gauge battery fixture - ies global, inc. high speed...

Gauge Battery FixtureGauge Battery FixtureGauge Battery FixtureGauge Battery Fixture

B Y S C O T T A . A G E R

S C O T T @ I E S G L O B A L I N C . C O M

2/12/2016 Copyright (c) 2015 IES Global, Inc. All rights reserved.

Battery FixtureBattery FixtureBattery FixtureBattery Fixture

The Battery Fixture is used to hold the Battery Pack. ◦ It is located inside the BATTERY SECTION of the gauge, which is between the OWR

Section and the Date Readout Section. The MASTER Battery Fixture always plugs into the OWR section of the gauge.

One or Two Batteries Packs can be used with a Gauge◦ An addition Battery Pack/Battery Fixture extends the time downhole, and provides a

backup battery.

◦ An extra Battery Fixture, Battery Pack, and Battery Section is required for running TWO batteries.

◦ The length of the gauge is increased by 17.5 inches when you use a second Battery.

Always use the Potted Battery Packs supplied by IES. ◦ They are specifically designed for the IES gauge.


“Red Kill Switch”“Red Kill Switch”“Red Kill Switch”“Red Kill Switch”IES Battery Pack shown IES Battery Pack shown IES Battery Pack shown IES Battery Pack shown installedinstalledinstalledinstalled....

Battery Fixture LocationBattery Fixture LocationBattery Fixture LocationBattery Fixture Location

Sensor SectionSensor SectionSensor SectionSensor Section

OWROWROWROWR SectionSectionSectionSection

Bull NoseBull NoseBull NoseBull Nose

Battery sectionBattery sectionBattery sectionBattery section

Data Readout Data Readout Data Readout Data Readout

SectionSectionSectionSection

The Battery Fixture is The Battery Fixture is The Battery Fixture is The Battery Fixture is

located located located located insideinsideinsideinside the the the the

Battery SectionBattery SectionBattery SectionBattery Section

(#IES(#IES(#IES(#IES----BATBATBATBAT----005 or #IES005 or #IES005 or #IES005 or #IES----

BATBATBATBAT----006)006)006)006)

Heat Shrink Heat Shrink Heat Shrink Heat Shrink Tubing for the Battery FixtureTubing for the Battery FixtureTubing for the Battery FixtureTubing for the Battery Fixture

1.1” dia. Kynar Heat Shrink tubing MUST ALWAYS be used on everyBattery Fixture

◦ The Heat Shrink is used to keep the battery pack and spacers from moving during the gun event

IMPORTANT NOTEIMPORTANT NOTEIMPORTANT NOTEIMPORTANT NOTE: : : : Store the 1.1” dia. Kynar Heat Shrink tubing

at room temperature (< 90°F).

1.1” Kynar Heat Shrink

Heat Shrink Tubing for the Battery FixtureHeat Shrink Tubing for the Battery FixtureHeat Shrink Tubing for the Battery FixtureHeat Shrink Tubing for the Battery Fixture

1.1” dia. 1.1” dia. 1.1” dia. 1.1” dia. KynarKynarKynarKynar heat shrink heat shrink heat shrink heat shrink

covers the entire length of the covers the entire length of the covers the entire length of the covers the entire length of the


Battery Fixture “Types”Battery Fixture “Types”Battery Fixture “Types”Battery Fixture “Types”

There are TWO Types of Battery Fixtures available.

◦ The 80°C and 120°C Gauge comes with the #IES-BAT-005 Battery Fixture. This can be used for either, alkaline or lithium battery packs.

◦ The 150°C and 175°C Gauge comes with the #IES-BAT-006 Battery Fixture, and can only be used with lithium battery packs.

*Additional Battery Fixtures can be purchased or Leased


#IES-BAT-005 Battery Fixture (120°C)

◦ DO NOT USE for applications above 120°C !

◦ ALL Alkaline or Lithium Battery Packs can be used

Marked as “ALKALINE OR LITHIUM BELOW 120°C”


#IES-BAT-006 Lithium Battery Fixture (180°C)◦ Can be used with the 80°C, 120°C, 150°C, or 175°C Gauges

◦ ONLY USE the 120°C, 150°C, or 180°C Lithium Battery Packs!

◦ DO NOT USE with the Alkaline Battery Packs!

Marked as “USE BELOW 180°C IES, Inc. 006 LITHIUM BATT”

Battery Fixture S/NBattery Fixture S/NBattery Fixture S/NBattery Fixture S/N

Battery Fixture Serial NumberBattery Fixture Serial NumberBattery Fixture Serial NumberBattery Fixture Serial Number

Each Battery Fixture has a Each Battery Fixture has a Each Battery Fixture has a Each Battery Fixture has a Serial NumberSerial NumberSerial NumberSerial Number. This can . This can . This can . This can

be programmed into the Gauge in the “EDIT: be programmed into the Gauge in the “EDIT: be programmed into the Gauge in the “EDIT: be programmed into the Gauge in the “EDIT:

Recorder Channel Data” menu. This allows tracking Recorder Channel Data” menu. This allows tracking Recorder Channel Data” menu. This allows tracking Recorder Channel Data” menu. This allows tracking

of a individual Battery Fixture in case there is a of a individual Battery Fixture in case there is a of a individual Battery Fixture in case there is a of a individual Battery Fixture in case there is a

failure.failure.failure.failure.

TheTheTheThe “Red Kill Switch”“Red Kill Switch”“Red Kill Switch”“Red Kill Switch”


“Red Kill Switch” “Red Kill Switch” “Red Kill Switch” “Red Kill Switch”

locationlocationlocationlocation


The “Red Kill Switch” plugs into the Battery Fixture and is used to TURN OFF the Battery Pack power to the Gauge.

NOTE: If you install the “Red Kill Switch” in the Battery Fixture, the data in the “Series 300” gauge will be ERASED!!!

Red Kill Switch

Battery Warnings!Battery Warnings!Battery Warnings!Battery Warnings!


NEVER re-use a Battery Pack. The combination of high temperature and high shock damages the battery cells and can they can start to leak after time. This could cause damage to the Battery Fixture or the Gauge, and could result in the LOSS OF YOUR DATA!

