totalflow

2017286-001 (AA)

Totalflow

6300 Series Pump-Off Controllers

Installation - Operations - Maintenance

Manual

Copyright Notice

1999 by ABB Automation Inc., Totalflow Division, Bartlesville, Oklahoma 74005, U.S.A. All rights reserved. This publication is for information only. The contents are subject to change without notice and should not be construed as a commitment, representation, warranty, or guarantee of any method, product, or device by Totalflow. Inquiries regarding this manual should be addressed to ABB Automation Inc., Totalflow Division, Technical Communications, P. O. Box 8900, Bartlesville, Oklahoma 74005, U.S.A.

TOTALFLOW 6300 Pump-Off Controller i

Table of Contents Chapter 1: System Description Overview 1-2 Theory of Operation 1-2 Model 6310/6313 Specifications 1-3 Model 6310/6313 POC Hardware 1-5 Introduction 1-5 Enclosure 1-5 Base Controller Board (2015480) 1-5 Smart Card (2015483) 1-7 Warning Beeper 1-7 Sensor Probe 1-7 Sensor Magnet 1-9 Display 1-9 Battery 1-9 Communication's Kit 1-9 Solar Panel 1-10 Communication's Module 1-10 System Description 1-11 Description 1-11 Model 6310 POC Typical Installation 1-11 Model 6313 POC Typical Installation 1-12

Chapter 2: Installation Unpacking and Inspection 2-2 Unpacking 2-2 Packing List 2-2 Initial Inspection 2-2 Reporting Damage 2-2 Installing the Model 6310/6313 POC 2-3 Basic Installation Steps 2-3 Mounting The POC Enclosure 2-3 Installing The Step-down Transformer 2-4 Installing the Interposing Relay 2-4 Wiring the POC to Main Electrical Disconnect Box 2-5 Mounting PVC Version of Sensor Probe 2-6 Mounting Stainless Steel Version of Sensor Probe 2-8 Sensor Probe to POC Enclosure Wiring 2-9 POC to Flow Computer/RTU Wiring 2-10 6310 POC to 6313 POC Wiring 2-10 Communications 2-11

ii TOTALFLOW 6300 Pump-Off Controller

Table of Contents, Continued

Chapter 3: Operations Setup 3-2 Terminal Emulator 3-2 Entering Local Port Protocol Code 3-3 Parameter Screen 3-4 Terminal Mode Edit Keys 3-5 Parameter Definitions 3-6 Theory Of Operation 3-10 POC Startup 3-13 Display Information 3-14 Annunciators 3-15 Programming POC Display Information 3-16 Programming FCU Display Information 3-17

Chapter 4: Maintenance & Troubleshooting Replace POC Fuse 4-3 Replace POC Battery Pack 4-5 Replace POC Smart Card (2015483) 4-7 Replace POC Circuit Board (2015480) 4-9 Replace POC Display 4-11 Replace Warning Beeper 4-13 Replace Sensor Probe 4-14 Troubleshooting a POC Without Smart Card 4-16 Troubleshooting a POC With a Smart Card 4-18

TOTALFLOW 6300 Pump-Off Controller iii

Introduction About the Manual Audience & Purpose

This manual is written to provide an experienced technician with the knowledge and skills necessary to install setup and operate the TOTALFLOW Model 6300 Pump-Off Controller.

Organization & Style

Readers are able to look at the headings and get a broad picture of the content without reading every word. At the beginning of each chapter is an overview that provides you with an idea of what is in the chapter and how it fits into the overall manual.

Chapter Contents This manual provides the following information:

Chapter Description 1. System Description Provides a description of the Totalflow Pump-Off

Controller system components, specifications, system description and typical installations.

2. Installation Includes unpacking and detailed procedures for installation.

3. Operations Provides information on setup, display information, theory of operation and startup procedures.

4. Maintenance & Troubleshooting

Provides instructions on how to remove and replace major components in the system.

iv TOTALFLOW 6300 Pump-Off Controller

Getting Help

Technical Support

At Totalflow, we take pride in the on going support we provide our customers. When you purchase a product, you receive documentation which should answer your questions; however, our technical support service provides an 800 number as an added source of information. If your require assistance, call: (800) 442-3097

Before You Call Know your Totalflows serial number. Serial numbers can be found on the

escutcheon plate located on the side of each unit. Prepare a written description of the problem.

How to Describe Your Problem

Be prepared to give the customer service representative a detailed description of the problem. Note the alarms or messages as they appear on the PCCU, Terminal Emulator or front panel LCD.

TOTALFLOW 6300 Pump-Off Controller 1 - 1

Chapter 1 System Description

Overview Introduction This Chapter introduces you to the Totalflow Model 6310 and Model 6313

Pump-Off Controllers. The Model 6310 is the modular approach requiring it to be connected to a Flow Computer or Remote Terminal Unit(RTU) running the control algorithm whereas the Model 6313 is a stand-alone unit with integrated communications.

Chapter Contents This chapter provides the following information

Topic Page

Overview 1-2

Theory of Operation 1-2

Model 6310/6313 Specifications 1-3

Model 6310/6313 POC Hardware 1-5

Introduction 1-5

Enclosure 1-5

Base Controller Board (2015480) 1-5

Smart Card (2015483) 1-7

Warning Beeper 1-7

Sensor Probe 1-7

Sensor Magnet 1-9

Display 1-9

Battery 1-9

Communication's Kit 1-9

Solar Panel 1-10

Communication's Module 1-10

System Description 1-11

Description 1-11

Model 6310 POC Typical Installation 1-11

Model 6313 POC Typical Installation 1-12

1 - 2 TOTALFLOW 6300 Pump-Off Controller

Overview, Continued

Theory of Operation

The benefits of pump off control are well established within the oil production industry. When pumping equipment continues to run in the absence of production fluids excessive pump wear will result. Pumping, without the lubricating effects of the fluid, can cause premature degradation of stuffing box rubbers. Leaky stuffing boxes can cause serious environmental damage to the immediate area. Continuing to pump while ingesting gas can cause gas locks that impede production. Fluid pound generally accompanies pump off and generates destructive shock waves that are detrimental to your pumping equipment. Many operators use timers in an attempt to avoid pump off and fluid pound. Timers are generally far more expensive than their initial purchase may suggest. If you set the timer on time too long you may be risking fluid pound. If you set it too short you may be putting your production at risk. Pump off controllers avoid this problem by allowing pumping action only in the presence of production fluids. Pump off controllers can generally reduce equipment run times by as much as 50% with no reduction in fluid production. If the POC is replacing a timer that was set for too short of a run time an increase in fluid production may occur. By avoiding the detrimental effects of fluid pound and dry pumping, equipment workovers can be virtually eliminated. Workover costs increase with well depth. The economic advantage of using pump off control becomes extremely evident in wells deeper than 3000 feet. The TOTALFLOW POC is based on the pumpoff algorithm developed by DJAX Corporation of Midland, Texas. Determination of pumpoff is based on pump speed. Pump speed is relatively constant while moving a given amount of production fluid. When the pump ceases to move sufficient fluid and begins to ingest gas, pump speed tends to surge due to the lessening fluid load. This speed increase generally ranges between 10 and 100 milliseconds per stroke, depending on the well characteristics. A typical speed change might be in the range of 30 milliseconds per stroke. Each stroke interval is accurately measured by the Pump-Off Controller (POC). During calibration an operator must determine the appropriate speed change representing pump off. This speed delta is programmed into the POC. When this speed change is detected the pumping unit will be turned off. Pumping action will resume after the Down time has expired.


Model 6310/6313 Specifications Enclosure Aluminum, white powder coated finish,

with stainless steel hardware

Dimensions Model 6310 Model 6313

Width: 8.50 inches (215.9 mm) Height: 10.00 inches (254.00 mm) Depth: 8.85 inches (224.79 mm) Width: 11.12 inches (282.45 mm) Height: 14.62 inches (371.35 mm) Depth: 10.25 inches (260.35)

Supply Voltage

115-132 VAC @ 50/60 Hz (Industrial 220/110 VAC 0.05 KVA transformer recommended for primary power input)

Power Requirements Model 6310 Model 6313

5 watts + (Charger for FCU battery = 20 watts if connected) 8 watts + (Charger for FCU battery = 20 watts if connected)

Mounting

Pipe or wall mount

Temperature Limits

Operational -40 to 140F (-40 to 60C)

Inputs Model 6310 Model 6313

One zener protected input for sensor probe One zener protected input for sensor probe ; Four optically-isolated inputs (factory programmable)

Outputs Model 6310 Model 6313

One N. C. relay contacts for pump control; One 24 VDC @ 0.5 amps (communications, etc.) One 16 - 20 VDC @ 1 amps (charging for FCU battery) One N. C. relay contacts, 24 VDC @ 0.5 amps for pump control; Six open collector outputs (factory programmable); One 24 VDC @ 0.5 amps (communications, etc.) One 16 - 20 VDC @ 1 amps (charging for FCU battery)

Data Storage

128K RAM, lithium battery backed

Communication Ports

One - RS232 or RS485 port; 1200 bps to 19,200 bps One - RS232 port for setup

Sensor Probe

Magnetic reed switch (normally closed)

Shock

Maximum of 25 G's in any axis, 11 ms duration


Model 6310/6313 Specifications, Continued

Humidity 0 - 95 percent R.H., non-condensing Hazardous Area Classification

Designed to meet NEC Class 1, Division 2, Groups C & D Certification Pending


Model 6310/6313 POC Hardware Introduction, See Figure 1-1

The Totalflow Model 6310 Pump-Off Controller is housed in a lightweight aluminum case. The 6310 case looks similar to the 6313 but is smaller since it does not require space to house a radio or battery. Major components of the two models are:

Model 6310 POC Enclosure Base Controller Board Warning Buzzer POC Sensor Magnet

Model 6313 POC Enclosure Base Controller Board Smart Card Warning Buzzer POC Sensor Magnet Options: Display Battery Remote Communications Charger (Solar Panel) Communications Module (RS-232

or RS-485)

Enclosure The enclosure consists of hinged-lid box. The lid provides a watertight,

corrosion resistant seal between the outside elements and the POC components. It is designed to meet Class 1, Division 2, Groups C&D and is NEMA 4X rated. A single clasp is used to secure the lid to the enclosure on a 6310 and two clasps on the 6313.

