GE Oil & Gas

Drilling & Production

Sondex* Wireline

XTU Downhole Controller

111/16”, Ultralink™ / Ultrawire™
Operation & Maintenance Manual

Tool Code: XTU009

Document: MN-XTU009
Revision: A
Date: 28 October 2011

* Denotes a trademark of the General Electric Company

 XTU009
XTU Downhole Controller Contents

Contents

0 About This Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0-1

0.1 Manual History ..................................................................................................................................0-1
0.2 Technical Help ...................................................................................................................................0-1
0.3 Feedback..............................................................................................................................................0-1

1 Overview. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-1
1.1 Features................................................................................................................................................1-1
1.2 Interfacing & Tool Combinations ..............................................................................................1-1
1.3 Specifications.....................................................................................................................................1-2

2 Safety. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-1
2.1 Hazardous Areas & ‘Hotwork’ ...................................................................................................2-1
2.2 Electrical Hazard .............................................................................................................................2-1
2.3 Stored Energy.....................................................................................................................................2-2
2.3.1 Trapped Pressure Safety Precautions 2-2
[Link] REMEMBER - Do NOT do the Following 2-2
[Link] Recommended Precautions to Follow - DO the Following 2-3
2.4 Irritants..................................................................................................................................................2-3
2.4.1 Liquid-O-Ring® Type 101 Lubricant 2-4
2.5 Greases & Sealants ........................................................................................................................2-4
2.6 Electrostatic Discharge (ESD)......................................................................................................2-4
2.7 Hot Surfaces .......................................................................................................................................2-4
2.8 WEEE Disposal Information ........................................................................................................2-5

3 Theory of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-1

3.1 Block Diagram ...................................................................................................................................3-1
3.2 Description ..........................................................................................................................................3-1
3.2.1 PSU 3-1
3.2.2 Controller 3-2
3.2.3 Ultralink™ Modem 3-2
3.2.4 Ultrawire™ Modem 3-2

4 Operating Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-1

4.1 Pre-Logging Checks ........................................................................................................................4-1
4.1.1 Mechanical 4-1
4.1.2 Electrical 4-1
4.1.3 Operating 4-1
4.2 Connecting to Toolstring ..............................................................................................................4-1
4.3 Logging .................................................................................................................................................4-1
4.3.1 Default Operation 4-2
4.3.2 Operator Control 4-2
4.3.3 Logging Speed 4-3
4.4 Post-Logging Checks .....................................................................................................................4-3
4.4.1 Relief of Trapped Pressure from Tool Joints 4-4
4.4.2 Toolstring Disassembly 4-4
4.5 Transport, Handling & Storage .................................................................................................4-4

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Document: MN-XTU009 Revision: A Created: 28 October 2011 i
 XTU009
XTU Downhole Controller Contents

5 Mechanical Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-1

5.1 Disassembly........................................................................................................................................5-1
5.1.1 Trapped Pressure - Tool Disassembly 5-1
5.1.2 Electronics Section 5-1
5.1.3 Servicing the Feedthrough Assembly 5-2
5.2 Reassembly.........................................................................................................................................5-2
5.2.1 Electronics 5-2
5.3 Routine Maintenance ....................................................................................................................5-3

6 Electrical Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-1

6.1 Processor Circuit Board.................................................................................................................6-1
6.2 PSU/Telemetry Board.....................................................................................................................6-1

7 Extended Checks. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-1

7.1 Preventative Maintenance...........................................................................................................7-1
7.1.1 Greases & Lubricants 7-1
7.1.2 Mechanical 7-1
7.1.3 Electrical 7-1
7.1.4 Ageing of Electronics 7-2
7.1.5 Heat Testing Above 150°C (302°F) 7-2
7.2 Extraordinary Maintenance ........................................................................................................7-2
7.2.1 O-Ring Replacement 7-2
7.3 Troubleshooting................................................................................................................................7-3

Appendix A Equipment & Spares . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-1

A.1 Main Equipment............................................................................................................................... A-1
A.2 Ancillary Equipment ....................................................................................................................... A-1
A.3 Maintenance Equipment ............................................................................................................. A-1
A.3.1 Greases, Lubricants & Thread Lock A-1
A.3.2 Field Handling Tools A-1
A.3.3 Shop Service Tools A-1
A.4 Recommended Spares ................................................................................................................. A-2
A.4.1 Mechanical Spares A-2

Appendix B Drawings & Parts Lists . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-1

B.1 Mechanical Drawings .................................................................................................................. B-1
B.2 Electrical Drawings ........................................................................................................................ B-1

Appendix C Fitting of Anti-Extrusion Rings . . . . . . . . . . . . . . . . . . . . . . . . . . . .C-1

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Document: MN-XTU009 Revision: A Created: 28 October 2011 ii
 XTU009
XTU Downhole Controller Chapter 0. About This Manual

0 ABOUT THIS MANUAL

0.1 Manual History

Date Issue Description Auth Chk App
27/10/11 A First Issue PR/CW PR/ PR
SL/
CH/
TG

0.2 Technical Help

For further technical help contact GE Oil & Gas Technical Services as follows:

Address: GE Oil & Gas

Building X107
Range Road
Cody Technology Park
Farnborough
Hampshire
GU14 0FG
United Kingdom

Telephone: +44 (0)1252 862200
Fax: +44 (0)1252 862349
Web: [Link]/downholetechnology

0.3 Feedback
Please help us to improve future issues of this manual by adding your comments or corrections to
[Link]/downholetechnology, referencing the document number.

Thank you.

Photographs and sketches are for illustration purposes only. Depending on the tool model
that you have, certain features or dimensions may differ from those shown.

Documents from external sources (i.e.: MSDS) either supplied with or referenced to in this
manual, are considered the latest version at the time the manual was issued. However, the
document may be altered by the external source without prior notice to Sondex Wireline
Ltd.

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Document: MN-XTU009 Revision: A Created: 28 October 2011 0-1
 XTU009
XTU Downhole Controller Chapter 1. Overview

1 OVERVIEW

The XTU Downhole Controller is an intelligent bridge between the

Ultrawire™ toolbus and the Ultralink™ telemetry system. It serves as a
communications interface and a programmable logging controller. It
also incorporates a DC-DC converter (switch mode power supply) to
convert the high voltage on the Ultralink™ line to power the Ultrawire™
toolbus.

In its capacity as a logging controller, the XTU polls each tool on the
toolstring for its data packet and assembles these data packets into
frames for uplink to the surface. The sequence, in which the tools are
polled, is either automatically generated by a logging program or
specified by the operator. By default, the polling program is generated
and executed by the XTU without any intervention from the surface
system.

1.1 Features
The XTU features:

• Fully automatic "plug and play" configuration and start-

up.
• Automatic identification of all the tools in the toolstring.
• Automatic generation of a default polling program that
enables all the identified tools to share the available
bandwidth on the wireline.
• Automatic transmission of the toolstring configuration to
the surface system.
• Selectable Ultralink™ bit rate (50-200kbits/s) to suit
varying demands and conditions.
• Automatic downlink failure detection triggers reversion to
default bit rate.
• Support for sophisticated downloadable user defined
logging programs.
• Detailed toolbus error detection and logging to facilitate
fault finding.
• Measurement of the XTU’s head voltage and its internal
temperature.

1.2 Interfacing & Tool Combinations

The XTU Downhole Controller can:

• Collect data from tools on the Ultrawire™ toolbus and to

transmit the data to surface via the Ultralink™ line (via
user control or automatically).
• Facilitate bi-directional communication between the
surface system and individual Ultrawire™ tools.
• Convert high voltage DC power from the Ultralink™ line to
supply the low voltage tools on the Ultrawire™ toolbus.

Figure 1-1 XTU009

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Document: MN-XTU009 Revision: A Created: 28 October 2011 1-1
 XTU009
XTU Downhole Controller Chapter 1. Overview

1.3 Specifications
Table 1-1 XTU009 Specifications

Parameter Specification Remarks

Maximum Operating 177°C (350°F) ---
Temperature
Pressure 20,000psi (138Mpa) ---
Diameter 111/16” (43mm) ---
Tool Length 19.9” (506mm) ---
Shipping Length 22.8” (579mm) ---
Weight 7.4lbs (3.4kg) Thread Protectors fitted
Operating Voltages:

• Range • +180 to 400VDC 

• Absolute Maximum • +600VDC Max. 10 secs


Current Consumption at 200V • 20mA (No Load)

• 28 to 30mA (running SCT)
Ultrawire™ Toolbus Current at 1.5A
Ambient (Max)
Ultrawire™ Output Voltage 16.2V to 17.2VDC Bottom Connector
Ultrawire™ Toolbus Current at 1A
177°C (350°F) Max.
End Threads (top/bottom) 13/16” UNF female/male
End Connectors (top/bottom) 4mm Banana single conductor pin/socket
Tools allowed on toolbus 62 Subject to power requirements
Ultrawire™ to toolbus data rate 500kbits/s
Ultralink™ uplink data rates 50, 71, 100, 143, 200kbits/s ---
Ultralink™ downlink rate 300bits/s ---

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Document: MN-XTU009 Revision: A Created: 28 October 2011 1-2
 XTU009
XTU Downhole Controller Chapter 2. Safety

2 SAFETY

In normal use, there are a few specific safety instructions for the safe handling of the XTU009. The
information that follows is a guideline only and should be followed in addition to any specific Company
and Local Rules & Regulations (Directives).

When the equipment is not installed, commissioned and used in accordance with the specifications of GE
Oil & Gas, any protection that may have been provided may be impaired.

2.1 Hazardous Areas & ‘Hotwork’

HAZARDOUS AREAS AND 'HOT WORK'!
WARNING!
This equipment may, under certain circumstances or failure modes,
become a potential source of ignition.
It may be used only in Safe Areas and may not be used in classif ied
Hazardous Areas ('Zoned' areas) unless a suitable system of work is in
place (e.g.: Hot Work Permit) and appropriate precautionary measures
have been followed (e.g.: monitoring for gas leaks, site inspection, f ire
f ighting equipment , work procedures).
This must be done in accordance with local and national legislation with
regard to the use of electrical equipment in potentially explosive
atmospheres.