AFTER downloading your data and verifying the gauge data is good, ALWAYS immediately remove the “used” Battery Pack after every job to prevent possible battery acid leakage and damage to the battery fixture.


The MASTER Battery Fixture must ALWAYS be plugged into the OWRsection of the gauge.

NOTE: IF you plug a SLAVE battery fixture directly into the OWR section of the gauge, the gauge will STOP working as soon as you remove the External Power from the Interface Box, and the gauge will NOT record data.

MASTER Battery Fixture

(No jumper)


The MASTER battery fixture must always be installed, FIRST, into the OWR Section of the gauge. THEN, the SLAVE battery fixture plugs into the MASTER battery fixture

SLAVE Battery Fixture (Jumper wire installed)

Battery Warnings for the Series 300!Battery Warnings for the Series 300!Battery Warnings for the Series 300!Battery Warnings for the Series 300!

The Series 300 Gauge uses Volatile Data Memory, so if you remove the battery power from the Gauge…

◦ the Gauge Data will be ERASED and permanently LOST!

If you disconnect the Battery Fixture from the Series 300 Gauge (OWR Section)…


If you install the “RED KILL SWITCH” in the Battery Fixture…


Battery Fixture Warning!Battery Fixture Warning!Battery Fixture Warning!Battery Fixture Warning!

Sensor SectionSensor SectionSensor SectionSensor Section

OWROWROWROWR SectionSectionSectionSection

Bull NoseBull NoseBull NoseBull Nose

Battery SectionBattery SectionBattery SectionBattery Section

Data Readout Data Readout Data Readout Data Readout

SectionSectionSectionSection NEVER break the gauge between NEVER break the gauge between NEVER break the gauge between NEVER break the gauge between

the the the the OWROWROWROWR and BATTERY Sectionsand BATTERY Sectionsand BATTERY Sectionsand BATTERY Sections. . . .

You will lose ALL your data if you You will lose ALL your data if you You will lose ALL your data if you You will lose ALL your data if you

are using a Series 300 gauge !!! are using a Series 300 gauge !!! are using a Series 300 gauge !!! are using a Series 300 gauge !!!

ALWAYS break the Gauge at the ALWAYS break the Gauge at the ALWAYS break the Gauge at the ALWAYS break the Gauge at the Data Readout Data Readout Data Readout Data Readout SectionSectionSectionSection

to download the data!to download the data!to download the data!to download the data!

“Red Kill Switch” Warning!“Red Kill Switch” Warning!“Red Kill Switch” Warning!“Red Kill Switch” Warning!

When the “Red Kill Switch” is plugged into

the Battery Fixture, it turns OFFOFFOFFOFF the battery

power to the gauge! The gauge will NOT

record data if the Red Kill Switch is installed.

Battery OFF

Battery ONBattery ONBattery ONBattery ON

NOTE: If you install the “Red Kill Switch” ALL the DATA will be

lost (in the Series 300 Gauge)!!!

Battery Pack OptionsBattery Pack OptionsBattery Pack OptionsBattery Pack Options

Alkaline and Lithium Alkaline and Lithium Alkaline and Lithium Alkaline and Lithium Battery PacksBattery PacksBattery PacksBattery Packs

The 80°C Alkaline, 120°C Lithium, 150°C Lithium and 180°C Lithium

Packs are all packaged inside a BLACK colored tube.

Teflon Heat Shrink surrounds each Battery Pack. NEVER remove this

tubing that covers the Battery Pack!

Note: Be sure to read the Labeling on the Battery Pack so you know

which Battery Pack you are using.

Battery Pack LabelingBattery Pack LabelingBattery Pack LabelingBattery Pack Labeling

Each Battery Pack has a Label indicating the

Battery Serial Number, Battery Type, Part

Number, and Construction Date

Battery Pack OptionsBattery Pack OptionsBattery Pack OptionsBattery Pack Options

80°C Alkaline Battery Pack

◦ #IES-BAT-BA2C

120°C Lithium Battery Pack

◦ #IES-BAT-BL32AA120

150°C Lithium Battery Pack

◦ #IES-BAT-BL32AA150 (for the Series 300)

◦ #IES-BAT-BL02AA150 (for the Series 400 ONLY)

◦ #IES-BAT-BL22AA150 - Double Power (for the Series 400 ONLY)

180°C Lithium Battery Pack (use only above 80°C)

◦ #IES-BAT-BL02AA180 (for the Series 400 ONLY)

◦ #IES-BAT-BL22AA180 - Double Power (for the Series 400 ONLY)

* Lithium battery packs CANNOT be used with the Series 200 gauges.

Alkaline Battery PackAlkaline Battery PackAlkaline Battery PackAlkaline Battery Pack

80°C Alkaline Battery Pack◦ Part # IES-BAT-BA2C

◦ 20°C to 80°C1

◦ ~9.0 volts (6 AA Cells)

◦ With connector ONLY

◦ NO BACKUP BATTERY

◦ Can ONLY be used with the #IES-BAT-005 Battery Fixture

◦ Can not be used with the Series 400 gauge

1WARNING – EXCEEDING 80°C can possibly result in the Battery Pack exploding and LOSS of your data!

Lithium Battery Pack WARNINGLithium Battery Pack WARNINGLithium Battery Pack WARNINGLithium Battery Pack WARNING

ALL Lithium Battery Packs will have this sticker.

NOTE: Every Lithium Battery Pack has an internal 2 amp fuse. If the connector on the Battery Pack is accidentally shorted, the internal fuse will blow and the Battery Pack will be rendered useless (0 volts). This fuse CANNOT be replaced, so be very careful when handling the Lithium Battery Packs

120120120120°C Lithium Battery PackC Lithium Battery PackC Lithium Battery PackC Lithium Battery Pack

120°C1 Lithium Battery Pack◦ Part # IES-BAT-BL32AA120

◦ For Series 300 and 400 gauges ONLY

◦ 40°C to 120°C1

◦ ~10.8 volts (3 AA Cells/2 AA Cell)

◦ 2.5g Lithium


◦ Backup Battery included

◦ Can be used with:◦ the #IES-BAT-005 Battery Fixture

◦ the #IES-BAT-006 Battery Fixture

1Warning – If the Temperature EXCEEDS 120°C,

the battery will FAIL, causing the loss of your data!


