Installation Manual for SG-SMARTS 90-90-844 (Rev. a)
Installation Manual for Sg-Smarts...
INSTALLATION MANUAL FOR SG-SMARTS
Swaco, A Division of M-I L.L.C. A Smith/Schlumberger Company 5950 North Course Drive Houston, Texas 77072 Tel: 281-988-1868 Fax: 281-988-1888 MANUAL PART #90-90-844 (Rev. A)
TABLE OF CONTENTS
1.1 DESCRIPTION OF THE MAJOR COMPONENTS 1.1.1 CPU box 1.1.2 F.O.C. module 1.1.3 Barrier box 1.1.4 Driller’s monitor 1.1.5 Satellite box 1.2 FIBER OPTICS 1.3 INSTALLATION 1.3.1 Fiber optics 1.3.2 F.O.C. module 1.3.3 Repeater box 1.3.4 C.P.U. box 1.3.5 Barrier box 1.3.6 Driller’s monitor 1.3.7 Satellite box 1.3.8 Intrinsically safe horn 1.3.9 Horn disabled warning light 1.3.10 Circular chart recorder 1.3.11 Remote monitor printer 1.3.12 Printer 1.3.13 Slave monitors APPENDIX A PXR105 CIRCULAR CHART RECORDER 1.0 SCOPE 2.0 SETUP 2.1 Electrical connections 2.2 Familiarization with controls and displays 2.3 Installing the pens 2.4 Installing charts 3.0 CONFIGURATION 4.0 CALIBRATION APPENDIX B PX105 CIRCULAR CHART RECORDER 1.0 SCOPE 2.0 SETUP 2.1 Electrical connections 2.2 Familiarization with controls and displays 2.3 Installing the pens 2.4 Installing charts 3.0 OPERATION 4.0 CONFIGURATION 5.0 CALIBRATION APPENDIX C REMOTE OFFICE CRT 1.0 SCOPE 2.0 INSTALLATION PROCEDURES
6 6 7 7 8 8 8 9 9 9 10 10 10 10 11 11 11 11 11 11 12 14 14 14 14 14 16 16 17 21 21 21 21 21 22 23 23 24 24 27 27 27 28
2.1 Removing the cover 28 2.2 Disk drive installation 28 2.2.1 Hard disk drive (HDD) (80-16-748) 28 2.2.2 Floppy disk drive (FDD) (80-16-744) 29 2.3 Add on card installation 29 2.4 Parallel port cable installation 29 2.5 Hold down clamp installation 29 2.6 Mounting brackets 30 3.0 COMPONENT PREPLACEMENT PROCEDURES 31 3.1 Changing the filter (80-30-220) 31 3.2 Power supply (70-74-091) 31 3.3 Power supply pin assignments 32 APPENDIX D PANASONIC PRINTER 33 STEP 1 CONNECTING 33 STEP 2 INSTALLING RIBBON CASSETTE (80-71-525) 34 STEP 3 PAPER INSTALLATION 35 APPENDIX E SLAVE MONITOR MODEL KV-13TR28 35 1.0 SCOPE 35 2.0 SETTING UP THE T.V. 36 3.0 ELECTRICAL ADJUSTMENTS USING THE REMOTE CONTROL 37 APPENDIX F SLAVE MONITOR MODEL KV-13M10 38 1.0 SCOPE 38 2.0 SETTING UP THE T.V. 38 3.0 ELECTRICAL ADJUSTMENTS USING THE REMOTE CONTROL 38 APPENDIX G SLAVE MONITOR MODEL KV-13M20 40 1.0 SCOPE 40 2.0 SETTING UP THE T.V. 40 3.0 ELECTRICAL ADJUSTMENTS USING THE REMOTE CONTROL 41 APPENDIX H CIRCUIT BOARD SETUP 42 1.0 SCOPE 42 2.0 CMOS SETUP FOR THE 386DX AND PENTIUM CPU 42 APPENDIX I 44 GLASS VERSATILE LINK TYPE FIBER OPTIC 44 CONNECTOR TERMINATION INSTRUCTIONS 1.0 STRIP OUTER JACKET (CABLE STRIPPER TOOL) 44 2.0 INSTALL CRIMP RING 44 3.0 STRIP BUFFER (FIBER STRIPPER TOOL) 44 4.0 INSTALL VERSATILE LINK-PIN CONNECTOR 44 5.0 CLEAVER FIBER 44 POSITIONER PLATE REPLACEMENT 45 CLEANING DIAMOND BLADE AND ANVIL 45 APPENDIX J 45 PLASTIC VERSATILE LINK TYPE FIBER OPTIC 45 CONNECTOR TERMINATION INSTRUCTIONS 1.0 CONNECTORING 45 2.0 STRIPPING OUTER JACKET 45
3.0 INSTALLING CONNECTOR 4.0 POLISHING THE FIBER APPENDIX K GLASS ST TYPE FIBER OPTIC CONNECTOR TERMINATION INSTRUCTIONS 1.0 INSTALL STRAIN RELIEF BOOT 2.0 STRIP OUTER JACKET (CABLE STRIPPER TOOL) 3.0 STRIP BUFFER (FIBER STRIPPER TOOL) 4.0 INSTALL CABLE ANCHOR (CRIMP TOOL) 5.0 INSTALL CRIMP SLEEVE (CRIMP TOOL) 6.0 INSTALL FERRULE ASSEMBLY 7.0 CLEAVE FIBER (ST-2 CLEAVE TOOL) 8.0 POSITION STRAIN RELIEF BOOT 9.0 POSITIONER PLATE REPLACEMENT 10.0 CLEANING DIAMOND BLADE AND ANVIL
46 46 47 47
APPENDIX L BIT TRACKING 1.0 THEORY OF OPERATION 2.0 HARDWARE INSTALLATION 2.1 Preparation 2.2 Installation 3.0 TAGGING SENSORS 4.0 CALIBRATION 4.1 Calculating the calibration value 4.2 Calibrating bit tracking 5.0 BIT TRACKING NOTES
51 51 53 54 54 55 55 55 57 58
47 47 48 48 48 49 50 50 50 50
APPENDIX M INSTALLATION AND IDENTIFICATION DRAWINGS 59 Level I 96-27-025 60 Level II 96-27-125 61
INSTALLATION PROCEDURES FOR S.M.A.R.T. SYSTEM 1.0 OVERVIEW OF SYSTEM The SWACO Geolograph S.M.A.R.T. System is a state of the art data acquisition system that is used to monitor variables around a drilling rig. It is designed to be intrinsically safe for operation in hazardous areas. 1.1 DESCRIPTION OF THE MAJOR COMPONENTS Refer to drawing 96-27-025 for the major components of Level 1 or drawing 96-27-125 for the major components of Level 2. Since Level 1 and Level 2 only differ in the amount and types of sensors used, the description of the major components will be the same for both. 1.1.1 CPU BOX The CPU Box (Central Processing Unit) controls how all the major components communicate with each other. It is responsible for acquiring the data from the satellite box or boxes and relaying that information to the monitors. It is also responsible for controlling the horn, the alarm indication light (if applicable), and the circular chart recorders. Inside the box is an uninterruptible power supply (UPS) that supplies power to all of the other units except those located in the remote trailers or offices. This UPS generates the voltages 5VDC and 12VDC. It is battery backed up, so that in case of a power outage, it will maintain these voltages under a full load for more than 30 minutes. It also has a 110 VAC output that can be used to maintain power to the circular chart recorder during these outages. The card cage, located to the right of the UPS, is an 8 slot, common buss backplane. Into these slots are plugged the main control boards for the unit. These cards can be plugged into any of the slots. Because of the lengths of cables that plug into these cards, they should be located as follows: FIRST CARD – serial I/O card. This card is the serial controller card and is responsible for the communication between the CPU box and monitors, satellites, or other devices. *SECOND CARD – 4 channel D/A card. This card takes the signals from the CPU card and converts them to 0 – 10VDC signals to send to a recorder THIRD CARD – CPU card. This card contains the microprocessor and as such controls the rest of the system. FOURTH CARD – RAM/ROM card. This card contains the solid state disk drives used to hold the software program and some of its data files. FIFTH CARD – relay card. This card takes the signals from the CPU card and converts them to relay contact closures to turn on alarms, lights or other devices.
