20 21 PDF

Part Number 20-21
Revision A
INSTALLATION, CALIBRATION, AND OPERATION
Load Pin Sensor System

P/N 221736
Manufacturers of Precision Instruments
Printed in U.S.A. June 15, 1998

Manual 20-21 contains 56 pages, divided as follows:
Cover. . . . . . . . . . . . . . . . . . . . . . . . . . . . . June 1998

Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . June 1998
TOC-1 through TOC-2 . . . . . . . . . . . . . . . June 1998
Pages 1 through 40 . . . . . . . . . . . . . . . . . . June 1998
Section 11 drawings . . . . . . . . . . . . . . . . . June 1998
Section 13 drawings . . . . . . . . . . . . . . . . . June 1998
All product, brand, or trade names used in this publication are the trademarks or registered
trademarks of their respective owners.
IMPORTANT SAFETY NOTICE
Proper service and repair is important to the safe, reliable operation of all M/D TOTCO equipment.
The service procedures recommended by M/D TOTCO and described in the technical manuals are
recommended methods of performing service operations. When these service operations require
the use of tools specially designed for the purpose, those special tools should be used as recom-
mended. Warnings against the use of specific service methods that can damage equipment or
render it unsafe are stated in the manuals. These warnings are not exclusive, as M/D TOTCO
could not possibly know, evaluate and advise service people of all conceivable ways in which ser-
vice might be done or of all possible associated hazardous consequences. Accordingly, anyone
who uses service procedures or tools which are not recommended by M/D TOTCO must first sat-
isfy themselves thoroughly that neither personnel safety nor equipment safety will be jeopardized
by the method selected.
June 15, 1998 iii

M/D TOTCO
LIMITED PRODUCT WARRANTY
THE FOLLOWING WARRANTY IS EXCLUSIVE AND IN LIEU OF ALL OTHER WARRANTIES, WHETHER
EXPRESS, IMPLIED OR STATUTORY, INCLUDING, BUT NOT BY WAY OF LIMITATION, ANY WARRANTY
OF MERCHANTABILITY OR FITNESS FOR ANY PARTICULAR PURPOSE.
Martin-Decker TOTCO (“Company”) warrants to Buyer (“Purchaser”) of new products manufactured or

supplied by the Company that such products are, at the time of delivery to the Purchaser, free of material and
workmanship defects, subject to the following exceptions:
A. Any product which has been repaired or altered in such a way, in the Company's judgement, as to affect
the product adversely, including any repairs, rebuilding, welding or heat treating outside of Company
authorized facility.
B. Any product which has, in the Company's judgement, been subject to negligence, accident, or improper
storage.
C. Any product which has not been installed, operated and maintained in accordance with normal practice
and within the recommendations of the Company.
D. For all items of special order by Buyer which are not manufactured by Company, Buyer should submit
warranty claims directly to the manufacturer thereof.
The Company's obligation under this warranty is limited to repairing, or at its option, replacing any products
which in its judgement proved not to be as warranted within the applicable warranty period. All costs of
transportation of products claimed not to be as warranted to authorized Company service facility shall be
borne by Buyer. Costs of return transportation to Buyer of products accepted for repair or replacement by
Company under the warranty provisions of the Sales Agreement shall be borne by the Company. Company
may, at its sole option elect to refund the purchase price of the products, and Company shall have no further
obligation under the Sales Agreement.
The cost of labor for installing a repaired or replacement part shall be borne by Buyer. Replacement parts
provided under the terms of this warranty are warranted for the remainder of the warranty period of the
product upon which installed to the same extent as if such parts were original components thereof.
The warranty periods for various products are:
A. Hydraulic, Mechanical, Electronic Equipment: one (1) year from date of installation or fifteen (15) months
from date of shipment from Company, whichever occurs first.
B. All Elastomer Diaphragms: six (6) months from date of shipment from Company.
No deviations from the Company's standard warranty terms or period as stated herein will be honored unless
agreed to in writing by an authorized Company representative prior to acceptance of the order.
EXCLUSIVITY OF REMEDY AND LIMITATION OF LIABILITY. THE REMEDIES PROVIDED FOR IN THIS
WARRANTY SHALL CONSTITUTE THE SOLE RECOURSE OF BUYER AGAINST COMPANY FOR
BREACH OF ANY OF COMPANY'S OBLIGATIONS UNDER THE SALES AGREEMENT WITH BUYER,
WHETHER THE CLAIM IS MADE IN TORT OR IN CONTRACT, INCLUDING CLAIMS BASED ON
WARRANTY, NEGLIGENCE, OR OTHERWISE.
IN NO EVENT SHALL COMPANY BE LIABLE FOR DIRECT, INDIRECT, INCIDENTAL OR

CONSEQUENTIAL DAMAGES, REGARDLESS OF THE FORM OF ACTION, WHETHER IN CONTRACT,
STRICT LIABILITY OR IN TORT (INCLUDING NEGLIGENCE), NOR FOR LOST PROFITS.
iv June 15, 1998

M/D TOTCO
Table of Contents
Paragraph/Title Page
1. INTRODUCTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2. SYSTEM OVERVIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
3. SYSTEM DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
4. SYSTEM COMPONENT SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
4-1 Load Pin Assemblies (P/N 221601 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
4-2 Signal Conditioner Assembly (P/N 221535-001) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
4-3 Barrier Box Assembly (P/N 221513-001 or 221789-001 and 221995-001) . . . . . . . . . . . . . . . 10
4-4 Power Supply Assembly (P/N 221516-001) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
4-5 Derrick Junction Box (Varco P/N 92927) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
5. INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
5-1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
5-2 Installation Guidelines and Issues . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
5-2-1 Intrinsic Safety Guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
5-2-2 Wiring Guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
5-3 Installation of Load Pins . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
5-4 Installation of Power Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
5-5 Installation of Barrier Assemblies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
5-6 Installation of Signal Conditioner Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
6. CALIBRATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
6-1 Calibration of load pins with factory calibration information . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
6-1-1 Field Calibration Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
6-1-2 Creating 10 point table algorithms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
6-1-3 Summing channel with load offset algorithm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
6-1-4 Creating Sensor Channels. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
6-1-5 Create Ten Point Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
6-1-6 Analog Channel Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
6-1-7 Verify channels Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
6-2 Calibration of load pins without factory calibration information . . . . . . . . . . . . . . . . . . . . . . . . . 22
6-2-1 Purpose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
6-2-2 Two Point Field Calibration Procedure - One Load Pin . . . . . . . . . . . . . . . . . . . . . . . . 22
6-2-3 Two Point Field Calibration Procedure - Two Load Pins . . . . . . . . . . . . . . . . . . . . . . . 23
6-3 Barrier Box Checkout Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
7. OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
8. PERIODIC INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
8-1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
8-2 Periodic Inspection Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
9. MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
10. RECOMMENDED SPARE PARTS LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
11. SYSTEM WIRING DRAWINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
June 15, 1998 i

