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Part Number 27-60

Revision B

INSTALLATION, OPERATION, AND MAINTENANCE


WITH
ILLUSTRATED PARTS BREAKDOWN

RateMaster System
P/N 230256-001
THRU
P/N 230256-006

Manufacturers of Precision Instruments

Printed in U.S.A. March 15, 1985


INSTRUCTION MANUAL 27-60
LIST OF EFFECTIVE PAGES

Total number of pages in this publication is 66 consisting of the following:

PAGE ISSUE
NO. DATE

Cover ................... .15March 1984


A ....................... 15 March 1984
ithruv ................... .15March1984
viBlank .................. .15March1984
l-l thru l-7 ................ 15March 1984
l-8Blank ................. .15March 1984
2-l thru2-14 .............. .15March 1984
3-l and3-2 ............... .15March1984
4-l and 4-2 ................ 15 March 1984
5-l thru 5-3 ................ 15 March 1984
5-4Blank ................. .15March1984
6-l thru6-3 ............... .15March1984
7-O thru 7-l 8 ............... 15 March 1984
8-l thru8-3 ............... .15March1984
8-4Blank ................. .15March1984
9-l ..................... .15March1984
9-2Blank ................. .15March1984
CommentSheet(2) .......... .15March 1984

“1984, by TOTCO, All Rights Reserved

A
INSTRUCTION MANUAL 27-60
U.S., SI UNIT, AND METRIC
CONVERSION FACTORS

LISTING BY PHYSICAL QUANTITY

TO CONVERT FROM MULTIPLY TO CONVERT FROM


U.S. TO %/METRIC BY WMETRIC TO U.S.
MULTIPLY BY:

AREA square foot fft2) square meter (m2) 0.0929 10.7642


square inch (in2) square centimeter (cm2) 6.4516 0.1550

DENSITY pounds mass per U.S. kilogram per 119.826 0.008345


gallon (lb/gal) cubic meter (kg/m3)

FORCE pounds-force (Ibf) Newtons IN) 4.448 0.2248


pounds-force (Ibf) decanewtons (daN) 0.4448 2.2482
pounds-force (Ibf) kilograms (kg) 0.4536 2.2045

LENGTH inch (in) centimeter (cm) 2.54 0.3937


foot fft) meter (ml 0.3048 3.2808

PRESSURE atmosphere (atm) kilopascal IkPa) 101.325 0.009869


absolute
pounds per square inch kilopascals fkPa) 6.895 0.1450
(PSIG)
pounds per square inch kilograms per squa e
(PSIG) centimeter (kg/cm 1 ) 0.0703 14.2247

TORQUE foot pound-force Newton meter 1.355818 0.7376

VOLUME barrels, petroleum cubic meters (m3) 0.159 6.2893


(42 gallon) fbbl)
gallon (U.S. liquid) cubic meters fm3) 0.003785 264.173
(gal)

VOLUME barrels per inch, cubic meters per 0.626 1.5974


PER DEPTH petroleum (bbllin) centimeter (m3/cm)

TEMPERATURE Fahrenheit (OF) Celsius f°C) SUBTRACT 32 MULTIPLY by


and multiply 1.8 and add
by 0.556 32

^_
-__I-
INSTRUCTION MANUAL 27-60

TABLE OF CONTENTS

Section Page
I PURPOSE, DESCRIPTION AND THEORY OF OPERATION . . . . . . . . . . l-l
l-l Introduction. ................................. l-l
l-3 Purpose .................................... l-l
l-5 Description .................................. 1- 1
l-6 . Signal Conditioner ............................ l-l
l-8 .. Processor PC8 ............................. l-l
l-9 .. Barrier PCB ............................... l-l
l-10 . Sensor Assemblies. ........................... l-l
l-l 2 .. Proximity Sensor ........................... l-l
1-13 .. Clamp and Limit Switch ....................... l-l
1-14 .. Pump Stroke Sensor Assy ..................... l-l
l-l 5 .. Magnetic Probe ............................ l-l
1-16 Theory of Operation ........................... .I-3
l-l 7 . RateMasterTM Signal Conditioner .................. l-3
1-19 .. Signal Flow, Channel 1 ....................... l-3
l-20 .. Scaling Switches ........................... l-3
1-21 .. lnverter Switch ............................ l-4
l-22 .. Power Distribution .......................... l-4
1-23 . Sensors ................................... l-4
l-24 .. Proximity Sensor ........................... l-4
l-25 .. Limit Switch .............................. l-4
l-26 .. Magnetic Probe ............................ l-4
II INSTALLATION ................................... ..2- 1
2-l Installation ................................. .2- 1
2-3 . Proximity Sensor ............................ .2- 1
2-5 .. Preliminary Inspection ....................... .2- 1
2-6 .. Mounting Position. ......................... .2-3
2-7 .. Cable Connection .......................... .2-3
2-8 . Magnetic Probe ............................. .2-3
2-10 .. Mounting the Magnet ....................... .2-6
2-11 .. Magnetic Probe Mounting .................... .2-6
2-12 . Limit Switch ............................... .2-6
2-14 .. Mounting the Clamp and Limit Switch ............ .2-6
2-15 .. Limit Switch Connection ..................... .2-8
2-16 .. Limit Switch Position. ....................... .2-8
2-17 . Pump Stroke Sensor Assy ...................... .2-8
2-19 . Signal Conditioner ........................... .2-9
2-21 .. Ground Connection ......................... .2-9
2-22 AC Power Cable ........................... .2-9
III CALlBRATlbN .................................... ..3- 1
3-l Calibration. ................................. .3-l
3-3 . Proximity Sensor Calibration .................... .3-l
3-5 .. Pulse Check. ............................. .3-l
3-6 . Magnetic Probe Calibration ..................... .3-l
3-8 . Signal Conditioner Processor PCB ................. .3- 1
3-10 .. BCD Scaling Switches ....................... .3-l
3-11 .. lnverter Switch ........................... .3-l
3-l 2 Diagnostic Switch. ......................... .3-2
IV PERIODIC INSPECTION AND MAINTENANCE ................ .4-l
4-l General Information ........................... .4-l
TABLE OF CONTENTS (Cont’d)

Section Page
IV 4-3 Periodic Inspection ............................ .4-l
(Cont’d) 4-5 . Cleaning. ................................. .4-l
4-6 .. Electrical Components. ...................... .4-l
4-7 .. External Surfaces .......................... .4-l
4-8 Field Maintenance. ............................ .4-l
4-10 . Field Disassembly ........................... .4- 1
4-12 . Field Assembly ............................. .4-l
4-13 .. Proximity Sensor .......................... .4-l
4-14 Shop Maintenance ............................ .4-2
4-16 . Shop Disassembly ........................... .4-2
4-18 . Shop Assembly ............................. .4-2
4-20 .. Proximity Sensor .......................... .4-2
4-21 .. Clamp and Limit Switch ...................... .4-2
4-22 Pump Stroke Sensor Assy .4-2
V TROUBLESHOOTING.. .. ..... .... ::::::::::::::::::::.5-1
5-l General.....................................5- 1
5-3 Troubleshooting .............................. .5- 1
5-5 . Signal Conditioner ........................... .5- 1
5-6 .. Power Troubleshooting ...................... .5- 1
5-7 .. Signal Troubleshooting ...................... .5- 1
5-8 . Sensor Signal Circuit ......................... .5-3
5-10 .. Cable Continuity. .......................... .5-3
5-11 .. Proximity Sensor Amperage ................... .5-3
5-l 2 Magnetic Probe 5-3
VI INTRODUCTION TO ILLUSTRATED’PARTSBd;AKddWN : : : : : : : : : 6-l
6-l General .................................... .6-l
6-3 Group Assembly Parts List Section .................. 6-l
6-5 . Figure and Index Number Column ................. .6-l
6-6 . Part Number Column ......................... .6-l
6-7 . Description Column .......................... .6-l
6-9 . Units Per Assembly Column. .................... .6-l
6-10 . Use on Code Column ......................... .6-l
6-l 1 Numerical Index Section ........................ .6-l
6-l 3 Additional Parts Lists. .......................... .6-l
6-l 5 How to Use the Illustrated Parts Breakdown ........... .6-l
6-l 7 Abbreviations ............................... .6-l
VII GROUP ASSEMBLY PARTS LIST ......................... .7-O
VIII NUMERICAL INDEX .................................. .8-l
IX SPARE PARTS LIST .................................. .9-l

...
III
INSTRUCTION MANUAL 27-60

LIST OF ILLUSTRATIONS
Figure Page
l-l RATEMASTER System ................................. l-2
l-2 AC/DC Power Distribution, RATEMASTER Signal Conditioner. ...... 1-3
l-3 Processor PCB ...................................... l-4
l-4 Barrier PCB Schematic ................................. l-5
1-5 Interconnect of TS 10 1 and Signal Conditioner Jacks, ............ l-6
Channels 1 thru 3
1-6 Signal Flow Channel 1 ................................. l-7
2-l Hazardous Location Requirements ........................ .2-l
2-2 Proximity Sensor Dimensions ........................... .2-2
2-3 Proximity Sensor Mounting ............................. .2-2
2-4 Typical Proximity Sensor Mountings. ...................... .2-4
2-5 Cable Connections for Proximity Sensor .................... .2-5
2-6 RPM Sensor and Clamp Assembly Mounting Dimensions ......... .2-6
2-7 Rotary Table Mounting, RPM Sensor and Clamp Assembly ........ .2-7
2-8 Clamp and Limit Switch Mounting ........................ .2-7
2-9 Clamp and Limit Switch Mounting Dimensions ................ .2-8
2-10 Cable Connections for Limit Switches ...................... .2-9
2-1 1 Cable Connections for Pump Stroke Sensor Assy ............. .2-l 0
2-l 2 Signal Conditioner Mounting Dimensions .................. .2- 10
2-l 3 Cable Interconnects for RATEMASTER .................... .2-l 1
2-14 Schematic For Adapter and Transition Cables. ............... .2-l 2
2-15 Recommended Method of Splicing Shielded Cable ............ .2-l 3
2-16 AC Power Cable Connection ........................... .2- 14
3-l Calibration Set-Up, Proximity Sensor ...................... .3-2
5-l Pulse Simulator ..................................... .5-l
5-2 Logic Diagram, RATEMASTER Signal Conditioner Power ......... .5-2
Distribution to PCB
6-l Column Description of the Illustrated Parts Breakdown .......... .6-2
6-2 How to Use the Illustrated Parts Breakdown .................. .6-3
7-l RATEMASTER System. ............................... .7-O
7-2 RATEMASTER Signal Conditioner Assembly ................. .7-4
7-3 RATEMASTER Electronic Chassis ........................ .7-8
7-4 Proximity Sensor. .................................. -7-l 0
7-5 Clamp and Limit Switch Assembly ....................... .7-l 1
7-6 Pump Stroke Sensor Assembly ......................... .7- 12
7-7 RPM Bracket and Magnet Kit ........................... .7-l 4
7-8 Interconnect Cables .................................. .7-l 6

LIST OF TABLES
Table
3-l Diagnostic Switch Output. ............................. .3-2
9-l Spare Parts List. .................................... .9-l

iv
INSTRUCTION MANUAL 27-60

APPROVED EXPENDABLE ITEMS LIST

Part
Number Description
992217-001 Safety Solvent, Trichloroethane, 1, 1, 1
992405-009 Silicone Lubricant
99 1202-014 Silicone Adhesive (RTV 157)
99 19 15-002 Sealing Compound
992419-002 Anti-Seize Lubricant
99 1203-005 Epoxy Adhesive
991202-001 Silicone Adhesive (RTV-103)
991702-006 Lubricant (AP-5)

