GV500 Series Winch Manual.pdf

Geovista GV500 Series Winch Models 510, 530, 550 and 570 Operations Manual

(Model shown – GV510)

OPERATIONS MANUAL ..........................................................................................1 Included Documents & Drawings ..............................................................................2 Version Control ..........................................................................................................3 GV500 Series Winch Main features...........................................................................4 Drive Train .................................................................................................................4 Motor & Gearbox Orientation………………………………………………….….. Cable spooling device.................................................................................................5 Measure head with integral cable tension measuring device and depth encoder. ......6 Shaft Encoder .............................................................................................................8 Motor speed control & overtension cut-out................................................................8 Tips On Using The Over Tension Cut Out...............................................................10 GV500 Speed Controller Circuit Description. .........................................................11 Circuit "Safety Interlock"……………………………………………………..…………. Winch Variac Circuit……………………………………………………….………… Regenerative Drive ...................................................................................................11 Winch Torque Display & Limit................................................................................12 Opening The Speed Controller…………………………………………………………….. Installation ................................................................................................................13 Remote Control.........................................................................................................14 Slip Ring and Cable Clamp Assembly ......................................................................... Clutch Mechanism…………………………………………………………………………………. Included Documents & Drawings GV510Mechanical “GV510 General Assembly” Mechanical “GV510 Drum Assembly” Mechanical “GV510 GV530 Levelwind Assembly” GV530Mechanical “GV530 General Assembly” Mechanical “GV530 Drum Assembly” Mechanical “GV510 GV530 Levelwind Assembly” GV550Mechanical “GV550 General Assembly” Mechanical “GV550 Drum Assembly” Mechanical “GV550 Levelwind Assembly” Mechanical “GV550 Base” GV570Mechanical “GV570 General Assembly” Mechanical “GV570 Drum Assembly” Mechanical “GV570 Levelwind Assembly” Mechanical “GV570 Base“

GeoVista GV500 Winch Operations Manual Page 2 Of 17

Applicable to all modelsSchematic “GV500 Hand Held Remote” Schematic “GV500 Signal Connections” Schematic “GV500 Winch Torque Display & Limit” Schematic “GV500 Safety Interlock” Schematic “GV500 Winch Variac Wiring” Schematic “GV500 Speed Control Box GA” Mechanical “Measure Wheel Assembly” Version Control Release To Version 1.0 - 10 October 1999 June 2000 version 1.1: added the torque control override switch 2008 version 2: drawing update and KB speed controller 2009 version 3: new drawings 2010 version 4: combined manual

GeoVista GV500 Winch Operations Manual Page 3 Of 17

Purpose of this Manual. This manual is designed to allow the user to get the best out of their GeoVista winch and to operate efficiently and safely. Maintenance points are highlighted, where appropriate.

Safety Careless Operation Of This Piece Of Equipment Can Result In Personal Injury And Equipment Damage. Ensure That You Are Trained In The Operation. If In Doubt, Stop Activities. If In Doubt, Get Assistance From Competent Personnel. Observe Local Operating Procedures That Are In Place. Particular safety points will be highlighted throughout this manual. Please do take note.

Reliability Please note the section regarding winch installation. If these recommendations are not followed then the manufacturers warranty may be void. GV500 Series Winch main features The GV500 series winch comprises these main parts: Drive train-motor & gearbox. Cable spooling device. Levelwind clutch mechanism Measure head with integral cable tension measuring device and depth encoder. Slip-ring connection to the logging cable. Motor speed control & overtension cut-out. Signal wiring These will be discussed individually in the following sections. Drive Train This comprises a DC motor and 80:1 reduction bevel drive gear box. (Safety Note: the motor is DC but requires a 240 VAC supply for correct operation. Do not attempt to supply the winch with a DC supply. The speed controller generates the DC voltage required.) The gearbox is directly mounted onto the shaft of the cable drum; using no intermediate gears, drive belts or chains. This gives a steadier drive and increased reliability. The bevel drive is non-reversible, so that no other braking device in the winch is required. The cable tension will not turn the drive train when the motor is stopped.

