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GENTEX ECONOMIZED CDC SYSTEM MANUAL

GenTex Oilfield Manufacturing Inc. GenTex Economized CDC System Manual

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TABLE OF CONTENTS
TABLE OF CONTENTS ............................................................................................................................... 0
TABLE OF FIGURES ................................................................................................................................... 1
1 OVERVIEW ............................................................................................................................................ 2
1.1 DISPLAY ........................................................................................................................................... 2
1.2 CONTROLLER .................................................................................................................................... 2
1.3 INPUT / OUTPUT MODULE .................................................................................................................. 2
2 PROGRAMS OVERVIEW ..................................................................................................................... 2
2.1 HOT OIL UNIT PROGRAM ................................................................................................................... 2
2.2 PRESSURE UNIT PROGRAM ............................................................................................................... 3
3 SYSTEM MEASUREMENTS AND SETTINGS .................................................................................... 3
3.1 INLET AND DISCHARGE PRESSURE ..................................................................................................... 3
3.2 INLET AND OUTLET TEMPERATURE ..................................................................................................... 3
3.3 FLOW RATE AND TOTALIZER .............................................................................................................. 3
3.4 TRIPLEX HP AND RPM ...................................................................................................................... 3
3.5 TANK LEVEL...................................................................................................................................... 3
3.6 DISPLAY SETTINGS ........................................................................................................................... 4
3.6.1 Display Setting Screen Brightness ....................................................................................... 4
3.6.2 Display Setting Button Backlight .......................................................................................... 4
4 WARNING AND ERROR MESSAGES ................................................................................................. 4
4.1 WARNING MESSAGES........................................................................................................................ 4
4.2 ERROR MESSAGES ........................................................................................................................... 5
5 TROUBLESHOOTING .......................................................................................................................... 5
5.1 LED STATUS LIGHT .......................................................................................................................... 5
5.2 SYSTEM FAULT ................................................................................................................................. 6
5.3 SYSTEM POWER ............................................................................................................................... 6
5.4 SENSOR ERROR ............................................................................................................................... 6
5.5 INLET PRESSURE WARNING/ERROR MESSAGE ................................................................................... 6

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TABLE OF FIGURES
Figure 1: ECDC Hot Oil Unit, Page 1 ............................................................................................................ 7
Figure 2: ECDC Hot Oil Unit, Page 2 ............................................................................................................ 7
Figure 3: ECDC Hot Oil Unit, Page 3 ............................................................................................................ 8
Figure 4: ECDC Pressure Unit, Page 1 ........................................................................................................ 8
Figure 5: ECDC Hot Oil Unit, Triplex RPM Warning on Page 2 ................................................................... 9
Figure 6: ECDC Hot Oil Unit, Triplex HP Warning on Page 2 ...................................................................... 9
Figure 7: ECDC Hot Oil Unit, Inlet Pressure Warning on Page 2 ............................................................... 10
Figure 8: ECDC Hot Oil Unit, Outlet Temperature Warning on Page 1 ...................................................... 10
Figure 9: ECDC Hot Oil Unit, Triplex RPM Warning on Page 3 ................................................................. 11
Figure 10: ECDC Hot Oil Unit, Triplex HP Warning on Page 3 .................................................................. 11
Figure 11: ECDC Hot Oil Unit, Inlet Pressure Warning on Page 3 ............................................................. 12
Figure 12: ECDC Hot Oil Unit, Outlet Temperature Warning on Page 3 .................................................... 12
Figure 13: ECDC Hot Oil Unit, Triplex RPM, Triplex HP or Inlet Pressure Warning Indicator on Page 1 .. 13
Figure 14: ECDC Hot Oil Unit, Outlet Temperature Warning Indicator on Page 2 ..................................... 13
Figure 15: ECDC Hot Oil Unit, Rod Load Warning Indicator ...................................................................... 14
Figure 16: ECDC Pressure Unit, Triplex RPM Warning on Page 1 ............................................................ 14
Figure 17: ECDC Pressure Unit, Triplex HP Warning on Page 1 ............................................................... 15
Figure 18: ECDC Pressure Unit, Rod Load Warning Indicator ................................................................... 15
Figure 19: ECDC Hot Oil Unit, Triplex RPM Error on Page 2 ..................................................................... 16
Figure 20: ECDC Hot Oil Unit, Triplex HP Error on Page 2 ........................................................................ 16
Figure 21: ECDC Hot Oil Unit, Inlet Pressure Error on Page 2 .................................................................. 17
Figure 22: ECDC Hot Oil Unit, Outlet Temperature Error on Page 1 ......................................................... 17
Figure 23: ECDC Hot Oil Unit, Triplex RPM Error on Page 3 ..................................................................... 18
Figure 24: ECDC Hot Oil Unit, Triplex HP Error on Page 3 ........................................................................ 18
Figure 25: ECDC Hot Oil Unit, Inlet Pressure Error on Page 3 .................................................................. 19
Figure 26: ECDC Hot Oil Unit, Outlet Temperature Error on Page 3 ......................................................... 19
Figure 27: ECDC Hot Oil Unit, Triplex RPM, Triplex HP or Inlet Pressure Error Indicator on Page 1 ....... 20
Figure 28: ECDC Hot Oil Unit, Outlet Temperature Error Indicator on Page 2 .......................................... 20
Figure 29: ECDC Hot Oil Unit, Rod Load Error Indicator ............................................................................ 21
Figure 30: ECDC Pressure Unit, Triplex RPM Error on Page 1 ................................................................. 21
Figure 31: ECDC Pressure Unit, Triplex HP Error on Page 1 .................................................................... 22
Figure 32: ECDC Pressure Unit, Rod Load Error Indicator ........................................................................ 22
Figure 33: ECDC, Display Settings ............................................................................................................. 23
Figure 34: ECDC, Display Settings, Screen Brightness ............................................................................. 23
Figure 35: ECDC, Display Settings, Button LED ........................................................................................ 24