RELATED TOOLS AND TEST EQUIPMENT

Part
Number Description
233128 PULSE SIMULATOR

RELATED PUBLICATIONS

Publication
Number Title

26-56 E/P Transducer Assy, Combination

27-42A Electronic Mud System, Installation, Operation and Maintenance

27-33A Dual Display Digital Pump Stroke Counter, Combination

27-58 Battery Operated Pump Stroke Counter, Combination

28-l 1 VISULOGGER II@ System, Installation, Operation and Maintenance

v/vi
INSTRUCTION MANUAL 27-60
SECTION I
PURPOSE, DESCRIPTION AND THEORY OF OPERATION

l-l INTRODUCTION (CRl, 2, or 3) flashes when its respective sensor


produces a pulse. The output LED (CR8, 9, or 10)
l-2 This manual contains information and in- flashes with each output pulse of its respective
structions for the RATEMASTER System channel. The barrier shield has a slot for observing
PN’s 230256-001 thru 230256-006, manufac- the three output LED/s. If the signal is scaled (for ex-
tured by TOTCO. Information in this manual is suffi- ample, 2: 11, the input LED will flash twice but the
cient for installation, maintenance and part replace- output LED will flash only once (2 input pulses = 1
ment of the system. output pulse). The barrier PCB also contains a ter-
minal strip (TSl 01). Figure l-5 shows the input and
1-3 PURPOSE output connections of the terminal strip to the signal
conditioner jacks.
l-4 The RATEMASTER system (Figure I- 1) pro-
vides an electronic interface between RPM l-l 0 SENSOR ASSEMBLIES
(revolutions per minute) and SPM (strokes per
minute) sensors and various display and recording l-l 1 The signal conditioner is configured to
devices. The RATEMASTER signal conditioner sup- operate from four kinds of sensor assem-
plies a DC current to sensors. When the signal condi- blies: a proximity sensor, clamp and limit switch,
tioner receives pulses from the sensors, it modifies pump stroke sensor assembly, and a magnetic pro-
the pulses so that they are compatible with specified be.
display and recording devices. The system has a
maximum of three channels.
l-l 2 PROXIMITY SENSOR. The proximity sensor
(Figure l-l 1 is an electronic sensor designed
1-5 DESCRIPTION to mount in the pump housing inspection plate. #Ad-
justable mounting allows the sensor to be placed
1-6 SIGNAL CONDITIONER
close to the metal to be sensed. The sensor
assembly includes a junction box, mounting equip-
l-7 The signal conditioner is an environmentally
ment, and the sensor.
sealed enclosure. It has three jacks for sen-
sor inputs from a maximum of three sensors. Nine
jacks are available for output signal cables to other l-l 3 CLAMP AND LIMIT SWITCH. The limit
equipment. Three output jacks provide 2 digital switch (Figure l-1) mounts on the frame-
signals each; three provide O-4 milliamp output work of the pump near the splash plate. The move-
signals; and three provide O-l 0 vdc output voltage. ment of the splash plate striking the actuator rod, ac-
AC power is required for operation of the signal con- tuates the switch. The switch head can rotate 90° in
ditioner. The power supply changes the AC to DC for either direction and the switch can mount on the
operation of the sensors and PCB components C-clamp in several positions. This configuration
(Figure 1-2). Two PCB’s mount to the chassis: the allows the switch to mount in several positions on
processor PCB and the barrier PCB. the pump.

l-8 PROCESSOR PCB. The processor PCB con- l-l 4 PUMP STROKE SENSOR ASSEMBLY. The
tains two BCD switches per channel which pump stroke sensor assembly (Figure l-l 1
scale the signal. Scaling allows a sensor to be uses two limit switches to monitor two pumps, yet
mounted elsewhere (driveshaft, etc.) when it is not use only one cable from the pumps to the signal con-
practical to mount the sensor on the pump or rotary ditioner. Connecting the pump stroke sensor
table. In addition, a diagnostic switch is available to assembly requires a Y-cable to interface with the
calibrate the analog outputs. The PCB also has an in- signal conditioner.
verter switch for the digital signal paths. Figure 1-3
shows the processor PCB layout. l-l 5 MAGNETIC PROBE. The magnetic probe
(Figure l-l 1 produces a pulse when a mag-
l-9 BARRIER PCB. The barrier PCB (Figure l-4) net passes within the sensor range. The probe is
contains 10 safety barriers which ensure in- designed to mount on an adjustable arm (RPM
trinsic safety for the sensor and output circuits. Each Bracket and Magnet Kit) so that it can mount under
channel has two indicator LED’s. The input LED the rotary table platform.

l-l
INSTRUCTION MANUAL 27-60

CONDITIONER

PUMP STROKE
SENSOR
ASSEMBLY
PROXIMITY SENSOR

MAGNETIC PROBE
CLAMP AND
LIMIT SWITCH

RPM
BRACKET
AND
MAGNET
KIT

l-2 FIGURE l-l. RATEMASTER SYSTEM


INSTRUCTION MANUAL 27-60

+OUT

AC COM

ACC -OUT

LlJti
I I LED LED

AC PANEL TRANSIENT
PROTECTOR

J403b -
J402 D Pll Jll
-L-
J401
J303
J302
R#l
J301[1 ‘I I- -1 I I CABLE I
J203
J202
J201
J103
PROCESSOR PCB
j;;;w I- BARRIERPCB ITo GND lsuG I

rluunc I -L. nwuc. ruvVCn IA3 I IWDU I IUIU, nH I tlVlA3 I tll 3lWYHL LUNUI I IUNtIl

l-1 6 THEORY OF OPERATION When the signal conditioner receives 115 vat
power, pin A of JlOl has a potential of 5 vdc (for
l-l 7 RATEMASTER SIGNAL CONDITIONER the magnetic probe) and pin B has a potential of 12
13 vdc (for the proximity switch or limit switch).
l-l 8 The signal conditioner functions as an inter- Actuation of a sensor on channel 1 causes a drop in
face device between the sensor signals and voltage which produces a pulse. The pulse is routed
a unit using the signals for a display or a record. The across the barrier board causing the LED (CR11 to
electrical signal (pulse) from a limit switch, proximi- blink (See Figures l-6 & l-7). The signal passes
ty, or magnetic sensor is a sharp spike. A system or through the processor board and then back to the
unit using the signal may require a broader digital or barrier board in three forms: digital, O-4 mA, and
an analog signal. Consequently, the design of the O-l 0 vdc.
electronic circuits in the signal conditioner cause the
l-20 SCALING SWITCHES. SW2 and SW3 are
pulse to spread out to a high and low digital signal or
scaling switches (Figures l-6 & 1-7). If
an analog voltage or current. The outputs from the
channel 1 receives 2-l/2 input pulses for each
signal conditioner are compatible with a variety of
stroke or revolution, SW2 should be set at 2 and
other equipment.
SW3 set at 5 (2.5). The output will then equal one
pulse for every 2-l/2 input pulses. This allows a
NOTE
direct drive to the rotary table or pump to actuate the
J201 and J202 each have a Channel 1 and 2 sensor (even though it rotates at a faster rate) rather
digital output. J203 has two Channel 3 digital than connecting the sensor to the rotary table or
outputs. pump itself. If the scaling switches are positioned to
0.0 or 1 .O, the output LED (CR81 will blink once with
l-l 9 SIGNAL FLOW, CHANNEL 1. Channel 1 each input pulse. If the signal is scaled, the ouput
signal flow is typical of all three channels. LED will blink in proportion to the scaling ratio of the
input signal.

l-3
INSTRUCTION MANUAL 27-60

raNF
ollll
I 3 2I
INVERTER
SWITCH
(IN-OFF POSITION)

TYPICAL
SW2-SW8

TPl, 2, 3 = 10 f 0.1 VDC


WITH DIAGNOSTIC SWITCH
AT POSITION 2.

L3 @TPl TP7 = 10.00 zt 0.05 VDC


%-g-L a NOMINAL

1-21 INVERTER SWITCH. SW1 inverts the signal when metal is in close proximity to it. When metal
from the proximity sensor or limit switch. If enters the sensing area, the circuit current drops
the proximity sensor senses metal for a longer period which produces a pulse. The maximum sensing
than it does not sense it, the inverter switch can be range of the sensor is approximately three-eights
switched on. The pulse will then appear as a short inch.
spike. This same principle applies to the limit switch
if the switch is closed longer than it is open. Some l-25 LIMIT SWITCH. The limit switch is a normal-
equipment using the RATEMASTER system will not ly open switch. Closure of the switch pro-
respond properly to a broad pulse. duces a complete circuit which is recognized as a
pulse by the signal conditioner.
l-22 POWER DISTRIBUTION. Figure l-2 shows
the power distribution for the signal condi- l-26 MAGNETIC PROBE. The magnetic probe is
tioner. actuated by a magnet rotating on a revolving
unit (such as the rotary drive). As the magnet passes
1-23 SENSORS within the sensor’s range, the sensor actuates, pro-
ducing a pulse in the circuit.
l-24 PROXIMITY SENSOR. The proximity sensor
does not touch metal but only responds

l-4
INSTRUCTION MANUAL 27-60

I I I
: : : ! II I. ! ! ! ;
i i i i i i i i i

I:I
I-I
- II

1 1

rL

FIGURE l-4. BARRIER PCB SCHEMATIC


1-5
INSTRUCTION MANUAL 27-60

c
TSlOl (brmLUJ \ A
GRN (GND)
-B
Dcn In qn”+l 1 -c
1 mA-
, 1I
--
32 GRN (GND)
RED (O-lOV+) I-4 mA
CH 31 OUT
2 30 BLUlWHT (O-4 mA - 1
29 BLU (O-4 mA + 1
I I

--
BLU (O-4 mA+)
25
YELlWHT (
24
YEL (3E
ru 23

I’ u-i-l o-IOV
OUT

YEL (2 B+)
I .,-. ,.-...- 3-e. .
DIGITAL
OUT
I UHlilWlll (LA - 1
I 9
ORG (lA+) J201
I 81 !Ni --T
I ORG (2A +) --B
IIll 2-
CH 7-I-
s-11
NOT
USED I II I
I
’ I
-..._ .-.- -,
ORG/WHT (1 A - 1
I
.C

II 5-l- 1 WHT (SENSOR 3 IN) 9


JlO:
BLK (+ 5VI ! , l-xl
I GRN (GND)
WHT (SENSOR 2 IN)
I
,
I
I
TO BUSS
BAR
JlO;
A
p-B SENSORS
--C IN
I+ D

GRN/YEL (SHIELD)

FIGURE 1-5. INTERCONNECT OF TSl 01 AND SIGNAL CONDITIONER JACKS,


l-6 CHANNELS 1 THRU 3
INSTRUCTION MANUAL 27-60

Jll
-- 2 -
SW3 SW2’
. 6 G
/--5 DIGITAL
/---- ,SWlM
SIGNAL
12 O-4 mA PROCESSING
o-IOV CIRCUITS
13

I A 1 I
PROCESSOR PCB JIOI
1’ SENSOR
INPUT
\’ J201
TSIOI ”
I
BARRIER 1 2-- DIGITAL
6 I BARRIER 3 ;A+, 13 - OUTPUT
y-5 CR8 1
/- HI
12 - BARRIER 6 O-4 mr O-4 mA
13 o-1 ov OUTPUT
BARRIER 7
O-l OVDC
I- OUTPUT
27-601-26 BARRIER PCB

FIGURE l-6. SIGNAL FLOW, CHANNEL 1

l-711-8
INSTRUCTION MANUAL 27-60
SECTION II
INSTALLATION

2-l INSTALLATION 2-5 PRELIMINARY INSPECTION. Remove the


crosshead inspection plate, and gasket if
2-2 The design of the RATEMASTER system possible, from the pump housing and complete the
allows the sensors and signal conditioner to following:
be mounted in environments normally encountered
a. Rotate the pump through one complete
on a rig. See Figure 2-l for hazardous location re-
pump stroke by mechanical means or by
quirements. Refer to Related Publications (page v)
bumping the pump switch. Then measure
for requirements of associated equipment.
the distance that the crosshead travels in
one complete stroke (Figure 2-4).
2-3 PROXIMITY SENSOR
b. Select a position on the inspection plate to
2-4 The proximity sensor (Figure 2-2) mounts in best mount the sensor. The position should
the crosshead inspection plate (4, Figure be 90° to the crosshead or crosshead collar
2-3) of the mud pump (Figure 2-4 shows a typical in- (END VIEW, Figure 2-4). The distance from
stallation). the outside of the inspection plate and the
sensing point cannot exceed 8 inches.
LimamEl
-
DO NOT DAMAGE CROSSHEAD INSPECTION MOUNT THE SENSOR SO THAT THE MOVE-
PLATE GASKET DURING MOUNTING PRO- MENT OF THE CROSSHEAD WILL NOT
CEDURE. DAMAGE THE SENSOR.

HAZARDOUS LOCATION HAZARDOUS LOCATION


I CLASS I. DIV. 2, GROUPS C AND
CLASS I, DIV. 1, GROUPS C AND
D (PER NEC ART 500- 1984) D (PER NEC ART 500- 1984)
I

MAGNETIC
PROBE

PROXMITY REFER TO E-MUD


I CONSOLE
SENSOR RELATED r-l
I RATEMASTER PUBLICATIONS
SIGNAL FOR SAFETY
CONDITIONER INSTALLATION PUMP STROKE
CLAMP AND REQUIREMENTS
LIMIT SWITCH
I
PUMP
STROKE I PUMP STROKE
SENSOR
,
I O-IO VDC
METER
(IN DRILLER’S
27-W-6 rl CONSOLE)

FIGURE 2-l. HAZARDOUS LOCATION REQUIREMENTS


2-l
INSTRUCTION MANUAL 27-60

12-114

3-318 INCH (88.4 MM)


MAXIMUM ADJUSTMENT

ALL DIMENSIONS IN INCHES UNLESS


OTHERWISE NOTED.

FIGURE 2-2. PROXIMITY SENSOR DIMENSIONS

FIGURE 2-3. PROXIMITY SENSOR MOUNTING

2-2
INSTRUCTION MANUAL 27-60

LEGEND FOR FIGURE 2-3.


