Installation Procedure for the Pump Electronic Monitoring System for Well Stimulation Pumps {6002, 7490} Caterpillar

Well Pump

WS223 (S/N: SR31-UP)

WS223 SS (S/N: BM31-UP)

WS223 XD (S/N: SR41-UP)

WS255 (S/N: SR51-UP)

WS255 SS (S/N: AE31-UP; BM51-UP)

WS255 XD (S/N: SR61-UP)

WS273 XD (S/N: DG21-UP)

WS305 XD (S/N: EA21-UP)

WSF223 (S/N: FN41-UP; FNL1-UP)

WSF223 SS (S/N: BM41-UP; BM81-UP)

WSF223 XD (S/N: FN31-UP; FNM1-UP)

WSF243 SS (S/N: RX21-UP; RX31-UP; RX41-UP; RX51-UP)

WSF243 XD (S/N: FN91-UP; FNC1-UP; FND1-UP; FNE1-UP)

WSF253 SS (S/N: RWC1-UP; RWD1-UP)

WSF253 XD (S/N: FN81-UP; FNT1-UP)

WSF255 (S/N: AE51-UP; FN51-UP; FN61-UP; FN71-UP)

WSF255 SS (S/N: AE41-UP; BM61-UP; BM71-UP; BM91-UP)

WSF255 XD (S/N: AE21-UP; FN21-UP; P231-UP; FNP1-UP)

WSF273 XD (S/N: DG41-UP; DG51-UP; DG61-UP)

WSF275 SS (S/N: RX61-UP; RX71-UP; RX81-UP; RX91-UP)

WSF275 XD (S/N: FNB1-UP; FNF1-UP; FNG1-UP; FNH1-UP)

WSF305 XD (S/N: EA41-UP; EA51-UP; EA61-UP; EA71-UP)

WSP223 (S/N: FNJ1-UP)

WSP255 (S/N: FNK1-UP)

WSP273 (S/N: DG31-UP)

WSP305 (S/N: EA31-UP)

Introduction

This Special Instruction is intended for both Caterpillar and non-Caterpillar products. This Special Instruction will provide instructions for installing and configuring the Pump Electronic Monitoring System (PEMS) onto Caterpillar and third party well stimulation pumps.

This system is designed to monitor the operating conditions of the pump and provide the operator with feedback to extend the service life of both the power end and the fluid end.

Do not perform any procedure in this Special Instruction until you have read the information and you understand the information.

Safety Section

Work safely. Most accidents that involve product operation, maintenance, and repair are caused by failure to observe basic safety rules or precautions. An accident can often be avoided by recognizing potentially hazardous situations before an accident occurs.

A person must be alert to potential hazards. This person must also have the necessary training, skills, and tools to perform these functions properly.

Safety precautions and warnings are provided in this instruction and on the product If these hazard warnings are not heeded, bodily injury or death could occur to you or the other persons.

Caterpillar cannot anticipate every possible circumstance that might involve a potential hazard. The warnings in this publication and on the product are, therefore, not all inclusive. You must not use this product in any manner different from that considered by this manual without first satisfying yourself that you have considered all safety rules and precautions applicable to the operation of the product in the location of use, including site-specific rules and precautions applicable to the work site. If a tool, procedure, work method, or operating technique that is not specifically recommended by Caterpillar is used, you must satisfy yourself that it is safe for you and for others. You should also ensure that you are authorized to perform this work, and that the product will not be damaged or become unsafe by the operation, lubrication, maintenance, or repair procedures that you intend to use. The information, specifications, and illustrations in this publication are based on information that was available at the time that the publication was written, The specifications, torques, pressures, measurements, adjustments, illustrations, and other items can change at any time. These changes can affect the service that is given to a product. Obtain the complete and most current information before you start any job. Cat dealers have the most current information available.

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Do not operate or work on this machine unless you have read and understand the instructions and warnings in the Operation and Maintenance Manual. Failure to follow the instructions or heed the warnings could result in injury or death. Contact any Caterpillar dealer for replacement manuals. Proper care is your responsibility.

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Improper operation of an access platform could result in injury or death. Operators must carry out their duties properly and follow all instructions and guidelines given for the machine and access platform.

