OPERATIONS AND MAINTENANCE MANUAL WINCH OPERATORS PANEL BAKER ATLAS 5762XA PANEL

Transcription

1 OPERATIONS AND MAINTENANCE MANUAL WINCH OPERATORS PANEL BAKER ATLAS 5762XA PANEL Kerr p/n AMS4A045 TABLE OF CONTENTS SECTION DESCRIPTION 1.0 GENERAL DESCRIPTION 2.0 DESCRIPTION OF FEATURES 3.0 TOUCHSCREEN SOFTWARE INSTRUCTIONS 4.0 SYSTEM OPERATING INSTRUCTIONS 5.0 PARTS LIST 6.0 BACK PANEL CONNECTOR PINOUT AND WIRING DIAGRAMS 7.0 SOFTWARE UPDATE PROCEDURES 8.0 CE CERTIFICATE BenchMark Wireline Products 5762XA HOIST PANEL Rev E MAR 2007 Page 1 of 50

2 Manual Revision Log Current Revision E Mar 2007 Added schematics and flash removal Procedure Previous Revisions: D Dec 2006 Updated software procedures. Added CE certificate. C B A1 Aug 2006 Added Software Update Procedure Updated screen information Jul 2006 Added Additional Screens Jan 2006 UPDATED DRAWINGS, SCREENS BenchMark Wireline Products 5762XA HOIST PANEL Rev E MAR 2007 Page 2 of 50

3 1.0 INTRODUCTION 1.1 GENERAL DESCRIPTION This panel is designed to acquire and display depth, tension, and magnetic mark 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 encoder quadrature pulses are passed through to the acquisition system. The tension data is provided by a load pin and is also passed through to the acquisition system. COMPATIBLE WITH CURRENT AND NEW SYSTEMS CLS CASE HOIST ECLIPS FOCUS STANDALONE PANEL CONTAINS FUNCTIONALITY OF ECLIPS I/O BOARD SLAVE MODE FOR ECLIPS AND FOCUS BenchMark Wireline Products 5762XA HOIST PANEL Rev E MAR 2007 Page 3 of 50

4 2.0 DESCRIPTION OF FEATURES INTERNAL DEPTH PROCESSOR RUNS INDEPENDENT FROM PC PROCESSES & DISPLAYS DEPTH & TENSION REAL TIME OUTPUTS ENCODER PULSES, TENSION SIGNAL AND MMD PULSES TO ACQUISITION SYSTEM CONTROLLED BY INTERNAL PC OUTPUTS DATA TO INTERNAL PC INTERNAL PC MS WINDOWS XP EMBEDED OPERATING SYSTEM NOT AFFECTED BY POWER LOSS TOUCH SCREEN CONTROLLER ETHERNET READY WITH FULL-SCREEN BROWSER USB, R232 SERIAL PORTS AND PARALLEL PORT USB CONNECTORS FOR MOUSE AND KEYBOARD INTERNAL CRT MONITOR CONNECTOR FUNCTIONALITY UPGRADEABLE WITH SOFTWARE MULTIPLE POWER SOURCES AC : 120/240 50/60hz DC : V INTERNAL BATTERY (4 hours) Digital displays for depth, line speed, tension and magnetic marks (or CCL offset) BenchMark Wireline Products 5762XA HOIST PANEL Rev E MAR 2007 Page 4 of 50

5 2.0 DETAILED DESCRIPTION OF FEATURES 2.1 FRONT PANEL DEPTH DISPLAY This meter provides a digital display of depth. This meter displays depth independent of the PC LINE TENSION DISPLAY 2.2 REAR PANEL This meter provides a digital display of total line tension. This meter displays tension independent of the PC VDC This connector supplies dc power for the panel operation (9 VDC min, 30 VDC max). The panel can operate on either 12 or 24 vdc (12 vdc is U.S. truck standard voltage, 24vdc is European truck standard voltage). Pin A is positive, pin B is negative SIGNAL INPUT Encoder, tension, and magnetic mark signals and power are passed through this connector to/from the sensors on the measuring head SIGNAL OUTPUT Encoder, tension, and magnetic mark signals, processed and some unprocessed are passed through this connector to the acquisition system RS485 SERIAL INTERFACE This connector provides an RS485 interface from the panel to the acquisition system. Connectors are provided for both RS485 in and out. BenchMark Wireline Products 5762XA HOIST PANEL Rev E MAR 2007 Page 5 of 50

