Troubleshooting

Indications of encoder circuit problems

The most frequent indication that there is something wrong with the encoder circuit is when
the top drive is started and the driller’s console meters show zero (or near zero) RPM and
the torque ramps up to limit.

Other indications of encoder problems are fault messages on the drive that indicate encoder
fault codes. If the encoder circuit does not fail completely, it is possible to observe
intermittent erratic behavior of the top drive. This is indicated by rapid changes in RPM and/
or torque.

Failures of the encoder circuit are usually simple, but can sometimes be difficult to find.
Failures can include, but are not limited to, any one or more of the following:

■ short or open circuits in the cabling between the inverter and the encoder

■ broken solder connections in the cable plugs

■ wet or loose connectors

■ loose terminal block connections in the drive

■ noise induced due to improper cable routing (i.e., running the encoder leads too close to
higher voltage control circuits or blower motor cables)

■ noise induced due to improper grounding of the shields

■ simple electronic component failure

■ power supply failure

■ top drive operates properly for awhile, then it has all torque and no speed:
• intermittent short causing loss of pulses, the encoders short circuit protection
shuts off the outputs until it cools off.

7-6 Varco Systems

Troubleshooting
Disconnecting and Bypassing the DTI Board (Siemens drive)
Depending on the problems with the circuit, It may be necessary to disconnect the DTI
board and connect the encoder directly to the drive’s encoder input terminal blocks. The
encoder can be connected one of four ways. The way it is connected depends on what the
problem with the circuit is. Before disconnecting the DTI board, make sure you have
identified and marked the wires!!

Choose a circuit depending on the current need. Remember, if the drive does not turn and
torque iss up when you put it back into closed loop, the A and B leads may be backwards.
Reverse the connections and try it again. Remember that rotation is relative - it doesn’t
really matter which is A and which is B, as long as a combination is found that works.

+15VDC RET
+15VDC

A+
A

A-
Inverter terminal block
B+ B

B-

COM +15VDC

Use the A+ and B+ signals if there is a problem with A- or B-.

+15VDC
+15VDC RET
A+ 7
A- A

B+ Inverter terminal block

B- B

COM

+15VDC

Use the A- and B- signals if there is a problem with A+ or B+.

AC Top Drive Troubleshooting Guide 7-7

 Encoder troubleshooting instruction
The encoder provides rotational position information to the Variable Frequency Drive (VFD).
On most of the Top Drive Systems (TDS) in the field, the encoder signal comes into the
Varco interface terminal strip in the drive. The +15 VDC for the encoder is provided from the
drive and goes out on pin 37 (common) and pin 38 +15 VDC Most top drives use a
differential input signal. The Siemens drive uses an optional digital tach interface board to
convert this differential signal (A+, A- and B+, B-) to a single-ended signal A+ and B+. The
A+ signal is pin 40, the A- signal is 41, the B+ signal is 43 and the B- signal is 44. This can
be verified on the schematics. The waveforms for the respective signals are illustrated on
page 7-9.

The symptom of encoder failure is that the drive when assigned and throttle given does not
rotate or rotates very slowly (the torque gauge reads high). Failure indication on the drive
may or may not be apparent, or it may trip out due to overcurrent.

If you suspect the encoder, change the drive from speed control to frequency control per the
procedure described in this guide. If the top drive starts rotating, it is an encoder problem. If
it does not verify the changeover from speed control to frequency control correctly, try again.
If it still does not turn, examine the inputs to the drive and not the encoder. (On the Siemens
70, use Encoder By-pass Kit, Varco P/N 125580.)

The first check of the encoder should be measuring the signals with a voltmeter (this should
be done with the drive stopped). There should be approximately 15V between pin 38 and 37
(+15V and Common). If there is not, disconnect the encoder cable at the front of the house
to see if it is shorting out. There should be approximately 12V or greater between (A+ and A-
) and between (B+ and B-). If there is not and you have a scope, check the individual signals
to see which one(s) are missing. This requires running the top drive in the frequency mode.

7-8 Varco Systems

Encoder troubleshooting instruction

+15V
A+ 0V

+15V
A- 0V

+15V
B+ 0V

+15V
B- 0V

If a signal is missing, on the Siemens drive, signals can be rewires so that they do not pass
through the DTI CCA to keep running. If A+ and B+ are good, disconnect the A+ and B+
from the DTI CCA at X403. Then jump A+ to the A+ wire disconnected from X403-3, and B+
to the B+ wire disconnected from X403-3, and likewise with B- to B+.

n Miswired motors may look like an encoder problem.

AC Top Drive Troubleshooting Guide 7-9

 Product Bulletin No.: TDS-03-23
Release Top Drive Drilling Systems
September 22, 2003

Subject: Operation of AC Top Drives in Encoder Bypass Mode

Product: All TDS-8SA, 9SA, 10SA, 11SA and 11HP Top Drive Drilling Systems

Affected
Assemblies: Digital Encoder Assembly

Objective: Advise Operators of Possible Damage to Drill Pipe Connections during Make Up and
Break Out when Operating in Encoder Bypass Mode

Problem: All Varco AC Top Drive Drilling Systems utilize a digital encoder, which allows closed
loop control at near stall speeds when the Top Drive is making up or breaking out drill
pipe connections.

In the event that the digital encoder fails during normal operation, the control system
must be switched to Encoder Bypass mode or “open loop” control, which now
presents the operator with the ability to potentially damage drill string connections.
Failure of the encoder will not affect normal drilling operations, however, the torque
delivered by the Top Drive must be smooth and well regulated when making up and
breaking out drill pipe connections.

Solution: If an encoder fails during Top Drive operations, the encoder should be immediately
replaced. If operations do not allow immediate encoder replacement to be performed
or a replacement encoder is not available and operations cannot be halted, the
operator should be aware of the following recommendations:

1. Spinning In the Connection: This can be done in the normal manner as detailed
in the service manual, however, more movement from the Top Drive when the
connection shoulders up, should be expected.

Caution: If spinning up against the tongs, assure that ALL slack is out of the
tongs and that rig floor personnel are clear of the tongs at all times.

2003 Varco All Rights Reserved TDS-03-23

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 2. Torquing the Connection: Use the tongs or Automated Roughneck (if rig is so
equipped), to make up the lower connection. Remove the tongs or Automated
Roughneck from the drill pipe once the lower connection is made up and use the
Top Drive against the pipehandler back-up clamp to make up the upper
connection.

Caution: Do not make up the upper connection against a tong as this creates a
backlash movement with the Top Drive and may cause damage to the
equipment and/or injury to personnel.

3. Breaking Out Connections: Breaking out connections can be done in the

normal manner by breaking out against the pipehandler back-up clamp and
spinning out the connection.

Please contact your local Varco Service Center if you have any questions regarding this product
bulletin.

2003 Varco All Rights Reserved TDS-03-23

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