Base Controller Board

The 6310 Base Controller Board is mounted on the inside of the lid. Most input and output connections are made on snap in connector terminals mounted directly on the board. Primary features of the Base Controller Board are: DO (Digital Output) which terminates in a normally closed relay contact

capable of driving an interposing relay. DI (Digital Input) for the termination of the sensor, a magnetic proximity

switch. A RS-232 communications channel for supporting the PCCU or Laptop to do

setup. Provides 16-20 VDC to serve as a battery charger for the Flow Computer. Drives an alarm that sounds a warning prior to the pump startup. Provides connectivity to accommodate a 'smart card'. Provides circuitry for the switching of VBATT to power a radio up and down. Provides 24 VDC @ 0.5 amps available to user.


Model 6310 POC

Model 6313 POC

Figure 1-1 Model 6310 and 6313 Pump-off Controller

Battery Compartment

Communications Compartment


Model 6210/6313 POC, Continued

Smart Card The smart card plugs into the Base Controller Board and allows the unit along

with other added options to run it's own pump-off algorithm. In addition to the features of the Base Controller Board, the Smart Card adds the following additional features: Runs the Pump-Off algorithm internally Permits communication with CCU software via radio link. Supports local LCD display Four additional digital inputs (Factory/Project Programmable). Six additional digital outputs (Factory/Project Programmable).

Warning Buzzer Both the Model 6310 and the 6313 POC has a 12 VDC piezoelectric buzzer

mounted to the inside bottom of the enclosure. The buzzer sounds a 90 dB minimum alarm starting 15 - 20 seconds prior to outputting the signal to start the pump.

Sensor Probe There are two sensors available for the Model 6310 and 6313 POC. The first

version has two magnetic reed switches mounted inside a PVC housing. Only one of the switches would be connected with the other as a spare. (See Figure 1-2)

Figure 1-2 Sensor Probe (PVC Version)


Model 6310/6313 POC Hardware, Continued

Sensor Probe, Continued

The second version of the POC Sensor is enclosed in 3/8" stainless steel tubing. The 3/8" O. D. of the probe allows it to be mounted in a junction box using a conduit cord connector. The conduit cord connector makes it convenient for adjusting the spacing between the probe and the magnet which is attached to the crank arm. Unlike the PVC version, the stainless steel version has only one magnetic reed switch. (See Figure 1-3)

Figure 1-3 Sensor Probe (Stainless Steel Version)


Model 6310/6313 POC Hardware, Continued Magnet In order for the sensor to detect the speed of the pump jack, a magnet is

attached to the crank arm in a position which allows it to pass in front of the Sensor Probe. The magnet is a flexible high energy magnetic strip 2 .in Long X 3/4 .in Wide X 3/16 .in Thick. Each time the magnet passes in front of the sensor, it actuates the magnetic reed switch inside the sensor. (See Figure 1-4)

Figure 1-4 Magnet

Display An option of the Model 6313 POC is a 24 character wide by 2-line LCD

display. Shown on the display is some current, historical and status information. For more information on displayed data, see the operational section of this manual.

Battery An option of the Model 6313 POC is the capability of adding a battery. The

primary reason for adding a battery is to power a radio for remote communications. Although there is AC power available in the POC, the regulated 12 volt power is not available to power a radio. There are three battery sizes available, an 8 amp/hr., 13 amp/hr., and a 26 amp/hr.

Communications Kit

An option of the Model 6313 POC is the capability of adding remote communications. There are radio options, modem options and cellular telephone options available for the 6313 POC. Contact you local sales engineer or a project engineer for more information about these many communications options.


Model 6310/6313 POC Hardware, Continued

Solar Panel The POC has battery charging circuitry built-in which is derived from the 110

Volt AC. In the case of a Model 6313 which could have radio communications and hence a battery, there may be concern if AC power is lost for a sustained period of time. Therefore, a solar panel can be used in lieu of the onboard charging capabilities of the POC. There are three sizes of solar panels offered, a 10, 18, and 30 watt.

Communications Module

Remote communications with the Model 6313 POC is done through the use of plug in communication modules. There are two options available, an RS-232 and an RS-485 version. RS-485 is used when more than one unit is daisy chained together whereas RS-232 would normally be the choice for a site with a single POC.


System Description Description The Model 6300 series Pump-Off Controllers can be configured in many

ways and are programmable to your unique application requirements. With the many possible configurations, it would be advisable to consult with a sales engineer or projects engineer about your specific application. The 6300 series Pump-Off Controllers come in two basic varieties. First is the Model 6310 which is designed as a modular addition to a Totalflow Flow Computer or RTU. The 6310 would typically be used at a site in which both gas flow measurement and Pump-Off Control would be required. The Model 6310 Controller passes the pulse information from the sensor to the Flow Computer or RTU running the pump-off algorithm. The Flow Computer or RTU in turn outputs the digital output to the 6310 controller when pump-off conditions are met. The Model 6313 Controller is a standalone unit with integrated communications running it's own pump-off algorithm. It processes the pulse input information from the sensor and outputs a digital output when pump-off conditions are met. The 6313 can support up to four additional Model 6310 POCs. It also has the capability of communicating the pump-off information to Central Collection Unit software back at the office.

Model 6310 POC Typical Application

Figure 1-5 shows a typical application using the Model 6310 Pump-Off Controller.

Figure 1-5 (Model 6310 Typical Application)


System Description, Continued

Model 6313 POC Typical Application

Figure 1-6 shows a typical application using the Model 6313 Pump-Off Controller.

Figure 1-6 (Model 6313 Typical Application)

PUMP-OFF CONTROLLER

6313Applied AutomationApplied AutomationApplied AutomationHartmann & BraunHartmann & BraunHartmann & BraunHartmann & BraunHartmann & Braun

6313 POC

MOTOR STARTERENCLOSURE

MAGNET

SENSOR PROBE2015457-002

JUNCTION BOX

PUMP JACKCONDUIT CORD CONNECTOR


Chapter 2 Installation

Overview Introduction This chapter provides you with the information to do a field installation of the

Model 6310 and 6313 Pump-Off Controllers. After following the procedures within this chapter, the POC will be ready for operation. To ensure a safe and trouble free installation, follow all procedures and associated advisory information.

Installation Hint It is highly recommended that you thoroughly read through this chapter to

establish an installation plan. Have this manual handy during the installation process so that you can refer to any illustrations or installation processes.

Chapter Highlights

This chapter covers the following topics.

Topic Page

Unpacking and Inspection 2-2

Unpacking 2-2

Packing List 2-2

Initial Inspection 2-2

Reporting Damage 2-2

Installing the Model 6310/6313 POC 2-3

Basic Installation Steps 2-3

Mounting The POC Enclosure 2-3

Installing The Step-down Transformer 2-4

Installing the Interposing Relay 2-4

Wiring the POC to Motor Starter Enclosure 2-5

Mounting PVC Version of Sensor Probe 2-6

Mounting Stainless Steel Version of Sensor Probe 2-8

Sensor Probe to POC Enclosure Wiring 2-9

POC to Flow Computer/RTU Wiring 2-10

6310 POC to 6313 POC Wiring 2-10

Communications 2-11


Unpacking and Inspection Unpacking Both the Model 6310 and 6313 POCs are shipped in boxes. There may be

more than one box, depending the type of Sensor Probe or if there is a battery or additional items ordered. Carefully remove all internal packing material and items from the box. Care should be taken especially when items are foamed, that smaller items are not inadvertently thrown away.

Packing List Compare the contents of the boxes with the packing list. Individual items

should be called out on the Packing List.

Initial Inspection It's always a good idea to examine the outside of boxes or cartons for visible

damage which could indicate possible damage to the contents. Other points of inspection are: Inspect the POC enclosure for external damage. Inspect the interior of the POC enclosure and verify circuit boards are

secure. Inspect the loose items such as the Sensor Probe for any damage.

