AMS4A048 WINCH OPERATORS PANEL USER MANUAL RevD · Raw2 Depth Displays the current uncorrected encoder 2 depth Shim Adds or subtracts depth continually. If 1 is entered then 1 foot

BenchMark Wireline Products AMS4A048 PANEL Rev D. AUG 2007 Page 1 of 60

OPERATIONS AND MAINTENANCE MANUAL AMS4A048 TOUCH SCREEN WINCH OPERATORS PANEL

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


Manual Revision Log Current Revision: C: OCT 2006 – ADDED LAYOUT DRAWINGS Previous Revisions: B JULY 2006 – UPDATED SOFTWARE INSTRUCTIONS

A JAN 2006 – INITIAL RELEASE


1.0 INTRODUCTION

1.1 GENERAL DESCRIPTION

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

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

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

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


1.2 HARDWARE FEATURES

Power Input 12 - 24 VDC 120 – 240 VAC 50/60 HZ Internal UPS with 2 hour battery Internal PC board Intel based personal computer board 1 gb solid state media device Embedded windows XP operating system Three USB ports (2 front, 1 rear) 1 RS232 port RJ 45 Ethernet port USB Mouse / Keyboard included Color Display TFT LCD Backlit 400 NITS Sunlight readable Touch Screen Interface (replaces current key pad) 5 wire resistive USB interface Real Time Acquisition board Kerr Measurement Systems proprietary design 8051 Microprocessor based Provides power to encoders, mag mark detector, and load cell Processes encoder quadrature, mag mark signal, and load cell

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

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

Dual Intercom system


1.3 USER INTERFACE FEATURES

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

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

one that moved the furthest since the previous reading.


2.0 SPECIFICATIONS

WEIGHT: 13 LBS 5.92 KG DIMENSIONS: INCHES - 8.72 H x 5.5 D x 19 W CM - 22.15 H x 13.97 D x 48.26 W

POWER REQUIREMENTS:

INPUT VOLTAGE: 12-24 VDC OR 115-230 VAC 50/60 HZ INPUT CURRENT: 4 AMPS STARTUP SURGE 3 AMPS NORMAL OPERATION OPERATING TEMPERATURE Min Max

14 149 degrees F -10 65 degrees C

STORAGE TEMPERATURE Min Max

-22 158 degrees F -30 70 degrees C


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

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


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.


3.2 TENSION

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

Pressing Tension Cal will activate the tension relay inside the panel which will ground pin G. The load pin should then return a calibrated signal of 10000 lbs.


3.2.1 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.


3.2.2 TENSION LOADCELL ANGLE

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

2 90 degrees = 1.414 120 degrees = 2.000

Note that this function is only available when line size selected is “Other”.


3.3 ALARMS

3.3.1 TENSION SHUTDOWN

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

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


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

Default Values

7-32 2000 9-32 3000

5-16 3500 3-8 3500

7-16 3500 15-32 3500 SLAM 3500

S-SLAM 3500

3.3.3 SURFACE SHUTDOWN

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

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

Default Values

7-32 1500 9-32 2400

5-16 2400 3-8 2400

7-16 2400 15-32 2400 SLAM 2400

S-SLAM 2400


3.3.5 DIFFERENTIAL TENSION ALARM When this setting is reached the alarm sounds and "DIFF TENSION ALARM" flashes on the screen. In incremental mode (see 3.1.2), you must periodically press meter reset or this alarm will sound when the tension reaches the set value. In differential mode, the meter will reset itself and the alarm will only sound on a quick change of tension.

3.3.6 SURFACE ALARM

When this depth value is reached, the alarm will sound

3.3.7 TEST ALARM

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

3.3.8 ALARM OFF This button silences the alarm until a new alarm condition occurs.

3.3.9 ALARM VOLUME This button will bring up a slider bar which is used to adjust the alarm volume. Use the "Test Alarm" button to test the volume.


3.3.10 TEST SHUTDOWN When this button is pressed, the contact closure pins (A and B) on J8 are shorted. This can be used to test the winch shutdown mechanism or any other mechanism that uses these contacts. 3.3.11 RELEASE SHUTDOWN When this button is pressed, the contact closure pins (A and B) on J8 are open.


3.4 AUTO CORRECT

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

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

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

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


3.5 SETUP SCREEN

The Setup Menu allows changes to the peripheral hardware.


3.5.1 LINE SIZE SETUP

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


3.5.2 WHEEL SIZE SETUP

This setting allows you to change the size of the depth measuring wheel that is used to measure depth. To use a different measuring head from the Kerr head, this setting will need to be changed to match the wheel size of the new head. To change Wheel Size, the line size must be first be set to OTHER. At this time, the loadcell angle will also need to be set. Default value is 2ft - .6096 meters 3.5.3 ENCODER PPR SETUP The screen allows you to set the encoder pulses per revolution setting. This number should be printed on the encoder label. Note: The pulses per foot/meter are not set by this screen, only the encoder input. Pulses per foot/meter are calculated from encoder PPR and Wheel Size.


3.5.4 STRETCH PARAMETERS

TOOL WEIGHT

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

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

Stretch Adjustment needs to be performed at T.D.


