The URCC is connected to the control system through a 38 m (125 ft) cable. This cable has socket connectors that plug into the URCC on one end and into the main junction box on the other end. The main junction box is the connection point of the wiring for the following components: deck engine, deck transmission, pump controls and pump sensors.
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| Illustration 1 | g00724027 |
(1) Module for pump delivery rate and tachometer (2) Discharge pressure module (3) "LAMP TEST" switch (4) "DECK ENGINE WARNING" light (5) "NEUTRAL TRIPPED WARNING" light (6) "DECK TRANSMISSION WARNING" light (7) "CONVERTER LOCKUP INDICATION" light (8) "DECK PUMP WARNING" light (9) "LINE TEST INDICATION" light (10) Panel illumination lights (11) "PUMP BRAKE" switch (12) "INSTANT NEUTRAL/LINE TEST" switch (13) "EMERGENCY KILL" switch (14) "MASTER POWER" switch (15) "STARTER ENGINE START/RUN/KILL" switch (16) "STARTER ENGINE RPM INC/DEC" switch (17) "DECK START/RUN/KILL" switch (18) "DECK RPM CONTROL" switch (19) "GEAR SELECTOR" switch | |
Module for pump delivery rate and tachometer
The module for the pump delivery rate and the module for the tachometer (1) provide a digital display of the pump delivery rate in barrels per minute. The module also displays the speed of the deck engine in revolutions per minute. The operator must configure the pump delivery rate and the tachometer module. For additional information, refer to the "OEM Service Manual".
Discharge Pressure Module
The discharge pressure module (2) provides a digital display in psi of pump discharge pressure. The module will provide overpressure shutdown protection. The operator must configure the discharge pressure module. The overpressure trip point may be selected by using the module. This module will also allow the operator to calibrate the fluid end pressure transducer. For additional information, refer to the "OEM Service Manual".
"LAMP TEST" Switch
The "LAMP TEST" switch (3) is a two-position toggle switch. The ON position will momentarily establish contact. Moving the switch to the ON position illuminates all the warning lights on the remote panel.
"DECK ENGINE WARNING" Light
The red "DECK ENGINE WARNING" light (4) indicates the following conditions: low engine oil pressure, low coolant levels, high engine oil temperature and high coolant temperature. The "DECK ENGINE WARNING" light is set to activate at the following values:
- Low engine oil pressure is 48 kPa (7 psi) at 600 rpm.
- Low engine oil pressure is 179 kPa (26 psi) at 1900 rpm.
- High coolant temperature is 102 °C (216 °F).
| NOTICE |
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This light operates via pressure switches and temperature switches that are located on the gauges themselves. The gauges are plumbed directly into the engine. These switches do not have adjustable set points. |
"NEUTRAL TRIPPED WARNING" Light
The red "NEUTRAL TRIPPED WARNING" light (5) indicates that the deck transmission has been set to neutral due to a fault condition. The "NEUTRAL TRIPPED WARNING" light will illuminate when the following fault conditions exist:
- Pump discharge overpressure is sensed by the discharge pressure module.
- "EMERGENCY KILL" has been initiated by the discharge pressure module.
- "INSTANT NEUTRAL/LINE TEST" switch is in the INSTANT NEUTRAL position.
In order to turn off the light during an instant neutral condition, the "DECK RPM CONTROL" knob must be turned counterclockwise. Turn the knob past the "RESET START" position.
In order to turn off the light in the case of overpressure or an emergency stop condition, the "RESET" button on the discharge pressure module must be pressed. Also, select the RESET START position on the "DECK RPM CONTROL".
"DECK TRANSMISSION WARNING" Light
The red "DECK TRANSMISSION WARNING" light (6) indicates low oil pressure or high oil temperature of the transmission. The "DECK TRANSMISSION WARNING" light is set for the following conditions:
- Low oil pressure of 207 kPa (30 psi)
- High oil temperature of 110 °C (230 °F)
| NOTICE |
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This light operates via pressure switches and temperature switches that are located on the gauges themselves. The gauges are plumbed directly into the transmission. These switches do not have adjustable set points. |
"CONVERTER LOCKUP INDICATION" Light
The amber "CONVERTER LOCKUP INDICATION" light (7) indicates that the deck transmission is in the lockup mode. When the light is off, the transmission is operating in the converter mode.
"DECK PUMP WARNING" Light
The red "DECK PUMP WARNING" light (8) indicates low oil pressure or high oil temperature of the pump. This light is also illuminated when the pump filter goes into bypass mode. This indicates a filter restriction. The "DECK PUMP WARNING" light is set for the following conditions:
- Low oil pressure of 207 kPa (30 psi)
- High oil temperature of 66 °C (151 °F)
| NOTICE |
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This light operates via pressure switches and temperature switches that are located on the gauges themselves. The gauges are plumbed directly into the pump. These switches do not have adjustable set points. |
"LINE TEST INDICATION" Light
The "LINE TEST INDICATION" light (9) is an amber light. The light indicates that the "INSTANT NEUTRAL/LINE TEST" switch is set to the LINE TEST position. The deck transmission operates in the continuous converter mode at this point.
Panel Illumination Lights
Two panel illumination lights (10) on the face of the universal remote control console provide the operator with complete illumination of the control panel.
"PUMP BRAKE" Switch
The "PUMP BRAKE" switch (11) is a two-position toggle switch. The normal position of the "PUMP BRAKE" switch is downward. The "PUMP BRAKE" switch must be lifted in order to activate the pump brake. This switch is only active while the gear selector is in the NEUTRAL position. The deck engine will not start with the pump brake switch in the ON position.
| NOTICE |
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When the pump brake is on, pump packing lubrication is automatically turned off. |
"INSTANT NEUTRAL/LINE TEST" Switch
The "INSTANT NEUTRAL/LINE TEST" switch (12) is a three-position toggle switch. The INSTANT NEUTRAL position will momentarily establish contact. The other two switch positions maintain contact.
