SM00053 D

Automated Iron Roughneck Service Manual
AR3200C
SM00053 Revision D
July 1, 2005
Copyright 2005, 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.
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AR3200
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C o n t en t s
Preface
Manual conventions ............................................................................................ xi Safety information ........................................................................................ xi Product Bulletins ......................................................................................... xii Directional references .................................................................................. xii PLC configurations ...................................................................................... xii Illustrations .................................................................................................. xii Varco Service Centers ........................................................................................ xii
Chapter 1
Description
General description ........................................................................................... 1-5 Makeup mode ..............................................................................................1-5 Breakout mode ............................................................................................ 1-6 Operator controls ......................................................................................... 1-6 Manual Control Station ........................................................................ 1-6 Operating in manual mode .............................................................. 1-6 Automatic Control Station ................................................................... 1-6 Tool J-box controls .............................................................................. 1-7 Major component description ............................................................................ 1-8 Chassis assembly ...................................................................................... 1-10 Frame .................................................................................................. 1-10 Carriage .............................................................................................. 1-10 Drive foot assemblies ......................................................................... 1-12 TW-102 Hydraulic Torque Wrench assembly .......................................... 1-14 Soft clamp feature .............................................................................. 1-14 SSW-50 Spinning Wrench assembly ........................................................ 1-16 Electrical control system ........................................................................... 1-18 Power distribution .............................................................................. 1-18 Systems with optional purge systems ............................................ 1-19 PLC assembly and enclosure ............................................................. 1-21 Siemens PLC .................................................................................1-21 Central Processing Unit (CPU) microprocessor ............................1-21 CPU Random Access Memory (RAM) ......................................... 1-21 Erasable Programmable Read-Only Memory (EPROM) slot .......1-22 Backup battery............................................................................... 1-22 Input/Output (I/O) interface...........................................................1-23 PLC power supply .........................................................................1-23 Digital I/O module.........................................................................1-23 Solenoid drivers .............................................................................1-23 Power supply (encoder) .................................................................1-25
Contents
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IS isolation amplifiers and Zener barriers......................................1-25 Expo PLC purge air system (optional) ..........................................1-25 Position and proximity sensors/switches ............................................ 1-26 Hydraulic system ..................................................................................... 1-30 Hydraulic manifold assembly ............................................................. 1-30 Pressure-reducing Valve (PRV) ......................................................... 1-30 Lift cylinder circuit ............................................................................. 1-31 Linear position slave cylinder assembly ............................................ 1-31 Horizontal travel circuit ...................................................................... 1-31 Spinning wrench clamp circuit ........................................................... 1-31 Spinning wrench spin circuit .............................................................. 1-31 Tilt cylinder circuit ............................................................................. 1-32 Torque wrench clamp circuit .............................................................. 1-32 Torque cylinders makeup and breakout circuit .................................. 1-33 NFPA 496 Type Y roughneck J-box purge system (UL only) .......................................................................... 1-33 Internal Blow Out Preventer (IBOP) hanger kit (optional) ................ 1-33 Specifications .................................................................................................. 1-34 Other specifications .................................................................................. 1-37 Drive rails/adapter plates ...............................................................1-37 Spinning wrench (pipe spinner).....................................................1-37 Torque wrench ...............................................................................1-38 Horizontal movement ....................................................................1-38 Vertical movement.........................................................................1-38 Tilt movement................................................................................1-39 Main materials of construction (type and grade) ...................................... 1-40 Cylinders ........................................................................................1-40 Hydraulic hose ...............................................................................1-41
Chapter 2
Installation
Unpacking and handling procedure ................................................................... 2-5 Short and long term storage ............................................................................... 2-6 Initial inspection ................................................................................................ 2-6 Preinstallation requirements .............................................................................. 2-7 General requirements .................................................................................. 2-7 Electrical requirements ............................................................................... 2-7 Hydraulic requirements ............................................................................... 2-7 Pneumatic requirements .............................................................................. 2-8 UL tool J-box purge system requirements .................................................. 2-8 PLC purge system requirements ................................................................. 2-8 Special tools and support equipment .......................................................... 2-8 Installation procedures ....................................................................................... 2-9 Referenced drawings ................................................................................... 2-9 Component installation ............................................................................. 2-10 Installing the AR3200 adapter plate ................................................... 2-10 Installing the AR3200 rails ................................................................. 2-11
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Installing the AR3200 assembly ........................................................ 2-12 Installing the derrick J-box mounting plate and hydraulic derrick plate assembly .................................................................................... 2-14 Derrick J-box mounting plate ....................................................... 2-14 Hydraulic derrick plate assembly ................................................. 2-14 Installing the hydraulic pressure transducer ....................................... 2-17 Installing the hydraulic torque gauge ................................................. 2-18 Installing the hydraulic service loop .................................................. 2-19 Interconnecting purge air (UL configurations) .................................. 2-20 Installing the monitor and optional control stations ........................... 2-21 Control station options.................................................................. 2-21 Installing the AC voltage regulator .................................................... 2-23 Nonpurged installation ................................................................. 2-23 UL and EEx installation ............................................................... 2-23 General notes ................................................................................ 2-23 Installing the PLC enclosure (nonpurged) ......................................... 2-24 Installing the optional PLC enclosure purge unit ............................... 2-24 Installing the electrical service loop ................................................... 2-25
Chapter 3
Operation
AR3200 operator controls ................................................................................. 3-5 About the operator control panels ........................................................ 3-5 Torque gauge ................................................................................. 3-5 Automatic Sequence controls ............................................................... 3-6 Controls in sequenced operation .................................................... 3-6 Controls in manual mode ............................................................... 3-7 EMERGENCY STOP (ESD) control ............................................ 3-7 Tool J-box controls .............................................................................. 3-7 Manual Control Station ........................................................................ 3-7 Automatic Control Station ........................................................... 3-10 Remote Monitor Station ..................................................................... 3-11 Optional Remote Control Station ....................................................... 3-13 Tool J-box controls ............................................................................ 3-15 Preoperation .................................................................................................... 3-16 Preoperational checklist ............................................................................ 3-16 AR3200 PLC startup .......................................................................... 3-21 Installing the EPROM ........................................................................ 3-21 Indexing the AR3200 ......................................................................... 3-22 Initializing an automatic sequence ..................................................... 3-23 Setting up the AR3200 LEARN MODE ............................................ 3-24 AR3200 function tests .............................................................................. 3-26 Function checks .................................................................................. 3-26 Pressure-reducing valve ............................................................... 3-26 Torque Wrench ............................................................................ 3-27 Spinning Wrench ......................................................................... 3-27 Carriage vertical positioning ....................................................... 3-27 Rolling operations ........................................................................ 3-27
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Contents
Tilt operation ................................................................................ 3-27 Automatic makeup ....................................................................... 3-28 Automatic breakout ...................................................................... 3-29 Semiautomatic makeup with manual height positioning ............. 3-30 Semiautomatic breakout with manual height adjustment ............ 3-31 Automatic makeup, PS MODE .................................................... 3-32 Automatic breakout, PS MODE .................................................. 3-33 Automatic makeup, Torque Wrench backup mode (soft clamp) . 3-34 Automatic breakout, Torque Wrench backup mode (soft clamp) 3-35 LEARN MODE ........................................................................... 3-36 Operating procedures ....................................................................................... 3-37 AR3200 checkout procedures ................................................................... 3-37 Manual control switches ........................................................................... 3-38 Setting the makeup torque ........................................................... 3-38 Mousehole operations ......................................................................... 3-39 End-of-stroke interlock ....................................................................... 3-40 Resetting after an interlock condition .......................................... 3-40 Automatic sequence control ...................................................................... 3-41 Torque Wrench backup mode ............................................................ 3-41 Automatic makeup ............................................................................. 3-42 Automatic breakout ............................................................................ 3-43 Auto/manual height adjustment operation ......................................... 3-44 Manual positioning mode ............................................................ 3-44 Autopositioning mode .................................................................. 3-44 Tool joint length and tool joint height ................................................ 3-45 Horizontal/vertical position adjustments ............................................ 3-46 Purge operation ................................................................................................ 3-47 Operating the purge unit for PLC enclosure ............................................. 3-49 Operating the J-box purge control unit ..................................................... 3-50 IBOP hanger operation (optional) ................................................................... 3-52 Commissioning Procedure (FIP00055) ........................................................... 3-52
Chapter 4
Maintenance
General inspection requirements ....................................................................... 4-5 Scheduled inspection requirements ............................................................. 4-6 Removal and installation procedures ............................................................... 4-13 Mechanical components ............................................................................ 4-13 Tong die .............................................................................................. 4-13 System hydraulic components .................................................................. 4-14 Inlet pressure gauge ............................................................................ 4-14 Torque gauge ...................................................................................... 4-15 Torque adjustment valve .................................................................... 4-16 Dump valve ........................................................................................ 4-17 Pressure-reducing valve ..................................................................... 4-18 Carriage lift cylinders ......................................................................... 4-19 Spinning Wrench main motors ........................................................... 4-20
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Spinning Wrench jaw motors ............................................................. 4-21 Pressure-reducing valve (2,000/2,500 psi) ......................................... 4-22 Speed control valve ............................................................................ 4-23 Foot motor .......................................................................................... 4-23 Control manifold hydraulic components .................................................. 4-24 EEx and UL directional control valves .............................................. 4-26 Electrical components ............................................................................... 4-27 Tool joint position sensor ................................................................... 4-27 Torque jaw position sensor ................................................................ 4-28 Adjustment procedures .................................................................................... 4-29 Adjusting the Spinning Wrench speed control ......................................... 4-29 Adjusting the carriage lift counterbalance ................................................ 4-30 Adjusting the vertical travel speed ........................................................... 4-30 Adjusting the horizontal travel speed ....................................................... 4-30 Adjusting the tilt cylinder speed control ................................................... 4-31 Adjusting the regenerative valves of the torque wrench clamp cylinder .. 4-31 Adjusting the manual torque pressure control valve ................................ 4-32 Adjusting the hydraulic pressure relief valve ........................................... 4-32 Adjusting the wear plate and tool joint detector sensor ............................ 4-32 Adjusting the torque wrench position sensor ............................................ 4-33 Adjusting the torque wrench dump valve ................................................. 4-33 Adjusting the horizontal index sensor ...................................................... 4-34 Adjusting the 2,500 psi hydraulic pressure valve ..................................... 4-34 Adjusting the 2,000 psi hydraulic pressure valve ..................................... 4-35 Adjusting the horizontal position sensor .................................................. 4-35 Adjusting the spinout sensor ..................................................................... 4-35 Adjusting the tool joint length switch voltage supply .............................. 4-36 Adjusting the end-of-stroke proximity sensor .......................................... 4-36 Adjusting the stabbing guide .................................................................... 4-36
Chapter 5
Lubrication
Lubrication schedules ........................................................................................ 5-5 Lubrication procedures .................................................................................... 5-10 Lubricating the frame and carriage ........................................................... 5-10 Lubricating the foot assemblies ................................................................ 5-11 Lubricating the tilt lever ........................................................................... 5-12 Lubricating the TW-102 Hydraulic Torque Wrench ................................ 5-13 Lubricating the SSW-50 Spinning Wrench Assembly ............................. 5-14
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Chapter 6
Troubleshooting
Troubleshooting components ............................................................................ 6-5 Troubleshooting mechanical components ................................................... 6-6 Torque Wrench ................................................................................... 6-11 Spinning Wrench ................................................................................ 6-14 Troubleshooting hydraulic circuits and valves ......................................... 6-16 Pressure-reducing valve circuit (PRV) ............................................... 6-17 Lift cylinder circuit ............................................................................. 6-19 Horizontal travel circuit ...................................................................... 6-20 Spinning Wrench clamp circuit .......................................................... 6-21 Spinning Wrench spin circuit ............................................................. 6-22 Tilt cylinder circuit ............................................................................. 6-23 Torque Wrench clamp circuit ............................................................. 6-24 Soft clamp mode .......................................................................... 6-24 Torque cylinders circuit ...................................................................... 6-25 Directional valves ............................................................................... 6-26 About directional solenoid-controlled valves .............................. 6-26 General diagnostic procedure for solenoid-controlled valves ..... 6-26 Isolating a faulty solenoid-operated directional valve ................. 6-27 Repairing a stuck spool ................................................................ 6-27 Two-position, solenoid-operated, four-way, (spring offset) ........ 6-28 Three-position, solenoid-operated, four-way (spring-centered), float center ................................................................................... 6-29 Three position, pilot-operated, solenoid controlled, four-way (spring-centered), float center ...................................................... 6-30 Load-holding valves ........................................................................... 6-32 Counterbalance valve, pilot assisted ............................................ 6-32 Relief valve, pilot-operated .......................................................... 6-35 Check valve, pilot-operated ......................................................... 6-37 Pressure control valves ....................................................................... 6-39 Pilot-operated, pressure-reducing valve ...................................... 6-39 Auxiliary valves ................................................................................. 6-41 Check valve, pilot-to-close .......................................................... 6-41 Check valve .................................................................................. 6-43 Flow valves ......................................................................................... 6-44 Orifice .......................................................................................... 6-44 Pressure-compensated, fixed orifice ............................................ 6-45 Flow control valve, adjustable, pressure compensated, full reverse free flow .................................................................... 6-47 Output actuators ........................................................................................ 6-49 Hydraulic cylinders ............................................................................ 6-49 Hydraulic motors ................................................................................ 6-51 Troubleshooting electrical and control system components ........................... 6-53 Causes of malfunction ............................................................................... 6-53 AR3200 control system ............................................................................. 6-53 Troubleshooting the PLC .......................................................................... 6-56 Last resort PLC troubleshooting procedure ........................................ 6-56
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PLC power supply .............................................................................. 6-62 Digital input/output module ............................................................... 6-62 Control system inputs ......................................................................... 6-65 Encoders ...................................................................................... 6-65 Proximity sensors ............................................................................... 6-66 Intrinsic safety devices ....................................................................... 6-67 Zener safety barriers .................................................................... 6-67 Intrinsically safe amplifiers ......................................................... 6-68 Transformer isolated barriers ....................................................... 6-70
Chapter 7 Chapter 8
Supplemental Materials
Supplement list .................................................................................................. 7-5
Drawings
Drawings by assembly ...................................................................................... 8-5 Drawings in numerical order ............................................................................. 8-7
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Contents
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AR3200
SM00053, Rev D
Preface
Manual conventions
This Preface contains the conventions used throughout this manual. Avoid injury to personnel and/or equipment damage by reading this manual and related documents before operating, inspecting, or servicing the equipment.
Safety information
The following examples explain the symbols for notes, cautions, and warnings. Please pay close attention to these important advisories. Note
z e
Provides additional information on procedures involving little or no risk of injury to personnel or equipment damage. Caution Alerts the reader to procedures involving a risk of equipment damage. Warning Warns the reader of procedures involving a definite risk of injury to rig personnel.
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Product Bulletins
The Product Bulletin tab defines a section of the manual in which you can store Product and Safety bulletins that may be issued from time to time by Varco.
Directional references
References to locations to the right or left of components described in this manual assume the perspective of the tool assembly itself (e.g., the torque gauge located on the roughneck is defined to be on the right side of the tool).
PLC configurations
The PLC configurations described in this manual are typical, but not universal. See your Technical Drawings Book for rig-specific information.
Illustrations
Figures present a graphical representation of tool components for use in identifying parts or establishing nomenclature. For more specific component information pertinent to your rig configuration, see the technical drawings that accompany your Varco documentation.
Varco Service Centers

If you need technical assistance, see the back cover of this manual for a complete list of Varcos Worldwide Service Centers.
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AR3200 Automated Iron Roughneck
Description
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C h ap t e r 1 C o n t en t s
Chapter 1 Description
General description ........................................................................................... 1-5 Makeup mode ..............................................................................................1-5 Breakout mode ............................................................................................ 1-6 Operator controls ......................................................................................... 1-6 Manual Control Station ........................................................................ 1-6 Operating in manual mode .............................................................. 1-6 Automatic Control Station ................................................................... 1-6 Tool J-box controls .............................................................................. 1-7 Major component description ............................................................................ 1-8 Chassis assembly ...................................................................................... 1-10 Frame .................................................................................................. 1-10 Carriage .............................................................................................. 1-10 Drive foot assemblies ......................................................................... 1-12 TW-102 Hydraulic Torque Wrench assembly .......................................... 1-14 Soft clamp feature .............................................................................. 1-14 SSW-50 Spinning Wrench assembly ........................................................ 1-16 Electrical control system ........................................................................... 1-18 Power distribution .............................................................................. 1-18 Systems with optional purge systems ............................................ 1-19 PLC assembly and enclosure ............................................................. 1-21 Siemens PLC .................................................................................1-21 Central Processing Unit (CPU) microprocessor ............................1-21 CPU Random Access Memory (RAM) ......................................... 1-21 Erasable Programmable Read-Only Memory (EPROM) slot .......1-22 Backup battery............................................................................... 1-22 Input/Output (I/O) interface...........................................................1-23 PLC power supply .........................................................................1-23 Digital I/O module.........................................................................1-23 Solenoid drivers .............................................................................1-23 Power supply (encoder) .................................................................1-25 IS isolation amplifiers and Zener barriers ..................................... 1-25 Expo PLC purge air system (optional) ..........................................1-25 Position and proximity sensors/switches ........................................... 1-26 Hydraulic system ..................................................................................... 1-30 Hydraulic manifold assembly ............................................................ 1-30 Pressure-reducing Valve (PRV) ......................................................... 1-30 Lift cylinder circuit ............................................................................ 1-31 Linear position slave cylinder assembly ............................................ 1-31 Horizontal travel circuit ..................................................................... 1-31 Spinning wrench clamp circuit ........................................................... 1-31
Description
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Spinning wrench spin circuit .............................................................. 1-31 Tilt cylinder circuit ............................................................................. 1-32 Torque wrench clamp circuit .............................................................. 1-32 Torque cylinders makeup and breakout circuit .................................. 1-33 NFPA 496 Type Y roughneck J-box purge system (UL only) .......................................................................... 1-33 Internal Blow Out Preventer (IBOP) hanger kit (optional) ................ 1-33 Specifications .................................................................................................. 1-34 Other specifications .................................................................................. 1-37 Drive rails/adapter plates ...............................................................1-37 Spinning wrench (pipe spinner).....................................................1-37 Torque wrench ...............................................................................1-38 Horizontal movement ....................................................................1-38 Vertical movement.........................................................................1-38 Tilt movement................................................................................1-39 Main materials of construction (type and grade) ...................................... 1-40 Cylinders ........................................................................................1-40 Hydraulic hose ...............................................................................1-41
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AR3200
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C ha p t er 1 Description
General description
The AR3200 Automated Roughneck (sometimes referred to as the Roughneck) allows one operator to make up or break out drill string connections automatically. The AR3200 uses a Programmable Logic Controller (PLC), PLC software, sensors, and solenoid-actuated hydraulic valves to operate the unit through a makeup or breakout sequence. The base control system allows the operator to initiate tool function sequences that automatically position the torque wrench at the tool joint and make up or break out the joint.
Makeup mode
In the makeup mode, the sequence of functions stops before applying makeup torque (allowing the tool to be used as a stabbing guide), stops again while makeup torque is applied (allowing the operator/driller to verify correct torque), and returns to the Home position with a single operator action.
Description
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July 1, 2005
Breakout mode
In the breakout mode, the unit executes a full sequence and returns to the Home position with a single operator action.
Operator controls
Operator controls allow for horizontal and vertical positioning, breakout/spin, spin/torque and mousehole tilt (up to 7), using electrohydraulic controls.
MANUAL CONTROL STATION

The Manual Control Station can be on either the right or left side of the unit and contains all switches that control AR3200 functions individually. (For detailed information see the Operation chapter.) Operating in manual mode By using manual mode switches you can interrupt any automatic sequence in progress and initiate the manual function.
Normally, the AR3200 operates at a setting of 2,000 psi. When set to 2,500 psi, the AR3200 must be operated manually. Integrated sensors and interlocks enable the AR3200 to perform several functions sequentially without operator intervention. Interlocks also prevent the operator from inadvertently initiating inappropriate operating sequences. When the AR3200 is operating in manual mode, only the end-of stroke interlock is in effect. The other interlocks do not function. For drill collars or special operations, you can switch to manual mode at a setting of 2,500 psi.
AUTOMATIC CONTROL STATION

The Automatic Control Station is located either beside the Manual Control Station (UL) or on the Manual Control Station panel (EEx). (For detailed information see the Operation chapter.)
EMERGENCY STOP
You can stop tool operation at any time by using the EMERGENCY STOP pushbutton located on the manual control station or the remote monitor station. You also can set the tool to operate in OVERRIDE mode.
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Operator controls
TOOL J-BOX CONTROLS

The tool J-box holds a two-switch panel for selecting the tool joint length and power slip mode. The top switch selects either manual mode or a preset tool joint length for 8, 10, 12., 14., or heavy weight (HW) tool joints. With a preset tool joint length, the AR3200 finds the tool joint automatically. The lower switch selects the power slip mode: ON (when using a power slip) or OFF. When set to ON, the AR3200 adjusts its carriage height to clear a power slip. See the Operation chapter for the control panel layout.
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Description
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Major component description

The AR3200 consists of the following basic assemblies: t Chassis assembly (page 1-10) t TW-102 Hydraulic Torque Wrench (page 1-14) t SSW-50 Spinning Wrench (page 1-16) t Electrical control system (page 1-18) t Hydraulic system (page 1-30) t NFPA tool J-box purge system (UL configurations, page 1-33) Figure 1- 1 shows the general arrangement of the AR3200 in relation to the derrick. Figure 1-2 shows the general arrangement of the AR3200.
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SM00053, Rev D
To Remote Controller Mounting Plate Derrick Plate
INTRINSICALLY SAFE CIRCUITS
Derrick
Service Loop Bracket
Hydraulic Service Loop Electrical Service Loops Remote Controller (PLC) AC Regulator AR3200 Automated Roughneck
Drill Floor C L Well
Figure 1- 1. Typical AR3200 General arrangement

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July1, 2005
Chassis assembly
The primary AR3200 chassis assembly components include the frame, carriage and drive feet.
FRAME
The frame consists of two uprights connected by a removable strong back and a cross beam at the top. Two hydraulic motor-driven feet support the frame at the base. The motors in the feet propel the AR3200 from the standby, or Home, position to well center and back. The feet mount on rails welded to the rig floor on opposite sides of the well bore and across the rotary table.
CARRIAGE
The carriage assembly is located between the two uprights of the frame, supported by vertical guides, rollers, and two hydraulic vertical lift cylinders. The carriage supports a torque wrench and Spinning Wrench. Two vertical lift cylinders move the carriage up and down to position the torque wrench jaws above and below the pipe joint. The carriage can tilt up to 7 to match the angle of the pipe in a mousehole. An optional reverse tilt feature allows the AR3200 to reach a mousehole installed between the rotary table and the drawworks. A wear plate, mounted under the carriage, supports and positions the tool joint sensor
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AR3200
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SSW-50 Spinning Wrench Assembly
Tool Electrical J-Box
Carriage Lift Cylinders (2)
Clamp Rollers (2)
Pressure Rollers (2)
Hydraulic Roller Drives (4)

10" 8" MAN 12" 14" HW
TJ LENGTH
OFF ON
PS-16
Stabbing Guide
Frame Assembly
Uprights(2)
Upper Torque Wrench Jaw
TW-102 Torque Wrench Assembly Control Station
Lower Torque Wrench Jaw
Motor Driven Foot (2)
Hydraulic Horizontal Drives (2)
Figure 1-2. Typical AR3200 Automated Iron Roughneck

July 1, 2005
DRIVE FOOT ASSEMBLIES

Two motor-driven feet on either side of the AR3200 chassis support the AR3200 (Figure 1-3). The feet move on cogged drive rails, allowing the tool to travel to and from well center and the Home position. The right foot contains a horizontal index sensor. (See the Maintenance chapter for adjustment procedures.) The left foot contains a horizontal position sensor and a J-box routed to the horizontal position sensor. The gearbox cover of each drive foot faces the inside of the roughneck, while the motor access covers face the outside. Both drive feet include the following: t An idler roller located at the front of each foot t A cogged drive roller located at the rear of each foot t A hydraulic motor t A gearbox t A motor access cover t A gearbox cover
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Gearbox Cover Gearbox Foot Access Cover Cogged Drive Roller
Foot Assy.
Idler Roller
Hydraulic Motor Motor Access Cover
Figure 1-3. Typical AR3200 drive foot
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Description
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TW-102 Hydraulic Torque Wrench assembly

The TW-102 Hydraulic Torque Wrench (Figure 1-4) is an open throat design that eliminates all gates and latches. The torque wrench can make and break connections for 3 1/2 in. drill pipe to 9 3/4 in. drill collars and provides up to 100,000 ft-lb of makeup torque and 120,000 ft-lb of breakout torque. The torque wrench consists of two gateless, upper and lower clamping jaws. A 9 in. (229 mm) hydraulic cylinder located at the back of each jaw provides sufficient clamping force to apply torque without distorting the box and pin, nor allowing the gripping dies to slip. Two hydraulic cylinders mount to the sides of the upper wrench, enabling the upper jaw to partially rotate up to 28 during make up or break out. Bolted to each clamping jaw are gripping dies. Each gripping die consists of a special tong die and die retainer. The die retainers and the tong dies are easily removable. You must change the tong dies and die retainers when changing pipe size. For details on changing the dies, see the Operation chapter.
SOFT CLAMP FEATURE

When set to backup mode, only the lower jaw clamps during spinning operation. This feature is also known as a soft clamp.
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Upper Jaw Clamp Cylinder
Upper Jaw Torque Cylinder
Tong Dies and Retainer
Figure 1-4. Hydraulic Torque Wrench Assembly

July 1, 2005
SSW-50 Spinning Wrench assembly

The SSW-50 Spinning Wrench (Figure 1-5) spins tubulars from 3 1/2 to 9 3/4 in. in diameter without requiring manual size adjustment. A floating mount design compensates for minor pipe misalignment. The roller arms open sufficiently to pass 18 in. diameter drilling stabilizers. The spinner rotates 5 in. diameter pipe at up to 150 rpm and produces up to 2,000 ft-lb of rotational torque. Table 1-1 describes the operational modes of the Spinning Wrench assembly.
Table 1-1. Spinning Wrench operational modes

Mode Normal Drill Collar Description Function
Pressure mode switched to The spinner rotates at full speed for the 2,000 psi position drill pipe. Pressure mode switched to The spinner rotates at reduced speed the 2,500 psi position for walking in large drill collars.
For more information on the operating modes, see the Operation chapter. The Spinning Wrench contains four drive rollers: two pressure rollers and two clamping rollers. Four hydraulic motors drive one each of the four rollers. Hydraulic flow dividers supply fluid to the four motors to ensure positive spinning force without the need for a complicated transmission. This system transfers power to the drill pipe and collars more efficiently, increasing the spinning torque by 50%, while requiring 50% less clamping force on a tubular.
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Pressure Rollers (2)
Clamp Cylinder (2)
Clamping Rollers (2)
Hydraulic Motors (4)
Figure 1-5. SSW-50 Spinning Wrench assembly
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Description
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Electrical control system

The electrical control system (Figure 1-6 and Figure 1-7) includes a Programmable Logic Controller (PLC) assembly, PLC software, sensors, and electrically actuated solenoids. The solenoids control hydraulic valves for operating the unit during makeup and breakout sequences. The electrical control system also includes a manual control station, which allows you to manually initiate Roughneck functions. PLC programming directs all normal makeup and breakout functions. An operator can perform makeup and breakout functions with the AR3200 manually-one function at a time, or automatically with a single operator action. The automatic and manual controls are located on either the left or right side of the tool, depending on the configuration purchased. (See the Operation chapter for details on the automatic and manual controls.
POWER DISTRIBUTION
Input power for the AR3200 can range from 90 to 520 VAC, single phase at 50/60 Hz. Input power first enters an AC voltage regulator. The AC voltage regulator converts the input power to 115 VAC, single phase, 50/60 Hz and must be mounted in a nonhazardous area. The voltage regulator outputs the 115 VAC to the following circuit breakers: t 1-amp and 5-amp circuit breakers on standard configurations with no optional purge systems t t 1-amp and 5-amp circuit breakers on EEx configurations with an optional PLC purge system, through a purge loss-of-pressure switch 1-amp and 5-amp circuit breakers on UL configurations with AR3200 tool J-box and optional PLC purge systems, through the PLC purge loss-ofpressure switch and isolation relay (controlled by the AR3200 tool J-box loss of pressure switch)
t 1-amp and 5-amp circuit breakers on UL configurations with the AR3200 tool J-box purge system, through a purge loss-of-pressure switch
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Systems with optional purge systems Purge loss-of-pressure-switch contacts close when the required minimum purge pressure is reached. purge loss-of-pressure switch contacts open when the purge pressure falls below the minimum requirement. Two 1-amp circuit breakers connect to the 24 and 12-volt DC power supplies located inside the PLC assembly enclosure. Two 5-amp circuit breakers connect to the AR3200 solenoids via a kill relay and solenoid drivers. The kill relay is part of the ESD circuit. In normal operation, the kill relay is activated and the ESD circuit is closed. When the ESD circuit is open, the kill relay prevents the 115 VAC required by the solenoids from passing through the solenoid drivers.
AR3200
Manual Controls
Service Loops (3)
Voltage Regulator Solenoid Operated DCV
Tool J-Box
PLC Assembly Remote Monitor Station
Sensors Optional Driller's Control
Figure 1-6. Typical AR3200 electrical control system
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Description
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AR3200
Manual Controls
Purge
Purge Loss of Pressure Switch
Voltage Regulator Solenoid Operated DCV
Tool J-Box
PLC Assembly Remote Monitor Station
Sensors
Service Loops (3)
Figure 1-7. Typical AR3200 electrical control system with PLC purge
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SM00053, Rev D
PLC ASSEMBLY AND ENCLOSURE

The AR3200 PLC assembly is located in an enclosure remotely located from the tool. The primary PLC assembly components include the following items, as shown on Figure 1-8 on page 1-24: t Siemens S5-95U PLC (page 1-21)
Central Processing Unit (CPU) microprocessor (1-21) CPU Random Access Memory (RAM) (1-21) Erasable Programmable Read-Only Memory (EPROM) receptacle (slot) (page 1-22) Digital input/output (I/O) module (page 1-23) PLC power supply (1-23)
t Backup battery (page 1-22) t Solenoid drivers (page 1-23) t Power supplies (page 1-25) t Intrinsically Safe (IS) and Zener barriers (page 1-25) t Expo PLC purge air system (optional) (page 1-25) Siemens PLC The Siemens S5-95U PLC consists of the following main components: Central Processing Unit (CPU) microprocessor The CPU microprocessor processes all data provided by AR3200 control system components. CPU Random Access Memory (RAM) The RAM temporarily stores the data that the CPU microprocessor uses.
RAM requires electrical power to retain data. If power to the PLC is interrupted, all data in the RAM is lost. (See Backup battery on page 1-22.)
SM00053, Rev D
Description
1-21
July 1, 2005
Erasable Programmable Read-Only Memory (EPROM) slot The Varco-supplied software is stored in a 32-kilobyte Erasable Programmable Read-Only Memory (EPROM). The EPROM receptacle provides an interface between the EPROM and the CPU. The CPU copies (loads) the Varco software from the EPROM to the RAM for actual use by the microprocessor.
The memory in the EPROM is nonvolatile; i.e., it does not require power to keep the software in its memory. As it is read-only memory, the software in the EPROM cannot be accidentally changed. Backup battery The PLC lithium backup battery continues to supply power to prevent loss of data stored in the RAM if the regular power supply to the CPU is interrupted.
All data in the RAM is lost if power interruptions last long enough to completely discharge the backup battery. Under normal operating conditions, the lithium backup battery supplied with the AR3200 PLC should last approximately one year. Replace batteries older than one year with new lithium batteries to prevent data loss.
1-22
AR3200
SM00053, Rev D
Input/Output (I/O) interface The I/O interface allows the CPU to transfer data to and from external I/O modules. (See Potentiometer driver on page 1-23.) PLC power supply The PLC power supply is part of the Siemens PLC assembly. The power supply provides 24 VDC electrical power to the following PLC assembly components: t Siemens PLC t Intrinsically Safe (IS) isolation amplifiers and barriers t Emergency Shutdown (ESD) manual control switches t Potentiometer driver Digital I/O module
The digital I/O module allows for additional connections (interfaces) between the CPU and other control system components, such as proximity switches and solenoid drivers.) Solenoid drivers The solenoid drivers in the PLC assembly are solid state relays. The drivers switch 115 VAC power to actuate the solenoids that direct hydraulic valves on the AR3200. The CPU determines when to actuate a particular solenoid.
SM00053, Rev D
Description
1-23
July 1, 2005
24V Power Supply
Backup Battery
CPU
EPROM
I/O Module
PLC Box Assy
Learn Mode Switch
OFF
ON
MODULE A
Solenoid Drivers
1 2 3 4 5
12V Power Supply (Encoder) IS Amplifier/ Barrier IS Potentiometer Driver Encoder Safety Barrier
TB 1
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36
1 2 3
SPARE
4
OFF
ON
5 6 7 8 9
6 7 8 9
TEACH
MODULE B
1 2 3 4 1 2 3 4
TB 8 TB 7
2 3 4 5 6 7 8 2 A2 A2 A1 1 1
Kill Relay (ESD)
5 6 7 8 9
6 7 8 9
3 4 5 6 7 8 24 21 22 14 11 12 1 2 3 4 1 2 3 4
B
1
MODULE C
1
Solenoid Drivers
2 3
2 3
TB 2
1 2 3 4 5 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24
TB 4
1 2 3 4 5 6 7 8 9 10 1 2 3
5 6 7 8
6 7 8
4 5 6 7 8 9 10
715
6 7
764
8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24
MODULE D
1 1
TB 5
1 2 3 4 5 6 7 8 9 10 11 12 13 1 2 3 4
2 3 4 5
2 3 4 5
5 6 7 8 9
10 11 12 13 14 15 16 17 18 19 20 21 22 5 1 5
9 9
TB 3
1 2 3 4 5 6 7 8 9 10 1 2 3 4 5 6 7 8 9 10
14 15 16 17 18 19 20 21 22
1AMP Circuit Breakers 5 AMP Circuit Breakers
6 7 8
7 8
TB 6
TB 9
8 1 2 3 1 2 3 4 1 2 3 4 4 5 6
5 1 2 3 4 5 6
IS Terminal Blocks (Knife Switch Type)
Isolation Relay (BEBCO UL Purge on Tool J-Box)
Figure 1-8. AR3200 PLC assembly and enclosure

