Operations Manual Blackstar EM MWD

Printed By: kanagasabair Printed On: 2012.11.06.16.01.
42
Operations Manual
BlackStar EM MWD Tool
Reference Reference Description

BlackStar EM MWD Tool Field Operations Manual
This document contains proprietary and confidential
information which is the property of National Oilwell Varco, National Oilwell Varco
L.P., its affiliates or subsidiaries (all collectively referred to Downhole Instrumentation
hereinafter as "NOV"). It is loaned for limited purposes only 10302 Mula Rd.
and remains the property of NOV. Reproduction, in whole or in Stafford, TX 77477
part, or use of this design or distribution of this information to
others is not permitted without the express written consent of
NOV. This document is to be returned to NOV upon request or
upon completion of the use for which it was loaned. This
document and the information contained and represented
herein is the copyrighted property of NOV © National Oilwell
Varco
Document Number Rev.
D9A1000051-MAN-001 E
www.nov.com
TC Number: D9A1000051-MAN:9A Printed REV: E Latest REV: E

Printed By: kanagasabair Printed On: 2012.11.06.16.01.42

Revision History
Raj Kanagasabai
E 10.28.11 Add New Topics Mary Taylor Raj Kanagasabai
& Roger Rabb
Raj Kanagasabai
D 06.30.10 Add TOT Mary Taylor Raj Kanagasabai
& Roger Rabb
C 11.19.2009 Revision C Release Mary Taylor Raj Kanagasabai Raj Kanagasabai
B 10.09.2009 Updates Raj Kanagasabai Raj Kanagasabai Raj Kanagasabai
Raj Kanagasabai
A 08.01.2009 Initial Release Mary Taylor Scott Kesler Raj Kanaasabai
Mike Curtain
Rev Date (dd.mm.yyyy) Reason for issue Prepared Checked Approved
Change Description
Revision Change Description
A Initial Release
B Reorganized manual chapter structure, added and revised original release
C Update and Release for Chinese Translation
D Add Triple Output Transmitter
Add Topics for Software Installation, SQL Server Installation Software, and Laptop Required Power
E
Options Settings
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Table of Contents
Chapter 1: General Information
Conventions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Advisories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Illustrations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Safety Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Personnel Training . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Recommended Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
General System Safety Practices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
Chapter 2: Electro Magnetic (EM) Transmission

Basic EM Transmission Theory . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Antenna Placement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Connecting the Wellhead Antenna . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
The Cable and Rod Selection for the Reference Antenna . . . . . . . . . . . . . . . . . . . 6
Reference Antenna Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Increasing Signal Methods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Methods for Locating Antenna . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Operating Multiple EM Tools in Close Proximity . . . . . . . . . . . . . . . . . . . . . . 8
Configuration Possibilities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
EM Receiver Antenna Placement to Minimize Inter-Well Interference . . . . . . . . . 12
Power Loss Due to Improper Tool Spacing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Chapter 3: Tool String Components

Directional Only . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Required Tubulars . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Required MWD Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
360/Gamma/Focus Gamma . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Required MWD Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Dynamic Rotational Gamma (DRG) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
BlackStar Dual-Channel Amplifier (DCA) Configuration . . . . . . . . . . . . . . . . . . . . 21
BlackStar Single-Channel Amplifier (SCA) Configuration . . . . . . . . . . . . . . . . . . . 23
Chapter 4: EM MWD Tool Assembly

Directional Only . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Connecting the Transmitter to Directional Probe . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Connecting the Transmitter Battery Bulkhead . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Assembling the Second Transmitter Battery and Battery Bulkhead . . . . . . . . . . . 28
360 Gamma/Focus Gamma . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Assembling the Gamma Battery Housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Assembling the Directional Probe to the Gamma Battery Housing . . . . . . . . . . . . 29
Dynamic Rotational Gamma (DRG) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Assembling DRG Battery Housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
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Chapter 5: Rig Up
DCA Configuration. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Connecting the Dual-Channel Amplifier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Installing NOV BlackStar Device Drivers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Install the BlackStar USB Composite Device Driver . . . . . . . . . . . . . . . . . . . . 34
Install the USB to UART Bridge Controller Device Driver . . . . . . . . . . . . . . . . 38
Install the DT9840 Controller Device Driver . . . . . . . . . . . . . . . . . . . . . . . . . . 42
DCA Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Connecting DCA Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Powering Up the DCA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Troubleshooting the DCA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
SCA Configuration. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Connecting the SCA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
Troubleshooting the SCA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
How to Ping the Amplifier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
Configuring the Laptop Computer for the SCA . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
Windows XP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
Windows 2000 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
Setting Windows 7 Static IP Address . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
Chapter 6: Tool String Testing

Configuring and Testing the BlackStar EM Tool with DCA . . . . . . . . . . . 69
BlackStarEMVue . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
Configuring the Tool with DCA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
Connecting the DCA to the Computer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
Checking the BlackStar DCA Meter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
Starting BlackStar EMXConfig . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
Transmitter Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
Selecting Survey and Steering Frame Parameters . . . . . . . . . . . . . . . . . . . . . 83
Gamma Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
Annulus Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
Testing and Configuring the Pressure Transducer . . . . . . . . . . . . . . . . . . . . . 89
Gamma Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
Dynamic Rotational Gamma (DRG) Parameters . . . . . . . . . . . . . . . . . . . . . . 91
Gamma Collar Attenuation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
Highsiding the Tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
BlackStar EMDataMgr . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
Creating a New Job . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
Creating a New Track . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
Attach a Tool to a Track . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
Archiving Job Data and Tool Configurations . . . . . . . . . . . . . . . . . . . . . . . . . 106
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Running BlackStarEMVue . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109

Verifying the Proper Signal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
Checking Tool Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
Calibrating the DCA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
Alerts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
Down-Link Alerts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
Loop-Back Testing for the DCA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
Functionality . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
Performing the Loop-Back Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
Configuring and Testing the BlackStar EM Tool with SCA . . . . . . . . . . 114
BlackStar EM Control Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114
Configuring the Tool with SCA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118
Connecting the BlackStar Programming Box . . . . . . . . . . . . . . . . . . . . . . . . . . . 119
Troubleshooting the Programming Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121
Starting BlackStar EMXConfig . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122
Transmitter Configurations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123
Gamma Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131
Annulus Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132
Testing and Configuring the Pressure Transducer . . . . . . . . . . . . . . . . . . . . 133
Gamma Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133
Dynamic Rotational Gamma (DRG) Parameters . . . . . . . . . . . . . . . . . . . . . . 134
Highsiding the Tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136
BlackStar EMDataMgr . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139
Creating a New Job . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139
Creating a New Track . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141
Attach a Tool to a Track . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148
Archiving Job Data and Tool Configurations . . . . . . . . . . . . . . . . . . . . . . . . . 149
Running EM Control Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152
Verifying the Proper Signal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153
Checking Tool Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153
Calibrating the SCA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155
Alerts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 156
Down-Link Alerts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 156
Loop-Back-Testing for SCA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 156
Performing the Loop-Back Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 156
Chapter 7: Field Maintenance and Service

BlackStar EM Gap Sub Tester . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 164
Testing Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 164
Product Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 164
Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 165
Self-testing the Gap Sub Meter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 166
Charging the EM Gap Sub Meter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 167
Testing a Gap Sub using the EM Gap Sub Tester . . . . . . . . . . . . . . . . . . . . . . . 168
Interpreting the LED Indicator Results on the EM Gap Sub Tester . . . . . . . . . . . 169
Inspecting a Gap Sub . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 170
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Servicing the UBHO . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 172

Tools and Supplies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 172
How to Service the UBHO . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 173
Inserting the Key into the Sleeve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 174
UBHO Torque Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 180
Unloading Sleeve from the UBHO . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 180
Parts, Tools, and Supplies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 181
Servicing the Transmitter Contact Collet Assembly. . . . . . . . . . . . . . . . 183
Replacing O-rings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 183
Assembling the Collar and Sleeve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 187
Installing O-rings and Parbak Rings on the Stinger Assembly. . . . . . . 194
Greasing the Annular Pressure Lower Assembly . . . . . . . . . . . . . . . . . . . 198
Installing the Push-On-Fin (POF) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 202
How to Install the Push-On-Fin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 203
Reference Drawing: Fin Installation Tool Assembly - 391-114-01 . . . . . . . . 203
Chapter 8: Lifting and Seating the Tool

Measuring the Tool Length and Collars . . . . . . . . . . . . . . . . . . . . . . . . . . . . 209
Collar Measurement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 209
MWD Tool Measurement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 209
Highside Universal Bottom Hole Orientation (UHBO) Sleeve . . . . . . . . . . . . . . . 213
Lift and Seat the Tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 216
Prerequisite to Moving the Tool to the Rig . . . . . . . . . . . . . . . . . . . . . . . . . . 220
Positioning and Lifting the Tool on the Rig . . . . . . . . . . . . . . . . . . . . . . . . . . 221
Loading the Tool into the Collar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 222
Verifying that the Tool is Seated . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 226
Chapter 9: Shop Maintenance and Service

Installing SQL Server Express . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 229
Setting Up the Laptop Computer for BlackStar EM Suite Software . . . . . . . . . . 240
Configuring Power Settings for Windows XP . . . . . . . . . . . . . . . . . . . . . . . . 240
Installing the BlackStar EM Suite . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 244
BlackStar EM Suite 3.16.1 or Higher System Requirements . . . . . . . . . . . . . . . 244
RAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 244
Hard Disk Space . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 244
Processor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 244
Hardware . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 244
Operating Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 244
Installing on Windows Vista/Windows 7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 245
Options for Installing BlackStar EM Suite . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 245
Install from CD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 245
Install from FTP Download . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 246
Re-installing the BlackStar EM Suite . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 247
Software Release . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 247
Updating the Dual Channel Amplifier (DCA) Software . . . . . . . . . . . . . . . . . . . . 248
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Servicing the Battery Bulkhead . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 250

Tools and Supplies Required . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 250
Servicing the Battery Bulkhead . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 251
Testing the Battery-to-Battery Centralizer . . . . . . . . . . . . . . . . . . . . . . . . . 256
Testing the Battery Bulkhead . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 260
Downhole Tool Firmware Upgrade. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 263
Changing Internal O-rings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 265
Recommended Tools and Supplies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 265
Change the Transmitter Assembly O-rings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 266
Transmitter Assembly Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 266
Disassemble the Bow-Spring Collet Assembly . . . . . . . . . . . . . . . . . . . . . . . 267
Remove Old O-rings from the Bow-Spring Collet . . . . . . . . . . . . . . . . . . . . . 269
Replace O-rings on the Bow-Spring Collet . . . . . . . . . . . . . . . . . . . . . . . . . . 269
Disassemble the Gap Sub Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 270
Replace O-rings on the Gap Sub Assembly . . . . . . . . . . . . . . . . . . . . . . . . . 271
Reassemble Gap Sub Component to Transmitter Assembly . . . . . . . . . . . . 272
Reassemble the Cable Wiring Harness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 273
Reassemble Bow-Spring Collet to Pressure Housing . . . . . . . . . . . . . . . . . . 274
Changing O-rings on the Transmitter Gap Sub Assembly . . . . . . . . . . . . . . . 275
Change O-rings on the Triple-Output Transmitter (Gap-Sub Assembly) . . . . 278
Change the Directional Sensor Assembly O-rings . . . . . . . . . . . . . . . . . . . . 279
Directional Sensor Assembly Components . . . . . . . . . . . . . . . . . . . . . . . . . . 279
Disassemble the Cross-Over Sub Assembly . . . . . . . . . . . . . . . . . . . . . . . . . 280
Replace O-rings on the Cross-Over Sub Assembly . . . . . . . . . . . . . . . . . . . 283
Change the O-rings on the Snubber Centralizer . . . . . . . . . . . . . . . . . . . . . . 284
Replace O-rings on the Snubber Centralizer . . . . . . . . . . . . . . . . . . . . . . . . . 286
Reassemble the Snubber Centralizer to Pressure Housing Component . . . . 287
Reassemble the Cable Harness Wiring Connection . . . . . . . . . . . . . . . . . . . 287
Reassemble Cross-Over Sub Assembly to Pressure Housing Component . . 288
Change O-rings in the Gamma (PTG) Tool Assembly . . . . . . . . . . . . . . . . . . . . 289
Gamma Tool Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 289
Reassemble the Gamma Tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 294
Servicing the EM BlackStar Single Channel Amplifier (SCA) . . . . . . . . 295
Computer Power and Cooling Fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 302
Cleaning the Amplifier Internal Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . 303
Testing the BlackStar Surface Amplifier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 304
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Chapter 10: Product Support Information

Technical Support. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 305
Appendix A: Drawings and Schematics

List of Drawings and Schematics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-1
Appendix B: Lithium Battery Safe Handling

Safe Handling and Disposal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-1
Appendix C: Worksheets
Job EM Modeling Worksheets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-1
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D9A1000051-MAN-001
Revision E
Page 1 of 4
General Information
Conventions
This manual is intended for use by field engineering, installation, operation, and repair personnel. Every
effort has been made to ensure the accuracy of the information contained herein. National Oilwell Varco
(NOV), will not be held liable for errors in this material, or for consequences arising from misuse of this
material.
Advisories
Graphic symbols and bracketed text indicate advisories for a specific topic. This information provides the
reader with additional details and may advise the reader to take a specific action to protect personnel from
potential injury or lethal conditions. These advisories may also inform the reader of actions necessary to
prevent equipment damage. Please pay close attention to this information.
Note
The note symbol indicates that additional information is

provided about the current topic.
Caution
!
The caution symbol indicates that potential damage to
equipment, or injury to personnel exists. Follow
instructions explicitly. Extreme care should be taken when
performing operations or procedures preceded by this
caution symbol.
Warning
The warning symbol indicates a definite risk of

equipment damage or danger to personnel. Failure to
follow safe work procedures could result in serious or
fatal injury to personnel, significant equipment
damage, or extended rig down time.
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TC Number: D9A1000051-MAN:9A
D811001123-GEN-001/04
Printed REV: E Latest REV: E
D9A1000051-MAN-001
Revision E
Page 2 of 4
General Information 1
Conventions
Advisories
Hot Surfaces
The hot surface symbol indicates the presence of a

hot surface or component. Touching this surface
could result in bodily injury. To reduce the risk of
injury from a hot component, allow the surface to cool
before touching.
Electrostatic Discharge
The Electrostatic Discharge (ESD) symbol indicates the

potential for static electrical discharge is present. ESD can
damage or destroy sensitive electronic components. ESD
can also set off explosions or fires in flammable environ-
ments. Always discharge static electricity prior to working
on sensitive components or in flammable environments.
Illustrations
Illustrations (figures) provide a graphical representation of equipment components or screen snapshots for
use in identifying parts, or establishing nomenclature, and may or may not be drawn to scale.
For component information specific to your rig configuration, see the technical drawings included with your
NOV documentation.
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D9A1000051-MAN-001
1 General Information Revision E
Page 3 of 4
Safety Requirements
The NOV equipment is installed and operated in a controlled drilling rig environment involving hazardous
situations. Proper maintenance is important for safe and reliable operation. Procedures outlined in the
equipment manuals are the recommended methods of performing operations and maintenance.
!
To avoid injury to personnel or equipment damage,
carefully observe requirements outlined in this section.
Safety Precautions
When assembling and/or operating the Tool String or equipment described in this manual, follow the
guidelines below:
 Use extreme caution when using fin-cutting guides to trim centralizers.
 Wear PPE at all times while working with the tools on the rig floor.
 Wear safety glasses at all times when in work areas on the rig.
 Respect and follow oil company and rig contractor safety policies.
Personnel Training
All personnel performing installation, operations, repair, or maintenance procedures on the equipment, or
those in the vicinity of the equipment, should be trained in rig safety, tool operation, and maintenance to
ensure their safety.
!
Personnel should wear protective gear during installation,
maintenance, and certain operations.
Contact the NOV training department for more information about equipment operation and maintenance
training.
Recommended Tools
Service operations may require the use of tools designed specifically for the purpose described. The
equipment manufacturer recommends that only those tools specified be used when stated. Ensure that
personnel and equipment safety are not jeopardized when following service procedures and that personnel
are not using tools that were not specifically recommended by the manufacturer.
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D9A1000051-MAN-001
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Page 4 of 4
General Information 1
General System Safety Practices

The equipment discussed in this manual may require or contain one or more utilities such as electrical,
hydraulic, pneumatic, or cooling water.
!
Read and follow the guidelines below before installing
equipment or performing maintenance to avoid
endangering exposed persons or damaging equipment.
 Isolate energy sources before beginning work.

 Avoid performing maintenance or repairs while the equipment is in operation.
 Wear proper protective equipment during equipment installation, maintenance, or
repair.
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D9A1000051-MAN-001
Revision E
Page 5 of 14
Electro Magnetic (EM) Transmission
Basic EM Transmission Theory
The majority of the EM signal travels up the drill pipe, and leaks off through the surrounding formations and
then returns to the opposite side of the Gap Sub. The objective is to detect the limited signal on the
wellhead.
There are two antennas in the EM-MWD applications to include the following:
 Wellhead
 Reference
The wellhead antenna connects to the surface of the BOP.
The reference antenna connects to the ground some distance from the wellhead. In most cases, the
wellhead antenna receives the signal, and the reference antenna provides a ground reference to form an
electronic loop.
No matter how good the antenna is, the contact resistances (between reference antenna and ground and
between the wellhead antenna and the surface of BOP) always exist. When the resistance is increased,
the input signal voltage to the amplifier decreases. The goal is to reduce the contact resistance to its
lowest.
Antenna Placement
Connecting the Wellhead Antenna
1. Use a file to remove any oxide or paint from the BOP bolt.
2. Clean the flat copper end of the antenna cable and attach it to the bare metal on the BOP bolt with a
C-Clamp.
Note
If noise becomes an issue, remove the wellhead

connection and move to a stake beside the cellar. This will
resolve some noise issues, but will drop signal strength
approximately 12dB.
3. Use DC111 or another type silicone grease to cover the connection area.
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D9A1000051-MAN-001
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Electro Magnetic (EM) Transmission 2
The Cable and Rod Selection for the Reference Antenna

The EM signal is very small, any electro-magnetic interference (EMI) will deteriorate the signal reception.
For blocking EMI, a coaxial cable is needed.
The resistance is closely related to the contact of the antenna to the ground. Drive the rod as deep as
possible into the ground, (a minimum two feet). The more surface area the grounding rod has with the
ground, results in better signal transmission.
The recommended distance between the reference antenna and the wellhead antenna is minimum 200ft.
Due to the differential properties, the EM BlackStar amplifier input require that the distance between the
wellhead antenna and reference antenna is far enough from each other.
Reference Antenna Locations

The first choice location of the reference antenna should be placed in the direction that the well is being
drilled. The best reference antenna locations are in a very conductive area or around a conductive object.
If these conditions exist, they should be the first choice for a reference antenna if they are in a locations
opposite to the well being drilled.
The location can include and may not be limited to the following:
 A pond.
 A lake.
 A metal fence.
 An anchor.
 A neighboring well.
Increasing Signal Methods
Any methods that reduce the contact resistance of the reference antenna helps increase the signal level.
There are many ways to accomplish this, including the following:
 Soak the area with salt water around the reference antenna rod.
 Put the reference antenna rod deeper.
 Use a thicker reference antenna copper rod.
 Use a longer reference antenna copper rod.
 Put the rod in a shallow area.
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D9A1000051-MAN-001
2 Electro Magnetic (EM) Transmission Revision E
Page 7 of 14
Methods for Locating Antenna
Refer to the following two method examples to locate the antenna:
Method 1: Rig Floor Generating Lots of Noise
Using a top drive rig usually generates a lot of noise. The noise combines with the signal transferring from
drill pipe and deteriorates the EM signal reception. Usually, the wellhead antenna can be moved 5-20 feet
away from the BOP. When the noise is removed the signal to noise ratio will improve. Signal strength will
drop.
Method 2: Drilling a Shallow Well
When a shallow well (TVD less than 400 feet) with long total depth (TD) is drilled, the signal transferred
through the drill pipe might be smaller than the signal transferred through the ground to the reference
antenna, if the reference antenna is located just above the drilling trajectory. When the measured (depth
MD) is 4 times larger than TVD depth, we recommend that the operators move the wellhead antenna 200ft
away from BOP and put the reference antenna just above the drilling trajectory. During the drilling process,
the operators need to move the reference antenna to catch the bit location to get stronger signals.
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D9A1000051-MAN-001
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Operating Multiple EM Tools in Close

Proximity
When drilling multiple shallow wells in close proximity, it is important to minimize the interference from the
signals of the EM Transmitters located in adjacent wells. The purpose of this discussion is to describe the
interference, and provide methods to minimize it effects on drilling operations.
With EM simulation, it can be seen that the EM signals generated at the gap depth contain the most
energy, and penetrates the greatest distance horizontally into the formation.
Figure 2-1. EM Signals
The EM field distribution map along the drill pipe. Strongest horizontal penetration into the formation
located at the gap sub. Arrows indicate the direction of current flow in the formation and the colors
represent the intensity of the induced EM Signal distributed along the borehole.
The majority of the inter-well interference when using multiple EM Transmitters in close proximity situations
is caused by the mutual inductions of transmitted EM signals into the adjacent wells. The closer the
spacing between EM Transmitters, the stronger the mutual induction between the wells, with the strongest
points being concentrated at the TVD of the gap subs. The total interference observed in an individual well
can be described as the integral of all the mutually induced signals into the well along the drill sting and
surface casing moderated by the formation attenuations factors.
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D9A1000051-MAN-001
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Because the EM transmission system provides considerable flexibility in it’s modes of operation, the effects
of mutually induced signals can be easily minimized by selection of appropriate transmission frequencies
and data baud rates. A simple summary of interference reduction steps are as follows:
1. Configure the EM Transmitters to operate on different base band frequencies and baud rates as
described in the following discussion.
Theoretically, the signal spectrum of the BlackStar EM Transmission System concentrates on the
range CF ± 0.5BR. Here CF is the carrier frequency and BR represents the baud rate. Thus the delta
between carrier frequencies should be lager than the baud rate.
2. Position the EM Transmitters that are operating at the closest base band frequencies as far apart as
physically possible in the drill pattern.
3. Arrange the antenna location of the individual EM Receivers so that the partial interference can be
cancelled.
4. Keep the drilling depth the same in each well. (This may not be practical in actual field operations)
Configuration Possibilities
There are several possible configurations of the BlackStar EM Transmission system which will provide
minimum interference from EM Transmitters located adjacent to one another. Three possible configurations
are described below:
Configuration 1: - EM Transmitters set to a data transmission rate of 1 Baud:

The EM Transmitters are configured with the carrier frequencies positioned 1Hz apart in a range from 3Hz
to 11Hz. In all cases the data rate set to 1 Baud. In this configuration the majority of the inner well
interference is out of the signal band of the individual EM Transmitters and its associated EM Receiver.
See Figure 2. The x/y nomenclature used in the tables indicates the base band frequency and the data
transmission baud rate. Example, 3/1 = 3Hz and 1 Baud Rate.
Using this configuration it is possible to position as many as 7 EM Transmitters (TX1 to TX7) in close
proximity.
Table 2-1. Configuration 1
Group TX1 TX 2 TX 3 TX 4 TX 5 TX 6 TX 7
1 3/1 4/1 5/1 6/1 7/1 8/1 9/1
2 4/1 5/1 7/1 9/1 suggested
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D9A1000051-MAN-001
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Page 10 of 14
Figure 2-2. The spectral distribution for carrier frequency difference equal to baud rate
If there are less than or equal to 4 EM Transmitters being operated in close proximity at the same time, it is
recommended that the base band frequencies be set to 3Hz, 5Hz, 7Hz, and 9Hz. At this separation of the base
band transmission frequencies the interference will be completely eliminated by using a band-pass filter that is
incorporated into the BlackStar EM Receiver as shown in Figure 2-3.
Figure 2-3. The spectral distribution for wider carrier frequency separation. The inner-well signal
interference can be eliminated easily.
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D9A1000051-MAN-001
Page 11 of 14
Configuration 2: EM Transmitters set to a data transmission rate of 2 Baud to

provide faster date updates.
In this configuration the EM Transmitters are set at base band frequencies that are 2Hz apart in a range
from 4Hz to 10Hz, and all are set at transmission data rates of 2 Baud. Notice there will still be minimal
inner-well interference at the 2 baud data rate.
3 4/2 6/2 8/2 10/2
Figure 2-4. The Spectral Distribution for Group 3 Settings
Configuration 3: Configuring the EM Transmitter at different base band frequen-

cies and at different data rates.
4 3/1 4.5/1.5 6/1 7.5/1.5 9/1 10/5/1.5 suggested
This configuration provides good frequency separation and fast data rates. It is recommended to set the
EM Transmitters operating at 3Hz and 4.5Hz a far apart as physically possible to minimize inner-well
interference.
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D9A1000051-MAN-001
Revision E
Page 12 of 14
EM Receiver Antenna Placement to Minimize Inter-Well

Interference
When drilling wells in a grid pattern, taking advantage of the BlackStar's EM Surface Receiver's differential
characteristics by symmetrical placement of the Receiver's antenna can greatly reduce the signal
interference caused by mutual induction.
In the following sketch well A and C contain EM Transmitters and the objective is to position the well A's
Receiver's antenna to minimize the interference caused by the EM Transmitter located in well C.
Assuming that the signal generated from an EM Transmitter positioned in a well is symmetric around its
drill pipe, and well A is the well of interest, then wells B, C, and D can be considered as sources of
interference or noise. Due to the symmetry, the C well generates an equal waveform on A well-head and
the location Ag1, which could be any point on the circle A-Ag1. Therefore, by using the A well-head as the
primary antenna and Ag1 as reference antenna, the BlackStar EM Receiver will automatically cancel some
interference from C well.
This same analogy applies to receiving the signals from EM Transmitters located in wells B and D, or any
situation where symmetrical placement of the EM Receivers Antenna can be utilized.
Figure 2-5. The Reference Antenna Setting for the Interference Cancellation
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Revision E
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Power Loss Due to Improper Tool Spacing
Figure 2-6. Power Loss Due to Improper Tool Spacing
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D9A1000051-MAN-001
Page 14 of 14
Figure 2-7. Power into Formation vs. ARC over Loss
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D9A1000051-MAN-001
Revision E
Page 15 of 24
Tool String Components
Directional Only
Figure 3-1. Directional Only Tool Layout
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D9A1000051-MAN-001
Revision E
Page 16 of 24
Tool String Components 3
Required Tubulars
 Oriented Pressure Sub.
 Instrument Collar.
 Gap Sub.
 Battery Collar.
 Battery Collar (optional if running a dual-battery).
Note
When running the dual battery configuration, a second

instrument collar can be used instead of two battery
collars.
Required MWD Components
Table 3-1. Directional Only MWD Required Parts and Part Numbers
Item Description Part Numbers

1. Stinger 301-447-08
2. X-Over, Spacer Bar to Stinger 303-437-01
3. Spacer Bar(s)/Spacer Bar Extension 303-383-02/303-339-10
4. X-Over, Sensor to Spacer Bar 303-382-02
5. Directional Probe 301-284-04
6. Transmitter 301-282-14
NOTE: For Triple-Output Transmitter (TOT) use the

part number 301-282-16/17.
7. Battery Bulkhead 301-605-03
8. Battery Housing 301-137-03
9. Battery-to-Battery Centralizer 301-293-19
11. Battery Housing 301-137-03
12. Top Contact 301-324-14
Note
Components 9-11 are optional and are used for the Dual-
Battery Configuration.
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D9A1000051-MAN-001
3 Tool String Components Revision E
Page 17 of 24
360/Gamma/Focus Gamma
Figure 3-2. 360 Gamma/Focus Gamma Tool Layout
Required Tubulars

 Gap Sub.
 Battery Collar.
 Battery Collar (optional if running the dual-battery).
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D9A1000051-MAN-001
Page 18 of 24
Note

collars.
Required MWD Parts
Table 3-2. 360 Gamma/Focus Gamma Required Parts and Part Numbers
Listings

1. Stinger 301-447-08
2. Adjustable Orienting Subr 301-471-01
3. AP Spacer Bar to Stinger 301-333-01
4. 360 Gamma/Focus Gamma 301-286-09
6. 28V Gamma Battery 301-140-05
7. Gamma Battery Housing 301-118-02
11. 14V Transmitter Battery 301-137-03
12. Transmitter Battery Housing 301-137-03
17. Top Contact 301-324-14
Note
Items 12-17 are optionally used for the dual-battery

configuration. Item 2 is required to run the Focus Gamma.
Item 3 is optional and can be used with Focus and 360
Gamma. The Gamma AP Spacer is used for the TX Gap-
to-Collar Gap Spacing.
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D9A1000051-MAN-001
Page 19 of 24
Dynamic Rotational Gamma (DRG)
Figure 3-3. DRG Tool Layout
Required Tubulars

 Spacer Sub.
 Gap Sub Dual-Battery.
 Battery Collar.
 Battery Collar (optional if running the dual-battery).
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D9A1000051-MAN-001
Page 20 of 24
Note

collars.
Required MWD Parts and Part Numbers
Table 3-3. DRG Required Parts and Part Numbers

1. Stinger 301-447-08
2. Adjustable Orienting Sub 301-471-01
3. AP Spacer Bar to Stinger 301-333-01
4. DRG 301-286-08
6. 28V Gamma Battery 301-140-05
7. DRG Battery Housing 301-118-04
17. Top Contact 301-324-14
Note
Items 10-12 are optionally used for the dual-battery

configuration. Item 2 is required to run the DRG Gamma.
The Gamma AP Spacer is used for the Transmitter Gap-to-
Collar Gap Spacing.
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D9A1000051-MAN-001
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Surface Components
BlackStar Dual-Channel Amplifier (DCA) Configuration
Table 3-4. Components and Part Numbers
Programming Cable Communication Plug BlackStar EM DCA

P/N 361-124-01 P/N 371-146-04 P/N 351-100-06
Computer USB Cable Power Cords

P/N 115175 P/N 115256 P/N 10329
EM Test Cable Ground Wire UPS Power Supply

P/N 361-112-01 P/N not listed P/N 11475
2x Antenna Cables Rig Floor Display Cable Rig Floor Display (RFD)
P/N 361-140-03 P/N 361-134-01 P/N 341-100-01
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Table 3-4. Components and Part Numbers
Copper Grounding Rod Copper Grounding Clamp C-Clamp

P/N 12337 P/N 12358 P/N 12724
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D9A1000051-MAN-001
Revision E
Page 23 of 24
Tool String Components 3
BlackStar Single-Channel Amplifier (SCA) Configuration
Table 3-5. Parts & Components
Programming Box Programming Cable Communication Plug

P/N 361-120-03 P/N 371-146-04 P/N 371-146-04
Single Channel Amplifier Computer Power Cords

P/N 351-100-04 P/N 115175 P/N 10329
EM Test Cable Ground Wire UPS Power Supply

P/N 361-112-01 P/N not listed P/N 11475
Cross-wired Network Cable DB 9 M/F RS 232 Cable 2x Antenna Cables

P/N 114285 P/N 11343 P/N 361-140-03
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D9A1000051-MAN-001
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Table 3-5. Parts & Components
Rig Floor Display Cable Rig Floor Display (RFD) Copper Grounding Rod
P/N 361-134-01 P/N 341-100-01 P/N 12337
Copper Grounding Clamp C-Clamp

P/N 12358 P/N 12724
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D9A1000048-MAN-001
Revision E
Page 15 of 22
EM MWD Tool Assembly
Directional Only
Connecting the Transmitter to Directional Probe
To connect the Transmitter to the Directional Probe, complete the following steps:
1. Place the transmitter and the directional sensor on the jack stands.
2. Connect the bottom-end of the transmitter (male) to the top-end of the directional sensor (female).
3. Use a marker or paint pen to mark two corresponding half-moon keys on the outside of each end of
the directional sensor and transmitter.
4. Align the marks as you engage them.
5. Attach a backup parmelee wrench on the directional probe. Using a spanner wrench, tighten the
threads until the top o-ring on the transmitter is at the edge of the directional probe's box connection.
You should feel it getting tight.
6. Wiggle the transmitter left and right. The operator should be able to feel it click into place.
Caution
!
If the the connection can not be felt, clicking into place,
stop tightening the connection and check the alignment
marks to ensure that they are properly aligned and then
retry tightening the connections.
7. Finish tightening the threaded ring.
Caution
!
Do not force this connection. It is normal to see a gap
(approximately 1/8” wide) between the Directional Sensor
hose string and the transmitter threaded ring.
8. Torque at specifications with a heavy duty spanner wrench.

