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SAM Well Manager™ Progressing Cavity Pump

User Manual

PCP Flow & Measurement Control Variable Speed Pump Control Historical Data Display

Lufkin Automation 11375 W. Sam Houston Parkway South, Suite 800 Houston, Texas 77031 Tel: 281.495.1100 Fax: 281.495.6333 www.lufkinautomation.com

SAM Well Manager™ Progressing Cavity Pump
User Manual

INSTRUCTIONS FOR INSTALLATION AND OPERATION OF THE SAM WELL MANAGER PROGRESSING CAVITY PUMP CONTROLLER AND ANALYSIS SYSTEM

Lufkin Automation 11375 W. Sam Houston Parkway South, Suite 800 Houston, Texas 77031 Tel: 281.495.1100 Fax: 281.495.6333 www.lufkinautomation.com

IMPORTANT
READ THIS NOTICE BEFORE USING THIS PRODUCT
Information in this document is subject to change without notice and does not represent a commitment on the part of LUFKIN AUTOMATION. No part of this manual may be reproduced or transmitted in any form or by any means, electronic or mechanical, including photocopying and recording, for any purpose other than the purchaser's personal use without the written permission of LUFKIN AUTOMATION.

SAM Well Manager™ is a trademark of Lufkin Automation, Inc. All other trademarks are the property of their respective owners and are used for explanation purposes only with no intent to infringe. Copyright © 2008 Lufkin Automation, Inc. All rights reserved.

Part No. 099.5028

Limited Warranty
Lufkin Automation warrants the Product it manufactures, including all parts and components thereof to be free from defects in material and workmanship. Lufkin Automation will, at its option, either repair or replace such a Product, subject to the conditions of this Limited Warranty. This Limited Warranty commences on the date of shipment of the Product and shall remain in effect for a period of one year except for shop repairs and service repair exchange (SRE) items, which carry a 90-day warranty. This Limited Warranty does not apply if failure is caused or contributed by any of the following: (1) improper handing, storage or installation (2) abuse, (3) unsuitable application of the product, (4) lack of reasonable and necessary maintenance, (5) repairs made or attempted by other than Lufkin Automation, (6) neglect or accident, (7) damage by wind, freezing, lightning, Act of God or other cause or (8) damage in transit or during installation. This Limited Warranty applies only to Products that have been installed and maintained in strict accordance with the Lufkin Automation installation procedure and to Products that have been connected to the supply voltage marked on the Product. The Limited Warranty does not apply to any Product on which the serial number has been altered, effaced or removed. IMPLIED WARRANTIES, WHEN APPLICABLE, SHALL COMMENCE UPON THE SAME DATE AS THE EXPRESS WARRANTY PROVIDED ABOVE, AND SHALL EXTEND ONLY FOR THE DURATION OF THE EXPRESS WARRANTY. SOME STATES DO NOT ALLOW LIMITATION ON HOW LONG AN IMPLIED WARRANTY LASTS, SO THE ABOVE LIMITATIONS MAY NOT APPLY TO YOU. THE ONLY REMEDY PROVIDED TO YOU UNDER AN APPLICABLE IMPLIED WARRANTY AND THE EXPRESS WARRANTY SHALL BE THE REMEDY PROVIDED UNDER THE EXPRESS WARRANTY, SUBJECT TO THE TERMS AND CONDITIONS CONTAINED THEREIN, LUFKIN AUTOMATION SHALL NOT BE LIABLE FOR INCIDENTAL AND CONSEQUENTIAL LOSS AND DAMAGES UNDER THE EXPRESS WARRANTY AND APPLICABLE IMPLIED WARRANTY, OR CLAIMS FOR NEGLIEGENCE, EXCEPT TO THE EXTENT THAT THIS LIMITATION IS FOUND TO BE UNENFORCEABLE UNDER APPLICABLE STATE LAW. SOME STATES DO NOT ALLOW THE EXCLUSION OR LIMITATION OF INCIDENTAL OR CONSEQUENTIAL DAMAGES SO THE ABOVE LIMITATION OR EXCLUSION MAY NOT APPLY TO YOU. Lufkin Automation will repair or replace, at its option, any Product which is found to be defective in material or workmanship. The Limited Warranty does not cover the labor costs of repair or replacement of the unit or part unless done at our factory. If you elect to ship the part or Product to Lufkin Automation, authorization to return the Product to the factory must first be obtained from Lufkin Automation and shipping instructions received from Lufkin Automation must be followed. Lufkin Automation is not responsible for the cost of removal of the Product or its components, damage due to removal or any other expenses incurred in shipping the Product or parts to or from the factory or for the installation of the repaired or replacement unit. The owner must bear these expenses and should insure the shipment against loss or damage in transit. This Limited Warranty gives the owner specific legal rights and the owner may also have other rights, which vary from State to State. Lufkin Automation does not authorize any person to create for it, any other obligations of liability in connection with its Product.

Revision Record

SAM Well Manager™ — Progressing Cavity Pump User Manual
Date 1/18/08 Revision No. 1.00 Section All sections Description First release

Issue Date: 1/18/08

Revision 1.00

Safety Procedures
• Park vehicles upwind of the wellhead. Stand upwind when installing or dismantling equipment.
WARNING: Injection fluid lines operate at high pressure. If breaking loose flange

connections or opening valves, use all proper energy isolation procedures and wear proper personal protection equipment.
WARNING: Hydrogen sulfide gas (H2S) may be present in high concentrations in

injection fluids and around injection wellheads. Be sure to have proper H2S detection equipment on your person and practice all recommended safety precautions when working around injection wellheads. • Before leaving the location, return all wellhead equipment to their normal operating positions.

Issue Date: 1/19/08

Revision 1.00

.............. 3-3 Section 4: Parts Lists 4...................1 3......................................4 3..............................................4.............................5 Shorthand Method for Interface Menu Selection..............2................................. 3-1 Internal Component Layout .......................................................4 SAM PCP Controller................2 SAM PCP Controllers ............................................ 4-1 Revision 1.....2.... 3-2 Environmental Operating Range....4 Control Parameter Programming ........3 Menu Option Selection ......................................... 2-8 2................... 3-2 120-VAC System ........................4.................. 1-4 Technical Support .............................7 Enclosure..................................1 Entering Data and Executing Commands .................4.......1 Operator Interface Keypad..................................................2 Manual Overview...................... 2-4 2......................................2 Displayed Messages.. 1-3 1...6 Notes ................... 2-8 2............Table of Contents Section 1: Introduction to this Manual 1..................3 Section 2: Description of the SAM Progressing Cavity Pump Controller System 2.1 2...2 LCD Graphics Display............................................................5 Section 3: Technical Specifications 3........... 2-4 Terminal Blocks ..................................2.............. 1-2 1................. 1-3 1.............................................................. 2-5 2.........................................1 1.........00 vii Issue Date: 1/18/08 ....................... 4-1 Spare Parts......................................4 Procedural Steps... 1-3 1................................................ 3-3 Serial Communications .........................3 Section Levels .................... 2-8 Modbus Master Feature..........4....2 2...................... 1-2 1..............5 3...........2.................................................... 1-4 1...........................................................................................2............6 3.................2 3..................................................................................................................................... 1-3 1... 1-1 How to Use this Manual....... 2-4 Controller Operator Interface .....1 4............3 2.3 3. 2-1 12 Volt Power Supplies................. 3-3 Microprocessor and Memory ........................................ 2-5 2.................................................................................................................................... 3-3 Brownout/Blackout Protection...................2...

4 4.......................1 Wiring Specifications and Recommended Tools.......................................... 7-23 Configuring Special Features ...........................3.................2 7.................................................................... 5-6 5...............................2................................3 8......................3............... 6-3 Radio Communications Port ............SAM Well Manager™ — Progressing Cavity Pump User Manual 4.............................4 7................................................... 5-7 PCP Controller System Wiring ............................. 5-8 5.................. 6-9 VSD Configuration ............2...... 8-5 Communication Parameters Configuration ...................3. 5-12 5............5 7............6 4.............................................................................. 8-4 Setting the Controller Date and Time ..........................................4 viii Overview of SAM PCP Controller Parameter Programming ...........4 Wiring the Polished Rod Hall-Effect Transducer ...............................7 SAM PCP Optional Hardware ............................................................................................................. 6-4 RS-485 Communication Expansion Board .............. 7-25 Section 8: SAM Controller Programming 8... 5-14 5...................................3 6.................................. 7-1 Configuring Control Parameters ...................5 6................................ 5-17 Performing Power-Up Voltage Checks................3................. 4-2 How to Order Parts............... 6-2 4–20 MA Transmitters .............. 4-2 Documentation ......................2 Installing the Stepdown Transformer.................................3................... 7-19 Configuring Production and Motor Information. 5-2 PCP Controller System Installation.....................2 6................................... 7-13 Configuring End Devices ..6 Overview of PCP Parameter Programming......... 5-4 5.. 5-2 5.......2 Grounding the System.....................3 4.........................................................2 8...........................3 5..................... 6-1 Battery Disconnect Jumper Pins ...........3 7..... 4-3 Section 5: System Installation and Wiring 5....................6 6.................5 4...1 6...................3 Mounting the Controller............. 6-10 Section 7: PCP Parameter Programming 7....3 Wiring the Stepdown Transformer.. 4-2 SAM PCP Optional Hardware ............... 5-18 5...5 Wiring the Motor Control Relay.. 5-6 5...5 Installing the Rod RPM Hall-Effect Transducer...........4 6....1 8............................ 8-7 Revision 1.....................................................00 Issue Date: 1/18/08 ............................................................ 5-10 5................2 Overview of the System Installation ..... 5-5 5..........................2.....7 Overview of the Hardware Configuration...4 Installing Flow Rate Meters and Process Variable Transmitters ..2.......................................1 5....................... 5-16 5..........1 7......................... 8-2 RTU Level Menu ........... 6-6 Turbine Meter Board...................................1 Installing the Mounting Post or Pedestal and Ground Rod... 7-3 Configuring Parameter Violations ...........................2.... 4-2 Operator Interface Systems .................4 Section 6: Hardware Configuration 6...........................

.................................................1 Programming a Logic Expression..............................................10...10.. 8-73 8..4 Configuring Auxiliary Accumulators ................... 8-99 Section 9: Status Screens 9.... 8-14 8.......14........... 8-68 8............. 8-22 8.. 8-54 8......7 8........4. 8-65 8.12................ 8-12 Modbus Master and Slave Device Configuration ... 9-9 9.......................................................... 8-37 8..10.........................2 Displaying AUX Analog Input Status ............ 9-11 9............. 8-31 Setting Gauge Off Time and Peak Energy Management ................ 8-33 Auxiliary I/O Configuration...........10........14........................................................................ 9-12 Revision 1...........4...... 8-8 8.............................3 Clearing the Logic Expression State....17 8............4 Enabling and Disabling Logic Expressions ......6 8..............10 8.............................................. 8-30 Configuring the Default Screen..... 8-15 8...........4......... 9-2 Displaying the Status of PCP Parameters .................2.....5.............. 8-48 Logic Expressions ...5.3 Configuring Register Calculations.......11.....2 Configuring Auxiliary Analog Outputs . 9-10 9.....................................3 Configuring Auxiliary Digital Inputs and Outputs .............2 9.....1 Configuring Communication Parameters................................ 9-7 Auxiliary Functions............5..............................................4 Configuring the Communication Expansion Port .................................16 8.......11....... 8-24 8........... 8-41 8................................ 8-79 Register Configuration .... 9-8 9........ 8-97 Configuring VSD Parameters........................................................ 8-36 8.2 Configuring Modbus Transmission Mode .......1 Configuring Auxiliary Analog Inputs .................................... 8-28 Resetting Parameters to Factory-Default Values .11 8...............9 8... 9-2 9.12..............5 8. 8-88 Configuring and Enabling/Disabling HOA.................2 Writing Register Values to Registers and the Slave Device ........ 8-53 8........1 Current PCP Operating Status..........3 Specifying a Polling Routine Rate ........4 Enabling and Disabling AGA 3 Calculations .............12 8.................................1 9...... 8-80 8...........1 Configuring Slave Device Parameters ...............4...1 Configuring a Register Alarm..................... 8-62 8.......4 Overview of the Status Screens...5...11.. 8-70 8......14 8..........................................................12..............8 8...... 8-79 8............4...............14..... 8-83 8........................ 8-26 Changing Passwords ....... 8-78 Custody Transfer .......................3 9...........................2 Configuring a Register Log............... 8-94 Configuring Alarm (Coil) Tracking ............................ 9-2 Displaying the Status of SAM PCP Controller Parameters ....3 Displaying AUX Analog Output Status........... 8-45 8.............................................1 Configuring AGA 3 Parameters....................00 ix Issue Date: 1/18/08 .......................12................ 8-67 AGA 3 Parameter Configuration.......13 8.......3 Configuring Temperature and Pressure ..11......................4..2 Programming a Logic Expression Action . 8-75 8................................1 Auxiliary Input Status Screens.............Table of Contents 8..................................................2 Configuring NX-19 Design Parameters .............4 Displaying Digital Input Status......15 8.....

............................................5......................................................................................................................1 Overview of the System Tools ........... 10-12 10....... 10-5 10..........................1 Overview of the Historical Data Features ........4..........................................................4 60 Day Historical Data................3 Main Board I/O Diagnostics ................6 AGA 3 Data......... 10-13 10.......................................... 10-9 10. 10-10 10.............1 Register Log ...... 10-8 10..............................................1 Displaying Register Digital Output Status.5...4...9 9..............................8 9...................................................... 9-23 Displaying Alarm Tracking Status........5 SAM Data. 10-7 10...............2 Alarm Log ..... 9-28 Section 10: Historical Data 10........ 10-8 10...5 Displaying AUX Accumulator Status...................... 14-2 14.......1 24 Hour AGA 3 Gas Flow .....1 Starting Period.............................. 9-20 9.................7.............. 10-4 10...............5................. 9-21 9.....................................3 PCP Data ............................3....................2 Displaying Register Calculations Status ............................... 14-3 x Revision 1........ 10-2 10...... 10-7 10................................................2 60 Day AGA 3 Gas Flow ... 9-16 9................4.. 9-22 Displaying Alarm/Alert Status ........ 9-15 9.............................................................................................8 Displaying Logic Expression Status .. 10-8 10..5 60 Day Pump Efficiency ...................4........4..... 10-7 10.....................................................5.........6 Displaying AUX I/O Boards Status ..4..................................2 Maintenance Log............7 Displaying AGA 3 Status..... 9-14 9.........................................4 60 Day Daily Production....................... 10-8 10.........6... 9-24 Displaying the Status for a Modbus Master Slave Device.......................................2 Normal Operation Period ..5 9................................................................ 14-1 14.......... 10-13 10.......... 10-14 Section 11: System Starting and Stopping Section 12: Reset Malfunctions Section 13: Firmware Versions Section 14: System Tools 14...................................................... 9-26 VSD Diagnostics ......7 9....7................................ 10-6 10..3 60 Day Peak Torque.....................................2 60 Day Alarm Tracking ....................... 10-11 10.......................................6 9...............................00 Issue Date: 1/18/08 .......................................................1 60 Day Peak Speed Measured........... 10-11 10..........3 Power Off Delay Period .... 10-8 10........... 10-7 10..........................................4..............2 60 Day Peak Speed Output ....................4.........SAM Well Manager™ — Progressing Cavity Pump User Manual 9.................................................................6.....4.............3.. 9-19 Register Functions...3.......................... 10-9 10..............................2 Plotting Data Menu ...................7 Events ...................................................................3.4 Stopping Period.......................1 Event Log ...................

4 Using the Quick Start Feature ....................................00 xi ..............................................2 Specifying Communication Parameters in the Laptop Computer ............................................................. 16-7 16.2 Methods for Navigating the Quick Start Programming Screens ........................................1 Quick Start Programming Processes...............................2................ 16-2 16....................... 14-6 14......................... 14-8 14.......2 Main Board Manual DIO Diagnostics ............ 16-20 Appendix A: Well State List A.......................................................................1 Main Board I/O Status ...............4 Specifying Communications Between the Controller and Laptop.....2........................................................4..................................5 Keypad ..............................3 Resetting Parameters to Factory-Default Values ...4 Message Window Section ......3 Downtime and Malfunction Well States ... 16-13 16......................1 Software Overview........................................ 16-3 16. 15-4 Section 16: Sam Flash Upgrade Utility Software 16................................................................. 16-11 16.............9 Upgrading Application Firmware .......................................................... 16-5 16...............4... 14-7 14.................................................................2............................ 16-9 16.................................. A-4 Issue Date: 1/18/08 Revision 1... 15-3 15........... 15-1 15......................................1 RX/TX Messages .........4 Communication Diagnostics ........5 Command Buttons..1 Specifying the Communication Baud Rate in the SAM PCP Controller ...... 14-5 14..................................1 File To Upload Section ....... 16-16 16... 16-14 16.......4.......................... 16-2 16........Table of Contents 14.................. 16-7 16.......................................................... A-2 A.3 Installing the Software on a Laptop Computer .............................1 PCP Quick Start ..........3....................2 Starting the Quick Start Process.......................2 Sam Flash Upgrade Utility Screen .......... 15-2 15.......10 Disconnecting Communications Between the Controller and Laptop Computer........................................................ A-2 A.....2 Normal Operation Well States ................................... 14-4 14.........7 Saving the Controller Configuration to a File......................................... 16-8 16.............................1....................................2 MB Register Map Check............... 16-12 16...................................................................8 Uploading a Saved Configuration File into the SAM PCP Controller ....................................................5 Connecting the Controller to the Laptop Computer....... 15-3 15......... 16-18 16................................................. 16-14 16.................2....................1. 15-2 15... 16-10 16.............3..2 Comm Parameters Section .1 Overview of Well States ..............................6 Establishing Communications Between the Controller and Laptop Computer...................4.........3 Status Section.... 14-9 Section 15: Quick Programming Using the Quick Start Feature 15...................2.........................

............4 Malfunction Run Well States .................. A-8 Quick-Start Well States.....................3........2......B-8 B..........1..2........................6 Logic Expression Violation Well States ..3 NX-19 Formulas........6 Real Gas Relative Density (Specific Gravity) Factor – Fgr ................4 A..............1................................................................1 Basic Orifice Factor — Fb ...........................2...... A-7 HOA Well States ............. A-5 A....3.....5 Flowing Temperature Factor — Ftf ......4 Temperature Base Factor — Ftb.......................................3 Pressure Base Factor — Fpb ......1..........................B-13 B.....B-5 B....B-12 B..........B-15 B..............................5 A......14 Supercompressibility Factor — Fpv........B-4 B...........2..................B-2 B... A-9 Monitor Mode Well States ......3.......................................6 A.................2............................B-10 B.....1.................11 A..............................10 Pressure Base Factor — Fpb ...................... A-11 Appendix B: AGA 3 Definitions B.. A-6 A....................8 Miscellaneous Downtime States .....................................................3...........1............6 Orifice Calculation Factor — Fc .......... A-10 Sand Blowout Well States..................................1..1.........1................2 Reynolds Number Factor — Fr .....................7 Malfunction ...................B-4 B........................B-11 B..................................B-15 B.....3...........B-9 B............................7 Reynolds Number — ReD ..................................1.................................................................. A-10 Power Fail Lockout .............................................................................................................................................1 AGA-3 1992 Tap Type Factors Method ...............................5 Velocity Approach Factor — Ev ..............3 Violation Downtime Well States .....00 Issue Date: 1/18/08 ..........................1......................................................B-16 B..............B-12 B......7 Supercompressibility Factor — Fpv.........2 Violation Run Well States.........SAM Well Manager™ — Progressing Cavity Pump User Manual A..5 Malfunction Shutdown Well States .........................Drive Fault .....B-9 B.......B-10 B.8 A.............4 Numeric Conversion Factor — Fn ...1........1 Violation Conditions and Types ...1..............2 Orifice Flow Constant — C’ .............3.....1 AGA 3 Formulas . A-6 A........................................................2 Pressure Measured at Upstream Tap Pf1 .................................................. A-8 Host Mode Well States.............3 Orifice Flow Constant C’ ..........................................15 AGA-3 1985 Formula — Pipe Taps ................................................... A-7 A... A-5 A............................9 A...........B-6 B.......10 A..................... A-4 A......... A-8 Timed Mode Well States.................8 Orifice Slope Factor – Fsl ........11 Temperature Base Factor — Ftb......13 Real Gas Relative Density (Specific Gravity) Factor — Fgr .......B-9 B..............12 A.............................3...............B-8 B.1.............. A-10 Error Well States ..3................................B-5 B................B-15 B........................................B-16 xii Revision 1..........1........ A-6 A......................................7 A.1.........................B-7 B........B-16 B.B-2 B.............. A-10 Speed Control Well States......................................................2......2.12 Flowing Temperature Factor — Ftf ..........................9 Expansion Factor – Y.........

..5 Base Compressibility — Zb........1 Adjusted Pressure And Temperature Calculations .........B-24 B......2 Pressure and Temperature Correlation Parameters......B-21 B..B-21 B...................3....................2 Water Manometer Correction Factor — Fam .....................7 Mercury Manometer Temperature Factor — Fhgt .......B-26 Index Issue Date: 1/18/08 Revision 1...............4 Water Manometer Temperature Correction Factor — Fwt........6 Correction for Gas Column in Mercury Manometer Instruments – Fhgm ....B-17 B......................................3........4.5 Local Gravitational Correction Factor For Weight Standards — Fpwl ...............4 Calibration Factors .................B-22 B...4................4 Flowing Compressibility — Zf ............B-24 B.................4.................B-23 B.........B-21 B........3 NX-19 Natural Gas Regions and E Equations ...........00 xiii ...........................B-22 B.................4.........Table of Contents B.....3..................B-25 B.........3....4........3 Local Gravitational Correction Factor For U-Tube Manonmeters — Fwl ......1 Orifice Thermal Expansion Factor — Fa .........................................B-19 B....................4............B-19 B............3........4................

...............................2........................................................................4 Procedural Steps .................................................... 1.................... The topics covered in this section include: 1............ 1-3 1.............. 1-2 1.......... 1-1 How to Use this Manual............... installation procedures.........6 Notes.................................2 Manual Overview........3 The Lufkin Automation SAM Well Manager™ for PCP Control can perform a wide range of operations.................................. Every attempt is made to provide enough information and explain each procedure clearly so that you can easily and quickly learn how to operate this controller.00 1-1 ....1 Manual Overview The SAM Well Manager™ — Progressing Cavity Pump User Manual is designed to provide you with information about the SAM PCP Controller hardware specifications........... Please take the time to understand how this manual is organized..............................2... All information in this manual falls into three categories......... 1-3 1... 1-4 Technical Support ......2........................2 Displayed Messages ............ 1-3 1.... Issue Date: 1/18/08 Revision 1.. 1-3 1........1 1....... and system operations.....2............ 1-2 1....................... 1-4 1. and how to use this manual before reading how to install and operate the controller.....................Section 1 Introduction to this Manual This section explains the topics covered in this manual and how to use this manual.2.......................5 Shorthand Method for Interface Menu Selection ............................2.1 Entering Data and Executing Commands.........3 Section Levels ......

how to program the SAM PCP Controller. Typographical conventions are used to represent keyboard functions and to highlight important operations. Refer to the components’ respective manuals for specific information about these products. and are surrounded with the less-than symbol (<) and the greater-than symbol (>).2. 1. and how to use the SAM PCP Controller analysis capabilities. if you are instructed to press the ENTER key.2 How to Use this Manual This section explains the typographical conventions used throughout this manual. it is explained to you as: Press <ENTER>. For example.00 Issue Date: 1/18/08 . 1. Other hardware and software components may be used in conjunction with the SAM PCP Controller. A breakdown of the topics covered is: • Typographical conventions used • How to obtain technical support when needed • Description of SAM PCP Controller system • Description of the SAM PCP Controller system components • Technical specifications • Parts lists Category Two explains how to install the SAM PCP Controller and its components. preceded by the word “press”. A breakdown of the topics covered is: • Installing and Wiring the SAM PCP Controller system • Programming and operating the SAM PCP Controller Category Three provides you with an index for quick and easy access to specific information you need.SAM Well Manager™ — Progressing Cavity Pump User Manual Category One introduces you to this manual and to the SAM PCP Controller.1 Entering Data and Executing Commands All keys used to execute commands are presented in bold type. 1-2 Revision 1.

4 Procedural Steps A procedure that must be followed in a specific order is numbered similar to the following: 1. From the MAIN Menu screen.X First Level X. To the right of many paragraphs. From the SAM Configuration Menu screen.Section 1: Introduction to this Manual 1. For example. select option 3.2. select option 3. Perform step two second. Perform step three third. CONFIGURATION. 3.2.00 1-3 . 2. uppercase type: ALARM ALERT 1.X Second Level Third Level 1. select option 1 RTU LEVEL. From the Configuration Menu screen. Perform step one first.X.3 Section Levels Each chapter has up to three section levels. 1.2. 2.2 Displayed Messages All messages that are displayed on the optional LED graphics display are represented in bold. Issue Date: 1/18/08 Revision 1. The three section level headings are presented as: X. you will find a box displaying “SAM” (shorthand access method) and below it numbers separated with a forward slash (/). 3. SAM CONFIGURATION.5 Shorthand Method for Interface Menu Selection A shorthand access method for selecting menu options using the SAM PCP Controller interface is provided throughout this manual to quickly explain the procedure required to get to your desired operation. the box to the right of this paragraph represents the following: SAM 3/3/1 1.2.

2. please have all information that applies to your problem readily available. Write down or print out any onscreen messages you get when the problem occurs. 1-4 Revision 1. Central Time.M. For example: Note: If another screen is displayed.6 Notes Notes draw your attention to important messages within this manual. To help us answer your question as quickly as possible.com. Monday through Friday. between 8:00 A. and 5:00 P. press <MENU> to instantly return to the Main Menu screen. You can also e-mail us at lufkinautomationsupport@lufkin.. 1.00 Issue Date: 1/18/08 .3 Technical Support Assistance is available when needed from Lufkin Automation Technical Support Services at (281) 495-1100.M. and have your manual with you when you call.SAM Well Manager™ — Progressing Cavity Pump User Manual 1.

.... Issue Date 1/18/08 Revision 1. 2-5 2......................2 LCD Graphics Display ............ 2-5 2...... The topics covered in this section include: 2...4 Control Parameter Programming.5 Note: Technical specifications for the SAM PCP Controller are provided in section 3..........................4..................................3 2..........4......... 2-4 Controller Operator Interface ...........4 SAM PCP Controller.... 2-1 12 Volt Power Supplies...............2 2.......................................................3 Menu Option Selection.............” 2.. 2-8 2.............. 2-4 Terminal Blocks . “Technical Specifications...............Section 2 Description of the SAM Progressing Cavity Pump Controller System This section describes the major components making up the SAM PCP Controller... 2-8 Modbus Master Feature....................... 2-8 2......................1 SAM PCP Controller Lufkin Automation’s SAM Progressing Cavity Pump (PCP) Controller complements the field-proven electronics hardware of the SAM Well Manager™ Rod Pump Control unit with new application firmware for monitoring and controlling the PCP activity at the wellhead...............................................................1 Operator Interface Keypad ......................00 2-1 ......................................... 2-4 2....4.........................................................1 2................................4..................................

As long as sufficient fluid is available at the pump intake to completely fill the pump cavities.SAM Well Manager™ — Progressing Cavity Pump User Manual The SAM PCP Controller is a pre-programmed device mounted at the wellsite that gathers. and then establishes a speed/rate relationship. The SAM PCP Controller begins an operating cycle at a user-defined startup speed. Secondary Control Algorithms The SAM PCP Controller also has secondary control algorithms that monitor the following: • Torque signal from the variable speed drive • Polished rod RPM as indicated by a Hall-Effect transducer sensing a magnet mounted on the polished rod • Low/high fluid rate limits 2-2 Revision 1.00 Issue Date 1/18/08 . Primary Speed Control Algorithm The SAM PCP Controller works in conjunction with a variable speed drive (VSD) to optimize fluid production while protecting the pump. processes. a linear relationship occurs between fluid production and pump speed. The control algorithm continues to test the optimum production rate by repeating the speed increase/decrease sequence. stores. The surface fluid production rate at that speed is measured over a user-defined sampling period after a programmed settling time. The controller continues to increase the pump speed in user-defined steps. the SAM PCP Controller starts to slow the speed by steps until a reduction in fluid production rate is measured. The SAM PCP Controller then increases the pump speed by a step and measures the fluid production rate at this new speed. The patented control algorithm varies the speed of the pump in steps while measuring the amount of fluid production from the pump. and analyzes data obtained from transmitters and meters. The data collected from these input devices is used to monitor and control pump operation to maximize fluid production efficiency and protect the pump. At a point when a step increase in speed does not produce the proportional step increase in fluid production rate. measures production rate at each step after the settling time.

Historical data can be displayed graphically in a format easy to understand on the LCD display that is included as part of the SAM PCP Controller.500 one-minute samples are maintained for process variables that include: • Production rate • Speed output to the VSD • Actual measured speed of the polished rod • Torque signals from the VSD • Pump efficiency A 60-day record of production totals for the day is also stored in the SAM PCP Controller. If the monitored variable continues to be in an alarm condition when a programmed minimum speed is reached.Section 2: Description of the SAM Progressing Cavity Pump Controller System All secondary control features slow the pump when one or more of these set point limits is violated.00 2-3 . Communication Protocol The SAM PCP Controller uses Modbus-based communications protocol. Production Measurement Options Production measurement options supported by the SAM PCP Controller include the following: • An accumulator for dry contact inputs pulses • An analog input from a flow meter • A differential pressure signal from a wedge meter run Historical Records Historical records of the previous 1. or it can be displayed on a portable laptop computer. and also offers the advantages of the Extended Lufkin Automation Modbus (ELAM) protocol for SCADA software packages that goes beyond the limitations of conventional Modbus. the SAM PCP Controller will stop the pump to prevent damage to the pumping equipment. Issue Date 1/18/08 Revision 1.

3 Terminal Blocks Terminal blocks are provided for field termination of all transmitter leads. 50/60 Hz prmary power. and provides you with a single source for rod pump. and progressing cavity pump automation. 2-4 Revision 1.SAM Well Manager™ — Progressing Cavity Pump User Manual All of the configuration. The terminal blocks are front-access compression-clip type.00 Issue Date 1/18/08 .2 12 Volt Power Supplies The standard SAM PCP Controller system is powered by 85 – 264 VAC.4 Controller Operator Interface Several parameters need to be defined to program the SAM PCP Controller. This operator interface is menu driven. and historical data available at the local keypad interface are also available via data telemetry link to SCADA software. and access and display current and historical data instead of using the SamScreen Terminal emulator program that runs on a laptop computer. Common Hardware Platform The SAM PCP Controller operates on the Lufkin Automation SAM Well Manager hardware platform. 2. simplifies training. Using this common platform reduces the number of spare parts that must be kept on hand. which consists of a full-function LCD graphics display and 20-key keypad. Programming is done through the local operator interface. The field leads do not require crimp lugs. It allows you at the wellsite to program and calibrate the SAM PCP Controller. including individual shield termination points. 2. status. 2. A 12-VDC power supply is included to provide the DC voltage required by the electronics. injection well.

Section 2: Description of the SAM Progressing Cavity Pump Controller System 2. Operator Interface Keypad Below is a description about each key’s function on the keypad.2 LCD Graphics Display The SAM PCP Controller user interface is menu-driven. Displays the Main Menu screen. ENTER EDIT NEXT EXIT MENU DELETE 2. The keypad is not absolutely required for programming and calibration. Issue Date 1/18/08 Revision 1. All menus and screens are displayed in the LCD graphics display. because programming can also be done using the SamScreen Terminal emulator interface program installed in your laptop computer.1 Operator Interface Keypad The 20-key operator interface keypad (Figure 2-1) is mounted in the SAM PCP Controller enclosure. In some cases. Also scrolls available options in several programming screen fields. It allows you at the wellsite to program and calibrate the controller and access and display current and historical data without using a laptop computer. Confirms a correct entry when changing programming data. It is the quickest and easiest way to program the SAM PCP Controller. data is updated. <NEXT> is used to execute a control function. Changes set point position or cursor location in the direction specified by the arrow key.00 2-5 . Voids an incorrect numerical entry if <ENTER> is not pressed.4. In those cases.4. Key 1—0 ↑↓←→ Function Selects an option from a menu screen or enters new data in fields on the programming screens. Selects the next screen for display. Cancels any changes made on the current screen if <ENTER> is not pressed. Figure 2-1. Displays the previously displayed menu. screen prompts are provided. When this key is pressed. Edit mode is selected on a per-field basis. Selects the edit mode so that programming changes can be made.

SAM Well Manager™ — Progressing Cavity Pump User Manual The Main Menu screen (Figure 2-2) is the first screen that appears after the SAM PCP Controller is turned on and the initialization process is completed. Figure 2-2. The menu map (Figure 2-3) shows all programming options available through the SAM PCP Controller operator interface. 2-6 Revision 1. This screen also appears any time after <MENU> is pressed on the operator interface keypad.00 Issue Date 1/18/08 . Main Menu Screen Note: The PCP Status screen (Figure 8-1) automatically appears when a key is not pressed for eight minutes.

00 2-7 . SAM PCP Controller Menu Map Issue Date 1/18/08 Revision 1.Section 2: Description of the SAM Progressing Cavity Pump Controller System Figure 2-3.

• Return up one level in the menu tree by pressing <EXIT>. • Press <↑> and <↓> to highlight the desired option shown on the LCD display and then press <ENTER>. 2. you can do either of the following to exit from the screen: • Return to the Main Menu screen by pressing <MENU>.4.3 Menu Option Selection Two methods are available for selecting an option when a menu screen displays. This feature allows a single on-location radio in the SAM PCP Controller to read data from and write data to any of up to 10 Modbusprotocol RTUs at the wellsite.4.SAM Well Manager™ — Progressing Cavity Pump User Manual 2. use the number keys to enter the desired value. press <EDIT>. 2. When the data field displays the desired number. After the data field displays the correct entry.5 Modbus Master Feature The SAM PCP Controller can read and store data from other Modbus RTUs on location. After all parameters are correctly programmed on the screen. • Press the number key on the keypad that represents the desired option shown on the LCD display. press <↑> or <↓> to highlight the desired parameter field. if you are working with the Clock Calendar Configuration screen. and then do one of the following: • When the parameter is a numerical entry.00 Issue Date 1/18/08 . This data is stored in the SAM PCP Controller Modbus register map. 2-8 Revision 1. • When the data field requires a text entry. press <ENTER> to complete the programming step. press <↑> and <↓> to scroll through the available options. press <ENTER> to complete the programming step. To program a parameter. and can be read on the local LCD and/or with host SCADA software.4 Control Parameter Programming Control parameters are edited (programmed) on a data field basis. For example. pressing <EXIT> returns you to the RTU Level Menu screen.

and a two-wire or four-wire RS-485 data cable network must be installed to connect the SAM PCP Controller master with each slave device. The write function requires a manual command to execute. The Modbus Master feature can be programmed to poll and collect data from a maximum of 10 slave devices. Desired values can be programmed for up to 25 registers in each slave device. The SAM PCP control algorithm uses the Modbus Master feature to read data from and write commands to compatible models of variable speed drives. The SAM PCP Controller can also be configured to write data to the slave devices. An optional RS-485 expansion communication board must be added to the SAM PCP Controller.00 2-9 .Section 2: Description of the SAM Progressing Cavity Pump Controller System Slave RTUs must be compatible with the Modbus RTU protocol and have an RS-485 communication port available. Data is polled automatically at a programmable interval. Up to 125 data registers can be read from each configured slave device. Issue Date 1/18/08 Revision 1.

.4 3.49 inch (39. The topics covered in this section include: 3................. 15..34 inch (21..................................Section 3 Technical Specifications This section lists the specifications for the SAM PCP Controller and the transducers available for use with it........... hinged door with pad lockable hasp.....................5 3............. 3-3 Serial Communications ....... 3-4 3.....3 3. operator interface........................ 3-3 Microprocessor and Memory .................... 3-3 120-VAC System ..34 cm) 13..................1 Enclosure Enclosure Type: Height: Width: Depth: Weight: NEMA4X fiberglass enclosure..................................1 3.... 3-2 Environmental Operating Range....................................00 3-1 ............................................................................. (10 kg).................................................20 cm) 8.................... including controller.........6 3....7 Enclosure...................18 cm) Approximately 22 lbs........................ 3-1 Internal Component Layout .. and data radio Issue Date 1/18/08 Revision 1.....86 inch (35..........2 3. 3-3 Brownout/Blackout Protection...

