M/D Totco: Part Number 60-60 Revision B

Part Number 60-60
Revision B
™
M/D TOTCO
I N S T RU M E N TAT I O N
INSTALLATION, OPERATION, AND MAINTENANCE
BLOCK CONTROL SYSTEM
Manufacturers of Precision Instruments
Printed in U.S.A. October 31, 1997

Manual 60-60 contains 162 pages as follows:
Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . October 1997

iii through iv. . . . . . . . . . . . . . . . . . . . . . . . . October 1997
TOC-1 through TOC-6 . . . . . . . . . . . . . . . . October 1997
LOF-1 through LOF-4 . . . . . . . . . . . . . . . . . October 1997
LOT-1 through LOT-2 . . . . . . . . . . . . . . . . . October 1997
1-1 through 1-2 . . . . . . . . . . . . . . . . . . . . . . October 1997
2-1 through 2-14 . . . . . . . . . . . . . . . . . . . . . October 1997
3-1 through 3-16 . . . . . . . . . . . . . . . . . . . . . October 1997
4-1 through 4-28 . . . . . . . . . . . . . . . . . . . . . October 1997
5-1 through 5-24 . . . . . . . . . . . . . . . . . . . . . October 1997
6-1 through 6-8 . . . . . . . . . . . . . . . . . . . . . . October 1997
7-1 through 7-4 . . . . . . . . . . . . . . . . . . . . . . October 1997
8-1 through 8-12 . . . . . . . . . . . . . . . . . . . . . October 1997
9-1 through 9-16 . . . . . . . . . . . . . . . . . . . . . October 1997
A-1 through A-2 . . . . . . . . . . . . . . . . . . . . . October 1997
B-1 through B-12 . . . . . . . . . . . . . . . . . . . . October 1997
C-1 through C-4 . . . . . . . . . . . . . . . . . . . . . October 1997
D-1 through D-4 . . . . . . . . . . . . . . . . . . . . . October 1997
IMPORTANT SAFETY NOTICE
Proper service and repair is important to the safe, reliable operation of all M/D TOTCO equipment.
The service procedures recommended by M/D TOTCO and described in the technical manuals are
recommended methods of performing service operations. When these service operations require
the use of tools specially designed for the purpose, those special tools should be used as recom-
mended. Warnings against the use of specific service methods that can damage equipment or
render it unsafe are stated in the manuals. These warnings are not exclusive, as M/D TOTCO
could not possibly know, evaluate and advise service people of all conceivable ways in which ser-
vice might be done or of all possible associated hazardous consequences. Accordingly, anyone
who uses service procedures or tools which are not recommended by M/D TOTCO must first sat-
isfy themselves thoroughly that neither personnel safety nor equipment safety will be jeopardized
by the method selected.
October 31, 1997 iii

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

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

CONSEQUENTIAL DAMAGES, REGARDLESS OF THE FORM OF ACTION, WHETHER IN CONTRACT,
STRICT LIABILITY OR IN TORT (INCLUDING NEGLIGENCE), NOR FOR LOST PROFITS.
iv October 31, 1997

M/D TOTCO
Table of Contents
CHAPTER 1
INTRODUCTION
1-1 PURPOSE OF MANUAL .................................................................................................. 1-1
1-2 SCOPE OF MANUAL ....................................................................................................... 1-1
1-3 INTENDED AUDIENCE................................................................................................... 1-1
1-4 PERSONNEL QUALIFICATIONS ................................................................................... 1-1
1-5 NOTES, CAUTIONS AND WARNINGS ......................................................................... 1-2
1-6 RELATED DOCUMENTS ................................................................................................ 1-2
CHAPTER 2
SYSTEM DESCRIPTION & OVERVIEW
2-1 INTRODUCTION ............................................................................................................. 2-1
2-2 SYSTEM COMPONENTS................................................................................................ 2-1
2-3 DAQ (DATA ACQUISITION UNIT) - M/D TOTCO PN 219554 .................................. 2-3
2-4 BRAKE SYSTEM ............................................................................................................. 2-4
2-4-1 Baylor 2025B Brake Controller................................................................................ 2-4
2-4-2 Eddy Current Brake .................................................................................................. 2-5
2-4-3 Friction Brake ........................................................................................................... 2-5
2-4-4 Battery Backup ......................................................................................................... 2-6
2-4-5 Throttle...................................................................................................................... 2-7
2-5 DRILLER'S DISPLAY...................................................................................................... 2-7
2-6 SENSORS & CALIBRATION SWITCH BOX ................................................................ 2-9
2-6-1 Shaft Encoder Assembly........................................................................................... 2-9
2-6-2 Drawworks Proximity Sensor - M/D TOTCO P/N 220378 ..................................... 2-9
2-6-3 Railmount Proximity Sensors - M/D TOTCO P/N H11094A-01........................... 2-10
2-6-4 Hook Load Pressure Transducer............................................................................. 2-10
2-6-5 Calibration Switch Box - M/D TOTCO P/N 219255-001 ....................................... 2-10
2-7 CONFIGURATION & CALIBRATION LAPTOP PC .................................................. 2-11
2-8 VXC GRAPHICS DISPLAY, SAC................................................................................. 2-11
2-9 SPECIFICATIONS: DAQ AND SENSORS................................................................... 2-12
2-10 OVERVIEW: SYSTEM SETUP PROCEDURES .......................................................... 2-14
CHAPTER 3
THEORY OF OPERATION
3-1 INTRODUCTION .............................................................................................................. 3-1
3-2 DAQ SYSTEM FUNCTIONS............................................................................................ 3-2
3-3 BAYLOR 2025B BRAKE CONTROLLER FUNCTIONS ............................................... 3-2
3-4 SYSTEM SIGNAL PATHS ............................................................................................... 3-3
3-4-1 NON-CRITICAL Error Condition Signal ................................................................. 3-3
3-4-2 CRITICAL Error Condition Signal ........................................................................... 3-3
3-4-3 NORMAL THROTTLE Signal ................................................................................. 3-3
October 31, 1997 Table of Contents-1

M/D TOTCO
Table of Contents Block Control System
Manual 60-60
3-4-4 REVERSE THROTTLE Signal................................................................................. 3-3

3-4-5 CURRENT FEEDBACK Signal ............................................................................... 3-4
3-4-6 COMMAND FEEDBACK Signal............................................................................. 3-4
3-4-7 DAQ ALARM Signal ................................................................................................ 3-4
3-5 DAQ ALARM RESPONSE ............................................................................................... 3-6
3-5-1 Zones.......................................................................................................................... 3-6
3-5-2 Alarm Classification .................................................................................................. 3-8
3-5-3 Alarm Response ......................................................................................................... 3-8
3-5-4 Matrix Definition ....................................................................................................... 3-9
3-6 SYSTEM ALARM CONDITIONS.................................................................................. 3-11
3-6-1 Acceleration Alarm.................................................................................................. 3-11
3-6-2 Brake Critical ........................................................................................................... 3-11
3-6-3 Current Alarm .......................................................................................................... 3-11
3-6-4 EDMS Prox Alarm................................................................................................... 3-12
3-6-5 Encoder Alarm (Encoder Operation) ....................................................................... 3-12
3-6-6 Derrick Prox Alarm (Encoder Operation) ............................................................... 3-12
3-6-7 Position Alarm ......................................................................................................... 3-12
3-6-8 Velocity Down Alarm.............................................................................................. 3-12
3-6-9 Velocity Up Alarm................................................................................................... 3-13
3-6-10 Brake Non-Critical................................................................................................... 3-13
3-6-11 Brake Cooling .......................................................................................................... 3-13
3-6-12 Friction Brake Pressure Switch................................................................................ 3-14
3-6-13 Hook Load Alarm .................................................................................................... 3-14
3-6-14 UPS Alarm ............................................................................................................... 3-14
3-6-15 Non-Critical Position ............................................................................................... 3-14
3-7 SET POINTS..................................................................................................................... 3-15
3-7-1 Corners..................................................................................................................... 3-15
3-8 BATTERY BACKUP ENABLED ................................................................................... 3-15
CHAPTER 4
INSTALLATION
4-1 INTRODUCTION .............................................................................................................. 4-1
4-2 HAZARDOUS AREA LOCATIONS ................................................................................ 4-1
4-3 DAQ INSTALLATION...................................................................................................... 4-3
4-3-1 Mount the DAQ ......................................................................................................... 4-3
4-3-2 Ground the DAQ........................................................................................................ 4-5
4-3-3 Connect Primary AC Power Cable ............................................................................ 4-6
4-3-4 Digital Board Dip Switch Settings............................................................................. 4-7
4-3-5 Communications Board Dip Switch Settings ............................................................ 4-8
4-3-6 EDMS Board Dip Switch Settings............................................................................. 4-9
4-4 I.S. BARRIER BOX INSTALLATION ........................................................................... 4-10
4-5 SENSOR INSTALLATION ............................................................................................. 4-10
4-5-1 Cabling Guidelines .................................................................................................. 4-10
4-5-1-1 Guidelines for Preventing Cable Damage ..................................................... 4-10
4-5-1-2 Electrical Interface .......................................................................................... 4-10
Table of Contents-2 October 31, 1997

M/D TOTCO
Block Control System Table of Contents
Manual 60-60
4-5-1-3 Shielded Cable Splicing.................................................................................. 4-11

4-5-2 Proximity Sensor Installation................................................................................... 4-12
4-5-2-1 Drawworks Proximity Sensor Installation...................................................... 4-12
4-5-2-2 Railmount Proximity Sensors Installation ..................................................... 4-14
4-5-3 Shaft Encoder Installation........................................................................................ 4-17
4-5-4 Calibration Switch Box Installation......................................................................... 4-18
4-5-5 Hook Load Pressure Transducer Installation........................................................... 4-19
4-5-6 DAQ Sensor Connections ........................................................................................ 4-21
4-6 FRICTION BRAKE SOLENOID INSTALLATION ...................................................... 4-23
4-7 DAQ POWERUP.............................................................................................................. 4-27
CHAPTER 5
CONFIGURATION & CALIBRATION
5-1 INTRODUCTION .............................................................................................................. 5-1
5-2 CALCONF SOFTWARE STARTUP ................................................................................ 5-2
5-3 LOADING CONFIGURATION FROM FLOPPY ............................................................ 5-4
5-4 CONFIGURATION............................................................................................................ 5-5
5-5 CALIBRATION ................................................................................................................. 5-6
5-5-1 Hook Load Sensor Channel Calibration .................................................................... 5-6
5-5-2 Block Height Sensor Calibration ............................................................................. 5-14
5-5-2-1 Block Control System Two Point Calibration ................................................ 5-15
5-5-2-2 Block Control System Ten Point Calibration ................................................. 5-18
5-5-3 “Resetting” Block Control System Height Calibration ........................................... 5-21
5-5-3-1 System without a Safe Area CID (SAC) or DataWatch display..................... 5-22
5-5-3-2 Systems with a Safe Area CID (SAC) or DataWatch display ........................ 5-22
5-6 SAVE CONFIG/CALIBRATION TO FLOPPY.............................................................. 5-23
CHAPTER 6
SETUP
6-1 INTRODUCTION .............................................................................................................. 6-1
6-2 RAILMOUNT PROXIMITY SENSOR SETUP................................................................ 6-1
6-3 SET POINTS SETUP ......................................................................................................... 6-7
CHAPTER 7
DRILLER’S DISPLAY OPERATION
7-1 INTRODUCTION .............................................................................................................. 7-1
7-2 GREEN “SYSTEM ON” LED ........................................................................................... 7-1
7-3 YELLOW “ALARM” LED................................................................................................ 7-1
7-4 RED “FRICTION BRAKE ENABLED” LED .................................................................. 7-1
7-5 OVERRIDE/RESET NORMAL SWITCH ........................................................................ 7-1
7-6 LEARN BUTTON .............................................................................................................. 7-2
7-7 EMERGENCY STOP BUTTON........................................................................................ 7-3
7-8 LOWER SPEED POTENTIOMETER ............................................................................... 7-3

M/D TOTCO
Manual 60-60
7-9 DRILL/TRIP SWITCH....................................................................................................... 7-3

7-10 ALARM HORN.................................................................................................................. 7-3
CHAPTER 8
MAINTENANCE
8-1 INTRODUCTION .............................................................................................................. 8-1
8-2 RECOMMENDED DAQ INSPECTION ........................................................................... 8-1
8-3 DAQ AND SENSOR TROUBLESHOOTING .................................................................. 8-1
8-3-1 General Checks .......................................................................................................... 8-1
8-3-2 Fault Isolation Table: DAQ and Sensors ................................................................... 8-2
8-4 SYSTEM DEBUG .............................................................................................................. 8-6
8-5 SENSOR PROBLEMS ....................................................................................................... 8-7
8-6 REPLACING DAQ DIGITAL BOARD E-PROMS.......................................................... 8-7
8-7 POWER SUPPLY & WIRING HARNESS CHECKOUT PROCEDURE........................ 8-9
8-8 EDMS BATTERY TEST ................................................................................................. 8-10
8-9 AC POWER DISTRIBUTION WIRING DIAGRAM ..................................................... 8-11
8-10 DAQ INTERFACE CONNECTIONS.............................................................................. 8-12
CHAPTER 9
ILLUSTRATED PARTS BREAKDOWN
9-1 INTRODUCTION .............................................................................................................. 9-1
9-2 INDEX NUMBERS............................................................................................................ 9-1
9-3 PARTS LIST....................................................................................................................... 9-1
9-3-1 Figure & Index Number............................................................................................. 9-1
9-3-2 Part Number ............................................................................................................... 9-1
9-3-3 Description................................................................................................................. 9-1
9-3-4 Units Per Assembly ................................................................................................... 9-1
9-3-5 Abbreviations............................................................................................................. 9-2
9-4 M/D TOTCO SYSTEM CABLES ................................................................................... 9-14
9-5 M/D TOTCO PROXIMITY SENSORS & LAPTOP PC................................................. 9-14
9-6 BAYLOR SYSTEM COMPONENTS ............................................................................. 9-14
9-7 APPROVED SPARE PARTS FOR M/D TOTCO COMPONENTS............................... 9-15
APPENDIX A
INTERCONNECT DRAWINGS
A-1 OVERVIEW ...................................................................................................................... A-1
APPENDIX B
2025B BRAKE CONTROLLER
B-1 INTRODUCTION ..............................................................................................................B-1
B-2 FIRING BOARD CONNECTIONS ...................................................................................B-1
B-3 FIRING BOARD SWITCHES ...........................................................................................B-2

M/D TOTCO
Block Control System Table of Contents
Manual 60-60
B-4 FIRING BOARD SETUP ...................................................................................................B-3

B-5 AUXILIARY BOARD LED'S............................................................................................B-3
B-6 AUXILIARY BOARD INTERFACES ..............................................................................B-6
B-7 RELAY LOGIC ..................................................................................................................B-7
B-8 BRAKE CONTROLLER TROUBLESHOOTING..........................................................B-11
APPENDIX C
BRAKE MONITORING SYSTEM (BMS)
C-1 INTRODUCTION ..............................................................................................................C-1
C-2 BRAKE MONITORING SYSTEM COMPONENTS .......................................................C-2
C-2-1 Safe Area Computer Interface Device (SAC)............................................................C-2
C-2-2 Temperature Switch ...................................................................................................C-2
C-2-3 Flow Switches............................................................................................................C-2
C-2-4 Solenoid .....................................................................................................................C-2
C-2-5 Air Pressure................................................................................................................C-2
C-2-6 Pressure Switch..........................................................................................................C-2
C-2-7 “Crownamatic” ..........................................................................................................C-3
C-2-8 Friction Brake ............................................................................................................C-3
C-2-9 Uninterruptable Power Supply (UPS)........................................................................C-3
C-2-10 UPS Switch ................................................................................................................C-3
APPENDIX D
ZONE MANAGEMENT SYSTEM INTERFACE
D-1 INTRODUCTION ............................................................................................................. D-1
D-2 THEORY OF OPERATION ............................................................................................. D-2
D-3 BLOCK CONTROL SYSTEM INPUTS FROM THE ZMS COMPUTER ..................... D-2
D-4 BLOCK CONTROL SYSTEM OUTPUTS TO THE ZMS COMPUTER ....................... D-2
D-5 ZMS (II)-REVISED ZMS ................................................................................................. D-3

M/D TOTCO
Manual 60-60

M/D TOTCO
List of Figures
CHAPTER 1
INTRODUCTION
CHAPTER 2
Figure 2-1 Block Control System Overview ......................................................................... 2-2
Figure 2-2 M/D TOTCO Data Acquisition Unit (DAQ) ....................................................... 2-4
Figure 2-3 Baylor 2025B Brake Controller........................................................................... 2-5
Figure 2-4 Baylor Driller’s Display....................................................................................... 2-8
Figure 2-5 M/D TOTCO Shaft Encoder Assembly (P/N H12321A) .................................... 2-9
Figure 2-6 M/D TOTCO Calibration Switch Box............................................................... 2-10
Figure 2-7 VXC Graphics Display System (SAC) .............................................................. 2-11
Figure 2-8 Overview- System Setup Procedure .................................................................. 2-14
CHAPTER 3
THEORY OF OPERATION
Figure 3-1 Block Control System Communication Paths ..................................................... 3-1
Figure 3-2 Block Control System Signal Paths ..................................................................... 3-5
Figure 3-3 Block Operation Zones - Block Traveling Up..................................................... 3-7
Figure 3-4 Block Operation Zones - Block Traveling Down ................................................ 3-7
Figure 3-5 Brake Control System Signal Flow ................................................................... 3-10
CHAPTER 4
INSTALLATION
Figure 4-1 System Component Location Requirements........................................................ 4-2
Figure 4-2 DAQ (standard) Installation Dimensions ............................................................ 4-4
Figure 4-3 DAQ (Permanent Location) Installation Dimensions.......................................... 4-4
Figure 4-4 DAQ Ground, Power, and Signal Connectors ..................................................... 4-5
Figure 4-5 AC Primary Power Connections.......................................................................... 4-7
Figure 4-6 DAQ Digital Board Dip Switch Settings............................................................. 4-8
Figure 4-7 DAQ Communication Board Dip Switch Settings .............................................. 4-9
Figure 4-8 EDMS Board Dip Switch Settings....................................................................... 4-9
Figure 4-9 Drawworks Proximity Sensor and Target.......................................................... 4-13
Figure 4-10 Mounting Dimensions - Drawworks Proximity Sensor..................................... 4-13
Figure 4-11 Railmount Proximity Sensor Installation........................................................... 4-15
Figure 4-12 Mounting Locations - Railmount Proximity Sensors & Target......................... 4-16
Figure 4-13 Traveling Block Target Dimensions.................................................................. 4-16
Figure 4-14 Shaft Encoder Dimensions................................................................................. 4-17
Figure 4-15 Encoder Mounting Bracket ................................................................................ 4-18
Figure 4-16 Calibration Switch Box Dimensions.................................................................. 4-18
October 31, 1997 List of Figures-1

M/D TOTCO
List of Figures Block Control Manual
Manual 60-60
Figure 4-18 Typical Hook Load Transducer Installation ...................................................... 4-20

