Controller and Display Version 4.

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T.Bachman, June 8, 2010

Volume 3: Flexible Electronic Control System (FLECS) Cementing Application Manual

Halliburton Part No. 101324382

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Table of Contents
CHAPTER 1 UNIT CALIBRATION ................................................................................................................................. 8 1.1 1.2 1.3 1.4 1.5 1.6 1.7 1.8 1.9 1.10 1.11 1.12 1.13 1.14 1.15 1.16 1.17 1.18 1.19 1.20 PRELIMINARY CONSIDERATIONS.............................................................................................................. 8 POWERING UP THE UNIT .............................................................................................................................. 9 ACCESSING SYSTEM CALIBRATION SCREEN ........................................................................................ 10 I/O CONFIGURATION SCREEN.................................................................................................................. 11 PASSENGER SIDE PRESSURE ...................................................................................................................... 12 DRIVER SIDE PRESSURE .............................................................................................................................. 13 THE RED SEND BANNER ............................................................................................................................. 14 3 INCH MIX WATER FLOWMETER ............................................................................................................. 15 HT400 PUMP CALIBRATION ......................................................................................................................... 16 R/A DENSOMETER CALIBRATION ........................................................................................................... 17 MICRO-MOTION F300 DENSITY SENSOR ................................................................................................ 20 CEMENT VALVE CALIBRATION ................................................................................................................. 22 WATER VALVE CALIBRATION .................................................................................................................... 25 TUBL LEVEL CALIBRATION SCREEN....................................................................................................... 27 EXPANDING I/O TO INPUTS ON EXTRA SCREEN ................................................................................ 29 UNITS OF MEASURE AND TRUCK TYPE CONFIGURATION SCREEN ............................................. 31 USING THE UOM BUTTON .......................................................................................................................... 32 SET TIME SCREEN ......................................................................................................................................... 34 ENDING THE UNIT SETUP SESSION ........................................................................................................ 35 FTP ACCESS....................................................................................................................................................... 35

CHAPTER 2 CEMWIN CONFIGURATION ................................................................................................................. 36 CHAPTER 3 REAL TIME DATA (RTD) STORAGE ................................................................................................... 40 CHAPTER 4 CONTROLLER FLASH DRIVE FILE STRUCTURE .......................................................................... 41 CHAPTER 5 USB PEN DRIVE FILE STRUCTURE .................................................................................................... 41 5.1 5.2 5.3 USB PEN DRIVE FILE STRUCTURE ...................................................................................................................... 41 USEFUL BATCH FILES ON THE USB PEN DRIVE .................................................................................. 43 AUTOMATING COMMANDS AT BOOTUP ON THE USB PEN DRIVE. ............................................... 45 CREATING USB PEN DRIVES FROM PEN DRIVE IMAGES................................................................... 46 USING UPGRADE ZIP FILES ON EXISTING USB PEN DRIVES............................................................ 49 INSTALL METHOD ......................................................................................................................................... 50 UPGRADE METHOD....................................................................................................................................... 52 FOR CONTROLLER VERSIONS 2.0.3 OR EARLIER ............................................................................................... 53 DEALING WITH DISPLAY SOFTWARE UPLOAD PROBLEMS .............................................................. 55 FLECS BIOS CONFIGURATION ................................................................................................................... 57

CHAPTER 6 CREATING AND UPGRADING USB PEN DRIVES ............................................................................ 46 6.1 6.2

CHAPTER 7 FLECS CONTROLLER SOFTWARE INSTALLATION ..................................................................... 50 7.1 7.2

CHAPTER 8 FLECS DISPLAY SOFTWARE INSTALLATION ................................................................................ 53 8.1 8.2

CHAPTER 9 FLECS CONTROLLER HARDWARE CONFIGURATION................................................................ 57 9.1

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9.2

REPAIRING A CORRUPTED COMPACT FLASH DRIVE ......................................................................... 58 FLECS DISPLAY POWER ON SETUP SETTINGS ...................................................................................... 66 PROGRAMMING DISPLAY WITH PROGRAMMERS CABLE ON INSTRUMENT BENCH ............. 67 PROGRAMMING DISPLAY WHILE IT IS STILL ON THE UNIT ............................................................ 74 USING FLECS DISPLAY AUTOUPDATE FEATURE ................................................................................. 74 PROGRAMMING DISPLAY VIA ETHERNET ON THE INSTRUMENT BENCH ............................... 75 PROCEDURE FOR PROGRAMMING DISPLAY VIA ETHERNET ......................................................... 78

CHAPTER 10 FLECS DISPLAY CONFIGURATION.................................................................................................. 66 10.1 10.2 10.3 10.4 10.5 10.6

CHAPTER 11 CEMENT MIX HEAD INSTALLATION AND SETUP....................................................................... 82 11.1 WHEN DOES THE MIX HEAD NEED SERVICE? ..................................................................................... 82 11.2 PROCEDURE FOR MARKED POSITION REMOVAL AND REASSEMBLY OF CEMENT MIX HEAD AND SETTING OF VALVE POSITIONS. .................................................................................................................. 82 11.3 PROCEDURE FOR A FRESH INSTALL OF THE CEMENT MIX HEAD AND SETTING OF VALVE POSITIONS..................................................................................................................................................................... 84 CHAPTER 12 FLECS SYSTEM REPAIR AND RETURN........................................................................................... 86 12.1 12.2 12.3 FLECS DISPLAY REPAIR AND RETURN PROCEDURES........................................................................ 86 FLECS CONTROLLER REPAIR AND RETURN PROCEDURE ............................................................................... 87 USEFUL PART NUMBERS.............................................................................................................................. 87

Electronic Documents for Appendices are contained in the FLECS Ver 4.16 USB Pen Drive for Electronics Technicians. SAP# 101743269. Look in USB pen folder \DOCS\1. FLECS Tech Manual\Tech Manual Volume 3
APPENDIX A FLECS Software APPENDIX B Manufacturing Test and Setup Specs APPENDIX C Welding Precautions APPENDIX D FLECS Display APPENDIX E Data Communication APPENDIX F Electrical Schematics APPENDIX G Technical Bulletins and Product Notifications APPENDIX H Tub Level Sensor APPENDIX I F300 Density Sensor APPENDIX J Radioactive Densometers APPENDIX K Magnetic Flow Sensors APPENDIX L Ampro Mother Boards APPENDIX Z Miscellaneous

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HALLIBURTON ENERGY SERVICES

FLEXIBLE Electronic Control System (FLECS) Controller FLECS Cementing Application Manual
Halliburton Technology Center 2600 South 2nd Street Duncan, OK 73536

All information contained in this publication is confidential and proprietary of Halliburton Energy Services, Inc. Any reproduction or use of these instructions, drawings, or photographs without the written consent of an officer of Halliburton Energy Services, Inc is forbidden. Copyright 2004, Halliburton Energy Services, Inc All Rights Reserved. Printed in the United States of America

Printing History: Version 1.0 - First Release (April 18, 2005) Version 1.2 - Second Release (July 7, 2005) Version 2.1 Third Release (August 8, 2005) Version 2.3 Fourth Release (August 22, 2005) Version 2.4 Fifth Release (February 27, 2006) Version 2.5 Sixth Release (October 1, 2006) Version 2.6 SeventhRelease (February 6, 2007) Version 2.7 Eighth Release(June 8, 2010)

FLECS Elite Cementing Controller

FLECS USB Pen with Software version 4.16 and Documentation: SAP# 101743269 FLECS USB Pen with Software version 4.16 and No Documentation: SAP# 101742919 FLECS Controller SAP#:101288476 C FLECS Display SAP#: 101310277 G This document contains detailed instructions for configuring a cementing unit equipped with the FLECS control system for field operations. The instructions contained herein describe instrument calibration and unit configuration only. This document does not cover operating instructions or mixing techniques.

Chapter 1 Unit Calibration

1.1 PRELIMINARY CONSIDERATIONS

1.1.1 UNIT TEST: DUNCAN MANUFACTURING This document is to be used in conjunction with unit test specification; D00171055: Elite FLECS Setup, Calibration, and Test. A copy of this spec can be found in Appendix B section of USB Pen for Technicians. A section in that specification will refer you to a Unit Calibration section contained in the FLECS Cementing Application Manual for the version of software installed. This is that section. 1.1.2 FIELD OPERATONS If you have received a FLECS retrofit kit for upgrading existing Elite units we highly recommend you obtain a copy of the unit test specification D00171055 and follow it. Take electronics precautions to prevent damage to the kit if there is welding to done on the unit during kit installation. If possible, it is recommended that all welding be completed before installing the kit. Reference welding precautions in Appendix C section of USB pen for Technicians. You may benefit by contacting someone at the unit test facility in Duncan, Oklahoma for tips, recommendations and history on following the unit test specification D00171055 and using this document in conjunction with it. 1.1.3 DOCUMENT UPDATES The front page of this document specifies the software and hardware versions for which this document applies. Electronic versions of this document and later versions specific to later software and hardware releases should be available via a portal site on the HalWeb. Contact Duncan Technology to obtain the site address. 1.1.4 SAVING DATA In the following procedures you will be making numerous data entries and saving them. You must however commit those changes permanently to disk at the end of the unit setup session by performing a proper shutdown. This is done by pressing MENU, SHUTDOWN and waiting until the unit tells you it is safe to power off the unit. If you have been collecting job data., enter an End Job event first before shutting down and allow at least 5 minutes for the RTD data to be saved from the temporary location in RAM to a permanent location on the Controller Flash Drive. Then issue a SHUTDOWN command to save your changes. 1.1.5 UNITS This release of software has the ability to present Operator display data in Metric or English units. The unit of measure selected can be any one of four standard sets. The basic sets can be customized further with other units by using the UOM Units Of Measure buttons on many of the instrument calibration screens. Recorded Data can be modified to display in other units as well by using the conversion tools in the HalWin or OptiCem data collection software.

1.2 POWERING UP THE UNIT

Follow spec D00171055 for first time power ups at unit test in manufacturing or for first power up after a retrofit kit install. 1. Turn Power on to the FLECS system at the control stand. 2. Check that the Job Screen comes on shortly after turning on power. All the numeric fields will contain text descriptions until data is received from the FLECS Controller. The FLECS display should begin receiving data after approximately 45 seconds and the text descriptions of the number fields will be replaced by numeric values. 3. Serial Port Health Status is indicated by two LED like green squares inside the Menu button on the lower right hand side of the Job Screen. The top green square flashes on and off to represent when data is being received at the FLECS Display serial port. The bottom square indicates the status of the data being received; the color green represents good data, while the color red indicates bad data. A red square usually indicates a poor serial line driver at the Controller or at the Display or that the Display Baud rate for COM1 is not correctly set to 38400,8,n,1. JOB SCREEN

Flashing green square indicates display data is being received.

1.3 ACCESSING SYSTEM CALIBRATION SCREEN

1. Press the [F6] key or press the {Menu} button on the touch screen to go to the Menu Screen shown below. Press Escape to exit out of any screen at any time. MENU SCREEN

2. Press the [8] key or press the {System Calibration} button on the touch screen to go to the Calibration Screen shown below. Press Escape to exit out of any screen at any time. Note the [Next >>>] button. This indicates that the calibration screen is continued into a second screen. CALIBRATION SCREEN

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1.4 I/O CONFIGURATION SCREEN

From the Calibration screen press the {I/O Config} button or press the [3] Hot Key to select the I/O Configuration screen. The I/O Configuration Screen is used to assign specific I/O points on the FLECS Controller to a particular device. For example: In the picture below Densometer Input #1 has been assigned to the Recirculation Densometer. I/O CONFIGURATION SCREEN

Default channels are shown in gray.

Device Names

Field Terminal Numbers for this channel.

List of I/O channels that can be assigned (wired) to the device described in the Tab Device Name.

The I/O configuration screen is a tabbed screen. Each Tab has an abbreviated device name identifying the instrument or device being configured. When you select a device name by selecting a Tab, a list of possible I/O ports that can receive or output signals from that device is listed. There will be at least one darkened default selection on each Tab page. This is the default channel that will be used for that device. In the box on the lower left hand side will be terminal numbers and descriptions. These terminations show the associated wiring for the I/O channel selected. Typically, the signal terminal # is always correct. However, depending on the device and the wiring techniques employed signal commons, shield grounds and power wiring may differ in whether or not they use the terminal #s provided by the Field Terminal Assembly, so keep a schematic handy. There are two default selections for Densometers. In the example screen on the previous page, the default channels for the Recirc Densometer are Densometer Input 1 and Analog Input 7. You will note the black radio button is visible on Analog Input 7. This indicates that the Recirc Densometer is running in Analog Input mode and that the 4-20mA current signal is coming in on Field Terminal #7.

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If you move the I/O channel to another available channel you will have to physically move the wires to the terminals indicated and you will need to double check the calibration for that device after making the move. To select a new channel you can either touch the text or the button for that channel with your finger or use one of the hotkeys. In the Recirc Densometer screen above the Hot Keys are [F1], [F2] and numbers [0] through [8]. Hot Keys [F1] and [F2] will select either of the Densometer input frequency channels and Hot Keys [1] through [8] will select any of the 8 available analog input channels. [0] selects a modbus density device like the F300 micromotion density sensor. Modbus devices have to be connected to the COM3 serial port. SAVE, SAVE, SAVEThe Last Tab in the list is the SAVE Tab. Go there and save your changes or press the Hot Key [F3] to save from any of the Tabs you happen to be on. This will save all the Tab changes.

1.5 PASSENGER SIDE PRESSURE

From the Calibration screen press the [F1] key or touch the {PS Pressure} button on the calibration screen and you will be brought to the passenger side pressure calibration screen shown below. Enter the cal points from the pressure transmitter in the white text box fields. PS PRESSURE

Red Lines indicate active object

HOT KEY

Unit Of Measure HOT KEY

The red hash lines indicate which text box is active and which text box the numbers will be sent to when entering data. You can move to the next text box by touching it on the screen

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or by pressing the Hot Key indicated in the upper right region of the text box. The data entered above shows a typical 4-20mA 15000 psi WECO Union transmitter calibration. You will also see a new button on many instrument calibration screens marked UOM. This stands for Unit Of Measure and allows you to go in and specify an different display unit from a list of available alternatives. UOM changes should be done prior to a Start Job event and should be saved with a Shutdown command before catching and logging a job. This feature will be discussed further in section 1.16 Units of Measure and Truck Type Configuration. After data has been entered, touch the {SAVE} button or press the [F5] Hot Key to save the data. You must SAVE any changes you enter. When you are finished hit the {EXIT} button or the [F6] key and your will be returned to the JOB SCREEN.

1.6 DRIVER SIDE PRESSURE

Access the system calibration screen and calibrate the driver side pressure in the same manner as the driver side pressure.