1-24 AR3200 SM00053, Rev D
Power supply (encoder) A 12-volt power supply (encoder) is located in the PLC assembly enclosure and provides electrical power for the optical encoder. (For more information on the optical encoder, see Table 1-2, Sensor functions, on page 1-27.) IS isolation amplifiers and Zener barriers The AR3200 PLC uses IS isolation amplifiers and Zener barriers for the sensors and the optical encoder to provide required protection against an explosion in hazardous areas. This method of protection limits the energy in devices located in hazardous areas. In the event a fault results in either excessive voltage or current, an internal fuse ruptures, preventing unsafe energy levels in the hazardous area. Expo PLC purge air system (optional) The optional Expo PLC purge system mounts on the PLC assembly enclosure. The PLC purge system allows locating the PLC assembly enclosure in Zone 2 (European) or Division 2 (NEC) hazardous areas. The purge system uses clean, dry pressurized air plumbed into the PLC assembly enclosure to prevent accumulation of flammable or explosive fumes inside the enclosure. The system also eliminates heat, moisture and dust contamination within the PLC assembly enclosure. A purge pressure switch monitors the purge system and detects a loss of purge air supply pressure in the PLC enclosure.
SM00053, Rev D
Description
1-25
July 1, 2005
POSITION AND PROXIMITY SENSORS/SWITCHES

The AR3200 contains the following sensors: t Five proximity sensors t One vertical position encoder t One flow sensor t One spinout (proximity) sensor Proximity sensors (Figure 1-9) monitor equipment functions. These sensors detect the presence or absence of metal. AR3200 proximity sensors sense the presence or absence of a metal target located on various moving components. The PLC uses input from theses sensors to help direct operating sequences. Figure 1-10 and Figure 1-11 indicate the locations of the proximity sensors on the AR3200. The sensors function as shown in Table 1-2.
Figure 1-9. Typical proximity sensor
1-26
AR3200
SM00053, Rev D
Table 1-2. Sensor functions

Sensor Function
Torque wrench position sensor Enables the PLC to direct positioning of the torque wrench bodies before performing a makeup or breakout sequence. It also allows the PLC to determine when a restroke is required during a makeup sequence. This sensor is on the left side of the torque wrench body. Tool joint detector sensor End-of-stroke sensor Detects the upset of the drill pipe joint when it senses the absence of metal as it vertically scans. Prevents bending the carriage when the slips are not holding the pipe tightly enough. Detects when the carriage is approximately 3/4 in. (19 mm) from its lowest position. This sensor also functions as a vertical index sensor, providing a fixed point of reference in determining the absolute carriage position. Provides the PLC with input to determine the AR3200 position on its track relative to an index cutout in the cogged drive rails. (See the Installation and Operation chapters for details on the cogged drive rails and indexing.) This sensor allows the PLC to count the number of drive rail cogs detected relative to the index cutout when the tool moves back and forth. Resets the horizontal position count in the PLC when the AR3200 moves over the index cutout in the cogged drive rails. It provides a fixed point of reference in determining the absolute horizontal position of the tool. This incremental optical encoder, measures the carriage height of the torque wrench jaws relative to the pipe joint. Monitors hydraulic return flow and signals the PLC when the following conditions exist: The torque wrench jaws are fully opened, closed, or clamped.
Horizontal position sensor
Horizontal index sensor
Vertical position optical encoder Flow sensor

Spinout sensor
The torque wrench body is in the full makeup or breakout position. The Spinning Wrench spins pipe in and the joint is shoulder-to shoulder. The Spinning Wrench arms are fully open, closed, or clamped.
Located on the back of the Spinning Wrench in a junction box, this sensor detects spinout activity (bumping) and relays this information to the PLC. This proximity sensor contains a target and spring. Varying the target distance of the proximity sensor inside the sensor J-box adjusts the spinout sensor sensitivity.
SM00053, Rev D
Description
1-27
July 1, 2005
Spinout Sensor (Behind SSW-50)
10" 8" MAN
12" 14" HW
TJ LENGTH
OFF ON
PS-16
Tool Joint Detector Torque Wrench Position Sensor
Horizontal Position Sensor
Figure 1-10. AR3200 sensor locations

1-28 AR3200 SM00053, Rev D
Flow Switch (Behind Intake Manifold)
EOS Sensor
Horizontal Index Sensor
Vertical Position Encoder
Figure 1-11. AR3200 sensor locations

July 1, 2005
Hydraulic system
The AR3200 hydraulic system includes the following components: t Hydraulic manifold assembly (page 1-30) t Pressure-reducing valve (PRV) (page 1-30 t Lift cylinder circuit (page 1-31) t Linear position slave cylinder assembly (page 1-31) t Horizontal travel circuit (page 1-31) t Spinning wrench clamp circuit (page 1-31) t Spinning wrench spin circuit (page 1-31) t Tilt cylinder circuit (page 1-32) t Torque wrench clamp circuit (page 1-32) t Torque cylinders make up and breakout circuit (page 1-33) See the Troubleshooting chapter for additional information on the hydraulic circuit components.
HYDRAULIC MANIFOLD ASSEMBLY

A hydraulic manifold assembly mounts on the AR3200 carriage. The hydraulic manifold assembly consists of electrically actuated solenoids controlling the hydraulic valves that direct all hydraulic functions of the AR3200.
PRESSURE-REDUCING VALVE (PRV)

The pressure-reducing valve (PRV) sets the hydraulic pressure at either 2,000 psi or 2,500 psi (128 - 172 Bar) to spin in and make up drill pipe and drill collars. The AR3200 has 100,000 ft-lb of torque available for makeup and 120,000 ft-lb of torque available for breakout torque.
The tool applies the full 120,000 ft-lb of torque when breaking out. The PRV changes pressure by activating a solenoid valve. The operator selects 2,000 psi or 2,500 psi using a switch on the manual control station located on the roughneck.
1-30
AR3200
SM00053, Rev D
LIFT CYLINDER CIRCUIT

Hydraulic pressure travels through the directional control valve (DCV) and two flow control valves, allowing lift cylinder speed control. If the driller starts to lower the string in the hole while drilling with the torque wrench clamped onto the drill pipe, pressure builds up on the rod end of the lift cylinder. When the hydraulic pressure reaches a preset level, the counterbalance valve opens and the carriage lowers.
LINEAR POSITION SLAVE CYLINDER ASSEMBLY

The slave cylinder assembly is located behind the tool carriage, adjacent to the right side lift cylinder. The slave cylinder provides positive drive for the optical encoder, converting the vertical motion of the carriage to the rotary motion of the optical encoder. The end-of-stroke sensor is located in the slave cylinder assembly. When the endof-stroke sensor detects that the carriage is within 3/4 in. (19 mm) of reaching bottom, the torque wrench jaws and the Spinning Wrench clamp open solenoids energize, preventing damage to the AR3200.
HORIZONTAL TRAVEL CIRCUIT

The horizontal travel hydraulic circuit moves through directional control valves (DCV) and flow control valves allowing horizontal speed control. As the AR3200 approaches the well center, a deceleration valve (PLC control) automatically reduces the tools speed.
SPINNING WRENCH CLAMP CIRCUIT

Hydraulic flow travels through the DCV directly to the clamp cylinders. The Spinning Wrench clamp contains a hydraulic check valve that maintains full clamp force on the Spinning Wrench jaws.
SPINNING WRENCH SPIN CIRCUIT

The Spinning Wrench spin circuit contains four hydraulic motors that can work at two different speeds-fast (at 2,000 psi) and slow (at 2,500 psi). DCVs control the direction and flow dividers ensure that all motors run at an equal speed. The speed adjustment control works in 2,500 psi mode only.
SM00053, Rev D
Description
1-31
July 1, 2005
TILT CYLINDER CIRCUIT

Hydraulic flow travels through the DCV to the tilt cylinder. The tilt cylinder circuit contains check and flow control valves. The check valves maintain the cylinders position in the event a pressure drop occurs. The flow control valves allow adjustment of the tilting speed.
TORQUE WRENCH CLAMP CIRCUIT

The AR3200 torque wrench clamp circuit has a regenerative circuit to increase operating speed. The regenerative circuit directs hydraulic pressure to the blind end from the rod end, allowing greater flow and increased speed. The AR3200 torque wrench clamp circuit directs hydraulic pressure out of the B working port of the DCV to the blind end of the torque wrench clamp cylinder. This causes the cylinder to start stroking, causing pressure to build up on the rod side of the cylinder. A check valve allows additional fluid to empty the B Line circuit, allowing greater flow into the blind end of the cylinder. This increases the clamping speed. The AR3200 soft clamp mode enables the tool to hold the box while spinning in drill pipe. See the Operation chapter for details.
1-32
AR3200
SM00053, Rev D
TORQUE CYLINDERS MAKEUP AND BREAKOUT CIRCUIT

The torque wrench makeup/breakout circuit directs hydraulic flow through the DCV directly to the torque cylinders. A pressure reducing valve allows the operator to select the required makeup torque from 5,000 to 100,000 ft-lb. Breakout torque is fixed at 120,000 ft-lb.
NFPA 496 TYPE Y ROUGHNECK J-BOX PURGE SYSTEM (UL ONLY)

The NFPA 496 purge system allows operating the AR3200 in Class 1, Division 1 areas. The purge system uses pressurized air plumbed into the electrical tool J-box located on the roughneck. A purge pressure loss switch monitors the purge system and detects a loss of purge pressure.
INTERNAL BLOW OUT PREVENTER (IBOP) HANGER KIT (OPTIONAL)

The IBOP hanger is an optional feature of the AR3200 and is installed on the AR3200 at the factory when purchased. The IBOP hanger assembly is bolted onto the left side of the carriage and supports and aids in stabbing and connecting an IBOP.
SM00053, Rev D
Description
1-33
July 1, 2005
Specifications
Figure 1-12 and Figure 1-13 provide dimensional information on the AR3200.These illustrations are based on 59" track spacing. For 75" track spacing, see your rig-specific documentation.
1-34
AR3200
SM00053, Rev D
Specifications
* - FOR 37-1/2" ROTARY TABLE ** - FOR 49 -1/2" ROTARY TABLE 66.0(1676) TW-102 CONTROLS
89.92(2284)-REF 31.0(787)* 38.0(965)** 31.0(787)* 38.0(965)** HINGED ADAPTER PLATE
59.0(1499) RAIL SPACING
70.0(1778)
Alternate Mousehole
34.4(874)DIA Mousehole
17.0 (432) MIN
COG DRIVE TRACK (LENGTHAS REQUIRED)
48.0(1219) MIN 32.0(813)MIN 80.0(2032)MAX
EXPOSED ROTATING SURFACES COVERED (BY CUSTOMER)
84.0(2134)MIN, 132.0(3353)MAX 127.0(3226)MIN, 175.0(4445)MAX ALL DIMENSIONS ARE FOR REFERENCE ONLY 48.0(1219) MIN
Figure 1-12. Dimensional data
SM00053, Rev D
Description
1-35
July 1, 2005
66.0 [1676] 62.5 [1588] SSW Fully Extended 33.0 [838] Stroke 63.6 [1615] 31.8 [808] C LWell Bore
135.0 [3429]
102.0 [2591]
28.25 [718]
Pin/Box Shoulder Foot Bottom 2500 LB [1228 KG] WHEEL C L Well Bore
3500 LB [1720 KG] Driven Wheel
28.0 [711] 60.0 [1290]
RIGHT HAND
65.4 [1661]
LEFT HAND
ALL DIMENSIONS ARE FOR REFERENCE ONLY
Typical unit weight with accessories is 12,000 lb. The weight of heaviest component to be handled during maintenance is Torque Wrench Assembly-3,400 lb.
Figure 1-13. Dimensional data

1-36 AR3200 SM00053, Rev D
Specifications
Other specifications
Hydraulic operating pressure required Hydraulic flow rate required (min.) Hydraulic pressure at max. flow PLC purge air pressure required UL tool purge air pressure required Air flow rate required (max.) Drive rails/adapter plates Adapter plates (hinge to hinge) Overall rail length Width over rails Rail section (size) Fastening method Spinning wrench (pipe spinner) Minimum pipe size capacity Maximum pipe size capacity Open jaw width Number of spinner motors Gripping force adjustable Spinning speed adjustable (5 in. d.p.) Number of driven rollers Spin-in speed max. (6 5/8 in. d.p.) Spin-out speed max. (6 5/8 in. d.p.) Spin-in torque at stall Spin-out torque at stall 3 1/2 in. (drill pipe) 9 3/4 in. (drill collar) 18 1/2 in. (470 mm) 4 (four) No 0-150 rpm 4 (four) 100 rpm 100 rpm 2,000 ft-lb with 5 in. pipe 2,000 ft-lb with 5 in. pipe 70 in. (1778 mm) 127 in. (3226 mm) (min.) 59 in. (1499 mm) or 75 in. (1905 mm) 1 in. x 5 in. (25 mm x 127 mm) Welded to rig floor 2,000 - 2,500 psi (138 - 172 Bar) 45 gpm (170 lpm) 2,500 psi (172 Bar) 60 psi (min.) 100 psi (max.) 4 Bar (min.) 7 Bar (max.) 5 psi (min.) 120 psi (max.) .34 Bar (min.) 8 Bar (max.) 4 SCFM
SM00053, Rev D
Description
1-37
July 1, 2005
Torque wrench Minimum pipe size capacity Maximum pipe size capacity Makeup torque (maximum) Breakout torque (fixed) Torque range adjustable Gripping force adjustable Degrees of rotation Length of stroke (torque) Length of stroke (clamp) Cylinder bore (torque) Cylinder bore (clamp) Requirement for jaw gates Horizontal movement Drive type Number of drive motors Number of driven wheels Speed Vertical movement Drive type Number of cylinders Vertical movement Adjustable end stops Speed adjustable Speed Hydraulic 2 (two) 33 in. (838 mm) No No 6 in./sec. (152 mm/sec), nom. Hydraulic 2 (two) 2 (two) 1 ft./sec. (.30 m/sec.), nom. 3 1/2 in. (drill pipe) 9 3/4 in. (drill collar) 100,000 ft-lb (135600 N-m) 120,000 ft-lb (162700 N-m) Yes Yes, with Variable Clamp Force Kit 28 8.5 in. (216 mm) 5.98 in. (152 mm) 5 in. (127 mm) 9 in. (229 mm) No
1-38
AR3200
SM00053, Rev D
Specifications
Tilt movement Drive type Number of tilt cylinders Cylinder bore Cylinder stroke Maximum tilt angle Tilt angle adjustable Hydraulic 2 rev. tilt, 1 forw. tilt 2 1/2 in. (64 mm) 7 in. (178 mm) 7 (rev. & forw. tilt) Yes (Forward only)
SM00053, Rev D
Description
1-39
July 1, 2005
Main materials of construction (type and grade)

Main body Torque wrench die holders Torque wrench die Spinner rollers Cylinders Body Piston Rod Seals Guide rails Wheels Adapter plate Hydraulic tube Hydraulic tube/hose fittings ASTM A36 Steel ASTM A36 Steel 17-4 PH BUNA-N M1020 Steel 86 L20 Steel A36 Steel (Diamond Patt.) Cadmium-plated steel Cadmium-plated steel MS 00001 Grade 150-135 4130 Steel 86 L20 Steel 4140 Steel
1-40
AR3200
SM00053, Rev D
Specifications
Hydraulic hose Specification/type 100R2 Size

3/8 in. 1/2 in. 3/4 in. 1 in.
Pressure rating
5,000 4,250 3,000 2,500
Burst pressure
16,000 14,000 9,000 8,000
Fire resistance
Yes Yes Yes Yes
Material
Rubber/Wirebraid Rubber/Wirebraid Rubber/Wirebraid Rubber/Wirebraid
Specification/type 100R9 Size

3/8 in. 1/2 in. 3/4 in. 1 in.
Pressure rating
4,500 4,000 3,000 3,000
Burst pressure
18,000 16,000 12,000 12,000
Fire resistance
Yes Yes Yes Yes
Material
Rubber/Wirebraid Rubber/Wirebraid Rubber/Wirebraid Rubber/Wirebraid
SM00053, Rev D
Description
1-41
July 1, 2005
1-42
AR3200
SM00053, Rev D
AR3200 Automated Roughneck
Installation
July 1, 2005
2-2
AR3200
SM00053, Rev D
Chapter 2 Contents
Chapter 2 Installation
Unpacking and handling procedure ................................................................... 2-5 Short and long term storage ........................................................................................ 2-6 Initial inspection ................................................................................................ 2-6 Preinstallation requirements .............................................................................. 2-7 General requirements .................................................................................. 2-7 Electrical requirements ............................................................................... 2-7 Hydraulic requirements .............................................................................. 2-7 Pneumatic requirements .............................................................................. 2-8 UL tool J-box purge system requirements .................................................. 2-8 PLC purge system requirements ................................................................. 2-8 Special tools and support equipment .......................................................... 2-8 Installation procedures ...................................................................................... 2-9 Referenced drawings .................................................................................. 2-9 Component installation ............................................................................. 2-10 Installing the AR3200 adapter plate ................................................... 2-10 Installing the AR3200 rails ................................................................ 2-11 Installing the AR3200 assembly ........................................................ 2-12 Installing the derrick J-box mounting plate and hydraulic derrick plate assembly ........................................................................ 2-14 Derrick J-box mounting plate ...................................................... 2-14 Hydraulic derrick plate assembly ................................................ 2-14 Installing the hydraulic pressure transducer ....................................... 2-17 Installing the hydraulic torque gauge ................................................. 2-18 Installing the hydraulic service loop .................................................. 2-19 Interconnecting purge air (UL configurations) .................................. 2-20 Installing the monitor and optional control stations ........................... 2-21 Control station options ................................................................. 2-21 Installing the AC voltage regulator .................................................... 2-23 Nonpurged installation ................................................................ 2-23 UL and EEx installation .............................................................. 2-23 General notes ............................................................................... 2-23 Installing the PLC enclosure (nonpurged) ......................................... 2-24 Installing the optional PLC enclosure purge unit ............................... 2-24 Installing the electrical service loop ................................................... 2-25
Installation
2-3
July 1, 2005
2-4
AR3200
SM00053, Rev D
C ha p t er 2 Installation
Unpacking and handling procedure

To unpack the AR3200: 1. Remove crate from component or part.
The roughneck assembly is shipped on its back. 2. Unwrap protective covering from component or part. 3. Remove tape from machined and/or gasket surface. 4. Remove any remaining adhesive using a clean cloth and solvent. 5. Clean component or part of any nonessential oil or grease used as a protective coating for shipment or storage. 6. Remove protective caps from electrical and hydraulic connectors.
Installation
2-5
July 1, 2005
Short and long term storage

See Pipehandling Systems Preshipment Preparation Short & Long Term Storage, QA 00016 in the Supplemental Materials chapter.
Initial inspection
For initial inspection, use the following drawings in the Drawings chapter: t AR3200 Installation - 59" (or 75") Track Spacing drawing t AR3200 Electrical Installation Kit drawing t Also use the packing list. After unpacking components and parts, inspect as follows: 1. Inventory all components and parts. In case of missing or incorrect parts, notify Varco. 2. Inspect all components and parts for shipment damage and corrosion. If damage to a component or part occurred during shipment, notify the carrier. If corrosion beyond reasonable limits is present, notify Varco.
2-6
AR3200
SM00053, Rev D
Preinstallation requirements
Preinstallation requirements e
Be sure to satisfy all electrical and hydraulic requirements before installing the AR3200. UL installations with an AR3200 J-box purge system, AR3200s with an optional PLC purge system, and casing AR3200s also have pneumatic requirements.
General requirements
Before installing the AR3200, be sure to satisfy the following requirements: t The rig floor must be capable of supporting the weight of the AR3200 [approximately 12,000 lb (5,896 kg.)]. When using rig tongs, the AR3200 home (standby) position must be located far enough away from well center to clear the tongs and prevent equipment collisions. Otherwise, use snub lines on the tongs to ensure tool clearance.
Electrical requirements
The AR3200 requires an electric supply of 95 to 520 VAC at 15 amps, 50/60 Hz single phase. (For detailed information, see the electrical installation drawings in the Drawings chapter.)
Installation of an AC regulator for the AR3200 is required.
Hydraulic requirements
The AR3200 requires a closed-center hydraulic power supply capable of providing at least 45 gpm (170 lpm) at 2,500 psi (172 Bar). When using an open-center hydraulic power supply, use a converter. Varco offers an optional open-to-closed center converter.
SM00053, Rev D
Installation
2-7
July 1, 2005
Pneumatic requirements
The following configurations of the AR3200 require a clean, dry, pressurized air supply: t UL configuration with a purge system on the AR3200 tool J-box ( t All configurations with a purge system on the PLC t All casing configurations
UL tool J-box purge system requirements

The UL configuration with tool J-box purge system (API Class I, Division I) requires the following: t 80-120 psi (550-830KPa) at 2.21 SCFM/cu. ft. (60 L/Min.) depending upon the rate of leakage.
PLC purge system requirements

The PLC purge system (API Class I, Division II or European Standard Zone 2 Area) requires the following: t a minimum of 60 psi (4 Bar) and a maximum of 100 psi (7 Bar) at 4 SCFM.
Special tools and support equipment

Table 2-1 lists special tools and support equipment required for the AR3200.
Table 2-1. Special tools and support equipment

Description Multimeter Hydraulic Pressure Test Gauge *Pneumatic Pressure Test Gauge Supplier & Model No. Various Various Various Accuracy <1% FS 3-5% FS 3-5% FS Range N/A 0-3000 psi (0-206 Bar) 0-150 psi (0-10 Bar)
*Only required on UL installations with purge system on the roughneck, any configuration with a purge system on the PLC, and casing roughneck configurations.
2-8
AR3200
SM00053, Rev D
Installation procedures
To install the AR3200 components and parts, use the referenced drawings in the Drawings chapter.
Referenced drawings
t AR3200 Installation - 59" (or 75" ) Track Spacing t AR3200 Hydraulic Service Loop Assembly t AR3200 Electrical Assembly t AR3200 Electrical Installation Kit t AR3200 Automated Iron Roughneck Assembly t AR3200 Interconnect Diagram t AR3200 Remote Controller Assembly (PLC) t AR3200 Derrick Plate Assembly t Rig Floor - 59 " Outside Rail Spacing Kit t Hinged Cog Drive Adapter Plate
SM00053, Rev D
Installation
2-9
July 1, 2005
Component installation
Installing the AR3200 involves installing the following components: t AR3200 adapter plate (page 2-10) t Rails (page 2-11) t AR3200 assembly (page 2-12) t Derrick J-box mounting plate and hydraulic derrick plate assembly (page 2-14) t Hydraulic torque gauge (page 2-17) t Hydraulic torque gauge (page 2-18) t Hydraulic service loop (page 2-19) t Monitor and optional control stations (page 2-21) t AC voltage regulator (page 2-23) t PLC enclosure, nonpurged (page 2-24) t Optional PLC purge unit (page 2-24)
INSTALLING THE AR3200 ADAPTER PLATE

See the following drawings in the Drawings chapter: t Hinged Cog Drive Adapter Plate t AR3200 Installation - 59" (or 75") Track Spacing The adapter plate places rails on opposite sides of the well bore and across the rotary table, allowing the AR3200 to travel between home, well center, and the mousehole. The length of the rails varies, based on the desired home position and the position of the mousehole. Install rails and a hinged two-piece adapter plate to the rig floor so the AR3200 drive rails can clear the rotary table. See the drawings for adapter plate installation specifications and details.
2-10
AR3200
SM00053, Rev D
INSTALLING THE AR3200 RAILS

See the following drawings in the Drawings chapter: t Rig Floor - 59" (or 75") Outside Rail Spacing Kit t AR3200 Installation - 59" (or 75") Track Spacing The feet of the AR3200 mount on cog drive rails welded to the rig floor. Use continuous shims to elevate the cog drive rails so they are level with the rails of the adapter plate. Use a gauge (see the Rig Floor - 59 " Outside Rail Spacing Kit drawing) to mount the cog drive rails. Locate the forward and aft rail stops as specified on the AR3200 Installation - 59" Track Spacing. The AR3200 requires an index slot to be cut into the cog drive rail so the automatic control system recognizes the tool position relative to the index slot. Cut an index slot in the right cog drive rail as shown on the drawing.
Rig configurations with removable track or those that require the AR3200 to travel more than 197 ft (60046 mm) from the well center may require an alternate index slot configuration and/or software enhancements.
SM00053, Rev D
Installation
2-11
July 1, 2005
INSTALLING THE AR3200 ASSEMBLY

See the following drawings in the Drawings chapter: t Automated Iron Roughneck Assembly drawing for steps 1 through 5. t Installation - 59" (or 75") Track Spacing drawing for step 6. To install the AR3200 Assembly (Figure 2-1): 1. Lift the AR3200 assembly and place it on the installed cog drive rails. Make sure the wheel cogs align with rail notches. 2. Remove the wire rope sling. 3. Remove the shackles. 4. Remove the shipping strap. 5. Remove the shipping bar. 6. Attach lock brackets to the AR3200 drive feet with bolts. Verify adequate clearance between bracket and rail to permit the tool to travel.
2-12
AR3200
SM00053, Rev D
Derrick Plate (With J-Box) Hydraulic Mounting Plate
PLC Box Mounting Plate (Plate supplied by others)
Rig Air for Purge AC Regulator
To AC Power Source
Hydraulic Service Loop Mounting Bracket
18' or 30' Mounting Height Safe Area
(Mount in Derrick)
Electrical Service Loops
Monitor Station (Optional) Control Station
Hydraulic Service Loop
(At Drillers's Console)
AR3200 Automated Iron Roughneck
Track
Well Center
Rotary Table Adapter PLates
Figure 2-1. AR 3200 typical installation

SM00053, Rev D Installation 2-13
July 1, 2005
INSTALLING THE DERRICK J-BOX MOUNTING PLATE AND
HYDRAULIC DERRICK PLATE ASSEMBLY

Ground all J-boxes (i.e., PLC J-box and derrick J-box). Varco-supplied J-boxes have 10mm grounding studs. Attach one end of a ground strap (customer supplied) to the J-box grounding stud and attach the other end to rig earth. Derrick J-box mounting plate A derrick J-box is required to interconnect the AR3200 electrical service loops to the PLC enclosure with derrick wiring (Figure 2-2). See the following drawings in the Drawings chapter for instructions on mounting the derrick J-box mounting plate to the assembly: t AR3200 Installation - 59" (or 75") Track Spacing The mounting height depends on the length of the service loop and rig arrangement. The plate contains lifting holes and mounting holes. A bracket securely supports the service loop ends. Service loop pigtails terminate in the derrick J-box (mounted on the plate) through glands in the bottom of the J-box. Make rig connections through the side plates. Use the supplied clamp brackets to secure the rig wiring to the derrick plate. Hydraulic derrick plate assembly See the following drawings in the Drawings chapter: t AR3200 Installation - 59" (or 75") Track Spacing t AR3200 Electrical Installation Kit See Figure 2-2, Hydraulic Derrick Plate, for identification of main components. The hydraulic derrick plate assembly provides connections for the following: t Pneumatic supply for UL installations and casing roughnecks t Hydraulic supply t Hydraulic return t Hydraulic torque gauge option or Hydraulic pressure transducer option
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AR3200
SM00053, Rev D
1 1/4" NPT 1" NPT 1/2" NPT 1/4" NPT J-Box Torque Gauge
Torque Gauge Option
Pressure Transducer
J-Box
Pressure Transducer Option
1 1/4" NPT 1" NPT 1/2" NPT 1/4" NPT
Figure 2-2. Hydraulic Derrick Plate

SM00053, Rev D Installation 2-15
July 1, 2005
The hydraulic derrick plate assembly also provides a place to mount a power J-box for UL configurations with an AR3200 J-box purge system. Mount the plate on the derrick 30 ft (9144 mm) above the rig floor (when using the standard 37 ft [11278 mm] service loop) and no more than 220 in. (5588 mm) away from well center (Table 2-2).
z
Table 2-2. Service loop table
Service Loop Configuration Standard Option Loop Length 37 ft + 1 ft (11278 mm) 25 ft + 1 ft (7620 mm) Loop Mounting Height 30 ft + 1 ft (9144 mm) 18 ft + 1 ft (5486 mm) Recommended Maximum Travel 18 ft (5486 mm) 13 ft (3962 mm)
For UL installations with a purge system on the tool, plumb the rig purge air supply into the 1/2 in. bulkhead fitting on the derrick mounting plate.
Table 2-3. Thread size table

Thread size 1/4 in. NPT Service Description Hydraulic Torque Gauge option or Hydraulic Pressure Transducer option 1/2 in. NPT 1 in. NPT 1 1/4 in. NPT Pneumatic Instrument, Quality Air/Purge System Hydraulic Power Supply (Pressure) Hydraulic Power Supply (Return)
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AR3200
SM00053, Rev D
INSTALLING THE HYDRAULIC PRESSURE TRANSDUCER

See the following drawing in the Drawings chapter: t AR3200 Electrical Installation Kit Mount the hydraulic pressure transducer on the hydraulic derrick plate as specified on the drawing. Read the following installation note before installing the hydraulic pressure transducer. (See the drawing for mounting dimensions.)
The transducer uses the 1/4 in. hydraulic line in the hydraulic service loop.
SM00053, Rev D
Installation
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July 1, 2005
INSTALLING THE HYDRAULIC TORQUE GAUGE

See the following drawings in the Drawings chapter: t AR3200 Installation - 59" (or 75") Track Spacing Mount the hydraulic torque gauge in the drillers control console as specified on the drawing. Make sure the operator has an unobstructed view of the gauge dial and the roughneck area of the drill floor. Read the following installation notes before installing the hydraulic torque gauge. (See the drawings for mounting dimensions.)
n
z z
The gauge uses the 1/4 in. hydraulic line in the hydraulic service loop.
Install a gauge damper in series between the hydraulic torque gauge and the hydraulic service loop.
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AR3200
SM00053, Rev D
INSTALLING THE HYDRAULIC SERVICE LOOP

