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WINCH OPERATORS PANEL

OPERATIONS AND MAINTENANCE MANUAL

AMS4A043SAP# 101409408

D01085218

AMS4A043 panel BenchMark June 2015 of 120

TABLE OF CONTENTS

SECTION DESCRIPTION

1.0 GENERAL DESCRIPTION, FEATURES & SPECIFICATIONS

2.0 WELL SITE OPERATING INSTRUCTIONS

3.0 SOFTWARE OPERATING INSTRUCTIONS

4.0 DESCRIPTION OF ALGORITHMS

5.0 SCHEMATICS AND WIRING DIAGRAMS

6.0 BILL OF MATERIALS

7.0 SETUP AND SOFTWARE UPDATE PROCEDURES

8.0 VNC SETUP PROCEDURES


Manual Revision Log

Current Revision K June 2015 Added SAP number to first page

Added uninstall previous Hoistman Display in the Windows Control panel section 7.3

Current Revision J Sept 2014 Removed 12-24vdc reference. Should be 12vdc only

Current Revision I Mar 2013New gauges and features

Previous Revision H Nov 2010Added CF removal procedure for Advantech PCBAdded VNC procedure

Previous Revision G Jun 2010Version 2.06 Software update

Previous Revision F Dec 2009Version 2.04 Software updateAdded Depth Control procedureAdded GPIB revision to About screenAdded ability to view Stretch ProfileAdded Total Mark Correction to log fileAdded Mark Intensifier Enable signalAdded ability to change Deep Groove tension factorAdded CAN outputAdded table of tension factors and Shunt cal valuesUpdated schematics, wire list, and parts list

Previous Revision E Nov 2006Added new software screen shots and informationAdded schematics and wirelist

Previous Revision D Sep 2006Updated drawing on page 45 to show VGA connectorUpdated MMD stretch correction description on page 40Included flash card removal procedure on page 55

Previous Revision C May 2006Updated Spec page on page 7


UPDATED page 9 – Feature to turn on/off depth display boxes.Updated parts list in section 6.0Added Section 7.0 – software update procedure

Previous Revision: B FEB 2006 UPDATED SIGNAL AND POWER BLOCK DIAGRAMSADDED NEW SCREEN PICTURES


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.

It is designed to be a drop in replacement for the current SDDP-A or SDDP-B panel. It provides the same functionality, footprint, signal/control interfaces, and input/output connectors used by the SDDP. In addition to the GPIB interface, the panel also includes some additional functionality such as an encoder quadrature and analog tension output to drive Cased Hole Interface Panel (CHIP) in LOGIQ-CH system.

The panel consists of three main components, the real time acquisition board, the GPIB interface processor 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.

The GPIB interface processor board receives and transmits data and commands from the acquisition board and the BenchMark logging system.

1.2 HARDWARE FEATURES

12 VDC Power Input

Internal PC board1. Intel based personal computer board2. 4 GB solidstate media device3. Embedded windows XP operating system4. Three USB ports (2 front, 1 rear)5. 1 RS232 port6. RJ 45 Ethernet port7. USB Mouse / Keyboard included


Color Display1. TFT LCD2. Backlit3. 400 NITS Sunlight readable4. Touch Screen Interface (replaces current key pad)5. 5 wire resistive6. USB interface

Real Time Acquisition board1. BenchMark proprietary design based on 8051 Microprocessor2. Provides power to encoders, magnetic mark detector, and load cell3. Processes encoder quadrature pulses, magnetic mark signal, and load cell 4. Runs independent of windows embedded PC 5. Connected to digital displays for real time display of depth and tension6. Runs can-bus output for line speed, depth, and tension

Rig Floor Display1. Either surface or downhole tension can be sent to the rig floor display2. RS232 input with a 4-20MA Current Loop output

GPIB interface to link with Host Computer1. Depth, Tension, Magnetic Mark, and CCL data sent to host2. Setup commands sent from host3. Down hole tension data sent from host4. Tested with Excell 2000 B/C/D/G, INSITE (LogIQ-OH), LogIQ-CH (Warrior)

Systems5. Optional CAN bus interface (replaces GPIB interface)6. Provides depth and tension data every 10 milliseconds7. Provides CCL and magnetic mark data every 100 milliseconds

Overtension Relay Contact Closure output for Safe Winch Control System1. Line Tension Signal Output 0-10V 2. Up/Down and Quadrature depth pulses output

Dual 2mv / Volt Load Cell Inputs

Analog output interface for LOGIQ-CH system:1. Encoder quadrature output2. 0 – 10vdc tension output

Can-bus output, depth, tension, and line speed

Day and night screen setting – day on top – night below


1.3 USER INTERFACE FEATURES


Approaching surface alarm Estimated time of arrival for surface and TD. Log file recorded on solid state media containing depth, line speed and tension

recorded at 1 sec intervals. All parameters and commands sent to log file. 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 Digital MMD or CCL selection button (touch screen control) Mark Detection Window (touch screen control) MMD meter graphic for analog detector 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 (PPF 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. Supports standard HES encoder values – 300 PPF and 600 PPF, both +5vdc and

+12vdc power Down hole Tension numeric graphic display


1.4 SPECIFICATIONS

HEIGHT: 7"WIDTH: 19" Retma Rack MountDEPTH: 7.5"

WEIGHT: 10 LBSMINIMUM OPERATING TEMPERATURE: 32deg F 0 deg CVOLTAGE INPUT: 12 VDC +/- 1.5 VDCCURRENT INPUT: 3 AMPS

NOTE: Lab power supplies need to be able to provide a minimum of 3 amps continuous.


2.0 WELL SITE OPERATING INSTRUCTIONS


2.1 STARTUP

2.1.1 Power up panel and verify it is working properly.

2.1.2 Verify the panel is configured to match the system (Front End Acquisition System).

2.1.3 Connect to the acquisition system:

2.1.4 Configure parameters (refer to the Summary of Parameters section 3.4.15)

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

2.1.6 Set all Tension Alarm values (refer to section 3).

2.1.7 Set all Depth Alarm values (refer to section 3).

2.1.8 Install cable in measuring head and lay it slack on the ground.

2.1.9 Press Tension Zero in Calibrate menu to zero the tension value.

2.1.10 Press Tension Shunt and verify that panel tension reads 3250 lbs (1475 kg) assuming line factor equals 1.0. Verify tension is being properly recorded on acquisition system.

2.1.11 Pull tool to depth 0 position. Set Depth and verify that panel depth reads 0. Set acquisition system depth to 0 if necessary.


2.2 DEPTH CONTROL

2.2.1 WSDP Default - Depth Control Using Magnetic Mark Correction

The WSDP panel defaults are configured for Magnetic Mark Correction with Cable Stretch and Pipe Stretch enabled.

NOTE: do not use Pipe Stretch Enabled to determine the encoder wheel calibration factors. This will be covered later in this section. Refer to: Determining Encoder Wheel Calibration Factors.

The following is the list of parameters that must be accurate for proper depth controlUsing magnetic mark correction:

2.2.1.1. Good marks on a seasoned cable:Rule-of-thumb – a cable is effectively seasoned after 30 pulls at maximum anticipated tension. An unseasoned cable will permanently stretch during a logging run resulting in the winch operator pulling in more cable than was let out to reach the top of the well. The magnetic mark correction algorithm in the WSDP will NOT correct depth accurately in this scenario. This also applies to inaccurate magnetic mark placement on the cable.

NOTE: If the operator knows that he must work with an unseasoned cable there are several things that can be done to manually attempt to correct for the depth inaccuracy. It is important to note that the determination of proper depth with an unseasoned cable will inherently be inaccurate. This will be discussed later in this section. Refer to: Working With An Unseasoned Cable.

2.2.1.2. Accurate Cable, Mud, and Tool Weight Parameters:

The WSDP software builds a theoretical magnetic mark table based on Cable Weight, Cable Volume, Cable Stretch Coefficient, Mud Weight, and Tool Weight.

CAUTION: it is important to note that if any of the above parameters are changed, the theoretical magnetic mark table is re-built and the magnetic mark corrections that the WSDP has performed are zeroed and depth is changed accordingly.

Therefore, it is recommended that all parameters are set at the top of the well. If any parameters must be changed, for example, at T.D. make a note of the depth before changing the parameter and then perform a Set Depth command to change the depth back to where it was. Also, keep in mind that the logging system sends the Tool Weight command to the WSDP after exiting the Logging Setup Menu and if the new Tool Weight is different from the old Tool Weight, the theoretical magnetic mark table will be re-built and the magnetic mark correction will be zeroed and depth will change accordingly.


Parameters for Built-in Cable Sizes

The WSDP software includes typical parameters for eight (8) built-in cable sizes. These are provided for convenience and may not exactly match the particular cable being used. In the case that the operator needs to change a parameter because it does not match the cable being used, the operator must choose cable type ‘Other’ or “Other2” first and then make the necessary parameter changes. Note that the theoretical magnetic mark table is re-built every time that one of these parameters is changed.

Theoretical Magnetic Mark Table

The table can be viewed (version 2.04 and up) for verification purposes. Go to the Setup – Stretch Parameters – View/Save Profile Table. Several examples follow:

For default parameters the theoretical cable stretch at 10,000 Ft is: 4.38 Ft.This means that if the first valid mark was detected at zero (0) feet depth, a mark will be detected at 10,004.38 Ft. If the mark at this depth is slightly shallower or deeper, the WSDP will automatically correct the depth such that the mark is at 10,004.38 Ft.

NOTE: The maximum correction allowed for each mark is +/- ½ the Mark Window Width. Also, note that the correction is gradually implemented by the panel at a rate of 1 Ft/10 Ft of cable travel.

Theoretical Magnetic Mark Table Without Pipe Stretch Enabled

If pipe stretch is disabled, the table is built to “True Depth”. As an example:Make sure that all parameters are set to default and then disable pipe stretch. Refer to the table again (Go to the Setup – Stretch Parameters – View/Save Profile Table) and note that the theoretical cable stretch at 10,000 Ft is now 10,009.01.

The difference in stretch between enabling and disabling pipe stretch is:10,009.01 Ft. – 10,004.38 Ft. = 4.63 Ft., which is exactly the pipe stretch coefficient used by the WSDP. This coefficient has been accepted by BenchMark as the standard and cannot be changed in the software.