1. Lock Nut 7. Modified Case With Cap
2. Bulkhead Union 8. Terminal Crimp
3. Lock Nut 9. Threaded Pipe
i 4. Crosshead Inspection Plate 10. Adapter
5. Reducer Bushing 1 1. Proximity Sensor
6. Strain Relief

2-6 MOUNTING POSITION. After determining i- Thread the first locknut on the pipe with the
the position of the crosshead path to the in- nylon end toward the bulkhead union and
spection plate, mount the sensor. Give careful atten- tighten it.
tion to the following:
k. Thread the remaining locknut on the pipe
a. Drill a 7/8-inch (22.2 mm) mounting hole in with the nylon end toward the case.
the inspection plate which will position the
sensor to best detect one pump stroke. NOTE

NOTE For best mounting conditions, cut the threaded


pipe (9) so that the case fits close to the inspec-
A small pilot hole (3/8-inch recommended) pro- tion plate. The threaded pipe is stainless steel;
vides accuracy for the larger drill. use a sharp hacksaw. Do not cut the sensor
leads.
b. To determine the distance from the
crosshead to the inside edge of the inspec- I. Guide the terminal lugs (8) through the
tion plate, place a straight edge across the bushing and into the case.
opening and measure the perpendicular
distance. Allow a 3/l 6 to 3/8-inch (4.8 to m. Thread the pipe into the bushing and tighten.
9.5 mm) space between the sensor and the Do not secure with the locknut nor connect
part of the crosshead being sensed. The the terminal lugs at this time.
6-inch, threaded pipe (9, Figure 2-3) allows
adjustment after installation. n. Adjust the case (7) so that the cable and
strain relief point downward.
C. Loosen locknut (3) from reducer bushing (5)
and remove the threaded pipe from the o. Tighten the locknut (3) against the reducer
bushing. bushing (5) and connect the terminal lugs to
the terminal strip.
d. Remove the locknuts (3) and the bulkhead
union (2) from the threaded pipe.
2-7 CABLE CONNECTION. Connect the signal
e. Mount the bulkhead union (2) and tighten cable to the sensor housing terminal strip by
locknut (1). stripping insulation and connecting terminal lugs to
the wires as shown in Figure 2-5. Cut unused wire
f. Screw the threaded pipe (9) through the
and shield back to the edge of the insulation.
bulkhead union until the sensor adapter is
near the union.
2-8 MAGNETIC PROBE
9. Install the crosshead inspection plate.
2-9 The RPM sensor and clamp assembly (Figure
h. Rotate the threaded pipe until the sensor
2-6) is designed to mount in any location
touches the sensing target (crosshead or col-
that provides an RPM count of the rotary table.
lar). Usually, the best mounting position is under the rig
i. Back the pipe off 5 complete turns (approx- floor next to the rotary table (Figure 2-7). In this
imately l/4-inch) (1 -l/8 turns moves the position, the magnet (7) is mounted to rotate with
sensor l/l 6 inch or 1.6 mm). The sensor the rotary table (5) and the sensor and clamp
should be positioned 3/l 6 to 3/8-inch (4.8 assembly (6) can mount out of the way of routine rig
to 9.5 mm) from the metal being sensed. activity.

2-3
INSTRUCTION MANUAL 27-60

FIGURE 2-4. TYPICAL PROXIMITY SENSOR MOUNTINGS


2-4 (SHEET 1 OF 2)
INSTRUCTION MANUAL 27-60

INSPECTION
PLATE

PROXIMITY
SENSOR

FIGURE 2-4. TYPICAL PROXIMITY SENSOR MOUNTINGS (SHEET 2 OF 2)

SJO 18/3 (OPTIONAL)

EXANE 1813 (STANDARD)

FIGURE 2-5. CABLE CONNECTIONS FOR PROXIMITY SENSOR

2-5
INSTRUCTION MANUAL- 27-60

ALL DIMENSIONS IN INCHES UNLESS


OTHERWISE NOTED.

0.5 OPEN (266.7 MM)


5 CLOSED (165.1 MM

20.50
(520.7 MM)

< 21 .oo
2754 9
(533.4 MM)

HtilJllt Z-0. HPM StNSUl-4 ANU CLAMP A3StMbLY MUUN I INb UIMtNSlUNS

2-10 MOUNTING THE MAGNET. The magnet is be so that the LED in the body of the probe can be
mounted in the following manner: seen). Ensure that the spacer is under the probe.
Complete the following:
a. Connect the RPM sensor cable to the probe.
ANY WELDING ON THE ROTARY TABLE RE-
b. Attach the clamp of the clamp assembly to a
QUIRES THAT THE GROUND CLAMP OF THE
substructure support which permits the pro-
WELDER CONTACT THE METAL TO WHICH
be to respond to the magnet’s rotation.
THE BOLT IS BEING WELDED. OTHERWISE,
DAMAGE MAY OCCUR TO THE ROTARY C. Adjust the clamp assembly so that the probe
TABLE BEARINGS. is within range of the magnet while rotating
(2-l/2 inches maximum to l/2-inch
a. Weld the head of the six-inch bolt to the
minimum; 63.5 mm maximum to 12.7 mm
outer edge of the rotary table (5, Figure 2-7)
minimum).
so that the threaded end points downward.
d. Tighten the extension adjustment screws on
b. Wrap the magnet with three to four layers of
the clamp assembly.
electrical tape over two-thirds of the
magnet.
2-12 LIMIT SWITCH
C. Clamp the magnet to the end of the bolt with
a hose clamp. The clamp should be tight 2-l 3 The limit switch is designed to mount to the
enough to force the bolt threads to bite into pump housing near the splash plate or other
the tape on the magnet. mechanism that will actuate the switch.

2-l 1 MAGNETIC PROBE MOUNTING. Attach the 2-14 MOUNTING THE CLAMP AND LIMIT
magnetic probe (3, Figure 2-7) to the clamp SWITCH. Mount the C-clamp to the pump
assembly using the two u-bolts (2) (position the pro- housing so that the splash plate will activate the

2-6
INSTRUCTION MANUAL 27-60

FIGURE 2-7. ROTARY TABLE MOUNTING, RPM SENSOR AND CLAMP ASSEMBLY

C-CLAMP

27-421-31
I

FIGURE 2-8. CLAMP AND LIMIT SWITCH MOUNTING

2-7
INSTRUCTION MANUAL 27-60

switch in one direction only, not to exceed a 90° arc mounted to the switch C-clamp and the direction of
(Figure 2-8). The hub need rotate only 5O for activa- switch actuation. The switch must be set to actuate
tion of the switch. Figure 2-9 shows the dimensions in one direction only. Complete the following:
of the clamp and limit switch.
a. After adjusting the switch head (Figure 2-81,
2-l 5 LIMIT SWITCH CONNECTION. If the limit remount the switch head to the body of the
switch is not connected to the sensor cable, switch. Actuate the switch actuator rod
complete the following: while listening to the switch to make sure it
is operating on one direction only and ac-
a. Strip insulation from the cable and the wires
tuating in the proper direction.
required for the limit switch.
b. Loosen the two switch screws (Figure 2-8) b. Mount the switch to the C-clamp so that the
that hold the body of the switch; carefully actuator rod responds in an arc not to ex-
separate the body without damaging the ceed 90°. If necessary, rotate the switch
gasket. head.
c. Loosen the shell of the stress relief and
2-17 PUMP STROKE SENSOR ASSEMBLY
thread the end of the cable through the rub-
ber grommet. Connect the wires to the
2-18 Install the pump stroke sensor assembly
switch (Figure 2-l 0).
following the procedures listed for the limit
d. With some slack in the wires inside the switch, Paragraph 2-l 2 thru 2-l 6. Use Figure 2-l 1
switch, tighten the stress relief shell until the to connect the cable leads to the limit switches. A
rubber grommet makes good contact with sensor input adapter Y-cable is required to interface
the cable. Reassemble the switch. between the assembly and the signal conditioner.

2-16 LIMIT SWITCH POSITION. Determine the


position in which the switch is to be

FIGURE 2-9. CLAMP AND LIMIT SWITCH MOUNTING DIMENSIONS


2-8
INSTRUCTION MANUAL 27-60

TO
SIGNAL
CONDITIONER

G’RN
SJO 18/3 [OPTIONAL)

WHT

TO
SIGNAL
CONDITONER

2-l 9 SIGNAL CONDITIONER 2-21 GROUND CONNECTION. Connect a number


8 ground wire to the ground lug on the signal
2-20 The signal conditioner mounts between the conditioner box. Use a compression connector to
sensors and the units using the signal. Figure connect the ground wire to earth ground or rig
2-l gives the classification for hazardous locations. ground. Grounding equipment is listed in Section VII,
Figure 2-l 2 shows the dimensions needed for Figure 7-l. Ensure that all connections are clean and
mounting. Mount the enclosure so that it is accessi- free of corrosion.
ble for service and calibration. Figure 2-l 3 shows
the cable interconnections for the sensors and NOTE
related systems and Figure 2-l 4 shows the schema-
All connections to earth ground must be in a
tic for the adapter and transition cables. Figure 2-l 5
non-hazardous area.
shows the recommended splicing method.
2-22 AC POWER CABLE. Connect the type of AC
NOTE
power cable to the signal conditioner as re-
Devices using exane, shielded, 3-conductor quired by local safety regulations. Figure 2-l 6
cable require the red lead for ground rather than shows the required conductor connections. Item 2 1,
green. The shield is grounded to the signal con- Figure 7-l lists a cable and cord connector (strain
ditioner only, not to the sensors. Signal cables relief) for standard applications.
between the signal conditioner and units using
the signal must be grounded to either the signal
conditioner or the unit, but not both.

2-9
INSTRUCTION MANUAL 27-60

8LK
I GRN TO PUMP 1
I
I WHT (NOT USED) LlM’T SWlTCH
; I I

TO A 8LK ---
SENSOR B, WHT --
INPUT GRN
ADAPTER C --
Y-CABLE D (NOT USED) JgJ BLK (NOT USED)
: ; GRN TO PUMP 2
SJO 1813 I,,, LIMIT SWITCH
(OPTIONAL)
WHT (NOT USED) ,q,
I
I 8LK ! I
1 i TO PUMP 1
I I RED ’ C LIMIT SWITCH
I II a, I, SHIELD I I
TO A 8LK
SENSOR 7 WHT --
INPUT - -- I I
GRN ’ -- I I
ADAPTER 2
RED (NOT USED) -- - I
SHIELD
SHIELD F$iQ;,
RED I I
I I I I : !TOPUMP2
WHT ; : LlMlT SWITCH
‘8LK (NOT USED) ! 1
EXANE 18/4 AND 1813 (STANDARD)

FIGURE 2-l 1. CABLE CONNECTIONS FOR PUMP STROKE SENSOR ASSEMBLY

DEPTH OF ENCLOSURE
IS 6-318 INCHES

NOTE:
DIMENSION IN INCHES.
PARENTHETICAL DIMENSIONS
ARE IN MILLIMETERS.
2760’9

FIGURE 2-l 2. SIGNAL CONDITIONER MOUNTING DIMENSIONS

2-10
INSTRUCTION MANUAL 27-60

TO
PROXIMITY r B-m-
DRILLERS CONSOLE
1
SENSORS OR SPM
LIMIT SWITCHES TO
2 RPM I
MAGNETIC
PROBE

STROKE INPUT
SENSOR ADAPTER
ASSY

/ ASSY/- II
J
I ’I I
ASSY

SENSOR INPUTS (JlOl-J103)


/
1’l- I VOLTAGE OUTPUTS
I J301 -J3031

U-IAN 3 CHAN 1 CHAN 2 CHAN 3


J103 J301 5302 J303
CHAN 1 6
JlOl

CHAN 1 & 2 Q CHAN 3


J203
CHAN 1
5401
CHAN 2
J402
CHAN 3
5403
DIGITAL OUTPUTS (J201 -J203) CURRENT OUTPUTS
(J401 -J4031
LI w

DIGITAL 4 7SlGNAL
OUTPUT CABLE
TRANSITION I ASSY
CABLE

TO
E-MUD CONSOLE,
2l;_a, r
s
DUAL DIGITAL
PSC CONSOLE, I 2
OR BATTERY
OPERATED PSC I
I
I VISULOGGER J-BOX
WITH BARRIERS I
I PNEUMATIC
DRILLING
I

I
I
I RECORDER
I
I I
27.me13
I--m---d ,I

FIGURE 2-l 3. CABLE INTERCONNECTS FOR RPM/SPM SYSTEM (TYPICAL)


2-1 1
INSTRUCTION MANUAL 27-60

PIN SOCKET

PIN NOCKET

SHIELD I

SENSOR INPUT ADAPTER Y CABLE DIGITAL OUTPUT ADAPTER Y CABLE

SHIELD

27-601-25 DIGITAL OUTPUT TRANSITION CABLE

FIGURE 2-l 4. SCHEMATIC FOR ADAPTER AND TRANSITION CABLES

2-12
INSTRUCTION MANUAL 27-60

2.6l63.5 mm)

2.5t63.5 mm) 18/3 SHIELDED


SIGNAL CABLE

STEP 1. CUT EACH CABLE AND STRIP OUTER INSULATION BACK


4 INCHES FROM BOTH ENDS.

STEP 2. UNRAVEL BRAIDED SHIELD AND TWIST INTO A SINGLE


CONDUCTOR THAT WILL FIT SNUGLY INTO A BUTT SPLICE.

STEP 3. CUT EACH CONDUCTOR IINCLUDING TWISTED SHIELD) TO


LENGTHS SHOWN ABOVE (OBSERVE COLOR CODE).

STEP 4. STRIP 0.25 INCH (6.4 MMI OF INSULATION FROM THE END OF
EACH CONDUCTOR.