See the following drawings in the Drawings chapter: t AR3200 Hydraulic Service Loop Assembly t AR3200 Electrical Installation Kit The hydraulic service loop hangs in the service loop bracket. Depending upon the configuration purchased, the AR3200 has either three or four hydraulic lines as follows: t 1 in. supply t 1 1/4 in. return t 1/4 in. hydraulic torque gauge t 1/2 in. air (UL purge and/or casing line)
e e
The hydraulic service loop contains an electrical line on UL configurations with purge systems on the tool and on casing-ready roughnecks. If used for any purpose, this electrical line must be terminated in the J-box. The self-sealing hydraulic line quick disconnects (QDs) must be fully shouldered when fastened together. If not fully shouldered, the self-sealing valves do not open or only open partially. This causes a severe drop in pressure through the QD. The drop in pressure causes the hydraulic fluid to overheat and overload the hydraulic power supply. The overload prevents the AR3200 from working correctly. To interconnect the rig hydraulic system and the AR3200: 1. Connect the 1 1/4 in. threaded hose connector from the service loop to the 1 1/4 in. hydraulic return bulkhead fitting on the hydraulic derrick mounting plate. 2. Connect the 1 in. threaded hose connector from the service loop to the 1 in. hydraulic supply bulkhead fitting on the hydraulic derrick mounting plate. 3. Use a 1 in-to-1 1/4 in. adapter (customer supplied) to connect the supply to the return line at the tool end of the service loop. 4. Operate the hydraulic power supply for approximately 15 minutes to remove contaminants from the system. Reconnect the supply and return lines to their respective fittings after flushing the system. 5. Connect the 1 1/4 in. QD hose connector from the service loop to the 1 1/4 in. hydraulic return QD fitting on the AR3200 inlet manifold assembly. 6. Connect the 1 in. QD connector from the service loop to the 1 in. hydraulic supply QD fitting on the AR3200 inlet manifold assembly.
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Installation
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July 1, 2005
7. Connect the 1/4 in. threaded hose connector from the service loop to the 1/4 in. hydraulic torque gauge bulkhead fitting on the hydraulic derrick mounting plate. 8. Connect the 1/4 in. QD hose connector from the service loop to the 1/4 in. hydraulic torque gauge QD fitting on the AR3200 inlet manifold assembly. 9. After connecting the AR3200 to a hydraulic power supply, remove air trapped in the system. 10. Secure the service loop to the AR3200 using brackets and bolts provided. 11. Inspect the service loop for any binding kinks, areas of contact with rig structures or other equipment, which may be detrimental to the life of the service loop.
INTERCONNECTING PURGE AIR (UL CONFIGURATIONS)

See the following drawing in the Drawings chapter: t AR3200 Hydraulic Service Loop Assembly To interconnect purge air: 1. Connect the 1/2 in. threaded hose connector from the service loop to the 1/2 in. purge air bulkhead connector on the derrick mounting plate. 2. Connect the 1/2 in. QD hose connector from the service loop to the 1/2 in. purge air QD connector on the AR3200 inlet manifold assembly.
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SM00053, Rev D
INSTALLING THE MONITOR AND OPTIONAL CONTROL STATIONS

See the following drawings in the Drawings chapter: t AR3200 Installation - 59" Track Spacing t AR3200 Remote Controller Assembly (PLC) t AR3200 Electrical Installation Kit t AR3200 Interconnect Diagram Mount both the monitor and control stations at the drillers control console in a convenient location for operation as specified on the drawing. Make sure the operator can see the hydraulic torque gauge and the roughneck area of the rig floor, as well as the controls. Read the following installation notes before installing the monitor and control stations. Control station options The AR3200 has either of two control options: t A monitor station, but no control station t A monitor station and a control station Table 2-4 shows the control station options and what each includes.
Table 2-4. Control station options

Station type UL monitor station Includes Two indicator lights (one for ENGAGED and one for CLEAR) and an EMERGENCY SHUTDOWN switch (ESD). Two indicator lights (one for ENGAGED and one for CLEAR) and an EMERGENCY SHUTDOWN switch (ESD). One trip in/trip out switch and one auto start button. One trip in/trip out switch and one auto start button.
EEx monitor station
UL control station EEx control station
SM00053, Rev D
Installation
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July 1, 2005
To install the monitor and optional control stations: 1. Connect the control station and monitor station cables from the drillers console to the PLC box as specified on the wiring diagram. The AR3200 Installation - 59" Track Spacing drawing provides mounting specifications.
z e
The monitor control station uses cable S01.The drillers control stations uses cable S02. 2. When installing the monitor station, remove the jumper between TB3-5 and TB36 in the PLC assembly enclosure. Remove the jumper between TB3-5 and TB3-6 in the PLC assembly enclosure if the monitor station is installed. Failure to remove this jumper disables the monitor station ESD.
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AR3200
SM00053, Rev D
INSTALLING THE AC VOLTAGE REGULATOR

Read the following notes before installing the AC voltage regulator. Procedures vary between nonpurged and (optional) purged installations. Nonpurged installation In a nonpurged installation, the AC voltage regulator (2,000VA, 50Hz) connects rig power to a PLC box. (See Installing the PLC enclosure (nonpurged) on page 2-24.) The AC voltage regulator must be installed in a safe area UL and EEx installation In a UL or EEx installation, the AC regulating transformer (1,500 VA, 60Hz) connects rig power to a power J-box. General notes Terminate derrick power leads into the AC Regulator with line power connected according to Table 2-5:
Table 2-5. Rig power

Line Voltage 95-130 VAC 175-235 VAC 190-260 VAC 380-520 VAC AC Regulator Terminal H1 and H2 H1 and H3 H1 and H4 H1 and H5
Terminate the output of the AC voltage regulator to the PLC J-box terminal TB61 for a regulated line and to terminal TB6-2 for neutral. Wire the ground to terminal TB6-3.
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Installation
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July 1, 2005
INSTALLING THE PLC ENCLOSURE (NONPURGED)

See the following drawings in the Drawings chapter: t AR3200 Electrical Installation Kit drawing t AR3200 Interconnect Diagram drawing The PLC enclosure contains all components necessary for the automatic control system, except for sensors and switches. Mount the PLC in an accessible, nonhazardous area. To install the PLC enclosure: 1. Mount the PLC enclosure onto a customer-supplied steel plate. (See the Electrical Installation Kit drawing for layout.) 2. Mount the steel plate assembly onto the rig structure in a location that is protected from the elements if possible.
INSTALLING THE OPTIONAL PLC ENCLOSURE PURGE UNIT

See the following drawings in the Drawings chapter: t AR3200 Installation - 59" (or 75") Track Spacing drawing t AR3200 Remote Controller Assembly (PLC) drawing The optional PLC purge unit mounts on top of the PLC enclosure. To install the optional PLC enclosure purge unit: 1. Remove the stiffener plate. 2. Assemble the following components: a. Purge Airline b. Gasket c. PLC enclosure d. Stiffener plate 3. Connect the purge air line and fitting to the purge air exit fitting. 4. Route the air line behind the J-box panel. 5. Use the four supplied screws to attach the PLC purge unit to the PLC enclosure.
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AR3200
SM00053, Rev D
INSTALLING THE ELECTRICAL SERVICE LOOP

See the following drawings in the Drawings chapter: t AR3200 Electrical Installation Kit drawing
t AR3200 Interconnect Diagram drawing t AR3200 Derrick Plate Assembly drawing To install and interconnect the electrical service loop: 1. Connect the electrical service loops to the derrick plate assembly. 2. Terminate pigtails in the derrick J-box. 3. Trim the wires at the end of the pigtails to length and terminate (see AR3200 Interconnect Diagram drawing).
Varco recommends the use of crimp ferrules. 4. Make sure that the glands connecting the wire mesh armor of the cable to the J-box are properly installed to provide airtight and leakage free (U.L purge systems) shielding. Two nuts on each gland connect it to the cable. The first nut traps the wire braid in place. The second nut provides an environmental seal. If necessary, tighten first the inner, then the outer nut to prevent dust or moisture from entering the J-box. 5. Clamp pigtails in place on the right side of the left torque wrench guard (see AR3200 Electrical Installation Kit drawing) and in two places on the left leg of the roughneck assembly. 6. Allow enough slack to cover the AR3200 travel distance to prevent binding or kinking. 7. Trim the wires at the end of the pigtails to length and terminate. (See AR3200 Interconnect Diagram drawing.) 8. Install the service loop guard over the electrical cables.
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Installation
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July 1, 2005
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Operation
July 1, 2005
3-2
AR3200
SM00053, Rev D
Chapter 3 Contents
Chapter 3 Operation
AR3200 operator controls ................................................................................ 3-5 About the operator control panels ........................................................ 3-5 Torque gauge ................................................................................. 3-5 Automatic Sequence controls ............................................................... 3-6 Controls in sequenced operation .................................................... 3-6 Controls in manual mode ............................................................... 3-7 EMERGENCY STOP (ESD) control ............................................ 3-7 Tool J-box controls .............................................................................. 3-7 Manual Control Station ........................................................................ 3-7 Automatic Control Station ........................................................... 3-10 Remote Monitor Station ..................................................................... 3-11 Optional Remote Control Station ....................................................... 3-13 Tool J-box controls ............................................................................ 3-15 Preoperation .................................................................................................... 3-16 Preoperational checklist ............................................................................ 3-16 AR3200 PLC startup .......................................................................... 3-21 Installing the EPROM ........................................................................ 3-21 Indexing the AR3200 ......................................................................... 3-22 Initializing an automatic sequence ..................................................... 3-23 Setting up the AR3200 LEARN MODE ............................................ 3-24 AR3200 function tests .............................................................................. 3-26 Function checks .................................................................................. 3-26 Pressure-reducing valve ............................................................... 3-26 Torque Wrench ............................................................................ 3-27 Spinning Wrench ......................................................................... 3-27 Carriage vertical positioning ....................................................... 3-27 Rolling operations ........................................................................ 3-27 Tilt operation ............................................................................... 3-27 Automatic makeup ....................................................................... 3-28 Automatic breakout ..................................................................... 3-29 Semiautomatic makeup with manual height positioning ............. 3-30 Semiautomatic breakout with manual height adjustment ............ 3-31 Automatic makeup, PS MODE ................................................... 3-32 Automatic breakout, PS MODE .................................................. 3-33 Automatic makeup, Torque Wrench backup mode (soft clamp) . 3-34 Automatic breakout, Torque Wrench backup mode (soft clamp) 3-35 LEARN MODE ........................................................................... 3-36 Operating procedures ...................................................................................... 3-37 AR3200 checkout procedures ................................................................... 3-37 Manual control switches ........................................................................... 3-38 Setting the makeup torque ........................................................... 3-38
Operation
3-3
July 1, 2005
Mousehole operations ......................................................................... 3-39 End-of-stroke interlock ....................................................................... 3-40 Resetting after an interlock condition .......................................... 3-40 Automatic sequence control ...................................................................... 3-41 Torque Wrench backup mode ............................................................ 3-41 Automatic makeup ............................................................................. 3-42 Automatic breakout ............................................................................ 3-43 Auto/manual height adjustment operation ......................................... 3-44 Manual positioning mode ............................................................ 3-44 Autopositioning mode .................................................................. 3-44 Tool joint length and tool joint height ................................................ 3-45 Horizontal/vertical position adjustments ............................................ 3-46 Purge operation ................................................................................................ 3-47 Operating the purge unit for PLC enclosure ............................................. 3-49 Operating the J-box purge control unit ..................................................... 3-50 IBOP hanger operation (optional) ................................................................... 3-52 Commissioning Procedure (FIP00055) ........................................................... 3-52
3-4
AR3200
SM00053, Rev D
Chapter 3 Operation
AR3200 operator controls

The AR3200 contains the following types of controls: t Manual Operator Control Panels (Figure 3-1 and Figure 3-2) t Automatic Control Station on the tool (Figure 3-3) t Remote Monitor Station (Figure 3-4 and Figure 3-5) t Optional Remote Control Station (Figure 3-6 and Figure 3-7) t Tool J-box controls (Figure 3-8)
ABOUT THE OPERATOR CONTROL PANELS

The operator controls are located on either the right or left side of the AR3200, depending upon the configuration purchased. In this manual, the left-hand configuration is illustrated, but the controls function identically, regardless of the side of the tool on which they are located. Torque gauge A torque gauge, located on the frame of the AR3200, helps set and verify torque when operating the tool manually. A remote torque gauge, usually mounted at the drillers console, also indicates makeup torque.
Operation
3-5
July 1, 2005
AUTOMATIC SEQUENCE CONTROLS

Automatic sequence controls are located as follows: t Automatic Control Station on the tool (Figure 3-3) t Remote Monitor Station (Figure 3-4 and Figure 3-5) t Optional Remote Control Station (Figure 3-6 and Figure 3-7) These remote stations can be mounted almost anywhere, although they are typically located on or near the drillers control console. The AR3200 requires minimal operator intervention. You set the torque and tool joint length only once per trip for each type of pipe used. Controls in sequenced operation After the selecting TRIP IN or TRIP OUT, press the AUTO SEQUENCE button for the AR3200 to begin a sequence of makeup or breakout functions automatically. A sequence can include positioning the unit, spinning in or out, and torquing or breaking out a joint. PLC software directs the tool to perform all normal makeup and breakout functions. Normally, the AR3200 operates at a setting of 2,000 psi. Integrated sensors and interlocks enable the tool to perform several functions sequentially. Interlocks also prevent the operator from inadvertently initiating inappropriate operating sequences.
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AR3200
SM00053, Rev D
Controls in manual mode For drill collars or special operations, set the TJ LENGTH switch to MAN (manual mode) and set the tool to 2,500 psi. This slows the Spinning Wrench speed to prevent thread damage.
In manual mode, none of the interlocks function, except for the end-of-stroke interlock. In this mode, only the index and position-counting sensors function. EMERGENCY STOP (ESD) control You can stop tool operation at any time, whether in operating manually or in sequenced mode, by pushing the EMERGENCY STOP button located on the Manual Control Station. Pulling the button out allows you to restart the operation.
TOOL J-BOX CONTROLS

The tool J-box contains switches for selecting either manual or automatic tool joint height detection and for turning the power slips mode (PS-MODE) on or off (Figure 3-9).
MANUAL CONTROL STATION

The Manual Control Station (Figure 3-1 and Figure 3-2) is located on either the right or left side of the unit and contains switches that allow you to control AR3200 functions individually. The Manual Control Station also contains an EMERGENCY STOP button. Table 3-1 describes the controls and their function.
SM00053, Rev D
Operation
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July 1, 2005
UP OUT IN UNCLAMP CLAMP ON OFF OVERRIDE 2500 PSI 2000 PSI
WELL
HOME SPIN SPIN SPINNING WRENCH
PUSH TO STOP
BREAK OUT
MAKE UP
UNCLAMP
CLAMP PULL TO RESET
NORMAL
BACKUP
VERTICAL
TILT
TORQUE DONE
TORQUE
TORQUE WRENCH
TW MODE
10
11
12
13
Figure 3-1. Manual Control Station (left UL configuration)
14
13
12
IN
OUT
UP
OFF
ON
OVERRIDE
VERTICAL
TILT
OUT
IN
UNCLAMP
CLAMP
WELL TRIP
HOME SPIN SPIN. WRENCH
NORMAL
BACKUP AUTO SEQUENCE DOWN EMERGENCY STOP 2500 PSI 2000 PSI BREAK OUT MAKE UP UNCLAMP CLAMP TW MODE
TORQUE
TORQUE WRENCH
15
10
11
Figure 3-2. Manual Control Station (left EEx configuration)
3-8
AR3200
SM00053, Rev D
Table 3-1. AR3200 Manual Control Station

# 1 Switch 2500 PSI/2000 PSI Switch Type Function Two-position Selects two hydraulic operating levels. The normal operational level is 2,000 psi. Select 2,500 psi for drill collars or special operations.
2 3 4 5 6 7 8 9
OFF/ON/OVERRIDE EMERGENCY STOP SPINNING WRENCH UNCLAMP/CLAMP SPIN OUT/IN HOME UP DOWN WELL
Three-position Selects the operating mode of the AR3200 from the Manual Control Station. Pushbutton Stops operation of the AR3200 when the button is pushed in. Pull out to allow operation.
Three-position Selects the clamping or unclamping function of the Spinning Wrench. Three-position Selects the Spinning Wrench rotational direction. Pushbutton Pushbutton Pushbutton Pushbutton Moves the AR3200 away from well center. Moves the AR3200 carriage upward. Moves the AR3200 carriage downward. Moves the AR3200 toward well center.
10 TORQUE BREAKOUT/MAKEUP 11 TORQUE WRENCH UNCLAMP/CLAMP 12 TW MODE NORMAL/BACKUP
Three-position Selects partial rotation of the upper Torque Wrench jaws in one direction or the other when the TW MODE BACKUP/NORMAL switch in the NORMAL position. Three-position Selects clamping or unclamping of the upper and lower Torque Wrench jaws. Two-position Selects specific combinations of operations. In backup mode, only the lower jaws are clamped, allowing the Torque Wrench to back up the spinning function (soft clamp). This mode forces the upper jaws to unclamp. selects the vertical or tilted position of the carriage. Use tilting for making mousehole connections. Selects the tripping mode for either making up (TRIP IN) or breaking out (TRIP OUT) sequences. Initiates the automatic makeup or breakout sequence.
13 VERTICAL/TILT 14 TRIP IN/OUT 15 AUTO SEQUENCE
Two-position Two-position Pushbutton
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Operation
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July 1, 2005
Automatic Control Station The Automatic Control Station (Figure 3-3) is located either on the side of the tool adjacent to the Manual Control Station (UL) or on the Manual Control Station panel (EEx).This control station contains an AUTO SEQUENCE button that initiates a sequence. The TRIP IN/OUT switch selects the sequence for making up (TRIP IN) or breaking out (TRIP OUT) sequences.
OUT
IN
TRIP AUTOMATIC SEQUENCE
Figure 3-3. Automatic Control Station (UL)
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SM00053, Rev D
REMOTE MONITOR STATION

The remote monitor station (Figure 3-4 and Figure 3-5) is typically located on or near the drillers control console. The station includes two indicator lights (one for ENGAGED and one for CLEAR) and an Emergency Shutdown (ESD) pushbutton. .
ENGAGED PUSH TO STOP
CLEAR
PULL TO START
Figure 3-4. Remote monitor station (UL)
SM00053, Rev D
Operation
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July 1, 2005
ENGAGED
CLEAR
PUSH TO STOP RELEASE TO START
Figure 3-5. Remote Monitor Station (EEx)
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AR3200
SM00053, Rev D
OPTIONAL REMOTE CONTROL STATION

The optional Remote Control Station (Figure 3-6 and Figure 3-7) is typically located on or near the drillers control console. The station includes a duplicate set of Automatic Control Station controls: one TRIP IN/OUT switch and one AUTO SEQUENCE button.
OUT
IN
TRIP AUTOMATIC SEQUENCE
Figure 3-6. Optional Remote Control Station (UL)
SM00053, Rev D
Operation
3-13
TRIP OUT IN
AUTOMATIC SEQUENCE
Figure 3-7. Optional Remote Control Station (EEx)
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AR3200
SM00053, Rev D
TOOL J-BOX CONTROLS

Two switches are mounted on the tool J-box (Figure 3-8). Table 3-2 explains the function of each switch.
Table 3-2. Tool joint length and power slip switches

Selector Switch Function
TJ LENGTH (MAN, MAN = Allows you to manually set the 8", 10", 12", 14", HW) tool joint size for an irregular tool joint length when in AUTO SEQUENCE MODE. 8", 10", 12", 14" = Specifies a preset length. The AR3200 finds the tool joint automatically. HW = Sets the tool joint size to accommodate Heavy Weight tubulars. PS MODE (ON, OFF) Selects the power slip mode. ON = when using a power slip. The carriage mode adjusts the AR3200 carriage height to clear a power slip. OFF = when not using a power slip.
10" 8" MAN
12" 14" HW
Tool Joint Length Switch
TJ LENGTH
OFF ON
PS-MODE
Figure 3-8. Tool joint length and power slip mode switches
SM00053, Rev D
P/N 107475
Power Slip Switch
Operation
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July 1, 2005
Preoperation
Preoperation activities include t Completing the preoperational checklist t Starting up the PLC t Performing the AR3200 function tests
Preoperational checklist
Complete the preoperational checklist Table 3-3 before operating the AR3200.
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AR3200
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Preoperation
Table 3-3. Preoperational checklist

Component/ Assembly t Derrick J-box mounting plate Inspection Inspect the derrick J-box plate assembly for mounting security by checking bolts and lock wire for tightness. Action Secure the J-box as required.
Check electrical wiring in the derrick J-box for Make sure all wires are proper termination. The maximum resistance is secured. (See the electrical 2 Ohm end-to-end. wiring diagrams in the Drawings chapter. Check all electrical cables from the PLC to the Adjust. derrick J-box and the derrick J-box to the AR3200 (service loops) for abrasion, pinching, cracking, kinking, and excessive bending or twisting. t Service loops Inspect the connection between the derrick Tighten as required. hydraulic supply line to the 1 in. hydraulic supply bulkhead connector on the mounting plate. Make sure threaded fittings are fluid-tight. Inspect the connection between the 1 in. Tighten as required. hydraulic supply bulkhead connector on the mounting plate to the AR3200 hydraulic supply hose. Make sure threaded fittings are fluidtight. Inspect the connection between the 1 1/4 in. derrick hydraulic return line to the inlet manifold bulkhead connector on the mounting plate. Make sure threaded fittings are fluidtight. Tighten as required.
Inspect the connection between the 1 1/4 in. Tighten as required. hydraulic return bulkhead connector on the mounting plate to the AR3200 hydraulic return hose. Make sure threaded fittings are fluidtight. Inspect the connection between the derrick Tighten as required. hydraulic instrument line to the 1/4 in. hydraulic bulkhead connector on the mounting plate. Make sure threaded fittings are fluid-tight. Inspect the connection between the 1/4 in. Tighten as required. hydraulic instrument bulkhead connector on the mounting plate to the AR3200 hydraulic hose. Make sure threaded fittings are fluid-tight.
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Operation
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July 1, 2005
Table 3-3. Preoperational checklist (continued)

Component/ Assembly u Inlet manifold Inspection Check hydraulic supply, hydraulic return, and hydraulic instrument QDs for fluid-tight connection to the inlet manifold. Check the filter in the hydraulic system for clogging. Action Tighten as required.
To clean the filter:

1. Disconnect the supply and return line QDs. 2. Remove the bolt at the bottom of the filter for drainage. 3. Drain the filter. 4. Remove the filter.
Main hydraulic manifold Drive tracks
Check manifold-mounted pressure-reduction valves, directional control valves, pressure gauge, and hoses for tightness. Inspect for rail cog damage. Inspect mechanical stops for damage (broken stops). Inspect for level alignment and proper span. Inspect mounting welds for cracks.
Tighten as required.
Repair or replace as required. Repair as required. Relevel and/or align as required Tighten or replace hardware as required. Reweld if required. Tighten.
Check hinges on the hinged rails. u Frame
Inspect the frame for loose or missing hardware Tighten or replace as and fittings. required. Check the lift cylinder, tilt cylinder, and main hydraulic manifold hoses for abrasion, pinching, kinking, cracking, and excessive bending or twisting. Replace damaged hoses as required.
Check all hydraulic hose connections from the Use a wrench to tighten the main hydraulic manifold to the lift cylinder, tilt connections as required. cylinder, and main hydraulic manifold for tightness. Check all electrical cables for abrasion, pinching, kinking, cracking, and excessive bending or twisting. Replace damaged cables as required.
Check all hoses for abrasion, pinching, kinking, Replace damaged hoses as cracking and excessive bending or twisting. required.
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AR3200
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Preoperation

Component/ Assembly u Carriage Inspection Inspect for loose or missing hardware and fittings. Check all electrical cables for abrasion, pinching, and excessive bending or twisting. Check the rollers for damage and freedom of movement. Inspect proximity sensors for mounting security. Inspect the proximity sensor for damage, obstructions, and proper installation. Check all hydraulic hose connections from the main hydraulic manifold to the foot assembly hydraulic motors for tightness. u Torque Wrench Inspect the Torque Wrench for loose hardware and fittings. Check the Torque Wrench hoses for abrasion, pinching, cracking, kinking, and excessive bending or twisting. Check all hydraulic hose connections from the main hydraulic manifold to the upper and lower Torque Wrench clamping cylinders for tightness. Action Tighten or replace as required. Replace damaged cables as required. Repair or replace as required Secure as required. Adjust; replace as required. Tighten as required.
Tighten or replace as required. Replace damaged hoses as required. Tighten as required.
Check all hydraulic hose connections from the Tighten as required. main hydraulic manifold to the upper and lower Torque Wrench torque cylinders for tightness. Inspect the Torque Wrench jaw and make sure See the Maintenance chapthe tong dies are properly installed and service- ter for details on changing able. Make sure the Torque Wrench jaw assem- tong dies. bly has the correct tong dies for the pipe size used. Make sure the tool joint sensor assembly is in proper position for the pipe size. Inspect the proximity sensors for damage, obstructions, and proper installation. Adjust as required. Adjust; replace as required.
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Operation
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July 1, 2005

Component/ Assembly u Spinning Wrench Inspection Inspect for loose hardware and fittings. Action Tighten.
Check the Spinning Wrench hoses for abrasion, Replace damaged hoses as pinching, cracking, kinking, and excessive required. bending or twisting. Check all hydraulic hose connections from the main hydraulic manifold to the Spinning Wrench clamp cylinder for tightness. Check all hydraulic hose connections from the main hydraulic manifold to the Spinning Wrench hydraulic manifold for tightness. Check all hydraulic hose connections from the Spinning Wrench hydraulic manifold to the Spinning Wrench hydraulic motors for tightness. Inspect guide rollers for damage and freedom of movement. u Control cubicle Inspect the exterior of the control cubicle for signs of damage and gland tightness. If necessary, adjust the gland nuts to form a climateresistant seal. Open the electrical enclosure and inspect the door seal for signs of deterioration or damage. u Hydraulic supply Make sure the hydraulic power supply is serviceable and capable of a minimum output of 2,500 psi and 45 gpm Tighten as required.
Repair or replace as required. Repair as required.
Replace door seal as required. Adjust.
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AR3200
SM00053, Rev D
Preoperation
AR3200 PLC STARTUP

To prepare the AR3200 for startup requires the following procedures: 1. Installing the EPROM (page 3-21) 2. Indexing the AR3200 (page 3-22) (Allows the system to detect the relative position of the tool.)
3. Initializing an automatic sequence (page 3-23)
4. Setting up the AR3200 LEARN MODE (page 3-24) Before beginning these procedures, verify that no hazardous gases are present, then install a jumper wire at the purge loss of pressure switch to enable the PLC enclosure to be energized during startup. Be sure to remove the jumper switch before operating the AR3200.
INSTALLING THE EPROM

To install the EPROM: 1. Make sure the PLC power is off. 2. Remove the battery (if already installed). 3. Insert the AR3200 EPROM into the PLC. 4. Set the Run/Stop switch to RUN. 5. Turn power on. A yellow lamp that normally indicates a low battery illuminates. 6. The red and green LEDs on the front of PLC illuminate as follows: a. The red LED lights up for a few seconds. b. The red LED flickers for about two seconds. c. The red LED extinguishes and the green LED illuminates. 7. Reinstall the battery. The yellow lamp indicating low battery turns off.
SM00053, Rev D
Operation
3-21
INDEXING THE AR3200

1. Make sure all AR3200 switches are set to OFF, Safe, or neutral positions. 2. Start the HPU. 3. Set the tool mode switch to ON. 4. Turn the Torque Wrench (TW) and Spinning Wrench (SW) clamp switches to the open position, then set to the center (OFF) position for automatic operation. 5. Turn the TW Make/Break switch so that the TW position proximity sensor makes contact at both ends of the stroke. 6. Drive the AR3200 forward and reverse over the cutout index slot in cog drive rail to index the horizontal counting system. 7. Six inches before well center, the AR3200 automatically sets the pressure to 2,500 psi and slows its forward speed. 8. Raise the carriage all the way up. 9. Turn the Torque Wrench and Spinning Wrench switches to the Clamp position. 10. Lower the carriage all the way to the end-of-stroke to index the vertical counting system. As the carriage moves downward, near the bottom of the stroke, it activates the end-of-stroke sensor, which causes the interlocks to open the jaws.
3-22
AR3200
SM00053, Rev D
Preoperation
INITIALIZING AN AUTOMATIC SEQUENCE

To initialize the AR3200 automatic sequence mode: 1. Set the Torque Wrench and Spinning Wrench clamp switches to the center (off) position. 2. Set the tilt switch to VERTICAL. 3. Set the pressure select switch to 2,000 psi. 4. Set the LEARN MODE switch to Off. 5. Set the tool mode switch to ON. 6. Set the trip mode to IN or OUT.
SM00053, Rev D
Operation
3-23
SETTING UP THE AR3200 LEARN MODE

See Figure 3-9 before setting up the AR3200 LEARN MODE. To set up the AR3200 LEARN MODE: 1. Set the Torque Wrench and Spinning Wrench CLAMP switches the center (OFF) position. 2. Set the TILT switch to VERTICAL. 3. Set the PRESSURE SELECT switch to 2,000 psi. 4. Set the LEARN MODE switch located in the PLC enclosure to ON. 5. Set the TOOL MODE switch to ON. 6. Drive the AR3200 forward to the well. It is not necessary to have a pipe in the slips, but the tool must be at well center position to start. 7. Select a height (not above tool joint height) and position the carriage at that height. 8. Press the AUTO SEQUENCE button. a. If there is an overhead obstruction, drive the AR3200 away from well at least 10 track cogs (21.5 in. minimum). b. If there is no overhead obstruction, no duck height programming is required. Drive the AR3200 directly to the HOME position and press the AUTO SEQUENCE button. 9. Lower the carriage to the end-of-stroke and press the AUTO SEQUENCE button. This programs the duck height. 10. Drive the AR3200 to the HOME position, and press the AUTO SEQUENCE button again. 11. Set LEARN MODE switch to OFF.
Selecting a default height of up to 7 in. (178 mm) above the end-of-stroke allows the AR3200 to follow the same positioning procedures as if the PS MODE were selected. If no overhead obstruction exists, the tool presets vertical height in the HOME position at the end of each makeup or breakout routine. If an overhead obstruction is present, the tool performs vertical positioning on the way to well center as soon as it clears the obstruction. If the learned height is zero (below detection of end-of-stroke) the carriage is left at end-of-stroke following either positioning function.
3-24
AR3200
SM00053, Rev D
Preoperation
Forward With Obstruction

At Well PS Zone Overhead Obstruction Learned Height PS Height Note: If PS is selected, learned height will be ignored and carriage destination will be PS height. No vertical adjustment allowed behind obstruction.
Forward Without Obstruction

At Well PS Zone Vertical height reset at "Home" position. Learned Height PS Height
Reverse With Obstruction

At Well PS Zone Overhead Obstruction Learned Height PS Height No vertical adjustment allowed behind obstruction.
Reverse Without Obstruction

At Well PS Zone Vertical height reset at "Home" position. Learned Height PS Height Note: If PS is selected, learned height will be ignored and carriage destination will be PS height.
Figure 3-9. AR3200 LEARN MODE diagram

