Part Number 27-58

INSTALLATION, OPERATION, AND MAINTENANCE

WITH
ILLUSTRATED PARTS BREAKDOWN

BATTERY-OPERATED
PUMP STROKE COUNTER SYSTEM
PART NUMBER
230217

Manufacturers of Precision Instruments

Printed in U.S.A. June 15, 1983

 INSTRUCTION MANUAL 27-58

LIST OF EFFECTIVE PAGES

Total number of pages in this publication 26 consisting

is 28 of the following:

PAGE ISSUE
NO. DATE

Cover .................... .15 June 1983

A ........................ 15 June 1983
iandii .................... .15June 1983
l-l thrul-3 ................ .15June1983
l-4Blank .................. .15June 1983
2-l thru2-5 ................ .15June1983
2-6Blank .................. .15June1983
3-l ...................... .15June1983
3-2Blank .................. .15June1983
4-1 ...................... .15June1983
4-2Blank .................. .15June1983
5-1 thru5-3 ................ .15June1983
6-Othru6-4 ................ .15June1983
CommentSheet(2) ........... .15June1983

Qlg83, by TOTCO, All Rights Reserved

ii A
 IMPORTANT SAFETY NOTICE

Proper service and repair is important to the safe, reliable operation of all M/D TOTCO equipment.
The service procedures recommended by M/D TOTCO and described in the technical manuals are
recommended methods of performing service operations. When these service operations require
the use of tools specially designed for the purpose, those special tools should be used as recom-
mended. Warnings against the use of specific service methods that can damage equipment or
render it unsafe are stated in the manuals. These warnings are not exclusive, as M/D TOTCO
could not possibly know, evaluate and advise service people of all conceivable ways in which ser-
vice might be done or of all possible associated hazardous consequences. Accordingly, anyone
who uses service procedures or tools which are not recommended by M/D TOTCO must first sat-
isfy themselves thoroughly that neither personnel safety nor equipment safety will be jeopardized
by the method selected.

April 1981 iii

M/D TOTCO
 LIMITED PRODUCT WARRANTY

THE FOLLOWING WARRANTY IS EXCLUSIVE AND IN LIEU OF ALL OTHER WARRANTIES, WHETHER
EXPRESS, IMPLIED OR STATUTORY, INCLUDING, BUT NOT BY WAY OF LIMITATION, ANY WARRANTY
OF MERCHANTABILITY OR FITNESS FOR ANY PARTICULAR PURPOSE.

Martin-Decker TOTCO (“Company”) warrants to Buyer (“Purchaser”) of new products manufactured or

supplied by the Company that such products are, at the time of delivery to the Purchaser, free of material and
workmanship defects, subject to the following exceptions:

A. Any product which has been repaired or altered in such a way, in the Company's judgement, as to affect
the product adversely, including any repairs, rebuilding, welding or heat treating outside of Company
authorized facility.

B. Any product which has, in the Company's judgement, been subject to negligence, accident, or improper
storage.

C. Any product which has not been installed, operated and maintained in accordance with normal practice
and within the recommendations of the Company.

D. For all items of special order by Buyer which are not manufactured by Company, Buyer should submit
warranty claims directly to the manufacturer thereof.

The Company's obligation under this warranty is limited to repairing, or at its option, replacing any products
which in its judgement proved not to be as warranted within the applicable warranty period. All costs of
transportation of products claimed not to be as warranted to authorized Company service facility shall be
borne by Buyer. Costs of return transportation to Buyer of products accepted for repair or replacement by
Company under the warranty provisions of the Sales Agreement shall be borne by the Company. Company
may, at its sole option elect to refund the purchase price of the products, and Company shall have no further
obligation under the Sales Agreement.

The cost of labor for installing a repaired or replacement part shall be borne by Buyer. Replacement parts
provided under the terms of this warranty are warranted for the remainder of the warranty period of the
product upon which installed to the same extent as if such parts were original components thereof.

The warranty periods for various products are:

A. Hydraulic, Mechanical, Electronic Equipment: one (1) year from date of installation or fifteen (15) months
from date of shipment from Company, whichever occurs first.

B. All Elastomer Diaphragms: six (6) months from date of shipment from Company.

No deviations from the Company's standard warranty terms or period as stated herein will be honored unless
agreed to in writing by an authorized Company representative prior to acceptance of the order.

