OPERATIONS AND MAINTENANCE MANUAL WINCH …...operations and maintenance manual winch operators...

Kerr Measurement Systems AMS4A049 PANEL Rev C JUL 2006 of 56

Rosenberg, TX 77471Phone:Fax:Homepage: www.kerrms.comE-Mail: [email protected]

6415 Reading Road

281-342-6415281-342-4848

OPERATIONS AND MAINTENANCE MANUAL WINCH OPERATORS PANEL

WEATHERFORD INTERNATIONAL

TABLE OF CONTENTS

SECTION DESCRIPTION 1.0 GENERAL DESCRIPTION AND FEATURES 2.0 SPECIFICATIONS 3.0 SOFTWARE OPERATING INSTRUCTIONS 4.0 WELLSITE OPERATING SUMMARY 5.0 PARTS LIST 6.0 SCHEMATICS, WIRELISTS AND SETUP PROCEDURES 7.0 SOFTWARE UPDATE PROCEDURE 8.0 CABLE DRAWINGS



6415 Reading Road

281-342-6415281-342-4848

Manual Revision Log Current Revision: C JUL 2006 Added depth setup screen information Added software update procedure Current Revision: B MAR 2006 Added Signal and Power block diagrams Updated screen shots Previous Revision: A1 JAN 2006 – UPDATED DRAWINGS, SCREENS



6415 Reading Road

281-342-6415281-342-4848

1.0 INTRODUCTION

1.1 GENERAL DESCRIPTION

This panel is used to acquire and display depth and tension data from a wireline logging winch unit. The panel provides the operator a means to set and make adjustments to the data as necessary. Depth is displayed from data provided from an encoder mounted on a measuring device. The tension data is provided by a load pin and is also passed through to the acquisition system. The panel will operate with the Kerr AM5K Dual Wheel Measuring Device for both open hole and cased hole services.

The system consists of two main components, the real time acquisition board and

the PC. The acquisition board provides power to and processes the signals from the encoders, load pin, and magnetic mark detector. This board operates independent from the PC and is instantly on when power is applied. It also is connected to displays for depth and tension. This allows depth and tension to be displayed immediately on power up and always be displayed regardless of the PC status.

The PC uses an Intel based high speed processor running MS Windows XP embedded. The PC includes a color touch screen for operator input and command entry. The PC is Ethernet ready for connection to the internet for remote display and control.



6415 Reading Road

281-342-6415281-342-4848

1.2 HARDWARE FEATURES

12 - 24 VDC Power Input Internal PC board Intel based personal computer board 1 gb solid state media device Embedded windows XP operating system Three USB ports (2 front, 1 rear) 1 RS232 port RJ 45 Ethernet port USB Mouse / Keyboard included Color Display TFT LCD Backlit 400 NITS Sunlight readable Touch Screen Interface (replaces current key pad) 5 wire resistive USB interface Real Time Acquisition board Kerr Measurement Systems proprietary design 8051 Microprocessor based Provides power to encoders, mag mark detector, and load cell Processes encoder quadrature, mag mark signal, and load cell

Runs independent of PC board Connected to digital displays for real time display of depth and

tension Overtension Relay Contact Closure output Analog output interface Encoder quadrature output 0 – 10vdc tension output 4-20ma tension output



6415 Reading Road

281-342-6415281-342-4848

1.3 USER INTERFACE FEATURES

Total Tension numeric graphic Incremental or Differential tension meter graphic Meter reset button graphic (touch screen control) Over_tension Warnings and Shutdown settings for both Differential and

Total Tension readings (touch screen activated) Numeric graphic display of Last Mark Depth Magnetic Mark or CCL depth table display MMD or CCL selection button (touch screen control) Mark Detection Window (touch screen control) Mark Spacing Window (touch screen control) Magnetic Mark Automatic Correction (touch screen control) CCL depth numeric graphic CCL meter graphic CCL depth offset setting (touch screen control) Tension Calibration Setup Window (touch screen control) Encoder Resolution Settings (PPR value set by touch screen control) Single / Dual Encoder Selection: (touch screen control) Encoder 1, Encoder 2, or Both Both (reads both encoders every 10 msec and takes value from the

one that moved the furthest since the previous reading.



6415 Reading Road

281-342-6415281-342-4848

2.0 SPECIFICATIONS



6415 Reading Road

281-342-6415281-342-4848

WEIGHT: PANEL ONLY: 10 LBS 4.55 KG OVERHEAD MOUNT: 3 LBS 1.37 KG POWER REQUIREMENTS:

INPUT VOLTAGE: 12 – 24VDC INPUT CURRENT: 4 AMPS STARTUP SURGE 3 AMPS NORMAL OPERATION OPERATING TEMPERATURE Min Max

14 149 degrees F -10 65 degrees C

STORAGE TEMPERATURE Min Max

-22 158 degrees F -30 70 degrees C



6415 Reading Road

281-342-6415281-342-4848

3.0 SOFTWARE OPERATING INSTRUCTIONS When the system first boots up, the main screen will appear.

Most of the commands are accessed through the buttons across the top of the screen. EXIT Exits the program and returns to MS-Windows. DEPTH Invokes the keypad. The depth can be directly entered using the keypad. The valid range of depths is listed. TENSION Refer to section 3.1 ALARMS Refer to section 3.2 AUTOCORRECT Refer to section 3.3 SETUP Refer to section 3.4 HELP Invokes the Help Screen. This document can be displayed from the help menu. Also, the program revision information is displayed.



6415 Reading Road

281-342-6415281-342-4848

3.1 DEPTH

Set Depth

Invokes the keypad. The depth can be directly entered using the keypad. The valid range of depths is listed.

