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Sensia INSTRUCT PCP Hardware Installation Manual

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INSTRUCT PCP
INTELLIGENT CONTROLLER
Hardware Installation Manual
LCS-ENG-M0017,

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  • Page 1 INSTRUCT PCP INTELLIGENT CONTROLLER Hardware Installation Manual LCS-ENG-M0017,...
  • Page 2 Read user instructions carefully and visually inspect the equipment to become familiar with the device before installing, operating, or maintaining it. Equipment should be installed, operated, serviced, and maintained only by qualified personnel. Sensia assumes no responsibility for consequences arising from the use of this material.
  • Page 3 Sensia. In addition, covers, page headers, custom graphics, icons, and other design elements may be service marks, trademarks, and/or trade names of Sensia and may not be copied, imitated, or used, in whole or in part, without the express prior written permission of Sensia. WARRANTY Product warranty is specified in Sensia Terms and Conditions at the time of purchase.

  • Page 4: Table Of Contents

    Outdoor Use ..............................7 Indoor Use ..............................8 Understanding the INSTRUCT PCP Controller Measurement Units .............. 8 Section 2: Install the INSTRUCT PCP Controller Panel .............. 9 Required Tools and Materials ........................10 Installation Overview ..........................10 Preparing the Panel ........................... 10 Panel Fuses ..............................
  • Page 5 INSTRUCT PCP Intelligent Controller Table of Contents Other Sensors ............................39 Section 7: Complete the INSTRUCT PCP Controller Installation ..........40...

  • Page 6: Section 1: Introduction To This Manual

    INSTRUCT PCP Intelligent Controller Section 1: Introduction to this Manual The INSTRUCT PCP Controller is an advanced pump-off controller for automating a progressing cavity pumped. It is comprised of the following components: A Remote Terminal Unit (RTU) that manages operation of the variable frequency drive (VFD) for electric •...

  • Page 7: System Components

    Section 1: Introduction to this Manual SYSTEM COMPONENTS The INSTRUCT PCP Controller consists of a panel with a SCADA Pack 334E RTU to control the PCP and collect data about its functioning. Any option ordered with the INSTRUCT PCP Controller is delivered wired in the panel.

  • Page 8: Indoor Use

    Verify that all values are entered in the appropriate measurement unit in the INSTRUCT • PCP Controller. Failure to follow these instructions can result in equipment damage. The following table summarizes the imperial measurement units used in the INSTRUCT PCP Controller and provides the metric conversion. Measurement Imperial Measurement Unit...

  • Page 9: Section 2: Install The Instruct Pcp Controller Panel

    Section 2: Install the INSTRUCT PCP Controller Panel Section 2: Install the INSTRUCT PCP Controller Panel The INSTRUCT PCP Controller panel has a pre-wired front panel. It needs to be mounted and connected to the drive and sensors. The INSTRUCT PCP Controller panel provides the following hardware components: •...

  • Page 10: Required Tools And Materials

    Wiring details can be found in the Terminal Block Connection Overview. INSTALLATION OVERVIEW If the INSTRUCT PCP Controller is to be used in an environment with extreme heat, consider installing the panel in a position where it is sheltered from direct sunlight.

  • Page 11: Replacing Fuses

    7. Reconnect power to the panel. USB DRIVE The INSTRUCT PCP Controller copies alarm, event, and log data into CSV files directly to a USB drive connected to the Magelis HMI. A USB drive is not shipped with the INSTRUCT PCP Controller. The INSTRUCT PCP Controller supports USB drives formatted to FAT32 of sizes of 4 GB or greater.

  • Page 12: Section 3: Terminal Block Connection Overview

    Failure to follow these instructions can result in loss of communication. The terminal block, which is included in the INSTRUCT PCP Controller panel, is used to connect the sensors (analog and Modbus) to the controller, provide communication to the VFD or hydraulic drive, and ground the connections.
  • Page 13 INSTRUCT PCP Intelligent Controller Section 3: Terminal Block Connection Overview Signal Type Signal Connection New Panel Connection Point (T: Top, B: Bottom, M: Middle) Analog Output (AO) Generic Drive Speed Signal Generic Drive Speed Return A0 COM Digital Input (DI)

  • Page 14: Section 4: Connect An Electric Drive Or Hydraulic Motor

    INSTRUCT PCP Intelligent Controller Section 4: Connect an Electric Drive or Hydraulic Motor The INSTRUCT PCP Controller can be used with various types of variable frequency drives (VFD) or with a hydraulic motor. This section explains how to install the following: Altivar Drive •...

  • Page 15: Connecting An Altivar Drive

    COM terminal to the SCADAPack 334E RTU ground is recommended. Failure to follow these instructions can result in loss of communication. To connect an Altivar drive to the INSTRUCT PCP Controller: 1. Open the drive cover. 2. Make an RJ45 cable connecting: a.

