AMS4A047 PANEL USER MANUAL Rev K

36220 FM 1093 P. O. BOX 850 Simonton,Texas 77476 Phone: 281.342.6415 Fax: 281.342.4848 benchmarkwireline.com

OPERATIONS AND MAINTENANCE MANUAL WINCH OPERATORS PANEL PRECISION WIRELINE CONFIGURATION PWL p/n LMS WIN KA Kerr p/n AMS4A047

TABLE OF CONTENTS

SECTION

DESCRIPTION

1.0

GENERAL DESCRIPTION

2.0

DETAILED DESCRIPTION OF FEATURES

3.0

MENU OPERATING INSTRUCTIONS

4.0

SYSTEM OPERATING INSTRUCTIONS

5.0

PARTS LIST

6.0

INTERNAL WIRING AND SETTINGS

7.0

CABLE DRAWINGS AND WIRING DIAGRAMS

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Manual Revision Log Current Revision:

K

Added schematics for mother board Added new signal output cable Added new encoder in cable (blue)

Current Revision:

J

Oct 2004

Previous Revision:

I

Sep 2004

Panel Revision:

C (added +5vdc output)

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1.0

INTRODUCTION 1.1

GENERAL DESCRIPTION This panel is designed 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 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.

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1.2

FEATURES

--

Digital displays for depth, line speed, tension and magnetic marks (or CCL offset)

--

Analog incremental tension meter, 4 inch (108 mm) dia., 270 degree

--

Differential or Incremental tension zero push button switch

--

Excessive tension alarm setting allows operator to set tension alarm to a predetermined value. Contact closure is provided for winch shutdown

--

Zero Depth button - sets depth to 0. Depressing button again resets depth to previous setting. Can only be set when line speed is zero

--

Approaching surface alarm

--

Depth adjust up or down switches. Can only be set when winch is stopped

--

Load pin zero & calibrate controls.

--

Depth & tension saved in non-volatile memory at power loss

--

Outputs for Magnetic Marks, Tension and Encoder to interface to an acquisition system.

--

RS232 Interface for additional control and data outputs.

--

Can be configured for any combination of FEET/METERS or POUNDS/KGS

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1.3

SPECIFICATIONS

1.3.1

WEIGHT

5.5 LBS (2.5 KG)

1.3.2

TEMPERATURE RATING

-20 to 140 deg F

1.3.3

POWER SUPPLY

9 – 30 VDC @ 2 AMP MAX

1.3.4

MAXIMUM LINE SPEED

3000 FT/MIN @ 600 PULSES/FT

1.3.5

MINIMUM LINE SPEED

.6 FT (.18 M) per MINUTE

1.3.6

MAXIMUM LINE TENSION

25,000 LBS (11,340 KG)

1.3.7

DIGITAL TENSION

6 DIGITS WITH 1 LB OR 1KG RESOLUTION

1.3.8

DIGITAL LINE SPEED

6 DIGITS WITH .1 FT OR .1 M RESOLUTION

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2.0 DETAILED DESCRIPTION OF FEATURES 2.1

FRONT PANEL

2.1.1 ANALOG TENSION METER This meter displays either differential or incremental tension. This provides a more visual display of tension change.

2.1.2 INCREMENTAL/TOTAL TENSION SWITCH This switch will change the analog meter from Incremental tension to Differential tension. Incremental tension provides a high resolution tension scale. It must be periodically reset as tension increases or decreases to keep it from pegging out. Differential tension provides a delta tension reading. The meter will slowly reset itself to 0 so it is not necessary to periodically press the reset switch.

2.1.3 METER RESET SWITCH This switch will reset the meter to the 0 (center) position.

2.1.4 DEPTH DISPLAY This meter provides a digital display of depth. AMS4A047 PANEL MANUAL

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2.1.5 LINE TENSION DISPLAY This meter provides a digital display of total line tension.

2.1.6 LINE SPEED DISPLAY This meter provides a digital display of line speed.

2.1.7 MMD / CCL DEPTH DISPLAY This meter provides a digital display of the CCL offset depth. This depth can be set to provide a visual indication of the CCL depth in addition to “bull-plug” depth. If magnetic marks are used, this meter will display the depth of the last mark detected.

2.1.8 MAGNETIC MARK RESET Pressing the MMD reset button clears the last mark setting. The next mark detected will be used to set the window for any subsequent marks.

2.1.9 ZERO DEPTH Pressing this button will reset the depth to 0. Depressing the button again will reset the depth to the previous setting. The Zero Depth button will only work when the line speed is zero (i.e. winch not moving).

2.1.10 MENU Pressing this button will activate the menu software. The software feature to be set will be displayed on the DEPTH display. The features can be toggled through by pressing the menu button until the desired feature is displayed.

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2.1.11 + / - SWITCH This switch is used for different functions. It is used to change the depth setting in either an up or down direction. The winch must be stopped before the depth can be set. In menu mode (see section 3.0) the switch is used to set menu parameters. During logging this switch can also be used to add or subtract depth while moving. Pressing the switch up one time will add .1 feet if in feet mode or .1 meters if in metric mode. Pressing the switch down will subtract depth (depth will be shallower). The rate that the depth is added or subtracted is .1 foot per foot or .1 meter per meter. If the switch is depressed longer, the amount of depth to add or subtract will be increased. This amount to be added or subtracted will be displayed on the depth display. Example – if you continue to hold the switch until .5 is displayed, then .5 feet will be added over the next 5 feet.

