AutoTrak

Operations Manual

Section 4
Operating
Procedures

Tool Communication
System and Cabling

ATK-20-70-0000-04-01
 AutoTrak
Operations Manual
Operating Procedures
ATK-20-70-0000-04-01 Revision: E January, 2008

Confidential

Revision History
All revisions to the document should be listed here. At the minimum, entries should include the section
altered, the approver of the revision, and the date. All revisions to this document must have an associated
Document Change Request (DCR). Changes cannot be made to this document without an approved DCR.

REV DCR Amendment Detail Approval Date

A -- Initial release M. Menge 09/2004
B # 2919 table 4-1 on page 4-7 replaced M. Menge 10/2004
Table 4-1 updated;
C # 3126 “Well Planning considerations” deleted
M. Menge 13.12.04

D # 3565 paragraph “Dump Port Hatch” on page 4-5 added M. Menge 23.03.05
E # 8928 / AH Correction of OnTrak Resistance Testing G. Mader 14.01.08

This manual is provided without any warranty of any kind, either expressed or implied. The
information in this document is believed to be accurate; however, Baker Hughes INTEQ will not
be liable for any damages, whether direct or indirect, which results from the use of any
information contained herein.

© 2008 Baker Hughes Incorporated. All rights reserved.

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 Section 4
Operating Procedures
Tool Communication System and Cabling
Two systems can be used to communicate to the OnTrak/AutoTrakG3 tool. This is the TCS (Tool
Communication System) kit and the RiBox III. The TCS kit is the primary system and should be
used on all installations offshore. The RiBox III is a modified RiBox that allows higher amps to
the G2.5 tools. The RiBox III is not supplied in the standard kit, as it doesn’t support memory
dump by Ethernet. It is mainly used in the workshop, hence no further explanation of how to use
this system will be mentioned.

Never use PowerComms or earlier versions of the RiBox as these systems cannot deliver the
Note:
potential >5.0 Amps of current required by the complete tool.

The following information deals with TCS kit and how to use it and technical aspects.
Furthermore the additional cables and equipment required for AutoTrak 2.5 will be presented.

Tool Communication System (TCS)

TCS is a cabin based system that replaces the existing PowerComms system. There are several
differences between the two systems.
TCS can communicate via the following protocols:
• M33
• IO 1039
• Ethernet (memory dump only) allowing memory dump approximately 100 times faster
than M33 / IO 1039 protocol.
This means that you can use this system for most legacy MWD – AutoTrak systems that use M30
or IO 1039 communications protocol.

DV485 communication is not supported by TCS, which for some of the probe based
Note: services is the only protocol in the tool. Service with NaviTrak, NaviGamma, and USMPR
3-1/8" DPS (drilling performance sub) will continue to use PowerComms.

A couple of additional features are included in TCS:

• Pulse detection is built in so decoding electrically while deck testing the tool can be
done without the need for additional cabling such as the ROD box, etc.
• The power to the tool can be cycled from the cabin.

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TCS has an auto-switching power supply for use in 110V or 220/240V applications and is
capable of delivering an output current of 9 Amps.

Note: A Hot Work permit will be required to operate this system in a rig environment.

TCS carries the CE mark. The CE mark is the official marking required by the European
Community for all electric and electronic equipment that will be sold, or put into service for
Note: the first time, anywhere in the European community. It proves to the buyer or user that this
product fulfills all essential safety and environmental requirements as they are defined in the
European Directives.

TCS Hardware Rig-Up

WARNING!
The diagram below shows all the acceptable (blue) and unacceptable (red)
connection points for the TCS system with a complete AutoTrakG3 setup. Do
not power up the complete tool from any additional subs (MAP, CCN, ORD,
etc) added above the BCPM as shown below. This will cause excessive
current to pass through these subs causing catastrophic damage.
Explanation: a high current draw of the steering unit (e.x. when in steermode)
will damage these subs when TCS is connected above. You may plug in at
these points when NO steering unit is attached.
A u t o T r a k 2 .0
S t e e r in g U n it M o d . S t a b / F le x






. . .. .. .. .. .. .. .. ..
O n T ra k S e ns or S ub
.. .. .. .. ..
M o d . S ta b BCPM




 
 

ORD CCN C o P ilo t Sto p S u b




 

( O p t io n a l A d d it io n a l M o d u la r S u b s )



AC PO W ER
110 or 220/240V

TCS

C a b in
B rea k o u t
box

M 30 - IO 1039

E t h e rn e t

P u ls e d e c o d e

Figure 4-1 TCS Tool Communication Hardware Setup

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Tool Communication System and Cabling Operating Procedures

TCS Box
The TCS box is very simple with a power switch for the box, a power switch for the tool, and a
third switch to select either IO 1039 or M33 communications.

