10660418-Man Tds-11sa

TDS-11SA - Top Drive Drilling System
User Manual
Customer References
Customer: NOV JEBEL ALI
Rig / Hull: STOCK UNIT 3
Tag Number: N/A
National Oilwell Varco References:

SO Number / Project Number: 135125
Document Number: 10660418-MAN
Revision: 01
Volume: 1
www.nov.com
Document number 10660418-MAN
Revision 01
Page 2
REVISION HISTORY
01 29.01.2013 For Information L. Krajenbrink I. Vargas H. Lim

Rev Date (dd.mm.yyyy) Reason for issue Prepared Checked Approved
CHANGE DESCRIPTION
Revision Change Description

01 For Initial Release
www.nov.com
Bill of Material
Item Quantity Part Number Description
1 1 SM00856 Service Manual, TDS-11SA

2 1 SM01053 Service Manual, Washpipe Assembly
3 1 50000870-MAN-001 Links User Manual
4 1 D811004302-MAN-001 Service Manual Supplement, Stateless Driller’s Control Console
5 1 10660418-DOS Technical Drawing Package, TDS-11SA
6 1 M804000494-SPL-001 Control Spares, ABB VFD House
7 1 M614003549-SPL-001 Mechanical Spares LFT, TDS-11SA, EEX
8 1 127425 Electrical Trouble Shooting Guide (TDS-9SA / TDS-11SA)
9 1 D392001271-MKT-001 TDS-11SA, Pocket Guide
10 1 D25TDS11-MAN-001 TDS-11SA VFD Operation Manual
11 1 D614000166-PRO-001 Service Loop Jacket Installation Instructions
12 1 VDR00029 Reliance Manual (180-449)
13 1 VDR00030 Reliance Manual (L210-L400)
14 1 ASP00019 Safety Wiring Procedure
15 1 DS00008 Design Torque Standard
16 1 D811000719-PRO-001 Recommended Lubricants and Fluids
17 1 SM00081 Hydraulic Fluid Cleanliness
18 1 D811001337-DAS-001 Service Center Directory
NEXT ASSY PRODUCT
10657452-GEN
10657453-GEN TDS-11SA
10656189-GEN
This document contains proprietary and confidential information which is the property of
National Oilwell Varco, L.P., its affiliates or subsidiaries (all collectively referred to
hereinafter as "NOV"). It is loaned for limited purposes only and remains the property of
NOV. Reproduction, in whole or in part, or use of this design or distribution of this
information to others is not permitted without the express written consent of NOV. This
document is to be returned to NOV upon request or upon completion of the use for which
it was loaned. This document and the information contained and represented herein is the
copyrighted property of NOV. © National Oilwell Varco User Manual
CURRENT INITIAL NOV-Houston, Rigs: ME-13, ME-14 & Stock Unit 3

TDS-11SA
DRAWN T. Harmon T. Harmon SCALE: WT LBS: SIZE: SHT:
CHECKED H. Lim H. Lim AV 1 OF 1
DWG NO.: REV:
APPVD H. Lim H. Lim
10660418-MAN 03
DATE 01/29/2013 05/16/2012
D811000457-GEN-001/04
FINAL DOCUMENTATION
TDS-11SA – Top Drive Drilling System
Chapter 1.0
Service Manual, TDS-11SA
www.nov.com
Service Manual
TDS-11SA Top Drive
Reference Reference Description
This document contains proprietary and confidential

information which is the property of National Oilwell Varco,
L.P., its affiliates or subsidiaries (all collectively referred to
hereinafter as "NOV"). It is loaned for limited purposes only National Oilwell Varco
and remains the property of NOV. Reproduction, in whole or in RIG SOLUTIONS
part, or use of this design or distribution of this information to
others is not permitted without the express written consent of
11000 Corporate Centre Drive
NOV. This document is to be returned to NOV upon request or Houston, TX 77041
upon completion of the use for which it was loaned. This
document and the information contained and represented
herein is the copyrighted property of NOV.
© National Oilwell Varco
Document Number Rev.
SM00856 D
www.nov.com
Form D811001123-GEN-001/06
SM00856
Revision D
Revision History
D 15.08.2012 Engineering Update J. Roman H. Lim M. Clark
C 11.11.2011 Engineering Update T. Drake H. Lim M. Clark
B 2006 Teamcenter migration version. – – –
A 2003 Teamcenter migration version. – – –
– 2000 First Issue: Original Instructions – – –
Change Description
– First Issue: Original Instructions. No relevant issue history.
A Revision migrated in Teamcenter. No relevant revision history.
B Revision migrated in Teamcenter. No relevant revision history.
• Updated cover illustration, applied latest FrameMaker template, and reorganized material.
• Removed outdated VFD references and added ABB ASC800 reference and specs (page 2-3).
• Added Noise Data (page 2-5).
• Updated upper main body seals lubrication interval and procedure (page 5-59 and page 5-60).
• Added optional NOV Mechanical Washpipe information (various locations throughout manual).
• Added new control house illustration, dimensions and weight (various pages, starting with page 3-6).
• Added new guide beam warning information (page 3-9, page 3-12, page 3-16, page 3-23).
• Changed procedure so it was not specific to option 2 (page 3-26).
• Added auxiliary cable jacket installation procedure (page 3-29).
• Added secondary retention to counterbalance illustration (page 3-34).
• Added bail lock components to decommissioning illustration (page 3-42).
C • Added additional long-term storage and return-to-service instructions (CE fix) (page 3-43).
• Added new console illustrations and operation information (starting on page 3-30 and page 4-1).
• Moved Making and Breaking Tool Joint Connections to Operation (page 4-19).
• Added Well Control Procedure (page 4-28)
• Added Joint Pin and Bushing wear limits to Guide Beam Joint Inspection (page 5-6).
• Removed Blower Motor Inspection illustration from red lined instructions.
• Updated Non-Destructive Examination section (page 5-56).
• Replaced Link Tilt in illustrations where maintenance procedure are affected (various pages).
• Added driller’s control console maintenance information (page 5-97)
• Moved hydraulic setup to Maintenance and troubleshooting to the new troubleshooting chapter.
• Moved hydraulic symbol description to Appendix A.
• Moved PH-50 Pipe Handler service manual information to Appendix B.
• Corrected Guide Beam Joint illustration (page 5-6).

D
• Corrected Plan View dimensions; added 30.0” setback illustration (page 2-7 and page 2-8).
www.nov.com
SM00856
Revision D
Page i of viii
Table of Contents
Chapter 1: General Information

Conventions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
Advisories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
Note . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
Caution . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
Warning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
Hot Surfaces . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
Electrostatic Discharge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
Illustrations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
Safety Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
Proper Use of Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
Safe Lifting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
Personnel Training . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
Recommended Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
General System Safety Practices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
Replacing Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5
Routine Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5
Equipment Documentation Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5
Equipment Disposal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5
Service Centers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5
Chapter 2: Description
Introduction to the TDS-11SA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Major Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
General Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
Performance Curve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
Noise Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
Top Drive Height . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6
Top Drive Plan View . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7
30.0" Setback Top View Dimensions (Standard) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7
39.5" Setback Top View Dimensions (Optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8
Identification Labels and Numbers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9
Lifting Points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10
Typical Equipment Arrangement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11
Chapter 3: Installation
Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Illustrated Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
Pre-Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
Installing the Crown Padeye and Hang-Off Link . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
Installing the Intermediate Tieback . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
Installing the Main Tieback . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5
Locating the Control House . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6
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Revision D
Page ii of viii
Table of Contents
Installing Power Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7

Grounding the Control House (Land Rigs) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9
Checklist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9
Identifying Guide Beam Sections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9
Raising the Top Guide Beam Section to the Drill Floor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10
Attaching the Carriage Sling to the Hook . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11
Moving Guide Beam Sections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12
Hooking the First Guide Beam Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13
Hoisting the First Guide Beam Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14
Stabbing and Pinning the First Guide Beam Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-15
Completing Guide Beam Section Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-16
Hoisting and Attaching the Guide Beam . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-17
Removing the Hoist Carriage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-18
Moving the Top Drive to the Rig Floor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-19
Attaching the Top Drive to the Hook . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-20
Lifting the Top Drive into the Rig . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-21
Connecting the Top Drive to the Guide Beam . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-22
Bottom Intermediate Section Warning Label . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-23
Attaching the Torque Tieback . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-24
Pinning the Top Drive to the Guide Beam . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-25
Releasing the Top Drive from the Skid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-26
Installing Derrick Termination . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-27
Installing Service Loops at the Derrick . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-28
Installing Service Loop Jackets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-29
Installing the Driller’s Control Console . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-30
Installing the Console Cabling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-31
Motor Rotation Checkout Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-32
Installing the Elevator Links . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-33
Installing the Counterbalance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-34
Commissioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-35
Initial Checkout Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-35
Hydraulic System Checkout Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-36
Electrical System Checkout Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-37
Mechanical Checkout Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-38
Adjusting the Link Tilt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-39
Decommissioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-40
Securing the Top Drive for Rig-Down . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-40
Removing and Storing Cables and Service Loops . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-41
Setting the Latches and Locking the Bail . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-42
Long Term Storage. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-43
General Guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-43
Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-43
Storage Location and Position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-43
Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-43
Pre-Storage Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-44
ii
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Table of Contents
Storage Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-45

Returning the Top Drive to Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-46
Chapter 4: Operation
Stateless Driller’s Control Console . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Front Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
Internal Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4
Alarms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5
Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6
Top Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6
IBOP and Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8
Pipe Handler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9
E-Stop, BX Elevator, Counterbalance, and Dolly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-12
Meters and Limit Adjustment Knobs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-14
Amphion™ Touchscreen Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-15
Basic Usage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-16
Drilling Ahead with Singles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-16
Drilling Ahead with Triples . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-17
Back Reaming . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-18
Making and Breaking Tool Joint Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-19
Breaking out the Saver Sub . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-19
Making up the Saver Sub . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-21
Breaking out the Lower IBOP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-21
Making up the Lower IBOP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-23
Breaking out the Upper IBOP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-24
Making up the Upper IBOP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-26
Well Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-28
Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-28
Component Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-29
Chapter 5: Maintenance
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
Pre-Maintenance Checklist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
Documentation You Will Need . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
Regulatory Standards You Will Use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
Spare Parts You May Need . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
Spare Parts and Fluids Disposal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
Safety Precautions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2
Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2
Equipment Records . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3
Torque Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3
Safety Wire (Lockwire) Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3
Secondary Retention Guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3
Equipment Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4
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Inspecting Rig Interface Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4

Inspection Schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4
Inspecting the Guide Beam and Carriage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5
Crown Padeye and Hang-Off Link . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5
Guide Beam Joints . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6
Main Tieback . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7
Intermediate Tieback . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8
Carriage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-9
Inspecting the Motor Housing and Transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-10
Illustrated Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-10
Inspection Schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-11
Internal Lubrication Flow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-13
Belt-Driven Encoder Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-14
Gearbox Lube Pump Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-16
Gear Backlash . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-18
Bail and Main Body . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-19
S-Pipe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-20
Upper Main Shaft Liner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-21
Standard Washpipe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-22
Upper Bonnet Seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-25
Main Shaft and Load Collar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-26
Main Shaft End Play . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-27
Motor Brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-28
Drilling Motors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-29
Transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-30
Inspecting the PH-75 Pipe Handler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-32
Illustrated Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-32
Inspection Schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-33
Stopping and Starting the Top Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-35
Elevator Links . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-36
Link Tilt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-38
Torque Wrench Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-40
Stabilizer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-44
IBOP Actuator Cylinder and Yoke . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-45
Tool Joint Locks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-47
IBOP Valves and Saver Sub . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-49
Shot Pin Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-50
Rotating Link Adapter and Load Stem . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-52
Nondestructive Examination . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-56
Making Visual Inspections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-56
Magnetic Particle Inspection (MPI) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-56
Ultrasonic Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-57
IBOP Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-57
Recommended Lubricants and Fluids . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-58
Lubrication Schedules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-58
Daily . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-59
Weekly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-59
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Monthly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-60
Every Three Months . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-60
Every Six Months . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-60
Yearly and As Required . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-61
Lubrication Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-62
General Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-62
Gearbox Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-65
Motor Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-66
Hydraulic System Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-67
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-67
General Inspection Schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-67
Location of Hydraulic Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-68
System Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-69
Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-70
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-73
Hydraulic Fluid Level and Indicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-73
Hydraulic Reservoir Bladder (Yearly) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-74
Heat Exchanger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-75
Using the Hydraulic System Ports . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-76
Precharging the Accumulators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-77
IBOP Timing Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-78
IBOP and Oil Pressure Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-79
Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-80
Adding Hydraulic Fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-81
Draining Hydraulic Fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-82
Setting Up Hydraulic Circuits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-83
Hydraulic Pumps and Unloading Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-83
Counterbalance Circuit and Stand-Jump Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-88
AC Motor Brake Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-92
Shot Pin Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-93
Link Tilt Cylinder Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-95
Rotating Link Adapter Hydraulic Motor Relief Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-96
Control Console Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-97
Chapter 6: Troubleshooting
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
Personnel Qualifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2
Troubleshooting Guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2
Determining the Nature of Problem . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3
Identifying Troubleshooting Categories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3
Mechanical Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3
Hydraulic System and Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3
Electrical System and Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3
Lubrication and Cooling System Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4
Pre-Troubleshooting Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4
Service Centers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5
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Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6
HPU and Reservoir Bladder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6
Troubleshooting Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6
Schematic Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7
Counterbalance and Stand Jump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-8
Counterbalance Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-8
Stand Jump Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-8
Troubleshooting Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-9
Schematic Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-10
Motor Brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-12
Troubleshooting Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-12
Shot Pin Cylinder and Clamp Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-14
Link Tilt Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-16
Gearbox Lubrication Hydraulic System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-18
Tool Rotation and Movement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-20
Rotating Link Adapter Motor Schematic Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-21
IBOP Actuator Schematic Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-22
Appendix A: Hydraulic Symbols
Appendix B: PH-50 Pipe Handler

Inspection Schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-2
Safety Precautions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-3
Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-3
Equipment Records . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-4
Torque Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-4
Safety Wire (Lockwire) Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-4
Elevator Links . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-5
Disassembly/Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-5
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-6
Link Tilt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-7
Disassembly/Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-7
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-8
Torque Wrench Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-9
Clamp Cylinder Body Disassembly/Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-9
Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-9
Removing the Clamp Cylinder Body . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-10
Disassembling the Clamp Cylinder Body . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-11
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Inspecting the Clamp Cylinder Body . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-12

Inspecting the Stabilizers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-13
Disassembling the IBOP Actuator Cylinder and Yoke . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-15
Inspecting the IBOP Actuator Cylinder and Yoke . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-16
IBOP Stack . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-17
Tool Joint Locks Disassembly/Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-17
Inspecting the Tool Joint Locks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-18
Inspecting IBOP Valves and Saver Subs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-19
Shot Pin Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-20
Disassembly/Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-20
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-21
Rotating Link Adapter/Load Stem . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-22
Removing the Rotating Link Adapter (while the top drive is in the mast) . . . . . . . . . . . . . . . . . B-22
Disassembling the Link Tilt Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-22
Inspecting the Rotating Link Adapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-23
Assembling the Link Adapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-24
Installing the Rotating Link Adapter (while the top drive is in the mast) . . . . . . . . . . . . . . . . . . B-25
Wireline Adapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-26
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-26
Nondestructive Examination . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-27
Making Visual Inspections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-27
Magnetic Particle Inspection (MPI) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-27
Ultrasonic Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-28
IBOP Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-28
Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-28
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Figure 2-1. TDS-11SA Top Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2

Figure 2-2. Performance Curve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
Figure 2-3. Top Drive Height . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6
Figure 2-4. Top Drive Plan View (30.0" Setback). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7
Figure 2-5. Top Drive Plan View (39.5" Setback). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8
Figure 2-6. Identification Labels and Numbers. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9
Figure 2-7. Lifting Points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10
Figure 2-8. Typical Installed Equipment Arrangement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11
Figure 3-1. Illustrated Installation Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
Figure 3-2. Installing the Crown Padeye and Hang-Off Link . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
Figure 3-3. Installing the Intermediate Tieback . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
Figure 3-4. Installing the Main Tieback . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5
Figure 3-5. Locating the Control House . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6
Figure 3-6. Installing Power Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7
Figure 3-7. Grounding the Control House (Land Rigs). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8
Figure 3-8. Raising the Top Guide Beam Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10
Figure 3-9. Attaching the Carriage Sling to the Hook. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11
Figure 3-10. Moving Guide Beam Sections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12
Figure 3-11. Hooking the First Guide Beam Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13
Figure 3-12. Hoisting the First Guide Beam Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14
Figure 3-13. Stabbing and Pinning the First Guide Beam Section. . . . . . . . . . . . . . . . . . . . . . . . 3-15
Figure 3-14. Completing Guide Beam Section Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-16
Figure 3-15. Hoisting and Attaching the Guide Beam . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-17
Figure 3-16. Removing the Hoist Carriage. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-18
Figure 3-17. Moving the Top Drive to the Rig Floor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-19
Figure 3-18. Attaching the Top Drive to the Hook . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-20
Figure 3-19. Lifting the Top Drive into the Rig . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-21
Figure 3-20. Connecting the Top Drive to the Guide Beam . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-22
Figure 3-21. Bottom Intermediate Guide Beam Section Warning Label . . . . . . . . . . . . . . . . . . . 3-23
Figure 3-22. Attaching the Torque Tieback . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-24
Figure 3-23. Pinning the Top Drive to the Guide Beam . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-25
Figure 3-24. Releasing the Top Drive from the Skid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-26
Figure 3-25. Installing Derrick Termination . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-27
Figure 3-26. Installing Derrick Service Loops at the Derrick . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-28
Figure 3-27. Installing the Driller’s Control Console . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-30
Figure 3-28. Installing the Console Cabling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-31
Figure 3-29. Motor Rotation Checkout Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-32
Figure 3-30. Installing the Elevator Links . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-33
Figure 3-31. Installing the Counterbalance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-34
Figure 3-32. Initial Checkout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-35
Figure 3-33. Hydraulic System Checkout. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-36
Figure 3-34. Electrical System Checkout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-37
Figure 3-35. Mechanical Checkout. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-38
Figure 3-36. Adjusting the Link Tilt. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-39
Figure 3-37. Securing the Top Drive for Rig-Down . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-40
Figure 3-38. Removing and Storing Cables and Service Loops . . . . . . . . . . . . . . . . . . . . . . . . . 3-41
Figure 3-39. Setting the Latches and Locking the Bail. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-42
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Figure 4-1. NOV Stateless Driller’s Control Console (Front Panel Closed) . . . . . . . . . . . . . . . . . 4-2
Figure 4-2. NOV Stateless Driller’s Control Console (Front Panel Opened) . . . . . . . . . . . . . . . . 4-3
Figure 4-3. Alarms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5
Figure 4-4. Top Drive Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6
Figure 4-5. IBOP and Brake Controls. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8
Figure 4-6. Pipe Handler Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9
Figure 4-7. E-Stop, BX Elevator, Counterbalance, and Dolly Controls . . . . . . . . . . . . . . . . . . . 4-12
Figure 4-8. Meters and Limit Adjustment Knobs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-14
Figure 4-9. Default Top Drive Amphion Touchscreen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-15
Figure 4-10. Drilling Ahead With Singles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-16
Figure 4-11. Drilling Ahead With Triples. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-17
Figure 4-12. Back Reaming . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-18
Figure 4-13. Breaking Out the Saver Sub . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-20
Figure 4-14. Breaking out the Lower IBOP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-22
Figure 4-15. Breaking out the Upper IBOP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-25
Figure 4-16. Well Control Component Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-29
Figure 5-1. Inspecting the Crown Padeye and Hang-Off Link . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5
Figure 5-2. Inspecting the Guide Beam Joints . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6
Figure 5-3. Inspecting the Main Tieback . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7
Figure 5-4. Inspecting the Intermediate Tieback . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8
Figure 5-5. Inspecting the Carriage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-9
Figure 5-6. Motor Housing and Transmission Illustrated Index . . . . . . . . . . . . . . . . . . . . . . . . . 5-10
Figure 5-7. Inspecting Internal Lubrication Flow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-13
Figure 5-8. Adjusting the Belt-Driven Encoder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-15
Figure 5-9. Inspecting the Gearbox Lube Pump Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-17
Figure 5-10. Inspecting Gear Backlash . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-18
Figure 5-11. Inspecting the Bail and Main Body. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-19
Figure 5-12. Inspecting the S-Pipe. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-20
Figure 5-13. Inspecting the Upper Main Shaft Liner. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-21
Figure 5-14. Inspecting the Washpipe (1 of 2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-23
Figure 5-15. Inspecting the Washpipe (2 of 2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-24
Figure 5-16. Inspecting the Upper Bonnet Seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-25
Figure 5-17. Inspecting the Main Shaft and Load Collar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-26
Figure 5-18. Inspecting Main Shaft End Play . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-27
Figure 5-19. Inspecting the Motor Brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-28
Figure 5-20. Inspecting the Drilling Motors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-29
Figure 5-21. Disassembling/Assembling the Transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-30
Figure 5-22. PH-75 PIpe Handler Illustrated Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-32
Figure 5-23. Stopping and Starting the Top Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-35
Figure 5-24. Inspecting the Elevator Links . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-37
Figure 5-25. Inspecting the Link Tilt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-39
Figure 5-26. Removing the Clamp Cylinder Body . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-41
Figure 5-27. Disassembling the Clamp Cylinder Body. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-42
Figure 5-28. Inspecting the Clamp Cylinder Body . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-43
Figure 5-29. Inspecting the Stabilizer. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-44
Figure 5-30. Inspecting the IBOP Actuator Cylinder and Yoke . . . . . . . . . . . . . . . . . . . . . . . . . . 5-46
Figure 5-31. Inspecting the Tool Joint Locks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-48
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List of Figures
Figure 5-32. Inspecting the IBOP Valves and Saver Sub . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-49
Figure 5-33. Inspecting the Shot Pin Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-51
Figure 5-34. Inspecting the Rotating Link Adapter and Load Stem . . . . . . . . . . . . . . . . . . . . . . . 5-53
Figure 5-35. General Lubrication (1 of 3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-62
Figure 5-38. Gearbox Lubrication. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-65
Figure 5-39. Motor Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-66
Figure 5-40. Hydraulic System Major Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-68
Figure 5-41. Hydraulic System Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-69
Figure 5-42. Inspecting the Hydraulic Fluid Level and Indicator . . . . . . . . . . . . . . . . . . . . . . . . . 5-73
Figure 5-43. Inspecting the Hydraulic Reservoir Bladder (Yearly) . . . . . . . . . . . . . . . . . . . . . . . . 5-74
Figure 5-44. Inspecting the Heat Exchanger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-75
Figure 5-45. Using the Hydraulic System Test Ports . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-76
Figure 5-46. Precharging the Accumulators. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-77
Figure 5-47. Inspecting the IBOP Timing Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-78
Figure 5-48. Inspecting the IBOP and Oil Pressure Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-79
Figure 5-49. Adding Hydraulic Fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-81
Figure 5-50. Draining Hydraulic Fluid. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-82
Figure 5-51. Hydraulic Pumps and Unloading Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-83
Figure 5-52. Pressure Cycle Graph . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-85
Figure 5-53. Pump Setup Manifold Ports . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-86
Figure 5-54. Pump Setup Circuit Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-87
Figure 5-55. Counterbalance Setup Manifold Ports . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-90
Figure 5-56. Counterbalance Setup Circuit Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-91
Figure 5-57. Motor Brake Setup Manifold Ports . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-92
Figure 5-58. Setting up the Shot Pin Circuit (1 of 2). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-93
Figure 5-59. Setting up the Shot Pin Circuit (2 of 2). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-94
Figure 5-60. Setting up the Rotating Link Adapter Hydraulic Motor Relief Circuit . . . . . . . . . . . . 5-96
Figure 6-1. HPU and Reservoir Bladder Schematic Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7
Figure 6-2. Counterbalance and Stand Jump Schematic Diagram . . . . . . . . . . . . . . . . . . . . . . 6-10
Figure 6-3. Brake Circuit Schematic Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-13
Figure 6-4. Shot Pin Cylinder and Clamp Cylinder Schematic Diagram . . . . . . . . . . . . . . . . . . 6-15
Figure 6-5. Link Tilt Cylinders Schematic Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-17
Figure 6-6. Gearbox Lubrication Hydraulic System Schematic Diagram . . . . . . . . . . . . . . . . . . 6-19
Figure 6-7. Rotating Link Adapter Motor Schematic Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . 6-21
Figure 6-8. IBOP Actuator Schematic Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-22
Figure A-1. Hydraulic Symbols (1 of 3). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-2
Figure B-1. PH-50 Major Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-1
Figure B-2. PH-50: Inspection Schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-2
Figure B-3. PH-50: Elevator Link Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-6
Figure B-4. PH-50: Link Tilt Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-8
Figure B-5. PH-50: Removing the Clamp Cylinder Body . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-10
Figure B-6. PH-50: Disassembling the Clamp Cylinder Body. . . . . . . . . . . . . . . . . . . . . . . . . . . B-11
Figure B-7. PH-50: Inspecting the Clamp Cylinder Body . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-12
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List of Figures
Figure B-8. PH-50: Inspecting the Stabilizer. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-14

Figure B-9. PH-50: Inspecting the IBOP Actuator Cylinder and Yoke . . . . . . . . . . . . . . . . . . . . B-16
Figure B-10. PH-50: Inspecting the Tool Joint Locks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-18
Figure B-11. PH-50: Inspecting IBOP Valves and Saver Subs . . . . . . . . . . . . . . . . . . . . . . . . . . B-19
Figure B-12. PH-50: Inspecting the Shot Pin Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-21
Figure B-13. PH-50: Inspecting the Rotating Link Adapter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-23
Figure B-14. PH-50: Inspecting the Wireline Adapter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-26
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General Information 1
Conventions
This manual is intended for use by field engineering, installation, operation, and repair personnel.
Every reasonable effort has been made to ensure the accuracy of the information contained
herein. National Oilwell Varco® (NOV) will not be held liable for errors in this material, or for
consequences arising from misuse of this material.
Advisories
Graphic symbols and bracketed text indicate advisories for a specific topic. This information
provides additional details and may advise the reader to take a specific action to protect personnel
from potential injury or lethal conditions. Advisories may also describe actions necessary to
prevent equipment damage.
Note
The note symbol indicates that additional information is

provided about the current topic.
Caution
!
The caution symbol indicates that potential damage to
equipment, or injury to personnel exists. Follow
instructions explicitly. Extreme care should be taken when
performing operations or procedures preceded by this
caution symbol.
Warning
The warning symbol indicates a definite risk of

equipment damage or danger to personnel. Failure to
follow safe work procedures could result in serious or
fatal injury to personnel, significant equipment
damage, or extended rig down time.
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Conventions
Advisories
Hot Surfaces
The hot surface symbol indicates the presence of a

hot surface or component. Touching this surface
could result in bodily injury. To reduce the risk of
injury from a hot component, allow the surface to cool
before touching.
Electrostatic Discharge
The Electrostatic Discharge (ESD) symbol indicates the

potential for static electrical discharge is present. ESD can
damage or destroy sensitive electronic components. ESD
can also set off explosions or fires in flammable environ-
ments. Always discharge static electricity prior to working
on sensitive components or in flammable environments.
Illustrations
Illustrations (figures) provide a graphical representation of equipment components or screen
snapshots for use in identifying parts, or establishing nomenclature, and may or may not be drawn
to scale.
For component information specific to your rig configuration, see the technical drawings included
with your NOV documentation.
Safety Requirements
The NOV equipment is installed and operated in a controlled drilling rig environment involving
hazardous situations. Proper maintenance is important for safe and reliable operation. Procedures
outlined in the equipment manuals are the recommended methods of performing operations and
maintenance.
!
To avoid injury to personnel or equipment damage,
carefully observe requirements outlined in this section.
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Safety Requirements
Proper Use of Equipment
NOV equipment is designed for specific functions and applications, and should be used only for its
intended purpose.
Safe Lifting
When lifting and handling NOV equipment, use approved lifting procedures and safe methods.
Lifting equipment improperly creates a hazardous

working environment. To avoid lifting hazards, only lift
equipment with material handling equipment rated for
the expected load and only from the designated lift
points. Failure to follow safe lifting guidelines may
result in serious or fatal injury to personnel,
significant equipment damage, and extended rig down
time.
!
Individuals working with rig equipment must never lift
anything over 55 lb (25 kg) without assistance. Always get
help from additional rig personnel or use lifting equipment.
Always follow all federal, state and local rules, codes, and
rig-specific safety guidelines when lifting and handling
NOV equipment. Operators and maintenance personnel
should be properly trained in safe lifting procedures and
the inspection of material handling equipment and lifting
components. Safe lifting recommendations provided in this
manual do not take precedence over local safety rules and
regulations, OSHA regulations, or instructions issued by
the manufacturers of rig hoisting equipment and other tools
on the rig.
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Safety Requirements
Personnel Training
All personnel performing installation, operations, repair, or maintenance procedures on the
equipment, or those in the vicinity of the equipment, should be trained in rig safety, tool operation,
and maintenance to ensure their safety.
!
Personnel should wear protective gear during installation,
maintenance, and certain operations.
Contact the NOV training department for more information about equipment operation and
maintenance training.
Recommended Tools
Service operations may require the use of tools designed specifically for the purpose described.
The equipment manufacturer recommends that only those tools specified be used when stated.
Ensure that personnel and equipment safety are not jeopardized when following service
procedures and that personnel are not using tools that were not specifically recommended by the
manufacturer.
General System Safety Practices

The equipment discussed in this manual may require or contain one or more utilities such as
electrical, hydraulic, pneumatic, or cooling water.
!
Read and follow the guidelines below before installing
equipment or performing maintenance to avoid
endangering exposed persons or damaging equipment.
 Isolate energy sources before beginning work.

 Avoid performing maintenance or repairs while the equipment is in operation.
 Wear proper protective equipment during equipment installation, maintenance, or
repair.
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Safety Requirements
Replacing Components
 Verify that all components (such as cables, hoses, etc.) are tagged and labeled
during assembly and disassembly of equipment to ensure correct installation.
 Replace failed or damaged components with original equipment manufacturer
certified parts. Failure to do so could result in equipment damage or injury to
personnel.
Routine Maintenance
Equipment must be maintained on a routine basis. See product-specific service manuals for
maintenance recommendations.
!
Failure to conduct routine maintenance could result in
equipment damage or injury to personnel.
Equipment Documentation Location

The User Manual provided with the equipment order contains this service manual, the engineering
installation and commissioning procedures, the Technical Drawing Package (TDP), along with
specifications, parts lists, and other instructions. These documents must be used by the
installation and commissioning crew, equipment operators, and maintenance personnel. Make
sure an equipment User Manual is available in the location where the equipment is being installed,
commissioned, operated, and maintained.
Equipment Disposal
The equipment owner is responsible for removing and dismantling the equipment at the end of the
equipment’s useful operating life. It is also the equipment owner’s responsibility to conform to all
applicable regulatory policies, standards, and recycling guidelines when removing the equipment,
dismantling equipment components, disposing of fluids, and disposing of consumable spare parts
after scheduled and unscheduled equipment maintenance.
Service Centers
For a directory of NOV Service Centers, see NOV document number D811001337-DAS-001, titled
“Service Center Directory.” This document is located in the User Manual.
The link below provides after-hours contact information for emergencies or other equipment issues
requiring an immediate response by NOV service personnel.
www.nov.com/ContactUs/24HrEmergencyContacts.aspx
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Description 2
Introduction to the TDS-11SA

Overview
The TDS-11SA Top Drive is an AC-motor top drive developed for use as a portable or permanent
unit on a wide variety of land and offshore applications. Its compact size also allows for installation
on small workover and portable rigs. The top drive is driven by a Variable Frequency Drive (VFD)
control system.
The TDS-11SA generates 800 HP with a hoisting capacity of 500 tons and a continuous drilling
torque rating of 37,500 foot-pounds (ft-lb) (50,843 [N-m]). The top drive has a maximum speed of
228 rpm and a make-up / break-out torque capacity of 50,000 ft-lb / 60,000 ft-lb (65,791 N-m /
81,349 N-m). Speed can be maintained from 114 rpm to 180 rpm without downgrading the 800 HP
rating of the motors.
The following are components of the TDS-11SA Top Drive:
 Integrated swivel
 Single-speed gear box
 Bi-directional link tilt system
 Remote and manual internal blowout preventers (IBOPs)
 PH-75 Pipe Handler (75,000 ft-lb backup capacity [101,686 N-m])
 A dual guide-rail assembly to react torque
Figure 2-1 shows the TDS-11SA Top Drive and the location of major components.
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Introduction to the TDS-11SA

Major Components
Counterbalance
System
Motor Cooling
System
Hydraulic Disc Gooseneck

Brakes (2) (S-Pipe)
AC Drilling
Motors (2)
Transmission/
Motor Housing
Hydraulic
System
Rotating Link
Adapter
Guide Beam
and Carriage
Rear Right Side
Pipehandler
Left Side Front
Figure 2-1. TDS-11SA Top Drive
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Description 2
Specifications
General Specifications
Component Item Description
• 35,000 lb (15,876 kg) – Top Drive/Shipping Skid

Weight
• 31,000 lb (14,061 kg) – Top Drive only
Stack-up height 19 ft (5.8 m)
Power requirements 700 KVA @ 575-600 VAC, 50/60 Hz
Horsepower 800 hp
Output torque (continuous) 37,500 ft-lb (50,843 N-m) (800 hp)

Top Drive
Tool torque (intermittent and stall) 55,000 ft-lb (74,570 N-m)
Maximum speed (at full power) 228 rpm
Hoisting capacity 500 ton (453.6 mt)
Load path Single
Gooseneck entry 3 in. 1002 female union
S-Pipe mud hose connection 4 in. API line pipe or 4 in. 1002 female union
Drill Pipe Sizes 3-1/2 in. to 5 in. (4 in. to 6-5/8 in. OD tool joint)
Pipe Handler Type PH-75 (75,000 ft-lb [101,686 N-m] backup torque)
Drilling Motor Type Reliance AC-575 VAC (2 x 400 hp)
Variable
Type ABB ASC800 2 (800 hp, 600/690 VAC input)
Frequency Drive
Motor Braking Type Hydraulic caliper disc brakes
Type Local intake pressure blower

Motor Cooling
Power (2) 5 hp AC motors
System
Speed 3,600 rpm
Type Single speed, double reduction helical gear system

Gearcase
Gear ratio 10.5:1 (4.38:1 optional)
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Specifications
General Specifications
Component Item Description
Type Pressure feed
Reservoir capacity 15 gallons (56.8 liters)
Full internal flow 10 gpm (37.9 lpm)

Gearcase
Lubrication EP grade
Oil type (see Recommended Lubricants and Hydraulic Fluids,
D81100719-PRO-001)
Oil pressure 10 psi (minimum), 30 psi (maximum)
Power 10 hp, AC motor
Flow 8.0 gpm/3.5 gpm (30.3 lpm/13.2 lpm) (high/low)
Hydraulic System Reservoir capacity 25 gallons (95 liters)
Mineral-based hydraulic oil

Oil type (see Recommended Lubricants and Hydraulic Fluids,
D81100719-PRO-001)
Size 14’6" L x 7’0" W x 7’8" H

Electrical and
Control House Weight 8,000 lb (3630 kg) (with single A/C unit)
(Drive House)
Input requirement 600 VAC (50/60 Hz), or 750 VDC, or 690 VAC (50 Hz)
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Description 2
Specifications
Performance Curve
55,000
50,000
45,000
800 HP
40,000
Drill Pipe Torque (ft-lbs)
35,000
Dual AC Motor Top Drive TDS-11SA
2 x 400 = 800 HP, 500 Ton System
30,000 10.5:1 Transmission
25,000
20,000
15,000
10,000
5,000
0
0 25 50 75 100 125 150 175 200 225 250
Drill Pipe RPM
Figure 2-2. Performance Curve
Noise Data
The following data was taken one meter (39.4 in) radially outward from the outer diameter of the
gearbox and at a height of 1.6 meters (63 in) above the drill floor, with the top drive in its lowest
position. Noise data was recorded at eight equal angles around the top drive.
The highest noise level is at the rear (91.3 dB(A)).
Front 86.2 dB(A)
Front+45° 86.6 dB(A)
Right 90.4 dB(A)
Right+45° 87.7 dB(A)
Rear 91.3 dB(A)
Rear+45° 88.3 dB(A)
Left 89.0 dB(A)
Left+45° 89.9 dB(A)
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Specifications
Top Drive Height
Bail
120 in
31.0 in (78.7 cm) (304.8 cm)
Bail
88 in
(223.5 cm)
260.0 in
(660.4 cm)
230.0 in (584.2 cm)
To Center
of Gravity
160.0 in
(406.4 cm)
To Center
of Gravity To Center
25.0 in (63.5 cm) 50.0 in of Gravity
(127 cm) = 35,000 lb 41.5 in
(15876 kg) (105.4 cm)
67.0 in 65.0 in
(170.2 cm) (165.1 cm)
Figure 2-3. Top Drive Height
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Description 2
Specifications
Top Drive Plan View
30.0" Setback Top View Dimensions (Standard)
Rear
2.5 in (Shipping Skid Only) 35.9 in

(6.35 cm) (91.2 cm)
C Guide
L Beam
30.0 in
Setback
(76.2 cm)
56.1 in O.A. 34 in
(142.5 cm) (86.4 cm)
C Well
L
15.8 in
(40.1 cm) 22.1 in
(56.1 cm)
21 in
(53.3 cm)
26.0 in 31.0 in
(66.0 cm) (78.7 cm)
32.6 in
(82.8 cm)
Service Loop Bracket
C
L (Left-Hand Option)
Well
65.2 in
(165.6 cm)
Front S-Pipe (Outside Guard)

(Left-Hand Option)
Figure 2-4. Top Drive Plan View (30.0" Setback)
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Specifications
Top Drive Plan View
39.5" Setback Top View Dimensions (Optional)
Rear
2.5 in (Shipping Skid Only) 35.9 in
(6.35 cm) (91.2 cm)
C Guide
L Beam
39.5 in
Setback
(76.2 cm)
65.6 in O.A.
(166.6 cm)
43.5 in
(110.5 cm)
C Well
L
15.8 in
(40.1 cm) 22.0 in
(55.8 cm)
21 in
(53.3 cm)
26.0 in 31.0 in
(66.0 cm) (78.7 cm)
32.6 in
(82.8 cm)
Service Loop Bracket
C
L (Left-Hand Option)
Well
65.2 in
(165.6 cm)
S-Pipe (Outside Guard)
Front (Left-Hand Option)
Figure 2-5. Top Drive Plan View (39.5" Setback)
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Description 2
Identification Labels and Numbers
Trace code identifies the

configuration of your equipment.
Encoder TOP DRIVE DRILLING SYSTEM

Instruction Label MODEL: TDS-11SA
Located on the righthand SERIAL NO: GROSS WT (LBS):
PART No & REV: (KG):
brake cover SALES ORDER: MFG DATE:
SAFE WORKING LOAD: 500 TONS MAX RPM: 228
RATED VOLTAGE: 550V/3 PHASE FULL LOAD CURRENT: 732A
MAX MUD PRESSURE (PSI):
AC Motor
Identification Label
Located on the side
of each AC motor Top Drive
Identification Plate
Located on the front
of the motor housing
Warning Labels
Located on the side
of each AC motor
Warning Label
Located on the
side of the bonnet
If an equipment label is worn, dirty,

or otherwise illegible, clean it or
order a new label. Failure to adhere
to this warning could result in
severe injury to rig personnel.
Figure 2-6. Identification Labels and Numbers
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Lifting Points
Lifting Point
For lowering/hoisting the
Top Drive and
Guide Beam/Skid
Tag Line
Attachment Points
For the Guide
Beam/Skid with
Top Drive attached
Optional
Lifting Point
For the Guide
Beam/Skid with
Top Drive attached
Crane
Lifting Points
For the Guide Crane
Beam/Skid with Lifting Points
Top Drive attached For the Guide
Beam/Skid with
Top Drive attached
(1 each side)
Figure 2-7. Lifting Points
2-10
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SM00856
Revision D
Page 2-11 of 12
Description 2
Typical Equipment Arrangement

Existing Crown
Traveling Equipment
500-ton Hook/Block Combo-Typ.
Clearance
12.5 ft. (3.8 m)**
* Dimensions are subject Block Top
to verification.
TDS-11SA Top Drive Stroked-Typ.
** Standard configuration 13.5 ft. (4.1 m)*
with two IBOPs and
120 in. elevator links. Bail Rest
Sectional Guide Beam TDS Work Height

19.0 ft. (5.8 m)**
Tool Joint
Derrick Termination
at ~73 ft. (24.4 m) Level*
Mud Hose
75 ft. (22.9 m)* Drill Stand
Connected to Standpipe Made-up at
at 73 ft. (22.3 m) Level 4 ft. (1.2 m)
Level
93 ft. (28.3 m)
Service Loop
Portable Torque Reaction Beam

“U”- Bolted to Spanners - (by Customer) Clear
Working
Height
10.0 ft. (3 m)-Minimum*

142 ft.
7.0 ft. (2.1 m)-Minimum

Two (2) Custom Spanners
(43.3 m)
On A-Frames or Mast Side Panels (by Customer)
Driller’s Control Console
Control Cable with Connectors

150 ft. (45.7 m)
C
L
Beam
Service Loop
NOV Drive House Tool Joint
4.0 ft. (1.2 m)
Local Power Supply Drill Floor
Diesel/Alternator Set/AC Buss
AC Power and
AC Cables Control Cables
Figure 2-8. Typical Installed Equipment Arrangement
2-11
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SM00856
Page 2-12 of 12
2-12
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SM00856
Revision D
Installation 3
!
The User Manual provided with the equipment order
contains this service manual, the engineering installation
and commissioning procedures, the Technical Drawing
Package (TDP), along with specifications, parts lists, and
other instructions. These documents must be used by the
installation and commissioning crew. Make sure an
equipment User Manual is available in the location where
the equipment is being installed and commissioned.
Preparation
The top drive interfaces with the rig’s hoisting system and electrical power system. Derrick and
electrical system modifications are required when installing the top drive on existing rigs.
For derricks that handle triples, the required top drive travel is about 100 ft. (30.5 m) compared to
about 75 ft. (23 m) when using a Kelly. It is generally necessary to replace the regular rotary hose
(which is normally 60 ft. [18 m] long) with a 75 ft. (23 m) hose, and extend the standpipe height to
approximately 73 ft. (22 m).
Although many rig floor layouts are possible, installing the guide beam on the drawworks side of
the derrick, or mast, and opposite the V-door is an ideal arrangement for handling tubulars from the
V-door. The location of the electrical loop and mud hose is an important installation consideration
for pipe setback purposes, to ensure proper clearance and to help prevent wear to the service loop
and mud hose. Other important installation considerations include the location of the following:
 The casing stabbing board
 Floor and derrick accessories
 Drawworks fastline
 Guide beam hang-off bracket and torque reaction beam
 Mud stand pipe extension
 Driller’s control console location
 Variable frequency drive/electrical house location
To successfully install the TDS-11SA, it is critical to know

the precise height and length of the travelling equipment,
as well as the location of the tie backs. Refer to the rig GA
drawing for these critical dimensions. The GA drawing is
located in the Technical Drawing Package (TDP).
3-1
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Form D811001123-GEN-001/06
SM00856
3 Installation Revision D
Page 3-2 of 48
Illustrated Index
Crown Padeye and
Hang-off Link
Page 3-3
Counterbalance
Page 3-34
Rotary Hose
Guide Beam Derrick

Page 3-9 Termination
Page 3-27
Service Loops
Page 3-28
Intermediate
Tieback
Page 3-4
Driller’s Control
Console
Page 3-30
Control Cable
with Connectors
Page 3-31 Main Tieback
Page 3-5
Variable Frequency Drive (VFD)

Electrical House (Drive House)
Page 3-6
Local Power Supply

Diesel/Alternator Set/AC Bus
Power Cables
Page 3-7
AC Power and
Control Cables
Figure 3-1. Illustrated Installation Index
3-2
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SM00856
Revision D
Page 3-3 of 48
Installation 3
Pre-Installation
Installing the Crown Padeye and Hang-Off Link
Crown Padeye
Weld at 30 inches
from well center
Padeye to be suitable
for 25 ton load
Crown
30 inches
25 Ton
Shackle
For land rig applications,

when possible, install crown
padeye, hang-off link and
tieback with mast layed down.
Hang-off Link
Adjust length per
General Arrangement
Drawing
Hang-off
Tieback
Drill Typical
Floor Cross Girt
Below Crown
C
L
Well
Figure 3-2. Installing the Crown Padeye and Hang-Off Link
3-3
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SM00856
Page 3-4 of 48
Pre-Installation
Installing the Intermediate Tieback
To rotate intermediate tieback

loosen locking bolt and rotate
out of the way. To secure after Intermediate
rotating tighten locking bolt. Tieback
(Shown in Locked
Position)
Rotate
Locking
Bolt
Pivot
Point
Drill
Floor
Refer to General Arrangement
30.0 inches Drawing for installation height.
C
L
Well
Figure 3-3. Installing the Intermediate Tieback
3-4
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SM00856
Revision D
Page 3-5 of 48
Installation 3
Pre-Installation
Installing the Main Tieback
Procedure
Install the main spreader beam at the
appropriate distance from well center
Install the tieback plate and tieback link
Torque and lock wire all bolts
Typical (depending Tieback Link

on block and hook
configuration.
Tieback
Plate
Main
Spreader
Beam
Apply Anti-seize
Compound
Typical
Auxiliary
Spreader Beam
Optional
Main Tieback and
Spreader Beam
Adjust after
installation
of TDS and
guide beams
Mast Leg
Drill
Floor
30.0 inches
C
L
Well
Figure 3-4. Installing the Main Tieback
3-5
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SM00856
Page 3-6 of 48
Pre-Installation
Locating the Control House
Recommended Area for

VFD House Location
Drawworks
V-Door
Ramp
C
L
Well
TDS
Driller’s
Control
Console
8,000 lb
(3630 kg)
VFD House w/
single AC unit C
L
Well
Typical installation
VFD
House Recommendations
Position the VFD house off-driller’s side or
behind the drawworks
Position as close to derrick plate as possible
to minimize cable lengths
92 in. Ensure a safe distance from direct sources of
(2337 mm) heat (i.e. diesel engines, general exhausts)
174 in.
(4420 mm) Location of the VFD house must ensure
84 in. accessibility from all sides
(2134 mm)
Do not expose the control house to H2S
Figure 3-5. Locating the Control House
3-6
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SM00856
Revision D
Page 3-7 of 48
Installation 3
Pre-Installation
Installing Power Cables
Plug Panel
C1
COM
P
P
AUX 5
PW P6
R VDC
P7
HM
I
C2
VDC Typical installation
C3
HM
I
P10
-A
Blanking Plates
Spare incoming power connections
(3 Places)
P11
-B
VFD
Grounding Incoming Power Cables
Lug P12
-C
600/690VAC to main circuit breaker
P10 (3 Places)
BLK
P11 Outgoing Power Cables

WH
T to Top Drive
(3 Places)
P10 P12
BLK RED
P11
WH
T
P12
RED
Procedure
Clean all connector contacts Plug Panel
Connect the power cables with the isolation circuit
breaker turned OFF VFD House
Rain Cover Typical
Connect cables in accordance with the electrical
schematic provided in the Technical Drawing
Package (TDP)
Lockwire all connector nuts
Earth the control house with the Ground Rod Kit
Figure 3-6. Installing Power Cables
3-7
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SM00856
Page 3-8 of 48
Pre-Installation
Grounding the Control House (Land Rigs)
Copper Plated
Steel Rod
Cable Clamp
Cable Lug
Copper Wire
10 ft
The control house must

be properly grounded to
prevent injury to personnel
Procedure
Insert the grounding rod into the soil (the rod
must be in contact with ground water) Ground Rod Kit
Grounding Points
Connect the rod to the control house Located at opposite
(connection must be clean) corners of the house floor
For offshore installations the control house

must be grounded to the ground point on the
rig structure
Figure 3-7. Grounding the Control House (Land Rigs)
3-8
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SM00856
Revision D
Page 3-9 of 48
Installation 3
Installation
Checklist
The following assumes that all pre-installation planning and rig-up is complete prior to installation
of the guide beam assembly and top drive. This includes:
 Make sure the derrick/mast is vertical, with the block over the center of the rotary
table.
 Derrick/mast modifications are completed (if required) and the guide bean support
bracket and torque reaction beam are installed per recommendations on the general
arrangement drawing.
 The service loop bracket is installed in the derrick/mast.
 The control panel and the variable frequency drive (VFD) are installed.
 All rigging is inspected to ensure there is no interference with the top drive.
 The hook or adaptor becket is installed. The hook should open toward the
drawworks when possible.
Identifying Guide Beam Sections

Thoroughly review the Guide Beam Kit engineering drawing in the TDP prior to beginning the
guide beam installation procedure. The guide beam sections must be installed in the correct order.
Failure to install them in the correct order may result in a guide beam section falling to the rig floor.
The bottom hinge joint on the bottom intermediate guide beam section is specifically designed
to be connected to the upper hinge joint on the top drive shipping skid/guide beam section.The
bottom intermediate guide beam section has a warning label identifying where it connects to the
top drive shipping skid/guide beam section (see the section titled "Bottom Intermediate Section
Warning Label" on page 3-23).
Always make sure to identify the bottom intermediate

guide beam section and the location where the top
drive skid/guide beam section connects to it. If these
are installed improperly, a guide beam section could
fall to the rig floor. A falling guide beam section will
damage equipment and could result in severe injury or
death.
If the warning label on the bottom intermediate guide

beam section is worn, dirty, or otherwise illegible,
clean it or order a new warning label to affix to the
same place on the bottom-intermediate guide beam.
Failure to adhere to this warning could result in severe
injury or death.
3-9
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SM00856
Page 3-10 of 48
Installation
Raising the Top Guide Beam Section to the Drill Floor
Procedure
Locate the top guide beam section near the
V-Door
Ensure the hoist carriage is free to slide the
entire length of the guide beam
Ensure the latch moves freely
Attach lifting slings to the lifting eyes of the
hoist carriage
Eusure the transport shipping pins are in
place and secure
Hoist the guide beam section to the drill floor
using a tugger line with a backup line to tail
Remove tugger line after top guide beam is in Hoist
position on drill floor Carriage
Tugger Line
Attachment
Points
(Rig UP)
RIG DOWN UP
Tugger Line
30,000 lb Attachment
Tugger Pull Points
(Rig DOWN)
Top Guide
Beam
Shipping
Latch Pins
2 places
Drill
Floor
Backup
Line
Figure 3-8. Raising the Top Guide Beam Section
3-10
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SM00856
Revision D
Page 3-11 of 48
Installation 3
Installation
Attaching the Carriage Sling to the Hook
Hoist
Carriage
Cable Sling
Attachment
Points
(RIG UP)
RIG DOWN UP
Cable Sling
Attachment
Points
(RIG DOWN)
Top Guide
Beam
Disengage
Shipping Pins
Hoist
Procedure
Cable Sling Attach a short cable sling from the hook/block
to the hoist carriage at the RIG UP
attachment points
Disengage the shipping pins
Hoist the top guide beam using the
drawworks
Figure 3-9. Attaching the Carriage Sling to the Hook
3-11
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SM00856
Page 3-12 of 48
Installation
Moving Guide Beam Sections
Do not move the bottom intermediate guide Procedure

beam section until all other sections are moved
Locate the remaining guide beam sections
to the rig floor. The bottom intermediate guide
near the V-Door
beam section is designed to be hooked to the
top drive shipping skid/guide beam section Attach tugger lines to the lifting eyes of the
only. Connecting the bottom intermediate first guide beam section to be hoisted
section out of order may result in a guide beam Hoist the guide beam section to the drill floor
section falling to the rig floor. using the rear tugger line or tailing line to
stabilize and balance the guide beam
Tugger
3,200 lb Line
(1450 kg)
24 ft. Guide Beam Section
Tugger
Line
3
Guide Beam Section Guide Beam
Hoist to the drill floor Section
Tugger
Line
Tugger
Line
2
Lifting Eyes
Attach tugger lines
for hoisting
Drill
Floor
1
Guide Beam Sections
Prior to Installation
Figure 3-10. Moving Guide Beam Sections
3-12
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SM00856
Revision D
Page 3-13 of 48
Installation 3
Installation
Hooking the First Guide Beam Section
Guide Beam
Top Section
1 2
Present Match
Grease
the bores on
both joint halves
Guide
Surface
Radius locks joint

from unhooking
at 8° rotation
Hook Pin Grease

the bores on
both joint halves
3 4
Engage Hook
Hook Pin
In fully engaged
position
Present
and Hook
the first guide
beam section Hook Pin
Saddle
Procedure
Tugger Line
Guide Beam Leave attached Locate the guide beam to be hooked
Section to stabilize the under the top guide beam section
Hooked back end of
Grease the bores on both joint halves
the guide beam
Align the guide surface with the hook pin as
shown
Lower the top guide beam to match and
engage the hook pin to the hook pin saddle
Hoist the top guide beam to fully engage the
hook pin
Manually stabilize the back end of
the guide beam
Figure 3-11. Hooking the First Guide Beam Section
3-13
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SM00856
Page 3-14 of 48
Installation
Hoisting the First Guide Beam Section
Guide Beam
Top Section
Hoist
Hook Pin
First Guide
Beam Section
Initially hoisted
by the hook pin
Bar and Radius

Locates pin bores for
easy insertion of pins
Hoist
Using the
drawworks
Figure 3-12. Hoisting the First Guide Beam Section
3-14
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SM00856
Revision D
Page 3-15 of 48
Installation 3
Installation
Stabbing and Pinning the First Guide Beam Section
Guide Beam 1
Top Section Stab
the guide beam
joints together
Lynch Pin
2
Joint Pin
Install after stabbing
4 3
Secure Retainer Pin
with the Apply grease
lynch pin and insert
Stab
and Pin
the guide
beam joint
Block as Procedure
Required Lower the guide beam to drill floor and stab
the guide beam joints together
Block the guide beam in a vertical position if
required
Install the cleaned and greased joint pin
Grease and install the retainer pin
Secure the retainer pin with the lynch pin as
shown
Figure 3-13. Stabbing and Pinning the First Guide Beam Section
3-15
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SM00856
Page 3-16 of 48
Installation
Completing Guide Beam Section Installation
Do not move the bottom intermediate guide

beam section until all other sections are moved
to the rig floor. The bottom intermediate guide
beam section is designed to be hooked to the
top drive shipping skid/guide beam section
only. Connecting the bottom intermediate
section out of order may result in a guide beam
section falling to the rig floor.
Repeat the previous steps until

guide beam sections are installed
Tugger
Line Tugger
Line
Procedure
Move the next guide beam section to the drill floor
Present the end of the guide beam to be hooked
Ensure that the bores on both joint halves have
been greased
Drill
Floor Engage the hook pin saddle around the hook pin
Hoist the guide beam with the drawworks
Lower the guide beam to the drill floor and stab
the guide beam joints together
Install the joint pin
Install the retainer pin
Secure the pins with the lynch pin
Figure 3-14. Completing Guide Beam Section Installation
3-16
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SM00856
Revision D
Page 3-17 of 48
Installation 3
Installation
Hoisting and Attaching the Guide Beam
Latch is held in Latch locks beam

unlock position to hang-off link when
when carriage is carriage is lowered
at top position
Diverter To Protect
Against Accidental
Unlatching
Procedure
Hoist Carriage
Attach guide beam Extension
assembly to hangoff link
Procedure Tieback
Handle
Rotate intermediate
tieback handle UP 90
degrees
Insert the intermediate
tieback into the slot
located on the lower
guide beam
Rotate intermediate
tieback handle DOWN 90
degrees to lock the guide
beam in place
Adjust the tieback bracket
so the center of the guide Guide
beam is 30 inches from Beam
well center Slot
Intermediate
Tieback
Attach Intermediate
Tieback into Lower
Guide Beam Slot
Figure 3-15. Hoisting and Attaching the Guide Beam
3-17
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SM00856
Page 3-18 of 48
Installation
Removing the Hoist Carriage
Hoist
Carriage
Drill
Floor Procedure
Lower hoist carriage to drill floor
Remove hoist carriage from drill floor and
store (to be used again for rig down and
transport)
Figure 3-16. Removing the Hoist Carriage
3-18
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SM00856
Revision D
Page 3-19 of 48
Installation 3
Installation
Moving the Top Drive to the Rig Floor
Procedure
Ensure the safety of all personnel
Locate the Top Drive at the bottom of the
V-Door ramp
Attach a lifting sling to the bail
Attach backup lines to the skid
Hoist the Top Drive and skid to the drill floor
35,000 lb Crane Lift
35,000 lb
(15,876 kg)
TDS-11SA
on the skid
Lifting
Block
Hoist using
the drawwork
Optional Crane Placement
Side Bracket
TDS
2 hoisted up
V-Door Ramp
Drill Bail
Floor Lifting Detail
60 ft Slings
1 TDS Backup
on skid Line
Figure 3-17. Moving the Top Drive to the Rig Floor
3-19
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SM00856
Page 3-20 of 48
Installation
Attaching the Top Drive to the Hook
There are two basic methods for installing the TDS-11SA top drive, depending on
the travelling equipment configuration. Follow the installation procedures for option 1
or option 2 as appropriate for the rig.
Bail Bail Lock TDS-11SA V-Door

Post
Attach Sling
or Tugger Lines
to Secure Skid
V-Door
Ramp
Procedure
Remove hoist cable slings
Attach bail to block or hook
Secure lower end of skid to prevent
movement toward or down V-door
ramp
Hoist using drawworks
Figure 3-18. Attaching the Top Drive to the Hook
3-20
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SM00856
Revision D
Page 3-21 of 48
Installation 3
Installation
Lifting the Top Drive into the Rig
Option 1 Procedure Option 2 Procedure

Set TDS on the rig floor Hoist the TDS from the v-door
Secure the bottom end of the to a vertical position using
skid to the floor or the v-door slings
posts to prevent the TDS Connect the TDS skid to the
from moving back down the guide beam
v-dor ramp
If the traveling equipment
and the TDS bail length
allows, the bail can be
connected directly to the
hook/block (refer to the
general arrangement
drawing)
Hook open
towards
drawworks
Hook open
towards Depending on the
v-door traveling equipment and
bail length, variations of
this procedure may be
required
Figure 3-19. Lifting the Top Drive into the Rig
3-21
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SM00856
Page 3-22 of 48
Installation
Connecting the Top Drive to the Guide Beam
Bottom 1 2
Intermediate
Section Present Hook
Insert hook pin Lower TDS/Skid
into hook pin saddle until it makes
contact with Lower
Tieback
Hook Pin
Grease
the bores on Hook Pin
both joint In fully engaged
halves position
Grease
the bores on Hook Pin
both joint Saddle
halves
Guide Beam
/Skid Section
Skid not shown
3
Attach
Lower
Tieback
OPTION
2
Lower
Tieback
Present
and Hook
TDS to the guide
beam section Guide Beam
Hook /Skid Section
Joint Skid not shown
OPTION
1
Procedure
Lower
Tieback Backup Locate the TDS skid to be hooked under the
Line bottom intermediate guide beam section
Grease the bores on both joint halves
Align the guide surface with the hook pin as shown
Lower the TDS skid to match and engage the hook
pin to the hook pin saddle
The bottom intermediate guide beam section and
skid will contact the lower tieback
Figure 3-20. Connecting the Top Drive to the Guide Beam
3-22
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SM00856
Revision D
Page 3-23 of 48
Installation 3
Installation
Bottom Intermediate Section Warning Label
Bottom Intermediate
Guide Beam Section
Warning Plaque
(P/N P614000138)
If an equipment warning plaque

is worn, dirty, or otherwise
illegible, clean it or order a new
warning label. Failure to adhere
to this warning could result in
severe injury or death.
Top Drive
Shipping Skid/
Guide Beam
Section
Figure 3-21. Bottom Intermediate Guide Beam Section Warning Label
3-23
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SM00856
Page 3-24 of 48
Installation
Attaching the Torque Tieback
Tieback
Retainer
Pins
Tieback
Tieback Hook
Pivot Pin
OPTION
2
Tieback
Pivot Pin
OPTION Tieback
1 Hook
Procedure
Engage tieback hooks to secure the
lower guide beam/skid
Insert retainer pins
Figure 3-22. Attaching the Torque Tieback
3-24
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SM00856
Revision D
Page 3-25 of 48
Installation 3
Installation
Pinning the Top Drive to the Guide Beam
Guide Beam
Bottom Section
4
Secure
with the Lynch
Pin Seating
lynch pin Surfaces
2 3
Lower
Joint Pin Retainer Pin
Tieback
Install Apply grease
and insert
OPTION
2
1
Guide Beam
/Skid Section
Hoist until it seats
Hoist Skid not shown
Using the
drawworks
OPTION
1 The bottom end of guide
beam/skid should be
approximately 7 ft plus
or minus 6 inches above
Drill the drill floor
Floor Procedure
Hoist guide beam/skid section until it seats
Install the joint pin
Grease and install the retainer pin
Secure the retainer pin with the lynch pin as
shown
Figure 3-23. Pinning the Top Drive to the Guide Beam
3-25
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SM00856
Page 3-26 of 48
Installation
Releasing the Top Drive from the Skid
After hoisting the TDS

disengage the Lower
Carriage Latch and pin it
as shown.
Pin
View of 1
Carriage Upper
from Rear Latch
Engaged
Lower
Latch
Pin Disengaged
Pin
OPTION
Latches
2
Both sides
engaged
Pin
Pin 2
Upper
Latch
Disengaged
Lower
OPTION Latch
1 Lower the TDS, disengage the Disengaged
Upper Carriage Latch
and pin it as shown.
Pin
Procedure
Lower the blocks (option 2 only)
Remove the slings (option 2 only)
Connect the hook/block to the bail (option 2 only)
Disengage the carriage latches
Remove the Bail Lock and store it for future use
Figure 3-24. Releasing the Top Drive from the Skid
3-26
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SM00856
Revision D
Page 3-27 of 48
Installation 3
Installation
Installing Derrick Termination
Hoist Line Derrick/

Attachment Point Mast Leg
Derrick
Leg Plate
Hoist Line Service Loop
Attachment Brackets
Points
Mount
Derrick
Termination
Plate
as recommended
83 ft
from drill floor
Recommendations
Mount on the side of the derrick adjacent to the
service loop brackets on the Top Drive
Drill Mount as far as practical from well center, to
Floor maintain a 36 inch minimum bend radius
Maintaining a larger radius increases loop life and
! reduces damage due to “pinching”
Location must ensure that the loops do not
catch under the guide beam during operations
and provide clearance for tong lines, the
stabbing board, tugger lines, etc
Figure 3-25. Installing Derrick Termination
3-27
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SM00856
Page 3-28 of 48
Installation
Installing Service Loops at the Derrick
Hoist
Derrick
Termination Plate
1,000 lb
(450 kg)
Each
Service Loop
Sling
!
Avoid damage to
the service loops
by using care when
dragging it near TDS
sharp edges and Service Loop
allow room for
passing under the
V-door
Lifting Eyes
Do not remove
Derrick
Service Loop
Recommendations
!! Do not unpack the service loops until they are
Avoid damage to the ready to hang
service loops by maintaining a
Use a sling attached to the lifting eyes to hoist
40 inch minimum
each service loop
bend radius
Use the swivel at the tugger line attachment to
Service Loop allow each service loop to uncoil without
and Storage Tub twisting
3,600 lb Take care so the service loop pigtails are not
(1600 kg) ! damaged during installation.
Figure 3-26. Installing Derrick Service Loops at the Derrick
3-28
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SM00856
Revision D
Page 3-29 of 48
Installation 3
Installation
Installing Service Loop Jackets
There are service loop jackets that are assembled around the service loops. Install the jackets
after the service loops have been attached at the derrick termination plate.
!
The double Velcro construction is hard to disassemble.
Make sure the orientation of the jacket is correct before
you close the strap.
Refer to Installation Instructions, Service Loop Jackets (D614000166-PRO-001) for annotated

photographs showing how to install a service loop jacket. This engineering procedure is located in
the equipment user manual.
To install each jacket:
1. Velcro the inner straps around the biggest cable/hose.
2. Close the flaps around the whole bundle and close the double Velcro edge. Leave a
little room so the cables/hoses can move up and down the jacket.
3. Secure the double Velcro edge with the two lock straps.
3-29
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SM00856
Page 3-30 of 48
Installation
Installing the Driller’s Control Console
Drawworks
V-Door
TDS Ramp
Recommended Area
for Driller’s Control
Console Location
Y
NC
GE
ER OP
EM ST
AS E
RE
INC
UP E
T KE DECREAS
SE MA
PM
UE
RQ
S TO
TD ILL RE
AS E
SR
TD
INC
DR
BX
LE DECREAS
AB
UP
EN
OR EN
KE
AT OP
EV AS E
EL RE
24 VDC Power MA
BX
INC
D
ME
AR
CE E
AN P DECREAS
AL UM
RB DJ
TE AN
ILL
L UN ST
RA CO /
ILL
DR
NE DR
GE
hard-wired E-Stop
ER
D DL P
AN
VF T AM LD OR
UL CL HO AT
EH
FA TWAND EV
MS
EL ED
BX CLOS
PIP
SH
AR TOR
PU
AL ILL MOMP TIL

T
TE K T
DR ER LIN OA
OV FL U
HP / ON
TO
S AU
ES
PR
OIL SS
LO UE
RQ TE CW
TA
DE
TO RO
PH
OW
ER
BL SS S MO CC
W
LO
TD SP
IN
T TILT
K TIL
/ LIN
CE
EN
SILECK ILL
M DR
AR CH ILL
AL MP DR
LA
E E
AK
RS
N VE
BR
RE
IO
CT
AU
TO
IREF
SD
Profibus Cable
OF
P TD
IBO
ED D
OS AR
CL
RW
FO
E
AK
BR OFF
/
ON
E
OS
P CL
IBO
EN
OP
!
Customers who choose to use
control systems not manufactured
by NOV should be aware that NOV
systems are specifically designed
with operational interlocks and Recommendations
safety devices to prevent possible
injury to personnel and damage to Mount within easy reach and in plain view of the
the system. Other control systems driller while the drawworks brake and clutches
must meet NOV requirements. are being operated
NOV highly recommends the use Location must ensure that the gauges are easily
of its system, as it is specifically seen by the driller during drilling operations
made for use with the Top Drive. Location must be visible and readable at night
Figure 3-27. Installing the Driller’s Control Console
3-30
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SM00856
Revision D
Page 3-31 of 48
Installation 3
Installation
Installing the Console Cabling
24VDC Power /
Hard-Wired E-Stop
to Driller’s Console
Profibus Serial Link

to Driller’s Console
C1
COM
P
P
AUX 5
PW P6
R VDC
P7
HM
I
C2
VDC Typical installation
C3
HM
I
P10
-A
P11
-B
P12
-C
P10 Plug Panel
BLK
P11
WH
T
P10 P12
BLK RED
P11
WH
T
P12
RED
Recommendations
Ensure that the Driller’s Control Console is Plug Panel
properly located
Connect the power cables with the isolation VFD House
circuit breaker turned OFF Rain Cover Typical
Connect cables in accordance with the
electrical schematic provided in the Technical
Drawing Package
Tighten connector nuts
Lockwire connector nuts to prevent loosening
Figure 3-28. Installing the Console Cabling
3-31
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SM00856
Page 3-32 of 48
Installation
Motor Rotation Checkout Procedure
Procedure Direction
of Rotation
Assign the Top Drive and inverter by selecting Counterclockwise
FORWARD or REVERSE TDS DIRECTION on the
driller’s console
Direction
Check the rotation direction of the cooling and oil of Rotation
pump motors Clockwise
Rotate the drill stem using the TDS RPM knob on the
driller’s console and observe proper operation
S
ES
PR
OIL OSS
L UE
RQ
TO
D E
MO Cooling Motors
S
TD SP
IN
2 Places
LI
ILL
DR
ILL
DR
E E
AK
RS
VE
N RE
BR T IO
AU
TO
IR EC
SD OF
F
TD
D
AR
RW
FO
Driller’s
Control
GEN
ER OP
EM ST
CY
Console
A SE
RE
I NC
EUP DE CR EAS
E
SET MAK
QUE
S TOR PM
TD L RE
A SE
SR
I NC
DRIL
TD
E
DE CR EAS
BLE
ENA BX OR N P
KEU
VAT OPE
ELE A SE
RE
MA
BX
I NC
ED
ARM
CE DECR EAS
E
LAN
UMP
RBANDJ
ILL
NTESTA
L COUL /
ERA
DR
GEN DRIL
R
LE
VFD
LT ND MP D
CLA HOL VAT
OR
FAU
HA TWAND ELESED
MS H
PIPE
BX CLO
PUS
AR
AL L MOTMPOR TILT
DRIL RTE LINK AT
OVE FLO HPU/ ON
O
AUT
SS
PRE
OIL S
LOS
QUE ATE CW
TOR ROT
DE PH
S MO
WER
BLO S CCW
LOS
TD SPIN
TILT TILT
/ LINK
NCE
SILECK L
RM CHE L DRIL
ALA P DRIL
LAM
E E
AK N REV
ERS
BR IO
O
CT
AUT RE
S DI OFF
TD
IBOP
SED D
CLO WAR
FOR
KE
BRAOFF
/
ON
SE
CLO
IBOP
N
OPE
ASE
RE
INC
E
DECREAS
PM
RE
ASE
SR
TD
INC
E
DECREAS
P
R EAS
E
K EU
MA
INC
E
DECREAS
ILL Direction
DR of Rotation
Counterclockwise
Oil Pump
Motor
Drill Stem
Direction
of Rotation
Reverse
Forward
Figure 3-29. Motor Rotation Checkout Procedure
3-32
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SM00856
Revision D
Page 3-33 of 48
Installation 3
Installation
Installing the Elevator Links
Procedure
Rotate the pipehandler 90˚
(positioning the link catch under
the front of the motor guard)
Lubricate the elevator link eyes Link Catch Pin
with pipe dope
Hoist the elevator link onto the
rotating link adapter (small eye
at bottom)
Secure the link catch with the pin
and fasteners
Link Tilt
Secure the elevator link to the
link tilt
Rotate the pipehandler 180˚ and Link
install the other elevator link Catch
Install the elevator (refer to the
elevator manual)
Clevis Pin
Rear
Pipehandler
Rotate Switch RA
L UN ST
CO L /
NE IL
GE DR
ER
N DL P
AM LD
CL HO
E HA TWAND
SH
PIP PU
ILT
K TT
LIN OA
FL U
HP / ON
TO
AU Link
UE E
RQ TAT CW
TO RO
PH
W
CC
T
ILT TIL
LIN
KT Front
ILL
DR
E
Driller’s
RE
VE
RS
Control
Console 600-2,400 lb
GEN
ER OP
EM ST
CY (270-1100 kg)
RE
A SE
Elevator Link
I NC
EUP E
DE CR EAS
SET MAK
QUE
S TOR PM
TD L RE
A SE
SR
I NC
DRIL
TD
E
DE CR EAS
BLE
ENA BX OR N P
KEU
VAT OPE
ELE A SE
RE
MA
BX
I NC
ED
ARM
CE DECR EAS
E
LAN
UMP
RBANDJ
ILL
NTESTA
L COUL /
ERA
DR
GEN DRIL
R
LE
VFD
LT ND CLAMP HOL
D
VAT
OR
FAU
HA TWH AND ELESED
MS
PIPE
BX CLO
PUS
AR OR
AL L MOTMP TILT
DRIL RTE LINK AT
OVE FLO HPU/ ON
O
AUT
SS
PRE
OIL S
LOS
QUE ATE CW
TOR ROT
DE PH
S MO
WER
BLO S CCW
LOS
TD SPIN
TILT TILT
/ LINK
NCE
SILECK L
RM CHE L DRIL
ALA P DRIL
LAM
E E
AK N REV
ERS
BR IO
O
CT
AUT RE
S DI OFF
OP TD
IB
SED D
CLO WAR
FOR
KE
BRAOFF
/
ON
SE
CLO
IBOP
N
OPE
Take care when installing

elevator links. Links weigh
up to 2,400 lb (11,00 kg) and
can fall if handled improperly.
Figure 3-30. Installing the Elevator Links
3-33
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SM00856
Page 3-34 of 48
Installation
Installing the Counterbalance
Procedure
Refer to Setting up the circuits in the Hook
Hydraulic section of this manual for initial
system set up
Install the pear links to the ears on the hook
Turn on the Top Drive power Pear Link
Rotate the counterbalance mode valve from 2 Places
the RUN position to the RIG-UP position
When the cylinders reach the end of stroke,
slide the cylinder clevis over the pear link Cylinder
and install the cylinder clevis pin Clevis
After securing the counterbalance cylinder to 2 Places
the pear link, rotate the counterbalance
mode valve to the RUN position
Adjust PCC clockwise to raise the pressure
at test port CB until the bail just begins to lift
off of the block
Reduce the pressure slowly (25 psi) to allow
pressure to stabilize
Cylinder
Clevis Pin
2 Places
Counterbalance
Rig-up/Run/ Cylinder
Shutdown Valve 2 Places
Shown in RIG-UP (8.5 inch stroke)
position (switch to RUN
after the counterbalance
is installed) Bail
RUN
SHUTDOWN
RIG-UP
COUNTERBALANCE MODE
N
W
O
R
D
U
T
N
U
H
S
C
Hydraulic
O
U
N
R
TE
IG
R
BA
-U
LA
P
N
C
E
M
O
Manifold
D
E
Figure 3-31. Installing the Counterbalance
3-34
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SM00856
Revision D
Page 3-35 of 48
Installation 3
Commissioning
Initial Checkout Procedure
Initial Rig-Up
Pre-charge all accumulators (See the
Hydraulics System section of this manual)
Adjust the hydraulic system
Cork Ball
Bleed the air from the hydraulic system
(Level Indicator)
Constantly monitor the hydraulic fluid level,
and never allow the level to fall below the
middle of the sight glass (power OFF)
Checkout Procedure
Lubricate all grease points (See Lubrication)
Check for loose or missing connectors Sight
Lockwire all connector nuts Glass
Check for interference along entire mast
Remove exhaust covers from AC drilling Hydraulic
motors Oil Sight
Gauge
Check blower inlets and outlets for blockage
Set the air conditioner to 75˚F (27˚C)
Turn on the main breaker
Air Inlet
Between motor
and brake housing,
2 Places
Exhaust Cover
TOP DRIVE
4 Places INS
T
WH ALL
UN EN
ST IT IS
VARCO
OR
ED
Exhaust Outlet
Through louvers at
bottom of AC drilling motors,
6 Places
Figure 3-32. Initial Checkout
3-35
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SM00856
Page 3-36 of 48
Commissioning
Hydraulic System Checkout Procedure
Cork Ball
(Level Indicator)
Red
“Pop-up”
Dirt Alarm
Sight
Glass
Hydraulic
Oil Sight
Gauge
Hydraulic
Oil Filter
Procedure
Ensure that the pipehandler clamp cylinder is
unclamped, the counterbalance cylinders are
connected to the hook, the bail is resting in
the hook, and the system power is OFF
Check to see that the hydrulic fluid level is at
the middle of the sight glass
If the fluid is low, add hydraulic fluid (see the
Lubrication and Maintenance section of this
manual
Check the red “pop-up” alarm on the
hydraulic filter for contamination
Replace the filter if the indicator has
popped up
Use care to prevent contamination from
entering the hydraulic system during
maintenance activities
Figure 3-33. Hydraulic System Checkout
3-36
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SM00856
Revision D
Page 3-37 of 48
Installation 3
Commissioning
Electrical System Checkout Procedure
Emergency Stop
Y
NC
GE
ER OP
EM ST
ASE
RE
INC
P
T KEU DECREAS
E
SE MA
UE
TD
S TO
RQ
PM
DR
ILL RE
ASE
SR
TD
INC
E
DECREAS
BX
LE
AB
EN R N P
BX
EL
EV
ATOOPE
RE
ASE
K EU
MA
INC
MED
AR
E
NC P DECREAS
E
ALA M
RB DJU
TE AN
UN ST
L
RIL
AL CO L /
ER IL
GEN DR
D
ER
D DL MP LD R
AN
VF LT
U CLA HO ATO
EH
FA TWAND EV
24 VDC Power
D
S EL SE
BX CLO
RM R PIP
SH
PU
A
AL TO
MO P
ILL TEM
LT
K TIT
hard-wired E-Stop
DRVER LIN OA
O FL HPU/ ON
TO
AU
RPM Meter
S
ES
PR
OIL SS
LO UE
RQ TA
TE CW
DE
TO RO
PH
O
SM
WER W
BLO SS CC
LO
TD SPIN LT TILT
K TI
E/ LIN
NC
SILE
EC
K ILL
RM CH DR
ALA MP ILL
LA
AK
E
DR
N REV
ER
SE
Torque Meter
BR IO
CT
AU
TO
IRE
SD OFF
OP TD
IB
D
SE D
CLO AR
RW
FO
E
AK
BR OFF
/
ON
SE
P CLO
IBO
N
OPE
Profibus Cable
Procedure
All personnel must stand clear

All personnel operating the top drive should be
trained in rig safety and tool operation
Operate each control on the driller’s control console
(See the Operations chapter)
Check for alarm conditions and resolve any alarms
at this time (See the Operations chapter)
Check all connectors for tightness and lockwire
Check operation of meters
Check operation of emergency stop
Check the latches on the driller’s console for
tightness
Figure 3-34. Electrical System Checkout
3-37
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SM00856
Page 3-38 of 48
Commissioning
Mechanical Checkout Procedure
Procedure
With the drive motors and hydraulic
system off, check to see that the oil
level (identified by a floating cork ball)
is at the middle of the glass located
on the lube pump adapter plate
mounted on the side of the gearbox
Always check the oil level, not foam
level (oil is dark brown, foam is tan)
after the unit has been running and
the transmission oil is warm
If the oil level is low, add gear oil (see
the Lubrication and Maintenance
section of this manual
Check the red “pop-up” alarm on the
gear oil filter for contamination
Replace the filter if the indicator has
popped up
Cork Ball
(Level Sight
Indicator) Glass
i
Gear Oil Gearbox Oil Fill
Sight Gauge Clean area before removing
Check with Top Drive plug,then use a 1 3/8 inch,
“OFF” 12 point socket to remove plug
“Pop-up”
Dirt Alarm
Gear Oil Filter
Figure 3-35. Mechanical Checkout
3-38
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SM00856
Revision D
Page 3-39 of 48
Installation 3
Commissioning
Adjusting the Link Tilt
Jam Nut
Adjust the derrickman position
with the adjusting screw and
lock in position with the jam nut
Link Tilt
Crank
Assembly
Pin
26 inches
(660 mm)
Typical
Clamp
Mousehole
Position Cable 3-4 inches
Pull “up” or “down” (76-102 mm)
to set mousehole
position
Drill Down
Position
Bottom of elevator
Link should be above
the bottom of the
Mousehole stabbing guide
Position
Derrickman’s Position
Link clamps should be adjusted
so that the elevator does not Elevator
hit the diving board in this position Well Center
Float Position
Figure 3-36. Adjusting the Link Tilt
3-39
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SM00856
Page 3-40 of 48
Decommissioning
Securing the Top Drive for Rig-Down
Procedure
Lower the Top Drive to the drill floor
Remove the mud hose, drill pipe elevator
and links
Power may be needed to turn rotating head
into position for removing the links
Locate the RIG-UP/RUN/SHUTDOWN valve
on the hydraulic manifold
With the hydraulic power ON select the
“RIG-UP” position and remove the extended
counterbalance cylinders from the hook ears
Select the “SHUTDOWN” position and turn
off the Top Drive
Isolate and lock out ALL power to the Varco
control house
Hydraulic
Manifold
N
RU
W
O
N
D
T
U
H
Lower
S
CO
UN
TE
RB
R
IG
ALA
-U
NC
P
EM
TDS to OD
E
drill floor
Rig-up/Run/
Shutdown Valve
Rotate from RIG-UP to
SHUTDOWN for Top Drive rig-down
RUN
SHUTDOWN
RIG-UP
Drill
Floor
COUNTERBALANCE MODE
Figure 3-37. Securing the Top Drive for Rig-Down
3-40
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SM00856
Revision D
Page 3-41 of 48
Installation 3
Decommissioning
Removing and Storing Cables and Service Loops
Derrick
Termination Lower
Plate
1,000 lb
(450 kg)
Each
Service Loop
Sling
!
!
Avoid damage
to the service
loops. Use care
when dragging
them near
sharp edges
and allow room
for passing
under the Derrick
V-door Service
TDS Loop
Service
Loop
!! Lifting Eyes
Avoid damage to Do not remove
the service loops by
maintaining a Procedure
36 inch minimum
bend radius Position the service loop tubs for convenient
! loading of the service loops
Disconnect the derrick service loop from the
An electrical short can occur if quick derrick termination plate and the control house
connectors are not kept clean and dry. Disconnect jumper cables (if installed)
Whenever separating quick
connector(s), immediately install Cap all connectors and lower the derrick service
the weather plugs to prevent loop into a service loop tub
connectors from becoming Use a sling attached to the lifting eyes to lower
contaminated with water or debris. each service loop and a swivel at the tugger line
When the connector is not in use attachment to allow each service loop to coil
secure/locate the connector so that is Service without twisting
does not lie on the ground and make Loop and Disconnect the top drive service loop and repeat
sure to minimize any exposure to water, Storage Tub the above procedure
mud, etc. Prior to re-connecting, inspect 3,600 lb Remove the service loop tubs from the area
the inside of the connectors to make (1600 kg)
sure they are clean and dry. Remove the derrick termination plate if necessary
Figure 3-38. Removing and Storing Cables and Service Loops
3-41
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SM00856
Page 3-42 of 48
Decommissioning
Setting the Latches and Locking the Bail
Counterbalance
View of Cylinders
Carriage Disconnect
from Rear from the hook
Bail
Lock
Exhaust
Cover
TOP DRIVE
INST
WH ALL
UN EN
4 Places ST IT IS
VARCO
OR
ED
Pin
Latches
Both sides
Lower engaged
TDS to
drill floor
Pin
Procedure
Lower the top drive to the drill floor
It is NOT necessary to drain gear oil or
hydraulic fluid for rig down
Drill Attach the bail lock by placing u-bolt behind
Floor the gooseneck and attaching it to the tube as
shown
Disconnect the counterbalance cylinders from
the hook
Install exhaust covers
Engage the upper and lower carriage latches
as shown
Figure 3-39. Setting the Latches and Locking the Bail
3-42
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SM00856
Revision D
Page 3-43 of 48
Installation 3
Long Term Storage

When the top drive will be idle for six months or more, use the following long-term storage
recommendations in order to preserve the top drive and to properly store equipment associated
with its care and maintenance.
General Guidelines
Before leaving the factory, top drives are protected only for shipment to the destination. The
following guidelines and procedures should be followed for storage after arrival or extended
storage (six months or longer) on the rig.
Safety
Safety must be a prime consideration during application of any rust inhibitors, since they are
combustible and generate explosive vapors. Follow the manufacturer’s recommended safety
precautions. All personnel must understand these precautions and be properly protected.
Before using combustible products on the rig, make

sure to read and understand the manufacturer’s safety
precautions.
Storage Location and Position

Store the top drive and accessories under cover, or indoors, if possible. Top drives should be
stored away from blowing dust, salt spray, sources of vibration, etc. Also, avoid storage areas
where rapid temperature changes occur as this type of environment produces condensation.
Store the top drive in a vertical position if possible. If the top drive cannot be stored in a vertical
position, store the top drive on its shipping skid. Racks or pallets should be used for all other parts
of the top drive to make sure they are stored off the ground, concrete, etc. Care must be given to
positioning of stored components to allow periodic reapplication of rust inhibitors, rotating of
machinery, and so forth.
Cleaning
Steam cleaning is acceptable, but should be limited to painted surfaces. Unpainted surfaces must
be thoroughly dried and protected with rust inhibitors. Care must be used to avoid getting steam or
water into gearboxes, hydraulic system, bearing housings, and bushings. No diesel-based
cleaners should be used in cleaning junction boxes, hoses and electrical items.
3-43
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SM00856
Page 3-44 of 48
Long Term Storage

Pre-Storage Procedure
In addition to the items indicated in the section titled "Storage Procedure" on page 3-45, perform
the following procedures at initial long-term storage of the top drive.
1. If the top drive is to be stored in vertical position, drain oil from gearbox. Refill to the
full level in the sight glass full with an AGMA mild EP gear oil with rust inhibitor, or
equivalent (see the Recommended Lubricants and Fluids document located in the
User Manual). Rotate gears and bearings to distribute lubrication.
2. Relieve all hydraulic pressure, including accumulators. If the top drive is stored in a
horizontal position, drain hydraulic lines to prevent hydraulic fluid leaking out into the
immediate storage area.
3. Seal or plug exposed ends of air, hydraulic, water and lube/oil lines.
4. Remove washpipe packing assembly, disassemble and remove O-rings and packing
rings. Clean and coat washpipe assembly with rust preventative and store
separately. Protect all exposed threads on washpipe, gooseneck and stem (grease
all threads before installing threaded protectors).
5. Cover all electrical control boxes (junction boxes, etc.) with paper impregnated with
a volatile-type inhibitor followed by thick black plastic sheeting (at least .006" thick).
All sharp corners should be protected with wood blocking. Add desiccant packs to
keep dry.
The instrument junction box will stay on the top drive. Seal all openings with plastic NPT caps, and
add desiccant packs inside each box.
3-44
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SM00856
Revision D
Page 3-45 of 48
Installation 3
Long Term Storage

Storage Procedure
Complete the following steps at the monthly intervals indicated.
Step Procedure Description 0.0 1.5 3.0 6.0

mo mo mo mo
1 Rotate all rolling elements, and raceways (gearbox, handling ring

X X
etc) to prevent etching or staining.
2 • Coat all exposed bare metal and moving parts with rust
preventative (dry-film type rust inhibitors can also be used).
• Remove all covers/guards to gain access to all moving parts
when necessary. X X
• Rotate parts involved while applying rust preventative to ensure
parts are fully coated. Make sure that covers/guards are
replaced after coating.
3 • Grease all pins and dowels.