2.1.12 ALARM RESET LED AND ALARM This LED is lit and an audible alarm is sounded when the depth is less than 200' (61 m) or what ever value the user has set. This provides a warning to the hoist operator that they are approaching surface and should take care to get the equipment safely out of the well. When the LED is depressed, the alarm will stop but the LED will continue to blink. Once the depth reading is greater than the set value, both the alarm and the LED will turn off. This switch also has a second function. In the event of an overtension condition that sets the overtension relay, this button must be pressed to reset the relay (refer to section 3.1).

2.1.13 ENGLISH / METRIC UNITS These LEDs will indicate if the panel is in English (FEET) or metric (METERS) mode. If the depth is set to English, the English LED will be lit. If the depth is set to Metric the Metric LED will be lit. The tension can be set to English (LBS) or Metric (KG) but it will not light the LED. AMS4A047 PANEL MANUAL

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2.1.14 T-ZERO SWITCH Use this switch to set the tension to 0 at the start of a logging run. This will zero out the tension circuit. The line should be slack through the head at this time.

2.1.15 T-TEST SWITCH Press T-TEST and verify that the panel tension reads 3250 lbs. (1475 kg). This can also be used to verify tension is being properly recorded on acquisition system. 2.2

REAR PANEL

Refer to Section 6.0 for Pin Out information 2.2.1 J1 - 12 – 24 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 North American truck standard voltage, 24vdc is European truck standard voltage). Pin A is positive, pin B is negative.

2.2.2 J2 – ENCODER 1 IN +5 vdc power is provided to encoder 1 and signal is received from encoder 1 on this connector. AMS4A047 PANEL MANUAL

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2.2.3 J3 – ENCODER 2 IN +5 vdc power is provided to encoder 2 and signal is received from encoder 2 on this connector.

2.2.4 J4 – LOAD CELL IN Load Cell excitation voltage is provided to the load pin and signal is received from the load pin on this connector

2.2.5 J5 – MMD IN DC power is provided to the magnetic mark detector and signal is received from the mark detector on this connector.

2.2.6 J6 – RS232 SERIAL INTERFACE This connector provides an RS232 interface from the panel to the acquisition system. This provides a means to control the panel and read data from the panel using a PC. Refer to section 6 for details on using this port.

2.2.7 J7 - SIGNAL OUTPUT Encoder, tension, and magnetic mark signals, processed and some unprocessed are passed through this connector to the acquisition system

2.2.8 J8 - OVER TENSION CONTACT This connector provides a connection to the overtension circuit relay. When an overtension condition is active, the two pins are connected together. In normal position the two pins are open. This feature can be used to interface to the winch unit control system to provide automatic hoist shutdown when an overtension condition is reached.

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3.0 MENU COMMANDS This panel has internal software which allows it to be set for various configurations. To change the settings, press the MENU button. The feature to be set will be displayed on the DEPTH display. Press the MENU button again until the feature you want to set is displayed. The parameters for each feature will be displayed on the LINE TENSION display. Press the +/- switch to cycle through all the available parameters. When the value you want to select is displayed, press the MENU button. ACCEPT will then be displayed. Press + for yes, - for no. Following is a listing of all the available settings. 3.1

TENSION ALARM Functionality: When preset tension value is reached the warning alarm will sound. If the tension alarm is set to a value higher than the over tension shutdown value (see 3.2), then the over tension shutdown value will automatically be set to the same value as the tension alarm. Note: This value can be adjusted “on the fly” without stopping the hoist. The ACCEPT (Yes or No) is not used on this function. Procedure:

Use +/- switch to set the tension alarm setting.

Indication:

TALARM will be displayed on the DEPTH display and the value will be displayed on the TENSION display as it is being set.

Selection:

Each cable size will have a corresponding Tension Alarm setting. Only the setting for the cable size selected can be adjusted.

Note:

The alarm will not sound when using the tension test button.

3.2

DELTA TENSION ALARM

Functionality: When the delta tension setting is reached the alarm sounds. In incremental mode, 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 AMS4A047 PANEL MANUAL

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Procedure: Indication:

3.3

alarm will only sound on a quick change of tension. The Alarm Reset switch must be pressed to reset the over tension relay. Use +/- switch to set the Delta Tension setting. DTALRM will be displayed on the DEPTH display and the value being set will be displayed on the TENSION display as it is being adjusted.

OVER TENSION SHUTDOWN Functionality: When preset tension value is reached the over tension relay is set. The Alarm Reset switch must be pressed to reset the over tension relay. If the over tension shutdown is set to a value lower than the tension alarm value (see 3.1), then the tension alarm value will automatically be set to the same value as the over tension shutdown.

3.4

Procedure:

Use +/- switch to set the tension alarm setting.

Indication:

OVRTEN will be displayed on the DEPTH display and the value will be displayed on the TENSION display as it is being set.