STEP 5. WRAP TWISTED SHIELD WITH BLACK ELECTRICAL TAPE AS


SHOWN ABOVE.

STEP 6. JOIN MATCHING CONDUCTORS (BLACK TO BLACK, WHITE TO


WHITE, ETC.) WITH CRIMPED BUlT SPLICES.

STEP 7. WRAP SPLICED AREA WITH MASTIC TAPE APPROX. 7 INCHES


WIDE.

STEP 8. WRAP SEALED AREA SECURELY WITH BLACK ELECTRICAL TAPE.

NOTE:
ALL DIMENSIONS IN INCHES
28 11 534 UNLESS OTHERWISE STATED.

FIGURE 2-l 5. RECOMMENDED METHOD OF SPLICING SHIELDED CABLE


2-13
INSTRUCTION MANUAL 27-60

FIGURE 2-l 6. AC POWER CABLE CONNECTION

2-14
INSTRUCTION MANUAL 27-60
SECTION Ill
CALIBRATION

3- 1 CALIBRATION 63.5 mm). With the power on to the signal condi-


tioner and the magnet rotating, adjust the position of
3-2 The RATEMASTER System requires calibra- the probe so that the LED on the case of the
tion of three units: the proximity sensor, the magnetic sensor gives an indication with each rota-
magnetic probe, and the processor PCB in the signal tion. The LED responds to the magnet by momentari-
conditioner. ly flashing on.

3-3 PROXIMITY SENSOR CALIBRATION 3-B SIGNAL CONDITIONER PROCESSOR PCB

3-4 The proximity sensor (1 1, Figure 2-3) must 3-9 The processor PCB of the signal conditioner
be close enough to the crosshead to sense has switches which perform three functions
the metal of the crosshead. The l/4, threaded pipe of calibration:
(9) adjusts the sensor when the locknut on the
bulkhead union (2) is loosened (1 -l/8 turns of the a. BCD switches 2 thru 7 for scaling the signal
pipe moves the sensor 1 /16 inch or 1.6 mm; 2-l /4 (Figure I-3)
turns of the pipe moves the sensor l/8 inch or 3.2 b. Switch 1 to invert the signal
mm). The proximity sensor senses in the range of
3/16 to 3/8 inch (4.8 to 9.5 mm). C. BCD switch 8, a diagnostic switch.

3-5 PULSE CHECK. After the sensor is position- 3-10 BCD SCALING SWITCHES. Sensors moni-
ed next to the crosshead (Figure 2-41, use a toring RPM or SPM on a 1: 1 ratio require the
volt-ohmmeter (multimeter) to ensure that the sen- BCD switches to be set at 0.0 or 1 .O. The purpose of
sor pulses when the crosshead completes one full the BCD switches are to allow a sensor to monitor a
pump stroke. Complete the following: rotary movement other than directly from the rotary
table or pump. The rotation, however, must be in
a. Apply power to the signal conditioner. direct ratio to the rotation of the rotary table or
pump. If a 1: 1 ratio is not a practical application,
b. Remove the cap from the top of the proximi- consult the rig specifications for the drive ratio of the
ty sensor terminal housing (7, Figure 2-3). rotary movement to be used. The scaling switches
will reduce the input pulses so that the output signal
C. Complete the calibration set-up per Figure will indicate the proper RPM/SPM. For example: if
3-l. With no metal within sensing range of sensor 1 pulses 2 times for 1 revolution, BCD switch
the sensor, the multimeter should indicate 2 can be set at 2 and switch 3 at 0. The ratio would
7.0 l l .O mA. be 2.0: 1 (maximum setting is 9.9: 1). If 2-l /2 pulses
are input for each revolution, switch 2 should be set
d. Bump the pump with the switch until the at 2 and switch 3 at 5. This would give a 2.5: 1 ratio.
sensor senses the crosshead. The To check the input and output ratio of Channel 1,
multimeter should read less than 1 .O mA. observe the input LED (CR1 , Figure l-4) and the out-
put LED (CR81 on the barrier board. If the ratio is 2: 1,
e. If the sensor does not respond to the metal, the input LED (CRI) will blink twice for one RPM and
remove the signal cable, loosen the bulkhead the output LED (CR8) will blink once.
union locknut (3, Figure 2-31, and screw the
l/4 inch threaded pipe (9) until the sensor 3-l 1 INVERTER SWITCH. The inverter switch
responds to the crosshead. This operation (SW1 , Figure l-3) applies to the proximity
may require several attemps until the sensor sensor and the limit switch input only. If the proximi-
is correctly positioned (3/l 6 to 3/8 inch or ty sensor senses the target metal for a longer period
4.8 to 9.5 mm). than it does not sense the metal, the signal should be
inverted (SWI-1 to ON for Channel 1). If the limit
3-6 MAGNETIC PROBE CALIBRATION switch (normally off) is on longer than it is off, use
the same procedure. Some equipment using the
3-7 The magnetic probe must mount within a signal from the signal conditioner will not respond
distance of l/2 to 2-l/2 inches (12.7 to properly to the input if the signal is not inverted.

3-l
INSTRUCTION MANUAL 27-60

MULTIMETER
(mA)

PROXIMITY SENSOR
TERMINAL BOARD

FIGURE 3-l. CALIBRATION SET-UP, PROXIMITY SENSOR

3-l 2 DIAGNOSTIC SWITCH. The diagnostic O-4 mA outputs (J401-J403) are designed to drive
switch (SW8, Figure l-3) provides analog the E/P transducers of the drilling recorders (O-250
signal outputs for calibration of gauges and drilling RPM/SPM). Full scale (300 RPM/SPM) will over-
recorders. The O-10 vdc outputs (J301-J303) are range the recorders; use 83% scale for 250
designed to drive gauges (O-300 RPM/SPM). The RPMSPM. Table 3-l gives switch positions of SW8.

TABLE 3-l. DIAGNOSTIC SWITCH OUTPUT

3-2
INSTRUCTION MANUAL 27-60
SECTION IV
PERIODIC INSPECTION AND MAINTENANCE

4-l GENERAL INFORMATION 4-8 FIELD MAINTENANCE


4-2 This section contains procedures for periodic 4-9 The RATEMASTER system is designed for
inspection and maintenance. The periodic in- continuous trouble-free operation and disas-
spection emphasizes equipment safety, security, sembly is rarely necessary. Modular construction
and cleanliness. Maintenance includes removal and allows for easy removal of assemblies, subassem-
replacement of major assemblies and parts shown in blies, and parts from the signal conditioner. Only
Section VII. Approved expendable items used for good maintenance practices and hand tools are re-
maintenance are listed on page v. quired.

4-3 PERIODIC INSPECTION


USE CARE IN HANDLING PCB’s. DO NOT
4-4 The RATEMASTER system is fabricated for
ALLOW STATIC DISCHARGE TO DESTROY IC
long and continuous service in hostile envi-
CHIPS. STORE PCB’S IN STATIC-SHIELDED
ronments. Good preventive maintenance begins
BAGS.
with periodic inspection of the system. Establish an
inspection cycle based on calendar dates and opera-
4-l 0 FIELD DISASSEMBLY
ting hours. Pay particular attention to the following:
a. Inspect all electrical cables for cuts, cracks,
and frayed areas.
DISCONNECT THE AC POWER CABLE FROM
b. Check all wire connections for security, cor- RIG POWER BEFORE DISASSEMBLING
rosion, and dirt. SIGNAL CONDITIONER.
C. Ensure that all strain reliefs are secure.
4-l 1 Disassembly in the field should be limited to
d. Ensure that mountings and supports are major components and parts which require a
secure and stable. minimal down time. Extensive disassembly should
be limited to the shop. Disassembly should follow
e. Ensure that the ground connection is secure
the numerical sequence given in Section VII. Ob-
and free of corrosion.
serve the following requirements during disassem-
bly:
4-5 CLEANING
a. Do not replace any components on the signal
conditioner PCB’s. Replace the entire PCB.
DISCONNECT THE AC POWER CABLE FROM b. Replace the corrosion inhibitor (17, Figure
RIG POWER BEFORE CLEANING THE SIGNAL 7-2) every 24 months under normal environ-
CONDITIONER. mental conditions. Under conditions of high
humidity or high temperature, replace the in-
4-6 ELECTRICAL COMPONENTS. Parts such as hibitor at least once a year or more often.
PCB connector pads and connectors should
be cleaned with safety solvent. Observe all safety 4-l 2 FIELD ASSEMBLY
precautions specified on the container label.
4-l 3 PROXIMITY SENSOR. Assembly of the prox-
4-7 EXTERNAL SURFACES. For general cleaning imity sensor follows the reverse order of
of external surfaces, use a mild detergent disassembly. Observe the following requirements:
with water. Wipe with a clean cloth.
a. Apply anti-seize lubricant to all male connec-
tions on the proximity sensor.

4-1
INSTRUCTION MANUAL 27-60

b. To replace the power cable assy (21, Figure


a. Apply anti-seize lubricant to all male connec-
7-l), connect the leads as shown in Figure
tions.
2-l 6.
b. Apply Epoxy adhesive to the terminal block
4-14 SHOP MAINTENANCE (6, Figure 7-4).
C. Apply silicone adhesive (RTV 157) to the
4-l 5 Shop maintenance includes information and
area of the case for the identification plate
procedures used in field maintenance (Refer
(2) prior to installing the plate.
to Paragraph 4-8). The units of the RATEMASTER
system are shown in Figures 7-l thru 7-8. Some d. Apply silicone lubricant to the threads of the
subassemblies are modular in construction and cap before closing the case.
should not be disassembled beyond what is shown.
4-21 CLAMP AND LIMIT SWITCH. Assemble the
4-16 SHOP DISASSEMBLY clamp and limit switch by applying lubricant
(AP-5) to the threads of the clamp (10, Figure 7-5;
4-l 7 Follow the disassembly sequence shown in 1 1, Figure 7-6).
Section VII. Observe the special require-
ments described in field disassembly, Paragraph 4-22 PUMP STROKE SENSOR ASSEMBLY. As-
4-10. semble the pump stroke sensor assembly by
applying the following as required:
4-18 SHOP ASSEMBLY
a. Apply silicone lubricant to the cover threads
of the outlet conduit (27, Figure 7-6) and to
4-l 9 Assemble units and parts of the RATE-
the gland threads of the cable connectors
MASTER system in reverse order of disas-
(25).
sembly. Refer to Approved Expendable Items List
(Page v) for part numbers of lubricants, adhesives, b. Apply silicone adhesive (RTV-103) to the
etc. Observe special precautions given in Paragraph pipe threads of the cable connectors (25).
4-l 2.

4-20 PROXIMITY SENSOR. Assemble the prox-


imity sensor by applying the following as re-
quired:

4-2
INSTRUCTION MANUAL 27-60
SECTION V
TROUBLESHOOTING

5-1 GENERAL 5-5 SIGNAL CONDITIONER

5-2 This section contains information for isola- 5-6 POWER TROUBLESHOOTING. Power loss to
ting and correcting troubles which may arise the electronic chassis assembly is indicated
during operation or calibration of the RATEMASTER by the LED’s on the transient protector (6, Figure
system. The system requires only one special piece 7-3). If one LED is off, replace the transient protec-
of test equipment: the pulse simulator (See Figure tor. If both LED’s are off, Figure 5-2 provides a logic
5-I). Other tools and test equipment are standard diagram to troubleshoot the power distribution to
equipment for field service. the processor PCB (the logic diagram coordinates
with Figure l-2). If power is available to PCB but the
5-3 TROUBLESHOOTING PCB does not respond, replace the PCB.

5-4 The first indication that trouble exists in the 5-7 SIGNAL TROUBLESHOOTING. To trouble-
system is when the systems or units depen- shoot an input signal problem, complete the
ding upon the RATEMASTER system do not receive following using Figures l-4 and l-5 as a guide (en-
signals. To ensure that problems do not exist in the sure that voltage is present at sockets A and B of
cable connections, perform the periodic inspection JlOl, J102 and J103):
described under Paragraph 4-3. Complete necessary
repairs if needed.

26-47/-135

FIGURE 5-l. PULSE SIMULATOR


5-l
INSTRUCTION MANUAL 27-60

START HERE
(SEE FIGURE l-2)

1 CHECKP12FOR 1 \/
I DC VOLTAGES 1 v

I I

NO

v
REPLACE FUSE.
NOTE: IF FUSE
CONTINUES TO BLOW,
REPLACE POWER
SUPPLY

RETURN UNIT
- w
TO SERVICE

CHECK VOLTAGE
REPLACE TRANSIENT
AT TBl ON
PROTECTOR
AC PANEL

REPLACE AC CHECK VOLTAGE


PANEL AT RIG SOURCE

REPLACE AC
CABLE

27-601-l 0

FIGURE 5-2. LOGIC DIAGRAM, RATEMASTER SIGNAL CONDITIONER POWER


5-2 DISTRIBUTION TO PROCESSOR PCB
INSTRUCTION MANUAL 27-60

a. Connect pulse simulator to the channel probe also requires a cable continuity test but a
(Jl 01, J102, or J103 of the signal condi- visual test of the magnetic probe LED indicates if the
tioner) where the problem is suspected. probe is operating.