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Accidental engine starting can cause injury or death to personnel working on the equipment. To avoid accidental engine starting, disconnect the battery cable from the negative (−) battery terminal. Completely tape all metal surfaces of the disconnected battery cable end in order to prevent contact with other metal surfaces which could activate the engine electrical system. Turn the battery disconnect switch to the OFF position and lockout the battery disconnect switch with a safety lock. Place a Special Instruction, SEHS7332, "Do Not Operate" tag at the start switch and battery disconnect location to inform personnel that the machine is being worked on.

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Care must be taken in handling lithium batteries. Lithium batteries are not a serviceable part. Personal injury can result from battery exploding. Caution must be used because there is risk of an explosion if the battery is replaced by an incorrect type. Do not dispose of battery or batteries in a fire. The battery is capable of exploding and emitting caustic chemicals. Dispose of used batteries according to federal and local laws.

Reference Section

Operation and Maintenance Manual, SEBU9149, Well Stimulation Pumps

Special Instruction, REHS8177, Troubleshooting for Caterpillar Well Stimulation Pumps

Special Instruction, M0092311, Power End Filtration Installation for Well Stimulation Pumps

Systems Operation and Troubleshooting, M0078614, Well Stimulation Pump Electronic Monitoring System

Required Parts

The Pump Electronic Monitoring System (PEMS) kit can be installed on both Caterpillar branded well stimulation pumps and third party well stimulation pumps. The parts included in the PEMS kit can be used to install on either type of well stimulation pump. The PEMS kit includes all the hardware required to complete the installation, however, additional hardware may be required for specific applications.

PEMS Kit - 519-5726 Pump Monitoring Wiring Gp

Components Not Included in the PEMS Kit

Block Diagram and System Components

Illustration 1	g06334770

Installation Procedure

Identify a mounting location for the 491-6842 Electronic Control Module (A6:P1 ECM). The ECM should only be mounted on the power end of the well stimulation pump, or remotely. Measure the location to ensure correct spacing for the ECM "footprint" and the wiring harness routing. The ECM, must be mounted in a location that will not allow exposure to temperatures above 85° C (185° F). If the temperature at the location is unknown, mount the ECM in a location that can be properly ventilated. Determine the appropriate mounting method for each specific application. The ECM must be shock mounted.

The ECM is normally mounted on the driveshaft side of the well stimulation pump. Attachment of the ECM and bracket to the floor of the trailer is not recommended. The ECM and the ECM bracket should be mounted to a single component on the power end or other rigid surface, clear of routine maintenance operations.

Certain components in this kit must be welded onto the pump to complete the installation. Follow all the guidelines for welding. Refer to Operation and Maintenance, SEBU9149, Welding on Machines and Engines with Electronic Controls - Well Stimulation Pumps.

Note: Ensure that power is disconnected from the battery during the beginning steps of the installation.

Note: Pictures show approximate locations of component installation.

Components that must be welded onto the Well Stimulation Pump

Illustration 2	g06149968
(1) 8D-3508 Boss

Illustration 3	g06210958
Dimensions for welding the bosses onto the pump cover. (A) 325 mm (12.795 inch) (B) 168 mm (6.614 inch) (C) 287 mm (11.299 inch) (D) 200 mm (7.874 inch) (E) 175 mm (6.889 inch)

1. Remove the cover from the pump to weld bosses (1). Set aside associated hardware for reuse. Refer to the appropriate Disassembly and Assembly guide for additional information.

2. Weld 5 bosses (1) onto the pump cover to mount the 517-7130 Bracket As. Follow the instructions above to make sure that the ECM is mounted in a ventilated location.

   Note: Use Loctite 243 Threadlocker on the cover bolts.

3. Reinstall the cover onto the pump with the original hardware. Refer to the appropriate Disassembly and Assembly guide for additional information.
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   Illustration 4	g06155864
   (1) 8D-3508 Boss (2) 511-9831 Boss

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   Illustration 5	g06325745
   Dimensions for welding the bosses onto the suction manifold. (F) 45 mm (1.772 inch)

4. Weld 3 bosses (1) onto the suction manifold to install the vibration sensors. To weld these bosses onto the suction manifold, the suction manifold may have to be removed for clearance. Refer to Disassembly and Assembly, UENR3290, Manifold (Suction) - Remove and Install for additional information.
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   Illustration 6	g06325739
   Dimensions for welding the bosses onto the suction manifold. (G) This dimension depends on the geometry of the fluid end and the geometry of the intake manifold.