Note that this coefficient is defined as a function of the depth squared. For example:The pipe stretch at 1,000 Ft is: 0.05 Ft. and,The pipe stretch at 10,000 Ft is: 4.63 Ft. and,The pipe stretch at 20,000 Ft is: 18.51 Ft.

NOTE: enabling pipe stretch results in depth represented shallower than true depth by the WSDP depth panel such that Wireline depth matches pipe depth. In other words, when inserting 10,000 Ft of drill pipe into a well, the bottom of the drill pipe is actually at 10,004.38 Ft. because the pipe stretched. The driller will consider this


depth to be nominally 10,000 Ft. and the WSDP depth panel is assumed to match that nominal depth when pipe stretch is enabled even if it is not the true depth.

2.2.1.3. Encoder Wheel Sizes:

The BenchMark standard for the encoder wheel circumference is 2 Ft. (.608 meters). An oversized encoder wheel results in depth measurements being shallow and a worn, undersized encoder wheel results in depth measurements being deep.

NOTE: it is important to note that when the WSDP is operated in the default mode with magnetic mark correction enabled the fact that the wheels may be slightly oversized or slightly undersized is NOT important for proper depth control. The magnetic mark correction in the WSDP will compensate for this and keep the panel on depth.

In other words, the encoder wheel calibration factors that are set in the Setup – Wheel Cals – Wheel1 Factor and Wheel2 Factor menus can be set at 0.0 Ft/1000 Ft and the panel will remain on depth if the magnetic marks and the panel parameters are accurate. Disabling wheel correction accomplishes the same as setting the values to 0.0.

NOTE: if the WSDP panel is operated with magnetic mark correction disabled, wheel calibration then becomes the most important factor to determine accurate depth. Remember to enable wheel correction if the intent is to use the WSDP panel with encoder wheel calibration factors.The only time that it is necessary to compensate for oversized or undersized encoder wheels is if the error in wheel size is greater than the WSDP panel’s ability to correct for the error in wheel size. For example, with the default window size of 4 Ft. (+/- 2 Ft), the encoder wheel circumference can vary between 1.98 Ft. and 2.02 Ft. and the WSDP panel will still correct to the proper depth assuming that it catches and corrects to every valid mark.

NOTE: the above example is the best case scenario where the WSDP panel catches and corrects to every valid mark on the cable. Since some marks can be weak and missed, the wheel circumference should probably be in the range: 1.995 Ft. -> 2.005 Ft.

Determining Whether a Stretch Adjustment is required at T.D.:A stretch adjustment is not necessary in shallow wells with relatively light tool strings and tension pulls and a stretch adjustment is recommended in deep wells with relatively high tension pulls. It is the discretion of the Logging Engineer to make this determination.

The theory behind a stretch adjustment is that the WSDP in magnetic mark correction enabled mode has been correcting depth to the marks on the cable according to the


theoretical mark table all the way down hole based on a theoretical tension curve. When at T.D. the tool string is then pulled up hole, the tension pull usually rises higher than the theoretical tension calculated for the theoretical mark table. This results in the subsequent magnetic mark corrections actually causing the panel to be slightly off-depth at every mark going up hole. The error diminishes as the tool string gets shallower and, in fact, the tool string will get back to zero (0) depth in the same spot it was before the logging run.

An Example to Help Visualize the Need for Stretch Adjustment in a Deep Well:

The following example uses approximated numbers and is only intended to help visualize the need for a stretch adjustment at T.D. in a deep well.

Example: WSDP panel parameters all set to default … ie …Magnetic Mark and Pipe Stretch enabled, Tool Weight is 1000 Lbs, …etc. The tool string approaches T.D. near 20,000 Ft and tension is 7680 Lbs. The Calculated Cable Stretch is 17.52 Ft. and the Actual Cable Stretch is 17.62 Ft.

The hoist operator then stops the winch and begins pulling the tool string up hole and tension increases to 9540 Lbs and the Actual Cable Stretch increases by approximately 20 Ft (37.70 total).

NOTE: A phenomenon occurs when first pulling the tool string up hole in that the cable begins moving the encoder wheels, the WSDP panel begins decreasing depth, but, the bottom of the tool string does not move until the extra stretch due to the increased tension is imparted on the cable.For the sake of simplicity in this example, the tool string does not move until the WSDP depth reads 19,980 Ft. AND THE BOTTOM OF THE TOOL STRING IS STILL AT 20,000 FT!

If the zone of interest to log is near T.D. and the Logging Engineer wants to be on depth, he then decides to perform a depth adjustment. The steps to perform a Stretch Adjustment follows:

Continue traveling up hole at logging speed (for example 20 Ft/Min).Watch the Calculated and Actual Stretch on the WSDP. (these values are also available on the In-Site Logging System Depth Display).The Logging Engineer sees that the Actual Stretch is greater than the Calculated Stretch by approximately 20 Ft.The Logging Engineer issues the command Change Calculated Stretch AND Depth by 20 Ft.The WSDP immediately increases Depth by 20 Ft. The theoretical Magnetic Mark table is re-built using an effective tool string weight of 1000 Lbs + 1860 Lbs = 2860 Lbs. (1860 Lbs is the increase in effective Tool Weight when pulling up hole). The Logging Engineer looks in Setup – Summary – Diff In Wgt Due To Str Adj = 1860 for


confirmation that the calculation matches the real world events. The Logging Engineer also looks at the Actual and Calculated Stretch again and notes that they are both approximately 37.50 Ft. The Stretch Adjustment procedure is complete.

The hoist operator can now stop, go back to T.D. (which is now at 20,020 Ft) and begin logging up hole and can expect catching good marks (which are now listed as 20 Ft deeper) without having to do anything else on the WSDP depth panel because the Magnetic Mark Window is automatically opened by the Stretch Adjustment command.

Note: A stretch adjustment can only be performed once after a – Set Depth – command. If the operator determines that he wants to perform a second stretch adjustment, he will need to perform a – Set Depth – command before proceeding with a stretch adjustment.

2.2.2 Determining Encoder Wheel Calibration Factors

To determine what the encoder wheel calibration factors should be for the WSDP panel there are a number of conditions that must be met for the numbers to be meaningful and accurate.

Seasoned CableAccurate magnetic marking on cableAccurate cable, mud, and tool parameters.Magnetic Mark Correction enabledPipe Stretch disabledWheel Correction disabled or set both encoder wheel factors to 0.0Dynamic Stretch disabledVertical well free of obstructionsConstant line speed (down hole preferable)At least 1000 Ft. of travel (catch at least 10 valid marks, for example)Encoder 1 enabledEncoder 2 disabled

Once all of the previously listed conditions are met and the tool string is down hole 1000+ Ft. Stop the winch and view the encoder 1 factor by going to the Setup – Encoders – Encoder1 Cal Fac display.

The factor is calculated as follows:

Encoder1 Cal Factor = (corrected depth - raw depth 1) / corrected depth * 1000

This procedure should be repeated again with all previously listed conditions except with Encoder 2 enabled and encoder 1 disabled.


2.2.3 Dual Encoder Algorithm

The WSDP differs from the SDDP with respect to disabling a bad encoder. The SDDP will automatically disable a bad encoder if it lags the good encoder in depth by 6 inches. This results in an error of up to 3 inches before the bad encoder is disabled (the SDDP averages the two encoder depths). Additionally the SDDP will not re-enable the bad encoder if it starts working again.

The WSDP samples the amount of movement from the two encoders every 10 milliseconds and chooses the encoder that moves the most. If both encoders move the same, then encoder 1 is chosen. The WSDP does not attempt to analyze whether an encoder is bad and does not automatically disable a bad encoder. A bad encoder is simply ignored by virtue of the algorithm. In the case that an encoder wheel slips and then begins functioning properly again, the algorithm with utilize it delta counts if they are greater than the other encoder in the 10 millisecond sample.

2.2.4 Working With an Unseasoned Cable

The basic premise for working with an unseasoned cable is that the cable will permanently stretch during the logging job such that the hoist operator reels in more cable than he lets out during the trip down and back up the well. The WSDP depth panel magnetic mark correction will not work correctly when the cable is unseasoned.

Keep in mind that a thoroughly seasoned cable to 15,000 Ft with maximum pulls up to 7,000 Lbs, for example, will be partially unseasoned if the next job calls for a trip down hole to 18,000 Ft with a tension pull of 8,000 Lbs, for example.

Two methods will be discussed for dealing with unseasoned cable.

Method 1: Enable magnetic mark correction for the seasoned length of cable, then disable corrections for the unseasoned length.

Method 1 requires that the Hoist Operator make note of the WSDP depth BEFORE disabling correction, then disable corrections, and then perform a Set Depth command to put the WSDP panel back on depth.

CAUTION: disabling corrections while down hole zeroes out the magnetic mark correction component that was added (or subtracted) to the WSDP depth to that point and therefore depth will change by that amount.

The biggest problem with staying on depth with an unseasoned line is when going up hole, after T.D., for example. The increase in tension will result in even more permanent stretch (and more elastic stretch) in the cable, therefore the tool string will be deeper than the WSDP reports.


At T.D.:The Hoist operator will probably be required to perform a set depth at T.D. AFTER pulling the cable at the maximum tension pull up hole for several hundred feet. This ensures that a significant amount of permanent stretch has been imparted to the cable. The operator, obviously, has to be able to tie-in the new depth set on the WSDP to a known reference at T.D., for example, the point where it is obvious that the tool string is ‘setting-down’ and then ‘Setting Depth’ on the WSDP to the depth that the driller provided as ‘set-down’ depth.

Method 2: If entire cable length is unseasoned, disable magnetic and stretch corrections at the beginning of the job.

The WSDP panel will actually stay on depth with an unseasoned cable going down hole, assuming that the encoder wheel circumferences are within tolerance and/or the wheel calibration factors have been determined and inputted in the panel.

NOTE: The reason for the above statement is that the encoders actually measure stretched line as it passes the encoder wheels on the measuring head.