Add Depth If line is not moving, ½ foot (.15 m) is immediately added. If line is moving, ½ foot (.15 m) is added over the next 5 foot (1.5m) interval. Sub Depth If line is not moving, ½ foot (.15 m) is immediately subtracted.

If line is moving, ½ foot (.15 m) is subtracted over the next 5 foot (1.5m) interval.

Raw1 Depth Displays the current uncorrected encoder 1 depth Raw2 Depth Displays the current uncorrected encoder 2 depth Shim

Adds or subtracts depth continually. If 1 is entered then 1 foot or 1 meter will be added every 1000 feet or 1000 meters.

If -.2 is entered then .2 feet or .2 meters will be subtracted every 1000 feet or 1000 meters.



6415 Reading Road

281-342-6415281-342-4848

3.2 TENSION

Pressing Tension Zero will null out any tension offset voltage up to 2000 lbs.

Pressing Tension Cal will activate the tension relay inside the panel which will provide 12VDC to shunt cal line on pin G. The load pin should then return a calibrated signal of 3250 lbs.



6415 Reading Road

281-342-6415281-342-4848

3.1.2 TENSION SCALE

The Tension Scale Screen allows the changing of both Bar Meter Scale near the top and the Needle Gauge Scale at the center of the screen. It also allows the Gauge Scale to be used either in a Differential or Incremental scale.

Incremental tension provides a high resolution tension scale. It must be periodically reset as tension increases or decreases to keep it from “pegging out”.

Differential tension provides a delta tension reading. The meter will slowly reset itself to 0 so the reset switch is not necessary.

A note at the bottom of the screen it advises you of your measurement setting,

kilograms or pounds.



6415 Reading Road

281-342-6415281-342-4848

3.1.3 TENSION LOADCELL ANGLE

Loadcell angle is used to compensate when a loadcell is not hung vertically (i.e. bottom sheave). Enter the value derived from the formula: Factor = 1 Examples: 30 degrees = 1.035 Cosign(angle) 45 degrees = 1.082

2 90 degrees = 1.414 120 degrees = 2.000

Note: This function is only available when line size selected is “Other”.



6415 Reading Road

281-342-6415281-342-4848

3.2 ALARMS

3.2.1 TENSION SHUTDOWN

When this value is reached, alarm sounds, tension display flashes value, and tension contact closure switch is closed. This can be used to provide a signal to automatically stop the winch.

Each cable size will have a corresponding Tension Alarm setting. Only the setting for the cable size selected can be adjusted. Default Values 7-32 2000 9-32 3000 5-16 3500 3-8 3500 7-16 3500 15-32 3500 SLAM 3500 S-SLAM 3500



6415 Reading Road

281-342-6415281-342-4848

3.2.2 DIFFERENTIAL TENSION SHUTDOWN When this value is reached, alarm sounds, tension display flashes value, and tension contact closure switch is closed. This can be used to provide a signal to automatically stop the winch. Each cable size will have a corresponding Tension Alarm setting. Only the setting for the cable size selected can be adjusted.

Default Values

7-32 2000 9-32 3000

5-16 3500 3-8 3500

7-16 3500 15-32 3500 SLAM 3500

S-SLAM 3500

3.2.3 SURFACE SHUTDOWN

When this depth value is reached, the alarm will sound and tension contact closure switch is closed. This can be used to provide a signal to automatically stop the winch. Default value is 100’

3.2.4 TENSION ALARM When preset tension value is reached, alarm sounds and "TENSION ALARM" flashes on the screen. Each cable size will have a corresponding Tension Alarm setting. Only the setting for the cable size selected can be adjusted.

Default Values

7-32 1500 9-32 2400

5-16 2400 3-8 2400

7-16 2400 15-32 2400 SLAM 2400

S-SLAM 2400



6415 Reading Road

281-342-6415281-342-4848

3.2.5 DIFFERENTIAL TENSION ALARM When this setting is reached the alarm sounds and "DIFF

TENSION ALARM" flashes on the screen. In incremental mode (see 3.1.2), you must periodically press

meter reset or this alarm will sound when the tension reaches the set value. In differential mode, the meter will reset itself and the alarm will only sound on a quick change of tension.

3.2.6 SURFACE ALARM

When this depth value is reached, the alarm will sound. This

value is used to calculate the ETA (Estimated Time of Arrival) when coming out of the hole.

3.2.7 TEST ALARM

This button will sound the alarm. This can be used to verify the alarm is working and to determine if the volume is adequate.

3.2.8 ALARM OFF This button silences the alarm until a new alarm condition

occurs. 3.2.9 ALARM VOLUME This button will bring up a slider bar which is used to adjust the

alarm volume. Use the "Test Alarm" button to test the volume.



6415 Reading Road

281-342-6415281-342-4848

3.2.10 TEST SHUTDOWN When this button is pressed, the contact closure pins (A and B) on J8 are shorted. This can be used to test the winch shutdown mechanism or any other mechanism that uses these contacts. 3.2.11 RELEASE SHUTDOWN When this button is pressed, the contact closure pins (A and B) on J8 are open.



6415 Reading Road

281-342-6415281-342-4848

3.3 AUTO CORRECT

This menu allows changes to be made to the stretch parameters as required by the wireline, drilling mud and logging tools that are being used on the job.

MMD CORRECTION

Enabling this allows depth correction to magnetic marks on the wireline

STRETCH CORRECTION Enabling this allows depth correction to tool, line, and mud parameters

PIPE STRETCH CORRECTION Enabling this causes depth to agree with ‘Driller’s Depth’



6415 Reading Road

281-342-6415281-342-4848

3.4 SETUP SCREEN

The Setup Menu allows changes to the peripheral hardware.