*In some installations the 4 channel D/A card is removed and replaced by an 8 channel D/A card. In this case, the 8 channel card would be placed between the RAM/ROM card and the relay card. Below the card cage is the J-Box Interface Board. This board takes the +5VDC and the +12VDC from the UPS and puts them on field terminatable connectors. The +12 volts are sent through self resetable fuses to the connectors P4, P5, and P6. This voltage is used for the satellite boxes. The +5 volts is used to generate other voltages via the onboard DC-DC converters. The larger of the DC-DC converters is a special 12VDC 1% output. This voltage goes to P6 and is used to power the driller’s monitor only. The other two DC-DC’s use the 5 volts to generate +24VDC that is connected to P7, P8, P9, and P10. This is used by the satellite boxes. With a four channel D/A card installed, the signals for the recorder output come through the trim pots R12-R15 (used to trim the voltage if the full 0-10 volt output is not needed) and then are sent to connector P11. The signals for the relay output come through the connector P12 via the ribbon cable connected to the relay card. The relays for the horn and the alarm light are sent to P13. The other relays go to P15. P16 is for future expansion. With an eight channel D/A card installed, a Y cable is used and the signals for both the relay card and the eight channel card come through P12. The signals for the relays stay the same, but the outputs to the recorders now go to P16 and no longer go through the trimmers and P11. Note: the middle connector of the Y cable must connect to P12 of the breakout board. Below the UPS is the 8 channel breakout board. This board takes the serial signal from the serial I/O card and sends it to a standard RS-232 type 25 pin D-connector. 1.1.2 F.O.C. MODULE A F.O.C. module will plug into the D-Connectors on the 8 channel breakout board and convert the RS-232 signal to an optical signal. These are a universal communication module which means they can be used on any device with RS-232 output. If they are plugged into the 8 channel breakout board or the satellite board, they will pick up the power they need from the connector. If they are used on other devices they will need to be powered through the connector P2 with the power supply (70-74-497). 1.1.3 BARRIER BOX To maintain the intrinsic safety of the system, all power for the units in hazardous areas must go through approved safety barriers. These barriers are located in the barrier box. There are two types of barriers used, one rated to 12VDC and one rated to 24VDC. As implied by their ratings, the 12 volt ones are used to barrier the 24 volts to the Satellite box and the horn.
1.1.4 DRILLER’S MONITOR The driller’s monitor (96-27-041) is an intrinsically safe computer. It will take the signals from the CPU box and convert them into graphics and numbers to be displayed on its liquid crystal display (LCD). Located inside the box are three circuit boards and the LCD. The larger board is the monitor interface board. This board brings in the fiber optic signal from the barrier box and converts it back into an RS-232 signal, sending it through P3 to the monitor CPU. The +12 volts comes into this board and goes to a DCDC where it is converted to +5 volts and sent through P2 to the monitor CPU. Also on this board is the keypad converter chip that brings in the key strokes from the keypad through P6, translates them and sends them to the monitor CPU via P2. This board also generates the voltages to control the brightness of the LCD, which is done via the potentiometer on the front panel connected to P7. the signals to drive the LCD are generated on the mini module/LCD board, then sent out J3 to P4 on the monitor interface board, which is the top board of the two stacked boards, does all the calculation, storing, and manipulating of the data. The mini module/LCD controls the way the display is generated. 1.1.5 SATELLITE BOX Refer to drawing 96-27-030. The satellite box is an intrinsically safe microcontroller capable of bringing in analog and digital signals and converting them to a RS-232 signal. Across the bottom of the board are 8 connectors labeled CHAN 0 through CHAN 7, these are used for the analog inputs. On the lower right side are two connectors labeled DIGITAL 0 and DIGITAL 1 that are used for the digital inputs. Refer to wiring diagram (96-27-027) for proper wiring connections. The inputs from the sensors are sent through the microcontroller where they are converted to a RS-232 signal. This signal is sent to a F.O.C. module via the 25 pin D-connector and then on to the CPU box. 1.2 FIBER OPTICS A new concept for this system is the used of fiber optic cable for the transmission of the communication signals between major components. This cable was used to eliminate the problems of noise in the system. The way fiber optics works is by sending pulses of light down a carrier (in this case a plastic rod or glass fiber) instead of electrical current or voltage. Because the signal is light, it cannot be affected by electrical noise caused by lightning, generators, motors, or ground loops. Because no carrier is a perfect transmitter of light, some of the lights energy is lost traveling the length of the carrier. These limits the distance a signal can be sent. Other factors affecting distance are the number of connections made and the number and radius of bends in the cable. The light signal tends to travel in the center of the carrier. Every time it encounters a bend in the cable it bounces off the wall and loses some of its energy. The sharper the bend, the more energy it loses. Each connection is a source of energy loss due to the fact you can’t make a perfect termination of the fiber.