Selection:

Each cable size will have a corresponding Tension Alarm setting. Only the setting for the cable size selected (see menu option 2) can be adjusted.

CABLE SIZE Functionality: Cable size selection automatically sets load pin angle setting for the selected cable size. Wheel size is also automatically set for the selected cable size. If other is selected, the LCA value needs to be entered. This value is based on the bend angle of the cable over the tension wheel. This value is empirically derived and must be furnished by the measuring head manufacturer (Kerr Measurement Systems Inc.). Contact Kerr with the line specifications. Procedure:

Use +/- switch to select cable size.

Indication:

CABLE will be displayed on the DEPTH display and the selections will be displayed on the LINE TENSION display.

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Cable Size Values available 7-32 9-32 5-16 3-8 15-32 SLAM S-SLAM Other OTHER When OTHER is selected, two additional options will be made available. Load Cell Angle (LCANGL) and Wheel Circumference (WHLCIR). LCANGL is used to set the included angle of the cable and provide for different load cell sensitivities. If the load cell is mounted to a top sheave with the cable going around it at 180 degrees, enter 0 as the Load Cell Angle. If the load cell is mounted to a bottom sheave with the cable coming off at a 90 degree angle, enter 90 as the Load Cell Angle. WHLCIR is used to change the circumference of the measuring wheel. This option allows the panel to be set for a measuring head that uses different sized measuring wheels. Options are 0 – 4’. 3.5

DEPTH ADJUST (Shim) Functionality: The shim amount selected will automatically be added or subtracted from the depth input.

3.6

Procedure:

Use +/- switch to set the shim setting.

Indication:

DP-ADJ will be displayed on the DEPTH display and the value will be displayed on the TENSION display as it is being set. The values are feet / thousand. Default value is 0.

DEPTH ALARM Functionality: When Alarm depth value is reached, the alarm will sound and LED will flash. Pressing the LED will turn off alarm but the light will continue to flash. Procedure:

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Use +/- switch to set the depth alarm value. Rev K

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Indication:

AMS4A047 PANEL MANUAL

DALARM will be displayed on the DEPTH display and the value will be displayed on the TENSION display as it is being set. Default value is 200’

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3.7

MMD or CCL Functionality: Either MMD or CCL can be selected. MMD provides the ability to detect magnetic marks. CCL provides a means to display the offset between the CCL depth and the bull plug depth. Procedure:

Use +/- switch to select either MMD or CCL.

3.7.1 CCL Functionality: The CCL depth will be displayed on the MMD meter. This makes it easier to monitor CCL depth in addition to bottom of tool depth. Procedure:

Use +/- switch to set the CCL offset depth

Indication:

CCL will be displayed on the DEPTH display and the value will be displayed on the TENSION display as it is being set.

3.7.2 MMD The following menu options are available. MMDCOR (MMD Correction) Use +/- switch to toggle between ON or OFF When MMD Correction is on, the panel will automatically correct depth to correspond to magnetic mark spacing. SPACNG Use +/- switch to toggle between 100, 25 M, 50 M. DETECT Functionality: If STRONG is selected, only marks greater than 4 gauss will be detected. If ALL is detected, any mark stronger than .3 gauss will be detected. Procedure:

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Indication:

DETECT will be displayed on the DEPTH display and either STRONG or ALL will be displayed on the TENSION display.

Use +/- switch to toggle between ALL and STRONG. WINDOW Functionality: The MMD window determines when the next mark can be detected. The cable must travel at least the distance of the mark spacing (100’, 50m or 25m) – the window setting, before a mark can be detected. Marks can only be detected if they occur within this window. If the window is set for 5' and the mark spacing is 100’, the cable must travel no less than 95' and no more than 105’ from the last mark before a new mark can be detected. Procedure:

Use +/- switch to change MMD window value.

Indication:

MMD will be displayed on the DEPTH display and the window value will be displayed on the TENSION display as it is being set.

Pressing the MMD reset button clears the last mark setting. MMD LOG Functionality: The depth of the first 25 detected marks is stored in memory and can be displayed. Procedure:

Use +/- switch to toggle through all of the marks that have been detected. This starts from the last mark detected. Pressing depth 0 will clear all the stored marks.

Indication:

MMD DP will be displayed on the DEPTH display and the mark depth will be displayed on the TENSION display.

Following is a more detailed explanation of the Magnetic Mark Correction process. AMS4A047 PANEL MANUAL

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The AMS4A047 panel has 3 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 no stretch correction. 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. If the panel output is ‘corrected’ the panel quadrature output will be 3*600 pulses less than the output would have been if the panel output was ‘direct’. MODE 3: Magnetic mark correction with stretch correction. This mode is similar to mode 2 except that the line stretch due to tension is accounted for. The panel is input 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. 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, mmk correction on, window width to 5.1 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 195 and simulate a mark. Advance the panel depth to 305. There should be 18000 pulses given to the system. The AMS4A047 panel added the 5 feet to make up for the error at depth 195.

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3.8

ENCODER SELECT Functionality: This function allows the user to change encoders or utilize two encoders to read the one with the least wheel slippage. Procedure:

Use +/- switch to select which encoder input on the rear panel will be used.