EXCLUSIVITY OF REMEDY AND LIMITATION OF LIABILITY. THE REMEDIES PROVIDED FOR IN THIS
WARRANTY SHALL CONSTITUTE THE SOLE RECOURSE OF BUYER AGAINST COMPANY FOR
BREACH OF ANY OF COMPANY'S OBLIGATIONS UNDER THE SALES AGREEMENT WITH BUYER,
WHETHER THE CLAIM IS MADE IN TORT OR IN CONTRACT, INCLUDING CLAIMS BASED ON
WARRANTY, NEGLIGENCE, OR OTHERWISE.

IN NO EVENT SHALL COMPANY BE LIABLE FOR DIRECT, INDIRECT, INCIDENTAL OR

CONSEQUENTIAL DAMAGES, REGARDLESS OF THE FORM OF ACTION, WHETHER IN CONTRACT,
STRICT LIABILITY OR IN TORT (INCLUDING NEGLIGENCE), NOR FOR LOST PROFITS.

iv April 1981
M/D TOTCO
 INSTRUCTION MANUAL 27-58

TABLE OF CONTENTS

Section Page
I PURPOSE AND DESCRIPTION ............................ l-l
l-l introduction .................................. 1- 1
l-3 Purpose .................................... l-l
l-5 Description .................................. 1- 1
l-7 . BOPSC Assembly ............................ l-l
l-9 .. Switches., .............................. .1-l
l-10 .. Displays ................................ .1-l
l-l 1 .. Solar Panel ............................... l-l
l-12 . Pump Stroke Sensor Assembly. ................... l-l
l-14 .. Proximity System ........................... l-l
II INSTALLATION ................................... ..2- 1
2-l Introduction. ................................ .2-l
2-3 Installation ................................. .2-l
2-4 . BOPSC Assembly ........................... .2-l
2-6 .. Grounding ............................... .2-l
2-7 .. BOPSC Connectors ......................... .2- 1
2-B . Pump Stroke Sensor Assembly. .................. .2-l
2-10 .. Clamp and Limit Switch Mounting ............... .2-l
2-11 .. Cable and Junction Box Connection .............. .2-l
2-12 .. Limit Switch Position. ....................... .2-l
2-13 .. Cable Connection .......................... .2-l
2-14 . Proximity System Installation .................... .2-l
2-l 6 Operational Check ........................... .2-5
III INSPECT;ON AND MAINTENANCE. ....................... .3-l
3-l Introduction ................................. .3- 1
3-3 Periodic Inspection ............................ .3- 1
3-5 . Cleaning. ................................. .3-l
3-7 Field and Store Maintenance ...................... .3-l
3-8 . Disassembly ............................... .3- 1
3-10 Assembly ................................. .3- 1
IV TROUBLESHOOTING ................................. .4-l
4-l Troubleshooting .............................. .4-l
V INTRODUCTION TO ILLUSTRATED PARTS BREAKDOWN ........ .5-l
5-l General .................................... .5- 1
5-3 Group Assembly Parts List Section ................. .5-l
5-5 . Figure and Index Number Column ................. .5-l
5-6 . Part Number Column ......................... -5-l
5-7 . Description Column .......................... .5- 1
5-9 . Units Per Assembly Column. ..................... 5-l
5-10 . Use on Code Column ......................... .5-l
5-l 1 Numerical Index Section ........................ .5-l
5-13 Additional Parts Lists (Sections) .................... 5-l
5-l 5 How to Use the Illustrated Parts Breakdown ............ 5-l
5-17 Abbreviations ............................... .5-l
VI GROUP ASSEMBLY PARTS LIST ......................... .6-O

I
 INSTRUCTION MANUAL 27-58

LIST OF ILLUSTRATIONS

Figure Page
l-l Battery Operated Pump Stroke Counter BOPSC System . . . . . . . . . . 1-2
l-2 BOPSC Face Plate Switches and Display . . . . . . . . . . . . . . . . . . . . .I-3
2-l BOPSC Installation Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . .2-2
2-2 BOPSC Rear Panel Connectors. . . . . . . . . . . . . . . . . . . . . . . . . . . .2-3
2-3 Limit Switch Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . , -2-3
2-4 Clamp and Limit Switch Mounting Dimensions . . . . . . . , . . . . . . . . .2-4
2-5 Pump Stroke Sensor Assembly Interconnect . . . . . . . . . . . . . . . . . .2-4
5-l Column Description of the Illustrated Parts Breakdown . . . . . . . . . , . 5-2
5-2 How to Use the Illustrated Parts Breakdown . . . . , . , . , . . . . . . . . . .5-3
6-l Battery Operated Pump Stroke Counter (BOPSC) System . . . . . . . . . .6-O
6-2 Pump Stroke Sensor Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . .6-3