Reporting Damage

If there is any damage or noticeable defects, notify your local Totalflow representative or call the main office listed below. Keep all shipping materials as evidence of damage for inspection by the carrier. Totalflow will arrange for immediate repair or replacement. Telephone: (800) 442-3097 toll free


Installing the Model 6310/6313 POC Note: Due to the diversity of Motor Starter Enclosures and the diversities of existing

sites, all POC installations will vary somewhat. The following installation procedure is an attempt to cover the major steps for a typical installation.

Basic Installation Steps

Below are the basic steps to install the Model 6310/6313 POC. Each step will be expounded upon in this chapter. 1. Mounting the POC enclosure. 2. Installing a step-down transformer in the pump jack's Motor Starter

Enclosure to provide 110 VAC for the POC power. 3. Installing the interposing relay in the pump jack's Motor Starter Enclosure. 4. Wiring between the POC enclosure and the pump jack's Motor Starter

Enclosure. 5a. Mounting the PVC Version Sensor Probe and the Magnet. 5b. Mounting the Stainless Steel Version Sensor Probe and the Magnet. 6. Wiring between the Sensor Probe and the POC enclosure. 7a. Wiring between the POC and the Flow Computer / RTU. (6310 Only) 7b. Wiring between a 6310 POC and a 6313 POC. (6313 Only) 8. Communications wiring for Model 6313. (6313 Only)

Caution

All wiring must meet electrical codes for the area of installation and should be done only by a qualified electrician. If this unit is being installed to comply with Class 1, Division 2, NRTL / C specifications, see drawing 2015470-CD enclosed as part of the drawing package with the equipment.

Step 1 Mounting the POC Enclosure

The Model 6310 POC has interconnect wiring between the pump jack's Motor Starter Enclosure, the pump jack, and the Flow Computer. Therefore, try to locate the POC enclosure in close proximity to each of them. Mounting the enclosure on the same pole as the Motor Starter Enclosure is the most practical because of the 110 VAC wiring between the two units. The brackets that accompany the enclosure are designed to either mount to a 2" pipe or they can be turned around for wall mount. If mounting to a wooden pole, attach the brackets to the enclosure for wall mount and use lag screws to secure to the pole. See Figure 2-1 for mounting options.


Installing the Model 6310/6313 POC, Continued

Pipe Mount Wall Mount Figure 2-1 Enclosure Mounting

Step 2 Install Step-down Transformer

The POC circuitry requires 110 VAC for input power. If 110 VAC is not readily available, the most efficient and economical method is to install a step-down transformer in the Motor Starter Enclosure. The transformer needs to be rated at 0.05 KVA. The step-down transformer will depend on the primary voltage available in the Motor Starter Enclosure, which a typical voltage would be 440 VAC. In this case the transformer would need to be a 440 to 110 VAC. The primary power tap to feed the step-down transformer must be prior to the contactor so that power is available at all times. (See Figure 2-2 for a typical wiring scheme)

Step 3 Install Interposing Relay

The POC provides a contact closure to turn the pump jack on and off. This is done by opening and closing the circuit to the coil of the contactor in the Motor Starter Enclosure. The contactor when closed passes the power on to the pump jack motor. The POC can drive the contactor coil directly if it requires no more than 110 VAC and no more than 0.5 amps. If the contactor coil requires more than 110 VAC or 0.5 amps, an interposing relay must be provided in the Motor Starter Enclosure. The contact closure from the POC will then drive the coil of the interposing relay which in turn will open or close the circuit to the contactor coil. Select an interposing relay with a 110 VAC coil which will allow you to use the 110 VAC referred to in Step 1. The contact rating of the interposing relay must match or exceed the contactor coil power requirements. (See Figure 2-2 for a typical wiring scheme)



Figure 2-2 Typical AC Wiring Scheme

Step 4 (See Figure 2-3) Wiring POC to Motor Starter Enclosure

Connect 110 VAC from the Motor Starter Enclosure to the two POC terminals of connector TB1B.

Connect ground wire from the Motor Starter Enclosure to the ground screw

on bottom of POC enclosure. Connect wiring from interposing relay or contactor coil circuit to the two POC

terminals of connector TB1A labeled 'N.C. CONTACT'.



Figure 2-3 (6310 POC Board Connections)

Step 5a (See Figure 2-4) Mount the PVC Version Sensor Probe and Magnet

Select a position typically on the front side of the gearbox, preferably on the frame and as high as possible. Use the side opposite the drive belts to protect the Sensor from possible damage caused from broken belts. Align the Sensor so that it is perpendicular to the innermost inside of the crank arm. With a Stud Gun and .190 (#10 - 32 UNF X 3/4" LG. threaded studs or by other means mount the two cable clamps (1684053-005) to the frame. It may be easier to slide the cable clamps over the Sensor Probe prior to attaching the clamps to the frame. Do not tighten clamps until alignment is complete.



Caution

Cast iron may crack if shot with a stud gun. Never attempt to shoot studs into cast iron.

Figure 2-4 (PVC Sensor & Magnet Installation) Step 5a (Continued) (See Figure 2-4) Mount the PVC Version Sensor Probe and Magnet

Route the Sensor Probe Cable along the inside rail of the pumping unit frame and clamp every few feet. The cable should terminate in a weather proof junction box permanently attached to the pumping unit frame. Attach the flexible Magnet (2015467-001) to the inner surface of the crank arm. Magnetism will hold the Magnet in place. Position the magnet such that it will pass immediately in front of the Sensor Probe with each revolution of the crank arm. Adjust the Sensor Probe so that no more than 1/4 inch air gap exists between the Sensor tip and the Magnet, then tighten the Sensor clamps.



Step 5b (See Figure 2-5) Mount the Stainless Steel Version Sensor Probe and Magnet

Install the 1/2" Conduit Cord Connector (1201000-100) in a small weather proof junction box or condulet box. The Sensor Probe can slide back and forth in the Cord Connector, providing ease of adjustment between the end of the probe and the magnet. Select a position for the junction box typically on the front side of the gearbox, preferably on the frame and as high as possible. Use the side opposite the drive belts to protect the Sensor from possible damage caused from broken belts. Locate the box so that the Sensor Probe will be perpendicular to the innermost inside of the crank arm. Locate the junction box close enough to allow the Sensor Probe to be adjusted within a 1/4" of the magnet which will be attached to the inside of the crank arm. It may be easier to have the Sensor Probe installed in the junction box when selecting the location. With a Stud Gun and .190 (#10 - 32 UNF X 3/4" LG. threaded studs or by other means mount the junction box to the pump jack frame.

Caution

Cast iron may crack if shot with a stud gun, so never attempt to shoot studs into cast iron.

Figure 2-5 (SS Sensor & Magnet Installation)



Step 5B, Continued (See Figure 2-5) Mount the Stainless Steel Version Sensor Probe and Magnet

Attach the flexible Magnet (2015467-001) to the inner surface of the crank arm. Magnetism will hold the Magnet in place. Position the magnet such that it will pass immediately in front of the Sensor Probe with each revolution of the crank arm. Adjust the Sensor Probe so that no more than 1/4 inch air gap exists between the Sensor tip and the Magnet, then tighten the Cord Connector enough that the Sensor Probe will not slide back and forth.

Step 6 (See Figure 2-6) Sensor Probe to POC Enclosure Wiring

Run a minimum of a 2-conductor cable or pair of wires, 20-22 AWG, between the Sensor Probe junction box and the POC Enclosure. The PVC Sensor Probe (-001) has two magnetic reed switches with 2-pair of wires whereas the Stainless Steel version (-002) has only one magnetic reed switch, hence 1-pair of wires. Terminate the wires in the junction box using the butt splices provided on the end of the Sensor Probe wires. Either pair of the PVC Sensor version can be used. Terminate the wires in the POC at J5.

Figure 2-6 (Sensor Probe Wiring)



Step 7a Wiring from POC to Flow Computer or RTU

The Model 6310 must be connected to a Totalflow Flow Computer, RTU or a 6313 POC which is running the Pump-Off algorithm. See step 7b if connected to a Model 6313 POC. The wiring will typically take a 4-conductor, 20-22 AWG cable consisting of 2 twisted pairs with an overall shield. The four connectors on J3 of the POC board are labeled as 'PUMP CONTRL', 'SENSOR OUT', 'FCU GND', and 'FCU CHRG'. 'FCU CHRG' allows the POC to be the charging source for the Flow Computer battery. This is optional as far as needing to be connected but can be used in lieu of the solar panel for the Flow Computer. 'Pump Cntrl' is an input to the 6310 from a digital output of the Flow Computer / RTU to turn the pump on or off. 'Sensor Out' is the Sensor Probe signal being passed on to the Flow Computer / RTU. 'FCU Gnd' is the 6310's logic ground and will be connected to the Flow Computer / RTU logic ground. This is required even if 'FCU CHRG' is not connected. See Wiring & Interconnect Dwgs 2018205 thru 2018208 for wiring to the various models of Flow Computers and RTUs. This would complete the installation process for a Model 6310 if it were connected to a flow computer or an RTU.

