TM 120 Commissioning Manual - Rev.01 REVISADO

Commissioning Manual
Rev.01
TM120 / TM80
Commissioning Instruction Manual
Canrig Drilling
Technologies Canada 10/10/2006
Rev.01
Table of Contents
1. PLC Setup
1.1. PLC Program Installation (CX Programmer)

1.2. PLC Memory Installation
1.3. NS Screen Program Installation (NS Designer)
1.4. NS Screen Set UP
2. IO Check and Electrical Check
2.1. Drillers Console IO

2.2. Radio IO
2.3. Analog Input
2.4. Output Function Test
3. Hydraulic System Startup
3.1. Pump
3.1.1 Compensator
3.1.2 Differential
3.1.3 4VP01 Pressure Control
3.1.4 Torque Limiter
3.2 Tong Assembly
3.3 Spinner Assembly
3.4 Arm Assembly
4. Hydraulic Systems Settings
4.1. Horizontal Counter Balance Valve

4.2. Vertical Counter Balance Valve
4.3. Rotate Counter Balance Valve
4.4. Spinner Clamp Pressure
4.5. Spinner Motor Pressure
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Rev.01
5. Calibration
5.1. Pump
5.2. Pressure Transducers
5.3. Hawe Cards (Flow)
5.4. Hawe Cards (Pressure)
6. Options and Parameter Setup
6.1 General
6.2 Vertical / Rotate
6.3 Horizontal Slide
6.4 Clamps
6.5 Torque Cylinder
6.6 Spinner
7. Functional Testing
7.1. Spinner Test
7.2. Torque Test
7.3. Interlock / ErrorTest
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Section 1 Rev.01
1. PLC Setup
1.1 PLC Program Installation
With the laptop connected to the PLC, open CX

Programmer. Once the CX is open, select the File
menu and click the Open command. This will launch
the Open dialog window. This window will allow you
to navigate to where the wrench program is saved.
For the Service Department, this is the “S drive” root

directory in a folder called PLC Programs.
For the Commissioning Department, this is located on

the “Commissioning” drive in a folder called PLC
Programs.
Once you have located the correct file name, select it in

the window and click Open. This will open the PLC
program in CX Programmer.
You can also use Windows Explorer to open the PLC

program. Locate the file using Windows Explorer and double click the file with the .cxp extension.
This will open the CX Programmer software and load the program project file.
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Technologies Canada Section 1 - Page 1 10/10/2006
Section 1 Rev.01
Once you have the project file open in CX Programmer, you can connect to the PLC. This is done by
clicking the PLC drop down menu and selecting Work Online.
You can also use the shortcut: Ctrl + W.
The message below will appear. Click Yes

to connect to the PLC. If there are any
errors while connecting, refer to the
Appendix for a trouble shooting guide or
additional information.
When the computer connects to the PLC, the

working area of the project screen will turn
gray and all the active rungs will turn green. If your
screen is not gray, then the attempt to connect to the
PLC has failed. Refer to the trouble shooting guide for
more information.
With the computer connected, you can now download

the program to the PLC. Use either the PLC dropdown
menu to transfer or the Transfer icon at the top of the
screen.
Be sure to Transfer to PLC or your local copy of the

PLC program will be corrupt and need to be copied
from the network again. After you have selected
Transfer to PLC a window will appear asking you
what you want to transfer. The first time that you
transfer the program, you must select the boxes as they
appear here. If you do not select “Settings” and “IO
Table” the PLC might not connect to the NS screen
after the program is installed.
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Section 1 Rev.01
Select all the corresponding option boxes and click OK. The program will begin the transfer process.
This may take up to a few minutes. Depending on what state the PLC was in before the transfer
attempt, it may warn you that you are about to
change the state of the PLC and to make sure
that all connected devices are stopped. In this
case, check to make sure nothing is running,
as it will stop once you hit Yes. The transfer
is now started and this box will show the
progress as the files are written to the PLC.
When the transfer is finished, this box will
notify you that it has successfully completed
the transfer and ask you if you would like to
put the PLC to run mode. Click Yes and the
program will launch.
1.2 PLC Memory Install
The PLC Memory Installs the initial

settings for the parameters of the
wrench. You can view these settings
and make changes as needed once the
NS software installation is complete.
The memory for the program also
contains all the scaling information for
the Transducers and Position Sensors.
With out this memory all visible areas of
the screen will read “0”.
Double click on the memory section of

the program on the left side in the
navigation plan. You will see a new
window open with all the memory
locations in it.
Use the File dropdown menu and select Open File. Use the navigation window to locate the “Generic
Wrench Memory” file and select Open. Load all the settings from that memory file to the open
window.
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Section 1 Rev.01
Open the Online dropdown menu and select

Transfer to PLC to start the transfer.
The “Transfer to PLC” window will appear.