9. Install the appropriate lower contact bow springs for the required size (3-¾, 4-¾, 6-½, or 8).
10. Assemble directional probe to spacer bars and torque the cross-over to the bottom of the directional
probe.
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EM MWD Tool Assembly 4
11. Torque the cross-over to the spacer bar and add the additional spacer bars for proper tool spacing
(transmitter gap to collar gap).
12. Torque spacer bar to the cross-over and then torque the stinger to the cross-over.
13. Highside the stinger when you have verified that all the connection torques are accurate and
complete. The tool can now be programmed.
Note
For detailed information on programming the tool, refer to

Chapter 6, Tool String Testing in this manual.
14. Insert the transmitter battery into the transmitter battery housing component and then torque the
battery bulkhead to the battery housing component.
15. Attach and torque the bottom battery to the transmitter.
Connecting the Transmitter Battery Bulkhead
1. Lube the o-rings on the transmitter and battery bulkhead with Dow 111 lubricator.
Figure 4-1. Transmitter Battery Bulkhead O-rings
2. Connect the male-end of the battery bulkhead with the battery using a 3/16” allen wrench and
a ¼ - 20” socket-head screw. Use blue Loctite 242 on the socket head screw.
Figure 4-2. Connecting the Male-End of the Battery Bulkhead with the Battery
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3. Using Kapton or electrical tape, wrap the area where the battery bulkhead meets the battery,
ensuring to cover the socket head screw.
Figure 4-3. Wrapped Socket Head Screw using Kapton Tape
4. Screw the transmitter battery housing onto the bulkhead.
Figure 4-4. Connecting Battery Housing to Bulkhead
5. Align the keyway on the male-end of the transmitter with the female-end of the battery bulkhead and
screw them together until fully engaged.
6. Torque at the transmitter top-end and the female-end of the bulkhead.
Warning
Do not torque below the transmitter gap.
7. Torque the battery bulkhead to the transmitter battery housing according to

specifications.
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Assembling the Second Transmitter Battery and

Battery Bulkhead
To assemble the second transmitter battery and battery bulkhead, complete the following steps:
1. Connect the male-end of the battery bulkhead with the battery using a 3/16” allen wrench and a ¼ -
20” socket-head screw. Use blue Loctite 242 on the socket-head screw.
2. Using Kapton or electrical tape, wrap where the battery bulkhead meets the battery, ensuring to
cover the socket-head screw.
3. Screw the transmitter battery housing onto the bulkhead.
4. Align the keyway on the battery bulkhead with the keyway on the battery-to-battery
centralizer.
5. Using a multimeter, set to Volts Direct Current (VDC).
a. Place one lead on the silver exterior of the lemo connector.
b. Place the other lead on the gold interior of the lemo connector. A reading of 13 -
14VDC should display on the multimeter.
6. Screw the bottom-end of the assembly (the lemo-end) into the top of the bottom
battery (battery connected to the transmitter).
7. Install the top contact into the top of the top battery (second battery).
360 Gamma/Focus Gamma

Follow the steps in the section titled "Assembling the Directional Probe to the Gamma Battery
Housing" on page 4-19 for following assembly instructions to assemble the 360 Gamma/Focus
Gamma. The following procedures are included:
 section titled "Assembling the Directional Probe to the Gamma Battery Housing" on
page 4-19.
 section titled "Connecting the Transmitter Battery Bulkhead" on page 4-16.
 section titled "Assembling the Second Transmitter Battery and Battery Bulkhead" on
page 4-18.
Note
The adjustable orienting sub is not necessary for the 360

gamma.
Note
When running the Focus Gamma, use the adjustable

orienting sub to line up the key way of the stinger with the
“X” on the PTG/Gamma.
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Assembling the Gamma Battery Housing
To assemble the Gamma Battery Housing, complete the following steps:

1. Attach gamma battery to battery bulkhead.
2. Insert gamma battery in to the gamma battery housing component.
Note
Ensure that the gamma battery is screwed into the short

threaded end of the gamma battery housing.
3. Torque the battery bulkhead to the battery housing component.

4. Attach and torque the battery housing component to the top of the PTG/Gamma module.
Assembling the Directional Probe to the Gamma

Battery Housing
To assemble the Directional Probe to the Gamma Battery Housing component, complete the
following steps:
1. Torque the bottom of the directional sensor to the gamma battery housing.
2. Check the annular pressure.
Note
Check the annular pressure before highsiding the tool.
3. Program the tool. Refer to Chapter 6, Tool String Testing in this manual for
detailed information on programming the tool.
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Follow the steps in the Directional Only section and 360 Gamma/Focus Gamma for the following
sections for assembly instructions:
 section titled "Connecting the Transmitter to Directional Probe" on page 4-15.
 section titled "Connecting the Transmitter Battery Bulkhead" on page 4-16.
 section titled "Assembling the Second Transmitter Battery and Battery Bulkhead" on
page 4-18.
 section titled "Assembling the Gamma Battery Housing" on page 4-19.
 section titled "Assembling the Directional Probe to the Gamma Battery Housing" on
page 4-19.
Assembling the DRG
1. Grease the stinger, AP spacer, and the adjustable orienting sub (annular pressure
lower sub assembly) with the grease fitting tool (P/N # 371-110-01). For detailed
information on greasing the annular pressure sub-assembly, refer to Chapter 7,
“Field Maintenance,” Greasing the Annular Pressure Lower Assembly, in this
manual.
Caution
!
Only torque the annular pressure sub-assembly to the
bottom of the PTG/Gamma after testing the Annular
Pressure in EMXConfig.
2. Torque the stinger to the AP spacer bars and the adjustable orienting sub.
Note
When running the DRG, use the adjustable orienting sub

to line up the key way of the stinger with the notch on the
DRG.
3. Torque the adjustable orienting sub assembly to the bottom of the DRG.
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Warning
Torque the stinger connections AFTER the assembly

is attached to the tool. Trying to torque/untorque these
connections before they are attached to the tool may
result in injury to personnel.
Assembling DRG Battery Housing
To assemble the DRG Battery Housing, complete the following steps:

1. Attach the DRG battery bulkhead.
2. Insert the DRG battery into the DRG battery housing.
Note
Ensure that the gamma battery is screwed into the short

threaded end of the gamma battery housing.
3. Attach and torque to the top of the DRG module.

4. Torque the battery bulkhead to the battery housing.
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Rig Up
DCA Configuration
Figure 5-1. DCA Connection Diagram
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Connecting the Dual-Channel Amplifier
Connect the DCA and the computer with the provided USB A-B cable. Refer to Figure 5-1. Power on the
computer. If Found New Hardware Wizard is prompted, follow the steps for Installing NOV BlackStar
Device Driver.
Note
Read all the steps carefully before connecting the DCA to

the computer. The order of the steps might vary depending
on the USB port enumeration sequence on the host
computer.
Installing NOV BlackStar Device Drivers
Install the BlackStar USB Composite Device Driver
1. If the following dialog window opens, select the Install the software automatically
(Recommended) option and click Next.
Figure 5-2. NOV BlackStar Device Drivers Installation Wizard
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The wizard displays the following dialog window as it searches for the NOV BlackStar USB Composite
Device.
Figure 5-3. NOV BlackStar Installation Wizard Searching for Device Drivers
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2. Wait for the Install Wizard to search for the NOV BlackStar USB Composite Device. When the
search process is complete, the following dialog window opens:
Figure 5-4. Continue or STOP Installation Option Screen
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3. Click Continue Anyway. The installation wizard has finished installing the software for the NOV
BlackStar USB Composite Device. The following dialog window opens:
Figure 5-5. Installation Wizard Completes NOV BlackStar Device Drivers
4. Click Finish. Repeat steps 1 through 3 four times for installing NOV BlackStar USB Composite
Device. Next, the user is prompted to install the NOV BlackStar USB to UART Bridge Controller.
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Install the USB to UART Bridge Controller Device Driver

When the Installation Wizard displays to install the NOV BlackStar USB to UART Bridge Controller
device driver, complete the following steps:
1. Select the Install the software automatically (Recommended) option.
Figure 5-6. NOV BlackStar Device Drivers Installation Wizard
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The install wizard begins searching for the BlackStar USB to UART Bridge Controller device
driver.
Figure 5-7. NOV BlackStar USB to UART Bridge Installation Wizard
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When the search process is complete, the following dialog window opens, indicating that it has found
the NOV BlackStar USB to UART Bridge Controller device driver.
Figure 5-8. Continue or STOP Installation Process Option Screen
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2. Click Continue Anyway. The hardware installation wizard completes the installation process for the
NOV BlackStar USB to UART Bridge Controller device driver.
Figure 5-9. Finish Installing USB to UART Bridge Controller Device Driver
3. Click Finish to close the wizard. Repeat Step 1 through 3, four times to complete installing the NOV
BlackStar USB to UART Bridge process.
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Install the DT9840 Controller Device Driver

When the Installation Wizard displays to install software for the DT9840 Controller, complete the following
steps:
Figure 5-10. Install DT9840 Device Drivers
1. Select the Install the software automatically (Recommended) option. The Welcome to the
Found New Hardware Wizard dialog window opens.
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2. Click Next to continue installing the DT9840 device driver. The wizard searches for the DT9840
device driver.
Figure 5-11. NOV BlackStar Installation Wizard Searching for Device Drivers
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When the search process is complete, the following dialog window opens, indicating that it has found
the DT9840 device driver.
Figure 5-12. Continue or STOP Installation Process Option Screen
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3. Click Continue Anyway. The installation completes installing the DT9840 device driver.
Figure 5-13. Finish Installing the DT9840 Device Driver
4. Click Finish to close the wizard.

5. Repeat steps 1 through 4 two times (once for each port) for the DT9840 installation process.
After installing all device drivers successfully, ensure that the DTX driver and COM Ports are functioning
properly. The BlackStar DCA Status can be located by hovering over the icon
( ) located in the system tray of your computer (normally located in the bottom-right corner next to the
computer time display.
Congratulations! All DCA drivers have been successfully installed and configured. Proceed to
connecting the DCA to the BlackStar EM Tool test equipment.
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DCA Components
Table 5-1.
Item Description Part Number
1. Programming Cable 361-124-01
2. Communication Plug (Dongle) 371-146-04
3. DCA 351-100-06
4. Computer 115175
5. USB Cable 115256
6. Power Cords 10329
7. EM Test Cable 361-112-01
8. Ground Wire (14 gauge) Not Listed
9. UPS Power Supply 11475
10. RFD Fuse 1 AMP 250V 115246
11. AMP Fuse 3 AMP 250V 115297
Figure 5-14. DCA Components
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Connecting DCA Components
1. Connect the USB Cable from the Computer to the BlackStar DCA Computer Port.
Figure 5-15. DCA Connected to Computer
2. Connect the programming cable from the BlackStar DCA to the communication plug.
Figure 5-16. Program Cable Connected to Communication Plug
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Note
Do not connect the communication plug to the transmitter

at this time.
3. Connect the EM Test cable to the BlackStar DCA: Plug the red end of the cable into the Well Head
connection (line). Plug the black end of the cable into the Reference connection (line) (Figure 5-17).
Figure 5-17. Connect Test Cables to DCA
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Connect the clamps of the EM Test Cable to the BlackStar Transmitter. Attach the red end of the cable to
the housing above Transmitter Gap and attach the black end of the cable to the housing below the
ransmitter Gap.
Figure 5-18. EM Test Cables Connected to the Transmitter
4. Before connecting the communication plug to the BlackStar transmitter, ensure that the tool power is
turned OFF.
5. Connect the communication plug to the BlackStar transmitter.
Figure 5-19. Communication Plug Connected to the Transmitter
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Note
Avoid any metal contact between the transmitter gap and

the jack stands, which may short the transmitter gap.
Powering Up the DCA
Perform the following test before turning on the power to the equipment:
 AC Power Ground Fault Test
 Check the power outlets in the operator shack
 Rig to Shack Ground Fault Test
 Ground the DCA
1. Connect all power cords, either directly to UPS (as illustrated below) or to a power strip that is
plugged into the UPS.
Figure 5-20. Connect Power Cords to UPS
2. Turn on the UPS.

3. Turn on the computer.
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4. Power on the BlackStar DCA.
Figure 5-21. Power Button
Note
Ensure that the power to the BlackStar EM Tool is OFF at

this time.
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Troubleshooting the DCA
If you experience difficulties running BlackStarEMVue or EMXConfig, check for any of the following
problems and solutions:
Table 5-2. Troubleshooting the DCA
Trouble Solution
Amplifier is not on • Check the amplifier power button to ensure that it is on and ensure that the red
LED is on.
• Check AMP Fuse.
USB cable that connects Change cable.

the amplifier is broken or
the connection end is worn
out.
The BlackStar DCA The DT9840 driver or the NOV USB - UART driver may not be installed or may be
Status on the system tray improperly installed. Wait a few minutes to see if the BlackStar DCA status
displays either DAQ not changes to DAQ OK or COM Ports OK. If problems still exist, open the Device
available” or COM Ports Manager and perform the following steps:
not available.
NOTE: Log on as an administrator to perform the following steps:
1. Open the Device Manager by clicking Start>Control Panel>System and
Maintenance>Device Manager. If prompted to enter an administrator
password or confirmation, enter that at this time or click OK to confirm the
existing entry.
2. Double-click Data Translation DSP Devices and Ports (COM & LPT). If
devices (i.e., as circled in the screen shot below) are not visible, the device
driver for the DCA is not loaded.
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Trouble Solution
Notice the four entries of NOV BlackStar USB Composite Devices.
3. Double-click Universal Serial Bus Controllers and check to see that all USB
ports, hubs, and controllers are functioning properly. Any malfunctioning devices
will have a yellow exclamation mark in front of them.
4. Select the computer icon.
5. Click the Action menu and then click Scan for hardware changes. The
user will be prompted to install the device driver. Follow the procedure for
installing the BlackStar DCA drivers.
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Trouble Solution
The following message BlackStar DCA requires the user to connect to a USB port which is USB 2.0 to
displays: A hi-speed USB work properly. Use a computer that supports USB 2.0.
device is plugged into
non-hi-speed USB hub.
USB 2.0 Ports aren't If the high-speed USB 2.0 ports doesn't work, the ports may be defective. Correct
working the drivers installed for the ports in the host computer. Check the Device Manager
in Control Panel to determine if the USB ports or hubs are functioning properly.
Complete the following steps:
existing entry.
2. Double-click Universal Serial Bus Controllers and check to ensure that
USB ports, hubs, and controllers are functioning properly. Any malfunctioning
devices will have a yellow exclamation mark in front of them.
How can I tell if the host BlackStar DCA requires a connection to the host computer using a USB 2.0 port.
computer has USB 2.0 USB 2.0 is faster than previous versions, which makes large volume file transfers
capability? possible. To determine if the host computer has a USB 2.0 port, complete the
following steps.
NOTE: Log on as an administrator to perform the following steps:
existing entry.
2. Double-click Universal Serial Bus Controllers.
3. If the word Enhanced is included in any of the listed controllers, the host
your computer has USB 2.0 controller drivers installed.
RFD does not power up. Check RFD Fuse
No power to tool when • Check RFD Fuse.

configuring the tool. • Check AMP Fuse.
Gain is over 12dB or signal Ohm out the test cable. Clean the transmitter pressure housing where the test
is not good. cable paddles are connected.
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SCA Configuration
Figure 5-22. SCA Connection Diagram
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Table 5-3.
Item Description Part Number
1. Programming Box 301-120-03
2. Programming Cable 361-124-01
3. Communication Plug 371-146-04
4. SCA 351-100-04
5. Computer 115175
6. DB9 M/F RS 232 Cable 11343
7. Cross Wired Network Cable 114285
8. Power Cords 10329
9. EM Test Cable 361-112-01
10. Ground Wire (14 gauge) Not Listed
11. UPS Power Supply 11475
Figure 5-23. BlackStar SCA Rig Up Connections
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Connecting the SCA
1. Connect the cross-wired network cable from the computer to the BlackStar SCA Computer port.
Figure 5-24. Connect SCA to Computer
2. Connect the DB9 cable from the programming box to the COM port of the computer.
Figure 5-25. DB9 Cable Connected to the Computer
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3. Connect the programming cable from the programming box to the communication plug.
Figure 5-26. Programming Plug Connected to Programming Cable
Note
Do not connect the communication plug to the BlackStar

Transmitter at this time.
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4. Connect the EM test cable to the BlackStar SCA. On the back of the SCA, plug the end of the red
cable into the WELL HEAD connection (line). Plug the end of the black cable into the REFERENCE
connection (line).
Figure 5-27. Testing Cables Connected to the SCA
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5. Connect the clamps of the EM test cable to the BlackStar transmitter and attach the red end of the
cable to the housing above transmitter gap. Attach the black end of the cable to the housing the
transmitter gap as illustrated below.
Figure 5-28. EM Testing Cable Connected to the Transmitter
6. Before connecting the communication plug to the BlackStar Transmitter, ensure that the
programming box is turned OFF.
7. Connect the communication plug to the transmitter.
Figure 5-29. Communication Plug Connected to the Transmitter
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Note
Avoid any metal contact between the transmitter gap and

the jack stands, which may short the transmitter gap.
8. Perform the following tests before connecting any power or cabling to the equipment.
 AC Power Ground Fault Test.
 Check the power outlets in the Operator Shack.
 Rig to Shack Ground Fault Test.
 Ground the SCA.
9. Connect all power cords directly to the UPS. If additional power outlets are required, use a power
strip to access additional power sources to the UPS.
Figure 5-30. Power Cord Connections
10. Turn on the UPS.

11. Turn on the computer.
12. Turn on the BlackStar SCA.
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Troubleshooting the SCA
If establishing communication between the transmitter and the SCA is unsuccessful, consider the
following:
1. If the computer is not configured to communicate with the SCA, refer to the section titled
"Configuring the Laptop Computer for the SCA" on page 5-55 topic.
2. Check the SCA fuse.
3. Ping the SCA to check if there is communication between computer and SCA. Refer to section
titled "How to Ping the Amplifier" on page 5-52 topic.
4. Change the ethernet cable and ensure that it is a cross-wired cable.
5. Listen to hear a beep when turning on the amplifier. If the beep can not be heard, there is a problem
with the SCA. Turn the SCA off and unplug the power cord.
 Pull the cover off and check to ensure that all the boards and connections are properly secured.
 Plug the power cord back into the SCA and then turn the power back on. If the beep is still not
heard, send the BlackStar Surface Amplifier back to National Oilwell Varco for further evaluation
and repairs.
How to Ping the Amplifier
To ping the amplifier, complete the following steps:

1. Click Start in the Windows task bar and then click Run.
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The Run dialog window opens.
Figure 5-31. Run cmd.exe Command Dialog Window
2. Type cmd.exe and click OK. The command execute dialog window opens.
3. At the command prompt, enter ping 192.168.1.XXX (i.e., refer to the previous screenshot ping
192.168.1.141).
Figure 5-32. Enter Ping Command
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If the BlackStar SCA is communicating with the EM Control Panel, the following screen displays:
Figure 5-33. BlackStar SCA Communication Confirmation
If the following message displays after pinging the SCA, communication between the computer and
the SCA has not been established.
Figure 5-34. SCA Failed Communication Dialog Window
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Configuring the Laptop Computer for the SCA
Windows XP
1. Click Start>Control Panel, and then double-click Network Connections.

2. Double-click Local Area Connection.
3. Click the Properties button on the General tab.
4. On the General tab, under This connection uses the following items, select Internet Protocol (TCP/
IP), and then click Properties.
5. Click Use the following IP address, and in the IP address field, type the IP address.
6. In the Subnet Mask field, type 255.255.255.0
7. Click OK.
8. Click OK again on Local Area Connection Properties.
Windows 2000
1. Click Start>Settings>Control Panel.
2. Double-click the Network and Dialup Connections icon.
3. Double-click Local Area Connection.
4. On the General tab, under Components checked are used by this connection, select Internet
Protocol (TCP/IP), and then click Properties.
5. Click Use the following IP address, and in the IP address field, type the IP address.
Note
For example, if the Surface Amplifier serial number is

192.168.1.47 type 192.168.1.165 (The last number must
be less then 250 and different from the IP Address of the
amplifier that will be running.
6. In the Subnet Mask field, type 255.255.255.0

7. Click OK.
8. Click OK again on Local Area Connection Properties.
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Setting Windows 7 Static IP Address

To set or change the computer’s Static IP address in Windows 7, complete the following steps:
1. Type Network and Sharing in the search box in Windows Start Menu and select Network and
Sharing Center from the menu list.
Figure 5-35. Network Sharing Menu
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The Network and Sharing Center opens (Figure 5-36).
Figure 5-36. Change Adapter Settings Option
2. Right-click on Local Area Connection.
Figure 5-37. Select Local Area Connection Properties Dialog Window
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The Internet Protocol Version 4 (TCP/IPv4) Properties dialog window opens

(Figure 5-38).
Figure 5-38. Set IP Address Properties Dialog Window
3. Click on the Use the following IP address radio button.

4. Enter your IP address in the IP Address field.
5. In the Subnet Mask field, enter 255.255.255.0. It is not necessary to enter values in the Default
Gateway, Preferred and Alternate DNS Server fields.
6. Click OK.
7. Close and exit out of the Local Area Connection Properties to allow the settings to become
effective.
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Tool String Testing
Configuring and Testing the BlackStar EM

Tool with DCA
BlackStarEMVue
1. Click the BlackStarEMVue icon ( ) on your desktop. The user will be prompted to select
the correct Job and Track that data will be logged to from the available tracks field.
Figure 6-1. Select Track Dialog Window
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2. Select the Job and Track to log and click OK. If the Down-link is enabled, the user will be prompted
to select an active frequency and baud rate.
Figure 6-2. BlackStarEMVue Main Dialog Window
Selecting Frequency
To analyze the noise, have the rig turn on all equipment possible such as pumps, top drives, mud pumps,
rotary table, nitrogen generators, air compressors, air-conditioners and the like to simulate normal drilling
conditions to find the best frequency to configure the tool. A good time to run the frequency analyzer is
when the rig is drilling the surface hole.
Note
Antenna Cables, (BOP, Reference) and Ground wire must

be ran out and properly connected. Refer to Chapter 5,
RIG UP in this manual.
1. Verify that antenna cables are properly connected and the DCA is grounded.
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Tool String Testing 6
2. From BlackStarEMVue main dialog window, click Receiver in the application menu bar and then
click Frequency Analyzer.
Figure 6-3. Open Frequency Analyzer
The Frequency Analyzer window opens.
Figure 6-4. Frequency Analyzer Dialog Window
3. Select Channel 1 or Channel 2 or both. Ensure that the transmitter power is OFF.
4. Click Start. Allow the program to run and note the best frequency and baud rates. The program
always recommends the best frequency and baud rates for the local noise condition. Higher
frequencies are more susceptible to noise at greater depths.
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Note
Wait 10 to 15 minutes to allow the receiver adequate time

to analyze the signal. The frequency analyzer displays the
results.
5. To view the noise using spectrum view, from the BlackStarEMVue main dialog window, select the
Spectrum option in the View Selection field.
Figure 6-5. Select Channel Option
6. Click the drop-down arrow in the Spectrum Settings field to expand the drop-down list and then
select Average Linear.
Figure 6-6. Select Spectrum Option
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7. Right-click in the Spectrum display to set the frequency range to 0-10Hz.
Figure 6-7. Frequency Range Options
In the example below, most of the noise is in the 0-3 Hz range. If this were the actual noise present, avoid
these frequencies.
Figure 6-8. Frequency Noise Range
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8. Click Stop to end frequency analyzer.
Note
Make a note of the suggested frequencies and baud rates.
Figure 6-9. Frequency Range Options
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Configuring the Tool with DCA
Figure 6-10. Voltage Reader
Note
The BlackStar DCA is a 14-Volt System when connected to

the transmitter, but is a 28-Volt System when connected to
the PTG/DRG.
Note
Before connecting any cables to the DCA, ensure that the

TOOL POWER switch is turned Off.
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Connecting the DCA to the Computer
The USB Cable runs from the BlackStar DCA COMPUTER Port to the host computer’s USB Port.
Figure 6-11. DCA to Computer Connection
The programming cable runs from the BlackStar DCA TOOL Port to the Communication Plug. The
communication plug connects to the top of the BlackStar transmitter as shown below:
Figure 6-12. Communication Plug Connected to Transmitter
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1. Turn the DCA Power on.

