Top Drive Electric Manual

Top Drive Drilling Equipment
Electric Manual
Model DQ70BSC
Serial No
06032
Preface
The design, manufacture and service of this product are based on the following quality
assurance system:
GB/T19001:2000 idt ISO9001:2000 Quality Management System-- Requirements
API Spec Q1 Specification for Quality Programs for the Petroleum and Natural Gas Industry
This manual contains information relating to Top Drive operation, service and maintenance.
The technical information of this product is included respectively in the following documents:
<Operation Manual>
<Electric Manual>
<Hydraulic Manual>
< Installation and Trouble Shooting Manual>
<Maintenance Manual>
<Electric House Manual>
<HSE Manual>
<Data Backup and Recovery Manual>
<Electric Drawing>
<Mechanical Drawing>
<Hydraulic Drawing>
With individualized design provided for the Top Drive based on the service operating
condition and special requirements of the customers, the technical document for this product
may not be suitable for the other products of the same type. Product type and No. shall be
checked when the technical document is used.
For information not covered by the accompanying documents and other problems arising
from the installation, operation and maintenance, contact the manufacturer if necessary:
BPM
Beijing Petroleum Machinery Factory
Ads:
No.41, Zhixin Road, Haidian District, Beijing P.R China
Postcode:
100083
Tel:
( 010) 62097381
Fax:
( 010) 62097613
E-mail:
Bpm.zhaojing@vip.163.com
-I-
Contents
1.
Summary ....................................................................................................................1
2.
Safety notice ...............................................................................................................2
3.
Main specification ......................................................................................................4
3.1.
Basic specification......................................................................................................4
3.2.
Motor specification.....................................................................................................4
3.3.
Drilling parameter.......................................................................................................4
4.
Electric control system................................................................................................5
4.1.
The introduction of Top Drive.....................................................................................5
4.1.1. Top Drive assembly ....................................................................................................5

4.1.2. Top Drive structure.....................................................................................................6
4.1.3. Top Drive Communication..........................................................................................7
4.1.4. The curve of motor output torque and rotating speed...................................................7
4.2.
Electric House ............................................................................................................8
4.3.
AC variable frequency drive system............................................................................9
4.3.1. Rectifier cabinet..........................................................................................................9

4.3.2. Inverter cabinet ......................................................................................................... 11
4.4.
PLC/MCC ................................................................................................................12
4.5.
Local control box (LCB)...........................................................................................14
4.6.
HPU Control Box .....................................................................................................15
4.7.
Driller Console .........................................................................................................17
4.8.
Auxiliary Control Box (Option) ................................................................................21
4.9.
Main power cable .....................................................................................................22
4.10. Other cables..............................................................................................................23

4.10.1. LCB control cable.....................................................................................................23
4.10.2. HPU control cable ....................................................................................................23
4.10.3. Driller Console control cable ....................................................................................24
4.10.4. Auxiliary control box cable (option) .........................................................................24

4.10.5. Earth cable................................................................................................................24
5.
Operating procedure .................................................................................................25
5.1.
Start/stop electric control system...............................................................................25
5.1.1. Checking before start ................................................................................................25

5.1.2. Power on procedure ..................................................................................................25
5.1.3. Startup system ..........................................................................................................25
5.1.4. Stop system ..............................................................................................................26
5.2.
Start/stop of hydraulic system (HPU) ........................................................................27
5.2.1. HPU local control .....................................................................................................27

5.2.2. HPU remote control..................................................................................................27
5.2.3 Hydraulic system cooling..........................................................................................28
5.3.
Main motor heating...................................................................................................29
5.4.
Main motors cooling fan..........................................................................................30
5.5.
Brake........................................................................................................................31
5.6.
Drilling operation .....................................................................................................32
5.6.1. Drilling operation procedure .....................................................................................32

5.6.2. Reverse drilling under Drill Mode.............................................................................34
5.6.3. Speed control and torque control...............................................................................35
5.6.4. Stop drilling..............................................................................................................35
5.7.
Make-up/break-out operation....................................................................................36
5.7.1. Make-up operation....................................................................................................37

5.7.2. Break-out operation ..................................................................................................38
5.7.3. Release reactive torque .............................................................................................39
5.8.
Rotating head lock operation.....................................................................................40
5.9.
Link operation ..........................................................................................................41
5.10. IBOP operation .........................................................................................................42

5.11.
E. Stop......................................................................................................................43
5.12. Fault/Alarm ..............................................................................................................44

5.13. Encoder switch .........................................................................................................46
5.14. Running without encoder ..........................................................................................46
5.15. Local Control Box Cable operation .......................................................................47
5.15.1. Start Cable operation .............................................................................................47
5.15.2. Stop Cable operation .............................................................................................47
5.16. Driller Console emergency operation ........................................................................48
5.16.1. Start Em-operation....................................................................................................48
5.16.2. Stop Em-operation ....................................................................................................48
6.
Remote communication and diagnostic (self-select part)...........................................49
6.1.
Diagnostic setting .....................................................................................................49
6.2.
SINAUT TIM4R module ..........................................................................................50
6.3.
GSM kit....................................................................................................................52
7.
Windows Control Center (WINCC) ..........................................................................53
7.1.
Operation picture function ........................................................................................53
7.2.
System help ..............................................................................................................54
7.3.
Power system............................................................................................................55
7.4.
Top Drive system......................................................................................................56
7.5.
Network structure .....................................................................................................57
7.6.
Control status............................................................................................................58
7.7.
Auxiliary system.......................................................................................................59
7.8.
Trend curve picture...................................................................................................60
7.9.
Alarm logging...........................................................................................................62
7.10. System logon ............................................................................................................63

7.11.
Setting function ........................................................................................................64
7.12. Exit system ...............................................................................................................65

8.
System software and hardware..................................................................................66
8.1.
PLC system hardware ...............................................................................................66
8.2.
Program download or upload ....................................................................................70
8.3.
PROFIBUS network system .....................................................................................71
8.4.
Distribute I/O station and communication module.....................................................72
8.4.1 ET200X distribute I/O station ...................................................................................72

8.4.2 ET200M distribute I/O station ..................................................................................74
8.4.3 Optical fiber connection module/ OLM.....................................................................75
8.4.4 REPEATER ..............................................................................................................77
8.5.
Variable frequency drive system ...............................................................................79
8.5.1 Rectifier....................................................................................................................79
8.5.2 Inverter.....................................................................................................................81
8.6.
Parameter upload and download for Rectifier and Inverter........................................83
8.7.
Trouble shooting.......................................................................................................84
8.7.1 Air switch diagnosing ...............................................................................................84

8.7.2 Earth fault.................................................................................................................84
8.7.3 PLC fault checking ...................................................................................................84
8.7.4 Network checking.....................................................................................................85
8.7.5 Drive system.............................................................................................................85
8.8.
System Power Down and Disconnection...................................................................86
9.
Installation, troubleshooting and maintenance...........................................................87
9.1.
Electric System Reinstallation...................................................................................87
9.2.
Power on and Checking ............................................................................................88
9.3.
Daily maintenance ....................................................................................................89
Drive cabinet initial state......................................................................................................90

PLC/MCC cabinet initial state..............................................................................................90
Driller Console initial state...................................................................................................90
Auxiliary Control Box initial state........................................................................................91
HPU Control Box initial state...............................................................................................91
BPM Top Drive
Electric Manual
1. Summary
Top Drive Drilling Equipment (short for Top Drive), it is a new-type petroleum drilling
equipment which replaces rotary table. Its a high-tech product which is integrated with
machinery, electric and hydraulic system. It is a very important work for trouble shooting,
operating and maintaining the electric system.
The electric system of BPM Top Drive which is installed, operated and maintained, that need
one personnel who have certain qualifications or have enough experience. It is the customers
obligation to train above-mentioned capacitates personnel.
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BPM Top Drive
Electric Manual
2. Safety notice
This manual uses the following warning sign
Notes:
This sign is used for additional notes for matters relating to

bodily and equipment safety.
Caution:
This sign is used for prompting a condition that may lead

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

likely lead to bodily or equipment damage.
The following safety notices are very important for correct install, operate, maintain of Top
Drive, all the operators must read it carefully and understand it:
a) Do not work with power on, include: dont open safeguard with high voltage; dont
repair or dismantle any electrical device with power on, dont plug in/out each cable
connector with power on.
b) Dont open the junction box or Driller Console under having flammable gas
environment.
c) Do not try to change the DC fuse between DC bus and Inverter when Rectifier is
working or DC voltage is above safety range (DC 24V), It is dangerous for human
safety and electrical equipment!
d) If need maintain Rectifier, motor or Inverter, please turn main switch (3WL) to right
side (lock position), in order to prevent faulty operation.
e) The insulation of Inverter and Rectifier cant be checked by high-resistor meter or
else the high test voltage will damage the equipment.
f)
Driller Consoles protection air must keep pressure when power on! When air lost,
filling gas as quickly as possible and shut down the control power of Driller Console!
g) Each motor and control box should be correctly connected to PE connector in

Electric House!
h) Forbid to bypass the safety interlock of Top Drive System. If necessary, recover
bypass function of interlock as soon as possible after having solved the problem.
i)
Forbid unprofessional person change any parameter of each Rectifier and Inverter,
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BPM Top Drive
Electric Manual
otherwise may damage the mechanical or electrical equipment!

j)
When temperature is more than 40, and humidity percent is higher than 95% or
dew exists, dont start drivers or switch on control power before starting air
conditioning to lower down the temperature and decrease wet.
k) When system main power shut down by accident for more than half an hour, before
restart the system, must make sure that there is no dew in Electric House.
l)
Under the moist environment, when electric house temperature is lower than the
outside, forbid long time opening the electric house door, otherwise may produce dew
on the electric equipments!
In this manual, the words with indicates that it is an operating parts
of the electric system.
As for the installation, trouble shooting, operation and maintenance of
Top Drives electric system, the operator should read the manual before
operating. For continuous improvement and changing, you must check
the product serial number printed in the cover of this manual to ensure
that the product confirming to the technical manuals.
Unprofessional person not being specially trained can not do the work
of installation, trouble shooting, operation and maintenance. It may
damaged to the body or equipment. During operation, it is not permitted
to repair and maintain.
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BPM Top Drive
Electric Manual
3. Main specification
3.1. Basic specification
Supply voltage
600 V AC
Rated current
445 A 2
Max. Current
770 A 2
Ambient temperature
35 +55
Altitude
1200 m
3.2. Motor specification