Select D and under the Transfer Range area
select All then click Transfer To PLC. This
will take approximately 1-2 minutes to transfer
all the memory in this file.
If there are any errors while transferring, the CX

Programmer will let you know. Once the transfer is
complete you will be notified.
Depending on what state the PLC is in when you open the memory, you may need to change it to
allow a memory transfer. To change the state of the PLC, right-click on the PLC name at the top
of the navigation plan in CX Programmer and select “Program” mode from the operating mode
list. You can now go back to the memory transfer and complete the upload.
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Section 1 Rev.01
1.3 NS Screen Program Installation (NS Designer)
After installing the PLC program and memory, the NS

Designer screen will appear. The Omron NS series
screens use NS Designer to design and communicate
with the screen. To download the screen project file,
you first need to open NS Designer 6.2. From the File
drop down menu, choose Open Project. After the
project has opened, the Open Screen window will
appear. Select “Boot Screen” and click ok. This will
open the main Boot Screen for editing. Be sure not to
click on the screen and move the object around, as they
may overlap and make your screen program unusable.
If you wish to look at different parts of the screen
project, you can use the Open Screen command from
the File drop down menu to make the open screen box
re-appear. Then simply select the screen that you
would like to view and click OK.
Once you are done viewing the screen,

you can close it without closing the
complete project. From the File
dropdown menu, click Close Screen
or click the lower “x” in the upper
right corner.
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Section 1 Rev.01
The next step is to transfer the screen project data to the NS12 screen. From the File menu, select
“Transfer Data”. This will
bring up a window to connect
to the NS Screen. Press the
Connect button and check to
make sure the screen displays
are connected. If you have
trouble connecting to the NS
Screen, check that you are
using a CBL210 Omron cable
and that the correct port is
displayed in the “Comms
Method” area. To change the
Comm. Port, click Comms
Method and select the desired
Comm. Port.
After the computer has

connected to the NS Screen,
you will see the project files on
the left side of the window and
the right should be blank.
Click the Select All box then
click the D arrow in the center.
This will now download all the
project data from the computer
to the screen. Once this
download is complete, you will be prompted to reboot the NS screen. This is required anytime a
system setting or screen change is made. Once the boot up sequence is complete, the boot screen
should appear.
If the Boot Screen does NOT appear, check the communication settings for the screen. To check these
settings, press any two corners of the screen simultaneously. You can now look at all the system
settings in the NS Hardware. Press the communications tab at the top. Check that the Comm. Port A
is set to NT Link 1:N, then select “Details”, and set the speed to “High”.
If you are still experiencing communication problems between the screen and the PLC, check the
cable pin out and that the settings in the CPU are correct. If you have followed the instructions from
the start, all the CPU settings should have been transferred in the PLC Program Installation.
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Section 2 Rev.01
2. IO Check and Electrical Check

Note: For all of the following steps, record all the results on the corresponding sections of the
Commissioning Check List located in the Appendix of this manual.
Before starting the IO Check, be sure that the Main

Hydraulic Pump Motor Breaker is in the “Off” position
as well as the Heater Breaker.
2.1 Driller’s Console IO
Using the PLC Diagnostic Screen, you can operate all the
inputs from the Driller’s Console to check wiring and
cable pin out to the PLC enclosure. This screen will
allow you to confirm that the labeled output on the
console corresponds with the input on the PLC. This can
be done for all the inputs on the Driller’s Console, Radio
and HPU. Use the devices and check each output before
starting the HPU.
2.2 Radio IO
As with the Driller’s Console, this screen will allow you to confirm that the labeled output on the radio
or wired remote corresponds with the input on the PLC. This can be done for all the inputs on the
radio. Use the devices and check each output before starting the HPU.
2.3 Analog Input
All of the analog inputs for the system are displayed on the PLC Diagnostic Input screen. Refer to this
screen for the next steps for checking the analog inputs.
All analog inputs when connected should read between 3.98 at 4.05 mA and the low end of the scale.
If the numbers displayed are less than 3.98, the analog signal coming back to the PLC may be
interrupted. To check this, click the “PLC Output” button at the lower right corner of the screen and
look at the analog card error box. Channel 1 = 2001, Channel 2 = 2002….etc. If the light on the
screen is red, then there is no loop between the PLC and the Analog Device.
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Section 2 Rev.01
2001 Spinner Flow Joystick
Actuate the joystick and check that the input goes from 0-10 VDC in both directions. While actuating
the joystick, a digital input light for “Spin In” and “Spin Out” should be displayed. If these inputs are
not displayed, there is a problem in the Radio or Wired Remote Harness. Have the Electrical
Department check the wiring and re-test.
2003 Torque Position
Disconnect the Torque Cylinder