6415 Reading Road

281-342-6415281-342-4848

3.4.1 LINE SIZE SETUP

Select the line size by pressing the corresponding gray box. This menu also allows the changing to a grooved wheel on the measuring head. Note that line size must be set to Other (Not Inline) at this menu to allow some other parameters to be set, as noted on their individual menu’s.



6415 Reading Road

281-342-6415281-342-4848

3.4.2 WHEEL SIZE SETUP

This setting allows you to change the size of the depth measuring wheel that is used to measure depth. To use a different measuring head from the Kerr head, this setting will need to be changed to match the wheel size of the new head. To change Wheel Size, the line size must be first be set to OTHER. At this time, the loadcell angle will also need to be set. Default value is 2ft - .6096 meters 3.4.3 ENCODER PPR SETUP The screen allows you to set the encoder pulses per revolution setting. This number should be printed on the encoder label.

Note: The pulses per foot/meter are not set by this screen, only the encoder input. Pulses per foot/meter are calculated from encoder PPR and Wheel Size.



6415 Reading Road

281-342-6415281-342-4848

3.4.4 STRETCH PARAMETERS

TOOL WEIGHT

The weight of the tool string at the end of the cable.

MUD WEIGHT The fluid weight of the well bore fluid. ACTUAL AND CALCULATED STRETCH These are static displays that provide useful information if a

Stretch Adjustment needs to be performed at T.D.



6415 Reading Road

281-342-6415281-342-4848

3.4.5 ENGLISH / METRIC UNITS

This menu allows you to select the display units for either depth or tension. 3.4.6 ENCODER DIRECTION This screen allows you to change the direction of the encoder. If the depth is changing in the opposite direction to which the line is moving, this option can be used to correct it. On a dual wheel measuring device with two encoders, the encoder on one of the wheels will turn in the opposite direction from the other. If you change encoders, this feature can be used to change the encoder direction.

The encoder output direction corresponds to the direction of the encoder connected to the encoder 1 input.



6415 Reading Road

281-342-6415281-342-4848

3.4.7 MMD SETUP SCREEN

MARK SPACING

The amount of correction possible is determined by the mark window width. After resetting the magnetic mark window the first mark detected is assumed to be a valid mark (put on when the line was marked.) If the mark interval is 100 feet and the window width is 5 feet, the first mark detected from 95 to 105 feet from the first mark is assumed to be a valid mark. The panel will add or subtract the difference between the last mark +100 feet – current mark. If the current mark occurs at the last mark + 103 feet, the panel will subtract 3 feet from the displayed depth in the next 30 feet.

WINDOW SIZE

The MMD window determines when the next mark can be detected. The cable must travel at least the distance of the value set before a mark can be detected. Marks can only be detected if they occur within this window. I.E. If the window is set for 95', the cable must travel 95' from the last mark before a new mark can be detected.

Default value is 5’

RESET MARKS

Pressing the MMD reset button clears the last mark setting.



6415 Reading Road

281-342-6415281-342-4848

MARK CORRECTION

Line stretch due to tension is accounted for by entering the tool weight and fluid density. A theoretical tension vs depth curve is calculated and used to establish the mark locations. At each mark the error is added or subtracted to the depth so that the depth will match the theoretical mark depth. As an example, if a tool weight of 1000# and fluid weight of 8.3 lbs/gal is used the mark at 10000 feet is 10.8 feet + the mark at surface. At 20000 feet it is 43 feet + mark at surface.



6415 Reading Road

281-342-6415281-342-4848

3.4.8 CCL SELECTION

This value adjusts the CCL Offset ..ie... the distance from the CCL tool to the tool zero reference (usually bottom of tool or bullplug).

3.4.9 ENCODER STATUS

This screen displays the actual output from the encoders before any corrections are applied.

This screen is useful for checking encoders and wheel wear.



6415 Reading Road

281-342-6415281-342-4848

3.4.10 MARK TABLE

This table allows the viewing of all the Marks found while logging. This can help in differentiating between good marks and false marks.



6415 Reading Road

281-342-6415281-342-4848

3.4.11 CCL TABLE

This table allows the viewing of Collars found while logging



6415 Reading Road

281-342-6415281-342-4848

3.4.11 SUMMARY

The Summary Menu is a quick reference to what parameters are set. This is a static display.

3.4.13 RESTORE DEFAULTS

When this button is pressed, all the settings will be restored to their default values. This functions as a software reset. Depth will be zeroed.



6415 Reading Road

281-342-6415281-342-4848

3.5 HELP MENU

The HELP button will display the three options displayed above.



6415 Reading Road

281-342-6415281-342-4848

3.5.1 ABOUT SCREEN

The ABOUT button displays the software revisions.

There are two programs that can be updated, the HOISTMAN program which is run by the PC and the ACQUISITION program that is run by the real time board.



6415 Reading Road

281-342-6415281-342-4848

3.5.2 HELP MANUAL

The HELP button will bring up this manual. You can scroll up or down to find the information you need.



6415 Reading Road

281-342-6415281-342-4848

4.0 WELLSITE OPERATING SUMMARY

4.1 Power up panel and verify it is working properly.

4.2 Verify the panel is configured to match the system (Acquisition System, encoder, etc.)

4.3 Set up acquisition system:

4.4 Press T-Zero and verify that panel tension reads 0. Verify tension is recorded

on acquisition system.