The plastic cable is rated at a maximum distance of 300 feet. If longer runs are needed repeater boxes (96-27-062 – refer to section 1.3.3 for installation procedures) can be added to give an additional 300 feet per box. The glass cable is rated at a maximum distance around 3000 feet. A repeater box can also be used to increase the distance if needed. 1.3 INSTALLATION Refer to drawing 96-27-027 for proper wiring of sensors and communication lines up to the Barrier box. 1.3.1 FIBER OPTICS The fiber optics is the twin plastic zip cord inside the blue cable if it is plastic or the orange cable if it is glass. One of the fibers is marked with either white dots (plastic) or white writing (glass) down the length of it to help orient transmit and receive. If you connect the marked cable to the transmitter at one end, then the marked cable must go to the receiver at the other end. Refer to Appendix I for proper connectoring of the Glass Fiber Optics and Appendix J for the plastics fiber optics. 1.3.2 F.O.C. MODULE
The F.O.C. Module is used for serial communications between all the components of the S.M.A.R.T. system, except for the driller’s monitor which has F.O. transmitter and receiver at the other end. The blue one is the receiver and the black one is the transmitter. The board is also marked as to which is which. When the modules are plugged into either the Satellite board or the 8 channel breakout board, they need no external power. If they are used anywhere else they will have to have power applied to the power jack P2 located next to the F.O. transmitter. This voltage can be any D.C. voltage between 7 and 14 volts with at least 80 milliamps of current.
1.3.3 REPEATER BOX The repeater box is a junction box with two connectors for plugging in F.O.C. modules and one for power. The light signal is brought into one F.O.C. module where it is converted to voltage amplified and sent to the other F.O.C. Module where it is converted back to light and sent down the line. It does not matter which F.O.C. module is connected to what device as long as you remember to connect transmit to receive and vice versa for each cable. The repeater box will have to have 12 V.D.C. power brought to the power connector for the unit to work. Refer to figure 2.
1.3.4 C.P.U. BOX The C.P.U. box comes with 4 mounting tabs so it can be attached directly to a wall. It can be mounted on an optional stand (96-27-028) that can also be used to mount the barrier box. This stand will fold with both boxes in place for easy transportation. Only the A.C. connections need to be made now. All other connections will be covered in their corresponding sections. The main A.C. input will connect to the terminal strip on the middle left side of the base plate. Follow the directions on the decal for A.C. in. The terminals marked A.C. out are for the uninterruptible A.C. output which can be used by the recorder. 1.3.5 BARRIER BOX Refer to drawing 96-27-027 for proper wiring of the barrier box. 1.3.6 DRILLER’S MONITOR Refer to drawing 96-27-027 for proper wiring of the driller’s monitor to the barrier box. The 12 volts needed for the monitor must come from the P6 of the CPU interface board. Red wire to +, black wire to -. (Note: P6 has the + and – reversed from the rest of the connectors to further identify it as the connector for monitor only). The fiber optic cable for the monitor will go to a D-connector connected to either PORT 4, PORT 5, PORT 6, OR PORT 7 of the 8 channel breakout board.
1.3.7 SATELLITE BOX Refer to drawing 96-27-027 for proper wiring of the satellite box to the barrier box. The 12 volts needed for the satellite can come P3, P4, or P5 of the CPU interface board. Red wire to +, black wire to -. The 24 volts for the Satellite boxes can come from P7, P8, or P9, or P10. white wire to +. The – is picked up through the black wire on the 12 volts. The fiber optic cable for the satellite box will go to a D-connector connected to either PORT 0, PORT 1, PORT 2, or PORT 3 of the 8 channel breakout board. 1.3.8 INTRINSICALLY SAFE HORN Refer to drawing 96-27-027 for proper wiring of the horn lines up to the barrier box. The cable from the horn barrier is connected to the position marked HORN on P13 of the CPU interface board. Red wire to +, black wire to -. NOTE: this is 24 VDC output to drive the intrinsically safe horn only. DO NOT APPLY ANY EXTERNAL VOLTAGES TO THESE TERMINALS. 1.3.9 HORN DISABLED WARNING LIGHT Located on the lower left corner of the C.P.U. interface board (96-52-137) is connector P13. The lower three connections are labeled RELAY 1. This relay is toggled every time the horn is disabled or enabled. A signal up to 24 VDC 2 Amp. Maximum may be switched through the relay control a light or another relay. 1.3.10 CIRCULAR CHART RECORDER The signals to drive the recorder come from P11 of the CPU interface board if using a 4 channel card or from P16 of the CPU interface board if using an 8 channel card. Located behind the chart plate in the recorder, there are two terminal strips for signal inputs. The recorder is shipped ready to work with the system. The configuration is stored in battery backed memory with a 10 year life. As it is configured, the displays on the front panel show the percent of the incoming signal. Example: if trip tank is being displayed and is calibrated to 50 units full scale. When the pen shows 25 units, the display will read 50. Refer to Appendix A for installation and configuration information of the model PXR105 and Appendix B for the model PX 105. 1.3.11 REMOTE MONITOR The remote monitor consists of a monitor C.P.U. box, a keyboard, a V.G.A. monitor, and a F.O.C. module with adapter hardware. All connections on the C.P.U. box will be made on the back. Each connector is keyed to only fit in one spot. After located the equipment in the appropriate locations, make the following connections: 1. 15 pin connector from V.G.A. monitor to 15 pin connector on C.P.U. box
2. 3. 4. 5. 6. 7. 8.
A.C. power cord to C.P.U. box A.C. power cord to V.G.A. monitor 6 pin mini-DIN connector from keyboard to 6 pin mini-DIN on C.P.U. box 9 pin D-connector on 9-25 adapter to either 9 pin connector on C.P.U. box 25 pin D-connector on 9-25 adapter to F.O.C. module wall adapter to one pin jack on F.O.C. module Fiber optic cable to F.O.C. module.
1.3.12 PRINTER The basic unit ships without a printer or the necessary cables. To install a printer, you will need to order 1 each of: 1. 2. 3. 4.
80-67-401 printer 80-06---2 cable printer parallel 12ft min. 96-27-052 cable assy. Parallel to C.P.U. LIT00308 paper computer 1 ply 8.5 x 11.
NOTE: item 3 is only needed if the monitor C.P.U. box has not already been modified for printer. Refer to appendix B for installation procedures. Refer to appendix C for printer setup. 1.3.13 SLAVE MONITORS Slave monitors are remote video displays without any keyboard input. They must be connected to a remote monitor assembly and can only display what is being shown on that monitor. To install a slave monitor, you will need: 1. 2. 3. 4. 5. 6.