LIST OF TABLES
Table Page
l-l BOPSC Switch Functions , . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . l-3
4-l Troubleshooting, BOPSC System . . . . . . . . . . . . . . . . . . . . . . . . . .4-l

APPROVED EXPENDABLE ITEMS LIST

Part Number Description
992405-009 Silicone Lubricant
991202-001 Silicone Adhesive
99 1702-006 Lubricant
999264-001 Grounding Clamp, l/2-inch
999263-002 Copper Clad Ground Rod, l/2-inch x 8 ft.
946624-002 Copper Wire, No. 8

RELATED PUBLICATIONS

Publication
Number Title
27-54 Proximity System, PN 232402-101 thru 106, Installation, Opera-
tion and Maintenance with Illustrated Parts Breakdown
 INSTRUCTION MANUAL 27-58
SECTION I
PURPOSE AND DESCRIPTION

l-l INTRODUCTION l-9 SWITCHES. The BOPSC assembly has three

operational switches (Figure l-2):
l-2 This manual contains information about the
Battery Operated Pump Stroke Counter RESET l/RESET 2
(BOPSC) System, manufactured by TOTCO. Infor- TEST
mation in this manual is sufficient to install, operate, ON/OFF
maintain, and replace parts.
Table l-l gives the function of the switches.
1-3 PURPOSE
l-l 0 DISPLAYS. Two back-lit LCD’s display ac-
1-4 The BOPSC provides a visual count of pump cumulated strokes (left side) and SPM (right
strokes and strokes per minute (SPM) for side). In addition, whenever the BOPSC senses a
one or two pumps. pump stroke from PUMP 1 or PUMP 2, a dash [ - 1
blinks in the middle of the corresponding LCD. PUMP
l-5 DESCRIPTION 1 display also lights up the BAT indicator [ L I when
the lithium battery is low on power. The backlights
l-6 The BOPSC system (Figure l-l 1 has four operate only in a dark environment.
mounting configurations: a freestanding
unit, a basic unit (for choke control consolel, a
l-l 1 SOLAR PANEL. The middle part of the win-
driller’s console 6-inch gauge hole unit, and a fixed
dow allows ambient light to strike the solar
mount unit for mounting to a wall or framework.
panel. The panel then supplies current to charge the
nicad batteries. The panel need not be in direct
l-7 BOPSC ASSEMBLY
sunlight because the panels supply sufficient
B!liml recharging current even on cloudy days.

DO NOT BREAK THE SEALS OR PUNCTURE l-l 2 PUMP STROKE SENSOR ASSEMBLY
THE CASE OF THE BOPSC BASIC UNIT. DIS-
TURBANCE OF CIRCUIT PATHS OR REMOVAL
l-l 3 The pump stroke sensor assembly consists
OF COMPONENTS MAY AFFECT BUILT-IN
of a cable assembly with a junction box. Two
SAFETY FEATURES.
cables extend from the junction box to limit switches
l-8 The BOPSC assembly is a self-contained mounted on clamp assemblies. The cable which con-
unit. High-capacity lithium batteries supply nects the junction box to the BOPSC has a 4-pin con-
power for the circuitry and have a life expectancy of nector.
up to five years. Lithium batteries are not recharge-
able. Nicad batteries supply power for the LCD l-l 4 PROXIMITY SYSTEM. The proximity system
backlights. Power from the solar cells recharge the may be used instead of limit switches. For a
nicad batteries. complete description, refer to Related Publications.

l-l
 INSTRUCTION MANUAL 27-58

&INCH GAUGE HOLE UNIT BASIC UNIT (CHOKE

(DRILLER’S CONSOLE) CONTROL CONSOLE)

FIXED MOUNT UNIT FREESTANDING UNIT

:-f:r:PlN) CABLE
ASSEMBLY,
4-CONDUCTOR

(PUMPS 4-PIN)

v
PUMP STROKE
SENSOR ASSEMBLY
PROXIMITY
27-581-I SYSTEM

FIGURE l-l. BATTERY OPERATED PUMP STROKE COUNTER (BOPSC) SYSTEM

l-2
 INSTRUCTION MANUAL 27-58

LITHIUM BATTERY
LOW CHARGE
INDICATOR
PUMP STRO!?E COUNTER
LCD
TOGGLE RESET
/ SWITCH

SOLAR
PANEL - TEST -
PUSHBUlTON
TEST SWITCH

nnnn,nnn
uu uu uu u p"yp
2
@STROKES SPM @ \ TOGGLE ON/OFF
YIIAL II-3
LCD POWER SWITCH

