BM WellPilot 01

Setup Guide for Rod Pumps WellPilot

Page 56 January 2008 BM-WellPilot-01 / Rev. A

3. The most common card displayed is the “LIVE” card. The well must be running, then select “6 - LIVE” and press “ENTER”. Plotting can be stopped at any time by again pressing “ENTER”. Press “CLEAR” on the keypad to remove all currently displayed cards from the screen.

Note: An “*” must be displayed, on the screen as shown, in order to see a ”live” card following unit startup.

“2 STARTUP” – Select this option to see the startup

card and the 4 cards leading up to the event.

WellPilot “3 SHUTDN” - Select this option to see the shutdown card and the 4 cards leading up to the event.

Startup Manual “4 SU-SD” - Select this option to see the startup card and the shutdown card.

“SINGLE” – Select this option to see “one” current card (well must be running).

Manual Part No. BM-WellPilot-01

For Questions That Need Answered:

January 2008

Revision: Original

Step 1: Talk to your company automation tech.

Step 2: Refer to the ePIC RPC User Manual, if available.

Step 3: Call an eProduction Solutions representative.


Page ii January 2008 BM-WellPilot-01 / Rev. A

Record of Revisions

Revision Description Date Original (A) Initial Release January 2008

Copyright Notice

This document contains information proprietary to Weatherford, with all rights reserved worldwide. Any reproduction or disclosure of this publication, or any part hereof, to persons other than Weatherford personnel or ePIC/ePAC II customers is strictly prohibited, except by written permission of Weatherford, 22001 North Park Drive, Kingwood, Texas 77339-3804.

Unauthorized disclosure, reproduction or translation of this publication will result in eP exercising the maximum possible legal action against all persons and/or organizations involved.

Disclaimer

Weatherford makes no representations or warranties with respect to the contents hereof. Further, Weatherford reserves the right to revise this publication and to make changes in the content hereof without obligation to notify any person or organization of such revision or changes.

The following products and organizations have been mentioned in this documentation. Various trademarks are owned by the respective owners.

Microsoft®, Windows 95®, Windows 98®, Windows 2000® and Windows NT® are either registered trademarks or trademarks of Microsoft Corporation in the United States and/or other countries, http://www.microsoft.com.

WellPilot Setup Guide for Rod Pumps

January 2008 Page 55 BM-WellPilot-01 / Rev. A

The Daily Well Site RPC Routine

The following items guide you for normal running well routine:

• Check to see if the “alarm light” (on the side or top of the RPC enclosure) is flashing. If the light is not flashing – and if there is not an immediate need for gathering operating data from the RPC, it is quite likely that the unit and well are operating normally.

• If the “alarm light” is flashing – take time to look at the RPC “STATUS SCREEN”.

• If the message following “ALARMS:” on the “STATUS SCREEN” is anything but a “load-based” shutdown, press “CLEAR ERROR” and then “PUMP ON”. If the “alarm” returns to the “STATUS SCREEN” (alarm light flashing – shown to the right) after the well has been running a few minutes, assess the cause and take action to correct the problem. This may require a company automation technician or a phone call to eP.

• If the “alarm” is a load-based shutdown, exercise great care before restarting the unit. Use company troubleshooting procedures, knowledge of dynamometer card shapes, and – if available – rod pumped analysis software to understand exact downhole conditions.

• Other than alarms, probably the most important item to watch on an ongoing basis is – “How long did the well run in the previous 24 hours?” - or simply “Daily Runtime”.

View Surface Dynamometer Cards

1. To see current dyno cards or stored cards, select “Dynagraph Data” from the “View Data Menu”. Press “ENTER” and the display will go to the Dynagraph Card display.

2. Choose the dyno card(s) to display from this menu.

http://www.microsoft.com/com



Table 14: U3 Fault History Parameters U3-02 Fault Message 2 U3-12 Fault Message 8

U3-03 Fault Message 3 U3-13 Fault Message 9

U3-04 Fault Message 4 U3-14 Fault Message 10

U3-05 Elapsed Time 1 U3-15 Elapsed Time 5




U3-09 Fault Message 5 U3-19 Elapsed Time 9

U3-10 Fault Message 6 U3-20 Elapsed Time 10

Note: Fault trace is not executed at CPF00, CPF01, CPF03, UV1, and UV2.

Tips To Keep In Mind …

There are more setup parameters that may need adjustment as more is learned about individual wells. If a well with a newly commissioned RPC loses production, the RPC setup requires attention to properly control the well. Refer to the WellPilot User Manual, part number BM-WellPLT-00, for additional details.


January 2008 Page iii BM-WellPilot-01 / Rev. A

Documentation Nomenclature

This manual uses the following protocol to present information.

Bold type sets apart keystrokes that must be pressed on the keyboard or numeric keypad for a defined action or input.

The <Keyname> notation refers to a specific key on the keyboard or keypad. For example, <Ctrl> refers to the control key, which is labeled Ctrl.

The <Keyname1> + <Keyname2> notation means that two keys must be pressed at the same time. The user does this by holding down one key and pressing the other key. Situations in which this occurs usually include the <Shift>, <Alt>, or the <Ctrl> keys.

The DOS® Operating System, used on IBM® and compatible computers, does not differentiate between upper and lower case characters. DOS commands in this manual appear in lower case and bold type.

When the computer generates characters on the monitor or display and a response is required from the user, these are italicized in the documentation.

Microsoft Windows

The phrase “choose” followed by a command in bold text means that the cursor is to be moved to the command in question and left-mouse click. A trailing right bracket followed by another command indicates to highlight the first command, move the cursor to the right, and highlight the second command. For example:

Choose File > Open filename

The expression “click” instructs the user to left-mouse click on the Window buttons that display on the screen. For example:

Click EXIT to return to the main menu screen.


Page iv January 2008 BM-WellPilot-01 / Rev. A

Click OK to accept the values in the fields.

Data Conventions

In certain instances, this manual sets specific information aside from the normal format of the text. This is done to attract the attention of the reader. This manual uses the terms “NOTE,” “Caution” and “Warning”.

NOTE: The note highlights information that will benefit the reader.

Caution: A caution denotes conditions under which lack of care or attention to instructions could result in damage to equipment.

WARNING: A warning tells of a situation in which lack of care or attention to instructions could result in injury or death to personnel.



Use the and arrow keys to scroll through the Fault Trace List items.

Table 13: U2 Fault Trace List U2-01 Current Fault U2-08 DC Bus Voltage at Fault*

U2-02 Previous Fault U2-09 Output Power at Fault*

U2-03 Frequency Reference at Fault*

U2-10 Torque Reference at Fault

U2-04 Output Frequency at Fault*

U2-11 Input Terminal Status at Fault*

U2-05 Output Current at Fault* U2-12 Output Terminal Status at Fault*

U2-06 Motor Speed at Fault* U2-13 Drive Operation Status at Fault*

U2-07 Output Voltage at Fault* U2-14 Cumulative Operation Time at Fault*

Note: * Represents fault condition prior to current fault state. Note: Fault trace is not executed at CPF00, CPF01, CPF03, UV1, and UV2.

VSD Drive U3 Fault History List

After viewing the “Fault Trace” parameter list, follow the key operations below to access the “Fault History” parameter list.

Use and keys to scroll through the Fault History List items.

Table 14: U3 Fault History Parameters U3-01 Last Fault U3-11 Fault Message 7



Table 12: U1 Monitor List U1-11 Output Terminal Status U1-40 Cooling Fan Elapsed Time

U1-12 Drive Operation Status U1-59 Compensated Fluid Level Control Set Point

U1-13 Cumulative Operation Time

U1-90 Compensated Pump Intake Pressure

U1-14 Software Number U1-91 Pump Intake Pressure

U1-15 Terminal A1 Input Voltage

U1-92 Casing Pressure


U1-93 Water Flow


U1-94 Water Production ( 1 units)

U1-18 Motor Secondary Current (Iq)

U1-95 Water Production ( 1000 units)

U1-19 Motor Excitation Current (Id)

U1-96 Flowline Pressure

U1-20 Output Frequency after Soft-start

U1-97 Speed ( Scaled)

U1-24 PI Feedback Value U1-98 Output Current

U1-25 DI-16 H2 Input Status U1-99 Output Torque (ft-lb)

Note: Some monitors are not available for all Control Modes (A1-02).

VSD Drive U2 Fault Trace List

After viewing the “Monitor” parameter list, follow the key operations below to access the “Fault Trace” parameter list.