• Rotate parts while applying grease to ensure parts are fully X X
coated.
4 Add/replace desiccant packs inside each electrical box. X X
5 If the top drive is to be stored in a horizontal position:

• drain gear box and bearing cavities, then
• coat the inside of gear box (all gears, pinions, etc.) and bearing
X X
cavities with grease type rust inhibitor and then drain.
• Rotate gears and bearings while applying rust inhibitor to ensure
parts are fully coated.
6 Perform recommended Lubrication and Maintenance procedures

X X
as indicated in this service manual.
7 • Thoroughly grease all fittings with rust inhibiting grease. Use

enough to completely coat all rotating surfaces.
X X
• Rotate/actuate all parts involved while applying grease to ensure
full distribution.
8 Make sure all openings and covers are tightly sealed. X X
9 • Clean exterior of the top drive to remove all mud, dirt or other
foreign material.
X X
• Remove any rust and then coat area with red oxide or zinc rich
primer.
For long-term storage procedures of original equipment

manufacturer (OEM) parts and components, see the
manufacturer’s documentation located in the User Manual
supplied with the equipment.
3-45
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SM00856
Page 3-46 of 48
Long Term Storage

Returning the Top Drive to Service
For bringing OEM parts and components out of storage for

use, see the manufacturer’s documentation located in the
User Manual supplied with the equipment.
1. Remove all protective covers, wrappings and desiccant packs. Inspect for corrosion
or damage. Repair as required.
2. Remove all storage plugs.
3. Drain and flush all oil, preservatives, and inhibitors.
4. Change all filters and clean all strainers.
5. Check and replace (as needed) all rubber/elastomer parts. For example: air hoses,
water hoses, hydraulic hoses, seals, and counterbalance bags.
6. Replace all parts removed for separate storage, such as the washpipe assembly.
7. Fill all lubrication systems to correct levels with specified lubricants (see the
Recommended Lubricants and Fluids document located in the User Manual).
8. Perform recommended lubrication and maintenance procedures (see Revision
DMaintenance).
9. A qualified electrician must test motor windings and service loops.
Accumulated moisture in motor windings and service loops

should be driven out by several hours of low amperage
use.
10. Prior to starting and operating the top drive:

 perform a thorough inspection and checkout to verify that all of the top drive's
systems are fully functional and operational before returning the top drive to
service. Refer to the mechanical and electrical inspections in the appropriate
installation documents or mechanical and electrical checkout procedures.
 lubricate the rotating head or link adapter with 25ml of hydraulic fluid. Manually
rotate the component clockwise and then counter-clockwise for two rotations.
3-46
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Revision D
Page 3-47 of 48
Installation 3
 make sure the top drive is oriented vertically for two hours prior to energizing the
top drive hydraulic system.
!
Allow adequate run-in time. Start slowly with no load for
two hours to assess the top drive for wear or damage.
3-47
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Page 3-48 of 48
3-48
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SM00856
Revision D
Operation 4
!
All procedures and methods provided in this manual are
superseded by the procedures and methods approved for
use at the location where the equipment is installed and
commissioned.
Stateless Driller’s Control Console

Overview
A stateless NOV Driller’s Control Console is typically used to operate the TDS-11SA Top Drive.
Some top drive installations may also include an Amphion™ Human-Machine Interface (HMI)
system, in addition to the stateless driller’s control console. In this chapter, the controls on the
stateless driller’s control console are provided to explain top drive operations. All the operator
controls described are replicated in the Amphion HMI.
The control console provides the control circuitry for all top drive and pipe handler functions. The
console enclosure also contains Intrinsically Safe (I.S.) barrier components that support Zone 2
certification.
The control console is integrated with the Variable Frequency Drive (VFD). The VFD is located in
an environmentally-controlled drive house. The communication path from the driller’s control
console to the VFD is via a common data bus. Functional changes can be implemented by NOV
using utilities that are common for NOV top drive systems.
Control commands from the console are processed through a single-board computer (SBC). The
SBC controls the actions of the cooling system, the solenoid valves, the brakes, IBOP functions,
switches and sensors. The SBC also monitors all component sensors and switches, and acts as a
safety interlock to prevent inadvertent tool operation. Additionally, the SBC notifies the driller of the
operational status of the top drive and diagnoses abnormal operating conditions.
Refer to the section titled "Installing the Driller’s Control Console" on page 3-30 for installation
information.
The illustrations in this chapter show a typical control

console panel layout. Depending on the top drive system
options, the layout of the console controls may vary. Refer
to the engineering drawings in the Technical Drawing
Package (TDP) for the rig-specific console layout for the
equipment order.
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SM00856
4 Operation Revision D
Page 4-2 of 30

Front Panel
Figure 4-1 shows the front panel for a typical stateless NOV Driller’s Control Console. Figure 4-2
shows the internal components with the front panel opened.
Refer to later sections of this chapter for

console button, switch, and gauge descriptions.
Front Panel (Door Closed)
For Reference Only. The illustrations in this supplement

show a typical control console panel layout. Depending
on the top drive system options, the layout of the console
controls may vary. Refer to the engineering drawings in the
Technical Drawing Package (TDP) for the rig-specific console
layout for the equipment order.
Figure 4-1. NOV Stateless Driller’s Control Console (Front Panel Closed)
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Operation 4

Internal Components
Figure 4-2 shows the internal components with the front panel opened.
Low Voltage
Wiring Only AC Voltage I. S. Wiring Only
2x3
N. I. S. 1.5 x 3 I. S. 1.5 x 3
I. S.
N. I. S.
1.5 x 3
Field Cabling 1.5 x 3
Front Panel (Door Opened) Segregated

I.S. Wiring
For Reference Only. Refer to the engineering drawings

in the Technical Drawing Package (TDP) for the rig-specific
console wiring diagrams and other details.
Figure 4-2. NOV Stateless Driller’s Control Console (Front Panel Opened)
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Specifications
Enclosure ATEX, Zone 2
Weight 120 lb (54 kg)
Power Input Range • 0-24 V DC, 0-9.5 A

(non I.S. terminals) • 120 V AC, 1.1 A
Power Input Range

28 V DC, 4-20 mA, 0.65 W
(I.S. terminals)
Operating Temperature Range - 40°C to 45°C (-40°F to 113°F)
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Operation 4

Alarms
Alarms
Figure 4-3. Alarms
 Alarm Silence / Lamp Check

 When any alarm indicator light flashes and the horn sounds, press this button to
silence the alarm. The indicator will remain lit until the fault is cleared. If the fault
is not cleared in five minutes, the alarm horn sounds and the indicator flashes.
 When the button is pressed and held for two seconds, the console indicators are
tested. When the button is pressed and held for four seconds, the TORQUE and
RPM meters go to full scale for a meter test.
 Hyd Press Loss – Indicator flashes and horn sounds when hydraulic system
pressure loss is detected.
 Oil Press Loss – Indicator flashes and horn sounds when oil pressure loss is
detected.
 Drill Motor Overtemp – Indicator flashes and horn sounds when high temperature
is detected for the drilling motor.
 Cooling Water Flow – Indicator flashes and horn sounds when a loss of pressure
in the cooling system flow is detected.
 VFD Fault – Indicator flashes and horn sounds when a fault in the VFD is detected.
 General – Indicator flashes when any of the alarms activate. For example, this
indicator flashes and the horn sounds when IBOP Close pressure loss is detected.
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Controls
Top Drive
TDS
TDS Mode
TDS Direction
Figure 4-4. Top Drive Controls
 TDS – There is a green button and a three-position momentary switch in this

console area.
 Enable – Pushing this illuminated button enables top drive operation from the
Driller’s Control Console. When the green indicator is illuminated, the operator
has control of the top drive from the console, the lubrication pump and cooling
system are turned on, and the hydraulic supply is ready for top drive operation.
 Torque Set – This three-position momentary switch allows the operator to set
maximum drill and makeup torque setpoints. Turning the switch to DRILL and
then turning the DRILL encoder knob sets the maximum drill torque for DRILL
mode. Turning the switch to MAKEUP and then turning the MAKEUP encoder
knob sets the maximum makeup torque for TORQE mode, in the FORWARD
direction. This switch automatically returns to the center position (off) when
released.
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Operation 4

Controls
Top Drive
 TDS Mode – There are three illuminated buttons in this console area.
 Drill mode – When pushed, the green indicator illuminates to show that the top
drive is in DRILL mode. This mode is used for normal drilling operations. When
in this mode, the driller uses the DRILL and TDS RPM incremental encoder
knobs to set drilling operation limits.
 Spin mode – When pushed, the green indicator illuminates to show that the top
drive is in SPIN mode. This mode is used for shouldering up pipe while making
up connections. When in this mode, the RPM and torque settings are fixed at
standard SPIN mode rotational speed and torque values.
 Torque mode – When pushed and held, the green indicator illuminates to show
that the top drive is in TORQUE mode. This mode is used for making up and
breaking out connections. When this mode is selected in the FORWARD
direction, RPM is fixed and torque gradually ramps up to the makeup torque
setpoint. When this mode is selected in the REVERSE direction, RPM is fixed
and torque gradually ramps up to the maximum torque of the top drive, or until
the connection is broken, whichever happens first.
 TDS Direction – There are three buttons in this console area.
 Forward – When pushed, the rotational direction of the top drive is set to
forward (clockwise), the lubrication pump starts, and rotation ramps up to the
RPM setpoint. The green indicator illuminates when the top drive is assigned to
rotate clockwise (forward).
 Off – When pushed, the top drive is de-assigned and rotation will stop.
 Reverse – When pushed, the rotational direction of the top drive is set to
reverse (counterclockwise), the lubrication pump starts, and rotation ramps up
to the RPM setpoint. The green indicator illuminates when the top drive is
assigned to rotate counter-clockwise (reverse).
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Controls
IBOP and Brake
IBOP
Brake
Figure 4-5. IBOP and Brake Controls
 IBOP – The IBOP area has a yellow indicator and a switch. The yellow indicator is
illuminated when the IBOP is closed. Turning the switch will open or close the IBOP.
 Brake – There are two controls in this console area:
 Auto – When pressed, the green indicator on this button illuminates to show
that the motor brakes are in AUTO mode. In this mode, the brakes are
automatically released when a speed command is sent to the VFD (in FWD or
REV mode). The brakes are automatically set when the speed command is
removed (OFF mode).
 On / Off – The red indicator on this button lights whenever the motor brakes
have been applied and are engaged (ON). This indicator lights any time the
brake is set, regardless of whether or not the button has been pressed. When
this button is pressed once, the brakes are set and the light comes on. When
pressed again, the light goes out to show the brakes have been released.
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Operation 4

Controls
Pipe Handler
Pipe Handler
Figure 4-6. Pipe Handler Controls
 Link Tilt Float – When pressed, the elevator links float to the center position. When
the elevator links are in float position, the green indicator illuminates. When the
elevator links are in float position, the pipe handler can be rotated.
 Link Tilt Drill / Tilt – This is a three-position momentary switch.
 When switched to DRILL, the elevator links tilt to the Drilldown position. This
position allows the top drive to continue operating close to the drill floor.
 When switched to TILT, the elevator links extend the elevator to the Derrickman
position. If the switch is released at Derrickman position, then reapplied, the
links will tilt out to Mousehole position.
 When the switch is in the center position, the elevator links are held in the
current position.
Any time the switch is released, tilt motion stops immediately.
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Controls
Pipe Handler
 TW Clamp Push and Hold – When this button is pressed and held:
 the pipe handler rotates counter-clockwise into position
 the pipe handler locking mechanism locks the pipe handler in place
 the torque wrench clamp engages
Once engaged, the clamp is used to make up and break out connections.
 The clamp is used to make up connections when the top drive is in TORQUE
mode and when the FORWARD direction is selected. The torque will gradually
ramp up to the MAKEUP torque limit setpoint.
 The clamp is used to break out connections when the top drive is in TORQUE
mode and when the REVERSE direction is selected. The torque will gradually
ramp up to 125% of the preset make-up torque limit. If break-out torque is
insufficient to break out the connection, exit TORQUE mode and increase the
MAKEUP torque limit setpoint.
The clamp disengages when the TW Clamp Push and Hold button is released.
The pipe handler clamp will not engage if the top drive
motor brakes are applied.
The pipe handler clamp will not engage if the elevator links
are not in float position
Refer to the section titled "Torque Wrench Auto Mode" on page 4-11 for information
about the Torque Wrench Auto Mode button.
 PH Rotate CCW / CW – Turning this three-position momentary switch to the right
rotates the pipe handler clockwise. Turning the switch to the left rotates the pipe
handler counterclockwise. When released, the spring-centered switch returns to the
off position (center) and the pipe handler stops.
The pipe handler will not rotate if the elevator links are
tilted to any off-center position.
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Operation 4

Controls
Pipe Handler
Torque Wrench Auto Mode
When this button is pressed, the light turns green and the torque wrench will operate automatically.
When the torque wrench is in Auto Mode, the operator can move directly from Drill mode to
Torque mode and initiate automatic make-up or break-out operations, depending on the direction
of rotation.
Auto Mode Sequence: FORWARD Rotation
1. Operator switches from Drill mode to Torque mode.
2. Rotating Link Adapter jogs and the shot pin locks rotation.
3. The torque wrench clamp closes.
4. The top drive spins in the connection. The VFD provides feedback that the
connection is shouldered.
5. The top drive ramps up torque to the make-up torque setpoint.
If the pipe slips or the operator releases the Torque mode

button before the sequence reaches the make-up torque
setpoint, the sequence is aborted, the top drive is turned
off, and the brake is set.
6. The operator releases the Torque mode button.

7. Torque ramps down and the clamp releases.
Auto Mode Sequence: REVERSE Rotation
4. The top drive gradually ramps up torque to the maximum torque of the top drive, or
until the VFD provides feedback indicating the connection is broken.
When the connection breaks, the torque drops back to the spin torque setpoint.
5. The top drive spins out the connection.
7. Rotation stops and the clamp releases.
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Controls
E-Stop, BX Elevator, Counterbalance, and Dolly
E-Stop
Counterbalance
Dolly
BX Elevator
Figure 4-7. E-Stop, BX Elevator, Counterbalance, and Dolly Controls
 Emergency Stop – The Emergency Stop button is hard-wired to the Variable

Frequency Drive (VFD).
When pressed, the:
 VFD slows down the shaft speed and then shuts off
 power to the top drive shuts off
 hydraulic supply shuts off
 motor brakes are applied
To reset the system, reset the VFD and physically pull this switch back to its original
position.
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Operation 4

Controls
E-Stop, BX Elevator, Counterbalance, and Dolly
 BX – There are two controls in this console area:
 BX Elevator – This is a three-position switch. (The center position is neutral.)
Open opens the elevator and releases the pipe. Armed arms the elevator. This
readies the hydraulic cylinders in the elevator. In Armed mode, the elevator will
automatically close and hold a pipe that enters the elevator. The yellow indicator
illuminates when the elevator has closed on a pipe.
 BX Rotate – This is a three-position switch. (The center position is neutral.)
Down tilts the elevator down. Up tilts the elevator up. This allows the elevator to
be better positioned for pipe handling from multiple locations.
 Counterbalance – The counterbalance area has a green button indicator. When
pressed once, the light illuminates to indicate the counterbalance system is in Stand
Jump mode, retracting the counterbalance cylinders. When pressed again, the light
goes out to indicate that the counterbalance system has returned to DRILL mode.
Stand Jump mode is typically used immediately before breaking out a connection.
When the button is pressed, the top drive is lifted slightly off the connection by
elevated pressure to the cylinders. Normally, the counterbalance pressure is set to
about 1100 psi. During Stand Jump, 300 psi is added.
 Dolly – The dolly area has a three-position momentary switch. The switch is used to
extend the dolly or retract the dolly to the guide beam.
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Meters and Limit Adjustment Knobs
Torque Meter
RPM Meter
Limit Knobs
Figure 4-8. Meters and Limit Adjustment Knobs
 TORQUE meter – Shows the drill pipe torque in ft-lb (x 1000) increments from 0 to
80,000 ft-lb. In DRILL mode, the torque limit is set by the DRILL torque encoder
knob below the meter. In TORQUE mode and in the FORWARD direction, the
torque limit is set by the MAKEUP torque encoder knob below the meter.
 RPM meter – Shows the rotational speed of the top drive from 0 to 250 RPM.
Rotational speed is controlled using the TDS RPM knob below the meter.
 Drill knob – Sets the maximum allowable drill pipe torque when in DRILL mode. The
drilling torque limit is adjusted by turning the knob and observing the ft-lb of torque
displayed in the TORQUE meter.
 Makeup knob – Sets the maximum allowable makeup torque in TORQUE mode, in
the FORWARD direction. The makeup torque limit is adjusted by turning the knob
and observing the ft-lb of torque displayed in the TORQUE meter.
 TDS RPM knob – This is the top drive throttle. It controls the speed of the drilling
motor when in DRILL mode. The drilling speed is adjusted by turning the knob and
observing the RPM displayed in the RPM meter.
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Operation 4
Amphion™ Touchscreen Controls

The equipment and rig configuration may include one or more Amphion™ Control System
Touchscreen units in place of, or in addition to, the NOV Driller’s Control Console. This control
system interface allows the driller to control top drive operations using a touchscreen display.
Refer to the Amphion Operator’s Guide included with the

complete NOV rig equipment documentation package for
detailed Amphion control system information.
Figure 4-9 shows an example of an Amphion touchscreen display. This is a typical display and may
not represent your configuration.
Figure 4-9. Default Top Drive Amphion Touchscreen
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Basic Usage
Drilling Ahead with Singles
Step 1 Step 2 Step 3 Step 4 Step 5

Set slips on string Tilt links to Pickup single Lower block to Pull slips
mousehole with elevator stab motor into
Stop circulation top of single Open IBOP
Latch drill pipe Release link tilt
Close IBOP elevator around Spin in motor Start circulation
single Stab bottom of and single
Breakout connection single onto string Begin drilling
using pipehandler Makeup both
and drilling motor connections
(in reverse) with motor in
torque mode
Makeup
Open
IBOP
Link Tilt
Close IBOP
Stab Makeup
Figure 4-10. Drilling Ahead With Singles
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Operation 4
Basic Usage
Drilling Ahead with Triples

Set slips on string Raise block Pickup stand Lower block to Pull slips
with elevator stab motor into
Stop circulation Tilt link tilt to top of stand Start circulation
derrickman Stab bottom of
Breakout connection stand onto string Spin in motor Begin drilling
using pipehandler and stand
and drilling motor
(in reverse) Makeup both
connections
with motor
Link Tilt Makeup
Start
Circulation
Stop
Circulation
Stab Makeup
Figure 4-11. Drilling Ahead With Triples
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Basic Usage
Back Reaming

Hoist while Set slips on string Hoist free stand Setback stand Lower block, stab
circulating and with elevator using link tilt motor into string
rotating Break out
connection using Spin in motor
When 3rd pipehandler and and make up
connection drilling motor connection with
surfaces, stop (reverse) motor
rotation and
circulation Break out and Start circulation,
spin out stand pull slips, hoist
at floor and rotate
Breakout Hoist Setback
Hoist and
Rotate
Breakout
Figure 4-12. Back Reaming
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Operation 4
Making and Breaking Tool Joint Connections
Tool joint locks become a pinching hazard once they

are loosened. Make sure to support them as they are
loosened. The tool joint locks can fall and injure rig
personnel.
Breaking out the Saver Sub

During normal operation, the torque backup clamp cylinder is sitting on the springs, which are
supported by the spring plate of the torque arrestor. Refer to Figure 4-13 for the following steps.
1. Loosen the tool joint lock between the saver sub and the lower IBOP valve by
unscrewing all the bolts. Refer to the tool joint lock assembly and disassembly
procedures in the Maintenance chapter. Slide the tool joint lock down until it rests on
the clamp cylinder body.
2. Raise the clamp cylinder until the clamp cylinder positioning slot lines up with the
first hole on the torque arrestor. Insert the safety pin through the clamp cylinder and
torque arrestor.
3. Select TORQUE mode. Pressurize the clamp cylinder to clamp on the saver sub by
pressing and holding the TW CLAMP PUSH AND HOLD button.
4. Switch the drilling motor to REVERSE to break out the connection.
5. Once the connection is broken out, switch to SPIN and allow the motor to spin until
the saver sub and lower IBOP valve separate. Remove the safety pin. Lower the
clamp cylinder with the saver sub. The saver sub is ready for removal.
6. Unclamp the saver sub by releasing the TW CLAMP PUSH AND HOLD button.
Stand clear. The saver sub must be supported before

unclamping it. It will fall through the bottom of the
stabbing guide if not supported.
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Breaking Out the Saver Sub
V1 V1
CB1 CB1
CB2 V2 CB2 V2
Upper IBOP
Valve
Clamp
Lower IBOP Body
Valve Positioning
1 Holes
Tool Joint Lock
Torque Clamp
Loosen Screws Arrestor Cylinder
Safety
Pin
2
Tool Joint Lock
Rest on Clamp
Cylinder
Positioning
Slot
Saver Sub
3
Clamp Cylinder Raise to Next Hole
In Torque Arrestor
4 Support Saver Sub and release

Select TORQUE mode. 8 from Torque Back-up Clamp Cylinder.
5 TW CLAMP PUSH AND HOLD.
6 Drilling Motor REVERSE.
7 Drilling Motor SPIN.
Figure 4-13. Breaking Out the Saver Sub
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Operation 4

Making up the Saver Sub
1. Manually screw in the replacement saver sub into the lower IBOP valve.
To manually screw in the replacement saver sub into the lower IBOP valve:
a. Raise the clamp cylinder until the lower IBOP valve is exposed below the
stabbing guide (a pup joint may be used).
b. Lower the clamp cylinder until the hole and the correct clamp position lines up.
c. Insert the clamp positioning safety pin.
pressing and holding the TW CLAMP PUSH AND HOLD button.
3. Switch the drilling motor to FORWARD. Select SPIN mode and rotate the drilling
motor until the saver sub shoulders against the lower IBOP valve. Select TORQUE
mode and apply the correct torque.
4. Release the TW CLAMP PUSH AND HOLD button to unclamp. Lower the clamp
cylinder all the way to its lowest position.
5. Position the tool joint lock correctly and follow the proper assembly procedure
described in the Tool Joint Locks section.
Breaking out the Lower IBOP

Remove the saver sub first, as described in the previous section. Refer to Figure 4-14 for the
following steps.
1. Loosen the tool joint lock between the lower IBOP valve and the upper IBOP valve
by unscrewing the bolts. Slide the tool joint lock down until it rests on the tool joint
lock sitting on the clamp cylinder body.
2. Raise the clamp cylinder (along with the two tool joint locks) until the clamp cylinder
positioning slot lines up with the second hole on the torque arrestor. Insert the pin.
3. Select TORQUE mode. Pressurize the clamp cylinder to clamp on the lower IBOP
by pressing and holding the TW CLAMP PUSH AND HOLD button.
4. Switch the drilling motor to REVERSE to break out the connection.
the lower IBOP valve and upper IBOP valve separate.
6. Remove the safety pin. Lower the clamp cylinder with the lower IBOP. The lower
IBOP is ready for removal.
7. Unclamp the IBOP valve by releasing the TW CLAMP PUSH AND HOLD button.
Stand clear. The lower IBOP valve and saver sub must
be supported before unclamping them. They will fall
through the bottom of the stabbing guide if not
supported.
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Breaking out the Lower IBOP
V1 V1
CB1 CB1
CB2 V2 CB2 V2
Torque
Arrestor
Upper IBOP
Valve
Lower IBOP
Valve 7 Clamp
Loosen Screws Cylinder
Safety
8 Pin
1 Rest on
Tool Joint Lock Clamp Cylinder
Loosen Screws
9
Raise
2 Clamp
Tool Joint Lock Cylinder
Rest on Clamp to Next Hole
Cylinder
3
Clamp
Cylinder Raise to Next Hole
In Torque Arrestor
4 Select TORQUE mode. 10 Select TORQUE mode.
5 TW CLAMP PUSH AND HOLD. 11 TW CLAMP PUSH AND HOLD.
6 Drilling Motor REVERSE. 12 Drilling Motor REVERSE.
13 Drilling Motor SPIN.
14 Support IBOP Valve and Release From

Torque Back-up Clamp Cylinder
Figure 4-14. Breaking out the Lower IBOP
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Operation 4

Making up the Lower IBOP
1. Screw in the replacement saver sub and the lower IBOP valve together manually
and stand them under the clamp cylinder (a pup joint may be used to support it).
Position the clamp cylinder by stabbing over the lower IBOP valve. Make sure the
lower IBOP valve comes up through both tool joint locks sitting on the clamp cylinder
body.
2. Tighten four alternate screws on the top tool joint lock to secure it to the lower IBOP
valve to provide a temporary shoulder to support the weight of the lower IBOP valve
and the saver sub.
Make sure all four screws are tightened sufficiently so

that the tool joint will not slide through when the clamp
cylinder is raised.
3. Select SPIN and FORWARD modes.

4. Raise the clamp cylinder with the lower IBOP valve and saver sub while rotating the
upper IBOP to engage the threads. Once the upper IBOP valve and the lower IBOP
valve start to spin together, stop the drilling motor.
5. Lower the clamp cylinder and line up the first slot and hole on the clamp cylinder
and the torque arrestor. The clamp cylinder jaws line up with the saver sub.
6. Select TORQUE mode. Pressurize the torque backup clamp cylinder to clamp on
the saver sub by pressing and holding the TW CLAMP PUSH AND HOLD button.
7. Switch the drilling motor to FORWARD. Select SPIN mode and rotate the drilling
motor. Select TORQUE mode, apply desired torque and make up both connections.
cylinder all the way down.
9. Loosen the temporarily made-up tool joint lock. Position both tool joint locks
correctly and assemble. (See the Tool Joint Locks section.)
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Breaking out the Upper IBOP
Refer to Figure 4-15 for the following steps.
1. Remove the saver sub and the lower IBOP first, as described previously.
The saver sub and lower IBOP can be removed as one unit
by breaking out the connection between the upper and
lower IBOPs.
2. Lower the clamp cylinder with the broken out lower IBOP valve and the saver sub.
3. Unclamp the lower IBOP valve/saver sub assembly by releasing the TW CLAMP
PUSH AND HOLD button.
4. Remove the two tool joint locks sitting on the clamp cylinder.
Stand clear. The lower IBOP valve and saver sub must
be supported before unclamping them. They will fall
through the bottom of the stabbing guide if not
supported.
5. Remove the IBOP actuator yoke by unpinning it.

6. Remove the two upper IBOP cranks by unscrewing the two sets of screws.
7. Loosen the top tool joint lock and let it sit on the actuator shell.
8. Raise the clamp cylinder with the actuator shell and the tool joint lock until the third
slot and hole line up. Insert the safety pin.
9. Select TORQUE mode. Pressurize the clamp cylinder to clamp on the upper IBOP
valve by pressing and holding the TW CLAMP PUSH AND HOLD button.
10. Switch the drilling motor to REVERSE to break the connection.
the upper IBOP valve and drive stem separate.
12. Remove the safety pin. Lower the clamp cylinder with the upper IBOP. The upper
IBOP is ready for removal from the clamp cylinder.
13. Unclamp the upper IBOP valve by releasing the TW CLAMP PUSH AND HOLD
button.
14. Remove the tool joint lock and actuator shell.
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Operation 4

Breaking out the Upper IBOP
V1 V1
CB1 CB1
CB2 V2 CB2 V2
10
Tool Joint
Lock
Loosen
Upper IBOP 9 Screws
Valve Remove Clamp
Actuator Cylinder
1 Yoke Safety
Tool Joint Pin
Lock
Loosen
Screws
2
Tool Joint
Lock
Rest on
Clamp
Cylinder
11
Raise to Next Hole
Clamp
Cylinder
8 In Torque Arrestor
Support Saver Sub/
Lower IBOP Valve
and release from
Clamp Cylinder.
3 Remove Lower
Raise to Next Hole Tool Joint Locks.
In Torque Arrestor
4 Select TORQUE mode. 11 Select TORQUE mode.
5 TW CLAMP PUSH AND HOLD. 12 TW CLAMP PUSH AND HOLD.
6 Drilling Motor REVERSE. 13 Drilling Motor REVERSE.
7 Drilling Motor SPIN. 14 Drilling Motor SPIN.
Figure 4-15. Breaking out the Upper IBOP
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Making up the Upper IBOP
1. Place the upper IBOP valve on the floor under the clamp cylinder so that the clamp
cylinder can be stabbed over it (a pup joint may be used to support it). Lower the
clamp cylinder so that the upper IBOP comes up through the clamp cylinder.
2. Place the actuator shell and tool joint lock over the upper IBOP and tighten four
alternate locking screws to secure it to the upper IBOP, providing a temporary
shoulder to support its weight.
3. Install the actuator shell and cranks. (Refer to the engineering drawing the Technical
Drawing Package for details about actuator and crank installation.)
4. Raise the clamp cylinder with the upper IBOP valve while rotating the drive stem
clockwise to engage the threads. Once the drive stem and upper IBOP valve start to
spin together, stop the motor, switch to FORWARD and SPIN and press and hold
the TW CLAMP PUSH AND HOLD button to spin in.
5. Spin the lower IBOP and saver sub into position (refer to the appropriate procedures
in the previous sections). Make sure that the two tool joint locks are properly
installed on the clamp cylinder and in the correct sequence.
cylinder until it lines up with the first hole, which is lined up with the saver sub.
pressing and holding the TW CLAMP PUSH AND HOLD button and apply desired
torque to makeup all three connections.
8. Place the three tool joint locks at their respective joints. Install the three tool joint
locks. (See the section titled Tool Joint Locks.)
9. Install the IBOP actuator yoke and secure it.
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Operation 4
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Well Control
The TDS-11SA can stab into the string at any point in the derrick. While drilling, the remotely
controlled upper IBOP valve is available for immediate use as needed. On indication of a kick, use
the following well control procedure in conjunction with standard well control procedures.
Refer to section titled "Making and Breaking Tool Joint Connections" on page 4-19 for information
about breaking out and making up connections.
Procedure
1. On indication of a kick, set the slips and stab the top drive into the drill string
connection.
2. Make up the connection.
3. Remotely close the upper IBOP.
4. Lower the string to the drill floor and reset the slips.
5. Manually close the lower IBOP.
6. Loosen the intermediate and bottom tool joint locks. Let them both slide down until
they rest on top of the clamp cylinder body.
7. Raise the clamp cylinder and clamp onto the lower IBOP.
8. Break out the lower IBOP.
9. Remove the two joint locks loosened earlier.
10. Lower the clamp cylinder to Drill position and hoist the top drive clear of the
connection.
11. Install the crossover sub and a well control check valve (provided by others) onto the
lower IBOP. Make up both connections using the floor tongs or iron roughneck.
12. Slide the intermediate joint lock over the crossover sub and check valve and let it
rest on top of the clamp cylinder body.
13. Place the spacer sub onto the check valve, lower the top drive and stab into the
spacer sub.
14. Energize the clamp cylinder and make up the spacer sub to upper IBOP connection.
15. Lift the intermediate joint clamp and secure the connection between the upper IBOP
and spacer sub.
16. Spin out the spacer sub to check valve connection while hoisting the top drive.
17. Proceed with standard well control procedures.
Figure 4-16 shows the component configuration for normal drilling operations and for well control.
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Operation 4
Well Control
Component Configuration
Normal Drilling Well Control
upper joint lock

main shaft
main shaft
upper joint lock NC50 connection
intermediate joint lock
upper ibop
NC50 connection
NC50 connection
upper ibop intermediate joint lock
spacer sub
NC50 connection drill pipe connection
lower ibop bottom joint lock

drill pipe
NC50 connection
saver sub
drill pipe connection
drill pipe
drill pipe
check valve
(supplied by others)
crossover sub
NC50 connection
The intermediate and bottom joint lower ibop

locks are removed when changing
over to well control operations. The NC50 connection
upper lock is not removed. saver sub
The bottom joint lock is not used
during well control operations. Reinstall
this lock when the stack is reconfigured
drill pipe
for normal drilling operations.
TDS11156
Figure 4-16. Well Control Component Configuration
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Revision D
Maintenance 5
Introduction
The following sections describe periodic inspections and routine maintenance required to keep the
TDS-11SA Top Drive functioning properly.
In general, inspect all hoses and connections weekly.

Inspect pins, bushings, and bearings monthly.
Pre-Maintenance Checklist
Documentation You Will Need
 Electrical Interconnects and Hydraulic Schematics
 TDS-11SA Technical Drawing Package
 TDS-11SA User Manual
 Recommended Lubricants and Hydraulic Fluids (D811000719)
 Links Service Manual (D6350000870)
 Design Specification, Design Torque Standard (DS00008)
 Safety Wiring Procedure (ASP00019)
Regulatory Standards You Will Use

 ASTM A 275, Standard Practice for Magnetic Particle Examination of Steel Forgings
 ASTM E 709, Standard Guide for Magnetic Particle Testing
 ASTM A 388, Standard Practice for Ultrasonic Examination of Heavy Steel Forgings
 API RP 8B, Recommended Practice for Procedures for Inspections, Maintenance,
Repair, and Remanufacture of Hoisting Equipment
 API SPEC 8C, Specification for Drilling and Production Hoisting Equipment
(PSL 1 and PSL 2)
Spare Parts You May Need

Refer to the documents that list spare parts in your User Manual and contact your NOV
representative or an NOV Service Center.
Spare Parts and Fluids Disposal

The equipment owner is responsible for conforming to applicable regulatory policies, standards,
and recycling guidelines when removing the equipment, dismantling equipment components,
disposing of fluids, and disposing of consumable spare parts during and after maintenance.
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Form D811001123-GEN-001/06
SM00856
5 Maintenance Revision D
Page 5-2 of 98
Safety Precautions
Warnings
Avoid equipment damage or injury to personnel by paying close attention to the important safety
notes highlighted as Notes, Cautions, and Warnings used throughout this manual.
To avoid serious injury or death, read and understand the following warning advisories before
performing maintenance or troubleshooting procedures.
Complete all appropriate job safety analysis (JSA),

permits, and crew safety briefings immediately prior to
each maintenance activity or session. If, at any point
during the maintenance session, the planned activities
change for any reason, review the job safety
requirements again to ensure the crew involved is
aware of the changes in activities. Ensure all
appropriate personal safety equipment is in good
condition and used when necessary.
Unless specifically noted in this manual, properly lock

out the main power source before performing
lubrication, inspection, or replacement procedures.
Wear protective glasses to prevent eye injuries from

fluids under pressure, as well as other hazards.
Do not attempt any adjustments while the machine is

moving.
Read and understand all safety precautions and

warnings before performing maintenance procedures.
Do not attempt repairs you do not understand.
Use caution when draining lubricant. It can be hot.
Never check for hydraulic leaks with your hands. Oil

under pressure escaping from a hole can be nearly
invisible and can penetrate skin causing serious
injury. Always check for leaks with a piece of wood or
cardboard and always wear protective eyewear when
working on hydraulic components.
Always discharge all accumulators before servicing

the hydraulic system.
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Page 5-3 of 98
Maintenance 5
Safety Precautions
Top drive maintenance requires personnel working at

height and there exists the potential for injury or
dropped objects.
Equipment Records
Keep a record book of all maintenance procedures performed. Date each procedure, followed by a
description and the technician who performed it. This data is valuable for fault finding and problem
solving, should technical problems arise.
Procedures in this chapter relate to NOV-only components.

See the appropriate vendor-supplied OEM manuals for
inspection schedules and maintenance procedures for
non-NOV equipment and components.
Torque Values
Refer to the Design Torque Standard (DS00008) in the equipment User Manual for the torque
standards to follow when tightening component fasteners.
Install bolts with anti-seize compound and tighten based

on the Design Torque Standard (DS00008). This document
is included in the equipment User Manual.
Safety Wire (Lockwire) Procedures

Refer to the Safety Wiring Procedure (ASP00019) in the equipment User Manual for the
procedures required for installing safety wire (lockwire) on component fasteners.
Secondary Retention Guidelines

Refer to Design Guideline, Secondary Retention and Prevention of Dropped Objects
(D411000342-SPC-001) in the equipment User Manual for information related to secondary
retention of equipment components. Adhering to the recommendations and guidelines in this
specification will greatly reduce any risk of components falling from installed equipment.
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Equipment Inspection
The following service intervals are based on average

operating conditions. More frequent service intervals are
required if you operate the equipment in conditions where
excessive load, dusty or corrosive operating atmosphere,
or extreme temperatures occur.
Inspecting Rig Interface Components

Inspection Schedule
Daily Inspection Page Number
 Check guide beam lynch pins and retainer pins page 5-6
 Make sure the top drive is aligned over well center page 5-7
 Check all detent pins in the carriage page 5-9
Weekly Inspection Page Number
 Check crown padeye and hang-off link welds and fasteners page 5-5
 Check guide beam joint pin bushing page 5-6
 Check main and intermediate tieback welds and fasteners page 5-7, page 5-8
 Check all carriage rollers page 5-9
Monthly Inspection Page Number
 Check crown padeye, cotter pin, shackle, and hang-off bores page 5-5
 Check guide beam joint pin page 5-6
Yearly Inspection Page Number
 Check crown padeye page 5-5
 Check guide beam joints page 5-6
 Check main tieback link page 5-7
 Check all carriage bogeys page 5-9
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Page 5-5 of 98
Maintenance 5
Inspecting the Guide Beam and Carriage
Crown Padeye and Hang-Off Link
Crown
Cotter Pin
2.1" Replace if missing
(52 mm) Yearly
Monthly
minimum
Crown Padeye
Monthly
Crown Padeye
Visually inspect
weld for cracks
Shackle
2.0"
(50 mm)
minimum
Monthly
Shackle
Inspect and
replace if worn
Monthly
1.5" Hang-off Link Bores
(37 mm) Inspect and
minimum repair if worn
Hang-off Link Bores
Weekly
Typical all welds
and connections
Inspect clamped connections
for tightness and double nuts.
Inspect welds for cracks.
Figure 5-1. Inspecting the Crown Padeye and Hang-Off Link
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Page 5-6 of 98
Guide Beam Joints
!
Verify that the joint pins,
retainer pins and lynch pins are
in place and secure. Inspect joint pins and
bushings for wear. Replace any worn
or damaged components.
Component Replace when

Inside diameter is more
Bushings than 2.050 in (52.07 mm).
Secure
Joint Pins Outside diameter is less
than 1.963 in (49.86 mm).
Daily
Lynch Pin
Weekly
Bushing
Inspect for
wear replace
as needed
Yearly
Typical Guide
Monthly Beam Joint
Joint Pin
Inspect for
wear replace
as needed Daily
Retainer Pin
Monthly
Inspect welds
for cracks
Figure 5-2. Inspecting the Guide Beam Joints
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Maintenance 5
Main Tieback
Guide Beam
Bottom Section
Daily
Check that the tool is aligned
directly over well center
Main
Spreader Beam
Tieback Plate
Yearly
Tieback Link
Inspect retainer pins,
tieback hooks, and
pivot pins for wear.
Weekly
Typical all welds
and connections
Auxiliary Spreader Beam
Mast Leg
Figure 5-3. Inspecting the Main Tieback
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Intermediate Tieback
Intermediate
Tieback
(Shown in Locked
Position)
Locking
Bolt
Pivot
Point
Weekly
Typical all welds
and connections
Figure 5-4. Inspecting the Intermediate Tieback
5-8
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Page 5-9 of 98
Maintenance 5
Carriage
Weekly
Typical
all rollers
Inspect for uneven
wear, damage and
looseness, replace
as required
Yearly
Bogey (16)
Disassemble,
inspect for wear,
and relubricate
Daily
Typical all
detent pins
Verify that pins
are in place
and secure
Figure 5-5. Inspecting the Carriage
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Inspecting the Motor Housing and Transmission
Illustrated Index
Bail
Page 5-19
S-Pipe
Page 5-20
AC Motor
Brakes (2)
Page 5-28
AC Drilling Washpipe
Motors (2) Assembly
Page 5-29 Page 5-22
Gearbox
Gearbox
Lubrication
Assembly
Pump Assembly
Page 5-13
Page 5-16
Gear Oil Filter

Page 5-66
For AC motor and

transmission lubrication
see Page 5-66, 5-67
Figure 5-6. Motor Housing and Transmission Illustrated Index
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Page 5-11 of 98
Maintenance 5
Inspection Schedule
 Check for missing lockwire and cotter pins
 Check for loose or broken parts and leaks
 Check for damaged hoses and fittings
 Check the wash pipe assembly for leaks page 5-22
 Check fluid levels and filter condition page 5-65
 Check the AC motor louvers for damage page 5-29
 Check the AC motor screens for contamination page 5-29
 Check the flow of oil throughout the main body while the lube
page 5-13
pump is running
 Check the blower motor assemblies for loose bolts
 Check brake pads for wear page 5-28
6 Month Inspection Page Number
 Check the gear teeth for pitting and corrosive wear page 5-18
 Check for primary and secondary gear set backlash page 5-18
 Check the S-pipe for pitting, corrosion, or erosion page 5-20
 Check the upper main shaft liner for erosion caused by

page 5-21
leaking wash pip packing
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Inspection Schedule
 Check the gearbox lubrication pump assembly for wear or

page 5-17
damage
 Check bail, bushings and bail pins for wear page 5-19
 Check the upper bearing retainer o-ring, bearing isolator, and

page 5-25
oil seal for wear
 Check the radial grooves on the main shaft and the load
page 5-26
collar for wear
 Perform a Magnetic Particle Inspection (MPI) on the main

page 5-26
shaft, landing collar, and split load collar
 Check the main shaft for axial movement page 5-27
 Meggar motors
5 Year Inspection Page Number
 Perform a Magnetic Particle Inspection (MPI) page 5-56
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Maintenance 5
Internal Lubrication Flow
Procedure
Remove the 3 in pipe plugs from the main
body and check the flow of oil coming from
the four spray nozzles (two in the body,
two in cover) while the lube pump is
operating
Check that oil is running out of the upper
gear drain holes in each compound gear
set (indicates upper orifice is not blocked)
and that oil is running through the spillway
running from the thrust bearing (indicates
orifice is not blocked)
Pipe Plug
Pipe Plugs
Monthly
Upper
Compound
Gear Drain Hole
Check flow
Monthly
Body Spray
Nozzles
Cover spray Monthly
nozzles not shown
Spillway
Check flow
Pipe Plug
Remove using a
2 inch, 12 point socket
Main Body
Figure 5-7. Inspecting Internal Lubrication Flow
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Page 5-14 of 98
Belt-Driven Encoder Adjustment
Certain top drive models are equipped with non belt-driven

encoders. Refer to the detailed engineering drawings in the
Technical Drawing Package for information about non belt-
driven encoders.
Use the following procedure to adjust the encoder belt tension:

1. Remove the access covers.
2. Disconnect all of the electrical connectors from the encoder.
3. Remove the lockwire and loosen the four sled hold-down screws.
4. Allow the sled to move freely, allowing the belt tension spring to apply the proper
tension to the belt.
!
Do not tighten the belt by hand.
5. Carefully tighten the sled hold-down screws and torque them to 7 ft-lb.
6. Lockwire the sled hold-down screws.
7. Reconnect the encoder electrical connections.
8. Replace both access covers and tighten the access cover screws to 15 ft-lb and
lockwire them.
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Maintenance 5
Belt-Driven Encoder Adjustment
Sled
Hold-down
Screws
Belt Tension
4 Places
Spring
View from Side
Encoder Belt Sled
View from Top

(Blower Motor
removed for clarity)
Electrical
Connector
Sled
Encoder Belt
Encoder
Belt Tension Sled Hold-down

Spring Screws
(Allow the sled to move
freely before tightening)
4 Places
Figure 5-8. Adjusting the Belt-Driven Encoder
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Gearbox Lube Pump Assembly
Disassemble the gearbox lubrication pump assembly and inspect the pump assembly components
yearly for wear and damage as follows:
1. Drain the gearbox oil and disconnect the hydraulic lines from the pump assembly.
2. Remove the pump assembly by removing the eight lockwired capscrews that attach
the pump adapter plate to the main body.
3. Disassemble the spline adapter, pump, and housing using the pump vendor service
instruction HS15 (located in the User Manual).
4. Inspect the pump assembly components, replacing any parts that are worn or
damaged. Pay particular attention to the spline between the pump and motor, the
gears, and the motor and pump side plates.
5. Assemble the lubrication pump assembly in the reverse order of disassembly.
!
Follow the pump vendor service instruction HS15 (located
in the User Manual) when assembling the lubrication pump
components, and torque all fasteners in accordance with
DS00008.
!
When reinstalling the pump assembly into the main body,
inspect the O-ring for damage. Replace the O-ring if any
flat spots, nicks, or other damage is found.
6. Install the pump assembly into the main body. Torque the fasteners in accordance
with DS00008, and reconnect the hydraulic and electrical connections.
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Page 5-17 of 98
Maintenance 5
Gearbox Lube Pump Assembly
End Cover
Thrust Plate
Yearly 2 Places
Ring Seal
Gearbox Lubrication
Body Seal
Pump Assembly
2 Places
Check parts for wear or damage
Gear
Housing
Gear Set
Roller Bearing
4 Places
Pump
Adapter Plate
Capscrew
10 Places
Hydraulic Motor
Low-Speed/High-Torque
O-ring Main Body
Procedure
Drain the gearbox oil and disconnect the
hydraulic lines from the pump assembly
Remove the pump assembly by removing the
ten lockwired capscrews that attach the pump
adapter plate to the main body
Disassemble using the drawings in the
Technical Drawing Package as well as the
pump vender service instruction
Inspect and relace any parts that are worn or
damaged
Figure 5-9. Inspecting the Gearbox Lube Pump Assembly
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Page 5-18 of 98
Gear Backlash
A 6 Months
Gear Teeth
Check for wear, pitting,
and gear set backlash
B Solid Wire Solder
A B
Dim. A + Dim. B = Backlash
Procedure
Inspect the pump adapter plate at the same
time the gear backlash is checked
Drain the gearbox oil
Remove the access cover and the pump
adapter plate to check primary and secondary
gear set backlash
Run a piece of solid wire solder through the
primary and secondary gear meshes and
measure the thickness of the two flat spots
made by the gear teeth surfaces with a
micrometer
If the primary gear mesh backlash exceeds
.030 in. or the secondary gear mesh backlash
exceeds .040 in., excessive gear wear or
bearing failure may be indicated
Check the gear teeth for pitting or corrosive

wear at the same time the gear set backlash
is checked
Record backlash data for future reference
Figure 5-10. Inspecting Gear Backlash
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Page 5-19 of 98
Maintenance 5
Bail and Main Body
Bushing Inner diameter is more than 4.450 in.

Bail Pin Outer diameter is less than 4.125 in.
Bail
Yearly
Bushing
2 Places
Yearly
Main Body Cover

5 Years
Main Body
5 Years
Bail Pin
2 Places
Yearly
Figure 5-11. Inspecting the Bail and Main Body
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Page 5-20 of 98
S-Pipe
Procedure
Unscrew the two nuts that hold the S-pipe in Wing Nut
place along with the six bolts that secure the
clamp to remove and inspect the S-pipe
Clean the bore of the S-pipe and inspect for Seal Ring
visible signs of pitting, corrosion, or erosion
Use a flashlight and mirror to visually inspect the Plug
6 Months
bore of the S-pipe. A Bore-o-Scope is best for
inspection, if available. Pressure test to
rated working pressure
Remove and perform an ultrasonic inspection
on the S-pipe if visual inspection indicates
erosion or corrosion
Check condition of the seals 6 Months
Apply pipe dope to the threads before S-Pipe
re-installing Check for
visible signs of pitting,
corrosion, or erosion
(pitting or corrosion
should be no deeper
than 0.125 inch)
Clamp
Bolts
Seal Ring
Right-hand (inside of guard)

configuration shown. Your S-pipe Wing Nut
configuration may vary.
Figure 5-12. Inspecting the S-Pipe
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Revision D
Page 5-21 of 98
Maintenance 5
Upper Main Shaft Liner
Procedure
Remove the wash pipe assembly
Check the upper mainshaft liner for erosion
caused by leaking wash pipe packing and
replace the liner if erosion is found. The
upper surface of the mainshaft liner must be
flat and smooth
The Polypack Seal must also be replaced
whenever the upper stem liner is replaced
Grease the Polypack Seal and clean the

mainshaft bore before re-installing Wash Pipe
Make sure the O-ring of the seal is facing Assembly
down when the seal is installed on the liner
6 Months
Upper
Mainshaft Liner
Replace ONLY if
erosion is found
during inspection
Polypack
Seal
Polypack Seal
Replace the Polypack
Seal when the upper
mainshaft liner is replaced
Main Shaft
Remove any
corrosion found on
bore of mainshaft
Upper
Mainshaft Liner
Figure 5-13. Inspecting the Upper Main Shaft Liner
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Standard Washpipe
If the optional NOV mechanical washpipe is installed in the

unit, refer to the NOV Mechanical Washpipe Service
Manual (D811000200-PRO-001) for detailed maintenance
information. This manual is provided in the equipment User
Manual.
Assembly and Disassembly

1. With the packing box upside down, assemble the packing seals and spacers into the
packing box using care to line up the upper spacer slot with the dowel pin.
2. Hand pack all seals with multipurpose lithium-based or high temperature moly-
based grease using care not to grease the outside diameter of the spacers.
3. Install the socket head dog nose screw, ensuring that the screw nose is fully
engaged in the groove of the lower spacer.
4. Install the grease fitting and turn the packing box upright.
5. Install the wash pipe into the packing box assembly (slotted end up).
6. Install the wash pipe nut onto the wash pipe.
7. Grease the packing seal and install into the holding ring using care not to grease the
outside diameter of the holding ring.
8. Install the packing seal and holding ring over the slotted end of the wash pipe.
9. Install the snap ring.
10. Install the upper and lower o-rings using grease to hold them in place.
11. Compress the assembly to the length of the wash pipe.
Disassemble the washpipe packing in the reverse order of the above procedure. Refer to the
Standard Washpipe Manual, SM01053, for additional information.
Figure 5-14 shows disassembly and Figure 5-15 shows components that need to be inspected
after disassembly.
5-22
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Revision D
Page 5-23 of 98
Maintenance 5
Standard Washpipe
!
The wash pipe nut and
the packing box have
left-handed threads
Dowel Slide the

Pin wash pipe nut
and the packing box
together for installation
Hand pack all seals

with multipurpose
lithium-based or
high temperature
moly-based grease
completely filling
the void
Ensure that the nose of the

socket head dog nose screw
is fully engaged in the groove of
the lower spacer
Special Tools
3" Bore
Wash Pipe Wrench
Recommended for proper

tightening of the wash pipe
nut and packing box
Figure 5-14. Inspecting the Washpipe (1 of 2)
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Standard Washpipe
O-Ring
Snap Ring
Holding Ring
Upper Spacer
Packing Seal
Daily 5 per set
Wash Pipe
Assembly Wash Pipe
Inspect for leaks Nut
Middle Spacer
Wash Pipe
Middle Spacer
Packing
Assembly Box
Straight Ext. Lower Spacer

Grease Fitting
Socket Head
Dog Nose Screw
O-Ring
Procedure
Visually inspect the wash pipe assembly for leaks
Replace any worn or damaged parts
Apply pipe dope to the threads before installing in
the Top Drive
Figure 5-15. Inspecting the Washpipe (2 of 2)
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Maintenance 5
Upper Bonnet Seals
Procedure
Remove the bearing shield, the bearing retainer Bearing
cap screws, and the bearing retainer Retainer
Inspect the bearing isolator, the oil seal, and the Cap Screw
retainer o-ring for wear 6 Places
Replace any worn or damaged parts
Align the shims so that the bearing lube Bearing
tube bore is not blocked Shield
Bearing
Retainer
Lube Tube
Bearing
Oil Isolator Bearing
Seal Retainer Lube Tube O-Ring
Cap Screw 2 Places
Bearing 6 Places
Shield
Bearing
Retainer
Retainer Yearly
O-Ring Retainer O-Ring
Yearly
Bearing Isolator
Yearly
Lube Tube Oil Seal
Shims
Hand pack the

void with grease
Figure 5-16. Inspecting the Upper Bonnet Seals
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Main Shaft and Load Collar
Stem Grooves Groove width (female) is greater

than 0.650 in.
Load Collar Groove width (male) is less
Grooves than 0.579 in.
Stem
5 Years
Split Load Collar
Yearly
Radial Grooves
Inspect for groove
wear and pitting Radial Grooves
0.650 Inspect for groove
Yearly wear and pitting
max
Yearly
0.579
min
Retainer Ring
Figure 5-17. Inspecting the Main Shaft and Load Collar
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Maintenance 5
Main Shaft End Play
Dial
Indicator
Mainshaft Bearing Retainer

Check for Cap Screw
axial movement 6 Places
Yearly
Shims
Bearing
Retainer
Procedure
Check mainshaft endplay with every washpipe
changeout
Remove the washpipe assembly
Check the mainshaft axial movement by
applying an upward force to the mainshaft and
measuring the amount of axial movement with a
dial indicator
If axial shaft movement is not .001 in. to .002 in.,
remove the bearing retainer and adjust the
number of shims under the bearing retainer as
required to allow .001 in. to .002 in. of axial shaft
movement (end play) with the bearing retainer
capscrews tightened to 250-270 ft lb
Figure 5-18. Inspecting Main Shaft End Play
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Motor Brakes
Procedure
Remove the brake housing covers to access
the drilling motor brakes
Inspect the brake pads for wear, and replace
the pads if worn below the allowable lining
wear limit
If the brake pads are wearing unevenly, adjust
the pads by adjusting the bolts on the brake Calipers and Pads
calipers to acheive an equal gap as descibed Check pads for wear
below
Monthly
Inspect the brake hydraulic lines for leaks
Never check for hydraulic Brake Rotor

leaks with your hands. Oil
under pressure escaping
from a hole can be nearly
invisible and can penetrate
skin causing serious injury.
Always check for leaks with
a piece of wood or
cardboard.
Caliper
Mounting Steel
Bolts Plate
0.09 in.
Min.
Adjust
Caliper Brake Equal

Mounting Pads Gap
Bracket
Figure 5-19. Inspecting the Motor Brakes
5-28
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SM00856
Revision D
Page 5-29 of 98
Maintenance 5
Drilling Motors
Procedure
Check for missing or damaged louvers
Check screens for contamination
Check motor leads for damage
Check for missing lockwire
Megger motors yearly
Weekly
Motor Leads
Check for damage
Weekly
Louvers
Check for damage
Weekly
Screen
Check for contamination
Figure 5-20. Inspecting the Drilling Motors
5-29
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SM00856
Page 5-30 of 98
Transmission
Stem Sleeve
Taper Roller
Main Body Cover Bearing
Cap Screw Dowel Pin

Upper Spray
Nozzles Dowel Lock
Pin Washer
Upper Compound Bull Gear
Roller Bearing
Internal
Retaining Ring
Compound Gear Upper Stem

Liner
Internal
Retaining Ring
Poly Pack
Oil Seal
Spacer Ring Gallery
O-Ring
Lower Compound
Roller Bearing
Bearing Lock
Washer
Main Shaft
Internal Stem
Locknut Retainer
Main Body O-Ring
Tapered Roller
Main Body Thrust Bearing
Main Shaft
Sleeve
Lower Main
Bearing Main Lower
Roller Bearing
Lube Plate Wear Sleeve

Oil Assembly Bearing
Lock Washer Retainer
Cap Screw
Figure 5-21. Disassembling/Assembling the Transmission
5-30
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SM00856
Revision D
Page 5-31 of 98
Maintenance 5
5-31
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SM00856
Page 5-32 of 98
Inspecting the PH-75 Pipe Handler
Illustrated Index
Rotating Link
Adapter
Page 5-52
Link Tilt
Page 5-38
IBOP Actuator
Yoke and Cylinder
Page 5-46
Stabilizer
Page 5-44
IBOP Stack
Page 5-49
Clamp Cylinder
Body
Page 5-40 to 5-43
Stabbing Guide
Page 5-42
For pipehandler lubrication

see Page 5-64
Drill Pipe Elevator

and Elevator Links
Page 5-36
Figure 5-22. PH-75 PIpe Handler Illustrated Index
5-32
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SM00856
Revision D
Page 5-33 of 98
Maintenance 5
Before beginning any inspection procedures, make

sure to read and understand the warnings in the
section titled "Safety Precautions" on page 5-2. Failure
to adhere to these warnings could result in severe
injury or death.
Inspection Schedule
 Check for missing lockwire and cotter pins
 Check for loose or broken parts and leaks
 Check for damaged hoses and fittings
 Check tong dies for wear page 5-42
 Check clamp cylinder for leaks page 5-42
 Check hoses for wear or damage page 5-46
 Check tool joint locks for tightness page 5-48
 Check upper and lower IBOP valves for proper operation page 5-49
 Check link tilt clamps for position and tightness page 5-37
 Check stabbing guide and flippers for damage and wear page 5-42
 Check clamp cylinder gate hinge pin for wear page 5-42
 Check IBOP actuator cylinder for leaks page 5-46
 Check IBOP actuator cam followers for wear or excessive

page 5-46
play
 Check upper and lower IBOPs and IBOP crank for damage (if
page 5-49
equipped)
 Check shot pin assembly for leaks page 5-51
5-33
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SM00856
Page 5-34 of 98
Inspection Schedule
 Check elevator link eyes for wear page 5-36
 Check link tilt bushings for wear page 5-39
 Check link tilt actuator cylinders for leaks page 5-39
 Check link tilt actuator cylinder pins for wear page 5-39
 Check clamp cylinder body wear bushings for wear page 5-42
 Check stabilizer springs for damage page 5-44
 Check front and rear stabilizers for wear page 5-44
 Check pins and bushing on IBOP actuator cylinder and yoke

page 5-46
for wear
 Check shot pin assembly for wear page 5-51
 Check piston ring for pitting and chipping page 5-53
 Check stem for pitting, grooves and chipping page 5-53
 Replace GLYD rings, o-rings, and bushings on rotating link

page 5-53
adapter
5 Year Inspection Page Number
 Perform a Magnetic Particle Inspection (MPI) page 5-56
5-34
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SM00856
Revision D
Page 5-35 of 98
Maintenance 5
Stopping and Starting the Top Drive
Shutting Down the Top Drive Starting Up the Top Drive
Use the following procedure before Before turning the main power back on,
performing any work on the top drive. be sure that all rig personnel are well
clear of the top drive, pipehandler and
Operate the Link Tilt control on the console all link tilt system components.
to the FLOAT position prior to shutting down
the top drive. Turn the hydraulic control switch on the top
Make sure that the elevator links are hanging drive from SHUTDOWN to RUN mode.
vertically. Turn the main power ON at the main power
Turn the IBOP valve control to the OPEN breaker in the VFD house. Reset brake. You
position on the console. may then function test the top drive after
Turn the main power OFF at the main power repairs have been made.
breaker in the VFD house.
Turn the hydraulic control switch on the top
drive hydraulic manifold from RUN to
SHUTDOWN mode.
Attempt to function test the LINK TILT
(Derrickman and Drilldown), the IBOP, and
pipehandler left and right rotation. If none of
these functions operate, all hydraulic
pressure is off.
Rig-up/Run/
Shutdown Valve
Shown in RIG-UP
position (switch to RUN
after the counterbalance Typical location for
is installed) Rig-up/Run/
Shutdown Valve.
RUN This valve may be in
a different location
on your top drive.
SHUTDOWN
RIG-UP
COUNTERBALANCE MODE
N
W
O
R
D
U
T
N
U
H
S
C
Hydraulic
O
U
N
R
TE
IG
R
BA
-U
LA
P
N
C
E
M
O
Manifold
D
E
Figure 5-23. Stopping and Starting the Top Drive
5-35
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SM00856
Page 5-36 of 98
Elevator Links
Once a month, use calipers to measure the amount of wear on the elevator link eyes. Compare the
measurement with the link wear charts in the Links User Manual (D6350000870). This manual is
included in the equipment User Manual.
Complete the following steps to remove the elevator links for inspection:
1. Disconnect and remove the drill pipe elevator from the elevator links.
2. Using the driller’s control console, rotate the pipe handler 90° to position one of the
elevator links directly below the front of the motor guard. (There is a recess at the
front of the motor guard that allows the elevator link to be hoisted away from the pipe
handler.)
3. Remove the catch link bolt from the catch link.
4. Remove the clevis pin from the link, which connects the link tilt to the elevator link.
5. Using the sling, hoist the elevator link away from the pipe handler.
6. Rotate the pipe handler 180°, repeat the procedure to remove the other elevator
link.
5-36
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SM00856
Revision D
Page 5-37 of 98
Maintenance 5
Elevator Links
Recess in
Motor Guard
Catch Link Pin
Elevator Link
2
Link Tilt Lift and
remove
Link
Catch
Monthly
Elevator
26" Link Eyes
(635mm) Inspect for wear
Typical
(see table)
Clevis Pin
Rear
Pipehandler
Rotate Switch
Weekly
Link Tilt Clamps
EH T AN
SH
PIP PU
Inspect for position
IL
K TT
LIN OA
T
and tightness
FL U
HP / ON
TO
AU
Front
E
QU E
AT CW
ROT
PH
W
CC
T
T ILT TIL
L INK
DR
ILL
1
Rotate
Driller’s
VE
RS
E
Control
Console
CY
GEN
Monthly
ER OP
EM ST
A SE
RE
I NC
EUP E
DE CR EAS
SET MAK
QUE
S TOR PM
TD L RE
A SE
SR
I NC
DRIL
TD
ECREASE
D
BLE
ENA BX OR N P
KEU
VAT OPE
A SE
Elevator
ELE RE
MA
BX
I NC
ED
ARM
CE DECR EAS
E
LAN
UMP
RBANDJ
ILL
NTESTA
L COUL /
ERA
DR
GEN DRIL
R
LE
VFD
LT ND CLAMP HOL
D
VAT
OR
FAU
HA TWH AND ELESED
MS
PIPE
BX CLO
Link Eyes
PUS
AR OR
AL L MOTMP TILT
DRIL RTE LINK AT
OVE FLO HPU/ ON
O
AUT
SS
PRE
OIL S
LOS
QUE ATE CW
TOR ROT
DE PH
S MO
WER
BLO S CCW
LOS
TD
Inspect for wear

SPIN
TILT TILT
/ LINK
NCE
SILECK L
RM CHE L DRIL
ALA P DRIL
LAM
E E
AK N REV
ERS
BR IO
O
CT
AUT RE
S DI OFF
(see table)
TD
IBOP
Take care when inspecting

SED D
CLO WAR
FOR
KE
BRAOFF
/
ON
SE
CLO
elevator links. Links weigh

IBOP
N
OPE
up to 2,400 lb (11,00 kg) and

can fall if handled improperly.
Figure 5-24. Inspecting the Elevator Links
5-37
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SM00856
Page 5-38 of 98
Link Tilt
1. Shut down the power and bleed the system (turn the valve on the bottom of the
gearcase to the SHUT DOWN position).
2. Disconnect the hydraulic lines from the link tilt cylinders and cap all connections.
3. Unpin and remove the link tilt cylinders.
4. Unpin and remove the link tilt crank.
Use the recommended spanner wrench to remove the rod

gland seal.
5-38
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SM00856
Revision D
Page 5-39 of 98
Maintenance 5
Link Tilt
Pins
Inspect for wear
replace as needed
Monthly
Bushings should be
pressed in using the
mating pin as an
installation mandrel.
Monthly
Bushings
Inspect for
wear replace
as needed
Monthly
Yearly Link Tilt

Actuator
Pipehandler Cylinders
Dissassemble and Inspect the
inspect per illustration hydraulic Link Tilt
connections
for leaks
Monthly
Bushings
Inspect for wear
replace as needed
Component Replace when Monthly
Pins Wear exceeds .06 in. on diameter as measured by Moving Components
comparing worn surfaces to un-worn surfaces Observe operation and
Bushings Metal backing is visible through the lining look for excessive wear
and replace as needed
End cap of the metal backing exceeds .04 in. wear
Figure 5-25. Inspecting the Link Tilt
5-39
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SM00856
Page 5-40 of 98
Torque Wrench Assembly
Disassembling/Assembling the Clamp Cylinder Body
2. Disconnect the hydraulic lines on the clamp cylinder body and cap all connections.
3. Support the clamp cylinder body.
4. Remove the two hex-head capscrews and lockwashers that hold the end cap in
place.
5. Remove the end cap, spring spacer, spring sleeve, and spring.
6. Slowly lower the clamp cylinder body off the torque wrench frame and move it to a
suitable work area.
7. Remove the 16 hex-head screws and lockwashers that hold the wear bushings on
8. Remove the four wear bushings, and replace the wear bushings as necessary.
9. Remove the two hinge pin retainer hex-head screws.
10. Swing out the two hinge pin retainers.
11. Remove the two hinge pins.
12. Remove the gate, front jaw, front stabilizer, and front stabbing guide.
13. Remove the two socket-head capscrews and hi-collar washers from the front jaw.
14. Remove the front jaw from the gate.
15. Repeat steps 11 and 12 for the rear jaw.
16. Push the cylinder head in enough to relieve the load on the cylinder head ring.
Remove the cylinder head ring. Use care in this operation.
17. Slowly pull out the cylinder head using the threaded holes. Remove and discard the
piston seal.
18. Carefully push the piston out of the body. Remove and discard the piston seal.
19. Remove the wiper rod and rod seal from the body. Discard the seals.
20. Clean the piston, cylinder head, and the body. Clean and lightly lubricate the new
seals and seal surfaces prior to reassembly.
Use recommended spanner wrench to remove the rod

gland seal.
Assembly is performed in reverse order of disassembly.
5-40
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SM00856
Revision D
Page 5-41 of 98
Maintenance 5
Clamp Cylinder
Safety Pin
Store Position
Torque
Arrestor
Clamp Cylinder
Safety Pin
Clamp Cylinder
Hanger
Clamp
Cylinder
Assembly
Spring
Spring
Post
Support clamp
cylinder body
Bottom before removing
Plate Bottom Plate.
Figure 5-26. Removing the Clamp Cylinder Body
5-41
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SM00856
Page 5-42 of 98
Socket-head
Capscrews
Stabilizer
Liner
Jaw
Retainer
Hex-head
Screw Hi-collar
Washers
Hinge Pin
Retainer
Rod
Seal
Wiper
Rod Stabilizer
Liner
Rear
Jaw
Screw
Front
Stabilizer
Washer
Hinge
Pin Front
Jaw
Gate
Nut
Spring
Front
Stabbing Front
Guide Stabbing
Retainer Guide
Cylinder
Head
Ring Arm Guide
Cylinder
Spring
Head
Piston
Seal Piston
Seal Piston
Figure 5-27. Disassembling the Clamp Cylinder Body
5-42
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SM00856
Revision D
Page 5-43 of 98
Maintenance 5

Stabilizer Wear exceeds 1/8 in. (radius >3.625")
Flippers Wear exceeds 1/8 in. (radius >3.625")
Gate Hinge Pins Wear exceeds .06 in.
V1
CB1
CB2 V2
Clamp Cylinder
Front and Gate Hinge Pin
Rear Stabilizers Check for pin wear,
Inspect for wear replace as necessary
Weekly 6 Months
Tong Dies
Inspect for
excessive wear Daily
Clamp Cylinder
Daily
Check for leaks,
replace seals
as necessary
Swing Clear
Weekly
Clamp Weekly Stabbing Guide
Cylinder Gate Inspect for damage
Flippers
Shown open
Inspect for damage
and excessive wear
Figure 5-28. Inspecting the Clamp Cylinder Body
5-43
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SM00856
Page 5-44 of 98
Stabilizer
Procedure
Remove the two screws (with slotted
nuts and cotter pins) that hold the
front stabilizer
Check the springs for damage and
replace if needed
Pack spring cavities with grease and
reassemble
Be sure all safety wire, cotter pins,
and screws are tight, and tighten or
replace as necessary.
Screw
Washer
Nut
6 Month
Cotter
Stabilizer Springs Pin
Check for damage,
replace as necessary
Figure 5-29. Inspecting the Stabilizer
5-44
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SM00856
Revision D
Page 5-45 of 98
Maintenance 5
IBOP Actuator Cylinder and Yoke
Disassembling the IBOP Actuator Cylinder and Yoke
2. Remove one gate hinge pin, open the gate, and pull back the torque wrench
assembly.
3. Disconnect the hydraulic lines from the IBOP actuator cylinder and cap all
connections.
4. Unpin and remove the IBOP actuator cylinder and yoke.
5. Replace the hydraulic lines as necessary.
6. Check for cylinder leaks.
5-45
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SM00856
Page 5-46 of 98
IBOP Actuator Cylinder and Yoke
Daily Weekly 6 Months
Hoses Actuator Cylinder Actuator Cylinder
Replace if worn and Yoke and Yoke
or damaged Check for looseness, etc. Dissassemble and
inspect per illustration
Weekly
IBOP
Actuator Cylinder
Check for leaks,
tighten fittings
Monthly
Pins and Bushings
Check for wear
or excessive play
Monthly Weekly
IBOP IBOP
Actuator Yoke Actuator Yoke
Check pins and Check cam followers for wear
bushings for wear or excessive play
or excessive play
Pins Wear exceeds .06 in. on diameter

Bushings Metal backing is visible through the lining
Bushings should be pressed in using the mating pin

as an installation mandrel
Figure 5-30. Inspecting the IBOP Actuator Cylinder and Yoke
5-46
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SM00856
Revision D
Page 5-47 of 98
Maintenance 5
Tool Joint Locks
Assembling/Disassembling the Tool Joint Locks
!
Do not reuse locking screws.
1. Lubricate the locking screw threads, screw head bearing area, and the tapers of the
inner rings with molybdenum disulfide grease, such as Molykote Gn paste.
2. Make sure the save sub, IBOPs, and main shaft are free of “high spots”, such as
tong marks. If high spots exist, remove with file or light grinding.
3. Slide the tool joint lock over the main shaft, IBOP valves, and saver sub.
4. Clean the IBOP valves, main shaft, and saver sub surfaces thoroughly. Make sure
these surfaces are smooth and free of grease, oil, and pipe dope.
5. Locate the tool joint lock symmetrically at each joint.
!
Never tighten locking screws before the tool joint lock is at
the correct location, otherwise it will not slide freely.
6. Take any three or four locking screws equally spaced and tighten them to establish
parallel or perpendicular position of the tool joint lock collars relative to the main
shaft, IBOP valves, and saver sub respectively. This properly seats the collars on
the taper of the inner ring and aligns the collars.
7. Using a torque wrench, tighten all locking screws gradually in either a clockwise or
counterclockwise sequence (not in a diametrically opposite sequence). Continue
tightening all of the screws until they reach 185 +/- 5 ft-lb.
8. Make sure no screw turns any more. The gap between the tool joint collars should
be as equal as possible all the way around.
9. Safety wire all screws.
5-47
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SM00856
Page 5-48 of 98
Tool Joint Locks
Tool Joint Lock to be Equally
Spaced on Upper IBOP and
Main Stem Joint Connection
1.4" Tool Joint

Shoulder
1.4"
Tapered
Inner Ring
Remove O-Ring
and Look through
this Space and
Split on Inner Ring Tool Joint Lock to
be Offset on Upper
and Lower IBOP
Joint Connection
Tool Joint
1.0" Shoulder
I.D. Groove
First Line Up this Point with the
Tool Joint Shoulder. Then Move
Inner Ring Down 3/8" with the
Outer Assembly. Replace O-Ring
Daily
Tool Joint
Locks
1.4" Tool Joint Inspect for loose bolts.
Shoulder Repair or replace if necessary.
Torque to 1855 ft lb.
1.4"
Spaced on Lower IBOP and
Saver Sub Joint Connection
Removing the Tool Joint Locks

Gradually release the locking screws all the way around. Initially release each screw
about a quarter of a turn, avoid tilting and jamming the collars. Do not remove the
screws completely at this time, otherwise the collars may spring off.
Remove any rust formed or dirt collected adjacent to the tool joint lock. Once the screws
are loose, remove the tool joint lock from the saver sub, IBOP valves, and main shaft.
Figure 5-31. Inspecting the Tool Joint Locks
5-48
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SM00856
Revision D
Page 5-49 of 98
Maintenance 5
IBOP Valves and Saver Sub
Saver Sub Threads have been recut to a minimum

shoulder-to-shoulder length of 5 in.
Weekly Daily
Upper IBOP Valve
(Remote) Check for
Close Inspect for damage proper operation
and pressure test
for leaks
Weekly
Open IBOP Crank

(Remote)
Inspect for damage
Weekly Daily
Lower IBOP Valve
(Manual) Check for
(Optional) proper operation
Inspect for damage and pressure test
for leaks
5 Years
Upper and Lower IBOP
Figure 5-32. Inspecting the IBOP Valves and Saver Sub
5-49
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SM00856
Page 5-50 of 98
Shot Pin Assembly
Disassembling the Shot Pin Assembly
1. Disconnect the hydraulic and electrical lines.
2. Remove the capscrews that attach the shot pin assembly to the main body.
3. Remove the capscrew and lockwasher holding the shot pin cover in place.
4. Remove the shot pin components as shown in Figure 5-33 (end cap, o-rings, rod
seal assembly, shot pin).
5. Inspect the shot pin bearing and press the bearing out of the shot pin mounting
bracket if the bearing is scored or damaged.
6. Remove the capscrew and lockwasher that hold the pinion gear in place, and
remove the gear.
7. Remove the capscrews and lockwashers that hold the hydraulic motor in place and
remove the motor.
8. Inspect the disassemble parts and replace any worn or damaged parts.
Assemble the shot pin in the reverse order of disassembly.
5-50
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SM00856
Revision D
Page 5-51 of 98
Maintenance 5
Shot Pin Assembly
Shot Pin Outer diameter is Gear

less than 1.375 in. Shaft
Shot Pin Sleeve Inner diameter is

greater than 1.510 in.
Flanged
Bearing
Hydraulic
Motor
Compound
Gear
Hydraulic
Dowel Manifold
Pin Flanged
Bearing
Bearing
Drive
Weekly Gear
Shot Pin Assembly
Check for leaks,
tighten fittings Bearing
Shot Pin
Housing
Assembly
Rod Seal
Assembly
Monthly Bearing
Shot Pin Retainer
Check for wear,
remove burrs
Rod Seal
Assembly
Monthly O-ring
Shot Pin Sleeve
Check for wear Retaining
Ring
Shot Pin
Flange Bushing
Figure 5-33. Inspecting the Shot Pin Assembly
5-51
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SM00856
Page 5-52 of 98
Rotating Link Adapter and Load Stem
Removing the Rotating Link Adapter (while the top drive is in the mast)
1. Drain the oil from the gearbox.
2. Disconnect and cap all tubing, remove the shot pin assembly and the landing collar.
3. Build a support over well center to support the weight of the link adapter.
4. Lower the top drive to the support built in Step 3.
5. Remove the bolts that attach the load stem to the main body.
6. Raise the top drive slowly to separate the link adapter from the main body.
7. Move the link adapter assembly to a clean, safe work area.
8. Orient the assembly with the stem flange up and block the entire assembly so that it
is secure in this position.
Disassembling the Rotating Link Adapter
1. Attach a 3-point sling to the stem and pull the stem out of the link adapter.
2. Turn the stem over and place it on its flange.
!
Protect the internal surfaces of the rotating link adapter
and the surfaces of the drive stem when separating the two
components. When removing the rotating link adapter from
the stem, carefully tap with a mallet. There can be
misalignment between the two bores when raising the
drive stem and gear assembly.
The piston ring is assembled with a light press fit. Provide

a support under the gear so that it does not drop when it
breaks loose.
3. Remove and discard all rotary seals, O-rings, thrust ring, and the wear bushings
from inside the rotating link adapter and gear inside dimension.
4. Remove and discard the stem flange O-rings and stem bore shaft seals.
5-52
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Revision D
Page 5-53 of 98
Maintenance 5
Eye Bolts
Rotary GLYD Ring
(10 Places)
Remove, discard and replace
Yearly
Rotary GLYD Ring

Yearly
Rotary Link Adaptor

O-Ring
Remove, discard
and replace
Yearly
Thrust Ring
Retainer Ring Remove, discard and replace
Yearly
Turcite Bushing
O-Ring
Yearly
Rotary GLYD Ring
Wiper Seal
Yearly
Piston Ring
Inspect for pitting
Rotating Link and chipped plating
Adapter Gear
Wear Allowances
Yearly
Thrust Ring Thickness is less than 0.105 in.
Turcite Thickness is less than 0.112 in. Stem
Bushing Inspect for pitting,
grooves and chipped plating
Stem O-Ring
Index Mark
Indicates front of stem
Yearly
Level Work Surface
Figure 5-34. Inspecting the Rotating Link Adapter and Load Stem
5-53
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SM00856
Page 5-54 of 98
Assembling the Rotating Link Adapter
1. Orient the stem so the drive stem flange is down on a suitably protected surface.
2. Install the gear with its rotating seal and wiper in place.
3. Install the O-ring for the piston ring.
4. Install the piston ring by tapping on it lightly with a mallet to press it into place (heat
to 220-250°).
5. Install the retainer ring.
6. Install all of the rotary seals on the rotating link adapter, and an O-ring on the top
surface.
7. Install the two wear bushings and the thrust ring in the rotating link adapter.
8. Rest the rotating link adapter on its bottom surface.
9. Clean and then lubricate (with hydraulic oil) the sealing surface of the stem and the
inside diameter of the rotating link adapter.
10. Attach three lifting slings symmetrically through the holes on the top of the stem
flange and slowly lower the assembly into the rotating link adapter body. Hammering
with a large plastic mallet is an aid when assembling the stem to the link adapter.
Make sure the seals do not twist in the grooves.
11. Install the gear onto the link adapter and install the bolts.
12. Pressure test each port at 1,000 psi and inspect for leaks at the adjacent ports.
13. Grease all lubrication points on the assembly.
14. Inspect the lower gearbox seal (located inside the stem flange), and replace as
necessary.
Installing the Rotating Link Adapter (while the top drive is in the mast)
1. Check the condition of the main shaft wear ring and replace if there is any evidence
of grooving.
2. Place the rotating link adapter assembly back on the support built over well center,
orienting the assembly so that the stem flange is up, and so that the index mark
faces forward.
3. Carefully lower the top drive to engage the main shaft in the stem bore and then the
stem flange pilot diameter is in the main body bore.
4. Install the flange bolts.
5. Install the link tilt cylinders, pin, and secure in place.
This procedure continues on the next page.
5-54
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SM00856
Revision D
Page 5-55 of 98
Maintenance 5
Installing the Rotating Link Adapter (while the top drive is in the mast), continued
6. Install the link tilt crank and pin, and secure in place.
7. Install all hose assemblies.
8. Install tubing.
9. Install the shot pin assembly.
10. Fill the gearcase with gear oil (see the Lubrication section of this chapter).
11. Check and fill the hydraulic oil as necessary.
12. Turn on the top drive and perform all pipe handler functions several times, checking
for proper function and any leaks.
13. Re-check the hydraulic oil level and fill as necessary.
!
Always install a new main shaft seal and use care not to
damage the seal or the case.
A light coating of grease applied to the O-ring helps in

installing the rotating link adapter assembly into the main
body.
!
Always install a new drive stem O-ring and use care not to
damage the O-ring or the case.
5-55
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Page 5-56 of 98
Nondestructive Examination
Yearly (or after approximately 3,000 operating hours), perform a Nondestructive Examination
(NDE) of all critical load path items. NDE inspection includes visual examination, dye penetrant
examination, magnetic particle inspection, ultrasonic inspection, x-ray examination, and other
methods of nondestructive testing for metallurgical integrity.
Making Visual Inspections

Use calipers on a regular basis to measure the amount of wear on the elevator link eyes. Compare
the measurements with the information provided in the Links User Manual (D635000870) to
determine the current strength of the elevator links. The capacity of the links equals the capacity of
the weakest link.
Magnetic Particle Inspection (MPI)

Every five years, NOV recommends that customers inspect all top drive hoisting equipment using
the wet fluorescent method of Magnetic Particle Inspection (MPI). Refer to the documentation
listed in the following section before beginning the MPI for any equipment component.
Refer to the following standards that define the use of the wet fluorescent method of MPI when
examining machined surfaces for any equipment component.
 ASTM A-275, Standard Method for Magnetic Particle Inspection of Steel Forgings
 ASTM-E-709, Standard Recommended Practice for Magnetic Particle Inspection
 I.A.D.C., Drilling Manual
 API RP 8B, Recommended Practice for Procedures for Inspection, Maintenance,
Repair and Remanufacture of Hoisting Equipment
 API 8C, Specification for Drilling and Product Hoisting Equipment (provides MPI
inspection acceptance criteria)
Any indications found are a potential cause for replacing one or more of the following:
 Main shaft (lower portion)
 Bail
 Split Load Collar
 Upper and lower IBOP
 Link adapter
 Saver, crossover, and spacer subs
 Power subs
 Power swivels
 Elevator links
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Maintenance 5
The drilling operator may determine that the MPI schedule should occur more frequently, based on
one or more of the following factors:
 environment
 load cycles
 regulatory requirements
 operating time
 testing
 repairs
Please contact your NOV Service Center if you have any questions.
Ultrasonic Inspection
In addition to the MPI, NOV also recommends performing an ultrasonic Inspection of the
previously listed components to detect any erosion of the inside diameter. Any erosion reduces the
load carrying capability of the part. Any subsurface irregularity can also compromise a
component’s integrity.
Details on Ultrasonic Inspection procedures are in the publication:
ASTM A-388 Std. Practice for Ultrasonic Examination of Heavy Steel Forgings
IBOP Inspection
Upper and lower IBOP valves, because of their internal grooves and shoulders, are particularly
susceptible to corrosion fatigue cracking. These internal diameter changes act as stress risers for
bending and tensile loads. It is especially important to properly inspect the IBOP valves on a
frequent basis.
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Recommended Lubricants and Fluids

Refer to Recommended Lubricants and Fluids (D811000719) in the equipment User Manual for
recommended lubricants and hydraulic fluids for NOV drilling equipment.
The lubrication intervals described in this manual are based on lubricant supplier
recommendations. Severe conditions such as extreme loads or temperature, corrosive
atmosphere, and so on, may require more frequent lubrication.
Worn bushings, binding parts, rust accumulations, and other abnormal conditions indicate more
frequent lubrication is necessary.
Lubrication Schedules
!
Replace the gearbox oil in new units after initial break-in
(the first month of operation). New units can contain metal
contaminants and contaminants caused by initial break-in.
!
Do not over-lubricate parts. Over-lubricating a fitting can
cause a bearing seal to pop out. Over-lubricated parts may
also drip, creating a slipping hazard.
The following service intervals are based on average

operating conditions. More frequent service intervals are
required if you operate the equipment in conditions where
excessive load, dusty or corrosive operating atmosphere,
or extreme temperatures occur.
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Maintenance 5
Unless otherwise specified, use general purpose grease to

lubricate top drive components. Refer to Recommended
Lubricants and Fluids (D811000719) in the User Manual.
Daily
Lubrication Page Number
 Standard washpipe (twice daily) (one place)

Note: If installed, the optional NOV mechanical washpipe does
not require daily lubrication. Refer to the NOV Mechanical page 5-62
Washpipe Service Manual for maintenance information
(D811000200-PRO-001 in the User Manual).
 Upper bonnet (main body) seal: If a grease fitting is installed

in the location shown in Figure 5-35, lubricate the upper
bonnet seal daily. page 5-62
Note: If a pipe plug is installed in this location, do not
lubricate daily (refer to the six-month lubrication schedule).
 IBOP actuator yoke and cylinder pins page 5-63
 IBOP actuator cranks page 5-63
 Stabilizer liner page 5-63
 Clamp cylinder gate page 5-63
Weekly
 Bail pins (2 places) page 5-62
 Rotating link adapter gear page 5-62
 Rotating link adapter (2 places) page 5-62
 Shot pin assembly page 5-51
 Upper IBOP valve (1 place) page 5-63
 Torque arrestor at clamp cylinder page 5-41
 Elevator link eyes (4 places) page 5-63
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Monthly
 After the first month of initial break-in: Replace the gearbox

oil. New top drives can contain metal contaminants and other page 5-65
contaminants caused by initial break-in.
 Traveling Block Sheaves (3 places)

Refer to the Traveling Block Supplement (10668162-MAN)
for additional block maintenance information. This manual is
Every Three Months

 Replace the top drive lubrication system filter, the top drive
hydraulic filter, and any hydraulic filters supplying hydraulic
page 5-65
system pressure to the equipment (optional NOV HPU or
other hydraulic system).
 Lubricate the AC drilling motors (4 places) page 5-66
 Lubricate the AC blower motors (4 places) page 5-66
 Lubricate the hydraulic pump AC motor (2 places) page 5-66
Use Chevron Black Pearl® EP2 motor grease (do not substitute) to lubricate AC
motors. NOV recommends that the rig electrician lubricate all AC motors.
Every Six Months

 Upper bonnet (main body) oil seal: If a pipe plug is installed

in the location identified in Figure 5-35, lubricate the upper
bonnet seal every six months. Remove the pipe plugs (front
and rear) and install a grease fitting and relief fitting. Replace page 5-62
plugs after lubricating the seals.
Note: If a grease fitting is installed in this location, lubricate
daily (see daily lubrication schedule).
 Landing collar (1 place). Use Jet Lube™ Arctic™ extreme

page 5-26
service grease.
 Guide beam (grease running surfaces) (12 places)
 Replace the lubrication system oil (and filter element). page 5-65
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Maintenance 5
Every Six Months
 Perform an oil analysis. Oil viscosity should be adjusted based on the expected
ambient conditions for the next six months.
 Perform a hydraulic system oil analysis. (If oil analysis recommends it, replace the
hydraulic fluid; otherwise, change hydraulic fluid once a year.)
Yearly and As Required

 Replace the hydraulic fluid used by the top drive equipment. page 5-80
 Remove, clean, and replace the magnetic drain plug. page 5-65
 Every Two Years – Replace the hydraulic reservoir bladder. page 5-74
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Lubrication Procedures
General Lubrication
The NOV Mechanical Apply general purpose

washpipe (if installed) grease to designated
does not require daily grease fittings with
lubrication. grease gun. Use a brush
when greasing other parts.
Daily
Standard
Wash Pipe
Assembly
Apply one pump
twice daily
Upper Bonnet Seal

One pump
Use Hand Pump Only
Weekly
Upper Bonnet Seal
Bail Pins (2) lubrication frequency
Two pumps each side can vary based on
component design.
See lubrication
schedule for details.
Weekly
Rotating Link
Adapter Gear Weekly
Brush with grease
Rotating Link Adapter
Three pumps each
Figure 5-35. General Lubrication (1 of 3)
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Maintenance 5
General Lubrication
Apply general purpose grease to

designated grease fittings with
grease gun. Use a brush when
greasing other parts.
Daily
IBOP Actuator Yoke
One pump each side
Daily
IBOP Actuator Cranks
One pump each side
Daily
Weekly Stabilizer Liner
One pump each side
Upper IBOP Valve
Remove 1/4" NPT plug,
install grease fitting
Apply ten pumps Weekly
Replace Clamp Cylinder Gate
! plug before
operating
One pump each side
Daily Weekly
Stabilizer Liner Elevator Link Eyes
One pump each side (4)
Pipe Dope
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General Lubrication
Apply general purpose grease

to designated grease fittings
with grease gun
Weekly
Guide Rollers
4 Places
One pump each
(if equipped)
Weekly
Guide Rollers
16 Places
One pump each
(if equipped)
Weekly
Bogies
4 Places
One pump each
(if equipped)
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Maintenance 5
Gearbox Lubrication
Cork Ball
(Level Sight
Indicator) Glass
Gearbox
Oil Drain
Gear Oil
Sight Gauge
Check with Top Drive
“OFF” Replace gear oil every
6 Months
Gearbox Oil Fill
Clean area before
removing plug, then
use a 1 3/8 inch, 12 point
socket to remove plug
“Pop-up”
Dirt Procedure
Alarm
Check oil level, prior to adding oil
(do not mistake the tan colored
foam for the dark brown oil)
Make sure the unit is turned OFF
Gear Oil Filter The area must be wiped clean
Replace every prior to adding gearbox oil
3 Months Recheck oil level and replace the
plug after adding oil
Run the unit and recheck the oil
Yearly
level (not foam level), after the
Magnetic Drain Plug unit has been running and the
Remove and clean contamination transmission oil is warm
Figure 5-38. Gearbox Lubrication
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Motor Lubrication
! Grease Fittings
NOV recommends that
the rig electrician Grease
lubricate all AC motors. Fitting
1/8 inch
!
3 Months Pipe Plug
1/8 inch
AC Blower (remove and
Motor (2) reinstall after
3 pumps lubricating)
(2 grease fittings
each motor)
As Viewed From Below
3 Months
AC Drilling
Motor (2)
5 pumps
(2 grease fittings
each motor) 3 Months
Hydraulic Pump AC Motor
3 pumps
(2 grease fittings)
Procedure
Remove the lubrication point plug
Install a grease fitting
Grease with a hand pump only
Re-install the plug
Apply motor grease
to designated
grease fittings
with hand grease gun
Figure 5-39. Motor Lubrication
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Maintenance 5
Hydraulic System Maintenance

Overview
The hydraulic control system is a completely self-contained, onboard system. A 10-horse power,
1800 rpm, AC motor, drives two hydraulic pumps and powers the hydraulic system. A fixed
displacement pump drives the lube oil system motor. A variable displacement pump provides
hydraulic power for the AC motor brakes, powered rotating head, remote actuated IBOP, pipe
backup clamp cylinder, link tilt, and counterbalance system. Three hydro-pneumatic accumulators
are located on the main body.
The hydraulic manifold attaches to the main body and contains solenoid, pressure and flow control
valves.
A sealed stainless steel reservoir supplies hydraulic oil, eliminating the need for draining and
refilling during normal rig moves. The reservoir is mounted between the AC drilling motors and is
equipped with strainers and an oil level sight gauge.
The hydraulic system diagrams provided in this section are

for reference only. Refer to the engineering hydraulic
schematics provided in the Technical Drawing Package
(TDP) for rig-specific schematics.
Refer to Appendix A, titled "Hydraulic Symbols" for a

description of the hydraulic symbols used in the schematic
diagrams shown in this section.
General Inspection Schedule

 Check the condition of the hydraulic filter indicator. page 5-73
 Check hydraulic fluid levels. page 5-73
 Check for hydraulic fluid leaks.
 Check the condition of hydraulic hoses.
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Location of Hydraulic Components
Specifications
Pump Motor 10 hp, 1,800 rpm, AC motor

Reservoir Capacity 25 gal
Hydraulic Oil Filter

Page 5-73 Counterbalance
Manifold
Counterbalance Page 5-88
Accumulator
Page 5-77
Upper IBOP Time- Main Hydraulic

Delay Accumulator Manifold
Page 5-77, -78 Page 5-76
Hydraulic Oil Fill Link Tilt

Page 5-81 Manifold
Page 5-95
Oil Pressure
Switch
Page 5-79 Link Tilt
Cylinders
Page 5-95
System Counterbalance
Accumulator Cylinders
Page 5-77 Page 5-88
IBOP Pressure
Switch
Hydraulic Oil
Page 5-79
Reservoir
Page 5-74
Upper IBOP
Actuator Cylinder
Page 5-77, -78 Rotating Head
Front Motor and
Shot Pin
Assembly
Rear Page 5-93
10 HP AC
Motor and
Front
Pump Assembly
Page 5-83
Rear
Figure 5-40. Hydraulic System Major Components
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Maintenance 5

System Diagram
Drilling Upper IBOP Link Tilt Pipehandler

Motor Brake Actuator Cylinder Cylinders Clamp Cylinder
Link Tilt
Counterbalance Manifold
Accumulator
Rotating Head
(Elevator Positioner)
Counterbalance Shot Pin Rotating

Cylinders Cylinder Link Adapter
Lift
Rotating
Head Gearbox Lube
Motor Oil Distribution
Pre-Fill Valve
Manifold
Main Hydraulic Manifold
Low Speed Lube Oil

Hydraulic Pump
Motor
Upper IBOP System

Time-Delay Accumulator Gearbox Sump
Accumulator
M
Variable Fixed
10 HP A.C. Displacement Displacement
Motor Pump Pump (Mtr. Lube) Hydraulic
Reservoir
Figure 5-41. Hydraulic System Diagram
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Precautions
To avoid serious injury or death, read and understand the following precautions before performing
inspection and maintenance procedures.
Properly lockout the main power source before

performing lubrication, inspection, or replacement
procedures, unless specifically noted in this manual.


moving.

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Maintenance 5

Precautions
Always discharge the three hydro-pneumatic

accumulators before performing repairs on the
hydraulic system.