Rated power
400Hp 2, S1
Rated rotating speed
1150 rpm
Max. Rotating speed
2400 rpm
3.3. Drilling parameter

Main shift of rotating speed
0220 rpm
Working torque (S1)
50 kN.m0 ~ 110 r/min
Max. Torque1min
75 kN.m
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BPM Top Drive
4.
Electric Manual
Electric control system
4.1. The introduction of Top Drive

4.1.1. Top Drive assembly
Top Drive drilling equipment is Power Converter, Pipe Handler Device, Electric drive and
control system, Hydraulic system, Driller Console, Auxiliary Control Box, etc.
Local control box
Auxiliary control box
Top Drive
Driller Console
Electric house
Auxiliary
control cable
Main power
cable
HPU
The electric control system mainly includes AC variable frequency drive system and
PLC/MCC system, and mainly consists of drive cabinet, PLC cabinet, Driller Console,
Auxiliary Control Box, Local Control Box, HPU Control Box, main power cable, auxiliary
control cable, etc. The Drive is SIEMENS SIMOVORT MASTERDRIVERS 6SE70 serial
product, with the variable frequency speed regulation system, drive two 400 hp AC variable
frequency motors, which could work together (master/slave) or separately. The whole system
possesses perfect diagnosing and protecting function, could realize all operations of Top
Drive.
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BPM Top Drive
Electric Manual
4.1.2. Top Drive structure

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

separate generator to supply power for Top Drive system.
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BPM Top Drive
Electric Manual
4.1.3. Top Drive Communication

There are two kinds of control and communication methods between PLC system and control
stations: Cable connect; Profibus cable connect.
As for cable connect, PLC communicates with control stations by cable directly. The station
contains HPU and Local Control Box.
As for Profibus cable connect, PLC communicates with control stations and drive systems by
PROFIBUS-DP. PLC connects with other stations by SIEMENS PROFIBUS communication
cable. PLC is Siemens SIMATIC S7-300 serial: CPU is 315-2DP. Driller Console station
adopts ET200M I/O.
H-type network drawing:
4.1.4. The curve of motor output torque and rotating speed

See Fig1: when theDrilling Torquesetting is 35 kN.m, the red color curve shows the
relation between the output torque and rotating speed.
Torque continuous kN.m
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BPM Top Drive
Electric Manual
4.2. Electric House

The electric house, with AC variable frequency drive cabinet and PLC/MCC cabinet installed
inside For detail information, please refer to <Electric House Manual>.
Whether the temperature is too high or too low will lead to system damage.
A suitable temperature and humidity inside is very important for Top Drives
safe running. High humidity will lead to elements defective insulation and
short circuit, also damage the equipment.
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BPM Top Drive
Electric Manual
4.3. AC variable frequency drive system

AC variable frequency drive system, includes Rectifier cabinet, Inverter cabinet and relevant
control circuit, it could provide power for AC frequency motor of Top Drive.
4.3.1. Rectifier cabinet
The Rectifier cabinet is made up of Power In part and Rectifier part.
Power In cabinet includes main air switch, transformer, insulation meter, line reactor, voltage
meter, current meter, etc. It provides power for Rectifier cabinet and PLC/MCC cabinet.
Rectifier cabinet includes Rectifier, current meter, voltage meter, etc.
When main air switch is power on, the rectifier unit will work to transfer 600V power comes
from Power In cabinet to 810V for DC bus.
Aux.Current
Input Voltage
Control
Earth Fault
Power On
DC Current
DC Voltage
E.Stop
Main Air Switch
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Voltage Select
BPM Top Drive
a)
Electric Manual
Meter
Input current: show the current value of 600V main power supply.
Aux. current: show the current value of auxiliary power supply.
Input voltage: show the voltage value of every phase of main power.
DC current: show the output current value of the Rectifier.
DC voltage: show the output value of the Rectifier.
b) Indicator light
Control power: this indicate light will on if control power (220V) is power on.
Earth fault: if system insulation faults, the light will on.
Power on: when main air switch in Power cabinet is closed, this indicator light will on.
c)
Button
Voltage Select: show the three-phase voltage of Power In power supply.

E. Stop: be used to emergency stop of Top Drive System(normally closed).
All E.Stopbuttons are interlocked, press one of E.Stopwill Stop the system.
If Top Drive was just shut down, during a period of time, the Rectifier cabinet will
discharge high voltage large capacitance. So, at this time, it is forbidden to open
Rectifier cabinet door.
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BPM Top Drive
Electric Manual
4.3.2. Inverter cabinet

Inverter cabinet is made up of Inverter, output reactor, brake unit, etc.
Output Current
Encoder Select
a)
Output Voltage
E.Stop
Meter
Output current: show the output current value of Inverter.
Output voltage: show the output voltage value of Inverter.
b) Switch and button

Encoder Select: used to switch encoder.
E.Stop: used to stop system promptly (normally closed)
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BPM Top Drive
Electric Manual
4.4. PLC/MCC
PLC/MCC includes PLC and AC/DC power distribution system.
a)
Meter
Make Up Counter: show make up counter times.

Cumulative running time: show Top Drive main motors cumulative running time.
b) Indicator light
System ready: WhenSystem Startswitch is on, but system doesnt ready, this indicator
light will Flash, When main air switch is on, and system is ready, the indicator
light will on constantly.
Heat: When main motor heater is running, the indicator light will on.
Fault: When system has alarm, this indicator light will flash. If fault happens, the indicator
light will on constantly. When error reset, its off.
Encoder fault: When system is running without encoder, the indicator light will on.
c)
Manual switch
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BPM Top Drive
Electric Manual
System StartWhen system was power on, this switch could realize systems start; start
Rectifier and main air switch, etc.
Control ModeSelect the control mode..:By pass, Profibus. Or Cable. Mode.
IBOP DisableWith this switch,the IBOP couldnt close except Well Control.
This switch is used to insure right operation of IBOP and safe of work at
unusual task.
Do not disable IBOP at usual drilling task to insure it can be close when it is
needed.
Encoder FaultWith this switch, system could run without encoder if the two encoders
were fault.
Motor HeaterWith this switch, motor heater could work independently without PLC.
When motor is running, heater is forbidden to run by PLC logical.
ResetIt has reset and silence function.
E. StopBe used to stop system promptly. All E.Stop in electric system are interlocked.
d) Industry PC
There is one Industry PC in PLC cabinet, and its self-contained display screen, mouse, and
keyboard are all in the electric house. This Industry PC is used to monitor and debug Top
Drive system.
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BPM Top Drive
Electric Manual
4.5. Local control box (LCB)

The Local Control Box (LCB) is fixed on main body of Top Drive. It provides AC and DC
power for main motors cooling fan, motor heater, magnet valve, etc. Also it could read the
signal from main motor, temperature sensor, gear box (for instance: oil temperature), etc.
The LCB adopts ET200X module, which have high-grade protection IP65; with
self-diagnostic function, which could be used in harsh environment. Insides this box there is a
heater, which makes LCB could work in low temperature; LCB adopts optical fiber to
communicating with CPU in PLC/MCC cabinet. The fiber has good anti-interference ability;
Control cables from LCB are all shielding and have good anti-interference ability, so they
could be reliable to control accurately.
Local Control Box
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BPM Top Drive
4.6.
Electric Manual
HPU Control Box
Hydraulic Control system is in HPU Box. It controls two hydraulic pumps (one use and one
backup) and one hydraulic oil cooling fan. The two pumps could be started locally or
remotely by Driller Console, but the local control has the priority. There is motor protector in
front of hydraulic pump motor, through setting protective current, which could realize protect
motors overload, current leakage, etc.
HPU Control Box panel:
Power On
Pump A
Cooling Fan
a)
Power
Pump Select
Pump B
HPU Pump
Indicator light
Power on: when 380V power supply is ready, this indicator light will on.
Pump A: When pump A is selected, this indicator light will on.
Pump B: When pump B selected, this indicator light will on.
b) Manual switch
Pump Select:Select pump A or pump B.
HPU Pump:Be used to control hydraulic pump locally. Turn to on means local start HPU
pump; turn to off means stop running HPU pump; turn to auto means Driller Console will
control the HPU Pump remotely.
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BPM Top Drive
Electric Manual
Cooling Fan: Be used to control cooling pump. Turn to on means local start cooling fan;
turn to off means stop running cooling fan; turn to auto means PLC will remote control the
cooling fan.
Powerswitch: Be used to control HPU Control Boxs 380V power supply. Turn to on
means HPU Control Box is power on; turn to off means HPU substaition is power off. When
power is off, coil in terminal line, Q52, S4, K1 still have electric power, and ET200X also has
electric power.
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BPM Top Drive
Electric Manual
4.7. Driller Console

The Driller Console has all basic functions that drilling demands; it adopts ET200M module,
and could realize speed setting, torque setting, operation mode and all auxiliary operations.
Driller Console has three alarm/fault indicator lights, which could notice different kinds of
alarm/faults through different kinds of combinations.
The Driller Console is explosion proof ExpniaIIT4; it could work only when shielding gas
pressure is ready. On side face, there is a gas supply element for control the Driller Consoles
power by achieve a certain pressure inside.
The preset pressure of air supply element pressure reducing valve is
0.015MPa. Timely inspect and remove the accumulated water in wate/air filter
is necessary.
Incorrectly preset the pressure of pressure reducing valve, may result in
Driller Console Boxs pressure too high, and finally damage the elements in it
or even hurt the operator.
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BPM Top Drive
No
Indicator light
Electric Manual
Type
Function
If hydraulic pump runs normally, it will on.
Pump Running
Green indicator light
If pressure lower than normal value, it will flash.