3.5.5 ENGLISH / METRIC UNITS

This menu allows you to select the display units for either depth or tension. 3.5.6 ENCODER DIRECTION This screen allows you to change the direction of the encoder. If the depth is changing in the opposite direction to which the line is moving, this option can be used to correct it. On a dual wheel measuring device with two encoders, the encoder on one of the wheels will turn in the opposite direction from the other. If you change encoders, this feature can be used to change the encoder direction.


3.5.7 MMD SETUP SCREEN

MARK SPACING

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

WINDOW SIZE

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

Default value is 5’ RESET MARKS

Pressing the MMD reset button clears the last mark setting.


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


3.5.8 CCL SELECTION

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

3.5.9 ENCODER STATUS

This screen displays the encoder settings and shows which encoders are used to calculate depth.


3.5.10 MARK TABLE

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

3.5.11 CCL TABLE

This table allows the viewing of Collars found while logging


3.5.12 SUMMARY

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


3.5.13 RESTORE DEFAULTS

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


3.6 SERIAL COMMAND LIST

The panel can be controlled for the serial port installed on the rear of the panel.

Run a program such as MS Windows HyperTerm using the following parameters

BAUD 38,400 BITS 8 PARITY N STOP 1 HANDSHAKING NONE The port wiring is:

J6 - 2 COM1 TXD J6 - 3 COM1 RXD J6 - 5 COMMON

Serial Command Definitions - Model 48 Touch Screen Panel The following are one character only commands Depth command. D ADD_HALF_FOOT ? SUB_HALF_FOOT q ENABLE_GROOVED H DISABLE_GROOVED V RESET_MARKS O ZERO_CAL_TENSION_COMMAND o SHUNT_CAL_TENSION_COMMAND t ENERGIZE_SHUNT_RELAY F DEENERGIZE_SHUNT_RELAY f TEST_SHUTDOWN R RELEASE_SHUTDOWN r ENCODER_DIRECTION E MMK_CORR_ON/OFF (Toggle) m STRETCH_CORR_ON/OFF (Toggle) k ALARM_ON * ALARM_OFF n ENCODER1_ON x ENCODER1_OFF g ENCODER2_ON y ENCODER2_OFF z RESTORE_DEFAULTS ~ CORRECTED/RAW_OUT (Toggle) + The following require a parameter after the command Load-cell factor L


Pulse per revolution. P UNITS_MEASURE U Wheel size (circumference) W SET DEPTH Z Depth Alarm A Max Depth Alarm l Select line size N TENSION_ALARM M TENSION_SD_ALARM G TOOL_WEIGHT T MMK_SPACE X MMK_WINDOW_WIDTH Y VOLUME_COMMAND v ENTER_MUD_WEIGHT B DELTA_TEN_ALARM ( DELTA_TEN_SD ) SHIM % The following describes commands w/parameters usage D - Display Units, Mark, Direction, Depth, Speed, and Tension. L - Modify Load Cell Angle Factor - Usage: L1.2 P - Modify Encoder Pulses/Revolution - Usage: P600 W - Modify Wheel Size (Head OTHER Only) - Usage: W4.125 Z - Preset Depth - Usage: Z0.0 U - Modify Units - UF (feet), UM (meters), UP (pounds), UK (kilograms) A - Depth Alarm - Usage: A100 l - Max Depth Alarm - Usage: l10000 N - Line Size - N0 7/32; N1 9/32; N2 5/16; N3 3/8; N4 7/16; N5 15/32; N6 SLAM; N7 S-SLAM; N8 OTHER M - Tension Alarm - Usage: 'M2500' (for 2500 LB./KG Alarm) G - Tension S/D Alarm - Usage: 'G3500' (for 3500 LB/KG S/D) ( - Delta Tension Alarm - Usage: '(250' (for 250 LB/KG Diff Alarm) ) - Delta Tension S/D Alarm - Usage: ')750' (for 750 LB/KG diff S/D) B - Enter Mud Weight - Usage: B12.3 (Lbs/Gal Or Kgs/Lit) T - Enter Tool Weight - Usage: T1000 (Lbs Or Kgs) X - Modify MMK Spacing - XC (100 Foot), XL (50 Meter), XT (25 Meter) Y - Modify MMK Window Size - Usage: Y4.0 v - Adjust Alarm Volume - Usage: v0 -> v255 % - Shim (ft/kft) The following commands will return a parameter or a flag (0 -> Disabled, 1 -> Enabled) CA - Request Sheave Factor CB - Request Depth Alarm CC - Request Tension Alarm CD - Request Mark Corr Enable CE - Request Stretch Corr Enable CF - Request Dual Encoder Enable CH - Request Line Size CI - Request Wheel Size CJ - Request Mark Spacing CK - Request Window Size CL - Request Encoder PPR CM - Request Encoder Direction


CN - Request Depth Units CO - Request Tension Units CP - Request Tension S/D Alarm CQ - Request Intensify Enable CR - Request Corrected Out CS - Request Delta Tension Alarm CT - Request Delta Tension S/D Alarm CU - Request Surface Shutdown Flag CV - Request Max Depth Alarm CW - Request Tool Weight CX - Request Mud Weight C( - Request Raw Encoder 1 Depth C) - Request Raw Encoder 2 Depth C* - Request Depth Offset Value C& - Request MMK Depth Corrected Value C% - Request Actual Stretch Value C^ - Request Calculated Stretch Value C$ - Request Shim Value C: - Request Grooved Wheel Flag


4.0 WELLSITE OPERATING SUMMARY

4.1 Power up panel and verify it is working properly.

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

4.3 Set up acquisition system:

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

on acquisition system.