Step 7b Wiring from 6310 POC to 6313 POC

The Model 6313 is a totally integrated Pump-Off Controller capable of running it's own Pump-Off algorithm and with it's own communications. In addition to it's own Pump-Off Controller, the Model 6313 can support up to four Model 6310 POCs. All wiring for the Model 6313 is the same through step 6 as the Model 6310. The only additional wiring would be required if 6310s are connected to the 6313 and/or if communications are being used (see communications below). The 6313 has an additional card referred to as the Smart Card plugged into the base card. The Smart Card has additional digital inputs and outputs to support the Model 6310s. POCs 2 thru 5 are assigned by default to specific digital inputs and outputs on the Smart Card as shown below. These can be re-assigned if necessary as explained in the Chapter 3 of this manual. The signals required from the 6310 to the 6313 are 'PUMP CONTRL', 'SENSOR OUT', and 'FCU GND'. 'FCU CHRG' which can be used with a flow computer or RTU would not typically be used with a Model 6313 since it has it's own charger output. 'Pump Cntrl' is an input to the 6310 from the digital output of the 6313 to turn the pump on or off. 'Sensor Out' is the Sensor Probe signal being passed on to a digital input of the 6313. 'FCU Gnd' is the 6310's logic ground and will be connected to the 6313's logic ground. See Wiring & Interconnect drawing 2018514 for wiring between the Model 6310 and Model 6313 POCs.

Digital Inputs Digital Outputs POC #2 J4 1 & 5 (DI0) J2 6 (DO2) POC #3 J4 2 & 6 (DI1) J2 5 (DO3) POC #4 J4 3 & 7 (DI2) J2 4 (DO4) POC #5 J4 4 & 8 (DI3) J2 3 (DO5)



Step 8 Communications

The Model 6313 supports either RS-232 or RS-485 communications. Use either Figure 2-7 or the tag inside the unit for pin assignments. If the POC is ordered with additional communication's equipment such as a radio, all required wiring harnesses should be in place and any additional terminations provided. There are many communication's options including radios, cellular phones, modems, etc., therefore refer to the drawing package that accompanies the unit for specific wiring diagrams. Verify that a communication's module is in the XA1 socket which is immediately behind the J2 and J9 communications terminals on the 2015480 board. Module Pt. # 2015192 is RS-232 and Pt. # 2015193 is RS-485. If using RS-485, verify the Termination jumper (J1) behind communication's module is in the correct position. If RS-485 and the unit is the end device, place jumper on pins 2 & 3. If RS-485 and not the end device, place the jumper on pins 1 & 2.

Figure 2-7 (POC With Smart Card)

Installation Complete

This concludes the installation process. As previously mentioned, all sites differ somewhat, so there may be requirements specific to your site that could not be covered here. Hopefully this has been a thorough enough guide to lead you through a successful installation.


Chapter 3 Operations

Overview Introduction This chapter provides the information necessary to successfully startup a

Model 6310 and Model 6313 Pump-Off Controller. At this point, the POC system including the controller, sensor and all interconnect wiring should be complete. As a reminder, the Model 6310 must be interfaced to a Totalflow Flow Computer (FCU), Remote Terminal Unit (RTU), or a Model 6313 POC running the pumpoff control algorithm. The Model 6313 is capable of running it's own algorithm, plus it can support up to four additional Model 6310 POCs. The Model 6400 and 6700 Flow Computers typically only support one POC but can support more if required. This is especially true of the 6700 which theoretically could support up to six. The Model 6790 RTU can support up to eight 6310 POCs.

Chapter Contents This chapter provides the following information.

Topic

Page

Setup 3-2

Terminal Emulator 3-2

Entering Local Port Protocol Code 3-3

Parameter Screen 3-4

Terminal Mode Edit Keys 3-5

Parameter Definitions 3-6

Theory Of Operation 3-10

POC Startup 3-13

Display Information 3-14

Annunciators 3-15

Programming POC Display Information 3-16

Programming FCU Display Information 3-17


Setup Overview A Model 6310 POC requires it to be connected to a Flow Computer Unit (FCU)

or Remote Terminal Unit (RTU). The FCU or RTU is the device actually running the Pump-Off algorithm and sending the information to the POC to turn the pump jack on or off. Therefore, setup information will be entered at the FCU or RTU. A Model 6313 POC runs it's own Pump-Off algorithm, therefore the setup information will be entered at the 6313. Setup is done by connecting a Laptop computer to the PCCU connector of the FCU, RTU or POC and using a Terminal Emulator to change the setup parameters. As an example, Microsoft Windows 3.1 provides a program called Terminal.exe. Microsoft Windows 95/98 and Windows NT provide a program called HyperTerminal.exe

Terminal Emulator Setup

After starting the Terminal Emulator program, emulation and communications parameters must be set up to match the device. Terminal Emulation: Emulation = VT52 Communications: Com Port = Com1, Com2, etc. Baud Rate = 2400 Data Bits = 8 Stop Bits = 2 Parity = None Flow Control = None

Terminal Mode After making the above setup and the Laptop is connected to the PCCU

connector of the device, type "TERM" to enter the Terminal Mode of the device. The device should respond with a "TF>" prompt indicating that your are in Terminal Mode.


Setup, Continued

Entering the Local Port Protocol Code for a POC

At the "TF>" prompt, enter "LPP=4". Four is the Local Port Protocol code for a POC. If the device supports more than one POC, options like shown below will appear allowing you to select more than one POC. For example, If you connected to a Model 6313 you would see the following screen because the 6313 supports up to four additional Model 6310 POCs. The 6313 it's self would be PumpOff 1 and the four slave POCs would be PumpOff 2, PumpOff 3, PumpOff 4 and PumpOff 5. If the device was an RTU, it could display PumpOff 1 through PumpOff 8. Flow Computers are typically setup to support only one 6310 POC, therefore no additional POC selections are available.

6313 Console Screen


Setup, Continued

Parameter Screen Select one of the group numbers from the previous page and you see data

applicable to that particular POC as shown below. The same information will be provided whether the device is a POC, flow computer, or RTU but may be presented slightly different. The POC as shown below displays both operational and statistical by using the Edit keys described on the following page as would the RTU. The flow computer would have the operational and statistical data divided by individual selections on the previous screen. An (*) beside the parameter indicates that it can be modified, whereas one without an (*) is information only or statistical data. There are approximately fifty total parameters and fifteen of which are setup data. Setup data being the ones that can be modified.


Setup, Continued

Edit Keys Below is a complete definition of each editing function. The edit position on the

page is indicated by the cursor ">". (U)p - Depress the "U" key and the cursor moves up one position. (D)own - Depress the "D" key and the cursor moves down one position. (Ctrl) (U)p - Holding down the "Ctrl" key and depressing the "U" key displays the previous screen full of parameters. (Ctrl) (D)own - Holding down the "Ctrl" key and depressing the "D" key displays the next screen full of parameters. (C)hange - To change a parameter, place the cursor on the appropriate line and depress the "C" key. If the parameter is expecting a value, you simply type in the value followed by the 'Enter' key. If you have selections to choose from the 'Space Bar' toggles through the selections and when the desired one is showing press the 'Enter' key. (M)on - Depressing the "M" key for monitor causes the parameters on the current screen to be continually updated. The screen will continue to update until any key is depressed. c(Y)cle - Depressing the "Y" key causes each parameter to update and the screen will cycle through each parameter, causing one to roll off the top and the next parameter to appear at the bottom. (R)efresh - Refresh the display. (E)xit - Exit and return to top level 'Group Display'. (ESC) - Ends the Console Mode.


Setup, Continued

Parameter Definitions

* Date/Time: FCU System Date/Time * StateTimer: Amount of time spent in current operating state (Oper State). * OperState: Current POC Operating State. Only the first 3 states are operator selectable. Valid States:

Disabled POC Algorithm is not running. Down Period of time between pumping cycles for

well to recover production fluids. PumpUp Priming period allowed before POC enters

automatic pump-off mode of operation. POC Auto Run pump until pump off detected. Standby Timer pumping mode. Unit will pump for

programmed Standby time and then shutoff for Down time. Operation continues in this timer mode indefinitely. If a failed sensor is detected, the POC will default to this mode in an effort to keep production up.

Manual Sensor detected when pump should be off. OverRide POC operation has been suspended by an

external override. * Oper Mode: Current operating mode. Valid States:

POC Auto Run pump until Pump-Off detected. Standby Timer pumping mode. Unit will pump for

programmed Standby time and then shutoff for Down time. Operation continues in this timer mode indefinitely. If a failed sensor is detected, the POC will default to this mode in an effort to keep production up.

* Down: Programmable time (HH:MM:SS) unit is off and allowing well to recover production fluids. Applies to both Standby timer mode and POC Auto mode. * Pump Up: Programmable time (HH:MM:SS) allowed for pumping unit to stabilize before POC begins automatic operation. Period allowed for pumping equipment to prime and begin to move steady quantity of fluid. * Standby: Programmable time (HH:MM:SS) that pump will run when in 'Standby' mode. Pump will then rest for 'Down' time. (See 'Standby' under 'Oper Mode' above)


Setup, Continued

Parameter Definitions, Continued

* Max POCrun: Maximum allowable programmable runtime in POC Auto mode before POC assumes a system problem and is forced into 'Down' period.