2. Turn the TOOL POWER on.
Checking the BlackStar DCA Meter
Meter readings are described below:

 First tick = 0mA
 Second tick = 200mA
 Third tick = 300mA
 Fourth tick = 400mA
 Fifth tick = 500mA
When the transmitter is off (console mode), the needle should sit on or around the first tick. When the
transmitter is on (main), the needle should sit between the second and third tick.
Note
When first powering up the BlackStar EM Tool, closely

monitor the dial of the BlackStar DCA. The needle should
sit between the second and third tick and show a little jump
as the tool transmits.
If the needle sits at or over the fifth tick, turn the TOOL POWER OFF. There could be a problem with the
tool. The tool may be drawing excessive currents.
Check each of the following components before changing the transmitter.
 Programming Cable
 Communications Plug
 BlackStar DCA
If it becomes necessary to change any of the above mentioned components, recycle power to the
transmitter and observe the dial again.
If running a PTG/DRG setup, unplug and reseat the Gamma Battery. This usually solves the problem. If no
problems exist with the items listed above and the needle still reads over the fifth tick, the transmitter could
be malfunctioning.
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Starting BlackStar EMXConfig
Start the BlackStar EMXConfig and complete the following steps:
1. From your desktop, double-click the BlackStar EMXConfiguration icon ( ). The

EMXConfig startup window displays.
Note
Ensure that the DCA is up and running before running the

BlackStar EMXConfig application.
Figure 6-13. BlackStar EMXConfig Main Dialog Window
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If the tool power is already on, wait for the tool’s response. The software should start communicating
with the tool and should download the tool settings.
2. When the download is complete, select the Frequency and Baud rates (i.e., the following):
Figure 6-14. Frequency and Baud Rates
Note
For the MWD application, it is recommended the

Frequency is set no greater than 7Hz.
Note
Record the transmitter serial number. Remember the tool

serial number to attach to a track in EMDataMgr.
Transmitter Configuration
Transmitter Power Output
Select the power setting located below the Frequency drop-down list. Setting are:
 5W for low power
 10W for high power
Figure 6-15. Transmitter Configurations Dialog Window
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The active battery will either read bottom or top if you are running the dual-battery configuration.
Table 6-1. Delay to Switch to 10 Watts
Parameter Description
Delay to switch to 10 Displays the number of hours before switching to 10 Watts. If the value is 0, the tool
watts will operate in 5 watts. The timer starts as soon as the user clicks Done. Even if the
tool is disconnected from the power source, as soon as the tool is powered, if time
intervals have elapsed, the tool switches to 10 watts.
Table 6-2. Transmission System
Parity Correction The parity correction is supported by all tools and is very reliable. Error detection
ability has a faster data rate.
Hamming Coding The hamming coding has a slower data rate, but has the error detection ability.
Table 6-3. Modulation Type
Modulation Type BPSK is the default; however, use QPSK if it is available.
For optimum signal reception, the carrier Frequency (F) and the Baud Rate (BR)
should meet the following requirements:
 F/BR>=3 (for BPSK)
NOTE: It is not possible to select the wrong frequency.
 2*F/BR>=4 (for QPSK)
Table 6-4. Frame Switching
Frame Switching Frame Switching means that the operating type will be in a Timed or Vibration mode.
In the vibration mode, the tool switches between “Survey” and “Steering,” depending on the vibration level.
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Table 6-5. Vibration Mode
Surveys before power- Surveys before power-down represents the number of survey frames that are
down transmitted before the tool goes into the sleep mode. A valid range is 0 through 99. A
value of 99 keeps the tool from entering the sleep mode and continues to send survey
frames until the vibration limit is met.
Check Vibration every The Check Vibration Every Minute mode represents the time that the tool is in the
minute sleep mode before waking to take samples to determine if it should wake up and start
transmitting. The default setting is 1.
Vibration Time This parameter determines the amount of dampening applied by the vibration filter.
Constant The larger the value, the heaver the dampening applied. The range of valid values is
from 1.0 to 10.0, with a value of 1.0 effectively turning off the filter.
Vibration Limit (G) The Vibration Limit parameter determines the vibration limit in G for switching
between survey and steering. A valid range is 0.5 or less.
Vibration Hysteresis Vibration Hysteresis determines the vibration limit hysteresis levels. A valid range is
0.5 or less.
Vibration Tare The Vibration Tare displays the current vibration tare value. Click Read to calculate a
new vibration tare value.
Down-Link
Figure 6-16. Down-Link Option Dialog Window
To configure the tool for Down-Link, the Operating Type mode must be set to vibration within the frame
switching box.
When Down-Link is enabled, the configuration program enables the Frequency B selection and Baud
Rate stages 2, 3, and 4. The operator can then select two frequency selections for Frequency A and B. In
addition, the operator can select four baud rate selections for Baud Rate stages 1 though 4.
Initially, the transmitter can be turned off if Down-Link On & Initially Power Off is selected from the
Down-Link drop-down list. Selecting the Down-Link On Initial Power Off option require the operator to
turn on the transmitter using the Tool Power On Down-Link command.
When turning on the transmitter after tool configuration the setup will be Frequency A and the Baud Rate
Stage 1.
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Hysteresis
Hysteresis is used to filter vibration readings so that the output reacts slowly by taking recent history into
account. For example, a vibration limit controlling frame switching may switch to the Survey mode when the
vibration drops below A (in Gs), but will not switch back to Steering mode until the vibration rises above B
(in Gs.) Thus, frame switching on the transmitter when the vibration is between A and B depends on the
history of the vibration. This prevents rapid switching between Surveys and Steering when the vibration
drifts around the vibration limit.
Figure 6-17. Filtered Vibration Reading
Timed Mode
In the Timed mode, the tool switches between Survey and Steering after transmitting a specified number
of frames.
Figure 6-18. Frame Switching
Table 6-6. Timed Mode
Survey Count In the Time mode, the Survey Count represents the number of
survey operations before changing to steering mode.
Steering Count The tool's Steering Count is the count before changing to the
survey mode.
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Selecting Survey and Steering Frame Parameters

1. Double-click a Survey or Steering frame. The Edit Frame dialog window opens and displays the
currently selected frame.
Figure 6-19. Edit Frame Dialog Window
To add parameters, drag and drop an Available Word Parameter to the Frame Parameter column.
The following parameters are available:
 Incl = inclination
 Azm = azimuth
 Dip = magnetic dip
 Tf = tool face
 Temp = temperature
 Gtot = gravity totals
 Htot = magnetic totals
 TStat = tool status; displays top or bottom battery, current baud rate, current frequency,
down-link stage, TX battery voltage, Gamma battery voltage (will display 30V if string is
directional only)
 VSw = vibration switch; used mainly for in house testing
 PAnu = annular pressure; available with the gamma module only
 Gamma = gamma readings; available with the gamma module only
 Vtot = vibration total; displays vibration in Gs, available with gamma module only
 Mags = magnetic field, Hx Hy Hz
 Gravs = gravity field Gx Gy Gz
 HSGamma = highside gamma; DRG module only
 LSGamma = low-side gamma; DRG module only
 DHRpm = Down hole rpm; DRG module only
 NBInc = near bit inclination; DRG module only
To delete parameters in the frame, drag the desired parameter out of the window.
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In the selected parameter box, the time until the next word is received is displayed next to the parameter.
This is directly related to the baud rate. A faster baud rate increases the speed in which data is
transmitted.
2. Click OK when finished editing frames.
Note
Use Gtot in Steering Frame when running Directional Only

to monitor vibrations.
Monitor Transmitter A/D
Monitor Transmitter A/D can be used to check whether the directional sensor is working properly by
examining the Mag X, Mag Y, Mag Z, Acc X, Acc Y, and Acc Z values.
1. In the BlackStar EMXConfig main dialog window, click Transmitter from the top menu bar and then
select Monitor A/D. The Monitor Transmitter A/D dialog window opens.
Figure 6-20. Open Monitor A/D
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Figure 6-21. Run Monitor Transmitter A/D
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2. Click the Run button in the Monitor Transmitter A/D window. Let the tool sit for a minute until the
Mag X, Mag Y, Mag Z, Acc X, and Acc Y, and Acc Z values are stable.
Figure 6-22. Monitor Transmitter A/D Requested Data
3. When the values are stable, turn the tool a ¼-turn position and let the tool sit at this position for a
minute until the Mag and ACC values stop fluctuating.
Note
If the numbers continue to fluctuate without any movement

of the tool, there could be a problem with the directional
sensor.
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Vibration
Vibration is used to determine if the vibration sensor is working properly.
1. Run the Monitor Transmitter A/D and record the Vibration value.
2. Tap on the transmitter. An increase in the vibration value should be evident.
Figure 6-23. Vibration Value
The Vibration Switch is located 17 inches below the transmitter gap.
Gamma Configuration
1. If the Gamma Module is in use, from the PTG menu, select Setup in the EMXConfig main dialog
window. The PTG Setup dialog window opens.
Figure 6-24. PTG Setup Dialog Window
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2. The following information is displayed in the Tool Information field of the PTG Setup dialog window.
 Firmware Version
 PTG S/N
 Pressure Transducer S/N
Annulus Pressure
The Annulus Pressure information is used to test and calibrate the pressure transducer on the gamma
module.
Figure 6-25. Annulus Pressure Dialog Window
The Full Scale drop-down list is used to set the transducer resolution. Available ranges are from 1000 to
15000 psi.
Note
The lower the scaling, the higher the resolution. However,

resolutions will never read ranges higher than the selected
range.
The Offset (PSI) value is what the pressure transducer reads.
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Testing and Configuring the Pressure Transducer
To test and configure the Pressure Transducer, complete the following steps:
1. Select the desired full scale.
2. Click the Tare Pressure button.
3. Click the Read button next to the “Offset PSI. The window value should read
zero (0).
4. Connect the pressure plug and Enerpac pump to the bottom of the gamma.
5. Pump the pressure up to approximately 1500 PSI unless the range is set to 1000. In that case, use
500 psi.
6. Click the Read button. The offset should read approximately the same as the gauge on the pump.
7. Release the pressure from the pump by turning the knob on the pump counter-clockwise.
8. Disconnect the pump and the pressure plug from the gamma module.
9. Click Read again. The Offset should read 0 psi again. If this is the case, the testing is complete and
should resemble the window in Figure 6-26.
Figure 6-26. Annulus Pressure Reading
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Gamma Calibration
To calibrate the Gamma, complete the following steps:

1. Click the Run button next to the Gamma Count field. Allow the program to run until the gamma
counts are stable.
2. Click the Set button next to the Background Count field.
3. Locate the API factor on the gamma blanket and enter it into the Calibrator Scale field.
4. Wrap the gamma blanket around the gamma probe using the following criteria:
a. For the 360 or Focused Gamma, wrap blanket approximately five inches above the bottom pin-
wrench connection.
b. Wrap only one layer of the blanket around the pressure housing.
c. For the DRG, ensure that the milled slot is facing the sky.
5. Wait for the gamma counts to stabilize based on the following criteria:
 For directional gamma and DRG, the typical counts should be approximately 70 to 100 counts
per second (cps).
 For 360 gammas, the typical counts should be approximately 180 to 275 cps.
6. When the counts stabilize, click the Set button next to the Hot Count field.
This completes the Gamma Calibration and the results are reflected Figure 6-27 below.
Figure 6-27. Gamma API Calibration Dialog Window
7. Click the Stop button once the calibration is complete.
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Dynamic Rotational Gamma (DRG) Parameters
Default settings with the exception of window size which can be changed from 0-180 are recommended.
Input settings in the DRG dialog window.
Figure 6-28. DRG Dialog Window
Table 6-7. DRG Parameter Descriptions
Parameters Description
Window Size Determines where the DRG window samples gamma data. The default setting is 120
degrees.
Index Toolface Limit Determines the vibration limit in which the DRG resets its internal toolface to match
the directional sensor toolface.
Index Hysteresis A hysteresis controlling the Index Tool Limit may set the internal toolface when the
vibration drops below X1 G, but will not try to set it again until it rises above X2 G.
Thus, the set internal toolface between X1 and X2 depends on the history of the
vibration. This prevents repetitive settings of the internal toolface.
Index Tare The Index Tare set what the DRG Vibration Sensor reads as 0 G's. The tare value is
measured in mV. Click the Tare button to set the value.
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Gamma Collar Attenuation
In the Gamma Collar Attenuation field, select the size collar that will be used down hole. It should be one
of the following:
 3.75
 4.75
 6.50
 8.00
Refer to the following:
If the collar size is not in the list, select user and manually enter the collar factor.
1. Click the OK button in the PTG setup window. EMXConfig prompts the user to confirm the settings.
Figure 6-29. Tare Pressure Confirmation Dialog Window
a. Click Yes to perform the tare pressure and set the real-time-clock. Setting the
real-time clock sets the tool string time to match the time of the laptop.
b. Click No to skip this step.
c. Click Cancel to return to the setup dialog window.
Note
Ensure that there is no pressure before clicking Yes. In

addition, before this task begins, ensure that the host
computer’s clock is set to the correct time.
2. Click Yes to confirm settings.
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Highsiding the Tool
Before reading the Toolface Offset, highside the tool.

1. Assemble tool string from the transmitter to the stinger, including spacer bars needed.
Figure 6-30. Highsiding the Tool
2. Tighten all connections.

3. Turn tool until the slot of the stinger keyway is at the top dead center facing up.
4. Place level across stinger slot.
Figure 6-31. Leveling the Tool
5. Rotate the tool until it is leveled.
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Figure 6-32. Leveling the Tool, continued
6. In the EMXConfig main dialog window at the lower right-hand corner, look for the Directional field.
Figure 6-33. Directional Toolface Offset Reading
7. In the Toolface Offset field, click Read. Notice the number that displays. This represents the
toolface offset. The Toolface Offset value will be saved to the database. Setting the Highside is
complete.
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Setting the Inclination Limit and the Inclination Hysteresis
Setting the Inclination Hysteresis (cross-over angle) is where the tool switches from a magnetic toolface to a
gravity toolface. The inclination hysteresis is the threshold where the tool will switch from magnetic to a gravity
toolface in plus or minus X amount of degrees. For example, with the default settings of a 5 degree limit and 0.3
degree hysteresis, the tool will switch from magnetic to gravity tool face at angles bigger than 5.3 degrees and
will switch back into magnetic from a gravity toolface at angles less than 4.7 degrees as shown below:
Figure 6-34. Inclination Limit and Hysteresis Readings
1. Click the Done button when desired entries are completed. A dialog window opens, requesting the
user to set the Toolface Offset.
2. If this step has already been completed, select NO. Another dialog window opens, providing the user
with the option to erase the battery consumption and set values to zero.
3. Click YES to reset the battery Amp hours and set the active battery to bottom.
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BlackStar EMDataMgr
Creating a New Job
1. Double-click the EMDataMgr icon ( ) on the host computer’s desktop. The EMDataMgr main
dialog window opens:
Figure 6-35. BlackStar EMDataMgr Main Dialog Window
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2. In EMDataMgr top menu bar, click Job and select New. The Job Information dialog window
displays.
Figure 6-36. Create New Job Form
3. Enter the requested information about the new job.
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4. Click OK to accept the information on the new job.
Figure 6-37. Enter Information for New Job
Creating a New Track
Setting Up a New Track (Step 1)
1. In EMDataMrg main dialog window, click Track and select New. The Track Setup dialog window
opens.
Note
If creating the first track, there will not be an Available

Tracks displayed.
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This is the first of six steps to setting up a new track.
Figure 6-38. Create a New Track
2. Click Next. The Track Setup (step 2) window opens to enter a new track description.
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Entering a Track Description (Step 2)
1. Click Next. The Track Setup (step 2 of 6) window opens.
Figure 6-39. Enter New Track Description
Note
Entering a description for the track is mandatory. If the user

clicks Next before entering a value in the description field,
the following prompt displays, requesting that a track
description be entered in the description field.
2. Click OK to return to Step 2 and enter a description.

3. In the Operation Type field, select MWD. This is the default selection.
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4. Select BlackStar (WITS) in the Rig Floor Display field. Normally, this is the default selection, but if
a different Rig Floor Display (RFD) is used, select the appropriate RFD from the drop-down list.
5. Click Next to go to step 3 (Set up unit of measure) in setting up a new track. The Track Setup step
3 of 6 window opens.
Setting the Unit of Measures (Step 3)
1. Select the desired units of measure (standard or metric) for the following:
 Depth (feet or meters)
 Temperature (Fahrenheit or Centigrade)
 Pressure (PSI or Kpa)
 Weight (Lbs or DecaNewtons)
Figure 6-40. Set Unit of Measures
2. Click Next to move to step 4. The Track Setup (Step 4 of 6) window opens.
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Entering Tie-in Information (Step 4)
1. Enter relevant Tie-in Information, ensuring that in the Magnetic Declination, the East Declination
is positive and the West declination is negative.
Figure 6-41. Entering Tie-in Information
2. Click Next. The prompt to enter Sensor-to-Bit Information (Step 5) dialog window opens.
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Enter Sensor-to-Bit Spacing

1. Enter Sensor-to-Bit Spacing values.
Figure 6-42. Sensor-to-Bit Spacing Entries
Table 6-8. Tool Spacing
Sensor Description
DRG Accel The distance from the bit where the near bit inclination is measured. This setting only
applies to DRG.
Directional The distance from the bit where the inclination and azimuth is read in the directional
sensor. This measurement is always required.
Gamma The distance from the bit where the gamma counts are measured here. This setting is
only found in tool strings where a gamma module is used.
Pressure The distance from the bit where the annular pressure data is measured. This setting is
2. Click Next to move to the final step in creating a new track. Refer to the tool layout drawing in
BlackStarEMSuite Help for sensor spacing.
The directional sensor package is 12” (30 cm) above the pin wrench connection on the bottom connection
of the directional sensor.
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Track Setup (Step 6)
1. In the Track Setup dialog window, (Step 6) enter or select a value from the provided drop-down list
for the following parameters:
Table 6-9. Parameter Description
North Reference (Grid/True) Choose Grid or True - used for LAS and reports.
Reference Datum (KB, DF, GL) Choose KB, DF, or GL - used for LAS and reports.
Latitude at Surface Enter value - used for LAS and reports.
Longitude at Surface Enter value - used for LAS and reports.
Survey Type Choose Survey Calculation method, Minimum Curvature, Average Angle,
or Tangential.
Depth Type Choose the measurement for MWD Course Length for the Utility Operation
type.
2. Click Finish to complete the track.
Figure 6-43. Track Setup (Step 6)
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Attach a Tool to a Track

To attach to the tool, first, ensure that the desired job and track is selected.
1. From the EMDataMgr main dialog window, click Track and then select Attach Tool. The Attach
Tool dialog window opens.
Figure 6-44. Attach Tool Dialog Window
2. Select the Serial Number of the transmitter that will be used.

3. Click OK. Double-check to ensure in the EMDataMgr dialog window, the correct serial number
transmitter is attached to the correct job and track.
Figure 6-45. Serial Numbers
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Archiving Job Data and Tool Configurations

It is important to archive the job data and tool configuration for the possibility that the current computer
malfunctions while the tool is in the hole.
Archive a Job or Track
Archive data in BlackStar database. Archived data can be transferred from one computer to another, or
shipped to different locations via e-mail. Archived files use the Job999_2_1.cab file format.
1. Click the Utilities menu and then select one of the following options, depending on which option
needing archiving.
Figure 6-46. Archive Job Utility
 Archive Job - saves all the job data for the selected job including available tracks and tool
configurations that are associated with it.
 Archive Track - saves all the data for a specific track.
 Export Tool Config - saves the selected tool configuration to a file.
Note
Use this as an example to back up job data.
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If selecting the Archive Job option, the Archive Data dialog window displays the Archive Directory
path to save the data. The default location is the C:\Program Files\BlackStarEMSuite\JobDir folder;
However, that path can be changed.
Figure 6-47. Archive Data Dialog Window
1. Click the ( ) button next to the Archive directory field. The Browse for Folder dialog window
opens.
Figure 6-48. Browse Folder Dialog Window
2. Select the directory path where the file will be saved and click OK.
3. Select the job to be archived from the Available Jobs list.
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Note
If the Delete Job from database after archive is checked,

the job will be deleted from the BlackStar Database after
an archived file has been created.
4. Click OK when the correct job has been selected. View the archiving progress bar at the bottom of
the EMDataMrg main dialog window.
Figure 6-49. Archiving Confirmation Screen
BlackStar EMDataMrg displays the Archive Completed confirmation dialog window.
5. Click OK and copy the file to a removable media device.
Table 6-10. Archive Filename Formats
Data Type Filename
Job Data JobXXXX.cab
Track Data TrkXXXX.cab
Tool Configuration TcfXXXX.cab

Data
Archiving data provides a backup of the data on the host computer with the following benefits:
 The data can be installed on another computer with the BlackStar EM Suite installed in the event
that the host computer malfunctions.
 Archiving at the end of the job helps to save the data for future reference.
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Running BlackStarEMVue
To run Job and/or Track data, open BlackStarEMVue.
1. From your desktop, click the BlackStarEMVue ( ) icon. The user will be prompted to
select the job and track that the data will be logged, from the Available Tracks.
Figure 6-51. Select Track Dialog Window
2. Click OK. If Downlink is enabled the system prompts the user to set an active frequency and baud
rate.
3. Select the down-link stage and click OK. The BlackStarEMVue main window will display with an
Oscilloscope similar to the figure below. The signal should represent a sine wave.
Figure 6-52. BlackStarEMVue Oscilloscope Window
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Verifying the Proper Signal

When the tool is connected directly to the amplifier, verify proper signal using the following checklist:
Figure 6-53. Verifying Proper Connectivity Signal
Table 6-11. Signals
Parameter Criteria
Gain 0dB to 6db and locked
Raw Signal Greater than 3000 mV
Signal PP Greater than 3000 mV
A/D PP Greater than 3000 mV
Signal to Noise (S/N) Greater than 5
Sync 3
AGC On
Reliability 5
Checking Tool Functions
Check the following tool functions:

 In the corrected data received window, inclination should be approximately 90 if the tool is parallel
to the ground.
 The toolface should be a gravity toolface and not magnetic as long as the inclination is greater than
the set inclination limit.
 Rotate the tool approximately at 0, 90, 180, and 270-degree tool face to check the directional
sensor.
 If a gamma probe is being used, check for differences in gamma readings by placing a gamma
source on the tool and later removing it.
 Verify that the Frame Switching works. Using a rubber mallet, hit the tool repeatedly about
approximately 17-inches below the transmitter gap. This should cause the tool to switch from
survey frame to steering frame.
 Install battery on the tool and observe the signal for the same characteristics seen during previous
testing of the tool.
 Check the receiver calibration.
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Note
To optimize communication between the receiver and

transmitter, tool calibration should be performed
approximately every 30 days.
Determine which Tools are Calibrated
1. From the BlackStarEMVue top menu bar, select View, and then select Calibrated Tools.
Figure 6-54. Open BlackStarEMVue Calibrated Tools
The calibrated tools dialog window opens a list of transmitter serial numbers along with calibration
dates.
Figure 6-55. BlackStarEMVue Calibrated Tools Dialog Window
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Calibrating the DCA
1. From BlackStarEMVue’s main dialog window, click Receiver in the top menu bar.
2. Select Calibration from the drop-down list.
Figure 6-56. Calibrate Dialog
Wait until calibration reaches 100%.
Alerts
The following Alert Messages that display under certain conditions:

 High Vibration
 PTG Communication failure
 Low Transmitter Battery Voltage
 Transmitter Power Level Change
Down-Link Alerts
For detailed information on Down-Link Alerts, refer to BlackStar EM Suite Help.
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Loop-Back Testing for the DCA
Functionality
The Loop-Back test checks the communication link between the BlackStar DCA and Communications
Plug. If the Loop-Back does not pass, a communication breach exists in the Programming Plug, DCA, or
the connecting cable.
Performing the Loop-Back Test
1. Connect DCA and laptop using the USB A-B cable. Connect the programming cable with one end to
the programming plug and the other end connected to the DCA TOOL connector.
Note
Do not connect the programming plug to the transmitter at

this time. This prevents possible damaging to the
transmitter if there is a shortage in the programming plug.
2. Turn on the DCA.

3. Turn on TOOL POWER on the DCA. Run EMXConfig.
4. While the EMXConfig is in the startup dialog window, press [F2] on the computer to enter the
Terminal Mode.
5. Click the Transmitter menu and select Loop-Back Test.
a. If the loop-back test fails, either the USB Cable, programming cable,
programming plug, or DCA is bad. If possible, troubleshoot by replacing parts
with known good parts and repeat steps 1 thru 4.
b. If the loop-back test passes, power down TOOL POWER on the DCA. Connect
the programming plug to the transmitter and directional sensor string. Repeat
steps 2 thru 5 and then continue on to step 9.
c. If the loop-back test fails, either the transmitter or programming plug is bad.
d. If the loop-back test passes, then the programming plug, programming cable,
DCA, and USB cable are good parts. When trying to program the tool, if the
EMXConfig main dialog window continuously display Wait for tool power up
or the Tool ready for re-configure response message, there is a problem with
the transmitter.
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Configuring and Testing the BlackStar EM

Tool with SCA
BlackStar EM Control Panel
BlackStar EM Control Panel works as an user interface to the EM Server. The EM Server runs on the
BlackStar Surface Amplifier.
Running EM Control Panel
The EM Control Panel main dialog window is where all BlackStar EM Control Panel functions are
executed. To begin, set up the surface system and run the Wellhead and Reference cables.
1. From the host computer’s desktop, double-click the EM Control Panel icon( ). The EM
Control Panel Main Window opens.
Figure 6-57. BlackStar EM Control Panel Main Window
2. Ensure that the IP address displayed in the EM Control Panel matches the IP address of the
amplifier in use. The IP address displayed should resemble the 192.168.1.XXX format. Refer to
Figure 5-58 illustration below to see the IP location example.
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3. Click Connect to establish communication with the amplifier. When connected, the IP address field
is greyed out and the Connect button toggles to the Disconnect option.
Figure 6-58. IP Address Connect/Disconnect Field
Selecting Frequency
To analyze the noise, have the rig turn on all equipment possible such as pumps, top drives, mud pumps,
rotary table, nitrogen generators, air compressors, air-conditioners and the like to simulate normal drilling
conditions to find the best frequency to configure the tool. A good time to run the frequency analyzer is
when the rig is drilling the surface hole.
Note
Antenna Cables, (BOP, Reference) and Ground wire must

be ran out and properly connected. Refer to Chapter 5,
RIG UP in this manual.
1. Verify that the antenna cables are properly connected and the SCA is grounded.
2. From EM Control Panel main dialog window, click Receiver in the application menu bar and then
select Frequency Analyzer. The Frequency Analyzer window opens as illustrated below.
Figure 6-59. Open BlackStar EM Control Panel Frequency Analyzer
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The Control Panel Frequency Analyzer dialog window opens.
Figure 6-60. Frequency Analyzer Dialog Window
3. Click Start. Allow the program to run and note the best frequency and baud rates. The program
always recommends the best frequency and baud rates for the local noise conditions. Higher
frequencies are more susceptible to noise at greater depths.
Note
Wait 10 to 15 minutes to give the receiver adequate time

to run the Frequency Analyzer.
4. To view noise using spectrum, from the EM Control Panel main dialog window, select the Spectrum
option in the View Selection field.
Figure 6-61. Select Spectrum Option
5. Click the drop-down arrow in the Spectrum Settings field to expand the drop-down list and then
select Average Linear.
Figure 6-62. Spectrum Settings
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6. Right-click in the Spectrum Analyzer to set the frequency range to 0-10Hz.
Figure 6-63. Frequency Range Settings
In the example below (Figure 6-64), most of the noise is in the 0-3 Hz range. If this was the actual
noise present, you would want to avoid these frequencies.
Figure 6-64. Replicated Frequency Settings
7. Click Stop to end Frequency Analyzer.
8. Make a note of the suggested frequencies and baud rates.
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Configuring the Tool with SCA
Figure 6-65. BlackStar Programming Box - Top View

Note
The BlackStar Programing Box is a 14-Volt system when

connected to the transmitter, but is a 28-Volt System when
connected to the PTG/DRG.
Figure 6-66. Programming Box Power Button, Power Cord Outlet, and Fuse
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Connecting the BlackStar Programming Box
1. Ensure that the power switch is turned to OFF before connecting any cables.
2. Connect the DB9 cable from the programming box to the COM port on your computer.
Figure 6-67. Connect Programming Box to Computer
3. Connect the programming cable from the programming box to the communications plug and then
connect the communications plug into the top of the BlackStar transmitter.
Figure 6-68. Communication Plug Connected to Transmitter
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4. Check the meter on the programming box.
Figure 6-69. Programming Box Meter
The following are meter readings on the programming box meter:

 The first tick is 0mA - Transmitter off (console mode): The needle should sit around the first tick.
 The second tick is 200mA - Transmitter on (main): The needle should sit between the second and
third tick.
 The third tick is 300mA.
 The fourth tick is 400mA.
 The fifth tick is 500mA.
IMPORTANT NOTE
When first powering on the BlackStar EM Tool, closely

monitor the dial of the programming box. The needle
should sit between the second and third tick and should
display a little jump as the tool transmits.
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Warning
If the needle sits at or over the fifth tick, turn the

POWER OFF. There could be a problem with the tool.
The tool may be drawing excessive currents.
Troubleshooting the Programming Setup
If unable to communicate with the tool, check and/or change any of the following items before changing
transmitter or directional sensor.
 Check the programming cable to ensure that it is securely connected.
 Check the communications plug to ensure that it is securely connected.
 Check the programming box connections.
 Recycle power to the transmitter and observe the dial again.
 Check the programming box fuse.
If none of the above conditions exist, but the needle still reads over the fifth tick, there could be a problem
with the transmitter.
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Starting BlackStar EMXConfig
1. From your desktop, double-click the EMXConfig icon ( ). The EMXConfig dialog window
opens.
Figure 6-70. BlackStar EMXConfig Main Window
2. Turn on the BlackStar programming box.