M/D TOTCO
Manual 20-21 Table of Contents
Paragraph/Title Page
12. ILLUSTRATED PARTS LISTINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

12-1 Signal Conditioner Assembly - P/N 221535-001 and -002 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
12-2 Barrier Box Assemblies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
12-2-1 Barrier Box - P/N 221513-001 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
12-2-2 Barrier Box - P/N 221789-001 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
12-2-3 Barrier Box - P/N 221995-001 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
12-3 Power Supply Assembly - P/N 221516-001 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
13. INSTALLATION CONTROL DRAWING - 222051 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
ii June 15, 1998

M/D TOTCO
221736 Load Pin Sensor System
Installation, Calibration, and Troubleshooting
1. INTRODUCTION
This manual contains installation and operation instructions relative to the M/D TOTCO
221736 Load Pin Sensor system. Read the appropriate section of this manual before
installing or operating this equipment. Make sure that personnel operating this sensor are
familiar with the procedures in this manual.
2. SYSTEM OVERVIEW
The Top Drive Load Pin System was developed to improve the accuracy of Hookload
measurement over hydraulic dead line anchor systems and provide Torque and accelera-
tion measurements not available with dead line anchor systems. The major advantage of
the Top Drive sensor over the hydraulic dead line anchor system is the Hookload measure-
ment is down stream of friction effects in the hoisting equipment resulting in improved
accuracy of the system.
The system consists of strain gage load pins mounted in place of the Top Drive bail pins.
These pins measure static and dynamic Hookload, as well as static and dynamic Torque. In
addition, there is a vertical acceleration signal produced from accelerometers mounted
inside of each load pin.
The total Hookload and Torque is obtained by summing the channels configured for the
two load pins. Signals from the load pin are conditioned and amplified from milli-volts to
a 4-20ma signal though a signal conditioner mounted on the Top Drive. Specialized signal
conditioning is used to filter off the static portion of the load pin signal output to provide a
separate dynamic signal for Torque and Hookload. The 4-20ma signals are passed to the
rig floor through a service loop from the Top Drive to a derrick junction box on the rig
floor. Finally it passes through a barrier box before being processed by the data acquisition
system. Barrier boxes are available for use with a barrierless DAQ or for use with a UL
certified system.
Refer to Section 13 (Control Drawing 222051) for Intrinsic Safety Installation
instructions.
NOTE
Three Barrier Boxes are available: one for use with a Barrierless
DAQ and two for use with a UL DAQ.
June 15, 1998 Page 1

M/D TOTCO
Installation, Calibration, and Troubleshooting Manual 20-21
Figure 1. System Block Diagram - (with Barrierless DAQ)
Page 2 June 15, 1998

M/D TOTCO
Manual 20-21 Installation, Calibration, and Troubleshooting
Figure 2. System Block Diagram - with UL DAQ

M/D TOTCO
3. SYSTEM DESCRIPTION
The M/D TOTCO 221736 Load Pin Sensor System consists of a pair of custom bail pins, a
signal amplification/processing unit, and power/barrier box. The system was designed for
Varco model TDS-3S and TDS-4S Top Drives. The part numbers for the components are
as follows:
• Load Pins . . . . . . . . . . . . . . . . .221601
• Signal Conditioner Assy . . . . . .221535-001 (12 T.P. Service Loop)
. . . . . . . . . . . . . . . . . . . . . . . . .221535-002 (14 T.P. Service Loop)
• Barrier Box Assembly . . . . . . .221513-001 (For use w/ Barrierless DAQ)
. . . . . . . . . . . . . . . . . . . . . . . . .221789-001 (For use w/ UL DAQ)
. . . . . . . . . . . . . . . . . . . . . . . . .221995-001 (For use w/ UL DAQ)
• Power Supply . . . . . . . . . . . . . .221516-001
• Derrick Junction Box . . . . . . . .92927 (Varco P/N)
NOTE
The Derrick Junction Box (P/N 92927) is provided by Varco.
Inside each Load Pin, strain gauges and an accelerometer provide individual output signals
for Hookload, Torque, and axial acceleration to the Signal Conditioner Assembly, which
amplifies these signals and converts them to 4-20mA current loop signals. Each of the sys-
tem’s Load Pins is factory calibrated to output 4 mA at minimum load and 20 mA at full
scale load (650,000 LB Hookload, 30,000 Ft-LB Torque, & 2g acceleration). Hookload
and Torque outputs are summed to provide system load values.
NOTE
Only Hookload signal equals 4mA for zero and 20mA for full scale.
Torque has a negative to positive full range, with 4mA equal to full
negative scale, 12mA equal to zero and 20mA equal to full positive
scale.
• Example: Torque
-30,000 Ft Lbs = 4mA
0 (zero) = 12mA
+30,000 Ft Lbs = 20mA

M/D TOTCO
Features of the Load Pins are:

• Hermetically sealed, steel construction withstands shock and vibration.
• Ease of installation (attachment and calibration).
• High resistance, isolated strain gage bridge offers low power drain, rapid
warm-up time and better stability.
• NEMA Type 4 classification is suitable for outdoor use with frequent
wash-downs.
• Designed for compliance with UL, CSA, IEC, and CENELEC standards
for intrinsic safety.
• Accuracy better than 2% (including linearity, hysteresis, and repeatability).
• Torque values are obtained by measuring horizontal loading at the load pin
and multiplying by the moment arm from the center of the Top Drive to the
end of the load pin.
4. SYSTEM COMPONENT SPECIFICATIONS

The 221736 system consists of five main components: Two load pins (221601), a Signal
Conditioner Assembly (221535-001 or -002), a barrier box assembly (221513-001,
221789-001, and 221995-001), a power supply (221516-001) and a derrick junction
box (92927).
4-1 Load Pin Assemblies (P/N 221601)

The Load Pin sensors contain internal mounted strain gages used to sense static and
dynamic Hookload, as well as Torque. The strain gages are mounted in reduced sections of
the load pin and measure vertical or horizontal shear. In addition, there is a vertical accel-
eration signal produced from accelerometers mounted inside of the load pins. Hookload is
measured using a strain gauge bridge, 350-ohm nominal resistance. Each bridge is
mounted in the large cross section of the load pin. Torque is sensed by one bridge mounted
under the groove of the small end of the load pin with a 350-ohm nominal resistance.
Each Load Pin is constructed of modified 4340 (Varco MS-00004 COND A) and measures
5 inches (diameter) X 15.03 inches in (length) (See Figure 3 for basic dimensions). The
Hookload strain gage bridge outputs 6mV/V, the Torque bridge outputs 1mV/V and the
accelerometer outputs 8mV/V. Each load pin is load rated at 650,000 LB and Torque load
rated 15,000 LB (30,000 Ft-LB) (See Table 2-1 for summary of load pin specifications).