5. Weld 1 boss (2) vertically onto the top of the suction manifold to install the 502-8275 Pressure Sensor.

   Note: The boss needs to be such that the sensor will clear the fluid end when installed. Attempt to stay clear of the weld joint of the flange as drilling will be more difficult. This boss can also be up to 45 degrees off vertical to clear fluid end.

6. Drill a 1/4 inch drill through the suction manifold at location in Illustration 6. Weld boss with 1/4 inch through hole centered. Remove any debris from the suction manifold.

7. Cover all 4 bosses with tape or install sensors before painting the suction manifold to prevent paint in threads. Do NOT paint the mounting surface for the sensors.

Component Installation

Lube Oil Pressure and Temperature Sensor Installation

Illustration 7	g06154881
(1) 117-0291 Adapter (2) 5P-1907 Cross (3) 005-8615 Pipe Nipple (4) 284-3468 Adapter

Note: The lube oil and temperature sensor must be installed on the side of the inlet side of the power end lube system.

1. Remove the lube oil supply hose from the lube bar fitting on the oil inlet side of the pump (if necessary).

2. Use Loctite 577 Thread Sealant on the threads of pipe nipple (3). Install the pipe nipple into the existing tee or cross fitting.

3. Use Loctite 577 Thread Sealant on the threads of cross (2). Install the cross onto pipe nipple (3). The cross should be at a horizontal angle if possible.

   Note: The pressure sensor cannot be mounted vertically on the bottom of the cross or the pressure sensor will not accurately measure the pressure in the lube system.

4. Use Loctite 577 Thread Sealant on the threads of adapter (1). Install the adapter into the bottom-most side of cross (2).

5. Use Loctite 577 Thread Sealant on the threads of adapter (4). Install the adapter into the top most of the cross (2).
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   Illustration 8	g06154884
   (1) 117-0291 Adapter (4) 284-3468 Adapter (5) 320-3065 Pressure Sensor Gp (6) 3J-1907 O-Ring Seal (7) 106-0735 Temperature Sensor Gp (8) 3K-0360 O-Ring Seal

6. Install one pressure sensor (5) and one O-ring (6) into adapter (1).

   Torque pressure sensor . . . . . . . . . . 34 N·m (25 lb ft)

7. Install one temperature sensor (7) and one O-ring (8) into adapter (4).

   Torque temperature sensor . . . . . . . 20 N·m (15 lb ft)

8. Reinstall the lube supply oil hose into the cross if the hose was removed.

9. Plug the open end of the cross if there are no lines going to the cross. If available, reuse the plug removed from the lube rail into the end of the 117-0291 Adapter.

Speed Sensor Installation

1. The speed sensor and mounting bracket should be installed on the same side of the pump as the ECM. Itis recommended to install the ECM onto the driveshaft side of the well stimulation pump.
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   Illustration 9	g06150017

2. Remove the lube oil supply hose and the fitting from the lube oil supply bushing. Drain the oil into a suitable container for storage or for disposal.

3. To install the speed sensor onto the well stimulation pump, the lube oil bushing into the crankshaft of the power end must be removed. Remove 36 mm nut that connects the lube oil supply bushing to the crankshaft on the power end. Remove the oil supply bushing.
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   Illustration 10	g06150023

4. Remove and set aside the 5 bolts that hold the oil seal housing in place around the oil bushing.
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   Illustration 11	g06178890
   (9) 518-1668 Bracket As

5. Install bracket (9) around the oil bushing. Install the original 5 bolts back into their proper locations to hold the bracket.

   Torque bolts . . . . . . . . . . . . . . . . . . . 47 N·m (35 lb ft)

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   Illustration 12	g06178893
   (10) 518-3141 Gear

6. Install gear (10) onto the oil bushing. Leave the 3 010-2571 Socket Setscrews on the timing gear loose.
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   Illustration 13	g06178894
   (9) 518-1668 Bracket As (11) 527-8908 Cable As (12) 535-0458 Speed Sensor Gp

7. Install speed sensor (12) into bracket (9) until there is an air gap of 2 mm (0.079 inch) or less between the sensor pickup and the timing gear. Confirm uniform clearance between the timing gear and the 6 bolts directly behind the gear.