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The bevel gearbox is oil filled for life and should require no attention in the field. The motor has brushes that bear on the commentator. The motor manufacturer recommends that the brushes be changed after 3,000 hours operation at 75% of rated load. In this application the load is usually much less than 75%, but the operator can use these figures to make an estimate of when to fit new brushes. One of the brushes is easily accessed while the other brush requires removing the motor from the gearbox flange. This requires the removal of the 4 bolts. It is recommended that the condition of the easily accessed brush be inspected. An option available is the installation of a clutch device. This allows the user to disengage the coupling between the cable drum shaft and the gearbox drive shaft. To activate the clutch, locate the steel knob on the outside of the gearbox. Pull this out approximately 10mm and insert the supplied spacer to hold the knob in this position. Note that now the drum is free to rotate and no braking is available. To re-establish the drive, first ensure that the drum is not turning. Now remove the spacer and allow the steel knob to engage. Rotate the drum until the clutch pins are heard to engage and the steel knob is fully home. Safety Note: Never disengage the clutch when there is tension on the cable. The drum will rotate rapidly and represent a safety hazard. Re-engaging the clutch under these circumstances could cause damage to the winch. Motor & Gearbox Orientation (GV510/530 models only) One of the attractive features of the GV510 and GV530 models is that the motor can be placed into one of two different positions, depending on the space available in the vehicle where it is mounted. Also, the motor is mounted high & externally to the main winch body. This allows the winch to be pushed over the wheel arch of the vehicle, permitting better use of the space available. To move the position of the motor requires these steps to be followed: 1. Locate the 4 screws retaining the motor to the motor foot plate and remove them. The motor weight can safely be supported on the gearbox as long as no extra weight or shock is applied when in this position. 2. Locate the 8 screws holding the flange onto the winch side plate and remove them. 3. Rotate the motor out of the way so that the base plate can be removed from the side of the winch. Locate this base plate into the required position and replace the screws. 4. Rotate the motor to the required location and replace the screws in the flange and the base plate. Cable Spooling device. It is important that the cable be spooled neatly to avoid damaging the cable. If the cable crosses itself, then the tension can cause internal damage to the cable. The GV500 winch GeoVista GV500 Winch Operations Manual Page 5 Of 17

has a lead screw arrangement that is driven from the main cable drum shaft via a chain. The spooling device is mounted on a carriage that traverses backwards and forwards with the cable movement. If the cable becomes out of synchronisation with the spooling device, then this is corrected by use of the special tool supplied with the winch. This is a -‘T-handled’ tool.

Inserting the cable spooling adjustment tool To apply the tool, first stop the winch drive. Firmly push the tool into the hole on the end of the spooling device, pressing to engage the tool with the castellated section and simultaneously disengage the drive. Then the tool can be turned to rotate the lead screw independently of the cable drum. When alignment is reached remove the tool. As the drum is then turned the drive will re-engage with a click and spooling should continue correctly. Note that it is possible to set the lead screw such that the spooling head moves in the wrong direction. The consequence of this is that as the cable leaves the drum from, for example, left to right, the head will move from right to left. To correct this situation, continue rotating the lead screw tool until the spooling head reaches the end of the travel and returns in the reverse direction. Now align the cable exit point and the measure head. Rotate the cable drum to ensure that the direction of travel is now correct. Caution: If the winch is operated with the direction of travel incorrect, then damage to both the cable and the winch can occur. GeoVista GV500 Winch Operations Manual Page 6 Of 17

Keep the lead screw and guide bars clean and lightly greased. Make sure that the measure wheel is free of dirt. Clean the grooves in the wheels regularly or incorrect depth measurements will occur. N.B. Never let the drum unwind fully. The base layer of cable should remain on the drum as the friction helps the security of the cable to the drum. If it is necessary to reach greater depths, at least half of the base layer of cable must remain on the drum. Levelwind Clutch Mechanism A mechanical torque-limiting mechanism is fitted between the motor and the levelwind sprocket. It can be accessed from the outside of one of the winch side plates. It can be seen as the black cylinder in the photograph below.

GV500 Levelwind Clutch Mechanism Measure head with integral cable tension measuring device and depth encoder. The sonde depth is measured by passing the cable over a measure wheel coupled to shaft encoder. Two jockey wheels are used so that the measure wheel does not slip as the cable moves. If it is required to remove the cable from the measure head, then these two jockey wheels must be moved. Safety Note: Do not attempt to remove the measure head jockey wheels when the cable is in the hole or the mains power is attached to the winch. Always disconnect the mains power before working on the winch. To remove the jockey wheels, remove the circlips on the shaft (one on each shaft) and slide out the shaft. Note that there are two spacers with each wheel, which must be replaced after the operation. The cable tension measuring device is a load beam mounted below the measure wheel bearing. A pin is located below the measure wheel bearing and bears down onto the load cell to transmit the load as required. Ensure that this is free to move and is not stuck with GeoVista GV500 Winch Operations Manual Page 7 Of 17