M/D TOTCO
Figure 3. Load Pin Dimensions
NOTE
Reference drawing 221600, 221601 and 221618 for load pin
specifications and basic dimensions.
Table 1. Load Pin Specifications
Category Specification
Material Construction Varco MS-00004 Condition A
(Modified 4340)
Temperature Range -40 to 150 F Operating
-40 to 180 F Storage
Calibration Error Less than 2% of Full Scale, including Hysteresis
Repeatability, and Non-Linearity
Load Capacity 650,000 LB - Hookload
15,000 LB - Torque (relates to 30,000 FT-LB)
Overload 150% of capacity without damage
280% of Capacity without failure
Bridge Excitation 3 Volts DC
Electrical Output Hookload - 6mV/V per Volt Output at FS (approx*)
Torque - 1mV/V per Volt Output at FS (approx*)
* Exact output provided with calibration data.
Temperature Effects Less than .01% of full scale output shift per ° F
Less than .01% of full scale output zero shift per ° F

M/D TOTCO
4-2 Signal Conditioner Assembly (P/N 221535-001)

Signals from each Load Pin are conditioned and amplified from milli-volts to a 4-20ma
signal though a signal conditioner enclosure mounted on the Top Drive.The signal condi-
tioner provides signals for static Hookload (4mA at no load and 20mA at full scale) and
static Torque (4mA at -30,000 FT-LB, 12mA at no load and 20mA at +30,000 LB).In
addition, the Signal Conditioner Assembly provides high-pass, filtered versions of the
Hookload and Torque signals, referred to as Dynamic Hookload and Dynamic Torque.
Mounted in the Signal Conditioner Assembly are 3 sets of PCB’s. Each set consists of two
PCB’s. If replaced, the appropriate board must be installed in it’s correct location, refer to
Figure 5.
The signal conditioner requires 16-20VDC power to operate and provide the 3VDC exci-
tation to the Load Pin strain gage bridges. The Signal Conditioner Assembly enclosure is
constructed of stainless steel and measures approximately 19.68 inches (length) X 15.98
inches (width) X 8.07 inches (depth) (See Figure 4 for basic dimensions).
Figure 4. Signal Conditioner Assembly Dimensions

M/D TOTCO
Figure 5. Location of PCB’s in Signal Conditioner Assembly

M/D TOTCO
Table 2. Signal Conditioner Assembly Specifications
Material Construction Stainless steel enclosure and external Hardware.
Temperature Range -40 to 150 F Operating
Calibration Error Linear within +0.03% to -0.01%
Temperature Effects Less than .01% of full scale output shift per degree F
Less than .01% of full scale output zero shift per degree F
Power 16-20VDC
Output Lo Input Lo Output Hi Input Hi Output

Hookload (**Static) 0.0 mV/V 4mA 6.0 mV/V 20mA
Hookload (*Dynamic) -6.0mV/V 4mA +6.0mV/V 20mA
Torque (**Static) -1.0 mV/V 4mA +1.0mV/V 20mA
Torque (*Dynamic) -1.0 mV/V 4mA +1.0mV/V 20mA
Acceleration -8.0mV/V 4mA +8.0mV/V 20mA
*Dynamic signal is AC coupled at about .2 HZ, with a band

width of 1000 HZ.
**Static signal has filter cut off of 25 HZ
Rating
Enclosure NEMA 4X, IP66
Electronics Class I Division 1/ Groups C and D
Class I Zone 0 Group IIB
(Certifications Pending) EEx ia IIB T4 UL/CENELEC

M/D TOTCO
4-3 Barrier Box Assembly (P/N 221513-001 or 221789-001 and 221995-001)

Three versions of the barrier box have been developed, one (P/N 221513-001)for use with
the barrierless DAQ and two (P/N 221789-001 and 221995-001) for use with the UL
DAQ. The barrier boxes contain certified intrinsic safety barriers which provide connec-
tions to an intrinsically safe signal conditioner (P/N 221535) located in a hazardous area.
The barrierless DAQ must be installed in a safe area, while the UL DAQ can be installed in
a Class I Div 2 environment. Refer to pages 31, 33, and 35 for internal components.
Figure 6. Barrier Box Dimensions (P/N 221513-001)
Table 3. Barrier Box Specifications
Material Zinc Sprayed and Painted Sheet Steel
Rating
Assembly Supplies I.S. circuits to devices installed
in Class I Div 1, Groups C and D hazard-
ous locations. (Barrier Assembly must be
installed in a non-hazardous location)
Page 10 June 15, 1998

M/D TOTCO
Figure 7. Barrier Box Dimensions (P/N 221789-001)
Figure 8. Signal Repeater Barrier Box Dimensions (P/N 221995-001)
June 15, 1998 Page 11

M/D TOTCO
4-4 Power Supply Assembly (P/N 221516-001)

The Power Supply Assembly supplies +24VDC required for each of the Top Drive Load
Pin System 4-20 mA channels. For specifications, refer to Table 4.
The Power Supply must be installed in a safe area environment. The Power Supply powers
the Signal Conditioner Assembly (221535) through a barrier box connection. AC power to
the Power Supply can be 90 -132 VAC or 175 - 264 VAC at 47 - 63 HZ. Range selection is
fully automatic, no manual switch over is required. Output from the power supply to the
barrier box is 24VDC. The mounting hole pattern of the enclosure is 10.94 X 6.00 (See
Figure 9 for dimensions).
NOTE
The Power Supply must be installed in a non-hazardous location.
Figure 9. Power Supply Dimensions
Page 12 June 15, 1998

M/D TOTCO
Table 4. Power Supply Specifications
Construction Enclosure - Fiberglass Polyester
Temperature Range 32 to 122 F Operating @ Full Rated Power
122 F to 158 F de-rated 50% Linearly
Power 60 Watts Output 24VDC
Input 90-132 VAC or 175-264VAC
Fully Automatic Range Selection
(47 - 63 HZ)
Rating
4-5 Derrick Junction Box (Varco P/N 92927)

The Derrick Junction Box allows the service loop wiring from the Signal Conditioner to
the System Barrier Box.
Figure 10. Derrick Junction Box Dimensions
June 15, 1998 Page 13

M/D TOTCO
Table 5. Derrick Junction Box Specifications
Material Enclosure - Stainless Steel
Rating EExe II T6
Assembly 60 terminal with I.S. Ground
5. INSTALLATION
5-1 General
This Section contains guidelines and procedures for installing the components of the
system described in the previous section (221601 Load Pins, 221535 Signal Conditioner
Assembly, 221516 power supply, 221513-001, 221789-001 and 221995-001 barrier
boxes).
5-2 Installation Guidelines and Issues
5-2-1 Intrinsic Safety Guidelines