3 Environmental Operating Range Operating Temperature: Humidity: Circuit Boards: -40° to +140° F (-40° to +60° C) LCD: -4o to +140o F ( -20o to +60o C) 95% non-condensing 3-2 Revision 1. The LCD can be read from the front of the hinged panel through a panel cutout. one of which is used as a speed control signal to the VFD/VSD. • A 20-key membrane keypad with an integral contrast adjust potentiometer is mounted on the front of the hinged front panel and connects to the motherboard with a ribbon cable. • An expansion board with isolated power and signal lines plugs onto the motherboard. • A 320 × 240 liquid crystal display (LCD) is mounted on the backside of the hinged front panel underneath the motherboard. Optional signal cables connect the RJ12 radio port on the motherboard to the radio. 3.2 Internal Component Layout The SAM PCP Controller is modular in design with surface-mount components on all circuit board assemblies.00 Issue Date 1/18/08 . Two analog outputs are included. including the CPU and all memory devices plus eight discrete input/output points and two pulse inputs. • Back panel space is provided for mounting a radio or other data transmission device. is mounted on the backside of a hinged front panel.0221) is available and must be used if production is to be measured using a direct connection to a turbine meter pick-up.0 VDC) and mounting hole patterns for popular radios are included. The LCD is connected to the motherboard by a 20-pin header. This module includes amplifiers and analog-to-digital conversion circuitry for analog inputs that may also be used as discrete inputs. • An optional Turbine Meter board (P/N 060. SAM PCP Controller units include the following “modules” or components: • A motherboard.SAM Well Manager™ — Progressing Cavity Pump User Manual 3. Power supply terminals (12. The motherboard includes two communication port connections.

the second driver becomes the active driver and any activity on the RJ12 radio port is ignored.8 VDC output.4 120-VAC System Primary power to the switching power supply: Power supply: 85 to 264 VAC.Section 3: Technical Specifications 3. 3. 50/60 Hz. 38400.7 Serial Communications The SAM PCP Controller motherboard has two RS-232 ports. The second driver is connected to a DB-9 connector designated as the laptop port. 3. When a laptop computer is plugged in. 9600. 13. or 115200 baud. 19200. • Standard SAM PCP Controller units include 4 megabytes of Flash ROM.5 Brownout/Blackout Protection A watchdog circuit initiates an orderly shutdown of the microprocessor and memory circuits if the DC input voltage level to the motherboard falls below approximately 10. Automatic lockout features protect memory read/write circuits when a power loss is detected.5 VDC. Only one of the two ports can be active at a particular time.6 Microprocessor and Memory • Coldfire XCF/MCF5307 microprocessor operated at 33 MHz. the SAM PCP Controller system automatically reinitializes. 2400. 3. • 512 Kbytes of battery-backed SRAM. 4800. Flash ROM can be expanded up to 32 megabytes.00 3-3 . rated for 42 Watts continuous. 1200. • 4 megabytes of SDRAM for use as general operating memory. Issue Date 1/18/08 Revision 1. The lithium batteries used will provide data retention for approximately one year without operating power. When proper voltage is re-applied. The default active driver is connected to an RJ12 connector designated as the radio port. and SAM PCP Controller interrogation software raises the DTR line. The two serial ports on the motherboard are separately programmable for a baud rate of 300.

00 Issue Date 1/18/08 . Ask your Lufkin Automation representative for more information about the ELAM protocol.SAM Well Manager™ — Progressing Cavity Pump User Manual The RJ12 radio port has programmable time delays for key up and key down.295 RTUs on the same communication channel. Extended Lufkin Automation Modbus (ELAM) protocol is used for RTU addresses of 248 and above. and has a multiple instruction read/write capability. no parity. Communication protocol is Modbus RTU with a data format of 8 data bits. ELAM supports up to 2. and two stop bits. allows much larger data block sizes to be transmitted. 3-4 Revision 1.

... 4-2 How to Order Parts........ The topics covered in this section include: 4....... 4-3 4............................2 Spare Parts Part No......................6 4... 520.................4 4............5003A 181................. 060........... It also describes how you can order these parts from Lufkin Automation..................5400 Part Description SAM PCP Stand-alone Controller with LCD/Keypad and window SAM PCP Stand-alone Controller with LCD/Keypad and no window 060........5401 4.................. 250 Volt Mini Jumper Issue Date: 1/18/08 Revision 1.............. 4-1 SAM PCP Optional Hardware ...........................5000A 520............. 11/2 Amp. 4-2 Documentation .............................3 4.........................................................5400 530........0122 Part Description Mother Board LCD Assembly Operator Interface Keypad VSD Expansion Board Fuse..Section 4 Parts Lists This section provides parts lists that have all the SAM PCP Controller components available...................... 4-2 Operator Interface Systems ...........1 SAM PCP Controllers Part No...... 4-1 Spare Parts.....7 SAM PCP Controllers .........................................................1 4... 4-2 SAM PCP Optional Hardware ......0018 151.......5 4..............................5010B 184.....2 4.................00 4-1 .........

153.5012 060. 099. 4 Terminal Part No. 2 Terminal Terminal Block.4454 Part Description RS-485 Communication Expansion Board Turbine Meter Board 75 VA capacity stepdown transformer Electro-mechanical octal-based 12 VDC relay with panel-mount socket and voltage transient suppression diode Panel-mount electro-mechanical relay with a 12 VDC coil and SPDT 840.7040 020. 3 Terminal Terminal Block.4457 151.3955A 510.4550 4.1002 Part Description SamScreen Terminal software Lufkin Automation Sam Flash Upgrade Utility software Pocket SAM Pocket SAM connection cable (required) 4.5028 099.2264 530.0221 161. 291. 520.0050 output contacts rated to switch up to 600 VAC 24 V Option for PCP Stand alone controller Ground lug PD Fluid Meter — Floco 2" Wedge Meter RPM Sensor Kit 530.00 Issue Date: 1/18/08 .1030A 291.3 SAM PCP Optional Hardware Part No.7513 530.4 SAM PCP Optional Hardware Part No.5 Operator Interface Systems Part No.7050 090.SAM Well Manager™ — Progressing Cavity Pump User Manual Part Description Terminal Block.0318 4.5000 Part Description SAM Well Manager™ — Progressing Cavity Pump User Manual SAM Well Manager™ — Rod Pump Control User Manual 4-2 Revision 1.6000A Part Description Pad Mount for 10-30 HP Pad Mount for 40-50 HP Pad Mount for 60-100 HP 4.6 Documentation Part No.0094 153.4050A 291.0285 062.0317 153.2500 062. 090.

Texas directly at 281.495.7 How to Order Parts Call your local Lufkin Automation representative or contact the factory in Houston. Issue Date: 1/18/08 Revision 1.00 4-3 .1100.Section 4: Parts Lists 4.

3...................................... 5-6 5.....2....... 5-5 5........................3 Mounting the Controller.............. 5-18 5..............5 Installing the Rod RPM Hall-Effect Transducer......................................2 Installing the Stepdown Transformer..................... The topics covered in this section include: 5.........................................................2.2.......4 Wiring the Polished Rod Hall-Effect Transducer .......00 5-1 ..2 Grounding the System...........................2 Overview of the System Installation . Following these guidelines for the SAM PCP Controller and its accompanying devices is crucial for obtaining optimum performance. 5-10 5........................ 5-12 5................................ 5-4 5........1 Wiring Specifications and Recommended Tools ..1 5...................2.....1 Installing the Mounting Post or Pedestal and Ground Rod .. 5-14 5..........3.................................3... 5-7 PCP Controller System Wiring .....2...........3 Wiring the Stepdown Transformer.......5 Wiring the Motor Control Relay .................... 5-2 5...................4 Installing Flow Rate Meters and Process Variable Transmitters.........................3.. 5-6 5...........................3.... 5-8 5.... 5-2 PCP Controller System Installation...............Section 5 System Installation and Wiring This section briefly describes key points you should follow when mounting and wiring the components making up the PCP control system......4 Issue Date: 1/18/08 Revision 1......... 5-17 Performing Power-Up Voltage Checks...................................................3 5............ 5-16 5........

• Mount the VSD so that the power leads from VSD to the motor are no longer than 30 feet. Only key points that serve as installation guidelines are discussed. If you need help locating skilled personnel.00 Issue Date: 1/18/08 . • If possible.SAM Well Manager™ — Progressing Cavity Pump User Manual 5. contact your Lufkin Automation representative. keep the following conditions in mind: • Mount the SAM PCP Controller in a location near the VSD panel so that it is easily accessible to the operator.2 PCP Controller System Installation A typical PCP controller installation includes the following: • SAM PCP Controller • Variable speed drive • Mounting post or stand • Stepdown transformer • Ground rod 5-2 Revision 1. keep in mind the radio signal path from the well to the base radio location. • Keep the transducer signal wires and ground conductors as short as possible to reduce signal attenuation and extraneous noise that can affect the operation of the control system. When selecting a site for installing the SAM PCP Controller. The Yagi antenna for the SAM PCP Controller should have an unobstructed line of sight with the base radio location. The PCP control system should be installed by skilled personnel that have experience mounting and wiring PCP well systems. orient the SAM PCP Controller so that the LCD display is not subject to prolonged direct sunlight.1 Overview of the System Installation The topics covered in this section do not provide step-by-step procedures for mounting and wiring. • If the SAM PCP Controller has a radio. 5. In the northern hemisphere this would indicate that the window for LCD viewing should face to the north. This practice will optimize the performance of the LCD.

Typical SAM PCP Controller Installation Interfaced with a VSD Issue Date: 1/18/08 Revision 1.00 5-3 . Figure 5-1.Section 5: System Installation and Wiring • Telemetry system (optional) • Production measurement transducer • Rod speed (RPM) transducer Figure 5-1 shows an example of a typical SAM PCP Controller installation interfaced with a VSD.

4.2.SAM Well Manager™ — Progressing Cavity Pump User Manual Note: The system should only be installed by a qualified technician who has experience working with the motor control box and its highvoltage circuits. Tools Required • Shovel or posthole digger • Ground rod driver • Level • Lifting equipment. Make sure that the mounting post or pedestal for the VSD will support the weight. Variable speed drives may weigh up to 450 pounds in the larger horsepower ratings. 2. with 30 inches being a preferred depth. Striking them will cause serious injury or death.1 Installing the Mounting Post or Pedestal and Ground Rod DANGER: Be very careful of power cables buried around the motor control box. 5. Pour concrete in the hole. 3. such as a crane or fork truck for VSD installation Installation Procedure Follow the steps below to properly install the mounting post and ground rod. Place the mounting post in the hole and position it facing outward so that it is accessible to the monitor. Use a shovel or posthole digger to dig a hole at least two feet deep.00 Issue Date: 1/18/08 . 5-4 Revision 1. An appropriately sized concrete pad may be required for the VSD pedestal. Make sure that the mounting post structure can support at least 40 pounds if only the controller will be installed and 75 pounds if a radio and antenna system will be included. Consult the VSD manufacturer. 1. Plan to place the mounting post for the SAM PCP Controller near the VSD so that it is convenient for electrical hookup.

Open the VSD panel.2 Installing the Stepdown Transformer The SAM PCP Controller requires primary input power in the range of 85 VAC to 264 VAC. 4. 5. 161. Allow sufficient time for the concrete to cure. The mounting post and ground rod are now installed. use that manufacturer’s mounting instructions. Turn off all power at the main power supply.7513). Select an appropriate empty space on the back panel of the VSD. Issue Date: 1/18/08 Revision 1.Section 5: System Installation and Wiring 5. Measure the incoming power legs with a voltmeter to verify that the power is off. 1. If your installation requires a stepdown transformer. and if you purchased a power transformer from another manufacturer. If a transformer is required. Lock out the master disconnect so that no one can turn on the power without your knowledge. and therefore.2. 6. follow the steps below. Lufkin Automation suggests you use one with a secondary voltage of 115 VAC. 5. Power available at most wellsites is higher voltage. Use a level to verify that the mounting post is positioned upright. 7. 2. a stepdown transformer may be required. 3. Tools Required • Voltmeter • Four #8 self-tapping screws • Drill Installation Procedure Follow the steps below to properly install the stepdown transformer. Lufkin Automation offers a 75-VA capacity stepdown transformer (Part No. If you purchased the stepdown transformer from Lufkin Automation.00 5-5 . Drive a ten-foot copper grounding rod into the earth within two feet of the VSD enclosure.

Check the transmitter load limitations to determine the voltage required for the 250-Ohm termination resistor that the SAM PCP Controller provides. the Lufkin Automation turbine meter board will probably not be required. adding an optional 24-VDC power converter to the SAM PCP Controller may be necessary. etc. 5.5016). Figure 5-1 is a typical installation showing the location of process variable monitoring devices. Use four #8 self-tapping screws to mount the stepdown transformer.2.SAM Well Manager™ — Progressing Cavity Pump User Manual 6.2. If the turbine meter assembly already includes a signal conditioning/pulse output module. an additional turbine meter board may be required (Part No. The stepdown transformer is now installed. the transmitter power provided by the SAM PCP Controller is 12 VDC. 5-6 Revision 1. Note: The SAM PCP Controller is designed for use with low-power 1 to 5–VDC transmitters. Drill holes if necessary.3 Mounting the Controller Mount the SAM PCP Controller on a mounting post. flow-rate metering devices. If the SAM PCP Controller is to be included in a radio data telemetry network. If the selected flow transducer is a turbine meter . For information about installing a mounting post see “Installing the Mounting Post or Pedestal and Ground Rod” on page 5-4.00 Issue Date: 1/18/08 . A bypass capability for the flow meter is usually included so that it can be serviced without shutting down the well. 520. 5. The antenna mast design should allow mast/antenna rotation to facilitate antenna alignment so that maximum signal strength reception is possible. Therefore.4 Installing Flow Rate Meters and Process Variable Transmitters Select and plumb the flow-rate metering equipment and process variable transmitters according to the recommendations of the manufacturers. a “tilt-up” antenna mounting mast can be attached to the same mounting post. If 4 to 20–MA transmitters are used. Contact your Lufkin Automation representative if you need help selecting pressure transmitters.

Ensure that the rods have quit turning and that the potential for back spin is eliminated. Use the proper lock out and tag procedures.Section 5: System Installation and Wiring 5. Extra “T” brackets are available if needed. Contact your Lufkin Automation representative if you have problems.5 Installing the Rod RPM Hall-Effect Transducer The magnet assembly must be mounted on the polished rod and the HallEffect transducer probe must be mounted so that the magnet passes within about 1/4 inch of the probe tip when it passes the probe. 2. 1. The installation technician may need to be innovative at some locations. Issue Date: 1/18/08 Revision 1. See Figure 5-2. Cut off excess hose clamp after it is tightened.00 5-7 . Attach the magnet (mounted in holder) to the polished rod with a stainless steel hose clamp. 3. Tools Required • Socket set or wrench set • Screwdriver Parts Required • Transducer assembly with motor bracket and “T” bracket • Magnet assembly • Hose clamp Installation Procedure Follow the steps below to properly install the Rod RPM Hall-Effect transducer.2. Turn off the main power switch to the motor. This mounting method will work for most installations.

Tighten all bracket connections. Assemble and adjust the “T” bracket linkage so that the magnet passes approximately 1/4 inch from the transducer. 5.SAM Well Manager™ — Progressing Cavity Pump User Manual Figure 5-2. and system wiring order. Install the RPM transducer bracket on a drive head housing bolt. 5.3 PCP Controller System Wiring This section provides information about terminal wiring. The motor Rod RPM Hall-Effect transducer is now installed. Since the PCP well system should be installed and wired by skilled personnel. step-by-step wiring procedures are not described here. conduit use. 6. Motor Transducer Assembly Diagram Showing “T” Bracket Linkage 4. Figure 5-3 illustrates a typical field-wiring diagram that can assist you to wire the system correctly. terminal strips.00 Issue Date: 1/18/08 . Select a housing bolt that will easily allow the transducer to align with the magnet. 5-8 Revision 1. shielded cables.

Typical Field Wiring Diagram Issue Date: 1/18/08 Revision 1.00 5-9 .Section 5: System Installation and Wiring Figure 5-3.

and shielding the SAM PCP Controller system. Recommended Wiring Specifications Local codes and/or company standard procedures will dictate if and where conduit or EMT must be used to protect the cable and or personnel. All shield leads should be terminated in the SAM PCP Controller at the hinge mounting screw on the lower right-hand edge of the front panel on which the motherboard is mounted.1 Wiring Specifications and Recommended Tools This subsection covers the recommended wiring specifications to follow for power wiring.3. The table below lists the recommended wire types that should be used. The transducer end of the shield should be left unconnected. Signal Type Power Earth Ground Hardwire Communications Hardwire with Repeater Modem-to-Radio Communications Minimum Wire Number of Size Conductors 16 AWG #2 Stranded Green 22 AWG 22 AWG 18—20 AWG 2 1 2 4 4 Shield No No No No Preferred Comments Separate from signal wires Keep short as possible Twisted pair Twisted pair — Shielding The shield of each cable must be connected at only the controller end. system grounding. otherwise a ground loop could form that can cause erroneous signals to develop. A list of the minimum tools recommended for effectively wiring the system is also provided.SAM Well Manager™ — Progressing Cavity Pump User Manual 5. This point is recognizable by the factoryinstalled green wire that connects the front panel to the system ground. Note: Special considerations should be taken for the type of wire used in hazardous or highly corrosive environments.00 Issue Date: 1/18/08 . 5-10 Revision 1.

Strip the insulation on the wire to expose about 1/4 inch of conductor. insert the wire. Terminals work best with leads that are not “tinned” with solder. and the VSD output wiring. the following tools: • Wire cutters • Wire strippers • Small flat-bladed (slotted) screw driver • Voltage/ohmmeter (VOM) • Slip joint or water pump pliers Wiring Terminals and Terminal Strips All field-wiring terminals are located on one of the SAM PCP Controller circuit boards mounted on the front panel assembly.00 5-11 . insert the wire. You will probably want to clip off the “tinned” ends of the HallEffect cable and strip back the insulation to expose the stranded wire. and then release the orange tab. Shields should be terminated only at the hinge mounting screw on the lower right-hand edge of the front panel on which the motherboard is mounted. press in the orange tab with a small screwdriver (or your thumbnail). Terminal strips for transmitter inputs and the motor drive output are also a pressure-clip type. Press the orange tab with a small screwdriver. Observe the “half moon” design that keys the terminal block for proper insertion. To insert a wire. This point is recognizable by the factoryinstalled green wire that connects the front panel to the system ground. and then release the orange tab. The terminal strips on the SAM PCP Controller motherboard are a pressure-clip type for the Hall-Effect transducer. See Figure 5-3. Pull slightly on the wire lead to ensure that the wire is firmly gripped by the spring clip in the terminal block. at the very minimum. Issue Date: 1/18/08 Revision 1. you should have. Terminal blocks are a plug-in type so that they can be removed for wire insertion and then plugged back in. Shielded Cables Shielded cables must be used for the signal leads from the pressure and temperature transmitters. the production meter.Section 5: System Installation and Wiring Recommended Tools To help make your wiring tasks easier.

3.00 Issue Date: 1/18/08 . Consult your VSD supplier for information regarding input and out put wiring to the VSD. System Wiring When wiring the system. Wire the SAM PCP Controller primary power (85 VAC to 264 VAC) source leads to terminals L1 (hot) and L2 (neutral) on the SAM PCP Controller back panel. Do not make a connection to the GND terminal at this time. the components should be wired in the order recommended below. Conduit is not absolutely necessary for preventing serious electrical shock because system power to transmitters is typically 12 VDC maximum.2 Grounding the System DANGER: Be very careful of power cables that are buried around the wellhead area and the VSD cabinet. make sure the controller hardware is configured properly for your system. conduit may be useful for protecting wiring cable from damage caused by rodents gnawing on the insulation. Wire the end devices and the process variables to their respective terminals on the SAM PCP Controller.SAM Well Manager™ — Progressing Cavity Pump User Manual Conduit Local codes and customer standards dictate whether conduit is used for cable and wire protection. see section 6. 2. 4.3. System Configuration Before you begin configuring and programming the SAM PCP Controller. Striking them could cause serious injury or death. For information about hardware configuration.” 5. “Hardware Configuration. However. Wire power leads to the VSD and from the VSD to the motor. 5-12 Revision 1. Wire signal leads for control and monitoring to their respective terminals in the VSD and in the SAM PCP Controller. 1. Lufkin Automation strongly suggests that these high-voltage leads be run in conduit to protect personnel from possible shock.

Section 5: System Installation and Wiring Proper earth grounding of the SAM PCP Controller is critical to minimize transient voltage that can damage the control system electronics. Terminations at each end should use approved irreversible crimp connectors. and it must be sufficiently coated afterward to prevent any corrosion. Lufkin Automation recommends that you use the wellhead as the system ground electrode. The system is now grounded. If your VSD does not have a ground bus. The ground bus in the VSD should be connected to the wellhead. The connection to the wellhead should be cleaned down to bare metal before you install the clamp. Refer to Figure 5-1 for a visual of the grounding described below.00 5-13 . Terminations at each end should use approved irreversible crimp connectors. The ground bus in the VSD should be connected to the motor chassis with an uninterrupted length of stranded #2 AWG green ground wire. This wire should be terminated at the VSD ground bus with an approved irreversible crimp connector and to the wellhead with an approved pipe ground clamp rated for #2 wire. obtain one and install it according to manufacturer’s instructions. The ground bus in the VSD should be connected to the ground post on the lower left corner of the SAM PCP Controller with an uninterrupted length of stranded #2 AWG green ground wire. Recommended Grounding Practices for SAM for additional information. and all other parts of the system should in turn be connected to the VSD ground bus. All signal cable shields should be terminated at the ground lug provided on SAM PCP Controller’s front door hinge. Ask your Lufkin Automation representative for a copy of Technical Bulletin TB-07-1019. Issue Date: 1/18/08 Revision 1. The VSD ground bus should be connected to the wellhead with an uninterrupted length of stranded #2 AWG green ground wire. The connection to earth ground will have previously been established and any additional paths to ground could create ground loops. This bonds the shield directly to the ground conductor. Note from Figure 5-1 that the ground lead from the wellhead to the VSD ground bus should be connected “in line” to the ground rod adjacent to the VSD. it will no longer be necessary to route a green wire to the “GND” terminal of TB-1 on the SAM PCP Controller back panel. The primary power service ground lead should be terminated on the VSD ground bus. For the PCP application. If the above procedure is followed.

Power and Control Relay Wiring Diagram Wiring the Stepdown Transformer to the Motor Starter Panel Follow the steps below to wire the stepdown transformer to the motor starter panel. Refer to the suggested control panel wiring diagram in Figure 5-4 when wiring the stepdown transformer.SAM Well Manager™ — Progressing Cavity Pump User Manual 5. a stepdown transformer must be installed in the starter panel to convert 460 VAC to 115 VAC. such as the motor control relay. Other components. The suggested method in Figure 5-4 will obviously not work in every situation. Figure 5-4.00 Issue Date: 1/18/08 . have sections that explain how they are wired to the motor control circuit. In most cases. Many types of motor starter panels are used with varied control wiring methods and control voltages. but the general idea should provide a qualified electrician with enough information to figure out the best way to wire a particular control panel. 5-14 Revision 1. Two subsections are devoted to wiring the stepdown transformer to the motor starter panel and the SAM PCP Controller.3 Wiring the Stepdown Transformer The SAM PCP Controller requires primary power in the range of 85 to 264 VAC.3.

Other jumper arrangements on the transformer are available. 16 gauge wire.Section 5: System Installation and Wiring 1. Cut two lengths of 18-to-12 gauge single-conductor wire that will reach from the transformer to the 460-VAC power source. 5. The stepdown transformer is now wired to the motor starter panel. Determine the input side of the transformer by looking at the markings on the ends of the transformer. Loosen a screw on the input side of the transformer and insert the wire under it. Lufkin Automation recommends that you install fuses in the VSD cabinet on the primary/high voltage side of the transformer. 3. The wires should be connected to the AC power terminals on the SAM PCP Controller as follows (see Figure 5-5): Issue Date: 1/18/08 Revision 1. 2. see “Installing the Stepdown Transformer” on page 5-5. 6. Tighten the screw. Therefore. as a minimum. Note: Some local codes require you to install fuses. but the 115-VAC power lines and the stepdown transformer are not protected from a short-circuit condition. See the diagram on the transformer. Strip off approximately 1/4 inch of the insulation from the end of the wires and crimp a spade lug on one end of the wire. Lufkin Automation recommends that you use. 8. Use a voltmeter to check that no power is coming to the motor starter panel. The SAM PCP Controller has fusing for internal protection. Note: A 460 VAC power source is assumed.00 5-15 . Wiring the Stepdown Transformer to the SAM PCP Controller Connect the SAM PCP Controller to the 115-VAC stepdown transformer located in the motor starter panel. Install the stepdown transformer. For instruction to install it. 7. Route the single conductor wires to the 460-VAC power source and strip off approximately one inch of insulation from the end of the wire. Connect the two wires to the incoming 460-VAC power source at L1 and L2. 4. MAKE SURE THE POWER IS OFF TO THE MOTOR STARTER PANEL.

SAM Well Manager™ — Progressing Cavity Pump User Manual Figure 5-5. Consult the wiring diagram in Figure 5-6. Figure 5-6.4 Wiring the Polished Rod Hall-Effect Transducer The polished rod Hall-Effect transducer cable is a molded assembly that is pre-wired at the sensor end.3. Hall-Effect Transducer to SAM PCP Controller Wiring Diagram 1. 5-16 Revision 1. white. and green wires on each cable. Use the following procedures to route and wire the cable from the Hall-Effect transducer to the SAM PCP Controller. Stepdown Transformer to SAM PCP Controller Wiring Diagram • 115 VAC to terminal 1 — “LIN”. Strip back the insulation about 1/4 inch from the end of the red. 2. 5. • 115 VAC Neutral to terminal 3 — “NEU” The stepdown transformer is now wired to the SAM PCP Controller.00 Issue Date: 1/18/08 . Strip off the outer insulation and remove the stress relief material so that only the insulated wire is left. The only field wiring necessary is to connect the leads at the SAM PCP Controller.

Follow the steps below to wire the motor control relay. Issue Date: 1/18/08 Revision 1. 4. Consult Figure 5-6.3. Connect one side of the motor control relay coil to terminal block TB5 and terminal 3 on the SAM PCP Controller logic board. 1. The SAM PCP Controller should be wired as follows for the electromechanical relay option (see Figure 5-7): Figure 5-7. The relay is labeled “Motor Control Relay” in Figure 5-4. The motor control relay provides a contact closure that enables the VSD to run the motor. The motor control relay has a set of normally open contacts that are wired to the Run Enable input of the VSD.Section 5: System Installation and Wiring 3. Insert the wires in the appropriate terminal in TB4. The polished rod Hall-Effect transducer is now wired.5 Wiring the Motor Control Relay The motor control relay is energized when the SAM PCP Controller issues a Start command to the VSD and is de-energized when the SAM PCP decides to Stop the pump.00 5-17 . The other side of the relay coil connects to the +12-DC terminal on the back panel of the SAM PCP Controller. Terminate the cable shield lead on the hinge mounting screw on the lower right hand edge of the front panel on which the motherboard is mounted. 2. terminal 3 on the SAM PCP Controller motherboard. This point is recognizable by the factory-installed green wire that connects the front panel to the system ground. Electro-Mechanical Motor Control Relay Wiring to SAM PCP Controller • Connect terminal 2 on the octal socket to terminal strip TB5. 5.

00 Issue Date: 1/18/08 . WARNING: Use this procedure to make sure that the SAM PCP Controller is receiving proper voltage from the motor control box and that the proper voltage is provided to the SAM PCP Controller. Make sure the SAM PCP Controller power switch is off. The motor control relay is now wired. go to step 3. 2. Use the generic “coil” and “normally open” designations if terminal numbers do not agree with Figure 5-7.SAM Well Manager™ — Progressing Cavity Pump User Manual • Connect terminal 7 of the octal socket to one of the “+12V” terminals provided on the SAM PCP Controller back panel located in the upper left. Note: Terminal numbers on the relay will vary depending on the type of relay used. Wire the control relay output contacts to the run enable input terminals on the VSD. 5-18 Revision 1. and then turn on the main power switch to the motor control panel. 5. Tools Required • AC/DC voltmeter SAM PCP Controller Follow the steps below to make sure that the proper voltage is connected to the SAM PCP Controller. • If the voltage is correct. Use an AC voltmeter to check for 110-120 VAC between the terminals labeled LIN and NEU on terminal strip on the lower right corner of the SAM PCP Controller panel.4 Performing Power-Up Voltage Checks Power-up voltage checks should only be performed by a qualified technician who has experience working with the motor control box and its high-voltage circuits. put the HOA switch in the Off position. 3. 1.

Wiring is now complete for the PCP control system and you are ready to program the SAM PCP Controller. Leave the H-O-A switch switched off and the main power switch to the motor switched on. 3. and the turn on the SAM PCP Controller.Section 5: System Installation and Wiring • If the voltage is not correct.00 5-19 . 4. observe the RPM light on the left edge of the SAM PCP Controller motherboard. 5. If a Hall-Effect transducer is used to measure rod speed. The power on/off switch is located on the front cover. Issue Date: 1/18/08 Revision 1. The RPM light should be blinking on and off rapidly as the magnet on the polished rod passes the Hall-Effect sensor. The unit should start. check the wiring to the stepdown transformer and the fuses associated with the transformer. VSD Consult manufacturers user manual for recommended check procedures for the VSD. Turn the H-O-A switch to the position wired for control by the SAM PCP Controller.

........................1 6.... The topics covered in this section include: 6................................... 6-6 Turbine Meter Board.....1 Overview of the Hardware Configuration The following items pertaining to hardware configuration must be checked to ensure that the SAM PCP Controller is properly configured for the meter run inputs and valve control actuation: • Battery disconnect jumper is on both pins • 4-20 MA transmitters are configured Issue Date 1/18/08 Revision 1........... 6-3 Radio Communications Port .............................. 6-10 VSD Configuration ........................................4 6........................ 6-11 6.........00 6-1 .............. 6-2 4–20 MA Transmitters .............................Section 6 Hardware Configuration You must ensure that the SAM PCP Controller hardware is configured properly in order to obtain accurate input data and have pump control.......................................................6 6.................................5 6..........................................7 Overview of the Hardware Configuration......... 6-5 RS-485 Communication Expansion Board ... 6-1 Battery Disconnect Jumper Pins ........2 6............3 6.............

Mother Board Showing Lithium Battery.00 Issue Date 1/18/08 . Battery disconnect jumper pins are located next to the battery. locate the motherboard with the SAM VSD expansion board assembly on the back of the hinged front panel. 6-2 Revision 1. and Radio Communication Port To check the jumper configuration.SAM Well Manager™ — Progressing Cavity Pump User Manual 6. Battery jumper pins Lithium battery Radio Comm Port Figure 6-1. Failure to include the battery will cause the SAM PCP Controller to loose programming when the power switch is turned off. Battery Jumper Pins. A jumper is installed at the factory to connect the two pins to place the battery in service.2 Battery Disconnect Jumper Pins Many of the parameters programmed for PCP control are stored in RAM on the SAM PCP Controller microprocessor circuit board (motherboard). It is recommended that you ensure that the shorting jumper is on both pins so that the battery is included in the circuit. The green battery should be easy to notice. This memory is supported during power outages by a lithium battery located near the top of the motherboard. Look downward from the top between the expansion board and the motherboard. The battery jumper is just above the end of the battery nearest the door hinge.

See Figure 6-2 to locate the termination resistor jumpers. To identify the proper jumper for a given input. Termination resistor jumpers Quick connect terminal Figure 6-2. 6.00 6-3 . To change the inputs to be used for current input. read the resistor designation located to the left of the JP1 header and use the table below to reference it. I/O Expansion Board Showing Termination Resistor Jumpers. you need to temporarily unplug the expansion board to move the jumper so that the two pins are connected.Section 6: Hardware Configuration If the jumper is not connecting the two pins. Termination resistor jumpers are provided and mounted on only one of the two pins. 520. and Ground Wire A 16-pin header designated as JP1 is located on the upper left edge of the installed expansion board to the right of the terminal block for connecting the analog inputs.5003A) used with the SAM PCP Controller is shipped with all eight inputs configured as voltage inputs. move the jumpers to the right to connect the two pins and place the 250Ohm termination resistor in the input circuit.3 4–20 MA Transmitters The SAM VSD expansion board (Part No. Issue Date 1/18/08 Revision 1. The jumper pins are not numbered. Quick Connect Terminal for Earth Ground.

The port connector is labeled RJ 12. 6. See Figure 6-2. Below is the pin-out configuration for RJ 12. Pin Out 1 2 3 4 5 6 Function CD (input — not used) TXD (output) RXD (input) Ground RTS (output) CTS (input — not used) The wiring diagram in Figure 6-3 shows how the radio should be wired to the radio communication port (RJ 12) on the motherboard. and it is imperative that the ground wire be connected to the hinge screw on the front panel. 6-4 Revision 1.00 Issue Date 1/18/08 .SAM Well Manager™ — Progressing Cavity Pump User Manual Analog Input AI 1 AI 2 AI 3 AI 4 AI 5 AI 6 AI 7 AI 8 Termination Resistor R2 R3 R4 R5 R6 R7 R8 R9 The I/O expansion board includes a 1/4-inch quick connect terminal for an earth ground (chassis ground). A green ground wire is included with this board.4 Radio Communications Port The communications port on the motherboard (see Figure 6-1 on page 6-2) is most commonly connected with MDS Transnet or Freewave board-level radios. Pin 1 is located at the bottom of the connector. When the motherboard is mounted vertically in the SAM PCP Controller. The signals are RS-232 and support Modbus RTU slave protocol.

” Issue Date 1/18/08 Revision 1.00 6-5 .Section 6: Hardware Configuration Figure 6-3. see Figure 6-4 for the proper wire-toplug configuration. Figure 6-4. “SAM Controller Programming.200 baud. The software controls baud rate on a slavedevice basis. For information about configuring baud rate. MDS Radio Transmission Cable Configuration Baud Rate The radio communications port can support data communication rates from 300 to 115. see “Communication Port Configuration” in section 8. PCP Radio Comm Port Wiring Diagram Radio Transmission Cable If you need to construct a radio transmission cable to connect an MDS radio to the SAM PCP Controller.

When installing the RS-485 board on the I/O expansion board. The board is properly installed when the terminal block is on the left edge of the SAM PCP Controller front panel.5002 and 520. 520. with the panel open. make sure the connectors are configured as follows: • JP1 on RS-485 expansion board to JP2 on I/O expansion board • JP2 on RS-485 expansion board to JP3 on I/O expansion board The field connection terminal block for the RS-485 communication expansion board should be placed to the left edge and over the terminal block of the I/O expansion board.5 RS-485 Communication Expansion Board The optional RS-485 communication expansion board (Part No. 520. 6-6 Revision 1.SAM Well Manager™ — Progressing Cavity Pump User Manual 6. RS-485 Communication Expansion Board The RS-485 communication expansion board provides an interface for the SAM PCP Controller to the Modbus Master data network.00 Issue Date 1/18/08 . Terminal Block Connector The RS-485 expansion board has a five-position terminal block connector used for the data network wiring.5003A).5012) (see Figure 6-5) is designed to piggyback mount on either of the I/O expansion boards (Part Nos. Terminal block connector Dip switches Figure 6-5.

Termination Resistors 120-Ohm termination resistors are pre-installed at locations R3 and R6. only one terminating resistor needs to be active (that is. • Constant receive mode should be used for four-wire mode. • Receiver disabled during transmission should be used for two-wire mode. see “Communication Port Configuration” in section 8. only set dipswitch 3 or 4 to the ON position).” Biasing Resistors The RS-485 expansion board comes standard with 1K biasing resistors. These resistors can be activated in the circuit by setting dipswitches 3 and 4 to the ON position. Constant Receiver Enable/Disable The RS-485 expansion board comes standard with the receiver set up for constant receiver mode.Section 6: Hardware Configuration The connector is labeled as follows from top to bottom. Issue Date 1/18/08 Revision 1. For information about configuring baud rate. Position 1 2 3 4 5 Signal Description R+ R– T+ T– SH Receiver + Receiver – Transmitter + Transmitter – Cable Shield Baud Rate The RS-485 expansion board can support data communication rates from 300 to 115.200 baud. To change the value of biasing resistors. The software controls baud rate on a slave-device basis. See Figure 6-5 for dipswitch locations. See Figure 6-5 for resistor locations. It can be set up for receiver disabled during transmission by setting dipswitch 5 to the ON position. Terminating resistors should only be used on the ends of the RS-485 data line. “SAM Controller Programming.00 6-7 . See Figure 6-5 for resistor locations. remove R1 and R4 and replace with new values. In two-wire mode.

then you must determine which terminal “A” or “B” is the “+” terminal.” Data Line Polarity The polarity of the two RS-485 lines must be correct. See Figure 6-5 for dipswitch locations on the RS-435 expansion board. Dipswitch Assignments Dipswitch 1 Dipswitch 2 Dipswitch 3 Dipswitch 4 Dipswitch 5 Dipswitch 6 OFF ON OFF ON OFF ON OFF ON OFF ON NA Four-Wire Mode Two-Wire Mode — Connects RX+ and TX+ Four-Wire Mode Two-Wire Mode — Connects RX. the “–” terminal should be negative with respect to the “+” terminal. see “Communication Port Configuration” in section 8. The “+” lines should be connected together.00 Issue Date 1/18/08 . and the “–” lines should be connected together between devices on the network.and TXNo Termination for RX 120 Ohm Termination for RX No Termination for TX 120 Ohm Termination for TX Receiver Always Enabled (Four-Wire Mode) Receiver Disabled During Transmission (Two-Wire Mode) Not Used Two-Wire Mode Configurations Dipswitch Settings Mode Constant Receiver Enabled No Terminating Resistors Receiver Disabled on Transmit No Terminating Resistors Constant Receiver Enabled Terminating Resistors Connected State ON OFF ON OFF ON OFF ON OFF 1 2 3 4 5 6 Receiver Disabled on Transmit Terminating Resistors Connected 6-8 Revision 1.SAM Well Manager™ — Progressing Cavity Pump User Manual For information about how to enable and disable receiver mode. Dipswitch Configuration Dipswitch assignments for two-wire and four-wire mode are provided in the tables below. When no data is being transmitted. If a device uses “A” and “B” designation. “SAM Controller Programming.