The biggest problem with staying on depth with an unseasoned line is when going up hole, after T.D., for example. The increase in tension will result in even more permanent stretch (and more elastic stretch) in the cable, therefore the tool string will be deeper than the WSDP reports.

At T.D.:The Hoist operator will probably be required to perform a set depth at T.D. AFTER pulling the cable at the maximum tension pull up hole for several hundred feet. This ensures that a significant amount of permanent stretch has been imparted to the cable. The operator, obviously, has to be able to tie-in the new depth set on the WSDP to a known reference at T.D., for example, the point where it is obvious that the tool string is ‘setting-down’ and then ‘Setting Depth’ on the WSDP to the depth that the driller provided as ‘set-down’ depth.

2.2.5 Dynamic Stretch

Dynamic Stretch mode is provided for certain cased hole services where there are no magnetic marks in use, therefore magnetic mark correction is disabled when Dynamic Stretch mode is enabled.

The WSDP panel depth is affected by the real-time tension reading when operating in the Dynamic Stretch Enabled mode.

CAUTION: Do not use Dynamic Stretch Enabled mode if accurate tension readings are not available. Inaccurate tension readings will cause the depth to be inaccurate.


An interesting phenomenon associated with Dynamic Tension is that using the example above when the winch is stopped after going down hole 20,000 Ft and then turned around to begin moving up hole – the WSDP will momentarily not show any depth change EVEN THOUGH THE REEL IS OBVIOUSLY MOVING until the tool string actually lifts off of T.D.

It has been reported that certain open hole and imaging services produce bad looking logs due to the tension pulls and slacks (and therefore strange depth increments/decrements) if operating the WSDP in Dynamic Tension enabled mode.


3.0 SOFTWARE OPERATING INSTRUCTIONSAfter the system boots up, the main screen will appear.

Main Screen in magnetic mark mode

Most of the commands are accessed through the buttons across the top of the screen.

EXIT Exits the program and returns to Embedded XPDEPTH Refer to section 3.1TENSION Refer to section 3.2ALARMS Refer to section 3.3AUTOCORRECT Refer to section 3.4SETUP Refer to section 3.5HELP Invokes the Help Screen. This document can be

displayed from the help menu. Also, the program revision information is displayed.

NOTE: The boxes on the left of the screen (MARK, CCL, DHTENSION) can be hidden by pressing them twice. Press them again twice to turn them back on. This provides a means to set what depth information is displayed on the customers display.


EXPLANATION OF MAIN SCREEN FEATURES

Mrk / Str, Pipe, Wheel: The correction mode that the panel is currently set to.

LAST MARK: The depth at which the last valid magnetic mark was detected.

MARK SPACING: The distance between the last two valid marks.

SEC DEPTH: A secondary depth can be displayed. This depth is for display only and can be set to CCL depth or other location on the tool string. The actual depth is usually set to the bottom of the tool string.

DH TENSION: The cable head tension value. This value is provided by the logging system.

RAW1: Raw encoder 1 depth with no corrections added.

RAW2: Raw encoder 2 depth with no corrections added.

TENSION GAUGE: Graphically displays the line tension value. This larger gauge represents total tension and the smaller gauge represents incremental or differential tension.

TENSION DISPLAY: Digitally displays the line tension value.

ALARM SILENCE: Silences the alarm for the current event only.

RESET: Resets the Differential Tension meter.

ETA: The Estimated Time of Arrival at surface or TD (total depth) – depending on direction of tool travel. The TD is used is the value of the maximum depth alarm. This time is calculated using current depth and line speed.

DEPTH: The current logging depth. This is the depth is passed to the logging system.

SPEED: The current speed at which the cable is moving.

CCL METER: Displays CCL signal. See main screen in CCL Mode below.


Main Screen in CCL mode

Note: MAXPULL on the lower-center of the main screen is a new feature to Hoistman Version 3.07. MAXPULL is the maximum tension value recorded by that program. This value may also reflect the load cell tension calibration shunt, therefore it is the responsibility of the operator to re-set the MAXPULL value after a shunt cal by double tapping on the display box. The MAXPULL value can also be resent by setting the depth to zero.


3.1 DEPTH MENU

SET DEPTH

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

ADD

If in FEET mode then one foot will be added over the next ten foot interval.If in METERS mode then .3 meters will be added over the next 3 meter interval.

SUBIf in FEET mode then one foot will be subtracted over the next ten foot interval.If in METERS mode then .3 meters will be subtracted over the next 3 meter interval.


TOTAL DEPTH OFFSET

This provides a snapshot of the sum of all ADD and SUB operations performed. This value is displayed in either feet or meters, depending on the units selected.

A SET DEPTH operation will zero this value.


SECONDARY DEPTH

This feature allows the operator to input a number that represents a point in the tool string that is used as a visual reference depth. For example, if there is a sensor of interest that is 30 feet from the bottom of the tool string, the operator can set secondary depth to -30 and the main screen will display the secondary depth 30 feet shallower than the depth display at all times.


3.2 TENSION

Tension setup when Load Cell 1 is chosen

Note: This option selects which loadcell input connector is used. J9 is used for loadcell 2 and J10 is used for loadcell 1. Only one load cell can be read at any time.


Tension setup when Load Cell 2 is chosen



LOADCELL 1 – Line Size

This menu is only available for load cell 1. This menu is also available from the setup menu.


Note: Loadcell 1 is recommended for the in-line load pin mounted on the Benchmark Wireline 5K measuring head, and loadcell 2 is recommended for a hanging sheave mounted loadcell.

TENSION CALIBRATE Refer to following sectionTENSION SCALE Refer to following section50K LOADCELL 2 Refer to following sectionEXIT Exits this screen and returns to the main menu


TENSION CALIBRATE

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 according to the table below:

The load pin will remain in shunt until RELEASE CAL or EXIT is depressed. Tension calibrate is performed on the selected load cell only. If two load cells are used, the operator must select each load cell and perform the tension calibration for each load cell. The panel stores the two tension calibrations independently.


TENSION FACTORS

SHALLOW GROOVED WHEEL

LINE SIZE K FACTOR CAL FACTOR 7/32 1.83 5948 1/4 1.66 5395

9/32 1.48 4807 5/16 1.41 45960.472 1.00 32500.474 1.00 32500.484 1.00 32500.490 1.00 3250

DEEP GROOVED WHEEL

LINE SIZE K FACTOR CAL FACTOR0.472 2.41 78320.474 2.41 78320.484 2.28 74100.492 2.17 7052

Note 1: The Shallow Grooved Wheel should not be used with wirelines larger than .472 slammer.

Note 2: The Deep Grooved Wheel should not be used with wirelines smaller than .472 slammer.

Note 3: As the groove in the tension wheels wears deeper, the angle will decrease causing the output signal to decrease. To compensate for this the Line (K) Factor will need to be increased. If this is the case, the “Line Other” or the “Line Other 2” would be chosen and all line parameters would have to be manually entered.


TENSION SCALE

The Tension Scale Screen allows the changing of both gauges at the center of the screen. It also allows the Gauge type to be set to ether Differential or Incremental scale.

Note: The tension units, at the bottom of the screen, display either kilograms or pounds.


LOAD CELL 2 ANGLE

Loadcell angle is used to compensate when a loadcell is not hung vertically. Enter the value in degrees from vertical.

Note that this function is not available for loadcell 1. It is always available for loadcell 2.


50K LOAD CELL 2

Note: This is a new feature in the Version 3.07 Hoistman & Acquisition software which supports the 50K load cell with 2.8 mV/V sensitivity.


3.3 ALARMS MENU

SURFACE ALARM

When this depth value is reached when traveling uphole, the alarm will sound. “DEPTH ALARM” flashes on the screen

Default value is 100’

Note: Refer to Dis/Enable Surface Shutdown. When enables the surfaces shutdown will cause the shutdown relay contact closure based on the surface alarm depth value.


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 15001-4 15009-32 24005-16 2400.472 Slam 2400.474 Slam 2400.484 Slam 2400

.490 Slam 2400 Other (not inline) 2400

Other2 (not inline) 2400

Note that the Tension Alarm value must be less than the Tension Shutdown (S/D) Alarm value.

DIFFERENTIAL TENSION ALARM

When preset tension value is reached, alarm sounds and "DIFF TENSION ALARM" flashes on the screen. The default value is 500.

In incremental mode (see 3.2.2), 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.

Note that the Differential Tension Alarm value must be less than the Differential Tension S/D Alarm value.

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.


DIS/ENABLE SURFACE SHUTDOWN

TENSION SHUTDOWN

When this value is reached, alarm sounds, tension display flashes value, and if shutdown is enabled the 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 Shutdown setting. Only the setting for the cable size selected can be adjusted.

Default Values7-32 20001-4 20009-32 30005-16 4000.472 Slam 3500.474 Slam 3500.484 Slam 3500

.490 Slam 3500 Other (not inline) 3500

Other2 (not inline) 3500

Note the Tension S/D Alarm value must be greater than the TensionAlarm value.


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. The default value is 750.

Note the Differential Tension S/D Alarm value must be greater thanthe Differential Tension Alarm value.

ALARM OFF

This button silences the alarm until a new alarm condition occurs.

MAX DEPTH ALARM

When the preset depth is reached the alarm sounds and “MAX DEPTH ALARM!” flashes on screen.

TEST SHUTDOWN

When this button is pressed, the contact closure pins (L and J) on J8 are shorted. This can be used to test the winch shutdown mechanism or any other mechanism that uses these contacts.

RELEASE SHUTDOWN

When this button is pressed, the contact closure pins (L and J) on J8 are open.

CASING ALARM

When this value is reached tracking uphole, the alarm will sound and a “casing alarm” message will flash on the main screen.


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.

Note: The alarm volume is reset to high after a panel power cycle.


DISABLE / ENABLE TENSION SHUTDOWN

This function determines whether the tension shutdown contact closure switch is activated (closed) when an overtension condition occurs.

WARNING: use this feature with care. Disabling tension shutdown is dangerous!

TEST LOAD PIN SHUNT

This feature is handy for testing the load pin shunt without recalibrating the tension parameters.

RELEASE LOAD PIN SHUNT

This feature is used to release the load pin shunt if it had previously been in the test shunt mode.