SM00053, Rev D Operation 3-25
AR3200 function tests

This section describes all AR3200 preoperational function tests. Use these checklists to make sure the AR3200 is operating properly before using the tool.
FUNCTION CHECKS
Perform function checks on the following: t Pressure-reducing valve (page 3-26) t Torque Wrench (page 3-27) t Spinning Wrench (page 3-27) t Carriage vertical positioning (page 3-27) t Rolling operations (page 3-27) t Tilt operation (page 3-27) t Automatic makeup (page 3-28) t Automatic breakout (page 3-29) t Semiautomatic makeup with manual height positioning (page 3-30) t Semiautomatic breakout with manual height adjustment (page 3-31) t Automatic makeup, PS MODE (page 3-32) t Automatic breakout, PS MODE (page 3-33) t Automatic makeup, Torque Wrench backup mode (soft clamp) (page 3-34) t Automatic breakout, Torque Wrench backup mode (soft clamp) (page 3-35) t LEARN MODE (page 3-36) Pressure-reducing valve 1. Select 2,000 psi on the manual controller and verify the pressure on the AR3200 gauge. 2. Select 2,500 psi on the manual controller and verify the pressure on the AR3200 gauge.
3-26
AR3200
SM00053, Rev D
Preoperation
Torque Wrench 1. Operate the Torque Wrench in torque mode, both fully clamped and fully unclamped (clamping speed approximately 2-3 seconds). 2. Check the dump valve for proper operation. When activated, the torque gauge should read 0-5 ft-lb. 3. Check the proximity sensor alignment with the target. The correct alignment is.16 in. + .062 in. 4. Check all fittings and hoses for leaks. 5. Operate the Torque Wrench clamp with the Normal/BACKUP switch in backup position and verify that only the lower jaw clamps. Spinning Wrench 1. Operate the Spinning Wrench in clamp, spin in, spin out, and unclamp mode. Do not run the spinner on the tool joint to prevent damage to the spinner motor housing. 2. Check the Spinning Wrench rpm. It should be 110-155 rpm at 2,000 psi and 30 rpm at 2,500 psi. 3. Check the clamp speed. It should be 1 1/2 to 3 seconds. 4. Check all hoses and fittings for leaks. Carriage vertical positioning 1. Move the carriage up and down. The carriage should stay in any given position when the switch is released, without creeping. 2. Check all hoses and fittings for leaks. Rolling operations 1. Extend and retract the tool, checking for smooth operation across the rails. 2. Make sure the tool stays in position when releasing the control. Tilt operation 1. Check the operation of the tilt function for interference and binding. The tilt is adjustable from 3 - 7 and is preset at the factory to customer specifications.
Forward tilt is adjustable from 3 - 7. Reverse tilt is fixed at 7. 2. Check all fittings and hoses for leaks.
SM00053, Rev D
Operation
3-27
July 1, 2005
Automatic makeup
For any automatic sequence, the TORQUE WRENCH CLAMP and SPINNING WRENCH CLAMP, TILT, and TEACH switches must be in the OFF position. 1. Locate the tool in the HOME position and fully lower the carriage. 2. Set a joint of drill pipe in the slips. 3. Lower the pin of an additional joint(s) into the box of the joint in the slip. Hold the joint loosely in elevators.
Secure the slips before making up a single joint to prevent the drill pipe from spinning the slips in the rotary table. Do not use power slips for this operation. 1. Set the tool control switches as follows: Switch Setting
OFF/ON/OVERRIDE ON TJ LENGTH TRIP Select the proper tool joint length, e.g., 8", 10", 12", etc. IN
2. Press the AUTO SEQUENCE button and verify that the tool moves to well center. The Torque Wrench cycles to the makeup ready (full breakout) position and the tool slows down before contacting the pipe. The tool joint is positioned between the upper and lower Torque Wrench jaws. 3. Press the AUTO SEQUENCE button again and verify that the tool performs as follows: a. Spinning Wrench clamps. b. Performs a short spinout to engage threads. c. Spins pipe fully into the box section. d. Torque Wrench jaws clamp on tool joint. e. Applies correct makeup torque (as selected by the operator using the pressure-reducing valve [PRV]). Torque should hold until you press the AUTO SEQUENCE button again.
3-28
AR3200
SM00053, Rev D
Preoperation
4. Press the AUTO SEQUENCE button again and verify that the tool performs as follows: a. Spinning Wrench unclamps. b. Torque Wrench unclamps. c. Tool moves to the HOME position. 5. When the tool is in the HOME position, verify the following: a. Torque Wrench recycles to makeup ready (full breakout) position. b. Carriage is fully lowered (or at learned height). Automatic breakout 1. Locate the tool in the HOME position and fully lower the carriage. Set the tool control switches as follows: Switch Setting
OFF/ON/OVERRIDE ON TJ LENGTH TRIP Select the proper tool joint length, e.g., 8", 10", 12", etc. OUT
2. Press the AUTO SEQUENCE button. 3. Verify that the tool moves to well center. The Torque Wrench cycles to breakout ready (full makeup) position. The tool slows down before contacting the pipe and performs as follows: a. The tool joint is positioned between the upper and lower Torque Wrench jaws. b. The Torque Wrench and Spinning Wrench jaws clamp onto the pipe. c. Applies breakout torque. d. Torque Wrench unclamps. e. Spins pipe fully out. f. Spinning Wrench unclamps.
g. Moves to HOME position. 4. When the tool is in the HOME position verify the following: a. Torque Wrench recycles to breakout (full makeup) position. b. Carriage lowers fully (or at learned height).
SM00053, Rev D
Operation
3-29
July 1, 2005
Semiautomatic makeup with manual height positioning 1. Make sure the tool is in the HOME position and the carriage is fully lowered. Set the tool control switches as follows: Switch Setting
OFF/ON/OVERRIDE ON TJ LENGTH TRIP MAN IN
2. Press the AUTO SEQUENCE button. 3. Verify that the tool moves to well center. The Torque Wrench cycles to makeup ready (full breakout) position, and the tool slows down before contact with pipe. The tool height should not change. 4. Position the Torque Wrench to proper height using the manual control vertical switches. 5. Press the AUTO SEQUENCE button again and verify that the tool performs as follows: a. Spinning Wrench clamps. b. Performs a short spinout to engage the threads. c. Spins pipe fully into the box section. d. Torque Wrench jaws clamp onto the tool joint. e. Applies correct makeup torque (as selected using the PRV). Torque should hold until you press the AUTO SEQUENCE button again. 6. Press the AUTO SEQUENCE button again and verify that the tool performs as follows: a. Spinning Wrench unclamps. b. Torque Wrench unclamps. c. Tool moves to HOME position. 7. When the tool is in the HOME position, verify that the tool performs the following: a. Torque Wrench returns to makeup ready position. b. Carriage height does not change.
3-30
AR3200
SM00053, Rev D
Preoperation
Semiautomatic breakout with manual height adjustment 1. Locate the tool in the HOME position and fully lower the carriage. Set the tool control switches as follows: Switch Setting
OFF/ON/OVERRIDE ON TJ LENGTH TRIP MAN OUT
2. Press the AUTO SEQUENCE button. 3. Verify that the tool moves to well center. The Torque Wrench moves to breakout ready (full makeup) position, and the tool slows down before contacting the pipe. Tool height should not change. 4. Position the Torque Wrench to the proper height using the manual control vertical switches. 5. Press the AUTO SEQUENCE button again and verify that the tool performs as follows: a. Torque Wrench and Spinning Wrench clamp on pipe. b. Applies breakout torque. c. Torque Wrench unclamps. d. Spins pipe fully out of the box section. e. Spinning Wrench unclamps. f. Tool moves to HOME position.
6. When the tool is in the HOME position, verify that the tool performs as follows: a. Torque Wrench returns to breakout ready position. b. Carriage height does not change.
SM00053, Rev D
Operation
3-31
July 1, 2005
Automatic makeup, PS MODE 1. Make sure the tool is in the HOME position and the carriage is fully lowered. 1. Set the tool control switches as follows: Switch PS MODE Setting ON
2. Press the AUTO SEQUENCE button. Verify that the tool moves to well center, raises to power slip height, and slows down before contacting the pipe. 3. Press the AUTO SEQUENCE button again and verify that the tool performs as follows: a. Spinning Wrench clamps. b. Tool performs a short spin out. c. Spins pipe fully into the box section. d. Torque Wrench jaws clamp onto the pipe. e. Applies correct makeup torque (as selected using the PRV). The torque should hold until the AUTO SEQUENCE button is depressed. 4. Press the AUTO SEQUENCE button again and verify that the tool performs as follows: a. Spinning Wrench unclamps. b. Torque Wrench unclamps. c. Tool moves to HOME position. 5. When the tool is in the HOME position, verify that the tool performs as follows: a. Torque Wrench returns to makeup ready position. b. Carriage lowers fully and then raises 7 in. (178 mm) minimum, i.e., power slip height.
3-32
AR3200
SM00053, Rev D
Preoperation
Automatic breakout, PS MODE 1. Set the tool control switches as follows: Switch PS MODE Setting ON
OFF/ON/OVERRIDE ON TJ LENGTH TRIP Select the proper tool joint length, e.g., 8", 10", 12", etc. OUT
2. Press the AUTO SEQUENCE button. Verify that the tool moves to well center, raises to power slip height, and that the tool slows down before contacting the pipe. Make sure that the tool joint is properly positioned between the upper and lower Torque Wrench jaws. 3. Press the AUTO SEQUENCE button again and verify that the tool performs as follows: a. Torque Wrench and Spinning Wrench jaws clamp on tool joint. b. Breakout torque is applied. c. Torque Wrench unclamps. d. Spins pipe fully out of box section. e. Spinning Wrench unclamps. f. Tool moves to HOME position.
4. When the tool is in the HOME position, verify that the tool performs as follows: a. Torque Wrench recycles to breakout position. b. Carriage lowers fully and then raises 7 in. (178 mm) minimum, i.e., power slip height.
SM00053, Rev D
Operation
3-33
July 1, 2005
Automatic makeup, Torque Wrench backup mode (soft clamp) 1. Locate the tool in the HOME position and fully lower the carriage. Set the tool control switches as follows: Switch TW MODE Setting BACKUP
2. Press the AUTO SEQUENCE button and verify that the tool moves to well center. The Torque Wrench cycles to makeup ready (full breakout) position, and the tool slows down before contacting the pipe. Make sure the tool joint is properly positioned between the Torque Wrench jaws. 3. Press the AUTO SEQUENCE button again and verify that the tool performs as follows: a. Spinning Wrench and lower Torque Wrench jaws clamp. Upper Torque Wrench jaw remains unclamped. b. Performs a short spin out. c. Spins pipe fully into the box section. d. Upper Torque Wrench jaw clamps on tool joint. e. Applies correct makeup torque (as selected using the PRV). Torque should hold until the AUTO SEQUENCE button is depressed again. 4. Press the AUTO SEQUENCE button again and verify that the tool performs as follows: a. Spinning Wrench unclamps. b. Torque Wrench unclamps. c. Tool moves to HOME position. 5. When the tool is in the HOME position, verify that the tool performs as follows: a. Torque Wrench recycles to makeup ready position. b. Carriage lowers fully (or at learned height).
3-34
AR3200
SM00053, Rev D
Preoperation
Automatic breakout, Torque Wrench backup mode (soft clamp) 1. Locate the tool in the HOME position and fully lower the carriage. Set the tool control switches as follows: Switch TW MODE Setting BACKUP
OFF/ON/OVERRIDE ON TJ LENGTH TRIP (Select the proper tool joint length, e.g., 8", 10", 12", etc.) OUT
2. Press the AUTO SEQUENCE button. Verify that the tool moves to well center and slows down before contacting the pipe Make sure that the tool joint is properly positioned between the Torque Wrench jaws. Torque Wrench cycles to breakout ready position. 3. Press the AUTO SEQUENCE button again and verify that the tool performs as follows: a. The Torque Wrench and Spinning Wrench jaws clamp on tool joint. b. Breakout torque is applied. c. The upper Torque Wrench unclamps. d. The pipe is fully spun out of box section. e. The lower Torque Wrench jaw unclamps. f. The Spinning Wrench unclamps.
g. The tool moves to HOME position. 4. When the tool is in the HOME position, verify the tool performs as follows: a. Torque Wrench recycles to breakout ready position. b. Carriage is fully lowered.
SM00053, Rev D
Operation
3-35
July 1, 2005
LEARN MODE LEARN MODE initializes the AR3200 positions.
Depending on the rig configuration, the AR3200 may be parked beneath or in front of a structure or object. During the Learn Mode program, program the tool so that it is not possible for it to elevate or travel into these structures or objects to prevent damage to the tool. To initialize the height, duck, and HOME positions: 1. Set the tool control switches as follows: Switch Setting
OFF/ON/OVERRIDE ON LEARN MODE 2. Drive the AR3200 to well center. 3. Set the carriage to the desired height and press the AUTO SEQUENCE button. 4. Drive the AR3200 in reverse from the well to the duck or HOME position. 5. Lower the carriage to the end-of-stroke and press the AUTO SEQUENCE button. If this is the desired HOME position, set the LEARN MODE to OFF. 6. Drive the tool in reverse to the HOME position and press the AUTO SEQUENCE button. 7. Set LEARN MODE to OFF. Selecting a default height of up to 7 in. (178 mm) above the end-of-stroke allows the AR3200 to follow the same positioning procedures as if the PS MODE were selected. If no overhead obstruction exists, the tool presets vertical height in the HOME position at the end of each makeup or breakout routine. If an overhead obstruction is present, the tool performs vertical positioning on the way to well center after it clears the obstruction. If the learned height is zero (below detection of end-of-stroke) the carriage is left at end-of-stroke following either positioning function. ON
3-36
AR3200
SM00053, Rev D
Operating procedures
This section describes the AR3200 operating procedures. Verify the items listed in AR3200 checkout procedures before operating the tool.
AR3200 checkout procedures

The AR3200 is preset to the following settings at the factory. Before operating the tool, verify the switch settings and conditions listed on Table 3-4:
Table 3-4. Verify before operating

Switch AIR SUPPLY (on PLC purge system) Pressure control regulator Setting ON Adjusted so the pressure indicator rests on the safe reading on the purge pressure gauge.
z Run the purge cycle at least 5 times to be sure no possible contaminated air is removed from the enclosure.
Electrical supply switch
ON
z The PLC control unit contains two 1-Amp and two 5-Amp circuit breakers. Make sure both sets of circuit breakers are ON.
TEACH SPARE PURGE PRESSURE PLC EPROM ESD for monitor station in Drillers Control Station ESD for manual control box Manual control box switches HPU
OFF OFF ON PLC RUN (Inserted) Pulled out Pulled out Neutral (generally, the center position) ON
z
SM00053, Rev D
When operating the tool in normal operation select the 2,000 psi mode and the vertical position.
Operation
3-37
July 1, 2005
Make sure the correct-size tong dies are installed for the pipe selected. Pipe size 3 3/4 - 7 3/4 in. 5 3/4 - 9 3/4 in. Configuration 86711-2 86771-1
See the Instruction Plate, Jaw Sizing Data drawing for details.
Manual control switches

Manual control switches allow you to control each function of the tool individually by setting the switches mounted on the Torque Wrench guard on the side of the tool. To operate the tool in the manual mode: 1. Verify the following settings: Switch Setting
OFF-ON-OVERRIDE ON EMERGENCY STOP Pulled out. switches on the tool and on the drillers console 2. Set the makeup torque. Setting the makeup torque Adjust the torque adjustment knob located on the carriage below the torque gauge.
Make the adjustment while making up a joint. 1. Turn the knob clockwise to increase torque and counterclockwise to decrease torque. The torque gauge indicates the actual torque. Turning the knob counterclockwise while making up a joint reduces the pressure and the gauge reading, but not the torque. In this case, break the joint, then torque it to the new, lower value.
If you apply too much torque (overtorque), break out the pipe, then make up again. Turning the torque adjustment knob counterclockwise while in backup mode reduces the torque reading on the gauge, but not the actual torque applied to the pipe connection.
3-38
AR3200
SM00053, Rev D
2. Open the Torque Wrench jaws and Spinning Wrench arms. Once these initial settings are made, operation in the manual mode consists of using the appropriate switches to control the tools position, the Spinning Wrench, and the Torque Wrench functions. See AR3200 function tests on page page 3-26 for detailed operating procedures.
MOUSEHOLE OPERATIONS
The AR3200 performs mousehole operations in manual mode because of the angle of the pipe in the mousehole. The tool can be tilted or in vertical position to make the connection, depending on how close to the rotary table the mousehole is located. Set the TW MODE to BACKUP for mousehole operations to keep the single joint below the tool from spinning.
SM00053, Rev D
Operation
3-39
July 1, 2005
END-OF-STROKE INTERLOCK
The end-of-stroke interlock prevents damage to the AR3200. Without this safeguard, pipe could slip down when the tool is clamped to it. The resultant weight of the drill string causes the carriage counterbalance valve to relieve pressure and the carriage to drop, while still supporting the weight of the drill string. When the AR3200 reaches the end-of-stroke, the jaws are forced open and remain open. The Spinning Wrench and Torque Wrench CLAMP/UNCLAMP switches becomes inoperative. A manual override is not possible because the tool would be damaged. The interlock also activates when you operate the AR3200 manually. Make sure the tool operates above the 3/4 in. (19 mm) zone whenever the Torque Wrench and Spinning Wrench jaws are clamped. Resetting after an interlock condition To reset the tool after an interlock condition: 1. Turn the Spinning Wrench and Torque Wrench CLAMP/UNCLAMP switches to the UNCLAMP position, then to the neutral (center, OFF) position. 2. Raise the carriage to clear the interlock zone.
3-40
AR3200
SM00053, Rev D
Automatic sequence control

With automatic sequence control you press one button to send the tool through a sequence of operations that either makes up or breaks out a connection. Set up the tool as follows: Switch Setting
OFF-ON-OVERRIDE ON EMERGENCY STOP Pulled out. switches on the tool and on the drillers console TORQUE WRENCH and SPINNING WRENCH TRIP TORQUE ADJUSTMENT KNOB Center (OFF)
IN or OUT Set the makeup torque. Make this adjustment while making up a joint.Turn the knob clockwise to increase the torque. Turning counterclockwise while making up a joint reduces the pressure and the gauge reading, but not the torque. In this case, break the joint, then torque it to the new, lower value.
Once these initial settings are made, press the AUTO SEQUENCE button to begin the automatic sequence.
TORQUE WRENCH BACKUP MODE

To operate in backup mode, turn the TW MODE switch to the BACKUP position. Backup mode has lockouts that hold the upper jaws open; only the lower jaws clamp, allowing the Torque Wrench to back up the spinning function. This feature is also known as a soft clamp. Use the backup mode to back up the spin in and spin out operations when the slips used are not designed to react torque. Using backup mode prevents the Spinning Wrench from turning the pipe in the slips. Backup mode also is useful for lightweight pipe or short strings or when the down hole orientation of the drill string must be maintained.
Always use the backup mode for mousehole operations.
SM00053, Rev D
Operation
3-41
July 1, 2005
AUTOMATIC MAKEUP
To initiate a makeup sequence, press the AUTO SEQUENCE button. In a makeup sequence, the AR3200 does the following: 1. Automatically moves to well center and positions itself so that the joint is located against the back of the Torque Wrench cutout. 2. Raises the carriage until it detects the upset of the tool joint. Then the tool raises or lowers to adjust the Torque Wrench to the preselected length of the tool joint: (Dependent upon the TJ LENGTH switch setting at 8", 10", 12", 14", or HW.) 3. Halts and waits for the next stand to be stabbed into the box in the rotary table. When this operation is complete, press the AUTO SEQUENCE button again. 4. Clamps the Spinning Wrench onto the pipe and spins in the joint. If the AR3200 does not detect that the joint has been shouldered, press the AUTO SEQUENCE button again and continue on to the next step. 5. Clamps the Torque Wrench jaws and makes up the joint to the previously selected torque. When the driller confirms the torque, press the AUTO SEQUENCE button to unclamp the Torque Wrench jaws. 6. Unclamps the Spinning Wrench and the sequence continues. If the AR3200 does not reach the selected torque in the full rotation of the upper jaw, the tool automatically restrokes. 7. Moves back to the HOME position and lowers the carriage to be ready for the next sequence.
3-42
AR3200
SM00053, Rev D
AUTOMATIC BREAKOUT
To initiate a breakout sequence, press the AUTO SEQUENCE button. In a breakout sequence, the AR3200 does the following: 1. Automatically moves to well center and positions itself so that the joint is located against the back of the Torque Wrench cutout. 2. Raises the carriage until it detects the upset of the tool joint. Then the tool raises or lowers to adjust the Torque Wrench to the preselected tool joint length. (Dependent upon the TJ LENGTH switch setting at 8", 10", 12", 14", or HW.) 3. Clamps the Torque Wrench and Spinning Wrench jaws and breaks out the joint a full 28 of rotation. When complete, the Torque Wrench upper jaws unclamp partially. 4. Spins out the joint. When spinout is complete, the Spinning Wrench unclamps. If the tool does not detect the spin out it automatically recycles. 5. Moves back to the HOME position and cycles the Torque Wrench. It then lowers the carriage to be prepared for the next sequence.
SM00053, Rev D
Operation
3-43
July 1, 2005
AUTO/MANUAL HEIGHT ADJUSTMENT OPERATION

Manual positioning mode To set the tool to the manual mode, set the TJ LENGTH switch on the J-box (Figure 3-8 on page 3-15) to MAN. Pressing the AUTO SEQUENCE button causes the tool to move to well center and stop. After you make the necessary height adjustments, press the AUTO SEQUENCE button again to continue with a breakout or makeup sequence. Autopositioning mode To set the tool to the autopositioning mode, set the TJ LENGTH switch (Figure 3-8 on page 3-15) to any position other than MAN. Pressing the AUTO SEQUENCE button causes the tool to move to well center and scan up to find the tool joint. If a makeup sequence is in progress, the tool stops to allow the pin to be stabbed. Pressing the AUTO SEQUENCE button again causes the tool to continue with the makeup routine. If a breakout sequence is in progress, the tool continues with the breakout routine without stopping.
3-44
AR3200
SM00053, Rev D
TOOL JOINT LENGTH AND TOOL JOINT HEIGHT

The TJ LENGTH switch on the tool J-box (Figure 3-8 on page 3-15) selects the tool joint box length of the current string of drill pipe. The AR3200 uses this input to correctly position the Torque Wrench on the box section. Figure 3-10 defines the tool joint length.
Tool Joint Length {8", 10", 12", 14" & HW (21.5")}
Figure 3-10. Tool joint length
SM00053, Rev D
Operation
3-45
July 1, 2005
HORIZONTAL/VERTICAL POSITION ADJUSTMENTS

You can adjust the tools horizontal and vertical position by manually adjusting the four-position buttons. These buttons position the tool toward or away from well center and raise and lower the carriage. Using any of the manual switches terminates an automatic sequence.
64.0" (Maximum)
31.0" Minimum
Figure 3-11. Tool joint height
3-46
AR3200
SM00053, Rev D
Purge operation
Purge operation
Two purge control units are available for the AR3200: one unit for the AR3200 U.L. tool J-box and an optional one for the PLC enclosure. Figure 3-12 shows the PLC purge control unit. Table 3-5 describes the component functions.
Table 3-5. PLC purge control unit functions

# 1 2 3 Component Purge pressure gauge Pressure regulator Timer restrictor Controls the rate of purge air flow to the reservoir, thereby adjusting the time required for PURGE COMPLETE status. Function Displays the purge pressure. Normal operating pressure is 10 mbarg.
4 5 6 8
Brass collar Red collar Green collar Alarm Pressurized indicator When the electronics enclosure pressurizes to the correct level and the low pressure switching valve opens, this normally red pressurized indicator changes to green. When the electronics enclosure pressurizes to the proper level and the time delay and the purge timer switching valve actuates, this normally red PURGE COMPLETE indicator changes to green. Produces a pneumatic pressurized signal when the enclosed pressure is above 0.1" wc (0.25 mb). When pressurized, the Alarm Pressurized indicator changes from red to green. When pressure falls below the set point of the sensor, the pressurized signal goes off, causing the Alarm Pressurized indicator to come o
Purge Complete indicator
14
Minimum pressure sensor
15 17 18
Manual drain filter Flow control valve Timer valve Adjusts enclosure pressure. When pressurized, the Alarm Pressurized indicator turns green. Contains an indicator. When the timer has timed out, the indicator should return to the out position when pressed. For alarm only option; allows air flow either to the red collar (hold-on pipe) or green collar (alarm and trip pipe).
20
Plug in or gate
SM00053, Rev D
Operation
3-47
July 1, 2005
Table 3-5. PLC purge control unit functions (continued)

# 23 24 25 26 76 Component Alarm and trip pipe Hold on pipe Logic base blank plate Plug (PE test point) Purge time selector Function
8 Timer Pinch Valve

16min
308 1
To Reservoirs
0 DO NOT OVERTIGHTEN
Door Internal 2 17 25 3 76 Purge Time Selector
16min
308 1
0 DO NOT OVERTIGHTEN
For Alarm Only Option 15 1

MIN
24
Plug-in "or" Gate (Item 20) 23
RED
BRASS
GREEN
17
14
Figure 3-12. PLC purge control unit
3-48
AR3200
SM00053, Rev D
Purge operation
Operating the purge unit for PLC enclosure

To operate the PLC enclosure purge unit: 1. Make sure the purge rate restrictor is fully closed. 2. Verify that the pressure gauge reads 10 mbarg. 3. Turn the unit on and open the purge restrictor until the PRESSURIZED lamp is on. 4. reduce the flow rate until the PRESSURIZED lamp is off. Make sure the pressure is 5 mbarg or greater. 5. Increase the purge flow rate until the PRESSURIZED lamp is on. At this point, the purge timer starts. Make sure the purge time is at least 10 minutes. 6. When the purge timer stops, turn the power to the enclosure on.
Varco recommends setting the purge flow rate 15 to 20 percent above the flow rate at which the PRESSURIZED lamp is on to allow a safety margin for absorbing fluctuations in the system supply pressure.
SM00053, Rev D
Operation
3-49
July 1, 2005
Operating the J-box purge control unit

To operate the purge system for the AR3200 J-box (Figure 3-13): 1. Pull the pressure control into its adjustment position. 2. Open the pressure control regulator by turning it counterclockwise to set the pressure indicator to .25 in. pressure (safe range). 3. Push the pressure control valve to snap it into its lock position. 4. Verify that the pressure indicator maintains .25 in. pressure (safe range) for one minute. 5. The nameplate mounted on the purge control unit indicates the required purge time. Turn the power switch on at completion of the purge procedure.
3-50
AR3200
SM00053, Rev D
Purge operation
Purge Control J-Box Pressure Control Regulator Knob
Purge Pressure Indicator
Purge Time Nameplate
Figure 3-13. AR3200 J-box purge control unit

SM00053, Rev D Operation 3-51
July 1, 2005
IBOP hanger operation (optional)

The IBOP (Internal Blowout Preventer) hanger is an optional feature with the AR3200. The IBOP and its extender are stored in a hanger that swings to the side of the tool and locks into position. In the ready-to-stab position, the bottom of the IBOP thread is located about 2 in. (51 mm) above the Torque Wrench upper and lower jaw split line. The IBOP hanger assembly is locked in its stored position. To operate the IBOP hanger: 1. Raise the carriage. 2. Unlock the IBOP hanger assembly by pulling the pin. 3. Swing the IBOP valve into working position. 4. Move the AR3200 to well center. 5. Clamp the Spinning Wrench onto the IBOP. 6. Stab the IBOP by lowering the carriage so that the IBOP hanger does not interfere with the clamp assembly as the IBOP is threaded in. 7. Spin in and open the Spinning Wrench. 8. Clamp the Torque Wrench onto the IBOP, apply torque, and open the Torque Wrench jaws. 9. Open the hanger at the hinges by removing the pin. 10. Move the arm back to the storage position and relock it in place. 11. Move the AR3200 to the HOME position.
Commissioning Procedure (FIP00055)

See Commissioning Test Specification, FIP00055, in the Supplemental Materials chapter as preoperation and function test checklists when performing these activities.
3-52
AR3200
SM00053, Rev D
Maintenance
July 1, 2005
4-2
AR3200
SM00053, Rev D
Chapter 4 Maintenance
General inspection requirements ....................................................................... 4-5 Scheduled inspection requirements ............................................................ 4-6 Removal and installation procedures .............................................................. 4-12 Mechanical components ........................................................................... 4-12 Tong die ............................................................................................. 4-12 System hydraulic components .................................................................. 4-13 Inlet pressure gauge ............................................................................ 4-13 Torque gauge ...................................................................................... 4-14 Torque adjustment valve .................................................................... 4-15 Dump valve ........................................................................................ 4-16 Pressure-reducing valve ..................................................................... 4-17 Carriage lift cylinders ......................................................................... 4-18 Spinning Wrench main motors ........................................................... 4-19 Spinning Wrench jaw motors ............................................................. 4-20 Pressure-reducing valve (2,000/2,500 psi) ......................................... 4-21 Speed control valve ............................................................................ 4-22 Foot motor .......................................................................................... 4-22 Control manifold hydraulic components .................................................. 4-23 EEx and UL directional control valves .............................................. 4-25 Electrical components ............................................................................... 4-26 Tool joint position sensor ................................................................... 4-26 Torque jaw position sensor ................................................................ 4-27 Adjustment procedures .................................................................................... 4-28 Adjusting the Spinning Wrench speed control ......................................... 4-28 Adjusting the carriage lift counterbalance ................................................ 4-29 Adjusting the vertical travel speed ........................................................... 4-29 Adjusting the horizontal travel speed ....................................................... 4-29 Adjusting the tilt cylinder speed control ................................................... 4-30 Adjusting the regenerative valves of the torque wrench clamp cylinder .. 4-30 Adjusting the manual torque pressure control valve ................................ 4-31 Adjusting the hydraulic pressure relief valve ........................................... 4-31 Adjusting the wear plate and tool joint detector sensor ............................ 4-31 Adjusting the torque wrench position sensor ............................................ 4-32 Adjusting the torque wrench dump valve ................................................. 4-32 Adjusting the horizontal index sensor ...................................................... 4-33 Adjusting the 2,500 psi hydraulic pressure valve ..................................... 4-33 Adjusting the 2,000 psi hydraulic pressure valve ..................................... 4-34 Adjusting the horizontal position sensor .................................................. 4-34 Adjusting the spinout sensor ..................................................................... 4-34 Adjusting the tool joint length switch voltage supply .............................. 4-35
Maintenance
4-3
4-4
AR3200
SM00053, Rev D
C ha p t er 4 Maintenance
General inspection requirements

This section describes inspection procedures for AR3200 assemblies and components that require routine maintenance. For information on repair or replacement parts, see the individual assembly and disassembly procedures in this chapter and the Engineering Drawings in the Drawings chapter. t Inspect the assemblies and components listed in the inspection tables (Table 4-1 through Table 4-5) as noted.
t Special inspection requirements for specific assemblies and components are described later in this section. Before checking hoses for damage, make sure all AR3200 components are stationary, the OFF-ON-OVERRIDE switch is off and the HPU is off.
Maintenance
4-5
July 1, 2005
Scheduled inspection requirements

This section describes scheduled inspection requirements for specific assemblies and components. Perform these inspections at the intervals noted in the inspection tables.
Table 4-1. Every trip

Assembly AR3200 Assembly Component All Hydraulic hose connections Check for Loose hardware and fittings. Action Tighten or replace as necessary.
Before checking hoses for
damage, make sure all AR3200 components are stationary, the OFF/ON/OVERRIDE switch is off and the HPU is off.
Loose connections. Hydraulic hoses (Operate in manual mode using all functions.) Valves, plugs, fittings, and tubes
Abrasion, pinching, kinking, Replace damaged hoses as required. cracking, or excessive bending or twisting of hydraulic hoses. Damage or leaks. Repair or replace as necessary. Tighten as required.
Connections are properly Hydraulic cylinder rod end-to cle- shouldered and tight. vis connections All cylinders Damage and leaks.
Repair or replace as necessary.
Abrasion, pinching, kinking, Replace damaged cables as required. Electrical cables (Operate in man- cracking or excessive bendual mode using all ing or twisting. functions.) Oil filter element Cleanliness. Clean or replace.
4-6
AR3200
SM00053, Rev D
Table 4-1. Every trip (continued)

Assembly Component Check for Visual inspection. Action Wire brush before each trip.
TW-102 Tong dies Hydraulic Torque Wrench All tool joint detector and torque wrench position sensor mounting hardware Hydraulic hoses
Tightness.
Tighten; Replace.
Abrasion, pinching, kinking, Observes the hoses while cycling the torque wrench through clamp and cracking, and excessive unclamp functions and while cycling bending or twisting. the torque wrench through makeup and breakout in fully clamped and unclamped positions. Replace damaged hoses as required.
Before checking hoses for damage, make sure all AR3200 components are stationary, the OFF/ON/OVERRIDE switch is off and the HPU is off.
Electrical cables of Abrasion, pinching, kinking, cracking, and excessive the tool joint bending or twisting. detector and torque wrench position proximity sensor SSW-50 Spinning Wrench Rollers Clean and check for excessive wear, pitting, or cracking.
Observe the cables while cycling the torque wrench through clamp and unclamp functions and while cycling the torque wrench through makeup and breakout in fully clamped and unclamped positions. Replace damaged cables as required. Repair; replace.
Body
Clamp the SSW-50 on pipe Adjust. and verify sufficient clearance exists between the Spinning Wrench body and drill pipe. Adjust; lubricate. Smooth movement through the clamp and unclamp functions; rollers turn smoothly without excessive noise. Damage and leaks. Repair; replace
Clamping arms
Clamp cylinders and motors
SM00053, Rev D
Maintenance
4-7
July 1, 2005
Table 4-1. Every trip (continued)

Assembly SSW-50 Spinning Wrench (continued) Component Hydraulic hoses Check for Action
Abrasion, pinching, kinking, Observe the hoses while clamping and unclamping the spinner on drill pipe at cracking, and excessive well center. Replace damaged hoses as bending or twisting. required.
Before checking hoses for damage, make sure all AR3200 components are stationary, the OFF/ON/OVERRIDE switch is off and the HPU is off.
Spinout sensor electrical cables
Abrasion, pinching, kinking, Observe the cables while clamping and unclamping the spinner on drill pipe at cracking, and excessive the well center. Replace damaged bending or twisting. cables as required.
Table 4-2. Daily inspection