If the programming box is already on, wait for the tool to respond. The software
should begin to communicate with the tool and should download its current settings.
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3. When the download is complete, select the frequency and baud rates (Figure 6-71).
Figure 6-71. Select Frequency/Baud Rate in EMXConfig
Note
For the MWD application, we recommend that the

frequency is set no greater than 7Hz.
Transmitter Configurations
Select the power setting located below the frequency drop-down list. The setting ranges are:
 5W for low power
 10W for high power
The active battery will either read bottom or top if you are running the dual-battery configuration.
Table 6-12. Delay to Switch to 10 Watts
Delay to switch to 10 Displays the number of hours before switching to 10 Watts. If the value is 0, the tool
watts will operate in 5 watts. The timer starts as soon as the user clicks Done. Even if the
tool is disconnected from the power source, as soon as the tool is powered, if time
intervals have elapsed, the tool switches to 10 watts.
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Table 6-13. Transmission System
Parity Correction The parity correction is supported by all tools and is very reliable. Error detection
ability has a faster data rate.
Hamming Coding The hamming coding has a slower data rate, but has the error detection ability.
Table 6-14. Modulation Type
Modulation Type BPSK is the default; however, use QPSK if it is available.
For optimum signal reception, the carrier Frequency (F) and the Baud Rate (BR)
should meet the following requirements:
 F/BR>=3 (for BPSK)
NOTE: It is not possible to select the wrong frequency.
 2*F/BR>=4 (for QPSK)
Table 6-15. Frame Switching
Frame Switching Frame Switching means that the operating type will be in a Timed or Vibration mode.
In the vibration mode, the tool switches between “Survey” and “Steering,” depending on the vibration level.
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Down-Link
Table 6-16. Vibration Mode
Surveys before power- Surveys before power-down represents the number of survey frames that are
down transmitted before the tool goes into the sleep mode. A valid range is 0 through 99. A
value of 99 keeps the tool from entering the sleep mode and continues to send survey
frames until the vibration limit is met.
Check Vibration every The Check Vibration Every Minute mode represents the time that the tool is in the
minute sleep mode before waking to take samples to determine if it should wake up and start
transmitting. The default setting is 1.
Vibration Time This parameter determines the amount of dampening applied by the vibration filter.
Constant The larger the value, the heaver the dampening applied. The range of valid values is
from 1.0 to 10.0, with a value of 1.0 effectively turning off the filter.
Vibration Limit (G) The Vibration Limit parameter determines the vibration limit in G for switching
between survey and steering. A valid range is 0.5 or less.
Vibration Hysteresis Vibration Hysteresis determines the vibration limit hysteresis levels. A valid range is
0.5 or less.
Vibration Tare The Vibration Tare displays the current vibration tare value. Click Read to calculate a
new vibration tare value.
To configure the tool for Down-Link, the Frame Switching and Operating Type modes must be set to
vibration.
When Down-Link is enabled, the configuration program enables the Frequency B selection and Baud
Rate stages 2, 3, and 4. The operator can then select two frequency selections for Frequency A and B. In
addition, the operator can select four baud rate selections for Baud Rate stages 1 though 4.
Initially, the transmitter can be turned off if Down-Link On & Initially Power Off is turned off from the
Down-Link drop-down list. Selecting the Down-Link On Initial Power Off option require the operator to
turn on the transmitter using the Tool Power On Down-Link command.
Using Initial Power On when turning on the transmitter, will set Frequency to A and the Baud Rate to
Stage 1.
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Hysteresis
Hysteresis is used to filter vibration readings so that the output reacts slowly by taking recent history into
account. For example, a vibration limit controlling frame switching may switch to the Survey mode when the
vibration drops below A (in Gs), but will not switch back to Steering mode until the vibration rises above B
(in Gs.) Thus, frame switching on the transmitter when the vibration is between A and B depends on the
history of the vibration. This prevents rapid switching between Surveys and Steering when the vibration
drifts around the vibration limit.
Figure 6-72. Filtered Vibration Reading
Timed Mode
In the Timed mode, the tool switches between Survey and Steering after transmitting a specified number
of frames.
Figure 6-73. Frame Switching
Table 6-17. Timed Mode
Survey Count In the Time mode, the Survey Count represents the number of
survey operations before changing to steering mode.
Steering Count The tool's Steering Count is the count before changing to the
survey mode.
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1. Double-click a Survey or Steering frame. The Edit Frame dialog window opens and displays the
currently selected frame.
Figure 6-74. Edit Frame Dialog Window
To add parameters, drag and drop an Available Word Parameter to the Frame Parameter column.
The following parameters are available:
 Incl = inclination
 Azm = azimuth
 Dip = magnetic dip
 Tf = tool face
 Temp = temperature
 Gtot = gravity totals
 Htot = magnetic totals
 TStat = tool status; displays top or bottom battery, TX battery voltage, Gamma battery
voltage (will display 30V if string is directional only)
 VSw = vibration switch; used mainly for in house testing
 PAnu = annular pressure; available with the gamma module only
 Gamma = gamma readings; available with the gamma module only
 Vtot = vibration total; displays vibration in Gs, available with gamma module only
 Mags = magnetic field, Hx Hy Hz
 Gravs = gravity field Gx Gy Gz
 HSGamma = highside gamma; DRG module only
 LSGamma = low-side gamma; DRG module only
 DHRpm = Down hole rpm's; DRG module only
 NBInc = near bit inclination; DRG module only
To delete parameters in the frame, drag the desired parameter out of the window.
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In the selected parameter box, the time until the next word is received is displayed next to the parameter.
This is directly related to the baud rate. A faster baud rate increases the speed in which data is
transmitted.
2. Click OK when finished editing frames.
Note
Use Gtot in Steering Frame when running Directional Only

to monitor vibrations.
Monitor Transmitter A/D
Monitor Transmitter A/D can be used to check whether the directional sensor is working properly by
examining the Mag X, Mag Y, Mag Z, Acc X, Acc Y, and Acc Z values.
1. In the BlackStar EMXConfig main dialog window, click Transmitter from the top menu bar and then
select Monitor A/D. The Monitor Transmitter A/D dialog window opens.
Figure 6-75. Open Monitor A/D
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Figure 6-76. Run Monitor Transmitter A/D
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2. Click the Run button in the Monitor Transmitter A/D window. Let the tool sit for a minute until the Mag
X, Mag Y, Mag Z, Acc X, and Acc Y, and Acc Z values are stable.
Figure 6-77. Running Monitor Transmitter A/D
3. When the values are stable, turn the tool a ¼-turn position and let the tool sit at this position for a
minute until the Mag and ACC values stop fluctuating. If the numbers continue to fluctuate without
any movement of the tool, there could be a problem with the directional sensor.
Vibration
Vibration is used to determine if the vibration sensor is working properly.

1. Run the Monitor Transmitter A/D and record the Vibration value.
2. Tap on the transmitter. An increase in the vibration value should be evident.
Figure 6-78. Testing the Vibration Value
The Vibration Switch is located 17 inches below the transmitter gap.
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Gamma Configuration
1. If the Gamma Module is in use, from the PTG menu, select Setup in the EMXConfig main dialog
window. The PTG Setup dialog window opens.
Figure 6-79. PTG Setup Main Window
2. The following information is displayed in the “Tool Information” field of the PTG Setup window.
 Firmware Version
 PTG S/N
 Pressure Transducer S/N
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Annulus Pressure
The Annulus Pressure information is used to test and calibrate the pressure transducer on the gamma
module.
Figure 6-80. Annulus Pressure Settings
The Full Scale drop-down list is used to set the transducer resolution. Available ranges are from 1000 to
15000 psi.
Note
The lower the scaling, the higher the resolution. However,

resolutions will never read ranges higher than the selected
range.
The Offset (PSI) value is what the pressure transducer reads.
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Testing and Configuring the Pressure Transducer
To test and configure the Pressure Transducer, complete the following steps:
1. Select the desired full scale.
2. Click the Tare Pressure button.
3. Click the Read button next to the “Offset PSI. The window value should read
zero (0).
4. Connect the pressure plug and Enerpac pump to the bottom of the gamma.
5. Pump the pressure up to approximately 1500 PSI unless the range is set to 1000. In that case, use
500 psi.
6. Click the Read button. The offset should read approximately the same as the gauge on the pump.
7. Release the pressure from the pump by turning the knob on the pump counter-clockwise.
8. Disconnect the pump and the pressure plug from the gamma module.
9. Click Read again. The Offset should read 0 psi again. If this is the case, the testing is complete and
should resemble the window in Figure 6-81.
Figure 6-81. Annulus Pressure Reading
Gamma Calibration
To calibrate the Gamma, complete the following steps:

1. Click Run next to the Gamma Count field. Allow the program to run until the gamma counts are
stable.
2. Click the Set button next to the Background Count field.
3. Locate the API factor on the gamma blanket and enter it into the Calibrator Scale field.
4. Wrap the gamma blanket around the gamma probe using the following criteria:
a. For the 360 or Focused Gamma, wrap blanket approximately five inches above the bottom pin-
wrench connection.
b. Wrap only one layer of the blanket around the pressure housing.
c. For the DRG, ensure that the milled slot is facing the sky.
5. Wait for the gamma counts to stabilize based on the following criteria:
 For directional gamma and DRG, the typical counts should be approximately 70 to 100 counts
per second (cps).
 For 360 gammas, the typical counts should be approximately 180 to 275 cps.
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6. When the counts stabilize, click the Set button next to the Hot Count field.
This completes the Gamma Calibration and the results are reflected Figure 6-82 below.
Figure 6-82. Gamma API Calibration Dialog Window
7. Click the Stop button once the calibration is complete.
Dynamic Rotational Gamma (DRG) Parameters

Default settings with the exception of window size which can be changed from 0-180 are recommended.
Input settings in the DRG dialog window.
Figure 6-83. DRG Dialog Window
Table 6-18. DRG Parameter Descriptions
Parameters Description
Window Size Determines where the DRG window samples gamma data. The default setting is 120
degrees.
Index Toolface Limit Determines the vibration limit in which the DRG resets its internal toolface to match
the directional sensor toolface.
Index Hysteresis A hysteresis controlling the Index Tool Limit may set the internal toolface when the
vibration drops below X1 G, but will not try to set it again until it rises above X2 G.
Thus, the set internal toolface between X1 and X2 depends on the history of the
vibration. This prevents repetitive settings of the internal toolface.
Index Tare The Index Tare set what the DRG Vibration Sensor reads as 0 G's. The tare value is
measured in mV. Click the Tare button to set the value.
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In the Gamma Collar Attenuation field, select the size collar that will be used down hole. It should be one
of the following:
 3.75
 4.75
 6.50
 8.00
Refer to the following:
If the collar size is not in the list, select user and manually enter the collar factor.
1. Click the OK button in the PTG setup window. EMXConfig prompts the user to confirm the settings.
Figure 6-84. Tare Pressure Confirmation Dialog Window
a. Click Yes to perform the tare pressure and set the real-time-clock. Setting the
real-time clock sets the tool string time to match the time of the laptop.
b. Click No to skip this step.
c. Click Cancel to return to the setup dialog window.
Note
Ensure that there is no pressure before clicking Yes. In

addition, before this task begins, ensure that the host
computer’s clock is set to the correct time.
2. Click Yes to confirm settings.
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Highsiding the Tool
Before reading the Toolface Offset, highside the tool.

1. Assemble tool string from the transmitter to the stinger, including spacer bars needed.
Figure 6-85. Highsiding the Tool
2. Tighten all connections.

3. Turn tool until the slot of the stinger keyway is at the top dead center facing up.
4. Place level across stinger slot.
Figure 6-86. Leveling the Tool
5. Rotate the tool until it is leveled.
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Figure 6-87. Leveling the Tool, continued
6. In the EMXConfig main dialog window at the lower right-hand corner, look for the Directional field.
Figure 6-88. Directional Toolface Offset Reading
7. In the Toolface Offset field, click Read. Notice the number that displays. This represents the
toolface offset. The Toolface Offset value will be saved to the database. Setting the Highside is
complete.
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Setting the Inclination Limit and the Inclination Hysteresis
Setting the Inclination Hysteresis (cross-over angle) is where the tool switches from a magnetic toolface to a
gravity toolface. The inclination hysteresis is the threshold where the tool will switch from magnetic to a gravity
toolface in plus or minus X amount of degrees. For example, with the default settings of a 5 degree limit and a.3
degree hysteresis, the tool will switch from magnetic to gravity tool face at angles bigger than 5.3 degrees and
will switch back into magnetic from a gravity toolface at angles less than 4.7 degrees as shown below:
Figure 6-89. Inclination Limit and Hysteresis Readings
1. Click Done when desired entries are completed. A dialog window opens, requesting the user to set
the Toolface Offset.
2. If this step has already been completed, select NO. Another dialog window opens, providing the user
with the option to erase the battery consumption and set values to zero.
3. Click YES to reset the battery AMP hours and set the active battery to bottom.
Next Step
Please refer to the procedure “BlackStar EMDataMgr”on

how to create jobs, tracks, and attaching the tool.
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BlackStar EMDataMgr
Creating a New Job
1. Double-click the EMDataMgr icon( ) on the host computer’s desktop. The EMDataMgr main
dialog window opens:
Figure 6-90. BlackStar EMDataMgr Main Dialog Window
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2. In EMDataMgr top menu bar, click Job and select New. The Job Information dialog window
displays.
Figure 6-91. Create New Job Form
3. Enter the requested information about the new job.
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4. Click OK to accept the information on the new job.
Figure 6-92. Enter Information for New Job
Creating a New Track
Setting Up a New Track (Step 1)
1. In EMDataMrg main dialog window, click Track and select New. The Track Setup dialog window
opens.
Note
If creating the first track, there will not be an Available

Tracks displayed.
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This is the first of six steps to setting up a new track.
Figure 6-93. Create a New Track
2. Click Next. The Track Setup (step 2) window opens to enter a new track description.
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Entering a Track Description (Step 2)
1. Click Next. The Track Setup (step 2 of 6) window opens.
Figure 6-94. Enter New Track Description
Note
Entering a description for the track is mandatory. If the user

clicks Next before entering a value in the description field,
the following prompt displays, requesting that a track
description be entered in the description field.
2. Click OK to return to Step 2 and enter a description.

3. In the Operation Type field, select MWD. This is the default selection.
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4. Select BlackStar (WITS) in the Rig Floor Display field. Normally, this is the default selection, but if
a different Rig Floor Display (RFD) is used, select the appropriate RFD from the drop-down list.
5. Click Next to go to step 3 (Set up unit of measure) in setting up a new track. The Track Setup step
3 of 6" window opens.
Setting the Unit of Measures (Step 3)
1. Select the desired units of measure (standard or metric) for the following:
 Depth (feet or meters)
 Temperature (Fahrenheit or Centigrade)
 Pressure (PSI or Kpa)
 Weight (Lbs or DecaNewtons)
Figure 6-95. Set Unit of Measures
2. Click Next to move to step 4. The Track Setup (Step 4 of 6) window opens.
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Entering Tie-in Information (Step 4)
1. Enter relevant Tie-in Information, ensuring that in the Magnetic Declination, the East Declination
is positive and the West declination is negative.
Figure 6-96. Entering Tie-in Information
2. Click Next. The prompt to enter Sensor-to-Bit Information (Step 5) dialog window opens.
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Enter Sensor-to-Bit Spacing
1. Enter Sensor-to-Bit Spacing values.
Figure 6-97. Sensor-to-Bit Spacing Entries
Table 6-19. Tool Spacing
Sensor Description
DRG Accel The distance from the bit where the near bit inclination is measured. This setting only
applies to DRG.
Directional The distance from the bit where the inclination and azimuth is read in the directional
sensor. This measurement is always required.
Gamma The distance from the bit where the gamma counts are measured here. This setting is
Pressure The distance from the bit where the annular pressure data is measured. This setting is
2. Click Next to move to the final step in creating a new track. Refer to tool layout drawing in BlackStar
EM Suite Help.
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Track Setup (Step 6)
1. In the Track Setup dialog window, (Step 6) enter or select a value from the provided drop-down list
for the following parameters:
Table 6-20. Parameter Description
North Reference (Grid/True) Choose Grid or True - used for LAS and reports.
Reference Datum (KB, DF, GL) Choose KB, DF, or GL - used for LAS and reports.
Latitude at Surface Enter value - used for LAS and reports.
Longitude at Surface Enter value - used for LAS and reports.
Survey Type Choose Survey Calculation method, Minimum Curvature, Average Angle,
or Tangential.
Depth Type Choose the measurement for MWD Course Length for the Utility Operation
type.
2. Click Finish to complete the track.
Figure 6-98. Track Setup (Step 6)
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Attach a Tool to a Track

To attach to the tool, first, ensure that the desired job and track is selected.
1. From the EMDataMgr main dialog window, click Track and then select Attach Tool. The Attach
Tool dialog window opens.
Figure 6-99. Attach Tool Dialog Window
2. Select the Serial Number of the transmitter that will be used.

3. Click OK. Double-check to ensure in the EMDataMgr dialog window, the correct serial number
transmitter is attached to the correct job and track.
Figure 6-100. Serial Numbers
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Archiving Job Data and Tool Configurations

It is important to archive the job data and tool configuration for the possibility that the current computer
malfunctions while the tool is in the hole.
Archive a Job or Track
Archive data in BlackStar database. Archived data can be transferred from one computer to another, or
shipped to different locations via e-mail. Archived files use the Job999_2_1.cab file format.
1. Click the Utilities menu and then select one of the following options, depending on which option
needing archiving.
 Archive Job - saves all the job data for the selected job including available tracks and tool
configurations that are associated with it.
 Archive Track - saves all the data for a specific track.
 Export Tool Config - saves the selected tool configuration to a file.
Note
Use this as an example to back up job data.
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If selecting the Archive Job option, the Archive Data dialog window displays the Archive Directory
path to save the data. The default location is the C:\Program Files\BlackStarEMSuite\JobDir folder;
However, that path can be changed.
Figure 6-102. Archive Data Dialog Window
1. Click the ( ) button next to the Archive field. The Browse for Folder dialog window opens.
Figure 6-103. Browse Folder Dialog Window
2. Select the directory path where the file will be saved and click OK.
3. Select the job to be archived from the Available Jobs list.
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Note
If the Delete Job from database after archive is checked,

the job will be deleted from the BlackStar Database after
an archived file has been created.
4. Click OK when the correct job has been selected. View the archiving progress bar at the bottom of
the EMDataMrg main dialog window.
Figure 6-104. Archiving Confirmation Screen
BlackStar EMDataMrg displays the Archive Completed confirmation window.
5. Click OK and copy the file to a removable media device.
Table 6-21. Archive Filename Formats
Data Type Filename
Job Data JobXXXX.cab
Track Data TrkXXXX.cab
Tool Configuration TcfXXXX.cab

Data
Archiving data provides a backup of the data on the host computer with the following benefits:
 The data can be installed on another computer with the BlackStar EM Suite installed in the event
that the host computer malfunctions. Archiving at the end of the job helps to save the data for
future reference.
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Running EM Control Panel
1. From your desktop, click the BlackStar Control Panel ( ) icon. The user will be prompted
to select the Job and Track that the data will be logged, from the Available Tracks.
Figure 6-106. Select a Track Dialog Window
2. Click OK. If prompted to set an active frequency and baud rate, Downlink is enabled.
3. Verify the proper signal on Oscilloscope window.
Figure 6-107. Oscilloscope Window
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Verifying the Proper Signal
When the tool is connected directly to the amplifier, verify proper signals using the following checklist:
Figure 6-108. Verifying Proper Signal
Table 6-22. Signal Parameter Descriptions
Parameter Criteria
Gain 0dB to 6db and locked
Raw Signal Greater than 3000 mV
Signal PP Greater than 3000 mV
A/D PP Greater than 3000 mV
Signal to Noise (S/N) Greater than 5
Sync 3
AGC On
Reliability 5
Checking Tool Functions

Check the following tool functions:
 In the corrected data received window, inclination should be approximately 90 if the tool is parallel
to the ground.
 The toolface should be a gravity toolface and not magnetic as long as the inclination is greater than
the set inclination limit.
 Rotate the tool approximately at 0, 90, 180, and 270-degree tool face to check the directional
sensor.
 If a gamma probe is being used, check for differences in gamma readings by placing a gamma
source on the tool and later removing it.
 Verify that the Frame Switching works. Using a rubber mallet, hit the tool repeatedly about
approximately 17-inches below the transmitter gap. This should cause the tool to switch from a
survey frame to a steering frame.
 Install battery on the tool and observe the signal for the same characteristics seen during previous
testing of the tool.
 Check the receiver calibration.
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Note
To optimize communication between the receiver and

transmitter, tool calibration should be performed
approximately every 30 days.
Determine which Tools are Calibrated
1. From the EM Control Panel menu bar, select View, and then click Calibrated Tools.
Figure 6-109. Open Calibrated Tools in EM Control Panel
The calibrated tools window displays a list of transmitter serial numbers along with calibration dates.
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Figure 6-110. Calibrated Tools Dialog Window
Calibrating the SCA
1. From EM Control Panel main dialog window, click Receiver in the top menu bar.
2. Select Calibration from the drop-down menu.
Figure 6-111. Open Control Panel Calibration
The calibration process begins. Wait until calibration reaches the 100% level.
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Alerts
The following Alert Messages that display under certain conditions:

 High Vibration
 PTG Communication failure
 Low Transmitter Battery Voltage
 Transmitter Power Level Change
Down-Link Alerts
For detailed information on Down-Link Alerts, refer to BlackStar EM Suite Help.
Loop-Back-Testing for SCA
The Loop-Back test checks the communication link between the BlackStar SCA and the Communications
Plug. If the loop-back does not pass, a communication breach exists in the programing plug, programing
box, or the connecting cable.
Performing the Loop-Back Test

1. Connect programming box to laptop and programming plug with a DB9 cable and programming
cable.
Note
Do not connect the plug to the transmitter at this time. This

prevents possibly damaging the transmitter if there is a
shortage in the programming plug.
2. Turn on programming box and open EMXConfig software on the laptop.

3. While the software is in the startup mode, press F2 on the computer to enter the terminal mode.
4. Click the Transmitter menu and the select Loop-back Test.
a. If the loop back test fails, either the DB9 cable, programming cable,
programming plug, or programming box is bad. If possible, troubleshoot by
replacing parts with known good parts and repeat steps 1 thru 4.
b. If the loop-back test passes, power down the BlackStar Programming Box.
Connect the programming plug to the transmitter and directional sensor string.
Repeat steps 2 thru 4 and then continue on to step 7.
c. If the loop-back test fails, either the transmitter or programming plug is bad.
d. If the loop back test passes, then the programming plug, programming cable,
programming box, and DB9 cable are good parts. When trying to program the
tool, if the EMXConfig main startup window continually display “Wait for tool
power up” or “Tool ready for re-configure response,” there is a problem with the
transmitter.
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Field Maintenance and Service
Operating the BlackStar Battery Test Box
Figure 7-1. BlackStar Battery Test Box
The left side of the battery test box is used to test batteries that are not connected to a battery bulkhead.
Before testing the battery, check the battery pack for defect or damage to housing and connectors.
Figure 7-2. BlackStar Battery Test Box - Left-Side View
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Field Maintenance and Service 7
Warning
If damage to the battery pack is suspected, do not use

the battery. Stop the procedure immediately.
The drop in reading from NO LOAD to LOAD should be no more than 1% of the No Load value.
1. Connect the battery directly to the left side of the battery test box as shown below:
Figure 7-3. BlackStar Battery Test Box Switch
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If the battery is a transmitter battery, move the switch to the 14V. If the battery is a gamma battery,
move the switch to 28V. This switch is located on the front of the Battery Test Box and is circled in red
in the figure below.
Figure 7-4. BlackStar Battery Test Box Voltage Switch
2. Start checking the battery voltage with the LOAD OFF. The LOAD switch is pictured below and
emphasized in red.
Figure 7-5. BlackStar Battery Test Box - Load On/Off Switch
3. Check the voltage meter on the front of the Battery Test Box. A transmitter battery should read
between 12V DC and 15V DC. A gamma battery will read between 26V DC to 30V DC. The voltage
meter is emphasized in red (Figure 7-6).
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If available, use a Digital Volt Meter (DVM) for a more accurate voltage reading.
Figure 7-6. BlackStar Battery Test Box - Voltage Meter
Figure 7-7. Digital Voltage Meter
4. To depassivate the batteries, turn the load switch to the LOAD ON and OFF several times and then
let it sit with LOAD OFF. Record the voltage, repeat the procedure with LOAD ON and record the
voltage. The needle on the voltage meter should drop and slowly return back to its original position.
When a battery is depleted, the needle will not return to a normal operating voltage.
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Warning
Do not leave the batteries under Load for more than

ten minutes. If the battery becomes too hot to touch,
disconnect the battery from the “Battery Test Box”
and stop the procedure.
With the BlackStar Battery Test Box it is also possible to check and/or depassivate the battery while the
pack itself is attached to the battery bulkhead. The battery bulkhead is attached to the right-side of the
Battery Test Box.
Figure 7-8. BlackStar Battery Test Box - Right Side
5. Check the battery bulkhead for damage.
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6. Attach the battery to the end of the bulkhead Figure 7-9.
Figure 7-9. Battery Bulkhead
7. Use a ¼” - 20 x 5/8” socket cap screw to attach the bulkhead to the battery.
Figure 7-10. Cap Screw
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When plugging the bulkhead into the Battery Test Box, notice the keyway on both the bulkhead and the
Battery Test Box (Figure 7-11). Align the two for proper orientation.
Figure 7-11. Keyway Connections
With the bulkhead and the battery connected to the Battery Test Box, the functions are the same as
described earlier in this procedure. Using this connection on the Battery Test Box is also a good way to
test continuity on a completed battery assembly.
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BlackStar EM Gap Sub Tester
Testing Equipment
The BlackStar EM Gap Sub testing package includes the following:

 DC Charger
 Gap Sub Tester
 Testing Probes
Figure 7-12. Gap Sub Testing Components
Product Description
The EM Gap Sub Tester is a portable test unit that checks the quality of a signal traveling across the gap
sub, based on the impedance of the dielectric insulation of a gap sub.
When the test is conducted, the sinusoidal signal output from the tester attenuates “X” amount across the
gap. This causes the tester circuitry to react and display the results to an LED light bar, effectively
indicating the gap sub's electrical pass/fail condition.
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Features
Figure 7-13. Gap Sub Tester
Table 7-1. BlackStar EM Gap Sub Tester Components
Item Feature Description
1. Probes Probe Inputs -+/- probe test leads
2. Battery Test Indicator  Green Lights indicate a good battery

 Red Lights indicate that recharging is required
3. Test Button Illuminates red with power on. Press and hold to perform test
4. Power-On Button Illuminates with power on. Toggles ON/OFF
5. Signal Strength LEDS Eight-LED signal level indicator.

 red indicates a bad gap sub
 yellow indicates a marginal gap sub
 green indicates that the gap sub is good
6. Self-testing Input Test input to verify meter accuracy
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Self-testing the Gap Sub Meter
To use the Self-testing Gap Sub Meter, complete the following steps:
1. Turn on Gap Sub tester.
2. Verify that the battery indicator LED light is green upon power up.
3. Ensure that the white test button indicator light is red. If the battery indicator LED is red, the battery
voltage is low and needs charging. Charge the battery if required. (Refer to the section titled "Self-
testing the Gap Sub Meter" on page 7-166.
4. If the battery indicator light is green, firmly input the test leads into the self-test input on the meter.
5. Press and hold the red test button for 5-10 seconds to verify operation of the Gap Sub Tester. If the
meter is working properly, the LED signal strength bar will light up two red and two yellow indicators,
as shown in Figure 7-14.
Note
The last yellow LED will sometimes blink lightly, which

indicates that the signal voltage is sitting on the border of a
resolution point for the LED. Ensure that fourth yellow LED
is lit or blinking when conducting the self-test.
Figure 7-14. Self-Testing Gap Sub Meter
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Charging the EM Gap Sub Meter
1. Ensure that the testing meter is turned off.