Figure 4-19 DAQ Field Termination Board .......................................................................... 4-22
Figure 4-20 Typical “Crownamatic” Type Installation ......................................................... 4-25
Figure 4-21 Friction Brake Solenoid Installation .................................................................. 4-26
CHAPTER 5
Figure 5-1 Recommended Configuration & Calibration Procedure...................................... 5-1
Figure 5-2 Laptop PC Connection to DAQ ........................................................................... 5-2
Figure 5-3 Software Start-up Screen ..................................................................................... 5-3
Figure 5-4 Configuration & Calibration Main Menu Screen ................................................ 5-3
Figure 5-5 Floppy:[LOAD ALL] Menu Screen .................................................................... 5-5
Figure 5-6 SOFTWARE CALIBRATION SOFTWARE Screen ......................................... 5-7
Figure 5-7 [CHANNELS] Submenu ..................................................................................... 5-8
Figure 5-8 HOOK LOAD Calibration Screen....................................................................... 5-9
Figure 5-9 Raw Minimum Calibration Screen ...................................................................... 5-9
Figure 5-10 Value Minimum Calibration Screen .................................................................. 5-10
Figure 5-11 Raw Maximum Calibration Screen.................................................................... 5-12
Figure 5-12 Value Maximum Calibration Screen ................................................................. 5-13
Figure 5-13 EDMS Two Point Calibration............................................................................ 5-16
Figure 5-14 EDMS Calibration Screen ................................................................................. 5-19
Figure 5-15 EDMS Calibration Screen ................................................................................. 5-20
CHAPTER 6
SETUP
Figure 6-1 CONFIGURATION Submenu ............................................................................ 6-2
Figure 6-2 SYSTEM/DAQ Configuration Screen................................................................. 6-3
Figure 6-3 EDIT Channels Submenu .................................................................................... 6-4
Figure 6-4 PROX LOW Channel Configuration Screen ....................................................... 6-4
Figure 6-5 DIAGNOSTIC CHANNEL VALUES Screen–Page 1 ....................................... 6-5
Figure 6-6 DIAGNOSTIC CHANNEL VALUES Screen–Page 2 ....................................... 6-5
CHAPTER 7
CHAPTER 8
MAINTENANCE
Figure 8-1 DAQ Main Components ...................................................................................... 8-5
Figure 8-2 DAQ Digital Board Main Components ............................................................... 8-8
Figure 8-3 DC Power Distribution Wiring Diagram ........................................................... 8-10
Figure 8-4 DC Power Distribution Cabling Diagram.......................................................... 8-11
Figure 8-5 AC Power Distribution Wiring Diagram ........................................................... 8-12
CHAPTER 9
Figure 9-1 DAQ (P/N 220425) Assembly Drawing (1 of 3) ................................................. 9-3
Figure 9-2 Shaft Encoder Assembly...................................................................................... 9-9
List of Figures-2 October 31, 1997

M/D TOTCO
Block Control Manual List of Figures
Manual 60-60
Figure 9-3 Calibration Switch Box...................................................................................... 9-10

Figure 9-4 Hook Load Transducer Assembly ..................................................................... 9-11
Figure 9-5 Hook Load Transducer Assemblies (continued) ............................................... 9-12
APPENDIX A
APPENDIX B
Figure B-1 Brake Controller Auxiliary Board ...................................................................... B-4
Figure B-2 Emergency Relay Schematic .............................................................................. B-8
Figure B-3 Friction Brake Relay Schematic ......................................................................... B-9
Figure B-4 Battery Backup Relay (K3) Schematic ............................................................. B-10
APPENDIX C
Figure C-1 Brake Monitoring System Overview .................................................................. C-1
APPENDIX D
Figure D-1 General Schematic for the ZMS Interface .......................................................... D-1
October 31, 1997 List of Figures-3

M/D TOTCO
List of Figures Block Control Manual
Manual 60-60
List of Figures-4 October 31, 1997

M/D TOTCO
List of Tables
CHAPTER 1
INTRODUCTION
CHAPTER 2
Table 2-1 DAQ and Sensor Specifications ........................................................................ 2-12
CHAPTER 3
THEORY OF OPERATION
Table 3-1 Alarm Responses ................................................................................................. 3-9
CHAPTER 4
INSTALLATION
Table 4-17 Suggested Transducer Ranges ........................................................................... 4-20
CHAPTER 5
CHAPTER 6
SETUP
CHAPTER 7
CHAPTER 8
MAINTENANCE
Table 8-1 Fault Isolation Table: DAQ and Sensors ............................................................. 8-2
CHAPTER 9
Table 9-1 Parts List Abbreviations....................................................................................... 9-2
Table 9-2 M/D TOTCO System Cables............................................................................. 9-14
Table 9-3 Miscellaneous M/D TOTCO Components ........................................................ 9-14
Table 9-4 Baylor-Supplied Components............................................................................ 9-14
Table 9-5 Approved M/D TOTCO Spare Parts ................................................................. 9-15
October 31, 1997 List of Tables-1

M/D TOTCO
List of Tables Block Control System
Manual 60-60
APPENDIX A
APPENDIX B
Table B-1 Firing Board Interfacing Connectors ...................................................................B-1
Table B-2 FTB-1 Pinouts......................................................................................................B-2
Table B-3 Auxiliary Board LED Summary ..........................................................................B-5
Table B-4 Auxiliary Board Interface Connectors.................................................................B-6
Table B-5 Auxiliary Board TB-1 Pinouts.............................................................................B-7
APPENDIX C
APPENDIX D
List of Tables-2 October 31, 1997

M/D TOTCO
CHAPTER 1
INTRODUCTION
1-1 PURPOSE OF MANUAL
This manual describes the Block Control System designed by M/D TOTCO and The Bay-
lor Company. The information in this manual should enable qualified personnel to operate
the Block Control System and to install,calibrate, troubleshoot and replace parts in the M/
D TOTCO components. For details on Baylor components, refer to the Baylor manual.
1-2 SCOPE OF MANUAL
This manual is divided into the following chapters:

• Chapter 1 - Introduction to manual
• Chapter 2 - Overview of the Block Control System and description of
system components
• Chapter 3 - Theory of Block Control System operation
• Chapter 4 - Installation of M/D TOTCO system components
• Chapter 5 - System configuration and calibration
• Chapter 6 - System setup
• Chapter 7 - Operation of the Driller's Display
• Chapter 8 - Maintenance and troubleshooting of M/D TOTCO components
• Chapter 9 - Illustrated parts breakdown and approved spare parts for
M/D TOTCO components
• Appendix A - Installation drawings
• Appendix B - 2025B Brake Controller reference
• Appendix C - Brake Monitoring System (BMS)
• Appendix D - Zone Management System Interface (ZMS)
1-3 INTENDED AUDIENCE
This manual is intended for use by operation, maintenance, repair and field engineering
personnel.
1-4 PERSONNEL QUALIFICATIONS
Installation and maintenance of Block Control System should be attempted only by per-
sonnel who have read the safety notice on Page B and who are fully qualified and trained
to perform the procedures described in this manual.
October 31, 1997 Page 1-1

M/D TOTCO
Chapter 1 Block Control System
Introduction Manual 60-60
1-5 NOTES, CAUTIONS AND WARNINGS
Notes, cautions and warnings are presented, when applicable, to aid in understanding and
operating the equipment or to protect personnel and equipment. Examples and explana-
tions for each are presented below:
NOTE
Provides additional information that may aid in understanding the current
topic.
CAUTION
Provides information to prevent equipment malfunction or damage that
could result in interruption of service.
WARNING
Provides information to prevent equipment malfunction or damage that

could result in major property loss or serious or fatal injury to personnel.
1-6 RELATED DOCUMENTS
Detailed descriptions and instructions for installing, operating and troubleshooting Block
Control System devices is presented in separate manuals, as follows:
Manual Number Manual Description

60-10 Data Acquisition Unit (DAQ) and sensors
60-40 TOTAL System Configuration and Calibration Soft-
ware
60-24 VXC Graphics Display, Safe Area
Baylor Manual 2025B Brake Controller
Baylor Manual Battery Backup Unit
Page 1-2 October 31, 1997

M/D TOTCO
CHAPTER 2
2-1 INTRODUCTION
The MDT/BAYLOR Block Control System is a backup system for controlling the
traveling block.
The Block Control System continually monitors block speed and position and provides a
backup to the operator in controlling block velocity. The system uses an eddy current
brake and friction brake (when needed) to bring the block to a controlled stop as the
crown and rig floor are approached or at any position along its range of travel.
This chapter describes Block Control System components and presents an overview of the
procedures for setting up a system.
NOTE
The block control system is a backup system only. it should not be used
in place of the manual braking controls. Under normal conditions, the
operator should use the manual braking controls at the driller's station to
control the block.
2-2 SYSTEM COMPONENTS
The main components of the Block Control System are shown in Figure 2-1. These
components can be grouped into the following categories:
• Data Acquisition Unit (DAQ)
• Brake System
• Driller's Display
• Sensors and Calibration Switch Box
• Configuration & Calibration Laptop PC

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System Description & Overview Manual 60-60
Figure 2-1 Block Control System Overview

M/D TOTCO
Block Control System Chapter 2
Manual 60-60 System Description & Overview
2-3 DAQ (DATA ACQUISITION UNIT) - M/D TOTCO PN 219554
The DAQ (Figure 2-2) is the primary Block Control System device. Its main functions are:
• System Configuration & Calibration - Via a laptop PC, Configuration/Cali-
bration software in the DAQ is used to configure the system and calibrate sen-
sors.
• Interface for System Components - The DAQ receives and processes rig sen-
sor data to determine the amount of braking required. The DAQ then sends this
braking information to the Brake Controller and Driller's display so that the
appropriate action is taken.
• Houses the System Software -The Block Control System software in the
DAQ continually calculates the amount of braking required, using data from
the shaft encoder and hook load pressure transducer.
• Issues Braking Command Signals - After each calculation, the DAQ sends
command signals to the Brake Controller regarding the required current flow
in the eddy current brake and regarding application of friction brake (if
needed).
• Monitors the System and Issues Alarms - Upon initialization of the eddy
current brake, the DAQ checks to insure that the required current is flowing in
the brake. If it is not, the DAQ immediately commands application of the fric-
tion brake, if needed. The DAQ also checks for discrepancies between the
shaft encoder and proximity sensors. If a discrepancy exists, the DAQ issues
an alarm that is appropriate for the current error condition (Table 3-1).

M/D TOTCO
Figure 2-2 M/D TOTCO Data Acquisition Unit (DAQ)
2-4 BRAKE SYSTEM
Brake system components are listed below and described in the paragraphs that follow.
• Baylor 2025B Brake Controller
• Eddy Current Brake
• Friction Brake
• Battery Backup (optional)
• Throttle
• Power Select Switch Box/J-Box
2-4-1 Baylor 2025B Brake Controller
During normal operation, the Brake Controller (Figure 2-3) receives braking com-
mand signals from the throttle and from the DAQ. Throttle signals represent the
current to the eddy current brake that is commanded by the operator. DAQ signals
represent the current prescribed by Block Control software calculations to safely
control block velocity.
The main functions of the Baylor 2025B Brake Controller are to:
• Compare the throttle braking command signal with that from the DAQ
and send the current associated with the higher signal to the eddy cur-
rent brake

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• House a relay that is activated by the DAQ when the friction brake is
required. This relay, in turn, operates a solenoid at the friction brake to
fully engage the brake.
• House a relay that energizes a battery backup unit, if one is installed.
Figure 2-3 Baylor 2025B Brake Controller
2-4-2 Eddy Current Brake
The eddy current brake is an electric brake that is attached to the drawworks and
driven by current from the Brake Controller. The current sent to the eddy current
brake is the higher of the current commanded manually by the operator via the
throttle and that commanded by the DAQ, based upon Block Control software cal-
culations.
2-4-3 Friction Brake
The friction brake is attached to the drawworks and can be engaged from the
driller's station at any time with activation of the Emergency Stop Pushbutton. The
friction brake solenoid is installed in a manner which allows any operation by
existing crown protector equipment. However, the Brake Controller will automati-
cally command activation of the friction brake (via a solenoid) if any of the fol-
lowing conditions exist:
• Block Control software calculations determine that the friction brake is
required to safely stop the block.

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• A malfunction is detected in the DAQ, Brake Controller, eddy current

brake or connecting cable.
• The operator pulls the EMERGENCY STOP button on the Driller's
Display.
CAUTION
When the Block Control System commands application of the friction
brake, a one second delay occurs, then the brake is fully engaged. This
results in rapid movement of the brake handle at the driller's station
which could cause injury to personnel and damage to rig equipment.
2-4-4 Battery Backup
An optional stand-by power supply available from Baylor can be used to power
the electric brake if any of the following conditions occur:
• DC power loss or
• The operator pulls the EMERGENCY STOP button on the Driller's
Display or
• The current prescribed by the DAQ is not flowing in the eddy current
brake.

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2-4-5 Throttle
The operator uses the throttle to control the eddy current brake directly. During
tripping, the throttle is used in conjunction with the Power Select Switch Box/J-
Box.
The throttle controls the eddy current brake as long as either of the following con-
ditions exist:
• The braking command signal from the throttle is higher than that from
the DAQ
• The OVERRIDE/RESET NORMAL switch on the Driller's Display is
positioned to OVERRIDE.
WARNING
When the OVERRIDE/RESET NORMAL switch is in the OVERRIDE

position, the Block Control System is completely unable to provide a back-
up to the operator in controlling the block. It is the full responsibility of the
operator to control the block. Fatal injury to personnel and severe damage
to rig may result if the operator fails to control the block.
2-5 DRILLER'S DISPLAY
The Driller's Display (Figure 2-4) is an enclosure that is mounted at the driller's station. Its
main functions are summarized below. Refer to Chapter 7 for detailed instructions on
using the display.
• The OVERRIDE/RESET NORMAL switch is used to override the Block Con-
trol System, clear system alarms and select the normal operating mode.
• The LEARN button is used to define upper and lower set points.
• The EMERGENCY STOP button is used to command full application of the
friction brake and eddy current brake and to engage the battery backup unit.
• An alarm horn inside the display box sounds when the system is in alarm.
• Three LED's communicate the Block Control System's current operating con-
dition: Friction Brake Enabled (Red LED), Alarm (Yellow LED) or System On
(Green LED).
• When in OVERRIDE, the green LED will blink. The red or yellow lights may
blink alternately with the green, if an alarm condition exists.

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WARNING

position, the Block Control System is completely unable to provide a
backup to the operator in controlling the block. It is the full responsibility
of the operator to control the block. Fatal injury to personnel and severe
damage to rig may result if the operator fails to control the block.
Figure 2-4 Baylor Driller’s Display

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2-6 SENSORS & CALIBRATION SWITCH BOX
Block Control System sensors and the calibration switch box are described in the follow-
ing paragraphs.
2-6-1 Shaft Encoder Assembly
The shaft encoder (Figure 2-5) is an optical encoder that attaches to either end of
the drawworks at the rotoseal and is used to determine block position. The encoder
measures drawworks rotation by turning in a one-to-one relationship with the
drawworks drum shaft and providing pulses as the drum rotates. Data from the
encoder is sent to the DAQ, where it is used by the Block Control software to cal-
culate block position and velocity.
Figure 2-5 M/D TOTCO Shaft Encoder Assembly (P/N H12321A)
2-6-2 Drawworks Proximity Sensor - M/D TOTCO P/N 220378
The drawworks proximity sensor provides a redundant check on shaft encoder

operation. The sensor is calibrated to detect a metal target placed on the draw-
works and sends a pulse to the DAQ each time it detects the target. The Block
Control software compares the proximity sensor signals with those from the shaft
encoder and, if a discrepancy exists, the DAQ issues an alarm.

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2-6-3 Railmount Proximity Sensors - M/D TOTCO P/N H11094A-01
Two railmount proximity sensors are used as a redundant check of block height
sensor integrity.
2-6-4 Hook Load Pressure Transducer
The hook load pressure transducer is a hydraulic system transducer with built-in
signal amplifier that is used to determine the weight on the drill line. It senses and
converts hydraulic pressure from the rig's weight indicating system into a 4-20 mA
DC electrical signal. This signal is sent to the DAQ, where it is used by the Block
Control software to compute hook load and maximum allowed block velocity.
2-6-5 Calibration Switch Box - M/D TOTCO P/N 219255-001
The calibration switch box (Figure 2-6) is a remotely-operated, dual-switch enclo-

sure used to input layer changes (L/C START button) and block height (CON-
NECTION button) during block height channel calibration. Information from the
encoder is sent to the DAQ, where it is used in conjunction with the Configuration
and Calibration software to define the relationship between block height and sen-
sor counts.
Figure 2-6 M/D TOTCO Calibration Switch Box

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2-7 CONFIGURATION & CALIBRATION LAPTOP PC
A laptop PC, temporarily connected to the DAQ, is used to configure, calibrate and set up
the Block Control System.
2-8 VXC GRAPHICS DISPLAY, SAC

The Safe Area VXC system displays and plots sensor data collected by a TOTAL DAQ
(Data Acquisition Unit). It is designed for use in non-hazardous locations only. Audio and
visual indicators let the operator know when alarm conditions exist. Refer to Figure 2-7.
T-POT
MODEM
SAFE AREA VXC
COMPUTER & MONITOR
PRINTER
(EPSON LQ2550 OR HP PAINTJET)
DESKTOP KEYPAD
Figure 2-7 VXC Graphics Display System (SAC)

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2-9 SPECIFICATIONS: DAQ AND SENSORS
Table 2-1 lists the specifications for the DAQ and sensors. For specifications on the 2025B
Brake Controller and other Baylor instruments, consult the appropriate Baylor manual.
Table 2-1 DAQ and Sensor Specifications
Parameter Requirements/Limits
DAQ Electrical:
Primary Power 90 to 250 VAC, no modifications required
Frequency 47 to 65 Hz
Current 2.0 amperes maximum
Primary Power Fuse Time delay fuse, FLM, 2.0 amperes
DC Power Two 40-watt fused supplies: +/- 15 VDC and +5/+28 VDC
DAQ Environmental:
Ambient Operating Temperature -20C to +60C
Ambient Storage Temperature -30C to +85C
Internal Humidity 5% to 90% Non-condensing
DAQ Mechanical
Enclosure Stainless Steel, NEMA 4X
Dimensions 21.5" H x 19.0" W x 8.5" D (546 mm x 482 mm x 216 mm)
Mounting Brackets 19.5" H x 13.8" W (495 mm x 351 mm)

Mounting Hole 0.40" (10.2 mm) diameter
Door Clearance Area 21.5" H x 48" W (546 mm x 122 mm) @ 90° arc
Weight 57 lb. (126 kg)
SENSORS:
Analog Channels 23 analog input channels per DAQ.
Analog Voltage 0-10 volts maximum in two ranges: 0-5 volts, 0-10 volts
Analog Current 0-20 mA in three ranges: 0-20 mA, 4-20 mA, 12-20 mA
Analog Accuracy 0.5% of full scale, maximum
Digital Channels 14 digital input/output channels
Digital Inputs Maximum frequency - 100 Hz (6000 pulses/minute); Minimum

pulse width - 7ms
Digital Standard Input Sensors Proximity sensors: 2- or 3- wire. To use 4-wire sensor, utilize
two input channels.
Contact closure: Closed - 500 ohms maximum. Open - 10K

ohms minimum.
Digital Outputs Maximum frequency: 110 Hz. Output jitter: 0.5% maximum

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Table 2-1 DAQ and Sensor Specifications
Parameter Requirements/Limits
Digital Output Functions Pulse-width modulation: 0-100% duty cycle; 0-10 volt output,
Maximum frequency response of driven device: 102 Hz, Simu-
lated analog output voltage range - 0-10 volts. Signal can drive
analog chart recorders and meters with frequency response of
less than 40 Hz.
Digital Alarm Outputs User-defined high and low set points.
0- and 10-volt levels.
Normally high and normally low signal levels available.
Digital Discrete Outputs User-defined trip point.