80-59-452 monitor color 13 in Sony Trinitron 80-67-051 P.C.B converter V.G.A to N.T.S.C 80-01-095 adaptor B.N.C Fem to phone plug 80-01-096 adaptor tee B.N.C. fem-male-fem YKM99008 connector B.N.C RG54/U co-axial YMA01006 cable c0-axial 75 ohm (order the required footage)
For the V.G.A. to N.T.S.C. board that uses the cable with a 15 pin D- connector on one end and the round DIN connector on the other, refer to figure 3 to connect the cables. For the V.G.A. to N.T.S.C. board that uses the cable with three 15 pin D-connectors, refer to figure 4 to connect the cables. One item 3 is needed for each item 1 and one for item 2. One item 5 is needed for each end of the cable. One item 4 is needed for each additional item 1 added.
NOTE: the V.G.A. to T.V. board shown in figure 4 requires software version 3.1 or greater in the unit it is installed in. To setup item 1, refer to appendix E for model number KV-13TR28, appendix F for model number KV-13M10 and to Appendix G for model number KV-13M20. The model number can be found on a label on the back of the monitor.
APPENDIX A PXR105 CIRCULAR CHART RECORDER 1.0 SCOPE The following procedures are provided to assist in the operation and setup of the PXR105 circular chart recorder. 2.0 SETUP 2.1 ELECTRICAL CONNECTIONS 2.1.1 2.1.2
Loosen captive knob on door and open. Swing chart plate forward by loosening screw located in the middle of the right hand side. The unit comes preset for 110 V.A.C. follow the instructions below to change to 220 V.A.C. operation: A. Locate protective cover on right hand side of main circuit board. B. Loosen the captive thumb screw and remove cover to the extend of the attached grounding cable. C. On the far right hand side of the circuit board is a “handbag” style jumper. The lower position is for 110 V.A.C. operation and the upper position is for 220 V.A.C. operation. D. Set jumper for the appropriate voltage E. Reinstall protective cover The main A.C. input is connected to terminal strip TB1 located on the right hand side of the main circuit board under the protective cover. Remove the protective cover as described above and verify the input is wired as follows: A. Line input (black wire) to position marked ‘MAIN INPUT L’. B. Neutral input (white wire) to position marked ‘MAIN INPUT N’. C. Ground wire to the ground lug on the chassis. The D.C. signals from the main unit will connect to the two terminal strips located on the bottom of the board to the left of the A.C. input. The terminal block on the right is for the red pen and the one on the left is the green pen. The positive input is position 2 and the negative is position 1 on both strips.
2.2 FAMILIARIZATION WITH CONTROLS AND DISPLAYS NOTE: some switches are used for configuration only and will not operate during normal operation.
‘Pen Lift’ switch – located inside the door, above the chart and used to raise and lower the pens on alternate operations. When the pens are raised using the ‘pen lift’ switch all pens move to a position just outside the chart full scale. NOTE: if the switch is not operated to lower the pens, they will automatically return to their operating position after a five minute time-out.
2.3 INSTALLING THE PENS
APPENDIX B PX105 CIRCULAR CHART RECORDER 1.0 SCOPE The following procedures are provided to assist in the operation and setup of the PX-105 Circular chart recorder. 2.0 SETUP 2.1 ELECTRICAL CONNECTIONS 2.1.1
Loosen captive knob on door and open. Swing chart plate forward by loosening screw located in the middle of the right hand side. 21
The unit comes preset for 110 V.A.C. follow the instructions below to change to 220 V.A.C. operation: A. Locate protective cover on right hand side of main circuit board. B. Loosen the captive thumb screw and remove cover to the extent of the attached grounding cable. C. On the far right hand side of the circuit board is a “handbag” style jumper. The lower position is for 110 V.A.C. operation and the upper position is for 220 V.A.C. operation. D. Set jumper for the appropriate voltage E. Reinstall protective cover 2.1.3 The main A.C. input is connected to terminal strip TB1 located on the right hand side of the main circuit board under the protective cover. Remove the protective cover as described above and verify the input is wired as follows: A. Line input (black wire) to position marked ‘MAIN INPUT L’ B. Neutral input (white wire) to position marked ‘MAIN INPUT N’ C. Ground wire to the ground lug on the chassis. 2.1.4 The D.C. signals from the main unit will connect to the two terminal strips located on the bottom of the board to the left of the A.C. input. The terminal block on the right is for the red pen and the one on the left is the green pen. The positive input is position 2 and the negative is position 1 on both strips. 2.2 FAMILIARIZATION WITH CONTROLS AND DISPLAYS NOTE: some switches are used for configuration only and will not operate during normal operation. Pen lift switch – located inside the door, above the chart and used to raise and lower the pens move to a position just outside the chart full scale. NOTE: if the switch is not operated to lower the pens, they will automatically return to their operating position after a five minute time-out.
APPENDIX C REMOTE OFFICE CRT 1.0 SCOPE The following procedures are provided to assist in the installation of drives, plug-in cards and the hold-down clamp or the replacement of components to the Remote Office CRT.
2.0 INSTALLATION PROCEDURES 2.1 REMOVING THE COVER To remove the cover, proceed as follows: 2.1.1
Remove the two screws, one on each side, which secure the cover to the card cage (see figure 7). Lift the lid to expose the interior of the chassis.
2.2 DISK DRIVE INSTALLATION To install a hard disk or floppy drive, refer to figure 8 and proceed as follows: 2.2.1 HARD DISK DRIVE (HDD) (80-16-748): A. B. C. D. E.
open the cover to the chassis detach the mounting brackets by removing four screws align the holes on the side of the HDD with those f the mounting brackets attach the HDD to the mounting brackets with four 6-32 x ¼” screws Connect one end of the 40 pin ribbon cable to the HDD. Match pin 1 of the cable (marked with a red strip or an arrow on the connector) to pin 1 on the HDD. F. Connect the power cable to the HDD. G. Attach the mounting brackets to the chassis with four screws H. If a C.P.U. board is installed, connect the other end of the 40 pin ribbon cable to CN1 on the board. Match pin one of the cable to pin one on the board.
2.2.2 FLOPPY DISK DRIVE (FDD) (80-16-744): A. B. C. D.
open the cover to the chassis remove the cover for the floppy disk drive insert the FDD with its front facing inward, into the mounting bracket Connect the middle connector of the 34 pin ribbon cable. Match pin 1 of the cable (marked with a red strip or an arrow on the connector) to pin 1 on the FDD. E. Connect the power cable to the FDD. F. Attach the FDD to the bracket with four screws G. If a C.P.U. board is installed, connect the other end of the 34 pin ribbon cable to CN2 on the board. Match pin one of the cable to pin one on the board. 2.3 ADD-ON CARD INSTALLATION Located on the bottom of the chassis is the passive backplane’s expansion slots. Remove screw and blanking plate associated with the slot to be used. Gently insert your plug-in cards making sure that they fit securely into the expansion slots. Using the blanking plate’s screw, tighten the mounting bracket of the card to the chassis. 2.4 PARALLEL PORT CABLE INSTALLATION Remove large blanking plate from back of the lid. Attach cable (96-27-052) to lid using this hole. Attach the 26-pin connector to CN3 of C.P.U. board (96-52-148) observing pin 1 polarity. 2.5 HOLD DOWN CLAMP INSTALLATION
2.5.1. Insert the rubber buffers that have been provided into the hold-down clamp (see figure 9). For XT-size cards, the narrow end should face upwards. For AT-size cards, the wide end should face upwards. 2.5.2 When the rubber buffers are inserted, fasten the hold-down clamp to the card cage with the two screws that are provided. 2.6 MOUNTING BRACKETS 2.6.1 The brackets may be attached to the chassis by inserting the 6 screws through the left and right mounting brackets. Refer to figure 10.