  • Page 16: Configuring An Altivar 71 Drive

    CONFIGURING AN ALTIVAR 71 DRIVE When configuring Modbus communication with your Altivar drive, some parameters are set using information found in the drive manual, some parameters are set by the INSTRUCT PCP Controller, and other parameters are set using the Graphical Display Terminal (GDT).
  • Page 17 Deceleration • Low speed (set by the INSTRUCT PCP Controller to 0) • High speed (set by the INSTRUCT PCP Controller to Max. frequency) • To configure an Altivar 71 drive: 1. On the GDT set the following parameters. a. DRIVE MENU > 1.4 MOTOR CONTROL:...

  • Page 18: Configuring An Altivar 930 Drive

    CONFIGURING AN ALTIVAR 930 DRIVE When configuring Modbus communication with your Altivar drive, some parameters are set using information found in the drive manual, some parameters are set by the INSTRUCT PCP Controller, and other parameters are set using the Graphical Display Terminal (GDT).
  • Page 19 INSTRUCT PCP Intelligent Controller Section 4: Connect an Electric Drive or Hydraulic Motor To configure an Altivar 930 drive: 1. On the GDT set the following parameters: a. Simply start > Simply start: OPTION VALUE CODE Motor Th Current Per motor nameplate...

  • Page 20: Connecting An Abb Acs550, Acs580, Acs800, Or Acs880

    SCADAPack 334E RTU ground is recommended. Failure to follow these instructions can result in loss of communication. To connect an ABB ACS550, ACS580, ACS800, or ACS880 drive to the INSTRUCT PCP Controller: 1. Open the drive cover.

  • Page 21: Configuring An Abb Acs550 Drive

    INSTRUCT PCP Intelligent Controller Section 4: Connect an Electric Drive or Hydraulic Motor 4. Connect the other end of the cable to COM2 on the SCADAPack 334E RTU. 5. Close the drive cover. 6. Configure Modbus communication with the drive, as described in Configuring an ABB ACS550 Drive, Configuring an ABB ACS800 Drive, or Configuring an ABB ACS880 or ACS580 Drive.

  • Page 22: Configuring An Abb Acs800 Drive

    1 = SAVE 3. To verify that you have a Modbus connection between the SCADAPack 334E RTU and the drive, refer to the INSTRUCT PCP Intelligent Controller Configuration Manual. CONFIGURING AN ABB ACS800 DRIVE Set up the ACS800 prior to commissioning to allow the drive to communicate with the SCADAPack 334E RTU.

  • Page 23: Configuring An Abb Acs880 Or Acs580 Drive

    1 = SAVE 3. To verify that you have a Modbus connection between the SCADAPack 334E RTU and the drive, refer to the INSTRUCT PCP Intelligent Controller Configuration Manual. CONFIGURING AN ABB ACS880 OR ACS580 DRIVE Set up the ABB ACS880 or ACS580 prior to commissioning to allow the drive to communicate with the SCADAPack 334E RTU.
  • Page 24 2. Ensure that you save changes to the permanent memory of the ABB ACS800 or ACS580, go to PARAMETERS > SYSTEM CONTROLS. Parameter Description Value 96.07 PARAMETER SAVE [1] SAVE 3. To verify that you have a Modbus connection between the SCADAPack 334E RTU and the drive, refer to the INSTRUCT PCP Intelligent Controller Configuration Manual.

  • Page 25: Connecting A Toshiba Vf-As1 Drive

    SCADAPack 334E RTU ground is recommended. Failure to follow these instructions can result in loss of communication. To connect a Toshiba VF-AS1 drive to the INSTRUCT PCP Controller: 1. Open the drive cover. 2. Make an RJ45 cable connecting the Toshiba drive pins 3 and 4 to SCADAPack 334E RTU pin 6 (A+), Toshiba drive pins 5 and 6 to SCADAPack 334E RTU pin 5 (B-), and Toshiba drive pins 2 and 8 to SCADAPack 334E RTU ground.

  • Page 26: Configuring A Toshiba Vf-As1 Drive

    Section 4: Connect an Electric Drive or Hydraulic Motor INSTRUCT PCP Intelligent Controller 4. Connect the other end of the cable to COM2 on the SCADAPack 334E RTU. 5. Close the drive cover. 6. Configure Modbus communication with the drive, as described in Configuring a Toshiba VF-AS1 Drive...

  • Page 27: Connecting A Yaskawa Drive

    SCADAPack 334E RTU ground is recommended. Failure to follow these instructions can result in loss of communication. To connect a Yaskawa A1000 drive to the INSTRUCT PCP Controller: 1. Open the drive cover. 2. On the drive, connect jumpers HC and H2 to H1.