150°C2 Lithium Battery Pack◦ Part # IES-BAT-BL32AA150 (for Series 300 only)

◦ Part # IES-BAT-BL02AA150 (2-cell)

◦ Part # IES-BAT-BL22AA150 (4-cell Double Power)

◦ For Series 300 and 400 gauges ONLY

◦ 40°C to 150°C1

◦ ~7.9 or 11.8 volts (2 AA/4 AA/5 AA Cell)

◦ 3.25g Lithium or less


◦ Can be used with:






180°C2 Lithium Battery Pack◦ Part # IES-BAT-BL02AA180 (2-cell)

◦ Part # IES-BAT-BL22AA180 (4-cell Double Power)

◦ For Series 400 gauges ONLY

◦ 40°C to 180°C1

◦ ~7.9v (2 AA/4 AA)

◦ 3.25g Lithium or less


◦ Can be used with:




Using Lithium Battery PacksUsing Lithium Battery PacksUsing Lithium Battery PacksUsing Lithium Battery Packs

IMPORTANT NOTES:

• Series 200 Gauges:

• If you MUST use the 120°C Lithium Battery Pack, you can ONLY program the Series 200 gauge as a ONE Channel (Pressure) gauge because of current limitations.

• You MUST always use TWO 120°C Lithium battery packs with the Series 200 gauge. NOTE: You CANNOT use the 150°C Lithium Battery Pack…

• IMPORTANT: If you use a Lithium Battery Pack AND you EXCEED the maximum temperature rating, the Lithium battery will FAIL, causing you to lose ALL your data!

Using Lithium Battery Packs with the Interface Using Lithium Battery Packs with the Interface Using Lithium Battery Packs with the Interface Using Lithium Battery Packs with the Interface BoxBoxBoxBox

IMPORTANT NOTES:

• If you use the 120°C or 150°C Lithium Battery Pack, you should use the lastest version INTERFACE BOX marked as Ver. E.

• Use the 15 VDC Power Adapter for Series 300 gauges.

• Use the 9 VDC Power Adapter for Series 400 gauges.

Using Lithium Battery PacksUsing Lithium Battery PacksUsing Lithium Battery PacksUsing Lithium Battery Packs

IMPORTANT NOTES:

• You CAN NOT use the 150°C or 180°C Lithium Battery Pack with the older Series 200 style gauge*!

*The older gauges drain too much current and will cause the Lithium Battery Pack to FAIL and you will lose ALL your data!

Using Lithium Battery PacksUsing Lithium Battery PacksUsing Lithium Battery PacksUsing Lithium Battery PacksNote: You can identify the Gauge Series by going to the “VIEW: RECORDER STATUS” menu in the software when the gauge LINKED to the computer.

Contact Scott Ager ([email protected]) if you have any questions.

Lithium Battery Pack ShippingLithium Battery Pack ShippingLithium Battery Pack ShippingLithium Battery Pack Shipping

- For Lithium Battery Pack shipping information, please call IES, Inc. and talk with Josh Teyler at +1 850 515-1244 or email:

Josh Teyler ([email protected])

For older gauges…. Replace For older gauges…. Replace For older gauges…. Replace For older gauges…. Replace anyanyanyany White Teflon White Teflon White Teflon White Teflon Spacers with the Tan Spacers with the Tan Spacers with the Tan Spacers with the Tan PEEKPEEKPEEKPEEK SpacersSpacersSpacersSpacers

In high shock and vibration environments, always use the Tan colored PEEKBattery Pack Spacers, instead of the OLDER White Teflon Spacers. The PEEK spacers are much stronger and resist deformation.

PEEK Spacers

Note: All new Battery Fixtures are shipped with Note: All new Battery Fixtures are shipped with Note: All new Battery Fixtures are shipped with Note: All new Battery Fixtures are shipped with

the TAN PEEK Spacers…the TAN PEEK Spacers…the TAN PEEK Spacers…the TAN PEEK Spacers…

Procedure for Rebuilding the Battery Procedure for Rebuilding the Battery Procedure for Rebuilding the Battery Procedure for Rebuilding the Battery Fixture Before Fixture Before Fixture Before Fixture Before EveryEveryEveryEvery JobJobJobJob

Immediately after every JOB…Immediately after every JOB…Immediately after every JOB…Immediately after every JOB…

• Cut off the OLD 1.1” dia. Kynar heat shrink, and remove the “used” battery pack.

• Properly dispose of the battery pack according to your local laws and regulations.

• DO NOT return battery packs to IES.

Inspect the NEW Battery Pack Inspect the NEW Battery Pack Inspect the NEW Battery Pack Inspect the NEW Battery Pack “Connector”“Connector”“Connector”“Connector”

IMPORTANT!IMPORTANT!IMPORTANT!IMPORTANT! BOTHBOTHBOTHBOTH these NUTS these NUTS these NUTS these NUTS MUSTMUSTMUSTMUST be be be be

installed on the Battery Pack Connector!! This installed on the Battery Pack Connector!! This installed on the Battery Pack Connector!! This installed on the Battery Pack Connector!! This

helps prevent the battery pack connector from helps prevent the battery pack connector from helps prevent the battery pack connector from helps prevent the battery pack connector from

disconnecting when the guns are fired, which disconnecting when the guns are fired, which disconnecting when the guns are fired, which disconnecting when the guns are fired, which

could cause a loss of data.could cause a loss of data.could cause a loss of data.could cause a loss of data.

Inspect the Battery Pack Pins on the Battery Inspect the Battery Pack Pins on the Battery Inspect the Battery Pack Pins on the Battery Inspect the Battery Pack Pins on the Battery FixtureFixtureFixtureFixture

Carefully inspect the Male Pins on the Carefully inspect the Male Pins on the Carefully inspect the Male Pins on the Carefully inspect the Male Pins on the

battery pack connector. There should be battery pack connector. There should be battery pack connector. There should be battery pack connector. There should be FIVEFIVEFIVEFIVE

pins, and they should all be perfectly pins, and they should all be perfectly pins, and they should all be perfectly pins, and they should all be perfectly

straight, with no bends.straight, with no bends.straight, with no bends.straight, with no bends.