4.5 Set line size to match cable size installed in head (refer to section 3).

4.6 Set Tension Alarm value (refer to section 3).

4.7 Set depth adjust value (refer to section 3).

4.8 Install cable in measuring head and lay it slack on the ground. 4.9 Press T-Zero to zero the tension value.

4.10 Press T-Test and verify that panel tension reads 3250 lbs. Verify tension is being properly recorded on acquisition system.

4.11 Pull tool to depth 0 position. Press D-Zero and verify that panel depth reads 0. Set acquisition system depth to 0 at this time.



6415 Reading Road

281-342-6415281-342-4848

5.0 PARTS LIST

AMS4P134E PC BOARD AMS40 REV E W/2xRS232 1 EA AMS4P326 COMPUTER SINGLE BOARD 650MHZ 1 EA AMS4P319 LICENSE WINDOWS XP EMBEDDED 1 EA AMS4P318 MEMORY RAM 256MG PC133 SODIMM 1 EA AMS4P317 MEMORY COMPACTFLASH 1.0GB OR 1 EA AMS4A204 PCB ASSY IN CICUIT PROGRAMM CB 1 EA AMS4P577 LCD 12.1 COLOR TFT SHARP 1 EA AMS4P513 SCREEN TOUCH RESISTIVE 12.1 4W 1 EA AMS4P511 CNTROLLER BD TOUCH PNL USB 1 EA AMS4P499 INVERTER CCFL 12VIN 1200V 6mA 1 EA AMS4P128 DISPLAY LED RED 0.5" 14 SEGMNT 2 EA AMS4P307 SONALERT SC616N MALLORY 4-16V 1 EA AMS4A322 PCB ASSY VOLUME BRD 1 EA AMS4A653 PCB ASSY CCL/MMK NTRF AMS4A049 1 EA AMS4A102 PCB ASSY FUSE BOARD 1 EA AMS4A570 CABLE ASSY LANNER USB TOUCH 1 EA AMS4A566 CABLE ASSY LANNER VID HIRSE41 1 EA AMS4A571 CABLE ASSY LANNER 2 X USB 1 EA AMS4M136 BEZEL LCD 12.1" LCD SHARP TUCH 1 EA AMS4M135 CHASSIS 8-3/4 TOUCH SCRN OH 1 EA AMS4M131 PANEL REAR 8-3/4 TOUCH SCRN 1 EA AMS4M132 PANEL FRONT WINCH OP TOUCH SCR 1 EA AMS4M134 PANEL TOP TOUCH SCRN OH OP PNL 1 EA AMS4M138 YOKE PIVOT 8.75 X 15.5 PNL 1 EA AMS4M137 MOUNT PIVOT 5U PANEL 2 EA AMS4M076 WINDOW LED RECESSED SERIAL 2 EA AMS4M012 BRACKET SONALERT TWO LEG 1 EA AMS4P423 HANDLE KEYSTONE 7147 4-9/16 2 EA AMS4P028 SWITCH DPDT TOGGLE LOCKING 1 EA AMS4P290 TERMINAL INSULATED SOLDR 6-32 2 EA AMS4P579 CABLE INVERTER INPUT TO JKL 1 EA AMS4P580 CABLE INVERTER OUTPUT TO JKL 1 EA AMS4P687 CABLE CAT5 3' RJ45 GRAY FLEX 1 EA AMS4P274 COUPLING RJ45F/RJ45F SHIELDED 1 EA AMS7P021 CONN 102398-4 AMP 12 POS PCB 11 EA AMS7P023 CONN 102536-4 AMP 12 POS BACK 11 EA AMS7P024 CONN 102681-1 AMP 12 POS FRONT 11 EA AMS7P025 CONN 102681-3 AMP 16 POS FRONT 2 EA AMS7P022 CONN 102398-6 AMP 16 POS PCB 2 EA AMS7P026 CONN 102536-6 AMP 16 POS BACK 2 EA AMS2P021 CONN 102398-3 AMP 10 POS PCB 1 EA AMS2P022 CONN 102536-3 AMP 10 POS BACK 1 EA AMS2P023 CONN 102540-3 AMP 10 POS FRONT 1 EA AMS4P168 SOCKET AMP M39029/63-368 USED 34 EA AMS4P169 CONN KPSE02E12-3P RECEPTACLE 1 EA



6415 Reading Road

281-342-6415281-342-4848

AMS4P172 CONN KPSE02E14-12S RECEPTACLE 2 EA AMS4P170 CONN KPSE02E12-10P RECEPTACLE 1 EA AMS4P171 CONN KPSE02E12-10S RECEPTACLE 1 EA AMS4P164 CONN DB9S CRIMP AMP USED WITH 1 EA AMS4P166 CONN DB25S CRIMP AMP USED WITH 1 EA AMS4P179 CONN KPSE02E12-3S RECEPTACLE 1 EA AMS4P270 CONN KPSE02E12-8P RECEPTACLE 1 EA AMS4P163 CONN DB9P CRIMP AMP USED WITH 1 EA AMS4P167 PIN AMP M39029/64-369 USED 9 EA AMS7P030 CONN 102398-8 AMP 20 POS PCB 1 EA AMS7P058 CONN 102536-8 AMP 20 POS BACK 1 EA AMS7P035 CONN 102681-5 AMP 20 POS FRONT 1 EA ACMU1P71 CONN 09-50-3061 MOLEX W/LOCKNG 1 EA AMS4P352 CONN .156 SERIES CRIMP TERMINA 6 EA AMS4P581 CONN HOUSING 4POS .2 DISK PWR 1 EA AMS4P582 TERM CONN FEMALE CRIMP DISK PW 4 EA AMS4P583 CONN HSG 10 POS 2MM MILLI-GRID 1 EA AMS4P584 TERM CONN FEM CRIMP 2MM 24-30 10 EA AMS4P675 TAPE DBL SIDE 1/32 X 1 MMM 24 IN AMS4P590 KEYBOARD USB MINI TOUCH BLACK 1 EA AMS7P068 SCREW JACK D-CONNECTOR KEYSTON 4 EA AM5KP181 SCREW 3/8-16 X 3/4 BUTTON HD 2 EA AMS4P198 SPACER UNTHREADED RND NYLON #4 8 EA AMS4P422 SCREW 10-32 X 1/2 FH SOC SST 4 EA AMS8P092 SCREW 6-32 X 3/8 FH PHIL SST 14 EA AMS4P330 CONN .1 CRIMP TERM HOUSING 4CT 1 EA AMS4P331 CONN CRIMP PIN FOR AMS4P330 4 EA AMS4P650 CIRCUIT BREAKER 5A THER PNL MN 1 EA