2.2 Electrical Hazard

ELECTRICAL HAZARD!
WARNING!
Do not touch the chassis or the housing when powered. It might be at a
high potential in case of a loss of a return circuit .

Make sure the Tool Safety Clamp (P/N: 42703) is attached correctly to the
toolstring.

Within the XTU009 there are high voltages (above 50VDC / 50Vrms), care must be taken not to touch any
exposed electrical connections, wires or metal as they could be at a dangerous potential.

The tool is NOT intended for use in an explosive atmosphere because of the high voltages used within the
tool.

Extra care must be taken when handling the XTU009 when either the tool is wet or there are wet
conditions in the area of the XTU009. ALWAYS power down the XTU009 before you dismantle it.

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 XTU009
XTU Downhole Controller Chapter 2. Safety

2.3 Stored Energy

2.3.1 TRAPPED PRESSURE SAFETY PRECAUTIONS

TRAPPED PRESSURE!
WARNING!
The XTU009 has spaces within it that after a down hole leakage could
retain trapped pressure. As this pressure can be released at any time
without warning:
• Contact GE Oil & Gas Technical Services IMMEDIATELY for advice before
ANY maintenance is attempted
• Make sure all trapped pressure has been removed from the XTU009
before it is transported anywhere
Wear an approved protective faceshield when you handle a tool that
may contain trapped pressure.
Wear an approved protective apron when you handle a tool that may
contain trapped pressure.

Logging tools are subjected to harsh conditions downhole. High hydrostatic-pressure, high-temperature,
shock, vibration and contact with corrosive substances can all contribute to causing possible leaks into
sealed housings. Leak paths include but are not limited to:

• Permeation through the seals

• Seal failures
• Hairline cracks in welds

Should such a leak occur downhole, then as the tool is removed from the well and the external
hydrostatic-pressure reduces the liquid/gas that has leaked into the tool is expected to leak out again
through the path by which it entered. However, some of the liquid/gas may be retained and, occasionally,
the leak path may either partially or completely re-seal. This will trap the liquid/gas inside the tool. In this
case, when the tool returns to the surface, it can potentially have a significant volume of liquid/gas
stored inside with a significant amount of potential energy!

The trapped and pressurised fluid/gas could pose a safety hazard during handling, transportation or
storage as well as when the tool is dismantled for maintenance.

When the XTU009 displays any of these characteristics it should be considered as potentially containing
trapped and pressurised fluid/gas:

• Telemetry failures downhole

• Signs of mechanical damage
• Unusual seepage of fluid out of the tool or bubbling / hissing noises
• Tools that have been fished
• Tools that have been downhole for extended periods
• Hard to undo housings or housing split nuts.

[Link] REMEMBER - Do NOT do the Following

1 DO NOT point parts of the tool (that may become projectiles) at either yourself or others.

2 DO NOT try to release the pressure by removing filler plugs or other small plug items, unless
the instruction manual indicates specifically (Section 4.4.1, Relief of Trapped Pressure from
Tool Joints) that this is the correct method to release the trapped pressure.

3 DO NOT ignore the risk of trapped pressure and return the tool to its transportation packaging.
The tool may explode at any time due to sudden mechanical shock or changes in atmospheric
pressure. This could be dangerous dependant on the method of transport of the tool. For
example, when the tool is being transported within an aircraft.

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 XTU009
XTU Downhole Controller Chapter 2. Safety

4 DO NOT open the tool either in a confined space or inside a building as there could be a risk of
releasing toxic chemicals.

[Link] Recommended Precautions to Follow - DO the Following

1 Always wear Personal Protective Equipment (PPE) - hard toe boots, safety glasses and fluid
resistant gloves are a minimum.

2 Always leave the tool to stand in a cordoned-off safe area (preferably outside) marked with
hazard signs, for as long as possible (not less than 24hrs). Pressure may leak out slowly and
(with sufficient time) the pressure will reduce to a less dangerous and more manageable level.

3 Always put (in a prominent position) a noticeable warning indicator on the tool (marker pen,
sticky label, etc.) to tell others that it is suspected the tool contains trapped pressure. It is
advisable also to display (at a safe distance from the tool) large signs that can be read clearly
and convey the same warning.

4 Always make all colleagues and other operators in the area aware that the tool may contain
trapped pressure.

5 Always allow time for the tool to cool down to the ambient (room) temperature. Fluids
(especially gases) have more stored potential energy at a high temperature than at the
ambient (room) temperature. When the tool is allowed to cool down, it will reduce this potential
energy.

6 Always be aware that the well fluid inside the tool may be hazardous or toxic. For example, it
may contain Hydrogen Sulphide (H2S). Take the appropriate precautions to prevent harm to
operators, such as attempting to open the tool outside and the use of toxic-chemical
monitoring equipment.

7 Always be aware that the well fluid inside the tool may be a flammable gas or mist. Open the
tool away from sources of ignition or sparking.

8 Always make sure the suspect tool is disassembled until all volumes inside have been found to
be safe and free of pressure.

9 Refer to Section 5.1.1, Trapped Pressure - Tool Disassembly.

2.4 Irritants
Take these precautions when handling, storing or disposing of an irritant:

• Refer ALWAYS to the applicable Material Safety Data Sheet (MSDS) for the irritant
• Do NOT touch either your skin or your eyes whilst protective gloves are worn
• Do NOT allow the irritant to either contact the mouth or to be ingested

Should it be necessary to dispose of an irritant, the disposal MUST be in accordance with all Local Rules &
Regulations (Directives) that are in force in the country where the disposal is to take place. Should there
not be any, then International Rules & Regulations (Directives) MUST be obtained and followed.

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 XTU009
XTU Downhole Controller Chapter 2. Safety

2.4.1 LIQUID-O-RING® TYPE 101 LUBRICANT

LIQUID-O-RING® TYPE 101 LUBRICANT

IRRITANT!
Contact with the skin or the eyes can cause irritation.
Wear approved protective gloves.
Wear approved protective goggles/glasses.
Wash hands after use.
For more details, refer to the Material Safety Data Sheet (MSDS) for
Liquid-O-Ring® type 101.

2.5 Greases & Sealants

G REASES & S EALANTS !
C AUTION !
The use of certain greases and sealants that contain a volatile content can
cause electrical failure due to the production of corrosive gasses inside the
tool when heated.

GE Oil & Gas recommend users to use ONLY the greases and sealants as
specif ied for the Tool.

2.6 Electrostatic Discharge (ESD)

E LECTROSTATIC D ISCHARGE !
C AUTION !
The XTU009 contains electronic circuits and devices that can suffer
permanent damage when subjected to an electrostatic discharge.
When servicing the tool, take appropriate precautions to avoid
electrostatic discharge damage.

The tool should be handled with care. Whenever the tool is serviced, observe these precautions:

• All work on the electronics within this tool should be carried out at a safe anti-static
workstation
• Wear an ESD wrist strap that is connected to an approved ESD point
• Where applicable, wear approved electrostatic conducting footwear
• Avoid touching the tool electronics, unless stated otherwise in this manual.

2.7 Hot Surfaces

HOT SURFACES!
WARNING!
The XTU009 may, under certain circumstances or failure modes, become
hot .
Wear suitable protective gloves when the tool is handled.

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 XTU009
XTU Downhole Controller Chapter 2. Safety

2.8 WEEE Disposal Information

E LECTRICAL E QUIPMENT D ISPOSAL !
C AUTION !
Electrical equipment must be disposed of in accordance with any Local /
International Rules and Regulations for the collection framework available to
customers for the return, recycling and treatment of electrical wire and
components.
For more information see: [Link]

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 XTU009
XTU Downhole Controller Chapter 3. Theory of Operation

3 THEORY OF OPERATION

3.1 Block Diagram

ULTRALINK™

80891 XTU PSU / Telemetry PCB

180 to 400 VDC

Ultralink Modem
Ultrawire PSU (SMPS)

15 to 18 VDC

+5V

Controller

Ultrawire Modem

80897 XTU Processor PCB

ULTRAWIRE™

Figure 3-1 Block Diagram XTU

3.2 Description
The XTU Telemetry Controller consists of 4 main functional blocks as shown in the block diagram.

3.2.1 PSU

The PSU is a switched mode power supply, which steps down the high voltage DC on the Ultralink™ line
to provide for local power requirements and to power the Ultrawire™ toolstring.

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 XTU009
XTU Downhole Controller Chapter 3. Theory of Operation

3.2.2 CONTROLLER

The Controller is responsible for controlling communication and logging activities on the Ultrawire™
toolbus and for sending data to the surface system via the Ultralink™ Telemetry System. A full duplex
downlink allows the user to configure and control operation from the surface prior to and during logging.

Control is exercised by means of commands, which may be executed by the controller, or passed to other
tools via the toolbus. Where command execution generates a response, this is generally uplinked to the
surface via the Ultralink™. Commands may originate from the surface or from the logging program,
which runs on the local CPU.

3.2.3 ULTRALINK™ MODEM

The Ultralink™ Modem forms the hardware interface between the controller and the e-line mono-cable,
which carries data to and from the surface system. Uplinks are modulated onto the line as AMI (alternate
mark inversion) at selectable bit rates of 50, 71, 100, 143 and 200kbits/s with amplitude of 5V (nom. pk.).
The Ultralink™ uplink is synchronous. It maintains bit, word and frame lock at all times by transmitting
NULL Frames whenever there is no active data traffic. Downlinks at 300bits/s are asynchronous AMI, with
amplitude of 8V (typ). The Ultralink™ is full duplex so the uplink is not disturbed during a downlink.

3.2.4 ULTRAWIRE™ MODEM

The Ultrawire™ Modem forms the hardware interface between the controller and the Ultrawire™ toolbus.
The single pin bus carries power to the tool in addition to its telemetry function. The return for both power
and signal is via the chassis. Telemetry is modulated onto the line as 1.5V AMI (alternate mark inversion)
at 500kbits/s. Ultrawire™ is a half-duplex master slave protocol. The controller, which is always the
master, sends a command to the toolbus and the tools respond as appropriate for the command. Both
command and response packets may optionally carry attached data packets.