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1.7 THE RED SEND BANNER

Hitting the {SAVE} button will send the data to the controller for saving and then the controller will echo the saved data back to the display for your verification. When data is being sent from the display to the controller a Red banner is displayed and remains displayed until a copy of the saved data is echoed back by the controller. If the red bar remains, this indicates that the data sent by the Display was not received by the Controller. Hit the [ESC] key to clear the red banner and resave the data again. If the red banner persists you are experiencing communication problems between the Display and the Controller and you will need to trouble shoot the serial connection between them. Red Send Banner

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1.8 3 INCH MIX WATER FLOWMETER

The 3 inch flow meter should be tagged with a flow meter calibration factor indicating the number of pulses for each gallon of fluid. For example: 54.3 ppg. If we pumped fluid through the system such that 54.3 pulses was generated every second (or 1 gallon each second) we would be pumping at 60 gallons per minute. So the only data that really needs to be entered is the flow meter factor into the box indicated below. After entering flow meter data {SAVE} it and then {EXIT} out. 3 IN. FLOWMETER CALIBRATION SCREEN

Flow meter factor

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1.9 HT400 PUMP CALIBRATION

Make sure the calibration numbers for the displacement pumps match the fluid ends and gear ratio on the unit. These numbers are calculated from a combination of 3 things. 1) The fluid end size, 2) the gear reduction ratio, 3) The number of teeth on the sprocket mounted on the pump drive shaft. A set of look up tables should be available to obtain the correct values to be entered. You will need to access both Driver Side and Passenger Side pump calibration screens and enter your data. Passenger Side Pump Calibration Screen is shown below. Technology recommends using cal factors assuming 95% pump efficiency. PASSENGER SIDE PUMP CALIBRATION

Be sure this matches fluid end, gear ratio and sprocket size.

HT400 Pump calibrations

PLUNGER TEETH/INPUT SIZE (In.) REV 3.375 26 4 26 4.5 26 5 26 6 26 MF (100%TEETH/BBL) 10103.79 7193.03 5683.38 4603.54 3196.90 MF (95%TEETH/BBL) 10635.57 7571.61 5982.51 4845.83 3365.16 HZ for 10BPM (100%) 1683.97 1198.84 947.23 767.26 532.82 HZ for 10BPM (95%) 1772.60 1261.94 997.08 807.64 560.86

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1.10 R/A DENSOMETER CALIBRATION

It is required that all Radioactive Densometers on all automatically controlled cementing systems be operated in frequency mode only. This is especially important for the Recirculating Densometer. The following screens and information will discuss the multipoint calibration of a Radioactive Densometer running in frequency mode. The Densometer calibration screen makes use of a tab object for entering multi-point data. The tab that is highlighted red is the active object. Make sure when you enter data into the white text fields that one of the Tabs is highlighted red. You can move through the tabs using the [] or [] keypad arrows as long as the entire screen has the red hash marks across it (indicating the tab object is active) as shown in the following screen snapshot. You can also move to specific tabs using a combination hot key. Combination hot keys are Hot Keys with an underline. This indicates that the [CTRL] key has to be pressed before pressing the Hot Key displayed. For example to move directly from Cal Point 1 Tab to Cal Point 5 tab you would press [CTRL] then [5] on the keypad. RECIRCULATING DENSOMETER CALIBRATION SCREEN Combo Hot Keys are under lined. [CTRL] then [3]. Red Tab indicates point being displayed.

HOT KEY

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1.10.1 RECIRC SCREEN INTERFACE HINTS 1.10.1.1 MOVING TO DIFFERENT CAL PT TABS. 1. Combo Key : [CTRL] then [3] for Cal Point 3.or. 2. Touch Yellow screen object to move to next group of 3 tabs. Then select one of the tabs by touching to highlight it Red and view the data for that Cal Pt..or. 3. You can use [] or [] keys to navigate from tab to tab as long as the tab object is the active object (entire screen has hash marks as shown above). 4. Press the [F5] or [F6] Hot Keys to move backwards and forwards in groups of 3 tabs at a time. DONT FORGET!!! You must touch one of the tabs and turn the tab red in order to see and edit the cal points for that particular point. The tab interface will allow you to see the very last tab but still be editing Tab 1 if it was the last tab selected and turned red. RECIRCULATING DENSOMETER CALIBRATION ENTRY

1.10.1.2 ENTERING VALUES IN WHITE TEXT BOXES 1. Touch a white edit box on the screen to make that object active then use the keypad to enter the numbers.

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2. Use the hot keys [F1] or [F2] to make the text box object active then begin entering numbers from the keypad. 1.10.1.3 REMOVING A CAL POINT Removing a cal point from the list is can be done by simply entering a letter x anywhere in one of the number fields. (You will have to press the [Shftloc] key on the keypad so that alpha characters will be output to the textbox). After entering an x in one of the number fields hit the {SAVE} button and that Cal Point will be removed from the table. A maximum of 10 cal points is available. If you are only using 6 or 7 points of the 10 points available the remaining tab entries will have NOT IN USE in the text fields. 1.10.2 LOCAL AND HICAL ENTRY The last tab in the Densometer Calibration Screen is the Hi Cal and Lo Cal screen. This is where you enter your final set of data. After you have entered all your data you can go back through the tabs to verify data for correctness and then press the {Save} button to save the data. When saving you will get the Red Send Banner pop up again as data is being transferred and saved. After the data is saved the controller will then echo the data it saved back to the display. When the data is received and written back into Densometer Calibration Tabs the Red Banner will disappear. Double check again for correct entries and then hit the {Exit} button to return to the Job Screen. RECIRCULATING DENSOMETER CALIBRATION SCREEN LOCAL/HICAL

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1.11 MICRO-MOTION F300 DENSITY SENSOR

The F300 Density Sensor can be configured to output its density and flow as raw current and frequency signals via a remote transmitter, or output its data digitally as a MODBUS RS485 serial device. The following locations contain detailed information on how to setup and configure the F300 sensor and remote transmitters for raw signals or MODBUS. Using CWI or SAP look up Manual D00301004 : Installation Suggestions for Micromotion F300 Densometer in Cementing Recirculation Line Applications and download a pdf or word copy for personal use. The above document can also be found on the FLECS Technicians USB pens in the \DOCS\1. FLECS Tech Manual\Tech Manual Volume 3\Appendix I . F300 Density Sensor folder. Look for F300_installation_notes_D00301004B.pdf. Halliburtons internal collection of MicroMotion information can also be found in the SENSORS section at the E-Tech Web Portal. http://halworld.corp.halliburton.com/HES/Hesps/hespspe/hespspe_fracacid/hesp spe_fracacid_eqsensors/hespspe_fracacid_eqsensors.asp Micro-Motion Manuals can also be downloaded directly from www.MicroMotion.com. Contact Dick Headrick at Duncan Technology if you have additional questions. dick.headrick@halliburton.com.

1.11.1 FLECS CONFIGURATION FOR RAW SIGNALS FLECS Setup for F300 Sensor with Remote model 2700 or 2500 remote transmitter outputting a 420mA current for density and a frequency output for flow rate. Go to the I/O Configuration screen and select the {RDen} Tab, then select {Analog In 7}. Note termination numbers and wire accordingly. {Save} and {Exit}. Return to System Calibration and calibrate the Recirc Densometer. Enter 4.0 mA = 0.0 ppg, 20.0 mA = 26.0 ppg in the recirc densometer cal sheet as shown in example below. (These values must match the 2 point calibration configuration contained in the Micro Motion model 2700 Remote Transmitter. Reference Documentation on F300 Installation and all Micro Motion Documentation on the F300 and the model 2700 transmitter.)

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F300 DENSITY CALIBRATION

Return to I/O Configuration Screen, Select {RDenRate} Tab, select {Freq. In 4} for input channel. {Save} and {Exit}. Note terminal numbers and connect Flow Output Signal from F300 transmitter to the terminal numbers shown. Press {Menu}, {System Calibration}, {Next}, {RDen Rate} and enter the calibration values for the F300 flow rate. 0gpm = 0Hz, 1000gpm = 1000Hz. (This requires that the frequency output at the remote transmitter be configured to output 60 pulses per gallon of fluid. Ref Manual D00301004: Installation Suggestions for Micromotion F300 Densometer in Cementing Recirculation Line Applications)

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F300 FLOW CALIBRATION

1.11.2 FLECS CONFIGURATION FOR MODBUS MODBUS is a serial communication protocol common to many intelligent sensors. Configuring the F300 as a MODBUS device will bring both the F300 density and flow rate in through COM3 of the FLECS Controller. You will not need to wire the raw signals for density and flow as described previously. To Configure the F300 as a MODBUS device go to the I/O Configuration Screen, Select the {RDen} Tab and then select the {MODBUS input} radio button. This selection requires you to wire the F300 sensor to COM 3 of the FLECS Controller. This can be done via the 2500/2700 transmitters or directly from the sensor. An RS485 to RS232 converter will be required to convert the RS485 signals from the F300 to RS232 before they are fed into COM 3 of the FLECS Controller. Reference the Micromotion Documentation for details on proper configuration.

1.12 CEMENT VALVE CALIBRATION

The Cement and Water Valve Calibration Screen is shown below and has the following entries 1. Delivery: This number indicates the volume cement in dry gallons that is delivered per minute for every degree the valve is open. A 3.3 entry for cement valve is just under a sack of cement (3.6 dry gallons) per minute per degree open. 2. Start Fill %: This is the valve position in percent open that you want the cement valve to go to during the Start Cement Command.

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3. Open %: This is the valve open position value in terms of the full scale output of the Valve Analog Output channel. Follow Cement Valve Setup Procedure in next section to obtain proper value to be entered in this field. 4. Close %: This is the valve closed position value in terms of the full scale output of the Valve Analog Output channel. Follow Cement Valve Setup Procedure in next section to obtain proper value to be entered in this field. 5. Tub Vol: This value sets the tub size for the type of unit or tub you have. Selecting this field brings up a popup dialog box that presents you with a list of tub sizes for typical cementing equipment. (The actual Pre-Mix Tub Volume on an Elite unit is 216.9 gallons). CEMENT AND WATER VALVE CALIBRATION SCREEN

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1.12.1 CEMENT VALVE OPEN AND CLOSED POSITION SETUP PROCEDURE The following procedure will help you determine the proper open and closed valve positions for your cement mix head valve and actuator. 1.12.1.1 PRELIMINARIES 1. Cement Mix Head and Feedback potentiometer must be properly installed and set. Reference document section Cement Mix Head Installation and Setup. 2. Hydraulic System needs to be on and functional. 1.12.1.2 PROCEDURE To set cement valve open and close % positions. 1. Go to MENU, System Calibration, Cement Valve. 2. Write down old values for open % and close %. 3. Set Open % to 100. Close % to 0. Press [F1] key or the {SAVE} button. 4. Press {EXIT} button to exit Valve Calibration screen. 5. Have partner view valve position of valve head with flashlight. 6. Go to MENU, Manual. 7. Open valve to 50% and open 1% at a time until valve just reaches the fully open point. Write this down. This is your open %. 8. Open valve to 50% and back down 1% at a time until valve fully closes. Write this value down. This is your close %. 9. Go to MENU, System Calibration, Cement Valve and enter your new open % and close % values and SAVE. 10. Go to MENU, manual and open valve 50%. The knife valve should now be about halfway open. Hit the close all valves and exit button. Make sure valve is fully closed. If it didnt close completely, go back and lower your close % a percent or two and repeat this step until valve completely closes. 11. The Cement mix head should have no more than 6 degrees of travel slop. To check it, get your hydraulics warmed up and running at mixing pressure. On the FLECS display go to MENU, Manual Control and open the cement valve to 40% then make 1% increments to 50%. Make the 48, 49, and 50 steps with a 2 second pause between each. Now place hand on needle indicator and back down the valve slowly one percent at a time and count the number of down steps it takes until the valve physically moves. You should feel it move on or before you reach 45%. Service the valve if this value is 6% or more. 10% or more indicates a very badly worn valve and job quality will be very poor in automatic. The mix head should be repaired as soon as possible. NOTE: The main culprit in wear is usually the white fiber glass gear that interfaces the hydraulic actuator to the mixing head. A mix head should have this gear frequently replaced when it is serviced. Wear often occurs on the gear teeth and in the bolt holes that hold the gear in place.

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1.13 WATER VALVE CALIBRATION

The Valve Calibration Screen is shown below and has the following entries 1. Delivery: This number indicates the volume of water in gallons that is delivered per minute for every degree the valve is open. A 4.5 entry indicates 4.5 gallons of water per minute per each degree the valve is open. 2. Start Fill %: This is the valve position in percent open that you want the water valve to go to during the Start Water Command. 3. Open %: This is the valve open position value in terms of the full scale output of the Valve Analog Output channel. Follow Water Valve Setup Procedure in next section to obtain proper value to be entered in this field. 4. Close %: This is the valve closed position value in terms of the full scale output of the Valve Analog Output channel. Follow Water Valve Setup Procedure in next section to obtain proper value to be entered in this field. 5. Tub Vol: This value sets the tub size for the type of unit or tub you have. Selecting this field brings up a popup dialog box that presents you with a list of tub sizes for typical cementing equipment. (The actual Pre-Mix Tub Volume on an Elite unit is 216.9 gallons). CEMENT AND WATER VALVE CALIBRATION SCREEN

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1.13.1 WATER VALVE OPEN AND CLOSED POSITIONS SETUP PROCEDURE The following procedure will help you determine the proper open and closed valve positions for your mix water control valve and actuator. 1.13.1.1 PRELIMINARIES 1. Make sure that in the closed position the feedback voltages for the cement valve has been set to approximately 1.0 volts. This adjustment is done by setting the feedback potentiometer in the cement valve head to the proper position while the cement head is closed. Make sure feedback voltage rises steadily from the closed position to the open position. Check this with a voltmeter and move the valve slowly by hand. 2. Hydraulic System needs to be functional. 3. A water supply will be needed to check flow rates through mix water valve. 1.13.1.2 PROCEDURE To set water valve open and close % positions. 1. Go to MENU, System Calibration, Water Valve. 2. Write down old values for open % and close %. 3. Set Open % to 100. Close % to 0. Press [F1] key or the {SAVE} button. 4. Bring on enough water to flow rate test. 5. Run your mix pump up to job speed. 6. Go to MENU, Manual and open water valve until you get about 50 gpm through the 3 flow meter. 7. Close water valve 1% at a time until water through flow meter stops. Write this down this is your close %. 8. Now open water valve past 50% and step up 1% at a time until a maximum rate is achieved. Be careful here. You can open the valve far enough that flow rate will reach a peak and begin to fall off as you continue to open the water valve. This is because some of the holes start to get shut off on the back side of the valve. If this occurs, backup 15% or so and re-approach the peak flow rate 1% at a time. Write this value down. This is your open %. 9. Go to MENU, System Calibration, Water Valve and enter your new open % and close % for your water valve and SAVE. 10. You now need to calculate your water delivery rate with the new position settings. 11. With water pump and engine running at mixing speed go to MENU, Manual Control and open the water valve until you get about 225 gpm through the 3 flow meter. Write the percentage and the flow rate in gpm down. 12. Now open beyond 225 gpm and then back down back to 225 gpm. Write this percentage down and the flow rate down.

