Horseshoe Load Cell Transducer Troubleshooting Guide
This document will help you troubleshoot and identify problems with acquiring data using your
30K or 50K horseshoe transducer. To determine if the load cell transducer is working properly,
there is a multi-step process that should be followed that will checkout the well analyzer, cables,
and/or load cell transducer. Follow the steps in the order listed:
1. Verify Horseshoe Load Cell Wiring is intact
2. Use the Equipment Check Tab to Verify that the Well Analyzer is communicating with
TWM software
3. Test the Operation of the Electronic Hardware and Cables
4. Determine the Dynamometer Sensor Zero Offset
5. Simulate acquisition of a Valve Test with Dynamometer Sensor in Office
Please follow the procedures outlined below:
Step 1 – Verify Horseshoe Load Cell Wiring is intact
This step assumes that the connector or the Horseshoe Transducer Load Cell, HT, is not broken (If
the connector is broken then send HT to Echometer for repair). Normally, the Load Cell requires
some cleaning for handling purposes. Use a degreaser or electrical contact cleaner sprayed on a
cloth rag to wipe off dirt and grime. You should use an OHM-meter to verify that the HT wiring
is intact and is capable of working correctly. Test the HT by verifying the resistance readings
between the various lettered electrical conductors (A-F) housed with-in the cable connector on the
HT. The readings should be as follows.
Resistance values for the Horseshoe Transducers:
Echometer Dynamometer Transducer Resistance Values
All values are +/- 25%
Four-inch 30,000 lb Load Cells and
Five-inch 50,000 lb Load Cells
Pins Values Circuit
Pins A to B 730 Ohms Load
Pins A to F 730 Ohms Load
Pins D to B 730 Ohms Load
Pins D to F 730 Ohms Load
Pins A to C 2.2 K Ohms Accel.
Pins A to E 2.2 K Ohms Accel.
Pins D to C 2.2 K Ohms Accel.
Pins D to E 2.2 K Ohms Accel.
Pins A to D 840 Ohms Load and Accel.
Pins B to F 1.1 K Ohms Load bridge output
Pins C to E 4.3 K Ohms Accel. bridge output
Load Cells with serial numbers HT137 through HT508 had pin "D" grounded to case when
manufactured. The grounding wire from pin "D" to the case was removed, if Echometer Company
has ever serviced the HT.
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Horseshoe Load Cell Transducer Troubleshooting Guide
If the measured readings are not with-in 25%
of these stated values, then you should send
the Horseshoe Transducer Load Cell in to
Echometer for repair.
Connector pin designation for the Horseshoe Load Transducer
2) Use the Equipment Check Tab to Verify that the Well Analyzer is communicating with
TWM software
Equipment Check Screen – Make sure the Laptop Computer is connected to the Echometer Well
Analyzer using the proper cable. Turn on the computer, execute the TWM software, and from the
Acquire Mode select the Equipment Check tab. Blue bars in the upper left hand corner of the
screen indicate the battery is charged and the Well Analyzer is communicating with the Laptop
computer. The user should verify that the voltage values are within the indicated limits.
Discrepancies could be caused either by faulty batteries or by faulty electronics or cables and
connectors.
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Horseshoe Load Cell Transducer Troubleshooting Guide
A display of internal battery voltage and battery temperature indicates that the computer is
communicating with the well analyzer's internal electronics and additional testing of the horseshoe
transducer may be performed using the well analyzer. Otherwise a warning message will be
displayed indicating problems with communication.
3) Test the Operation of the Electronic Hardware and Cables
The most common problem is that the cables may have been damaged or the connections could be
wet. Be sure there is no moisture in any of the ends of the connectors on the cables or HT. A bad
cable can make the HT appear to not be functioning properly. A defective well analyzer can make
the cables or HT appear to not be operating properly.
Trouble Shoot Wizard - When communication between the Well Analyzer and the Computer is
operating properly, the data acquisition functions are tested using the Troubleshoot Wizard.
Testing the operation of the electronic hardware and cables is undertaken using the Trouble Shoot
Wizard in the Equipment Check Tab from the SETUP module. The purpose of the utility is to
quickly determine whether a hardware fault is present and in particular test that the batteries are
properly charged, the transducer circuits are not shorted, the cables and connectors are not shorted
or open, and that the Well Analyzer amplifiers are operating within specifications.
If the cables fail the Trouble Shoot Wizard, then you will probably need to purchase new cables.
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Horseshoe Load Cell Transducer Troubleshooting Guide
Tapping the (Alt-2) keys will begin the Trouble Shoot Wizard (Alt-2).
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Horseshoe Load Cell Transducer Troubleshooting Guide
Voltage Check - The screen displays the existing Well Analyzer battery voltage and the voltage
used to power the transducers. If the values were not within the accepted limits, the battery should
be recharged and the test repeated later.
Transducer Check - If the battery voltage is within limits but the excitation voltage is not within
limits or it drops significantly when the HT transducer is connected to the Well Analyzer (using
the master cable) there is a good probability that the transducer is defective.