Intrinsic safety is a technique for insuring that the amount of energy available in a circuit
is too low to ignite the most ignitable mixture of gas and air. Safety is then inherent, and
not affected by the failure of equipment. Basic wiring requirements:
1. I.S. wiring must be kept separate from non-IS wiring.
2. The I.S. ground must be kept separate from the power system ground (except
at one point).
3. The total ground connection resistance must be less than one ohm.
4. Barriers must not be defeated or bypassed. Replacement of barriers must be
with the same manufacturer and part number.
The installation instructions in the next sections will outline intrinsic safety issues
related to each component. The following are some general system issues that must be
considered.
Refer to Section 13 (Control Drawing 222051) for Intrinsic Safety Installation details.
Page 14 June 15, 1998

M/D TOTCO
5-2-2 Wiring Guidelines

To insure wiring meets the intrinsic safety requirements above and to avoid damage to
system components follow the guidelines below. Refer to Section 13 (Control Drawing
22205)1 for Intrinsic Safety Installation details.
1. Always provide an appropriate ground, per NEC or other local electrical code,
to the barrier box ground stud (Marked barrier ground).
2. Always connect the shields as shown in the Top Drive Load Pin System instal-
lation drawing P/N 221506 for the barrierless DAQ system or 221758 for the
UL DAQ system.
3. Install system components in the proper location to meet the hazardous
location defined in the system block diagram 221736 for both UL and Barrier-
less DAQ systems.
4. To prevent expensive replacement of blown barriers, always verify wiring
using a multi-meter prior to installation of the barriers (ensure there is not a
short, etc.)
5. Be sure to make power connections (+24V) through model 779 barriers and
signal connections through model 786 barriers (barrierless DAQ) or model
KFD0-CS-EX2.52 barriers (UL DAQ). Incorrect wiring will result in blown
barriers.
5-3 Installation of Load Pins

Installation of the Load Pin sensors system is performed by replacing the standard Top
Drive bail pins with the instrumented Load Pins. Additionally an electronics package and
service loop signal cable must be installed on the Top Drive. M/D TOTCO and Varco
Drilling Systems technicians must perform the service loop installation.
Each Load Pind can be installed in a Class I Division 1, Groups C and D or Zone 0 Group
IIB hazardous locations. Refer to control drawing 222051. The Load Pins require keeper
plates, which keep the pins from rotating, and insures the pins are loaded on their sensitive
axis. In addition, a bail spacer kit is used to limit bail flexure and the amount the bail shift
on the pin.
NOTE
The serial number for each Load Pin is located on stainless steel
labels riveted on the TDS Motor Frame at the base of the trunnion
tubes. The labels are approximately a foot away from their respective
pin and are easily visible. When completing the calibration
procedure, the technician must use the specific Load Pin serial
number calibration data when setting-up the DAQ chanel and it’s
specific position.
June 15, 1998 Page 15

M/D TOTCO
WARNING
Failure to install keeper plates and bail spacer kit may allow Load
Pins to rotate and cause system inaccuracies.
Bail Pin
Location
Figure 11. Location of Top Drive Bail Pins
5-4 Installation of Power Supply

The Power Supply must be installed in a safe area environment. The Power Supply powers
the Signal Conditioner Assembly (221535) through a barrier box connection. AC power to
the Power Supply can be 90 -132 VAC or 175 - 264 VAC at 47 - 63 HZ. Range selection is
fully automatic, no manual switch over is required. Output from the power supply to the
barrier box is 24VDC. The mounting hole pattern of the enclosure is 10.94 X 6.00 (See
Figure 9 for dimensions).
Page 16 June 15, 1998

M/D TOTCO
5-5 Installation of Barrier Assemblies

Three versions of the barrier box have been developed, one (P/N 221513-001)for use with
the barrierless DAQ and two (P/N 221789-001 and 221995-001) for use with the UL
DAQ. The barrier boxes contain certified intrinsic safety barriers which provide connec-
tions to an intrinsically safe signal conditioner (P/N 221535) located in a hazardous area.
The barrierless DAQ must be installed in a safe area, while the UL DAQ can be installed in
a Class I Div 2 or Zone 2 environments.
The barrier box hole mounting pattern for both versions are shown in Figure 6, Figure 7,
and Figure 8.
5-6 Installation of Signal Conditioner Assembly

The Signal Conditioner Assembly is designed to meet intrinsic safe requirements for
Class I Division 1, Groups C and D or Zone 0 Group IIB hazardous locations.The Signal
Conditioner Assembly is mounted on the Top Drive behind the guard. Mounting holes are
15.98 (W) X 13.78 (H) (See Figure 4 for complete dimensions).
6. CALIBRATION
6-1 Calibration of load pins with factory calibration information
6-1-1 Field Calibration Procedure

The sensors consist of static and dynamic Hookload and Torque signals produced from
strain gages mounted inside a load pin with reduced sections designed to measure vertical
or horizontal shear. In addition, there is a vertical acceleration signal from accelerometers
mounted inside of the load pins. The total Hookload and Torque is obtained by summing
the channels configured for the two load pins. The general steps to configure and calibrate
Hookload channels is as follows (See CALCONF manual for detailed instructions on per-
forming these operations):
1. Create algorithm for a 10 point table if file does not already exists in
CALCONF configuration options for algorithms. The 10-point algorithm is
used for Hookload channels only.
2. Create algorithm for summing Hookload and Torque channels for load pin #1
and load pin #2 with offset if required.
3. Configure channels for Hookload, acceleration, Torque, Torque sum and
Hookload sum channels.
4. Enter calibration numbers supplied by factory into ten point tables.
5. Calibrate channels using a simulator for 4-20mA signals
6. Verify channels read correctly using simulator.
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6-1-2 Creating 10 point table algorithms

The Following is a general procedure for creating an algorithm to read a 10 point table, if
the algorithm does not already exist in the algorithm list:
System 3
Through the system/DAQ configuration screen [ADD+EDIT] add ten point table algo-
rithm as follows:
Table #1 (assign algorithm to TDHL1 STAT channel)
1: X=100.000000
2: STORE X IN ALGORITHM FLAG FOR THIS CHANNEL
3: X=1.000000
4: X=VALUE OF OUT[X] FROM TABLE 1
5: X=0.000000
6: IF X==Y
7: X=INVALID
8: STORE X IN CURRENT VALUE FOR THIS CHANNEL
9: ELSE
10: X=SENSOR VALUE FOR THIS CHANNEL
11: X=SCALE FACTOR FOR THIS CHANNEL
12: X=Y*X
13: X=INTERCEPT FOR THIS CHANNEL
14: X=Y+X
15: X=VALUE FROM TABLE 1
16: PUSH X
17: X=OFFSET FOR THIS CHANNEL
18: X=Y-X
19: X=0.000000
20: IF X>Y
21: POP
23: END IF
24: X=SMOOTH(X)
25: PUSH X
26: STORE X IN FILTER VALUE FOR THIS CHANNEL
28: END IF
END OF ALGORITHM
Table #2 (assign algorithm to TDHL2 STAT channel)