Ethernet communication is a straight through connection so it is available regardless of the

Note:
position of the tool communication switch, i.e., it can be set to either IO 1039 or M33.

Tool Voltage and

C urrent displays

Input Pow er B us Activity

Output Power

Figure 4-2 TCS Box – Front View

T o C a b in

To Tool
Pow er

Figure 4-3 TCS Box – Rear View

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Breakout Box
The Breakout box resides in the cabin and incorporates a switch to cycle power to the tool.

Remote
To TCS Box Power Reset

Figure 4-4 Read Out Box – Front View

Ethernet M33
Decode
IO 1039

Figure 4-5 Read Out Box – Rear View – and Cables

• 15 Pin Decode cable connects to SPP1 on the Real-time PC.
• Ethernet cable connects to a second Ethernet card (only connector on card) on off-line
PC
• 9 Pin Serial cable connects to com1 of off-line PC

There is no communication port on a laptop equivalent to the SPP1 port on the BA PCs or
Note:
the DCI PCs. This means that Decode cannot be carried out on a laptop.

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Tool Communication System and Cabling Operating Procedures

Connection to the OnTrak / AutoTrak tool

The Primary connection method is through the communications port on the OnTrak Sensor sub.
This is an 8 pin connector.
Dump Port Hatch
The Data Dump Port Hatch Cover for all OnTrak, AutoTrak 2.5 and AutoTrak 3.0 tools is
identical. The 4 screws on the hatch cover should not have Loctite applied, as leftovers could plug
the thread and make it difficult to install the tension screws when closing the hatch cover.

Figure 4-6 Bolt, Tension Double Hex Head; P/N 10068372

When fitting the hatch cover, visually check the O-ring and bolts and replace if damaged
otherwise they can be reused. Apply a thin layer of silicon grease around the outer edge to
prevent mud sedimentation. Clean each bolt (P/N 10068372, Figure 4-6) and the four thread
boxes inside the hatch port with cleaner spray provided with the surface equipment. Allow it to
dry and then put the hatch cover into its hatch port and torque the bolts without any lubrication
crosswise to 10 Nm / 7.5 lbf-ft (¼" double hex socket required). During disassembly the screws
can remain in the hatch cover due to reduced diameter at shank.
M33

Ground

Comms
OnTrak
Port Cable
Sub

Figure 4-7 Read Out Port (left) and Data Dump Connector (right)
On the OnTrak Sub pins 1 and 6 (these are the power lines) have a larger gauge than the other
pins. A “locating pin” allows the cable to go on in one way. Attached to the data dump cable
connector is a strap to keep it firmly attached to the OnTrak Sub.

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The secondary connection method is using the Comms Block with the TCS M33 adapter cable
arrangement shown below.

Figure 4-8 TCS-M33 Adapter Cable (left) and Comm Block (right)
The Comm Blocks are similar to, but more substantial than, the existing old connectors we have
at present. Unlike the screw on Comm Caps (Figure 4-9) the Comm Blocks can be used for all T2
thread sizes (9-1/2” T2, 6-3/4” T2 and 4-3/4” T2) as well as for NC46 and 6 5/8” REG MOD
threads. A strap is used to keep it firmly attached to the sub.

Prior to tool communications being established, both the TCS and the tool need to be tested
Note:
individually.

Resistance Testing
Tool
Initial resistance checks should be carried out prior to connecting TCS. All modular connection
protectors, if applicable, should be removed to ensure the modular ring is clean and dry. Remove
the M30 readout hatch and again ensure it is clean and dry.
Check the resistance of the subs by means of a multimeter (Ω - test). Connect the measure probes
with the tips to the modular ring and the collar and compare the reading to the table below.

Note: The reading must be in the range of "kΩ".

Expected values for resistance are:

Sub Resistance Range

BCPM 2-50 KΩ
Sensor Sub 29-30 KΩ
Steering Unit 2-20 KΩ

Any add-on subs, such as ORD/CCN, should be checked for resistance across their modular ring
to ground also.