Component TW-102 Torque Wrench Location Check for Motion between the TW102 upper and lower jaw sets is smooth when cycling. Drive rollers Spin the pipe in until a connection shoulders and check for slippage. Proper operation Cam followers rotate freely. Adjust; lubricate. Action Correct any interference between the upper and lower jaw sets.
SSW-50 Spinning Wrench
Spinout sensors Frame and carriage
Vertical movement of car- Adjust; lubricate. riage in the frame is smooth and free of binding. Tilt lever Assembly operates smoothly without binding. Attachment pins and bearings for excessive wear and binding. Foot assemblies Assemblies travel fully forward and backward smoothly and without excessive noise. Adjust; lubricate.
4-8
AR3200
SM00053, Rev D
Table 4-2. Daily inspection (continued)

Component EXPO PLC purge system (optional) Location Purge air supply Check for Contains enough air to complete the operation without interruption. Shows green when the system is activated. Increase air Action
PRESSURIZED indicator
PRESSURIZATION Shows green after the COMPLETE indica- purge cycle is complete (about 10 minutes). tor Filter bowl NFPA 496-type Purge Pressure Y tool J-box Gauge purge system (optional) Accumulated liquid. Reading is stable within the safe operating range. Clean, dry as necessary. Adjust as necessary.
Table 4-3. Weekly inspection

Assembly AR3200 Assembly Component All functions in manual mode. Check for All directional control valves operate properly (i.e., their spools shift fully to both sides.) System pressure functions 1. Select MANUAL mode. properly. 2. Select 2,500 psi and verify that pressure gauge indicates 2,500 psi. 3. Select 2,000 psi and verify that pressure gauge indicates 2,000 psi. TW-102 Torque Dump valve Wrench Position proximity sensor Entire assembly Proper operation. Gap between the sensor and target place is .12 to .20 in. (3 to 5 mm). Excessive wear or hardware breakage. See Adjusting the torque wrench dump valve on page 4-33. Adjust. Action
Carriage
Repair; replace.
SM00053, Rev D
Maintenance
4-9
July 1, 2005
Table 4-3. Weekly inspection (continued)

Assembly Component Check for Action
SSW-50 Spinning Wrench
All of the following pins: Hinge pins Clamp cylinder pins Clevis clamp pins Trunnion pins
Excessive wear.
Repair; replace.
Manifold
Valves, plugs, fittings, and tubes Directional control valves
Damage and leaks. Excessive humming noise, Repair; replace heat build up, or high current indicate when spools are not shifting fully. Typical operating current is .6 Amp. Cleanliness; inspect for excessive wear or hardware breakage.
Inlet manifold
Filter element
Inspect for cleanliness
Clean as required. A popout indicator on the filter housing protrudes when you need to replace the filter. Repair; replace faulty components.
EXPO PLC purge system (optional)
Purge control unit Indications of damage.
PLC enclosure
Signs of damage, leaks, and moisture accumulation. Damage and leaks Loose fittings, damage, and leaks. Accumulated liquid Inspect for cleanliness.
Repair; replace faulty components.
Pressure switch Purge tubing Filter bowl Filter element
Replace. Replace. Clean, dry as necessary. Clean as required. A popout indicator on the filter housing pops out when you need to replace the filter.
4-10
AR3200
SM00053, Rev D
Table 4-3. Weekly inspection (continued)

Assembly Component Leaks Check for Action Tighten as required.
Optional NFPA Fittings 496-type Y tool J-box purge system Filter (if used)
Cleanliness.
Clean or drain as necessary. Adjust; replace.
Purge loss-of-pres- Switch operates properly sure switch Pressure gauge sintered vent on the bottom of the tool J-box Air supply Cleanliness and passage of air.
Cleanliness and dryness.
Change air supply if necessary.
Table 4-4. Every three months

Assembly Component Check for Action
Foot assemblies Foot gearbox
After inspection, repack the gearboxes Remove the covers and inspect the gearboxes for with grease. Replace the gaskets when play in the bearings and for reinstalling the cover. See excessive shaft wear. Pressure is correct. Adjust as necessary
EXPO PLC purge system (optional)
Air supply inlet
Purge flow NFPA 496 type Y tool J-box purge system (optional) Tool J-box
Flow rate is correct.
Adjust as necessary.
Clean and dry. Check air supply. Accumulation of moisture, dirt, or oil due to dirty supply air. Proper operation. Repair, replace as necessary.
Enclosure protection vent Inlet pressure
Inspect for proper pressure. Adjust pressure.
SM00053, Rev D
Maintenance
4-11
July 1, 2005
Table 4-5. Every six months

Component TW-102 Torque Wrench Check for Wear on the following: Hinge pins Clamp cylinder pins Clamp cylinder pins Torque cylinder clevis pins Torque cylinder trunnion pins Action Repair/replace
4-12
AR3200
SM00053, Rev D
Removal and installation procedures
This section describes removal and installation procedures for AR3200 components. See the appropriate drawings in the Drawings chapter when removing or installing a component. Make sure maintenance personnel are familiar with the lockwire procedures contained in ASP00019 in the Supplemental Materials chapter.
Mechanical components
This section describes removal and installation procedures for mechanical components.
TONG DIE
t See Engineering Drawing: Instruction Plate, Jaw Sizing Data Change the tong dies to fit the selected pipe size. Use configuration 86711-2 for pipe size 3 1/2" to 7 3/4" and configuration 86711-1 for pipe size 5 3/4" to 9 3/4." Removal t See Engineering Drawing: Torque Wrench Jaw Assembly 1. Open the jaws fully. 2. Turn off the hydraulic power supply. 3. Reduce the hydraulic pressure to zero. 4. Turn off all electrical power to the AR3200. 5. Remove the mounting bolts from die retainer and remove retainer. If the retainer is difficult to pull out, remove the two outer plugs and tighten the pry-out set screws, forcing the retainer assembly out of its socket. 6. Remove the die stop mounting bolts from the die retainer. 7. Remove the tong die. Installation t See Engineering Drawing: Torque Wrench Jaw Assembly 1. Clean the groove of any debris. 2. Install the new tong die in the retainer. 3. Install the die stop against the tong die and tighten the bolts. 4. Install the retainer into its socket and secure the mounting bolts.
SM00053, Rev D Maintenance 4-13
July 1, 2005
System hydraulic components

This section describes removal and installation procedures for hydraulic components.
INLET PRESSURE GAUGE

Removal t See Engineering Drawing: AR3200 Iron Roughneck Assembly 1. Turn off the hydraulic power supply. 2. Reduce the hydraulic pressure to zero. 3. Turn off all electrical power to the AR3200. 4. From the rear of the AR3200, locate the inlet pressure gauge tubing and connector on the right side of the carriage. 5. Remove the tubing connector from the elbow mounted on the rear of the inlet pressure gauge. 6. Install a plug in the open connector to prevent debris and contaminants from entering the hydraulic line. 7. From the right side of the AR3200 carriage remove three screws securing the gauge to the carriage. 8. Remove the inlet pressure gauge from the carriage. 9. Note the position of the elbow relative to the gauge. 10. Remove the elbow from the inlet pressure gauge. Installation t See Engineering Drawing: AR3200 Iron Roughneck Assembly 1. Wrap the threads of the elbow with antiseize tape. 2. Install the elbow in the pressure port of the inlet pressure gauge and position the elbow to the position noted in step 9 of the removal procedure. 3. From the right side of the AR3200, place the elbow and body of the inlet pressure gauge through the mounting hole in the carriage and secure the gauge to the carriage using three screws. 4. From the rear of the AR3200, locate the gauge hydraulic line and remove the protective plug from the connector. 5. Attach the connector to the gauge elbow and secure.
4-14
AR3200
SM00053, Rev D
TORQUE GAUGE
Removal t See Engineering Drawing: AR3200 Iron Roughneck Assembly 1. Turn off the hydraulic power supply. 2. Reduce the hydraulic pressure to zero. 3. Turn off all electrical power to the AR3200. 4. From the rear of the AR3200, locate the torque gauge tubing and fittings on the right side of the carriage. 5. Disconnect the gauge tubing connector from the tee. 6. Install a cap over the open tee to prevent debris and contaminants from entering the hydraulic line. 7. From the right side of the AR3200 carriage, remove three hex bolts securing the gauge to the carriage. 8. Remove the torque gauge from the carriage. 9. Disconnect the tubing from the gauge and remove. Installation t See Engineering Drawing: AR3200 Iron Roughneck Assembly 1. Install the tubing assembly on the torque gauge and secure. 2. From the right side of the AR3200, place the elbow and body of the torque gauge through the mounting hole in the carriage and secure the gauge to the carriage using three hex-head bolts. 3. From the rear of the AR3200, locate the gauge hydraulic line and remove the protective cap from the tee. 4. Connect the gauge tubing connector to the tee and secure.
SM00053, Rev D
Maintenance
4-15
July 1, 2005
TORQUE ADJUSTMENT VALVE

Removal t See Engineering Drawing AR3200 Iron Roughneck Assembly 1. Turn off the hydraulic power supply. 2. Reduce the hydraulic pressure to zero. 3. Turn off all electrical power to the AR3200. 4. From the rear of the AR3200 locate the torque adjustment valve tubing and connector on the right side of the carriage. 5. Remove the tubing connector from the elbow mounted on the rear of the torque adjustment valve. 6. Install a plug in the open connector to prevent debris and contaminants from entering the hydraulic line. 7. From the right side of the AR3200 carriage remove four socket-head cap screws securing the valve to the carriage. 8. Remove the torque adjustment valve from the carriage. 9. Note the position of the elbow relative to the valve. 10. Remove the elbow from the torque adjustment valve. Installation t See Engineering Drawing AR3200 Iron Roughneck Assembly 1. Wrap the threads of the elbow with antiseize tape. 2. Install the elbow in the pressure port of the torque adjustment valve and position the elbow to the position noted in step 9 of the removal procedure. 3. From the right side of the AR3200, place the elbow and body of the torque adjustment valve through the mounting hole in the carriage and secure the valve to the carriage using socket-head cap screws. 4. From the rear of the AR3200, locate the valve hydraulic line and remove the protective plug from the connector. 5. Attach the connector to the valve elbow and secure.
4-16
AR3200
SM00053, Rev D
DUMP VALVE
Removal t See Engineering Drawing: TW-102 Torque Wrench Assembly 1. Turn off the hydraulic power supply. 2. Reduce the hydraulic pressure to zero. 3. Turn off all electrical power to the AR3200. 4. From the left side of the AR3200, remove the retaining pin from the TW guard and swing the guard open. 5. Disconnect the hydraulic line from the side of the dump valve. 6. Install a plug in the open line connector to prevent debris and contaminants from entering the hydraulic line. 7. Disconnect the hydraulic line from the end of the dump valve. 8. Install a plug in the open line connector to prevent debris and contaminants from entering the hydraulic line. 9. Remove the hex retaining nut from the valve body. 10. Remove the dump valve from the valve mounting bracket. Installation t See Engineering Drawing: Torque Wrench Assembly 1. From the left side of the AR3200, install the dump valve in the valve mounting bracket and secure with hex nut. 2. Remove the protective plug from the side hydraulic line. 3. Install the hydraulic line on the valve side nipple and secure. 4. Remove the protective plug from the end hydraulic line. 5. Install the hydraulic line on the valve end nipple and secure. 6. Check for proper operation and adjust as necessary. (See Adjusting the torque wrench dump valve on page 4-33.) 7. Close the TW guard and secure with the retaining pin.
SM00053, Rev D
Maintenance
4-17
July 1, 2005
PRESSURE-REDUCING VALVE
Removal t See Engineering Drawing: Valves, Manifold Assembly 1. Turn off the hydraulic power supply. 2. Reduce the hydraulic pressure to zero. 3. Turn off all electrical power to the AR3200. 4. From the rear of the AR3200, locate the pressure-reducing valve on the rear of the main hydraulic manifold. 5. Remove the 3/8" connector from the tee. 6. Install a cap over the open tee to prevent debris and contaminants from entering the hydraulic line. 7. Remove the 1/4" connector from tee. 8. Install a cap over the open tee to prevent debris and contaminants from entering the hydraulic line. 9. Remove four socket-head cap screws and four lockwashers from the reducing valve and manifold. 10. Remove the pressure-reducing valve from the main manifold. 11. Remove all packing from the valve and manifold ports. 12. Discard packing. Installation t See Engineering Drawing: Valves, Manifold Assembly 1. Install new packing in the pressure-reducing valve ports. 2. Align the pressure-reducing valve mounting holes with the mounting holes in the main manifold, install four lockwashers and four socket-head cap screws. 3. Secure the socket-head cap screws. 4. Remove the cap from the 1/4" tee, install the line, and secure. 5. Remove the cap from the 3/8" tee, install the line, and secure.
4-18
AR3200
SM00053, Rev D
CARRIAGE LIFT CYLINDERS

Removal t See Engineering Drawing: AR3200 Iron Roughneck Assembly 1. Lower the carriage to the full bottom position. 2. Turn off the hydraulic power supply. 3. Reduce the hydraulic pressure to zero. 4. Turn off all electrical power to the AR3200. 5. From the rear of the AR3200, locate the faulty cylinder. 6. Support the AR3200 carriage so it cannot move. 7. Remove the cotter pin from the lower cylinder pivot pin. 8. Remove the bottom pivot pin from the cylinder and carriage mount. 9. Support the bottom of the cylinder before removing the upper pivot pin. 10. Remove the cotter pin from the upper cylinder pivot pin. 11. Remove the top pivot pin from the cylinder and remove the cylinder from the AR3200. 12. Remove the clevis from the cylinder rod end. Installation t See Engineering Drawing: AR3200 Iron Roughneck Assembly 1. Install the clevis on the cylinder rod end. 2. Place the cylinder in AR3200 with the rod end upward. 3. Align the cylinder clevis with the frame bracket and install the pivot pin. 4. Install a new cotter pin in the pivot pin. 5. Align the lower cylinder yoke with the carriage mount and install the pivot pin. 6. Install a new cotter pin in the pivot pin.
SM00053, Rev D
Maintenance
4-19
July 1, 2005
SPINNING WRENCH MAIN MOTORS

Removal t See Engineering Drawing: Spinning Wrench-50 Assembly 1. Turn off the hydraulic power supply. 2. Reduce the hydraulic pressure to zero. 3. Turn off all electrical power to the AR3200. 4. Disconnect the 1/4" connector from the motor. 5. Install a plug in the open connector to prevent debris and contaminants from entering the hydraulic line. 6. Disconnect and match-mark as A and B the two 1/2" connectors from the motor. 7. Install a plug in the open connectors to prevent debris and contaminants from entering the hydraulic lines. 8. Support the motor before removing the retaining bolts. 9. Remove three hex-head bolts and lock wire from the motor and wrench body. 10. Remove the motor from the wrench body. Installation t See Engineering Drawing: Spinning Wrench 50 Assembly 1. Insert the spline shaft of the motor in the wrench body and align with the splines in the roller shaft. 2. Align the mounting holes of the motor with the mounting holes in the wrench body and install three hex bolts and lock wire. 3. Secure the bolts with lockwire in accordance with ASP00019 in the Supplemental Materials chapter. 4. Remove the plugs from the 1/2" connector and connect the lines to the 1/2 motor fittings using the A and B marks to match the proper connectors and secure. 5. Remove the plug from the 1/4" connector and connect the line to the 1/4 motor fitting and secure.
4-20
AR3200
SM00053, Rev D
SPINNING WRENCH JAW MOTORS

Removal t See Engineering Drawing: Spinning Wrench 50 Assembly 1. Turn off the hydraulic power supply. 2. Reduce the hydraulic pressure to zero. 3. Turn off all electrical power to the AR3200. 4. Disconnect the 1/4 hydraulic line from the motor. 5. Install a plug in the open connector to prevent debris and contaminants from entering the hydraulic line. 6. Disconnect and match-mark as A and B the two 1/2 hydraulic lines from the motor. 7. Install a plug in the open connectors to prevent debris and contaminants from entering the hydraulic lines. 8. Support the motor before removing the retaining bolts. 9. Remove three hex-head bolts and lock wire from the motor and wrench arm. 10. Remove the motor from the wrench jaw. Installation t See Engineering Drawing: Spinning Wrench SSW-50 Assembly 1. Insert the spline shaft of the motor in the wrench arm and align with the spline in roller shaft. 2. Align the mounting holes of the motor with the mounting holes in the wrench jaw and install three hex bolts. 3. Secure the bolts with lockwire. 4. Remove the plugs from the 1/2" hydraulic lines and connect the lines to the 1/2 motor fittings and secure. 5. Remove the plug from the 1/4 hydraulic line and connect the line to the 1/4 motor fitting, using the A and B marks to match the proper fitting, and secure.
SM00053, Rev D
Maintenance
4-21
July 1, 2005
PRESSURE-REDUCING VALVE (2,000/2,500 PSI)

Removal t See Engineering Drawing: Valves, Manifold Assembly B16 1. Turn off the hydraulic power supply. 2. Reduce the hydraulic pressure to zero. 3. Turn off all electrical power to the AR3200. 4. From the rear of the AR3200, locate the 2,000/2,500 psi pressure-reducing valve on the rear of the main manifold. 5. Disconnect the electrical connector from the valve solenoid. 6. Remove four socket-head cap screws and four lockwashers. 7. Remove the reducing valve from the manifold. 8. Remove all packing from the valve and manifold ports. 9. Discard packing. Installation t See Engineering Drawing: Valves, Manifold Assembly 1. Install new packing on all valve ports. 2. Align the mounting holes on the valve with the mounting holes on the main manifold and install four lockwashers and four socket-head cap screws. 3. Secure the socket-head cap screws. 4. Connect the electrical connector to valve solenoid.
4-22
AR3200
SM00053, Rev D
SPEED CONTROL VALVE

Removal t See Engineering Drawing: Valves, Manifold Assembly 1. Turn off the hydraulic power supply. 2. Reduce the hydraulic pressure to zero. 3. Turn off all electrical power to the AR3200. 4. From the rear of the AR3200, locate the speed control valve mounted on the rear of the main manifold. 5. Unscrew the speed control valve from the manifold. 6. Remove packing from valve or manifold and discard. Installation t See Engineering Drawing: Speed Control Valve 1. Install new packing on speed control valve. 2. Install the valve in the mounting hole in the manifold and secure.
FOOT MOTOR
Removal t See Engineering Drawing: Foot Assembly 1. Turn off the hydraulic power supply. 2. Reduce the hydraulic pressure to zero. 3. Remove the cover plate. 4. Remove the gear cover plate. 5. Remove the gear cover gasket. 6. Remove the cotter pin, nut, and gear motor retainer. 7. Remove the drive gear. 8. Disconnect and match-mark the two hose assemblies A and B. 9. Unbolt the motor assembly by removing the cotter pin and retaining nut. Remove the assembly.
SM00053, Rev D
Maintenance
4-23
July 1, 2005
Installation t See Engineering Drawing: Foot Assembly 1. Mount the motor assembly using the retaining nut and new cotter pin. 2. Connect the two hose assemblies using the A and B marks to make the proper connections. 3. Mount the drive gear and replace the cotter pin, nut, and gear motor retainer. 4. Replace the gear cover gasket with a new one. 5. Reinstall the cover plate.
Control manifold hydraulic components

See Table 4-6 and the Valves, Manifold Assembly drawing for a listing and stacking order of control manifold hydraulic components when performing the maintenance procedures in this section.
Table 4-6. Manifold-mounted components

Top component name Wrench Spin 3-Position, 35 gpm Valve Vertical Travel 3-Position, 15 gpm Valve Horizontal Travel 3-Position, 15 gpm Valve Spinning Wrench 3-position, 15 gpm Valve Carriage Tilt 2-Position, 15 gpm Valve TW Upper Clamp 3-Position, 35 gpm Valve Second component name None Third component name None Fourth component None
Dual Flow-control Valve Decel Valve
Counterbalance Valve Anticavitation Valve
Cross-Port Relief Valve None
None
Pressure Port Check Valve Pressure Port Check Valve Regenerative Valve
None
Dual Flow-control Valve None
None
None
4-24
AR3200
SM00053, Rev D
Table 4-6. Manifold-mounted components (continued)

Top component name TW Lower Clamp 3-Position, 35 gpm Valve Torque Wrench 3-position, 35 gpm Valve Second component name Regenerative Valve Third component name None Fourth component None
"T" Check Sandwich Valve
None
None
SM00053, Rev D
Maintenance
4-25
July 1, 2005
EEX AND UL DIRECTIONAL CONTROL VALVES

This section contains removal and installation procedures for the following stacked EEx and UL directional control valves: t Vertical Travel Directional Control Valve t Horizontal Travel Directional Control Valve t Spinning Wrench Directional Control Valve t Carriage Tilt Directional Control Valve t TW Upper Clamp Directional Control Valve t TW Lower Clamp Directional Control Valve t Torque Wrench Directional Control Valve Removal 1. Turn off the hydraulic power supply. 2. Reduce the hydraulic pressure to zero. 3. Turn off all electrical power to the AR3200. 4. Remove four bolts from the carriage front plate and remove the front plate. 5. Locate the valve on the front of the main manifold. 6. Remove one socket-head cap screw (EEx)/nut (UL) from the end of each solenoid coil housing and remove both solenoid coil housings from the valve. 7. Remove four socket-head cap screws (EEx)/nuts (UL) from the valve assembly. 8. Remove the valve and the valve stackup from the main manifold. 9. Remove packing from all manifold ports and discard. 10. Separate stacked components from the valve assembly. (See Table 4-6.) 11. Remove packing from valve ports and discard.
Improperly installed solenoids may damage armature tubes.
4-26
AR3200
SM00053, Rev D
Installation 1. Install new packing in valve ports. 2. Stack up the Dual Flow Control valve, the Counterbalance valve, the Anticavitation valve, and the valve assembly as per Table 4-6. 3. Align the valve mounting holes in the stackup and install four lock washers and four socket-head cap screws (EEx)/nuts (UL). 4. Align the screws (EEx)/nuts (UL) with the mounting holes in the main manifold and attach the valve stackup to the manifold. 5. Secure the socket-head cap screws (EEx)/nuts (UL). 6. Install both solenoid coil housings on the valve assembly and install one socket-head cap screw (EEx)/nut (UL) in each. 7. Secure the screws (EEx)/nuts (UL). 8. Align the mounting holes in the carriage front plate with the mounting holes in the carriage and install four hex bolts. 9. Secure the hex bolts.
Electrical components
TOOL JOINT POSITION SENSOR
Removal t See Engineering Drawing: AR3200 Auto Electrical Assembly Drawing 1. Turn off the hydraulic power supply. 2. Reduce the hydraulic pressure to zero. 3. Turn off all electrical power to the AR3200. 4. From the left side of the carriage remove the retaining pin and open the TW guard. 5. Open the sensor J-box and disconnect the tool joint sensor wiring from the terminal strip. 6. From the front of the unit below the torque wrench lower jaw, remove the retaining nut from the tool joint position sensor. 7. Remove the sensor and wiring from AR3200.
SM00053, Rev D
Maintenance
4-27
July 1, 2005
Installation 1. From the front of the AR3200, install the tool joint sensor in the sensor mounting bracket and install the retaining nut. 2. Adjust the sensor per the adjustment procedure provided later in this guide. 3. Secure the retaining nut. 4. Crimp the ferrules to the lead wires. 5. Route the sensor wiring to the sensor J-box and connect it to the terminal strip. 6. Close the sensor J-box. 7. Close the TW guard and secure it with the retaining pin.
TORQUE JAW POSITION SENSOR

Removal t See Engineering Drawing: AR3200 Auto Electrical Assembly Drawing
1. Turn off the hydraulic power supply. 2. Reduce the hydraulic pressure to zero. 3. Turn off all electrical power to the AR3200. 4. From the left side of the carriage, remove the retaining pin and open the TW guard. 5. Open the sensor J-box and disconnect the torque jaw position sensor wiring from the terminal strip. 6. Remove the retaining nut from the torque jaw position sensor. 7. Remove the sensor and wiring from the AR3200. Installation 1. From the front of the AR3200, install the torque jaw position sensor in the sensor mounting bracket and install the retaining nut. 2. Adjust the sensor per the adjustment procedure provided later in this guide. 3. Secure the retaining nut. 4. Crimp the ferrules to the lead wires. 5. Route the sensor wiring to the sensor J-box and connect it to the terminal strip. 6. Close the sensor J-box. 7. Close the TW guard and secure it with the retaining pin.
4-28
AR3200
SM00053, Rev D
Adjustment procedures
This section describes adjustment procedures necessary to maintain optimal AR3200 operation. In general, refer to the appropriate adjustment procedure after replacing or servicing any component.
Adjusting the Spinning Wrench speed control

t See Engineering Drawing: Valves, Manifold Assembly Adjusting the hydraulic flow to the Spinning Wrench motors changes the spin-in/ spin-out speed. The speed control valve is located high on the back of the hydraulic valve manifold and is labelled SC. To adjust the Spinning Wrench speed control: 1. Set the AR3200 to 2,500 psi. 2. Adjust the SC valve on the hydraulic valve manifold clockwise (faster) or counterclockwise (slower) to adjust the Spinning Wrench speed for 5 in. OD pipe to 30 + 5 rpm. 3. Set the AR3200 to 2,000 psi. 4. The Spinning Wrench speed for 5 in. OD pipe should be 125 + 25 rpm.
SM00053, Rev D
Maintenance
4-29
July 1, 2005
Adjusting the carriage lift counterbalance

t See Engineering Drawing: Valves, Manifold Assembly The carriage lift counterbalance allows the raised carriage lift cylinder to relieve pressure when the carriage is supporting a large weight. The counterbalance is located behind the Vertical Travel directional control valve, between the Speed Control and Anticavitation valves. To adjust the carriage lift counterbalance: 1. Loosen the lock nut and turn the valve counterclockwise all of the way out. 2. Raise the carriage and release the button. The carriage should not move. 3. Turn the valve in clockwise until the carriage begins to lower. 4. Adjust the valve until it is to the balance point (the valve setting at which the carriage just holds without dropping). 5. Turn the valve out counterclockwise an additional 1/4 turn. 6. Tighten the lockout.
Adjusting the vertical travel speed

t See Engineering Drawing: Valves, Manifold Assembly Two vertical travel speed control valves are located behind the vertical travel solenoid. Adjusting the vertical travel speed control valves changes the vertical speed in both directions at which the carriage moves. One valve adjusts the speed of travel when the carriage raises (on the left from the tools perspective). The other valve adjusts the speed of travel when the carriage lowers (on the right from the tools perspective). Turning either valve clockwise increases the associated vertical travel speed. Turning either valve counterclockwise decreases the associated vertical travel speed. Set the vertical travel speed in both directions to approximately 5 - 6 in./sec (127 -152mm/sec).
Adjusting the horizontal travel speed

t See Engineering Drawing: Valves, Manifold Assembly Adjusting the horizontal travel speed changes the speed of the drive foot motors. The horizontal travel speed adjustment valve is located behind the horizontal travel solenoid valve. Adjust the drive foot motors to travel approximately 12 + 2 in./sec. (304 + 51 mm/sec.) The deceleration speed is set by an orifice at the 2,500 psi mode.
4-30
AR3200
SM00053, Rev D
Adjusting the tilt cylinder speed control

t See Engineering Drawing: Valves, Manifold Assembly The tilt cylinder speed control valves control the speed of the tilt cylinder function. The two valves are located behind the tilt cylinder solenoid valve. Turning the right valve clockwise increases the tilt cylinder speed when traveling to the vertical position. Turning the right valve counterclockwise decreases the tilt cylinder speed when traveling to the vertical position. Turning the left valve clockwise increases the cylinder speed when tilting. Turning the left valve counterclockwise decreases the tilt cylinder speed when tilting.
Adjusting the regenerative valves of the torque wrench clamp cylinder

t See Engineering Drawing: Valves, Manifold Assembly The regenerative valves of the torque wrench clamp cylinder control the speed boost of the clamp cylinder. One regenerative valve is located on the left side of each torque wrench clamp solenoid valve. Turning the regenerative valve counterclockwise increases the clamp cylinder speed; turning it clockwise decreases the clamp cylinder speed. Turn the valve counterclockwise until maximum speed is reached. Adjust the speed to obtain equal clamping speed of the upper and lower jaws, within approximately 2-3 seconds. Then adjust the speed as required to avoid false reading of the flow switch. If the flow switch reading is wrong, the torque wrench prestrokes.
SM00053, Rev D
Maintenance
4-31
July 1, 2005
Adjusting the manual torque pressure control valve

The manual torque pressure control valve controls the makeup torque. The valve is located below the torque gauge, on the right side of the roughneck. To adjust the torque pressure control valve:
z z
Make the adjustment while making up a joint. Turn the knob clockwise to increase torque and counterclockwise to decrease torque. The torque gauge indicates the actual torque. Turning the knob counterclockwise while making up a joint reduces the pressure and the gauge reading, but not the torque. In this case, break the joint, then torque it to the new, lower value. If you apply too much torque (overtorque), break out the pipe, then make up again. Turning the torque adjustment knob counterclockwise while in backup mode reduces the torque reading on the gauge, but not the actual torque applied to the pipe connection.
Adjusting the hydraulic pressure relief valve

t See Engineering Drawing: Valves, Manifold Assembly The hydraulic pressure relief valve controls the hydraulic pressure of the torque wrench. It is located on the lower back of the valve manifold assembly. Turn the valve clockwise to obtain the maximum pressure setting.
Adjusting the wear plate and tool joint detector sensor

t See Engineering Drawing: AR3200 Auto Electrical Assembly t AR3200 Automated Iron Roughneck Assembly The wear plate is mounted under the carriage and supports the tool joint detector sensor. The tool joint detector sensor senses the presence of the metal pipe and is located under the torque wrench.
4-32
AR3200
SM00053, Rev D
To adjust the wear plate for the selected pipe size: 1. Remove the two fitted screws on the bottom left and right side of the wear plate. 2. Loosen the two screws in the slotted holes. 3. Slide the wear plate out (toward well center) for pipe sizes 3 1/2 in. to 7 3/4 in., or slide it in for pipe size 5 3/4 in. to 9 3/4 in. until the loosened screws slide into the new slotted position on the carriage. 4. Tighten the loosened screws and the fitted screws. 5. Adjust the sensor to .12 to .18 in. behind the face of the bracket. 6. Adjust the bracket to .63 in. travel available using the travel adjustment screw.
Adjusting the torque wrench position sensor

t See Engineering Drawing: AR3200 Auto Electrical Assembly The torque wrench position sensor senses the position of the torque wrench during makeup end-of-stroke (EOS) and breakout EOS. Adjust the sensor to .10 to .22 in. from the target as required.
Adjusting the torque wrench dump valve

t See Engineering Drawing: TW 102 Torque Wrench Assembly The torque wrench dump valve dumps torque wrench pressure to a faulty reading on the torque meter. Adjust the valve to dump pressure on the torque meter when the torque wrench torque cylinder reaches the end-of-stroke. Once the valve is activated, the torque gauge should read 0 to 5 ft lb.
SM00053, Rev D
Maintenance
4-33
July 1, 2005
Adjusting the horizontal index sensor

t See Engineering Drawing: AR3200 Auto Electrical Assembly The horizontal index sensor, located in the right foot of the tool, detects slots in the track. The sensor controls initiation of deceleration when approaching the pipe. On upgraded AR3000 tools only, adjust the sensor to .31 to .34 in. (7.8 to 8.6 mm) above the track by loosening three attachment bolts on the side of the right foot. Then adjust the height manually. The AR3200 does not require adjustment of the horizontal index sensor.
Adjusting the 2,500 psi hydraulic pressure valve

t See Engineering Drawing: Valves, Manifold Assembly The 2,500 psi hydraulic pressure valve sets the operating pressure in 2,500 psi mode. The valve is located high on the back of the valve manifold assembly, below the Spinning Wrench speed control valve. To adjust the pressure: 1. Adjust the power unit to 2,500 to 3,000 psi. 2. Set the 2,000/2,500 psi mode switch to 2,500 psi. 3. Adjust the valve to 2,500 psi, using the tool pressure gauge on the right side of the tool. 4. Turn the valve clockwise to increase the pressure and counterclockwise to decrease the pressure.
4-34
AR3200
SM00053, Rev D
Adjusting the 2,000 psi hydraulic pressure valve

t See Engineering Drawing: Valves, Manifold Assembly The 2,000 psi hydraulic pressure valve sets the tools operating pressure in 2,000 psi mode. The valve is located with the 2,500 psi hydraulic pressure valve described above. To adjust the pressure: 1. set the 2,000/2,500 psi mode switch to 2,000 psi. 2. Adjust the valve to 2,000 psi, using the tool pressure gauge. 3. Turn the valve clockwise to increase the pressure and counterclockwise to decrease the pressure.
Adjusting the horizontal position sensor

t See Engineering Drawing: Valves, Manifold Assembly The horizontal position sensor counts the cogs as the drive wheel rotates. The sensor is located in the left foot of the tool. Adjust the sensor to .08 to .10 in. (distance between the sensor and the top of the cog). Verify the correct distance between the sensor and each cog by measuring.
Adjusting the spinout sensor

t See Engineering Drawing: AR3200 Auto Electrical Assembly The spinout sensor detects the amount of shock as the threads disengage. It is located on a bracket that is attached to the Spinning Wrench. To adjust the sensor, remove the J-box housing cover. Adjust the sensor to .100 in. Increase the distance to increase the sensors sensitivity.
SM00053, Rev D
Maintenance
4-35
July 1, 2005
Adjusting the tool joint length switch voltage supply

t See Engineering Drawing: AR3200 Remote controller (PLC Assembly). The tool joint length switch voltage is supplied by the potentiometer driver. The voltage supply is located inside the PLC box. Set the voltage to 10 V. To adjust the value, turn the screw on top of the potentiometer clockwise to increase the voltage and counterclockwise to decrease the voltage.
Adjusting the end-of-stroke proximity sensor

t See Engineering Drawing: AR3200 Electrical Assembly The end-of-stroke proximity sensor, located at the top of the slave cylinder, detects the target at the bottom of the stroke. Adjust the sensor to .04 to .06 in. (1 to 1.5 mm) above the target.
Adjusting the stabbing guide

t See Engineering Drawing: AR3200 Automated Iron Roughneck Assembly 1. Use the horizontal travel and vertical travel controls to position the torque wrench on the tool joint box. 2. Close the lower jaws. 3. Stab the next stand. 4. Loosen two adjusting nuts and align the inside edge of the stabbing guide with the outer circumference of the pipe. Tighten the nuts. 5. When coming out of the hole or when handling drill collars, unscrew the front nuts and push the guide back, out of the way.
4-36
AR3200
SM00053, Rev D
Lubrication
July 1, 2005
5-2
AR3200
SM00053, Rev D
Chapter 5 Lubrication
Lubrication schedules ........................................................................................ 5-5 Lubrication procedures .................................................................................... 5-10 Lubricating the frame and carriage ........................................................... 5-10 Lubricating the foot assemblies ................................................................ 5-11 Lubricating the tilt lever ........................................................................... 5-12 Lubricating the TW-102 Hydraulic Torque Wrench ................................ 5-13 Lubricating the SSW-50 Spinning Wrench Assembly ............................. 5-14
Lubrication
5-3
July 1, 2005
5-4
AR3200
SM00053, Rev D
C ha p t er 5 Lubrication
Lubrication schedules
This section identifies recommended lubricants and hydraulic fluids (Table 5-1), and provides lubrication schedules for AR3200 assemblies and components (Table 5-2 through Table 5-4). See the referenced figures and engineering drawings for grease fitting locations.
Lubrication
5-5
Table 5-1. Recommended lubricants and hydraulic fluids