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 XTU009
XTU Downhole Controller Chapter 4. Operating Procedure

4 OPERATING PROCEDURE

4.1 Pre-Logging Checks

4.1.1 MECHANICAL

LIQUID-O-RING® TYPE 101 LUBRICANT

WARNING!
For more information refer to Section 2.4.1, Liquid-O-Ring® Type 101 Lubricant.

Ref.: General Assembly AD-09800

Clean and grease lower O-Ring seals with Liquid-O-Ring® type 101. Refer to Section 5.2, Reassembly.

Make sure that upper and lower electrical connectors are clean, dry and undamaged. Replace when
necessary.

4.1.2 ELECTRICAL

Using a Multimeter, check the Current Consumption @200V. The readings should be as follows:

• 18mA ±2mA (no tools connected below).

• 25-35 mA for a typical PL toolstring.

Using a Multimeter, check the voltage out at lower connector. The readings should be 16.7V ±0.5V.

4.1.3 OPERATING

The XTU009 must be operated as part of a compatible telemetry and logging system, such as the Sondex
ULP (Ultralink™ Logging Panel) together with the Warrior logging system. Only Sondex Ultrawire™
compatible tools can be logged, using the XTU controller. However compatibility features are available to
allow alternative telemetry protocols to co-exist on the toolbus.

The logging system may be tested with a dummy cable in place of a real cable. It is not recommended
that the XTU009 is connected directly to the Ultralink™ Surface Panel.

4.2 Connecting to Toolstring

The XTU telemetry controller must be connected above the top Ultrawire™ tool. Up to 62 Ultrawire™ tools
may be connected below it, provided that maximum toolbus currents are not exceeded. Upper and lower
tool joint O-rings and seal surfaces should be clean, undamaged and lightly greased.

Note: A GO-Sondex Adapter is supplied with the tool.

Centralisers: The tool does not require any centralising.

4.3 Logging
The XTU009 may be operated over a wide range (120 - 400V) of input voltage though the PSU will not
start until the head voltage reaches about 170V.

The optimum head voltage will depend on the cable and the tools in the string, but in general the aim
should be to keep the line current to a reasonable level. A typical PL string on standard 7/32” cable should
be run at about 200V. If the line current exceeds 100mA, then it is preferable to increase the voltage to
keep the current to a minimum. Low power strings, such as the Sondex Short Compact Toolstring (SCT),
may be run at voltages as low as 120V.

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 XTU009
XTU Downhole Controller Chapter 4. Operating Procedure

The voltage at the tool head is sensed and sent to the surface to facilitate setting the appropriate
operating voltage.

4.3.1 DEFAULT OPERATION

The Ultralink™ uplink bit rate will default to 50kbits/s on power up. The controller will commence
delivering NULL frames to the surface within a few seconds to allow the surface system to synchronise.
Toolstring configuration is plug and play and configuration of the default logging program is fully
automatic. The XTU polls the toolstring to determine which tools are present and then builds a tool table
and a logging program. Information on the toolstring and the logging program is sent to the surface in a
set of configuration frames. The default logging program shares the available bandwidth between the
detected tools and will be an appropriate program for a majority of logging operations. However, for
specialized requirements, an alternative user generated logging program may be downloaded from the
surface system.

Once configuration is complete, the controller will send configuration frames continuously for a period of
one minute, unless the surface system initiates logging by sending a start polling command. After one
minute, the controller will automatically enter logging mode and execute the default logging program.

Execution of the logging programme will cause Main data frames to be uplinked to the surface. Each
main data frame will contain a timestamp indicating the time at which tools were sampled and the data
returned by each of the tools in the string.

If the toolstring contains more complex tools, which deliver large data sets (>27 words) or have sampling
latency greater than about 100ms, a secondary polling table will be created for these tools. Secondary
data frames containing the response from a single secondary loop tool will then be alternated with Main
data frames. This ensures that simple rate-meter tools are polled sufficiently frequently without being
squeezed out by slow or bandwidth hungry tools. The program will cycle through secondary tools,
skipping those that return ‘Not Ready’ when polled.

The operation of the telemetry may be monitored by the surface logging system, which will usually
support a telemetry monitor window. Errors are detected and reported to the surface system and may be
displayed or logged.

4.3.2 OPERATOR CONTROL

Commands may be sent from the surface to exercise user control of the XTU009 or any of the Ultrawire™
tools on the string. Although the Ultralink™/Ultrawire™ protocol supports a large set of commands, only
a few are likely to be required for standard production logging runs. The surface system will give the user
access to an appropriate sub-set of the possible commands. These will include as a minimum,
commands to start and stop logging and to change the bit rate on the Ultralink. If power is cycled, the
XTU controller will rebuild the configuration and then deliver Config frames for one minute. These can be
skipped by sending the Start Polling command to the controller. Commands are ignored during
configuration, therefore the operator should wait until Config frames are indicated before sending
commands.

The bit rate may be changed by sending a ‘Bit Rate’ command to the controller. The new bit rate will be
retained until either the operator modifies it again or until a ‘health timeout’ (see below) occurs. In the
event of a health timeout, the bit rate will default to 50kbits/s, unless the operator has set a higher
default bit rate by sending the ‘Default Bit Rate’ command.

The XTU controller monitors the health of the Ultralink™ downlink. To allow this to happen in the absence
of operator intervention, the surface system will normally send a NULL command on the downlink at
least once a minute. When no commands are received from the surface, the controller will generate a
health timeout. This will cause the uplink bit rate to revert to the default bit rate and also cause the
controller to transmit Config frames to the surface at regular intervals. If the downlink is restored,
transmission of Config frames will cease, but the default bit rate will be retained until the operator once
again changes it.

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 XTU009
XTU Downhole Controller Chapter 4. Operating Procedure

A PRT sensor is located within the Electronics Chassis to monitor the internal temperature, which should
not be allowed to rise above 200°C (392°F).

4.3.3 LOGGING SPEED

Table 4-1 are guidelines only and must be used in conjunction with local policy and specific well site
conditions both downhole and at surface. The table below is appropriate for near vertical wells and must
be adjusted accordingly when in deviated wells. Use of a Head Tension Unit is highly recommended.

Note: Do not exceed the calculated safe working load of your selected weak point. If in doubt, use a head
tension unit, especially in deviated wells where calculation from surface tension is less accurate.

Table 4-1 Logging Guidance

Depth (ft) Speed Pulling Out of Hole Speed Running in Hole
In/out of catcher  Dead slow or manual.
(pressure rig up only)
30 to 150 30ft/min
150 to 400 60ft/min
>400 clear cased hole Surface tension not to exceed Surface tension should not be
120% of tension when tool less than 80% of tension when
stationary. Speed not to exceed tool stationary. Speed not to
150ft/min. exceed 150ft/min.
>400 clear open hole Surface tension not to exceed Surface tension should not be
130% of tension when tool less than 70% of tension when
stationary. Speed not to exceed tool stationary. Speed not to
150ft/min. exceed 150ft/min.
Approaching  30ft/min
potential obstaclesa
Logging Data Do not exceed the above speeds.

Recommended speed is <30ft/min.

a.
For example: Reduced diameters, gas lift mandrels, fluid levels, valves, tubing shoes, packers, cross
overs and other downhole equipment.

4.4 Post-Logging Checks

TRAPPED PRESSURE!
WARNING!
The XTU009 has spaces within it that after a down hole leakage could retain
trapped pressure. As this pressure can be released at any time without warning:

Refer to Section 2.3.1, Trapped Pressure Safety Precautions to familiarise

yourself with the required safety procedures before attempting to dismantle the
tool.

When any of the following circumstances are encountered or it is suspected that the tools may have
leaked then you must proceed as if the tools contain trapped pressurised fluid/gas until otherwise
determined. The characteristics of trapped pressure are:

• Telemetry failures downhole

• Signs of mechanical damage
• Unusual seepage of fluid out of the tool or bubbling / hissing noises
• Tools that have been fished
• Tools that have been downhole for extended periods
• Hard to undo housings or housing split-nuts.

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 XTU009
XTU Downhole Controller Chapter 4. Operating Procedure

4.4.1 RELIEF OF TRAPPED PRESSURE FROM TOOL JOINTS

To relieve the trapped pressure at the tool joint, complete these steps:

1 Place a rag over the tool joint. This will diffuse any jet of gas or fluid emerging from the joint.

2 SLOWLY unscrew the tool joint. Should there be trapped pressure inside the tool joint, the tool
joint may well be tighter than usual and require more torque than normal to undo.

3 At some point, well before the threads of the tool joint disengage, fluid or gas release will occur.
As soon as any hissing or fluid appearance is noted, cease immediately unscrewing the tool
joint and allow the pressure to dissipate before unscrewing it further. This way, the pressure
load on the tool joint can be retained safely by the threads that remain engaged.

4 Once the operator is satisfied that no more fluid is escaping, resume to SLOWLY unscrew the
tool joint. When further hissing or signs of fluid escape are evident, cease immediately the
unscrewing and allow the pressure to dissipate.

5 Repeat these steps until all trapped pressure within the tool joint is released and there is no
pressure loading on the tool joint.

On the XTU009 the Secondary Pressure Barrier on the Female MonoConn Connector (item 23, 42713)
fitted to the Lower Sub (item 5, 09800) tool joint is free to disengage from the Lower Sub under the action
of internal pressure within the XTU009.

During operation downhole, it is retained in place by the neighbouring tool connected beneath the
XTU009. As this tool is disconnected from the XTU009, the MonoConn Connector will emerge from the
Lower Sub and relieve the internal pressure before the tool joint thread disengages.

The MonoConn Connector is prevented from exiting the Lower Sub completely by means of a Spirol
Retaining Ring (item 24, 42713) which allows the MonoConn Connector to emerge just far enough to
release the O-Ring seal. Refer to Section 5.1.1, Trapped Pressure - Tool Disassembly to check that the
MonoConn Connector is seated correctly and has not been pushed out by internal pressure release.