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

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

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

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

4.10 Press T-Test and verify that panel tension reads 10000 lbs. Verify tension is being properly recorded on acquisition system.

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


5.0 PARTS LIST Component Description Qty AMS4P134E PC BOARD AMS40 REV E W/2xRS232 1 EA MAIN PROCESSOR BOARD AMS4P326 COMPUTER SINGLE BOARD 650MHZ 1 EA AMS4P319 LICENSE WINDOWS XP EMBEDDED 1 EA AMS4P318 EMORY RAM 256MG PC133 SODIMM 1 EA AMS4P317 EMORY COMPACTFLASH 1.0GB OR 1 EA AMS4A204 PCB ASSY IN CICUIT PROGRAMM CB 1 EA AMS4P577 LCD 12.1 COLOR TFT SHARP 1 EA AMS4P513 SCREEN TOUCH RESISTIVE 12.1 4W 1 EA AMS4P511 CNTROLLER BD TOUCH PNL USB 1 EA AMS4P499 INVERTER CCFL 12VIN 1200V 6Ma 1 EA AMS4P128 DISPLAY LED RED 0.5" 14 SEGMNT 2 EA ACMU1P02 POWER SUPPLY 45W 12V 90-264VAC 1 EA AMS4A322 PCB ASSY VOLUME BRD 1 EA AMS4A644 PCB ASSY CCL/MMK BD AMS4A045 1 EA AMS4A102 PCB ASSY FUSE BOARD 1 EA ALS3A032 PCB ASSY INTERCOM 12V 3 INCH 1 EA AMS4A566 CABLE ASSY LANNER VID HIRSE41 1 EA VIDEO 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 AMS4M144 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 AMS4P362 POT 500 OHM 1/4W CARB LNR W/SW 1 EA AMS4P363 KNOB INSTRUM SKIRTED RND .5"DI 1 EA AMS4P021 SWITCH CAP ALCO C-22 BLACK 1 EA AMS7P028 SWITCH 4PDT TOGGLE LOCKING 1 EA POWER ALS2P008 SWITCH DPDT MOM PB MPA206R 1 EA PUSH TO TALK AMS4P290 TERMINAL INSULATED SOLDR 6-32 2 EA GROUND BUS C276P155 CABLE BELDEN 177431 10' AC 1 EA POWER INPUT AMS4A570 CABLE ASSY LANNER USB TOUCH 1 EA AMS4A571 CABLE ASSY LANNER 2 X USB 1 EA AMS4P579 CABLE INVERTER INPUT TO JKL 1 EA AMS4P580 CABLE INVERTER OUTPUT TO JKL 1 EA AMS4P687 CABLE CAT5 3' RJ45 GRAY FLEX 1 EA AMS4P274 COUPLING RJ45F/RJ45F SHIELDED 1 EA AMS4P276 RECEPTACLE 115/240 VAC FUSED 1 EA AMS4P691 FUSE 2.5A 250V 5MM X 20MM GMC 2 EA AC INPUT AMS7P021 CONN 102536-4 AMP 12 POS BACK 11 EA AMS7P024 CONN 102681-1 AMP 12 POS FRONT 11 EA AMS7P025 CONN 102681-3 AMP 16 POS FRONT 2 EA AMS7P022 CONN 102398-6 AMP 16 POS PCB 2 EA AMS7P026 CONN 102536-6 AMP 16 POS BACK 2 EA AMS2P021 CONN 102398-3 AMP 10 POS PCB 1 EA DCI DISPLAYS