Last POCrun: Displays the length of time pump ran in POC Auto mode before detecting pump-off.

* ESO Intrvl: Programmable percent of 'Last POCrun' time for early shut-off of pump. This feature allows the POC to shut off the pump some time earlier than the normal pump-off time to avoid fluid pound. This early shut-off will happen for the programmed number of 'ESO Cycles' before running through a normal pump-off cycle to re-calibrate the POC and establish a new 'Last POCrun' time.

* ESO Cycles: Programmable number of pump cycles used by the Early Shut-Off feature before running through a normal pump-off cycle. Entering a 5 would cause the POC to run 5 early shutoff cycles before running a normal cycle. A normal pump-off cycle keeps the pumping time and well conditions in sync.

* Oper Delta: Programmable amount of speed change in milliseconds that the pump will speed up to determine pump off. The speed change is determined by the difference between 'LastStroke' and 'FullBarrel'.

Last Delta: Displays the number of milliseconds between 'LastStroke' and 'FullBarrel'.

* Max Stroke: Maximum stroke interval allowed to determine sensor fail. Unit is put into Standby mode if sensor fail detected.

LastStroke: Average length of the last 3 strokes.

FullBarrel: Longest 3 stroke average measured during the pump cycle.

* OverRide: Override enable switch. Valid states: Disabled OverRides are not allowed. Enabled OverRide assertion allowed from external

source (such as EXIO). RS Open OverRide State asserted if Remote Sense

Contact is open. (FCU only) RS Closed OverRide State asserted if Remote Sense

Contact is closed. (FCU only) J4 - 1&5 OverRide State asserted if DI0 on the POC

Smart Card senses a contact closure. J4 - 2&6 OverRide State asserted if DI1 on the POC



Smart Card senses a contact closure.


Setup, Continued


* Output: Digital Output assignment for motor activation. Selections will vary with the device running the Pump-Off algorithm. (Model 6313 POC assignments shown):

TB1A J2-6 J2-5 J2-4 J2-3 J2-2 J2-1

Motor: Pump motor switch. Valid States:

ON Auxiliary contact is closed. OFF Auxiliary contact is open.

* Input: Digital Input assignment for sensor. Selections will vary with the device running the Pump-Off algorithm. (Model 6313 POC assignments shown):

J5 - 1&2 J4 - 1&5 J4 - 2&6 J4 - 3&7 J4 - 4&8

Sensor: Sensor status flag: Valid States:

OK Pump stroke detected within maximum stroke interval.

FAIL Pump stroke not detected within maximum stroke interval.

C-Cyc Stat: Current Cycle Status

Down Pump Motor is Off. Running Pump Motor is On.

C-Cyc Spd: Current Cycle Speed (previous stroke interval) C-FBl Spd: Current Full Barrel Speed (longest average stroke interval) P-Cyc Run: Previous Cycle Run Time


Setup, Continued


P-Cyc SPM: Previous Cycle Average Strokes per Minute C-Day ET: Current Day Elapsed Time C-Day Run: Current Day Accumulated Run Time C-Day Down: Current Day Accumulated Down Time C-Day #Cyc: Current Day Number of Run Cycles C-Day Duty: Current Day Duty Cycle C-Day SPM: Current Day Average Strokes per Minute P-Day ET: Previous Day Elapsed Time P-Day Run: Previous Day Accumulated Run Time P-Day Down: Previous Day Accumulated Down Time P-Day #Cyc: Previous Day Number of Run Cycles P-Day Duty: Previous Day Duty Cycle P-Day SPM: Previous Day Average Strokes per Minute C-Month ET: Current Month Elapsed Time C-Month Run: Current Month Accumulated Run Time C-Month Down: Current Month Accumulated Down Time C-Month #Cyc: Current Month Number of Run Cycles C-Month Duty: Current Month Duty Cycle C-Month SPM: Current Month Average Strokes per Minute P-Month ET: Previous Month Elapsed Time P-Month Run: Previous Month Accumulated Run Time P-Month Down: Previous Month Accumulated Down Time P-Month #Cyc: Previous Month Number of Run Cycles P-Month Duty: Previous Month Duty Cycle P-Month SPM: Previous Month Average Strokes per Minute


Setup, Continued

Theory of Operation

*State Timer 00:46:17 *Oper State: Down *Oper Mode: POC Auto *Down 01:00:00 *Pump Up 00:00:30 *Standby 00:15:00 *Max POCrun 08:00:00 last POC run 00:17:14 *ESO Intrvl 0.0% *ESO Cycles 0 *Oper Delta 30 ms last Delta 37 ms *Max Stroke 13000 ms last Stroke 8745 ms Full Barrel 8773 ms *Override Disabled *Motor OFF Sensor OK

There are three operating states employed in the TOTALFLOW POC. To disable the POC function simply select the Disabled state (operating states can be toggled with the 'C' key). In our current example the POC is in a Down state and POC Auto mode. To manually force a rest, or Down period select the Down state. In this example the POC has automatically entered the Down period by detecting pump off. The POC will remain in a Down state until the programmed Down time has expired. To start the TOTALFLOW POC simply enter the Pump Up state while in the POC Auto operating mode. During the Pump Up state the POC will ignore pump off. The Pump Up state lasts for a user specified time and allows the well and pump to stabilize. The TOTALFLOW POC incorporates two operating modes; Standby and POC Auto. Standby mode is a simple on/off timer. The pump will be on during the programmed Standby time and off during the Down time. The POC Auto mode selects the automatic POC operation. In our example we are in the POC Auto operating mode and the Down state. The Down period is user programmable. After moving the cursor to the Down selection (using the U and D keys) press C for change. Hours, minutes and seconds ( ex: 01:00:00) must all be entered. Seconds do not automatically zero if not entered. In the example we have programmed a 1 hour Down period. The Pump Up period represents a period of time immediately after the Down period. This period allows the well and pumping equipment to stabilize without attempting to detect pump off. In the example weve programmed the POC for a 30 second Pump Up time. Again, Standby is a simple on/off timer mode. The Standby, or timer, mode is entered through two means. Standby can be entered manually by simple selecting Standby mode in the POC menu.


Setup, Continued


Theory of Operation, Continued

Otherwise Standby mode is entered whenever a sensor failure is detected. If the POC sensor fails and a sensor closure is not detected within the Max Stroke period, the POC will default to Standby mode. This feature ensures that production can be maintained even if the system should experience a sensor failure. In the example we are discussing, Standby has been programmed for 15 minutes. It has been determined by the operator that this particular well tends to pump for about fifteen minutes before pumping off (assuming the 1 hour Down time). The next menu item is Max POCrun. This represents the maximum allowable runtime before the POC will enter a Down mode. In our example, the assumption has been made that if the pump should run for more than eight consecutive hours without detecting a valid pump off, we want to restart the system. Operator attention is most likely required if Max POCrun is exceeded. It may be necessary for the operator to adjust the speed delta to more accurately reflect the requirements of that specific well. Last POCrun is not a user programmable variable. It simply displays how long the pump ran before pump off was detected on the previous pumping cycle. ESO Intrvl, or early shutoff interval, is a feature that can significantly reduce equipment wear due to fluid pound at pump off. The POC runs a normal cycle and determined how long it ran before detecting pump off. With this information the POC can shutoff the equipment prior to actual pump off and fluid pound. If a normal runtime were determined to be fifteen (15) minutes (as in our example) before fluid pound occurred, we might want to shut down the equipment at fourteen (14) minutes. To do this we would enter an ESO Intrvl of 93.3%. This interval would cause the POC to shutdown equipment prior to actual pump off and its inherent fluid pound. This mode of operation would continue for ESO Cycles before running a normal pump off cycle. If ESO Cycles were set at five (5), the POC would run five (5) early shutoff cycles before executing one normal pump off cycle. Running the normal pump off cycle keeps the pumping time and well conditions in sync. This encourages maximum production. The Oper Delta, or operating speed delta, is the speed change associated with pump off. During normal fluid producing cycles the pump runs at a vary steady speed that is associated with the production fluid load. When this fluid load is reduced at pump off a slight increase in pump speed will be evident. This speed increase will typically be between 10 and 100 milliseconds. In the example Oper Delta is set for 30 milliseconds. If the pump speeds up by more than 30 milliseconds pump off will be assumed as the cause. Last Delta is not configurable by the operator. It is simply a display of the speed difference between two previous cycles. If the well has been stabilized the speed difference between successive cycles will be very small. When the pump starts to ingest gas at pump off the pump speed will begin to increase somewhat. A visual representation (horizontal bar graph) of this speed increase can be activated on the FCU display. Eventually the speed will increase to the pump off threshold.