Turbine Meter Board and Ground Wire Issue Date 1/18/08 Revision 1.00 6-9 . 6.Section 6: Hardware Configuration Four-Wire Mode Configurations Dipswitch Settings Mode Constant Receiver Enabled No Terminating Resistors Receiver Disabled on Transmit No Terminating Resistors Constant Receiver Enabled Terminating Resistors Connected State ON OFF ON OFF ON OFF ON OFF 1 2 3 4 5 6 Receiver Disabled on Transmit Terminating Resistors Connected Note: The setting assigned for dipswitch 6 has no effect on performance.6 Turbine Meter Board The optional turbine meter board (Part No. 060. Quick connect terminal Figure 6-6.0221) serves as a conditioning board for the turbine meter. See Figure 6-6.

If the only option in the drive is a 4-20 MA input. and it is imperative that the ground wire be connected to the hinge screw on the front panel. 0-5 VDC is also acceptable. Program the reference speed input in the drive to analog DC voltage.SAM Well Manager™ — Progressing Cavity Pump User Manual The terminal connections are shown in the table below.5004 is available that provides a 4-20 MA output. 6-10 Revision 1. but it requires the 0-5– VDC voltage module to be installed in the SAM PCP Controller VSD expansion board (Part No. Connector Function OUT1 GND OUT2 GND +12V GND IN1 GND CHGND IN2 GND CHGND Pulse Output #1 (open collector) Signal Ground Pulse Output #2 (open collector) Signal Ground 10 TO 15 VDC Input Power Signal Ground Turbine Meter #1 Input (millivolt AC signal) Signal Ground Chassis Ground Turbine Meter #2 Input (millivolt AC signal) Signal Ground Chassis Ground The turbine meter board includes a 1/4-inch quick connect terminal for an earth ground (chassis ground). The information below is therefore general in nature. 0-10 VDC is preferred.00 Issue Date 1/18/08 . A green ground wire is included with this board. 6.” Note: The VSD must be capable of using an external voltage signal for speed control. an optional analog expansion board #520.5003A). Refer to the VSD manufacturer’s instructions for specific details about configuring the drive. Many VSDs on the market can be configured to properly interface with the SAM PCP Controller. 520.7 VSD Configuration VSD configuration requirements depend on the brand of VSD used.

the Hand side should be wired so that the drive’s keypad operates the well (start/stop control and speed reference setting) when the switch is in the Hand position. The drive uses these parameters for scaling of the analog reference. the minimum frequency is 0 Hz and the maximum frequency is 90 Hz. retry attempts are allowed Refer to the drive’s manufacturer for proper setup and commissioning of the drive for warranty purposes. The Auto position side then looks to the drive’s external control connections for run/stop contacts and speed control input. Issue Date 1/18/08 Revision 1. For example.Section 6: Hardware Configuration If the drive has an H-O-A switch. Drives typically have plenty of parameters that determine how the system works. which is connected to the SAM PCP Controller. if 0-10 VDC is used. A 10-VDC reference from the SAM PCP Controller tells the drive to operate at 90 Hz. Some consideration should be given to the following features and how they affect the operation of the progressing cavity pump: • Ramp to speed on startup • Flying catch start if the progressing cavity pump is already in motion when a start command is given • Coasting to stop/or ramp to stop • Verify that the correct motor parameters are entered • Auto restart on a drive fault.00 6-11 . Make note of the analog speed reference scaling in the drive (usually in Hz).

...2 7..............” The topics covered in this section include: 7.... 7-14 Configuring End Devices ................. 7-3 Configuring Parameter Violations ......................... For information about programming configuration parameters that control operations of the SAM PCP Controller..... see section 8........................6 Overview of PCP Parameter Programming. “SAM Parameter Programming.1 7................ Note: Only information about programming PCP configuration is described in this section..4 7....................... 7-20 Configuring Production and Motor Information................... • Minimum and maximum operation speeds allowed • Speed and production violations • End device parameter configurations Issue Date: 1/18007 Revision 1......... 7-1 Configuring Control Parameters ...........1 Overview of PCP Parameter Programming Several PCP configuration screens are used to program general parameters that control PCP operations at the wellsite...... 7-26 7........................00 7-1 ..............Section 7 PCP Parameter Programming Parameter values that define variable speed drive control action and production must be properly programmed before you can obtain accurate and reliable PCP control and historical data............................5 7.... 7-23 Configuring Special Features ............................3 7..............

3/1 first select 3. PCP CONFIGURATION from the Configuration Menu screen. “Description of the SAM PCP Controller System.SAM Well Manager™ — Progressing Cavity Pump User Manual • Production input and speed output • Special features General PCP parameter programming must be completed regardless of the type of end devices used in the system or else effective well control. For information about passwords. The actual PCP configuration values are available under the PCP SAM Configuration Menu screen (Figure 7-1). see “Changing Passwords” in section 8 “SAM Controller Programming. For information about this operator interface and how to use it. see “Controller Operator Interface” in section 2. To display this screen.00 Issue Date: 1/18007 . and well data accumulation is not possible. Figure 7-1. PCP Configuration Menu Screen Note: A user password is required to access this menu screen if password protection is enabled. CONFIGURATION from the Main Menu screen and then select 1.” 7-2 Revision 1. well monitoring.” All PCP programming parameter values are entered through an interface using the 20-key operator interface keypad mounted in the SAM PCP Controller enclosure.

Battery disconnect jumper pins are located next to the battery. If the jumper is not on both pins. the expansion board must be temporarily removed to properly place the jumper. This memory is supported during power outages by a lithium battery located near the top of this circuit board. see “Controller Operator Interface” in section 2.” RAM Backup Protection Many of the parameters programmed for PCP control are stored in RAM on the SAM PCP Controller circuit board. such as • Power on and off delays • Minimum and maximum pump operating speed • Settling and sampling periods • Maximum speed increases and decreases Issue Date: 1/18007 Revision 1. Failure to include the battery will cause the SAM PCP Controller to loose programming when the power switch is turned off. “Hardware Configuration.00 7-3 . If the battery is not included.2 Configuring Control Parameters SAM 3/1/1 PCP control parameters control operations of the progressing cavity pump. The battery jumper configuration can be checked by looking down between the expansion board and the main board from the top.” 7. see “Battery Disconnect Jumper Pins” in section 6. For information about this operator interface and how to use it. Before programming the SAM PCP Controller. the SAM PCP Controller will loose programming when the power switch is turned off. “Description of the SAM PCP Controller System. ensure that the shorting jumper is on both pins so that the battery is included in the circuit. For more information about the battery.Section 7: PCP Parameter Programming Operator Interface Keypad Programming All SAM PCP Controller programming parameter values are entered through the 20-key operator interface keypad mounted in the SAM PCP Controller enclosure.

The default value is 10 seconds. Power On Delay Specify the time. To display these screens. The SAM PCP Controller delays starting the pumping unit for the number of seconds specified. This feature is included to allow an operator to stagger the startup of multiple pumping units on a transformer bank or distribution line after a power outage. When power is applied to the SAM PCP Controller. the initial control state is Downtime Power On Delay. You can toggle between screens by pressing <NEXT>.SAM Well Manager™ — Progressing Cavity Pump User Manual These control parameters are configured through two Control Parameter CFG screens.00 Issue Date: 1/18007 . CONTROL PARAMETERS CFG from the PCP Configuration Menu screen. Each screen is described separately below. that the SAM PCP Controller must wait before issuing a command to start the PCP pump. 7-4 Revision 1. Control Parameters CFG Screen (1 of 2) Data Field Descriptions Information about each data field for this screen is provided below. in seconds. Figure 7-2. Screen 1 of 2 Figure 7-2 is an example of the first Control Parameter CFG screen. select 1.

that the SAM PCP Controller is allowed to ramp the speed from the Minimum Operating Speed to the target Start Up Speed in an interval defined in the Number of Start Up Ramp field during the Starting state. a Power On Delay equaling 30 seconds and Start Delay equaling 10 seconds will cause the Well State to switch to a Start Alert state of 20 seconds for the Power On Delay. Start Alert is executed whenever the SAM PCP Controller attempts to restart the motor due to any of the following conditions: • Automatic restart due to Peak Energy Management feature • Restart after a power shutdown or outage • After Downtime period • Operator Start command • Reset Malfunctions command Number of Start Up Ramp Specify a value to be used to calculate the speed ramp rate and the number of ramp up steps during the starting period. For example. when the Start Up Period equals 120 seconds. the speed will ramp at the rate of 40 RPM every 24 seconds.00 7-5 . This feature is either a stand-alone function or it is embedded in the Power On Delay process. Issue Date: 1/18007 Revision 1. Start Up Period Specify the time period. and Minimum Operating Speed equals 50. The Number of Start Up Ramp equals 5. that the SAM PCP Controller must wait before issuing a command to start the pump. For example. in seconds. in seconds. when Start Alert is embedded in the Power On Delay process.Section 7: PCP Parameter Programming This feature is only available under the following conditions: • Automatic restart when the Peak Energy Management feature is enabled • Restart after a power shutdown or power outage Start Alert Delay Specify the time. Start Up Speed equals 250 RPM.

7-6 Revision 1. and Minimum Operating Speed equals 100. Number of Power Off Ramp Specify the value used to calculate the speed decrease rate during the Power Off Delay period. This is only used by the Production Control operation mode. the SAM PCP Controller uses the following as the startup speed: Operation Mode Speed Control Host Timed Monitor Start Up Speed Speed Control Run Speed Host ON/OFF: ON Speed or Host HI/LO: HI Speed Timed ON/OFF: ON Speed or Timed HI/LO: HI Speed N/A Production Control Pre-programmed startup speed. During this period. in seconds. For other operation modes. it declares a Stopped state and proceeds to the corresponding Downtime or Shutdown state. before the SAM PCP Controller turns off the pump. Stopping Period Specify the time period. Number of Power Off Ramp equals 3.00 Issue Date: 1/18007 . the SAM PCP Controller declares Unable to Stop state. the speed will decrease by the rate of 100 RPM every 10 seconds. Otherwise. the SAM PCP Controller continuously monitors the Speed Monitor Input when the rod is still rotating. Power Off Delay Specify the delay time. Current Speed equals 400 RPM. in seconds. when Power Off Delay equals 30 seconds. This period allows the SAM PCP Controller to decrease the speed to Minimum Operating Speed in an interval defined by the Number of Power Off Ramp. For example. set for the SAM PCP Controller to attempt stopping the pump. When the stopping period expires and the rod is still rotating.SAM Well Manager™ — Progressing Cavity Pump User Manual Start Up Speed Specify the target speed that the pump is to operate at by the end of the Start Up Period.

Rod Speed at Full Scale Specify the maximum polished rod RPM used for scaling the speed sent to the drive. in RPM. operator.00 7-7 . If the controller algorithm. operator. and editable when the Prime Mover type is Hydraulic. and then press <ENTER>. a CALC option is available to the right that can display a screen to help you calculate a rod speed at full scale value (Figure 7-3). or host tries to operate the drive above the maximum operating speed.Section 7: PCP Parameter Programming Max Operating Rod Speed Specify the maximum polished rod speed. If Prime Mover type is programmed as Hydraulic. Calculate Approx Rod Speed at Full Scale Screen Issue Date: 1/18007 Revision 1. in RPM. This rod speed is automatically calculated when the Prime Mover type is Electric Motor. or host tries to operate the drive below the minimum operating speed. If the controller algorithm. To display the screen. Min Operating Rod Speed Specify the minimum polished rod speed. see “Configuring Production and Motor Information” on page 7-23. that the SAM PCP Controller will allow the pump to operate. press <→> to highlight CALC. For information about programming for a prime mover. that the SAM PCP Controller will allow the pump to operate. the SAM PCP Controller will automatically clip the speed to the configured Minimum Operating Speed. Figure 7-3. the SAM PCP Controller will automatically clip the speed to the configured Maximum Operating Speed.

• If you want to keep the new calculated value. Control Parameters CFG Screen (2 of 2) You can return to the first Control Parameters CFG screen (Figure 7-2) at any time by pressing <NEXT>. Screen 2 of 2 To display the second screen. Figure 7-4 is an example. Use the numerical keys to enter the pump RPM. Rod Speed at Full Scale field. 7-8 Revision 1. press <↓> to highlight STORE AND EXIT and press <ENTER>. Figure 7-4. The new calculated value displays in the Calc. After you make a selection. and then press <ENTER>. Rod Speed at Min Scale Specify the minimum polished rod RPM used for scaling the speed sent to the drive.00 Issue Date: 1/18007 . press <NEXT>. • If you want to keep the previous calculated value. you are returned to the Control Parameters CFG screen with the value displayed in the Rod Speed at Full Scale field.SAM Well Manager™ — Progressing Cavity Pump User Manual The Enter Hydraulic Pump RPM field highlights. press <↓> twice to highlight DISCARD AND EXIT and then press <ENTER>.

and low speed is specified in the Min Operating Speed field. Down Time Period Specify the time period. The algorithm searches for the most efficient operating speed. and then it sends a command for the motor to operate and remain operating at a slower speed during the entire TIMED LO time period. For TIMED HI/LO. that the SAM PCP Controller will operate under a Downtime or Violation Run Minimum condition. • SPEED CTRL — Speed Control mode allows you to specify a predefined speed. • TIMED — Timed mode allows the SAM PCP Controller to automatically operate the motor in an ON/OFF or HI/LO speed cycle for specified time periods. Enabled violations are monitored and checked accordingly. such as torque limiting. are still in effect in this operating mode. The following choices are available: • PROD CTRL — Production Control mode allows the SAM PCP Controller to operate under Lufkin Automation’s patented production control algorithm.00 7-9 . the SAM PCP Controller sends a command for the motor to operate at a high speed and continue operating at this speed during the entire TIMED HI time period. the SAM PCP Controller sends a command for the motor to start and remain operating during the Timed ON period. Enabled violations. No violations are checked during Timed mode. in hours and minutes. and it sends a command to the motor to shut down and remain off during the Timed OFF period.Section 7: PCP Parameter Programming Data Field Descriptions Information about each data field for this screen is provided below. Operation Mode Specify the mode of operation used by the SAM PCP Controller. High speed is specified in the Max Operating Speed field. The speed can be changed at any time at an update rate of once a minute. Issue Date: 1/18007 Revision 1. For TIMED ON/OFF.

to be used when the PROD CTRL operating mode is selected. Max Speed Decrease Specify the maximum speed decrease. For HOST ON/OFF. No violations are checked during this mode. send speed commands to the drive. to be used when the PROD CTRL operating mode is selected. If the production control algorithm suggests a speed decrease greater than the Max Speed Decrease value.SAM Well Manager™ — Progressing Cavity Pump User Manual • HOST — Host mode allows you to control the motor operation either by manually switching the motor to HOST ON/OFF or by running the motor at HOST HI/LO speed. the SAM PCP Controller gathers the data and averages it at the end of the sampling period. All enabled violations are checked except for Low Production and High Production. or check for any violations. which are checked at the end of the sampling period. • MONITOR — Monitor mode allows the SAM PCP Controller to operate as a PCP data gathering unit only. Max Speed Increase Specify the maximum speed increase. in RPM. and it operates at a slower speed when the switch is set to LO. the motor operates at high speed when the switch is set to HI. Settling Period Specify the settling period. in RPM. The average production value is then used to determine whether to increase or decrease the speed before the next settling/sampling cycle. the Max Speed Increase value overrides the speed increase suggested by the production control algorithm. allowed every settling/sampling cycle. During this period. The SAM PCP Controller will not start or stop the motor. in minutes. the SAM PCP Controller allows the system to stabilize before gathering data for sampling. the motor operates when the switch is set to ON and it turns off when the switch is set to OFF. allowed every settling/sampling cycle.00 Issue Date: 1/18007 . For HOST HI/LO. Sampling Period Specify the sampling period. the Max Speed Decrease value overrides the speed decrease suggested by the production control algorithm. During this period. in minutes. 7-10 Revision 1. If the production control algorithm (PROD CTRL) suggests a speed increase greater than the Max Speed Increase value.

an increase in speed by a minimum five percent would only give you a speed change of 2. the algorithm will increase speed by the Percent Min Speed Change value. the algorithm will challenge the process by increasing the speed by the Percent Min Speed Change value.00 7-11 .5 RPM (50 × 5%). the algorithm will increase speed by the Percent Min Speed Change value.Section 7: PCP Parameter Programming Percent Min Speed Change Specify the minimum speed change as a percent of the current control speed. • When no data exists for previous sampling history during the initial run of the algorithm. This setting allows a sufficient speed change to occur at lower RPMs. • When the speed decreases (due to decrease in production) for the specified consecutive speed decreases. • When the SAM PCP Controller is running at maximum operating speed and no change in production occurs. This speed is used for special conditions when the SAM PCP Controller is required to challenge the process by either increasing or decreasing the speed. Min Prod Change Requirements Specify the required production change as a percent difference between the previous sampling period production and the current sampling period production. Issue Date: 1/18007 Revision 1. Hard-Set Minimum Speed Change Specify the minimum RPM that the rod speed will be changed. If the percent difference is less than the Minimum Production Change Requirement. if you do not specify a hard-set minimum speed change and you are running at a rod speed of 50 RPM. the algorithm will decrease speed by the Percent Min Speed Change value. For example. the production control algorithm will consider the current state to be a NO CHANGE IN PRODUCTION and will reduce rod speed. Some of the conditions and the responses the SAM PCP Controller will execute are provided below. • When the SAM PCP Controller is running at minimum operating speed and the Low and High Production violations are inactive. regardless of the minimum value specified for Percent Min Speed Change.

To execute this override feature. press <MENU> to instantly return to the Main Menu screen. • Select NO to prevent the pump from starting when polished rod rotation is detected. especially during backspin. You cannot start the pump until the SAM PCP Controller does not detect rod speed. 1. highlight the EXECUTE field and then press <ENTER>. Momentary Speed Override Use this feature to immediately change the speed of the PCP to the value specified in this field. The message SPEED CHANGE INITIATED displays for a few seconds to notify you that the SAM PCP Controller executed this feature. This speed remains in effect until the end of the next sampling period or when a violation occurs. From the Main Menu screen. select 3. 7-12 Revision 1.00 Issue Date: 1/18007 . • Select YES to allow the pump to start even when polished rod rotation is detected.SAM Well Manager™ — Progressing Cavity Pump User Manual No of CSC Speed Dec Allowed Specify the number of consecutive speed decreases allowed before challenging the production control algorithm and increasing speed. Procedure Follow the steps below to program the PCP control parameters in both screens. Note: If another screen is displayed. WARNING: Selecting YES to override stop protection can cause pump damage or personnel injury to occur if you start the pump while it is rotating. Stopping Protection Override Specify whether you want to prevent or allow the pump to start even when the SAM PCP Controller detects polished rod rotation. Otherwise the speed will continuously drop until you reach minimum speed specified in the Min Operating Speed field. CONFIGURATION to display the Configuration Menu screen.

Repeat steps 3 and 4 for each field you want to edit. The next field highlights. and then press <ENTER>. do either of the following: • Press <EXIT> to return to the PCP Configuration Menu screen. Issue Date: 1/18007 Revision 1. 3. select 2. Select 1. You must remember to return to this screen and enable the control functions you need. PCP CONFIGURATION. After all numerical values are correct. After you press a key. the next digit to the right highlights. 7. Do one of the following: • To enter numerical values. CONTROL PARAMETERS CFG to display the first PCP Control Parameters CFG screen. 5. When finished editing fields.00 7-13 . The values you entered into both screens are saved. 6. At times.3 Configuring Parameter Violations Several SAM PCP Controller control functions can be disabled SAM (D) or enabled (E) individually by using the Violation 3/1/2 Configuration programming screen (Figure 7-5). 7. Repeat steps 3 and 4 for each field you want to edit. and then press <EDIT> 4.Section 7: PCP Parameter Programming 2. press <EDIT>. press <↑> or <↓>. and then select 1. press <ENTER>. press <EDIT> and then press the number keys. To display the Violation Configuration programming screen. You can press <←> to return to a digit to the left to change it. VIOLATION CONFIGURATION from the PCP Configuration Menu screen. disabling all control functions is helpful for troubleshooting purposes until the problem is resolved. press <NEXT> to display the second screen. 8. • To select field options. • Press <MENU> to return to the Main Menu screen. When finished with all fields on this screen. Press <↑> or <↓> to highlight the appropriate data field.

Once it exceeds the CSC (consecutive) value.SAM Well Manager™ — Progressing Cavity Pump User Manual Figure 7-5. Violation Configuration Programming Screen Data Field Descriptions Rows Information about the data fields in each row is provided below. The current speed captured through the sensor connected to the polished rod is monitored and compared to the specified LIMIT value. Each column is described at the bottom of this screen. you must manually reset the malfunction. This violation provides the SAM PCP Controller early warning with any evidence of a stalled pump or sensor malfunction at the rate of onesecond resolution. If the violations continue and it exceeds the Consecutive Malfunction allowed.00 Issue Date: 1/18007 . in RPM. the SAM PCP Controller automatically restarts. the SAM PCP Controller either enters SHUTDOWN (S) or MALF RUN MIN SPEED (R). After it enters this state. the SAM PCP Controller either operates in Downtime or Violation Run Min Speed mode. Low RPM Specify the minimum pump motor speed allowed. 7-14 Revision 1. After the mode period expires. No RPM Specify if you do not want the SAM PCP Controller to check for an RPM signal.

After the mode period expires. After it enters this state. thus increasing the torque. you must manually reset the malfunction. you must manually reset the malfunction. For information about scaling the torque signal input. the SAM PCP Controller either operates in Downtime or Violation Run Min Speed mode. the SAM PCP Controller either enters SHUTDOWN (S) or MALF RUN MIN SPEED (R). the SAM PCP Controller either enters SHUTDOWN (S) or MALF RUN MIN SPEED (R). The current torque (input from the drive) is compared to the specified LIMIT value to detect if the pump is beginning to show evidence of stalling or fluid starvation that can cause friction between the stator and elastometer. At this state. the SAM PCP Controller either operates in Downtime or Violation Run Min Speed mode.Section 7: PCP Parameter Programming Critical Torq Specify the maximum motor torque allowed. Issue Date: 1/18007 Revision 1. Torq Limiting Specify the desired maximum operating motor torque. After the mode period expires. The critical torque limit should be set higher than the Torq Limiting value described below. the SAM PCP Controller will decrease the speed by the specified torque limiting speed value. This limit should be set lower than the Critical Torq limit value described above. If the violation continues and it exceeds the Consecutive Malfunction allowed. and once it is violated. After it enters this state. the SAM PCP Controller automatically restarts. and continue reducing speed until the minimum operating speed is reached. the SAM PCP Controller automatically restarts. If the violation continues and it exceeds the Consecutive Malfunction allowed. This is an instantaneous action that reduces the speed in a single step to the minimum operating speed (Low RPM). Note: A CSC value of zero will shut down the pump or run the pump at minimum speed with no restarts. Once it exceeds the CSC (consecutive) value. The current torque (an analog input from the variable speed drive) is compared to the specified LIMIT value. Torque is monitored every second.00 7-15 . see “Configuring End Devices” on page 7-20.

Speed continues decreasing until it reaches the Minimum Operating Speed. Production for the current sampling period is compared to this value to detect a fluid starvation/dry pump condition. After the mode period expires. the SAM PCP Controller decreases rod speed by the value specified in the Hi/Lo Prod Speed Change field. the SAM PCP Controller either enters SHUTDOWN (S) or MALF RUN MIN SPEED (R). If the violations continue and it exceeds the Consecutive Malfunction allowed. At this state. you must manually reset the malfunction. When a violation occurs. The SAM PCP Controller compares the present rod speed captured through the sensor connected to the polished rod and the speed control output that the SAM PCP Controller sends to the variable speed drive. you must manually reset the malfunction. After it enters this state. Speed continues decreasing until it reaches the Minimum Operating Speed.00 Issue Date: 1/18007 . Production for the current sampling period is compared to this value to detect a production transmitter malfunction at the rate of one-minute resolution for Speed Control Operation mode or at end of every sampling period for Production Control Operation mode. the SAM PCP Controller automatically restarts. This feature also helps monitor (at the rate of one-minute resolution) to detect if something is wrong with the production transmitter for Speed Control Operation mode or at the end of every sampling period for Production Control Operation mode. At this state. When a violation occurs. the SAM PCP Controller either operates in Downtime or Violation Run Min Speed mode. If the violations continue and it exceeds the Consecutive Malfunction allowed. the SAM PCP Controller either enters SHUTDOWN (S) or MALF RUN MIN SPEED (R). After mode period expires. After it enters this state. the SAM PCP Controller issues an alarm informing the operator that the controller and drive speeds are out of sync. the SAM PCP Controller either operates in Downtime or Violation Run Min Speed mode. If the difference is greater than the speed difference limit.SAM Well Manager™ — Progressing Cavity Pump User Manual Low Prod Specify the minimum amount of fluid production allowed. the SAM PCP Controller decreases motor speed by the value specified in the Hi/Lo Prod Speed Change field. Speed Diff Specify the speed difference allowed between measured polished rod speed and the speed control output. 7-16 Revision 1. High Prod Specify the maximum amount of fluid production allowed. the SAM PCP Controller automatically restarts.

CSC ALLOWED Specify the number of consecutive times the SAM PCP Controller can detect the limit being violated before entering SHUTDOWN or MALF RUN MIN SPEED mode. The options available are: • Shutdown (S) — Shuts down the pump and remains shut down until the operator resets the malfunction. E/D Specify if the violation is to be enabled (E) or disabled (D). LIMIT Specify the limit required to trigger a violation. The malfunction must be manually reset to remove it from this state. MLF ALLOWED Specify the number of consecutive downtime cycles allowed before the SAM PCP Controller issues a Malfunction state. The options available are: • Shutdown (S) — Shuts down the pump during the Downtime period. DT ACTION Specify the downtime action to occur once the violation exceeds the CSC ALLOWED consecutive violations allowed. • Run Minimum (R) — Operates the pump at minimum operating speed during the Downtime period. This feature is not available for Speed Diff. MLF ACTION Specify the malfunction action to occur once the violation exceeds the MLF ALLOWED consecutive violations allowed. The action the Malfunction State issues depends on the action specified for DT ACTION. Issue Date: 1/18007 Revision 1.00 7-17 . This feature is not available for Speed Diff.Section 7: PCP Parameter Programming Columns Information about the data fields in each column is provided below.

certain default control functions are automatically enabled. From the Main Menu screen.SAM Well Manager™ — Progressing Cavity Pump User Manual • Run Minimum Speed (R) — Operates the pump at minimum operating speed until the operator resets the malfunction. Any violations occurring during the start delay are not considered. Press <→> to move to the next field to the left in the row. Note: If another screen is displayed. press <ENTER>. and then select 2. The next field highlights. You can press <←> to return to a digit to the left to change it. the next digit to the right highlights. 2. Select 1. 1. 7-18 Revision 1. Note: If the control mode is changed. CONFIGURATION to display the Configuration Menu screen. and then press <ENTER>. 5. press <EDIT>. PCP CONFIGURATION. and then press <EDIT> 4. This feature is not available for Speed Diff. Do one of the following: • To enter numerical values. press <MENU> to instantly return to the Main Menu screen. press <EDIT> and then press the number keys. 3. select 3. press <↑> or <↓>. After all numerical values are correct. either manually or automatically. • To select field options.00 Issue Date: 1/18007 . Procedure Follow the steps below to enable or disable the SAM PCP Controller control functions and specify violation values and actions. The countdown starts as soon as the controller switches to STARTING STATE. VIOLATION CONFIGURATION to display a Violation Configuration programming screen. After you press a key. DELAY Specify the delay time allowed before the SAM PCP Controller starts checking for violations. Press <↑> or <↓> to highlight the appropriate data field.

4 Configuring End Devices All end device (wedge meter. 7. END DEVICES CFG from the PCP Configuration Menu screen.) SAM configuration is done through the End Devices CFG 3/1/3 programming screen (Figure 7-6). When finished editing fields. select 3. etc. Repeat steps 3 and 4 for each field you want to edit. Figure 7-6. The values you entered are saved.Section 7: PCP Parameter Programming 6. do either of the following: • Press <EXIT> to return to the PCP Configuration Menu screen. turbine meter. End Devices CFG Programming Screen Example (for Electric Prime Mover and Wedge Meter) Issue Date: 1/18007 Revision 1. scaled flow.00 7-19 . 8. To change field values in the next row. To display this screen. press <↑> and <↓>. 7. • Press <MENU> to return to the Main Menu screen.

• SCALED FLOW — When this option is selected. Speed Monitor Input This field is defaulted to the TB4 (RPM) port. in engineering units. the following additional fields display: 7-20 Revision 1. An analog input channel can be selected to monitor an analog speed. or a 1 — 5 VDC output. in engineering units. Speed Control Output Channel This field is hard coded to A01specifying the output port designated for speed control output. – Scaled Min — Select the minimum scaled value. • WEDGE METER — When this option is selected. Virtual analog channel 3 is set as the default and cannot be changed. Production Input Channel Select the option SCALED FLOW.SAM Well Manager™ — Progressing Cavity Pump User Manual Data Field Descriptions Information about each data field is provided below. – Input Type — Refer to the end device for the range of output signal. It is always set to virtual AI 1. WEDGE METER. or TURBINE METER. which is the output to the variable speed drive for speed control. the following additional fields display: – Scaled Production Analog # — Analog input channel used to measure flow.00 Issue Date: 1/18007 . – Scaled Max — Select the maximum scaled value. Typical devices provide a 4 — 20 MA DC output.

Water is 1. – Max Scaled Pressure — Specify the maximum scale of the transducer in inches of water.000. – Input Type — Enter the range of the output from the end device. Virtual analog channel 6 is set as the default and cannot be changed. the Turbine Meter Factor field displays. – Min Scaled Pressure — Specify the minimum scale of the transducer in inches of water. Hydraulic Pressure Analog Displays the analog input channel used to control the hydraulic prime mover. This value is the height of the wedge versus the diameter of the pipe squared. Input Type Specify the input signal type used for measuring motor torque. Motor Torque Analog # Displays the analog input channel used to measure polished rod torque. It is always set to virtual AI 1. Virtual analog channel 6 is set as the default and cannot be changed. – Turbine Meter Factor — Specify the number of pulses generated by the meter that equal one gallon. This field cannot be edited and is only available if a hydraulic prime mover is specified. – Fluid Density (in kg/m^3) — Specify the density of the fluid. – Kd^2 — Specify the wedge meter flow coefficient.00 7-21 . Issue Date: 1/18007 Revision 1. Max Scaled Motor Torque Specify the full scale of VSD analog output used for motor torque. • TURBINE METER — When this option is selected. This field is only available if an electric prime mover is specified.Section 7: PCP Parameter Programming – Differential Pressure Analog # — Analog input channel used to measure pressure. Typically either 4 — 20 Ma or 1— 5 VDC.

and then select 3. 3. For channels 10 and above. 5. press <ENTER>. type the value for the tens and then type the value for the ones. Procedure Follow the steps below to configure end devices. Drive Fault Status Dig Channel Specify the digital input port used for receiving the drive fault status. • Press <MENU> to return to the Main Menu screen. • To select field options. This field is only available if a hydraulic prime mover is specified. and then press <ENTER>. CONFIGURATION to display the Configuration Menu screen. After all numerical values are correct. press <EDIT>. press <EDIT> and then press the number keys. PCP CONFIGURATION. From the Main Menu screen. press <MENU> to instantly return to the Main Menu screen. select 3. After you press a key. 7-22 Revision 1. Press <↑> or <↓> to highlight the appropriate data field.SAM Well Manager™ — Progressing Cavity Pump User Manual Hydraulic Pressure Max Range Specify the maximum hydraulic pressure allowed for the hydraulic prime mover when it is operating at full range. When finished editing fields. The choices are DI1 through DI64. press <↑> or <↓>. You can press <←> to return to a digit to the left to change it. Select 1. END DEVICES CFG to display an End Devices CFG programming screen. 2.00 Issue Date: 1/18007 . Do one of the following: • To enter numerical values. The next field highlights. do either of the following: • Press <EXIT> to return to the PCP Configuration Menu screen. Note: If another screen is displayed. the next digit to the right highlights. 1. 6. Repeat steps 3 and 4 for each field you want to edit. and then press <EDIT> 4.

PRODUCTION/MOTOR INFO from the PCP Configuration Menu screen. select 4. The calculation parameter data is entered through the 3/1/4 Production/Motor Information programming screen (Figure 7-7).00 7-23 . 7. Prime Mover Type Specify whether the prime mover is Electric or Hydraulic driven.Section 7: PCP Parameter Programming The values you entered are saved. Prod K-Factor Specify the K-factor multiplier to apply to the production input to refine the production calculation. Issue Date: 1/18007 Revision 1. To display this screen. Theoretical Pump Displacement Specify the pump manufacturer’s design displacement in barrels per 100 RPM.5 Configuring Production and Motor Information Production K-factor is used as a correction to measured SAM production. Production/Motor Information Programming Screen Example (for Electric Prime Mover) Data Field Descriptions Information about each data field is provided below. Figure 7-7.

You should be able to find this information on the motor nameplate. • Hydraulic — When this option is selected. The SAM PCP Controller takes the current output speed to the drive and the current input RPM speed from the rods and calculates a new sheave ratio based on the difference.SAM Well Manager™ — Progressing Cavity Pump User Manual • Electric — When this option is selected. To use this option. – Motor Full Load RPM — Specify the rated full load RPM of the pump motor. You can use the CALC option located to the right of the field to automatically calculate this value. You should be able to find this information on the motor nameplate. the following additional fields display: – Horse Power — Specify the rated horsepower of the pump motor. – Hydraulic Motor Displacement — Specify the maximum displacement of the hydraulic motor that is connected to the polished rod via belts and sheaves. the sheave ratio equals 4. For example.00 Issue Date: 1/18007 . Take the size of the drive head sheave and divide it by the size of the motor sheave. the following additional fields display: – Hydraulic Pump Max Displacement — Specify the maximum displacement of the hydraulic pump that is driving the hydraulic motor. This value allows you to convert RPM to rod speed. if drive head sheave equals 28 and motor sheave size equals 7. 7-24 Revision 1. The value is calculated and displayed in the Sheave Ratio field. Sheave Ratio Specify the ratio of motor RPM to rod RPM to yield the number of revolutions the motor makes for each revolution of the rod. press <→> to highlight CALC and then press <ENTER>.

After all numerical values correct. the next digit to the right highlights. Press <↑> or <↓> to highlight the appropriate data field. Note: If another screen is displayed. From the Main Menu screen. When the value you want is correct press <ENTER>. press <ENTER>. The next field highlights. 5.00 7-25 . and length of time used for sand blowout. press <EDIT> and then press the number keys. To Issue Date: 1/18007 Revision 1. CONFIGURATION to display the Configuration Menu screen. do either of the following: • Press <EXIT> to return to the PCP Configuration Menu screen. Do one of the following: • To enter numerical values. select 3. press <MENU> to instantly return to the Main Menu screen. When finished editing fields.Section 7: PCP Parameter Programming Procedure Follow the steps below to configure production K-factor and motor information. such 3/1/5 as rod torque. After you press a key. 3. and then select 4. • To select field options.6 Configuring Special Features The Special Features programming screen (Figure 7-8) is used to SAM configure parameters for the sand blowout (SBO) feature. press <EDIT>. • Press <MENU> to return to the Main Menu screen. PCP CONFIGURATION. Repeat steps 3 and 4 for each field you want to edit. 6. 1. 7. You can press <←> to return to a digit to the left to change it. press <↑> or <↓>. and then press <EDIT> 4. 7. and then press <ENTER>. PRODUCTION/MOTOR INFO to display Production/Motor Information programming screen. Select 1. 2. motor speed. You can also specify whether you want the VSD to be able to restart the pump when power has resumed after a power failure.

SBO Fast Speed Increase Specify the rod speed to be used for sand blowout. Figure 7-8. 7-26 Revision 1. Speed Decrease Number of Ramp Down Specify the number of consecutive ramp downs before sand blowout speed is initiated. Sandy Well High Torque Threshold Specify the rod torque limit required to enable sand blowout control. SBO State Speed Decrease Period Specify the length of time to be in the speed decrease state to allow the fluid in the annulus to build up. select 5. Feature Enabled Specify whether to enable or disable the sand blowout feature. SBO State Speed Decrease Specify the rod RPM speed decrease for each ramp down.SAM Well Manager™ — Progressing Cavity Pump User Manual display this screen. Special Features Programming Screen Data Field Descriptions Information about each data field is provided below.00 Issue Date: 1/18007 . SPECIAL FEATURES from the PCP Configuration Menu screen.

The next field highlights.00 7-27 . Note: If another screen is displayed. PCP CONFIGURATION. Issue Date: 1/18007 Revision 1. press <↑> or <↓>. and then press <EDIT> 4. press <ENTER>. 1. After you press a key. 2. select No. • To allow the pump to start. SPECIAL FEATURES to display the Special Features programming screen for the sand blowout feature. You can press <←> to return to a digit to the left to change it. Press <↑> or <↓> to highlight the appropriate data field. and then press <ENTER>. Procedure Follow the steps below to configure for special features. Do one of the following: • To enter numerical values. When Yes is selected to enable this feature. CONFIGURATION to display the Configuration Menu screen. POWER FAILURE LOCKOUT: Feature Enabled Specify whether you want the SAM PCP Controller to prevent the VSD from starting the pump after a power failure. • To prevent the pump from starting. press <EDIT> and then press the number keys. and then select 5. This feature is used to clear out the buildup of sand above the pump to prevent high torque and possible rod parts. the operator must manually restart the pump. • To select field options. the next digit to the right highlights. Select 1. select 3.Section 7: PCP Parameter Programming SBO State Speed Increase Period Specify the length of time the motor is to run at the speed specified for sand blowout. After all numerical values are correct. From the Main Menu screen. select Yes. press <MENU> to instantly return to the Main Menu screen. 3. press <EDIT>.