1: X=100.000000
2: STORE X IN ALGORITHM FLAG FOR THIS CHANNEL
3: X=1.000000
4: X=VALUE OF OUT[X] FROM TABLE 2
5: X=0.000000
6: IF X==Y
7: X=INVALID
9: ELSE
10: X=SENSOR VALUE FOR THIS CHANNEL
11: X=SCALE FACTOR FOR THIS CHANNEL
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M/D TOTCO
12: X=Y*X
13: X=INTERCEPT FOR THIS CHANNEL
14: X=Y+X
15: X=VALUE FROM TABLE 2
16: PUSH X
18: X=Y-X
19: X=0.000000
20: IF X>Y
21: POP
23: END IF
24: X=SMOOTH(X)
25: PUSH X
28: END IF
END OF ALGORITHM
System 4
Through the system/DAQ configuration screen [ADD+EDIT] add ten point table algo-
rithm as follows (NOTE: “TDHL STAT 1” and “TDHL STAT 2” text in the algorithms
below should be substituted by the unique channel types assigned to the TDHL STAT 1
and TDHL STAT 2 channels):
TDLP 1 TABLE (assign algorithm to TDHL STAT 1 channel)
1 PRE-OFFSET VAL FOR TDHL STAT 1=LOOK UP SCALE VAL FOR TDHL STAT 1 IN
TABLE #1
2 END OF ALGORITHM
TDLP 2 TABLE (assign algorithm to TDHL STAT 2 channel)

1 PRE-OFFSET VAL FOR TDHL STAT 2=LOOK UP SCALE VAL FOR TDHL STAT 2 IN
TABLE #2
2 END OF ALGORITHM
June 15, 1998 Page 19

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6-1-3 Summing channel with load offset algorithm

The Following is a general procedure for creating a sum channel with offset load, if the
algorithm does not already exist in the algorithm list:
System 3
Through the system/DAQ configuration screen [ADD+EDIT] add summing channel algo-
rithm as follows:
LOAD PIN SUM (with offset) ---- calculate offset
1: X=4.000000 | i.e. 40 klbs
2: X=10.000000 |
3: X=Y*X |
----
4: X=CURRENT VALUE FOR TDHL STAT 1
5: X=Y+X
7: X=Y+X
8: SMOOTH(X)
9: PUSH X
END OF ALGORITHM
LOAD PIN SUM (without offset)

3: X=Y+X
4: SMOOTH(X)
5: PUSH X
END OF ALGORITHM
System 4
Through the system/DAQ configuration screen [ADD+EDIT] add summing channel algo-
rithm as follows (NOTE: “TD Hookload”,“TDHL STAT 1” and “TDHL STAT 2” text in
the algorithm below should be substituted by the unique channel types assigned to the TD
Hookload, TDHL STAT 1 and TDHL STAT 2 channels):
TD LOAD SUM
1 PRE-OFFSET VAL FOR TD Hookload=DISPLAY VAL FOR TDHL STAT 1+DISPLAY VAL
FOR TDHL STAT 2
2 END OF ALGORITHM
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6-1-4 Creating Sensor Channels.

Use the CHANNEL, SENSOR, & OTPUT:[ADD] OPTION to add channels to the system
channel list, as follows (reference CALCONF manual for detailed instructions):
TDHL1 STATIC Top Drive load pin static Hookload #1
TDHL1 DYN Top Drive load pin dynamic Hookload #1 (Optional)
TDHL2 STAT Top Drive load pin static Hookload #2
TDHL2 DYN Top Drive load pin Dynamic Hookload #2 (Optional)
TD Hookload Top Drive static hook sum of load pins #1 and #2
TD HOOK DYN Top Drive dynamic hook sum of pins #1 and #2 (Optional)
TORQ1 STAT Top Drive load pin static Torque load #1
TORQ1 DYN Top Drive load pin dynamic Torque load #1 (Optional)
TORQ2 STAT Top Drive load pin static Torque load #2
TORQ2 DYN Top Drive load pin Dynamic Torque load #2 (Optional)
TORQ LOAD S Top Drive static Torque sum of load pins #1 and #2
TORQ LOAD D Top Drive dynamic Torque sum of pins #1 and #2 (Optional)
ACCEL 1 Acceleration on load pin #1
ACCEL 2 Acceleration on load pin #2
6-1-5 Create Ten Point Table

Enter calibration numbers supplied by factory into ten point tables (see CALCONF
manual for detailed instructions). Enter data into table as follows.
Table 6. Ten Point Table #1 (Example)
Input Output
4.041 0
4.285 10
5.107 40
6.178 80
7.220 120
8.233 160
9.225 200
10.700 260
12.283 325
16.242 490
20.024 650
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6-1-6 Analog Channel Calibration

Calibrate each channel as follows (excluding summing channels):
1. Connect a current simulator to analog channel being calibrated
2. Set simulator current to 4.000 mA
3. Set VALUE MIN to 4
4. Capture Raw data counts as RAW MIN
5. Set simulator current to 20.000 mA
6. Set VALUE MAX to 20
7. Capture Raw data counts as RAW MAX
6-1-7 Verify channels Configuration

Use current simulator to vary input into each channel and compare output to that expected
from calibration points and tables.
6-2 Calibration of load pins without factory calibration information
6-2-1 Purpose
This calibration procedure is to be used only to calibrate Top Drive Load Sensors which
have not been calibrated at the factory or have lost the factory calibration. Do not
recalibrate a factory calibrated system unless you are absolutely sure the system has lost
calibration.
6-2-2 Two Point Field Calibration Procedure - One Load Pin

Use this procedure if only one load pin is operational. This procedure will calibrate one
load pin channel to display a weight value using the rig’s hydraulic Hookload weight indi-
cator as a reference.
NOTE
As with any two point calibration, the greater the load change
between the minimum and maximum load applied to the sensor, the
more accurate the calibration results will be.
1. Connect the CALCONF computer to the TOTAL DAQ and access the channel
calibration screen for the appropriate load pin channel.
2. Remove as much weight as possible from the Top Drive (drill string in slips).
Page 22 June 15, 1998

M/D TOTCO
3. Note the weight displayed on the hydraulic Hookload weight indicator.

