1 or
P361 > 1 or
P310 = 2 and P361 > 1
280.3
r010 Visualization parameter for the current thermal utilization Dec.Plc.: 0 Menus:
Drive Utilizat. of the converter or inverter. Unit: % - Parameter menu
10 The utilization is determined byan i2t calculation of the Type: O2 - Upread/free access
output current. A value of 100 % is achieved in
continuous operation with the rated current.
If a 100 % utilization is exceeded, an alarm message
(A024) is tripped and the output current is reduced to 89
% of the rated current..
r011 Visualization parameter for the currently active motor data Dec.Plc.: 0 Menus:
act. MotDataSet sets. Unit: - - Parameter menu
11 1 = Data set 1 Type: O2 - Drive setting
2 = Data set 2 - Upread/free access
3 = Data set 3
4 = Data set 4
A motor data set is selected with control word bits 18 and

19. The relevant BICO parameters
for linking the control word bits are P578 and P579.
20.5
r012 Visualization parameter for the currently active BICO data Dec.Plc.: 0 Menus:
Active BICO DSet set. Unit: - - Parameter menu
12 1 = Data set 1 Type: O2 - Upread/free access
2 = Data set 2
A BICO data set is selected with control word bit 30. The
relevant BICO parameter for linking the control word bit is
P590.
20.5
r013 Visualization parameter for the currently active function Dec.Plc.: 0 Menus:
Active FuncDSet data set. Unit: - - Parameter menu
13 1 =Data set 1 Type: O2 - Upread/free access
2 = Data set 2
3 = Data set 3
4 = Data set 4
A function data set is selected with control word bits 16

and 17. The relevant BICO parameters for linking the
control word bits are P576 and P577.
20.5
r014 Visualization parameter for the speed setpoint at the Dec.Plc.: 1 Menus:
Setp Speed speed controller input or at the frequency input of the v/f Unit: 1/min - Parameter menu
control. Indices: - + General parameters
14 Type: I4 - Upread/free access
360.4, 361.4, 362.4, 363.4
r015 Visualization parameter for the speed actual value. Dec.Plc.: 1 Menus:
n(act) Unit: 1/min - Parameter menu
In function diagram: Indices: - + General parameters
15 350.7, 351.7, 352.7 Type: I4 - Upread/free access
P028* BICO parameter for selecting connectors which contain a Index1: 0 Menus:
SrcDispPowerConn power and are to be displayed in visualization parameter Unit: - - Parameter menu
r029 in (%). The connector numbers entered in the Indices: 5 + General parameters
28 respective index are displayed in the same index of Type: L2, C - Upread/free access
parameter r029. changeable in:
- Ready
In function diagram: - Run
30.7
r029 Visualization parameter for displaying connectors given in Dec.Plc.: 1 Menus:

DispPowerConn P028 in (%). The connectors displayed in the respective Unit: % - Parameter menu
index have been selected in the same index of parameter Indices: 5 + General parameters
29 P028. Normalization is determined in P352 and P354. Type: I4 - Upread/free access
30.8
P030* BICO parameter for selecting binectors which are to be Index1: 0 Menus:
Src Disp Binec shown in visualization parameter r031. The binector Unit: - - Parameter menu
numbers entered in the respective index are displayed in Indices: 5 + General parameters
30 the same index of parameter r031. Type: L2, B - Upread/free access
changeable in:
- Ready
- Run
r031 Visualization parameter for displaying the binectors given Dec.Plc.: 0 Menus:
Display Binector in P030. The binectors displayed in the respective index Unit: - - Parameter menu
have been selected in the same index of parameter P030. Indices: 5 + General parameters
31 Type: O2 - Upread/free access
P032* BICO parameter for selecting connectors which are to be Index1: 0 Menus:
Src Disp Conn displayed in visualization parameter r033 in [%]. The Unit: - - Parameter menu
connector numbers shown in the respective index are Indices: 5 + General parameters
32 displayed in the same index of parameter r033. Type: L2, CC - Upread/free access
changeable in:
- Ready
- Run
r033 Visualization parameter for displaying the connectors Dec.Plc.: 3 Menus:

Display Conn given in P032. The connnectors displayed in the Unit: % - Parameter menu
respective index have been selected in the same index of Indices: 5 + General parameters
33 parameter P032. A connector value of 4000 H or 4000 Type: I4 - Upread/free access
0000 H is shown at 100 %.
SrcDispVoltsConn voltage and are to be displayed in visualization parameter Unit: - - Parameter menu
r035 in [V]. The connector numbers entered in the Indices: 5 + General parameters
- Ready
- Run
r035 Visualization parameter for displaying connectors given in Dec.Plc.: 1 Menus:

Disp Volts Conn P034 in [V]. The connectors displayed in the respective Unit: V - Parameter menu
index have been selected in the same index of parameter Indices: 5 + General parameters
35 P034. The normalization is specified in P351. The Type: I4 - Upread/free access
following method of calculation must be used:
r035 = P351 xConnector Value in [%]/100%.
SrcDispAmpsConn current and are to be displayed in visualization parameter Unit: - - Parameter menu
r037 in [A]. The connector numbers entered in the Indices: 5 + General parameters
- Ready
- Run
r037 Visualization parameter for the display of connectors Dec.Plc.: 2 Menus:

Disp Amps Conn given in P036 in [A]. The connectors displayed in the Unit: A - Parameter menu
37 parameter P036. The normalization is specified in P350. Type: I4 - Upread/free access
The following method of calculation must be used:
r037 = P350 xConnector Value in [%]/100%.
Src DispTorqConn torque and are to be displayed in visualization parameter Unit: - - Parameter menu
r039 in (%). The connector numbers entered in the Indices: 5 + General parameters
- Ready
In function diagram: - Run
30.4

Disp Torq Conn given in P038 in (%). The connectors displayed in the Unit: % - Parameter menu
39 parameter P038. Normalization is determined in P354. Type: I4 - Upread/free access
30.5
SrcDisp SpdConn torque and are to be displayed in visualization parameter Unit: - - Parameter menu
r041 in [1/min]. The connector numbers entered in the Indices: 5 + General parameters
40 respective index are displayed in the same index of Type: L2, CC - Upread/free access
- Ready
- Run

Disp Speed Conn given in P040 in [1/min]. The connectors displayed in the Unit: 1/min - Parameter menu
The following method of calculation must be used: r041 =
P353 xConnector Value in [%]/100%.
SrcDispFreqConn frequency and are to be displayed in visualization Unit: - - Parameter menu
parameter r043 in [Hz]. The connector numbers entered in Indices: 5 + General parameters
42 the respective index are displayed in the same index of Type: L2, CC - Upread/free access
- Ready
- Run

Disp Freq Conn given in P042 in [Hz]. The connectors displayed in the Unit: Hz - Parameter menu
The following method of calculation must be used:
r043 = P352 x Connector Value in [%]/100%.
P044* BICO parameter for selecting connectors which are to Index1: 0 Menus:
SrcDisp DecConn displayed in visualization parameter r045 as an integral Unit: - - Parameter menu
decimal number preceded by a plus or minus sign. The Indices: 5 + General parameters
44 connector numbers entered in the respective index are Type: L2, CC - Upread/free access
displayed in the same index of parameter r045. changeable in:
- Ready
- Run

Disp DecConn given in P044 as an integral whole decimal number. The Unit: - - Parameter menu
connectors displayed in the respective index have been Indices: 5 + General parameters
45 selected in the same index of parameter P044. Type: I4 - Upread/free access
P046* BICO parameter for selecting connectors which are to be Index1: 0 Menus:
SrcDisp HexConn displayed in visualization parameter r046 as an integral Unit: - - Parameter menu
value (hexadecimal). The connector numbers entered in Indices: 5 + General parameters
46 the respective index are displayed in the same index of Type: L2, CC - Upread/free access
- Ready
- Run

Disp Hex Conn given in P045 as a hexadecimal number. Unit: - - Parameter menu
If word connectors have been selected in P046, then Indices: 10 + General parameters
47 Indices 1 to 5 = Value of the connector Type: L2 - Upread/free access
Indices 6 to 10 = 0
If double word connectors have been selected in P046,
then:
Indices 1 to 5 = Upper 16 bits of the connector
Indices 6 to 10 = Corresponding lower 16 bits of the
connector
Example:
KK0091 = 1234 5678
P046.1= 91
r047.1 = 1234
r047.6 = 5678
P048* Function parameter for selecting parameter whose value Init: 2 Menus:
PMU OperDisp is to be shown in the operating display of the PMU. Min: 0 - Parameter menu
Max: 3999 + General parameters
48 Unit: - - Upread/free access
Indices: - changeable in:
Type: O2 - Ready
- Run
P049* Function parameter for selecting parameters whose Index1: 4 Menus:

OP OperDisp values are to be shown in the operating display of the Min: 0 - Parameter menu
optional OP1S user-friendly operator control panel. Max: 3999 + General parameters
Index 1: 1st line left Indices: 5 changeable in:
Index 2: 1st line right Type: O2 - Ready
Index 3: 2nd line (actual value), only visualization - Run
parameters
Index 4: 3rd line (setpoint), only function parameters
Index 5: 4th line
P050* Function parameter for setting the language in which texts Init: 0 Menus:
Language are to be displayed on the optional OP1S user- friendly Min: 0 - Parameter menu
operator control panel. Max: 4 + General parameters
0 = German Indices: - changeable in:
1 = English Type: O2 - Ready
2 = Spanish - Run
3 = French
4 = Italian
P053* Function parameter for releasing interfaces for Init: 6 Menus:

Parameter Access parameterization. Min: 0 all Menus
Max: 65535 changeable in:
53 0 = None Unit: - all states
1 = Cbx communication board Indices: -
2 = PMU operator control panel Type: V2
4 = Serial interface (SST/SST1), also OP1S and PC
8 = SCB serial input/output modules
16 = Txxx technology board
32 = Serial interface 2 (SCom2)
Each interface has a code number. When the number or

the sum of different numbers assigned to the interfaces
is/are entered, the interface(s) is/are released for use as a
parameterizing interface.
Example:
The factory-setting value 6 is the sum of 2 and 4. This
means that parameterization is allowed via the PMU and
serial interface 1 and thus for the OP1S as well.
The parameter can always be written from any interface.

This also applies if this interface has not been released
for parameterization purposes.
P060* Function parameter for selecting the current menu. Init: 1 Menus:
Menu Select Min: 0 all Menus
0 = User parameter (selection of the visible parameters in Max: 8 changeable in:
60 P360) Unit: - all states
1 = Parameter menu Indices: -
2 = Fixed settings (also contains factory settings) Type: O2
3 = Quick parameterization (changes to "Drive Setting"
state)
4 = Board configuration (changes to "Board Configuration"
state)
5 = Drive setting (changes to "Drive Setting" state)
6 = Download (changes to "Download" state)
7 = Upread/Free access
8 = Power section definition (changes to "Power section
definition" state)
If it is not possible to change to another state due to the

currently valid state, the corresponding menu cannot be
selected either.
Example:
"Operating" state, change to "Download" not possible.
"Ready for switching on" state, change to "Download" not
possible.
With parameters P358 Key and P359 Lock, menus can

be locked with the exception of the menus "User
parameters" and "Fixed settings".
P068* Function parameter for entering the output filter. Init: 0 Menus:
Output Filter Min: 0 - Parameter menu
Parameter values Max: 2 + General parameters
68 0 = without output filter Unit: - - Drive setting
1 = with sinusoidal output filter Indices: - - Upread/free access
2 = with dv/dt output filter Type: O2 changeable in:
- Drive setting
The parameter value 1 limits the depth of modulation to
the range of space vector modulation (see also P342 and
r345, maximum depth of modulation).
The pulse frequency P340 is adapted to the envisaged
sinusoidal filter after leaving the drive setting (see P060 =
5).
Notes:
· For n/f/Torque control and for temperature adaption
(P386 > 0), the sinusoidal filter for the converter is taken
into account. .
·The parameter value 2 limits the adjustable pulse
frequency P340 to 3 kHz.
430.3, 390.7, 405.6
r069 Visualization parameter for displaying the software Dec.Plc.: 1 Menus:

SW Version versions of the basic board as well as the optional boards Unit: - - Parameter menu
in slots A to G Indices: 8 + General parameters
69 Type: O2 - Fixed settings
Index 1: Software version of basic board - Quick parameterization
Index 2: Software version of optional board Slot A - Board configuration
Index 3: Software version of optional board Slot B - Drive setting
Index 4: Software version of optional board Slot C - Download
Index 5: Software version of optional board Slot D - Upread/free access
Index 6: Software version of optional board Slot E - Power section definition
Index 7: Software version of optional board Slot F
Index 8: Software version of optional board Slot G
The slots D-G are not available in type COMPACT PLUS.
For optional boards which contain no software, (e.g. SBR,

SLB), the parameter value in the respective index is
always 0.0.
P070* Function parameter for entering the order numbers of Init: 0 Menus:
Order No. 6SE70. converter or inverter modules. These numbers tell the Min: 0 - Parameter menu
control board which power section it works with. Max: 254 + General parameters
For parameter values, see annex "Compendium". Indices: - - Power section definition
Type: O2 changeable in:
- Power section definition
P071 Function parameter for entering the line voltage of the Init: ~ Menus:
Line Volts converter or inverter. Min: 90 - Parameter menu
Max: 1320 + General parameters
71 Converter (AC/AC): rms value of the line AC voltage Unit: V - Quick parameterization
Inverter (DC/AC): input direct voltage Indices: - - Drive setting
Type: O2 - Upread/free access
The value is for calculating the rated DC link voltage as a changeable in:
basis for the voltage limits of the Vd(max) and Vd(min) - Drive setting
[KIB) controller
(e.g. undervoltage failure limit).
P072 Parameter for displaying the rated current of the converter Init: ~ Menus:
Rtd Drive Amps or inverter. The rated current is the current which can be Min: 4,5 - Parameter menu
output continuously. It must be identical to the current Max: 6540,0 + General parameters
72 indicated on the rating plate of the converter. Unit: A - Drive setting
Indices: - - Upread/free access
Type: O4 - Power section definition
changeable in:
P073 Parameter for displaying the rated power of the converter Init: ~ Menus:
Rtd Drive Power or inverter. Min: 0,3 - Parameter menu
Max: 6400,0 + General parameters
73 Unit: kW - Upread/free access
Indices: - - Power section definition
P075 Function parameter for the motor magnetizing reactance Index1: 150,0 Menus:
X (magnet,d)tot (saturated) along the rotor axis (d axis) , referred to the Min: 1,0 - Parameter menu
rated motor impedance. Max: 999,0 + Motor/encoder
75 Unit: % + Motor data
Indices: 4 - Upread/free access
- Ready
- Run
P076 Function parameter for the motor magnetizing reactance Index1: 150,0 Menus:
X (magnet,q)tot. (saturated) transverse to the rotor axis (q axis), referred to Min: 1,0 - Parameter menu
the rated motor impedance. Max: 999,0 + Motor/encoder
- Ready
- Run
P077 Function parameter for motor leakage reactance of the Index1: 9,00 Menus:
X (sigma,d) damp damper winding along the rotor axis (d axis), referred to Min: 0,10 - Parameter menu
the rated motor impedance. Max: 49,99 + Motor/encoder
Automatic parameterization (P115=1) should be executed Indices: 4 - Upread/free access
after the parameter value is changed. Type: O2 changeable in:
- Ready
Precondition: - Run
P095 = 12 (synchronous motor)
P078 Function parameter for motor leakage reactance of the Index1: 9,00 Menus:
X (sigma,q) damp damper winding transverse to the rotor axis (q axis) Min: 0,10 - Parameter menu
referred to the rated motor impedance. Max: 49,99 + Motor/encoder
- Ready
Precondition: - Run
P079 Function parameter for motor resistance of damper Index1: 8,00 Menus:
R (damping,d) winding along the rotor axis (d axis), referred to the rated Min: 0,10 - Parameter menu
motor impedance. Max: 49,99 + Motor/encoder
- Ready
Precondition: - Run
P080 Function parameter for the motor resistance of the Index1: 8,00 Menus:
R (damping,q) damper winding transverse to the rotor axis (q axis), Min: 0,10 - Parameter menu
referred to the rated motor impedance. Max: 49,99 + Motor/encoder
Automatic parameterization (P115=1) has to be executed Indices: 4 - Upread/free access
- Ready
Precondition: - Run
P081 Function parameter for the ratio between no-load and Index1: 50,0 Menus:
Iexc(0)/Iexc(n) rated excitation current. Min: 1,0 - Parameter menu
Max: 100,0 + Motor/encoder
81 The parameter corresponds to the transmission factor Unit: % + Motor data
between the rotating-field system of the current model Indices: 4 - Upread/free access
and the direct-current system of the excitation current Type: O2 changeable in:
control. - Ready
- Run
Precondition:
P082 Function parameter for entering the first (lowest) flux Index1: 60,0 Menus:
Psi(sat.char.,1) value of the saturation characteristic, referred to the rated Min: 10,0 - Parameter menu
rotor flux (rated EMF) of the motor. Max: 200,0 + Motor/encoder
82 The value belongs to the first excitation current value Unit: % + Motor data
P083. Indices: 4 - Upread/free access
Precondition: - Ready
P095 = 12 (synchronous motor) - Run
P083 Function parameter for entering the first (lowest) current Index1: 30,0 Menus:
Iexc(sat.char,1) excitation value of the saturation characteristic, referred to Min: 5,0 - Parameter menu
the no-load excitation current of the motor. Max: 799,0 + Motor/encoder
The value belongs to the first flux value P082. Indices: 4 - Upread/free access
P084 Function parameter for entering the second flux value of Index1: 80,0 Menus:
Psi(sat.char.,2) the saturation characteristic, referred to the rated rotor Min: 10,0 - Parameter menu
flux (rated EMF) of the motor. Max: 200,0 + Motor/encoder
84 The value belongs to the second excitation current value Unit: % + Motor data
P085 Function parameter for entering the second current Index1: 45,0 Menus:
Iexc(sat.char,2) excitation value of the saturation characteristic, referred to Min: 5,0 - Parameter menu
the no-load excitation current of the motor. Max: 799,0 + Motor/encoder
The value belongs to the second flux value P084. Indices: 4 - Upread/free access
P086 Function parameter for entering the third (highest) flux Index1: 90,0 Menus:
Psi(sat.char.,3) value of the saturation characteristic, referred to the rated Min: 10,0 - Parameter menu
rotor flux (rated EMF) of the motor. Max: 200,0 + Motor/encoder
86 The value belongs to the third excitation current value Unit: % + Motor data
A value of 100 % corresponds to an induced terminal - Ready
voltage amounting to the rated motor voltage (in no-load - Run
at synchronous speed).
Precondition:
P087 Function parameter for entering the third (highest) Index1: 65,0 Menus:
Iexc(sat.char,3) excitation current value of the saturation characteristic, Min: 5,0 - Parameter menu
referred to the no-load excitation current of the motor. Max: 799,0 + Motor/encoder
87 The value belongs to the third flux value P086. Unit: % + Motor data
A value of 100 % corresponds to the rating plate value of Type: O2 changeable in:
the excitation current which produces a terminal voltage - Ready
amounting to the rated motor voltage in no-load at - Run
synchronous speed.
Precondition:
P088 Function parameter for entering the torque constant (kTn Index1: 0,00 Menus:
kT(n) (100 Kelvin)). Min: 0,00 - Parameter menu
The value corresponds to the current/motor torque Max: 655,35 + Motor/encoder
88 proportionality constants. Unit: Nm/A + Motor data
Indices: 4 - Drive setting
Precondition: Type: O2 - Upread/free access
P095 = 13 (synchronous motor, permanently excited) changeable in:
- Drive setting
P095* Function parameter for changing between international Index1: 10 Menus:

Type of Motor (IEC) and US (NEMA) motor data parameterization. If Min: 0 - Parameter menu
NEMA is selected, the efficiency and the rated motor Max: 13 + Motor/encoder
95 output instead of the power factor cos(PHI) are displayed Unit: - + Motor data
during motor parameterization. Indices: 4 - Drive setting
Parameter values: changeable in:
10: IEC induction motor - Drive setting
11: NEMA induction motor
12: Synchronous motor (externally excited)
13 Synchronous perm.
Note:
Selection of a synchronous motor (12, 13) is only
considered for certain special applications.
P95 can also be at "0" (factory settging) during operation
of permanently-excited synchronous motors.
In both cases, the following functions are disabled:
Synchronizing (P582),
Flying restart (P583, P525, P526),
Automatic restart (P373),
DC braking (P395),
Motor identification (P115=2,3,4,6),
Control mode (P100=0,1,2,3 for P95=12),
Control mode (P100=0,2,4,5 for P095=13).
Synchronizing (P582) is used for P095=12 for resetting

to the initial position if P172 is not connected.
P100* Function parameter for selecting the open/closed loop Index1: 1 Menus:
Control Mode control mode Min: 0 - Parameter menu
Max: 5 + Motor/encoder
100 Parameter values: Unit: - + Motor data
0: v/f contol with superposed speed control Indices: 4 - Drive setting
(only for P095 = 10, 11) Type: O2 - Upread/free access
1: v/f control changeable in:
(only for P095 = 10, 11, 13) - Drive setting
2: v/f control for textile applications;
allows no frequency corrections (e.g. by the current
limitation controller)
(only for P095 = 10, 11)
3: Frequency control (without tachometer)
(only for P095 = 10, 11, 13)
4: Speed control
(only for P095 = 10, 11, 12)
5: Torque control
(only for P095 = 10, 11, 12)
14
P101* Function parameter for entering the rated motor voltage. Index1: ~ Menus:
Mot Rtd Volts Min: 100 - Parameter menu
The rating plate value of the voltage for the current kind of Max: 2000 + Motor/encoder
101 connection (star/delta) and for line duty has to be entered. Unit: V + Motor data
Note: Type: O2 - Upread/free access
Input for Siemosyn motors is the rated voltage at rated changeable in:
motor frequency. - Drive setting
For P95=13 (motor type =sync.perm.), the motor rated

voltage is only used as a normalization quantity for the
rated motor impedance to which all resistances and
reactances are referred (e.g. P075).
in function diagram:
405.3
P102* Function parameter for entering the rated motor current Index1: ~ Menus:
Motor Rtd Amps for the connected synchronous or induction motor. The Min: 0,6 - Parameter menu
rating plate value for the current kind of connection Max: 6553,5 + Motor/encoder
102 (star/delta) has to be entered. Unit: A + Motor data
Permissible values: 0.125 * P072 <= P102 < 1.36 * P072 Type: O4 - Upread/free access
changeable in:
- Drive setting
P103* Function parameter for entering the motor magnetizing Index1: ~ Menus:
Motor Magn Amps current referred to the rated motor current. Min: 0,0 - Parameter menu
The correct input improves the calculation of motor Max: 95,0 + Motor/encoder
103 parameters in automatic parameterization (P115=1). Unit: % + Motor data
The value is determined during motor data identification Type: O2 - Upread/free access
(P115=2,3) and during the no-load test (P115=4). changeable in:
- Drive setting
Synchronous motor (P95=12): - Ready
Reactive current component at the motor rating point.
Note:
The value always has to be set to 0.0% so that the rated
motor current is contributed completely to torque
generation.
Precondition:
P095 = 10,11,12
(Motor type = Induc.IEC, Induc.NEMA, synchronous
motor)
P104* Function parameter for entering hte power factor for the Index1: ~ Menus:
MotPwrFactor connected induction motor. The rating plate value has to Min: 0,500 - Parameter menu
be entered. Max: 1,000 + Motor/encoder
104 Unit: - + Motor data
Precondition: Indices: 4 - Drive setting
P95 = 10,12 (motor type: induc.IEC, synchronous motor) Type: O2 - Upread/free access
changeable in:
- Drive setting
P105* Function parameter for entering the rated motor power in Index1: ~ Menus:
Motor Rtd Power Hp (rating plate value). Min: 0,1 - Parameter menu
105 Precondition: Unit: hp + Motor data
P095 = 11 (motor type: NEMA induction motor) Indices: 4 - Drive setting
changeable in:
- Drive setting
P106* Function parameter for entering the rated motor efficiency Index1: ~ Menus:
Motor Rtd Effic. (rating plate value). Min: 50,0 - Parameter menu
106 Precondition: Unit: % + Motor data
P095 = 11 (motor type: NEMA induction motor) Indices: 4 - Drive setting
changeable in:
- Drive setting
Menu levels The parameter menus have several menu levels. The first level
contains the main menus. These are effective for all sources of
parameter inputs (PMU, OP1S, SIMOVIS, field bus interfaces).
The main menus are selected in parameter P60 Menu Selection.
Examples:
P060 = 0 "User parameters" menu selected
P060 = 1 "Parameter menu" selected
...
P060 = 8 "Power section definition" menu selected
Menu levels 2 and 3 enable the parameter set to be more extensively
structured. They are used for parameterizing the units with the OP1S
operator control panel.
Main menus
P060 Menu Description
0 User parameters • Freely configurable menu

1 Parameter menu • Contains complete parameter set
• More extensive structure of the functions achieved by
using an OP1S operator control panel
2 Fixed settings • Used to perform a parameter reset to a factory or user
setting
3 Quick parameterization • Used for quick parameterization with parameter modules
• When selected, the unit switches to status 5 "Drive
setting"
4 Board configuration • Used for configuring the optional boards
• When selected, the unit switches to status 4 "Board
configuration"
5 Drive setting • Used for detailed parameterization of important motor,
encoder and control data
• When selected, the unit switches to status 5 "Drive
setting"
6 Download • Used to download parameters from an OP1S, a PC or an
automation unit
• When selected, the unit switches to status 21 "Download"
7 Upread/free access • Contains the complete parameter set and is used for free
access to all parameters without being restricted by further
menus
• Enables all parameters to be upread by an OP1S, PC or
automation unit
8 Power section definition • Used to define the power section (only necessary for units
of the Compact and chassis type)
• When selected, the unit switches to status 0 "Power
section definition"
Parameter reset to factory setting
The factory setting is the defined initial state of all parameters of a unit.
The units are delivered with this setting.
You can restore this initial state at any time by resetting the parameters
to the factory setting, thus canceling all parameter changes made since
the unit was delivered.
The parameters for defining the power section and for releasing the
technology options and the operating hours counter and fault memory
are not changed by a parameter reset to factory setting.
Parameter number Parameter name
P070 Order No. 6SE70..
P072 Rtd Drive Amps
P073 Rtd Drive Power
P366 Select FactSet
Parameters which are not changed by the factory setting
NOTE Parameter factory settings which are dependent on converter or motor

parameters are marked with ’(~)’ in the block diagrams.
Grant parameter access

P053 = 6
6: Parameter changes permitted via PMU and serial interface
SCom1 (OP1S and PC)
P060 = 2 Select "Fixed settings" menu
Select desired factory setting

P366 = ?
0: Standard
1: Standard with OP1S
2: Cabinet unit with OP1S (BICO1) or terminal strip (BICO2)
3: Cabinet unit with PMU (BICO1) or terminal strip (BICO2)
4: Cabinet unit with NAMUR terminal strip (SCI)
Note: This parameter was correctly set prior to
delivery of the unit and only needs to be
changed in exceptional cases.
Start parameter reset
P970 = 0
0: Parameter reset
1: No parameter change
Unit carries out parameter
reset and then leaves the
"Fixed settings" menu
PROFIBUS
Product description of the CBP communications board
The CBP communications board (Communications board PROFIBUS)

is for linking SIMOVERT MASTERDRIVES to higher-level automation
systems via PROFIBUS-DP.
Fastening screw
System connector
LED (green)
LED (yellow)
LED (red)
9-pole Sub-D connec-

tion X448
Fastening screw
Technical data The communications board has three LEDs (green, yellow, red) for
providing information on the current operating status.
Voltage is supplied from the basic unit through the system’s plug-in
connector.
The CBP has a 9-pole SUB D socket (X448) which is provided for
connecting it up to the PROFIBUS system in accordance with the
PROFIBUS standard. All connections of this RS485 interface are short-
circuit-proof and floating.
The CBP supports baud rates of 9.6 kBaud to 12 MBaud and is also
suitable for connecting fiber-optic cable by means of optical link plugs
(OLPs).
Functionality ♦ Useful data is exchanged with the master according to the

"PROFIBUS profile for variable-speed drives", PROFIDRIVE.
♦ Acyclical communications channel for transferring parameter values

up to a length of 101 words with a SIMATIC S7-CPU
♦ Acyclical communications channel for linking the PC-based

SIMOVIS start-up and service tool
♦ Automatic adoption of the useful data structure defined in the master
♦ Supporting of diagnostic alarms in conjunction with a

SIMATIC S7
♦ Monitoring of the bus interface
♦ Supporting of SYNC-type PROFIBUS control commands for

synchronized data transfer from the master to several slaves
♦ Supporting of FREEZE-type PROFIBUS control commands for

synchronized data transfer from several slaves to the master
♦ Extremely simple parameterization of the CBP via the PMU of the

basic unit.
Description of the CBP’s functions on the PROFIBUS-DP
Definition The PROFIBUS-DP is an international and open standard field bus as

specified in field bus standard EN 50170 Part 2.
Its specification as an international standard guarantees its openness

and its independence from any particular manufacturer.
The PROFIBUS-DP enables very fast, time-critical transfer of data on

the field level.
With the PROFIBUS, a distinction is made between masters and

slaves.
♦ Masters determine data traffic on the bus and are also designated in
the literature as active nodes. There are two classes of master:
• DP-Master Class 1 (DPM1):

These are central stations (e.g. SIMATIC S5, S7 and SIMADYN
D) which exchange information with the slaves in defined
communications cycles.
• DP-Master Class 2 (DPM2):

Units of this type are programming units, planning units or control
and monitoring units which are used for configuring, starting up or
monitoring systems in operation.
♦ Slaves (e.g. CBP, CB15 etc.) can only acknowledge the messages
they receive or transfer messages to a master when the latter
requests a slave to do so. Slaves are also designated as passive
nodes.
Protocol The protocol architecture of the PROFIBUS-DP is oriented to the OSI

architecture (Open System Interconnection) reference model in accordance with the
international standard, ISO 7498, and uses layers 1 and 2 as well as the
user interface.
Transmission When transmission equipment is being selected, criteria such as high

equipment transmission speed and simple, inexpensive wiring and cabling is of
primary importance. PROFIBUS supports transmission according to
RS485 and also transmission by means of fiber-optic cable.
The transmission speed can be selected between 9.6 kBaud and 12
MBaud. The same speed is specified for all units on the bus when
the system is started up for the first time.
Bus-access The PROFIBUS works according to the token-passing procedure, i.e.

procedure the masters become token holders for a defined time window in a
logical ring. Within this time window, the master can communicate with
other masters. Alternatively, it can communicate with slaves by using a
lower-level master-slave procedure.
The PROFIBUS-DP mainly uses the master-slave method and data is

usually exchanged with the drives cyclically.
Data exchange via This enables very rapid data exchange between the higher-level
PROFIBUS systems (e.g. SIMATIC, SIMADYN D, PC/PGs) and the drives. Access
to the drives is always made according to the master-slaves method.
The drives are always the slaves and each slave is clearly defined by its
address.
Higher-level MASTERDRIVES Other

computer "Slave" "Slave"
"Master"
CBP
Other
nodes
PROFIBUS interface (PROFIBUS cable)
The cyclical communications functions are determined by the

PROFIBUS-DP basic functions in accordance with EN 50170.
For purposes of parameterization, diagnosis and alarm-handling during

cyclical data exchange with intelligent drives, acyclical extended
communications functions are also used which are defined in
PROFIBUS Guideline No. 2.081 (German) or 2.082 (English).
The following illustration contains an overview of the communications

functions which are enabled with the CBP.
CBP slots in Compact and chassis-type units with the CUs of
function classes FC (CU1), VC (CU2) or SC (CU3)
Electronics box
Adaption board
+1.B1
+1.B3
+1.B2
Optional board
CBP
The adaption board with optional board

can be mounted in the electronics box in 1.B2
and/or 1.B3.
On the adaption board (MRPD 6SE7090-0XX84-0KA0), only one CBP

can be mounted in slot X 198, i.e. at the BOTTOM.
If the CBP is mounted with adaption board, the LBA (Local Bus Adaptor,
LBA, MRPD 6SE7090-0XX84-4HA0) must first be mounted.
NOTE If only one optional board is used, it must always be inserted in slot
+1.B2 (on the RIGHT) in the electronics box.
If, in addition to the CBP, a technology board (T100 / T300 or T400) is

inserted in the electronics box. it must be inserted in slot +1.B2. In this
case, the CBP is inserted in slot +1.B3.
Connecting up the CBP to the PROFIBUS
Assignment of plug-in connector X448
Connecting up The CBP optional board has a 9-pin Sub-D socket (X448) which is
provided for connecting the CBP to the PROFIBUS system. The
connections are short-circuit proof and floating.
Pin Designation Significance Area

9 5
1 SHIELD Ground connection
2 - Not connected
3 RxD/TxD-P Receive/transmit data P (B/B´) RS485
4 CNTR-P Control signal TTL
6
1 5 DGND PROFIBUS data reference potential
(C/C´)
6 VP Power supply Plus 5 V ± 10 %
7 - Not connected
8 RxD/TxD-N Receive/transmit data N (A/A´) RS485
9 - Not connected
Bus connectors You need bus connectors in order to connect the PROFIBUS to a CBP.
There are different types of bus connector with degree of protection IP
20. Their different uses are shown in the table below.
Order No. 6ES7 972-0BA10-0XA0 6ES7 972-0BA20-0XA0

6ES7 972-0BB10-0XA0 6ES7 972-0BB20-0XA0
Appearance
PG socket 0BA10: no 0BA20: no

0BB10: yes 0BB20: yes
Max. baud rate 12 MBaud 12 MBaud
Terminating resistor Can be connected as required Can be connected as required
Outgoing cable Vertical Swivel-type: slanting / vertical
Interfaces
• PROFIBUS nodes • 9-pole Sub-D socket • 9-pole Sub-D socket
• PROFIBUS cable • 4 terminal blocks for wires up • 4 terminal blocks for wires up
to 1.5 mm2 to 1.5 mm2
Connectable diameter of 8 ± 0.5 mm 8 ± 0.5 mm
PROFIBUS cable
Recommended for
• IM 308-B n
• IM 308-C
n
• S5-95U
n
• S7-300
n
• S7-400
n n
• M7-300
n
• M7-400
n
• CBP
n n
Installing the bus Bus cable connection for first Bus cable connection for
and last nodes on the bus1 other nodes on the bus
cable
1 The bus cable can be connected either on the left or on the right!
Bus termination Each bus segment must be fitted with a resistor network, the bus
termination, at each end.
If the recommended bus connectors can be used, the bus termination

can be connected or disconnected by means of switches.
Terminating resistor on Terminating resistor on

connected off not connected off
If these bus connectors are not used, the user must ensure installation
of a bus termination network at the first and last bus station in
accordance with the following illustration.
VP (PIN 6)
390 Ohm
Data line
RxD/TxD-P (PIN 3)
220 Ohm
Data line
RxD/TxD-N (PIN 8)
390 Ohm
DGND (PIN 5)
WARNING A bus segment must always be terminated at both ends with a
! matching resistor. This is not the case, for example, if the last slave
with bus connector is not live. Because the bus connector obtains its
voltage from the station, the matching resistor has no effect.
Make sure that the stations at which the matching resistor is connected
is always supplied with voltage.
Pulling out the bus You can pull out the bus connector with looped-through bus cable from
connector the PROFIBUS-DP interface at any time without interrupting data
transfer on the bus.
First bus node Other bus nodes Last bus node
Connection
example
Bus Bus
termination termination
From preceding bus node To next bus node

Diagnosis and troubleshooting
NOTE With regard to basic parameterization, please note the differences to

the types of unit with the older function classes FC (CU1), VC (CU2)
and SC (CU3). These differences are described below.
In order to make these differences clear, the parameter numbers and

other deviations are either printed in dark grey or have a dark-grey
background.
Evaluating the possibilities of hardware diagnosis
LED displays The three LED displays are located on the front of the CBP. These are
as follows:
• CBP operating (red)
• Data exchange with the basic unit (yellow)
• Transfer of useful data via the PROFIBUS (green)
Diagnostic LEDs give the user rapid information on the status of the
CBP at any particular instant.
More detailed diagnostic information can be read out directly from the
diagnostics memory of the CBP by means of a diagnostic parameter.
NOTE During normal operation, all three LEDs repeatedly light up at the same
time and for the same length of time (flashing)! If an LED is
continuously on or off, this indicates an exceptional condition
(parameterization phase or fault)!
LED Status Diagnostic information

Red Flashing CBP operating; voltage supply on
Yellow Flashing Fault-free data exchange with the basic unit
Green Flashing Fault-free useful data transfer via the PROFIBUS