Release all hydraulic oil pressure by bleeding

accumulators before disconnecting hydraulic lines.
Turn the counterbalance valve to shutdown mode to
bleed the hydraulic system. Hydraulic oil under
pressure can penetrate skin and cause serious injury.
Before opening the hydraulic system, thoroughly clean

work area, and maintain system cleanliness by
promptly capping all disconnected lines. Dirt is
extremely harmful to hydraulic system components
and can cause equipment failure and subsequent
injury to personnel.
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Precautions
Hydraulic fluid escaping under pressure can penetrate

the skin causing serious injury. Avoid injury by
discharging the three accumulators and relieving
pressure before disconnecting hydraulic lines. Always
search for hydraulic leaks with a piece of cardboard or
wood-not with your bare hands. Get immediate
medical attention for hydraulic fluid injuries. Fluid
injected into the skin must be surgically removed
within a few hours or gangrene may result. Do not
tighten hydraulic fittings while they are under
pressure.
!
Inspect the hydraulic system daily for leaks at fittings,
damaged hose covers, kinked or crushed hoses, hard or
stiff hoses, and damaged or corroded fittings. In addition,
during the inspection, tighten or replace any leaking port
connections, and clean any dirt build-up from hydraulic
components. Use care when handling components to
prevent nicking close tolerance finishes.
Replace worn or damaged hydraulic system

components immediately.
!
Inspect the hydraulic fluid level in the hydraulic reservoir
located between the AC drilling motors daily. Inspect the
hydraulic filter located on the upper left AC drilling motor
daily.
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Maintenance 5

Inspection
Hydraulic Fluid Level and Indicator
Cork Ball
(Level Indicator)
Daily
Red
“Pop-up”
Sight
Dirt Alarm
Glass
Hydraulic
Oil Sight
Gauge
Hydraulic
Oil Filter
See the Lubrication

section for fluid
replacement
instructions
Procedure
Check the red “pop-up” alarm on the hydraulic
filter daily
Replace the filter if the indicator has popped
up or as recommended
Use care to prevent contamination from
entering the hydraulic system during
maintenance activities
Figure 5-42. Inspecting the Hydraulic Fluid Level and Indicator
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Inspection
Hydraulic Reservoir Bladder (Yearly)
Reservoir
! Hydraulic Oil
Never put oil in the reservoir Reservoir
Breather bladder. Add oil at the Between AC
hydraulic oil fill only. Drilling Motors
Reservoir
Cover
Apply gasket
sealing compound
to prevent leaks
Yearly
Reservoir Bladder
Check for wear and damage
Gasket
Front
Apply gasket Rear

sealing compound
to prevent leaks
Hydraulic Oil
Reservoir
Procedure
Drain hydraulic fluid and clean area before
inspecting the reservoir bladder
Remove the 10 cap screws and lock washers
from the cover
Remove cover with bladder attached
Check the bladder yearly for wear or damage
Replace the bladder every two years
Replace the bladder if fluid is found inside or
if fluid escapes the reservoir breather when
the top drive is on its back
Figure 5-43. Inspecting the Hydraulic Reservoir Bladder (Yearly)
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Maintenance 5

Inspection
Heat Exchanger
Blower and
Brake Covers
Monthly
Oil Heat
Exchanger
Remove any dirt
and inspect for leaks,
corrosion, and cleanliness
Drill Motor
Assembly
Left side
Figure 5-44. Inspecting the Heat Exchanger
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Inspection
Using the Hydraulic System Ports
Stand Jump Brake Clamp/

SV9 SV1 P1 Shot Pin Float
Link
IBOP SV5 SV8 Tilt
L4 PV PF * B8
SV4 SV6
A4 G5
CB
* SA
* P
* T1
C4
A6
SV2
C5
Rotating B6
Link B5
Adapter
B9 * These test ports are on sides
Z1 B1 or bottom of manifold.
As Viewed From Below
Figure 5-45. Using the Hydraulic System Test Ports
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Maintenance 5

Inspection
Precharging the Accumulators
Accumulator Setting Port
System Accumulator (125-cubic inch displacement) 800 psi precharge SA

Counterbalance Accumulator (728-cubic inch displacement) 900 psi precharge CB
Time-Delay Accumulator (30-cubic inch displacement) 800 psi precharge C4
Bleed the accumulator if the pressure is higher, or add

nitrogen if the pressure is lower than specified above
Accumulator
Charging Assembly
Counterbalance
Accumulator
Upper IBOP
Time- Delay
Accumulator
Hydraulic
System Manifold
Accumulator (Reference)
Procedure
Disconnect the hydraulic lines to the accumulators
and drain them of all hydraulic fluid
Front
With the hydraulic system shut down, and the
counterbalance mode valve in the “shut down”
position, test the hydraulic pressure at CB, SA and Rear
C4 on the hydraulic manifold, mounted to the
transmission housing
Verify that all three points measure 0 psi
Note that there is a time delay in pressure decay

on port C4
Test the precharge pressure on the three

nitrogen-filled accumulators
Figure 5-46. Precharging the Accumulators
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Inspection
IBOP Timing Circuit
IBOP Actuator Cylinder

2.500" Dia. Bore X 2.00" Stroke
1.750" Dia. Rod Hydraulic
Cylinder
Open
Close
Time-Delay
Accumulator
30 Cubic Inches
800 PSI Precharge
Gas Charged
Accumulator
(Small)
Rotating
Link Adapter
-6
-6
A4 B4
A4 B4
-6
-6
IBOP Close Solenoid

(Solenoid Valve 4)
Double Solenoid Valve IBOP Close
Cable ID
A B
Number
b
C04
P T
-6
-6
-6
A4 SV4 B4 C4 Manifold Assembly
D03
500 PSI CV4

D4 Flow Control
1 T-11A Valve
3 1 2
T-11A
2 3
PC4
System
Tank
Pressure
Figure 5-47. Inspecting the IBOP Timing Circuit
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Maintenance 5

Inspection
IBOP and Oil Pressure Switch
Hoses
Inspect for wear
or damage.
Replace yearly
or as required.
Yearly
IBOP Pressure Switch Oil Pressure Switch

Configuration Configuration
Pressure
Adjusting Screw
Yearly
Wires
Inspect for wear
or lose connections.
Component Setting
IBOP Pressure Switch Factory preset at 1500 psi (102.0 BAR) rising
+0
Oil Pressure Switch Factory preset at 10.0 -1.0 psi decreasing
Figure 5-48. Inspecting the IBOP and Oil Pressure Switch
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Lubrication
Before disconnecting hydraulic lines, release all

hydraulic oil pressure by bleeding accumulators. Turn
the counterbalance valve to shutdown mode to bleed
the hydraulic system. Hydraulic oil under pressure can
penetrate skin and cause serious injury.

the work area. Maintain system cleanliness by
!
Use care when handling components to prevent nicking
close tolerance finishes.
!
Use care to prevent contamination from entering the
hydraulic system during maintenance activities.
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Maintenance 5

Lubrication
Adding Hydraulic Fluid
Procedure
The area must be clean prior to adding
hydraulic fluid Reservoir
Remove dust plug from the male quick capacity is
disconnect at the TDS hydraulic oil fill 25 gallons
Remove dust plug from the female quick
disconnect on the lubrication kit and connect
it to the male fitting Cork Ball
Pump fluid until the level reaches the middle (Level Indicator)
of the sight glass as shown
After adding fluid, replace the dust plugs
Red Sight
"Pop-up" Glass
Dirt Alarm
Hydraulic
Replace every Oil Sight
Gauge
3 Months
Hydraulic
Oil Filter
Hydraulic Oil Fill

Male Quick Disconnect
Replace
hydraulic fluid
Yearly
or earlier based
on oil analysis
Dust Plug
Female
Quick
Disconnect
Hydraulic
Hydraulic
Oil Drain
Lubrication Kit
55 gal Drum
Figure 5-49. Adding Hydraulic Fluid
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Lubrication
Draining Hydraulic Fluid
Precautions
Hydraulic fluid may be hot
Use care when opening the valve
Avoid spills
Holds 25 gallons
Pump
Valve
Inlet/Drain
Handle
Adapter
10 HP AC
Pump Motor
Procedure
Isolate power to the pump motor Fixed
Ensure that the valve is closed Displacement
Pump
Remove the plug and attach a hose
Open the valve and drain the fluid
Close the valve and remove the hose Variable
Displacement
Replace the plug Pump
Figure 5-50. Draining Hydraulic Fluid
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Maintenance 5

Setting Up Hydraulic Circuits
Hydraulic Pumps and Unloading Circuit
There are two pumps – a fixed displacement pump runs the
transmission lubrication system and a variable displacement pump
provides hydraulic flow to the hydraulic system.
Pump Pressure
Compensator
Adjustment Point
Guide Beam Pump/Motor
Variable Fixed 10 HP AC
Displacement Displacement Pump Motor
Pump Pump
Figure 5-51. Hydraulic Pumps and Unloading Circuit
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Fixed Displacement (lube) and Variable Displacement Pumps
!
Make sure the top drive is properly filled with hydraulic fluid
and lube oil before performing this procedure. Also make
sure the Rig-Up/Shutdown valve is in the SHUTDOWN
position.
1. Locate the tube connecting manifold port PF to the lubrication motor. Disconnect the
tube at the manifold end, cap the tube and plug the PF port using steel fittings.
2. Set the relief valve RV1 for the variable displacement pump to a minimum setting,
fully counterclockwise, which allows the hydraulic system to operate without building
up pressure, and turn the motor off.
3. Set the relief valve RV2 to minimum pressure, fully counterclockwise.
4. Jog-start the electric motor to make sure the direction of rotation is correct
(clockwise when looking into pump shaft/ electric motor fan). Correct as required.
5. Start the electric motor and allow both hydraulic pumps to circulate oil. Listen for
unusual noises that would indicate cavitation; check for leaks.
6. Connect a gauge to test point PF. Increase the pressure by adjusting relief valve
RV2 clockwise until the pressure increases to 400 psi at test point PF. Set the jam
nut on RV2. A steel cap is installed over the adjustment screw to discourage
unauthorized adjustment.
!
While adjusting valves, verify a linear relationship between
turning the adjustment screw and observing the pressure
change.
7. Turn off the electric motor. Reconnect the tube between manifold port PF and the
lubrication motor.
8. Connect an ammeter to the electric motor. Note the full-load amps on the motor
nameplate.
9. Restart the hydraulic system electric motor.
10. Set the counterbalance mode valve to the RUN position.
11. Adjust UV1, fully clockwise, to maximum pressure.
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Maintenance 5

12. Connect a gauge to test point PV. Note the ammeter reading while RV1 is at
minimum setting.
13. Raise the setting of relief valve RV1 from 0 psi to 1,500 psi at a steady rate. During
the pressure rise, observe the ammeter. The motor current should rise to a
maximum value at 800 psi, then drop off and begin to rise again. The point where
the current drops is the pump pressure compensator setpoint.
14. Adjust relief valve RV1 to its minimum setting. If maximum motor current does not
occur at 800 psi, adjust the pump pressure compensator as required.
15. Adjust relief valve RV1 again from 0 psi to 1,500 psi, and back to 0 psi to verify
maximum motor current at 800 psi.
16. Connect a gauge to test point SA, and leave the gauge on PV.
17. Adjust relief valve RV1 to 2,200 psi and secure the jam nut.
18. Install steel cap over the adjustment screw to discourage unauthorized adjustment.
19. Adjust unloading valve UV1 counterclockwise until the pressure at PV drops off,
then an additional two turns counterclockwise. The pressure cycles like a sawtooth
wave.
3000 Pressure at PV
Pressure at SA
2000
Pressure 1700
(psi)
1000
800
150
0 10 20 30 40 50 60
Approximate Time
(seconds)
Figure 5-52. Pressure Cycle Graph
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20. Observe the unloaded pressure at PV (about 0 psi) while SA reads about 2,000 psi.
The pressure at SA decays until UV1 reloads. After reloading, the pressure rapidly
rises to the unload pressure.
21. Observe several unload-reload cycles to determine the unload pressure.
22. Adjust the setting of UV1 as required to a 2,000 psi unload pressure.
!
Perform the adjustment with reasonable speed. The
process takes no longer than two minutes. Taking longer
increases the temperature of the hydraulic fluid.
23. Observe the cycle of loading and unloading of the relief valve. To verify the setting of
UV1, note the difference in pump noise level between the loaded and unloaded
condition.
RV2 RV1
CB6 CA6 CV5
CV4
A2
B2 CDR CV1
PC1 RV1
LC5 RV2 PCC
LB6 LA6 T1
T1
B1
C5 A2 B2
Manifold
Side View
Manifold
Manifold End View
Bottom View B6 A6 DR Z1
P
TF
B5 B4
B5 C5 B9
TR
T1
SA
CTR
SA
SV5
B1
B4 SV2 SV1 SV9 CV2
G6 E6 E5 PV
P5
C4
B8
PF
CB
SA
RIG-UP
UV1
G5 SV4 PF
COUNTERB NCE MODE
RUN
P/N 0181
PV
XC
MV
SHUTDOWN
DF
UV1
PF
Figure 5-53. Pump Setup Manifold Ports
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Maintenance 5

Manifold Assembly
T-21A 4 UV1 2200 PSI

2 T-10A
2 RV2
3
T-11A
3 1
2000 PSI Z1
1 400 PSI
1 2
RV1
PV PF
800 PSIG
Variable Displacement
Pump-Motor Assembly
B
1.00 IN^ 3/REV.

L
Fixed
1.10 IN^ 3/REV. MAX. Displacement
.50 IN^ 3/REV. MIN. Pump
L1
S
Figure 5-54. Pump Setup Circuit Diagram
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Counterbalance Circuit and Stand-Jump Circuit
1. For the counterbalance circuit there are three adjustments:
 Relief valve (on counterbalance cylinder)
 PCC – operator set
 SJR – operator set
2. To set the relief valve, make sure the pumps are operating.
3. Adjust pressure reducing valve PCC to the maximum setting, fully clockwise.
4. Connect a gauge to test port CB.
5. Adjust the cylinder-mounted relief valve to mid-scale to lower the pressure setting.
6. Increase the pressure clockwise using a 5/32 in. Allen wrench and 9/16 in. open-end
wrench.
7. Observe the relationship of turning the relief valve adjustment clockwise to pressure
increase.
8. When the relief valve reaches system pressure, turn the setting one full turn
clockwise beyond the setting and set the jam nut.
9. Install a steel cover over the valve.
10. Adjust PCC to 1,200 psi.
11. Measure pressure at test port CB.
12. Prepare the hardware to attach the cylinder pear links to the hook.
13. Rotate the counterbalance mode valve from the RUN position to RIG-UP position.
This causes the counterbalance cylinders to slowly extend.
!
Cylinders stroke to the end of stroke with the mode valve in
the RUN position.
14. Once cylinders reach end of stroke, attach hardware to the pear links on the hook.
15. Rotate the counterbalance mode valve back to the RUN position.
16. Adjust PCC counterclockwise to raise the pressure at test port CB until the rail just
begins to lift off of the hook.
17. Reduce the pressure slowly (25 psi) to allow the pressure to stabilize.
18. Rotate the counterbalance mode valve to the SHUTDOWN position to bleed down
counterbalance cylinders and system accumulator before shipping or performing
maintenance.
19. Adjust pressure reducing valve PCC counterclockwise until the bail rests on the
hook. Note the pressure at CB.
This procedure continues on the next page.
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Maintenance 5

20. Reduce PCC an additional 25 psi. The pressure at CB is about 1,600 psi.
21. Connect a gauge to test point B9. Activate the STAND JUMP mode on the drilling
console. Adjust relief valve SJR until the bail lifts off the hook. The gauge at B9
should read about 190 psi.
22. Switch back to DRILL counterbalance mode and observe the pressure at test point
CB.
23. Switch back to STAND JUMP mode and observe the pressure CB increase by 200
psi.
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PCC
CB6 CA6 CV5
CV4
A2
B2 CDR CV1
PC1 RV1
LC5 RV2 PCC
LB6 LA6 T1
T1
B1
C5 A2 B2
Manifold
Side View
Manifold
RIG-UP/SHUTDOWN End View
Manifold Valve
P
TF
B5 B4
B5 C5 B9
CTR
SA
TR
T1
SV5
B1
B4 SV2 SV1 SV9 CV2
G6 E6 E5 PV
P5
CB
SA
C4
B8
PF
UV1
RIG-UP
G5 SV4 PF
COUNTERB NCE MODE
1
RUN
P/N 0181
XC
PV MV
SHUTDOWN
DF
CB
Manifold
Side View SJR
D4 A4 PC5 AR5
CV3 PC4 D1
SJR P1
PF
A8
PV
A4 A5
D5
C4
CB G5 DF
2
Figure 5-55. Counterbalance Setup Manifold Ports
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Maintenance 5

Pressure 1500 PSI
Relief Valve T-3A 1
-4 2
ZC CP
OR1 OR2
CP -12
.075ø .075ø
75 PSI 75 PSI
1 2 1 2 CP -12 Counterbalance Cylinders
T-13A T-13A 2.000" Dia. Rod
CV1 CV2 -12
T
-12 Counterbalance
Normally-Open Accumulator
T
.010ø Logic Cartridge 728 Cubic Inches
Metering 900 PSI Precharge
T -16
5 PSI
-6
XC 90 PSI
25mm
Prefill Cable ID Stand Jump Solenoid
Valve Number (Solenoid Valve 9)
.047ø
Counterbalance Mode Stand

Jump 2 Position
Rig-up Shut-down Valve
Run
A B A B
b
C09
P T P T
-6
3 Position D03 MV .055ø CB SV9 Manifold Assembly

Valve with D03
XC
Detent
CV3 Test
B9
75 PSI 1 Port
T-21A 4 B9
CB
3
CDF 2 Pressure
4 PSI 1 Relief
T-10A
DF 2 1 1 Valve
SJR
PCC 4
T-13A 2 200 PSI
T-21A
System DF 2 3
Accumulator
126 Cubic Inches
800 PSI Precharge 2 1
System Pressure
TF CTF
T-5A
30 PSI
SA To Tank
Figure 5-56. Counterbalance Setup Circuit Diagram
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AC Motor Brake Circuit
The AC drilling motor brakes are spring released and hydraulic pressure applied at 1,500 psi. The
pressure reducing valve regulates the pressure to 1,500 psi. The solenoid valve operates to apply
pressure, setting the brakes, or stop pressure to release the brakes.
To test the system, turn the auto brakes switch on the driller’s console to the ON position. Attach a
pressure gauge to B1 in the manifold. The pressure reading should be 1,500 psi. If the reading is
not 1,500 psi, adjust the pressure control reducing valve PC 1 to 1,500. Turn the auto brakes
switch to the OFF position. The pressure reading should be very low.
PC1
CB6 CA6 CV5
CV4
A2
B2 CDR CV1
PC1 RV1
LC5 RV2 PCC
LB6 LA6 T1
T1
B1
C5 A2 B2
Manifold
Side View
Manifold
TF
B5 B4
B5 C5 B9
TR
T1
SV5
B1
B4 SV2 SV1 SV9 CV2
G6 E6 E5 PV
P5
C4
B8
PF
RIG-UP
G5 SV4 PF
COUNTERB NCE MODE
RUN
P/N 0181
PV MV
SHUTDOWN
DF
B1
Figure 5-57. Motor Brake Setup Manifold Ports
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Maintenance 5

Shot Pin Circuit
1. Set the adjustable relief valve near the body of the cylinder. The shot pin often
misses the hole in the rotating gear. The force the shot pin exerts is limited until the
pin engages a hole.
!
The electrical system jogs the rotating head until the pin
engages a hole.
2. To limit the amount of force, you set the valve by operating solenoid valve SV5
manually, forcing the pin to stop on the face of the gear.
3. When the pin stalls out, measure the pressure at B5. Set the relief valve pressure to
400 psi.
4. Tighten the jam nut on the relief valve.
5. At rest, the SV5 valve is de-energized.
6. Test the pressure at C5. Adjust reducing valve AR5 to 1,000 psi.
Hydraulic
Drive Motor
SV5
C5
Link Adapter
Rotation Gear
Hydraulic Manifold
Shot Pin
View from Below
Simplified for Clarity
Figure 5-58. Setting up the Shot Pin Circuit (1 of 2)
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Shot Pin Circuit

Drive Motor and
Shot Pin Assembly
10 HP AC Motor
and Pump Assembly
(Simplified for Clarity) Hydraulic

Drive Motor
Motor
A
Relief Valve
B
Rotating Motor
Link Shot Pin Relief Valve
B5
Adapter Relief Valve
C5
Link Adapter
A5
Rotation Gear
Shot Pin
Figure 5-59. Setting up the Shot Pin Circuit (2 of 2)
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Maintenance 5

Link Tilt Cylinder Circuit
1. There is nothing to adjust on the manifold for the link tilt circuit.
2. Adjust the four load holding valves in pairs – the upper pair and lower pair. Adjust all
four counterbalance valves fully clockwise, then one turn counterclockwise.
If the valves are not adjusted correctly, link tilt operation is

not synchronized.
3. The correct pressure setting is 1,500 psi. The procedure is the same for both valves.
Adjust the valves one at a time.
4. There are two test points on the link tilt cylinder manifold.
5. From the driller’s console, move the link tilt to go to the mousehole position.
6. The cylinders go to full extension and the pressure at the test port C1 is 2,000 psi.
7. Command the link tilt to the OFF position and observe the pressure decay at C1.
This decayed pressure is the setpoint of the counterbalance valve.
8. Raise the valve setpoint by turning the adjusting screw 1/4 turn counterclockwise.
9. Repeat steps 6 and 7 until the decayed pressure is 1,500 psi.
This is an iterative process. Continue to set the driller’s

console control to the mousehole position and OFF, taking
present and decayed pressure readings.
!
Turning the counterbalance valve counterclockwise
increases the pressure.
10. Command the link tilt to the DRILL position and repeat the procedure above, using
test port C2 to set the counterbalance valve on the DRILL side.
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Rotating Link Adapter Hydraulic Motor Relief Circuit
1. Set the relief valves mounted on rotation motor.
2. Operate the clamp. The shot pin must go through the hole, which locks up the gear.
3. Turn the manual override on the SV2-rotation circuit to drive the head in the
counterclockwise direction. Test the pressure at A and adjust the relief valve to
1,700 psi.
4. Turn the manual override on the SV2-rotation circuit to drive the rotating head in the
clockwise direction and test the pressure at B. Adjust the relief valve to 1,700 psi.
Hydraulic
Drive Motor
Test Points
(3)
Motor
Relief
Valve
(2)
Link Adapter
Rotation Gear
Figure 5-60. Setting up the Rotating Link Adapter Hydraulic Motor Relief Circuit
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Maintenance 5
Control Console Maintenance
Inspect the console on a routine basis. Failure to

conduct routine inspections and maintenance may
result in equipment damage or injury to personnel.
The following is a general maintenance checklist.
Maintenance Checklist
Location Procedure Frequency
Test using the Alarm Silence / Lamp

Console Indicator Lamps Each time the top drive is assigned.
Check button on the console.
Heater Check operation with an Ohm meter. Monthly
Check fastener tightness, especially

Console mounting fasteners Monthly
in vibration-prone areas.
Check for integrity. Monthly

Enclosure seals and gaskets
Apply a light film of silicone lubricant. Every Three Months
 If the console enclosure is damaged or faulty, the enclosure should be returned to

an NOV Service Center or other authorized service facility for repair.
 If there is a faulty terminal or communication module, contact your NOV
representative, NOV Service Center, or authorized service facility for a replacement.
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Revision D
Troubleshooting 6
Introduction
This chapter provides guidelines to inspect and troubleshoot the components and circuits for the
TDS-11SA Top Drive.
!
All procedures and methods provided in this manual are
superseded by the procedures and methods approved for
use at the location where the equipment is installed and
commissioned.
There is no way to anticipate every issue that may be encountered. If the issue cannot be resolved
using the troubleshooting instructions, contact an NOV Service Center. A list of NOV Service
Centers is provided in the equipment User Manual.
For top drives using an Amphion™ control system, make

sure that all data cables are properly connected to the
single-board computer (SBC). Many issues can be
resolved by making sure these connections are working
properly.
Refer to the Maintenance chapter in this service manual for

specific maintenance procedures and other information
that may help you identify the cause of the issue.
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6 Troubleshooting Revision D
Page 6-2 of 22
Introduction
Personnel Qualifications
Personnel conducting the troubleshooting procedures should be experienced and thoroughly
familiar with this NOV top drive. The personnel conducting troubleshooting procedures must read
and understand the information in all equipment documentation as well as understand all the
functions of the top drive.
!
Follow the general system safety practices included in this
manual before troubleshooting or performing maintenance
on the top drive system.
!
Personnel troubleshooting the top drive must be
experienced and thoroughly familiar with its function,
operation and maintenance requirements.
Failure to follow safe work procedures could result in

serious or fatal injury to personnel, significant
equipment damage, and/or extended rig down time.
Troubleshooting Guidelines
NOV top drive hydraulic and electrical systems use standard components and follow industry-
standard design practices. For the hydraulic or electrical systems to function (produce flow at all
times and pressure when a load is present), the following basic operating conditions must be
present at all times:
 The hydraulic and lubrication pump(s) must be running and rotating in the correct
direction.
 There must be clean fluid and adequate fluid flow to the top drive.
 The temperature of the hydraulic and lubrication fluids must be in the correct range
to ensure the viscosity is not too high (low temp) or low (high temp). Refer to
Recommended Lubricants and Fluids (D811000719) in the equipment User Manual
for recommended lubricants and hydraulic fluids for NOV drilling equipment.
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Troubleshooting 6
Introduction
Troubleshooting Guidelines
 The hydraulic and electric circuits must be correctly connected and operable.
 The piping, hoses, and service loops must positioned properly and unobstructed.
Make sure all electrical and hydraulic lines and valves

are isolated before any work is started on top drive
hydraulics. Failure to follow safe work procedures
could result in serious or fatal injury to personnel,
significant equipment damage, and rig downtime.
Determining the Nature of Problem

When troubleshooting the top drive, determine the nature of the problem using the troubleshooting
tables, detailed theory of operation information for components, and diagnostic procedures.
Potential component failure for most top drives falls into the following three categories:
 Mechanical System components
 Hydraulic System components
 Electrical System components
 Lubrication and Cooling System components
Identifying Troubleshooting Categories

Potential top drive system failure typically falls into one or more of the following categories.
Mechanical Components
Mechanical problems are usually related to damaged or worn out parts. Another factor that can
contribute to mechanical failures is a lack of periodic preventive maintenance. Periodic inspections
and equipment maintenance must be completed to ensure proper mechanical operation.
Hydraulic System and Components

Hydraulic circuit and component problems are usually related to faulty valves, hydraulic actuators,
contamination, fluid leakage, or damage not related to maladjusted hydraulic circuit components.
Changes to adjustments should only be made after eliminating all other possible causes.
Electrical System and Components

Electrical system and component problems are usually related to faulty discrete control switches,
electrical supply voltage, and or improper interconnection wiring.
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Introduction
Identifying Troubleshooting Categories
Lubrication and Cooling System Components
Lubrication and cooling system problems are usually related to contamination, faulty discrete
control switches, faulty valves and dirty filters. Making changes to the flow rate, system pressure,
or other adjustments should only be completed after eliminating all other possible causes.
Make sure to have the hydraulic, electrical, and lubrication

engineering schematics available before troubleshooting
system problems. These schematics are located in the
Technical Drawing Package (TDP).
Pre-Troubleshooting Inspection
Complete the following steps before troubleshooting the top drive system:
1. Make sure the top drive is properly installed and positioned in the rig structure. If
troubleshooting the top drive prior to rig installation, make sure the top drive is
secure and the drill shaft is lifted clear from the floor.
2. Check that all hoses and quick disconnects are properly connected.
3. Check lubrication system pressure output (the unit must be upright).
!
Lubrication oil pressure is critical to the performance and
proper operation of the top drive. Oil pressure must be
carefully monitored and maintained. Failure to adhere to
this advisory may result in damage to the top drive.
4. Check the flow and maximum pressure of the NOV hydraulic power unit (HPU) or
customer-supplied hydraulic power supply.
5. Check the lubrication system and hydraulic system filters for dirt pop-up indicators.
6. Check whether hydraulic fluid leaks are visible at hydraulic components, hoses, and
quick-disconnect couplings.
7. Review the lubrication system maintenance information in the Maintenance chapter
in this manual.
8. Determine the nature of the problem using standard diagnostic methods, the
troubleshooting tables, maintenance information, and operating information for the
equipment.
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Troubleshooting 6
Introduction
Service Centers
When problems cannot be solved, contact an authorized NOV Service Center. For a directory of
NOV Service Centers, see NOV document number D811001337-DAS-001, titled “Service Center
Directory.” This document is located in the equipment User Manual.
www.nov.com/ContactUs/24HrEmergencyContacts.aspx
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Troubleshooting
HPU and Reservoir Bladder
Troubleshooting Table
Problem Probable Cause Remedy
Hydraulic system is overheating. Relief valves RV1 and RV2 are out Test pressure and adjust relief
of adjustment. valves.
Test and adjust UV1 or replace

Unloading valve is not working.
unloading valve.
Counterbalance mode valve left in

shut down position too long and Check system pressure.
pressure bleeds down.
No precharge in system
Charge system accumulator.
accumulator.
Hydraulic components do not First make sure the RIG-UP

operate. SHUTDOWN valve is in the correct
position. Test pumps and motors.
System pressure is down. Test relief valve pressures. Adjust
as required. Check for leaks, loose
fittings, loose cylinders, worn
hoses, fluid levels and seals.
Piston pump is not working. Replace the piston pump.
Flexible coupling is damaged. Replace flexible coupling.
Lubrication pump is not working. Replace the lubrication pump.
Pressure at UV1 is too low. Adjust pressure at UV1.
Pumps are rotating in the wrong Inspect hydraulic connections and

direction. correct rotation.
Suction valve closed. Open suction valve.
Low oil level in reservoir. Fill hydraulic reservoir.
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Troubleshooting 6
Troubleshooting
HPU and Reservoir Bladder
Schematic Diagram
PV PF TR DR Manifold Assembly
Hydraulic Fill
Disconnect
System
Pressure
6m
50 PSID
Prefill Valve
Pressure -12
Compensator T
Filter with
Control Bypass
T -16
800 PSIG Valve
-6
XC
B
1.00 In^ 3/Rev.
L
1.10 In^ 3/Rev. Max.

M .50 In^ 3/Rev. Min.
10 HP
1800 RPM 4 PSI
L1 Filter Vent
S
(Strainer)
Variable Fixed
Displacement Displacement
Pump Pump
Reservoir Assembly
Figure 6-1. HPU and Reservoir Bladder Schematic Diagram
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Troubleshooting
Counterbalance and Stand Jump
The accumulator, with precharge pressure of 900 psi, along with check valve CV3, maintains a
hydraulic pressure.
A three-position manually operated valve controls counterbalance operation for rig-up, run, and
shut down modes. In the rig-up mode, system pressure is applied to XC and the prefill valve,
causing both cylinders to extend. When the cylinders extend, you make up the mechanical
connection to the bail. In the run mode, for counterbalance operation, approximately 1,600 psi is
needed at the counterbalance cylinders to lift the TDS-11SA off the hook.
The optional stand jump feature is controlled by solenoid valve SV9. With the counterbalance in
the run mode and the stand jump switch on, additional pressure of approximately 300 psi is
applied to over the normal counterbalance pressure to lift the TDS-11SA and drill string off the
hook.
In the shutdown mode, the hydraulic system bleeds down the system accumulator and the
counterbalance accumulator pressure.
Counterbalance Testing
For the counterbalance operation, a lift of approximately 30,000 lb is achieved with a pressure of
1600 psi at CB. Perform the following steps to adjust the force:
1. Set the counterbalance mode valve on the bottom of the manifold to the RUN mode.
Set the pressure control valve PCC to the minimum setting (fully counterclockwise).
2. Test the pressure at port B9. There should be a 0 psi reading.
3. Test the pressure at port CB. Observe the position of the top drive on the hook.
4. Adjust the pressure at pressure control valve PCC clockwise, observing pressure at
CB, until the top drive just lifts off the hook. Back off the pressure 25 psi, as the top
drive rests on the hook.
Stand Jump Testing

For the optional stand jump feature, a lift of about 33,000 lb is achieved with a pressure of
approximately 1800 psi at CB. The additional 300 psi pressure over the normal counterbalance
pressure is provided by energizing the stand jump solenoid valve SV9. Perform the following steps
to adjust the pressure:
1. Set the counterbalance mode switch to RUN and engage the stand jump switch.
Test the pressure at port CB and B9. Adjust relief valve SJR fully counterclockwise
to the minimum setting.
2. Slowly increase the pressure at CB by adjusting relief valve SJR clockwise until the
bail lifts off the hook with a stand of pipe in the elevator.
Adjust relief valve SJR slowly to allow pressure at CB to

stabilize.
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Troubleshooting 6
Troubleshooting
Counterbalance does not Inspect cylinder and repair or

Cylinder damaged. Seal leaks.
function. replace seal.
Test pressure and adjust pressure

No hydraulic pressure.
reducing valve.
Test electrical and hydraulic

Solenoid valve SV9 is not
operation. Replace or repair as
operating.
applicable.
PCC is not operating. Replace the valve.
Relief valve is not operating. Replace the valve.
Precharge on the accumulator is

Charge the accumulator.
low.
Stand jump does not function. Inspect cylinder and repair or

Cylinder damaged. Seal leaks.
replace seal.
Test pressure and adjust pressure

No hydraulic pressure.
reducing valve.
Test electrical and hydraulic

Solenoid valve SV9 is no
operation. Replace or repair as
operating.
applicable.
PCC is no operating. Replace the valve.
Relief valve is not operating. Replace the valve.
Precharge on the accumulator is

Charge the accumulator.
low.
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Troubleshooting
Schematic Diagram
Pressure 1500 PSI
Relief Valve T-3A 1
-4 2
ZC CP
OR1 OR2
CP -12
.075ø .075ø
75 PSI 75 PSI
1 2 1 2 CP -12 Counterbalance Cylinders
T-13A T-13A 2.000" Dia. Rod
CV1 CV2 -12
T
-12 Counterbalance
Normally-Open Accumulator
T
.010ø Logic Cartridge 728 Cubic Inches
Metering 900 PSI Precharge
T -16
5 PSI
-6
XC 90 PSI
25mm
Prefill Cable ID Stand Jump Solenoid
Valve Number (Solenoid Valve 9)
.047ø
Counterbalance Mode Stand

Jump 2 Position
Rig-up Shut-down Valve
Run
A B A B
b
C09
P T P T
-6
3 Position D03 MV .055ø CB SV9 Manifold Assembly

Valve with D03
XC
Detent
CV3 Test
B9
75 PSI 1 Port
T-21A 4 B9
CB
3
CDF 2 Pressure
4 PSI 1 Relief
T-10A
DF 2 1 1 Valve
SJR
PCC 4
T-13A 2 200 PSI
T-21A
System DF 2 3
Accumulator
126 Cubic Inches
800 PSI Precharge 2 1
System Pressure
TF CTF
T-5A
30 PSI
SA To Tank
Figure 6-2. Counterbalance and Stand Jump Schematic Diagram
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Troubleshooting 6
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Troubleshooting
Motor Brakes
Brake does not release. Test the valve and replace if

Directional valve is stuck.
necessary.
Brake releases but still drags. Check valve is blocked or tube is Replace the check valve or tube as
pinched. required.
Mechanical problem with brakes. Repair brake mechanism.
Brakes do not engage or slip. Check for hydraulic leaks and

Hydraulic oil on brake pads.
repair.
Pressure is not 1,500 psi or does Reducing valve is plugged or

not rise crisply to 1,500 psi. needs to be adjusted or replaced.
Directional valve is stuck (check Replace valve or check electrical

pressure at B1). signal.
Delay in brakes actuating after Hydraulic oil is contaminated. Replace hydraulic oil.
console switch is turned on.
Pressure reducing valve is faulty. Replace valve.
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Troubleshooting 6
Troubleshooting
Motor Brakes
Schematic Diagram
Brake Calipers
2 Position
Solenoid Valve
Brakes On
Cable ID
Number
A B
b
C01
P T
-4
SV1 B1 Manifold Assembly

.071ø
D03
Non-Adjustable
Orifice
P1
Test Point
1500 PSI
PC1 1 T-11A
Reducing 2 3
Valve
System Tank Drain

Pressure
Figure 6-3. Brake Circuit Schematic Diagram
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Troubleshooting
Shot Pin Cylinder and Clamp Cylinder
Shot pin does not engage. Solenoid valve is not operating or Check electrical actuation and test
relief valve is not adjusted. pressure. Adjust as required.
Abnormal pressure change at B5

Replace directional control valve.
and C5 indicates a valve problem.
Normal pressure change indicates

Repair plumbing or shot pin
plumbing or shot pin cylinder are
cylinder.
faulty.
Shot pin applies excessive force Relief valve is not operating or is Test pressures and adjust as
to rotating head gear. out of adjustment. required.
Clamp cylinder does not No pressure or reduced pressure Test pressures and adjust and
actuate. at the cylinder. repair as required.
Inspect cylinder and repair or

Cylinder is damaged.
replace.
To provide high pressure

to the clamp circuit,
pressure at C5 must be
2,000 psi and G5 must be less than
100 psi. If this condition is met, Repair plumbing, rotating head, or
pressure at CP should increase clamp cylinder.
from less than 100 psi to higher
than 2,000 psi. If not, check the
plumbing, rotating link adapter, and
clamp cylinder.
While clamping, pressure at CR

should be 2.7 times the pressure at
CP. When the dies contact the
pipe, pressure at CR should be Clean or repair CNEC valve.
less than 100 psi. If the pressure
does not fade, check valve CNEC
for contamination.
Shot pin engages but clamp Check pressure at C5. Replace

cylinder does not activate. Control valve not operating. valve CV5 if required or the
regenerate manifold.
6-14
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SM00856
Revision D
Page 6-15 of 22
Troubleshooting 6
Troubleshooting
Shot Pin Cylinder and Clamp Cylinder
Schematic Diagram
Clamp Cylinder
8.000" Dia. Rod
Hydraulic Cylinder
Cavity Plug CP CR
1 3
Pilot-to-Close CKEB
T-2A
Check Valve 2
30 PSID
2 1
CNEC
Shot-Pin Cylinder 3 T-2A
2.000" Dia. Bore X 2.31" Stroke 1 T-5A
Relief Valve 1.500" Dia. Rod COFA
.047ø
Shot Pin 400 PSI 2 30 PSID

Cylinder 2x .094ø 2
VP VR
1
2 Position
T-10A Non-Adjustable
Solenoid
B5 C5 Flow Control
Valve 5
Clamp/Shot Pin
-8
-8
Clamp
E5 G5
Cable ID Rotating Link

A B
Number b E5 G5 Adapter Assembly
C05
-8
-8
P T
-6
-6
A5 SV5 B5 C5 E5 G5
D03
Pressure
.159ø T-11A 1
50 PSI .031ø Reducing
3 AR5 Valve
3
1 2
LC5 2
Logic .031ø 1000 PSI
T-11A
Cartridge
Externally-Drained
Pilot-to-Open
3 2 Valve
T-21A
4 75 PSI
CV5 1
P5
Drain 1
T-11A 3
System Pressure
PC5 2
Tank Drain
System Pressure
Tank
T1 T1 D5 Manifold Assembly
Figure 6-4. Shot Pin Cylinder and Clamp Cylinder Schematic Diagram
6-15
www.nov.com
SM00856
Page 6-16 of 22
Troubleshooting
Link Tilt Cylinders
Drill pipe elevator does not

reach mouse hole/derrickman Link clamp incorrectly adjusted. Readjust.
position.
Links drift when valve is Pressure at B8 does not decay to Replace the pilot to open check
released. less than 100 psi. valve.
Pilot to open check valve is stuck Replace the pilot to open check
open or contaminated. valve.
Faulty cylinder seal. Replace the seal.
Load holding relief valves are out

Adjust or replace the load holding
of adjustment, stuck open, or
relief valve.
contaminated.
Drill pipe elevator does not float Use manual override. If the link
back to center position. tilts, the problem is electrical. If the Test the solenoid and connectors.
links do not tilt, the problem is Test the hydraulic system.
hydraulic.
Link tilt does not tilt. Solenoid valve is not shifting. Check electrical continuity.
6-16
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SM00856
Revision D
Page 6-17 of 22
Troubleshooting 6
Troubleshooting
Link Tilt Cylinders
Schematic Diagram
Link Tilt Cylinder
1.380" Dia. Rod
Mousehole
Drill Down
C1 C1 C1 X1 C2 C2 C2
1500 PSI T-11A 1500 PSI T-11A

CV1
T-11A 1 CB1 1 CB2
1 CV2 1 X2
3 3 T-11A 3 3
2 2 2 2
V1 V2
V1 V2
FL
-6
-6
-8
-8
-8
-8
X -8
X -8
X
B8 B8 E6 E6 G6 X G6 H J
B8 E6 G6 H J
-8 X
-8 X
-8
-8
Rotating Link
-8
Adapter Assembly
Link Tilt Link Tilt Link Tilt

"Float" Solenoid "Drill Down" Solenoid "Tilt" Solenoid
(Solenoid Valve 8) (Solenoid Valve 6) (Solenoid Valve 6)
Link-Tilt Float Link Tilt

Cable ID
A B A B Logic
Number b b a Cartridge
C08 C07 C06
P T Drill Down P T M'hole
-6
-8
-8
SV8 D03 B8 E6 .031ø .031ø SV6 D03 .031ø G6

Logic
Cartridge LA6 T-11A .071ø
.031ø
75 PSI B6
1 2
50 PSI 2 3 T-11A
4 3
CA6 1
1 T-21A
3 .071ø
.031ø 50 PSI 2
A6
LB6 2
4 3
1
Pressure
CB6 75 PSI
Tank T-21A
A8 D1 Manifold Assembly
X
Figure 6-5. Link Tilt Cylinders Schematic Diagram
6-17
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SM00856
Page 6-18 of 22
Troubleshooting
Gearbox Lubrication Hydraulic System
Oil leaking from lower seal. Worn oil seals. Replace seals.
Oil leaking from upper bearing

Worn oil seals. Replace seals.
retainer.
Gearbox oil temperature (less Adjust oil level to middle of sight

Oil level too low or too high.
than 230° F). glass.
Check recommended lubricants

Incorrect lubricant used.
chart and replace as needed.
Damaged gears or bearings. Repair and replace as needed.
Oil pump loss alarm is on. Oil level is too low. Oil overheated. Add oil.
Adjust the switch (see the section

Oil pressure switch is out of
titled "IBOP and Oil Pressure
adjustment.
Switch" on page 5-79).
Gear spray nozzle missing. Replace spray nozzle.
Excessive oil viscosity. Lower oil viscosity.
Faulty motor. Intermittent

Replace motor.
operation.
Oil pump hydraulic motor failure. Replace motor.
Broken lube pump adapter plate

Replace adapter plate spline.
spline.
Check pressure at PF. Replace

Faulty fixed displacement pump.
pump if pressure is low.
Low hydraulic fluid in reservoir. Add hydraulic fluid.
Suction valve closed on fixed

Open suction valve.
displacement pump.
Water/mud in oil. Missing inspection plugs. Replace inspection plugs.
Upper gearbox seals worn. Replace seals.
Excessive foaming. Water in oil. Replace oil.
Excessively viscous oil. Cold oil. Lower oil viscosity.
Metal in oil. Worn gears or damaged bearings. Replace gears or bearings.
Damaged oil pump. Replace oil pump.
Restricted oil flow. Foreign particles blocking orifice or

Clean orifice or nozzle.
nozzle.
6-18
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SM00856
Revision D
Page 6-19 of 22
Troubleshooting 6
Troubleshooting
Gearbox Lubrication Hydraulic System
Schematic Diagram
Pressure Spray
Switch Nozzles (4) Orifices (6)
S04 10 PSI
Decreasing
-16
1.0 1.5 .062ø .205ø .059ø .059ø .047ø .047ø L4
GPM GPM
Ea. Ea.
Upper Lower Upper Lower Upper Lower
Compound Compound Mainshaft Radial/Main Compound Compound
Gear Gear Bearing Thrust Bearing Bearing
Bearings
Lube-Oil
Filter
Lube Pump 5.10 In.^ 3/Rev. 60m
L1 -16
Lube-Oil Pump
-10
A B
Tank
-10
3.0 In.^ 3/Rev.
Lube Pump Motor
Hydraulic Hydraulic
Motor Heat Exchanger
Tank
2 T-10A
RV2
400 PSI
Manifold PF
1.00 IN^ 3/REV.
Part of Reservoir
Pump Motor Assembly
Assembly
Figure 6-6. Gearbox Lubrication Hydraulic System Schematic Diagram
6-19
www.nov.com
SM00856
Page 6-20 of 22
Troubleshooting
Tool Rotation and Movement
Tool does not rotate. Direct control valve or relief valve is Inspect, repair, or replace the
sticking valve.
When you override a

directional valve, you
bypass the safety
interlock. Top drive components
can then move, possibly causing
serious injury or death.
Solenoid valve is not electrically Check electrical connections and

operating. valve functions.
Motor is worn out or gear teeth are

Replace the motor.
broken.
Shot pin is engaged. Adjust the relief valve.
Mechanical interference. Inspect and repair.
Test pressure left and right.

Directional valve does not shift.
Replace the valve.
Fixed valve orifice is plugged. Clear orifice or replace the valve.
Hydraulic lines are damaged. Replace hydraulic lines.
Tool does not return to the home Valve is sticking or relief valve is Test pressure and inspect valves.
position. out of adjustment. Adjust relief valve as required.
Sensor is broken. Replace sensor.
If the motor will drive normally, but

not drive to the home position, the Check out the control system.
cause could be the control system.
Links are not synchronized. Adjust valves together. Make sure

Counterbalance valves are out of
pressure is the same for all four
adjustment.
valves.
6-20
www.nov.com
SM00856
Revision D
Page 6-21 of 22
Troubleshooting 6
Troubleshooting
Rotating Link Adapter Motor Schematic Diagram
Rotating Head Motor
A B
Fixed
Displacement
Motor
1 2
Pressure
Relief Valves
T-10A 1700 PSI
1700 PSI T-10A
2 1
A B
Rotate Left Rotating Head Rotate Right

Solenoid Solenoid
Cable ID A B Cable ID
Number Number
b a
C03 C02
Left P T Right
-6
-6
A2 SV2 B2 Manifold
.071ø
Assembly
D03
Non-Adjustable Pressure Tank 3 Position

Orifice Solenoid Valve
Figure 6-7. Rotating Link Adapter Motor Schematic Diagram
6-21
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SM00856
Page 6-22 of 22
Troubleshooting
IBOP Actuator Schematic Diagram
IBOP Actuator Cylinder

1.750" Dia. Rod Hydraulic
Cylinder
Open
Close
Time-Delay
Accumulator
30 Cubic Inches
800 PSI Precharge
Gas Charged
Accumulator
(Small)
Rotating
Link Adapter
-6
-6
A4 B4
A4 B4
-6
-6
IBOP Close Solenoid

(Solenoid Valve 4)
Double Solenoid Valve IBOP Close
Cable ID
A B
Number
b
C04
P T
-6
-6
-6
A4 SV4 B4 C4 Manifold Assembly
D03
500 PSI CV4

D4 Flow Control
1 T-11A Valve
3 1 2
T-11A
2 3
PC4
System
Tank
Pressure
Figure 6-8. IBOP Actuator Schematic Diagram
6-22
www.nov.com
SM00856
Revision D
Hydraulic Symbols A
The following pages provide descriptions for hydraulic symbols used in the hydraulic schematic
diagrams.
A-1
www.nov.com
Form D811001123-GEN-001/06
SM00856
A Hydraulic Symbols Revision D
Page A-2 of 4
Description Symbol Schematic Reference
2 Position 4 Way Valves SV1, SV4, SV5, SV8, SV9

(Single Solenoid)
Solenoid
33-1
Operated
Valves
3 Position 4 Way Valves
(Double Solenoid) SV2, SV6
33-2
Manual
Valve 3 Position 4 Way Valve MV
(Rotary)
33-3
Fixed Displacement
33-4
Pumps
Variable Displacement
33-5
Standard Valve RV2, A2R, B2R, SJR
33-6
Pressure
Relief Ventable Relief Valve RV1
Valves
33-7
Differential Unloading Valve UV1
33-8
Pressure Reducing Valve PC1, PC4
33-9
Pressure Reducing/Relieving Valve PCC
33-10
CDF, CTF, CV2, CTR,

CDR, CXCD
Chack Valve
Prefill valve assembly
33-11
CV1, CV2
Figure A-1. Hydraulic Symbols (1 of 3)
A-2
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SM00856
Revision D
Page A-3 of 4
Hydraulic Symbols A
Description Symbol Schematic Reference
Pilot-To-Open CKCB (Link Tilt)

Check 33-12
Valves
CA6, CB6, CV3, CV4
Pilot-To-Close
(Clamp Body)
33-13
1
3
Cavity Plug PC5
2
33-14
Internal Plug
33-15
Non Adjustable Flow Control Valves CV1
33-16
Non Adjustable Orifice Diameter in inches
33-17
3 Port (Internal Drain) CBCA (Link Tilt Circuit)

Counter-
33-18
balance
Valves
4 Port (External Drain) CWCK (Link Tilt Circuit)
33-19
Standard Cartridge LA6, LB6, LC5, LODC
Logic 33-20
Cartridge
With Metering See Prefill Assembly
33-21
Quick Disconnect Coupling
33-22
A-3
www.nov.com
SM00856
A Hydraulic Symbols Revision D
Page A-4 of 4
Description
Description Symbol
Symbol Schematic Reference
Schematic Reference
Non Bypass Filter See Lube Oil Circuit
33-23
Filter with Bypass See Return Circuit
33-24
Manual Shutoff Valve
33-25
Thermostat Lube Oil Circuit
33-26
Pressure Switch Lube Oil Circuit
33-27
Heat Exchanger Hydraulic Circuit

(Inside Brake Housing)
33-28
Pressure Compensator Control Part of the Pump
33-29
Hydro-Pneumatic Accumulator
33-30
Hydraulic Motor (Bi-Directional)
33-31
Hydraulic Cylinder
33-32
Tank (Reservoir)
33-33
Test Point
33-34
A-4
www.nov.com
SM00856
Revision D
PH-50 Pipe Handler B
Appendix B provides information about the PH-50 Pipe Handler. Refer to section titled "Inspecting
the PH-75 Pipe Handler" on page 5-32 for information about the PH-75 Pipe Handler.
Remote IBOP Link Tilt

Actuator
Manual IBOP
Torque Back-up Clamp

Assembly
Elevator Links
Drive Pipe
Elevator Assembly
Figure B-1. PH-50 Major Components
B-1
www.nov.com
Form D811001123-GEN-001/06
SM00856
B PH-50 Pipe Handler Revision D
Page B-2 of 28
Inspection Schedule
Each Use Page Reference
Check wireline adapter sheaves for excessive wear or damage See page B-26
Daily
Check for missing lockwire and cotter pins
Check for loose or broken parts and leaks
Check for damaged hoses and fittings
Check tong dies for wear See page B-12
Check clamp cylinder for leaks See page B-12
Check hoses for wear or damage See page B-16
Check tool joint locks for tightness See page B-18
Check upper and lower IBOP valves for proper operation See page B-19
Weekly
Check link tilt clamps for position and tightness See page B-6
Check stabbing guide and flippers for damage and wear See page B-7
Check clamp cylinder gate hinge pin for wear See page B-12
Check IBOP actuator cylinder for leaks See page B-16
Check IBOP actuator cam followers for wear or excessive play See page B-16
Check upper and lower IBOPs and IBOP crank for damage (if equipped) See page B-19
Check shot pin assembly for leaks See page B-21
Monthly
Check elevator link eyes for wear See page B-6
Check link tilt bushings for wear See page B-8
Check link tilt actuator cylinders for leaks See page B-8
Check link tilt actuator cylinder pins for wear See page B-8
Check clamp cylinder body wear bushings for wear See page B-12
Check stabilizer springs for damage See page B-14
Check front and rear stabilizers for wear See page B-12, B-14
Check pins and bushings on IBOP actuator cylinder and yoke for wear See page B-16
Check shot pin assembly for wear or damage See page B-21
Yearly
Check piston ring for pitting and chipping See page B-23
Check stem for pitting, grooves and chipping See page B-23
Replace GLYD rings, o-rings and bushings on rotating link adapter See page B-23
5 Years
MPI Inspection See page B-27
Figure B-2. PH-50: Inspection Schedule
B-2
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SM00856
Revision D
Page B-3 of 28
Safety Precautions
Warnings
Avoid equipment damage or injury to personnel by paying close attention to the important safety
notes highlighted as Notes, Cautions, and Warnings used throughout this manual.
To avoid serious injury or death, read and understand the following warning advisories before
performing maintenance or troubleshooting procedures.
Complete all appropriate job safety analysis (JSA),

permits, and crew safety briefings immediately prior to
each maintenance activity or session. If, at any point
during the maintenance session, the planned activities
change for any reason, review the job safety
requirements again to ensure the crew involved is
aware of the changes in activities. Ensure all
appropriate personal safety equipment is in good
condition and used when necessary.
Unless specifically noted in this manual, properly lock

out the main power source before performing
lubrication, inspection, or replacement procedures.


moving.


Always discharge all accumulators before servicing

the hydraulic system.
B-3
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SM00856
Page B-4 of 28
Safety Precautions
Top drive maintenance requires personnel working at

height and there exists the potential for injury or
dropped objects.
Equipment Records
Keep a record book of all maintenance procedures performed. Date each procedure, followed by a
description and the technician who performed it. This data is valuable for fault finding and problem
solving, should technical problems arise.
Procedures in this chapter relate to NOV-only components.

See the appropriate vendor-supplied OEM manuals for
inspection schedules and maintenance procedures for
non-NOV equipment and components.
Torque Values
Refer to the Design Torque Standard (DS00008) in the equipment User Manual for the torque
standards to follow when tightening component fasteners.
Install bolts with anti-seize compound and tighten based

on the Design Torque Standard (DS00008). This document
is included in the equipment User Manual.
Safety Wire (Lockwire) Procedures

Refer to the Safety Wiring Procedure (ASP00019) in the equipment User Manual for the
procedures required for installing safety wire (lockwire) on component fasteners.
B-4
www.nov.com
SM00856
Revision D
Page B-5 of 28
Elevator Links
Once a month, use calipers to measure the amount of wear on the elevator link eyes. Compare the
measurement with the link wear charts in the Links User Manual (D6350000870). This manual is
Disassembly/Assembly
1. Disconnect and remove the drill pipe elevator from the elevator links.
2. Using the Driller’s Control Console, rotate the pipe handler 90° to position one of the
elevator links directly below the front of the motor guard.
3. Remove the catch link bolt from the catch link.
4. Remove the clevis pin from the link, which connects the link tilt to the elevator link.
5. Using the sling, hoist the elevator link away from the pipe handler.
6. Rotate the pipe handler 180°, repeat the procedure to remove the other elevator
link.
B-5
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SM00856
Page B-6 of 28
Elevator Links
Inspection
Recess in
Motor Guard
950 lb
(431 kg)
Elevator Link
2
Lift and
Link Tilt remove
Catch Link Pin Upper

Catch
Link Monthly
Elevator
Link Eyes
Inspect for wear
26"
(see table)
(635mm)
Typical
Rear
Clevis Pin
Link
Pipehandler
Rotate Switch
EH T AN
SH
PIP PU
IL T Weekly
K TT
LIN OA
FL U
AU
HP / ON
TO Front Link Tilt Clamps
E
Inspect for position
QU TE CW
PH
RO
TA
and tightness
C CW
T
ILT TIL
KT
ILL
LIN
1
DR
Rotate
E
RS
Driller’s
VE
Control
Console
CY
GEN
ER OP
EM ST
A SE
RE
I NC
EUP E
DE CR EAS
SET MAK
QUE
S TOR PM
TD L RE
A SE
SR
I NC
DRIL
TD
Monthly
ECREASE
D
BLE
ENA BX OR N P
KEU
VAT OPE
ELE A SE
RE
MA
BX
I NC
ED
ARM
CE DECR EAS
E
LAN
UMP
RBANDJ
ILL
NTESTA
L COUL /
ERA
DR
GEN DRIL
R
LE
VFD
LT ND CLAMP HOL
D
VAT
OR
FAU
HA TWH AND ELESED
MS
PIPE
BX CLO
PUS
AR OR
AL L MOTMP TILT
DRIL RTE LINK AT
Elevator
OVE FLO HPU/ ON
O
AUT
SS
PRE
OIL S
LOS
QUE ATE CW
TOR ROT
DE PH
S MO
WER
BLO S CCW
LOS
TD SPIN
TILT TILT
/ LINK
NCE
SILECK L
Link Eyes
RM CHE L DRIL
ALA P DRIL
LAM
E E
AK N REV
ERS
BR IO
O
CT
AUT RE
S DI OFF
OP TD
IB
Inspect for wear

SED D
CLO WAR
FOR
KE
BRAOFF
/
ON
SE
CLO
IBOP
(see table)
N
OPE
Figure B-3. PH-50: Elevator Link Inspection
B-6
www.nov.com
SM00856
Revision D
Page B-7 of 28
Link Tilt
2. Disconnect the hydraulic lines from the link tilt cylinders and cap all connections.
3. Unpin and remove the link tilt cylinders.
4. Unpin and remove the link tilt crank.
Use the recommended spanner wrench to remove the rod

gland seal.
B-7
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SM00856
Page B-8 of 28
Link Tilt
Inspection
Pins
Inspect for wear
replace as needed
Monthly
Monthly
Bushings
Inspect for wear
replace as needed
Monthly
Link Tilt
Actuator Cylinders
Inspect the hydraulic
connections for leaks
Link Tilt
Monthly
Bushings
Inspect for wear
replace as needed


i as an installation mandrel.
Figure B-4. PH-50: Link Tilt Inspection
B-8
www.nov.com
SM00856
Revision D
Page B-9 of 28

Clamp Cylinder Body Disassembly/Assembly
Procedure
1. Shutdown power and bleed the system (turn the valve on the bottom of the
2. Disconnect the hydraulic lines on the clamp cylinder body and cap all connections.
3. Support the clamp cylinder body.
4. Remove the two hex-head capscrews and lockwashers that hold the end cap in
place.
5. Remove the end cap, spring spacer, spring sleeve, and spring.
6. Slowly lower the clamp cylinder body off the torque wrench frame and move it to a
suitable work area.
7. Remove the 16 hex-head screws and lockwashers that hold the wear bushings on
8. Remove the four wear bushings, and replace the wear bushings as necessary.
9. Remove the two hinge pin retainer hex-head screws.
10. Swing out the two hinge pin retainers.
11. Remove the two hinge pins.
12. Remove the gate, front jaw, front stabilizer, and front stabbing guide.
13. Remove the two socket-head capscrews and hi-collar washers from the front jaw.
14. Remove the front jaw from the gate.
15. Repeat steps 11 and 12 for the rear jaw.
16. Push the cylinder head in enough to relieve the load on the cylinder head ring.
Remove the cylinder head ring. Use care in this operation.
17. Slowly pull out the cylinder head using the threaded holes. Remove and discard the
piston seal.
18. Carefully push the piston out of the body. Remove and discard the piston seal.
19. Remove the wiper rod and rod seal from the body. Discard the seals.
20. Clean the piston, cylinder head, and the body. Clean and lightly lubricate the new
seals and seal surfaces prior to reassembly.
Use recommended spanner wrench to remove the rod

gland seal.
Assembly is performed in reverse order of disassembly.
B-9
www.nov.com
SM00856
Page B-10 of 28

Removing the Clamp Cylinder Body
RUN
SHUTDOWN
RIG-UP
Hydraulic
COUNTERBALANCE MODE
Manifold
Rig-up/Run/
Shutdown Valve
Shown in SHUTDOWN
position
(Shown with
link tilt removed)
Torque Arrestor
Spring
Spring Spacer
Spring Shims
Adjust to ensure
the torque wrench
clamps fully onto
the saver sub Support clamp
cylinder body
before removing
end cap.
End Cap
Clamp Cylinder
Body
Figure B-5. PH-50: Removing the Clamp Cylinder Body
B-10
www.nov.com
SM00856
Revision D
Page B-11 of 28

Disassembling the Clamp Cylinder Body
Manifold
Rear
Stabilizer
Front
Stabilizer
Hinge Pin
Retainer Spring
Hex Head
Screws
Cylinder Clamp
Head Ring Cylinder
Body
Cylinder
Head Body
Piston Seals
Seals
Jaw
Piston Assembly
Tong
Dies
Gate
Wear
Bushing Socket
Head Cap
Screws
Hinge
Pin
Front
Rear Stabbing
Stabbing Guide
Guide
Flippers
Spring Retaining
Plate
Figure B-6. PH-50: Disassembling the Clamp Cylinder Body
B-11
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SM00856
Page B-12 of 28

Inspecting the Clamp Cylinder Body
Stabilizer Wear exceeds 1/8 in.

Flippers Wear exceeds 1/8 in.
Tugger
Line
V
A
R
C
O
P
H
5
0
Front and
Wear Bushings
Rear Stabilizers
Check for wear,
Inspect for wear
replace as necessary
Weekly Monthly
Tong Dies
Inspect for
excessive wear
RCO Daily
Daily VA Clamp Cylinder
Check for leaks,
replace seals
as necessary
Swing Clear
Weekly
Clamp Stabbing Guide
Cylinder Gate Inspect for damage
Shown open
Weekly
Weekly Clamp Cylinder
Flippers Gate Hinge Pin
Inspect for damage Check for pin wear,
and excessive wear replace as necessary
Figure B-7. PH-50: Inspecting the Clamp Cylinder Body
B-12
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SM00856
Revision D
Page B-13 of 28

Inspecting the Stabilizers
Remove the two bolts (with slotted nuts and cotter pins) that hold the front stabilizer. Check the
springs for damage and replace if needed. Pack spring cavities with grease and reassemble.
Be sure all safety wire, cotter pins, and capscrews are tight, and tighten or replace as necessary.
B-13
www.nov.com
SM00856
Page B-14 of 28

Inspecting the Stabilizers
Stabilizer Springs Monthly

Check for damage,
replace as necessary Stabilizers
Inspect for wear, replace
Monthly if wear exceeds 1/8 in.
Cotter Pin
Figure B-8. PH-50: Inspecting the Stabilizer
B-14
www.nov.com
SM00856
Revision D
Page B-15 of 28

Disassembling the IBOP Actuator Cylinder and Yoke
1. Shutdown the power and bleed the system (turn the valve on the bottom of the
2. Remove one gate hinge pin, open the gate, and pull back the torque wrench
assembly.
3. Disconnect the hydraulic lines from the IBOP actuator cylinder and cap all
connections.
4. Unpin and remove the IBOP actuator cylinder and yoke.
5. Replace the hydraulic lines as necessary.
6. Check for cylinder leaks.
B-15
www.nov.com
SM00856
Page B-16 of 28

Inspecting the IBOP Actuator Cylinder and Yoke
Weekly
IBOP
Actuator Cylinder
Check for leaks,
tighten fittings
Daily Monthly
Hoses Pins and Bushings
Replace if worn Check for wear
or damaged or excessive play
Monthly
IBOP Weekly
Actuator Yoke IBOP
Check pins and Actuator Yoke
bushings for wear Check cam followers for wear
or excessive play or excessive play


i as an installation mandrel
Figure B-9. PH-50: Inspecting the IBOP Actuator Cylinder and Yoke
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IBOP Stack
Tool Joint Locks Disassembly/Assembly
!
Do not reuse locking screws.
1. Lubricate the locking screw threads, screw head bearing area, and the tapers of the
inner rings with molybdenum disulfide grease, such as Molykote Gn paste.
2. Make sure the save sub, IBOPs, and main shaft are free of “high spots”, such as
tong marks. If high spots exist, remove with file or light grinding.
3. Slide the tool joint lock over the main shaft, IBOP valves, and saver sub.
4. Clean the IBOP valves, main shaft, and saver sub surfaces thoroughly. Make sure
these surfaces are smooth and free of grease, oil, and pipe dope.
5. Locate the tool joint lock symmetrically at each joint.
!
Never tighten locking screws before the tool joint lock is at
the correct location, otherwise it will not slide freely.
6. Take any three or four locking screws equally spaced and tighten them to establish
parallel or perpendicular position of the tool joint lock collars relative to the main
shaft, IBOP valves, and saver sub respectively. This properly seats the collars on
the taper of the inner ring and aligns the collars.
7. Using a torque wrench, tighten all locking screws gradually in either a clockwise or
counterclockwise sequence (not in a diametrically opposite sequence). Continue
tightening all of the screws until they reach 185±5 ft lb.
8. Make sure no screw turns any more. The gap between the tool joint collars should
be as equal as possible all the way around.
9. Safety wire all screws.
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IBOP Stack
Inspecting the Tool Joint Locks
Spaced on Upper IBOP and
Main Stem Joint Connection
1.4" Tool Joint

Shoulder
1.4"
Remove O-Ring Tapered

and Look through Inner Ring
this Space and
Split on Inner Ring
Tool Joint Lock to
be Offset on Upper
and Lower IBOP
Joint Connection
Tool Joint
1.0" Shoulder
I.D. Groove
First Line Up this Point with the
Tool Joint Shoulder. Then Move
Inner Ring Down 3/8" with the
Outer Assembly. Replace O-Ring
Daily
Tool Joint
Locks
1.4" Tool Joint Inspect for loose bolts.
Shoulder Repair or replace if necessary.
Torque to 1855 ft lb.
1.4"
Spaced on Lower IBOP and
Saver Sub Joint Connection
Removing the Tool Joint Locks

 Gradually release the locking screws all the way around. Initially release each screw
about a quarter of a turn, avoid tilting and jamming the collars. Do not remove the
screws completely at this time, otherwise the collars may spring off.
 Remove any rust formed or dirt collected adjacent to the tool joint lock. Once the screws
are loose, remove the tool joint lock from the saver sub, IBOP valves, and main shaft.
Figure B-10. PH-50: Inspecting the Tool Joint Locks
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IBOP Stack
Inspecting IBOP Valves and Saver Subs
Saver Sub Threads have been recut to a minimum

shoulder-to-shoulder length of 5 in.
Weekly Daily
Upper IBOP Valve
(Remote) Check for
Close Inspect for damage proper operation
and pressure test
for leaks
Weekly
Open IBOP Crank

(Remote)
Inspect for damage
Weekly Daily
Lower IBOP Valve
(Manual) Check for
(Optional) proper operation
Inspect for damage and pressure test
for leaks
5 Years
Upper and Lower IBOP
Figure B-11. PH-50: Inspecting IBOP Valves and Saver Subs
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Shot Pin Assembly

1. Disconnect the hydraulic and electrical lines.
2. Remove the capscrews that attach the shot pin assembly to the main body.
3. Remove the capscrew and lockwasher holding the shot pin cover in place.
4. Remove the shot pin components as shown in Figure B-12 (end cap, o-rings, rod
seal assembly, shot pin).
5. Inspect the shot pin bearing and press the bearing out of the shot pin mounting
bracket if the bearing is scored or damaged.
6. Remove the capscrew and lockwasher that hold the pinion gear in place, and
remove the gear.
7. Remove the capscrews and lockwashers that hold the hydraulic motor in place and
remove the motor. Inspect the disassemble parts and replace any worn or damaged
parts.
Assemble the shot pin in the reverse order of disassembly.
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Page B-21 of 28
Shot Pin Assembly

Inspection
Weekly
Shot Pin Assembly
Check for leaks,
Shot Pin tighten fittings
Base
Dowel Pin
Rod Seal
Assembly Monthly Dual Port
Manifold
Shot Pin
Check for wear,
remove buurrs
Rod Seal
Assembly
Monthly
Shot Pin Sleeve
Check for wear
Hydraulic
Motor
O-ring
Monthly
Shot Pin Bushing
Check for wear
Shot Pin
Cap
Pinion Gear

Shot Pin
Shot Pin Outer diameter is less than 1.375 in. Cover
Shot Pin Sleeve Inner diameter is greater than 1.510 in.
Shot Pin Bushing Inner diameter is greater than 1.475 in.
Figure B-12. PH-50: Inspecting the Shot Pin Assembly
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Rotating Link Adapter/Load Stem

Removing the Rotating Link Adapter (while the top
drive is in the mast)
1. Drain the oil from the gearbox.
2. Disconnect and cap all tubing, remove the shot pin assembly and the landing collar.
3. Build a support over well center to support the weight of the link adapter.
4. Lower the top drive to the support built in Step 3.
5. Remove the bolts that attach the load stem to the main body.
6. Raise the top drive slowly to separate the link adapter from the main body.
7. Move the link adapter assembly to a clean, safe work area.
8. Orient the assembly with the stem flange up and block the entire assembly so that it
is secure in this position.
Disassembling the Link Tilt Assembly

1. Attach a three-point sling to the stem and pull the stem out of the link adapter.
2. Turn the stem over and place it on its flange.
!
Protect the internal surfaces of the rotating link adapter
and the surfaces of the drive stem when separating the two
components. When removing the rotating link adapter from
the stem, carefully tap with a mallet. There can be
misalignment between the two bores when raising the
drive stem and gear assembly.
The piston ring is assembled with a light press fit. Provide

a support under the gear so that it does not drop when it
breaks loose.
3. Remove and discard all rotary seals, O-rings, thrust ring, and the wear bushings
from inside the rotating link adapter and gear inside dimension.
4. Remove and discard the stem flange O-rings and stem bore shaft seals.
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Page B-23 of 28

Inspecting the Rotating Link Adapter
Eye Bolts
Rotary GLYD Ring
(10 Places)
Yearly
Rotary GLYD Ring

Yearly
Rotary Link Adaptor

O-Ring
Remove, discard
and replace
Yearly
Thrust Ring
Retainer Ring Remove, discard and replace
Yearly
Turcite Bushing
O-Ring
Yearly
Rotary GLYD Ring
Wiper Seal
Yearly
Piston Ring
Inspect for pitting
Rotating Link and chipped plating
Adapter Gear
Wear Allowances
Yearly
Thrust Ring Thickness is less than 0.105 in.
Turcite Thickness is less than 0.112 in. Stem
Bushing Inspect for pitting,
grooves and chipped plating
Stem O-Ring
Index Mark
Indicates front of stem
Yearly
Level Work Surface
Figure B-13. PH-50: Inspecting the Rotating Link Adapter
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Page B-24 of 28

Assembling the Link Adapter
1. Orient the stem so the drive stem flange is down on a suitably protected surface.
2. Install the gear with its rotating seal and wiper in place.
3. Install the O-ring for the piston ring.
4. Install the piston ring by tapping on it lightly with a mallet to press it into place (Heat
to 220-250°).
5. Install the retainer ring.
6. Install all of the rotary seals on the rotating link adapter, and an O-ring on the top
surface.
7. Install the two wear bushings and the thrust ring in the rotating link adapter.
8. Rest the rotating link adapter on its bottom surface.
9. Clean and then lubricate (with hydraulic oil) the sealing surface of the stem and the
inside diameter of the rotating link adapter.
10. Attach three lifting slings symmetrically through the holes on the top of the stem
flange and slowly lower the assembly into the rotating link adapter body. Hammering
with a large plastic mallet is an aid when assembling the stem to the link adapter.
!
Make sure the seals do not twist in the grooves.
11. Install the gear onto the link adapter and install the bolts.
12. Pressure test each port at 1,000 psi and inspect for leaks at the adjacent ports.
13. Grease all lubrication points on the assembly.
14. Inspect the lower gearbox seal (located inside the stem flange), and replace as
necessary.
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Installing the Rotating Link Adapter (while the top drive
is in the mast)
1. Check the condition of the main shaft wear ring and replace if there is any evidence
of grooving.
2. Place the rotating link adapter assembly back on the support built over well center,
orienting the assembly so that the stem flange is up, and so that the index mark
faces forward.
3. Carefully lower the top drive to engage the main shaft in the stem bore and then the
stem flange pilot diameter is in the main body bore.
4. Install the flange bolts.
5. Install the link tilt cylinders, pin, and secure in place.
6. Install the link tilt crank and pin, and secure in place.
7. Install all hose assemblies.
8. Install tubing.
9. Install the shot pin assembly.
10. Fill the gearcase with gear oil (see Lubrication).
11. Check and fill the hydraulic oil as necessary.
12. Turn on the top drive and perform all pipe handler functions several times, checking
for proper function and any leaks.
13. Re-check the hydraulic oil level and fill as necessary.
!
Always install a new main shaft seal and use care not to
damage the seal or the case.
A light coating of grease applied to the O-ring helps in

installing the rotating link adapter assembly into the main
body.
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Wireline Adapter
Inspection
i
Inspect the condition of the
sheaves before and after each use
Each Use
Sheaves
Replace or repair damaged
parts as necessary
Figure B-14. PH-50: Inspecting the Wireline Adapter
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Yearly (or after approximately 3,000 operating hours), perform a Nondestructive Examination
(NDE) of all critical load path items. NDE inspection includes visual examination, dye penetrant
examination, magnetic particle inspection, ultrasonic inspection, x-ray examination, and other
methods of nondestructive testing for metallurgical integrity.
Making Visual Inspections

Use calipers on a regular basis to measure the amount of wear on the elevator link eyes. Compare
the measurements with the information provided in the Links User Manual (D635000870) to
determine the current strength of the elevator links. The capacity of the links equals the capacity of
the weakest link.

Every five years, NOV recommends that customers inspect all top drive hoisting equipment using
the wet fluorescent method of Magnetic Particle Inspection (MPI). Refer to the documentation
listed in the following section before beginning the MPI for any equipment component.
Refer to the following standards that define the use of the wet fluorescent method of MPI when
examining machined surfaces for any equipment component.
 ASTM A-275, Standard Method for Magnetic Particle Inspection of Steel Forgings
 ASTM-E-709, Standard Recommended Practice for Magnetic Particle Inspection
 I.A.D.C., Drilling Manual
 API RP 8B, Recommended Practice for Procedures for Inspection, Maintenance,
Repair and Remanufacture of Hoisting Equipment
 API 8C, Specification for Drilling and Product Hoisting Equipment (provides MPI
inspection acceptance criteria)
Any indications found are a potential cause for replacing one or more of the following:
 Main shaft (lower portion)
 Bail
 Split Load Collar
 Upper and lower IBOP
 Link adapter
 Saver, crossover, and spacer subs
 Power subs
 Power swivels
 Elevator links
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The drilling operator may determine that the MPI schedule should occur more frequently, based on
one or more of the following factors:
 environment
 load cycles
 regulatory requirements
 operating time
 testing
 repairs
Please contact your NOV Service Center if you have any questions.
Ultrasonic Inspection
In addition to the MPI, NOV also recommends performing an ultrasonic Inspection of the
previously listed components to detect any erosion of the inside diameter. Any erosion reduces the
load carrying capability of the part. Any subsurface irregularity can also compromise a
component’s integrity.
Details on Ultrasonic Inspection procedures are in the publication:
ASTM A-388 Std. Practice for Ultrasonic Examination of Heavy Steel Forgings
IBOP Inspection
Upper and lower IBOP valves, because of their internal grooves and shoulders, are particularly
susceptible to corrosion fatigue cracking. These internal diameter changes act as stress risers for
bending and tensile loads. It is especially important to properly inspect the IBOP valves on a
frequent basis.
Lubrication
Refer to the section titled "Lubrication Schedules" on page 5-58 for pipe handler component
lubrication schedules. Refer to Figure 5-36 on page 5-63 for general pipe handler lubrication
procedures.
B-28
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FINAL DOCUMENTATION
Chapter 2.0
Service Manual, Washpipe
Assembly
www.nov.com
WASHPIPE ASSEMBLY
Service Manual
SM01053
Revision A
© Copyright 2004 Varco® LP. All rights reserved.
Varco® is a registred trademark of Varco I/P Reg. U.S. Patent & Trademark Office. This
publication is the property of, and contains information proprietary to, Varco International, Inc. No
part of this publication may be reproduced or copied in any form, or by any means, including
electronic, mechanical, photocopying, recording, or otherwise without the prior written permission
of Varco International, Inc.
All product, brand, or trade names used in this publication are the trademarks or registered
trademarks of their respective owners. Information in this manual is subject to change without
notice.
General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Intended Audience and Use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Conventions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Illustrations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Safety Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Personnel Training . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Recommended Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
General System Safety Practices . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Replacing Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Routine Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Proper Use of Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
General Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Washpipe Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Washpipe Assembly Pressure Ratings . . . . . . . . . . . . . . . . . . . . . 10
General Maintenance Practices . . . . . . . . . . . . . . . . . . . . 11
Equipment Maintenance Records . . . . . . . . . . . . . . . . . . . . . . . . . 11
Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Standard Washpipe Assembly . . . . . . . . . . . . . . . . . . . . . . 12
Initial Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Maintenance Schedules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Inspection Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Lubrication Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Illustrated Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Hammerless Washpipe Assembly . . . . . . . . . . . . . . . . . . 36
Initial Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Maintenance Schedules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Inspection Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Lubrication Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Removing the Washpipe Assembly . . . . . . . . . . . . . . . . . . . . . . . 49
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
Illustrated Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
Glossary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
Washpipe 3
4 Varco
General Information
Intended Audience and Use
This manual is intended for use by field engineering, installation, operation, and repair
personnel. Every effort has been made to ensure the accuracy of the information
contained herein. Varco International, Inc., will not be held liable for errors in this
material, or for consequences arising from misuse of this material.
This manual is intended as a supplement to the service manuals supplied with the Varco
Top Drive System (TDS) and/or the Varco Integrated Drilling System (IDS).
Conventions
Notes, Cautions, and Warnings
Notes, cautions, and warnings are used throughout this manual to provide readers with
additional information, and to advise the reader to take specific action to protect
personnel from potential injury or lethal conditions. They may also inform the reader of
actions necessary to prevent equipment damage.
Please pay close attention to these advisories.
Note:
i
provided about the current topics.
Caution:
!
equipment or injury to personnel exists. Follow
instructions explicitly. Extreme care should be taken when
performing operations or procedures preceded by this
caution symbol.
Warning:
The warning symbol indicates a definite risk of

equipment damage or danger to personnel. Failure to
observe and follow proper procedures could result in
serious or fatal injury to personnel, significant
property loss, or significant equipment damage.
Illustrations
Figures provide a graphical representation of equipment components or screen
snapshots for use in identifying parts or establishing nomenclature, and may or may not
be drawn to scale.
For more specific component information pertinent to your rig configuration, see the
technical drawings included with your Varco documentation.
Washpipe 5
Safety Requirements
Varco equipment is installed and operated in a controlled drilling rig environment
involving hazardous operations and situations. Proper service and repair is important for
safe and reliable operation. Operation and service procedures provided by Varco
manuals are the recommended methods of performing those operations.
!
carefully observe the following safety requirements.
Personnel Training
All personnel performing installation, operations, repair, or maintenance procedures on
the equipment, or those in the vicinity of the equipment, should be trained on rig safety,
tool operation, and maintenance to ensure their safety.
!
During installation, maintenance, or repair of equipment,
personnel should wear protective gear. Protective gear
must be worn during certain operation.
Contact the Varco training department for more information about equipment operation
and maintenance training.
Recommended Tools
Service operations may require the use of tools designed specifically for the purpose
being described. Varco recommends that only those tools specified be used when
stated. Ensure that personnel and equipment safety are not jeopardized when using
service procedures or tools not specifically recommended by Varco.
6 Varco
Safety Requirements
The equipment discussed in this manual may require or contain one or more utilities,
such as electrical, hydraulic, pneumatic, or cooling water.
!
Before installing or performing maintenance or repairs on
equipment, read the following instructions to avoid
Isolate all energy sources before beginning work.

Avoid performing maintenance or repairs while the equipment is in operation.
Wear proper protective equipment during equipment installation, maintenance, or
repair.
Verify that all components (such as cables, hoses, etc.) are tagged and labeled
during disassembly and reassembly of equipment to ensure correct installment.
Replace failed or damaged components with Varco certified parts. Failure to do so
could result in equipment damage, or personal injury.
Routine Maintenance
Equipment must be maintained on a regular and routine basis. See the service manual
for maintenance recommendations.
!

Varco equipment is designed for specific functions and applications, and should be used
only for their intended purpose.
Washpipe 7
General Description
Washpipe Assembly
The washpipe assembly is located between the main shaft and the gooseneck (S-pipe)
on the TDS/IDS, supported by a bonnet. The washpipe assembly allows for the rotation
of the TSD/IDS drilling string. Two types of washpipe assemblies are available: standard
and hammerless.
8 Varco
General Description
Special Tools
The standard washpipe assembly has hammer nuts on its washpipe nut and packing
box. The hammer nuts are provided so that a special wrench and a hammer can be
used to tighten to washpipe nut and packing box during installation.
The hammerless washpipe assembly uses gear nuts which are tightened more precisely
without a hammer but with a special torque wrench kit. This feature makes the unit
easier to install by allowing the unit to swing in and out of its support bonnet before being
torqued and does not require the use of a hammer.
Standard Washpipe
Standard Washpipe Wrench
Strike here
Hammerless Washpipe
Torque Wrench
30-250 ft lb
Hammerless Washpipe
Torque Multiplier
3200 ft lb
Removable extension
not shown
Socket Adapter
Washpipe 9
Specifications
Washpipe Assembly Pressure Ratings
i
Assembly descriptions are repeated for similar units. Use
the assembly part number when referencing pressure
ratings.
Standard Washpipe Assembly
Description Part No. Pressure Rating

(psi)
Small Bore (3-inch) 30123290 7,500
Large Bore (4-inch) 30123440 7,500
Large-to-Small Bore 30153491-50 7,500
Hammerless Washpipe Assembly
Description Part No. Pressure Rating

(psi)
Large Bore (4-inch) 30156883 7,500
Large-to-Small Bore 30173058-50 7,500
10 Varco
General Maintenance Practices
Equipment Maintenance Records
Keep a record book of all maintenance procedures performed. Date each procedure,
followed by a description and the technician who performed it. This data is valuable for
fault finding and problem solving, should technical problems arise.
i
Procedures in this chapter relate to Varco only
components. See the vendor manuals for maintenance
procedures and schedules for the vendor equipment.
Maintenance Schedules
Maintenance schedules list preventive maintenance tasks.
Inspection schedules assume normal operating conditions. Some conditions (excessive
loading, dusty or corrosive atmosphere, temperature extremes, etc.) may warrant more
frequent inspection intervals. Perform the procedures indicated, as warranted by the
inspection.
Safety Precautions
Avoid equipment damage or injury to personnel by paying close attention to the
important safety notes highlighted as Notes, Cautions, and Warnings used throughout
this manual.
To avoid serious injury or death, read and understand the following Warnings before
performing maintenance or troubleshooting procedures:
Unless instructed otherwise, properly lock out the

main power source before performing any
maintenance procedure.
Wear protective glasses to prevent eye injuries.

moving.

Washpipe 11
Initial Installation
Procedure
1. Install the washpipe assembly on the TDS/IDS and hand-tighten
the washpipe nut and packing box, then back off the packing box
and washpipe nut by 1/4 turn.
the packing box.
securely tighten.)
Nut
12 Varco
Washpipe 13
Procedure
11. Check washpipe alignment. Install dial indicator base on packing
box. Adjust dial indicator to contact the washpipe approximately
one inch above the packing box.
12. Rotate main shaft through one revolution, noting the minimum
and maximum readings on the dial indicator. Subtract the
minimum reading from the maximum reading to obtain the Total
Indicated Runout (TIR). Maximum allowable TIR is 0.007 inch.
Washpipe
Dial
Indicator
Packing
Box
14 Varco
Inspection Schedule
Item Inspect for Interval
Mating surface of stem liner(s) while • Surface should be When washpipe

it is installed in the TDS/IDS main smooth and free of flaws assembly is to be
shaft or gooseneck or burrs removed from TDS/
IDS
• ID of stem liners
TDS/IDS main shaft bearing endplay Endplay is within Once every six months
specification (refer to and immediately after
TDS/IDS Service jarring
Manual)
Washpipe Assembly grease fitting Proper operation Replace every six

months
Washpipe pilot on the gooseneck Proper alignment After TDS/IDS main

and the washpipe pilot on the TDS/ between pilots shaft bearing endplay
IDS main shaft has been checked and
is within specification
All parts Refer to Disassembly Upon disassembly of

Procedure washpipe assembly
Cleaning Schedule
Item Procedure Interval
TDS/IDS bonnet (inside) Remove residual mud Weekly
Lubrication Schedule
Washpipe Assembly grease fitting Apply 3 to 4 pumps of Twice daily or every 10

grease (refer to rotating hours
Lubrication Procedure)
Washpipe 15
Inspection Procedures
When Washpipe is to be Removed from TDS/IDS
Service Limit
(inches)
3.090
3.840
3.120
16 Varco
Every Six Months
Procedure
1. Remove the washpipe assembly and replace

the grease fitting.
2. Check the main shaft axial movement by
applying an upward force to the main shaft and
dial indicator.
3. If axial shaft movement is not .001 in. to .003
in., remove the bearing retainer and adjust the Washpipe
number of shims under the bearing retainer as Grease Fitting
required to allow .001 in. to .003 in. of axial Replace
shaft movement (end play) with the bearing
retainer capscrews tightened to the required
torque depending on the size of the capscrew
(refer to the Initial Installation Procedure for
proper torque requirements).
Dial
Indicator
Washpipe 17
Every Six Months
Gooseneck
Pilot
Dial
Indicator
0.002 TIR between Bonnet removed

these two surfaces for clarity.
Main Shaft
Pilot
18 Varco
Daily Lubrication
Description
Cyprina grease fitting.
2.
Washpipe 19
Troubleshooting
i
The troubleshooting table does not necessarily cover all
possible symptoms. The table provides an insight to typical
symptoms, their possible causes, and what components to
check.
Symptom Probable cause Remedy

Leakage at threads Poly Pak seal failure in main Replace seal by removing the stem liner
between packing box and shaft stem liner and installing the new seal. Be sure to
TDS/IDS main shaft deburr the edges of the main shaft as
sharp edges will cut the seal on
installation. Reinstall the stem liner.
Lower O-ring failure 1. Remove washpipe assembly.
2. Inspect the main shaft and stem liner
for any burrs that can damage the O-ring
and deburr as required. The surface of
the stem liner should be smooth and flat.
If it is not, replace stem liner.
3. Replace the O-ring and reinstall the
washpipe assembly.
Stem liner not smooth and Follow instructions outlined in the
does not allow O-ring to seal Inspection Procedures, When Washpipe
properly Is To Be Removed From TDS/IDS.
Stem liner not flat and does Follow instructions outlined in the
not allow O-ring to seal Inspection Procedures, When Washpipe
Spacers not flat and prevents Follow inspection procedures as outlined
packing seals from sealing in step 8 of the Disassembly Procedure.
between spacers proper
Leakage at grease fitting Poly Pak seal failure in main Replace seal by removing the stem liner
access hole shaft stem liner and installing the new seal. Be sure to
deburr the edges of the main shaft as
washpipe assembly.
20 Varco
Troubleshooting
Leakage through grease Spacers not flat and prevents Follow inspection procedures as outlined
fitting access hole (cont) packing seals from sealing the Inspection Procedure.
Leakage at grease fitting Grease fitting failure Follow inspection procedures as outlined
in step 12 of the Disassembly Procedure.
Leakage between the Packing failure Disassemble and inspect components.
washpipe and the packing Replace worn or damaged components
box on reassembly of the washpipe.
Leakage between the Packing failure or packing is Disassemble and inspect components.
washpipe and the improperly seated Replace worn or damaged components
washpipe nut on reassembly of the washpipe.
Upper O-ring failure 1. Remove washpipe assembly. and
replace O-ring.
2. Inspect the gooseneck and, for big
bore units with lined goosenecks, the
stem liner for any burrs that can damage
the O-ring and deburr as required. The
surface of the stem liner should be
smooth and flat. If it is not, replace stem
liner.
washpipe assembly.
Leakage at threads Upper O-ring failure 1. Remove washpipe assembly. and
between washpipe nut and replace O-ring.
gooseneck 2. Inspect the gooseneck and, for big
liner.
washpipe assembly.
Packing failure or packing Disassemble and inspect components.
is improperly seated Replace worn or damaged components
on reassembly of the washpipe.
Premature failure after Improper greasing Greasing can cause the seal to unseat
greasing procedure from the washpipe and cause premature
failure of the assembly. Running the TDS/
IDS without standpipe pressure allows
the seals to reseat. Follow greasing
procedure as outlined in the Lubrication
Procedures.
Washpipe 21
Troubleshooting
Premature failure Washpipe alignment caused If necessary, reinstall washpipe or realign
accompanied by by improper installation, or the gooseneck. Check washpipe
occasional spurts of mud misalignment of the alignment as follows (see illustration on
from packing box gooseneck, or excessive following page):
bearing endplay 1. Install dial indicator base on packing
box. Adjust dial indicator to contact the
washpipe approximately one inch above
the packing box.
2. Rotate main shaft through one
revolution, noting the minimum and
maximum readings on the dial indicator.
Subtract the minimum reading from the
maximum reading to obtain the Total
Indicated Runout (TIR). Maximum
allowable TIR is 0.007 inch.
3. If out of specification, check
gooseneck alignment.
Premature failure Misalignment of gooseneck- Inspect main shaft and mainshaft-to-
accompanied by to-washpipe pilot gooseneck alignment as described in the
occasional spurts of mud Every Six Months Inspection procedure.
from packing box
Installation problems The proper installation sequence allows
the packing and washpipe to align to each
other, and ensures that both the
washpipe nut and the packing box
engage their pilots. Follow proper
installation procedures (refer to the Initial
Installation Procedure).
Premature failure due to Nut not torqued Improper torque prevents metal-to-metal
flanged packing contact between the flat surfaces of the
spacers. When pressure is applied, it will
extrude the packing between the spacers.
Follow proper torquing procedures as
described in the Initial Installation
Procedure.
Too mush grease during Too much grease prevents metal-to-metal
assembly of the unit contact between the flat surfaces of the
spacers during operation. The grease can
sustain a hydrostatic pressure that resists
torque during the installation.
During operation the grease gradually

leaks out resulting in loosening of the
packing box. Follow proper greasing
procedure during reassembly and check
for proper spacer contact during
installation (refer to the Initial Installation
Procedure).
22 Varco
Troubleshooting
Washpipe
Dial
Indicator
Packing
Box
Washpipe 23
Troubleshooting
Packing is worn out Poor greasing schedule or Follow proper lubrication procedures.
improper grease.
RPM, pressure and mud Friction between the seals and the
temperature too high washpipe create heat. TDS/IDS rpm and
standpipe pressure contribute equally to
the amount of heat generated. If
pressure of rpm is increased, so is the
amount of heat generated. Heat
generation goes up with the square of the
bore size. Mud is what cools the system.
The hotter the mud, the less cooling it
provides. The greater the amount of heat
generated is relative to the amount of
cooling the mud will provide, the hotter
the seals run. As the seals run hotter, the
wear resistance of the rubber drops. If
using a large-bore washpipe, convert to a
small-bore washpipe.
Packing extruding Spacers too flat If the spaces are not flat, then metal-to-
between spacers metal contact cannot be maintained even
when they are bottomed out against each
other. The resulting small gaps will allow
the packing to extrude into these areas.
Follow instructions outlined in the
Inspection Procedures.
Nut not torqued Improper torque prevents metal-to-metal
contact between the flat surfaces of the
Procedure.
Blue spacers Improper torque or grease Improper torque on the nut can lead to
on the OD of the spacers situations where the lower and middle
spacers spin the packing box. The
resulting heat achieves temperatures
high enough to turn the spacers blue.
Unable to maintain torque Improper assembly or 1. Remove washpipe assembly from
on packing box installation TDS/IDS.
2. Disassemble the washpipe assembly,
setting aside the packing seals for the
lower, middle, and upper spacers.
3. Reassemble the washpipe assembly
without the packing seals for the lower,
middle, and upper spacers.
24 Varco
Troubleshooting
Unable to maintain torque 4. Reinstall the washpipe assembly on
on packing box (cont) the TDS/IDS as follows:
a. Install the packing box onto the TDS/
IDS main shaft. Tighten until spacers are
firmly held.
b. Install the holding ring into the
washpipe nut and install washpipe nut
onto the TDS/IDS goosneck until the
holding ring is firmly in place.
c. Using a dial indicator, measure and
record the distance between the flat
surfaces on the washpipe nut and the
packing box. Also for future use, mark the
location where the measurement is taken.
NOTE
To ensure that the washpipe assembly
has been sufficient tightened, measure
the distance with each subsequent
installation of the washpipe assembly.
Washpipe 25
Disassembly
Procedure
Snap Ring
1. Remove washpipe assembly from the TDS/IDS.
2. Completely disassemble the washpipe assembly.
Take care to prevent damage to the sharp edge Holding Ring
of the upper and middle spacers.
3. Dispose of packing, washpipe and O-rings.
These parts are not serviceable and must be
replaced.
Washpipe Nut
O-Ring
Packing Box
Grease
i Fitting
Discard and replace
Washpipe these non-serviceable
parts from the
washpipe assembly.
Socket Head
Dog Nose
Upper Spacer Screw
Packing Set Middle Spacer

(5 per Set)
Middle Spacer
O-Ring
26 Varco
Disassembly
Procedure
4. Thoroughly clean and inspect remainder of parts.
5. Check that the ID of each spacer is within specification.
6. Check that the flat portions of each spacer are free of burrs that
could prevent the spacers from seating properly. Burrs should be
lightly filed flush. If surfaces are out-of-flat, replace spacer.
7. The edge that directly backs up the packing should be free of
cuts, nicks, and burrs. If edge is damaged replace spacer.
This surface to be
smooth and flat
ID This edge to be
This surface to be
sharp
smooth and flat
Varco Proper Service

Washpipe Part ID Limit ID
Assembly Spacer No. (inches) (inches)
Small Bore Upper 123585 3.635 to 3.640 3.645

Upper Spacer
Middle 30123286 3.635 to 3.640 3.645
Lower 123287 3.635 to 3.640 3.645
Large Bore Upper 30123434 4.895 to 4.900 4.905

Middle 30123435 4.895 to 4.900 4.905 Middle Spacer
Lower 30123436 4.895 to 4.900 4.905
Large to Small Bore Upper 123585 3.635 to 3.640 3.645
Middle 30123286 3.635 to 3.640 3.645 Middle Spacer
Lower 123287 3.635 to 3.640 3.645
Washpipe 27
Disassembly
Procedure
8. Check that the ID of the washpipe nut where the washpipe
passes through.
9. Check that the ID of the packing box where the washpipe passes
through.
Washpipe
Nut
ID
Packing
Box
Washpipe Washpipe Nut Proper ID Service Limit ID

Assembly Part No. (inches) (inches)
Small Bore 123284 3.655 to 3.660 3.665
Large Bore 30123431 4.905 to 4.910 4.915

Large to 30153493 3.655 to 3.660 3.665
Small Bore
Washpipe Packing Box Proper ID Service Limit ID

Small Bore 30123563 3.637 to 3.644

Large Bore 30123626 4.900 to 4.905
Large to 30153494 3.637 to 3.644
Small Bore
28 Varco
Disassembly
Procedure
10. Inspect the holding ring drive dogs. Each dog has a slight
undercut. If the undercut is no longer visible, replace the holding
ring.
Holding
Ring
This surface to be
smooth and flat
Undercut
rease
i
This surface to be
smooth and flat
11. Check that the flat portions of the holding ring are free of burrs
that could prevent the ring from seating properly. Burrs should
be lightly filed flush.
12. Inspect the spring tension in the ball of the grease fitting. If the
ball is not properly tensioned, replace the grease fitting. If in
doubt, replace the grease fitting. Replace the grease fitting every
six months or every other rebuild of the washpipe assembly,
whichever period is longer, even if the grease fitting is working
properly.
13. Reassemble the washpipe assembly as described in the
Reassembly Procedure.
Washpipe 29
Reassembly
Procedure
1. Apply a light grease film to the outside of each packing seal and
fill the plunge with grease, flush with the packing.
Packing
Seal
Fill with grease

to level shown
Spacer
2. Install one packing seal into each of the four spacers (one upper,
two middle, one lower) that go into the packing box. Wipe all
excess grease from the top edge of the packing and all excess
grease from the spacers. Take care to prevent damage to the
sharp edges of the spacers.
Upper Spacer
Sharp edge
of spacer Wipe grease
from area shown, Middle Spacer
all the way around
Sharp edge on each spacer.
of spacer
Sharp edge
of spacer Middle Spacer
30 Varco
Reassembly
Procedure
3. Install each spacer (with packing seals) in the proper sequence in
the packing box. Handle each spacer from the ID to ensure that
no grease gets between the metal portions of the spacer, or on
the outside diameter of the spacer. When installing the upper
spacer, line up the slot in the upper spacer with the dowel pin in
the packing box.
Dowel
Grease Pin
Fitting
Socket Head
Dog Nose
Screw
Packing
Box

the lower spacer (screw should
not push spacer off center)
.010" Min
i
In the following step, an Arbor press may be required
to compress the packing enough to in stall the screws.
4. Install the socket head cap screws. The heads of the screws
should bottom out in the nut casing. The dog head should not
bottom out on the space er. The screw prevents the spacers from
not otherwise constrain them.