User-defined hysteresis.
0- and 10-volt levels.
Normally high and normally low signal levels available.

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2-10 OVERVIEW: SYSTEM SETUP PROCEDURES
The flow chart in Figure 2-8 shows the general procedures for setting up a Block Control
System and the order in which they should be done.
Figure 2-8 Overview- System Setup Procedure

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CHAPTER 3
THEORY OF OPERATION
3-1 INTRODUCTION
This chapter describes the operational theory of the Block Control System, including the
following:
• System functions of the DAQ and Brake Controller
• Signal paths between Block Control System components
• DAQ Alarm Levels
• System Error Conditions
• Block Operation Zones
Figure 3-1 illustrates how the Block Control System functions as a backup to the operator
by showing the typical communication paths between the throttle, DAQ, Brake Controller
and eddy current brake.
Figure 3-1 Block Control System Communication Paths

M/D TOTCO
Theory of Operation Manual 60-60
3-2 DAQ SYSTEM FUNCTIONS
During operation of the Block Control System, the DAQ performs the functions listed
below:
• Receives signals from the shaft encoder, drawworks proximity sensor, rail-
mount proximity sensors and hook load pressure transducer.
• Continually compares signals from the shaft encoder and drawworks proximity
sensor to insure that they agree on drawworks rotation. When applicable, the
DAQ compares block position signals from the railmount proximity sensor
with that from the shaft encoder. If any of the block position sensors disagree,
an error condition exists and the DAQ issues an alarm.
• Continually computes block position, block velocity and hook load and uses
these values, along with the direction of block travel, to determine the braking
required.
• Continually sends two pulse-width modulated signals to the Brake Controller,
representing the required current flow in the eddy current brake (NORMAL
THROTTLE and REVERSE THROTTLE).
• If the friction brake is required, the DAQ energizes a relay housed in the Brake
Controller and issues an alarm.
• When the eddy current brake is utilized, the DAQ receives a signal from the
Brake Controller (CURRENT FEEDBACK) representing the current flowing
in the brake. If the current required by the Block Control software is not flow-
ing in the brake, an error condition exists and the DAQ issues an alarm.
• Sends signals to the Driller's Display regarding Block Control System status so
that the status can be represented on the display.
• Receives operator input signals from the Driller's Display.
• Monitors the COMMAND FEEDBACK signal.
• Monitors the system for NON-CRITICAL and CRITICAL error conditions.
• Monitors status of input UPS.
3-3 BAYLOR 2025B BRAKE CONTROLLER FUNCTIONS
The Baylor 2025B Brake Controller performs the functions listed below:
• Receives and compares braking command signals from the throttle and DAQ.
• Converts the higher of the throttle and DAQ braking command signals into
current command and sends that current to the eddy current brake.
• When the eddy current brake is utilized, the Brake Controller sends a signal to
the DAQ (CURRENT FEEDBACK) representing the current flowing in the
brake.

M/D TOTCO
Manual 60-60 Theory of Operation
• If the current flowing in the brake is less than that required by the Block Con-
trol software, an error condition exists and the DAQ issues an alarm and takes
appropriate action.
• Checks for NON-CRITICAL and CRITICAL error conditions in the Brake
Controller and informs the DAQ of these conditions, so that the DAQ can issue
an alarm.
• When the eddy current brake is controlled by the throttle, the Brake Controller
receives signals from the Power Select Box restricting the maximum current
output to the eddy current brake (50% or 100% of the rated current excitation)
and regulates the output current accordingly.
3-4 SYSTEM SIGNAL PATHS
Figure 3-2 illustrates the signal paths between Block Control System components. Signals
that require explanation are described in Paragraphs 3-4-1 through 3-4-7.
3-4-1 NON-CRITICAL Error Condition Signal
This voltage signal is sent to the DAQ when a non-critical error condition is
detected in the Brake Controller.
3-4-2 CRITICAL Error Condition Signal
This voltage signal is sent to the DAQ when a critical error condition is detected in
the Brake Controller.
3-4-3 NORMAL THROTTLE Signal
This pulse-width modulated signal tells the Brake Controller how much current to
send to the eddy current brake. The Brake Controller converts this signal to a 0-10
VDC signal, where 0 VDC corresponds to 0 current and 10 VDC corresponds to
the maximum rated current excitation.
3-4-4 REVERSE THROTTLE Signal
This pulse-width modulated signal is the inverse of NORMAL THROTTLE. The

Brake Controller converts this signal to a 0-10 VDC signal, where 0 VDC corre-
sponds to the maximum rated current excitation and 10 VDC corresponds to 0 cur-
rent. The presence of this signal insures that full application of the eddy current
brake will be commanded if the DAQ loses power or malfunctions.

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3-4-5 CURRENT FEEDBACK Signal
This scaled 4-20mA signal (0-160 braking amps) represents the current flowing in
the eddy current brake. If the current flow in the eddy current brake does not reach
the rate requested by the DAQ, the DAQ assumes that a problem exists in the eddy
current brake, Brake Controller or connecting cables and issues an alarm that com-
mands application of the friction brake.
3-4-6 COMMAND FEEDBACK Signal
This scaled 4-20mA signal (-10% to 100% current command) represents the per-
centage of current command sent by the Brake Controller to the eddy current
brake. It is used to insure that the NORMAL THROTTLE and REVERSE
THROTTLE signals sent by the DAQ are in agreement. If this current is not repre-
sentative of that intended by the DAQ's NORMAL THROTTLE and REVERSE
THROTTLE signals, the DAQ assumes that one of the two signals is faulty and
issues an alarm.
3-4-7 DAQ ALARM Signal
Whenever the DAQ senses an error condition, it sends a DAQ Alarm signal to the
Brake Controller's auxiliary board, mounted on the Brake Controller door (Appen-
dix B). Upon receiving this signal, the auxiliary board turns on a red LED, indicat-
ing the error condition and alarm.

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Figure 3-2 Block Control System Signal Paths

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3-5 DAQ ALARM RESPONSE
The brake handle on most drilling rigs is firmly and mechanically linked to the friction
brake bands, assuring the driller is always able to activate the brake. Less understood by
those unfamiliar with drilling equipment, however, is the fact the system can also rapidly
and forcefully move the handle. Hence application of the friction brake can involve move-
ments that could endanger the driller. Further, application of any braking force, even the
relatively slow acting eddy current brake, when heading upward, could cause line spool-
ing problems and severely shorten wireline life.
3-5-1 Zones
In the design of the Block Control System it was decided to divide the operation of
the hoisting equipment into “zones” of operation. These zones relate to when oper-
ations would be endangered by a failure of the eddy current braking ability.
In a Zone “0”, a failure of the eddy current brake would be of no immediate conse-
quence. The driller and/or system would not need to take immediate action. This
was defined to be true, only when raising, and above 5 feet of the floor, but at a
height less than where braking should be initiated to bring the blocks to a stop at
the appropriate Hi setpoint (Corner Up).
Zone “1” is an area of operation where full application of the eddy current brake
could (by itself) bring the block to a minimal safe speed. These areas are:
• Physically anytime the block is headed downward, and the system cal-
culates that electric brake activation can stop the block before it reaches
its lower target.
• When headed upward above the Corner Up, but less than the Hi Set-
point.
Zone “2” is an area where application of the eddy current brake alone might not be
sufficient to bring the blocks to minimal speed before encountering one of the
physical setpoints. Physically these areas are located below the point where the
system calculates both brakes must be applied to avoid block travel beyond the set
limits.

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Figure 3-3 Block Operation Zones - Block Traveling Up
Figure 3-4 Block Operation Zones - Block Traveling Down

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3-5-2 Alarm Classification
All alarms originally generated by the 2025B brake control are classified as either
“critical” or “not-critical”. Critical alarms are those that immediately and
adversely affect the output of the brake control and non-critical alarms are those
that alert us to a failure of a redundant component or to a tolerable situation, which
allows the controls to fully operate. For example, the failure of one of the two
redundant control power supplies or the grounding of only one input power phase
are “non-critical’ alarms.
These classifications are further extended to non-brake control components. For

example, the Brake Cooling Alarm is non-critical because it should not immedi-
ately affect brake performance, but should be alarmed. Similarly, if the DAQ
receives conflicting signals as to where the block is located, the only sure action is
to treat the situation as a critical alarm.
3-5-3 Alarm Response
When the alarm system portion of the Block Control System is active, it can only
take one of the four predefined actions as described below.
1. Alarm response “0” - Take no action, no alarms were activated. The

System On LED is continuously lit, indicating all is OK.
2. Alarm response “1” - Sound an audible horn and give a visual alarm. A
yellow LED indicates to the driller that something is wrong with the
system.
3. Alarm response “2” - Sound an audible horn and give a visual alarm, as
in “1” above, but also command the eddy current brake control to come
on fully. The eddy brake will safely control the block by itself.
4. Alarm response “4” - Performs all actions as in “1” and “2” above, but
also activates a solenoid energizes the "crownamatic". This actuates the
friction brake and releases any pressure available to the drawworks
clutches.

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3-5-4 Matrix Definition
The proper alarm response is determined from whether an alarm is “critical” or

“non-critical” and in which “zone” the alarm has occurred. Refer to Table 3-1.
Table 3-1 Alarm Responses
ALARMS
Non Critical Critical
ZONE No Alarm Alarm Alarm
“0” 0 1 1
“1” 0 1 2
“2” 0 1 3
Alarm Summary: The system will alarm with only an audible and visual indication
to those alarm conditions that do not immediately adversely affect the ability of
the system to bring about a safe stopping, or near stopping, of the block. If in a sit-
uation where only the eddy current brake is required to bring about a safe condi-
tion of the block, then only the eddy current brake should be energized. If, on the
other hand, the eddy current brake alone is not sufficient to safely bring about the
stopping of the blocks, then the friction brake will be applied.

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Figure 3-5 Brake Control System Signal Flow

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3-6 SYSTEM ALARM CONDITIONS
An alarm is issued by the DAQ when an error condition or sensed malfunction exists. The
DAQ uses these error conditions in conjunction with block operation zones to determine
the proper alarm response. The DAQ alarms are determined on channels available for
viewing on the laptop with CALCONF or with a SAC or DataWatch, if the system is so
equipped. Normal system operation is indicated by a “0” alarm value while a “1” indicates
an alarm.
There are also two associated summary channels, a “Critical Summary” and a “Non/Criti-
cal Summary”, each of which will be a 1 if any of the respective critical or non-critical
alarms are high. As a further aid in troubleshooting, there is a channel within the DAQ
called “Last Alarm #” the value of which is the alarm number of the last alarm. This chan-
nel is not usually erased (except by system restart) and hence the last offending alarm is
recorded, even if reset by the operator before the maintenance personnel could hook-up
the laptop computer. Most of the alarms described below are fully spelled, though such is
not the case on the DAQ channels themselves because of a 14 character limit. The descrip-
tions of the DAQ alarms are as follows:
3-6-1 Acceleration Alarm
This alarm indicates an inability of the Block Control System to keep the down-
ward acceleration of the block within previously defined limits. This alarm might
occur if the allowed acceleration is quite low because of a low maximum allowed
velocity (as when the speed limit potentiometer is turned down quite low) or if the
brake is quite hot and ineffective. If the electric brake is not impaired, alarm avoid-
ance could be done by having the driller pull on the electric brake prior to mechan-
ical brake release, and then slow electric brake release. Note that this is the
normally recommended method of operation of the electric brake.
3-6-2 Brake Critical
This alarm condition is the result of the brake control sending a signal to the DAQ
indicating a critical alarm that seriously affects the brake or brake control’s ability
to absorb torque. Critical alarms within the brake control include, SCR Misfire,
Over-Current, Over-KW, Throttle Mismatch, Battery Back-Up In Use, Coil Fuse
and Input Power Quality. Any of these alarms should turn the appropriate LED
indicator on the brake control mimic panel fro GREEN to RED and also sink the
available source voltage on the appropriate DAQ analog channel, announcing the
alarm.
3-6-3 Current Alarm
This alarm is essentially a DAQ backup of the brake control’s throttle mismatch
alarm. If the DAQ senses that it is commanding near full output current, but has
not gotten a sufficient response, this alarm will occur. Consistent occurrence with a
properly acting brake control might indicate improper calibration of the current
feedback signal.

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3-6-4 EDMS Prox Alarm
This alarm will go high (become a “1”) if there is a sensed discrepancy between
the counts recorded from the encoder and the counts sensed by the prox switch
mounted to detect the target on the drawwork’s drum clutch (the “EDMS” prox).
An alarm could indicate that the prox switch or its target is improper or that the
encoder is inactive. An inactive encoder could trip both this alarm and the
“Encoder Alarm”.
3-6-5 Encoder Alarm (Encoder Operation)
This alarm indicates that the system has detected drum rotation via the “EDMS
prox” switch, yet has sensed no rotation of the drawworks encoder itself. Possible
causes of this alarm include the unscrewing of the encoder assembly from the
drawworks shaft assembly, and a severance of the encoder cabling.
3-6-6 Derrick Prox Alarm (Encoder Operation)
This alarm indicates that the system has sensed the position of the derrick prox
switches at a point outside the allowable range (“Derrick Prox Lo” to “Derrick
Prox Hi”). The most frequent cause for this is system miscalibration, usually after
the drill crew has cut and slipped the line without resetting the system’s zero point.
Note that this alarm does not reset with system RESET or OVER-RIDE as it’s
occurrence indicates a serious system miscalibration. The alarm will clear itself
when the derrick prox switches are sensed within the allowable range. Note that
during system commissioning, the allowable range should be determined, account-
ing for not only normal line stretch and movement, but also for variances as a
result of a retractable block and/or a crown or block mounted heave compensator.
3-6-7 Position Alarm
This alarm is the most frequently occurring alarm. It will occur anytime the eleva-
tors go beyond the allowable range, i. e. above the Hi Setpoint, or below the Lo
Setpoint. Further note that this alarm will occur on those systems with the ZMS
option whenever the elevators go below a “ZMS Target” that has been
“Activated”. It is important for the operator to realize that this alarm doesn’t nec-
essarily indicate system mis-operation, but perhaps a need for the driller to rede-
fine the allowable area of operation. He need only push the “learn” push-button
(sometimes called the “HI-LO Limit Set”) to redefine the allowable limits.
3-6-8 Velocity Down Alarm
This alarm indicates an inability of the Block Control System to control the down-
ward velocity of the block. Its occurrence might indicate the brake is quite hot, de-
clutched, or otherwise ineffective.

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3-6-9 Velocity Up Alarm
This alarm indicates an inability of the Block Control System to control the
upward velocity of the block. This alarm most frequently occurs when the driller
mistakenly continues powering upward past the Hi Setpoint, usually occurring just
before the position alarm.
NOTE
The preceding alarms, Section 3-6-1–Section 3-6-9, are considered
“Critical” and are summarized with the “Critical Summary” channel
3-6-10 Brake Non-Critical
This alarm condition is the result of the brake control sending a signal to the DAQ
indicating that a non-critical alarm has been sensed by the brake control. Non-crit-
ical alarms are those that do not immediately and adversely affect the ability of the
brake or brake control to control the block. These include an AC ground, DC
ground, loss of one of the two control power sources, or phase rotation. Any of
these alarms should turn the appropriate LED indicator on the brake control mimic
panel from GREEN to RED and also sink the available source voltage on the
appropriate DAQ analog channel, signaling the alarm.
3-6-11 Brake Cooling
This alarm is on those systems that have the Brake Monitoring System option. It
indicates a high temperature has been sensed for the outlet cooling water, or a loss
of cooling water flow on the input. There is a two second delay on activation of the
alarm with the flow sensors, to account for flow fluctuations, and a disarming of
the alarm after five minutes of no brake use. This is to allow the driller to stop the
cooling water if not required for a period of time without the nuisance occurrence.
Note however that the alarm is immediately reactivated if the brake is used with-
out proper cooling water flow being sensed.

M/D TOTCO
3-6-12 Friction Brake Pressure Switch
This alarm is on those systems that have the Brake Monitoring System option,
monitoring the air pressure used to set the friction brake (the pressure to the
“Crownamatic” activation solenoid). This must be available to back up operation
of the electric brake, and hence is sensed to comply with requirements for North
Sea operation. This alarm and/or pressure switch can be eliminated if there is a
battery back-up available. Note that occurrence of this alarm will frequently occur
if the driller over-rides the Crownamatic, which should be an alarm situation any-
way.
3-6-13 Hook Load Alarm
This alarm indicates that the sensed hookload is below a value of zero, usually
indicating that the hydraulic pressure has been lost to the cell.
3-6-14 UPS Alarm
This alarm is on most systems having the Brake Monitoring System option, and
indicates that the systems UPS is running on its battery reserve. This alarm might
also be on other systems, and possibly not on some with the Brake Monitoring
System option that utilize a rig’s central UPS system.
3-6-15 Non-Critical Position
This alarm, used on some systems, indicates that a critical position alarm is about
to occur. Hence it serves as a warning for some operators of impending friction
brake activation.
NOTE
The preceding alarms, Section 3-6-10–Section 3-6-15, are considered
“Non-Critical” and are summarized with the “Non-Critical Summary”
channel.

M/D TOTCO
3-7 Set Points
The operator programs an upper and lower set point into the Block Control System using
the LEARN button on the Driller's Display (Chapter 6). Upper and lower set points are
defined below:
• Upper Set Point - the highest working position that the block should reach
• Lower Set Point - the lowest working position that the block should reach
Each set point has a prescribed buffer, or distance above and below the set point. The
function of the Block Control Software is to stop the block within the buffer zone. Buffer
zones are part of the Block Control Software and cannot be changed by the operator.
NOTE
The operator can change the upper and lower set points, but not the buffers.
3-7-1 Corners
The Block Control Software continually calculates upper and lower corner values
and uses them to determine when and how to apply the brakes. Upper and lower
corners are defined below:
• Upper Corner - When the block is traveling up at maximum velocity,
the upper corner is that point at which the block should begin to slow
down, or decelerate. The upper corner exists only when the block is
traveling up.
• Lower Corner - When the block is traveling down at maximum veloc-
ity, the lower corner is that point at which the block should begin to
slow down, or decelerate. The lower corner exists only when the block
is traveling down.
* When this condition occurs, the Brake Controller Auxiliary Board's Battery
Backup LED comes on.
** When this condition occurs, the Brake Controller Auxiliary Board's DAQ
Alarm LED comes on.
3-8 BATTERY BACKUP ENABLED
When the battery backup is enabled, the Brake Controller Auxiliary Board's Battery
Backup LED comes on. The battery backup is enabled by either of the conditions below:
• The Brake Controller's Throttle Mismatch alarm or
• The EMERGENCY STOP button on the Driller's Display is activated.