NOTE 5-l 0 CABLE CONTINUITY. Test the signal cable


continuity by using a multimeter.
If the pulse simulator does not pulse, momen-
tarily depress RESET.
NOTE
b. Observe the two LED’s on the barrier PCB in
To test continuity of the digital output adapter
the circuit of the channel under test. If both
Y cable, use a multimeter on the 2K scale. Use
LED’s respond to the pulse simulator, a cir-
the block lead (neg) on the 5-pin connector.
cuit malfunction exists in the sensor input
Continuity between pin A of the 5-pin connec-
circuit outside the case. If the input LED
tor and A and B of one of the 4-socket connec-
(CRl, 2, or 3) does not respond, replace the
tors will be 600 to 1000 ohms and the same
barrier PCB. If the output LED (CR8, 9, or
for pin C and the A and B sockets of the other
IO) does not respond, either the barrier or
socket connector.
the processor PCB may need to be replaced.
C. Check the voltage at TP7 (Figure l-3) on the 5-l 1 PROXIMITY SENSOR AMPERAGE. Test the
processor PCB (I 0.00 ho.05 vdc). Replace amperage of the proximity sensor by using a
the processor PCB if voltage is not correct. multimeter in the calibration set-up shown in Figure
3-l. Connect the multimeter in line by disconnecting
d. Position the diagnostic switch (SW81 to 6.
the black lead and its sensor cable lead from the ter-
Use a multimeter at test point 1, 2, or 3
minal board of the case. With no metal within sens-
(8.33 &to.10 vdc). Use the ground lug for
ing range of the sensor, the reading is 7.0 f 1 .O mA.
the negative lead of the multimeter. Refer to
With the metal in sensing range, the reading is less
Table 3-l for other diagnostic switch setting
than 1 .O mA. If the sensor does not respond within
and voltage reading. Replace processor PCB
these limits, replace the sensor and recalibrate.
if voltage is not present.
e. Use a multimeter to check the voltage at pins 5-l 2 MAGNETIC PROBE. The magnetic probe is a
27, 31, and 35 of TSlOl, or check the visual test. The LED in the shell of the
voltage at socket A of J301, 302, or 303. A magnetic probe must momentarily blink (on or off)
voltage drop (0.5 vdc or more) from the when one end of a magnet is passed within l/2 to
reading at TPl, 2, or 3 indicates a problem 2-l /2 inches (12.7 to 63.5 mm) of the sensing end
with the barrier PCB. of the probe. A 5 ho.5 dc voltage should be pre-
sent across pins A and C of the connecting cable; 12
5-8 SENSOR SIGNAL CIRCUIT &3 dc voltage should be present across pins B and
C. If voltage is present on the cable, the LED should
5-9 The signal circuit from the signal conditioner blink when a magnet passes within range of the sen-
to a proximity sensor requires two tests: sor. If the probe does not respond, replace the probe.
cable continuity and sensor amperage. The magnetic

5-315-4
INSTRUCTION MANUAL 27-60
SECTION VI
INTRODUCTION TO ILLUSTRATED PARTS BREAKDOWN

6-l GENERAL of a part or assembly, note the column in which the first word of
the nomenclature appears. The first item directly above which ap-
6-2 This section describes how to use the GROUP pears one column to the left (except for attaching parts) is the
ASSEMBLY PARTS LIST (SECTION VII), NUMERICAL NHA.
INDEX (when included ) (SECTION VIII), and other related infor-
mation. 6-9 UNITS PER ASSEMBLY COLUMN. This column lists the
number of units required for one NHA (Step 7).
6-3 GROUP ASSEMBLY PARTS LIST SECTION
6-10 USE ON CODE COLUMN. Code letters in this column
6-4 The GROUP ASSEMBLY PARTS LIST section (See show variations in parts on two or more similar
Figures 7-l and subsequent) includes exploded views assemblies (Step 8).
accompanied by parts lists keyed to the index numbers on the il-
lustrations. Each assembly is listed in its disassembly order. When 6-11 NUMERICAL INDEX SECTION (When Includ-
an assembly illustration cannot show detail parts of one or more of ed)
its subassemblies, a separate detail illustration is furnished for the
subassembly. Figures 6-l and 6-2 describe and explain how to 6-12 The NUMERICAL INDEX section contains a numerical
use the parts list. listing of parts and/or drawings that are listed in the
GROUP ASSEMBLY PARTS LIST. Figure 6 2 explains how to use
6-5 FIGURE AND INDEX NUMBER COLUMN. Three groups the index.
of digits separated by dashes make up this column (i.e.
X-X-XX). The first two groups represent the figure number of the 6-13 ADDITIONAL PARTS LISTS (SECTIONS)
corresponding illustration. The last group of digits is the index (When Included)
number of each part. Most parts appear on the illustration (See
Steps 1, 2, and 3 of Figure 6-l 1. 6-14 Additional informative lists, such as SPARE PARTS LIST
and FUSE LIST, follow the GROUP ASSEMBLY PARTS
6-6 PART NUMBER COLUMN. This column lists TOTCO
LIST section or NUMERICAL INDEX section (as applicable).
part numbers. Information for order or purchase of these
items is contained in the DESCRIPTION column.
6-15 HOW TO USE THE ILLUSTRATED PARTS
BREAKDOWN
6-7 DESCRIPTION COLUMN. This column describes each
assembly, its attaching parts, and detail parts of the
6-16 Figure 6-2 demonstrates the use of the Illustrated Parts
assembly. A description may contain a parenthetical note. The
Breakdown.
note may cross-reference a subassembly to its detail illustration,
or the note may refer to its figure and index number of its NHA il-
lustration (Steps 5 and 9). 6- 17 ABBREVIATIONS

6-8 Listed parts indent to indicate relationship to their next 6-18 The following standard abbreviations may be used in the
higher assembly (NHA) (Step 6). To determine the NHA parts lists contained in this manual:

AP attaching parts HD head PHH phillips head


AR as required HDW hardware PN part number
ASSY assembly ID inside diameter PNH pan head
BDGH binding head INTL internal SLFLKG self-locking
CSK countersunk LED light emitting diode SLTD slotted
CT count LCD liquid crystal display SST stainless steel
CTN carton MTG mounting ST self-tapping
EXT external NHA next higher assembly STD standard
FILH fillister head NPT national pipe thread UNC unified coarse thread
FLH flat head NP not procurable UNF unified fine thread
GA gauge PCB printed circuit board UNS unified straight thread

6-l
INSTRUCTION MANUAL 27-60
SECTION VII
GROUP ASSEMBLY PARTS LIST

DRILLER’S
CONSOLE _

PNEUMATIC
DRILLING I
RECORDER
I
J402
---- A
J302 I
L -RIG AIR

r------
1 :
VISULOGGER
J-BOX
i
I
I
I ’ aTO E-MUD CONSOLE, DUAL
DIGITAL PSC CONSOLE, OR
BATTERY OPERATED PSC
(PUMPS 1 AND 2)

THRU

11

FIGURE 7-l. RATEMASTER SYSTEM


7-o
INSTRUCTION MANUAL 27-60

FIG. & UNITS USE


INDEX DESCRIPTION PER ON
NO. PART NUMBER 1234567 ASSY CODE

7-l -1 230256-001 RATEMASTER SYSTEM, With 2 proximity pump. . . .1


sensors and 1 RPM sensor
-2 230256-002 RATEMASTER SYSTEM, With 2 proximity pump. . . .1
sensors
-3 230256-003 RATEMASTER SYSTEM, With 2 limit switches . . . . ,1
and 1 RPM sensor
-4 2302 56-004 RATEMASTER SYSTEM, With 2 limit switch . . . . . .1
sensors
-5 230256-005 RATEMASTER SYSTEM, With 2 limit switch . . . . . .1
sensors (dual pump stroke) and 1 RPM
sensor
-6 235056-006 RATEMASTER SYSTEM, With 2 limit switch . . . . . .1 F
sensors (dual pump stroke)
-7 230251 . SIGNAL CONDITIONER ASSY, RATEMASTER . . . .1
(See Figure 7-2 for details)
-8 232389 . PROXIMITY SENSOR ASSY . . . . . . . . . . . . . . . .2 A,B
(See Figure 7-4 for details)
-9 270630-l 02 . CLAMP AND LIMIT SWITCH ASSY . . . . . . . . . . .2 CD
(See Figure 7-5 for details)
-10 272804-l 04 . PUMP STROKE SENSOR ASSY, Dual . . . . . . . . . .1 E,F
(See Figure 7-6 for details)
-11 235002 . MAGNETIC PROBE FINAL ASSY . . . . . . . . . . . . .I A,C,E
-12 232245 . RPM BRACKET AND MAGNET KIT. . . . . . . . . . . .1 A,C,E
(See Figure 7-7 for details)
-13 230352-004 . CABLE ASSY, Signal, shielded, 3-conductor, . . . . .2 A,B,
1 connector, for proximity sensor or C,D
clamp and limit switch (See 1, Figure
7-8 for details)
-14 232603-001 . CABLE ASSY, Rotary RPM sensor, shielded, . . . . .1 A,C,E
3-conductor, 2 connectors (See 11, Figure
7-8 for details)
-15 230368 . CABLE ASSY, Sensor input adapter, . . . . . . . . . . .1 ES
(Y-cable) for dual pump stroke sensor assy
See 17, Figure 7-8 for details)
-16 230367 . CABLE ASSY, Digital output adapter . . . . . . . . . .3 A,C,E
(Y-cable) for VISULOGGER J-box connection
(See 24, Figure 7-8 for details)
-17 230367 . CABLE ASSY, Digital output adapter . . . . . . . . . .2 B,D
(Y-cable) for VISULOGGER J-box connection
(See 24, Figure 7-8 for details)
-18 230366 . CABLE ASSY, Digital output transition, . . . . . . . AR
(1 required to interconnect between signal
conditioner jack and the cable from E-Mud
console, dual digital pump stroke counter,
or battery operated pump stroke counter)
(See 28, Figure 7-8 for details)
-19 230349-002 . CABLE ASSY, Signal, shielded . . . . . . . . . . . . . AR
(1 required for each pump or RPM to the
VISULOGGER J-box. 1 required for two
pumps to the E-mud console, dual digital
PSC, or the battery operated pump
stroke counter) (See 33, Figure 7-8
for details)

7-1
INSTRUCTION MANUAL 27-60

FIG. & UNITS USE


INDEX DESCRIPTION PER ON
NO. PART NUMBER 1234567 ASSY CODE

7-l -20 230348-011 . CABLE ASSY, Gauge, shielded (1 required . . . . . AR


for each gauge in driller’s console)
(See 38, Figure 7-8 for details)
-21 2 18023-001 . CABLE KIT, AC power, for signal . . . . . . . . . . . . AR
conditioner, Index No. 7 (Use only
as local safety codes permit (See 44,
Figure 7-8 for details)
-22* 2 18022-001 . INTERFACE KIT, Pneumatic drilling recorder, . . . . AR A,C,E
(Includes E/P transducer installation manual),
required to interface with 2 pumps (SPM) and
1 RPM (Includes Items 24 and 26).
-23” 2 18022-002 . INTERFACE KIT, Pneumatic drilling recorder, . . . . AR B,D,F
(Includes E/P transducer installation manual)
required to interface with 2 pumps (SPM)
and no RPM (Includes Items 25 thru 27).
-24 230352-002 . . CABLE ASSY, Signal, shielded, 3 conductors, . . . 3 ACRE
1 connector (See 6, Figure 7-8 for details)
-25 230352-002 . . CABLE ASSY, Signal, shielded, 3 conductors, . . . 2 B,D,F
1 connector (See 6, Figure 7-8 for details)
-26 272820-l 01 . . TRANSDUCER ASSY, E/P, Intrinsically safe . . . .3 A,C,E
(Refer to Related Publications for details)
-27 272820-l 01 . . TRANSDUCER ASSY, E/P, Intrinsically safe . . . . 2 B,D,F
(Refer to Related Publications for details)
-28” 230017 GROUNDING INSTRUCTIONS (Order any of the follow-
ing equipment, Items 30 thru 33, as required to install
the RATEMASTER Signal Conditioner, Index No. 7)
Refer to Paragraph 2-21 for applications)
-29” 999263-002 . ROD, Ground, copper clad, l/2 x 8 ft . . . . . . . . . AR
-30” 999264-001 . CLAMP, Ground, l/2-in. . . . . . . . . . . . . . . . . . AR
-31* 946624-002 , WIRE,solidcopper,No.8. . . . . . . . . . . . . . . . .AR
-32* 946940-014 . WIRE, Stranded copper, bare . . . . . . . . . . . . . . AR
-33” 94766 l-004 . WIRE, Stranded copper, exane insulated . . . . . . . AR

* Not Illustrated

7-2
INSTRUCTION MANUAL 27-60

THIS PAGE INTENTIONALLY LEFT BLANK.