January 2008 Page v BM-WellPilot-01 / Rev. A

Table of Contents

List of Paragraphs

On-Site Physical Mounting and Connections...............1 Hardware Configuration .............................................. 1 ePAC II Wiring .......................................................... 4

VSD Drive Setup.........................................................6 Drive Digital Operator Keypad ..................................... 6 Drive Main Menu........................................................ 8 General ePAC II Start-Up Procedures.......................... 10

System Initialization ....................................................... 11 Open Loop Vector Start-up List ......................................... 11

Auto-Tuning............................................................ 12 Auto Tuning - Standard ................................................... 12 No Rotate Tuning............................................................ 13

Typical RP Startup Parameter Items ........................... 15 Quick Setting Menu (-QUICK-).......................................... 17 Additional Settings.......................................................... 20

Rod Pumping Specifics .............................................21 Overvoltage Suppression .......................................... 21

Basic concept/principle .................................................... 21 Limitations (based on inverter capacity, control Mode, application, etc., if any)................................................... 21 Function description........................................................ 22 Belt Break Detection ....................................................... 23 Specific Rod Pump Parameters ......................................... 23

WellPilot Rod Pump Controller Setup .......................26 WellPilot Status Screen (P1250 Set to “2”) .................. 26 Step 1: Main Menu................................................... 26

Step 1A: Setup Menu ...................................................... 26 Step 2: Set Time and Date........................................ 26

Step 2A: Setting Time..................................................... 27 Step 2B: Setting Date ..................................................... 27

Step 3: Pumpoff Control Setup .................................. 27 Step 4: Set Idle Time ............................................... 27 Step 5: Set Pumpoff Position ..................................... 28 Step 6: Set Pumpoff Load (P0023) ............................. 28


Page vi January 2008 BM-WellPilot-01 / Rev. A

Step 7: Parameters to Leave at Default ...................... 28 Step 8: Set the Position Sensor Type (P0034).............. 29 Step 9: Select Load Sensor Type (P0035) ................... 29 Parameter Selection................................................. 29 Step 10: VSD Control Setup Menu.............................. 30

Step 10A: Clear Errors.....................................................30 Step 10B: Setting Minimum SPM (P1256) ...........................30 Step 10C: Software Reset (P351) ......................................31 Step 10D: SPM Startup Value (P1268) ...............................31 Step 10E: Fill Tolerance (P1252) .......................................31 Step 10F: VSD Initial Speed Change (P1253) ......................32 Step 10G: VSD Min Speed Change (P1258) ........................32 Step 10H: VSD Speed Tolerance. ......................................32 Step 10I: Evaluation Time (P1261)....................................33 Step 10J: VSD SPM Override Value (P1263)........................33 Step 10K: Minimum Pump Fillage % (P1273) ......................33 Step 10L: VSD SPM Override Flag (P1264) .........................34 Step 10M: Minimum Fill Stroke Count (P1274) ....................34 Step 10N: Minimum Fill Action (P1275) ..............................34 Step 10O: Calibrate (P1251).............................................35 Step 10P: Enable VSD (P1250) .........................................35

Step 11: Verify Correct Load Cell Rating ..................... 36 Step 12: Set “Gauge Off” Time (P429)........................ 37 Step 13: Set Basic Load Alarm and Load Shutdown Limits............................................................................ 37 Step 13A: Accessing Load Violations Setup Menu.................38 Step 13B: High-High Load Alarm (Shutdown)......................38 Step 13C: High Load Alarm ..............................................39 Step 13D: Load Violations -High........................................39 Step 13E: Low Load Alarm ...............................................40 Step 13F: Load Violations - Low ........................................40 Step 13G: Low-Low Load Alarm ........................................40 Step 13H: Minimum Load Span Alarm................................41 Step 13I: Minimum Average Load Alarm.............................42

Step 14: Fluid Stroke (Estimated Total Fluid Production) Configuration .......................................................... 42

Step 14A: Fluid Stroke Calculation Method (P0805)..............43 Step 14B: Fluid Calculation X1 Point (P0800) ......................43 Step 14C: Fluid Calculation X2 Point (P0801) ......................43 Step 14D: Fluid Calculation Y1 Point (P0802) ......................43 Step 14E: Fluid Calculation Y2 Point (P0803).......................43 Step 14F: Surface Stroke Length (P0806)...........................44 Step 14G: Pump Size (P0807) ..........................................44 Step 14H: Band Fraction (P0841), Preset Fluid Stroke (P0843) & Pump Efficiency (P0810) ..................................................44



VSD Drive Operation Menu (-DRIVE-)

This menu is used for setting the frequency reference (Local Mode) or monitoring values such as output frequency and output current. It is also used for displaying the fault history and the fault traces. The Drive must be in this menu in order to run. See parameter b1-08 (Run Command Selection During Program).

VSD Drive U1 Monitor List

Follow the key operations below to access the Operation Menu:

Use Up and Down Arrow keys to scroll through the Monitor List of items.

Table 12: U1 Monitor List U1-01 Frequency Reference U1-26 Output Voltage Reference

(Vq)

U1-02 Output Frequency U1-27 Output Voltage Reference (Vd)

U1-03 Output Current U1-28 CPU Number

U1-04 Control Method U1-32 ACR(q) Output

U1-05 Motor Speed U1-33 ACR(d) Output

U1-06 Output Voltage U1-34 OPE Detected

U1-07 DC Bus Voltage U1-36 PID Input

U1-08 Output Power U1-37 PID Output

U1-09 Torque Reference U1-38 PID Setpoint

U1-10 Input Terminal Status U1-39 Modbus Error Code




Position the “Pump Off Setpoint” - 2

1. A second way to re-position the setpoint is to move the cursor (>) (when a dyno card is displayed) until it is positioned by the current “POSN:” value. Press “Modify” to change the value.

2. Then move the cursor (>) until it is positioned by the current “LOAD:” value. Press “Modify” to change the value. Changing these two values will move the setpoint to a new location.

3. Note the more correct positioning of the pump off setpoint in the two examples to the right. The rectangles represent more acceptable areas of the surface dynamometer where the setpoint could be positioned to properly control these situations.

4. Note the difference is the shape of these two cards – based on pump depth, rod string design, stroke length, pump size, etc.


1. A third method is to select option 2 – “Pumpoff Control Setup” from the “SETUP MENU”. Press “ENTER” to invoke the selection.

2. Using this menu, the “Pumpoff Position” and “Pumpoff Load” values can be modified to move the pumpoff setpoint to a desired new location.

January 2008 Page vii BM-WellPilot-01 / Rev. A

Step 15: WellPilot Config Sreen ................................. 45 Step 15A: Max Speed (P1787, Register 37, E1-04). ............. 45 Step 15B: Min Speed (P1792, Reg. 42, P2-01).................... 45 Torque (Calculated) ........................................................ 45 Step 15C: Max Fwd Torque (P1788, Reg 38, L7-01)............. 46 Fault Restarts ................................................................ 46 Restart T/D.................................................................... 46 Speed Setpoint .............................................................. 46 Step 15D: Lo Spd Setting (P1789, Reg 39, P1-01)............... 46 Step 15E: PMP FILL (Load) SPT (P0023) ............................ 47 Step 15F: Accel Time (P1785, Reg. 35, C1-01) ................... 47 Step 15G: Decel Time (P1786, Reg. 36, C1-02) .................. 48 Step 15H: Max Current (P1803, Reg. 53, T1-04) ................. 48

Position the “Pump off Setpoint” for Routine Operation.................................................................................49

Position the “Pump Off Setpoint” - 1.................................. 49 Position the “Pump Off Setpoint” - 2.................................. 50 Position the “Pump Off Setpoint” - 3.................................. 50

VSD Drive Operation Menu (-DRIVE-) ......................... 51 VSD Drive U1 Monitor List................................................ 51 VSD Drive U2 Fault Trace List........................................... 52 VSD Drive U3 Fault History List......................................... 53

Tips To Keep In Mind … ............................................ 54

The Daily Well Site RPC Routine ...............................55 View Surface Dynamometer Cards ............................. 55

For Questions That Need Answered: ........................56

List of Tables Table 1: Typical Configuration of S1 Dip Switch................ 1 Table 2: Typical Configuration of Jumper Block CN15 ........ 2 Table 3: Operator Keypad Keys Function ......................... 6 Table 4: Main Menu Structure........................................ 9 Table 5: Input Voltage Record Table ............................. 10 Table 6: Auto Tune Menu Items ................................... 14 Table 7: VSD Controller Communications Settings .......... 16 Table 8: Quick Setting Menu........................................ 17 Table 9:Additional WellPilot Settings............................. 20 Table 10: Rod Pumping VSD Specific Parameters............ 23 Table 11: Rod Pumping Specific Faults .......................... 25


Page viii January 2008 BM-WellPilot-01 / Rev. A

Table 12: U1 Monitor List ............................................ 51 Table 13: U2 Fault Trace List ....................................... 53 Table 14: U3 Fault History Parameters.......................... 53

List of Figures Figure 1: Typical Drive Terminal Panel showing S1 and CN15

in Factory Default Settings........................................ 2 Figure 2: Example Power Supply Voltage Jumper Setting... 3 Figure 3: WellPilot Overall Wiring Diagram ...................... 5 Figure 4: Iq Pgain – Increase gain above base speed ...... 22



Position the “Pump off Setpoint” for Routine Operation

1. To view a dyno card and the current position of the pump off setpoint, press “MENU”, then select “View Data” (ENTER) from the “MAIN MENU”.

2. Then select “Dynagraph Data” (ENTER) from the “VIEW DATA MENU”.

3. Select either option “2”, “3”, “4”, or “5” to display dyno card types and their history or “6” to see real-time cards. In the example to the right note that the current position of the pump off setpoint at 30% load and 30% position.