Indication:

ENCSEL will be displayed on the DEPTH display and the encoder selected appears on the Depth display. Selections available a. ENC 1 b. ENC 2 c. BOTH

Note: Encoder 1 will always turn the opposite direction from encoder 2. In direct mode (see section 3.12), the encoder output will be in the same direction as encoder 1. 3.9

ALARM VOLUME Functionality: This setting determines the audio volume of the alarm.

3.10

Procedure:

Use +/- switch to set the volume value from 0 (off) to 100 (max).

Indication:

VOLUME will be displayed on the DEPTH display and the value will be displayed on the TENSION display as it is being set.

DEPTH UNITS Functionality: The depth values will be displayed in the units selected. Procedure:

Use +/- switch to set the DEPTH UNITS setting.

Indication:

DEPTH will be displayed on the DEPTH display. The selection can be toggled between FEET or METERS. The selection will be displayed on the TENSION display. The ENGLISH (green) LED display will be lit when FEET is selected and the METRIC (red) LED will be lit when METERS is selected.

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3.11

TENSION UNITS Functionality: The tension value will be displayed in the units selected.

3.12

Procedure:

Use +/- switch to set the TENSION UNITS setting.

Indication:

TENSION will be displayed on the DEPTH display. The selection can be toggled between POUNDS and KILOGM. The selection will be displayed on the TENSION display.

ENCODER Functionality: The value selected will automatically be used as the encoder input pulses per revolution (PPR) setting.

3.13

Procedure:

Use +/- switch to set the ENCODER Pulse Per Revolution setting.

Indication:

ENCODR will be displayed on the DEPTH display and the value will be displayed on the TENSION display as it is being set.

Selection:

Default value is 1200 (600 ppf or 1968 ppm with a 2' measuring wheel)

ENCODER OUT Functionality: This setting determines which encoder pulses that will be output to the acquisition system. Two options are available, Direct or Corrected pulses. Direct will send out encoder pulses identical to the uncorrected pulses coming from the encoder 1. None of the corrections applied by the panel will be sent to the acquisition system. Correct will send out encoder pulses to the acquisition system that include all the corrections that the panel applies such as Depth Adj (shim), MMD Correction, Wheel Size, etc. Procedure:

Use +/- switch to switch between Direct (DIRECT) or Corrected (CORRECT) pulses.

Indication:

DIRECT or CORECT will be displayed on the DEPTH display.

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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 (Acquisition System, encoder, etc.)

4.3

Set up acquisition system.

4.4

Press T-Zero and verify that panel tension reads 0. Verify tension is recorded on acquisition system.

4.5

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

4.6

Set Tension Alarm value (refer to section 3).

4.7

Set depth adjust value (refer to section 3).

4.8

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

4.9

Press T-Zero to zero the tension value.

4.10

Press T-Test and verify that panel tension reads 3250 lbs (1475 kg). Verify tension is being properly recorded on acquisition system. Note: When the T-Test switch is pressed, the load pin will return a test signal of 3250 lbs. If the button remains pressed for a few seconds, the tension multiplier will be added and the tension value will change and remain at this value for as long as the button is depressed. At this time, the acquisition system can be calibrated.

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.

4.12

While logging, depth can be added or subtracted "on the fly by using the +/switch (refer to paragraph 2.1.11). When stationary, the +/- switch can be used to preset the depth.

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5.0 SPARE PARTS LIST AMS4A047 PANEL WINCH OPERATOR DISPLAY PANEL

Kerr p/n

Description

Qty Reference

AMS4P134E AMS4P110 AMS4P128 ACMU1P06 ACMU1P11 AMS4P020 AMS4P018

PC BOARD AMS40 REV E METER ANALOG DIFF TENSION (+/- 1000 LBS) DISPLAY LED .5" SERIAL 2"X3.5" LED RED DIALIGHT 5V SONALERT #SC628D MALLORY SWITCH MTL-106D ALCO LOCKING SWITCH MPA-106F ALCO PUSH MOM

1 1 4 1 1 2 5

AMS4P044 AMS4P021

SWITCH TOGGLE DPDT MOM OFF MOM SWITCH CAPS ALCO C-22 BLACK

1 3

AMS7P017 AMS4P169 AMS4P179

SWITCH CAP ALCO C-22 RED CONN KPSE02E12-3S RECEPTACLE CONN KPSE02E12-3P RECEPTACLE

1 1 1

MOTHER BOARD M1 D1 – D4 APPROACHING SURF ALARM POWER ON/OFF MENU,T-ZERO,T-TEST,DZERO,METER RESET +/T-ZERO,D-ZERO,METER RESET D-ZERO, MENU J1 – POWER IN J8 – OVERTENSION

AMS4P178 AMS4P166 AMS4P172 AMS4P170 AMS4P041 AMS4P042 AMS4P043

CONN KPSE06J12-3P RECEPTACLE CONN DB25S CONN KPSE02E14-12S RECEPTACLE CONN KPSE02E12-10P RECEPTACLE SWITCH PUSHBUTTON LIGHTED SPST LENS RED C&K SWITCH LED RED FOR C&K PUSHBUTTON SW