4. Capture the current raw count minimum on the CALCONF computer.
5. Enter the value displayed on the hydraulic Hookload weight indicator into the
minimum value field on the CALCONF computer.
6. Suspend as much weight as possible on the Top Drive (drill string out of slips).
8. Capture the current raw count maximum on the CALCONF computer.
9. Enter the value displayed on the hydraulic Hookload weight indicator into the
maximum value field on the CALCONF computer.
10. The two point field calibration for one load pin is now complete.
11. Two Point Field Calibration Procedure - Two Load Pins
6-2-3 Two Point Field Calibration Procedure - Two Load Pins
Use this procedure if both load pins are operational. This procedure will calibrate each
load pin channel to display a weight value using the rig’s hydraulic Hookload weight indi-
cator as a reference. The two load pin channel values should be summed and displayed on
another channel for the best results.
NOTE
As with any two point calibration, the greater the load change
between the minimum and maximum load applied to the sensor, the
more accurate the calibration results will be.
June 15, 1998 Page 23

M/D TOTCO
Connect the CALCONF computer to the TOTAL DAQ and access the channel calibration
screen for the #1 load pin channel.
1. Remove as much weight as possible from the Top Drive (drill string in slips).
3. Capture the current raw count minimum on the CALCONF computer for the
#1 load pin.
4. Divide the value displayed on the hydraulic Hookload weight indicator by two
and enter the resulting value into the minimum value field on the CALCONF
computer for the #1 load pin.
5. Access the channel calibration screen for the #2 load pin channel.
6. Capture the current raw count minimum on the CALCONF computer for the
#2 load pin.
and enter the resulting value into the minimum value field on the CALCONF
8. Suspend as much weight as possible on the Top Drive (drill string out of slips).
10. Capture the current raw count maximum on the CALCONF computer for the
#2 load pin.
and enter the resulting value into the maximum value field on the CALCONF
12. Access the channel calibration screen for the #1 load pin channel.
13. Capture the current raw count maximum on the CALCONF computer for the
#1 load pin.
and enter the resulting value into the maximum value field on the CALCONF
15. The two point field calibration for the two load pins is now complete.
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6-3 Barrier Box Checkout Procedure

1. Verify that the correct barrier type is in each circuit both visually and by mak-
ing the following resistance measurements:
MTL779 pins1 and 2 to 24V supply: less than 1 Ohm.
MTL786 pins 1 and 2 to GND: 31 Ohms.
2. Turn on the 24V power and measure the barrier voltages listed in Table 8. The
table is organized just like the barriers are located in the 221513-001 barrier
box. Start with the right column so that the supply voltage is verified before
making the other measurements. The measurements to GND are made with the
meter negative connected to the IS ground rails. If voltages do not agree with
the voltage chart, follow the troubleshooting chart below.
WARNING
To prevent explosion- Barrier test must be run with field wiring

disconnected.
Table 7. Troubleshooting Chart
Symptom Cause Remedy

Low voltage on Supply Voltage Low Adjust Supply
DAQ side of 779’s
Low voltage on sen- PCB drawing too much current Replace PCB
sor side of 779’s
Wiring is faulty Remove short or replace wire
Bad barrier (check resistance, Replace barrier
below)
Voltage too high on DAQ not configured correctly Set rocker switches in DAQ for
DAQ side of 786’s (high resistance) current loop input.
Current from PCB is above 20mA Check load pin and current loop
connections; Replace PCB
Voltage too low on Current from PCB is less than 4 Check load pin and current loop
DAQ side of 786’s mA connections.
Bad barrier (check barrier resis- Replace barrier
tance to GND, below)
Voltage too high on Bad barrier Replace barrier
sensor side of 786’s
Current from PCB is too high Replace PCB or check with
bridge calibrator to isolate
June 15, 1998 Page 25

M/D TOTCO
Table 8. Barrier Box Voltage Table
Voltage
Barrier Voltage
Type Section (Sensor Voltage
No. (DAQ side)
side)
Left to GND Left to Right Right to GND
1 MTL779 Top 16V/20V 4V/8V 24V
Bottom 16V/20V 4V/8V 24V
2 MTL786 Top 2.4V/3.4V 2.3V/2.8V 0.12V/.62V

Bottom 2.4V/3.4V 2.3V/2.8V 0.12V/.62V
3 MTL779 Top 16V/20V 4V/8V 24V
4 MTL786 Top 2.4V/3.4V 2.3V/2.8V 0.12V/.62V
Bottom 2.4V/3.4V 2.3V/2.8V 0.12V/.62V
5 MTL779 Top 16V/20V 4V/8V 24V
6 MTL786 Top 2.4V/3.4V 2.3V/2.8V 0.12V/.62V
Bottom 2.4V/3.4V 2.3V/2.8V 0.12V/.62V
7 MTL779 Top 16V/20V 4V/8V 24V
8 MTL786 Top 2.4V/3.4V 2.3V/2.8V 0.12V/.62V
Bottom 2.4V/3.4V 2.3V/2.8V 0.12V/.62V
9 MTL779 Top 16V/20V 4V/8V 24V
10 MTL786 Top 2.4V/3.4V 2.3V/2.8V 0.12V/.62V
Bottom 2.4V/3.4V 2.3V/2.8V 0.12V/.62V
11 MTL779 Top 16V/20V 4V/8V 24V

NOTE
These are typical min/max voltages with DAQ and Load Pins
connected.
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Table 9. Barrier Resistance Measurements
Barrier Any Pin to

Pins 1 to 3 Pins 2 to 4
Type GND
MTL779 300 to 340 Ohms 300 to 340 Ohms Open Circuit
MTL786 N/A* N/A* Open Circuit
NOTE
The wires must be disconnected from both sides to make these
measurements. *This is not a useful test for the MTL786.
7. OPERATION
Each Load Pin in the system is factory calibrated to provide 4-20 mA output representing
50 percent of the Top Drive System’s full load range for Hookload and Torque
(0-650,000 LBs Hookload, ± 30,000 Ft-LBs Torque). The Hookload and Torque signals
will be summed by the data acquisition system to provide actual Top Drive loads.
8. PERIODIC INSPECTION
8-1 General
This section contains procedures for periodic inspection and field maintenance. Periodic
inspection includes preventative maintenance and service for equipment safety, security,
and cleanliness.
8-2 Periodic Inspection Procedures

The procedures below should be routinely performed to ensure the system performs
correctly:
• Periodically inspect cables for damage. Replace as necessary
NOTE
The conduit hose on the Load Pins can be replaced, but the cable
inside the conduit is integral to the Load Pin. The internal cable must
be replaced at the M/D TOTCO factory.
June 15, 1998 Page 27