Red Flashing No transfer of useful data via the PROFIBUS-DP
due to e.g. EMC interference, bus connector pulled
Yellow Flashing
out, polarity reversal of connections, node number
Green Off not supplied with useful data by the master.
Red Off/On Voltage supply for CBP cut off; replace CBP or basic
unit
Yellow Off/On Data exchange with the basic unit not possible;
replace CBP or basic unit
Green Off/On Transfer of useful data via PROFIBUS not possible;
PROFIBUS cable not connected or defective
In the following, all exceptional operating conditions are listed which are
displayed as such by the CBP.
Red Flashing CBP is waiting for the basic unit to begin
initialization
Yellow Off
Green On
Red On CBP is waiting for the basic unit to complete
initialization
Yellow Off
Green Flashing
Red Flashing Checksum error in flash EPROM of the CBP
Yellow On (Download firmware again or replace CBP)
Green Off
Red Flashing Error in RAM test of the CBP
Yellow On Replace CBP (external RAM, DPRAM or SPC3-RAM
defective)
Green On
Fault and alarm display
If faults in PROFIBUS communication with the CBP occur,

corresponding faults or alarms are also displayed on the PMU or on the
OP of the basic unit.
Alarms Alarm number Meaning

A 081 The identification-byte combinations which are sent in
the configuration telegram by the DP master do not
tally with the permitted combinations of identification
bytes (see Table 8.2-12).
Effect:
No connection is established with the PROFIBUS-DP
master; re-configuration is necessary
A 082 A valid PPO type cannot be found in the configuration
telegram from the DP master.
Effect:
No connection is established with the PROFIBUS-DP
master; re-configuration is necessary
A 083 No useful data or invalid useful data (e.g. complete
control word STW1 = 0) are received by the DP master.
Effect:
The process data are not passed on to the DPR. If
parameter P722 (P695) is not equal to zero, this leads
to fault trip F082 (see chapter "Process data
monitoring".
A 084 Telegram traffic between the DP master and the CBP
has been interrupted (e.g. broken cable, bus connector
pulled out or DP master switched off).
Effect:
If parameter P722 (P695) is not equal to zero, this
leads to fault trip F 082 (see chapter "Process data
monitoring".
A 085 Error in the DPS manager software of the CBP.
Effect:
If this error occurs, the heartbeat-counter for the basic
unit is no longer incremented. The consequence is fault
trip F 081.
NOTE The alarm A 082 can even be displayed on the basic unit the first time
the CBP is started as long as telegrams are not being exchanged with a
DP master, e.g. because the bus cable has not yet been connected.
F ault dis plays F ault number Meaning
F 080 F ault in the dual-port A
RM
R emedial meas ure:
C B P probablydefec tive, i.e. replac e CB P
F 081 F ault in monitoring of the heartbeat-c ounter.
T he heartbeat-c ounter is no longer being inc remented
due to an internal fault c aus ed bythe CB P .
C B P is not c orrec tlyplugged in or is defec tiv
e
R emedial meas ure:
C hec k for c orrec t ins tallation; if nec es s,ary
replac e
CBP
F 082 T elegram failure in the dual-portAM R (DP R )
T he telegram-failure w a tc hdog time s et bymeans of
parameter P 722 (P 695) has exp ired. (s ee c hapter
" P roc es s data monitoring" .
B us is interrupted or all us eful data are trans ferred
with 0 (s ee als o A 083).
R emedial meas ure: :
C hec k bus c able inc l. c onnec tor plug; in the
P D
mas ter, as s ign av lues not equal to ero
z to c ontrol
word S TW 1
Faults and Alarms
Faults General information regarding faults
For each fault, the following information is available:
Parameter r947 Fault number
r949 Fault value
r951 Fault list
P952 Number of faults
r782 Fault time
If a fault message is not reset before the electronic supply voltage is
switched off, then the fault message will be present again when the
electronic supply is switched on again. The unit cannot be operated
without resetting the fault message. (Exception: Automatic restart has
been selected, see P373).
Fault Fault Counter-measure

number
F001 Main contactor checkback P591 Src Contactor Msg
If a main contactor checkback is configured, Parameter value must be in conformance
no checkback takes place within the time set with the connection of the main contactor
in P600 after the power-up command. checkback.
In the case of externally excited synchronous Check the checkback loop of the main
motors (P095 = 12), there is no checkback contactor (or the checkback of the excitation
for the excitation current unit. current unit in the case of synchronous
motors).
F002 Pre-charging Check the supply voltage,
When pre-charging, the minimum DC link Compare with P071 Line Volts (compare
voltage (P071 Line Volts 1.34) of 80 % has P071 with the DC link voltage on DC units).
not been reached. Check the rectifier/regenerative unit on DC
The maximum pre-charging time of 3 units. The rectifier/regenerative unit must be
seconds has been exceeded. switched on before the inverter is switched
on.
number
F006 DC link overvoltage Check the supply voltage or input DC
Shutdown has occurred due to excessive DC voltage.
link voltage. Converter is operating in regenerative mode
without rectifier possibility.
Line voltage I DC voltage I Shutdown
I range I threshold
If the converter supply voltage is at the upper
tolerance limit and it is operating at full load,
208 V - 230 V I 280 V – 310 V I appr. 410 V F006 can also be caused by a line phase
380 V - 460 V I 510 V – 620 V I appr. 820 V failure.
500 V - 575 V I 675 V – 780 V I appr. 1020 V Possibly:
660 V - 690 V I 890 V – 930 V I appr. 1220 V • Increase P464 Decel Time,
• Activate P515 DC Bus Volts Reg
(check P071 beforehand)
• Reduce P526 Fly Search Speed.
• Reduce P259 Max Regen Power
(only for P100 = 3, 4 or 5)
For parallel-connected converters (BF L)
r949 = 1: Overvoltage in the DC link
of the master
r949 = 2: Overvoltage in the DC link
of the slave.
F008 DC link undervoltage Check:
The lower limit value of 76 % of the DC link • Input DC voltage
voltage (P071 Line Volts), or of 61 % when
• DC link
kinetic buffering has been enabled, has been
fallen short of.
Undervoltage in the DC link in 'normal'
operation (i.e. no SIMULATION).
Undervoltage in the DC link with active kinetic
buffering and speed less than 10 % of the
rated motor speed.
It was a 'brief power failure' which was not
detected until system recovery (auto restart
flag).
F011 Overcurrent Check
Overcurrent shutdown has occurred. • the converter output for short-circuit or
The shutdown threshold has been exceeded. ground fault
• the load for an overload condition
• whether motor and converter are correctly
matched
• whether the dynamic requirements are
too high.
F012 I too low Only for closed loop n/f/T control
During excitation of the induction motor, the (P100 = 3, 4 or 5)
current did not rise above 12.5 % of the If no motor is connected, go into the
setpoint magnetizing current for no-load simulation mode P372.
operation. Check current detection, check power
section.
number
F015 Motor stall • Reduce load
Motor has stalled or is locked: • Release brake
• if the static load is too high • Increase current limits
• if the acceleration or deceleration time is • Increase P805 PullOut/BlckTime
too fast or if load change is too fast and
too great, • Increase P792 response threshold for
set/actual deviation
• due to incorrect parameterization of the
pulse encoder pulse number P151 or of Only for f/n/T control (P100 = 3, 4, 5)
the analog tachometer scaling P138. • Increase torque limits or torque setpoint
• due to disturbed speed signals Only n/T control or v/f control with speed
(tachometer shield not connected) controller: (P100 = 0, 4, 5)
• Check tachometer cable breal
The fault is only generated after the time set
• Check pulse encoder pulse number
in P805.
• Check analog tachometer scaling
The binector B0156 is set, in the status word
2 r553 Bit28. • Connect shield of tachometer cable on
motor side and converter side
To detect whether the drive is locked, see
P792 (Perm Deviation) and P794. With n/f • Reduce smoothing of speed pre-control
control, this fault is tripped if the torque limits P216 (only n/T control)
have been reached (B0234). Only frequency control: (P100 = 3)
With speed control (P100 = 4) and master • Slow down acceleration time (see also
drive (see P587), the fault can also point to P467-ProtRampGen Gain)
an interruption in the encoder cable. This
• Increase current in the lower frequency
case has the same significance as if the drive
range (P278, P279, P280)
is locked.
• Switch in speed controller pre-control
(P471>0)
With v/f control, the I(max) controller has to
be activated (P331). The monitor does not • Set EMF controller more dynamically
operate with v/f textile applications (P100 = 2). (P315) to max. approx. 2
• Increase changeover frequency for the
Motor has stalled or is locked: EMF model (P313)
• By reaching the maximum frequency in • Replace by speed control with pulse
the case of synchronous motors encoder
(P095 = 12,13) In the case of overmodulated n/f controller:
As a result of missing or excessively high • Track speed setpoint with the speed
excitation current in the case of externally actual value so that the set/actual
excited synchronous motors (P095 = 12): deviation is always less than that set in
(flux is too small or too great). P792.
When the maximum frequency (including Only for synchronous motor: (P095 = 12)
control reserves) (B0254) has been reached
on synchronous motors, the fault is • Check current limits of the excitation unit.
generated immediately. If the deviations in • Check excitation current setpoint and
the rotor flux are too great, first of all, the actual value (incl. wiring)
converter current is switched to zero, the • Check voltage limits of the excitation unit
excitation current is reduced and, after some during dynamic current changes.
time, the fault message is tripped at the level
of the double damping time constant • Check drive system for resonance
(2*r124.1). During this wait time, the status oscillations.
word bit is set already B0156 (r553.28)
number
F017 SAFE OFF in operation Check whether the switch for SAFE OFF
(X009/5-6) is open (only for devices with
Order No....-11, ...-21,...-31).
F018 F set fly Check additional setpoint.
The found set-frequency could not be Power up after coasting.
implemented because the additional setpoint
is too high. Release both directions of rotation.
F019 Motor not found Power up after coasting.

Motor has not been found (during flying Possibly increase P525 Fly Search Amps.
restart without tachometer).
F020 Motor temperature Check the motor (load, ventilation, etc.). The
The motor temperature limit value has been actual motor temperature can be read in
exceeded. r009.
Check P381 Mot Tmp Fault
r949 = 1 Limit value of motor temperature
exceeded Check the KTY84 input at connector
X103:29,30 for short-circuit.
r949 = 2 Short-circuit in the cable to the
motor temperature sensor or sensor defective
r949 = 3 wire break in the cable to the motor
temperature sensor or sensor defective
F021 Motor I2t Check: P383 Mot Tmp T1
Parameterizable limit value of the I2t
monitoring for the motor has been exceeded.
F023 Inverter temperature Measure the air intake and ambient
The limit value of the inverter temperature temperature. Please observe the reduction
has been exceeded. curves at >40 ºC.
r949 = 1: Limit value of inverter temperature Check:

has been exceeded. • Whether the fan -E1 is connected and is
r949 = 2: Sensor 1: Wire break of sensor rotating in the correct direction.
cable or sensor defective • That the air entry and discharge openings
r949 = 18: Sensor 2: Wire break of sensor are not restricted.
cable or sensor defective • Temperature sensor at -X30
r949 = 34: Sensor 3: Wire break of sensor
cable or sensor defective
r949 = 50: Sensor 4: Wire break of sensor
cable or sensor defective
F025 UCE Ph. L1 Check:
There has been an UCE shutdown in phase • Phase L1 for short-circuit or ground fault
L1. (-X2:U2 – including motor).
• That CU is correctly inserted.
• That the switch for ‘SAFE OFF’ (X9/5-6)
is open (only for units with
Order No. ...-11, ...-21,...-31).
number
F026 UCE Ph. L2 Check:
L2. (-X2:V2 – including motor).
• That the switch for ‘SAFE OFF’ (X9/5-6) is
open (only for units with Order No. ...-11,
...-21,...-31).
F027 UCE Ph. L3 Check :
L3. (-X2:W2 – including motor).
• That the switch for ‘SAFE OFF’ (X9/5-6) is
open (only for units with Order No. ...-11,
...-21,...-31).
F028 Supply phase Check the supply voltage.
The frequency and the amplitude of the DC
link ripple indicate a single-phase power
failure.
F029 Meas. value sensing Fault in measured value sensing.
A fault has occurred in the measured value Fault in power section (valve cannot block)
sensing system; Fault on CU
• (r949 = 1) Offset adjustment not possible
in phase L1
in phase L3
in phases L1 and L3
• (r949=65) Autom. Adjustment of the
analog inputs is not possible
F035 Ext. fault 1 Check:
Parameterizable external fault input 1 has • whether there is an external fault
been activated • whether the cable to the appropriate
digital input has been interrupted
• P575 Src No ExtFault1
F036 Ext. fault 2 Check:
Parameterizable external fault input 2 has • Whether there is an external fault
been activated • Whether the cable to the appropriate
digital input has been interrupted
• P586 Src No ExtFault2
number
F037 Analog input Check the connection to
• Analog input 1 -X102:15, 16.
• Analog input 2 -X102: 17, 18.
Check parameters
• P632 CU AnaIn Conf
• P634 CU AnaIn Smooth
• P631 CU AnaIn Offset
F038 Voltage OFF during parameter storage Re-enter the parameter. The number of the
During a parameter task, a voltage failure parameter concerned can be seen in fault
occurred on the board. value r949.
F040 AS internal Replace CU (-A10)
Incorrect operating status
F041 EEPROM fault Replace CU (-A10)
A fault has occurred when storing the values
in the EEPROM.
F042 Calculating time Reduce the calculating time load:
Calculating time problems • Increase P357 Sampling Time
• Calculate individual blocks in a slower
sampling time
Observe r829 CalcTimeHdroom.
F044 BICO Manager
F045 Opt. Board HW Replace CU
A hardware fault has occurred when Check connection of the board subrack to the
accessing an optional board. boards
F046 Par. Task Power the unit down and up again.
Replace CU (-A10).
F047 Internal calculating time Replace CU (-A10).
The calculating time in the gating unit
computer is not sufficient.
For synchronous motors (P095 = 12):
Pulse frequency is set too high
(P340 > 2kHz).
F048 Internal pulse frequency Change P340 Pulse Frequency.
F049 SW Version Use uniform firmware
The firmware versions on the CU have a
different firmware release.
F050 TSY Init. Check:
Error when initializing the TSY board • Whether the TSY is correctly inserted
number
F051 Speed encoder Check the parameters:
Digital tachometer or analog tachometer • P130 Src SpdActV
sensing are faulty. • P151
• P138 AnalogTachScale
• P109 Motor #PolePairs
The product of P109 and P138 must be
smaller than 19200.
Check or replace tachometer. Check
connection to tachometer.
Replace CU
F052 n-Cntr. Input Cancel tachometer with control track
The fault input on the TSY has been active. P130 Src Spd ActV
Replace TSY.
Check the tachometer connection at the TSY.
Several versions are possible, depending on
the type of tachometer.
F053 Tachometer dn/dt Check tachometer cables for interruptions.
The permissible change value of the speed Check earthing of tachometer shield.
encoder signal P215 dn(act,perm) has been
doubly exceeded. • The shield must be connected both at the
motor and the converter side.
• The encoder cable must not be
interrupted.
• The encoder cable must not be laid
together with the power cables.
• Only recommended encoders should be
used.
• In the case of a signal fault, the DT1
board may have to be used.
If necessary, change P215
F054 Sensor board initialization fault Fault value r949
1: Board code incorrect
2: TSY not compatible
20: TSY board double
F056 SIMOLINK telegram failure Check:
• Fiber-optic cable ring
• Whether an SLB in the ring is without
voltage
• Whether an SLB in the ring is faulty
• Check P741 (SLB Tlg OFF)
F058 Parameter error during parameter task No counter-measure
number
F059 Parameter error after factory The number of the inconsistent parameter is
setting/initialization indicated in fault value r949. Correct this
parameter (ALL indices) and power down and
power up the voltage again. Depending on
circumstances, several parameters may be
concerned, i.e. repeat the procedure.
F060 MLFB is missing After acknowledgement, in INITIALIZATION
This is set if the MLFB = 0 after exiting enter a suitable MLFB in parameter P070
INITIALIZATION (0.0 kW). MLFB = order MLFB (6SE70..). (Only possible with the
number. corresponding access stages to both access
parameters).
F061 Incorrect parameterization Acknowledge the fault and change the
A parameter entered during drive setting (e.g. corresponding parameter value. The missing
P107 Mot Rtd Freq, P108 Mot Rtd Speed, parameter is indicated in r949 as a fault
P340 Pulse Frequency) is not in a value.
permissible range (depending on control
type)
number
F062 Multi-parallel circuit r949 = 10: Communications card does
Fault in connection with the multi-parallel not reply. When writing the control word,
circuit or board ImP1 has been detected. BUSY is not active if CSOUT is inactive.
Communications card is probably not
inserted.
r949 = 11,12: Timeout during BUSY during
initialization. BUSY does not become active
within 1 sec.
r949 = 15: Timeout during BUSY during
normal communication. BUSY does not
become active within 1 sec.
r949 = 18: Timeout when reading out the
fault information from the ImPIs.
Within one second after activation of FAULT
no fault cause can be supplied by the ImP1.
r949 = 20+i: HW conflict. This is set if bit
HWCONF is set in status word of slave i.
(Fault in the configuration of the multi-parallel
circuit)
r949 = 30+i: HW version of ImPI is not
compatible. The relevant slave number is
contained in i.
r949 = 40: Number of slaves does not tally
with the setpoint number of slaves of the unit.
r949 = 50+i: Inconsistency in the number of
slaves. The number of slaves notified by the
ImPI is not in conformance with the number
of status words or with the setpoint number of
slaves of the MLFB.
Counter-measure:
• Check ImPI or communications card and
replace, if necessary.
• Check configuration of multi-parallel
circuit.
• Check parameterization.
• Replace CU.
• Replace ImPI.
F065 SCom Telegram r949 = 1 SCom1
No telegram was received at an SCom r949 = 2 SCom2
interface (SCom/USS protocol) within the
telegram failure time. • Check the connection CU -X100:1 to 5
and check the connection PMU -X300.
• Check ”Scom/SCB TLG OFF” P704.01
(SCom1) and P704.02 (SCom2)
• Replace CU (-A10).
number
F070 SCB Init. r949 = 1: Board code incorrect
Error during initialization of the SCB r949 = 2: SCB board not compatible
r949 = 5: Initialization data error
• Check parameter SCB Protocol P696
parameter and Scom/SCB Baud
Rate P701.03
r949 = 6: Timeout during initalization
r949 = 7: SCB board double
r949 = 10: Error in configuration channel
F072 EB initialization error r949 = 2: 1. EB1 not compatible
r949 = 3: 2. EB1 not compatible
r949 = 21: There are three EB1 boards
r949 = 22: There are three EB2 boards
F073 AnaIn1 SL1 Check the connection between the signal
4 mA at analog input 1, slave1 fallen short of source and the SCl1 (Slave 1) -X428:4, 5.
4 mA at analog input 2, slave1 fallen short of source and the SCI1 (Slave 2) -X428:7, 8.
4 mA at analog input 3, slave1 fallen short of source and the SCI1 (Slave 3) -X428:10, 11.
4 mA at analog input 1, slave2 fallen short of source and the SCI1 (Slave1) -X428:4, 5.
F077 AnaIn2 SL2 Check connection between signal source and
4 mA at analog input 2, slave2 fallen short of SCI1 (Slave 2) -X428:7,8.
F078 AnaIn3 SL2 Check connection between signal source and
4 mA at analog input 3, slave2 fallen short of SCI1 (Slave 3) -X428:10, 11.
F079 SCB Telegram • Check connection of SCB1(2).
No telegram has been received by the SCB • Check P704.03”SCom/SCB TLG OFF”.
(USS, Peer-to-Peer, SCI) within the telegram • Replace SCB1(2).
failure time.
• Replace CU (-A10).
number
F080 TB/CB Init. r949 = 1: TB/CB not inserted or TB/CB board
Error during initialization of the board at the code incorrect
DPR interface r949 = 2 TB not compatible
r949 = 3: CB not compatible
r949 = 5: Error in initialization data
Check that the T300 / CB board is inserted
correctly
r949 = 6: Timeout during initialization
r949 = 7: TB/CB board double
r949 = 10: Error in configuration channel
Check the CB initialization parameter:
• P918 CB Bus Address
• P711 to P721 CB parameters 1 to 11
F081 Opt. Board Heartb r949 = 0: TB/CB Heartbeat counter
TB, CB or SCB no longer processes the r949 = 1: SCB Heartbeat counter
monitoring counter
• Replace SCB, TB or CB
• Check connection between subrack and
optional boards
F082 TB/CB Tlg r949 = 1: TB/CB
No new process data have been received by r949 = 2: 2. CB
the TB or the CB within the telegram failure • Check the connections of the CB/TB.
time.
• Check P722 ”CB/TB TLG OFF”.
• Replace CB or TB.
F087 SIMOLINK initialization fault • Replace CU
• Replace SLB
F090 MId Param. Power down and power up again. If it re-
An error occurred when attempting to change occurs, replace the CU.
a parameter from the standstill measurement
or the rotating measurement (Mot ID).
F091 MId Time Eliminate the cause and re-start the
The rotating measurement takes longer than measurement (power up the converter
programmed in a measured status. Possible again). If it re-occurs, replace the CU.
causes:
• Load torque too high
• Load torque not uniform
• Ramp-function generator disabled
number
F095 MId n(set) There must be a 10% frequency range which
Due to entries for lies above 1.1 times the changeover
frequency and below 0.9 times the start of
• Permissible phase sequence field-weakening frequency.
• Maximum frequency, Possible counter-measures;
• Minimum speed, • Permit both phase sequences
• Changeover frequency between V and I • Increase maximum frequency
model, • Reduce minimum speed,
• Start of field-weakening frequency, • Reduce changeover frequency between
• Frequency suppression bandwidth the V and I model.
It was not possible to determine a permissible • Reduce or remove the frequency
frequency range for the rotating suppression bandwidth.
measurement.
F096 MId abort The fault value in r949 defines the type of
The rotating measurement was aborted due intervention:
to inadmissible external intervention. 4 Setpoint inhibit
5 Changeover, setpoint channel
8 Unexpected change in the converter
status
12 Motor data set changeover (for function
selection "Compl. Mot ID”)
13 Changeover to slave drive
14 Motor data set changeover to data set
with v/f_charac
15 Controller inhibit is set
16 Ramp-function generator is disabled
17 Selection "Tacho test" for F controller
18 Ramp-function generator stopped
inate cause
F097 MId measured value If necessary, increase the torque limit values
The measured values for the nominal ramp- to 100 percent
up time when optimizing the controller
deviate too greatly.
Cause: very unsteady load torque
number
F098 MId Tachof The fault value in r949 defines the type of
The rotating measurement has detected a intervention
fault in the speed actual value signal. The 4 No speed signal present
fault value defines the type of fault. 5 Sign of the signal is incorrect
The fault message may have been 6 A track signal is missing
erroneously generated if the drive speed is
externally forced (e.g. completely locked 7 Incorrect gain
drive generates the "no signal" message) 8 Incorrect pulse number
Checking the measurement cables.
Checking the parameters
• P130 Src Speed ActV
• P151 Encoder Pulse #
F100 GRND Init The cause of the fault can be read out from
During the ground fault test, a current not r376 "GrdFltTestResult".
equal to zero has been measured, or an UCE Check the converter output for short-circuit or
or overcurrent monitoring has responded, ground fault
although no valve has yet been triggered. (-X2:U2, V2, W2 – including motor).
Check that the CU is inserted correctly.
Sizes 1 and 2:
• Check the transistor modules on the PEU
board -A23 for short-circuit.
Size 3 and 4:
• Check the transistor modules -A100,
-A200, -A300 for short-circuit
F101 GRND UCE Check valves in the power section for short-
During the ground fault test, the UCE circuit, and on converters with fiber-optic
monitoring has responded in a phase in gating, check the gating unit wiring and the
which no valve has been triggered. UCE checkbacks for correct assignment.
r376 can be interrogated to indicate which
UCE monitoring has responded.
F102 GRND Phase The fault value can be read out from r949.
During the ground fault test, a current flows in The digit of the xth position indicates the
a phase in which no valve has been triggered valve where the fault occurred at power-up
or the UCE monitoring has responded in the x = 1 = V+ x = 2 = V- x = 3 =U+
phase in which the valve has been triggered. x = 4 = U- x = 5 = W+ x = 6 =W-
The figure of the xth digit indicates the phase