7-3
INSTRUCTION MANUAL 27-60

16,

(SEE DETAIL Dl

(SEE DETAIL Cl
23
/

A’9

,211

I ti THRU 33
18 (SEE DETAIL F)

FIGURE 7-2. RATEMASTER SIGNAL CONDITIONER ASSEMBLY (SHEET 1 OF 2)


7-4
INSTRUCTION MANUAL 27-60

C d

VIEW E
38

2760 18 VIEW G

FIGURE 7-2. RATEMASTER SIGNAL CONDITIONER ASSEMBLY (SHEET 2 OF 2)


INSTRUCTION MANUAL 27-60

FIG. & UNITS USE


INDEX DESCRIPTION PER ON
NO. PART NUMBER 1234567 ASSY CODE

7-2-l 230251 RATEMASTER SIGNAL CONDITIONER ASSY ..... .I


(Refer to 7, Figure 7-l for NHA)
-2 230269 . PLATE, Identification ..................... 1
-3 999401-001 . RIVET, Univ hd, l/16 x 3/l 6, al (AP) ......... .4
-4 232398-001 . LABEL, Ground ......................... 1
-5 232398-007 . LABEL,ACIN ......................... .I
-6 969161-001 . ADAPTER, Conduit ...................... 1
-74 235272 . GROUNDLUGASSY .................... .I
-8 999449-l 64 .. SCREW, Slt, pnh, No. 1 O-32 x 5/l 6, ........ 1
sst (AP)
-9 999269-004 .. WASHER, Lock, ext tooth, sst (AP) .......... 1
-10 999279-007 .. NUT, Slflkg, hex, 3/8- 16, sst (AP) .......... 1
-11 99931 O-01 5 .. WASHER, Flat, special, sst (AP) ........... .4
-12 999397-503 .. NUT, Hex, 3/8- 16, silicone bronze (AP) ...... 1
-13 99932 l-008 .. WASHER, Helical lock, 3/8, sst (AP) ......... 1
-14 999217-I 42 .. WASHER, Flat, neopreme (AP) ............. 1
-15 232039 .. LUG, Grounding. ...................... 1
-16 230268 . LABEL, I/O identification. .................. 1
-17 99 1701-002 . ENCLOSURE, Corrosion inhibiting ............ 1
-18 218019 . SHIELD, Connector (Intrinsic safety) ........... 1
-19 218018 . SHIELD, Barrier PCB (Intrinsic safety) (spacers .... 1
must be removed first)
-20 23024 1 . ELECTRONICS CHASSIS ASSY (See Figure 7-3 ... 1
for details)
-21 999449-l 66 . SCREW, Sltd, pnh, No. 1 O-32 x 3/8, (AP) ..... .4
-22 999445-006 . WASHER, Flat, thin, No. 10 ............... .4
-23 999231-030 . HANDLE ............................ .I
-24 999440-018 . NUT, Stamped, 3/8- 16, (AP) ............. .2
-25 999445-010 . WASHER, Flat, 3/8, sst (AP) ............... .2
-26 99941 I-01 6 . WASHER, Shoulder, 3/8, fiber (AP) .......... .4
-27 232036 . BUSSBARASSY ...................... ..I
-28 999449-l 20 . SCREW, Pnh, No. 8-32 x l/2 (AP) .......... .6
-29 999279-024 . NUT, Slflkg, No. IO-32 (AP) .............. .2
-30 999445-006 . WASHER, Flat, thin, No. 10 (AP) ............. 2
-31 232069-l 08 . CABLE, Ground. ....................... .I
-32 999269-004 . WASHER,Star,No.lO .................. .l
-33 999484-266 . SPACER,No. IO-32x3/8(AP) ............ .2
-34 999449-l 84 . SCREW,Pnh,No. 10-32x l-1/8(AP). ....... .I
-35 999216-070 . WASHER,No. lO,nylon(AP) .............. .2
-36 999449-l 82 . SCREW,Pnh,No. 10-32x 1 (AP). .......... .I
-37 947645-002 . TIE POINT ........................... .3
-38 947619-001 . WRAP,Tie ......................... ...5
-39 230362 . HARNESS, Wiring, sensor input. ............. 1
-40 230263 . HARNESS, Wiring, digital output ............. 1
-41 230264 . HARNESS, Wiring, analog output. ............ 1
-42 999449-034 . SCREW,Pnh,No.4-40x1/2 (AP) ......... .48
-43 950859-024 . CAPWITHCHAIN ...................... .12
-44 999442-001 . WASHER, Sealing ..................... .12
-45 970118-008 . NUT,Ring .......................... .I2
-46 235386-002 . GASKET .......................... ..12
-47 230266 . LABEL, Intrinsic safety .................... 1
-48 999401-001 . RIVET,Univhd, l/16x3/16,al(AP) ......... .6
-49 230250 . BOX, Modified ........................ .I

7-6
INSTRUCTION MANUAL 27-60

THIS PAGE INTENTIONALLY LEFT BLANK.

7-7
INSTRUCTION MANUAL 27-60

PC230091
FAB REY
0

1
I c

t
9

FIGURE 7-3. RATEMASTER ELECTRONIC CHASSIS ASSEMBLY


7-8
INSTRUCTION MANUAL 27-60

FIG. & UNITS USE


INDEX DESCRIPTION PER ON
NO. PART NUMBER 1234567 ASSY CODE

7-3-l 230241 ELECTRONIC CHASSIS ASSY, RATEMASTER. ... REF


(See 20, Figure 7-2 for NHA)
-2 230278 . CABLE ASSY .......................... 1
-3 230242 . ACPANELASSY. ...................... .l
-4” 938201-030 .. FUSE,3Amp,SB ..................... .I
-5 230252 . TRANSIENT PROTECTOR ASSY ............. 1
-6 230253 . POWER SUPPLY ASSY ................... .I
-7 230276 . RIBBON CABLE ASSY .................... 1
-8 230092 . PCB ASSY, Processor .................... 1
-9 999449-064 . SCREW,Pnh,No.6-32xl/4(AP). ......... .3
-10 230086 . PCBASSY, Barrier. ...................... 1
-11 999531-001 . SPACER (API ......................... .2
-12 999449-068 . SCREW,Pnh,No.6-32x3/8(AP) .......... .4
-13 230254 . PANELASSY, Isolation ................... 1
-14 999449-068 . SCREW,Pnh,No.6-32x3/8(AP) .......... .4
-15 230232 . BASEPLATEASSY .................... ..l

* Not Illustrated

7-9
INSTRUCTION MANUAL 27-60

FIGURE 7-4. PROXIMITY SENSOR

FIG. & UNITS USE


INDEX DESCRIPTION PER ON
NO. PART NUMBER 1234567 ASSY CODE

7-4-l 4 232389 SENSOR, Proximity (Refer to 29, Figure 7-l for . . . REF
NHA)
-2 218163 PLATE, Identification .................... 1
-3 999245-005 SCREW, Drive, 0.067 x 3116 (API .......... .2
-4 955701-009 STRAIN RELIEF ........................ 1
-5 978915-001 GASKET ........................... ..l
-6 9 5 1508-004 BLOCK, Terminal ...................... .I
-7 9 508 14-004 TERMINAL, Crimp, No. 6. ................ .2
-8 232393 CASE, Modified, proximity sensor ............ 1
-9 969602-027 BUSHING, Reducer. ..................... 1
-10 999298-002 NUT,Lock, 1/4NPT(AP). ................ .2
-1 1 232397 PIPE, Threaded, l/4 NPS (National Pipe ........ 1
Special)
-12 232399 UNION, Bulkhead, l/4-1 8 (National ......... .I
Pipe Special, Mechanical), l/2-1 4 O.D.
-13 999298-004 NUT,Lock, l/2-14NPTIAP) ............... 1
-14 969602-027 BUSHING, Reducer. .................... .I
-15 230118 ADAPTER .......................... ..l
-16 932814-005 SENSOR, Proximity, with locknut ............ 1

7-10
INSTRUCTION MANUAL 27-60

27 60’20

FIGURE 7-5. CLAMP AND LIMIT SWITCH ASSEMBLY

FIG. & UNITS USE


INDEX DESCRIPTION PER ON
NO. PART NUMBER 1234567 ASSY CODE

7-5-l 4 270630- 102 CLAMP AND LIMIT SWITCH ASSY, . . . . . . . . . . . .1


(Refer to 9, Figure 7-l for NHA)
-24 27064 1 . LIMIT SWITCH ASSY . . . . . . . . . . . . . . . . . . . . .1
-3 999397-031 . NUT,Hex,No. IO-24,sst(AP) . . . . . . . . . . . . .2
-4 999321-118 . LOCKWASHER, No. 10, sst (API . . . . . . . . . . . . .2
-5 999368-801 . BOLT,Hex,No. lo-24x2,sstIAP) . . . . . . . . . .2
-6 270559 . . ROD, Actuator, 0.125 dia x 18 in., sst . . . . . . . .1
-7 933014-001 . . SWITCH, Limit (cutler/hammer) . . . . . . . . . . . .1
-8 933014-002 . . OPERATING LEVER . . . . . . . . . . . . . . . . . . . .1
-9 955701-007 . . CONNECTOR, Cable. . . . . . . . . . . . . . . . . . . .1
-10 270639 . CLAMPASSY . . . . . . . . . . . . . . . . . . . . . . . . . .1

7-l 1
INSTRUCTION MANUAL 27-60

TO ODD NUMBERED
PUMP SENSOR 7
0 EVEN NUMBERED (SEE INDEX 10)
UMP SENSOR

FIGURE 7-6. PUMP STROKE SENSOR ASSEMBLY

FIG. & UNITS USE


INDEX DESCRIPTION PER ON
NO. PART NUMBER 1234567 ASSY CODE

7-6-l 4 272804-l 04 PUMP STROKE SENSOR ASSY, Dual, for . . . . . . . REF A


Class 1, Group D hazardous area, Exane cables
(Refer to 10, Figure 7-l for NHA)
-14 272804-l 02 PUMP STROKE SENSOR ASSY, Dual, for . . . . . . . REF B
Class 1, Group D hazardous area, SJO cables,
may be used as optional equipment for
PN 272804-l 04; refer to local safety reg-
ulations. (Refer to 10, Figure 7-l for NHA)
-24 270630-l 02 . CLAMP AND LIMIT SWITCH ASSY . . . . . . . . . . .2
-34 270641 . . LIMIT SWITCH ASSY . . . . . . . . . . . . . . . . . . .I
-4 999397-031 . . NUT,Hex,No. IO-24,sst(AP). . . . . . . . . . . .2
-5 999321-118 . . LOCKWASHER, No. 10, sst (AP) . . . . . . . . . . .2
-6 999368-801 . . SCREW, Hex, No. lo- 24 x l-l /4, sst (API . . . .2
-7 270559 . . . ROD, Actuator, 0.125 dia x 18 in., sst . . . . . . 1
-8 933014-001 . . . SWITCH, Limit (cutler/hammer) . . . . . . . . . . .1
-9 9330 14-002 . . . OPERATING LEVER . . . . . . . . . . . . . . . . . . .I
-10 955701-007 . . CONNECTOR, Cable. . . . . . . . . . . . . . . . . . . . 1
-11 270639 . . CLAMP ASSY . . . . . . . . . . . . . . . . . . . . . . . .I
-12 272836-l 02 . LABEL (FM approval) . . . . . . . . . . . . . . . . . . . . .I

7-l 2
INSTRUCTION MANUAL 27-60

FIG. & UNITS USE


INDEX DESCRIPTION PER ON
NO. PART NUMBER 1234567 ASSY CODE

7-6-l 34 272800-l 04 . JUNCTION BOX ASSY (For Class 1, Group D . . . . . 1


hazardous area)
-144 272800-l 02 . JUNCTION BOX ASSY (For Class 1, Group D . . . . . 1
hazardous area)
-154 232617-I 02 . . CABLE ASSY, Shielded, sensor extension (used . 1
only on PN 272800-l 04)
-164 232616-I 03 . . CABLE ASSY, Sensor, 3 conductor (used . . . . . . 1
only on PN 272800-I 02)
-17 947619-055 . . . STRAP, Cable. . . . . . . . . . . . . . . . . . . . . . .3
-18 949807-389 . . . CONNECTOR, 4-Pin . . . . . . . . . . . . . . . . . . 1
-19 946927-002 . . . CABLE, 18/4, Shielded Exane (used . . . .250 ft A
only on PN 232616-l 04)
-20 946927-003 . . . CABLE, Power, SJO 18/3 (used . . . . . . .250 ft B
only on PN 232617-I 03)
-21 271209-103 . . CABLE ASSY, Exane, JB to SW2, red . . . . . . . . 1 A
and white leads (25 ftl
-22 271209-104 . . CABLE ASSY, Exane, JB to SW1 , red . . . . . . . .I A
blk leads (25 ft)
-23 271209-101 . . CABLE ASSY, JB to SW2 or 4, grn and . . . . . . . 1 B
wht leads (25 ft)
-24 27 1209-l 02 . . CABLE ASSY, JB to SW 1 or 3, blk and . . . . . . . . 1 B
grn leads (25 ft)
-25 955701-007 . . CONNECTOR, Cable. . . . . . . . . . . . . . . . . . . .3
-26 978915-001 . . GASKET (Replacement part for. , . . . . . . . . . . . 1
PN 955220-025)
-27 955220-025 . . CONDUIT, Outlet . . , . . . . . . . . . . . . . . . . . . . 1
-28 949864-004 . . CONNECTOR, Wirenut . . . . . . . . . . . . . . . . . .4

7-13
INSTRUCTION MANUAL 27-60

FIGURE 7-7. RPM BRACKET AND MAGNET KIT

FIG. & UNITS USE


INDEX DESCRIPTION PER ON
NO. PART NUMBER 1234567 ASSY CODE

7-7-l 232245 RPM BRACKET AND MAGNET KIT (Refer to 12, . . REF
Figure 7-l for NHA)
-2 999356-002 . BOLT,Hexhd,6in. . . . . . . . . . . . . . . . . . . . . .l
-3 970604-005 . CLAMP, Hose, worm (only one required; . . . . . . .2
one is spare)
-4 967402-001 MAGNET, Polished (only one required; two. . . . . . .3
are spares)
-54 232350 . RPM BRACKET ASSY (consisting of index items . . 1
6 thru 14)
-6 232363 . . EXTENSION, RPM bracket . . . . . . . . . . . . . . . 1
-7 999279-005 . . NUT, Hex, slflkg, l/4-20, sst (API. . . . . . . . . .4
-8 9992 17-785 . . WASHER,Flat, 1/4,sst(AP) . . . . . . . . . . . . .8
-9 232364 . . SPACER, RPM bracket (API . . . . . . . . . . . . . .2
-10 99937 I-006 . . U-BOLT, l/4-20 x l-3/4, 1 inch I.D. (AP) . . . . .2
-1 1 999279-005 . . NUT, Hex, slflkg, l/4-20, sst (API. . . . . . . . . .4
-12 9992 17-785 . . WASHER,Flat, 1/4,sst(AP) . . . . . . . . . . . . .4
-13 999393-226 . . SCREW, Hex, 1/4-20x l,sst(AP) . . . . . . . . .4
-14 232362 . . BRACKET, RPM . . . . . . . . . . . . . . . . . . . . . . 1

7-14
INSTRUCTION MANUAL 27-60

THIS PAGE INTENTIONALLY LEFT BLANK.