Position Sensor from the bottom
of the Torque Cylinder and move
it from the retracted position to
the extended position. The
analog input should move from
4.00 mA to 20 mA. If there is no
change, check that the memory
has been installed correctly and
the wiring is correct.
2004 Horizontal Position
As with the Torque Cylinder,

disconnect the Transducer from
the mount and move it from the
retracted position to the extended
position. The input should change from 4 mA to 20 mA.
2005 Make / Spin In Pressure, 2006 Break Pressure, System Pressure
Before starting the HPU and adding trapped pressure to the Transducer Circuit, the Pressure
Transducers can be zeroed. With the PLC input screen visible, use a small flat blade screwdriver in
the “Zero Adjust” port on the side of the Transducer. Turn the screw in to increase the milliamps,
and out to decrease. Adjust the analog inputs for all Transducers to 4.00 – 4.02. This will zero the
Pressure Transducers before adding oil to the systems and trapping air/oil in the Transducer Lines.
Note: If you have already started the HPU and have readings more than a few PSI on the
screen, then you must bleed the Transducer Lines to eliminate any trapped pressure before
zeroing the Transducers.
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Section 2 Rev.01
2.4 PLC Output Test
Note: This test is for a unit that has an attached Power Pack. For units that have no Power
Pack, this test can be skipped as the unit will be run from the Test Pack in the shop. Alternately,
you can still perform the test if the cable is connected to the shop Power Pack.
Once you have checked that all the inputs are correct, the PLC outputs can be tested. The only outputs
you can test with the HPU off are the Motor Start, Cooler Fan Start and the Heater Start. Check that
the Main Motor Overload Breaker is in the “Off” position and all the ESD buttons are off, then press
“Motor Start.” Check that the Main Motor Contactor pulls in and latches. Next, pressure the “Cooler
Fan Start” button in the Device Test Screen and ensure the Cooler Fan starts and rotates the right
direction. Finally press the “Heater Start” button and ensure the Heater Contactor pulls in.
Once you have confirmed that all the inputs and outputs are correctly wired, check the rotation on the
Main Power Pack Motor.
Remove the cover to view the coupling.

Check that the tank is full of hydraulic oil and the pump compensator is completely screwed
out.
Check that the suction valve for the hydraulic pump is open.
Set the pump compensator to lowest setting.
Press the “Motor Start” button momentarily and view the rotation of the pump. The rotation
indicator for the pump is located on the rear of the pump. If the rotation is correct, the test is finished.
If it is incorrect, consult the Electrical Department to correct the rotation.
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Section 3 Rev.01
3. Hydraulic System Startup
3.1 Pump
After completing all the IO testing, the HPU Startup should be addressed. If the wrench system that is
being commissioned does not include an HPU, the following “Pump 3.1” section should be performed
on the rig at the time of install. The remaining sections 3.2 – 3.4 should be completed to ensure proper
direction of movement and function before attempting to set any of the Hydraulic or Electrical
parameters.
After confirming the Rotation, Suction Valve and Compensator settings in the previous section, we
can start the HPU.
Disconnect the 4VP01 line and cap it.

Check that the pressure and return lines are connected correctly
(Incorrect connection of the P&T line will result in valve failure and spring cap
replacement.)
Ensure the Compensator Screw is at the Minimum setting.
Press the “Motor Start” button and check for leaks.
Set the Compensator to 2500 psi and
re-check for leaks. Parker P2 - 145 Piston Pump
Torque Limiter
Max Volume
Stop Adjustment
Differential
3.1.1 Compensator Adjustment
Compensator
Adjustment
Ensure that the 4VP01 line is disconnected
and the pump is set to 2500.
Set the Torque Limiter on the Pump to

the Maximum setting.
Set the Compensator to 5100 - 5150
psi and lock down.
Once the Compensator is set, shut down the

HPU and reconnect the 4VP01 line.
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Section 3 Rev.01
3.1.2 Differential Pressure

Using the pressure measurement from the Device Test Screen, restart the HPU and cycle the lower or
upper clamps rapidly to release the pressure. Turn the Differential Pressure out until it reads 250-275
psi. You may need to recycle the clamps rapidly to release the pressure. Readjust the Differential
until 250-275 psi is reached. It may be easier to lower the Differential until the pressure is lower than
desired and then readjust upward until 250 psi.
3.1.3 4VP01 Pressure Control Valve
To set the 4VP01 Valve, use the “Pump Test” button in the Device Test Screen and set the Pump
Output to 2000. From the diagram, you can see the Adjustment Screw and the Bleed Screw at
opposite ends of the Valve.
Before you start to set the Max
Pressure, use the Bleed Screw
Max Pressure Adjust
to release any air that is trapped (Caution when adjusting see Note)
behind the Spool. If this air is
not released, the Pump will
“hunt” while trying to adjust
the pressure. Denison 4VP01 Pressure Control Valve
Start the Power Pack and press