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1 OVERVIEW
The GenTex Economized Central Digital Controls (ECDC) system is a Programmable Logic Controller
(PLC) system that includes a Human Machine Interface (HMI) display to show unit data and comes with
warning and error messages programmed into the system. There are 3 main components for the ECDC
system the 4.3 display, the controller and the input/output module.

The input/output module receives the signals from the various system sensors and sends a signal to the
controller. The controller receives the signals from the input/output module as well as various system
sensors; the controller turns the signals into useful data. The display receives the data from the controller
and displays the information on the screen.

This system is limited as it cannot record the data for the customer however if the system is updated to a
larger 7 display it provides the operator the ability to record the data to a USB drive.

1.1 Display
The GenTex ECDC system includes a 4.3 display screen which contains 6 LED push buttons and 1 LED
arrow pad. The screen display varies between the units as there are different sensors used for each unit.
The screens displays the information from the controller, GenTex has a standard screen for each unit
type however the screens can be completely customizable if required. The display has an IP65 rating
which allows the display the option of being mounted outside of the cab.

1.2 Controller
The controller in the system will take the signal from the various sensors installed on the unit and convert
the signal into a useful value. The controller is considered the hub of the CDC system as all the
information and data passes through the controller. The controller is also completely customizable which
can expand the required application of the controller if needed.

1.3 Input / Output Module

The Input / Output Module is the connection for the pressure and temperature sensors, the sensors will
connect to this module. The sensors will send a signal to the module which is then transferred from the
module to the controller.

2 PROGRAMS OVERVIEW
Since the system is completely programmable there are two different versions of the program depending
on what unit the system is being installed on. There is a hot oil unit system and a pressure unit system.
The screen varies with each system as there are different sensors being used, this provides a cleaner
screen for each application as it eliminates unused information.

2.1 Hot Oil Unit Program

The program used for the Hot Oil Unit has 3 main pages to display the system data from the controller.
The first page shows the discharge pressure and outlet temperature, flow rate, totalizer and the tank level
as seen in Figure 1. The second page shows the inlet pressure and temperature, triplex HP, triplex RPM
and tank level as seen in Figure 2. The third page shows all the information on one screen as seen in
Figure 3.

On each page the user can select the settings page using button 1, reset the totalizer using button 2,
change between imperial and metric using button 4 and switch between pages using left or right on the
arrow button.

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2.2 Pressure Unit Program

The program used for the Pressure Unit has 1 main page to display the system data from the controller.
The main page shows the inlet and discharge pressure, flow rate, totalizer, triplex HP, triplex RPM and
the tank level 1 and 2, see Figure 4.

The user can select the settings page using button 1, reset the totalizer using button 2, and change
between imperial and metric using button 4.

3 SYSTEM MEASUREMENTS AND SETTINGS

3.1 Inlet and Discharge Pressure
The system measures the inlet pressure of the fluid before it enters into the heater on a hot oil unit and
triplex pump on a pressure unit. The discharge pressure is measured after the fluid exits the triplex pump.
The pressures have two standard units of measurement, psi (imperial) and kPa (metric). The standard
units of measurement can be changed as per customer request however, it would require custom
programming.

3.2 Inlet and Outlet Temperature

The system measure the inlet temperature of the fluid before it enters into the heater. The outlet
temperature is measured after the fluid exits the heater on the hot leg. The temperatures have two
standard units of measurement, F (imperial) and C (metric). The standard units of measurement can be
changed as per customer requests however, it would require custom programming.

3.3 Flow Rate and Totalizer

The system measures the flow rate and totalizer indirectly; since there isnt a flow meter installed the flow
rate and totalizer are measured using the RPM of the driveshaft and theoretical calculations.