3.0 COMPONENT REPLACEMENT PROCEDURES Should it be necessary to replace the filter, fan, power supply or backplane, please refer to the following section? 3.1 CHANGING THE FILTER (80-30-220)
To change the filter, located at the front side of the chassis, see figure 11 and proceed as follows: 3.1.1 3.1.2 3.1.3
Remove the two screws located at the bottom of the filter cover. Gently, but firmly, pull the cover free of the chassis. Remove the filter and replace it with a new one Reinsert the filter and cover into the chassis.
3.2 POWER SUPPLY (70-74-091) To connect the power supply, located on the front left side of the chassis, to the disk drives and backplane, refer to figure 12 and do the following: 3.2.1 Secure the power supply to the chassis with the four screws 3.2.2 Connect the cables to the appropriate place in the system. P8 and P9 connectors are located on the backplane.
3.3 POWER SUPPLY PIN ASSIGNMENTS The following diagram provides the pin assignments for the power supply, giving the color of each wire which corresponds to the voltage. Refer to figure 13.
APPENDIX D PANASONIC PRINTER This is the procedure for setting up the Panasonic KX-P2023 Printer (80-67-401). Note: the printer must have 110 Volts A.C. For 220 Volt service an appropriate converter must be used. CONNECTING STEP 1
APPENDIX E SLAVE MONITOR MODEL KV-13TR28 1.0 SCOPE The following procedures are provided to assist in the operation and setup of the Sony Color T.V. Model KV-13TR28 (80-59-452). 2.0 SETTING UP THE T.V.
APPENDIX I GLASS VERSATILE LINK TYPE FIBER OPTIC CONNECTOR TERMINATION INSTRUCTIONS SAFETY NOTE: Wear eye protection during and dispose of fiber properly. 1.0 Strip outer jacket (cable stripper tool) A. select the 1.6 cutting hole of the cable stripper B. place 3” (75mm) of cable in designated cutting hole C. apply quick squeezing action to cut cable D. Remove cut portion of cable. 2.0 Install Crimp Ring A. slide the crimp ring, large diameter first, onto the cable until it bottoms completely onto the jacket B. Holding cable and crimp ring in left hand and crimp tool in right, insert small end of crimp ring completely into the front die nest of the crimp tool. C. Crimp by fully squeezing the handles together and releasing. 3.0 Strip Buffer (fiber stripper tool) A. Insert fiber through guide hole of the fiber stripper tool until tip of crimp ring is fully seated in tool. If unable to insert fiber through the guide tube, tri tip of buffer/fiber using scissors. B. Holding cable securely, squeeze handles to cut buffer and pull straight to slightly separate the buffer C. Release handles and remove the tool D. Using fingers, carefully slide bugger off fiber E. Inspect fiber to cladding damage (i.e. white dusty appearance). (NOTE: if damage has occurred, cut off crimp ring and repeat procedure from “STRIP OUTER JACKET”. If stripper blade is worn, replace tool immediately. 4.0 Install Versatile Link-PIN Connector A. Slide the connector body onto the fiber and push completely into the outer flange of the crimp ring. Insert the connector/crimp ring completely into the rear die nest of the crimp tool. Be sure the connector shoulder is flush against the edge of the die nest. B. Crimp in place by fully squeezing the handles together and releasing. 5.0 Cleaver Fiber (CT-2V Cleave tool) NOTE: pads, diamond blade and anvil should be cleaned after every 50 cleaves. Clean with a non-alcohol or oil base solvent. A. Holding the cleave tool in a horizontal position, grip the handle while leaving your index finger free.
B. Carefully insert the ferrule of the connector into the slot until the ferrule rests securely against the connector adaptor. C. Check to see that the fiber is positioned evenly between the two fiber clamps and that the connector face is in proximity to the cleaving blade. If connector of fiber is not positioned correctly, remove assembly and repeat steps 1 and 2. D. Release your hold on the ferrule. The connector will remain in place since the cleave tool is held in the horizontal position. E. Using your index finger, SLOWLY depress the cleave tool trigger completely. This motion activates the fiber clamps and diamond blade to cleave the fiber. The connector will snap back slightly after the cleaving process. F. Remove the cleaved connector assembly form the adaptor slot. G. Release the trigger H. Gently remove the remaining fiber from the fiber clamps by pulling top end of fiber up through clamps so it does not touch the diamond blade or anvil. POSITIONER PLATE REPLACEMENT A. B. C. D.
remove the two screws securing the positioner plate remove the positioner plate Depress and hold the trigger. Place desire positioner plate on the tool. Insert and tighten the two screws. Release the trigger.
CLEANING DIAMOND BLADE AND ANVIL A. Using a Phillips screwdriver, remove the positioner plate. B. We small bristle brush with alcohol and slide gently over blade and anvil. DO NOT LET THE METAL PORTION OF THE BRUSH COME INTO CONTACT WITH THE BLADE. MAKE SURE ALCOLHOL DOES NOT DRIP ONTO FIBER CLAMP PAD MATERIAL. Let dry thoroughly. C. Replace positioner plate per instructions. APPENDIX J PLASTIC VERSATILE LINK TYPE FIBER OPTIC CONNECTOR TERMINATION INSTRUCTIONS 1.0 CONNECTORING Materials needed for the connectorizing procedure are: 1. polishing kit (96-27-084) 2. connector 1 pin male F.O.C. gray (65-01-051) 3. 16 gauge wire strippers 2.0 STRIPPING OUTER JACKET The zip cord structure of the duplex cable permits easy separation of the channels. The channels should be separated approximately 50 mm (2.0in) back from the ends to permit
connectoring and polishing. After cutting the cable to the desired length, strip off approximately 7 mm (0.3 in) of the outer jacket with the 16 gauge wire strippers. Strip both cables to equal lengths. This allows for easy and proper seating of the cable into the connectors.