27-581-2

FIGURE l-2. BOPSC FACE PLATE SWITCHES AND DISPLAY

TABLE t-1. BOPSC SWITCH FUNCTIONS

SWITCH FUNCTION
RESET l/RESET 2 Resets the total pump strokes on the left side of the
displays to zero. RESET 1 applies to PUMP 1 display;
RESET 2, to PUMP 2 display.

TEST Tests the BOPSC internal electronics. Push and hold for
10 seconds and [ 30 I appears on the right side of both
displays. After 10 seconds, any number other than 30 in-
dicates malfunction of the BOPSC. If the pumps are in
operation during the test, total strokes will continue to ac-
cumulate during the test. The display will return to its nor-
mal display 10 to 12 seconds after release of the
pushbutton.

ON/OFF Applies battery power to the unit.

I-311 -4
 INSTRUCTION MANUAL 27-58
SECTION II
INSTALLATION

2- 1 INTRODUCTION netted, complete the connections as shown in

Figure 2-5. Connect the limit switch as follows:
2-2 The Battery Operated Pump Stroke Counter a. Strip insulation from the cable and the wires re-
(BOPSC) assembly operates in a normal rig quired for the limit switch.
environment. The BOPSC should mount so that it is
easily visible to the operator yet in sufficient light b. Crimp two spade lugs on the wires.
during the day to charge the nicad battery. Mount
the equipment out of the way of normal rig traffic. C. Loosen the two switch screws (Figure 2-31 that
hold the body of the switch; carefully separate
2-3 INSTALLATION the body without damaging the gasket.

2-4 BOPSC ASSEMBLY d. Loosen the shell of the stress relief and thread
the end of the cable through the rubber grom-
2-5 The design of the BOPSC assembly allows met. Connect the wires to the switch (Figure
for panel mount in the driller’s console 2-5) and tag the junction box end of the cable
(6-inch gauge hole), panel mount in the choke con- as PUMP SWITCH 1, etc.
trol console, fixed mount, or a free standing unit.
The pump stroke counter should be mounted and ad- e. With some slack in the wires inside the switch,
justed to avoid light glare on the LCD displays. tighten the stress relief shell until the rubber
Mounting dimensions are shown in Figure 2-l. grommet makes good contact with the cable.
Reassemble the switch.
2-6 GROUNDING. Connect a ground wire from
the GROUND connection on the rear of the 2-l 2 LIMIT SWITCH POSITION. Determine the
BOPSC to a copper sheath ground rod using a com- position in which the switch is to be
pression connector (Refer to Approved Expendable mounted to the switch C-clamp and the direction of
Items List). If an earth ground rod is not practical, switch actuation. The switch must be set to actuate
use an approved grounding structure. in one direction only. Complete the following:

2-7 BOPSC CONNECTORS. The BOPSC has a. After adjusting the switch head (Figure 2-31,
three cable connectors on the rear panel. remount the switch head to the body of the
Figure 2-2 shows the connectors and their pin func- switch. Actuate the switch actuator rod while
tions. listening to the switch to make sure it is
operating on one direction only and actuating in
2-B PUMP STROKE SENSOR ASSEMBLY the proper direction.

2-9 Install the pump stroke sensor assembly so b. Mount the switch to the C-clamp so that the ac-
that the cables and junction box are free of tuator rod responds in an arc not to exceed
normal rig traffic. Tie wrap cables away from mud 90°. If necessary, rotate the switch head.
and water if possible.
2-l 3 CABLE CONNECTION. Connect the cable of
2-10 CLAMP AND LIMIT SWITCH MOUNTING. the pump stroke sensor assembly to the
Mount the C-clamp to the pump housing so PUMPS 4 PIN connector on the rear of BOPSC
that the splash plate will activate the switch in one (Figure 2-2).
direction only, not to exceed a 90° arc (Figure 2-3).
The hub need rotate only 5O for activation of the 2- 14 PROXIMITY SYSTEM INSTALLATION
switch. Figure 2-4 shows the dimensions of the
clamp and limit switch. 2-l 5 Install the proximity system as described in
Related Publications. Use 4-conductor cable
2-l 1 CABLE AND JUNCTION BOX CONNECTION. assembly supplied with BOPSC system (Refer to 16,
If the junction box or switches are not con- Figure 6-l 1.