in which I 0 and thus a valve must be
defective (always conductive).
x = 1 = Phase 1 (U)
x = 3 = Phase 3 (W)
x = 4 = Phase 1 (U) or 3 (W)
Examine phase for defective valves (always

conductive).
number
F103 Ground fault Read out fault value from r949. The digit of
There is a ground fault or a fault in the power the xth position indicates the valve where the
section. fault occurred at power-up.
During the ground fault test, a current flows x = 1 = V+ x = 2 = V- x = 3 =U+

from the phase in which a valve has been x = 4 = U- x = 5 = W+ x = 6 =W-
triggered, the overcurrent comparator has
responded, or a UCE monitoring has Check the motor including the feeder cable
responded in a phase in which a valve has for short-circuit. If no ground fault is present,
been triggered. check the power section for defective valves
(always conductive).
The digit of the xth position indicates the
phase in which I 0 and therefore a valve
must be defective (always conductive).
1 = Current in phase 1 (U)
2 = UCE in phase 2 (V) 1)
3 = Current in phase 3 (W)
4 = Only overcurrent occurred
The speed of the motor shaft during the
ground fault test should be less than 10 % of
the nominal speed!
1) A ground fault or a defective valve (aways
conductive) is present in phase V or the
switch for ‘SAFE OFF’ (X9/5-6) is open
(only for units with Order No. ...-11, ...-
21,...-31).
F107 MId I = 0 Read out fault value from r949. The figures of
A fault has occurred during the test pulse the grey shaded areas indicate which fault
measurement. has occurred.
xx = 01: Both current actual values
remain 0
xx = 02: Motor-converter cable phase U
interrupted
xx = 03: Motor-converter phase V
interrupted
xx = 04: Motor-converter phase W
interrupted
xx = 05: Current actual value I1
remains 0
xx = 06: Current actual value I3
remains 0
xx = 07: Valve U+ does not trigger
xx = 08: Valve U- does not trigger
xx = 09: Valve V+ does not trigger
xx = 10: Valve V- does not trigger
xx = 11: Valve W+ does not trigger
xx = 12: Valve W- does not trigger
xx = 13: Sign I1 incorrect
xx = 14: Sign I3 incorrect
xx = 15: Sign I1 and I3 incorrect
xx = 16: I1 confused with I3
xx = 17: I1 confused with I3 and both
currents have an incorrect sign
The digit of the grey shaded area indicates
where the fault has occurred.
number
x = 0 = Single converter
x = 1 = Inverter 1
x = 2 = Inverter 2
x = 3 = Inverters 1 and 2
Check that all 3 motor feeder cables and the
motor windings do not have any interruption.
Check the connection between the current
converter and the electronics and check the
current converter itself. Check the correct
input of the rating plate data for the motor
data set valid during the measurement.
F108 MId Unsym Read out fault value from r949. The digit of
During the DC measurement, the the xth position indicates;
measurement results for the individual Transverse voltage too high
phases differ significantly. The fault value x = 1 = phase R; x = 2=phase S;
indicates which quantity(ies) is (are) x = 3 = phase T
concerned and in which phase the greatest
Dev. stator resistance
deviation occurred. (1, 2, 3 as above)
Dev. rotor resistance

(1, 2, 3 as above)
Dev. dead-time compensation

(1, 2, 3 as above)
Deviation valve voltage

(1, 2, 3 as above)
The motor, power section or actual-value

sensing are significantly non-symmetrical.
F109 MId R(L) • Incorrect input of rated speed or rated
The rotor resistance determined during DC frequency
measurement deviates too significantly from • Pole pair number incorrect
the value which was calculated by the
automatic parameterization from the rated
slip.
F110 MId di/dt • There may be a short-circuit between two
During test pulse measurement, the current converter outputs.
has increased significantly faster than was • The motor rating plate data have not been
expected. Thus for the 1st test pulse, an correctly parameterized.
overcurrent condition occurred within the first
half of the minimum switch-on time. • The motor leakage is too low.
F111 Fault e_Func

A fault has occurred while calculating the
equalization function.
F112 Unsym l_sigma
The individual leakage test results deviate too
significantly.
number
F114 MId OFF For P115 Function Select = 2 restart "Motor
The converter has automatically aborted the data identification at standstill". The ON
automatic measurement as the time limit was command must be provided within 20 s after
exceeded up to converter power-up, or due to the alarm message A078 = standstill
an OFF command during the measurement; measurement appears.
the selection in P115 Function Select is reset. Withdraw the OFF command, and restart the
measurement.
F115 KF internal Power-down the converter and electronics
and power-up again.
F148 Fault 1 Function blocks Check cause of fault,
see function diagram 710
F151 Fault 4 Function blocks Check cause of fult,
F243 Link int. Replace CU (-A10).
Faults in internal linking. One of the two
linked partners does not reply.
F244 ParaLink int. Release comparison of MWH software and
Fault in the internal parameter linking CU software regarding the transfer
parameters.
Replace CU (-A10).
F255 Fault in the EEPROM Switch off the unit and power it up again. If it
occurs again, replace the CU.
Alarms The alarm message is periodically displayed on the PMU by A = alarm/
alarm message and a 3-digit number. An alarm cannot be
acknowledged. It is automatically deleted once the cause has been
eliminated. Several alarms can be present. The alarms are then
displayed one after the other.
When the converter is operated with the OP1S operator control panel,
the alarm is indicated in the lowest operating display line. The red LED
additionally flashes (refer to the OP1S operating instructions).
Alarm Param. Cause Counter-measure

number No.
Bit No.
A001 r953 Calculating time • Observe r829 CalcTimeHdroom
The CUVC board calculating time • Increase P357 Sampling Time or
0
utilization is too high
• Reduce P340 Pulse Frequency.
A002 SIMOLINK start alarm Check
• the fiber-optic cable ring
• whether there is an SLB without voltage
in the ring
• whether there is a faulty SLB in the ring
• P741 (SLB Tlg OFF)
A014 r953 Simulation active alarm • Set P372 to 0
The DC link voltage is not equal to 0 • Reduce DC link voltage (disconnect the
13
when the simulation mode is converter from the supply)
selected. (P372 = 1)
A015 r953 External alarm 1 Check
Parameterizable external alarm input • Whether the cable to the corresponding
14
1 has been activated digital input is interrupted.
• Parameter P588 Src No Ext Warn1
A016 r953 External alarm 2 Check
Parameterizable external alarm input • Whether the cable to the corresponding
15
2 has been activated digital input is interrupted.
• Parameter P589 Src No Ext Warn2
A017 r954 SAFE OFF alarm active Close switch X9 5-6 and thus release the
The switch for blocking the inverter inverter pulses.
0
pulses (X9 terminal 5-6) has been
opened (only for units with Order No.
...-11, ...-21,...-31).
A020 r954 Overcurrent Check the driven load for an overload
An overcurrent condition has condition.
3
occurred. • Are the motor and the converter
matched?
• Have the dynamic performance
requirements been exceeded?
number No.
Bit No.
A021 r954 Overvoltage Check the supply voltage.
An overvoltage condition has The converter regenerates without
4
occurred. regeneration possibility.
A022 r954 Inverter temperature • Observe r833 Drive Tmp.
The threshold for initiating an alarm Measure intake air or ambient
5
has been fallen short of. temperature. Observe reduction curves
at >40 ºC .
Check:
• Whether the fan -E1 is connected and is
rotating in the correct direction.
• The air intake and discharge openings
for blockage.
• The temperature sensor at -X30.
A023 r954 Motor temperature Check the motor (load, ventilation, etc.).
The parameterizable threshold for The current temperature can be read in
6
initiating an alarm has been r009 Motor Tmp.
exceeded. Check the KTY84 input at connector
X103:29,30 for short-circuit.
A024 r954 Motor movement Lock the motor
The motor has moved during motor
7
data identification in first start-up.
A025 r954 I2t Inv. Motor load cycle exceeded! Check the
If the instantaneous load condition is parameters:
8
maintained, then the inverter will be P382 Motor Cooling
thermally overloaded. P383 Mot Tmp T1
P384 Mot Load Limits
A029 r954 I2t motor Motor load cycle is exceeded! Check the
The parameterized limit value for the parameters:
12
I2t monitoring of the motor has been P382 Motor Cooling
exceeded. P383 Mot Tmp T1
P384 Mot Load Limits
A033 r955 Overspeed P804 Overspeed Hyst plus
Bit 3 in r553 status word 2 of the P452 n/f(max, FWD Spd) or
0
setpoint channel. The speed actual P453 n/f(max,REV Spd) has been
value has exceeded the value of exceeded.
maximum speed plus the set Increase the parameter for the maximum
hysteresis. frequencies or reduce the regenerative
load.
A034 r955 Setpoint/actual value deviation Check:
Bit 8 in r552 status word 1 of setpoint • Whether an excessive torque
1
channel. The difference between requirement is present.
frequency setpoint/actual value is
greater than the parameterizable • Whether the motor has been
value and the control monitoring time dimensioned too small.
has elapsed. Increase values P792 Perm Deviation Frq/
set/actual DevSpeed and
P794 Deviation Time
A035 r955 Wire break Check whether cable(s) to the
number No.
Bit No.
2 The clockwise and/or the counter- corresponding digital input(s),
clockwise rotating field is not P572 Src REV Speed/ P571 Src FWD
enabled, or a wire breakage is Speed is (are) interrupted or released.
present in the terminal wiring (both
control word bits are zero)
A036 Brake checkback "Brake still Check the brake checkback (see FD 470)
closed”
A037 Brake checkback "Brake still Check brake checkback (see FP 470)
open"
A041 r955 Vdmax controller inhibit Check:
The line voltage is too high or the • Line voltage
8
drive line voltage (P071) is
incorrectly parameterized. The • P071 Line Volts
Vdmax controller is disabled despite
parameter access (P515), as
otherwise the motor would
accelerate immediately in operation
to the maximum frequency.
A042 r955 Motor stall/lock Check:
Motor is stalled or locked. • Whether the drive is locked.
9
The alarm cannot be influenced by • Whether the encoder cable is
P805 ” PullOut/BlckTime”, but by interrupted during speed control and
P794 ”Deviation Time”. whether the shield is connected.
• Whether the drive has stalled.
• For synchronous motors (P095=12):
excitation current injection
A043 r955 n-act jump Check the tachometer cables for
The permissible change value of the interruptions.
10
speed encoder signal (P215) has Check the earthing of the tachometer shield.
been exceeded. • The shield must be connected both on
Additionally for synchronous motors the motor and on the converter side.
(P095=12): • The encoder cable must not be
The motor rotates with more than 2 interrupted.
% of the rated speed at the time of
inverter release. The inverter status • The encoder cable must not be laid with
"Ready for operation" is not exited. the power cables.
• Only the recommended encoders should
be used.
• If there is a signal fault, use the DTI
board if necessary.
• If necessary, change P215
• Additionally for synchronous motors
(P095=12):
Do not grant inverter release until the
motor is at standstill.
A044 r955 I too low Only for synchronous motors P095 = 12
Only for synchronous motors Check:
11
number No.
Bit No.
(P095=12) in operation: • Whether the current limitation of the
The difference smoothed with P159 excitation current control is too small.
between excitation current setpoint • Whether the dynamic performance of
and actual value (r160 - r156 ) the excitation current injection is too low.
deviates from zero by more than
• Whether the excitation current injection
25 % of the rated magnetizing
function is operating,
current.
• Whether the wiring of excitation current
actual-value P155 is correct,
• Whether the wiring of excitation current
setpoint r160 is correct,
• Whether there is a wire breakage
between MASTERDRIVES and the
excitation device.
• Whether the voltage limitation is too low
for dynamic excitation current control.
• Whether the analog output for r160
takes place without isolating amplifiers
(despite cable length > 4m).
A045 r955 DC braking activated • Increase frequency at which DC
The DC braking function has been braking begins.
12
activated and the motor frequency is
still above the frequency at which DC
braking begins (P398).
A049 r956 No slave P690 SCI AnaIn Conf
At ser. I/O (SCB1 with SCI1/2) no • Check slave.
0
slave is connected or fiber-optic
cable is interrupted or slaves are • Check cable.
without voltage.
A050 r956 Slave incorrect Check P690 SCI AnaIn Conf
At ser. I/O the slaves required
1
according to a parameterized
configuration are not present (slave
number or slave type).
A051 r956 Peer Bdrate Adjust the baud rate in conjunction with the
In a peer-to-peer connection, a baud SCB boards P701 SCom/SCB Baud Rate
2
rate has been selected which is too
high or too different.
A052 r956 Peer PcD L Reduce number of words
In a peer-to-peer connection, a PcD P703 SCom PcD #.
3
length has been set which is too high
(>5).
A053 r956 Peer Lng f. Adjust the word length for transmitter and
In a peer-to-peer connection, the receiver
4
PcD length of transmitter and P703 SCom/SCB PcD #
receiver do not match.
A057 r956 TB Param Replace TB configuration (software).
Occurs when a TB is logged on and
8
number No.
Bit No.
present, but parameter tasks from
the PMU, SCom1 or SCom2 are not
answered by the TB within 6
seconds.
A061 Alarm 1 function blocks Check cause of alarm (see FP 710)
A065 r957 Auto restart active Caution!
The auto restart option (P373) Personnel could be in danger when the
0
restarts the drive. A possibly drive automatically restarts. Check whether
parameterized power-up delay time the auto restart function is really required!
(P374) expires if flying restart is not
selected. During pre-charging of the
DC link, there is no time monitoring
i.e. with an external electronics
power supply, it is also switched-in
again.
A066 r957 fsyn > fmax Check:
The measured target frequency of • P452 n/f(max, FWD Spd)/
1
the external converter (or supply) is P453 n/f(max,REV Spd) are correct and
greater than the parameterized
maximum frequency of the • Correct motor data set
synchronizing converter. P578 Src MotDSet Bit0 are selected.
A067 r957 fsyn < fmin Check:

The measured target frequency of • r533 Sync Target Freq
2
the external converter (or supply) is
less than the minimum frequency • Synchronising cable
required for synchronizing.
A068 r957 fsyn<>fsoll Adjust total setpoint (main and additional
The setpoint frequency of the setpoints) to the target frequency displayed
3
synchronizing converter deviates too in visualization parameter r533.
significantly from the measured
target frequency of the external
converter (or supply).
The permissible deviation can be set
in P529.
A069 r957 RGen active Wait until acceleration has been completed.
Synchronizing is not started as long Check whether:
4
as the ramp-function generator in the
synchronizing converter setpoint • P462 Accel Time
channel is active. This alarm is only • P463 Accel Time Unit has been
output if synchronizing is selected. correctly set.
A070 r957 Sync. Error The alarm can only be deleted after
This alarm is output if the phase synchronization has been exited.
5
difference goes outside the
synchronizing window (P 391) after
successful synchronization.
number No.
Bit No.
A071 r957 TSY missing Insert the TSY board in the subrack.
An attempt was made to start
6
synchronization with either the
synchronizing board not inserted or
not parameterized.
A076 r957 t-comp lim The converter output and the motor output
The determined compensation time are too different.
11
was limited to the value range of Check motor data entries P095 to P109.
0.5µs - 1.5µs.
A077 r957 r-g limit Converter output and motor output are too
The measured resistance was different.
12
limited to the maximum value of Check motor data entries P095 to P109.
49 %.
A078 r957 Stands. Meas If the standstill measurement can be
The standstill measurement is executed without any danger:
13
executed when the converter is • Power up the converter
powered-up. With this measurement,
the motor can align itself in any
direction of rotation.
A079 r957 MId Inv Stop P561 Src InvRelease – Release the inverter
The rotating measurement has been or re-start the measurement by powering-up
14
aborted or cannot commence the converter.
because an inverter stop command
is present.
A080 r957 MotId:Dr.M. If the rotating measurement can be
When the converter is powered-up, executed without any danger:
15
the rotating measurement • Power-up the converter
automatically accelerates the drive.
The drive can then only be externally
controlled in a very restricted
fashion.
A081.. r958 CB alarm
A096 See user manual for CB board
1...15
A097.. r959 TB alarm 1
A112 See user manual for TB board
1...15
A113.. r960 TB alarm 2
A128 See user manual for TB board
1...15
Fatal errors (FF) Fatal errors are serious hardware or software errors which no longer
permit normal operation of the unit. They only appear on the PMU in
the form "FF<No>". The software is re-booted by actuating any key on
the PMU.
FFxx Error message Power-down the converter and power-up

again. Call the service personnel if a fatal
error message is displayed again
FF01 Time slot overflow • Increase sampling time (P357) or reduce
A non-removable time sector overflow was pulse frequency (P340)
identified in the higher priority time sectors. • Replace CU
FF03 Access error, optional board • Replace CU
Fatal errors occurred when accessing • Replace LBA
external optional boards
(CB, TB, SCB, TSY ..) • Replace optional board
FF06 Stack overflow • Increase sampling time (P357) or reduce

Overflow of the stack. pulse frequency (P340)
• Replace CU
FFxx Other fatal errors • Replace CU
E Fatal hardware errors • Replace CU
EEEE Fatal firmware errors • Replace CU
• Re-load firmware
Maintenance and Repair
WARNING SIMOVERT MASTERDRIVES units are operated at high voltages.

All work carried out on or with the equipment must conform to all the
national electrical codes (VBG 4 in Germany).
Maintenance and service work may only be executed by qualified
personnel.
Only spare parts authorized by the manufacturer may be used.
The prescribed maintenance intervals and also the instructions for
repair and replacement must be complied with.
Hazardous voltages are still present in the drive units up to 5 minutes
after the converter has been powered down due to the DC link
capacitors. Thus, the unit or the DC link terminals must not be worked
on until at least after this delay time.
The power terminals and control terminals can still be at hazardous
voltage levels even when the motor is stationary.
If it is absolutely necessary that the drive converter be worked on when
powered-up:
♦ Never touch any live parts.
♦ Only use the appropriate measuring and test equipment and
protective clothing.
♦ Always stand on an ungrounded, isolated and ESD-compatible pad.
If these warnings are not observed, this can result in death, severe
bodily injury or significant material damage.
Replacing the Fan
T he fan is des igned for an operating time of L 10 ³ 35 000 hours at an
ambient temperature of T u = 40 °C . It s hould be replaced in good time
to maintain the availability of the unit.
Torx M8x12 Torx M8x12
F an F an hous ing
T he fan as s embly cons is ts of:

¨ the fan hous ing
¨ a fan.
T he fan as s embly is ins talled at the top of the chas s is .
¨ W ithdraw connector X 20.
¨ Undo the two M8 s crews of the fan as s embly.
¨ P ull out the fan as s embly towards the front (if neces s ary, tilt it
s lightly downwards at the front) and lay it down s afely.
CAUTION The fan assembly weighs up to 38 kg, depending on its design.
♦ Undo the cable fastenings and fan connections.

♦ Take the fan support plate out of the fan assembly and remove the
fan from the support plate.
♦ Install the new fan assembly in the reverse sequence.
Prior to start-up, check that the fan can run freely and check for correct
direction of air flow.
The air must be blown upwards out of the unit.
The direction of rotation is counter-clockwise when seen from above.
Replacing the fan fuse

The fuses are in a fuse holder which is mounted on a DIN rail in the
bottom of the unit. The fuse holder has to be opened to replace the
fuses.
Replacing the fan transformer fuse -F3, -F4
: Fuses -F3, -F4
The fuses are in a fuse holder which is arranged below the fan in front
of the air baffle plate. To replace the fuses, the fuse holder has to be
opened.
Replacing the fan transformer
♦ Mark the connecting cables on the transformer and disconnect

them.
♦ Undo the screw connections at the bottom on the transformer plate
and remove the transformer.
Secure the transformer against falling down!
♦ Install the new transformer in the reverse sequence.
The starting capacitor is situated
• inside the fan housing (, -C110).

♦ Withdraw the plug connections on the starting capacitor.
♦ Unscrew the starting capacitor.
♦ Install the new starting capacitor in reverse sequence (4.5 Nm).
Replacing the capacitor battery

The unit is an assembly which consists of the DC link capacitors, the
capacitor support and the DC link bus module.
The capacitor battery consists of three modules. Each module has a

capacitor support and a DC link bus module.
♦ Withdraw the plug connections.
♦ Detach the mechanical fastening (four screws: two on the left, two
on the right).
Swing the capacitor battery out as far as it will go, slightly raise the unit
and pull it forwards out of the converter.
CAUTION The capacitor battery weighs up to 15 kg, depending on the converter

output!
Replacing the SML and the SMU
SML: Snubber Module Lower
SMU: Snubber Module Upper
♦ Remove the capacitor battery.
♦ Undo the fixing screws (4 x M8, 8 - 10 Nm or 4 x M6, 2.5 - 5 Nm, 1 x
M4, max 1.8 Nm).
♦ Remove the modules.
Install the new modules in the reverse sequence.
Removing and installing the module busbars
Removal ♦ Remove the capacitor battery.

♦ Undo the screws of the module busbars.
M8 power connections
M6 fastening on spacers
M4 circuit.
♦ Take out the insulation of the SMU / SML.
♦ Lift out the module busbars.
Installation
The spacing between the plus busbar and the minus busbar must be at
NOTE least 4 mm. In order to install the module busbars, you must therefore
use a template, e.g. a 4 mm thick piece of plastic.
♦ Place the module busbars and SMU/SML insulation on spacer bolts
and fix in place (M6).
♦ Place the template instead of the DC link bus module in the module
busbars.
♦ Locate the SMU and SML and tighten the modular connections (M8,
8 - 10 Nm, M6, 2.5 - 5 Nm).
♦ Screw the nuts tight on the spacer bolts (6 Nm).
♦ Connect the circuit resistors (M4, 1.8 Nm).
♦ Tighten the power connections (M8, 13 Nm).
♦ Remove the template from the module busbars.
Template 4 mm
Module screw Module

connection screw con-
+ nection −
4
Replacing the balancing resistor
The balancing resistor is situated in the rear installation level on the
heat sink between the inverter modules, i.e. behind the capacitor
battery and the module busbars.
♦ Remove the capacitor battery.
♦ Remove the module busbars and the IGD module.
♦ Undo the fixing screws and take out the balancing resistor.
♦ Install the new component in reverse sequence.
♦ The balancing resistor is tightened with 1.8 Nm.
Coat the base plate evenly and thinly with a thermo-lubricant, paying
attention to correct contact assignment.
Replacing the IVI Board ♦ Unscrew the two screws of the electronics slide-in unit and pull it out
to its endstops.
♦ Disconnect the ground cable of the electronics slide-in unit.
♦ Remove all boards from the electronics box and place them on a
suitable surface which cannot be statically charged.
♦ Unscrew the two fixing screws of the electronics box.
♦ Push the electronics box out of its interlock and take it out towards
the front.
♦ Pull out the ABO Adaption Board.
♦ Disconnect the fiber-optic cables.
♦ Unscrew the IVI board and take it out.
♦ Install the new IVI in the reverse sequence.
Replacing the VDU and the VDU resistor

VDU: Voltage-Dividing Unit
The VDU and the VDU resistor are only found on converters with higher
supply voltages. The VDU bracket is an integral component of the
electronics slide-in unit.
VDU ♦ Detach the plug-in connections.
♦ Undo the fixing screw
♦ Take out the VDU.
♦ Install the new VDU in the reverse sequence.
VDU resistor ♦ Unscrew the cable fasteners.
♦ Detach the plug-in connections.
♦ Take out the VDU resistor.
♦ Install the new VDU resistor in the reverse sequence.
Replacing the PSU2 ¨ R emove the V DU and the V DU res is tor (if pres ent).
¨ R emove the V DU retainer plate.
¨ Detach the plug-in connections on the P S U.
¨ Undo the s crews (s ix T orx M4 s crews ) on the P S U.
¨ T ake out the P S U.
¨ Ins tall the new P S U in the revers e s equence.
R eplacing the IG D
NOT E T he s pacing between the plus bus bar and the minus bus bar mus t be at
leas t 4 mm. In order to ins tall the module bus bars , you mus t therefore
us e a template, e.g. a 4 mm thick piece of plas tic.
¨ T he IG D board is s ituated behind the module bus bars .
¨ T ake out the capacitor battery.
¨ T ake out the S ML and S MU modules .
¨ R emove the module bus bars .
¨ R emove the nine fiber-optic cables at the top of the IG D.
¨ W ithdraw the P 15 feeder cable.
¨ Undo the fixing s crews and remove the IG D board.
¨ Ins tall the new IG D in the revers e s equence.
Make s ure when doing s o that you pus h in the fiber-optic cables up
to the ends top.
Replacing the TDB
TDB: Thyristor Drive Board
The TDB is arranged in front of the thyristor modules. These are
situated in the rectifier section between the fan assembly and the
inverter.
♦ Remove the cover (undo screws, then first of all detach the right-
hand snap hook, and then the left-hand snap hook)
♦ Withdraw connectors X246, X11, X12 and X13.
♦ Disconnect the PUD and NUD connections of the pre-charging
resistors R1 and R2 (M4, Torx).
♦ Disconnect the connections to phases U, V, W .
♦ Disconnect the NUD1, NUD2, NUD3 connections.
♦ Remove the TDB board.
♦ Install the new TDB in the reverse sequence.
See figure under section "Replacing the thyristor modules"
Replacing the IGBT module
Replacement is carried out as in the case of the IGD board, with the
following additions:
♦ Remove the fixing screws of the faulty IGBT module and take it out.
♦ Install a new IGBT module, paying attention to the following:
• Coat the contact surfaces thinly and evenly with a thermo-
lubricant.
• Tighten the fixing screws of the IGBT module with 5 Nm,
observing the sequence of tightening.
♦ Modules with the same type designation
e.g. FZxxxxRYYKF4 must be installed in every phase
C E
1 3 3 6
1 2
4 2
5 4
Screw on IGBT module:

1. Hand-tighten (~ 0.5 Nm)
Sequence 1 - 2 - 3 - 4 - 5 - 6
2. Tighten with 5 Nm
(Order No. 6SE7031-8EF60: 2.5 - 3.5 Nm)
Sequence 1 - 2 - 3 - 4 - 5 - 6
Replacing the thyristor modules (V1 to V3, )
Replacement as in the case of the TDB, with the following additions:
♦ Disconnect the supply cables C+ D− of the option terminals
♦ Disconnect the connection of the C and D bars between the rectifier
and the inverter.
♦ Disconnect the connections U, V, W of the modules.
♦ Disconnect the connections between modules and C(+) bar.
♦ Remove the connecting bar C(+).
♦ Disconnect the connections between modules and D(−) bar.
♦ Remove the connecting bar D(−).
♦ Undo the module fixing screws (M6, Torx).
♦ Remove the module (weight approx. 500 g).
♦ Clean the contact surface.
♦ Coat the new modules thinly and evenly with a thermo-lubricant and
mount them.
Tightening torque of the fixing screws: 6 Nm ± 15 %.
♦ Further installation is performed in the reverse sequence.
Tightening torque of the electrical connections (C and D): 12 Nm (+
5 %, − 10 %).
Replacing the PMU
♦ Remove the ground cable on the side panel.
♦ Carefully press the snap catches on the adapter section together,
remove the PMU with adapter section from the electronics box.
♦ Withdraw connector X108 on the CUx board.
♦ Carefully lift forward the PMU out of the adapter section using a
screwdriver.
♦ Install the new PMU in the reverse sequence.
Adapter section
PMU
Snap catches
E-box
Replacing the pre-charging resistors (R1 - R4, )
These are situated on the right next to the TDB board in the rectifier
section.
♦ Remove the cover (undo screws, then detach first the right-hand
snap catch and then the left-hand snap catch).
♦ Disconnect the PUD and the NUD connections of the pre-charging
resistors R1 - R4 (M4, Torx).
♦ Detach the pre-charging resistors and take them out.
♦ Install the new pre-charging resistor with torque of 20 Nm ± 10 %.
CAUTION Do NOT tilt the pre-charging resistor!
♦ Mount the fastenings and the connections in the reverse sequence.

See figure under section "Replacing the thyristor modules"
Replacing the circuit resistor

♦ Take out the capacitor battery.
♦ Take out the SML and SMU modules.
♦ Remove the module busbars.
♦ Undo the fixing screws (2 x M5, torque: max. 1.8 Nm) and take out
the circuit resistor.
♦ The new resistor must be thinly and uniformly rolled in a thermo-
lubricant.
♦ Max. torque of the electrical connections: 1.8 Nm.
♦ Install the new circuit in the reverse sequence.
Forming
If a unit has been non-operational for more than one year, the DC link
capacitors have to be newly formed. If this is not carried out, the unit
can be damaged when the line voltage is powered up.
If the unit was started-up within one year after having been
manufactured, the DC link capacitors do not have to be re-formed. The
date of manufacture of the unit can be read from the serial number.
How the serial (Example: A-J60147512345)
number is made up
Digit Example Significance
1 and 2 A- Place of manufacture
3 H 1996
J 1997
K 1998
4 1 to 9 January to September
O October
N November
D December
5 to 14 Not relevant for forming
The following applies for the above example:
Manufacture took place in June 1997.
During forming, the DC link of the unit is connected up via a rectifier, a
smoothing capacitor and a resistor.
As a result, the DC link capacitors receive a defined voltage and a
limited current, and the internal conditions necessary for the function of
the DC link capacitors are restored.
3AC
A C R
Forming
Motor-
C / L+ D / L- connection
Disconnect Pre-charging
U1/L1 U2/T1
V1/L2 V2/T2
W1/L3 W2/T3
DC link Inverter
PE1 Rectifier
PE2
Components for the Types E to G:
forming circuit
Vrated A R C
(suggestion)
3AC 380 V to 480 V SKD 62 / 16 330 Ω / 150 W 22 nF / 1600 V
3AC 500 V to 600 V 3 x SKKD 81 / 22 470 Ω / 200 W 22 nF / 1600 V
Type K:
Vrated A R C
3AC 380 V to 480 V SKD 62 / 16 100 Ω / 500 W 22 nF / 1600 V
Procedure ♦ Before you form the unit, all mains connections must be
disconnected.
♦ Connect the required components in accordance with the circuit
example.
♦ Energize the forming circuit. The duration of forming depends on the
idle time of the converter.
Forming time
6
in hours
5
2
Off-circuit idle
1
time in years
1 2 3 4 5
TDS Training Manual

Montrose Scotland
AC TOP DRIVE
Section 15
Parameter Listings
AC Electrical
TDS-9S SIEMENS SERIES 70 DRIVE (WITH CUVC CONTROL)
LISTING OF INVERTER PARAMETERS
VIEW
PAR. NO. IND. PARAMETER DESC. VALUE(Units) COMMENTS
YES
P050 - Language 1 Language (1=English)
YES
P053 - Parameter Access 6 Access for Parameters
YES
P060 2 - Menu Select 0 Parameter Menu (7 = Free Access)
P068 0 Output Filter 0 No Output filter
P070 - Order No. 6SE70 38-6U.6. MLFB: Drive Size 128
P071 - Line Volts 780V Rated Drive Voltage
P072 - Rated Drive Amps 860.0A Rated Drive Current
P073 - Rated Drive Power 630.0 kW Rated Drive Power
P075 1 X (magnet,d)tot 150.0% (Default)
P076 1 X (magnet,q)tot 150.0% (Default)
P095 1 Type of Motor 11 NEMA Induction Motor
P100 1 Control Mode 4 Speed Regulation
P100 2 Control Mode 3 Frequency Regulation
P101 1 Motor Rated Volts 550V Motor Nameplate
YES
P102 1 Motor Rated Current 662.0A Motor Nameplate
YES
P103 1 Motor Magn Current 0 Typ = 22.1%
P104 1 Motor Power Factor 0.87 Motor Nameplate
YES
P105 1 Motor Rated Power 700.0 Hp Motor Nameplate
YES
P106 1 Motor Rated Efficiency 92.0% Motor Nameplate
P106 2 Motor Rated Efficiency 92.0% Motor Nameplate
P107 1 Motor Rated Frequency 39.2 Hz Motor Nameplate
P108 1 Motor Rated Speed 1155 1/min Motor Nameplate
P109 1 Motor #Pole Pairs 2 Motor Nameplate
YES
P113 1 Motor Rated Torque 4203.0 Nm Calculated From Motor Nameplate
YES
YES
P115 3 - Calc Motor Model 0 Auto Tune (P115=2, 4, 5)
P116 1 Start-Up Time 0.18 s typ Auto Tuned
P120 1 Main Reactance 380.5 typ (Auto tuned)
P121 1 Stator Resistance 3.24% typ (Auto tuned)
P122 1 Total Leakage React 25.61% typ (Auto tuned)
P127 1 RotResistTmpFact 82.8% typ Resistance Temp Factor (Auto tuned)
YES
P128 1 Imax 1169.5 A Maximum current setpoint (1.5 x P102)
YES
P130 1 Select Motor Encoder 11 11 = Encoder
P130 2 Select Motor Encoder 10 10 = No encoder
TDS-9S SIEMENS DRIVE PARAMETERS (CUVC) 23/03/2001 126743 REV.-