Inspect the Guide PinsInspect the Guide PinsInspect the Guide PinsInspect the Guide Pins

Be careful to observe the Guide Pin Be careful to observe the Guide Pin Be careful to observe the Guide Pin Be careful to observe the Guide Pin

alignments when plugging the battery into alignments when plugging the battery into alignments when plugging the battery into alignments when plugging the battery into

the connectorthe connectorthe connectorthe connector

MALE Guide PinMALE Guide PinMALE Guide PinMALE Guide Pin

FEMALE Guide PinFEMALE Guide PinFEMALE Guide PinFEMALE Guide Pin

Plug in the NEW Battery PackPlug in the NEW Battery PackPlug in the NEW Battery PackPlug in the NEW Battery Pack

Line up the MALE and FEMALE pins Line up the MALE and FEMALE pins Line up the MALE and FEMALE pins Line up the MALE and FEMALE pins

carefully. Do not force the connector. It carefully. Do not force the connector. It carefully. Do not force the connector. It carefully. Do not force the connector. It

should plug in easily.should plug in easily.should plug in easily.should plug in easily.

Plug in the NEW Battery PackPlug in the NEW Battery PackPlug in the NEW Battery PackPlug in the NEW Battery Pack

Plug in the battery pack connector.Plug in the battery pack connector.Plug in the battery pack connector.Plug in the battery pack connector.

Position the Battery Pack WiresPosition the Battery Pack WiresPosition the Battery Pack WiresPosition the Battery Pack Wires

Position the battery in the fixture and bend Position the battery in the fixture and bend Position the battery in the fixture and bend Position the battery in the fixture and bend

the wires inside to prevent pinching.the wires inside to prevent pinching.the wires inside to prevent pinching.the wires inside to prevent pinching.

Insert Short Tan Insert Short Tan Insert Short Tan Insert Short Tan PEEKPEEKPEEKPEEK SpacerSpacerSpacerSpacer

Position the Position the Position the Position the SMALLERSMALLERSMALLERSMALLER Tan colored Tan colored Tan colored Tan colored PEEKPEEKPEEKPEEK

spacer on the “connector” side of the spacer on the “connector” side of the spacer on the “connector” side of the spacer on the “connector” side of the

battery.battery.battery.battery.

Insert Long Tan Insert Long Tan Insert Long Tan Insert Long Tan PEEKPEEKPEEKPEEK SpacerSpacerSpacerSpacer

Position the LARGER Position the LARGER Position the LARGER Position the LARGER Tan colored Tan colored Tan colored Tan colored PEEKPEEKPEEKPEEK

spacer on the opposite side of the battery, spacer on the opposite side of the battery, spacer on the opposite side of the battery, spacer on the opposite side of the battery,

next to the female connector side of the next to the female connector side of the next to the female connector side of the next to the female connector side of the

battery fixture.battery fixture.battery fixture.battery fixture.

Checking Battery Pack FitChecking Battery Pack FitChecking Battery Pack FitChecking Battery Pack FitBe sure the Battery Pack fits snuggly into the Battery Fixture. There should be no more than a 1/32” gap between the Battery Pack and the spacers. If the spacing is larger, try NEW spacers.

IMPORTANTIMPORTANTIMPORTANTIMPORTANT: ALWAYS use the PEEK spacers!!: ALWAYS use the PEEK spacers!!: ALWAYS use the PEEK spacers!!: ALWAYS use the PEEK spacers!!

Checking Battery Pack FitChecking Battery Pack FitChecking Battery Pack FitChecking Battery Pack Fit

If the Battery Pack will not fix, carefully TRIM a small amount of material off the end of the BLACK Tube with a file. If there is any excess Teflon tubing on the Battery Pack, cut off the excess first. If the Battery Pack still will not fit, then carefully file some of the BLACK Tube material off. Be very careful not to nick the

wires.

Installing Kynar Heat Shrink TubingInstalling Kynar Heat Shrink TubingInstalling Kynar Heat Shrink TubingInstalling Kynar Heat Shrink Tubing

The 1.1” Kynar Heat Shrink MUST ALWAYS be used on every Battery Fixture, to contain the Battery Pack. This prevents the Battery Pack from moving, which could cause you to lose battery power and lose your data. Do NOT use tape of any kind.

Each Battery Pack purchased comes with one 1.1” Kynar Heat Shrink

tube.

Additional Kynar heat shrink tubes can be purchased, if needed.

Installing Kynar Heat Shrink TubingInstalling Kynar Heat Shrink TubingInstalling Kynar Heat Shrink TubingInstalling Kynar Heat Shrink TubingAlways use the HEAT GUN supplied with the Gauge. The Kynar Heat Shrink requires very high temperatures to shrink the tubing properly

NOTE: The HEAT GUN supplied with the Gauge, uses 110VAC. DO NOT plug it

directly into a 220VAC system. This will burn out the HEAT GUN.

Use the 220VAC to 110VAC voltage converter supplied with the Gauge.

110V ONLY


Starting on the side of the battery fixture with the Starting on the side of the battery fixture with the Starting on the side of the battery fixture with the Starting on the side of the battery fixture with the

guide pinguide pinguide pinguide pin, heat shrink the 1.1” , heat shrink the 1.1” , heat shrink the 1.1” , heat shrink the 1.1” KynarKynarKynarKynar heat shrink, heat shrink, heat shrink, heat shrink,

slowly working your way to the opposite side of slowly working your way to the opposite side of slowly working your way to the opposite side of slowly working your way to the opposite side of

the battery fixture…the battery fixture…the battery fixture…the battery fixture…

Set the heat gun to the Set the heat gun to the Set the heat gun to the Set the heat gun to the MAXMAXMAXMAX setting for shrinking setting for shrinking setting for shrinking setting for shrinking

the 1.1” the 1.1” the 1.1” the 1.1” KynarKynarKynarKynar heat shrink. heat shrink. heat shrink. heat shrink.

DO NOT DO NOT DO NOT DO NOT over heatover heatover heatover heat the heat shrink which can result the heat shrink which can result the heat shrink which can result the heat shrink which can result

in the tearing of the heat shrink.in the tearing of the heat shrink.in the tearing of the heat shrink.in the tearing of the heat shrink.