6 3.0 TOUCHSCREEN 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 SET DEPTH Exits the program and returns to MS-Windows. 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. BenchMark Wireline Products 5762XA HOIST PANEL Rev E MAR 2007 Page 6 of 50

7 3.1 DEPTH Set Depth Invokes the keypad. The new 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. BenchMark Wireline Products 5762XA HOIST PANEL Rev E MAR 2007 Page 7 of 50

8 3.2 TENSION 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 ground shunt cal line pin G. The load pin should then return a calibrated signal of lbs. BenchMark Wireline Products 5762XA HOIST PANEL Rev E MAR 2007 Page 8 of 50

9 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. Note at the bottom of the screen it advises you of your measurement setting, kilograms or pounds Sheave factor 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 = Cosign ( angle ) 45 degrees = degrees = degrees = Note that this function is only available when line size selected is Other. BenchMark Wireline Products 5762XA HOIST PANEL Rev E MAR 2007 Page 9 of 50

10 3.2 ALARMS 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 SLAM 3500 S-SLAM 3500 BenchMark Wireline Products 5762XA HOIST PANEL Rev E MAR 2007 Page 10 of 50

11 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 SLAM 3500 S-SLAM 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 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 SLAM 2400 S-SLAM 2400 BenchMark Wireline Products 5762XA HOIST PANEL Rev E MAR 2007 Page 11 of 50

12 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 x.x.x), 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 SURFACE ALARM When this depth value is reached, the alarm will sound 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 ALARM OFF This button silences the alarm until a new alarm condition occurs 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. BenchMark Wireline Products 5762XA HOIST PANEL Rev E MAR 2007 Page 12 of 50

13 TEST SHUTDOWN When this button is pressed, 12v is applied between J2 pin 7 (+) and J2 pin 31 (gnd). This can be used to test the winch shutdown mechanism RELEASE SHUTDOWN When this button is pressed, the voltage is removed. BenchMark Wireline Products 5762XA HOIST PANEL Rev E MAR 2007 Page 13 of 50

14 3.3 AUTO CORRECT 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 WHEEL CORRECTION Enabling this allows depth correction to Wheel Size Shimming PIPE STRETCH CORRECTION This feature is only used when stretch correction is enabled. Total stretch is decreased by the amount of drill pipe stretch at any given depth. BenchMark Wireline Products 5762XA HOIST PANEL Rev E MAR 2007 Page 14 of 50

15 3.4 SETUP Following are explanations for each of these menus. BenchMark Wireline Products 5762XA HOIST PANEL Rev E MAR 2007 Page 15 of 50

16 3.4.1 LINE SIZE 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. BenchMark Wireline Products 5762XA HOIST PANEL Rev E MAR 2007 Page 16 of 50

17 3.4.2 WHEEL SIZE 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 tension sheave factor will also need to be set. Default value is 2ft (.6096) meters BenchMark Wireline Products 5762XA HOIST PANEL Rev E MAR 2007 Page 17 of 50

18 3.4.3 MMD 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 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 BenchMark Wireline Products 5762XA HOIST PANEL Rev E MAR 2007 Page 18 of 50

19 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 feet is 10.8 feet + the mark at surface. At feet it is 43 feet + mark at surface. BenchMark Wireline Products 5762XA HOIST PANEL Rev E MAR 2007 Page 19 of 50

20 Magnetic Mark correction will force every mark to 100 spacing (or 25/50 meter) accounting for stretch due to line tension. The Cummulative Mark Correction window display the total amount of correction made from all of the marks combined. BenchMark Wireline Products 5762XA HOIST PANEL Rev E MAR 2007 Page 20 of 50

21 3.4.4 CCL (casing collar locator) The CCL Offset..ie... the distance from the CCL tool to the tool zero reference (usually bottom of tool or bullplug) can be adjusted to create a CCL depth. BenchMark Wireline Products 5762XA HOIST PANEL Rev E MAR 2007 Page 21 of 50

22 3.4.5 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. All detected marks are listed in the table but only marks with * listed in front are considered good marks and used by the system. BenchMark Wireline Products 5762XA HOIST PANEL Rev E MAR 2007 Page 22 of 50

23 3.4.6 CCL TABLE This table allows the viewing of Collars found while logging BenchMark Wireline Products 5762XA HOIST PANEL Rev E MAR 2007 Page 23 of 50