00 Issue Date: 1/18007 . 6. do either of the following: • Press <EXIT> to return to the PCP Configuration Menu screen.SAM Well Manager™ — Progressing Cavity Pump User Manual 5. When finished editing fields. 7-28 Revision 1. • Press <MENU> to return to the Main Menu screen. Repeat steps 3 and 4 or each field you want to edit.

............ 8-36 8........................ 8-33 8.................... 8-37 Issue Date: 1/18/08 Revision 1...................................... 8-28 8...............................6 Changing Passwords .............................. 8-2 RTU Level Menu ............................................5..........................1 Configuring Slave Device Parameters ..... For information about programming general PCP parameters that control PCP monitoring and control... 8-31 8.............. 8-14 8... 8-30 8.............2 8..................1 Configuring Communication Parameters..1 Configuring Auxiliary Analog Inputs ............... 8-7 8........7 Resetting Parameters to Factory-Default Values .............................4........................................” The topics covered in this section include: 8..................3 8.................................... 8-4 Setting the Controller Date and Time .........................1 8.... 8-5 Communication Parameters Configuration .......... 8-26 8. 8-12 8..........8 Configuring the Default Screen. 8-8 8....5 Modbus Master and Slave Device Configuration ..5........ 8-15 8. “PCP Parameter Programming..5.. 8-24 8....10 Auxiliary I/O Configuration.......Section 8 SAM Controller Programming Parameter values controlling basic operations of the SAM PCP Controller must be properly programmed in order for any effective well management and control to occur.4 Configuring the Communication Expansion Port ..........10..................4 Overview of SAM PCP Controller Parameter Programming .......................9 Setting Gauge Off Time and Peak Energy Management ...00 8-1 ..............................2 Configuring Modbus Transmission Mode ......5........ Note: Only information about programming configuration parameters that control PCP operations of the SAM PCP Controller is described in this section...... 8-22 8...............2 Writing Register Values to Registers and the Slave Device...........3 Specifying a Polling Routine Rate .....4................. see section 7.....

....................12..............................................11...........3 Configuring Register Calculations .................................14 8...............4 Enabling and Disabling Logic Expressions . 8-97 Configuring VSD Parameters...... 8-54 8.......... 8-78 Custody Transfer .........13 8..........12 8..... 8-75 8..............10......11 8...........SAM Well Manager™ — Progressing Cavity Pump User Manual 8......................17 8.... 8-65 8.................... 8-73 8...................1 Configuring a Register Alarm ............ 8-94 Configuring Alarm (Coil) Tracking ............................ 8-45 8....................2 Configuring NX-19 Design Parameters .. and accumulator values • Logic expression commands • AGA 3 parameters 8-2 Revision 1.. Some of the necessary parameters include: • Date........................................10................................14................. and user passwords • Communication parameters • Analog.................................... 8-99 8. 8-67 AGA 3 Parameter Configuration.................1 Configuring AGA 3 Parameters ...................2 Programming a Logic Expression Action ..............3 Configuring Auxiliary Digital Inputs and Outputs ....... 8-53 8..... 8-79 8...... 8-80 8............................. 8-41 8..12.. 8-62 8..................4 Configuring Auxiliary Accumulators...2 Configuring a Register Log.... 8-68 8..1 Programming a Logic Expression ................. 8-79 Register Configuration ....................16 8..................3 Configuring Temperature and Pressure.....12.........1 Overview of SAM PCP Controller Parameter Programming Several parameters need to be defined (programmed) that control basic daily routine operations performed by the SAM PCP Controller.....3 Clearing the Logic Expression State ..............00 Issue Date: 1/18/08 ..........................4 Enabling and Disabling AGA 3 Calculations ....... 8-88 Configuring and Enabling/Disabling HOA...11............11...........................................14.. digital. time....2 Configuring Auxiliary Analog Outputs..15 8.......... 8-48 Logic Expressions .......10.11.........14............................. 8-70 8................. 8-83 8........12......

CONFIGURATION from the Main Menu screen and then select 3.” on page 8-28. first select 3. 3/3 To access this screen. For information about this operator interface and how to use it. Figure 8-1. see “Controller Operator Interface” in section 2.” Issue Date: 1/18/08 Revision 1. Operator Interface Keypad Programming All SAM PCP Controller programming parameter values are entered through the 20-key operator interface keypad mounted in the SAM PCP Controller enclosure. SAM Configuration Menu Screen Note: A user password is required to access this menu screen if password protection is enabled. SAM CONFIGURATION.00 8-3 .Section 8: SAM Controller Programming • Register logs and calculations • Alarm parameters • VSD parameters The actual SAM PCP Controller configuration values are SAM available under the SAM Configuration Menu screen (Figure 8-1). see “Changing Passwords. “Description of the SAM PCP Controller System. For information about passwords.

If the battery is not included. which is required for recording and plotting historical data • Communication parameters. Before programming the SAM PCP Controller. such as establishing baud rates. see “Battery Disconnect Jumper Pins” in section 6. handshake protocol. If the jumper is not on both pins. To display this screen. Battery disconnect jumper pins are located next to the battery. ensure that the shorting jumper is on both pins so that the battery is included in the circuit. the SAM PCP Controller will loose programming when the power switch is turned off. the expansion board must be temporarily removed to properly place the jumper. The parameters include: • Date and time. The battery jumper configuration can be checked by looking down between the expansion board and the main board from the top. on very rare occasions.2 RTU Level Menu SAM 3/3/1 Several fundamental operating parameters within the SAM PCP Controller need to be configured. Usually these parameters only need to be configured once. or at the most.SAM Well Manager™ — Progressing Cavity Pump User Manual RAM Backup Protection Many of the parameters programmed for SAM control are stored in RAM on the SAM PCP Controller circuit board. “Hardware Configuration. This memory is supported during power outages by a lithium battery located near the top of this circuit board.” 8. select 1. RTU LEVEL from the SAM Configuration Menu screen. 8-4 Revision 1. For more information about the battery. and key up and key down times • User and supervisor passwords to restrict unauthorized access to the configuration screens • Restoration of factory-default parameters values • Mainboard I/O diagnostics for troubleshooting purposes These configuration operations are performed using options available through the RTU Level Menu screen (Figure 8-2).00 Issue Date: 1/18/08 . Failure to include the battery will cause the SAM PCP Controller to lose programming when the power switch is turned off.

The SAM PCP Controller can automatically adjust the time setting for daylight saving time (DST). CONTROLLER DATE AND TIME from the RTU Level Menu screen. The North American — United States dates are used to define the beginning and end of the DST period. Issue Date: 1/18/08 Revision 1.3 Setting the Controller Date and Time SAM 3/3/1/1 In order for historical data to be accurate. Date and time are set using the Clock Calendar Configuration screen (Figure 8-3).Section 8: SAM Controller Programming Figure 8-2. To display this screen. select 1.00 8-5 . RTU Level Menu Screen 8. If your area does not recognize DST. the date and time in the SAM PCP Controller must be programmed to agree with local time. disable the DST feature at this time.

3. CONTROLLER DATE AND TIME to display the Clock Calendar Configuration screen. Be sure to use the date format shown of MM/DD/YYYY. Clock Calendar Configuration Screen Procedure Follow the steps below to set the date and time. 8-6 Revision 1. 5. Press <EDIT> and use the number keys to enter the present local time. Select 1. RTU LEVEL.SAM Well Manager™ — Progressing Cavity Pump User Manual Figure 8-3. Press <EDIT> and use the number keys to enter the present month/date/year. 2. select 3. Be sure to use the 24-hour clock format of HH:MM:SS.00 Issue Date: 1/18/08 . Note: If another screen is displayed. 1. From the Main Menu screen. CONFIGURATION. and then press <ENTER>. 4. and then press <ENTER>. Press <↓> until the New Time field highlights. The New Date field highlights. and then select 3. press <MENU> to instantly return to the Main Menu screen. and then select 1. SAM CONFIGURATION to display the SAM Configuration Menu screen.

Figure 8-4. The SAM PCP Controller now resumes operations based on the new date and time you programmed.Section 8: SAM Controller Programming 6. If you want to use daylight saving time. select 2.) connected to it. COMMUNICATION PARAMETERS from the RTU Level Menu screen. 8. 7.” If it does not. Communication Parameters Menu Screen Issue Date: 1/18/08 Revision 1. you must program the communication parameters. When finished editing fields. press <EDIT>. etc. do either of the following: • To return to the RTU Level Menu screen. press <EXIT>. make sure the Enable DST field reads “ENABLE.00 8-7 .4 Communication Parameters Configuration SAM 3/3/1/2 If the SAM PCP Controller has data telemetry equipment (radio. press <↑> or <↓> to toggle to ENABLE. and then press <ENTER>. To display this menu. • To return to the Main Menu screen. press <MENU>. Communication parameters are programmed using the options available under the Communication Parameters Menu screen (Figure 8-4). press <↓> to highlight this field. Default parameter values are preset with factory-default values that you may need to edit. cell phone.

To display this screen.SAM Well Manager™ — Progressing Cavity Pump User Manual 8. SAM 3/3/1/2/1 Figure 8-5.4.1 Configuring Communication Parameters The communication parameters that you usually need to configure are: • RTU address • Data transmission rate • Keying properties • Handshake protocol These parameters are programmed using a Communication Parameters Menu screen similar to Figure 8-4.00 Issue Date: 1/18/08 . select 1. Communication Administration Screen 8-8 Revision 1. COMMUNICATION PORT CFG from the Communication Parameters Menu screen.

Enable/Disable Radio CTS and DCD The SAM PCP Controller does not need these “handshake” signals. The Extended Lufkin Automation Modbus (ELAM) protocol is used for addresses of 248 through 2295. Key Down Time At the end of the message string. from the time that the controller recognizes an incoming message addressed to it before the RTS line is raised to key the radio to send a reply. Delay before Key Up The time delay. the RTS is held high for this amount of time.00 8-9 . and it also allows standard Modbus messages to be combined together.200 baud. RTU Address Specify a unique identifier number for the controller that must be coordinated with the address entry in the host computer SCADA software. Radio Port Baud Rate The SAM PCP Controller supports a range of data transmission rates from 300 to 115. Issue Date: 1/18/08 Revision 1. leave this value set to DISABLE. the controller will delay this amount of time before actually starting to send data. Key Up Time Once the RTS line is raised. The SAM PCP Controller uses standard RTU Modbus protocol for address settings of 247 and below. they can be enabled. Typically. For more information on the ELAM protocol.Section 8: SAM Controller Programming Data Field Descriptions Information about each data field is provided below. ELAM protocol allows for much larger blocks of data to be transmitted. contact your Lufkin Automation representative. The baud rate of the front panel DB-9 RS232 laptop port can be set at a different value from that of the radio port. but if your radio requires that protocol. in milliseconds.

the RTS is held high for this amount of time. The settings available include: • RS485 • RS232 • FSK Modem • Ethernet • None Expansion Comm Baud Rate The SAM PCP Controller supports a range of data transmission rates from 300 to 115.00 Issue Date: 1/18/08 . 8-10 Revision 1. If those gaps are longer than the 3. Key Up Time Once the RTS line is raised from the second communication port.200 baud on the expansion port. These situations can resolve by programming a longer character gap timeout. the end of a message is marked by a break or gap in the message string that is greater than 3. the SAM PCP Controller will not receive a valid message. Key Down Time At the end of the message string from the second communication port. Expansion Comm.SAM Well Manager™ — Progressing Cavity Pump User Manual Character Gap Timeout The SAM PCP Controller uses RTU Modbus communication protocol. the SAM PCP Controller will delay this amount of time before actually starting to send data.5 data characters in length.5-character time. In that protocol. Mode Option The SAM PCP Controller processor has a second communication port that is presently used for the Modbus master function. Enable RTS/CTS For the second communication port. In some communication networks. therefore leave this value set to DISABLE. repeaters or relay stations may break a message into two or more parts with gaps between the parts. the SAM PCP Controller does not need these “handshake” signals.

2. including the RTU Address. Select 1. When finished editing fields. press <MENU>. press <EDIT>. press <MENU> to instantly return to the Main Menu screen. After you press a key. CONFIGURATION.Section 8: SAM Controller Programming Reset Comm Regs to Default Executing this option resets all communication parameters. Procedure Follow the steps below to configure the communication parameters. press <↑> or <↓>. 7. 4. After all numerical values are correct. • To select field options. the next digit to the right highlights. 5. and then select 3. 6. do either of the following: • To return to the Communication Parameters Menu screen. Do one of the following: • To enter numerical values.00 8-11 . Issue Date: 1/18/08 Revision 1. SAM CONFIGURATION to display the SAM Configuration Menu screen. press <EXIT>. press <EDIT> and then press the number keys. COMMUNICATION PORT CFG. 3. Select 1. Note: If another screen is displayed. select 3. From the Main Menu screen. 1. Repeat steps 4 and 5 for each field you want to edit. and then select 2. to the factory default values. COMMUNICATION PARAMETERS to display the Communication Parameters Menu screen. • To return to the Main Menu screen. press <ENTER>. The next field highlights. Press <↓> until the first field you want to change is highlighted. and then press <ENTER>. RTU LEVEL. You can press <←> to return to a digit to the left to change it. This option should only be executed by a trained Lufkin Automation technician. The Communication Administration screen appears with the RTU Address field highlighted.

4. select 2. 8-12 Revision 1. This programming is done through a Modbus Transmission Mode CFG screen similar to Figure 8-6. MODBUS TRANMISSION MODE CFG from the Communication Parameters Menu screen. To display this screen.SAM Well Manager™ — Progressing Cavity Pump User Manual The communication parameters you configured now take affect in the SAM PCP Controller. Figure 8-6. All other fields must remain as shown to support the Modbus RTU protocol used by the SAM PCP Controller. but redirected to the front panel with DTR.2 Configuring Modbus Transmission Mode You can program the parity and stop bits for the Modbus SAM transmission to ensure that it is compatible with the host 3/3/1/2/2 SCADA software.00 Issue Date: 1/18/08 . Note: The same parameters should be applied for the laptop and radio ports. because the laptop port is really the same communications port. 8. Transmission Mode Only the Modbus RTU protocol is supported. Modbus Transmission Mode CFG Screen Data Field Descriptions Information about each data field is provided below.

SAM CONFIGURATION to display the SAM Configuration Menu screen. 3. COMMUNICATION PARAMETERS to display the Communication Parameters Menu screen. Select 2. NO PARITY should be selected to support the Modbus RTU protocol. press <↑> or <↓>. the choices are NO PARITY and ODD/EVN. Stop Bits.00 8-13 . For Parity. These settings must be the same as the host SACADA software. 1. Note: If another screen is displayed. • To select field options. RTU LEVEL. select 3. the next digit to the right highlights. Select 1. CONFIGURATION. press <MENU> to instantly return to the Main Menu screen. Procedure Follow the steps below to configure the communication parameters. After all numerical values are correct. and then select 3. From the Main Menu screen. After you press a key. 2. press <EDIT>. MODBUS TRANSMISSION MODE CFG. The Modbus Transmission Mode CFG screen appears with the Parity field highlighted. Do one of the following: • To enter numerical values. and then select 2. Error Checking Only the CRC (Cyclical Redundancy Check) Modbus protocol is supported. press <EDIT> and then press the number keys. You can press <←> to return to a digit to the left to change it.Section 8: SAM Controller Programming Data Bits. and then press <ENTER>. and Parity These three fields define the data format to be used by the SAM PCP Controller. Issue Date: 1/18/08 Revision 1. press <ENTER>. 4. The next field highlights.

Desired values can be programmed for a maximum of 25 registers in each slave device. press <MENU>. Slave Device #1 is automatically configured with all necessary parameters when a Rosemount 3095FB device is selected for one or more of the process variable inputs in the monitored transmitter configuration.00 Issue Date: 1/18/08 . 520. Repeat step 3 and 4 for each field you want to edit.SAM Well Manager™ — Progressing Cavity Pump User Manual 5. When finished editing fields. If you do need to change the Modbus configuration. The SAM PCP Controller plays the role of master unit and the other devices are configured as slave devices. Modbus/slave device configuration involves the following five processes: • Assigning a number to a slave device • Configuring slave device communication parameters 8-14 Revision 1. The write function requires a manual command to execute. A maximum of 125 data registers can be read from each configured RTU slave device. contact your Lufkin Automation representative for information about this process. The SAM PCP Controller can automatically poll the slave devices at a programmable interval. • To return to the Main Menu screen. The communication parameters you configured now take affect in the SAM PCP Controller. 8. Typically. If necessary. press <EXIT>. do either of the following: • To return to the Communication Parameters Menu screen.5 Modbus Master and Slave Device Configuration A SAM PCP Controller equipped with an RS-485 SAM communication expansion board (Part No. The SAM PCP Controller can also be configured to write data to the slave devices configured to it. you will not use this configuration option.5012) can use 3/3/1/2/3 the Modbus Master function and be programmed to poll and collect data from a maximum of 10 slave devices. 6. you can change the Modbus communication configuration to accommodate these devices.

00 8-15 .Section 8: SAM Controller Programming • Configuring a Modbus slave device • Specifying a polling routine rate • Configuring a transmission mode for compatibility with host SCADA software All Modbus and slave device configuration is done with the options available under the Modbus Master Menu screen (Figure 8-7). For information about expansion board configuration. Modbus Master Menu Screen Note: The SAM PCP Controller must be programmed to recognize an RS-485 communication expansion board before any Modbus master/slave device programming can occur. To display this menu. and each device must be programmed separately. select 3. This programming is done using the Modbus Master Config selection screen (Figure 8-8). Figure 8-7. To display this screen. Issue Date: 1/18/08 Revision 1. Each Modbus RTU to be polled 3/3/1/2/3/1 by the SAM PCP Controller must have a slave device number assigned to it. see “Configuring the Communication Expansion Port” on page 8-26. CONFIGURATION from the Modbus Master Menu screen.5. MODBUS MASTER CFG from the RTU Level Menu screen.1 Configuring Slave Device Parameters The SAM PCP Controller can be programmed to poll a SAM maximum of 10 slave devices. 8. select 1.

you should see a slave device communication configuration screen similar to Figure 8-9 with the slave device number you selected displayed at the top of the screen. You can also return to this screen at any time when you need to change parameter values.SAM Well Manager™ — Progressing Cavity Pump User Manual Figure 8-8. Note: Refer to the user manual for the slave device for information about its parameters. Modbus Master Config Screen After you assign a number to a slave device. 8-16 Revision 1.00 Issue Date: 1/18/08 .” You need to use these fields to specify the type of slave device used as an RTU and its communication parameters. such as “Slave Device 1.

RTU ADDRESS Each slave device must have a different address number. • SIEMENS LS1000 LEVEL SENSORS — A special application of the RS-485 master/slave capabilities of the SAM PCP Controller. • MODBUS SLAVE — Select for any RTU that uses Modbus RTU protocol. The address must match the slave device setting. BAUD RATE Select from a range of options from 300 to 115. Issue Date: 1/18/08 Revision 1.200 baud.00 8-17 . The pre-set parameters include the Rosemount factory default data transfer rate of 9600 baud.Section 8: SAM Controller Programming Figure 8-9. The value must match the slave device setting. DEVICE TYPE Three options are available for specifying a slave device type. • Rosemont 3095 — Slave Device #1 is automatically configured with all necessary parameters when a Rosemount 3095FB device is selected for one or more of the process variable inputs in the monitored transmitter configuration. Slave Device Communication Configuration Screen Data Field Descriptions Information about each data field is provided below. Address numbers of less than 247 are indicated by the standard Modbus guidelines.

# FAILURES ALLOWED Specify the number of times that the SAM PCP Controller will continue to try to poll a slave device once that device is enabled.00 Issue Date: 1/18/08 . KEY DOWN TIME Specify the time. and PARITY These three fields define the data format to be used by the SAM PCP Controller. STOP BITS.SAM Well Manager™ — Progressing Cavity Pump User Manual DATA BITS. in milliseconds. If the SAM PCP Controller does not receive a valid response after this number of consecutive polling attempts. Polling must be enabled to activate the polling function. For more information. that the RTS line is held high at the end of the outgoing message string. see the description about the Status field. a communication failure alarm is flagged for the slave device to alert the operator that data from the slave is not current. in milliseconds. that the processor needs to pause before raising the RTS line when the SAM PCP Controller is ready to poll a slave device. 8-18 Revision 1. in milliseconds. in milliseconds. STATUS This field is used to enable or disable the polling of the slave device. TIMEOUT Specify the time. These settings must be the same as the slave device. disable it to prevent nuisance communication failure alarms. Communication failure flags can be checked using the local LCD display. that the SAM PCP Controller waits after sending a poll message to check the reply message buffer. that are to be added before data is actually transmitted once the RTS line is raised. DELAY BEFORE KEY UP Specify the time. KEY UP TIME Specify the time. If a slave device is to be offline for service.

and it reduces data access time. You need to perform this operation separately for each Modbus slave device on the data network. you need to configure register addresses to register indices. Figure 8-10. keep in mind the generic Modbus organization guidelines.Section 8: SAM Controller Programming Address Association to Registers After the type of slave device used is specified as an RTU. Register Address Configuration Programming Screen The numbers in the Register Index column are the numbers assigned in the SAM PCP Controller buffer of values. • Group together all registers read with a given function code • Read contiguous groups of registers where possible Issue Date: 1/18/08 Revision 1. This configuration is performed using a Register Address Configuration Programming Screen similar to Figure 8-10.00 8-19 . This type of organization minimizes the number of data transmissions required to read all of the desired data. The values in the Register Address column must be programmed with the register numbers in the slave device that contain the data you want to read. press <NEXT>. To display this screen. The Modbus Master function is capable of reading data from a maximum 125 register addresses per Modbus slave device. at the Slave Device Communication Configuration screen. and the slave device communication parameters to be used for it are specified. When you assign register numbers. These addresses are associated to register indices in groups of 20 to a screen.

and then select 1. 8-20 Revision 1. press <↓> to highlight it. 1. Press <↑> or <↓> to highlight the slave device you want to configure. Note: If another screen is displayed. MODBUS MASTER CFG. press <MENU> to instantly return to the Main Menu screen. b. press <↑> or <↓> to scroll through the list to highlight the device number you want assigned. For 10. 4. SAM CONFIGURATION to display the SAM Configuration Menu screen. Note: Every slave device that is to be polled by the SAM PCP Controller must have a number assigned to it. RTU LEVEL and then select 2. CONFIGURATION to display the Modbus Master Config selection screen. Slave Device 1 highlights. select 3. A Slave Device Communication configuration screen similar to Figure 8-9 displays.00 Issue Date: 1/18/08 . Select 1. and then select 3.SAM Well Manager™ — Progressing Cavity Pump User Manual • Arrange the Register Address column with the smaller register numbers at the top of each group Procedure Follow the steps below to configure slave device parameters. 5. press the number key representing the slave device number. Select 3. COMMUNICATION PARAMETERS to display the Communication Parameters Menu screen. 2. CONFIGURATION. For all numbers. For numbers 1 through 9. and then press <ENTER>. From the Main Menu screen. and then press <ENTER>. 3. Do one of the following: a.

Press <↑> or <↓> to highlight the data field you want to edit and then do one of the following: • To enter numerical values.00 8-21 . This action prevents nuisance communication failure alarms from displaying. After you press a key. • Press <MENU> to return to the Main Menu screen. Press <ENTER> when the desired option is displayed. Press the number keys to enter the value you want. Repeat steps 9 and 10 for each field on the screen you want to configure. and then press <ENTER>. 9. 13. and then press <NEXT> to display the Register Address Configuration programming screen (Figure 8-10). the next digit to the right highlights. Note: If the slave device is to be offline for service. and then press <EDIT>. press <NEXT> to display the next screen. 12. After all numerical values are correct. 11. and then repeat steps 9 through 11. Press <↑> or <↓> to highlight the Register Address field you want to configure. press <ENTER>. Issue Date: 1/18/08 Revision 1. 10. press <EDIT> and then press the number keys. do one of the following: • Press <EXIT> to return to the Slave Device Communication Configuration screen (Figure 8-9). press <NEXT>. Make sure all fields in the Slave Device Communication configuration screen (Figure 8-9) have the correct data entered in them. The screen that appears next is determined by the type of slave device specified in the Device Type field. The next field highlights. press <↑> or <↓> to scroll through available options. • To select field options. 7. select DISABLED in the Status field to disable it. When all parameters are specified correctly. When all register numbers are configured.Section 8: SAM Controller Programming 6. You can press <←> to return to a digit to the left to change it. To configure the next group of 20 register numbers. press <EDIT>. 8.

5. To display this screen. 8. select 2. The remaining five register values appear on a second screen similar to Figure 8-12. The Modbus Master Write Utility programming screen (Figure 8-11) is used to write and send to the slave device. WRITE UTILITY from the Modbus Master menu screen. Figure 8-11. you need to specify the Modbus slave device that is to receive these values and then write them to it. Register 3/3/1/2/3/2 values can be assigned to a maximum of 25 register addresses.SAM Well Manager™ — Progressing Cavity Pump User Manual The slave device parameters are saved.00 Issue Date: 1/18/08 . First Modbus Master Write Utility Programming Screen The SAM PCP Controller writes to one register at a time.2 Writing Register Values to Registers and the Slave Device The Modbus Master function can write register values to one SAM or multiple registers of a Modbus slave device. After the addresses are configured. 8-22 Revision 1. so the Modbus guidelines regarding function codes and contiguous registers do not affect a write operation. This screen is also where you find the option to write the values to the Modbus slave device.

5. 3. The Register Address field for Register Index 1 highlights. 1. Press the number keys to enter the value you want. 4. WRITE UTILITY to display the Communication Parameters Menu screen. MODBUS MASTER CFG. and then select 2. 2.Section 8: SAM Controller Programming Figure 8-12. and then press <ENTER>.00 8-23 . Note: If another screen is displayed. Select 1. and then press <EDIT>. select 3. press <MENU> to instantly return to the Main Menu screen. and then select 3. SAM CONFIGURATION to display the SAM Configuration Menu screen. WRITE UTILITY to display the Modbus Master Write Utility screen. Select 3. From the Main Menu screen. Second Modbus Master Write Utility Programming Screen with Write Option Procedure Follow the steps below to write register values to register addresses and the slave device. RTU LEVEL and then select 2. Press <↑> or <↓> to highlight the Register Address field you want to configure. CONFIGURATION. Issue Date: 1/18/08 Revision 1.

The SAM PCP Controller writes the register values to the specified register addresses in the slave device. and then press <EDIT>. When finished configuring the pairs. and then press <ENTER>. Press <↓> to highlight the Write to Device field. Repeat steps 5 through 9 for each Register Address/Register Value pair you want to configure. press <↓> to highlight the Device Number field. After you configure the first 20 pairs on this screen. You can specify the poll rate (or interval) for the routine. 8.SAM Well Manager™ — Progressing Cavity Pump User Manual 6. Repeat steps 5 through 9 for them also. and then press <ENTER>. press <NEXT> to configure the remaining five pairs. • Press <MENU> to return to the Main Menu screen.00 Issue Date: 1/18/08 . 8.5. 9. 7. press the number keys to enter the device number of the Modbus slave device to which you want to write the register values.3 Specifying a Polling Routine Rate The Modbus Master function uses a polling routine to retrieve data from all enabled slave devices in the data network. SAM 3/3/1/2/3/3 8-24 Revision 1. The register values written to the register addresses and the slave device are saved. 14. Press <→> to highlight the corresponding Register Value field. Press <EDIT>. and then press <ENTER>. 12. Do one of the following: • Press <EXIT> to return to the Modbus Master Config Selection screen. 11. Press <←> and then press <↑> or <↓> to highlight the next Register Address field you want to configure. 10. 13. Press the number keys to enter the value you want.

or 6 seconds. After all programmed poll messages are completed. Master Communication Setup Programming Screen Issue Date: 1/18/08 Revision 1. the reply buffer is checked. select 3. If the reply is valid. If the reply is invalid or no reply occurs.000 milliseconds per device times two devices. The Modbus Master function is not designed for an online realtime control function application. Poll rate times around 60 seconds are recommended.000 milliseconds. Figure 8-13. and each data reading takes 500 milliseconds. Each device requires five data transmissions to read all of the desired data. The timeout is set for 600 milliseconds to give some leeway for the data response. the SAM PCP Controller remains idle for the remainder of the poll rate time. the consecutive communication failure counter is incremented. Here is an example for a wellsite that has two slave devices connected to the SAM PCP Controller. the register index is updated with the new value. The total poll time for both devices will be 5 × 600 = 3. MASTER CONFIGURATION from the Modbus Master Menu screen. which should be adequate time for this type of historical supervisory data. After the timeout interval elapses.00 8-25 .Section 8: SAM Controller Programming The polling routine occurs after the SAM PCP Controller sends a polling message to a slave device. The quickest possible poll rate would therefore be 6 seconds. which equals 6. The Master Communications Setup programming screen (Figure 8-13) is used to specify the poll routine rate. To display this screen. Data from a slave device would be no more than 1 or 2 minutes old when read from the SCADA software. The next polling message is transmitted without further delay.

8-26 Revision 1. select 1.00 Issue Date: 1/18/08 . CONFIGURATION. press <MENU> to instantly return to the Main Menu screen. COMMUNICATION PARAMETERS to display the Communication Parameters Menu screen. SAM CONFIGURATION to display the SAM Configuration Menu screen. COMMUNICATION PORT CFG from the Communication Parameters menu screen. 1. Note: If another screen is displayed.5. From the Main Menu screen. To display this screen. MODBUS MASTER CFG to display the Modbus Master Menu screen. • Press <MENU> to return to the Main Menu screen. Select 3. Do one of the following: • Press <EXIT> to return to the Modbus Master Menu screen. 4. select 3. 6. and then select 3. Mode Option field in a Communication Administration screen similar to Figure 8-14. 5. Press <EDIT> and use the number keys to specify the desired poll rate in seconds. and then select 3. When the rate is correct. 8. 3.4 Configuring the Communication Expansion Port The SAM PCP Controller must be programmed to recognize SAM the RS-485 communication expansion port. 2. press <ENTER> to complete the programming. MASTER CONFIGURATION. The polling routine rate value is saved. RTU LEVEL and then select 2. The Master Communication Setup programming screen appears with the Poll Rate field highlighted.SAM Well Manager™ — Progressing Cavity Pump User Manual Procedure Follow the steps below to configure the poll routine rate. Select 1. This 3/3/1/2/1 configuration is accomplished using the Expansion Comm.

1. and then select 1. press <MENU> to instantly return to the Main Menu screen. RTU LEVEL. SAM CONFIGURATION to display the SAM Configuration Menu screen. Mode Option field highlights. COMMUNICATION PORT CFG to display the Communication Administration screen. and then select 3. 4. Communication Administration Screen Displaying Options for Configuring the RS-485 Procedure Follow the steps below to configure the communication expansion port.Section 8: SAM Controller Programming Configure this field for RS-485 Figure 8-14. 2. and then select 2. select 3. CONFIGURATION. Note: You will not see most of the fields shown in Figure 8-14 until after you select RS485. and then press <EDIT>.00 8-27 . From the Main Menu screen. Press <↓> until the Expansion Comm. and then press <ENTER>. Note: If another screen is displayed. Press <↑> or <↓> to scroll through the available options until the RS485 option displays. Issue Date: 1/18/08 Revision 1. Select 1. COMMUNICATION PARAMETERS. 3.

Passwords are assigned and enabled/disabled with a Password Administration screen similar to Figure 8-15. both passwords levels are disabled so that you can commission the controller with a minimum of difficulty. 8-28 Revision 1.6 Changing Passwords SAM 3/3/1/3 The SAM PCP Controller has available two levels of password protection (User and Supervisory) for programming parameters. You do not need to program the baud rate or other handshake and timing parameters.SAM Well Manager™ — Progressing Cavity Pump User Manual A new Communication Administration screen similar to Figure 8-14 appears. Figure 8-15. 8. Password Administration Screen Data Field Descriptions Information about each data field is provided below. PASSWORD ADMINISTRATION from the RTU Level Menu screen.00 Issue Date: 1/18/08 . You are now ready to configure slave devices. These parameters are overridden when a slave device is programmed. 5. To display this screen. By default. select 3. Press <EXIT> to return to the Communication Parameters menu screen.

• USER Password Only • SUPV Password Only When password protection is enabled. SUPV Password Specify a password that can be used for all PCP Configuration and SAM PCP Configuration operations.Section 8: SAM Controller Programming Password Control — The following options are available: • DISABLE BOTH — Disables the password protection feature for users and supervisors (SUPV). Select 1. Issue Date: 1/18/08 Revision 1. 2. The Password Administration screen appears with the Password Control field highlighted. RTU LEVEL. select 3. Procedure Follow the steps below to change a password. including operations available under the RTU Level Menu screen.00 8-29 . and then select 3. and then select 3. press <MENU> to instantly return to the Main Menu screen. • ENABLE BOTH — Enables the password protection feature for users and supervisors. except operations available under the RTU Level Menu screen. so full access to all programming menus is available on new units until passwords are assigned. CONFIGURATION. 1. From the Main Menu screen. SAM CONFIGURATION to display the SAM Configuration Menu screen Note: If another screen is displayed. you can change either password. PASSWORD ADMINISTRATION. User Password Specify a password that can be used for all PCP Configuration and SAM PCP Configuration operations. The factory default is set for no password.

Each parameter must be reprogrammed one field at a time. To execute this operation. press <EDIT>. Press <↓> to highlight the New Password field. a message appears with the YES option highlighted. • Press <MENU> to return to the Main Menu screen. Press <↓> to highlight the Verify New Password field. After you execute this operation. select 4. If one of the ENABLED options is not displayed. Repeat step 4 if you need to change another password. Procedure Follow the steps below to reset the SAM PCP Controller to the factorydefault settings. parameters will not need to be reset. Change the password you want changed (USER or SUPV) by doing the following: a.7 Resetting Parameters to FactoryDefault Values SAM 3/3/1/4 This feature returns many parameters to a factory-default value.00 Issue Date: 1/18/08 . and then press <ENTER>. Normally. b. the userdefined parameters cannot be easily restored. 6. 4. When finished. When this option is selected. and then press <ENTER>. do one of the following: • Press <EXIT> to return to the RTU LEVEL Menu screen. RESET TO DEFAULTS from the RTU Level Menu screen. 8-30 Revision 1. use the number keys to enter the same four-digit number. 8. use the number keys to enter a four-digit number. and then press <ENTER>. press <↓> to select the desired option. 5. press <EDIT>. Make sure that you really need to use this feature. The passwords are changed.SAM Well Manager™ — Progressing Cavity Pump User Manual 3. press <EDIT>.

The PCP Status screen is the screen normally used. select 5. From the Main Menu screen. ADDITIONAL CONFIGURATION from the RTU Level Menu screen. CONFIGURATION. • Press <MENU> to return to the Main Menu screen. and then press <ENTER> to complete the reset process.00 8-31 . press <←> or <→> to highlight NO. 3. This screen is the screen you will normally see when you arrive at the wellsite. and then select 3. To display this screen. Do one of the following: • To restore the factory default settings. you can specify the Main Menu screen or the Gas Measurement screen as the default screen. RESET TO DEFAULTS. A message appears to confirm that you want to reset to the factorydefault parameter values. Select 1. Issue Date: 1/18/08 Revision 1. make sure YES is highlighted. and then select 4. The SAM PCP Controller is reset to the factory-default settings. You can also specify the units of measurement for production volumes displayed by the SAM PCP on this screen. 8. RTU LEVEL. SAM CONFIGURATION to display the SAM Configuration Menu screen. • To cancel the reset operation and keep the current settings. You specify the default screen with the Additional Configuration screen (Figure 8-16). 4. 2.Section 8: SAM Controller Programming 1. and it is the default screen set at the factory. select 3. Note: If another screen is displayed. When finished. press <MENU> to instantly return to the Main Menu screen. or you can restore the PCP Status screen. At any time. and then press <ENTER> to abort the reset procedure.8 Configuring the Default Screen SAM 3/3/1/5 You can specify the screen that automatically displays when no keypad activity occurs for eight minutes. do either of the following: • Press <EXIT> to return to the SAM Configuration Menu screen.

RTU LEVEL. From the Main Menu screen. 3. and then select 5. Note: If another screen is displayed. ADDITIONAL CONFIGURATION.00 Issue Date: 1/18/08 . Select 1. 8-32 Revision 1. Press <EDIT>and then <↑> or <↓> to scroll through the options until the screen you want is displayed. and then select 3. 2. and then press <ENTER>. press <MENU> to instantly return to the Main Menu screen. SAM CONFIGURATION to display the SAM Configuration Menu screen. CONFIGURATION.SAM Well Manager™ — Progressing Cavity Pump User Manual Figure 8-16. The Additional Configuration screen appears with the No Key Operation Default Screen field highlighted. select 3. 1. Additional Configuration Screen used to Specify the Default Screen Procedure Follow the steps below to reset the SAM PCP Controller to the factorydefault settings.