1 1 1 1 1 1 1

J8 - MATING CNTR J7 – SIG OUT J2,J3 - ENCODER J4/J5 – MMD, LOAD PIN APPROACHING SURF RED LENS RED LED

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6.0 WIRING DIAGRAMS 6.1

REAR PANEL WIRING

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6.2 MAIN PROCESSOR BOARD

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6.2.1

ENCODER AND MMD INPUTS

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6.2.2 ENCODER OUTPUT AND COM PORT I/O

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6.2.3 LOAD PIN AND TENSION I/O

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6.2.4 JUMPERS – BUTTONS

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6.2.5 POWER SUPPLIES

AMS4A047 PANEL MANUAL

Rev K

Apr 2007

Page 28 of 44

36220 FM 1093 P. O. BOX 850 Simonton,Texas 77476 Phone: 281.342.6415 Fax: 281.342.4848 benchmarkwireline.com

6.2.6 FUSE BOARD AND POWER WIRING Refer to 6.3 for wirelist

AMS4A047 PANEL MANUAL

Rev K

Apr 2007

Page 29 of 44

36220 FM 1093 P. O. BOX 850 Simonton,Texas 77476 Phone: 281.342.6415 Fax: 281.342.4848 benchmarkwireline.com

6.3

INTERNAL WIRING LIST

P2 - Screw Terminal Block P2 -1

BATT +

RED

22

P1 - 1 (FUSE BRD)

P2 -2

BATT -

BLK - B

18

J1 - B

P2 -3

CONTACT CLOSURE N.O.

P2 -4

CONTACT CLOSURE N.C.

GRN - B

18

J8 - A

Tension Contact Closure Back Panel

P2 -5

CONTACT CLOSURE COM

BRN - A

18

J8 - B

Tension Contact Closure Back Panel

BLK

22

SWITCHED POWER

P4 - USER SWITCHES P4 - 2

DCM

BLK

P4 - 6

ZERO DIFF. TENSION

GRY

22

P4 - 7

TEN TEST

GRN

22

SW5A N.O.

P4 - 8

ZERO CAL

BRN

22

SW6 N.O.

P4 - 9

CANCEL DEPTH ALARM

BLU

22

SW10 N.O

P4 - 10

ZERO DEPTH

VIO

22

SW9 N.O.

P4-11

DEPTH ADJ DOWN

BLU

22

SW7 N.O. DN

Dn Contact of SW7

P4-12

DEPTH ADJ UP

ORA

22

SW7 N.O. UP

Up Contact of SW7

One side SW2, SW3, SW4, SW5A, SW6, SW7, SW8, SW9, ENGLISH LED-,SW 10,P1-3VOL SW4 N.O. SW 5 (DPDT)

P5 - SPARE P5 - 1

+5V

RED

22

P1 - 2, P1- 6

ENCODER POWER TO FUSE BOARD

P5 - 2

MENU

YEL

22

SW8

MENU SELECT

P5 - 3

DIFF / INC

GRN

22

SW 3

P5 - 6

MMD RESET

VIO

22

SW 2

P6 - ANALOG IN/OUT P6 - 3

LOAD PIN SIG+

ORA

22

J4 - A

LOAD PIN SIG+

P6 - 4

LOAD PIN SIG-

BLK

22

J4 - E

LOAD PIN SIG-

P6 - 8

ACM

BLK

22

J4 - B

EXCITATION - (GROUND)

P6 - 9

4to20OUT

BRN

22

J7-12

4 to 20 mA to system

P6 - 10

ACM

BLK

22

J7 - 21

TENSION COMMON (TO SYSTEM)

P6 - 11

0-2V OUT (TENSION)

GRAY

22

TENSION OUT+ TO SYSTEM

P6 - 13

TENSION METER -

VIO

22

P6 - 15

DIFF TENSION METER -

YEL

22

J7 - 9 P1-2 VOL BRD M1 -

P6 - 16

DIFF TENSION METER +

BLU

22

M1 +

RED

22

D1 - 4

VOLUME SIGNAL

P7 - COMMUNICATIONS P7 - 6

+ 5 VDC

AMS4A047 PANEL MANUAL

Rev K

Apr 2007

DISPLAY POWER

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P7 - 7

COM2 TXD

ORG

22

D1-5, D2-5, D3-5, D4-5

DISPLAY DATA - FOUR WIRES CONNECTED TOGETHER

P7 - 9

GND

BLK

22

D1-1

DISPLAY GND

P7- 10

COM1 TXD

BLU

22

J6 - 2

TXD OUT

P7 - 11

COM1 RXD

WHT

22

J6 - 3

RXD OUT

P7 - 12

GND

ORN

22

J6 - 5

GND

P8 - QUADRATURE OUT / INDICATORS P8 - 1

METRIC LED -

BRN

22

P8 - 2

METRIC LED+ & 6.8VZKathode

ORN

22

BRN

22

YEL

22

VIO

22

SW 10

+1 (inline with silver plate)

BLU

22

SW 10

-1 (opposite silver plate)