5.
packing box.
6.
NOT OVER GREASE.
Washpipe 31
Reassembly
Procedure
7. Lightly grease the washpipe, then install the washpipe into the
packing box, with the slotted end of the washpipe up and the non-
slotted end flush with the bottom edge of the packing box.
8. Install the washpipe nut onto the washpipe.
Washpipe
Nut
Washpipe
Packing
Box
32 Varco
Reassembly
Procedure
9. Lightly grease the packing seal, fill the plunge with grease, and
install in the holding ring, taking care to not damage the seal on
the splines of the washpipe. Wipe all excess grease from the top
edge of the packing and wipe all grease from the holding ring.
Holding
Ring
Wipe grease
from area shown,
all the way around
the holding ring. Packing
Seal
Fill with grease
to level shown. Holding
Ring
10. Insert the holding ring and packing, seal side down, over the
slotted end of the washpipe.
Packing
11. Install the snap ring. Seal
12. Install the upper and lower O-rings. Apply a light coat of grease
to the O-rings.
Snap
Ring
O-ring
13.
approximately the length of the washpip
pe.
14.
Initial Installation Procedure.
Washpipe 33
Illustrated Parts List
O-Ring
Snap Ring
Holding Ring
Upper Spacer
Packing Set
5 per set
Washpipe
Nut
Middle Spacer
Middle Spacer
Washpipe
Lower Spacer
Packing Box
O-Ring
Grease Fitting
Socket Head
Dog Nose Screw
Long-Arm
Allen Wrench
34 Varco
Description Small Bore Large Bore Large-to-Small

(3-inch) (4-inch) Bore
Washpipe Assembly 30123290 30123440 30153491
O-Ring 51300-348-F 51300-359-F 51300-348-F
Snap Ring 30123562 123634 30123562
Holding Ring 30123288 30123437 30123288
Washpipe Nut 123284 30123431 30153493
Washpipe 30123289 30123438 30123289

(7,500 psi) (7,500 psi) (7,500 psi)
Packing Box 30123563 30123626 30153494
Grease Fitting 53219-1 53219-1 53219-1
Socket Head Screw 30123564 30123564 30123564
Upper Spacer 123585 30123434 123585
Middle Spacer 30123286 30123435 30123286
Lower Spacer 123287 30123436 123287
Pressure Seal Kit 30123290-PK 30123440-PK 30123290-PK

(Packing Set)
Stem Liners 98290 112871 30153492
Poly Pak Seal 98291 112895 112895
Grease 56005-1 56005-1 56005-1
Washpipe 35
Procedure
i
During installation the washpipe assembly is brought into
place as one unit and handled by a tugger line. Ensure that
the washpipe assembly is strapped together securely
before lifting.
1. Unlock the TDS/IDS handling yoke from its stored position

and swing it out to accept the washpipe assembly.
Makes the washpipe assembly

easier to install by allowing it to
swing in and out of the motor-
support bonnet.
Nut
Yoke 2 places
36 Varco
Procedure
the TDS/IDS main shaft.

4.
it until it makes contact with the top of the main shaft.
5.
packing box and the washpipe nuts.
6. Apply pipe dope to the threads and hand-tighten the
washpipe nut and packing box.
7.
align the pipe in the packing box.
8. Set the TDS/IDS brake.
Torque Multiplier Torque Wrench

Ratio – 18.5 to 1
Removable extension
9. Loosen the thumb screw on the pinion gear and raise the
pinion gear from its stored position and lock the thumb
screw in place when it aligns with the gear on the packing
box. It may be necessary to rotate the square drive shaft
to engage the gears.
10. Install the torque kit assembly over the square shaft. Set
the torque wrench to 100 ft-lb and begin applying torque to
the packing box gradually until the torque wrench clicks.
Torque Wrench Applied Torque to

Setting-ft.-lbf. Nut-ft.-lbf.
75 4,500
100 6,000
125 7,500
150 9,000
11. Disengage the pinion gear from the packing box gear and
engage it with the washpipe nut gear and secure it in
place. Similarly, apply torque to the washpipe nut,
completing the installation of the washpipe assembly.
12. Apply 6 to 8 pumps of grease to the grease fittings.
13. Return the pinion gear to its stored position and secure it
with the thumb screw. Secure the handling yoke to its
stored position by pinning it with the two pins.
14. Release the TDS/IDS brake and rotate the TDS/IDS at
approximately 50 rpm for one minute.
Washpipe 37
Inspection Schedule
Item Inspect for Interval
Mating surface of stem liner(s) while • Surface should be When washpipe

it is installed in the TDS/IDS main smooth and free of flaws assembly is to be
shaft or gooseneck or burrs removed from TDS/
IDS
• ID of stem liners
TDS/IDS main shaft bearing endplay Endplay is within Once every six months
specification (refer to and immediately after
TDS/IDS Service jarring
Manual)
Washpipe Assembly grease fitting Proper operation Replace every six

months
Washpipe pilot on the gooseneck Proper alignment After TDS/IDS main

and the washpipe pilot on the TDS/ between pilots shaft bearing endplay
IDS main shaft has been checked and
is within specification
All parts Refer to Disassembly Upon disassembly of

Procedure washpipe assembly
Cleaning Schedule
TDS bonnet (inside) Remove residual mud Weekly
Lubrication Schedule
Washpipe Assembly grease fitting Apply 3 to 4 pumps of Twice daily or every 10

grease rotating hours
!
To prevent rust from damaging parts, properly clean and
grease the following parts before storage:
1. Jacking nut and shaft threads

2. Square shaft from top to bottom
3. Gear teeth on all three gears
38 Varco
Every Six Months
Washpipe Assembly Alignment
Satisfactory packing life depends on good washpipe alignment. Use the following
procedure to check sleeve-to-gooseneck support alignment:
1. Attach an indicator base to the gooseneck support and place the indicator at the
top of the sleeve.
2. Raise and lower the sleeve and record the total indicator reading.
3. Attach a magnetic indicator base or an improvised holding fixture to the sleeve or
packing box.
4. Rotate the sleeve 360° and record the TIR.
Washpipe Assembly Tolerances
Use the following procedure to check washpipe assembly tolerances:
1. Shim the gooseneck support to obtain a required bearing clearance of 0.001 to
0.003 inch.
2. Check the clearance by raising and lowering the sleeve. The maximum allowable
misalignment at the gooseneck support bore is 0.008 inch TIR. The maximum
allowable misalignment at the gooseneck pilot is 0.010 inch TIR. The maximum
allowable misalignment after complete assembly of the washpipe assembly is
0.010 inch TIR.
i
Inspection may indicate misalignment exceeding
recommended limits. The packing box assemblies are
designed to accommodate misalignment of the sleeve to
the gooseneck and can operate with some excessive
misalignment. However, to achieve maximum packing life,
maintain the misalignment at the washpipe within the
recommended limits.
Washpipe 39
Every Six Months
Procedure
1. Remove the washpipe assembly and replace
the grease fitting.
2. Check the mainshaft axial movement by
applying an upward force to the mainshaft and
dial indicator.
3. If axial shaft movement is not .001 in. to .003
in., remove the bearing retainer and adjust the Washpipe
number of shims under the bearing retainer as Grease Fitting
required to allow .001 in. to .003 in. of axial Replace
shaft movement (end play) with the bearing
retainer capscrews tightened to the required
torque depending on the size of the capscrew
(refer to the Initial Installation Procedure for
proper torque requirements).
Dial
Indicator
40 Varco
Every Six Months
Gooseneck
Pilot
Dial
Indicator
0.002 TIR between Bonnet removed

these two surfaces for clarity.
Main Shaft
Pilot
Washpipe 41
Daily Lubrication
Recommended Grease Procedure
Manufacturer Description 1. Twice daily or once every 10 hours of rotation,
apply 3 to 4 pumps of grease to the washpipe
Shell Cyprina grease fitting.
2. Rotate the TDS/IDS at 50 rpm for one minute
with 0 psi standpipe pressure.
3. Turn on the mud pumps and check for leaks.
42 Varco
Troubleshooting
i
The troubleshooting table does not necessarily cover all
possible symptoms. The table provides an insight to typical
symptoms, their possible causes, and what components to
check.

Leakage at threads Poly Pak seal failure in main Replace seal by removing the stem liner
between packing box and shaft stem liner and installing the new seal. Be sure to
TDS/IDS main shaft deburr the edges of the main shaft as
washpipe assembly.
Stem liner not smooth and Follow instructions outlined in the
does not allow O-ring to seal Inspection Procedures, When Washpipe
Stem liner not flat and does Follow instructions outlined in the
not allow O-ring to seal Inspection Procedures, When Washpipe
Spacers not flat and prevents Follow inspection procedures as outlined
packing seals from sealing in step 8 of the Disassembly Procedure.
Leakage at grease fitting Poly Pak seal failure in main Replace seal by removing the stem liner
access hole shaft stem liner and installing the new seal. Be sure to
deburr the edges of the main shaft as
washpipe assembly.
Washpipe 43
Troubleshooting
Leakage through grease Spacers not flat and prevents Follow inspection procedures as outlined
fitting access hole (cont) packing seals from sealing the Inspection Procedure.
Leakage at grease fitting Grease fitting failure Follow inspection procedures as outlined
in step 12 of the Disassembly Procedure.
Leakage between the Packing failure Disassemble and inspect components.
washpipe and the packing Replace worn or damaged components
box on reassembly of the washpipe.
Leakage between the Packing failure or packing is Disassemble and inspect components.
washpipe and the improperly seated Replace worn or damaged components
washpipe nut on reassembly of the washpipe.
Upper O-ring failure 1. Remove washpipe assembly. and
replace O-ring.
2. Inspect the gooseneck and, for big
liner.
washpipe assembly.
Leakage at threads Upper O-ring failure 1. Remove washpipe assembly. and
between washpipe nut and replace O-ring.
gooseneck 2. Inspect the gooseneck and, for big
liner.
washpipe assembly.
Packing failure or packing Disassemble and inspect components.
is improperly seated Replace worn or damaged components
on reassembly of the washpipe.
Premature failure after Improper greasing Greasing can cause the seal to unseat
greasing procedure from the washpipe and cause premature
failure of the assembly. Running the TDS/
IDS without standpipe pressure allows
the seals to reseat. Follow greasing
procedure as outlined in the Lubrication
Procedures.
44 Varco
Troubleshooting
Premature failure Washpipe alignment caused If necessary, reinstall washpipe or realign
accompanied by by improper installation, or the gooseneck. Check washpipe
occasional spurts of mud misalignment of the alignment as follows (see illustration on
from packing box gooseneck, or excessive following page):
bearing endplay 1. Install dial indicator base on packing
box. Adjust dial indicator to contact the
washpipe approximately one inch above
the packing box.
2. Rotate main shaft through one
revolution, noting the minimum and
maximum readings on the dial indicator.
Subtract the minimum reading from the
maximum reading to obtain the Total
Indicated Runout (TIR). Maximum
allowable TIR is 0.007 inch.
3. If out of specification, check
gooseneck alignment.
Premature failure Misalignment of gooseneck- Inspect main shaft and mainshaft-to-
accompanied by to-washpipe pilot gooseneck alignment as described in the
occasional spurts of mud Every Six Months Inspection procedure.
from packing box
Installation problems The proper installation sequence allows
the packing and washpipe to align to each
other, and ensures that both the
washpipe nut and the packing box
engage their pilots. Follow proper
installation procedures (refer to the Initial
Installation Procedure).
Premature failure due to Nut not torqued Improper torque prevents metal-to-metal
flanged packing contact between the flat surfaces of the
Procedure.
Too mush grease during Too much grease prevents metal-to-metal
assembly of the unit contact between the flat surfaces of the
spacers during operation. The grease can
sustain a hydrostatic pressure that resists
torque during the installation.
During operation the grease gradually

leaks out resulting in loosening of the
packing box. Follow proper greasing
procedure during reassembly and check
for proper spacer contact during
installation (refer to the Initial Installation
Procedure).
Washpipe 45
Troubleshooting
Washpipe
Dial
Indicator
Packing
Box
46 Varco
Troubleshooting
Packing is worn out Poor greasing schedule or Follow proper lubrication procedures.
improper grease.
RPM, pressure and mud Friction between the seals and the
temperature too high washpipe create heat. TDS/IDS rpm and
standpipe pressure contribute equally to
the amount of heat generated. If
pressure of rpm is increased, so is the
amount of heat generated. Heat
generation goes up with the square of the
bore size. Mud is what cools the system.
The hotter the mud, the less cooling it
provides. The greater the amount of heat
generated is relative to the amount of
cooling the mud will provide, the hotter
the seals run. As the seals run hotter, the
wear resistance of the rubber drops. If
using a large-bore washpipe, convert to a
small-bore washpipe.
Packing extruding Spacers too flat If the spaces are not flat, then metal-to-
between spacers metal contact cannot be maintained even
when they are bottomed out against each
other. The resulting small gaps will allow
the packing to extrude into these areas.
Follow instructions outlined in the
Inspection Procedures.
Nut not torqued Improper torque prevents metal-to-metal
contact between the flat surfaces of the
Procedure.
Blue spacers Improper torque or grease Improper torque on the nut can lead to
on the OD of the spacers situations where the lower and middle
spacers spin the packing box. The
resulting heat achieves temperatures
high enough to turn the spacers blue.
Unable to maintain torque Improper assembly or 1. Remove washpipe assembly from
on packing box installation TDS/IDS.
2. Disassemble the washpipe assembly,
setting aside the packing seals for the
lower, middle, and upper spacers.
3. Reassemble the washpipe assembly
without the packing seals for the lower,
middle, and upper spacers.
Washpipe 47
Troubleshooting
Unable to maintain torque 4. Reinstall the washpipe assembly on
on packing box (cont) the TDS/IDS as follows:
a. Install the packing box onto the TDS/
IDS main shaft. Tighten until spacers are
firmly held.
b. Install the holding ring into the
washpipe nut and install washpipe nut
onto the TDS/IDS goosneck until the
holding ring is firmly in place.
c. Using a dial indicator, measure and
record the distance between the flat
surfaces on the washpipe nut and the
packing box. Also for future use, mark the
location where the measurement is taken.
NOTE
To ensure that the washpipe assembly
has been sufficient tightened, measure
the distance with each subsequent
installation of the washpipe assembly.
48 Varco
Removing the Washpipe Assembly
Remove the washpipe assembly by reversing the Installation Procedure.
!
Once the packing box and washpipe nuts are unscrewed,
the assembly must be strapped together as one unit before
it is picked up by the handling yoke.
i
The hammerless washpipe assembly must always be
handled as one unit. Avoid disassembly unless you
suspect faulty parts (refer to Troubleshooting).
Washpipe 49
Disassembly
Procedure Snap Ring
1. Remove washpipe assembly from the TDS/IDS.

2. Completely disassemble the washpipe assembly.
Holding Ring
Take care to prevent damage to the sharp edge
of the upper and middle spacers.
3. Dispose of packing, washpipe and O-rings.
These parts are not serviceable and must be
replaced.
Washpipe
Nut
O-Ring
Packing
Box
i
Grease
Discard and replace
Washpipe Fitting
these non-serviceable
parts from the
washpipe assembly. Socket Head
Dog Nose Screw
Upper Spacer
Packing Set Middle Spacer

(5 per Set)
Middle Spacer
O-Ring
50 Varco
Disassembly
Procedure
4. Thoroughly clean and inspect remainder of parts.
5. Check that the ID of each spacer is within specification.
6. Check that the flat portions of each spacer are free of burrs that
could prevent the spacers from seating properly. Burrs should be
lightly filed flush. If surfaces are out-of-flat, replace spacer.
7. The edge that directly backs up the packing should be free of
cuts, nicks, and burrs. If edge is damaged replace spacer.
This surface to be
smooth and flat
ID This edge to be
This surface to be
sharp
smooth and flat
Varco Proper Service

Washpipe Part ID Limit ID
Assembly Spacer No. (inches) (inches)
Large Bore Upper 30123434 4.895 to 4.900 4.905

Upper Spacer
Middle 30123435 4.895 to 4.900 4.905
Lower 30123436 4.895 to 4.900 4.905
Large to Small Bore Upper 123585 3.635 to 3.640 3.645

Middle Spacer
Middle 30123286 3.635 to 3.640 3.645
Lower 123287 3.635 to 3.640 3.645
Washpipe 51
Disassembly
Procedure
8. Check that the ID of the washpipe nut where the washpipe
passes through.
9. Check that the ID of the packing box where the washpipe passes
through.
hpipe
ut
ID
Packing
Box
Washpipe Washpipe Nut Proper ID Service Limit ID

Large Bore 30123431 4.905 to 4.910 4.915

Large to 30153493 3.655 to 3.660 3.665
Small Bore
Washpipe Packing Box Proper ID Service Limit ID

Large Bore 30123626 4.900 to 4.905
Large to 30153494 3.637 to 3.644 3 650

Small Bore
52 Varco
Disassembly
Procedure
10. Inspect the holding ring drive dogs. Each dog has a slight
undercut. If the undercut is no longer visible, replace the holding Holding
ring. Ring
This surface to be
smooth and flat
Undercut
Grea
Fitti
This surface to be
smooth and flat
11. Check that the flat portions of the holding ring are free of burrs
that could prevent the ring from seating properly. Burrs should
be lightly filed flush.
12. Inspect the spring tension in the ball of the grease fitting. If the
ball is not properly tensioned, replace the grease fitting. If in
doubt, replace the grease fitting. Replace the grease fitting every
six months or every other rebuild of the washpipe assembly,
whichever period is longer, even if the grease fitting is working
properly.
13. Reassemble the washpipe assembly as described in the
Reassembly Procedure.
Washpipe 53
Reassembly
Procedure
1. Apply a light grease film to the outside of each packing seal and
fill the plunge with grease, flush with the packing.
Packing
Seal
Fill with grease

to level shown
Spacer
2. Install one packing seal into each of the four spacers (one upper,
two middle, one lower) that go into the packing box. Wipe all
excess grease from the top edge of the packing and all excess
grease from the spacers. Take care to prevent damage to the
sharp edges of the spacers.
Upper Spacer
Sharp edge
of spacer Wipe grease
from area shown,
all the way around Middle Spacer
Sharp edge on each spacer.
of spacer
Sharp edge
of spacer
54 Varco
Reassembly
Procedure
3. Install each spacer (with packing seals) in the proper sequence in
the packing box. Handle each spacer from the ID to ensure that
no grease gets between the metal portions of the spacer, or on
the outside diameter of the spacer. When installing the upper
spacer, line up the slot in the upper spacer with the dowel pin in
the packing box.
Dowel
Grease Pin
Fitting
Socket Head
Dog Nose Packing
Screw Box

the lower spacer (screw should
not push spacer off center)
.010" Min
i
In the following step, an Arbor press may be required
to compress the packing enough to in stall the screws.
4. Install the socket head cap screws. The heads of the screws
should bottom out in the nut casing. The dog head should not
bottom out on the space er. The screw prevents the spacers from
not otherwise constrain them.

5.
packing box.
6.
NOT OVER GREASE.
Washpipe 55
Reassembly
Procedure
7. Lightly grease the washpipe, then install the washpipe into the
packing box, with the slotted end of the washpipe up and the non-
slotted end flush with the bottom edge of the packing box.
8. Install the washpipe nut onto the washpipe.
Washpipe
Nut
Washpipe
Packing
Box
56 Varco
Reassembly
Procedure
9. Lightly grease the packing seal, fill the plunge with grease, and
install in the holding ring, taking care to not damage the seal on
the splines of the washpipe. Wipe all excess grease from the top
edge of the packing and wipe all grease from the holding ring.
Holding
Ring
Wipe grease
from area shown,
all the way around
the holding ring. Packing
Seal
Fill with grease
to level shown. Holding
Ring
10. Insert the holding ring and packing, seal side down, over the
slotted end of the washpipe.
Packing
11. Install the snap ring. Seal
12. Install the upper and lower O-rings. Apply a light coat of grease
to the O-rings.
Snap
Ring
O-ring
13.
approximately the length of the washpip
pe.
14.
Initial Installation Procedure.
Washpipe 57
O-Ring
Snap Ring
Holding Ring
Upper Spacer
Packing Set
5 per set
Washpipe
Nut
Middle Spacer
Middle Spacer
Washpipe
Lower Spacer
Packing Box
O-Ring
Grease Fitting
Socket Head
Dog Nose Screw
Long-Arm
Allen Wrench
58 Varco
Description Large Bore Large-to-Small Bore

(4-inch)
Washpipe Assembly 30156883 & 30156883-750 30173058-50 & 30173058-100
O-Ring 51300-359-F 51300-348-F
Snap Ring 123634 30123562
Holding Ring 30123437 30123288
Washpipe Nut 30152547 30173057
Washpipe - Low Pressure 30123438 (7,500 psi) 30123289 (7,500 psi)
Washpipe - High Pressure 30123438-TC (7,500 psi) 30123289-TC (10,000 psi)
Packing Box 30156884 30173056
Grease Fitting 53219-1 53219-1
Socket Head Screw 30123564 30123564
Upper Spacer 30123434 123585
Middle Spacer 30123435 30123286
Lower Spacer 30123436 30123287
Pressure Seal Kit (Packing 30123584-2 (7,500 psi) 123292-2 (7,500 psi)
Set)
Stem Liner 112871 30153492
Poly Pak Seal 112895 112895
Grease 56005-1 56005-1
Washpipe 59
Glossary
ID - Inner Diameter
IDS - Integrated Drilling System
OD - Outer Diamaeter
TDS - Top Drive System
TIR - Total Indicator Reading
60 Varco
FINAL DOCUMENTATION
Chapter 3.0
Links User Manual
www.nov.com
LINKS
Weldless Links
Perfection Links
USER’S MANUAL
Original Instructions
REFERENCE REFERENCE DESCRIPTION
Links Weldless Links and Perfection Links
This document contains proprietary and confidential VarcoBJ BV

information which is the property of National Oilwell Nijverheidsweg 45
Varco, L.p, its affiliates or subsidiaries (all collectively referred
to hereinafter as "NOV"). It is loaned for limited purposes
4879 AP Etten-Leur
only and remains the property of NOV. Reproduction, in P.O. Box 17
whole or in part, or use of this design or distribution of this 4870 AA Etten-Leur
information to others is not permitted without the express The Netherlands
written consent of NOV. This document is to be returned to
NOV upon request or upon completion of the use for which Tel + 31-76-5083000
it was loaned. This document and the information contained Fax + 31-76-5046000
and represented herein is the copyrighted property of NOV. www.nov.com
DOCUMENT NUMBER REV
50000870-MAN-001 E
Nov 2011
www.nov.com
User’s Manual
Weldless Links
Perfection Links

Link Links
National Oilwell Varco, L.p., its affiliates or subsidiaries (all collectively referred to
VarcoBJ B.V.
hereinafter as "NOV"). It is loaned for limited purposes only and remains the property of Nijverheidsweg 45
information to others is not permitted without the express written consent of NOV. This 4879AP Etten-Leur
it was loaned. This document and the information contained and represented herein is
Tel: +31-76-5083000
the copyrighted property of NOV. Fax: +31-76-5046000
DOCUMENT NUMBER REV
50000870-MAN-001
E
www.nov.com
Document number 50000870-MAN-001
Revision E
Page 2 of 20
Revision History

- First Issue
A New style
B Corrections
C Corrections
D Info added
E Corrections
This document is PDM-link controlled
Change Description
E 21.11.2011 Corrected link compatibility

E 21.11.2011 Added information about allowable twist & wear data
D 01.06.2009 Added Link connectors info
C 18.05.2009 Added wear size Perfection links
B 28.10.2008 Added Link connector info
B 30.06.2008 Page 14: The SLX 5.1/2” - 24.1/2” link DOES fit in 500 tons 3.1/2” links, pn 25469
A 26.03.2007 Data updated; part numbers, inspection,handle
- 12.03.2007 Issued for Implementation
Rev Date Reason for issue
© Copyright 2011 NOV®. All rights reserved.
Varco is a registered trademark of Varco I/P reg. U.S. Patent & Trademark Office. This publication is the property of, and
contains information proprietary to NOV. No part of this publication may be reproduced or copied in any form, or by any means,
including electronic, mechanical, photocopying, recording or otherwise, without the prior written permission of NOV®.
All product, brand, or trade names used in this publication are the trademarks or registered trademarks of their respective
owners. Information in this manual is subject to change without notice.
Patents Pending US & Worldwide (D) Varco I/P, Inc. No US. D533,432.
www.nov.com
Revision E
Page 3 of 20
Table of Contents
General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Conventions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Notes, Cautions, and Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Illustrations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Safety Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Personnel Training . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Recommended Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
General System Safety Practices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Replacing Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Routine Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Proper Use of Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Lifting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Link restrictions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Design safety factor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Safe Working Load . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Limited warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Identification numbers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
CE marking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
General specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Weldless Links . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Perfection Links . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Intended usage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Reference Numbers* . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Perfection links . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Link handle kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Fitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Elevator link compatibility . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Link connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Inspection & wear data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Wear chart shaft (shank) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Wear chart forged links . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Wear data Perfection links. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
MPI and inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
References . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Qualifications and certification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Evaluation of indications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Acceptance criteria . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Equipment covered . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
www.nov.com
Revision E
Page 4 of 20
Table of Contents
www.nov.com
1: General Information Revision E
Page 5 of 20
General Information
This manual contains installation, operation, maintenance and parts information. Information in
this manual should enable qualified personnel to install, operate and troubleshoot this system.
Every effort has been made to ensure the accuracy of the information contained herein. National
Oilwell Varco (NOV) will not be held liable for errors in this material, or for consequences arising
from misuse of this material.
Conventions
Notes, Cautions, and Warnings
Notes, cautions, and warnings provide readers with additional information and advise the reader
to take specific action to protect personnel from potential injury or lethal conditions. They may
also inform the reader of actions necessary to prevent equipment damage. Please pay close
attention to these advisories
Note: The note symbol indicates that additional information is provided about the
current topics.
Caution: The caution symbol indicates that potential damage to equipment or injury
to personnel exists. Follow instructions explicitly. Extreme care should be
taken when performing operations or procedures preceded by this caution
symbol.
Warning: The warning symbol indicates a definite risk of equipment damage or

danger to personnel. Failure to observe and follow proper procedures
could result in serious or fatal injury to personnel, significant property
loss, or significant equipment damage.
Illustrations
snapshots for use in identifying parts or establishing nomenclature, and may or may not be
drawn to scale.
For component information specific to your application, see the technical drawings included with
your NOV documentation.
Safety Requirements
NOV equipment is installed and operated in a controlled drilling rig environment involving
hazardous situations. Proper maintenance is important for safe and reliable operation.
Procedures outlined in NOV manuals are the recommended methods of performing operations
and maintenance.
Caution: To avoid injury to personnel or equipment damage, carefully observe

requirements outlined in this section.
www.nov.com
Revision E 1: General Information
Page 6 of 20
Personnel Training
equipment, or those in the vicinity of the equipment, should be trained on rig safety, tool
operation, and maintenance to ensure their safety.
Caution: Personnel should wear protective gear during installation, maintenance, and
certain operations.
Recommended Tools
NOV recommends that only those tools specified be used when stated. Ensure that personnel
and equipment safety are not jeopardized when following service procedures or using tools not
specifically recommended by NOV.

The equipment discussed in this manual may require or contain one or more utilities, such as
Caution: Read and follow the guidelines below before installing equipment or performing
maintenance to avoid endangering exposed persons or damaging equipment.
Isolate energy sources before beginning work.

Avoid performing maintenance or repairs while the equipment is in operation.
Wear proper protective equipment during equipment installation, maintenance, or repair.
Verify that all components (such as cables, hoses, etc.) are tagged and labeled during
assembly and disassembly of equipment to ensure correct installment.
Replace failed or damaged components with genuine NOV parts. Failure to do so could
Routine Maintenance
Equipment must be maintained on a routine basis. See the service manual for maintenance
recommendations.
Caution: Failure to conduct routine maintenance could result in equipment damage or


NOV equipment is designed for specific functions and applications, and should be used only for
its intended purpose.
Lifting
The lifting procedures should carefully be observed and carried out according to the manual.
Link restrictions
The Link is designed to be used as an connecting element between Top Drive Systems and
elevators, or between Hooks and elevators, and must not be used for any other purpose.
www.nov.com
1: General Information
Revision E
Page 7 of 20
Design safety factor

The design-safety factor and design verification of the links is in accordance with requirements
of API specification 8A, 8C PSL 1 or 8C PSL2.
During manufacturing the link is proof load tested to 1.5 times the rated load.
Safe Working Load

Per API Specification 8C – The operator of the equipment shall be responsible for determination
of the safe working load for any hoisting operation. The Safe working load is equal to the design
load minus the dynamic load.
Limited warranty
The warranty will be void if the Link were either:
unauthorized modified, repaired or serviced
replacement parts not manufactured by NOV were utilized
not properly stored or maintained
any welding is carried out
Identification numbers
You will find the serial number of the tool stamped into the shank near the small eye.
CE marking
The link complies with the Machinery Directive 98/37/EC and 2006/42/EC
The marking is as follows:
www.nov.com
Revision E 1: General Information
Page 8 of 20
www.nov.com
2: Specifications
Revision E
Page 9 of 20
General specifications
Description
Weldless Links
Weldless links are forged from a single billet of high strength alloy steal and heat treated to
provide maximum strength and toughness. Additional material is added in critical wear areas for
extended life. NOV Weldless Links are available in 250, 350, 500, 750, and 1000 ton ratings.
Perfection Links
Dependable, efficient perfection links are designed for light loads. They are made by forging,
bending and electric welding of high quality steel bar stock, which is then heat-treated and
magnafluxed. For loads which exceed capacity ratings of perfection links Varco BJ Weldless
links are recommended.
Intended usage
The links are designed to hang elevators from Top Drive Systems, Hooks, Beckets and Link
Adapters.
Fig. 1
www.nov.com
Revision E 2: Specifications
Page 10 of 20
Part No. Nominal link Size, in (mm) Rated Capacity /Set, Weight/Set,
size (inch) tons (tonnes) lb (Kg)
16363-1060 2.1/4 x 60 60” (1524) 250 (226.8) 480 (218)
16363-1072 2.1/4 x 72 72” (1828.8) 250 (226.8) 530 (241)
16363-1084 2.1/4 x 84 84” (2133.6) 250 (226.8) 580 (264)
16363-1096 2.1/4 x 96 96” (2438.4) 250 (226.8) 630 (286)
16363-1108 2.1/4 x 108 108” (2743.2) 250 (226.8) 680 (309)
16363-1132 2.1/4 x 132 132” (3353) 250 (226.8) 780 (355)
16363-1168 2.1/4 x 168 168” (4267) 250 (226.8) 880 (399)
26940-1060 2.3/4 x 60 60” (1524) 350 (317.5) 620 (282)
26940-1072 2.3/4 x 72 72” (1828.8) 350 (317.5) 685 (311)
26940-1084 2.3/4 x 84 84” (2133.6) 350 (317.5) 740 (336)
26940-1096 2.3/4 x 96 96” (2438.4) 350 (317.5) 805 (366)
26940-1108 2.3/4 x 108 108” (2743.2) 350 (317.5) 870 (395)
26940-1120 2.3/4 x 120 120” (3048) 350 (317.5) 935 (425)
26940-1132 2.3/4 x 132 132” (3353) 350 (317.5) 1,000 (454)
26940-1144 2.3/4 x 144 144” (3657) 350 (317.5) 1,064 (483)
26940-1150 2.3/4 x 150 150” (3810) 350 (317.5) 1,095 (498)
26940-1168 2.3/4 x 168 168” (4267.2) 350 (317.5) 1,190 (541)
26940-1180 2.3/4 x 180 180” (4572) 350 (317.5) 1,255 (571)
26940-1192 2.3/4 x 192 192” (4876.8) 350 (317.5) 1,320 (600)
26940-1200 2.3/4 x 200 200” (5080) 350 (317.5) 1,363 (618)
26940-1216 2.3/4 x 216 216” (5486.4) 350 (317.5) 1,450 (659)
26940-1240 2.3/4 x 240 240” (6096) 350 (317.5) 1,580 (718)
26940-1264 2.3/4 x 264 264” (6705) 350 (317.5) 1,770 (800)
26940-1290 2.3/4 x 290 290” (7366) 350 (317.5) 1,944 (882)
26940-1350 2.3/4 x 350 350” (8890) 350 (317.5) 2,180 (988)
26940-1360 2.3/4 x 360 360” (9144) 350 (317.5) 2,235 (1014)
26940-1480 2.3/4 x 480 480” (12192) 350 (317.5) 2,885 (1306)
26940-1540 2.3/4 x 540 540” (13716) 350 (317.5) 3,187 (1446)
26940-1600 2.3/4 x 600 600” (15240) 350 (317.5) 3,408 (1546)
25469-1072 3.1/2 x 72 72” (1829) 500 (453.6) 705 (320)
25469-1096 3.1/2 x 96 96” (2438) 500 (453.6) 1058 (480)
25469-1108 3.1/2 x 108 108” (2743.2) 500 (453.6) 1,450 (659)
25469-1120 3.1/2 x 120 120” (3048) 500 (453.6) 1,622 (736)
25469-1132 3.1/2 x 132 132” (3353) 500 (453.6) 1,670 (759)
25469-1144 3.1/2 x 144 144” (3688) 500 (453.6) 1,780 (809)
25469-1160 3.1/2 x 160 160” (4064) 500 (453.6) 1,927 (876)
25469-1168 3.1/2 x 168 168” (4267.2) 500 (453.6) 2,000 (909)
25469-1180 3.1/2 x 180 180” (4572) 500 (453.6) 2,110 (959)
25469-1190 3.1/2 x 190 190” (4826) 500 (453.6) 2,202 (998)
25469-1192 3.1/2 x 192 192” (4826) 500 (453.6) 2,220 (1007)
25469-1216 3.1/2 x 216 216” (5486) 500 (453.6) 2,422 (1098)
25469-1226 3.1/2 x 226 226” (5740) 500 (453.6) 2,596 (1177)
25469-1264 3.1/2 x 264 264” (6705.6) 500 (453.6) 2,882 (1307)
25469-1360 3.1/2 x 360 360” (9144) 500 (453.6) 3,174 (1440)
25469-1480 3.1/2 x 480 480” (12192) 500 (453.6) 3,968 (1800)
25469-1540 3.1/2 x 540 540” (13716) 500 (453.6) 4,519 (2050)
www.nov.com
2: Specifications
Revision E
Page 11 of 20
Part No. Nominal link Size, in (mm) Rated Capacity /Set, Appr. weight/
size (inch) tons (tonnes) Set, lb (Kg)
16143-1132 4.3/4 x 132 132” (3352) 750 (680.4) 1,741 (790)
16143-1144 4.3/4 x 144 144” (3688) 750 (680.4) 2,312 (1051)
16143-1160 4.3/4 x 160 160” (3688) 750 (680.4) 3,178 (1445)
16143-1180 4.3/4 x 180 180” (4572) 750 (680.4) 3,900 (1769)
16143-1200 4.3/4 x 200 200” (5080) 750 (680.4) 4,550 (2063)
16143-1216 4.3/4 x 216 216” (5486) 750 (680.4) 5,200 (2364)
16143-1240 4.3/4 x 240 240” (6096) 750 (680.4) 5,864 (2660)
16143-1264 4.3/4 x 264 264” (6705) 750 (680.4) 7,275 (3300)
16143-1300 4.3/4 x 300 300” (7620) 750 (680.4) 8,800 (3991)
70101-1200* 5.1/2 x 200 200” (5080) 1000 (907.2) 5,100 (2315)
M614000320Y1180 5.1/2 x 180 200” (5080) 1,250 (1133) 4,550 (2063)
M614000320Y1200 5.1/2 x 200 200” (5080) 1,250 (1133) 5,100 (2315)
M614000320Y1240 5.1/2 x 240 200” (5080) 1,250 (1133) 7,275 (3300)
For TDS-4 and TDS-5
15386-1108 2.3/4 x 108 108” (2743.2) 350 (317.5) 920 (418)
* other lengths on request
Reference Numbers*
Link P/N Nominal Dim. A B C D E F G H
250 Ton
16363 2.1/4” in 2.5/16" 5.1/2" 7.1/2" 2.7/8" 9.1/2" 12" 5" 15"
“ “ (mm) 58.7 139.7 190.5 73 241.3 304.8 127 381
350 Ton
26940 2.3/4 in 2.13/16" 5.5/8" 8.3/8" 3.1/2" 9.1/2" 12" 5" 15"
" “ (mm) 71.4 142.9 212.7 88.9 241.3 304.8 127 381
500 Ton
25469 3.1/2 in 3.5/8" 6.1/2" 10.1/8" 4.1/2" 9.1/2" 12" 6" 17"
" “ (mm) 92.1 165.1 257.2 114.3 241.3 304.8 152.4 431.8
750 Ton
16143 4.3/4 in 7.1/2" 10" 14.5/8" 6" 10" 14.5/8" 7.1/2" 23"
" “ (mm) 190.5 254 371.5 152.4 254 371.5 190.5 584.2
1000 Ton
70101 5.1/2 in 8.1/4" 12.3/4" 17.1/2" 6" 12.3/4" 17.1/2" 8.1/4" 29.1/4"
" “ (mm) 209.6 323.9 444.5 152.4 323.9 444.5 209.6 743
1250 Ton
M614000320 5.1/2 in 8.1/4" 12.3/4" 17.1/2" 6" 12.3/4" 17.1/2" 8.1/4" 29.1/4"
" “ (mm) 209.6 323.9 444.5 152.4 323.9 444.5 209.6 743
* The dimensions are nominal and actual dimensions will vary slightly due to manufacturing
tolerances. All API contact radius dimensions are manufactured to API specifications, see Fig. 1
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Page 12 of 20
Perfection links
9.00
5.00
Fig. 2
2.00
3.12
Part No. Size, in (mm) Rated Cap/Set, Weight/Set, lb Dimension X inch

tons (tonnes) (Kg) (mm))
200450-130 2” x 30” (50.8 x 762) 100 (89.3) 49 (108) 30 (762)
200450-136 2” x 36” (50.8 x 914) 100 (89.3) 58 (128) 36 (914)
200450-142 2” x 42” (50.8 x 1,067) 100 (89.3) 67 (148) 42 (1,067)
200450-148 2” x 48” (50.8 x 1,219) 100 (89.3) 76 (168) 48 (1,219)
200450-160 2” x 60” (50.8 x 1,524) 100 (89.3) 95 (208) 60 (1,524)
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2: Specifications
Revision E
Page 13 of 20
Link handle kit

The Link handle kit can be used in combination with any Manual Operated Elevator. It is
developed for easier handling of links and functions as a safe gripping point when closing and
opening elevators. It suitable for 250 (2.1/4”) and 350 (2.3/4”)ton links.
Part number 50006435.
Fitting
The handle(s) must be mounted to the eye of the link, and not to the shank.
Ensure no interference occurs between handle and elevator when rotating the elevator.
Fitted
handle
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Page 14 of 20
Elevator link compatibility

WARNING: Never use links which have a capacity too low
for carrying the load intended (dynamic + static), even if the
links may fit on the elevator.
Elevator links Top Drive Solid Body Elevator Rating
250T 400T 500T 650T 750T
250 Ton 2.1/4" pn 16363 yes no no no no
350 Ton 2.3/4" pn 26940 yes yes yes yes yes
500 Ton 3.1/2" pn 25469 no yes yes yes yes
750 Ton 4.3/4" pn 16143 no no no yes yes
1000 Ton 5.1/2" pn 70101 no no no no no
1250 Ton 5.1/2" pn M14000320Y no no no no no
Elevator links Elevator Y series

YC MYC HYC YT HYT LYT* MYT
250 Ton 2.1/4" pn 16363 yes yes yes yes yes no yes
350 Ton 2.3/4" pn 26940 yes yes yes yes yes no yes
500 Ton 3.1/2" pn 25469 no no yes no yes no no
750 Ton 4.3/4" pn 16143 no no no no no no no
1250 Ton 5.1/2" pn M14000320Y no no no no no no no
*Requires link 7/8” - 1.3/4
Elevator links Elevator T(M)A series

TA 4.3/4 - 8.5/8 TA 4.3/4 - 11.1/4
TA 1.050 - 2.7/8 TMA 2.3/8 - 5
up to 100 ton 150 ton only
250 Ton 2.1/4" pn 16363 no yes yes yes
350 Ton 2.3/4" pn 26940 no yes yes yes
500 Ton 3.1/2" pn 25469 no no no yes
750 Ton 4.3/4" pn 16143 no no no no
1000 Ton 5.1/2" pn 70101 no no no no
1250 Ton 5.1/2" pn M14000320Y no no no no
Elevator links Elevator G series

MG RGG MGG GG HGG RGA GA GGA
250 Ton 2.1/4" pn 16363 yes yes yes yes no yes yes yes
350 Ton 2.3/4" pn 26940 yes yes yes yes yes yes yes yes
500 Ton 3.1/2" pn 25469 no no yes yes yes no yes yes
750 Ton 4.3/4" pn 16143 no no no no yes no no no
1000 Ton 5.1/2" pn 70101 no no no no no no no no
1250 Ton 5.1/2" pn M14000320Y no no no no no no no no
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2: Specifications
Revision E
Page 15 of 20
Elevator links Elevator X series

SSD SX SX
SLX SLX SSD SLX
8.5/8-10.3/4 except 350
1.66-5.1/2 5.1/2-24.1/2 1.66-7.5/8 SD
+ 11.3/4-14 350 ton ton
250 Ton 2.1/4" pn 16363 yes yes yes yes no yes yes
350 Ton 2.3/4" pn 26940 yes yes yes yes yes yes yes
500 Ton 3.1/2" pn 25469 no yes no yes yes yes yes
1250 Ton 5.1/2"
no no no no no no no
pn M14000320Y
Elevator links Elevator X series *250 and 350 ton SMX

SMX SMX elevators in
150 Ton 250 + 350 Ton combination with 500
250 Ton 2.1/4" pn 16363 yes yes ton links gives reduced
350 Ton 2.3/4" pn 26940 yes yes rotation possibility. Be
500 Ton 3.1/2" pn 25469 no yes* (rotation limited) advised to use 350 ton
750 Ton 4.3/4" pn 16143 no no links.
1000 Ton 5.1/2" pn 70101 no no
1250 Ton 5.1/2"
no no
pn M14000320Y
Casing Elevators / Casing Elevators /

Elevator links
Spiders Varco Type Spiders BJ Type
750T 750T 1000T
200T 350T 500T 250T 350T 500T 1000T
14” 24.1/2” 24.1/2”
250 Ton 2.1/4" pn 16363 yes yes no no no no yes no no no
350 Ton 2.3/4" pn 26940 yes yes yes no no no yes yes no no
500 Ton 3.1/2" pn 25469 yes yes yes yes yes no yes yes yes yes
750 Ton 4.3/4" pn 16143 no no no yes yes yes no yes yes yes
1000 Ton 5.1/2" pn 70101 no no no no no yes no no no no
1250 Ton 5.1/2"
no no no no no yes no no no no
pn M14000320Y
Elevator links Riser handling solid body elevator rating

250 T 400 T 500 T 650T 750 T 1000T
250 Ton 2.1/4" pn 16363 yes no no no no no
350 Ton 2.3/4" pn 26940 yes yes yes yes yes no
500 Ton 3.1/2" pn 25469 no yes yes yes yes no
750 Ton 4.3/4" pn 16143 no no no yes yes yes
1000 Ton 5.1/2" pn 70101 no no no no yes yes
1250 Ton 5.1/2"
no no no no yes yes
pn M14000320Y
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Page 16 of 20
Elevator links BX1 BX2 BX3 BX4-35

450 T 500 T 350 T 350 T
250 Ton 2.1/4" pn 16363 yes no no no
350 Ton 2.3/4" pn 26940 yes yes yes yes
500 Ton 3.1/2" pn 25469 yes yes yes yes
750 Ton 4.3/4" pn 16143 no no yes yes
1000 Ton 5.1/2" pn 70101 no no no no
1250 Ton 5.1/2"
no no no no
pn M14000320Y
Elevator links BX4-50 BX4-75 BX5 BX7 BXS, Slip type

500 T 750 T 1000 T 1250 T 350 T
250 Ton 2.1/4" pn 16363 yes no no no yes
350 Ton 2.3/4" pn 26940 yes no no no yes
500 Ton 3.1/2" pn 25469 yes yes no no yes
750 Ton 4.3/4" pn 16143 no yes yes no no
1000 Ton 5.1/2" pn 70101 no no yes yes no
1250 Ton 5.1/2"
no no yes yes no
pn M14000320Y
NOTES:
1. Compatibility is based on API 8C radii unless specific link part No's are listed.
2. If a link part No. is not listed, suitable fit with the SBE is to be confirmed
3. In some cases special links are required for use on Top Drive SBE's to permit proper
operation of link tilt.
4. In general, an elevator will fit one size larger and one size smaller noted link. However, fit
should always be confirmed when combining sizes of links and elevators.
Link connectors
The link connector can be used to make a link assembly up to 50/60 Feet long.
Part number 350 ton: 250167.
Part number 500 ton: not available yet.
Partnumber 750: 250341
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3: Inspection and wear data
Revision E
Page 17 of 20
Inspection & wear data

Safety
WARNING: NOV does not allow welding of links and bails. Links and
bails cannot be repaired or reconditioned by welding.
WARNING: Ensure daily if the secondary retention (wire, cotter pins) is

in good condition. Replace or repair if needed.
NOTE: Capacity of set is that of the weakest link.
Wear chart shaft (shank)

Wear/damage may result in a reduced section of the material, hence this will lead to a derating
of the link according to below table.
250 Ton Link 350 Ton Link 500 ton link 750 Ton Link 1000 Ton Link 1250 Ton Link
Diameter Rating Diameter Rating Diameter Rating Diameter Rating Diameter Rating Diameter Rating
2.75" 250 3.25" 350 3.688" 500 4.55" 750 5.25" 1000 5.25" 1250
2.688" 215 3.188" 325 3.625" 480 4.438" 725 5.125" 962 5.125" 1202
2.625" 200 3.125" 312 3.5" 450 4.375" 700 5" 915 5" 1143
2.5" 185 3" 288 3.375" 415 4.25" 662 4.875" 870 4.875" 1087
Wear chart forged links
Fig. 3
Upper eye Lower eye
NOTE: In general, an allowable twist between the upper and lower eye is 2
degrees
Link Upper Eye (A) Lower Eye (B) Rating

(greater or equal to) (greater or equal to) (Short Ton)
1.3/4" - 150 TON 3.38" 1.625" 150
3.25" 1.50" 125
3.13" 1.44" 112.5
Height less than 3.13 Height less than 1.44 Scrap
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Revision E 3: Inspection and wear data
Page 18 of 20

2.1/4" - 250 TON 4.75" 2.06" 250
4.63" 1.88" 200
4.5" 1.75" 180
Height less than 4.5" Height less than 1.75" Scrap

2.3/4" - 350 TON 4.75" 2.56" 350
4.63" 2.38" 290
4.5" 2.25" 260

3.1/2" - 500 TON 5.625" 3.25" 500
5.25" 3" 440
5." 2.75" 375
Height less than 5" Height less than 2.75" Scrap

750 TON 7" 7" 750
6.75" 6.75" 700
6.5" 6.5" 600

1000 TON 7.875" 7.875" 1000
7.5" 7.5" 900
7.125" 7.125" 800

1250 TON 7.875" 7.875" 1250
7.5" 7.5" 1125
7.125" 7.125" 1000
Wear data Perfection links.

Standard diameter of a Perfection link is 2.00”.
Minimum allowable diameter is 1.75”
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3: Inspection and wear data
Revision E
Page 19 of 20
MPI and inspection

References
1. ASTM E 709 (latest edition)
Standard Practice for Magnetic Particle Examination
2. ASTM A 275 (latest edition)
Standard Test Method for Magnetic Particle Examination of Steel Forgings.
3. API Specification 8A & 8C (latest edition)
4. API Recommended Practice RP 8B (latest edition)
Qualifications and certification
All personnel performing and interpreting examinations shall be qualified in accordance with the
guidelines of ASNT-TC-1A (latest edition) or an equivalent standard recognized by ASNT. All
personnel performing NDE shall also be trained in the NDE of forgings as well as trained in the
interpretation of the MPI with regard to the acceptance criteria.
Evaluation of indications
Relevant indications:
Only those indications with major dimensions greater than 1/16 inch (1.6mm) and associated
with a surface rupture shall be considered relevant. Relevant indications are indications that
results from discontinuities within the test part. Non relevant indications are indications that
results from excessive magnetizing current, structural design or permeability variances within
the test parts. Any indication believed to be non relevant shall be regarded as relevant and shall
be re-examined to determine whether an actual defect exists. Linear indications shall be
considered as those having a length of more than three times the width. Rounded indications
shall be considered as those having a length less than three times the width. Aligned indication
should be considered as a group of three or more indications which touch an imaginary straight
line connecting any two of the group.
Acceptance criteria
The link is considered critical in all area’s.
Equipment covered
Wrought material: In all cases as specified in the following table.
Relevant Indications
No relevant indications with a major dimension equal to or greater than
3/16 inch (4.8 mm)
No more than ten indications of 1/16 inch (1.6 mm) long or greater in
any continuous 6-square-inch (40 cm2) area
No more than three 1/16 inch (1.6 mm) long or greater indications in a
line separated by less than 1/16 inch (1.6 mm) edge to edge
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Revision E 3: Inspection and wear data
Page 20 of 20
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FINAL DOCUMENTATION
Chapter 4.0
Service Manual Supplement,
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Service Manual Supplement
Top Drive Operation


and remains the property of NOV. Reproduction, in whole or in RIG SOLUTIONS
part, or use of this design or distribution of this information to
others is not permitted without the express written consent of
11000 Corporate Centre Drive
D811004302-MAN-001 02
www.nov.com
Form D811001123-GEN-001/06
D811004302-MAN-001
Revision 02
Revision History
02 10.10.2011 Engineering Update T. Drake S. Sobreira H. Lim
01 17.02.2011 First Issue A. Donovan S. Sobreira H. Lim
Change Description
01 First Issue
• Changed title and text so the document is not TDS-11 specific, since the console is used for other top
drive models.
• Added safety information from the General Information chapter of the service manual template.
02
• Added sections requested from engineering: Specifications, Unpacking and Inspection, Installation,
Calibration, Checkout, Proper Use of Equipment, and Maintenance.
• Updated all illustrations and descriptions to show the -10 configuration of the console panel layout.
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D811004302-MAN-001
Revision 02
Page i of ii
Table of Contents
Stateless Driller’s Control Console Supplement

Conventions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Advisories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Illustrations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Safety Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Proper Use of Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Safe Lifting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Personnel Training . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Recommended Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
General System Safety Practices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Replacing Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Routine Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Service Centers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Front Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Internal Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Unpacking and Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Checkout Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Alarms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Top Drive Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
IBOP and Brake Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Pipe Handler Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
E-Stop, BX Elevator, Counterbalance, and Dolly Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Meters and Limit Adjustment Knobs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
i
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D811004302-MAN-001
Revision 02
Page ii of ii
Table of Contents
ii
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D811004302-MAN-001
Revision 02
Page iii of iv
List of Figures
Figure 1. NOV Stateless Driller’s Control Console (Front Panel Closed) . . . . . . . . . . . . . . . . . 2-6
Figure 2. NOV Stateless Driller’s Control Console (Front Panel Opened) . . . . . . . . . . . . . . . . 2-7
Figure 3. Alarms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10
Figure 4. Top Drive Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11
Figure 5. IBOP and Brake Controls. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-13
Figure 6. Pipe Handler Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14
Figure 7. E-Stop, BX Elevator, Counterbalance, and Dolly Controls . . . . . . . . . . . . . . . . . . . 2-17
Figure 8. Meters and Limit Adjustment Knobs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-19
iii
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D811004302-MAN-001
Revision 02
Page iv of iv
List of Figures
iv
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D811004302-MAN-001
Revision 02
Stateless Driller’s Control Console TD
Conventions
This service manual supplement is intended for use by field engineering, installation, operation,
and repair personnel. Every reasonable effort has been made to ensure the accuracy of the
information contained herein. National Oilwell Varco® (NOV) will not be held liable for errors in this
material, or for consequences arising from misuse of this material.
Advisories
Graphic symbols and bracketed text indicate advisories for a specific topic. This information
provides the reader with additional details and may advise the reader to take a specific action to
protect personnel from potential injury or lethal conditions. These advisories may also inform the
reader of actions necessary to prevent equipment damage.
Note

provided about the current topic.
Caution
!
equipment, or injury to personnel exists. Follow instruc-
tions explicitly. Extreme care should be taken when per-
forming operations or procedures preceded by this caution
symbol.
Warning
The warning symbol indicates a definite risk of equip-

ment damage or danger to personnel. Failure to follow
safe work procedures could result in serious or fatal
injury to personnel, significant equipment damage, or
extended rig down time.
1
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Form D811001123-GEN-001/06
D811004302-MAN-001
TD Stateless Driller’s Control Console Revision 02
Page 2 of 20
Conventions
Advisories
Hot Surfaces
The hot surface symbol indicates the presence of a

hot surface or component. Touching this surface
could result in bodily injury. To reduce the risk of
injury from a hot component, allow the surface to cool
before touching.
Electrostatic Discharge
The Electrostatic Discharge (ESD) symbol indicates the

potential for static electrical discharge is present. ESD can
damage or destroy sensitive electronic components. ESD
can also set off explosions or fires in flammable environ-
ments. Always discharge static electricity prior to working
on sensitive components or in flammable environments.
Illustrations
snapshots for use in identifying parts, or establishing nomenclature, and may or may not be drawn
to scale.
For component information specific to your rig configuration, see the technical drawings included
with your NOV documentation.
The illustrations in this supplement show a typical control

console panel layout. Depending on the top drive model
and system options, the layout of the console controls will
vary. Refer to the engineering drawings in the Technical
Drawing Package (TDP) for the rig-specific console layout
for the equipment order.
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Safety Requirements
The NOV equipment is installed and operated in a controlled drilling rig environment involving
hazardous situations. Proper maintenance is important for safe and reliable operation. Procedures
outlined in the equipment manuals are the recommended methods of performing operations and
maintenance.
This NOV component is certified for use in Zone 2

environments. Compliance with this certification
requires that the equipment be installed per the
manufacturer’s guidelines and that no modifications
be made to the component once it is installed, unless
directed by NOV. Failure to adhere to this warning
could result in equipment damage and severe injury or
death to rig personnel.
!
carefully observe requirements outlined in this section.

NOV equipment is designed for specific functions and applications, and should be used only for its
intended purpose.
Safe Lifting
When lifting and handling NOV equipment, use approved lifting procedures and safe methods.
!
Individuals working with rig equipment must never lift
anything over 55 lb (25 kg) without assistance. Always get
help from additional rig personnel or use lifting equipment.
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Safety Requirements
Personnel Training
equipment, or those in the vicinity of the equipment, should be trained in rig safety, tool operation,
and maintenance to ensure their safety.
!
Personnel should wear protective gear during installation,
maintenance, and certain operations.
Contact the NOV training department for more information about equipment operation and
maintenance training.
Recommended Tools
The equipment manufacturer recommends that only those tools specified be used when stated.
Ensure that personnel and equipment safety are not jeopardized when following service
procedures and that personnel are not using tools that were not specifically recommended by the
manufacturer.

The equipment discussed in this manual may require or contain one or more utilities such as
!
Read and follow the guidelines below before installing
equipment or performing maintenance to avoid
R Isolate energy sources before beginning work.

R Avoid performing maintenance or repairs while the equipment is in operation.
R Wear proper protective equipment during equipment installation, maintenance, or
repair.
R Verify that all components (such as cables, hoses, etc.) are tagged and labeled
during assembly and disassembly of equipment to ensure correct installment.
R Replace failed or damaged components with original equipment manufacturer
certified parts. Failure to do so could result in equipment damage or injury to
personnel.
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Safety Requirements
Routine Maintenance
Equipment must be maintained on a routine basis. See product-specific service manuals for
maintenance recommendations.
!
Service Centers
For a directory of NOV Service Centers, see NOV document number D811001337-DAS-001, titled
“Service Center Directory.” This document is located in the User Manual.
www.nov.com/contact_us/24hr_EmergencyList.asp
Description
The following sections contain basic guidelines, operational instructions, and maintenance
information for the NOV Stateless Driller’s Control Console. This control console is available in
multiple configurations for multiple NOV top drive models. Make sure to review the engineering
drawings in the Technical Drawing Package (TDP) for rig-specific control console information.
Overview
The stateless NOV Driller’s Control Console is typically used to operate the IDS-350P(E), TDS-9,
TDS-10SA, TDS-10SH, and TDS-11 Top Drives. This NOV control console provides the control
circuitry for all top drive and pipe handler functions. The console enclosure also contains
Intrinsically Safe (I.S.) barrier components that support Zone 2 certification.
The control console is integrated with the Variable Frequency Drive (VFD). The VFD is located in
an environmentally-controlled drive house. The communication path from the driller’s control
console to the VFD is via a common data bus. Functional changes can be implemented by NOV
using utilities that are common for NOV top drive systems.
Control commands from the console are processed through a single-board computer (SBC). The
SBC controls the actions of the cooling system, the solenoid valves, the brakes, IBOP functions,
switches and sensors. The SBC also monitors all component sensors and switches, and acts as a
safety interlock to prevent inadvertent tool operation. Additionally, the SBC notifies the driller of the
operational status of the top drive and diagnoses abnormal operating conditions.
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Description
Front Panel
Figure 1 shows the front panel for a typical stateless NOV Driller’s Control Console. Figure 2 on
page 2-7 shows the internal components with the front panel opened.
Refer to the Operation section of this manual for

console button, switch, and gauge descriptions.
Front Panel (Door Closed)
For Reference Only. The illustrations in this supplement

show a typical control console panel layout. Depending
on the top drive model and system options, the layout of the
console controls will vary. Refer to the engineering drawings
console layout for the equipment order.
Figure 1. NOV Stateless Driller’s Control Console (Front Panel Closed)
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Description
Internal Components
Figure 2 shows the internal components with the front panel opened.
Low Voltage
Wiring Only AC Voltage I. S. Wiring Only
2x3
N. I. S. 1.5 x 3 I. S. 1.5 x 3
I. S.
N. I. S.
1.5 x 3
Field Cabling 1.5 x 3
Front Panel (Door Opened) Segregated

I.S. Wiring
For Reference Only. Refer to the engineering drawings

console wiring diagrams and other details.
Figure 2. NOV Stateless Driller’s Control Console (Front Panel Opened)
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Description
Specifications
Enclosure ATEX, Zone 2
Weight 120 lb (54 kg)
Power Input Range • 0-24 V DC, 0-9.5 A

(non I.S. terminals) • 120 V AC, 1.1 A
Power Input Range

28 V DC, 4-20 mA, 0.65 W
(I.S. terminals)
Operating Temperature Range - 40°C to 45°C (-40°F to 113°F)
Preparation
Unpacking and Inspection
The shipping container has been built to protect the console from normal shocks and vibrations
encountered during shipment. Unpack the unit carefully and inspect it thoroughly for damage. If
there is any obvious damage, notify the shipping agency and contact your NOV representative
immediately.
Installation
The NOV Stateless Driller’s Control Console must be installed in accordance with all applicable
Standards and Codes of Practice. It is the sole responsibility of the equipment end user to ensure
that the installation has been performed by a competent person.
Calibration
No calibration is required for the Stateless Driller’s Control Console.
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Preparation
Checkout Procedure
All personnel must stand clear for controls checkout.
See the section titled "Operation" for console control descriptions.

R Operate each control on the control console.
R Check for alarm conditions. Resolve any alarms at this time.
R Check all connectors for tightness.
R Check the operation of the meters.
R Check the operation of the E-Stop (Emergency Stop).
R Make sure all console latches are secure.
Refer to the engineering commissioning procedure in the

top drive User Manual for further details and rig-specific
information.
Operation
The following sections provide operational descriptions for the buttons, switches, and gauges on
the front panel.
The illustrations in this supplement show a typical control

console panel layout. Depending on the top drive model
and system options, the layout of the console controls will
vary. Refer to the engineering drawings in the Technical
Drawing Package (TDP) for the rig-specific console layout
for the equipment order.
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Operation
Alarms
Alarms
Figure 3. Alarms
R Alarm Silence / Lamp Check

Q When any alarm indicator light flashes and the horn sounds, press this button to
silence the alarm. The indicator will remain lit until the fault is cleared. If the fault
is not cleared in five minutes, the alarm horn sounds and the indicator flashes.
Q When the button is pressed and held for two seconds, the console indicators are
tested. When the button is pressed and held for four seconds, the TORQUE and
RPM meters go to full scale for a meter test.
R Hyd Press Loss – Indicator flashes and horn sounds when hydraulic system
pressure loss is detected.
R Oil Press Loss – Indicator flashes and horn sounds when oil pressure loss is
detected.
R Drill Motor Overtemp – Indicator flashes and horn sounds when high temperature
is detected for the drilling motor.
R Cooling Water Flow – Indicator flashes and horn sounds when a loss of pressure
in the cooling system flow is detected.
R VFD Fault – Indicator flashes and horn sounds when a fault in the VFD is detected.
R General – Indicator flashes when any of the alarms activate. For example, this
indicator flashes and the horn sounds when IBOP Close pressure loss is detected.
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Operation
Top Drive Controls
TDS
TDS Mode
TDS Direction
Figure 4. Top Drive Controls
R TDS – There is a green button and a three-position momentary switch in this

console area.
Q Enable – Pushing this illuminated button enables top drive operation from the
Driller’s Control Console. When the green indicator is illuminated, the operator
has control of the top drive from the console, the lubrication pump and cooling
system are turned on, and the hydraulic supply is ready for top drive operation.
Q Torque Set – This three-position momentary switch allows the operator to set
maximum drill and makeup torque setpoints. Turning the switch to DRILL and
then turning the DRILL encoder knob sets the maximum drill torque for DRILL
mode. Turning the switch to MAKEUP and then turning the MAKEUP encoder
knob sets the maximum makeup torque for TORQE mode, in the FORWARD
direction. This switch automatically returns to the center position (off) when
released.
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Operation
Top Drive Controls
R TDS Mode – There are three illuminated buttons in this console area.
Q Drill mode – When pushed, the green indicator illuminates to show that the top
drive is in DRILL mode. This mode is used for normal drilling operations. When
in this mode, the driller uses the DRILL and TDS RPM incremental encoder
knobs to set drilling operation limits.
Q Spin mode – When pushed, the green indicator illuminates to show that the top
drive is in SPIN mode. This mode is used for shouldering up pipe while making
up connections. When in this mode, the RPM and torque settings are fixed at
standard SPIN mode rotational speed and torque values.
Q Torque mode – When pushed and held, the green indicator illuminates to show
that the top drive is in TORQUE mode. This mode is used for making up and
breaking out connections. When this mode is selected in the FORWARD
direction, RPM is fixed and torque gradually ramps up to the makeup torque
setpoint. When this mode is selected in the REVERSE direction, RPM is fixed
and torque gradually ramps up to the maximum torque of the top drive, or until
the connection is broken, whichever happens first.
R TDS Direction – There are three buttons in this console area.
Q Forward – When pushed, the rotational direction of the top drive is set to
forward (clockwise), the lubrication pump starts, and rotation ramps up to the
RPM setpoint. The green indicator illuminates when the top drive is assigned to
rotate clockwise (forward).
Q Off – When pushed, the top drive is de-assigned and rotation will stop.
Q Reverse – When pushed, the rotational direction of the top drive is set to
reverse (counterclockwise), the lubrication pump starts, and rotation ramps up
to the RPM setpoint. The green indicator illuminates when the top drive is
assigned to rotate counter-clockwise (reverse).
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Operation
IBOP and Brake Controls
IBOP
Brake
Figure 5. IBOP and Brake Controls
R IBOP – The IBOP area has a yellow indicator and a switch. The yellow indicator is
illuminated when the IBOP is closed. Turning the switch will open or close the IBOP.
R Brake – There are two controls in this console area:
Q Auto – When pressed, the green indicator on this button illuminates to show
that the motor brakes are in AUTO mode. In this mode, the brakes are
automatically released when a speed command is sent to the VFD (in FWD or
REV mode). The brakes are automatically set when the speed command is
removed (OFF mode).
Q On / Off – The red indicator on this button lights whenever the motor brakes
have been applied and are engaged (ON). This indicator lights any time the
brake is set, regardless of whether or not the button has been pressed. When
this button is pressed once, the brakes are set and the light comes on. When
pressed again, the light goes out to show the brakes have been released.
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Operation
Pipe Handler Controls
Pipe Handler
Figure 6. Pipe Handler Controls
R Link Tilt Float – When pressed, the elevator links float to the center position. When
the elevator links are in float position, the green indicator illuminates. When the
elevator links are in float position, the pipe handler can be rotated.
R Link Tilt Drill / Tilt – This is a three-position momentary switch.
Q When switched to DRILL, the elevator links tilt to the Drilldown position. This
position allows the top drive to continue operating close to the drill floor.
Q When switched to TILT, the elevator links extend the elevator to the Derrickman
position. If the switch is released at Derrickman position, then reapplied, the
links will tilt out to Mousehole position.
Q When the switch is in the center position, the elevator links are held in the
current position.
Any time the switch is released, tilt motion stops immediately.
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Operation
R TW Clamp Push and Hold – When this button is pressed and held:
Q the pipe handler rotates counter-clockwise into position
Q the pipe handler locking mechanism locks the pipe handler in place
Q the torque wrench clamp engages
Once engaged, the clamp is used to make up and break out connections.
Q The clamp is used to make up connections when the top drive is in TORQUE
mode and when the FORWARD direction is selected. The torque will gradually
ramp up to the MAKEUP torque limit setpoint.
Q The clamp is used to break out connections when the top drive is in TORQUE
mode and when the REVERSE direction is selected. The torque will gradually
ramp up to 125% of the preset make-up torque limit. If break-out torque is
insufficient to break out the connection, exit TORQUE mode and increase the
MAKEUP torque limit setpoint.
The clamp disengages when the TW Clamp Push and Hold button is released.
The pipe handler clamp will not engage if the top drive
motor brakes are applied.
The pipe handler clamp will not engage if the elevator links
are not in float position
Refer to the section titled "Torque Wrench Auto Mode" on page 16 for information
about the Torque Wrench Auto Mode button.
R PH Rotate CCW / CW – Turning this three-position momentary switch to the right
rotates the pipe handler clockwise. Turning the switch to the left rotates the pipe
handler counterclockwise. When released, the spring-centered switch returns to the
off position (center) and the pipe handler stops.
The pipe handler will not rotate if the elevator links are
tilted to any off-center position.
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Operation
Torque Wrench Auto Mode
When this button is pressed, the light turns green and the torque wrench will operate automatically.
When the torque wrench is in Auto Mode, the operator can move directly from Drill mode to
Torque mode and initiate automatic make-up or break-out operations, depending on the direction
of rotation.
Auto Mode Sequence: FORWARD Rotation
4. The top drive spins in the connection. The VFD provides feedback that the
connection is shouldered.
5. The top drive ramps up torque to the make-up torque setpoint.
If the pipe slips or the operator releases the Torque mode

button before the sequence reaches the make-up torque
setpoint, the sequence is aborted, the top drive is turned
off, and the brake is set.

7. Torque ramps down and the clamp releases.
Auto Mode Sequence: REVERSE Rotation
4. The top drive gradually ramps up torque to the maximum torque of the top drive, or
until the VFD provides feedback indicating the connection is broken.
When the connection breaks, the torque drops back to the spin torque setpoint.
5. The top drive spins out the connection.
7. Rotation stops and the clamp releases.
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Operation
E-Stop, BX Elevator, Counterbalance, and Dolly Controls
E-Stop
Counterbalance
Dolly
BX Elevator
Figure 7. E-Stop, BX Elevator, Counterbalance, and Dolly Controls
R Emergency Stop – The Emergency Stop button is hard-wired to the Variable

Frequency Drive (VFD).
When pressed, the:
Q VFD slows down the shaft speed and then shuts off
Q power to the top drive shuts off
Q hydraulic supply shuts off
Q motor brakes are applied
To reset the system, reset the VFD and physically pull this switch back to its original
position.
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Operation
E-Stop, BX Elevator, Counterbalance, and Dolly Controls
R BX – There are two controls in this console area:
Q BX Elevator – This is a three-position switch. (The center position is neutral.)
Open opens the elevator and releases the pipe. Armed arms the elevator. This
readies the hydraulic cylinders in the elevator. In Armed mode, the elevator will
automatically close and hold a pipe that enters the elevator. The yellow indicator
illuminates when the elevator has closed on a pipe.
Q BX Rotate – This is a three-position switch. (The center position is neutral.)
Down tilts the elevator down. Up tilts the elevator up. This allows the elevator to
be better positioned for pipe handling from multiple locations.
R Counterbalance – The counterbalance area has a green button indicator. When
pressed once, the light illuminates to indicate the counterbalance system is in Stand
Jump mode, retracting the counterbalance cylinders. When pressed again, the light
goes out to indicate that the counterbalance system has returned to DRILL mode.
Stand Jump mode is typically used immediately before breaking out a connection.
When the button is pressed, the top drive is lifted slightly off the connection by
elevated pressure to the cylinders. Normally, the counterbalance pressure is set to
about 1100 psi. During Stand Jump, 300 psi is added.
R Dolly – The dolly area has a three-position momentary switch. The switch is used to
extend the dolly or retract the dolly to the guide beam.
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Operation
Meters and Limit Adjustment Knobs
Torque Meter
RPM Meter
Limit Knobs
Figure 8. Meters and Limit Adjustment Knobs
R TORQUE meter – Shows the drill pipe torque in ft-lb (x 1000) increments from 0 to
80,000 ft-lb. In DRILL mode, the torque limit is set by the DRILL torque encoder
knob below the meter. In TORQUE mode and in the FORWARD direction, the
torque limit is set by the MAKEUP torque encoder knob below the meter.
R RPM meter – Shows the rotational speed of the top drive from 0 to 250 RPM.
Rotational speed is controlled using the TDS RPM knob below the meter.
R Drill knob – Sets the maximum allowable drill pipe torque when in DRILL mode. The
drilling torque limit is adjusted by turning the knob and observing the ft-lb of torque
displayed in the TORQUE meter.
R Makeup knob – Sets the maximum allowable makeup torque in TORQUE mode, in
the FORWARD direction. The makeup torque limit is adjusted by turning the knob
and observing the ft-lb of torque displayed in the TORQUE meter.
R TDS RPM knob – This is the top drive throttle. It controls the speed of the drilling
motor when in DRILL mode. The drilling speed is adjusted by turning the knob and
observing the RPM displayed in the RPM meter.
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Maintenance
Inspect the console on a routine basis. Failure to

conduct routine inspections and maintenance may
The following is a general maintenance checklist.
Maintenance Checklist
Location Procedure Frequency
Test using the Alarm Silence / Lamp

Console Indicator Lamps Each time the top drive is assigned.
Check button on the console.
Heater Check operation with an Ohm meter. Monthly
Check fastener tightness, especially

Console mounting fasteners Monthly
in vibration-prone areas.
Drilling motor field current Verify and record. Weekly
Check for integrity. Monthly

Enclosure seals and gaskets
Apply a light film of silicone lubricant
Every Three Months
to the transfer panel door.
R If the console enclosure is damaged or faulty, the enclosure should be returned to

an NOV Service Center or other authorized service facility for repair.
R If there is a faulty terminal or communication module, contact your NOV
representative, NOV Service Center, or authorized service facility for a replacement.
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FINAL DOCUMENTATION
Chapter 5.0
Technical Drawing Package,
TDS-11SA
www.nov.com
Technical Drawing Package
TDS-11SA
NOV – Houston
Rigs: ME-13, ME-14 (2000 HP DC)
and Stock Unit 3
RIG/PLANT 10657452-GEN Customer Configuration

10657453-GEN
ADDITIONAL CODE SDRL CODE TOTAL PGS 10656189-GEN
This document contains proprietary and confidential information
REMARKS which is the property of National Oilwell Varco, L.P., its affiliates or
subsidiaries (all collectively referred to hereinafter as "NOV"). It is
loaned for limited purposes only and remains the property of NOV. National Oilwell Varco
MAIN TAG NUMBER DISCIPLINE Reproduction, in whole or in part, or use of this design or
distribution of this information to others is not permitted without the RIG SOLUTIONS
CLIENT PO NUMBER express written consent of NOV. This document is to be returned to 11000 Corporate Centre Drive
NOV upon request or upon completion of the use for which it was Houston, TX 77041
loaned. This document and the information contained and
CLIENT DOCUMENT NUMBER represented herein is the copyrighted property of NOV.
Client Document Number DOCUMENT NUMBER REV
10660418-DOS 03
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D811000461-GEN-001/04
Document number 10660418-DOS
Revision 03
Page 2
REVISION HISTORY
03 29/01/2013 Engineering Requested Change T. Harmon H. Lim H. Lim

02 10/01/2013 Publications Requested Change T. Harmon H. Lim H. Lim
01 16/05/2012 First Issue T. Harmon H. Lim H. Lim
CHANGE DESCRIPTION

03 Added rig name, Stock Unit 3.
Added customer configuration number 10656189-GEN.
02 AC Drive Parameters number was 301719483 is 30179483.
01 First issue
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D811000461-GEN-001/04
Revision 03
Page 3
TECHNICAL DRAWING PACKAGE

This document provides a list of drawings for the TDS-11SA. The actual drawings are arranged
in the binder, by assembly order.
Drawings by Assembly
General
Customer Configuration (ME-13).............................................................................. 10657452-GEN
Customer Configuration (ME-14).............................................................................. 10657453-GEN
Customer Configuration (Stock Unit 3) ..................................................................... 10656189-GEN
General Arrangement .........................................................................................................30170471
Schematic, Hydraulic ..............................................................................................................109550
Rig Cabling Diagram ...................................................................................... D804000934-DIA-001
Block Diagram……………. ............................................................................. D804000935-DIA-001
Interconnect System………………………. ..................................................... D804000936-DIA-001
I/O Map……………. ........................................................................................ D804000705-IDX-001
SBC Drive Parameters ................................................................................... D804000430-IDX-001
AC Drive Parameters ..........................................................................................................30179483
Top Drive Assemblies

Motor Housing Assembly ..................................................................……………………..120900-EX
AC Drilling Assembly (Helical) ………………………….. ..........................118217-40L60, 40R60
Lube Pump Assembly……………………….................................................................. 117603-1
Hydraulic Oil Reservoir Assembly……………………….. ............................................. 110068-2
Rotating Link Adapter Assembly……………………… ................................................ 30173277
Shot Pin Assembly……………. ............................................................................ 30151875-504
Electrical Package…………………………………….. ............................................ 30150517-A-60-R
Pump/Motor Assembly…………………………………………. ......................................30179191
BX with Rotator Kit ....................................................................................................... M611005788
Hydraulic Package……………………. ................................................................................ 121403-1
Pre-fill Valve Assembly………………….. ............................................................... M854000259
Carriage Package ...............................................................................................................30124540
Carriage Assembly (Left)................................................................. ................................124538
Carriage Assembly (Right).............................................................. ............................30124539
Counterbalance Package…………………………………………….................................. 112190-120
Cylinder Assembly………… ............................................................................................ 110703
Cylinder Assembly…………………… ...............................................................................110704
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Motor Guard Package…………………………. .......................................................................121740

S-Pipe Package…………………………………………………. ................................ 30156835-R75-2
Washpipe Assembly…………………………. ...............................................................30123290
Bail Package……………................................................................................................. 121442-120
Shipping Package with Skid…………………….. .................................................... 30171423-PH75
Pipe Handler
Pipe Handler Package PH-75 ………………………. ............................................. 30157366-35-B-H
Hydraulic Cylinder Assembly………. .......................................................................... 30119592
IBOP, Lower……………… ....................................................................................... 114706-500
IBOP, Upper …. ....................................................................................................... 110103-500
IBOP (External) Crank Assembly……… ............................................................................98898
Link Tilt Crank Assembly…………………. .................................................................. 30158189
Manifold Link Tilt Cylinder……………….. .................................................................... 118463-2
Torque Arrestor Assembly…………………………………….........................................30157288
Cylinder Assembly, IBOP Actuator………………….. ................................................125594
Cylinder Assembly, Clamp………………………… ................................................30157287
Stabbing Guide Assembly (6.25-7.50” OD Tool Joint) .....................................125158
Jaw Assembly (6.25-7.50” OD Tool Joint)....................................................30125052
Clamp Cylinder Manifold Assembly..................................................................118511
PH-75 Tool Kit……………………………………… ................................................... 30157616-NC50
Kits
Lubrication Kit………………. .............................................................................................. 92643-15
Ground Rod Kit…………………………… .......................................................................... 30116004
Counterbalance Attachment Kit ................................................................................ 118244-BLOCK
Guide Beam Kit……………………........................................................................... 30154688-147A
Intermediate Section Guide Beam.. .............................................................................30154381
Guide Beam Tieback Kit…………………. .................................................................. 30154685-100
Wear Guide, Master Bushing, for 3-1/2” to 5” Drill Pipe.. ..................................................... 85974-8
Cable Requirements
Service Loop Kit…………………………………………........................................... 30175021-86-200
Derrick Loop Assembly…………………………………………………………… 30150515-135-25-4-B
Derrick Termination Kit………………………… ...................................................................30126815
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VDC Cable Assembly .............................................................................................. 30181755-200-B
Cable Requirements (continued)

VDC Profibus Cable ................................................................................................30181756-200-B
Cable Kit, Jumper VFD ............................................................................................... 30157552-100
Cable Kit, Incoming Power ............................................................................................. 125274-100
Connection Kit, Incoming Power Cables ................................................................................114738
Control System
Control House………………………………………… ....................................... M8040004562A1DCE
Driller’s Console, Stateless...................................................................................... M804000483-15
Dual Power Feeder Kit, VFD House.. .................................................................... M614005349-200
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D811000461-GEN-001/02
FINAL DOCUMENTATION
Section 5.1
General
www.nov.com
This document contains proprietary information, and such information may not be disclosed to others for any purpose, nor used for manufacturing purposes without written permission from NOV.
REVISIONS
LTR DESCRIPTION PREPARED / DATE CHECKED/ DATE APVD / DATE
01 INITIAL RELEASE H. Lim 4/30/12 M. Clark 4/30/12 H. Lim 4/30/12
02 SEE EN C. George 16-May-12 H. Lim 16-May-12 H. Lim 16-May-12
STANDARD ORDER INFORMATION QUALITY REQUIREMENTS

SHIPMENT DATE: 22-JUNE-2012 CERTIFICATION: NONE
PRE-SHIP: NONE DATA BOOK: NONE
RIG TYPE: LAND
INSTALLATION LOCATION: JEBEL ALI
OPERATION LOCATION: JEBEL ALI CONTACT NOTES
RELATED CONFIGS: QP, D611005856-PLN-001 PROJECT MANAGER: N/A
SALES ORDER #: 134493 (26601) SYSTEM INTEGRATION: N/A
QUOTE # & REV: 151844 REV. 0 CONTRACT ADMINISTRATOR: Amalia Cruz
SPARES QUOTE #: N/A RESPONSIBLE ENGINEER: H. LIM
UNIT #: TBD ELECTRICAL ENGINEER: MICHAEL MASLYAR
SERIAL #: TBD SOFTWARE ENGINEER: TBD
ITEM ID #: TBD APPLICATION ENGINEER: N/A
APPLICATION NOTES:
1. Configured with “Quick-Rig-Up” Guide Beam Design and PH-75 Pipehandler.
2. Customer Configuration document to be inserted into the front of the Technical Drawing Package in the Owner’s Manual by the end user. The
Customer Configuration lists the rig specific part numbers used to identify the drawings.
3.
Sheet 1 of 7 REVISION CUSTOMER / OWNER
DOCUMENT NUMBER Customer: NOV HOUSTON

CUSTOMER
CONFIGURATION 10657452-GEN 02 Rig: ME-13 (2000 HP DC)
Equipment: TDS-11SA
FORM CC-4S (f:\eng\appe7000\tds\_tools\cc-4s.doc): 12:30 PM 5/21/2012
QTY
PART NUMBER S/O -001 -002 DESCRIPTION
“” INITIAL UNDEFINED PART NUMBERS: REFERENCE ONLY

CUSTOMER
Equipment: TDS-11SA
QTY
TOP DRIVE SYSTEM

10657452-001 1 TDS-11SA DRILLING PACKAGE
10657452-002 1 MOTOR/CARRIAGE ASSY, TDS-11SA
120900-EX 1 MOTOR HOUSING, TDS-11SA Pressure Rating: 5000-7500 psi
30150517-A60R 1 ELECTRIC PACKAGE, TDS-11SA
System Electrical: CENELEC Installation Type: Portable
Service Loop Loc: Right
M611005788 1 KIT, BX WITH ROTATOR
1 HYDRAULIC PLUMBING PACKAGE, TDS-11SA
121403-1
System Electrical: EEx
30124540 1 CARRIAGE PACKAGE, TDS-9/11SA Setback: 30.0”
30157366-35-B-H 1 PIPE HANDLER PACKAGE
Drill String Connection: NC50 IBOP Trim: H2S
Link Option: 350 Ton
112190-120 1 COUNTERBALANCE PACKAGE, TDS-9/11SA
121740 1 MOTOR GUARD PACKAGE, TDS-9/11SA
30156835-R75-2 1 S-PIPE PACKAGE, TDS-11SA
Mud Hose Connection: 4”, Female Fig 1002 S-Pipe Loc: Right
Pressure Rating: 7500 psi
121442-120 1 BAIL PACKAGE, TDS-9/11SA Bail Length: 120”
30171423-PH75 1 SHIPPING PACKAGE, GUIDE BEAM: W/SKID Setback: 30.0", PH-75
92643-15 1 LUBRICATION KIT, TDS-11SA Lubricant Temperature Class: High
30116004 1 GROUNDING ROD KIT
30157616-NC50 1 PIPE HANDLER KIT, PH-75 Drill String Conn: NC50
118244-BLOCK 1 COUNTERBALANCE ATTACHMENT KIT Attachment: To Block

CUSTOMER
Equipment: TDS-11SA
QTY
RIGGING
30154688-147A 1 GUIDE BEAM KIT
Mast Height: 147 Guide Beam Section Length: 24 ft
30154685-100 1 KIT, TIEBACK: INCLUDES LOWER, INTERMEDIATE, AND HANG OFF TIEBACK
30154381 1 GUIDE BEAM, INTERMEDIATE SECTION
CONTROL SYSTEM (TDCS)

1 CONTROL HOUSE, TDS-11SA, 600 VAC 60H INPUT, DUAL A/C, CE CERTIFIED
M8040004562A1DCE
Note: SOLA active line filters and main power line filter to be installed.
M804000483-15 1 DRILLER’S CONSOLE, EEx, TDS-11,STATLESS, WITH BX ELEV SWITCH
M614005349-200 1 KIT, DUAL POWER FEEDER, VFD HOUSE
SERVICE LOOPS AND DERRICK TERMINATION KIT

SERVICE LOOP KIT, 777 MCM (TDS to mid Derrick)
30175021-86-200 1 System Electrical: EEx Installation Type: Portable
Service Loop Length: 86 ft Aux. Loop Length: 200 ft
DERRICK LOOP ASSY, 777 MCM (mid Derrick to Derrick leg)
30150515-135-25-4-B 1
System Electrical: EEx Derrick Leg Cable Length: 200 ft
30126815 1 DERRICK TERMINATION KIT, 646 MCM/777 MCM, QD Installation Type: Portable
30181755-200-B 1 VDC CABLE ASSEMBLY, EEx/Non-EEx – 200 FT
30181756-200-B 1 VDC PROFIBUS CABLE, EEx/Non-EEx – 200 FT
30157552-100 1 CABLE KIT, JUMPER, EEx/VFD, 100 FT
125274-100 1 CABLE KIT, INCOMING POWER, 100 FT

CUSTOMER
Equipment: TDS-11SA
QTY
ACCESSORIES / SPECIAL ITEMS

114738 1 CONNECTION KIT, INCOMING POWER CABLES
85974-8 1 WEAR GUIDE, MASTER BUSHING, FOR 3-1/2” TO 5” DP
92045 1 ADATER RING, WEAR GUIDE, FOR 3-1/2” THRU 5” DP
108684 2 CONTAINER, SERVICE LOOP STORAGE
106046 1 BRACKET, GUIDE BEAM SUPPORT (PADEYE)
26940Y1132 1 WELDLESS LINKS, 350 TON, 2 3/4” X 132”
117782 1 PIN, JOINT
117783 1 PIN, RETAINER
117496-1 1 PIN, RETAINER, SELF-LOCK
SPARES

CUSTOMER
Equipment: TDS-11SA
QTY
SERVICE MANUALS AND SUPPLEMENTS

10660418-MAN 1 USER’S MANUAL: TDS-11SA , ELECTRONIC COPY
10660418-DOS REF TECHNICAL DRAWING PACKAGE: TDS-11SA
10657452-999 1 CUSTOMER CONFIG DOCUMENT: See Note 2 on sheet 1.
CLASSIFICATION SOCIETY / STATUTORY / INDUSTRIAL STANDARDS

Designed, Built and Tested to API-8C, PSL-1

CUSTOMER
Equipment: TDS-11SA
QTY
REFERENCE DRAWINGS
30170471 REF DRAWING, GENERAL ARRANGEMENT, TDS-11SA
109550 REF SCHEMATIC, HYDRAULIC, TDS-9/11SA
D804000934-DIA-001 REF RIG CABLING DIAGRAM, TDS-11SA, SBC System Electrical: EEX
D804000935-DIA-001 REF BLOCK DIAGRAM, TDS-11SA, SBC
D804000936-DIA-001 REF INTERCONNECT, SYSTEM, TDS-11SA, SBC
D804000705-IDX-001 REF I/O MAP, TDS-11SA, SBC
D804000430-IDX-001 REF DRIVE PARAMETER, TDS-11SA, SBC
M804000494-SPL-001 REF SPARES LIST, CONTROL, TDS-11SA, ABB VFD HOUSE
301719483 REF A-C DRIVE PARAMETERS, TDS-11SA VFD Options: ABB
ASP00020 REF TDS-9SA/11SA Motor Housing Assembly Procedure
3ASP00073 REF TDS-9SA/11SA Motor Installation Procedure, Brake Hub & Pinion Gear
3ASP00030 REF TDS Inspection Form
TS00259 REF Test Specification, Motor Housing Assembly, TDS-9SA/11SA
TS00271 REF TDS-9SA/11SA Final Function Test Procedure
TS00286 REF TDS-9SA/11SA Factory System Test
TS00282 REF Test Specification, TDS-9 Control Panel / Driller’s Console
TS00162 REF Test Specification, Hydrostatic Pressure & Post MPI Test (Gooseneck / S-Pipe)
TS00168 REF Test Specification, Mag Particle Inspection
TS00419 REF Post Function Test, Hydraulic Fluid Cleanliness
TS00465 REF Hydrostatic Pressure Test, Rotating Link Adapter Assembly, PH-75
TS00167 REF Test Spec Link Pull Test, All
TS00465 REF Hydrostatic Pressure Test, Clamp Cylinder Body
D744000275 REF TRACEABILITY WORK SHEEET, TDS-9/10/11
M614003549-SPL-001 REF SPARES LIST, MECHANICAL, TDS-11SA, EEx & PH-75

CUSTOMER
Equipment: TDS-11SA
REVISIONS
02 SEE EN C. George 16-May-12 H. Lim 16-May-12 H. Lim 16-May-12

SHIPMENT DATE: 22 JUNE 2012 CERTIFICATION: NONE
PRE-SHIP: NONE DATA BOOK: NONE
RIG TYPE: LAND
APPLICATION NOTES:
3.