6415 Reading Road

281-342-6415281-342-4848

6.0 WIRING DIAGRAMS AND SETUP PROCDURES 6.1 CHECKOUT PROCEDURE

6.1.1 Verify all switches, knobs, meters, and connectors are installed properly (refer to assy. Drawings and BOMS.

6.1.2 Visually inspect panel for any problems (loose wires, metal shavings, etc.)

6.1.3 Power up panel using 12vdc. Start up current should measure approximately 2 amps then drop to 1 amp.

6.1.4 Verify all digital displays display digits. 6.1.5 Set the digital displays for the correct address, baud rate, and brightness

The button nearest the connector selects the parameter (address, baud rate, brightness). The center button increments the parameter up The end button increments the parameter down.

After the parameter is set, press the parameter button again to store it.

The addresses should be set as follows: Line Tension = 1 Line Speed = 2

Set Baud Rate to 9600 Set Brightness to 15

6.1.6 On the AMS40 board, verify that JP9 is set to D. Verify R60 is 1.21k ohm/ Power up the panel and verify the hoistman screen loads (should take approximately 1.5

minutes).

6.1.7 Connect an encoder to the panel

Connect an AM5K 2mv/v voltage load pin or a load pin simulator to the panel.



6415 Reading Road

281-342-6415281-342-4848

6.2 DIGITAL DISPLAY SETUP

The two digital displays can be set for address, baud rate, and brightness

The button nearest the connector selects the parameter (address, baud rate, brightness).

The center button increments the parameter up The end button increments the parameter down.

After the parameter is set, press the parameter button again to store it.

The addresses should be set as follows: Line Tension = 1 Depth = 3

Set Baud Rate to 9600

Set Brightness to 15



6415 Reading Road

281-342-6415281-342-4848

6.3 POWER WIRING BLOCK DIAGRAM



6415 Reading Road

281-342-6415281-342-4848

6.4 SIGNAL WIRING BLOCK DIAGRAM



6415 Reading Road

281-342-6415281-342-4848

6.5 Rear Panel



6415 Reading Road

281-342-6415281-342-4848

6.6 Real Time Processor Board



6415 Reading Road

281-342-6415281-342-4848

6.7 CCL BOARD SCHEMATIC



6415 Reading Road

281-342-6415281-342-4848

6.8 INTERNAL WIRE LIST P2 - Screw Terminal Block

P2 -1 BATT + RED, RED 18 CB-bott, P3-1 ccl SWITCHED POWER - TO CIRCUIT BREAKER & CCL BRD

P2 -2 BATT - BLK 18 BUS BAR POWER RETURN TO BUS BAR P2 -3 CONTACT CLOSURE N.O. GRN 18 J8 - A Tension Contact Closure Back Panel P2 -4 CONTACT CLOSURE N.C.

P2 -5 CONTACT CLOSURE COM BRN 18 J8 - B Tension Contact Closure Back Panel

BUS BAR

BUS BAR BATT - BLK 18 J1 - B POWER RETURN TO REAR PANEL BUS BAR BATT - BLK 18 P3-2 CCL POWER RETURN TO CCL BOARD P5 - SPARE P5 - 1 +5V RED 22 P1 - 2, P1- 6 ENCODER POWER TO FUSE BOARD P6 - ANALOG IN/OUT P6 - 3 LOAD PIN SIG+ ORA 22 J4 - A LOAD PIN SIG+ P6 - 4 LOAD PIN SIG- BLK 22 J4 - E LOAD PIN SIG- P6 - 7 SHNT_CAL_SIGNAL GRY 22 P2 -11 CCL BRD SHUNT CAL SIGNAL TO CCL BRD P6 - 8 ACM BLK 22 J4 - B EXCITATION - (GROUND) P6 - 9 4to20OUT BRN 22 J7-12 4 to 20 mA to system P6 - 10 ACM BLK 22 J7 - 21 TENSION COMMON (TO SYSTEM) P6 - 11 0->10V OUT (TENSION) GRAY 22 J7 - 9 TENSION 0->10V OUT+ TO SYSTEM P6 - 13 TENSION METER - DAC VIO 22 P1-2 VOL BRD VOLUME SIGNAL