M/D TOTCO

M/D TOTCO
CHAPTER 4
INSTALLATION
4-1 INTRODUCTION
This chapter contains the following:

• Location requirements for Block Control System components
• DAQ installation
• MTL barrier box installation
• Sensor installation
• Sensor and Block Control System component connections to the DAQ
• Driller's display, power select switch box/j-box connections to the 2025B
Brake Controller
• Friction brake solenoid installation
Refer to Appendix A for detailed installation drawings. Refer to Baylor Company manuals
for procedures on installing all Baylor instruments.
4-2 HAZARDOUS AREA LOCATIONS
Figure 4-1 shows the location requirements for Block Control System components. Before
beginning installation, the installer should be thoroughly familiar with the code require-
ments and hazardous area classifications for all areas of the installation site and should be
experienced in the common methods of installing intrinsically safe equipment.

M/D TOTCO
Installation Manual 60-60
(Only connected & used

during calibration)
Figure 4-1 System Component Location Requirements

M/D TOTCO
Manual 60-60 Installation
4-3 DAQ INSTALLATION
To install the DAQ, follow the steps below.
1. Mount the DAQ ( Section 4-3-1).

2. Earth ground the DAQ (Section 4-3-2).
3. Connect the primary AC power cord to the DAQ and to the AC source
(Section 4-3-3).
4. Ensure that the switch positions on the DAQ digital board are properly set
(Section 4-3-4).
5. Ensure that the switch positions on the DAQ communications board are prop-
erly set (Section 4-3-5).
6. Ensure that the switch positions on the DAQ EDMS board are properly set.
(Figure 4-3-6).
4-3-1 Mount the DAQ
Mount the DAQ as close to the Brake Controller as possible, using the four mount-
ing holes on the DAQ rear door (Figure 4-2 or Figure 4-3). The DAQ may be
bolted directly to a rigid structure or bolted to mounting brackets and then clamped
securely to a rigid structure. A clearance of approximately 30 inches (76.2 cm) in
front and on the left side is required to allow the door and case to swing fully open.
Clearance below the DAQ should be adequate for service loops that allow opening
of the case to access the rear compartment.

M/D TOTCO
Figure 4-2 DAQ (standard) Installation Dimensions
Figure 4-3 DAQ (Permanent Location) Installation Dimensions

M/D TOTCO
4-3-2 Ground the DAQ
Connect the eight-gauge ground conductor, P/N 230017, from the DAQ to earth
ground as follows:
CAUTION
All earth ground connections must be made in non-hazardous areas.
Ensure that all connecting surfaces are bare metal and completely free of
grease, paint or oxidation and that the distance between the DAQ and
ground connection is minimal. Do not solder earth ground connections.
1. Connect one end of the ground conductor to the DAQ ground lug (Fig-
ure 4-4).
2. If a grounding rod will be used, proceed to Step 3. Otherwise, use an

appropriate-sized ground clamp to make a secure compression connec-
tion between the free end of the ground conductor and rig substructure.
3. Drive a clean, copper-clad grounding rod that is eight feet long and 1/2-
inch in diameter into the ground so that just enough of the rod is
exposed to attach a 1/2-inch ground clamp.
4. Use a 1/2-inch ground clamp to make a secure compression connection
between the free end of the ground conductor and the grounding rod.
Figure 4-4 DAQ Ground, Power, and Signal Connectors

M/D TOTCO
4-3-3 Connect Primary AC Power Cable
To connect the primary AC power cable from the rig power source to the DAQ,
refer to Figure 4-5 and follow the steps below.
CAUTION
Ensure that the ground wire is properly installed before connecting pri-
mary AC power cable
1. Open DAQ rear cover door.
2. Ensure that DAQ ON/OFF switch is set to OFF position.

3. Remove the protective cover which encloses the power terminals and
power supply.
4. Route end of AC power cable (PN 219531-002) with terminals through
DAQ cable gland.
5. Observe wire color coding and connect terminals to terminal block and
ground lug.
6. Tighten cable gland nut until cable is secured.
7. Connect other end of AC cable to rig power source.
8. Roll and tie excess cable away from rig traffic and working space.
9. Replace AC power protective cover.

M/D TOTCO
Figure 4-5 AC Primary Power Connections
4-3-4 Digital Board Dip Switch Settings
The digital board contains two dip switches. Figure 4-7 shows how SW2 should be
set for the Block Control System. Refer to this figure to insure that the switch posi-
tions on SW2 are properly set. For information on alternate settings for SW2 and
on other features of the DAQ digital board, refer to M/D TOTCO Manual 60-10.
SW3 is currently not used
NOTE
Switch position 2 on SW2 must be set to the OFF position. Otherwise, the
DAQ will not communicate with the EDMS board to receive block height
data.

M/D TOTCO
ON
SW2
OFF
1 2 3 4 5 6 7 8
Figure 4-6 DAQ Digital Board Dip Switch Settings
4-3-5 Communications Board Dip Switch Settings
The communications board contains two dip switches. Figure 4-7 shows the
default settings for SW2. Refer to this figure to insure that the switch positions on
SW2 are properly set. For information on alternate settings for SW1 and on other
features of the DAQ communications board, refer to M/D TOTCO Manual 60-10.
Dip switch 1 is currently not used.

M/D TOTCO
Figure 4-7 DAQ Communication Board Dip Switch Settings
4-3-6 EDMS Board Dip Switch Settings
The EDMS board contains one dip switch, as shown in Figure 4-8. This switch is
currently not used.
Figure 4-8 EDMS Board Dip Switch Settings

M/D TOTCO
4-4 I.S. BARRIER BOX INSTALLATION
The intrinsically safe barrier box provides safety barriers for connecting the Block Control
System to I.S. devices.
I.S. barrier box wiring must meet the local regulatory code requirements of the installation
location. Examples of local regulatory codes are NFPA-70, BS5345 Part 4 and ANSI-ISA
12.6. Check for local requirements, if necessary.
I.S. barrier box point-to-point wiring is specified in the installation drawing. Refer to
Appendix A for two types of block control installation.
4-5 SENSOR INSTALLATION
This section contains installation procedures for the proximity sensors, shaft encoder and
hook load pressure transducer, as follows:
• Installing the sensors onto the rig.
• Connecting the sensor signal cables to the DAQ field termination board.
4-5-1 Cabling Guidelines
The following paragraphs describe guidelines to follow when connecting sensor

signal cables.
4-5-1-1 Guidelines for Preventing Cable Damage
Observe the following practices when routing sensor signal cables to the
DAQ termination board:
• Route cables so that they are out of walkways and not exposed
to sharp corners that could wear through the insulation.
• Plan signal cable runs to avoid wet areas and close proximity to
power cables.
• Use nylon (land rig) or stainless steel (offshore rig) tie wraps to
dress, secure, and support the cables.
• Take special care to protect splices from moisture and exces-
sive strain.
4-5-1-2 Electrical Interface
When signal cables must be run such that power cables could cause elec-
trical interference, use shielded cables instead of the non-shielded cables.
This prevents induced noise from causing erratic sensor channel values.

M/D TOTCO
4-5-1-3 Shielded Cable Splicing
Sensor cables must typically be spliced in the field.
WARNING
PLAN EACH RIG UP SO THAT SPLICES ARE NOT LOCATED IN

HAZARDOUS AREAS.
Follow the guidelines below when splicing shielded cable:

• When joining two pieces of cable, always cut the individual
conductors.
• Stagger the butt splices along the length of the cable splice.
• Observe color code when cutting and splicing conductors.
• Use a crimping tool and apply enough pressure on each butt
splice connector to ensure a good compression connection
between the conductor and the connector.
• Always seal and protect each splice with a strip of mastic tape
that extends up the cable about one inch past both sides of the
splice and wrap the mastic tape securely with black electrical
tape.
WARNING
Check local electircal codes. Splicing is not allowed in some offshore areas.
Any cable termination or junctions must be protected by junction boxes in
these applications.

M/D TOTCO
4-5-2 Proximity Sensor Installation
The following paragraphs describe how to install the drawworks and railmount
proximity sensors.
4-5-2-1 Drawworks Proximity Sensor Installation
To install the drawworks proximity sensor and target, refer to Figure 4-9
through Figure 4-11 and follow the steps below.
1. Measure the circumference of the drawworks high clutch

assembly.
2. Mount the supplied target, P/N 220605-001.

3. Weld the sensor's metal mounting bracket to the rig floor.
4. Place the sensor into the bracket; then slowly rotate the draw-
works drum one revolution to insure that the sensor is not
struck by the target and that the gap between the sensor and
target is 1/8" to 1/4".
5. Connect the sensor cable to the DAQ (Section 4-5-6).
6. After the sensor is connected to the DAQ, refer to
Appendix A, if needed, and verify the following:
• Without the target present, the voltage across the proximity
sensor is less than 3.40 V (J7 DIGITAL IN (+) and J7
GROUND).
• With the target present, the voltage across the sensor is
more than 8 V.

M/D TOTCO
Figure 4-9 Drawworks Proximity Sensor and Target
A = Distance between metal mounting bracket and top of proximity sensor (min 1 inch).
B = Distance between proximity sensor and meta target (min 1/8 inch, max 1/4 inch).
C = Distance between proximity sensor and any metal object (min 1.25 inch).
Figure 4-10 Mounting Dimensions - Drawworks Proximity Sensor

M/D TOTCO
4-5-2-2 Railmount Proximity Sensors Installation
The railmount proximity sensors detect two metal targets on the travel-
ing block when the targets pass the sensor. Follow the steps below to
mount the sensors and targets.
1. Select the mounting position for the targets and sensors by

referring to Figure 4-11 and Figure 4-12 and honoring these
two requirements:
• The location of the proximity sensors must be such that,

when the block is traveling down, the sensor activates
before the block assembly base is close to the rig floor.
• The mounting location should be at a height maintenance
personnel can easily access at any time. This is typically
head high on the level of the doghouse.
2. Attach a metal target to the traveling block assembly.
(If the rig has heave compensation device, the target should be
mounted on the uncompensated side of the dolly.)
3. Weld the proximity sensor mounting bracket to the rail.
4. Insert the sensor and adjust as needed; then tighten the screws
to hold it in place.
5. Slowly move the block so that it passes the sensor and insure
that the sensor is not struck by the target.
6. Refer to Section 4-5-6 and Appendix A to connect the sensor
cables to the DAQ.
7. After the sensor is connected to the DAQ, refer to
Appendix A, if needed, and verify the following:
• Without the target present, the voltage across the proximity
sensor is less than 3.40 V (lower sensor: J8 DIGITAL IN
(+) and J8 GROUND; upper sensor: J9 DIGITAL IN (+)
and J9 GROUND).
• With the target present, the voltage across the sensor is
more than 8 V.

M/D TOTCO
Figure 4-11 Railmount Proximity Sensor Installation
NOTE
It is not imperative that the A and B proximity switches are at the same
height. But, It is imperative that the targets mounted on the dolly activate
both switches simultaneously.

M/D TOTCO
A= Distance from back of sensor to mounting bracket (min of 1.5 inches).

B= Distance from sensor to any other metal object (min of 6 inches).
C= Distance between sensor and target (min of 0.5 inch).
D= Distance between sensor and any other metal in absence of target (min of 4.8 inches).
Figure 4-12 Mounting Locations - Railmount Proximity Sensors & Target
Figure 4-13 Traveling Block Target Dimensions

M/D TOTCO
4-5-3 Shaft Encoder Installation
Refer to Figure 4-15, then follow the procedure below to attach the encoder to
either end of the drawworks at the rotoseal.
1. Ensure that rotoseal thread diameter is 1"- 14 and correctly mates with
encoder. Use adapters to match the threads, if needed.
NOTE
The encoder is designed to fit common drawworks configurations. If the
drawworks must be modified in order to mount the encoder, obtain approval
from rig personnel before making any modifications.
2. Check rotoseal area for possible interference with rig hardware, such as
shields or bolts.
3. Turn off rotoseal air supply.
4. Unscrew rotoseal from drawworks drum shaft.
5. Screw encoder onto drawworks drum shaft, using loctite compound.
6. Reinstall rotoseal on threaded end of encoder.
7. Turn rotoseal air on, then check assembly for leaks.
8. Fabricate a mounting bracket to hold encoder in a fixed position
(Figure 4-15); then weld bracket to the rig floor.
Figure 4-14 Shaft Encoder Dimensions

M/D TOTCO
9. Connect the cable, Part Number 219343, to the encoder.

10. Refer to Section 4-5-6 and Appendix A to connect the encoder cable to
the DAQ.
Figure 4-15 Encoder Mounting Bracket
4-5-4 Calibration Switch Box Installation
The calibration switch box should be stored inside the J-box near the driller's sta-
tion so that the driller can use it to calibrate block height. Figure 4-16 shows the
switch box dimensions. Refer to Section 4-5-6 and Appendix A to connect the
switch box to the DAQ field termination board.
Figure 4-16 Calibration Switch Box Dimensions

M/D TOTCO
4-5-5 Hook Load Pressure Transducer Installation
The hook load pressure transducer is connected to the rig's hydraulic weight indi-
cator system between the weight indicator and the load cell on the deadline anchor.
It should be located as close to the weight indicator or load cell as possible. Follow
the guidelines below to connect the pressure transducer.
• Choose the transducer assembly to match the rig's weight indicator
system. Use Table 4-17 to determine the appropriate transducer.
• Before connecting the transducer into the hydraulic line, make
sure that no air is trapped in the transducer assembly by con-
necting the transducer to a hydraulic pump and filling the res-
ervoir with hydraulic fluid.
• Before connecting the transducer into the hydraulic line, advise
the driller, tool pusher and company man that a connection will
be made in the weight indicator system.
• Make the hydraulic line connection when hook load is at a
minimum, so that the hydraulic pressure will be low. To
accomplish this, ask the driller to put the drill string on the
slips while the connection is made.
• Hook load transducer assemblies are available with two types
of hydraulic connectors. Check the rig's hydraulic system and
refer to Chapter 9 to determine which connectors are required.
Figure 4-18 shows a typical transducer installation with a
TOTCO load cell.
• After making the hydraulic line connection, connect the trans-
ducer signal cable to the DAQ, as described in Paragraph 4-5-6
and Appendix A.
• Insure that the transducer assembly and signal cable do not
interfere with the movement of the deadline or anchor.
• Check for leaks in the hydraulic system after installing the
transducer assembly.
CAUTION
It is critical to insure that there are no leaks in the hydraulic system after
installation.

M/D TOTCO
Table 4-17 Suggested Transducer Ranges
Maximum Suggested
Maximum Load
Type of Weight Indicator Deadline Load Transducer Range
Cell Output (psig)
(lbs) (psig)
TOTCO 30 or equivalent 30,000 970 0-1000
TOTCO 40 or equivalent M/D 40,000 1408 0-2000

type F,26
S

type D
type E

type EB
TOTCO 120 & Hercules 122A 120,000 1304 0-2000

or M/D type EH
TOTCO 120 & Hercules 150 120,000 1440 0-2000
TOTCO 150 & Hercules 150 150,000 1800 0-2000
Figure 4-18 Typical Hook Load Transducer Installation

M/D TOTCO
4-5-6 DAQ Sensor Connections
Each sensor cable must be connected to the DAQ field termination board
(Figure 4-19). The main features of the field termination board are summarized
below:
• Analog Sensor Terminal Blocks - J1A through J23A; used to receive
input from current- or voltage-type sensors.
• Analog Sensor Voltage/Current Switches - located to the right of J1A
through J23A, these red rocker switches are used to identify each ana-
log sensor input as current or voltage. A 24th rocker switch is present;
however, it serves no function and should be ignored.
• Digital Sensor Terminal Blocks - J1D through J14D; used to receive
input from digital sensors. These terminal blocks are also used if the
DAQ is used to drive other instruments, such as chart recorders.
• EDMS Sensor Terminal Block - J1E; used to receive input from
EDMS sensor.
• Calibration Switch Box Terminal Block - J1S; used to receive block
height input from the calibration switch box.
• Power Terminal Blocks - J1P - J6P; supplies +5 V to power other
instruments.
• E-DEPTHTM Terminal Blocks - J2S, J1R; used when E-DEPTH is
part of the system.
Refer to Appendix A for Block Control System installation and point-to-point wir-
ing diagrams for rigs with and without existing brake monitoring systems. To con-
nect sensor cables, use the DAQ sensor cable screwdriver (PN 999701-005) to
open the wire connector slot and then insert the wire. For analog sensors, set the
corresponding DAQ analog board rocker switch to “Current” or Voltage”, to
reflect the sensor type.
NOTE
Set the red rocker switch to “Current” for the hook load transducer.

M/D TOTCO
Figure 4-19 DAQ Field Termination Board

M/D TOTCO
4-6 FRICTION BRAKE SOLENOID INSTALLATION
The 2025B Brake Controller commands activation of the friction brake via a solenoid
valve generally supplied by M/D TOTCO. The specifications for this solenoid are given
below.
• Explosion Proof, NEMA 7, 9 Groups A and B
• 150 PSI or greater
• Normally closed 3 way valve
• Brass ports or equivalent
• Nominal 11 watt coil
• Coil voltages available in 120 volt or 240 volt, 60 Hz, 240 Volts 50 Hz, and 24 VDC.
The most frequently used solenoid is M/D TOTCO P/N 976756-007 (120 V, 50/60 Hz).
Follow the steps below for installation.
1. Start with a Crownamatic that is already fully operational. A “typical” sche-

matic for such is shown in Figure 4-20. The hose connections for a conven-
tional Crownamatic are frequently numerous and difficult to follow, hence the
reason for starting with a known good unit. There is often work being done on
a Crownamatic simultaneous with installation of the Block Control System but
it is imperative that the Crownamatic be operational beforehand.
2. Locate the “actuating” line that will go from the “toggle valve” located above
the drawworks to some assortment of actuators and/or relays. In every system
there will be a high pressure supply to the toggle valve, and a line from the tog-
gle valve that will be the “actuating” line.
3. Locate a source of usually high rig air pressure. The most commonly used
source is that just downstream of the Crownamatic override valve. This is so
that if the Block Control System sets the friction brake, over-ride with the
Crownamatic releases the friction brake regardless. Note however that it is also
acceptable to supply the solenoid valve with constant rig air pressure, thus
insuring the capability of the Block Control System even if the Crownamatic
system is in override.
4. Physically mount the solenoid so as to have convenient access to both of the
above lines. Hookup the electrical connections to the explosion-proof coil.
5. Remove rig air from the Crownamatic system. Referring to Figure 4-21, install
a “T” in the high pressure line, from the Crownamatic override valve and
reconnect the line, so as to have one available port. From that port run a hose to
the “HP” or high pressure port of the friction brake activation solenoid.

M/D TOTCO
6. Break the connection of the “actuating” line between the toggle valve and
whatever other equipment might exist (air cylinders, air relays, etc.).
Run a connection from the toggle valve port to the “A” or “LP” input of the
friction brake solenoid valve. Connect the hose that had previously gone to the
toggle valve to the “Out” port of the friction brake activation solenoid.
7. If the system has a BMS option, a friction brake pressure switch must be
installed in the high pressure air available to the friction brake solenoid valve.
Connect the electrical wires as per the system drawing.
8. Test the system in the following manner:
a. Restore air pressure to the Crownamatic system.
b. Ensure that the Crownamatic is not activated, i.e. that the brake handle can
be operated, and that the clutches have air pressure available to them.
c. Activate the Crownamatic by manually activating the toggle valve. Ensure
proper operation as normal. Reset the toggle valve, override the system if
necessary, and restore the system to normal.
d. Activate the friction brake solenoid valve by pushing the Emergency Stop
push-button. The coil should pick, and air should be placed on the “actuat-
ing” line bringing into play all the responses as per normal Crownamatic
activation seen in Step c.
e. Return the Emergency Stop push-button to normal. Ensure return of the
Crownamatic system to normal status.