CUSTOMER
Equipment: TDS-11SA
QTY

CUSTOMER
Equipment: TDS-11SA
QTY
TOP DRIVE SYSTEM

121403-1

CUSTOMER
Equipment: TDS-11SA
QTY
RIGGING
30154688-147A 1 GUIDE BEAM KIT
Mast Height: 147 Guide Beam Section Length: 24 ft
30154381 1 GUIDE BEAM, INTERMEDIATE SECTION

M8040004562A1DCE
M614005349-200 1 KIT, DUAL POWER FEEDER, VFD HOUSE

30150515-135-25-4-B 1

CUSTOMER
Equipment: TDS-11SA
QTY

85974-8 1 WEAR GUIDE, MASTER BUSHING, FOR 3-1/2” TO 5” DP
26940Y1132 1 WELDLESS LINKS, 350 TON, 2 3/4” X 132”
117782 1 PIN, JOINT
117783 1 PIN, RETAINER
117496-1 1 PIN, RETAINER, SELF-LOCK
SPARES

CUSTOMER
Equipment: TDS-11SA
QTY

10660418-MAN 1 OWNER’S MANUAL: TDS-11SA , ELECTRONIC COPY
10660418-DOS REF TECHNICAL DRAWING PACKAGE: TDS-11SA


CUSTOMER
Equipment: TDS-11SA
QTY
REFERENCE DRAWINGS
3ASP00073 REF TDS-9SA/11SA Motor Installation Procedure, Brake Hub & Pinion Gear
TS00167 REF Test Spec Link Pull Test, All

CUSTOMER
Equipment: TDS-11SA
REVISIONS
02 SEE EN H. Lim 8/10/12 M. Clark 8/10/12 H. Lim 8/10/12

SHIPMENT DATE: 13 JUL 2012 CERTIFICATION: NONE
PRE-SHIP: NONE DATA BOOK: STANDARD
RIG TYPE: LAND
APPLICATION NOTES:
3.
DOCUMENT NUMBER Customer: NOV JEBEL ALI

CUSTOMER
CONFIGURATION 10656189-GEN 02 Rig: STOCK UNIT 3
Equipment: TDS-11SA
QTY

CUSTOMER
Equipment: TDS-11SA
QTY
TOP DRIVE SYSTEM

121403-1

CUSTOMER
Equipment: TDS-11SA
QTY
RIGGING
30154688-152A REF GUIDE BEAM KIT
(EXCLUDED) Mast Height: 152 Guide Beam Section Length: 24 ft
30154381 1 GUIDE BEAM , BOTTOM SECTION
(10111315-001)

M8040004562A1DCE

30150515-135-25-4-B 1

CUSTOMER
Equipment: TDS-11SA
QTY

30122367 REF
U-BOLTS, FOR 500 TON ELEVATOR LINK
(EXCLUDED)
120165 REF
CLAMP, FOR 500 TON ELEVATOR LINK
(EXCLUDED)
30170508 REF
WIRELINE RUNNING ADAPTER, PH-75
(EXCLUDED)
25469Y1132 REF
WELDLESS LINKS, 500 TON, 3 ½” X 132”
(EXCLUDED)
26940Y1132 1
WELDLESS LINKS, 350 TON, 2-3/4” X 132”
(10394748-001)
SPARES

CUSTOMER
Equipment: TDS-11SA
QTY

10660418-001 1 USER MANUAL: TDS-11SA , ELECTRONIC COPY
10660418-DOS REF TECHNICAL DRAWING PACKAGE: TDS-11SA
10656189-998 1 STANDARD MANUFACTURING DATABOOK, TDS-11SA


CUSTOMER
Equipment: TDS-11SA
QTY
REFERENCE DRAWINGS
ASP00023 REF TDS-9SA/11SA Motor Shaft Installation Procedure
TS00020 REF Pull Test 350 Ton Links

CUSTOMER
Equipment: TDS-11SA
8 7 6 5 4 3 2 1
NOTES: UNLESS OTHERWISE SPECIFIED (EEx/EEx)
CABLE KIT, SERVICE LOOP
1. ALL CABLE ASSEMBLIES, SERVICE LOOPS, AND DERRICK LOOPS 5 IF INPUT TRANSFORMER IS SUPPLIED, TWO INCOMING DERRICK TERM KIT
ARE SUPPLIED WITH THE APPROPRIATE CONNECTORS INSTALLED, POWER CABLE KITS ARE REQUIRED. P/N: 126815
CHECK LENGTH (FT) KIT PART NO.
125274-X-P AND 125274-X-S MAIN POWER (3X 777MCM) ONE

EXCEPT EARTHING CABLES. EARTHING CABLES ARE SUPPLIED (EEx/EEx) MAIN POWER (3X 777MCM) MAIN POWER AUXILLIARY POWER/
2 3
PLATE (777MCM VFD) COMPOSITE
WITH LUGS INSTALLED ON ENDS. 6 CRT-350 INSTALLATION REQUIRES:
DERRICK LOOP ASSEMBLY 2/0 GRND X3
- HMI AND ASSOCIATED CABLES 86 200 30175021-86-200
2 MAXIMUM HOSED LENGTH IS 200 FEET. 3 X 777MCM
- REPLACEMENT OF COMPOSITE LOOP
1 X 444MCM GROUND
D 3 DESIGNATORS FOR SERVICE LOOP CABLE KIT DEFINE DIFFERENT
- CRT JUMPERS ON TOOL
CHECK LENGTH PART NO.
D
- CRT JUMPERS TO HOUSE (IF REQUIRED) 3 30175021-XX-XXX
CABLE LENGTHS WITHIN SAME KIT. - CRT PLUG PANEL CONNECTORS / PIGTAILS ONE
(FT)
135 30150515-135-25-4-B
AUXILLIARY POWER/
4 OPTIONAL CABLES AVAILABLE COMPOSITE CABLE LENGTHS
NONE
MAIN POWER
SADDLE CABLE LENGTH
444MCM GND 2/0 SHIELD BASIC PART NUMBER
NON-HAZARDOUS AREA
5
HAZARDOUS AREA
(EEx/NON-EEx) 4 (EEx/EEx)
CABLE KIT, INCOMING POWER WHEN INSTALLING A CRT-350, REPLACE COMPOSITE LOOP
3 x 646MCM POWER CABLE KIT, JUMPER CABLE KIT, JUMPER 126498-200-25-3-B FROM ABOVE KIT WITH CRT
1 x 444MCM GROUND 6
3 x 646MCM POWER 3 x 646MCM POWER COMPOSITE LOOP M614004368-200-25-3-B.
CHECK LENGTH 1 x 444MCM GROUND 1 x 444MCM GROUND
KIT PART NO.
ONE (FT) 1 x 42/C COMPOSITE 1 x 42/C COMPOSITE
50 125274-50
1 x 18/C AUX POWER 1 x 18/C AUX POWER
100 125274-100 CHECK LENGTH CHECK LENGTH
KIT PART NO. KIT PART NO.
150 125274-150 ONE (FT) ONE (FT)
175 125274-175 30157552-50 30150610-50
50 50
200 125274-200 MAIN POWER (3X 777MCM)
100 30157552-100 100 30150610-100
NONE
150 30157552-150 150 30150610-150
INPUT TRANSFORMER 175 30157552-175 175 30150610-175 TDS-11SA

BULKHEAD CONNECTORS BULKHEAD CONNECTORS
SUPPLIED IN KIT P/N 114738 114565-X-X SUPPLIED WITH HOUSE 200 30157552-200 200 30150610-200
C C
(PURCHASED SEPARATELY) (PURCHASED SEPARATELY NONE NONE
400HP
IF REQUIRED) DRILLING
TD CONTROL/DRIVE MOTOR
HOUSE
MCC AC
5
ROOM/ INVERTER
GEN SET (FREQUENCY 400HP

DRIVE) DRILLING
MOTOR
2/0 SHIELD
444MCM GND
2/0 GRND X3
INSTRUMENT
J-BOX
NON-HAZARDOUS AREA
HAZARDOUS AREA
AUX POWER (18 COND)
B M804000468
6 TDS COMPOSITE (42 COND) B
CRT 7 TSP PIGTAIL
CRT-350 COMPOSITE
W/ FLANGED CONNECTOR
(42 COND, 24 COND & 7 TSP)
M804000469 (EEx/EEx) ENCODER
6 6
CRT 24/C PIGTAIL CRT-350 JUMPER CABLE ASSY (EEx/EEx)
VDC COMM CABLE ASSY W/ FLANGED CONNECTOR 6 24/C, CONTROL CRT-350 JUMPER CABLE ASSY
PROFIBUS COMMUNICATION 6
CHECK LENGTH 6 7 TSP, INSTRUMENTATION
ASSY PART NO. 30183289-16
CHECK LENGTH
ASSY PART NO.
ONE (FT) CHECK LENGTH CRT 7 TSP JUMPER
30183288-16
ONE (FT) HMI COMM CABLE ASSY ASSY PART NO.
6
100 M614004369-100
(FT) CRT 24/C JUMPER
100 30181756-100-B 4/C FIBER OPTIC ETHERNET 150 M614004369-150
100 M614004370-100 6
150 30181756-150-B CHECK LENGTH 175 M614004369-175
150 M614004370-150
ASSY PART NO.
175 30181756-175-B ONE (FT) 200 M614004369-200
175 M614004370-175
200 30181756-200-B NONE
100 30188806-3-100 200 M614004370-200
250 30181756-250-B CRT-350
150 30188806-3-150 NONE
NONE
175 30188806-3-175
OPTIONAL 200 30188806-3-200 (EEx/NON-EEx)
VDC CABLE ASSY VDC HEATER KIT
250 30188806-3-150
CRT-350 JUMPER CABLE ASSY
P/N M804000482-XXX
7/C, POWER & CONTROL NONE
24/C, CONTROL
6
CHECK LENGTH
ASSY PART NO. P/N: M804000483-x HMI CABLE ASSY CHECK LENGTH
ONE (FT) 6 (EEx/NON-EEx) ASSY PART NO.
3/C, POWER
ONE (FT)
100 30181755-100-B
CRT-350 JUMPER CABLE ASSY 100 M614004371-100
150 30181755-150-B VDC CHECK LENGTH
A ASSY PART NO. 6 7 TSP, INSTRUMENTATION 150 M614004371-150
TDS-9/11
UNLESS OTHERWISE SPECIFIED DIMENSIONS ARE IN INCHES. THIS DOCUMENT CONTAINS PROPRIETARY AND CONFIDENTIAL
A
175 30181755-175-B ONE (FT) 175 M614004371-175
PRODUCT:
TOLERANCES ARE:
INFORMATION WHICH BELONGS TO NATIONAL OILWELL VARCO,
L.P., ITS AFFILIATES OR SUBSIDIARIES (ALL COLLECTIVELY
30157671-50-B CHECK LENGTH
200 30181755-200-B 50 ASSY PART NO.
END ITEM: X.X ±.1 ANGLES ± 1/2 DEG REFERRED TO HEREINAFTER AS "NOV"). IT IS LOANED FOR
200 M614004371-200 LIMITED PURPOSES ONLY AND REMAINS THE PROPERTY OF
250 30181755-250-B P/N: 30182147 100 30157671-100-B

ONE (FT) NEXT ASSY:
X.XX ±.03 FRACTIONS ± 1/16
NOV. REPRODUCTION, IN WHOLE OR IN PART, OR USE OF
TITLE:
RIG CABLING DIAGRAM (EEx)

NONE X.XXX ±.010 BREAK EDGES .02/.03
THIS DESIGN OR DISTRIBUTION OF THIS INFORMATION TO
NONE 150 30157671-150-B 100 M614004372-100 SIMILAR TO: OTHERS IS NOT PERMITTED WITHOUT THE EXPRESS WRITTEN
DO NOT SCALE DRAWING CONSENT OF NOV. THIS DOCUMENT IS TO BE RETURNED
150 M614004372-150
TDS-11SA (ABB VFD/SBC/CRT-350 READY)

TO NOV UPON REQUEST OR UPON COMPLETION OF THE
175 30157671-175-B WT LBS: CURRENT INITIAL USE FOR WHICH IT WAS LOANED. THIS DOCUMENT AND
30157671-200-B 175 M614004372-175 THE INFORMATION CONTAINED AND REPRESENTED HEREIN
6 200 FINISH DRAWN M. MASLYAR S. CURLEE IS THE COPYRIGHTED PROPERTY OF NOV.
250 30157671-250-B 200 M614004372-200

D
UNLESS OTHERWISE SPECIFIED SCALE: PROJECTION: SIZE: SHT:
CHECKED S. CURLEE M. MASLYAR
HMI NONE NONE TOL < ±.06 TOL > ±.06 RIG SOLUTIONS
N/A 1 OF 1
APPVD M. MASLYAR M. MASLYAR MECHANICAL ENGINEERING DWG NO. REV:
250 1000
DATE
5/17/10 4/9/10 D804000934-DIA-001 02
DRAWN IN ACAD
8 7 6 5 4 3 2 1 RS-MECH_D-TPL-001
8 7 6 5 4 3 2 1
NOTES:
1. RIG CABLE INSTALLATION: POWER DEVICES ENCODERS INPUT DEVICES
ARMOURED/SHIELDED CABLES SHOULD BE USED THROUGHOUT INSTALLATION. SINGLE LINE SYMBOL SCHEMATIC SYMBOL SINGLE LINE SYMBOL SCHEMATIC SYMBOL SINGLE LINE SYMBOL SCHEMATIC SYMBOL
PARTICULAR ATTENTION SHOULD BE MADE TO ENSURE THAT ALL AC MOTOR
POWER CABLES ARE "ARMOURED".

INCREMENTAL ENCODER INCREMENTAL LEVEL SWITCH - NC
2. CABLES SHOWN WITH SOLID LINE ARE PROVIDED AS STANDARD.

WYE/DELTA
D CABLES SHOWN WITH DASHED LINE ARE OPTIONAL. 3 PHASE D
TRANSFORMER LEVEL SWITCH - N0
3. IF INPUT TRANSFORMER IS SUPPLIED, TWO INCOMING POWER
CABLE KITS ARE REQUIRED. 125274-X-P AND 125274-X-S.
ABSOLUTE ENCODER ABSOLUTE ABSOLUTE ENCODER
FLOW SWITCH - NC
FLOW SWITCH - NO
PRESSURE SWITCH - NC
RELAYS
WYE/DELTA-WYE
3 PHASE
SINGLE LINE SYMBOL SCHEMATIC SYMBOL
TRANSFORMER
PRESSURE SWITCH - NO
NO RELAY CONTACT
CONDUCTORS IEC 07-02-01
TEMPERATURE SWITCH - NC
MUTI-CORE CABLE NC RELAY CONTACT
IEC 07-02-03
3/C CABLE
C 1 PHASE
TRANSFORMER
RELAY COIL TEMPERATURE SWITCH - NO C
IEC 07-15-01
TSP
NAMUR PROX SENSOR
CABLE LEGEND IEC 07-19-02
RECTIFIER IEC 07-20-02
EF ETHERNET FIBER VARCO
TRANSMITTER or
EF EF ETHERNET FIBER CUSTOMER OUTPUT DEVICES TRANSDUCER
E ETHERNET VARCO INVERTER

SINGLE LINE SYMBOL SCHEMATIC SYMBOL
2-WIRE
E E ETHERNET CUSTOMER
DIRECTIONAL RESISTANCE DEPENDANT

SOLENOID VALVE TEMPERATURE DEVICE
DP PROFIBUS DP VARCO
FUSED DISCONNECT (RTD / PTC)
IEC 07-21-09
DP DP PROFIBUS DP CUSTOMER 3-WIRE
PROPORTIONAL
CIRCUIT BREAKER SOLENOID VALVE
PF PROFIBUS FIBER VARCO
IEC 07-13-05 +
PF PF PROFIBUS FIBER CUSTOMER
SIG +
B 232 RS232 WITS VARCO
M 3 PH MOTOR M HORN LOAD CELL B
3 IEC 06-08-01 3
232 232 RS232 WITS CUSTOMER -
SIG -
M MODEM VARCO STROBE LIGHT
IEC 08-10-02
M M MODEM CUSTOMER
HEATER
E-STOP SWITCH
IEC 04-01-12
V CCTV VARCO
V V CCTV CUSTOMER
POWER VARCO
POWER CUSTOMER
TDS-11SA (EEx / SBC) REF DWG'S

D804000934-DIA-001 RIG CABLING DIAGRAM, TDS-11SA
D804000935-DIA-001 BLOCK DIAGRAM, TDS-11SA
D804000936-DIA-001 INTERCONNECT WIRING DIAGRAM, TDS-11SA
D804000705-IDX-001 I/O MAP, TDS-9/11SA
D804000430-IDX-001 VFD PARAMETER SET, ABB, TDS-11SA
CABLE CONNECTOR
M804000456-ASM-001 VFD HOUSE, ABB VFD, TDS-11SA
A PRODUCT: TDS-11SA
A
TOLERANCES ARE:
LIMITED PURPOSES ONLY AND REMAINS THE PROPERTY OF
NEXT ASSY:
TITLE:
GENERAL EARTH SYMBOL
BLOCK DIAGRAM, TDS-11SA (EEx)
X.XXX ±.010 BREAK EDGES .02/.03 OTHERS IS NOT PERMITTED WITHOUT THE EXPRESS WRITTEN
SIMILAR TO:
ABB VFD, SBC, CRT-350 READY

WT LBS: CURRENT INITIAL USE FOR WHICH IT WAS LOANED. THIS DOCUMENT AND
THE INFORMATION CONTAINED AND REPRESENTED HEREIN
FINISH DRAWN M. MASLYAR S. CURLEE IS THE COPYRIGHTED PROPERTY OF NOV.
D
CHECKED S.CURLEE M. MASLYAR
TOL < ±.06 TOL > ±.06 RIG SOLUTIONS
N/A 1 OF 5
APPVD M. MASLYAR M. MASLYAR ELECTRICAL ENGINEERING DWG NO. REV:
250 1000
DATE
5/17/10 4/10/10 D804000935-DIA-001 02
DRAWN IN ACAD
8 7 6 5 4 3 2 1 RS-MECH_D-TPL-001
8 7 6 5 4 3 2 1
DERRICK TERM KIT

TD-11SA TOP DRIVE (P/N 30126815)
D DM-01 D
(1C x 4/0 AWG) (1C x 646MCM)
U/T1 TD-JMP-U1
MOT-01 P/N 30155547-BLK-XXX

DRILL MOTOR ASSY
M
(1C x 4/0 AWG) (3Cx777MCM)+(3Cx2/0 AWG) (3Cx777MCM)+(1Cx444MCM) (1C x 646MCM)
P/N 118217 3
U/T2 TD-P01A TD-P01 TD-JMP-V1 CONTINUED TO
400 HP @ 50° C 5 B8
SERVICE LOOP DERRICK LOOP P/N 30155547-WHT-XXX
SH ZN
30175018-86-4-3-B 30150515-135-25-4-B
(1C x 4/0 AWG) (1C x 646MCM)
U/T3 TD-JMP-W1
P/N 30155547-RED-XXX
(1C x 444MCM)
TD-JMP-G1 CONTINUED TO
5 C8
2 P/N 125093-XXX
(1C x 70mm ) SH ZN
TD GROUND BAR
G
P/N 141108
DRILL MOTOR ASSY

2 INSTRUMENT J-BOX
DRILL MOTOR (3 TSP x 1.0mm )
C ENC-01 INCREMENTAL ENCODER TD-N20
TD-PNJB01 C
P/N 30122725 P/N 126421 ENCLOSURE
P/N 126817 MACHINE
2
(7C X 1.5mm )
DRILL MOTOR HEATER
HTR-01 TD-N03 TB1
TS-01 DRILL MOTOR

TS-02 TEMP SWITCHES
TS-03
DM-02
(1C x 4/0 AWG)

U/T1
MOT-02
DRILL MOTOR ASSY

M
(1C x 4/0 AWG)
B P/N 118217 3
U/T2 B
400 HP @ 50° C
(1C x 4/0 AWG)

U/T3
2 2 2
(1C x 70mm )
2
(18Cx2.5mm ) (18Cx2.5mm ) (18Cx2.5mm )
G TB1 TD-P04 TD-PO3 TD-JMP4 CONTINUED TO
5 B8
PIGTAIL AUX PWR S.L. AUX POWER JUMPER (OPTIONAL)
SH ZN
126801-01-20 M614000129-200-25-4-B P/N 30155551-XXX-B
2
(7CX 1.5mm )
DRILL MOTOR HEATER
HTR-02 TD-N04 TB1
(4TSPx14AWG) + (30Cx12AWG) (4TSPx14AWG) + (30Cx12AWG) (4TSPx14AWG) + (30Cx12AWG)
TB1 TD-C02 TD-CO1 TD-JMP5 CONTINUED TO
5 B8
PIGTAIL COMP SERVICE LOOP COMPOSITE JUMPER (OPTIONAL)
TS-04 DRILL MOTOR SH ZN
126800-01-20 126498-200-25-3-B 30155550-XXX-B
TS-05 TEMP SWITCH
TS-06 CABLE KIT CABLE KIT
SERVICE LOOP JUMPER (EEx/EEx)
P/N 30175021-86-200 P/N 30150610-XXX
OPTIONAL
A A
3 D6
SH ZN

SCALE: PROJECTION: SIZE: SHT:
3 D6 N/A D 2 OF 5
SH ZN
DWG NO. REV:
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DRAWN IN ACAD
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8 7 6 5 4 3 2 1
2 A6
SH ZN
TD-11SA TOP DRIVE 2 A6

SH ZN
2
HYD. PUMP MOTOR (4C x 2.5mm )
D MOT-03 7.5kW(10 HP) M
TD-P05 TB1 D
600VAC, 60Hz 3
P/N 30178347-600-60-120 2
(3C x 1.5mm )
TD-N21 TB1
TEMP SWITCHES - U, V, W
INSTRUMENT J-BOX
2
TD-PNJB01
RT. BLOWER MOTOR
M
(4C x 2.5mm )
MOT-04 3kW(4 HP) TD-P06 TB1
600VAC, 60Hz 3
P/N 30178348-600-60-120 2
(3C x 1.5mm )
TD-N22 TB1
DERRICK SADDLE
2
LT. BLOWER MOTOR (4C x 2.5mm ) (P/N 3026815)
M
MOT-05 3KW (4 HP) TD-P07 TB1
600VAC, 60Hz 3
P/N 30178348-600-60-120 2
(3C x 1.5mm )
TD-N23 TB1
2 2 2
(24Cx1.5mm ) (24Cx1.5mm ) (24Cx1.5mm )

CRT-C03 CRT-C01 CRT-JMP3 CONTINUED TO
4 D3
CRT JUMPER PART OF OPTIONAL CRT CRT JUMPER 5 A8
SH ZN
SH ZN
P/N 30183288-16 COMPOSITE LOOP P/N M614004369-XXX
C 2 2 2
C
(7TSPx1.0mm ) (7TSPx1.0mm ) (7TSPx1.0mm )
CRT-C04 CRT-C02 CRT-JMP4 CONTINUED TO
CRT JUMPER PART OF OPTIONAL CRT CRT JUMPER 5 A8

SH ZN
P/N 30183289-16 COMPOSITE LOOP M614004370-XXX
4 D6
SH ZN OPTIONAL CRT CABLES OPTIONAL
PROVIDED IN REPLACEMENT CRT-350
CRT COMPOSITE LOOP JUMPERS (EEx/EEx)
P/N M614004368-200-25-3-B
OPTIONAL CRT-350
2
CRT (3C x 1.5mm )
SLIPS UP
SOV-15 TD- N25
SOLENOID
2
CRT (3C x 1.5mm )
ELEVATOR OPEN
SOV-16 TD-N26
SOLENOID
2
CRT (3C x 1.5mm )
B SOV-17
LINK TILT EXTEND
SOLENOID
TD-N27 B
2
CRT (3C x 1.5mm )
LINK TILT RETRACT
SOV-18 TDS-N09
SOLENOID
2
CRT (3C x 1.5mm )
LINK TILT FLOAT
SOV-19 TD-N29
SOLENOID
CRT SLIPS SET (1TSPx1.0mm )

PS-15 PRESSURE SWITCH TD-N30
CRT SJ ELEV CLOSED (1TSPx1.0mm )

A A
2
CRT STOP LOWERING (1TSPx1.0mm )


N/A D 3 OF 5
DWG NO. REV:
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8 7 6 5 4 3 2 1
3 C6
SH ZN
3 C6
SH ZN
TD-11SA TOP DRIVE
D D
2
RT. BLOWER DIFF (3C x 1.5mm )
PS-01 PRESSURE SWITCH TDS-NO5 TB1
P/N 76841 INSTRUMENT J-BOX

2
TDS-PNJB01
LT. BLOWER DIFF (3C x 1.5mm )
PS-02 TDS-NO6 TB1
PRESSURE SWITCH
P/N 126421 ENCLOSURE
P/N 76841 P/N 126817 MACHINE
2
IBOP (3C x 1.5mm )
P/N 83095-1
2
LUBE OIL (3C x 1.5mm )
P/N 87541-1
TB1
2
BRAKES (3C x 1.5mm )
ON TB1
SOV-01 TDS-N09
SOLENOID
P/N 122554-D2
2
ROTATE (3C x 1.5mm )
C SOV-02
RIGHT
SOLENOID
TDS-N10 TB1 C
P/N 122554-J2
2
ROTATE (3C x 1.5mm )
LEFT TB1
SOV-03 TDS-N11
SOLENOID
P/N 122554-J2
2
IBOP (3C x 1.5mm )
CLOSE TB1
SOV-04 TDS-N12
SOLENOID
P/N 122554-D2
2
TORQUE (3C x 1.5mm )
WRENCH TB1
SOV-05 TDS-N13
SOLENOID
P/N 122554-D2
2
LINK TILT (3C x 1.5mm )
EXTEND TB1
SOV-06 TDS-N14
SOLENOID
P/N 122554-J2
2
DRILL TB1
SOV-07 TDS-N15
SOLENOID
P/N 122554-J2
2
FLOAT TB1
SOV-08 TDS-N16
SOLENOID
B P/N 122554-J2 B
2
STAND (3C x 1.5mm )
JUMP TB1
SOV-09 TDS-N17
SOLENOID
P/N 122554-D2
2
OPTIONAL (3C x 1.5mm )
ELEVATOR OPEN TB1
SOV-10 TDS-N18
SOLENOID
P/N 122554-D2
2
OPTIONAL (3C x 1.5mm )
ELEVATOR CLOSE TB1
SOV-11 TDS-N19
SOLENOID
P/N 122554-D2
A A

N/A D 4 OF 5
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8 7 6 5 4 3 2 1
VFD HOUSE
VFD-01
2 2
(7C x 1.5mm ) (7C x 1.5mm )
VDC-N101A VDC-N101 P6
DRILLER'S CONSOLE P/N 30181884-9 P/N 30181755-XXX-B

VDC PIGTAIL
D D
P/N M804000483-X (PROFIBUS DP) (PROFIBUS DP)
PBUS-01A PBUS-01 C2
P/N 30181908-9 P/N 30181756-XXX-B

VDC PIGTAIL
(3C x 1.5mm²) (3C x 1.5mm²)

VDC-HTR3 HTR-PWR2
P/N 30155867-9-P P/N 30155867-XXX-B

VDC PIGTAIL
OPTIONAL
VDC HEATER KIT
P/N M804000482-XXX
2 2
(3C x 1.5mm ) (3C x 1.5mm )
HMI-P101A HMI-P101 P7
OPTIONAL HMI P/N 30157672-9-P P/N 30157671-XXX-B

HMI PIGTAIL
P/N 30182147 (F.O. ETHERNET) (F.O. ETHERNET)

D-101A D-101 C3
INPUT TRANSFORMER
P/N 30178806-6-009 P/N 30178806-3-XXX 114565-X-X
HMI PIGTAIL
(PURCHASED SEPARATELY IF REQUIRED)
C C
CONTINUED FROM (1C x 444MCM) (1C x 444MCM) (1C x 444MCM) SCR ROOM
DERRICK FLOOR
TD-JMP-G1 TD-JMP-G VFD GND VFD GND TD-P02-G
2 C1
P/N 125093-XXX P/N 125093-XXX P/N 125093-XXX
SH ZN
(1C x 646MCM) (1C x 646MCM) (1C x 646MCM)

TD-JMP-U1 TD-JMP-U P13 P10 TD-P02-U
P/N 30155547-BLK-XXX P/N 30155933-BLK-XXX P/N 114724-BLK-XXX

CONTINUED FROM (1C x 646MCM) (1C x 646MCM)
DERRICK FLOOR
(1C x 646MCM)
TD-JMP-V1 TD-JMP-V P14 P11 TD-P02-V CUSTOMER SUPPLIED
2 D1
P/N 30155547-WHT-XXX P/N 30155933-WHT-XXX P/N 114724-WHT-XXX
SH ZN
600VAC, 3 PH, 60HZ
(1C x 646MCM) (1C x 646MCM) (1C x 646MCM)
TD-JMP-W1 TD-JMP-W P15 P12 TD-P02-W
P/N 30155547-RED-XXX P/N 30155933-RED-XXX P/N 114724-RED-XXX
INCOMING
CABLE KIT 3
2 2
P/N 125274-XXX
CONTINUED FROM
(18Cx2.5mm ) (18Cx2.5mm )
DERRICK FLOOR
TD-JMP4 TD-JMP2 P5
2 B1
AUX POWER JUMPER (OPTIONAL) AUX POWER JUMPER BULKHEAD
B SH ZN CONNECTOR KIT B
P/N 30155551-XXX-B P/N 30155934-XXX-B
P/N 114738
OPTIONAL
CONTINUED FROM
(4TSPx14AWG) + (30Cx12AWG) (4TSPx14AWG) + (30Cx12AWG)
DERRICK FLOOR
TD-JMP5 TD-JMP3 C1
2 A1
COMPOSITE JUMPER (OPTIONAL) COMPOSITE JUMPER
SH ZN
P/N 30155550-XXX-B P/N 30157551-XXX-B
CABLE KIT
JUMPER (EEx/NON-EEx)
CABLE KIT P/N 30157552-XXX
JUMPER (EEx/EEx)
P/N 30150610-XXX
OPTIONAL
2 2
CONTINUED FROM
(24Cx1.5mm ) (24Cx1.5mm )
DERRICK FLOOR
CRT-JMP3 CRT-JMP1 C4
3 C1 JUMPER JUMPER
SH ZN
P/N M614004369-XXX P/N M614004371-XXX
2 2
CONTINUED FROM
(7TSPx1.5mm ) (7TSPx1.5mm )
DERRICK FLOOR
CRT-JMP4 CRT-JMP2 C5
A 3 C1 JUMPER JUMPER A
SH ZN
P/N M614004370-XXX P/N M614004372-XXX
OPTIONAL OPTIONAL
CRT-350 CRT-350
JUMPERS (EEx/EEx) JUMPERS (EEx/NON-EEx)
N/A D 5 OF 5
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THIS DOCUMENT CONTAINS PROPRIETARY AND CONFIDENTIAL INFORMATION WHICH BELONGS TO NATIONAL-OILWELL,
L.P. IT IS LOANED FOR LIMITED PURPOSES ONLY AND REMAINS THE PROPERTY OF NATIONAL-OILWELL, L.P.
REPRODUCTION, IN WHOLE OR IN PART OR USE OF THIS DESIGN OR DISTRIBUTION OF THIS INFORMATION TO OTHERS IS
NOT PERMITTED WITHOUT THE EXPRESS WRITTEN CONSENT OF NATIONAL-OILWELL, L.P. THIS DOCUMENT IS TO BE
RETURNED TO NATIONAL-OILWELL, L.P. UPON REQUEST AND IN ANY EVENT UPON COMPLETION OF THE USE FOR WHICH
IT WAS LOANED. THIS DOCUMENT AND THE INFORMATION CONTAINED AND REPRESENTED IS THE COPYRIGHTED
TDS-9/11SA PROPERTY OF NATIONAL-OILWELL, L.P.

TITLE
NEXT ASSY USED ON CURRENT INITIAL I/O MAP TDS-9/11SA
DRAWN
APPLICATION R. HOLLADAY
CHECKED
M. MASLYAR SIZE DWG NO REV
APPVD
M. MASLYAR B D804000705-IDX-001 01
DATE
5/5/2009 SCALE NONE WT LBS SHEET 1 OF 6
DCF0051 (REV A)
NATIONAL OILWELL VARCO I/O MAP TDS-9/11SA DATE 9/7/2011 3:55:02 PM
I/O SIGNAL NETWORK NODE I/O DESCRIPTION I/O 1 FUNCTION 0 FUNCTION ENG. MIN ENG. MAX ENG. SETPOINTS REMARKS
ADDRESS TYPE ID No. LOCATION UNITS UNITS UNITS
10IB0 Encoder DP1 10 Incremental Encoder Status Byte SBC Cabinet
10IW1 Encoder DP1 10 Incremental Encoder Value Word SBC Cabinet
10IB3 Encoder DP1 10 Incremental Encoder Reserved Byte SBC Cabinet
10IW4 Encoder DP1 10 Incremental Encoder Latch Word SBC Cabinet
O
10DI6.0 N.I.S. 24VDC DP1 10 Right Drill Motor Overtemp Switch SBC Cabinet Motor Temp Okay Motor Temp High C 170 +/-5
O
10DI6.1 N.I.S. 24VDC DP1 10 Left Drill Motor Overtemp Switch SBC Cabinet Motor Temp Okay Motor Temp High C 170 +/-5
10DI6.2 N.I.S. 24VDC DP1 10 Right Blower Pressure Switch SBC Cabinet Blower Pressure Okay Blower Pressure Low
10DI6.3 N.I.S. 24VDC DP1 10 Left Blower Pressure Switch SBC Cabinet Blower Pressure Okay Blower Pressure Low
10DI6.4 N.I.S. 24VDC DP1 10 IBOP Pressure Switch SBC Cabinet IBOP Closed IBOP Open
10DI6.5 N.I.S. 24VDC DP1 10 Lube Pressure Switch SBC Cabinet Lube Pressure Okay Lube Pressure Low
Right Blower Motor Overtemp Switch (Eex 50Hz
10DI6.6 N.I.S. 24VDC DP1 10 SBC Cabinet Right Blower Motor Temp Okay Right Blower Motor Temp High
Units Only)
Left Blower Motor Overtemp Switch (Eex 50Hz Units
10DI6.7 N.I.S. 24VDC DP1 10 SBC Cabinet Left Blower Motor Temp Okay Left Blower Motor Temp High
Only)
10DI7.0 N.I.S. 24VDC DP1 10 CRT Slips Set Pressure Switch SBC Cabinet CRT Slips Set CRT Slips Open
10DI7.1 N.I.S. 24VDC DP1 10 CRT SJ Elev Closed Pressure Switch SBC Cabinet CRT SJ Elev Closed CRT SJ Elev Open
10DI7.2 N.I.S. 24VDC DP1 10 CRT Stop Lowering Pressure Switch SBC Cabinet Stop Lowering Okay to Lower
10DI7.3 N.I.S. 24VDC DP1 10 Spare SBC Cabinet
10DI8.0 N.I.S. 24VDC DP1 10 Right Blower Running Status SBC Cabinet CRT Slips Set CRT Slips Open
10DI8.1 N.I.S. 24VDC DP1 10 Left Blower Running Status SBC Cabinet CRT SJ Elev Closed CRT SJ Elev Open
10DI8.2 N.I.S. 24VDC DP1 10 Lube Pump Running Status SBC Cabinet Stop Lowering Okay to Lower
Lube Pump Motor Overtemp Switch (Eex 50Hz Units
N.I.S. 24VDC DP1 10 SBC Cabinet Lube Pump Motor Temp Okay Lube Pump Motor Temp High
10DI8.3 Only)
10QB0 Encoder DP1 10 Incremental Encoder Control Byte SBC Cabinet

10QW1 Encoder DP1 10 Incremental Encoder Setpoint Word SBC Cabinet
10QB3 Encoder DP1 10 Incremental Encoder Reserved Byte SBC Cabinet
10AQ6 N.I.S. 24VDC DP1 10 Torque SBC Cabinet Ft-Lbs 0 80k 4-20mA
10AQ8 N.I.S. 24VDC DP1 10 Spare SBC Cabinet 4-20mA
SHEET 2 OF 6 DWG NO D804000705-IDX-001 REV 01

10DQ10.0 N.I.S. 24VDC DP1 10 CRT LT Float Solenoid SBC Cabinet CRT Links Float CRT Links Maintain Position
10DQ10.1 N.I.S. 24VDC DP1 10 Spare SBC Cabinet
10DQ10.2 N.I.S. 24VDC DP1 10 CRT Slips Up Solenoid SBC Cabinet Open CRT Slips Close CRT Slips
10DQ10.3 N.I.S. 24VDC DP1 10 CRT Elevator Open Solenoid SBC Cabinet Open CRT Elevator Close CRT Elevator
10DQ10.4 N.I.S. 24VDC DP1 10 CRT LT Extend Solenoid SBC Cabinet CRT LT Extends CRT LT Stops and Maintains Position
10DQ10.5 N.I.S. 24VDC DP1 10 CRT LT Retract Solenoid SBC Cabinet CRT LT Retracts CRT LT Stops and Maintains Position
10DQ10.6 N.I.S. 24VDC DP1 10 Brake On Solenoid SBC Cabinet Brake is Applied Brake Off
10DQ10.7 N.I.S. 24VDC DP1 10 PH Rotate CCW Solenoid SBC Cabinet PH Rotates CCW PH Does Not Rotate
10DQ11.0 N.I.S. 24VDC DP1 10 PH Rotate CW Solenoid SBC Cabinet PH Rotates CW PH Does Not Rotate
10DQ11.1 N.I.S. 24VDC DP1 10 IBOP Close Solenoid SBC Cabinet IBOP Closes IBOP Opens
10DQ11.2 N.I.S. 24VDC DP1 10 Torque Wrench Solenoid SBC Cabinet Shot Pin Engages & TW Clamps Shot Pin Disengages & TW Unclamps
10DQ11.3 N.I.S. 24VDC DP1 10 LT Tilt Solenoid SBC Cabinet LT Extends toward Mousehole LT Stops and Maintans Position
10DQ11.4 N.I.S. 24VDC DP1 10 LT Drill Solenoid SBC Cabinet LT Retracts toward Drilldown LT Stops and Maintans Position
10DQ11.5 N.I.S. 24VDC DP1 10 LT Float Solenoid SBC Cabinet LT Floats to Center LT Maintains position
10DQ11.6 N.I.S. 24VDC DP1 10 Stand Jump Solenoid SBC Cabinet Stand Jump Activates Stand Jump De-activates
10DQ11.7 N.I.S. 24VDC DP1 10 Elevator Open Solenoid (Optional) SBC Cabinet Elevator Opens Elevator Remains Open
10DQ12.0 N.I.S. 24VDC DP1 10 Elevator Close Solenoid (Optional) SBC Cabinet Elevator Closes Elevator Remains Closed
10DQ12.2 N.I.S. 24VDC DP1 10 Right Blower Contactor SBC Cabinet Turn Right Blower On Turn Right Blower Off
10DQ12.3 N.I.S. 24VDC DP1 10 Hydraulic Pump Contactor SBC Cabinet Turn Hydraulic Pump On Turn Hydraulic Pump Off
10DQ12.5 N.I.S. 24VDC DP1 10 Left Blower Contactor SBC Cabinet Turn Left Blower On Turn Left Blower Off

30DI0.0 N.I.S. 24VDC DP1 30 Alarm Silence / Lamp Check Pushbutton Driller's Console Silence Alarms and Check Lamps
30DI0.1 N.I.S. 24VDC DP1 30 TDS Shutdown Pushbutton Driller's Console TDS Shutdown Requested TDS Shutdown Not Requested
30DI0.2 N.I.S. 24VDC DP1 30 TDS Torque Set Drill Selector Switch Driller's Console Set Drill Torque Limit Display Actual Torque
30DI0.3 N.I.S. 24VDC DP1 30 TDS Torque Set Makeup Selector Switch Driller's Console Set Makeup Torque Limit Display Actual Torque
30DI0.4 N.I.S. 24VDC DP1 30 TDS Enable Pushbutton Driller's Console Enable Ownership Request
30DI0.5 N.I.S. 24VDC DP1 30 Counterbalance Drill / Standjump Pushbutton Driller's Console Standjump Enable Request
30DI0.6 N.I.S. 24VDC DP1 30 HPU Auto / On Pushbutton Driller's Console HPU On Request
30DI0.7 N.I.S. 24VDC DP1 30 TDS Reverse Direction Pushbutton Driller's Console TDS Reverse Request
30DI1.0 N.I.S. 24VDC DP1 30 TDS Direction Off Pushbutton Driller's Console TDS Off Request
30DI1.1 N.I.S. 24VDC DP1 30 TDS Forward Direction Pushbutton Driller's Console TDS Forward Request
30DI1.2 N.I.S. 24VDC DP1 30 TDS Torque Mode Pushbutton Driller's Console TDS Torque Mode Request
30DI1.3 N.I.S. 24VDC DP1 30 TDS Spin Mode Pushbutton Driller's Console TDS Spin Mode Request
30DI1.4 N.I.S. 24VDC DP1 30 TDS Drill Mode Pushbutton Driller's Console TDS Drill Mode Request
30DI1.5 N.I.S. 24VDC DP1 30 Brake Auto Pushbutton Driller's Console Brake Auto Request
30DI1.6 N.I.S. 24VDC DP1 30 Brake On/Off Pushbutton Driller's Console Brake On/Off Request
30DI1.7 N.I.S. 24VDC DP1 30 Pipehandler Link Tilt Float Pushbutton Driller's Console PH Link Tilt Float Request
30DI2.0 N.I.S. 24VDC DP1 30 Pipehandler Rotate CCW Selector Switch Driller's Console PH Rotate CCW PH Stop Rotation
30DI2.1 N.I.S. 24VDC DP1 30 Pipehandler Rotate CW Selector Switch Driller's Console PH Rotate CW PH Stop Rotation
30DI2.2 N.I.S. 24VDC DP1 30 PH Link Tilt Drill Selector Switch Driller's Console Links Retract Toward Drill Position Links Stop Moving
30DI2.3 N.I.S. 24VDC DP1 30 PH Link Tilt Tilt Selector Switch Driller's Console Links Extend Toward Mousehole Links Stop Moving
Shot Pin Engagaes and Torque Wrench Shot Pin Disengagaes and Torque
PH Torque Wrench Clamp Pushbutton Driller's Console
30DI2.4 N.I.S. 24VDC DP1 30 Clamps Wrench Unclamps
30DI2.5 N.I.S. 24VDC DP1 30 IBOP Open Selector Switch Driller's Console IBOP Open Request
30DI2.6 N.I.S. 24VDC DP1 30 IBOP Close Selector Switch Driller's Console IBOP Close Request
30DI2.7 N.I.S. 24VDC DP1 30 Spare Driller's Console
30DI3.0 N.I.S. 24VDC DP1 30 Elevator Open Selector Switch Driller's Console Elevator Open Request
30DI3.1 N.I.S. 24VDC DP1 30 Elevator Close Selector Switch Driller's Console Elevator Close Request PH Stop Rotation
30IB4 Encoder 5VDC DP1 30 TDS RPM Setpoint Status Byte Driller's Console
30IW5 Encoder 5VDC DP1 30 TDS RPM Setpoint Value Word Driller's Console
30IB7 Encoder 5VDC DP1 30 TDS RPM Setpoint Reserved Byte Driller's Console
30IW8 Encoder 5VDC DP1 30 TDS RPM Setpoint Latch Word Driller's Console

30IB10 Encoder 5VDC DP1 30 TDS Drill Torque Setpoint Status Byte Driller's Console
30IW11 Encoder 5VDC DP1 30 TDS Drill Torque Setpoint Value Word Driller's Console
30IB13 Encoder 5VDC DP1 30 TDS Drill Torque Setpoint Reserved Byte Driller's Console
30IW14 Encoder 5VDC DP1 30 TDS Drill Torque Setpoint Latch Word Driller's Console
30IB16 Encoder 5VDC DP1 30 TDS Make-up Torque Setpoint Status Byte Driller's Console
30IW17 Encoder 5VDC DP1 30 TDS Make-up Torque Setpoint Value Word Driller's Console
30IB19 Encoder 5VDC DP1 30 TDS Make-up Torque Setpoint Reserved Byte Driller's Console
30IW20 Encoder 5VDC DP1 30 TDS Make-up Torque Setpoint Latch Word Driller's Console
30DQ0.0 N.I.S. 24VDC DP1 30 TD Enable Lamp Driller's Console Lamp On - TD Enabled Lamp Off - TD Not Enabled
30DQ0.1 N.I.S. 24VDC DP1 30 Counterbalnace Drill / Standjump Lamp Driller's Console Lamp On - Standjump Mode Lamp Off - Counterbalance Mode
30DQ0.2 N.I.S. 24VDC DP1 30 HPU Auto/On Lamp Driller's Console Lamp On - HPU On Mode Lamp Off - HPU Auto Mode
30DQ0.3 N.I.S. 24VDC DP1 30 TDS Reverse Direction Lamp Driller's Console Lamp On - TDS in Reverse Mode Lamp Off - TDS Not in Reverse Mode
30DQ0.4 N.I.S. 24VDC DP1 30 TDS Forward Direction Lamp Driller's Console Lamp On - TDS in Forward Mode Lamp Off - TDS Not in Forward Mode
30DQ0.5 N.I.S. 24VDC DP1 30 TDS Torque Mode Lamp Driller's Console Lamp On - TDS in Torque Mode Lamp Off - TDS Not in Torque Mode
30DQ0.6 N.I.S. 24VDC DP1 30 TDS Spin Mode Lamp Driller's Console Lamp On - TDS in Spin Mode Lamp Off - TDS Not in Spin Mode
30DQ0.7 N.I.S. 24VDC DP1 30 Spare
30DQ1.0 N.I.S. 24VDC DP1 30 TDS Drill Mode Lamp Driller's Console Lamp On - TDS in Drill Mode Lamp Off - TDS Not in Drill Mode
30DQ1.1 N.I.S. 24VDC DP1 30 Brake Auto Lamp Driller's Console Lamp On - Brake in Auto Mode Lamp Off - Brake Not in Auto Mode
30DQ1.2 N.I.S. 24VDC DP1 30 Brake On/Off Lamp Driller's Console Lamp On - Brake On Lamp Off - Brake Off
30DQ1.3 N.I.S. 24VDC DP1 30 Pipehandler Link Tilt Float Lamp Driller's Console Lamp On - PH in Float Mode Lamp Off - PH Not in Float Mode
30DQ1.4 N.I.S. 24VDC DP1 30 IBOP Closed Lamp Driller's Console Lamp On - IBOP Closed Lamp Off - IBOP Open
30DQ1.5 N.I.S. 24VDC DP1 30 Blower Loss Alarm Lamp Driller's Console Lamp On - Blower Loss Lamp Off - Blower Okay
30DQ1.6 N.I.S. 24VDC DP1 30 Oil Pressure Loss Alarm Lamp Driller's Console Lamp On - Oil Pressure Low Lamp Off - Oil Pressure Okay
30DQ1.7 N.I.S. 24VDC DP1 30 Drill Motor Overtemp Alarm Lamp Driller's Console Lamp On - Drill Motor Overtemp Lamp Off - Drill Motor Temp Oaky
30DQ2.0 N.I.S. 24VDC DP1 30 VFD Fault Alarm Lamp Driller's Console Lamp On - VFD Faulted Lamp Off - VFD Okay
30DQ2.1 N.I.S. 24VDC DP1 30 General Alarm Lamp Driller's Console Lamp On - General Alarm Active Lamp Off - Status Okay
30DQ2.2 N.I.S. 24VDC DP1 30 Horn Driller's Console Alarm Horn On Alarm Horn Off
30DQ2.3 N.I.S. 24VDC DP1 30 Spare Driller's Console
30AQ3 N.I.S. 4-20mA DP1 30 TDS RPM Meter Driller's Console RPM 0 250
30AQ5 N.I.S. 4-20mA DP1 30 TDS Torque Meter Driller's Console Ft-Lbs 0 80K
30QB7 Encoder 5VDC DP1 30 TDS RPM Setpoint Control Byte Driller's Console
30QW8 Encoder 5VDC DP1 30 TDS RPM Setpoint Word Driller's Console
30QB10 Encoder 5VDC DP1 30 TDS RPM Setpoint Reserved Byte Driller's Console

30QB13 Encoder 5VDC DP1 30 TDS Drill Torque Setpoint Control Byte Driller's Console
30QW14 Encoder 5VDC DP1 30 TDS Drill Torque Setpoint Word Driller's Console
30QB16 Encoder 5VDC DP1 30 TDS Drill Torque Setpoint Reserved Byte Driller's Console
30QB19 Encoder 5VDC DP1 30 TDS Make-up Torque Setpoint Control Byte Driller's Console
30QW20 Encoder 5VDC DP1 30 TDS Make-up Torque Setpoint Word Driller's Console
30QB22 Encoder 5VDC DP1 30 TDS Make-up Torque Setpoint Reserved Byte Driller's Console
30AQ25 N.I.S. 4-20mA DP1 30 Customer TDS RPM Driller's Console RPM 0 250
30AQ27 N.I.S. 4-20mA DP1 30 Customer TDS Torque Driller's Console Ft-Lbs 0 80K

FINAL DOCUMENTATION
Section 5.2
Top Drive Assemblies
www.nov.com
Printed On: 06\22\2012 11:12
Printed On: 06\22\2012 11:13
Printed On: 06\22\2012 11:14
Printed On: 06\22\2012 11:15
Printed On: 06\22\2012 11:15
8 7 6 5 4 3 2 1
NOTES: UNLESS OTHERWISE SPECIFIED CONFIGURATION TABLE
1. ADJUST TO ALLOW LIGHT CONTACT WITH ITEM 21. DASH NO SETBACK DESCRIPTION REF DIM A
20 2X -BSC 30.00 USED WITH ADDITIONAL SPACER

2. LUBRICATE ALL JAM NUTS (ITEM 13) & (ITEM 7) WITH GREASE, 1 -BSC
FOR SPECIAL 39.50" SETBACK
9.2
TORQUE JAM NUTS (ITEM 7: 300 LBS) (ITEM 13: 400 LBS) 19 A/R 2X
3. LUBRICATE ALL OTHER THREADS WITH ANTI-SEIZE COMPOUND, 29 -500 -500 33.75 13.0
AND TORQUE TO DS00008. DO NOT LOCKWIRE. 32 6X

D -502 39.50 STD FOR 39.50" SETBACKS 18.7
D
30 -502
4. GREASE CAM FOLLOWERS AFTER ASSY. 2X 23
-503 41.00 20.2
33 -503
5. PACK WITH GREASE PRIOR TO ASSY. 4X 25
27
6. DRILL SHANKS Ø.141 ON ASSEMBLY FOR ITEM 31. 4X 26
11 2X 24 2X
26 2X 15
16 2X
17 2X
(ITEM 27)
(20.8)
10 10 10 10 53201 FITTING, GREASE (1/8"-27 NPT) 34

C C
1 - - - 124535-503 CARRIAGE, (LEFT), 41.00" SETBACK 33
6 6 6 6 51219-2 FERRULE, CABLE 32

1
3 3 3 3 51402-12-S PIN, COTTER 31
- 1 - - 124535-502 CARRIAGE, (LEFT), 39.50" SETBACK 30
2X 3 12 3X 2 2X
10 4X
- - 1 - 124535-500 CARRIAGE, (LEFT), 33.75" SETBACK 29
34 4X 4X 34
13 2X 3 3 3 3 50812-N-C WASHER, FLAT 28
14 3X 6 2
7 1 1 1 1 113370 STRAP, ACCUMULATOR, Ø6" 27
28 3X 8 2X 6 6 6 6 50908-C WASHER, LOCK-REGULAR 26

4 8X 6
31 3X 5 2X 4 4 4 4 50008-10-C5D SCREW, HEX HD. CAP, 1/2 UNC X 1.25 25
2 8X 7 5 2 2 2 2 50108-10-CD SCREW, CAP-SOCKET HD. 1/2 UNC X 1.25 24
18 2X 13 2X 2 2 2 2 2 88710 STRAP 23
7 8X 4
1 1 1 1 125727-2 PLATE 22
8 2X
2 2 2 2 125727-1 PLATE 21
2 2 2 2 30152845 PIN 20
1 1 1 1 51220-2 CABLE RETAINING Ø.063 72" LONG 19
2 2 2 2 125727-3 FERRULE BAR 18

34 2X
2 2 2 2 50906-C WASHER, LOCK-REGULAR 17
22
B 2 2 2 2 50006-5-C5D SCREW, HEX HD. CAP 16 B
1 1 1 1 129375 BRACKET, ANGLE 15
3 3 3 3 30179918 BOLT, SHOULDER SOCKET HD (UNC-3A) (MODIFIED) 14
4 4 4 4 80569 NUT, JAM, 2"-12 UN-2B 13
3 3 3 3 50512-C NUT, HEX SLOTTED 12
2 2 2 2 30157306 PIN, LINCH Ø.188 11
4 4 4 4 109944 BUSHING, FLANGED, 2.75 ID 10
(A) 4 4 4 4 51132-C WASHER, LOCK, HI-COLLAR, 2" DIA. 8
8 8 8 8 55324-C NUT, HEX-JAM (1.50-12 UNF-2B) 7
8 8 8 8 30158767-04 BEARING, CAM FOLLOWER 6
2 2 2 2 30155438 CAM FOLLOWER 6" DIA 5
8 8 8 8 51024-C WASHER, LOCK - 1.5" 4

21 2X
2 2 2 2 124537 BOGEY 3
2 2 2 2 112875 PIN, BOGEY PIVOT 2
(68.0) - - - 1 124535 CARRIAGE, (LEFT), 30.00" SETBACK 1
-503 -502 -500 BSC ITEM

PART NO. DESCRIPTION
NO.
QTY REQD LIST OF MATERIAL

A CONFIG BSC SHOWN PRODUCT: TDS-9S
A
TOLERANCES ARE:
NEXT ASSY: 124540
TITLE:
CARRIAGE ASSEMBLY, LEFT

X.XXX ±.010 BREAK EDGES .02/.03
7 INSTALL CAM FOLLOWERS ON THE MILL SIDE OF BOGEY SIMILAR TO:
DO NOT SCALE DRAWING
OTHERS IS NOT PERMITTED WITHOUT THE EXPRESS WRITTEN
CONSENT OF NOV. THIS DOCUMENT IS TO BE RETURNED
WT LBS: 650 CURRENT INITIAL USE FOR WHICH IT WAS LOANED. THIS DOCUMENT AND
INSTALL LOCK WASHER AND NUT ON COUNTER BORE SIDE FINISH DRAWN A. PHILLIPS JOHN MARTINEZ
IS THE COPYRIGHTED PROPERTY OF NOV.
D
CHECKED H. LIM NEIL WEST
ENSURE ALL CAM FOLLOWERS ROTATE AFTER THEY ARE INSTALLED AND TORQUED TOL < ±.06 TOL > ±.06 RIG SOLUTIONS
1/4 1 OF 1
APPVD H. LIM NEIL WEST MECHANICAL ENGINEERING DWG NO. REV:
250 1000
DATE
1/26/10 3/17/98 124538 AA
DRAWN IN ACAD
8 7 6 5 4 3 2 1 RS-MECH_D-TPL-001
8 7 6 5 4 3 2 1
8 INSTALL CAM FOLLOWERS ON THE MILL SIDE OF BOGEY CONFIGURATION TABLE

NOTES: UNLESS OTHERWISE SPECIFIED
INSTALL LOCK WASHER AND NUT ON COUNTER BORE SIDE
DASH NO SETBACK DESCRIPTION REF DIM A
1 ADJUST TO ALLOW FREE MOTION OF ITEM 21.
ENSURE ALL CAM FOLLOWERS ROTATE AFTER THEY ARE INSTALLED AND TORQUED
-BSC 30.00 & 39.50 USED WITH ADDITIONAL SPACER 9.2
2 LUBRICATE ALL JAM NUTS (ITEM 13) WITH GREASE,
FOR SPECIAL 39.50" SETBACK
TORQUE JAM NUTS 300 TO 400 ft-lbs.
D 3. LUBRICATE ALL OTHER THREADS WITH ANTI-SEIZE COMPOUND, -500 33.75 13.0
D
AND TORQUE TO DS00008. DO NOT LOCKWIRE.
4 GREASE CAM FOLLOWERS AFTER ASSY. -502 39.50 STD FOR 39.50" SETBACKS 18.7
1 -BSC
5 PACK WITH GREASE PRIOR TO ASSY. -503 41.00 20.2
23 -500
6 DRILL SHANKS Ø.141 ON ASSEMBLY FOR ITEM 25.
24 -502
7. (OBSOLETE DWG 124539) CARRIES REVISION HISTORY FOR THIS DWG
27 -503
2X 3
C (20.5) C
10 10 10 10 GREASE CAP GREASE CAP 29
2 2 2 2 53000-2-C PLUG EXT. PIPE CTSK/HEX 28
1 - - - 124536-503 CARRIAGE, (RIGHT), 41.00" SETBACK 27
DELETED 26
3 3 3 3 51402-12-S PIN, COTTER 25
2X 11 - 1 - - 124536-502 CARRIAGE, (RIGHT), 39.50" SETBACK 24
- - 1 - 124536-500 CARRIAGE, (RIGHT), 33.75" SETBACK 23
3 3 3 3 50812-N-C WASHER, FLAT 22

4X 15 4X 10 6 1 3X 14 2 2X 15 4X 5 2X
4 8X 6 2 2 2 2 125727-1 PLATE 21
4X 29 3X 16 2
13 2X 29 4X 13 2X 2 2 2 2 2 30152845 PIN 20
2 8X 7
4 4 4 4 51220-2 CABLE RETAINING Ø.063, 48" LONG 19
6X 17 8 2X 8 2X
8 8X 4 2 2 2 2 125727-3 FERRULE BAR 18
2X 19 5 28 2X 6 6 6 6 51219-2 FERRULE CABLE 17
3 3 3 3 50512-C NUT, HEX-SLOTTED (UNF-2B) 16

2X 20
B 10 10 10 10 53201 FITTING, GREASE (1/8"-27 NPT) 15
B
3X 22
3 3 3 3 30179918 BOLT, SHOULDER SOCKET HD (UNC-3A) (MODIFIED) 14
4 4 4 4 80569 NUT, JAM, 2"-12 UN-2B 13

15 2X
3X 25 1 1 1 1 125727-2 PLATE 12
12
29 2X 2 2 2 2 30157306 PIN, LINCH Ø.188 11
2X 18
4 4 4 4 109944 BUSHING, FLANGED, 2.75 ID 10
4 4 4 4 51132-C WASHER, LOCK, HI-COLLAR, 2" DIA. 8
8 8 8 8 55324-C NUT, HEX-JAM (1.50-12 UNF-2B) 7
8 8 8 8 30158767-04 BEARING, CAM FOLLOWER 6
2 2 2 2 30155438 CAM FOLLOWER, 6" 5
(A) 8 8 8 8 51024-C WASHER, LOCK - 1.5" 4
2 2 2 2 124537 BOGEY 3
2 2 2 2 112875 PIN, BOGEY PIVOT 2
- - - 1 124536 CARRIAGE, (RIGHT), 30.00" SETBACK 1

-503 -502 -500 BSC ITEM
PART NO. DESCRIPTION
QTY REQD NO.
21 2X LIST OF MATERIALS
A PRODUCT: TDS-9S
A
TOLERANCES ARE:
(68.0) END ITEM: X.X
X.XX
±.1
±.03
ANGLES
FRACTIONS
± 1/2 DEG
± 1/16
REFERRED TO HEREINAFTER AS "NOV"). IT IS LOANED FOR
TITLE:
NEXT ASSY: 124540 NOV. REPRODUCTION, IN WHOLE OR IN PART, OR USE OF
CARRIAGE ASSEMBLY, RIGHT

SIMILAR TO:
-BSC SHOWN
WT LBS: 650 CURRENT INITIAL USE FOR WHICH IT WAS LOANED. THIS DOCUMENT AND
FINISH DRAWN A. PHILLIPS JOHN MARTINEZ IS THE COPYRIGHTED PROPERTY OF NOV.
D
CHECKED H. LIM NEIL WEST
1/4 1 OF 1
APPVD H. LIM NEIL WEST MECHANICAL ENGINEERING DWG NO. REV:
250 1000
DATE
1/26/10 3/17/98 30124539 U
DRAWN IN ACAD
8 7 6 5 4 3 2 1 RS-MECH_D-TPL-001
Printed On: 06\22\2012 12:11
Printed On: 06\22\2012 12:21
FINAL DOCUMENTATION
Section 5.3
Pipe Handler
www.nov.com
8 7 6 5 4 3 2 1
1. DELETED
2 LOCTITE AND TORQUE CLEVIS PER NOV DESIGN SPECIFICATION

D 3DS00082 SECTION 5 D
3 IMPRESSION STAMP VARCO PART NUMBER APPROXIMATELY
WHERE SHOWN.
4. PAINT PER VARCO SPECIFICATION VPS00001,

COLOR - YELLOW. MASK ALL THREADS AND BORES.
5. (OBSOLETE DWG 119592) CARRIES REVISION HISTORY FOR THIS DWG.
6 PEEN CYLINDER TIE ROD THREADS AT TOP OF NUTS. 4 PLACES
SAE #12 SAE #12

1
3
3
1.55
C C
2 2
5 5
4
4
B B
3
6
22.000 FULLY RETRACTED
(4.500 SQ) 32.30 FULLY EXTENDED
2 51435-16 PIN, COTTER 5
2 50512-C NUT,HEX SLOTTED 4
2 30172154 PIN, CYLINDER MOUNTING 3
1 103141-7 CLEVIS 2
1 119416 CYLINDER, HYDRAULIC 1
ITEM
PART NO. DESCRIPTION MATERIAL
QTY REQD NO.
LIST OF MATERIALS
A PRODUCT:
TDS-9S/11SA
A
TOLERANCES ARE:
END ITEM:
PH-50/75 X.X ±.1 ANGLES ± 1/2 DEG REFERRED TO HEREINAFTER AS "NOV"). IT IS LOANED FOR
X.XX ±.03 FRACTIONS ± 1/16 TITLE:
NEXT ASSY:
117820/30157366 NOV. REPRODUCTION, IN WHOLE OR IN PART, OR USE OF
ASSEMBLY, HYDRAULIC CYLINDER

SIMILAR TO:
FINISH DRAWN A. PHILLIPS H. OLSTYNSKI IS THE COPYRIGHTED PROPERTY OF NOV.
D
CHECKED B. KRUEGER JPSJ
TOL < ±.06 TOL > ±.06 RIG SOLUTIONS 1 OF 1
APPVD B. KRUEGER JPSJ MECHANICAL ENGINEERING DWG NO. REV:
250 1000
DATE
10/1/09 12/2/96 30119592 L
DRAWN IN ACAD
8 7 6 5 4 3 2 1 RS-MECH_D-TPL-001
Printed On: 06\22\2012 13:27
Printed On: 06\22\2012 13:30
Printed On: 06\22\2012 13:58
Printed On: 06\22\2012 14:27
FINAL DOCUMENTATION
Section 5.4
Kits
www.nov.com
Printed On: 06\22\2012 14:58
8 7 6 5 4 3 2 1
1. CLEAN OUT ALL HOSES PRIOR TO ASSEMBLY.
2. CYCLE CYLINDERS AFTER INSTALLATION OF HOSES

AND PRIOR TO ATTACHING TO HOOK.
3. FOLLOW ADJUSTMENT PROCEDURES IN SERVICE MANUAL.

D D
4 SEE DRAWING 112190 FOR ADDITIONAL COUNTERBALANCE
COMPONENTS.
C C
CONFIGURATION TABLE 4
-HOOK CONFIGURED FOR USE WITH HOOKS.
-BLOCK CONFIGURED FOR USE WITH BLOCKS
-BECKET CONFIGURED FOR USE WITH BECKET
B B
1 - - 95030-DWG DRAWING, COUNTERBALANCE PACKAGE (BECKET) 9
2 - - 88484 SHACKEL (13.5 TON) 8
2 - - 80392 LINK CONNECTING 7
2 - - 80390 CHAIN 9 LINK 6
- 1 1 112190-DWG DRAWING, COUNTERBALANCE PACKAGE 5
- 2 - 96575 SHACKLE 4
- 1 - 117076 BEAM, COUNTERBALANCE 3
- - 2 76717 PEAR LINK 2
- 2 2 51405-18-S PIN, COTTER 1

BECKET BLOCK HOOK ITEM
QTY REQD NO.
LIST OF MATERIALS
A DIMENSIONS UNLESS OTHERWISE SPECIFIED SURFACE FINISHES
A
PART FLAGS MACHINED *TORCH CUT
ARE IN INTERPRET DIMENSIONS &
TRACEABILITY 250 MAX 1000 MAX
INCHES TOLERANCES PER ANSI Y14.5 &
CRITICAL LOAD
ABBREVIATIONS PER ANSI Y1.1
PATH ITEM DO NOT
.X ±.1 CAN BE *TORCH CUT - -
CERTIFICATION
SCALE .XX ±.030 .XXX ±.010 TITLE
REQUIRED
DOCUMENT ANGULAR TOLERANCE ±0° 30' - -
SPARE PART KIT, TRAVELING

THIS DOCUMENT CONTAINS PROPRIETARY INFORMATION, AND SUCH
112190 TDS-9S
COMMISSIONING INFORMATION MAY NEITHER BE DISCLOSED TO OTHERS FOR ANY EQUIPMENT ATTACHMENT
PURPOSE NOR USED FOR MANUFACTURING PURPOSES WITHOUT
OPERATIONAL WRITTEN PERMISSION FROM VARCO INTERNATIONAL, INC. NEXT ASSY PRODUCT
SIZE DOCUMENT NO. REVISION
INSURANCE B A. PHILLIPS B. KRUEGER B. KRUEGER 5/5/09 D 118244 B
THIRD ANGLE PROJECTION
JRM B.SHUMSKI B.SHUMSKI 7/96 SCALE WEIGHT LB SHEET OF
LTR PREPARED BY CHECKED BY APPROVED BY DATE 1/10 125 1 2

20020219.09070623
8 7 6 5 4 3 2 1 DCF0022 (REV B)
8 7 6 5 4 3 2 1
BLOCK ASSEMBLY
TYPICAL
D D
BECKET ASSEMBLY
HOOK ASSEMBLY
TYPICAL
TYPICAL
C C
4
4
2X 2
3
1
4
2X 4
2X 6
2X 7
2X 8
32.7 FULLY EXTENDED

31.5 AS SHOWN
24.2 FULLY RETRACTED
B B
A A
THIS DOCUMENT CONTAINS PROPRIETARY TITLE SIZE DOCUMENT NO. REVISION

INFORMATION, AND SUCH INFORMATION MAY
NEITHER BE DISCLOSED TO OTHERS FOR ANY KIT, TRAVELING D 118244 B
EQUIPMENT ATTACHMENT
PURPOSE NOR USED FOR MANUFACTURING
SCALE SHEET OF
2 2
PURPOSES WITHOUT WRITTEN PERMISSION FROM
VARCO INTERNATIONAL, INC. 1/10

20020219.09070623
8 7 6 5 4 3 2 1 DCF0022 (REV B)
FINAL DOCUMENTATION
Section 5.5
Cable Requirements
www.nov.com
Printed On: 06\25\2012 06:38
Printed On: 06\25\2012 06:53
8 7 6 5 4 3 2 1
1. CONNECTORS TO BE CRIMPED ONTO CONDUCTORS PER CONNECTOR MFG. SPECIFICATION. 5. ALL CABLE ASSEMBLIES TO BE SUPPLIED WITH CONNECTOR DUST CAPS
2. ALL SHELL THREADED MEMBERS TO BE TIGHTENED PER MANUFACTURERS SPECIFICATION. INSTALLED AND TIGHTENED PER MANUFACTURERS SPECIFICATION.
3. POT NON-ATEX CONNECTORS USING ITEM 5 PER MANUFACTURERS SPECIFICATION. 6. CABLE ASSEMBLES TO BE SUPPLIED IN A BOX NO LARGER THAN 48" SQUARE X 24" HIGH.
BOX IS TO BE IDENTIFIED WITH VARCO PART NO (INCLUDING DASH NO) AND TEST CERTIFICATE.
4. POT ATEX CONNECTORS USING ITEM 7 PER MANUFACTURERS SPECIFICATION.
D 7. CONNECTORS MUST CONFORM TO VARCO DRAWINGS NO 114729 AND 126907. CABLE MUST D
5. AFTER ASSEMBLING CONNECTOR AND POTTING HAS CURED, THE FOLLOWING ELECTRICAL CONFORM TO VARCO DRAWING NO 56625.
TESTS ARE TO BE PERFORMED ON EACH CONDUCTOR. A SIGNED CERTIFICATE OF TEST
CONFORMANCE IS TO BE PROVIDED WITH EACH ASSY.
a. PERFORM A CONTINUITY CHECK THROUGH THE MATING CONNECTOR PAIRS.
THE TEST SHOULD UTILIZE AN AUDIBLE OR VISUAL CONTINUITY INDICATOR.
b. PERFORM A STANDARD MEGGER CHECK THROUGH THE MATING CONNECTOR PAIRS.
THE TEST SHOULD BE PERFORMED AT 500VDC MINIMUM. VERIFY CABLE INSULATION

IF NO CONNECTOR, CABLES TO BE
INTEGRITY TO CONNECTOR SHELLS AT BOTH ENDS; MUST BE 10 MEGA-OHMS MINIMUM. CUT TO LENGTH SHOWN. END OF
CABLE TO BE CAPPED TO PREVENT
c. ALL TESTING TO BE CONDUCTED THROUGH A MATING CONNECTOR HALF.
INGRESS OF WATER.
TYPICAL ALL CABLE ENDS
C 5 C
TABLE I
A ±2% CABLE
DASH DIM A LENGTH
QTY WEIGHT
NO (FT) (FT) ITEM #1 ITEM #2 ITEM #3 ITEM #6 (LB)
6"-18"
2 PL -50-P 50 50 1 - 2 2 26
1 2
-100-B 100 100 1 1 2 2 53
DUST CAP
-150-B 150 150 1 1 2 2 84
DUST CAP
-175-B 175 175 1 1 2 2 98
-200-B 200 200 1 1 2 2 110
-250-B 250 250 1 1 2 2 133
4
3
3 4 7 1 TYP
5
B 2 PL B
6
PIN END SOCKET END
(NON-ATEX) (ATEX) SPECIFICATION CONTROL DRAWING
A/R 126526 POTTING COMPOUND, EPOXY (ATEX) 7
30181755-XXX-X SEE TABLE I 84514-64-1 TUBING, HEAT SHRINK - CLR 6

1 1
1 1
2
2 2
2
A/R 127386 POTTING COMPOUND, 3M #2130 5
3 3 CONNECTOR DESIGNATORS: 2
3
4 4
3
B = CONNECTORS ON BOTH ENDS
SEE TABLE I 56625-1.5-07 CABLE, ARMORED, 7/C X 1.5 mm 4
4 4
5 5 P = CONNECTOR ON PIN END ONLY SEE TABLE I 114725 LABEL 3
5 5
6 6 S = CONNECTOR ON SOCKET END ONLY
6 6
7 7
SEE TABLE I 126907-133B-S354S-N CONNECTOR, 7 SOCKETS W/ STRAIGHT PLUG (ATEX) 2
7 7 LENGTH (IN FEET)
(SEE TABLE I) SEE TABLE I 114729-PL-354-14 CONNECTOR, 7 PINS W/ INLINE RECEPTACLE (NON-ATEX) 1
PIN END SOCKET END BASIC PART NUMBER ITEM

QTY REQD NO.
A (NON-ATEX) (ATEX) PRODUCT: IDS-350P

A
TOLERANCES ARE:
WIRING DIAGRAM END ITEM: X.X ±.1 ANGLES ± 1/2 DEG REFERRED TO HEREINAFTER AS "NOV"). IT IS LOANED FOR
NEXT ASSY: 30177280
TITLE:
CABLE ASSY, 7/C x 1.5mm

SIMILAR TO:
CONNECTORIZED, (EEx / NON EEx)

FINISH DRAWN R. HOLLADAY R. HOLLADAY IS THE COPYRIGHTED PROPERTY OF NOV.
D
CHECKED M. MASLYAR M. MASLYAR
1/2 1 OF 1
APPVD M. MASLYAR M. MASLYAR MECHANICAL ENGINEERING DWG NO. REV:
250 1000
DATE
02/22/10 9/7/06 30181755 A
DRAWN IN ACAD
8 7 6 5 4 3 2 1 RS-MECH_D-TPL-001
Printed On: 06\25\2012 07:36
Printed On: 06\25\2012 08:40
FINAL DOCUMENTATION
Section 5.6
Control System
www.nov.com
V131
V130
V127
V126
V123
V122
V121
V120
X1
Printed On: 06\25\2012 09:54
FINAL DOCUMENTATION
Chapter 6.0
Control Spares, ABB VFD House
www.nov.com
Control Spares List
TDS-9/11SA
ABB VFD House w/ SBC
NOTES:
1. M804000494-1 RECOMMENDED COMMISIONING SPARES
2. M804000494-2 RECOMMENDED OPERATIONAL SPARES
3. M804000494-3 RECOMMENDED INSURANCE SPARES
4. M804000494-4 SPECIAL ORDER SPARES
This document contains proprietary and confidential information National Oilwell Varco
which belongs to National-Oilwell Varco, L.P., its affiliates or
subsidiaries (all collectively referred to hereinafter as "NOV"). It is Rig Solutions
loaned for limited purposes only and remains the property of NOV. 743 N. Eckhoff St.
Reproduction, in whole or in part, or use of this design or Orange, Ca. 92868
distribution of this information to others is not permitted without the
express written consent of NOV. This document is to be returned to (714) 978-1900
NOV upon request and in any event upon completion of the use for
which it was loaned. This document and the information contained
and represented herein is the copyrighted property of NOV.
 National Oilwell Varco
DOCUMENT NUMBER REV
M804000494-SPL-001 03
www.nov.com
Document number M804000494-SPL-001
Revision 03
Page 2
REVISION HISTORY
03 05/21/2010 UPDATED SPARES LIST M. MASLYAR S. CURLEE M. MASLYAR

02 05/07/2010 UPDATED SPARES LIST M. EL ASSI S. CURLEE S. CURLEE
01 03/04/2010 INITIAL RELEASE M. EL ASSI M. MASLYAR M. MASLYAR
Rev Date Reason for issue Prepared Checked Approved
CHANGE DESCRIPTION

01 First issue
02 Added -4 configuration
03 Revised P/N’s for obsolete items
Inverter Module Is: P250000-9679-46 Was: 0000-9673-96
Isolation Module Is: 0001-0701-30 Was: 0000-9603-95
Incremental Encoder Is: 0001-0870-32 Was: 0000-0870-32
Lamp Module, Red Is: 0000-9652-70 Was: 0000-9652-70-27
Lamp, LED, Red Is: P250002-0011-91 Was: P250000-0011-91
www.nov.com
Revision 03
Page 3
-1 -2 -3 -4
Recom. Recom. Recom. Special
Comm. Opr. Ins. Order Where Description
Part No. Description Spare Spare Spare Spare Used Where Used
0000-6976-70 XFMR- 2KVA,

600:120/208/240 CVT, 1PH, - - 1 - M804000456 ABB VFD House
ISOLATION & VOLTS REG
0000-9671-60 XFMR- 30KVA, 600/690
PRIMARY, 208Y/120
- - 1 - M804000456 ABB VFD House
SECONDARY, 50/60 HZ,
ALUM
0000-9642-05 PC BOARD-ENCODER
CARD FOR USE 1 1 - - M804000456 ABB VFD House
WITH ABB ACS800 DRIVE
0000-9649-07 PCB-DISTRIBUTION CARD
FOR PARALLEL
OPERATION OF ABB 800
ACS INVERTER SECTIONS,
PPCS BRANCHING AND
DATALOGGER UNIT
(64669982) CONSISTING OF:
1 - EN/MD MOD CDR 1 1 - - M804000456 ABB VFD House
MULTIDRIVE (6821268)
1 - ELECTRICAL PLANNING
MANUAL (64783742)
1 - STANDARD SOFTWARE
(64527592)
1 - FIRMWARE MANUAL
(99999998) STD APPC 7.X
0000-9649-14 PC BOARD-MOTOR
CONTROL UNIT KIT FOR
ABB ACS80 INVERTERS
CONSISTING OF (64672606) 1 1 - - M804000456 ABB VFD House
1 -(X35/X34 CABLE)
1 -(64565168_)SOFTWARE
1 -(10024943/KV)
0000-9651-08 PC BOARD-PROFIBUS
MODULE,ABB PROFIBUS
ADAPTER MODULE
1 1 - 1 M804000456 ABB VFD House
OPTION/SP KIT (64606859)
FOR USE WITH ABB 800ACS
CONTROL MODULES
0000-9652-42 MODULE-FIBER,DDCS
1 1 - 1 M804000456 ABB VFD House
ACS800
0000-9653-29 KIT-CONTROL PANEL
MOUNTING PLATFORM KIT 1 1 - - M804000456 ABB VFD House
(WITH KED PAD)
www.nov.com
Revision 03
Page 4
P250000-9679-46 INVERTER-
450KW,690V,486A,AIRCL
ACS 800 AIR COOLED
INVERTER, 486A, 450KW
CONTINUOUS RATING,
DV/DT OUTPUT FILTERS,
SPEED CONTROLLED
COOLING FANS, UNIT CAN
BE PARALLELED X 12,
330LBS PER MODULE
CONSISTING OF:
- 1 1 - M804000456 ABB VFD House
1 - CURRENT FILTER
(64315811)
1 - FAST POWER CONNECT
(64698401)
1 - SOCKET BLOCK PIN
(64674081)
1 - BRACKET (64789104)
1 - (ACS800-104-580-7+E2)
INVERTER (64794086)
ABB# ACS800-104-0580-
7+E205+C126+Q950+V991
40943311-051 WAGO, 2 PT RELAY
2 2 - - M804000456 ABB VFD House
OUTPUT MODULE
40943311-050 WAGO, 8 PT INPUT
1 1 - - M804000456 ABB VFD House
MODULE, 24VDC
40943311-034 WAGO, 4 PT INPUT
1 1 - - M804000456 ABB VFD House
MODULE, 24VDC
40943311-030 WAGO, 2 PT ANALOG
OUTPUT MODULE, 4-20Ma 1 1 - - M804000456 ABB VFD House
40943311-059 WAGO, ENCODER MODULE 1 1 - - M804000456 ABB VFD House

40943311-052 WAGO, PWR SUPPLY, 0-
1 1 - -
23V, AC/DC
40943311-061 WAGO, PROFIBUS DP
1 1 - - M804000456 ABB VFD House
INTERFACE MODULE
P250000-9688-27 BECKHOFF, INDUSTRIAL
1 1 - - M804000456 ABB VFD House
SBC CONTROLLER
P800000-9686-67 APPLICOM, CARD-DP1 1 1 - - M804000456 ABB VFD House
P800000-9686-71 PWR SUPPLY FOR SBC 1 1 - - M804000456 ABB VFD House
0302-0007-02 CB-1250AF/AT, 690VAC,
85KIC, LSI TRIP UNIT,
FIXED, HORIZONTAL
CONNECTIONS, 5NO/5NC - - 1 - M804000456 ABB VFD House
CONTACTS, PADLOCK
PROVISION (OPEN), IEC
RATED
0305-0004-00 CB-UVR(YU), 24VDC, FOR
- 1 - - M804000456 ABB VFD House
E1 THRU E6 FRAME SIZE
0000-9641-88 DIODE-ASSY, DUAL, 1800V,
- 1 - - M804000456 ABB VFD House
AIR COOLED
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Revision 03
Page 5
0000-9653-26 CONTACTOR- 35A,

1000VDC, 3POLE IN
- 1 - - M804000456 ABB VFD House
SERIES, 1NO/1NC, 24VDC
COIL, 50/60HZ
0000-9660-27 CONT-AUX CONTACT, 2NO,
2NC,TOP MOUNT FOR ABB - 1 - - M804000456 ABB VFD House
CONTRACTORS
0000-9646-98 CHOPPER-BRAKING,
- 1 1 - M804000456 ABB VFD House
80AMPS
P250000-9679-45 FAN-ABB CHOPPER, 1PH,
- 1 - - M804000456 ABB VFD House
115V, 50/60 HZ
0000-9642-66 FILTER-LINE (TVSS), 20A,
- - 1 - M804000456 ABB VFD House
120VAC, DIN RAIL MTG
0000-9645-86 PWR SPLY- 24V/10A, INPUT
VOLTAGE 115/230VAC,
OUTPUT VOLTAGE 24V,
- 1 - 1 M804000456 ABB VFD House
4.88"H X 3.26"W X 4.55"D,
CLASS1 DIV2, 24-28V
ADJUSTABLE
1003-0095-00 XFMR- 50VA, 600: 26.5, CPT
1PH, 50HZ,
- - 1 - M804000456 ABB VFD House
ENCAPSULATED, CENTER
TAPPED
0000-6904-32 FUSE- 60A, 1000VAC, KIC,
CLASS, STUD TYPE, W/ 3 3 - 10 M804000456 ABB VFD House
INDICATOR
FUSE BLOCK, 2 PIECE
0000-9607-67 MODULAR STUD TYPE, 3 3 - - M804000456 ABB VFD House
0.25" STUD DIA., 1.75 IN.
MOUNTING HEIGHT
0001-0385-47 BUS-FUSE MTG,
3 3 - - M804000456 ABB VFD House
BUSSMANN AB03T
0000-6901-34 FUSE- 6A, 600V AC, 200KIC 3 3 - 20 M804000456 ABB VFD House
0000-9641-46 FUSE- 2A, 250VAC,
2 2 - 20 M804000456 ABB VFD House
FASTBLOW, 5 X 20MM
0301-0010-00 FUSE- 2A, 500VAC, 10KIC,
2 2 - 20 M804000456 ABB VFD House
CLASS M
0301-0019-00 FUSE- 30A, 600VAC, 100KIC 3 3 - 20 M804000456 ABB VFD House
0301-0009-00 FUSE- 0.6A, 500VAC, 10KIC, 3 3 - 20 M804000456 ABB VFD House
CLASS M
0000-6881-06 MOV- 750VRMS, 2600J,
70KA, 1880V@ 200A, - 1 - - M804000456 ABB VFD House
2KV@600A
0301-0043-00 FUSE- 15A, 500VAC, 10KIC, 3 3 - 20 M804000456 ABB VFD House
CLASS M
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Revision 03
Page 6
SW-MICRO,TWO ISOLATED
FORM C CONTACTS,
INSULATION RATING
F/SW 1250VAC OR DC,
NON INDUCTIVE -
0000-6979-92 30 VOLT 3A
- 2 - 1 M804000456 ABB VFD House
110 VOLT 3A
250 VOLT 3A
INDUCTIVE CIRCUIT -
30 VOLT 2A
110 VOLT 1A
250 VOLT 1A
0000-9666-71 RLY-LOGIC SOCKET - 1 - - M804000456 ABB VFD House
0000-9666-72 RLY- 24VDC,8A,PLUG 1 1 - 1 M804000456 ABB VFD House
RLY-PROTECTION DIODE
0000-9666-73 - 1 - 1 M804000456 ABB VFD House
6-230VDC
BDGE-RECTIFIER, 110A,
0000-9605-33 - - 1 - M804000456 ABB VFD House
1800V, 3PH
0000-9666-35 RECT-3 PHASE BRIDGE,
- 1 - - M804000456 ABB VFD House
25A, 1800V
SUPPRESSOR-SURGE,
6-240VDC DIODE, PROTECT
0000-6935-09
CONTROL CIRCUIT FROM - 1 - 1 M804000456 ABB VFD House
VOLTAGE TRANSIENT,
PLUG-IN
0000-6941-52 RLY- 24VDC, 4A0B0C, 10A,
1 1 - 1 M804000456 ABB VFD House
IEC DEVICE
0509-3000-00 PCA-VOLTAGE FEEDBACK - 1 - - M804000456 ABB VFD House
0000-6896-31 FUSE- 10A, 600VAC, 200KIC,
2 2 - - M804000456 ABB VFD House
CLASS M
0000-9668-89 CB- 16AT, 1P, 230V,
- 1 - - M804000456 ABB VFD House
MISSLINE
FUSE- 60A, 600VAC,
0000-6970-86
200KIC,CLASS J, TIME 3 3 - 10 M804000456 ABB VFD House
DELAY, DUAL ELEMENT
0000-6968-98 FUSE- 100A, 600VAC,
200KIC, CLASS J, TIME
3 3 - - M804000456 ABB VFD House
DELAY, SEC VOLTAGE
500VDC
MS-COMBINATION, IEC,
10HP@575V, 9-12.5 FLA,
0000-9657-48 INCLUDES MANUAL
- 1 - - M804000456 ABB VFD House
MOTOR PROTECTOR WITH
OVERLOAD PROTECTION,
STARTER,120VAC COIL
0000-9669-30 MS-COMBINATION, IEC,
- 1 - - M804000456 ABB VFD House
5HP@575V
1307-2018-03 CONT-BLK, 2A2B0C, IEC,
- 1 - - M804000456 ABB VFD House
TOP MOUNT
0000-6981-43 FUSE, 15A, 600VAC, 200KIC - - - 20 M804000456 ABB VFD House
0000-9642-27 FUSE-1000A, 1100V - - - 4 M804000456 ABB VFD House
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Revision 03
Page 7
FUSE-630A,1250V,100KIC
0000-9651-24 HIGH SPEED - - - 2 M804000456 ABB VFD House
SEMICONDUCTOR
0405-0016-00 LAMP BULB, 18V - - - 10 M804000456 ABB VFD House
PL-120V AC, 18MM W/O
0000-9611-72 - - - 1 M804000456 ABB VFD House
LENS, XFMR
PL-24VAC/DC,18MM,NO
0000-9650-24 - - - 1 M804000456 ABB VFD House
LENS
BATTERY,CPU
0000-6960-84 - - - 1 M804000456 ABB VFD House
BACKUP,FUW S7-300
FUSE,60A,600V,3P FUW J
0000-6939-93 - - - 1 M804000456 ABB VFD House
TYPE FUSES
SW-SEL,2 POS,LEVER,OT
0000-6854-44 - - - 1 M804000456 ABB VFD House
OPR
0403-0008-00 SW-TEMP, 165 DEG - - - 1 M804000456 ABB VFD House
WAGO PROFIBUS
40943311-061 1 1 - 1 M804000483 VDC
INTERFACE MODULE
WAGO 4 POINT DIGITAL
0000-9671-93 1 1 - 1 M804000483 VDC
INPUT MODULE
WAGO 4 POINT DIGITAL
0000-9671-92 1 1 - 1 M804000483 VDC
OUTPUT MODULE
WAGO 2 POINT ANALOG
40943311-030 1 1 - 1 M804000483 VDC
OUTPUT MODULE
WAGO ENCODER MODULE,
40943311-059 1 1 - 1 M804000483 VDC
16 BIT
WAGO FIELD SIDE POWER
40943311-105 1 1 - 1 M804000483 VDC
SUPPLY MODULE
WAGO POWER SUPPLY
40943311-080 1 1 - 1 M804000483 VDC
MODULE
938203-026 FUSE, 2A 1 1 - 1 M804000483 VDC
30178673-2 HEATER, ELECTRIC, 140W 1 1 - 1 M804000483 VDC
0000-6939-09 FUSE, 6A 1 1 - 1 M804000483 VDC
30155573-12 METER, 0-250 RPM 1 1 - 1 M804000483 VDC
30155573-27 METER, 0-80K FT-LBS 1 1 - 1 M804000483 VDC
PUSHBUTTON ACTUATOR,
P250000-9900-28 1 1 - 1 M804000483 VDC
ILLUMINATED, GREEN
PUSHBUTTON,
P250000-9900-29 1 1 - 1 M804000483 VDC
ILLUMINATED, GREEN
PUSHBUTTON ACTUATOR,
P250000-9900-25 1 1 - 1 M804000483 VDC
ILLUMINATED, RED
PUSHBUTTON,
P250000-9900-26 1 1 - 1 M804000483 VDC
ILLUMINATED, RED
P250000-9699-08 LAMP, LED, YELLOW 1 1 - 1 M804000483 VDC
P250000-9900-27 LAMP MODULE, YELLOW 1 1 - 1 M804000483 VDC
P250002-0011-91 LAMP, LED, RED 1 1 - 1 M804000483 VDC
0000-9652-70 LAMP MODULE, RED 1 1 - 1 M804000483 VDC
932504-108 PUSHBUTTON, ACTUATOR 1 1 - 1 M804000483 VDC
0000-9652-63 SWITCH, 3 POSITION 1 1 - 1 M804000483 VDC
0000-9652-59 SWITCH MODULE 1 1 - 1 M804000483 VDC
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Revision 03
Page 8
0000-9652-60 ESTOP, PUSHBUTTON 1 1 - 1 M804000483 VDC

0001-0870-32 ENCODER, INCREMENTAL 1 1 - 1 M804000483 VDC
0000-9604-54 HORN, I.S. 1 1 - 1 M804000483 VDC
0000-6991-41 BARRIER, ISOLATION 1 1 - 1 M804000483 VDC
0001-0701-30 BARRIER, ISOLATION 1 1 - 1 M804000483 VDC
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FINAL DOCUMENTATION
Chapter 7.0
Mechanical Spares LFT,
TDS-11SA, EEX
www.nov.com
STANDARD TDS-11SA
(EEx Electric & PH-75)
MECHANICAL
SPARES LIST
NOTES:
1. M614003549-1 Recommended Commissioning Spares
2. M614003549-2 Recommended Operational Spares
3. M614003549-3 Recommended Insurance Spares
4. Order IBOP and IBOP Repair Kits separately, in addition to this kit.
a. For Standard Trim Valves:
114859 Qty 1 Upper IBOP Repair Kit – Complete
114859-1 Qty 2 Upper IBOP Repair Kit – Soft Seals
99498-2 Qty 1 Lower IBOP Repair Kit – Complete
99498-1 Qty 2 Lower IBOP Repair Kit – Soft Seals
110103-500 Qty 1 Upper IBOP Assembly, Std Trim
114706-500 Qty 1 Lower IBOP Assembly, Std Trim
b. For H2S Trim Valves:
114860-2 Qty 1 Upper IBOP Repair Kit – Complete
114860-1 Qty 2 Upper IBOP Repair Kit – Soft Seals
99503-2 Qty 1 Lower IBOP Repair Kit – Complete
99503-1 Qty 2 Lower IBOP Repair Kit – Soft Seals
110103-502 Qty 1 Upper IBOP Assembly, H2S Trim
114706-502 Qty 1 Lower IBOP Assembly, H2S Trim
THIS DOCUMENT CONTAINS PROPRIETARY AND CONFIDENTIAL INFORMATION WHICH BELONGS

TO NATIONAL-OILWELL, L.P. IT IS LOANED FOR LIMITED PURPOSES ONLY AND REMAINS THE
PROPERTY OF NATIONAL-OILWELL, L.P. REPRODUCTION, IN WHOLE OR IN PART OR USE OF
THIS DESIGN OR DISTRIBUTION OF THIS INFORMATION TO OTHERS IS NOT PERMITTED WITHOUT
THE EXPRESS WRITTEN CONSENT OF NATIONAL-OILWELL, L.P. THIS DOCUMENT IS TO BE
RETURNED TO NATIONAL-OILWELL, L.P. UPON REQUEST AND IN ANY EVENT UPON COMPLETION
OF THE USE FOR WHICH IT WAS LOANED. THIS DOCUMENT AND THE INFORMATION CONTAINED
AND REPRESENTED IS THE COPYRIGHTED PROPERTY OF NATIONAL-OILWELL, L.P.
TITLE
CURRENT INITIAL SPARES LIST, MECHANICAL
DRAWN
H. LIM STANDARD TDS-11SA, EEX
CHECKED
D. Stepehens
SIZE DWG NO REV
APPVD
H. LIM A M614003549-SPL-001 01
DATE
9/10/09 SCALE NONE WT LBS SHEET 1 OF 5
DCF0045 (REV B)
-1 -2 -3
Recomm. Recomm. Recomm.
Commission Operational Insurance Where Description
Part No. Description Spare Spare Spare Used Where Used
Motor Housing
Assy
30173521 Bearing Isolator - - 1 Motor Housing Assy
30154362 Shield, Bearing - 1 - Motor Housing Assy
98290 Liner, Upper Stem, Std. Bore - 1 - Motor Housing Assy
98291 Seal, Polypak - 1 - Motor Housing Assy
91250-1 Seal, Oil - 1 - Motor Housing Assy
77039 Seal - 2 - Motor Housing Assy
141304 Valve, Relief - 1 - Motor Housing Assy
30123290 Assembly, Wash Pipe - 1 - Motor Housing Assy
Z6001 Lockwire, .051 - 168 ft - Motor Housing Assy
53003-16 Plug, Magnetic - 1 - Motor Housing Assy
53219-2 Fitting, Grease - 1 - Motor Housing Assy
51300-387-F O-Ring, Motor/Cover - 2 - Motor Housing Assy
51300-277-B O-Ring, Cover/Bearing Ret. - 1 - Motor Housing Assy
51300-016-B O-Ring, Oil Lube Tube - 2 - Motor Housing Assy
51300-425-B Seal, Hammer Lug Union - 1 - Motor Housing Assy
109523 Adapter, S-Pipe - - 1 Motor Housing Assy
108216-12 Ball Valve - - 1 Motor Housing Assy
118217-40L60 Drilling Motor Assy, LH - - 1 Motor Housing Assy
118217-40R60 Drilling Motor Assy, RH - - 1 Motor Housing Assy
109555 Rotor, Brake - - 2 Motor Housing Assy
109528 Brake, Caliper Disc - - 4 Motor Housing Assy
30122104 Heat Exchanger, Oil - - 1 Motor Housing Assy
117603-1 Pump Assembly, Lube - - 1 Motor Housing Assy
121272-2 Tube Assembly, Breather - - 1 Motor Housing Assy
121272-1 Tube Assembly, Breather - - 1 Motor Housing Assy
120117-3 Belt, Timing - 1 - Motor Housing Assy
30122725-HE Encoder, Digital - - 1 Motor Housing Assy
120118 Pulley, Timing - - 1 Motor Housing Assy
122948 Bearing, Ball - 1 - Motor Housing Assy
30151875-504 Shotpin Assembly - - 1 Motor Housing Assy
Reservoir Assy
30113165 Valve, Relief-Popoff - 1 - 110068 Reservoir, Assembly
108119-16B Sight Gage - 1 - 110068 Reservoir, Assembly
71613 Reservoir Breather - 1 - 110068 Reservoir, Assembly
51300-038-B O-Ring - 1 - 110068 Reservoir, Assembly
110132 Gasket - 1 - 110068 Reservoir, Assembly
110191-501 Bladder, Reservoir (5 gallons) - 1 - 110068 Reservoir, Assembly
Wash Pipe
Assembly
30123289 Pipe, Wash, 3 Inch Bore - 1 - 30123290 Wash Pipe Assembly
123292-2 Packing Seal Kit, Standard - 5 - 30123290 Wash Pipe Assembly
30123562 Ring, Snap - 1 - 30123290 Wash Pipe Assembly
53303-14 Wrench, Washpipe - 1 - 30123290 Wash Pipe Assembly
SIZE DWG NO REV
A M614003549-SPL-001 01
SCALE NONE WT LBS SHEET 2 OF 5
DCF0045 (REV B)
-1 -2 -3
Pipe Handler
Package
125098 Tube Assembly - - 1 30157366 Pipe Handler Package
98898 Crank Assembly - 2 - 30157366 Pipe Handler Package
110042 Shell, Actuator, IBOP - - 1 30157366 Pipe Handler Package
107052 Lock Tab - 8 - 30157366 Pipe Handler Package
30119592 Cylinder, Hydraulic Assembly - - 2 30157366 Pipe Handler Package
30122367 U-Bolt, 500 Ton - - 4 30157366 Pipe Handler Package
119139 U-Bolt, 350 Ton - - 4 30157366 Pipe Handler Package
See Sheet 1 Upper IBOP Repair Kit – Complete - 1 - 30157366 Pipe Handler Package
See Sheet 1 Upper IBOP Repair Kit – Soft Seals - 2 - 30157366 Pipe Handler Package
See Sheet 1 Lower IBOP Repair Kit – Complete - 1 - 30157366 Pipe Handler Package
See Sheet 1 Lower IBOP Repair Kit – Soft Seals - 2 - 30157366 Pipe Handler Package
See Sheet 1 Upper IBOP Valve - - 1 30157366 Pipe Handler Package
See Sheet 1 Lower IBOP Valve - - 1 30157366 Pipe Handler Package
Brake, Caliper
Disc
109528-1 Friction Pads (2 required) 4 8 - 109528 Brake, Caliper Disc
109528-2 Seal Kit - 1 - 109528 Brake, Caliper Disc
109528-3 Heavy Duty Spring (4 required) - 8 - 109528 Brake, Caliper Disc
109528-4 Screw, Return Spring (4 required) - 8 - 109528 Brake, Caliper Disc
109528-5 Pin, Guide (4 required) - 8 - 109528 Brake, Caliper Disc
109528-6 Bleed Screw Assembly - 1 - 109528 Brake, Caliper Disc
Rotating Link
500 Ton
51300-273-B O-Ring - 1 - 30173277 Rotating Link Adapter
51300-381-B O-Ring - 1 - 30173277 Rotating Link Adapter
30119319 Glyd Ring Rotary, 11.000 Rod - 1 - 30173277 Rotating Link Adapter
30119357 Ring, Thrust - 1 - 30173277 Rotating Link Adapter
119547 Seal, Wiper - 1 - 30173277 Rotating Link Adapter
30117775 Retainer Ring - 1 - 30173277 Rotating Link Adapter
119358 Bushing, Turcite - 2 - 30173277 Rotating Link Adapter
115176 Bushing - 2 - 30173277 Rotating Link Adapter
112754-130 Bearing, Flanged - 2 - 30173277 Rotating Link Adapter
53250-5 Relief Valve - 2 - 30173277 Rotating Link Adapter
77039 Seal - 2 - 30173277 Rotating Link Adapter
PH-75 Torque
Arrestor Assy
118844-16-08 Bearing, Self Lubrication - 2 - 30157288 Torque Arrestor Assy
71847 Roller - 2 - 30157288 Torque Arrestor Assy
125594 Cylinder Assy, IBOP Actuator - - 1 30157288 Torque Arrestor Assy
SIZE DWG NO REV
A M614003549-SPL-001 01
DCF0045 (REV B)
-1 -2 -3
PH-75 Clamp
Cylinder
72219 Seal, Piston - 2 - 30157287 Clamp Cylinder
72220 Seal, Rod - 2 - 30157287 Clamp Cylinder
72221 Ring, Wiper - 2 - 30157287 Clamp Cylinder
30158690 Ring, Stabilizer - 2 - 30157287 Clamp Cylinder
Hydraulic
Package
30173216-1 Filter Element, Hydraulic 2 2 - Hydraulic Package
30111013 Filter, 60 micron 1 1 - Hydraulic Package
110562-1 Counterbalance Accumulator - - 1 Hydraulic Package
110563-1 System Accumulator - - 1 Hydraulic Package
110564-1 Accumulator - - 1 Hydraulic Package
Pump Motor
Assembly
30179191 Motor Assy - - 1 Pump Motor Assy
30179068 Motor, 7.5KW, 600VAC, 60Hz - - 1 Pump Motor Assy
109542 Pump, Hyd. Piston, Press Comp. - - 1 Pump Motor Assy
107783-5C11R Pump, Hyd. Vane, 1.0 Cu in./min - - 1 Pump Motor Assy
110023-1 Flex Coupling - 1 - Pump Motor Assy
Electric
Package
30179069 Motor Blower, 3KW - - 2 Electrical Package
83095-1 Pressure Switch, IBOP - - 1 Electrical Package
87541 Pressure Switch - - 1 Electrical Package
76841 Pressure Switch, Air - - 2 Electrical Package
53219-3 Fitting, Grease - - 1 Electrical Package
Manifold
112554-D2 Solenoid Valve 1 2 - 114175 Manifold Assy
112554-J2 Solenoid Valve 1 2 - 114175 Manifold Assy
94520-1AN Valve, Relief - 2 - 114175 Manifold Assy
114375-1 Hydraulic Motor - - 1 114175 Manifold Assy
94522-1EN Valve, Relief - 1 - 114175 Manifold Assy
111664-1EN Relief Valve, Low Flow - 1 - 114175 Manifold Assy
109858-1AN Reducing/Relieving Valve - 3 - 114175 Manifold Assy
93667-M13 Cavity plug, T-13A Short - 1 - 114175 Manifold Assy
P614000063-1AN Relief Valve, Ventable - 1 - 114175 Manifold Assy
107029-175N Pilot – To – Open Check Valve - 4 - 114175 Manifold Assy
107028-1ANB Differential Unloading Valve - 1 - 114175 Manifold Assy
99353-1AN Reducing / Relieving Valve - 1 - 114175 Manifold Assy
98402-800D Flow Control Valve - 1 - 114175 Manifold Assy
94537-130N Pilot – To – Close Check Valve - 1 - 114175 Manifold Assy
94536-230N Check Valve - 2 - 114175 Manifold Assy
94536-14N Check Valve - 3 - 114175 Manifold Assy
94534-1CXN Logic Cartridge - 3 - 114175 Manifold Assy
94520-1NN Relief Valve - 1 - 114175 Manifold Assy
93667-M11 Cavity Plug, T-11A Short - 1 - 114175 Manifold Assy
30171921 Manual Valve, 3-pos. - 1 - 114175 Manifold Assy
SIZE DWG NO REV
A M614003549-SPL-001 01
DCF0045 (REV B)
-1 -2 -3
Carriage
Assembly
109944 Bushing, Flange - 8 - 124539 Carriage Assy, Right
124538 Carriage Assy, Left
30155438 Cam Followers 6” - - 2 124539 Carriage Assy, Right
30158767-04 Cam Followers 4” - - 16 124539 Carriage Assy, Right
55324-C Nut - - 16 124539 Carriage Assy, Right
51132-C Washers - - 2 124539 Carriage Assy, Right
51024-C Washers - - 16 124539 Carriage Assy, Right
80569 Nut - - 2 124539 Carriage Assy, Right
112875 Bogey Pin - - 2 124539 Carriage Assy, Right
109944 Bushing - 2 - 124539 Carriage Assy, Right
30152845 Retaining Pins - 4 - 124539 Carriage Assy, Right
30157306 Lynch Pins - 4 - 124539 Carriage Assy, Right
Counterbalance
Kit
108894-P40 Seal, Piston - 1 - 110687 Cylinder
94522-21N Relief Valve Cartridge - 1 - 110703 Cylinder Assy
108894-B40 Body Seal - 1 - 110687 Cylinder
108894-G20 Rod & Gland Seal - 1 - 110687 Cylinder
108894-Y4 Rod & Gland Wrench - 1 - 110687 Cylinder
108894-Z677 Spanner Wrench - 1 - 110687 Cylinder
94536-175N Check Valve - 2 - 111712 Pre-Fill Valve Assy
92654 Check Valve - 1 - 111712 Pre-Fill Valve Assy
112825 Cartridge - 1 - 111712 Pre-Fill Valve Assy
110704 Cylinder Assy, Counterbalance - - 1 112190 Counterbalance Kit
110703 Cylinder Assy, Counterbalance - - 1 112190 Counterbalance Kit
Guide Beam Kit

117496-1 Lynch Pin 2 30154688 Guide Beam Kit
117783 Retainer Pin 2 30154688 Guide Beam Kit
117782 Joint Pin 2 30154688 Guide Beam Kit
SIZE DWG NO REV
A M614003549-SPL-001 01
DCF0045 (REV B)
FINAL DOCUMENTATION
Chapter 8.0
Electrical Trouble Shooting Guide
(TDS-9SA / TDS-11SA)
www.nov.com
FINAL DOCUMENTATION
Chapter 9.0
TDS-11SA, Pocket Guide
www.nov.com
FINAL DOCUMENTATION
Chapter 10.0
TDS-11SA VFD Operation Manual
www.nov.com
Operation Manual
TDS11 VFD Operation Manual
RIG/PLANT REFERENCE REFERENCE DESCRIPTION
ADDITIONAL CODE SDRL CODE TOTAL PGS

112 This document contains proprietary and confidential information National Oilwell Varco
which belongs to National Oilwell Varco; it is loaned for limited Rig Solution Group
REMARKS purposes only and remains the property of National Oilwell.
Reproduction, in whole or in part; or use of this design or 1530 W. Sam Houston Pky N
MAIN TAG NUMBER DISCIPLINE distribution of this information to others is not permitted without the Houston, Texas 77043 (USA)
express written consent of National Oilwell Varco. This document is Phone + 713-935-8000
to be returned to National Oilwell Varco upon request and in any
CLIENT PO NUMBER event upon completion of the use for which it was loaned. Fax + 713-346-7426
CLIENT DOCUMENT NUMBER DOCUMENT NUMBER REV
D25TDS11-MAN-001 01
www.nov.com
Document number D25TDS11-MAN-001
Revision 01
Page 2
REVISION HISTORY
01 15.08.2006 INFORMATION CRR

CHANGE DESCRIPTION

01 First Issue
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Revision 01
Page 3
Technical Manual
Air-Cooled AC Drives
Model 800AC
www.nov.com
Revision 01
Page 4
TABLE OF ONTENTS
1 SAFETY INSTRUCTIONS ................................................................................................ 6

1.1 General................................................................................................................... 6
1.2 Safety Symbols....................................................................................................... 6
1.3 Basic Safety Precautions........................................................................................ 7
2 INTRODUCTION............................................................................................................... 9
2.1 Abbreviations and Definition ................................................................................... 9
3 SYSTEM DESCRIPTION ................................................................................................ 10
3.1 Input/Output Reactor ............................................................................................ 11
3.2 Input Rectifier ....................................................................................................... 11
3.3 DC Bus ................................................................................................................. 16
3.4 Inverter ................................................................................................................. 16
3.5 Braking Chopper and Resistor Bank..................................................................... 40
3.6 Assignment Contactors......................................................................................... 43
3.7 AC Induction Motors – Basic Principle of Operation ............................................. 44
3.8 PLC and interface for the Drilling Control System (DCS)...................................... 47
3.9 Technical Data...................................................................................................... 50
3.9.1 Weights and Dimensions........................................................................... 50
3.9.2 Performance Data ..................................................................................... 53
4 OPERATING INSTRUCTIONS ....................................................................................... 54
4.1 CONTROL PANEL ............................................................................................... 54
4.1.1 Panel operation mode keys and displays .................................................. 55
4.1.2 Status Row................................................................................................ 55
4.1.3 Drive control from panel ............................................................................ 56
4.1.4 Actual signal display mode........................................................................ 57
4.1.5 Parameter mode ....................................................................................... 61
4.1.6 Function mode .......................................................................................... 62
4.1.7 Drive selection mode................................................................................. 66
4.1.8 Reading and entering of Boolean values on the display ........................... 66
4.2 INITIAL MOTOR OPERATION SETUP ................................................................ 68
4.2.1 Visual Inspection ....................................................................................... 68
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Revision 01
Page 5
4.2.2 Configure Drive ......................................................................................... 68

4.2.3 General Set-up Procedures....................................................................... 71
5 INSTALLATION .............................................................................................................. 95
5.1 Mechanical Installation ......................................................................................... 95
5.2 Electrical Installation ............................................................................................. 95
6 TROUBLESHOOTING.................................................................................................... 99
6.1 Warning and fault indications................................................................................ 99
6.1.1 Programmable protection functions........................................................... 99
6.1.2 Preprogrammed faults............................................................................. 101
6.1.3 Warning messages generated by the drive ............................................. 102
6.1.4 Warning messages generated by the control panel ................................ 106
6.1.5 Fault messages generated by the drive .................................................. 107
7 MAINTENANCE............................................................................................................ 111
8 OPERATOR SKILLS AND TRAINING ......................................................................... 112
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1 SAFETY INSTRUCTIONS
Read the entire Safety Summary located in the ABB operation maintenance manuals prior to
performing any operations or maintenance to this equipment.
The following safety instructions must be followed when installing, operating and servicing the National
Oilwell air-cooled AC drives. If ignored, damage may occur to the operator and equipment. Read
these safety instructions before working on the system.
1.1 General
Safety is everyone’s business and must be of primary concern at all times during any
operations or maintenance. Knowing the guidelines covered in this manual will help to
provide for the safety of the individual, for the group and for the proper operation of the
equipment. Only qualified personnel who are well versed in safety procedures should
ever be allowed to operate and/or maintain this piece of equipment. If this guideline is
strictly followed, this will minimize problems. Safety summaries and safety
procedures can never replace good common sense. As detailed as some of these
documents may be, some situations will require good common sense. Recognize all
standard safety symbols. Understand their importance, read them carefully and make
sure you understand their meaning. If something is unclear, ask. Do not take chances
with your life and others.
1.2 Safety Symbols

There are three types of safety instructions used throughout this manual and on the
equipment: warnings, cautions and notes. Look for these standard safety terms and
conventions that point out items of importance to the safety of the individual as well as
others that may be in the area:
WARNING safety notes MUST be followed carefully.

