SERVICE MANUAL NO M-086

PAGE 1

Frank’s Style II Power Unit and Dual REVISION A

Control Panel For Varco FMS 375 REV DATE 02/07/06

FRANK’S CASING CREW & RENTAL TOOLS, INC.

Operation & Maintenance Manual

Frank’s Style II Power Unit and Dual Control Panel
For Varco FMS 375 & Remote Elevators

All materials contained herein, unless noted otherwise, are the copyrighted property of Frank’s Casing Crew &
Rental Tools, Inc., its subsidiaries, affiliated companies and/or licensors. To reproduce, republish, broadcast,
post transmit, modify, distribute or display this work, or a portion of material from this work, you must first obtain
written permission from an officer of Frank’s Casing Crew & Rental Tools, Inc.

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Frank’s Style II Power Unit and Dual REVISION A

Control Panel For Varco FMS 375 REV DATE 02/07/06

FOREWORD

This manual is intended as a general guide for the installation, operation, and servicing of the
Frank's Power Unit Style II and Dual Control Panel for the Varco FMS 375.

Before the equipment is put into use, it is recommended that the information contained within
this manual be carefully studied. By following the suggested procedures, the equipment
should give a long, trouble free service life.

The equipment covered by this manual, and information disclosed within, includes features
that are proprietary to FRANK'S and may be covered by one or more patents. Nothing within
this document shall be construed to be a license or permission for the disclosure of such
proprietary information to third parties nor the use of this information for purposes other than
the installation, operation, maintenance, inspection, and servicing of the covered equipment.

Improvements may be made from time to time, therefore the text and illustrations may differ to
some extent with respect to the subject unit of equipment. In any reference to the unit for
which this manual is used, it is essential that the equipment serial number is noted.

Applicability:

This manual applies to equipment with Serial Numbers of the form:

FCC XXXX beginning with S.N. 13304
FI XXXX beginning with S.N. 001-3855

* This manual is also applicable to older units which have been converted to Style II.

FRANK'S CASING CREW & RENTAL TOOLS, INC.

700 E. Verot School Road
Lafayette, LA 70508
USA
(337) 233-0303

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Frank’s Style II Power Unit and Dual REVISION A

Control Panel For Varco FMS 375 REV DATE 02/07/06

REVISION TABLE

RELEASE
PAGE
SECTION DATE REMARKS
NO.
All All 02/07/06 Initial Release

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Frank’s Style II Power Unit and Dual REVISION A

Control Panel For Varco FMS 375 REV DATE 02/07/06

TABLE OF CONTENTS

SECTION TITLE PAGE

1.0 INTRODUCTION & SPECIFICATIONS 6

1.1 Introduction 6
1.2 Specifications 6
1.3 Equipment List 7
1.4 Varco FMS 375 14” 500 Ton (FORM – Capabilities / 9
Limitations)

2.0 INSTALLATION & OPERATION 10

2.1 Installation – System Rig Up 10
2.1.1 Power Unit Rig Up 10
2.1.2 Control Console Rig Up 11
2.1.3 Interlock Mode 11
2.1.4 Stand Alone FMS & Non-interlock Manual Elevators 11
2.1.5 (Backup) Use of Tong Power Unit (Diesel or 12
Electric)
2.2 Operation 13
2.2.1 Starting the Unit 13
2.2.2 Operating the System 13
2.2.2.1 Interlock Mode 13
2.2.2.2 Non-Interlock Mode 14
2.2.3 Cold / Humid Weather Operation 15
2.2.4 Rigging Down After Use 16
2.2.4.1 Air / Hydraulic Power Unit 16
2.2.4.2 (Backup) Tong Power Unit 16

3.0 MAINTENANCE 17
3.1 New Unit Preparation 17
3.2 Before each Job 17
3.2.1 Tank and Hydraulic Oil 17
3.2.2 Air Motor Lubricator 18
3.2.3 Leak Checks 18
3.2.4 Power Unit Check List 19
3.2.5 Control Console – Before Every Job 19

4.0 SERVICING PROCEDURES 19

4.1 Troubleshooting 19
4.1.1 Power Unit 19
4.1.2 Control Console 20
4.1.2.1 Control Panel Using Air / Hyd. Power Unit 20
4.1.2.2 Control Panel Using Tong Power Unit 21
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Frank’s Style II Power Unit and Dual REVISION A

Control Panel For Varco FMS 375 REV DATE 02/07/06

SECTION TITLE PAGE

4.1.2.3 Varco FMS 375 23
4.2 System Adjustment 23
4.2.1 Air / Hyd. Power Unit Adjustment 23
4.2.2 Control Panel Adjustment 24
4.2.3 Tuning the Pneumatic Timer 24
4.2.4 Adjustment of the Varco FMS 375 26