P8 - 3 P8 - 6 P8 - 9 P8 - 10

FET EXCESSIVE TENSION ALM + APPROACHING SURFACE LED APPROACHING SURFACE LED +

METRIC LED KATHODE (-) METRIC LED+ & 6.8VZKathode J7 - 10 P1-1 VOL BRD

METRIC LED ANODE & 6.8VZKathode 6.8VZAnode to ENGLISH LED + MAG MARK COMMON COLLECTOR Beeper

P8 - 11

PHASE 1B*

YEL

22

J7 - 15

Quadrature Out - PHASE B*

P8 - 12

PHASE 1B

BLU

22

J7 - 3

Quadrature Out - PHASE B

P8 - 13

PHASE 1A*

RED

22

J7 - 14

Quadrature Out - PHASE A*

P8 - 14

DCM

BLK

22

J7 - 13

Digital common

P8 - 16

PHASE 1A

ORA

22

J7 - 2

Quadrature Out - PHASE A

P9 - ENCODER 1 P9 - 1

DCM

BLK

22

J2 - L

Encoder Ground

P9 - 5

12 VDC - TO FUSE

YEL

22

P1 - 10

EXCITATION

P9 - 8

ENCODER 1B

BLU

22

J2 - B

Encoder input

P9 - 9

ENCODER 1B *

GRN

22

J2 - E

Encoder input

P9 - 11

ENCODER 1A

ORA

22

J2 - A

Encoder input

P9 - 12

ENCODER 1A*

RED

22

J2 - C

Encoder input

P10 - ENCODER 2 P10 - 1

DCM

BLK

22

J3 - L

Encoder Ground

P10 - 5

12 VDC TO SW5

YEL

22

SW5B - NO

SHUNT CAL Encoder input

P10 - 8

ENCODER 2B

BLU

22

J3 - B

P10 - 9

ENCODER 2B *

GRN

22

J3 - E

Encoder input

P10 - 11

ENCODER 2A

ORA

22

J3 - A

Encoder input

P10 - 12

ENCODER 2A*

RED

22

J3 - C

Encoder input

P11 +/- 15 VDC P11-1

DIG GND

BLK

22

J5 - F

MMD POWER COMMON

P11-3

+5VDC

RED

22

J7 – 5

+ 5VDC OUT TO SYSTEM

P11 - 8

MARK+

VIO

22

J5 - C

MARK IN -

AMS4A047 PANEL MANUAL

Rev K

Apr 2007

Page 31 of 44

36220 FM 1093 P. O. BOX 850 Simonton,Texas 77476 Phone: 281.342.6415 Fax: 281.342.4848 benchmarkwireline.com P11 - 9

MARK-

WHT

22

J5 - D

MARK IN +

P11-10

+15 VDC

ORG

22

P1 - 3

MMD POWER + TO FUSE BOARD

P11-11

STRONG MARK +

BLU

22

J5 - H

STRONG MARK IN -

P11-12

STRONG MARK -

GRAY

22

J5 - G

STRONG MARK IN +

D1 DISPLAY - MMD DEPTH D1-2

GND

BLK

22

D2 - 1

GND OUT

D1-6

+5V OUT

RED

22

D2 - 4

POWER OUT

D2 DISPLAY - DEPTH D2-2

GND

BLK

22

D3 - 1

GND OUT

D2-6

+5V OUT

RED

22

D3 - 4

POWER OUT

D3 DISPLAY - LINE TENSION D3-2

GND

BLK

22

D4 - 1

GND OUT

D3-6

+5V OUT

RED

22

D3 - 4

POWER OUT

12V POWER IN

RED

18

SW1 NO

12V POWER TO PANEL

P1 - 7

SW1 ON/OFF 12V BATT

RED

22

SW1 - NC

SWITCHED POWER

P1 - 4

ENCODER1 PWR FUSED

WHT

22

J2 - J

P1 - 8

ENCODER2 PWR FUSED

GRY

22

J3 - J

P1 - 12

12 VDC POWER (FUSED)

BLU

22

J4 - C

LOAD PIN EXCITATION

P1 - 11

12 VDC POWER (FUSED)

GRN

22

J4 - G

SHUNT CAL

P1 - 5

MMD PWR (+15) FUSED

RED

22

J5 - E

POWER TO MMD

RED

22

P1 - 9

SHUNT CAL (12 VDC)