   Tighten the jamb nuts on either side of the speed sensor to lock the sensor in place.

   Torque speed sensor jamb nuts. . . . . 25 N·m (18 lb ft)

8. Plug (11) into speed sensor (12).
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   Illustration 14	g06155855
   Plunger at top dead center.

9. With the transmission in neutral, rotate the pump to the top dead center position for the plunger located closest to the driveshaft end. The plunger will be completely extended into the fluid end.
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   Illustration 15	g06178896

10. Align the timing gear with the center of the sensor making sure it does not contact the bolt holding the 518-1668 Bracket As.

    Rotate the timing gear until the hole in the timing gear is in alignment with the hole in the 518-1668 Bracket As. Tighten the socket setscrews to seat the timing gear onto the lube oil bushing.

    Torque set screws . . . . . . . . . . . . . . . . 12 N·m (9 lb ft)

11. Reinstall the lube oil supply bushing back onto the crankshaft. Leave the lube oil supply hose disconnected.

    Torque lube oil supply bushing . . . . . 60 N·m (44 lb ft)

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    Illustration 16	g06348341
    (13) 540-0395 Cover (14) 4F-4879 Bolt (15) 5M-2894 Hard Washer

12. Attach two covers (13) to the 518-1668 Bracket As using the 2 bolts (14) and 2 washers (15) per cover.

    Torque bolts . . . . . . . . . . . . . . . . . . . . 12 N·m (9 lb ft)

13. Reinstall the lube oil supply fitting hose onto the lube oil supply bushing.

Vibration Sensor Installation

Illustration 17	g06150038
(16) 502-8278 Detonation Sensor Gp (Vibration Sensor)

1. Install 3 vibration sensors (16) into the 3 8D-3508 Bosses that were welded onto the suction manifold.

   Torque vibration sensors . . . . . . . . 15 N·m (11 lb ft)

Suction Pressure Sensor Installation

Illustration 18	g06150039
(17) 502-8275 Pressure Sensor

1. Use Loctite 577 Thread Sealant on the threads of suction pressure sensor (17). Install the suction pressure sensor into the 511-9831 Boss that was welded onto the suction manifold.

2. Tighten the sensor by hand. Once the sensor is hand tight, turn the sensor an extra full turn to seat the sensor in the suction manifold.

Discharge Pressure Sensor Installation

Illustration 19	g06150040
(18) 502-8276 Pressure Sensor

Note: If a gauge tower is not present on the pump, a gauge tower must be installed. Refer to the optional parts list for the correct parts to order.

1. Install discharge pressure sensor (18) onto gauge tower.

2. Use a hammer union fitting to tighten the sensor down by hand to the gauge tower, ensuring the sensor remains level.

3. Tighten the hammer union fitting onto the gauge tower using a large hammer.

ECM Installation

Illustration 20	g06198476
(15) 5M-2894 Hard Washer (19) 517-7130 Bracket As (20) 0S-0509 Bolt (21) 352-3968 Clip

1. Attach bracket (19) to the 4 8D-3508 Bosses that were welded onto the pump with 4 bolts (20), 4 washers (15), and 1 clip (21). Refer to Illustration 20 for the correct location of the clip.
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   Illustration 21	g06198478
   (22) 453-1029 Electronic Control Gp (A5:P1 ECM) (23) 2T-2007 Spacer (24) 8T-9655 Isolation Mount

2. Install 4 spacers (23) and 8 isolation mounts (24) into ECM (22).
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   Illustration 22	g06198481
   (15) 5M-2894 Hard Washer (19) 517-7130 Bracket As (22) 491-6842 (A6:P1 ECM) (25) 0S-1590 Bolt (26) 132-5789 Clip (27) 5P-1075 Hard Washer (28) 4P-8134 Clip

3. Attach the top corners of ECM (22) to bracket (19) with 1 bolt (25), 1 washer (15), 1 clip (26), and 1 washer (27).

   Note: The 5P-1075 Hard Washer is installed between the 8T-9655 Isolation Mount and the clip.