“Pump Test.” Loosen the
Bleed Screw (not too much or
you will wear it). Let the oil
bleed for a few seconds and
then tighten. Repeat this step 3
or 4 times to ensure all the air
is released.
Spool Air Bleed Screw
Next, set the Pump to 4000 psi (Open on initial Startup)
and hold Reset while pressing
the “Pump Test” button. By pressing Reset while using the Pump Test button, the PLC sets the Max
Analog Out (4000 points) to the card.
This in turn sets the PR Driver Card to 75.0 (750mA) Max Output. With one hand on the Reset,
stretch your arm to the 4VP01 Valve and adjust the screw on the Valve until the pressure reads 5000 –
5075 psi. Unless you have 40ft arms you may need some help with this step. Once the pressure is set
at 5000-5075, lock the nut then re-check the settings by turning the “Pump Test” button “On” and
“Off.”
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Section 3 Rev.01
3.1.4 Torque Limiter Adjustment
With the Compensator, Differential and 4VP01 adjusted, the Torque Limiter setup is the last step.
Because all of the settings affect one another, we set the Torque Limiter to “High” to eliminate it from
changing all the other settings.
Hawe Tong Valve Inlet Section
To set the Torque Limiter, you will need a

current clip on one of the Motor Leads to view
the current draw to the motor.
Loosen the cap on the Main Pressure Relief

Main System
and set the relief to “Minimum.” With the Relief
Amp Clamp connected to the Motor Line, start
the HPU. Set the Pump Test pressure to 4000
and press the “Pump Test” button. Slowly
adjust the Main System Relief until the amps
read 95% of name plate motor amperage. For
a 480 VAC 50 HP motor, this value is 57-59
amps.
With the pump/motor combination drawing 57

amps, lower the Torque Limiter Adjustment
until the amps drop below 57. Slowly increase
the Torque Limiter setting until the amps
slowly increase back to 57 amps and then
tighten the Lock Nut.
The Torque Limiter is now set to 57 amps. To

test the Torque Limiter, lower the Main System Relief setting to 40 amps, then slowly increase the
relief and watch the amperage draw on the motor. The meter should not go over 57-59 amps. If it
does, you must reset the Torque Limiter.
If all of the settings are correct after performing the test, turn the Main System Relief all the way in
(5200 psi) and then lock and reinstall the cap.
Note: With the Main System Relief Valve set lower than the Pressure Compensator, all pump
flow is traveling over the Relief Valve. This will create high amounts of heat in a very short
period of time. For this setting, you may need to manually turn on the Oil Cooler to limit the
amount of heat in the system.
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Section 3 Rev.01
3.2 Tong Functional Test
Use the Device Test Screen and the “Make/Break”

buttons to perform the functional testing for the tongs
section. When pressing the “Break Out Test” button,
the Torque Cylinder should extend and the tong should
rotate.
Next, press the “Make up Test” button and the tong

should rotate back to the original position.
Note: Do not use the Horizontal Transducer Override

when performing this test. If the Horizontal Override
is on, the tong will automatically rotate to the original
position.
After confirming that the rotation direction for the tong is

correct, start the Pressure Test. This test is not calibrating
the pressure, it is only to determine that the correct
Pressure Control Valve is on when the corresponding
Flow Valve is on.
Enter 2500 psi in the Pump Test window and 1500 in the
Make/Break Press test window. Press Pump Test, Make Up Test, and Make Break Press Test. The
“Make Spin In” pressure should be reading 1500 -2500 psi. If there is no pressure reading, then check
the break out by switching the “Make Up” test to “Break Out” test.
If there is still no pressure displayed in the corresponding box, check the wiring to the Pressure
Control Coil on the Torque Cylinder Valve. If wires 2 & 3 are swapped, the coil tries to control the
pressure in the return side of the valve. Swap wires 2 & 3 and retest. If the retest fails, there may be a
problem with the internal pressure control Darts below the Pressure Control Coil. Refer to the Hawe
Valve Disassembly Manual for instructions for valve disassembly.
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Section 3 Rev.01
3.3 Spinner Function Test
To test the Spinners, you must use the Device Test Screen and the Radio. Rotate the Spinner Clamps
in and out to confirm the correct direction of travel.
Select the Settings screen and turn on the Horizontal Transducer Override to allow the spinners to spin
in any position. Using the Radio, press the “Spin In” and confirm the direction of rotation.
For “Spin In” the rollers should be turning in the direction labeled below. Check the direction
and correct if necessary.
Spin In Roller Directions
Spin Out Roller Directions
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Section 3 Rev.01
3.4 Arm Function Test
The last functional test before starting the calibrations and final setup is the Arm Test. Using the
joystick, rotate the arm in and out. Make sure the direction of travel corresponds with the label on the
Drillers Console.
• In – towards hole center.
• Out – away from hole center.
If the directions for the Horizontal Travel are backward, check the wiring for 2012 wires 2 & 3. If the
arm does not move, check the Manual Horizontal Values in the advanced settings screen and increase
the numbers if necessary.
The second step is to test the Vertical Lift. Check the Vertical Extend and Retract pressures in the
Advanced Settings screen. These values should be approximately 2500 psi. Move the joystick up and
down and ensure the wrench travels in that direction. Again, if the function is backward check the
wiring and the plumbing.
The final step is to rotate the wrench right and left. Using the Device Test screen, or the Manual
Operation screen, press the rotate button for right. Looking from the front of the wrench, the arm
should rotate to the right; pressing the left button should rotate it left. If the wrench reacts incorrectly,
check the wiring and the plumbing.
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Section 4 Rev.01
4. Hydraulic System Settings