If communication is interrupted or hydraulic pump stop
running, it will off.
This indicator light (2HZ) will become flash quickly
Locking
Red indicator light
when the switch is in lock.

This indicator light will become on after finish locking
operation.
If the indicator light is on, it means IBOP is closed.
IBOP
Red indicator light
Brake
Red indicator light It lights when brake is working.
If the indicator light is off, it means IBOP is opened.
This indicator light will flash when Driller Console is

5
Ready
Green indicator light power on but system not ready. When system start and
everything is ready, it will on constantly.
6
7
Through combination, these three light are used to

Fault/Alarm
Red indicator light indicate alarms and faults. For detail information,
please refer to Fault/alarm section of Chapter 5.12.
No
Meter
Type
Torque
Meter
10
Speed
Meter
No
Switch
Type
HPU
11
12
Run/Stop
E. Stop
Function
Show actual output torque of head shaft with unit being
kN.m.
Show actual output speed of head shaft with unit being
r/min.
Function
Turn to run, pump will run.
three-position switch Turn to stop, pump will stop running.

Turn to autopump will run according to pressure.
mushroom button
If press this button, drive unit will stop running, after a

short time, main air switch will be open.
Turn to lock means lock the rotating head.
Turn to unlock means unlock the rotating head.
13
Locking Pin
unlock/lock
two-position switch
Lockingindicator light could show the status of

rotating head.Link Rotationis invalid if already
operate Lock Pin.
14
Link Rotation
three-position switch Spring reset key, turn back to middle position

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BPM Top Drive
Electric Manual
automatically. This switch is used to operate rotating
ccw/stop/cw
head: ccw/stop/cw
15
Clamp
three-position switch
16
Auxiliary
two-position switch
17
Link Center
Black button
18
Link Incline
Rear/stop/Front
Turn this switch to clamp, Backup Tong will keep

clamp, it will reset when loose.
If this switch is on, the C-Box on monkey board could
operate the Pipe Handler Device. Otherwise not.
Press this button, the elevator link will on float.
Spring reset key, turn back to middle position
three-position switch automatically. The switch is used to realize the elevator

rear/front operation.
This switch is used to control main motors cooling
19
Air Cooling
On/Off/Auto
fan. Turn to auto, air cooling fan will be controlled by

procedure in PLC. Turn to on, cooling fan will start.
Turn to off, it will stop.
IBOP
20
Open/Close
Combination with the mud pump switch on signal.

two-position switch On open position, means open the IBOP valve gate.
On close position, means close IBOP valve gate.
Select motors work mode of Top Drive.
Motor
21
A/AB/B
Turn to A, motor A will work.

Turn to B, motor B will work.
Turn to A+B, two motors will work simultaneously.
Brake
22
off /Auto/ On
on means brake is working; off means brake is

three-position switch open; and auto means brake will work according to
PLC program.
Operation
23
Drill/Spin/Torque
Be used to choose the operation mode: drill, spin or

torque. Drill in zero position is the (initial state).
When alarm, press this button will stop the sound.
24
Reset/Silence
black button
After resolving system faults, press this button again

will reset the alarm or fault. Keep on press it for three
seconds will test all indicator lights.
Direction
25
Ccw/Stop/Cw
Be used to choose the motors direction. Stop position

is the initial state.
Be used to set a max torque for make up operation.
Under two motors working condition, full range torque
26
Makeup Torque
potentiometer
is 50kN.m; and under one motors working condition,

full range torque is 25kN.m. If set value is higher than
25kN.m, systems output torque will keep on 25kN.m.
27
Drilling Torque
potentiometer
Be used to set a max torque for drilling operation.

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BPM Top Drive
Electric Manual
Under two motors working condition, full range torque

is 50kN.m; and under one motors working condition,
full range torque is 25kN.m. If set value is higher than
25kN.m, systems output torque will keep on 25kN.m.
Be used to set drilling rotation speed.
28
Throttle
Potentiometer
Speed range is 110rpm or 220rpm. Different rated

speed could be realized bySpeed Rangeswitch on
Wincc system.
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BPM Top Drive
Electric Manual
4.8. Auxiliary Control Box (Option)

The Auxiliary Control Box, connects to electric house by cable, which is explosion proof, and
used for operating elevator link rotating device and incline device on monkey board. If Driller
Console Auxiliaryis on, Auxiliary Control Box will be valid, and Driller Consoles same
operation will be invalid.
The Auxiliary Control Box is shown as below:
Enable
Link Center
Link Incline
a)
Link Rotation
Indicator light:
Enable indicator: when Driller ConsolesAuxiliaryswitch is on, the indicator will on, this
means Auxiliary Control Box will be enable.
b) Manual switch:
Link Inclineswitch: Be used for link incline operation.
Link Rotationswitch: Be used for link rotating operation.
Link Centerpushbutton: Press this button, the elevator link will on float (center).
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BPM Top Drive
Electric Manual
4.9. Main power cable

The main power cables are used to connect the Inverter with Top Drives two main motors.
For installing and connecting easily, the cable has three parts:
a)
Ground cable (option): 38m, from electric house to the bottom of derrick.
b) Derrick cable: 38m, from the derrick bottom to supporter nearby monkey board.
c)
Traveling cable: 30m, from the supporter to main motor.
Quick connectors are used among three-cables, between main power cable and main motor,
also between main power cable and main control cabinet. This is very convenient for install
on local well site. They are shown as below:
Electric house
Top Drive
Plesse insure the cable connection is dependable, and avoid entrance of rain.
To avoid connector loosing or even destroying, timely check and maintain all
cables and their plugs/connectors is very importance because of bad
environment and complex drill condition on well site (check and maintain
period should be not more than five days).
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BPM Top Drive
Electric Manual
4.10. Other cables

4.10.1. LCB control cable
LCB control cable is multi-core cable, with quick connectors and very convenient for install
on well site. LCB cable includes two sections:
a)
A: 12-core power cable, provide 380V and 220V power for air cooling fan and heater.
b) B: 67-core shielded cable, used to transfer LCB 24V DC control power supply, manual
signal, and main motor encoder signal.
Plesse insure the cable connection is dependable, and avoid entrance of rain.
4.10.2. HPU control cable
The main power (380V) of HPU Control Box is from PLC/MCC cabinet, it connect with
electric house by use of quick connector which could be connected easily. HPU Control Box
control cable includes control signals (digital signals) cable and analog sensor (analog signals)
cable, its two sides use plugs.
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BPM Top Drive
Electric Manual
4.10.3. Driller Console control cable

There are four control cables for Driller Console, and cables two sides all use plugs:
a)
X1: it sends manual signal of Driller Console to PLC/MCC cabinet, used for emergency
operation.
b) X101: provides 24V control power for Driller Console, send signals of well control and
emergency stop.
c)
X102: shielded cable, used for output signal of Top Drive speed / torque (4-20mA
current).
d) X200: the festoon cable of Profibus communication, the ability of anti-interference is

very strong.
4.10.4. Auxiliary control box cable (option)
Auxiliary control box cable is one piece of cable, used to connect Auxiliary Control Box with
Electric House.
4.10.5. Earth cable
The electric system adopts two earth cables (each 5m) with two earth bars (1.8m) for
protection. Note: earth bar resistance must be less than 4 ohm, fix in deep earth and it is
necessary to water it timely to keep wet.
Galvanized earth bar shows as below:
Timely measure earthing resistance with megger, makes sure that earthing is
well.
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BPM Top Drive
Electric Manual
5. Operating procedure
5.1. Start/stop electric control system
5.1.1. Checking before start
Before starting electric system, should check the following items:
a)
Check the mechanical and hydraulic system first. Make sure that they are ready.
b) Check all operation cabinets and meters of electric system and Driller Console; ensure
they are in initial status. (Refer to appendix 1).
c)
The indicators on Driller Console could be tested by press the button of Reset/Silence
for three seconds.
5.1.2. Power on procedure

Ordinal close each degrees power switches, check line voltage, auxiliary voltage transformer,
control voltage transformers output voltage, and SITOP output power.
Make sure that all switches have been power on (except main air switch Q1,Q2), and the
power supply is in good condition.
5.1.3. Startup system
TurnSystem Startswitch on PLC/MCC cabinet to on, the system ready indicator light
will flash, and then the Rectifier begins to run, after a short time, the corresponding Rectifier
cabinets main air switch will power on. 600V power supplied to Rectifier, Inverter will run
when Driller Console gives an enable signal, and then Top Drive is ready.
When electric system is ready, at the same time the system ready and ready indicator light
on Driller Console will on constantly. Enable signal from Driller Console will startup the
Inverter.
The operation of system start will invalid if the system is not in initial status!
When system is running, operating System Startswitch on PLC/MCC cabinet

will cause fault stop.
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BPM Top Drive
Electric Manual
5.1.4. Stop system

Stop electric system:
a)
Turn Throttlehandle of Driller Console to zero, and turnDirection switch to the

Stop position. Inverter will stop and Top Drive will stop running.
b) TurnSystem Startswitch to off. The main air switch will disconnect when Rectifier
accept system stop signal, then, the system will stop running.
The power only can be shut off after the main air switch was opened.
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BPM Top Drive
Electric Manual
5.2. Start/stop of hydraulic system (HPU)

5.2.1. HPU local control
Start HPU locally:
a)
Operating thePump Selectswitch on HPU to A or B.
b) Turn HPU Control Box Powerto on.

c)
When Power On indicator light is on, turn HPU Pumpto on, the selected pump will
run, and Pump A Running or Pump B Running indicator light will on. When
communication is well, Pump Runningon Driller Console will on.
Stop HPU locally:

a)
Turn the HPU Pumpswitch to off, the pump will stop running, and indicator light
will off.
b) If HPU pump keep stop for a long time, operator should turn Poweron HPU Control
Box to off.
Compared with remote operation by Driller Console, local operation on HPU
has priority. When checking or repairing, it is important to disconnect power
supply to ensure personnel and equipment safety.
When HPU pump on local control mode, E_Stopoperation cannt stop the
HPU pump.
5.2.2. HPU remote control
When communication is well, Driller Console remote control HPU procedure:
a)
Turn HPU Control Box Powerto on.
b) Use HPU panel to select pump A or B.