HINT: slowly spin the batteries fixture in a 360HINT: slowly spin the batteries fixture in a 360HINT: slowly spin the batteries fixture in a 360HINT: slowly spin the batteries fixture in a 360°°°°

circle, as you heat the heat shrink tube. This will pull circle, as you heat the heat shrink tube. This will pull circle, as you heat the heat shrink tube. This will pull circle, as you heat the heat shrink tube. This will pull

the shrink tubing tight without wrinkles. the shrink tubing tight without wrinkles. the shrink tubing tight without wrinkles. the shrink tubing tight without wrinkles.

DO NOT OVERHEAT THE TUBING! BE SURE there are DO NOT OVERHEAT THE TUBING! BE SURE there are DO NOT OVERHEAT THE TUBING! BE SURE there are DO NOT OVERHEAT THE TUBING! BE SURE there are

NO wriggles in the heat shrink after you are done!NO wriggles in the heat shrink after you are done!NO wriggles in the heat shrink after you are done!NO wriggles in the heat shrink after you are done!


Be sure to shrink the Be sure to shrink the Be sure to shrink the Be sure to shrink the KynarKynarKynarKynar heat shrink tubing heat shrink tubing heat shrink tubing heat shrink tubing

TIGHTLYTIGHTLYTIGHTLYTIGHTLY around the battery fixture.around the battery fixture.around the battery fixture.around the battery fixture.

Trim Off Excess Kynar Heat ShrinkTrim Off Excess Kynar Heat ShrinkTrim Off Excess Kynar Heat ShrinkTrim Off Excess Kynar Heat Shrink

Trim the excess Trim the excess Trim the excess Trim the excess KynarKynarKynarKynar shrink shrink shrink shrink

tubing, to this point.tubing, to this point.tubing, to this point.tubing, to this point.

Trim Off Excess Kynar Heat ShrinkTrim Off Excess Kynar Heat ShrinkTrim Off Excess Kynar Heat ShrinkTrim Off Excess Kynar Heat Shrink

Trim the excess Trim the excess Trim the excess Trim the excess KynarKynarKynarKynar tubing, to tubing, to tubing, to tubing, to

this point.this point.this point.this point.

Heat Shrink TubingHeat Shrink TubingHeat Shrink TubingHeat Shrink Tubing

1.1” dia. Kynar Heat Shrink MUST cover the

entire length of the Battery Fixture

Shrink 1.1” dia. Shrink 1.1” dia. Shrink 1.1” dia. Shrink 1.1” dia. KynarKynarKynarKynar heat shrink over the heat shrink over the heat shrink over the heat shrink over the entireentireentireentire length length length length

of the Battery Fixture, using the 1400 Watt heat shrink of the Battery Fixture, using the 1400 Watt heat shrink of the Battery Fixture, using the 1400 Watt heat shrink of the Battery Fixture, using the 1400 Watt heat shrink

gun set on the highest setting. Do not overheat the gun set on the highest setting. Do not overheat the gun set on the highest setting. Do not overheat the gun set on the highest setting. Do not overheat the

tubing. Be sure to trim off the excess on both ends.tubing. Be sure to trim off the excess on both ends.tubing. Be sure to trim off the excess on both ends.tubing. Be sure to trim off the excess on both ends.

Checking the KYNAR Heat Shrink Tubing for Checking the KYNAR Heat Shrink Tubing for Checking the KYNAR Heat Shrink Tubing for Checking the KYNAR Heat Shrink Tubing for “Wrinkles”“Wrinkles”“Wrinkles”“Wrinkles”

Be sure there are Be sure there are Be sure there are Be sure there are NO WRINKLESNO WRINKLESNO WRINKLESNO WRINKLES in the in the in the in the KYNARKYNARKYNARKYNAR Heat Shrink Tubing Heat Shrink Tubing Heat Shrink Tubing Heat Shrink Tubing

after it is installed over the Battery Fixture. If there is, after it is installed over the Battery Fixture. If there is, after it is installed over the Battery Fixture. If there is, after it is installed over the Battery Fixture. If there is, removeremoveremoveremove the the the the

heat shrink, and install new heat shrink. heat shrink, and install new heat shrink. heat shrink, and install new heat shrink. heat shrink, and install new heat shrink. Additional tubing can be Additional tubing can be Additional tubing can be Additional tubing can be

obtained from IES.obtained from IES.obtained from IES.obtained from IES.

Always check the Battery Fixture to be sure it freely fits inside the Always check the Battery Fixture to be sure it freely fits inside the Always check the Battery Fixture to be sure it freely fits inside the Always check the Battery Fixture to be sure it freely fits inside the

BATTERY SECTION with no restrictions.BATTERY SECTION with no restrictions.BATTERY SECTION with no restrictions.BATTERY SECTION with no restrictions.

““““FIT CHECKFIT CHECKFIT CHECKFIT CHECK“ the Battery Fixture with the “ the Battery Fixture with the “ the Battery Fixture with the “ the Battery Fixture with the KynarKynarKynarKynarHeat Shrink Tubing InstalledHeat Shrink Tubing InstalledHeat Shrink Tubing InstalledHeat Shrink Tubing InstalledIMPORTANT: After installing the Kynar heat shrink over the Battery Pack/Fixture, you MUST “fit check” it to be sure it easily slides and spins into the Battery Section, with no restrictions. Slide it into the “reverse end” of the Battery Section…

Battery Section (reverse end) Battery Fixture with Heat Shrink

Be sure the Battery Fixture easily slides

into the Battery Section. You should be

able to freely “spin” the Battery Fixture

while it is inside the BATTERY SECTION…

The Battery Fixture can be DAMAGED if the The Battery Fixture can be DAMAGED if the The Battery Fixture can be DAMAGED if the The Battery Fixture can be DAMAGED if the Heat Shrink Tubing is Heat Shrink Tubing is Heat Shrink Tubing is Heat Shrink Tubing is ImproperlyImproperlyImproperlyImproperly InstalledInstalledInstalledInstalled

Below, shows how the Battery Fixture can get twisted and damaged after a JOB, if you have wrinkles in the Heat Shrink tubing when you install the Battery Fixture inside the Battery Section.