2. Plug the DC barrel of the charger into the charging port at the bottom of the gap sub testing meter.
Figure 7-15. Connect Charger to Testing Meter
3. Plug the DC charger into a wall outlet, ensuring that the current switch on the charger is set to 0.9A,
as illustrated below.
Figure 7-16. Charger Current Setting Switch
The LED turns red on the Smart Charger and automatically turns off when the batteries are fully
charged. The DC charger is a wideband and will take input voltages of 120-240VAC.
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Testing a Gap Sub using the EM Gap Sub Tester
Test a gap sub using the instructions below:

1. Place the gap sub on a non-conductive surface.
Note
Test gap subs independent of each other.
2. Place positive (+) and negative (-) probes across the gap sub, six to eight inches away from the gap.
Note
Ensure that the probes are touching an uncoated surface

of the gap sub. The tester will not work properly without a
conductive surface.
3. Press the Test button on the probe or meter and hold for five to ten seconds.
4. Record the LED signal strength indication.
5. Move the probes to a different area on the gap sub, and repeat step 3 to verify the results.
Figure 7-17. Testing Gap Sub
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Note
Step 5 is very important. Repeating the test in different

areas of the gap sub ensures valid results.
Interpreting the LED Indicator Results on the EM Gap

Sub Tester
Determining the Condition of the Gap Sub

When testing a gap sub with the EM Gap Sub Tester Equipment, the LED lights up to indicate specific
conditions. The interpretations are described below.
Figure 7-18. Signal Strength LED Indicators
Table 7-2. Signal Definitions
When the LED Signal is... Condition
7 - 8 Green LED Region Reflects a gap sub with a good signal quality
3 - 6 Yellow LED Region The gap sub is at the end of its expectancy cycle and will require
rework very soon
0 - 2 Red LED Region The gap sub with an insulation that has been significantly
degraded or damaged and will not provide any signal down hole.
This condition is a clear indication that the gap sub being tested
requires rework
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Note
A “0” LED signal refers to no LEDs lighting up on the LED

bar.
Table 7-3. Impedance Table
LED1 LED2 LED3 LED4 LED5 LED6 LED7 LED8
4-5K 6-7K 8-9K 10-11K 13-14K 16-17K 21-22K 28K+
Note
Blinking LED's equate to impedance levels falling between

the values stated in the impedance table (8-3) above.
Inspecting a Gap Sub
1. Inspect the gap sub for abnormal wear around the isolation joint.
Figure 7-19. Insulation Joint
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Inspecting the Gap Sub, continued...

2. Inspect the gap sub defects in uniform ID coating. These defects might cause the tool current to arc
over the gap.
Figure 7-20. Damaged ID Coating
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Servicing the UBHO
Tools and Supplies
Before beginning this procedure, ensure that the following tools and supplies are available to perform this
task.
 Loading Bar (P/N 373-118-01)
 UBHO Sleeve 3.75 (301-440-01) 4.75 (301-441-01) 6.5 (301-442-01) 8.0 (301-443-01)
 Hammer
 Alignment tool P/N (371-140-01) used on all sizes
 UBHO Sub
 High Temp grease Dow Corning 111 (DC-111)
 Hex set screws 3.75 (114761) 4.75 (114762) 6.5 (12922) 8.0 (11456)
 Hex pressure port screws P/N Gamma (114301) Directional (114908) used on all sizes
 O-rings
Figure 7-21. UBHO Tools and Supplies
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How to Service the UBHO
1. Inspect the sub for wear, ensuring that the threads on the connections are good. In addition, inspect
the plug and pressure ports to determine if taping the threads are required.
Figure 7-22. UBHO Quality Inspection
2. Prepare the surface by wiping it down and ensuring that it is free from debris.
Figure 7-23. UBHO Surface Preparation
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3. Inspect the sleeve for any damaged or missing parts.
Figure 7-24. Sleeve Inspection
Inserting the Key into the Sleeve
To insert the key into the sleeve, complete the following steps:
1. Check the UBHO to ensure that the sleeve is seated and that the key is correct and matches the key-
insertion slot. Ensure that the key length matches the length of the key slot.
Figure 7-25. Sleeve Key
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2. Check the UBHO sub sleeve and insert key into the sleeve.
Figure 7-26. Install Key into Sleeve
3. Use grease or tape to hold key in place.
Figure 7-27. Secure Key in Sleeve
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4. Inspect the o-rings before installing them on the sleeve.
Figure 7-28. Inspecting Sleeve O-rings
5. When inspection of the sleeve is complete, apply grease on all the o-rings and high surfaces. Apply
grease to the ID of the UBHO Sub.
Figure 7-29. Applying Grease to UBHO ID
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6. Insert the sleeve through the top-end of the sub. Using your hand, push the sleeve and wiggle at the
same time until it passes the first o-ring or until it does not go any further.
Figure 7-30. Sleeve inserted into the UBHO Sub
7. Insert the alignment tool into the sleeve ensuring that the slot is aligned with the key.
8. Using both hands push and turn the handle on the alignment tool at the same time until the sleeve
does not go in any further.
Figure 7-31. Install Sleeve into UBHO using the Alignment Tool
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9. Seat the sleeve by using the tool loading bar and hammer.
Figure 7-32. Seating the sleeve in the UBHO
10. When the sleeve is seated, ensure that it turns freely when using the alignment tool.
Figure 7-33. Turn Sleeve Freely in UBHO
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11. Look through the plug hole and ensure that the o-rings were not cut while pushing the sleeve into
place. Depending on the job configuration (Directional or Gamma), directional jobs require hex plugs
while gamma jobs require pressure port screws.
Figure 7-34. Inspect O-rings
12. Tighten the hex set plug until it is snug.

Note
Do not fully tighten the hex set plug and set screws at this
time.
Figure 7-35. Tightening Hex Plug Screws
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Note
Ensure that the set screw does not protrude pass the OD
of the UBHO.
UBHO Torque Specifications

The following are UHBO set screw torque specifications according to UBHO sizes:
 3-¾” UBHO = 75 ft./lb.
 4-¾” UBHO = 75 ft./lb.
 6-½” UBHO = 120 ft./lb.
 8” UBHO = 120 ft./lb.
 Pressure Port Screws & Plugs = 75ft./lb.
Unloading Sleeve from the UBHO
Warning
Before starting to hammer the sleeve out of the UBHO,

ensure that the unloading bar slides directly over the
bull nose or latch connection on the bottom of the
sleeve. If the unloading bar does not slide directly over
the bull nose or latch connection, they will be
damaged, especially the fingers of the latch.
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Parts, Tools, and Supplies
 UBHO
 Sleeve
 Unloading Bar
 Hammer
Figure 7-36. Parts, Tools, and Supplies to Unload Sleeve from UBHO
1. Always back set screws out before starting the unloading procedure.
2. Insert the unloading bar into the UBHO.
3. Check the position of unloading bar.
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4. Start hammering the unloading bar until the sleeve comes out the other end of the UBHO.
Figure 7-37. Unloading UBHO Sleeve
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Servicing the Transmitter Contact Collet

Assembly
Replacing O-rings
1. Using an o-ring installation tool, remove the first 2-213 old o-ring on the assembly.
Figure 7-38. Remove Old 2-213 O-ring
2. Remove the 2-220 old o-ring from the split ring.
Figure 7-39. Remove O-ring from Split-Ring
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3. Remove the split-rings.
Figure 7-40. Remove Split Rings
4. Remove the threaded ring.

Note
Dirt and debris can get wedged underneath the threaded

ring making it difficult to remove. In that case, place a
punch in one of the pin holes and gently tap with a
hammer.
Figure 7-41. Punch Pin Hole
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5. Remove the second 2-213 o-ring.
Figure 7-42. Remove Second 2-213 O-ring
6. Remove the first collar and the alignment pin underneath as shown below.
Figure 7-43. Collar and Alignment Pin
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7. Remove the sleeve and the remainder of retaining pins.
Retaining Pins
Figure 7-44. Remaining Retaining Pins
Figure 7-45. Remove Last Retainer Pin
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8. Clean dirt and debris from the assembly.
Figure 7-46. Clean Contact Collet Assembly
Assembling the Collar and Sleeve
1. Coat the alignment pin slots with a liberal amount of Dow-111 to keep the alignment pins from falling
out while installing the collars and sleeve.
Figure 7-47. Coat Alignment Pin Slots
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2. Reinstall the alignment pins.
Figure 7-48. Reinstall Alignment Pins
3. Coat the assembly with an anti-seize lubricant as shown below.
Figure 7-49. Coat with Anti-seize Lubrication
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4. Reinstall the first collar.
Figure 7-50. Reinstall First Collar
5. Reinstall the sleeve. Check for proper orientation of the alignment pins.
Figure 7-51. Sleeve Installation
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6. Reinstall the second collar.
Figure 7-52. Second Collar Installation
7. Install a new 2-213 o-ring.
Figure 7-53. 2-213 O-ring Installation
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8. Lubricate the o-ring.
Figure 7-54. Lubricate O-ring
9. Install the threaded ring.
Figure 7-55. Threaded Ring Installation
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10. Install a new 2-220 o-ring on the threaded ring and lube with Dow-111.
Figure 7-56. Install Threaded Ring O-ring
11. Reinstall the split ring with a new 2-022 o-ring. This o-ring does not need lubricating. It serves to hold
the split rings together.
Figure 7-57. New 2-022 O-ring Installation
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12. Complete the assembly by installing a new 2-213 o-ring and lubricating it with Dow 111.
Figure 7-58. New 2-213 O-ring Installation
Reference Drawing 301-433-08
For detailed information, refer to the Contact Collet Sub Assembly Drawing (301-433-08) in “Appendix A” of
this manual.
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Installing O-rings and Parbak Rings on the

Stinger Assembly
Follow the instructions below to install o-rings and parbak rings on the stinger assembly.
1. Install the first parbak backup ring on the stinger with the concave surface facing where the o-ring will
sit.
Concave Surface
Figure 7-59. Concave Surface on Stinger
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2. Loop a piece of lacing twine through the o-ring and begin pulling the o-ring over the end of the
stinger point as illustrated in Figure 7-60 below.
Figure 7-60. Lacing Twine used to Guide O-ring
3. Use the lacing twine to pull the o-ring towards the o-ring groove. Swing the lacing twine back and
forth to help prevent the o-ring from stretching.
Concave Surface
Figure 7-61. Prevent Stretching O-ring
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4. When the o-ring is seated, remove the twine.
Figure 7-62. Remove Lacing Twine
5. Pull the second parbak o-ring into place, ensuring that the concave surface faces the o-ring.
Figure 7-63. Install Second Parbak Ring
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6. Complete installing parbak rings.
Figure 7-64. Complete Parbak Ring Installation
Reference Drawing: 301-447-08
For detailing information, refer to Appendix A, Drawings and Schematics, “Stinger Muleshoe Assembly”
301-447-08 in this manual.
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Greasing the Annular Pressure Lower

Assembly
Tools and Supplies
The following tools and supplies are required to grease the Annular Pressure Lower Assembly
components.
 Grease Gun
Figure 7-65. Grease Gun
 Grease Fitting Tool
Figure 7-66. Grease Gun Fitting Tool
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Grease the following assembly components:

 AP Spacer Bar
 Adjustable Orienting Sub (DRG or Focus Only)
 Stinger
AP Spacer Bar
Adjustable Orienting Sub
Stinger Muleshoe Assembly
Figure 7-67. Annular Pressure Lower Assembly Components
1. Grease all o-rings.

2. Assemble the AP Spacer and the Adjustable Orienting Sub and attach to the Stinger.
3. Assemble the spacer bar and Fitting Tool.
Figure 7-68. Grease Gun and Fitting Tool Assembly
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4. Attach the grease gun fitting tool to the Annular Pressure Lower Assembly.
Figure 7-69. Attach Grease Gun to Tool Assembly
Note
Ensure that Dow 111 or another high-temp marine grease.
5. After attaching the grease gun assembly to tool assembly, begin pumping the grease.
Figure 7-70. Pressure Port
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6. When the old grease comes out of the pressure port, continue pumping until new grease replaces
the old grease.
Figure 7-71. Pressure Port Grease
Note
Grease individual components of the assembly if desired.
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Installing the Push-On-Fin (POF)
Table 7-4. Required Tools and Supplies
Item Part Number
Impact Wrench 1/2” Drive with Power Cord N/A
Handle, Hinge 1/2” Drive x 15-3/4’ LG 114363
Socket, Deep Hex, 7/8 x 1/2”, Drive Proto 5328 114364
Fin Installation Tool Assembly, EM/MWD 391-114-0
2 x Split Tube, Cone Extension, EM/MWD 393-108-01
Fin, Centralizer, EM/MWD, -4 Blade: 7/8 OD, 90 Duro 303-127-03.1
Plastic Welder (Adhesive) N/A
Direction Sensor N/A

Extension Cone for Fin Tool 393-146-01
Aluminum Spacer Bars N/A

Transmitter, PTG (Gamma, DRG (Gamma), Battery-to-Battery Centralizer N/A

Top Contact Sub Assembly N/A

DRG Pressure Transducer End N/A

Crossover 393-147-01
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How to Install the Push-On-Fin
Reference Drawing: Fin Installation Tool Assembly - 390-114-01

To install the POF, complete the following steps:
1. Place the tool in the vice or use jack stands and parmelee wrenches on the component as illustrated
below:
Figure 7-72. Staging the POF
2. Install extension cones to either side of the directional sensor.

3. Screw section one of the fine installation tool to the extension cone.
Figure 7-73. Installing Extension Cones
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4. Slide the new fin centralizer over section one.
Figure 7-74. Section One of the Fin Installation Tool
5. Slide section two of the fin installation tool over section one.
Figure 7-75. Section Two of the Fin Installation Tool
6. Attach the socket and handle.
Figure 7-76. Socket and Handle of Fin Installation Hand Tool
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7. Hold section two of the fin installation tool in place and then use the handle to turn section one
counter-clockwise.
Figure 7-77. Section Two of Fin Installation Tool
8. Hold section two of the fin installation and use the impact gun to turn section one counter-clockwise.
Figure 7-78. Turn Section One with Impact Gun
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Caution
!
Use the impact wrench in the shop only.
9. Push the fin up to the edge of the fin tool groove and then stop.
Caution
!
Avoid screwing section two all the way to the end of the
threads of section one to prevent damaging the threads.
10. Use the split tube extension to push the fin to its full distance.
Figure 7-79. Split Tube Extensions
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11. Apply plastic welder to the fin groove.
Figure 7-80. Plastic Welder Compound
12. Mix the two compounds together and spread evenly across the fin groove.
Figure 7-81. Spread Plastic Welder Compound
Note
Notice that the fin installation tool will not always be able to
push the fin the full distance. In that case, use the 2 x split-
tube, cone extensions to push the fin. Back the fin
installation tool off and install the 2x split-tube and cone
extension.
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Figure 7-82. 2x Split-Tube Cone Extensions
13. After installing the 2x split-tube and cone extensions, continue pushing the fin on.
Figure 7-83. Complete Installing Push-On-Fins
14. Push the fin until it is fully seated.

15. Using the appropriate adaptor cones, follow the same procedure from the example shown to install
fins to the top contact, battery-to-battery centralizer, transmitter, directional sensor, and the Gamma
Probe.
Note
When install the Push-On-Fin for the DRG Pressure

Transducer end, use Crossover (393-147-01) with the
longer Cone Extension (393-108-02)..
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Lifting and Seating the Tool
Measuring the Tool Length and Collars
The tool seating position can change due to following factors:

 Reworked collars
 dual-battery Vs single battery configuration
Collar Measurement
Measure and add together the total length of the following collar components to attain the total length of the
EM MWD Collar:
 Both Battery Collars
 Gap Sub
 Instrument Collar
 UBHO Sub (Key in the sleeve to the box-end connection)
MWD Tool Measurement
Measure the total length from the slot of the stinger to the top of the contact (spearpoint). To attain the
measurement of the seating distance, subtract the length of the EM Tool from the measurement of the
Collar EM Tool measurement. For example:
11.30m (EM Collar Total Length) minus

11.00m (EM Tool Total Length) equals
0.30m (Seating Distance)
The seating distance measurement indicates that the tool sits 0.30m below the battery collar when seated
correctly.
Note
The tool should sit below the battery collar box connection.
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Lifting and Seating the Tool 8
To measure the tool length and collar, complete the following steps:
1. With the tool seated on jack stands (assembled and ready to go downhole), attach
the J-latch to the top contact.
Figure 8-1. J-latch Connection to Top Contact
2. Mark a highside line on the fishing neck.
Figure 8-2. Highside Line Marking
3. Mark a highside line on the J-latch.
Figure 8-3. J-Latch Highside Markings
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4. Using the EM Collar total length value, measure from the stinger slot and then scribe this value on
the tool.
Figure 8-4. EM Collar Total Length Measurements
Note
The mark should be somewhere on the J-latch assembly.

This mark is used to align the box of the top battery collar
when seating the tool.
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5. Highside the scribe perpendicular to seating scribe. It should resemble the markings illustrated
below.
Figure 8-5. Tool Seating Alignment Marking
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Highside Universal Bottom Hole Orientation (UHBO)

Sleeve
To highside the UHBO, complete the following steps:
Caution
!
Ensure that set-screws and pressure port screws are
installed to the lowest point to prevent crushing and
damaging them with the tongs, dog collars, or slips.
Figure 8-6. UBHO
1. Verify that the highside of the motor is correct.

2. Attach the UBHO sub to the bottom hole assembly (BHA) and torque.
3. Mark a scribe line from the highside of the motor to the top of the UBHO sub.
Figure 8-7. UBHO Alignment Mark
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4. Back the set screws out half way.
Figure 8-8. Muleshoe Wrench
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5. Insert the muleshoe wrench into the UBHO. The slot on the muleshoe wrench should catch the key
in the sleeve.
Figure 8-9. Muleshoe Wrench and UBHO
6. Turn the sleeve until the key of the sleeve lines up with the highside mark scribed on the UBHO OD.
7. When the key is aligned to the highside mark, remove the muleshoe wrench.
Note
The MWD operator and the directional driller should look

inside the UBHO to verify that the key is aligned with the
highside mark on the OD.
8. After verifying that the key is aligned with the highside, apply anti-seize to the set screws and then
tighten to the recommended torque specifications.
9. Insert the muleshoe wrench into the UBHO sub. Ensure that the wrench catches the key and then
push back and forth against the wrench to ensure that the sleeve does not move.
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10. Pull the muleshoe wrench out of the UBHO and verify that the key and the highside mark on UHBO
OD are still aligned.
11. If key and highside marks are still aligned, continue making up the BHA.
Note
Ensure to remove set screws after each run, promptly after

the UBHO reaches surface.
Lift and Seat the Tool
Before carrying the EM Tool over to the rig, perform an evaluation of the rig setup to determine the best
place to lay the tool down. The tool should be laid in the optimum position for proper lifting. Choose a path
that is clear and carry the tool to its lifting position. Place three to four wood blocks in the area where the
tool will be laid.
To lift and seat the tool, complete the following steps:
1. Attach the lifting sling and stinger protector to the tool and ensure that the pin and
sling is properly secured.
Figure 8-10. Lifting Sling Assembly
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Figure 8-11. Top Contact Assembly
2. Insert the drop-pin through the top contact.
Figure 8-12. Insert Drop Pin
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3. Push the drop-pin through the lifting sling and the top contact.
Figure 8-13. Drop-Pin Installation
4. Insert the locking pin into the drop pin.
Figure 8-14. Locking Pin Installation
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5. Secure the lock-pin to the drop-pin.
Figure 8-15. Locking Pin Secured
The lifting sling assembly attached to the top contact and ready for lifting.
Figure 8-16. Lifting Sling Assembly Attached to Top Contact
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Prerequisite to Moving the Tool to the Rig
Before moving the tool over to the rig, use the following guidelines to properly lift and carry the tool.
Note
To ensure personnel safety and to avoid the risk of

dropping and damaging the tool, at least three people are
required to lift and move the tool.
1. Space at least three lifters evenly along the length of the tool.
2. Ensure that the lifters are standing on the same side of the tool when lifting the tool string.
Warning
The tool should be carried at either waist level or on

the shoulders to prevent injuries to personnel and to
avoid the risk of dropping and damaging the tool.
3. Carry the tool over to the designated area.

4. Before picking up the tool with the winch or cat line, ensure that the sight between the lifters and the
winch line operator is clear.
Note
Inform the driller of the tool length so he will know how high
to arrange the blocks for lifting the tool properly.
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Positioning and Lifting the Tool on the Rig
To position and lift the tool on the rig, complete the following steps:
1. Using the winch or cat line, lift the tool by attaching the hook attached to the winch
line to the clevis on the lifting sling.
2. Ensure that lifters stand in the same position as when they carried the tool to the rig.
3. When all lifters assume the lifting position, lift the tool to body-waist level.
4. Using the winch line, start lifting the tool.
5. When the tool leaves the first lifter's hand, beginning at the front of the tool, start walking towards the
rig while guiding the tool to its lifting position.
Note
Keep tension on the tool by pulling it in the opposite

direction against the winch line. Avoid using excessive
amounts of time or stopping while lifting the tool to alleviate
stress on the tool.
6. When the tool goes into the mast, continue observing it to ensure that the tool or winch line is not
caught in the blocks, top drive, or pipe on the derrick.
7. Ensure that the bottom-end of the tool does not drag on the ground, down the catwalk, or get banged
against the V-door or Sub.
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Loading the Tool into the Collar
To load the tool into the collar, complete the following steps:
1. When the tool is on the rig floor, remove the stinger protector.
2. Walk the tool over to the stump (battery collar sitting in the slips).
3. Insert the tool into the battery collar and lower the tool down.
For measurements to properly seat the tool, refer to the “MWD Tool Measurements”
in this chapter, page 8-1. The tool should seat below the box connection of the
battery collar.
4. Lower the tool down until the lifting sling attachment is seated on the shoulder of the battery collar.
Figure 8-17. Lowering Tool for Seating
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5. Maintain slack in the winch line.
Figure 8-18. Winch Line with Slack
6. Remove the hook from the clevis (lifting the sling).
Figure 8-19. Remove Hook from Lifting Sling
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7. Secure the J-latch to the top contact.
Figure 8-20. J-Latch and Clevis
Figure 8-21. Securing J-Latch
8. Attach the hook to the J-latch.

9. Pull up on the tool with the winch line until the pressure is off the lifting sling.
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10. Remove the locking and drop pin.
Figure 8-22. Removing Locking and Drop Pins
11. Remove lifting sling.
Figure 8-23. Removing Lifting Sling
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Verifying that the Tool is Seated
To verify that the tool is seated, complete the following steps:

1. Lower the tool into the battery collar until there is slack in the winch line and the seating position
marks match.
Figure 8-24. Seating Alignment Marking
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2. If the seating marks line up properly, scribe a line from the tool highside mark to the OD of the
battery collar.
Figure 8-25. Highside and Seating Marks
3. Pull the tool 1m (3 ft.) out of the battery collar and turn it clockwise so that the highside mark on the
tool is 90 degrees off the highside mark of the battery collar.
4. Lower the tool back into the collar. The highside mark should turn back to the corresponding mark on
the OD of the battery collar and drop. Both, the highside and seating marks should be aligned.
Figure 8-26. Seating and Highside Alignment
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5. Using a tape measure, measure the distance from the top of the tool to the top of the box connection
of the battery collar for the final verification.
Figure 8-27. Measure Seating Alignment
Note
Using the MWD Measurement formula example provided

early in the section titled "Measuring the Tool Length and
Collars" on page 8-209 in this chapter, the distance from
the top of the tool to the top of the box connection of the
battery collar should be 0.30m.
6. When the tool is properly seated, continue making up the BHA.
Note
Another method used to ensure that the tool is properly

seated is to insert pipe chalk or grease into the slot of the
stinger and run the tool to where it is approximately seated
and then pull the tool out to see if there is an indention in
the chalk or grease from the key in the UBHO Sleeve.
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Shop Maintenance and Service
Installing SQL Server Express
Install SQL Server Express (current version) before installing the BlackStar EM Suite.
SQL Server Express can be downloaded from the NOV FTP site or the Microsoft web site. Depending on
the Operating System, you may have to download the 32-bit or the 64-bit version.
To install SQLServer Express, complete the following steps:
1. Launch the SQL Server Install Program from the appropriate location. The SQL Server installation
Center dialog window opens (Figure 9-1).
Figure 9-1. SQL Server Installation Center Dialog Window
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Shop Maintenance and Service 9
2. Click the New SQL Server stand-alone installation or add features to an existing installation
option (Figure 9-2).
Figure 9-2. SQL Server Setup
3. Ensure that all Setup Support Rules display Passed in the Status column. In the Rule column, if
the Windows Firewall displays Warning, ignore that status. BlackStar uses SQL Server Express
as a desktop database and the firewall is not an issue.
4. Click Next.
5. If errors occur on any Rules, ensure to correct those errors before proceeding. Mostly, these errors
can be resolved by installing required Microsoft software components which can be downloaded
directly from the Microsoft web site www.microsoft.com.
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6. After installing the required Microsoft software components, click the Re-run button located to the
right of the Hide details button. The SQL Server Setup - Product Key dialog window opens
(Figure 9-3).
Figure 9-3. SQL Server Setup - Product Key Dialog Window
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7. Click Next. The SQL Server Setup - License Terms dialog window opens (Figure 9-4).
Figure 9-4. SQL Server Setup - Licence Terms Dialog Window
8. Check the box next to the I accept the license terms field.
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9. Click Next. The SQL Server Setup - Feature Selection dialog window opens (Figure 9-5).
Figure 9-5. SQL Server Setup - Feature Selection Dialog Window
10. Ensure that the following check boxes under the Instance Features option are checked.
 Database Engine Services
 SQL Server Replication
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11. Click Next to proceed. The SQL Server Setup - Instance Configuration dialog window opens
(Figure 9-6).
Figure 9-6. SQL Server Setup - Instance Configuration
12. Select the Named Instance option and type SQLExpress in the edit field.
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13. Click Next. The SQL Server Setup - Disk Space Requirements dialog window opens
(Figure 9-7).
Figure 9-7. SQL Server Setup - Disk Space Requirements Dialog Window
14. Click Next. The SQL Server Setup - Server Configuration dialog window opens (Figure 9-8).
Figure 9-8. SQL Server Setup - Server Configuration Dialog Window
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15. Click the down-arrow under the Account Name field and select SQL Server Database Engine
Account Name as the NT Authority\System.
16. Click Next. The Database Engine Configuration dialog window opens (Figure 9-9).
Figure 9-9. Database Engine Configuration Dialog Window
17. Select the Windows Authentication Mode option and then click the Add Current User button if no
user is listed in the Specify SQL Server Administrators field.
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18. Click Next to continue. The SQL Server Setup - Error and Usage Reporting dialog window opens
(Figure 9-10).
Figure 9-10. The SQL Server Setup - Error and Usage Reporting Dialog Window
19. Click Next. The SQL Server Setup - Installation Rules dialog window opens (Figure 9-11).
Figure 9-11. SQL Server Setup - Installation Rules Dialog Window
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20. Click Next. The SQL Server Setup - Ready to Install dialog window opens (Figure 9-12).
Figure 9-12. SQL Server Setup - Ready to Install Dialog Window
21. Click the Install button. The SQL Server Setup - Installation Progress dialog window displays the
installation progress (Figure 9-13).
Figure 9-13. SQL Server Setup - Installation Progress Dialog Window
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22. If the installation is successful the Install Success message window displays. Click Next. The SQL
Server Installation Center main dialog window opens (Figure 9-14).
Figure 9-14. SQL Server Installation Center Main Dialog Window
23. Click the Search for Product Updates option to ensure that your computer is up-to-date with the
latest SQL Server update.
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Setting Up the Laptop Computer for BlackStar EM Suite

Software
To set up the laptop computer for installing the BlackStar EM Suite software, complete the following steps:
1. Ensure that the laptop battery is in good working condition.
2. When running BlackStar EM Suite software, ensure that the laptop is powered via an AC outlet and
configure the power setting using the power setting procedure below to ensure that there is no loss
of power during the installation process.
Configuring Power Settings for Windows XP

To configure power settings for Windows XP operating system, complete the following steps:
1. Click Start>Control Panel. The Control Panel main dialog window opens (Figure 9-15 ).
Figure 9-15. Windows Control Panel Main Dialog Window
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2. Double-click the Power Options icon. The Power Options Properties dialog window opens (Figure
9-16).
Figure 9-16. Windows Power Options Dialog Window
3. In the Settings for Portable/Laptop Power Scheme field, select the parameter settings as
described in Table 1 and 2 below:
Table 1. Settings for Laptop Powered by AC Outlet T
Parameter Settings
Turn Off Monitor Never
Turn Off Hard Disks Never
System Standby Never
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Table 2. Settings for Laptop Powered by Battery T
Parameter Settings
Turn Off Monitor Never
Turn Off Hard Disks Never
System Standby Never
4. In the Power Options Properties dialog window, click the Hibernate tab. The following dialog
window displays:
Figure 9-17. Select Laptop Hibernation Settings
5. In the Hibernate field, ensure that the check box next to the Enable Hibernation option is
unchecked.
Depending on the laptop computer’s manufacturer, there may be other power management features
provided. Ensure that the computer peripherals (i.e., hard drive, ethernet card, etc.) are turned on when
running the computer on battery power.
To ensure that computer peripherals are enabled, complete the following steps:
1. Open the Device Manager ands select Ethernet Card.
2. Check the properties.
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3. Under Power Management, ensure that when on, the Battery Power Ethernet Card is never
turned off.
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Installing the BlackStar EM Suite
The following system requirements are necessary to install the BlackStar EM Suite:
BlackStar EM Suite 3.16.1 or Higher System

Requirements
RAM
 Minimum: 512 MB
 Recommended: 1GB
Hard Disk Space

A requirement of at least 600 MB of free space is recommended.
Processor
The processor should be Pentium III compatible or higher. Refer to the following recommendations.
 Minimum: 600 MHz
 Recommended: 1 GHz or higher
Hardware
 CD ROM or DVD ROM
 The DCA requires a USB 2.0 connection port
 The SCA requires a LAN 10/100 Base T connection port
 Serial Port: Db9 Connection
Operating Systems
The following operating systems are recommended for running the BlackStar EM Suite.
 Windows XP Professional SP2 or higher
 Windows 2000 Professional Edition SP4
 Windows Vista Business SP1 or higher
 Windows Seven
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Note:
If running Windows Vista or Windows 7, 2GB of RAM is

recommended.
Installing on Windows Vista/Windows 7

If installing Blackstar EM Suite on Windows Vista, disable User Account Control (UAC).
1. Open Control Panel.
2. Click User Accounts and then click Turn User Account Control On to Off.
3. Restart the computer.
Options for Installing BlackStar EM Suite
Install from CD
If you are installing BlackStar EM Suite on a computer for the first time, run Prerequisite using the
following procedure:
1. Insert the CD labeled BlackStar EM Suite into your CD-ROM drive. The BlackStar EM MWD Tools
Setup dialog window opens.
Figure 9-18. BlackStar EM Suite Setup Installation Dialog Window
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2. Click Install Prerequisites.