2-l
 INSTRUCTION MANUAL 27-58

FILISTER HEAD
6-32 x l-114
/(FOUR PLACES)
uuzl=d. BEZEL

/ BEZEL

~ DRILLER’S CONSOLE
PANEL BOPSC
BASIC
UNIT
DRILLER’S CONSOLE 6-INCH GAUGE HOLE UNIT
MOUNTING (DRILLER’S CONSOLE)
REMOVE 4 SCREWS (114-20 x 3/4) AND
USE EXlSTlNG AlTACHlNG HARDWARE -

1168.11 i I 11 I NdbI i \ I

cHtnKFr.nNTROL
-. .-..- --.* BASIC UNIT (CHOKE
._.____
MnllNTll _..UG CONTROL CONSOLE)
NOTE: DIMENSIONS ARE IN INCHES
(PAREI. YTHETICAL
- - DIMENSIONS
ARE IN MILLIMETERS1

t
CABLE 1146.1)
MOUNTING STAND, CONNECTOR
STAND-ALONE UNIT

II- 2 (50.8)

9.5
+ (241.3)

t --7 (177.81 FREESTANDING UNIT

FIGURE 2-l. BOPSC INSTALLATION DIMENSIONS

2-2
 INSTRUCTION MANUAL 27-58

,GROUND

PUMPS

H
A -GND
B -PUMP 1
Icl-PUMP 2

FIGURE 2-2. BOPSC REAR PANEL CONNECTORS

SPLASH
PLATE

.j.$
.,..
::..,..:
.;.;
.,..
:;,:;
..,.,I
fl

ACTUATOR A
ROD

C-CLAMP

SCREW

FIGURE 2-3. LIMIT SWITCH MOUNTING

2-3
 INSTRUCTION MANUAL 27-58

FIGURE 2-4. CLAMP AND LIMIT SWITCH MOUNTING DIMENSIONS

PUMPS

PUMP STROKE
SWITCH

FIGURE 2-5. PUMP STROKE SENSOR ASSEMBLY INTERCONNECT

2-4
 INSTRUCTION MANUAL 27-58

2-16 OPERATIONAL CHECK C. Activate both limit switches five times each.
PUMP 1 and PUMP 2 displays will show five
2-l 7 Perform an operational check of the installa- counts.
tion by completing the following:
NOTE
a. Position the ON/OFF switch to ON. Wait 10 The dash between the STROKES and SPM
seconds, SPM for each pump will read [OOOI. displays will blink with each pump stroke. The
dash will disappear when the switch is closed.
b. Position RESET 1 /RESET 2 switch to RESET 1 and
d. The SPM displays will indicate the strokes per
then to RESET 2. Both displays will clear the ac-
minute.
cumulated pump counts. STROKES display will be
blank after resetting. e. Reset both displays to zero.

2-512-6
 INSTRUCTION MANUAL 27-58
SECTION Ill
INSPECTION AND MAINTENANCE

3-1 INTRODUCTION
3-2 This section provides procedures for periodic
inspection and maintenance. Disassembly DO NOT DISASSEMBLE, BREAK THE SEALS,
should not exceed the level shown in Section VI, OR PUNCTURE THE CASE OF THE BOPSC
Group Assembly Parts List. BASIC UNIT. DISTURBANCE OF CIRCUIT
PATHS OR REMOVAL OF COMPONENTS MAY
3-3 PERIODIC INSPECTION AFFECT BUILT-IN SAFETY FEATURES.
RETURN UNITS WITH DAMAGED OR PUNC-
3-4 Periodically, inspect the system and replace TURED CASES TO TOTCO. REFER TO SER-
defective parts. Complete the following: VICE BULLETIN NO. 68 OR CONTACT NEAR-
EST TOTCO SALES OFFICE FOR SHIPPING IN-
a. Ensure that the cable connector of the pump FORMATION.
stroke sensor assembly is secure and that the
cables contain no cuts, cracks or frayed areas.
3-10 ASSEMBLY
b. Ensure that the limit switches are properly
mounted and the actuator rod is not worn exces- 3-l 1 Reassemble the parts in reverse order of
sively. disassembly. Section II provides information
C. Check BAT indicator on the BOPSC display. necessary for electrical connections. Complete the
following if assembly includes any parts listed below
3-5 CLEANING (Refer to Approved Expendable Items List):

3-6 Clean external surfaces of the BOPSC with a. Apply silicone lubricant to threads of the con-
mild detergent and water. Do not use abra- duit outlet cover (24, Figure 6-2).
sives or solvents on the face or on the case.
b. Apply silicone lubricant to gland threads of the
3-7 FIELD AND STORE MAINTENANCE cable connector (22).