Note: This configuration would likely result in this well never shutting down – except possibly in the event of very severe pump off.

4. Note the more correct positioning of the pump off setpoint in the two examples to the right. The rectangles represent more acceptable areas of the surface dynamometer where the setpoint could be positioned to properly control these situations.

5. Note the difference is the shape of these two cards – based on pump depth, rod string design, stroke length, pump size, etc.


One way to re-position the pump off setpoint is to select option “7” “POC PT” (“Enter”) when a dyno card is displayed “crosshairs” for both Load and Position appear. Use the four “arrow keys” to move the setpoint position to the desired new position. Press “ENTER” to save.



January 2008 Page 1

Step 15G: Decel Time (P1786, Reg. 36, C1-02)

This parameter sets the time to decelerate from maximum frequency to zero.

1. At the “DECEL TIME” item, press “Modify” and the parameter modify screen will appear.

2. Type in the new number of seconds needed to allow the pump to decelerate to minimum frequency.

3. Then press “ENTER” to save the value in Parameter 1786 and then be transmitted via Modbus to the ePAC II Controller. The display will return to the ePAC II Config screen.

Step 15H: Max Current (P1803, Reg. 53, T1-04)

Sets the motor rated current in Amperes (A).

1. At the “MAX CURRENT” item, press “Modify” and the parameter modify screen will appear.

2. Type in the new number of Amps needed to allow the pump motor to pull before shutting down.


BM-WellPilot-01 / Rev. A

On-Site Physical Mounting and Connections

Refer to the ePAC II User Manual, BM-ePACIIVSD-00, for complete instructions to physically installing the enclosure on site.

Hardware Configuration

Ensure that the DIP switches and jumpers are configured as required below.

Warning: Ensure that Power is OFF before performing the hardware configuration below!

Note: All references to ‘Top’ assume that the VSD is positioned in its’ normal, vertical, mounting position (i.e. such that the Drive’s wiring terminals are towards the bottom of the unit).

1. Ensure that unit is powered OFF (i.e. the unit’s circuit breaker is in the OFF position at a minimum).

2. Set any installed Thermostat’s adjustment to desired trip temperature (or greater than present room temperature).

3. Remove the Drive’s (wiring) Terminal Cover (See YASKAWA F7 Drive User Manual, Document # TM.F7.01.pdf).

4. Ensure that DIP switch S1 (see Figure 1 for relative location) is configured per Table 1.

Table 1: Typical Configuration of S1 Dip Switch Position # Setting1 Function

1 (Top) ON RS-485 / RS-422 Line Terminating Resistor in Circuit when ON.

Setup Guide for Rod Pumps WellPilot WellPilot Setup Guide for Rod Pumps


Position # Setting1 Function Step 15E: PMP FILL (Load) SPT (P0023)

2 (Bottom) ON Analog Channel 2 Configured for 4-20mA Input when ON.

OFF is to the Left of the unit; and ON is to the right. (These are typical Factory Default Settings)

The Pumpoff Load is set as a percentage of the maximum load. This sets the Pumpoff load limit percentage and is compared to the Pumpoff Position percentage to determine when Pumpoff has occurred. A control quadrant is formed by P021 POC position limit value and P023 POC load limit value. As long as the Dynamometer pump curve passes within any part of the quadrant, it has not gone beyond the POC limits and no action is taken. If the Dynamometer pump curve fails to pass within the boundaries of the control quadrant, the stroke is considered a pump-off stroke and action is taken after the defined consecutive number of pump-off strokes has accumulated. The consecutive pump-off stroke limit is set in P24.

0 = Minimum Load during stroke

100 = Maximum Load during stroke

Figure 1: Typical Drive Terminal Panel showing S1 and CN15 in Factory Default Settings Note: This parameter should have been set up previously.

1. At the “PMP FILL SPT” item, press “Modify” and the parameter modify screen will appear.

Note: Figure 1 is from the YASKAWA F7 Drive User Manual, Document # TM.F7.01.pdf.

2. Type in the new percentage value of the Pump Fill Setpoint and then press “ENTER” to save the value. The display will return to the ePAC II Config screen.

5. Ensure that Jumper Block CN15 (see Figure 1 for relative location) is configured per Table 2.

Table 2: Typical Configuration of Jumper Block CN15 Step 15F: Accel Time (P1785, Reg. 35, C1-01) Position Setting1 Function

CH1 Right FM Analog Output (CH1) Signal Type, 0-10V or 4-20mA

CH2 Right AM Analog Output (CH2) Signal Type, 0-10V or 4-20mA

When the Jumper is positioned to the Right, then the Analog Output will supply a 0-10Vdc signal; When positioned to the Left, then it will supply a 4-20mAdc signal. (These are typical Factory Default Settings)

This parameter sets the minimum time to accelerate from zero to maximum frequency.

1. At the “ACCEL TIME” item, press “Modify” and the parameter modify screen will appear.

2. Type in the new number of seconds needed to allow the pump to accelerate to maximum frequency.






6. Ensure that a 250 Ohm resistor is installed across the channel 3 Analog Input terminals (Green terminals A3 & AC) if needed.

Step 15C: Max Fwd Torque (P1788, Reg 38, L7-01)

This parameter sets the forward motoring torque limit value, as a percentage of the motor rated torque. 7. Ensure that a Jumper Bar is installed across the SC and

SP terminals (on the Green terminal block) if needed. 1. At the “Min Speed” item, press “Modify” and the

Modscan Register 38 modify screen will appear. 8. Hardware Configuration is complete for all Size 1 through 3 assemblies. Continue to step 9 for Size 4 assemblies with 125HP and higher rated Drives (e.g. CIMR-F7U4075, 4090, 4110, & 4160).

2. Type in the new percentage value of the rated torque for the pump motor and then press “ENTER” to save the value in Parameter 1788 and then be transmitted via Modbus to the ePAC II Controller. The display will return to the ePAC II Config screen.

Note: Step 9 is only performed on Drives with a Horse Power rating of 125HP or higher and an input Voltage of 380V and higher. These Drives are typically only installed in Size 4 VSD assemblies. Fault Restarts

Display only. Not programmable. 9. Ensure that the Power Supply Voltage Jumper is

installed on the Power tab that matches your drive voltage (this should be the factory default, and it is desired for eP Production Test). See Figure 2 as an example only. Your voltage and jumper position may vary.

Restart T/D

Display only. Not programmable.

Speed Setpoint

Display only. Not programmable.

Step 15D: Lo Spd Setting (P1789, Reg 39, P1-01)

This parameter sets the level for Low Speed detection as a percentage of maximum frequency (E1-04). A setting of 0.0% disables the low speed detection feature.

1. At the “Lo SPD SETNG” item, press “Modify” and the Modscan Register 39 modify screen will appear.

2. Type in the new percentage value of the maximum frequency and then press “ENTER” to save the value in Parameter 1789 and then be transmitted via Modbus to the ePAC II Controller. The display will return to the ePAC II Config screen.

Figure 2: Example Power Supply Voltage Jumper Setting





ePAC II Wiring

All internal wiring is done when the unit is manufactured at the factory except for connecting the Incoming Line Power, the drive motor line and any sensors that will be connected. For detailed connection instructions, refer to the wiring diagram on the inside of the front door on your unit and to your ePIC and ePAC II user manuals.


To return to the “STATUS SCREEN”, press the “MENU” key and then press “EXIT”.

Step 15: WellPilot Config Sreen

The WellPilot Config screen can be accessed by pressing the “F2”. Pressing “F2” again toggles the display to the WellPilot Status screen. The items in the following paragraphs must be set in the ePAC II Config screen.

Step 15A: Max Speed (P1787, Register 37, E1-04).

This modifies the Maximum ePAC II Output Frequency of 40.0 ~ 400.0Hz. The default value is 60.0Hz.

1. At the “Max Speed” item, press “Modify” and the Modscan Register 37 modify screen will appear.

2. Type in the new frequency value in Hertz and then press “ENTER” to save the value in Parameter 1787 and then transmitted via Modbus to the ePAC II Controller. The display will return to the WellPilot Config screen.

Step 15B: Min Speed (P1792, Reg. 42, P2-01)

Set as a percentage of maximum frequency (E1-04). This parameter acts as a lower limit on the PID output. When active, the PID integrator is held.

1. At the “Min Speed” item, press “Modify” and the Modscan Register 42 modify screen will appear.

2. Type in the new percentage value of the maximum frequency and then press “ENTER” to save the value in Parameter 1792 and then transmitted via Modbus to the ePAC II Controller. The display will return to the ePAC II Config screen.

Torque (Calculated)

This is a calculated display only. Not programmable.


Note: The values in the preceding Fluid Calculations should be used as “default” or beginning values and may have to be adjusted based on the estimated daily fluid production values or the surface dynamometer card shape.

Step 14F: Surface Stroke Length (P0806)

1. Use the “down arrow” to position the cursor (>) next to “Surface Stroke Length” item (P806) and push the "MODIFY" key to change the value. The Modifying screen will appear.