AMBIENT TEMPERATURE RANGE
5-6 AR3200 SM00053, Rev D
July 1, 2005
Manufacturer
General Purpose Grease Above -20 C Below -20 C
Motor Grease
Extreme Pressure/ Severe Service Grease Below -20 C Above -21 C
Gear Oil 7 to 30 C -6 to 16 C Alpha LS-68 NL Gear 68 Spartan EP68 EP Lube HD68 MobileGear 626 Omala68
Hydraulic Oil 40 to 65 C 25 to 55 C
All Above -20 C Temperatures P/C 70437
Castrol Chevron Exxon Gulf Mobile Shell Statoil Texaco Total Union NGLI AGMA ISO Viscosity Grade
MP grease Avi-Motive Lidok EP2 Gulf Crown EP32 Mobilux EP2 Alvania EP2 Avi-Motive Lidok EP1 Gulf Crown EP31 Mobilux EP1 Alvania EP1
Alpha LS-320 Alpha-150 Alpha LS-320 NL Gear 150 Alpha LS-320 Spartan EP 150 EP Lube HD320 MobileGear 632 Omala320 EP Lube HD150 MobileGear 629 Omala150
Hyapin AWS- Hyapin AWS46 32 AW Hyd oil 46 Nuto H46 Harmony 46 AW DTE25 Tellus46 AW Hyd Oil 32 Nuto H32 Harmony 32AW DTE24 Tellus32
Cyprina RA
Uniway EP2N Uniway EP2N Multifak EP2 Multis EP2 Unoba EP2 2 Multifak EP2 Multis EP2 Unoba EP2 1
P/C 54810 1
LoadwayEP3 LoadwayEP1 Statoil 20 50 Meropa 320 Carter EP 320 Extra Duty NL6EP Meropa 150 Meropa 68
HydrawayHM HydrawayHM A46 A32 Rando oil HD46 Azolia ZS46 Unax AW46 Rando oil HD32 Azolia ZS32 Unax AW32
CarterEP 150 Carter EP 68 Extra Duty NL4EP Extra Duty NL2EP
6EP 320 4EP 150
2EP 68
1 46
32
Table 5-2. Lubricate each trip

Component Frame and carriage Location Reference Figure 5-2 and AR3200 Automated Roughneck drawing Figure 5-1 Method Apply general purpose EP grease to all frame and carriage grease fittings. Apply general purpose EP grease to all foot assembly grease fittings each trip.
Foot assemblies
Tilt lever
Figure 5-3 and Stan- Apply general purpose EP dard Tilt Lever Assem- grease to all grease fittings. bly drawing Figure 5-4 and TW102 Torque Wrench Assembly drawing Clamp cylinder pins Hinge pins Torque cylinder clevis pins Upper and lower torque cylinder trunnion pins Upper roller bearing (Each side) Apply general purpose EP grease to all grease fittings. Apply greases to the four fittings. Apply grease to the four fittings. Apply grease to the four fittings. Apply grease to the four fittings. Apply grease to the two fittings.
TW-102 Hydraulic Torque Wrench
SM00053, Rev D
Lubrication
5-7
July 1, 2005
Table 5-2. Lubricate each trip (continued)

Component SSW-50 Spinning Wrench Location All grease fittings Reference Figure 5-5 and SSW-50 Spinning Wrench Assembly drawing Method Apply general purpose EP grease.
Upper roller bearing Clamp arm hinge pin Upper cylinder trunnioin Lower cylinder trunnion Rear cam roller Forward cam roller Spherical rod-end bearing Lower roller bearings Foot assembly Rear drive roller shaft Front idler roller shaft (Each side) (Each side) (Each side) (Each side) (Each side) (Each side) (Each side) (Each foot) (Each foot)
Apply grease to the two fittings. Apply grease. Apply grease. Apply grease. Apply grease. Apply grease. Apply grease. Apply grease to the two fittings. Apply grease to the fitting. Apply grease to the two fittings.
5-8
AR3200
SM00053, Rev D
Table 5-3. Weekly lubrication

Component SSW-50 Frame/carriage Location Forward spinner carriage rollers Rear spinner carriage rollers Upper cam followers Rear cam followers Lower cam followers Reference Figure 5-5 Method Apply grease to the two fittings. Apply grease to the two fittings. Apply grease to the two fittings. Apply grease to the two fittings. Apply grease to the two fittings. Figure 5-3 Apply grease to the two fittings. Apply grease to the two fittings.
Tilt lever/carriage
Pivot pin Cam follower bearing
Table 5-4. Every three months lubrication

Component Foot Assembly Location Gearboxes Reference Figure 5-1 Method After inspection, repack with grease and install new gaskets before reinstalling the foot gearbox covers.
SM00053, Rev D
Lubrication
5-9
July 1, 2005
Lubrication procedures
Lubricating the frame and carriage
Figure 5-1 shows the location of the frame and carriage grease fittings. Apply general purpose EP grease to all frame and carriage grease fittings each trip. (See also Table 5-1, Recommended lubricants and hydraulic fluids, on page 5-6.
Forward Spinner Carriage Rollers Grease Fitting (Farside) (2 PL)
Upper Cam Follower Grease Fitting (2 PL) Rear Cam Follower Grease Fitting (2 PL)
Rear Spinner Carriage Rollers Grease Fitting (2 PL)
Lower Cam Follower Grease Fitting (Far End) (2 PL)
Figure 5-1. Lubricating the AR3200 frame and carriage
5-10
AR3200
SM00053, Rev D
Lubricating the foot assemblies

See Figure 5-2 for foot assembly grease fitting locations. Apply general purpose EP grease to all foot assembly grease fittings each trip. (See also Table 5-1, Recommended lubricants and hydraulic fluids, on page 5-6.)
Rear Drive Roller Shaft (2) Front Idler Roller Shaft (2) Foot Gear Boxes (2) (Far Side)
(Same Lubrication Points on Both Feet)
Figure 5-2. Lubricating the AR3200 foot assemblies
SM00053, Rev D
Lubrication
5-11
July 1, 2005
Lubricating the tilt lever

See Figure 5-3 and the following engineering drawing: Tilt Lever Assembly, Standard, for grease fitting locations. (See also Table 5-1, Recommended lubricants and hydraulic fluids, on page 5-6.).
Tilt Lever / Carriage Pivot Pin Grease Fitting
Cam Follower Grease Fitting
Figure 5-3. Lubricating the tilt lever
5-12
AR3200
SM00053, Rev D
Lubricating the TW-102 Hydraulic Torque Wrench

See Figure 5-4 and the TW-102 Torque Wrench Assembly engineering drawing for torque wrench grease fitting locations. See also Table 5-1, Recommended lubricants and hydraulic fluids, on page 5-6.
Clamp Cylinder Pin Grease Fitting (2) Hinge Pin Grease Fitting (2) Clamp Cylinder Pin Grease Fitting (2) Hinge Pin Grease Fitting (2)
Torque Cylinder Trunnion Pin Grease Fitting (2)
Torque Cylinder Clevis Pin Grease Fitting
Figure 5-4. Lubricating the TW-102 Torque Wrench
SM00053, Rev D
Lubrication
5-13
July 1, 2005
Lubricating the SSW-50 Spinning Wrench Assembly

See Figure 5-5 and SSW-50 Spinning Wrench Assembly engineering drawing for Spinning Wrench grease fitting locations. (See also Table 5-1, Recommended lubricants and hydraulic fluids, on page 5-6.) .
Clamp Arm Hinge Pin Grease Fitting Upper Roller Bearing Grease Fitting Upper Roller Bearing Grease Fitting Upper Cylinder Trunnion Grease Fitting
Lower Cylinder Trunnion Grease Fitting Lower Roller Bearing Grease Fitting Lower Roller Bearing Grease Fitting Forward Cam Roller Grease Fitting (Far End) Rear Cam Roller Grease Fitting (Far End)
Spherical Rod End Bearing Grease Fitting
Figure 5-5. Lubricating the AR3200 Spinning Wrench
5-14
AR3200
SM00053, Rev D
Troubleshooting
July 1, 2005
6-2
AR3200
SM00053, Rev D
Chapter 6 Troubleshooting
Troubleshooting components ............................................................................ 6-5 Troubleshooting mechanical components .................................................. 6-6 Torque Wrench ................................................................................... 6-11 Spinning Wrench ................................................................................ 6-14 Troubleshooting hydraulic circuits and valves ......................................... 6-16 Pressure-reducing valve circuit (PRV) ............................................... 6-17 Lift cylinder circuit ............................................................................ 6-19 Horizontal travel circuit ..................................................................... 6-20 Spinning Wrench clamp circuit .......................................................... 6-21 Spinning Wrench spin circuit ............................................................. 6-22 Tilt cylinder circuit ............................................................................. 6-23 Torque Wrench clamp circuit ............................................................. 6-24 Soft clamp mode .......................................................................... 6-24 Torque cylinders circuit ..................................................................... 6-25 Directional valves ............................................................................... 6-26 About directional solenoid-controlled valves .............................. 6-26 General diagnostic procedure for solenoid-controlled valves ..... 6-26 Isolating a faulty solenoid-operated directional valve ................. 6-27 Repairing a stuck spool ................................................................ 6-27 Two-position, solenoid-operated, four-way, (spring offset) ........ 6-28 Three-position, solenoid-operated, four-way (spring-centered), float center ................................................................................... 6-29 Three position, pilot-operated, solenoid controlled, four-way (spring-centered), float center ...................................................... 6-30 Load-holding valves ........................................................................... 6-32 Counterbalance valve, pilot assisted ............................................ 6-32 Relief valve, pilot-operated ......................................................... 6-35 Check valve, pilot-operated ......................................................... 6-37 Pressure control valves ....................................................................... 6-39 Pilot-operated, pressure-reducing valve ...................................... 6-39 Auxiliary valves ................................................................................. 6-41 Check valve, pilot-to-close .......................................................... 6-41 Check valve ................................................................................. 6-43 Flow valves ........................................................................................ 6-44 Orifice .......................................................................................... 6-44 Pressure-compensated, fixed orifice ............................................ 6-45 Flow control valve, adjustable, pressure compensated, full reverse free flow .................................................................... 6-47 Output actuators ........................................................................................ 6-49 Hydraulic cylinders ............................................................................ 6-49 Hydraulic motors ................................................................................ 6-51
Troubleshooting
6-3
July 1, 2005
Troubleshooting electrical and control system components ........................... 6-53 Causes of malfunction ............................................................................... 6-53 AR3200 control system ............................................................................. 6-53 Troubleshooting the PLC .......................................................................... 6-56 Last resort PLC troubleshooting procedure ........................................ 6-56 PLC power supply .............................................................................. 6-62 Digital input/output module ............................................................... 6-62 Control system inputs ......................................................................... 6-65 Encoders ....................................................................................... 6-65 Proximity sensors ............................................................................... 6-66 Intrinsic safety devices ....................................................................... 6-67 Zener safety barriers .................................................................... 6-67 Intrinsically safe amplifiers ......................................................... 6-68 Transformer isolated barriers ....................................................... 6-70
6-4
AR3200
SM00053, Rev D
C ha p t er 6 Troubleshooting
Troubleshooting components
Potential AR3200 component failure falls into the following categories: t Mechanical components t Hydraulic components t Electrical and control system components Use the troubleshooting tables (Table 6-1 through Table 6-5) and the Troubleshooting Flow Chart, (Figure 6-10 on page 6-55) to help determine the source and remedy for an AR3200 operational problem. More detailed information on various components is presented later in this chapter.
Troubleshooting
6-5
July 1, 2005
Troubleshooting mechanical components

This section describes troubleshooting procedures for AR3200 mechanical components.
Table 6-1. Operating mode problems

Symptom Tool does not operate manually. Probable cause No AC power going to the solenoids. Remedy Verify the following: 1. ESD switches are pulled out (reset position) on the manual control box and drillers monitor station. 2. The ON/OFF/OVERRIDE switch on the manual control box is set to ON. 3. The purge system is set for proper operation. 4. PLC box circuit breakers have closed circuits. 5. Hydraulic pressure gauge provides the expected reading. When operating the tool manu- The tool has a loose connection or a defective coil. ally, one solenoid does not function when sequenced. Place the tool in an auto sequence and check the control function. If operating, check the manual control switch and circuit.
No hydraulic power.
Malfunction of the horizontal sole- Check solenoid operation and/or In an auto sequence, the tool does not move forward to well noid or malfunction of the solenoid solenoid driver. driver. center. Malfunction of the tool joint detecIn an auto sequence, the tool moves toward the well but fails tor sensor and/or the IS amplifier. to stop the hydraulic drive motor. Horizontal solenoid is sticking. With a preset height selected, tool does not stop vertical up movement at the shoulder. Vertical solenoid is sticking. Check the tool joint detector sensor and cable for physical damage. Check the amplifiers for correct operation. Check the horizontal solenoid. Check the vertical solenoid.
6-6
AR3200
SM00053, Rev D
Table 6-1. Operating mode problems (continued)

Symptom With a preset height selected, the tool finds the shoulder but not the tool joint. Probable cause Remedy
Vertical height sensor is not operat- Verify the following: ing. 1. All wiring associated with the vertical sensor is correct. 2. Encoder power supply, Zener barriers, and optical isolator function properly.
The tool does not spin the pin section completely out of the box.
Improper adjustment of the spinout Check sensor adjustment. (See Adjusting the spinout sensor in the sensor. Maintenance chapter.) Defective spinout sensor. Check all wiring associated with the spinout sensor. (See the Spin Out Sensor drawing in the Drawings chapter.) Check all wiring. See the Electrical drawings in the Drawings chapter and rig-specific electrical drawings.
Failure to detect no flow caused by The tool fails to detect when the pin has shouldered up with a defective flow switch. the box section during a spin in function.
z If the spinner rollers continue after shouldering, a no flow condition is not detected. Flow dividers in the Spinning Wrench hydraulic circuit should prevent this from occurring. (See Table 6-5, Troubleshooting the Spinning Wrench, on page 6-14.)
SM00053, Rev D
Troubleshooting
6-7
July 1, 2005
Table 6-1. Operating mode problems (continued)

Symptom Probable cause Remedy
Malfunction of the Torque Wrench 1. Check the Torque Wrench The Torque Wrench cycles over to one side in preparation position sensor and/or the IS proximity sensor for proper for either a makeup or breakout amplifier. height above the metal target. sequence and the sequence Adjust the height to within stops. 3/16" from the metal target. 2. Check the metal target alignment when the Torque Wrench is at both full makeup or breakout position. The target should cover the proximity sensor. 3. Place a metal object in front of the sensor and monitor the LED on the IS amplifier. The LED should be on when metal is present and off when not present. Replace the sensor and/or the IS amplifier. Tool runs slowly. Hydraulic quick disconnect (QD) on the supply or return line is not fully shouldered. Tighten until fully shouldered.
Power unit is not delivering the full Check the power supply flow while flow. the SSW-50 spinout valve is actuated. Flow should be 40 gpm minimum. Power unit return line filter is dirty. Replace the filter element. Pressure filter is dirty. System pressure gauge shows inconsistent pressure reading or gauge needle bounces. Contaminated or defective dual pressure-reducing valve on the back of the manifold. Replace the filter element. Inspect, clean, or replace.
6-8
AR3200
SM00053, Rev D
Table 6-2. Horizontal positioning problems

Symptom The AR3200 moves in one direction only or does not move at all. Probable cause Power supply is not operating. Remedy Check the power supply pressure gauge for indication. Make sure supply pressure remains high with the operating valve energized.
Flow control valve on the manifold Clean, repair or adjust the valve. is defective, contaminated, or is not adjusted properly. Motor is defective or contaminated. Dual cross-port relief valve on the manifold is defective, contaminated, or is not adjusted properly. Clean or repair the motor. Clean, repair, or adjust the valve.
Defective solenoid-operated valve. Operate the solenoid valve manually; replace if defective. Gears are jammed. Inspect and clean or replace.
Feet are not aligned with each other Check that both feet are properly (cog drive only). aligned on the rails.
SM00053, Rev D
Troubleshooting
6-9
July 1, 2005
Table 6-3. Vertical positioning problems

Symptom Probable cause Remedy Check the power supply pressure gauge for indication. Make sure supply pressure remains high with the operating valve energized. Clean, repair or adjust the valve.
Vertical positioning assembly Power supply is not operating. moves in one direction only or does not move at all. Counterbalance valve on the manifold is defective, contaminated, or is not adjusted properly.
Defective solenoid-operated valve. Operate the solenoid valve manually; replace if defective. Lift cylinders are damaged or dirty. Clean or repair the cylinder. Binding or carriage in the pedestal. Lubricate or replace the side rollers. Vertical positioning assembly does not maintain vertical position. Counterbalance valve is out of adjustment. Clean, replace or adjust the counterbalance valve to maintain vertical position with the operating valve in neutral. Replace the seals.
Lift cylinders leak.
Defective solenoid-operated valve. Operate the solenoid valve manually; replace if defective.
6-10
AR3200
SM00053, Rev D
TORQUE WRENCH
Table 6-4 describes troubleshooting procedures for the torque wrench.
Table 6-4. Troubleshooting the torque wrench

Symptom Torque cylinders do not make up. Probable cause Torque-adjusting valve is improperly set. Remedy Check that the valve is not set too low.
Check valves, clean or replace. Torque-adjusting valve or pressure-reducing valve is stuck closed, dirty, or damaged. Torque cylinder is damaged. Check, clean, or replace.
Manually actuate the valve, repair Dump valve is stuck open (depressed, pressure does not build or replace it is faulty. up). Check valve on the manifold is contaminated or defective. Check, clean or replace.
Defective solenoid-operated valve. Operate the solenoid valve manually; replace if defective. Flow divider valve on the manifold Check the valve, clean or replace. is contaminated or defective. Torque cylinders do not main- Flow divider valve on the manifold Check the valve, clean or replace. is contaminated or defective. tain equal stroke while the bodies clamp and unclamp. Check valve on the manifold is contaminated or defective. Torque cylinders do not break out. Check the valve, clean or replace.
Check valves, clean or replace. Torque-adjusting valve (makeup only) or pressure-reducing valve is stuck closed, dirty, or damaged. Check valves on the manifold are contaminated or defective. Check the valves, clean or replace.
Defective solenoid-operated valve. Operate the solenoid valve manually; replace it if defective.
SM00053, Rev D
Troubleshooting
6-11
July 1, 2005
Table 6-4. Troubleshooting the torque wrench (continued)

Symptom Torque cylinders drift in the makeup direction. Torque cylinders drift in the breakout direction. Probable cause Sticking or worn main operating valve. Excessive back pressure on the return line. Sticking or worn main operating valve. Dirty filter in the power supply. Air in the torque gauge or lines. Torque gauge does not indicate Dirty inlet port or gauge. pressure during make up. Remedy Disassemble the valve, inspect for contamination or wear, and repair or replace. Check for restriction in return line. Check the hydraulic power supply. Disassemble the valve, inspect for contamination or wear, and repair or replace. Replace the filter element. Bleed the gauge or the lines. Clean the inlet port or replace gauge.
Dump valve is stuck open Manually actuate valve, repair or (depressed, pressure does not build replace if faulty. up). Torque cylinders reached the end of stroke and actuated the dump valve. Gauge damper is closed. Torque gauge does not return to zero. Gauge is not adjusted to zero. Reset for additional stroke.
Open the damper (rotate counterclockwise). Rotate the zero adjust knob on the back of the gauge case. Recheck the torque setting. Replace. See the remedy provided for torque cylinders on this table.
Defective gauge. Joint is not centered in the torque wrench upper jaws when clamped. Torque cylinders do not maintain equal stroke while bodies are clamping.
6-12
AR3200
SM00053, Rev D
Table 6-4. Troubleshooting the torque wrench (continued)

Symptom Jaws slip on the tool joint. Probable cause Worn or broken dies. Pressure from hydraulic power supply is too low. Remedy Replace the dies. Set the pump outlet pressure to above 2,500 psi.
Set AR3200 dual pressurePressure setting of the AR3200 dual pressure-reducing valve is set reducing valve (on the AR3200 manifold) to 2,000 psi when the too low. selector switch is at 2,000 psi and to 2,500 psi when the selector switch is at 2,500 psi position. Pressure is bleeding off from the clamp cylinders. Upper torque wrench body set lifts while cycling in makeup or breakout mode. Torque Wrench clamp cylinders are too slow or uneven. Inspect for defective or contaminated pressure port check valve under the main operational valve.
Interference between the upper and Check and remove interference. lower body sets. Regenerative valves on the mani- Clean, repair, or adjust the valves. fold are contaminated, defective, or not adjusted properly. Check the defective solenoid oper- Operate the solenoid valve ated valve. manually; replace if defective. Lack of lubrication Lubricate all grease fittings.
SM00053, Rev D
Troubleshooting
6-13
July 1, 2005
SPINNING WRENCH
Table 6-5 describes troubleshooting procedures for the Spinning Wrench.
Table 6-5. Troubleshooting the Spinning Wrench

Symptom Spinning Wrench arms do not clamp or unclamp and/or motor does not run. Probable cause Flow is restricted. Remedy Locate the cause of the restriction and correct it. Check the power supply pressure gauge for indication. make sure the supply pressure remains high with the operating valve energized.
Power supply is defective.
Defective solenoid-operated valve. Operate the solenoid valve manually; replace if defective. Defective solenoid driver. Arms or motor creep with the valve in neutral position Leaking or sticky control valve. Replace the solenoid driver. Return the valve to center position manually. If the problem persists, inspect the valve spool for wear or contamination. Clean the motor. Repair the motor or replace. Check the hinge pins and bores and repair or replace as required. Lube all the grease fittings.
Motor runs irregularly.
Contaminated motor. Defective motor.
Arms to not move in unison.
Defective linkage. Lack of lubrication.
Defective bearing in the arm, body, Repair or replace. or cylinder. Drive roller does not turn with Sheared drive roller key. the motor running. Broken motor drive shaft. Drive roller does not turn, motor stalls at full torque. Loss of power or torque. Motor seal is blown. Power supply is not operating. Replace the key. Replace the motor. Replace the motor seal. Check that motor drain lines are open to tank. Check the power supply pressure gauge for indication. Make sure the supply pressure remains high with the operating valve energized. Check for pinched, clogged, or otherwise obstructed hydraulic lines. Clean the obstruction. Replace the motor. Replace the valve.
Restricted hydraulic lines.
Worn motor. Worn valve.
6-14
AR3200
SM00053, Rev D
Table 6-5. Troubleshooting the Spinning Wrench (continued)

Symptom Probable cause Remedy
Worn internal valves on the motor. Repair the motor Pressure filter on the AR3200 is dirty. Motor stops rotating while spinning in or spinning out. Flow to the motor is restricted. Defective drive roller bearings. Defective motor. Motor drive shaft is broken. Drill pipe or collars rub against Drive roller is worn excessively. the body of the wrench during spinning. Drive rollers slip. Insufficient clamping pressure. Replace the filter element. Locate the cause of restriction and correct it. Replace the bearings. Repair the motor. Replace the shaft. Replace the drive roller.
Check the power supply outlet and set it above 2,500 psi. Check for leaks in the clamping lines and replace as required. Inspect for defective or contaminated pressure port check valve under the main operating valve and clean or replace as required.
Corrosion- preventing coating on Remove the coating. new drill pipe is making the surface too slippery. Rollers are worn. One or two drive rollers slip. Replace the rollers.
Defective, leaking, or sticking flow Inspect the flow divider(s), repair divider(s). or replace as necessary. Roller is worn. Replace the roller.
Speed-control valve on the back of Adjust, clean, or repair the valve. SSW-50 does not spin, spins too fast, or too slowly when the the manifold is defective, contamipressure selection switch is at nated, or not adjusted properly. 2,500 psi.
SM00053, Rev D
Troubleshooting
6-15
July 1, 2005
Troubleshooting hydraulic circuits and valves

This section describes the AR3200 hydraulic components, their function, and operation. The AR3200 contains the following hydraulic circuits and valves: t Pressure-reducing valve circuit (page 6-17) t Lift cylinder circuit (page 6-19) t Horizontal travel circuit (page 6-20) t Spinning Wrench clamp circuit (page 6-21) t Spinning Wrench spin circuit (page 6-22) t Tilt cylinder circuit (page 6-23) t Torque Wrench clamp circuit (page 6-24) t Torque cylinders circuit (page 6-25) t Directional valves (page 6-26) t Load-holding valves (page 6-32) t Pressure-control valves (page 6-39) t Auxiliary valves (page 6-41) t Flow valves (page 6-44)
6-16
AR3200
SM00053, Rev D
PRESSURE-REDUCING VALVE CIRCUIT (PRV)

Hydraulic fluid flows from the hydraulic power unit through a high-pressure filter mounted on the AR3200 (Figure 6-1), and to the main manifold through a pressure-reducing valve. The PRV is a large, normally open valve controlled by smaller pilot-operated valves. Valve A is set to 2,000 psi and valve B to 2,500 psi. An electrical solenoid valve that can select either 2,000 psi or 2,500 psi controls the pilot line from the main PRV and the A and B PRVs. When the solenoid valve deenergizes, the pilot line from the 2,000 psi PRV flows to the tank. When pressure reaches 2,000 psi in the pilot line going to the A valve, the valve opens. The pressure on the inlet side of the PRV reduces more than the pilot pressure applied to the side of the main PRV opposite the spring. This closes the main PRV. The pilot line going to the A and B PRVs also goes to a speedcontrol valve. At 2,000 psi, the normal operating pressure of the AR3200, all circuits work at full speed. Selecting 2,500 psi takes the A PRV out of the circuit by placing it into a loop, where it opens, but the flow is back into the incoming circuit. The B PRV, set to 2,500 psi, is in the circuit and operates identically to the A PRV valve circuit when using 2,000 psi operational mode. The speed control pilot line also goes to the tank. The manual setting of the speedcontrol valve adjusts the speed of the Spinning Wrench for spinning in drill collars.
SM00053, Rev D
Troubleshooting
6-17
July 1, 2005
2000 PSI
50 PSID
2500 PSI
Pressure
Main PRV
Filter Speed Control
Spin Valve
Tank
Figure 6-1. Pressure-reducing valve circuit

6-18 AR3200 SM00053, Rev D
LIFT CYLINDER CIRCUIT

The lift cylinder circuit hydraulic fluid flows through the check valve of the counterbalance manifold and to the rod end of the lift cylinders, causing the carriage and the torque wrench to rise (Figure 6-2). To lower the torque wrench, actuate the valve to the lower position. Hydraulic fluid flows through the valve, through a flow-control valve and to the blind end of the lift cylinders, lowering the carriage. As the carriage lowers, hydraulic pressure builds up on the rod side of the lift cylinder. This pressure opens the counterbalance valve, relieving the hydraulic pressure and allowing the carriage to lower.
Pressure
Tank
Figure 6-2. Lift cylinder circuit
SM00053, Rev D
Troubleshooting
6-19
July 1, 2005
HORIZONTAL TRAVEL CIRCUIT

When the AR3200 travels in either direction with the solenoid valve deenergized, all hydraulic fluid flow stops on the motor side of the valve (Figure 6-3). To prevent shearing, since the motors are unable to turn, the AR3200 uses cross-port relief valves. As pressure builds up from the motor attempting to turn, the pilot opens the cross-port relief to the other side of the line. This also creates a braking effect, but allows movement if pressures become too great. In 2,500 psi mode, the Decel valve is activated and flow to the motors is restricted, reducing the roughneck travel speed.
Foot Motors
Pressure
Crossport Relief Tank

Horizontal Travel Circuit
Figure 6-3. Horizontal travel circuit
6-20
AR3200
SM00053, Rev D
SPINNING WRENCH CLAMP CIRCUIT

In the Spinning Wrench clamp circuit (Figure 6-4), hydraulic pressure flows through a check valve. The check valve maintains full pressure on the clamp circuit with drops in supply pressure. Hydraulic fluid flows through the directional valve directly to the clamp cylinders.
Pressure
Tank
Figure 6-4. Spinning Wrench clamp circuit
SM00053, Rev D
Troubleshooting
6-21
July 1, 2005
SPINNING WRENCH SPIN CIRCUIT

The Spinning Wrench spin circuit is a high-flow volume circuit. Hydraulic fluid flows from the main PRV through the speed-control valve to the spin valve, flow dividers, the four hydraulic motors and then to tank (Figure 6-5). Pressure-reducing valve circuit (PRV) on page 6-17 contains information on speed control in 2,500 psi (slow) and 2,000 psi (fast and normal) modes.
2000 PSI
2500 PSI
Pressure
Main PRV
Speed Control
Spin Valve
Tank
Figure 6-5. Spinning Wrench spin circuit
6-22
AR3200
SM00053, Rev D
TILT CYLINDER CIRCUIT

In the tilt cylinder circuit, hydraulic pressure flows through a check valve (Figure 6-6). The check valve maintains full pressure on the tilt cylinder with drops in supply pressure. Hydraulic fluid flows through the directional valve directly to the tilt cylinder.
Pressure
Tank
Figure 6-6. Tilt cylinder circuit
SM00053, Rev D
Troubleshooting
6-23
July 1, 2005
TORQUE WRENCH CLAMP CIRCUIT

When the AR3200 torque wrench clamp function energizes, hydraulic oil flows out of the B port to the blind end of the torque wrench clamp cylinder (Figure 6-7). This causes the cylinder to start stroking, resulting in pressure buildup on the rod side of the cylinder. The counterbalance valve in the return line prevents this pressure (flow) from going to tank. A check valve allows the hydraulic oil to flow into the B line, allowing a greater flow to fill the blind end of the clamp cylinder. This condition is known as regenerative mode. When pressure builds up on the blind end of the cylinder, the counterbalance valve opens from pilot pressure of the upper clamp B line and allows the flow from the rod end of the cylinder to go to tank. The system applies 2,000 psi to the blind end of the clamping cylinder. Soft clamp mode The AR3200 has a soft clamp mode to safely hold the box while spinning in drill pipe. In the soft clamp mode, only the lower clamp solenoid energizes. Pressure (flow) only goes to the B line, applying force to the blind end of the cylinder. The rod end of the cylinder oil enters a regenerative mode. Because there is never enough force to open the counterbalance valve, the lower clamp stays in the regenerative mode. In this case, the clamping force is equal to the area of the cylinder, minus the area of the rod, multiplied by the pressure (2,000 psi).
Torque Wrench Clamp Upper
Pressure
Torque Wrench Clamp Lower
Figure 6-7. Torque Wrench clamp circuit
6-24
AR3200
SM00053, Rev D
TORQUE CYLINDERS CIRCUIT