Note: The flow rate and totalizer are only based off of fluid being discharged from the triplex pump.

The flow rate is measured in US gallons per minute (US GPM) (imperial) and litres per minute (LPM)
(metric). The totalizer measures the volume through the system and is measured in US gallons (imperial)
or litres (metric). As mentioned in Section 2.1 when on page 1, 2 or 3 the totalizer can be reset by
pushing button 2, this will reset the totalizer to zero as soon as the button is pressed. The standard units
can be changed as per customer requests however, it would require custom programming.

3.4 Triplex HP and RPM

The system measures the triplex HP and RPM indirectly, using the RPM of the driveshaft and theoretical
calculations. The triplex HP is measured in horse power (HP) (imperial) and kilowatt (kW) (metric). The
triplex RPM is just the rotational speed of the triplex pump, and the value is rotations per minute (RPM)
for both imperial and metric. The standard units for triplex HP can be changed as per customer requests
however, it would require custom programming.

3.5 Tank Level

The system measures the tank level of the fluid in tank 1 and tank 2 if on a pressure unit. The standard
unit of measurement for the tank level is US gallons (imperial) or litres (metric). On pages 1 and 2 the
tank level is displayed using a level gauge to give a quick indication of the fluid level, the volume value is
displayed below the level gauge. The standard units can be changed as per customer request however, it
would require custom programming.

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3.6 System Settings

On the settings page you are able to adjust the brightness of the screen and turn on/off the buttons back
light see Figure 33. Using the up and down on the arrow allows the user to select between screen
brightness and the button back light, to adjust each parameter select the OK button. The ESC button will
return the user to the previous page. When the parameter is selected the boarder will flash, this means
the user can change that current display setting.

3.6.1 System Setting Screen Brightness

For the screen brightness, button 1 sets the brightness to 100%, button 2 sets the brightness to 50%,
button 3 decreases brightness by 5%, button 4 increases brightness by 5% and the left and right arrow
decrease and increase brightness by 1%. When finished changing brightness select the OK button to stay
on the display settings page or select the ESC button to return to previous page, see Figure 34.

Note: The settings change automatically, if ESC button is selected when changing parameters the
parameters save automatically.

3.6.2 System Setting Button Backlight

For the button background light, the left and right arrow turns the light on and off. When finished with the
changes select the OK button to stay on the display settings page or select the ESC button to return to
the previous page, see Figure 35.

Note: The settings change automatically, if ESC button is selected when changing parameters the
parameters save automatically.

4 WARNING AND ERROR MESSAGES

The system has warning and error messages programmed in to inform the operator when certain
parameters are reaching there maximums or minimums. The warning will be activated when the system
reaches 90% of the maximum value or 10% above the minimum value, which allows the operator time to
adjust the system to prevent the maximum or minimum from being reached. When the maximum or
minimum is reached an error message will be activated which notifies the operator they are operating the
equipment above or below the manufacturers specifications.

4.1 Warning Messages

The parameters that are monitored include the triplex pump HP, RPM and rod load along with heater
outlet temperature and inlet pressure. The warning message for the triplex HP, RPM, inlet pressure and
heater outlet temperature is the background changing from grey to yellow. Figure 5-12, 16 and 17 show
the various warnings for both systems.

Since the values arent displayed on all the pages, if a warning is activated and the parameter isnt shown
on the current page a W !!! in yellow will appear at the bottom of the page to indicate that a warning is
activated. Figure 13 and 14 show the warning indication on the bottom of the page.

Since the rod load isnt a parameter that is displayed, when the rod load warning is activated RD W !! in
yellow will appear at the bottom of the page. Figure 15 and 18 show the rod load warning indicator, on the
Hot Oil Unit system the warning indicator will show on all 3 main pages, on the pressure unit this indicator
will only show on page 1.

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4.2 Error Messages

The error messages for the triplex HP, RPM, inlet pressure and outlet temperature is the background
flashing between yellow and red. Figure 19-26, 30 and 31 show the various errors for both systems.

Similar to the warning, if an error message is activated and the parameter isnt shown on the current page
a E !!! flashing yellow and red will appear at the bottom of the page to indicate that an error is activated.
Figure 27 and 28 show the error indication on the bottom of the page.

Since the rod load isnt a parameter that is displayed, when the rod load error is activated RD E !!
flashing yellow and red will appear at the bottom of the page. Figure 29 and 32 shows the road load error
indicator, on the Hot Oil Unit system the error indicator will show on all 3 main pages, on the pressure unit
this indicator will only show on page 1.

Note: If multiple warnings or errors are activated for parameters not currently shown on the display, E !!!
will always be displayed even if there is both an error and warning activated.