3.0 INSTALLING CONNECTOR Place the connector over the end of the cable; the fiber should protrude about 3 mm (0.12 in) through the end of the connector. Carefully place a drop of super glue through the hole at the other end of the connector.
4.0 POLISHING THE FIBER After the glue has set, any excess fiber protruding from the connector end should be cut off. The trimmed fiber should extend at least 1.5 mm (0.06 in.) from the connector end. Insert the connector fully into the polishing fixture with the trimmed fiber protruding from the bottom of the fixture. This plastic polishing fixture can be used to polish both connectors simultaneously. NOTE: The four dots on the bottom of the polishing fixture are wear indicators. Replace the polishing fixture when any dot is no longer visible. Place the 600 grit abrasive paper on a flat smooth surface. Pressing down on the connector, polish the fiber and the connector using a figure eight pattern of strokes until the connector is flush with the bottom of the polishing fixture. Wipe the connector and fixture with a clean cloth or tissue.
Place the flush connector and polishing fixture on the dull side of the 3 micron pink lapping film and continue to polish the fiber and connector for approximately 25 strokes. The fiber end should be flat, smooth, and clean. The cable is now ready to use. NOTE: Use of the pink lapping film fine polishing step results in approximately 2 dB improvement in coupling performance over the 600 grit polishing alone. The fine polishing step may be omitted in short length such as less than 150 feet. This will be something you will have to get used to and decide for yourself if it is needed. APPENDIX K GLASS ST TYPE FIBER OPTIC CONNECTOR TERMINATION INSTRUCTIONS SAFETY NOTE: Wear eye protection during cleaving and dispose of fiber properly. 1.0 INSTALL STRAIN RELIEF Slide strain relief boot (tapered end first) onto cable and move up out of the way for easy stripping. (NOTE: Boot may need trimming in order to slide onto the cable.) 2.0 STRIP OUTER JACKET (CABLE STRIPPER TOOL) A. B. C. D. E.
select cutting hole 1.6 Place 1” (24 mm) of cable in designated cutting hole. Apply quick squeezing action to cut cable Remove cut portion of cable Repeat steps b, c and d until approximately 2-1/2” (57mm) of buffer/fiber is exposed.
3.0 STRIP BUFFER (FIBER STRIPPER TOOL) A. Separate fiber from yellow Aramid yarn strength members by pulling yarn back along cable. B. Insert fiber through guide hole of the stripper tool and insert cable completely into the guide tube. If unable to insert fiber through guide tube, trim tip of buffer/fiber using scissors. Also, if less than a meter of cable is used, it may be necessary to wrap the cable around finger to avoid pulling out the fiber and yarn. C. Hold cable securely, squeeze handles to cut buffer and pull straight to slightly separate the buffer. D. Release handles and remove the tool. E. Using fingers, carefully slide buffer off fiber (i.e., less than 5/16” (8mm) of buffer should be exposed) F. Inspect fiber for cladding damage (i.e., white dusty appearance). NOTE: if damage has occurred, cut the damaged portion of fiber, repeat procedure from “Strip Outer Jacket”. If blade is worn, replace immediately. 4.0 INSTALL CABLE ANCHOR (CRIMP TOOL) A. Pull Aramid yarn strands back over stripped fiber. B. Holding yarn and fiber at very top, thread through the anchor so that the anchor is seated on the cable. C. Using the crimp tool, center large portion of cable anchor on crimp die. D. Crimp the anchor towards the back of the larger diameter, refer to Figure 17. Squeeze the handles together until they release.
E. Inspect cable anchor crimp. 5.0 INSTALL CRIMP SLEEVE (CRIMP TOOL) A. Divide the yarn into approximately two equal halves. B. Fold both halves of yarn back over the cable anchor so that they cover dimples created by 1st crimp and are opposite each other. Fiber should be centered not leaning against side of anchor.
C. Slide the crimp sleeve over the cable anchor until it rests firmly on the bottom portion of the anchor and traps the yarn. D. Align the crimp sleeve in the crimp tool by: positioning the crimp die pins over the yarn halves, which are located under the crimp sleeve and also position so that the pin crimp mark will line up with the crimp mark on the anchor, aligning the bottom edge of the crimp sleeve with the edge of the die. Refer to figure 18.
E. Crimp in place by fully squeezing the handles together. 6.0 INSTALL FERRULE ASSEMBLY A. Insure that the lock nut is correctly positioned on the ferrule assembly (threaded end first onto back end of the ferrule assembly) B. Slide the ferrule assembly onto the fiber until it rests securely in the crimp sleeve. The slots on the side should be at a 900 angle to the crimp marks on the anchor/crimp ring assembly. C. Align the crimp sleeve in the crimp tool by: positioning the crimp die pins 900 to the ferrule assembly slots and also by aligning the top edge of the crimp sleeve with the edge of the die. D. Crimp in place by fully squeezing the handles together. All three crimp marks should be in a straight line opposite the ferrule assembly slots. Refer to figure 19.
7.0 CLEAVE FIBER (ST-2 CLEAVE TOOL) NOTE: Pads, diamond blade and anvil should be cleaned after every 50 cleaves. Clean with a non-alcohol or oil base solvent. A. Holding the cleave tool in a horizontal position, grip the handle while leaving your index finger free. B. Carefully insert the ferrule of the connector into the slot until the ferrule rests securely against the connector adapter. (see photo #6). C. Check to see that the fiber is positioned evenly between the two fiber clamps and that the connector face is in close proximity to the cleaving blade. If connector or fiber is not positioned correctly, remove assembly and repeat steps 1 and 2. D. Release your hold on the ferrule. The connector will remain in place since the cleave tool is held in the horizontal position. (see photo #7). E. Using your index finger, SLOWLY depress the cleave tool trigger completely. This motion activates the fiber clamps and diamond blade to cleave the fiber. The connector will snap back slightly after the cleaving process. F. Remove the cleaved connector assembly from the adapter slot. G. Release the trigger (see photo #8) H. Gently remove the remaining fiber from the fiber clamps by pulling top end of fiber up through clamps so it does not touch the diamond blade of anvil. 8.0 POSITION STRAIN RELIEF BOOT A. Using scissors completely cut off the exposed yarn. B. Slide strain relief boot into place over connector assembly. NOTE: the boot should abut the connector nut (see photo #13) C. Place the connector protective cap on ferrule tip. (see photo #14) 9.0 POSITIONER PLATE REPLACEMENT A. B. C. D. 10.0
Remove the two screws securing the positioner plate Remove the positioner plate Depress and hold the trigger. Place desire positioner plate on the tool Insert and tighten the two screws. Release the trigger. CLEANING DIAMOND BLADE AND ANVIL
A. Using a Phillips screwdriver, remove the positioner plate B. Wet small bristle with alcohol and slide gently over blade and anvil. DO NOT LET THE METAL PORTION OF THE BRUSH COME INTO CONTACT WITH THE BLADE. MAKE SURE ALCOHOL DOES NOT DRIP ONTO FIBER CLAMP PAD MATERIAL. Let dry thoroughly. C. Replace positioner plate per instructions.