Section 8: SAM Controller Programming

4. When finished, do either of the following: • Press <EXIT> to return to the SAM Configuration Menu screen. • Press <MENU> to return to the Main Menu screen. The SAM PCP Controller from now on will display your selection as the default screen.

8.9

Setting Gauge Off Time and Peak Energy Management

Gauge off time (GOT) is the time of day that the SAM PCP SAM Controller updates all of the 60-day historical data buffers. This 3/3/2 time is typically set for early in the morning shortly before operator personnel report for work so that the SAM PCP Controller can display valid and fresh data from the previous day for analysis. Oil producers may have contracts with their electric power provider to minimize power consumption during peak demand times of the day in return for a more economical rate. The SAM PCP Controller has a Peak Energy Management feature that has the controller shut down the pump during peak times, go into a Downtime Peak Energy Management state, and suspend all normal operation. You can program the period of day and which days this function is to take affect. Normal operation resumes at the end of the programmed period. The Gauge Off Time/Peak Energy Management screen (Figure 8-17) is used to specify GOT and Peak Energy Management times. To display this screen, select 2. GAUGE OFF/PEAK ENERGY MGNT from the SAM Configuration Menu screen.

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Figure 8-17. Gauge Off Time/Peak Energy Mgnt Screen

Data Field Descriptions Information about each data field is provided below. Gauge Off Time Specify the time of day that the SAM PCP Controller updates all of the 60-day historical data buffers. Time is specified using the 24-hour clock format of HH:MM:SS. Peak Energy Management Specify whether you want the Peak Energy Management function to take affect. • To disable it, select DISABLE. This feature can be useful when times are specified for its use, but you want it cancelled temporarily, such as when you are servicing or testing the equipment. Disabled is the default state. • To enable it, select ENABLE. After you select this option, additional fields display for you to specify the days and times this feature is to take affect.

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– Period — Specify the start time for the desired shutdown period, and then the end time. End time must be later in the day than the start time. The period may not include a rollover to the next day. For example, a start time of 22:00 and a stop time of 03:00 are not allowed. – Days Applicable — Specify which days this feature is to take affect by selecting between ENABLE and DISABLE. The same time period applies to each day of the week that is enabled. Procedure Follow the steps below to program GOT and peak energy management. 1. From the Main Menu screen, select 3. CONFIGURATION, and then select 3. SAM CONFIGURATION to display the SAM Configuration Menu screen.
Note: If another screen is displayed, press <MENU> to instantly return

to the Main Menu screen. 2. Select 2. GAUGE OFF TIME/PEAK ENERGY MGNT to display the Gauge Off Time/Peak Energy Mgmt screen with the Gauge Off Time field highlighted. 3. Press <EDIT>, use the number keys to specify the gauge off time, and then press <ENTER>. Be sure to use the 24-hour clock format of HH:MM. 4. To enable Energy Peak Management, press <↓> to highlight the Peak Energy Management field. 5. Press <EDIT> and then press <↑> or <↓> to scroll to ENABLE, and then press <ENTER>. 6. Fields for Period and Days Applicable display. 7. Do the following to specify the start and stop times for Peak Energy Management: a. Press <EDIT> and then press the numerical keys to specify the start time. After you press a number key for the digit that is highlighted, the next digit to the right highlights. You can press <←> to return to a digit to the left. b. After the time is specified for the start time, press <ENTER>.
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c. Press <↓> or <→> to highlight the field for specifying the stop time. d. Repeat steps a and b to specify the numerical values in this field. e. Press<↓>. The time field for Monday highlights. 8. Press <EDIT> and then press <↑> or <↓> to scroll between ENABLE and DISABLE, and then press <ENTER>. The field for the next day highlights. 9. Press<↓>. 10. Repeat steps 8 and 9 for each day. 11. When finished editing fields, do either of the following: • Press <EXIT> to return to the SAM Configuration Menu screen. • Press <MENU> to return to the Main Menu screen. The times for GOT and Peak Energy Management are saved.

8.10 Auxiliary I/O Configuration
The SAM PCP Controller firmware design supports analog SAM inputs and outputs, digital inputs and outputs, and 3/3/3/1 accumulators. Up to 32 auxiliary analog inputs and eight analog outputs can be configured. Sixty-four discrete points can also be configured for virtual digital inputs, digital outputs, and accumulators. All 64 can be configured for the digital inputs and outputs. Ten of them can be configured for accumulators. Optional expansion board hardware is required to implement these auxiliary inputs and outputs. The hardware design of the SAM PCP Controller is modular in concept to allow auxiliary I/O circuit boards to be developed as customer applications arise. An auxiliary expansion board (Part No. 520.5003) is included in the SAM PCP Controller to provide eight analog inputs and two analog outputs. Three of the analog inputs (AI1, AI3, and AI6) are hard-coded for use by the PCP control algorithm. The PCP control algorithm will not work properly if these three inputs are programmed from the default values. The other five analog inputs are available to monitor other wellhead process variables.

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Four points available on the motherboard can be configured for the digital input/output points or for accumulators. Optional expansion boards can be used to provide other points. The SAM PCP Controller uses a “virtual I/O” concept that allows you to program any hardware point as any logical input/output point. During the initializing process, the SAM PCP Controller firmware reads the expansion port to identify which expansion boards are installed. Expansion board address numbers, and in many cases the available range of inputs/outputs, are hardware-configured by jumpers on the expansion board. All inputs and outputs are configured through the options available on the AUX I/O Configuration Menu screen (Figure 8-18). To display this screen, select 3. AUX I/O from the Auxiliary Functions Menu screen.

Figure 8-18. AUX I/O Configuration Menu Screen

8.10.1 Configuring Auxiliary Analog Inputs
Analog inputs are configured through the AUX Analog Input SAM Configuration programming screen (Figure 8-19). To display 3/3/3/1/1 this screen, select 1. AUX ANALOG INPUT CONFIGURATION from the AUX I/O Configuration Menu screen.

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Figure 8-19. AUX Analog Input Configuration Programming Screen

The top portion of this screen lists all 32 of the potentially available “logical” analog input points. The SAM PCP Controller must be told which physical input is associated with that “logical” or virtual input point. After the input is selected, the Setup portion of the screen can be used to define the logical points.
Note: The current operating status of analog inputs is available on a

SAM status screen. For information about this screen, see section 9, “Status Screens.”

Data Field Descriptions Information about each data field is provided below. Board # Enter the physical board number as set by the jumpers on the board. The motherboard is always designated as Board #0. Channel # Enter the physical terminal designation on the expansion board to which the transmitter is connected. Units Specify the engineering units for device being measured.

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This value will typically be zero. Analog input alarms can be used as Logic Expression inputs to control wellsite functions. Max. Value Enter the full scale engineering value for the maximum output from the transducer. Logging This is not a selectable item. Value Enter the engineering units for the minimum output level from the transducer/transmitter.Section 8: SAM Controller Programming Range Specify one of the following input ranges that the SAM PCP Controller is to expect from the process transducer: • 1 — 5V • 0 — 5V • 4 — 20ma • 0 — 20ma Min. Low and High Delay Specify the delay time before the alarm is declared.00 8-39 . but if the transducer has a known offset. the SAM PCP Controller is able to compensate if the correct value is entered in this field. Issue Date: 1/18/08 Revision 1. Alarms and Alerts The SAM PCP Controller can set flags for the following analog input conditions if limit setpoints are programmed and the alarm status is enabled: • Low (Alert) • Low (Alarm) • High (Alert) • High (Alarm) Low and high alert and alarm setpoints should be entered in Engineering units.

4. Engineering Value Indicates the present value of that input expressed in engineering units. • Current reading indicates the present value of that input. AUX I/O to display the AUX I/O Configuration Menu screen. The Board # field highlights.00 Issue Date: 1/18/08 . Procedure Follow the steps below to configure analog inputs. 5. Press <←>. Note: If another screen is displayed. Select 1. select 3. and <↓> to highlight the analog input (AI) you want to configure. 2. The field for AI 1 highlights in the top portion of the screen. 1. press <MENU> to instantly return to the Main Menu screen. <→>. 8-40 Revision 1. Capability and Current Readings The Capability and Current Readings portions of the programming screen are read only. Select 1. <↑>. and then press <ENTER> to move into the Setup portion of this screen. From the Main Menu screen. Select 3. and then select 3. AUX ANALOG INPUT CONFIGURATION to display the AUX Analog Input Configuration programming screen. SAM CONFIGURATION to display the SAM Configuration Menu screen. • Capability is a report about what the SAM PCP Controller reads during the initialization process regarding the hardware capabilities of the expansion board.SAM Well Manager™ — Progressing Cavity Pump User Manual Alarm Status Be sure to enable alarm status if this feature is to be used. 3. AUXILIARY FUNCTIONS to display the Auxiliary Function Config Menu screen. CONFIGURATION.

2 Configuring Auxiliary Analog Outputs Analog outputs are configured through the AUX Analog SAM Output Configuration programming screen (Figure 8-20). AUX ANALOG OUTPUT CONFIGURATION from the AUX I/O Configuration Menu screen. select 2. 7. do one of the following. and then press <ENTER>. press <EXIT> to save your settings and return to the analog input selection portion of the screen to configure another analog input. Repeat step 6 for each data field you want to edit. press <EDIT> and then press the number keys.Section 8: SAM Controller Programming 6. You can press <←> to return to a digit to the left to change it. 8. To 3/3/3/1/2 display this screen. 8. 9. press <ENTER>. press <↑> or <↓>.00 8-41 . The next field highlights. After you press a key. • To select field options. When you are finished configuring analog inputs. After all numerical values are correct. Press <↑> and <↓> to highlight the data field you want to edit. press <EDIT>. • Press <MENU> to return to the Main Menu screen. the next digit to the right highlights. • Press <EXIT> twice to return to the AUX I/O Configuration Menu screen.10. The analog input values are saved. Issue Date: 1/18/08 Revision 1. Repeat steps 5 through 8 for each analog input you want to configure. and then do one of the following: • To enter numerical values. 10. When you are finished configuring the analog input.

” Data Field Descriptions Information about each data field is provided below. The motherboard is always designated as Board #0. After the output is selected. Board # Enter the physical board number as set by the jumpers on the board. the Setup portion of the screen can be used to define the logical points. “Status Screens. The top portion of this screen lists all eight of the potentially available “logical” analog output points. Default settings for analog outputs should only be changed by a qualified Lufkin Automation technician. AUX Analog Output Configuration Programming Screen The SAM PCP application firmware supports only analog output number 1 (AO 1). For information about this screen. Note: The current operating status of analog outputs is available on a SAM status screen.00 Issue Date: 1/18/08 .SAM Well Manager™ — Progressing Cavity Pump User Manual Figure 8-20. The following programming information is provided for informational purposes only. 8-42 Revision 1. see section 9. The SAM PCP Controller must be told which physical output is associated with that “logical” or virtual output point.

Override Val Specify the value to output through the analog output if the override feature is enabled. Value Enter the full-scale engineering value to be displayed on the Aux I/O Status screen for the maximum analog output. Resolution Indicates the number of bits (resolution) that make up a full scale signal for the analog output selected.00 8-43 . Volt Range (Capability) Describes the minimum and maximum (range) of the voltage signal that can be output from the channel for the analog output selected. Note: Min and Max scaling values are used for the status display only. the application has no control over the analog output.Section 8: SAM Controller Programming Channel # Enter the physical terminal designation on the expansion board to which the transmitter is connected. Max. Issue Date: 1/18/08 Revision 1. Range Specify one of the following output ranges that the SAM PCP Controller is to use: • 0 — 5V • 0 — 10V • 4 — 20ma DC Min. When override is enabled. Units Specify the engineering units for the device being controlled. Value Enter the engineering units that you desire to display on the Aux I/O Status screen when the analog output is set for zero. Override Enable or disable the override feature.

6. Note: If another screen is displayed. and <↓> to highlight the logical point of interest (AO) and then press <ENTER> to move into the Setup portion of this screen. Procedure Follow the steps below to configure analog outputs. 5. press <EDIT> and then press the number keys. AUXILIARY FUNCTIONS to display the Auxiliary Function Config Menu screen. and then select 3. SAM CONFIGURATION to display the SAM Configuration Menu screen. 8-44 Revision 1. Press <↑> and <↓> to highlight the data field you want to edit. the next digit to the right highlights. press <ENTER>. press <EDIT>. Select 3. After all numerical values are correct. 4. CONFIGURATION. The field for AO 1 highlights in the top portion of the screen. • To select field options. 1. The Board # field highlights.00 Issue Date: 1/18/08 . 3. Voltage (Current Readings) Displays the current voltage being output from the channel. AUX I/O to display the AUX I/O Configuration Menu screen. Press <←>. press <↑> or <↓>. <↑>. This ranges from zero to 23 bits of resolution. After you press a key. 2. Select 1. and then press <ENTER>. From the Main Menu screen. <→>.SAM Well Manager™ — Progressing Cavity Pump User Manual Raw (Current Readings) Describes the current reading in an unscaled format. You can press <←> to return to a digit to the left to change it. press <MENU> to instantly return to the Main Menu screen. and then do one of the following: • To enter numerical values. select 3. Select 2. AUX ANALOG OUTPUT CONFIGURATION to display the AUX Analog Output Configuration programming screen.

10. do one of the following. The analog output values are saved.10.Section 8: SAM Controller Programming The next field highlights. Repeat step 6 for each data field you want to edit. • Press <MENU> to return to the Main Menu screen. When you are finished configuring analog outputs.3 Configuring Auxiliary Digital Inputs and Outputs Digital inputs and outputs are configured through a Digital SAM Configuration programming screen similar to Figure 7-22. Repeat steps 5 through 8 for each analog output you want to configure.00 8-45 . When you are finished configuring the analog output. Figure 7-22. AUX DIGITAL I/O CONFIGURATION from the AUX I/O Configuration Menu screen. Digital Configuration Programming Screen Issue Date: 1/18/08 Revision 1. 8. To 3/3/3/1/3 display this screen. 7. 9. 8. select 3. • Press <EXIT> twice to return to the AUX I/O Configuration Menu screen. press <EXIT> to save your settings and return to the analog output selection portion of the screen to configure another analog input.

SAM Well Manager™ — Progressing Cavity Pump User Manual The top portion of this screen lists all potentially available “logical” digital input/output points. Procedure Follow the steps below to configure digital inputs and outputs.00 Issue Date: 1/18/08 . the Setup portion of the screen can be used to define the logical points. the alarm state is the digital state which triggers an alarm. 8-46 Revision 1.” Field Descriptions Information about each data field is described below. and then select 3. State Change Delay Specify the number of seconds that a digital state change must be observed before SAM PCP Controller acknowledges the change. Board # Enter the physical board number as set by the jumpers on the board. Note: The current operating status of digital inputs is available on a SAM status screen. CONFIGURATION. The motherboard is always designated as Board #0. Alarms Enabled Tells if the alarming functionality for the digital inputs is enabled. Channel # Enter the physical terminal designation on the expansion board to which the transmitter is connected. The SAM PCP Controller must be told which physical input/output is associated with that “logical” or virtual input/output point. For information about this screen. Input/Output Specify whether the digital point is for Input or Output. SAM CONFIGURATION to display the SAM Configuration Menu screen. From the Main Menu screen. select 3. Alarm State If the alarm is enabled. 1. “Status Screens. After the input/output is selected. see section 9.

press <↑> or <↓>. press <ENTER>. 4. You can press <←> to return to a digit to the left to change it. and <↓> to highlight the logical digital point of interest and then press <ENTER> to move into the Setup portion of this screen. press <MENU> to instantly return to the Main Menu screen. After all numerical values are correct. 6. Select 3. AUXILIARY FUNCTIONS to display the Auxiliary Function Config Menu screen.Section 8: SAM Controller Programming Note: If another screen is displayed. and then press <ENTER>. • To select field options. The Board # field highlights. press <EDIT>. Press <←>. When you are finished configuring the digital input or output. 5. Select 3. 2. 7. <→>. <↑>. Repeat step 6 for each data field you want to edit. press <EXIT> to save your settings and return to the Digital Input or Output selection portion of the screen to configure another analog input. the next digit to the right highlights. Press <↑> and <↓> to highlight the data field you want to edit. AUX I/O to display the AUX I/O Configuration Menu screen.00 8-47 . 3. Select 1. The field for D 01 highlights in the Digital Input or Output (top) portion of the screen. press <EDIT> and then press the number keys. AUX DIGITAL I/O CONFIGURATION to display the Digital Configuration programming screen. 8. Repeat steps 5 through 8 for each digital input and output you want to configure. After you press a key. and then do one of the following: • To enter numerical values. do one of the following: Issue Date: 1/18/08 Revision 1. 10. When you are finished configuring digital inputs and outputs. 9. The next field highlights.

The virtual I/O for the SAM PCP Controller must be defined using an AUX Accumulator Configuration screen similar to Figure 8-21. • Press <MENU> to return to the Main Menu screen.00 Issue Date: 1/18/08 . For example.10. For information about these screens. The discrete SAM input points on the SAM PCP Controller are pulled up 3/3/3/1/4 internally and must be switched down to DC common by a dry contact closure to “accumulate. produced volume for a well with an ESP can be monitored by the SAM PCP Controller on an adjacent pumped well. select 4.SAM Well Manager™ — Progressing Cavity Pump User Manual • Press <EXIT> twice to return to the AUX I/O Configuration Menu screen.” The SAM PCP Controller will reliably count contact closures up to a maximum frequency of about 500 HZ. see section 9. For more information about the expansion board. and the data collected can be read for both wells with a single telemetry network. “Status Screens. contact you Lufkin representative. 8. Note: The current operating status of accumulator inputs is available on two SAM status screens. Optional expansion board hardware is required to take advantage of the additional accumulators that the firmware can support. The digital inputs and outputs are configured.4 Configuring Auxiliary Accumulators Digital inputs can be configured as accumulators. The motherboard has four auxiliary digital points that can be configured as accumulators. The motherboard inputs are not designed to work with inputs direct from a turbine meter pickup. AUX ACCUMULATOR CONFIGURATION from the AUX I/O Configuration Menu screen. 8-48 Revision 1. The SAM PCP Controller uses a “virtual I/O” concept that allows an operator to program any hardware point as any logical input/output point. To display this screen.” Accumulator Programming The SAM PCP Controller firmware design supports a maximum of 10 accumulator inputs. One advantage of having accumulator input capability included in the SAM PCP Controller is the ability to monitor the operation of facilities adjacent to a pumped well without having the additional cost of installing a remote terminal unit (RTU) and data telemetry equipment for that facility.

The SAM PCP Controller must be told the physical input point that is to be associated with any given logical/virtual accumulator.00 8-49 . Data Field Descriptions Information about each data field is provided below. Channel # The table below provides the channel number designations for digital points on the motherboard. After you select an accumulator. The Current Reading portion displays the number of pulses counted in the last second. the fields in the Setup portion become active for you to define. Channel # Physical Marking 1 2 3 4 DIO5 (TB5-9) DIO6 (TB5-11) DIO7 (TB5-13) DIO8 (TB5-15) Issue Date: 1/18/08 Revision 1. Board # The motherboard is always board # 0. This field only provides information and cannot be edited. Board numbers are assigned to expansion boards by setting dip switches on those boards.Section 8: SAM Controller Programming Figure 8-21. AUX Accumulator Configuration Screen This screen is divided into three portions. The top portion lists all potentially available “virtual” or logical accumulators supported by the firmware.

At the end of the userdefined period. PPM Pulses per unit of measure (PPM) is an integer that programs the SAM PCP Controller to scale this given number of pulses counted at the defined accumulator input point as a single Unit. As an example. The range is 1 – 999. It is logically related to the PPM field below. Rate Interval User-defined sampling period. a 24-hour rate will be calculated based on the number of pulses accumulated during the most recent eight-minute period.999. A message displays to inform you that the value was cleared. The formula for this example of a rate interval of 8 minutes is as follows: Rate = # of pulses for last 8 minutes 1440 minutes × PPM 8 minutes User Defined Accumulator Period The SAM PCP Controller will accumulate a total for this user-defined number of days. The range is 0 to 1440 minutes. In addition to the User Defined Accumulator Period.00 Issue Date: 1/18/08 . 8-50 Revision 1. The range is 1 to 365 days. but the unit selected does not impact the actual scaling of the accumulator input. The units selected only displays on the status screen of the SAM PCP Controller local LED display. Units The SAM PCP Controller offers approximately 29 options for the unit of measurement to be associated with each auxiliary input. Reset Total Accu Press <0> and <1> to reset the total accumulated value since the last reset of this value.SAM Well Manager™ — Progressing Cavity Pump User Manual A DC common terminal is provided next to each digital input terminal so you can conveniently terminate the second lead from the dry contact input. the accumulated value for that period is saved in a “Previous User-defined Accumulator” register in the memory map and then the accumulator is cleared to start the accumulation for the next user-defined period. in minutes. if a value of 8 is programmed. the SAM PCP Controller also maintains a 60-day record of the totals accumulated for the each of the previous sixty 24-hour days specified by Gauge Off Time.

Press <↑> and <↓> to highlight the data field you want to edit. and then do one of the following: Issue Date: 1/18/08 Revision 1. AUXILIARY FUNCTIONS to display the Auxiliary Function Config Menu screen. 6. Reset User Define Accum Press <0> and <3> to reset the user-defined accumulated value. 3. 4. A message displays to inform you that the value was cleared. A message displays to inform you that the value was cleared. which normally is reset at the rate interval. select 3. <→>. and then select 3. From the Main Menu screen. CONFIGURATION. 5. Note: If another screen is displayed. The Board # field highlights. SAM CONFIGURATION to display the SAM Configuration Menu screen. 1. Select 1. Select 4. Number of Pulses/Sec Displays the actual number of pulses read for the second that just expired. The field for ACCUM 1 highlights in the top portion of the screen. AUX I/O to display the AUX I/O Configuration Menu screen. 2. ACCUMULATOR to display the AUX Accumulator Configuration screen (Figure 8-21). <↑>.Section 8: SAM Controller Programming Reset Today’s Accum Press <0> and <2> to reset the total accumulated value since Gauge Off Time. Select 3.00 8-51 . Procedure Follow the steps below to configure accumulators. and then press <ENTER> to move into the Setup portion of this screen. and <↓> to highlight the accumulator you want to configure. Press <←>. press <MENU> to instantly return to the Main Menu screen.

SAM Well Manager™ — Progressing Cavity Pump User Manual • To enter numerical values. After all numerical values are correct. press <EDIT>. press <EXIT> to save your settings and return to the accumulator selection portion of the screen to configure another accumulator. the next digit to the right highlights. The values for accumulators are saved. Procedure for Resetting Accumulator Totals Accumulator totals for the selected accumulator can be reset (cleared) using the AUX Accumulator Configuration screen by pressing the key combinations indicated at the bottom of the Setup portion of the programming screen. • To select field options. 10. The next field highlights. When you are finished configuring the accumulator. 7. After you press a key. 8. 9. press <ENTER>. When you are finished configuring accumulators. Repeat steps 5 through 8 for each accumulator you want to configure. do one of the following: • Press <EXIT> twice to return to the AUX I/O Configuration Menu screen. • Press <MENU> to return to the Main Menu screen. Repeat step 6 for each field you want to edit. 8-52 Revision 1. and then press <ENTER>.00 Issue Date: 1/18/08 . press <EDIT> and then press the number keys. press <↑> or <↓>. You can press <←> to return to a digit to the left to change it.

Program the type of action desired if the condition specified by the logic expression occurs (proves true) After a logic expression (complete with the desired action) is programmed and enabled. Configure the auxiliary analog inputs and/or digital inputs/outputs ahead of time so that they can be included in the logic expression (see “Configuring Auxiliary Analog Inputs on page 8-37 and “Configuring Auxiliary Digital Inputs and Outputs” on page 8-45) 2. OR.Section 8: SAM Controller Programming 8.11 Logic Expressions Logic expressions can be written and used to perform actions when a specific well condition occurs at the wellsite. and NOT. That is. Multiple logic expressions can be chained so that the result of one logic expression of higher priority can be used as an input in another logic expression of lower priority.00 8-53 . such as • Starting or stopping the pump • Turning on one of the extra digital outputs to start a pump • Closing a valve • Sounding an alarm The SAM PCP Controller logic expression feature uses the three fundamental Boolean logic operators AND. Issue Date: 1/18/08 Revision 1. Program each logic expression needed 4. its function can be disabled when necessary for operational reasons. Enable the logic expression function 3. SAM 3/3/3/2 The SAM PCP Controller can monitor well conditions from analog and/digital input signals from a variety of sensors or transmitters used to monitor conditions. Logic expression priority is based on the line/row number. A maximum of eight logical statements can be programmed to act on a selected digital output when a prescribed combination of input conditions occurs. logic expression 1 has a higher priority than logic expression 2. In order to use the logic expression function. Logic expressions can be programmed in the SAM PCP Controller using these sensor inputs to make decisions. it is necessary to 1.

select 2. SAM 3/3/3/2/1 8-54 Revision 1. Figure 8-22. An expression is proven true when the condition defined by the expression occurs.11. All logic expression enabling.SAM Well Manager™ — Progressing Cavity Pump User Manual Note: A Clear Logic Expression State option is included so that a latched output can be cleared or reset. 8. and enabling/disabling features are performed using the options available on the Logic Expression Configuration Menu screen (Figure 8-22). Logic Expression Configuration Menu Note: Options 1 through 3 are not accessible when the Logic Expression feature is “disabled. See page 8-65 for more information. LOGIC EXPRESSION from the Auxiliary Function Config Menu screen.1 Programming a Logic Expression A logic expression must be written (programmed) to define the condition that triggers an action when the expression is proven true. To display this menu. clearing.00 Issue Date: 1/18/08 . programming. see “Enabling and Disabling Logic Expressions” on page 8-67.” For information about enabling logic expressions.

see “Enabling and Disabling Logic Expressions” on page 8-67. The Program Logic Expression programming screen (similar to Figure 8-23) has a row for each logic expressions that can be programmed. You can write eight logic expressions to define eight unique conditions. For information about enabling logic expressions. see “Auxiliary I/O Configuration” on page 8-36. When it is disabled. select 1. PROGRAM LOGIC EXPRESSION from the Logic Expression Configuration Menu screen Figure 8-23. Program Logic Expression Programming Screen All logic expressions already programmed are displayed (row 1 is an example). Issue Date: 1/18/08 Revision 1.00 8-55 . Note: Auxiliary analog inputs and digital inputs/outputs must be configured before they can be included in a logic expression. For help programming auxiliary inputs and outputs. To display this screen. the message NOT REQUIRED displays.Section 8: SAM Controller Programming Note: The logic expression feature must be enabled before a logic expression can be programmed. Any row not having a logic expression programmed displays the message No Logic Expression.

a syntax error message displays prompting you to correct the invalid parameter. etc. If the expression is invalid. VALID displays to the right of the expression row if it is valid. Channel numbers are the virtual. Entry Code Groups Three entry code groups are available: • Channel selection • I/O and Logic Selection • Alarm and Special Selection Channel Selection Channel selection entry codes correspond one-to-one to the actual numbers for the desired channel. or logical. As you write an expression. You can scroll through the entry code groups by pressing <NEXT>.). For a list of the error messages possible and their definitions. input/output point numbers configured as described in “Configuring Auxiliary Analog Inputs” on page 8-37 and “Configuring Auxiliary Analog Outputs” on page 8-41. 8-56 Revision 1. see “Syntax Error Messages” on page 8-58. .SAM Well Manager™ — Progressing Cavity Pump User Manual Entry code options display at the bottom of the screen when you press <EDIT> to program the logic expression. the SAM PCP Controller automatically checks the expression to verify that the expression is valid. and alarms. The three entry code groups are described in the subsection below. Channel number selection must always be two digits (01. the SAM PCP Controller automatically presents the most likely entry code group for the next character entry.00 Issue Date: 1/18/08 . logical operators. These entry code options define the number keys you press for selecting various inputs and outputs. I/O and Logic Selection The table below describes the codes that can be used for input/output (I/O) and logic selection. 09. 23. After you complete an expression and press <ENTER>.

Key No. Analog input alert states cannot be used as logic expression inputs. Analog input alert states cannot be used as logic expression inputs. Erase All Logic Expression. • Maximum number of characters per expression is 40. 1 2 3 4 5 Selection Made Using this Key H = Analog input in High Alarm state.Section 8: SAM Controller Programming Key No. 1 Selection Made Using this Key “M” output point = one of the four dedicated discrete points on TB5 on the motherboard. • Spaces between characters before X character are not allowed. Character definition. Erase Logic Expression. This selection erases all programmed logic expressions. This selection presents a screen that defines characters used in writing logic expressions. and are labeled: • M01 = DIO1 (TB5-1) Error Lamp • M02 = DIO2 (TB5-3) Motor Control • M03 = DIO3 (TB5-5) Start Alert • M04 = DIO4 (TB5-7) Fault Output 2 3 4 5 6 7 8 9 0 “D” discrete point = virtual digital input or output “A” analog input “C” accumulator input “ [ “ = Opening bracket for nesting logical operations “ ] ” = Closing bracket for nesting logical operations “ * ” = Logical AND operator “ + ” = Logical OR operator “ ‘ “ = Logical NOT operator “ X “ =End of logical expression Alarm and Special Section The table below describes the codes that can be used for alarm and special selection. Syntax and Programming Rules A list of the syntax and programming rules that must be followed are provided below.00 8-57 . L = Analog input in Low Alarm state. Issue Date: 1/18/08 Revision 1. This selection erases the logic expression highlighted by the cursor. • Each expression must contain the X character to signify the end of the expression.

• Dxx or Mxx (with xx representing the channel number) are the only parameters/characters allowed on the left side of the “=” character.00 Issue Date: 1/18/08 . A01L′ is valid and ′A01L is invalid. and DO that have been configured as auxiliary inputs/outputs can be assigned. • Logical “NOT” must always be at the end of the IO block. Do not skip a line. For example. • Always write expressions in consecutive number to avoid priority conflict. that is.SAM Well Manager™ — Progressing Cavity Pump User Manual • No adjacent operators are allowed except + or *. Error Code No 00 01 02 03 04 05 06 07 08 09 10 11 12 13 14 15 16 Error Code Definition None End of expression not defined Multiple terminating characters First character not an output Wrong equal sign location Wrong motherboard digital channel Wrong digital channel Wrong analog channel Wrong accumulator channel Wrong analog alarm Wrong accumulator alarm Mismatching parenthesis Start with OR Start with AND Start with NOT Start with close parenthesis End with OR 8-58 Revision 1. • Low and High flags can only be assigned to analog inputs with High/Low flag enabled. • Any character after X is invalid. • AI. Syntax Error Messages The table below defines the logic expressions error messages that may appear when an invalid logic expression is written. • No adjacent parenthesis of different types. “) (”. DI.

The keystrokes sequence used to program this expression is provided below. <2> Issue Date: 1/18/08 Revision 1.Section 8: SAM Controller Programming Error Code No 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 Error Code Definition End with And End with open parenthesis Illegal space Or out of order And out of order Open parenthesis out of order Close parenthesis out of order Not out of order Input out of order Analog not configured Analog alarms not enabled Digital not configured as output Invalid main board number Accumulator not configured Digital not configured Logic Expression Example An operator wants to monitor flow line pressure and be able to shut down the pumping unit if the pressure falls too low or rises too high. <1> (display M) 3. <EDIT> 2. High and low alarm levels are configured and enabled. 1. A float switch type of stuffing box leak detector is connected to the SAM PCP Controller and configured as auxiliary digital input D01. The logic expression required is M02=A01H+A01L+D01X. The switch contacts are normally closed and open when fluid accumulates from a leak. <0> 4.00 8-59 . A pressure transmitter is installed on the flow line and connected to the SAM PCP Controller as auxiliary analog input A01. A leak detector is also connected to shut down the pumping unit in the event of a stuffing box leak.

select 3. <2> (display D) 16. CONFIGURATION. This procedure can also be used to modify an existing expression. Procedure Follow the steps below to write a logic expression. <0> 12. press <MENU> to instantly return to the Main Menu screen. 2. <1> 13. 8-60 Revision 1. <1> 8. AUXILIARY FUNCTIONS and then select 2. 1. <0> 17. and then select 3. From the Main Menu screen. <8> (display + for logical OR) 10. <0> 7. <1> 18. <0> (display X for end of expression) 19. <2> (display L for low) 14.00 Issue Date: 1/18/08 . LOGIC EXPRESSION to display the Logic Expression Configuration Menu screen. Select 3. <3> (display A) 11. SAM CONFIGURATION to display the SAM Configuration Menu screen. <3> (display A) 6. <ENTER> 20.SAM Well Manager™ — Progressing Cavity Pump User Manual 5. <1> (display H for high) 9. <8> (display + for logical OR) 15. Press <EXIT> to program the desired action. Note: If another screen is displayed.

Highlight the row you want used for the logic expression and press <EDIT>.Section 8: SAM Controller Programming 3. 4. Select 1. A list of possible syntax error messages is defined in the table in “Syntax Error Messages” beginning on page 8-58. virtual channel 1 is entered as 01. Enter the characters to write the desired logic expression. The next two characters are the channel number. 6. press <ENTER>. Issue Date: 1/18/08 Revision 1. For example. enable it now. VALID displays to the right of the row. an error message displays to prompt the necessary action that must be taken to make it valid. the SAM PCP Controller automatically adds the “=” sign. • If the expression is valid. 5. The SAM PCP Controller automatically checks the logic expression to verify that it is valid.00 8-61 . The first character at the left hand end of the row highlights. b. The first character must therefore be “M” (motherboard output point) or “D” (virtual discrete point). a. Enter “X” as the final character on the line to signify the end of the expression. keeping in mind the syntax and programming rules discussed on page 8-57. 7. You can now use the Program Logic Expression Action option to program the desired action for the logic expression. Use the keypad to enter the characters needed by referring to the entry code group at the bottom of the screen. • If the expression is invalid. 9. After the logic expression row reads as desired. 8. The first three characters of the expression must define the digital output on which you want to act. Note: If the logic expression feature is not enabled. After the digital output to use is defined. Press <EXIT>. PROGRAM LOGIC EXPRESSION to display the Program Logic Expression programming screen (Figure 8-23). Channel numbers must be two digits.

SAM Well Manager™ — Progressing Cavity Pump User Manual

8.11.2 Programming a Logic Expression Action
After you write a logic expression, you must program an SAM action for the expression. A Program Logic Expression Action 3/3/3/2/2 programming screen similar to Figure 8-24 is used to write actions. To display this screen, select 2. PROGRAM LOGIC EXPRESSION ACTION from the Logic Expression Configuration Menu screen.
Note: The logic expression feature must be enabled before a logic

expression action can be programmed. When it is disabled, the message NOT REQUIRED displays. For information about enabling logic expressions, see “Enabling and Disabling Logic Expressions” on page 8-67.

Figure 8-24. Program Logic Expression Action Screen

Column Descriptions Information about each column is provided below. Action An action must be programmed for each logic expression. The available options for a program action are linked to the type of digital output to be acted upon. A logic expression written to act on the motor control output M02 has the following action options available:

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• START — When the logic expression proves true, start the pumping unit. Pump until pump off is detected, or one of the other control limits is violated, such as peak torque allowed. • MALF — When the logic expression proves true, stop the pumping unit. Restart it after the programmed down time for the number of successive retries. If the consecutive Malf. Allowed count limit is reached, shut down the unit in a Malfunction Logic state. Operator intervention is required to clear and restart the unit. • STOP — When the logic expression proves true, stop the unit in normal downtime. The unit automatically starts after the programmed downtime expires. A logic expression written to act on a general-purpose digital output has the following action options available: • FLAG — When the logic expression proves true, set a flag to alert the operator. No control action is taken. • TEMP — When the logic expression proves true, close the programmed digital output. Continue to evaluate the logic expression and hold output on/closed as long as the logic expression proves true. When the logic expression proves false, open the output. • LATCH — When the logic expression proves true, close the programmed digital output and hold it closed until an operator clears the latch. To clear a latched output, go to the Logic Expression Configuration menu (Figure 8-22) and select 3. CLEAR CURRENT LOGIC EXPR STATE. • TIMER — When the logic expression proves true, close the programmed digital output and hold it closed for the programmed Timer Period. When the timer period times out, open the digital output and re-evaluate the logic expression.

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Consec. Malf Allowed or Timer Period Accessibility to this column depends on the action programmed for the logic expression. • If the programmed action is MALF, edit this column to program the desired number of consecutive malfunctions allowed, which is the number of retries allowed before the pumping unit is shut down in a Malfunction well state. Operator intervention is required to reset the unit. • If the programmed action is TIMER, edit this column to program the desired time in minutes to hold closed the designated digital output. Logic Time Delay This is a delay before executing the programmed action when a logic expression proves true. This time delay is in addition to any programmed time delays for the analog alarms and/or digital inputs that are included in a logic expression. Time delays are programmed from the auxiliary input configuration screens discussed in “Configuring Auxiliary Analog Inputs” on page 8-37 and “Configuring Auxiliary Digital Inputs and Outputs” on page 8-45. Procedure Follow the steps below to program a logic expression action. 1. From the Main Menu screen, select 3. CONFIGURATION, and then select 3. SAM CONFIGURATION to display the SAM Configuration Menu screen.
Note: If another screen is displayed, press <MENU> to instantly return

to the Main Menu screen. 2. Select 3. AUXILIARY FUNCTIONS and then select 2.LOGIC EXPRESSION to display the Logic Expression Configuration Menu screen. 3. Select 2. PROGRAM LOGIC EXPRESSION ACTION to display the Program Logic Expression Action programming screen. 4. Highlight the Action column field in the row for the logic expression to be programmed and press <EDIT> to enter the edit mode. 5. Press <↑> and <↓> to view the options available.
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6. Press <ENTER> when the desired option displays. 7. Use arrow keys to move cursor to the next field to be programmed (for example, Logic Time Delay), and then press <EDIT> to enter the edit mode. 8. Use the number keys to enter the desired value and then press <ENTER> to select the entered value and end the edit mode for that field. 9. Repeat steps 7 and 8 until all fields are programmed as desired. 10. After all the fields on this screen are programmed as desired, do either of the following: • Press <EXIT> to return to the Logic Expression Configuration Menu screen. • Press <MENU> to return to the Main Menu screen. The logic expression program is saved.