4. Attach the bottom left corner of ECM (22) to bracket (19) with 1 bolt (25), 1 washer (15), 1 clip (28), and 1 washer (27).

   Note: The 5P-1075 Hard Washer is installed between the 8T-9655 Isolation Mount and the clip.

5. Attach the bottom right corner of ECM (22) to bracket (19) with 1 bolt (25) and 1 washer (27).
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   Illustration 23	g06198483
   (29) 3S-2093 Cable Strap (30) 515-0551 Harness As (31) 0S-1615 Bolt (32) 5P-0537 Hard Washer

6. Attach the ECM ground strap loosely to the weld nut of the 517-7130 Bracket As with 1 bolt (31) and 1 washer (32).
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   Illustration 24	g06198496
   (30) 515-0551 Harness As (33) 153-3568 Bolt

7. Attach wiring harness (30) to the ECM. Route the wiring harness over the top of the ECM, and down the right side.

8. Install the 31-pin connector of wiring harness (30) into the downward hole on the 517-7130 Bracket As and securing the connector with the nut that comes on the receptacle.

9. Attach the 6-pin power/ground and CAN supply pin of wiring harness (30) into the top hole on the right side of the 517-7130 Bracket As with 2 bolts (33).

10. Install the 9-pin service port connector of wiring harness (30) into the bottom hole on the right side of the 517-7130 Bracket As and securing the connector with the nut that comes on the receptacle.

11. Secure wiring harness (30) to the 132-5789 Clips and the 352-3968 Clip inside the 517-7130 Bracket As.

Wiring Harness Installation

Illustration 25	g06198500
(29) 3S-2093 Cable Strap (30) 515-0551 Transmission Harness As (31) 0S-1615 Bolt (32) 5P-0537 Hard Washer (34) 502-8277 Pump Harness As (35) 206-1346 Cable Strap

1. Attach wiring harness (34) to wiring harness (30). If the ECM is being mounted in a location where the wiring harness cannot reach the necessary points, the 508-2039 Wiring Harness (15 ft. Wiring Harness Extension) can be used.

   Attach the ground wiring of wiring harness (34) and the ground strap of the ECM to the weld nut of 517-7130 Bracket As.

   Note: Ensure that the grounding location is free of paint, dirt, and debris.

2. Install cable strap (35) into the 8D-3508 Boss.

3. Secure wiring harness (34) to cable strap (35).

4. Plug the speed/timing sensor into wiring harness (34).

5. Secure wiring harness (34) and the speed/timing sensor to the 4P-8134 Clip with one cable strap (29).

6. Secure wiring harness (34) to the handle on the 434-9943 Cover with one cable strap (29).
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   Illustration 26	g06325812
   (15) 5M-2894 Hard Washer (19) 517-7130 Bracket As (20) 0S-0509 Bolt (36) 528-3029 Identification Plate (37) 517-7127 Cover

   Note: Use Loctite 243 Threadlocker on the cover bolts.

7. Install cover (37) onto bracket (19) with 4 bolts (20) and 4 washers (15).

8. Install identification plate (36) onto cover (37).
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   Illustration 27	g06198508
   (15) 5M-2894 Hard Washer (26) 132-5789 Clip

   Note: Use Loctite 243 Threadlocker on the cover bolts.

9. Attach 4 clips (26) and 4 washers (15) to the pump with the original bolts.

   Note: The washers are installed on top of the clips.

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   Illustration 28	g06325816
   (26) 132-5789 Clip (29) 3S-2093 Cable Strap (34) 502-8277 Pump Harness As (38) 508-5818 Sensor Harness As (39) 508-4266 Sensor Harness As (40) 508-4265 Wiring Harness

10. Plug wiring harnesses (38), (39), and (40) into wiring harness (34).

11. Secure wiring harnesses (38), (39), and (40) to clips (26) with one cable strap (29) per clip.
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    Illustration 29	g06325818
    (40) 508-4265 Wiring Harness

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    Illustration 30	g06325821
    (17) 502-8275 Pressure Sensor (40) 508-4265 Wiring Harness

12. Route wiring harness (40) to suction pressure sensor (17). Plug the wiring harness into the suction pressure sensor.

13. Secure wiring harness (40) with the 3S-2093 Cable Straps as needed.
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    Illustration 31	g06325822
    (16) 502-8278 Detonation Sensor Gp (Vibration Sensor) (38) 508-5818 Sensor Harness As

    Note: Fasten the wiring harness for the vibration sensor to the stay rod.