5 TROUBLESHOOTING
5.1 LED Status Light
The controller, display and input/output module all have a status LED to inform the operator the status of
the equipment. If there is an issue with the ECDC system, the status LED of the equipment should be
checked to ensure the equipment is working as intended. Below is a table of the various status LEDs for
the equipment:

Display and Controller

Colour Status Description
- Permanently Off No Supply Voltage
Green 2 Hz Application is Running
Permanently On Application is Stopped
Red 10 Hz Application Stopped with an Error
5 Hz Application Stopped Due to Under Voltage
Permanently On System Fault

Input / Output Module

LED Status Description
PWR Permanently Off No Supply Voltage
(Green) On Module in Stand-By Mode
2 Hz Module Activated
DIA Off Communication OK
(Red) On Communication Error

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5.2 System Fault

If the system is experiencing a system fault (permanent red LED), cycle the power and allow the system
to reset. If there is still an issue after cycling the power, contact GenTex for support.

5.3 System Power

If the system isnt powering up, check the fuse in the power connection for the controller, if this fuse is
blown that will not allow power to the ECDC system. For this system the fuse should be 2A, if the
system receives more than 2A there is potential for damage to the electric circuits and equipment.

5.4 Sensor Error

If a single sensor is reading zero or incorrectly verify that the cable is connected correctly at the sensor as
well as the input/output module or controller. If its multiple sensors reading incorrectly ensure the
input/output module cable is connect to the controller. If there is any issue contact GenTex for support.

5.5 Inlet Pressure Warning/Error Message

When cold pumping if the inlet pressure is below 83 psi the warning message will be activated if the inlet
pressure is below 75 psi the error message will be activated. This is normal as when cold pumping the
system doesnt need to have a minimum inlet pressure of 75 psi, which is required when using the heater.
If there are issues with having these messages contact GenTex.

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Figure 1: ECDC Hot Oil Unit, Page 1

Figure 2: ECDC Hot Oil Unit, Page 2

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Figure 3: ECDC Hot Oil Unit, Page 3

Figure 4: ECDC Pressure Unit, Page 1

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Figure 5: ECDC Hot Oil Unit, Triplex RPM Warning on Page 2

Figure 6: ECDC Hot Oil Unit, Triplex HP Warning on Page 2

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Figure 7: ECDC Hot Oil Unit, Inlet Pressure Warning on Page 2

Figure 8: ECDC Hot Oil Unit, Outlet Temperature Warning on Page 1

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Figure 9: ECDC Hot Oil Unit, Triplex RPM Warning on Page 3

Figure 10: ECDC Hot Oil Unit, Triplex HP Warning on Page 3

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Figure 11: ECDC Hot Oil Unit, Inlet Pressure Warning on Page 3

Figure 12: ECDC Hot Oil Unit, Outlet Temperature Warning on Page 3

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Figure 13: ECDC Hot Oil Unit, Triplex RPM, Triplex HP or Inlet Pressure Warning Indicator on Page 1

Figure 14: ECDC Hot Oil Unit, Outlet Temperature Warning Indicator on Page 2

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Figure 15: ECDC Hot Oil Unit, Rod Load Warning Indicator

Figure 16: ECDC Pressure Unit, Triplex RPM Warning on Page 1

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Figure 17: ECDC Pressure Unit, Triplex HP Warning on Page 1

Figure 18: ECDC Pressure Unit, Rod Load Warning Indicator

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Figure 19: ECDC Hot Oil Unit, Triplex RPM Error on Page 2

Figure 20: ECDC Hot Oil Unit, Triplex HP Error on Page 2

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Figure 21: ECDC Hot Oil Unit, Inlet Pressure Error on Page 2

Figure 22: ECDC Hot Oil Unit, Outlet Temperature Error on Page 1

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Figure 23: ECDC Hot Oil Unit, Triplex RPM Error on Page 3

Figure 24: ECDC Hot Oil Unit, Triplex HP Error on Page 3

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Figure 25: ECDC Hot Oil Unit, Inlet Pressure Error on Page 3

Figure 26: ECDC Hot Oil Unit, Outlet Temperature Error on Page 3

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Figure 27: ECDC Hot Oil Unit, Triplex RPM, Triplex HP or Inlet Pressure Error Indicator on Page 1

Figure 28: ECDC Hot Oil Unit, Outlet Temperature Error Indicator on Page 2

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Figure 29: ECDC Hot Oil Unit, Rod Load Error Indicator

Figure 30: ECDC Pressure Unit, Triplex RPM Error on Page 1

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Figure 31: ECDC Pressure Unit, Triplex HP Error on Page 1

Figure 32: ECDC Pressure Unit, Rod Load Error Indicator

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Figure 33: ECDC, Display Settings

Figure 34: ECDC, Display Settings, Screen Brightness

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Figure 35: ECDC, Display Settings, Button LED

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