Trouble shooting for an OTK tool internal short at the open read out port Ground Pin to
Note: M30 Pin should not be performed. The resultant values will be erratic and of no use. Test
the resistance at M30 ring and collar.

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Tool Communication System and Cabling Operating Procedures

TCS
1. Ensure both power switches are in the Off position.
2. Ensure the complete TCS system is assembled and properly connected to the cabin
and all communication boxes.
3. Ensure the tool cable is connected to the TCS box, do not plug into tool yet.
4. Activate the input power switch and observe the power LED. The LED should be
lit and both meters should read ± 0.
5. Activate the tool power switch and check the voltmeter reads ± 33 volts.
6. Deactivate the tool power switch and verify the voltmeter reads ± 0 volts
At this point, the TCS is tested. With this test completed, along with completion of the tool
resistance checks, you can proceed and attach the tool cable to the tool.

Standard Volt and Current Readings of the Tool

Activate the power switch and observe both meters. The voltmeter should read ± 33 volts.
Current is dependent on the tool configuration
Table 4-1 Current Draw of AutoTrak BHA Components
AutoTrak BHA Component Current Draw [mA]
AutoTrak G3 Steering Unit (*) 500 – 4500
AT G3 Steering Unit in Ribs off Mode 600 – 1200
AT G3 Steering Unit in Hold/ Steer Mode 1500 – 2500
OnTrak Sensor Sub 450 – 550
BCPM 150 – 1650 (pulsing)
APLS (ORD) 230 – 400
APLS (CCN) 230 – 400
SDN 250 – 300
MAP 60 – 80
CoPilot 340 – 400
APX 300 – 1100 (while firing)
TesTrak 300 – 6400 (while testing)
RNT/ RNT II 300 – 350
AT 2.5 SHE (w/ RNT/ RNT II) 450 – 550
AutoTrak 1.5 900 – 1500
MagTrak 300
DeepTrak (Receiver) 300 – 1100
DeepTrak (Transmitter) 300
(*) The AutoTrak G3 Steering Unit current draw can be as much as 4500 mA when initially powered up!

If at any time power is cycled to the tool, allow a minimum of 10 seconds between turning
Note: the power off and turning it on again. This reduces the risk of damage to the tool or TCS
caused by residual capacitance.

**Once verified you are now ready to communicate to the tool**

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T2 Comm Caps and Cabling (AutoTrak G2.5)

There is an AutoTrak 2.5 TCS kit, which contains the specific cables to communicate to the
Note:
tool via TCS.

Next to the above mentioned Comm Blocks there are Comm Caps available (Figure 4-9), which
are screw on connectors. These Comm Caps are only available for 6-3/4” T2 and NC46 (Box and
Pin) and they are part of the Communication Kit for AT2.5 (this kit is only required when
operating the RiBox III, but part of it can be used with the TCS system).

Figure 4-9 Test Adapter Subs / Comm Cap

The T2 Comm Caps can be connected to the top of the BCPM and to the bottom of the AT 2.5
Sensor Sub or a T2 connection below. The 4 way Junction Box (Figure 4-10) can be used to
connect the above mentioned two sections of the tool (with an additional extension cable, if
required) with a third connection going to the TCS box. The naming convention of these
connectors is:
Line A – M30 Line D – Ground

Figure 4-10 4 Way Junction Box with Cannon Connector Cables

With this setup, an opening of the Readout port will not be necessary, but it is also possible to
connect to the Read Out Port via Data Dump Cable.
The NC46 Comm Caps are required to connect additional modular subs (APLS, APX, etc).

Do not power the tool from above the center electronics due to the high current draw
Note:
required by the Steering Head.

When connecting an AT 2.5 tool with a TCS box via Data Dump Cable the cable should not
Note: be longer than 20ft because of the decrease in peak height of the communication signal =>
no communication.