AMS2P022 CONN 102536-3 AMP 10 POS BACK 1 EA AMS2P023 CONN 102540-3 AMP 10 POS FRONT 1 EA AMS4P169 CONN KPSE02E12-3P RECEPTACLE 1 EA J1 - POWER IN AMS4P172 CONN KPSE02E14-12S RECEPTACLE 1 EA J2 – ENCODER AMS4P172 CONN KPSE02E14-12S RECEPTACLE 1 EA J3 – ENCODER AMS4P171 CONN KPSE02E12-10S RECEPTACLE 1 EA J4 - LOAD PIN IN AMS4P170 CONN KPSE02E12-10P RECEPTACLE 1 EA J5 - MAG MARK DET AMS4P164 CONN DB9S CRIMP AMP USED WITH 1 EA J6 - RS232 AMS4P698 CONN MS3102E-22-14S 19 SOC 1 EA J7 - SIG OUT AMS4P179 CONN KPSE02E12-3S RECEPTACLE 1 EA J8 - OVER TENSN OUT AMS4P270 CONN KPSE02E12-8P RECEPTACLE 1 EA J9 - CCL IN AMS4P179 CONN KPSE02E12-3S RECEPTACLE 1 EA J10 - SPEAKER 1 AMS4P179 CONN KPSE02E12-3S RECEPTACLE 1 EA J11 - SPEAKER 2 AMS7P068 SCREW JACK D-CONNECTOR KEYSTON 8 EA F244888000 HANDLE OVAL 1-1/2 X 4-9/16 AL 2 EA AMS4P198 SPACER UNTHREADED RND NYLON #4 8 EA ALS3P018 STANDOFF 8-32 X 1 M/F HEX 6 EA INTERCOM PCB 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 POWER SUPPLY AMS4P692 STANDOFF 4-40 X 1/4 F/F HEX 2 EA MMD/CCL PCB CONN AMS4P583 CONN HSG 10 POS 2MM MILLI-GRID 3 EA AMS4P584 TERM CONN FEM CRIMP 2MM 24-30 30 EA ACMU1P70 CONN 09-50-3031 MOLEX W/LOCKNG 1 EA ACMU1P71 CONN 09-50-3061 MOLEX W/LOCKNG 1 EA AMS4P596 CONN 09-50-3101 MOLEX W/LOCKNG 1 PK 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 AMS4P581 CONN HOUSING 4POS .2 DISK PWR 4 EA AMS1P052 SCREW 10-24 X 5/8 SOC HD SST 2 EA AMS1P054 WASHER #10 FLAT SS 2 EA C276P035 WASHER #10 LOCK SS 2 EA AM3KP070 SCREW 10-24 X 5/8 FH SOC SST 2 EA


6.0 WIRING DIAGRAMS AND SETUP PROCDURES 6.1 CHECKOUT PROCEDURE

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

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

6.1.3 Power up panel using 12vdc. Start up current should measure approximately 4 amps then drop to 2 amps.

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

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

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

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

Set Baud Rate to 9600 Set Brightness to 15

6.1.6 On the AMS40 board, verify that JP9 is set to D. Verify R60 is 44.2k ohm/ Power up the panel and verify the hoistman screen loads (should take approximately 1.5

minutes).

6.1.7 Connect an encoder to the panel

Connect an AM5K low voltage load pin or a load pin simulator to the panel.


6.2 POWER WIRING BLOCK DIAGRAM


6.3 SIGNAL WIRING BLOCK DIAGRAM


6.4 Real Time Processor Board


6.4 Main Processor Board Schematics 6.4.1 ENCODER AND MMD INPUTS


6.4.2 ENCODER OUTPUT AND COM PORT I/O


6.4.3 LOAD PIN AND TENSION I/O


6.4.4 JUMPERS – BUTTONS


6.4.5 REAL TIME ACQ BOARD POWER SUPPLIES


6.4.6 AMS4A644 5v Power Supply / CCL board


6.4.7 ALS3A032 Intercom board


6.5 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 6.6 BACK PANEL CONNECTOR PINOUT

POWER INPUT J1 - A BATT + J1 - B BATT - ENCODER 1 J2 - A ENCODER 1A J2 - B ENCODER 1B J2 - C ENCODER 1A* J2 - E ENCODER 1B * J2 - J ENCODER1 PWR J2 - L ENCODER 2 J3 - A ENCODER 2A J3 - B ENCODER 2B J3 - C ENCODER 2A* J3 - E ENCODER 2B * J3 - J ENCODER2 PWR J3 - L


LOAD PIN J4 - A LOAD PIN POWER + J4 - B LOAD PIN POWER - J4 - C LOAD PIN POWER + J4 - E LOAD PIN SIG- J4 - G SHUNT CAL ENABLE J4 - J MAGNETIC MARK J5 - C MARK+ J5 - D MARK- J5 - E MMD POWER + J5 - F COMMON J5 - G STRONG MARK - J5 - H STRONG MARK + RS232 J6 - 2 COM1 TXD J6 - 3 COM1 RXD J6 - 5 COMMON SYSTEM OUTPUTS J7 - A PHASE 1A J7 - B PHASE 1B J7 - U 0-10V OUT (TENSION) J7 – K MARK + J7 – S COMMON J7 – E PHASE 1A* J7 – F PHASE 1B* J7 – N COMMON J7 - P MARK - OVERTENSON J8 - A CONTACT CLOSURE N.O. J8 - B CONTACT CLOSURE COM CCL J9 – A CCL + J9 – B CCL -