M/D TOTCO
Figure 4-20 Typical “Crownamatic” Type Installation

M/D TOTCO
Figure 4-21 Friction Brake Solenoid Installation

M/D TOTCO
4-7 DAQ POWERUP
After all Block Control System components have been installed, apply primary power to
the DAQ, as follows:
1. Open DAQ rear door.

2. Set power ON/OFF switch to ON position (Figure 4-5).
3. Close DAQ rear door.

M/D TOTCO

M/D TOTCO
CHAPTER 5
5-1 INTRODUCTION
This chapter contains procedures for the following:

• Block Control System Configuration & Calibration software start-up
• Hook load and block height sensor channel calibration
• Saving the calibration (and configuration, if modified) to floppy
Figure 5-1 Recommended Configuration & Calibration Procedure

M/D TOTCO
Configuration and Calibration Manual 60-60
5-2 CALCONF SOFTWARE STARTUP
The Configuration & Calibration software is downloaded via a laptop PC connected to the
DAQ. Follow the steps below to connect a laptop to the DAQ and initialize the software.
1. Place the OVERRIDE/RESET NORMAL switch on the Driller's Display to

OVERRIDE.
2. Connect the calibration cable assembly (PN 219812) to the laptop 9-pin serial
port and to the DAQ connector labeled “CAL.CONFIG” (Figure 5-2).
3. Turn the laptop PC on. The current date and time are displayed, followed by
the C>> prompt.
4. Insert the Configuration and Calibration software disk into the A: drive.
5. Change from drive C: to drive A: by typing A: and then pressing ENTER. The
A>> prompt is displayed.
6. Insure the version of CALCONF is correct for the rig and application. The
BCS version will frequently vary from that used by the drilling instrumenta-
tion’s TOTAL system.
7. Initialize the software by typing CALCONF and then pressing ENTER. The
floppy disk is accessed and checked for configuration units (Figure 5-3), and
the Configuration and Calibration Main Menu is displayed (Figure 5-4).
Figure 5-2 Laptop PC Connection to DAQ

M/D TOTCO
Manual 60-60 Configuration and Calibration
Figure 5-3 Software Start-up Screen
Figure 5-4 Configuration & Calibration Main Menu Screen

M/D TOTCO
5-3 LOADING CONFIGURATION FROM FLOPPY
The Block Control System configuration disk contains a complete description of all sys-
tem components connected to the DAQ, including the following:
• All sensors
• All Brake Controller outputs to the DAQ
• All Driller's Display outputs to the DAQ
• All DAQ outputs to the Brake Controller
• All algorithms and numerical constants used by the Block Control software
Follow the steps below to download the configuration to the DAQ from floppy.
1. Select FLOPPY: [LOAD ALL] from the Configuration and Calibration

Main Menu screen (Figure 5-4). A submenu listing the configuration by name
is displayed (for example, BLKCTRL in Figure 5-5).
2. Use the arrow keys to highlight the configuration name and then press
ENTER. Downloading begins and a series of messages like those shown below
is displayed.
When downloading is complete, the Configuration and Calibration Main Menu screen is
displayed again.

M/D TOTCO
Figure 5-5 Floppy:[LOAD ALL] Menu Screen
5-4 CONFIGURATION
The configuration must be edited if:

• The Block Control System components were not connected to the DAQ field
termination board exactly as specified in Appendix A, or
• The manual value for any channel differs from that on the floppy configuration
(for example, if the number of lines strung on the floppy configuration is 12
and the actual number of lines strung is 14).
Refer to Manual 60-40 for instructions on editing the configuration.
WARNING
The configuration must be updated if there are any differences between

the configuration downloaded from floppy and the actual rig
configuration. NOT UPDATING THE CONFIGURATION INVALIDATES
BLOCK CONTROL SYSTEM OPERATION AND MAY RESULT IN FATAL
INJURY TO PERSONNEL AND SEVERE DAMAGE TO THE RIG.

M/D TOTCO
5-5 CALIBRATION
Under most circumstances, the hook load pressure transducer and EDMS sensor are the
only sensors that require calibration. The following paragraphs explain how to calibrate
the Hook Load and Block Height sensor channels.
5-5-1 Hook Load Sensor Channel Calibration
The hook load pressure transducer output is continuous and proportional to the
quantity being measured. Calibration defines the relationship between transducer
output in raw A/D counts and data values in engineering units. This is accom-
plished by specifying the four values listed below:
• Raw Minimum - the raw value of the A/D converter when the trans-
ducer is set to minimum output (Note: A/D counts vary from 0–4095
counts)
• Value Minimum - the engineering units value corresponding to the
raw minimum
• Raw Maximum - the raw value of the A/D converter when the trans-
ducer is set to maximum output (Note: A/D counts vary from 0–4095
counts)
• Value Maximum - the engineering units value corresponding to the
raw maximum
In the analog calibration procedure presented here, Raw Minimum is determined
first, then Value Minimum, then Raw Maximum, then Value Maximum; however,
these values may be determined in any order.
Follow the steps below to calibrate the hook load sensor channel.
1. Ensure that the hook load sensor cable is properly connected to the
DAQ (Appendix A).
2. From the Configuration & Calibration Main Menu, use the arrow keys
to highlight [CALIBRATION] and press ENTER. The SYSTEM
CALIBRATION SOFTWARE screen (Figure 5-6) is displayed.

M/D TOTCO
Figure 5-6 SOFTWARE CALIBRATION SOFTWARE Screen
3. Highlight [CHANNELS] and press ENTER. A submenu of channels is

displayed (Figure 5-7).

M/D TOTCO
Figure 5-7 [CHANNELS] Submenu
4. Use the arrow keys to highlight “HOOKLOAD” and press ENTER. The
hook load calibration screen is displayed (Figure 5-8), with default
minimum and maximum values listed. The current sensor reading in
raw counts and in engineering units is presented on the line labeled
CURRENT READING. The CALIBRATION MIN and CALIBRA-
TION MAX values are used to calculate the current sensor reading in
engineering units.
NOTE
HOOKLOAD calibration is done on a per line basis. For example, if you
have 10 lines, and the value max for the dead line is 100K pounds, this will
correspond to a 1M pound hookload capacity.
5. Calibrate the raw minimum by setting the sensor to its zero point and
viewing the raw counts displayed next to CURRENT READING.
6. When the reading stabilizes, or you have a good estimate of what the
minimum reading should be, record the raw sensor minimum by high-
lighting RAW MIN and pressing ENTER. The Raw Minimum Calibra-
tion screen is displayed (Figure 5-9). The NEW RAW MINIMUM
VALUE field lists the sensor output, in raw counts, at the time RAW
MIN was selected. The CURRENT RAW MINIMUM VALUE field lists
either raw counts from the previous calibration or the default minimum
raw counts.

M/D TOTCO
Figure 5-8 HOOK LOAD Calibration Screen
Figure 5-9 Raw Minimum Calibration Screen

M/D TOTCO
7. To accept the NEW RAW MINIMUM VALUE, press ENTER.To enter a

different NEW RAW MINIMUM VALUE, type in the value, up to 6
numbers, and press ENTER. The following messages are displayed:
NOTICE:
SENDING CALIBRATION DATA
REQUESTING CALIBRATION DATA

To disregard the NEW RAW MINIMUM VALUE, press <Esc >. The following
message is displayed:
NOTICE:

8. The Hook Load Calibration Screen is displayed and the value accepted
in Step 7 is displayed on the CALIBRATION MIN line.
9. Enter the value minimum by selecting VALUE MIN from the Hook
Load Calibration screen and pressing ENTER. The Value Minimum
screen is displayed (Figure 5-10).
Figure 5-10 Value Minimum Calibration Screen

M/D TOTCO
10. The NEW MINIMUM VALUE field lists the current value sent from the
DAQ, in engineering units, that corresponds with the raw minimum.
The CURRENT MINIMUM VALUE lists either the value minimum
from the previous calibration or the default value minimum.
11. To accept the NEW MINIMUM VALUE, press ENTER. To enter a dif-
ferent NEW MINIMUM VALUE, type in the new value and then press
ENTER. The following messages are displayed:
NOTICE:

To disregard the NEW MINIMUM VALUE default, press <Esc>. The following
NOTICE
12. The Hook Load Calibration screen is displayed and the value accepted
in Step 11 is displayed on the CALIBRATION MIN line.
13. To calibrate the raw maximum, set the sensor to maximum output and
view the raw counts displayed next to CURRENT READING.
14. When the reading stabilizes, or you have a good estimate of what the
maximum reading should be, record the raw sensor maximum by high-
lighting RAW MAX and pressing ENTER. The Raw Maximum Calibra-
tion screen is displayed (Figure 5-11). The NEW RAW MAXIMUM
VALUE field lists the output, in raw counts, at the time RAW MAX was
selected. The CURRENT RAW MAXIMUM VALUE field lists either the
raw counts from the previous calibration or the default maximum raw
counts.

M/D TOTCO
Figure 5-11 Raw Maximum Calibration Screen
15. To accept the NEW RAW MAXIMUM VALUE, press ENTER.To enter a
different NEW RAW MAXIMUM VALUE, type in the value, up to 6
numbers, and press ENTER. The following messages are displayed:
NOTICE:

To disregard the NEW RAW MAXIMUM VALUE, press <Esc >. The following
NOTICE:
16. The Hook Load Calibration Screen is displayed and the value accepted
in Step 14 is displayed on the CALIBRATION MAX line.
17. Enter the maximum value by selecting VALUE MAX and pressing
ENTER. The Value Maximum Calibration screen is displayed (Figure
5-12). The NEW MAXIMUM VALUE field lists the output, in engineer-
ing units, at the time CURRENT MAXIMUM VALUE was selected. The
CURRENT MAXIMUM VALUE field lists either the value maximum
from the previous calibration or the default.

M/D TOTCO
Figure 5-12 Value Maximum Calibration Screen
18. To accept the NEW MAXIMUM VALUE, press ENTER.
To enter a NEW MAXIMUM VALUE, type in the new value and press
ENTER. The following messages are displayed:
NOTICE:

To disregard the NEW MAXIMUM VALUE, press ENTER. The following mes-
sage is displayed:
NOTICE

19. The Hook Load Calibration screen is displayed and the value accepted
in Step 18 is displayed on the CALIBRATION MAX line.
20. When the channel is calibrated, highlight QUIT and press ENTER. The
SYSTEM CALIBRATION SOFTWARE Menu is displayed.

M/D TOTCO
21. To calibrate the Block Height sensor channel, proceed to Section 5-5-2.
To exit CALIBRATION, highlight [QUIT] from the SYSTEM CALI-
BRATION SOFTWARE screen and press ENTER. The following message
is displayed:
22. Highlight SEND and press ENTER. A series of messages is displayed

as the calibration data is sent to the DAQ.If the calibration is unsatis-
factory, highlight ABORT, press ENTER and begin calibration again.
23. The Configuration & Calibration Main Menu screen is displayed.
5-5-2 Block Height Sensor Calibration
Block height sensor calibration defines the relation between shaft encoder sensor
counts and block height. There are two calibration procedures used with the Block
Control System. They are the simple “Block Control System Two Point Calibra-
tion” and the more involved “Block Control System Ten Point Calibration”. There
is also a procedure for resetting the calibration system after a cut and slip opera-
tion. Before these are explained, a description of the goals of the Block Control
System in regards to block height determination and measurement should be
given.
The normal M/D TOTCO TOTAL EDMS system used for tracking and displaying
the block height does an outstanding job with great accuracy. The system does
however require operator input to a keypad and a several step process to maintain
that accuracy after the initial calibration. With the Block Control System this was
considered to be too great a trouble and expense. For block control needs, the
absolute accuracy in the block height is not as stringent, but of greater importance
is the ability to return to the same position repeatably. This is done with the high
resolution incremental encoder used by the Block Control System. Thus the Block
Control System is calibrated and then reset in the simplest possible means that
insures adequate accuracy for the task.

M/D TOTCO
For our purposes the following terms are defined:

“Calibration” of the EDMS system means to input to the EDMS system values of
encoder counts versus block height that allow it to generate a set of values for
“table 4" of the ten point tables. This table is then used by the DAQ to interpolate
and extrapolate all other values. This must be done, by the maintenance personnel
with the assistance of the driller, during initial commissioning or if the rig has
changed the number of lines strung.
“Resetting” of the EDMS system is done after cut and slip operations. It's intent is
to communicate to the DAQ when the elevators are at the rig floor, so that it knows
the proper place to begin. This is generally done by the driller and his crew and is
covered in Section 5-5-3-1.
5-5-2-1 Block Control System Two Point Calibration
The procedure below is used to calibrate most Block Control Systems

where absolute accuracy is not required. Generally that is those systems
that do not have to interface with the Varco ICS to enable a Zone Man-
agement System. Follow the steps below to calibrate the EDMS sensor
channel.
1. Ensure that the normally used drilling bails are on the Top
Drive. If not, remove the existing bails and replace with the
drilling bails.
2. Lock the Top Drive heave compensator (if present) in closed

(OFF) position (i.e., lock the pin in the heave compensator).
3. Lower the elevator so that it is just touching the rig floor.
4. Attach a 100’ tape measure to the bottom of the elevator.
5. Remove the calibration switch box from J-box and begin cali-
bration by simultaneously pressing the L/C START and CON-
NECTION buttons; the red LED should come on.
6. While elevator is on floor, press CONNECTION button.
7. Raise block up 90' and stop. Then press CONNECTION but-
ton.
8. Simultaneously press L/C START and CONNECTION on
switch box and verify that red LED goes out.
9. At laptop PC, select [CALIBRATION] from Configuration &
Calibration software Main Menu (Figure 5-4). The SYSTEM
CALIBRATION SOFTWARE screen (Figure 5-6) is displayed.

M/D TOTCO
10. Use arrow keys to highlight [EDMS] and press ENTER. The
data gathered in Steps 4 through 7 is downloaded and dis-
played on EDMS Calibration screen (Figure 5-13)
Figure 5-13 EDMS Two Point Calibration
11. Ensure the following:

• Output is TEN POINT TABLE # 4. If it is not, use
arrow keys to highlight “Output” and press ENTER. A sub-
menu of output tables is displayed. Then use arrow keys to
highlight TEN POINT TABLE #4 and press ENTER.
• CALIBRATION FACTORS is FEET. If it is not, use arrow
keys to highlight CALIBRATION FACTORS and press
ENTER. A submenu is displayed. Use arrow keys to high-
light FEET and press ENTER.
• The correct value is entered for lines strung. If not, use
arrow keys to highlight “lines strung”, then type in correct
value and press ENTER.
12. Two-point calibration assumes that block height is linear
between the two endpoints (typically 0 feet and 90 feet). To
avoid the layer change slope corrections used in full calibra-
tion and ensure that two-point calibration is based upon being
on the first drawworks layer, enter the following values on the
EDMS calibration screen:

M/D TOTCO
• 0 for “cable diameter”

• 9999 for “counts per wrap”
• 99 for “average wraps per layer”
13. Ensure 0 feet is entered for 0 BLOCK HEIGHT and enter 90
feet for 1 BLOCK HEIGHT, as shown in Figure 5-15.
NOTE
In two-point calibration, 0 BLOCK HEIGHT is always the entry at 0 feet
and 1 BLOCK HEIGHT is always the entry at 90 feet.
14. Use arrow keys to highlight [CALCULATE] and then press

ENTER.
15. To exit EDMS calibration, highlight [QUIT] and press
ENTER. The SYSTEM CALIBRATION SOFTWARE screen
is displayed.
16. To exit CALIBRATION, highlight [QUIT] from the SYS-
TEM CALIBRATION SOFTWARE screen and press
ENTER. The following message is displayed:
17. Highlight SEND and press ENTER. A series of messages is

displayed as the calibration data is sent to the DAQ.If the cal-
ibration is unsatisfactory, highlight ABORT, press ENTER and
begin calibration again.
18. The Configuration & Calibration Main Menu screen is dis-
played.

M/D TOTCO
5-5-2-2 Block Control System Ten Point Calibration
On those systems that require better accuracy throughout the full block
travel range, for example those with ZMS, the following procedure
builds into the calibration table a “bow” so as to compensate for the
increasing effective diameter of the drawworks drum with increasing
block height.
1. Ensure that the normally used drilling bails are on the Top
Drive. If not, remove the existing bails and replace with the
drilling bails.
2. Lock the Top Drive heave compensator (if present) in closed

(OFF) position (i.e. lock the pin in the heave compensator).
3. Lower elevator so that it is barely touching the rig floor. The
amount of line on the drum should be the minimum accept-
able amount to the drilling crew, with many wraps before the
first layer change. If not, ask the drill crew to spool line back
onto the reel to arrive at such a point.
4. Attach a 100’ tape measure to the bottom of the elevator.
5. Remove the calibration switch box from the J-Box and begin
calibration by simultaneously pressing the L/C START and
CONNECTION buttons; the red LED should come on. Press
just the CONNECTION button and on the calibration data
sheet, record 0’.
6. Raise the blocks to 11' and stop. Press CONNECTION and
record 11'.
7. Raise the block another 11', to 22' and stop. Press CONNEC-
TION and record 22'.
8. Continue raising the block in 11' increments, pressing CON-
NECTION each time and recording the height until the block
is at 99', or the highest point possible in that particular der-
rick. Press the CONNECTION button once more.
9. Simultaneously press L/C START and CONNECTION. The
red LED on switch box should go out.
10. At laptop PC, select [CALIBRATION] from the Configura-
tion & Calibration software Main Menu (Figure 5-4). The
system calibration software screen (Figure 5-6) is displayed.

M/D TOTCO
11. Use the arrow keys to highlight [EDMS] and press ENTER.
The data gathered in Steps 4 through 8 is downloaded and dis-
played on the EDMS Calibration Screen (Figure 5-14).
Figure 5-14 EDMS Calibration Screen
The events recorded in Steps 5 through 8 are numbered in the order they were
recorded beginning with 0. For each event, the event type (block height) and sen-
sor counts are listed.
NOTE
The events Care always numbered in the order they were recorded
(0 = the first event recorded, 1 - the second event, etc.). "CONN" events are
labeled block heights.
12. Ensure the following:

• Output is TEN POINT TABLE # 4. If it is not, use the
arrow keys to highlight [Output] and press ENTER. A
submenu of output tables is displayed. Then use arrow keys
to highlight TEN POINT TABLE #4 and press ENTER.
• CALIBRATION FACTORS is FEET. If it is not, use the
arrow keys to highlight CALIBRATION FACTORS and
press ENTER. A submenu is displayed. Use arrow keys to
highlight FEET and press ENTER.