The Battery Fixture below was “Twisted” because the Heat Shrink Tubing

had wrinkles in it, causing the Battery Fixture to grab onto the inside of the

Battery Section as it was “unscrewed” and removed after a JOB...

Be sure the Heat Shrink has NO “wrinkles”,

and the Battery Fixture easily slides into

the Battery Section after installing the Heat

Shrink Tubing, BEFORE you install it in the

gauge…

Install the Greased WASHER!Install the Greased WASHER!Install the Greased WASHER!Install the Greased WASHER!

VERY IMPORTANT!!

The greased washer is REQUIRED and

MUST BE USED with the Battery Fixture!

Installing KAPTON Tape (if needed)Installing KAPTON Tape (if needed)Installing KAPTON Tape (if needed)Installing KAPTON Tape (if needed)

Install KAPTON Tape (if needed)0.0035” thick x 0.5” wide (2 mill)

Use ONE single layer of Use ONE single layer of Use ONE single layer of Use ONE single layer of KAPTONKAPTONKAPTONKAPTON tape on the battery tape on the battery tape on the battery tape on the battery

fixture (supplied with the Gauge) ONLY IF NEEDED!! fixture (supplied with the Gauge) ONLY IF NEEDED!! fixture (supplied with the Gauge) ONLY IF NEEDED!! fixture (supplied with the Gauge) ONLY IF NEEDED!! This

prevents the Battery Fixture from rattling against the

outer Battery Section.

NOTENOTENOTENOTE: If the battery fixture fits : If the battery fixture fits : If the battery fixture fits : If the battery fixture fits too tightly too tightly too tightly too tightly when the when the when the when the

outer BATTERY Section is put over it, then outer BATTERY Section is put over it, then outer BATTERY Section is put over it, then outer BATTERY Section is put over it, then removeremoveremoveremove the the the the

KAPTONKAPTONKAPTONKAPTON tape.tape.tape.tape.

Install the “Install the “Install the “Install the “Red Kill SwitchRed Kill SwitchRed Kill SwitchRed Kill Switch””””

Install the Install the Install the Install the RED KILL SWITCHRED KILL SWITCHRED KILL SWITCHRED KILL SWITCH afterafterafterafter the the the the

Battery Pack is installed in the Battery Battery Pack is installed in the Battery Battery Pack is installed in the Battery Battery Pack is installed in the Battery

Fixture.Fixture.Fixture.Fixture.

Test Battery Pack and Battery Fixture with the Test Battery Pack and Battery Fixture with the Test Battery Pack and Battery Fixture with the Test Battery Pack and Battery Fixture with the GaugeGaugeGaugeGauge

To test the new Battery Pack installed in the Battery Fixture, you can connect it to the OWR section of the gauge with an “extension cable”.

This allows you to easily test the battery fixture without having to install it inside the gauge and external battery section.

If you are using both a MASTER and SLAVE battery fixture, you will need to use two cables. The MASTER battery fixture MUST always be plugged into the OWRsection, FIRST.

Test the Test the Test the Test the InstalledInstalledInstalledInstalled Battery Pack and Battery Battery Pack and Battery Battery Pack and Battery Battery Pack and Battery FixtureFixtureFixtureFixture

1. REMOVE the “Red Kill Switch” .

2. Plug the MASTER Battery Fixture into the OWR Section of the Gauge, and install the external Battery Section over the battery fixture.

You can also use the “extension cable” to connect the battery fixture to the OWR Section of the gauge, instead of installing the external Battery Section.

3. If you are also using a SLAVE Battery Fixture, plug this into the MASTER Battery Fixture.

You can use the 2nd “extension cable” if you don’t want to install the 2nd external Battery Section on the gauge.


4. Plug the Interface Box into the Gauge (at the Battery Fixture).

5. Be sure the External 9 or 15 VDC Power is plugged into the

Interface Box.

8. Make LINK to the Gauge with the computer.

9. Go to the CONTROL menu and select TEST BATTERY, so the gauge is in the “STANDBY” Mode.

10. REMOVE the External 9 or 15 VDC Power from the Interface Box. The gauge will then use its INTERNAL battery pack to power it.


11. The Gauge should remain in the “STANDBY” mode. If so, then the Internal Battery Pack is powering the Gauge successfully!

◦ Alkaline Battery Pack Voltage should be > 8.5 volts

◦ Lithium Battery Pack Voltage should be > 8.5 volts (3 cell)

◦ Lithium Battery Pack Voltage should be > 6.8 volts (2 cell)

12. Note:

- If you are using Lithium Batteries, and the voltage is BELOW8.5 / 6.8 volts, THEN, you must depassivate the Lithium Battery Pack for 15 minutes in the “Standby” mode. If the internal battery voltage does not test OK, the battery should be replaced.

13. Disconnect the Interface Box, and re-install the “Red Kill Switch”

ReReReRe----install the “install the “install the “install the “Red Kill SwitchRed Kill SwitchRed Kill SwitchRed Kill Switch””””

ReReReRe----Install the Install the Install the Install the RED KILL SWITCH RED KILL SWITCH RED KILL SWITCH RED KILL SWITCH after testing after testing after testing after testing

the voltagethe voltagethe voltagethe voltage

Completed Battery FixtureCompleted Battery FixtureCompleted Battery FixtureCompleted Battery Fixture

Your battery fixture is now ready Your battery fixture is now ready Your battery fixture is now ready Your battery fixture is now ready

to be installed in the Gauge for to be installed in the Gauge for to be installed in the Gauge for to be installed in the Gauge for

your next JOB!your next JOB!your next JOB!your next JOB!

Storing the Battery PacksStoring the Battery PacksStoring the Battery PacksStoring the Battery Packs

Battery Pack StorageBattery Pack StorageBattery Pack StorageBattery Pack Storage

DO NOT build up a Battery Fixture with a NEW Battery Pack, unless you are going to use it in a Job within the next couple of weeks!

Even though the Battery Fixture is turned OFF with the “Red Kill Switch” installed, the Battery Pack still draws a “small” amount of current. This is why you shouldn’t build up a Battery Fixture until you are ready to use it for your job.