APPENDIX L BIT TRACKING 1.0 THOERY OF OPERATION The SG-Smart Bit tracking sensor assembly is a pair of inductive proximity sensors mounted on a bracket, so that they are both facing the same direction and are a set distance apart (see figure 20). It is intended to be installed so that it faces the flat side of the fast sheave (see figure 21). The supplied targets for the proximity sensors are ¾” thick foam blocks with aluminum sheeting on the sides, cut into 6” x 3 ½” (150mm x 88mm) rectangles. These targets are glued to the fast sheave, so that each target will be centered across the mounting bracket as it passes by. Like the sensor bracket, the targets will have their long edges perpendicular to the radius of the fast sheave. They should be evenly spaced around the fast sheave (see figure 21). The number of targets (not all targets need to be used) and the distance from the center of the fast sheave to the targets are not important, as long as the gap between targets is longer than the targets.
When the block is being raised or lowered, the fast sheave rotates as the line goes up and around it. The rotation is proportional to the distance the block has moved. In the following description, remember that the sequence can start at any point. Starting with the sensor assembly between targets is not necessary. The gap between the targets must be large enough so that the next target will not trigger a sensor while another target is triggering the other sensor. The entire process shown in figure 22 provides one directional pulse to the SG-SMART system bit tracking satellite box. The process of detecting a directional pulse occurs in this sequence (see figure 22). A. B. C. D.
The sensor assembly starts out between targets. A passing target will trigger one of the proximity sensors first This sensor will stay triggered until the other sensor is triggered. Both sensors will stay triggered until the target completely passes the first sensor – the second sensor will be the only one triggered at this point.
E. The target will rotate past the second sensor also, and both sensors will not be triggered during the gap between targets.
2.0 HARDWARE INSTALLATION The installation kit contains: 1 carrying bag 1 bit tracking sensor assembly 1 sensor test assembly 1 male cap 1 5-pin female connector 500 ft 18/3 cable 1 putty knife 1 can or bottle of a cleaner or degreaser 1 roll of paper towels 53
2 10 25
tubes silicon adhesive sensor targets cable ties
2.1 PREPARATION Connect the tester to the sensor and verify that the LED indicators on both proximity switches light up. Wave a sensor target in front of the proximity switches and make sure the LEDs go out when the target is in range. Keep the tester in the carrying bad, since it will be needed again during installation of the targets. The 18/3 cable should be long enough to reach the fast sheave at the top of the derrick. Connect the 18/3 cable to the 5pin female connector. Position 3 is positive, use the red wire. Position 2 is the signal wire for the right proximity switch, use the black wire and position 4 is for the left, use the white wire. Leave the other end of the 18/3 cable disconnected. If the manufacturer’s specifications for the drill line and the fast sheave are not available, you will need to measure the diameter to be used for calibration. Put a tape measure in the carrying bag. See the calibration section for more information on the measurements needed. 2.2 INSTALLATION Select a good time to install the sensors. The work will be done at the top of the rig. It is simplest to install the bit tracking sensors before the rig is standing. Installing during slow drilling is good, since the fast sheave will be turning slowly, but will still bring the next sensor location around within reach. Cable: Run the 18/3 cable safely to the top of the rig, avoiding pinch points, moving parts, etc., and securing it where necessary. If the rig is laid over, keep in mind how it will be raised. The 5-pin connector should be at the end of the cable at the top of the rig. At the top of the rig, tie the cable securely to provide strain relief. Leave enough cable to make the connection to the sensor bracket assembly. Sensor Bracket: select a place to clamp the sensor bracket, so that it faces the side of the fast sheave as straight as possible. The proximity sensors will need to be 1 to 1-1/2 inches away from the sheave to leave space for the targets underneath the sensors. The bracket should be far enough out from the center of the sheave to allow installation of the desired number of targets. In determining the spacing, remember that each sensor is approximately 6 inches long, and there should be at least 7 inch gaps between sensors. Loop the chain around a pole or railing so that if the clamp comes loose, the sensor will not fall to the rig floor. Avoid placing it so that it will fall toward the sheave or other moving parts. Make sure the chain will not come loose as well. Check the full possible range of motion in case the bracket swings on the chain. It may be helpful to pull the bracket out of the way while installing the targets.
Targets: select locations for the targets. Avoid gluing targets over any slots in the sheave. The targets should be spaced evenly around the sheave, and should all be the same distance from the center. Keep in mind that the targets must pass directly underneath the sensor bracket and that the bracket should be centered on the target as it passes the bracket. Using the putty knife, scrape an area clean for each sensor on the side of the fast sheave. Use the cleaning fluid and paper towels to clean the surface completely. Use the silicone adhesive to glue the sensors in place. Test: Verify that the sensors detect the targets by connecting the tester to the connector on the sensor bracket. Make sure both of the proximity sensor LEDs light up, and that the LEDs go off as the target passes under the sensors. When the sensor bracket is adjusted properly, remove the tester and connect the 18/3 cable to the sensor bracket. Connect the other end of the 18/3 cable to the two digital inputs in the bit tracking satellite box. The red wire will go to the + positions on one of the digital inputs, the black signal wire will go to the PROX position of a digital input, and the white signal wire will go to the PROX position on the other input. Tag and calibrate bit tracking (see following paragraphs for procedures). Set the satellite board switch S4 positions 5 and 6 to ON. This is labeled as UNUSED, but is now used for bit tracking. NOTE: bit tracking will not work if the switches are not set correctly and the satellite board has not been re-logged. Verify that the bit and block locations increase as the block moves downward (deeper into the hole). If not, swap the two digital inputs. 3.0 TAGGING SENSORS Bit location and block location variables must be tagged to get bit tracking to work. Tag one variable to one of the sensors and the other variable to the remaining sensor. It does not matter which is which. Also, Hook load must be tagged for bit tracking to work. NOTE: Hook load must be installed in the same Satellite Box as bit tracking. 4.0 CALIBRATION 4.1 CALCULATING THE CALIBRATION VALUE The calibration value for the SG-SMART system is the number of directional pulses that will be received by the system per increment of block movement. Pulses per increment = lines x targets / 3.1415 / diameter
Where: Lines is the number of lines running through the block Diameter is the diameter of the fast sheave with the cable wrapped around it To calculate the total diameter of the fast sheave plus cable, measure from the inside edge of the cable at one side of the fast sheave to the outside edge of the cable on the exact opposite side of the fast sheave, as shown in figure 23. These numbers can be measured directly, or calculated from the sheave and cable manufacturers’ specifications. Another way of calculating the calibration value is to use table 1. Divide the number given in this table by the measured diameter of the sheave to get the pulses-per-increment calibration value.