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Horseshoe Load Cell Transducer Troubleshooting Guide
Amplifier Checks - The Well Analyzer's amplifiers are checked using the built-in tester, accessible
through the plug provided on the top panel. The appropriate cables are connected to the test plug
and to the corresponding inputs. Signals are generated manually using the push button. When the
appropriate response is not obtained it is important to check that the failure is not due to a faulty
cable or connector. Either a spare cable should be used or continuity and ground checks using an
Ohmmeter should be made on the questionable cable before concluding that the amplifiers are not
operating properly. The instructions presented in the following screens should be followed in
order to check both the cables and the amplifiers.
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Horseshoe Load Cell Transducer Troubleshooting Guide
Acoustic Channel Test - This tests both the coaxial cable and the Acoustic channel amplifier.
Depressing the test button should display approximately a 20 Hz frequency signal of constant
amplitude, as shown in the following figure:
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Horseshoe Load Cell Transducer Troubleshooting Guide
Cables, amplifiers and A/D converter check - This test verifies that the main transducer cable
and the A/D converter are performing properly. The coiled cable can also be checked out
using the Trouble shoot wizard, but should be tested in both un-stretched and stretched
conditions. The test should be repeated using all the cables individually and connected in
series so as to check the connectors as well as the cable. One last check would be to wiggle
and pull on all of the connections and cables while holding down the test button. Whenever
the test button is depressed the signal should increase from zero to 1 mV/v as shown below.
This completes the testing sequence. If all of the test has been completed successfully, then the
TWM software, the Well Analyzer Electronics, and the cable tested are working properly. Next
step is to further check out the horseshoe transducer’s operation with the TWM software.
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Horseshoe Load Cell Transducer Troubleshooting Guide
4) Determine Dynamometer Sensor Normal Zero Offset
Using the well analyzer, with the TWM software running, and the dynamometer setup page open,
select the proper HT serial number and verify that the proper coefficients are entered (C1, C2 and
C6), then click on the “Obtain Zero Offset” button. The present output of the transducer should be
a small number less than +/-1.5 Klb. A large number for the Present Zero Offset indicates a
large offset load; the load cell may have been damaged and needs to be sent into Echometer for re-
calibration and/or repair. The Accelerometer Output (with the HT in the upright position) should
read between +8 and -8 mv/v. A high number indicates that the Accelerometer is bad or needs
adjustment.
Set the Load Cell in its normal upright operating position on a flat surface. The Accelerometer
Output in the lower left hand corner of the screen should display a reading near 0.0mV/V. Turn
the load cell 90 degrees (on edge) and set on the flat surface of the load cell opposite the handle,
then the reading should be a negative number close to the value of the C6 coefficient. Turn the
load cell over and set the Load Cell upside down on its upper plate, then the reading should be
about double the number read when the Load Cell was setting on its flats. This test indicates that
the accelerometer is working properly and communicating with the Well Analyzer and laptop
computer.
If the transducer fails to pass any of these tests, it would indicate some type of failure with-in the
horseshoe transducer and the load cell transducer should be sent to Echometer for repair.
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Horseshoe Load Cell Transducer Troubleshooting Guide
5) Simulate acquisition of a Valve Test with Dynamometer Sensor in Office
The load cell transducer should be
connected to the well analyzer by the
transducer cable and the coiled cable.
The well analyzer should be powered
on, with the TWM software operating
in the Acquire mode, and the step to
determine Dynamometer Sensor Zero
Offset should have been completed.
A Base Well File should be opened to
perform this test. Select the “Valve
Test (Standing and Traveling)
“VALVE”” type of test from the
Dynamometer tab.
Position the Load Cell in its normal
upright operating position. Press F5 to
begin acquiring load data. Observe the
Measured load text box on the lower
right corner of the screen. The reading
should be near zero.
Tap the Alt-S key to begin acquiring
load and acceleration data. With the
load cell resting in its normal operating
position, press down on the load cell
with both hands cupped on the Upper
Plate and apply a uniform force with a
downward motion. Stop pressing for a
short time. Again, press down on the
load cell with both hands cupped on the
Upper Plate and apply a fairly uniform
downward force and then release the
force. While applying the force to the
load cell, observe the screen for any
spikes. In the example shown to the
left, units of the vertical axis is Klbs,
the 1st time a force of approximately 36
lbs was applied to the load cell and the
2nd time a force of approximately 42
lbs. was applied to the load cell.
Flip the Load Cell over 180 degrees on
its Upper Plate. Wait approximately 15
seconds and then rotate the load cell
back to its normal mounting position.
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Horseshoe Load Cell Transducer Troubleshooting Guide
The line will continue to travel across the bottom of the plot.
Tap the Alt-Q key to stop acquiring data and then save the data.
No Load Load Applied No Load Load Cell upside down
Click the F6 button to analyze the data collected. Check the Show Acceleration Data box to
display the acceleration data. The load trace should be uniformly flat when no force is being
applied and should increase when load is applied. The acceleration data should be flat when the
load cell is resting on the surface and quickly change when turned over.
If the test results are bad, the probable cause is some type of internal damage to the load cell. If
the test results are good, then Dynamometer data can be acquired with the load cell mounted on a
well.
One last check would be to wiggle and pull on all of the connections and cables while acquiring
load data. If the load measurements become erratic then the cable may have a short or bad
connector,
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