Setup, Continued


Theory of Operation, Continued

The next entry is Max Stroke. This variable is set to be about 10-20% greater than the longest expected pump stroke. For example, suppose that the pump in our example is pumping at 5.3 strokes per minute. At this pumping rate each stroke would be about 11.3 seconds long. Now increase the 11.3 seconds by about 15%. You will find that to be about 13 seconds. Max Stroke is measured in milliseconds so Ive set it in our example to 13000 milliseconds (13 seconds). If something should cause the sensor to fail and we do not get a sensor closure within 13000 milliseconds, the POC would log a sensor failure and go into Standby (on/off timer) mode. The pumping equipment would continue to run for the Standby period and be off for the Down time. Last Stroke and Full Barrel are not programmable by the operator. These entries only display the period associated with each item. Last Stroke displays the length of the previous stroke in milliseconds. Full Barrel acts like a peak detector for Last Stroke. Any time during a cycle, if Last Stroke is greater than Full Barrel, Full Barrel will be set to Last Stroke. In this way Full Barrel represents a reference point from which to measure Oper Delta. Full Barrel is the slowest stroke within any pumping run cycle. When the pump speeds up Oper Delta faster than Full Barrel, pump off is detected. POC operations can be overridden by several events. The ability to Override normal POC operation can be Disabled. To enable POC overrides select RS Open or RS Closed depending on the hardware configuration. RS Open or Closed pertains to the remote sense input on the FCU.A hardware event that can override normal POC operation is whether remote sense is open or closed (RS Open, RS Closed). The next entry, Motor, allows the operator to turn the pump motor Off or On. As well as being able to turn the motor on and off, it informs the operator as to the motor state. Sensor reports the status of the sensor. The sensor is either OK or FAILED. If the POC has been running in POCAuto mode and a sensor failure is reported, the POC defaults to Standby mode. The State Timer reports the time that the POC has spent in the current operational state. In our example above, the POC has been in the Down state for 46 minutes and 17 seconds. From this it is easy to see that the POC will turn on the pumping equipment in about 14 minutes.


Setup, Continued

Typical POC Startup

NOTE: Refer to previous pages for definitions of parameters.

Step 1 Turn the pump off and allow the well to build up sufficient fluid to perform a normal pump-off routine. If the well is already in a pumped off condition, it is impossible to detect the speed change that indicates pump off.

Step 2 Enter the correct Date/Time. Example: 05/01/99 10:40:00 Step 3 Set the Override condition, if one applies. Step 4 Enter Standby interval. Example: 08:00:00 (8 hours.) Make sure this is ample

time for the well to completely pump-off.

Step 5 Enter a typical Down time. - Example: 04:00:00 Step 6 Enter Pump Up interval - Example: 00:01:00 (1 minute) Step 7 Switch Oper Mode to Standby. Step 8 Switch Oper State to Pump Up. - When the Pump Up interval expires, the

Oper State will automatically switch to Standby.

Step 9 Leave pump running and return after pump-off to complete final setup. Be sure to return after Standby time elapses but before Down time elapses. If not, well will startup again. If not sure of return time, enter a large Down time.

Following steps are after pump-off. Step 10 Multiply FullBarrel interval by 1.15 and enter this value into Max Stroke

interval. - Example: 6000 * 1.15 = 7000 (15% increase is an estimate)

Step 11 Enter value of Last Delta interval into the Oper Delta. Step 12 Enter Max POCrun interval. - Example: 05:15:00 This would typically be the

Last POCrun time extended some amount.

Step 13 Enter a more reasonable Standby interval. This would typically be the Last POCrun time.

Step 14 Enter ESO Intrvl and ESO Cycles if desired. - Example: 95% and 5 cycles Step 15 Enter typical pump Down time if modified per Step 9. - Example: 04:00:00 Step 16 Switch Oper Mode to POC Auto. Pump will start again after Down time

elapses.

NOTE: Times can always be tweaked later if necessary.


Display Information Description There is basic information that shows up on the LCD display of a POC. For the

Model 6313 standalone POC, this information is displayed on the optional display of the POC's own LCD display. In the case of a Model 6310, this information can be displayed on the Flow Computer's display or the 6313's display but must be programmed to do so. Display programming can be done with PCCU32 software or with the same Terminal Emulator that was used on the previous POC setup. See the next page for display commands when using a Terminal Emulator. There are three basic sets of POC information in addition to the Date/Time display which will be sequentially shown on the LCD display. Two of the information displays takes on two different looks. Along with each displayed set of information are annunciators displaying status codes. Below is an example of the information provided on the LCD display.

Date/Time A1 A3 A5 A7 09/03/97 14:02:20 A2 A4 A6 A8

Current Date = 09/03/97 Current Time = 14:02:20

Display 1 when current POC status is RUNNING:

RUN - 00:14:25 - 09263 A1 A3 A5 A7 RAN - 00:16:38 - 8.4spm A2 A4 A6 A8

Current Run Time = 00:14:25, Current Stroke Interval = 9263 ms Previous Run Time = 00:16:38, Previous Average Strokes/Min = 8.4

Display 1 when current POC status is DOWN:

DOWN - 00:04:35 - 09262 A1 A3 A5 A7 RAN - 00:13:10 - 8.4spm A2 A4 A6 A8

Current Down Time = 00:04:35, Current Stroke Interval = 9262 ms Previous Run Time = 00:13:10, Previous Average Strokes/Min = 8.4

Display 2

TD - 40% - 05.6Hr A1 A3 A5 A7 YD - 40% - 09.8Hr - Lm39% A2 A4 A6 A8

Today's Duty Cycle = 40% Today's Accumulated Run Time = 5.6 Hours Yesterday's Duty Cycle 40% Yesterday's Accumulated Run Time = 9.8 Hours Last Month's Duty Cycle = 39%

Continued on next page


Display Information, Continued

Display 3 when current POC status is RUNNING:

RUN - 00:04:25 - 09260 025 - 028 - 94.2% - 09288

Current Run Time = 00:04:25, Current Stroke Interval = 9260 ms Operating Delta = 28 ms, Last Delta = 25 ms (93.5% of OD) Current Full Barrel Stroke Interval = 9288 ms Graph = % of PumpOff

Display 3 when current POC status is DOWN:

RAN - 00:04:25 - 09260 025 - 028 - 94.2% - 09288

Previous Run Time = 00:14:35, Current Stroke Interval = 9260 ms Operating Delta = 28 ms, Last Delta = 25 ms (93.5% of OD) Current Full Barrel Stroke Interval = 9288 ms Graph = % of PumpOff

Annunciators The annunciators (A1 - A8) of Displays 1 & 2 provide information about the

flow computer and/or POC.

A1 Current status for POC1 (6313 POC only) A3 Current status for POC2 (6313 POC and flow computer) A5 Current status for POC3 (6313 POC only) A7 Current status for POC4 (6313 POC only) A2 Current status for POC5 (6313 POC only) A4 Displays POC no. of current display (6313 POC only) A6 Displays Local Port status (6313 POC and flow computer) A8 Displays Remote Port status (6313 POC and flow computer) Current Status Codes: P POC Disabled S POC in PumpUp Delay Mode A POC in AUTO RUN Mode a POC in AUTO Down Mode T POC in TIMER RUN Mode t POC in TIMER DOWN Mode F POC in SENSOR FAIL RUN Mode f POC in SENSOR FAIL DOWN Mode B Bypass - Receiving Sensor Input When Motor Should Be Off O Override - External Override Sensed / Motor Disabled

Graph Area

Graph Area



Programming POC Display With Terminal Emulator

The Model 6313 supports it's own pump-off controller as well as having support for four additional Model 6310 POCs. By default, the three display views as shown on pages 11 & 12 plus the date/time display are setup for it's own POC but not for any additional 6310 POCs. Therefore, the display items for the additional POCs must be programmed. The sensor input for the wand, relay or the motor activation, and the DIs and DOs for the 6310s can also be displayed if desired. Connect to the flow computer and start up Terminal Emulator as described on pages 2 & 3 of this section. Each additional POC can have any or all three of the display views assigned to the 6313's display. Use the FCU display programming procedure on the previous page but substituting the following display numbers to add any additional POC views.

Display No. Display No. POC No. DSP=1 Loc/ID (typically not

displayed) Loc/ID

DSP=2 6313's date/time Date/Time DSP=3 Display 1 POC 1 (Model 6313) DSP=4 Display 2 POC 1 (Model 6313) DSP=5 Display 3 POC 1 (Model 6313) DSP=6 Display 1 POC 2 (1st Model 6310) DSP=7 Display 2 POC 2 (1st Model 6310) DSP=8 Display 3 POC 2 (1st Model 6310) DSP=9 Display 1 POC 3 (2nd Model 6310) DSP=10 Display 2 POC 3 (2nd Model 6310) DSP=11 Display 3 POC 3 (2nd Model 6310) DSP=12 Display 1 POC 4 (3rd Model 6310) DSP=13 Display 2 POC 4 (3rd Model 6310) DSP=14 Display 3 POC 4 (3rd Model 6310) DSP=15 Display 1 POC 5 (4th Model 6310) DSP=16 Display 2 POC 5 (4th Model 6310) DSP=17 Display 3 POC 5 (4th Model 6310) I/O POC DSP=18 Wand Wand sensor input for POC 1 (6313) DSP=19 DI0 Wand sensor input from POC 2 (6310) DSP=20 DI1 Wand sensor input from POC 3 (6310) DSP=21 DI2 Wand sensor input from POC 4 (6310) DSP=22 DI3 Wand sensor input from POC 5 (6310) DSP=23 Relay Motor activation for POC 1 (6313) DSP=24 DO2 Motor activation to POC 2 (6310) DSP=25 DO3 Motor activation to POC 2 (6310) DSP=26 DO4 Motor activation to POC 2 (6310) DSP=27 DO5 Motor activation to POC 2 (6310) DSP=28 DO6 Motor activation to POC 2 (6310) DSP=29 DO7 Motor activation to POC 2 (6310)



Programming FCU Display with Terminal Emulator, Continued

Connect to the flow computer and start up Terminal Emulator as described on pages 2 & 3 of this section. There are three displays to choose from as shown above. The display numbers are typically 26, 27, and 28 but may differ on some flow computers. The following procedure will cause all three to added to the display cycle and remain up for 5 seconds. At the TF> prompt enter the following:

Step 1 DSP=26 - You should receive a response of dsp=POC Disp 1 and the display will be shown on the device's display.