grit or mud. There are no user serviceable parts inside the load cell and it should not be dismantled. The measure wheel should be free to rock side to side on its bearing. Only a small amount of movement is required, but there must be some or else there will be a preload on the loadcell, which may damage it. The shaft encoder is mounted on the measure wheel spindle underneath a black cover. There are three retaining screws around the periphery of this cover. Remove these to gain access. There is a fourth special screw on the top of the cover, which is a torque reaction screw that prevents the shaft encoder from rotating. This engages with a tang on the side of the shaft encoder and must be correctly seated or depth errors will occur. The only maintenance required is washing down to prevent the build up of mud on the moving parts. All the bearings are sealed and greased for life. Ensure that the jockey wheel spindles are free to move. After washing down, allow the parts to dry in free air before storage. Application of a water repellent spray (e.g. WD-40) is a good idea to keep everything working well. Shaft Encoder The shaft encoder normally installed is the Lika Electronics CK46-H-1000-B-C-U-4-6-PL4/S644. The important characteristics of this encoder are: Series Output driver Pulses per revolution Power supply Shaft diameter Measure Wheel Circumference

CK46 PP/LD universal circuit 1,000 5-30VDC 6mm 0.4m

The colour code for the wires is: Yellow Green Red Black

Phase A Phase B Positive supply Ground supply

This range of encoder offers a wide range of pulses per revolution. Special encoders can be supplied on request. Motor speed control & overtension cut-out. There are two control boxes related to the winch; the speed controller and the safety switch unit. The safety switch is a red “mushroom” type which, when pressed, will disconnect all power to the winch motor and electronics. It is mounted in a prominent position so that it can be GeoVista GV500 Winch Operations Manual Page 8 Of 17

operated quickly in the event of an emergency. In normal operation, the cap needs to be rotated until it pops up. At this point, mains power is applied to the speed controller. Also mounted on the safety switch unit is a pair of fuses. These are 20mm types rated at 10 Amperes 250VAC. Both the “Live” and “Neutral” are fused. The schematic for this unit is attached to this manual. The GV510 and GV530 are available with either a variac or a KB electronic controller. Both control boxes are operated in a similar way. They can be identified by their outward appearance, if servicing or spare parts are required. GV550 and GV570 winches are supplied only with a KB-type controller.

Variac-type Winch Control

KB Electronic-type Winch Control The speed controller has a large top mounted rotary control for motor control and a motor direction switch. To apply power to the motor, assuming that 240VAC is applied and the safety switch is in the up position, requires two actions. Firstly select up or down direction as appropriate with the toggle switch. At this point no power will be applied to the motor, independent of the position of the speed knob. The user must then rotate the knob fully counter clockwise, to the minimum position. At this point the interlock will be energised and rotating the knob in a clockwise direction will apply an increasing voltage to the motor.

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A bargraph display with a small knob for the tension control is mounted on the sloping panel of the winch speed controller. The motor current is monitored and displayed on the bargraph during logging. The motor current is proportional to the motor torque and is a good indication of cable tension. The lower 7 segments are green coloured and the top 3 are red. As the tension increases then more segments will light up. When all 3 red segments are lit up, then any increase in motor current will cause the power to the motor to be interrupted and the motor will stop turning. The braking effect of the bevel gearbox will prevent the cable from being pulled downhole. At this point, if the over tension condition is released then no power will be applied to the motor. The user must rotate the speed control knob back to the minimum position then rotate clockwise again to apply power. This safety feature prevents unexpected motion, which may injure personnel. Similarly when the safety switch is lifted, no power will be applied to the motor until the speed controller is returned to the minimum position. Tips On Using The Over Tension Cut Out Note that the Over Tension Cut Out only operates in the UP Hole direction, on the KB Electronic-type winch control. The purpose of this is to prevent excessive pull on the cable, ensuring equipment damage does not occur. The knob labelled “Set Torque” is a sensitivity control for the bargraph display. Rotating the clockwise decreases the sensitivity and will, with a constant motor load, reduce the number of bargraph segments that are illuminated. For best operation, follow these simple procedures: 1 2

3

4

When at the bottom of the hole about to start pulling up, turn the “Set Torque” control fully clockwise and turn the “Speed” knob clockwise until the correct logging speed is reached. When the speed has stabilised as required, observe the bar-graph display. There should be a few green segments illuminated. Now rotate anticlockwise the “Set Torque” control and more segments will be illuminated. Continue anticlockwise rotation until the first red segment becomes illuminated. Now rotate clockwise a small amount until the first red segment goes out and just 7 green segments are illuminated. Leave the “Set Torque” control in this position. In the event that the cable pull increases, the red segments will illuminate. If the overpull is sufficient, then all 3 red segments will illuminate and the cut-out will activate. The winch will stop pulling and motor current will be removed. The winch is in a safe condition. To reactivate the winch, the “Speed” control must be reduced to minimum then rotated clockwise again to apply power to the motor. While logging up, under normal conditions, the number of green segments illuminated will decrease as the weight of the cable is spooled in. Occasionally rotate the “Set Torque” control anticlockwise until all 7 green segments are illuminated to maintain protection against unexpected overpulls.