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13. Calculate the water delivery rate. a. Example Delivery Calculation 232 gpm on open at 55% = 232 55 = 4.22 gallons per minute per degree 223 gpm on close at 46% = 223 46 = 4.84 gallons per minute per degree Water Deliver Rate = (4.22 + 4.84) 2 = 4.53 gpm/degree b. Enter 4.53 in the Delivery field of Water Valve Calibration Screen and SAVE 14. The Water valve should have no more than 8 degrees of travel slop. To check it, get your hydraulics warmed up and running at mixing pressure. On the FLECS display go to MENU, Manual Control and open the water valve to 40% then make 1% increments to 50%. Make the 48, 49, and 50 steps with a second pause between each. Now place hand on needle indicator and back down the valve slowly one percent at a time and count the number of down steps it takes until the valve physically moves. You should feel it move on or before you reach 42%. Service the valve if this value is exceeded.

1.14 TUBL LEVEL CALIBRATION SCREEN

Some Elite Systems may come with Automatic Tub Level Control or be retrofitted with this feature by installing a kit ordered with SAP# 101471580. Below are the typical calibration values to be entered at the FLECS Display for the Milltronics Tub Level Sensor kit. You will need to properly configure and calibrate the Tub Level Transmitter itself in addition to entering the values shown in the screen below. A procedure to do this is detailed in the following subsection. Tub Level Calibration (Milltronics Tub Level Sensor)

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1.14.1

Milltronics Tub Level Sensor Installation and Calibration

Procedure to Calibrate Milltronics The Probe Level Sensor Models 7ML12011EC10 and 7ML12011ED10 for use on FLECS Systems.
The Probe level sensor is a two-wire, loop-powered, ultrasonic level sensor. Power for the sensor is provided through the data cable. The data cable is included in the Elite Tub Level Kit SAP# 101471580. Install the level sensor on the down hole side of the mixing tub according to the instructions in the level sensor kit. Read the manufacturers operating manual to become familiar with the operation and setup of the sensor. A manual was packaged with the sensor and a link to a copy of the manual in PDF format is listed below (7ml19981gc61.1.pdf). Important: To power up correctly, The Probe level sensor requires a surface to measure when the power is turned on. Therefore, apply power to The Probe only after the down hole side of the mixing tub contains slurry or water. To initially set up the sensor for use, either fill the mixing tub with water to a level of 2 to 3 feet from the face of the sensor, or remove the sensor from the bracket and aim it at a wall 1 to 16 feet away. Apply 24 V DC power to the sensor. If on the cementing unit, attach the data cable and turn on the power at the junction box; if on a bench top, apply power to the terminals inside the lid. Inside the lid are two buttons and a display screen. The buttons are labeled 4 and 20. These buttons are used to set the operating parameters. Pressing both buttons simultaneously selects the operating parameters. After a parameter is selected, pressing the 20 button increases the value and pressing the 4 button decreases the value. To setup The Probe level sensor, perform the following steps. 1. Set the unit of measurement to feet or meters, whichever is preferred for the location. a. Press the 4 and 20 buttons simultaneously until Un appears in the display. b. Press the 20 button to change the units. A 1 in the display indicates meters. A 2 in the display indicates feet. c. When the proper units are selected, allow the sensor to process for 6 seconds and it will automatically store the selection and return to run mode. 2. Set current output (or calibration values). a. Set 4 mA output to 16 ft (or 5 m): i. Press the 4 and 20 buttons simultaneously until c4 is displayed. ii. Press and hold the 20 button until 16 ft or 5 m is shown on the display. iii. Allow the sensor to process until it returns to run mode (6 seconds). b. Set 20 mA output to 0 ft (or 0.0 m): i. Press the 4 and 20 buttons simultaneously until c20 is displayed. ii. Press and hold the 4 button until 0 ft or 0.0 m is shown on the display.

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iii. Allow the sensor to process until it returns to run mode. 3. Set the blanking distance to 1.0 ft (or 0.3125 m). a. Press the 4 and 20 buttons simultaneously until bl is displayed. b. Press the 20 or 4 button until 1.0 ft (or 0.3125 m) is shown on the display. c. Allow the sensor to process until it returns to run mode. 4. Set the speed of response to 3 (immediate). a. Press the 4 and 20 buttons simultaneously until SP is displayed. b. Press the 20 button until 3 is shown on the display. c. Allow the sensor to process until it returns to run mode. Below is link to MillTronics Manual on Halliburton Techweb http://halworld.halnet.com/hes/hesps/hespszi/hespszipm/hespszipm_manl/hespszipm_m anl_101353312/vendor_manuals/7ml19981gc61.1.pdf NOTE 1: The calibration numbers entered for the Milltronics Sensor and the calibration values entered in the FLECS Tub Level Calibration screen may at first appear to not make sense. This is because we want the FLECS to display the distance from the fluid surface to the bottom of the tank rather than the distance from the sensor element to the surface of the fluid. IMPORTANT: It is important that the tub level sensor be turned on with fluid in the downhole side of the compartment in order for it to work correctly. For the sake of convenience you should have a technician install a power switch for the Tub Level Sensor in the 24 VDC power line to that device and mount that switch somewhere convenient. This will allow you to have the FLECS System on before having fluid in the downhole compartment. You can then fill the downhole side of the compartment when you desire and power the tub level sensor up when you choose. Otherwise, you will be required to put fluid in the downhole side of the mixing tub BEFORE you turn on your FLECS System.

1.15 EXPANDING I/O TO INPUTS ON EXTRA SCREEN

I/O expansion is currently limited to 2 Frequency Inputs and 2 Current (4-20mA) inputs. Here is the procedure to add I/O to your existing system. 1.15.1 ADD NEW DEVICE 1. Press MENU, System Calibration, I/O Config. 2. Press F6 or the key until you see one of the tabs with the following descriptions a. ExPress1 - This is the 1st available 4-20mA input b. ExPress2 - This is the 2nd available 4-20mA input c. ExRate1 - This is the 1st available frequency input d. ExRate2 - This is the 2nd available frequency input 3. Select one of the Expandible I/O tabs. For example, ExPress1.

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4. Note that the Not Assigned selection for that device is selected. 5. For illustration purposes select Analog In 3. Notice in the Pin Out Box the pins for that input. These are the actual terminals the expanded I/O device needs to be connected to on the Field Terminal Assembly located in the Junction Box with the Controller. For example, Analog In 3 comes in on Terminal 3. This is the terminal that a 4-20mA transmitter signal return would be attached to. If the transmitter needs to be powered you would use Termnal 75 (+24VDC) to power the sensor. If the signal cable has a shield you would use Teminal 111 to ground the shield. 6. Press the F3 key to save your new I/O selection or go to the other Expandible I/O tabs and select inputs for more add-on I/O devices. Once you are finished press F3 to save OR go to the SAVE tab, which is the last tab and press the SAVE IO CONFIG button. 7. After saving press ESC key to exit I/O Config Screen. 1.15.2 CALIBRATE NEW DEVICE 1. Now that you have added a new input channel you need to calibrate it. 2. Press MENU, System Calibration, Next>>>. 3. Select the button for the Extra Device you added. For example, Extra Pressure 1. 4. Press the UOM button and select the Unit of Measure you wish to use for this new device. 5. Now enter your calibration points and press save. 6. You are now ready to connect your new device. 7. The new device will also appear in your HalWin Serial Data Stream. You will need to go into GENCOM under HalWin and define the new data field and set the unit for it. You will then be able to add it to Technical Graphs and the like. 8. Extra Pressure Channels 1 and 2 also have a Set Extra Pressures screen for setting or zeroing pressures or other sensors to specific values. This can be accessed by pressing the Extra Pressure display on screen 2. Press the key on the keypad to view screen 2. Press the F4 key or touch the Extra Pressure 1 or 2 field on the touch display. You can also access it from the Job Screen by pressing MENU, Set Extra Pressures.

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1.16 UNITS OF MEASURE AND TRUCK TYPE CONFIGURATION SCREEN

The Unit Type Screen allows you to switch between different sets of national measures and to select a double pump or single pump truck type. As of this writing there are 4 basic selections. The buttons indicate the units of measure for density, pressure, and pump rate as a means of identifying the different sets. UNIT CONFIGURATION SCREEN

1. Press the Units of Measure you desire. 2. The Change Alert Screen shown below will appear informing you to verify all your calibrations and to perform a shutdown to keep unit change and other adjustments for subsequent startups. UNIT CHANGE ALERT

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Below is summary of the units of measure and their abbreviations in the FLECS system. These abbreviations may not match common SI or English abbreviations because of the need to keep them very short and absent of special characters. We tried to stick to 3 or at most 4 characters. FLECS Unit Abbreviation Listing

ppg = pounds per gallon psi = pounds per square inch bpm = barrels per minute gpm = gallons per minute gal = gallons bbl = barrels (42 gallons).

sg = specific gravity atm = atmospheres lpm = liters per minute m3 = cubic meters ltr = liters

km3 = kg per cubic meter mpa = megapascals m3m = cubic meters per minute m3 = cubic meters ltr = liters Other selectable units are: kpa = kilopascals ksc = kg per square centimeter kgm3 = kg per square meter m3s = cubic meter per second lps = liters per second f3s = cubic feet per second f3m = cubic feet per minute

kgl = kilograms per liter bar = bars lpm = liters per minute m3 = cubic meters ltr = liters ft = feet in = inches m = meter cm = centimeter c = celsius f = fahrenheit lb = pound kg = kilogram

1.17 USING THE UOM BUTTON

Several calibration screens will have a UOM Unit Of Measure that will allow you to further customize your units of measure from the 4 basic sets. Press the UOM button on the calibration screen or use the hot key combination by pressing [CTRL] then [2] on the membrane keypad.

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You will then see a list of possible alternative choices. Press your selection on the touchscreen or select the corresponding number on the keypad to highlight you choice. Then press the [Enter] key on the membrane keypad to save your new selection.

You will then be returned to the calibration screen. You should now see the cal points configured in the new unit of measure. Make any needed calibration value adjustments and save your settings. Repeat for any other instruments, then perform a Shutdown to save new settings. Restart the system and make sure all changes remain in place.

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1.18 SET TIME SCREEN

The Time indicated on the Menu button of the FLECS Display is based on the internal clock of the FLECS Display and is not an indication of the date and time on the Control Stack. The Set Time Screen allows you to set and synchronize both system clocks on the FLECS Display and on the FLECS Controller. This ensures that RTD data and other files saved and written to disk on the FLECS controller agree with the time being displayed to the operator. Set up is fairly self explanatory. The time shown in the scroll boxes is the time and date from the FLECS Controller. The time shown in the balloon and the date adjacent to it are the clock and calendar settings for the FLECS Display. Set the correct time for both using the scroll boxes and click the set button to synchronize the two systems. NOTE: All clock settings must be done prior to performing a Start Job. Set Time requests done after a Start Job will not be applied because RTD data is already being time stamped and you will be rudely rebuffed for making the attempt. SET TIME SCREEN

FLECS Controller Date and Time FLECS Display Date and Time

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1.19 ENDING THE UNIT SETUP SESSION

During this whole calibration and unit Setup session you have been hitting save buttons. All this does is save the setting changes you have made for the CURRENT session. If you want all the changes you have made to be used on every subsequent session you must perform a SHUTDOWN. This will commit all the changes to the startup files and the changes will be effective for every session afterwards. To perform a Shutdown, Press MENU and then press the SHUTDOWN button. You will be asked if you really are wanting to Shutdown. Press the YES button. SHUTDOWN PROCEDURE 1. Exit out to the Job Screen. 2. Press the MENU button or its Hot Key. 3. Press the SHUTDOWN button or its Hot Key. 4. Press YES button to confirm you want to shutdown. 5. You will be told that the system is shutting down, saving files and starting and FTP server and you will be told to wait. In about 10 to 30 seconds 6. Another screen will come up and tell you it is safe to shut off the system power unless you want to wait for the FTP server to come on line. 7. Turn off the Power OR wait for the FTP server. If Ethernet port 1 on the FLECS controller (in the Junction Box) is NOT connected to a Halliburton network it may take about 90 seconds for the server to start and post the IP addresses to the FLECS display. Ethernet port 1 is NOT usable other than on a Halliburton Network because it has been configured to obtain an IP address from a network server. Ethernet port 2 is always usable, but only with a crossover Ethernet cable. Its IP address will always be 10.0.0.1.

1.20 FTP ACCESS

FTP access is restricted only to those who have a good working knowledge of the protocol and understand the tools required to connect to the FLECS Controller via Ethernet. Software and Training in the use of FTP is no longer provided in the FLECS classes. The FTP server and connectability will remain however for those who have a need for it and are comfortable using it. If you want FTP access to the files on the FLECS Controller use the following usernames and passwords. The RESTRICTED logon only allows you to view and copy files from the Controller. It will not allow you to upload, delete or rename files. The ADMINISTRATOR logon has no restrictions. You can read, write, copy, move and rename files and create absolute mayhem should you choose to do so. We recommend you use the RESTRICTED logon if your only intent is to view and retrieve files. This will help guard against mistakes. RESTRICTED SAFE ACCESS USER: cement PASSWORD: cement ADMINSTRATOR ACCESS USER: root PASSWORD: bigkahuna

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Chapter 2 CEMWIN Configuration

2.1 HOW TO COPY SERIAL DEFINITION FILES TO YOUR PC
In the FLECSWIN folder of the USB Pen Drive is a batch file loadtemp.bat that will load Serial Definition files *.ssd for CemWin and/or *.ssf for OptiCem-Insite. These serial definition files define the different variables coming from a FLECS unit via the serial port. In the past we included a job template, but job templates seem to be very inconsistent in their transportability. Because of this issue, we decided to only release tserial definition files. You will have to create your own job templates from here on out. 2.1.1 PROCEDURE 1. Insert USB Pen Drive into Laptop PC with HalWin installed. 2. Browse the pen with File Explorer and find the FLECSWIN folder as shown in screen snapshot below. 3. Double click the loadtemp.bat file. This will run a batch file that will load the *.ssd files to your P.C. The copy is extremely quick. A black DOS box will appear and show where the files were copied. In Version 4.16 this box will remain on the screen to show where files were copied successfully. (In earlier versions the DOS box automatically disappears once copying is completed.)