Failure to do so may result in catastrophic equipment
failure resulting in SERIOUS INJURY or DEATH.
CAUTION safety notes are also very important and

should be followed carefully. Failure to do so may
*
Recommended safety conventions. American Petroleum Institute
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result in EQUIPMENT DAMAGE and/or PERSONAL

INJURY.
NOTE
NOTE is used to notify personnel of information that
is IMPORTANT but NOT HAZARD RELATED.
1.3 Basic Safety Precautions

As mentioned earlier, all personnel performing operations or maintenance tasks of any
kind should be trained in both general safety and hazard recognition around a drilling rig,
as well as specific instructions pertaining to the particular rig they are working. All
operators and maintenance personnel should be versed in the specifics regarding
performance characteristics and limitations of all rig equipment.
Any personnel who intend to operate the unit needs to be both qualified and trained on
the AC drive operating controls and have a thorough understanding of the limitations and
functions of this piece of rig equipment.
All personnel should be protected from exposed mechanical dangers such as guards
fabricated from expanded metal and other similar hazards. Safeguards such as keeping
hands, hair, clothing, jewelry, rags, tools, etc. away from all moving parts should be
familiar and a part of all activities.
Do not attempt equipment operation with inadequate visibility. Poor lighting can
aggravate this, as can bad weather conditions, or other reasons. If you cannot see what
you are doing, then do not do it!
Operating and maintenance personnel should wear suitable protective clothing in addition
to any other personal safety devices that conditions may dictate.
Equipment used in heavy lifting and moving of the unit and accessories during operations
must be sufficiently rated to handle the weights involved.
Promote good safety measures at all times around the equipment and throughout all
phases of operations. It is the equipment owners’ / operators’ responsibility to establish
good safety measures including personnel training and enforcement of safety practices.
The first person hurt by poor safety practices is most commonly the operator in the field.
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Operating instructions tend to be general in nature to

make them clear and easy to understand, giving
minimal details on individual component operation.
If the operator is not thoroughly familiar with all
control functions, equipment limits, and safety
features – DO NOT OPERATE THIS EQUIPMENT.
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2 INTRODUCTION
This manual is intended for personnel who plan the installation, install, commission, use and service of
the system. A fundamental knowledge of electricity, wiring, electrical components and electrical
schematic symbols is required.
This technical manual includes data and information concerning the National Oilwell air cooled series of
Variable Speed Drive Systems (VSDS) referred to as the model 800AC. National Oilwell VSDS are
built from adjustable speed frequency converters, inverters, or combinations of both. This manual is
written to include all of these devices and their respective system components. All National Oilwell AC
variable speed drive systems are similar, but there are many variations according to each customer’s
specific requirements. Therefore, it is recommended that the user review the reference document list in
conjunction with this manual so that a thorough understanding of your specific system is ensured.
The basic function of a model 800AC system is to convert a fixed frequency 3 phase AC voltage into a variable frequency, variable voltage
source that is utilized to control motor speed and torque. To accomplish this, the model 800AC utilizes the following three steps:
• Standard three phase 50 or 60 Hz voltage is converted from AC to DC by 3-phase, full

wave rectifiers.
• The DC voltage is inverted to variable frequency / variable voltage by the inverters.
• The variable frequency / variable voltage output is applied to a motor to control speed and
braking.
The rectifier installed in the model 800AC system is composed of individual diode
semiconductors arranged in a full wave rectifier bridge. These diodes are mounted on a finned
heat sink which utilizes an electric powered fan motor for cooling. The inverters in the model
800AC systems utilize the ABB model ACS800 inverter modules. These modules are
combined to form the inverter or drive part of the system. More detailed information about the
individual components, software, or systems can be found later in this manual, in vendor
supporting documents or from the factory upon request.
2.1 Abbreviations and Definition
ASIC Application Specific Integrated Circuit

AHD Active Heave Draw works
CW Clockwise
CCW Counter Clock Wise
CCS Cyberbase Control System
DCS Driller’s Control System
DW Draw works
FDS Functional Design Specification
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GPM Gallons per minute

HMI Human-Machine Interface
HP Horsepower
Hz Hertz
IGBT Insulated Gate Bipolar Transistor
LED Light Emitting Diode
MMI Man-Machine Interface
MCC Motor Control Center
MP Mud Pump
M/U Make Up
P&ID Piping & Instrument Diagram
PHE Plate Heat Exchanger
PLC Programmable Logic Controller
PSI Pounds per Square Inch
PWM Pulse Width Modulation
RAM Random Access Memory
RISC Reduced Instruction Set Computer
SVM Space Vector Modulation
STEP7 Siemens PLC Programming Software
TD Top drive
VFD Variable Frequency Drive
FC Frequency Converter
VSDS Variable Speed Drive System
DB Dynamic Braking
VAR Volt-Amp Reactive
Converter An arrangement of solid-state devices that converts AC power to DC power
Operator The person assigned the responsibility of physically operating and
maintaining the equipment
3 SYSTEM DESCRIPTION
A typical Model 800AC drive system (VSDS) includes most or all of the following components:
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Input/Output Reactor
Input Rectifier
DC Bus
Inverter (VFD)
Braking Chopper and Resistor Bank
Assignment Contactors
AC Induction Motors – Basic principle of operation
PLC and Interface for the Drilling Control System (DCS)
If you are not sure about what equipment is installed in your particular system, review the
electrical drawings referenced in the job specific detail drawings and document list.
3.1 Input/Output Reactor

Input reactors are used in most systems to reduce the current ripple on the DC bus.
Reducing the current ripple extends the bus capacitor lifetime. Input reactors also
attenuate harmonics that are injected onto the AC bus by the rectifier bridge. Line
reactors are generally dimensioned to provide 3% impedance at full load current, but may
be less than this depending upon the source impedance of the system in which they are
installed. Most input reactors are iron core, 3 phase inductors, but some systems utilize 3
single-phase reactors in order to save space.
The primary function of the output reactor is to filter the output waveform of the inverter.
The output reactor reduces motor temperature and audible noise caused by high
frequency switching of the inverter. In addition, it reduces the risk of motor bearing
currents and provides short circuit protection for the motor.
3.2 Input Rectifier

The input rectifier transforms incoming AC voltage into DC voltage using a three-phase
full wave diode bridge arrangement. The most basic three-phase bridge arrangement
utilizes 6 diodes arranged as follows:
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Figure 3-1: Basic Three-Phase Rectifier Bridge
In the arrangement above, two of the diodes are “on” at a time. The diodes turn “on”
when they are forward biased. The AC input supply voltage determines which diodes are
forward biased at a given time. During operation, diodes A+ and C-, C- and B+, B+ and
A-, A- and C+, C+ and B-, B- and A+ are forward biased at the same times. The resulting
output of this operation is a DC output voltage with magnitude related to the AC input
voltage magnitude.
Various voltage sources are possible when using an AC drive. Transformers are used
primarily in offshore applications, and generally have multiple secondary windings. The
multiple winding supply transformer steps down incoming generator voltage to either 480
or 600/690 volts, depending on the system. Multi-winding transformers are used in high
power offshore systems. Multiple phase-shifted windings make it possible to build VSDS
systems that introduce very low harmonic distortion to the system supply bus. The most
common power source for a portable land based VSDS are synchronous generators.
The number and size of the generators varies from one system to another, however
nearly all are 3 phase, 600VAC generators.
Model 800 VSDS rectifiers typically fall within two basic classes, 6-pulse and 12-pulse.
Both the 6 and 12 pulse diode bridges are built using assemblies made from 6
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semiconductor diodes in a 3 phase, full wave bridge arrangement. A 6-pulse rectifier is

built from a single assembly, while a 12 pulse bridge is constructed using two 6-pulse
assemblies. In the 12-pulse arrangement, the two 6-pulse assemblies are supplied from
the secondary of a Δ||Δ/Y transformer whose secondary outputs are phase shifted by 30
electrical degrees. Occasionally, 24 pulse rectifiers systems are built using dual 12 pulse
rectifiers and 2 Δ||Δ/Y transformers, where each is phase shifted at the primaries +/- 7.5
electrical degrees. The 6-pulse rectifier is shown in figure 3-1 on the previous page.
Figure 3-2 below shows the 12-pulse rectifier with an inter-phase reactor for load sharing.
Optional
Interphase
Reactor
6 Pulse
Rectifier
6 pulse Transformer
To AC
Mains
12 Pulse DC
Output
6 Pulse
Rectifier
Figure 3-2: 12 Pulse Diode Rectifier with Inter-phase Reactor
The inter-phase reactor balances current in 12 pulse rectifiers by forcing current sharing
between the Δ and Y bridges of the system. Current can become unbalanced in the
rectifiers when there are slightly different impedances in the Δ and Y windings of the
transformer.
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The relationship between the AC input voltage and the output voltage of the 6-pulse
rectifier is given by the equation VLL x 1.35 = Vdc. For a 12 pulse rectifier, the relationship
is VLL x 1.39 = Vdc For either bridge, the unloaded DC value is approximately equal to the
peak RMS value of the input voltage, or VLL x 1.414 = Vdc . The following table (3-1)
shows some typical DC voltages for various inputs:
Input Voltage - RMS 6 Pulse Average DC 12 Pulse Unloaded

line to line Output Voltage DC output Voltage
480 648 667
600 810 848
690 932 960
Table 3-1: AC-DC Rectifier Voltages
Note that under heavy load, the drive’s DC link voltage may drop slightly. The DC link
voltage can be monitored at the drive controller keypad in the main monitor menu.
The following figures show the output waveforms of the 6 and 12-pulse rectifier bridges.
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Figure 3-3: 6 Pulse Rectifier Bridge Output Waveform, Vin = 600VAC
Figure 3-4: 12 Pulse Rectifier Bridge Output Waveform: Vin = 600VAC
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3.3 DC Bus
The Model 800AC VSDS systems may utilize a common DC bus. This means that 2 or
more inverters are connected to the DC bus via disconnect switches and share a one or
more rectifier bridges. There are certain advantages to the common DC bus, the most
important being input power is conserved when one or more of the motors in the system
are braking while others are motoring. An AC motor that is braking behaves as a
generator, and its power is returned to the DC bus by the inverter. Therefore, the power
required to operate the VSDS is reduced by utilizing the energy required to brake the
VSDS motors. The net power supplied to the VSDS by the system generators is the load
power less the regenerated power. For example, if 2 motors are consuming 1500 kW
while another motor is braking and supplying 700kw to the DC bus, the net power
required to run the system is 1500 – 700 = 800kW. Therefore, the system generators
need only supply 800kW and 700kW have been conserved during the braking cycle.
A DC link reactor may be used on systems with a common DC bus. This device is similar
to an input reactor in that its purpose is to smooth the current ripple on the DC bus. DC
link reactors are typically smaller than input reactors.
Systems containing only one inverter cubicle typically will not require a DC bus. In these
systems the output of the input rectifier is usually cabled to the input of the inverters
directly. Please refer to the job specific drawings for more information.
3.4 Inverter
The inverter section is the output section of the VSDS and is composed of IGBT
semiconductor switches and electrolytic capacitors mounted on aluminum heat sinks.
The IGBT collectors and emitters are electrically connected between the positive and
negative DC busses, respectively. They are switched on and off in a specific sequence to
produce a three phase output voltage of variable amplitude and frequency. The switching
technique employed in National Oilwell VSDs is a variation of Pulse Width Modulation
(PWM) used in high performance motor control. By varying the duration of the switching
pulses, the inverter can directly control the magnitude of the motor voltage, and in so
doing control motor current and torque. The fundamental frequency of the Model 800AC
is adjustable from 0 to 300 Hz.
The inverter converts filtered DC into variable frequency, variable voltage three phase
AC. An inverter cubicle contains a single 2 pole disconnect switch, a pre-charge circuit,
protective fusing, one or more IGBT inverter modules, and a digital control module with
keypad.
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The output current of the voltage source inverter is nearly sinusoidal and can be
measured with any quality current probe. If measuring the output current, be sure to
adjust the inverter’s output frequency to within the tolerance range of the current probe,
as most current probes are designed to work at frequencies between 40 and 60 Hz.
Unlike the current, the inverter’s output voltage is non-sinusoidal and cannot be
measured with ordinary test instruments. Fortunately, the line-to-line output voltage can
be viewed on the DCM’ s LCD display by accessing the motor voltage parameter in the
monitor menu.
Figure 3-5: Inverter Power Units
Inverter Main Circuit Components and Operation – Model 800AC VSDS
Each inverter cubicle is supplied DC voltage through either the input rectifier bridge directly, or
a common DC bus.
Pre-charge Circuit
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The pre-charge circuit is designed to gradually charge the DC bus capacitors and avoid
damaging them. Voltage transients applied to capacitors produce sharp temperature rises and
may cause them to rupture or explode. There are several different pre-charge methods
employed depending on the system, but the general principle is the same for all. In every
case, a resistance is temporarily inserted between the DC source and the capacitor bank so
that the charging current is limited to a safe level. All drives are pre-charged before the main
rectifier’s power is directly applied to the drive. Never attempt to bypass or defeat the pre-
charge circuit or serious damage to the converter could result.
Pressing the “Push to Charge” button initiates the capacitor pre-charge sequence. The
operator can monitor the pre-charge status via the “DC Bus Charged” lamp. The purpose of
the capacitor bank is to filter the rectified DC voltage and supply magnetizing VARs to the
motor. The pre-charge circuit is utilized to prevent damage to the capacitor bank that would
otherwise occur if the main rectifier’s output voltage were suddenly applied. Recall that a
capacitor acts like a short circuit to a voltage transient; therefore the pre-charge circuit is
designed to charge the capacitors slowly. It does this by temporarily inserting a resistance
between the capacitor bank and the applied main rectifier voltage. By controlling the charging
current, the pre-charge circuit gradually increases the voltage of the capacitor bank. It typically
takes between 500ms-1s for the DC bus to reach nominal voltage. The AINT board senses the
rising DC voltage, which reports the voltage level to the control module. Although it takes less
than a second to reach nominal DC voltage, it may take many additional seconds for the
control module to indicate that pre-charge is complete. The control module will then close a
contact which controls the “DC Bus Charged” lamp. Once the
”DC Bus Charged” lamp is lit, the operator may close the disconnect switch (or circuit breaker)
which connects the main DC supply bus directly to the inverter’s DC link. (Note: please refer
to the job specific details. Not all systems contain disconnect switches in the inverter cubicles.
Pre-charge circuit operation may vary.)
Inverter Control
Each Inverter module contains 3 output phases each consisting of a set of full-bridge IGBT’s
and associated gate-firing and measurement electronics. With motor and cable attached, the
IGBTs have a voltage rise time of between 3 and 5kV/uS. The switching frequencies are non-
adjustable on the Model 800, fixed at 1.5kHz. Parallel 1000 amp fuses protect each of the
inverter units. These fuses act to limit fault current between inverter units in the event of an
internal short circuit.
An RDCU drive control unit controls each inverter module used in a Model 800AC VSDS.
These units are found behind the swing out compartment in the door of a VSD cubicle.
Communication between the RDCU and each inverter unit is made through a fiber optic link.
Fiber optical lines are run from the RDCU unit to an optical branching unit, then from the
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branching unit to each inverter. Fiber optic connections can be made to its internal AINT
board on the front face of the inverter modules.
The inverter is controlled, protected, and monitored by a Digital Control Module (DCM). The
DCM is responsible for all motor control operations and inverter bridge control. The control
module is loaded with a firmware file. This file contains the all-necessary motor control
programs as well as the DCM’s operating system.
The two basic embedded motor control programs to choose from in the model 800AC inverter
are open and closed loop control. Figures 3-6a and 3-6b show the two main components of
the DCM installed in a NOI VSDS system.
Figure 3-6a: Motor Control Board (RDCU) Figure 3-6b: Display/Keypad

The DCM receives inverter bridge feedback from the AINT board via a fiber optic
communication link. IGBT current, DC link voltage, and heat-sink temperatures are the
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primary feedback signals processed by the AINT board and transmitted to the DCM. Phase
current is sensed directly at the IGBTs by the measurement boards, which have the added
responsibility of delivering gate pulses to the IGBTs. Based on input speed commands, load
torque, motor speed, the DCM adjusts the switching patterns of the IGBTs so that the
commanded motor speed and torque is realized.
The DCM itself consists of a RMIO board and a LCD control panel. The RMIO board is
designed with 3 open slots for I/O extension modules in addition to a section with designated
I/O used with predetermined external signals. Slot 1 may host one of many option modules
including: I/O extension (RAIO, RDIO), pulse encoder interface (RTAC), or Fieldbus adapter
(RPBA). Slot 2 can house either I/O extension (RAIO, RDIO) or a pulse encoder interface
(RTAC). Option module slot 3 is configured for a DDCS communication option module
(RDCO-02). In addition, a keypad with an LCD display is mounted to the face of the control
module’s enclosure via ADP1-01 adapter. The next two figures show the DCM control
interface (3-7) and the typical I/O connections (3-8).
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Figure 3-7: Control Interface of Inverter Unit
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STANDARD APPLICATION PROGRAM I/O
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Figure 3-8: External Control Connections
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Data Sheet 3-1: RMIO Board Technical Specifications
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Figure 3-9: Isolation and Grounding Diagram
Figure 3-9 above details the proper isolation and grounding arrangements to be followed. Care should be
taken to ensure all signal grounds are as per this arrangement.
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Option Modules / Extended I/O
Profibus-DP Adapter Module (RPBA-01)

The PROFIBUS-DP Adapter module is an optional device designed to enable the connection of a drive to a
PROFIBUS network. Each drive connected to the PROFIBUS network through an RPBA-01 module is
considered a slave device. The RPBA-01 PROFIBUS-DP Adapter module allows the following:
• Give control commands to the drive

• Start,Stop, Run Enable, etc…
• Feed a motor speed or torque reference to the drive
• Read status information and actual valures from the drive
• Change drive parameter values
• Reset a drive fault
Figure 3-10: RPBA-01 Option Module
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The Profibus cable is connected to the connector labeled X1 on the RPBA-01 module. The diagram and
table below depict the connector pin allocation. This configuration follows PROFIBUS standard.
Table 3-2: X1 Connector Pin Allocation for the RPBA-01 Module
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Bus termination is achieved by switching on a DIP switch located on the front of the RPBA-01 module. Bus
termination prevents signal reflections from the cable ends. If the module is the first or last module on the
network, bus termination must be set to ON. If using PROFIBUS specific D-sub connectors with built in
termination, the RPBA-01 termination must be switched off. Figure 3-11 below shows the DIP switch
details.
***Note: The built-in termination circuitry of the RPBA-01 is of the active type, so the module has to be
powered for the termination to work. If the module needs to be switched off during operation of the
network, the bus can be terminated by connecting a 220 ohm, 1/4 W resistor between the A and B lines.
Figure 3-11: Bus Termination DIP Switch
Rotary node address selectors on the RPBA-01 module are used to select the node address number of the
drive. Each node address number is of decimal type ranging in value from 01 to 99. The left selector
represents the first digit and the right selector the second digit. Node addresses may be changed while
operating, but the module must be re-initialized for changes to take effect.
***Note: If 00 is selected, the node number is defined by a parameter in the fieldbus parameter group of
the drive.
Figure 3-12: Node Selectors
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The diagram below is a demonstration of PROFIBUS network wiring. The PROFIBUS cable shields are
directly earthed at all nodes. All cable is standard PROFIBUS cable consisting of a twisted pair and
screen.
Figure 3-13: Cable Connection and Grounding Diagram for Standard Profibus Cable
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Pulse Encoder Interface Module (RTAC-01)

The RTAC-01 Pulse Encoder Interface Module allows a digital pulse encoder feedback to be used for
determining accurate motor speed or position. In most NOI Model 800AC systems the RTAC-01 module
will be installed in slot 2 on the RMIO board. Signal and power connection is automatically made through a
38-pinm connector, upon installation of the module.
Figure 3-14: RTAC-01 Module Layout
Table 3-3 on the next page details the terminal designations for the encoder module. Most
NOI model 800AC systems supply power to the encoder module using an external 24VDC
power supply. When this is the case, the external 24VDC power supply should be connected
to terminal X1-5 and the factory installed jumper across X1-5 and X1-6 should be removed.
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Table 3-3: Encoder Board Terminal Definitions and Signal Descriptions
***Note: Encoder inputs can be used with encoders having +15V to +24V signal levels.
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DDCS Communication Module (RDCO-02)

A DDCS Communication Module may be used in NOI Model 800AC systems where a
Master/Slave drive configuration is desired. The DDCS module offers an optical communication
link between 2 drives. There are four fiber optical channels available on the DDCS module
designated as shown below. DDCS modules will be installed in Slot 3 on the drive RMIO board.
CH1 – Overriding system (e.g. fieldbus adapter)

CH1 – I/O extensions
CH2 – Master/Follower link
CH3 – PC tools (such as Drive Ware)
Figure 3-15: RDCO-02 Module Layout
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Branching Unit (NDBU-44C)

The NDBU-44C Branching Unit (shown in figure 3-16) is used to link the AINT boards of multiple inverter
power units to one DCM. The optical inputs and outputs of the module are separated into sections labeled
CH1-4 and AMC. Each of the optical channels has a transmitter and receiver. A channel is assigned to
each inverter and then two optical cables are run between each inverter unit and the NDBU-42 module.
Figure 3-16: NBDU-44C Module Layout
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The TXD connector on the NPBU-44C unit is cabled to the RXD connector on the Inverter AINT board.
The RXD connector on theNPBU-44C unit is cabled to the TXD connector. The RXD and TXD connectors
are distinguished by color: Black= RXD and Gray=TXD. The AMC channel of the NDBU unit is cabled to
the RMIO board of the DCM. Figure 3-17 on the next page shows an actual picture of the front of an
inverter module where the fibers are connected to the AINT board.
Figure 3-17: AINT Board Connections on the Front Face of the Inverter Power Unit
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Motor Control
The firmware program is the interface between the user I/O and the motor control program. Its job
is to process all external control inputs such as start, stop, motor direction, and speed. The
processed input data is then passed from the firmware program to the motor control program.
Likewise, the firmware program receives information from the motor control program about such
things as the inverter output current, motor speed, and DC bus volts, and passes it back to
keypad display or the fieldbus. User control is most commonly exercised via fieldbus, but discrete
control signals are also commonly used. The fieldbus protocol used with most NOI equipment is
Profibus DP. Figure 3-18 is an inverter control block diagram illustrating the basic control theory
of the Model 800AC.
Typical Inverter Block Diagram
SPEED FEEDBACK
Dc link voltage feedback
DIGITAL CONTROL MODULE LINE REACTOR
Firing
Firing pulses INVERTER
FREQUENCY pulses
REF
SHAFT
Motor and application Motor Control ENCODER
SPEED REFERENCE
control processor
V REF
0
AC Motor
Torque Current BUS CAPACITORS

feedback
Vector
calculation
Flux
DC LINK
AC MAIN POWER
INPUT REACTOR
Rectifier
Bridge
FREQUENCY CONVERTER
Figure 3-18 Frequency Converter / Inverter Control
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Multi-motor Modes of Operation

There are two basic modes of operation that are used by National Oilwell when motors are
operated in parallel. The first mode is known as master/follower mode, the second mode
simply parallel inverter units. Each has certain advantages and disadvantages and they are
utilized accordingly in each application.
When a common shaft mechanically couples two or more motors, the optimum solution is for
the associated inverters to force load sharing among the respective motors. This can be
achieved using the master/follower mode of operation, in which the master drive is given a
speed reference by the PLC or hardwired input. The remaining ‘followers’ receive a torque
reference from the master drive via the controller’s system bus. In this way, the follower drives
all receive the same torque reference as the master, insuring that load sharing is achieved. In
this mode, the master drive is a “speed master” while those receiving their torque references
from the master are known as “torque followers”. If one motor or drive is lost in a two drive
system while in operating in master/follower mode, the remaining drive will automatically be
configured to operate in master mode as soon as the other is removed from the fieldbus, or
has it’s input power removed. Master/follower mode of operation is generally employed where
precise load sharing between motors is required. An example of such an application is a multi-
motor drawworks.
The second most commonly applied mode of operation employs dividing the output of one
drive between multiple motors. In this mode of operation a single drive receives a speed
reference, and generates an internal torque reference according to the load. Load sharing is
achieved by virtue of the mechanical coupling between motors. Each motor receives the same
voltage and current output as its counter part. This mode of operation is used quite frequently
in dual motor top drives and mud pumps. It is also used in active heave drawworks
applications where operation of the drawworks must continue without interruption. The reason
this method is preferred to master/follower mode in a multi-motor system (more than 2 on a
common shaft) is that in the event of a motor or drive fault, it is not necessary to re-wire or re-
configure the drive’s system bus in order to continue operation. With this method, the drive
only responds to a single speed reference and is never looking to another drive for a torque
reference in order to function.
Motor Control Modes

There are two basic types of motor control available from the National Oilwell VSDs. Open
loop frequency control, or scalar control is the first method, and generally applied to motors
connected to pumps, fans or other applications in which precise torque control isn’t required. In
this type of control, the digital control module operates without speed feedback, and simply
applies a constant ratio of voltage to output frequency. Without speed feedback, the DCM has
no direct knowledge of the rotor slip or position. Consequently, precise speed and torque
control in open loop is not possible. This mode of operation is still adequate where high
starting torque is not required, such as a pump.
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The second method of motor control is known as closed loop speed control. In this mode, the
DCM receives speed feedback via an incremental encoder, which is normally mounted on the
motor shaft. In this mode of operation, precise speed and torque control is possible
throughout the entire speed range of the inverter. This mode of operation is quite useful in
applications that require holding a load stationary, such as a drawworks or a crane, as well as
in applications where the motor operates above its base speed. For closed loop control to be
successful, the encoder must supply information about rotor position and speed. Closed loop
speed control is the most efficient and precise means of controlling a 3-phase induction motor.
Closed loop speed control is used on all National Oilwell drawworks, cranes, pipe-handling
equipment, and top drives. It may or may not be employed on other drilling machinery,
depending on the customer’s performance requirements for the installed system. The
summary of the major physical components of each inverter can be found in the following
table.
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INVERTER COMPONENT SUMMARY

Device Function
Pre-charge Circuit
Digital Control User interface with the inverter. The keypad is used for changing drive
Module operating parameters, monitoring drive data, and issuing control
(DCM) commands.
Provide filtering of the DC bus voltage and furnish magnetizing VARs to

Bus Capacitors
the motor
Insulated Gate
Bipolar Transistors
Converts DC voltage into 3-phase AC voltage of variable frequency and
(IGBT) (qty 2-6
amplitude.
modules per
inverter)
Controls inverter firing and serves as an interface between the IGBT
AINT board
measurement boards and the digital control module.
Table 3-4: Inverter component summary
3.5 Braking Chopper and Resistor Bank

The brake chopper is a semiconductor switch used to reduce the DC link voltage when
the motors are overhauling. The set point varies depending on the system voltage and
the application. The proper set point for your system may be found on the parameter list
in the Operating Parameters section of the manual.
All AC drives installed on a drawworks, TD, or cranes employ a DB chopper of some kind.
Some, but not all AC driven mud pumps also employ a braking chopper, depending on
the nature of the drilling program, and the type of pump used. Generally speaking,
drawworks and cranes require full braking capacity from the DB choppers and resistor
banks, so they tend to be sized quite differently than systems that require only intermittent
use or light braking. Stand-alone TD choppers are typically rated to provide longer
deceleration ramps and braking cycles than a drawworks or crane, but their operation is
the same.
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Figure 3-19 on the next page illustrates the basic configuration of a chopper unit. Note
that the braking resistor is connected to the (+) DC bus and the collector of the lower
IGBT switch, so that the lower switch provides the path between the braking resistor and
the (–) DC bus. The upper switch is unused in this arrangement.
In current NOI systems that do not require intensive dynamic braking, the choppers used
are typically air cooled, non-programmable, “dumb” units that trigger on a fixed voltage.
These units carry an 80kW to 400kW continuous rating, and are not re-configurable.
There may or may not be an external DCM.
Dynamic braking or electrical braking is achieved by forcing an AC motor to operate as an

induction generator. This occurs whenever the inverter’s output frequency is less than
the corresponding rotor speed. A common example of this is when the load drives a
motor, and the commanded inverter frequency is slower than the actual motor speed. In
this mode of operation, the inverter issues firing pulses and supplies magnetizing VARs to
the stator. As long as the inverter supplies the stator with a magnetic field, the motor will
operate as generator. When acting in this manner, the interaction between the stator’s
rotating magnetic field and the induced magnetic field in the rotor will generate a torque
that opposes the load torque. As soon as the inverter is stopped (firing pulses are
suppressed), the stator and rotor magnetic fields will collapse and all braking torque will
be lost. The power flow between the inverter and the motor is such that real power flows
from the motor to the drive, while reactive power flows from the drive to the motor.
The AC current flowing back to the drive is rectified by the inverter’s fly back diodes and
flows into the inverter’s DC bus as direct current. The direct current charges the DC link
capacitors, causing DC bus voltage to rise. Once the voltage reaches a pre-determined
set point, the chopper will switch on and connect the braking resistor bank across the
positive and negative DC bus terminals. In addition to lowering the DC bus voltage, the
braking choppers and resistor banks will dissipate the excess power in the resistor bank.
The total dissipated power in the resistor, inverter, and motor will equal the braking power
applied to the load.
In systems that share a DC bus and chopper(s), the other inverters may consume much
of the regenerated energy, in which case the braking chopper is only required to dissipate
the excess power. Mechanical braking is only needed for emergency braking or for
parking the load when the AC Drive is stopped. In general, the dynamic braking power
and torque can reach 150-175% of the motor’s nominal ratings over brief periods of time
in hoisting applications, or where very short deceleration ramps are used. The shorter
the deceleration ramp, the higher the peak braking torque and power will be.
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Figure 3-19: Typical DC Chopper Circuit
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3.6 Assignment Contactors

Assignment contactors are used to control the inverter output to meet system needs.
One inverter can be switched between two or more motors, or one motor can be switched
between two or more inverters. The number of contactors varies depending on the
system’s requirements. Not all systems utilize assignment contactors. Figure 3-20
shows a few possibilities for assignment contactors.
M M M M
TYPICAL ASSIGNMENT CONTACTOR

ARRANGEMENTS
Figure 3-20 Sample Output Contactor Single Line Drawing

Assignment contactors are either 3-phase AC contactors, or constructed from individual, single
phase contactors. The VSDS PLC ordinarily controls their operation, but they are electrically
interlocked to prohibit undesirable states in the event of a PLC malfunction.
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The following components are not considered part of the VSD, but a working knowledge of how
they operate and the function they serve is useful in understanding and maintaining the variable
speed drive system.
• One or more 3-phase AC induction motors. Ordinarily, each VSD powers a single motor
at a time.
• Drilling Control System (DCS). The Drilling Control System provides the MMI for the
driller and interfaces with the Model 800 VSDS to provide control of drilling equipment
and to receive feedback information.
3.7 AC Induction Motors – Basic Principle of Operation

The motors controlled by the Model 800AC VSDS are used to operate specific rig equipment,
such as the drawworks, top drive, pumps, cranes, etc. The most commonly used motor is the 3-
phase “squirrel cage” induction motor. In most drilling systems, the motors are open frame and
are cooled by an external blower, that forces cooling air directly onto the rotor and stator windings.
Some motors installed on cranes are closed frame, and cooled using a combination of channels
cut into the stator frame with fans mounted on the non-load end of the motor. In both types, the
cooling blowers and fans are controlled from independent voltage sources located in the VSDS.
Since the motor’s main shaft is not used to drive a cooling fan or blower, these motors may
operate indefinitely at very low speeds as long as the cooling fans are functioning.
Induction motors have certain characteristics that distinguish themselves from DC motors,
including:
• They require little maintenance other than periodic lubrication of the bearings.
• They are intrinsically safe – they don’t generate arcing or sparks as with DC motors.
• They are capable of holding full torque at zero speeds indefinitely without sustaining
damage to internal components.
• Generator operation (for braking purposes) is somewhat easier with an AC induction motor
than a DC motor.
The induction motor is composed of two main parts: a stator winding and a rotor. The stator is a
set of copper coils wound into slots in the motor frame. As its name implies, it is stationary. The
leads of the stator are connected to the 3 phase terminals of inverter. The stator windings are
spatially arranged so that a 3-phase voltage source establishes a rotating magnetic field around
the rotor. Stators are made up of pole pairs, so the minimum number of poles is 2. Nearly all AC
drilling motors have 6 poles, however 4 pole motors are also commonly found on cranes and
winches.
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The squirrel cage rotor is made of copper or aluminum bars that are held in place by the motor
bearings at each end of the motor frame. Rotation is caused by the interaction of magnetic fields
between the stator and the rotor. Specifically, the rotating magnetic fields of the stator induce a
voltage in the rotor bars, which cause a current to flow in the rotor. In turn, the rotor current
generates its own magnetic field, which attempts to align itself with the stator field. It is the relative
motion between the stator and rotor magnetic fields that generates motor torque. Rotor speed is
dependent on both the stator frequency and the motor load. Rotor speed is related to the stator
frequency by the formula:
Synchronous Rotor Speed = (120 x stator frequency)

Number of poles
It’s important to note the rotor’s fields never actually catch up with the stator fields; instead the
rotor turns at some speed slower than the synchronous speed. So in practice, the actual speed of
the rotor will differ from the synchronous speed, and is referred to as the motor slip. Slip is usually
expressed as a percentage, and in which case it is expressed by the formula:
%Slip = (Synchronous speed – Actual speed) x 100

Synchronous Speed
The nominal or base speed of the motor expresses actual rotor speed for a fully loaded motor
running at base frequency, usually 60 Hz. Therefore the rated slip of the motor can be found from
this number, and it is at the rated slip the nameplate full load current, torque, and power apply.
The nominal speed is usually found on the manufacturer’s nameplate. The following table lists
motor nameplate information that is required input to the inverter’s DCM parameter list:
MOTOR PARAMETER UNIT EXPLANATION / DEFINITION

Nominal Voltage VAC Rated RMS line to line voltage
Nominal Frequency Hz Field Weakening point
Nominal Speed RPM No load motor speed @
nominal frequency
Nominal Current AAC Full load current
Nominal Power KW Rated Power [kW] = (HP x
746)/1000
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Power Factor (cos phi) N/A Typically 0.85

Maximum Safe Speed RPM Highest speed at which motor
should be operated
Table 3-5 Required Motor Nameplate Data
There are 2 basic regions of operation for an induction motor. The first region is between 0 RPM
and the nominal motor speed, and is known as the constant torque region. The second region is
between the motor’s nominal speed and it’s maximum speed, and is known as the constant
horsepower region.
In the constant torque region, the stator voltage is applied linearly with increasing frequency, so
that the ratio of Voltage/stator frequency is held constant. Full (rated) voltage is applied when the
motor speed is equal to the nominal nameplate speed. At this point, the FC has reached its
voltage limit (output voltage cannot exceed input voltage), so the converter’s voltage is held
constant as the stator frequency is increased. As frequency increases, the induction motor’s
back-emf increases, and stator current begins to drop off because the difference between the
converter’s output voltage and the motor’s opposing voltage becomes less. As current drops off,
so does torque, but the horsepower remains constant even as torque drops off because the speed
is increasing. Figure 1-9 illustrates these 2 regions.
14000
OVERLOAD TORQUE TYPICAL SPEED VS TORQUE PROFILE
OF AN INDUCTION MOTOR
12000
MOTOR TORQUE (Lb-Ft)
10000
RATED TORQUE CONSTANT HORSEPOWER

8000 REGION
CONTANT
TORQUE REGION
6000
4000
2000
2450 Max. RPM

0
0 200 400 600 800 1000 1200 1400 1600 1800 2000 2200 2400 2600
MOTOR SPEED ( RPM )
Figure 3-21 Typical Induction Motor Curve
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The motor receives varying voltage and frequency from the IGBTs. Lowering the VFDs output
frequency will change the motor’s speed. When the load forces the motor to rotate faster than the
applied inverter frequency, the motor becomes a generator and converts rotational energy into
electrical power. This electrical power is fed to the DC Bus via the inverter phase cells. The brake
choppers and braking resistors then dissipate the excess power as heat.
3.8 PLC and interface for the Drilling Control System (DCS)
The Drilling Control System is based on the Siemens S7 300 family of modular mini-PLCs. The PLC
provides the link between the operator and the inverter either through a touch screen or other control
panel. The PLC is responsible for controlling the inverter’s start, stop, and speed commands based on the
user input, load conditions, and other system information. The PLC communicates with the inverter using
the Profibus DP protocol, and therefore can access information from the converter and provide information
to it. Among other things, the PLC may be used to change the inverter’s operating parameters, monitor
and control the cooling system, manage system power, and report system alarm/system fault data to the
operator. The PLC acts as the bridge between the MMI (Man-Machine Interface) console and the VFDS
system components. A typical DCS is illustrated in below in Figure 3-22.
Fig. 3-22 Sample Drilling Control System with Supervisory PLC
The Siemens S7 PLC is usually located in the Incomer cubicle, or its own PLC cubicle. The PLC
communicates with the other devices over a PROFIBUS communications network. There is I/O located on
the PLC rack, as well as Remote I/O racks typically located in the MCC and the Operator Console. The
purpose of having remote is to reduce the number of wires that need to be run between the field, the MCC,
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and the PLC cubicle. By using remote I/O only the 2 wire PROFIBUS cable needs to be run. For remote
racks located far away from the PLC, such as in the operator’s console that is normally located on the drill
floor, fiber optic cables are used instead of the hard-wired system. In this case, an Optical Link Module is
used to convert from the Profibus signal to the fiber optic communications.
The variable inverters and the choppers also communicate with the PLC over the same PROFIBUS
network. Each device on the network has a unique address to distinguish itself to the PLC.
The Operator’s Console allows the operator to control the system with devices such as switches, throttles
and potentiometers. The console also displays system status with pilot lights and gauges. These inputs
and outputs are wired into a remote I/O rack that is connected to the PLC over the Profibus network.
The PLC also switches on the auxiliary motors by controlling the motor starters. Some systems may
include a remote I/O rack that controls this action.
Based on the operator’s commands, the PLC sends commands to the drives. By communicating over the
PROFIBUS network, the PLC can start the drive, send it speed and torque commands, as well as read
back drive’s status information. The status information includes items such as voltage, current, run status
and fault information. This information inside the PLC is usually sent to a touchscreen or remote
monitoring system for troubleshooting purposes.
The following table contains the fault and alarm codes and descriptions that can be read by the PLC.
FAULT/WARNING BUFFER READ BY THE PLC ID NUMBERS 95-99
Fault Code Comment

ACS 800 TEMP 4210 Inverter Temp
AI< MIN FUNC 8110
BRAKE ACKN ff74
COMM MODULE 7510 Check Field Bus
DC OVERVOLT 3210
EARTH FAULT 2330 Short circuit
ENCODER A<>B 7302 See sub codes
ENCODER ERR 7301 Check encoder module wiring
IN CHOKE TEMP ff81
MOTOR STALL 7121
MOTOR TEMP 4310 (programmable fault fcn)
MOTOR 1 TEMP 4312 (not used typically)
MOTOR 2 TEMP 4313 (not used typically)
PANEL LOSS 5300 (progammable fault fcn)
SHORT CIRC 2340
THERMISTOR 4311 (progammable fault fcn)
UNDERLOAD Ff6a (progammable fault fcn)
DC UNDER VOLTAGE 3220 Check mains and fuses
EXTERNAL FLT 9000 (progammable fault fcn)
I/O COMM 7000 Check fiber on CH1
MOTOR PHASE ff56 (progammable fault fcn)
OVERCURRENT 2310 Check encoder/Accel time
OVERFREQ 7123
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PANEL LOSS 5300 (progammable fault fcn)

PPCS LINK 5210 Check fibres at AINT board
SUPPLY PHASE 3130 Check mains for imbalance
Table 3-6: PLC Fault/Alarm code Reference Table
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3.9 Technical Data

The following table (3-7) includes technical specifications about the National Oilwell inverters and
choppers. If more information is required, please consult the National Oilwell Factory in Houston,
Texas.
MODEL 800 INVERTER

Parameter Specification Unit
Environmental/Mechanical
Ambient Operating Temperature 0/32 to +50/122 C/F
Reduced Output (1%/1C) +40/104 to +50/122
Storage Temperature -40/-40 to +70/158 C/F
Transportation -40/-40 to +70/158 C/F
Relative Humidity (no condensation) 5< 95%
Altitude (w/o derating) 0..3000/0..1000 Ft/M
Altitude (w/ derating) 3000..12000/1000..4000 Ft/M
TYPICAL CHOPPER UNIT
Parameter Specification Unit
Environmental/Mechanical
Ambient Operating Temperature -10/14 to +40/104 C/F

Storage Temperature -40/-40 to +70/158 C/F
Relative Humidity (no condensation) 5< 95%
Altitude (w/o derating) 3300/1000 Ft/M
Table 3-7 National Oilwell Technical Specifications
3.9.1 Weights and Dimensions

The components of a Model 800AC VSDS will vary from job to job. Assignment
cubicles, if utilized, may contain different numbers of contactors. The number of
VFDs may vary also, as will the size of the cooling system. The item that can vary
the most is the incomer cubicle, depending on whether it is multi-pulse and what it’s
amperage capacity is. Refer to the weight and outline dimensions as shown on the
drawings for each job-specific system. A general guideline for dimensions of
individual component cubicles of the system is as follows:
CUBICLE DIMENSIONS
DEPTH
CUBICLE HEIGHT WIDTH DEPTH LAND
OFFSHORE
INVERTER (2X Inverter units) 90” / 2286mm 24” / 559 mm 38” / 966mm 50” / 1270mm
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INCOMER (powering up to 4 Inverters) 90” / 2286mm 24” / 914mm 38” / 966mm 50” / 1270mm
ASSIGNMENT
90” / 2286mm 30” / 762mm 38” / 966mm 50” / 1270mm
Table 3-8 National Oilwell Cubicle Typical Weights and Dimensions
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Inverter Module Dimensions and Diagrams
INVERTER UNIT PHYSICAL DIMENSIONS [in]

MODEL W1 H1 D1
MODEL 800AC 9.6450 54.4880 21.1800
Figure 3-23 Inverter Model Outline Drawings and Dimensions
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3.9.2 Performance Data

The following table (3-9) provides some fundamental performance information about National
Oilwell VSDs.
Ratings
Nominal ratings Light-overload use Heavy-duty use
Drive type Icont.max IMAX IN IHD Frame Noise level Heat dissipation Air flow
A (AC) A A A dBA kW m3/h
UN=690 V
ACS800-104-0580-7 486 724 467 362 R8i 73 7.0 1200
ACS800-104-1160-7 953 1419 914 710 2xR8i 74 14.0 2400
ACS800-104-1740-7 1414 2107 1358 1053 3xR8i 75 21.0 3600
ACS800-104-2320-7 1866 2780 1792 1390 4xR8i 76 28.0 4800
ACS800-104-3490-7 2770 4127 2659 2063 6xR8i 78 42.0 7200
Table 3-9 Inverter Model Performance Data Summary
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4 OPERATING INSTRUCTIONS
The Inverters are normally controlled from the Driller’s Cabin via Profibus DP. During normal
operation, the operator will provide start / stop commands and speed references, and monitor
the performance of the equipment as it operates. No other operator interactions are normally
required. The control keypad mounted on the front of the Inverter cubicles allows local
monitoring and parameter adjustments of the Inverters. The details of this keypad are listed
below. More information regarding the keypad and control unit is available in the ABB User
Manual.
4.1 CONTROL PANEL

The control panel is the link between the ABB frequency converter and the user. The ABB control
panel features an alphanumeric display with 4 lines of 20 characters. There are four modes of
operations:
• Actual Signal Display Mode (ACT key)

• Parameter Mode (PAR key)
• Function Mode (FUNC key)
• Drive Selection Mode (DRIVE key)
The operation mode of the panel dictates the uses of the arrow keys and ENTER. The drive
control keys are described below
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Figure 4-1: Illustrates the ABB control panel and control keys
4.1.1 Panel operation mode keys and displays
Figure 4-2: Panel Operation
4.1.2 Status Row
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Figure 4-3: Description of status row
4.1.3 Drive control from panel

The user may elect to control the drive by control panel as described below:
• Start, stop, and change direction of motor
• Give the motorspeed reference or torque reference
• Reset the fault and warning messages
• Change between local and external drive control
The drive can always be controlled from the control panel while the drive is under local
control and the status row is visible on the display. The next figure shows how to start, stop
and change direction and how to set a speed reference both from the control panel.
Figure 4-4: Start, Stop and Change Direction from Keypad
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Figure 4-5: Setting a Speed Reference from Keypad
4.1.4 Actual signal display mode

While in Actual Signal Display Mode, the user may:
• Show three actual signals on the display at a time
• Select the actual signals to display
• View the fault history
• Reset the fault history
The panel will enter Actual Signal Display Mode automatically within one minute if the
keypad is left alone.
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Figure 4-6: Selecting Actual Signals to the Display
Figure 4-7: Displaying Full Name of Actual Signals
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Figure 4-8: Displaying Fault History
***Note: Fault history cannot be reset if there are active faults or warnings.
Figure 4-9: Resetting an Active Fault
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Fault history updates information on current events (faults, warnings, and resets) of
the drive. Below demonstrates how events are displayed in the fault history.
Figure 4-10: Displaying Events
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4.1.5 Parameter mode

In the Parameter Mode, the user may:
• View parameter values
• Alter parameter settings
Figure 4-11: How to Select a Parameter and Change the Value
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4.1.6 Function mode

In the Function Mode, the user can:
• Start a guided procedure for adjusting the drive settings (assistants)
• Upload the drive parameter values and motor data from the drive to the panel
• Download group 1 to 97 parameter values and motor data from the drive to the
panel
• Adjust the contrast of the display
Below is an example of how the Motor Setup task can be executed with Start-up
Assistant.
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Figure 4-12: Motor Set-up with Start-up Assistance
Uploading data from the drive to the control panel
Note:
• Upload before downloading
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• Ensure the program versions of the destination drive are the same as
the versions of source drive, see parameters 33.01 and 33.02
• Before removing the panel from a drive, ensure the panel is in remote
operating mode (change with the LOC/REM key)
• Stop the drive before downloading
_____________________________________________________________
___
Before upload, repeat the following steps in each drive:

• Setup the motors
• Activate the communication to the optional equipment (See parameter
group 98 OPTION MODULES)
Before upload, do the following in the drive from which the copies are to be
taken:
• Set the parameters in groups 10 to 97 as preferred
• Proceed to the upload sequence (below)
Figure 4-13: Uploading Data from the Drive to the Panel
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Downloading data from the control panel to the drive
Figure 4-14: Downloading Data from the Panel to the Drive
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Figure 4-15: Setting the Contrast of the Display
4.1.7 Drive selection mode

**Not applicable to NOI Model 800 VSDS systems. This mode would allow users to select
drive of interest if multiple drives were to share one control panel.
4.1.8 Reading and entering of Boolean values on the display

Some actual values and parameters are packed Boolean, i.e. each individual bit has
a defined meaning (explained at the corresponding signal or parameter). On the
control panel, packed Boolean values are read and entered in hexadecimal format.
In this example, bits 1, 3 and 4 of the packed Boolean value are ON:
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Figure 4-16: Example of Reading Boolean Values
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4.2 INITIAL MOTOR OPERATION SETUP

The following steps are to be performed prior to running a motor for the first time.
1. Verify the machine’s lubrication system is functioning properly, if applicable.

2. Verify the machine’s associated auxiliary motors are functioning properly bye briefly
energizing them from the MCC or local control panel. Ensure the motor blower rotation is
correct.
3. Ensure the motor is un-loaded. Verify the motor/machine brakes are operation if so
equipped, and any shipping bolts installed to lock the rotor have been removed.
4. Verify that the motor cables and motor have undergone an appropriate insulation test by
a trained electrician or technician.
5. Verify the motor’s frame is solidly earthed.
6. If equipped with an encoder, verify the encoder shaft coupling is tight and properly
installed. Carefully inspect the encoder cable and verify it is properly terminated, in
accordance with the electrical drawings. Verify the encoder cable is run at least 12” from
any of the AC motor’s phase conductors.
4.2.1 Visual Inspection

A visual inspection of the entire system should be performed before any other steps are taken
during the system set-up. The system should be inspected for any damage that may have occurred
during shipping or unpacking. Verify there are no loose electrical connections in both the control
and main circuits of the entire system. Be sure to correct any problems before proceeding.
4.2.2 Configure Drive

Each VFD of a NOI VSDS system must be specifically configured for the intended application. The
following sections briefly describe the drive configuration procedure.
4.2.2.1 Inverter Drive Size

Under normal conditions, the inverter size dimensioning parameters only need to be set once; and
this is done at the factory prior to shipping the drive. When the drive is powered up, pressing the
“Drive” button on the Control Panel can check the inverter size. If the inverter size is incorrect, it
must be corrected before the Motor ID run can be performed. To do this, please contact NOI in
order to obtain the information on reconfiguring drive size.
4.2.2.2 Performing a Motor ID Run

A Motor ID run should be performed before any other action is taken with the drive. The motor data
should be entered from the information found on the motor nameplate.
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4.2.2.2.1 Entering Motor Data

The motor data can be entered in two ways. The first is by going to Parameter group 99 and
entering the data as it appears on the motor nameplate. The second method is to press the “Func”
button on the Control Panel and then selecting “Motor Set-up.” This will begin the Start-up
Assistant, which will guide you through the motor set-up. The parameters should be set-up as
follows:
• 99.01 Language English or English AM

If English is chosen, the motor nominal power must be in kilowatts, and if
English AM is chosen, the nominal power is in horsepower.
• 99.02 Application Macro

This should be set to “Factory” unless the drive will be acting as a slave drive. In a
slave drive, this is set this to “T-Ctrl” (Torque Control)
• 99.03 Application Restore No
• 99.04 Motor Control Mode DTC

In most cases DTC (Direct Torque Control) will be suitable.
• 99.05 Motor Nominal Voltage (off motor nameplate)
• 99.06 Motor Nominal Current (off motor nameplate)
• 99.07 Motor Nominal Frequency (off motor nameplate)
• 99.08 Motor Nominal Speed (off motor nameplate)
• 99.09 Motor Nominal Power (off motor nameplate)
• 99.10 Motor ID Run Standard

The standard ID run will achieve the best accuracy. The motor must be uncoupled
from the load. The procedure will take about 1 minute, however times will vary so
do not be alarmed. If motor ID Run has not completed within 5 minutes, then look at
Group 20 limit parameters as described below that may interfere with the ID Run
profile. The drive will spin the motor and will run between 50% and 80% of the motor
nominal speed, so make sure it is safe to spin the motor. Note that the motor is
accelerated at a very fast ramp during the ID Run, thus the motor will tend to rock do
to the rotor inertia. Make sure that the motor is placed on a solid base. The Motor
ID Run is always operated in the Forward direction according to the drive phasing,
so make sure the motor rotation during the test is consistent with forward rotation of
the load/machine. If motor rotation is reversed with respect to the load, interchange
any 2 motor cable phases after the ID Run is complete.
Before performing the ID run, other parameters must be checked. See the following
section.
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4.2.2.3 Parameters for Motor ID Run
4.2.2.3.1 Group 20
Go to Parameter Group 20 “Limits” and check the following parameters:
• Parameter 20.02 Maximum Speed

The default for this is motor nominal speed. It should be kept there for the ID run.
• Parameter 20.03 Maximum Current

The default for this is two times the motor nominal current. For the ID run it needs to be
greater than the nameplate value
• Parameter 20.04 Torque Max Lim 1

This needs to be at least 100%. It is best to keep it at default (300%) for the ID run.
• Parameter 20.05 Overvoltage Control

This should be set turned ON for the ID run. Under normal operation of the drive, if there is
a chopper and brake resistor in the system, this should be turned off in order for the chopper
to turn on.
4.2.2.3.2 Remove PROFIBUS Control

Profibus control must also be removed from the system. In order to do this, check the following
parameters:
• Parameter 10.01 EXT1 STRT/STP/DIR

This should be set to “Keypad” during the ID run.
• Parameter 11.03 EXT REF1 SELECT

This should be set to “Keypad” during the ID run.
• Parameter 11.02 EXT1/EXT2 SELECT

This should be set to “EXT1” during the ID run.
4.2.2.3.3 Run Enable

In Parameter Group 16 “System Control Inputs,” set parameter 16.01 “Run Enable” to “YES” during
the ID run.
4.2.2.3.4 Encoder
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If an encoder is being used for speed feedback for the control of the drive, the encoder must be
disabled during the ID run. By default, the encoder is not activated; Parameter 98.01 ENCODER
MODULE will be set to “NO”. If the encoder feedback was already enabled by setting parameter
98.01 to a value other than “NO”, then disable the speed feedback of the encoder by going to
Parameter Group 50 “Encoder Module” and set Parameter 50.06 “Encoder FB Sel” to “Internal”
during the ID run. If motor rotation has been proven to be correct, then while the ID Run is running
it is also beneficial to check the encoder wiring. To do this, compare ACTUAL SIGNALS 2.18
SPEED MEASURED (Encoder measured RPM) to 1.02 SPEED (drive’s internal calculated speed).
Both numbers should be approximately equal and with the same polarity. If rpm does not match
then check accuracy of encoder configuration in Group 50 ENCODER MODULE or look for
improper wiring or encoder supply voltage (RTAC-01 module does not work with 5V DC encoder
signals). If polarity is opposite, and motor rotation is correct, then swap “A” for “B” and “A-“ for “B-“
on the encoder feedback wiring. Note, “Z and Z-“ wires are unused in the ABB drives.
4.2.2.3.5 Master/Follower
If the drive that you are working on is set up in the follower mode, this must be disabled in order to
perform the ID run. In order to do this, go to Parameter Group 60 “Master/Follower” and change
parameter 60.01 “Master Link Mode” to “Not in Use.” Also remember to set Parameters 10.01,
11.02, 11.03 as described above.
4.2.2.3.6 Start Interlock

The Start Interlock must be active to start the ID run. To do this, place a jumper between X22:8 and
X22:11.
4.2.2.4 Starting the Motor ID Run

In order to start the motor ID run, put the Keypad in the Local mode by pressing the “Loc/Rem” key
on the Panel. An “L” should appear in the upper left hand corner of the display. Return to
Parameter Group 99 and change parameter 99.10 “Motor ID Run” and choose “Standard.”
Once this is chosen, the screen should read “**Warning** ID Run Sel.” After pressing the green
button to start the ID run the screen will read “**Warning** Motor Starts.” During the ID Run, the
screen will read “**Warning** ID Run.” By pressing the “ACT” key on the keypad, you can monitor
the drive current and speed. When the ID run finishes, the screen will read “**Warning** ID Done.”
4.2.2.5 ID Run Completed

Once the ID run has been completed, the parameters that have been changed can be returned to
their original values. Now the drive can be customized for the current application.
4.2.3 General Set-up Procedures

The following procedure assumes that main power is available to the VSDS. It also assumes all
normal procedures relating to resistance and insulation tests have been performed on the VSDS
cabinet, supply bus, and the motors it powers. Each VSDS undergoes a system hi-potential test at
the factory; however it is important to inspect the main power source network prior to starting the
VFD.
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1. Before attempting to energize the inverters, verify that the VSDS system preliminary
startup procedure has been followed. See the Reference Documents section for the
appropriate procedure.
2. Verify that the inverter is isolated from its main power source.
3. Inspect all main power connections and verify they agree with the system drawings.
Inspect each connection and Verify the motor cables not connected to the inverter, either
at the plug panel, or at the motor itself.
4. Inspect all control connections to the inverter and verify they agree with the system
drawings. Inspect each connection for tightness.
5. Ensure no condensation is evident on the inverter’s phase cells or electronics.
6. Ensure all fiber optic lines and control cables are properly installed according to VFD
module interconnect drawings.
7. Ensure that all inverter cubicle doors are closed.
All VSDS cubicle doors must remain closed while the system is energized
8. Connect converter to the main power supply by closing the feeder circuit breaker or main
disconnect switch. Verify that the control panel has powered up and no fault or warning
message is displayed. If the display indicates a warning or fault message, see the
troubleshooting section and clear the fault before proceeding.
9. Using either the keypad or the Drive Windows commissioning tool, set the parameters
according to the requirements of your application. See the Reference Document list for
the proper parameters if these are not known.
10. Start the drive from the control console and monitor the output frequency on the keypad
from the Actual Signal Display Mode. Issue a frequency reference from the operator’s
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console and verify that the converter output frequency follows the reference. If this does
not occur, refer to the troubleshooting section for assistance.
11. EMERGENCY STOP While the inverter is running activate the Emergency Stop switch for
the drive. Usually this is located on the users remote console. If operating properly, the
drive will stop issuing firing pulses and the output frequency will drop to 0. Be sure the
emergency stop logic is working properly before proceeding to run any motors.
12. From the operator’s console, stop the inverter and remove power by opening the circuit
breaker or main disconnect switch. The LCD display should go blank within 1 minute
after removing power from the inverter. Wait at least 3 minutes after the LCD goes blank
before opening the cubicle doors or touching the drive. Always use a voltmeter to check
the converter’s DC bus before proceeding.
13. Lockout the inverter’s CB or main power source. Connect the motor cables to the inverter
output at the appropriate panel. Make certain the motor/machine brakes are released,
and there is no load on the motor.
14. Restore power to the inverter, verify there are no faults displayed, and start the drive from
the console. Give a forward speed reference to the inverter and verify the rotation of the
motor is correct. If not, reverse any two phases at the motor and re-test.
15. Speed Feed Back: Change encoder module parameter 50.06 to ENCODER. While
monitoring both actual and estimated speed on the keypad, give the drive a speed
reference and verify the following Table:
Variable Direction
Speed Reference Forward
Output Frequency (hz) Positive
Estimated Speed (rpm) Positive, equal to Speed Reference
Actual Speed (rpm) Positive, equal to Estimated Speed
Speed Reference Reverse
Output Frequency (hz) Negative
Estimated Speed (rpm) Negative, equal to Speed Reference
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Actual Speed (rpm) Negative, equal to Estimated Speed
Table 4-1: Variable VS. Direction
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The proper motor start sequence is diagramed in Figure 4-15 below. The diagram shows the
relationship between several drive parameters and the role they play in that sequence.
Ts Start torque at brake release (Parameter 42.07 and 42.08)

tmd Motor magnetizing delay
tod Brake open delay (Parameter 42.03)
ncs Brake close speed (Parameter 42.05)
tcd Brake close delay (Parameter 42.04)
Figure 4-15: Drive/Motor Starting Sequence (w/ brake control function)
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Table 4-2 Actual Drive Signals
No. Name/Value Description FbEq

01 ACTUAL SIGNALS Basic signals for monitoring of the drive.
Process variable based on settings in parameter group 34 1=1
01.01 PROCESS VARIABLE PROCESS VARIABLE.
-2000 = -100% 2000 =
Calculated motor speed in rpm. Filter time setting by parameter 100% of motor abs. max.
01.02 SPEED 34.04. speed
-100 = -1 Hz
01.03 FREQUENCY Calculated drive output frequency. 100 = 1 Hz
01.04 CURRENT Measured motor current. 10= 1 A
-10000 = -100% 10000 =
Calculated motor torque. 100 is the motor nominal torque. Filter 100% of motor
01.05 TORQUE time setting by parameter 34.05. nom. torque
0 = 0%
1000 = 100% of motor
01.06 POWER Motor power. 100 is the nominal power. nom. power
01.07 DC BUS VOLTAGE V Measured intermediate circuit voltage. 1=1V
01.08 MAINS VOLTAGE Calculated supply voltage. 1=1V
01.09 OUTPUT VOLTAGE Calculated motor voltage. 1=1V
01.10 ACS 800 TEMP Temperature of the heatsink. 1 = 1 °C
External reference REF1 in rpm. (Hz if value of parameter 99.04 is 1 = 1 rpm
01.11 EXTERNAL REF 1 SCALAR.)
External reference REF2. Depending on the use, 100% is the motor 0 = 0%
maximum speed, motor nominal torque, or maximum process 10000 = 100%
01.12 EXTERNAL REF 2 reference.
01.13 CTRL LOCATION Active control location. (1,2) LOCAL; (3) EXT1; (4) EXT2. See Descr.
1=1h
01.14 OP HOUR COUNTER Elapsed time counter. Runs when the control board is powered.
01.15 KILOWATT HOURS kWh counter. 1 = 100 kWh
Application block output signal. E.g. the process PID controller 0 = 0%
01.16 APPL BLOCK OUTPUT output when the PID Control macro is active. 10000 = 100%
Status of digital inputs. Example: 0000001 = DI1 is on, DI2 to DI6
01.17 DI6-1 STATUS are off.
01.18 AI1 [V] Value of analogue input AI1. 1 = 0.001 V
01.19 AI2 [mA] Value of analogue input AI2. 1 = 0.001 mA
01.20 AI3 [mA] Value of analogue input AI3. 1 = 0.001 mA
Status of relay outputs. Example: 001 = RO1 is energized, RO2
01.21 RO3-1 STATUS and RO3 are de-energized.
01.22 AO1 [mA] Value of analogue output AO1. 1 = 0.001 mA
01.23 AO2 [mA] Value of analogue output AO2. 1 = 0.001 mA
Feedback signal for the process PID controller. Updated only when 0 = 0% 10000
01.24 ACTUAL VALUE 1 parameter 99.02 = PID CTRL
Feedback signal for the process PID controller. Updated only when -10000 = -100%
01.25 ACTUAL VALUE 2 parameter 99.02 = PID CTRL 10000 = 100%
-10000 = -
Deviation of the process PID controller, i.e. the difference between 100% 10000 =
the reference value and the actual value. Updated only when 100%
01.26 CONTROL DEVIATION parameter 99.02 = PID CTRL.
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01.27 APPLICATION MACRO Estimated motor temperature. 0 / No Inversion

01.28 EXT AO1 [mA] 1 = 0.001 mA
Value of output 1 of the analogue I/O extension module (optional).
01.29 EXT AO2 [mA] 1 = 0.001 mA
Value of output 2 of the analogue I/O extension module (optional).
01.30 PP 1 TEMP IGBT maximum temperature in inverter no. 1 (used only in high 1 = 1 °C
power units with parallel inverters).
01.34 ACTUAL VALUE 0 = 0% 10000 = 100%
Process PID controller actual value. See parameter 40.06.
01.35 MOTOR 1 TEMP 1 = 1 °C
Measured temperature of motor 1. See parameter 35.01
01.36 MOTOR 2 TEMP 1 = 1 °C
Measured temperature of motor 2. See parameter 35.04.
01.37 MOTOR TEMP EST Estimated motor temperature. 1 = 1 °C
Value of analogue input AI5 read from AI1 of the analogue I/O 1 = 0.001 mA
01.38 AI5 [mA] extension module (optional). A voltage signal is also displayed in
mA (instead of V).
Value of analogue input AI6 read from AI2 of the analogue I/O 1 = 0.001 mA
01.39 AI6 [mA] extension module (optional). A voltage signal is also displayed in
mA (instead of V).
Status of digital inputs DI7 to DI12 read from the digital I/O 1=1
01.40 DI7-12 STATUS extension modules (optional). E.g. value 000001: DI7 is on, DI8 to
DI12 are off
Status of the relay outputs on the digital I/O extension modules 1=1
(optional). E.g. value 0000001: RO1 of module 1 is energized.
01.41 EXT RO STATUS Other relay outputs are de-energized.
Motor actual speed in percent of the Absolute Maximum Speed. If 1=1
01.42 PROCESS SPEED REL parameter 99.04 is SCALAR, the value is the relative actual output
frequency.
01.43 MOTOR RUN TIME Motor run time counter. The counter runs when the inverter 1 = 10 h
modulates. Can be reset by parameter 34.06.
Running time of the drive cooling fan. 10
01.44 FAN ON-TIME Note: The counter can be reset by the DriveWindow PC tool.
Resetting is recommended when the fan is replaced.
01.45 CTRL BOARD TEMP Control board temperature.
No. Name/Value Description FbEq
02 ACTUAL SIGNALS Speed and torque reference monitoring signals.
02.01 SPEED REF 2 Limited speed reference. 100% corresponds to the Absolute 0 = 0%
Maximum Speed of the motor. 20000 = 100% of
motor absolute max.
speed
02.02 SPEED REF 3 Ramped and shaped speed reference. 100% corresponds to the 20000 = 100%
Absolute Maximum Speed of the motor.
02.09 TORQ REF 2 Speed controller output. 100% corresponds to the motor nominal 0 = 0%
torque. 10000 = 100% of
motor nominal torqu
02.10 TORQ REF 3 Torque reference. 100% corresponds to the motor nominal torque. 10000 = 100%
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02.13 TORQ USED REF Torque reference after frequency, voltage and torque limiters. 100% 10000 = 100%
corresponds to the motor nominal torque.
02.14 FLUX REF Flux reference in percent. 10000 = 100%
02.17 SPEED ESTIMATED Estimated motor speed. 100% corresponds to the Absolute 20000 = 100%
Maximum Speed of the motor.
02.18 SPEED MEASURED Measured motor actual speed (zero when no encoder is used). 20000 = 100%
100% corresponds to the Absolute Maximum Speed of the motor.
03 ACTUAL SIGNALS Data words for monitoring of fieldbus communication (each signal is
a 16-bit data word).
03.01 MAIN CTRL WORD A 16-bit data word.

03.02 MAIN STATUS WORD A 16-bit data word.
03.03 AUX STATUS WORD A 16-bit data word.
03.04 LIMIT WORD 1 A 16-bit data word.
03.05 FAULT WORD 1 A 16-bit data word.
03.07 SYSTEM FAULT A 16-bit data word.
03.08 ALARM WORD 1 A 16-bit data word.
03.11 FOLLOWER MCW A 16-bit data word.
03.12 INT FAULT INFO A 16-bit data word.
03.13 AUX STATUS WORD 3 A 16-bit data word.
03.14 AUX STATUS WORD 4 A 16-bit data word.
3.20 LATEST FAULT Fieldbus code of the latest fault.
3.21 2. LATEST FAULT Fieldbus code of the 2nd latest fault.
3.23 3. LATEST FAULT Fieldbus code of the 3rd latest fault.
3.24 4. LATEST FAULT Fieldbus code of the 4th latest fault.
3.25 5. LATEST FAULT Fieldbus code of the 5th latest fault.
3.26 LATEST WARNING Fieldbus code of the latest warning.
3.27 2. LATEST WARNING Fieldbus code of the 2nd latest warning.

3.28 3. LATEST WARNING Fieldbus code of the 3rd latest warning.
3.29 4. LATEST WARNING Fieldbus code of the 4th latest warning.
3.30 5. LATEST WARNING Fieldbus code of the 5th latest warning.
09 ACTUAL SIGNALS Signals for the Adaptive Program
09.01 AI1 SCALED 20000 = 10 V

Value of analogue input AI1 scaled to an integer value.
09.02 AI2 SCALED 20000 = 20
Value of analogue input AI2 scaled to an integer value. mA
09.03 AI3 SCALED 20000 = 20
09.04 AI5 SCALED Value of analogue input AI5 scaled to an integer value.
20000 = 20
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mA
09.05 AI6 SCALED 20000 = 20
09.06 DS MCW 0 ... 65535
Control Word (CW) of the Main Reference Dataset received from (Decimal)
the master station through the fieldbus interface
09.07 MASTER REF1 Reference 1 (REF1) of the Main Reference Dataset received from -32768 ...
the master station through the fieldbus interface 32767
09.08 MASTER REF2 Reference 2 (REF2) of the Main Reference Dataset received from -32768 ...
the master station through the fieldbus interface 32767
09.09 AUX DS VAL1 Reference 3 (REF3) of the Auxiliary Reference Dataset received -32768 ...
from the master station through the fieldbus interface 32767
Table 4-3 Relevant Drive Parameters/Selections
Index Name/Selection Description FbEq

10 START/STOP/DIR The sources for external start, stop and direction control
10.01 EXT1
STRT/STP/DIR Defines the connections and the source of the start, stop and direction
commands for external control location 1 (EXT1).
NOT SEL No start, stop and direction command source. 1
DI1 Start and stop through digital input DI1. 0 = stop; 1 = start. Direction is
fixed according to parameter 10.3 DIRECTION.
WARNING! After a fault reset, the drive will start if the start signal is
ON. 2
DI1, 2 Start and stop through digital input DI1. 0 = stop, 1 = start. Direction
through digital input DI2. 0 = forward, 1 = reverse. To control direction,
parameter 10.03 DIRECTION must be REQUEST.
WARNING! After a fault reset, the drive will start if the start signal is
ON. 3
DI1P, 2P Pulse start through digital input DI1. 0 -> 1: Start. Pulse stop through
digital input DI2. 1 -> 0: Stop. Direction of rotation is fixed according to
parameter 10.03 DIRECTION. 4
DI1P, 2P, 3 Pulse start through digital input DI1. 0 -> 1: Start. Pulse stop through
digital input DI2. 1 -> 0: Stop. Direction through digital input DI3. 0 =
forward, 1 = reverse. To control direction, parameter 10.03 DIRECTION
must be REQUEST. 5
DI1P, 2P, 3P Pulse start forward through digital input DI1. 0 -> 1: Start forward. Pulse
start reverse through digital input DI2. 0 -> 1: Start reverse. Pulse stop
through digital input DI3. 1 -> .0.: stop. To control the direction,
parameter 10.03 DIRECTION must be REQUEST. 6
DI6 See selection DI1. 7
DI6, 5 See selection DI1, 2. 8
KEYPAD Control panel. To control the direction, parameter 10.03 DIRECTION
must be REQUEST. 9
COMM.CW Fieldbus Control Word. 10
DI7 See selection DI1 11
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DI7, 8
See selection DI1, 2. 12
DI7P, 8P
See selection DI1P, 2P. 13
DI7P, 8P, 9 See selection DI1P, 2P, 3. 14
DI7P, 8P, 9P See selection DI1P, 2P, 3P. 15
PARAM 10.04 Source selected by 10.04 16
10.02 EXT2 Defines the connections and the source of the start, stop and direction
STRT/STP/DIR commands for external control location 2 (EXT2).
NOT SEL See parameter 10.01. 1
DI1 See parameter 10.01. 2
DI1, 2 See parameter 10.01. 3
DI1P, 2P See parameter 10.01. 4
DI1P, 2P, 3 See parameter 10.01. 5
DI1P, 2P, 3P See parameter 10.01. 6
DI6, 5 See parameter 10.01. 8
KEYPAD See parameter 10.01. 9
COMM.CW See parameter 10.01. 10
DI7,8 See parameter 10.01. 12
DI7P, 8P See parameter 10.01. 13
DI7P, 8P, 9 See parameter 10.01. 14
DI7P, 8P, 9P See parameter 10.01. 15
PARAM 10.05 Source selected by 10.05 16
10.03 DIRECTION Enables the control of direction of rotation of the motor, or fixes the
direction.
FORWARD Fixed to forward 1
REVERSE Fixed to reverse 2
REQUEST Direction of rotation control allowed 3
11 REFERENCE Panel reference type, external control location selection and external
SELECT reference sources and limits
11.01 KEYPAD REF SEL Selects the type of the reference given from panel.
REF1(rpm) Speed reference in rpm. (Frequency reference (Hz) if parameter 99.04
is SCALAR.) 1
REF2(%) %-reference. The use of REF2 varies depending on the application
macro. For example, if the Torque Control macro is selected, REF2 is
the torque reference. 2
11.02 EXT1/EXT2 SELECT Defines the source from which the drive reads the signal that selects
between the two external control locations, EXT1 or EXT2.
DI1 thru DI6 Digital input DI1 – D6. 0=EXT1, 1=EXT2 1-6
EXT1
Decel Time 2 7
EXT2
Sp.ref interp TC 8
COMM.CW(11) Fieldbus Control Word, bit 11. 9
DI7 thru DI12 See selection DI1 10-15
PARAM 11.09 Source selected by parameter 11.09. 16
11.03 EXT REF1 SELECT Selects the signal source for external reference REF1
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KEYPAD Control panel. The first line on the display shows the reference value. 1
VARIOUS AI and
JOYSTICK SELECTIONS See parameter 11.03 2-19, 21-38
COMM. REF See parameter 11.03. 20
11.04 EXT REF1 Defines the minimum value for external reference REF1 (absolute
MINIMUM value). Corresponds to the minimum setting of the source signal used.
0… 18000 rpm Setting range in rpm. (Hz if parameter 99.04 is SCALAR.)
Example: Analogue input AI1 is selected as the reference source
(value of parameter 11.03 is AI1). The reference minimum and
maximum correspond the AI minimum and maximum settings as
follows:
EXT REF1 Range
Note: If the reference is given through fieldbus, the scaling differs from
that of an analogue signal. See the chapter Fieldbus control for more
information. 1 … 18000
11.05 EXT REF1 Defines the maximum value for external reference REF1 (absolute
MAXIMUM value). Corresponds to the maximum setting of the used source signal.
0 ... 18000 rpm Setting range. (Hz if value of parameter 99.04 is SCALAR.)
See parameter 11.04. 1 . 18000 1... 18000
12 CONSTANT Constant speed selection and values. An active constant speed
SPEEDS overrides the drive speed reference.
Note: If parameter 99.04 is SCALAR, the constant speeds are given in
Hertz and only speeds 1 to 5 and speed 15 are in use.
********** GROUP NOT TYPICALLY USED IN NOI APPLICATIONS **********
13 ANALOGUE
INPUTS The analogue input signal processing
14 RELAY OUTPUTS Status information indicated through the relay outputs, and the relay
operating delays
14.01 RELAY RO1 Selects a drive status indicated through relay output RO1. The relay
OUTPUT energizes when the status meets the setting.
NOT USED Not used. 1
READY Ready to function: Run Enable signal on, no fault. 2
RUNNING Running: Start signal on, Run Enable signal on, no active fault. 3
FAULT Fault 4
FAULT(-1) Inverted fault. Relay is de-energized on a fault trip. 5
FAULT(RST) Fault. Automatic reset after the autoreset delay. See parameter group
31 AUTOMATIC RESET. 6
STALL WARN Warning by the stall protection function. See parameter 30.10. 7
STALL FLT Fault trip by the stall protection function. See parameter 30.10. 8
MOT TEMP WRN Warning trip of the motor temperature supervision function. See
parameter 30.04. 9
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MOT TEMP FLT Fault trip of the motor temperature supervision function. See parameter
30.04. 12\0
ACS TEMP WRN Warning by the drive temperature supervision function: 115 °C (239°F). 11
ACS TEMP FLT Fault trip by the drive temperature supervision function: 125 °C(257°F). 12
FAULT/WARN Fault or warning active 13
WARNING Warning active 14
REVERSED Motor rotates in reverse direction. 15
EXT CTRL Drive is under external control. 16
REF 2 SEL External reference REF 2 is in use. 17
CONST SPEED A constant speed is in use. See parameter group 12 CONSTANT
SPEEDS. 18
DC OVERVOLT The intermediate circuit DC voltage has exceeded the overvoltage limit. 19
DC UNDERVOLT The intermediate circuit DC voltage has fallen below the undervoltage
limit. 20
SPEED 1 LIM Motor speed at supervision limit 1. See parameters 32.01 and 32.02. 21
SPEED 2 LIM Motor speed at supervision limit 2. See parameters 32.03 and 32.04. 22
CURRENT LIM Motor current at the supervision limit. See parameters 32.05 and 32.06. 23
REF 1 LIM External reference REF1 at the supervision limit. See parameters 32.11
and 32.12. 24
REF 2 LIM External reference REF2 at the supervision limit. See parameters 32.13
and 32.14. 25
TORQUE 1 LIM Motor torque at supervision limit 1. See parameters 32.07 and 32.08. 26
TORQUE 2 LIM Motor torque at supervision limit 2. See parameters 32.09 and 32.10. 27
STARTED The drive has received the start command. 28
LOSS OF REF The drive has no reference. 29
AT SPEED The actual value has reached the reference value. In speed control, the
speed error is less or equal to 10% of the nominal motor speed. 30
ACT 1 LIM Process PID controller variable ACT1 at the supervision limit. See
parameters 32.15 and 32.16. 31
ACT 2 LIM Process PID controller variable ACT2 at the supervision limit. See
parameters 32.17 and 32.18. 32
COMM.REF3(13) The relay is controlled by fieldbus reference REF3. See the chapter
Fieldbus control. 33
BRAKE CTRL On/Off control of a mechanical brake. See parameter group 42 BRAKE
CONTROL. 35
14.02 RELAY RO2 Selects the drive status to be indicated through relay output RO2. The
OUTPUT relay energizes when the status meets the setting.
SELECTIONS SAME AS
14.01 See parameter 14.01. 1-32
COMM. REF3(14) See parameter 14.01. 33
BRAKE CTRL See parameter 14.01. 35
14.03 RELAY RO3 Selects the drive status to be indicated through relay output RO3. The
OUTPUT relay energizes when the status meets the setting.
SELECTIONS SAME AS
14.01 See parameter 14.01. 1-3, 5-30
FAULT See parameter 14.01 4
MAGN READY The motor is magnetized and ready to give nominal torque (nominal
magnetizing of the motor has been reached). 31
USER 2 SEL User Macro 2 is in use. 32
COMM. REF3(15) See parameter 14.01. 33
BRAKE CTRL See parameter 14.01. 35
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15 ANALOGUE Selection of the actual signals to be indicated through the analogue

OUTPUTS outputs. Input signal processing.
16 SYSTEM CTRL
INPUTS Run Enable, parameter lock etc.
16.01 RUN ENABLE Sets the Run Enable signal on, or selects a source for the external Run
Enable signal. If Run Enable signal is switched off, the drive will not
start or stops if it is running. The stop mode is set by parameter 21.07.
YES Run Enable signal is on 1
DI1 External signal required through digital input DI1. 1 = Run Enable. 2
DI2 thru DI12 See selection DI1. 3-7, 9-14
COMM.CW(3) External signal required through the Fieldbus Control Word (bit 3). 8
16.04 FAULT RESET SEL Selects the source for the fault reset signal. The signal resets the drive
after a fault trip if the cause of the fault no longer exists.
NOT SEL Fault reset only from the control panel keypad (RESET key).
1
DI1 Reset through digital input DI1 or by control panel:
- If the drive is in external control mode: Reset by a rising edge of DI1.
- If the drive is in local control mode: Reset by the RESET key of the
control panel. 2
DI2 thru DI12 See selection DI1. 2-7, 10-15
COMM.CW(7) Reset through the fieldbus Control Word (bit 7), or by the RESET key of
the control panel. 8
ON STOP Reset along with the stop signal received through a digital input, or by
the RESET key of the control panel. 9
20 LIMITS Drive operation limits.
20.01 MINIMUM SPEED Defines the allowed minimum speed. The limit cannot be set if
parameter 99.04 = SCALAR.
Note: The limit is linked to the motor nominal speed setting i.e.
parameter 99.08. If 99.08 is changed, the default speed limit will also
change.
-18000 / (no. of pole pairs) . Minimum speed limit
Par. 20.02 rpm 1 = 1 rpm
20.02 MAXIMUM SPEED Defines the allowed maximum speed. The value cannot be set if
Note: The limit is linked to the motor nominal speed setting i.e.
parameter 99.08. If 99.08 is changed, the default speed limit will also
change.
-18000 / (no. of pole pairs) . Maximum speed limit

Par. 20.01 rpm 1 = 1 rpm
20.03 MAXIMUM Defines the allowed maximum motor current in percent of the rated
CURRENT heavy-duty use output current (I2hd).
0.0… 200.0% · Ihd Current limit 0… 20000
20.04 TORQ MAX LIM1 Defines the maximum torque limit 1 for the drive.
0.0… 600.0% Value of limit in percent of motor nominal torque. 0… 60000
20.05 OVERVOLTAGE Activates or deactivates the overvoltage control of the intermediate DC
CTRL link. Fast braking of a high inertia load causes the voltage to rise to the
overvoltage control limit. To prevent the DC voltage from exceeding the
limit, the overvoltage controller automatically decreases the braking
torque.
Note: If a brake chopper and resistor are connected to the drive, the
controller must be off (selection NO) to allow chopper operation.
OFF Undervoltage control deactivated. 0
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ON Undervoltage control activated. 65535