10:56 SHEET 2 OF 14
VIEW
P151 1 Encoder Pulse # 1024 Number of encoder pulses
YES
P215 1 Max dn/dt 8.10 Hz Speed Error Allowed
YES
P216 1 Smooth n/f (FWD) 0.0 ms typ Smoothing Value for Speed Reg (Auto tuned)
P221 1 Smooth n/f (Set) 4 ms (Default)
P222 1 Source of n/f (act) 0 (Default)
P223 1 Smooth n/f (act) 4 ms typ (Auto tuned)
P233 1 n/f Reg. Adapt.1 0.0% (Default)
P235 1 n/f-reg. Gain 1 2.6 typ Porport Gain of Speed Regulator (Auto tuned)
P240 1 n/f Reg. Time 134 ms typ Integral time of speed controller (Auto tuned)
YES
P259 1 Max Regen Power -30.0% Maximum allowed regenerative power.
YES
P273 1 Smooth Isq (set) 7 ms typ Torque smoothing time constant (Auto tuned)
P274 1 Isq (set) grad. 2648.0 A typ Rise limitation for Isq setpoint (Auto tuned)
P283 1 Current Reg Gain 0.324 typ Gain of the PI current controller (Auto tuned)
P284 1 Current Reg Time 6.4 ms typ Adjust. time of the PI controller (Auto tuned)
P287 1 SmoothDCBusVolts 9 DC link bus V smoothing time const (Default)
P291 1 Fsetp Flux (set) 100.0% Flux setpoint from rated rotor flux (Default)
YES
P295 1 Efficiency Optim 50.0% Better Control at Reduced Load
YES
P303 1 Smooth Flux (Set) 20 ms typ Flux setpt smoothing time const (Auto tuned)
P305 1 FieldWeakRegTime 150 ms Field weakening time for PI contoller (Default)
P313 1 f(cEMF Mod) 3.92 Hz typ Frequency of switch for models (Auto tuned)
P314 1 f(cEMF->AMP-mod) 50.0% Frequency of switch for models (Default)
P315 1 cEMF Reg Gain 0.162 typ PI for counter EMF model (Auto tuned)
P316 1 cEMF Reg Time 50.0 ms typ Integral time for counter EMF (Auto tuned)
P338 1 Common Mode Comp 3.00 us Edge pulse modulator compensate (Default)

10:56 SHEET 3 OF 14
VIEW
P339 1 ModSystemRelease 0 Freq system type to release P338 (Default)
P340 1 Pulse Frequency 2.5 kHz Drive Carrier Frequency (Default)
P342 1 Max ModulatDepth 96.0% Max modulation depth of modulator (Default)
P344 1 ModDepth Headroom 0.0% Modulator headroom depth (Default)
P347 1 ON VoltsCompens. 1.1 V typ IGBT voltage diff compensation (Auto tuned)
P348 - Dead Time Comp 0 Select deadtime Comp,0=off (Auto tuned)
P349 - T(DeadtimeComp.) 2.50us Gate unit intrlock compens time (Auto tuned)
YES
P350 - Ref Amps 662.0 A Set to P102 (Motor Rated Current)
P351 - Ref Volts 550 V Set to P101 (Motor Rated Voltage)
P352 - Ref Frequency 81.50 Hz Motor Nameplate
P353 - Ref Speed 2400 1/min Motor Nameplate
YES
P354 - Ref torque 4203.00Nm Set to P113 (Motor Rated Torque)
P357 - Sampling time 1.2 ms Base Sampling Time
YES
P360 1 Select User Parameter P060 Always select P060 (Menu Access)
P360 2 Select User Parameter P053 Always select P053 (Parameter access)
P360 3 Select User Parameter P358 Always select P358 (Key unlock parameter)
P360 4 Select User Parameter r001 Select Drive Status.
P360 5 Select User Parameter r002 Select Rotational Frequency
P360 6 Select User Parameter r003 Select Output Volts
P360 7 Select User Parameter r004 Select Output Amps
P360 8 Select User Parameter r005 Select Output Power
P360 9 Select User Parameter r006 Select DC Bus Volts
P360 10 Select User Parameter r007 Select Motor Torque
P360 11 Select User Parameter r008 Select Motor Utilization
P360 12 Select User Parameter r011 Select Active Motor Data Set
P360 13 Select User Parameter r012 Select Active BICO Data Set
P360 14 Select User Parameter r013 Select Active Function Data Set
P360 15 Select User Parameter r014 Select Set Point Speed
P360 16 Select User Parameter r015 Select Speed Actual Input
P360 17 Select User Parameter P050 Select Language
P360 18 Select User Parameter P102 Select Motor Rated Amps
P360 19 Select User Parameter P105 Select Motor Rated Power
P360 20 Select User Parameter P113 Select Motor Rated Torque
P360 21 Select User Parameter P115 Select Motor Calculation (Auto Tune)
P360 22 Select User Parameter P128 Select Imax
P360 23 Select User Parameter P215 Select max. dn/dt
P360 24 Select User Parameter P259 Select Max Regen Power
P360 25 Select User Parameter P295 Select Efficiency Optim
P360 26 Select User Parameter P350 Select Reference Amps
P360 27 Select User Parameter P354 Select Reference Torque
P360 28 Select User Parameter P401 Select Fixed Setpoint 1
P360 29 Select User Parameter r419 Select # of Active Fault Setpoints
P360 30 Select User Parameter P492 Select FixTorque 1 Set
P360 31 Select User Parameter r496 Select Fix Torque 1
P360 32 Select User Parameter r497 Select Actual Upper Torque Limit
P360 33 Select User Parameter P498 Select FixTorq 2 Set

10:56 SHEET 4 OF 14
VIEW
P360 35 Select User Parameter r550 Select Control Word 1
P360 37 Select User Parameter r552 Select Status Word 1
P360 39 Select User Parameter P590 Select Src BICO Dset
P360 40 Select User Parameter P602 Select Excitation time
P360 41 Select User Parameter P640 Select Src Analog Out
P360 42 Select User Parameter P643 Select CU AnalogOutGain
P360 43 Select User Parameter P644 Select CU- AnalogOutOff
P360 44 Select User Parameter r782 Select Last 8 Fault Trip Times
P360 45 Select User Parameter r783 Select n/f actual (r218) at time of last trip
P360 46 Select User Parameter r784 Select n/f actual/second at time of last trip
P360 47 Select User Parameter r785 Select actual torque current at time of trip
P360 48 Select User Parameter r786 Select actual converter out V at time of trip
P360 49 Select User Parameter r787 Select Control Status at time of trip
P360 50 Select User Parameter r825 Select Operating Hours (Inverter Pulsing)
P360 51 Select User Parameter r947 Select Last 8 Faults
P360 52 Select User Parameter r949 Select Last 8 Fault Values
P360 53 Select User Parameter P971 Select EEPROM Saving
P360 54 Select User Parameter U002 Select Fixed Setpt 18 (Meter Torque Scaling)
P361 - OP1s Backlight 0 0= Always On
P366 - Select FactSet 1 Select Factory Setting (Default)
P368 - Select Setp Src 1 Analog Input & Terminal Strip (Default)
P370 - Quick Param 0 P370=1 Will Factory DEFAULT Parameters!!!!
P375 - Ground Flt Test 0 Blocked (Default)
P382 1 Motor Cooling 1 1 = Forced Vent
P383 1 Mot ThermT-Const 1800 s Max Time Allowed in Stall = 30 min.
P401 1 Fixed Setpoint 1 0.00% Additional Drill Speed
P401 2 Fixed Setpoint 1 10.00% Spin Speed Set to 10% of Rated Speed
P401 3 Fixed Setpoint 1 5.00% Torque Speed Set to 5% of Rated Speed
P421 - MOP (max) 100.0% Upper Limit of OP1S (Default)
P422 - MOP (min) 0.0% Lower Limit of OP1S (Default)
P423 - Src MOP inv. 2111 BICO for Direction Change on OP1S
P425 - Conf MOP 0110 Configuration of MOP
P426 - StartValue MOP 0.0% MOP Starting Value
P427 - Src Set MOP 0 BICO Source for MOP Use (Default)
P428 - Src SetV MOP 0 BICO Source for MOP Set Value (Default)
P429 - Src Auto SetP 0 BICO Source for MOP Auto Setpt (Default)
P430 - Src Manual/Auto 0 BICO Source for Manual/Auto Switching
P433 1 Src AddSetpoint1 41 BICO to Set Spin, Torque, and Speed
P434 1 Scale Add Setpoint 100.00% Gain for Additional Setpoint 1 (Default)
P443 1 Src MainSetpoint 3002 BICO for Main Setpoint
P444 1 Scale Main Setp 100.00% Scaling factor for Main Setpoint (Default)
P445 1 Base Setpoint 0.0% Basic Setpoint (Added to Main Setpoint)(Def)

10:56 SHEET 5 OF 14
VIEW
P448 - Jog Setp 1 10.00% Jogging Setpoint 1 (Default)
P452 1 n/f(max, FWD Spd) 100.0% Max Setpoint for CW (Forward) Rotating Field
P453 1 n/f(max,REV Spd) -50.00% Max Setpoint for CCW(Reverse) Rotating Field
P457 1 Min setp 0.0% Minimum Setpoint of the Drive (Default)
P462 1 Accel. Time 5.0 Acceleration Time (P463) From 0 to 100%
P463 1 Accel. Time Unit 0 0 = Seconds
P464 1 Decel. Time 2 Deceleration Time (P465) From 100 to 0%
P465 1 Decel. Time Unit 0 0 = Seconds
P466 1 Decel. Time OFF3 2.0 s Keypad "quickstop" from 100% to standstill
P467 1 ProtRampGen Gain 2.9 typ Acceleration Time (P462) Gain Factor(Auto Tn)
P467 2 ProtRampGen Gain 1.0 typ Acceleration Time (P462) Gain Factor
P467 3 ProtRampGen Gain 1.0 typ Acceleration Time (P462) Gain Factor
P468 - Rgen Round Type 0 Mode for Ramp Function Rounding (Default)
P469 1 Ramp StartSmooth 0.50 s Initial Rounding Up Time for Ramp Func (Def)
P470 1 Ramp End Smooth 0.50 s Final Rounding Up Time for Ramp Func (Def)
P471 1 Scale Torq (PRE) 100.0% Gain of the n/f controller precontrol (Default)
P475 - Ramp Limitation 0.0% "0.0" Deactivates Ramp-Func Tracking (Def)
P476 - RampGen Act Hyst 1.0% Hysteresis for "Rmp-Func Gen Active" msg.
P492 1 FixTorque 1 Set 100.0% Forward Maximum Drill Torque
P492 2 FixTorque 1 Set 10.0% Forward Spin Torque
P492 3 FixTorque 1 Set 150.0% Maximum Make-up Torque (Forward)
P493 1 Src Fixtorque 1 3003 BICO Source for Upper Torque Limitation
P494 1 FixTorque 1 Gain 100.00% Scaling Factor for Upper Torque Limitation
P498 1 FixTorque 2 Set -100.00% Reverse Maximum Drill Torque
P498 2 FixTorque 2 Set -10.00% Reverse Spin Torque
P498 3 FixTorque 2 Set -200.00% Maximum Breakout Torque (Reverse)
P499 1 Src FixTorque 2 3005 BICO Source for Lower Torque Limit
P500 1 Scale TorqLim2 100.00% Scaling Factor for Lower Torque Limit (Def)

10:56 SHEET 6 OF 14
VIEW
P535 1 SIMO Sound 1 Adjusts Noise Spectrum of Machine
P536 1 n/f RegDyn (set) 50% Dynamic Response of n Control Circuit (Def)
P537 1 n/f RegDyn (act) 50% typ P536 Adjustment After P115=5 (Auto Tuned)
P554 1 Src ON/OFF1 3100 Drive ON/OFF Command,P590=0 (PLC Cntrl)
P554 2 Src ON/OFF1 2100 Drive ON/OFF Command,P590=1 (OP1S Ctrl)
P555 1 Src1 OFF2 (Coast) 22 Drive OFF Command From E-STOP (Coast)
P556 1 Src2 OFF2 (Coast) 1 2nd BICO Source for OFF (Coast Stop)(Def)
P557 1 Src3 OFF2 (Coast) 1 3rd BICO Source for OFF (Coast Stop)(Def)
P558 1 Src1 OFF3 (Qstop) 2102 Drive OFF Command From OP1S (Qck Stop)
P559 1 Src2 OFF3 (Qstop) 1 2nd BICO Source for OFF (Quick Stop)(Def)
P560 1 Src3 OFF3 (Qstop) 1 3rd BICO Source for OFF (Quick Stop)(Def)
P561 1 Src InvRelease 1 BICO Source for Releasing Inverter (Def)
P562 1 Src RampGen Rel 1 BICO Source for Releasing Ramp Gen (Def)
P563 1 Src RampGen Stop 1 BICO Source for Starting Ramp Gen (Def)
P564 1 Src Setp Release 1 BICO for Releasing Setpoint (cw1,bit 1)(Def)
P565 1 Src1 Fault Reset 18 Digital In 5 (Not used)
P566 1 Src2 Fault Reset 3107 AutoReset Drive From PLC
P566 2 Src2 Fault Reset 0 Reset Drive From OP1S Keypad
P568 1 Src Jog Bit0 3108 Jog from Bit 8, Control Word 1
P568 2 Src Jog Bit0 2108 Jog from OP1S Keypad
P569 1 Src Jog Bit1 0 BICO Src to Jog ( Sets Bit 9, cw1)(Not Used)
P571 1 Src FWD Speed 3111 BICO Source to Command Fwd Rotation(PLC)
P571 2 Src FWD Speed 2111 BICO Source to Command Fwd Rot (Keypad)
P572 1 Src REV Speed 3112 BICO Source to Command Rev Rotation (PLC)
P572 2 Src REV Speed 2112 BICO Source to Command Rev Rot (Keypad)
P573 1 Src MOP UP 2113 BICO Source to Increase MOP (Not Used)
P573 2 Src MOP UP 2113 BICO Source to Increase MOP (Keypad)
P574 1 Src MOP Down 2114 BICO Source to Decrease MOP (Not Used)
P574 2 Src MOP Down 2114 BICO Source to Decrease MOP (Keypad)
P575 1 Src No ExtFault1 20 BICO Source for External Fault 1
P576 1 Src FuncDSet Bit0 3400 BICO Src for Func Data Set (cw2,bit16)
P576 2 Src FuncDSet Bit0 0 BICO Src for Func Data Set (cw2,bit16)(Def)
P578 1 Src MotSSet Bit0 3402 BICO Src for Motor Data Set (cw2,bit 18)

10:56 SHEET 7 OF 14
VIEW
P579 1 Src MotSSet Bit1 0 BICO Src for Motor Data Set (cw2,bit 19)(Def)
P590 - Src BICO Dset 0 Set PLC or OP1S Control (0=PLC)
P602 1 Excitation Time 0.20 s Wait Time Before Releasing Frequency
P603 1 De-MagnetizeTime 3.00 s Time to DE-excite Motor (Auto Tuned)
P640 1 Src AnaOut 148 BICO for Analog 1 Out (Speed)
P640 2 Src AnaOut 24 BICO for Analog 1 Out (Torque)
P643 1 CU AnalogOutGain 10.00 V Porportional Gain for Analog Outputs (Def)
P644 1 CU--AnalogOutOFF 0.00 V Offset Voltage for P643 Analog Outs (Def)
P652 1 Src DigOut2 122 Undervoltage Fault (Status Word 1, Bit 11)
P722 1 CB/TB TlgOFF 10 ms Fault if No Communication for 10 ms (Def)
P734 1 SrcCB/TBTrnsData 32 Status Word 1(To PLC)
P734 2 SrcCB/TBTrnsData 467 Speed to Meter (To PLC)
P734 3 SrcCB/TBTrnsData 33 Status Word 2 (To PLC)
P734 4 SrcCB/TBTrnsData 468 Torque to Meter (To PLC)
P734 5 SrcCB/TBTrnsData 170 Spin Torque (To PLC)
P734 6 SrcCB/TBTrnsData 250 Fault Number (To PLC)
P952 - # of Faults 7 Number of Stored Fault Trips
P970 - Factory Setting 1 P970=0 Will Factory DEFAULT Parameters!!!!
P971 - EEPROM Saving 0 Save Parameters(Ram To EEPROM)(P971=1)
U001 1 FixSetp 17 95.00% RPM Scaling (For VDC Meter)
U002 1 fixSetp 18 54.50% Torque Scaling (For VDC Meter)
U107 1 Src Conn Mult1 491 Multipliers for RPM Meter
U108 1 Src Conn Mult2 492 Multipliers for Torque Meter
U117 - Src ConnAbsV1 148 BICO Source for 1st Abs Value Generator
U118 - Mode ConnAbsV1 1 Mode Sel for Ist Abs Value Gen (1=| Signal |)
U119 - SmoothConAbsV1 0 ms Smoothing Time Const for 1st Abs Val Gen
U120 - Src ConnAbsV2 24 BICO Source for 2nd Abs Value Generator
U121 - Mode ConnAbsV2 1 Mode Sel for 2nd Abs Value Gen (1=| Signal |)
U122 - SmoothConAbsV2 0 ms Smoothing Time Const for 2nd Abs Val Gen
U950 031 Sampling Times1 2 Sampling time