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4. If running loadtemp.bat was successful then proceed to step 14. If the program was unsuccessful then proceed with step 5. 5. Go to the \FLECSWIN folder on the FLECS USB Pen Drive using Windows Explorer. 6. Right click on the \Template folder contained in the \FLECSWIN folder. 7. You should see a popup menu. 8. Click on the copy selection. 9. Browse to the root or C:\ directory of your PC using Windows Explorer. 10. Right click on the \HalWin folder on your PCs root or C drive a. (This should be the currently installed version of HalWin. If it is not present you probably do not have HalWin installed and will need to install it first before proceeding).

11. A popup menu will appear again. This time select paste.

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12. A Confirm Folder Replace prompt will appear telling you that a folder of the same name already exists and wants to know if you want any of the contents overwritten if the files are of the same name.

13. Click Yes to All to proceed with the copy. 14. Connect your laptop to the HalWin serial output on a running FLECS controller and use the Serial Definition files just copied to create a new Job or Job Template for the cementer. NOTE: A document titled Configuring CemWin for FLECS.doc is available in the \DOCS\1. FLECS Tech Manual\Tech Manual Volume 3\Appendix E. Data Communications folder of your USB pen drive. This will provide you with step by step instructions on loading and creating a new HalWin Template for this version of software.

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2.2 SERIAL OUTPUT SIGNAL DESCRIPTIONS AND UNITS

Below is the serial data stream signal order and the units of measure for the four predefined sets of units. If you modify one of the basic units further you will need to modify one of the existing templates or create your own serial templates. Previous version 3.06 serial templates will still work with version 4.16 software for the first 20 variables. The remaining variables will be improperly labeled. If you require the trailing variables shown below in blue, you will need to load the version 4.16 serial definition files using the loadtemp.bat file and recreate your job templates. Description 1. Recirc Density 2. Downhole Density 3. Mix Water Flow Rate 4. Combined Pump Rate 5. Passenger Side Pressure 6. Driver Side Pressure 7. Mix Water Stage Total 8. Mix Water Job Total 9. Combined Pump Stage Total 10. Combined Pump Job Total 11. Cement Valve Command % 12. Water Valve Command % 13. Passenger Side Pump Rate 14. Driver Side Pump Rate 15. Digital Output 16. Event Codes 17. FLECS Display Internal Temp 18. rho12_hat Density Tracking Term 19. h2_hat Height Tracking Term 20. vhp_density HiPress Density 21. Hfiltered Filtered Tub Level 22. Extra Analog Input 1 23. Extra Analog Input 2 24. Extra Frequency Input 1 Rate 25. Extra Frequency Input 1 Total 26. Extra Frequency Input 2 Rate 27. Extra Frequency Input 2 Total 28. Water/Slurry Ratio 29. Mud Cup Density 30. Passenger Side Pump Stage Total 31. Driver Side Pump Stage Total 32. Mag Meter Belly Line Pump Rate set1 ppg ppg gpm bpm psi psi gal gal bbl bbl % % bpm bpm num_ num_ degF ppg ft ppg ft num_ num_ num_ num_ num_ num_ % ppg bbl bbl bpm set2 km3 km3 m3m m3m mpa mpa m3 m3 m3 m3 % % m3m m3m num_ num_ degF km3 num_ num_ m num_ num_ num_ num_ num_ num_ % km3 m3 m3 m3m set3 kgl kgl lpm lpm bar bar m3 m3 m3 m3 % % lpm lpm num_ num_ degF kgl num_ num_ m num_ num_ num_ num_ num_ num_ % kgl m3 m3 lpm set4 sg sg lpm lpm atm atm m3 m3 m3 m3 % % lpm lpm num_ num_ degF sg num_ num_ m num_ num_ num_ num_ num_ num_ % sg m3 m3 lpm

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Note: The Serial Signal Definition files (*.ssd and *.ssf) can also be opened and viewed using notepad. You can see the signal description and the assigned unit. The ssd files are located in the C:\HalWin\Templates folder.

Chapter 3 REAL TIME DATA (RTD) STORAGE

3.1 WHAT IS AN RTD?
Real Time Data (RTD) is collected serially from COM1 or COM4 of the FLECS Controller and stored in a special compressed file format on your desktop PC using either HalWin or OptiCem. This is done using the GenCom application and usually has a gencom#.rtd file name. The FLECS Controller also collects and stores RTD data of the same job on the FLECS Controller in a duplicate RTD. These RTDs have a numeric name that indicates the year, month, day, hour, minute and second the job was started. A typical file name might be 20060305_125445.rtd. This name indicates the job was started in 2006, March, 5th at 12:54:45 pm. The RTD on the FLECS Controller has a much longer list of extended data. This RTD is sometimes referred to as the Gold Copy. The Gold Copy RTD contains extensive additional information that can be used to troubleshoot, diagnose and follow how the job occurred. It stores raw sensor data, control algorithm data, massaged data (what the operator sees), errors, events and job functions (example- Densometer was base fluid calibrated). It is basically a highly detailed log of what occurred on the FLECS controller during the job. The RTD on the FLECS is stored during the job in a temporary location called RAMDisk. This is a portion of RAM memory set aside for data storage. The RAMDisk allows very fast writing of data with little impact to the control system timing. When an End Job event or a Shutdown is initiated the system copies the job out of RAMDisk to the FLASH Drive. The FLASH drive is where all the system files and past RTD jobs are kept. The RAMDisk is 31 Megabytes in size. This allows for a continuous job of about 24 hours. When RAMDisk space reaches 4 megabytes of remaining space you will begin to get periodic alerts showing you how much log time you have left. If space runs out, the system automatically saves the job to the FLASH drive, clears the RAMDisk and Auto Starts a new job and continues logging data. It is preferable that the operator end the job at a proper time and restart a new job if space gets critically low. This is because the file save from RAMDisk to the Flash Drive could take as long as 90 seconds to complete and that period would not be recorded in an RTD file. A history of past RTD jobs will be kept on the Flash Drive with a limit set to a maximum of 28 jobs or a minimum of 4 MB of available drive space on the Flash Drive. Whichever comes first. Most flash drives on FLECS units are 128MB or larger and it would take several very long jobs to occupy 128 MB or more of storage with 28 files. The RTD storage rate is about 1 MB per hour. Most FLECS systems start up with about 118+ MB of storage on the first start up. This equates to about 118+ hours of job storage before the oldest RTD files

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start to be deleted to make space for new jobs. If you run multiple 12+ hour long jobs you may find it necessary to save the RTDs off the unit more frequently if you require more than a 10 job history to be kept on the unit. Reference Chapter 6, Retrieving RTD files from FLECS for instructions on how to download the RTD files from the FLECS control stack. Note: The Gold Coppy RTD file on the FLECS flash drive can only be accessed after the job.

Chapter 4 Controller Flash Drive File Structure

Below is a listing of the files and folders you would find on the FLECS Controller Flash Drive after software has been installed. The \DATA and \RTD folders will be created by the ADC.EXE application on the first startup. 1. \ <ROOT or TOP Directory> a. FLECS Controller Operating System DISKMON.BIN b. FLECS Controller Application ADC.EXE c. FLECS Display Binary FLECSADC.BFF d. FLECS Elite IO Board Configuration File CONFIG.DTA 2. \RTD Folder a. RTD files from completed jobs yyyymmdd_hhmmss.rtd i. RTD filenames are based on the calendar date and time the job was started. ii. Yyyy = year, mm=month, dd=day, hh=hour, mm=minute, ss=second 3. \DATA Folder a. Contains unit calibration files for all instruments. b. First startup creates all the cal files from default system settings.

Chapter 5 USB Pen Drive File Structure

The USB Pen Drive file structures and contents are detailed in this chapter. 5.1 USB Pen drive file structure
Below is a description of files and folders on the FLECS Technical USB Pen Drive. SAP# 101743269. 1.\ <ROOT or TOP Directory> c. FLECS Controller Operating System DISKMON.BIN d. FLECS Controller Application ADC.EXE e. FLECS Display Binary FLECSADC.BFF f. FLECS Elite IO Board Configuration File CONFIG.DTA g. Various Useful Batch Files - *.BAT h. Various DOS and ETS system Utilities and System Files for booting, installation and drive management.

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4. \FDOS a. FreeDOS Operating System Files. This is the OS that the USB Pen Drive boots up to. Version 4.16 marks the first move to FreeDOS to avoid any Microsoft Licensing Ambiguities. 5. \TEMP a. TEMP directory needed by DOS utilities at times when doing file operations. 6. \FLECSWIN a. LOADTEMP.BAT Batch file to load templates from USB Pen Drive to the HalWin Directory on a laptop PC. HalWin will show the template as i. FLECS ELITE X_Y_Z or FLECS ELITE METRIC X_Y_Z ii. X_Y_Z will correspond to the Controller Version Number. b. Ver411SerialOrder.txt Listing of serial output data in field order. c. See Readme.txt file in this folder for more details d. \FLECWIN\TEMPLATE i. Serial Definition Files for HalWin. e. \FLECSWIN\INSITE i. Serial Definition Files for OptiCem-Insite. Refer to Insite documentation on how to import this file. 7. \DOCS a. Contains Manuals, Technical Documents, Engineering Bulletins, Schematics and Technical Software Utility Programs. 8. \USBPENS a. Self Extracting Executable that can be used to create duplicate bootable USB Pen Drives. These are Lite versions and contain only software. No Documentation. 9. \RTDFILES a. This where RTD files are copied to on the USB Pen drive when the GETRTD command is ran. This command can be configured to run automatically at boot up. 10. \RTDBAK1 and \RTDBAK2 and \RTDBAK3 a. Beginning with ver 4.16 each retrieve is copied to a fresh and empty RTDFILES folder. If the RTDFILES folder pre-exists with files in it from a previous retrieve, that folder will be named RTDBAK1 and a new RTDFILES folder will be created for the new file retrieve. This will process continue for up to four continuous retrieves. The most number of retrieves you can keep on a pen is four. After that the oldest retrieve (RTDBAK3) is deleted, but is recreated and filled with data from RTDBAK2. b. RTDFILES = Data from Latest Retrieve, RTDBAK1 = Data from Previous Retrieve, RTDBAK2 = Data from three retrieves ago, RTDBAK3 = Data from 4 retrieves ago. Data from 5th retrieve ago is deleted. 11. \UNITCOPY a. This is where a complete copy of all the files on the FLECS Controller are copied to if you use the UNITCOPY command.

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5.2 USEFUL BATCH FILES ON THE USB PEN DRIVE

MENU.BAT This is an automated DOS selection menu which can call and execute all the batch commands listed below. It can also be used to create an AUTORUN.BAT file that will run certain commands at every time the USB pen is booted. Commands like retrieving RTD files or backup up cal numbers. AUTORUN.BAT This file can be created by the MENU batch file or created manually using notepad. The file is used to CALL other batch files and run them automatically each time the USB pen is booted up. AUTOEXEC.BAT This is a DOS System Startup file and is ran by DOS automatically when the USB pen drive is booted up on a FLECS controller. This file should not be edited or tampered with. INSTALL.BAT This is the INSTALL command batch file for loading fresh software onto a FLECS Controller. This is the preferred install method. It formats the Controller flash drive, erasing all existing files and then copies a fresh set of software to the controller flash drive. Any previous calibration files are overwritten with default calibration files. HAMMERIT.BAT This is a variant of the INSTALL command except this version does a low level format accompanied by a surface scan. This takes a very long time to complete and is only recommended as a means to recover corrupted flash drives. UPGRADE.BAT This the UPGRADE command batch file. This file is used to upgrade systems with earlier versions of software with the software contained on this pen drive. The UPGRADE command does not reformat the drive or delete any RTD files or calibration data. It simply upgrades the binaries to the version contained on the USB Pen Drive. GETRTD.BAT This is the GETRTD command batch file. This batch file checks the Controller for existing RTD files and then copies those files to a folder named RTDFILES on the USB Pen Drive. This batch file currently runs every time the USB Pen Drive is booted up because it is called from within the AUTORUN.BAT file. RTD files are automatically copied from the Controller to the RTDFILES folder of the USB Pen Drive. CLNRTD.BAT This is identical to the GETRTD command batch file except after copying the files to the USB pen drive it deletes ALL the RTD files off of the FLECS control stack.

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BACKCAL.BAT and BACKUP.BAT The BACKCAL and BACKUP command files are identical in their function. They allow you to backup a trucks calibration files to a folder named BACKUP on the USB Pen Drive. You can only have 1 truck backed up to the USB pen drive at any one time , but you can keep multiple copies of those backups on your PC. This copies ONLY the truck calibration data. It does not copy the software that is currently installed on the Controller or the Display. Use the BACKALL command if you want to back up the FLECS software. CAUTION: Do not use this command to back up files on systems with suspected corrupted flash drives. The files themselves may have erroneous data from residing on a corrupted sector. It is best to recalibrate the units manually. UNITCOPY.BAT The UNITCOPY command creates a folder on the USB Pen drive named UNITCOPY. This command copies every file contained on Controller to the UNITCOPY folder on the USB pen drive. A LOADBACK command does not restore data backed up with the UNITCOPY command. BACKALL.BAT This BACKALL command allows you to back up the truck calibration data as well as the software binaries for the display and the controller. CAUTION: Using the LOADBACK command after issuing a BACKALL will restore the software binaries contained in the backup folder back to the truck. If you intend only to restore calibration data rather than the old software you need to use the BACKCAL or BACKUP commands rather than the BACKALL command. LOADBACK.BAT This is the LOADBACK command batch file. This command allows you to restore the files contained in the BACKUP folder on the USB pen drive back to the Controller. What files are restored depends on which command you used to populate the BACKUP folder. The BACKCAL or BACKUP command only copies calibration data to the BACKUP Folder. A subsequent LOADBACK command will restore only calibration data. If you use the BACKALL command, the BACKUP folder will contain calibration data as well as the software for the FLECS Display and Controller. A subsequent LOADBACK command will then restore not only calibration files but the original FLECS Software that was on the unit. LOADSIM.BAT This is the LOADSIM command batch file. This copies a simulation binary suitable for training to the FLECS Controller. It will simulate a mixing system. UNLDSIM.BAT and RESTORE.BAT The UNLDSIM and RESTORE command batch files are identical. They remove the simulation ADC.EXE binary and restore the controller ADC.EXE binary. OTHER BATCH FILES The other batch files are not for technician use and are mainly used by the batch files already listed above.

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5.3 AUTOMATING COMMANDS AT BOOTUP ON THE USB PEN DRIVE.