24 3.4.7 ENCODER The value selected will automatically be used as the encoder input pulses per revolution (PPR) setting. Selection: 1200 (600 ppf or 1968 ppm) 780 (390 ppf or 1280 ppm) 512 (256 ppf or 1680 ppm) Default value is 780. NOTE: Encoder output to the system is fixed at 256 pulses per foot 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. BenchMark Wireline Products 5762XA HOIST PANEL Rev E MAR 2007 Page 24 of 50

25 3.4.9 ENCODER STATUS ENG MET UNITS The depth and tension values will be displayed in the units selected. FT - LBS FT - KG MT - LBS MT - KG RESTORE DEFAULTS Default value is FT KG When this button is pressed, all the settings will be restored to their default values. This functions as a software reset. BenchMark Wireline Products 5762XA HOIST PANEL Rev E MAR 2007 Page 25 of 50

26 SUMMARY The Summary Menu is a quick reference to what parameters are set. This is a static display. BenchMark Wireline Products 5762XA HOIST PANEL Rev E MAR 2007 Page 26 of 50

27 ABOUT SCREEN (UNDER HELP MENU) 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. The HELP button will bring up this manual. You can scroll up or down to find the information you need. BenchMark Wireline Products 5762XA HOIST PANEL Rev E MAR 2007 Page 27 of 50

28 4.0 SYSTEM OPERATING INSTRUCTIONS 4.1 Power up panel and verify it is working properly. 4.2 Verify the panel is configured to match the system (head type, 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 Press T-Test and verify that panel tension reads 5000 (mode 3) or (mode 5). Verify tension is being properly recorded on acquisition system 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. BenchMark Wireline Products 5762XA HOIST PANEL Rev E MAR 2007 Page 28 of 50

29 5.0 PARTS LIST AMS4A045 PANEL WINCH OPERATOR DISPLAY Component Description Qty UM 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 CIRCUIT PROGRAMMG 1 EA AMS4P577 LCD 12.1 COLOR TFT SHARP 1 EA AMS4P513 SCREEN TOUCH RESISTIVE W 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 ACMU1P02 POWER SUPPLY 45W 12V VAC 1 EA AMS4A322 PCB ASSY VOLUME BRD 1 EA AMS4A644 PCB ASSY CCL/MMK BD AMS4A045 1 EA ALS3A032 PCB ASSY INTERCOM 12V 3 INCH 1 EA AMS4A566 CABLE ASSY LANNER VID HIRSE41 1 EA AMS4P307 SONALERT SC616N MALLORY 4-16V 1 EA ALS1P032 SPEAKER ALNICO 8 0HM 2W 77MM 1 EA AMS4P252 BATTERY LEAD-ACID SEALED 12V 1 EA AMS4M136 BEZEL LCD 12.1" LCD SHARP TUCH 1 EA AMS4M095 CHASSIS 8-3/4 TOUCH SCRN OH 1 EA AMS4M093 PANEL REAR 8-3/4 TOUCH SCRN 1 EA AMS4M092 PANEL FRONT WINCH OP TOUCH SCR 1 EA AMS4M034 PANEL TOP TOUCH SCRN OH OP PNL 1 EA AMS4M037 CLAMP BATTERY 12VDC TOUCH SCRN 1 EA AMS4M057 TRAY BATTERY 12VDC TOUCH SCRN 1 EA AMS4M039 STANDOFF BATTERY CLAMP 12VDC 2 EA AMS4M076 WINDOW LED RECESSED SERIAL 2 EA AMS4M012 BRACKET SONALERT TWO LEG 1 EA ALS3M015 HEATSINK AMPLIFIER INTERCOM 1 EA ALS1P011 POT 250 OHM CLAROSTAT 381N250 1 EA AMS4P362 POT 500 OHM 1/4W CARB LNR W/SW 1 EA AMS4P363 KNOB INSTRUM SKIRTED RND.5"DI 2 EA AMS4P021 SWITCH CAP ALCO C-22 BLACK 1 EA AMS7P028 SWITCH 4PDT TOGGLE LOCKING 1 EA ALS2P008 SWITCH DPDT MOM PB MPA206R 1 EA C276P604 CABLE USB B TO A PANEL MOUNT 1 EA AMS4P290 TERMINAL INSULATED SOLDR EA C276P155 CABLE BELDEN ' AC 1 EA AMS4P512 CABLE RTP/USB 4 WIRE FUJITSU 1 EA AMS4P304 CABLE USB X 2 PANEL MOUNT 1 EA AMS4P579 CABLE INVERTER INPUT TO JKL 1 EA AMS4P580 CABLE INVERTER OUTPUT TO JKL 1 EA C276P603 CABLE USB A TO SERIAL ADAPTER 1 EA BenchMark Wireline Products 5762XA HOIST PANEL Rev E MAR 2007 Page 29 of 50