3.4 AUTOCORRECT MENU

The Automatic correction Menu enables or disables WHEEL, MARK, STRETCH, DYNAMIC STRETCH and PIPE STRETCH corrections.


WHEEL CORRECTIONEnabling this allows depth correction to ‘Wheel Size Shimming’ which is performed by entering wheel calibration factors in the setup menu.

MARK CORRECTION Enabling this allows depth correction to magnetic marks on the wireline

Note: Mark and stretch correction must both be enabled or disabled together.

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

DYNAMIC STRETCH CORRECTIONThis feature dynamically calculates stretch using the actual load cell tension and affects depth. Tension must be accurate. CAUTION! This mode is not recommended for open-hole or image logging services.

PIPE STRETCH CORRECTIONThis feature is only used when stretch correction is enabled. Total stretch is decreased by the amount of drill pipe stretch at any given depth.


3.5 SETUP MENU

The Setup Menu allows changes to the peripheral hardware. This is also the menu page that changes the Front End software, for example Warrior.

Note: The figure above shows the Loadcell 1 Line Size inactive (grayed-out) because load cell 2 is selected.


LINE SIZE SETUP MENU

This menu is only available when loadcell 1 is selected.

Select the line size by pressing the corresponding gray box.

Cable weight, volume, and stretch coefficient are automatically determined for all Inline types. Tension coefficients are also automatically set for inline tension measurements. Any previously set load cell angle values will be ignored.

The DEEP Grooved Wheel selection is used if the high tension wheel is installed on the AM5K measuring head. When this is box is selected, the software will calculate the correct tension coefficients.


LINE FACTOR DEEP GROOVE

This factor applies only to the deep grooved wheel selected as ‘yes.’ It can only be changed when line size ‘other’ or ‘other 2’ selected.

Note: These factors are multiplied to the tension reading.


LINE FACTOR

This feature applies only when deep grooved wheel is selected as ‘no.’

Note: Line size must be set to ‘other’ or ‘other 2’.(Not Inline) at this menu to allow cable parameters to be changed as noted on their individual menus.


STRETCH PARAMETER MENU

These menus allow changes to be made to the stretch parameters as required by the wireline, mud and tools that are being used on the job.

Note: Cable weight, cable volume, and cable stretch coefficient can only be changed if line size is set to ‘other’ or ‘other 2.’

Note: All parameters should be set at surface before proceeding down hole except for adjust stretch which is usually performed near T.D.


CABLE WEIGHTDisplayed in lbs per 1000 ft.

TOOL WEIGHTUsually determined by logging system and sent via GPIB command to panel.

ACTUAL AND APPLIED STRETCHThese are static displays that provide useful information if a Stretch Adjustment needs to be performed at T.D.

Applied Stretch is the theoretical stretch based on depth, line size (weight and stretch coefficient), mud weight, tool string weight and the theoretical tension at the current depth.

Actual Stretch is calculated using all of the above parameters in Applied Stretch, except that the actual tension is used in the stretch calculation instead of the theoretical value.

CABLE VOLUMEDisplayed in gal per 1000 feet.

TOOL WEIGHT EQUALS TENSIONThis sets tool weight equal to the tension reading. This setting is only recommended when logging system software tool weight is inaccurate.

CABLE STRETCH COEFFICIENTThis determines the amount of stretch in the cable. This parameter is typically published by the cable manufacturer in feet / 1000 lbs / 1000 feet.

Range = 0.04 to 0.4 e-6

NOTE: Line size must be set to “OTHER” or “OTHER 2” to change this value otherwise theoretical value for line size is displayed.


MUD WEIGHTDisplayed in lbs per gallon.

The fluid weight of the well bore fluid.Range is 120-12000 Kg/cu.M or 1-100 lb/gal.Default: 8.30 lb/gal for English and 994.56 kg/cu.M for Metric.

ADJUST STRETCHThis feature is intended for performing a stretch adjustment near T.D. at normal logging up speed. Note that depth will also be changed by the amount of stretch changed.

Note: The logging system software sends the tool weight command upon exiting the service setup screen, and may change the tool weight.

VIEW / SAVE PROFILE TABLE

This allows the operator to view the stretch profile table that is automatically generated by the program. This table is based on mark interval, line size, line weight, line volume, cable stretch coefficient, mud weight, and tool weight.

This table is also saved to a file on the compact flash drive Root Directory C:\, the filename is xxyyzz.txt where xx is hour, yy is minutes and zz is seconds when table is saved.

Note: The hoistman program creates a log file upon program start located in the compact flash drive directory (c:\windows\security\logs\), the filename is xxyyzz.txt where xx is hour, yy is minutes and zz is seconds.

The data in this file is time stamped.


WHEEL MENU

This menu allows changes to the wheel calibration factors (shim) in Ft/K-Ft to compensate for over-sized or worn wheels.

Note: Wheel correction must be enabled for these factors to have any effect on depth.

Also note that the wheel size button is inactive (grayed-out) because the logging system software is setup for nominal 2 foot wheels and cannot be changed.

Also note that the terms: wheel cal factor and encoder cal factor refer to the same concept. i.e. wheel size error.


ENCODER SETUP MENU

ENCODER RAW DEPTH & CAL FACTORSThese displays are static and are useful for checking encoders and wheel wear.The cal factors are meaningful only when magnetic mark correction is enabled and all parameters are set correctly and well conditions are favorable.

Note: Encoder cal factors are only informational and can be misleading and/or wrong if the parameters are set wrong, if there is wheel slippage, bad magnetic marking, unseasoned cable, etc.


ENCODER DIRECTION

This option is useful if the encoder cables are swapped and the direction sensed by the depth panel is reversed.Note: Depth must be set to zero to perform this operation.


ENCODER STATUS

ENCODER ENABLE/DISABLEEither encoder can be disabled, but not both

ENCODER OUT – RAW VS. CORRECTEDRaw – raw counts from encoder 1 is output. No corrections applied

Corrected – corrected depth output from either or both encoders

When Encoder Output is set to RAW – only encoder 1 pulses will be output REGARDLESS OF encoder 1 being Enabled or Disabled.

Discussion of Possible Scenarios:

Scenario 1: Bad Encoder


It is observed from the main screen RAW1/RAW2 displays that one of the depth encoders is not counting properly, it is recommended to disable the faulty encoder immediately.

Scenario 2: Corrected Pulses Out Required For Warrior System and Either Encoder 1 or Encoder 2 fails.

Set encoder output to CORRECTED and disable either Encoder 1 or Encoder 2.

Scenario 3: RAW Pulses Out Required For Warrior System and Encoder 2 fails.

Set encoder output to RAW and disable Disable Encoder #2.

Scenario 4: RAW Pulses Out Required For Warrior System and Encoder 1 Fails.

Set encoder output to RAW and swap encoder cables on the head (or rear panel) such that the good encoder is connected to the Encoder 1 connector. Therefore Encoder 1 is enabled and Encoder 2 is disabled.

Next navigate back to the Encoders Menu and Change Encoder Direction if swapping the encoder cables causes the cable movement to appear in the opposite direction.

ENCODER PPF SETUP

The screen allows you to set the encoder pulses per foot setting. Wheel Size is always 2 feet in circumference.


MARK DETECTOR SETUP MENU

MARK SPACING

If the mark interval is 100 feet and the window width is 5 feet, the first mark detected from 97.5 to 102.5 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 + 102 feet, the panel will subtract 2 feet from the displayed depth in the next 20 feet.

WINDOW WIDTH

The amount of correction possible is determined by the mark window width. The cable must travel at least the Mark Spacing distance minus one half the Window Width before a valid mark can be detected.

Default value is 4’


FIND 1ST MARK

After resetting, the first mark detected is assumed to be a valid mark (put on when the line was marked). Pressing the Find 1ST Mark button clears the last mark setting but does not clear the Magnetic Mark Table.

MARK CORRECTION

This provides a snapshot of the sum of all magnetic mark corrections. This value is in either feet or meters, depending on what units have been selected.

A Set Depth command will zero this value.

This is the static display of mark correction at the current depth.

Note: Magnetic mark with stretch correction must be enabled for value to be displayed. Refer to section 3.4.1.

MARK RATIO

This display is useful for determining if the marks on the line are getting weak. The ratio is calculated as the number of strong marks divided by the number of all marks.

Only valid marks are used in this ratio, so magnetic mark with stretch correction must be enabled for this function to work. Refer to section 3.4.1.


MARK INTENSIFIER

This button turns on the Mark Intensifier Enable signal. This signal is output to the BenchMark ALS5A105 Magnetic Mark Intensifier device. When the output enable signal is pulled LOW the Magnetic Mark Intensifier device is disabled. The output signal is pulled LOW except during a Valid Mark Window.


CCL MENU SETTINGSWhen CCL is selected, the CCL meter is displayed on the main screen and the CCL offset depth keypad will be displayed.

This screen provides a means to adjust the CCL Offset... ie... the distance from the CCL tool to the tool zero reference (usually bottom of tool or bullplug).


ENG/METRIC SETTINGS

The depth and tension values will be displayed in the units selected.

FT - LBS FT - KGMT - LBSMT - KG

Default value is FT – LBS


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.

This will also clear the static ram (similar to program on MEMDISK eprom).


MMD TABLE

This table allows the viewing of all the Marks found while logging. This can help in differentiating between good marks and false marks. The table is stored at C:\mmrklogX.txt where X is 0 to 5.


CCL TABLE

This table allows the viewing of collars detected while logging. The CCL signal is provided from the logging system so only collars detected by the logging system will be detected by this panel. The table is stored at C:\ccllogX.txt where X is 0 to 5.


RIG FLOOR DISPLAY MENU – NEW SELECTED

Note: When new RFD is selected the original RFD display mode is grayed out.


RIG FLOOR DISPLAY MENU – ORIGINAL SELECTED

RIG FLOOR DISPLAY MENU

Note: When original RFD is selected there are two display mode options:

- Show tension

- Downhole tension


This option is unnecessary with the new RFD because it has four displays

SIMULATOR MENU

By setting a speed, positive or negative, a simulated change in depth is produced.