4.4.2 TOOLSTRING DISASSEMBLY

1 The toolstring should be cleaned before disassembly.

2 Make sure that well fluid does not reach the electrical connectors. Disassemble in a horizontal
position wherever possible.

3 Refit thread protectors immediately after disassembly to prevent damage.

4.5 Transport, Handling & Storage

LIQUID-O-RING® TYPE 101 LUBRICANT
WARNING!
For more information refer to Section 2.4.1, Liquid-O-Ring® Type 101 Lubricant.

Store with end threads lightly greased with Liquid-O-Ring® type 101 and with water tight thread
protectors fitted.

The tool should be transported to site in the transport case provided.

Do not subject the tool to extreme shock, such as dropping or hitting with a hard object.

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Document: MN-XTU009 Revision: A Created: 28 October 2011 4-4
 XTU009
XTU Downhole Controller Chapter 5. Mechanical Description

5 MECHANICAL DESCRIPTION

The principal elements of the XTU009 telemetry controller are the Pressure Housing and Electronics
Cartridge, containing a PSU/Telemetry PCB and a Processor PCB. The upper and lower joints have
standard GE Oil & Gas connectors. Below are instructions about how to disassemble and reassemble the
tool for servicing.

5.1 Disassembly

5.1.1 TRAPPED PRESSURE - TOOL DISASSEMBLY

Before disassembling the XTU009 check the condition of the Female Monoconn Connector (item 23,
42713) in the Lower Sub (item 5, 42713). When seated correctly the face of the Monoconn Connector
should be at least 4mm back from the Spirol Retaining Ring. Should the Monoconn Connector be pushed
out against the Spirol Retaining Ring (item 24, 42713) then it is likely that the XTU009 has suffered a
pressure leak and the internal pressure was purged when the XTU009 was disconnected from the
toolstring.

Inspect the Electronics Assembly carefully, it is likely that the complete Electronics will have suffered from
pressure, fluid and/or corrosion damage and will need to be replaced in its entirety.

5.1.2 ELECTRONICS SECTION

Ref.: General Assembly AD-09800

Electronics Assembly AD-42713
Electronic Chassis Assembly AD-10589

1 Unscrew and remove the Pressure Housing (item 3, 09800) from Electronics Assembly (item 1,
09800).

The Electronics section internal chassis is hard wired to the Lower Sub (item 5, 42713) and
remains fixed by three Grub Screws (item 9, 10589).

It is not normally necessary to separate the Electronics Chassis from the Lower Sub but should
you need to do this, screw in the Grub Screws (clockwise) just far enough to release the Lower
Sub.

Take care not to damage the Line wire which will need to be unsoldered to separate the
Electronics and Lower Sub completely.

2 To access the Electronics boards, remove the four Csk Screws (item 6, 10589) from the Top Half
Shell (item 1, 10589) and lift the Top Half Shell clear of the Electronics Chassis.

T HE L OWER C OVER FORMS AN INTEGRAL PART OF THE CHASSIS AND SHOULD NOT BE
C AUTION ! REMOVED .

H ARDWIRED E LECTRONICS A SSEMBLY :

C AUTION !
The PSU/Telemetry PCB is soldered into the Electronics Assembly and mounted to
the Heatsink. It is advised not to service the Electronics boards, but to return to GE
Oil & Gas for repair.

3 On the Upper Bulkhead (item 3, 42713) of the Electronics Chassis there is a Canted Coil Spring
(item 26, 42713) that provides the ground connection between the Electronics Chassis and the
Pressure Housing.

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XTU Downhole Controller Chapter 5. Mechanical Description

4 The Canted Coil Spring (item 26, 42713) should be checked every time the Electronics Chassis is
removed from the Pressure Housing to make sure that it is clean and in good condition, replace
as required.

5 The Upper Connector Assembly should not normally require any servicing. It is retained inside
the Upper Bulkhead (item 3, 42713) by a spring (item 6, 42714) and circlip (item 5, 42714).

To access the upper connector assembly separate the Upper Bulkhead (item 3, 42713) from the
Heatsink Bulkhead (item 1, 42713) by removing the two M3 Csk screws (item 10, 42713).

5.1.3 SERVICING THE FEEDTHROUGH ASSEMBLY

LIQUID-O-RING® TYPE 101 LUBRICANT

WARNING!
For more information refer to Section 2.4.1, Liquid-O-Ring® Type 101 Lubricant.

Ref.: General Assembly AD-09800

Electronics Assembly AD-42713

1 Remove the Upper Thread Protector (item 4, 09800).

2 Unscrew the Pressure Feedthrough Assembly (item 2, 09800) from the top of the Pressure
Housing (item 3, 09800).

3 Inspect the Feedthrough Assembly for damage and replace as required.

4 Inspect and clean or replace the O-Ring (item 12, 09800) and grease the O-Ring with a light
coating of Liquid-O-Ring® type 101.

5 Replace the Feedthrough Assembly into the housing and screw in fully.

6 Refit the Upper Thread Protector (item 4, 09800).

5.2 Reassembly

5.2.1 ELECTRONICS

LIQUID-O-RING® TYPE 101 LUBRICANT

WARNING!
For more information refer to Section 2.4.1, Liquid-O-Ring® Type 101 Lubricant.

Ref.: General Assembly AD-09800

Electronics Assembly AD-42713
Electronics Chassis Assembly AD-10589
Wiring Diagram XTU Chassis Assembly WD-80893

Note: All item numbers in this section refer to drawing AD-09800, unless stated otherwise.

1 When the chassis mounted transistors/diodes have been removed or replaced, they should be
re-fitted with the insulators as shown in WD-80893.

2 Check for damaged and crushed wires.

3 Make sure the that the PCBs are fitted correctly, that all wiring is routed correctly and secure,
then refit the Top Cover Half Shell (item 1, 10589) and secure with the four Csk Screws (item 6,
10589).

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 XTU009
XTU Downhole Controller Chapter 5. Mechanical Description

4 Check that the Upper Bulkhead Assembly (item 3, 42713) including the connector contacts is in
good condition and that the Canted Coil Spring (item 26, 42713) is fitted and in good condition.

5 Clean and grease the O-Ring seals and Anti-Extrusion Rings with Liquid-O-Ring® type 101.
Replace the O-Rings when required, refer to Section 5.2, Reassembly.

6 Clean the pressure seal surfaces at both ends of the Pressure Housing (item 3, 09800). Make
sure that the housing is free from debris.

7 Make sure the Electronics Assembly (item 1, 09800) is free from any dirt / debris.

8 Slide the Pressure Housing (item 3, 09800) onto Electronics Assembly (item 1, 09800) and screw
onto the Lower Sub.

5.3 Routine Maintenance

LIQUID-O-RING® TYPE 101 LUBRICANT
WARNING!
For more information refer to Section 2.4.1, Liquid-O-Ring® Type 101 Lubricant.

Ref.: General Assembly AD-09800

Electronics Assembly AD-42713

GE Oil & Gas recommend that all the primary O-Ring seals are replaced after every run and that
secondary O-Ring seals are replaced at least every 25 runs (more often if the tool is run in hot wells or
corrosive gasses). The Anti-Extrusion Rings should be cleaned and checked every time the O-Rings are
replaced and replaced at least every 25 runs. Refer to Section Appendix C, Fitting of Anti-Extrusion
Rings for further information.

All O-Rings should be lightly greased with Liquid-O-Ring® type 101 before they are refitted. Complete the
instructions below to service the primary and secondary O-Rings and Ant-Extrusion Rings:

1 Remove the Lower Thread Protector (item 5, 09800). There are two primary seal O-Rings 
(item 13, 09800) each fitted with an Anti-Extrusion Ring (item 10, 09800).

2 Unscrew and remove the Pressure Housing (item 3, 09800) from the Electronics Assembly 
(item 1, 09800). There are two primary seal O-Rings (item 14, 09800) each fitted with an Anti-
Extrusion Ring (item 11, 09800) on the upper end of the Lower Sub (item 5, 42713).

3 With the Pressure Housing (item 3, 09800) removed check the condition of the Canted Coil
Spring (item 26, 42713) fitted to the Upper Bulkhead (item 3, 42713) on the Electronics Chassis
(item 1, 09800) to make sure that it is clean and in a serviceable condition, replace the Canted
Coil Spring as required.

4 There is a secondary seal O-Ring (item 27, 42713) on the Female Monoconn Connector (item
23, 42713). To access this O-Ring do the following:

i. Remove the Spiral Retaining Ring (item 24, 42713).

ii. Insert and engage the threads of a M4 screw (minimum length 25mm) with the female
threads at the bottom of the Monoconn Connector (item 23, 42713) and gently pull on the
screw to extract the Monoconn Connector from the Lower Sub (item 5, 42713).
iii. Take care when extracting the Monoconn Connector as the Ultrawire Line wire feeds
through the Lower Sub from the Electronics Chassis and is soldered to the rear of the
Monoconn Connector.
iv. After servicing or replacing the secondary O-Ring seal (item 27, 42713), refit the
Monoconn Connector by gently easing it back into the Lower Sub. Take care not to trap or
otherwise damage the Ultrawire Line wire.

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 XTU009
XTU Downhole Controller Chapter 5. Mechanical Description

v. Push the Monoconn fully home until it comes up against a hard stop. When correctly
seated, the end face of the Monoconn Connector should be at least 4mm beyond the
retaining ring groove.
vi. Refit the Spiral Retaining Ring (item 24, 42713).

5 Unscrew the Upper Thread Protector (item 4, 09800). There is an O-Ring fitted to the Upper
Thread Protector (P/N: 95211). This O-Ring provides an environmental seal during transit and
storage and should be cleaned and lightly greased with Liquid-O-Ring® type 101. It should be
replaced when damaged.

6 In the top of the Pressure Housing (item 3, 09800) there is a secondary seal O-Ring (item 12,
09800) on the Pressure Feedthrough Assembly (item 2, 09800). Refer to Section 5.1.3, Servicing
the Feedthrough Assembly for instructions on servicing this O-Ring.