The batch file commands listed above can be called and executed automatically at boot time by creating an AUTORUN.BAT file on the USB Pen drive and telling it to CALL those commands at boot up. This will allow you to perform automated backups, intalls and upgrades to the FLECS controller without the need for a VGA monitor or external keyboard. In order for this to work, it is ASSUMED that the Controller will boot to the USB pen drive and run the commands called. This is pretty much a step of faith and if things do not go as planned you will need to connect a VGA monitor and keyboard to the Controller so you can monitor what is going on. The following lines show a series of automated commands that have been entered in the AUTORUN.BAT file. These commands will first backup the calibration data, install new software and then restore the calibration data back to the unit shortly after the USB pen is booted up. call backcal.bat ;Backup unit calibration files only. call install.bat ;Format drive and install fresh operating system and apps. call loadback.bat ;Restores all backed up files in USB "BACKUP" folder. This can be a very handy tool for performing field fixes quickly. However, you must be diligent in deleting the AUTORUN.BAT once you have completed your task. If it is not deleted the AUTORUN call statements will be executed EVERY time the USB pen is booted up. AUTORUN.BAT files can be created and edited using notepad in Windows OR by using the MENU command when booted to the USB pen drive on a control stack with a VGA monitor and keyboard. The MENU automated menu system will allow you create and select commands to run without actually editing a file. How do I know when the commands are done? There are two ways to determine that. One way is to give the unit at least 5 minutes to complete its tasks. The other way is to watch the LED on the USB Pen drive. A flashing LED indicates that work is being conducted. A solid burning LED means that work is completed. When the LED burns solid for about 15 seconds, the task is completed. We recommend you test these automated commands using a VGA monitor so you can get a feel for whether youve been successful or not and to get a sense of the amount of time it takes.

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Chapter 6 Creating and Upgrading USB Pen Drives

Procedure for creating USB Pen drives from Pen Drive images. 6.1 CREATING USB PEN DRIVES FROM PEN DRIVE IMAGES
A shipped USB Pen Drive ordered under SAP# 101743269 with software pre-installed will have Self Extracting USB Pen drive images included on the pen drive in the USBIMAGE folder of the pen drives. The pen images are large self extracting executables that will automatically create a bootable FLECS USB Pen Drive on compatible USB Pen Drives from your desktop PC. Lite versions of Pen Drives images (that is software only, no documentation) may also be made available on the FLECS Web Site o in the E-Tech Community files area for download. 1. To ensure success in creating more bootable pen drives we recommend you purchase blank USB pen drives under SAP# 101461207. These USB Pens are custom tested by Halliburton to ensure bootability. Other manufacturers or makes may be successfully used and you are encouraged to experiment, however your results will vary depending on the make. It is for this reason we decided to have our USB pens custom built for us. 2. Place the Self Extracting Executable on your PCs hard drive. Do not run the executable from a USB Pen Drive. 3. Insert the USB Pen Drive to be burned into your PCs USB Port and take note of the Logical Drive letter assigned to it. It should be drive D, E or F and the drive label should say LOCAL DISK. (The USB Pen must be at least the same size or larger than the USB image you will be using. The image name will indicate the minimum size required) 4. Double Click the Self Extracting Executable. You should see the screen showed below. (Disregard version numbers and dates. This is an example only)

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5. Click the NEXT button.

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6. Select the drop down box and choose the drive letter assigned to your USB Pen Drive. In the example screen below it is drive D.

7. Click the CREATE button. 8. A popup box will appear warning you that the drive is about to be overwritten. Make sure the drive letter and drive size is correct and then click YES. 9. A progress meter will come up showing the drive progress as it is been created. 10. A Drive Successfully created box will then appear. Click the OK. 11. Eject the USB Pen Drive. 12. Inset USB Pen Drive into Powered Off FLECS Controller. 13. Turn FLECS Controller on and verify that USB is booting up into DOS.

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6.2 USING UPGRADE ZIP FILES ON EXISTING USB PEN DRIVES Procedure for upgrading USB Pen drives from zip file upgrade files.
At times upgrades to existing software may distributed as ZIP files. Below is a procedure detailing how to upgrade an existing USB Pen Drive with upgrade files from a ZIP file. 1. Insert your USB Pen Drive in your laptop PC. 2. Copy any files you would like to keep as backups from the USB Pen Drive to a folder on your PC. I recommend copying the entire file drive contents to a folder with a name of the old Controller version that is currently on the USB Pen Drive. For example: Controller BAKUP 3. Double Click the FLECSverXYZ.zip upgrade file you have downloaded. 4. Extract the contents of the file to the drive letter assigned to your USB Pen Drive. In the Graphic below I have selected Local Disk E: which is my USB Pen drive as the destination to unzip the files. Note that I have selected the radio button to have ALL files/folders in Archive extracted and that I want to overwrite existing files and to use the folder names in the zip archive.

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5. After you have copied the files to the USB Pen Drive. Open the FLECSWIN folder on the USB Drive and double click the LOADTEMP.BAT file. This will load the new HalWin Serial Definition Files for this version of software to your laptop PC. 6. Your USB pen drive is now ready to do Controller Version XYZ installations and upgrades. Remove USB drive from laptop PC and follow directions on the following pages to UPGRADE or INSTALL the software on your FLECS Elites. 7. Be sure to copy the new HalWin Serial Definition SSD Files to the Cementers laptops and create new Job Templates for them if needed. The SSD files will have the name FLECS Elite X_Y_Z. Where X_Y_Z is the Controller version number. Refer to document Configuring CemWin for FLECS.doc in \DOCS\1. FLECS Tech Manual\Tech Manual Volume 3\Appendix E. Data Communications folder if you need detailed steps in how to load and use SSD files to create a new Job Template for the cementers.

Chapter 7 FLECS Controller Software Installation

Procedure for Installing the FLECS Operating System and CONTROL Application onto a FLECS Control Stack..
Equipment Needed. 1. FLECS controller stack. (Not the Display). 2. VGA monitor and cable. 3. Standard PC Keyboard with PS/2 connector. 4. FLECS USB boot disk: SAP# 101743269 or 101742919. 5. DC power supply : Set DC voltage to 12.0 volts. Current should be greater than 1 amp but less than 2 amps.

7.1 INSTALL METHOD

NOTICE!: FLECS Ver 4.16 has significant differences in calibration file formats from earlier versions and will require you to perform an install rather than an upgrade for systems prior to ver 4.16. Be sure to commit your unit calibration to paper and manually re-enter it after performing the install. If unit calibration and settings are to be kept we recommend you use the UPGRADE command over the INSTALL command. However, if you suspect that files or the flash drive is corrupted the INSTALL method may correct some issues because it reformats and reinstalls the software. You can backup the Controllers calibration data to the pen drive by using the BACKUP command. After the install you can restore the backup data to the freshly installed system using the LOADBACK command. 1. Connect a VGA monitor and keyboard to your FLECS stack. 2. Insert USB Pen in Controller stack. 3. Turn on power and boot to USB Pen Drive.

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4. You can choose to run MENU to perform the install OR you can use the DOS command line and enter commands manually. MENU is an automated system that will run commands and tasks you select without typing the commands in. The MENU option can be restarted by typing MENU at the command line and pressing enter. 5. Select the Install option in the MENU system OR type "INSTALL" at the c:\ prompt. This will reformat and install the software and all related files from scratch. Previous calibrations and settings will be lost unless you use the BACKUP command prior to issuing the INSTALL command. 6. After install is finished, power off unit, remove USB Pen Drive and reconnect the Controller to the FLECS Display. The next step is to allow the newly installed Controller software to upload the new Display software to the FLECS Display. 7. If your previous Controller version was 2.1.0 you can turn the unit back on and the system will handle updating the software on the FLECS Display automatically. If your previous version was Controller version 2.0.2 or 2.0.3 you will need to proceed to the FLECS Display Software Installation procedure further below. 8. Install the HalWin Templates for this version on the Cementers laptops You will find a FLECSWIN folder on your USB Pen Drive that contains HalWin Templates for this version of software. Follow the README.TXT file in that folder for instructions on how to install the templates to a laptop. 7.1.1 BLIND INSTALL OPTION The USB Pen Drives AUTORUN.BAT file can be edited so that the system automatically performs an install to the FLECS Controller without connecting a keyboard or VGA monitor. The down side to this procedure is that you will be taking it on faith that your USB pen drive is bootable and that the FLECS controller will boot to the device and that the files will be successfully copied. Using a keyboard and VGA display allows you to verify the USB boot and install completed successfully. 1. Open the AUTORUN.BAT file on your USB Pen Drive in an ASCII text editor like notepad. Do not use Microsoft Word, Works or Write. Use notepad. If AUTORUN.BAT does not exist then create it. 2. Insert the words CALL INSTALL.BAT line in the AUTORUN.BAT file. 3. Save the changed file. 4. Insert USB Pen in Controller Stack and turn power to unit on. Install will occur automatically. Give system about 3 minutes to complete the task. 5. After 3 minutes turn power off, remove USB Pen Drive. Turn power to unit back on. If you upgraded from Controller version 2.0.2 or 2.0.3 proceed to the FLECS DISPLAY SOFTWARE INSTALLATION section below to complete the software upgrade. If you upgraded from Controller version 2.1.0 the system will automatically upgrade the FLECS Display within about 3 minutes of power up.

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NOTE! Keep in mind this will install software to every controller it is booted to! Once youre finished with using it for blind installs, delete the AUTORUN.BAT file from the USB Pen drive. NOTE! AUTORUN files and tasks can be created using the MENU command system. Start MENU and make your selections.

7.2 UPGRADE METHOD

NOTICE!: FLECS Ver 4.16 has significant differences in calibration file formats from earlier versions and will require you to perform an install rather than an upgrade for systems prior to ver 4.16. Be sure to commit your unit calibration to paper and manually re-enter it after performing the install. 1. Connect a VGA monitor and keyboard to your FLECS stack. 2. Insert USB Pen in Controller stack. 3. Turn on power and boot to USB Pen Drive. 4. You can choose to run MENU to perform the upgrade OR you can use the DOS command line and enter commands manually. MENU is an automated system that will run commands and tasks you select without typing the commands in. The MENU option can be restarted by typing MENU at the command line and pressing enter. 5. Select the Upgrade option in the MENU system OR type "UPGRADE" at the c:\ prompt and the new software will be installed. This only upgrades the binaries and will not overwrite the unit calibration. 6. After upgrade is finished, power off unit, remove USB Pen Drive and reconnect the Controller to the FLECS Display. The next step is to allow the newly installed Controller software to upload the new Display software to the FLECS Display. 7. If your previous Controller version was 2.1.0 or later you can turn the unit back on and the system will handle updating the software on the FLECS Display automatically. If your previous version was Controller version 2.0.2 or 2.0.3 you will need to proceed to the FLECS Display Software Installation procedure further below. 8. Install the HalWin Templates for this version on the Cementers laptops. You will find a FLECSWIN folder on your USB Pen Drive that contains HalWin Templates for this version of software. Follow the README.TXT file in that folder for instructions on how to install the templates to a laptop. 7.2.1 BLIND UPGRADE OPTION The USB Pen Drives AUTORUN.BAT file can be edited so that the system automatically performs an upgrade to the FLECS Controller without connecting a keyboard or VGA monitor. The down side to this procedure is that you will be taking it on faith that your USB pen drive is bootable and that the FLECS controller will boot to the device and that the files will be

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successfully copied. Using a keyboard and VGA display allows you to verify the USB boot and upgrade completed successfully. 1. Open the AUTORUN.BAT file on your USB Pen Drive in an ASCII text editor like notepad. Do not use Microsoft Word, Works or Write. Use notepad. If it does not exist then create one. 2. Insert the words CALL UPGRADE.BAT in the AUITORUN.BAT file. 3. Save the changed file. 4. Insert USB Pen in Controller Stack and turn power to unit on. Files will be copied automatically. Give system about 3 minutes to complete the task. 5. After 3 minutes turn power off, remove USB Pen Drive. Turn power to unit back on. If you upgraded from Controller version 2.0.2 or 2.0.3 proceed to the FLECS DISPLAY SOFTWARE INSTALLATION section below to complete the software upgrade. If you upgraded from Controller version 2.1.0 or later the system will automatically upgrade the FLECS Display within about 3 minutes of power up. NOTE! Keep in mind this will upgrade EVERYTHING it is booted to. Once youre finished with using it for blind upgrades, delete the AUTORUN.BAT file from the USB Pen drive. NOTE! AUTORUN files and tasks can be created using the MENU command system. Start MENU and make your selections.

Chapter 8 FLECS DISPLAY SOFTWARE INSTALLATION

Procedure on how to Upgrade FLECS Display Software on early systems that do not have the Auto Update feature implemented. (Controller Versions 2.0.3 or earlier, Display Versions 2.1.1 or earlier). 8.1 For Controller Versions 2.0.3 or Earlier
NOTICE: This procedure is for early systems running FLECS Controller versions 2.0.2 or 2.0.3 and FLECS Display versions 2.1.1 or earlier. These versions pre-date the auto update feature for the FLECS Display and will require a technician to set the FLECS Display into download mode by initiating a Power-On Setup at the FLECS display. Once this is done the FLECS Controller 3.0 Software will upload the new display software to the FLECS Display. To check your Controller Version number, go to the FLECS Display and Press MENU, System Information. Note the Controller version number displayed. If it is 2.0.3 or 2.0.2 you will need to follow the procedure below to get the Controller to upload the new Display Software to you FLECS Display. 8.1.1 UPGRADE TO CONTROLLER MUST BE APPLIED FIRST. 1. Controller version 3.0 must be loaded on FLECS stack first from the USB Pen drive using the upgrade or install commands mentioned earlier. This will put the correct display software onto the Controller so that the controller can upload it to the display.

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8.1.2

GO INTO POWER ON SETUP. 2. With system power off, place left hand thumb in upper left hand corner of the touch screen on the FLECS Display. 3. Turn power on to the FLECS system while holding thumb down. 4. You should see a multicolored Power On Setup screen appear on the FLECS Display. When you first see these words you may lift your thumb from the touch screen. 5. At the bottom of the touch screen are two green BACK and NEXT arrow buttons and one green square SELECT button.

8.1.3

SET FLECS DISPLAY TO DOWNLOAD MODE. 6. The FLASH MEMORY text in the upper left hand side of the screen should be highlighted. (White background with black letters). If it is not highlighted use the arrow keys to move through the menu headings until FLASH MEMORY is highlighted. 7. Press the green SELECT button. 8. This should move the highlighted field to the App mode: text of the FLASH MEMORY group of selections. 9. Press the green SELECT button. 10. This should move the highlighted field to the Run App field located to the right of the App mode text. 11. Press the green NEXT arrow to change the selections in this field. Press NEXT until Download is shown in the highlighted region. 12. Press the green SELECT button to select this setting. App mode should now be highlighted again.