c)
Turn HPU Pump to auto, set HPU pump to remote control.
d) Turn HPU on Driller Console to run, could start the selected pump. TurnHPU
on Driller Console to stop, could stop the selected pump. If turn to auto, the pump
will run automatically when pressure is lower than 14Mpa, while pump will stop
automatically when pressure is higher than 16Mpa.
e)
If HPU keep stop for a long time, operator should turn HPU Control Box Powerto
off.
When HPU pump on remote control mode, E_Stopoperation will stop the
HPU pump. If need pump running, control the pump locally.
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BPM Top Drive
Electric Manual
5.2.3 Hydraulic system cooling

HPU Cooling Fan has two control modes: Auto and Manual. Operate Cooling Fan could
realize switch its modes.
Turn to on means manually startup the cooling fan.
Turn to off means manually stop the cooling fan.
Turn to auto means the cooling pump will be controlled by oil temperature logic in PLC
program.
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BPM Top Drive
Electric Manual
5.3. Main motor heating

When main motors are not running, switch Motor Heaterof PLC/MCC cabinet to on
could startup the heater of two main motors. The Heat on PLC/MCC will show the status of
motor heater.
In PLC logic, heater and motors running are interlocked. Namely when main motors are
running, heater is forbidden to work; if start main motor when heater is working, the heater
will stop automatically.
If it has been rained for a long time outside or Top Drive has not been worked
for a long time, it is necessary to start heaters to enhance motors insulation
before starting motors. So that two motors could work safely.
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BPM Top Drive
Electric Manual
5.4. Main motors cooling fan

Two air cooling fans are installed on the top of main motors.
The on position of Air Coolingon Driller Console could startup the air cooling fan
directly. If Air Coolingswitch is on off position, after delay time, the main motors
cooling fan will stop. But when motors are running, no matter which position ofAir
Cooling, the air cooling fan will not stop.
When Air Coolingswitch is on auto position, before Top Drive start running, system
preset main motors corresponding cooling fan will start.
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BPM Top Drive
Electric Manual
5.5. Brake
The brake function could only be used under Drill Mode. When receive brake signal, the
Brake indicator light will on constantly. When receive stop brake signal, the Brake
indicator light will off.
TurnBreak switch to On before motors running, motors will output torque equal to the
scale of Drilling Torque, but no speed.
If motors are running, turn Breakswitch to On, motors will reduce its speed. When the
speed is suitable, brake will work to stop the motor.
When Breakis on auto, Top Drive main motor will startup, and brake will release
automatically after a practical torque is founded. When stopping system, brake will work and
hold on brake state after speed lower down to a suitable range; If system work mode will
change from Drill Mode to Spin Mode, and motor brake will open automatically.
WhenBrakeis off, Top Drive could be started, when stopping system; main motor will
decrease its speed and keep on zero speed, brake will not work.
When Break switch is on Off position, Top Drive could start or run
normally, but when system stops, brake will not work automatically.
When fault happens and system stops emergently, system will reduce its
speed quickly. When speed is suitable, brake will work to keep on brake status.
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BPM Top Drive
Electric Manual
5.6. Drilling operation

5.6.1. Drilling operation procedure
Check the system before operating, follow chapter 5.1 to startup system correctly. Make sure
that system is in following status:
Name
Button or Switch
Status
Driller Console
Brake
Auto
Driller Console
HPU
Run
Driller Console
Locking
Unlock
Driller Console
Link Rotation
Center position
Driller Console
Link Incline
Center position
Driller Console
IBOP
Open
Driller Console
Auxiliary
Off
Driller Console
Air Cooling
Onor Auto
Driller Console
Operation
Drill
Driller Console
Direction
Stop
Driller Console
Makeup Torque
Zero position
Driller Console
Drilling Torque
Zero position
Driller Console
Throttle
Zero position
Driller Console
Clamp
Center position
HPU Control Box
Power
ON
HPU Control Box
ON OFF AUTO
AUTO
HPU Control Box
Cooling Fan
AUTO
Follow below items:

a)
Make sure that HPU pump runs normally, when communication is well, Pump Running
indicator light on Driller Console will on constantly.
b) Set speed range on the Wincc system.

c)
Operating the Motor switch to select motors (motor A or motor B or motor A+B).
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BPM Top Drive
Electric Manual
d) Slowly turn Drilling Torqueswitch to a need torque.

e)
Operating the Direction switch to select cw position.
f)
Turn Throttleslowly away from zero position, the main motor will rotate clockwise
with the speed given by Throttle.
Only system is not working andThrottleis on zero position, Operation
switch is valid. Otherwise, Operationswitch is invalid.
Only system is not working andThrottleis on zero position, Direction
switch is valid. Otherwise, Directionswitch is invalid.
Only system is not working,Directionis on stop position, andThrottle
is on zero position, theMotorswitch is valid. Otherwise, Motorswitch
is invalid.
If the operation of Motoror Operationhas a mistake, the system will
give a three seconds sound alarm but no light alarm; After system returning to
normal, this sound will disappear.
Throttle, Drilling torqueandMakeup torquehandle back to zero
position, means set these switches to left end (throttle no input data).
When startup main motors, for safety, the presetDrilling Torquevalue
shouldnt be very high. After the main shaft begin to rotate, operator could
increase Drilling Torquevalue at this time.
Before startup the main motor, make sure that Brake is in right status and
Drilling Torquevalue is right.
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BPM Top Drive
Electric Manual
5.6.2. Reverse drilling under Drill Mode

In normal condition, it is not permitted to do drilling ccw. But in order to solve some complex
working conditions, Top Drive has the function of drilling ccw, which needs to do some
setting in the Wincc system.
Check the system before this operation, follow chapter 5.1 to startup system correctly. Make
sure that system is in following status:
Name
Button or Switch
Status
Driller Console
Brake
Auto
Driller Console
HPU
Run
Driller Console
Locking
Unlock
Driller Console
Link Rotation
Center position
Driller Console
Link Incline
Center position
Driller Console
IBOP
Open
Driller Console
Auxiliary
Off
Driller Console
Air Cooling
Onor Auto
Driller Console
Operation
Drill
Driller Console
Direction
Stop
Driller Console
Makeup Torque
Driller Console
Drilling Torque
Zero position
Driller Console
Throttle
Zero position
Driller Console
Clamp
Center position
HPU Control Box
Power
ON
HPU Control Box
ON OFF AUTO
AUTO
HPU Control Box
Cooling Fan
AUTO
Zero position
Follow below items:

a)
Make sure that HPU pump runs normally, when communication is well, Pump Running
indicator light on Driller Console will on constantly.
b) Set speed range in the Wincc system. After logon, operate DRILLING_CCW
SETTINGbutton could realize drill ccw under Drill Mode. If successful, this button will
become red color.
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BPM Top Drive
c)
Electric Manual
Operating the Motor switch to select motors (motor A or motor B or motor A+B).
d) Slowly turn Drilling Torqueswitch to a need torque.

e)
Turn Directionswitch to ccw when Throttleis on zero position and system is not
running.
f)
Turn Throttle slowly away from zero position, the main motor will rotate
counterclockwise with the speed given by Throttle.
g) Logout Ccw Mode on Wincc after finishing ccw drill operation.

When drilling ccw under Drill Mode, pay more attention to drilling torques
preset value, in order to avoid drill pipe back out and accident.
5.6.3. Speed control and torque control
During drilling, when actual torque gets toDrilling Torquepreset value, the main shaft will
stop drilling (speed is zero), and system will keep this torque. When drill torque decereases,
system will rotates as preset speed.
During drilling, when system detects motor temperature is alarming, system will auto limit
main shafts output: speed 60rpm. For safe, at this time, stop to cooling the main motor and
troubleshooting equipments is necessary. If keep on running the motor when its temperature is
over high, this may burn the insulation layer. Therefore, except special needs, stop the mian
motor in time.
During drilling, when system detects that the flow rate switch of gearbox lubrication oil is
alarming, system will auto limit main shafts output: speed 60rpm. For safe, at this time,
stop the main motor and troubleshooting equipments is necessary. If flow rate switch of
gearbox lubrication oil begins to alarm, this means the lubrication is insufficient to meet the
high-speed of rotating. At this time, keep on running system will lead to mechanical damage.
Therefore, except special needs, stop the mian motor in time.
5.6.4. Stop drilling
Under Drill Mode, turnThrottleto zero position andDirectionswitch to Stop position,
Top Drive will stop running normally. If break is on auto position, the brake will work when
the speed is suitable.
When system is running under Drill Mode, if incorrect operateDirection
switch away from Cw position, or incorrect operate theBrakeswitch, or
some electric faults occur, the system will decrease the speed and finally stop
running.
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BPM Top Drive
Electric Manual
5.7. Make-up/break-out operation

Check the system before this operation, follow chapter 5.1 to startup system correctly. Make
sure that system is in following status:
Name
Button or Switch
Status
Driller Console
Motor
A+B
Driller Console
Brake
Auto
Driller Console
HPU
Run
Driller Console
Locking
Unlock
Driller Console
Link Rotation
Center position
Driller Console
Link Incline
Center position
Driller Console
IBOP
Open
Driller Console
Auxiliary
Off
Driller Console
Air Cooling
Onor Auto
Driller Console
Operation
Drill
Driller Console
Direction
Stop
Driller Console
Makeup Torque
Zero position
Driller Console
Drilling Torque
Zero position
Driller Console
Throttle
Zero position
Driller Console
Clamp
Center position
HPU Control Box
Power
ON
HPU Control Box
ON OFF AUTO
AUTO
HPU Control Box
Cooling Fan
AUTO
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BPM Top Drive
Electric Manual
5.7.1. Make-up operation

1
a)
Make-up with stand
Make sure that HPU is in good condition. When communication is well, Pump Running
indicator light will on.
b) Turn Makeup Torqueto a preset value.