The AR3200 torque adjust circuit (Figure 6-8) operates by selecting the appropriate make or break solenoid. Selecting the break out solenoid provides full breakout torque by allowing the 2,000/2,500 psi to flow to the blind end of the cylinders. It applies full torque because there is no control on the blind end of the cylinder. In makeup mode, hydraulic flow first goes through a pressure-reducing valve that is set at maximum pressure. This PRV has an external port which, if left open to atmosphere, only allows about 100 psi of pressure to be generated through the PRV valve. By controlling this external port, an AR3200 operator can control the makeup pressure required for torquing the drill pipe connection. The AR3200 also has another pressure-reducing valve on the external port of the PRV. Adjusting this valve allows adjusting the external port pressure, thus adjusting the pressure of the primary PRV. This allows achieving the torque required for makeup. A dump valve on the external port, on the end-of-stroke, is used for makeup. When end-of-stroke is reached in the makeup mode, the valve actuates, releasing the pressure on the external port of the PRV. The AR3200 uses this signal for another restroke during an automatic sequence.
Set at Max
Pressure
Tank
Remote Adjust
Figure 6-8. Torque cylinders circuit
SM00053, Rev D
Troubleshooting
6-25
July 1, 2005
DIRECTIONAL VALVES
The AR3200 contains the following directional valves: t Solenoid-operated, 2-position, 4-way (spring offset) (page 6-28) t Solenoid-operated, three-position, four-way (spring-centered), float center (page 6-29) t Solenoid-controlled, pilot-operated, 3 position, 4-way (spring-centered), float center (page 6-30) About directional solenoid-controlled valves Four-way directional valves contain a cylindrical piece called a spool, which slides in a machined bore in the valve housing. The housing has a number of ports to which the pressure, tank, and working lines for the actuator are connected. Internally, the ports are connected to cast or machined passages in the valve housing, which terminate at the machined bore where the spool is located. The axial movement of the spool in the bore determines which ports are connected together. A manual override button is located on the end of the solenoid housing. Pressing this button performs the same function as the solenoid coil by manually shifting the spool against the spring. This valve is a manifold-mounted valve in that the ports are all located on the valve mounting surface and are equipped with O-ring face seals. General diagnostic procedure for solenoid-controlled valves A problem with this type of valve is usually related to improper shifting of the spool. For example, the spool doesnt shift when the solenoid is energized, the spring doesnt return or hold the spool offset when the solenoid is deenergized, or the spool does not shift fully in one or both directions. The most common cause of a stuck spool is particulate contamination of the hydraulic fluid. (See Hydraulic Fluid Cleanliness, SM00081, in the Supplemental Materials chapter.) The other type of potential failure is an O-ring failure at the mounting surface, but the external leakage of hydraulic fluid makes this easy to detect. The detection procedure assumes there is no electrical problem; i.e., the coil is drawing the proper amount of current when energized.
6-26
AR3200
SM00053, Rev D
Isolating a faulty solenoid-operated directional valve To isolate the valve: 1. Verify that supply pressure (usually 2,500 psi) is available at the pressure port of the valve by connecting a test gauge to the appropriate test point. If the required pressure is not present, the valve is probably not the problem. Check for problems upstream of the supply port. 2. Using a test gauge on the test points for the A and B work ports, verify that a change in state occurs on the work ports when the valve is cycled. The valve can be actuated either electrically or by using the manual override button on the solenoid housing. If the manual override button is used, the coil should be in the deenergized state. With a normally operating valve, the pressure at a work port should alternate between a relatively low value and a much higher value, with the opposite value at the opposite work port. If no change of state is present, the spool is probably stuck in one position. (See Repairing a stuck spool to correct the problem.) 3. Using a test gauge on the test points for the A and B work ports, verify that the pressure at each work port equalizes with the supply pressure measured in step 1. You may have to wait for an actuator to move to its end of stroke before the pressure can stabilize. If the pressure does not stabilize, the valve is probably not the problem. There may be an internal leak somewhere downstream of the valve. Repairing a stuck spool To repair a stuck spool: 1. Try to free the spool by pressing on the manual override button, or apply a light tapping action on the body of the valve. It may help to turn off the HPU (or press the EMERGENCY STOP button on the operators console) while performing step 1. 2. If performing step 1 doesnt free the spool, remove the valve to expose the spool through its ports. Clean the area around the valve before removing it to prevent contamination of the exposed sealing surfaces and passageways. 3. Attempt to free the spool using a screwdriver in between the lands of the spool. (Do not pry on the outside diameter of the spool.) 4. If the spool appears to move freely when the manual override button is pressed, lubricate the inside of the valve with a light mineral based oil and remount the valve. If you cannot free the spool, or the problem reoccurs, replace the valve.
SM00053, Rev D
Troubleshooting
6-27
July 1, 2005
Two-position, solenoid-operated, four-way, (spring offset) Function This valve is identified on hydraulic schematic drawings using the following symbol:
A a P T B
2 Position, Solenoid-Operated Valve, 4 Way (Spring Offset)
The two-position, solenoid-operated, four-way directional valve directs hydraulic fluid between one of two flow paths. The flow path selection is determined by the presence or absence of electrical current in the single solenoid coil. This valve is a low-flow valve and supplies hydraulic fluid to small actuators. Or, this valve may be used as pilot operator for larger valves. Theory of operation The valve contains a spool held in one of two positions by a spring. In this position, the P (pressure) port is connected to the A working port and the B working port is connected to the T (tank) port. A solenoid is located at the end of the spool opposite the spring. If the coil is energized, the solenoid armature moves the spool through a push pin, enough force is generated to overcome the spring, and the spool shifts in the housing. In this position, the P port is connected to the B working port, and the A working port is connected to the T port. When the solenoid coil is deenergized, the spring returns the spool to its original position. Diagnostic procedure See Isolating a faulty solenoid-operated directional valve on page 6-27.
6-28
AR3200
SM00053, Rev D
Three-position, solenoid-operated, four-way (spring-centered), float center This valve is identified on hydraulic schematic drawings using the following symbol:
A a P T B b
3 Position, Solenoid-Operated Valve, 4 Way (Spring Centered), Float Center
Function The three-position, solenoid-operated, four-way (spring-centered), directional valve directs hydraulic fluid to one of three possible flow paths. The flow path selection is determined by the presence or absence of electrical current in the two solenoid coils. This low-flow valve supplies hydraulic fluid to small actuators. Or, it can be used as pilot operator for larger valves. Theory of operation The valve contains a spool held in one of two positions by springs. In this position, the P (pressure) port is blocked and both the A and B ports are connected to the T (tank) port. Solenoids are located at either end of the spool. If one of the coils is energized, the solenoid armature moves the spool through a push pin, enough force is generated to overcome the spring and the spool shifts in the housing. In this position, the P port is connected to the B working port, and the A working port is connected to the T port. When the a solenoid coil is deenergized, the spring returns the spool to its center position. When the b solenoid coil is energized, enough force is generated to overcome the spring and the spool will shift in the housing. In this position, the P port is connected to the A working port and the B working port is connected to the T port. When the b solenoid coil is deenergized, the spring returns the spool to its center position. Diagnostic procedures See Isolating a faulty solenoid-operated directional valve on page 6-27.
SM00053, Rev D
Troubleshooting
6-29
July 1, 2005
Three position, pilot-operated, solenoid controlled, four-way ( spring-centered), float center The valve is shown here in a typical circuit and as identified on hydraulic schematic drawings.
A a x P
B b T y
3 Position, Pilot-Operated Directional Control Valve, Solenoid-Controlled, 4 Way (Spring Centered), Float Center, Typical Circuit
A x P
B y T
Pilot-Operated Valve, 4 Way (Spring Centered), Float Center
Function The three-position, pilot-operated, solenoid controlled, four-way directional control valve directs hydraulic fluid between one of three flow paths. The presence or absence of sufficient hydraulic pressure acting on the two pilot pistons determines the selection of flow path. This valve normally handles medium to large flows and is controlled by a small, solenoid-operated, four-way pilot valve.
6-30
AR3200
SM00053, Rev D
Theory of operation This valve consists of a pilot-operated main valve with a solenoid-operated pilot valve directly coupled, hydraulically and mechanically, to the main valve. The pilot valve takes its pressure supply and directs its return flow through the main valve. Similarly, the two working ports (A and B) of the pilot valve are connected to the pilot pistons of the main valve through internal passages in the main valve. the main valve has provisions to allow the supply pressure for the pilot valve to come from an external source (the x port). An internal plug is used to isolate the pressure supply of the main valve in this case. a similar port (the y port) exists for external pilot drain (return). Diagnostic procedures See Isolating a faulty solenoid-operated directional valve on page 6-27.
SM00053, Rev D
Troubleshooting
6-31
July 1, 2005
LOAD-HOLDING VALVES
This section describes the load-holding valves contained in the AR3200. Counterbalance valve, pilot assisted The valve is shown here in a typical circuit and as identified on hydraulic schematic drawings.
Counterbalance Valve
Weight
Counterbalance Valve - Typical Circuit
Major Bias Spring Adjustment
Cylinder Port Free-flow Check Valve
Pilot Assist Port
Valve Port Counterbalance Valve
6-32
AR3200
SM00053, Rev D
Function The counterbalance valve with pilot assist is used for overrunning load control and hydraulic load locking. These valves restrict flow out of a hydraulic cylinder or motor to prevent cavitation, or formation of a partial vacuum. (Such cavitation can occur if the load causes the actuator to move faster than the supply coming from the pump.) The counterbalance valve locks the loaded actuator in place, should the hydraulic line of the actuator break, and also provides relief protection if the actuator is driven by an external force. Theory of operation Circuits using counterbalance valves use a directional control valve that connects the working ports A and B to the tank in the center position. This type of directional valve allows the best control and positioning of the load and provides an unrestricted path to the tank for any oil displaced when the counterbalance valves act as reliefs. As illustrated in the counterbalance valve symbol, counterbalance valves respond to pressure from two different sources. These are the pressure induced by the load acting on the cylinder or motor and the pressure at the pilot assist port. The forces generated by pressure at these two ports open the valve when the sum of the two forces is high enough to overcome the major bias spring (valve pressure setting). The reverse free flow check valve permits a free flow of fluid toward the actuator in the reverse direction of operation. Diagnostic procedure This valve can fail in either the open or closed position. If it fails while open, the load causes the actuator to drift over time. If the actuator appears to be drifting, troubleshooting consists of verifying that the valve has, indeed, failed in the open position and that it is not open due to incorrect adjustment or being piloted open. If the valve fails while closed, actuator movement is impaired in the protected direction (i.e., opposite the free flow direction). Blocked flow across the check valve in the free flow direction is unlikely because of the large forces available to move the valve stem in this direction.
SM00053, Rev D
Troubleshooting
6-33
July 1, 2005
To isolate a faulty load-holding valve: 1. If the actuator holds its position when the direction controlling valve is in neutral and the actuator is not at the end of its travel, proceed to step 4. 2. Measure the pressure at the pilot assist port. With the actuator's control valve in the center (neutral) position, the pilot pressure should be relatively low, usually less than 100 psi. Higher pressures may allow the valve to open, so check for a failure in the part of the circuit related to the pilot assist port. 3. If the pilot pressure measured in step 2 is normal (less than 100 psi), try increasing the valve pressure setting by turning the adjusting screw counterclockwise. If the load continues to drift, contamination may be preventing the valve from closing. Remove the valve and replace it with a new one. 4. Activate the control valve in the direction that will cause pressure to be applied to the pilot assist port. If the actuator does not move, measure the pressure at the pilot assist port while the control valve is actuated. With no load induced pressure acting on the valve, 800 psi at the pilot assist port should open the valve and allow the actuator to move. Higher load induced pressures reduces the required pilot pressure by approximately 30 psi for every 100 psi acting directly on the valve's cylinder port. If the required amount of pilot pressure is present and the actuator does not move, reduce the pressure setting by turning the adjusting screw clockwise. If this does not correct the problem, replace the valve.
6-34
AR3200
SM00053, Rev D
Relief valve, pilot-operated The relief valve is identified on hydraulic schematic drawings using the following symbol.
Inlet
Bias Spring (Adjustment) Outlet (Tank) Pilot-Operated Relief Valve
Function The pilot-operated relief valve smoothly regulates maximum system pressure in a hydraulic system or subsystem over widely varying flow conditions. Theory of operation A pilot-operated relief valve consists of two sections: the main valve and a pilot section. The main valve contains inlet and outlet ports, a spool with an orifice in the center, and a spool bias spring. The pilot section consists of a small capacity, direct-acting, relief valve with a screw adjustment. The pilot supply orifice in the piston end of the main spool connects the inlet of the valve to the bias spring cavity. The areas of the piston at the inlet and in the spring cavity are essentially equal, so the pressure/area forces on the main spool are in balance. If fluid entering through the pilot supply orifice cannot escape, the piston is in hydraulic balance and the bias spring holds the spool in the closed position, blocking the passage from inlet to return. The small capacity, direct acting, relief valve is held in position by the adjustable pilot spring. This pilot spring establishes the pressure level at which the inlet pilot flow will be directed to a lower pressure level - return to tank. When pressure in the bias spring cavity is high enough to open the small relief, fluid flows from the cavity to the return. This flow creates a pressure differential across the orifice. When this pressure differential is high enough to overcome the force of the bias spring, the piston opens and creates a large flow path from the inlet to return to tank.
SM00053, Rev D
Troubleshooting
6-35
July 1, 2005
Diagnostic procedure If a problem occurs with this component, it is usually that it relieves at too low a pressure, or that it does not relieve at all. To isolate a faulty relief valve: 1. If the relief valve opens at a pressure below what is expected, measure the differential pressure across the valve (the difference in pressure between the valves inlet and outlet ports) and compare it to the required setting. Increase the valve setting as required. Turning the adjustment screw in (clockwise) increases the setting of the valve. If the valve stays open regardless of the setting and/or differential pressure across the valve, it is probably stuck open and should be replaced. 2. If the valve opens at too high a pressure or does not open at all, measure the differential pressure across the valve (the difference in pressure between the valves inlet and outlet ports) and compare it to the required setting. Decrease the valve setting as required. Turning the adjustment screw out (counterclockwise) decreases the setting of the valve. If reducing the valve set point still does not allow the valve to open, it may be stuck and should be replaced.
6-36
AR3200
SM00053, Rev D
Check valve, pilot-operated The valve is shown here in a typical circuit and as identified on hydraulic schematic drawings.
Pilot-Operated Check Valve
Weight
Pilot-Operated Check Valve, Typical Circuit
Cylinder Port
Pilot Port Valve Port Pilot-Operated Check Valve
Function The pilot-operated check valve positively locks a pressurized load, but releases the load upon application of a pressure signal at the pilot port. This valve is normally used to lock an actuator in position when the directional valve is centered (neutral). The valve is used in applications where overrunning load control and/or a relief function is not needed or is provided by other means.
SM00053, Rev D
Troubleshooting
6-37
July 1, 2005
Theory of operation A pilot-operated check valve consists of a valve body with inlet and outlet ports and a poppet held against a seat by a spring, as in an ordinary check valve. Directly Opposite the check valve poppet is a plunger and a plunger piston, which is biased by a light spring. Pilot pressure is sensed at the plunger piston through the pilot port. The valve allows free flow from its inlet port to its outlet port like an ordinary check valve. Fluid flow attempting to pass through the valve from the outlet port to the inlet port forces the poppet onto its seat, blocking flow through the valve. When enough pilot pressure is sensed at the plunger piston, the plunger moves and unseats the check valve, allowing fluid to pass. The ratio of the load pressure to the pilot pressure required to release the load is called the pilot ratio. Diagnostic procedure If this valve fails, usually it is in the open position. That is, the valve does not positively lock the pressurized load. If the valve fails closed, in the free flow direction, severe contamination or damage to the internal sliding surfaces probably exists. To isolate a faulty pilot-operated check valve: 1. If the valve does not pass flow in the free-flow direction, measure the pressure on both sides of the valve using test gauges. If the upstream pressure is significantly higher than the downstream pressure, the valve is probably stuck closed and should be replaced. 2. If the valve does not lock the pressurized load with the directional valve centered, measure the pressure at the pilot port. This pressure should be relatively low (usually less than 100 psi). Higher pressures may allow the valve to open, so check for a problem with the part of the circuit connected to the pilot port. 3. If the pressurized load cannot be released, check the pressures at both the pilot port and the outlet port (the port connected to the actuator). If the pilot pressure is greater than the actuator pressure divided by the pilot ratio (usually 3:1), the valve should open. If it does not, replace the valve.
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AR3200
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PRESSURE CONTROL VALVES

Pilot-operated, pressure-reducing valve The valve is shown here in a typical circuit and as identified on hydraulic schematic drawings.
Hydrostat Insert
W
Fixed Orifice (Proportional Valve) Control Cover Pilot-Operated Pressure Reducing Valve Typical Circuit
Inlet Bias Spring (Adjustment)
Pilot Drain
Outlet Pilot-Operated Pressure Reducing Valve
Function The pilot-operated, pressure-reducing valve regulates pressure in a hydraulic circuit.
SM00053, Rev D
Troubleshooting
6-39
July 1, 2005
Theory of operation The pilot-operated, pressure-reducing valve consists of two sections: the main valve and a pilot section. The main valve contains inlet (nonregulated pressure) and outlet (regulated pressure) ports, a spool with an orifice in the center, and a spool bias spring. The pilot section consists of a small-capacity, direct-acting, relief valve with a screw adjustment. The orifice in the spool connects the regulated pressure of the valve to the bias spring cavity. The areas of the spool at the inlet and in the spring cavity contain equal pressure, so the forces on the main spool are in balance. When fluid enters through the pilot supply orifice (the relief valve is closed), the fluid cannot escape. A hydraulic balance exists, and the bias spring holds the spool in the open position, allowing full flow from inlet to return. The screw adjustment compresses the pilot spring, which establishes the pressure level at which the pilot flow ends up at a lower pressure (drain). When pressure in the bias spring cavity is high enough to open the small relief valve, fluid flows from the cavity to return. This flow creates a pressure differential across the orifice. When this pressure differential is high enough to overcome the force of the bias spring, the spool begins to close, creating a restriction in the flow path. This restriction limits the flow from the inlet to the outlet to a value which maintains the selected reduced pressure in the outlet portion of the circuit. Any pressure at the drain port is additive to the pressure setting of the valve. This characteristic can be used to implement remote control of the valve. Diagnostic procedure Usually, if the pressure-reducing valve fails, it fails to close down. Hence, the valve does not provide the required pressure reduction. To isolate a faulty pilot-operated pressure-reducing valve: 1. If the outlet pressure is too high, try reducing the setting of the valve by turning the adjusting screw out (counterclockwise) while observing the pressure at the outlet port. If this procedure does not reduce the pressure to the desired level, measure the pressure at the pilot drain port. If this pressure is higher than the desired set point, a condition exists in the pilot drain circuit that prevents the pressure-reducing valve from being adjusted lower. Correct this problem and then readjust the valve. 2. If the pilot drain pressure measured in step 1 is below the desired valve setting and the valve will not adjust lower, the spool may be stuck and the valve should be replaced.
6-40
AR3200
SM00053, Rev D
AUXILIARY VALVES
Check valve, pilot-to-close This valve is identified on hydraulic schematic drawings using the following symbol:
Outlet Pilot Port
Inlet
Check Valve, Pilot to Close
Function The pilot-to-close check valve allows flow in one direction only but prevents flow in the free-flow direction upon application of sufficient pressure at the pilot port. This valve normally locks an actuator in position when the directional valve is centered (neutral). The valve is used in applications where multiple functional modes are required, such as for regenerative circuits. Theory of operation A pilot-to-close check valve consists of a valve body with inlet and outlet ports and a poppet, which is held against a seat by a spring, as in an ordinary check valve. Directly opposite the check valve poppet is a pilot piston. The pilot piston and the poppet are held apart by a light spring. Pilot pressure is sensed at the pilot piston through the pilot port. The valve allows free flow from its inlet port to its outlet port. Fluid flow attempting to pass through the valve from the outlet port to the inlet port forces the poppet onto its seat, blocking flow through the valve. When enough pressure is present at the pilot piston, the piston moves against the poppet, preventing flow in either direction. The ratio of the load pressure to the pilot pressure required to lock the load is called the pilot ratio.
SM00053, Rev D
Troubleshooting
6-41
July 1, 2005
Diagnostic procedure If this valve fails, it usually fails in the open position. That is, the valve allows flow in both directions. If the valve fails closed, in the free-flow direction, severe contamination or damage to the internal sliding surfaces probably exists. To isolate a faulty check valve: 1. If the valve does not pass flow in the free-flow direction, measure the pressure on both sides of the valve using test gauges. If the upstream pressure is significantly higher than the downstream pressure, the valve is probably stuck closed and should be replaced. 2. If the valve does not block flow from the outlet to the inlet, measure the pressure at the inlet and outlet ports of the valve. If the pressure on the outlet is higher than at the inlet, remove the valve and check for damaged seals and replace as necessary. If the seals are not damaged, the poppet is probably stuck open due to contamination and the valve should be replaced. 3. Perform this step if the valve does not appear to block flow in the free-flow direction when piloted closed. Measure the pressure at the pilot and inlet ports. If the pilot pressure is at least 1.8 times the inlet pressure, flow in the free flow direction should be prevented. If it is not, remove the valve and check for damaged seals and replace as required. If the seals are not damaged, the poppet is probably stuck open due to contamination and the valve should be replaced.
Any pressure at the outlet port reduces the required pilot ratio to values below 1.8.
6-42
AR3200
SM00053, Rev D
Check valve This valve is identified on hydraulic schematic drawings using one of the following symbols:
Outlet Outlet
Inlet
Inlet
Check Valve
Function The check valve allows flow in one direction only. Theory of operation A check valve consists of a valve body with inlet and outlet ports and a poppet held against a seat by a spring. The valve allows free flow from its inlet port to its outlet port when the differential pressure between the inlet and outlet is greater than the cracking pressure of the valve. The cracking pressure is determined by the strength of the spring and the areas exposed to the differential pressure across the valve. Fluid flow attempting to pass through the valve from the outlet port to the inlet port forces the poppet onto its seat, blocking flow through the valve. Diagnostic procedure If this valve fails, it is usually in the open position. That is, the valve permits flow in both directions. If the valve fails closed, in the free flow direction, severe contamination or damage to the internal sliding surfaces probably exists. To isolate a faulty check valve: 1. If the valve does not pass flow in the free flow direction, measure the pressure on both sides of the valve using test gauges. If the upstream pressure is higher than the downstream pressure by an amount at least 50 psi greater than the cracking pressure, the valve is probably stuck closed and should be replaced. 2. If the valve does not block flow from the outlet to the inlet, measure the pressure at the inlet and outlet ports of the valve. If the pressure on the outlet is higher than at the inlet, remove the valve, check for damaged seals and replace as necessary. If the seals are not damaged, the poppet is probably stuck open due to contamination and the valve should be replaced.
SM00053, Rev D
Troubleshooting
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July 1, 2005
FLOW VALVES
This section describes troubleshooting various types of flow valves. Orifice This component is identified on hydraulic schematic drawings using the following symbol:
Orifice
Function Orifices are used in hydraulic circuits to provide a known restriction in a flow path. Theory of operation An orifice is a relatively small opening in a fluids flow path. For a given fluid type, the flow rate through an orifice is affected by the diameter of the orifice, the pressure differential across the orifice, and the temperature of the fluid. Common examples of fixed orifices used in hydraulics are threaded plugs or check valves with a hole drilled through their centers. Diagnostic procedure This component fails to perform if it becomes plugged, either fully or partially, by contamination. If a circuit that includes an orifice is not performing properly, remove and clean the orifice.
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SM00053, Rev D
Pressure-compensated, fixed orifice This component is identified on hydraulic schematic drawings using the following symbol:
Flow Control Valve, Pressure Compensated, Fixed Orifice
Function This flow-control valve uses a fixed orifice to control the flow rate in a circuit. The valve is pressure-compensated to provide constant regulated flow, regardless of load variations. The flow rate is factory set by means of a fixed orifice. This valve is capable of reverse, noncompensated flow equal to the flow setting (orifice size). Theory of operation This valve consists of a body with an inlet and outlet, a compensator spool with a fixed orifice and a spring. Flow passes through the orifice in the center of the compensator spool, then out the side of the spool through a series of radially located holes. The valve body also contains a series of radially located holes in the area of the outlet port. The compensator spool senses both the incoming pressure and the load pressure and moves to restrict the flow through the two sets of holes, maintaining a constant pressure drop across the orifice. This movement causes the valve to maintain a constant flow output, regardless of variations in the upstream or downstream pressure. Reverse flow from the outlet to the inlet causes the compensator spool to move all the way to one side, fully opening the two sets of holes to the outlet port. Only the fixed orifice acts to regulate the flow and is, therefore, not pressurecompensated.
SM00053, Rev D
Troubleshooting
6-45
July 1, 2005
Diagnostic procedure This component fails to perform when the orifice becomes plugged or the compensator spool sticks because of contamination. To check this component: 1. If the valve allows too much flow to pass in the controlled direction, remove it and check for damaged seals and replace as required. If the seals are not damaged, the compensator spool or the check function may be stuck open by contamination and the valve should be replaced. 2. If the valve does not allow enough flow to pass in the controlled direction, the orifice may have become plugged. Remove the valve, check for contamination, and clean it. If this does not solve the problem, the compensator spool may be stuck closed by contamination and should be replaced.
6-46
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SM00053, Rev D
Flow control valve, adjustable, pressure compensated, full reverse free flow This component is identified on hydraulic schematic drawings using the following symbol:
Flow Control Valve, Adjustable, Pressure-Compensated, Full-Reverse Free Flow
Function This flow-control valve uses a variable orifice spool to control the flow rate in a circuit. The valve is pressure compensated to provide constant regulated flow regardless of load variations. The flow rate is adjustable by means of a threaded screw. This valve is capable of full reverse, noncompensated flow, regardless of the flow setting. Theory of operation This valve consists of a body with an inlet and outlet, a compensator spool with a fixed orifice, and a bias spring. It also contains a smaller spring to provide full reverse free flow. Flow must pass through the orifice in the center of the compensator spool and then out the side of the spool through a series of holes that are radially located. The valve body also has a series of radially located holes in the area of the outlet port. A second set of holes in the valve body in conjunction with an annular groove on the outside of the compensator spool allows for full reverse free flow. The compensator spool senses both the incoming pressure and the load pressure and moves to restrict the flow through the two sets of holes maintaining a constant pressure drop across the orifice. This causes the valve to maintain a constant flow output, regardless of variations in the upstream or downstream pressure. The value of the bias spring adjustment controls the maximum compensated flow through the valve. Reverse flow from the outlet to the inlet causes the compensator spool to move against the small spring all the way to one side connecting the inlet to the outlet through the second set of holes in the valve body in conjunction with the annular groove on the outside of the compensator spool.
SM00053, Rev D
Troubleshooting
6-47
July 1, 2005
Diagnostic procedure This component fails to perform if the orifice becomes plugged or the compensator spool sticks because of contamination. (See Diagnostic procedure for Flow control valve, adjustable, pressure compensated, full reverse free flow on page 6-47.)
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Output actuators
HYDRAULIC CYLINDERS
This section describes troubleshooting procedures for hydraulic cylinders. Hydraulic cylinders are identified on hydraulic schematic drawings using the following symbols:
Single Rod Cylinder
Double Rod Cylinder Hydraulic Cylinders
Tandem Cylinder
Function The hydraulic cylinder converts hydraulic energy into straight-line mechanical energy. A hydraulic cylinder can also be used to hold and lower a load against gravity forces, with the addition of suitable hydraulic circuitry. Theory of operation A hydraulic cylinder consists of a cylinder body, a movable piston, and a piston rod attached to the piston. End caps attach to the cylinder body barrel by threads, tie rods, or a weld. The end through which the rod extends is called the head (or rod) end; the opposite end is called the cap (or blind) end. Each end cap contains a port that allows fluid to enter and exit that end of the cylinder. As the cylinder rod moves in and out, it is guided and supported by a removable bushing called a rod gland or rod bearing. The rod gland contains a piston rod wiper and a primary seal. The piston is equipped with one or more primary seals and, in some cases, wear rings.
SM00053, Rev D
Troubleshooting
6-49
July 1, 2005
Diagnostic procedure A hydraulic cylinder problem is usually related to the cylinder not producing the required push or pull force. If the fault is with the cylinder, and not its related hydraulic circuitry, the fault is likely being caused by internal or external leakage of the pressurized fluid. External leakage is easy to detect and is not dealt with here. If the piston seals fail, fluid from the high pressure side of the piston passes to the low pressure side, which is generally connected to tank through a directional valve. If this leak is large enough, the hydraulic power unit cannot maintain the pressure at the intended level. If the cylinder is supporting a gravity load, internal leakage may allow the rod to extend or retract until end of stroke is reached. Internal seal failure To troubleshoot an internal seal failure, you should determine if the cylinder can hold pressure over time. To diagnose a hydraulic cylinder problem: 1. If the cylinder is required to support a gravity load and is not holding its position, verify that the related load-holding valves are functioning properly. (See Load-holding valves on page 6-32.) 2. Attach a test gauge to the appropriate test point in the line for the cylinder in question. Actuate the appropriate directional valve and observe the pressure as the cylinder strokes. When the cylinder reaches end of stroke, the reading should rise and stabilize at the supply pressure value. In diagnosing, it may help to operate only a single pump and use the slowest speed available for the function. A faulty piston seal can prevent the pressure from stabilizing. You may hear the flow of the oil leaking across the piston. If so, replace the piston seals.
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AR3200
SM00053, Rev D
HYDRAULIC MOTORS
Hydraulic motors are identified on hydraulic schematic drawings using the following symbol:
Case Drain Hydraulic Motor
Function The hydraulic motor converts hydraulic energy into rotary mechanical energy. Theory of operation Hydraulic motors operate by causing an imbalance that results in the rotation of a shaft. A Geroler motor is a type of internal gear motor with an inner drive gear and an outer drive gear with one more tooth than the inner gear. The inner gear is attached to a shaft connected to the load. The outer gear in a geroler motor consists of several rollers held in place by a slotted ring. The imbalance in this type of motor is caused by the difference in gear area exposed to hydraulic pressure at the motor inlet. The exposed area of the inner gear increases at the inlet. Fluid pressure acting on these unequally exposed teeth results in a torque at the motor shaft. Larger gears or higher pressures create higher torques at the output shaft. A cylindrical porting ring directs fluid between the inlet and outlet ports and the rotating group through passages in the motor housing. A case drain is sometimes provided to protect the shaft seals from damage due to internal motor leakage. Hydraulic motors are identified on hydraulic schematic drawings using the following symbol:
SM00053, Rev D
Troubleshooting
6-51
July 1, 2005
Diagnostic procedure A problem with this component is usually related to a loss of output torque due either to internal binding or to excessive internal leakage. Perform the following steps to check the motor: 1. If the motor fails to rotate freely when not under load or excessive heat or noise is generated, internal damage has occurred, and the motor should be replaced. 2. To check for excessive internal leakage, operate the motor in a stalled condition. Check the pressure at both the inlet and outlet ports of the motor. The inlet pressure should be very near the supply pressure for this circuit, normally 2,500 psi. The pressure at the outlet port should be near that of the tank pressure, less than 100 psi. If this is not the case, or excessive flow across the stalled rotor is evidenced by heat or noise, replace the motor.
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Troubleshooting electrical and control system components

Causes of malfunction
The most common causes of control system malfunction are t Lack of hydraulic pressure or t Electrical supply voltage The AR3200 PLC control boxes are located remotely from the tool. Interconnection is through service loops that run from the tool J-box to the derrick J-box and through rig wiring to the PLC. Numerous wire runs and connections that interconnect the AR3200 and the PLC must be properly marked and terminated to avoid improper wiring and high resistance.
Improper interconnection wiring is another common cause of control system malfunction.
AR3200 control system