30 AMS4P275 CABLE CAT5 2' SHIELDED RJ45 1 EA AMS4P274 COUPLING RJ45F/RJ45F SHIELDED 1 EA AMS4P276 RECEPTACLE 115/240 VAC FUSED 1 EA AMS4P691 FUSE 2.5A 250V 5MM X 20MM GMC 2 EA AMS4P257 CONN KPT02E8-33P RECEPTACLE 1 EA F CONN DDC-50S 50 PIN CANNON 1 EA AMS7P021 CONN AMP 12 POS PCB 11 EA AMS7P023 CONN AMP 12 POS BACK 11 EA AMS7P024 CONN AMP 12 POS FRONT 11 EA AMS7P025 CONN AMP 16 POS FRONT 2 EA AMS7P022 CONN AMP 16 POS PCB 2 EA AMS7P026 CONN AMP 16 POS BACK 2 EA AMS2P021 CONN AMP 10 POS PCB 1 EA AMS2P022 CONN AMP 10 POS BACK 1 EA AMS2P023 CONN AMP 10 POS FRONT 1 EA AMS4P164 CONN DB9S CRIMP AMP USED WITH 2 EA AMS4P163 CONN DB9P CRIMP AMP USED WITH 3 EA AMS4P168 SOCKET AMP M39029/ USED 59 EA AMS4P167 PIN AMP M39029/ USED 9 EA FSU1P025 NUTPLATE SHELL EA AMS4P581 CONN HOUSING 4POS.2 DISK PWR 1 EA AMS4P582 TERM CONN FEMALE CRIMP DISK PW 4 EA AMS1P052 SCREW X 5/8 SOC HD SST 2 EA AMS1P054 WASHER #10 FLAT SS 2 EA C276P035 WASHER #10 LOCK SS 2 EA AM3KP070 SCREW X 5/8 FH SOC SST 2 EA AMS7P068 SCREW JACK D-CONNECTOR KEYSTON 8 EA F HANDLE OVAL 1-1/2 X 4-9/16 AL 2 EA F POST SLIDE LOCK D53018 CANON 2 KIT AMS4P198 SPACER UNTHREADED RND NYLON #4 8 EA ALS3P018 STANDOFF 8-32 X 1 M/F HEX 6 EA AMS8P092 SCREW 6-32 X 3/8 FH PHIL SST 14 EA AMS4P695 STANDOFF 6-32 X 1-1/4 M/F BRS 4 EA AMS4P692 STANDOFF 4-40 X 1/4 F/F HEX 2 EA AMS4P583 CONN HSG 10 POS 2MM MILLI-GRID 3 EA AMS4P584 TERM CONN FEM CRIMP 2MM EA ACMU1P70 CONN MOLEX W/LOCKNG 1 EA ACMU1P71 CONN MOLEX W/LOCKNG 1 EA AMS4P596 CONN MOLEX W/LOCKNG 1 EA AMS4P675 TAPE DBL SIDE 1/32 X 1 MMM 24 IN AMS4P590 KEYBOARD USB MINI TOUCH BLACK 1 EA AMS4P330 CONN.1 CRIMP TERM HOUSING 4CT 1 EA AMS4P331 CONN CRIMP PIN FOR AMS4P330 4 EA AMS4P165 CONN DB25P CRIMP AMP USED WITH 1 EA AMS4A740 PCB ASSY FUSE BD TCHSCREEN BAT 1 EA AMS4P738 DUSTCAP PLUG CAPUSB-A 2 EA BenchMark Wireline Products 5762XA HOIST PANEL Rev E MAR 2007 Page 30 of 50

31 WIRING AND PINOUT DIAGRAMS 6.1 POWER WIRING BLOCK DIAGRAM BenchMark Wireline Products 5762XA HOIST PANEL Rev E MAR 2007 Page 31 of 50

32 6.2 SIGNAL WIRING BLOCK DIAGRAM BenchMark Wireline Products 5762XA HOIST PANEL Rev E MAR 2007 Page 32 of 50