8.1.4

ERASE THE FLASH FILE SYSTEM 13. Press the green NEXT arrow key. Erase FFS should now be highlighted. 14. Press the green SELECT button. A new field will appear to the right and the word No will be highlighted. 15. Press the green NEXT arrow key until Yes appears. 16. Press the green SELECT button. The system will tell you to please wait while it erases the flash. 17. FLASH MEMORY should now be highlighted again. If not, press the green BACK arrow button until it is.

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8.1.5

SAVE SETTINGS AND EXIT 18. Press the green BACK arrow again and the screen will move to a new page with the text DONE highlighted. 19. Press the SELECT key. The text Save and Exit should be highlighted. 20. Press the SELECT key. The Display will clear and indicate for the user to Download the application. 21. The FLECS stack will upgrade the terminal in 1 to 2 minutes and then autostart the stack and the terminal.

8.2 DEALING WITH DISPLAY SOFTWARE UPLOAD PROBLEMS

If a display upload failed with CRC errors please check the following list and proceed to the next section before calling Duncan Technology. CHECK 1: Check your serial display communications wiring. In particular, make sure the RTS and CTS lines of the serial cable are straight wired and not crossover wired. Earlier units were delivered with the RTS/CTS lines crossover wired. The crossover wiring does not impact communications with the controller except when attempting to upload the new display software. Later units were correctly wired with the CTS and RTS lines wired straight through. Pin 7 to Pin 7, Pin 8 to Pin 8. CHECK 2: Go into Power On Setup and set COM1 Flow Control from RTS/CTS to NONE. (After verifying and correcting any wiring issues). CHECK 3: If there is a shield and drain wire on the RS232 Communications cable, make sure it has been grounded at the FLECS controller junction box to the 12 volt ground side of TB1 and that the shield and drain at the other end near the FLECS display is floating, that is to say, unconnected and isolated from any other connection or short to chassis ground or adjacent signal wires. If the RS232 cable is NOT shielded you may need to change out the cable for a shielded CAT 5 cable or similar shielded instrument cable to correct your problem. Ground the shield as recommended here and also ground the unused pair mates of the TXD and RXD line. (Shielded CAT 5 cable can be ordered from Halliburton SAP# 326464) CHECK 4: If there is a large amount of excess length in the display RS232 cable, shortening it up may improve signal integrity. CHECK 5: FIX ATTEMPTMost Cat 5 cables have 4 twisted pairs. You can effectively create a shielded transmission line by grounding one of the two wires in a twisted pair and letting the other line carry data. In the display serial cable the TXD line should be an orange wire and the RXD line should be a white/green wire. Each of these wires should be one of a twisted pair. The other member of the pair is currently unterminated. A shielded transmission line can be effectively created by grounding the other member of the pair. Provided that your TXD line is using the orange wire and the RXD line is using the white/green wire per the Elite Master Wiring Prints, ground the white/orange wire and the green wire at the controller end of the display cable. This can be done inside the backshell of the 9 pin DB9 connector located at the Controller in

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Junction Box. Solder the 3 wires to be grounded together in a 3 to 1 pigtail and then connect the single wire end to Pin 5 of the DB9 metal shell connector (which is ground). See diagram below. In addition to grounding the unused conductor of the signal carrying pairs, you might want to consider getting a shielded CAT5 cable if the current FLECS Display Serial Cable does not have an overall cable shield and drain wire. Ground the drain wire at the Controller end to the filtered battery ground side of battery power. (Shielded CAT 5 cable can be ordered from Halliburton SAP# 326464).

After making these checks reattempt the upload again. If this fails you may need to program the display manually on the instrument bench. See next section.

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Chapter 9 FLECS Controller Hardware Configuration

Procedures for hardware specific configuration of the FLECS Controller Stack. 9.1 FLECS BIOS CONFIGURATION
This procedure instructs the user on how to configure enter the BIOS of a FLECS Control Stack so that it can be configured for use as a cementing control system. This is usually needed only once at the first install of an Ampro CPU board to a Controller Stack. New controllers should come from the manufacturer with the card already configured correctly. However, if you are experiencing problems or have recently replaced the CPU board in your stack should consider checking the BIOS settings. There are currently two CPU boards in existence. The first board is the Ampro LB700. It has been in use since 2005. A new board, the LB620 will start appearing in 2009. Bios configuration documents are available on the USB pens in \DOCS\1. FLECS Tech Manual\Tech Manual Volume 3\Appendix L. Ampro Mother Boards.

9.1.1

ENTERING BIOS ON AMPRO LB700 BASED SYSTEMS

POWER ON FLECS PRESS THE DELETE KEY ONCE EVERY 2 SECONDS DURING BOOT-UP TO ENTER STANDARD CMOS SETUP SELECT BIOS and Hardware Settings AND PRESS ENTER Refer to LB620 BIOS Settings Documents in \DOCS\1. FLECS Tech Manual\Tech Manual Volume 3\Appendix L. Ampro Mother Boards\Ampro LB700

LB700 BIOS SCREEN

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9.1.2

ENTERING BIOS ON AMPRO LB620 BASED SYSTEMS

POWER ON FLECS PRESS THE DELETE KEY ONCE EVERY 2 SECONDS DURING BOOT-UP TO ENTER STANDARD CMOS SETUP Refer LB620 BIOS Document in \DOCS\1. FLECS Tech Manual\Tech Manual Volume 3\Appendix L. Ampro Mother Boards\Ampro LB700

LB620 BIOS SCREEN

9.2 REPAIRING A CORRUPTED COMPACT FLASH DRIVE

This procedure instructs the user on how to repair a corrupted compact flash. Symptoms of a corrupted flash are problems with file storage, copying files from the compact flash, Scan disk diagnostic routine errors, Scandisk diagnostic routine running slow, etc.. Consider the procedure below to repair the compact flash. This problem can occur on FLECS controllers that were installed with the early Controller version 2.0.2 Software. This corruption can occur when FLECS systems are turned on and then powered off while they are still in the process of booting up. Later controller versions do not have this vulnerability and we highly recommend you upgrade to Controller version 2.0.3 or later to reduce the probability of disk corruption. Software can be retrieved at the FLECS Web Site. Press the CTRL key and click here to go to the FLECS web site. 9.2.1 SYMPTOMS OF A CORRUPTED FLASH ARE 1. Problems with calibration data or unit setup storage. This usually shows up as calibration data or blend data that can not be changed or retained between sessions. For examples a cal point comes up missing and attempts to change it wont stick. 2. RTD data files are not being created on the machine or can not be retrieved with data intact.

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3. Controller lock ups. When a controller locks up you will lose serial communication on all 4 serial ports. If you lose communication to the FLECS display on COM2 and the HalWin job data on COM1 simultaneously it is likely the controller has locked up. However, if you have serial communication out any of the 4 serial ports the controller is still running and you most likely have a connector or cable problem. 9.2.2 EQUIPMENT NEEDED:

1. FLECS controller stack. (The display is not needed for this procedure). 2. VGA monitor and cable. 3. Standard PC Keyboard with PS/2 connector. 4. FLECS USB boot disk: SAP# 101743269 or 101742919. 5. DC power supply: Set DC voltage to 12.0 volts. Current should be greater than 1 amp but less than 2 amps without a FLECS display attached. 9.2.3 PROCEDURE: BACKUP, FORMAT AND RE-INSTALL

1. Apply Power to the FLECS Controller. 2. The stack should boot to the USB disk, the USB disk will become the C: drive and the compact flash will become the D: drive. 3. If the unit calibration was still good when the system went down, run the backup command to backup all the unit calibration to the USB pen drive for later restoration. Type backup at the command prompt followed by pressing the enter key to copy the units calibration data to the USB disk. 4. Run the program installation program to reformat the drive and install a fresh copy of the FLECS software. Type install at the command prompt followed by pressing the enter key to begin installation. You will see the system reformat the drive and copy several files to the system. 5. To restore the unit calibration from a backup copy that was made earlier using the backup command. Type loadback at the command prompt followed by pressing the enter key to place the backed up calibration back on the controller. Software Installation is complete. DOS 6.22 USB Pens (Versions prior to 4.10, such as 3.06 and 4.03) 6. After the install is completed run scandisk on the D:\ drive to verify that the FLECS flash drive is in good health. Type scandisk d: Scandisk will run some quick checks and then ask if you would like to do a surface scan. Select YES to accept a surface scan. 7. If scandisk reports any errors OR if it locks up completely the flash drive may need to be replaced. Scandisk may take hours to run if problems are

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detected. The system may still be recoverable by proceeding to the next section. 8. If installation went well with no reported errors by scandisk , power of the system and remove the USB Pen Drive. Power the FLECS controller back up and verify that the FLECS will boot up and run. FREEDOS USB Pens (Versions 4.10 and later) 9. After the install is completed run dosfsck on the D:\ drive to verify that the FLECS flash drive is in good health. Type dosfsck a v d: dosfsck will run some quick checks. If no errors are reported you are good to go. 10. If dosfsck reports any errors OR if it locks up completely the flash drive may need to be replaced. The system may still be recoverable by proceeding to the next section. 11. If installation went well with no reported errors by dosfsck , power of the system and remove the USB Pen Drive. Power the FLECS controller back up and verify that the FLECS will boot up and run.

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9.2.4

PROCEDURE: DELETE AND RECREATE PARTITION

This section is a last ditch effort to recover a problematic or unrecoverable flash disk. It is important that you follow instructions carefully. It is assumed you have already attempted a disk format and reinstall without success. (See section 1.1.3). If the following procedures are improperly executed you could accidentally delete the partition on the USB Pen drive rather than the FLECS flash drive. Two procedures are provided. The FreeDOS procedure and the DOS 6.22 procedure. All USB pens prior to Version 4.10 use DOS 6.22. FREEDOS PROCEDURE FOR USB PENS VERSIONS 4.10 AND LATER 1. Power up the Controller Stack 2. The stack will attempt to boot from the USB disk, the USB disk will become the C: drive and the compact flash will become the D: drive. 3. Run the disk drive management tool fdisk by typing the following command fdisk. 4. At (FAT 32) Support. Type Y and hit Enter key. 5. The FDISK Options screen should be displayed. Choose option 5. Change current fixed drive, by pressing the 5 key to select that option followed by pressing the enter key to verify your selection and proceed to the next screen. 6. You should now be at the Change Current Fixed Disk Drive screen. You should see Disk 1 which is the C drive or the USB Pen drive in this case, and you should see Disk 2 which is the FLECS Controller Flash Drive. This is the drive we want to select. 7. Press the 2 key to select Disk 2 followed by pressing the enter key. 8. You should now be back at the FDISK Options screen. Make sure the Current fixed disk drive: has disk 2 shown as the selected disk. 9. Choose option 3. Delete partition or Logical Dos Drive by pressing the 3 key followed by pressing the enter key. 10. You should now be at the Delete DOS Partition or Logical DOS Drive screen. Choose option 1. Delete Primary DOS partition by pressing the 1 key followed by pressing the enter key. 11. You should now be at the Delete Primary DOS Partition screen. There should only be one partition shown which is partition D: 1. Press 1 to select

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partition 1. At the bottom of the screen partition 1 should be the partition selected for deletion. Press the enter key to confirm partition 1 is to be deleted. You will be asked to confirm your action. Press Y for yes followed by pressing the Enter key. 12. The partition has now been deleted. The bottom of the screen should say Primary DOS Partition deleted. Press the Esc key to return to the FDISK Options screen. 13. Choose option 1. Create DOS partition or Logical DOS drive followed by pressing the enter key. 14. You should now be at the Create DOS partition and Logical DOS drive screen. Choose option 1. Create Primary DOS Partition followed by pressing the enter key. 15. You should now be at the Create Primary DOS Partition screen. Look at the top of the screen and make sure the current fixed disk drive is 2. You will be asked if you want to use the maximum available size for the new partition. Y for yes should already be selected. Press the enter key to confirm Yes. 16. The new partition has now been created. Bottom of screen should say Primary DOS Partition created. 17. You should now be back at the FDISK Options screen. Press 2 to select Set Active Partition and press the Enter key. 18. You should now be at the Set Active Partion Screen. Current Fixed Disk Drive should still be 2. Partition should be D: 1. Press 1 to set partition 1 active and the press the Enter key. 19. You should see the letter A appear beneath the Status heading indicating that partion 1 is now the active partition. This is important. An operating system will not boot unless the partition is active. 20. Press the Esc key to return to the FDISK Options menu. 21. Press the Esc key to exit the FDISK Options menu. 22. You will be notified that the system will need to be restarted. Press the Esc key again to exit FDISK. 23. Power off the system and reboot back to DOS on the USB pen drive. 24. Run the program install.bat to automatically format the new partition and install the cementing software on the compact flash. (If you get some kind of error. Try running format d: first and then run the install command again).

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25. After the install is completed run dosfsck on the D:\ drive to verify that the FLECS flash drive is in good health. Type dosfsck a v d:. This utility will run some quick checks and attempt to automatically fix certain errors. a. NOTE: This check always reports a discrepancy between the boot sector and its backup. This is due to the ETS OS install and is perfectly normal. This appears as a long stream of characters like , 406:0a/00, 407:b4/00, 408:0e/00 followed by the statement Not automatically fixing this. This is normal and will not effect the flash drive operation. b. A copy of a normal dosfsck output stream is in \DOCS\1. FLECS Tech Manual\Tech Manual Volume 3\Appendix A. FLECS Software\normal_dosfsck_test_results.txt 26. If dosfsck reports any errors it can not fix OR if it locks up completely, the flash drive is most likely unrecoverable and needs replaced. 27. Power down system. Installation is complete. Remove USB pen drive and power up FLECS system. Verify system is up and running and communicating with display 28. Recalibrate the unit instrumentation. 29. Perform a Shutdown after calibration to save settings. 30. Power off unit and then re-power system up and verify that all calibration settings have been properly saved and recalled on following power up. 31. Test the unit to verify functionality and operational aspects.

DOS 6.22 PROCEDURE USING USB PENS PRIOR TO VER 4.16 1. Power up the Controller Stack 2. The stack will attempt to boot from the USB disk, the USB disk will become the C: drive and the compact flash will become the D: drive. 3. Run the disk drive management tool fdisk by typing the following command fdisk. 4. The FDISK Options screen should be displayed. Choose option 5. Change current fixed drive, by pressing the 5 key to select that option followed by pressing the enter key to verify your selection and proceed to the next screen. 5. You should now be at the Change Current Fixed Disk Drive screen. You should see Disk 1 which is the C drive or the USB Pen drive in this case, and you should see Disk 2 which is the FLECS Controller Flash Drive. This is the drive we want to select. 6. Press the 2 key to select Disk 2 followed by pressing the enter key.