M/D TOTCO
9. MAINTENANCE
Maintenance of the Load Pin Sensor System should follow the requirements of the
standard bail pin maintenance as outlined by Varco Drilling Systems.
Grease Load Pins through grease ports located on the Top Drive bail on a weekly basis.
10. RECOMMENDED SPARE PARTS LIST

Listed in Table 1 are the recommended spare parts for two years of service for the
221736 Load Pin Sensor System.
Table 10. Recommended Spares
Part Number Description Qty

221568-003 PCBA, Trq Ld, Static/Dynamic 1
221568-001 PCBA, Hook Ld, Static/Dynamic 1
221568-005 PCBA, Acclrm, Top Drv Sn 1
H10992A-786P Barrier, 786P 2
H10992A-779P Barrier, 779P 2
951540-023 Barrier, P & F 2
11. SYSTEM WIRING DRAWINGS

This Section contains system wiring drawings for both sensor systems- Barrierless DAQ
and UL DAQ.
Table 11. Wiring Diagram Drawings
Drawing # Description # Pages

221506 Wiring Diagram, Top Drive Sensor System installed with 4
Barrierless DAQ
221758 Wiring Diagram, Top Drive Sensor System installed with 4
UL DAQ
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12. ILLUSTRATED PARTS LISTINGS

In this section are illustrated parts listing for the following assemblies:
• Signal Conditioner . . . . . . . . P/N 221535-001 and -002
• Barrier Box Assembly . . . . . P/N 221513-001
• Barrier Box Assembly . . . . . P/N221789-001
• Barrier Box Assembly . . . . . P/N 221995-001
• Power Supply Assembly . . . . P/N 221516-001
June 15, 1998 Page 29

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12-1 Signal Conditioner Assembly - P/N 221535-001 and -002
Page 30 June 15, 1998

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Table 12. Signal Conditioner Parts List - P/N 221535-001 and -002
Find No Part No Description Qty
1 221534-001 ENCL MOD, SIG. COND, TDS 1
2 221536-001 CARD CAGE, SIDE WALL 2
3 221537-001 GUIDE, CARD CAGE 4
4 952111-008 GUIDE CARDT-309-51 12
5 952111-030 SPACER, CARD GUIDE, .5W 48
6 A11424A-17 TRACK, MTG, 8.5" (PERF) 2
7 221568-001 PCB ASSY, TDS LOAD PIN 2
10 971186-012 CONN, TERM BLK, 12 POS 6
11 951511-029 TERM BLK, RAIL MNT, SGL 64
12 951511-030 END PLATE, TERM BLK, SGL 2
13 221704 CARD CAGE SUPPORT, TOP 1
14 999449-010 SCREW, #2-56X.37, PNH, SL 12
15 999449-568 SCREW, #6-32x.37, PNH, XR 16
16 999291-010 WASHER, FLAT, #6, .138x.2 16
17 999321-116 WASHER, LOCK, HEL, #6 8
18 J10481A-01 HUB, CONDUIT, .50" NPT 4
21 999356-026 BOLT, M 6x10mm, HEX HD, SS 4
22 991201-013 LOCTITE #271 (THD LOCK) AR
23 221533 WIRING DIAGRAM, ELEC MD 1
24 971101-009 ADAPTER 4
25 951511-032 MARKER, TERM BLK, SGL 2
26 952111-027 SPACER, CARD GUIDE, .25 20
27 6059-00001 CABLE, #18, 4/C, GREY PVC FT 6
28 946924-009 CABLE, #18, 3PR, PVC, TWIFT 8
40 999449-620 SCREW, #8-32x.50, PNH, XR 4
41 999291-012 WASHER, FLAT, #8, .164x.3 4
42 H10711A-03 TERMINAL, FERRULE, 17-18 128
43 999524-002 RUBBER, .50THK w/ ADHESIVE 20
44 955706-017 CONN, CORD, 1.42-1.78 1
45 963700-004 NUT, LOCK, CND, 2.00" NPS 1
50 948500-001 END BRACKET, TERMINAL 4
51 221748 TEST PROCEDURE, ELEC MO
52 221799-001 MOUNTING PLATE, SIG COND 1
53 999216-027 WASHER, FLAT 4
June 15, 1998 Page 31

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12-2 Barrier Box Assemblies
12-2-1 Barrier Box - P/N 221513-001
Page 32 June 15, 1998

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Table 13. Barrier Box Parts List - P/N 221513-001
Find No. Part No. Description Qty

2 221512-001 BARRIER BOX MOD, TDS 1
4 H10992A-786P BARRIER, I.S 28V DIODE 5
5 H10992A-779P BARRIER, I.S., 28V/28V 6
9 955706-004 CONN, CORD, .25-.38, 1/2" 1
10 955706-008 CONN, CORD, 1.00-1.13"1 2
13 948513-001 TERMNL BLK, RAIL MNT 4
16 948512-001 PARTITION, TERMINAL, 2.5 2
17 948511-001 JUMPER, TERMINAL, 2.5mm 2
19 J857-2 NUT, LOCK, CND, 0.50"NPS 1
20 B1833-1 SLRING, CND, .38"/.50 1
21 J857-4 NUT, LOCK, CND, 1.00"NPS 2
22 B1833-3 SLRING, CND, 1.0"NPT 2
23 B10516A NAME PLATE, ID, POLY 1
24 A11442A-05 RAIL, RTH, 3mm X10mm 1
25 948517-001 CLAMP, RTH RAIL MTG 2
28 946613-075 WIRE IPVC 18 AWG RED FT 3
29 948517-002 CLAMP, RTH TERM, 3mmx1 13
30 950801-028 TERMINAL, RING .38x#1 1
31 946634-003 WIRE HYPOLON 12 AWG GRE FT 1
33 221607-001 BARRIER BOX LABEL, TDS 1
35 221514 FIELD WIRING DIAGRAM 1
June 15, 1998 Page 33

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12-2-2 Barrier Box - P/N 221789-001
Page 34 June 15, 1998

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1 221994-001 BARRIER BOX, POWER 1
2 955706-004 CONN, CORD, .25-.38, 1/2" 1
3 955706-009 CONN, CORD, .50-.63, 3/4" 1
6 963700-001 NUT, LOCK, CND, 0.50" NPS 1
7 2530-00016 SLRING, CND, .50" NPT 1
8 963700-002 NUT, LOCK, CND, 0.75" NPS 1
9 2530-00009 SLRING, CND, .75" NPT 2
11 946613-075 WIRE IPVC 18 AWG RED FT 3
12 950801-028 TERMINAL, RING.38x#1 1
13 946634-003 WIRE HYPOLON 12 AWG GRE FT 1
16 H10992A-779P BARRIER, I.S., 28V/28V 6
June 15, 1998 Page 35