M/D TOTCO
• The correct value is entered for lines strung. If not, use the
arrow keys to highlight [LINES STRUNG], then type in
correct value and press ENTER.
• 0 for [CABLE DIAMETER]
• 9999 for [COUNTS PER WRAP]
• 99 for [AVERAGE WRAPS PER LAYER]
13. Using the arrow keys highlight the footage figures and, if nec-
essary, change them to read 0, 11, 22, 33, etc. up to 99, as was
recorded.
14. To insure readings are given outside of the normal range of
travel, make the following two changes to the ten point table:
• Edit the "0" counts - "0" feet entry so as to be the negative
of the 11 foot entry. In other words, for the number of
counts that represent 11 feet in the table, negate that num-
ber and enter it instead of the "0" counts entry. Then enter
"-11" feet instead of the "0" feet entry.
• Edit the 99 feet entry by multiplying both the feet and
counts by ten. Figure 5-15 shows what Figure 5-14 would
look like after the modifications.
Figure 5-15 EDMS Calibration Screen

M/D TOTCO
15. Use the arrow keys to highlight [CALCULATE] and then

press ENTER.
16. To exit EDMS calibration, highlight [QUIT] and press
ENTER. The SYSTEM CALIBRATION SOFTWARE screen
is displayed.
17. To exit CALIBRATION, highlight [QUIT] from the SYS-
TEM CALIBRATION SOFTWARE screen and press
ENTER. The following message is displayed:
18. Highlight [SEND] and press ENTER. A series of messages is

displayed as the calibration data is sent to the DAQ.If the cal-
ibration is unsatisfactory, highlight ABORT, press ENTER
and begin calibration again.
19. The Configuration & Calibration Main Menu screen is displayed.
5-5-3 “Resetting” Block Control System Height Calibration
After the Block Control System has been calibrated as described in Section 5-5-2-
1 or Section 5-5-2-2, there has effectively been a “yard stick” placed in the derrick
with the graduations placed on it by the procedure. After a “cut and slip” opera-
tion, this yardstick still remains but the entire length has been moved. It is neces-
sary to “reset” the yardstick, that is re-align the bottom “zero point” with the rig
floor. This is described in the next two sections. The system should only have to be
“reset” after a cut and slip operation or a period of time where the DAQ has lost
power long enough to have lost its memory of block position. The “Calibration”
should only need to be redone if the number of lines have changed.
NOTE
The “HI” and “LO” setpoints input by the driller are “marked” on the
yardstick. Hence resetting the system does not change the setpoints.

M/D TOTCO
5-5-3-1 System without a Safe Area CID (SAC) or DataWatch display
1. Connect the Calibration Switch Box as described in Section

2-6-5. Note that the switch box should always be kept conve-
nient for the driller so as to do this resetting in a timely man-
ner with each “cut and slip” operation. Often the switch box is
left hooked up permanently, as long as the buttons would not
be inadvertently or accidentally pushed.
2. Lower the elevators until they just touch the floor. It might be
necessary to place the system in OVER-RIDE.
3. Push both the “L/C” and the “CONN” buttons on the switch
box simultaneously. Observe that the red LED comes on.
4. Again push both the “L/C” and the “CONN” buttons on the
switch box simultaneously. Observe that the red LED goes off
on.
5. Return the switch box to a secure location. The system should
now be recording a "0" block height. After lifting above the
LO Setpoint the driller can place the system in NORMAL.
5-5-3-2 Systems with a Safe Area CID (SAC) or DataWatch display
1. Lower the elevators until they just touch the floor. It might be
necessary to place the system in OVER-RIDE.
2. On the SAC or DataWatch display, call up the “EDMS

CALIB” screen.
3. There should be at least two channels displayed, Block Posi-
tion or Elevator Position, and EDMS Counts. Choose the
“Zero Channel” option and zero first one channel and then the
other. If, while zeroing the second channel, the first channel's
value changes, re-zero it. You are seeking both the EDMS
Counts channel and the Elevator Position simultaneously
reading “0”.
4. Exit from the menu, saving the changes. The system should
now be recording a “0” Elevator Position and, after lifting
above the LO Setpoint, the driller can place the system in
NORMAL.

M/D TOTCO
5-6 SAVE CONFIG/CALIBRATION TO FLOPPY
Follow the steps below to save configuration and calibration data to a floppy disk.
1. Select FLOPPY: [SAVE ALL] from the Configuration and Calibration

Main Menu screen. A message similar to the following is displayed, where
BLKCTRL is the name of the configuration loaded from floppy:
2. Type in the new name (maximum of eight characters) to assign to the data file
and press ENTER. We recommend using the rig name as the file name.
NOTE
Always assign a new name to the modified data file.
A series of messages is displayed as the calibration data file is copied to floppy.

3. When all data is copied to floppy disk, the Configuration and Calibration Main
Menu screen is displayed.
4. If system set-up has not yet been completed, proceed to Chapter 6 without exit-
ing the Configuration and Calibration software. If system set-up has been per-
formed, highlight [QUIT] and press ENTER to exit the Configuration and
Calibration software.

M/D TOTCO

M/D TOTCO
CHAPTER 6
SETUP
6-1 INTRODUCTION
Before the Block Control System is engaged, perform the two setup procedures described
below:
1. Railmount Proximity Sensor Setup - A two-part procedure that consists of:

1) determining the allowable sensor activation range for each railmount sensor
and then, 2) moving the block to insure that the sensor activates within that
range.
2. Set Points Setup - Using the Driller's Display LEARN button to enter the
upper and lower set points.
WARNING
Do not engage the Block Control System until the setup procedures
described in this chapter have been performed. Only after completing
these procedures is the system ready to provide a backup to the driller.
6-2 RAILMOUNT PROXIMITY SENSOR SETUP
To set up the railmount proximity sensors follow the steps below.
1. Place OVERRIDE/RESET NORMAL switch on Driller's Display to OVER-

RIDE position.
WARNING

backup to the operator in controlling the block. IT IS THE FULL
RESPONSIBILITY OF THE OPERATOR TO CONTROL THE BLOCK.
FATAL INJURY TO PERSONNEL AND SEVERE DAMAGE TO THE RIG
MAY RESULT IF THE OPERATOR FAILS TO CONTROL THE BLOCK.

M/D TOTCO
Setup Manual 60-60
2. Hook up the laptop and have the Block Control System CALCONF running
and communicating with the DAQ. Use F3 to see the channel values and find
the “Derrick Prox Position” channel (Drk Prx Psn).
3. Lock the heave compensator (if present) in the OFF position, (i.e. lock the pin
in the heave compensator).
4. Ensure the block height system has been calibrated as described in Section 5
and the normal (drilling) bails are on.
5. Run the block past the derrick prox switches several times in both the upwards
and downwards direction. Each time the block moves past the derrick prox
switches, the value displayed on the DAQ's “Derrick Prox Position” channel
should change slightly. Note and record each of the values.
6. If there is a block retract system, retract the block and again run the block past
the prox switches several times, again recording the value of the “Derrick Prox
Position” each time.
7. Determine both the highest and lowest values seen from the above movements.
Add 2 feet to the highest value and subtract 2 feet from the lowest.
8. At the laptop PC, press the “ESCAPE” key to return to the MAIN MENU and
then use the arrow keys to highlight [CONFIGURATION] (Figure 5-4) and
then press ENTER. The submenu shown in Figure 6-1 is displayed.
Figure 6-1 CONFIGURATION Submenu

M/D TOTCO
Manual 60-60 Setup
9. Highlight SYSTEM/DAQ and press ENTER. The SYSTEM/DAQ configura-

tion screen (Figure 6-2) is displayed.
10. Highlight CHANNEL, SENSOR, & OUTPUT: [EDIT] and press ENTER. A
submenu of channels is displayed (Figure 6-3).
11. Use Page Down and arrow keys to scroll through menu and highlight DRK
PROX LOW; then press ENTER. The DRK PROX LOW configuration screen
is displayed (Figure 6-4).
12. Use arrow keys to highlight Manual value; then type in the (lowest-2) value
calculated in Step 7 and press ENTER. The new value is displayed.
13. Highlight [QUIT] and press ENTER. The EDIT Channels submenu is dis-
played (Figure 6-3).
14. Repeat Steps 11, 12 and 13 to enter values for DRK PROX HI and the channel
entering the (highest+2) value determined in step 7. When all values are
entered, press [Esc] from EDIT Channels screen to close submenu.
Figure 6-2 SYSTEM/DAQ Configuration Screen

M/D TOTCO
Setup Manual 60-60
Figure 6-3 EDIT Channels Submenu
Figure 6-4 PROX LOW Channel Configuration Screen

M/D TOTCO
Manual 60-60 Setup
Figure 6-5 DIAGNOSTIC CHANNEL VALUES Screen–Page 1
Figure 6-6 DIAGNOSTIC CHANNEL VALUES Screen–Page 2

M/D TOTCO
Setup Manual 60-60
15. From EDIT Channels screen, highlight [QUIT] and press ENTER. The follow-
ing message is displayed.
16. Highlight SEND and press ENTER. Messages are displayed as the configura-
tion is sent to the DAQ. When the configuration has been sent, the Configura-
tion and Calibration Main Menu is displayed.
17. Select FLOPPY: [SAVE ALL] from Configuration and Calibration Main Menu
screen. A message similar to the following is displayed, where BLKCTRL is
the name of the configuration loaded from floppy:
18. Type in the same name (typically the rig name) used when saving to floppy
after configuration and calibration (Figure 5-6) and press ENTER.
CAUTION
Always assign the same name used in Section 5-6.
A series of messages is displayed as the data is copied to floppy.

19. When all data is copied to floppy, the Configuration and Calibration Main
Menu screen is displayed. Highlight [QUIT] and press ENTER to exit the
Configuration and Calibration software.

M/D TOTCO
Manual 60-60 Setup
6-3 SET POINTS SETUP
The upper set point is the highest working position that the block should reach and the
lower set point is the lowest working position that the block should reach. Use the LEARN
button on the Driller's Display and follow the steps below to define the upper and lower
set points.
1. Slowly raise block until upper set point is reached and then press LEARN
button.
2. If the new upper set point is above the current upper set point, select OVER-
RIDE on the OVERRIDE/RESET NORMAL selector switch to avoid an alarm.
3. Lower block until lower set point is reached and then press LEARN button.
4. If the new lower set point is below the current low set point, select OVERRIDE
on the OVERRIDE/RESET NORMAL selector switch to avoid an alarm.
WARNING

backup to the operator in controlling the block. IT IS THE FULL
RESPONSIBILITY OF THE OPERATOR TO CONTROL THE BLOCK.
FATAL INJURY TO PERSONNEL AND SEVERE DAMAGE TO THE RIG
MAY RESULT IF THE OPERATOR FAILS TO CONTROL THE BLOCK.
NOTE
Upon detection of learn button activation, the system assumes that if the
block height is above 25’, you are setting an upper set point. Likewise, if the
block height is less than 25’, it is assumed you are setting a lower set point.

M/D TOTCO
Setup Manual 60-60

M/D TOTCO
CHAPTER 7
7-1 INTRODUCTION
The Driller's Display contains three LED's, an OVERRIDE/RESET NORMAL switch, a

LEARN button, an EMERGENCY STOP button and alarm horn button (Figure 2-4). The
following paragraphs describe these features.
7-2 GREEN “SYSTEM ON” LED
When the Block Control System is operating and no error conditions are present, the green
“SYSTEM ON” LED is on steady.
7-3 YELLOW “ALARM” LED
When the Block Control System is operating and there is an error condition requiring a
Level 1 or Level 2 DAQ alarm, the yellow “ALARM” LED is on steady and the alarm
horn sounds.
7-4 RED “FRICTION BRAKE ENABLED” LED
When the Block Control System is operating and an error condition exists that requires a
Level 3 DAQ alarm (Table 3-2), the red “FRICTION BRAKE ENABLED” LED is on
steady and the alarm horn sounds. This tells the operator that the friction brake is enabled.
7-5 OVERRIDE/RESET NORMAL SWITCH
The functions of the OVERRIDE/RESET NORMAL switch are summarized below.
NORMAL - When this switch is in the NORMAL position, the operator controls the eddy
current brake and/or friction brake and the Block Control System operates as a backup. In
this mode, the green, yellow or red LED’s indicate the Block Control System status.
OVERRIDE - When this switch is in the OVERRIDE position, the Block Control System
is ignored and only the operator is in control of both brakes. In OVERRIDE, green always
blinks alternately with yellow or red if in alarm condition.

M/D TOTCO
Driller’s Display Operation Manual 60-60
WARNING

to the rig may result if the operator fails to control the block.
SYSTEM RESET - When the Block Control System is operating under a system error
condition, the OVERRIDE switch is used to reset the system and turn the alarm horn off.
To do this, position the switch from NORMAL to OVERRIDE/RESET and then back to
NORMAL.
7-6 LEARN BUTTON
The LEARN button is used to define the upper and lower set points (Section 3-7).
The set points are initially defined during system set-up (Chapter 6) but may be redefined
at any time, if needed. To define the set points, follow the steps below:
1. From normal Block Control System operation (green LED is on and

OVERRIDE/RESET NORMAL switch is in NORMAL position)
set the OVERRIDE/RESET NORMAL switch to OVERRIDE.
WARNING

to the rig may result if the operator fails to control the block.
2. Move the block to the new set point and then press the LEARN button.
3. To change the other set point, repeat Step 2. Position the OVERRIDE/RESET
NORMAL switch to NORMAL. The green LED comes on and normal system
operation resumes.

M/D TOTCO
Manual 60-60 Driller’s Display Operation
7-7 EMERGENCY STOP BUTTON
The EMERGENCY STOP button can be pulled any time during Block Control System
operation. When the EMERGENCY STOP button is pulled, the DAQ issues a Level 3
alarm. The results are:
• The eddy current brake and friction brake are fully engaged.
• The alarm horn in the Driller's Display sounds.
• The red LED on the Driller's Display comes on.
To disable the friction brake, eddy current brake and alarm horn, press and turn the
EMERGENCY STOP button in the direction of the arrow on the button (clockwise).
Then position the OVERRIDE/RESET NORMAL switch to OVERRIDE and then back to
NORMAL.
7-8 LOWER SPEED POTENTIOMETER
The lower speed potentiometer can be adjusted any time during Block Control System
operation. Turning the dial to a higher number allows the block to lower more quickly. If a
slower speed of block lowering is desired, turn this dial to a lower number.
7-9 DRILL/TRIP SWITCH
When drilling, set this switch to DRILL. When tripping, set this switch to TRIP. This
switch setting is monitored by the BCS, and must be set correctly for proper operation of
the Block Control System.
7-10 ALARM HORN
An alarm horn in the Driller's Display sounds when either of the conditions listed below
occurs:
• The DAQ issues a Level 1, Level 2 or Level 3 alarm or
• The red EMERGENCY STOP button on the Driller's Display is pulled.
To silence the alarm horn, position the OVERRIDE/RESET NORMAL switch to OVER-
RIDE and then back to NORMAL.

M/D TOTCO
Driller’s Display Operation Manual 60-60

M/D TOTCO
CHAPTER 8
MAINTENANCE
8-1 INTRODUCTION
This chapter contains the following:

• Procedures for inspecting and troubleshooting the DAQ and sensors
• Procedure for replacing DAQ E-PROM's
• Procedure for checking the EDMS battery
• DAQ interface cabling diagram
Refer to Chapter 9 for parts lists and illustrations depicting component locations, assembly
and disassembly. For maintenance information regarding the 2025B Brake Controller and
all other Baylor instruments, refer to the appropriate Baylor manuals.
8-2 RECOMMENDED DAQ INSPECTION
Perform the following checks periodically, or each time the DAQ is opened:
• Ensure that all component mounting bolts are securely fastened; tighten if nec-
essary.
• Check enclosure for moisture ingression; correct as necessary.
8-3 DAQ AND SENSOR TROUBLESHOOTING
The following paragraphs list general checks and a fault isolation table for identifying and
repairing problems in the DAQ.
8-3-1 General Checks
Field experience indicates that most electronic equipment failures can be corrected
or avoided by performing the general checks listed below. These checks should
always be completed prior to performing more extensive repairs.
1. Verify that primary power is supplied to the unit and that it is the power
required by the unit (Table 2-1).
2. Check for loose, crushed, frayed, cut or otherwise damaged cables.

3. Check wiring connections for loose or broken leads.
4. Verify that all components are properly interconnected and seated in
their mating connector or socket (see Chapter 4).

M/D TOTCO
Maintenance Manual 60-60
8-3-2 Fault Isolation Table: DAQ and Sensors
For system alarms, refer to Section 3-6 for alarm descriptions and troubleshooting
suggestions.
Use Table 8-1 to isolate and correct malfunctions associated with the DAQ and
sensors. For each malfunction, the table lists probable causes and corrective
actions. Refer to Figures 8-1 through 8-4 as needed for interface wiring, cabling
and component locations. Note that after replacement of any circuit board or
related component, the system must be recalibrated. Refer to Figure 8-1, if needed,
to identify DAQ components.
Table 8-1 Fault Isolation Table: DAQ and Sensors
Problem Probable Cause Corrective Action

System inoperative 1. No power to the system 1. Check and correct power
source.
2. Blown fuse 2. Replace fuse (Figure 4-5).
3. Defective power supply 3. Perform power supply checkout

(Section 8-7).
4. Digital board failure 4. Replace digital board
DAQ digital board “analog” 1. Analog processor malfunction 1a. Press analog processor reset
LED off SW4 (Figure 4-6).
1b. If problem persists, press both

processor resets, SW1 and
SW4 (Figure 4-6).
1c. If problem persists, set switch

8 on SW2 to OFF (Figure 4-6).
Press both processor resets,
SW1 and SW4; then set switch
8 on SW2 to ON.
2. Digital board failure 2. Replace board (Figure 8-1).
3. Analog board failure 3. Replace board (Figure 8-1).

DAQ digital board “analog” 1. Analog processor malfunction 1a. Press analog processor reset,
LED on steady (not blink- SW4 (Figure 4-6).
ing)

processor resets SW1 and
SW4 (Figure 4-6).
1c. If problem persists, set switch

8 of SW2 to OFF (Figure 4-6).
Press both processor resets
8 on SW2 to ON.

M/D TOTCO
Manual 60-60 Maintenance
2. Digital board failure. 2. Replace board (Figure 8-1).

DAQ digital board “watch- 1. Defective power supply 1. Check voltages and replace
dog timer” LED off. supply, if needed.
2. Main processor malfunction 2a. Turn main power to DAQ off

and wait 5 seconds; then turn
main power to DAQ on.
2b. If problem persists, set switch
8 on SW2 to OFF (Figure 4-6).
8 on SW2 to ON.
DAQ digital board “watch- 1. Main processor malfunction 1a. Turn main power to DAQ off
dog timer” LED blinking and wait 5 seconds. Then turn
(not on steady) main power to DAQ on.
1b. If problem persists set switch 8

on SW2 to OFF (Figure 4-6).
8 on SW2 to ON.
DAQ digital board “com- No malfunction indicated. No action required.

munications” LED off
All three DAQ digital board 1. No power to system 1. Check and correct power
LEDs off source.
2. Blown fuse 2. Replace fuse (Figure 4-6).
3. Defective power supply 3. Perform power supply checkout

(Section 8-7).
Erratic indication from 1. Analog processor malfunction 1a. Press analog processor reset
sensor channel SW4 (Figure 4-6).

SW4 (Figure 4-6).
1c. If problem persists set switch 8
on SW2 to OFF (Figure 4-6).
8 on SW2 to ON.