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7. You should now be back at the FDISK Options screen. Make sure the Current fixed disk drive: has disk 2 shown as the selected disk. 8. Choose option 3. Delete partition or Logical Dos Drive by pressing the 3 key followed by pressing the enter key. 9. You should now be at the Delete DOS Partition or Logical DOS Drive screen. Choose option 1. Delete Primary DOS partition by pressing the 1 key followed by pressing the enter key. 10. You should now be at the Delete Primary DOS Partition screen. There should only be one partition shown which is partition D: 1. At the bottom of the screen partition 1 should be the partition selected for deletion. Press the enter key to confirm partition 1 is to be deleted.You will be asked to enter the volume label to confirm your request to delete the partition. Look at the partition Volume Label shown towards the top of the screen. If the partition has a volume label enter it exactly as shown and press the enter key. If it is blank then just press the enter key. 11. You will be asked to confirm your action. Press Y for yes followed by pressing the enter key. 12. The partition has now been deleted. Press the Esc key to return to the FDISK Options screen. 13. Choose option 1. Create DOS partition or Logical DOS drive followed by pressing the enter key. 14. You should now be at the Create DOS partition and Logical DOS drive screen. Choose option 1. Create Primary DOS Partition followed by pressing the enter key. 15. You should now be at the Create Primary DOS Partition screen. Look at the top of the screen and make sure the current fixed disk drive is 2. You will be asked if you want to use the maximum available size for the new partition. Y for yes should already be selected. Press the enter key to confirm Yes. 16. The new partition has now been created. 17. Press the Esc key to return to the FDISK Options menu. 18. Press the Esc key to exit the FDISK Options menu. 19. You will be notified that the system will now restart. Press any key to restart the system and reboot back to DOS on the USB pen drive. 20. Run the program install.bat to automatically format the new partition and install the cementing software on the compact flash.

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21. After the install is completed run scandisk on the D:\ drive to verify that the FLECS flash drive is in good health. Type scandisk d: Scandisk will run some quick checks and then ask if you would like to do a surface scan. Select YES to accept a surface scan. 22. If scandisk reports any errors OR if it locks up completely the flash drive is most likely unrecoverable and needs replaced. 23. If scandisk completes without errors, exit scan disk. 24. Power down system. Installation is complete. Remove USB pen drive and power up FLECS system. Verify system is up and running and communicating with display 25. Recalibrate the unit instrumentation. 26. Perform a Shutdown after calibration to save settings. 27. Power off unit and then re-power system up and verify that all calibration settings have been properly saved and recalled on following power up. 28. Test the unit to verify functionality and operational aspects.

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Chapter 10 FLECS Display Configuration

10.1 FLECS DISPLAY POWER ON SETUP SETTINGS
The QSI terminal uses the serial port to communicate with the FLECS control stack. Com port 1 on the terminal is the serial port being used. Serial port 2 is not used. FLASH MEMORY App Mode: RUN Set to download to get FLECS Controller to upload Display Software. DISPLAY Backlight (255) Orient: Landscape Dcache: Eff. Enabled CALIBRATION Temp: <Current Temp> Use calibrated sensor if setting temp. Bring display and reference temp device into office environment allow each to sit for 1 hour. Power up both and set temp on display immediately. Date: <Current Date> Time: <Current Time> Date and time can be set in FLECS Software as well. Touch Screen Selecting this field goes through a touch screen calibration procedure. NETWORK DHCP: OFF <The DHCP selection only appears in 2.6 Firmware and later IP: 010.000.000.002 Sub: 255.255.252.000 Gate:000.000.000.000 COM1 and COM2 Baud Rate: 38400 Data Bits: 8 Parity: N Stop Bits: 1 Flow Ctrl: None KEYPAD Key Click: Key Repeat: Rpt Delay: Rpt Rate: AutoShift: AutoPower: Off On 520ms 100ms Off Off

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Backlight: FEEDBACK Type: Disp

Off

Version 2.6 firmware or later Serial: Off Video: On UDP: Off MISCELLANEOUS Information Selecting this field gives you technical info about the display. Use Password: No DIAGNOSTICS KeyPad Key: Transmit Key: DONE Save and Exit Exit w/o save Selecting this field allows you to trouble shoot keypad. No Save all changed settings and exit Exit without saving changes

10.2 PROGRAMMING DISPLAY WITH PROGRAMMERS CABLE ON INSTRUMENT BENCH

NOTICE: FLECS Controller Software version 2.1.0 and later and FLECS Display Software 2.2.0 and later have provisions to automatically handle programming the FLECS display from the FLECS Controller. The following procedure is provided in the event you need to program the FLECS display manually due to extenuating circumstances.

10.2.1 EQUIPMENT NEEDED 1. FLECS Display to be Upgraded. 2. FLECS Display Serial Programmers Cable: SAP# 101405874 if programming display when not installed on unit 3. FLECS Application Binary located on FLECS support CDROM or from FLECS support website. 4. Laptop PC with 9 pin RS232 serial port OR a USB to 9 pin RS232 adapter cable. 5. A copy of the STPdownloader.exe Terminal Programmer Software. (Runs on Laptop). Which is on your FLECS support CDROM or USB Pen Drive or from FLECS support website.

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The procedure on the following pages incorporates a special programmers cable that supplies 12 volts to the FLECS display to power it and perform off unit firmware/software installs.

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10.2.2 1. 2. 3. 4.

PROCEDURE Hookup Serial Programmers cable to rs-232 com port on your laptop. Plug AC adapter of programmers cable into 110 AC outlet. Do not connect second 9 pin adapter to the FLECS display. Asuming your CDROM or USB Pen Drive is drive N:\. Open explorer and browse to N:\Display\STPdownloader.exe. Double click the executable and you should see the application shown below. 5. Set your com port settings as shown below. a. Com Port = COM1 or the first available serial port on your Laptop. On USB to RS232 adapter or an EDGEPORT type device, you may have to choose a port well down the list. In the example below Com7 was the first available port. b. Baud Rate = 38400 is the default baud rate to connect to the FLECS display. c. Data Format = 8n1 d. Flow Control = Hardware e. Download Type = Application Download 6. Click on browse button and navigate to root directory or N:\ folder. You should see a file there with a *.bff file extension. This is the FLECS display binary. Click on this file and it should now show up in the Filename field of the application shown below. 7. Click on the Red Port State button and open the com port. If successful it will turn green as shown below.

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8. Initiate a Power-On Setup on the FLECS display. f. Place left hand thumb in upper left hand corner of the touch screen on the FLECS Display. g. Plug in the 2nd 9 pin serial adapter of the programmers cable into the com port located on the back of the FLECS display while simultaneously keeping your left hand thumb held down on the touch screen 9. If done correctly you will see a multicolored Power On Setup screen appear. When you first see these words you may lift your thumb from the touch screen. 10. At the bottom of the touch screen are two green BACK and NEXT arrow buttons and one green square SELECT button. 11. The FLASH MEMORY text in the upper left hand side of the screen should be highlighted. (White background with black letters). If it is not highlighted use the arrow keys to move through the menu headings until FLASH MEMORY is highlighted. 12. Press the green SELECT button. 13. This should move the highlighted field to the App mode: text of the FLASH MEMORY group of selections. 14. Press the green SELECT button. 15. This should move the highlighted field to the Run App field located to the right of the App mode text. 16. Press the green NEXT arrow to change the selections in this field. Press NEXT until Download is shown in the highlighted region. 17. Press the green SELECT button to select this setting. App mode should now be highlighted again. 18. Press the green BACK arrow key. FLASH MEMORY should be highlighted again. 19. Press the green BACK arrow again and the screen will move to a new page with the text DONE highlighted. 20. Press the SELECT key. The text Save and Exit should be highlighted. 21. Press the SELECT key. The Display will clear and indicate for the user to Download the application.

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22. If you look at the STP downloader application you should see the same message that is on the FLECS display screen appear in the download results box at the bottom.

This indicates your com settings are correct and that you have established a connection to the display.

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23. Click the Download button. System should show a progress bar and status in the download results field box indicating that it is receiving the new application. See below.

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24. After download is completed the system should show the application was received and programmed. Cycle power and verify that application is retained in memory.

FLECS Display tells you the application was received and programmed.

25. The newly downloaded application should now be running on the FLECS display. 26. On the FLECS Display, press MENU SYSTEM INFORMATION on the FLECS display. This will display the software version on the controller. 27. If you get errors while downloading or if the application fails to come up and run you will need to cycle power on the FLECS display and repeat all the steps. Double check all connections and check com port settings for correctness. 28. Close the STPdownloader application. 29. Disconnect the 110 AC adapter on the FLECS programmers cable and install Display back on unit.

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10.3 PROGRAMMING DISPLAY WHILE IT IS STILL ON THE UNIT

You can perform upgrades to the FLECS display while it is on the unit by substituting the following numbered steps for the corresponding steps of the same number in the previous section, (Section 10.2). This will allow you perform an on unit software install. FOR STEPS 1 thru 3 substitute the following steps. 1. Turn FLECS system power off on the truck. 2. Open junction box on side of the truck and disconnect the 9 pin RS232 connector on COM2 of the FLECS Controller Stack. (This is the FLECS Display communication port) 3. Connect a STANDARD (Not a Null Modem) RS232 Serial Cable from your laptops COM port to the 9 pin RS232 connector you unplugged in step 2. You should now have a serial connection from you laptop PC to the FLECS Display in the control stand. FOR STEP 8 above substitute the following step 8. 8. Initiate a Power-On Setup on the FLECS display. h. Place left hand thumb in upper left hand corner of the touch screen on the FLECS Display. i. Turn on the system electrical power and allow FLECS system to power up. FOR STEPS 28 and 29 above substitute the following steps 28, 29 and 30. 28. Shut system electrical power off at the control stand. 29. Disconnect Serial Cables and reconnect FLECS display serial connector to COM2 on the FLECS controller stack. 30. Power FLECS system back up and verify that new application is communicating with controller and performing expected functions.

10.4 USING FLECS DISPLAY AUTOUPDATE FEATURE

Follow the procedure below that best describes your situation. Procedure A: Auto-update Incompatible Software on FLECS Display or No Software at all on FLECS Display. After installing new software on the FLECS control stack (Refer to Chapter 2) you will need to perform a Power On Setup on the FLECS Display and put it in download mode. 1. Initiate a Power-On Setup on the FLECS display. a. Place left hand thumb in upper left hand corner of the touch screen on the FLECS Display. b. Turn FLECS System Power On. 2. If done correctly you will see a multicolored Power On Setup screen appear. When you first see these words you may lift your thumb from the touch screen. 3. At the bottom of the touch screen are two green BACK and NEXT arrow buttons and one green square SELECT button.

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4. The FLASH MEMORY text in the upper left hand side of the screen should be highlighted. (White background with black letters). If it is not highlighted use the arrow keys to move through the menu headings until FLASH MEMORY is highlighted. 5. Press the green SELECT button. 6. This should move the highlighted field to the App mode: text of the FLASH MEMORY group of selections. 7. Press the green SELECT button. 8. This should move the highlighted field to the Run App field located to the right of the App mode text. 9. Press the green NEXT arrow to change the selections in this field. Press NEXT until Download is shown in the highlighted region. 10. Press the green SELECT button to select this setting. App mode should now be highlighted again. 11. Press the green BACK arrow key. FLASH MEMORY should be highlighted again. 12. Press the green BACK arrow again and the screen will move to a new page with the text DONE highlighted. 13. Press the SELECT key. The text Save and Exit should be highlighted. 14. Press the SELECT key. The Display will clear and indicate for the user to download the application. You should see the FLECS Application begin a download in about 60 seconds after setting the unit in download mode. If the download does not occur you may have taken too long putting the unit in download mode. You have about a minute to do this. Just shut the unit off and perform a power on setup again and try to accomplish putting it in download mode in under a minute. Procedure B: Auto-update Compatible Systems FLECS Cementing Software that is Auto-update compatible is Control ver 2.1.0 or later and Display version 2.2.0 or later. Both the display and the controller need to have the versions above or later for Auto-update to work. On systems with compatible Auto-update software you need only install the software on the FLECS controller and then cycle power. On the first power up after the install the FLECS controller will check the software version on the FLECS display. If it is an older version of software it will tell the FLECS display to put itself in download mode and then upload the version of software it is supposed to be using. During this process the system will come up normally and then you will see the FLECS display reset itself. A black screen with white characters will then come up. In a minute or less you should see the new application being uploaded to the display.

10.5 PROGRAMMING DISPLAY VIA ETHERNET ON THE INSTRUMENT BENCH

FLECS Displays are equipped with an Ethernet port on the backside of the display and this port can be used to upload the display software to the display. On later FLECS Displays an Ethernet

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bulkhead connector is provided on the backshell along with the serial port. On earlier FLECS Displays you will have to remove the backshell to obtain access to the Ethernet port.

EQUIPMENT REQUIRED 1. Bench Power Supply: Set to 12 Volts. Bench supply capable of at least 1 Amp. 2. 9 pin DB9 connector for connecting bench power through COM1 DB9 connector. a. +12V Pin 9 b. GND Pin 5 3. Standard Ethernet Cable 4. Qlarity Downloader Utility Program 10.5.1 LOCATE AN UNUSED IP ADDRESS ON YOUR NETWORK SUBNET 1. Connect your laptop to the Halliburton Network in your lab and boot it up to the network. 2. Open a DOS box and type the command ipconfig at the command line and hit the Enter key. 3. You should get a response like the one below that shows your laptops IP address, subnet and gateway addresses.

4. Record the subnet address and gateway address for entry into the FLECS display. 5. Now start looking for an unused ip address on your subnet by adding or subtracting numbers from the last number of your laptops IP Address

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6. My IP address was 34.2.61.76. I started looking by adding 1 to the last number and then pinging the network to see if I got a reply. 7. I pinged 34.2.61.77 by opening a dos box and typing ping 34.2.61.77 and hitting enter. See box below. As you can see I got a reply which means that address is not available.

8. Next I pinged 34.2.61.79. See box below. As you can see I didnt get a reply and the ping timed out. This means that address 34.2.61.79 is available to use.