6.7 INTERNAL WIRE LIST

P2 - Screw Terminal Block

P2 -1 BATT + P1 - 7 (FUSE BRD) AND->

P1-2 CCL/MMK BRD AND -> PS4M1-1 LANNER CPU

P2 -2 BATT - BUS BAR P2 -3 CONTACT CLOSURE N.O. J8 A Tension Contact Closure Back Panel P2 -5 URE COM J8 B Tension Contact Closure Back Panel P3 - THUMBWHEEL DATA P3-8 MARK+ J7-K MARK+ SIGNAL OUT TO SYSTEM P5 - SPARE P5 - 1 +5V D1 - 4 DISPLAY POWER P6 - ANALOG IN/OUT P6 - 1 LOAD PIN POWER + P1-10 FUSE BRD LOAD PIN +15V - unfused side P6 - 2 LOAD PIN POWER - P1-9 FUSE BRD LOAD PIN -15V - unfused side P6 - 3 LOAD PIN SIG+ J4 A LOAD PIN SIG+ P6 - 4 LOAD PIN SIG- J4 E LOAD PIN SIG- P6 - 7 SHUNT CAL ENABLE J4 G SHUNT CAL P6 - 8 ACM J4 J GROUND P6 - 9 4to20OUT J7-R 4 to 20 mA to system P6 - 10 ACM J7-S P6 - 11 0-10V OUT (TENSION) J7-U TENSION OUT+ TO SYSTEM P6 - 13 TENSION METER DAC P1 - 2 VOLUME PCB DAC OUT TO SONALERT VOLUME PCB P7 - COMMUNICATIONS - RS232 P7-5 COM3 TXD J6-2 TXD TO REAR PANEL

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

P7-8 COM3 RXD J6-3 RXD TO REAR PANEL P7 - 9 GND D1-1 DISPLAY GND

P7- 10 COM1 TXD LANNER COM1 DB9-2

TO LANNER COM1 RXD FOR HOISTMAN TO 40 BRD COMM

P7 - 11 COM1 RXD LANNER COM1 DB9-3

TO LANNER COM1 TXD FOR HOISTMAN TO 40 BRD COMM

P7 - 12 GND LANNER COM1 DB9-5

TO LANNER COM1 GND FOR HOISTMAN TO 40 BRD COMM

P8 - QUADRATURE OUT / INDICATORS

P8 - 6 EXCESSIVE TENSION ALM + P1 - 1 VOLUME PCB BEEPER +12V POWER

P8 - 11 PHASE 1B* J7 - F Quadrature Out - PHASE B* P8 - 12 PHASE 1B J7 - B Quadrature Out - PHASE B P8 - 13 PHASE 1A* J7 - E Quadrature Out - PHASE A* P8 - 14 DCM J7 - N Digital common P8 - 16 PHASE 1A J7 -A Quadrature Out - PHASE A P9 - ENCODER 1 P9 - 1 DCM J2 - L Encoder Ground P9 - 5 ENCODER PWR 12V P1:2 FUSE BOARD P1:2 P9 - 8 ENCODER 1B J2 - B Encoder input P9 - 9 ENCODER 1B * J2 - E Encoder input P9 - 11 ENCODER 1A J2 - A Encoder input P9 - 12 ENCODER 1A* J2 - C Encoder input P10 - ENCODER 2 P10 - 1 DCM J3 - L Encoder Ground P10 - 5 ENCODER PWR 12V P1-6 FUSE BOARD P1:6 P10 - 8 ENCODER 2B J3 - B Encoder input P10 - 9 ENCODER 2B * J3 - E Encoder input P10 - 11 ENCODER 2A J3 - A Encoder input P10 - 12 ENCODER 2A* J3 - C Encoder input P11 +/- 15 VDC P11-1 DIG GND J5 - F MMD POWER COMMON P11 - 8 MARK+ J5 - C MARK IN - P11 - 9 MARK- J5 - D MARK IN + P11-10 MMD POWER +15V P1-3 FUSE BRD MMD POWER + P11-11 STRONG MARK + J5 H STRONG MARK IN - P11-12 STRONG MARK - J5 G STRONG MARK IN +


AC/DC POWER SUPPLY CN1-L AC HOT S1 - 2 NO (BOTTOM) AC HOT PWR THROUGH SWITCH

CN1-N AC NEUTRAL J14-N (AC POWER IN) TO POWER SUPPLY AC NEUTRAL

CN2-3 +12V_ACPWR (CCL/MMK PWR) J1-7 12V OUT OF POWER SUPPLY

CN2-4 GND (CCL/MMK PWR) J1-6 12V RETURN TWISTED PAIR W/ ABOVE WIRE

CCL/MMK INTERFACE PWR DISTRIBUTION BOARD P1-1 GND BUS BAR GND

P1-2 BATT + P1 - 7 (FUSE BRD) AND ->

P2-1 (TERMINAL BLOCK) AND PS4M1-1 LANNER CPU

P1-5 CCL+ J9-A CCL + IN FROM REAR PANEL P1-6 CCL- J9 - B CCL RETURN FROM REAR PANEL P1-10 TX1 COM B-3 LANNER COM 2 TO CCL/MMK P1-11 RX1 COM B-5 LANNER COM 2 TO CCL/MMK P1-12 GND COM B-9 LANNER COM 2 TO CCL/MMK J1-1 +5V_SYSTEM PS4M1 PIN 4 PWR +5V FOR LANNER CPU BRD J1-2 GND PS4M1 PIN 3 TWIST W/ WIRE BELOW J1-3 12V_SYSTEM_POWER S1 - 1 COM (MIDDLE) 12V SYSTEM PWR TO SWITCH J1-4 GND BUS BAR J1-5 PANEL BATTERY + S1 - 4 NO (BOTTOM) PWR +12V FROM JELL CELL THROUGH SWITCH

J1-6 GND CN2-4 (AC/DC PWR SUP) 12V RETURN (TWISTED PAIR)