6415 Reading Road

281-342-6415281-342-4848

P7 - COMMUNICATIONS P7 - 6 + 5 VDC RED 22 D1 - 4 DISPLAY POWER

P7 - 7 COM2 TXD ORG 22 D1-5, D2-5 DISPLAY DATA - TWO WIRES CONNECTED TOGETHER

P7 - 9 GND BLK 22 D1-1 DISPLAY GND P7- 10 COM1 TXD BLU 22 COMA1 - 2 40 BRD TXD OUT TO RX ON COM1 LANNER CPU P7 - 11 COM1 RXD WHT 22 COMA1 - 3 40 BRD RXD OUT TO TX ON COM1 LANNER CPU P7 - 12 GND ORN 22 COMA1 - 5 40 BRD GND TO GND ON COM1 LANNER CPU P8 - QUADRATURE OUT / INDICATORS P8 - 3 EXC TEN LED BRN 22 J7 - 10 MAG MARK COMMON COLLECTOR P8 - 6 EX TEN ALM + POWER YEL 22 P1-1 VOL BRD 12 VDC POWER FOR BEEPER P8 - 7 KEY ----- ----- P8 - 8 KEY ----- ----- P8 - 11 PHASE 1B* YEL 22 J7 - 15 Quadrature Out - PHASE B* P8 - 12 PHASE 1B BLU 22 J7 - 3 Quadrature Out - PHASE B P8 - 13 PHASE 1A* RED 22 J7 - 14 Quadrature Out - PHASE A* P8 - 14 DCM BLK 22 J7 - 13 Digital common P8 - 15 KEY ----- ----- P8 - 16 PHASE 1A ORA 22 J7 - 2 Quadrature Out - PHASE A P9 - ENCODER 1 P9 - 1 DCM BLK 22 J2 - L Encoder Ground P9 - 5 12 VDC - TO FUSE YEL 22 P1 - 10 Fuse Brd EXCITATION P9 - 7 KEY ----- ----- P9 - 8 ENCODER 1B BLU 22 J2 - B Encoder input P9 - 9 ENCODER 1B * GRN 22 J2 - E Encoder input P9 - 10 KEY ----- -----



6415 Reading Road

281-342-6415281-342-4848

P9 - 11 ENCODER 1A ORA 22 J2 - A Encoder input P9 - 12 ENCODER 1A* RED 22 J2 - C Encoder input P10 - ENCODER 2 P10 - 1 DCM BLK 22 J3 - L Encoder Ground P10 - 5 12 VDC P10 - 7 KEY ----- ----- P10 - 8 ENCODER 2B BLU 22 J3 - B Encoder input P10 - 9 ENCODER 2B * GRN 22 J3 - E Encoder input P10 - 10 KEY ----- ----- P10 - 11 ENCODER 2A ORA 22 J3 - A Encoder input P10 - 12 ENCODER 2A* RED 22 J3 - C Encoder input P11 +/- 15 VDC P11-1 DIG GND BLK 22 J5 - F MMD POWER COMMON P11-3 +5VDC RED 22 P1 - 9 fuse brd +5VDC OUT Thru FUSE BRD P11 - 8 MARK+ VIO 22 J5 - C MARK IN - P11 - 9 MARK- WHT 22 J5 - D MARK IN + P11-10 +15 VDC ORG 22 P1 - 3 Fuse Brd MMD POWER + TO FUSE BOARD P11-11 STRONG MARK + BLU 22 J5 - H STRONG MARK IN - P11-12 STRONG MARK - GRAY 22 J5 - G STRONG MARK IN + D1 & D2 DISPLAYS - DEPTH & TENSION D1-2 GND BLK 22 D2 - 1 GND OUT D1-6 +5V OUT RED 22 D2 - 4 POWER OUT D2 -2 GND BLK 22 P1 - 3 VOL BRD GND OUT

J1 12V POWER IN



6415 Reading Road

281-342-6415281-342-4848

J1-A 12V POWER IN RED 18 SW1-MIDDLE 12V POWER TO FRONT PANEL SWITCH SW1-BOTTOM 12V POWER IN RED 18 CB-TOP 12V POWER FROM SWITCH TO CIRCUIT BREAKER

FUSE BOARD P1 - 4 ENCODER1 PWR FUSED WHT 22 J2 - J P1 - 8 ENCODER2 PWR FUSED GRY 22 J3 - J

P1 - 12 12 VDC POWER (FUSED) BLU 22 J4-C, P2-13 CCL LOAD PIN EXCITATION, SHUNT CAL PWR CCL BRD (2 WIRES)

P1 - 11 5 VDC POWER (FUSED) RED 22 J7 - 5 5 VDC POWER OUT TO SYSTEM P1 - 5 MMD PWR (+15) FUSED RED 22 J5 - E POWER TO MMD COM B (LANNER COM2) COMB1- 5 COM1 TXD BLU 22 P2 - 9 CCL TXD OUT TO CCL RXD COMB1- 3 COM1 RXD WHT 22 P2 - 8 CCL RXD OUT TO CCL TXD COMB1- 9 GND ORN 22 P2 -10 CCL GND J9 - REAR PANEL - CCL J9 - A CCL + RED 22 P2 - 3 CCL CCL + IN FROM REAR PANEL TO CCL BRD J9 - B CCL - BLK 22 P2 - 4 CCL CCL - IN FROM REAR PANEL TO CCL BRD CCL BRD - POWER & SHUNT CAL P3 - 5 5 VDC POWER TO CPU RED 18 PS4M1 - 4 5 VDC POWER TO LANNER CPU BRD P3 - 6 GND BLK 18 PS4M1 - 3 GND TO LANNER CPU BRD