There are seven valves that need to be adjusted in the hydraulic circuit of the wrench. These are
Counterbalance Valves, Clamp Pressure Control and Max Motor Pressure. For these settings you will
need two 5000 psi gauges and two #4 BSP x #4 JIC adapters.
4.1 Horizontal Counterbalance valve
The first of the valves is the Horizontal

Counterbalance Valve. This valve
controls the motion of the arm when
there is no pressure signal from the
Hydraulic Valve. The Counterbalance
Valve holds the load of the cylinder
when you are not actuating the handle. If
this valve is not set correctly, the wrench
arm will drift backward unexpectedly.
There are 2 cartridges on the horizontal Increase (CCW)

Decrease (CW)
cylinder; one for extend and one for
retract. Retract is the first one that needs Extend Counterbalance
to be set in the sequence. cartrige
Retract Counterbalance
This valve setting should be reduced Cartridge
until the arm starts to drift rearward. This setting needs to be done with the arm in the retracted/home
position. Extend the arm until the cylinder shows approximately 2 inches of rod. Loosen the Lock
Nut on the correct valve and turn the adjustment in until the arm starts to move slowly.
Caution: DO NOT put your arm in between the Link Arm and the Main
Boom to adjust the valve. The arm may move without warning.
Turn the adjustment CCW (out) 1 full turn and ensure that the arm will not move in any position. If
the arm still creeps at the fully retracted position, increase the setting on the valve (CCW) ¼ turn at a
time.
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Section 4 Rev.01
To set the extend side of the Counterbalance Valve, extend the arm fully and set the pump to 1000 psi
in the Device Test screen. Increase the valve to the maximum set point (full CCW). Actuate the
Horizontal Retract Leave manually on the side of the wrench arm. The arm should not move.
Decrease the Counterbalance Valve setting until the arm moves slowly and then increase it by ½ turns.
The Extend Valve is now set.
4.2 Vertical Counterbalance Valves & Speed
The Vertical Counterbalance Valves are set in a similar way to the Horizontal Retract. Set the Vertical
Counterbalance Valves on either side of the Vertical Tubes to the maximum setting (full CCW).
Extend the wrench fully and lower and raise the vertical lift to synchronize the cylinders. This is
achieved when the cylinder bottoms on the stop and oil is allowed to pass from side to side in the Flow
Divider.
With the vertical lift fully raised, decrease the

Counterbalance Valve on one side until the wrench starts to
drop, then increase the setting (CCW) by ¾ turns. Proceed Valve Handle Position
to the next side and do the same. Once both valves are set,
operate the vertical lift through its complete stroke and
ensure the cylinders are moving in sync. If one cylinder is
lagging the other, you can increase the setting from the
Counterbalance Valve of the faster cylinder by ¼
increments to sync the movement.
The vertical speed must now be set using the spool stops.
This is an initial setting and will need to be adjusted after
the horizontal motion has been tuned. Set the spool stop so 1
4" - of Stop
that ¼” is past the handle base (see diagram). Operate the
vertical lift to check the speed, while ensuring that it is not
bottoming out the cylinders at high speed. This is all that needs to be set at this time.
4.3 Rotate Counterbalance Valve & Speed
The Rotate Counterbalance Valve is the final valve to set on the arm system. Set the valve to the
minimum setting (full CW). Extend the wrench fully and lower the vertical lift half way. Push on the
side of the Vertical Lift Tube and the wrench should rotate. Slowly increase the Counterbalance Valve
setting until you are unable to rotate the wrench by hand. Then increase that setting by ½ turn. Do the
same for the opposite direction.
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Section 4 Rev.01
Once you have set the Rotate Counterbalance Valve, set the rotate speed. Initially, set the Spool Stops
on the valve ¼” out from the handle base. With the wrench retracted to home position, use the buttons
on the Device Test screen to actuate the rotate function. When the rotate speed is set correctly, the
wrench should rotate 90 degrees in 4 seconds. Readjust the Spool Stops until this speed is achieved.
4.4 Spinner Clamp Pressure
To set the Spinner Clamp Pressure, install one gauge in either gauge port on the work section. In the
Device Test screen set the pump to 3000 psi.
SLF Valve Section
Remove the caps on the Work Port Relief
Valves using a 12 mm wrench. Actuate the A&B Port Relief Control
(Remove Cap and use a 4mm
valve to close the Spinner Clamps, and using a alen key, and 12mm wrench to adjust
4mm key, adjust the pressure to 2800 psi.
Actuate the valve to open the Spinner Clamps

and adjust the opposite Relief Valve to limit the
pressure to 500 psi.
The Spinner Clamp is now set. Turn off the

HPU, remove the gauges, and reinstall the caps.
4.5 Spinner Motor Pressure
The Spinner Motor is adjusted the same way as

the clamps. Before starting, remove the Spinner Spool Stop Screw
Motor Hoses and cap the valve and hoses.