2. Input the measured polished rod stroke length in inches and hundredths of an inch (xxx.xx) and press “ENTER” to save the value. The display will return to the Estimated Fluid Production Setup menu screen.

Step 14G: Pump Size (P0807)

1. Use the “down arrow” to position the cursor (>) next to “Pump Size” (P807) and push the "MODIFY" key to change the value. The Modifying screen will appear.

2. Input the installed downhole pump ID in inches and hundredths of an inch (xxx.xx) and press “ENTER” to save the value. The display will return to the Estimated Fluid Production Setup menu screen.

Step 14H: Band Fraction (P0841), Preset Fluid Stroke (P0843) & Pump Efficiency (P0810)

Leave the following items in the Estimated Fluid Production Setup screen set at the default values for now. They may need to be changed at a later date for fine tuning the RPC.

• Band Fraction (P841) Figure 3: WellPilot Overall Wiring Diagram

• Preset Fluid Stroke (P843)

• Pump Efficiency (P810)

Page 44 January 2008 January 2008 Page 5 BM-WellPilot-01 / Rev. A BM-WellPilot-01 / Rev. A


VSD Drive Setup Step 14A: Fluid Stroke Calculation Method (P0805)

The following instructions are meant for those operators that are familiar with the installation and operation of these drives. Refer to the Installation Section of the ePAC II PCP User Manual, BM-ePACIIPCP-00 for detailed instructions.

With the cursor (>) next to the “Calculation Method” item (P805) and push the "MODIFY" key to change the value. The Modifying screen will appear. Input “1” for changing to the Short Method of calculation and press “ENTER” to save the new value. The display will return to the Estimated Fluid Production Setup menu screen. Drive Digital Operator

Keypad Step 14B: Fluid Calculation X1 Point (P0800)

Leave “X1 Location” (P800) at the default value of “0”.

Step 14C: Fluid Calculation X2 Point (P0801)

Use the “down arrow” to position the cursor (>) next to “X2 Location” (P801). Press "MODIFY" to change the setting and the Modifying screen appears. Input “100”, and press “ENTER” to save the entry. The display returns to the Estimated Fluid Production Setup menu screen.

This unit monitors drive conditions and controls the ePAC unit and pump motor when it is set to Local Mode. When set to Remote Mode, it allows monitoring of drive conditions. In either mode it may be used for programming. The names and functions of the Digital Operator Keys are described in Table 3.

Step 14D: Fluid Calculation Y1 Point (P0802)

1. Use the “down arrow” to position the cursor (>) next to “Y1 Location” (P802). Press the "MODIFY" key to change setting. The Modifying screen will appear. Table 3: Operator Keypad Keys Function

Key Name Function

LOCAL / REMOTE

• Switches between operation via the Digital Operator (LOCAL) and the settings in parameter b1-01 (Frequency Reference Selection) and b1-02 (Run Command Selection) (REMOTE).

• This key can be enabled or disabled by the setting in parameter o2-01.

• The Drive must be in a stopped condition before it can be transferred to “LOCAL” or “REMOTE” mode.

2. Input “30” and press “ENTER” to save the new setting. The display returns to the Estimated Fluid Production Setup menu screen.

Step 14E: Fluid Calculation Y2 Point (P0803)

1. Use the “down arrow” to position the cursor (>) next to “Y2 Location” (P803).

2. Press the "MODIFY" key to change the value and the Modifying screen will appear. Input “10” and press “ENTER” to save the new value. The display returns to the Estimated Fluid Production Setup menu screen.





4. Use the numeric keypad to change the number of consecutive “Low Load span strokes” for shutdown – if desired. Press “ENTER” to save if a change is made.

Table 3: Operator Keypad Keys Function Key Name Function

MENU • Scrolls through the five main menus:

• Operation (-DRIVE-), Quick Setting (-QUICK-), Programming (-ADV-), Modified Constants (-VERIFY-), and Auto-Tuning (-A.TUNE-).

ESCAPE • Returns to the previous display, before the DATA/ENTER key was pressed.

JOG • Enables jog operation when the Drive is being operated from the Digital Operator (LOCAL).

FWD / REV • Selects the rotation direction of the motor when the Drive is being operated from the Digital Operator (LOCAL).

INCREASE • Increases parameter numbers and set values.

• Used to move to the next item or data value.

DECREASE • Decreases parameter numbers and set values.

• Used to move to the previous item or data value.

SHIFT/RESET • Selects the digit to be changed. The selected digit will blink.

• Also resets the Drive when a fault has occurred. The run command must be removed before the reset command will be accepted.

DATA/ENTER • Enter menus and parameters as well as to set values.

5. Use the “down arrow” key to position the cursor (>) next to the “Action” option. Press "MODIFY" to change.

6. Use the numeric keypad to select “3 = OFF / RESET”. Press “ENTER” to save. “Off / Reset” will cause the unit to shutdown when a “Low Load span” load value is detected for the set number of consecutive strokes. The unit will not restart until the user issues a “CLEAR ERROR” followed by a “PUMP ON” command.

Step 13I: Minimum Average Load Alarm

“Minimum Average Load” is generally not used except in the case of “rod float” - which usually occurs in wells producing viscous crude or when paraffin or other downhole friction is present. Leave the “Limit” value set to “0” to disable this alarm.

Step 14: Fluid Stroke (Estimated Total Fluid Production) Configuration

If you want the ePIC RPC to calculate total fluid production each day, do the following:

1. Press the “Menu” key and then select option 2 (“SETUP MENU”). Using the “SETUP MENU”, enter a “4” or use the “down arrow key” to position the cursor (>) next to “Est. Fluid Production”.

2. Press “ENTER” and the Estimated Fluid Production Setup screen appears.




Table 3: Operator Keypad Keys Function 2. Use the numeric keypad to enter the calculated (normal

low - 2000) “Low-Low” load shutdown alarm value.

Example: 2058 - 2000 = 58 lbs.

Press “Enter” to save.

Key Name Function

RUN • Starts Drive operation when the Drive is being controlled by the Digital Operator (LOCAL).

STOP Key • Stops Drive operation.

• This key can be enabled or disabled when operating from the external terminal or communications by setting user parameter o2-02.

Note: The “No. Violations” option is not available using the “Low-Low” load alarm setup screen.


4. Use the numeric keypad to select “3 = OFF / RESET”. Press “ENTER” to save. “OFF / RESET” will cause the unit to shutdown when a “low-low” load occurs for the set number of consecutive strokes. The unit will not restart until the user issues a “CLEAR ERROR” followed by a “PUMP ON” command.

Drive Main Menu

The Drive’s parameters and monitoring functions are organized into groups called menus that make it easier to read and set parameters. The Drive is equipped with five menus. Step 13H: Minimum Load Span Alarm The menu selection display will appear when the MENU key is pressed from a monitor or setting display. While viewing the menu selection display, press the MENU key repeatedly to scroll between the menu selections. Press the DATA/ENTER key to enter the desired menu selection.

1. Press the “PgDn” key to advance to the “Minimum Load Span” screen. The “Minimum Load Span” defaults to “1000 lbs.”. Calculate a better value by subtracting the previously determined “normal” minimum load from the “normal” maximum load. Then, multiply the result x “0.6” (60%). Press "MODIFY" to change. The five menus and their primary functions are shown in the

table following. 2. Use the numeric keypad to enter the calculated (normal high – normal low x 0.6) “Min valid load span” load alarm value. Press “ENTER” to save.

Example: 19500 - 12000 = 7500 x .6 = 4500 lbs.

3. Use the “down arrow” key to position the cursor (>) next to the “No. Violations” option. The value entered here is the number of consecutive strokes that trigger the “Minimum Load Span” shutdown alarm. Note that the default value is “10”. Press "MODIFY" to change.



Table 4: Main Menu Structure Step 13E: Low Load Alarm Main Menu

Primary Functions Flow Chart

Operation The Drive can run in this menu. Use this menu for monitoring values such as frequency reference or output current, displaying fault history or displaying the fault traces.

Quick Setting

The Drive can be programmed in this menu. Use this menu to set/read the most commonly used parameters.

Program-ming

The Drive can be programmed in this menu or parameters can be copied into the Digital Operator. Use this menu to set/read every parameter.

Modified Constants

The Drive can be programmed in this menu. Use this menu to set/read the parameters that have been modified from their factory default settings.

Auto-Tuning

The Drive can be programmed in this menu. Use this menu to Auto-Tune the Drive in order to optimize motor control. The motor parameters are calculated and set automatically after successfully completing Auto-Tuning.

Note: The Auto-Tuning menu item may not be available if a fault or alarm is present.

1. Press the “PgDn” key to advance to the “Low Load Limit” screen. The “Low Load Limit” is generally determined by subtracting “1500 lbs.” from the “normal” low load. Use an average value from the displayed “Value Last Stroke” & “Value since Cycle Start” data as the basis for this calculation. Then press "MODIFY" to change.

2. Use the numeric keypad to enter the calculated (normal low - 1500) “low” load alarm value. Press “Enter” to save.

Example: 2242 - 1500 = 742 lbs.