Note: When set, a flashing “Simulator On!” is seen in the top center of the display. Setting the simulator speed to zero turns the simulator off. Be careful about using the simulator while in the well, as the simulator depths will be added/subtracted to real depths.


FRONT END MENU

This menu provides a means to select the type of logging system front end the panel will be interfacing with.

UNLOCK MENU

This should only be used in case of a communication problem where the unlock commands were not properly received by the GUI program from the host system.


SERIAL NUMBER

DISPLAY MODE


SUMMARY MENU

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


Comm I/FThis feature is not functional in this revision changing the interface communications with the logging system between GPIB and CAN.

I.S. Barrier 1This option allows the use of a load pin through a barrier box.

I.S. Barrier 2This option allows the use of a load pin through a barrier box.

3.6 HELP MENU

The HELP button will display the three options displayed above.


MANUAL

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


ABOUT

The ABOUT button displays the software revisions. There are three 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 and the GPIB program (SDDP.HEX)

COMPORT TIMEOUT MESSAGEThe Comport Timeout Message is a new feature that alerts the operator COM1 or COM2 serial ports are not communicating properly.

ENCODER ERROR MESSAGEThe Encoder Error Message is a new feature that alerts the operator if one of the two enabled encoders is malfunctioning.


4.0 DESCRIPTION OF ALGORITHMS

MMD or CCL FUNCTIONALITY: Either MMD or CCL can be selected. MMD provides the ability to detect magnetic marks and correct depth if enabled. There is support for both Analog or Digital mark detectors.

STRCOR (stretch correction)

When STRETCH Correction is enabled, the panel will automatically correct depth to compensate for cable stretch. The following parameters need to be entered:

TOOL WEIGHT: The weight of the tool string at the end of the cable. Host computer provides this when the service is loaded.

MUD WEIGHT: The fluid weight of the well bore fluid.

DYNAMIC STRETCH CORRECTION ALGORITHM: Stretch in the wireline is compensated in the following manner:

As the tool is lowered into the well the depth traveled is measured using the optical encoders 100 times a second. The tension is used to “back out” the stretch on the wireline for that segment and a non stretched depth is calculated by keeping a tally of all of the segments. This summed value is used in the following manner to calculate the depth: If the tension is less than the calculated line weight the tool is assumed to be floating or supported in some other manner. The tension is due to the line weight so the stretch added is = summed depth * tension * Ks * 1/2 where Ks is the stretch coefficient. If the tension is greater than the line weight the stretch due to the line weight is calculated as above and all other weight is assumed to be acting over the entire length of the cable= sum depth *((line weight * ½) + (tension-line weight)) * Ks


MAGNETIC MARK CORRECTION: The panel has 2 modes of operation using magnetic marks.

MODE 1: No magnetic mark correction. Magnetic marks are displayed in the MMK Depth window but the depth is not corrected or changed in any way.MODE 2: Magnetic mark correction with stretch correction.

MAG MARK WINDOW: The amount of correction possible is determined by the mark window width. After resetting the magnetic mark (find 1st mark) 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 97.5 to 102.5 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 + 102 feet, the panel will subtract 2 feet from the displayed depth in the next 20 feet. If the panel output is ‘corrected’ the panel quadrature output will be 2*600 pulses less than the output would have been if the panel output was ‘raw’.

If MARK & STRETCH CORRECTION is set to ENABLE: The panel uses the tool weight and fluid density and 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 lbs 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. A depth add/subtract feature allows the operator to add /subtract depth while logging or stopped. To demonstrate the panel operation set encoder PPR to 120, MMD correction on, window width to 5 feet, and encoder out to direct. Zero the panel depth, the system depth and reset the MMD. Rotate the encoder so that the depth says 100.0 feet. The system will see 6000 pulses. Advance the depth to 198 and simulate a mark. Advance the panel depth to 302. There should be 18000 pulses given to the system. The panel added the 2 feet to make up for the error at depth 198.

DIGITAL MARK DETECTION FUNCTIONALITY: Any mark stronger than .3 gauss will be detected. The MMD window determines when the next valid mark can be detected. The cable must travel at least the distance of the mark spacing (100’, 50m or 25m) before a valid mark can be detected. Marks can only be detected if they occur within the mark window. If the window is set for 5' and the mark spacing is 100’, the cable must travel no less than 97.5' and no more than 102.5’ from the last mark before a new valid mark can be detected.

NOTE - Encoders with different pulses per revolutions (up to 2000 PPR) can be used with the panel. Number of pulses per revolution can be changed from depth panel menu.The rear panel Encoder connector wiring supports both 5VDC and 12VDC encoders.


5.0 WIRING DIAGRAMS AND SETUP INSTRUCTIONS

5.1 INTERNAL VIEW

AMS4A043 panel Halliburton Rev K June 2015 of 120

5.2 POWER WIRING BLOCK DIAGRAM


5.3 SIGNAL WIRING BLOCK DIAGRAM


5.4 REAR PANEL


5.5 MAIN PROCESSOR BOARD PINOUTS


5.5 MAIN PROCESSOR BOARD - ENCODER AND MMD INPUTS


ENCODER OUTPUT AND COM PORT I/O


LOAD PIN AND TENSION I/O


JUMPERS – BUTTONS


POWER SUPPLIES


5.6 CCL / 5VDC POWER SUPPLY BOARD


5.7 GPIB BOARD SCHEMATIC


5.8 INTERNAL WIRE LIST


J1 12VDC POWER IN


J2 MAGNETIC MARK DETECTOR

J3 MARK INTENSIFIER

J4 ENCODER 2

J5 ENCODER 1

J6 RIG FLOOR DISPLAY

J7 CCL

J8 REEL

J9 LOAD CELL 2

J10 LOAD CELL 1

J20 ENCODER PULSES OUT

J21 TENSION OUT BNC

J22 CAN BUS

P2 - SCREW TERMINAL BLOCK

P2 - 1 BATT +12VDC ORNCB-BOT,CCL J3 -1 & CN1 - 1 INV & FUSE BRD2 P1 - 6, 9, & 10

+12VDC

P2 - 2 BATT - BLK BUS BAR

P2 - 3 CONTACT CLOSURE N.O. GRN J8 - J Tens Cont Close Back

Panel (REEL S/D)

P2 - 5 CONTACT CLOSURE COM BRN J8 - L & BUS BAR

Tension Contact Closure Back Panel - SPLICE

P5 - INPUTS FROM GPIB I/F PCB

P5-1 PWR +5V RED D1 - 4 PWR +5V TO DCI LED DISPLAYS

P5-12 PWR +5V RETURN BLK D1 - 1 GND(+5V PWR RET FROM DCI LEDS)

P5-2->11 POINT-TO-POINT DISCRETE WIRED P5 - 2 ->11 P5 GPIB I/F BRD

P6 - ANALOG IN/OUT

P6 - 3 LOAD PIN 1 SIG+ ORN P3 - 4 CCL BRD LOAD PIN 1 SIG+

P6 - 4 LOAD PIN 1 SIG- BLK P3 - 3 CCL BRD LOAD PIN 1 SIG-

P6 - 7 SHUNT CAL SIG GRN P3 - 10 CCL SHUNT CAL TO


RELAY ON CCL/MMK

P6 - 10 ACM BLK J21 LUG & J8 - B

TEN OUT- TO BNC & J8 - SPLICE TWO WIRES

P6 - 11 0-10V OUT (TENSION) GRY J21 MID & J8 - A

TEN OUT+ TO BNC & J8 - SPLICE TWO WIRES

P6 - 13 TENSION METER DAC GRN P1 - 2 VOL BRD

DAC OUT TO SONALERT VOLUME PCB

P7 - COMMUNICATI ONS

P7 - 5 COM3 TX BLU D1 - 5, D2 - 5DISPLAY DATA - 2 WIRES CONNECTED

P7 - 6 ENCODER2 PWR +5VDC RED P1 - 2 FUSE BRD2

ENC2 PWR +5VDC TO FUSE BRD 2

P7 - 9 GND BLK CN22 - 5RS232 GND (ADVANTECH COM1)

P7 - 10 RS232 TXD (COM1) GRN CN22 - 2RS232 TXD (ADVANTECH COM1)

P7 - 11 RS232 RXD (COM1) GRY CN22 - 3RS232 RXD (ADVANTECH COM1)