Step 2 DSI=5 - Sets the display time to 5 seconds. Step 3 DSP=27 - You should receive a response of dsp=POC Disp 2 and

the display will be shown on the device's display.

Step 4 DSI=5 - Sets the display time to 5 seconds. Step 5 DSP=28 - You should receive a response of dsp=POC Disp 3 and

the display will be shown on the device's display.

Step 6 DSI=5 - Sets the display time to 5 seconds. Step 7 DSP=0 - Starts the flow computer's display to cycling.


Chapter 4 Maintenance & Troubleshooting

Overview

Introduction This chapter provides you with standard Maintenance information, instructions on how to remove and install components and some troubleshooting tech-niques.

Chapter Highlights

In this chapter you will learn how to:

Topic See Page

Replace POC Fuse 4-3

Replace POC Battery Pack 4-5

Replace POC Smart Card (2015483) 4-7

Replace Base Controller board (2015480) 4-9

Replace POC Display 4-11

Replace Warning Beeper 4-13

Replace Sensor Probe 4-14

Troubleshooting a POC Without Smart Card 4-16

Troubleshooting a POC With a Smart Card 4-18

Maintenance Support

If installation, calibration, maintenance or parts assistance is required, user can contact the Totalflow Service Department.

Inside or Outside Oklahoma 1-(800)-442-3097


Overview, Continued

How to Use This Chapter

We recommend that you develop regularly scheduled daily, weekly or monthly maintenance program. By establishing such a maintenance program POC downtime can be at a minimum. The majority of POC maintenance is simply cleanliness and detecting any failures as soon as possible.

This chapter is broken down into the replacement of major parts. As part of the maintenance program, keep a log of any replaced parts. Log the date when a part was replaced, it's part number and symptom or reason for replac-ing.

Maintaining Cleanliness of POC

Because a POC installation is primarily exposed to external environmental conditions, it is important that it be regularly inspected for cleanliness, both ex-ternally and internally. Foreign contaminants can cause damage to interior mounted components rendering POC inoperable.

Front Mounted LCD Display

The two lines by 24 alphanumeric character LCD display displays status in-formation on the right side of display window. By observing this display, user is informed of operational problems.

Returning Parts for Repair

If a TOTALFLOW component is to be returned for repair, securely wrap it in protective anti-static packaging. Before returning a component, call us for a Return Authorization Number (RA). Affix this number to the outside of return package.

Part shipments must be prepaid by customer. Any part, not covered by origi-nal SYSTEM WARRANTY, will be shipped to customer, F.O.B.


Replacing POC Fuse

Description This section presents the procedures for removal and installation of the POC fuse. There is only one fuse in the POC and is located on the Base Controller board (2015480). To access the board and fuse, open POC door. The Base Controller board is attached to the back side of the door. The fuse is located beneath the red 110 Volt AC Warning tag. The tag acts as a removal and in-stallation tool.

The fuse is a 3/4 A, 250V, cylindrical, 1/4 x 11/4. Approved fuses are Buss MDL -3/4 and Littlefuse 310.750.

Important When replacing the fuse, if a Smart Card (2015483) is mounted on the Base Controller board, verify that the Lithium battery (BT1) is in place on the Smart Card and the paper tab has been removed. This prevents any data stored in system RAM, from being lost when the power is removed.

Warning!

Before doing maintenance inside the POC enclosure, make certain that the 110 VAC power source has been removed. Open the disconnect at the panel box so that POC power and pump jack power are turned off. This will keep the pump jack from starting inadvertently.

(See Figure 4-1) Step Procedure

1. Make sure paper tab has been removed from lithium battery (BT1) if a Smart Card exists.

2. Measure lithium battery and make sure it is > 3.0V if a Smart Card exists.

3. Turn off the 110 VAC power to the POC.

4. Grab hold of the 110 Volt AC Warning tag and pull outward. The fuse will stay attached to the tag.

5. Slip a small screwdriver under the end of the fuse and pry upwards to remove the fuse.

6. Snap a new fuse into the clips on the back side of the tag.

7. While holding the tag, place the fuse against the fuse holders on the board and push. You should feel the fuse snap into place.

8. Close and secure the door.

9. Turn on the 110 VAC power.


Figure 4-1 Maintenance Reference


Replacing POC Battery Pack

Description

This section presents the procedures for removal and installation of POC bat-tery pack. To access battery pack, open POC door. Battery pack is located behind front mounted keeper plate.

Important When removing battery pack, DO NOT remove Lithium battery from POC Smart Card (2015483). This prevents any data stored in system RAM, from being lost when power is removed.

Warning!

Before doing maintenance inside the POC enclosure, make certain that the 110 VAC power source has been removed. Throw the disconnect at the panel box so that POC power and pump jack power are turned off. This will keep the pump jack from starting inadvertently.


1. Make sure paper tab has been removed from lithium battery (BT1).

2. Measure lithium battery and make sure it is > 3.0V.


4. Disconnect charging source wiring from charger regulator, Array (+) & Array (-). Not required if the charging source is coming from A1J3 of the Base Controller board (2015480).

5. Unplug the battery connector.

6. Remove keeper plate which secures battery pack in its mounting location, by slightly loosening the three mounting screws. It is not necessary to remove screws.

7. Remove battery pack from battery compartment.



Replace POC Battery Pack, Continued

Step Procedure

8. Insert new battery pack into battery compartment. Battery pack must be positioned so its longest dimension fits snugly against keeper plate when plate is installed.

Reinstall keeper plate and tighten three keeper plate mounting screws.

9. Reconnect battery pack cable connector.

10. Reconnect charging source wiring to charger regulator terminals Array (+) & Array (-).

11. Verify that all connections have been made then apply 110 VAC power.

12. Check the LCD display for normal operational readings.


Replacing POC Smart Card (2015483)

Description The POC Smart Card (2015483) is typically only found in the Model 6313 POC. It is mounted on top of the Base Controller board (2015480) which is mounted to the backside of POC access door.

Caution

The Smart Card is susceptible to damage by static electricity build-up or im-proper handling. To prevent this from occurring, user should use a grounding strap.

A grounding strap is a conductive device used to make connection between the person handling the board, and a high quality ground potential.

Before handling the card you should install the ground strap on the wrist and then connect it to ground potential. This discharges electrical static buildup from the persons body to ground. This prevents any electrical static buildup from discharging to the board.

Note The user may want to copy down setup times if Smart Card is responsive unless backed up by other means.

Warning!




2. Remove the following connectors.

POC LCD Display port connector J3.

Connectors from J2 & J4 (if wiring exits)



Replacing POC Smart Card (2015483), Continued

3. Back the four mounting screws only part way out of the standoffs.

4. Connectors J6 & J7 are plugged into the Base POC board such that you need to work each side of the card out and then finish backing the four screws out.

5. Remove the EPROM U2 from the removed board and install in the new board, making sure the notch is toward the J6 connector.

6. Configure jumpers J1 & J5 the same as on the removed board.

7. Turn the LCD contrast potentiometer R15 3 - 4 turns clockwise.

8. Install the new board by aligning connectors J6 & J7 with their counter-part connectors on the Base Controller board. Run the four mounting screws in part way and then push on both sides of the card to seat the connectors further. Move back and forth between the screws and seating the connectors so that the board is not bowed. Finish by securing the screws but do not over-tighten.

9. Reinstall connectors, previously removed, to their original associated board mounted connectors.

LCD Display Connector

Connectors J2 & J4

10. Verify that all connectors and wiring are in place and apply power.

11. Turn LCD contrast potentiometer R15 counterclockwise until characters on the display becomes visible.


Replacing Base Controller Board (2015480)

Description The Base Controller board (2015480) is found in both the Model 6310 and

6313 POCs and is mounted to the backside of POC access door. The Model 6313 POC will typically have a Smart Card (2015483) mounted on top of the Base board.

Caution

The Base Controller board is susceptible to damage by static electricity build-up or improper handling. To prevent this from occurring, user should use a grounding strap.

A grounding strap is a conductive device used to make connection between the person handling the board, and a high quality ground potential.

Before handling the boards you should install the ground strap on the wrist and then connect it to ground potential. This discharges electrical static buildup from the persons body to ground. This prevents any electrical static buildup from discharging to the board.

Warning!