Install the gauges in the correct work ports and start the HPU.
Using the Device Test screen, set the pump at 3500 psi. Actuate the Spinner Motor Valve by hand and
adjust the Max Pressure for each port to 3000 psi. Turn off the HPU, remove the gauges, reconnect
the hoses and install the caps.
Note: Do not cap only one motor line to set the pressure. This can back pressure the motors and
cause the Shaft Seals to leak.
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Section 5 Rev.01
5. Calibration
5.1 Pump Calibration
To calibrate the pump for the Pressure Control Valve, you must first complete all the Pump Setup
Steps in Section 3. If you have not completed these steps and calibrated the pump, you calibration will
be off once the pump settings have been complete.
Start the HPU and have the Pump Calibration

Sheet ready. This sheet is located in the
Appendix of this manual and can be printed out
before hand. Using the Device Test screen,
enter the first set point number in the pump test
box and while holding the “Reset” button on the
screen, press “Pump Test.”
By holding “Reset” as outlined earlier, the PLC

moves that number into the Analog Output.
Once the pressure has stabilized, record the
pressure in the corresponding box on the
Calibration Sheet. Repeat these steps for every
setting on the sheet. Once you have finished the
sheet, stop the HPU and open the Curve Expert
program. Enter the pressures in column X and
the set points in column Y. You can see a

preview of what the curve looks like. You
may have to remove a few data sets from
the start of the curve to get a linear line.
Once you have finished filling out the

table, press the “Linear Fit” icon at the
top of the screen. This will give you a
large view of the curve. If you find this
data satisfactory, press the “Info” button
to get the numbers to enter into the PLC.
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Section 5 Rev.01
This is the window that will give you the calibration information. A=Offset, and B=Scale are the 2
numbers that you are looking for. Remember that
the number that is entered into the PLC for the
scale is multiplied by 1000. For example, in the
window to the left B=0.733. The number that you
want to enter into the PLC should be 733.
The offset number should be entered how it is

displayed here. There is no need to enter 471, just
round the value to the nearest 10, ie. 470. These
numbers are entered in the Advanced Settings
screen on the General tab.
After entering the numbers, test the calibration

using the Device Test screen. Enter the numbers
from 1000 to 5000 in 1000 psi increments. The
pump should never be below the requested number.
If the output is low on the bottom end and low on the top end, adjust the offset higher.
If the output is high on the low end and low on the high end, increase the scale.
The output number can be higher than what was requested. Generally, the limit is 150-200 psi above
what was requested. If the numbers are any higher than this, a new pump curve should be done.
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Section 5 Rev.01
5.2 Pressure Transducers
In Section 2.3 the analog signals from all three pressure transducers were zeroed. Check that these
pressure transducers are reading the correct values. Note that running the pump traps pressure in the
transducer lines; so these values are not going to be zero.
To recalibrate the transducers after the pump has been run, see Section 2.3.
5.3 Hawe Card Flow Calibration
To calibrate the Hawe cards, you must have first set all the counterbalance valves for the horizontal
extend and retract. The pump differential must be set at 250 psi as outlined in section 3.1.2. Using the
PLC Output Diagnostic Screen, you can enter raw
numbers from 0 – 2000 positive and negative to
make the valve move.
Note: When entering values into the

corresponding box, the function may or may
not move with the values entered. It depends
on the minimum pressure required to move
that selected function. When using the
Calibrate section of the screen, the PLC does
not tell the pump to produce any pressure, so
with the standby pressure set at 250 psi, the
function may or may not move.
Before starting
the calibration,
install a meter
(set to Amps) into the test ports on the front of the Hawe card. This
meter is for reference only; the values that are displayed on the
meter should not be used to calibrate the card to the valve. The
object of the calibration is to set the card and the valve movement
in a linear line. This is the final setting of the valve.
Setting Qmin
Start the calibration with the horizontal flow at 2012. Using the
Calibrate box, enter 80 in the value window and press “Calibrate”.
The indicator light for the channel that is currently energized is lit.
Using a small flat blade screwdriver, adjust the Q Minimum on the
card until the valve handle moves the correct amount.
Canrig Drilling
Section 5 Rev.01
Using the Qmin setting, increase the current until

the handle moves this amount. The meter should
read between 200 – 250 mA. If the handle does not
move until the meter is at 300 - 350, the spool in Valve Handle Position at Initial Movement
this section is sticking. (Adjust Qmin until Handle Moves this Amount)
Remove this spool and check for burrs or marks

from contact with the body. Polish the marked area 1
16" - 18" Movment
using 1000 grit sand paper and reinstall.
Once you have set the Qmin to the desired current,

record the value in the settings sheet attached in the
Appendix of this manual.
Setting Qmax
The next step is to set the Qmax using the

maximum volume stop. Ensure that the volume
stops are not protruding from the bottom of the
Handle Mount before setting the Qmax. Set the
calibrate value to 2000 and press the “Calibrate” button.
Using the Qmax setting, adjust the value
until the value just contacts the stop.
This value should be between 350-500
mA. The value on the meter is only for
Valve Handle Position at Initial Movement
(Adjust Qmax until Handle Moves this Amount)
reference, the position of the handle is
the critical setting.
Repeat all these steps for the Channel 1