5.0 ASSEMBLY DRAWINGS AND PARTS LIST 27

Power Unit Assembly – Drawing No. 78022 27
Air / Hyd. Power Unit Assembly – Drawing No. 29
78048
Control Box Assembly – Drawing No. 78025 30
Installation FMS 375 – Drawing No. 2000005050 35
Hyd. Hose Configuration – Drawing No. 95007048 36
Lift Assembly – Drawing No. 95007008 37
Opening / Closing Instruction – Drawing No. 38
95007009
Schematic, Air / Hyd. Power Unit – Drawing No. 39
95007043
Hyd. Schematic, Control Console – Drawing No. 40
95007095
Hyd. Schematic, FMS 375 – Drawing No. 95007038 41
Pneu. Schematic, Varco 500 Ton Elevator – 42
Drawing No. 2000005055

6.0 RECOMMENDED SPARE AND CONSUMABLE 43

PARTS LIST
6.1 Recommended Spare Parts for FMS Control 43
Console
6.2 Recommended Spare Parts for FMS Power Unit 44

7.0 APPENDIX A 45
Weston Hydraulics Pneumatics Co., Inc. – Overhaul 46
Manual

8.0 APPENDIX B 63
Gast Pneumatic Motor Operating Manual 64
Ingersoll Rand Pneumatic Motor Operating Manual 72

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Frank’s Style II Power Unit and Dual REVISION A

Control Panel For Varco FMS 375 REV DATE 02/07/06

1.0 INTRODUCTION AND SPECIFICATIONS

1.1 INTRODUCTION

The Varco FMS 375 flush mounted spider is powered by a hydraulic unit and was
originally used with a Varco manufactured control panel. As these tools were used
several problems occurred. First was an incompatibility between the diesel power units’
control system and the Varco control panel. The second concern was the ability of the
FMS slips to be opened with a string of pipe suspended in the slips. To overcome this
problem, an interlock system between the FMS and a conventional Varco pneumatic
elevator was incorporated into the Frank’s Control Panel. The Air Powered Hydraulic
Unit Style II and Dual Control Panel eliminates the need for a dedicated diesel
powered hydraulic unit to run the system. The Air Powered Hydraulic Unit Style II has a
second motor and pump built into the unit, for backup operation, to improve reliability.
The dual control panel also allows use of the air interlock system when using a remote
controlled elevator equipped with the Frank’s Casing Tool Interlock System. The dual
control panel can also be powered with a Diesel or Electric powered Tong Hydraulic
Unit as an emergency backup if the Air Powered Hydraulic Unit goes down. The dual
control panel can also operate a remote pneumatic spider and remote pneumatic
elevator, both equipped with interlock.

1.2 SPECIFICATIONS FOR THE AIR POWERED HYDRAULIC UNIT AND

CONTROL PANEL

1.2.1 Dimensions

1.2.1.1 Power Unit (Including Skid, Cage, and Hoses)

Length 62.75 inches (1.6 m)

Width 33 inches (0.84 m)
Height 60 inches (1.5m)
Weight (Wet) 1950 lbs. (885 kg)

1.2.1.2 Control Panel (Inclusive of Quick Disconnect Fittings)

Length 27 inches (0.68 m)

Width 20 inches (0.51 m)
Height 45 inches (1.14 m)
Weight 500 lbs. (230 kg)
Combined Wt. (Wet) 2450lbs. (1115 kg)

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Frank’s Style II Power Unit and Dual REVISION A

Control Panel For Varco FMS 375 REV DATE 02/07/06

1.2.2 Supply / Output

1.2.2.1 Power Unit

Supply (Air): for Motors 1 & 2
Pressure 100 psi min. - 150 psi max.
Flow Rate (Min.) 150 scfm (4.3m3/min.)
(Opt.) 175 scfm (5.0m3/min.)
Output (Hydraulic): for Pumps 1 & 2
Pressure .2500 psi (172.4 bar) - 3000 psi (206.8 bar)
max.
Flow Rate (1) Pumps Only: 4 gpm ea. (15 litres/min.)
(2) Max Flow Rate when discharging 3
accumulators: 45 gpm (171 liters/min.)
1.2.2.2 Control Console
Supply (Hydraulic):
Pressure 2500 psi (172.4 bar) - 3000 psi max. (206.8
bar)
Flow 45 gpm (171 liters/min.)
Output (Hydraulic):
Pressure – Slips Up 250 psi min. – 500 psi max. (17 bar - 34.5 bar)
Pressure – Slips Down 1500-2300 psi (110.3 bar – 158.6 bar)
Flow – Slips Up 22 gpm (84 liters/min.)
Flow – Slips Down 32 gpm (122 liters/min.)