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12-2-3 Barrier Box - P/N 221995-001
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1 222001-001 BARRIER BOX, SIGNAL REP 1
2 A11424A-02 TRACK, MTG, 7.88"(PERF) 1
3 999449-170 SCREW, #10-32x.50, PNH 2
4 G180A-02743 WASHER, FLAT, #10 2
5 2802-10000 WASHER, SPLITC, #10, SS 2
6 951540-023 BARRIER, TIB, LOOP PWRD 5
8 955706-006 CONN, CORD, .88-1.0, 1.0" 2
9 963700-003 NUT, LOCK, CND, 1.00"NPS 2
10 2530-00017 SL RING, CND, 1.0"NPT 2
11 2800-49080 SCREW, M 6x12mm, SCH, SST 4
13 221607-004 BARRIER BOX LABEL TDS 1
14 221984-001 LABEL SET BARRIER BOX 1
15 222002-001 PANEL, FAB, SIGNAL REP 1
16 999268-011 WASHER, LOCK, SPLIT, .250 4
17 999291-015 WASHER, FLAT, 1/4, .25x.4 4
18 950801-028 TERMINAL, RING.38x #1 3
20 991201-024 SLANT, RTV167, NON-CO. .1
21 999449-568 SCREW, #6-32x.37, PNH, XR 4
22 999291-010 WASHER, FLAT, #6, .138x.2 4
23 999397-040 NUT, #6-32X.114, MACH, HE 4
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12-3 Power Supply Assembly - P/N 221516-001
Page 38 June 15, 1998

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Table 16. Power Supply Parts List - P/N 221516-001

1 221517-001 POWER SUPPLY ENCL, TDS 1
2 943413-021 PWR SPLY, SGL OUTPUT, 24 1
3 935676-006 PROT, AC, I-201, 240V, 1AM 1
4 221472 FUSE HOLDER, MODIFIED 1
5 947601-009 CLAMP, CBL, NYL, .625x.50 2
6 999449-568 SCREW, #6-32x.37, PNH, XR 6
7 999291-010 WASHER, FLAT, #6, .138x.2 6
8 951508-003 TERM.BLK, 3CKT/DBL 1
9 999449-576 SCREW, #6-32x.62, PNH, XR 8
10 221518-001 PLATE, BASE, POWER SUPPLY 1
11 955704-001 CONN, CORD, .25-.40, 1/2" 2
12 2530-00003 S, LRING, CND, .50" NPT 2
13 963700-001 NUT, LOCK, CND, 0.50" NPS 2
15 221264-003 GROUND LUG, BASE TO AC 4
16 946613-082 WIRE IPVC 18 AWG WHITE FT 1
17 946613-073 WIRE IPVC 18 AWG BLACK FT 1
18 946613-075 WIRE IPVC 18 AWG RED FT .25
19 950827-002 TERMINAL, SPADE #6 X #2 6
20 221520-001 A/C POWER CABLE, PWR SUPY 1
25 991715-007 GR, SE, THERMAL, 0.699 Wm. .1
26 938201-032 FUSE 4A, SLO-BLO 1
27 X10092A-008 LOCTITE #242 (.02oz). .1
28 999449-572 SCREW, #6-32x.50, PNH, XR 2
29 951508-004 TERM. BLK, 4CKT/DBL 1
30 235272 GROUND LUG ASSY, CASE
31 H10248A-000512 WIRE, 12AWG GREEN FT. .5
32 950801-025 TERMINAL, RING #10 X #1 1
33 950801-023 TERMINAL, RING #6 X #1 1
June 15, 1998 Page 39

M/D TOTCO
13. INSTALLATION CONTROL DRAWING - 222051

Refer to control drawing 222051 for intrinisci safety installation instructions.
Page 40 June 15, 1998

M/D TOTCO

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Part Number 20-21

INSTALLATION, CALIBRATION, AND OPERATION

Load Pin Sensor System

Manufacturers of Precision Instruments

Printed in U.S.A. June 15, 1998

Cover. . . . . . . . . . . . . . . . . . . . . . . . . . . . . June 1998

June 15, 1998 iii

Martin-Decker TOTCO (“Company”) warrants to Buyer (“Purchaser”) of new products manufactured or

The warranty periods for various products are:

IN NO EVENT SHALL COMPANY BE LIABLE FOR DIRECT, INDIRECT, INCIDENTAL OR

iv June 15, 1998

June 15, 1998 i

12. ILLUSTRATED PARTS LISTINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

ii June 15, 1998

June 15, 1998 Page 1

Figure 1. System Block Diagram - (with Barrierless DAQ)

Page 2 June 15, 1998

Figure 2. System Block Diagram - with UL DAQ

June 15, 1998 Page 3

Page 4 June 15, 1998

Features of the Load Pins are:

4. SYSTEM COMPONENT SPECIFICATIONS

4-1 Load Pin Assemblies (P/N 221601)

June 15, 1998 Page 5

Figure 3. Load Pin Dimensions

Table 1. Load Pin Specifications

Page 6 June 15, 1998

4-2 Signal Conditioner Assembly (P/N 221535-001)

Figure 4. Signal Conditioner Assembly Dimensions

June 15, 1998 Page 7

Figure 5. Location of PCB’s in Signal Conditioner Assembly

Page 8 June 15, 1998

Table 2. Signal Conditioner Assembly Specifications

Output Lo Input Lo Output Hi Input Hi Output

Hookload (*Dynamic) -6.0mV/V 4mA +6.0mV/V 20mA

Torque (**Static) -1.0 mV/V 4mA +1.0mV/V 20mA

Torque (*Dynamic) -1.0 mV/V 4mA +1.0mV/V 20mA

Acceleration -8.0mV/V 4mA +8.0mV/V 20mA

*Dynamic signal is AC coupled at about .2 HZ, with a band

June 15, 1998 Page 9

4-3 Barrier Box Assembly (P/N 221513-001 or 221789-001 and 221995-001)

Figure 6. Barrier Box Dimensions (P/N 221513-001)

Table 3. Barrier Box Specifications

Page 10 June 15, 1998

Figure 7. Barrier Box Dimensions (P/N 221789-001)

Figure 8. Signal Repeater Barrier Box Dimensions (P/N 221995-001)

June 15, 1998 Page 11

4-4 Power Supply Assembly (P/N 221516-001)

Figure 9. Power Supply Dimensions

Page 12 June 15, 1998

Table 4. Power Supply Specifications

4-5 Derrick Junction Box (Varco P/N 92927)

Figure 10. Derrick Junction Box Dimensions

June 15, 1998 Page 13

Table 5. Derrick Junction Box Specifications

5-2 Installation Guidelines and Issues

5-2-1 Intrinsic Safety Guidelines

Page 14 June 15, 1998