D4 DISPLAY - LINE SPEED

J1 12V POWER IN J1-A FUSE BOARD

SWITCH 5 (DPDT PUSH BUTTON) SW 5B COM

12 VDC POWER (FUSED)

AMS4A047 PANEL MANUAL

Rev K

Apr 2007

Page 32 of 44

36220 FM 1093 P. O. BOX 850 Simonton,Texas 77476 Phone: 281.342.6415 Fax: 281.342.4848 benchmarkwireline.com

6.4

BACK PANEL CONNECTOR PINOUT POWER INPUT J1 - A J1 - B

BATT + BATT -

ENCODER 1 J2 - A J2 - B J2 - C J2 - E J2 - J J2 - L

ENCODER 1A ENCODER 1B ENCODER 1A* ENCODER 1B * ENCODER1 PWR

ENCODER 2 J3 - A J3 - B J3 - C J3 - E J3 - J J3 - L

ENCODER 2A ENCODER 2B ENCODER 2A* ENCODER 2B * ENCODER2 PWR

LOAD PIN J4 - A J4 - B J4 - C J4 - E J4 - G J4 - J

LOAD PIN SIG+ LOAD PIN POWER LOAD PIN POWER + LOAD PIN SIGSHUNT CAL ENABLE

MAGNETIC MARK J5 - C J5 - D J5 - E J5 - F J5 - G J5 - H

MARK+ MARKMMD POWER + COMMON STRONG MARK STRONG MARK +

RS232 J6 - 2 J6 - 3 J6 - 5

COM1 TXD COM1 RXD COMMON

SYSTEM OUTPUTS AMS4A047 PANEL MANUAL

Rev K

Apr 2007

Page 33 of 44

36220 FM 1093 P. O. BOX 850 Simonton,Texas 77476 Phone: 281.342.6415 Fax: 281.342.4848 benchmarkwireline.com

J7 - 2 J7 - 3 J7 – 5 J7 - 9 J7 - 10 J7 - 13 J7 - 14 J7 - 15 J7 - 21

PHASE 1A PHASE 1B +5vdc OUT 0-10V OUT (TENSION) MARK- (OUT TO SYSTEM) COMMON PHASE 1A* PHASE 1B* COMMON

OVERTENSON J8 - A J8 - B

AMS4A047 PANEL MANUAL

CONTACT CLOSURE N.O. CONTACT CLOSURE COM

Rev K

Apr 2007

Page 34 of 44

36220 FM 1093 P. O. BOX 850 Simonton,Texas 77476 Phone: 281.342.6415 Fax: 281.342.4848 benchmarkwireline.com

6.5

RS232 SERIAL INTERFACE

To connect the panel to a computer, connect a serial cable from the PC to J6 on the rear of the panel. The wiring is as follows: DB9 PIN OUT: 2 = TRANSMIT, 3 = RECEIVE,

5 = GROUND

Run a program such as MS Windows HyperTerm using the following parameters BAUD BITS PARITY STOP

38,400 8 N 1

Press H or ? to display the help screen * * * AMS4A047 Help Screen * * * H,? D L P V W Z U A N M J S B T k p m

-

-

This screen. Display units, direction, depth, speed, and tension. Modify load cell angle (factor) Usage: L1.2 Modify encoder pulses/revolution. Usage: P600 Verify setup status. Modify wheel size (line other) (feet) Usage: W4.0 Preset depth.Usage: Z0.0 |_|--> New depth. Modify units of measure UF(feet);UM(meters);UP(pounds);UK(kg) Depth Alarm. Usage: A100 |_|--> Depth Alarm. Line Size N0 7/32; N1 9/32; N2 5/16; N3 3/8;N4 7/16; N5 15/32; N6 15/32HT; N7 SLAM N8 SLAMHT; N9 SSLAM Tension Alarm. Usage: 'M2500' for 2500 pound alarm. Depth Adjust. Usage: 'J-1' for -1 ft per 1000 feet System PPF Usage: 'S125' for 125 PPFoot to system Enter Mud Weight B12.3 lbs/gal Enter Tool Weight T1000 lbs Toggle stretch correction on/off Display depth and stretch data Use MMK Correction

AMS4A047 PANEL MANUAL

Rev K

Apr 2007

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36220 FM 1093 P. O. BOX 850 Simonton,Texas 77476 Phone: 281.342.6415 Fax: 281.342.4848 benchmarkwireline.com

Press V to display the Verification Screen * * * AMS4A047 Setup Status * * * Software revision Line Size = Depth Units = Depth Units = Depth alarm = Tension alarm = Tension shutdown = Encoder PPR = Depth Adjust = Wheel Circumference = Load Cell Angle Factor = System Pulse per Foot = Cable volume = Cable weight = Weight fluid = Cable weight fluid = Tool weight = Stretch Corr is MMK correction is Line stretch tool =

S4100.01 slam Feet Pounds 100 ft 2400 lbs 3500 lbs 1200 0.0 2.000 feet 1.00 600.0 2118 cubic inches per 1000 feet 1.0 8.300 1.000 1000 OFF OFF 8.3

Press D to display the Data Screen DATA STRING DESCRIPTION 12345678901234567890123456 U D Zddddd.d ssss.s tttttt WHERE: U – UNITS (Depth, Tension) 'E' - English, English, 'G' - English, Metric, 'M' - Metric, Metric, 'F' - Metric, English D - DIRECTION ('U' - UP; 'D' - DOWN; 'S' - STOPPED) Z - ZERO DEPTH REF. ('+' BELOW GROUND; '-' ABOVE GROUND) d - DEPTH s - LINE SPEED t - TENSION - CARRIAGE RETURN, - LINEFEED

AMS4A047 PANEL MANUAL

Rev K

Apr 2007

Page 36 of 44

36220 FM 1093 P. O. BOX 850 Simonton,Texas 77476 Phone: 281.342.6415 Fax: 281.342.4848 benchmarkwireline.com

6.6

DIGITAL DISPLAY SETUP

The four digital displays can be set for address, baud rate, and brightness Two buttons are located on the rear of the display which are used to change these settings. 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 Depth = 3 MMD = 4 Set Baud Rate to 9600 Set Brightness to 15 Digital Display Pinout PINS 1, 2, 7, 9

GND

PINS 4, 6, 8, 10

+5 VDC

PIN 3

TXD

PIN 5

AMS4A047 PANEL MANUAL

Rev K

Apr 2007

RXD

Page 37 of 44

36220 FM 1093 P. O. BOX 850 Simonton,Texas 77476 Phone: 281.342.6415 Fax: 281.342.4848 benchmarkwireline.com

6.7

INTERNAL PROCESSOR BOARD

Changes to the internal processor board are required in two instances. Changing software and changing the default depth and tension unit settings.