P3 - 3 12 VDC POWER YEL, RED 18 PS4M1-1,CN1-6,7 12 VDC TO LANNER CPU & SPLICE TO INVERTER WIRES

P3 - 4 GND BLK,BLK 18 PS4M1-2,CN1 -> CN1 PINS 3,4 & 5 SPLICED TOGETHER - GND TO INVERTER

P2 - 12 SHNT_CAL_OUT YEL 22 J4 - G LOAD CELL SHUNT CAL OUT TO REAR PANEL



6415 Reading Road

281-342-6415281-342-4848

CN1 - INVERTER INPUT CN1 - 1 DIMMING CONTROL BLU, BLK 22 CN1 - 2 SPLICE TOGETHER CN1 - 3 ENABLE WHT,BLK 22 CN1 - 4, CN1 - 5 SPLICE TOGETHER CN1 - 6 12 VDC IN RED,RED 22 CN1 - 7 SPLICE TOGETHER CN2 - INVERTER OUTPUT CN2 - 1 HV - 1 WHT,PINK 22 CCFL LAMP SPLICE TOGETHER CN2 - 2 HV - 2 WHT,BLU 22 CCFL LAMP SPLICE TOGETHER CN2 -5 RTN WHT,BRN 22 CCFL LAMP SPLICE TOGETHER CN2 -6 RTN WHT,WHT 22 CCFL LAMP SPLICE TOGETHER USBA1 - DUAL USB PORTS

USBA1 - 1 USB_VCC RED 22 MOLDED CABLE 2mm CONNECTOR TO MOLDED SINGLE USB REAR PANEL

USBA1 - 5 USBD0- WHT 22 MOLDED CABLE 2mm CONNECTOR TO MOLDED SINGLE USB REAR PANEL

USBA1 - 7 USBD0+ GRN 22 MOLDED CABLE 2mm CONNECTOR TO MOLDED SINGLE USB REAR PANEL

USBA1 - 9 GND BLK 22 MOLDED CABLE 2mm CONNECTOR TO MOLDED SINGLE USB REAR PANEL

USBA1 - 10 USB_VCC RED 22 TC CONTROLER CABLE TO TOUCHSCREEN CONTROLLER USBA1 - 6 USBD0- WHT 22 TC CONTROLER CABLE TO TOUCHSCREEN CONTROLLER USBA1 - 4 USBD0+ GRN 22 TC CONTROLER CABLE TO TOUCHSCREEN CONTROLLER USBA1 - 2 GND BLK 22 TC CONTROLER CABLE TO TOUCHSCREEN CONTROLLER USBA2 - DUAL USB PORTS

USBA2 - 1 USB_VCC RED 22 MOLDED CABLE 2mm CONNECTOR TO MOLDED DUAL USB FRONT PANEL

USBA2 - 5 USBD0- WHT 22 MOLDED CABLE 2mm CONNECTOR TO MOLDED DUAL USB FRONT PANEL

USBA2 - 7 USBD0+ GRN 22 MOLDED CABLE 2mm CONNECTOR TO MOLDED DUAL USB FRONT



6415 Reading Road

281-342-6415281-342-4848

USBA2 - 9 GND BLK 22 MOLDED CABLE 2mm CONNECTOR TO MOLDED DUAL USB FRONT PANEL

USBA2 - 10 USB_VCC RED 22 MOLDED CABLE 2mm CONNECTOR TO MOLDED DUAL USB FRONT PANEL

USBA2 - 6 USBD0- WHT 22 MOLDED CABLE 2mm CONNECTOR TO MOLDED DUAL USB FRONT PANEL

USBA2 - 4 USBD0+ GRN 22 MOLDED CABLE 2mm CONNECTOR TO MOLDED DUAL USB FRONT PANEL

USBA2 - 2 GND BLK 22 MOLDED CABLE 2mm CONNECTOR TO MOLDED DUAL USB FRONT PANEL



6415 Reading Road

281-342-6415281-342-4848

7.0 SOFTWARE UPDATE PROCEDURE PREREQUISITES:

1. The real-time data acquisition board must have a socket for the MicroController and a piggy-back PCB installed in that socket with a DS89C450 MicroController installed.

2. USB keyboard/touchpad.

3. USB floppy drive or USB CompactFlash card reader or USB thumb-drive or

equivalent or a Ethernet connection with the new revision real-time data acquisition HEX file program.

7.1 HOISTMAN PROGRAM UPDATE (PC BASED PROGRAM)

7.1.1 Close all running programs in Windows XP Embedded.

7.1.2 Copy Hoistman Display.EXE to the directory C:\ Program Files\Kerr\

7.1.3 Shutdown Windows XP Embedded, and cycle power. When the Hoistman Display program comes up check the HELP – ABOUT menu and confirm that both software versions are at the latest revision.

7.1.4 Copy this file (manual.pdf) to C:\. This manual can then be evoked from the

help menu. 7.2 REAL TIME BOARD PROGRAM UPDATE (AMS40 BOARD)

The following Instructions for programming the DS89C450 MicroController'sinternal Flash memory with the real-time data acquisition program.

NOTE: the rear panel screws need to be removed to gain access to the switches on the CPU piggy-back PCB. 7.2.1 Close all running programs in Windows XP Embedded. 7.2.2 Copy the TPLUS.EXE file to the root directory C:\

7.2.3 Copy the file S430000?.HEX to the root directory C:\

Transfer these files to the CompactFlash (C:\) root directory

via Ethernet or USB connection using the Windows Explorer



6415 Reading Road

281-342-6415281-342-4848

7.2.4 Start the provided terminal emulation program (TPLUS.EXE located in the root C:\ directory).

Note: The TPLUS program comes with a license message. Press the ESCAPE key and continue.