Step 13F: Load Violations - Low

1. Use the “down arrow” key to position the cursor (>) next to the “No. Violations” option. The value entered here is the number of consecutive strokes that trigger both the “Low” load alarm and the “Low-Low” shutdown alarm (default = 1). Press "MODIFY" to change.

2. Use the numeric keypad to change the number of consecutive “Low Load viol. strokes” (default = 1) for shutdown – if desired. Press “Enter” to save if a change is made.


4. Use the numeric keypad to select “0 = LAMP ONLY”. Press “ENTER” to save. “Lamp Only” will cause the alarm light on the side (or top) of the RPC enclosure to flash. This serves as a warning only that the minimum load is decreasing from normal levels.

Step 13G: Low-Low Load Alarm

1. Press the “PgDn” key to advance to the “Low-Low Load Limit” screen. The “Low-Low Load Limit” is generally determined by subtracting “2000 lbs.” from the “normal” low load. Use an average value from the displayed “Value Last Stroke” & “Value Since Cycle Start” data as a basis for this calculation. Then press "MODIFY" to change.




General ePAC II Start-Up Procedures

WARNING: HIGH VOLTAGES, POSSIBLY AS HIGH AS 750 VOLTS, EXIST WITHIN THE DRIVE ENCLOSURE. USE EXTREME CAUTION WHEN MEASURING OR HANDLING CONNECTIONS.

1. Confirm that all three phases are present and that the input voltage is correct for the Drive being set up. Measure the voltages on the line side of the Drive’s Molded Case Circuit Breaker and record below.

Table 5: Input Voltage Record Table Measurement Location Voltage (Vac) L1 – L2 L2 – L3 L1 – L3

2. If the voltage level is within the Drive’s specification, APPLY POWER to energize the Drive. The STOP, AUTO SEQ and AUTO REF indicators should be lit on the keypad.

3. REMOVE POWER from the Drive. Wait for the Red CHARGE LED (near the power terminals) to go out.

4. Connect the motor leads to the Drive at terminals U/T1, V/T2 and W/T3.

5. APPLY POWER to the Drive.

6. Proceed to the Programming menu to initialize the drive (A1-03=2220)

7. Ensure that o2-04 is set to the proper kVA setting (per Drive Model). If o2-04 needs to be changed, change the setting and then cycle power to the drive.

8. Determine the proper control method for the application: Open Loop Vector Control or V/F control.



3. Use the “down arrow” key to position the cursor next to the “Action” option. Press "MODIFY" to change.

4. Use the numeric keypad to select “3 = OFF / RESET”. Press “ENTER” to save. “OFF / RESET” will cause the unit to shutdown when a “High-High” load occurs. The unit will not restart until the user issues a “CLEAR ERROR” followed by a “PUMP ON” command.

Step 13C: High Load Alarm

1. Press the “PgDn” key to advance to the “High Load Limit” screen.

2. Multiply the previously determined normal high load value x “1.1”. Press "MODIFY" to change.

3. Use the numeric keypad to enter the calculated (normal high X “1.1”) “High” load alarm value. Press “Enter” to save.

Example: 11,337 x 1.1 = 12,470.7 lbs. (rounded to 12,470)

Step 13D: Load Violations -High

1. Use the “down arrow” key to position the cursor next to the “No. Violations” option. The value entered here is the number of consecutive strokes that triggers the “High” load alarm (default = 1). Press "MODIFY" to change.

2. The default “High Load viol. strokes” value is “1”. Enter a different value using the numeric keypad if desired and press “ENTER”.


4. Use the numeric keypad to select “0 = LAMP ONLY”. Press “ENTER” to save. “Lamp Only” will cause the alarm light on the side (or top) of the RPC enclosure to “flash”. This serves as a warning only that the maximum load is increasing from normal levels.



Step 13A: Accessing Load Violations Setup Menu

Press “5” or use the arrow keys to position the cursor (>) next to “Load Violations Setup” option – then press “Enter”.

Note: There are five load alarms which should be configured – three are “shutdown” alarms (alarm light flashing) while the other two are alarms only (alarm light flashing).

IMPORTANT! If any of these load values (alarm or shutdown) values are set to “0”, that alarm is disabled!

Note: The suggested “rules of thumb” of how to calculate these alarm limit values may have to be adjusted based on individual well operating conditions.

IMPORTANT! If the VSH2 SPM or stroke length is changed or if changes are made to pump size / rod string, it likely will be necessary to re-adjust current load alarm values as maximum and minimum loads change to prevent excessive or invalid alarms.

Step 13B: High-High Load Alarm (Shutdown)

1. The “High-High Load Limit” is generally determined by multiplying the “normal” high load X “1.2”. Use an average value from the displayed “Value Last Stroke” & “Value Since Cycle Start” data as a basis for this calculation. Then press "MODIFY" to change.

Note: The “Number of Violations” option is not available using this screen.

2. Use the numeric keypad to enter the calculated (normal high X “1.2”) “High-High” load shutdown value. Press “Enter” to save.

Example: 11,440 X 1.2 = 13,728 lbs. (round of at 13,700).



System Initialization

1. Apply input power to the WellPilot

2. Set all VSD parameters to factory default by accessing parameter A1-03 “Initialize Parameters”. Press DATA/ENTER to edit this parameter, and using the UP and DOWN arrow keys, change the value of the entry to “2. 2-Wire Initialization”; then press DATA/ENTER to accept the value change.

3. Set all ePIC-II Parameters to factory default by doing the following:

• From the Status Screen, press MENU to access the Main Menu screen. Then press “4” or use the “arrow” keys to point the cursor (>) at the “Parameter Table” option, then press ENTER

• Using the Numeric Keypad, enter 473, and press ENTER. The cursor (>) should now be pointing to parameter 473.

• Press the “Modify” key to change the value of this parameter. Enter the value 5500, then press ENTER.

• Use the “arrow” key to point the cursor (>) at parameter 472. Press “Modify” to access this parameter, then press ENTER to execute a software reset.

Open Loop Vector Start-up List

1. Perform the General Drive Start-Up Procedure steps for the ePAC II.

2. Apply input power to the ePAC II Drive.

3. Set the control method of the Drive to Open Loop Vector Control by pressing the MENU key three times for the Programming menu.

• Press the Arrow Key until A1-02 is displayed and then press the ENTER key to display A1-02 “Control Method”.

• Use the UP and DOWN keys and the DATA/ENTER key to set this parameter to “2: Open Loop Vector”.

Setu lot p Guide for Rod Pumps WellPi


• Ensure the DATA/ENTER key is pressed to enter the selection in the Drive. “Entry Accepted” will briefly appear.

4. Switch the Drive Hand-Off-Auto Switch to “Hand”. Press the MENU key once to display the Operation menu. Then, press DATA/ENTER to display “Frequency Reference”. The AUTO SEQ and AUTO REF indicators turn off. The FWD light turns on.

WARNING: THE NEXT KEY-PRESS WILL CAUSE THE MOTOR TO ROTATE. TAKE APPROPRIATE PRECAUTIONS.

5. The RUN light turns on and the STOP light is off. “Frequency Ref” (U1-01) now displays 6.00Hz on the Digital Operator. Check the motor rotation. If the motor rotation is incorrect, swap any two motor leads (U/T1, V/T2, W/T3) on the Drive terminal, and repeat the motor rotation check.

Auto-Tuning

Auto-Tuning the motor is required for smooth operation. Refer to Table 6 for a listing of Auto Tune Parameters.

Note: This menu item may not be available is the unit is in fault or has an alarm.

Auto Tuning - Standard

Note: Always use Standard Tuning when operating in Open Loop Vector (A1-02 = 2) and it is possible to run the motor uncoupled from the load. If the motor cannot be uncoupled from the load, use “No rotate Tuning”.

1. Select the Auto-Tuning Menu. Then, select “Standard Tuning” in the “Tuning Mode Sel” parameter (T1-01 = 0).



5. If parameter 74 has been changed as shown above, then the multiplied load values will reflect this change and thus the controller will needs the calculated values reset. This can be done by accessing P94 (Reset Minimum/Maximum Loads) and modifying that parameter to reflect the new value in P74. Use the same procedure above to access P94 as shown here.

6. To perform the action to reset the existing load values – press the “MODIFY” key and press the “ENTER” key to perform the action. All the values in the load values screens will now reflect the new load cell factor entered in parameter 74.

Step 12: Set “Gauge Off” Time (P429)

1. Use “Parameter Table” from the “MAIN MENU” to find P429 or simply enter “429” (“ENTER”) when the “STATUS SCREEN” is displayed to set the desired “Gauge period start time”. Press "MODIFY" to change.

Note: If this parameter is set to all zero’s (00:00:00), this function will no work.

Note: This is the time that you want the controller to reset the runtime and collected history and to start collecting again.

2. Use the numeric keypad to enter the desired “Gauge period start time” (HHMMSS). Press “Enter” to save. (no “:” needed between values)

Step 13: Set Basic Load Alarm and Load Shutdown Limits

Use the “MENU” key to access the “SETUP MENU”. With the cursor pointing to “SETUP MENU”, press “Enter”.