J1-7 + 12V_ACPWR CN2-3 (AC/DC PWR SUP) 12V OUT OF POWER SUPPLY

J1-8 PANEL BATTERY - PANEL BATTERY - TWISTED PAIR FROM BATTERY J1-9 SW_12v_SYSTEM S1 - 3 NO (BOTTOM) SWITCHED 12 VOLTS TO BOARD

J1-10 GND J1-B (BACK PANEL) RETURN FOR 12V POWER TO PANEL (TWISTED PAIR)

TB1-1 GND BUS BAR RETURN CN1 - INVERTER INPUT CN1 - 1 DIMMING CONTROL CN1 - 2 SPLICE TOGETHER

CN1 - 3 ENABLE CN1 - 4,CN1 - 5,PS4M1 - 2 SPLICE TOGETHER

CN1 - 6 12 VDC IN CN1 - 7 SPLICE TOGETHER CN2 - INVERTER OUTPUT CN2 - 1 HV - 1 CCFL LAMP SPLICE TOGETHER CN2 - 2 HV - 2 CCFL LAMP SPLICE TOGETHER CN2 -5 RTN CCFL LAMP SPLICE TOGETHER CN2 -6 RTN CCFL LAMP SPLICE TOGETHER D1 DISPLAY - DEPTH

D1-1 GND P7-9 COMMUNICATIONS DISPLAY GND

D1-2 GND D2 1 GND OUT D1-4 + 5V P5-1 (SPARE) DISPLAY POWER

D1-5 COM2 TXD P7-7(COMM), D2-5 DISPLAY DATA - 2 WIRES CONNECTED TOGETHER

D1-6 +5V OUT D2 4 POWER OUT D2 DISPLAY - TENSION D2-1 GND D1-2 DISPLAY GND OUT D2-4 + 5V OUT D1-6 POWER IN

D2-5 COM2 TXD P7-7(COMM), D1-5 DISPLAY DATA - 2 WIRES CONNECTED TOGETHER

FUSE BOARD P1-1 S1 ON/OFF 12V BATT S1 - 1 NO (BOTTOM) PANEL 12V FROM POWER SWITCH P1-2 ENCODER1 PWR FUSED P9-5 ENCODER1 ENCODER1 12V POWER UNFUSED SIDE P1-3 MMD PWR (+15) FUSED P11-10 +/-15VDC POWER +15V P1-4 ENCODER1 PWR FUSED J2 - J ENCODER1 12V POWER FUSED P1-5 MMD PWR (+15) FUSED J5 - E POWER +15V TO MMD FUSED P1-6 ENCODER2 PWR FUSED P10-5 ENCODER2 ENCODER2 12V POWER UNFUSED SIDE

P1-7 BATT + P2-1(TERMINAL BLOCK) AND

P1-2 CCL/MMK BRD AND -> PS4M1-1 LANNER CPU

P1-8 ENCODER2 PWR FUSED J3 - J ENCODER2 12V POWER FUSED

P1-9 LOAD PIN POWER - P6-2 ANALOG IN/OUT LOAD PIN -15V - unfused side


P1-10 LOAD PIN POWER + P6-1 ANALOG IN/OUT LOAD PIN +15V - unfused side

P1-11 LOAD PIN -15V FUSED J4 B POWER -15V TO LOAD PIN FUSED P1-12 LOAD PIN +15V FUSED J4 C POWER +15V TO LOAD PIN FUSED INTERCOM PCB P1-1 9TO40V SWITCHED SW2-A 9TO40V SWITCHED P1-2 GND BUS BAR GND P1-3 MUTE SW1-NC MUTE P1-4 VOL POT WP R1-W VOL POT WP P1-5 RIG SPK + J10 - A RIG SPK + P1-6 RIG SPK - J10 - B RIG SPK - P1-7 TRK SPK + J11 - A TRK SPK + P1-8 TRK SPK - J11 - B TRK SPK - P1-9 VOL POT CW R1-CW VOL POT CW P1-10 2.5V R1-CCW 2.5V P1-11 GND GND P1-12 GND SW1-2-W GND P1-13 PAN SPKR + SPKR+ PAN SPKR + P1-14 PAN SPKR - SPKR- PAN SPKR - P1-15 PUSH TO TALK SW1-2-NO PUSH TO TALK P1-16 5V SW1-1-W 5V PS4M1 - 1 9TO40V IN SW2-B, CN1 - 6 9TO40V IN LANNER CPU COM1

DB9-2 COM1 RXD P7-10 COMMUNICATIONS TO LANNER COM1 RXD FOR HOISTMAN TO 40 BRD COMM

DB9-3 COM1 TXD P7-11 COMMUNICATIONS TO LANNER COM1 TXD FOR HOISTMAN TO 40 BRD COMM

DB9-5 GND P7-12 COMMUNICATIONS TO LANNER COM1 GND FOR HOISTMAN TO 40 BRD COMM

LANNER CPU COM2 COM B-3 RX1 P1-10 (CCL/MMK) LANNER COM2 TO CCL/MMK COM B-5 TX1 P1-11 (CCL/MMK) LANNER COM2 TO CCL/MMK COM B-9 GND P1-12 (CCL/MMK) LANNER COM2 TO CCL/MMK LANNER CPU PS4M1