Change the baud rate by first mouse clicking on SETUP - PORT SETUP - < > USER (A DOT NOW APPEARS) and then typing: 16457 in the USER BAUD RATE text box. The others settings should be OK - so close the connections settings box by clicking on the OK button. For your information the settings should be as follows:

Serial Port: COM1 Baud Rate: 16457 Data Bits: 8 Parity: None Stop Bits: 1

7.2.5 Set the switches on the piggy-back PCB to PROGRAM mode as follows:

SW1 - position away from CPU

SW2 - position away from CPU SW3 - position towards CPU

7.2.6 Press the keyboard ENTER key. The MicroController ROM Loader will

respond with a banner and then a '>' prompt. 7.2.7 Type an uppercase 'K' for Klean and Erase. When complete the prompt

should appear. If the prompt does not appear, cycle the switches and repeat steps 7.2.5 and 7.2.6

7.2.8 Type an uppercase 'L' and the ROM Loader will wait to Load a HEX file.

7.2.9 Pull down the FILE menu and choose: OPEN. The file browser will open and

then go to the C:\ root directory and choose the new revision HEX file to transfer. Next choose DOWNLOAD in the same FILE menu.

7.2.10 The ROM Loader will begin programming the Flash and will report a GOOD

status for the duration of the programming procedure (about 5 minutes) as follows:

GGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGG



6415 Reading Road

281-342-6415281-342-4848

GGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGG >

7.2.11 To re-initialize memory by running the MEMDISK program installed in the EPROM instead of the Micro-Controllers internal memory, set the switches on the CPU piggy-back PCB as follows:

SW1 - position towards CPU

SW2 - position towards CPU SW3 - position towards CPU Wait approximately 10 seconds

7.2.12 After the ROM Loader is finished programming the Flash and the MEMDISK program is complete set the switches on the piggy-back PCB as follows:

SW1 - position towards CPU SW2 - position towards CPU SW3 - position away from CPU

The real-time data acquisition program will start and the front panel Depth and Tension LED's will flash and then show a Depth of 0.0. the Tension reading will vary depending on whether there is a load cell connected to the panel.

7.2.13 The terminal emulation program uses the same serial port as the Hoistman

program, so close it before opening the Hoistman program.



6415 Reading Road

281-342-6415281-342-4848

8.0 CABLE DRAWINGS 8.1 AMS4A807 CABLE ASSEMBLY – DC POWER IN

A = RED (+12 VDC) B = BLACK (GND) Component Description Qty Required UM --------------- ------------------------------ ---------------- --- AMS4P177 CONN KPSE06J12-3S STR PLUG 1 EA AMS4P222 CABLE 20/4C ALPHA 25154 BLACK 10 FT



6415 Reading Road

281-342-6415281-342-4848

8.2 AMS4A130 CABLE ASSEMBLY – ENCODER IN

Component Description Qty Required UM --------------- ------------------------------ ---------------- --- AMS4P184 CONN MS3106F-16S-1S 7 SOCKETS (encoder end) 1 EA AMS4P182 CONN KPSE06J14-12P STR PLUG (panel end) 1 EA AMS4P245 CABLE 20/4P ALPHA 45294 BLACK 20 FT AM5KP113 DUST CAP MS25042-16DA 1 EA AMS7P064 BUSHING #9779-513-8 AMPHENOL 1 EA



6415 Reading Road

281-342-6415281-342-4848

8.3 AMS4A131 CABLE ASSEMBLY – MMD IN

Component Description Qty Required UM ITEM --------------- ------------------------------ ---------------- --- ---- AMS4P245 CABLE 20/4P ALPHA 45294 BLACK 20 FT 1 ACMU2P21 CONN MS3106F-20-27S UMBILICAL (mmd end) 1 EA 2 ACMU2P24 DUST CAP MS25042-20DA UMBILICL 1 EA 3 AMS4P181 CONN KPSE06J12-10P STR PLUG (panel end) 1 EA 4 AMS7P064 BUSHING #9779-513-8 AMPHENOL 1 EA ACMU2P23 BUSHING #9779-513-10 AMPHENOL 1 EA



6415 Reading Road

281-342-6415281-342-4848

8.4 AMS4A132 CABLE ASSEMBLY – LOAD PIN IN

Component Description Qty Required UM --------------- ------------------------------ ---------------- --- AMS4P245 CABLE 20/4P ALPHA 45294 BLACK 20 FT AMS4P180 CONN KPSE06J12-10S STR PLUG (panel end) 1 EA AMS1P123 CONN 34120-18-1SN DEUTSCH (load pin end) 1 EA AMS1P130 CONN BACKSHELL RSI G61307-185 1 EA AM5KP148 DUST PLUG CW50N16A CANNON CWL 1 EA



6415 Reading Road

281-342-6415281-342-4848

8.5 AMS4A133 CABLE ASSEMBLY – SIGNAL OUT TO COMPUTER SYSTEM OPEN HOLE SYSTEM WIRING

Component Description Qty Required UM --------------- ------------------------------ ---------------- --- C276P352 CONN DB25P ITT (to panel) 1 EA 249994000 CABLE ALPHA 2219/12C 22GA 20 FT AMS4P299 CONN KPSE06F22-21S STR PLUG (to computer) 1 EA



6415 Reading Road

281-342-6415281-342-4848

8.6 AMS4A134 CABLE ASSEMBLY – SIGNAL OUT TO COMPUTER SYSTEM CASED HOLE SYSTEM WIRING

Component Description Qty Required UM --------------- ------------------------------ ---------------- --- C276P352 CONN DB25P ITT (to panel) 1 EA 249994000 CABLE ALPHA 2219/12C 22GA 20 FT AMS4P299 CONN KPSE06F22-21S STR PLUG (to computer) 1 EA

OPERATIONS AND MAINTENANCE MANUAL WINCH …...operations and maintenance manual winch operators...

Documents

Transcript of OPERATIONS AND MAINTENANCE MANUAL WINCH …...operations and maintenance manual winch operators...