P8 - QUADRATURE OUT / INDICATORS

P8 - 3 MMI INTENSIFY ENABLE GRY J3 - G

MAG MARK INTENSIFIER ENABLE

P8 - 6 EXCESSIVE TENSION ALM + RED P1 - 1 VOL PCB Beeper +12VDC

POWER

P8 - 9 APPROACHING SURFACE LED - GRN P3 - 7 CCL

LC_SELECT TO RELAY ON CCL BRD

P8 - 11 PHASE 1B* YEL J20 - D & J8 - F

Quad Out - PHASE B* - SPLICE TWO WIRES

P8 - 12 PHASE 1B BLU J20 - G & J8 - G

Quad Out - PHASE B - SPLICE TWO WIRES

P8 - 13 PHASE 1A* RED J20 - C & J8 - H Quad Out - PHASE A* - SPLICE TWO


WIRES

P8 - 14 DCM BLK J20 - B GND

P8 - 16 PHASE 1A ORN J20 - E & J8 - K

Quad Out - PHASE A - SPLICE TWO WIRES

P9 - ENCODER 1

P9 - 1 DCM BLK J5 - L Encoder Ground

P9 - 5 LOADCELL 1 PWR 12V - TO FUSE YEL P1 - 10 FUSE BRD1

LC 1 PWR 12V - TO UNFUSED SIDE

P9 - 8 ENCODER 1B BLU J5 - B, P3 - 15 (CCL)Enc input (2 WIRES) Rear panel & CCL

P9 - 9 ENCODER 1B * GRN J5 - E Encoder input

P9 - 11 ENCODER 1A ORN J5 - A, P3 - 16 (CCL)Enc input (2 WIRES) Rear panel & CCL

P9 - 12 ENCODER 1A* RED J5 - C Encoder input

P10 - ENCODER 2

P10 - 1 DCM BLK J4 - L Encoder Ground

P10 - 5 LC2 PWR 12V ORN P1 - 9 FUSE BRD1 LC2 PWR 12V

P10 - 8 ENCODER 2B BLU J4 - B Encoder input

P10 - 9 ENCODER 2B * GRN J4 - E Encoder input

P10 - 11 ENCODER 2A ORN J4 - A Encoder input

P10 - 12 ENCODER 2A* RED J4 - C Encoder input

P11 +/- 15 VDC

P11 - 1 DIG GND BLK J2 - K MMD POWER COMMON

P11 - 3 5V ENCODER PWR - TO FUSE BRD RED P1 - 2 FUSE BRD1

FUSE BOARD1 P1-2 NON-FUSED SIDE

P11 - 7 MMD POWER -15V RED P1 - 6 FUSE BRD1MMD POWER -15V NON-FUSED SIDE

P11 - 8 WEAK MARK+ WHT J2 - B WEAK MARK IN-

P11 - 9 WEAK MARK- VIO J2 - A WEAK MARK IN+


P11 - 10 MMD POWER +15 RED P1 - 3 FUSE BRD1MMD POWER +15V NON-FUSED SIDE

P11 - 11 STRONG MARK + BLU J2 - H

STRONG MARK IN- FROM REAR PANEL CONNECTOR

P11 - 12 STRONG MARK - GRY J2 - G

STRONG MARK IN+ FROM REAR PANEL CONNECTOR

P1 - IN-CIRCUIT PROGRAMMING PCB

P1 - 1 CAN_H (TWIST WITH P1 - 2) WHT J22 - 7 (DB9) CAN_H

P1 - 2 CAN_L (TWIST WITH P1 - 1) VIO J22 - 2 (DB9) CAN_L

P1 - 3 GND BLK J22 - 3 (DB9) GND

VOLUME PCB

P1 - 3 GND BLK BUS BAR GND TO VOLUME BRD

D1 DISPLAY - DEPTH

D1 - 2 GND BLK D2 - 1 GND OUT

D1 - 6 +5V OUT RED D2 - 4 POWER OUT

FUSE BOARD 1

P1 - 4 ENCODER1 +5VDC PWR FUSED RED J5 - J

FUSED ENCODER1 PWR +5V

P1 - 5 MMD PWR +15V FUSED ORN J2 - E FUSED MMD

PWR +15V

P1 - 8 MMD -15V PWR FUSED RED J2 - F FUSED MMD

PWR -15V

P1 - 11 LOADCELL2 PWR 12V FUSED ORN J9 - C LOAD PIN 12V

PWR FUSED

P1 - 12 LOADCELL1 PWR 12V FUSED ORN J10 - C & P3 - 8 OF

CCL PCB

LOAD PIN AND SHUNT CAL 12V PWR FUSED

FUSE BOARD 2

P1 - 4 ENC2 +5VDC PWR FUSED RED J4 - J ENC2 +5VDC

PWR FUSED


P1 - 8 MMI +12VDC FUSED ORN J3 - F MMI +12VDC

FUSED

P1 - 11 ENC2 PWR FUSED +12VDC ORN J4 - K

FUSED ENCODER2 PWR +12VDC

P1 - 12 ENC1 PWR FUSED +12VDC ORN J5 - K

FUSED ENCODER1 PWR +12VDC

J1 - 12V POWER IN

J1 - A 12V POWER IN ORN S1 - 1 MIDDLE 12V POWER TO PANEL

J1 - B 12V POWER RTN BLK BUS BAR 12V POWER RETURN

S1 - BOT 12V POWER IN ORN CB - TOP

12V IN FROM FP SWITCH TO CIRCUIT BREAKER

J2 - MMD CONNECTORJ2 - C GND BLK BUS BAR 12VDC GND

J3 - INTENSIFIER

J3 - L GND (12V / 5V RETURN) BLK BUS BAR GND (12V / 5V

RETURN)

J3 - M SHIELD BLK BUS BAR SHIELD

J3 - P TRUCK 12V RETURN BLK BUS BAR

TRUCK 12V RETURN(MMI PWR RET)

J3 - R GND (12V / 5V RETURN) BLK BUS BAR GND (12V / 5V

RETURN)

J6 - RIG FLOOR DISPLAY

J6 - A RIG FLOOR DISPLAY PWR BLU P2 - 3 (CCL)

RFD PWR (FROM CCL PCB)

J6 - B ISO RETURN RFD BLK P2 - 4 (CCL)ISO RETURN (FROM CCL PCB)

J6 - C RFD 4-20 MA GRN P2 - 5 (CCL)RFD 4-20 MA (FROM CCL PCB)

J6 - D RFD 4-20 MA RETURN BLK P2 - 6 (CCL)

RFD 4-20 MA RET (FROM CCL PCB)