7-15

_-
INSTRUCTION MANUAL 27-60

FOR E/P TRANSDUCERS, PROXIMITY SENSOR,


AND CLAMP AND LIMIT SWITCH

13 15 16 12
SOCKET I I I PIN

011 FOR MAGNETIC PROBE

PIN

017 FOR PUMP STROKE SENSOR, DUAL

SOCKET

PIN

024 FOR DIGITAL OUTPUTS

SOCKET PIN

27-m 23
028 DIGITAL OUTPUT TRANSITION
(SINGLE CABLE, TWO CHANNELS)

FIGURE 7-8. INTERCONNECT CABLES (SHEET 1 OF 2)


7-16
INSTRUCTION MANUAL 27-60

PIN
PIN

INTERFACE OUTPUT CABLE

39
PIN SOCKET

I 044 AC POWER CABLE KIT FOR


SIGNAL CONDITIONER
27-601-24

FIGURE 7-8. INTERCONNECT CABLES (SHEET 2 OF 2)

FIG. & UNITS USE


INDEX DESCRIPTION PER ON
NO. PART NUMBER 1234567 ASSY CODE

7-8-14 230352-004 CABLE ASSY, Shielded signal, 3-conductor, . . . . . REF


1 connector (Refer to 13, Figure 7-l for NHA)
-2 949807-389 . CONNECTOR, 4-Pin . . . . . . . . . . . . . . . . . . . . . 1
-3 947619-055 . STRAP, Cable. . . . . . . . . . . . . . . . . . . . . . . . . .4
-4 996857-028 . TUBING, Heat shrink, l/2 dia. . . . . . . . . . . . . . . AR
-5 946941-002 . CABLE, Shielded Exane, 18/3 (SJO cable may 125 ft
be substituted where safety codes allow) (a sub-
stitute length may be specified in increments
of 25 ft)
-64 230352-002 CABLE ASSY, Shielded signal, 3-conductor, . . . . . REF
1 connector (Refer to 24 and 25, Figure 7-l
for NHA)
-7 949807-389 . CONNECTOR, 4-Pin . . . . . . . . . . . . . . . . . , . . . 1
-8 9476 19-055 . STRAP, Cable. . . . . . . . . . . . . . . . . . . . . . . . . .4
-9 996857-028 . TUBING, Heat shrink, l/2 dia . . . . . . . . . . . . . . AR
-10 946941-002 . CABLE, Shielded Exane, 18/3 (SJO cable may .75 ft
be substituted where safety codes allow) (a sub-
stituted length may be specified in increments
of 25 ft)
-114 232603-001 CABLE ASSY, Rotary RPM sensor (Refer to 14, . . . REF
Figure 7-l for NHA)

7-l 7
INSTRUCTION MANUAL 27-60

FIG. & UNITS USE


INDEX DESCRIPTION PER ON
NO. PART NUMBER 1234567 ASSY CODE

7-8-l 2 949807-389 . CONNECTOR, 4-Pin .................... .I


-13 949807-220 . CONNECTOR, 4-Socket ................... 1
-14’ 996857-024 . TUBING, Heat shrink, l/8 dia .............. AR
-15 947619-055 . STRAP, Cable. ........................ .3
-16 94694 I-002 . CABLE, Shielded Exane, 18/3 (SJO cable may .75 ft
be substituted where safety codes allow)
-174 230368 CABLE ASSY, Sensor input adapter (Refer to 15, . . REF
Figure 7-8 for NHA)
-18 949807-220 . CONNECTOR, 4-Socket ................... 1
-19 949807-389 . CONNECTOR, 4-Pin .................... .2
-20 947619-055 . STRAP, Cable. ........................ .3
-21 996864-004 . TUBING, Heat shrink, transition-Y ............ 1
-22 996857-025 . TUBING, Heat shrink, 3/l 6 dia ............. AR
-23 94694 I-002 . CABLE, Shielded Exane, 18/3 ............ .3 ft
-244 230367 CABLE ASSY, Digital output adapter (Refer to 16 . . REF
and 17, Figure 7-l for NHA)
-25 949809-006 . CONNECTOR, 5-Pin ..................... 1
-26 949807-220 . CONNECTOR, 4-Socket .................. .2
-27 947619-055 STRAP, Cable, ... ..... ....... .... .. ... .3
-284 230366 CABLE ASSY, Digital output transition (Refer to 18, REF
Figure 7-8 for NHA)
-29 949807-220 . CONNECTOR, 4-Socket ................... 1
-30 949809-006 . CONNECTOR, 5-Pin ..................... 1
-31 947619-055 . STRAP, Cable. ........................ .2
-32 946941-003 CABLE, Shielded Exane .... .... .. .2 ft
-334 230349-002 CABLE ASSY, Signal, shielded (Refer to 19, ............ REF
Figure 7-l for NHA)
-34 949807-389 . CONNECTOR, 4-Pin .................... .2
-35 947619-055 . STRAP, Cable. ........................ .4
-36” 996857-024 . TUBING, Heat shrink, l/8 dia .............. AR
-37 946941-003 . CABLE, Shielded Exane, 18/4 (SJO may be .. .75 ft
substituted where safety codes allow) (a sub-
stitute length may be specified in increments
of 25 ft)
-384 230348-011 CABLE ASSY, Gauge, shielded (Refer to 20, ..... REF
Figure 7-l for NHA)
-39 949807-393 . CONNECTOR, 3-Pin .................... .I
-40 949807-39 1 . CONNECTOR, 3-Socket ................... 1
-41 947619-055 . STRAP, Cable. ........................ .4
-42 * 996857-024 . TUBING, Heat shrink, l/8 dia .............. AR
-43 946941-002 . CABLE, Shielded Exane, 18/3 (SJO cable may .75 ft
be substituted where safety codes allow) (a
substitute length may be specified in incre-
ments of 25 ft)
-444 218023-001 CABLE KIT, AC power (Refer to 21, Figure 7-l ... REF
for NHA)
-45 955706-004 . CONNECTOR, Cord grip .................. .1
-464 234667 . CABLEASSY,ACin .................... .I
-47 950827-001 .. TERMINAL, Spade .................... .3
-48 947619-055 .. STRAP, Cable ....................... .I
-49 996857-029 .. TUBING, Heat shrink, 3/4 dia ........... .2-in.
-50 9469 1 O-002 .. CABLE,SO18/3.. ................. .60ft

* Not Illustrated

7-18

_.-“---.-.. -
INSTRUCTION MANUAL 27-60
SECTION VIII
NUMERICAL INDEX

FIGURE & FIGURE &


PART NUMBER INDEX NO. PART NUMBER INDEX NO.

218018 7-2-l 9 230368 7-l-l 5


218019 7-2-l 8 7-8-l 7
218022-001 7-1-22 232036 7-2-27
218022-002 7-l-23 232039 7-2-l 5
218023-001 7-l -21 232069-l 08 7-2-3 1
7-8-44 232245 7-1-l 2
230017 7-l-28 7-7-l
230086 7-3-l 0 232350 7-7-5
230092 7-3-8 232362 7-7-14
230118 7-4-l 5 232363 7-7-6
230232 7-3-l 5 232364 7-7-9
230241 7-2-20 232389 7-l-8
7-3-l 7-4-l
230242 7-3-3 232393 7-4-8
230250 7-2-49 232396-001 7-4-2
23025 1 7-l-7 232397 7-4- 11
7-2-l 232398-001 7-2-4
230252 7-3-5 232398-007 7-2-5
230253 7-3-6 232399 7-4-l 2
230254 7-3-l 3 232603-001 7-1-14
230256-001 7-l-l 7-8-l 1
230256-002 7-l-2 232616-l 03 7-6-l 6
230256-003 7-l-3 232617-I 02 7-6-l 5
230256-004 7-l-4 234667 7-8-46
232056-005 7-l -5 235002 7-l-l 1
230256-006 7-l-6 235272 7-2-7
230263 7-2-40 235386-002 7-2-46
230264 7-2-41 270559 7-5-6
230266 7-2-47 7-6-7
230268 7-2-l 6 270630-l 02 7-l-9
230269 7-2-2 7-5-l
230276 7-3-7 7-6-2
230278 7-3-2 270639 7-5-l 0
230348-010 7-l -20 7-6-l 1
7-8-38 270641 7-5-2
230349-001 7-1-19 7-6-3
7-8-33 271209-l 01 7-6-23
230352-001 7-l -24 27 1209-l 02 7-6-24
7-l-25 27 1209- 103 7-6-2 1
7-8-6 27 1209-I 04 7-6-22
230352-004 7-1-13 272800-l 02 7-6-l 4
7-8-l 272800-l 04 7-6-l 3
230362 7-2-39 272804-l 02 7-I-10
230366 7-1-18 7-6-l
7-8-28 272804-I 04 7-l-10
230367 7-1-16 7-6-l
7-1-17 272820-l 01 7-l -26
7-8-24 7-l-27

8-1
INSTRUCTION MANUAL 27-60

FIGURE & FIGURE &


PART NUMBER INDEX NO. PART NUMBER INDEX NO.

272836-l 02 7-6-l 2 955701-007 7-5-9


9328 14-005 7-4- 16 955701-007 7-6-l 0
933014-001 7-5-7 955701-007 7-6-25
933014-001 7-6-8 955701-009 7-4-4
933014-002 7-5-8 955706-004 7-8-45
7-6-9 967402-001 7-7-4
938201-030 7-3-4 969161-001 7-2-6
946624-002 7-l -31 969602-027 7-4-9
9469 1 O-002 7-8-50 7-4-l 4
946927-003 7-6-20 970118-008 7-2-45
946940-014 7-l-32 970604-005 7-7-3
94694 I-002 7-8-5 978915-001 7-4-5
7-8-l 0 7-6-26
7-8-l 6 991701-002 7-2-l 7
7-8-23 996857-024 7-8-l 4
7-8-32 7-8-40
7-8-43 996857-024 7-8-36
946941-003 7-8-32 7-8-42
7-8-37 996857-025 7-8-22
947619-001 7-2-38 996857-028 7-8-4
947619-055 7-6-l 7 7-8-9
7-8-3 996857-029 7-8-49
7-8-8 996864-004 7-8-21
7-8-l 5 999216-070 7-2-35
7-8-20 999217-l 42 7-2-l 4
7-8-27 999217-785 7-7-8
7-8-31 7-7-l 2
7-8-35 999231-030 7-2-23
7-8-4 1 999245-005 7-4-3
7-8-48 999263-002 7-l -29
947645-002 7-2-37 999264-001 7-l -30
94766 l-004 7-l-33 999269-004 7-2-9
949807-220 7-8-l 3 7-2-32
7-8-l 8 999279-005 7-7-7
7-8-26 7-7-l 1
7-8-33 999279-007 7-2-l 0
949807-389 7-6-l 8 999279-024 7-2-29
7-8-2 999298-002 7-4-l 0
7-8-7 999298-004 7-4-l 3
7-8-l 2 99931 O-01 5 7-2-l 1
7-8- 19 999321-008 7-2-l 3
7-8-34 999321-118 7-5-4
949807-39 1 7-8-40 7-6-5
949807-393 7-8-39 999356-002 7-7-2
949809-006 7-8-25 999368-801 7-5-5
7-8-34 7-6-6
949864-004 7-6-28 99937 l-006 7-7-l 0
950814-004 7-4-7 999393-226 7-7-l 3
950827-001 7-8-47 999397-03 1 7-5-3
950859-024 7-2-43 7-6-4
955220-025 7-6-27 999397-503 7-2-l 2

8-2
INSTRUCTION MANUAL 27-60

FIGURE & I FIGURE & I


PART NUMBER INDEX NO. I PART NUMBER INDEX NO. I

999401-001 7-2-3 999449-068 7-3-l 2


7-2-48 999449-068 7-3-l 4
99941 l-01 6 7-2-26 999449-l 20 7-2-28
999440-018 7-2-24 999449-l 64 7-2-8
999442-001 7-2-44 999449-l 66 7-2-21
999445-006 7-2-22 999449-l 82 7-2-36
999445-006 7-2-30 999449-I 84 7-2-34
999445-010 7-2-25 999484-266 7-2-33
999449-034 7-2-42 999531-001 7-3-l 1
999449-064 7-3-9

8-318-4
INSTRUCTION MANUAL 27-60
SECTION IX
SPARE PARTS LIST

9-1 GENERAL INFORMATION will reduce the equipment downtime when replace-
ment of parts is necessary. Standard hardware items
9-2 This section contains information for spare are not included. Sufficient information for obtaining
parts. Part numbers and quantities to be these items is contained in the parts listing in the
ordered will depend on each repair facility’s ex- Group Assembly Parts List in Section VII. For conve-
perience. The system configuration used will deter- nience, spare parts (Refer to Table 9-l 1 are arranged
mine whether some spares are required for replace- in ascending numerical order by Figure and Index
ment. An inventory of readily available spare parts Numbers.