“A” direction by entering a negative
number into the calibration value. Be
sure to only adjust the “A” pots, if you
adjust the “B” pot you will need to
recalibrate the “B” section of the valve.
0 - Clearence Between
Stop and Handle
Canrig Drilling
Section 5 Rev.01
Setting Dither
After setting the Qmin and Qmax, we can use the meter to set the Dither. Enter 80 into the calibrate
value, and set your meter to AC milliamps. Adjust the Dither until the meter reads 30 mA. This is
now set and can be checked by placing your hand on the valve handle. You should feel a distinct
vibration of the handle back and forth.
Setting Manual Ramps
To set the manual ramps on the card, change the manual move settings in the advanced screen to 60-
70%. Adjust the ramp pots on the card to Max. Run the horizontal slide back and forth to see that the
ramps are working. Reduce the ramp settings until the wrench stops moving within 1-4 inches, once
you have removed your hand from the control. Do the same from ramp up.
Repeat all these steps for all of the cards for each function. Do not use this calibration process for the
torque pressure control. Record all of the Qmin and Qmax for every card in the commissioning check
sheet at the back of this manual.
5.4 Hawe Card Pressure Calibration
To set the pressure control card for the Toque cylinder, use the Device Test screen and a meter in the
test ports on the Hawe card. Enter 250 psi in the test pressure box. With the meter connected, press
the “Make Test” and the “Make/Break Pressure” test buttons. Set the Qmin for the channel that is
lit to the absolute minimum setting by turning the post CCW until the meter does not change.
Set the pump test pressure to 4500 psi and press the pump test button. Increase the Make/Break Test
Pressure to 4000 and Adjust the Qmax pot until 4000 or slightly above is achieved. This is as close to
the final setting. You must now enter 500 – 5000 in the Make/Break pressure Test in 1000 psi
increments and adjust the pot until the values are close to all the way up the scale. Repeat the same
process for the Break Pressure by changing the Make Test Button to Break Test.
This may take some time as every valve is slightly different. Use your judgment; if your setting is
high at the bottom but correct at the top, adjust the min. Remember that this is a Zero and Span card,
so every adjustment at the low end affects the high end and vise versa. If you have adjusted either low
or high, check the complete scale before recording your values in the table.
Canrig Drilling
Section 6 Rev.01
6. Options and Parameters

Using the Advanced Settings in the screen, you can tune the wrench for fast and smooth operation, as
well as set all the options that are included in each wrench. For example, if the wrench is not shipped
with a Power Pack, you can remove the Motor Start function and all of the inputs that are associated
with the Tank.
The Memory File that was initially installed at the start of the setup procedure has all of these settings
located in the Advanced Settings screen. This loads all of the settings from a generic file, but any one
of these settings may need to be altered to make each wrench run consistently.
Below are screen shots of each tab in the Advanced Screens with data that was collected from an
install on a rig (Rowan-Hank Boswell). These setting were altered from the file that was loaded to
smooth the operation of the wrench.
6.1 General
The General Setting Screen is where most of the HPU settings are located, as well as any Global
Timers that are used in various places in the system. You can also select the options that are on this
particular wrench. This should be done before tuning any of the other parameters. This also may
need to be
completed
before the
functional
testing in
Section 3 to
override any
errors associated
with the HPU on
a non-HPU
wrench.
Canrig Drilling
Section 6 Rev.01
6.2 Vertical / Rotate Settings
The Vertical/Rotate Settings screen is for setting the pressures to extend and retract. A timer for the
proximity and a position for the vertical clear.
The Vertical Clear Timer allows you to set how far the vertical lift retracts after the clear proximity
turns on. This timer does not need to change on an arm type wrench - but on a carriage unit, this can
be used to lower the wrench farther past the flag for clearance with the Torque Tube.
The Vertical Clear position is used to block the vertical motion until the wrench is far enough forward
not to collide with the floor or the derrick. This value should be set the same as the Trip Position.
Canrig Drilling
Section 6 Rev.01
6.3 Horizontal Slide Settings