3. When installing SQLServer Express, select Windows Authentication.
4. Following the successful installation of Prerequisites, click Install BlackStar EM Suite.
Install Without Auto Start

To install the BlackStar EM Suite, complete the following steps:
1. From the BlackStar EM Suite CD, navigate to the PreReq folder and run Setup.exe.
2. When installing SQLServer Express, select Windows Authentication.
3. After installing the prerequisites, navigate to the BlackStar folder.
4. Run Setup to install the BlackStar EM Suite.
Install from FTP Download
To install BlackStarEMSuite from the FTP site, complete the following steps:
1. Download BlackStarEMSuite.exe from EMSuite 9.99.9 folder, where 9.99.9 is the version number.
2. If installing BlackStarEMSuite on a computer for the first time, the user will need to download the
following files from the EMSuitePreReq folder.
a. WindowsInstaller-KB893803-v2-x86.exe
b. Dotnetfx.exe
c. SQLEXPR_ADV.exe
3. Uninstall the previous BlackStarEMSuite by following steps 1 through 8 in the Re-Installing
BalckStarEMSuite section.
4. If installing the BlackStar software for the first time, it may be necessary to install
WindowsInstaller-KB893803-v2-x86.exe and/or Dotnetfx.exe depending upon the user’s
operating system version. Windows prompts the user to decide if an update is needed or not when
running item A and/or B.
5. If installing SQL Server Express, select Windows Authentication. Select the default selections on
the remaining windows while installing. Ensure that the server name is SQLEXPRESS. The Server
name should be preceded with the computer name which is selected by default.
6. Now install the BlackStarEMSuite by running BlackStarEMSuite.exe.
7. After installing the BlackStar EM Suite, click
Start>Programs>BlackStarEMSuite>Utilities>Database Utility.
8. From the Database Utility window, click Initialize to initialize the database for the BlackStar EM
Suite.
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Re-installing the BlackStar EM Suite
1. Uninstall BlackStar EM Suite x.xx.x.

2. Run SQL Server Management Studio Express.
3. Click All Programs>Microsoft SQL Server 2005>SQL Server Management Studio Express.
4. Click Connect. The current database server displays.
5. Open the “Databases” folder.
6. Select BlackStar.
7. From the “Edit” menu, click Delete. The “Delete Object” window displays.
8. Click OK. Now you can reinstall the BlackStar EM Suite.
9. After installing the BlackStar EM Suite, click
Start>Programs>BlackStarEMSuite>Utilities>Database Utility.
10. From the “Database Utility” window, click Initialize to initialize the database for the BlackStar EM
Suite.
Software Release
To download the latest software release, follow the directions below.

1. Go to the following address in your internet browser:
ftp://software_eng@ftp.nov.com. The user will be prompted to enter the following Username and
Password.
Username: software_eng
Password: software
2. Navigate to the EMSuite99.99.9 folder. Only the current version is posted on this site.
Refer to releasenotes.txt for software revisions since the previous release. The file
can also be located in the …\BlackStarEMSuite\Programs folder once the
software is installed.
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Updating the Dual Channel Amplifier (DCA) Software
To update the DCA software, complete the following steps:

1. Connect the DCA to the computer.
2. Wait for the computer to recognize the DCA.
3. Click Start>Programs>BlackStar EM Suite>Utilities>DCA Update. The DSP Flash Programmer
window opens.
Figure 9-19. DSP Flash Programmer
4. From DSP Flash Programmer window, click Browse. Wait until the computer searches for the DCA
board.
5. Select the PSK.out file from C:\Program Files\BlackStarEMSuite\RcvrFirmware folder.
Note
Depending on where the BlackStarEM SuiteC:\Program

File is installed, parts of the path may vary.
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6. Click Program. The Program Flash confirmation window opens.
Figure 9-20. Program Flash Memory
7. Click Yes to proceed. You can observe the download progress.

8. When the download is complete, click Close.
9. Restart the DCA.
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Servicing the Battery Bulkhead
Figure 9-21. Battery Bulkhead
Tools and Supplies Required
The following tools and supplies are needed to perform this procedure.
 Dow-111
 Loctite 242, medium strength thread locker
 2-220 o-rings, 2 each
 2-218 o-rings, 2 each
 Torque wrench
 Brass o-ring removal tool
 7/8th inch socket with ½ inch drive
 Corded impact wrench with ½ inch drive
 Wrench, collar retaining, NOV part number 393-226-01
 Petol vise with 1-7/8th inch pillow blocks
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Servicing the Battery Bulkhead
1. Using the Petol vise, clamp down on the male half of the battery bulkhead.
Figure 9-22. Battery Bulkhead Female View
2. Insert the collar-retaining wrench inside the female end of the bulkhead, ensuring that the teeth on
the collar-retaining wrench are aligned with the collar inside the bulkhead.
Figure 9-23. Collar Retaining Wrench
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3. Attach the 7/8th-inch socket and the impact wrench to the end of the collar retaining wrench.
Figure 9-24. Collar Retaining Wrench
4. The collar is reverse threaded. Turn clockwise to loosen the collar. Once the collar is off, slide the
sleeve off the bulkhead. The bulkhead should now be in three pieces.
Figure 9-25. Bulkhead Breakdown
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5. Replace o-rings with size 2-219 o-rings. Lube the o-rings with Dow-111. Apply a light coat of Loctite
242 medium-strength thread locker as indicated in the illustration below.
Figure 9-26. Replacing O-rings
6. Replace the sleeve and then the collar.

Note
Do NOT use the impact wrench.
Note
The collar is reverse threaded. To tighten, turn counter-

clockwise.
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7. Place a torque wrench with the 7/8 inch socket on the end of the collar-retaining wrench. Tighten to
75 ft./lbs.
Figure 9-27. Torque Collar
8. On the male-end of the bulkhead, replace the two o-rings with size 2-220 o-rings.
Figure 9-28. Bulkhead O-ring Replacement
9. Lube with Dow-111.
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Reference Drawing
For detailed information, refer to the Bulkhead Service Specification Drawing (300-015-01) in Appendix A
of this manual.
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Testing the Battery-to-Battery Centralizer
For detailed information, refer to the “Wiring Schematic (305-293-20),” and Drawing
(301-293-19), in Appendix A of this manual.
Tools and Supplies
To test the Battery Centralizer, the following tools are required:

 Fluke Meter
 Needle Points
Figure 9-29. Battery-to-Battery Centralizer
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Use the following procedure to test the battery centralizer.

1. Dial to the continuity setting on the fluke meter.
Figure 9-30. Battery Centralizer Testing Equipment
2. Locate pin one on the ten-pen connection side of the battery centralizer.
Figure 9-31. Transmitter and Lemo Connection
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3. Touch the black lead to pin one and touch the red lead to the brass shield (inner ring) of the lemo
connection. Upon touching the pin one, a listen for a beep to sound.
Figure 9-32. Testing Pin 1 and Lead to Brass Shield (Inner Ring)
4. Touch the black lead to pin two, and touch the red lead to the center pin of the lemo connection.
Upon touching pin two, listen for a beep to sound.
Figure 9-33. Red Lead to Center Pin
5. Touch black lead to pin five, and touch red lead to the silver aluminum ground shield (outer ring) of
the lemo connection. Upon touching pin five, listen for another beep.
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6. Touch black lead to pin six and touch the red lead to the silver aluminum ground shield (outer ring) of
the lemo connection. When touching pin six, listen for the beep.
Figure 9-34. Lead to Center Pin
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Testing the Battery Bulkhead
Figure 9-35. Battery Bulkhead Testing
To test the Battery Bulkhead, the following parts, tools, and/or supplies are required.
 The Battery Bulkhead
 A Fluke Meter
 Needle Points
Figure 9-36. Testing Meter
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Use the following procedure to test the battery bulkhead.

1. Dial to the continuity setting on the fluke meter. Refer to the wiring schematic in the previous section.
2. Locate pin one on the transmitter side.
Figure 9-37. Transmitter Connection
3. Locate pin one on the 15-pin connection side of the battery bulkhead.
Figure 9-38. Battery Connection
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4. Switch the dial on the fluke meter to the Continuity setting.
Figure 9-39. Setting the Fluke Meter Dial
5. Touch red lead to pin one on the transmitter-side connection at the same time you touch the black
lead to pin one on the battery-side connection. When the connection is made, a beep should sound.
6. Switch dial on the multimeter to the Ohms setting.
7. Using the lead needle points touch red lead to pin one on the transmitter-side connection at the
same time that you touch the black lead to pin one on the battery-side connection. The ohms should
read 0.1 (a different ohms reading will display depending on the type of meter being used). This
ensures continuity.
8. Continue testing all ten pins.
9. Move counter clockwise on the transmitter-side connection.
10. Move left to right on the top row of the battery-side connection. Pins 9 and 10 will be on the bottom.
Continue moving from the left side to the right side.
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Downhole Tool Firmware Upgrade
Note
When reprogramming a transmitter it is necessary to

connect the transmitter to a directional sensor before
starting firmware download sequence.
1. Run EMXConfig. When prompted to enter the Terminal mode, press the [F2] key.
2. Click Program Loader menu and select MCM from the terminal menu. The Program MCM window
displays as shown below:
Figure 9-40. Program MCM Dialog Window
3. Select the Module type (Transmitter or PTG) for Transmitter or Gamma.

4. Enter the correct serial number using four digits. (Example 0175)
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5. If programming a transmitter, select the Open Circuit Voltage (OCV) voltage setting. When using
the Triple-Output Transmitter, select the 3-6-12 setting.
6. Select the program file by clicking the Browse ( ) button.

7. Click Start. Program MCM prompts the user to use the Red Programming Dongle (371-146-05).
8. Follow the programming steps in the Program MCM window.
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Changing Internal O-rings
This section describes how to replace internal o-rings in the following components of the EM EWM Tool.
 The Transmitter Assembly
 The Directional Sensor Assembly
 The Gamma PTG Tool Assembly
Recommended Tools and Supplies
To perform procedures described in this section of the manual, use only the following recommended tools
and supplies. Using non-recommended tools and/or supplies when performing the following procedures
may void warranties on the tool.
Table 9-1. Recommended Tools and Supplies to Change Internal O-rings
Item Qty Part Numbers
Blue Loctite 1 11200
Dow 111 Corning Grease- Lubricant Compound 1 11779
3.0 x 6mm Flat Screw Driver 1 Not Listed
7/64 Ball-end Allen Key 1 Not Listed
Spanner Wrench - 1/4” Pin 1 114379
Spanner Wrench - Heavy Duty 1.875 1 391-112-01
Parmelee Wrench 1 11497
2-220 O-rings 4 10122
2-219 O-rings 4 114709
Jack Screws 2 10071
O-ring Tool 1 11780
Lacing Twine 1 Not Listed
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Change the Transmitter Assembly O-rings
The information in this section describes how to disassemble the Transmitter Assembly, change old or
worn o-rings, and reassemble the sub assembly components.
Transmitter Assembly Components

The Transmitter Assembly contains the following components:
 Bow Spring Collet Assembly
 Pressure Housing
 Internal Electronics (includes the cable harness)
 Gap Sub Assembly
Figure 9-41. Transmitter Assembly Components
Note
When replacing o-rings throughout the transmitter

assembly, leave assembly components disengaged until all
o-ring are replaced if necessary.
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Disassemble the Bow-Spring Collet Assembly

This section describes how to disassemble the Bow-Spring Collet Assembly and how to replace old or
worn o-rings in the assembly.
Important Note
To disassemble the transmitter components, start the

breakdown at the bow-spring collet first.
Caution
!
When breaking down the tool, turn all parts counter-
clockwise to avoid the risk of damaging the tool threads.
1. Attach spanner wrench to the bow-spring collet component and the parmelee wrench to the
pressure-housing component.
Figure 9-42. Attach Hand Tools
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2. Using the spanner wrench, turn counter-clockwise until the bow-spring collet component is
disengaged from the pressure-housing component.
Figure 9-43. Disengage Bow-Spring Collet from the Pressure-Housing
3. Unscrew the jack screws from jack screw posts on the wiring harness connection.
Jack Screw Posts
Wiring Harness Connection
Figure 9-44. Jack Screw Post and Wiring Harness Connection
4. Disconnect the wiring harness from the bow-spring collet connection.
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Remove Old O-rings from the Bow-Spring Collet

Using an o-ring tool, remove old o-rings from the bow-spring collet assembly.
Figure 9-45. Removing Old O-rings from Box-spring Collet Assembly
Replace O-rings on the Bow-Spring Collet

To replace o-rings on the Bow-Spring Collet, complete the following steps:
1. Install two new 2-220 o-rings on the bow-spring collet assembly using the o-ring installation tool and
lacing twine.
2. Apply Dow 111 Grease to two 2-220 o-rings.
3. Grease the bow-spring collet threads.
Note
Set aside the bow-spring collet assembly component until

you are ready to reassemble.
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Disassemble the Gap Sub Assembly

To disassemble the Gap Sub Assembly, complete the following steps:
Note
The collet assembly must be removed before this step 1.
1. Using two parmelee wrenches, attach one to the pressure-housing component and one to the gap
sub component.
Figure 9-46. Attaching Hand Tools
Caution
!
clockwise to avoid damaging the tool.
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2. Turn counter-clockwise until the gap sub assembly is disengaged from the pressure-housing
component.
Figure 9-47. Removing Internal Electronics from Pressure Housing
Replace O-rings on the Gap Sub Assembly

To replace o-rings on the Gap Sub Assembly, complete the following steps:
1. Using an o-ring tool, remove the 2-220 o-rings and the 2-219 o-rings.
2. Install the new or-rings in the appropriate locations on the gap sub.
3. Apply Dow 111 grease to o-rings and threads on the gap sub.
Figure 9-48. Gap Sub O-rings
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Reassemble Gap Sub Component to Transmitter Assembly

To reassemble the Gap Sub Component to the Transmitter Assembly, complete the following steps:
1. Insert the gap sub electronics components back into the pressure-housing component.
Figure 9-49. Reassembling Gap Sub Component to Pressure Housing Component
2. Turn the gap sub assembly clockwise to engage with the pressure-housing component.
Caution
!
Use caution when engaging gap sub components to
pressure housing component to avoid damaging the
threads and cable harness.
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3. Attach parmelee wrenches to the pressure-hosing component and to the gap sub component as
shown below.
4. Using parmelee wrenches, torque to 175 ft./lbs.
Reassemble the Cable Wiring Harness

To reassemble the Cable Wiring Harness, complete the following steps:
1. Apply Blue Loctite to jack screws.
2. Reconnect the wiring harness to the bow-spring collet.
3. Insert jack screws in the jack post and tighten using the appropriate screw driver.
Figure 9-51. Wiring Harness Components
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Reassemble Bow-Spring Collet to Pressure Housing

To reassemble the Bow-Spring Collet to the Pressure Housing, complete the following steps:
1. Twist the harness three to four revolutions, counter clockwise before re-engaging the assembly into
the pressure housing.
Figure 9-52. Wiring Harness Connection
2. Re-engage the bow-spring collet into the pressure-housing component until the threads are fully
engaged.
Figure 9-53. Reconnecting the Bow-Spring Collet to Pressure Housing
3. Turn the bow-spring collet assembly clockwise to tighten to the pressure-housing component.
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4. Using spanner and parmelee wrenches, torque to 175 ft./lbs.

Attach Spanner Wrench
Attach Parmelee
Figure 9-54. Reassembled Bow-Spring Collet Assembly to Pressure Housing
Changing O-rings on the Transmitter Gap Sub Assembly

To change the o-rings on the Transmitter Gap Sub Assembly, complete the following steps:
Transmitter Internal Electronics Gap Sub Assembly
Figure 9-55. Transmitter Gap Sub Assembly
1. Refer to the Changing Internal O-rings in the Transmitter Assembly section of this document to
disassemble the transmitter components.
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Note
There are only four screws to remove to disconnect the

Transmitter Internal Electronics component from the Gap
Sub Assembly.
Note
Remove the RTV coating to access the screws.
2. Remove the four screws to detach the transmitter gap sub assembly from the internal electronics
component as indicated in the figure below.
Figure 9-56. Removing Screws
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3. Disconnect the internal electronics component from the transmitter gap-sub assembly.
Internal Electronics Gap Sub Assembly
Figure 9-57. Disconnect Internal Electronics from Gap Sub Assembly
4. Replace Gap Sub o-rings and reconnect to the internal electronics component.
Note
To change o-rings on the Triple-Output Transmitter, refer to

the following instructions and illustrations to disassemble,
change gap-sub o-rings, and then reassemble the internal
electronic component to the gap-sub.
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Change O-rings on the Triple-Output Transmitter (Gap-Sub Assembly)

Refer to Changing Internal O-rings in the Transmitter Assembly section of this document, with the
exception of the following slight difference in changing the gap-sub assembly o-rings.
Note
There are only four screws to remove to disconnect the

TOT Internal Electronics component from the Gap Sub
Assembly.
Note
Remove the RTV coating to access the screws.
1. Remove the four screws (on both sides) to detach the transmitter gap sub assembly from the internal
electronics component as indicated in the figures below.
Figure 9-58. Remove Screws from TOT Electronics Component
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2. Disconnect the Internal Electronics component from the TOT gap-sub component.
Figure 9-59. Disengaged TOT Assembly
3. Change the o-rings (follow the same instructions as detailed in Changing O-rings on the Directional
Only Transmitter in this manual.
4. Reconnect the TOT gap sub assembly to the internal electronics component.
5. Replace the four screws and tighten to secure connection.
Note
Use blue loctite on the threads of the screws and apply a

new coat of RTV over the screws.
6. Reverse the order of this procedure to reassemble the transmitter components.
Change the Directional Sensor Assembly O-rings

To change the Directional Sensor Assembly O-rings, complete the following steps:
Directional Sensor Assembly Components

 Cross-Over Sub
 Pressure-Housing
 Internal Electronics (Cable Harness)
 Snubber Centralizer
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Figure 9-60. Directional Sensor Assembly Components

Note
When replacing o-rings throughout the directional sensor

assembly, leave assembly components disengaged until all
o-rings are replaced if necessary.
Disassemble the Cross-Over Sub Assembly

To disassemble the Cross-over Sub Assembly, complete the following steps:
Important Note
To disassemble the directional sensor, start with the cross-

over component first.
Caution
!
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1. Attach wrenches on the cross-over and the pressure housing components as illustrated below.
2. Using the spanner wrench, turn counter-clockwise until the cross-over component is disengaged
from the pressure-housing component.
Note
Be careful when pulling the cross-over assembly from the

pressure housing to avoid damaging the cable harness.
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3. Disconnect the cable harness from the cross-over sub assembly.

a. Unscrew both jack screws until fully disengaged.
b. Disconnect cable wiring harness connection from the cross-over connection.
Figure 9-62. Disconnecting Wiring Harness from Cross-Over Sub Assembly
4. On the Cross-Over Sub Assembly, attach hand tools where indicated below.
Figure 9-63. Attaching Hand Tools on Cross-Over Sub Assembly
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5. Secure the cross-over sub assembly in a petol-vice and use the pin wrench to remove the fin
assembly from the sleeve.
Figure 9-64. Removing Fin Assembly from Sleeve
Replace O-rings on the Cross-Over Sub Assembly

To replace o-rings on the Cross-over Sub Assembly, complete the following steps:
1. Apply Dow 111 grease to both 2-220 o-rings and threads.
2. Install new o-rings on the cross-over sub.
3. Reinstall the sleeve onto the fin assembly. Torque to 175 ft/lbs.
Note
After changing the o-rings on the cross-over assembly, set

the cross-over component aside until all o-rings throughout
the directional sensor component are changed if
necessary.
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Change the O-rings on the Snubber Centralizer

To change the o-rings on the Snubber Centralizer, complete the following steps:
1. Attach parmelee wrenches where indicated below.
Figure 9-65. Attaching Hand Tools to Snubber Centralizer
2. Using a spanner wrench, turn components counter clock-wise until the snubber centralizer
disengages from the pressure-housing component.
3. Holding the snubber centralizer, slide the internal electronic component out of the pressure-housing
component. The internal electronics component is exposed.
Figure 9-66. Internal Electronic’s O-rings
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Warning
Do not attempt to change o-rings on the internal

electronics component. Contact Technical Services at
National Oilwell Varco if it is necessary to change
these o-rings. Contact information is provided in
Chapter 10 of this manual.
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Replace O-rings on the Snubber Centralizer

To replace o-rings on the Snubber Centralizer, complete the following steps:
Figure 9-67. Snubber Centralizer O-rings
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1. Using the o-ring tool, grasp and lift old o-rings from the snubber centralizer.
2. Grease two 2-220 o-rings and the threads on the snubber centralizer with Dow 111 grease.
3. Slide both o-rings (one at a time) from the snubber centralizer using lacing twine to guide and adjust
o-rings to fit appropriately.
4. Reconnect internal electronics component to snubber centralizer and insert and tighten screws.
Reassemble the Snubber Centralizer to Pressure Housing Component

To reassemble the Snubber Centralizer tot he Pressure Housing Component, complete the following steps:
1. Insert the internal electronic component back into the pressure housing.
2. Attach parmelee wrenches to snubber centralizer and pressure-housing.
3. Turn clockwise until ends are fully engaged.
4. Tighten the snubber centralizer to the pressure-housing component.
5. Torque at 175 ft/lbs.
Reassemble the Cable Harness Wiring Connection

To reassemble the Cable Harness Wiring Connection, complete the following steps:
1. Apply blue Loctite to jack screws and insert jack screws into connection posts.
Figure 9-68. Cable Harness Wiring Connector
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2. Reconnect the wiring harness connection from the cross-over sub assembly to the wiring cable from
the internal electronics component attached to the snubber centralizer.
Figure 9-69. Internal Electronics Connection
3. Tighten screws using the appropriate screw driver.
Reassemble Cross-Over Sub Assembly to Pressure Housing Component
To reassemble the Cross-over Sub Assembly, to the Pressure Housing component, complete the following
steps:
1. Twist the snubber centralizer assembly harness three to four revolutions counter clock-wise before
engaging the pressure-housing to cross-over sub assembly.
Note
Twisting the harness counter clock-wise is preformed to

alleviate twisting tension of the cable wiring harness
connection.
2. Re-engage the cross-over sub assembly with pressure-housing component.

3. Turn clockwise to tighten.
4. Torque to 175 ft/lbs.
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Change O-rings in the Gamma (PTG) Tool Assembly
To change the o-rings in the Gamma (PTG) Tool Assembly, complete the following steps:
Gamma Tool Components

 Upper Bulkhead
 Upper Pressure Housing
 Internal Electronics
 Lower Pressure Housing
Figure 9-70. Gamma (PTG) Assembly Components
Caution
!
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Follow the instructions below to break down the gamma (PTG) tool.
1. Attach the parmelee wrenches to the tool where illustrated below:
Figure 9-71. Attaching Hand Tools to Gamma Battery Bulkhead Sub Assembly
2. Use the spanner wrench to hold the bulkhead in place and remove the lower end of the pressure-
housing with a gear wrench.
3. Replace two 2-010 o-rings, two 2-218 o-rings, and one 2-220 o-ring where indicated in Figure 9-55.
Apply a light coat of Dow 111 to the o-rings. Do not remove any of the o-rings on the internal
electronics component.
Figure 9-72. O-ring Placement on Gamma Battery Bulkhead Sub Assembly
4. Replace the lower housing and re-torque to 175 ft./lbs.
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5. Break the upper bulkhead assembly from the upper pressure-housing where indicated in
Figure 9-56 below.
Figure 9-73. Breaking Down Upper Bulkhead Sub Assembly from Upper Pressure Housing
6. Carefully untwist the harness and disconnect the harness by unscrewing the jack screws where
indicated in Figure 9-57. Replace the o-rings on the bulkhead with two 2-220 o-rings and lube with a
light coat of Dow 111.
Figure 9-74. Battery Bulkhead O-ring Placement
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7. Place the upper pressure-housing in a petol vice and use a heavy duty pin-wrench to loosen the
bulkhead from the upper pressure-housing.
Figure 9-75. Pin-Wrench Hand Tool Placement
8. Carefully slide the electronics out of the housing.
Figure 9-76. Removing Internal Electronics Component
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9. Replace the two 2-220 o-rings by carefully sliding the new o-rings over the harness and electronics
module. Coat the o-rings with a light coat of Dow 111.
Figure 9-77. Replace 2-220 O-rings
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Reassemble the Gamma Tool
To reassemble the Gamma tool, complete the following steps:

1. Slide the electronics back into the upper pressure-housing.
2. Torque the lower housing onto the upper housing at 175 ft./lbs.
3. Place Loctite 242 medium-strength on the pigtail jack screws and reconnect it to the gamma
bulkhead.
Figure 9-78. Reconnecting the Cable Wiring Harness Connection
4. With the bulkhead attached to the pigtail, twist the bulkhead counter-clockwise five times to alleviate
any excess stress on the harness when tightening the bulkhead to the upper pressure housing.
5. With the bulkhead, engage the threads of the upper pressure-housing and turn clockwise.
Caution
!
Use caution when turning components to avoid cross-
threading or damaging tool components.
6. Torque the bulkhead to the pressure-housing at 175 ft./lbs.
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Servicing the BlackStar Single Channel

Amplifier (SCA)
To service the SCA, complete the following steps:

1. Ensure that the power is OFF to the amplifier and that the power cord is disconnected.
Figure 9-79. SCA (Back View)
Four (832) 4 x 8 screws hold the cover in place on each side of the surface amplifier.
Figure 9-80. SCA (Side View)
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2. Remove the four screws from each side of the amplifier.
Figure 9-81. Removing Outer Case Screws
3. Remove the amplifier cover. The amplifier’s internal components are exposed.
Figure 9-82. SCA Internal Components
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4. Remove the two screws (1032) holding the retaining clamp in place.
Figure 9-83. SCA Retaining Clamp
5. Remove the five (632) screws as shown in Figure 9-67 below:
Figure 9-84. Retaining Screws
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6. Pull and re-seat the DSP board.
Figure 9-85. DSP Board
7. Pull and re-seat the Single Board Computer (SBC).
Figure 9-86. Single Board Computer
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8. Pull and re-seat the Hard Drive PC board.
Figure 9-87. Hard Drive
9. Check the PC processor fan to ensure that it is working properly when the board is secured and
powered up.
Figure 9-88. PC Processor
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10. Ensure that all the connections are secured properly.
Figure 9-89. Old Style - Outside Connection
Figure 9-90. Old Style Single Channel Inside Connection
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Figure 9-91. New Style Single Channel Amplifier
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Computer Power and Cooling Fan
Warning
Before connecting the power cable and turning the

power on the amplifier, ensure that you move your
hands, wiring, tools, or any other objects away from
the fan.
Figure 9-92. Computer Power and Cooling Fan
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Cleaning the Amplifier Internal Components
Use the following guidelines when cleaning the amplifier internal components:
 Never spray or squirt any type liquid onto the amplifier components. If a spray is
needed, spray the liquid onto a cloth and then use that cloth to rub down the
component.
 Never get any component inside the computer or any other circuit board damp or
wet.
 Spray the circuit boards with a compressed gas duster. You can purchase
compressed gas duster from any office supply store. Spray it over the motherboard
to remove any loose dust or debris that may be caught in the circuit boards.
 Use compressed air only to clean filter and the cover. Do not use compress air to
clean the inside of the amplifier.
Warning
Do not use regular compressed air to clean electronic

parts.
 Clean or replace the filter cover.
Figure 9-93. Computer Cooling Fan and Filter Cover
303
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D9A1000051-MAN-001
Page 304 of 304
Testing the BlackStar Surface Amplifier
When testing the BlackStar Surface Amplifier, complete the following steps:
1. Connect the 15-pin Monitor Cable to the BlackStar Surface Amplifier.
Figure 9-94. Monitor Cable Connection
2. Turn on the amplifier power. The EMServeX window should display as illustrated below:
Figure 9-95. EMServeX Window
If the EMServerX Window fails to display as illustrated in Figure 9-78 above, the amplifier is
malfunctioning and should be returned to National Oilwell Varco for service and repair. See
Chapter 10 in this manual for Product Support Contact information.
304
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D9A1000051-MAN-001
Revision E
Page 305 of 306
Product Support Information
Technical Support
Office: 10302 Mula Rd
Stafford TX 77477
Phone: 281-568-1336
Fax: 281-568-1405
305
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D811001123-GEN-001/04
D9A1000051-MAN-001
Revision E
Page 306 of 306
Product Support Information 10
306
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D9A1000051-MAN-001
Revision E
Page A-1 of 2
Drawings and Schematics
List of Drawings and Schematics