1.3 EQUIPMENT LIST

1.3.1 Body, FMS 375
♦ Spare set of appropriately dressed slips
♦ Hose Guard (Flat Top Tools)
1.3.2 Control Console
♦ Sets of hoses, console to FMS
1.3.3 Air/Hydraulic Power Unit
♦ 2 Sets of hoses, Power Unit to Console
♦ 2 Air hoses, Rig Supply to Power Unit
1.3.4 Lift Sling, (95007008)
♦ Spreader Bar (95007006)
1.3.5 Adapter Ring
♦ Spacer for National 37½” Rotary (95007063)
♦ Oilwell (95007067)
♦ Emsco (95007067)
♦ Gardner Denver (95007067)
1.3.6 Interlock Pneumatic Hoses (Supplied with Elevator Equipment)

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Frank’s Style II Power Unit and Dual REVISION A

Control Panel For Varco FMS 375 REV DATE 02/07/06

1.4 VARCO FMS 375 14” 500 TON FLUSH MOUNT SPIDER (FORM)

Capabilities/Limitations Form, see page 9

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Frank’s Style II Power Unit and Dual REVISION A

Control Panel For Varco FMS 375 REV DATE 02/07/06

2.0 INSTALLATION & OPERATION

Warning: Do not use oxygen as an air supply for the power units,
control console, or as a pre-charge for the accumulators. If
oxygen is used an explosion WILL occur. Use only
compressed air for the power units and control console. Only
nitrogen should be used for pre-charging the accumulators
contained in the power unit and control panel.

2.1 INSTALLATION (See Dwg. 2000005050)

System Rig Up (After removal of the control console from the skid)

2.1.1 Power Unit Rig Up

ƒ Open the accumulator drain valve near the quick disconnects on

the tubing (Item 21 Dwg. 78022).
ƒ Push in red plunger on the air cut-off valve (Item 6 Dwg. 78022).
ƒ Connect the hoses from the power unit (Items 15 & 31 Dwg.
78022) to the control console input quick disconnects (Items 27
& 24 Dwg. 78025) located on the FRONT inside of the control
console door.
ƒ Connect the hoses from the spider to the control console output
connections located INSIDE the console door (Items 80 & 81
Dwg. 78025). The tool quick disconnects and power unit
disconnects are different sizes to
avoid incorrect setups.
ƒ Connect the case drain hose from
the control console to the power
unit tank (Item 20 Dwg. 78048).
See tank assembly Dwg. 78048.
ƒ Connect the air hose from the rig
air supply (DO NOT CONNECT TO
PURE OXYGEN SUPPLY) to the
power unit. Connect the safety
hair cotter pin to the Universal
Claw coupling (Item 1 Dwg.
78022).
ƒ Check the sight glass (Item 2 Dwg.
78048) on the tank, verify
adequate oil supply. It should be
more than half way up the upper
sight glass before starting the unit.
ƒ DO NOT START POWER UNIT AT
THIS TIME
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Frank’s Style II Power Unit and Dual REVISION A

Control Panel For Varco FMS 375 REV DATE 02/07/06

2.1.2 Control Console Rig Up

ƒ Verify that all hoses are connected properly to and from the
control console.
ƒ Inside of the cabinet is a ball valve (Item 57 Dwg. 78025) near
the return line. Close this valve by turning the handle such that
it makes a right angle to the pipe direction.
ƒ Check spider to see if slips are up or down (set).
ƒ In the previous step, if the slips were observed to be up, move
the spider control lever (Item 3 Fig. 1) to the up position. If the
slips were observed to be down, move the spider control lever
to the down position.

2.1.3 Interlock Mode (Refer to Drawing 2000005050)

All of the hoses are color coded or sized to match. If a hose won’t
connect to a fitting, make sure it’s the right bundle and the correct
end is being used.

ƒ Connect the air hose (Item 10) from rig air supply to the FMS
control console.
ƒ Connect the 75' gray air hose bundle (Item 6 ) to the control
console
ƒ Connect the other end of the 75’ gray air hose bundle to the
elevator’s interlock valve assembly located on the elevator. Note
additional 75’ gray hose bundles may be required.
ƒ Tie off the gray hose bundle to the derrick and bail, leaving
enough slack for elevator travel.
ƒ Set the control panel elevator bypass/interlock handle to
“interlock”.
ƒ Set the control panel spider bypass/interlock handle to “interlock”
(See Fig.1).

2.1.4 Stand Alone FMS & Non-Interlock Manual Elevators

ƒ The FMS control console is connected to the FMS spider and

the console is switched to the bypass mode.
ƒ The manual non-interlock elevator is installed per
manufacturer’s instructions. During the casing running
operation, the equipment operator must use extreme
caution not to open the spider before the elevator is in the
correct position securing the casing string.

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Frank’s Style II Power Unit and Dual REVISION A

Control Panel For Varco FMS 375 REV DATE 02/07/06

Warning: If the FMS is in bypass mode, the slips can be

raised with up to 12,500-25,000 lbs. of pipe in the
string. Double check that the elevator is set before
opening FMS.

2.1.5 (Backup) Use of Tong Power Unit (Diesel or Electric)

Note: Ensure that hydraulic oil in replacement power unit is of

same type and weight as hydraulic oil in Air / Hydraulic
power unit. If oil is not of same type and weight, determine if
oil types are compatible.