PS4M1-1 BATT + P1 - 7 (FUSE BRD) AND -> P2-1 (TERMINAL BLOCK) AND P1-2 CCL/MMK PCB

PS4M1-3 GND J1-2 (CCL/MMK PWR) + 5V RETURN PS4M1-4 + 5V J1-1 (CCL/MMK PWR) PWR +5V FOR LANNER CPU BOARD PANEL BATTERY PNL_BAT+ S1 - 4 COM (MIDDLE) TO POWER SWITCH PNL_BAT- (CCL/MMK PWR) J1-8 TWISTED PAIR W/ ABOVE WIRE SW1 PWR SWITCH S1-1NO(BTM) S1 ON/OFF 12V BATT P1-1 (FUSE BRD) PANEL 12V FROM POWER SWITCH S1-1COM(MID) 12 VOLT SYSTEM POWER

J1-3 (CCL/MMK PWR) 12V SYSTEM PWR TO SWITCH

S1-2NO(BTM) AC HOT FUSED G

CN1-L (AC/DC PWR SUP) AC HOT PWR THROUGH SWITCH

S1-2COM(MID) AC HOT FUSED G J14-L (AC PWR IN) TO POWER SWITCH AC HOT S1-3NO(BTM) SW 12V SYSTEM

J1-9 (CCL/MMK PWR) SWITCHED 12 VOLTS TO BOARD

S1-3COM(MID) 12V POWER IN J1-A (BACK PANEL) 12V POWER TO PANEL S1-4NO(BTM) PANEL BATTERY +

J1-5 (CCL/MMK PWR) PWR +12V FORM JELL CELL THROUGH SWITCH

S1-4COM(MID) PANEL BATTERY + FROM BATTERY VOLUME BRD

P1-1 EXCESSIVE TENSION ALM + P8-6 QUADRATURE OUT BEEPER +12V POWER

P1-2 TENSION METER DAC P6-13 ANALOG IN/OUT DAC OUT TO SONALERT VOLUME PCB P1 - 3 GND BUS BAR GND TO VOLUME BRD USBA1 - DUAL USB PORTS

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


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

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

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

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

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

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

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

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

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

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

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

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

J1 12V POWER IN J1-A 12V POWER IN S1 - 3 COM (MIDDLE) 12V POWER TO PANEL J1-B GND PWR_DIST_BRD J1-10 TWISTED PAIR W/ ABOVE WIRE J2 ENCODER 1 INPUT

J2-A ENCODER 1A P9-11ENCODER 1 ENCODER INPUT

J2-B ENCODER 1B P9-8 ENCODER 1 ENCODER INPUT

J2-C ENDODER 1A* P9-12 ENCODER 1 ENCODER INPUT

J2-E ENCODER 1B* P9-9 ENCODER 1 ENCODER INPUT J2-L DCM P9-1 ENCODER 1 ENCODER GROUND J2-J ENCODER1 PWR P1-4 (FUSE BRD) ENCODER1 12V POWER FUSED J3 ENCODER 2 INPUT

J3-A ENCODER 2A P10-11ENCODER 2 ENCODER INPUT

J3-B ENCODER 2B P10-8 ENCODER 2 ENCODER INPUT

J3-C ENDODER 2A* P-10-12 ENCODER 2 ENCODER INPUT

J3-E ENCODER 2B* P10-9 ENCODER 2 ENCODER INPUT

J3-L DCM P10-1 ENCODER 2 ENCODER GROUND

J3-J ENCODER2 PWR P1-8 (FUSE BRD) ENCODER2 12V POWER FUSED J4 - LOAD CELL

J4-A LOAD PIN SIG + P6-3 ANALOG IN/OUT LOAD PIN SIG +

J4-B LOAD PIN -15V FUSED P1-11 (FUSE BRD) POWER -15V TO LOAD PIN FUSED

J4-C LOAD PIN +15V FUSED P1-12 (FUSE BRD) POWER +15V TO LOAD PIN FUSED

J4-E LOAD PIN SIG - P6-4 ANALOG IN/OUT LOAD PIN SIG -

J4-G SHUNT CAL ENABLE P6-7 ANALOG IN/OUT SHUNT CAL

J4-J ACM P6-8 ANALOG IN/OUT GROUND

J5 MMD J5-C MARK + P11-8 +/-15VDC MARK IN -


J5-D MARK - P11-9 +/-15VDC MARK IN + J5-E MMD PWR(+15V) FUSED P1-5 (FUSE BRD) POWER +15V TO MMD FUSED J5-F DIG GND P11-1 +/-15VDC MMD POWER COMMON J5-G STRONG MARK - P11-12 +/-15VDC STRONG MARK IN + J5-H STRONG MARK + P11-11 +/-15VDC STRONG MARK IN - J6 RS232 IN DB9F