Leave the Battery Pack SEALED Leave the Battery Pack SEALED Leave the Battery Pack SEALED Leave the Battery Pack SEALED

inside the shipping bag until you inside the shipping bag until you inside the shipping bag until you inside the shipping bag until you

are ready to use it.are ready to use it.are ready to use it.are ready to use it.

Battery Pack Date CodeBattery Pack Date CodeBattery Pack Date CodeBattery Pack Date Code

Each Battery Pack has a Date Code of

when it was constructed. DO NOT use

a Battery Pack that is older than ONE

Year.


◦ Store the Alkaline Battery Packs in a refrigerator (40°F to 60°F)

◦ Store the Lithium Battery Packs at room temperature (do not exceed 90°F)

◦ Leave the Battery Packs SEALED inside their storage bags until you are ready to use them for your Job

◦ Record the battery pack S/N and when it was used

Installing the Battery Fixture Installing the Battery Fixture Installing the Battery Fixture Installing the Battery Fixture in the Gaugein the Gaugein the Gaugein the Gauge

Install the “Red Kill Switch”Install the “Red Kill Switch”Install the “Red Kill Switch”Install the “Red Kill Switch”

“Red Kill Switch”

ALWAYSALWAYSALWAYSALWAYS be sure the ”RED KILL SWITCH” is plugged into the Battery be sure the ”RED KILL SWITCH” is plugged into the Battery be sure the ”RED KILL SWITCH” is plugged into the Battery be sure the ”RED KILL SWITCH” is plugged into the Battery

Fixture Fixture Fixture Fixture BEFOREBEFOREBEFOREBEFORE it is installed inside the gauge.it is installed inside the gauge.it is installed inside the gauge.it is installed inside the gauge.

Inspect the Connector Pins in the Inspect the Connector Pins in the Inspect the Connector Pins in the Inspect the Connector Pins in the OWROWROWROWR Section Section Section Section of the Gauge of the Gauge of the Gauge of the Gauge

Connector Pins

Carefully inspect all the pins

in the OWR Section of the

Gauge. If there are any bent

or broken pins, you will

need to ship back the OWR

Section to IES for repair.

OWR Section

Installing the MASTER Battery Fixture Installing the MASTER Battery Fixture Installing the MASTER Battery Fixture Installing the MASTER Battery Fixture in the in the in the in the OWROWROWROWR Section of the Gauge Section of the Gauge Section of the Gauge Section of the Gauge

Guide PIN

DO NOT force the

connectors together. If they

don’t go together, check

the guide pin alignment.

Be Be Be Be VERYVERYVERYVERY careful when connecting the Battery Fixture to the careful when connecting the Battery Fixture to the careful when connecting the Battery Fixture to the careful when connecting the Battery Fixture to the

gauge. Be sure the pins on the connector line up gauge. Be sure the pins on the connector line up gauge. Be sure the pins on the connector line up gauge. Be sure the pins on the connector line up perfectlyperfectlyperfectlyperfectly. . . .

There is a guide PIN which must line up with the hole on There is a guide PIN which must line up with the hole on There is a guide PIN which must line up with the hole on There is a guide PIN which must line up with the hole on

the main the main the main the main OWROWROWROWR section.section.section.section.

OWR Section

Installing the Battery FixtureInstalling the Battery FixtureInstalling the Battery FixtureInstalling the Battery Fixture

You MUST install the greased washer.

After connecting the Battery Fixture, After connecting the Battery Fixture, After connecting the Battery Fixture, After connecting the Battery Fixture, DO NOT FORGETDO NOT FORGETDO NOT FORGETDO NOT FORGET to install the to install the to install the to install the

greased washer. greased washer. greased washer. greased washer.

NOTENOTENOTENOTE: first look inside the exterior Battery Section to see if there : first look inside the exterior Battery Section to see if there : first look inside the exterior Battery Section to see if there : first look inside the exterior Battery Section to see if there

already is a already is a already is a already is a washer inside itwasher inside itwasher inside itwasher inside it. This washer is . This washer is . This washer is . This washer is REQUIREDREQUIREDREQUIREDREQUIRED to prevent to prevent to prevent to prevent

damage to the battery fixture.damage to the battery fixture.damage to the battery fixture.damage to the battery fixture.


Be sure the Be sure the Be sure the Be sure the “RED Kill Switch”“RED Kill Switch”“RED Kill Switch”“RED Kill Switch” is is is is

installed on the Battery Fixture installed on the Battery Fixture installed on the Battery Fixture installed on the Battery Fixture

BEFOREBEFOREBEFOREBEFORE you plug it into the you plug it into the you plug it into the you plug it into the

GaugeGaugeGaugeGauge

ALWAYS use ALWAYS use ALWAYS use ALWAYS use TWOTWOTWOTWO PEOPLEPEOPLEPEOPLEPEOPLE to to to to

hold and assemble the hold and assemble the hold and assemble the hold and assemble the

Battery Section/Fixture in Battery Section/Fixture in Battery Section/Fixture in Battery Section/Fixture in

the Gauge!the Gauge!the Gauge!the Gauge!


NOTE: Only install the NOTE: Only install the NOTE: Only install the NOTE: Only install the

Battery Fixture in the Battery Fixture in the Battery Fixture in the Battery Fixture in the

VERTICALVERTICALVERTICALVERTICAL positionpositionpositionposition. . . .

Carefully slide the Battery Carefully slide the Battery Carefully slide the Battery Carefully slide the Battery

Section over the Battery Section over the Battery Section over the Battery Section over the Battery

Fixture.Fixture.Fixture.Fixture.

ALWAYS use ALWAYS use ALWAYS use ALWAYS use TWOTWOTWOTWO

PEOPLEPEOPLEPEOPLEPEOPLE to hold and to hold and to hold and to hold and

assemble the Battery assemble the Battery assemble the Battery assemble the Battery

Section!Section!Section!Section!


NOTE: If the “RED Kill Switch”“RED Kill Switch”“RED Kill Switch”“RED Kill Switch” is installed, the

Gauge will be “OFFOFFOFFOFF”, and will NOT record data.