2. Type in “2” and then press “ENTER” to select the ePAC II VSD. The display will return to the VSD Setup Menu.

Note: For an initial first time setup, this step needs to be done after step 12N, all of the other items in this menu are set. If this step is done before the other Step 12 steps are done, an error will occur.

Step 11: Verify Correct Load Cell Rating

1. Press the “Menu” key to display the “Main Menu”. Press “4” or use the “arrow” keys to point the cursor (>) at “Parameter Table” – then press “Enter”.

2. Enter “74” using the numeric keypad and press “ENTER” to point the cursor at P74. The default value is “1500” for a 30K (30,000 lbs) load cell. If the installed load cell has a 50K (50,000 lbs) rating, press "MODIFY" to change.

3. If a 50K (50,000 lbs.) load cell is being used, enter “2500” using the numeric keypad. Press “ENTER” to save.

P74 (or any other ePIC RPC parameter) can be also be 4. accessed when the “STATUS SCREEN” is displayed (Press “MENU” – then “EXIT” at any time). Use the numeric keypad to enter “74” (or any other ePIC RPC parameter) and press “ENTER” from the “STATUS SCREEN”.



2. Set the motor output power (T1-02), motor rated voltage (T1-03), motor rated current (T1-04), motor base frequency (T1-05), number of motor poles (T1-06), motor rated speed (T1-07) obtained from the motor nameplate information. After entering all of the motor parameters press the UP key to display “0Hz/ 0.00A Tuning Ready?”.

3. Confirm that the motor is uncoupled from the load and make sure it is safe to rotate the motor. Press the RUN key to start Auto-Tuning. The Drive will energize the motor without rotating it for approximately 1 minute. Then, the Drive will set the required motor parameters automatically while rotating the motor for approximately 1 minute. If the Auto-Tuning was successful, the operator keypad will display “Tune Successful”.

4. Go to the Quick Setting menu items to set and check the settings of all other required parameters.

No Rotate Tuning

Use No Rotate Tuning when operating in Open Loop Vector (A1-02 = 2) and it is impossible to uncouple the load from the motor.

1. Select the Auto-Tuning Menu. Then, select “Tune-No Rotate” in the “Tuning Mode Sel” parameter (T1-01 = 1).

2. Set the motor output power (T1-02), motor rated voltage (T1-03), motor rated current (T1-04), motor base frequency (T1-05), number of motor poles (T1-06), and motor rated speed (T1-07) obtained from the motor nameplate information. After entering all of the motor parameters press the UP key to display “0Hz/0.00A Tuning Ready?”.

3. Press the RUN key to start Auto-Tuning. The Drive will set the required motor parameters automatically while energizing the motor (without rotation) for approximately 1 minute. If the Auto-Tuning is successful, the operator keypad will display “Tune Successful”.

Set p Guide for Rod Pumps WellPiu lot


4. Go to the Quick Setting Parameters section to set up items there.

Table 6: Auto Tune Menu Items Para Default

Value Units Parameter

Name Parameter Description

T1-00 1 def

Select Motor - Motor Selection 1 / 2

Selects which set of motor parameters are to be used and set during Auto-Tuning. If Motor 2 selection (H1-XX=16) is not selected, this parameter will not be displayed.

1: 1st Motor - E1 to E2 2: 2nd Motor - E3 to E4

T1-01 0 def Tuning Mode Sel - Auto-Tuning mode selection

Selects the Auto-Tuning mode:

0: Rotational Auto-Tuning (A1-02 = 2 or 3) 1: Stationary Auto-Tuning (A1-02 = 2 or 3) 2: Terminal resistance only, (stationary) Auto-Tuning (A1-02 = 0, 1, 2, or 3)

T1-02 Note 1 kW Mtr Rated Power - Motor Rated Power

Set the motor rated power in kilowatts (kW).

NOTE: If motor power is given in horsepower, power in kW can be calculated using the following formula: kW = Hp * 0.746

T1-03 460.0 Vac Rated Voltage - Motor Rated Voltage

Set the motor rated voltage in Volts (V).



2 = Control Transfer

3 = Off/Reset

4 = Idle Time

5 = Idle Time plus Alarm

1. Scroll to “Action” and press the MODIFY button. The Min Fill Action (P1275) modify screen will appear.

2. Type in the setting for the Minimum Fill Action you desire and press “ENTER”. The display will return to the VSD Control Setup Menu.

Step 10O: Calibrate (P1251)

Use the arrow keys to scroll past “Calibrate”. Skip this item for now. Set to 1 to force SPM calibration via learn mode when VSD is re-enabled. P1250 must be set to 0.

0 = No (Default)

1 = Yes

Step 10P: Enable VSD (P1250)

This parameter (1250) must be set to 2 to enable ePAC II VSD Control, otherwise the controller performs like a standard EPIC RPC. This parameter is set by the operator. The choices are as follows:

0 = Disable: Choosing this option disables the VSD function in the ePIC controller. (Default)

1 = Future

2 = EPAC II: This option sets up the ePIC controller to interface with the ePAC II VSD only. Selecting this option initializes Scanner 1 and scan blocks 1 to 12 to read various register values from the VSD Controller.

1. Select VSD Setup from the VSD Setup Menu. At the

“Enable” item, press “Modify” and the VSD Enable Modify screen will appear.




1. Scroll to “MinFillage” and press the MODIFY button. The Min Pump Fillage (P1273) modify screen will appear.

2. Type in the setting for the Minimum Pump Fillage in % that is required and press “ENTER”. The display will return to the VSD Control Setup Menu.

Step 10L: VSD SPM Override Flag (P1264)

When this setting is set to zero (Disabled), VSD control operates normally. When this setting is set to 1, the VSD control output is defined by P1263. Default = 0

0 = Disabled

1 = Enabled

1. Scroll to “Override” and press the MODIFY button. The VSD SPM Override Flag (P1264) modify screen will appear.

2. Type in the setting for the VSD SPM Override Flag value that is required and press “ENTER”. The display will return to the VSD Control Setup Menu.

Step 10M: Minimum Fill Stroke Count (P1274)

This is the minimum number of strokes required to achieve the minimum Fillage required in P1273. Default = 0.

1. Scroll to “No.Strokes” and press the MODIFY button. The Min Fill Stroke Count (P1274) modify screen will appear.

2. Type in the setting for the Minimum Number of Strokes that are required and press “ENTER”. The display will return to the VSD Control Setup Menu.

Step 10N: Minimum Fill Action (P1275)

This is the action taken if the minimum fill Percent in P1273 remains continuously outside the fill value required for the minimum number of strokes set in P1256. Default = 0 (Lamp Only)

0 = Lamp Only

1 = Soft Time January 2008 Page 15 BM-WellPilot-01 / Rev. A

Table 6: Auto Tune Menu Items Para Default

Value Units Parameter

Name Parameter Description

T1-04 Note 1 Amp Rated Current - Motor Rated Current

Set the motor rated current in Amperes (A).

T1-05 60.0 Hz Rated Frequency - Motor Base Frequency

Set the base frequency of the motor in Hertz (Hz).

T1-06 4 qty Number of Poles - Number of Motor Poles

Set the number of motor poles.

4 – 1800 6 - 1200

T1-07 1750 RPM Rated Speed - Motor Base Speed

Set the base speed of the motor in revolutions per minute (RPM).

Note 1: The Default value of these two parameters varies with the KVA rating of the drive.

Typical RP Startup Parameter Items

The following table contains communications parameters that must be checked and set for the VSD Controller to function with the RPC controller.



Table 7: VSD Controller Communications Settings

Para No.

Memobus Address

Para Name/ Digital

Operator Display

Description Rng Dflt Set

H5-01 425h

Drive Node Address

Serial Comm Adr

Selects Drive station node number (address) for Modbus terminals R+, R-, S+, S-. The Drive’s power must bey cycled for the setting to take effect. Set H5-01 to 0 to disable drive responses to Modbus communications.

0 ~ FF 1 7

H1-04 403h

Multi-Function digital Input Terminal S6 Function Selection

Terminal S6 Sel

Sets the function of terminal S6.

04: Multi-Step Control 19: PID Disable

0 ~ 89 19 4

H1-03 Multi-Function Digital Input

85: Terminal S5 Function – H-O-A switch control 85



Step 10I: Evaluation Time (P1261)

This setting is the time period for the time limit for the Out of Tolerance time alarm and periodic re-evaluation of average control output. Default = 04:00:00.

1. Scroll to “EvalTime” and press the MODIFY button. The VSD Evaluation Time (P1261) modify screen will appear.

2. Type in the setting for the VSD Evaluation time that is required and press “ENTER”. The display will return to the VSD Control Setup Menu.

Note: Colons are not needed when typing in a time. Simply type in the Hours, Minutes, and Seconds (XXXXXX) and the colons will be automatically inserted.