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GV500 Speed Controller - Circuit Description. Refer to the attached circuits. Circuit “GV500 Safety Interlock”. This is the unit that gives the user the emergency stop switch and is an important safety feature. By rotating the red knob in the direction indicated by the arrows, the knob will pop up and close its contacts. This will allow power to be applied to the speed controller. There are two fuses installed, each having a 10 amperes rating. In the event that either of these “blows”, then investigate the reason before simply putting a new fuse in. Under normal operation, these should not blow. Always use a fuse of similar rating. If this box is disassembled for any reason, then do ensure that the “Earth” connections are remade correctly. Safety Note: If the winch is not properly earthed then a potentially lethal safety hazard exists. Winch Variac Circuit (only available on GV510/530) This is the speed controller section and interlock mechanism. 240VAC supply is applied to the input “terminal J1” connector. The mains current is supplied from the “GV510 safety Interlock” unit as described above. Never connect mains directly to the input of the variac circuit as no fuse protection or emergency switch will be available. Mounted on the variac control is a microswitch labelled SW1 on the diagram. When the variac is at the minimum position, this microswitch will close. In this position, Relay 1 coil connection #0 will be connected to the Line input via switch SW2, the “Up Stop Down” switch, if SW2 is in any position other than “Off”. Assuming that terminals A and N on the board GV5_2 (See next section) are shorted, Relay 1 will then operate, shorting out the microswitch with the contact pair #4 and #2 on the Relay 1. This will latch Relay 1 as long as terminals A and N on the board GV5_2 are shorted. With Relay 1 operated, the Line voltage will be applied to the variac terminal K. Rotating the variac clockwise will increase the voltage on variac terminal T. This voltage is applied to the bridge rectifier BR1. The direction of rotation of the motor is dependant on the polarity of the voltage applied. This is controlled by Relay 2. Activating the coil will reverse the polarity applied to the motor. The position of the relay is controlled directly by the “Up Down Off” switch. Increasing the Variac output voltage will increase the voltage applied to the motor, resulting in speed control as required. The current drawn by the motor is measured by the current transformer mounted on the underside of PCB GV5_2. The wire from the variac passes through the centre of the current transformer to form the primary. The resulting voltage is developed across a resistor on the GV5_2 board and amplified to drive the bar-graph display. GeoVista GV500 Winch Operations Manual Page 11 Of 17

Regenerative Drive (KB models only) The GV500 Winch uses a full-wave regenerative control from Penta KB Power, part number KBRG-240D. The control unit provides excellent control and will provide reverse torque to maintain the set speed when the applied load is in the same direction as the motor rotation. If this box is disassembled for any reason, then do ensure that the “Earth” connections are remade correctly. Safety Note: If the winch is not properly earthed then a potentially lethal safety hazard exists. Winch Torque Display & Limit This is the board mounted inside the speed controller box and provides the bargraph display and the overtension cut-out function. Models with Variac controlTransformer T1 takes the mains input and generates a stabilised +/-6VDC via regulators U3 & U4. The current transformer T2 input signal is shown, with the signal being taken off the Yellow & Purple wires. This will be a 50/60Hz sine wave signal and it is rectified amplified by amplifier U5B. Amplifier U5C, with diodes D2-D4, forms a peak detect circuit. This peak value is then held on capacitor C1, which has a drain current via R1. This gives the circuit a low frequency response, suitable for the application in hand. The reference Rhi (pin 6 of U1) is generated from the potentiometer VR1, labelled “Set Torque” on the front panel, giving the sensitivity control. The measure signal is applied to SIG (U1 pin 5). The signal on Rhi is the full-scale sensitivity of the bar-graph driver U1 and the level control signal is on SIG. The number of bars illuminated on the bar graph is a function of the percentage of Rhi that SIG achieves. The bar #10 is dealt with differently. In the event that the bar-graph driver tries to illuminate this bar, then the low voltage that appears on LED10 (U1 pin 10) will cause the comparator U6 to detect this and operate the relay Rly1. This will disconnect the terminal A from the N (neutral) line and cause Relay1 on the main chassis to drop out and power to be removed from the winch. In the event that there are problems with this circuit, it can be easily disabled by shorting terminals A and N on the terminal block. In this way, the winch can be used but without and overload protection. Models with KB winch controlThe winch motor current is sampled using a 0.1R 50W. This is then rectified and smoothed to give a DC level ‘signal’. This DC signal is then applied to the input of the bargraph generator U5 pin SIG. This signal is compared with the reference applied to U5 on pin Rhi. GeoVista GV500 Winch Operations Manual Page 12 Of 17