ƒ Shut off air over hydraulic power unit by pushing in red plunger
on the air cut-off valve (Item 6 Dwg. 78022).
ƒ Slowly open the accumulator drain valve near the quick
disconnects on the tubing (Item 21 Dwg. 78022). Check
pressure gauge reading on pressure gauges located on air over
hydraulic power unit. Gauge readings should drop to zero (0).
ƒ Turn off rig air valve, reopen air cut-off valve by pulling red
handle. This will depressurize the air hose to the power unit.
Disconnect the air hose from the rig valve.
ƒ Disconnect hydraulic supply and hydraulic return hoses at the
FMS Spider control console.
ƒ Disconnect the case drain hose at the air over hydraulic power
unit.
ƒ Connect the hydraulic supply and hydraulic return hoses from
the diesel driven or electric power unit, to the FMS Spider
control console.
ƒ Connect the case drain hose to the reservoir of the replacement
power unit.
ƒ Verify that all hoses are connected properly to and from the
control console and replacement power unit.
ƒ Inside of the FMS control console cabinet is a ball valve (Item
57 Dwg. 78025) near the return line. When the replacement
power unit is a typical diesel driven system or an “open loop”
electric system, open this ball valve by turning the handle such
that the handle is parallel to the pipe direction. (See reference
decal inside of the console door.) When operating a hydraulic
system equipped with fixed displacement pumps the control
console ball valve must be in the open position. Hydraulic
system with variable displacement pumps, the console ball
valve should be in the closed position. Note: when using
Frank’s dual 40 HP Electric units to operate the FMS 375,
the ball valve in the console should be in the closed
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Frank’s Style II Power Unit and Dual REVISION A

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position and the hydraulic unit running in tubing mode.

ƒ Diesel powered units manufactured by FRANK’S are equipped
with a tubing/casing selector valve. This valve is to be turned
toward the tubing mode when using the diesel power unit to run
a Varco 375 FMS.
ƒ Note the position of the slips in the FMS Spider and verify that
the spider handle on the FMS control console is in the proper
position. If the slips are set, make sure the spider handle on the
FMS control console is also in the set position and vise versa.
ƒ The replacement power unit can now be started and operated
per manufacturers instructions.

2.2 OPERATION

2.2.1 Starting the Unit (Refer to Drawing 78022)

After all of the above steps outlined in Section 2.1.1 – 2.1.4 have
been completed, the unit can be started.

ƒ Open the accumulator drain valve (Item 21) by turning counter-

clockwise.
ƒ Open the ball valve (Item13) going to one of the two available
motors. Only one motor is used to power the system. The
second motor is for backup use only.
ƒ Open the main air supply that will be feeding the power unit.
ƒ Pull the red handle on the air cut-off valve (Item 6) on the power
unit. The motor will be running at a high RPM, indicated by a
high pitch buzzing sound.
ƒ Increase the oil flow from the pneumatic lubricator located on
the power unit and allow the motor to run for 1 – 2 minutes.
ƒ Re – adjust the pneumatic lubricator to deliver 1 drop of oil
every 15-20 seconds.
ƒ Slowly close the accumulator drain valve and allow 2 ½ minutes
for the accumulators to become fully charged. If the slips were
in mid stroke, they will either completely open or close before
the accumulators build pressure. This will take approximately
15 seconds.
ƒ The system is now ready for use.

2.2.2 Operating the System

After the system has completely charged, the Flush Mount Spider
(FMS) is now ready for use.

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Frank’s Style II Power Unit and Dual REVISION A

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2.2.2.1 Interlock Mode

BEFORE RUNNING THE PIPE:

ƒ Check that the power unit is fully charged. The motor should be
chugging slowly and both power unit gauges should read a
minimum of 2500 psi (Item 47 Dwg. 78022).
ƒ Make sure that both bypass/interlock handles on the control
panel are pointing to “interlock” (See Dwg. 2000005050).
ƒ Set slips on FMS by pulling the spider handle on the control
panel back (Item 3 Fig. 1). They should set in about 3
seconds and the slips down gauge on the panel should read
between 1500-2300 psi (Item 2 Fig. 1).
ƒ With the elevator slips up, try to open the FMS slips by
pushing the spider handle forward. If they open while the
elevator is open, the interlock is not working and all of the
connections should be checked.
ƒ Close elevator slips.
ƒ Open FMS slips. If they won’t open, check that the elevator is
closed and that all the air fittings to the cabinet are intact.
ƒ If the tools appear to be working correctly, the job can begin. IF
NOT, refer to troubleshooting section in 4.1.

A) FIGURE 1
(Ref. FCC Drawing No. 2000005050)

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Frank’s Style II Power Unit and Dual REVISION A

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2.2.2.2 Non-Interlock Mode

The FMS system should always be used in interlock mode

when using interlock capable elevators. The only exceptions
are if the elevators are not equipped with interlock systems
or the interlock system malfunctions.

WARNING: The FMS can raise the slips with as much as

12,500-25,000 lbs. on the pipe string. If the
interlock system is NOT being used, double
check that the elevator is set before opening
FMS.