c)
SelectDirectionswitch to Cw position and Operationswitch to Spin . At this time

system will work clockwise under Spin Mode, with fixed speed and torque.
d) When system keep 15% of rated torque and direction of rotation keep clockwise, turn
Operationswitch to Torque, the make-up operation will be finished automatically
with the preset torque ofMakeup Torque.
2
a)
Make-up with single
b) Turn Makeup Torqueto a preset value.

c)
TurnLocking Pinon Driller Console to Lock to do locking operation. When the

locking indicator light become on, means locking operation has finished. Clamp
operation should be done after finishing the clocking operation.
d) Turn Directionswitch to CW position,Operationto Spin will realize clockwise

Spin Mode. System will clockwise spin with fixed speed and torque.
e)
After finishing spin, ensure rotating head is locked, then turnClampto lock by left
hand, and turnOperationto Torque at the same time, system will switch to Make-up
Mode. After a short time, system will Make-up with value given byMakeup Torque.
Before operating clamp, confirm that the rotating head locking operation has
completed, namely, has already detected the locking pin insert ready signal, the
Locking indicator light will become on.
Before Make-up operation, pay attention to Torque meter, make sure that the actual
Make-up torque reaches to the preset value given byMakeup Torque.
f)
When torque reach to preset value, left hand release theClamp, right hand turn
Operationswitch to Drill, this finish the make-up operation.
g) TurnLocking Pin switch to Unlock position to let the locking pin out. If the locking
indicator is off, means unlock operation has finished.
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BPM Top Drive
Electric Manual
5.7.2. Break-out operation

a)
b) TurnLocking Pinon Driller Console to Lock to do locking operation. When the

locking indicator light become on, means locking operation has finished. Clamp
operation should be done after finishing the clocking operation.
c)
Turn Directionswitch to ccw.

Before operating clamp, confirm that the rotating head locking operation has
completed, namely, has already detected locking pin insert ready signal, the Locking
indicator light become on.
d) Turn Clamp to lock, and turnOperationto torque. Backup Tong will close firstly,
after a short time system will counterclockwise rotates with a speed not more than Max
torque value 75kN.m. When speed is faster than value of spin speed, the system will stop
automatically. Left hand release theClamp, right hand away from Operationswitch,
then finish the break-out operation.
When Top Drive under Torque Mode, release Clampswitch or releaseOperation
switch, PLC system will stop the drive unit.
e)
TurnOperationswitch to spin, then the system will switch to counterclockwise Spin

Mode with fixed speed and torque.
f)
When drill pipe tool joint loosen completely, turnDirectionswitch to stop and
Operationswitch to drill, system will stop running.
g) Turn Locking Pin switch to unlock position to do the unlock operation. When the
indicator is off, means unlock operation has finished.
When the drive is running under Spin Mode, if incorrectly operateDirection or
electric faults happens, the system will stop running.
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BPM Top Drive
Electric Manual
5.7.3. Release reactive torque

When the load torque is larger than preset torque, drill pipe may be jammed and could not
drill; two methods are recommended shown as below to release the reactive torque.
Releasing torque reverse:
a) Keep the Throttle handle and the brake switch position, ensure the master motor can
output torque continually. Decrease the setting value of Drilling Torque handle. It makes
the master motors output torque down slowly. The drill reverses slowly until the
Drilling Torque handle to Zero; The reverse velocity of drill is down to Zero.
b) Keep the value of Drilling Torque handle and the Throttle handle goes back to ZERO
position when the drill torque is limited. The system brakes down when the motor stop to
output. Operation Mode and Direction switches hold their status. The drill starts to
reverse slowly after releasing the brake switch. Based on the reverse velocity, the
operator will apply the brake in suitable situation to ensure the drills interface can not be
thrown off. Repeated the above process until the drills reverse velocity cuts down to
Zero.
The using of method 2 is decided by the ability and status of the brake. And it is also
influenced by the experience for the drilling operator. So we recommend you to use the
method 1 for releasing reverse torque. Only when the drive device can not work, we can adopt
the method 2.
To avoid drill pipe thread off happens during the release reactive torque operation,
all operations should strictly follow the routine procedure. To avoid the accident,
the ccw rotate speed should be strictly controlled during release reactive torque
operation.
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BPM Top Drive
Electric Manual
5.8. Rotating head lock operation

After starting the HPU, operateLocking Pinswitch of Driller Console could realize lock and
unlock of rotating head. Before operating the clamp, operator should operateLocking Pin
switch to complete rotating head lock operation firstly.
TurnLockingswitch to lock position, the rotating head will rotate with a small increments
and the locking pin will act. After locked, the Locking indicator light will on, means lock
operation has completed. If the indicator light does not on, turn Locking Pinswitch to
unlock, do lock operation again.
Locking Pinand Link Rotationswitches are interlocked.

In order to keep equipment and personal safe, after finishing rotating head lock
operation, then operator could operate clamp.
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BPM Top Drive
Electric Manual
5.9. Link operation

After starting the hydraulic system, when making sure that the rotating head locking device
has unlocked, turnLink Rotationswitch could control the elevator link clockwise or
counterclockwise rotation.
Driller Consoles Link Inclineswitch could realize the control of elevator link front/rear.
Link Rotation and Link Inclinecan not operate at the same time.
PressLinks Centerbutton could operate the elevator link back to center position. Pay
attention to avoid colliding drill string when operating.
Before the link rotation operation, make sure that the lock pin has unlocked; otherwise link
rotation operation is invalid.
If the master computer system has set the interlock between link rotation and link incline,
after finishing link incline operation, press Link Center,then a few times later the link
rotation operation will be valid.
Locking PinandLink Rotationare interlocked. When operating link rotation
operation, locking pin operation is invalid; when operation locking pin operation,
the link rotation operation is invalid.
When Driller ConsolesAuxiliaryswitch is on and the Auxiliary Control Box indicator
lights is on, operate the switch on Auxiliary Control Box could realize the same function
mentioned above. Auxiliary Control Box and Driller Console are interlocked.
Max. Load weight of tilt oil cylinder is 2ton, when hoisting overweight things
such as drill collar, make sure that elevator link is in floating status, namely tilt oil
cylinder runs without strength.
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BPM Top Drive
Electric Manual
5.10.IBOP operation
When system stops running, IBOPcould control IBOPs movement.
Turn urn IBOPto off, if system has received mud pump running signal, the IBOP
indicator light will flicker, the sound will on (silence button is useless).Operator could turn
IBOPto on (the switch in on),IBOP keep on opening. Operator also could close the mud
pump: after closing it, the IBOP will off, the indicator light will on. If Operator does nothing,
IBOP will off delay 10 seconds, and then the indicator light will on, and the sound will off.
During well testing etc., turn PLC/MCC cabinets IBOP Disableto Disable for protect
cable in the well, the operating procedure shown as follow:
a) Turn IBOP to Open ,open the IBOP.
b) Turn PLC/MCC cabinetsIBOP Disableto Disable.
c) The well testing finished, turnIBOP Disableto Enable, IBOP could be controlled by
Driller Consoles IBOP.
During well testing etc., turn PLC/MCC cabinets IBOP Disableto Disable
for protect cable in the well.
After well testing finished, please turn PLC/MCCs IBOP Disableto Enable
for IBOP control reliability, it could be controlled by Driller ConsolesIBOP.
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BPM Top Drive
Electric Manual
5.11.E. Stop
When urgent condition taking place, operator could press any ofE. Stopswitch, then, all
equipments of Top Drive will stop quicklyif HPU. Pump on remote contorl mode.
After pressE. Stop, it is forbidden to do any further operations, except that operator has
finished below procedures:
a)
TurnThrottlehandle back to zero position; turnDirectionto stop; turnOperation

to Drill.
b) Turn PLC/MCC cabinetsSystem Startto off.

c)
Solve the emergency, and make sure that there is no fault or alarm in system.
d) Reset E. Stop.
e)
PressReset/Silenceto silence the alarm, then press this button again to reset and rescind
emergency status.
f)
Turn System Startto on, restart the system.
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BPM Top Drive
Electric Manual
5.12.Fault/Alarm
The error can be divided into 4 types:
a)
System fault: The drive system faults, the system will stop quickly.
b) Communicating fault: either of PROFIBUS substation communication is interrupted,

(under cable mode, it will not give alarm when Top Drive Local substation
communication is interrupted), the system will stop quickly.
c)
Electric fault : Such as main air switch, auxiliary power supply, I/O power supply,
Driller Console power supply, E-stop, etc. the system will stop quickly.
d) Electric fault : Such as UPS power supply, HPU power supply, etc. the system will
normal stop automatically.
There are three Fault/Alarm indicator lights on Driller Console, which could notice different
kinds of alarm/faults through different kinds of combinations.
H1
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H2
H3
BPM Top Drive
H1
H2
off
flash
flash
off
on
flash
off
on
flash
off
flash
H3
Electric Manual
Alarm type
Top Drive description
off
other alarms
flash
encoder loss alarm
off
Alarm
air pressure loss alarm
flash
main motors overtemperature
off
other communication faults
flash
off
communication fault of Inverter
Communication fault
communication fault of Rectifier.
flash
communication fault of Local Control Box (LCB)
off
other equipment faults
flash
off
Rectifier fault
System fault
Inverter fault
flash
braking unit over temperature
off
flash
off
other electric faults

on
auxiliary power fault
Electric fault
emergency stop
flash
air cooling power fault
When fault or alarm happens, sound will on.

After system stop running, operator should turnThrottlehandle back to zero position,
Directionto stop,Operationto Drill, and turnSystem Starton PLC/MCC cabinet
to off.
After fault or alarm happens, pressReset/Silenceto stop sound, but Fault/Alarm indicator
lights will keep on its status. At this time, operator could search for alarm record in the Wincc
system. After solving the fault, pressReset/Silenceagain to reset the system and extinguish
Fault/Alarm indicator lights.
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BPM Top Drive
Electric Manual
5.13.Encoder switch
If the encoder of main motor was damaged, the Wincc system will give record of alarm. At
this time, switchEncoder Selectswitch could realize system work with the other encoder.
a)
TurnThrottleto the zero position, turnDirectionswitch to stop position, turn

Operationswitch to drill, and turn theSystem Startto off.
b) Turn ENCODER SELECTon Inverter 1 cabinet.

c)
Turn System Starton PLC cabinet to on, Top Drive enter into ready state.
At this time, change the encoder or solve the problem immediately.