Table A-1 Referenced Drawings and Schematic, list drawings and schematics referred to in this manual.
Table A-1. Referenced Drawings and Schematics
Drawing or Schematic Drawing or Schematic Name

Number
301-605-03 Battery Bulkhead Drawing Assembly
305-605-03 Battery Bulkhead Schematic
301-293-19 Battery-to-Battery Centralizer Assembly
305-293-20 Battery-to-Battery Schematic
301-433-08 Contact Collet Sub Assembly
301-324-04 Contact Spring Assembly
301-324-14 Contact Sub Assembly Flat Bow Spring
301-137-03 Housing Assembly, Transmitter Battery
301-282-14 Transmitter Assembly
301-284--04 Directional Sensor Assembly
301-286-09 Gamma Pressure Assembly
301-471-01 Adjustable Orienting Sub Assembly
301-447-08 Stinger Muleshoe Assembly
301-447-03 Stinger Muleshoe Assembly with Contact
Not Listed Orienting Pressure Muleshoe Sleeve Assembly
Not Listed Orienting Pressure Sub Assembly
300-016-01 Service Spec. Orienting Pressure Sub Assembly
300-015-01 Bulkhead Service Specifications
A-1
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D811001123-GEN-001/04
D9A1000051-MAN-001
A Drawings and Schematics Revision E
Page A-2 of 2
A-2
www.nov.com

LTR REVISIONS DATE
A TITLE WAS X-OVER 10-14-04

NOTE CONNECTOR ORIENTATION 5
6
4 B ADD BLOW OUT PLUG 10-19-04
MDM 15 S
7 C REMOVE BLOW OUT PLUG 12-3-04
10
D 6-32 SET SCREW WAS 4-40 3-28-05
3
E ADD FRONT VIEW OF 10 PIN CONN 1-25-06
8 9
F RING TORQUE WAS 75 Ft. Lbs. 3-14-06
2 G TORQUE WAS 100 Ft. Lbs. ADD T.P. 5-24-06

FRONT VIEW Index Marks
END VIEW 1 SCREWS ARE FOR
4P/6S CONNECTOR BACK VIEW CONNECTOR ALIGNMENT ONLY
"DO NOT OVER TIGHTEN"
4P/6S CONNECTOR
3 USE BLUE LOC-TITE #242
10808
LUBE O-RING USING
CONNECTOR
6 4 ALCO METALUBE
9 3 11 2PL
MDM 15 S
RING
ADAPTER, MDM 15 2-219 SET SCREW
SCREW, 2PL 10 303-673-01 114709
303-665-01
2-56x1/4 USE BLUE
6-32x1/4
2PL 10596
114391 LOC-TITE
#242
SHC SCREW, 2PL

6-32x1/2
10591
12
LUBE O-RING & CAREFULLY

.580 REF INSERT CONNECTOR TO
PREVENT DAMAGING O-RING
14 8 1 2 7 5
THREAD PROTECTOR 2-220 BULKHEAD COLLAR, COUPLING 10 PIN CONN.(4P/6S) THREAD PROTECTOR
373-292-01 10122 303-605-03 303-664-01 114595 373-299-01
2PL
3 DEGREASE THREADS ON SUB & RING
THEN APPLY LOC-TITE #242 & TORQUE

COUNTER CLOCKWISE TO 75 Ft. Lbs.
TOLERANCES UNLESS OTHERWISE SPECIFIED: DRAWN
DECIMALS FRACTIONS ± 1/64
CHECKED
JDH 7-1-04
BlackStar
EM MWD TOOLS
USING WRENCH 393-226-01
.000 ±.005 ANGLES ± 1/2°
.00 ±.01 FINISHES 125 MAX
APPROVED FOR
.0 ±.05 INTERNAL RADIUS .015 MAX
BULKHEAD, BATTERY
2. USE BLUE LOC-TITE ON ALL SCREWS CONCENTRICITY OF COAXIAL DIA'S .005 TIR PROTOTYPE
REMOVE BURRS AND SHARP EDGES .006
DIMENSIONS ARE IN INCHES PRODUCTION 1 7/8" EM/MWD
1. FOR PARTS LIST SEE 301-605-03
THIS DOCUMENT MAY CONTAIN BlackStar SYSTEM WeTech 10 PIN TO MDM 15 SCALE SIZE DRAWING NO. REV
FOR WIRING DIAGRAM SEE 305-605-03
PROPRIETARY INFORMATION AND MAY
NEXT ASSY XMIT or GAMMA BATTERY 1/1B 301-605-03 G
NOTES: UNLESS OTHERWISE SPECIFIED. NOT BE DISCLOSED TO OTHERS FOR ANY
PURPOSE WITHOUT WRITTEN PERMISSION REF. 1/4-20 X .625 SHCS DO NOT SCALE PRINT SHEET 1 OF 1

LTR REVISIONS DATE
BLK 1
BRN 2
RED 3
ORN 4
YEL
GRN 5
BLU 6
VIO 7
GRY 8
WHT 9
WHT/BLK 10
WHT/BRN
WHT/RED
WHT/ORN
WHT/YEL WETECH 6S/4P
114595
MNR-15S6E5
1. USE THIS SCHEMATIC FOR 301-605-03 AND 301-605-05
NOTES: UNLESS OTHERWISE SPECIFIED

CHECKED
JDH 1-4-07
BlackStar
EM MWD TOOLS
.000 ±.005 ANGLES ± 1/2°
APPROVED FOR
CONCENTRICITY OF COAXIAL DIA'S .005 TIR PROTOTYPE
SCHEMATIC, BATTERY BULKHEAD
DIMENSIONS ARE IN INCHES PRODUCTION EM/MWD
THIS DOCUMENT MAY CONTAIN BlackStar SYSTEM SCALE SIZE DRAWING NO. REV
NEXT ASSY 1/1 A 305-605-03
NOT BE DISCLOSED TO OTHERS FOR ANY
PURPOSE WITHOUT WRITTEN PERMISSION REF. DO NOT SCALE PRINT SHEET 1 OF 1

LTR REVISIONS DATE

5
4 A ADD 10 PIN CONN VIEWS 1-31-06
6
3
10
7
2 9
CENTRALIZER PLUG MAKE-UP TORQUE
8 303-293-16 4 NOT TO EXCEED 180 in-lb.
Index Marks FRONT VIEW 2-220
1 VENT PLUG
BACK VIEW
6P/4S CONNECTOR 2 1 3 11 10122
303-414-01
6P/4S CONNECTOR 2PL
CENTRALIZER FIN
2-219 THREAD
303-127-04
2PL 10 15 9 14 5 PROTECTOR
114709 373-292-01
24AWG 2-016 SPRING
10442 10105 114773
SOLDER WIRES TO TERMINALS &

THREAD GND WIRE TO FLAT ON CONNECTOR
PROTECTOR 6 12 POT USING EMERSON COMING
3
FAA.2S.650.CTA
373-298-01 LUBE O-RING STYCAST #1495 7 LEMO CONN.
6-32 X 3/8 & CAREFULLY
SET SCREW 2PL INSERT CONNECTOR 12252

TO PREVENT
114760 DAMAGING O-RING
10 PIN (6P/4S) SCREWS ARE FOR
INSULATOR 6-32x1/4
WeTech CONN 8 CONNECTOR ALIGNMENT ONLY 4 13
"DO NOT OVER TIGHTEN" 303-685-01 SET SCREW
114710
USE BLUE LOC-TITE #242 10060
4 REF. USE FIN TOOL 393-149-01

CHECKED
JDH 2-14-05
BlackStar
EM MWD TOOLS
.000 ±.005 ANGLES ± 1/2°
3 USE WRENCH #393-135-02 .0 ±.05 INTERNAL RADIUS .015 MAX
APPROVED FOR
CENTRALIZER ASSY,
CONCENTRICITY OF COAXIAL DIA'S .005 TIR PROTOTYPE BATTERY TO BATTERY
2. USE BLUE LOC-TITE ON ALL SCREWS REMOVE BURRS AND SHARP EDGES .006
DIMENSIONS ARE IN INCHES PRODUCTION
1 7/8" EM/MWD
1. FOR PARTS LIST SEE 302-293-19 THIS DOCUMENT MAY CONTAIN BlackStar SYSTEM WeTech 10 PIN TO 2S LEMO SCALE SIZE DRAWING NO. REV
NEXT ASSY 1/1 B 301-293-19 A
NOTES: UNLESS OTHERWISE SPECIFIED.
PURPOSE WITHOUT WRITTEN PERMISSION REF. 2-219 & 2-220 DO NOT SCALE PRINT SHEET 1 OF 1

5 LTR REVISIONS DATE

4
6
3
10
7
2 9
8
Index Marks FRONT VIEW
1
BACK VIEW
6P/4S CONNECTOR
6P/4S CONNECTOR
1 LEMO FAA.2S.650.CTA
2 12252
3
4
5
6
7
8
9
10
WETECH 6S/4P
114710
1. USE THIS SCHEMATIC FOR 301-293-20
NOTES: UNLESS OTHERWISE SPECIFIED

CHECKED
LN 9-16-08
BlackStar
EM MWD TOOLS
.000 ±.005 ANGLES ± 1/2°
APPROVED FOR
SCHEMATIC, CENTRALIZER ASSY
DIMENSIONS ARE IN INCHES PRODUCTION BATTERY TO BATTERY 1 7/8" EM/MWD
NEXT ASSY 1/1 A 305-293-20

LTR REVISIONS DATE
13.75
REF 8.38
6-32X1/4
PN 10811 10122 303-702-01 BOW SPRING OPTION 10117 10122 11244 SET SCREW
3.75" 303-705-01
11 16 4 2PL
7,8,9,10 4.75" 303-706-01 15 16 14 18
6.00" 303-707-01 2-213
(MDM 21 S) 2-220 COLLAR 2-220 2-022 2PL
2PL 8.00" 303-708-01 2PL
JS1
S1
11307 SLEEVE THD RING SPLIT RING 10135

SUB PIN
4-40X3/8
SCREW 17 5 1 2 12 4
PH 3 4PL 6
303-703-01 303-295-04
#4 LUG 13 303-433-08 303-704-01 303-296-01 2567-15 WETECH
10617
4. USE CONN. INSERTION GUIDE 393-289-01
3. USE BLUE LOCK-TITE ON ALL SCREWS
NOTE: APPLY A THIN COAT OF "ALCO METALUBE"
TO SHAFT UNDER ALL COLLARS & SLEEVES 2. FOR SCHEMATIC SEE 305-433-01
1. FOR PARTS LIST SEE 301-433-08
NOTES: UNLESS OTHERWISE SPECIFIED.
TOLERANCES UNLESS OTHERWISE SPECIFIED:

DRAWN
CHECKED
JDH 8-8-05
BlackStar
EM MWD TOOLS
.000 ±.005 ANGLES ± 1/2°
.00 ±.01 FINISHES 125 MAX APPROVED FOR
.0 ±.05 INTERNAL RADIUS .015 MAX CONTACT COLLET SUB ASSY
DIMENSIONS ARE IN INCHES PRODUCTION EM/MWD 1 7/8"
NEXT ASSY 1/1 B 301-433-08













BlackStar
EM MWD TOOLS

D9A1000051-MAN-001
Revision E
Page B-1 of 2
Lithium Battery Safe Handling
Safe Handling and Disposal

For information regarding Lithium Battery Safety, the manufacture of lithium batteries has published
detailed information on the safe use, handling, and storage of lithium batteries. For your convenience,
National Oilwell Varco has included this information in this manual, titled Appendix B. For further
information on safe handling, storage, and disposal, please contact the manufacturer or access the
manufacturer's website.
B-1
www.nov.com
D811001123-GEN-001/04
D9A1000051-MAN-001
B Lithium Battery Safe Handling Revision E
Page B-2 of 2
B-2
www.nov.com

Electrochem Solutions
Subsidiary of Greatbatch Inc.
670 Paramount Drive
Raynham, MA 02767 USA
Tel 716-759-6901 Fax 716-759-2562
`
MATERIAL SAFETY DATA SHEET

Issued: 1/15/2009
Section 1 – IDENTIFICATION
Product Name:
LITHIUM THIONYL CHLORIDE
CELLS AND BATTERIES
Hermetically-Sealed Lithium Thionyl Chloride Cells & Batteries

All Electrochem 100, 150, 150/165MR, 180/180MR, 200/200MR series, QTC, MWD, VHT Cells and Batteries
Section 2 – COMPOSITION/INFORMATION ON INGREDIENTS
Thionyl Chloride OSHA: 1.0ppm (5.0mg/m3) ceiling

7719-09-7 ACGIH: 1.0ppm (5.0mg/m3) ceiling
Lithium
7439-93-2 TLV/PEL N/A
Carbon
ACGIH: 3.5 mg/m3 TLV/TWA
1333-86-4
Section 3 – HAZARDS IDENTIFICATION
**DANGER** INTERNAL CONTENTS ARE EXTREMELY HAZARDOUS. LEAKING FLUID IS CORROSIVE AND
DANGEROUS UPON INHALATION. BATTERY MAY BE EXPLOSIVE AT HIGHER TEMPERATURES.
Do not expose to temperatures above the maximum rated temperature as specified by the manufacturer due to leak hazard.
If cell or battery leaks or vents

Primary Routes of Entry: Inhalation
Carcinogenicity: Not listed by NTP, IARC, or regulated by OSHA.
Health Hazards: Acute – Vapors are very irritating to skin, eyes, and mucous membranes. Inhalation of thionyl chloride or
sulfuryl chloride vapors may result in pulmonary edema.
Chronic – Overexposure can cause symptoms of non-fibrotic lung injury
Signs and Symptoms of Exposure: Eye and mucous membrane irritation.
Medical Conditions Generally Aggravated by Exposure: Asthma, other respiratory disorders, skin allergies, and eczema.
Section 4 – FIRST AID MEASURES
Eye Contact: Flush with running water for at least 15 minutes. Hold eyelids apart. Seek immediate medical attention. Contact
results in acidic burns.
Skin Contact: Rinse with large amounts of running water. Avoid hot water and rubbing skin. If burns develop, seek medical
attention. Contact results in acidic burns.
Inhalation: Remove to fresh air. If breathing is difficult, administer oxygen. If not breathing, give artificial respiration. May
result in pulmonary edema.
Ingestion: Drink copious amounts of water (or milk if available). Do not induce vomiting. NEVER GIVE ANYTHING BY
MOUTH TO AN UNCONSCIOUS PERSON. Immediately seek medical attention.
Page 1 of 4
Section 5 – FIRE FIGHTING MEASURES
Flash Point: N/A Auto-Ignition Temp: N/A Flammable Limits: N/A

Danger - Do not use water
Extinguisher Media: Lith-X powder, Class D fire extinguisher, Dry Lithium Chloride, Graphite Powder, Pyrene G-1.
Special Fire Fighting Procedures: Cover with Lith-X powder, Class D fire extinguisher, dry lithium chloride, or graphite
powder. DO NOT USE WATER, moist sand, CO2, Class ABC, or soda ash extinguisher. Wear protective breathing apparatus;
a positive pressure Self Contained Breathing Apparatus (SCBA), or Air Purifying Respirator (APR). Be prepared for secondary
fires.
Unusual Fire and Explosion Hazards: Do not short circuit, recharge, over discharge (discharge below 0.0 Volts), puncture,
crush or expose to temperatures above the maximum rated temperature as specified by the manufacturer. Cell may leak, vent, or
explode. If a bright white flame is present, lithium content is exposed and on fire; use a Class D fire extinguisher, Do not use
water.
Section 6 – ACCIDENTAL RELEASE MEASURES
Accidental Releases: Do not breathe vapors or touch liquid with bare hands (see section 4).
Waste Disposal Methods: Evacuate area. If possible, a trained person should attempt to stop or contain the leak by neutralizing
spill with soda lime or baking soda. A NIOSH Approved Acid Gas Filter Mask or Self-Contained Breathing Apparatus should be
worn. Seal leaking battery and soda lime or baking soda in a plastic bag and dispose of as hazardous waste.
Other: Follow North American Emergency Response Guide (NAERG) #138 for cells involved in an accident, cells that have
vented, or have exploded.
Section 7 – HANDLING & STORAGE
Storage: Cells should be stored at room temperature, approx. 21oC (70oF). Do not store batteries in high humidity environments
for long periods. High Temperature storage will degrade performance.
Precautions: Do not short circuit or expose to temperatures above the maximum rated temperature as specified by the
manufacturer. Do not recharge, over discharge, puncture or crush.
Other Conditions: Do not store cells in close proximity of other combustible / flammable materials.
Section 8 – EXPOSURE CONTROLS / PERSONAL PROTECTION
When handling internal components:
Respiratory Protection: NIOSH Approved Acid Gas Filter Mask, or Self-Contained Breathing Apparatus.
Protective Gloves: Nitrile or PVC, Gloves should be 15 ml (0.015 in), or thicker.
Eye Protection: Chemical Worker Safety Glasses or face shield.
Ventilation To Be Used: Negative pressure chemical fume hood.
Other Protective Clothing & Equipment: Chemical Laboratory Safety Glasses, Protective Apron, Acid Resistant Protective
Clothing, and face shield.
Hygienic Work Practices: Use good chemical hygiene practice. Do not eat or drink when handling contents. Avoid
unnecessary contact.
Section 9 – PHYSICAL/CHEMICAL CHARACTERISTICS
Boiling Point: Thionyl Chloride: 77oC

Vapor Pressure: Thionyl Chloride: 92mm @ 20 C
Vapor Density: Thionyl Chloride: 4.1 (air = 1)
Solubility in Water: Thionyl Chloride: Decomposes violently on contact with water.
Specific Gravity: Thionyl Chloride: 1.63 g/cm3
Melting Point: Thionyl Chloride: -105 C
Evaporation Rate: No Data
Water Reactive: Thionyl Chloride hydrolyzes to form SO2 and HCl gasses and strongly acidic wastewater.
Appearance & Odor: Thionyl Chloride – Colorless to pale yellow; sharp, pungent odor.
Other: Internal contents contain Bromine and Chlorine
Section 10 – STABILITY & REACTIVITY
Stability: Stable Incompatibility: N/A Hazardous Polymerization: Will not occur.

Conditions to Avoid: Temperatures above the maximum rated temperature as specified by the manufacturer due to leak hazard.
High humidity for extended periods.
Hazardous Decomposition Products: Sulfur Dioxide (g), Hydrogen Chloride (g)., Hydrogen (g)
Page 2 of 4
Section 11 – TOXICOLOGICAL INFORMATION
Acute Toxicity (as applicable):

Thionyl Chloride Sulfuryl Chloride
LC50 (Inhalation): 500 ppm (rat 1-hr) LC50 (Inhalation): 130-250 ppm (rat 1-hr)
LD50: N/A LD50: N/A
Eye Effects: Corrosive Eye Effects: Corrosive
Skin Effects: Corrosive Skin Effects: Corrosive
Section 12 – ECOLOGICAL INFORMATION
Aquatic Toxicity: Do not let internal components enter marine environments. Avoid releases into waterways,
wastewater or groundwater.
Section 13 – DISPOSAL CONSIDERATIONS
Proper Shipping Name: Waste Lithium Batteries

UN Number: 3090
Hazard Classification: Class 9 (Misc.)
Packing Group: II
Labels Required: MISCELLANEOUS, HAZARDOUS WASTE
Waste Disposal Code: D003
Other: All lithium thionyl chloride batteries should be disposed of by a certified hazardous waste disposal facility.
Section 14 – TRANSPORT INFORMATION
US DOT (per 49 CFR 172.101) and IATA/ICAO

Proper Shipping Name: Lithium Metal Batteries
UN Number: UN 3090 (UN 3091 for Lithium Metal Batteries Contained in Equipment or Lithium Metal Batteries Packed With
Equipment)
Hazard Classification: Class 9 (Misc.)
Packing Group: II
Labels Required: MISCELLANEOUS HAZARD CLASS 9, LITHIUM BATTERY LABEL (IATA 7.4.8)
Other: CARGO AIRCRAFT ONLY (Forbidden as cargo aboard passenger aircraft)
Shipping Requirements:
DOT: Lithium batteries and cells are subject to shipping requirements exceptions under 49 CFR 173.185.
IATA: Shipping of lithium batteries in aircrafts are regulated by the International Civil Aviation Organization
(ICAO) and the International Air Transport Association (IATA) requirements in Special Provisions A48, A88, A99,
A154, and A164 and Packing Instruction 968, 969, or 970.
Section 15 – REGULATORY INFORMATION
OSHA Status: This product is considered an “Article” and the internal component (thionyl chloride / sulfuryl chloride) is
hazardous under the criteria of the Federal OSHA Hazard Communication Standard 29 CFR 1920.1200.
Section 16 – OTHER INFORMATION
Lithium Battery Safety

With proper use and handling, lithium batteries have demonstrated an excellent safety record. The success and wide use of
lithium batteries is partially due to the fact that they contain more energy per unit weight than conventional batteries. However,
the same properties that result in a high energy density also contribute to potential hazards if the energy is released at a fast-
uncontrolled rate. In recognition of the high-energy content of lithium systems, safety has been incorporated into the design and
manufacture of all Electrochem batteries. However, abuse or mishandling of lithium batteries can still result in hazardous
conditions. The information provided here is intended to give users some guidelines to safe handling and use of Electrochem
lithium batteries.
Page 3 of 4
Cell Abuse
In general, the conditions that cause damage to cells and jeopardize safety are summarized on the label of each cell. These
conditions include:
 Short Circuit
 Charging
 Forced Over discharge
 Excessive heating or incineration
 Crush, puncture or disassembly
 Very rough handling or high shock and vibration could also result in cell damage.
Cell Handling and Inspection Guidelines

The most frequent forms of cell abuse can easily be identified and controlled in the workplace. It is our experience that
inadvertent short circuits are the largest single cause of field failures.
Problems associated with shorting as well as other hazardous conditions can be greatly reduced by observing the
following guidelines:
 Cover all metal work surfaces with an insulating material.
 The work area should be clean and free of sharp objects that could puncture the insulating sleeve on each cell.
 Never remove the shrink-wrap from a cell or battery pack.
 All persons handling cells should remove jewelry items such as rings, wristwatches, pendants, etc., that could come in
contact with the battery terminals.
 If cells are removed from their original packages for inspection, they should be neatly arranged to preclude shorting.
 Cells should be transported in plastic trays set on pushcarts. This will reduce the chances of cells being dropped on the
floor, causing physical damage.
 All inspection tools (calipers, rulers, etc.) should be made from non-conductive materials, or covered with a non-
conductive tape.
 Cells should be inspected for physical damage. Cells with dented cases or terminal caps should be inspected for
electrolyte leakage. If any is noted, the cell should be disposed of in the proper manner.
Cell Storage
Cells should be stored in their original containers. Store cells in a well ventilated, cool, dry area. Store cells in an isolated area,
away from combustible materials. Never stack heavy objects on top of boxes containing lithium batteries to preclude crushing or
puncturing the cell case.
Handling During Product Assembly

All personnel handling batteries should wear appropriate protective equipment such as safety glasses.
 Do not solder wires or tabs directly to the battery. Only solder to the leads welded to the cell by the manufacturer.
 Never touch a cell case directly with a hot soldering iron. Heat sinks should be used when soldering to the tabs, and
contact with the solder tabs should be limited to a few seconds.
 Cells should not be forced into (or out of) battery holders or housings. This could deform the cell causing an internal
short circuit, or fracturing the glass to metal hermetic seal.
 All ovens or environmental chambers used for testing cells or batteries should be equipped with an over-temperature
controller to protect against excessive heat.
 Only precision convection ovens should be used for cell testing. Lesser ovens may exhibit uneven heating and hot spots
that can exceed the rated temperature of the battery.
 Do not connect cells or batteries of different chemistries together.
 Do not connect cells or batteries of different sizes together.
 Do not connect old and new batteries together.
 Consult Electrochem before encapsulating batteries during discharge. Cells may exceed their maximum rated
temperature if insulated.
 Although we have provided a general overview of lithium battery safety and handling, we urge you to call us with any
questions. Our technical services staff will be pleased to assist you with your questions.
NFPA RATING  For cells or battery packs involved in an

accident, cells that have vented, or exploded,
follow the North American Emergency Response
Guide (NAERG) #138.
 24-HOUR EMERGENCY RESPONSE

PHONE NUMBER:
(800) 255-3924
Prepared by: Jon Levis
Rev. 2009B
Date: 01/14/2009
Page 4 of 4
D9A1000051-MAN-001
Revision E
Page C-1 of 2
Worksheets
%-Worksheets
The following worksheets are included.
 BlackStar EM-MWD Signal Modeling Worksheet

 Loadout Checklist
 Drill Collar Measurement Worksheet
C-1
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D811001123-GEN-001/04
D9A1000051-MAN-001
C Worksheets Revision E
Page C-2 of 2
C-2
www.nov.com

Rev 06/12/09 KHD/RK
BlackStar EM-MWD Signal Modeling Worksheet

Job & Well Site Information
Customer Operator
Name: Name:
Address: Well Name:
County:
Contact: Location:
Phone: Latitude:
Fax: Longitude:
Job Information
Job Type Underbalanced Conventional
Well Data Units of Measure Meters Feet
Vertical or Build Section Horizontal Section

Surface Casing OD ID DEPTH KOP.
Intermed Casing OD ID DEPTH
O
Build Rate /100ft. OR O /30M
O
Max Dog leg /100ft. OR O /30M
Drill Pipe OD ID Drill Pipe OD ID
Drill Collars OD ID Drill Collars OD ID
BHA OD ID LENGTH BHA OD ID LENGTH
Hole Size: Hole Size:
TVD at TD TVD at TD
MD at TD MD at TD
Max R.O.P. Max R.O.P.
Mud Type Mud Type
Flow Rate gpm/lpm Flow Rate gpm/lpm
Air/Mist Air/Mist
Mist Fluid: Mist Fluid:
Solids Content: % Solids Content: %

Salt Brine ppm Salt Brine ppm
KCL ppm KCL ppm
Rig Site
Is there availability of a service rig anchor for antenna placement? Yes No
Is there a offset well in proximity of the drill rig? Yes No
Modeling Data
For accurate modeling a log is required from the Surface through the Zone of Interest.
Resistivity log information can be following formats: LAS,TIF, Spreadsheet or Hard Copy.
A Resistivity log from offset well or from a well in the same general area as the target well is acceptable.
Comments:/ Additional Data


MWD LOADOUT LIST

MWD No: TYPE:
DATE OUT: CUSTOMER:

REVIEWED BY: JOB No.:
DATE IN: LSD:
ASSETS SERIAL No. SERIAL No.
TX
FOCUSED
GAMMA 360
ROTATIONAL
BATTERY SWITCH
DIRECTIONAL SENSOR
SURFACE AMP
LAPTOP
RIG FLOOR DISPLAY
BATTERY TEST BOX
PROGRAMMING BOX(Only with SCA)
PRINTREX
UPS
BATTERY BULKHEADS
EM DEDICATED TUBULARS SERIAL No. SERIAL No.
ORIENTING PRESSURE SUB
ORIENTING PRESS. SLEEVE SIZE: QTY:
INSTRUMENT COLLAR
GAP SUB
BATTERY COLLAR
EM DEDICATED TUBULARS SERIAL No. SERIAL No.
ORIENTING PRESSURE SUB
ORIENTING PRESS. SLEEVE SIZE: QTY:
INSTRUMENT COLLAR
GAP SUB
BATTERY COLLAR
OTHER ASSETS PART NO. QTY. RETURN
PRESSURE TRANDUCER 10639
GEOLOGRAPH ENCODER 115198 DRUM TRACKER ROTARY ENCODER 114535