20.07 MINIMUM FREQ Defines the minimum limit for the drive output frequency. The limit can
be set only parameter 99.04 = SCALAR.
-300.00 . 50 Hz Minimum frequency limit. -30000 .
Note: If the value is positive, the motor cannot be run in the reverse 5000
direction.
20.08 MAXIMUM FREQ Defines the maximum limit for the drive output frequency. The limit can
be set only if parameter 99.04 = SCALAR
-50… 300.00 Hz -5000 .
Maximum frequency limit 30000
20.11 P MOTORING LIM Defines the allowed maximum power fed by the inverter to the motor.
0… 600% Power limit in percent of the motor nominal power 0… 60000
20.12 P GENERATING
LIM Defines the allowed maximum power fed by the motor to the inverter.
-600… 0%
Power limit in percent of the motor nominal power -60000 . 0
20.13 MIN TORQ SEL Selects the minimum torque limit for the drive.
MIN LIM1 Value of parameter 20.15. 1
DI1 Digital input DI1. 0: Value of parameter 20.15. 1: Value of parameter
20.16. 2
DI2 thru DI12 See selection DI1. 3-13
AI1 Analogue input AI1. See parameter 20.20 on how the signal is
converted to a torque limit. 14
AI2 thru AI6 See selection AI1. 15-18
PARAM 20.18 Limit given by 20.18 19
NEG MAX TORQ Inverted maximum torque limit defined by parameter 20.14 20
20.14 MAX TORQ SEL Defines the maximum torque limit for the drive.
MAX LIM1 Value of parameter 20.14. 1
DI1 Digital input DI1. 0: Value of parameter 20.04. 1: Value of parameter
20.17. 2
AI1 Analogue input AI1. See parameter 20.20 on how the signal is
converted to a torque limit. 14
AI2 See selection AI1. 15-18
PARAM 20.19 Limit given by 20.19 19
20.15 TORQ MIN LIM1 Defines the minimum torque limit 1 for the drive.
-600.0… 0.0% Value of limit in percent of motor nominal torque 0… 60000
21 START/STOP Start and stop modes of the motor.
21.01 START FUNCTION Selects the motor starting method.
AUTO Automatic start guarantees optimal motor start in most cases. It
includes the flying start function (starting to a rotating machine) and the
automatic restart function (stopped motor can be restarted immediately
without waiting the motor flux to die away). The drive motor control
program identifies the flux as well as the mechanical state of the motor
and starts the motor instantly under all conditions.
Note: If parameter 99.04 = SCALAR, no flying start or automatic restart
is possible by default. The flying start feature needs to be activated
separately by parameter 21.08. 1
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DC MAGN DC magnetizing should be selected if a high break-away torque is

required. The drive pre-magnetizes the motor before the start. The pre-
magnetizing time is determined automatically, being typically 200 ms to
2 s depending on the motor size. DC MAGN guarantees the highest
possible break-away torque.
Note: Starting to a rotating machine is not possible when DC
magnetizing is selected.
Note: DC magnetizing cannot be selected if parameter 99.04 =
SCALAR. 2
CNST DC MAGN Constant DC magnetizing should be selected instead of DC
magnetizing if constant pre-magnetizing time is required (e.g. if the
motor start must be simultaneous with a mechanical brake release).
This selection also guarantees the highest possible break-away torque
when the pre-magnetizing time is set long enough. The pre-
magnetizing time is defined by parameter 21.02.
Note: Starting to a rotating machine is not possible when DC
magnetizing is selected.
Note: DC magnetizing cannot be selected if parameter 99.04 =
SCALAR.
WARNING! The drive will start after the set magnetizing time
has passed although the motor magnetization is not completed. Ensure
always in applications where a full break-away torque is essential, that
the constant magnetizing time is long enough to allow generation of full
magnetization and torque. 3
21.02 CONST MAGN TIME Defines the magnetizing time in the constant magnetizing mode. See
parameter 21.01. After the start command, the drive automatically pre-
magnetizes the motor the set time.
30.0… 10000.0 ms Magnetising time. To ensure full magnetising, set this value to the same
value as or higher than the rotor time constant. If not known, use the
rule-of-thumb value given in the table below:
30… 10000
21.03 STOP FUNCTION Selects the motor stop function.
COAST Stop by cutting of the motor power supply. The motor coasts to a stop.
WARNING! If the mechanical brake control function is on, the

application program uses ramp stop in spite of the selection COAST
(see parameter group 42 BRAKE CONTROL). 1
RAMP Stop along a ramp. See parameter group 22 ACCEL/DECEL. 2
21.07 RUN ENABLE Selects the stop mode applied when the Run Enable signal is switched
FUNC off. The Run Enable signal is put into use by parameter 16.01.
Note: The setting overrides the normal stop mode setting (parameter
21.03) when the Run Enable signal is switched off.
WARNING! The drive will restart after the Run Enable signal
restores (if the start signal is on).
RAMP STOP The application program stops the drive along the deceleration ramp
defined in group 22 ACCEL/DECEL. 1
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COAST STOP The application program stops the drive by cutting off the motor power
supply (the inverter IGBTs are blocked). The motor rotates freely to
zero speed.
WARNING! If the brake control function is on, the application

program uses ramp stop in spite of the selection COAST STOP (see
parameter group 42 BRAKE CONTROL). 2
OFF2 STOP The application program stops the drive by cutting off the motor power
supply (the inverter IGBTs are blocked). The motor rotates freely to
zero speed. The drive will restart only when the Run Enable signal is on
and the start signal is switched on (the program receives the rising
edge of the start signal). 3
OFF3 STOP The application program stops the drive along the ramp defined by
parameter 22.07. The drive will restart only when the Run Enable is on
and the start signal is switched on (the program receives the rising
edge of the start signal). 4
21.09 START INTRL
FUNC
OFF2 STOP Drive running: 1 = Normal operation. 0 = Stop by coasting.
Drive stopped: 1 = Start allowed. 0 = No start allowed.
Restart after OFF2 STOP: Input is back to 1 and the drive receives
rising edge of the Start signal. 1
OFF3 STOP Drive running: 1 = Normal operation. 0 = Stop by ramp. The ramp time
is defined by parameter 22.07 EM STOP RAMP.
Drive stopped: 1 = Normal start. 0 = No start allowed.
Restart after OFF3 STOP: Start Interlock input = 1 and the drive
receives rising edge of the Start signal. 2
22 ACCEL/DECEL Acceleration and deceleration times.
22.01 ACC/DEC SEL Selects the active acceleration/deceleration time pair.
ACC/DEC 1 Acceleration time 1 and deceleration time 1 are used. See parameters
22.02 and 22.03. 1
ACC/DEC 2 Acceleration time 2 and deceleration time 2 are used. See parameters
22.04 and 22.05. 2
DI1 Acceleration/deceleration time pair selection through digital input DI1. 0
= Acceleration time 1 and deceleration time 1 are in use. 1 =
Acceleration time 2 and deceleration time 2 are in use. 3
PAR 22.08&09 Acceleration and deceleration times given by parameters 22.08 and
22.09 15
22.02 ACCEL TIME 1 Defines the acceleration time 1 i.e. the time required for the speed to
change from zero to the maximum speed.
- If the speed reference increases faster than the set acceleration rate,
the motor speed will follow the acceleration rate.
- If the speed reference increases slower than the set acceleration rate,
the motor speed will follow the reference signal.
- If the acceleration time is set too short, the drive will automatically
prolong the acceleration in order not to exceed the drive operating
limits.
0.00… 1800.00 s Acceleration time 0… 18000
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22.03 DECEL TIME 1 Defines the deceleration time 1 i.e. the time required for the speed to
change from the maximum (see parameter 20.02) to zero.
- If the speed reference decreases slower than the set deceleration
rate, the motor speed will follow the reference signal.
- If the reference changes faster than the set deceleration rate, the
motor speed will follow the deceleration rate.
- If the deceleration time is set too short, the drive will automatically
prolong the deceleration in order not to exceed drive operating limits. If
there is any doubt about the deceleration time being too short, ensure
that the DC overvoltage control is on (parameter 20.05).
Note: If a short deceleration time is needed for a high inertia
application, the drive should be equipped with an electric braking option
e.g. with a brake chopper and a brake resistor.
0.00… 1800.00 s Deceleration time 0… 18000
22.07 EM STOP RAMP Defines the time inside which the drive is stopped if
TIME - the drive receives an emergency stop command or
- the Run Enable signal is switched off and the Run Enable function has
value OFF3 (see parameter 21.07).
The emergency stop command can be given through a fieldbus or an
Emergency Stop module (optional). Consult the local ABB
representative for more information on the optional module and the
related settings of the
Standard Application Program
0.00… 2000.00 s Deceleration time 0… 200000

27 BRAKE Control of the brake chopper. For more information, see the Brake
CHOPPER Chopper User's Manual (code: 3AFE 64273507 [English])
27.01 BRAKE CHOPPER
CTL Activates the brake chopper control.
OFF Inactive 0
ON Active. Note: Ensure the brake chopper and resistor are installed and
the overvoltage control is switched off (parameter 20.05). 6553
30 FAULT Programmable protection functions
FUNCTIONS
30.10 STALL FUNCTION Selects how the drive reacts to a motor stall condition. The protection
wakes up if:
- the motor torque is at the internal stall torque limit (not user-
adjustable)
- the output frequency is below the level set by parameter 30.11 and
- the conditions above have been valid longer than the time set by
parameter
30.12.
FAULT The drive trips on a fault. 1
WARNING The drive generates a warning. The indication disappears in half of the
time set by parameter 30.12. 2
NO Protection is inactive. 3
30.17 EARTH FAULT Activates the motor phase loss supervision function
WARNING The drive generates a warning. 0
FAULT The drive trips on a fault. 65535
30.18 COMM FLT FUNC Selects how the drive reacts in a fieldbus communication break, i.e.
when the drive fails to receive the Main Reference Data Set or the
Auxiliary Reference Data Set. The time delays are given by parameters
30.19 and 30.21.
FAULT Protection is active. The drive trips on a fault and stops the motor as
defined by parameter 21.03. 1
NO Protection is inactive. 2
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CONST SP 15 Protection is active. The drive generates a warning and sets the speed
to the value defined by parameter 12.16.
WARNING! Make sure that it is safe to continue operation in

case of a communication break. 3
LAST SPEED Protection is active. The drive generates a warning and freezes the
speed to the level the drive was operating at. The speed is determined
by the average speed over the previous 10 seconds.
WARNING! Make sure that it is safe to continue operation in

case of a communication break. 4
42 BRAKE Control of a mechanical brake. The function operates on a 100 ms time
CONTROL level. For the function description, see the chapter Program features.
42.01 BRAKE CTRL Activates the brake control function.
OFF Inactive 1
ON Active 2
42.02 BRAKE Activates the external brake on/off supervision and selects the source
ACKNOWLEDGE for the signal. The use of the external on/off supervision signal is
optional.
OFF Inactive 1
DI5 Active. Digital input DI5 is the signal source. DI5 = 1: The brake is
open. DI5 = 0: the brake is closed. 2
DI6 See DI5. 3
DI11 See DI5. 4
DI12 See DI5. 5
42.07 START TORQ REF Selects the source for the motor starting torque reference applied at the
SEL brake release. The value is read in percent of the motor nominal torque.
NO No source selected. This is the default value 1
AI1 Analogue input AI1 2
AI2-AI6 Analogue input AI2-6 3-6
PAR 42.08 Defined by parameter 42.08. 7
42.08 START TORQ REF Defines the motor starting torque at brake release if parameter 42.07
has value PAR 40.28.
-300… 300% Torque value in percent of the motor nominal torque -30000… 30000
50 ENCODER Encoder connection. Visible only when a pulse encoder module
MODULE (optional) is installed and activated by parameter 98.01.
The settings will remain the same even though the application macro is
changed.
50.01 PULSE NR States the number of encoder pulses per one revolution.
0… 29999 ppr Pulse number in pulses per round (ppr) 0… 29999
50.02 SPEED MEAS
MODE Defines how the encoder pulses are calculated.
A -B DIR Channel A: positive edges calculated for speed. Channel B: direction.
1
A - Channel A: positive and negative edges calculated for speed. Channel
B: not used. 2
A - B DIR Channel A: positive and negative edges are calculated for speed.
Channel B: direction. 3
A - B - All edges of the signals are calculated. 4
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50.03 ENCODER FAULT Defines the operation of the drive if a failure is detected in
communication between the pulse encoder and the pulse encoder
interface module, or between the module and the drive. Encoder
supervision function activates if either of the following conditions is
valid:
-There is a 20% difference between the estimated speed and the
measured speed received from the encoder.
- No pulses are received from the encoder within the defined time (see
parameter 50.04) and the motor torque is at the allowed maximum
value.
WARNING The drive generates a warning indication. 1
FAULT The drive trips on a fault, gives a fault indication and stops the motor. 65535
50.05 ENCODER DDCS Defines the fibre optic channel of the control board from which the drive
CHANNEL program reads the signals coming from the pulse encoder interface
module. The setting is valid only if the module is connected to the drive
via the DDCS link ( i.e. not to the option slot of the drive).
CHANNEL 1 Signals via channel 1 (CH1). The pulse encoder interface module must
be connected to CH1 instead of CH2 in applications where CH2 is
reserved by a Master station (e.g. a Master/Follower application). See
also parameter 70.03. 1
CHANNEL 2 Signals via channel 2 (CH2). Can be used in most cases. 2
50.06 SPEED FB SEL Defines the speed feedback value used in control.
INTERNAL Calculated speed estimate
ENCODER Actual speed measured with an encoder 65535
51 The parameters are visible and need to be adjusted, only when a
COMMUNICATION fieldbus adapter module (optional) is installed and activated by
parameter 98.02. For details on the parameters, refer to the manual of
MODULE the fieldbus module. These parameter settings will remain the same
even though the macro is changed.
52 STANDARD The settings for the Standard Modbus Link. See the chapter Fieldbus
MODBUS control.
60 MASTER/ Master/Follower application. For more information, see the chapter
FOLLOWER Program features and a separate Master/Follower Application Guide.
60.01 MASTER LINK Defines the role of the drive on the Master/Follower link.
MODE
NOT IN USE The Master/Follower link is not active. 1
MASTER Master drive 2
FOLLOWER Follower drive 3
70 DDCS CONTROL Settings for the fibre optic channels 0, 1 and 3.
70.01 CHANNEL 0 ADDR Defines the node address for channel 0. No two nodes on-line may
have the same address. The setting needs to be changed when a
master station is connected to channel 0 and it does not automatically
change the address of the slave. Examples of such masters are an
ABB Advant Controller or another drive.
1… 125 Address. 1… 125
70.02 CHANNEL 3 ADDR Node address for channel 3. No two nodes on-line may have the same
address. Typically the setting needs to be changed when the drive is
connected in a ring which consists of several drives and a PC with the
DriveWindow® program running.
1… 254 Address. 1… 254
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70.03 CH1 BAUDRATE The communication speed of channel 1. Typically the setting needs to
be changed only if the pulse encoder interface module is connected to
channel 1 instead of channel 2. Then the speed must be changed to 4
Mbits. See also parameter 50.05.
8 Mbits 8 megabits per second 0
70.04 CH0 DDCS HW
CONN Selects the topology of the channel 0 link
RING Devices are connected in a ring. 0
STAR Devices are connected in a star. 1
83 ADAPT PROG Control of the Adaptive Program execution. For more information, see
CTRL the Adaptive Program Application Guide (code: 3AFE 64527274
[English]).
83.01 ADAPT PROG CMD Selects the operation mode for the Adaptive Program.
STOP Stop. The program cannot be edited.
START Run. The program cannot be edited.
EDIT Stop to edit mode. Program can be edited.
****NOTE: Edit mode must be selected on the target and source when
trying to download an adaptive program.*****
84 ADAPTIVE - selections of the function blocks and their input connections.
PROGRAM - diagnostics
THIS GROUP SHALL NOT BE ALTERED BY ANY PERSONS
********** **********
OTHER THAN QUALIFIED NOI PERSONEL
84 ADAPTIVE Storage of the Adaptive Program constants and messages.
PROGRAM
THIS GROUP SHALL NOT BE ALTERED BY ANY PERSONS
********** **********
OTHER THAN QUALIFIED NOI PERSONEL
98 OPTION
MODULES
98.01 ENCODER Activates the communication to the optional pulse encoder module. See
MODULE also parameter group 50 ENCODER MODULE.
NTAC Communication active. Module type: NTAC module. Connection
interface: Fibre optic DDCS link.
Note: Module node number must be set to 16. 1
NO Inactive 2
RTAC-SLOT1 Communication active. Module type: RTAC. Connection interface:
Option slot 1 of the drive 3
RTAC-SLOT2 Communication active. Module type: RTAC. Connection interface:
Option slot 2 of the drive. 4
RTAC-DDCS Communication active. Module type: RTAC. Connection interface:
Option module rack of the drive (communicates with the drive through a
fibre optic DDCS link).
Note: Module node number must be set to 16. 5
98.02 COMM. MODULE
LINK Activates the external serial communication and selects the interface.
NO No communication 1
FIELDBUS The drive communicates via a fieldbus adapter module in option slot 1
of the drive, or via CH0 on the RDCO board. See also parameter group
51 COMMUNICATION MODULE. 2
ADVANT The drive communicates with an ABB Advant OCS system via CH0 on
the RDCO board (optional). See also parameter group 70 DDCS
CONTROL. 3
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STD MODBUS The drive communicates with a Modbus controller via the Modbus
Adapter Module (RMBA) in option slot 1 of the drive. See also
parameter 52 STANDARD MODBUS. 4
CUSTOMISED The drive communicates via a customer specified link. The control
sources are defined by parameters 90.04 and 90.05. 5
99 START-UP DATA Language selection. Definition of motor set-up data.
99.01 LANGUAGE Selects the display language.
ENGLISH(AM) American English. If selected, the unit of power used is HP instead of
kW. 1
99.02 APPLICATION Selects the application macro. See the chapter Application macros for
MACRO more information.
Note: When you change the default parameter values of a macro, the
new settings become valid immediately and stay valid even if the power
of the drive is switched off and on. However, backup of the default
parameter settings (factory settings) of each standard macro is still
available. See parameter 99.03.
FACTORY Factory for basic applications 1

HAND/AUTO Two control devices are connected to the drive:
- device 1 device communicates through the interface defined by
external control location EXT1.
- device 2 communicates through the interface defined by external
control location EXT2.
- EXT1 or EXT2 is active at a time. Switching through a digital input. 2
PID-CTRL PID control. For application in which the drive controls a process value.
E.g. pressure control by the drive running the pressure boost pump.
Measured pressure and the pressure reference are connected to the
drive. 3
T-CTRL Torque Control macro
****Note this selection is set on the slave drive, if application utilizes the
master/slave drive arrangement**** 4
SEQ CTRL Sequential Control macro. For applications that are frequently run
through a pre-defined speed pattern (constant speeds and acceleration
and deceleration ramps). 5
USER 1 LOAD User 1 macro loaded into use. Before loading, check that the saved
parameter settings and the motor model are suitable for the application. 6
USER 1 SAVE Save User 1 macro. Stores the current parameter settings and the
motor model.
Note: There are parameters that are not included in the macros. See
parameter 99.03. 7
USER 2 LOAD User 2 macro loaded into use. Before loading, check that the saved
parameter settings and the motor model are suitable for the application. 8
USER 2 SAVE Save User 2 macro. Stores the current parameter settings and the
motor model.
Note: There are parameters that are not included in the macros. See
parameter 99.03. 9
99.05 MOTOR NOM Defines the nominal motor voltage. Must be equal to the value on the
VOLTAGE motor rating plate
½… 2 · UN Voltage. Allowed range is 1/2… 2 · UN of the drive 1=1V

99.06 MOTOR NOM Defines the nominal motor current. Must be equal to the value on the
CURRENT motor rating plate.
Note: Correct motor run requires that the magnetizing current of the
motor does not exceed 90 percent of the nominal current of the
inverter.
0… 2 · I2hd Allowed range: 1/6 . 2 · I2hd of ACS800 (parameter 99.04 = DTC).
Allowed range: 0 . 2 · I2hd of ACS800 (parameter 99.04 = SCALAR). 1 = 0.1 A
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99.07 MOTOR NOM FREQ Defines the nominal motor frequency.

8… 300 Hz Nominal frequency (50 or 60 Hz typically) 800… 30000
99.08 MOTOR NOM Defines the nominal motor speed. Must be equal to the value on the
SPEED motor rating plate. The motor synchronous speed or another
approximate value must not be given instead!
Note: If the value of parameter 99.08 is changed, the speed limits in
parameter group 20 LIMITS change automatically as well.
1… 18000 rpm Nominal motor speed 1… 18000
99.09 MOTOR NOM Defines the nominal motor power. Set exactly as on the motor rating
POWER plate.
0... 9000 kW Nominal motor power 0… 90000
99.10 MOTOR ID RUN Selects the type of the motor identification. During the identification, the
drive will identify the characteristics of the motor for optimum motor
control. The ID Run Procedure is described in the chapter Start-up; and
control through the I/O.
Note: The ID Run (STANDARD or REDUCED) should be selected if:
- The operation point is near zero speed, and/or
- Operation at torque range above the motor nominal torque within a
wide speed range and without any measured speed feedback is
required.
Note: The ID Run (STANDARD or REDUCED) cannot be performed if
NO No ID Run. The motor model is calculated at first start by magnetizing
the motor for 20 to 60 s at zero speed. This can be selected in most
applications. 1
STANDARD Standard ID Run. Guarantees the best possible control accuracy. The
ID Run takes about one minute.
Note: The motor must be de-coupled from the driven equipment.
Note: Check the direction of rotation of the motor before starting the ID
Run. During the run, the motor will rotate in the forward direction.
WARNING! The motor will run at up to approximately 50 . 80%

of the nominal speed during the ID Run. ENSURE THAT IT IS SAFE
TO RUN THE MOTOR BEFORE PERFORMING THE ID RUN! 2
REDUCED Reduced ID Run. Should be selected instead of the Standard ID Run:
- if mechanical losses are higher than 20% (i.e. the motor cannot be de-
coupled from the driven equipment)
- if flux reduction is not allowed while the motor is running (i.e. in case
of a motor with an integrated brake supplied from the motor teminals).
Note: Check the direction of rotation of the motor before starting the ID
Run. During the run, the motor will rotate in the forward direction.
WARNING! The motor will run at up to approximately 50 . 80%

of the nominal speed during the ID Run. ENSURE THAT IT IS SAFE
TO RUN THE MOTOR BEFORE PERFORMING THE ID RUN! 3
Designates Parameter Group
Typical NOI Application Setting
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5 INSTALLATION
This section contains guidelines for installing NOI Model 800AC VSDS systems. This installation
section is not intended to be a step-by-step procedure for installing the system, but more of an overall
guide to aid in the installation. It will be necessary to refer to system drawings and documents for
specific details about sub-systems. Once the system has been installed, the start up procedure should
be followed.
Any information not contained in this document can be found in the system manual or the system
drawings. Any personnel involved in the installation and start up of this system should read all the
documentation to before proceeding with any part of system installation and startup.
5.1 Mechanical Installation

The VSDS system should only be lifted according to the job specific requirements. The systems
may vary depending on customer requirements. Most systems are designed to be lifted either by
forklift, or crane. Most systems lifted by forklift are provided with a lifting base with forklift fork
accommodations typically in the base of the system. Systems that require a crane for movement
typically have lifting bars or eyes for overhead lifting.
Some systems will include shipping splits which are used to reduce the length and weight of the
shipping sections. It is important to ensure that the individual shipping splits are placed in the
correct orientation and bolted tightly together.
5.2 Electrical Installation

The following section provides general guidelines that should be observed before applying power
to the VSDS.
It is important to ensure the VSDS system has the adequate ground connections. For stand
alone systems installed in drilling modules, ensure that the base of the systems is seam welded to
the deck. Also ensure that the cubicle frames are bolted (with star washers if cubicles are painted
metal) properly to the system base. For systems which include a drive house, ensure that the
proper size grounding conductor is installed to the dedicated ground bus on the house.
Ensure the required control connections (encoders, profibus, fiber, etc.) are connected per the job
specific drawings. Also ensure that the shielding on these signals is correct.
The input and output power connections vary from system to system, so it is important to refer to
your job’s electrical drawings in conjunction with this manual. Table 5-1 contains main terminal
markings.
Terminal
Designator Definition Connected to
B+ Positive DC bus + DC main bus
B- Negative DC bus - DC main bus
U Inverter output phase A Motor phase A
V Inverter output phase B Motor phase B
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W Inverter output phase C Motor phase C

Table 5-1 Inverter Main Terminal Designations
Input power cables to the VSDS should be sized according to the cable schedule provided in the
document package. As a general rule, the cable insulation should be rated for 600V and a
temperature rise of 90°C. It is also recommended that multi-core, 3 conductor cable be used to
supply the input rectifiers. If not specified in the cable schedule, the ampacity of the cable should
be adequate to carry the full load of the source which supplies the VSDS. It is recommended that
multi-core, shielded VFD cable be used to connect the VSDS to the motor(s). For a 600V system,
this cable is typically rated for 2000V, and a minimum of a 90 degree Celsius temperature rise.
Be sure to consult the factory if unsure about cable sizes or ratings. See job specific drawings for
exact termination point for input and output cables.
The following list of guidelines should be observed before connecting any cable to the VSDS
1. Before connecting the motor or input cables to the VSDS, a qualified electrician or
service technician should perform insulation tests on the cable. Check both the
phase to ground insulation resistance and the phase to phase insulation resistance.
In both cases, the resistance should be equal to or greater than 1 MΩ
2. Before connecting the cables to the motors, be sure a qualified electrician or service
engineer tests the motor insulation. The phase to ground and phase-to-phase
insulation resistance should be a minimum of 1 MΩ. The test voltage should be
appropriate for the motor’s rated voltage.
3. Do not place the VSDS motor cables near other cables, such as supply or control
cables. Avoid placing the motor cables in long parallel lines with other cables
wherever possible. If motor cables are to be run along other cables, the following
table is a guideline to use for establishing minimum distance between cables:
DISTANCE BETWEEN CABLES SHIELDED CABLE

0.3m (1 foot) Less than or equal to 50m (164 feet)
1.0m (3.3 feet) Greater than 50m (164 feet)
Table 5-2 Cable Spacing Guideline
4. Wherever possible, motor cables should cross other cables at 90° angles
Special care must be given to the motor cables. They are unlike standard three phase cables.
Each motor cable contains three drain wires as well as an overall shield.
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Figure 5-1 VFD Motor Cable Drawing
The three phase conductors are connected to the inverter and motor using crimp style lugs and
stainless steel hardware (except in the case where plugs are used). The drain wires and overall
shield should be connected as per the diagram below.
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Figure 5-2 VFD Motor Cable Connection Diagram
Care should be taken to ensure that the earth cables or overall shield does not make contact with
the phase conductors. This condition will create an electrical short in the cable and damage either
the motor or the inverter. A solid connection to chassis ground must be established for the earth
cables as well as the shield wire. These wires should be connected to an unpainted surface using
crimp style lugs and stainless steel hardware. The length of these wires should be kept to the
shortest length that is possible. The three earth cables are to be connected at both the motor and
AC drives ends to provide the system earth connection. The shield armour connection only
occurs at the inverter end of the cable. The motor end of the cable is left unconnected.
It is important to ensure that all electrical cables have a tight connection. It is advisable to go over
the entire system and check each connection point for loose connections. During shipment, some
of the screws or bolts may have become loose due to vibrations.
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6 TROUBLESHOOTING
The following troubleshooting guideline is intended to act as an aid to fault tracing in the
inverter. The majority of fault tracing is done through the inverter’s keypad. The information
provided deals with the most common problems you may encounter. Therefore, a familiarity
with the drive’s keypad/LCD display and how to navigate through its various menus is
essential to being able to isolate the source of a problem.
Due to the complex and unique operating environment in which this equipment operates, it is
impossible to anticipate every possible problem and solution. If the equipment continues to
present problems, or if the type of trouble exhibited by the equipment is not covered in this
section, please contact your nearest National Oilwell representative to arrange service.
6.1 Warning and fault indications

The drive is equipped with an internal system for indicating abnormal or failure conditions. In the
event the drive detects an undesirable condition, it will display a warning or fault message on the
control panel display. The latest warnings and faults are recorded together in the Fault History
along with a time stamp identifying when the event occurred. Once the fault has been traced to
its cause and then corrected, the drive may be reset. The drive can be reset by pressing the
RESET key on the keypad, by digital input or fieldbus, or powering down the drive.
6.1.1 Programmable protection functions

AI<Min
AI<Min function defines the drive operation if an analogue input signal falls below the preset
minimum limit.
Settings
Parameter 30.01.
Panel Loss
Panel Loss function defines the operation of the drive if the control panel selected as control
location for the drive stops communicating.
Settings
Parameter 30.02.
External Fault
External Faults can be supervised by defining one digital input as a source for an external
fault indication signal.
Settings
Parameter 30.03.
Motor Thermal Protection
The motor can be protected against overheating by activating the Motor Thermal Protection
function and by selecting one of the motor thermal protection modes available.
The Motor Thermal Protection modes are based either on a motor temperature thermal
model or on an over temperature indication from a motor thermistor.
Motor temperature thermal model
The drive calculates the temperature of the motor on the basis of the following assumptions:
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1. The motor is in the ambient temperature of 30 _C when power is applied to the drive.
2. Motor temperature is calculated using either the user-adjustable or automatically
calculated motor thermal time and motor load curve (see the figures below). The load
curve should be adjusted in case the ambient temperature exceeds 30 °C.
Figure 6-1 Motor Thermal Load Curves
Use of the motor thermistor

It is possible to detect motor overtemperature by connecting a motor thermistor (PTC)
between the +24 VDC voltage supply offered by the drive and digital input DI6. In normal
motor operation temperature, the thermistor resistance should be less than 1.5 kohm
(current 5 mA). The drive stops the motor and gives a fault indication if the thermistor
resistance exceeds 4 kohm__
Settings
Parameters 30.04 to 30.09.
Note: It is also possible to use the motor temperature measurement function. See the
subsection Motor temperature measurement through the standard I/O.
Stall Protection
The drive protects the motor in a stall situation. It is possible to adjust the supervision limits
(frequency, time) and choose how the drive reacts to the motor stall condition (warning
indication / fault indication & stop the drive / no reaction).
Settings
Underload Protection
Loss of motor load may indicate a process malfunction. The drive provides an under-load
function to protect the machinery and process in such a serious fault condition. Supervision
limits – under-load curve and under-load time - can be chosen as well as the action taken by
the drive upon the under-load condition (warning indication / fault indication & stop the drive
/ no reaction).
Settings
Motor Phase Loss
The Phase Loss function monitors the status of the motor cable connection. The function is
useful especially during the motor start: the drive detects if any of the motor phases is not
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connected and refuses to start. The Phase Loss function also supervises the motor
connection status during normal operation.
Settings
Parameter 30.16.
Earth Fault Protection
The Earth Fault Protection detects earth faults in the motor, the motor cable or the inverter.
This protection is based on earth leakage current measurement with a summation current
transformer at the input of the converter with the following provisions:
• An earth fault in the mains does not activate the protection.
• In an earthed (grounded) supply, the protection activates in 200 microseconds.
• In floating mains, the mains capacitance should be 1 microfarad or more.
• The capacitive currents due to screened copper motor cables up to 300 metres do
not activate the protection.
Settings
Parameter 30.17.
Communication Fault
The Communication Fault function supervises the communication between the drive and an
external control device (e.g. a fieldbus adapter module).
Settings
Supervision of optional IO
The function supervises the use of the optional analogue and digital inputs and outputs in
the application program, and warns if the same input (output) is used for two purposes
simultaneously.
Settings
Parameter 30.22.
6.1.2 Preprogrammed faults

Overcurrent
The overcurrent trip limit for the drive is 3.5 · I2hd (rated output current, heavy-duty use
rating).
62
DC overvoltage
The DC overvoltage trip limit is 1.3 ·U1max, where U1max is the maximum value of the
mains voltage range. For 400 V units, U1max is 415 V. For 500 V units, U1max is 500
V. For 690 V units, U1max is 690 V. The actual voltage in the intermediate circuit
corresponding to the mains voltage trip level is 728 VDC for 400 V units, 877 VDC for 500 V
units, and 1210 VDC for 690 V units.
DC undervoltage
The DC undervoltage trip limit is 0.65 · U1min, where U1min is the minimum value of the
mains voltage range. For 400V and 500V units, U1min is 380V. For 690 V units, U1min is
525V. The actual voltage in the intermediate circuit corresponding to the mains voltage trip
level is 334VDC for 400V and 500V units, and 461VDC for 690V units.
Drive temperature
The drive supervises the inverter module temperature. If the inverter module temperature
exceeds 115 °C, a warning is given. The temperature trip level is 125 °C.
Short circuit
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There are separate protection circuits for supervising the motor cable and the inverter short
circuits. If a short circuit occurs, the drive will not start and a fault indication is given.
Input phase loss
Input phase loss protection circuits supervise the mains cable connection status by
detecting intermediate circuit ripple. If a phase is lost, the ripple increases. The drive is
stopped and a fault indication is given if the ripple exceeds 13%.
Ambient temperature
The drive will not start if the ambient temperature is below -5 to 0 °C or above 73 to 82 °C
(the exact limits vary within the given ranges depending on drive type).
Overfrequency
If the drive output frequency exceeds the preset level, the drive is stopped and a
fault indication is given. The preset level is 50 Hz over the operating range absolute
maximum speed limit (Direct Torque Control mode active) or frequency limit (Scalar Control
active).
Internal fault
If the drive detects an internal fault the drive is stopped and a fault indication is given.
6.1.3 Warning messages generated by the drive
Figure 6-2 Drive Warning Messages
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6.1.4 Warning messages generated by the control panel
Figure 6-3 Control Panel Warning Messages
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6.1.5 Fault messages generated by the drive
Figure 6-4 Drive Fault Messages
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7 MAINTENANCE
This section reviews general maintenance issues and provides basic guidelines for
consideration in preparing maintenance procedures. These are guidelines only however, and
all items may not apply to every rig or component part. Specific maintenance procedures
and details on replacement parts, filters, etc. are located throughout the Maintenance Manual.
Regular operating personnel may carry out preventive maintenance as outlined in the
Maintenance Manual. Specialists should perform other more complex types of maintenance.
A qualified and experienced mechanic who is familiar with the equipment and the proper use
of appropriate tools to complete each task should perform the disassembly, mechanical
inspection and repair during equipment strip down.
The National Oilwell Model 800 VSDS is designed and constructed to provide many years of
reliable and cost-effective service. The only way this can be achieved is to maintain the
equipment at optimum performance levels. The bottom line is that better maintenance equals
better performance, equals better productivity, equals longer equipment life, and in some
cases, the lives of personnel as well.
The mechanical components used to create the operating systems on this piece of equipment
have been selected to provide the most reliable yet cost-effective operation. Proper
preventative maintenance should be considered an investment in smooth field operations with
minimum downtime. Another consideration should be that when equipment is in the yard or
shop for repairs or strip-down, new parts might be installed at far less expense than when the
equipment is at a field location. In fact, if equipment is on location and the entire operation of
the platform is shut down for emergency repairs, the cost of that repair can be many times that
of a regular overhaul time repair.
Under normal operating conditions, no regular maintenance is required. For systems that are shipped
or moved regularly, it is recommended that the user check the tightness of all electrical connections
after each move is completed. In general, the equipment must be kept clean and free of dust, dirt, or
other contaminants. If the equipment is used in particularly dirty environments, it is recommended that
the equipment is shutdown periodically and cleaned. This should be done with dry, compressed air.
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8 OPERATOR SKILLS AND TRAINING

The operator shall receive on-the-job training from National Oilwell or a technician experienced in the operation of the Model 800AC VSDS.
The operator shall have experience with the types of operations that the Model 800AC VSDS is to perform. The operator shall ensure that all
safety procedures are followed while operating and maintaining the equipment. The operator shall study the available documentation during
and after training to gain an overall understanding of how the equipment operates and what the limitations of the equipment are. Any
questions about the operation and maintenance of the Model 800AC VSDS not covered in the available documentation should be referred to
National Oilwell, Inc. Additional training regarding the operation and theory of AC drives is available by contacting National Oilwell’s Training
Department at 713-935-8121.
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FINAL DOCUMENTATION
Chapter 11.0
Service Loop Jacket Installation
Instructions
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Procedure
Installation Instructions,
Jacket, Service Loop
This document contains proprietary and confidential information National Oilwell Varco
which belongs to National Oilwell Varco; it is loaned for limited Rig Solution Group
purposes only and remains the property of National Oilwell.
Reproduction, in whole or in part; or use of this design or 743 N. Eckhoff St.
distribution of this information to others is not permitted without the Orange, CA 92868 (USA)
express written consent of National Oilwell Varco. This document is Phone + 714-978-1900
to be returned to National Oilwell Varco upon request and in any
event upon completion of the use for which it was loaned.
DOCUMENT NUMBER REV
D614000166-PRO-001 02
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Document number D614000166-PRO-001
Revision 02
Page 2
REVISION HISTORY
02 9/6/2011 Material Upgrade E. Leon H. Lim H. Lim

01 5/1/08 Initial Release A. Phillips H. Lim H. Lim
CHANGE DESCRIPTION

01 First Issue
02 Material Upgrade
Note:
Old Version – Follow instructions on pages 3-12
New Version – Follow instructions on pages 13-20
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Revision 02
Page 3
Old Version
Service Loop Wrap Laid

Out for Installation
Inner Velcro Straps to

Secure Wrap to Power
Loop
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Revision 02
Page 4
Old Version
Inner Velcro Strap

Installed Around Power
Loop, 3 Places
Inner Velcro Strap

Installed Around
Power
Velcro Closure
Strap
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Page 5
Old Version
Velcro Closure
Secured Over Velcro
Strap
Lay in Control or
Auxiliary Power Loop
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Page 6
Old Version
Lay in Second Auxiliary Power

or Control Loop, and Second
Power Loop if applicable
Overlay One Side of Service

Loop Wrap over Power Loop,
Aux Power and Control Loop
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Page 7
Old Version
Velcro End
Flaps
Overlay opposite Side of Service

Loop Wrap and Lay in Between
Two Velcro
End Flaps
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Page 8
Old Version
Close End Flaps Over

Opposite Side of Service
Loop Wrap
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Page 9
Old Version
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Revision 02
Page 10
Old Version
Service Loop Wrap Secured

Around Power Loop, Aux
Power Loop and Control
Loop
Fold over Velcro End

Straps to Secure Velcro
Flaps at Each End of
Service Loop Wrap
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Page 11
Old Version
Velcro End Strap Secured

Over End Flaps
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Old Version
Install Heavy Tie Wrap

through Grommets to
Secure End Strap
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Page 13
NEW Version
Service Loop Wrap Laid

Out for Installation
Inner Velcro Straps to

Secure Wrap to Power
Loop
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Page 14
NEW Version
Inner Velcro Strap to be

Installed Around Power
Loop, 3 Places
Velcro Strap Installed

Around Power Loop
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Page 15
NEW Version
Lay in Control or
Auxiliary Power Loop
Lay in Second Auxiliary Power

or Control Loop, and Second
Power Loop if applicable
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Page 16
NEW Version
Overlay One Side of Service

Loop Wrap over Power Loop,
Aux Power and Control Loop
Velcro End
Flaps
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Page 17
NEW Version
Overlay opposite Side of Service Close End Flaps Over

Loop Wrap and Lay in Between Opposite Side of Service
Two Velcro Loop Wrap
End Flaps
Service Loop Wrap Secured

Around Power Loop, Aux
Power Loop and Control
Loop
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Page 18
NEW Version
Fold over Velcro End

Straps to Secure Velcro
Flaps at Each End of
Service Loop Wrap
Velcro End Strap Secured

Over End Flaps
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NEW Version
Use Heavy Tie Wrap

through Grommets
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NEW Version
Install Heavy Tie Wrap

through Grommets to
Secure End Strap
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FINAL DOCUMENTATION
Chapter 12.0
Reliance Manual (180-449)
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Installation, Operation and Maintenance
Of Reliance® Standard Industrial
AC Induction Motors
z 180 – 449 Frames (NEMA)
z 112 – 280 Frames (IEC)
NEXT ASSY PRODUCT
TDS-9S
it was loaned. This document and the information contained and represented herein is the TITLE USER MANUAL
copyrighted property of NOV. © National Oilwell Varco
CURRENT INITIAL RELIANCE MOTOR MANUAL

180-449 Frames (NEMA), 112-280 Frames (IEC)
DRAWN T. Harmon J. Hensley
SCALE: WT LBS: SIZE: SHT:
CHECKED H. Lim S. Hansen AV 1 OF 1
DWG NO.: REV:
APPVD H. Lim S. Hansen
VDR00029 A
DATE 07/22/2011 11/01/1996
D811000457-GEN-001/04
FINAL DOCUMENTATION
Chapter 13.0
Reliance Manual (L210-L400)
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Installation, Operation and Maintenance
Of RPM AC Inverter Duty Induction Motors
FL180 – L440 Frames
(Specifically designed for operation with
Adjustable Speed Controls)
NEXT ASSY PRODUCT
TDS-9S
it was loaned. This document and the information contained and represented herein is the TITLE USER MANUAL
copyrighted property of NOV. © National Oilwell Varco
CURRENT INITIAL BALDOR RELIANCE MOTOR MANUAL

FRAMES FL180 - L440
DRAWN T. Harmon J. Hensley
SCALE: WT LBS: SIZE: SHT:
CHECKED H. Lim S. Hansen AV 1 OF 1
DWG NO.: REV:
APPVD H. Lim S. Hansen
VDR00030 B
DATE 08/02/2011 11/01/1996
D811000457-GEN-001/04
RPM AC Inverter Duty Induction Motors
FL180 - L440 Frames
(Specifically designed for operation with
adjustable Speed Controls)
Installation & Operating Manual
9/08 MN406
Any trademarks used in this manual are the property of their respective owners.
Table of Contents
Section 1
General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
Limited Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
Safety Notice . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
Receiving . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
Handling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
Preparation for Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
Greater than 3 months . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
Greater than 18 months . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
Removal From Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
Section 2
Installation & Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Mechanical Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Stub Shaft Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Stub Shaft Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
Alignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
Doweling & Bolting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
Guarding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
Electrical Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
Thermostat Leads Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
Blower Motor Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
Grounding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
Shipping Blocks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6
Encoder Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6
Drain Plugs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6
Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6
Optional Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8
First Time Start Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10
Section 3
Maintenance & Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
General Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Relubrication & Bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Lubrication Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Type of Grease . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
Troubleshooting Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
Suggested bearing and winding RTD setting guidelines for Non-Hazardous Locations ONLY . . . . . . . . . . . . 3-4
MN406 Table of Contents i

Section 1
General Information
ii Table of Contents MN406

Section 1
General Information
Overview This manual contains general procedures that apply to BaldorReliance Motor products. Be sure to read and
understand the Safety Notice statements in this manual. For your protection, do not install, operate or attempt
to perform maintenance procedures until you understand the Warning and Caution statements.
A Warning statement indicates a possible unsafe condition that can cause harm to personnel.
A Caution statement indicates a condition that can cause damage to equipment.
Important: This instruction manual is not intended to include a comprehensive listing of all details for all
procedures required for installation, operation and maintenance. This manual describes general
guidelines that apply to most of the motor products shipped by Baldor. If you have a question
about a procedure or are uncertain about any detail, Do Not Proceed.
Please contact your Baldor District office for more information or clarification.
Before you install, operate or perform maintenance, become familiar with the following:
NEMA Publication MG‐2, Safety Standard for Construction and guide
for Selection, Installation and Use of Electric Motors and Generators.
ANSI C51.5
The National Electrical Code
Local codes and Practices
Limited Warranty
www.baldor.com/support/warranty_standard.as
Safety Notice: This equipment contains high voltage! Electrical shock can cause serious or fatal injury.
Only qualified personnel should attempt installation, operation and maintenance of electrical equipment.
Be sure that you are completely familiar with NEMA publication MG‐2, safety standards for construction and
guide for selection, installation and use of electric motors and generators, the National Electrical Code and
local codes and practices. Unsafe installation or use can cause conditions that lead to serious or fatal injury.
Only qualified personnel should attempt the installation, operation and maintenance of this equipment.
WARNING: Do not touch electrical connections before you first ensure that power has been disconnected.
Electrical shock can cause serious or fatal injury. Only qualified personnel should attempt the
installation, operation and maintenance of this equipment.
WARNING: Disconnect all electrical power from the motor windings and accessory devices before
disassembly of the motor. Electrical shock can cause serious or fatal injury.
WARNING: The Adjustable Speed Controller may apply hazardous voltages to the motor leads after power to
the controller has been turned off. Verify that the controller is incapable of delivering hazardous
voltages and that the voltage at the motor leads is zero before proceeding. Failure to observe this
precaution may result in severe bodily injury or death.
WARNING: Be sure the system is properly grounded before applying power. Do not apply AC power before
you ensure that all grounding instructions have been followed. Electrical shock can cause
serious or fatal injury. National Electrical Code and Local codes must be carefully followed.
WARNING: Avoid extended exposure to machinery with high noise levels. Be sure to wear ear protective
devices to reduce harmful effects to your hearing.
WARNING: Surface temperatures of motor enclosures may reach temperatures which can cause discomfort
or injury to personnel accidentally coming into contact with hot surfaces. When installing,
protection should be provided by the user to protect against accidental contact with hot surfaces.
Failure to observe this precaution could result in bodily injury.
WARNING: This equipment may be connected to other machinery that has rotating parts or parts that are
driven by this equipment. Improper use can cause serious or fatal injury. Only qualified
personnel should attempt to install operate or maintain this equipment.
WARNING: Do not by‐pass or disable protective devices or safety guards. Safety features are designed to
prevent damage to personnel or equipment. These devices can only provide protection if they
remain operative.
WARNING: Avoid the use of automatic reset devices if the automatic restarting of equipment can be
hazardous to personnel or equipment.
WARNING: Be sure the load is properly coupled to the motor shaft before applying power. The shaft key
must be fully captive by the load device. Improper coupling can cause harm to personnel or
equipment if the load decouples from the shaft during operation.
WARNING: Use proper care and procedures that are safe during handling, lifting, installing, operating and
maintaining operations. Improper methods may cause muscle strain or other harm.
WARNING: Incorrect motor rotation direction can cause serious or fatal injury or equipment damage. Be sure
to verify motor rotation direction before coupling the load to the motor shaft.
WARNING: Motors that are to be used in flammable and/or explosive atmospheres must display the CSA
listed logo. Specific service conditions for these motors are defined in NFPA 70 (NEC) Article 500.
MN406 General Information 1-1

Section 1
General Information
Safety Notice Continued

WARNING: Pacemaker danger - Magnetic and electromagnetic fields in the vicinity of current carrying
carrying conductors and permanent magnet motors can result result in a serious health hazard to
persons with cardiac pacemakers, metal implants, and hearing aids. To avoid risk, stay way from
the area surrounding a permanent magnet motor.
WARNING: RPM AC permanent magnet motors can induce voltage and current in the motor leads by rotating
the motor shaft. Electrical shock can cause serious or fatal injury. Therefore, do not couple the
load to the motor shaft until all motor connections have been made. During any maintenance
inspections, be sure the motor shaft will not rotate.
WARNING: Before performing any motor maintenance procedure, be sure that the equipment connected to
the motor shaft cannot cause shaft rotation. If the load can cause shaft rotation, disconnect the
load from the motor shaft before maintenance is performed. Unexpected mechanical rotation of
the motor parts can cause injury or motor damage.
WARNING: Do not use non UL/CSA listed explosion proof motors in the presence of flammable or
combustible vapors or dust. These motors are not designed for atmospheric conditions that
require explosion proof operation.
WARNING: UL Listed motors must only be serviced by UL Approved Authorized Baldor Service Centers if
these motors are to be returned to a hazardous and/or explosive atmosphere.
WARNING: Guards must be installed for rotating parts such as couplings, pulleys, external fans, and unused
shaft extensions, should be permanently guarded to prevent accidental contact by personnel.
Accidental contact with body parts or clothing can cause serious or fatal injury.
WARNING: C-Face motor is intended for mounting auxiliary equipment such as pumps and gears. When
mounted horizontally Frames FL, RL and L280C thru L360C, and frames L400D thru L4461D must
be supported by the feet and not by the C-Face on D-Flange alone. C-Face motors should be
supported by the feet and not by the C-Face. Installations requiring a horizontally mounted motor
in frames L280C - L440D must be supported by the feet as well as C-Face or D-Flange.
Failure to observe these precautions can result in bodily injury and equipment damage.
Caution: Use only a shielded motor power cable with a complete circumferential braided or copper
film/tape ground jacket around the power leads. This ground should be secured to the motor
frame from within the motor terminal box and must return without interruption to the drive ground.
In addition, if the motor and coupled equipment are not on a single common metal baseplate, it is
important to equalize the equipment ground potentials by bonding the motor frame to the coupled
equipment using a high frequency conductor such as a braided strap.
Caution: Do not over-lubricate motor as this may cause premature bearing failure.
Caution: Do not lift the motor and its driven load by the motor lifting hardware. The motor lifting hardware
is adequate for lifting only the motor. Disconnect the load (gears, pumps, compressors, or other
driven equipment) from the motor shaft before lifting the motor.
Caution: If eye bolts are used for lifting a motor, be sure they are securely tightened. The lifting direction
should not exceed a 20° angle from the shank of the eye bolt or lifting lug. Excessive lifting
angles can cause damage.
Caution: To prevent equipment damage, be sure that the electrical service is not capable of delivering more
than the maximum motor rated amps listed on the rating plate.
Caution: If a HI POT test (High Potential Insulation test) must be performed, follow the precautions and
procedure in NEMA MG1 and MG2 standards to avoid equipment damage.
Caution: Do not use an induction oven to heat noise tested bearings. Arcing between the balls and races
may damage the bearing. Failure to observe this precaution may result in equipment damage.
Caution: Do not operate motors with a roller bearing unless a radial load is applied so that damage to the
roller bearing does not occur.
Caution: RPM AC permanent magnet motors with an open enclosure, such as DP-FV, should not be used
where ferrous dust or particles may may be present . Totally enclosed permanent magnet motors
are recommended for these applications.
If you have any questions or are uncertain about any statement or procedure, or if you require additional
information please contact your Baldor District office or an Authorized Baldor Service Center.
Receiving Each BaldorReliance motor is thoroughly tested at the factory and carefully packaged for shipment.
When you receive your motor, there are several things you should do immediately.
1. Observe the condition of the shipping container and report any damage immediately to the
commercial carrier that delivered your motor.
2. Verify that the part number of the motor you received is the same as the part number listed on your
purchase order.
1-2 General Information MN406

Handling The motor should be lifted using the lifting lugs or eye bolts provided.
1. Use the lugs or eye bolts provided to lift the motor. Never attempt to lift the motor and additional
equipment connected to the motor by this method. The lugs or eye bolts provided are designed to lift
only the motor. Never lift the motor by the motor shaft or the hood of a WPII motor. If eye bolts are
used for lifting a motor, be sure they are securely tightened. The lifting direction should not exceed a
20° angle from the shank of the eye bolt. Excessive lifting angles can cause motor damage.
2. When lifting a WPII (Weather Proof Type 2) motor, do not lift the motor by inserting lifting lugs into
holes on top of the cooling hood. These lugs are to be used for hood removal only.
A spreader bar should be used to lift the motor by the cast lifting lugs located on the motor frame.
3. If the motor must be mounted to a plate with the driven equipment such as pump, compressor etc.,
it may not be possible to lift the motor alone. For this case, the assembly should be lifted by a sling
around the mounting base. The entire assembly can be lifted as an assembly for installation.
Do not lift the assembly using the motor lugs or eye bolts provided. Lugs or eye bolts are designed to
lift motor only. If the load is unbalanced (as with couplings or additional attachments) additional slings
or other means must be used to prevent tipping. In any event, the load must be secure before lifting.
Storage If the motor is not put into service immediately, the motor must be stored in a clean, dry area protected
from extremes of temperature, moisture, shock and vibration.
Storage temperatures of 15°C (50°F) to 50°C (120°F) with a maximum relative humidity of 60% must be
observed.
Preparation for Storage
Improper motor storage will result in seriously reduced reliability and failure. An electric motor that does
not experience regular usage while being exposed to normally humid atmospheric conditions is likely to
cause the bearings to rust or rust particles from surrounding surfaces to contaminate the bearings.
The electrical insulation may absorb an excessive amount of moisture leading to the motor winding
failure. The following preparations should be accomplished for storage.
1. Motors are to be kept in their original containers or provided with equivalent protection and stored in a
warehouse free from extremes in temperature, humidity, and corrosive atmosphere.
2. If unusual vibrations exist at the storage location, the motor should be protected with isolation pads.
3. Some motors have a shipping brace attached to the shaft to prevent damage during transportation.
The shipping brace, if provided, must be removed and stored for future use. The brace must be
reinstalled to hold the shaft firmly in place against the bearing before the motor is moved.
4. To avoid condensation inside the motor, do not unpack until the motor has reached room temperature.
(Room temperature is the temperature of the room in which it will be installed). The packing provides
insulation from temperature changes during transportation.
5. When the motor has reached room temperature, remove all protective wrapping material from the motor.
6. Motor space heaters (when present) are to be connected and energized whenever there is a
possibility that the storage ambient conditions will reach the dew point. Space heaters are optional.
7. Measure and record the electrical resistance of the winding insulation resistance meter. Minimum
accepted meg ohm level is 5 Meg ohms at 40°C (104°F). If resistance decreases below this level,
contact your Baldor District office. Measure and record these values every 30 days during storage.
8. All breathers and drains are to be operable while in storage and/or the moisture drain plugs removed.
The motors must be stored so the drain is at the lowest point. All breathers and automatic drains must
be operable to allow breathing at points other than through he bearing fits.
9. Coat all external machined surfaces with a rust preventing material. An acceptable product for this
purpose is Exxon Rust Ban # 392.
10. Rotate motor shaft at least 15 turns every three months during storage (more frequently if possible).
11. After the first dielectric withstand test and rotating the shaft, etc., the vapor bag should be re-sealed
by taping it closed with masking or similar tape. Also place new desiccant inside the bag before
closing. The shell should then be placed over the motor and the lag bolts replaced.
12. If a zipper-closing type bag is used instead of the heat-sealed type bag, then zip the bag closed
instead of taping it. Be sure to add new desiccant inside bag after each periodic inspection.
13. When motors are not stored in the original containers, but are removed and mounted on other
machinery, the mounting must be such that the drains and breathers and space heaters are fully
operable. In this respect the drains must be kept at the lowest point in the motor so that all
condensation can automatically drain out. Motor space heaters when present are to be energized
whenever there is a possibility that the storage ambient conditions will reach the dew point. Space
heaters are optional.
MN406 General Information 1-3

Greater than 3 months
All requirements of general preparation and short term storage apply with the following additional
requirements.
Non-Regreaseable Motors
Non-regreasable motors with “Do Not Lubricate” on the nameplate should have the motor shaft rotated
15 times to redistribute the grease within the bearing every 3 months or more often.
All Other Motor Types

Upon placing the motor into extended storage (+ 3 months) the following procedure must be performed.
1. Remove the grease drain plug, if supplied, (opposite the grease fitting) on the bottom of each bracket
prior to lubricating the motor.
2. The motor with regreasable bearing must be greased per Table 1-1 .
3. Standard RPM AC Motors in frames FL180, FL210, and FL 250 (IEC frames FDL 112, FDL132 and
FDL160) use double shielded bearings with oversized grease reservoirs that provide lifetime
lubrication with no maintenance.
4. Replace the grease drain plug after greasing.
5. The motor shaft must be rotated a minimum of 15 times after greasing.
6. Motor Shafts are to be rotated at least 15 revolutions manually every 3 months and additional grease
added every nine months per Table 1-1 to each bearing.
7. Bearings are to be greased at the time of removal from storage.
Table 1-1 Lubrication Volume (Storage)

NEMA Frame Size (IEC) Vol. in Cubic In. (cm3)
L, RL, FL280, DL, RDL,FDL180 1.0 (16)
L320 thru L360 (200-225) 1.5 (24)
L400 thru L440 (250-280) 2.5 (40)
Greater than 18 months

All requirements of general preparation and short term storage apply with the following additional
requirements.
1. Motor is to be crated in a box similar to Export Boxing but that the “shell” (sides & top of box) must be
secured to the wooden base with lag bolts (not nailed as export boxes are). This design allows the
opening and reclosing the box many times without destroying the “shell”.
2. The Motor will be sealed in an airtight vapor barrier bag with desiccant inside. This airtight bag will
give added protection during shipment of motor to the permanent storage area.
3. After the first electrical resistance of the winding insulation resistance test measurement is recorded,
the bearings are regreased, the shaft is rotated 15 turns, etc., add new desiccant inside bag before
closing the vapor bag and re-seal by taping it closed with masking or similar tape. The shell should
then be placed over the motor and the lag bolts replaced.
4. If a “zipper” type bag is used instead of a heat-sealed type bag, add new desiccant inside bag then
zip the bag closed instead of taping it.
5. Be sure to add new desiccant inside bag after each periodic inspection.
6. Minimize the accumulation of condensed water in and around the storage area.
Removal From Storage
1. Remove all packing material.
2. Measure and record the electrical resistance of the winding insulation resistance meter at the time of
removal from storage. The insulation resistance must not be less than 50% from the initial reading
recorded when the motor was placed into storage. A decrease in resistance indicates moisture in the
windings and necessitates electrical or mechanical drying before the motor can be placed into
service.
3. Regrease the bearings per Table 1-1 .
1-4 General Information MN406

Section 2
Installation & Operation
Overview Installation should conform to the National Electrical Code as well as local codes and practices. When
other devices are coupled to the motor shaft, be sure to install protective devices to prevent future
accidents. Some protective devices include, coupling, belt guard, chain guard, shaft covers etc. These
protect against accidental contact with moving parts. Machinery that is accessible to personnel should
provide further protection in the form of guard rails, screening, warning signs etc.
RPM AC motors are high performance motors specifically designed for use with adjustable frequency
controllers. The basic design includes Class H insulation, 1.0 service factor, 40°C ambient, continuous
duty. Standard enclosures are totally enclosed blower cooled, totally enclosed fan-cooled, totally
enclosed nonventilated, totally enclosed air over piggy back and drip-proof force ventilated. Many
modifications, and accessories are available. Motors are available as both induction and permanent
magnet construction. RPM AC motors are equipped with metric hardware.
It is important that motors be installed in locations that are compatible with motor enclosure and ambient
conditions. Improper selection of the motor enclosure and ambient conditions can lead to reduced
operating life of the motor.
Proper ventilation for the motor must be provided. Obstructed airflow can lead to reduction of motor life.
1. Open Drip-Proof/WPI motors are intended for use indoors where atmosphere is relatively clean, dry,
well ventilated and non-corrosive.
2. Totally Enclosed and WPII motors may be installed where dirt, moisture or dust are present and in
outdoor locations.
Note: Motors located in a damp, moist environment must have space heaters to protect against
condensation when motor is not operating.
Mechanical Installation
WARNING: C-Face motor is intended for mounting auxiliary equipment such as pumps and gears. When
mounted horizontally Frames FL, RL and L280C thru L360C, and frames L400D thru L4461D must
be supported by the feet and not by the C-Face on D-Flange alone. C-Face motors should be
supported by the feet and not by the C-Face. Installations requiring a horizontally mounted motor
in frames L280C - L440D must be supported by the feet as well as C-Face or D-Flange.
Failure to observe these precautions can result in bodily injury and equipment damage.
Caution: Do not lift the motor and its driven load by the motor lifting hardware. The motor lifting hardware
is adequate for lifting only the motor. Disconnect the load (gears, pumps, compressors, or other
driven equipment) from the motor shaft before lifting the motor.
Caution: If eye bolts are used for lifting a motor, be sure they are securely tightened. The lifting direction
should not exceed a 20° angle from the shank of the eye bolt or lifting lug. Excessive lifting
angles can cause damage.
After storage or after unpacking and inspection to see that all parts are in good condition, do the following:
1. Rotate the motor shaft by hand to be sure there are no obstructions to free rotation.
2. A motor that has been in storage for some time should be tested for moisture (dielectric withstand
insulation test) and relubricated (regreaseable type) prior to being put into service.
3. A motor with roller bearings is shipped with a shaft block. After removing the shaft block, be sure to
replace any bolts used to hold the shaft block in place during shipment that are required in service.
MN406 Installation & Operation 2-1

Table 2-2
Recommended Torque
Hole Dia. Bolt Size lb-ft for Bolt Grade
Frame
(Inch) & Thread
SAE 5 SAE 8
FL180 0.44 3/ -16 33-37 47-53
8
RL210, FL210 0.44 3/ -16 33-37 47-53
8
RL250, FL250 0.56 1/ -13 83-93 117-132
2
L280, FL280, & RL280 0.56 1/ -13 83-93 117-132
2
L320 0.69 5/ -1 1 155-176 200-249
8
L360 0.81 3/ -10 274-310 389-440
4
L400 & L440 1.06 7/ -9 434-486 616-689
8
Stub Shaft Installation

1. Turn off and lock out power to the motor.
2. Remove in-line blower motor and cover assembly by removing the Hex head cap screws on cover (if
enclosure is TEAO-Blower cooled).
NOTE: An extended blower cover maybe required when a feedback device is installed.
Contact your local Baldor District Office for assistance with an in-line blower.
3. Check the motor shaft center hole for chips, dirt, or other residue and clean as required.
4. Apply an even coat of Loctite 271 (red thread lock) to stub shaft thread.
5. Place stub shaft in motor shaft threaded hole and hand tighten.
6. Use a spanner wrench on motor shaft drive end (or alternate means of locking motor shaft), tighten
the stub shaft to 20 lb-ft.
7. Use a dial indicator with .0005” graduations, indicate the stub shaft to within .002” T.I.R., except for
Inland tachometers. Inland tachometer stub shafts must indicate to within .001” T.I.R.
8. Mount feedback device per manufacturer's instructions.
Stub Shaft Removal
1. Turn off and lock out power to the motor.
2. Remove in-line blower motor and cover assembly by removing the Hex head cap screws on cover (if
enclosure is TEAO-Blower cooled).
3. After removal of blower assembly, motor shaft will need to be locked from turning. The use of a
spanner wrench on motor drive shaft or alternate means can be used. Place an open-end wrench on
stub shaft flats and turn counter clockwise (right-hand) threads).
4. Replace blower motor and cover assembly (if TEAO - blower cooled) with the correct extended
blower cover, using the hex head cap screws previously removed.
Mounting Location
All RPM AC motors are designed to be mounted by the “Mounting Feet”.
Use appropriate hardware (not furnished).
The motor should be installed in a location compatible with the motor enclosure and specific ambient.
Allow adequate air flow clearance between the motor and any obstruction. Locate the machine where the
ambient temperature is not over 40°C or 104°F unless otherwise marked on the nameplate and where
clean air has free access to ventilating intake and outlet openings. Except for machines with a suitable
protective enclosure, the location should be clean and dry.
Note: The cooling system on (Non-Finned) frame RPM AC drip proof guarded force ventilated and totally
enclosed, blower cooled motors requires clean air to be forced through ducts which are integral to
the frame. It is important that these air passages be kept clean and that sufficient clearance be
provided on the blower motor air inlets and outlets for unrestricted flow of air.
For Drip-Proof Force Ventilated Enclosures sufficient clearance must be provided on all inlet and
outlet openings to provide for unrestricted flow of air. Separately ventilated motors with exhaust to
ambient (pipe-in only) must have at least 6 inches of clearance between the opening and adjacent
walls or floor.
2-2 Installation & Operation MN406

The motor must be securely installed to a rigid foundation or mounting surface to minimize vibration and
maintain alignment between the motor and shaft load. Failure to provide a proper mounting surface may
cause vibration, misalignment and bearing damage. All hold down bolts must be the correct grade for the
type of mounting and must be torqued to their recommended value.
Foundation caps and sole plates are designed to act as spacers for the equipment they support. If these
devices are used, be sure that they are evenly supported by the foundation or mounting surface.
When installation is complete and accurate alignment of the motor and load is accomplished, the base
should be grouted to the foundation to maintain this alignment.
The standard motor base is designed for horizontal or vertical mounting. Adjustable or sliding rails are
designed for horizontal mounting only. Consult your Baldor District Office for further information.
Belted Drive
Motor slide bases or rails, when used, must be securely anchored to the foundation with the proper bolts.
Note: The motor shaft and the load shaft must be parallel and the sheaves aligned.
Coupled Drive
Standard RPM AC Motors will operate successfully mounted on the floor, wall or ceiling, and with the
shaft at any angle from horizontal to vertical. Special mountings may have duty or thrust demands that
may require a different bearing system.
Alignment Accurate alignment of the motor with the driven equipment is extremely important.
1. Direct Coupling
For direct drive, use flexible couplings if possible. Consult the drive or equipment manufacturer for
more information. Mechanical vibration and roughness during operation may indicate poor alignment.
Use dial indicators to check alignment. The space between coupling hubs should be maintained as
recommended by the coupling manufacturer.
Note: Roller bearing motors are not suitable for coupled duty applications.
2. End‐Play Adjustment
The axial position of the motor frame with respect to its load is also extremely important. The motor
bearings are not designed for excessive external axial thrust loads. Improper adjustment will cause
failure.
3. Pulley Ratio
The pulley ratio should not exceed 8:1.
Caution: Do not over tension belts. Over tension of the V-Belts may result in damage to the motor or
driven equipment. Unless otherwise indicated, V-belt load must not exceed values given in Table
2-1 .
4. Belt Drive
Align sheaves carefully to minimize belt wear and axial bearing loads (see End‐Play Adjustment). Belt
tension should be sufficient to prevent belt slippage at rated speed and load. However, belt slippage
may occur during starting.
Doweling & Bolting After proper alignment is verified, dowel pins should be inserted through the motor feet into the
foundation. This will maintain the correct motor position should motor removal be required.
(BaldorReliance motors are designed for doweling.)
1. Drill dowel holes in diagonally opposite motor feet in the locations provided.
2. Drill corresponding holes in the foundation.
3. Ream all holes.
4. Install proper fitting dowels.
5. Mounting bolts must be carefully tightened to prevent changes in alignment.
Use a flat washer and lock washer under each nut or bolt head to hold the motor feet secure.
Flanged nuts or bolts may be used as an alternative to washers.

Guarding
Guards must be installed for rotating parts such as couplings, pulleys, external fans, and unused shaft
extensions. This is particularly important where the parts have surface irregularities such as keys, key
ways or set screws. Some satisfactory methods of guarding are:
1. Covering the machine and associated rotating parts with structural or decorative parts of the driven
equipment.
2. Providing covers for the rotating parts. Covers should be sufficiently rigid to maintain adequate
guarding during normal service.
Electrical Installation
Bypass Mode
All RPM AC motors are inverter duty motors using optimum pole design. They are not intended to be
used in bypass mode (across the line). Consult your Baldor District Office to determine suitability of motor
for specific applications in bypass mode. Permanent magnet motors cannot be run in bypass mode.
1. Single Voltage/Three Lead Motors
Connect leads marked U/T1, V/T2 and W/T3 to the appropriate control output terminals (refer to the
Controller Instruction Manual). See Figure 2‐1.
2. Dual Voltage Motors
Be sure the motor leads are connected properly for “Low” or “High” voltage connection, see Figure
2‐1. Connect leads marked U/T1, V/T2 and W/T3 to the appropriate control output terminals (refer to
the Controller Instruction Manual).
Figure 2‐1 Connection Diagram
3 Phase Dual Voltage
Connection Diagram 422927-1
Low Voltage High Voltage
P1 P1 H1
P2 Thermo‐ P2 T'Stat
stat H2 Space Heater
U/T1 U/T1 L1
L1
T7 V/T2 L2
V/T2 W/T3 L3
L2
T8 T4 RTD or Thermistor
W/T3 T7 see Figure 2‐3.
L3
T9 T5
T4 T8
T5 T6
T6 T9
3 Phase Single Voltage
P1
P2 T'Stat
U/T1 L1
V/T2 L2
W/T3 L3

Leads P1 & P2 are thermostat leads. They are to be connected in series with the holding coil of the motor
controller, which uses a manual momentary start switch.
Thermostat Leads Connection
As a standard feature, RPM AC motors have three (3) normally closed thermostats (one per phase)
connected in series, with leads P1 and P2 terminated in the main conduit box.
To protect against motor overheating, thermostats must be connected to the appropriate controller circuit
(function loss). Failure to connect the thermostats will void the motor warranty. Follow the controller
instruction manual for correct thermostat lead connections.
Blower Motor Connection Three phase blower motors.
RPM AC motors which are blower cooled incorporate an independently powered three phase AC blower
motor to assure continuous cooling air flow regardless of RPM AC motor speed.
The specific RPM AC blower motor depends on frame size and enclosure, see Figures 2‐1 and 2‐2.
Figure 2‐2 Blower Motor Connections
U1= Black (Delta) (Star) (Delta) (Star)
U2= Green T6 T4 T5 T6 T4 T5 W2 U2 V2 W2 U2 V2
V1= Blue T1 T2 T3 T1 T2 T3 U1 V1 W1 U1 V1 W1
V2= White
W1= Brown L1 L2 L3 L1 L2 L3 L1 L2 L3 L1 L2 L3
* GND is ground lead normally connects W2= Yellow Low Volts High Volts Low Volts High Volts
to ground lug in blower terminal box. GND= Green/Yellow*
1. Connect the blower leads as shown in the connection diagram supplied with the blower motor, see
Figure 2‐2
2. Connect for low or high voltage as shown in Figure 2‐1.
Grounding In the USA consult the National Electrical Code (NEC), Article 430 for information on grounding of motors
and generators, and Article 250 for general information on grounding. In making the ground connection,
the installer should make certain that there is a solid and permanent metallic connection between the
ground point, the motor or generator terminal housing, and the motor or generator frame.
Motors with resilient cushion rings usually must be provided with a bonding conductor across the resilient
member. Some motors are supplied with the bonding conductor on the concealed side of the cushion ring
to protect the bond from damage. Motors with bonded cushion rings should usually be grounded at the
time of installation in accordance with the above recommendations for making ground connections. When
motors with bonded cushion rings are used in multimotor installations employing group fusing or group
protection, the bonding of the cushion ring should be checked to determine that it is adequate for the
rating of the branch circuit over current protective device being used.
There are applications where grounding the exterior parts of a motor or generator may result in greater
hazard by increasing the possibility of a person in the area simultaneously contacting ground and some
other nearby live electrical parts of other ungrounded electrical equipment. In portable equipment it is
difficult to be sure that a positive ground connection is maintained as the equipment is moved, and
providing a grounding conductor may lead to a false sense of security.
Select a motor starter and over current protection suitable for this motor and its application. Consult motor
starter application data as well as the National Electric Code and/or other applicable local codes.
Due to the high switching frequencies of inverter controls, the ground connection/path must be low
impedance, not only low resistance. The NEC grounding instructions are intended to protect from low
frequency, high current considerations and are not adequate for grounding of high frequency circuits.
RPM AC induction motors are designed to operate with a high frequency adjustable speed drive. To
avoid damage to the motor and driven equipment due to bearing currents, the motor must be grounded
and bonded properly. A low impedance ground conductor should be used to ground all RPM AC motors.
Failure to ground the motor properly for high frequency transients (1MHz to 10MHz) may result in electric
discharge damage to the motor bearings and/or the driven equipment.

The drive manufacturer should specify a shielded motor power cable that includes a complete
circumferential braided or copper film/tape ground. This ground should be secured to the motor frame
from within the motor terminal box and must return without interruption to the drive ground. In addition, if
the motor and coupled equipment are not on a single common metal baseplate, it is important to equalize
the equipment ground potentials by bonding the motor frame to the coupled equipment using a high
frequency conductor such as a braided strap.
Shipping Blocks
Motors supplied with roller bearings at the drive end are shipped with wooden blocking to prevent axial
movement of the shaft during shipment. Remove the blocking and bolts securing it and discard. Make
sure motor shafts turn freely. If motor is to be reshipped, blocking of bearing is required.
Encoder Connections
Due to the wide variety of brands and types of feedback devices provided for RPM AC motors, please
consult the encoder installation and instruction diagrams provided with the device.
Drain Plugs
If motor is totally enclosed it is recommended that condensation drain plugs be removed. These are
located in the lower portion of the end-shields or bottom of frame on each end for FL180 frame.
Totally enclosed “XT” motors have automatic drains which should be left in place as received.
Drive RPM AC motors FL180 thru FL/RL250 are supplied with a shaft suitable for a belt or coupled drive.
Belt loads should be verified with maximum allowable radial loads, see “Shaft Loads”.
Proper alignment is critical for long life of bearings, shafts and belts, and minimum downtime.
Misalignment can cause excessive vibration and damaging forces on shaft and bearings. For direct
coupled drives, flexible couplings facilitate alignment. For belt drives, the sheave must be placed as close
as possible to the motor bracket.
Minimum V-Belt Sheave Diameters
Application of Pulleys, Sheaves, Sprockets and Gears on Motor Shafts. To avoid excessive bearing loads
and shaft stresses, belts should not be tightened more than necessary to transmit the rated torque.
The pretension of the V-belt drive should be based on the total tightening force required to transmit the
horsepower divided by the number of belts. This procedure avoids the excessive load caused by
tightening individual belts to a prescribed level recommended by belt manufacturers.
Mounting
In general, the closer pulleys, sheaves, sprockets or gears are mounted to the bearing on the motor shaft,
the less will be the load on the bearing. This will give greater assurance of trouble-free service.
The center point of the belt, or system of V-belts, must not be beyond the end of the motor shaft.
The inner edge of the sheave or pulley rim should not be closer to the bearing than the shoulder on the
shaft but should be as close to this point as possible. The outer edge of a chain sprocket or gear must not
extend beyond the end of the standard motor shaft.
Shaft Extension and Method of Drive
RPM AC frames FL180 - FL/RL250 are supplied with a shaft and bearing system suitable for either
coupled or belted drives. Belt loads should be verified with maximum allowable radial loads, see “Shaft
Loads”. Frames L/FL/RL280-L440 are supplied with larger shafts and roller bearings when belted drives
are specified.

Shaft Loads - Axial and Radial
RPM AC motors are suitable for limited shaft loads as shown in Tables 2-1 and 2-2 .
Recommended maximum thrust loads depend on the mounting position, either horizontal or vertical.
For recommendations for loads in excess of those shown, for higher speeds and special shaft extensions
contact your local Baldor District office.
Caution: Use of these radial load capacities requires the accurate calculation of the radial load. Radial
loads for gears, sprockets, and flywheel are usually accurately determined but the radial loads
due to V-belt drives are subject to miscalculations because they do not include all of the
pre-tension load (belt tightening). The calculations of the radial load for a V-belt drive must
include the pre-tension for transmitting the horsepower, pretension for centrifugal force on the
belts, pre-tension for high start torques, rapid acceleration or deceleration, pre-tension for drives
with short act-of-contact between the V-belt and sheave, and low coefficient of friction between
belt and sheave caused by moisture, oil or dust. Over tension of the V-Belts may result in damage
to the motor or driven equipment. Unless otherwise indicated, V-belt load must not exceed
values given in Table 2-1 .
Table 2-1 Radial Load Capacity- No Axial Load
Radial Load Capacities at the End of the Shaft in Lbs.
Frame
2500 RPM 1750 RPM 1150 RPM 850 RPM
FL180 445 445 445 445
FL/RL210 875 875 875 875
FL/RL250 1375 1525 1525 1525
L280 1000 1175 1175 1175
UL, UFL, URL280 2400 2500 2500 2500
L320 1300 1475 1475 1475
UL320 2850 2850 2850 2850
L360 1800 2050 2300 2550
UL360 4550 4550 4550 4550
L400 1700 1950 2250 2500
UL400 3625 4090 4700 5190
L440 2100 2400 2800 3150
UL440 4650 4650 4650 4650
Data for motors with roller bearings at the drive end (back end).
Motors with ball bearings at the drive end are for coupled duty only.

Table 2--2 Axial Thrust Capacity in Pounds -- for Minimum L--10 Bearing Life
of 10,000 Hrs. With No External Overhung Load
Frame Horizontal Mounting Vertical Mounting Thrust Down ¡ Vertical Mounting Thrust Up ¡
2500RPM 1750RPM 1150RPM 850RPM 2500RPM 1750RPM 1150RPM 850RPM 2500RPM 1750RPM 1150RPM 850RPM
FL180 430 480 480 480 385 455 555 630 445 470 570 645
FL/RL210 775 880 1015 1125 705 805 905 1005 870 970 1070 1170
FL/RL250 1160 1310 1520 1680 1050 1205 1410 1580 1310 1465 1670 1840
L,FL/RL280 590 700 850 975 405 515 665 795 830 940 1090 1225
L320 705 835 1020 1170 405 540 730 885 1010 1145 1335 1490
L360 875 1075 1350 1525 380 570 850 1025 1180 1370 1650 1825
L400 1350 1630 2000 2250 760 1110 1500 1765 1955 2305 2695 2960
L440 1300 1550 1800 2050 110 345 610 825 2410 2645 2910 3125
¡ Thrust capacity for vertical mounting includes a constant whose value is plus or minus depending on the direction of the
thrust load. The constant is plus for thrust loads acting upward against the force of gravity and minus for loads acting downward
with gravity.
Optional Accessories
Figure 2-3 Accessory Connections
One heater is installed in each end of motor.
Leads for each heater are labeled H1 & H2.
(Like numbers should be tied together).
Three thermistors are installed in windings.

Leads are labeled TD1--TD6 for shutdown and TD7--TD12 for warning.
RTD CONNECTIONS
One Per Phase
Leads Phase1Phase2Phase3
Red(or Marked) 1TD1 2TD1 3TD1
White 1TD2 2TD2 3TD2
White 1TD3 2TD3 3TD3
Two Per Phase

Phase1 Phase2 Phase3
Leads #1 #2 #3 #4 #5 #6
Red(or Marked) 1TD1 2TD1 3TD1 4TD1 5TD1 6TD1
White 1TD2 2TD2 3TD2 4TD2 5TD2 6TD2
White 1TD3 2TD3 3TD3 4TD3 5TD3 6TD3
418057--549
* One bearing RTD is installed in Drive endplate (PUEP), leads are labeled RTDDE.
* One bearing RTD is installed in Opposite Drive endplate (FREP), leads labeled RTDODE.
* Note RTD may have 2--Red/1--White leads; or 2--White/1--Red Lead.
2--8 Installation & Operation MN406

First Time Start Up
1. Be sure that all power to motor and accessories is off.
2. Be sure the motor shaft is disconnected from the load and will not cause mechanical rotation of the
motor shaft.
3. Remove all unused shaft keys and loose rotating parts to prevent them from flying off.
4. Verify the mechanical installation is secure. All bolts and nuts are tightened etc., covers and protective
devices are securely in their places.
5. If motor has been in storage or idle for some time, check winding insulation integrity.
6. Inspect all electrical connections for proper termination, clearance, mechanical strength and electrical
continuity.
7. Be sure all shipping materials and braces (if used) are removed from motor shaft.
8. Manually rotate the motor shaft to ensure that it rotates freely.
9. Replace all panels and covers that were removed during installation.
10. Momentarily apply power and check the direction of rotation of the motor shaft. If motor rotation is
wrong be sure power is off and change the motor lead connections as follows:.
RPM AC motors are designed to be capable of bi-directional shaft rotation. When voltages in an
A-B-C phase sequence are applied to leads U/T1, V/T2, W/T3 clockwise shaft rotation facing the
opposite drive end will result. If shaft rotation is incorrect, change the direction of rotation as follows:
a. Turn off and lockout all power to the motor and verify that the voltage at the motor leads is zero.
b. Reverse any two of three motor power leads.
c. Restore power.
11. Start the motor and ensure rotation is correct and operation is smooth without excessive vibration or
noise. If so, run the motor for 1 hour with no load connected.
12. Momentarily apply power and check the direction of air flow is in agreement with the “direction of air
flow” arrows mounted on the motor. If directional flow is incorrect be sure power is off and interchange
power leads to T1 and T2 or U1 and V1, Figure 2‐2.
13. After 1 hour of operation, disconnect power and connect the load to the motor shaft.
Verify all coupling guards and protective devices are installed. Ensure motor is properly ventilated.
14. If motor is totally enclosed fan-cooled or non-ventilated it is recommended that condensation drain
plugs, if present, be removed. These are located in the lower portion of the end-shields.
Totally enclosed fan-cooled “XT” motors are normally equipped with automatic drains which may be
left in place as received.
While operating the motor, observe the performance. It should run smoothly with little noise. The bearings
should not overheat and should reach a leveling off temperature. Any undue noise, overheating, or erratic
performance should be investigated and necessary corrective action taken immediately to prevent serious
dam age. Please contact your Baldor District office.
All RPM AC motors are lubricated before shipment and will operate for a long period before regreasing is
required. The period will vary depending on environmental and service conditions.
Refer to Maintenance section.
Balance
Motors are dynamically balanced to commercial limits unless ordered differently. Balance is done with a
full length 1/2 height shaft key. A full shaft key is shipped with motor. Sheave or coupling should be
balanced with a V2 height shaft key.
Table 2-3 Standard Dynamic Balance Limits
Highest Rated Speed RPM Max. Amplitude in Inches
3.000 - 4,000 0.0010
1,500 - 2,999 0.0015
1,000 - 1,499 0.0020
Up to 999 0.0025

protection should be provided by the user to protect against accidental contact with hot surfaces.
Failure to observe this precaution could result in bodily injury.
Operation
During operation observe the motors' performance. It should run smoothly with little noise. The bearings
should not overheat and should reach a normal operating temperature. Any undue noise, overheating, or
erratic performance should be investigated and corrective action taken immediately to prevent serious
damage.
All RPM AC motors are lubricated before shipment and will operate for a long period before regreasing is
required. The period will vary depending on environmental and service conditions.
Refer to Maintenance section of this manual.
Balance
Motors are dynamically balanced to meet the dynamic balance limits of NEMA MG1 Part 7 second for
peak value of the unfiltered velocity in inches per second unless ordered differently. Balance is done with
a full length 1/2 height shaft key. A full shaft key is shipped with motor. Sheave or coupling should be
balanced with a 1/2 height shaft key. Std. Dynamic Balance Limits
Table 2-4 Dynamic Balance

RPM FL180-L440
Velocity (in/sec) Peak
0-1200 Per NEMA standard
1201-1800 0.15
1801-3600 0.15
3601-5000 0.2
5001-8000 0.2

Section 3
Maintenance & Troubleshooting
WARNING: UL Listed motors must only be serviced by UL Approved Authorized Baldor Service Centers if
these motors are to be returned to a hazardous and/or explosive atmosphere.
WARNING: Pacemaker danger - Magnetic and electromagnetic fields in the vicinity of current carrying
carrying conductors and permanent magnet motors can result result in a serious health hazard to
persons with cardiac pacemakers, metal implants, and hearing aids. To avoid risk, stay way from
the area surrounding a permanent magnet motor.
WARNING: RPM AC permanent magnet motors can induce voltage and current in the motor leads by rotating
the motor shaft. Electrical shock can cause serious or fatal injury. Therefore, do not couple the
load to the motor shaft until all motor connections have been made. During any maintenance
inspections, be sure the motor shaft will not rotate.
protection should be provided by the user to protect against accidental contact with hot
surfaces. Failure to observe this precaution could result in bodily injury.
General Inspection Inspect the motor at regular intervals, approximately every 500 hours of operation or every 3
months, whichever occurs first. Keep the motor clean and the ventilation openings clear.
The following steps should be performed at each inspection:
1. Check that the motor is clean. Check that the interior and exterior of the motor is free of dirt, oil, grease,
water, etc. Oily vapor, paper pulp, textile lint, etc. can accumulate and block motor ventilation.
If the motor is not properly ventilated, overheating can occur and cause early motor failure.
2. Perform a dielectric with stand test periodically to ensure that the integrity of the winding insulation
has been maintained. Record the readings. Immediately investigate any significant decrease in
insulation resistance.
3. Check all electrical connectors to be sure that they are tight.
Relubrication & Bearings Bearing grease will lose its lubricating ability over time, not suddenly.
The lubricating ability of a grease (over time) depends primarily on the type of grease, the size of the
bearing, the speed at which the bearing operates and the severity of the operating conditions.
Good results can be obtained if the following recommendations are used in your maintenance program.
Relubrication with the shaft stationary and a warm motor is recommended.
Lubrication Procedure
WARNING: Disconnect all electrical power from the motor windings and accessory devices before
disassembly of the motor. Electrical shock can cause serious or fatal injury.
1. Relubrication with the shaft stationary and a warm motor is recommended. If lubrication must be
done with motor running, stay clear of rotating parts and electrical circuits.
2. Wipe all dirt from the outside of the grease fills and drains.
3. Locate the grease inlet at the top of the bearing hub, clean the area and replace the 1/8-inch pipe
plug with a grease fitting if the motor is not equipped with grease fitting.
4. Remove grease drain plug located opposite the grease inlet.
5. Using a manual grease gun, pump in the recommended grease in the amount shown. This amount
of grease will provide an ample supply of lubricant between lubrication periods for the service
condition listed in Table 3‐5, Table 3‐6 and Table 3‐7. Use only clean, fresh grease from clean
containers and handle so as to keep it clean. In general, mixing of greases is not recommended.
If an incompatible grease is used, the lube system must be repacked completely with the new
grease.
6. Wipe away any excess grease at the grease drain or relief and replace drain plugs.
MN406 Maintenance & Troubleshooting 3-1

Type of Grease
See the motor nameplate for replacement grease or oil recommendation.
Use Exxon Polyrex EM or equivalent grease unless motor nameplate specifies special grease.
Amount of grease to be added to RPM AC motors. See Table 3‐7 for relubrication interval.
Table 3‐5 Relubrication Amount
Frame Size Volume Weight
in3 cm3 oz g
L, FL, RL280 1.0 16 0.5 14
L320 - L400 2.0 32 1.0 28
L440 3.0 48 1.5 42
Note: FL/RL180, FL/RL210 and FL/RL250 have maintenance free non regreasable double shielded ball
bearings as standard. The 280-440 frames have open ball bearings, with inner caps as part of
PLS System.
Determine service condition on the basis of the most severe operating parameter; that is temperature,
bearing load, atmosphere, or operating hours per day.
Table 3‐6 Service Condition
Service Condition Ambient Use/Day Atmosphere Bearing Load
-18 °C to 40°C
Standard 8 Clean Steady
(0°F to 104°F)
Medium Dirt,
-30 °C to 50°C Medium Shock, Vibration
Severe 8 to 24 Abrasives,
(-22 °F to 122°F) (less than .2 in/sec.)
Corrosion
Heavy Dirt,
-54 °C to 65°C Heavy Shock, Vibration
Extreme 8 to 24 Abrasives,
(-65 °F to 149°F) (more than .44 in/sec)
Corrosion
- Motors must be specially designed for operation in ambient in this range. Special grease is required.
Table 3‐7 Relubrication Periods For RPM AC Motors - Frames L, FL/RL280 - L440
Maximum Normal Frame Relubrication Interval in Months
Operating Speed RPM Standard Service Severe Service Extreme Service
3450 and higher All 9 4 1
2400 thru 3449 L, RL/FL280 thru L440 9 3 1
1700 thru 2399 L, RL/FL280 thru L320 36 12 3
L360 thru L440 18 6 2
UL360 thru UL440 9 3 1
800 thru 1699 L, FL/RL280 thru L320 36 24 8
L360 thru L440 36 12 3
UL360 thru UL440 9 6 1
500 thru 799 L, FL/RL280 thru L320 48 36 12
L360 thru L440 36 24 8
UL360 thru UL440 18 12 4
499 and lower L, FL/RL280 thru L440 48 36 12
UL360 thru UL440 24 18 6
- Maximum speed occurs more than 30%of operating time.
- For Tandem drives increase frequency of lubrication by multiplying values by 0.8
3-2 Maintenance & Troubleshooting MN406

Table 3‐8 Troubleshooting Chart
Symptom Possible Causes Possible Solutions
Motor will not start Usually caused by line trouble, such Check source of power. Check overloads, fuses,
as, single phasing at the starter. controls, etc.
Excessive humming High Voltage. Check input line connections.
Eccentric air gap. Have motor serviced at local Baldor service center.
Motor Over Heating Overload. Compare actual amps Locate and remove source of excessive friction in
(measured) with nameplate rating. motor or load.
Reduce load or replace with motor of greater capacity.
Single Phasing. Check current at all phases (should be approximately
equal) to isolate and correct the problem.
Improper ventilation. Check external cooling fan to be sure air is moving
properly across cooling fins.
Excessive dirt build‐up on motor. Clean motor.
Unbalanced voltage. Check voltage at all phases (should be approximately
equal) to isolate and correct the problem.
Rotor rubbing on stator. Check air gap clearance and bearings.
Tighten “Thru Bolts”.
Over voltage or under voltage. Check input voltage at each phase to motor.
Open stator winding. Check stator resistance at all three phases for
balance.
Grounded winding. Perform dielectric test and repair as required.
Improper connections. Inspect all electrical connections for proper
termination, clearance, mechanical strength and
electrical continuity. Refer to motor lead connection
diagram.
Bearing Over Heating Misalignment. Check and align motor and driven equipment.
Excessive belt tension. Reduce belt tension to proper point for load.
Excessive end thrust. Reduce the end thrust from driven machine.
Excessive grease in bearing. Remove grease until cavity is approximately 3/4 filled.
Insufficient grease in bearing. Add grease until cavity is approximately 3/4 filled.
Dirt in bearing. Clean bearing cavity and bearing. Repack with correct
grease until cavity is approximately 3/4 filled.
Vibration Misalignment. Check and align motor and driven equipment.
Rubbing between rotating parts and Isolate and eliminate cause of rubbing.
stationary parts.
Rotor out of balance. Have rotor balance checked are repaired at your
Baldor Service Center.
Resonance. Tune system or contact your Baldor Service Center
for assistance.
Noise Foreign material in air gap or Remove rotor and foreign material. Reinstall rotor.
ventilation openings. Check insulation integrity. Clean ventilation openings.
Growling or whining Bad bearing. Replace bearing. Clean all grease from cavity and
new bearing. Repack with correct grease until cavity
is approximately 3/4 filled.

Suggested bearing and winding RTD setting guidelines for Non-Hazardous Locations ONLY
Most large frame AC BaldorReliance motors with a 1.15 service factor are designed to operate below a
Class B (80°C) temperature rise at rated load and are built with a Class H winding insulation system.
Based on this low temperature rise, RTD (Resistance Temperature Detectors) settings for Class B rise
should be used as a starting point. Some motors with 1.0 service factor have Class F temperature rise.
The following tables show the suggested alarm and trip settings for RTDs. Proper bearing and winding
RTD alarm and trip settings should be selected based on these tables unless otherwise specified for
specific applications.
If the driven load is found to operate well below the initial temperature settings under normal conditions,
the alarm and trip settings may be reduced so that an abnormal machine load will be identified.
The temperature limits are based on the installation of the winding RTDs imbedded in the winding as
specified by NEMA. Bearing RTDs should be installed so they are in contact with the outer race on ball
or roller bearings or in direct contact with the sleeve bearing shell.
Winding RTDs - Temperature Limit In 5C (405C Maximum Ambient)
Class B Temp Rise 3 80°C
Class F Temp Rise 3 105°C Class H Temp Rise 3 125°C
Motor Load (Typical Design)
Alarm Trip Alarm Trip Alarm Trip
3 Rated Load 130 140 155 165 175 185
Rated Load 140 150 160 165 180 185
to 1.15 S.F.
Note: Winding RTDs are factory production installed, not from Mod-Express.
When Class H temperatures are used, consider bearing temperatures and relubrication requirements.
Bearing RTDs - Temperature Limit In 5C (405C Maximum Ambient)

Bearing Type Anti-Friction
Grease Alarm Trip
Standard 100 110
Axial Float
RPM AC motors have a wave spring washer between the drive end bracket and bearing. The opposite
drive end bearing is positioned axially by a float restricting inner cap. Axial float (including bearing
internal clearance) should be within the following limits:
Axial Float -In./Min.
Maximum Minimum
Frame Size In. mm. In. mm.
FL180 thru L440 .051 1.29 .013 .33
The L440 frame wavy spring is located on the opposite drive end.