TABLE 9-l. SPARE PARTS LIST

FIGURE & PART


INDEX NO. NUMBER DESCRIPTION QTY
7-l-8 232389 Proximity Sensor Assy 2
7-4-l
7-l-l 1 235002 Magnetic Probe 1
7-3-5 230252 Transient Protector Assy 1
7-3-6 230253 Power Supply Assy 1
7-3-8 230092 PC Board Assy, Processor 1
7-3-l 0 230086 PC Board Assy, Barrier 1
7-5-2 270641 Limit Switch 2
7-6-8
7-7-4 967402-001 Polished Magnet 3
7-8-24 230376 Digital Output Adapter Cable 1
7-8-28 230366 Digital Output Transition Cable 1

9-l 19-2
INSTRUCTION MANUAL 27-60
ADDENDUM A
PAGE 1 OF 7

A-l INTRODUCTION tions to meet specific needs. The system can


monitor up to 3 pumps and/or rotary table combina-
A-2 This addendum provides information about tions by using various combinations of input sensors
the differences between the standard Rate- and output display devices. Shielded flexible cable is
Master Ty and the new explosion-proof used for all intrinsically safe connections to the
RATEMASTER. General information concerning the peripheral devices. TOTCO will furnish the ap-
operation and maintenance of the standard RATE- propriate cable and/or cable assemblies with each
MASTER is covered in Instruction Manual 27-60; system unless the customer elects to furnish cable.
this addendum deals only with the explosion-proof Customer furnished cable must meet or exceed re-
RATEMASTER. quirements specified by TOTCO. The RATEMASTER
enclosure is equipped with seal fittings and cord
A-3 HAZARDOUS LOCATIONS grips on all cable openings for the input/output con-
nections.
A-4 Figure A-l shows the hazardous location re-
quirements for the RATEMASTER Signal NOTE
Conditioner. Note that the explosion-proof
The maximum number of input and output con-
RATEMASTER Signal Conditioner can be installed in
nections is limited by the enclosure design to a
a Class I, Division 1, Groups C and D, hazardous
total of 12 cables.
location.

A-5 WIRING INTERCONNECTIONS

A-6 The explosion-proof RATEMASTER can be


connected in a varity of different configura-

HAZARDOUS LOCATION HAZARDOUS LOCATION


CLASS 1, DIV. 1, GROUPS C AND I CLASS I. DIV. 2, GROUPS C AND
D (PER NEC ART 500- 1984) D (PER NEC ART 500- 1984)
I

I
MAGNETIC
PROBE
I

PROXIMITY I
REFER TO
SENSOR - RATEMASTER -- RELATED
SIGNAL PUBLICATIONS
CONDITIONER FOR SAFETY
(EXPLOSION- - - INSTALLATION
CLAMP AND PUMP STROKE
PROOF) -I- REQUIREMENTS
LIMIT SWITCH

I _
PUMP
STROKE PUMP STROKE
SENSOR I
b 4

2- 60 JO
1 - CONSOLE) 1
\

FIGURE A-l. HAZARDOUS LOCATIONS


INSTRUCTION MANUAL 27-60
ADDENDUM A
PAGE 2 OF 7

A-7 Figure A-2 shows wiring connections for NOTE


various types of input sensors and output
The following items have been approved as ex-
display devices. Note that the cable shields must be
pendable items for the installation and/or re-
connected to the buss bar inside the enclosure. The
placement of the potted sealing fittings. Apply
shield must only be connected at the end that is con-
anti-seize thread lubricant to all male threads of
nected to the main piece of equipment he., RATE-
fitting components.
MASTER Signal Conditioner). The shield at the op-
posite end of the cable must be cut off flush with the 991915-002 Sealing Compound, 1 Box
jacket. When connecting two pieces of electronic 992419-002 Lubricant, Thread, Anti-Seize
equipment that are grounded individually (such as 956288-007 Fitting, Sealing, (condulet)
the RATEMASTER Signal Conditioner and the VISU-
a. Remove the plugs from the sealing fittings.
LOGGER@ J-Box), the shield may be connected at
either end but not at both ends. b. Use packing fiber to form dams at both ends
of the fitting chamber. The packing must
NOTE hold the individual wires so that they do not
touch each other or the walls of the fitting.
Exane cable assemblies are available to meet all
interconnection applications and grounding C. Pack the fiber firmly and remove any loose
needs. When ordering exane cables, always pieces of packing fiber from inside the
consider which end must provide the shield chamber.
ground and specify the appropriate cable con-
d. Replace and tighten the large plug.
figuration. Each exane cable assembly is mark-
ed to either indicate the end where the shield is e. Mix the sealing compound according to the
grounded in a connector or to indicate the end directions on the package.
where the shield must be grounded during in-
f. Pour sealing compound into the fitting
stallation. Remember that a ground loop may
chamber through the hole for the small plug.
be created if the shield is grounded at both ends
Fill to the level as shown in Figure A-4.
of a cable; this could create an interference
problem. 9. Replace and tighten the small plug.
h. Allow sealing compound to cure 24 hours
A-8 Part numbers for applicable cable and/or
before operating the system.
cable assemblies are listed in Table A-l.
Dash numbers on part numbers specify cable length;
other lengths are available on request. Refer to
Figure A-3 for proper cable usage.

A-9 POTTING SEALING FITTINGS

DO NOT POT THE SEALING FITTINGS UNTIL


THE INSTALLATION IS COMPLETE AND THE
SYSTEM HAS BEEN SATISFACTORILY
TESTED.

A-l 0 Pot the sealing fitting as follows (See Figure


A-4) :

ALLOW THE SEALING COMPOUND TO CURE


FOR AT LEAST 24 HOURS BEFORE OPERA-
TING THE RATEMASTER.

@ REGISTERED TRADEMARK FOR BAKER INTERNATIONAL CORPORATION


INSTRUCTION MANUAL 27-60
ADDENDUM A
PAGE 3 OF 7

TSlOl
O-l OV + (BLK) -
,
r CH :“5 I 1
r--’
I
I
-1

II JI 1 -_.- .__.. _-. NC (

3 34k.1
I
33. ! ’ I
I E/P TRANSDUCER
?’ LPOTTEDa 1
TO BUSS BAR FITTING
0- 1 OV + (BLK)
f----1
1
NC (RED)- AB METER
CH ::,
2 30. ’ ! I I
29. !! I 1
1 E/P TRANSDUCER
LPOTTED’
TO B&S BAR FITTING

r
0- 1 OV + (BLK)
l----1
NC (RED)- AB METER
I
28, ;-; I
CH 27. ! : I 1 GND IWHT) c O-10 V
I I
1 26, ’ ! I I L
25 ” I
1 E/P TRANSDUCER
- ‘T’ LPOTTEDa 1
TO BUSS BAR O-4 mA - (WHTI O-4 mA
FITTING

/ r ---
24 1 NC (RED)- A
CH 23 I I
3 22 i-f (WHT) I 8 RPM
(BLK) LPOTTEDJ c
TO BUSS BAR FITTING
A
CH :;
(WHT) a PUMP
- 1
(BLK) LPOTTED’ NC (REDI- C
TO BUSS BAR FITTING
r---i A
I
W-IT) I y- PUMP
1 I - 2
(BLK) LPOTTEDd NC (RED)--
TO BUSS BAR FITTING

I I
(RED) r, --- 1 1
A
CH:: II I
10 !’ (WI-IT) I 8 MAGNETIC
3 I I - PROBE
L (BLKI 1-)~ LPOTTEDJ C
g ‘L FITTING
TO BUSS
- _ BAR (WHT) r---i
I I C
CH t ;i I I LIMIT
(BLK)
I I NC SWITCH
NC (RED)-
‘-POTTED J
TO BUSS BAR
FITTING
---
WHTI _ 1
1 I BLUE
CH : d I PROXIMITY
I I (BLKI 1 = ! BLK SENSOR
l : I NC (RED)-
LPOTTEDJ
TO BUSS BAR FITTING

FIGURE A-2. EXPLOSION-PROOF RATEMASTER WIRING DIAGRAM


(SHEET 1 OF 2)
INSTRUCTION MANUAL 27-60
ADDENDUM A
PAGE 4 OF 7

q
24
CH 23
3 22
21

(BLKI r---
-A

TO BUSS BAR FITTING

(BLK) r-r-1 A
(WHT) ! a--
(GRN) ! --+ E-MUD
(RED1 ; _ ;- -D
LPOTTEDJ
TO BUSS BAR
FITTING

(BLK) [NOT USED) .-.

DUAL PUMP STROKE


SENSOR ASSEMBLY
I I - i I
TO BUSS BAR I -
L--l
POTTED z -
FITTING (SHIELD)

(SHIELD)
A
(RED) ” c LIMIT
(BLKI i ! SWITCH
(WHTI (NOT USED) I ! .NC CHANNEL 1

FIGURE A-2. EXPLOSION-PROOF RATEMASTER WIRING DIAGRAM


(SHEET 2 OF 2)
INSTRUCTION MANUAL 27-60
ADDENDUM A
PAGE 5 OF 7
TABLE A-l. CABLE ASSEMBLIES AND RAW CABLE

PART NUMBER CABLE ASSEMBLY DESCRIPTION


230346-002 l 3 Conductor, 1 Connector, Gauge, Shielded, 75 feet
230350-011 l 4 Conductor, 1 Connector, Signal, Shielded, 75 feet
232603-003 Rotary RPM Sensor Interconnect
PART NUMBER RAW CABLE DESCRIPTION
946941-002 Exane Shielded Cable, 18/3, 600 V, 125 degrees C,
Flame Retardant, Sunlight and Oil Resistant
946941-003 Exane Shielded Cable, 18/4, 600 V, 125 degrees C,
Flame Retardant, Sunlight and Oil Resistant

*Note: Raw cable 946941-002 can be used in place of cable assemblies requiring 3 conduc-
tors. Raw cable 94694 l-003 can be used in place of cable assemblies requiring 4
conductors.
INSTRUCTION MANUAL 27-60
ADDENDUM A
PAGE 6 OF 7

TSlOl
CABLE ASSY 230346-002

CABLE EXANE 1 B/3 SHIELDED 94694 l-002


E/P TRANSDUCER
r) O-4 mA

CABLE ASSY 230346-002

CABLE EXANE 1813 SHIELDED 946941-002


E/P TRANSDUCER
r1 O-4 mA

CABLE ASSY 230346-002


CH f;
1 26 CABLE EXANE 18/3 SHIELDED 946941-002
25 E/P TRANSDUCER
cl FI O-4 mA

24
CH 23
3 22 CABLE ASSY 230350-011 RPM
21

t 1 -

CABLE ASSY 230350-011

CABLE ASSY 230350-011

CABLE ASSY 232603-003


I Fl
B MAGNETIC
CABLE ASSY 232603-003
PROBE
C
El

CABLE, EXANE SHIELDED 18/3, 946941-002


CH ‘: LIMIT
2 6 CABLE, EXANE SHIELDED 1813, 946941-002 SWITCH
5
cl

CABLE, EXANE SHIELDED 1 B/3, 946941-002


PROXIMITY
CABLE, EXANE SHIELDED 1 B/3, 946941-002 SENSOR

FIGURE A-3. CABLE USAGE


INSTRUCTION MANUAL 27-60
ADDENDUM A
PAGE 7 OF 7

PLUGS
.SEALJNG SEALING COMPOUND

1
PACKING COMPOUND
MATERIAL
/
DAM

PACKING MAiERlAL DAMS

VERTICAL INSTALLATION HORIZONTAL INSTALlATlON

FIGURE A-4. PACKING AND POTTED SEALING FITTINGS