8.11.3 Clearing the Logic Expression State
If a logic expression is programmed with a latch action, you SAM can reset the logic expression and clear the latched output by 3/3/3/2/3 using the Clear Current Logic Expr State screen (similar to Figure 8-25). To display this screen, select 3. CLEAR CURRENT LOGIC EXPR STATE from the Logic Expression Configuration Menu screen.
Note: The logic expression feature must be enabled before a logic

expression state can be cleared. When it is disabled, the message NOT REQUIRED displays. For information about enabling a logic expression, see “Enabling and Disabling Logic Expressions” on page 8-67.

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Figure 8-25. Clear Current Logic Expr State Screen

Procedure Follow the steps below to clear the logic expression state. 1. From the Main Menu screen, select 3. CONFIGURATION, and then select 3. SAM CONFIGURATION to display the SAM Configuration Menu screen.
Note: If another screen is displayed, press <MENU> to instantly return

to the Main Menu screen. 2. Select 3. AUXILIARY FUNCTIONS and then select 2.LOGIC EXPRESSION. 3. Select 3.CLEAR CURRENT LOGIC EXPR STATE to display the Clear Current Logic Expr State screen. 4. Press <↑> and <↓> to highlight the logic expression to be cleared, and then press <ENTER>. A pop up window appears to acknowledge that the logic state is cleared. Notice that row 9 offers the option to clear all logic expression states.

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5. When finished clearing the action, do either of the following: • Press <EXIT> to return to the Logic Expression Configuration Menu screen. • Press <MENU> to return to the Main Menu screen.

8.11.4 Enabling and Disabling Logic Expressions
The logic expression feature must be enabled before a logic expression can be programmed. If the logic expression feature is not enabled, a “Not Required” response displays when you try to program an expression.
SAM 3/3/3/2/4

This toggle feature allows you to enable and disable these expressions. After a logic expression and action are programmed, you can temporarily disable the logic expression (complete with the desired action), if necessary, for operational reasons. The programmed expression and action are retained in memory so it is not necessary to re-program the expression when you are ready to again enable the logic expression. The present enable/disable status can be easily determined by looking on the Logic Expression Configuration menu below option 4. It reads either LOGIC EXPRESSION – ENABLE if logic expressions are presently disabled or LOGIC EXPRESSION – DISABLE if they are enabled. Procedure Follow the steps below to enable or disable the logic expression feature. 1. From the Main Menu screen, select 3. CONFIGURATION, and then select 3. SAM CONFIGURATION to display the SAM Configuration Menu screen. 2. Select 3. AUXILIARY FUNCTIONS and then select 2. LOGIC EXPRESSION to display the Logic Expression Configuration Menu screen. 3. Select 4. ENABLE/DISABLE LOGIC EXPRESSION. A message appears asking you to confirm that you want to enable or disable the log expression. • If the logic expression feature is already disabled, ENABLE LOGIC EXPR? displays.

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8. • Differential pressure • Static (gauge) pressure • Flowing temperature 8-68 Revision 1. The SAM PCP Controller can use analog channel inputs for the following three gas meter run parameters. “AGA 3 Definitions. After the Logic Expression feature is enabled. You must configure the analog channels that will be used by the AGA algorithm to calculate gas flow. For more detailed explanations about the parameters available for AGA 3 configuration.00 Issue Date: 1/18/08 . The DeltaP input is required. Below option 4. and NX-19 supercompressibility is calculated once a minute and every time setup parameters are modified. 4. process transmitters must be installed and connected to available analog inputs on the SAM PCP Controller expansion board to monitor line pressure and pressure drop (DeltaP) across an orifice plate. DISABLE LOGIC EXPR? displays. you are informed whether the Logic Expression feature is enabled or disabled. Line pressure is optional. AGA-3 3/3/3/3 is calculated once a second.12 AGA 3 Parameter Configuration The SAM PCP Controller can perform AGA 3 gas flow rate SAM calculations and accumulate gas production volume data. the SAM PCP Controller implements the AGA-3 1992 Factors method of gas flow calculation. Press <←> and <→> to highlight the YES response and then press <ENTER>.SAM Well Manager™ — Progressing Cavity Pump User Manual • If the logic expression feature is already enabled. For flange tap measurement. The AGA-2 1985 Pipe Flow Calculation method is used for pipe tap measurement and NX19 calculation methods are used for the supercompressibility factor. see Appendix B. the other logic expression features can be used.” In order to perform these operations.

AGA from the Auxiliary Function Config Menu screen. Configure analog input channels (page 8-37) 2. select 3. Configure temperature and pressure (8-75) The first three options available under the AGA Configuration menu (Figure 8-26) are used to configure AGA 3. Static pressure and flowing temperatures can either be entered as constant values by the user or supplied through analog input channels.Section 8: SAM Controller Programming The SAM PCP controller requires that the differential pressure measurement be provided using an analog input channel.00 8-69 . Configure AGA 3 parameters (8-70) 3. Figure 8-26. The best method for you to use to configure all necessary parameters for AGA calculations is to perform all operations in the following order: 1. NX-19. Configure NX-19 parameters (8-73) 4. see “Configuring Auxiliary Analog Inputs” on page 8-37. For details about how to configure analog channels. To display this menu. AGA Configuration Menu Screen Issue Date: 1/18/08 Revision 1. and temperature and pressure.

To enable the operations. SAM 3/3/3/3/1 Figure 8-27. ENABLE/DISABLE AGA CALCULATIONS. AGA 3 Design Parameters Screen Note: Before you can configure parameters. 8-70 Revision 1. CONFIGURE AGA 3 PARAMS from the AGA Configuration Menu screen. see “Enabling and Disabling AGA 3 Calculations” on page 8-78. To display this screen. To enable them. see “Enabling and Disabling AGA 3 Calculations” on page 8-78. you must enable the AGA 3 calculation operations.00 Issue Date: 1/18/08 . For more information about this operation.1 Configuring AGA 3 Parameters Use the AGA 3 Design Parameters screen (Figure 8-27) to configure AGA parameters. ENABLE/DISABLE AGA CALCULATIONS. 8. select 1. For more information about this operation. you must use the fourth option to enable the AGA calculation operations.12. the message “NOT REQUIRED” displays and you remain at the AGA Configuration Menu screen.SAM Well Manager™ — Progressing Cavity Pump User Manual Before you configure parameters. If they are not enabled and you try to select any of the first three options. select 4. select 4.

000 in. The choices available are: • STAINLESS • MONEL • CARBON STAINLESS is the default value. The default value is 4.00 8-71 . The choices available are: • STAINLESS • MONEL • CARBON Issue Date: 1/18/08 Revision 1. TAP TYPE Specify the type of pressure tap. TAP LOCATION Specify the location of pressure tap. The choices available are: • FLANGE • PIPE FLANGE is the default value. The choices available are: • UPSTREAM • DOWNSTREAM UPSTREAM is the default value. ORIFICE DIAMETER Specify the measured diameter of the orifice in inches. ORIFICE MATERIAL Specify the material used to construct the orifice. PIPE MATERIAL Specify the material used to construct the pipe.Section 8: SAM Controller Programming Data Field Descriptions Information about each data field is provided below.

Associated factors are Fam. 2. press <MENU> to instantly return to the Main Menu screen.30000. The default value is 1. The default value is 68° F. Fhgm. NO is the default value. COMPRESSIBLE FLUID • Specify whether the fluid is compressible. The default value is 0. SAM CONFIGURATION to display the SAM Configuration Menu screen. MEASUREMENT TEMP Specify the temperature at which the orifice diameter was measured. PIPE DIAMETER Specify the measured diameter of the pipe in inches. and then select 3. Fpwl. select 3. 8-72 Revision 1. AUXILIARY FUNCTIONS and then select 3. 1. and Fhgt. Fwt.60. The default value is 1. This answer determines if the expansion factor Y is calculated. Select 3.00.01027 cP.00 Issue Date: 1/18/08 . CALIBRATION FACTORS Specify a value to calibrate the meter. Note: If another screen is displayed. From the Main Menu screen. CONFIGURATION. AGA to display the AGA Configuration Menu screen. ISENTROPIC EXPONENT Specify the ratio of specific heat at constant pressure to specific heat at constant volume (cp/cv) for the given gas composition. The default value is 0. Procedure Follow the steps below to configure AGA 3 design parameters. VISCOSITY Specify the viscosity of the gas.07 in.SAM Well Manager™ — Progressing Cavity Pump User Manual STAINLESS is the default value. The default value is 8. SPECIFIC GRAVITY Specify the gravity of the gas.

When finished. and then press <ENTER>. Default values are provided for all data fields. The next field highlights. 4. CONFIGURE NX-19 PARAMS from the AGA Configuration Menu screen.00 8-73 . • Press <MENU> to return to the Main Menu screen. Make the 3/3/3/3/2 appropriate selections and enter the correct data in each field. To display this screen. the next digit to the right highlights. Do one of the following: • To enter numerical values. press <EDIT> and then press the number keys.Section 8: SAM Controller Programming 3. press <ENTER>.12. but for best results. press <EDIT>. Select 1. 5. do either of the following: • Press <EXIT> to return to the AGA Configuration Menu screen. 8. You can press <←> to return to a digit to the left to change it. thought needs to be given to the data in each and every field.2 Configuring NX-19 Design Parameters Use the NX-19 Design Parameters programming screen SAM (Figure 8-28) to configure NX-19 parameters. The AGA 3 configuration values are saved. CONFIGURE AGA 3 PARAMS to display the AGA 3 Design Parameters programming screen. • To select field options. The Tap Type field highlights. After you press a key. After all numerical values are correct. select 2. Issue Date: 1/18/08 Revision 1. press <↑> or <↓>.

The default value is 0. Note that 5. which is the same value as the specific gravity on the AGA3 Design Parameters screen (Figure 8-27 on page 8-70). SPECIFIC GRAVITY Specify the specific gravity of the gas. N2 MOLE FRACTION Specify the mole fraction of N2.00000. 8-74 Revision 1. Configure NX-19 Parameters Programming Screen Note: Before you can configure parameters. ENABLE/DISABLE AGA CALCULATIONS. Note that 5. To enable them.05930. CO2 MOLE FRACTION Specify the mole fraction of CO2. The default value is 0.SAM Well Manager™ — Progressing Cavity Pump User Manual Figure 8-28. select 4. Data Field Descriptions Information about each data field is provided below. you must enable the AGA 3 calculation operations. The default value is 0.05930.93% should be entered as 0. For more information about this operation.93% should be entered as 0.00000.00 Issue Date: 1/18/08 .60. see “Enabling and Disabling AGA 3 Calculations” on page 8-78.

The next field highlights.3 Configuring Temperature and Pressure Use the Temperature/Pressure Configuration programming screen (Figure 8-29) to configure temperature and pressure values required for AGA 3 gas calculations. press <EDIT>. press <EDIT> and then press the number keys. The Specific Gravity field highlights. press <↑> or <↓>. the next digit to the right highlights. thought needs to be given to the data specified in every field. AGA to display the AGA Configuration menu. 4. When finished. From the Main Menu screen. The NX-19 configuration settings are saved. CONFIGURE NX-19 PARAMS to display the NX-19 Design Parameters programming screen. 1. press <MENU> to instantly return to the Main Menu screen. Note: If another screen is displayed. SAM 3/3/3/3/3 Default values are provided for all data fields. Select 2.00 8-75 . do either of the following: • Press <EXIT> to return to the AGA Configuration Menu screen. CONFIGURATION. You can press <←> to return to a digit to the left to change it. • To select field options. but for best results. • Press <MENU> to return to the Main Menu screen. and then press <ENTER>. SAM CONFIGURATION to display the SAM Configuration Menu screen. Select 3. press <ENTER>. 8. After all numerical values are correct. 3. AUXILIARY FUNCTIONS and then select 3. Make the appropriate selections and enter the correct data in each field. To display this Issue Date: 1/18/08 Revision 1. 5. select 3. and then select 3.12. 2. After you press a key.Section 8: SAM Controller Programming Procedure Follow the steps below to configure NX-19 design parameters. Do one of the following: • To enter numerical values.

8-76 Revision 1. see “Enabling and Disabling AGA 3 Calculations” on page 8-78. Data Field Descriptions Information about each data field is provided below. For more information about this operation.00 Issue Date: 1/18/08 . BASE PRESSURE Specify the base pressure for the volume flow rate calculation.73 PSIA. ADJ PRESSURE Specify the pressure to add to static “gauge” pressure to get “absolute” static pressure. select 4. To enable them. ENABLE/DISABLE AGA CALCULATIONS. The default value is 14. CONFIGURE TEMPERATURE AND PRESSURE from the AGA Configuration Menu screen. you must enable the AGA 3 calculation operations.SAM Well Manager™ — Progressing Cavity Pump User Manual screen. The default value is 60º F.73 PSIA. BASE TEMPERATURE Specify the base temperature for volume flow rate calculation. The default value is 14. Temperature/Pressure Configuration Programming Screen Note: Before you can configure parameters. Figure 8-29. select 3.

select 3. 1. FLOWING TEMPERATURE Specify the analog input channel to be assigned for flowing pressure. Select 3.Section 8: SAM Controller Programming DIFFERENTIAL PRESSURE Select from available analog input channels. 2. From the Main Menu screen. CONFIGURATION. press <ENTER>.00 F. The default value is AI02. press <EDIT> and then press the number keys. Do one of the following: • To enter numerical values. 3. You can press <←> to return to a digit to the left to change it. Analog channels must be set up using the AUX Analog Input Configuration Programming screen. SAM CONFIGURATION to display the SAM Configuration Menu screen. the next digit to the right highlights. Select 3. Issue Date: 1/18/08 Revision 1. Analog channels must be setup using the AUX Analog Input Configuration Programming screen (Figure 8-19 on page 8-38). or enter a user-defined value. Procedure Follow the steps below to enter the temperature and pressure configuration parameters. AGA to display the AGA Configuration Menu screen. The default value is AI1. Analog channels must be set up using the AUX Analog Input Configuration Programming screen. The default value is CONST 060.00 8-77 . Note: If another screen is displayed. After you press a key. After all numerical values are correct. and then select 3. or enter a user-defined value. The Base Pressure field highlights. AUXILIARY FUNCTIONS and then select 3. press <MENU> to instantly return to the Main Menu screen. CONFIGURE TEMPERATURE AND PRESSURE to display the Temperature/Pressure Configuration programming screen. 4. STATIC PRESSURE Specify the analog input channel to be assigned for static pressure.

The temperature and pressure configuration parameters are saved.12. and then select 3. 2. ENABLE/DISABLE AGA CALCULATIONS. After the AGA 3 calculations feature is enabled. AUXILIARY FUNCTIONS and then select 3. The present on/off state of AGA 3 calculations is displayed below option 4. • Press <MENU> to return to the Main Menu screen. CONFIGURATION. Select 4. press <↑> or <↓>. select 3. the other AGA 3 calculation features can be used.SAM Well Manager™ — Progressing Cavity Pump User Manual • To select field options. 3. press <EDIT>. you can see whether the AGA Calculations feature is presently enabled or disabled. From the Main Menu screen. 8. do either of the following: • Press <EXIT> to return to the AGA Configuration Menu screen. A message appears asking you to confirm that you want to enable or disable the AGA 3 calculations. When finished. and then press <ENTER>.00 Issue Date: 1/18/08 . AGA to display the AGA Configuration menu. Note: If another screen is displayed. Select 3. 5. SAM CONFIGURATION to display the SAM Configuration Menu screen.4 Enabling and Disabling AGA 3 Calculations The Enable/Disable AGA Calculations option on the AGA SAM Configuration menu (Figure 8-26) is a toggle option for 3/3/3/3/4 turning on and off the AGA 3 calculation feature. 8-78 Revision 1. Below option 4. Procedure Follow the steps below to enable and disable the AGA 3 calculations feature. The next field highlights. press <MENU> to instantly return to the Main Menu screen. 1.

8.00 8-79 . ENABLE AGA CALCS? displays. gas mixture. if desired.14 Register Configuration The SAM PCP Controller has three features that you can use to work with registers. you can 3/3/3/4 access the Custody Transfer Main Menu screen. and plate sizes. Custody transfer operations are where you program configuration parameters for transmitters.Section 8: SAM Controller Programming • If the logic expression feature is already disabled. For more information about the SAM EFM Utility software. They are: SAM 3/3/4 • Configuring eight register alarms based on any of the measured or calculated values in the controller memory files • Configuring ten historical plots from any physical input or calculated value in the SAM PCP Controller Issue Date: 1/18/08 Revision 1. • If the logic expression feature is already enabled. These menu options should be used as an alternative method for configuring EFM parameters. refer to the SAM EFM Utility Software User Manual (099. low flow cutoff.5070) or contact your Lufkin Automation representative. 8. well stream variables. Your selection immediately goes into affect and is displayed below option 4. DISABLE AGA CALCS? displays.13 Custody Transfer If the SAM PCP Controller has EFM (electronic flow SAM measurement or electronic flow metering) capabilities. This interface can be installed on a laptop computer connected to the communications port on the SAM PCP Controller. and then press <ENTER>. pipe diameters. All custody transfer operations can be password-protected so that users can only have access to these operations and no other SAM PCP Controller programming privileges. 4. Press <←> and <→> to highlight the response you want. An easier method you can use to perform custody transfer is to use the SAM EFM Utility software available from Lufkin Automation.

To display this menu. 8-80 Revision 1. REGISTER FUNCTIONS from the SAM Configuration Menu screen. by-pass valve activity. To display this screen. select 4.14. REGISTER ALARM CONFIG from the Register Function Config Menu screen. such as tank level.00 Issue Date: 1/18/08 .1 Configuring a Register Alarm The SAM PCP Controller has a register alarm feature that SAM allows you to program for actions based on any of the measured 3/3/4/1 or calculated values in the controller memory files. etc. select 1. Register alarms are configured using the Register Alarm Config screen similar to Figure 8-31. You can configure a total of eight register alarms.SAM Well Manager™ — Progressing Cavity Pump User Manual • Configuring ten register calculations that are a combination of status values from different register logs to obtain new values that can be used for monitoring and creating register alarms Each feature is a separate option available under the Register Function Config Menu screen (Figure 8-30). tank pressure. Register Function Config Menu Screen 8. Figure 8-30. These features might be useful when a wellsite is near a pump station and you want to monitor and control other process variables. This feature complements the logic expression capabilities to give the SAM PCP Controller some flexibility to perform functions other than PCP control.

Register Number Select the virtual register number you want to assign to a register alarm. Choices are WORD (16bit integer). For information about configuring digital outputs. Issue Date: 1/18/08 Revision 1. Addresses are listed in the PCP register map. Contact your Lufkin Automation representative to obtain the latest register map.Section 8: SAM Controller Programming Figure 8-31. Register Alarm Config Screen Note: You must configure the digital output you want to control before you can configure the register alarm.00 8-81 . and LONG (32-bit integer value). Reg Type Specify the type of register you want to use. Data Field Descriptions Information about each data field is provided below. Reg Address Specify the actual register address you want to use for the selected virtual alarm register. FLOAT (32-bit floating point value). see “Configuring Auxiliary Digital Inputs and Outputs” on page 8-45.

Action Mode Specify the action the digital output channel is to perform when the action is required for the Low Alarm Limit violation. TIMER.00 Issue Date: 1/18/08 . Low Delay Limit Specify the amount of time. and PULSE. 8-82 Revision 1. that the Low Alarm Limit value is to exist (delay) before the value is considered a violation. Choices are DYNAMIC. LOW Alarm DO Control Channel Specify the digital output channel that the register alarm is to control when the action is required for the Low Alarm Limit violation. and PULSE. High Alert Limit Specify the alert setpoint value that must be exceeded for the SAM PCP Controller to consider the monitored value a violation. High Delay Limit Specify the amount of time. Low Alarm Limit Specify the low point you want used as the violation setpoint to trigger the alarm. LATCHED. LATCHED. Choices are DYNAMIC. in milliseconds. that the High Alarm Limit value is to exist (delay) before the value is considered a violation. in milliseconds.SAM Well Manager™ — Progressing Cavity Pump User Manual HIGH Alarm DO Control Channel Specify the digital output channel that the register alarm is to control when the action is required for the High Alarm Limit violation. Action Mode Specify the action the digital output channel is to perform when the action is required for the High Alarm Limit violation. TIMER. Low Alert Limit Specify the alert setpoint value that the present monitored value must fall below for the SAM PCP Controller to consider the monitored value a violation. High Alarm Limit Specify the high point you want used as the violation setpoint to trigger the alarm.

REGISTER FUNCTIONS and then select 1. press <ENTER>. The Register 1 field highlights. Note: If another screen is displayed. Select 4. After all numerical values are correct. press <MENU> to instantly return to the Main Menu screen. Press <↑> and <↓> to select the register you want to configure and then press <ENTER>. 1. SAM CONFIGURATION to display the SAM Configuration Menu screen. Plot resolution is programmable to capture a value as Issue Date: 1/18/08 Revision 1. You can press <←> to return to a digit to the left to change it. press <↑> or <↓>. and then select 3. The configuration settings for the register alarm are saved. REGISTER ALARM CONFIG to display the Register Alarm Config screen. The next field highlights. press <EDIT> and then press the number keys. the next digit to the right highlights. • To select field options. From the Main Menu screen. 3. 8.Section 8: SAM Controller Programming Procedure Follow the steps below to configure a register alarm.14.2 Configuring a Register Log You can configure an historical plot for any of the data in the SAM SAM PCP Controller. and then press <ENTER>. Do one of the following to specify values for each remaining field: • To enter numerical values. 5. 4. • Press <MENU> to return to the Main Menu screen. press <EDIT>. select 3. 2. When finished.00 8-83 . do either of the following: • Press <EXIT> to return to the Register Function Config Menu screen. After you press a key. Any physical input or calculated value in 3/3/4/2 the SAM PCP Controller memory can be sampled and stored in a buffer for display. CONFIGURATION. The Reg Address field highlights.

The category selected displays its own subset of fields that require you to configure additional parameters. see “Register Log” in section 10. which is available under the Historical Data Menu screen. REGISTER LOG CONFIGURATION from the Register Function Config Menu screen. Register Number Select the virtual register number you want to assign to a register log.00 Issue Date: 1/18/08 . To display this screen. Register logs are configured using the Register Logging Config screen similar to Figure 8-32. For information about this historical plot. Figure 8-32. A total of ten plots can be configured. • None — Select this option when you want to cancel a register log already configured. Several categories are available. Register Logging Config Screen Example You can display this information as a plot by selecting the Register Log Plots option. 8-84 Revision 1. Reg Category Specify the category of data to be polled. select 2.SAM Well Manager™ — Progressing Cavity Pump User Manual often as once per minute or only once per day.” Data Field Descriptions Information about each data field is provided below. No additional fields display. “Historical Data.

Section 8: SAM Controller Programming • Analog Input Data — Select this option when you want to configure a register log for data acquired from an analog input channel. Addresses are listed in the PCP register map. • Register Data — Select this option when you want to configure a register log for data acquired from a memory register.00 8-85 . Choices are WORD (16-bit integer). LONG (32-bit integer value). FLOAT (32-bit floating point value). The following additional fields display: – Accumulator # — Specify the accumulator channel used for the data you want to log. Contact your Lufkin Automation representative to obtain the latest register map. – Data to Log — Specify whether the analog data is scaled or raw. and COIL. – Register Type — Specify the type of register used for the register address. For information about slave devices. see “Modbus Master and Slave Device Configuration” on page 8-14 The following additional fields display: Issue Date: 1/18/08 Revision 1. The following additional fields display: – Register # — Specify the actual register address used for the data you want to log. – Data to Log — Specify whether the analog data is scaled or raw. • Slave Data — Select this option when you want to configure a register log for data acquired from a slave device. The following additional fields display: – Analog Input # — Specify the analog input channel used for the data you want to log. • Accumulator Data — Select this option when you want to configure a register log for data acquired from an accumulator input channel.

and COIL. Flowing Temperature. see “Configuring Slave Device Parameters” on page 8-15. Diff. – AGA Log Data — Specify the type of AGA 3 data being measured. FLOAT (32-bit floating point value). – Register Type — Specify the type of register used for the register address.SAM Well Manager™ — Progressing Cavity Pump User Manual – Device # — Specify the slave device whose data you want to log. LONG (32-bit integer value). • AGA Data — Select this option when you want to configure a register log for calculated AGA 3 data. For more information about AGA 3. see “AGA 3 Parameter Configuration” on page 8-68.00 Issue Date: 1/18/08 . Sample Rate Specify how often. you want the data sampled. 8-86 Revision 1. and Supercompressibility. select YES. Sample Mode Specify whether you want the data logged as an average value during the sample period or you want a value logged once during each sample period. Logging Enabled Specify whether you want to start logging the data specified for the register. The duration of a sample period is specified with the Sample Rate field. Static Pressure. Pressure. – Register Index — Specify the index of the data point being read from the slave device. For more information. in seconds. Choices are WORD (16-bit integer). One additional field displays. This index can be found in the Modbus Master configuration for that particular device. Choices are Flow Rate. • To start the logging process.

press <↑> or <↓>. and Logging Enabled): • To enter numerical values. The next field highlights. press <MENU> to instantly return to the Main Menu screen. CONFIGURATION. From the Main Menu screen. Select 4. press <↑> or <↓> to select the register category type you want. After all numerical values are correct. Issue Date: 1/18/08 Revision 1. press <EDIT>. and then press <ENTER>. and then press <ENTER>. This option is useful when you want to configure the parameters now and then start logging data at a later date.00 8-87 . 5. 3. The REGISTER 1 field highlights. 4. 2. You can press <←> to return to a digit to the left to change it. SAM CONFIGURATION to display the SAM Configuration Menu screen. Do one of the following to specify values for each remaining field (including Sample Mode. 1. Note: If another screen is displayed. Press <↑> or <↓> to select the virtual register you want used to log the historical data. For all register category options except None. • To select field options. REGISTER LOG CONFIGURATION to display the Register Logging Config screen.Section 8: SAM Controller Programming • To prevent the logging process from occurring. REGISTER FUNCTIONS and then select 2. press <ENTER>. and then select 3. After you press a key. press <EDIT> and then press the number keys. additional fields display that are specific to your category choice. the next digit to the right highlights. select NO. Procedure Follow the steps below to configure a register log. Press <EDIT>. Sample Rate. and then press <ENTER>. or to turn off the logging process if you need to service the end device configured for the register log. The Reg Category field highlights. select 3.

A Save Configuration message displays for a few seconds to inform you that the data is saved for the register log. save the register log configuration. 8. The first screen is the Programmable Calculations screen (Figure 8-33).14. Highlight the SAVE CONFIGURATION field. The register log configuration settings are saved.00 Issue Date: 1/18/08 . After you are finished specifying values for all fields. and then press <ENTER>. • Press <MENU> to return to the Main Menu screen. To display this screen. When finished. Note: If you exit the Register Logging Config screen without saving the configuration. For information about the features this screen has. 8-88 Revision 1.3 Configuring Register Calculations You can combine status values from different register logs to obtain new values that can be used for monitoring and creating register alarms. “Status Screens. SAM 3/3/4/3 You can display the calculated results in the Programmable Calculations Status screen.SAM Well Manager™ — Progressing Cavity Pump User Manual 6. 7. You can configure up to ten register calculations. select 3. REGISTER CALCULATIONS CONFIG from the Register Function Config Menu screen. all parameters values are not saved to the register you selected.” Three screens are used to configure register calculations. see “Displaying Register Calculations Status” in section 9. which you use to select a programmable calculation register that is to contain the register calculation. do either of the following: • Press <EXIT> to return to the Register Function Config Menu screen.

The configuration process involves specifying an input value. Programmable Calculations Screen After you select a programmable calculation register in the Programmable Calculations Setup screen. and then selecting a second input value. which is where you combine the status values (referred to as inputs) for your calculation.00 8-89 . the Programmable Calculation screen displays (Figure 8-34). ×.Section 8: SAM Controller Programming Figure 8-33. Programmable Calculation Screen Issue Date: 1/18/08 Revision 1. choosing an operation (+. Figure 8-34. ÷). You can only define two input values and one operation for each calculation register. −.

SAM Well Manager™ — Progressing Cavity Pump User Manual After you press <ENTER> on the highlighted EDIT field or an input. you can return to the Programmable Calculation Setup screen to configure another register calculation.00 Issue Date: 1/18/08 . the Programmable Calculation Input Setup screen (Figure 8-35) displays for you to define the input type you want used in the calculation. Reg Category Specify the category of data to be polled. Programmable Calculation Input Setup Screen Example After you define the input and save its configuration. This option is illogical and would therefore never be selected. Figure 8-35. Several categories are available. After it is defined. Data Field Descriptions Information about each data field is provided below. • None — This option indicates that no data is to be used in the calculation. you can define the second input for the calculation using the same methods as you did for the first input. 8-90 Revision 1. When the calculation is correctly configured. you are returned to the Programmable Calculation screen where you can define the operation you want performed on the inputs. The category selected displays its own subset of fields that require you to configure additional parameters.

The following additional fields display: – Accumulator # — Specify the accumulator channel used for the data you want to use. Contact your Lufkin Automation representative to obtain the latest register map. – Data to Log — Specify whether the analog data is scaled or raw. • Accumulator Data — Select this option when you want to use data acquired from an accumulator input channel as an input to a calculation. FLOAT (32-bit floating point value). • Register Data — Select this option when you want to use data acquired from a memory register as an input to a calculation. – Data to Log — Specify whether the analog data is scaled or raw. Addresses are listed in the PCP register map. For information about slave devices. The following additional fields display: – Analog Input # — Specify the analog input channel used for the data you want to use. – Register Type — Specify the type of register used for the register address. • Slave Data — Select this option when you want to use data acquired from a slave device as an input to a calculation. LONG (32-bit integer value).Section 8: SAM Controller Programming • Analog Input Data — Select this option when you want to use data acquired from an analog input channel as an input to a calculation.00 8-91 . The following additional fields display: – Register # — Specify the register address used for the data you want to use in the calculation. and COIL. see “Modbus Master and Slave Device Configuration” on page 8-14 Issue Date: 1/18/08 Revision 1. Choices are WORD (16-bit integer).

• Calculator Result — This data type allows the use of the result of another register calculation in the current calculation. Static Pressure. – Register Type — Specify the type of register used for the register address. • Constant — A data type of constant is selected to use a constant number as an input to a calculation. – Register Index — Specify the index of the data point being read from the slave device. Diff. see “Configuring Slave Device Parameters” on page 8-15. For more information about AGA 3. Flowing Temperature. This result provides the ability to create longer calculations with a series of single calculations. 8-92 Revision 1. This index can be found in the Modbus master configuration for that particular device. and COIL. Choices are Flow Rate. and Supercompressibility. One additional field displays. Choices are WORD (16-bit integer). One additional field displays. see “AGA 3 Parameter Configuration” on page 8-68. • AGA Data — Select this option when you want to use calculated AGA 3 data as an input to a Register Calculation.SAM Well Manager™ — Progressing Cavity Pump User Manual The following additional fields display: – Device # — Specify the slave device whose data you want to log. FLOAT (32-bit floating point value).00 Issue Date: 1/18/08 . Pressure. For more information. – Value — Specify the constant value to be used as an input to the register calculation. LONG (32-bit integer value). – AGA Log Data — Specify the type of AGA 3 data being measured.

5.Section 8: SAM Controller Programming One additional field displays. SAM CONFIGURATION to display the SAM Configuration Menu screen. press <↑> or <↓> to select the register category type you want. The Programmable Calculation Input Setup screen displays with the Reg Category field highlighted. For all register category options except None. The Programmable Calculation screen displays with the EDIT field highlighted for Input 1. The PROGRAMMABLE CALCULATION 1 field highlights. From the Main Menu screen. additional fields display that are specific to your category choice. Press <ENTER>. select 3. REGISTER CALCULATIONS CONFIG to display the Programmable Calculations screen. Do one of the following to specify values for each remaining field: Issue Date: 1/18/08 Revision 1. 1. and then select 3. Press <EDIT>. and then press <ENTER>. 3. and then press <ENTER>. Note: If another screen is displayed. CONFIGURATION. Press <↑> or <↓> to select the field you want used to configure the calculation data. 6. press <MENU> to instantly return to the Main Menu screen. – Equation Num — Specify the number of the register calculations from which the result is to be pulled. REGISTER FUNCTIONS and then select 3. Select 4. 4. 2.00 8-93 . Procedure Follow the steps below to configure a register calculation.

• Press <MENU> to return to the Main Menu screen. 8. A Save Configuration message displays for a few seconds to inform you that your data is saved for the register log. press <→> to highlight the EDIT field for Input 2. Highlight the SAVE CONFIGURATION field. 7. The next field highlights. press <ENTER>. Note: If you exit the Programmable Calculation Input Setup screen without saving the configuration.00 Issue Date: 1/18/08 .15 Configuring and Enabling/Disabling HOA 8-94 Revision 1. When the correct operation is selected. all parameters values are not saved for the input. ×. When finished. press <EDIT>. Press <ENTER> to scroll through the four possible operations (+. press <↑> or <↓>. 8. Press <→> to highlight the CHANGE field for Operation. the next digit to the right highlights. After you finish specifying values for all fields. 9.SAM Well Manager™ — Progressing Cavity Pump User Manual • To enter numerical values. 12. −. repeat steps 4 through 8. To configure the register category type for Input 2. After all numerical values are correct. press <EDIT> and then press the number keys. Press <EXIT> to return to the Programmable Calculation screen. save the configuration. and then press <ENTER>. ÷) you can perform. do either of the following: • Press <EXIT> to return to the Programmable Calculations Setup selection screen to configure another register calculation. After you press a key. • To select field options. 10. and then press <ENTER>. 11. You can press <←> to return to a digit to the left to change it.

When SAM control is in Hand mode. Figure 8-36. HAND/OFF/AUTO (HOA) from the SAM Configuration Menu screen. To display this screen. the SAM PCP Controller ignores input data about pumping activity and makes no control decisions.Section 8: SAM Controller Programming You can allow the SAM PCP Controller to monitor the status to SAM know if SAM control has been bypassed when the HOA switch 3/3/5 is set to Hand. Issue Date: 1/18/08 Revision 1. HOA Hand DI Channel Specify the digital channel number that the SAM PCP Controller will use to go into a Pumping HOA Hand well state when grounded. HOA ENABLE/DISABLE Specify whether you want the SAM PCP Controller to monitor HOA activity. You can configure the SAM PCP Controller to monitor HOA activity and monitor the digital input channels used for Hand and Auto monitoring using the HOA Configuration screen (Figure 8-36). The SAM PCP Controller controls would stop the wells and keep them down until receiving a command to re-start. HOA Configuration Screen Data Field Descriptions Information about each data field is provided below.00 8-95 . select 5. The pump or downtime decision is made by the operator and requires operator intervention to change. A global data message can be sent to all SAM control units on the radio network to place them in the Downtime-HOA OFF well state.

press <EXIT>. 1. 4. 8-96 Revision 1. After you press a key. 5. Note: If another screen is displayed. Do either of the following: • To disable HOA monitoring. Note: When both the Hand and Auto DI channels are open. Select 5. 3. do either of the following: • To return to the SAM Configuration Menu screen. select ENABLE. CONFIGURATION.00 Issue Date: 1/18/08 . press <MENU> to instantly return to the Main Menu screen. SAM CONFIGURATION to display the SAM Configuration Menu screen.SAM Well Manager™ — Progressing Cavity Pump User Manual HOA Auto DI Channel Specify the digital channel number that the SAM PCP Controller will use to go into normal operation mode when grounded. the SAM PCP Controller is in a DT/HOA Off well state. 7. When finished. 2. For each of the DI Channel fields. press <EDIT> and then press the number keys. select 3. Procedure Follow the steps below to enable or disable HOA monitoring. From the Main Menu screen. HAND/OFF/AUTO (HOA) to display the HOA Configuration screen. select DISABLE. Press <EDIT>. press <ENTER>. Press <↓> to highlight the first DI Channel field. Note: It is an invalid HOA state to have both the Hand and Auto digital channels grounded. the next digit to the right highlights. 6. • To enable it HOA monitoring. The HOA Enable/Disable field highlights. and then select 3. You can press <←> to return to a digit to the left to change it. After all numerical values are correct.