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Document: MN-XTU009 Revision: A Created: 28 October 2011 5-4
 XTU009
XTU Downhole Controller Chapter 6. Electrical Description

6 ELECTRICAL DESCRIPTION

Ref.: Wiring Diagram XTU Chassis Assembly WD-80893

6.1 Processor Circuit Board

Ref.: Processor Circuit Diagram CD-80897

The XTU Processor Board comprises a micro-controller (U8), an FPGA (U6), and two FIFOs (U5 and U4)
together with associated glue logic. The clocks are derived from a crystal oscillator (X1), with 16MHz and
4MHz TTL level outputs.

U5 buffers data from the Ultrawire™ uplink whilst the controller decodes the control fields and checks for
data integrity. The MPU then passes the data to U4 where it is held until the Ultralink™ modulator (also
implemented in the FPGA) collects it for transmission to the surface.

Figure 6-1 shows a typical Ultrawire™ signal as seen on the bottom connector of the tool.

Figure 6-1 Ultrawire™ Signal Shape example

6.2 PSU/Telemetry Board

Ref.: PSU/Telemetry Circuit Diagram CD-80891

The PSU is a fly-back SMPS that steps down the high voltage DC at the tool head to provide low voltage
rails for the XTU and power to the Ultrawire™ bus, from which the other logging tools are powered. It is
based around the Siliconix 9120 current mode controller (U1). Start-up power is provided via Q8 and U10.
The primary winding of the transformer choke is switched by Q2. The secondary winding provides +16V
nom., which powers the Ultrawire™ toolstring and the XTU. An auxiliary SMPS (U6) provides 5V and -16V
for use locally in the XTU controller. The feedback for the SMPS controller is from the main +16V output.
Over-current and over-voltage conditions at the output are detected and used to shut down the PSU.

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 XTU009
XTU Downhole Controller Chapter 6. Electrical Description

The Ultralink™ uplink is driven onto the Ultralink™ line by U3, which is buffered by Q3 and Q4. U2 buffers
the input to the driver, ensuring a clean symmetrical signal is provided to the buffer amp. A typical uplink
signal as seen at the tool-head is shown in Figure 6-2.

Figure 6-2 Ultralink™ Uplink Signal

The downlink is recovered by a set of filters comprising U4 and U7 with associated components. The
recovered AMI at TP21 is demodulated into 5V NRZ by U5 and associated components, and passed to the
serial input of the processor. The recovered downlink at TP21 is shown in Figure 6-3.

Figure 6-3 Recovered downlink at TP21

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 XTU009
XTU Downhole Controller Chapter 7. Extended Checks

7 EXTENDED CHECKS

7.1 Preventative Maintenance

7.1.1 GREASES & LUBRICANTS

LIQUID-O-RING® TYPE 101 LUBRICANT

WARNING!
For more information refer to Section 2.4.1, Liquid-O-Ring® Type 101 Lubricant.

G REASES AND S EALANTS !

C AUTION !
The use of certain greases, which contain volatile content can cause electrical
failure due to production of corrosive gasses inside the tool when heated.

GE Oil & Gas recommend users to use ONLY the greases and sealants as
specified for the Tool.

All O-Rings and housing threads are assumed to be and must be lightly greased, unless specifically
indicated otherwise.

Correct use of grease and lubricants is essential to the maintenance of all GE Oil & Gas downhole
equipment.

Note: Some threads are internal, which can cause grease to get inside the tool. Do not use excessive quantities.

7.1.2 MECHANICAL

1 Remove dirt and old grease from pressure housing threads and the primary O-Rings and apply
a light coating of Liquid-O-Ring® type 101. Refer to Section 5.2, Reassembly. GE Oil & Gas
recommends to replace O-Rings after every run or every three months, whichever comes first.

2 Check for:

• Damaged wires.
• Wires that are loose and likely to be crushed on re-assembly.
• Damaged components.
• Loose screws/nuts/components/connectors.

Note: When RTV or similar compound is used to secure components, it must be fully cured before housing is
replaced.

• Electrical components shorting to chassis.

• Heat or chemical damage (discoloured components).
• Incorrect thread grease or excessive quantity, see Section 7.1.1.
• Check any connectors for cleanliness and loose/bent pins before replacing.

3 Check all fixings for tightness.

7.1.3 ELECTRICAL

1 Check current consumption at 200ºC: 18 ±2mA (no tools connected below).

2 Voltage out at lower connector: 16.7V ±0.5V.

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 XTU009
XTU Downhole Controller Chapter 7. Extended Checks

3 Connect to Logging System and check for correct data. Apply gentle vibration and rotation to
expose potential failure.

7.1.4 AGEING OF ELECTRONICS

At 150°C (302°F), significant electronic ageing failures are expected after 4000hrs typical use, hence PCB
replacement should be considered at this point. Every additional 10°C (18°F) halves the time. Life of the
electronics is also accelerated by vibration and corrosive gas inside the chassis. Visual inspection and
logging previous history is recommended, but is unlikely to predict premature failure. Tools that may be
suspected of reliability problems due to age or unusual log response may be heated to 120°C (248°F),
which would not normally age the electronics, and afterwards subjected to moderate vibration. A
moderately hard blow from a wooden hammer is recommended.

DO NOT USE METAL HAMMERS.

7.1.5 HEAT TESTING ABOVE 150°C (302°F)

This is not generally recommended since it shortens tool life expectancy. Heat testing may be required
for contractual reasons, tool out of use for a long period, or job with unusually high well temperature. The
test should be carried out slightly above expected well temperature only and the tool should not be kept
at temperature for more than 1 hour. Do not exceed the maximum rated temperature for the tool.

7.2 Extraordinary Maintenance

7.2.1 O-RING REPLACEMENT

Ref.: General Assembly AD-09800

Electronics Assembly AD-42713

Note: During the reassembly process, inspect all O-Ring seals for any signs of wear or damage and replace with
new seals where necessary.

The O-Ring grooves have been designed for the use of anti-extrusion rings. The anti-extrusion rings
should be fitted on the low pressure side of the O-Ring (refer to Appendix C, Fitting of Anti-Extrusion
Rings). GE Oil & Gas recommend that primary seal O-Rings are replaced after every job, when operating
above 15,000psi. Anti-extrusion rings should be checked for signs of wear and replaced as necessary.

When the tool is exposed to downhole environments that contain H2S or CO2 gas, or temperatures above
150°C, then the following O-Rings must be replaced. (Refer also to Section 5.3, Routine Maintenance):

• One O-Ring (item 12, 09800)

• Two O-Rings (item 13, 09800)
• Two O-Rings (item 14, 09800)
• Two Anti-Extrusion Rings (item 10, 09800)
• Two Anti-Extrusion Rings (item 11, 09800)
• One O-Ring (item 27, 42713).

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Document: MN-XTU009 Revision: A Created: 28 October 2011 7-2
 XTU009
XTU Downhole Controller Chapter 7. Extended Checks

7.3 Troubleshooting
Refer to 5, Mechanical Description and Appendix B, Drawings & Parts Lists.

An Oscilloscope, Multimeter and other basic test equipment will be required.

Table 7-1 Troubleshooting Checklist

Symptom Check
Initial Inspection Check for:

• Damaged wires.
• Damaged components.
• Electrical components shorting to chassis.
• Heat or chemical damage (discoloured components).
• Incorrect thread grease or excessive quantity, refer to
Section 7.1.1.

Also check all fixings are tight.

Excessive input current Disconnect any tools below the XTU009.

Apply power slowly to top connector and monitor current. If current

increases above 5mA before i/p reaches 80V, check for short
circuits or faulty Power MOSFET (Q2). Q2 is mounted on the top
bulkhead of the tool.

Disconnect +5V (red) and +16V (purple) between the two PCBs and
recheck current.

Check voltage on PSU (80891) at:

• TP11 16V nom.

• TP24 5V nom.
• TP16 -16V nom.

Should these voltages vary by more than 5%, replace or fault find
PCB.

Reconnect 5V to processor board (80897) via a milliammeter.

PCB80897 should draw about 60mA. Where it is drawing more than
100mA, check for short circuits on processor board. Check zener
diode D3, which may have blown short where it has been subjected
to over-voltage for an extended period.
Little or no current Check that line volts appear on PSU (80891) at TP1. If not, fault find
open circuit in top connector sub or wiring.

Check for 12V at TP4 and 10V at TP3 and pin 12 of U1. If U1 pin 12 is
oscillating, check for a short on the output or intermittent over
voltage on TP11 (16V nom).

Check for pulses on TP8. These should be 12V positive going at a

rep rate of ~125kHz.

Check for 16V at positive end of C5.

Check for current pulses in primary winding on TP5. These should

be skinny triangles of 100 - 300mV with no Ultrawire™ tools
connected.

If primary winding is pulsing and 16V is not present on C5, check

wiring to D1 (mounted on heatsink).

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Document: MN-XTU009 Revision: A Created: 28 October 2011 7-3
 XTU009
XTU Downhole Controller Chapter 7. Extended Checks

Table 7-1 Troubleshooting Checklist

Symptom Check
No telemetry frames at Check Ultralink™ line (centre pin at top of tool) for telemetry pulses
surface as shown in Figure 6-2.

When there are no pulses on line, check for TTL level negative going
pulses on wiring points UUP* and UUN* (pink and white wires
between PCBs). If pulses are present on UUP* and UUN* but not on
tool head, fault is on PSU/Telemetry PCB (PCB80891). Fault find or
replace PCB.

Disconnect UUP* and UUN*. When no pulses are present on UUP*

and UUN* at output of processor board, the fault is on processor
board (PCB80897).

Check power rails and basic signals on processor board (80897):

• CRES (U8 pin 18) Logic high.

• SYSCLK (U8 pin 16) 8MHz clock.
• X1 pin 1 16MHz clock.
• X1 pin 2 4MHz clock.

Fault find or replace board.