ƒ Turn the valve on the control panel (Item 4 Fig. 1) to BYPASS

mode. The slips in the spider are set or released by moving the
handle (Item 3 Fig. 1) on the control panel in the appropriate
direction. With the system fully charged, this movement takes
approximately 3-4 seconds.
ƒ After the slips have moved, there should be a slight increase in
the motor speed for a short time while the power unit recharges.
This time is much shorter than the time it takes to stab and
torque the pipe.
ƒ The “slips down” gauge (Item 2 Fig. 1) on the control panel
should read between 1500-2300 psi to indicate the slips are fully
pressurized.
ƒ The “slips up” gauge (Item 1 Fig. 1) on the control panel should
read 250-500 psi maximum to indicate the slips are in the up
position.

Note: Only one of the slip pressure gauges should show

pressure at one time.

2.2.3 Cold/Humid Weather Operation

ƒ If the unit is being operated in a cold environment with a high

relative humidity, muffler icing may present an operational issue.
The power unit has a built in filter/dryer to dry the air that is
supplied to the pneumatic motors, but in cold environments,
muffler icing is possible. If the unit begins to slow, follow these
steps:

ƒ Check the muffler to see if it is iced over.

ƒ If the muffler is iced over, stop the motor by closing the ball
valve located directly above the motor.

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ƒ Open the accumulator drain valve (Item 21 Dwg. 78022)

slowly, to drain the accumulators.
ƒ Start the second motor by opening the ball valve located
directly above it.
ƒ Increase the lubricant oil supply to the motor by adjusting the
pneumatic lubricator (Item 11 Dwg. 78022).
ƒ Allow the motor to run for 1-2 minutes.
ƒ Re-adjust the pneumatic lubricator to 1 drop every 15 - 20
seconds.
ƒ Slowly close the accumulator drain valve to build system
pressure.
ƒ Resume operation after system is fully charged.

Note: If muffler icing continues to be a problem, the muffler can be

removed from the motor. Use a length of 1” air hose to re-
direct noise away from the work area.

2.2.4 Rigging Down After Use

WARNING! Do Not disconnect hoses without depressurizing the

system as noted below:

2.2.4.1 Air/Hydraulic Power Unit

ƒ Push in red handle of air cutoff valve to stop power unit. Turn
off rig air and then reopen air cutoff valve by pulling on the red
handle. This will depressurize the air lines.
ƒ Slowly open the accumulator hydraulic drain valve (Item 21
Dwg. 78022) to drain the accumulators. Check all hydraulic
gauges to make sure they read zero.
ƒ Cycle the slips up & down to remove pressure in the hoses from
the console to the FMS and relieve pressure from the
accumulator in the control console.
ƒ It is now safe to remove all of the hoses from the spider and
control panel and return them to the basket on the skid.
ƒ Return the control console to the power unit skid.

2.2.4.2 (Backup) Tong Power Unit

ƒ Shut off the replacement power unit.

ƒ Cycle the slips up & down to remove pressure in the hoses from
the FMS control console to the FMS Spider. This also will
discharge the accumulator in the FMS control console. All
gauges on the control console should read zero (0).
ƒ It is now safe to remove all of the hoses from the FMS Spider
and control console and return them to the basket on the air
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over hydraulic power unit skid.

ƒ Return the control console to the air over hydraulic power unit
skid.

3.0 MAINTENANCE
3.1 NEW UNIT PREPARATION

Depending on how the power units were shipped to their final destination,
the accumulators may have been drained of nitrogen and oil. The power
unit and console also may have been drained of oil. The following
instructions tell how to refill and recharge the system. These steps are
also used if an existing system were drained due to overhaul or repair.

Accumulators -

There are four accumulators in the system, three each of a 3 gallon

size (Item 30 Dwg. 78022) on the skid and one each of a 1.5 gallon
size in the control panel (Item 4 Dwg. 78025). Each 3 gallon
accumulator on the power unit needs to be pre-charged with
Nitrogen to a pressure of 900 psi (6.20 MPa). The 1.5 gallon
accumulator in the control console should be charged with Nitrogen
to a pressure of 1000 psi (6.89 MPa).

WARNING: DO NOT USE OXYGEN OR COMPRESSED AIR TO

CHARGE ACCUMULATORS AS AN EXPLOSION IS
LIKELY TO OCCUR!!!!!

3.2 BEFORE EACH JOB - Table 3.2 lists various system fluid
requirements.

3.2.1 Tank and Hydraulic Oil

Fill the hydraulic tank with approximately 22 U.S. Gallons (83.5

liters) or to the red line on
the upper most sight glass on the side of the tank. Use a mineral
based hydraulic oil of a grade equivalent to or better than:

Shell Tellus S 46 or Chevron Clarity 46 for Ambient

Temperatures up to 100°F (38°C)

Shell Tellus S 68, or Chevron Clarity 68 for Ambient

Temperatures over 100° F (38°C)

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3.2.2 Air Motor Lubricator

Fill the lubricator reservoir (Item 11 Dwg. 78022) with Air Tool Oil
(Liquid O-Ring 840) or equivalent, to the fill line on the bowl.
Properly adjust the amount of lubrication delivered to the air motors
(one drop every 15-20 seconds).