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Part Numbers of the TCS and Cabling

Table 4-2 P/N 10076091 – TCS Assy (OnTrak / AutoTrak)
# Part Number Name Description/ Example
1 10075295 TOOL COMM BOX ASSY (ONTRAK) Figure 4-2/ 4-3
2 10075902 BREAKOUT BOX ASSY (ONTRAK) Figure 4-4/ 4-5
CABLE ASSY,RS232-42" M33/ IO 1039 Decoding Cable,
3 10072843 Figure 4-5 (right)
(TCS/ONTRAK)
CABLE ASSY,POWER 100FT
4 10072842 Connects to Figure 4-3 (left adapter)
(TCS/ONTRAK)
KIT,POWER CABLE 300FT
5 10091668 Connects to Figure 4-3 (left adapter)
(TCS/ONTRAK)
ETHERNET CARD-LAPTOP (3COM
6 10080490
#3CXFE575CT)
CABLE ASSY,COMMS 100FT Connect to Fig. 4-3 (middle adapter)
7 10072844 and Figure 4-4
(TCS/ONTRAK)
8 10091667 KIT,G3 (TCS/ONTRAK) See table below
9 10091670 KIT,TCS AUTOTRAK 2.5 See table below
ETHERNET CARD-DESKTP(3COM
10 10128495
#3C905CX-TX-M)
Connect to Fig. 4-3 (middle adapter)
11 10091719 KIT,300FT COMM CABLE (TCS) and Figure 4-4
CABLE ASSY,TRANSIT-25FT
12 10072848
(TCS/ONTRAK)
13 10101406 MUD DIVERTER ASSEMBLY

Table 4-3 P/N 10091667 – Kit, G3 (TCS / OnTrak)

# Part Number Name Description/ Example
CABLE ASSY,PULSE DECODE- Pulse Decoding Cable, Figure 4-5
1 10072846 (left)
42"(TCS/ONTRAK)
CABLE ASSY,ETHERNET
2 10072847 Ethernet Cable, Figure 4-5 (middle)
(TCS/ONTRAK)
DATA DUMP CONN/BELT ASSY
3 10059389 Figure 4-7 (right) with 50ft cable
(ONTRAK)
CABLE ASSY,M33/TCS 10FT Figure 4-8 (left), connects TCS with
4 10105520 Comm Block/ Cap
(TCS/ONTRAK)
CABLE ASSY M33/M33 30FT
5 10087893 Connects Comm Blocks/ Caps
(TCS/ONTRAK)
CABLE ASSY M33/M33 10FT
6 10084655 Connects Comm Blocks/ Caps
(TCS/ONTRAK)
7 10084932 CAP,COMMS-TCS/ONTRAK Figure 4-8 (right)

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Table 4-4 P/N 10091670 – Kit, TCS AutoTrak 2.5

# Part Number Name Description/ Example
DATA DUMP CONN/BELT ASSY
1 10087895 Figure 4-7 (right) with 20ft cable
(AUTOTRAK)
CABLE ASSY,M33/TCS 10FT Figure 4-8 (left), connects TCS with
2 10105520 Comm Block/ Cap
(TCS/ONTRAK)
CABLE ASSY M33/M33 10FT
3 10084655 Connects Comm Blocks/ Caps
(TCS/ONTRAK)
CABLE ASSY M33/M33 5FT
4 10087892 Connects Comm Blocks/ Caps
(TCS/ONTRAK)
5 10084932 CAP,COMMS-TCS/ONTRAK Figure 4-8 (right)
SPLITTER,MALE TO 2 RTANG FEM Connects to Comm Cap, allows to
6 10091662 connect two tools
(RCA)

Table 4-5 P/N 10078477 – Kit, Communication, f/Surf. Equip. 6.75 ATK 2.5
# Part Number Name Description/ Example
1 10076079 HANDLE,F/TESTADAPTER,BCPM,6.75 Handle to torque Adapter Subs
SUB,TESTADAPTER,ASSY,NC46
2 10075476 Figure 4-10 (right)
BOX,6.75ATK2.5
SUB,TESTADAPTER,ASSY,NC46
3 10075478 Figure 4-10 (left)
PIN,6.75ATK2.5
Connects Test Adapters/ Comm
4 10075052 CABLE,CONNECTION,M30/RIBOX Caps to RIBOX
Connects Test Adapters/ Comm
5 10075051 CABLE,CONNECTION,M30-TCS Caps to TCS
Connects Test Adapters/ Comm
6 10075053 CABLE,EXTENSION,M30,9m Caps
10075291 BOX,CONNECTION,M30 Junction Box, Figure 4-11 (middle)
SUB,TEST ADAPTER,ASSY,T2
10073016 Figure 4-10 (right)
BOX,BCPM,6.75
SUB,TESTADAPTER,ASSY,T2-
10073017 Figure 4-10 (left)
PIN,BCPM,6.75
CABLE,ADAPTER,RIBOX III/DDP
10086698 Ethernet Cable for RiBox III
CABLE,ATK2.5

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