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9. So here are my numbers to put in my FLECS Display to enable programming it via the network. a. IP= 34.2.61.79 b. Subnet = 255.255.252.0 c. Gateway=34.2.63.254

10.6 PROCEDURE FOR PROGRAMMING DISPLAY VIA ETHERNET

10.6.1 MAKE CONNECTIONS 1. Wire the DB9 for power only and connect it to +12V power supply to power up the FLECS Display. +12V to Pin 9, Ground to Pin 5. 2. Connect standard Ethernet cable from FLECS Display into HalNet port in your lab. a. A crossover wired cable can be used for direct PC to Display Ethernet connections but you will have to set both your laptops IP address and the FLECS display to a static IP address. Use 10.0.0.1 for your laptop and 10.0.0.2 for the FLECS Display. 10.6.2 GO INTO POWER ON SETUP. 3. With system power off, place left hand thumb in upper left hand corner of the touch screen on the FLECS Display. 4. Turn power on to the FLECS system while holding thumb down. 5. You should see a multicolored Power On Setup screen appear on the FLECS Display. When you first see these words you may lift your thumb from the touch screen. 6. At the bottom of the touch screen are two green BACK and NEXT arrow buttons and one green square SELECT button. 10.6.3 SET FLECS DISPLAY TO DOWNLOAD MODE. 7. The FLASH MEMORY text in the upper left hand side of the screen should be highlighted. (White background with black letters). If it is not highlighted use the arrow keys to move through the menu headings until FLASH MEMORY is highlighted. 8. Press the green SELECT button. 9. This should move the highlighted field to the App mode: text of the FLASH MEMORY group of selections. 10. Press the green SELECT button. 11. This should move the highlighted field to the Run App field located to the right of the App mode text. 12. Press the green NEXT arrow to change the selections in this field. Press NEXT until Download is shown in the highlighted region.

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13. Press the green SELECT button to select this setting. App mode should now be highlighted again. 10.6.4 ERASE THE FLASH FILE SYSTEM 14. Press the green NEXT arrow key. Erase FFS should now be highlighted. 15. Press the green SELECT button. A new field will appear to the right and the word No will be highlighted. 16. Press the green NEXT arrow key until Yes appears. 17. Press the green SELECT button. The system will tell you to please wait while it erases the flash. 18. FLASH MEMORY should now be highlighted again. If not, press the green BACK arrow button until it is. 10.6.5 SET THE FLECS DISPLAY IP ADDRESS 19. Press the green NEXT arrow key until NETWORK is highlighted 20. Press the green SELECT button. IP should now be highlighted. 21. Press the green SELECT button. Now enter the IP address using the green NEXT or BACK arrows to go up or down in numbers and SELECT button to move to the next number field. 22. Once IP address is entered and the label IP: is highlighted again. Press the NEXT key to move to the Sub: address field. 23. Press the green SELECT button. Now enter the subnet address. 24. Follow same procedure to enter the Gateway number. 25. Once all three addresses are entered press the green BACK arrow key until NETWORK is highlighted again. 10.6.6 SAVE SETTINGS AND EXIT 26. Press the green BACK arrow again until the screen moves to a new page with the text DONE highlighted. 27. Press the SELECT key. The text Save and Exit should be highlighted. 28. Press the SELECT key. The Display will clear and indicate for the user to Download the application. 10.6.7 DOWNLOAD THE FLECSADC.BFF FILE 29. Open the QlarityDownloader.exe application. 30. Click on the Ethernet Tab

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31. Enter the IP address you programmed into the FLECS display. See below.

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32. Click on the Browse button and select the FLECSADC.BFF file on your USB Pen Drive. In the picture below the file is shown in the File to download: box.

33. Now Click on the Download Application Button. 34. A progress bar will come up and show the progress. It will be very quick. Only 2 or 3 seconds. 35. You should now have a programmed display. Close the Qlarity Downloader application and install your display back on the unit.

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Chapter 11 CEMENT MIX HEAD INSTALLATION AND SETUP

PROCEDURES TO REMOVE AND REINSTALL CEMENT MIX HEAD AND SET OPEN AND CLOSED VALVE POSITIONS. 11.1 WHEN DOES THE MIX HEAD NEED SERVICE?
When the valve slop on the cement head exceeds 6% the unit will start to show degradation in density control performance. When valve slop is near 10% performance will be poor and the head must be serviced soon. We recommend servicing the mix head when valve slop exceeds 6% for optimum performance and it is a must when it reaches 10%. The main culprit in wear is usually the white fiber glass gear on the mix head and all rebuilt heads should have this gear frequently replaced. Wear occurs on the gear teeth and in the bolt holes that hold the gear in place. Determining Valve slop: 1. Get your mix hydraulics pressured up so valves will move crisply. 2. Place AUTO/MANUAL switch for cement valve in the AUTO position. 3. On the FLECS display press MENU then MANUAL CONTROL and open the cement valve to 50%. 4. Slowly close the valve 1% at a time with 2 second pauses between adjustments and count the number of times it takes before the cement head physically begins to move close. 6% or more indicates that the head is due for service. 10% or more indicates that it should be repaired as soon as possible. If your valve shows 6% of slop, some recovery of the slop may be obtained by checking the white fiberglass gear to see if the mounting bolts have become loose. Blue loctite the threads and retighten if the bolts are loose. You may recover a percent or two of slop from the head. Loose bolts left unattended will wear the holes quickly and 10% valve slop will arrive soon.

11.2 PROCEDURE FOR MARKED POSITION REMOVAL AND REASSEMBLY OF CEMENT MIX HEAD AND SETTING OF VALVE POSITIONS.

This procedure covers proper removal of a correctly positioned mix head for field service and rebuild and how to correctly reassemble it using marked reference points when the mix head was disassembled for service. Provided that the mix head was mounted correctly to begin with, (Closed cement valve calibration value is between 10 to 30% and Open position is between 70 and 100% and valve closes and opens completely.) Then the easiest way to reinstall and reset the mix head correctly after servicing it is to carefully mark the positions of the mating gears on both the hydraulic actuator and the mix head during disassembly.

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11.2.1 1. 2. 3.

Procedure to remove mix head using marked positions. Power up hydraulics on unit. Put cement head AUTO/MANUAL switch in the AUTO position. On the FLECS display press MENU then MANUAL CONTROL and close the cement valve completely. 4. Physically inspect the mix head valve position and ensure that it is physically closed completely. If valve is not closed go to the FLECS Display, Press MENU, then SYSTEM CALIBRATION, then CEMENT VALVE and drop your closed position setting by about 5%. Press SAVE and EXIT and see if this closes the valve to your satisfaction. If it doesnt, reduce the closed position setting again. If you are unable to get the valve fully closed you will need to perform a fresh install of the mix head using the procedure further below. 5. Once the cement valve is completely closed remove the hydraulic actuator and carefully mark the mating gear parts on both sides so they can be remounted in the same position.

11.2.2 Procedure to remount mix head using marked positions. 1. Take rebuilt or replacement mix head and physically move the mix head valve to the closed position. 2. Power up hydraulics and FLECS display on unit. 3. Put cement head AUTO/MANUAL switch in the AUTO position. 4. Prior to mounting the hydraulic actuator on the mix head, go to the FLECS display, press MENU then MANUAL CONTROL and close the cement valve hydraulic actuator completely.(Dont do this manually with the hydraulics off). 5. Stab hydraulic actuator on mix head using marked position references and secure with 2 bolts until settings are verified to be correct. 6. On the FLECS display press MENU then MANUAL CONTROL and verify that the valve closes completely and opens completely by physically inspecting the valve positions. If cement valve will not completely close or open you will need to remount your mix head and set your valve positions using the fresh install procedure below. 11.2.3 Procedure to reset open and closed valve positions. 1. On the FLECS Display, press MENU, then SYSTEM CALIBRATION, then CEMENT VALVE. 2. Change Open position to 100%. Closed position to 0% and Press SAVE. 3. Press MENU, then MANUAL CONTROL. 4. While someone is inspecting the cement valve position, open the cement valve slowly using the FLECS Display Manual Control Screen until the cement valve just reaches the fully open position. Write this value down. It is typically between 70 and 100%. 5. Now close the valve slowly until the cement valve is physically closed. Write this value down. It is typically between 10 and 30%. 6. On the FLECS Display, press MENU, then SYSTEM CALIBRATION, the CEMENT VALVE and enter your open and closed percentage settings and Press SAVE. 7. Return the to FLECS Manual Control screen and verify that the valve is fully closed at 0% and fully open at 100%.

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8. On the FLECS Display press MENU, then SHUTDOWN to save these new settings.

11.3 PROCEDURE FOR A FRESH INSTALL OF THE CEMENT MIX HEAD AND SETTING OF VALVE POSITIONS.

This procedure covers how to properly reassemble a cement mix head without the aid of reference marks taken during disassembly. Use this procedure for correcting improperly mounted mix heads that would not close or open completely or for new or rebuilt heads that were removed without the use of marked reference points. 1. Remove cement valve hydraulic actuator from the mixing head. 2. Physically close the cement mix head rotary metering valve completely using a stop bar. Visually verify that the mix head valve is closed completely. 3. With hydraulics off, open the bypass valve on the cement valve hydraulic actuator and physically roll the cement hydraulic actuator to the closed position. Close the bypass valve. 4. Get an electronics technician. With Hydraulics OFF, power up the FLECS system and open the feedback potentiometer housing on the backside of the cement hydraulic actuator and adjust the potentiometer position until the feed back voltage reads 1.0 volt or slightly less with the hydraulic actuator sitting in the fully closed position. Secure potentiometer in position with set screw.(See note on feedback potentiometers below.) 5. Open hydraulic bypass valve and roll the actuator open and ensure that the feedback voltage rises as the actuator opens up. The full open position should show a feedback voltage greater than 3 volts and less than 5. 6. Power off the FLECS System. 7. Return the actuator back to the closed position and close the bypass valve 8. Power up system hydraulics and FLECS Display. 9. On the FLECS Display, press MENU, then SYSTEM CALIBRATION, then CEMENT VALVE. 10. Change Open position to 100%. Closed position to 0% and Press SAVE. 11. Hydraulic actuator should be firmly stuck in the closed position with hydraulics on and the FLECS powered up. 12. On the FLECS Display press MENU, then MANUAL CONTROL. 13. While someone is watching the toothed gear on the hydraulic actuator. Open the cement valve position 1% at a time in the MANUAL CONTROL screen until the gear on the hydraulic actuator begins to slightly roll open. You may have to go as far as 30% open before it moves. The movement will be very slight so have a partner assist you. Open the cement valve actuator only 2% more after it starts to move. Leave the MANUAL CONTROL Position at that setting. Do not close the manual control screen or hit the {close valves and exit} button. 14. Leave system hydraulics powered up to hold actuator in position and stab the hydraulic actuator onto the fully closed mix head and secure with 2 bolts until settings are verified to be correct. 15. Return to the MANUAL CONTROL screen. 16. While someone is inspecting the cement valve position, open the cement valve slowly using the FLECS Display Manual Control Screen until the cement valve just

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17. 18. 19. 20.

reaches the fully open position. Write this value down. It is typically between 70 and 100%. Now close the valve slowly until the cement valve is physically closed. Write this value down. It is typically between 10 and 30%. On the FLECS Display, press MENU, then SYSTEM CALIBRATION, the CEMENT VALVE and enter your open and closed percentage settings and Press SAVE. Return to the FLECS Manual Control screen and physically verify that the cement valve is fully closed at 0% and fully open at 100%. On the FLECS Display press MENU, then SHUTDOWN to save these new settings.

NOTE ON FEEDBACK POTENTIOMETERS. A new a rotary cam linear potentiometer is replacing the old rotary shaft potentiometers on the cement hydraulic actuators. These new linear style potentiometers require a 15K dropping resistor to be installed in the 12Volt power supply line to the potentiometer in order to get the feed back voltage back down in the same range as the old rotary shaft potentiometers. Failure to include this dropping resistor will cause the feedback voltage to approach 7 to 8 volts in the fully open position. Consequently the FLECS controller will only be able to open the cement valve to only 40% or 50% and no more. Troy Bachman, P.E Halliburton Technology Center Duncan, Oklahoma

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Chapter 12 FLECS SYSTEM REPAIR AND RETURN

12.1 FLECS DISPLAY REPAIR AND RETURN PROCEDURES
The FLECS display is manufactured for Halliburton by the QSI Corporation and can be returned to them for repairs. You must obtain a Returned Material Authorization number from QSI before your display can be sent in. An RMA# can be obtained from QSI as follows. To return a terminal for repair there are two options. 1) GO TO QSI WEBSITE a) Access the QSI website www.qsicorp.com b) Click on the Support button c) Click on Request an RMA d) Fill out your return address and contact info. e) Specify G70 in the Terminal Model field. f) Include Serial Number. g) Fill out a detailed problem description. Please be specific. Describe circumstances, symptoms of failure and any suspected sources as to why it failed like it did. Things like cold, heat, water spray, abrasion, etc., 2) PLACE TELEPHONE CALL TO QSI a) Call QSI @ 801-466-8770 , request technical support b) Be prepared with the following information: c) Company Name / Division d) Employee name / Contact name e) Phone numbers f) Model and Serial number of the terminal (found on back) g) Detailed description of the problem (what it does and when it does it) Returned terminals are generally shipped back to the customer in three to five days if parts are available. All terminals should be returned to: QSI CORPORATION 2212 South West Temple #50 Salt Lake City, Utah 84115 USA Phone: 801-466-8770 QSI will allow certain spare parts to be ordered and installed in the field if a Repair and Return is not feasible. A parts listing is available on the FLECS Technicians USB pen in \DOCS\1. FLECS Tech Manual\Tech Manual Volume 3\Appendix D. FLECS Display folder.

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12.2 FLECS Controller Repair and Return Procedure

The FLECS Controller (a.k.a stack) and Field Terminal assemblies are to be returned to Duncan Technology for repairs. Contact Tony Simms or Wesley Sandefur in Tech Services at the Duncan Technology Center and initiate a repair and return. The process will be similar to the current arrangement between field camps and technology for the repair of ARC cards. Tony.Simms@Halliburton.com, Ph: 580-251-3124 Wesley.Sandefur@Halliburton.com, Ph: 580-251-3834

12.3 USEFUL PART NUMBERS

SAP# 101743269: USB Bootable Pen Drive with FLECS Software and Documentation. SAP# 101742919: USB Bootable Pen Drive with FLECS Software and No Documentation. SAP# 101461207: BLANK USB Pen Drive for making copies with USB Images. SAP# 101471580: Automatic Tub Level Sensor Kit. SAP# 101482692: FLECS Display Cooling Kit. SAP# 326464: Shielded CAT 5 Cable for FLECS Display Serial Cables. SAP# 101405874: Serial Programmers Cable (If Ordering Direct from QSI, QSI Part# P01-791) SAP# 101386993: FLECS Spare Parts Kit SAP# 101362450: FLECS Retrofit Kit for ELITE Trailers. SAP# 101508652: F300 Density Sensor Retrofit Kit for Elite Trailers. SAP# 101214591: Micro-Motion Sensors Service Kit (for F300 and other sensors as well). SAP# 101714195: USB to RS232 Opto-Isolated Serial Adapter. B&B Electronics Model US09ML2

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