3-8 DISASSEMBLY C. Apply silicone adhesive to pipe threads of the

pump stroke sensor assembly (Figure 6-2).
3-9 Limit the part replacement of the BOPSC
system to the level of disassembly shown in d. Apply lubricant to the screw threads of clamp
Section VI, Group Assembly Parts List. assembly (12).

3-l 13-2
 INSTRUCTION MANUAL 27-58
SECTION IV
TROUBLESHOOTING

4-l TROUBLESHOOTING

4-2 Table 4-l lists the trouble indicators, probable cause, and corrective measures necessary for repair
of the BOPSC system.

TABLE 4-l. TROUBLESHOOTING, BOPSC SYSTEM

INDICATION PROBABLE CAUSE CORRECTION

BAT indicator 1 L 1 appears Lithium batteries discharged. Replace BOPSC basic unit.
on PUMP 1 display Less than 3.0 vdc across TEST
pins A and E (Figure 2-2).

Backlights not on in dark Nicad batteries discharged. Place BOPSC basic unit in high
environment Less than 2.8 vdc across TEST ambient light and the unit
pins C and E (Figure 2-2). will recharge the nicad bat-
teries.

STROKES display miscounting Limit switch defective. Replace switch.

Limit switch not properly Mount switch as shown in
mounted. Figure 2-3.
Poor contact between pins Clean connectors or replace
and plug of cable connectors. cable assembly.
Defective BOPSC basic unit Replace defective BOPSC basic
unit

NOTE
The dash between the STROKES and SPM displays will blink with
each pump stroke. The dash will disappear when the switch is closed.

Pressing TEST pushbutton for Malfunction of BOPSC basic Replace BOPSC basic unit.
10 seconds causes any number unit.
other than 30 to appear on the
SPM display.

4-l 14-2
 INSTRUCTION MANUAL 27-58
SECTION V
INTRODUCTION TO ILLUSTRATED PARTS BREAKDOWN

5-1 GENERAL
5-2 This section describes how to use the GROUP ASSEMBLY PARTS LIST (SECTION VI), and other related information.

5-3 GROUP ASSEMBLY PARTS LIST SECTION

5-4 The GROUP ASSEMBLY PARTS LIST section (See Figures 6-1 and subsequent) includes exploded views accompanied by
parts lists keyed to the index numbers on the illustrations. Each assembly is listed in its disassembly order. When an assembly
illustration cannot show detail parts of one or more of its subassemblies, a separate detail illustration is furnished for the subassembly.
Figures 5-1 and 5-2 describe and explain how to use the parts list.

5-5 FIGURE AND INDEX NUMBER COLUMN. Three groups of digits separated by dashes make up this column (i.e. X-X-XX). The
first two groups represent the figure number of the corresponding illustration. The last group of digits is the index number of
each part. Most parts appear on the illustration (See Steps 1, 2, and 3 of Figure 5-l).

5-6 . PART NUMBER COLUMN. This column lists TOTCO part numbers. Information for order or purchase of these items is contain-
ed in the DESCRIPTION column.

5-7 DESCRIPTION COLUMN. This column describes each assembly, its attaching parts, and detail parts of the assembly. A
description may contain a parenthetical note. The note may cross-reference a subassembly to its detail illustration, or the note
may refer to its figure and index number of its NHA illustration (Steps 5 and 9).

5-6 Listed parts indent to indicate relationship to their next higher assembly (NHA) (Step 6). To determine the NHA of a part or
assembly, note the column in which the first word of the nomenclature appears. The first item directly above which appears
one column to the left (except for attaching parts1 is the NHA.

5-9 UNITS PER ASSEMBLY COLUMN. This column lists the number of units required for one NHA (Step 7).

5-10 USE ON CODE COLUMN. Code letters in this column show variations in parts on two or more similar assemblies (Step 6).

5-l 1 NUMERICAL INDEX SECTION (When Included)

5-12 The NUMERICAL INDEX section contains a numerical listing of parts and/or drawings that are listed in the GROUP ASSEMBLY
PARTS LIST. Figure 5-2 explains how to use the index.