The fraction of Rhi that the signal on SIG represents is reflected in the number of bargraph U6 segments illuminated. The reference Rhi is generated from the potentiometer VR1, “Set Torque” on the front panel, giving the sensitivity control. When the top Red LED segment is turn ON the output of the board will be switched off stopping any rotation of the winch. Note that the winch Torque limit only works in the up hole direction. Opening The Speed Controller (Variac model). The speed controller is usually supplied wired to the winch with suitable cable lengths. If it is required to lengthen or shorten the cables supplied, the correct method is to change the cable length. Splices are not acceptable and will eventually lead to problems and always represent a safety hazard. To change the wires requires opening the speed controller box. Safety note: Ensure that no power is applied to the speed controller and that power is not inadvertently applied while working on the unit. First, remove the knob on the motor speed control. This requires loosening the screws (2 of) located in the periphery of the knob. The knob can then be pulled off. Loosen the 4 screws, one in each corner, of the front panel. The top can then be lifted off. There are sufficient wire lengths on the other front panel controls to allow the top to be removed and put to one side while working inside the box. Observe the main components, as identified by the drawing GA_1 attached to this manual. Usually, the terminals of interest will be those to the mains power input and the motor, J1 and J2 respectively. Both these are accessible after the PCB is removed. This is achieved by removing the 6 M3 screws, 3 along each edge of the PCB. Again, the wires are sufficiently to allow putting this board to one side while working inside. Both J1 and J2 have screw fastenings, so changing the wire is quite easy. Always use similar wire to that supplied. Lengths are available from GeoVista if required. Reassembly is the reverse of disassembly. Note that there is a bush around the shaft of the variac. This is for lateral support for the variac. It is permissible, on assembly, to slacken the screws retaining this bush and retighten when the top panel is firmly fastened. This allows for minor misalignment to be taken out of the system. Installation Successful installation into a vehicle varies depending on the vehicle used. Some pointers to a successful installation are as follows; The use of a mounting frame is required and a drawing of a suitable mounting frame is attached to this manual. Usually this mounting frame-plate is manufactured locally, with GeoVista GV500 Winch Operations Manual Page 13 Of 17

modifications to suit the vehicle platform. The bodies of vehicles are usually a stressed member and will flex when driven over uneven surfaces. Without this mounting frame the structural alignment of the winch can be distorted and damage can occur when the winch is operated. Ensure that you are not overloading the vehicle chosen. Refer to the manufacturer’s information. For models GV510/530 – The externally mounted motor allows the winch to be pushed to one side of the vehicle, as the motor can be situated over the wheel arch of the vehicle, thus giving better use of the space available. Try to keep the main weight (which is the cable) over the axle or inside the wheel base of the vehicle. Avoid lifting the winch too high, as this will have a negative impact on the stability of the vehicle when drive. Refer to the wiring diagram attached. Perform a neat and well thought out positioning of the cables. Do not splice cables, as this is unreliable and dangerous. Do not place cables where they are prone to damage. Use conduit as much as possible. Remote Control With one-man operation, it is often convenient to be able to turn the winch when getting the sondes in and out of the hole. A connector on the side of the speed controller box is provided for connection to a pendant. This is a handheld switch box with an “UP” and “DOWN” switch. Operation is as follows. 1 First, put the UP\DOWN switch on the speed controller on to the OFF position (centre). 2 Connect the pendant to the connector provided. 3 Rotate the speed controller a small way of the stop position. 4 Pressing either of the two buttons on the pendant will now provide up or down motion as required. Models with Variac controlNote that the motor current trip is not active in this mode of operation. The bargraph will operate, but will not cause the motor to trip out under these conditions. In this mode of operation, there is no “soft start” of the motor so only a small clockwise rotation of the variac should be selected. Experimentation will give a reasonable position of the control know to use when in this mode of operation. Models with KB winch controlOptional wireless remote control is available for these models. The current trip is active with this controller.