Step 10J: VSD SPM Override Value (P1263)

This is the setting of the output value to be used when the controller is in VSD over-ride (P1264 = 1). This value is bounded by P1256 and P1257. Units = .01 SPM. Default = 0

1. Scroll to “Over Spm” and press the MODIFY button. The VSD SPM Override Valu (P1264) modify screen will appear.

2. Type in the setting for the VSD SPM Override Value that is required and press “ENTER”. The display will return to the VSD Control Setup Menu.

Note: P1263 must be set before P1264 in order for the RPC to correctly set this function up. Also, P1263 must be set to a value between the values of P1256 and P1257.

Step 10K: Minimum Pump Fillage % (P1273)

This is the Minimum pump fillage allowed. If the pump fillage is less than this set percentage value, for the number of strokes specified in P1274, then an alarm is generated and the action specified in P1275 will be taken. Default = 0



p Guide for Rod Pumps WellPilot Setu

Step 10F: VSD Initial Speed Change (P1253) Quick Setting Menu (-QUICK-) This sets the initial speed change and is in units of SPM. It will be performed when the actual pump fillage is outside of the set pump fillage by more than the Fill Tolerance percent rate. Default value at 0.5.

This menu is used to set/read the most commonly used parameters in the Drive. Follow the key operations to access the Quick Setting Menu.

Use the Up and Down Arrow keys to scroll through the parameter items. Use this menu to set up and/or change the parameters on the Quick Setting Menu. All needed parameters are not contained in the Quick Setting Menu. Some parameters are contained in the Programming Menu.

1. Scroll to “IniSpdChg” and press the MODIFY button. The VSD Init Spd Change” (P1253) will appear.

2. Type in the setting for the VSD Initial Speed Change that is required and press ENTER. The display will return to the VSD Control Setup Menu

Step 10G: VSD Min Speed Change (P1258) Notes: Set parameters as needed for start up. This sets the minimum change in speed per stroke setting and is in units of SPM. The default value is 0.2. ** Marked Parameters are GAUGE Specific. Do not change

unless Gauges are installed and connected. 1. Scroll to “MinSpdChg” and press the MODIFY

button. The Minimum Speed Change (P1258) will appear.

**** denote application specific setting.

2. Type in the setting for the VSD Minimum Speed Change in SPM that is required and press ENTER. The display will return to the VSD Control Setup Menu.Step

Table 8: Quick Setting Menu Param Default Setting Units Description Setting Description B5-19**

0 0 PID Loop Setpoint

Required Level Setpoint

A1-02 2 2 n/a Control Method

Output Control Method

P2-07**

0 2 Pressure Units

Compensated Level units

P2-09 0 0 Speed Units Set for required units

B5-01 0 0 sec PID MODE Activates PID function

C1-01 15 2 sec Accel Time Accel from min to max speed

C1-02 15 2 sec Decel Time Decel from Max to Min Speed

E1-04 60 90 Hz Max Hz Set to Max required output Hz

Step 10H: VSD Speed Tolerance.

This sets the VSD Speed Tolerance Limit in SPM. If, during operation, the actual VSD speed is different (above or below) the Speed that the unit should be operating at, the WellPilot will report a Lamp Only Alarm for Speed Tolerance Exceeded. Default value at 2.0 SPM.

1. Scroll to “SpeedTol” and press the MODIFY button. The “VSD Speed Tolerance” (P1278) will appear.

2. Type in the setting for the VSD Speed Tolerance that is required and press ENTER. The display will return to the VSD Control Setup Menu.




Table 8: Quick Setting Menu Param Default Setting Units Description Setting Description H3-05**

1F 1F A3 Setting Terminal A3 setting

H3-09 1F 3 A2 setting Terminal A2 setting

L5-01 5 5 n/a #of Restarts Fault Restarts

L7-01 100 100 % % FWD TORQUE

**** Set as required

O1-03 0 10900 n/a Speed Scale Set to MAX SPEED at E1-04

RPM

PRS

SPM

P1-01 0 15 % Low Speed FLT

% of MAX SPEED (varies with setting in ePIC)

P1-02 5 5 sec Low Speed T/D

Run T/D

P1-03 0.5 0.5 min Low Speed T/D

Start Bypass T/D

P1-04 0 15 % Low Torque FLT

% of Max Torque-10% less than stable operation

P1-05 0 3 sec Low Torque T/D

Run T/D

P1-06 0.5 0.5 min Low Torque T/D

Start Bypass T/D

P1-07 5 5 n/a SPD/TRQ FLT rsts

# of restarts after Spd/Torque Fault

P1-08 2 2.0 min Spd/Trq restart time

Time between restarts

P1-09 30 30 min Spd/Trq Restart Clear

Time to reset Fault Counter



2. Type in the setting for the Minimum SPM that the pump is configured to run and press “ENTER”. Units = .01 SPM. (i.e. 105 = 10.5 SPM) Default = 0. The display will return to the VSD Setup Menu.

Step 10C: Software Reset (P351)

1. Perform a software reset by going to Parameter 351 and pressing <Modify> and then press <ENTER> to initiate the command.

Step 10D: SPM Startup Value (P1268)

This SPM value will be used as the default SPM value which is sent to the VSD when entering the normal run state or pump down. Default = 4.

1. Scroll to “SPM Stup” and press the MODIFY button. The SPM Startup (P1258) modify screen will appear.

2. Type in the setting for the SPM Startup value that the pump is configured to run and press “ENTER”. Units = .01 SPM. (i.e. 105 = 10.5 SPM) Default = 4.0. The display will return to the VSD Control Setup Menu.

Step 10E: Fill Tolerance (P1252)

VSD Pumpoff Position Tolerance (+/-%). This setting defines the VSD pumpoff tolerance range relative to the setpoint P021. Default = 5.

1. Scroll to VSD Tolerance (+/-%) and press the MODIFY button. The VSD Tolerance (P1252) modify screen will appear.

2. Type in the setting for the VSD Tolerance that is required, relative to setpoint P021, and press “ENTER”. The display will return to the VSD Control Setup Menu.



4. Type in the corrected value and then press <ENTER>. The display will return to the Parameter Table screen with the pointer on the parameter you modified. The modified value will be displayed.

5. If the parameter you selected was a Command Parameter, pressing <ENTER> initiates the command.

6. Press <EXIT> to return to the Status Screen.

Step 10: VSD Control Setup Menu

The following items must be set in the VSD Control Setup Menu screen. This screen can be accessed by pressing the “Menu” button – “Setup Menu” – “VSD Setup”.

Note: An additional configuration screen is available if the ePAC II option (2=EPAC II) is chosen in this menu item. When viewing the EPAC II Status Screen, F2 can be used to toggle between the EPAC II status screen and the EPAC II configuration screen.

Note: Ensure that the HOA Switch is in the “OFF” position before proceeding.

Step 10A: Clear Errors

Press <EXIT> until you reach the ePAC II Status Screen. Press <CLEAR ERRORS> to reset any errors in the system. There should not be any errors listed at this time.

Turn H-O-A Switch to Auto.

Caution: Unit will start with Learn Mode.

Step 10B: Setting Minimum SPM (P1256)

This setting is the Minimum SPM that the pump is configured to run. Units = .01 SPM. (i.e. 105 = 10.5 SPM) Default = 0

1. Scroll to “SPM Minimum” and press “MODIFY”. The SPM Minimum (P1256) modify screen will appear.



Table 8: Quick Setting Menu Param Default Setting Units Description Setting Description P2-01 0 0 % Min Speed % of Max – 5 %

greater than P1-01

P3-01 2 2 min Fault Restart Time

Restart times for all other Faults

P2-02**

1000 **** PIP Max Range

Maximum PIP input range

P2-03**

250 **** CSG Max Range

Maximum CSG input range

P2-04**

0 **** Low Press Level

Low Level Fault

P2-06**

0 **** Low Press Rst Lvl

Level Auto Restart

02-03 User Defaults

Stores Settings in Non-volatile Memory



Additional Settings

Table 9:Additional WellPilot Settings Param Default Setting Units Description Setting

Description B1-03 0 1 Stopping

Method Selections:

0=Ramp to Stop 1=Coast to Stop 2=DC Injection Braking 3=Coast with Timer

H1-03 85

H1-04 4

H3-10 0 30.8 A1 Maximum A1 Maximum Speed Calibration

H3-11 0 7.7 A1 Minimum A1 Minimum Speed Calibration

L2-01 0 0 Stall Prevention Selection During Deceleration

Determines if stall prevention during deceleration prevents an overvoltage trip during deceleration by automatically extending the deceleration time.

0: Disabled 1: General Purpose 2: Intelligent 3: Stall Prevention with resistor

L3-04 1

P3-03 0 1 A1 speed Ref Enables speed pot

P5-01 1 (If OVS is enabled – Non Rotoflex)



“POC Method” (P0026) - (“0=QUADRANT”)

Step 8: Set the Position Sensor Type (P0034)

1. Use the Arrow Keys to scroll to “Position Sensor Type” and press Modify. The screen will advance to the Modify P0034 display.

2. Use the Keypad to enter the selection number (3) for “Continuous Position Switch With DPS” and press ENTER. The display will return to the Pumpoff Control Setup Menu.