After power up and configuration, the XTU009 will send Config
frames for a period of one minute before entering logging mode
Config frames only at and sending Main (and optionally Secondary) Data Frames.
surface Transmission of Config frames can be terminated and logging
started immediately by sending a Start Polling command from the
surface.
Main data frames but no tool Check operation of toolbus. Monitor toolbus (bottom connector of
counts at surface when tools XTU) with an Oscilloscope set to AC 1V/div, 5ms/div. and apply
are connected power. After 8 to10 seconds, a brief burst of bi-polar pulses (lasting
less than 1 second) should appear on the bus. This is the plug and
play configuration taking place. The bus will then go quiet for 1
minute (whilst Config frames are sent to the surface), after which
the controller should enter logging mode and start polling the bus.

When there is no bus activity, check 80897 at TP14 and TP15 for
logic pulses generated by the FPGA.

When there is activity on the bus, but one or more tools are not
delivering data, the controller may have polled the tools during
configuration but not seen a response. In that case, the tools will
not have been entered in the logging program and hence will not
be polled.

Check also that the toolstring is properly terminated, either with an

Ultrawire™ "Bullnose" or a bottom flowmeter containing a
terminator. Termination problems are characterized by erratic
configuration (sometimes the tool will work, sometimes not), and
often by tool errors such as Ack or Data timeouts shown on the
surface system's monitoring screen. On a long unterminated
toolstring, the tools may never be configured. Check for ringing on
the UW toolbus to confirm a termination problem.
No response to downlinks With an Oscilloscope set to 5ms/div, 5V/div, check signal integrity of
downlink on 80891 at TP12 (±8V, with Ultralink™ signal riding on
top), TP20 (±6V) and TP21 (±8V). Check thresholds on TP22. These
should switch between ±4V on each data pulse. Threshold should
relax to -4V in absence of data. TTL level NRZ data should be
evident at TP25 and can be traced to the H8 micro-controller (U8
pin 56) on 80897. Check that the bit period of the recovered data is
3.3ms. nom. Fault find or replace PCB as appropriate.

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Document: MN-XTU009 Revision: A Created: 28 October 2011 7-4
 XTU009
XTU Downhole Controller Appendix A. Equipment & Spares

APPENDIX A EQUIPMENT & SPARES

A.1 Main Equipment

Item Part No Description Qty Remarks

1 XTU009 Downhole Telemetry Controller 1 ---

A.2 Ancillary Equipment

Item Part No Description Qty Remarks

1 AGS001 GO to GE Oil & Gas Adapter Part of the Assembly

A.3 Maintenance Equipment

A.3.1 GREASES, LUBRICANTS & THREAD LOCK

Item Part No. Description Qty Remarks

1 LOR101 Grease for O-Rings and threads 1 5oz pot
2 LOR101L Grease for O-Rings and threads 1 16oz pot
3 A078-S35SL Silicone Compound AR

A.3.2 FIELD HANDLING TOOLS

Item Part No Description Qty Remarks

1 91050 Hand Tool Kit for 111/ 16” tools 1 ---

A.3.3 SHOP SERVICE TOOLS

Item Part No Description Qty Remarks

General Tools
1 42703 Tool Safety Clamp (Earthing kit) 1 Refer to Tools Safety Clamp
manual
(P/N: MN-TSC001)

Copyright © 2011 Sondex Wireline Limited. Proprietary Information - All rights reserved.
Document: MN-XTU009 Revision: A Created: 28 October 2011 A-1
 XTU009
XTU Downhole Controller Appendix A. Equipment & Spares

A.4 Recommended Spares

A.4.1 MECHANICAL SPARES

Item Part No Description Qty Remarks

1 KITB-XTU009 Basic Spares Kit 1 To support 1 run in hole
2 KITR-XTU009 Recommended Spares Kit 1 To support 25 runs in hole

PARTS LISTING
Part Issue

91050
91050 C
Description

Tool Kit for all 1 11/16 Tools SX and GO

PARTS LIST
Item Part No Description Qty Units Remarks
0001 91005 Spanner Open Ended 42mmx38mm 2 EA
0002 91019 Spanner C 50mm 35mm 2 EA
0003 10038 Spanner Box 3/8 x 5/16 Modified 2 EA
0004 91028 Spanner O/E 3/8x5/16 1 EA
0005 93876 Spanner Single Open End 18mm 1 EA
0006 91029 Key, Hex Metric (Set) 1 EA
0007 91030 Punch Pin Parallel set 1 EA
0008 00615 Assy Spanner PKJ 1 EA
0009 91293 Screwdriver Parallel tip (3 0 x 75) 1 EA
0010 91105 Toolroll With SX Badge Large Black 1 EA
0011 91104 Screwdriver Parallel tip (5 5 x 200) 1 EA
0012 91103 Pliers Circlip 812 Chrome/Van 1 EA
0013 91102 Pliers Mini Flat Nose 5 Inch 1 EA
0014 10037 Bar Tommy 2 EA
0015 10051 Kemlon tool Sondex - 4BA Hex Socket 1 EA
0016 91280 Hammer, 4oz ball pein 1 EA
0017 91130 Pin C Spanner 35-50mm 1 EA
0018 91822 Medium Flat Blade Screwdriver, 5mm 1 EA
0019 91255 T15 Torx driver, Sandvik Belzer 8915 2 EA

Copyright © 2011 Sondex Wireline Limited. Proprietary Information - All rights reserved.
Document: MN-XTU009 Revision: A Created: 28 October 2011 A-2
 XTU009
XTU Downhole Controller Appendix A. Equipment & Spares

PARTS LISTING
Part Issue

KITB

KITB-XTU009 A
Description

KIT, SPARES, BASIC, XTU009

PARTS LIST
Item Part No Description Qty Units Remarks
0010 99118 O-ring 118 Viton 90 2 EA
0020 99124 O-ring 124 Viton 90 4 EA

PARTS LISTING
Part Issue

KITR
KITR-XTU009 A
Description

KIT, SPARES, REC'D (25 RUN), XTU009

PARTS LIST
Item Part No Description Qty Units Remarks
0010 99118 O-ring 118 Viton 90 50 EA
0020 99124 O-ring 124 Viton 90 50 EA
0030 410084 RING BACKUP FOR 118 O RING 10 EA
0040 410085 RING BACKUP FOR 124 O RING 10 EA
0050 99008 O-ring 008 Viton 90 5 EA
0060 42747 ASSEMBLY PRESSURE FEED THROUGH 1 EA

Copyright © 2011 Sondex Wireline Limited. Proprietary Information - All rights reserved.
Document: MN-XTU009 Revision: A Created: 28 October 2011 A-3
 XTU009
XTU Downhole Controller Appendix B. Drawings & Parts Lists

APPENDIX B DRAWINGS & PARTS LISTS

B.1 Mechanical Drawings

Description Drawing Parts List

Crossover Toolbus Ultrawire™ to Ultralink™ Assembly  AD-09800-B See Drawing
(2 sheets)
Electronics Assembly XTU 20KSI (3 sheets) AD-42713-A See Drawing
Upper Bulkhead Assembly AD-42714-A See Drawing
Electronics Chassis Assembly XTU002 (Sondex End) AD-10589-B PL-10589-C

B.2 Electrical Drawings

Description Type Drawing

XTU Chassis Assembly Wiring Diagram WD-80893-F
PSU/Telemetry Board (2 sheets) Circuit Diagram CD-80891-P
Ultrawire™ Processor Assembly (3 sheets) Circuit Diagram CD-80897-E00x

Copyright © 2011 Sondex Wireline Limited. Proprietary Information - All rights reserved.
Document: MN-XTU009 Revision: A Created: 28 October 2011 B-1
 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
DO NOT SCALE
ITEM QTY. PART NUMBER DESCRIPTION
A NO. A

1 1 42713 ASSY ELECTRONICS XTU009

2 1 42747 ASSY PRESSURE FEED THROUGH
3 1 42717 HOUSING PRESSURE
4 1 10148 THREAD PROTECTOR$MALE SX STD UPR$(W ITH O'RING)
5 1 01019 ASSY LOW ER TP$and W ARNING LABEL 4
B B
10 2 410084 RING BACKUP FOR 118 ORING
11 2 410085 RING BACKUP FOR 124 ORING
12 1 99008 O'RING 008 VITON 90
13 2 99118 O'RING 118 VITON 90
14 2 99124 O'RING 124 VITON 90 5
C C

09800 3
12

D D
2

E E

F F

14

G G

H 11 H

10

J J

K K

13

L L

UNLESS OTHERWISE STATED: THIRD ANGLE PROJECTION TITLE

MODELLED DRAWN CHECKED APPROVED
DRAWN TO BS 8888
GENERAL TOLERANCES IN ACCORDANCE W ITH ISO 2768-mK
C
ASSEMBLY
METRIC THREADS TO BE COARSE SERIES H6/g6 FIT IH GJD TG S on dex CROSSOVER TOOLBUS
UNDERCUTS TO BS1936
SURFACE TEXTURE TO BE 1.6 ȝm MAXIMUM INTERNAL RADII 0.5 ALL DIMENSIONS IN MM 09/02/09 25/03/09 25/03/09 03/04/09 THIS DRAW ING IS TH E PR OPER TY
OF SONDE X AN D SH ALL NOT BE
COPIED OR USE D W ITH OUT
UW TO UL 20KSI
USED ON
MARK THE COMPONENT WITH ITS PART No & ISSUE IN / ON THE AREA
MATERIAL
PRIOR P ERMISS ION
Ø1 11/16
B REF ECR64128 16/12/2009 IDENTIFIED THUS: IF NO SYMBOL IS SHOW N THE COMPONENT XTU009 NOT APPLICABLE
M DOES NOT REQUIRE MARKING AND SHOULD BE IDENTIFIED SCALE DRAWING No. ISSUE SHEET

1 2 3
A

ISS
INITIAL RELEASE

DESCRIPTION APPR'D
03/04/2009

DATE
BY BAGGING & LABELLING. ALL TO PROCESS SPEC: PS-075
REMOVE ALL BURRS & SHARP EDGES.
MASS
1.23 Kg
HEAT TREATMENT
NOT APPLICABLE 1:1 AD-09800 B 1 OF
2
A1