Use the corresponding encoder for the stability,when running in single motor.
Switch Encoder Selecttimely, not more than two weeks, this kind of
alternately run of encoder could enhance systems reliability.
5.14.Running without encoder

If the encoder of two motors were damaged, switchEncoder Faultswitch to fault could
realize system running without encoder.
a)
TurnThrottleto the zero position, turnDirectionswitch to stop position, turn

Operationswitch to drill, and turn theSystem Startto off.
b) Turn PLCs Encoder Faultto fault. This time, Without Encoder indicator light will
power on.
c)
Turn System Starton PLC cabinet to on, Top Drive enter into ready state.
At this time, change the encoder or solve the problem immediately.
System running without encoder, the control definition for torque was reduced;
Please change the encoder for systems credibility.
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BPM Top Drive
Electric Manual
5.15.Local Control Box Cable operation

5.15.1. Start Cable operation
In case of PROFIBUS optic fiber of Top Drive system was interrupted, the system can be
switched to the Cable operating mode.
a)
TurnSystem Startto off, and reset all switches of Driller Console to initial position.
(Refer to appendix 1)
b) Turn Control Modeswitch on PLC/MCC cabinet to Cable, and System Start

switch to on, switch system to Cable operation mode.
c)
PLC system control signal is sent to Top Drive substation through multicore cable. Other
operations are same with that drill in the normal condition, but only can not collect the
reducing gear box temperature and oil pressure signals. At this time, main motor could
work, and Top Drive also could work, but the operator should settle the problem as soon
as possible.
When stop the electric system (include CPU restart), operator must turn
Control Modeswitch on PLC/MCC cabinet to Profibus mode.
5.15.2. Stop Cable operation

a)
After the communication of LCB has recovered, reset all switches on Driller Console to
the initial position (refer to appendix 1), then, turn System Start to off, and turn
Control Modeto Profibus..
b) Press the Reset/Silencebutton when system has no alarm or fault. After that
electric system will switch back to normal communication mode.
the
When stop the electric system (include CPU restart), operator must turn
Control Modeswitch on PLC/MCC cabinet to Profibus mode.
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Electric Manual
5.16.Driller Console emergency operation

5.16.1. Start Em-operation
When the CPU cant work due to some faults, emergency operation should be adopted. But
please replace a new CPU as soon as possible.
a)
TurnSystem Startto off, and reset all switches of Driller Console to original position.
(Refer to appendix 1)
b) Turn ON OFF AUTOswitch on HPU to on.

c)
Turn Control Modeswitch on PLC/MCC cabinet to Bypass, switch system to

manual emergency operation mode.
d) Turn Air Coolingto on to start main motors cooling fan.

e)
Turn System Startswitch to on, drive unit will ready.
f)
After ensuring the cooling fan has started, turn Directionto cw or ccw.. The main
shaft will rotate clockwise or counterclockwise with a fix speed.
Under this mode, operator should manually operate Brake, HPU pump, HPU
cooling fan, auto is invalid.
5.16.2. Stop Em-operation

a)
After system has recovered from faults, turnDirectionswitch to stop, system will stop
running.
b) Turn all switches of Driller Console back to original position first, then turn System
Startto off, turnControl Modeto Profibus at last.
c)
Press Driller Console Reset/Silence, Top Drive will run in normal status.
Under manual operation mode, it is possible to do some simple magnet valve
operation. But under this mode, although main shaft could rotate, Top Drive
could run only with the rotating speed and torque preset by system.
Under manual operation mode, system work without CPU. So that all the
interlocks, alarms and protections in programme can not be realized.
Under manual operation mode, all the interlocks are invalid, so the operator
should be more carefully, avoid damaging equipment or any person.
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Electric Manual
6. Remote communication and diagnostic (self-select part)

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

After logon, pressSettingbutton in the WINCC control system and then the setting
picture will be shown as below. In SMS MOBIL No., operator could set the mobile number
for receive alarm or fault message. The method is: blank + mobile number, then press
CHANGE for saves. This function is very convenient for maintaining on well site.
Diagnosis setting
Diagnosis setting
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Electric Manual
6.2. SINAUT TIM4R module

SINAUT TIM module, has 1MB data memory with the main function of communication
control, is the focus part of SINAUT ST7. See below picture:
TIM4R has MPI port. It is suitable for integration into the SIMATIC S7-300, and can also be
connected to one or more SIMATIC S7-300/ 400 or ST7cc via MPI. It also has two WAN
interfaces, provided by modem in TIM, or outlay MD connected by RS232 port, and third
party modem.
TIM 4R module indicate
LED
Relevant
Type of
Inscription
No.
TIM interface WAN driver
Description
Group error
SF
All
TXD
Internal
modem
interface
Dedicated
line
Indicates missing or incorrect settings as

well as RAM errors.
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Transmit Data
LED is continuously on and goes out
during transmission of messages (TXD).
BPM Top Drive
Electric Manual
LED
Relevant
Type of
Inscription
No.
TIM interface WAN driver
Description
Transmit Data
Dial-up
network
RXD
Internal
modem
interface
No connection made:
LED is out.
Connection made:
LED is continuously on and goes out
during transmission of messages (TXD).
Receive Data
Dedicated
line
The LED is on as long as the data carrier

level (DCD) is detected and goes out
during reception of messages (RXD).
Receive Data
Dial-up
network
Goes on with an incoming call (RI), stays

on after that as long as the data carrier
level (DCD) is detected and goes out
during reception of messages (RXD).
Data flow via MPI / partyline
MPI / K
MPI / K bus
(partyline)
TIM-BUS
TIM-BUS
DCF77
DCF77 radio
clock
The display status changes every time a

message is sent or received via MPI /
partyline.
(presently not used)
Status of the DCF77 clock (when
present)
The LED is on as long as the time of day

is clear and blinks for every second.
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6.3. GSM kit

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

7.1. Operation picture function
Each function operation can be done on operation picture. Four separate areas show different
information.
Toolbar: in this area, there is a picture exchange button.
Display area: main area for monitoring and operation.
Alarm area: display latest alarm/fault.
Status area: display current picture name and system time.
Click each function soft-button can change to related picture. The WINCC has the pictures as
below:
SYSTEM HELP picture
POWER SYSTEM picture
NETWORK STRUCTURE picture
TOPDRIVE SYSTEM picture
CONTROL STATUS picture
AUXILIARY SYSTEM picture
ALARM LOGGING picture
SYSTEM TREND picture
STSTEM SET picture
SYSTEM LOGON picture
SYSTEM EXIT picture
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Electric Manual
7.2. System help

Clicking HELP button could open system help picture.and help document
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Electric Manual
7.3. Power system

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

Clicking DRIVER button could open driver status picture. The picture shows all data and
status of Top Drive system. The picture could help operator to know system status well.The
INPUT MODIFY button in the picture is for setting each handles zero position on Driller
Console. If changing the handle (or its resistor) or the zero position is not correct, the value
must be reset. The INPUT MODIFY button will disappear when drive is running. To reset
the value, you must move the handle to its zero position first, click 0 button; then move the
handle to its 100% position, click 100%button. After finishing the operation, the handle
must go back to zero position.
Click Speed Range could change systems rotating speed range. Normal is 0~110r/min,
and Full Range is 0~220r/min. The original position is Normal.
.
Speed Range
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Electric Manual
7.5. Network structure

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

Clicking CW/SW button could open control status picture. The picture shows equipments
control word and status word. Operator could know other equipments status by watching
right bottom list.
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7.7. Auxiliary system

Clicking AUXILIARY button could open auxiliary system picture. The picture shows
auxiliary system operations and status information of all parts of Top Drives, but only except
Top Drives main control system.
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7.8. Trend curve picture

Clicking TREND button could open trend curve picture. The trend is divided into:
System trend
Current trend
Voltage trend
Torque trend
Frequency trend
Trend for NO.1 Rectifier
Trend for NO.2 Rectifier
Trend for NO.1 Inverter
Trend for NO.2 Inverter
Trend for decelerator
Driller Console operation record
Fault and alarm record
Clicking right bottom window of the picture could open select menu and select the above
trends, every trend has same arrangement:
Title bar: display the title of the current trend
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Toolbar: operation button

Trend display area: display trend curve
Status bar: show the status of the trend curve (historical data or real time data)
Button explanation:
Set and define the current display window to be the first window.
Set and define the current display window to be the last window.
Set and define the current display window forward a window.
Set and define the current display window backward a window.
(One trend window shows one time segment that the time axis defined.)
Clicking the button, one vertical line will display on trend window, and a data sheet
will jump out on the bottom of the window to show the actual value that the trend
curve is on. The data sheet shows the trend name, tag name, recorder file name,
actual value of tag and its recording time. The vertical line can be moved and the
value on data sheet will change according to the position on time axis. Clicking the
button again, the function will terminate.
Zoom in area can be selected after clicking the button. The time step in the selected
area will be zoomed in and the trend curve will show subtly in the area. Clicking the
button again, the function will terminate.
There are two ways to define the time range of trend curve, clicking the button can
select the ways:
1 Absolute time range: filling the begin time and date in From Data time
and filling the end time and date in Till date time.
2 Till now, how long it has been. Select from the defined time cycle.
Previous trend curve
Next trend curve
Clicking the button can switch the status of trend between stop and updating.
When click STOP with left key, the button will become to GO, the displayed
curve will be static, till click GO by left key (GO will become to STOP), then
curve will be back to dynamic.
Note: after click this button, then the button
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Electric Manual
7.9. Alarm logging