33 6.3 Main Processor Board Schematics ENCODER AND MMD INPUTS BenchMark Wireline Products 5762XA HOIST PANEL Rev E MAR 2007 Page 33 of 50

34 6.3.2 ENCODER OUTPUT AND COM PORT I/O BenchMark Wireline Products 5762XA HOIST PANEL Rev E MAR 2007 Page 34 of 50

35 6.3.3 LOAD PIN AND TENSION I/O BenchMark Wireline Products 5762XA HOIST PANEL Rev E MAR 2007 Page 35 of 50

36 6.3.4 JUMPERS BUTTONS BenchMark Wireline Products 5762XA HOIST PANEL Rev E MAR 2007 Page 36 of 50

37 6.3.5 REAL TIME ACQ BOARD POWER SUPPLIES BenchMark Wireline Products 5762XA HOIST PANEL Rev E MAR 2007 Page 37 of 50

38 6.3.6 AMS4A644 5v Power Supply / CCL board BenchMark Wireline Products 5762XA HOIST PANEL Rev E MAR 2007 Page 38 of 50

39 6.3.7 ALS3A032 Intercom board BenchMark Wireline Products 5762XA HOIST PANEL Rev E MAR 2007 Page 39 of 50

40 6.4 REAR PANEL PINOUTS J3 RS485 IN DB9-P (DB9-MALE) J3-1 CTS+ J3-2 CTS- J3-3 GND J3-4 RS485RX+ J3-5 RS485RX- J3-6 RTS+ J3-7 RTS- J3-8 RS485 TX+ J3-9 RS485 TX- J4 RS485 OUT DB9-S (DB9-FEMALE) J4-1 CTS+ J4-2 CTS- J4-3 GND J4-4 RS485RX+ J4-5 RS485RX- J4-6 RTS+ J4-7 RTS- J4-8 RS485 TX+ J4-9 RS485 TX- J2 EXTERNAL SIGNALS IN/OUT (DB50F) J2-1 TRUCK SPEAKER J2-2 RIG SPEAKER J2-3 M J2-4 M/ J2-5 MMD HI J2-6 J2-7 A-STOP RELAY (TENSION S/D) J2-8 ENCODER 1A J2-9 ENCODER 1B J2-10 ENCODER2A J2-11 ENCODER2A* J2-12 ENCODER2B J2-13 ENCODER2B* BenchMark Wireline Products 5762XA HOIST PANEL Rev E MAR 2007 Page 40 of 50

41 J2-14 MMD HI J2-15 MMD POWER +15V J2-16 MMI POWER +15V J2-17 MMD LO J2-18 TRUCK SPEAKER SHIELD J2-19 RIG SPEAKER SHEILD J2-20 DIFF WEIGHT COM J2-21 CCL IN- J2-22 MMD LO J2-23 CHASSIS LOAD CELL J2-24 DIG GND J2-25 ENCODER 1A* J2-26 ENCODER 1B * J2-27 ENCODER 1 POWER +5V J2-28 ENCODER 2 POWER +5V J2-29 ENCODER 1 DIG GND J2-30 ENCODER 2 DIG GND J2-31 A-STOP RELAY (TENSION S/D) J2-32 LOAD PIN POWER +15V J2-33 LOAD PIN POWER -15V J2-34 J2-35 MMD INTENSIFY ENABLE J2-36 DIFF WEIGHT J2-37 CCL IN+ J2-38 TRUE WEIGHT J2-39 LOAD PIN SIG+ J2-40 LOAD PIN SIG- J2-41 SHUNT CAL ENABLE J2-42 WEIGHT COM IN J2-43 ENC_B_OUT J2-44 J2-45 ENC_B_OUT J2-46 J2-47 ENC_A_OUT J2-48 J2-49 ENC_A_OUT J2-50 BenchMark Wireline Products 5762XA HOIST PANEL Rev E MAR 2007 Page 41 of 50

42 CCL/MMK POWER DIST BOARD P1-1 GND P V SYSTEM FUSED P1-5 CCL+ P1-4 MMK+ P1-3 MMK- P1-7 STRONG MARK + P1-8 STRONG MARK - J2-2 TX1 J2-3 RX1 J2-5 GND SMALL 3 PIN DC POWER IN CONNECTOR ON REAR PANEL J6 12V POWER IN J6-A 12V POWER IN J6-B GND J1 - AC POWER IN J1-L J1-N J1-GND AC HOT AC NEUTRAL PNL_BAT+ PNL_BAT- AC/DC POWER SUPPLY CN1-N CN1-L CN2-3 CN2-4 AC NEUTRAL AC HOT +12V_ACPWR GND CCL/MMK/POWER DISTRIBUTION BOARD J1-10 GND BenchMark Wireline Products 5762XA HOIST PANEL Rev E MAR 2007 Page 42 of 50