CALIBRATING BIT TRACKING 1. Calculate the calibration value (pulses-per-increment) as shown above. Either use the manufacturer’s specifications for the fast sheave and cable, or measure directly at the fast sheave to determine the diameter. 2. Install the sensor for hook load, and connect the sensor to one of the analog inputs in the bit tracking satellite box. Hook load is needed for bit location. Block location will work correctly even if no hook load sensor is installed. 3. From the calibration program, calibrate hook load, block location, and bit location. Verify that downward movement causes block location to increase, swapping the inputs at the bit tracking satellite box if necessary. Set the zero location for block location to be at the top of the rig. Set the current bit location. 4. From the user options screen in an SG-SMART monitor, set the minimum slip weight. Verify that bit location does not change while the drill string is in the slips, but that block location does change all the time. 5. Verify that the calibration value (pulses-per-increment) is correct.
4.2 CALIBRATING BIT TRACKING Install the bit tracking sensor assembly and sensor targets on fast sheave, connecting the two digital signals to the two digital inputs in a bit tracking satellite box. Either use the manufacturer’s specifications for the fast sheave and cable, or measure directly at the fast sheave to determine the diameter, and calculate the calibration value (pulses per foot). Install sensor for hook load, connecting the signal to one of the analog inputs in a bit tracking satellite box. Calibrate hook load, block location, and bit location. Verify that downward movement causes block location to increase, swapping the inputs at the bit tracking satellite box if necessary. Set the zero location for block location and set the current bit location. Set minimum slip weight. Verify that bit location does not change with block location while the drill string is in the slips. Verify that the bit location and block location calibration value is correct.
5.0 BIT TRACKING NOTES Once the SG-SMART system is calibrated and ready for operation, the movement of the block will be tracked automatically and displayed in the variable called “BLOCK LOCATION.” The speed of the block will be displayed in the variable called “BLOCK RATE,” in feet per minute. The location of the bit is displayed at “BIT LOCATION,” and the speed of the bit (and the entire drill string) is displayed as “PIPE VELOCITY.” In order to track bit movement as well as block movement, the hook-load sensor must be set up and calibrated, and minimum slip weight must be set properly. Set the minimum slip weight from the monitor program. The minimum slip weight should be set to a value that is slightly higher than the block weight – 10,000 pounds is usually enough. The number used for block weight is the calibrated hook-load reading when the drill string is set into the slips. The important point is to use a number that is enough higher than the hook-load to allow for a small amount of jitter in the hook-load signal, to account for any changed in the hook-load reading due to the block bouncing or picking up another joint. The minimum slip weight should be much less than the hook-load reading during drilling. The system uses the minimum slip weight value to determine when the block is connected to the drill string. When the drill string is not connected to the block the bit moves with the block. A good number for the minimum slip weight is essential for bit tracking to work properly. Bit tracking will not work if any one of the three sensors involved is not working properly: the hook-load sensor or either of the two directional proximity sensors on the bit tracking sensor assembly. An important effect that the use of the minimum slip weight has on bit location is that when the drill string is very short (a few hundred feet), the hook-load remains below the minimum slip weight and the system no longer detects changed in bit location. When tripping in after a complete trip out of the hole, the bit location should be set to known value after the drill string is beyond this threshold. During testing, the bit location often returned to within two or three feet of the correct value after a complete trip out and back in on its own. However, if the bit location is not set to a know value after it starts tracking again (while tripping in); there is no way of knowing how far off it has gotten. During a trip, a “drifting” effect of the block location is likely to be noticed. This happens to both the block location and bit location, but is more noticeable on the block location. The rig crew should be aware of the effect and should be advised to check the bit and block locations after a complete trip, and set them if necessary. To illustrate what is happening, consider the trip-out process. A stand is about to be pulled out and the drill string is in the slips. When the weight of the drill string is put on the cable, the cable stretches very slightly. As the drill string is lifted, the fast sheave rotates far enough to pull the extra length of the stretched, even when the weight of the stand is removed from the cable. The cable only relaxes (un-stretches) between the hook and the first wrap on the draw works drum. As the block is lowered without the weight of the drilling string, the cable relaxes as soon as it comes off the drum. Since it relaxes before it passes the fast sheave, the fast sheave only rotates enough to pull the relaxed cable, which is usually an inch or two shorter than the stretched cable, depending on the cable diameter, hook
load and the number of lines. During this process, the fast sheave rotated “up” in terms of block movement by more than it rotated “down.” The system receives signals indicating that the block position moved upward more than it moved downward, each time a stand is pulled out during the trip. This “drifting” effect accumulates over the entire trip out and can cause the block location to appear noticeably higher than the block really is. A properly zeroed block location might drift upward by twenty of thirty feet during an entire trip out from 10,000 feet. During the trip in, the opposite effect happens, and the block location drifts back down to very near its value before the trip out. Unlike the non-directional depth sensor, the bit tracking sensor does not need to have a minimum bit weight to determine depth while drilling. This value is used to determine when the bit is on bottom and actually drilling. In non-directional depth sensing, the system ignores depth pulses which are received when the bit weight is below the minimum bit weight. Inside the bit tracking satellite box, the directional pulses received on the digital inputs are accumulated and reported for the block location. The hook load must be connected to one of the eight analog inputs in the bit tracking satellite box. This ensures that no further changes are made to the bit location when the hook load drops below the minimum slip weight. The signals from the two bit tracking proximity sensors should be connected so that the block location operates this way. Thus, the zero point for bit location is at the surface, and the zero point for the block location is at the top of the derrick. This means that on a three stand rig when the block is at its lowest position, the block location should read 90 feet. If the bit and block locations are working in reverse (increasing when the block moves up and decreasing when the block moves down), swap the digital connectors in the bit tracking satellite box. The bit tracking satellite box is a modified version of a standard satellite box. The circuit board has a capacitor (C13) removed from the component side, and a jumper wire installed on the other side. The directional pulses occur at much higher rates than most other digital signals, and this change adjusts the de-bouncing circuitry specifically for these higher rates. Make sure this modification is in place on any board put into service in a bit tracking satellite box. A board that has been modified for bit tracking will not work with any satellite box software earlier than version 5.1. However, this board can be used with standard satellite box software versions 5.1 and above. APPENDIX M INSTALLATION AND IDENTIFICATION DRAWINGS Refer to the following drawings for proper installation of intrinsically safe components of the S.M.A.R.T. System.