Clicking ALARM button could open alarm logging picture. The fault/alarm is separated into
three classes: ALARM, FAULT (electric fault2), and FAILURE (equipment fault,
communication fault, and electric fault1).
Alarm including: Number, Date, Time, Type, Status, Message text, Help text.
Colors define:
Fault/alarm coming: red
After confirming all fault/alarm, the color will become black
After solving the fault/alarm, the color will become blue.
The button on toolbar could confirm the fault/alarm.
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7.10.System logon
Clicking LOGON button could open logon window; Clicking KEYBOARD button could
open soft-keyboard of windows. The logon is successful after inputting the user name and its
password correctly. Some special operation (for example: handle range setting, analog alarm
value setting, bypass setting, back to windows,etc.) needs the logon operation. After finishing
the operation, clicking LOGOFF button to exit logon status and cancel the operating
authorization.
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7.11.Setting function
Clicking SETTING button could open the setting window after logon. The system
parameter could be modified on this window.
Operator could bypass the system fault and alarm through items on below picture, also could
set procedure interlock if need. Red color words are fault and alarm, cancel means
bypass. White color words are procedure interlocks, means enforce this items interlock.
Operator could set Reverse Drill Mode in this procedure. Press

DRILLING_CCW SETTING, when this button turns to red color means
success. After finishing certain operation, operator should switch back to normal
mode, because reverse mode is easy to breakout.
Without special conditions, it is strictly forbidden to shield fault alarm or unlock
procedure interlock.
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Electric Manual
7.12.Exit system
Click EXIT button on main picture toolbar, enter the picture of exit windows, and please
operate according to the notes of the picture.
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8. System software and hardware

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

The power supply module has power input AC 220V and output DC 24V; the output power is
connected to CPU power terminal. If power supply modules switch turn to ON and power
indicator light (green light) become on, this means the power module works well.
The CPU module has indicator lights to show the status:
SF
System fault
On (red)
BUSF
DC5V
FRCE
RUN
STOP
Bus fault
Internal power supply
Force output
CPU run
CPU stop
On/flash (red)
On (green)
On (green)
On (green)
On /flash (yellow)
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Hardware or software is not correct

or damaged
Network system fault or station lose
Power supply for CPU is OK
When force output by programmer
CPU in run status
CPU in stop status
BPM Top Drive
Electric Manual
CPU work mode switch has three positions:

Up
Run + program
CPU running and can online programming
Middle
Stop
CPU stop
Down
Clear memory
Clear internal RAM
When turnMode Switchfrom stop to run, the run indicator light will flash until CPU has
detected that all hardwares and softwares has been ready, the indicator light then will on
contently (green). Otherwise, CPU will keep on stop mode.
The software of Top Drive has the function that even one or several distribute I/O stations are
lost or fault, the CPU still could keep on RUN mode, but the BUSF indicator light will
flash and SF indicator light will on.
The program of internal RAM can be cleared by pressingMode Switchto the down position,
the STOP indicator light will flash slowly; ReleasingMode Switchand press again, the
STOP light will fast flash, then releasing theMode Switchagain, the clean operation will
be finished after the STOP indicator light stops flashing.
After clearing the program of CPU internal memory and turning theMode Switchto RUN
position, the CPU will load program from memory card, and run it again. Programmer only
can clear the program in the memory card.
Before clearing the program of memory card, ensure already back up the
program!
When CPU power off happens, the memory card in the front of CPU is for
program protection. This memory card could only be inserted or pulled out
after CPU power is off!
CPU memory card

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

Each I/O modules and CPU are installed on back rail. When pulling out the module, one screw
must be loosed on the bottom of the module. For detail of installation of S7-300 PLC, Please see
the manual of SIEMENS S7-300 hardware installation. (In optical disk, name OEM)
Module installation
Each digital input module and output module has indicator light for each channel, the green
light means the channel is in logic 1 status.
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Electric Manual
Digital module and address

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

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

download.
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8.3. PROFIBUS network system

The network system of Top Drive is PROFIBUS-DP; all distribute I/O stations, and variable
frequency drive systems are connected to CPU by PROFIBUS. All bus cables from CPU to
each station are two twist-wire shielded cables except for the cable from CPU to Local
Control Box. The communication from CPU to Local Control Box is optical cable. The OLM
is used to change optical signal of PROFIBUS to electric signal. PROFIBUS cable connect
with each station by use of PROFIBUS connectors, terminal resistor switch must be set to
ON position when the station is on physical top or end of PROFIBUS except ET200X
station (ET200X doesnt need PROFIBUS connector.).
PROFIBUS connector and terminal resistor setting
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8.4. Distribute I/O station and communication module

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

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

The ET200X base module includes two power connectors and one PROFIBUS connector, the
top one is control power supply plug, the middle one is PROFIBUS bus connector, the bottom
one is I/O channel power supply plug. The base module also has eight digital input channels.
PROFIBUS address setting
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The base module has two DIP-switches under the three connectors, one is for PROFIBUS
station address setting, and another is for PROFIBUS terminal resistor setting. The terminal
switch must be set to ON position on every last station of PROFIBUS physical structure.
PROFIBUS terminal resistor setting

Top Drive electric systems Local Control Box address is 24, its 4, 5 should be set to
ON, the rest are on lower position. Local Control Boxs terminal resistances should be set to
ON.
There are indicator lights on base module to show the status.
Hardware configure or software is not
SF
System fault
On (red)
correct or damage
BF
Bus fault
ON
Internal power supply On (green)
DC24V I/O power supply
On/flash (red)
Communication error with CPU

Power supply for control is OK
On (green)
Power supply for I/O is OK
All ET200X digital I/O modules have indicator lights for each I/O channel, the indicator light
will be green when it is in 1 status.
The ET200X module could only be changed when power is off!
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8.4.2 ET200M distribute I/O station

Top Drive Driller Console is ET200M distribute I/O station.ET200M adopts high density
module. Its max transmit speed is 12Mbit/s, and expanded module could fit S7-300PLC I/O
module. This distribute I/O station contains ET200M interface module IM153, digital input
module, digital output module, analog signal input module and analog signal output module.
IM 153 base module schematic map
IM
153
interface
DI/DO and AI/AO module
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Electric Manual
ET200M status indication

SF
System fault
onred
Hardware or software failure or damaged
BF
Bus line fault
On/flash (red)
Communication with CPU fails, or Slave

station address wrong.
ACT
Out of use
yellow
Out of use in IM153-1
ON
DC 24Vpower supply ongreen
DC 24Vpower supply is good
In Top Drive electric system, Driller Console distribute I/O station address is 14, so set 2,
4, 8 to ON, while the rest are set to the other side. Terminal resistance of Profibus
connector should be set to ON.
8.4.3 Optical fiber connection module/ OLM
PROFIBUS optical fiber connection module (OLMhas three channels: Two optical fiber
interfaces and one electric interface. OLM is DC 24V.
OLM module has three indicator lights. Yellow shows communication is in good condition.
Two optical fibers connected to OLM must cross connection, namely first OLM output
terminal connect with second OLM input terminal.
Code switch
DC 24Vpower supply
Run indicator
RS485 joint
Optical fiber connect terminal

PROFIBUS optical fiber connection module OLM
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Electric Manual
OLM indicator light
OLM power supply

System
Light (green) means power supply is in good status
Electric interface indicate
CH1
Light(yellow) means electric circuit regular
Optical fiber interface indicate
CH2
Light(yellow)
means
CH2/CH3
CH3
communication regular
OLM DIP switch location:
Compatibility
Out. Power CH3
Out. Power CH2
Mode CH3
Mode CH2
Mode CH1
It is strictly forbidden to dial the code switch of OLM without permit.
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optical
fiber
BPM Top Drive
Electric Manual
8.4.4 REPEATER
PROFIBUS RS 485 REPEATER, is used to connect two PROFIBUS or MPI bus segment of
max 32 stations. It can increase station and transmit distance, could realize electric isolate bus.
There are three indicators lights show its running status:
DC 24V power supply terminal
Segment 1
RS 485 ProfiBus
Segment 2
DPSegment 1
PROFIBUS REPEATER
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Electric Manual
REPEATER function is below
Terminal for connecting the power supply of RS 485
repeater(pin M5.2 is the reference ground if you

want to measure the voltage between terminals A2
and B2)
Shield clamp for strain relief and ground the LAN

cable of bus segment 1 or bus segment 2
Terminal for the LAN cable of bus segment 1
Teminating resistor for bus segment 1
DIP switch, used to connect or cutoff part 1 and 2
Teminating resistor for bus segment 2
Terminal for the LAN cable of bus segment 2
Catch for mounting and removing the RS 485

repeater on a standard rail
Interface for PG/PC on bus segment 1
24V DC power supply indicate
Indicator for bus segment 1
Indicator for bus segment 2
Terminating resistor , , and DIP switch , of PROFIBUS REPEATER used

by Top Drive, all should be set to ON position.
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8.5. Variable frequency drive system