USE FLUID QUANTITY

Control Console Accumulator
Commercial Dry Nitrogen Charge to 1000 psi
Pre-charge
Dewpoint – 60°F Minimum (Approx. 14 scf)
(1.5 gal. Size)
Power Unit
Accumulator(s) (3) Commercial Dry Nitrogen Charge to 900 psi
Pre-charge Dewpoint – 60°F Minimum (Approx. 25 scf)
(3 gal. Size)
For Ambient Temp.
up to 100°F (38°C):
Fill to Red Line on Upper
Shell Tellus S 46
Power Unit Sight Glass on Reservoir
Chevron Clarity 46 or equivalent
Hydraulic Oil
For Ambient Temp.
Reservoir Approx. 22 US gallons
over 100°F (38°C):
(75.5 litres)
Shell Tellus S 68
Chevron Clarity 68 or equivalent
Power Unit Liquid O-Ring 840 Air Tool Oil Fill to Line on
Pneumatic Lubricator or equivalent Lubricator Reservoir

Table 3.2 System Fluid Requirements

3.2.3 Leak Checks (Refer to Drawing 78022)

After the above preparations have been completed, the unit can be
started.

ƒ Slowly open the accumulator drain valve (Item 21) by turning

clockwise.
ƒ Open one of the ball valves (Item 13) connected to the motors.
Only one motor is used to power the system. The second
motor is for backup use only.
ƒ Push red handle in on the large, yellow bodied air Lock Out
valve (Item 6)
ƒ Attach air hose to power unit. DO NOT CONNECT TO AN
OXYGEN SUPPLY!
ƒ Pull Red handle out from air Lock Out valve and allow the motor
to run for 1-2 minutes.
ƒ Slowly close the accumulator drain valve (Item 21) slowly, by
turning the valve clockwise until it is fully closed.
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ƒ Check for leaks around all fittings.

ƒ After leak check, push in red handle of air Lock Out valve.
ƒ SLOWLY open accumulator drain valve to let the accumulators
drain until the hydraulic pressure gauges read zero. MAKE
SURE THE HYDRAULIC CIRCUIT IS DEPRESSURIZED
BEFORE SERVICING.

3.2.4 Power Unit Check List

ƒ Maintain oil level in tank (Item 1 Dwg. 78048).

ƒ Maintain oil level in pneumatic oiler (Item 11 Dwg. 78022).
ƒ Check air filter (Item 8 Dwg. 78022) for contamination.
ƒ Pressure up unit per instructions in Section 3.1.4 and check for
leaks.
ƒ Open accumulator drain valve (Item 21 Dwg. 78022) and
observe return filter pressure gauge (Item 82 Dwg. 78022). This
indicates a clogged filter at 15 psi.
ƒ Once a year or 4000 hrs., clean the tank and suction strainer
(Item 18 Dwg. 78048), change the following filters:
ƒ Return Line Filter (Item 16 Dwg. 78048)
ƒ Air Preparation Filter within the Pneumatic Filter Unit (Item 8 Dwg.
78022)
ƒ Check hoses for damage.

3.2.5 Control Console - Before Every Job

ƒ Pressurize console using power unit, check for leaks.

ƒ Attach air supply to supply inlet on console (Item 21 Dwg.
78025).
ƒ Attach an open male fitting to female outlet on console (Item 22
Dwg. 78025).
ƒ Turn interlock/bypass on panel valve to “interlock” (Item 4 Fig.
1).
ƒ Cycle both handles and listen for air escaping (Item 3 Fig. 1).

4.0 SERVICING PROCEDURES

4.1 TROUBLESHOOTING

4.1.1 Power Unit

When fully charged, the power unit has enough stored pressurized
oil to stroke the slip cylinders 3 times without a total recharge. In
the case of a mis-set of the slips this allows them to be released
and reset without slowing the action of the spider. If it is noticed
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that the slips are moving very slowly (10 seconds or more) and the
power unit motor is racing, it means the power unit has completely
Function Possible Cause Remedy
Power Unit Will Not Low Hydraulic Fluid Make sure fluid is visible in the sight
Recharge glass. Check for leaks. Add hydraulic oil
if needed.
“ Accumulator drain valve Make sure the accumulator drain valve is
is not fully closed closed by turning clockwise until it stops.
Power Unit Recharges Air regulator is not set at Open the air regulator all the way by
but holding pressure is the correct pressure turning clockwise or until the pressure
less than 3000 PSI reaches 100 PSI
“ Relief valve setting too Adjust relief valve setting to 3000 PSI
low
“ Faulty relief Valve Have a qualified technician change the
valve and adjust to the proper pressure
Power Unit recharges, Accumulators have lost Have a qualified technician re-charge the
but motors run at full their nitrogen charge. accumulators.
speed each time the slips
are moved
discharged. If this occurs, set the slips and let unit recharge. It
only takes about 2 ½ minutes for the accumulators to fully
recharge. If the unit won’t recharge, check the following:

4.1.2 Control Console

The console contains several valves which are carefully balanced

to work together. NO ADJUSTMENTS SHOULD BE MADE IN
THE FIELD EXCEPT BY A QUALIFIED TECHNICIAN! (See
Section 4.2)

4.1.2.1 Control Panel Using Air/Hydraulic Power Unit

Function Possible Cause Remedy

Spider slips will set, but Spider handle is not fully Make sure the “Slips Up” handle is fully
will not rise engaged in the “Slips Up” engaged in the up position
position.
“ Elevator slips are open in Make sure the elevator slips are closed if
Interlock Mode. using the equipment in “Interlock Mode”
“ Loose or kinked air line Reattach or replace the air line.
inside the control console
cabinet
“ No air supply to the Connect air supply to the control console
control console
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Function Possible Cause Remedy

Spider Slips will set, but Air interlock valves on Make sure the air interlock valves on the
will not rise. control panel are not fully control panel are fully engaged to the
engaged interlock or bypass position
“ Faulty quick disconnects Check that all hose connections are fully
engaged. If necessary, depressurize the
system and check for clogged or broken
quick disconnects.
“ “Slips Up” hydraulic Have a qualified technician adjust the
circuit is not adjusted circuit. See Section 4.2.3
correctly
Spider Slips will not Set “Slips Down” control is Make sure the “Slips Down” handle is
not fully engaged fully engaged in the up position
“ Power Unit not Verify that the power unit is charged and
Pressurized holding pressure.
“ Faulty quick disconnects Check that all hose connections are fully
engaged. If necessary, depressurize the
system and check for clogged or broken
quick disconnects.

4.1.2.2 Control Panel Using (Backup) Tong Power Unit

Function Possible Cause Remedy

Spider slips will set, but Spider handle is not fully Make sure the spider handle is fully
will not rise. engaged in the “Slips Up” engaged in the “Slips Up” position
position
“ Elevator Slips are not Make sure the Elevator handle is fully
fully set when using engaged in the “Slips Down” position and
Interlock mode verify that the slips are actually set.
“ Loose or kinked air line Reattach or replace the air line
inside of control console
“ Power Unit pump is not Verify that the power unit pump is
engaged engaged.

“ No air being supplied to Connect air supply to the control console

the control console

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4.1.2.2 Control Panel Using (Backup) Tong Power Unit (continued)

Function Possible Cause Remedy

Spider slips will set, but Interlock valves not set to Make sure the interlock valves are set to
will not rise. “Bypass” when not using “Bypass”
interlock
“ Faulty or clogged quick Check that all hose connections are fully
disconnects engaged. If necessary, depressurize the
system and check for clogged or broken
quick disconnects.
“ “Slips Up” hydraulic Have a qualified technician adjust the
circuit is not adjusted system. See Section 4.2.3
properly.
Spider slips will not set “Slips Down” control is Make sure the “Slips Down” handle is
not fully engaged fully engaged in the down position.
“ Wrong flow setting on the Select the setting below 40 gpm (152
power unit liters/min) on the power unit pump.
Verify that the unit is set to tubing mode
and the pump is engaged.
“ Faulty or clogged quick Check that all hose connections are fully
disconnects engaged. If necessary, depressurize the
system and check for clogged or broken
quick disconnects.

ƒ If the diesel power unit will not UNLOAD after pressurizing the system DO NOT ADJUST
THE POWER UNIT
ƒ Verify that the bypass ball valve (Item 57 Fig.5) is open (Refer to the decal on the inside
of the control console door.
ƒ If the unloader valve needs to be adjusted, follow these steps:
ƒ Loosen the locknut on the unloader valve (Item 9 Fig.5)
ƒ Turn the valve slightly counter clockwise until the unit returns to idle.
ƒ Tighten the locknut
NOTE: DO NOT ADJUST ANY OTHER VALVES ON THE CONSOLE OR POWER UNIT.

ƒ If the power unit will not unload with the pressure set to 2300 PSI, service the power
unit for insufficient output pressure. Do not set the unloader valve lower than 2300
PSI.

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4.1.2.3 Varco FMS 375

Function Possible Cause Remedy

Slips do not move Faulty or clogged Check that all connections are fully
up or down when quick disconnects engaged. If necessary,
control valves are depressurize the system and
actuated check for clogged or broken quick
disconnects
“ Faulty Hoses Depressurize the system and rig
up with the spare set of hoses.
Can not achieve Slips not set Make sure the slips are set on the
set pressure when correctly pipe correctly. Check for
slips are set. obstructions or the slips setting on
the collar. Adjust as needed.
“ Dual pressure Check the position of the dual
valve not in the pressure valve (Refer to Fig. 2)
right position Adjust if necessary.
Set pressure to Dual pressure Adjust the dual control valve to 500
high when slips valve not adjusted psi (Refer to Fig.2).
are set on the to the correct
coupling. pressure setting.

4.2 SYSTEM ADJUSTMENT

The valves for the system have been factory set and should need no
adjustment. However, if a valve is replaced or the system goes out of
adjustment, the following steps should be taken by a qualified technician
to re-tune the system.