14. Route wiring harness (38) to vibration sensors (16). Plug the wiring harness into the vibration sensors.

15. Secure wiring harness (38) with the 3S-2093 Cable Straps as needed.
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    Illustration 32	g06325826
    (18) 502-8276 Pressure Sensor (39) 508-4266 Sensor Harness As

16. Route wiring harness (39) to discharge pressure sensor (18). Plug the wiring harness into the discharge pressure sensor.

17. Secure wiring harness (39) with the 3S-2093 Cable Straps as needed.
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    Illustration 33	g06198523
    (15) 5M-2894 Hard Washer (21) 352-3968 Clip (26) 132-5789 Clip

    Note: Use Loctite 243 Threadlocker on the cover bolts.

18. Attach 5 clips (21) onto the pump with the original bolts.

19. Attach 3 clips (26) and 3 washers (15) onto the pump with the original bolts.

    Note: The washers are installed on top of the clips.

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    Illustration 34	g06325829
    (5) 320-3065 Pressure Sensor Gp (7) 106-0735 Temperature Sensor Gp (21) 352-3968 Clip (29) 3S-2093 Cable Strap (34) 502-8277 Pump Harness As (41) 200-6345 Mount

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    Illustration 35	g06325832
    (22) 352-3968 Clip (27) 132-5789 Clip (30) 3S-2093 Cable Strap (35) 502-8277 Pump Harness As (41) 200-6345 Mount

20. Route wiring harness (34) to pressure sensor (5) and temperature sensor (7). Plug the wiring harness into the pressure sensor and the temperature sensor.

21. Secure wiring harness (34) to clips (21) and (26) with 1 cable strap (29) per clip.

22. Secure the wire of temperature sensor (5) and wiring harness (34) to the 5P-1907 Cross with 1 cable strap (29).

23. Attach one mount (41) to the 494-1116 Pipe on the left-hand side of the pump with one cable strap (30).

24. Attach one mount (41) to the 494-1116 Pipe on the right-hand side of the pump with one cable strap (29).

25. Secure wiring harness (34) to mounts (40) with 1 cable strap (29) per mount.

Customer J1939, Power, Key Switch, and Ground Connections

Note: Ensure that the equipment power is OFF, and the battery disconnect is OPEN when installing harnesses.

Recommended wire splicing practices should be followed for any of the harness splices.

Illustration 36	g06341025
PEMS Power/CAN Connection Diagram #1

Run wiring for the power (pin 1), ground (pin 2), keyswitch from trailer (pin3), and CAN (pin 5 for CAN+ and pin 6 for CAN-) to the 6-pin connector on the ECM mounting bracket. Refer to the equipment-specific wiring diagram to determine where to splice into power, ground, keyswitch, and CAN. Important to perform resistance check.

J1939 Network Connection Group

The J1939 network connection provides a standard "CAN" bus connection operating at a 250,000 baud rate. The J1939 network connection group must be connected to implement the PEM communication ECM’s J1939 to Modbus feature. Reference the "J1939 Communications Wiring Requirements" section for specific wiring requirements. The CAN A or CAN 1 is the correct CAN wiring. CAN B or CAN 2 is not to be used.

J1939 Communications Wiring Requirements

The J1939 communications connection provides a connection between PEMS ECM and the J1939 network. The J1939 network contains a bus along with wiring to connect the nodes to the bus. The bus is terminated with a 120 ohm resister on each end to complete the network. Refer to Table 5 for the J1939 network parameters.

Note: When connecting the J1939 / CAN wires from the PEMS ECM to the piece of equipment, ensure that the wires are connected to the CAN 1 / Global CAN wires on the equipment. Some pieces of equipment will have other connections labeled CAN 2 / Local CAN. If the PEMS ECM is connected to the wrong CAN connection, the proper data will not be recorded and sent to user interface.