M/D TOTCO
2. “Raw” input counts OK, but engi- 2a. Verify channel is configured
neering units erratic. properly.
2b. Recalibrate the channel.
3. Analog board voltage/current 3. Verify that switch is set correctly

switch set incorrectly for sensor type (Section 4-5-6).
Erratic indication from 4. Sensor connected improperly or 4. Ensure that all sensor connec-
sensor channel (cont) not at all tions are secure correct and to
the proper connector.
5. Faulty channel on analog board 5. Connect sensor to different con-
nector; then reconfigure and
recalibrate the channel.
7. Sensor malfunction 7. Replace sensor
No indication from sensor 1. Analog processor malfunction 1a. Press analog processor reset
channel SW4 (Figure 4-6).

SW4 (Figure 4-6).
1c. Set switch 8 on SW2 to OFF

(Figure 4-6). Press both pro-
cessor resets SW1 and SW4;
then set switch 8 on SW2 to
ON.
2. “Raw” input counts OK, but engi- 2a. Verify channel is configured
neering units not changing properly.
2b. Recalibrate channel.
3. Analog board voltage/current 3. Verify that switch is in correct

switch set incorrectly position for sensor type
(Section 4-5-6).
4. Sensor connected improperly or 4. Ensure that all sensor connec-

not at all tions are secure correct and to
the proper connector.
5. Faulty channel on analog board 5. Connect sensor to a different

channel; then reconfigure and
recalibrate the channel.

7. Sensor malfunction 7. Replace sensor.

M/D TOTCO
Figure 8-1 DAQ Main Components

M/D TOTCO
8-4 SYSTEM DEBUG
DAQ software version 4.0 enables you to use position 7 of SW2 on the DAQ digital board
to display debug screens containing information about the system's internal operation. The
debug screens present information regarding the conditions listed below:
• Analog task failure. Caused by analog processor malfunction or digital board
failure. This failure will cause the system to be RESET as the message indi-
cates.
• Copies of data stored in nonvolatile RAM are corrupted.
• Copies of data stored in the EEPROM are corrupted.
• Current time being sent to the T-POT network is 0.
• A channel value is being zeroed.
• Laptop PC polling responses
• EEPROM write errors are detected.
• T-POT device polling responses
• Polling time for EDMS processor
• EDMS processor is not responding.
• Analog processor is not responding.
• T-POT processor is not responding.
• BLOW WORLD AWAY switch (DIP SW2, position 8) is OFF at powerup.
To view these screens, follow the steps below:
1. From any point in the Configuration & Calibration software, press the F7 key.
If position 7 of DIP SW2 is ON, the following message is displayed:
NOTE
DEBUG output can be enabled by setting DIP SW2 (SW7) to OFF.
2. On DIP SW2, change the setting of position 7 to OFF.

3. Reset the DAQ by turning the main power to the DAQ off, waiting five sec-
onds and then turning the main power on. The debug screen assigned to posi-
tion 7 of DIP SW2 is displayed. This screen lists the error conditions being
checked and presents messages if any of the error conditions exist.
4. To exit this screen, change position 7 of DIP SW2 to ON.

M/D TOTCO
5. To view the other debug screen, change the setting of position 1 on DIP SW2.
The debug screen assigned to position 1 is displayed. This screen lists the con-
ditions being checked and their values at the time that position 1 was changed.
To view an updated version of this screen, change the setting of position 1 on
DIP SW2. Change the setting of SW2 position 1 as needed to view updated
versions of this screen.
6. To exit debug mode, press the F7 key.
8-5 SENSOR PROBLEMS
Sensor problems are generally caused by one of the following:

• Improper installation
• Improper alignment
• Faulty cables or connections
• Faulty sensor
If the sensor is properly installed, aligned and connected, and if the sensor cables are in
good condition, repair or replace the sensor; then recalibrate the sensor channel using a
laptop PC and the Configuration & Calibration software.
8-6 REPLACING DAQ DIGITAL BOARD E-PROMS
Digital board E-PROMs may require replacement either as a result of failure or routine
software updates. The E-PROM chips (U15, U16 and U19) are located on the digital
board shown in Figure 8-2. Follow the steps below to replace the chips.
1. Open DAQ rear door.

2. Set power ON/OFF switch to OFF.
CAUTION
STATIC DISCHARGE CAN DAMAGE INTEGRATED CIRCUITS. Do not
handle integrated circuits or component boards unless properly
grounded. Do not allow clothing or plain plastic materials in close proxim-
ity to these static-sensitive devices.
3. Observe CAUTION, note direction of integrated circuit notch, and carefully

remove chip from socket using an IC extractor tool.
4. Carefully install replacement chip. Make sure notch in chip faces same direc-
tion as previous chip.
5. Set power ON/OFF switch to ON.
6. Close DAQ rear door.
7. Reload configuration from floppy and recalibrate system.

M/D TOTCO
Figure 8-2 DAQ Digital Board Main Components

M/D TOTCO
8-7 POWER SUPPLY & WIRING HARNESS CHECKOUT PROCEDURE
The following procedure tests both power supply outputs and associated wiring.
Figure 8-3 is a DC power distribution schematic that includes interfaces, connector pins,
signal names and wire color-coding. Follow the steps below to check the power supply
and wiring harness.
1. Remove four screws securing power supply ON/OFF switch protective cover
(Figure 8-4). Remove cover and set aside.
2. Using digital voltmeter (DVM), measure voltages from power supply connec-
tors to chassis ground, as follows:
Connector-Pin
Volts DC
From (+) To (-)
P4-J5 Ground -15
P4-J2 Ground +15
P4-J1 Ground +15
P14-J1 Ground +28
P14-J2 Ground +5
3. If any voltages are incorrect, replace associated power supply. If voltages are
all correct, measure for the following voltages:
Connector-Pin
Volts DC
From (+) To (-)
P8-J1 Ground +5
P8-J2 Ground +15
P11-J1 Ground +28

P11-J5 Ground +15
P11-J8 Ground -15
P3-J9 Ground +28
P3-J10 Ground +15
4. If any of the above voltages are not present, repair or replace wiring between
power supply and associated connector.

M/D TOTCO
8-8 EDMS BATTERY TEST
Refer to Figure 8-3 and measure battery output voltage from connector-pin P3-J4 (+) to
P3-J2 (-). A reading between 10.5 and 12.0 VDC should be obtained. If the measured volt-
age is less than 10.5 VDC, replace the battery.
Figure 8-3 DC Power Distribution Wiring Diagram

M/D TOTCO
Figure 8-4 DC Power Distribution Cabling Diagram
8-9 AC POWER DISTRIBUTION WIRING DIAGRAM
Figure 8-5 shows the AC power distribution wiring. Refer to it as needed during trouble-
shooting and maintenance.

M/D TOTCO
BLK
WHT
BLK
WHT
LOAD
LINE
Figure 8-5 AC Power Distribution Wiring Diagram
8-10 DAQ INTERFACE CONNECTIONS
Refer to Figure 4-9 in Manual 60-10 for troubleshooting and maintenance assistance.

M/D TOTCO
CHAPTER 9
9-1 INTRODUCTION
This chapter contains the illustrated parts breakdown, parts lists and recommended spare
parts list for use in maintaining the M/D TOTCO DAQ, shaft encoder, calibration switch
box and hook load transducer.The illustrated parts breakdown contains illustrations of
major components and assemblies accompanied by parts lists keyed to index numbers on
the illustrations. The main features of the illustrated parts breakdown are described below.
9-2 INDEX NUMBERS
On the illustrations, each stand-alone part is assigned an index number, which is used to
identify the part described in the accompanying parts list. On the illustrations, each assem-
bly is identified by a circled number (for example: #36 in Figure 9-1).
9-3 PARTS LIST
The four columns of the parts list are described in Section 9-3-1 through Section 9-3-4.
9-3-1 Figure & Index Number
This column lists the figure and index number of the component, assembly or part
described.
9-3-2 Part Number
This column contains the M/D TOTCO part number.
9-3-3 Description
This column contains the name and description of each assembly, subassembly
and part. Descriptions of subassemblies and/or parts that make up the main assem-
bly are listed below the main assembly and indented one period (.) relative to it.
Descriptions of parts that make up subassemblies are listed below their corre-
sponding subassembly and indented one period (.) relative to it, or two periods rel-
ative to the main assembly (. . ).
The number of indents (i.e., two periods, three periods, etc.) in a parts list is dic-
tated by the number of subassemblies that make up the main assembly.
9-3-4 Units Per Assembly
This column lists the number of units required for one next higher assembly
(NHA).

M/D TOTCO
Illustrated Parts Breakdown Manual 60-60
9-3-5 Abbreviations
Table 9-1 contains the standard abbreviations used in the parts lists.
Table 9-1 Parts List Abbreviations
Abbreviation Explanation Abbreviation Explanation
AP Attaching Parts NHA Next Higher Assembly
AR As Required NPT National Pipe Thread

ASSY Assembly NP Not Procurable
AWG American Wire Gauge NYL Nylon
BDGH Binding Head OD Outer Diameter

BRS Brass PCB Printed Circuit Board
CSK Countersunk PHHD Phillips Head
CT Count PN Part Number
CTN Carton PNHD Pan Head
EXT External POS Position
FILH Fillister Head PT Point
FLHD Flat Head RD Root Diameter
GA Gauge RDHD Round Head
HD Head REF Reference

HDW Hardware SHLD Shield
HX Hexagonal SLFLKG Self-locking
ID Inner Diameter SLTD Slotted

INS Inside SST Stainless Steel
INTL Internal ST Self-Tapping
I.S. Intrinsically Safe STD Standard

LCD Liquid Crystal Display THD Thread
LED Light-emitting Diode UNC Unified Coarse Thread
LG Length UNF Unified Fine Thread
M/F Male/Female UNS Unified Straight Thread
MTG Mounting

M/D TOTCO
Manual 60-60 Illustrated Parts Breakdown
Figure 9-1 DAQ (P/N 220425) Assembly Drawing (1 of 3)

M/D TOTCO
Figure 9-1. DAQ (P/N 220425) Assembly Drawing (2 of 3)

M/D TOTCO
Figure 9-1. DAQ (P/N 220425) Assembly Drawing (3 of 3)

M/D TOTCO
220425-005

M/D TOTCO

M/D TOTCO

M/D TOTCO
Figure 9-2 Shaft Encoder Assembly
FIG. & UNITS

INDEX PART NUMBER DESCRIPTION PER
NO. ASSY.
9-2- H12321A SHAFT ENCODER ASSY AR
4* M10260A-002 Coupling, Shaft, 0.25" ID (3-PC) 1
24 H52-1 Terminal Ring, #6 x #22-16 5
25 220468 ID Label, Drawworks Encoder 1
26 220626-125 Encoder, Optical, 125 P/R, BASEFA 1
27 220464 Plate, Mounting Optical Encoder, Drwks 1
29 220463 Shaft Adapter, Drwks Optical Encoder 1
30 J814-4RB Screw, #6-32 x .5, RDH, Stl, CD PL 2
31 J814-4FB Screw, #10-32 x .31, SCH-HEX 1
32 999324-051 Setscrew, #10-32 x .31, SCH-HEX, cup, sst 1
33 J813-4RB Screw, #8-32 x .5, RDH, Stl, CD PL 2

34 H12390A-05 Adapter, Conduit M20-1/2 NPT 1
*Not Shown

M/D TOTCO
Figure 9-3 Calibration Switch Box

M/D TOTCO
9
8
1 7
6
5
3
2
4
Figure 9-4 Hook Load Transducer Assembly
FIG. & UNITS

INDEX PART NUMBER DESCRIPTION PER
NO. ASSY.
9-4- 221503-001 TRANSDUCER ASSY AR
1 H12353A-12100 Xdcr Assy, 1k/none 1

2 210367 Tee,Hex Strt,1/4"NPT 2
3 J234-5 Hose Assy, 1/4" x 5’ 1
4 J10900A-20 Coupler, Male, 1/4" NPT 1
5 J996 Nipple, Hex, 1/4" NPT 1
6 J10900A-02 Coupler, Female, 1/4" NPT 1
7 9993993-222 Screw, 1/4"-20 x .50, Hex 4

8 999279-005 Nut, 1/4"-20, Hex, SST 4
9 999310-011 Washer, Flat, .255 x .56 4

M/D TOTCO
1 0–100 PSIG 8 7
4 5
6
9
3
10
2
11 0–500 PSIG
18
12 19
15
16
17
13
14
20 0–1000 PSIG 21 0–5000 PSIG 28
25
26
27
23 29
30
24
22
Figure 9-5 Hook Load Transducer Assemblies (continued)

M/D TOTCO

M/D TOTCO
9-4 M/D TOTCO SYSTEM CABLES
Part numbers for three cable assemblies supplied by M/D TOTCO are listed in Table 9-2.
Table 9-2 M/D TOTCO System Cables
Part Number Description Quantity
220082 Calibration (RS232) Cable Assy. 1
219343-002 Encoder to J-Box Cable Assy 1

219344-002 Calibration Switch Box to J-Box Cable Assy 1
9-5 M/D TOTCO PROXIMITY SENSORS & LAPTOP PC
Part numbers for the proximity sensors and laptop PC are listed in Table 9-3.
Table 9-3 Miscellaneous M/D TOTCO Components
220893 Laptop Computer XT with Power Supply 1
220378 Drawworks Proximity Sensor 1
H11094A-01 Railmount Proximity Sensor 2
9-6 BAYLOR SYSTEM COMPONENTS
Part numbers for Baylor-supplied system components are listed in Table 9-4.
Table 9-4 Baylor-Supplied Components

55852 Brake Controller 1
55858 Throttle 1
55862 Driller's Display 1

M/D TOTCO
9-7 APPROVED SPARE PARTS FOR M/D TOTCO COMPONENTS
Table 9-5 lists part numbers of approved spare parts for M/D TOTCO components of the
Block Control System. Refer to Baylor documentation for approved spare parts for Baylor
components.
Table 9-5 Approved M/D TOTCO Spare Parts
Figure & Part

Description Quantity
Index No. Number
9-1-42 219493 PCB Assembly,DAQ Digital Board 1
9-1-26 219509 PCB Assembly,DAQ Field Termi- 1

nation Board
9-1-27 219506 PCB Assembly, Analog I/O Board 1
9-1-41 219484 PCB Assembly, Communication 1

Board
9-1-79 219770 PCB Assembly, EDMS Board 1
9-1-31 938203-020 Fuse, 2 Amp 5
9-1-33 943413-057 Power Supply, 5V/28V 1
9-1-83 943413-058 Power Supply, Dual Output, 15V/ 1

15V
9-1-78 219908 Battery Pack, EDMS 1
9-2 H12321A Shaft Encoder Assy 1
9-2-5 983606-001 Timing Belt, Encoder 1

M/D TOTCO

M/D TOTCO
APPENDIX A
A-1 OVERVIEW
The following drawings detail Block Diagrams and Interconnect Wiring Diagrams for a
typical Block Control System.
Drawing Number # of Pages Description

220419 2 Instrument Block Diagram, Basic
Block Control System
220420 9 Instrument Wiring Diagram, Block
Control System
October 31, 1997 Page A-1

M/D TOTCO
Appendix A Block Control System
Interconnect Drawings Manual 60-60
Page A-2 October 31, 1997

M/D TOTCO
APPENDIX B
B-1 INTRODUCTION
This chapter describes the 2025B Brake Controller. For a thorough description of the
Brake Controller, refer to the appropriate Baylor Company manual.
B-2 FIRING BOARD CONNECTIONS
The firing board is located inside the Brake Controller rectifier assembly. Table B-1 lists
the interfacing connectors for this board and Table B-2 lists the pinouts for firing board
terminal block 1 (FTB-1).
Table B-1 Firing Board Interfacing Connectors
Connector Description
J1 AC current transformer inputs

J2 DC voltage input
J3 AC voltage input
J101 Trigger pulses to A phase SCR module
J201 Trigger pulses to B phase SCR module
J301 Trigger pulses to C phase SCR module
J4 External (i.e. door) reset and meters (if used)
J5 Throttle relay for cooling pump or cooling alarm operation (if used)
J6 Alarm relay to operate the light on the door
October 31, 1997 Page B-1

M/D TOTCO
Appendix B Block Control System
2025B Brake Controller Manual 60-60
Table B-2 FTB-1 Pinouts
Pin Description
1 System ground
2 33% Maximum Current Limit (Not used)
3 67% Maximum Current Limit (Not used)
4 Throttle Signal Input

5 50% Maximum Current Limit
6 No Connection
7 -15 VDC for system use

8 +15 VDC for system use
9 No Connection
10 +15 VDC for system use
B-3 FIRING BOARD SWITCHES
The Brake Controller Firing Board contains the switches summarized below:
• “Current - Volts” Slide Switch - Used to designate the brake as voltage- or
current-regulated.For the block control system, this switch should always be
set to “Current”.
• “Normal - Reverse” Switch - Used to designate the throttle as reverse-acting.
This voltage is used to hold off the brake so that a cut cable will result in full
application of the brake. This switch should always be set to “Reverse”, unless
installed in an existing 1025 system.
• Unlabeled Dip Switches - There are two unlabeled dip switches, which are
used to reduce maximum power to the brake by 25% or 50%, in the event that
one or two coils to the brake burn out and must be disconnected. Contact The
Baylor Company in Houston for details on using these switches.
Page B-2 October 31, 1997

M/D TOTCO
Block Control System Appendix B
Manual 60-60 2025B Brake Controller
B-4 FIRING BOARD SETUP
For a reverse-acting throttle, the firing board should be set so that it commands from zero
up to the prescribed maximum amperage, as the throttle varies from its maximum to mini-
mum output. To set the firing board for a reverse-acting throttle, follow the steps below:
1. Set the “Normal-Reverse” switch to “Normal”.
2. With the throttle at maximum output, turn the “Zero” pot until both LED's
associated with the pot begin to turn on.
3. Fully release the throttle and adjust the "Gain" pot until both LED's are on.
4. Repeat Steps 2 and 3 several times to double check settings.
5. Set the “Normal-Reverse” switch to “Reverse”.
For a normal-acting throttle, the firing board should be set so that is commands from zero
up to the prescribed maximum amperage, as the throttle varies from its minimum to maxi-
mum position. To set the firing board for a normal-acting throttle, follow the steps below:
1. Set the “Normal-Reverse” switch to “Normal”.
2. With the throttle at minimum output, turn the “Zero” pot until both LED's asso-
ciated with the pot begin to turn on.
3. Turn the throttle on full and adjust the "Gain" pot until both LED's are on.
4. Repeat Steps 1 and 2 several times to double check settings.
B-5 AUXILIARY BOARD LED'S
The Auxiliary Board (Figure B-1) is mounted on the Brake Controller door. It contains 26
LED's, which identify alarm conditions by changing color from green to red or from off to
yellow. When an alarm condition exists, the auxiliary board also communicates a critical
or noncritical alarm to the DAQ. Each alarm LED is summarized in Table B-3 and illus-
trated in Figure B-1.

