Control Console For CPS361 Pumper, Cement Caterpillar

Illustration 1	g00556431
Instrument Panel (1) Digital Pressure Gauge. (2) Slurry King Remote. (3) Process Indicator. (4) Pneumatic Toggle Switch. (5) Temperature And Pressure Gauges. (6) Digital Tachometer/Hourmeter.

Digital Pressure Gauge

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Digital Pressure Gauge

The digital gauge system provides a digital readout of the following features: discharge pressure, pump flow rate, total barrels that are pumped by the front triplex pump and total barrels that are pumped by the rear triplex pump. Additionally, the setting for the over pressure trip is programmed from the digital gauges. The digital gauge system consists of the following components: two gauges, two transducers for the discharge pressure, two rate proximity switches and an interconnect barrier/junction box. The junction box is mounted directly underneath the control console. Although one interconnect junction box is used, both the front digital gauges and rear digital gauges are independent. Pressure signals and flow rate signals are fed from the sensors to the gauges through the junction box. In an over pressure condition, the gauge sends a signal to the control panel that interrupts the signal for engine throttle. This will trip the engine to idle. The engine stays at idle until the pressure has dropped below the threshold for the neutral trip and the throttle has been reset.

Programming The Digital Gauge

The digital gauges can be used for the following functions: calibration, "K-factor" setting for the pump, alarm setting, bar scale setting and zero barrel count. Follow the procedures that are listed below in order to program the digital gauge.

Automatic Calibration Of The Digital Gauge

1. Power UP the Digital Gauge.

2. Press the "MODE" key. "Z BBL" will flash. Press and hold the UP arrow key. While you are holding the UP arrow key, press and hold the DOWN arrow key until "CAL A" flashes on the display. You are now in the menu for special functions.

3. 1. Press "ACK". "ACAL" will flash.

   2. Press "ACK". "4-20" will flash.

   3. Press "ACK". "A/D--L" will flash.

   4. The adc count number should be between 950 and 1028 and the count changes no more than ±5 counts. Press "ACK".

   5. Enter the value for over calibration by pressing the UP arrow key or the DOWN arrow key.

   6. When you are finished with entering the value for over calibration, press "ACK".

   7. Press the "MODE" key until you are back at the main level.

Program "K-Factor" Information

1. Turn on the Digital Gauge.

2. Press the UP arrow key or the DOWN arrow key until "BPM" is displayed.

3. Press the "MODE" key. "Z BBL" will flash. Press and hold the UP arrow key. While you are holding the UP arrow key, press and hold the DOWN arrow key until "CAL D" flashes on the display. You are now in the menu for special functions.

4. Press the "ACK" key. "KFACT" will flash on the display. Press "ACK".

5. Select the desired "K-factor" by pressing the UP arrow key or the DOWN arrow key. Press "ACK".

6. Press the "MODE" key until you get back to the main level.

Program The Alarm Setting

1. From the main level, press the "MODE" key.

2. Press the DOWN key. "ALMHI" will flash.

3. Press "ACK". Enter the value for the alarm setting by pressing the UP arrow key or the DOWN arrow key. When the alarm setting is entered, press "ACK" until you are back at the main level. Failure to press "ACK" will result in failed setting.

When discharge pressure exceeds the alarm setting, the digital gauge will bring the unit to idle.

Change The Display For The Bar Scale

1. The high value for the bar scale is automatically calibrated to the high value for the alarm.

2. The low value for the bar scale can be set to a value that is not zero by doing the following steps:

   1. From the main level, press the "MODE" key. "Z BBL" will flash.

   2. Press the UP arrow key or the DOWN arrow key until "BAR" flashes.

   3. Press "ACK" and change the low value for the bar scale by pressing the UP arrow key or the DOWN arrow key.

   4. Press "ACK" in order to save the number.

   5. Press the "MODE" key until you are back at the main level.

Zero The Barrel Count

1. From the main level, press the "MODE" key. "Z BBL" will flash on the display.

2. Press "ACK". "SURE?" will flash. If you want to zero the count, press "ACK". If you do not want to zero the count, press "MODE" until you are back at the main level.

3. When the control system is powered down, the barrel count is automatically saved.

Over Pressure Condition

The digital gauge system works with the control panel in order to protect the CPS361 Cement Pumper from over pressure. When a discharge pressure signal from the pump exceeds the setting for the over pressure trip in the gauge, the gauge will activate the over pressure alarm. An alarm signal is displayed on the gauge. The gauge sends a signal to the control panel which interrupts the signal for the engine throttle. This will instantly bring the engine to idle until the over pressure condition is reset. In order to reset a over pressure trip, the control knob for the throttle that is located on the control panel must be rotated counterclockwise to the idle position. This will activate the reset switch that is inside the throttle potentiometer. The unit will reset after these two conditions are met:

• The pressure has dropped below the setting for the over pressure.

• The throttle has been placed in the reset position.

Throttle control will resume normally.

Slurry King Remote

Illustration 3	g00556515
Slurry King Remote

The Slurry King Remote is displayed on the instrument panel of the control console. However, this module is provided from Azonix as part of the DCS Control System that is incorporated in the Azonix Pro Panel. The Slurry King Remote includes 4 LED indicators and an auto/manual push button. The function of each component is described below.

"Density OKAY" LED - The "Density OKAY" LED lights when the density of the mix is within 0.2% of the desired setting.