XTU Downhole Controller XTU009

B-2

Copyright © 2011 Sondex Wireline Limited. Proprietary Information - All rights reserved.
 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
DO NOT SCALE
A A

B B

568 SHIPPING LENGTH

471 MAKE UP LENGTH

C C

D D

A A

E 4 5 E

2 12 3 1 11 14 13 10
F F
2 2 2 2

G G

H H
SECTION A-A

J J

K K

L L

UNLESS OTHERWISE STATED: THIRD ANGLE PROJECTION TITLE

DRAWN TO BS 8888
MODELLED DRAWN CHECKED APPROVED C ASSEMBLY
GENERAL TOLERANCES IN ACCORDANCE W ITH ISO 2768-mK
METRIC THREADS TO BE COARSE SERIES H6/g6 FIT IH GJD TG S on dex CROSSOVER TOOLBUS
UNDERCUTS TO BS1936
SURFACE TEXTURE TO BE 1.6 ȝm MAXIMUM INTERNAL RADII 0.5 ALL DIMENSIONS IN MM 09/02/09 25/03/09 25/03/09 03/04/09 THIS DRAW ING IS TH E PR OPER TY
OF SONDE X AN D SH ALL NOT BE
UW TO UL 20KSI
USED ON MATERIAL
COPIED OR USE D W ITH OUT
PRIOR P ERMISS ION
Ø1 11/16
MARK THE COMPONENT WITH ITS PART No & ISSUE IN / ON THE AREA
IDENTIFIED THUS: IF NO SYMBOL IS SHOW N THE COMPONENT XTU009 NOT APPLICABLE
M DOES NOT REQUIRE MARKING AND SHOULD BE IDENTIFIED SCALE DRAWING No. ISSUE SHEET

1 2 3
BY BAGGING & LABELLING. ALL TO PROCESS SPEC: PS-075
REMOVE ALL BURRS & SHARP EDGES.
MASS
1.23 Kg
HEAT TREATMENT
NOT APPLICABLE 1:1 AD-09800 B 2 OF
2
A1

XTU Downhole Controller XTU009

B-3

Copyright © 2011 Sondex Wireline Limited. Proprietary Information - All rights reserved.
 1 2 3 4 5 6 7 8 9 10 11 12
DO NOT SCALE

23 24
A 27 A

1 5

B B
4

18

C
42713 C

1
17 14
11 2 10
16
2 22
D 35 D
15 1
21
20
12 32 19
3 10
2 2
E E

30
36
13 3
26 31 3
33 34
F 3 3 F

1 1

G 10 G
2

UNLESS OTHERW ISE STATED: THIRD ANGLE MODEL'D DRAWN CHECK'D APPV'D TITLE
DRAW N TO BS 8888 C
PROJECTION
GENERAL TOLERANCES IN ACCORDANCE W ITH ISO 2768-mK
METRIC THREADS TO BE COARSE SERIES H6/g6 FIT IH IH RTM TG Sondex ASSY ELECTRONICS
UNDERCUTS TO BS1936 THIS DRAWING IS THE PROPERTY
OF SONDEX AND SHALL NOT BE
XTU009
SURFACE TEXTURE TO BE 1.6 ȝm MAXIMUM INTERNAL RADII 0.5 ALL DIMENSIONS IN MM 17/02/09 03/04/09 03/04/09 18/05/09 COPIED OR USED WITHOUT
PRIOR PERMISSION
MARK THE COMPONENT W ITH ITS PART No & ISSUE IN / ON THE AREA USED ON MATERIAL
IDENTIFIED THUS: IF NO SYMBOL IS SHOW N THE COMPONENT 09800 NOT APPLICABLE SCALE DRAWING No. ISSUE SHEET
DOES NOT REQUIRE MARKING AND SHOULD BE IDENTIFIED
BY BAGGING & LABELLING. ALL TO PROCESS SPEC: PS-075
REMOVE ALL BURRS & SHARP EDGES.
MASS
0.87 Kg
HEAT TREATMENT
NOT APPLICABLE 1:1 AD-42713 A 1 OF
3
A2

XTU Downhole Controller XTU009

B-4

Copyright © 2011 Sondex Wireline Limited. Proprietary Information - All rights reserved.
 1 2 3 4 5 6 7 8 9 10 11 12
DO NOT SCALE

A DISCARD SHOULDER WASHER A

USE MICA PAD ONLY

30 33 34 36

3 26 35 17 11 1 14 10 4 22
2 2 2
B B

C C
DISCARD SHOULDER WASHER
USE MICA PAD ONLY

31 33 34 13 32 33 34 36 2
DISCARD SHOULDER WASHER
USE MICA PAD ONLY
D D
21 12 10 16 15
27
A

E E

10
SECTION A-A 2
A
18 19 20 5 24
SEE NOTE 1
F F

NOTES
1. FILL ALL VOIDS IN TOP HEAD ASSEMBLY USING HEATSINK COMPOUND (ITEM 51).

G G

UNLESS OTHERW ISE STATED: THIRD ANGLE MODEL'D DRAWN CHECK'D APPV'D TITLE
DRAW N TO BS 8888 C
PROJECTION
GENERAL TOLERANCES IN ACCORDANCE W ITH ISO 2768-mK
METRIC THREADS TO BE COARSE SERIES H6/g6 FIT IH IH RTM TG Sondex ASSY ELECTRONICS
UNDERCUTS TO BS1936 THIS DRAWING IS THE PROPERTY
OF SONDEX AND SHALL NOT BE
XTU009
SURFACE TEXTURE TO BE 1.6 ȝm MAXIMUM INTERNAL RADII 0.5 ALL DIMENSIONS IN MM 17/02/09 03/04/09 03/04/09 18/05/09 COPIED OR USED WITHOUT
PRIOR PERMISSION
MARK THE COMPONENT W ITH ITS PART No & ISSUE IN / ON THE AREA USED ON MATERIAL
IDENTIFIED THUS: IF NO SYMBOL IS SHOW N THE COMPONENT 09800 NOT APPLICABLE SCALE DRAWING No. ISSUE SHEET
DOES NOT REQUIRE MARKING AND SHOULD BE IDENTIFIED
BY BAGGING & LABELLING. ALL TO PROCESS SPEC: PS-075
REMOVE ALL BURRS & SHARP EDGES.
MASS
0.87 Kg
HEAT TREATMENT
NOT APPLICABLE 1:1 AD-42713 A 2 OF
3
A2

XTU Downhole Controller XTU009

B-5

Copyright © 2011 Sondex Wireline Limited. Proprietary Information - All rights reserved.
 1 2 3 4 5 6 7 8 9 10 11 12
DO NOT SCALE

A A
ITEM NO. QTY. PART NUMBER DESCRIPTION
1 1 10589 ASSY CHASSIS ELECTRONICS$XTU002 (SONDEX END)
2 1 80975 pcb assy xtu processor
3 1 42714 ASSEMBLY UPPER BULKHEAD
4 1 80974 PCB Assy - XTU
5 1 42709 SUB LOWER ø1-11/16" 20KSI
B 10 5 01029 SCREW CSK HD SLOTTED M3 x 06mm LG SS B
11 2 93351 SCREW CSK HD SLOTTED M3 x 12mm LG SS
12 1 93594 SCREW CSK HD SLOTTED M3 x 25mm LG SS
13 3 93080 SCREW PAN HD SLOTTED M3 x 08mm LG SS
14 1 93261 SPACER - M3 THRU$4.75mm OD x 12.7mm LG
15 1 93028 M3 SERRATED WASHER
16 1 93097 Tag Solder M3
17 2 93953 SPACER - M3 THRU$4.75mmOD x 6mmLG
C 18 1 93234 SCREW PAN HD SLOTTED 10-32 x 1/4 LG SS C
19 1 93150 TAG SOLDER
20 1 93030 WASHER LOCK 10-32
21 1 93414 SPRING WAVE OD 25.3mm CrNi STEEL
22 1 91552 Washer Wavy 3 Waves Overlapped 0100 SS
23 1 93890 CONNECTOR FEMALE MONOCONN
24 1 93893 RING RETAINING INTERNAL SPIRAL 14mm SS
26 1 91875 SPRING CANTED CONTACT
D 27 1 99012 O'RING 012 VITON 90 D
30 1 D013-10060 DIODE
31 1 Q006-0F510 IRF510 N Channel Power MOSFET, 100V 5A6 43W (TH TO220)
32 1 Q006-NK90Z TRANSISTOR
33 3 Q100-T0220 PAD INSULATING MICA
34 3 Q100-00220 INSULATING KIT TRANSISTOR
35 1 80892 TRANSFORMER/CHOKE$XTU002 PSU/TELEMETRY
36 3 Q101-T0220 INSULATING SHOULDER WASHER
E E
37 2 C061-0390N Capacitor, SV Series, HV MLC 1kV 10% (DH, TH)
38 1 A079-00000 Sensor, Platinum Resistance, Thin Film, -50C to +500C PT1000 A
39 A/R W001-00108 Wire, PTFE, Type A, 300V, 6A, 200C 7/0.2 Grey
40 A/R W001-00109 Wire, PTFE, Type A, 300V, 6A, 200C 7/0.2 White
41 A/R W001-00110 Wire, PTFE, Type A, 300V, 6A, 200C 7/0.2 Pink
42 A/R W001-00100 Wire, PTFE, Type A, 300V, 6A, 200C 7/0.2 Black
43 A/R W001-00102 Wire, PTFE, Type A, 300V, 6A, 200C 7/0.2 Red
44 A/R W001-00103 Wire, PTFE, Type A, 300V, 6A, 200C 7/0.2 Orange
F F
45 A/R W001-00104 Wire, PTFE, Type A, 300V, 6A, 200C 7/0.2 Yellow
46 A/R W001-00106 Wire, PTFE, Type A, 300V, 6A, 200C 7/0.2 Blue
47 A/R W010-029SW Tinned Copper Wire
48 A/R W001-00107 Wire, PTFE, Type A, 300V, 6A, 200C 7/0.2 Violet
49 A/R A044-006M4 Kynar Heat Shrink Sleeving 6.4mm
50 A/R A044-003M2 Kynar Heat Shrink Sleeving 3.2mm
51 A/R A078-S35SL Heat Transfer Compound, Silicone
G G