Figure 3‐4 Cross Section View of Totally Enclosed Blower Cooled Motor
Conduit Box Ball Bearing

Grease Fitting Eye Bolt
Blower BE Bracket
Motor
Feedback
Connector Grease Fitting
Blower Motor
Conduit Box Frame/Stator
Rotor
Ball
Bearing
Key
Optional Feedback
Device
Motor
Blower Grill Shaft
FE Bracket Blower Cover Inner Cap Inner Cap

Baldor District Offices Baldor District Offices Baldor District Offices
BALDOR ELECTRIC COMPANY
World Headquarters
P.O. Box 2400 Fort Smith, AR 72901-2400
(479) 646-4711 Fax (479) 648-5792
www.baldor.com
© 2008 Baldor Electric Company All rights reserved. Printed in USA

MN406 9/08
FINAL DOCUMENTATION
Chapter 14.0
Safety Wiring Procedure
www.nov.com
PROCEDURE
THE USE OF AND APPLICATION OF

SAFETY WIRE FOR SECONDARY
RETENTION
National Oilwell Varco

This document contains proprietary and confidential information
which belongs to National Oilwell Varco; it is loaned for limited Rig Solutions
RIG/PLANT
purposes only and remains the property of National Oilwell.
Reproduction, in whole or in part; or use of this design or 11000 Corporate Centre Dr.
distribution of this information to others is not permitted without the
ADDITIONAL CODE SDRL CODE TOTAL PGS
express written consent of National Oilwell Varco. This document is Houston TX 77041 USA
to be returned to National Oilwell Varco upon request and in any Phone +1 (281) 854-0647
REMARKS event upon completion of the use for which it was loaned. Fax +1 (281) 854-0508
MAIN TAG NUMBER DISCIPLINE
DOCUMENT NUMBER REV
CLIENT PO NUMBER
ASP00019 A
CLIENT DOCUMENT NUMBER
Client Document Number

Document number ASP00019
Revision A
Page 2
REVISION HISTORY
A 15/04/2011 SEE ECN C. SILVA T. GORMSEN T. GORMSEN

- 10/03/1995 First Issue KTK K DAW JES
CHANGE DESCRIPTION

- First Issue
A SEE ECN
Revision A
Page 3
TABLE OF CONTENTS
1 SCOPE.............................................................................................................................. 3
2 APPLICABLE DOCUMENTS ........................................................................................... 4
3 REQUIREMENTS ............................................................................................................. 4
3.1 MATERIAL AND SIZE ............................................................................................ 4
3.2 GENERAL REQUIREMENTS ................................................................................. 5
3.3 LOCK-WIRING METHODS .................................................................................... 6
3.4 OTHER APPLICATIONS ........................................................................................ 7
3.5 ILLUSTRATION OF TYPICAL LOCK-WIRE APPLICATION .................................. 8
4 QA PROVISIONS.............................................................................................................. 9
5 NOTES .............................................................................................................................. 9
1 SCOPE
Revision A
Page 4
This procedure establishes the method for the selection and application of safety wire.
Lock wiring is the application of wire to prevent relative movement of structure or other
critical components subject to vibration, tension, torque, etc.
This procedure is intended to help eliminate the risk of dropped objects in

components or parts manufactured.
Bolts, Nuts and Screws are the common type of fasteners used on NOV
equipment. They need to be locked (secondary retention) against loss of torque / pre-
tension.
Use of safety wire to prevent rotation of fasteners is a safe and primarily

recommended secondary retention method for fasteners. It is the most preferred
method because it not only prevents fasteners from loosening but also keeps them from
falling in case of primary retention failure (bolt head Breaks off) and effectively prevents
dropped objects.
Note that the secondary retention will work only if the primary retention method is
properly in place, i.e. bolts and screws are tightened and torqued as per specifications,
and there is no play between the mating elements. Secondary retention methods aim in
preventing any compromise in primary retention, loss of pre-tension in assembled
fasteners, loosening and backing out.
Definitions:
Secondary Retention – The means of effectively retaining a fastener/joining component

such that the operating loads do not compromise the integrity of the primary fastening
component.
2 APPLICABLE DOCUMENTS
DS00008-DES DESIGN TORQUE STANDARDS

Machinery’s Handbook 27th Edition
3 REQUIREMENTS
3.1 MATERIAL AND SIZE
3.1.1 Material
Lock wire must be aircraft quality stainless steel 302/304 condition A.
3.1.2 Lock-wire sizes

Revision A
Page 5
a. 0.5080 mm (0.020 inch) diameter

b. 0.8128 mm (0.032 inch) diameter NOV P/N Z6000.8
c. 1.1938 mm (0.047 inch) diameter NOV P/N Z6000.9
d. 1.2950 mm (0.051 inch) diameter NOV P/N Z6001
e. 3.1750 mm (0.125 inch) diameter NOV P/N Z6002
3.2 GENERAL REQUIREMENTS
3.2.1 Safety wire shall be new upon each application.
3.2.2 Parts shall be lockwired in such a manner that the lockwire shall be put in tension
when the part tends to loosen.
3.2.3 The lockwire should always be installed and twisted so that the loop around the
head stays down and does not tend to come up over bolt head and leave a slack loop.
3.2.4 Care shall be exercised when installing lockwire to ensure that it is tight but not
over stressed.
3.2.5 Properly twisted lockwire will have 7-12 twists per inch for .032 wire and 6-8 turns
for .052 wire. More twists will over stress the wire and cause fatigue and breakage.
3.2.6 A pigtail should be ½” to 5/8” in length (4-8 twists) at the end of the wiring. This
pigtail shall be bent back or under to prevent it from becoming a snag.
3.2.7 As per the Machinery’s Handbook 27th edition the following rules apply:
a) No more than three (3) bolts may be tied together.

b) Bolt heads may be tied as shown only when the female thread receiver is
captive.(see figure 1)
c) Lockwire must fill a minimum of 50% of the drilled hole provided for the
use of lockwire.
d) Diameter of lockwire is determined by the thread size of the fastener to be
lockwired.
1) Thread sizes of 6 mm (0.25 inch) and smaller use 0.508mm (0.020
inch) wire.
2) Thread sizes of 6 mm (0.25 inch) to 12 mm (0.5 inch) use 0.8128 mm
(0.032 inch) wire.
3) Thread sizes > 12 mm (0.5 inch) use 1.1938 mm (0.047 inch) OR
1.295mm (0.051) wire.
The larger wire may be used in smaller bolts in cases of convenience, but smaller
wire must not be used in larger fastener sizes.
Revision A
Page 6
Figure 1: Safety Wire / Lock Wire
3.3 LOCK-WIRING METHODS
3.3.1 The method involves threading a wire through holes in the fastener to lock it
against being rotated loose. The wire is twisted before being threaded and is locked to
next bolt. Safety wire should be placed in and around bolt head to maintain the pre-load.
The use of safety wire ties is illustrated in figure 1 above. The illustrations assume the
use of right-hand threaded fasteners.
3.3.2 The double-twist method:

The double-twist method of lock-wiring shall be used as the common method of
lock-wiring.
CAUTION: screws in closely spaced geometric which secure hydraulic or air seals, hold
hydraulic pressure, or used in critical areas of clutch mechanism should use double twist
method of lock-wiring. Make sure that the wire is so installed that it can easily be broken
when required in an emergency situation.
3.3.3 Lock-wiring widely spaced multiple groups by the double twist method.
a) When the multiple fasteners are from 4-6 inches apart, three (3) fasteners
shall be the maximum number in a series that can be safety wired
together.
b) When the multiple fasteners are spaced more than 6 inches apart, the
multiple fastener application specified in Figure 1 shall not be used unless
tie points are provided on adjacent parts to shorten the span of the wire to
less than 6 inches.
c) One end of the safety wire shall be inserted through one set of lockwire
holes in the head of the bolt. The other end of the safety wire shall be
looped around the bolt head in the tightening direction.
Revision A
Page 7
d) The strands, while taut, shall be twisted until the twisted part is just short of
the nearest hole in the next bolt. The twisted portion shall be within 1/8” of
the holes in each bolt as shown in figure 1 above.
e) After wiring the last bolt, the wire shall be twisted to form a pigtail of 2-4
twists. The excess wire shall be cut off. The pigtail shall be bent back or
under the part to prevent it from becoming a snag.
3.3.4 Single wire method:

The single wire method may be used in a closely spaced, closed geometrical
pattern (triangle, square, circle, etc.) on parts in an electrical system, and in places that
would make the single-method more advisable as shown in figure 2 below. Closely
spaced shall be considered a maximum of two inches between centers. Maximum length
of wire shall not exceed 24” in total length.
Figure 2: Safety Wire / Lock Wire Single
3.4 OTHER APPLICATIONS

Revision A
Page 8
3.4.1 Hollow head bolts are safety wired in the manner prescribed for regular bolts.
3.4.2 Drain plugs and cocks may be wired to a bolt, nut, or other part having a free lock
hole in accordance with the general instructions contained herein.
3.4.3 External snap rings may be locked if necessary in accordance with the general
locking principles contained herein.
3.4.4 Internal snap rings shall never be lockwired.
3.4.5 Bolts and hardware may be wired using SAFE-T-Cable. Follow procedure
D744000087-PRO-001.
Safe-T-Cable® can be used similar to Safety/Lock wire to secure Fasteners. The safety
cable installation procedure is shown in Figure. The safety cable comes in pre-cut
lengths with stubs on one end. After sewing through the holes in the fasteners they are
tightened and crimped using a ferrule cartridge and crimping tool.
They are more convenient to use and take only a fraction of the time to secure fasteners
as compared to safety wire as no wire twisting is required. However additional tools like
ferrule cartridge and crimping tool are required. For additional information refer Safe-T-
Cable® (website http://www.dmctools.com/Catalog/safe_t_cable.htm).
Figure 3: Safety Cable Installation Procedure
3.5 ILLUSTRATION OF TYPICAL LOCK-WIRE APPLICATION

Revision A
Page 9
4 QA PROVISIONS
5 NOTES
FINAL DOCUMENTATION
Chapter 15.0
Design Torque Standard
www.nov.com
DS00008
Design Specification
Design Torque Standard
THIS DOCUMENT CONTAINS PROPRIETARY AND CONFIDENTIAL INFORMATION WHICH BELONGS

TO NATIONAL-OILWELL, L.P. IT IS LOANED FOR LIMITED PURPOSES ONLY AND REMAINS THE
PROPERTY OF NATIONAL-OILWELL, L.P. REPRODUCTION, IN WHOLE OR IN PART OR USE OF
THIS DESIGN OR DISTRIBUTION OF THIS INFORMATION TO OTHERS IS NOT PERMITTED WITHOUT
THE EXPRESS WRITTEN CONSENT OF NATIONAL-OILWELL, L.P. THIS DOCUMENT IS TO BE
RETURNED TO NATIONAL-OILWELL, L.P. UPON REQUEST AND IN ANY EVENT UPON COMPLETION
OF THE USE FOR WHICH IT WAS LOANED. THIS DOCUMENT AND THE INFORMATION CONTAINED
AND REPRESENTED IS THE COPYRIGHTED PROPERTY OF NATIONAL-OILWELL, L.P.
TITLE
CURRENT INITIAL Design Torque Standard
DRAWN
D.TRUONG A. Vargas
CHECKED
B.RICE B. Levay
SIZE DWG NO REV
APPVD
B.RICE JB A DS00008 F
DATE
7/25/11 11.13.1992 SCALE NONE WT LBS SHEET 1 OF 16
DCF0045 (REV B)
NOTES
1. Unless noted, all values are based on light machine oil or anti seize lubricated bolts (not high
pressure lubes)
2. NOV does not recommend assembling bolts dry
3. Proof Strength is 92% of minimum yield strength
4. Torque values given represent 70% to 80% of proof strength
5. Clamp force is based on 75% of proof strength
6. These torque values are to be followed unless otherwise specified
7. If torqueing into aluminum, contact engineering for appropriate torque value.
8. After proper torque has been established in accordance with specification, fasteners shall be
immediately identified as being torqued by either:
a) Being safety wired in accordance with ASP00019 and/or
b) Marked with an “X” using either a red or yellow paint marker.
SIZE DWG NO REV
A DS00008 F
DCF0045 (REV B)
TORQUE VALUES FOR LIGHT MACHINE OIL LUBRICATED BOLTS
GRADE 2 GRADE 5
T.S. = 74,000 PSI to ¾” DIA T.S. = 120,000 PSI to 1” DIA
PROOF STRENGTH = 55,000 PSI PROOF STRENGTH = 85,00 PSI
T.S. = 60,000 PSI 7/8” to 1-1/2” DIA T.S. = 105,000 PSI 1-1/8” to 1-1/2” DIA
COARSE THREAD SERIES - UNC
Max. Clamp Min. Max. Clamp
Dia-Threads Min. Torque
Torque Force Torque Torque Force
Per Inch (ft-lbf)
(ft-lbf) (lb) (ft-lbf) (ft-lbf) (lb)
1/4 – 20 5.7 6.3 1,320 7.6 8.4 2,020
5/16 – 18 10.5 11.6 2,160 16 18 3,340
3/8 – 16 19 21 3,200 29 32 4,940
7/16 – 14 29 32 4,380 48 53 6,800
1/2 – 13 48 53 5,840 71 79 9,050
9/16 – 12 67 74 7,500 105 116 11,600
5/8 – 11 95 105 9,300 143 158 14,400
3/4 – 10 166 184 13,800 247 273 21,300
7/8 – 9 157 173 11,400 409 452 29,400
1–8 238 263 15,000 608 672 38,600
1 1/8 – 7 333 368 18,900 760 840 42,300
1 1/4 – 7 475 525 24,000 1,064 1,176 53,800 7
1 3/8 – 6 627 639 28,600 1,387 1,533 64,100 7
1 1/2 – 6 827 914 34,800 1,843 2,037 78,000 7
FINE THREAD SERIES – UNF

1/4 – 28 5.7 6.3 1,500 9.5 10.5 2,320
5/16 – 24 11.4 12.6 2,400 18 20 3,700
3/8 – 24 22 24 3,620 33 37 5,600
7/16 – 20 33 37 4,900 52 58 7,550
1/2 – 20 52 58 6,600 86 95 10,700
9/16 – 18 76 84 8,400 114 126 12,950
5/8 – 18 105 116 10,600 162 179 16,300
3/4 – 16 185 205 15,400 285 315 23,800
7/8 – 14 176 194 12,600 447 494 32,400
1–4 257 284 16,400 665 735 42,200
1 1/8 – 12 380 420 21,200 836 924 47,500 7
1 1/4 – 12 523 578 26,600 1,178 1,302 59,600 7
1 3/8 – 12 703 777 32,500 1,596 1,764 73,000 7
1 1/2 – 12 931 1,029 39,100 2,090 2,310 87,700 7
SIZE DWG NO REV
A DS00008 F
DCF0045 (REV B)
GRADE 8 HOLO-KROME
TENSILE STRENGTH = 150,000 PSI TENSILE STRENGTH = 170,000 PSI

Per Inch (ft-lbf)
1/4 – 20 11.4 12.6 2,860 12 14 3,240
5/16 – 18 24 26 3,720 26 28 5,340
3/8 – 16 43 47 7,000 47 51 7,920
7/16 – 14 67 74 9,550 75 83 10,850
1/2 – 13 105 116 12,750 114 126 14,450
9/16 – 12 143 158 16,100 163 181 18,500
5/8 – 11 209 231 20,350 226 250 23,000
3/4 – 10 361 399 30,100 404 446 34,000
7/8 – 9 570 630 41,600 651 719 47,000
1–8 855 945 54,500 7 969 1,071 61,700 7
1 1/8 – 7 1,216 1,344 68,700 7 1,349 1,491 77,800 7
1 1/4 – 7 1,729 1,911 87,200 7 1,967 2,174 98,700 7
1 3/8 – 6 2,261 2,499 104,000 7 2,565 2,835 117,800 7
1 1/2 – 6 3,002 3,318 126,500 7 3,411 3,770 143,200 7

1/4 – 28 13.3 17.7 3,280 14 16 3,750
5/16 – 24 24 26 5,220 29 32 5,920
3/8 – 24 48 53 7,900 52 58 8,050
7/16 – 20 75 84 10,700 84 92 12,150
1/2 – 20 114 126 14,400 124 137 16,250
9/16 – 18 162 179 18,250 183 203 20,700
5/8 – 18 228 252 23,000 258 286 26,200
3/4 – 16 399 441 33,600 451 499 38,000
7/8 – 14 627 693 45,800 7 718 794 51,900 7
1–4 950 1,050 59,700 7 1,064 1,176 67,600 7
1 1/8 – 12 1,368 1,512 77,000 7 1,511 1,670 87,000 7
1 1/4 – 12 1,900 2,100 96,600 7 2,180 2,410 109,400 7
1 3/8 – 12 2,584 2,856 118,400 7 2,926 3,234 134,000 7
1 1/2 – 12 3,382 3,738 142,200 7 4,769 5,271 201,000 7
SIZE DWG NO REV
A DS00008 F
DCF0045 (REV B)
STAINLESS ASTM F593G & F593H STAINLESS ASTM F593U
T.S. = 100,000 PSI to 5/8” DIA TENSILE STRENGTH = 135,000 PSI
T.S. = 85,000 PSI 3/4” to 1-1/2” DIA
PROOF STRENGTH = 41,000 PSI
Per Inch (ft-lbf)
1/4 – 20 5.7 6.3 1,407 8.6 9.5 2,266
5/16 – 18 11.4 12.6 2,319 18.1 20.0 3,734
3/8 – 16 20.0 22.1 3,429 33.3 36.8 5,522
7/16 – 14 32 36 4,704 52 58 7,574
1/2 – 13 49 55 6,279 80 88 10,110
9/16 – 12 72 80 8,054 116 128 12,968
5/8 – 11 99 109 10,001 160 176 16,103
3/4 – 10 122 134 10,271 282 312 23,798
7/8 – 9 197 217 14,207 456 504 32,918
1–8 295 327 18,635 684 756 43,179
1 1/8 – 7 418 462 23,462 968 1,070 54,364 7
1 1/4 – 7 590 652 29,797 1,366 1,510 69,041 7
1 3/8 – 6 773 855 35,516 1,792 1,980 82,294 7
1 1/2 – 6 1,026 1,134 43,204 2,378 2,628 100,106 7

1/4 – 28 6.7 7.4 1,611 10.5 11.6 2,594
5/16 – 24 12.4 13.7 2,567 20.9 23.1 4,133
3/8 – 24 22.8 25.2 3,885 37 41 6,256
7/16 – 20 36 40 5,252 59 65 8,457
1/2 – 20 56 62 7,076 90 100 11,393
9/16 – 18 80 88 8,983 129 143 14,464
5/8 – 18 112 124 11,328 181 200 18,240
3/4 – 16 136 150 11,470 315 349 26,576
7/8 – 14 217 239 15,652 503 555 36,266
1–4 323 357 20,387 748 826 47,239 7
1 1/8 – 12 469 519 26,322 1,087 1,201 60,900 7
1 1/4 – 12 653 721 32,995 1,513 1,973 76,451 7
1 3/8 – 12 881 973 10,436 2,040 2,254 93,694 7
1 1/2 – 12 1,154 1,276 49,616 7 2,675 2,957 122,646 7
F593 F593
G or H U
SIZE DWG NO REV
A DS00008 F
DCF0045 (REV B)
TORQUE VALUES FOR BOLTS LUBRICATED WITH AN ANTI-SEIZE COMPOUND
GRADE 2 GRADE 5
T.S. = 74,000 PSI to ¾” DIA T.S. = 120,000 PSI to 1” DIA
T.S. = 60,000 PSI 7/8” to 1-1/2” DIA T.S. = 105,000 PSI 1-1/8” to 1-1/2” DIA
Per Inch (ft-lbf)
1/4 – 20 4.3 4.7 1,320 5.7 6.3 2,020
5/16 – 18 7.8 8.7 2,160 12.1 13.4 3,340
3/8 – 16 14.3 15.8 3,200 21.4 23.6 4,940
7/16 – 14 21.4 23.6 4,380 36 39 6,800
1/2 – 13 36 39 5,840 53 59 9,050
9/16 – 12 50 55 7,500 78 87 11,600
5/8 – 11 71 79 9,300 107 118 14,400
3/4 – 10 125 138 13,800 185 205 21,300
7/8 – 9 118 130 11,400 306 339 29,400
1–8 178 197 15,000 456 504 38,600
1 1/8 – 7 249 276 18,900 570 630 42,300
1 1/4 – 7 356 394 24,000 798 882 53,800 7
1 3/8 – 6 470 520 28,600 1,040 1,150 64,100 7
1 1/2 – 6 620 685 34,800 1,382 1,528 78,000 7

1/4 – 28 4.3 4.7 1,500 7.1 7.9 2,320
5/16 – 24 8.6 9.5 2,400 13.5 15 3,700
3/8 – 24 16.4 18.1 3,620 25 28 5,600
7/16 – 20 25 28 4,900 39 43 7,550
1/2 – 20 39 43 6,600 64 71 10,700
9/16 – 18 57 63 8,400 86 95 12,950
5/8 – 18 78 87 10,600 121 134 16,300
3/4 – 16 139 154 15,400 214 236 23,800
7/8 – 14 132 146 12,600 335 370 32,400
1–4 192 213 16,400 499 551 42,200
1 1/8 – 12 285 315 21,200 627 693 47,500 7
1 1/4 – 12 392 433 26,600 884 977 59,600 7
1 3/8 – 12 527 583 32,500 1,197 1,323 73,000 7
1 1/2 – 12 698 772 39,100 1,568 1,733 87,700 7
SIZE DWG NO REV
A DS00008 F
DCF0045 (REV B)
GRADE 8 HOLO-KROME
TENSILE STRENGTH = 150,000 PSI TENSILE STRENGTH = 170,000 PSI

Per Inch (ft-lbf)
1/4 – 20 8.6 9.5 2,860 9.3 10.2 3,240
5/16 – 18 17.8 19.7 3,720 19 21 5,340
3/8 – 16 32 35 7,000 35 39 7,920
7/16 – 14 50 55 9,550 56 62 10,850
1/2 – 13 78 87 12,750 86 95 14,450
9/16 – 12 107 118 16,100 123 135 18,500
5/8 – 11 157 173 20,350 170 187 23,000
3/4 – 10 271 299 30,100 303 335 34,000
7/8 – 9 428 473 41,600 488 539 47,000 7
1–8 641 709 54,500 7 727 803 61,700 7
1 1/8 – 7 912 1,008 68,700 7 1,012 1,118 77,800 7
1 1/4 – 7 1,297 1,433 87,200 7 1,475 1,630 98,700 7
1 3/8 – 6 1,696 1,874 104,000 7 1,924 2,126 117,800 7
1 1/2 – 6 2,252 2,489 126,500 7 2,558 2,827 143,200 7

1/4 – 28 10 11 3,280 10.7 11.8 3,750
5/16 – 24 17.8 19.7 5,220 21 24 5,920
3/8 – 24 36 39 7,900 39 43 8,050
7/16 – 20 57 63 10,700 63 69 12,150
1/2 – 20 86 95 14,400 93 102 16,250
9/16 – 18 121 134 18,250 138 152 20,700
5/8 – 18 171 189 23,000 194 214 26,200
3/4 – 16 299 331 33,600 338 374 38,000
7/8 – 14 470 520 45,800 7 539 595 51,900 7
1–4 713 788 59,700 7 798 882 67,600 7
1 1/8 – 12 1,026 1,134 77,000 7 1,133 1,252 87,000 7
1 1/4 – 12 1,425 1,575 96,600 7 1,635 1,807 109,400 7
1 3/8 – 12 1,938 2,142 11,840 7 2,195 2,426 134,000 7
1 1/2 – 12 2,537 2,804 142,200 7 3,577 3,953 201,000 7
SIZE DWG NO REV
A DS00008 F
DCF0045 (REV B)
STAINLESS ASTM F593G & F593H STAINLESS ASTM F593U
T.S. = 100,000 PSI to 5/8” DIA TENSILE STRENGTH = 135,000 PSI
T.S. = 85,000 PSI 3/4” to 1-1/2” DIA
PROOF STRENGTH = 41,000 PSI
Per Inch (ft-lbf)
1/4 – 20 4.3 4.7 1,407 6.4 7.1 2,266
5/16 – 18 8.6 9.5 2,319 13.5 15 3,734
3/8 – 16 15 16.5 3,429 24.9 27.6 5,522
7/16 – 14 24 27 4,704 39 43 7,574
1/2 – 13 37 41 6,279 60 66 10,110
9/16 – 12 54 60 8,054 87 96 12,968
5/8 – 11 74 82 10,001 120 132 16,103
3/4 – 10 91 101 10,271 212 234 23,798
7/8 – 9 147 163 14,207 342 378 32,918
1–8 222 245 18,635 513 567 43,179
1 1/8 – 7 314 347 23,462 726 802 54,364 7
1 1/4 – 7 442 489 29,797 1,025 1,132 69,041 7
1 3/8 – 6 580 641 35,516 1,344 1,485 82,294 7
1 1/2 – 6 770 851 43,204 1,783 1,971 100,106 7

1/4 – 28 5.0 5.5 1,611 7.8 8.7 2,594
5/16 – 24 9.3 10.2 2,567 15.7 17.3 4,133
3/8 – 24 17.1 18.9 3,885 28 31 6,256
7/16 – 20 27 30 5,252 44 49 8,457
1/2 – 20 42 46 7,076 68 75 11,393
9/16 – 18 60 66 8,983 97 107 14,464
5/8 – 18 84 93 11,328 135 150 18,240
3/4 – 16 102 113 11,470 237 261 26,576
7/8 – 14 162 180 15,652 377 417 36,266
1–4 242 268 20,387 561 620 47,239 7
1 1/8 – 12 352 389 26,322 815 901 60,990 7
1 1/4 – 12 489 541 32,995 1,135 1,254 76,451 7
1 3/8 – 12 660 730 40,436 1,530 1,691 93,694 7
1 1/2 – 12 866 957 48,616 7 2,006 2,218 112,646 7
F593 F593
G or H U
SIZE DWG NO REV
A DS00008 F
DCF0045 (REV B)
CLASS 4.6 CLASS 8.8
T.S. = 400 MPa T.S. = 830 MPa
PROOF STRENGTH = 225 MPa PROOF STRENGTH = 600 MPa
T.S. is for all dia. T.S. is for all dia
*Metric socket head screws*
METRIC SERIES
Min. Torque
Diameter - pitch Torque Force Torque Torque Force
(ft-Ibf)
(ft-Ibf) (Ib) (ft-Ibf) (ft-Ibf) (lb)
M3 - .5 .4 .5 183 .9 1.2 489
M3.5 - .6 .6 .73 247 1.5 1.9 659
M4 - .7 .9 1.1 320 2.1 2.9 854
M5 - .8 1.7 2.1 516 4.3 5.8 1,378
M6 - 1 2.9 3.7 732 7.2 9.9 1,954
M8 - 1.25 6.9 8.9 1,331 17 23 3,550
M10 - 1.5 14 17 2,106 33 47 5,617
M12 - 1.75 24 31 3,055 57 81 8,148
M14 - 2 38 48 4,177 91 129 11,141
M16 - 2 57 74 5,664 141 199 15,106
M18 – 2.5 81 104 6,975 195 278 18,600
M20 – 2.5 112 145 8,851 274 388 23,604
M22 – 2.5 151 196 10,940 372 524 29,174
M24 - 3 193 251 12,746 472 671 33,989
M27 – 3 280 365 16,570 690 974 44,186
M30 - 3.5 381 496 20,216 934 1,325 53,911 7
M33 – 3.5 514 670 24,961 1,267 1,787 66,563 7
M36 – 3.5 656 857 29,422 1,627 2,285 78,460 7
M39 - 4 852 1112 35,122 2,102 2,966 93,661 7
M42 - 4.5 1,059 1380 40,363 2,599 3,681 107,634 7
M48 - 5 1,586 2069 53,038 7 3,899 5,518 141,435 7
M56 - 5.5 2,535 3310 73,007 7 6,253 8,828 194,686 7
4.6 8.8
SIZE DWG NO REV
A DS00008 F
DCF0045 (REV B)
CLASS 10.9 CLASS 12.9
T.S. = 1040 MPa T.S. = 1220 MPa
T.S. is for all dia T.S. is for all dia.
* Metric socket head screws*
Min. Torque
(ft-Ibf)
M3 - .5 1.3 1.7 676 1.5 2.0 790
M3.5 - .6 2.1 2.7 911 2.5 3.1 1,065
M4 - .7 3.1 4.0 1,182 3.7 4.7 1,381
M5 - .8 6.2 8.0 1,906 7.3 9.4 2,228
M6 - 1 10.6 13.7 2,703 12 16 3,159
M8 - 1.25 25 33 4,910 29 38 5,739
M10 - 1.5 50 65 7,771 58 76 9,082
M12 - 1.75 87 112 11,271 101 131 13,172
M14 - 2 138 179 15,411 162 210 18,011
M16 - 2 212 275 20,897 247 321 24,422
M18 – 2.5 297 384 25,730 347 449 30,070
M20 – 2.5 414 537 53,911 483 628 38,159
M22 – 2.5 557 726 40,358 651 848 47,165 7
M24 – 3 715 929 47,019 7 836 1,086 54,950 7
M27 – 3 1,034 1,347 61,125 7 1,209 1,574 71,435 7
M30 - 3.5 1,408 1,833 74,577 7 1,646 2,142 87,157 7
M33 – 3.5 1,896 2,473 92,079 7 2,216 2,890 107,611 7
M36 – 4 2,421 3,161 108,536 7 2,829 3,695 126,843 7
M39 – 4 3,145 4,103 129,564 7 3,675 4,795 151,418 7
M42 - 4.5 3,907 5,093 148,894 7 4,566 5,952 174,009 7
M48 - 5 5,853 7,633 195,652 7 6,840 8,921 228,654 7
M56 – 5.5 9,352 12,212 269,316 7 10,930 14,272 314,743 7
10.9
12.9
SIZE DWG NO REV
A DS00008 F
DCF0045 (REV B)
TORQUE VALUES FOR BOLTS WITH AN ANTI-SEIZE COMPOUND
CLASS 4.6 CLASS 8.8
T.S. = 400 MPa T.S. = 830 MPa
T.S. is for all dia. T.S. is for all dia
*Metric socket head screws*
METRIC SERIES
Min. Torque
(ft-Ibf)
M3 - .5 0.3 0.4 183 0.7 0.9 489
M3.5 - .6 0.5 0.6 247 1.1 1.5 659
M4 - .7 0.7 0.9 320 1.6 2.0 854
M5 - .8 1.3 1.7 516 3.2 4.2 1,378
M6 - 1 2.2 2.8 732 5.4 7.0 1,954
M8 - 1.25 5 7 1,331 13 17 3,550
M10 - 1.5 11 14 2,106 25 32 5,617
M12 - 1.75 18 23 3,055 43 56 8,148
M14 - 2 29 37 4,177 68 89 11,141
M16 - 2 43 56 5,664 106 137 15,106
M18 – 2.5 61 79 6,975 146 190 18,600
M20 – 2.5 84 109 8,851 206 267 23,604
M22 – 2.5 113 147 10,940 279 363 29,174
M24 - 3 145 188 12,746 354 460 33,989
M27 – 3 210 273 16,570 518 673 44,186
M30 - 3.5 286 371 20,216 701 911 53,911 7
M33 – 3.5 386 501 24,961 950 1235 66,563 7
M36 – 3.5 492 640 29,422 1220 1586 78,460 7
M39 - 4 639 831 35,122 1577 2049 93,661 7
M42 - 4.5 794 1033 40,363 1949 2534 107,634 7
M48 - 5 1190 1546 53,038 7 2924 3802 141,435 7
M56 - 5.5 1901 2472 73,007 7 4690 6097 194,686 7
4.6 8.8
SIZE DWG NO REV
A DS00008 F
DCF0045 (REV B)
TORQUE VALUES FOR BOLTS WITH AN ANTI-SEIZE COMPOUND
CLASS 10.9 CLASS 12.9
T.S. = 1040 MPa T.S. = 1220 MPa
T.S. is for all dia T.S. is for all dia.
* Metric socket head screws*
Min. Torque
(ft-Ibf)
M3 - .5 1.0 1.3 676 1.1 1.5 790
M3.5 - .6 1.6 2.0 911 1.9 2.4 1,065
M4 - .7 2.3 3.0 1,182 2.8 3.6 1,381
M5 - .8 4.7 6.0 1,906 5.5 7.1 2,228
M6 - 1 8.0 10.3 2,703 9.0 11.7 3,159
M8 - 1.25 19 24 4,910 22 28 5,739
M10 - 1.5 38 49 7,771 44 57 9,082
M12 - 1.75 65 85 11,271 76 98 13,172
M14 - 2 104 135 15,411 122 158 18,011
M16 - 2 159 207 20,897 185 241 24,422
M18 – 2.5 223 290 25,730 260 338 30,070
M20 – 2.5 311 404 32,652 362 471 38,159
M22 – 2.5 418 543 40,358 488 635 47,165 7
M24 – 3 536 697 47,019 7 627 815 54,950 7
M27 – 3 776 1008 61,125 7 907 1179 71,435 7
M30 - 3.5 1056 1373 74,577 7 1235 1605 87,157 7
M33 – 3.5 1422 1849 92,079 7 1662 2161 107,611 7
M36 – 4 1816 2360 108,536 7 2122 2758 126,843 7
M39 – 4 2359 3066 129,564 7 2756 3583 151,418 7
M42 - 4.5 2930 3809 148,894 7 3425 4452 174,009 7
M48 - 5 4390 5707 195,652 7 5130 6669 228,654 7
M56 – 5.5 7014 9118 269,316 7 8198 10657 314,743 7
10.9
12.9
The following tables specify torque values for fasteners used

with Nord-Lock washers.
SIZE DWG NO REV
A DS00008 F
DCF0045 (REV B)
NORD-LOCK “Delta Protekt” Washers with Zinc Plated Bolt 8.8
Oil Graphite
Pitch Torque Clamp Torque Clamp
Washer Size Bolt Size
(mm) (ft-lbf) (lb) (ft-lbf) (lb)
NL3 M3 .5 1.2 540 1.2 540
NL4 M4 .7 3.0 944 2.7 944
NL5 M5 .8 5.8 1,529 5.2 1,529
NL6 M6 1.0 10 2,181 9.1 2,181
NL8 M8 1.25 24 4,047 22 4,047
NL10 M10 1.5 47 6,295 43 6,295
NL12 M12 1.75 82 8,992 74 8,992
NL14 M14 2.0 129 12,364 117 12,364
NL16 M16 2.0 197 16,861 177 16,861
NL18 M18 2.5 276 20,682 249 20,682
NL20 M20 2.5 385 26,527 348 26,527
NL22 M22 2.5 525 32,822 474 32,822
NL24 M24 3.0 664 37,993 599 37,993
NL27 M27 3.0 968 49,683 873 49,683
NL30 M30 3.5 1,322 60,474 1,192 60,474
NL33 M33 3.5 1,779 74,861 1,600 74,861
NL36 M36 4.0 2,295 88,125 2,067 88,125
NL39 M39 4.0 2,960 105,211 2,663 105,211
NL42 M42 4.5 3,663 120,947 3,297 120,947

Oil Graphite
Washer Pitch Torque Clamp Torque Clamp
Bolt Size
Size (mm) (ft-lbf) (lb) (ft-lbf) (lb)
NL3 M3 .5 1.7 719 1.5 764
NL4 M4 .7 3.9 1,259 3.5 1,326
NL5 M5 .8 7.8 2,046 6.7 2,158
NL6 M6 1.0 14 2,900 12 3,057
NL8 M8 1.25 33 5,171 29 5,620
NL10 M10 1.5 64 8,318 56 8,768
NL12 M12 1.75 110 12,140 95 12,814
NL14 M14 2.0 175 16,636 151 17,535
NL16 M16 2.0 268 22,481 230 23,830
NL18 M18 2.5 375 27,651 323 29,225
NL20 M20 2.5 524 35,070 451 37,093
NL22 M22 2.5 714 43,613 613 46,086
NL24 M24 3.0 903 50,582 776 53,505
NL27 M27 3.0 1,318 66,094 1,128 69,691
NL30 M30 3.5 1,798 80,482 1,542 84,978
NL33 M33 3.5 2,422 99,590 2,068 105,211
NL36 M36 4.0 3,125 117,350 2,673 123,870
NL39 M39 4.0 4,030 140,281 3,440 148,149
NL42 M42 4.5 4,988 160,963 4,262 170,180
SIZE DWG NO REV
A DS00008 F
DCF0045 (REV B)
Oil Graphite
Bolt Size
NL3 M3 .5 1.9 877 1.6 922
NL4 M4 .7 4.4 1,506 3.8 1,596
NL5 M5 .8 8.7 2,450 7.4 2,585
NL6 M6 1.0 15 3,462 13 3,664
NL8 M8 1.25 36 6,295 31 6,744
NL10 M10 1.5 72 9,892 61 10,566
NL12 M12 1.75 123 14,613 105 15,287
NL14 M14 2.0 196 20,008 167 21,132
NL16 M16 2.0 298 26,977 252 28,551
NL18 M18 2.5 419 33,272 355 35,070
NL20 M20 2.5 585 42,264 494 44,512
NL22 M22 2.5 797 52,380 670 55,303
NL24 M24 3.0 1,009 60,698 850 64,295
NL27 M27 3.0 1,470 79,133 1,235 83,629
NL30 M30 3.5 2,005 96,668 1,688 102,063
NL33 M33 3.5 2,699 119,598 2,265 126,343
NL36 M36 4.0 3,483 140,730 2,927 148,823
NL39 M39 4.0 4,490 168,157 3,763 177,599
NL42 M42 4.5 5,560 193,336 4,666 204,126
NORD-LOCK Stainless Steel with Stainless Steel Bolt A4

A4-70 w/ Graphite Lube A4-80 w/ Graphite Lube
Bolt Size
NL3 M3 .5 0.9 337 1.2 450
NL4 M4 .7 1.9 585 2.6 764
NL5 M5 .8 3.7 922 5.1 1,236
NL6 M6 1.0 7 1,326 9 1,754
NL8 M8 1.25 16 2,473 21 3,147
NL10 M10 1.5 32 3,822 41 5,171
NL12 M12 1.75 54 5,620 72 7,419
NL14 M14 2.0 85 7,644 114 10,116
NL16 M16 2.0 130 10,341 174 13,713
NL18 M18 2.5 183 12,589 244 16,861
NL20 M20 2.5 256 16,186 341 21,357
NL22 M22 2.5 349 20,008 465 26,527
NL24 M24 3.0 441 23,155 588 30,799
NL27 M27 3.0 643 30,124 858 40,241
NL30 M30 3.5 877 36,869 1,170 49,233
NL33 M33 3.5 1,182 45,636 1,576 60,698
NL36 M36 4.0 1,525 53,729 2,034 71,714
NL39 M39 4.0 1,968 64,071 2,624 85,652
NL42 M42 4.5 2,435 73,737 3,247 98,241
SIZE DWG NO REV
A DS00008 F
DCF0045 (REV B)
NORD-LOCK “Delta Protekt” Washers with Zinc Plated Bolt Grade 5
Oil Graphite
Washer Bolt Pitch Torque Clamp Torque Clamp
Size Size (TPI) (ft-lbf) (lb) (ft-lbf) (lb)
NL3 #5 40 1.1 550 1.0 550
NL3.5 #6 32 1.4 630 1.3 630
NL4 #8 32 2.7 970 2.4 970
NL5 #10 24 3.9 1,200 3.5 1,200
NL1/4” ¼ 20 9.1 2,200 8.3 2,200
NL8 5/16 18 18 3,600 16 3,600
NL3/8” 3/8 16 30 5,400 28 5,400
NL11 7/16 14 47 7,300 42 7,300
NL1/2” ½ 13 73 9,800 66 9,800
NL14 9/16 12 104 12,600 94 12,600
NL16 5/8 11 145 15,600 131 15,600
NL3/4” ¾ 10 254 23,100 230 23,100
NL22 7/8 9 408 31,900 369 31,900
NL 1” 1 8 617 41,800 557 41,800
NL30 1 1/8 7 771 46,400 697 46,400
NL33 1¼ 7 1075 58,900 969 58,900
NL36 1 3/8 6 1410 70,200 1,270 70,200
NL39 1½ 6 1860 85,500 1,670 85,500
NORD-LOCK “Delta Protekt” Washers with Zinc Plated Bolt Grade 8

Oil Graphite
(TPI) (ft-lbf) (lb) (ft-lbf) (lb)
NL3 #5 40 1.5 740 1.3 780
NL3.5 #6 32 1.9 840 1.7 890
NL4 #8 32 3.5 1,300 3.1 1,400
NL5 #10 24 5.1 1,600 4.6 1,700
NL1/4” ¼ 20 12 2,900 11 3,100
NL8 5/16 18 24 4,900 21 5,100
NL3/8” 3/8 16 41 7,200 36 7,600
NL11 7/16 14 64 9,800 56 10,400
NL1/2” ½ 13 99 13,100 86 13,900
NL14 9/16 12 138 16,800 122 17,800
NL16 5/8 11 197 20,900 171 22,100
NL3/4” ¾ 10 346 30,900 299 32,700
NL22 7/8 9 556 42,700 479 45,100
NL 1” 1 8 840 56,000 724 59,200
NL30 1 1/8 7 1,190 70,600 1,030 74,500
NL33 1¼ 7 1,660 89,600 1,430 94,600
NL36 1 3/8 6 2,180 107,000 1,880 113,000
NL39 1½ 6 2,870 130,000 2,470 137,000
SIZE DWG NO REV
A DS00008 F
DCF0045 (REV B)
NORD-LOCK Stainless Steel with ASTM A574 Bolt
Oil Graphite
(TPI) (ft-lbf) (lb) (ft-lbf) (lb)
NL3 #5 40 1.7 870 1.6 910
NL3.5 #6 32 2.2 990 2.0 1,050
NL4 #8 32 3.8 1,500 3.7 1,600
NL5 #10 24 5.8 1,900 5.5 2,000
NL1/4” ¼ 20 13 3,400 12 3,700
NL8 5/16 18 26 5,700 23 6,000
NL3/8” 3/8 16 45 8,400 39 8,900
NL11 7/16 14 70 11,500 60 12,200
NL1/2” ½ 13 109 15,400 93 16,300
NL14 9/16 12 148 19,800 141 20,900
NL16 5/8 11 216 24,600 184 26,000
NL3/4” ¾ 10 378 36,400 321 38,400
NL22 7/8 9 607 50,200 514 53,000
NL 1” 1 8 916 65,900 776 69,600
NL30 1 1/8 7 1,300 83,000 1100 87,700
NL33 1¼ 7 1,810 105,000 1530 111,000
NL36 1 3/8 6 2,380 126,000 2020 133,000
NL39 1½ 6 3,140 153,000 2640 161,000
NORD-LOCK Stainless Steel with ASTM F593 Bolt

Oil Graphite
(TPI) (ftlb) (lb) (ftlb) (lb)
NL3 #5 40 - - - -
NL3.5 #6 32 - - - -
NL4 #8 32 - - - -
NL5 #10 24 - - - -
NL1/4” ¼ 20 5.2 1,300 5.2 1,300
NL8 5/16 18 10.3 2,200 10.3 2,200
NL3/8” 3/8 16 18 3,300 18 3,300
NL11 7/16 14 28 4,500 28 4,500
NL1/2” ½ 13 43 6,000 43 6,000
NL14 9/16 12 61 7,700 61 7,700
NL16 5/8 11 85 9,500 85 9,500
NL3/4” ¾ 10 104 9,800 104 9,800
NL22 7/8 9 166 13,500 166 13,500
NL 1” 1 8 251 17,700 251 17,700
NL30 1 1/8 7 356 22,300 356 22,300
NL33 1¼ 7 497 28,300 497 28,300
NL36 1 3/8 6 653 33,800 653 33,800
NL39 1½ 6 859 41,100 859 41,100
SIZE DWG NO REV
A DS00008 F
DCF0045 (REV B)
FINAL DOCUMENTATION
Chapter 16.0
Recommended Lubricants and
Fluids
www.nov.com
Recommended
Lubricants and
Hydraulic Fluids
NOV Drilling System Products
Top Drive Systems
Power Swivel Systems
Iron Roughneck Systems
Hoisting Systems
Mud Pump Systems
Pipe Handling Systems
Rotating Systems
BOP Transporter Systems

hereinafter as "NOV"). It is loaned for limited purposes only
and remains the property of NOV. Reproduction, in whole or in National Oilwell Varco
part, or use of this design or distribution of this information to RIG SOLUTIONS
others is not permitted without the express written consent of 11000 Corporate Centre Drive
D811000719-PRO-001 05
www.nov.com
D811000719-PRO-001
Revision 05
Revision History
05 15.08.2012 Engineering Update B. Dominguez S. Sobreira R. Luher
04 21.02.2012 Engineering Update B. Dominguez B. Levay B. Levay
03 30.11.2009 Engineering Update B. Dominguez P. Williams P. Williams
02 09.14.2009 Publication update B. Dominguez P. Williams P. Williams
01 10.01.2008 First Issue TCD BMD BDW
www.nov.com
D811000719-PRO-001
Revision 05
Change Description
01 First Issue
1. Changed equipment reference to cover page.

2. Added temperature range reference to hydraulic fluids and gear lubricant pour point advisories to
page 1.
3. Changed and added frequency of fluid changes for hydraulic fluids and gear lubricants to pages 4
and 8.
4. Changed Non-Arctic Service heading to Non-Arctic Service Fluids to page 6.
5. Changed “Viscosity” reference to “Kinematic Viscosity” reference in Non-Arctic Service Fluid table
to page 6.
6. Changed Arctic Service heading to Arctic Service Fluids to page 7.
7. Changed “Viscosity” reference to “Kinematic Viscosity” reference in Arctic Service Fluid table to
page 7.
8. Added “SUS” viscosities to best choice supreme grade arctic service hydraulic fluids to
page 7.
9. Added “SUS” viscosities to alternative supreme grade arctic service hydraulic fluids to page
02
7.
10. Changed gearbox reference and added cross-reference information to operating temperature table
for draining of gear oil to page 8.
11. Added "Conventional" reference to washpipe lubricant recommendation section to page 10.
12. Removed "AC" reference to page 10.
13. Removed grease brand example to page 11.
14. Added External Pinion and Gear Sets section with recommended grease information tables to page
9 and 10.
15. Changed “Viscosity” cell title to “Kinematic Viscosity” cell title in Lubricants and Fluids Reference
Chart to pages 14 and 15.
16. Added "External Pinion and Gear Sets" component lubricant reference to page 15.
17. Removed "AC" reference from drilling motor bearings to page 15.
18. Changed all primary temperature degrees to Celsius and changed all reference temperature
degrees to Fahrenheit.
1. Added caution note and contact information note to page 2.

03
2. Removed oil additive recommendation note to page 15.
1. Moved Motor Bearings Lubricating Greases section from page 11 to page 12.
2. Moved External Pinion & Gear Set Lubricating Greases section from page 12 to page 13.
3. Moved Air Lubricator Misting Oil section from page 13 to page 17.
04
4. Add Wire Rope Lubricant section with recommended wire rope lubricant information (Titled:
Inspection, Lubricating, and Rope Lubricants) to page 14 through page 16.
5. Added Wire Rope reference information to Lubricants and Fluids Reference Chart to page 20.
1. Corrected cross-reference page information on page 9 to refer to the table on page 10.
2. Placed ambient temperature minus symbol in front of 9 celsius on column one, row two of
Recommended Gear Oil for the Transmission Gearbox Table (page 10).
3. Placed ambient temperature minus symbol in front of 4 celsius on column one, row three of
05 Recommended Gear Oil for the Transmission Gearbox Table (page 10).
4. Changed ambient temperature -10 Celsius to -9 Celsius on column two, row three of Recommended
Gear Oil for the Transmission Gearbox Table (page 10).
5. Corrected inverted primary (Celsius) and reference (Fahrenheit) temperature degree call-outs to
column two, row four of Recommended Gear Oil for the Transmission Gearbox Table (page 10).
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D811000719-PRO-001
Revision 05
Page i of i
Table of Contents
General Recommendations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
Additional Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
Hydraulic Fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5
Hydraulic Fluid Cleanliness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5
Change Interval . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5
Filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6
Non-Arctic Service Fluids . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7
Arctic Service Fluids . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8
Gear Oil. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9
Change Interval . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9
Low-Temperature Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-10
Gearbox Lubricants . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-10
Grease. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11
General Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11
Conventional Washpipe Lubricating Greases . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11
Motor Bearings Lubricating Greases . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-12
IBOP/Kelly Valve Actuator Lubricating Greases . . . . . . . . . . . . . . . . . . . . . . . . 1-12
External Pinion & Gear Set Lubricating Greases . . . . . . . . . . . . . . . . . . . . . . . 1-13
Wire Rope Lubricant. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-14
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-14
Lubricating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-15
Rope Lubricants . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-16
Misting Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-17
Air Lubricator Misting Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-17
Lubricants and Fluids Reference Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-18
i
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D811000719-PRO-001
Revision 05 Lubricants and Hydraulic Fluids
Page 1 of 20
General Recommendations
The lubrication intervals for NOV derrick-mounted equipment are based on lubricant
supplier recommendations, original equipment manufacturer instructions, and engineering
design criteria. Severe conditions such as extreme loads, extreme temperatures, or o
operating in a corrosive atmosphere may require more frequent lubrication intervals.
i
Hydraulic fluids must pour freely at the minimum operating
temperature. The Pour Point temperature of Hydraulic
Fluid should be at least 17°C or (30°F) lower than the
expected minimum ambient temperature. If the ambient
temperature approaches the Hydraulic Fluid Pour Point,
you may need to use a heater to get the fluid flowing and to
ensure proper lubrication of components.
i
Gear lubricant must pour freely at the minimum operating
temperature. The Pour Point temperature of Gear
Lubricant should be at least 6°C or (10°F) lower than the
expected minimum ambient temperature. If the ambient
temperature approaches the Gear Lubricant Pour Point,
you may need to use a heater to get the fluid flowing and to
ensure proper lubrication of components.
i
Clean or replace filters whenever lubricants and fluids are
replaced.
!
When adding or changing fluids (gear oil or hydraulic fluid),
take every precaution to prevent fluid contamination. 
Do not mix different types of fluids. Do not mix the same
type of fluid from different manufacturers.
1
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D811000719-PRO-001
Lubricants and Hydraulic Fluids Revision 05
Page 2 of 20
!
Always use NOV recommended lubricants in your NOV
equipment.
i
Contact an NOV Service Center for additional instructions
if none of the recommended lubricants have the correct
properties for ambient and operating temperatures ranges
at your location.
2
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D811000719-PRO-001
Page 3 of 20
Precautions
Make sure to read and understand the following prior to adding or changing lubricants.
!
Do not over-lubricate parts. Over-lubricating a fitting can
cause a bearing seal to pop out. Over-lubricated parts may
also drip, creating a slipping hazard.
Release all hydraulic oil pressure by bleeding

accumulators before disconnecting hydraulic lines.
Hydraulic oil under pressure can penetrate skin and
cause serious injury.

work area, and maintain system cleanliness by
i
Careful handling of all lubricants should always be
practiced. Avoid prolonged contact to skin, splashing into
eyes, ingestion or inhaling of vapor or mist. Refer to the
MSDS (Material Safety Data Sheet) for additional
information.
3
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D811000719-PRO-001
Page 4 of 20
Additional Information
Refer to the following for related information.
 The design notes provided on the assembly drawing in the Technical Drawing
Package (TDP) may list lubrication product information and instructions. The TDP is
located in the NOV equipment Owner’s Manual.
 There may be a nameplate on the equipment that provides lubrication product
information and instructions.
 The original equipment manufacturer’s (vendor) documentation may contain specific
lubrication and hydraulic fluid requirements. Vendor-supplied documentation is
located in the NOV equipment Owner’s Manual.
 The Maintenance chapter in the NOV equipment User Manual provides the specific
component lubrication instructions.
 The Long-Term Storage section provides lubrication instructions associated with
putting NOV equipment back into service after prolonged storage. This section is
located in the NOV equipment User Manual.
4
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D811000719-PRO-001
Page 5 of 20
Hydraulic Fluid
NOV recommends anti-wear (AW) hydraulic fluid of the proper viscosity grade. AW
hydraulic fluid is typically mineral-based and contains anti-wear additives, along with rust
and oxidation inhibitors.
The hydraulic oil viscosity should be adjusted based on expected ambient conditions, refer
to the recommended hydraulic fluid tables for specific hydraulic fluids for start-up and
operating in non-arctic and arctic environments.
Hydraulic Fluid Cleanliness

In order to ensure reliable operation, hydraulic fluid must be maintained at a minimum
particle count (cleanliness) level that meets or exceeds an ISO 4406 rating of 17/15/12
(NAS Class 6 or better). Refer to the following NOV documents for specific instructions
about maintaining hydraulic fluid cleanliness:
 FIP00121 – Specification for Fluid Cleanliness and for Cleaning and Flushing
Hydraulic Lines
 SM00081 – Hydraulic Fluid Cleanliness Supplement
Change Interval
The hydraulic fluid should be changed after the first initial start-up or if returning the
equipment to service after prolonged storage.
 Change all hydraulic fluids yearly or as frequently as operating conditions require.
 Fill all hydraulic fluid systems to correct levels with specified lubricants. Refer to the
recommended hydraulic fluid tables for specific hydraulic fluids.
!
Do not mix different types of fluids. Do not mix the same
type of fluid from different manufacturers.
 Maintain a clean, sludge-free oil of proper viscosity.
Filters
Filters should always be replaced when changing hydraulic fluid. Refer to the Maintenance
chapter (in the NOV equipment User Manual) for filter descriptions and details.
 Replace filters every three (3) months or whenever the lubricants are changed.
5
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D811000719-PRO-001
Page 6 of 20
Hydraulic Fluid
Inspection
 Check the hydraulic fluid level daily.
i
Keep the hydraulic reservoir full at all times. The oil level
should be visible in the sight gauge.
 Inspect for leaks daily.

 Perform hydraulic system oil analysis once every six (6) months.
6
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D811000719-PRO-001
Page 7 of 20
Hydraulic Fluid
Non-Arctic Service Fluids
The recommended hydraulic fluid to use for start-up and operating in non-arctic
environments are provide in the following table.
i
All temperatures are in degrees of Celsius. The Fahrenheit
temperature is the reference temperature.
Recommended Hydraulic Fluids for Non-Arctic Service
Operating Temperature Range -12°C to 52°C (10°F to 125°F)
Premium Grade AW Hydraulic Oil (with anti-wear and anti-rust additives)
Kinematic
6.9 cSt @ 100°C (49 SUS @ 210°F)
Viscosity
Best Choice Viscosity Index 105
Pour Point -30°C (-22°F)
ISO/ASTM
46
Viscosity Grade
Hydraulic Transmission Oil
Kinematic
6.9 cSt @ 100°C (49 SUS @ 210°F)
Viscosity
Alternative Viscosity Index 100 (minimum)
ISO/ASTM
46
Viscosity Grade
i
if none of the recommended hydraulic fluids have the
correct properties for the ambient and operating
temperature ranges at your location.
7
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D811000719-PRO-001
Page 8 of 20
Hydraulic Fluid
Arctic Service Fluids
The recommended hydraulic fluid to use for start-up and operating in arctic environments
are provide in the following table.
Recommended Hydraulic Fluids for Arctic Service
Operating Temperature Range -40° C to 17°C (-40° F to 63°F)
Supreme Grade AW Hydraulic Oil (with anti-wear and anti-rust additives;

high shear stability)
Kinematic
5.5 cSt @ 100°C (44 SUS @ 210°F)
Viscosity
Best Choice
Viscosity Index 377
ISO/ASTM
15
Viscosity Grade
Supreme Grade AW Hydraulic Oil (with anti-wear and anti-rust additives;

Kinematic
3.72 cSt @ 100°C (39 SUS @ 210°F)
Viscosity
Alternative
Viscosity Index 140
ISO/ASTM
15
Viscosity Grade
Premium Grade AW Hydraulic Oil (with anti-wear and anti-rust additives;

Kinematic
6.4 cSt @ 100°C (47.5 SUS @ 210°F)
Viscosity
Alternative
Viscosity Index 155
ISO/ASTM
32
Viscosity Grade
i
if none of the recommended hydraulic fluids have the
correct properties for the ambient and operating
temperature ranges at your location.
8
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D811000719-PRO-001
Page 9 of 20
Gear Oil
You should select gear oil based on the minimum ambient temperature expected before
the next oil change.
!
Using an oil with a viscosity greater than what is required
could reduce oil flow and damage the gearbox. Higher
viscosity oils may also damage the oil pump with excessive
load.
You should use an extreme pressure (EP) gear oil. EP gear oils are typically mineral oils
that contain sulfur-phosphorous additives. Most EP gear oils meet American Gear
Manufacturers Association (AGMA) extreme pressure performance requirements.
i
Check the gearbox oil level daily.
i
Change oil whenever it becomes contaminated. Oil
contamination depends on operating conditions and
temperature. Continuous operation at 180°F (82°C), or
above, will require more frequent oil changes.
Inspection
 Inspect the oil level and check for leaks every 250 operating hours.
 Examine oil for changes in its appearance and odor.
Change Interval
 The gear oil should be thoroughly drained after 500 operating hours or after the first
(1) month of operation, following the initial start-up or if returning the equipment to
service after prolonged storage.
 Under normal operating conditions, the gear oil should be changed every six (6)
months, and oil viscosity should be adjusted based on expected ambient conditions
for the next six (6) months.
 The gear oil should be drained when at normal operating temperatures. Refer to the
table titled "Recommended Gear Oil for the Transmission Gearbox" on page 10.
9
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D811000719-PRO-001
Page 10 of 20
Gear Oil
Low-Temperature Operation
Equipment operating in cold areas must be provided with gear oil that circulates freely and
does not cause high torque at start-up. Lubrication viscosity must be low enough to allow
the oil to flow freely at start-up, but high enough to carry the load at operating temperature.
Gearbox Lubricants
The recommended gear oil grades for ambient and operating temperature ranges are
provided in the following table.
i
All temperatures are in degrees of Celsius. The Fahrenheit
temperature is the reference temperature.
Recommended Gear Oil for the Transmission Gearbox
Operating Temperature Range
Ambient Temperature Gear Oil Minimum

Operating Temperature Recommended Grade
10°C to 52°C
16°C (60°F) AGMA No. 7 EP, ISO/ASTM VG 460
(50°F to 125°F)
-9°C to 16°C
4°C (25°F) AGMA No. 6 EP, ISO/ASTM VG 320
(15°F to 60°F)
-29°C to -4°C
-23°C (-9°F) AGMA No. 4 EP, ISO/ASTM VG 150
(-20°F to 25°F)
-46°C to -18°C
-40°C (-40°F) AGMA No. 4 EP, ISO/ASTM VG 100
(-50°F to 0°F)
i
if none of the recommended gear oils have the correct
properties for the ambient and operating temperature
ranges at your location.
10
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Page 11 of 20
Grease
General Lubrication
The recommended grease for general preventative maintenance is provide in the following
table.
General Lubricant Recommendation
Ambient Temperature Range  Ambient Temperature Range 

Above -20°C (above -4°F) Below -20°C (Below -4°F)
NLGI Grade Number 2 NGLI Grade Number 1
Lithium-based, general purpose, extreme- Lithium-based, general purpose, extreme-

pressure grease pressure grease
Conventional Washpipe Lubricating Greases

The recommended washpipe assembly grease for general preventative maintenance is
provide in the following table.
Washpipe Lubricant Recommendation
Moderate Operating Conditions Extreme Operating Conditions

(High Speed, Pressure, and Fluid Temp.)
NLGI Grade 2 NLGI Grade 3
Non soap-based moly grease Non soap-based moly grease
NOV Part Number – 7806084 NOV Part Number – 7806663
i
if none of the recommended greases have the correct
properties for the ambient and operating temperature
ranges at your location.
11
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Page 12 of 20
Grease
Motor Bearings Lubricating Greases
Some motors are equipped with greased bearings, which must be lubricated at
manufacturer-recommended intervals.
Generally, drilling motors and blower motors are vendor-supplied equipment. The motor
housing may have a nameplate attached to it that provides the recommended lubrication
product, amount to use, and lubrication intervals.
If there is no nameplate, refer to the vendor-supplied documentation in the Owner’s
Manual. If no vendor reference information is supplied, contact an NOV Service Center.
 Lubricate the drilling motor and blower motor bearings every six (6) months or as
specified by the original equipment manufacturer, refer to your User Manual or to the
vendor-supplied documentation in the Owner’s Manual.
!
Always use the recommended lubrication product specified
by the original equipment manufacturer.
IBOP/Kelly Valve Actuator Lubricating Greases

IBOPs and Kelly valve actuators may be vendor-supplied equipment. The actuator
assembly may have a nameplate that provides the recommended lubrication product,
amount to use, and lubrication intervals.
If there is no nameplate, refer to the vendor documentation in the Owner’s Manual.
If no vendor-supplied reference information is available, use grease with properties that
meet the NLGI Grade 1.5 specification.
!
Always use the recommended lubrication product specified
by the original equipment manufacturer.
12
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Page 13 of 20
Grease
External Pinion & Gear Set Lubricating
Greases
Lubricate all external pinion and gear sets, such as the following:
 Handling Ring Assembly
 Repositioner Assembly
 Crown Tooth Gear Coupling
Lubricate external pinion and gear sets weekly with a light coating to the entire pinion and
gear set.
The recommended external pinion and gear set grease for general preventative
maintenance is provide in the following tables.
Handling Ring Pinion & Gear Set Lubricant Recommendations
For all environment conditions:
Coat the gear teeth with an extreme pressure lubricant such as NOV "Copper Top", Jet Lube Inc.
"Kopr-Kote" compound, or equivalent.
Crown Tooth Gear Coupling Lubricant Recommendation
Moderate Operating Conditions Extreme Operating Conditions 

(High Speed, High Torque)
NLGI Grade Number 1 NGLI Grade Number 2
Lithium-based, general purpose, extreme- Lithium-based, general purpose, extreme-

pressure grease pressure grease
Repositioner Pinion and Gear Set Lubricant Recommendation
For all environment conditions:
Coat the gear teeth with an extreme pressure lubricant such as NOV "Copper Top", Jet Lube Inc.
"Kopr-Kote" compound, or equivalent.
13
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D811000719-PRO-001
Page 14 of 20
Wire Rope Lubricant

Lubrication of wire rope at proper intervals will maintain the initial lubrication of the wire
rope equipment. You should use an unleaded extreme pressure lubricant specifically
designed for wire rope lubrication. Wire rope lubricants are typically mineral oils that
contain additives and inhibitors for non sheening, extreme pressure, corrosion, low
temperature flexibility, and low fling off adhesive attributes.
Inspection
Periodically inspect the wire rope and determine the condition of the strand and the
condition of the lubricant coating, and if there is question on either the strand or lubricant
coating the following procedures should be followed:
 When performing wire rope lubrication inspection, use appropriate tools, dry clean
rags, and wear protective hand and eye safety equipment when examining or
cleaning the rope. Never use detergents or solvents to clean rope; the use of
solvents can effect or diminish the rope’s lubricant.
 Visually inspect the entire length of wire rope for bare rope surface, lubricant build
up, lubrication appearance, and contamination. Refer to the applicable OEM
literature in the User Manual for lubrication and inspection schedules for wire rope
equipment.
 Visually and physically examine the entire length of wire rope and determine if its
acceptable for service or requires replacement before re-dressing with rope
lubricant. Refer to the applicable OEM literature in the User Manual for additional
information for wire rope equipment.
i
Always follow all federal, state and local rules, code and
rig-specific wire rope guidelines for inspection and
maintenance of wire rope equipment. Inspection and
lubrication recommendations provided in this supplement
do not take precedence over local rules and regulations,
OSHA regulation, or instructions issued by the
manufactures of wire rope.
14
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Page 15 of 20
Wire Rope Lubricant

Lubricating
Lubricate wire rope equipment frequently. Lubricate whenever rope becomes
contaminated or shows a lack of lubrication. Lubricating depends on operating conditions,
severe conditions such as extreme loads or temperature, corrosive atmosphere, and so on
may require more frequent lubrication.
The following procedure provides basic field dressing for wire rope equipment:
 Clean wire rope before lubricating to ensure it is free of contamination, moisture,
and lubricant build up.
 Manually brush the rope uniformly as possible with new lubricant over the entire
length of wire rope.
i
The lubricant used must be compatible with the initial
lubricant applied by the wire rope manufacture.

Follow recommendations concerning the temperature of
the wire rope and atmosphere required when applying
lubricant.

The recommended wire rope lubricant for general
preventative wire rope maintenance is provide in the table
titled "Recommended Lubricant for Wire Rope" on page
16. See OEM literature for additional maintenance
information or contact your NOV representative.
15
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Page 16 of 20
Wire Rope Lubricant

Rope Lubricants
Recommended Lubricant for Wire Rope1
Ambient Temperature Range 

Above 6°C (Above 43°F)
Viscosity NGLI Grade Number 2
Color Blue
Texture Smooth/Creamy
Soap Type Lithium 12
Mineral Oil 50% Nominal
Oil Separation% (Fed 791-321.1 1.94%
Penetration: mm, (ASTM D217) 305
Viscosity, cST at 40 degrees Centigrade 320
Viscosity, cST at 100 degrees Centigrade 21-23
Dropping Point, C (F) 177 C (350 F)
Low Temperature Flexibility (Section 4.4.4, No

Pass
cracks @ 6 degrees C)
Rust Test, ASTM D-1743 Pass
Salt Fog Corrosion Resistance ASTM B117 1,000 hr. / Pass
Salt Spray, Fed, Standard 791, TM 4001 Pass
Accelerated Weathering (ASTM G 152, 153) Pass
Load Wear Index (ASTM D2596) 34.43
Adhesive% (Sec.4.6.6 150rpm @ 151 +/-2

99.7
leg/F)
Volatile Matter (2.0% Max.) 1.02
4-Weld, kg 250
4-Ball Wear Diameter, mm, max 0.65
LC50 Value (Over 25,000 PPM)
1. Coat the wire rope products with a lubricant designed for wire rope lubrication having the recom-
mended properties in the above table such as “Dynagard Blue”, or equivalent.
16
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Page 17 of 20
Misting Oil
Air Lubricator Misting Oil
Use misting type oil, 29-35 cSt @ 38°C (136-165 SUS @ 100°F), ISO Viscosity 
Grade 32.
17
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18
Lubricants and Fluids Reference Chart
ASTM/ Kinematic Viscosity
Component Environment Lube Type ISO-VG/SAE NLGI AGMA Viscosity Index Pour Point
6.9 cSt @ 100°C

Hydraulic Oil1 Grade 46 --- --- 105 -30°C (-22°F)
(49 SUS @ 210°F)
-12°C to 52°C
(-10°F to 125°F) Hydraulic
6.9 cSt @ 100°C
Transmission Grade 46 --- --- 100 min. -37°C (-35°F)
(49 SUS @ 210°F)
Oil
6.4 cSt @ 100°C

Hydraulic (47.5 SUS @ 210°F)
-30°C to 17°C)
System
-22°F to 63°F
7.5 cSt @ 100°C
AT Fluid Grade 10W --- --- 172 -48°C (-54°F)
(51 SUS @ 210°F)
3.72 cSt @ 100°C

Lubricants and Hydraulic Fluids
(39 SUS @ 210°F)

-40°C to 0°C
(-40°F to 32°F)
5.5 cSt @ 100°C
(44 SUS @ 210°F)
10°C to 52°C 30.3 cSt @ 100°C

Grade 460 --- #7 EP 95 -7°C (20°F)
(50°F to 125°F) (150 SUS @ 210°F)
-9°C to 16°C EP Gear Oil 24.0 cSt @ 100°C

Grade 320 --- #6 EP 95 -18°C (0°F)
(15°F to 60°F) (120 SUS @ 210°F)
Gearbox and
Swivel Bearing
-29°C to -4°C 14.5 cSt @ 100°C
Grade 150 --- #4 EP 95 -23°C (-10°F)
(-20°F to 25°F) 78.1 SUS @ 210°F
-46°C to -18°C Synthetic 14.4 cSt @ 100°C

Grade 100 --- --- 149 -46°C (-50°F)
(-50°F to 0°F) Gear Oil (77.1 SUS @ 210°F)
> -7°C (20°F) --- #2 --- --- --- ---

Repositioner
Bearing EP Grease4
< -7°C (20°F) --- #1 --- --- --- ---
1. Must be Premium Grade with Anti-Rust and Anti-Wear Additives.

2. Must be Premium Shear Stable High VI, anti-wear hydraulic oil.
3. Must be Supreme Grade High Shear stability, anti-wear hydraulic oil with anti-rust and anti-wear additives.
4. Lithium base, general-purpose, extreme pressure grease.
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Page 18 of 20
Revision 05
Revision 05
ASTM/
Page 19 of 20
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ISO-VG/ Kinematic Viscosity
Component Environment Lube Type SAE NLGI AGMA Viscosity Index Pour Point
D811000719-PRO-001
External Pinion
and Gear Sets,
and Elevator
All EP Grease1 --- #2 --- --- --- ---
and Main Links
contact
surfaces
Metalon 
IBOP/Kelly Hi-Tech 1.5
All --- #1.5 --- --- --- ---
Valve Actuator
Grease2
Drilling Motor
Bearings
All EP Grease3 #2 --- --- --- ---
Blower Motor
Bearings
29-35 cSt @ 38°C

Air Lubricators All Misting Oil Grade 32 --- --- 125 -12°C (10°F)
(136-165 SUS @ 100°F)
General > -4°C (20°F) --- #2 --- --- --- ---

Grease EP Grease4
Bearings < -4°C (20°F) --- #1 --- --- --- ---
Moderate
Primrose Plus
Operating --- #2 --- --- --- ---
Conventional # 327
Conditions
Washpipe
Packing
Extreme
Grease Primrose Plus
Operating --- #3 --- --- --- ---
# 327 C
Conditions
1. For example: Jet-Lube KOPR-KOTE or NOV “Copper Top.”

2. Use the lubrication product specified by the original equipment manufacturer.
3. Polyurea-based grease or as specified by the motor manufacturer.
4. Lithium base, general-purpose, extreme pressure grease.
19
20
ASTM/
ISO-VG/ Kinematic Viscosity
Component Environment Lube Type SAE NLGI AGMA Viscosity Index Pour Point
Wire Rope
Wire Rope > 6°C (43°F) --- #2 --- --- --- ---
Lubricant1
1. Lithium 12 base, containing additives and inhibitors for non sheening, extreme pressure, corrosion, low temperature flexibility, strong adhesion, and low fling off.
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Page 20 of 20
Revision 05
FINAL DOCUMENTATION
Chapter 17.0
www.nov.com
Hydraulic
Fluid
Cleanliness
Supplement
SM00081 Rev. C
October 26, 2000
Copyright 2000, Varco International, Inc.
All rights reserved. This publication is the property of

and contains information proprietary to Varco
International, Inc. No part of this publication may be
reproduced or copied in any form or by any means,
including electronic, mechanical, photocopying,
recording, or otherwise, without the prior written
permission of Varco International, Inc.
Product names mentioned in this publication may be

trademarks or registered trademarks of their respective
holders and are hereby acknowledged.
ii Hydraulic Fluid Cleanliness SM00081-C

Contents
Supplement

Scope .................................................................................................................... 5
Hydraulic Fluid Cleanliness ................................................................................. 6
Hydraulic fluid ............................................................................................... 6
Hydraulic Fluid Contamination ............................................................................ 7
Solid contamination ....................................................................................... 7
Classes of contamination ......................................................................... 7
Measuring the contamination of a system ............................................... 9
Taking samples .................................................................................. 9
Analyzing the samples .......................................................................... 10
Cleanliness during installation ........................................................................... 11
Service loops ................................................................................................ 11
Hydraulic pipe cleaning ............................................................................... 11
Reference documents: ........................................................................... 11
Pipe cleaning (carbon steel): ................................................................. 11
Pipe cleaning (stainless steel) ................................................................ 13
SM00081-C Contents iii

October 26, 2000
iv Hydraulic Fluid Cleanliness SM00081-C

Supplement
Hydraulic Fluid
Cleanliness
Scope
The purpose of this document is to provide guidance to the installers and users of
Varco’s hydraulically powered equipment and to ensure that each piece of equipment
performs as intended. Prior to connecting Varco equipment to a hydraulic system, the
piping/plumbing/hoses/service loops must be cleaned and the hydraulic fluid filtered to
minimize hydraulic fluid contamination. The following paragraph defines the
hydraulic fluid cleanliness levels required for operating Varco equipment. Failure to
maintain these cleanliness levels could result in premature equipment damage and
nullification of the equipment warranty.
This document outlines fluid cleanliness measurement and analysis criteria and also
describes procedures for filtering and cleaning a hydraulic system.
Each final assembly item from Varco will be function tested with clean hydraulic fluid
maintained at ISO 4406 18/15 (was 9) or better (See Table 1). The hydraulic fluid
cleanliness levels will be recorded on Test Specification document (TS00419) for each
piece of equipment prior to shipment.
SM00081-C Hydraulic Fluid Cleanliness 5

October 26, 2000
Hydraulic fluid
Varco recommends hydraulic fluid levels be maintained at a cleanliness level of ISO
4406 18/15 (was 9) or better prior to the initial connection, startup, and commissioning
of Varco equipment. After initial system operation, Varco recommends that the
hydraulic supply system be capable of continuously maintaining this level of
cleanliness or better to assure that fluid contamination is not a factor in any component
failure during the desired useful life of the hydraulic powered equipment. The final
level of acceptable cleanliness prior to equipment hook up must be determined by a
hydraulic fluid sample and should be analyzed by a qualified laboratory.
6 Hydraulic Fluid Cleanliness SM00081-C

Hydraulic Fluid Contamination
Hydraulic Fluid Contamination
Solid contamination
When determining contamination of hydraulic fluids, you must consider the size and
quantity of the solid particle contamination within a representative fluid sample. The
contamination of hydraulic fluids by solid particles is covered by a number of different
classification systems:
❏ ISO DIS 4406

❏ MIL STD 1246 A
❏ NAS 1638
❏ SAE 749 D
❏ CETOP RP 70 H
CLASSES OF CONTAMINATION
The various classes of contamination define the quantity of particles of a certain size in
a 100 ml sample of fluid.
A classification is determined by counting and sizing the contaminating solid particles.

The classification is performed either under a microscope, or by using an electronic
particle counter. The electronic counter method is more objective than using the
microscope.
Above a dirt concentration of about 20 mg per liter, or if the fluid is very turbid, the
contamination can only be ascertained by weight, i.e., by gravimetric analysis.
However, with this method, the individual dirt particles cannot be classified.

October 26, 2000
ISO DIS Particles ACFTD Mil STD NAS 1638 SAE 749 D
4406 per ml solids 1246 A (1967) (1963)
or >10 µm content (1967)
Cetop RP mg/L
70 H
26/23 140000 1000
25/23 85000 1000
23/20 14000 100 700
21/18 4500 12
20/18 2400 500
20/17 2300 11
20/16 1400 10
19/16 1200 10
18/15 580 9 6
17/14 280 300 8 5
16/13 140 1 7 4
15/12 70 6 3
Acceptable range for Varco equipment
Acceptable range for Varco equipment

14/12 40 200
14/11 35 5 2
13/10 14 0.1 4 1
12/9 9 3 0
18/8 5 2
10/8 3 100
10/7 2.3 1
10/6 1.4 0.01
9/6 1.2 0
8/5 0.6 00
7/5 0.3 50
6/3 0.14 0.001
5/2 0.04
Figure 1. Comparison of contamination classifications

Comparison of contamination classifications
MEASURING THE CONTAMINATION OF A SYSTEM

Solid particle contamination is measured by taking a sample of fluid from the output of
the hydraulic supply system at a location just prior to the Varco equipment and
analyzing it.
The analysis can reveal the following:
❏ Solid particle contamination of fluid delivered by suppliers

❏ Effectiveness of the system filters
❏ Flushing time when commissioning a system
❏ State of the system and any possible damage to components when making regular
checks
Taking samples
Take a sample from a moving fluid (known as dynamic sampling)
Sampling point: Take the sample within a system that is operating and which contains
turbulent flow. (See ISO 4021.)
Since obtaining a fluid sample can be an input for contamination the following general
measures should be utilized when taking a fluid sample.
❏ Utilize continuous flow monitoring equipment that records a cleanliness level over
a period of time whenever possible.
❏ Take a sample of the circulating fluid of a system that is at operating conditions and
temperature. All fluid samples shall be taken from a system test-port fitting using
a on/off flow sampling device. Never loosen or break a hydraulic fitting to establish
a leak point as a fluid source for fluid contamination sampling.
❏ Before attaching the sampling device, carefully flush out the device and clean the
system test-port fitting.
❏ Open sampling device and allow approximately 2 liters of fluid to flow through the
test port prior to sampling the fluid.
❏ Without shutting the test port, open and fill the sterile sampling bottle by holding
it in the continuous fluid stream. Cap and seal the test bottle.
❏ Label and date the sample bottle to identify the tool and sample hydraulic circuit
location.
e Only properly trained personnel should be allowed to take the fluid samples. Errors in
sampling procedures can greatly affect contamination classes below ISO 18/IS.

October 26, 2000
ANALYZING THE SAMPLES

Analyzing the fluid samples involves using a microscope to make a quick estimate of
the amount of solid particle contamination. From this assessment, you can roughly
assess the state of the system.
To avoid errors in sampling, conduct particle counting off site. Do not allow rig
personnel to attempt to check the samples at the time of sampling. Send the samples to
an appropriate institute for testing.
Usually, samples are analyzed by means of an electronic particle counter. These

particle counters are employed by major users of hydraulics, manufacturers of
hydraulic filters, and by various institutions. Since testing by an outside source may not
be easily accessible from a rig, you can make a quick assessment of the fluid samples
on the spot by using the assessment test charts in this document.
z Mobile laboratory services can also perform the measurements for customers.

Cleanliness during installation
Service loops
Varco service loops are blown clean in the factory and capped prior to shipment. They
are not flushed. All service loops and hoses should be flushed as part of the overall
hydraulic system prior to connecting Varco equipment.
Hydraulic pipe cleaning

z Clean hydraulic piping is critical to the cleanliness of the overall hydraulic system. The
following processes are examples of pickling, cleaning, and flushing procedures for
cleaning carbon steel and stainless steel pipes prior to hydraulic system installation and
are provided for information and reference only. Varco is typically not responsible for
any part of the pickling, cleaning, or flushing process of derrick and rig floor piping.
The process for cleaning and preparing hydraulic pipes is dependent on the type of pipe
(carbon or stainless), the condition of the pipe (pickled or not pickled), the types and
levels of contamination, the types and temperatures of the pickling and flushing
solutions in use, and the type of flushing equipment.
REFERENCE DOCUMENTS:
❏ ASTM Standard 5.02 D-4174, standard practice for cleaning, flushing, and
purification of petroleum fluid hydraulic system.
PIPE CLEANING (CARBON STEEL):

Obtain the following chemicals:
Hydrochloric acid - 35% commercial grade
Alkaline cleaner, KD-500
Potable water - Unless otherwise specified
Passivator - iron phosphate, KO-30
Inhibitor - Rodine 214 for HCL

October 26, 2000
Degrease
Spray, immerse, or circulate with alkaline cleaner. Degreasing time for pipe depends
on the nature of any contaminants present. Pipes and fittings with heavy rust, varnish
or other tough soils should be sandblasted prior to pickling.
Rinse
Rinse carbon steel pipe with potable water until all alkaline cleaner is removed.
Acid pickle
Immerse or spray the pipe with a 10-15% inhibited hydrochloric acid solution at
ambient temperature (for at least one hour) until all scale, slag, rust, etc. Is removed.
Rinse with potable water until all alkaline cleaner is removed.
Rinse
Rinse the pipe with potable water until the water reaches a neutral PH (7.0).
Flush
Begin flushing the piping with the hydraulic power unit until the desired state of
cleanliness is met.

PIPE CLEANING (STAINLESS STEEL)

Use the following recommended procedure for cleaning stainless steel pipe:
Obtain the following chemicals:
Nitric acid - 42% technical grade
Hydrofluoric acid - 35% technical grade
Alkaline cleaner, KD-500
Potable water - unless otherwise specified
Degrease
Spray, immerse, or circulate with alkaline cleaner. Degreasing time for pipe depends
on the nature of any contaminants present.
Rinse
Rinse pipe with portable water until all alkaline cleaner is removed.
Acid pickle
Immerse or spray the pipe with a 15-17% nitric acid/3-5% hydrofluoric acid mixture at
ambient temperature (for at least two hours) until all scale, slag, rust, etc. is removed.
Rinse
Rinse the pipe with potable water until the water reaches a neutral PH.
Passivate
Use a 10 - 15% nitric acid/75-80% potable water mixture at ambient temperature for
approximately one-half the time used in acid pickling.
Rinse
Rinse with potable water until the PH of the effluent equals the pH of the influent.
Dry
Dry with oil-free air until all visible traces of moisture are removed.
Final inspection
Use a white light to inspect all pipe and/or fittings for visible contamination. Prior to
hooking up equipment pump clean hydraulic fluid through the plumbing and measure
the contamination of the system per this specification. Additional flushing and cleaning
may be required if contamination levels do not meet the requirements of this
specification.

FINAL DOCUMENTATION
Chapter 18.0
Service Center Directory
www.nov.com
National Oilwell Varco
Service Center Directory

and remains the property of NOV. Reproduction, in whole
or in part, or use of this design or distribution of this RIG SOLUTIONS
information to others is not permitted without the express 11000 Corporate Centre Drive
written consent of NOV. This document is to be returned to Houston, TX 77041
NOV upon request or upon completion of the use for which
it was loaned. This document and the information
contained and represented herein is the copyrighted
property of NOV.
D811001337-DAS-001 04
www.nov.com
Form D811001123-GEN-001/06
D811001337-DAS-001
Revision 04
Revision History
04 12.11.2011 Operations update T. Drake S. Sobreira T. Harmon
03 18.01.2011 Operations update T. Drake T. Harmon T. Harmon
02 02.10.2009 Operations update T. Drake T. Harmon P. Williams
01 08.09.2009 First Issue T. Drake T. Harmon P. Williams
Change Description
01 First Issue
• Moved Cairo office under North Africa heading.

02
• Changed address information for India office.
• Removed outdated Louisiana contact information.

03
• Added the new Louisiana service and repair center contact information.
• Updated/added Brazil, Canada, Colombia, UK contact information (page 3 through page 8).
• Added North Dakota contact information (page 4).
04 • Updated the contact information for the China office (page 6).
• Added addresses and contact information for Singapore and India (page 6).
• Updated contact information for NOV Dubai and NOV Abu Dhabi. (page 8).
www.nov.com
D811001337-DAS-001
Revision 04
Service Center Directory SC
http://www.nov.com/ContactUs/24HrEmergencyContacts.aspx
Americas
Brazil
National Oilwell Varco do Brasil
Rodovia Amaral Peixoto, s/n KM164,5 - n° 8.500
Imboassica – Macaé – RJ – Brazil
CEP 27925-290
+55 22 2773 0600 (reception)
+55 22 9882 7591 (after hours)
+55 22 9702 8866 (drilling equipment)
+55 22 9974 7056 (PCE / MoComp equipment)
+55 22 9894 6608 (lifting and handling equipment)
+55 22 2773 0635 (repair shop)
+55 22 2773 0675 (inside sales)
+55 22 2123 2452 (tech college)
Canada
NOV Rig Solutions Aftermarket Service, Repair and Rentals (Leduc)
Varco Canada ULC CO 009
6621 – 45 Street
Leduc, Alberta, Canada
T9E 7E3
+1 780 986 1712 (main)
NOV Rig Solutions Spares (Edmonton)
Varco Canada ULC CO 009
7127 – 56 Ave
Edmonton, Alberta, Canada
T6B 3L2
+1 780 801 1800 (main)
+1 780 619 5579 (24 hour on-call)
Colombia
National Oilwell Varco de Colombia
Bogota, DC
Top Drive Rental and Service
+57 316 875 8748 (mobile)
+57 317 515 3321 (mobile)
3
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Form D811001123-GEN-001/06
D811001337-DAS-001
SC Service Center Directory Revision 04
Page 4 of 10
Americas
USA
Colorado
NOV Service and Repair (Colorado)
420 South Ash St.
Fruita, CO 81521
+1 970 858 4522
+1 281 569 3050 (after hours)
Louisiana
NOV Service and Repair (Covington)
73765 Penn Mill Rd.
Covington, LA 70435
+1 985 892 8216 (direct)
+1 800 722 4425 (toll free)
(Cranes: AmClyde, Unit, OS National, Dreco, Kingpost)
+1 985 871 8609 (service)
+1 985 871 8603 (parts
NOV Service and Repair Center (New Iberia)
5212 Highway 90 Service Road West
New Iberia, Louisiana 70560
(All NOV spare parts; legacy Shaffer, Varco, and NOI equipment)
+1 337 374 1400
Minnesota
NOV Service (St. Paul)
240 East Plato Blvd.
St. Paul, Minnesota 55107
(lifting and handling equipment)
+1 651 293 4745 (service)
+1 651 293 4776 (service)
+1 651 293 4600 (parts)
+1 651 293 4603 (parts)
North Dakota
NOV Service, Repair, and Spare Parts
3201 1st Avenue W.
Williston, ND 58801
+1 307 473 8888
+1 281 569 3050 (after hours)
Oklahoma
NOV Service and Repair (Oklahoma City)
7713 North West 3rd St.
Oklahoma City, Oklahoma 73127
+1 405 495 1000
+1 281 569 3050 (after hours)
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Americas
USA
Pennsylvania
NOV Service (Pittsburgh)
1349 Saw Mill Run Blvd.
Pittsburgh, Pennsylvania 15226
+1 412 884 1027
+1 281 569 3050 (after hours)
Texas
NOV Service and Repair (Alice)
2351 Energy Avenue
Alice, Texas 78380
+1 361 668 4154
+1 281 569 3050 (after hours)
NOV Service and Repair (Houston)
5100 North Sam Houston Parkway West
Houston, Texas 77086
+1 281 569 3050 (24/7 technical support)
+1 281 569 3051 (eHawk remote support)
Wyoming
NOV Service and Repair (Casper)
1080 North Robertson Road
Casper, Wyoming 82601
+1 307 473 8888
+1 281 569 3050 (after hours)
Venezuela
NOV Rental and Service (Maturin, Monagas)
Varco International de Venezuela
Top Drive Rental and Service
+58 291 651 6489
+58 414 394 2784 (mobile)
+58 291 651 4384 (fax)
5
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D811001337-DAS-001
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Asia
China
NOV Service
18th Floor, Raffles City Beijing Office Tower
No. 1, Dongzhimen South Street, Dongcheng District
Beijing 100007 P. R. China
+86 139 0121 9392
+86 800 810 5109 (24/7 technical support)
India
NOV Service and Repair
R-619, TTC Industrial Area
Rabale, MIDC
Navi Mumbai – 400 701
Maharashtra, India
+91 22 3916 9700
+91 982 009 1322
+91 983 349 6154 (after hours)
NOV Machining Centre (Pressure Control)
11A/2 (NP) Sidco Industrial Estate
Ambattur
Chennai, Tamil Nadu, India 600098
+91 44 4285 8074
+91 95 0008 4149 (after hours)
Singapore
NOV Service and Repair
29 Tuas Bay Drive
Singapore 637429
+65 6594 1000
+65 6594 1222 (24/7 technical support)
NOV Machining Centre (Pressure Control)
22 Jalan Terusan
Singapore 619299
+65 6265 1900
+65 9128 2545 (after hours)
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Europe
France
NOV Service
+33 24 068 3600
+33 24 068 3611
+33 24 068 3600 (after hours)
+33 677 790 943 (after hours)
Norway
NOV Service (Asker)
Blakstadmarka 26
1386 Asker – Norway
+47 6400 5000
+47 6400 5001 (after hours)
NOV Service (Kristiansand)
Skibaasen 2
4636 Kristiansand – Norway
+47 3819 2000
+47 3819 2482 (after hours)
NOV Service (Molde)
Granfjaera 24
6415 Molde – Norway
+47 7120 2020
+47 9169 9664 (after hours)
NOV Repair (Stavanger)
Dusavik Base
Notberget 46
4029 Stavanger – Norway
+47 5781 8181
NOV Service (Stavanger)
Lagerveien 8
4069 Stavanger – Norway
+47 5181 8181
+47 4140 0041 (after hours)
+47 9511 8181 (24/7 eHawk remote support)
Russia
NOV Service and Support
Russia, 119071, Moscow
Leninsky prosp., 15A, 7th floor
+7 495 287 2601 (direct)
+7 495 981 3470 (fax)
+7 985 410 5272 (mobile)
7
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D811001337-DAS-001
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Europe
UK
NOV Service and Repair (Aberdeen/Montrose)
Forties Road
Montrose
Scotland
DD10 9ET
+44 1674 677222
UK after hours, on-call contacts
+44 (0) 7711 415 485 (mechanical)
+44 (0) 7711 415 484 (electrical)
+44 (0) 7739 170 079 (repair workshop)
+44 (0) 7713 643 012 (spare parts)
+44 (0) 7770 325 333 (distribution)
+44 (0) 7801 078 092 (IMO/MD Totco)
Middle East
UAE
NOV Service and Repair (Abu Dhabi)
Varco Al Mansoori Services LLC
P. O. Box 27011
Abu Dhabi, United Arab Emirates
+971 2 555 2668
+971 2 554 2280 (fax)
+971 2 554 0012 (fax)
+971 50 811 6083 (after hours service)
+971 50 617 1235 (after hours workshop)
NOV Service and Repair (Dubai)
P.O. Box 61490
R/A No.13, Plot MO 0682
Daimler Chrysler Street
Jebel Ali Free Zone
Dubai, United Arab Emirates
+971 4 883 8776
+971 4 883 8795 (fax)
+971 56 686 2184 (after hours service on-call)
North Africa
NOV Service (Algeria)
Overseas Equipment Service Africa
BP 852 Zone Industrielle Algerie
Hassi Messaoud Ouargla
Algeria 30500
+213 29 73 1236
+213 29 75 4105 (fax)
8
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Middle East
North Africa
NOV Service and Repair (Badr City)
IMPEC (Sea Harvest Company)
Part B, 47 Acer Area
Badr City, Cairo, Egypt
+20 2 231 08001
+20 2 231 08002
+20 2 231 08003 (fax)
Saudi Arabia
NOV Service and Repair (Dammam)
P. O. Box 20754, Al-Khobar 31952
Al Khobar, Saudi Arabia
Gate No. 2, Makkah Street (opposite of Saudi Electricity Company)
Dammam Second Industrial City
Dammam, Saudi Arabia
+966 3 835 3061
+966 3 830 2453 (fax)
9
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10660418-Man Tds-11sa

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TDS-11SA - Top Drive Drilling System

National Oilwell Varco References:

01 29.01.2013 For Information L. Krajenbrink I. Vargas H. Lim

Revision Change Description

Item Quantity Part Number Description

1 1 SM00856 Service Manual, TDS-11SA

NEXT ASSY PRODUCT

CURRENT INITIAL NOV-Houston, Rigs: ME-13, ME-14 & Stock Unit 3

Reference Reference Description

This document contains proprietary and confidential

C 11.11.2011 Engineering Update T. Drake H. Lim M. Clark

B 2006 Teamcenter migration version. – – –

A 2003 Teamcenter migration version. – – –

– 2000 First Issue: Original Instructions – – –

Rev Date (dd.mm.yyyy) Reason for issue Prepared Checked Approved

Revision Change Description

– First Issue: Original Instructions. No relevant issue history.

A Revision migrated in Teamcenter. No relevant revision history.

B Revision migrated in Teamcenter. No relevant revision history.

• Corrected Guide Beam Joint illustration (page 5-6).

Chapter 1: General Information

Installing Power Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7

Storage Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-45

Inspecting Rig Interface Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4

Appendix A: Hydraulic Symbols

Appendix B: PH-50 Pipe Handler

Inspecting the Clamp Cylinder Body . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-12

Figure 2-1. TDS-11SA Top Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2

Figure B-8. PH-50: Inspecting the Stabilizer. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-14

The note symbol indicates that additional information is

The warning symbol indicates a definite risk of

The hot surface symbol indicates the presence of a

The Electrostatic Discharge (ESD) symbol indicates the

Lifting equipment improperly creates a hazardous

General System Safety Practices

 Isolate energy sources before beginning work.

Equipment Documentation Location

Introduction to the TDS-11SA

Introduction to the TDS-11SA

Hydraulic Disc Gooseneck

Rear Right Side

Left Side Front

Figure 2-1. TDS-11SA Top Drive

• 35,000 lb (15,876 kg) – Top Drive/Shipping Skid

Stack-up height 19 ft (5.8 m)

Power requirements 700 KVA @ 575-600 VAC, 50/60 Hz

Output torque (continuous) 37,500 ft-lb (50,843 N-m) (800 hp)

Maximum speed (at full power) 228 rpm

Hoisting capacity 500 ton (453.6 mt)

Load path Single

Gooseneck entry 3 in. 1002 female union

Drilling Motor Type Reliance AC-575 VAC (2 x 400 hp)

Motor Braking Type Hydraulic caliper disc brakes

Type Local intake pressure blower

Type Single speed, double reduction helical gear system

Type Pressure feed

Reservoir capacity 15 gallons (56.8 liters)

Full internal flow 10 gpm (37.9 lpm)

Oil pressure 10 psi (minimum), 30 psi (maximum)