The AR3200 control system consists of control loops made up of combinations of a few basic types of components. Figure 6-9 illustrates a typical control loop. Inputs from the operator and feedback on machine movement are directed into the Programmable Logic Controller (PLC). The PLC also initiates the system's outputs. Troubleshooting a problem with the control system involves determining which of the control system components has failed. Each PLC input and output has an associated diagnostic indicator showing each component's current state. Upon indication of AR3200 equipment failure, use the general troubleshooting flow chart illustrated in Figure 6-10 to help isolate the problem. Follow the appropriate diagnostic procedures to check the AR3200 components and consult the corresponding troubleshooting tables.
SM00053, Rev D
Troubleshooting
6-53
July 1, 2005
Operator Inputs (Switches)
PLC CPU CONTROL SOFTWARE
PLC Input Card INTERLOCK ROUTINE LED
Feedback Device (Sensor)
OUTPUT FUNCTION
OUTPUT ROUTINE PLC Output Card Output Device LED
Test Point
Figure 6-9.
6-54 AR3200
Typical control loop

SM00053, Rev D
Trouble Shooting
Actuate Input Switch
Is There A Communication Error?
Yes
Check Operator Interface Hardware
No
Is Output Indicator On?
No
Is Interlock On?
No
Check PLC Hardware
Yes
Yes
Check Output Device Does Interlock Condition Exist? No Check Interlock Circuit
Yes
Operation is Correct Clear Interlock Condition Before Proceeding
Figure 6-10. Troubleshooting flow chart
SM00053, Rev D
Troubleshooting
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July 1, 2005
Troubleshooting the PLC

This section describes general procedures for diagnosing and troubleshooting the PLC. See also the Siemens manual and Figure 6-12 and Figure 6-13 for additional PLC troubleshooting information.
The PLC configurations describes in this manual are typical, but not universal. See your Technical Drawings Book for rig-specific information. t If a particular function on the tool is not working, determine if the PLC received the input and if the corresponding output was energized. t If a control sensor is actuated and the input LED does not illuminate, check the devices (i.e., sensors and barriers) connected on the input side. t If a control switch is actuated and the input LED does not illuminate, check the devices (i.e., switches and barriers) connected on the input side. t If the output LED illuminates but the related output actuator does not function, check the devices (i.e., solenoid drivers) connected on the output side. t If an input LED illuminates but the related output LED does not illuminate, either the PLC and/or its related hardware has failed, or an interlock condition exists. This applies to the manual mode only. When in a sequenced operation, not all input LEDs have corresponding output LEDs. Replace any faulty PLC component upon detection.
LAST RESORT PLC TROUBLESHOOTING PROCEDURE

If you cannot bring the PLC into the RUN operating mode, the battery was probably installed or changed while power to the PLC was OFF. Use the following procedure to reset the PLC, load the software from the EPROM to the PLC, and return the PLC to the RUN operating mode: 1. Set the operating mode switch to STOP. 2. Remove the battery. 3. Set the ON/OFF switch to ON. 4. Set the RUN/STOP switch to RUN. 5. Install the battery. Contact Varco if the above measures are ineffective.
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July 1, 2005
Figure 6-12. Siemens digital I/O module

6-57 AR3200 SM00053, Rev D
July 1, 2005
Table 6-6. S5-95U LEDs, controls, and interfaces

# Component 1 Battery compartment 2 Front panel connector 3 Battery low LED 4 ON/OFF switch 5 LED display for digital inputs and outputs 6 Terminals for connecting the power supply 7 SINEC L2 bus fault LED for S5-95U, Order Nos. 6ES5 095-8MB...; SINEC L2-DP bus fault LED for S5-95U, Order Nos. 6ES5 095-8MD... 8 Cable connector for S5-100U modules 9 RUN/STOP LEDs: Green LED --> RUN, Red LED --> STOP 10 Interface 11 SINEC L2 interface for S5-95-U, Order Nos. 6ES5 095-8MB...; 2nd serial interface for S5-95U, Order Nos. 6ES5 095-8MC...; SINEC L2-DP interface for S5-95U, Order Nos. 6ES5 095-8MD... 12 RUN/STOP/COPY switch 13 Receptacle for E(E)PROM submodule 14 Interface for a programmer, PC, OP, or SINEC L1 bus 15 Interface For interrupt inputs (I 34.0 to 34.3) and for counter inputs (IW 36, IW 38) For analog inputs (IW 40 to IW 54) and for analog output (QW 40) For digital inputs (I 32.0 to I 33.7) and digital outputs (Q 32.0 to Q 33.7) Function
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AR3200
SM00053, Rev D
7 8
BF
1 2
Battery
3 4 5
6
L+ DC 24V M
1 a 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20
b 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20
RUN
10
STOP RUN STOP COPY
11
12 13 14 15
Figure 6-13. Siemens S5-95U LEDs, controls and interfaces
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Troubleshooting
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July 1, 2005
Table 6-7. PLC LEDs

Manual Control Switch UP PLC CPU Input Box TB2 LED 2 I32.0 CPU Output LED Q32.0 Cable C01 Solenoid driver A-1 Function Carriage up
DOWN
I32.1
Q32.1
C02
A-2
Carriage down
WELL HOME TW UNCLAMP1 TW CLAMP1 TW UNCLAMP TW CLAMP1, 2 SW UNCLAMP SW CLAMP TW MAKEUP TW BREAKOUT SW IN SW OUT TILT 2,000/2,500 Automode MANUAL mode ESD switch ESD switch Autostart TRIP IN
1, 2
4 5 10 11 10 11 8 9 12 13 6 7 15 14 16 17 18 19 20 21
I32.2 I32.3 I33.0 I33.1 I33.0 I33.1 I32.6 I32.7 I33.2 I33.3 I32.4 I32.5 I33.5 I33.4 I33.6 I33.7
Q32.2 Q32.3 Q32.4 Q32.5 Q32.6 Q32.7 Q33.0 Q33.1 Q33.2 Q33.3 Q33.4 Q33.5 Q33.6 Q33.7
C03 C04 C05 C06 C07 C08 C09 C10 C11 C12 C13 C14 C15 C16
A-3 A-4 B-1 B-2 B-3 B-4 C-1 C-2 C-3 C-4 D-1 D-2 D-3 D-4
Well center Home TW upper jaws open TW upper jaws close TW lower jaws open TW lower jaws close SW arms open SW arms close TW makeup TW breakout Spin in Spin out Tilt 2500 psi
I65.0 I65.1 I65.2
TW BACKUP mode 22 Spare Spare

1
23 24
Both upper and lower jaws close/open.
Only lower jaws close/open in TW backup mode.
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AR3200
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Sensor PS-Mode SW TW position TJD proximity
PLC Box TB1 1, 2 4, 5 7, 8
CPU Input LED I64.0 I64.1 I64.2 I64.3 I64.5 I64.5
PLC Box Check IS Barrier switches IS Barrier switches IS Barrier switches IS Barrier switches IS Barrier switches IS Barrier switches IS Barrier switches
Horizontal index (slot) 10, 11 Horizontal position Flow SW EOS proximity Vertical encoder Spinout proximity TJ length SW 13, 14 16, 17 19, 20 22, 23 28, 29 31, 32
25, 26
Zener safety barrier switches IS Barrier switches VR 9.9-10.IV IS potentiometer driver
Switch Drill cont. autostart TRIP IN Spare Drill Monitor station ESC REM IND1 REM IND2 -LEARN Spare
PLC Box TB3 2 3 4 5, 6 7 8 9
CPU Input LED I65.3 I65.4 I65.5
Q64.0 (output) Q64.1 (output) Q64.2 (output) 64.6 64.7
SM00053, Rev D
Troubleshooting
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July 1, 2005
PLC POWER SUPPLY

The PLC power supply provides all internal PLC power requirements. Theory of operation The 115/230 V switch must be on 115 V. It generates an open-circuit output voltage of 24 VDC at 2A. Diagnostic procedure The front panel of the power supply contains several test points for diagnosing problems. In case of any power supply fault indication, replace the power supply or battery.
DIGITAL INPUT/OUTPUT MODULE

The digital input/output module (Figure 6-12) converts the external discrete input signals to the internal signal level of the programmable controller. The module interfaces with all operator control switches and tool proximity switches. Theory of operation The input signals are first conditioned by input conditioning circuitry that suppresses any interference. Part of the input circuitry contains input status LEDs that provide visual indication of each input state. Each input on the module is galvanically isolated to 1,250 VAC and has a maximum signal input frequency of 100 Hz. Input signal voltage of 0 to 5 V is considered to be logic 0; 13 to 33 V is a logic 1. The modules require an enabling input voltage and power supply voltage.
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AR3200
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24V Power Supply
Backup Battery
CPU
EPROM
I/O Module
PLC Box Assy
Learn Mode Switch
OFF
ON
MODULE A
Solenoid Drivers
1 2 3 4 5
12V Power Supply (Encoder) IS Amplifier/ Barrier IS Potentiometer Driver Encoder Safety Barrier
TB 1
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36
1 2 3
SPARE
4
OFF
ON
5 6 7 8 9
6 7 8 9
TEACH
MODULE B
1 2 3 4 1 2 3 4
TB 8 TB 7
2 3 4 5 6 7 8 2 A2 A2 A1 1 1
Kill Relay (ESD)
5 6 7 8 9
6 7 8 9
3 4 5 6 7 8 24 21 22 14 11 12 1 2 3 4 1 2 3 4
B
1
MODULE C
1
Solenoid Drivers
2 3
2 3
TB 2
1 2 3 4 5 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24
TB 4
1 2 3 4 5 6 7 8 9 10 1 2 3
5 6 7 8
6 7 8
4 5 6 7 8 9 10
715
6 7
764
8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24
MODULE D
1 1
TB 5
1 2 3 4 5 6 7 8 9 10 11 12 13 1 2 3 4
2 3 4 5
2 3 4 5
5 6 7 8 9
10 11 12 13 14 15 16 17 18 19 20 21 22 5 1 5
9 9
TB 3
1 2 3 4 5 6 7 8 9 10 1 2 3 4 5 6 7 8 9 10
14 15 16 17 18 19 20 21 22
1AMP Circuit Breakers 5 AMP Circuit Breakers
6 7 8
7 8
TB 6
TB 9
8 1 2 3 1 2 3 4 1 2 3 4 4 5 6
5 1 2 3 4 5 6
IS Terminal Blocks (Knife Switch Type)
Isolation Relay (BEBCO UL Purge on Tool J-Box)
Figure 6-14. AR3200 PLC assembly and enclosure
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Troubleshooting
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July 1, 2005
Diagnostic procedure The basic diagnostic procedure of a defect is to replace the defective module. Each input on the module contains an associated green input status LED that illuminates when an input voltage of 13 + 33 VDC is applied. 1. If a known input does not turn on the appropriate LED, check the voltage to the input terminal. 2. Using a Digital Volt Meter (DVM), place the positive lead on the appropriate module input terminal and the negative lead on terminal 21. Verify that the measured voltage is 13 to 33 VDC. 3. If the input voltage is acceptable and the input LED is not on, the module is defective and should be changed. 4. If the input voltage is not acceptable, check the appropriate IS input module, switch, circuit, or power supply. 5. If known inputs exist on the module, and no input status LEDs are on, check the enable input voltage and/or module DC voltage supply. 6. Using a DVM, place the positive lead on terminal 1 and the negative lead on terminal 2. Verify that the enabling voltage is 13 to 33 VDC.
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SM00053, Rev D
CONTROL SYSTEM INPUTS

Encoders Encoders provide relative position measurements. Theory of operation The encoder contains a glass disc with 250 etched windows, an LED, and two photo-amplifiers with output transistors. As the disc rotates, the light from the LED passes through the etched windows where the photo-amplifier sense it, turning on their appropriate output transistors. This produces two square wave signals, channel A and B. The photo-amplifiers are precisely positioned so that channel B output leads channel A by 90o when the encoder shaft rotates clockwise (as viewed from the shaft end). The encoders are certified intrinsically safe (IS) when used with appropriate Zener safety barriers; these barriers are contained within the PLC assembly enclosure. Diagnostic procedure 1. At the encoder terminals, measure the IS Voltage source at terminal 1 with respect to terminal 4 (0 V side). Verify that the voltage is approximately 5.0 to 6.0 V. If no voltage is present, or if it is significantly out of range, check the appropriate field terminals, Zener barrier, and encoder voltage source located in the control enclosure. 2. The following procedure is used to verify channel A and B outputs. (Note: The encoder shaft gear may require removal.) t Measure the voltage at terminal 2 with respect to terminal 4 (0 volt side) for channel A and terminal 3 with respect to terminal 4 (0 volt side) for channel B. The voltage should change from 12 + 1 V to 0.7 + 0.5 V as the encoder shaft is slowly rotated. (Note: There are 250 transitions for each full rotation of the shaft.) Failure to detect a 12 V pulse level indicates an encoder device failure or possible field terminal or Zener barrier failure. Detecting a constant 0.7 V level indicates a barrier failure.
SM00053, Rev D
Troubleshooting
6-65
July 1, 2005
PROXIMITY SENSORS
Proximity sensors provide the information necessary to determine relative tool positions and also provide an absolute position for determining physical positions (index). They also provide input data and detect spinout completion. Theory of operation The proximity sensor employs a 2-wire technique known as NAMUR and meets DIN 19234 for intrinsic safety. The system proximity sensors are similar to standard DC and AC inductive proximity sensors that normally include an oscillator, amplifier, and trigger circuits. The sensors furnished in the AR3200 include only the oscillator and require an external IS amplifier and trigger circuit. When a metal target is outside the sensing range of the device, the oscillator oscillates and requires a current of greater than 3.0 mA. When a metal target is within the sensing range, the oscillator stops oscillating and the current reduces to less than 1.0 mA. The external amplifiers and trigger circuits detect these differences in currents, thereby signaling the presence or absence of a metal target in range of the proximity sensors. Diagnostic procedure 1. To verify operation of the device, monitor the LEDs located on the appropriate IS amplifier in the PLC assembly. Each amplifier channel contains two LED indicators. Yellow indicates the state of the proximity sensor (on or off) and red indicates the condition of the proximity sensor wiring. 2. A wiring short (current greater than 6.0 mA) or open condition (current less than 0.1 mA) causes the red indicator to illuminate. Check the field terminals and wire conductivity. If the red LED is not illuminated and the yellow LED does not change state with switch operation, measure the current in the proximity sensor. 3. Open one of the appropriate field terminals at the PLC assembly and, using a milliampere meter, measure the switch current. If the current is either 1.0 or 3.0 mA 0.5 and does not change when a metal target is moved in and out of range of the proximity switch, the proximity sensor is defective. If the above measurements are normal, the IS Amplifier may be defective.
6-66
AR3200
SM00053, Rev D
INTRINSIC SAFETY DEVICES

Zener safety barriers The Zener safety barriers provide protection for the encoder located within a hazardous area. These safety barriers provide intrinsic safety (IS) by limiting current and voltage so that the energy released is insufficient to ignite explosive mixtures during operation or if there is a short circuit. Diagnostic procedure Measure the input voltage at terminals 1 and 2 of the 715 barrier. Input voltage should be 12 VDC. The 715 Zener safety barrier is located between the power supply in the PLC box and the encoder. The 764 Zener safety barrier is located between the encoder and the PLC. Measure the output voltage of both barriers (terminals 3 and 4). Internal resistance of the barriers should cause a voltage drop. A measured voltage of 12 V indicates an open circuit. If the voltage measured at the barrier is .7 V, check the barrier resistance. Remove the 12-volt power source and measure the resistance between terminals 1 and 3 of the affected barrier. The resistance should be between 100 (715 barrier) and 1000 (764 barrier) Ohms. An open circuit indicates a failed barrier.
SM00053, Rev D
Troubleshooting
6-67
July 1, 2005
Intrinsically safe amplifiers The control system contains four two-channel IS amplifiers (Figure 6-15). The barriers operate in one of two available modes. You can set them to respond either to open circuits or to closed circuits.
PS-MODE Switch
Torque Wrench Position Sensor
Tool Joint Detector Sensor
Horizontal Index Sensor
Horizontal Position Sensor End of Stroke Sensor
Flow Switch
Spinout Sensor
Figure 6-15. IS amplifiers
The topmost LED on each IS amplifier is a green power indicator. The middle pair of LEDs on each IS amplifier are red fault indicators-one LED for each channel. The bottom pair of LEDs on each IS amplifier are yellow output indicators-one LED for each channel.
6-68
AR3200
SM00053, Rev D
Diagnostic procedure Open the PLC assembly enclosure (only if the area is known to be free of explosive gas) and check the red status LEDs on each IS amplifier. If any red LED is on, a short or open circuit exists between the IS amplifier and the sensors. A green LED indicates that the power to the IS amplifiers is on.
The Open/Short circuit diagnostic LED (red) does not work with the PS-MODE and flow switches. It works only with the proximity sensors. Six of the channels are used for sensors and two are used for switches. Each channel has a mode switch. The mode switches should be set as follows: Mode 1: PS-MODE switch and flow switch circuits. Mode 2: All other circuits. Make sure that the channels operate properly by checking the yellow output status LEDs for the following: 1. The end-of-stroke sensor LED is off when the carriage is at least 3/4" above the end-of-stroke line. 2. The torque wrench position sensor LED is on at the extreme end-of-stroke (full makeup or full breakout). 3. The horizontal position sensor LED flickers when the AR3200 moves. 4. The flow switch LED turns off when the hydraulic flow (e.g., in foot drive motors) begins. The LED illuminates again when the flow stops. 5. The tool joint length sensor LED illuminates when the sensor detects the pipe. It will flash off momentarily as the tool joint detector encounters the box upset as it moves up the pipe. 6. The horizontal index sensor LED turns off momentarily when the AR3200 passes over the index slot. 7. The PS-MODE switch LED illuminates when the PS-MODE mode is selected. 8. The spinout sensor LED is normally illuminated during operation. It turns off momentarily when the tool has finished spinning. (The bump at thread out causes the target to move away from the sensor momentarily.) Check the output status LED associated with each output. If the output is present at the driving source and there isn't a signal at the appropriate PLC terminal, the barrier in that circuit may be defective.
SM00053, Rev D
Troubleshooting
6-69
July 1, 2005
Transformer isolated barriers The potentiometer driver contains transformer isolated barriers that have a supply voltage of 20 - 35 VDC (terminal 7 and 8). The supply voltage is isolated from the input and output circuits. The excitation circuits are terminals 1 through 4. The input voltage to the transformer isolated barriers (terminals 7 and 8) is 24 V. When operating properly, an output voltage of 9.5 to 10.5 V is available to the potentiometer. Normally the voltage should be set to 10 V. It can, however, be adjusted to compensate for lead resistance. Diagnostic procedure A screw on top of the potentiometer allows you to adjust the voltage. t See Engineering Drawing: AR3200 Remote controller (PLC) Assembly 1. Measure the barrier input voltage between terminals 11 and 12. It should be 24 VDC. 2. Open the knife switches in TB1 terminal blocks 31 through 35. 3. Check the barrier excitation voltage between terminals 1 and Earth. It should 10 V. 4. Close the knife switches in TB1 terminal blocks 31 through 35. 5. Check the excitation voltage again for a voltage drop. If a significant voltage drop is evident, either the barrier or switch has failed. 6. Check the output voltage of the tool joint length selector switch between terminal 3 and 4 on the potentiometer driver. The voltage returned to the potentiometer driver for the tool joint length switch varies depending on the switch setting:
TOOL JOINT LENGTH Switch setting MAN 8" 10" 12" 14" HW
Output Voltage 0 2 4 6 8 10
7. Check the barrier output voltage between terminals 7 and 8. The output voltage should correspond to the setting in the table above.
6-70
AR3200
SM00053, Rev D
July 1, 2005
7-2
AR3200
SM00053, Rev D
Chapter 7 Supplemental Materials
Supplement list .................................................................................................. 7-5
7-3
July 1, 2005
7-4
AR3200
SM00053, Rev D
C ha p t er 7 Supplemental Materials
Supplement list
This section contains the following supplements: t Safety Wiring Procedures, ASP00019 t AR3200 Commissioning Procedure, FIP00055 t Pipehandling Systems Preshipment Preparation Short & Long Term Storage, QA00016 t Hydraulic Fluid Cleanliness, SM00081 t Eaton Hydraulics Division, 2000 Series Char-Lynn Motors 005, VDR00058 t Eaton Hydraulics Division, 2000 Series Char-Lynn Motors 006, VDR00059
7-5
July 1, 2005
7-6
AR3200
SM00053, Rev D
Hydraulic Fluid Cleanliness
Supplement
SM00081
Rev. B.
Copyright 1979 and 1984 by Rexroth Corp. Excerpts used by persmission from the Rexroth Corporation, 2315 City Line Road, Bethlehem, PA 18018.
SM00081-A
Contents
Supplement Hydraulic Fluid Cleanliness ..................... 5
Hydraulic contamination .................................................... 5 Solid contamination...................................................... 6 Classes of contamination......................................... 6 Using ISO DIS 4406 ........................................ 8 Measuring the contamination of a system ............. 10 Taking samples ............................................... 10 Fluid sampling procedure ............................... 11 Analyzing the samples ........................................... 11
SM00081-A
SM00081-A
Supplement Hydraulic Fluid Cleanliness
Hydraulic contamination
Varco recommends hydraulic fluid levels be maintained at a cleanliness level of ISO 4406 15/12 or better. This document presents measurement and analysis criteria. When determining contamination of hydraulic fluids, you must consider the degree of solid contamination.
SM00081-A
Solid contamination
The contamination of hydraulic fluids by solid particles is covered by a number of different classification systems: t ISO DIS 4406 t MIL STD 1246 A t NAS 1638 t SAE 749 D t 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. Table 1 compares the various classification systems.
SM00081-A
Table 1. Comparison of contamination classifications

ISO DIS 4406 or Cetop RP 70 H 26/23 25/23 23/20 21/18 20/18 20/17 20/16 19/16 18/15 17/14 16/13
w
Particles per ml > 10 m
ACFTD MIL STD 1246 A solids content (1967) mg/L 1000 1000 100 700
NAS 1638 (1964)
SAE 749 D (1963)
140000 85000 14000 4500 2400 2300 1400 1200 580 280 140 70 40 35 14 9 5 3 2,3 1,4 1,2 0,6 0,3 0,14 0,04
12 500 11 10 10 9 300 1 200 5 0,1 4 3 2 100 1 0,01 0 00 50 0,001 25 2 1 0 8 7 6 6 5 4 3

w
15/12 14/12 14/11 13/10 12/9 18/8 10/8 10/7 10/6 9/6 8/5 7/5 6/3 5/2
Acceptable range for Varco equipment
SM00081-A
Acceptable range for Varco equipment

w
Using ISO DIS 4406
To determine the degree of contamination for the ISO DIS 4406, for example, first count all particles larger than 5 m in the 100 ml sample and give it a code number. Then count all particles larger than 15m and give them another code number (Figure 1). Using the example, if the sample contains 7,500 particles over 5 m, the code number is 13. If the particles larger than 15 m is 300, the code number is 9. The code number for this sample would be stated as 13/9. These code numbers form the designation of the sample. Table 2 lists the contamination figures and their coding.
Figure 1. Contamination coding to ISO DIS 4406
SM00081-A
Table 2. Contamination data and short form coding

No. of particles per 100 ml over 5 um Code 20/17 20/16 20/15 20/14 19/16 19/15 19/14 19/13 18/15 18/14 18/13 18/12 17/14 17/13 17/12 17/11 16/13 16/12 16/11 16/10 15/12 15/11 15/10 15/9 14/11 14/10 14/9 14/8 13/10 13/9 13/8 12/9 12/8 11/8 more than and up to 500 k 500 k 500 k 500 k 250 k 250 k 250 k 250 k 130 k 130 k 130 k 130 k 64 k 64 k 64 k 64 k 32 k 32 k 32 k 32 k 16 k 16 k 16 k 16 k 8k 8k 8k 8k 4k 4k 4k 2k 2k 1k 1 1 1 1 M M M M over 15 um more than and up to 64 k 32 k 16 k 8k 32 k 16 k 8k 4k 16 k 8k 4k 2k 8k 4k 2k 1k 4k 2k 1k 500 2k 1k 500 250 1k 500 250 130 500 250 130 250 130 130 130 k 64 k 32 k 16 k 64 k 32 k 16 k 8k 32 k 16 k 8k 4k 16 k 8k 4k 2k 8k 4k 2k 1k 4k 2k 1k 500 2k 1k 500 250 1k 500 250 500 250 250
500 k 500 k 500 k 500 k 250 k 250 k 250 k 250 k 130 k 130 k 130 k 130 k 64 k 64 k 64 k 64 k 32 k 32 k 32 k 32 k 16 k 16 k 16 k 16 k 8k 8k 8k 4k 4k 2k
SM00081-A
Measuring the contamination of a system

Solid particle contamination is measured by taking a sample of fluid from the hydraulic system and analyzing it. The analysis can reveal the following: t Solid particle contamination of fluid delivered by suppliers t Effectiveness of the system filters t Flushing time when commissioning a system t 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) (Figure 2). Sampling point: Take the sample within a system that is operating and which contains turbulent flow. (See ISO 4021.)
Figure 2. Taking a sample
10
SM00081-A
Fluid sampling procedure
Apply the following general measures when taking a sample: t Before taking the sample, carefully flush out the sampling device with clean solvent. t Use only sample bottles that have been cleaned with fresh solvent. t Remove any remaining solvent before taking the sample. t Allow at least two liters of system fluid to flush through the sampling device before taking the actual sample. t Take a zero sample. This sample is not used for the analysis because it is not representative of the system contamination. t Place the fluid to be analyzed into a new, clean sample bottle. The protective foil on the bottle should only be lifted.
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.
Only properly trained personnel should be allowed to take the fluid samples. Errors in sampling procedures can greatly affect contamination classes below NAS 6. To avoid errors in sampling, conduct particle counting on 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.
Mobile laboratory services also can perform the measurements for customers.
SM00081-A
11
12
SM00081-A
Drawings
July 1, 2005
8-2
AR3200
SM00053, Rev D
Chapter 8 Drawings
Drawings by assembly ...................................................................................... 7-5 Drawings in numerical order ............................................................................. 7-7
8-3
July 1, 2005
8-4
AR3200
SM00053, Rev C
C ha p t er 8 Drawings
This chapter provides a list of drawings included in this manual. The drawings are arranged both by assembly and numerically.
Drawings by assembly
Assembly AR3200 Electrical Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107411 AR3200 Automated Iron Roughneck Assembly. . . . . . . . . . . . . . . 107413 Torque Wrench Jaw Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86711 SSW-50 Spinning Wrench Assembly . . . . . . . . . . . . . . . . . . . . . . . . 86990 TW-102 Torque Wrench Assembly . . . . . . . . . . . . . . . . . . . . . . . . . 89650 Foot Frame Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71446 IBOP Installation Kit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87864 Std. Tilt Lever Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87005 Reverse Tilt Lever Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87816 Hydraulic Subassembly Valve Manifold Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86700 Inlet Manifold Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86957
Drawings
8-5
July 1, 2005
Hydraulic Schematic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86965 Hydraulic Motor Arm Clamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87047 Manual Control Panel (EEx) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107535 Manual Control Panel (UL). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107729 Installation AR3200 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107808 AR3200 Electrical Installation Kit . . . . . . . . . . . . . . . . . . . . . . . . . 107412 AR3200 Interconnect Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107499 AR3200 Remote Controller (PLC) Assembly. . . . . . . . . . . . . . . . . . 99435 Rig Floor-59" Outside Rail Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86714 Hinged Cog Drive Adapter Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . 86911 Miscellaneous AR3200 Derrick J-Box Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . 107154 AR3200 Derrick Plate Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . 107151 AR3200 Electrical Service Loop. . . . . . . . . . . . . . . . . . . . . . . . . . . 108592 AR3200 Hydraulic Service Loop . . . . . . . . . . . . . . . . . . . . . . . . . . 108593 AR3200 I.S. Electrical Service Loop . . . . . . . . . . . . . . . . . . . . . . . 108594 AR3200 Flowcharts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108102 AR3200 Tool J-Box Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107462 AR3200 Solenoid Driver. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99871 AR3200 Switch Replacements . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109835 Instruction Plate, Jaw Sizing Data. . . . . . . . . . . . . . . . . . . . . . . . . . . 87519 Linear Position Slave Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96975 Spares Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108941 Spin Out Sensor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93788
8-6
AR3200
SM00053, Rev D
Drawings in numerical order

Foot Frame Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71446 Valve Manifold Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86700 Torque Wrench Jaw Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86711 Rig Floor-59" Outside Rail Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86714 Hinged Cog Drive Adapter Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . 86911 Inlet Manifold Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86957 Hydraulic Schematic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86965 SSW-50 Spinning Wrench Assembly . . . . . . . . . . . . . . . . . . . . . . . . 86990 Std. Tilt Lever Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87005 Hydraulic Motor Arm Clamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87047 Instruction Plate, Jaw Sizing Data . . . . . . . . . . . . . . . . . . . . . . . . . . 87519 Reverse Tilt Lever Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87816 IBOP Installation Kit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87864 TW-102 Torque Wrench Assembly . . . . . . . . . . . . . . . . . . . . . . . . . 89650 Spin Out Sensor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93788 Linear Position Slave Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96975 AR3200 Remote Controller (PLC) Assembly . . . . . . . . . . . . . . . . . 99435 AR3200 Solenoid Driver. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99871 AR3200 Derrick Plate Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . 107151 AR3200 Derrick J-Box Assembly . . . . . . . . . . . . . . . . . . . . . . . . . 107154 AR3200 Electrical Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107411 AR3200 Electrical Installation Kit . . . . . . . . . . . . . . . . . . . . . . . . . 107412 AR3200 Automated Iron Roughneck Assembly. . . . . . . . . . . . . . . 107413 AR3200 Tool J-Box Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107462 AR3200 Interconnect Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107499 Manual Control Panel (EEx). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107535 Manual Control Panel (UL) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107729 AR3200 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107808 AR3200 Flowcharts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108102 AR3200 Electrical Service Loop . . . . . . . . . . . . . . . . . . . . . . . . . . 108592 AR3200 Hydraulic Service Loop . . . . . . . . . . . . . . . . . . . . . . . . . . 108593 AR3200 I.S. Electrical Service Loop . . . . . . . . . . . . . . . . . . . . . . . 108594
SM00053, Rev D
Drawings
8-7
July 1, 2005
Spares Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108941 AR3200 Switch Replacements . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109835
8-8
AR3200
SM00053, Rev D

SM00053 D

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Automated Iron Roughneck Service Manual

Varco Service Centers

AR3200 Automated Iron Roughneck

MANUAL CONTROL STATION

AUTOMATIC CONTROL STATION

TOOL J-BOX CONTROLS

Major component description

Major component description

To Remote Controller Mounting Plate Derrick Plate

INTRINSICALLY SAFE CIRCUITS

Service Loop Bracket

Drill Floor C L Well

Figure 1- 1. Typical AR3200 General arrangement

Major component description

SSW-50 Spinning Wrench Assembly

Tool Electrical J-Box

Carriage Lift Cylinders (2)

Clamp Rollers (2)

Pressure Rollers (2)

Hydraulic Roller Drives (4)

Upper Torque Wrench Jaw

TW-102 Torque Wrench Assembly Control Station

Lower Torque Wrench Jaw

Motor Driven Foot (2)

Hydraulic Horizontal Drives (2)

Figure 1-2. Typical AR3200 Automated Iron Roughneck

DRIVE FOOT ASSEMBLIES

Major component description

Gearbox Cover Gearbox Foot Access Cover Cogged Drive Roller

Hydraulic Motor Motor Access Cover

Figure 1-3. Typical AR3200 drive foot

TW-102 Hydraulic Torque Wrench assembly

SOFT CLAMP FEATURE

Major component description

Upper Jaw Clamp Cylinder

Upper Jaw Torque Cylinder

Tong Dies and Retainer

Figure 1-4. Hydraulic Torque Wrench Assembly

SSW-50 Spinning Wrench assembly

Table 1-1. Spinning Wrench operational modes

Major component description

Pressure Rollers (2)

Clamp Cylinder (2)

Clamping Rollers (2)

Hydraulic Motors (4)

Figure 1-5. SSW-50 Spinning Wrench assembly

Electrical control system

Major component description

Service Loops (3)

Voltage Regulator Solenoid Operated DCV

PLC Assembly Remote Monitor Station

Sensors Optional Driller's Control

Figure 1-6. Typical AR3200 electrical control system

Purge Loss of Pressure Switch

Voltage Regulator Solenoid Operated DCV

PLC Assembly Remote Monitor Station

Service Loops (3)

Major component description

PLC ASSEMBLY AND ENCLOSURE

Major component description

24V Power Supply

PLC Box Assy

Learn Mode Switch