J1939 Port Characteristics

Illustration 37	g01157211
Typical J1939 communications network layout

Resistance Check

With the system installed and the customer wiring connected to the 6-pin connector on the ECM mounting bracket, check the resistance of the data link on the service tool connector on the side of the ECM bracket. The data link resistance between pins F and G should be approximately 60 +/- 10 ohms.

If the resistance of the wiring harness is not within specification, refer to Troubleshooting, M0078614, "Service Tool Does Not Communicate".

Flash the PEMS ECM

Note: Use the most recent software flash file available on SIS web.

The ECM is flashed to upgrade the software. Flash programming of the ECM must also be done if the ECM has been replaced. The Cat^® Electronic Technician (ET) contains the program WinFlash. WinFlash is used to load software into the ECM.

Using Winflash, connect to the PEMS ECM and install the most recent flash file available on SIS web. Refer to Systems Operation and Troubleshooting, M0078614 for additional information.

Programming the PEMS ECM

The ECM must be programmed to include information specific to the installation.

Items that must be programmed:

• Product ID: Engine Serial Number

• Equipment ID: Trailer VIN number

• Machine Serial Number: This is used to set the VIN for the trailer that the pump is on. This value must be set to identify the trailer that the pump is part of.

• Well Stimulation Pump Fluid End Serial Number: This is used to set the serial number of the Fluid end of the well stimulation pump.

• Well Stimulation Pump Power End Serial Number: This is used to set the serial number of the Power end of the well stimulation pump.

• Well Stimulation Pump Plunger Diameter: This information can be found in the pump specifications manual.

• Well Stimulation Pump Stroke Length: This information can be found in the pump specifications manual.

• Well Stimulation Pump Gear Ratio: Listed on the serial plate on the side of the pump

• Well Stimulation Pump Rated Speed: This information can be found in the pump specifications manual.

• Well Stimulation Pump Plunger Firing Order: This information can be found in the pump specifications manual.

PEMS software is capable of detecting additional information that can be presented to the operator of the well stimulation pump to help with preventative maintenance.

By default, these additional monitoring features are not turned on in the software.

To activate the additional features, there are 2 configuration parameters that must be set up properly.

Note: To enable these additional features, requires factory passwords and additional charges to the customer will apply.

Illustration 38	g06325836

Note: When the FPS system asks: Is this attachment being installed on a Caterpillar branded product? The user must select "No" since the well stimulation pump trailer is not manufactured by Caterpillar.

• Well Stimulation Pump Condition Monitoring System Installation Status: This feature must be set to "Installed".

• Well Stimulation Pump Condition Monitoring System Enable Status: This feature must be set to "Enabled".

• Well Stimulation Pump Oil Filtration System Installation Status: This feature must be set to "Enabled" when Cat filtration is present.

Once the parameters have been set up, the additional monitoring features will be enabled in software.

Extra event code trip points will be available in the configuration screen. The trip points may be set based on the customers recommendations.

Operation and Maintenance

This system is designed to monitor the operating conditions of the pump and provide the operator with feedback to extend the service life of both the power end and the fluid end.

The basic PEMS includes the following:

• Pump speed sensing

• Oil pressure monitoring

• Oil temperature monitoring

• Suction pressure monitoring

• Discharge pressure monitoring

• Vibration monitoring

By monitoring each of these inputs, the system is able to determine when the service life of the components is being reduced based on the operation of the pump. The system can also aid in determining when maintenance is required for the internal components of the pump.

Maintenance

Interval: Daily

Pump Electronics Monitoring System - Check

• Visually inspect the Pump Electronic Monitoring System to ensure that all connectors are connected, the wiring harness is secured firmly to the pump, and the sensors are properly installed.

Interval: Every 250 Hours

Pump Electronic Monitoring System - Inspect

• Visually inspect the Pump Electronic Monitoring System to ensure that all connectors are connected, the wiring harness is secured firmly to the pump, and the sensors are properly installed.

• Check to ensure all the mounting hardware is fastened securely to the pump.

Refer to Systems Operation and Troubleshooting, M0078614 for additional information.