Top Drive driver system includes Rectifier and Inverter. Rectifier could change AC to DC. AC
power supply is 600V50/60HZ, DC output is 810V.
Dont touch any of DC bus or power unit until the DC voltage has down to
safety area (24V)!
8.5.1 Rectifier
The Rectifier unit has the central controller board (CUR) and PROFIBUS interface board
(CBP2). The CBP2 is inserted in ADB expanded board. When the control power of Rectifier
has power on, the CUR will self check and show o009 on PMU screen. If it cant show o009,
the CUR is not in ready mode, operator could read the relevant manual of Rectifier (the status
code or error message). If it has error happened, operator could press the P key on PMU or
press reset key on Driller Console to reset the fault message (this fault is not caused by
hardware damage).
The communication board of Rectifier (CBP2) has three indicator lights, if the CPU is
running and communication with CPU is OK, the three indicator lights will flash in same
frequency.
.
The Rectifier can only be disassembled or repaired by related expert!
CUR and PMU
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Electric Manual
PROFIBUS base module (CBP2)
When CUR loses communication with CPU, it will stop and has fault message F082 on PMU.
When resetting the fault by pressing the P key on PMU, the fault message will become
alarm message A082 and flash on PMU screen.
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8.5.2 Inverter
Each Inverter has central controller CUVC, PROFIBUS communication board(CBP2) and
SIMOLINK board(SLB) in its electrical control box.
The CBP2 and SLB board are inserted on CUVC board directly. When control power of
CUVC has power on, the CUVC will self check and show o009 (or o008 OFF1 disable) on
the screen of PMU. If it couldnt show o009 (o008), the CUVC is not in ready mode, operator
could read relevant manual of Inverter (the status code or error message). If Inverter fault
happens, operator could press the P key on PMU or press reset key on Driller Console to
reset the fault message (this fault is not caused by hardware damage).
CUVC terminals
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Electric Manual
The communication board of Inverter (CBP2) has three indicator lights. When CPU is
running and communication with CPU is OK, the three indicator lights will flash in a same
frequency.
The SIMOLINK is used for communication between two Inverters. It has three indicator
lights, if the communication is OK, the three indicator lights will flash in a same frequency.
The cables between two SIMOLINK modules are plastic fiber optical cable, the two optical
fibers must cross connection, namely the first input channel must connect to the second output
channel, and the first output channel must connect to the second input channel.
If communication of SIMOLINK has communication fault, the fault message F056 will
display on PMU screen. When resetting the fault by press the P key on PMU or reset key on
Driller Console, the fault message will become alarm message A002 and flash on PMU
screen.
When SIMOLINK has fault, the Inverter will stop automatically; after reset the fault, Inverter
will run again.
SIMOLINK module (SLB)
The Inverter can only be disassembled or repaired by related expert!
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8.6. Parameter upload and download for Rectifier and Inverter

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

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

Top Drive control system has a monitor computer. Operator could check the fault or alarm
diagnosis on monitor screen if system cant work correctly.
8.7.1 Air switch diagnosing
If air switch broken by accident, the diagnose mainly consists of over current, the connection
cable or load equipment shorting cut to earth or phase shorting cut.
8.7.2 Earth fault
The top driver electrical system is IT system, it has isolation indication equipment in main
power line. The equipment can examine the isolation of rectifier input side, main power cable
and main transformer. If it gives an alarm, while main power is OK, the system can work
continually, but you must check the power systems isolation as quick as possible, because the
alarm shows that the power system isolation resistor has reduced or one phase of power
system is short cut to the earth.
The humidity or dirty of cable connector or isolation damage of power cable or transformer
can cause the isolation resistor reducing.
It is dangerous to human safety when one phase is short circuit to earth!

8.7.3 PLC fault checking
Top Drive PLC program has the function that the CPU can still run even lose a distributed I/O
station. But if CPU could not run, the CPU hardware or I/O module may be damaged.
Before checking the CPU, Please check its power supply first, the correct voltage is DC 24V.
To check the CPU, operator should remove the memory card after power off first, and then
power on the CPU and do memory clear operation. If CPU can run after this operation, this
means CPU is OK. Otherwise the CPU hardware may be damaged already.
Programmer with STEP7 software could exam the I/O equipment; it has fully diagnostic
function for fault checking. For detail please see STEP7 manual.
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8.7.4 Network checking

The network system of Top Drive is PROFIBUS-DP. If one or several stations are lost by
accident, interface power supply of the station must be checked first. The correct voltage is
DC24V. If the power supply is OK, operator could check the PROFIBUS cable to find
whether it has broken or loosed bus connector. If power supply and cable connection are OK,
the base module may be damaged already.
The network can also be diagnosed by STEP7 software.
To check the PROFIBUS cable by multimeter, operator must power off all
stations power supply and pull out every bus connector.
8.7.5 Drive system
The drive system includes Rectifier and Inverter. The Rectifier and Inverter have PMU
operation board to show the equipment status, fault, and alarm. The explanation can be found
in Rectifier and Inverter manual, the fault could be reset by P key on PMU or RESET key
on Driller Console (PROFIBUS communication is OK.) except hardware damage.
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8.8. System Power Down and Disconnection

a)
Turn Operationswitch to drill, Directionswitch to stop, Throttlehandle back

to zero position, and turn System Starton PLC/MCC cabinet to off. Then, system
will stop running.
b) Reset system back to original status. (see appendix 1)

c)
Close monitor computer before disconnecting the main air switch, this could avoid
creating alarm record in system when disconnecting the main air switch.
d) Disconnect the main air switch firstly, then close PLC power supply, disconnect UPS at
last.
e)
Power off HPU power supply.
f)
Power off the auxiliary transformer in Rectifier cabinet.
Below items must be operated if Top Drive electric system has powered off for a long time:
a)
Switch off each power supply from low level to high level. Make sure that all switches
are shut off finally.
b) Switch off 600V main switch in power supply. (diesel motor)

c)
Disconnect the cables which connect with electric house. Label those cables to prepare
for the next install.
d) Disconnect motor and local panels cables.
- 86 -
BPM Top Drive
Electric Manual
9. Installation, troubleshooting and maintenance

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

a)
The electric house must be put on horizontal place, and away from the ground to avoid
water flow in from the bottom.
b) All cables should be connected with motor or local panel side first. All cable connectors
must be locked strictly to avoid water and loosing.
c)
Earth bar must be built (resistor <4) near the electric house and connected with the
main PE point of electric house.
d) The insulation of motors and cables must be checked before being connected with electric
house.
e)
All cables must be checked carefully to make sure correct connection before power on.
f)
Checking element parts and relevant supporters inside control cabinet to find any loose or
damage caused by transportation.
g) Switch off all air switches inside PLC/MCC cabinet. Generally, it is no need to open all
air switches inside Inverter and Rectifier cabinets.
h) Checking initial position of some mode select switches (refer to appendix 1).
- 87 -
BPM Top Drive
Electric Manual
9.2. Power on and Checking

After main 600V power has ready, and every cable from electric house to local equipment has
been correctly connected, then operator could power on Top Drive electric system.
a)
Operating the voltage select switch on Rectifier cabinet to check that each phase voltage
is in correct range (-15 to +10% of rated voltage 600V).
b) Switch on the control power switch inside Rictifier cabinet.

c)
Switch on the light inside PLC/MCC cabinet and light of electric house.
d) If in wet or high temperature environment, air conditioning must be switched on first to

reduce humidity and temperature.
e)
Power on each function block from high level to low level.
f)
Checking power on status from monitor system, for detail, please see related chapter.
g) Switch on theSystem Starton PLC/MCC cabinet to start Rectifier, checking DC output

voltage, the correct voltage is 810V.
h) Manually start cooling fan of main motor to check motors cooling fan, Rectifier cooling
fan and Inverter cooling fan.
i)
Checking oil level of HPU and starting each pump manually.
j)
Operating each button and switch manually to check each hydraulic valve and auxiliary
mechanical system of Top Drive.
After checking the system status on monitor system and make sure that no fault or alarm
happens, the system is ready for operation.
- 88 -
BPM Top Drive
Electric Manual
9.3. Daily maintenance

a)
For electric system, dust proof and damp proof are most important. Operator should pay
attention to keep it dry and clean, and do not work in high (temperature higher than 45)
or low (temperature lower than -13) temperature environment. If Top Drive doesnt
work for a long time, before restart, operator should clean the dust on element parts by
dust collector, and dry them by hairdryer. Check the insulation resistance value finally, be
1M at least, generally the value is over 5M.
b) Start cooling fan first, and then select direction before start main motors.
c)
While running, pay attention to the current meter value of all control cabinet in electric
house.
d) Every cable should connect firmly, screw thread could not loose, and the weld parts
should be firm too.
e)
Because the light shine and air oxidation, cable will aging. Operator should pay attention
to check whether it split, flake or not after using two years. Usually operator should
change the cables after using four years.
f)
Driller Console is EX type, operator should use air filter and water separator to keep air
dry and clean, and make sure that there are no flammable and explosive gases exist.
- 89 -
BPM Top Drive
Electric Manual
Appendix 1: System initial state

Drive cabinet initial state
Before starting system, make sure that all switches and buttons of drive cabinet are in
following initial state.
Button or Switch
Initial position
E.Stop
Loose
Note
Loose is initial position
PLC/MCC cabinet initial state

Before starting system, make sure that all switches and buttons of PLC/MCC cabinet are in
Button or Switch
Initial position
Note
Loose
Loose is initial position
Profibus
Profibus is initial position
System Start
Off
On this position, system is stop
Motor Heater
Off
Motor heating is in stop state
E.Stop
Channel Select
Driller Console initial state

Before starting system, make sure that all switches and buttons on Driller Console are in
Button or Switch
Initial position
Note
E Stop
Loose
Brake
Auto
HPU
Stop
Locking
Unlock
Link Rotation
Center Position
Link rotation is not used
Link Incline
Center Position
Link tilt is not used
IBOP
Open
open is initial position
Auxiliary
Close
Auxiliary operation is forbidden
Air Cooling
Close
In initial position, it is on close position
Clamp
Center position
Hydraulic pump stop running

Lock pin is in unlock state
- 90 -
BPM Top Drive
Electric Manual
Motor
AB
Operation
Drill
Direction
Stop
Makeup Torque
Zero
Drilling Torque
Zero
Throttle
Zero
Throttle, Drilling torqueandMakeup torquehandle back to zero position,

means set these switches to left end (throttle no input data).
Auxiliary Control Box initial state

Before starting system, make sure that all switches and buttons of Auxiliary Control Box are
in following initial state.
Button or Switch
Initial position
Note
Link Rotation
Center position
Link rotation is not used
Link Incline
Center position
Link tilt is not used
HPU Control Box initial state

Before starting system, should make sure that all switches or buttons of HPU Control Box are
in following initial state.
Button or Switch
Initial position
Power
OFF
Note
Switch off 380V power supply in HPU
Control Box
HPU
Stop
Hydraulic pump is stop
Cooling
Stop
Cooling fan is stop
- 91 -

Top Drive Electric Manual

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Top Drive Drilling Equipment

Beijing Petroleum Machinery Factory

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

Main motors cooling fan..........................................................................................30

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

BPM Top Drive

BPM Top Drive

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