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Slip Ring Assembly The Slip Ring Assembly is designed so that it can be removed from the winch through the side wall even when the drum is full of cable (provided the drum is adequately supported) When fitting the cable into the cable clamp it is therefore useful to leave enough cable free in the drum so that the slip ring assembly can be removed. Once the cable is secured in the cable clamp and the end prepared for the slip ring connections the drum can be re-assembled. Self Amalgamating Tape can be used around the slip ring contacts to protect them from moisture.

Slip ring The complete slip ring assembly is shown below.

Complete slip ring assembly.

Once the Logging cable is connected to the slip ring it can be re-fitted into the drum.

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Feed the cable leads through the bearing opening.

Identify the correct terminals on the slip-ring

Connect the slip ring to the cable connectors

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Install the slip-ring housing to the winch

Install the covers To complete the assembly of the winch, reverse the disassembly as described above.

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1

2

3

4

Rear View Into Pendant

RS 340-673 A

A

Brown

Black

Cable Entry

Cable RS 363-402 Flexible CY 0.75mm 4 Core 5m Long

SW3A Bank1 LHS 2L

4L

Bank1 RHS 1L

2R

1R

3L

4R

3R

1

2

Green/Yellow

B

TH4

Connect Shield at This End

4 1

Shield Not Connected This End

3

Blue Green/yellow Black Brown

4

B

A B C D E

3

PL1 LMH 06F 14 05 PN

Blue

2

C

C

GeoVista Unit 6, Cae Ffwt Business Park Glan Conwy, Conwy, LL28 5SP Tel +44 (0)1492 573399 Fax +44 (0)1492 581177 D

Title: PCB Ident:

Hand Held Remote

D

Filename Project

1

2

3

4

Issue

1

2

3

4

Cannon Connector Pin Assignments A

PL1

B C L P N

B C D

A P

R

V

Strain gauge cable screen Strain Gauge -ve Signal IP (Green) Strain Gauge +ve Supply (Red) Strain Gauge +Ve Signal Ip (White) Strain Gauge -ve Supply (Blue)

L U

K

R U V D

Depth Encoder 0VDC Supply (Black) Depth Encoder Phase A (Brown) Depth Encoder Phase B (Blue) Depth Encoder Cable Screen

Depth Encoder with 8 Core Cable K Shaft Encoder +v Power Supply (Red)

Depth Encoder with Artic Braid K Shaft Encoder +v Power Supply (Red)

R Depth Encoder 0VDC Supply (Black) U Depth Encoder Phase A (Yellow) V Depth Encoder Phase B (Green) D Depth Encoder Cable Screen

R Depth Encoder 0VDC Supply (Black) U Depth Encoder Phase A (Pink) V Depth Encoder Phase B (Blue)

Red * Red

F Fish Reference Electrode (Yellow plug)

E

S

J

T G

Blue * Black Green White * Blue * Pink

S Not Used T Not Used E Not Used

B

F

A

Strain Gauge with Artic Braid C Strain Gauge -ve Signal IP (Blue) L Strain Gauge +ve Supply (Red) P Strain Gauge +Ve Signal Ip (Pink) N Strain Gauge -ve Supply (Black)

Depth Encoder with 4 Core Cable K Shaft Encoder +v Power Supply (Red)

M N

Strain Gauge Wiring

M Logging Cable Armour (Camera Power Supply and GeoVista current return)

CANNON 19 MALE

H

B Strain Guage Resistance Check

A Logging Cable # 1 (Red 4 core screened cable)

L to P 270 Ohm Red to White N to C 270 Ohm Blue to Green L to N 365 Ohm Red to Blue P to C 365 Ohm White to Green

These connections for 4 core cable winches only

Cannon 19 Male Solder View

G Logging Cable # 2 (Blue 4 core screened cable) H Logging Cable # 3 (White 4 core screened cable) J Logging Cable # 4 (Green 4 core screened cable)

* When Low Temperature Artic wire is used

These connections for 4 core cable Head only

1

1 Logging Cable # 1 (Red 4 core Logging cable) 2 Logging Cable # 2 (Green 4 core Logging cable) 3 Logging Cable # 3 (Black 4 core Logging cable) 4 Logging Cable # 4 (Clear 4 core Logging cable)

4

2 C

C

3 Looking into cable head end (socket)

Logging Cable Centre Conductor

SK1 (Optional) BNC

Armour

GeoVista - Unit 6, Cae Ffwt Business Park, Glan Conwy, Conwy, LL28 5SP. Tel +44 (0)1492 573399 Fax +44 (0)1492 581177 D