5-13 ADDITIONAL PARTS LISTS (SECTIONS) (When Included)

5-14 Additional informative lists, such as SPARE PARTS LIST and FUSE LIST, follow the GROUP ASSEMBLY PARTS LIST section
or NUMERICAL INDEX section (as applicable).

5-15 HOW TO USE THE ILLUSTRATED PARTS BREAKDOWN

5-16 Figure 5-2 demonstrates the use of the Illustrated Parts Breakdown.

5-17 ABBREVIATIONS
5-16 The following standard abbreviations may be used in the parts lists contained in this manual:

AP attaching parts HD head PHH phillips heed

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

5-1
 INSTRUCTION MANUAL 27-58
SECTION VI
GROUP ASSEMBLY PARTS LIST

/ PUMP STROi?E COVNTER ,’

25 ‘3---b

r 1
22 20 21 19 23

r TO BOPSC
(PUMPS 4-PINI

(PUMPS 4-PIN)

PROXIMITY
SYSTEM

FIGURE 6-l. BATTERY OPERATED PUMP STROKE COUNTER (BOPSC) SYSTEM

6-O
 INSTRUCTION MANUAL 27-58

FIG. & UNITS USE

INDEX DESCRIPTION PER ON
NO. PART NUMBER 1234567 . ASSY CODE

NOTE
For repair of defective, or disposition of depleted, BOPSC
units (basic) PN 235609, refer to Service Bulletin No. 68
or contact nearest TOTCO sales office. This procedure is
applicable for rental and customer-owned units.

BOPSC UNITS (BASIC) CONTAIN LITHIUM BATTERIES.

DO NOT CRUSH OR INCINERATE.

6-l-14 230217 SYSTEM CONFIGURATION, BOPSC (Choke . . . . . . . 1 A

control console unit with pump stroke
sensor assyl
-24 230217-001 SYSTEM CONFIGURATION, BOPSC (Fixed. . . . . . . . I B
mount unit with pump stroke sensor assy)
-34 2302 I 7-002 SYSTEM CONFIGURATION, BOPSC (g-inch . . . . . . . I C
gauge hole, driller’s console unit with
pump stroke sensor unit)
-44 2302 I 7-003 SYSTEM CONFIGURATION, BOPSC (Free- . . . . . . . . I D
standing unit with pump stroke sensor
unit)
-54 2302 I 7-004 SYSTEM CONFIGURATION, BOPSC (Choke . . . . . . . 1
control console unit with proximity system1
-64 230217-005 SYSTEM CONFIGURATION, BOPSC (Fixed. . . . . . . . I
mount unit with proximity system)
-74 2302 I 7-006 SYSTEM CONFIGURATION, BOPSC (6-inch . . . . . . . I
gauge hole, driller’s console unit with
proximity system)
-84 2302 I 7-007 SYSTEM CONFIGURATION, BOPSC (Free- . . . . . . . . I H
standing unit with proximity system)
-94 2302 I 7-008 SYSTEM CONFIGURATION, BOPSC . . . . . . . . . . . . 1 I
(Customer supplied sensors)
-104 2302 17-009 SYSTEM CONFIGURATION, BOPSC . . . . . . . . . . . . I J
(Customer supplied sensors)
-1 I4 2302 I 7-010 SYSTEM CONFIGURATION, BOPSC . . . . . . . . . . . . 1 K
(Customer supplied sensors)
-124 230217-011 SYSTEM CONFIGURATION, BOPSC . . . , . , . . . . . . I L
-13 235609 . FINALASSY, BOPSC (Basic) . . . . . . . . , . . . . . . . I
-14 272804-l 02 . PUMP STROKE SENSOR ASSY (See Figure . . . . . . I A,B,C,D
6-2 for details)
-15 232402-xxx . PROXIMITY SYSTEM (Requires PN 232617-l 02 . . I E,F,G,H
for interconnection)(Refer to Related
Publications for required configuration)
-16 232617-l 02 . CABLE ASSY, 4 Conductor (250 ft) . . . . . . . . . . . 1 E,F,G,H
-17 230216 . MTGPLATEASSY . . . . . . . . . . . . . . . . . . . . ..I D,H,L
-184 230225-001 . KIT, Mtg, BOPSC . . . . . . . . . . . . . . . . . . . . . . -1 B,D,F,H,
J,L
-19 235605 . . BRACKET, Gimbal . . . . . . . . . . . . . . . . . . . . . 1
-20 230277 . . KNOBASSY(AP)......................2