The Gauge should always be stored with the

“RED Kill Switch”“RED Kill Switch”“RED Kill Switch”“RED Kill Switch” installed.

The rest of the gauge can be assembled. The rest of the gauge can be assembled. The rest of the gauge can be assembled. The rest of the gauge can be assembled.

ALWAYSALWAYSALWAYSALWAYS screw the thread protector on the end of screw the thread protector on the end of screw the thread protector on the end of screw the thread protector on the end of

the battery section the battery section the battery section the battery section ifififif you want to connect the you want to connect the you want to connect the you want to connect the

Gauge to the Gauge to the Gauge to the Gauge to the computercomputercomputercomputer for programming.for programming.for programming.for programming.

IMPORTANT:IMPORTANT:IMPORTANT:IMPORTANT: ALWAYS Store the Gauge ALWAYS Store the Gauge ALWAYS Store the Gauge ALWAYS Store the Gauge Completely AssembledCompletely AssembledCompletely AssembledCompletely Assembled

ALWAYS store the gauge completely

assembled, to keep dirt and moisture out,

and to protect the gauge threads and O-

Rings.

When Using TWO Batteries in When Using TWO Batteries in When Using TWO Batteries in When Using TWO Batteries in ONE GaugeONE GaugeONE GaugeONE Gauge

When Using When Using When Using When Using TWOTWOTWOTWO Batteries Packs…Batteries Packs…Batteries Packs…Batteries Packs…

Why use two batteries with one gauge?

◦ Doubles the time the gauge can record data by providing EXTRA battery power

◦ If there are unexpected job delays downhole, the extra battery pack will give the gauge additional downhole time to collect data

◦ Helps provide redundancy/backup in case one battery pack fails

◦ An extra battery pack will provide more energy for maintaining the data while downhole

◦ Note: A “Double Power” battery acts like TWO battery packs


◦ The MASTER Battery Fixture must ALWAYS be installed first, into the OWR Section of the Gauge.

◦ When two battery fixtures are used in a gauge, one Battery Fixture must be configured as the MASTER . This is installed first into the OWR Section of the gauge. The 2nd battery fixture is the SLAVE. This is always plugged into the MASTER battery fixture.

◦ The MASTER Battery Fixture is the standard way all battery fixtures are configured when a gauge is used in a SINGLE BATTERYapplication.


◦ The MASTER battery fixture can be identified by looking under the battery fixture on the green circuit board. It WILL NOT have a wire jumper soldered on it (see below).

MASTER Battery Fixture (No jumper)


◦ The MASTER battery fixture MUST ALWAYS be connected directly to the OWR SECTION of the gauge, whether or not the gauge is using ONE or TWO batteries.

◦ When a gauge uses TWO battery fixtures, only ONE RED KILL SWITCH is used, and it is plugged into the SLAVE battery fixture.


◦ The SLAVE battery fixture is used ONLY when a gauge is being used in a TWO BATTERY application.

◦ The SLAVE battery fixture MUST ALWAYS be connected directly to the MASTER battery fixture of the gauge. Never connect the SLAVEbattery fixture to the OWR Section!

◦ When using two battery fixtures, the RED KILL SWITCH and the INTERFACE BOX CABLE are connected to the SLAVE battery fixture.

Using Using Using Using TWOTWOTWOTWO BatteriesBatteriesBatteriesBatteries

◦ The SLAVE battery fixture can be identified by looking under the battery fixture on the green circuit board. It will have a wire jumpersoldered on it (see below).

SLAVE Battery Fixture (Jumper wire installed)

Assembling the Battery Fixtures Assembling the Battery Fixtures Assembling the Battery Fixtures Assembling the Battery Fixtures (Using TWO Batteries for a Gauge Job)

Assembling TWO Battery Packs Assembling TWO Battery Packs Assembling TWO Battery Packs Assembling TWO Battery Packs in the Gaugein the Gaugein the Gaugein the Gauge

◦ Plug the RED KILL SWITCH into the SLAVE battery fixture.

◦ Install both battery packs in the MASTER and SLAVE battery fixtures, and then heat shrink the outer 1.1” Kynar tubing over each battery fixture.

◦ Plug the MASTER battery fixture (with no jumper wire) into the OWRSECTION first. Then, screw the External Battery Section Housing over the MASTER battery fixture until it is hand tight ONLY. Be sure the greased “Washer” is installed on the MASTER battery fixture.


◦ Next, plug the SLAVE battery fixture (with the jumper wire) into the MASTER battery fixture (and battery section). The RED KILL SWITCH should be installed in the SLAVE battery fixture.

◦ Then, screw the 2nd External Battery Section Housing over the SLAVEbattery fixture until it is hand tight ONLY. Be sure the greased “Washer” is installed on the SLAVE battery fixture.


◦ The gauge can now be connected to the interface box (through the SLAVE battery fixture) and the computer.

◦ It is ready for programming the gauge settings, STARTING the gauge.

◦ –OR- the RED KILL SWITCH can be installed in the SLAVE battery fixture, which turns off BOTH the MASTER and SLAVE batteries, together.


IMPORTANT NOTES:

◦ ALWAYS ONLY HAND TIGHTEN the battery sections together.

◦ NEVER use a wrench of any kind, to tighten the gauge sections or battery sections together.

If you do, this could damage the battery fixture, resulting in the lossof your data!


IMPORTANT NOTES:

◦ When the gauge is used in the MASTER/SLAVE battery mode, only ONE RED KILL SWITCH is used to turn off both batteries. It is plugged into the SLAVE battery fixture.

◦ NEVER break the gauge between the OWR Section and MASTERBattery Section, OR the MASTER and SLAVE battery sections. This would result in the LOSS of your data (in the Series 300 ONLY)!


IMPORTANT NOTES:

◦ When you recover the gauge from you job to download the data, ALWAYS break the gauge between the SLAVE Battery Section and the DATA PORT Section.

◦ NOTE: If you break the gauge ANYWHERE ELSE, this will result in the LOSS of your data (in the Series 300 ONLY)!

Gauge Battery FixtureGauge Battery FixtureGauge Battery FixtureGauge Battery Fixture

BY SCOT T AGER

gauge battery fixture - ies global, inc. high speed...

Documents