Drawn

Issue

Circuit Description

Checked

Date

Issue

Parts List

Checked

Date

Date

Title:

D

GV530 Winch Connections

Filename

PCB Ident:

Issue

GV530_A_3.SCH

Sheet Of 1

2

3

3 of 3

Project GV530 Winch 4

A

1

2

3 +6v

8 U5A

U6A

3

3

1

LMC6484

6 0R

Purple

U5C

R11

10

D4

-6v

D2

D3

J1

A N L

R17 10K

1 2 3

9 1N4002

-6v

5

100R 1N4002

6

1N4002

LMC6484

C1

+6V

CON 3 Way

9

R1 100K

+

7

10uF 16VDC

8 4

REF U5D WIP

U1 LM3914 LED1 LED2 LED3 LED4 LED5 LED6 LED7 LED8 LED9 LED10

SIG Rhi RefOut RefAdj Rld

DC-7G3HWA U2 1 18 17 16 15 14 13 12 11 10

20 19 18 17 16 15 14 13 12 11

K1 K2 K3 K4 K5 K6 K7 K8 K9 K10

Green Green Green Green Green Green Green Red Red Red

A1 A2 A3 A4 A5 A6 A7 A8 A9 A10

1 2 3 4 5 6 7 8 9 10

+ C4 10uF 16VDC

12 14 13

B R5 1K5

R13 10K

2

VR1 10K0

MODE

A

+6V

LM393

-6v

R12

8 O\C R10

Mount C3 Close To Bargraph1

+6V 3

R14 POT2

2

V+

U5B LMC6484 7

5

Yellow

11

T2

V-

T2

KNOB 1

2

4

A

K1

+6v

4

Change R17 from 10K to 1K With the current transformer disconnected adjust POT2 so that the resistance of R14 + R17 = 3K3

4

R4 1K2

LMC6484

B +6v OVERLOAD A

C9 1uF

100nF C5 +6v Line F1

T1 PCB MOUNT T'FORMER

BR1 BRIDGE1

115

2

+6v

Vin

+Vout

R15 1K

3

1N4002 240R R6

ADJ

FUSE2

10K R2

C8 C2 330uF 25VDC

0

C

+

Q1 LM393

C6 100nF

U4 LM317 +Vout

910R R8

ZVN2110

3

-6v C7

240R R7

+

Rly1 is normally closed, shown energised 10uF 16VDC

1

+

C

R3 100K

Vin ADJ

2

0

7 6 R16 5K1

BR2 BRIDGE1

C3 330uF 25VDC

R18 10K

5

+

115

neutral

U6B

10uF 16VDC

1

910R R9

RLY1 RELAY-SPST

D1

U3 LM317

-6v

GeoVista Unit 6, Cae Ffwt Business Park Glan Conwy, Conwy, LL28 5SP Tel +44 (0)1492 573399 Fax +44 (0)1492 581177 Title: Winch Torque Display & Limit

D

Filename

PCB Ident:

GV530A_4

1 Of 1 1

2

3

Issue

1

Project GV530 Speed Controller 4

D

1

2

3

4

A

A

FH1 FUSE HOLDER1 FH2 FUSE HOLDER1

Mains Supply Input

B

Blue Mains Cable RS 378-864. Entry via cable gland 4m long

CG3 Line IP Neutral IP Earth

3 2 1

Cable Gland

Brown

F1 FUSE1

FUSES 2 * 10 Ampere

Power To Speed Controller

EMERGENCY STOP SW3

CG4 Brown

3 2 1

Blue

Blue

Blue Mains Cable out to speed control unit. Through cable gland. 3m long.

Line Out Neutral Out Earth Out

B

MOTOR

F2 FUSE1 Yellow/Green

Cable Gland

Yellow/Green

VAC In/Out Motor Power In

Motor Power Out

CG5 Motor Power from Speed Control Unit

3 2 1

CG6 Brown

Brown

Blue

Blue

Yellow/Green

3 2 1

Yellow/Green

Cable Gland C Cable Gland

Motor Power out to Baldor Motor.