43 J1-9 SW_12v_SYSTEM J1-8 GND J V_ACPWR J1-6 GND J1-5 PANEL BATTERY + J1-4 GND J1-3 12V_SYSTEM_POWER J1-2 GND J1-1 +5V_SYSTEM TB1-1 GND TERMINAL BLOCK J5 RS232 IN DB25F J5-2 TX J5-3 RX J5-4 RTS J5-5 CTS J5-6 DSR J5-7 GND J5-8 CD J5-20 DTR J5-22 RI INTERCOM PCB P1-1 9TO40V SWITCHED P1-2 GND TO BUS BAR P1-3 MUTE P1-4 VOL POT WP P1-5 SPEAKER 2+ P1-6 SPEAKER 2- P1-7 SPEAKER 1+ P1-8 SPEAKER 1- P1-9 VOL POT CW P V P1-11 GND P1-12 GND P1-13 PAN SPEAKER+ P1-14 PAN SPEAKER- BenchMark Wireline Products 5762XA HOIST PANEL Rev E MAR 2007 Page 43 of 50

44 P1-15 PUSH TO TALK P1-16 5V P1-7 9TO40V IN FROM FUSE BRD CN2 - INVERTER OUTPUT CN2-1 HV - 1 CN2-2 HV - 2 CN2-5 RTN CN2-6 RTN USBA1 - DUAL USB PORTS USBA1-1 USBA1-5 USBA1-7 USBA1-9 USBA1-10 USBA1-6 USBA1-4 USBA1-2 USBA2 - DUAL USB PORTS USBA2-1 USBA2-5 USBA2-7 USBA2-9 USBA2-10 USBA2-6 USBA2-4 USBA2-2 USB_VCC USBD0- USBD0+ GND USB_VCC USBD0- USBD0+ GND USB_VCC USBD0- USBD0+ GND USB_VCC USBD0- USBD0+ GND J8 - CAL TEN 4 SHUNT CAL ENABLE 5 GND BenchMark Wireline Products 5762XA HOIST PANEL Rev E MAR 2007 Page 44 of 50

45 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) Close all running programs in Windows XP Embedded Copy Hoistman Display.EXE to the directory C:\ Program Files\Kerr\ 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 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's internal 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 Close all running programs in Windows XP Embedded Copy the file S HEX to the root directory C:\ Transfer these files to the CompactFlash (C:\) root directory via Ethernet or USB connection using the Windows Explorer BenchMark Wireline Products 5762XA HOIST PANEL Rev E MAR 2007 Page 45 of 50

46 7.2.3 Open a Hyperterminal session. Use the following settings: Serial Port: COM2 Baud Rate: Data Bits: 8 Parity: None Stop Bits: 1 Flow Control: None 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 Press the keyboard ENTER key. The MicroController ROM Loader will respond with a banner and then a '>' prompt 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 and Type an uppercase 'L' and the ROM Loader will wait to Load a HEX file 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 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: GGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGG GGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGG GGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGG GGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGG GGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGG GGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGG GGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGG GGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGG GGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGG GGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGGG G > BenchMark Wireline Products 5762XA HOIST PANEL Rev E MAR 2007 Page 46 of 50

47 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 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 HyperTerm uses the same serial port as the Hoistman program, so close it before opening the Hoistman program. BenchMark Wireline Products 5762XA HOIST PANEL Rev E MAR 2007 Page 47 of 50

48 7.3 REPLACING INTERNAL FLASH CARD Locate the PC processor board mounted to the front panel Press the reject tab. The card will then pop out of the holder The card can now be removed. BenchMark Wireline Products 5762XA HOIST PANEL Rev E MAR 2007 Page 48 of 50

49 7.3.4 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. BenchMark Wireline Products 5762XA HOIST PANEL Rev E MAR 2007 Page 49 of 50

50 8.0 CE CERTIFICATE BenchMark Wireline Products 5762XA HOIST PANEL Rev E MAR 2007 Page 50 of 50