UNLESS OTHERW ISE STATED: THIRD ANGLE MODEL'D DRAWN CHECK'D APPV'D TITLE
DRAW N TO BS 8888 C
PROJECTION
GENERAL TOLERANCES IN ACCORDANCE W ITH ISO 2768-mK
METRIC THREADS TO BE COARSE SERIES H6/g6 FIT IH IH RTM TG Sondex ASSY ELECTRONICS
UNDERCUTS TO BS1936 THIS DRAWING IS THE PROPERTY
OF SONDEX AND SHALL NOT BE
XTU009
SURFACE TEXTURE TO BE 1.6 ȝm MAXIMUM INTERNAL RADII 0.5 ALL DIMENSIONS IN MM 17/02/09 03/04/09 03/04/09 18/05/09 COPIED OR USED WITHOUT
PRIOR PERMISSION
MARK THE COMPONENT W ITH ITS PART No & ISSUE IN / ON THE AREA USED ON MATERIAL
IDENTIFIED THUS: IF NO SYMBOL IS SHOW N THE COMPONENT 09800 NOT APPLICABLE SCALE DRAWING No. ISSUE SHEET
DOES NOT REQUIRE MARKING AND SHOULD BE IDENTIFIED
BY BAGGING & LABELLING. ALL TO PROCESS SPEC: PS-075
REMOVE ALL BURRS & SHARP EDGES.
MASS
0.87 Kg
HEAT TREATMENT
NOT APPLICABLE 1:1 AD-42713 A 3 OF
3
A2
XTU Downhole Controller XTU009
B-6

Copyright © 2011 Sondex Wireline Limited. Proprietary Information - All rights reserved.
 1 2 3 4 5 6 7 8
DO NOT SCALE

A A
5
6
3
2
42714
1
B A A B
4

4 1
2

C C

3 SECTION A-A
D 6 5 D

ITEM QTY. PART NUMBER DESCRIPTION

NO.

1 1 42706 BULKHEAD UPPER

2 1 42707 INSULATOR BURNDY SOCKET
3 1 42858 SOCKET BURNDY MODIFIED
4 1 93170 PIN COILED ø2x 06mm LG - SPIROL MCK
E E
NOTES 5 1 93892 CIRCLIP INTERNAL 14mm SS DIN472
1. ITEM 3 NOT TO BE FITTED AT THIS STAGE. 6 1 91964 SPRING CREST TO CREST Ø14mm 6.6mm FL 13.67N/mm SR

UNLESS OTHERW ISE STATED: THIRD ANGLE TITLE

MODELLED DRAWN CHECKED APPR'D C
DRAW N TO BS 8888 PROJECTION ASSEMBLY UPPER
GENERAL TOLERANCES IN ACCORDANCE W ITH ISO 2768-mK
METRIC THREADS TO BE COARSE SERIES H6/g6 FIT IH GC TG Sondex
THIS DRAW ING IS THE PROPERTY BULKHEAD
UNDERCUTS TO BS1936 OF SONDEX AND SHA LL NOT B E

SURFACE TEXTURE TO BE 1.6 ȝm MAXIMUM INTERNAL RADII 0.5 ALL DIMENSIONS IN MM. 09/02/09 25/03/09 13/05/09 18/05/09 COP IED OR USED W ITHOUT
PRIOR PERMISS ION

MARK THE COMPONENT W ITH ITS PART No & ISSUE IN / ON THE AREA USED ON MATERIAL
A 18/05/2009
IDENTIFIED THUS: IF NO SYMBOL IS SHOW N THE COMPONENT XTU009 NOT APPLICABLE SCALE DRAWING No. ISSUE SHEET

ISS DESCRIPTION APPR'D DATE

DOES NOT REQUIRE MARKING AND SHOULD BE IDENTIFIED
BY BAGGING & LABELLING. ALL TO PROCESS SPEC: PS-075
REMOVE ALL BURRS & SHARP EDGES.
MASS:
13.68 g
HEAT TREATMENT
NOT APPLICABLE 1:1 AD-42714 A 1 OF
1
A3

XTU Downhole Controller XTU009

B-7

Copyright © 2011 Sondex Wireline Limited. Proprietary Information - All rights reserved.
 1 2 3 4 5 6 7 8 9 10
DO NOT SCALE

7 1
A A
SEE
NOTE 1
VIEW OF UNDERSIDE OF CHASSIS COVER (ITEM 1)
SHOWING POSITION OF TYGAFLOR TAPE (ITEM 7)

B B
10589

2 9
C C
3

D D

6
8
E E

3
1 7
SEE NOTE 1
4
NOTES
F F
1. APPLY TYGAFLOR TAPE (ITEM 7) TO CHASSIS AND COVER (ITEMS 1) IN BETWEEN
BULKHEAD MOUNTINGS (ITEM 2 AND HEATSINK MOUNTING (ITEM 3)

DRAWN: AV CHECKED: NGH APP'D: IH ISS DESCRIPTION APPD DATE USED ON TITLE
ASSY CHASSIS
DATE: 24/11/08 DATE: 24/11/08 DATE: 24/11/08 B ECR 5928 REFERS IH 24/11/08 Sondex 80893
ELECTRONICS
DIM IN
INCHES
MATL:
SEE DETAIL DRAWINGS
Tel. 0118 932 6755
THIS DRAWING IS THE PROPERTY OF MACHINE GEN TOL XTU002 (SONDEX END)
Sondex AND SHALL NOT BE COPIED FINISH 0.X 0.020"
OR USED WITHOUT PRIOR PERMISSION SHEET DRAWING No. ISSUE
SCALE HEAT TREATMENT/CONDITION: [Link] 0.010" S
1:1
A
3 SEE DETAIL DRAWINGS
THIRD ANGLE
PROJECTION
63
[Link] 0.005"
ANGLE 0.5°
11 AD 10589 B W

XTU Downhole Controller XTU009

B-8

Copyright © 2011 Sondex Wireline Limited. Proprietary Information - All rights reserved.
 XTU009
XTU Downhole Controller Appendix B. Drawings & Parts Lists

PARTS LISTING
Part Issue

10589 C
Description

PL-10589
Assy Chass Elec Mech parts XTU002 Sx end
PARTS LIST
Item Part No Description Qty Units Remarks
0001 16511 Half-Shells Electronics XTU 1 PR
0002 01006 Bk'hd, Elecs, Lower, Std (Non-Lemo) 1 EA
0003 16512 Bulkhead Heatsink 1 EA
0004 16513 Clamp Transformer 1 EA
0006 01029 Screw Csk Hd(Slotted) M3 x 06mm LG SS 8 EA
0007 T004-008AP Tape Tygaflor 208AP/03T 80mm x 30M 1 CM
0009 01030 Scr, Grb Skt Hd, M6 x 6mm Long, St/Steel 3 EA

Copyright © 2011 Sondex Wireline Limited. Proprietary Information - All rights reserved.
Document: MN-XTU009 Revision: A Created: 28 October 2011 B-9
 $66<
6,'(6+2:1722876,'(
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73
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73
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9
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73
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WHOID[ :' )
B-10

XTU Downhole Controller XTU009

Copyright © 2011 Sondex Wireline Limited. Proprietary Information - All rights reserved.
 CD-80891
B-11

XTU Downhole Controller XTU009

Copyright © 2011 Sondex Wireline Limited. Proprietary Information - All rights reserved.
B-12

XTU Downhole Controller XTU009

Copyright © 2011 Sondex Wireline Limited. Proprietary Information - All rights reserved.
 CD-80897
B-13

XTU Downhole Controller XTU009

Copyright © 2011 Sondex Wireline Limited. Proprietary Information - All rights reserved.
B-14

XTU Downhole Controller XTU009

Copyright © 2011 Sondex Wireline Limited. Proprietary Information - All rights reserved.
B-15

XTU Downhole Controller XTU009

Copyright © 2011 Sondex Wireline Limited. Proprietary Information - All rights reserved.
 XTU009
XTU Downhole Controller Appendix C. Fitting of Anti-Extrusion Rings

APPENDIX C FITTING OF ANTI-EXTRUSION RINGS

At high temperatures O-Rings become very soft and with corresponding high pressures they begin to
extrude into the gap between housing and bore. Eventually this can lead to failure and a subsequent tool
flood. To prevent this, anti-extrusion rings have been added to all seals on this tool, both static and
dynamic. These are made of plastic and plug the extrusion gap. Anti-extrusion rings must always be
fitted on the side AWAY from well pressure (see Figure C-1 below).

Anti-Extrusion Ring
Extrusion in gap

Pressure

1a. Standard O -Ring 1b. L-Seal + Anti- 1c. O-Ring + Anti-Extrusion

Extrusion Ring Ring (wider groove)

Figure C-1 Installation of Anti-Extrusion Rings

Anti-Extrusion Rings are scarf cut to allow assembly.

Make sure that the extrusion rings are concentric in their groove and they are uniformly seated.

Make sure the gap between the scarf cut is no more than 1mm.

Note: Anti-Extrusion Rings are often referred to as backup rings, particularly when used with standard O-Rings.

Note: Due to the increased friction, joints containing anti-extrusion rings will be slightly harder to tighten up
than previously with just O-Rings. However, do NOT force the joint together. This indicates part of the
extrusion ring has caught on the bore or lead in chamfer and excessive force may damage the ring and/
or seal. Slowly back off the joint, check the seating of the anti-extrusion ring and retighten.

Copyright © 2011 Sondex Wireline Limited. Proprietary Information - All rights reserved.
Document: MN-XTU009 Revision: A Created: 28 October 2011 C-1
GE Oil & Gas
Drilling & Production
GE Oil & Gas
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For complete contact information. please refer to our website:

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GE reserves the right to make changes in specifications or add improvements at any time without notice or obligation.
Copyright © 2011 Sondex Wireline Limited. Proprietary Information - All rights reserved.