16 Configuring Alarm (Coil) Tracking The amount of time that the SAM PCP Controller is in a SAM particular alarm condition can be accumulated. These alarm flags 3/3/6 are referred to as “coils. Ask your Lufkin Automation representative for more information. 8. Figure 8-37. The state you specified for HOA monitoring is saved in the SAM PCP Controller. Issue Date: 1/18/08 Revision 1. press <MENU>. see “60 Day Alarm Tracking” in section 10. which is available under the Historical Data Menu screen.” A record of how many minutes each configured alarm/coil was set for the day is maintained for each of the most-recent 60 days. ALARM TRACKING CONFIGURATION from the SAM Configuration Menu screen. For more information. “Historical Data.” Coil tracking is configured with the Coil Tracking Configuration screen (Figure 8-37). select 6. This alarm information can be a displayed as a plot by using the 60 Day Coil Track option. To display this screen. Coil Tracking Configuration Screen Data Field Descriptions Information about each data field is provided below.Section 8: SAM Controller Programming • To return to the Main Menu screen.00 8-97 .

3. DISABLE when you want specify the configuration (or keep an existing configuration). The COIL # field for INDEX 1 highlights. Note: If another screen is displayed. From the Main Menu screen. to highlight it. CONFIGURATION. If you want to select a specific COIL # field. 2. a.SAM Well Manager™ — Progressing Cavity Pump User Manual INDEX A reference to show which coil is being configured. press <MENU> to instantly return to the Main Menu screen. TRACKING FUNCTIONALITY Specify how multiple coils occurring simultaneously are monitored. Contact your Lufkin Automation representative to obtain the latest register map. 1. press <↑> or <↓>. and then select 3. 8-98 Revision 1. This field cannot be edited. COIL # Specify the number in the PCP register map you want to configure to monitor.00 Issue Date: 1/18/08 . but you do not want it to go into effect presently. Select 6. select 3. Do the following for each coil you want to configure. ALARM TRACKING CONFIGURATION to display the Coil Tracking Configuration screen. ENABLE must be selected to use this function. Choices are: • Normal • First Occurrence • Cascading TRACKING ENABLED Specify whether you want the coil tracking function to be enabled or disabled. Procedure Follow the steps below to configure for coil tracking. SAM CONFIGURATION to display the SAM Configuration Menu screen.

You can press <←> to return to a digit to the left. Issue Date: 1/18/08 Revision 1. press <↑> or <↓> to select between ENABLED and DISABLED. e. The next field highlights. press <MENU>. 8. refer to the SAM Well Manager™ — Variable Speed Drive Progressing Cavity Pump User Manual (Part No. 6. 8. 099. press <↑> or <↓> to select how you want multiple occurrences of coil alarms to occur..5029). 7. This conjunction provides a complete solution for control of a pumping unit system that uses a generic VSD. 4. do either of the following: • To return to the SAM Configuration Menu screen.17 Configuring VSD Parameters The VSD parameters operate in conjunction with the existing standard safety violation parameters. For information about the combo product. Press <↓> to highlight the TRACKING ENABLED field. After all numerical values for the field are correct. Press <EDIT>. press <EDIT>. 5. When the field is highlighted.00 8-99 . When you are finished configuring coils. SAM 3/3/7 Lufkin Automation offers a SAM VSD controller package that combines the PCP controller function in the same cabinet as a variable speed drive. d. and then press <ENTER>. Press the numerical keys to enter numerical values. • To return to the Main Menu screen. and then press <ENTER>.Section 8: SAM Controller Programming b. When finished. the next digit to the right highlights. Press <EDIT>. After you press a number key for the digit that is highlighted. Repeat steps a through d for each COIL # field you want to configure. press <EXIT>. c. The coil tracking configuration is saved in the SAM PCP Controller. This user manual does not address the SAM PCP Controller/VSD combo product. press <ENTER>. press <↓> to highlight the TRACKING FUNCTIONALITY field.

SAM Well Manager™ — Progressing Cavity Pump User Manual

For the generic VSD application, only one VFD/VSD Parameters screen (Figure 8-38) is used to configure VSD parameters and operating speed ranges. To display the VSD screens, select 7. VFD/VSD PARAMETERS from the SAM Configuration Menu screen. To navigate between screens, press <NEXT>.
Note: VSD configuration screens are not available if the prime mover

specified is Hydraulic. When you attempt to select this option, a message appears for a few seconds informing you that a hydraulic unit is specified, and you remain at the SAM Configuration Menu screen. To change the configuration to an electric prime mover, go to the Production/Motor Information screen and select the Electric option in the Prime Mover Type field. For more information about this screen and field, see “Configuring Production and Motor Information” in section 7, “PCP Parameter Programming.”

VSD Parameters The first screen is the VSD Parameters screen (Figure 8-38), which you use to select a VSD type and specify its allowable minimum and maximum operating speeds.

Figure 8-38. VFD/VSD Parameters Screen

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Data Field Descriptions Information about each data field for the VFD/VSD Parameters screen is provided below. VFD Drive Type Select the type of variable speed drive being used. The options available are: • Lufkin LFKA-1 — Select when using a Lufkin variable speed drive. Refer to the SAM Well Manager™ — Variable Speed Drive Progressing Cavity Pump User Manual (Part No. 099.5029). • Others — Select when using a generic inverter drive. This is the only option supported by the user manual you are reading. Scaling Unit Specify the engineering units to be associated with the display of the analog output value to the drive. The scaling unit corresponds to the maximum speed and minimum speed fields. It is easiest to match this with the units being used in the drive (for example, Hz). Available options are %, V, mA, SPM, RPM, and Hz (default). Maximum Speed Select a value to match the engineering unit maximum in the drive. This parameter associates the engineering value of maximum speed with the maximum hardware analog output (10 VDC or 5 VDC, depending on the header block selected). For example, if the drive scales the analog speed reference so that 0 to 10 VDC input corresponds to 0 to 90 Hz, the maximum speed in the SAM PCP Controller should be set at 90 Hz. Minimum Speed Select a value to match the engineering unit minimum in the drive. This parameter associates the engineering value of the minimum speed with the minimum hardware analog output (0 VDC). For example, if the drive scales the analog speed reference so that 0 to 10 VDC input corresponds to 0 to 90 Hz, the minimum speed in the SAM PCP Controller should be set at 0 Hz.

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Procedure Follow the steps below to configure the VSD parameters. 1. From the Main Menu screen, select 3. CONFIGURATION, and then select 3. SAM CONFIGURATION to display the SAM Configuration Menu screen.
Note: If another screen is displayed, press <MENU> to instantly return

to the Main Menu screen. 2. Select 7. VFD/VSD PARAMETERS to display the VFD/VSD Parameters screen.
Note: You cannot access the screens for this command if the prime

mover type specified is hydraulic. For more information, see the Note on page 8-100. The VFD Drive Type fields highlight. 3. Do one of the following to specify values for each remaining field: • To enter numerical values, press <EDIT> and then press the number keys. After you press a key, the next digit to the right highlights. You can press <←> to return to a digit to the left to change it. After all numerical values are correct, press <ENTER>. • To select field options, press <EDIT>, press <↑> or <↓>, and then press <ENTER>. 4. When you are finished programming parameters, do either of the following: • To return to the SAM Configuration Menu screen, press <EXIT>. • To return to the Main Menu screen, press <MENU>. The VSD parameters are saved in the SAM PCP Controller.

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Section 9

Status Screens
The SAM PCP Controller has several status screens that display information about current values for measured process variables, alarms and alerts, and reminders for you about how control parameters are configured. The topics covered in this section include: 9.1 9.2 9.3 9.4 Overview of the Status Screens...................................................... 9-2 Displaying the Status of PCP Parameters ...................................... 9-2 9.2.1 Current PCP Operating Status............................................ 9-2 Displaying the Status of SAM PCP Controller Parameters ........... 9-7 Auxiliary Functions........................................................................ 9-8 9.4.1 Auxiliary Input Status Screens........................................... 9-9 9.4.2 Displaying AUX Analog Input Status.............................. 9-10 9.4.3 Displaying AUX Analog Output Status ........................... 9-11 9.4.4 Displaying Digital Input Status ........................................ 9-12 9.4.5 Displaying AUX Accumulator Status .............................. 9-14 9.4.6 Displaying AUX I/O Boards Status ................................. 9-15 9.4.7 Displaying AGA 3 Status................................................. 9-16 9.4.8 Displaying Logic Expression Status ................................ 9-19 Register Functions........................................................................ 9-20 9.5.1 Displaying Register Digital Output Status ....................... 9-21 9.5.2 Displaying Register Calculations Status .......................... 9-22 Displaying Alarm/Alert Status ..................................................... 9-23 Displaying Alarm Tracking Status............................................... 9-24 Displaying the Status for a Modbus Master Slave Device........... 9-26 VSD Diagnostics .......................................................................... 9-28

9.5

9.6 9.7 9.8 9.9

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SAM Well Manager™ — Progressing Cavity Pump User Manual

9.1

Overview of the Status Screens

Two types of status screens can be displayed. • PCP Status screens displaying information about the primary PCP control functions. Most of this data is based on parameter values configured through the PCP Configuration Menu screens (see section 7, “PCP Parameter Programming”). • Several SAM Status screens displaying information useful to check and troubleshoot background tasks that the SAM PCP Controller performs (page 9-7). Most of this data is based on parameter values configured through the SAM Configuration Menu screens (see section 8, “SAM Controller Programming”). Both status screen types are accessed from the Main Menu screen.

9.2

Displaying the Status of PCP Parameters
SAM 1

The SAM PCP Controller PCP Status screen presents a combination of current operating values and some historical data about the PCP function.

To display the PCP Status screens, select 1. PCP STATUS from the Main Menu screen. Screen contents are described below.

9.2.1 Current PCP Operating Status
Information about the current PCP operating status and some historical data about motor performance and production are displayed on a status screen similar to Figure 9-1. This information provides the operating conditions of the well that are usually of most interest to the operator.

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Figure 9-1. PCP Status Screen Example

By default, the SAM PCP Controller automatically returns to this screen when no keypad activity occurs for eight minutes. Therefore, most of the time this screen displays when you arrive at the site. If it does not display, you can configure it as the default screen using the Additional Configuration feature. For more information, see “Configuring the Default Screen” in section 8, “SAM Controller Programming.” The exact information presented on the status screen depends on the end devices used, control mode selected, and control functions enabled. When you are finished with this screen, press <EXIT> or <MENU> to return to the Main Menu screen. Data Field Descriptions Information about the data field is provided below.
Note: All of the data fields described below may not necessarily be

displayed due to your PCP configuration. Top Row Section The very top row, starting from the left side, shows the following information: • States the firmware version number and version checksum for that version. This information is helpful when speaking with technical support.
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For information about this feature. Five operation modes are available. Operation Mode States the current operation mode that the SAM PCP Controller is programmed to operate. see Appendix A.SAM Well Manager™ — Progressing Cavity Pump User Manual • States the present date and time programmed for the SAM PCP Controller. “SAM Controller Programming. This address allows the central host computer software to identify and interrogate this specific SAM PCP Controller. For descriptions about SAM PCP Controller well states.00 Issue Date: 1/18/08 . The address is programmed at the RTU level under the Communication Parameters option. For information about date/time programming. Gauge-OFF Time States the time of day that the SAM PCP Controller updates all of the historical data buffers. see “Setting the Controller Date and Time” in section 8. This state is not operator-programmable. “Well State List.” Status Section RTU ADDRESS If the SAM PCP Controller is part of a SCADA network. it must have a unique address.” Current Well State States the present operating state of the SAM PCP Controller. see “Communication Parameters Configuration” in section 8. SAM Controller Programming. • PROD CTRL • SPEED CTRL • TIMED • HOST • MONITOR 9-4 Revision 1.” Elapsed Time States how long (HHH:MM:SS format) the SAM PCP Controller has been in the state specified in Current Well State.

” Current Prod Rate States the barrels per day production rate calculated at the end of the most recent sampling period. MLF Allowed States the number of consecutive malfunctions allowed before an alarm is triggered. Today’s Prod Since GOT States the total production that has occurred since gauge off time (GOT) was reset. such as low RPM. “PCP Parameter Programming. or high torque. Yesterday’s Prod States the total production for the previous 24-hour day as defined by Gauge Off Time. Projected Prod States the production rate projected for the 24-hour period based on the amount produced so far for the 24-hour period. low prod. Current Control Speed States the present RPM of the pump. Bottom Section Columns The columns in the bottom section represent the following information: E/D States whether the function is enabled (E) or disabled (D).00 9-5 . CURR States the present value for the feature specified in the row. Current Motor Torque States the present torque of the motor. see “Configuring Control Parameters” in section 7. Issue Date: 1/18/08 Revision 1.Section 9: Status Screens For descriptions about these modes. LIMIT Most of these malfunction controls have a user-defined limit.

Once it exceeds the consecutive (CSC) value. When the torque value is violated. After the Downtime or Violation Run period expires. The current torque (input from the drive) is compared to the specified LIMIT value to detect if the pump is beginning to show evidence of stalling or fluid starvation that can cause friction between stator and elastometer. the SAM PCP Controller decreases rod speed until minimum speed is reached and then shuts down the pump. when a violation occurs. Once it exceeds the CSC value. the SAM PCP Controller automatically restarts. the SAM PCP Controller either operates in Downtime or Violation Run mode. Low Prod States the minimum amount of fluid production allowed.00 Issue Date: 1/18/08 . the SAM PCP Controller immediately switches to either Downtime or Violation Run mode. Low RPM States the minimum pump speed allowed. the SAM PCP Controller starts slowing down the pump by steps until either the torque goes below the limit or the pump reaches minimum speed. For Speed Control Operation mode.SAM Well Manager™ — Progressing Cavity Pump User Manual MLF Current States the number of malfunctions that have occurred since last reset. Torq Limiting States the desired maximum operating torque. Bottom Section Rows The rows in the bottom section represent the following information: No RPM Monitors the RPM channel and alarms when no RPM is detected. or the end of the sampling period for Production Control Operation mode. After the Downtime or Violation Run period expires. The current speed captured through the sensor connected to the rod is monitored and compared to the specified LIMIT value. Critical Torq States the maximum rod torque allowed. This feature is to prevent pump off and for detecting if something is wrong with the production transmitter. the SAM PCP Controller automatically restarts. Once it exceeds the CSC value. 9-6 Revision 1. thus increasing the torque. This feature monitors (at the rate of one-minute resolution) the fluid produced and slows down the pump when it goes below the limit. the SAM PCP Controller either operates in Downtime or Violation Run mode. in RPM.

To display this menu. SAM STATUS from the Main Menu screen. If the difference is greater than the Speed Difference Limit. Pump Eff States the efficiency of the pump. Speed Diff States the speed difference allowed between the measured polished rod speed and the control output.00 9-7 . select 2. for the previous minute based on current production and speed as compared to the pump manufacturer’s specifications. or the end of the sampling period for Production Control Operation mode. These screens provide the following types of status information: • Analog I/O. Production for the current sampling period is compared to this value to detect a production transmitter malfunction at the rate of one-minute resolution for Speed Control Operation mode. digital I/O. The SAM PCP Controller compares the present pump rod speed captured through the sensor connected to the speed control output that the SAM PCP Controller sends to motor drive. accumulator. Issue Date: 1/18/08 Revision 1.3 Displaying the Status of SAM PCP Controller Parameters SAM 2 You can display several status screens that contain information useful for checking and troubleshooting background tasks that the SAM PCP Controller performs.Section 9: Status Screens High Prod States the maximum amount of fluid production allowed. in percent. 9. the SAM PCP Controller issues an alarm informing the operator that the controller and the drive are out of synch in terms of speed. and AGA 3 calculations • Values for programmed registers and register calculations • Alarms/alerts that are set and alarm tracking • Register addresses and values for Modbus slave devices • VSD parameters and VFD/SAM parameter comparisons These screens are available through the SAM Status Menu screen (Figure 9-2).

Raw numbers will therefore be in the range of zero to 4095. AUXILIARY FUNCTIONS from the SAM Status Menu screen.4 Auxiliary Functions SAM 2/1 Several auxiliary (AUX) status screens are used to view current values for all the process variable transmitters connected to the SAM PCP Controller. Analog I/O. SAM Status Menu Screen 9.SAM Well Manager™ — Progressing Cavity Pump User Manual Figure 9-2. current values for each configured auxiliary or expansion I/O points can be seen on these status screens. digital I/O. If the SAM PCP Controller is equipped with optional I/O expansion boards. Status screens are also available for the following: • AGA 3 calculations • Programmed logic expressions • Alarms and alerts An Auxiliary Functions Status Menu screen (Figure 9-3) is used as a secondary menu to access the I/O type you want displayed and the status of auxiliary boards. select 1.00 Issue Date: 1/18/08 . The SAM PCP Controller uses a 12-bit A/D converter for auxiliary analog points. accumulator values. and AGA 3 status can be displayed. To display this menu. 9-8 Revision 1.

select 1. digital I/O.1 Auxiliary Input Status Screens You can display the status of analog I/O. Auxiliary Functions Status Menu Screen 9.4. AUX I/O STATUS from the Auxiliary functions Status Menu screen. Figure 9-4. and boards.00 9-9 . To display this menu. AUX I/O Status Menu Screen Issue Date: 1/18/08 Revision 1.Section 9: Status Screens Figure 9-3. SAM accumulators. This information is displayed on 2/1/1 separate status screens that are selected from the AUX I/O Status Menu screen (Figure 9-4).

SAM Well Manager™ — Progressing Cavity Pump User Manual 9. AUX Analog Input Status Screen Auxiliary analog inputs are displayed in sets of eight per screen.” Data Field Descriptions Information about each data field is provided below.4.2 Displaying AUX Analog Input Status You can use an AUX Analog Input Status screen similar to Figure 9-5 to display status data about the analog inputs. For information about this screen. The present status for auxiliary analog inputs 1 through 8 displays on the first screen (see Figure 9-5). AI# States the virtual analog input number as programmed in section 8. SAM 2/1/1/1 Figure 9-5. To display this screen. “SAM Controller Programming. see “Configuring Auxiliary Analog Inputs” in section 8. Press <NEXT> to display the next set of eight. 9-10 Revision 1. Auxiliary analog input channels are configured using the Auxiliary Analog Input Configuration screen.00 Issue Date: 1/18/08 . select 1. Raw Counts States the numerical representation of the present value of the analog input as a raw BCD number (0 to 4095). AUX ANALOG INPUT STATUS from the AUX I/O Status Menu screen..

Alarm E/D States whether an alarm is enabled (E) or disabled (D) for the channel. see “Configuring Auxiliary Analog Outputs” in section 8. select 2. Units States the unit of measurement used. do either of the following: • Press <EXIT> to return to the AUX I/O Status Menu screen.00 9-11 . AUX Analog Output Status Screen Auxiliary analog output channels are configured using the Auxiliary Analog Input Configuration screen.” Issue Date: 1/18/08 Revision 1. • Press <MENU> to return to the Main Menu screen.Section 9: Status Screens Scaled Value States the present value of the analog input in engineering units. For information about this screen.3 Displaying AUX Analog Output Status You can use an AUX Analog Output Status screen similar to Figure 9-5 to display status data about the analog outputs. AUX ANALOG OUTPUT STATUS from the AUX I/O Status Menu screen. “SAM Controller Programming.4. SAM 2/1/1/2 Figure 9-6. 9. When you are finished with this screen. To display this screen.

AUX DIGITAL I/O STATUS from the AUX I/O Status Menu screen. Scaled Value States the present value of the analog output in engineering units. To display this screen. select 3. AO# States the virtual analog output number as programmed in section 8.4 Displaying Digital Input Status You can use a Digital Status screen similar to 9-13 to display status data about the digital inputs. When you are finished with this screen.4.00 Issue Date: 1/18/08 . Units States the unit of measurement used. 9-12 Revision 1. This data is useful for verifying the operation of input switches. 9. Raw Counts States the numerical representation of the present value of the analog output as a BCD number (0 to 4095). do either of the following: • Press <EXIT> to return to the AUX I/O Status Menu screen.SAM Well Manager™ — Progressing Cavity Pump User Manual Data Field Descriptions Information about each data field is provided below. • Press <MENU> to return to the Main Menu screen.

00 9-13 . When you are finished with this screen. Press <NEXT> to display the next set of digital inputs. DIG# States the digital channel number. The present status for auxiliary digital inputs 1 through 32 displays on the first screen (see Figure 9-7). Issue Date: 1/18/08 Revision 1. do either of the following: • Press <EXIT> to return to the AUX I/O Status Menu screen. Digital channels are configured using the Digital Configuration screen. • Press <MENU> to return to the Main Menu screen. “SAM Controller Programming.Section 9: Status Screens Figure 9-7. For information about this screen. see “Configuring Auxiliary Digital Inputs and Outputs” in section 8.” Data Field Descriptions Information about each data field is provided below. Digital Status Screen Auxiliary digital inputs status screens only display the open or closed state for each input that is configured. State States whether the digital channel is open or closed.

The motherboard has four auxiliary 2/1/1/4 digital points that can be configured as accumulators. AUX ACCUMULATOR STATUS from the AUX I/O Status Menu screen.00 Issue Date: 1/18/08 . Accum # States the virtual channel number for the accumulator. Optional expansion board hardware is required to take advantage of the additional six accumulators that the firmware can support. AUX Accumulator Status Screen These inputs provide the ability to monitor the operation of facilities adjacent to a well without having the additional cost of installing a remote terminal unit (RTU) and data telemetry equipment for that facility. You can use an Aux Accumulator Status screen similar to Figure 9-8 to display status data about the auxiliary accumulators. select 4.5 Displaying AUX Accumulator Status The SAM PCP Controller firmware design supports a maximum SAM of ten accumulator inputs. Units States the unit of measurement to be associated with each auxiliary input.SAM Well Manager™ — Progressing Cavity Pump User Manual 9.4. Data Field Descriptions Information about each data field is provided below. To display this screen. Figure 9-8. 9-14 Revision 1.

Current Rate States the instantaneous present value.Section 9: Status Screens PPM States the pulses per unit of measure (PPM). do either of the following: • Press <EXIT> to return to the AUX I/O Status Menu screen.00 9-15 . select 5. For each board. you can see its operating state. The range is 1 to 999. This value is an integer that programs the SAM PCP Controller to scale this given number of pulses counted at the defined accumulator input point as a single unit. checksum. AUX I/O Boards Status Screen Issue Date: 1/18/08 Revision 1. 9. A total of eight boards can be stacked to the motherboard. Figure 9-9.6 Displaying AUX I/O Boards Status You can use the AUX I/O Boards Status screen (Figure 9-9) as a SAM troubleshooting tool to see if the different auxiliary I/O boards 2/1/1/5 are present and working properly. When you are finished with this screen. • Press <MENU> to return to the Main Menu screen. and the number each has available for I/O configuration.4.999. Rate/User Defined Interval States the sampling period. model. in minutes. To display this screen. build. AUX BOARD STATUS from the AUX I/O Status Menu screen.

VER States the firmware version of the board. AI States the number of analog inputs available on the board. STATE Present state of the expansion board.4. do either of the following: • Press <EXIT> to return to the AUX I/O Status Menu screen. NUM States the board number as defined by the board dip switches. AO States the number of analog outputs available on the board. XSUM Displays the board’s checksum number.SAM Well Manager™ — Progressing Cavity Pump User Manual Data Field Descriptions Information about each data field is provided below. 9. BUILD States the secondary version description. ACC States the number of pulse accumulators available on the board. • Press <MENU> to return to the Main Menu screen. MODEL Model number read from the expansion board processor on power up. This number is used to check the validity of the firmware.7 Displaying AGA 3 Status 9-16 Revision 1. It should match the number written on the chip on the board.00 Issue Date: 1/18/08 . DIG States the number of digital inputs/outputs available on the board. When you are finished with this screen.

“SAM Controller Programming.Section 9: Status Screens If the SAM PCP Controller has proper optional hardware. For information about enabling it. this screen will not show current data. FLOWING PRESSURE States the present measured flowing pressure.” Figure 9-10.00 9-17 . or user-specified pressure if not measured. SAM 2/1/2 Note: If the AGA 3 Calculations feature is disabled. you can display the calculation results on a status screen similar to Figure 9-10. DIFFERENTIAL PRESSURE States the present measured differential pressure. ENABLED States whether or not the AGA calculations are enabled. see “Enabling and Disabling AGA 3 Calculations” in section 8. and it is configured to perform the AGA 3 gas flow rate and volume calculations. Issue Date: 1/18/08 Revision 1. AGA Status Screen Data Field Descriptions Information about each data field is provided below.

TOTAL PRODUCTION States the total production accumulated since last reset.SAM Well Manager™ — Progressing Cavity Pump User Manual FLOWING TEMPERATURE States the present measured flowing temperature.00 Issue Date: 1/18/08 . SUPERCOMPRESSIBILITY States the calculated supercompressibility factor. do either of the following: • Press <EXIT> to return to the Auxiliary Functions Status Menu screen. TODAY’S PRODUCTION States the production since last gauge off time (GOT). When you are finished with this screen. FLOW RATE States the present flow rate measured in MCF/DAY. 9-18 Revision 1. • Press <MENU> to return to the Main Menu screen. or user-specified temperature if not measured. Note: Press <DELETE> while viewing the AGA Status screen to reset the total production accumulator.

see “Enabling and Disabling Logic Expressions” in section 8. select 3. Data Field Descriptions Information about each data field is provided below. “SAM Programming.Section 9: Status Screens 9.00 9-19 . LOGIC EXP States the logic expression number. For information about enabling it. Note: If the Logic Expression function is disabled. Issue Date: 1/18/08 Revision 1. To display this screen.” Figure 9-11.4.8 Displaying Logic Expression Status You can display the present status for each logic expression and SAM the action programmed for that expression on a Logic 2/1/3 Expression Status screen similar to Figure 9-11. LOGIC EXPRESSION STATUS from the Auxiliary Functions Status Menu screen. this screen will not show current data. Logic Expression Status Screen The present condition of each programmed logic expression is displayed at the far right edge of the screen as T for true or F for false.

9. When you are finished with this screen. • If the programmed action is MALF.5 Register Functions The SAM PCP Controller has status screens that can display the SAM address and current value for any configured register alarm and 2/2 the status values obtained from register calculations. it states the number of retries allowed before the pumping unit is shut down in a Malfunction well state.SAM Well Manager™ — Progressing Cavity Pump User Manual Action States the action parameters programmed for the logic expression. REGISTER FUNCTIONS from the SAM Status Menu screen. This time delay is in addition to any programmed time delays for the analog alarms and/or digital inputs that are included in a logic expression. • If the programmed action is TIMER. “SAM Controller Programming. see “Programming a Logic Expression Action” in section 8. 9-20 Revision 1. select 2.00 Issue Date: 1/18/08 . Logic Time Delay (sec) States the delay before executing the programmed action when a logic expression proves true. To display this menu. For descriptions about each action available. Screens for displaying this data are available through the Register Functions Status Menu screen (Figure 9-12).” Consec Malf Allowed or Timer Period(min) States the action programmed for the logic expression. it states the desired time in minutes to hold closed the designated digital output. • Press <MENU> to return to the Main Menu screen. do either of the following: • Press <EXIT> to return to the Auxiliary Functions Status Menu screen.

select 1. Register Functions Status Menu Screen 9. To display this screen.1 Displaying Register Digital Output Status The SAM PCP Controller has a register alarm feature that can be SAM programmed for actions based on any of the measured or 2/2/1 calculated values entered in the controller memory files. Figure 9-13.Section 9: Status Screens Figure 9-12.00 9-21 . REGISTER DIGITAL OUTPUT STATUS from the Register Functions Status Menu screen.5. You can display a Register Digital Output Status screen similar to Figure 9-13 that shows the address and current value for each register alarm programmed. Register Digital Output Status Screen Issue Date: 1/18/08 Revision 1.

• Press <MENU> to return to the Main Menu screen. When you are finished with this screen. You can display the calculated results in a Programmable Calculations Status screen similar to Figure 9-14. REG # States the index of the register alarm described on that line.SAM Well Manager™ — Progressing Cavity Pump User Manual Data Field Descriptions Information about each data field is provided below.2 Displaying Register Calculations Status You can combine status values from different registers to obtain new values that can be used for monitoring and creating register alarms. select 2. To display this screen. REGISTER CALCULATIONS STATUS from the Register Functions Status Menu screen. 9. ADDRESS States the Modbus register address being monitored by the register alarm on that line. 9-22 Revision 1. do either of the following: • Press <EXIT> to return to the Register Functions Menu screen.5.00 Issue Date: 1/18/08 . CURRENT VALUE States the value of the Modbus register being monitored by the register alarm on that line.

Note: This notification box does not display when latched alarms are not cleared. Eight screens are available. Figure 9-15 is an example of a screen displaying an Alarm/Alert notification. do either of the following: • Press <EXIT> to return to the Register Functions Menu screen. 9. an alarm alert box blinks on and off at the top of every screen. To display this screen. select 3. Figure 9-15 is an example of the first. Programmable Calculations Status Screen For information about configuring register calculations.Section 9: Status Screens Figure 9-14.6 Displaying Alarm/Alert Status SAM 2/3 If a dynamic alarm and/or alert condition exists anywhere in the SAM PCP Controller. Issue Date: 1/18/08 Revision 1. ALARM STATUS from the SAM Status Menu screen. “SAM Controller Programming.” When you are finished with this screen. You can check which dynamic alarm/alert is set by using the Alarm Status screens. see “Configuring Register Calculations” in section 8.00 9-23 . • Press <MENU> to return to the Main Menu screen.

7 Displaying Alarm Tracking Status You can view the number of times that the SAM PCP Controller SAM went into a particular alarm condition for the day since gauge-off 2/4 time (GOT). select 4. To display this screen. • Press <MENU> to return to the Main Menu screen.” You can display this information on a Coil Tracking Status screen similar to Figure 9-16.00 Issue Date: 1/18/08 . ALARM TRACKING STATUS from the SAM Status Menu screen. For information about this historical data. When you are finished with the Alarm Status screens. 9. Note: You can view the coil tracking data displayed in a table and plotted for the amount of time each day for the previous 60 days. “Historical Data. Alarm Status (Log) Screen with Alarm Alert Message Press <NEXT> to scroll forward through the Alarm Status screens. see “60 Day Alarm Tracking” in section 10.” 9-24 Revision 1.SAM Well Manager™ — Progressing Cavity Pump User Manual Alarm Alert box Figure 9-15. do either of the following: • Press <EXIT> to return to the SAM Status Menu screen. These alarm flags are referred to as “coils.

TIME ACTIVE Displays the total amount of time the alarm has been active since GOT. # Occurrences States how many times the particular alarm condition has occurred since GOT or the last time it was reset. Coil Tracking Status Screen Data Field Descriptions Information about each data field is provided below. Issue Date: 1/18/08 Revision 1. COIL # States the number in the PCP register map configured to be monitored.00 9-25 . Contact your Lufkin Automation representative to obtain the latest register map. INDEX A reference to show which coil is configured.Section 9: Status Screens Figure 9-16.

see “Configuring Alarm (Coil) Tracking” in section 8. For information about enabling/disabling tracking. 9-26 Revision 1. This information is displayed in a Modbus Master Status Menu screen (Figure 9-17).” When you are finished with this screen. To display this screen.00 Issue Date: 1/18/08 .8 Displaying the Status for a Modbus Master Slave Device At any time you can retrieve and display the register addresses SAM and register values for a Modbus slave device configured to a 2/5 Modbus master in the data network. MODBUS MASTER STATUS from the SAM Status Menu screen.SAM Well Manager™ — Progressing Cavity Pump User Manual TRACKING FUNCTIONALITY States how multiple coils occurring simultaneously are monitored. Choices are: • Normal • First Occurrence • Cascading TRACKING ENABLED States whether the coil tracking function is enabled or disabled. “SAM Controller Programming. • Press <MENU> to return to the Main Menu screen. 9. select 5. do either of the following: • Press <EXIT> to return to the SAM Status Menu screen.

and then press <ENTER>. A register address and register value status screen similar to Figure 9-18 appears for a Modbus slave device.Section 9: Status Screens Figure 9-17. Typical Status Screen for a Modbus Slave Device Showing Its Register Addresses and Values Issue Date: 1/18/08 Revision 1. Modbus Master Status Menu Screen Highlight the slave device you want displayed. You can press <NEXT> to view the next status screen.00 9-27 . Figure 9-18.

9. SAM VFD COMM DIAGNOSTICS on the SAM Status Menu screen 2/6 is meaningless when the SAM PCP controller is used with a generic variable speed drive.00 Issue Date: 1/18/08 . no explanation about these features is included in this manual 9-28 Revision 1. • Press <MENU> to return to the Main Menu screen.9 VSD Diagnostics The VFD COMM Diagnostics Menu screen offered by option 6.SAM Well Manager™ — Progressing Cavity Pump User Manual When finished. do either of the following: • Press <EXIT> to return to the Modbus Master Status Menu screen. Therefore.

......1 Overview of the Historical Data Features .............................................................................2 Plotting Data Menu .1 60 Day Peak Speed Measured.............................................................................................................. 10-5 10.................6....................1 Register Log ....Section 10 Historical Data The SAM PCP Controller maintains historical data in various formats to provide useful information about PCP production and performance...4..........3........................3 PCP Data .....2 Normal Operation Period ..3......... 10-7 10...................... 10-13 10................1 24 Hour AGA 3 Gas Flow......... 10-8 10... 10-14 Issue Date: 11/18/08 Revision 1........................1 Starting Period... 10-9 10...........2 Alarm Log .................5 60 Day Pump Efficiency ........... 10-8 10......7.......4.... 10-8 10.............................................................................................1 Event Log ....................... 10-12 10......3.......4...........4 60 Day Historical Data.................. 10-8 10.......................................................................................................................... 10-6 10...................................... 10-7 10......3.................................2 60 Day Alarm Tracking................ 10-2 10..................5...................5.....................................00 10-1 .5 SAM Data. 10-9 10........... The topics covered in this section include: 10............................ 10-11 10............ 10-7 10............................................................. 10-7 10..........................6........................................................ 10-10 10........................... 10-8 10.... 10-13 10..........7................4.......6 AGA 3 Data...............3 60 Day Peak Torque ....2 60 Day AGA 3 Gas Flow ...... 10-4 10..............4 60 Day Daily Production..........................................4...............................4 Stopping Period .................................................2 60 Day Peak Speed Output...................3 Power Off Delay Period .....................................7 Events ........................... 10-11 10........

You can press <NEXT> to toggle between the formats for any screens that display NEXT at the bottom of them. calculated flow rates and volumes. VSD performance. Historical Data Menu Screen Data Display Formats Most historical data is displayed as a graphical plot while other data is only displayed in a table. Some data types can be displayed in both formats (see Figure 10-2 for examples). and alarm and event logs.00 Issue Date: 11/18/08 . This historical data can be retrieved and displayed for activity from the previous 24-hour period in one-minute intervals. All historical data is accessed from the Historical Data Menu screen (Figure 10-1). or the daily average for the previous 60 days. select 4.1 Overview of the Historical Data Features The SAM PCP Controller saves in onboard memory historical SAM data values for process variables. such as PCP production and 4 performance.SAM Well Manager™ — Progressing Cavity Pump User Manual 10. HISTORICAL from the Main Menu screen Figure 10-1. Note: Some screens accessed through the 60 Day Historical Data screen (see page 10-7) have the graphical plot and table data displayed in the same screen. 10-2 Revision 1. To display this screen.

A maximum of three variables can be plotted on a screen (see Figure 10-2). These keys are described in the table below. An Options title appears to the right of OPTIONS and the hotkeys available appear at the bottom of the screen. Issue Date: 11/18/08 Revision 1. Press the designate key to add the variable.Section 10: Historical Data Figure 10-2. press <EDIT>. To access the available hotkey functions. Not all historical screens have an OPTIONS field.00 10-3 . Historical Data Displayed as a Graphical Plot and Table on Separate Screens Additional Display Options Additional “hotkey” functions are available when an OPTIONS field is available in the lower left corner of the screen and it is highlighted (see the left screen in Figure 10-2 for an example). Options title OPTIONS field Hotkey functions Plot Selection Options The number keys are designated as “toggles” to include or remove a process variable from the plot. Navigation Options Several screens that display as a graphical plot have navigation options that you can also use as hotkeys. and then press it again to remove that variable.

).2 Plotting Data Menu The Plotting Data Menu screen (Figure 10-3) provides access to SAM all historical data plots and most of the historical data tables. Data points are displayed in groups (or “pages”) of 240 as indicated. 4/1 Only the alarm and event log are not accessed from this menu. This action allows you to redefine a “page” break.SAM Well Manager™ — Progressing Cavity Pump User Manual Key ←→ Function Moves the dashed vertical line “pointer” to select a particular data point. Toggles the display between table data and a graphical plot. Plotting Data Menu Screen 10-4 Revision 1. ↑↓ NEXT Selects the “page” of data points to be displayed. Refresh Options Refresh options are available to allow you to refresh the data displayed on the screen manually or allow the SAM PCP Controller to automatically refresh as new data becomes available.00 Issue Date: 11/18/08 . ENTER Centers the vertical dashed line pointer and the data point currently selected by the pointer. but instead are available from the Events Menu screen (see page 10-13. Figure 10-3. 10.

and ramp down activity. PLOTTING from the Historical Data Menu screen. select 1. This screen also provides access to another menu you can use to display 60-day plots (see “60 Day Historical Data” on page 10-7. PCP Data Menu Screen Issue Date: 11/18/08 Revision 1. select 1. PCP Data from the Plotting Menu screen. To display this menu.00 10-5 . 10. such as startup and 4/1/1 shutdown activity. Figure 10-4.3 PCP Data The PCP Data Menu screen (Figure 10-4) has options for you to SAM view historical data about PCP activity.). • PCP data about normal pumping operations and pump activity (page 10-5) • 60-day activity for production. normal operations. peak motor speed and torque. and pump efficiency (page 10-7) • Register log and alarm tracking activity (page 10-9) • AGA 3 gas flow (page 10-11) To display the Plotting Data Menu screen.Section 10: Historical Data The types of historical data available from the Plotting Data Menu screen include.