10:56 SHEET 8 OF 14
TDS-9S SIEMENS SERIES 70 DRIVE
LISTING OF RECTIFIER PARAMETERS
P050 0 Language 1
P051 0 Access Level 3
P052 0 Function Select 0
P053 0 Parameter Access 6
P054 0 Display Light 0
P071 0 Line Volts 575.0 V
P074 0 Limit LowVoltage 61
P075 0 Rtd Amps 1023
P076 0 Config. Pcircuit 1
P077 0 Factory Set type 0
P090 0 Board Position 2 0
P140 1 Rectifier Resistance 0.007
P141 1 Rectifier Inductance 0.21
P144 1 DC Bus Capacitance 32.22
P160 1 Motor Current Limit 150
P310 1 DC Current Reg Gain 0.15
P311 1 DC Current Reg Time 0.015
P312 1 DC Cur Reg CWord 2111
P313 1 DC Volts Reg Gain 8.8
P314 1 DC Volts Reg Time 3
P315 1 DC Volts Reg CWord 0010
P316 1 DC V-Reg +Limit 0.01
P317 1 DC V-Reg -Limit -1.00
P318 1 DC V(Set,red) 95.00 Set DC Bus to 780V
P319 1 DC V(Set,red)Hys 6.00
P320 1 Smooth Load Amps 5.00
P329 1 Pre Charge Time 500
P353 0 Thyristor Test 0
P354 0 Ground Flt Test 2
P366 0 Auto Restart 2 Restart After Power Recovery
P368 0 Time DC Bus Volts 6.1
P408 1 Caps Forming Time 10
P409 0 Contactor Delay 0
P486 1 Src Current Setup 0
P517 1 DC Volts Dev Limit 2
P518 1 Deviation Time 0.1
P554 1 Src ON/OFF1 1001
P555 1 Src1 OFF2(coast) 0001
P561 1 Src InvRelease 1003
P565 1 Src1 Fault Reset 1004
P566 1 Src2 Fault Reset 0000H
P568 1 Src Jog1 ON 0000H
P571 1 Src Reduce DC V 0001 Used To Reduce DC Bus Via P318
P575 1 Src No ExtFault1 0001
P578 1 Src RDataSet Bit0 0000H

10:56 SHEET 10 OF 14
P586 1 Src No ExtFault2 0001H
P587 1 Src Master/Slave 0000H
P588 1 Src No Ext Warn1 0001H
P590 0 Src Base/Reserve 0000H
P591 0 Src ContactorMsg 0001H
P600 1 Trg Bit Ready ON 0000H
P601 1 Trg Bit Ready Operator 0000H
P602 1 Trg Bit Oper 0000H
P603 1 Trg Bit Fault 1001
P604 1 Trg Bit No OFF2 0
P606 1 Trg Bit On blocked 0
P607 1 Trg Bit Warning 1002
P608 1 Trg Regen Ready 0
P610 1 Trg Low Voltage 0
P612 1 Trg Bit Contact 0
P613 1 Trg DC V reduced 0
P618 1 Trg Current Lim. 0
P619 1 Trg Bit Ext Flt1 0
P621 1 Trg Bit Ext Warn 0000H
P622 1 Trg Bit i2tInv 0000H
P623 1 Trg Bit Flt Tmp Inv 0000H
P624 1 TrgBitWarTmpInv 0000H
P631 1 Trig Bit Charging 0000H
P655 0 CUR AnaOutActVal 37
P656 0 CUR AnaOut Gain 10.00
P657 0 CUR AnaOut Offset 0.00
P658 0 AnaOut Conf Curr 0
P660 1 SCI AnaLogInConf 0
P661 1 SCI AnaInSmooth 2
P662 1 SCI AnaLogInOffs 0
P664 1 SCI AnaOutActVal 0
P665 1 SCI AnaOut Gain 10
P666 1 SCI AnaOut Offs 0
P680 1 SCom1 Act Value 968
P682 0 SCB Protocol 0
P683 1 SCom/SCB BusAddr 0
P684 1 SCom/SCB Baud 6
P685 1 SCom/SCB PCV 127
P686 1 SCOM/SCB # PrDat 2
P687 1 SCom/SCB TlgOFF 0 ms
P688 0 SCom2 Protocol 1
P689 1 SCB Peer2PeerExt 0
P690 1 SCB Act Values 0
P694 1 CB/TB Act Values 968
P695 0 CB/TB Tlg Off Time 20ms
P696 0 CB Parameter 1 0

10:56 SHEET 11 OF 14
P772 1 Thyr Voltg Corr 0
P773 1 Deadband Convert 0.01
P775 1 Min Gating Angle 0
P776 1 Max Gating Angle 150
P777 1 Max Gat Ang Ramp 20
P778 1 Line FrquFiltTime 200
P779 0 Phase Shift Corr 0.8
P780 1 Fault Masking 0
P785 0 I2T Control Word 1
P788 1 RAM Access Addr 0
P793 0 Line Voltg Delay 0.03
P799 0 Special Access 4
P917 0 Change Reports 0
P918 0 CB Bus Address 3
P971 0 EEPROM Storing 0

10:56 SHEET 12 OF 14
TDS-11S SIEMENS SERIES 70 DRIVE (WITH CUVC CONTROL)
LISTING OF INVERTER PARAMETERS
VIEW
YES
P050 - Language 1 Language (1=English)
YES
P053 - Parameter Access 6 Access for Parameters
YES
P060 2 - Menu Select 0 Parameter Menu (7 = Free Access)
P068 0 Output Filter 0 No Output filter
P070 - Order No. 6SE70 38-6U.6. MLFB: Drive Size 128
P071 - Line Volts 780V Rated Drive Voltage
P072 - Rated Drive Amps 860.0A Rated Drive Current
P073 - Rated Drive Power 630.0 kW Rated Drive Power
P100 1 Control Mode 4 Speed Regulation
P100 2 Control Mode 3 Frequency Regulation
YES
YES
YES
YES
P106 1 Motor Rated Efficiency 92% Motor Nameplate
P106 2 Motor Rated Efficiency 92% Motor Nameplate
YES
YES
YES
P115 3 - Calc Motor Model 0 Auto Tune (P115=2, 4, 5)
YES
YES
P130 1 Select Motor Encoder 11 11 = Encoder
P130 2 Select Motor Encoder 10 10 = No encoder
TDS-11S SIEMENS DRIVE PARAMETERS (CUVC) 14/02/2001 124965 REV.B

16:29 SHEET 2 OF 13
VIEW
YES
YES
YES
YES
YES
YES

16:29 SHEET 3 OF 13
VIEW
P348 - Dead Time Comp 0 Select deadtime Comp,0=off (Auto tuned)
P349 - T(DeadtimeComp.) 2.55us Gate unit intrlock compens time (Auto tuned)
YES
P350 - Ref Amps 732.0 A Set to P102 (Motor Rated Current)
P351 - Ref Volts 575 V Set to P101 (Motor Rated Voltage)
P352 - Ref Frequency 81.50 Hz Motor Nameplate
P353 - Ref Speed 2400 1/min Motor Nameplate
YES
P354 - Ref torque 4934.00Nm Set to P113 (Motor Rated Torque)
P357 - Sampling time 1.2 ms Base Sampling Time
YES
P360 1 Select User Parameter P060 Always select P060 (Menu Access)
P360 2 Select User Parameter P053 Always select P053 (Parameter access)
P360 3 Select User Parameter P358 Always select P358 (Key unlock parameter)
P360 4 Select User Parameter r001 Select Drive Status.
P360 5 Select User Parameter r002 Select Rotational Frequency
P360 6 Select User Parameter r003 Select Output Volts
P360 7 Select User Parameter r004 Select Output Amps
P360 8 Select User Parameter r005 Select Output Power
P360 9 Select User Parameter r006 Select DC Bus Volts
P360 10 Select User Parameter r007 Select Motor Torque
P360 11 Select User Parameter r008 Select Motor Utilization
P360 12 Select User Parameter r011 Select Active Motor Data Set
P360 13 Select User Parameter r012 Select Active BICO Data Set
P360 14 Select User Parameter r013 Select Active Function Data Set
P360 15 Select User Parameter r014 Select Set Point Speed
P360 16 Select User Parameter r015 Select Speed Actual Input
P360 17 Select User Parameter P050 Select Language
P360 18 Select User Parameter P102 Select Motor Rated Amps
P360 19 Select User Parameter P105 Select Motor Rated Power
P360 20 Select User Parameter P113 Select Motor Rated Torque
P360 21 Select User Parameter P115 Select Motor Calculation (Auto Tune)
P360 22 Select User Parameter P128 Select Imax
P360 23 Select User Parameter P215 Select max. dn/dt
P360 24 Select User Parameter P259 Select Max Regen Power
P360 25 Select User Parameter P295 Select Efficiency Optim
P360 26 Select User Parameter P350 Select Reference Amps
P360 27 Select User Parameter P354 Select Reference Torque
P360 28 Select User Parameter P401 Select Fixed Setpoint 1
P360 29 Select User Parameter r419 Select # of Active Fault Setpoints
P360 30 Select User Parameter P492 Select FixTorque 1 Set
P360 32 Select User Parameter r497 Select Actual Upper Torque Limit
P360 33 Select User Parameter P498 Select FixTorq 2 Set

16:29 SHEET 4 OF 13
VIEW
P360 39 Select User Parameter P590 Select Src BICO Dset
P360 40 Select User Parameter P602 Select Excitation time
P360 41 Select User Parameter P640 Select Src Analog Out
P360 42 Select User Parameter P643 Select CU AnalogOutGain
P360 43 Select User Parameter P644 Select CU- AnalogOutOff
P360 44 Select User Parameter r782 Select Last 8 Fault Trip Times
P360 45 Select User Parameter r783 Select n/f actual (r218) at time of last trip
P360 46 Select User Parameter r784 Select n/f actual/second at time of last trip
P360 47 Select User Parameter r785 Select actual torque current at time of trip
P360 48 Select User Parameter r786 Select actual converter out V at time of trip
P360 49 Select User Parameter r787 Select Control Status at time of trip
P360 50 Select User Parameter r825 Select Operating Hours (Inverter Pulsing)
P360 51 Select User Parameter r947 Select Last 8 Faults
P360 52 Select User Parameter r949 Select Last 8 Fault Values
P360 53 Select User Parameter P971 Select EEPROM Saving
P360 54 Select User Parameter U002 Select Fixed Setpt 18 (Meter Torque Scaling)
P361 - OP1s Backlight 0 0= Always On
P366 - Select FactSet 1 Select Factory Setting (Default)
P368 - Select Setp Src 1 Analog Input & Terminal Strip (Default)
P370 - Quick Param 0 P370=1 Will Factory DEFAULT Parameters!!!!
P375 - Ground Flt Test 0 Blocked (Default)
P401 1 Fixed Setpoint 1 0.00% Additional Drill Speed
P401 2 Fixed Setpoint 1 10.00% Spin Speed Set to 10% of Rated Speed
P401 3 Fixed Setpoint 1 5.00% Torque Speed Set to 5% of Rated Speed
P421 - MOP (max) 100.0% Upper Limit of OP1S (Default)
P422 - MOP (min) 0.0% Lower Limit of OP1S (Default)
P423 - Src MOP inv. 2111 BICO for Direction Change on OP1S
P425 - Conf MOP 0110 Configuration of MOP
P426 - StartValue MOP 0.0% MOP Starting Value
P427 - Src Set MOP 0 BICO Source for MOP Use (Default)
P428 - Src SetV MOP 0 BICO Source for MOP Set Value (Default)
P429 - Src Auto SetP 0 BICO Source for MOP Auto Setpt (Default)
P430 - Src Manual/Auto 0 BICO Source for Manual/Auto Switching

16:29 SHEET 5 OF 13
VIEW
P467 1 ProtRampGen Gain 2.9 typ Acceleration Time (P462) Gain Factor(AutoTn)
P467 2 ProtRampGen Gain 1.0 Acceleration Time (P462) Gain Factor (Def)
P467 3 ProtRampGen Gain 1.0 Acceleration Time (P462) Gain Factor (Def)
P468 - Rgen Round Type 0 Mode for Ramp Function Rounding (Default)
P475 - Ramp Limitation 0.0% "0.0" Deactivates Ramp-Func Tracking (Def)
P476 - RampGen Act Hyst 1.0% Hysteresis for "Rmp-Func Gen Active" msg.
P492 1 FixTorque 1 Set 100.0% Forward Maximum Drill Torque
P492 2 FixTorque 1 Set 10.0% Forward Spin Torque
P492 3 FixTorque 1 Set 133.0% Maximum Make-up Torque (Forward)
P498 1 FixTorque 2 Set -100.00% Reverse Maximum Drill Torque
P498 2 FixTorque 2 Set -10.00% Reverse Spin Torque
P498 3 FixTorque 2 Set -200.00% Maximum Breakout Torque (Reverse)

16:29 SHEET 6 OF 13
VIEW
P554 1 Src ON/OFF1 3100 Drive ON/OFF Command,P590=0 (PLC Cntrl)
P554 2 Src ON/OFF1 2100 Drive ON/OFF Command,P590=1 (OP1S Ctrl)
P566 1 Src2 Fault Reset 3107 AutoReset Drive From PLC
P568 1 Src Jog Bit0 3108 Jog from Bit 8, Control Word 1
P568 2 Src Jog Bit0 2108 Jog from OP1S Keypad
P571 1 Src FWD Speed 3111 BICO Source to Command Fwd Rotation(PLC)
P571 2 Src FWD Speed 2111 BICO Source to Command Fwd Rot (Keypad)
P572 1 Src REV Speed 3112 BICO Source to Command Rev Rotation (PLC)
P572 2 Src REV Speed 2112 BICO Source to Command Rev Rot (Keypad)
P573 1 Src MOP UP 2113 BICO Source to Increase MOP (Not Used)
P573 2 Src MOP UP 2113 BICO Source to Increase MOP (Keypad)
P574 1 Src MOP Down 2114 BICO Source to Decrease MOP (Not Used)
P574 2 Src MOP Down 2114 BICO Source to Decrease MOP (Keypad)

16:29 SHEET 7 OF 13
VIEW
P590 - Src BICO Dset 0 Set PLC or OP1S Control (0=PLC)
P640 1 Src AnaOut 148 BICO for Analog 1 Out (Speed)
P640 2 Src AnaOut 24 BICO for Analog 1 Out (Torque)
P734 1 SrcCB/TBTrnsData 32 Status Word 1(To PLC)
P734 2 SrcCB/TBTrnsData 467 Speed to Meter (To PLC)
P734 3 SrcCB/TBTrnsData 33 Status Word 2 (To PLC)
P734 4 SrcCB/TBTrnsData 468 Torque to Meter (To PLC)
P734 5 SrcCB/TBTrnsData 170 Spin Torque (To PLC)
P734 6 SrcCB/TBTrnsData 250 Fault Number (To PLC)
P952 - # of Faults 7 Number of Stored Fault Trips
P970 - Factory Setting 1 P970=0 Will Factory DEFAULT Parameters!!!!
P971 - EEPROM Saving 0 Save Parameters(Ram To EEPROM)(P971=1)
U117 - Src ConnAbsV1 148 BICO Source for 1st Abs Value Generator
U118 - Mode ConnAbsV1 1 Mode Sel for Ist Abs Value Gen (1=| Signal |)
U119 - SmoothConAbsV1 0 ms Smoothing Time Const for 1st Abs Val Gen
U120 - Src ConnAbsV2 24 BICO Source for 2nd Abs Value Generator
U121 - Mode ConnAbsV2 1 Mode Sel for 2nd Abs Value Gen (1=| Signal |)
U122 - SmoothConAbsV2 0 ms Smoothing Time Const for 2nd Abs Val Gen

16:29 SHEET 8 OF 13
TDS-11S SIEMENS SERIES 70 DRIVE
LISTING OF RECTIFIER PARAMETERS
P050 0 Language 1
P051 0 Access Level 3
P052 0 Function Select 0
P053 0 Parameter Access 6
P054 0 Display Light 0
P071 0 Line Volts 575.0 V
P074 0 Limit LowVoltage 61
P075 0 Rtd Amps 1023
P076 0 Config. Pcircuit 1
P077 0 Factory Set type 0
P140 1 Rectifier Resistance 0.007
P141 1 Rectifier Inductance 0.21
P144 1 DC Bus Capacitance 32.22
P160 1 Motor Current Limit 150
P310 1 DC Current Reg Gain 0.15
P311 1 DC Current Reg Time 0.015
P312 1 DC Cur Reg CWord 2111
P313 1 DC Volts Reg Gain 8.8
P314 1 DC Volts Reg Time 3
P315 1 DC Volts Reg CWord 0010
P316 1 DC V-Reg +Limit 0.01
P317 1 DC V-Reg -Limit -1.00
P318 1 DC V(Set,red) 95.00 Set DC Bus to 780V
P319 1 DC V(Set,red)Hys 6.00
P320 1 Smooth Load Amps 5.00
P329 1 Pre Charge Time 500
P353 0 Thyristor Test 0
P354 0 Ground Flt Test 2
P366 0 Auto Restart 2 Restart After Power Recovery
P368 0 Time DC Bus Volts 6.1
P408 1 Caps Forming Time 10
P409 0 Contactor Delay 0
P486 1 Src Current Setup 0
P517 1 DC Volts Dev Limit 2
P518 1 Deviation Time 0.1
P554 1 Src ON/OFF1 1001
P561 1 Src InvRelease 1003
P566 1 Src2 Fault Reset 0000H
P571 1 Src Reduce DC V 0001 Used To Reduce DC Bus Via P318
P575 1 Src No ExtFault1 0001

16:29 SHEET 9 OF 13
P586 1 Src No ExtFault2 0001H
P587 1 Src Master/Slave 0000H
P591 0 Src ContactorMsg 0001H
P600 1 Trg Bit Ready ON 0000H
P601 1 Trg Bit Ready Operator 0000H
P602 1 Trg Bit Oper 0000H
P603 1 Trg Bit Fault 1001
P604 1 Trg Bit No OFF2 0
P606 1 Trg Bit On blocked 0
P607 1 Trg Bit Warning 1002
P608 1 Trg Regen Ready 0
P612 1 Trg Bit Contact 0
P613 1 Trg DC V reduced 0
P618 1 Trg Current Lim. 0
P621 1 Trg Bit Ext Warn 0000H
P622 1 Trg Bit i2tInv 0000H
P623 1 Trg Bit Flt Tmp Inv 0000H
P624 1 TrgBitWarTmpInv 0000H
P631 1 Trig Bit Charging 0000H
P655 0 CUR AnaOutActVal 37
P656 0 CUR AnaOut Gain 10.00
P657 0 CUR AnaOut Offset 0.00
P658 0 AnaOut Conf Curr 0
P660 1 SCI AnaLogInConf 0
P661 1 SCI AnaInSmooth 2
P662 1 SCI AnaLogInOffs 0
P664 1 SCI AnaOutActVal 0
P665 1 SCI AnaOut Gain 10
P666 1 SCI AnaOut Offs 0
P682 0 SCB Protocol 0
P683 1 SCom/SCB BusAddr 0
P684 1 SCom/SCB Baud 6
P685 1 SCom/SCB PCV 127
P686 1 SCOM/SCB # PrDat 2
P687 1 SCom/SCB TlgOFF 0 ms
P688 0 SCom2 Protocol 1
P689 1 SCB Peer2PeerExt 0
P690 1 SCB Act Values 0
P694 1 CB/TB Act Values 968
P695 0 CB/TB Tlg Off Time 20ms