6-I
 INSTRUCTION MANUAL 27-58

FIG. & UNITS USE

INDEX DESCRIPTION PER ON
NO. PART NUMBER 1234567 ASSY CODE

6-l -21 999234-047 .. SPACER, Nylon, I /4 nom x 5/l 6 (AP) ....... .2

-22 999368-727 .. SCREW, Cap hex skt hd, No. 6-32 x I /4 .... .2
tAPI
-23 999445-008 .. WASHER,Flat, 1/4nom ................ .2
-244 230225-002 . KIT, Mtg, BOPSC ....................... I C,G,K
-25 230169 .. BEZEL, Faceplate ...................... 1
-26’ 999383-I 39 .. SCREW,Sltd,filh,No.6-32x.. .......... .4
I-I/4 (AP)
-27” 999264-001 CLAMP, Grounding, I/2-inch ................. I
-28” 999263-002 GROUND ROD, Copper clad, I/2-inch x 8 ft ....... I
-29” 946624-002 WIRE,Copper,No.8 .................... .AR

l Not Illustrated

6-2
 INSTRUCTION MANUAL 27-58

TO ODD NUMBERED
PUMP SENSOR
TO EVEN NUMBERED (SEE INDEX 11)
PUMP SENSOR
(SEE INDEX 11)

FIGURE 6-2. PUMP STROKE SENSOR ASSEMBLY

FIG. & UNITS USE

INDEX DESCRIPTION PER ON
NO. PART NUMBER I234567 ASSY CODE

6-2- 272804-l 02 PUMP STROKE SENSOR ASSY, for Class I, . . . . . REF

Group B and C hazardous area (Refer to
14, Figure 6-I for NHA)
-14 270630-l 02 . CLAMP AND LIMIT SWITCH ASSY . . . . . . . . . . .2
-24 270641 . . LIMIT SWITCH ASSY . . . . , . . . . . . . . . . . . . , 1
-3 999397-031 . * NUT, Hex, No. I O-24, sst (AP) . . . . . . . . . . . .2
-4 999321-l I8 . . LOCKWASHER, No. IO, sst (AP) . . . . . . . . . . .2
-5 999368-801 . . SCREW, Hex, No. 10-24x l-I/4, sst (API . . . .2
-6 270559 . . . ROD, Actuator, 0.125 dia x I8-in., sst . . . . . . I
-7 933014-001 . . . SWITCH, Limit (cutler/hammer1 . . . . . . . . . . . I
-8 933014-002 . . . OPERATING LEVER (Used only on . . . . . . . . . I
PN 933014-001)
-9 933015-001 . . . SWITCH, Limit (Microswitchl(alternate . . . . . .I
for PN 933014-001)
-10 933015-002 . . . HUB (Used only on PN 933015-001) . . . . . . .1
-1 I 955701-007 . . . CONNECTOR, Cable . . . . . . . . . . . . . . . . . . 1
-12 270639 . . CLAMPASSY . . . . . . . . . . . . . . . . . . . . . . ..I
-13 272836 . LABEL (FM approval) . . . . . . . . . . . . . . . . . . . . . I
-144 272800-l 02 , JUNCTION BOX ASSY (For Class I, . . . . . . . . . . . 1
Division I, Group B and C hazardous area)

6-3
 INSTRUCTION MANUAL 27-58

FIG. & UNITS USE

INDEX DESCRIPTION PER ON
NO. PART NUMBER I234567 ASSY CODE

6-2-I 5 NOT USED

-164 232616-l 03 .. CABLE ASSY, Sensor, 3 conductor .......... I
-17 947619-055 ... STRAP, Cable. ..................... .3
-18 949807-389 ... CONNECTOR.. ..................... .
-19 946927-002 ... CABLE, Power, SJO 1813 .......... ,225 ft
-20 271209-101 .. CABLE ASSY, JB to SW 2, grn and wht ....... I
leads (25 ft)
-21 271209-102 .. CABLEASSY,JBtoSW 1, blkandgrn ........ I
leads 125 ft)
-22 955701-007 .. CONNECTOR, Cable. .................. .3
-23 978915-001 .. GASKET (Replacement part for. ............ 1
PN 955220-025)
-24 955220-025 .. CONDUIT, Outlet ...................... 1
-25 949864-004 .. CONNECTOR, Wirenut ................. AR

6-4