6.7.1 Software Modification The software that controls this panel is stored in an EPROM Integrated Circuit located at U2 (see drawing on next page). To upgrade the software to a new version, simply remove the eprom I.C. and install a new eprom I.C. (be careful not to bend the legs during installation). After new software is installed, make sure and "reboot" the panel (refer to step 6.7.3).

AMS4A047 PANEL MANUAL

Rev K

Apr 2007

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36220 FM 1093 P. O. BOX 850 Simonton,Texas 77476 Phone: 281.342.6415 Fax: 281.342.4848 benchmarkwireline.com

6.7.2 Jumpers are used to select default depth and tension units. These units can also be set with the menu commands (see section 3) but when the panel is rebooted, it will be reset to the Jumper settings. Jumper J1 determines the depth units. A shorting bar across J1 will set the units to meters No shorting bar will set the units to feet. Jumper J2 determines the tension units A shorting bar across J2 will set the units to Kilo Grams No shorting bar will set the units to pounds. See drawing on previous page for location of jumpers.

6.7.3

PROCESSOR REBOOT In the event of a panel "lock up" or other malfunction, the processor in the panel can be rebooted by turning off the panel, depressing the T-ZERO and T-TEST buttons simultaneously then turning the power back on while the buttons are depressed. Keep buttons the depressed for at least five seconds after power is restored. When the panel is rebooted, all the menu settings will be returned to the factory default settings. The panel should always be rebooted after new software (eprom) has been installed.

AMS4A047 PANEL MANUAL

Rev K

Apr 2007

Page 39 of 44

36220 FM 1093 P. O. BOX 850 Simonton,Texas 77476 Phone: 281.342.6415 Fax: 281.342.4848 benchmarkwireline.com

7.0 CABLE AND ELECTRICAL DRAWINGS

7.1

AMS4A807 CABLE ASSEMBLY – DC POWER IN

A = RED (+12 VDC) B = BLACK (GND)

Component --------------AMS4P177 AMS4P222

Description -----------------------------CONN KPSE06J12-3S STR PLUG CABLE 20/4C ALPHA 25154 BLACK

AMS4A047 PANEL MANUAL

Rev K

Apr 2007

Qty Required ---------------1 10

UM --EA FT

Page 40 of 44

36220 FM 1093 P. O. BOX 850 Simonton,Texas 77476 Phone: 281.342.6415 Fax: 281.342.4848 benchmarkwireline.com

7.2

AMS4A140 CABLE ASSEMBLY – ENCODER IN (blue)

Component --------------AMS4P184 AMS4P182 AMS4P245 AM5KP113 AMS7P064

Description Qty Required --------------------------------------------CONN MS3106F-16S-1S 7 SOCKETS (encoder end) 1 CONN KPSE06J14-12P STR PLUG (panel end) 1 CABLE 20/4P ALPHA 45294 BLUE 20 DUST CAP MS25042-16DA 1 BUSHING #9779-513-8 AMPHENOL 1

AMS4A047 PANEL MANUAL

Rev K

Apr 2007

UM --EA EA FT EA EA

Page 41 of 44

36220 FM 1093 P. O. BOX 850 Simonton,Texas 77476 Phone: 281.342.6415 Fax: 281.342.4848 benchmarkwireline.com

7.3

AMS4A131 CABLE ASSEMBLY – MMD IN

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

AMS4A047 PANEL MANUAL

Rev K

Apr 2007

UM --FT EA EA EA EA EA

Page 42 of 44

ITEM ---1 2 3 4

36220 FM 1093 P. O. BOX 850 Simonton,Texas 77476 Phone: 281.342.6415 Fax: 281.342.4848 benchmarkwireline.com

7.4

AMS4A132 CABLE ASSEMBLY – LOAD PIN IN

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

AMS4A047 PANEL MANUAL

Rev K

Apr 2007

UM --FT EA EA EA EA

Page 43 of 44

36220 FM 1093 P. O. BOX 850 Simonton,Texas 77476 Phone: 281.342.6415 Fax: 281.342.4848 benchmarkwireline.com

7.5

AMS4A183 CABLE ASSEMBLY – SIGNAL OUT TO COMPUTER SYSTEM

Component --------------C276P352 249994000 AMS4P299

Description Qty Required --------------------------------------------CONN DB25P ITT (to panel) 1 CABLE ALPHA 2219/12C 22GA 25 CONN KPSE06F22-21S STR PLUG (to computer) 1

AMS4A047 PANEL MANUAL

Rev K

Apr 2007

UM --EA FT EA

Page 44 of 44