The Horizontal Slide section is used to tune the motion of the wrench in Automatic Mode as well as
Manual Mode. Most of the descriptions for the fields are well labeled and self-explanatory. On the
top left section of the screen, you can enter all the position information required to position the
wrench. Below that are the “Extend” and “Retract” settings for the acceleration and deceleration of
the wrench as it moves to and from hole center.
On the right side of the screen, you will find all the manual settings and error timers, as well as the
Extend and Retract pressures.
Note: Retract Pressure and Vertical Retract Pressure should be set very close to the same.
When the wrench is moving in Auto Mode, the pressure that is produced by the pump is driven
from the retract pressure of the Horizontal Cylinder. If you require more pressure than that to
lift the Vertical Cylinder, you must increase this setting to the Vertical Retract Pressure.
Canrig Drilling
Section 6 Rev.01
6.4 Clamp Settings
The Clamp Setting screen is also very basic. The labels on the field should tell you what these settings
change.
Clamp Close PCheck - Timer runs for the set time after the 1500 psi is reached keeping the
pump at 1500 psi until the timer expires.
Clamp Close Depressure Time -Timer runs for after the pressure check is compete for set
time with the pump at 250 psi.
Auto Clamp Open – Turns the clamps on after make or break is complete to extend the
clamps for the set time before retracting.
Auto Clamp Full Open - Runs the clamps for the set time once the wrench is finished
retracting.
Clamp Extend Pressure – Sets clamp extend pressure.
Clamp Extend Pressure Offset – Set the lower side of the window for the Pcheck.
Clamp Pressure Scale – Used in setting the clamp pressure while making or breaking, should
be set from 75 – 85.
Clamp Pressure Offset – Add this amount of pressure to the make pressure to set pump
pressure output should be set to 1800-2200 psi.
Canrig Drilling
Section 6 Rev.01
6.5 Torque Settings
The Torque Settings screen is the most complicated. Most of these setting will not need to be
adjusted. If you require a description of all the functions, it is attached in the appendix of this manual.
The main focus of this page should be on the speeds. These speeds may need to be increased or
decreased to achieve the correct torque output. This can only be done while the final testing is
completed. If a torque value is overshooting, you will need to slow the speed down to allow the PLC
time to control the torque.
These speeds should also be set that when the tong rotates the cylinder does not bottom out. If the
cylinder bottoms out while making a connection, the toque valve reading is incorrect. The same is true
for breakout.
Canrig Drilling
Section 6 Rev.01
6.6 Spinner Settings
The Spinner Clamps work the same as the Main Clamps. The Times and Pressure settings are labeled
the same. The Spinner Flows are a little different than anything that we have set so far. There are 3
different flows that you can set, one for “Spin In” and “Spin Out”, and the last for Remote. The first
2 are used to set the spinner speed while running in Auto Mode or Manual Mode from the screen. The
last Spinner Flow is used to limit the maximum speed when running from the Radio.
Canrig Drilling

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Commissioning Manual

Commissioning Instruction Manual

1.1. PLC Program Installation (CX Programmer)

2. IO Check and Electrical Check

2.1. Drillers Console IO

3. Hydraulic System Startup

4. Hydraulic Systems Settings

4.1. Horizontal Counter Balance Valve

6. Options and Parameter Setup

1.1 PLC Program Installation

With the laptop connected to the PLC, open CX

For the Service Department, this is the “S drive” root

For the Commissioning Department, this is located on

Once you have located the correct file name, select it in

You can also use Windows Explorer to open the PLC

The message below will appear. Click Yes

When the computer connects to the PLC, the

With the computer connected, you can now download

Be sure to Transfer to PLC or your local copy of the

1.2 PLC Memory Install

The PLC Memory Installs the initial

Double click on the memory section of

Open the Online dropdown menu and select

The “Transfer to PLC” window will appear.

If there are any errors while transferring, the CX

1.3 NS Screen Program Installation (NS Designer)

After installing the PLC program and memory, the NS

Once you are done viewing the screen,

After the computer has

2. IO Check and Electrical Check

Before starting the IO Check, be sure that the Main

2.1 Driller’s Console IO

2.3 Analog Input

 2001 Spinner Flow Joystick

 2003 Torque Position

Disconnect the Torque Cylinder

 2004 Horizontal Position

As with the Torque Cylinder,

 2005 Make / Spin In Pressure, 2006 Break Pressure, System Pressure

2.4 PLC Output Test

 Remove the cover to view the coupling.

3. Hydraulic System Startup

 Disconnect the 4VP01 line and cap it.

 Set the Torque Limiter on the Pump to

Once the Compensator is set, shut down the

3.1.2 Differential Pressure

3.1.3 4VP01 Pressure Control Valve

Start the Power Pack and press

3.1.4 Torque Limiter Adjustment

To set the Torque Limiter, you will need a

Loosen the cap on the Main Pressure Relief

With the pump/motor combination drawing 57

The Torque Limiter is now set to 57 amps. To

3.2 Tong Functional Test

Use the Device Test Screen and the “Make/Break”

Next, press the “Make up Test” button and the tong

Note: Do not use the Horizontal Transducer Override

After confirming that the rotation direction for the tong is

3.3 Spinner Function Test

Spin Out Roller Directions

3.4 Arm Function Test

4. Hydraulic System Settings

4.1 Horizontal Counterbalance valve

The first of the valves is the Horizontal

2001 Spinner Flow Joystick

2003 Torque Position

2004 Horizontal Position

2005 Make / Spin In Pressure, 2006 Break Pressure, System Pressure

Remove the cover to view the coupling.

Disconnect the 4VP01 line and cap it.

Set the Torque Limiter on the Pump to