Step 9: Select Load Sensor Type (P0035)

1. Use the Arrow Keys to scroll to “Load Sensor Type” and press Modify. The screen will advance to the Modify P0034 display.

2. Use the Keypad to enter the selection number for a Continuous Position Switch and press ENTER. The display will return to the Pumpoff Control Setup Menu.

Parameter Selection

Parameters can be selected directly from the Status Screen without having to enter the main menu. To select a parameter from the Status Screen:

1. Type in the parameter number (<xx>) and press <ENTER>. With the first number typed in, the screen will shift to the Parameter Table screen and when enter is pressed, the pointer will be placed in front of the parameter number typed.

2. You can also press the <MENU> button and scroll down to “Parameter Table” and press <ENTER>.

3. Press <MODIFY> and the Modify screen for the parameter selected will be displayed.



2. Enter the desired value (HHMMSS) and press “ENTER” to save. (no colons “:” are needed). The display will return to the Pumpoff Control Setup screen.

Note: In general – “Idle time” should be as long as possible without hurting well production. This means that the “Idle time” value for each well must be fine-tuned. If “Idle time” is too short, the unit will cycle too many times per day.

Step 5: Set Pumpoff Position

1. Use the “down arrow” key to position the cursor (>) next to the “Pumpoff Position” option. Press "MODIFY" to change. The Modifying screen will appear.

2. Enter a value of “70” as a default – or initial value, and press “ENTER” to save. The display will return to the Pump Off Control Setup screen.

Step 6: Set Pumpoff Load (P0023)

To set the “Pumpoff Load” position value:

1. Use the “down arrow” key to position the cursor (>) next to the “Pumpoff Load” option. Press "MODIFY" to change. The Modifying screen will appear.

2. Enter a value of “30” as a default – or initial value, and press “ENTER” to save. The display will return to the Pump Off Control Setup screen.

Step 7: Parameters to Leave at Default

Leave the following at their default values:

“Strokes for Pumpoff” (P0024) - (“2”)

“Pumpoff Action” (P0022) - (“4”=IDLE TIME)

“Pump up Delay” (P0025) - (“00:00:30”)



Rod Pumping Specifics

Overvoltage Suppression

This software was created so that Pump Jack oil wells (which are typically unbalanced) can run without the need for dynamic braking. Entering a “1” into P5-01 enables this feature.

Basic concept/principle

The software monitors the level of torque-producing current (Iq) in the motor, and regulates this against an Iq setpoint. If it sees that the torque producing current is below the setpoint, the output frequency is increased to force a higher (positive) Iq.

Limitations (based on inverter capacity, control Mode, application, etc., if any)

• Overvoltage Suppression is only active in V/F or O.L.V. control modes.

• Stopping method parameter b1-03 is ignored and stopping method (internally) is set to “Coast To Stop”

• When reverse operation is prohibited (b1-04 = 1) and the motor is moving in the reverse direction, O.V. Suppression is disabled (This condition can occur due to a bi-directional speed search).

• When O.V. Suppression is enabled, the current limit in V/Hz is disabled.

CAUTION: The motor connected to a drive with this software on it needs to be mechanically capable of operation at the maximum allowed frequency (Parameter E1-04).


Function description Step 2A: Setting Time

1. With the cursor (>) pointing to “Time”, press "MODIFY" to change the time of day. The Modifying screen will appear.

Overvoltage Regulator: The level of torque-producing current is detected in the motor and subtracted from a setpoint (Iq Setpoint), then the result is submitted to a PI algorithm (overvoltage regulator). The PI algorithm will add frequency to the frequency reference in order to maintain a constant Iq setpoint. The PI algorithm will NOT subtract frequency from the frequency reference. This is done to keep the torque producing current positive to prevent regeneration and subsequent overvoltage faults.

2. Enter the correct time in military format (HHMMSS) and press “ENTER” to save the new date. (no colons “:” are required) The display will return to the Set Time and Date screen.

Note: If the data already stored in any parameter to be modified is correct or does not need to be changed, simply press the “EXIT” key to “ABORT” the operation and return to the previous menu item.

Gain Increase Function: When parameters P5-06 & P5-07 are used, the gain of the overvoltage suppression regulator is automatically increased when the drive’s output goes higher than motor base frequency (E1-06). Shown below is an example when P5-06 = 60.00 Hz, and P5-07 = 2.000.

Step 2B: Setting Date

1. Use the “down arrow” key to point the cursor (>) to “Date”, then press "MODIFY" to change the date. The Modifying screen will appear.

2. Enter the correct date (MMDDYY) and press “ENTER” to save. (no slashes “/” are needed). The display will return to the Set Time and Date screen.

3. The Time and Date are now set.

4. Press “EXIT” to return to the “SETUP MENU”.

Step 3: Pumpoff Control Setup

Press “2” or use the “down arrow” key to point the cursor (>) at the “Pumpoff Control Setup” option and press “ENTER”. The Pumpoff Control Setup screen will appear.

Figure 4: Iq Pgain – Increase gain above base speed Step 4: Set Idle Time

1. With the cursor (>) next to “Idle Time”, press "MODIFY" to change the Idle Time. The Modifying screen will appear.




Setup Guide for Rod Pumps

WellPilot Rod Pump Controller Setup

This Section of the Setup Manual is meant for potential or existing users of eProduction Solutions’ WellPilot VSD (ePIC RPC included). These instructions are applicable for the VFD which has an ePIC II RPC integrated within the VFD.

WellPilot Status Screen (P1250 Set to “2”)

The “status screen” appears on the WellPilot LCD display after five minutes of “no keypad activity”. This screen provides the operator with basic information about the well performance. You can quickly compare the Run Time % today with yesterday which provides an indication of pumping consistency. The operator can also view the current pumping speed in “SPM” and also make adjustments to the pumpoff set points or idle time.

Step 1: Main Menu

To begin the RPC “setup” process or to access the “MAIN MENU” at any time – press the “MENU” key on the keypad.

Step 1A: Setup Menu

Go to the Main Menu by pressing “MENU” on the keypad. Press “2” on the keypad or use the “down arrow” key to move the cursor (>) to option “2” – “SETUP MENU” and press “ENTER”.

Step 2: Set Time and Date

Go to the Setup Menu. With the cursor (>) next to “Set Time and Date”, press the “ENTER” key. The Set Time and Date selection screen will appear.

WellPilot


Belt Break Detection

If the output of the soft starter is at maximum frequency for more than 30 seconds, the drive assumes that the drive belt or coupling between the motor and the load has become disconnected. At that time the drive will fault out on a belt-break fault and coast to stop.

Specific Rod Pump Parameters

The following table contains some specific rod Pumping parameters that may need to be set.

Table 10: Rod Pumping VSD Specific Parameters Parameter

No. Memobus Address

Name/ Operator Display

Description

Range Default

L3-04 TBA Digital Operator Display: Stall prevention Selection During Deceleration.

StallP Decel Sel

Determines if stall prevention during deceleration prevents an overvoltage trip during deceleration by auto extending the decel time.

0: Disable 1: General Purpose 2: Intelligent 3: Stall Prevention with Resistor

0 ~ 3 1



Table 10: Rod Pumping VSD Specific Parameters

P5-01 111h Overvoltage Suppression Selection

OVS Select

Selects whether the overvoltage suppression function will be active or not.

0: Disabled 1: Enabled

0 ~ 1 0

P5-02 112h Setpoint for the OV Suppression Regulator (Iq)

OVS Reg Setpoint

100% Iq = 100% Motor torque producing current. Iq is calculated based on FLA & NLA.

-100.0 ~

100.0%

12.0

P5-03 113h Current Limit / OVS Regulator Gain

I Lim/OVS Gain

This sets the responsiveness of the current limit / OVS regulator. Higher = more responsive.

0.00 ~ 25.00

2.20

P5-04 114h Current Limit / OVS Regulator Integral Time

I Lim/OVS I time

This sets the responsiveness of the current limit / OVS regulator. Lower = more responsive.

0.00 ~ 160.00 Sec.

0.10

P5-05 115h Current Limit / OVS Regulator Feedback Filter

Feedback Filter

1st order filter time on the feedback used for Current Limit or OVS control

5 ~ 10000

ms

80



Table 10: Rod Pumping VSD Specific Parameters

P5-06 116h OVS Regulator Gain Frequency

OVS Gain Freq

Gain change endpoint.

0.00 ~ 400.00

Hz

90.00

P5-07 117h OVS Regulator Gain Multiplier

OVS Gain Mult

Multiplication factor for the OV suppression gain based on output frequency

1.000 ~

10.000

1.300

The following table lists the Rod Pumping Specific Faults that may appear.

Table 11: Rod Pumping Specific Faults Fault

Display Description Cause Countermeasures

B-BRK

Belt Break

Belt Break Drive output was at fmax for more than 30 seconds.

Fix belt / coupling.

BM WellPilot 01

Documents

open loop vector

site physical mounting

epac ii vsd

rod string design

u1 monitor listu1

epac ii controller

00a tuning ready

preset fluid stroke