M/D TOTCO
Figure B-1 Brake Controller Auxiliary Board

M/D TOTCO
Table B-3 Auxiliary Board LED Summary
LED Indication Result
AUXILIARY CPT Red if Auxiliary Board power supply Sends a noncritical alarm to the
fails DAQ
NORMAL CPT Red if the main firing board power sup- Sends a noncritical alarm to the
ply fails DAQ
POWER QUALITY Red if input voltage drops below 80% Sends a critical alarm to the DAQ
ROTATION Red if the phase rotation of the supply *Sends a noncritical alarm to the
is counter clockwise DAQ
A PHASE AC Red if the incoming 240 V phase A line Sends a noncritical alarm to the
GROUND is grounded DAQ
B PHASE AC Red if the incoming 240 V phase B line Sends a noncritical alarm to the
C PHASE AC Red if the incoming 240 V phase C line Sends a noncritical alarm to the
SCR MISFIRE Red if any of six SCR's is not turning Sends a critical alarm to the DAQ
on*
+ DC GROUND Red if the Brake Controller is supplying Sends a noncritical alarm to the
current to the brake and a DC ground DAQ
exists on the positive end <MI>OR<D>
the negative brake is grounded and is
turning off
- DC GROUND Red if the Brake Controller is supplying Sends a noncritical alarm to the
current to the brake and a DC ground DAQ
exists on the negative end <MI>OR<D>
the positive brake is grounded and is
turning off
COIL FUSE Red if turned on by the switch in the Sends a critical alarm to the DAQ
fuse holder
BATTERY BACK UP Red if the battery back up is ON and Sends a critical alarm to the DAQ
supplying DC current to the brake
DAQ ALARM Red if the DAQ has issued an alarm --
OVERKW Red if a control puts out 125% of the Trips the control, sends a critical
rated KW to the brake for two seconds alarm to the DAQ and must be reset
OVERCURRENT Red if the brake current exceeds 150% Sends a critical alarm to the DAQ
of the rated current for 20 milliseconds and must be reset
THROTTLE MIS- Red if the actual brake current is less Generates a critical alarm and
MATCH than 50% of that commanded for a causes the battery backup unit to
period exceeding.5 second. come on. To reset, deactivate the
battery back-up and then reset.

M/D TOTCO
Table B-3 Auxiliary Board LED Summary
LED Indication Result

POWER SELECT ON if reduced power to the brake is --
selected by the driller on the rig floor
DRILL ASSIST Yellow if the driller has commanded full Power to brake is reduced to half lin-
current for 2 minutes or more early over a ten-minute period
Bar Graph Shows . . .

M/D T (leftmost) The current commanded by the DAQ
DRILLER (middle) The current commanded by the driller,

amended, if applicable, by the Power
Select or Drill Assist mode
ACTUAL (rightmost) The actual current flowing to the brake,

which should match the higher of the M/
D T or DRILLER bar graphs.
* The 2025B Brake Controller is phase rotation sensitive on the input, and attempted
operation with such is forbidden and would normally be considered “critical”. However,
in recognition of the fact that phase rotation should be checked upon start-up and then
remain correct, the alarm is categorized as “noncritical” to prevent inadvertent
Crownamatic and Battery Backup energization when power is first applied to the unit.
B-6 AUXILIARY BOARD INTERFACES
Table B-4 lists interface connectors and Table B-5 lists the pinouts for the auxiliary board
TB-1, located in the Brake Controller rectifier assembly.
Table B-4 Auxiliary Board Interface Connectors
Connector Description
J1 Auxiliary Power
J2 Override Switch
J3 Coil Fuse Switch
J4 “Battery Backup In Use” Switch
J5 DAQ Alarm Connection

J6 Auxiliary Use Connector (interface to Baylor equipment)
J7 DAQ Alarm Connector
J10 Firing Board Interface Connector

M/D TOTCO
Table B-5 Auxiliary Board TB-1 Pinouts
Pin Description
1 DAQ Normal Throttle current loop input

2 DAQ Normal Throttle current loop return
3 DAQ Reverse Throttle current loop input
4 DAQ Reverse Throttle current loop return

5 Current Command Feedback to DAQ input (4-20 ma for -10 to 100%)
6 Current Command Feedback to DAQ return (4-20 ma for -10 to 100%)
7 Current Feedback to DAQ input (4-20 ma for 0 to 160 amps DC)

8 Current Feedback to DAQ return (4-20 ma for 0 to 160 amps DC)
9 Input for reverse throttle defeat
10 Return for reverse throttle defeat
B-7 RELAY LOGIC
The Brake Controller contains three relays. The function of each relay is as follows:
K1 = Emergency Relay - As a fail-safe measure, upon de-energization of this relay, the

friction brake is activated and the battery back up unit is enabled.
K2 = Crownamatic - Upon energization of this relay, the friction brake is activated.
K3 = Battery Back Up - Upon energization of this relay, the battery back up unit is
enabled.
Figure B-2 through Figure B-4 are schematics for each relay.

M/D TOTCO
Figure B-2 Emergency Relay Schematic

M/D TOTCO
Figure B-3 Friction Brake Relay Schematic

M/D TOTCO
Figure B-4 Battery Backup Relay (K3) Schematic

M/D TOTCO
B-8 BRAKE CONTROLLER TROUBLESHOOTING
Refer to Figure B-1 and use the procedure below as a guide for troubleshooting the Brake
Controller.
1. Check the Auxiliary Board display on the front of the Brake Controller. If all
LED's are off, check for both main input power and auxiliary board power
input. Either should power the display.
2. If there is power to the LED's (or after restoring power in Step 1), clear any red
LED indications as directed below:
• Power Quality LED - Red if input power is not adequate - either the volt-
age level is too low or one phase is missing. Measure all three phases and
correct.
• Rotation LED - If red, check to see if input power LED is red and correct
input power, if needed. If input power LED is green, then remove power to
the Brake Controller and correct rotation.
• Normal Control Power LED - If red, check for blown fuse on firing board
and replace fuse, if needed. If fuse blows a second time, replace firing
board.
• Auxiliary Control Power - If red, check for the following: removal of
auxiliary 120 VAC to Auxiliary Board, disconnection of J-1 or blown fuse
on Auxiliary Board. Replace fuse, if needed. If fuse blows a second time,
replace Auxiliary Board.
• A Phase, B Phase or C Phase Ground - If any of these LED's are red, cor-
rect the ground as soon as possible.
• SCR Misfire LED's (6) - If any of these LED's are red, the representative
SCR did not carry current as required. Check the wiring to the gates,
including the J-01 connectors and push on connectors on the rectifier
assemblies. These LED's will reset to green when the circuit senses normal
current flow.
NOTE
These circuits are sensitive and may alarm when first turned on.
• (+) or (-) DC Bus Grounded - These LED's are red when the DC bus has
been grounded. Because of the regenerative nature of this control, a ground
on the (+) DC connection will indicate on the (-) during the short period of
regeneration (turning off).

M/D TOTCO
• Coil Fuse LED - Red if one or more of the coil fuses has blown. Measure
the coil resistance. If it is approximately 13 ohms, then check the associ-
ated selenium surge protector and then replace the fuse. If the coil is
shorted, contact Baylor Company before leaving coil disconnected and
continuing operation.
CAUTION
Operation of the Block Control System is not recommended with less than
four coils.
• Battery Backup LED - Red if the battery backup unit is enabled and is
sending battery power to the brake. Manual reset of the battery backup unit
will be necessary.
• DAQ Alarm LED - Red if the DAQ has calculated or sensed a serious
condition and is taking appropriate action.
• OverKW Led - Red if the Brake Controller has shut itself off because
excess power was sent to the coils, indicating brake control failure. To clear
this, press the RESET switch located either on the firing board or on the
front door of the Brake Controller. If after resetting, the Brake Controller
immediately turns on and the OverKW led turns red, replace the firing
board.
• Overcurrent LED - Red if the Brake Controller has shut itself off due to a
momentary 150% over current condition, typically caused by a shorted DC
load, SCR failure or firing board failure.
• Throttle Mismatch -Red if the actual brake current is less than 50% com-
manded for a period exceeding 0.5 seconds will generate a critical alarm to
the DAQ and cause the battery backup unit to come on. To clear, push the
RESET switch on either the firing board or on the front door of the Brake
Controller. Then manually reset the battery backup unit.
3. If after clearing any LED condition described above (i.e. all LED.s are green),
there is still no braking current, look at the bar graphs displayed on the Auxil-
iary Board. If neither the DAQ throttle command nor the driller’s manual input
is requesting current, verify that one should be and follow the troubleshooting
flow diagram in the Baylor 2025B manual.
4. If the DAQ or the driller’s control is requesting current but the actual braking
current bar graph is not showing current, determine if the Brake Controller is
actually outputting current through the use of a this means (i.e. clamp on DC
meter, shunt, etc.). If current is being output, the problem lies with the current-
sensing elements, the CT’s, interconnect cabling, J2 or input burden resistors.
If no current is coming from the Brake Controller with a legitimate input,
change the firing board.

M/D TOTCO
APPENDIX C
C-1 INTRODUCTION
The Brake Monitoring System is a collection of new and pre-existing rig components that,
when combined with the DAQ’s computational and monitoring capabilities, satisfy the
U.K.’s Department of Energy Offshore Installations: Guidance on Design, Construction
and Certification, paragraph 46.5.2..
Figure C-1 Brake Monitoring System Overview
October 31, 1997 Page C-1

M/D TOTCO
Appendix C Block Control System
Brake Monitoring System Manual 60-60
C-2 BRAKE MONITORING SYSTEM COMPONENTS
The following sub-sections describe each of the individual components of the BMS.
C-2-1 Safe Area Computer Interface Device (SAC)
The SAC is a personal computer designed to interface with the DAQ and serve as
a display for any information the DAQ gathers. Preformatted screen displays will
call up information for the Brake Monitoring System, the Zone Management Sys-
tem, BCS Alarms, BCS Operation and System Inputs and Outputs.
NOTE
In RLC configurations of the Block Control System, a DATAWATCH unit is
typically substituted for a SAC to display gathered information.
C-2-2 Temperature Switch
This item is used to monitor the temperature of the cooling water coming from the
eddy current brake. A high reading will signal an alarm to the SAC and the
Driller’s Display.
C-2-3 Flow Switches
These monitor the flow of cooling water to the eddy current brake and alarm with
loss of flow. Because of transient surges in most cooling flow systems, the alarm
has a time delay, and even disables if the brake is not used for 5 minutes. It is,
however, reactivated with a current command from either the driller of the DAQ.
C-2-4 Solenoid
This is used to activate the “Crownamatic” function which will immediately apply
the friction brake and remove air from the drawwork clutches.
C-2-5 Air Pressure
This is taken from the rig air supply, and is used by the “Crownamatic” to activate
the friction brake.
C-2-6 Pressure Switch
This is used to insure that the friction brake activation and back up of the electric
brake is possible. The pressure switch is inserted to monitor the air pressure avail-
able to energize the “Crownamatic.”
Page C-2 October 31, 1997

M/D TOTCO
Block Control System Appendix C
Manual 60-60 Brake Monitoring System
C-2-7 “Crownamatic”
This trade name is used here to denote any of a family of products which have
been developed and which activate a pneumatic actuator that applies the friction
brake and also releases air to the drawwork clutches.
C-2-8 Friction Brake
This is the positive torque device used to hold the drilling load. It can be of either
a disk or band type. Its proper operation and strength are assumed.
C-2-9 Uninterruptable Power Supply (UPS)
Used to insure electrical power to activate the solenoid in the event of complete
power failure.
C-2-10 UPS Switch
Connected from the UPS to the DAQ, it tells the system that the UPS is operating
on battery power. This allows the system to generate a non-critical alarm, identify-
ing a situation that might otherwise go unnoticed until the battery power was
depleted.
October 31, 1997 Page C-3

M/D TOTCO
Appendix C Block Control System
Brake Monitoring System Manual 60-60
Page C-4 October 31, 1997

M/D TOTCO
APPENDIX D
D-1 INTRODUCTION
The Block Control System provides for interfacing with the Varco Zone Management Sys-
tem (ZMS). The ZMS prevents collisions between various drilling and pipe handling
equipment. Areas of safe operation for each piece of equipment are defined by the soft-
ware, dependent upon both system operation and component position and direction of
movement. Equipment enabling signals are then communicated between the DAQ and the
Varco PLC in a fail-safe manner. Note that the M/D TOTCO equipment does not include
the Varco equipment necessary to implement the full system.
Figure D-1 General Schematic for the ZMS Interface
October 31, 1997 Page D-1

M/D TOTCO
Appendix D Block Control System
ZMS Interface Manual 60-60
D-2 THEORY OF OPERATION
The Block Control System (BCS) and the Zone Management System (ZMS) exchange
data used to prevent collisions between and among the protected equipment. The BCS
data exchanged with the ZMS prevents the lowering of the block into an area already
occupied by another piece of equipment. It also prevents the block from lowering into an
area where another piece of equipment is moving toward.
The BCS provides an “enable” signal when the block is clear of a specific area as queried
by an analog 4–20 mA signal from the ZMS processor, allowing other equipment to enter
the area.
D-3 BLOCK CONTROL SYSTEM INPUTS FROM THE ZMS COMPUTER
The BCS DAQ has an input for an analog signal from the ZMS that represents the lowest
block excursion height allowed by the BCS only if a digital input to the BCS DAQ is
active. The signal from the ZMS is in the form of a grounded high resistance pull up to
5 Volts. The analog signal input to the BCS will go high when either of the following
statements is true:
• the equipment deemed to be the most immediate concern by the ZMS is
starting a movement toward the area of possible conflict, or
• the equipment is already in the area of conflict.
The signal stays high until the associated equipment is completely clear of the area of con-
flict. The relay contact and power source are arranged for “fail-safe” operation by Varco.
In addition, there is another analog input to the BCS DAQ which represents any height of
interest in the ZMS deemed necessary to poll the BCS about. This is generally in response
to a “request to enter” query sent out by a piece of ZMS equipment. The DAQ responds
with a digital signal to the ZMS processor as outlined in Section D-4. These ZMS analog
signals will be 4–20 mA, and will represent the range of possible values of height. Maxi-
mum height above the floor is represented by a 4 mA signal, and the minimum height
above the floor is represented by a 20 mA signal. The BCS checks the integrity of the sig-
nal—if it falls below 2 mA an alarm is activated, but the signal it treated as a valid input of
4 mA.
D-4 BLOCK CONTROL SYSTEM OUTPUTS TO THE ZMS COMPUTER
There is one output of the BCS DAQ to the ZMS which is considered an “enable” of the
equipment chosen for query by the ZMS processor. This signal activates an output transis-
tor of the DAQ to choose a ZMS relay, and communicate a high voltage signal to the ZMS
equipment. The BCS constantly compares the analog query height, and if above or at the
safe distance for block travel, enables that signal. When the block goes below the queried
height or cannot stop itself from doing so with normal braking, the output transistor turns
off, thereby dropping out the associated relay and its signal. This makes the signal “fail-
safe” in terms of the DAQ losing power or computing ability.
Page D-2 October 31, 1997

M/D TOTCO
Block Control System Appendix D
Manual 60-60 ZMS Interface
D-5 ZMS (II)-REVISED ZMS
As of June 1997, a different version of the ZMS interface between M/D TOTCO and
Varco equipment was derived, and has been in use since that time. This version uses five
“channels” as before, but they are redefined as follows:
1. “ZMS-D_Stop_E”—an analog signal representing block height, where a 4 mA

signal represents zero feet, and a 20 mA signal represents 100 feet. This signal is
the “D_Stop_E” signal presently used by the Block Control System which repre-
sents not where the block is, but where it can safely stop using the electric brake
when headed down. The values are limited to those between 0 and 100 ft.
2. “ZMS Target”—an analog signal sent from the Varco PLC to the DAQ repre-
senting a height taken to be the highest piece of protected equipment in the
well center. It is scaled during rig up.
3. “ZMS Target Active”—a 5 volt signal sourced by the DAQ analog channel’s
source voltage and pulled to zero by the ICS’s PLC. Absence of the voltage
will be taken as indication that the “ZMS Target” is not active, thereby telling
the BCS to allow block movement past that point. The signal going high will
tell the BCS not to allow block movement past that point.
4. “ZMS Mirror”—an analog 4–20 mA signal, scaled to represent 0 to 100 feet,
that reflects the height being transmitted by channel 1 from the DAQ to the
PLC. This mirror signal is sent from the PLC to the DAQ to allow the DAQ to
check that its signal is transmitting properly.
5. “ZMS Alarm”—a 5 volt signal, normally high, that can be pulled low by the
DAQ to inform the PLC that a significant difference exists between the
“ZMS Height” and the “ZMS Mirror” channels.
The two modules comprising the ZMS-D_Stop_E analog feed to the PLC are contained
within the DAQ. The +24 volt power for the modules comes from the DAQ. Refer to fol-
lowing diagram for more detailed wiring information.
October 31, 1997 Page D-3

M/D TOTCO
Appendix D Block Control System
ZMS Interface Manual 60-60
Page D-4 October 31, 1997

M/D TOTCO

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Part Number 60-60

INSTALLATION, OPERATION, AND MAINTENANCE

BLOCK CONTROL SYSTEM

Manufacturers of Precision Instruments

Printed in U.S.A. October 31, 1997

Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . October 1997

October 31, 1997 iii

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

The warranty periods for various products are:

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

iv October 31, 1997

October 31, 1997 Table of Contents-1

3-4-4 REVERSE THROTTLE Signal................................................................................. 3-3

Table of Contents-2 October 31, 1997

4-5-1-3 Shielded Cable Splicing.................................................................................. 4-11

October 31, 1997 Table of Contents-3

7-9 DRILL/TRIP SWITCH....................................................................................................... 7-3

Table of Contents-4 October 31, 1997

B-4 FIRING BOARD SETUP ...................................................................................................B-3

October 31, 1997 Table of Contents-5

Table of Contents-6 October 31, 1997

October 31, 1997 List of Figures-1

Figure 4-18 Typical Hook Load Transducer Installation ...................................................... 4-20

List of Figures-2 October 31, 1997

Figure 9-3 Calibration Switch Box...................................................................................... 9-10

October 31, 1997 List of Figures-3

List of Figures-4 October 31, 1997

October 31, 1997 List of Tables-1

List of Tables-2 October 31, 1997

1-1 PURPOSE OF MANUAL

1-2 SCOPE OF MANUAL

This manual is divided into the following chapters:

1-3 INTENDED AUDIENCE

1-4 PERSONNEL QUALIFICATIONS

October 31, 1997 Page 1-1

1-5 NOTES, CAUTIONS AND WARNINGS

Provides information to prevent equipment malfunction or damage that

1-6 RELATED DOCUMENTS

Manual Number Manual Description

Page 1-2 October 31, 1997

2-2 SYSTEM COMPONENTS

October 31, 1997 Page 2-1

Figure 2-1 Block Control System Overview

Page 2-2 October 31, 1997

2-3 DAQ (DATA ACQUISITION UNIT) - M/D TOTCO PN 219554

October 31, 1997 Page 2-3

Figure 2-2 M/D TOTCO Data Acquisition Unit (DAQ)

2-4 BRAKE SYSTEM

2-4-1 Baylor 2025B Brake Controller

Page 2-4 October 31, 1997

Figure 2-3 Baylor 2025B Brake Controller

2-4-2 Eddy Current Brake

2-4-3 Friction Brake

October 31, 1997 Page 2-5

• A malfunction is detected in the DAQ, Brake Controller, eddy current