Placing the "INSTANT NEUTRAL/LINE TEST" switch into the INSTANT NEUTRAL position shifts the deck transmission into neutral. This brings the deck engine to idle speed. This also illuminates the "NEUTRAL TRIP" light. The "NEUTRAL TRIP" light will remain illuminated until the "NEUTRAL TRIP" condition is reset.
In order to reset a "NEUTRAL TRIP" condition, the "RESET START" switch must be activated. In order to activate the "RESET START" switch, turn the "DECK RPM CONTROL" switch counterclockwise to the RESET START position. This will extinguish the "NEUTRAL TRIP" light. This will also allow the transmission to return to the selected gear.
In order to reset an overpressure condition, the reset button on the pressure module must be pressed and the "DECK RPM CONTROL" switch must be moved to the RESET START position. Move the "INSTANT NEUTRAL/LINE TEST" switch to the LINE TEST position in order to activate the downshift enable solenoid. Activating the downshift enable solenoid takes the transmission out of the lockup mode. The transmission is in converter mode when the transmission is not in lockup mode.
The LINE TEST position is used in order to test for leaks in the treating line. In order to accomplish the line test, place the switch in the LINE TEST position. Select the desired gear. Slowly increase the speed of the deck engine. When the transmission remains in the converter mode, a smoother line test and a safer line test may be accomplished.
"EMERGENCY KILL" Switch
The "EMERGENCY KILL" switch (13) is a two-position toggle switch. Operation of the switch will immediately shut off the fuel and the air supply to the deck engine. This will result in a shutdown of the system.
To activate the switch, the red switch guard must be lifted. The switch must then be moved to the opposite keyway. A switch guard is necessary in order to prevent an accidental shutdown.
This switch is wired in order to allow the emergency shutdown even if the "MASTER POWER" switch is in the OFF position. In order to reset the switch after an emergency shutdown, manually open the flapper valves of the air inlet shutoff. You must also cycle the "MAIN POWER DISCONNECT" and the "MASTER POWER" switch for at least 15 seconds.
"MASTER POWER" Switch
The "MASTER POWER" switch (14) is a two-position toggle switch. This switch serves as the power switch for the universal remote control console. Activation of the "MASTER POWER" switch will energize certain auxiliary equipment. This will drain the batteries of the pumper while the system is not in operation. Activation of the "MASTER POWER" switch does not affect operation of the "EMERGENCY KILL" switch.
"STARTER ENGINE START/RUN/KILL" Switch
The "STARTER ENGINE START/RUN/KILL" switch (15) is a three-position toggle switch. The START position will momentarily establish contact. The other two switch positions maintain contact.
This switch serves as the remote control switch for the starting engine. When the switch is placed in the START position and the switch is held in the START position, the engine will start. If the switch is placed in the downward "KILL" position, fuel to the starting engine will be shut off, and the starting engine will shut down. The "STARTER ENGINE START/RUN/KILL" switch should remain in the "KILL" position when the engine is not running.
Note: This switch is only active on pumpers that have the capability to use a starting engine.
"STARTER ENGINE RPM INC/DEC" Switch
The "STARTER ENGINE RPM INC/DEC" switch (16) is a three-position toggle switch. The "RPM INC" position and the "RPM DEC" position are momentary contact positions. This switch controls the starting engine's rpm. When the switch is placed in the "RPM INC" position and the switch is held in the "RPM INC" position, the starting engine's speed will increase. When the switch is placed in the "RPM DEC" position and the switch is held in the "RPM DEC" position, the engine speed will decrease.
Note: This switch is only active on pumpers that have the capability to use a starting engine.
"DECK START/RUN/KILL" Switch
The "DECK START/RUN/KILL" switch (17) is a three-position toggle switch. The START position will momentarily establish contact. The other two switch positions maintain contact.
The "DECK START/RUN/KILL" switch functions as the remote control switch for the deck engine. When the switch is placed in the START position and the switch is held in the START position, the starting system will start the deck engine. If the "DECK START/RUN/KILL" switch is placed in the "KILL" position, the fuel to the deck engine will be shut off, and the deck engine will shut down.
The START position of this switch is inactive when the following conditions exist:
- The "PUMP BRAKE" switch is activated.
- The transmission is not in the NEUTRAL position.
"DECK RPM CONTROL" Switch
The "DECK RPM CONTROL" switch (18) is a rotary control that is used to control the speed of the deck engine. Turning the knob in a clockwise direction will increase the speed of the engine.
A reset start switch is included as an integral part of the throttle control assembly. This switch activates at approximately idle speed and functions as a reset for the throttle control in the event of an overpressure or neutral tripped condition. This switch prevents the engine from returning to full throttle speed once the overpressure or neutral tripped condition has been corrected.
"GEAR SELECTOR" Switch
The "GEAR SELECTOR" switch (19) is an eight-position rotary switch that is used in order to select the gear for the deck transmission. The handle of the switch must be depressed in order to select a gear. The downshift enable solenoid is activated when the handle is depressed. Activating the downshift enable solenoid takes the transmission out of the lockup mode. The transmission is in converter mode when the transmission is not in lockup mode. When the transmission is in converter mode, the transmission shifts more smoothly.
| NOTICE |
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The transmission will automatically go into neutral in the event of electrical power failure, overpressure, or neutral tripped conditions. |