MWD Loadout List
PART No. DESCRIPTION QTY. OUT RTN. STATUS

BIN # 1
2
301‐140‐05 Gamma Battery 15‐Pin
2
301‐138‐15 X‐MIT 15‐Pin Stackable
4
301‐137‐03 TRANSMITTER BATTERY HSG. ASSY. 1 7/8"
2
301‐118‐02 GAMMA BATTERY HSG. ASSY. 1 7/8"
2
301‐324‐14 CONTACT SPRING SUB ASSY, 1 7/8" EM/MWD NEW STYLE
4
12337 1/2" OD X 4 FT COPPER GROUNDING RODS
4
12358 COPPER GROUNDING CLAMPS
1
12315 POST POUNDER
1
371‐117‐01 UNLOADING BAR, M/S SLEEVE EM/MWD
1
371‐118‐01 LOADING BAR, M/S SLEEVE EM/MWD
1
114341 CORD, EXTENSION 100 FT. 14/3
6
12689 GLOVES, PVC DOTTED
2
114315 TOWEL, SHOP ROLL 11' x 10.4"
BIN # 2
1
12733 WIRE, 14AWG, SOLID COPPER, 500FT.
12
303‐689‐01 BOW SPRING CONTACT
12
303‐705‐01 BOW SPRING, CONTACT 3.75" EM/MWD FLAT ( NEW STYLE)
12
12
12
10
303‐127‐03.1 FIN, CENTRALIZER EM/MWD, 90 DURO
1
391‐114‐01 FIN INSTALLATION TOOL ASSY, W/ADPT. EM/MWD
1
393‐139‐01 GAUGE RING, FIN CENTRALIZER, 2.75" EM/MWD
1
1
2
393‐108‐01 SPLIT TUBE, CONE EXTENSION EM/MWD
1
393‐115‐03 GUIDE, FIN SHAVER FITS ALL SIZES OF TUBULARS EM/MWD
1
393‐118‐02 GUIDE, FIN SHAVER‐BATT. CENT. ALL SIZES EM/MWD
4
301‐136‐04 CENTRALIZER ASSY, BATTERY 1 7/8" EM/MWD
1
371‐133‐01 LIFTING SLING ASSY, EM/MWD
1
114309 OVERSHOT J‐LATCH HANDLING TOOL, 1 3/4" OD x 1.25"‐8 THD
1
114310 OVERSHOT, KUSTER TYPE. 1 3/4" OD, 1.25" ‐ 8 THD

MWD Loadout List

1
371‐151‐01 LIFT NIPPLE W/SHACKEL, 1.25" ‐ 8 THD, BOX
BIN # 3
2
301‐447‐08 PRESSURE STINGER ASSY.
2
11497 HANDLE, 20" PARMELEE, H2
2
11499 PARMELEE WRENCH, GIRTH 1 7/8" G2
2
391‐112‐01 WRENCH, SPANNER 1/4" PIN, 1 1/4" GRIP x 8 1/2" LG.
1
371‐140‐01 ALIGNMENT TOOL ASSY, MULESHOE EM/MWD
BIN # 4 – GAMMA ACCESSORIES
1
Gamma Only RADIOACTIVE LABEL ON BIN
1
11480 CALIBRATION BLANKET, THORIUM 232, 11" X 18", 150 ‐ 200 API
2
301‐471‐01 ADJUSTABLE ORIENTING SUB, 1 7/8"
2
303‐333‐01 AP SPACER BAR 12" TO STINGER
1
391‐105‐01 PLUG ASSY, PRESSURE TESTER EM/MWD
1
12085 P‐141 ENERPAC PUMP W/10K PSI GAUGE
1
10392 GREASE FITTING TOOL, MS ANNULAR PRESSURE, SLEEVE
1
371‐110‐01 GREASE FITTING TOOL ASSY, 1 7/8" EM/MWD
1
12712 DOW CORNING SILICON GREASE, 5.3oz, FOR KIT TOOL BOX
1
114348 GREASE GUN
1
114349 WHIP HOSE, 12" FOR GREASE GUN

Directional Only
2
303‐339‐10 SPACER BAR, EXTENSION 1 7/8" OD X 15" LG.
2
303‐382‐02 X‐OVER, SENSOR TO SPACER BAR
4
303‐383‐02 CENTRALIZER SPACER BAR 1 7/8" OD X 40" LG.
1
303‐383‐06 CENTRALIZER SPACER BAR 1 7/8" OD X 53" LG.
2
303‐437‐01 X‐OVER, SPACER BAR TO STINGER
DUAL BATTERIES ACCESSORIES
2
301‐293‐19 BATTERY TO BATTERY CENTRALIZER
1
114821 BATTERY MONITOR BOX
SURFACE AMPLIFIER ACCESSORIES
3
114190 PELICAN CASE, BLACK W/ FOAM INSERTS, 1600‐B
3
114191 PELICAN CASE, BLACK W/ FOAM INSERTS, 1550‐B
2
10329 POWER CORD, BELDON 7'6", 3‐CONDUCTOR
2
114285 10 BASE‐T CROSSOVER CABLE CATEGORY 5 ‐ 7 FT.

MWD Loadout List

1
115251 DB9 NULL MODEM CABLE
2
11343 CABLE, SHIELDED DB9 M/F (RS‐232), CSMN9MF‐5
DEPTH TRACKING EQUIPMENT
1
114191 PELICAN CASE, BALCK W/ FOAM INSERTS, 1550‐B
1
114190 PELICAN CASE, BALCK W/ FOAM INSERTS, 1600‐B
1
360‐100‐01 JUNCTION BOX, RIGFLOOR EM/MWD, LAYOUT
1
12090 CHIMO UNIVERSAL INTERFACE BOX
1
361‐102‐01 CABLE ASSY, J‐BOX EM/MWD
1
361‐103‐01 CABLE ASSY, J‐BOX TO HOOK LOAD SENSOR EM/MWD
1
361‐103‐02 CABLE ASSY, J‐BOX TO DEPTH ENCODER EM/MWD
1
361‐134‐03 CABLE ASSY, J‐BOX DRO EM/MWD
1
10639 SENSOR, HYDRAULIC HOOK LOAD (PRESSURE TRANSDUCER)
1
10640 SENSOR DEPTH TRACKING, GEO. LINE (GEOGRAPH ENCODER) GEO. ONLY
1
10641 DMS‐2 DEPTH MONITORING SYSTEM (GEOGRAPH BOX) GEO. ONLY
1
361‐152‐01 HOOK LOAD SIMULATOR BOX
1
114534 DRUM TRACKER DEPTH MONITOR STSTEM (ENCODER BOX) DRUM ONLY
1
114535 DRUM TRACKER SENSOR (ROTARY ENCODER) DRUM ONLY
1
10329 POWER CORD, BELDON 7'6", 3 CONDUCTOR
1
11343 CABLE DB9 M/F (RS232)
DRILL FLOOR DISPLAY
2
12356 SITECOM INTERCOM HANDSETS
2
12741 9 VOLTS BATTERY FOR RIG PHONES
1
361‐134‐04 DRO JUMPER CABLE ASSY.
2
361‐134‐01 CABLE ASSY, DRO EM/MWD
2
341‐111‐01 CONNECTOR BLOCK ASSY, DRILLERS REMOTE
PRINTER/PLOTTER ASSEMBLY
1
114161 CABLE ASSY, PRINTER DB25M‐CEN36M, CSM84AB‐2M
1
2
11500 PAPER, THERMAL FAN FOLD, 8 3/4"x 2 5/8" OD ROLLS
TESTING, CONFIGURATION AND POWER EQUIPMENT
2
1
361‐124‐01 CABLE ASSY, FIELD PROGRAMMING, EM/MWD, 75 FT.
2
371‐146‐04 COMMUNICATIONS PLUG ASSY, EM/MWD 10‐PIN

MWD Loadout List

1
361‐112‐01 CABLE ASSY, EM TEST
ANTENNAS
2
361‐140‐03 CABLE ASSY, EM ANTENNA, EM/MWD
6
12753 TOOL STAND
SMALL ACCESSORY BAG
12
114782 SCREW, 1/4‐20 X 5/8", 18‐8 SS BATTERY RETAINING SCREW 10‐PIN
4
114791 DOWEL PIN for spanner wrench
8
12040 ROLL PINS for stinger
3
12737 8‐32 X 1/4" ALLOY SOCKET SET SCREW KNURLED CUP
16
114935 BACK‐UP RING, ORIENTING PRESSURE STINGER,
8
114934 Stinger Extension O‐Ring
10
114360 O‐RING, VITON 75 DURO, SHORE A, 2‐143 (For 3.75 M/S Sleeve)
10
10
10
2
114244 1/4 x 1.5" Dowel Pin (for fishing neck)
4
114246 1/4‐20x1/2" Set Screw (for fishing neck)
4
6022 SET SCREW, SOCKET JAM , HOLO(pressure port) 3.75" 5/8‐11 X 5/16
8
6022 SET SCREW, SOCKET JAM, HOLO(Pressure Port) 4.75", 6.5", 8" 5/8‐11 X 1/2
PRESSURE PORT 4.75, 6.5, 8
10
114301 SET SCREW, SOCKET JAM , 5/8" ‐ 11 UNC‐2B X 5/16"L
4
11243 O‐RING, VITON 75 DURO, SHORE A 2‐013
12
12
4
24
4
10
24
114127 FUSE, BUSS AGC, 1 AMP, 1/4" x 1 1/4", AGC‐1
5
11592 FUSE, BUSS, 5 AMP, AGC‐5
5
114762 3.75 UBHO SET SCREW 5/8"‐11 X 1/2"
4
114352 4.75 UBHO SET SCREW 5/8"‐11 X 7/8"
4
6.5 UBHO SET SCREW 3/4"‐10 X 1 1/4"

MWD Loadout List

4
12922 8 UBHO SET SCREW 3/4"‐10 X 1 3/4"

OPERATOR'S HAND TOOL BOX FOR EM
1
114363 HANDLE, HINGE 1/2" DRIVE x 15‐3 /4" LG.
1
114313 TOOL BOX, TOOL ORGANIZER, FOR KIT HAND TOOLS
1
114379 WRENCH, SPANNER
15
114316 TIE WRAPS, 14" LNG. BLK HEAVY , L‐14‐120‐02‐C, FOR TOOL BOX
1
114317 HAND CLEANER, GO‐JO 22oz, FOR KIT TOOL BOX
1
114318 TAPE, ROLL DUCT CLOTH, 2" WIDE 2W504
1
114319 MULTIMETER, WAVETECK HEAVY DUTY, FOR KIT TOOL BOX
1
114320 LEVEL, TORPEDO, 9" LONG, FOR KIT TOOL BOX
1
114321 WRENCH, HEX SET, 9 PC, 5/64" ‐ 1/4", FOR KIT TOOL BOX
1
114322 TAPE MEASURE 8M/26FT, LUFKIN 2048CME, FOR KIT TOOL BOX
1
114350 POWER STRIP,6 OUTLETS W/ 6 FT CORD
1
114351 GROUND FAULT CIRCUIT TESTER, IDEAL BRAND, 61‐035
1
11780 O‐RING TOOL, SOLID BRASS, FOR KIT TOOL BOX
1
114323 SCREWDRIVER SET, 4 PC, 2 ‐ SLOT, 2 ‐ PHILLIP, FOR KIT TOOL BOX
2
114324 VICE GRIPS, 10" W/ WIRE CUTTER, 10WR, FOR KIT TOOL BOX
1
114325 WRENCH, CRESCENT 15", FOR KIT TOOL BOX
1
114326 PLIERS, 7 1/8" LONG NOSE W/ CUTTER, FOR KIT TOOL BOX
1
114327 PLIERS, 8" DIAGONAL CUTTING, KLEIN D228‐8, FOR KIT TOOL BOX
1
114328 PLIERS, 2‐PC. SLIP JOINT SET, 6" & 8", FOR KIT TOOL BOX
1
114329 PLIERS, TONGUE & GROOVE , 12", 422, FOR KIT TOOL BOX
1
114330 WIRE STRIPPERS, 10 GA STRIPPER CUTTER, 11045, FOR KIT TOOL BOX
1
114331 WIRE STRIPPERS, 16 GA STRIPPER CUTTER,11406, FOR KIT TOOL BOX
1
114332 FLASHLIGHT, RAYOVAC ROUGHNECK, R3D, FOR KIT TOOL BOX
6
114334 BATTERIES, D CELL, FOR KIT TOOL BOX
1
114335 BRUSH, WIRE MINI BRASS 7‐1/2", 55189 5/PK, FOR KIT TOOL BOX
1
114336 RUBBER MALLET, 2 LB, FOR KIT TOOL BOX
1
114337 HAND DRILLING HAMMER, 3 LB, FOR KIT TOOL BOX
1
114338 THREAD COMPOUND, ANTI‐SEIZE, COPPER BASED, 8oz, 5E203
1
11200 LOCTITE, 242, 10ML, BLUE
2
11311 TAPE, ELECTRICAL 3/4" W, SCOTCH 33, FOR KIT TOOL BOX
1
114339 MARKERS, BLACK DURA‐INK, FOR KIT TOOL BOX
2
114340 SCOURING PAD, #96 MED DUTY, FOR KIT TOOL BOX
1
114343 FILE, 12", FLAT AMERICAN, FOR KIT TOOL BOX
1
114344 FILE, 10" SECOND CUT, FLAT, FOR KIT TOOL BOX

MWD Loadout List

2
114345 HANDLE, PLASTIC FILE, 21514, FOR KIT TOOL BOX
1
114346 WRENCH, STRAIGHT PIPE, 18", FOR KIT TOOL BOX
2
114347 CLAMP, C LIGHT DUTY 3", FOR KITTOOL BOX
1
12351 WD‐40, 11 OZ SPRAY CAN, FOR KIT TOOL BOX
1
114364 SOCKET, DEEP HEX, 7/8" x 1/2", DRIVE PROTO 5328
1
12354 RASP, STANLEY SURFOAM WOOD, 6", 21‐399
2
12355 BLADE, STANLEY SURFOAM REPLACEMENT
1
114365 KNIFE, UTILITY STANLEY 10‐099
5
114366 BLADE, UTILITY, HEAVY DUTY, 2 7/16" LONG, .024" THICK
1
114303 WRENCH, LONG ARM ALLEN HEX 1/4", ALLEN 58018
2
2
1
393‐136‐01 WRENCH, BLOWOUT PLUG
2
CONTACT CLEANER



Drill Collar Measurements Worksheet

Connection
Serial No. Description Type OD ID Length
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.
21.
22.
23.
24.
25.
26.
27.
28.
29.
30.



D9A10000-MAN-001
Revision E
Page i of iv
Index
A Caution advisory, defined 1-1

Changing Internal O-rings 9-21
advisory definitions 1-1 to 1-2 Changing O-rings in the Gamma (PTG)
Alerts 6-43, 6-72 Tool Assembly 9-41
Annulus Pressure 6-20, 6-62 Changing the Directional Sensor Assembly
Antenna-Rig Floor Generating with O-rings 9-32
Lots of Noise 2-3 Changing the O-rings on the
Antenna Placement 2-1 Snubber Centralizer 9-36
Archive a Job or Track 6-37 Changing the Transmitter Assembly
Archive Filename Formats 6-39 O-rings 9-22
Archive Job Utility 6-37 Changing the Transmitter Gap Sub
Archiving Job Data and Tool Configurations 6-37 Assembly 9-30
Assembling the Collar and Sleeve 7-32 Charging the EM Gap Sub Meter 7-11
Attach a Tool to a Track 6-36 Check Vibration 6-13
Average Linear 6-47 Checking the BlackStar DCA Meter 6-9
Average Linear. 6-4 Checking Tool Functions 6-41, 6-70
Cleaning the Amplifier Internal
Components 9-55
B Collar Measurement 8-1
Communication Plug 6-8
Battery Bulkhead 7-6 Communication Plug
Battery Centralizer Testing Equipment 9-14 Connected to Transmitter 6-50
Battery Test Box - Voltage Meter 7-4 Component replacement notice 1-4
Battery-to-Battery Centralizer 9-13 Computer Cooling Fan and Filter Cover 9-55
Baud rate Stage 1 6-13 Computer Power and Cooling Fan 9-54
BlackStar Battery Test Box 7-1 Configuration
BlackStar Battery Test Box antenna 2-5
Load On/Off Switch 7-3 Configuration Possibilities
Voltage Switch 7-3 antenna 2-5
BlackStar DCA COMPUTER Port 6-8 Configuring and Testing the
BlackStar DCA TOOL Port 6-8 BlackStar EM Tool with DCA 6-1, 6-7
BlackStar EM Gap Sub Tester 7-8 Configuring the Tool with SCA 6-49
Components 7-9 Connecting DCA Components 5-11
BlackStar EM Suite Connecting the Battery Bulkhead
3.16.1 or Higher System Requirements 9-3 to the 10-Pin Transmitter 4-4
install from CD 9-1 Connecting the BlackStar
install from FTP Site 9-2 Programming Box 6-50
install on Windows Vista 9-4 Connecting the DCA to the Computer 6-8
install without auto start 9-1 Conventions 1-1
BlackStar Programming Box 6-49 Creating a New Job 6-28
BlackStarEMVue 6-1 Creating a New Track 6-30
Main Dialog Window 6-2
Oscilloscope Window 6-40
D
C DB9 cable 6-50
DCA COMPUTER Port 6-8
Cable and Rod Selection for DCA to Computer Connection 6-8
Reference Antenna 2-2 Delay to Switch to 10 Watts 6-12, 6-54
Calibrating the DCA 6-43 Determine which Tools are Calibrated 6-42, 6-71
Calibrating the SCA 6-72 Digital Voltage Meter 7-4
i
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D9A10000-MAN-001
Revision E
Page ii of iv
Index
Directional Only 4-1 Greasing the Annular Pressure

Directional Probe 4-9 Lower Assembly 7-43
Directional Rotational Gamma (DRG) 4-10
Disassemble the Bow-Spring
Collet Assembly 9-23 H
Disassembling the Gap Sub Assembly 9-26
Downhole Tool Firmware Upgrade 9-20 Hard Disk Space 9-3
Down-Link 6-13, 6-56 Highside and Seating Marks 8-17
Down-Link Alerts 6-43, 6-72 Highside Universal Bottom Hole Orientation
Down-Link Option Dialog Window 6-13 (UHBO) Sleeve 8-4
DRG Battery Housing 4-10 to 4-11 Highsiding the Tool 6-25, 6-66
DRG Parameter Descriptions 6-23, 6-64 hot surfaces advisory, defined 1-2
Drilling a Shallow Well 2-3 Hysteresis 6-14, 6-56
DSP Flash Programmer 9-5
Parameters 6-23, 6-64
I
Inclination Limit and the Inclination
E Hysteresis 6-27
Inspecting a Gap Sub 7-14
Electro Magnetic (EM) Transmission 2-1 Install BlackStar EM Suite from CD 9-1
Theory 2-1 Install BlackStar EM Suite from
Electrostatic discharge advisory, defined 1-2 FTP Download 9-2
EM MWD Tool Assembly 4-1 Install Without Auto Start 9-1
EM Receiver Antenna Placement to Installing BlackStar EM Suite 9-1
Minimize Inner-Well Interference 2-7 Installing on Windows Vista 9-4
EM Signals 2-4 Installing O-rings and Parbak Rings
End frequency analyzer. 6-6 on the Stinger Assembly 7-39
Entering Tie-in Information 6-33 Installing SQL Server Express 9-2
Equipment safety notice 1-3 Installing the Push-On-Fin (POF) 7-47
IP Address Connect/Disconnect Field 6-46
F K
Field Maintenance and Service 7-1
Filtered Vibration Reading 6-14 Keyway Connections 7-7
Frame Switching 6-12, 6-55
Frequency A 6-13
Frequency and Baud Rates 6-11
L
Frequency Range Options 6-5 LED Indicator Results on the
EM Gap Sub Tester 7-13
G Leveling the Tool 6-67
Lift and Seat the Tool 8-7
Gamma Battery Housing 4-8 Lifting and Seating the Tool 8-1
Gamma Calibration 6-22, 6-63 Lifting Sling Assembly 8-7
Gamma Collar Attenuation 6-24, 6-65 Loading the Tool into the Collar 8-12
Gamma Configuration 6-19, 6-61 Locating Antenna 2-3
Gamma Tool Components 9-41 Loop-Back Testing for the DCA 6-44
General Information 1-1 Loop-Back-Testing for SCA 6-73
general safety notice 1-3
General System Safety Practices 1-4
ii
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D9A10000-MAN-001
Revision E
Page iii of iv
Index
M R
Manual conventions RAM 9-3
notes, cautions, and warnings 1-1 to 1-2 Reassemble Bow-Spring
MCM 9-20 Collet to Pressure Housing 9-29
Measure Seating Alignment 8-18 Reassemble Cross-Over Sub Assembly
Measuring the Tool Length and Collars 8-1 to Pressure-Housing Component 9-40
Meter readings 6-9 Reassemble the Cable Harness
Modulation Type 6-12, 6-54 Wiring Connection 9-39
Monitor Transmitter A/D 6-16, 6-59 Reassembling Gap Sub Component
Muleshoe Wrench 8-5 to Transmitter Assembly 9-27
Multiple EM Tools in Close Proximity 2-4 Reassembling Snubber Centralizer to Pressure
MWD Tool Measurement 8-1 Housing Component 9-39
Reassembling the Cable Wiring Harness 9-29
Reassembling the Gamma Tool 9-46
N Recommended Tools 1-3
Recommended Tools and Supplies 9-21
New Style Single Channel Amplifier 9-53 Reconnecting Bow Spring
note advisory, defined 1-1 Collet to Pressure Housing 9-30
notices Reference Antenna Locations 2-2
component replacement 1-4 Referenced Drawings and Schematics A-1
general system safety practices 1-3 Re-installing the BlackStar EM Suite 9-3
personnel training 1-3 release notes.txt 9-4
recommended tools 1-3 Removing Old O-rings from the Bow-Spring
safety requirements 1-3 Collet 9-25
Replacing Components 1-4
O Replacing O-rings 7-27
Replacing O-rings on the Cross-Over
Old Style Single Channel Inside Sub Assembly 9-35
Connection 9-52 Replacing O-rings on the
Open Calibrated Tools in EM Gap Sub Assembly 9-27
Control Panel 6-71 Replacing O-rings on the
Open Circuit Voltage 9-20 Snubber Centralizer 9-38
Operating Multiple EM Tools 2-4 Replacing the O-rings on the
Operating Systems 9-3 Bow-Spring Collet 9-25
Oscilloscope Window 6-69 Replicated Frequency Settings 6-48
Running EM Control Panel 6-69
P S
Parameter Description 6-35
PC Processor 9-51 safety notice 1-3
Performing the Loop-Back Test 6-44, 6-73 Safety Requirements 1-3
Personnel Training 1-3 SCA (Side View) 9-47
personnel training requirements notice 1-3 SCA Internal Components 9-48
Positioning and Lifting the Tool on the Rig 8-11 Seating Alignment 8-16
Prerequisite to Moving the Tool to the Rig 8-10 Seating and Highside Alignment 8-17
Processor 9-3 Select Channel 6-4
Program Loader 9-20 Selecting Frequency 6-2, 6-46
programming box meter 6-51 Selecting Survey and Steering Frame
PTG Setup Main Window 6-61 Parameters 6-15, 6-57
iii
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D9A10000-MAN-001
Revision E
Page iv of iv
Index
Self-testing the Gap Sub Meter 7-10 Updating the Dual Channel Amplifier (DCA)
Servicing the Battery Bulkhead 9-7 to 9-8 Software 9-5
Servicing the EM BlackStar Single Verifying that the Tool is Seated 8-16
Channel Amplifier (SCA) 9-47 Verifying the Proper Signal 6-41, 6-70
Servicing the Transmitter Contact Verifying the proper signal on “Oscilloscope 6-69
Collet Assembly 7-27 Vibration 6-19, 6-60
Servicing the UBHO 7-16 Vibration Hysteresis 6-13
Setting the Inclination Limit Vibration Limit (G) 6-13
and the Inclination Hysteresis 6-68 Vibration Mode 6-13, 6-55
Setting the Unit of Measures 6-32 Vibration Tare 6-13
Setting Up a New Track 6-30 Vibration Time Constant 6-13
Shop Maintenance and Service 9-1 warning advisory, defined 1-1
Signal 6-70 Wellhead Antenna 2-1
Signal Methods 2-2 Windows Authentication 9-2
Signals 6-41
Software Release 9-4
Spectrum 6-4
SQLEXPRESS 9-2
Starting BlackStar EMXConfig 6-10
Survey and Steering Frame Parameters 6-15
Surveys before power-down 6-13
T
Testing a Gap Sub 7-12
Testing and Configuring the
Pressure Transducer 6-21, 6-63
Testing Equipment 7-8
Testing the Battery Bulkhead 9-17
Testing the Battery-to-Battery Centralizer 9-13
Testing the BlackStar Surface Amplifier 9-56
Timed Mode 6-14, 6-57
tool recommendation notice 1-3
Tool Seating Alignment Marking 8-3
Tool Spacing 6-34
Tools and Supplies Required 9-7
Top Contact Assembly 8-7
Transmission System 6-55
Transmitter and Lemo Connection 9-14
Transmitter Assembly Components 9-22
Transmitter Configurations 6-54
U–W
UBHO 8-4
UBHO Alignment Mark 8-4
UBHO Torque Specifications 7-24
Uninstall previous BlackStarEMSuite 9-2
Unloading Sleeve from the UBHO 7-24
iv
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Operations Manual Blackstar EM MWD

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Operations Manual Blackstar EM MWD

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Printed By: kanagasabair Printed On: 2012.11.06.16.01.

Reference Reference Description

TC Number: D9A1000051-MAN:9A Printed REV: E Latest REV: E

TC Number: D9A1000051-MAN:9A Printed REV: E Latest REV: E

C 11.19.2009 Revision C Release Mary Taylor Raj Kanagasabai Raj Kanagasabai

B 10.09.2009 Updates Raj Kanagasabai Raj Kanagasabai Raj Kanagasabai

Rev Date (dd.mm.yyyy) Reason for issue Prepared Checked Approved

Revision Change Description

B Reorganized manual chapter structure, added and revised original release

C Update and Release for Chinese Translation

D Add Triple Output Transmitter

TC Number: D9A1000051-MAN:9A Printed REV: E Latest REV: E

TC Number: D9A1000051-MAN:9A Printed REV: E Latest REV: E

Chapter 2: Electro Magnetic (EM) Transmission

Chapter 3: Tool String Components

Chapter 4: EM MWD Tool Assembly

TC Number: D9A1000051-MAN:9A Printed REV: E Latest REV: E

Chapter 6: Tool String Testing

TC Number: D9A1000051-MAN:9A Printed REV: E Latest REV: E

Running BlackStarEMVue . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109

Chapter 7: Field Maintenance and Service

TC Number: D9A1000051-MAN:9A Printed REV: E Latest REV: E

Servicing the UBHO . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 172

Chapter 8: Lifting and Seating the Tool

Chapter 9: Shop Maintenance and Service

TC Number: D9A1000051-MAN:9A Printed REV: E Latest REV: E

Servicing the Battery Bulkhead . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 250

TC Number: D9A1000051-MAN:9A Printed REV: E Latest REV: E

Chapter 10: Product Support Information

Appendix A: Drawings and Schematics

Appendix B: Lithium Battery Safe Handling

TC Number: D9A1000051-MAN:9A Printed REV: E Latest REV: E

The note symbol indicates that additional information is

The warning symbol indicates a definite risk of

The hot surface symbol indicates the presence of a

The Electrostatic Discharge (ESD) symbol indicates the

TC Number: D9A1000051-MAN:9A Printed REV: E Latest REV: E

TC Number: D9A1000051-MAN:9A Printed REV: E Latest REV: E

General System Safety Practices

 Isolate energy sources before beginning work.

TC Number: D9A1000051-MAN:9A Printed REV: E Latest REV: E

Electro Magnetic (EM) Transmission

Basic EM Transmission Theory

Connecting the Wellhead Antenna

If noise becomes an issue, remove the wellhead

The Cable and Rod Selection for the Reference Antenna

Reference Antenna Locations

Increasing Signal Methods

TC Number: D9A1000051-MAN:9A Printed REV: E Latest REV: E

Methods for Locating Antenna

Refer to the following two method examples to locate the antenna:

Method 1: Rig Floor Generating Lots of Noise

Method 2: Drilling a Shallow Well

TC Number: D9A1000051-MAN:9A Printed REV: E Latest REV: E

Operating Multiple EM Tools in Close

Figure 2-1. EM Signals

TC Number: D9A1000051-MAN:9A Printed REV: E Latest REV: E

Configuration 1: - EM Transmitters set to a data transmission rate of 1 Baud:

Table 2-1. Configuration 1

1 3/1 4/1 5/1 6/1 7/1 8/1 9/1

2 4/1 5/1 7/1 9/1 suggested

TC Number: D9A1000051-MAN:9A Printed REV: E Latest REV: E

TC Number: D9A1000051-MAN:9A Printed REV: E Latest REV: E

Configuration 2: EM Transmitters set to a data transmission rate of 2 Baud to