4.2.1 Air/Hydraulic Power Unit Adjustment

Using a sufficient air supply (See 1.2 Specifications):

ƒ Prepare the power unit per section 2.1.1.

ƒ Start the unit.
ƒ Turn valve on filter/regulator assembly (Item 10 Dwg. 78022) to
100 psi minimum.
ƒ Remove cap on hydraulic relief valve (Item 12 Dwg. 78048).
ƒ Loosen locknut and insert allen hex wrench in valve stem.
ƒ Turn valve clockwise to increase pressure and counter
clockwise to decrease pressure.
ƒ The valve should be set at 3000 psi when the motor slows to a
chugging sound, check both gauges.
ƒ Tighten locknut and replace dust cap.

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4.2.2 Control Panel Adjustment (Refer to Dwg. 78025)

ƒ Connect an air supply to the console and turn both pneumatic

ball valves (Item 48) to "bypass."
ƒ Connect the console to an air/hydraulic unit or a Tong Power
Unit. If using a diesel unit, open the ball valve in the console
(Item 57). If using a Frank’s Dual 40 hp electric unit, the ball
valve in the console must be closed.
ƒ Connect the Varco FMS 375 to console.
ƒ BEFORE STARTING POWER UNIT:
ƒ Connect a 3000 psi gauge to quick disconnect (Item 20).
ƒ Loosen locknuts on all valve cartridges (Items 9, 10, 14, 15,
89).
ƒ Using an Allen hex wrench, turn the Priority Flow control
valve (Item 10) until it seats, then back it out ¼ turn.
ƒ Start the unit and allow it to go to full pressure (3000 psi). If
using a diesel unit, use the tubing side.
ƒ Set the unloader valve (Item 9) at 2500 psi or if using a diesel,
adjust the valve in or out until the diesel unit unloads (2500 psi).
ƒ Move the spider handle into the “slips down” position.
ƒ Adjust the pressure reducing valve (Item 14) until the gauge on
the panel reads 1500 psi.
ƒ Open the Directional Control Valve (Item 89) all the way and
close 2 1/8 turns.
ƒ Adjust the Directional Control Valve (Item 89) to 1300 psi + 50
psi
ƒ Go back to the Pressure Reducing Valve (Item 14) and turn
clockwise until the gauge reads 1000 psi minimum. This
determines the pressure in the “slips down” position. Increase
to 2350 max. to use FMS as a backup.
ƒ Shift the spider handle on the control panel to “slips up.”
ƒ Adjust the other pressure reducing valve (Item 15) until the
“slips up” gauge reads 250-500 psi. Note: At 500 psi, the
slips can raise and drop a 25,000 lb. string of pipe. DO NOT
SET THIS VALVE HIGHER THAN 500 PSI!
ƒ Tighten the lock nuts on all valve cartridges

4.2.3 Tuning the Pneumatic Timer (Refer to Drawing 78025)

ƒ Connect control console to a diesel power unit or a Frank’s

Pneumatic/Hydraulic Unit with an adequate air supply.
ƒ Rig up a Varco FMS 375 and Varco Elevator equipped for
pneumatic interlock service.
ƒ Following the procedure in the manual, adjust the pressure
reducing valve (Item 14) to 1000. Adjust directional control
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valve (Item 89) per instructions in the manual. Re-adjust (Item

14) to 1500 psi if not using FMS as a backup and required
pressure for make-up torque if it is to be used as a backup
(2350 max.). See Varco FMS Manual for proper pressure vs.
torque.
ƒ Start the system and verify that the interlock/bypass valves on
the panel are set to “interlock.”
ƒ Set the elevator slips and open the FMS slips then set the
elevator control valve to the “slips open” position (slips should
remain closed) and leave it there.
ƒ Set the regulator in the console to 90 psi.
ƒ Turn the timer adjustment screw clockwise until it stops (DO
NOT OVER TORQUE) then back it out counter clockwise for 2½
turns. This will give you a rough setting.
ƒ Set the spider handles on the FMS control panel to “slips down,”
and using a stopwatch time the action from handle shift to full
opening of the elevator slips. This should take about 4 seconds.
ƒ If the cycle takes longer than 4 seconds, turn the screw counter
clockwise in 1/8” of a turn increments and time the cycle again.
ƒ If the cycle is less than 4 seconds or if the elevator opens before
the FMS sets then turn screw clockwise in 1/8” turn increments
and time the cycle again.
ƒ Proper timer adjustment is achieved with a minimum 2 second
time delay between spider slips reaching the down position and
the elevator slips first beginning to open.
ƒ Run the cycle numerous times to check repeatability.

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4.2.4 Adjustment of the Varco FMS 375

Figure 2 - View Inside Bowl of FMS 375

1. Position slips in the up position.

2. Remove necessary covers to gain access to valve
mounting screws.
3. Adjust height of Dual Pressure Valve to X = 4½" –
4¾" above base bracket.

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