2. If a Smart Card (2015483) is mounted on the Base Controller board, do Steps 1 thru 4 of Replacing POC Smart Card procedure to remove the Smart Card.

NOTE: It's possible that if a Smart Card does exist, the Lithium battery is good, the Smart Card is handled carefully, that the setup data in the Ram will be kept in tact.


Replacing Base Controller Board (2015480), Continued

3. Remove the following connections from the Base Controller board.

NOTE: Label wiring that does not stay in connectors for correct re-installation

Beeper wires from A1J10.

Unplug the PCCU connector from J4

Remove the 110 VAC wires from TB1B

Remove the motor activation wires from TB1A

Unplug the Sensor wiring connector A1J5

Unplug connector A1J3

Unplug connector A1J6

Unplug communication's connectors A1J2 & A1J9

4. Remove the four mounting screws and the board from the standoffs.

5. If POC has communications option, remove the communication module form XA1 and install on replacement board. Make sure pin 1 is toward the middle of the board. Verify also that Jumper A1J1 matches that of the removed board.

6. Install the new board with the four mounting screws.

7. Re-connect all wiring and connectors removed in Step 3

8. If a Smart Card (2015483) was removed, do steps 7 & 8 of Replacing POC Smart Card procedure to re-install the Smart Card.

9. Verify that all wiring and connectors have been re-installed before applying power.


Replacing LCD Display Board

Overview The LCD Display Board is mounted on the backside of the hinged door behind the Base Controller board (2015480) on Model 6313 POCs. To access and remove Display Board, perform the following procedures.

Warning!


Note To prevent power damage to the Circuit Boards and Display Board, it is rec-ommended that if a battery exists, disconnect the J9 connector from the Base Controller board (2015480).


1. To access the LCD Display Board, open the TOTALFLOW unit door. Board is located behind Digital Circuit Board.

2. DO NOT remove Digital Board mounted Lithium battery since it pro-vides power to RAM. This prevents loss of accumulated data.

3. Disconnect LCD Display Board cable connector from the Smart Card (2015483) Display Port connector J3. To remove connector, extend connector hold down fingers outward. Connector will pop outward.

4. Remove four mounting screws and lock washers that hold the Base Controller board to the standoffs. The Smart Card (2015483) will stay attached to the Base Controller board. DO NOT let screws and lock washers fall onto board circuitry.

Move board away from door then support it so its circuitry does not come in contact with any metal surface.



Replacing LCD Display Board, Continued

Step Procedure

5. Using a 3/16 nut driver, remove four Display Board hexagonal mounting standoffs. Lift Board from door mounted standoffs.

6. Align the mounting holes in the new display with the four studs and push into place (cable toward the inside). Replace the four hexagonal standoffs but do not over tighten.

7. Re-install the Base Controller board with the four mounting screws but do not over tighten.

8. Adjust the contrast potentiometer R15 on the Smart Card 2 - 3 turns clockwise.

9. Verify that everything is back in place and apply power.

10. Adjust contrast potentiometer R15 counterclockwise while watching the display. Turn until characters come into view and adjust for opti-mum viewing.


Replace Warning Beeper

Overview The warning beeper (Pt# 2017208-001) is mounted in the bottom center of the enclosure and is wired to beeper terminals A1J10 of the Base Controller board (2015480).

Warning!



1. To access the warning beeper, open the TOTALFLOW unit door. The Beeper is located on the very bottom center of the enclosure beneath a bracket.

2. Remove wiring from beeper terminals A1J10 of the Base Controller board.

3. Loosen the two hex nuts from underneath the enclosure just enough that the beeper can be removed.

4. Slide the replacement beeper under the bracket and align by looking up through the hole in the bottom of the enclosure. Align until the three small holes in the beeper can be viewed. Tighten hex nuts but do not over tighten.

5. Connect wiring to beeper terminals Red (+) Blk (-) (see tag on battery bracket).

6. Place beeper wiring inside the plastic retainer clips.


Replacing The Sensor Probe

Overview The sensor probe can be one of two varieties. A 3/8" O. D. stainless steel ver-sion which is typically mounted in a small junction box. The other sensor is a larger PVC version which is typically mounted directly to a surface such as the gear box.

Warning!

Remove power to the pump jack before doing any maintenance on the sensor so the POC cannot start the jack.

Note If it has been determined that the sensor is not working, first verify that the magnet is in it's correct proximity to the sensor probe. The magnet should pass in front of the probe and have no more than 1/4" gap between the mag-net and the probe end.

The PVC version of the sensor has two sets of reed switches. If the spare set has not been used, switch over to the unused set of leads at the probe junction box.

For reference, see the section on installing the sensor probe in Chapter 2.

Replacing Stainless Steel Version

Step Procedure

1. Remove power to the pump jack.

2. Disconnect sensor probe wiring in probe junction box.

3. Loosen cord connector and pull probe out of the connector.

4. Slide the replacement probe in the cord connector.

5. Adjust gap between probe and magnet to be no more than 1/4" and tighten cord connector.

6. Splice the probe wiring to the wiring leading to the POC.



Replacing The Sensor Probe, Continued

Replacing PVC Version

Step Procedure

1. Remove power to the pump jack.

2. Disconnect sensor probe wiring in probe junction box.

3. Loosen clamps and remove PVC probe.

4. Clamp replacement probe in position.

5. Adjust gap between probe and magnet to be no more than 1/4".

6. Splice the probe wiring to the wiring leading to the POC.


Troubleshooting

Overview Totalflow Pump-Off Controllers are fairly simple and typically have very few failures. However, a guide is presented below to help troubleshoot a problem if it does occur.

Troubleshooting Guide

If the POC is a Model 6313, a good troubleshooting tool is the Status codes on the Display. One of the best troubleshooting tools for the POC is the Laptop or PCCU running the Terminal mode. Terminal mode parameters may tell enough to diagnose or at least lead you to the cause. On a POC without a Smart Card, Terminal mode will be used on the flow computer or RTU. A POC with a Smart Card will support the Terminal mode.

Tip One thing to always look for when troubleshooting especially during startup is wires in terminal blocks that have not been stripped back far enough and the screw is tightened down on the insulation instead of the wire.

Guide For a POC Without a Smart Card (typically Model 6310)

Condition Things To Do

1 Pump does not run. Place HOA switch in Hand position to see if pump will run manually. If pump does not run in Hand position, a problem exists other than the POC. If pump runs in Hand position, switch it back to Auto position and go to Condition 2.

2 Pump runs in "Hand" position but not in "Automatic" position.

1. Is the POC suppose to be down? Go to the device (POC, FCU, RTU, etc.) running the algorithm and use Terminal Mode to verify the Operating State. If the Operating State is in a Mode in which the pump should be running, move to step 2 below.

2. Use Terminal mode to check the Motor Status.:

If OFF, the POC has turned it off for some reason. Re-check the Operate State, Operate Mode, Sensor and OverRide condition if used.

If ON, the pump should be running. Switch the power off at the Motor Starter Enclosure. Remove the two wires on TB1A of the POC driving the interposing relay, twist or jumper the two wires together and make sure they do not touch anything. Apply power and see if the pump runs. If not, the problem is either in the Motor Starter Enclosure or the wiring to TB1A. If the pump runs, turn the power off, replace the two wires to TB1A and move to step 3 below.



Troubleshooting, Continued

Condition Things To Do

3. Remove the wire from J3 pin 4 (PUMP CNTRL) and replace with a jumper from J3 pin 4 to J3 pin 2 (FCU GND) or to J6 pin 2 (GND). This simulates the Motor On signal coming from the device running the PumpOff algorithm. Reapply the power and see if the pump runs after a 10 - 15 second delay. If the pump doesn't run, the Base Controller board is probably bad. If the pump runs, either the wiring going back to the device running the algorithm is bad or there is no Motor On output from the device to turn the pump on.

3 Sensor "Fail" If the device running the algorithm does not see a pulse within the time entered for Max Stroke, the Sensor will be placed in a Fail status and the POC will be put in Standby (Timer) mode. If for some reason the pulse was missed and subsequent pulses are within the Max Stroke time, the POC will go back into POC Auto mode. If you find the POC with a failed Sensor do the following in sequence until the problem is found:

1. Verify that Max Stroke is larger than FullBarrel. Max Stroke should be at least 15% - 20% higher than FullBarrel.

2. Verify that the correct terminals are selected for Input. 3. Verify that the Sensor magnet is still in place and passes in front of the

Sensor. 4. Verify that the gap between the Sensor and the magnet is no more than

1/4". 5. Remove the two sensor wires from A1J5 of the POC. Measure across

the leads with an ohm meter with the pump running to see if the sensor contacts are opening and closing. A digital ohm meter may not respond fast enough to see any changes. An analog meter should show deflections of the needle when the magnet passes in front of the Sensor. If only a digital meter, another person could use a spare magnet and hold across the end of the sensor for a few seconds and then remove it to see if the sensor contacts are working. This would need to be done with the pump stopped.

If pulses are getting to the POC, do the following, if not go to

totalflow

Documents

poc enclosure

poc fuse

poc startup

poc hardware

poc smart card

poc typical installation

totalflow pump

totalflow model