"Alarm Aux" LED - The "Alarm Aux" LED lights when an alarm condition exists. There are two conditions that will enable the "Alarm Aux" LED. When there is a "over Alarm" or "Low Alarm", the LED will FLASH. This allows the operator to make corrections to the operation. When there is a "over over Alarm" or "Low Low Alarm", the LED will LIGHT CONTINUOUSLY.

"AUTO" LED - This indicator is green when the DCS Control System is in the automatic mode. This indicates that the control software governs the process.

"MAN" LED - This indicator is red when the DCS Control System is in the manual mode. This means that the operator has control of the process from the cement metering valve.

"AUTO/MAN" Push Button - This push button allows the operator to toggle between automatic mode and manual mode.

Process Indicator

Illustration 4	g00556517
Process Indicator

The process indicator is used to display the actual density of the cement mixture. The micromotion transmitter is used to transmit the signal. In order to indicate the density, the display uses a signal that is 4 to 20 mA. Additionally, the unit uses the same signal for internal power. The default scale for the process indicator is 0 lbs/gal at 4 mA and 25 lbs/gal at 20 mA. This can be adjusted or corrected. In order to program the process indicator, follow the procedure that is listed:

1. Apply a DC voltage with 4 mA to the "+" and "-" terminals of the indicator. Set the indicator to zero by using the zero potentiometer.

2. Apply a DC voltage with 20 mA to the "+" and "-" terminals of the indicator.

3. Adjust the span potentiometer until the LED displays the desired full scale reading.

4. Apply a DC voltage with 4 mA to the indicator. Check and adjust the zero reading. If you need to zero the indicator again, repeat step 2 and step 3.

5. If necessary, adjust the location of the decimal point by using the switch that is on the back of the panel.

Pneumatic Toggle Switch

Pneumatic toggle switches are used to control piping valves throughout the CPS361 Cement Pumper. When the switch is in the DOWN position the valve is closed. When the switch is in the UP position the valve is open. A diagram of the piping system is also included on the control panel in order to help the operator follow the flow. Additional pneumatic valves that are located on the lower portion of the panel are included in the control console. The quick cement shutoff valve and slurry recirculation valve use large pilot valves. All valves can be serviced by opening the console panels.

Temperature And Pressure Gauges

Gauges are used by the control console to monitor parameters for systems. The gauges are located on the lower portion of the instrument panel. The gauges are separated into two sections. The gauges provide a mechanical reading of temperature or pressure. The gauges also have an internal switch that activates the "Check Unit" LED on the control panel. The switch will activate when a parameter has exceeded the normal operating limits. When this occurs, the operator should find the parameter that is out of range. Then make adjustments to the process in order to avoid a possible failure of a component. See Table 1 for more information on the gauges.

Digital Tachometer/Hourmeter

Illustration 5	g00556551
Digital Tachometer/Hourmeter

The Digital Tachometer/Hourmeter is used to display engine speed and total engine hours. The meter is self-powered. The meter is composed of the display and a magnetic pickup. The two components are designed to work together in order to provide a display when the engine speed is above 600 RPM. The tachometer has two modes that are available to the operator, run mode and configuration mode. When the unit is started, the display will show the engine RPM. In order to view the engine hours, momentarily press and release the push button that is located on the face of the meter. After 20 seconds, the unit will display the RPM. The tachometers are programmed during assembly. However, if reprogramming is necessary, the unit will need to be placed into configuration mode. To enter the configuration mode, press and hold the push button for at least 10 seconds during the first 30 seconds of power up. This can be accomplished by starting the engine. Then press and hold the push button for the display within 30 seconds. The display will show "ProG?". Press the "Select" button. Release the button within a half of a second. The unit will enter the configuration mode. If you have reached this screen accidentally, press and hold the push button for more than 10 seconds in order to return to the run mode. Once you have entered configuration mode, follow the instructions that are listed below in order to program the tachometer.

1. "SSEL" Speed Select Screen

   The "SSEL" parameter should be 4. Press and hold the push button for at least 1 second in order to toggle the digit. Set the digit at 4. Press and release the push button within a half of a second in order to proceed to the next step.

2. "Exxx" Events Screen

   The number of events that occur in every revolution is displayed on the screen. For the control system on the CPS361 Cement Pumper, this is equal to the number of flywheel teeth on the engine. The 3176C has 113 teeth. The digit that is blinking is the first digit that should be programmed. In order to change the value of the blinking digit, press and hold the push button. The value of the digits will begin to increment. When the desired value has been obtained, release the push button. In order to move to the next digit, press and release the push button within a half of a second. The next digit will begin to blink. Continue this procedure until the digits read "113". Press and release the push button within a half of a second in order to move to the next step.

3. "HSEL" Hour Select Screen

   The "HSEL" parameter should be 1. This will enable the hourmeter to count upward. Press and hold the push button for at least 1 second in order to toggle the digit until the display reads "1". In order to proceed to the next step, press and release the push button within a half of a second.

4. Reset The Hourmeter Screen

   The hourmeter can be reset to zero. Follow the procedure that was in step 2. The meter should read "00000". Once the meter is set, press and release the push button within a half of a second. Proceed to the next step.

5. "TRIP" Value

   This feature is not used on the CPS361 Cement Pumper. Move out of this screen. Press and release the push button within a half of a second.

6. "PROG?"

   The digital tachometer is now programmed. To return to the RUN MODE, press and hold the push button for at least 10 seconds.