Ace pump section_3


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Ace pump section_3

  1. 1. Section 3 Basic Unit Operation Introduction The following section provides basic instructions for starting the computer, starting the engine, initializing the pumping unit, and shutting down the computer. Step 1—Starting the Computer The ACE pumping unit is equipped with an industrial computer that executes the pumping unit’s automatic control software. Before the unit’s engine will start, the software must be running. To start the software, perform the following steps: 1. Turn on the pumping unit’s main electrical power switch (A, Figure 3.1). 2. Turn on the industrial computer’s power switch (B, Figure 3.1). The computer will begin its boot-up process. After 1 to 2 minutes, the process will conclude and the NT operating system will display a Begin Logon window. 3. With the Begin Logon window displayed, press the Ctrl, Alt, and Del keys simultaneously. The computer will display a Logon Information window. 4. In the Logon Information window, type pump in the User Name entry field; then type pump in the Password entry field. Press OK and wait 1 to 2 minutes for the startup process to end. April 2001 Basic Unit Operation 3-1
  2. 2. A 12 14 16 OFF ON 10 18 8 VOLTS VOLTS POWER B ON ON RUN OFF OFF STOP START COMPUTER FLOOD LIGHTS ETHER RUN/STOP 8 15 15 15 TRANSMISSION FLOOD LIGHTS ETHER START ENGINE CHECK FUEL FILTER ENGINE DIAGNOSTIC CHECK ENGINE DISABLED PRELUBE OFF ACTIVE WARM TRANSMISSION ENGINE EMERGENCY KILL FRONT PANEL ASSEMBLY Figure 3.1—Main electrical power switch (A), and computer power switch (B) When the startup process is complete, the pump control screen (Figure 3.2, Page 3-3) will appear. 3-2 ACE Pump Operation and Service Manual April 2001
  3. 3. Resize Minimize Exit Figure 3.2—Main pump control screen Step 2—Starting the Engine To start the engine, perform the following steps: 1. With the pumping unit’s control software functioning, select the local unit to make it the active pumping unit for the control software. The local unit will have an asterisk beside its number. See the description of the Selected Pump list box in “Unit Information Area,” Section 5. 2. Place the engine RUN/KILL switch in the RUN position. 3. Confirm that the CHECK ENGINE light is off. Then start the pumping unit’s tractor and activate the PTO-driven hydraulic-start system. 4. Press the unit’s engine START switch to start the engine, depressing the switch for no more than 30 seconds. If the unit does not start on the first attempt, release the START switch and allow the unit to rest approximately 30 seconds; then press the START switch again. April 2001 Basic Unit Operation 3-3
  4. 4. Important If the engine does not start after several attempts, observe the CHECK ENGINE light. If this light is on, the engine will not start. Press the engine throttle Up button to turn the light off. If the light remains on, contact a mechanic or electrical technician. 6. Deactivate the tractor’s hydraulic-start system. Step 3—Initializing the Unit When the pumping unit’s engine has been started and the pumping unit has been selected as the control software’s active pumping unit, you are ready to initialize the unit. Important Do not engage the transmission until you have completed the initialization process to verify the accuracy and operational setpoints of the sensors. To initialize the unit, perform the following steps: 1. Check the operation of the pumping unit’s sensors by monitoring the Gauge function control display (Page 6-2). If any of the sensors display incorrect values, you may need to offset the sensors to the correct operating values. If necessary, adjust the slope and span of the sensors. For instructions on calibrating the sensors, see Page 6-6. Important Always offset the discharge pressure transducer to zero before bringing the pumping unit online against pressure. After the unit is online and pumping against pressure, offset the discharge pressure to match a “reference” pressure transmitter value if necessary. 2. Set the kickout pressure to a value determined by the stimulation supervi- sor. The pressure kickout limit defaults to 500 psi at startup. For instruc- tions on setting a unit’s kickout pressure, see Section 6. 3. Enter the desired pumping rate setpoint into the Ramp Setpoint system parameter. For instructions on entering a new Ramp Setpoint system parameter value, see Section 7. To place the pumping unit in gear, press the Selected Truck, Group, or All Trucks button. Then press the Engage button, and press the Ramp ON button to rapidly bring the unit up to the desired flow-rate setpoint. Shutting Down the Computer At the end of a pumping operation, shut down the ACE pumping unit to prevent potential startup problems during subsequent operations. This three-step process consists of shutting down the pumping control software, shutting down the JLAN software, and shutting down the NT operating system. 3-4 ACE Pump Operation and Service Manual April 2001
  5. 5. Shutting Down the Pumping Control Software To properly shut down the pumping control software, perform the following steps: 1. Verify that the pumping unit is in neutral. 2. Press the Close button in the top right corner of the control screen (Figure 3.2, Page 3-3). The pumping control software will close immediately. 3. If the Close button does not appear on your screen, press the Minimize button to bring your full screen into view; then press the Close button to close the control software. Shutting Down the JLAN Communications Software When the pumping-control software closes, the JLAN communications software for the pumping unit is displayed. This software must also be closed before the industrial computer can be shut down. To close the JLAN communications software, press the Close button (Figure 3.3). Resize Minimize Exit Figure 3.3—JLAN communications software window April 2001 Basic Unit Operation 3-5
  6. 6. Shutting Down the NT Operating System To shut down the NT operating system, perform the following steps: 1. Press the Start button (Figure 3.4). A Windows NT Workstation menu will be displayed (Figure 3.5, Page 3-6). Note The location of the START button may vary between computers, depending on whether the task bar that contains the START button is positioned. However, the button has the same appearance on all computers. 2. With the Windows NT Workstation menu active, select Shut Down…. The Shut Down Windows dialog box (Figure 3.6, Page 3-6) will be displayed. 3. Press the Yes button to continue the shutdown process. A Shutdown in Progress window will be displayed briefly. When the NT operating system has determined it is safe for the computer to be shut off, it will replace the Shutdown in Progress window with Shut Down Computer. 4. When the Shut Down Computer window displays the message “It is now safe to turn off your computer,” turn off the industrial computer’s power switch (Figure 3.1, Page 3-1). 5. Turn off the pumping unit’s main electrical power switch (Figure 3.1). Figure 3.4—Start button 3-6 ACE Pump Operation and Service Manual April 2001
  7. 7. Figure 3.5—NT system menu Figure 3.6—Shut Down Windows window April 2001 Basic Unit Operation 3-7
  8. 8. 3-8 ACE Pump Operation and Service Manual April 2001