J6-2 COM3 TXD P7-5 COMMUNICATIONS TXD TO REAR PANEL

J6-3 COM3 RXD P7-8 COMMUNICATIONS RXD TO REAR PANEL

J6-5 GND BUS BAR SERIAL PORT RETURN J7 - SYSTEM OUT REAR PANEL CONNECTOR

J7-A PHASE 1A P8-16 QUADRATURE OUT QUADRATURE OUT PHASE A

J7-B PHASE 1B P8-12 QUADRATURE OUT QUADRATURE OUT PHASE B

J7-E PHASE 1A* P8-13 QUADRATURE OUT QUADRATURE OUT PHASE A*

J7-F PHASE 1B* P8-11 QUADRATURE OUT QUADRATURE OUT PHASE B*

J7-K MARK + P3-8 THUMBWHEEL DATA MARK + SIGNAL OUT TO SYSTEM

J7-N DCM P8-14 QUADRATURE OUT DIGITAL COMMON

J7-P GND BUS BAR RETURN FOR MARK+ OUT TO SYSTEM J7-R 4to20 OUT P6-9 ANALOG IN/OUT 4 to 20mA OUT TO SYSTEM

J7-S ACM P6-10 ANALOG IN/OUT GROUND

J7-U 0-10V OUT TENSION P6-11 ANALOG IN/OUT TENSION OUT + TO SYSTEM

J8 TENSION CONTACT CLOSURE

J8-A CONTACT CLOSURE N.O. P2-3 (TERMINAL BLOCK)

J8-B CONTACT CLOSURE COM P2-5 (TERMINAL BLOCK)

J9 CCL J9-A CCL + P1-5 (CCL/MMK) CCL + IN FROM REAR PANEL J9-B CCL - P1-6 (CCL/MMK) CCL RETURN FROM REAR PANEL J10 RIG SPKR

J10-A RIG SPKR + P1-5 (INTERCOM) J10-B RIG SPKR - P1-6 (INTERCOM) J11 TRUCK SPEAKER

J11-A TRK SPKR + P1-7 (INTERCOM) J11-B TRK SPKR - P1-8 (INTERCOM)


7.0 SOFTWARE UPDATE PROCEDURE PREREQUISITES:

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

2. USB keyboard/touchpad.

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

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

7.1 HOISTMAN PROGRAM UPDATE (PC BASED PROGRAM)

7.1.1 Close all running programs in Windows XP Embedded.

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

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

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

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

The following Instructions for programming the DS89C450 MicroController'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. 7.2.1 Close all running programs in Windows XP Embedded.

7.2.2 Copy the file S4800XX.HEX to the root directory C:\

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

via Ethernet or USB connection using the Windows Explorer


7.2.3 Open a Hyperterminal session. Use the following settings:

Serial Port: COM2 Baud Rate: 57600 Data Bits: 8 Parity: None Stop Bits: 1 Flow Control: None

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

SW1 - position away from CPU

SW2 - position away from CPU SW3 - position towards CPU

7.2.5 Press the keyboard ENTER key. The MicroController ROM Loader will respond

with a banner and then a '>' prompt. 7.2.6 Type an uppercase 'K' for Klean and Erase. When complete the prompt should

appear. If the prompt does not appear, cycle the switches and repeat steps 7.2.4 and 7.2.5

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

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

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

7.2.9 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 >

7.2.10 To re-initialize memory by running the MEMDISK program installed in the EPROM instead of the Micro-Controllers internal memory, set the switches on


the CPU piggy-back PCB as follows:

SW1 - position towards CPU SW2 - position towards CPU SW3 - position towards CPU Wait approximately 10 seconds

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

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

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

7.2.12 HyperTerm uses the same serial port as the Hoistman program, so close it

before opening the Hoistman program.


7.3 REPLACING INTERNAL FLASH CARD 7.3.1 Locate the PC processor board mounted to the front panel.

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

7.3.3 The card can now be removed.


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.


8.0 CABLE DRAWINGS 8.1 AMS4A807 CABLE ASSEMBLY – DC POWER IN

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


8.2 AMS4A110 CABLE ASSEMBLY – LOAD PIN

AMS8P057 CONN KPT06A16-8S STR PLUG 1 EA LOAD PIN END AMS4P181 CONN KPSE06J12-1P STR PLUG 1 EA UNIT END AMS4P221 CABLE 20/8 ALPHA 25468 BLACK 20 FT AMS8P060 DUST CAP SHELL SIZE 16 1 EA


8.3 AMS4A108 CABLE ASSEMBLY – ENCODER

AMS1P028 CONN MS3106E-18-1S 1 EA ENCODER END AMS4P182 CONN KPSE06J14-12P STR PLUG 1 EA PANEL END AMS4P221 CABLE 20/8C ALPHA 25468 BLACK 20 FT AMS1P029 DUST CAP MS25042-18DA 1 EA


8.4 CCL / MARK DETECTOR CABLE AMS4A109

ACMU2P21 CONN MS3106E-20-27S 1 EA AMS4P180 CONN KPSE06J12-10S 1 EA AM5KP093 CABLE 20/8 20 FT ACMU2P24 DUST CAP 25042-20DA 1 EA

Documents

AMS4A048 WINCH OPERATORS PANEL USER MANUAL RevD · Raw2 Depth Displays the current uncorrected encoder 2 depth Shim Adds or subtracts depth continually. If 1 is entered then 1 foot