C

Note: The motor cable loops through the box

GeoVista - Unit 6, Cae Ffwt Business Park, Glan Conwy, Conwy, LL28 5SP. Tel +44 (0)1492 573399 Fax +44 (0)1492 581177 D

Drawn Date

Issue

MP Oct 99

Circuit Description

Checked

Date

Issue

Parts List

Checked

Date

Title:

GV530 Emergency Stop Switch

PCB Ident:

A

NA

D

Issue B

Filename GV530A_2.SCH

Sheet Of 1

2

3

Project 4

GV530 Winch

1

2

3

4

A

A

FH1 FUSE HOLDER1 FH2 FH_5*20_IP67_A

B

CG5

Blue Mains Cable Entry via cable gland. 4m long

3 2 1

Line IP Neutral IP

Brown Blue

RLY4

F1 FUSE1

4

2

Brown

Line Out

F2

8

6

Blue

Neutral Out

FUSE1

Cable Gland

Earth Yellow/Green

Brown

0

1

Yellow/Green

Blue

CG6 3 2 1

Blue Mains Cable out to Speed Control Unit. Through cable gland. 2m long

B

Cable Gland

RELAY-DPST Brown

SW4

EMERGENCY STOP

C

C

GeoVista - Unit 6, Cae Ffwt Business Park, Glan Conwy, Conwy, LL28 5SP. Tel +44 (0)1492 573399 Fax +44 (0)1492 581177 D

Drawn

Issue

MP

Date

Circuit Description

Checked

Date

Issue

Parts List

Checked

Date

Title:

PCB Ident:

A

Sheet Of 1

GV503 Winch Emergency Stop Enclosure

2

3

NA 2 of 3

Filename GV530_A_2.SCH

Project 4

Issue A

GV503 Winch

D

1

2

3

4

CG1 Blue Mains Cable in from Emergency Switch control Box through Cable Gland CG1 to Terminal J1. 3m Long

GV5_2 PCB

ANL 1 2 3

3 2 1

Through Current Transformer

PCB Connections

N1

Cable Gland

A

A

Mains Input Lead 3 m long KNOB Terminal J1

Line

T1 VARIAC5 4

Neutral SW2 SW-DPDT

RELAY-DPCO 3 RLY2

3T

4

B

Note 1

Earth 1

BRIDGE2

Power latch

N

RLY1

J2

CG2 1 2 3

2 8

7

Note 1

CON3

Brown Blue Earth

1 2 3

B

Cable Gland

6

SW1 SW-SPST

4

Motor Connection

Direction Relay

BR1

K

0

1

Blue Cable for motor power. 5m long. Loop through Emergency Switch Control Box.

2

8

6

Base Plate 1

Upper Cover

C

0 RELAY-DPNO

C

RELAY-DPCO 3 RLY3 4 2 8

7

J3

6 0

1 2 3 4 5

1

GeoVista Unit 6, Cae Ffwt Business Park Glan Conwy, Conwy, LL28 5SP Tel +44 (0)1492 573399 Fax +44 (0)1492 581177 Title: GV530 Winch Variac Wiring

LMH 07A 14.05SN D

Plus dust cap LMA1055-14-00-00

Notes:

PCB Ident:

SW1 is a microswitch mounted on the variac T1. This closes when the variac is rotated to the minimum position.

NA

Filename

GV530A_1

Project 1

2

3

4

Issue B GV530 WInch

D

1

2

3

4

A 0 110 0 110 Earth

A

Torque Pot-Rear View Black Blue Red Red Blue Black

Speed Pot Rear View

Green Blue Black

Torque_POT_C Torque_POT_B Torque_POT_A POT_A POT_B POT_C NEG_OP POS_OP POLE_2

B Black Blue Green

Remote Control TB1.13 TB1.12

6 Way Chassis Socket RS 301-4664 A B C D E F

A C D E

POLE_1 DOWNHOLE UPHOLE

6 Way Cable Plug RS 301-4399 A B C Yellow/Green D Brown E Blue F 3 Core White Mains Cable 4M Long

NO NC

NO

B

NC

KBRG-240D

ISAMP_A ISAMP_B

Sample Resistor 0.1R 50W RS 158-446

PCB? KB_CONT_B

TB1 1 2 3 4 5 6 7 8 910 11 12 13

C

C

L1

L2

M1 M2

Live Neutral Brown Blue Mains In 240VAC

Blue

Brown D

D

To DC Motor Rev

1

2

Changes To This Revision

GeoVista Ltd #6 Cae Ffwt Business Park Glan Conwy, Conwy Size: A4 Number: Revision: LL28 5SP United Kingdom Date: 15/07/2008 Sheet of Time: 09:36:22 File: X:\Drawings\Electrical Drawings\KB_Cont\KB_Cont_C_GA.SchDoc Title

KB Controller Assembly Wiring

3

4