16:29 SHEET 10 OF 13
P772 1 Thyr Voltg Corr 0
P773 1 Deadband Convert 0.01
P775 1 Min Gating Angle 0
P776 1 Max Gating Angle 150
P777 1 Max Gat Ang Ramp 20
P778 1 Line FrquFiltTime 200
P779 0 Phase Shift Corr 0.8
P780 1 Fault Masking 0
P785 0 I2T Control Word 1
P788 1 RAM Access Addr 0
P793 0 Line Voltg Delay 0.03
P799 0 Special Access 4
P917 0 Change Reports 0
P918 0 CB Bus Address 3
P971 0 EEPROM Storing 0

16:29 SHEET 11 OF 13
TDS Training Manual

Montrose Scotland
AC TOP DRIVE
Section 16
Encoder Troubleshooting
AC Electrical
Encoder Troubleshooting Instructions
CUVC Card Version
The encoder is used to provide rotational position

information to the Variable Frequency Drive (VFD). On the AC
TDS systems, the encoder signal comes into the Varco
Interface Terminal Strip (TB1 Drive on drawing) in the drive.
The +I5VDC for the encoder is provided from the CUVC card
and goes out on terminal 31 (Common) and terminal 32
(+15VDC). The AC Top Drives use a differential input signal
and on the Siemens drive an optional Digital Tach. Interface
board to convert this differential signal (A+,A- and B+,B-) to a
single ended signal (A+ and B+). The (A+) signal comes into
terminal 34, the (A-) signal is 35, the (B+) signal is 37 and the
(B-) signal is 38. This can be verified on the schematics. The
waveforms for the respective signals are shown above.
The symptom of encoder failure is that the drive when
assigned and throttle given will refuse to rotate or rotate very
slowly, with high Torque showing on the Torque meter. You
probably will not see a failure indication on the drive, or it may
trip out due to over-current.
If you suspect the encoder change the drive from speed
control (n) to frequency control (f) by using the encoder by-
pass switch. If the AC TDS starts rotating you have an encoder
problem. If it does not verify that you have performed the
changeover from speed control to frequency control correctly
by viewing the motor data set in the VFD (parameter r011, 1=n
speed control, 2 =f frequency control) and then try again. If it
still does not turn you should look at the inputs to the drive and
not the encoder.
The first check of the encoder should be measurement of
the signals with a voltmeter this should be done with the drive
stopped. There should be approximately 15V between
terminals 31 and 32 (+15DCV and Common) if there is not
disconnect the encoder cable, to see if it is being shortened
out. There should be approximately 15V between pins 34 and
35 (A+ and A-) and between terminals 37 and 38 (B+ and B-) if
there is not and you have a scope check the individual signals
to see which one or ones are missing this will require you to
run the AC TDS in the frequency mode.
If you are missing a signal remember that on the Siemens
drive you can rewire the signals so that they do not pass
through the DTI card to keep running. If (A+) and (B+) are both
good disconnect the (A+) and (B+) signals from the DTI card at
terminals X403 and X402. You can then connect (A+) to (A+)
and (B+) to the (B+) wire straight across, be sure to do the
same with both the (+15VDC) and both the (Common) signals
as well.
If you still can not get the top drive to turn and you have
signals that are 90 degrees from each other (See A+ and B+
above) try reversing the (A+) and (B+) wires.
Encoder Fuse
There is a "fuse" in line with the (+15VDC), if too much
current is drawn the fuse opens. This thermal fuse is self
resetting after it cools. With a short on one of the outputs, the
driver sources too much current “opening” the fuse. When
power is removed the fuse will reset after a short period of
time, and upon application of power the signals will come back.
If it appears that you have no output from the encoder
disconnect the encoder cable then reconnect after a few
minutes.
Cable Testing
A common fault with the encoder is a broken or a shorted
cable in the encoder loop, this can be checked by
disconnecting the encoder cable at the Top Drive end and also
at the Varco control house end, the cables should then be
checked for continuity and also tested between cores for
possible shorts. A common problem is that the Top drive will
fault at the same place in the derrick this is good way of telling
there is a problem with the service loop.
Waveforms
The above picture shows a scoped waveform from a rotating

Top Drive, this is what would be expected to see when looking
at both the (A+) and (B+) signals together with an oscilloscope.
If the Top drive was drilling ahead when checking the signals
you could expect to see the widths of the waveforms constantly
changing, this would be because when the Top Drive
experiences “down-hole Torque”, it would momentarily slow
down (remember that the encoder sends out 1024 pulses per
revolution of both the motor and encoder). What should be
noted from these waveforms is that the small “spikes” at the
edges of the waves are not a problem because the signal is a
digital signal, only when the “spike” was in the middle of the
waveform would there be a possibility that this would be a
problem, but it would be expected that the DTI card would
rectify that problem.
DTI Schematic
EEx Digital Encoder
Varco P/N = 122725
The Eex Digital Encoder used on the AC Top Drive, has a four channel
output (A+,A-,B+,B-) with 90° Displacement at 1024 pulses per
Revolution.
TDS Training Manual

Montrose Scotland
AC TOP DRIVE
Section 17
Simovis Version 5
AC Electrical
Table of Contents
Section 1 - Introduction (page 3)
Section 2 - Configuration of Control Card (page 4)
Section 3 - UPREAD from the AC DRIVE to a PC (page 6)
Section 4 - Viewing the UPREAD parameters (page 8)
Section 5 - DOWNLOADING from a PC to the AC DRIVE
(page 10)
Section 6 - Examination (page 12)
Section 7 - Examination Answers(page 13)
2
Section 1 - Introduction
SIMOVIS Version – 5, is for use with the Siemens 70 Series Drive, by

using the SIMOVIS PC program, you can UPREAD parameter sets from
the units, store them on the hard disk or on floppy disks and transfer
them back to the units by DOWNLOAD. You have the additional
possibility of editing the parameters off-line and of creating parameter
files especially for your application. These files do not have to contain
the complete parameter scope. They can be limited to parameters,
which are relevant for the particular application. This module is mainly
aimed at the newer Vector Control Card the CUVC, but the same
method is used for Upreading and Downloading parameters to a CU2
card, the communication differences are explained in Section 2.
This section is split into four parts, they are Configuration of Control
Card, UPREAD, View an UPREAD set and DOWNLOAD.
Section 2 – Configuration of Control Card

This part shows how to configure the type of control card that is inserted
in the Siemens 70 Series drive. For this section we are using a CUVC
card, but if the card that was to be configured the
Section 3 – UPREAD a parameter set

This part shows how to UPREAD a complete parameter set from the AC
Drive to a PC.
Section 4 – View an UPREAD parameter set.

The second part of this section shows how to view an upread set of
parameters once it has been upread from the AC Drive and stored to
disk.
Section 5 – DOWNLOAD a parameter set

The third part of this section shows how to DOWNLOAD a complete
parameter set into the AC Drive from a PC and how to check for errors.
3
Section 2 - Configuration of Control Card
To get ONLINE with SIMOVIS, firstly ensure that the cable (RS 232) is inserted into
the PMU and “Com Port 1” on the PC. Details on this cable can be found in the
SIMOVIS “Readme” file.
The Siemens Part Number for the cable is:- 6SX7005-0AB00
Above is the first window that is viewed when SIMOVIS is opened from the Desktop
of your PC. To configure a Drive you click on the “Blue Cross”.
This brings up the “Add a drive” screen, to set up for the CUVC card with software
version 3.1, click on the down arrows at “Drive type” and “SW-version”, and select
the type and version as above, then click on “OK”. For this section we are using a
CUVC card, but if the card that was to be configured was a CU2 card, this would be
selected from the list and would be “MASTERDRIVES VC(CU2).
4
The Drive Type, Software, etc. is then displayed under Bus Address 0, other Drive
types could be configured to different Bus Addresses, this would be done in “Add a
Drive”. To communicate with the Drive, double click on the blue highlighted bar for
the CUVC card.
This then communicates with the Drive and all the present value of the parameters
are displayed down the right hand side of the screen, the top of the screen displaying
“Online (EEPROM) identifies this. The Drive status is also displayed in the bottom
left of the screen, in this case the drive shows a green “OK” which means there is no
faults or alarms on the drive at present, but if there was a fault, it would then display
a red “F” here. If you cannot get ONLINE, check the cable connection or the “Drive
type” and then try again.
5
Section 3 - UPREAD from the AC DRIVE to a PC
To UPREAD all the parameters from the Drive, Select “Upread” then “Base unit all”
from “File”, as shown above.
The program then automatically defaults to save the parameter set to the
“Masterdives VC(CUVC)” folder in SIMOVIS, this can be changed to another folder
on the hard drive (c) or to a floppy disk (a), by clicking on the down arrow next to
“Masterdives VC(CUVC)” and then selecting the required option. It is best when
saving to the hard drive (c), to save to the SIMOVIS default, as it will also
automatically default to this when “DOWNLOAD” is selected. At this stage the
parameter set that is to be Upread from the AC Drive requires a name, for this
example “Test” is to be used, this should be written into the “File name” box. Once
the folder has been chosen and the parameter set has been given a name, click on
“Save” to start Upreading the parameter set.
6
When the “UPREAD” has started, the above dialog box will be displayed, this shows
that SIMOVIS is Upreading the parameters and saving them as “TEST” (top of box),
it also displays the amount of parameters to be upread (in this case 1030), how
many have been upread (in this case 37), how many have been upread successfully
(OK) and how many have not been upread successfully (E). This function can be
aborted by clicking on “Cancel”.
If the upread has been completed successfully, this will be displayed by a dialog box
as above, if there has been a problem, it will show a dialog box with the details of the
problem parameters (this will be shown later in the DOWNLOAD section). To
proceed, click on “OK”.
7
Section 4 - Viewing the UPREAD parameters
To view the Upread parameters, you have to change to the “OFFLINE” mode. To do
this, select “Offline” from the “View”, as shown above.
This will then display either “File New” (factory parameter set), or “File Open” (Open
a previously saved parameter set). Choose and click on “File Open” as above,
because you want to open your previously saved parameter set (TEST).
8
The “Open parameter set” dialog box then appears; this is asking you what
parameter set you require to open. The above dialog box shows three options,
TDS11S(CUVC), Test or Train CUVC. To open the “Test” parameter set, click on
“Test” as shown above, this is then shown in the “File name” box, finally click on
“Open”, thus opening “Test”.
The parameter set “Test” is then viewed in the Offline mode as shown at the top of
the screen as “offline (Test)” with all the parameters shown down the right hand side
of the screen. The “Drive status” in the bottom left of the screen is now shown as a
blue “O”, to signify that the drive is Offline. Note you do not have to be connected to
the drive to view parameter sets in the Offline mode.
9
Section 5 - DOWNLOADING from PC to the AC DRIVE
To Download a parameter set from a PC to the Siemens 70 Series Drive, you have
to be Online with the drive, and in the Online Status, this was previously shown in
the Upread part. Once SIMOVIS is successfully Online with the Drive, select
“Download” and then “Save (EEPROM)”, from “File” as shown above. It is best to
save to EEPROM, as the parameters are permanently stored into the Drive.
The “Open parameter set” dialog box appears which again automatically defaults to
“Masterdrives VC (CUVC)”, from this the previously saved program to be
downloaded can be selected. Shown above is “Test” set to be Downloaded, to do
this click on “Test”, this is then shown in the “File name” box, then click on “Open”,
this opens the parameter set to be downloaded, and starts the downloading process.
10
The dialog box “Download” appears as above, this shows at the top of the box, the
parameter set that is being downloaded, in this case “Test”. Also shown is the
number of parameters that are to be Downloaded in this case 829, the number of
parameters that have been downloaded in this case 15 and the number of
parameters that have been successfully Downloaded (OK) or not successfully
downloaded (E). This process can be aborted by clicking on “Cancel”. When the
Download is in process the drive will automatically default to download status 21, this
should be viewed on the PMU.
A dialog box will then be displayed explaining how many parameters have been
written and refused, in the case above from 829 parameters, 828 were written
successfully and 1 was refused, the parameters that were refused can be looked at
by clicking on “Details”. If no parameters were refused only the “OK” box would be
available.
If the “Details” box was selected in the previous dialog box, the “Error” dialog box will
be displayed as above, with the parameters that SIMOVIS was not able to Write to
the drive. In this case only one parameter was refused 368, this would have to be
checked and then manually changed by either the PMU, OP1S or SIMOVIS. Clicking
on “OK” returns you to the Online screen where all the parameters that have been
downloaded can now be viewed.
11
Section 6 – Examination
1. What type of cable is used to communicate a PC to a Siemens 70 Series drive?
___________________________________________________________________
___________________________________________________________________
2. What two type of Siemens 70 Series Drive control cards has Varco used to
control its AC Top Drives and Pipe Racking Systems?
___________________________________________________________________
___________________________________________________________________
3. What is the difference between UPREAD and DOWNLOAD when using SIMOVIS
version 5?
___________________________________________________________________
___________________________________________________________________
4. What type of files are used to store the parameter sets in SIMOVIS version 5?
___________________________________________________________________
___________________________________________________________________
5. If the Drive Status is shown as a Blue “O”, what does this mean?
___________________________________________________________________
___________________________________________________________________
6. If the Drive Status is shown as a Red “F”, what does this mean?
___________________________________________________________________
___________________________________________________________________
7. What is the difference between a “P” type parameter and an “r” type parameter?
___________________________________________________________________
___________________________________________________________________
8. Can Parameters be changed in the AC Drive through SIMOVIS when the PC is

connected to the AC Drive?
___________________________________________________________________
___________________________________________________________________
12
Section 7 – Examination Answers
1) What type of cable is used to communicate a PC to a Siemens 70 Series drive?
An RS232 cable is used to communicate a PC to a Siemens 70 Series Drive.
2) What two type of Siemens 70 Series Drive control cards has Varco used to
control its AC Top Drives and Pipe Racking Systems?
Varco use either a CU2 or a CUVC card to control the Siemens 70 Series drives
in their equipment.
3) What is the difference between UPREAD and DOWNLOAD when using SIMOVIS
version 5?
UPREAD is used to transfer parameters from the AC drive to a PC,
DOWNLOAD is used to transfer parameters from a PC to the AC drive.
4) What type of files are used to store the parameter sets in SIMOVIS version 5?
The File type that is used to store parameters in SIMOVIS version 5 is
Download files (*.DNL).
5) If the Drive Status is shown as a Blue “O”, what does this mean?
This signifies that the AC drive is OFFLINE from the PC and the parameter set
displayed is from an internal file in the PC and not from the AC drive.
6) If the Drive Status is shown as a Red “F”, what does this mean?
This signifies that the AC drive is ONLINE and communicating with the PC
satisfactory, but there is a fault at present with the AC drive.
7) What is the difference between a “P” type parameter and an “r” type parameter?
A “P” type parameter is an operator changeable parameter that can be
changed to alter the control of the AC drive. An “r” type parameter is a read
only parameter, this can only be viewed to gain information about the AC
drive.
8) Can Parameters be changed in the AC Drive through SIMOVIS when the PC is

connected to the AC Drive?
Yes, parameters can be changed in the AC drive when the PC is connected
and ONLINE, care should be taken NOT to change parameters unnecessarily.
13

Enviando - 1866228934 PDF

Uploaded by

Document Information

Original Description:

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

Enviando - 1866228934 PDF

Uploaded by

Copyright:

Available Formats

Varco Technical Education Center

Hydraulic Disc Gooseneck

Rear Right Side

Left Side Front

A new threshold in AC technology

Weight-Lbs. 30,700 24,000 18,000 28,000

Cont. Torque. 34,900 32,500 20,000 38,000

Horse Pwr. 1,000 700 350 800

Rated Ton. 500 400 250 500

TOP DRIVE COMPONENTS

TDS-9SA/TDS-11SA PLAN VIEW

POWER TRAIN CUTAWAY

Transmission/Motor Housing (Main Body) and

MOTOR COOLING SYSTEM

HYDRAULIC CONTROL SYSTEM

The hydraulic control system is a completely self-contained, onboard system. A 10-

Three hydro-pneumatic accumulators are located on the main body. The

AC DRILLING MOTOR BRAKES

Powered Rotating link

TWO WAY LINK TILT (PH-50)

The two way link-tilt cylinder assemblies consist of the cylinder

INTERNAL BLOWOUT PREVENTION

Internal Blowout Prevention

TORQUE BACK-UP CLAMP

The counterbalance system includes two hydraulic cylinders connected between

Notes, cautions, and warnings

i Provides additional information on procedures involving little or no risk of

! Alerts the reader to procedures involving a risk of equipment damage.

Warns the reader of procedures involving a definite risk of injury to

i To avoid injury to personnel or equipment damage, carefully observe the

i During installation, operation, maintenance, or repair of this equipment,

Contact the Varco Service Department to arrange for training for

Systems safety practices

i Before installing or performing maintenance or repairs on the equipment,

❏ Isolate all energy sources before beginning work.

❏ Avoid performing maintenance and repairs while the equipment is in

❏ Wear proper protective equipment during the installation,

❏ Before beginning work on this equipment, familiarize yourself with

❏ When performing installation, maintenance, or repairs on the

❏ Before beginning work on any portion of the hydraulic system,

❏ Take precautions when bleeding down residual system pressure,

n Hydraulic fluids can be extremely hot and under high pressure.

❏ Properly discharge all system accumulators.

❏ Prior to beginning work on any portion of the pneumatic system,

❏ Take precautions when bleeding down residual system pressure

❏ Properly discharge all system accumulators.

❏ Prior to beginning work on any portion of the cooling system

❏ Take precautions when bleeding down residual system pressure

❏ Take precautions to prevent cooling water from leaking into other

i Keep the working envelope/zone of the equipment free from personnel.

When replacing components

❏ Replace failed or damaged components with Varco certified parts.

i Failure to conduct regular maintenance can result in a hazard,

Visibility of equipment operation

Proper use of equipment

i Do not hoist personnel using this equipment.

Contact the Varco service center for questions regarding equipment

Varco Technical Education Center

How to use this manual ...................................... 1-2

How to use this manual

Where applicable, each section includes:

Notes, Cautions and Warnings