J6 - E SHIELD BLK BUS BAR SHIELD

J7 - CCL

J7 - A CCL IN+ GRY P2 - 9 (CCL) CCL IN+ FROM CCL BRD

J7 - B CCL IN- BRN P2 - 8 (CCL) CCL IN- FROM CCL BRD

J8 - REEL

J8 - C UP PULSES BLU P3 - 13 (CCL) UP PULSES CCL BRD

J8 - D DOWN PULSES VIO P3 - 14 (CCL) DOWN PULSES CCL BRD

J8 - E SHIELD BLK BUS BAR SHIELD

J9 - LOAD CELL 2

J9 - A LC2 IN+ BLU P3 - 2 (CCL) LC2 IN+ FROM CCL BRD

J9 - B LC2 EX- BLK BUS BAR LC2 EX- RETURN

J9 - E LC2 IN- BRN P3 - 1 (CCL) LC2 IN- FROM CCL BRD

J9 - G LC2 CAL YEL P3 - 9 (CCL) LC2 CAL FROM CCL BRD

J9 - J SHIELD BLK BUS BAR SHIELD

J10 - LOAD CELL 1

J10 - A LC1 IN+ ORN P3- 6 CCL LC1 IN+

J10 - B LC1 EX- BLK BUS BAR LC1 EX- RETURN

J10 - E LC1 IN- BLK P3 - 5 CCL LC1 IN-

J10 - G LC1 CAL GRN P3 - 12 (CCL) LC1 CAL FROM CCL/MMK PCB

J10 - J SHIELD BLK BUS BAR SHIELD

J3 - CCL PCB

J3 - 2 GND (+12V RETURN) BLK BUS BAR, CN8 - 11 GND

J3 - 3 PWR +5V OUT RED CN8 - 2, CN8 - 3, CN8 - 5, CN8 - 6

PWR CONN ADVANTECH PROCESSOR


PCB

J3 - 4 GND (+5V RETURN) BLK CN8 - 1, CN8 - 4, CN8 - 7, CN8 - 8

PWR CONN ADVANTECH PROCESSOR PCB

J3 - 5 PWR +12V OUT ORN CN8 - 12

PWR CONN ADVANTECH PROCESSOR PCB

J3 - 6 GND (+12V RETURN) BLK BUS BAR GND

P2 - CCL PCB

P2 - 7 RFD 232 IN VIO CN17 - 5

2mm 14pin conn ADVANTECH com2 xmit to RFD 232 in

CN1 - INVERTER INPUT

CN1 - 2 ENABLE WHT,BLKCN1 - 3 & DCI DISPLAY D2 - 2 - SPLICE TOGETHER

CN1 - 4 DIMMING CONTROL BLU, BLK CN1 - 5 SPLICE

TOGETHER

CN2 - INVERTER OUTPUT

CN2 - 1 HV OUT PNK,PNK CCFL LAMPSPLICE PINK WIRES TOGETHER

CN2 - 4 RTN WHT,WHT CCFL LAMPSPLICE WHITE WIRES TOGETHER

CN2 - ADVANTECH PROCESSOR DUAL USB PORTS

CN2 - 1 USB_A VCC RED MOLDED CABLE

2mm CONNECTOR TO MOLDED SINGLE USB REAR PANEL

CN2 - 2 USB_B VCC RED TC CONTROLERCABLE TO TOUCHSCREEN CONTROLLER

CN2 - 3 USB_A D0- WHT MOLDED CABLE 2mm CONNECTOR TO MOLDED SINGLE USB


REAR PANEL

CN2 - 4 USB_B D0- WHT TC CONTROLERCABLE TO TOUCHSCREEN CONTROLLER

CN2 - 5 USB_A D0+ GRN MOLDED CABLE


CN2 - 6 USB_B D0+ GRN TC CONTROLERCABLE TO TOUCHSCREEN CONTROLLER

CN2 - 7 USB_A GND BLK MOLDED CABLE


CN2 - 8 USB_B GND BLK TC CONTROLERCABLE TO TOUCHSCREEN CONTROLLER

CN3 - ADVANTECH PROCESSOR DUAL USB PORTS

CN3 - 1 USB_A VCC RED MOLDED CABLE

2mm CONNECTOR TO MOLDED DUAL USB FRONT PANEL

CN3 - 2 USB_B VCC RED MOLDED CABLE


CN3 - 3 USB_A D0- WHT MOLDED CABLE


CN3 - 4 USB_B D0- WHT MOLDED CABLE


CN3 - 5 USB_A D0+ GRN MOLDED CABLE


CN3 - 6 USB_B D0+ GRN MOLDED CABLE



CN3 - 7 USB_A GND BLK MOLDED CABLE


CN3 - 8 USB_B GND BLK MOLDED CABLE


P1 GPIB DB25F TO TERN DB25S

ALL RIBBON CONDUCTORS TERN DB25S

RIBBON CABLE IS 7 INCHES LONG

P3 GPIB

ALL RIBBON CONDUCTORS CCL P1

RIBBON CABLE IS 9 INCHES LONG

P4 GPIB USE ALL 26 WIRES ON THIS END

CUT OFF TWO WIRES (25 & 26) ON THIS END

ALL RIBBON CONDUCTORS REAR 488 CONN

REAR PANEL CONNECTOR IS 24 PINSRIBBON CABLE IS 15 1/2 INCHES LONG




ITEM P/N DESCRIPTION QTY REF

AMS4A043 PANEL HOIST OPERATOR DISPLAY WSDP - C TOUCH SCREEN PANEL

1 AMS4P134E-16 PC BOARD AMS40 REV E 16MHZ OSC 2XRS232, 1X485 MMD DIFF WEIGHT 1 MAIN PROCESSOR

BOARD

2 AMS4P545 IC OSCILLATOR 16MHZ 14PDIP 5V3 AMS4A626 ASSY COMPUTER 43 PNL 650MHZ CELERON W/RAM CF

4 AMS4A743 ASSY COMPUTER 43 PNL 1.6GHZ INTEL ATOM PROC W/RAM CF

5 AMS4P326 COMPUTER SINGLE BOARD 650MHZ INTEL CELERON6 AMS4P319 LICENSE WINDOWS XP EMBEDDED MICROSOFT 1

7 AMS4P318 MEMORY RAM 256MB PC133 SODIMM NON-ECC 144PIN NOTEBOOK MODULE

8 AMS5P041 MEMORY COMPACT FLASH 4.0GB 19 AMS4P287 PCB ASSY TERN BIRDBOX-A 512K RAM RTC+BAT ADC SW REG

10 AMS4P309 LCD 8.4 COLOR TFT OPTREX BACKLIT SUNLIGHT RDBLE 400NIT 111 AMS4P308 SCREEN TOUCH 8.4" RESISTIVE 4 WIRE 1

12 AMS4P511 CNTROLLER BD TOUCH PNL USB 4WR USE MODIFIED AMS4A549 OR 543

13 C276P604 CABLE USB A PANEL MOUNT 2FT 1

14 AMS4P128 DISPLAY LED RED 0.5" 14 SEGMNT SERIAL 2" x 3.5" 12 PIN HEADER 2

15 ALS4A204 PCB ASSY N CKT PROG W CAN 116 AMS4A322 PCB ASSY VOLUME BRD 117 AMS4A327 PCB ASSY GPIB BRD AMS4A043 118 AMS4A326 PCB ASSY MMK/CCL BRD AMS4A043 119 AMS4A102 PCB ASSY FUSE BOARD 220 AMS4A568 CABLE ASSY LANNERPC TO HIRSE3121 AMS4P307 SONALERT SC616N MALLORY 4-16V 6-22mA 122 AMS4M074 BEZEL LCD 8.4" LCD TOUCH SCRN 7" OH OPERATOR PANEL 123 AMS4M071 CHASSIS 7" TOUCH SCRN OH WINCH OP PNL 124 AMS4M073 PANEL REAR 7" TOUCH SCRN OH OP PANEL 125 AMS4M070 PANEL FRONT WINCH OP TOUCH SCR 7 X 19 126 AMS4M072 PANEL TOP TOUCH SCRN OH OP PNL 7 X 19 127 AMS4M077 PLATE DB9 COVER28 AMS4M079 BAR RETAINING HIR0SE 31 CONN29 AMS4M076 WINDOW LED RECESSED SERIAL DCI DISPLAY 230 AMS4M012 BRACKET SONALERT TWO LEG 131 AMS4P020 SWITCH SPDT TOGGLE LOCKING MTL-106D ALCO 1 POWER32 AMS4P028 SWITCH DPDT TOGGLE LOCKING ON-NONE-ON POWER33 AMS4P290 TERMINAL INSULATED SOLDR 6-32 FEM 2


6.1 BILL OF MATERIALS continued

ITEM P/N DESCRIPTION QTY REF34 AMS4P877 CABLE INVERTER CCFL INPUT TO JKL BXA-12665-5M/MOD1 135 AMS4P878 CABLE INVERTER CCFL OUTPUT TO DISPLAY 136 AMS4A571 CABLE ASSY 2 X USB PNL MT 137 AMS4P739 CABLE SVGA EXTENSION SUPR THIN HD15 MALE/FEMALE 3 FT 138 AMS4A570 CABLE ASSY LANNER USB TOUCH 139 AMS4P687 CABLE CAT5 3' RJ45 GRAY FLEX 140 AMS4P274 COUPLING RJ45F/RJ45F SHIELDED 90 DEG SNAP IN 1

41 ALS1P029 CONN AMP BNC FRONT MOUNT BULKHEAD RECEPTACLE 31-221-RFX 1 TENS OUT-WARRIOR

42 AMS4P270 CONN KPSE02E12-8P RECEPTACLE 8 PIN 1 ENCDR OUT-WARRIOR43 AMS4P169 CONN KPSE02E12-3P RECEPT 1 POWER IN44 AMS4P170 CONN KPSE02E12-10P RECEPTACLE 10 PIN 1 MMDT45 AMS4P248 CONN KPSE02E14-15S RECEPTACLE 15 SOCKETS 1 INT46 AMS4P172 CONN KPSE02E14-12S RECEPTACLE 12 SOCKETS 2 ENC1, ENC247 AMS4P264 CONN KPSE02E10-6S RECEPTACLE MS3122 1 RFD48 AMS4P263 CONN KPSE02E10-6P RECEPTACLE MS3122 1 CCL49 AMS4P173 CONN KPSE02E14-12P RECEPTACLE 12 PINS 1 REEL50 AMS4P171 CONN KPSE02E12-10S RECEPTACLE 12 SOCKETS 2 LC1, LC251 FSU1P026 NUTPLATE SHELL 10 4-40 AMPHENOL 252 FSU1P027 NUTPLATE SHELL 12 4-40 AMPHENOL 553 FSU1P028 NUTPLATE SHELL 14 4-40 AMPHENOL 454 AMS4P636 CONN GPIB SOCKET WIREMOUNT 3M 3549-100055 AMS4P322 SCREW JACK IEEE RS-488 3.5MM 0.32L 4-40 THD 256 AMS7P021 CONN 102398-4 AMP 12 POS PCB HARNESS BODY 1157 AMS7P023 CONN 102536-4 AMP 12 POS BACK COVER 1158 AMS7P024 CONN 102681-1 AMP 12 POS FRONT COVER 11

59 AMS7P025 CONN 102681-3 AMP 16 POS FRONT COVER 3

60 AMS7P022 CONN 102398-6 AMP 16 POS PCB HARNESS BODY 3

61 AMS7P026 CONN 102536-6 AMP 16 POS BACK COVER 365 AMS4P582 TERM CONN FEMALE CRIMP DISK PW FOR AMS4P58166 AMS4P581 CONN HOUSING 4POS .2 DISK PWR67 AMS4P163 CONN DB9P CRIMP AMP USED WITH PIN 205089-168 AMS7P030 CONN 102398-8 AMP 20 POS PCB HARNESS BODY69 AMS7P058 CONN 102536-8 AMP 20 POS BACK COVER70 AMS7P035 CONN 102681-5 AMP 20 POS FRONT COVER

71 AMS4P198 SPACER UNTHREADED RND NYLON #4 5/16L x 3/16 OD (100/PK) 8

72 AMS4P167 PIN AMP M39029/64-369 USED WITH 205162-1 18



ITEM P/N DESCRIPTION QTY REF73 AMS8P092 SCREW 6-32 X 3/8 FH PHIL SST 1474 AMS7P068 SCREW JACK D-CONNECTOR KEYSTONE 7231 275 F244888000 HANDLE OVAL 1-1/2 X 4-9/16 AL 276 AMS4P583 CONN HSG 10 POS 2MM MILLI-GRID CRIMP 1

77 AMS4P584 TERM CONN FEM CRIMP 2MM 24-30 AWG MILLI-GRID FOR AMS4P583 24

78 ALS4P008 STANDOFF 4-40 X 7/16 M/F HEX 3/16 NICKEL PL BRASS 4

79 AMS4P626 WASHER #4 FLAT NYLON TAPE DBL SIDE 1/16 X 1 3M URETHANE

80 AMS4P675 TAPE DBL SIDE 1/16 X 1 3M URETHANE 24 INCHES

81 AMS4P590 KEYBOARD USB MINI TOUCH BLACK 182 ACMU1P71 CONN 09-50-3061 MOLEX W/LOCKNG RAMP 0.156 6 POS 183 C276P351 CRIMP TERMINAL F/CONN WALDOM # 08-50-0106 684 AMS4P330 CONN .1 CRIMP TERM HOUSING 4CT MOLEX 22-01-2047 1 10-11-204385 AMS4P331 CONN CRIMP PIN FOR AMS4P330 MOLEX 08-50-0114 7

86 AMS4P650 CIRCUIT BREAKER 5A THER PNL MN CARLING TECH CMB-053-11C3N-BA 1

87 AMS4P651 CONN JACKSOCKET GPIB MOUNT88 AMS4P659 CONN TERMINAL RECPTACLE .25TAB AMP 2-520184-2 289 AMS4A687 CABLE ASSY 20 COND RIBBON 4" 190 AMS4A683 CABLE ASSY 26 COND RIBBON 9" 191 AMS4A684 CABLE ASSY 26 TO 24COND RIBBON 15.5" 192 AMS4A685 CABLE ASSY DB25 S TO P RIBBON 7" 193 AMS4A688 PC BOARD ASSY TERN BIRDBOX AMS4A043 PANEL 194 ALS2P012 CAPACITOR 22000UF 16V AXIAL ELECTROLYTIC 195 AMS4P738 DUSTCAP PLUG CAPUSB-A 396 AMS4P164 CONN DB9S CRIMP AMP USED WITH SOCKET 205090-1 197 AMS4A843 SOFTWARE COMPACTFLASH WINXPE FOR AMS4A043 REF - FIELD RPLCMNT98 AMS4P693 IC AT27C512R-70PU EPROM OTP 199 ALS4P015 CONN HOUSING CRIMP 3CKT .100 1

100 AMS5P031 CONN DEMAE9S CRIMP PN W/NUT PIN 205089-1 1 CAN CONNECTOR

101 AMS5P015 COMPUTER SINGLE BOARD 1.6GHZ 2GB RAM INTEL ATOM PROCESSOR 1

102 AMS4A374 CABLE ASSY ADVANTECH VIDEO 8.4" LCD DISPLAY 1

103 AMS5P069 STANDOFF HEX 1/4 MALE TO MALE 3/16" LG 6-32 TO 4-40 SCREW

104 AMS4A943 SOFTWARE IMAGE 43 PNL VER 3.05 4GB LOW TEMP CF

105 AMS5P070 CONN 12 PIN DUAL ROW FEMALE ADVANTECH POWER MOLEX 1 ADVANTECH POWER



ITEM P/N DESCRIPTION QTY REF

106 AMS5P071 CONN TERMINAL FEMALE 18-24 AWG MOLEX USED WITH AMS5P070 12 ADVANTECH POWER

107 AMS5A043 ASSY COMPUTER ADVANTECH 43 PNL

108 AMS4K743 KIT ADVANTECH PROC FIELD UPGRD REPLACES AMS4A626 (LANNER)

109 AMS5P076 MEMORY RAM 2GB DDR2 SODIMM NON-ECC 200 PIN ADVANTECH 1

110 SW-AMS4A043-305 SOFTWARE FOR THE 43 CMPT FLASH VER. 3.05 1

111 AMS5P072 CONN 2MM 14 CKT SOC PLUG 51110-1450 MOLEX 1112 AMS4A443 MICROCONTROLLER W/43 SOFTWARE113 SW-430204 SOFTWARE 43 PANEL 40 PCB 1114 ALS4A143 PCB ASSY CKT PROG W/CAN 43 PNL115 AMS4P874 INVERTER CCFL 12VIN 1200V 5.5M JKL COMPONENTS 1116 AMS4A543 PCB ASSY CONTROL SM TOUCH PNL USB 4-WIRE 1


7.0 SETUP PROCEDURES

7.1 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. Range is 0(dim) to 15 (bright).