  • Page 28: Configuring A Yaskawa Drive

    6. Close the drive cover. 7. Configure Modbus communication with the drive, as described in Configuring a Yaskawa Drive below. To connect a Yaskawa F7 drive to the INSTRUCT PCP Controller: 1. Open the drive cover. 2. On the drive, connect jumpers HC and H2 to H1.

  • Page 29: Connecting An Inovance Md200/Md500 Ac Drive

    Before beginning the procedure below, see the drive manual provided by the manufacturer for information about how to open and close the drive cover. To connect an Inovance MD200/MD500 drive to INSTRUCT PCP Controller: 1. Open the drive cover. 2. Make an RJ45 cable connecting the Inovance MD500 AC drive pin 485+ to SCADAPack 334E RTU pin 6, Inovance MD200/MD500 AC drive pin 485- to SCADAPack 334E RTU pin 5, and Inovance MD200/MD500 AC drive pin GND to SCADAPack 334E RTU pin 4.

  • Page 30: Configuring An Inovance Md200/Md500 Ac Drive

    Section 4: Connect an Electric Drive or Hydraulic Motor INSTRUCT PCP Intelligent Controller A view of the RJ45 connector is shown below. 3. Connect the cable to COM2 on the SCADAPack 334E RTU. 4. Close the drive cover. 5. Configure Modbus communication with the drive, as described in Configuring an Inovance MD200/MD500 AC Drive below.

  • Page 31: Connecting A Vacon Nx Drive

    SCADAPack 334E RTU ground is recommended. Failure to follow these instructions can result in loss of communication. To connect a Vacon drive to the INSTRUCT PCP Controller: 1. Remove the Vacon NX frequency converter cable cover. 2. Open the cover of the control unit.
  • Page 32 Section 4: Connect an Electric Drive or Hydraulic Motor INSTRUCT PCP Intelligent Controller A view of the RJ45 connector is shown in the figure below. 4. Make a sufficiently wide opening for your cable by cutting the grid as wide as necessary.

  • Page 33: Configuring A Vacon Nx Drive

    INSTRUCT PCP Intelligent Controller Section 4: Connect an Electric Drive or Hydraulic Motor 7. Connect the RJ45 cable connector to COM2 on the SCADAPack 334E RTU. 8. Configure the drive, as described in Configuring a Vacon NX Drive below. CONFIGURING A VACON NX DRIVE Set up the Vacon NX drive prior to commissioning to allow the drive to communicate with the SCADAPack 334E RTU.

  • Page 34: Hydraulic Motor

    ESD. Or use the spare analog input to monitor external conditions, such as the temperature of the drive. To connect a hydraulic motor controller to the INSTRUCT PCP Controller, use the figure below as a guideline for connecting the controller to the SCADAPack 334E RTU.

  • Page 35: Electric Generic Drive

    INSTRUCT PCP Intelligent Controller Section 4: Connect an Electric Drive or Hydraulic Motor CAUTION: UNINTENDED EQUIPMENT OPERATION AND PRODUCTION LOSS If over-temperature protection is not present or fails, the drive may overheat. If the drive • overheats, there may be equipment damage or loss of production.

  • Page 36: Section 5: Support The Hoa And Bypass System

    DI-6 is available to support the use of HOA/Bypass switches DI- 6. DI-6 Hand/Bypass Auto Support for the HOA and Bypass system also needs to be enabled on the INSTRUCT PCP Controller Magelis HMI. See the INSTRUCT PCP Intelligent Controller Configuration Manual for more information.

  • Page 37: Section 6: Connect The Sensors

    Section 6: Connect the Sensors Section 6: Connect the Sensors You can configure the INSTRUCT PCP Controller to use surface and downhole sensors. The sensors are connected to a 24 Vdc power supply that is provided by the system. The system is designed for 4...20 mA sensor signals.

  • Page 38: Installing The Analog Sensors On The Terminal Block

    Section 6: Connect the Sensors INSTRUCT PCP Intelligent Controller DANGER: HAZARD OF ELECTRIC SHOCK, EXPLOSION, OR ARC FLASH Before servicing the drive: Follow the applicable lock out/tag out (LOTO) procedure. • • Disconnect all power sources, including external control power.
  • Page 39 5. For Suction Pressure and BH Temperature, enable GEO PSI. See the INSTRUCT PCP Intelligent Controller Configuration Manual for details. If there is a good connection and the INSTRUCT PCP Controller is receiving data, values are displayed on the Sensor & Protection screen.
  • Page 40 DANGER: ELECTRIC SHOCK HAZARD • Read and understand this manual, the INSTRUCT PCP Intelligent Controller Configuration Manual, and the manuals for your variable frequency drive (VFD), motor, and progressing cavity pump before installing or operating the INSTRUCT PCP Controller. Installation, adjustment, repair, and maintenance must be performed by qualified personnel.

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