7.2 SOFTWARE UPDATE PROCEDURE

PREREQUISITES:

7.2.1 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.

7.2.2 USB keyboard/touchpad.

7.2.3 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.

7.3 HOISTMAN PROGRAM UPDATE (PC BASED PROGRAM)

7.3.1 Close all running programs in Windows XP Embedded.

7.3.2 Go to the Windows Control panel and uninstall the current Hoistman Display.

7.3.3 Copy the new Hoistman Display.msi installation to the directory C:\ Hoistman.

7.3.4 Double click with the mouse the Hoistman Display.msi program and follow the instructions.

7.3.5 When the program asks where to install the program, change it to C:\Windows\Program Files\Kerr

7.3.6 Make sure and check the use by everyone box at the bottom.

7.3.7 After the installation has finished, 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.

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


7.4 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.

7.4.1 Close all running programs in Windows XP Embedded.

7.4.2 Copy the TPLUS.EXE file to the root directory C:\

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

Transfer these files to the CompactFlash (C:\) root directoryvia Ethernet or USB connection using the Windows Explorer

7.3.4 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

7.4.5 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

7.4.6 Press the keyboard ENTER key. The MicroController ROM Loader will respond with a banner and then a '>' prompt.


Note: If there is no response, toggle the switches back and forth and repeat step 7.4.6 until there is a response.

7.4.7 Type an uppercase 'K' for Klean and Erase, and ‘ENTER’ key. 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

7.4.8 Type an uppercase 'L' and ‘ENTER’ key and the ROM Loader will wait to Load a HEX file.

7.4.9 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.

7.4.10 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:

GGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGG >

7.4.11 To re-initialize memory by running the MEMDIS 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 – There is no visual indication that MEMDIS is running.

7.4.12 After the ROM Loader is finished programming the Flash and the MEMDIS 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.

Note: There must be a depth of 0.0 (or 0.00) on the front panel LED. If not, toggle the switches repeatedly until the depth displays 0.0 (or 0.00).

7.4.13 The terminal emulation program uses the same serial port as the Hoistman program, so close it before opening the Hoistman program.

7.5 GPIB FLASH PROGRAMING

Description - This covers the Tern (GPIB Processor) with the Flash EPROM 29F010. This document assumes that the Flash device contains the ACTF Utility and that the Model 43 Panel is fully assembled except for the cover is removed and the back panel is pivoted down.

Equipment - computer with a serial port and serial port cable - db9F -> db9P. Files needed are:

lo_ee128.hex & SDDP.hex

Procedure:

7.5.1 Remove jumper JP1 from the GPIB PCB (AMS4A327). Connect the Serial Port cable to P1. Start Hyperterminal on computer @ 19200, 8 bits, No Parity, 1 Start, 1 Stop, No Hardware Handshaking.Ensure that the serial port is connected and ready to communicate before applying power to the panel.

7.5.2 Power-on the Model 43 Panel and observe on the Hyperterminal the ACTF Utility Menu:

ACTF/ACTR Copyright(c) 1996 STE CA USA. All rights reserved

>C C Functions>D Download An Intel Extend Hex File Into SRAM>G GoTo And Run>H HELP>M MENU


>U Upload A Block Of Binary Data

If the menu does not appear on the Hyperterminal screen - then the Flash is not prepared with the Utility or there is a serial port communication problem. Correct the problem before proceeding.

7.5.3 Press Caps Lock and then type D on the Hyperterminal screen. The utility will reply with:

Ready To Receive Intel Extend Hex File at 19200 Baud

7.5.4 Pull down Hyperterminal menu: Transfer - Send Text File - All Files *.* And Then Choose File:

lo_ee128.hex

The utility screen will fill with:

UUUUUUUUUUUUUUUUUUUUUUUUUUUUUUUUUUUUUUUUUUUUUUUUUUUUUUUUUUUUUUUUUUUUUUUUUUUUUUUUUUUUUUUUUUUUUUUUUUUUUUUUUUUUUUUUUUUUUUUUUUUUUUUUUUUUUUUUUUUUUUUUUUUUUUUUUUUUUUUUUUUUUUUUUUUUUUUUUUUUUUUUUUUUUUUUUUUUUUUUUUUUUUUUUUUUUUUUUUUEnd Of File Record ETC

USE Gxxxxx To Run Downloaded Code

7.5.5 Now Type G04000 - The utility will respond with:

Erasing AM29F010 EE Sector 0-6 (0xE0000 - 0xFBFFF)ETCETCReady To Receive Intel Extend File APP.Hex At 19200

7.5.6 Pull down Hyperterminal menu: Transfer - Send Text File - All Files *.* And Then Choose File:

SDDP.hex

The utility screen will fill with:

VVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVVV


ETCETCFINISHED

7.5.7 Now Type G80000 - re-install the jumper JP1, remove the serial cable. The only way to confirm that the Tern has been properly programmed is to connect to the BenchMark Logging System Via 488 bus.

This concludes the procedure.

7.6 REPLACING INTERNAL FLASH CARD (Advantec PC)

7.6.1 Locate the PC processor board mounted to the front panel. Remove zip tie from the top left corner. The card is on the back side of this board.

7.6.2 Using a pen or small screwdriver press the reject tab. The card will then


pop out of the holder.

7.6.3 The card can now be removed using small needle nose pliers.

7.6.4 To re-install a card place it in the slot, then press it in until you feel it latch


into place. A small screwdriver or pen may be required to fully insert.

7.7 REPLACING INTERNAL FLASH CARD (Lanner PC)

7.7.1 Locate the PC processor board mounted to the front panel.

7.7.2 Press the reject tab. The card will then pop out of the holder.


7.7.3 The card can now be removed.

7.7.4 To re-install a card place it in the slot then press it in until you feel it latch into place.


BELOW IS A PICTURE SHOWING THE BACKSIDE OF THE PC WITH THE CARD INSTALLED.


8.0 WINDOWS REMOTE ADMINISTRATION (Using VNC)This procedure is for the use of controlling one Windows based PC from another using VNC. VNC (Virtual Network Connection) as a free means to controlling a remote system and does work “cross-platform”. Windows XP has the ability for remote administration; however, some of the functions are disabled in embedded systems (BenchMark Panels). This process does require some knowledge in networking as VNC communicates over the IP protocol. This mean that the two systems need to be communicating thru TCP/IP before this program will work.

Networking the Systems

Though networking can be difficult, this project will be quite simple. First off, a RJ45 Crossover (Ethernet CAT5) cable will be needed to physically connect the systems together. They can also be connected together with 2 regular RJ45 (CAT5) cables and an Ethernet Hub or Switch.

Both systems will be setup in the same way except the IP address we assign will be one number off. We will be using IP: 192.168.0.1 for server (BenchMark Panel) and IP: 192.168.0.2 for the remote system. Please insure the systems have administrative users up. To configure the systems go to [Network Connections] and right-click on the interface that is being used (typically “local internet connection”). Scroll down the box and select [Internet Protocol TCP/IP] and click the properties.


Once in the “TCP/IP” properties, check the radio button “Use the following IP Address”. Input the IP address of the system you are setting up and insure the “Subnet Mask” is “255.255.255.0”. Please refer to the picture below for how this should look. Once completed, click the [OK] to close that window and click the [OK] to close the properties. Set network is setup.


Next, the network needs to be tested to insure proper connection between the server and the remote. Click on the [Start] button and click the [RUN] button. Type “cmd” and click the [OK] to open a terminal.

In the terminal type “ping 192.168.0.X” with “X” being the system not currently in use, meaning that if operator is currently on the remote, they will ping the server IP, and if they are on the server, ping the remote IP. Best idea is to ping both IPs to be certain connections are made.


The connections are completed and the systems are ready for VNC. The Firewall to the server will need to be disabled for the VNC protocol communication to get thru. However, the remote will is able to keep its firewall up.

Getting the VNC Program

VNC can be downloaded at http://www.vnc.com/products/download.html . Select the “free edition” of VNC. Do not bother putting any information in the next page and continue to the download at the bottom. On the download page, select the Windows Executable for download. Except the “terms and conditions” and click the download. From there, you will be able to save the program where you wish.

The setups for both systems are the same except for what options will be installed. Double-click install program to begin the install of VNC to the systems.


Most of the setup be just clicking Next.

This next screen is where the change is made. For the server, check the “VNC Server” and uncheck the “VNC Viewer”. The remote system is the opposite.


Again, clicking next a few more times.


Keeping clicking [Next] till the [Finish] comes up and click that to complete the setup.

When the server setup finishes the properties of the server will come up. Insure “No Authentication” is selected and click the [OK]. The server is now ready to receive requests from the remote.


The remote will have the options below. This would be user choice.


Communication

The server is ready for the remote to connect. Double-click the “VNC Viewer 4” and input the IP address of the server.

Click the [OK]. Welcome to remote desktop…..


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