00 Issue Date: 11/18/08 . you can select and display up to three plots on the screen. 10-6 Revision 1. Screen with Three Plots Displayed Tabular Data Display At any time you can press <NEXT> to display the data in tabular format. 10. press the number key again. Press the number key representing the data type you want plotted.3. You can select and display any three of these operations on one screen. Plot types available for display Figure 10-5. In Figure 10-5. Data can be displayed as a table and graphical plot. If you selected multiple plots for display. All normal operations available using the Normal Operation Data option are available for Start Buffer.1 Starting Period You can display historical data of the selected variables from SAM the time the well was at the Starting state. and then five “hotkey” options appear below this field. notice that the OPTIONS field in the lower left corner is highlighted. Press <EDIT> until Plot Selection Options appears. data for each selection displays in a separate column. One sample point is 4/1/1 recorded each second for the previous four minutes (240 sample points). To remove a data type from the plot.SAM Well Manager™ — Progressing Cavity Pump User Manual Multiple Plot Display When you use any one of the first four options.

and pump efficiency for the previous 60 days. One sample point is recorded each second for the previous four minutes (240 sample points). 10.2 Normal Operation Period You can display historical data about several normal PCP SAM operations for the previous 1.4 60 Day Historical Data The 60 Day Historical Data Menu screen (Figure 10-6) has SAM options to plot historical data for VSD speed and torque. Day 1 is the most-recent day shown.4 Stopping Period You can display historical data about the torsional effects of the SAM polished rod on normal PCP operations after the pump receives 4/1/4 no more power from the motor.Section 10: Historical Data 10. which is yesterday.00 10-7 . The daily values are updated each day at gauge off time (GOT). You can select and display any three of these operations on one screen. Issue Date: 11/18/08 Revision 1. After 60 days. Data can be displayed as a table and graphical plot.3 Power Off Delay Period You can display historical data about normal PCP operations SAM from the time the well is at the ramp down state due to a 4/1/3 violation or when the Start/Stop command is issued. pump efficiency. Some of 4/1/2 the normal operations include speed output. All normal operations available using the Normal Operation Data option are available for Stopping Period. Data can be displayed as a table and graphical plot. select 5.3.500 minutes (25 hours). One sample point is recorded each second for the previous four minutes (240 sample points). 10. One sample point is recorded each minute for each operation. All normal operations available using the Normal Operation Data option are available for Power Off Delay. data from the oldest day is deleted from memory and replaced with data from the newest day. 10. 60 DAY HISTORICAL DATA from the PCP Data Menu screen. and measured speed. fluid 4/1/1/5 production. production.3.3. You can select and display any three of these operations on one screen. To display this menu. Data can be displayed as a table and graphical plot. You can select and display any three of these operations on one screen. rod torque.

00 Issue Date: 11/18/08 .4. SAM SAM 4/1/1/5/2 4/2/3 10.4.4.5 60 Day Pump Efficiency This plot displays the average daily pump efficiency as compared with the measured production.4.3 60 Day Peak Torque This plot displays the highest daily value recorded for polished rod torque.2 60 Day Peak Speed Output This plot displays the highest daily value recorded for output polished rod speed output signal.4 60 Day Daily Production This plot displays the daily totals for measured production.SAM Well Manager™ — Progressing Cavity Pump User Manual Figure 10-6. 60 Day Historical Data Menu Screen 10. SAM 4/1/1/5/3 10. SAM 4/1/1/5/4 10. The tabular numbers need to be divided by a factor of 10 for actual volumes. SAM 4/1/1/5/5 10-8 Revision 1.1 60 Day Peak Speed Measured This plot displays the highest daily value recorded for measured polished rod speed. SAM 4/1/1/5/1 10.4.

register log. such as the category of data (analog input. select 2. Because each register log has a varying sample rate based on its particular setting. For more information about this screen. and whether the data is a sample point taken each period or a sample average for the period.).5.1 Register Log The register log has a buffer with 1440 entries. see “Configuring a Register Log”.” Issue Date: 11/18/08 Revision 1. SAM 4/1/2/1 The data displayed is based on parameters specified for the register log in the Register Logging Config screen. SAM Historical Data Menu Screen 10. sample rate. etc. in section 8.5 SAM Data The SAM Data Menu screen (Figure 10-7) has options to display 60-day historical data about the SAM PCP Controller activity.00 10-9 . “SAM Parameter Programming. SAM DATA from the Plotting Menu screen.Section 10: Historical Data 10. SAM 4/1/2 • Plots displaying physical input or calculated values from configured register logs • Plots and tables displaying the amount of time each day specific alarm coil actions occurred To display this menu. this buffer can store data for anything from one day (once-a-minute sampling) to 1440 days (once-a-day sampling). Figure 10-7. accumulator.

2 60 Day Alarm Tracking This 60-day historical data is the amount of time each day that the SAM PCP Controller was in a particular alarm condition. a message displays to inform you that it is not configured. 10.” 10-10 Revision 1. This data can be displayed as a plot or table. highlighting the Register Log field. “SAM Controller Programming. Register Log Screen Selecting a Specific Log for Display You can select the register log you want plotted. select 1. To select a plot. A maximum of 10 logs are available. REGISTER LOG from the SAM Data Menu screen. SAM 4/1/2/2 Alarm flags are referred to as “coils. The log type displays above the plot. but the actual number available depends on which register logs were configured with the Register Logging Config screen. press <EDIT>. use the number keys to specify the log. To display this screen. and then press <ENTER>.” Alarm coils are configured using the Coil Tracking option.SAM Well Manager™ — Progressing Cavity Pump User Manual Register log data displays in the Register Log screen (Figure 10-8). see “Configuring Alarm (Coil) Tracking” in section 8. For information about this option.00 Issue Date: 11/18/08 .5. If you select a register log that is not configured. Figure 10-8.

AGA Data Menu Screen 10. When the coil number displays. SAM 4/1/3 Figure 10-9. press <ENTER>. Press <EDIT>.Section 10: Historical Data Selecting a Specific Alarm Coil for Display You can select for display any one of a possible sixteen different alarm coils.6 AGA 3 Data The AGA Data Menu screen (Figure 10-9) has options for you to view AGA 3 historical data from the previous 24 hours and 60 days. Press <↑> or <↓> to scroll through coil track numbers. 24 HOUR AGA GAS FLOW from the AGA Historical Data Menu screen. select 1. 1. 2. AGA DATA from the Plotting Menu screen. 10. Use the procedure described below to display a specific alarm coil. The Coil Track # field at the top of the plot displays the current coil track number. select 3. 3.440 samples recorded in the data buffers at one-minute intervals or as 180 values that are an average value for an eight-minute interval. Issue Date: 11/18/08 Revision 1. To display this screen. To display this menu.00 10-11 .6.1 24 Hour AGA 3 Gas Flow Historical data collected over the previous 24-hour period for SAM AGA 3 gas flow can be displayed as a graphical plot and in a 4/1/3/1 table. This data can consist of 1.

“SAM Controller Programming. To display this screen. This field is located along the right edge of the display screen.6. see “Enabling and Disabling AGA 3 Calculations” in section 8. To return to the original scaling. highlight the Pk or Min field. To change the rescaling. 10. 60 DAY AGA GAS FLOW from the AGA Historical Data Menu screen. “SAM Controller Programming. select 2. use the number keys to enter a new value. 24 Hour AGA 3 Gas Flow Plot Plot Rescaling The Y-axis is automatically scaled to fit in the minimum and maximum values for the 24-hour period. and then press <ENTER>.” Figure 10-10.2 60 Day AGA 3 Gas Flow The last 60-day averages of the calculated gas flow rate can be plotted and displayed as a table. This axis can be rescaled so that you can view small variances easily by editing the Y-AXIS SCALE field. press <DEL>. see “Enabling and Disabling AGA 3 Calculations” in section 8.” 10-12 Revision 1.00 Issue Date: 11/18/08 . For information about enabling it. For information about enabling it. press <EDIT>. SAM 4/1/3/2 Note: This plot will not display when the AGA 3 calculation function is disabled.SAM Well Manager™ — Progressing Cavity Pump User Manual Note: This plot will not display when the AGA 3 calculation function is disabled.

This field is located along the right edge of the display screen. select 1. EVENTS from the Historical Data Menu screen. Issue Date: 11/18/08 Revision 1. This axis can be rescaled so that you can view small variances easily by editing the Y-AXIS SCALE field. EVENT LOG from the Events Menu screen. Figure 10-11. highlight the Pk or Min field. To return to the original scaling. Figure 10-12 is an example. press <DEL>. and then press <ENTER>.7. To change the rescaling. press <EDIT>. 10. Events Menu Screen 10.7 Events The Events Menu screen (Figure 10-11) has options for you to SAM display historical logs of PCP control events and alarms that 4/2 occurred. To display this menu. To display this screen. Both logs list the type of events that occurred along with time/date stamps for when they were recorded. use the number keys to enter a new value.Section 10: Historical Data Plot Rescaling The Y-axis is automatically scaled to fit in the minimum and maximum values for the previous 60 days. select 2.1 Event Log The Event Log screen displays the recorded date and time that SAM events relating directly to the PCP control processes occurred 4/2/1 during the past 60 days.00 10-13 .

7. select 2.SAM Well Manager™ — Progressing Cavity Pump User Manual Figure 10-12. ALARM LOG from the Events Menu screen. “System Tools. Event Log Screen This event log is a complement to the maintenance log feature provided in the System Tools menu.2 Alarm Log The Alarm Log screen can display a maximum of 100 recorded alarm logs with date and time stamps and descriptions of each alarm. see “Maintenance Log” in section 11. Figure 10-12 is an example. To display this screen.” 10. SAM 4/2/2 10-14 Revision 1.00 Issue Date: 11/18/08 . For more information.

Alarm Log Screen Issue Date: 11/18/08 Revision 1.00 10-15 .Section 10: Historical Data Figure 10-13.

If you attempt to restart the pump while rotation is detected.00 11-1 . one of the following messages displays for five seconds: • MOTOR STOP appears when the system is operating to notify you that the system is shutting down. SAM 5 Be aware that the pump cannot stop immediately due to residual polished rod rotation (torsion) from forward spin or backspin. You can override the stop protection feature. “PCP Parameter Configuration. especially during backspin. • MOTOR START appears when the system is shut down to notify you that the system is starting. see “Configuring Control Parameters” in section 7. but Lufkin Automation does not recommend it. For information about enabling and disabling the stop protection override. Pump damage or personnel injury can occur if you start the pump while it is rotating. START/STOP from the Main Menu screen. Issue Date: 1/18/08 Revision 1. a message appears to warn you that the pump will not start. This safeguard feature should only be overridden for emergency purposes. The SAM PCP Controller has a safeguard feature to prevent the pump from being restarted when it detects polished rod rotation. The action this command executes is based on the current state of the well.” After you select 5.Section 11 System Starting and Stopping The PCP system can be started or stopped at the SAM PCP Controller or remotely by Modbus using the Start/Stop command available from the Main Menu screen.

the Current Well State field in the PCP Status screen reads SD – Operator Stop. 11-2 Revision 1.SAM Well Manager™ — Progressing Cavity Pump User Manual Note: When the system is stopped.00 Issue Date: 1/18/08 .

RESET MALFUNCTIONS from the Main Menu screen. the malfunctions are reset and the message Reset Malf Completed appears.Section 12 Reset Malfunctions When the SAM PCP Controller is in a malfunction state.00 12-1 . After you select this command. To reset malfunctions. SAM 6 Note: You can also use Reset Malfunctions to reset VSD drive faults and malfunctions. Issue Date 1/18/08 Revision 1. the malfunction must be cleared. select 6.

To display this screen. When you contact technical support with questions. Figure 13-1.00 13-1 . FIRMWARE VERSIONS from the Main Menu screen. Code Versions and Checksum Screen Issue Date: 1/18/08 Revision 1. you should either have this screen displayed or write down these numbers. select 7.Section 13 Firmware Versions A Code Versions and Checksum screen similar to Figure 13-1 SAM lists the different firmwares installed in the SAM PCP Controller 7 and their version numbers and checksums.

............................... contact your Lufkin Automation representative.................... Issue Date: 1/18/08 Revision 1.... The diagnostic tools are accessed from the System Tools Menu screen (Figure 14-1).............................. select 8..........2 MB Register Map Check..................... 14-9 14..... and other operational features in the controller.......... 14-1 14...... For more information about these functions............................ 14-3 14....... 14-6 14......5 Keypad .. This section only provides a brief overview about them.............4 Communication Diagnostics ..................................................................1 RX/TX Messages ............................3..2 Maintenance Log........... 14-7 14....3 Main Board I/O Diagnostics .. The topics covered in this section include: 14...........1 Main Board I/O Status..00 14-1 ............1 Overview of the System Tools ......2 Main Board Manual DIO Diagnostics .. SYSTEM TOOLS from the Main Menu screen..................................... local keypad integrity...... To display this menu............................. 14-5 14.........................Section 14 System Tools The SAM PCP Controller has several diagnostic tools for checking data communications.....1 Overview of the System Tools Several useful diagnostic tools are available for troubleshooting SAM PCP control system installations............4...4................ They are primarily intended for 8 use by trained Lufkin Automation service technicians..........................3........... 14-2 14.............. 14-8 14......... 14-4 14..................

System Tools Menu Screen 14. SAM 8/1 This information is displayed in an Event Log screen similar to Figure 14-2. To display this screen. MAINTENANCE LOG from the System Tools Menu screen. etc. This log can be useful for checking when programming changes were made.SAM Well Manager™ — Progressing Cavity Pump User Manual Figure 14-1. 14-2 Revision 1.00 Issue Date: 1/18/08 . All events are recorded with a date/time stamp. power outages occurred. select 1.2 Maintenance Log The maintenance log feature displays a record of the last 200 significant events.

14. • Press <MENU>To return to the Main Menu screen. 8/2 and to view the status and diagnose digital inputs and outputs on the main board. Clears all events from the screen. Event Log Screen You can use key commands while viewing the event log data: Key ↑ ENTER DELETE Function Returns to the previous screen of events. To display this menu. Returns to the first screen to view the most-recent events.00 14-3 . After you are finished viewing this screen. Issue Date: 1/18/08 Revision 1. do one of the following: • Press <EXIT>To return to the System Tools Menu screen.3 Main Board I/O Diagnostics The Main Board I/O Diagnostics Menu screen (Figure 14-4) has SAM screens to view the status of the turbine meter and pump motor.MAIN BOARD I/O DIAG from the Systems Tools Menu screen.Section 14: System Tools Figure 14-2. NEXT or ↓ Displays the next screen of events. select 2.

and the status of the digital inputs and outputs. Main Board I/O Status Screen 14-4 Revision 1.1 Main Board I/O Status The Main Board I/O Status screen (Figure 14-4) is a SAM troubleshooting tool for the main board to determine the I/O 8/2/1 status of signals for rod RPM and the turbine meter. To display this screen. MAIN BOARD I/O STATUS from the Main Board I/O Diagnostics Menu screen. select 1. Main Board IO Diagnostics Menu Screen 14.3. Figure 14-4.00 Issue Date: 1/18/08 .SAM Well Manager™ — Progressing Cavity Pump User Manual Figure 14-3.

use the Main Board Manual DIO Diag screen (see page 14-5).” After you are finished viewing this screen. “Status Screens. To display this screen. • Press <MENU>To return to the Main Menu screen. 1 represents open and 0 represents closed. • For digital outputs. For information about status screens. use their status screens. The data is not scaled in flow rate.3. do one of the following: • Press <EXIT>To return to the System Tools Menu screen. MAIN BOARD MANUAL DIO DIAG from the Main Board I/O Diagnostics Menu screen. • For digital inputs. The open and closed status are represented by 0 (zero) and 1.Section 14: System Tools The turbine meter signal from the PCP interface board is connected to the digital input used for the crank switch in the PCP application. select 2. Issue Date: 1/18/08 Revision 1. see section 9. but is merely a raw number indication of input signal.00 14-5 . The Counts and HZ fields indicate whether the turbine meter input is working properly. Be aware that 0 and 1 do not represent the same status for both inputs and outputs. You can also use this screen to turn on and off specific digital outputs. 0 represents open and 1 represents closed. 14. If you need to check the operating status of any inputs and outputs for piggyback boards.2 Main Board Manual DIO Diagnostics The Main Board Manual DIO Diag screen (Figure 14-4) is a SAM troubleshooting tool to show the open and closed status of digital 8/2/2 inputs and outputs on the main board. If you have questions about the open/closed status of any of the digital inputs or outputs.

To display this menu. select 3. After you are finished viewing this screen. You can turn on or off any specific digital output (but not digital inputs). COMMUNICATIONS from the System Tools Menu screen.00 Issue Date: 1/18/08 .4 Communication Diagnostics The Communication Diagnostics Menu screen (Figure 14-6) provides options for troubleshooting radio network communications problems and for locating memory locations in the Modbus register map. • To turn off a digital output.SAM Well Manager™ — Progressing Cavity Pump User Manual Figure 14-5. press its number on the keypad. do one of the following: • Press <EXIT>To return to the System Tools Menu screen. 0 represents open and 1 represents closed. • For digital inputs. Main Board Manual DIO Diag Screen The open and closed status are represented by 0 (zero) and 1. • For digital outputs. 14. • Press <MENU>To return to the Main Menu screen. • To turn on a digital output. hold down <0> on the keypad and then press its number. SAM 8/3 14-6 Revision 1. Be aware that 0 and 1 do not represent the same status for both inputs and outputs. 1 represents open and 0 represents closed.

00 14-7 .4.Section 14: System Tools Figure 14-6. To display this screen. RX/TX MESSAGES from the Communication Diagnostics Menu screen. RX/TX Messages Screen Issue Date: 1/18/08 Revision 1.1 RX/TX Messages The RX/TX Messages screen (Figure 14-7) shows the SAM hexadecimal characters received and transmitted by the SAM 8/3/1 PCP Controller. Figure 14-7. Communication Diagnostics Menu Screen 14. This information should be useful when troubleshooting radio network communications problems. select 1.

This tool is only useful to a systems integrator that is writing host software for reading and displaying data from the SAM PCP Controller.2 MB Register Map Check The MB Register Map Check screen (Figure 14-8) is a quick SAM reference for locating memory locations in the Modbus register 8/3/2 map for certain types of data.SAM Well Manager™ — Progressing Cavity Pump User Manual After you are finished viewing this screen. 14. do one of the following: • Press <EXIT>to return to the System Tools Menu screen. To display this screen. MB REGISTER MAP CHECK from the Communication Diagnostics Menu screen. MB Register Map Check Screen After you are finished viewing this screen. contact your Lufkin Automation representative. • Press <MENU>To return to the Main Menu screen. Figure 14-8.4. 14-8 Revision 1. • Press <MENU>to return to the Main Menu screen. For a copy of the complete Modbus register map. do one of the following: • Press <EXIT>To return to the System Tools Menu screen. select 2.00 Issue Date: 1/18/08 .

5 Keypad The Keypad Diagnostic screen (Figure 14-9) helps you determine if all keys on the SAM PCP Controller keypad are operating properly.00 14-9 . select 4.Section 14: System Tools 14. Issue Date: 1/18/08 Revision 1. SAM 8/4 Figure 14-9. the corresponding square on the Keypad Diagnostic screen darkens. When you press a key and the square representing it on the screen does not darken. Do one of the following: • Press <1> to continue testing. • Press <2> to exit from the keypad test and return to the System Tools Menu screen. When you test the <EXIT> key. you need to return the SAM PCP Controller to Lufkin Automation for service. When you are at the System Tools Menu screen. a message appears below the key squares that asks you to indicate whether you want to continue with the keypad test or actually exit from the test. Keypad Diagnostic Screen As you press each key on the membrane keypad. you can return to the Main Menu screen by pressing <MENU>. To display this screen. KEYPAD from the System Tools Menu screen.

.......1...1 PCP Quick Start The Quick Start feature is added to the application firmware to SAM make the SAM PCP Controller more “user friendly........................ 15-1 15....... 15-3 15....” Quick Start 3/2 walks you through the screens necessary to program (configure) control parameters that enable the SAM PCP Controller to work properly.......3 Resetting Parameters to Factory-Default Values ..........................2 Starting the Quick Start Process............................... The topics covered in this appendix include: 15.......Section 15 Quick Programming Using the Quick Start Feature This section provides information about using the Quick Start feature....... 15-2 15.......2 Methods for Navigating the Quick Start Programming Screens ..................................... This section also shows you typical representations of each configuration screen you will see.................... 15-2 15................................... This feature is designed to help you quickly enter the basic programming parameters necessary to configure the SAM PCP Controller and get it into operation................. 15-3 15......... This screen display method simplifies the programming process because only the screens required for the selected end devices and control methods are presented..............1... Issue Date: 1/18/08 Revision 1...1 Quick Start Programming Processes .1 PCP Quick Start ..................00 15-1 ... 15-4 15........................4 Using the Quick Start Feature .................

2. • Press <NEXT> to move forward one screen in the Quick Start process. Press <EDIT> and then do one of the following: a. Moving Between Quick Start Feature Screens Use the methods below to move between Quick Start Feature screens. • Press <EXIT> to move back one screen in order to double-check or change a parameter value that was entered. Configuring operating parameters 4. Starting the pump 15. When the parameter field reads as desired.00 Issue Date: 1/18/08 .2 Methods for Navigating the Quick Start Programming Screens The keys you need to press on the SAM PCP Controller operator interface keypad and the operations they will perform are provided below.1. Press <↑> and/or <↓> to display the options available for the field. Press <↑> and/or <↓> to move the cursor to highlight the parameter of interest. press <ENTER> to complete the edit/program operation.SAM Well Manager™ — Progressing Cavity Pump User Manual 15.1 Quick Start Programming Processes Quick Start involves four processes that must be performed in the following sequence: 1. b. 1. 15-2 Revision 1. Editing Parameters Use the procedure below to edit parameters on screen. Resetting operating parameters to factory-default values 3. Use the number keys to write in the desired value.1. Stopping the pump 2.

press <ENTER>. from the Main Menu screen.2 Starting the Quick Start Process To start the Quick Start feature.00 15-3 . WARNING: After you execute this operation. Figure 15-1. Issue Date: 1/18/08 Revision 1. After the PCP Quick Start Instruction screen displays. press <EDIT>.3 Resetting Parameters to FactoryDefault Values Lufkin Automation recommends that you reset the SAM PCP Controller to the factory-default values. Resetting ensures that any previous programming of the SAM PCP Controller does not cause problems.Section 15: Quick Programming Using the Quick Start Feature 15. the user-defined parameters cannot be easily restored. PCP QUICK START. • If YES is highlighted. Each parameter must be re-programmed one field at a time. You are presented with an instructions screen similar to Figure 15-1. This operation is not required. CONFIGURATION. and then press <ENTER>. • If NO is highlighted. PCP Quick Start Instructions Screen 15. select 3. A message appears for you to confirm that you want to reset to the factorydefault parameter values. and then select 2. press <←> or <→> to highlight YES.

A Quick Start Communication Administration screen similar to Figure 15-2 displays for you to begin the Quick Start setup process.” 15-4 Revision 1. This screen has the communication parameters that you usually need to configure. such as RTU Address. press <NEXT> to continue with the Quick Start process.00 Issue Date: 1/18/08 . data transmission rate. For information about the parameters on this screen.SAM Well Manager™ — Progressing Cavity Pump User Manual A notification appears informing you that the SAM PCP Controller is reset to the factorydefault settings. press <NEXT>. At the PCP Quick Start Instruction screen. use one of the following options: • If you choose not to reset to the default values. 15.4 Using the Quick Start Feature When the Quick Start feature begins. you are presented with several screens for you to enter basic programming information. see “Configuring the Communication Expansion Port” in section 8. Configuring Communication Ports After you are finished with the Quick Start Instruction screen shown in Figure 15-1. Below each screen in this section you are directed where to find detailed descriptions about the screens and the fields they contain. and handshake protocol. • Press <EXIT> to cancel the Quick Start process. keying properties. “SAM Controller Programming. Most screens contain several parameters that require you to enter values specific to your site setup and the end devices installed.

” Issue Date: 1/18/08 Revision 1. “SAM Controller Programming. Quick Start Communication Administration Screen Specifying GOT and Peak Energy Management After you are finished specifying communication port parameters. Peak Energy Management is a time period during the day you want the controller shut down the pump because of contractual agreements with the electric power provider to receive a more economical rate. see “Setting Gauge Off Time and Peak Energy Management” in section 8.Section 15: Quick Programming Using the Quick Start Feature Figure 15-2. press <NEXT> to display a Quick Start Gauge Off Time/Peak Energy MGNT screen similar to Figure 15-3.00 15-5 . Gauge off time (GOT) is the time of day that the SAM PCP Controller updates all of the historical data buffers. For information about these features and the parameters on this screen.

SAM Well Manager™ — Progressing Cavity Pump User Manual Figure 15-3. “PCP Parameter Programming.” 15-6 Revision 1. press <NEXT> to display a Quick Start Production/Motor Information configuration screen similar to Figure 15-4. Production Kfactor is used as a correction to measured production. Quick Start Gauge Off Time/Peak Energy MGNT Screen After you are finished specifying GOT and peak energy management parameters. Be aware that fields unique to the motor type will appear after you select it. see “Configuring Production and Motor Information” in section 7. and additional motor information you should be able to find on the motor nameplate. Motor information includes whether the prime mover is electric-driven or hydraulic-driven. For information about the parameters on this screen.00 Issue Date: 1/18/08 .

fluid pressure metering. or scaled flow). Quick Start Production/Motor Information Screen Configuring End Devices After you are finished specifying production and motor information parameters. press <NEXT> to display a Quick Start End Devices Configuration screen similar to Figure 15-5. For information about the parameters on this screen. see “Configuring End Devices” in section 7.00 15-7 . “PCP Parameter Programming. Quick Start End Devices Configuration Screen Issue Date: 1/18/08 Revision 1.Section 15: Quick Programming Using the Quick Start Feature Figure 15-4.” Figure 15-5. End devices include meters for flow rate (wedge meter. turbine meter. and motor torque.

For information about the parameters on this screen.00 Issue Date: 1/18/08 . minimum and maximum pump operating speed. Quick Start Control Parameters CFG Screen (Screen 1 of 2) After you are finished specifying PCP control parameters on Figure 15-6.SAM Well Manager™ — Progressing Cavity Pump User Manual Configuring PCP Control Parameters After you finish configuring end devices. see “Configuring Control Parameters” in section 7. press <NEXT> to display a Quick Start Control Parameters CFG screen similar to Figure 15-6. and maximum speed increases and decreases. PCP control parameters control operations of the progressing cavity pump. such as power on and off delays. 15-8 Revision 1. settling and sampling periods.” Figure 15-6. “PCP Parameter Programming. press <NEXT> to display a second Quick Start Control Parameters CFG screen similar to Figure 15-7.

“SAM Controller Programming. This screen is where you select a VSD type and specify its allowable minimum and maximum operating speeds. press <NEXT> to display a Quick Start VFD/VSD Parameters screen similar to Figure 15-8. see “Configuring VFD/VSD Parameters”.” Note: VFD Drive Type of OTHERS must be selected to use the SAM PCP controller with a generic variable speed drive.00 15-9 . Quick Start Control Parameters CFG Screen (Screen 2 of 2) Configuring VSD Type and Operating Speed Parameters After you are finished specifying PCP control parameters. Issue Date: 1/18/08 Revision 1. in section 8. For information about the parameters on this screen.Section 15: Quick Programming Using the Quick Start Feature Figure 15-7.

“PCP Parameter Programming. For information about the parameters on this screen and how to enable/disable them later. press <NEXT> to display a Quick Start Violation Configuration screen similar to Figure 15-9.00 Issue Date: 1/18/08 . see “Configuring Parameter Violations” in section 7. Quick Start VFD/VSD Parameters Screen Configuring Parameter Violations After you are finished specifying VFD/VSD configuration parameters.SAM Well Manager™ — Progressing Cavity Pump User Manual Figure 15-8. You must remember to enable or disable the control functions you need later.” 15-10 Revision 1. This screen is used to enable and disable several SAM PCP Controller control functions.

press <NEXT> to display a Quick Start Sequence Completion screen similar to Figure 15-9.Section 15: Quick Programming Using the Quick Start Feature Figure 15-9. Quick Start Violation Configuration Screen Quick Start Sequence Completion After you are finished specifying violation parameters. PCP Quick Start Sequence Completion Screen All the parameter configuration values required for the Quick Start configuration process are completed. To exit from the screen. Issue Date: 1/18/08 Revision 1. You are retuned to the Configuration Menu screen.00 15-11 . Figure 15-10. press <ENTER>.

digital inputs and outputs.” 15-12 Revision 1. “SAM Controller Programming. see section 8. “PCP Parameter Programming. • For information about configuring PCP control parameters. see section 7.SAM Well Manager™ — Progressing Cavity Pump User Manual Additional parameter configurations.00 Issue Date: 1/18/08 .” • For information about configuring basic SAM PCP Controller parameters. and logic expressions to fine-tune the PCP controller can now be performed using the configuration screens available. such as alarms.

........................................................Section 16 Sam Flash Upgrade Utility Software Lufkin Automation offers a utility software that can help you easily and quickly program one or more SAM PCP Controllers at the wellsite ..........................6 Establishing Communications Between the Controller and Laptop Computer.......................................... 16-7 16....................... 16-5 16...................2 Comm Parameters Section .........00 16-1 ....... 16-19 Issue Date: 1/18/08 Revision 1....................................... 16-2 16...........................4....................................2...............3 Status Section .......3 Installing the Software on a Laptop Computer ........................................................................2 Sam Flash Upgrade Utility Screen ....... 16-13 16..... 16-2 16............5 Connecting the Controller to the Laptop Computer.......1 Specifying the Communication Baud Rate in the SAM PCP Controller.......4... 16-8 16.....8 Uploading a Saved Configuration File into the SAM PCP Controller ....... 16-10 16......... 16-14 16.2.... 16-11 16........... 16-15 16......................create backup files storing these parameters................ 16-7 16..................... 16-12 16..............................................2.4 Message Window Section .......................... 16-9 16... The topics covered in this section include: 16................ and upgrade the application firmware in the controller...............................2 Specifying Communication Parameters in the Laptop Computer ............................9 Upgrading Application Firmware ............................4 Specifying Communications Between the Controller and Laptop.................................2.......................................................... 16-3 16............1 Software Overview.................1 File To Upload Section ......................................................5 Command Buttons.. 16-16 16.......2.7 Saving the Controller Configuration to a File...........

............00 Issue Date: 1/18/08 . 16-2 Revision 1. You can also keep this file as a backup in case the controller programming is lost or corrupted or you need to upgrade the application firmware.SAM Well Manager™ — Progressing Cavity Pump User Manual 16. It is accessed after you launch the SAM Flash Upgrade Utility software... you can selectively reprogram specific parameters using the local keypad... This software can be used to download all programming parameters from one SAM PCP Controller to a laptop computer file............ After the file is uploaded. 16..... you can use the Sam Flash Upgrade Utility software available from Lufkin Automation.....2 Sam Flash Upgrade Utility Screen The Sam Flash Upgrade Utility screen (Figure 16-1) is the interface used to: • Download the configuration parameters to a configuration file • Upload the configuration file to the SAM PCP Controller • Upgrade application firmware All operations are performed through this single screen......10 Disconnecting Communications Between the Controller and Laptop Computer......... You can then upload this “template” file with the complete block of parameters to a new SAM PCP Controller... 16-21 16. especially when you need to program several controllers......... To expedite the programming process.......1 Software Overview Programming the SAM PCP Controller with the local keypad at the wellsite involves several steps and takes considerable time.

00 16-3 . see “Installing the Software on a Laptop Computer” on page 16-9. Sam Flash Upgrade Utility Screen If you do not have the Sam Flash Upgrade Utility software installed on your laptop computer or you do not know how to display it. • File To Upload • Comm Parameters • Status Message • Message Window • Command Buttons • Incoming Data • Outgoing Data Each section is described below. 16.1 File To Upload Section This section has fields used to select the application code you want uploaded to the SAM PCP Controller. You also can verify the upload file type and that the correct file will be uploaded by viewing its checksum number. Figure 16-2 is an example. Issue Date: 1/18/08 Revision 1.2.Section 16: Sam Flash Upgrade Utility Software Figure 16-1. This utility screen is divided into seven sections.

00 Issue Date: 1/18/08 . A checksum value (other than 00000000) only displays in this field if Application displays in the Upload Type field. or Table/Database displays in the Upload Type field. The supported upload types are: • Application • Low Level • Table/Database File Checksum The checksum for the *. A checksum value (other than 00000000) only displays in this filed if Low Level displays in the Upload Type field. Application Checksum The checksum for the Application (App) file selected. Browse Button Click this button to open a dialog box used to select the file for upload to the SAM PCP Controller. 16-4 Revision 1. its file name and path display in the Filename field and its type (Application. Low Level. Filename Name of the file selected for uploading.sam file selected.SAM Well Manager™ — Progressing Cavity Pump User Manual Figure 16-2. Low Level Checksum The checksum for the low level (LL) file selected. The type is selected using the Browse button. After a file is selected. File To Upload Section Example Data Field Descriptions Information about each field is provided below. Upload Type The current type of firmware code file to be uploaded to the SAM PCP Controller.

retrieve the existing configuration parameters. Comm Port The communication port on the laptop computer where the RS-232 cable is connected.00 16-5 . Figure 16-3. Figure 16-3 is an example of the Comm Parameters section. Comm Parameters Section Example Data Field Descriptions Information about each field is provided below.Section 16: Sam Flash Upgrade Utility Software 16. Allowable baud rates are: • 1200 • 2400 • 4800 • 9600 • 19200 • 38400 • 57600 • 115200 Most new laptop computer models can use 115200. These communication values are necessary in order for the Sam Flash Upgrade Utility software to communicate with the SAM PCP Controller. Issue Date: 1/18/08 Revision 1.2.2 Comm Parameters Section This section has fields for specifying the RTU address of the SAM PCP Controller and communication parameters. and download the upgraded programming. Flash Upgrade Baud Rate Baud rate of the laptop computer. such as timeout values and baud rates.

SAM Well Manager™ — Progressing Cavity Pump User Manual Timing Factor The timing factor is only used for flash upgrades and must be adjusted for each user’s system. For information about setting these parameters. see “Configuring Communication Parameters” in section. Use Modbus to Start Upload You can enable this feature to allow an upload to be performed automatically. Too low a value can cause a communication failure when the upgrade is attempted. The Sam Flash Upgrade Utility software uses Modbus communications to switch the controller into flash upload mode and start the uploading process automatically. This is necessary for transferring data between the SAM PCP Controller and laptop. RTU Address The SAM PCP Controller address. A lower value results in faster uploads. “SAM Controller Programming. 16-6 Revision 1.” Reply Timeout The timeout between the computer sending a modbus request to the SAM PCP Controller and the response from the SAM PCP Controller.00 Issue Date: 1/18/08 . The allowable baud rates are: • 1200 • 2400 • 4800 • 9600 • 19200 • 38400 • 57600 • 115200 Note: RTU Address and Config Save/Load Baud Rate must be set with the same values as the values in the SAM PCP Controller. These values are set using the Communication Administration screen. Config Save/Load Baud Rate The baud rate used for reading and writing the SAM PCP Controller configuration parameters.

It provides a graphical representation of the time remaining until the task is completed. 16. such as a successful or unsuccessful configuration file upload. Figure 16-4 is an example of the Status section.4 Message Window Section This section is a scrollable window used to view the last 100 messages from the system. Total The total number of packets to transfer. Retries The number of retries attempted for the current packet.Section 16: Sam Flash Upgrade Utility Software 16.3 Status Section This section provides status information about the data being transferred between the SAM PCP Controller and the laptop computer. Progress Indicator This bar is active for any communications to the SAM PCP Controller. Figure 16-5 is an example. Status Window This window displays the current message pertaining to the system status.2. System messages allow you to track the success or failure of any task. Figure 16-4. Issue Date: 1/18/08 Revision 1. Current Packet The current packet being transferred. Status Section Example Data Field Descriptions Information about each field is provided below.2.00 16-7 . Error messages display in red text. notification that the configuration file is being sent. or configuration verification failure.

see “Connecting the Controller to the Laptop” on page 16-13.SAM Well Manager™ — Progressing Cavity Pump User Manual Figure 16-5. 16-8 Revision 1.5 Command Buttons Command buttons are clicked to perform the necessary operations that the upgrade utility software can offer.00 Issue Date: 1/18/08 . make sure that the laptop computer is connected to the SAM PCP Controller. Message Window Example 16. These operations include the following: • Starting and stopping the upload process • Connecting (establishing communications) and disconnecting with the SAM PCP Controller • Retrieving (downloading) the configuration parameters presently defined in the SAM PCP Controller and restoring (uploading) them to it Note: Before you use the command buttons. For information about properly connecting both components.2.

cfg file. 2. After this button is clicked. Insert the diskette or CD ROM distribution disk(s) that has the Sam Flash Upgrade Utility software into the laptop computer. Disconnect Save Config Load Config Verify Config Confirms that the configuration parameters in the SAM PCP Controller match the parameters saved to the *. The software operates in the Windows 2000 and XP operating systems.Section 16: Sam Flash Upgrade Utility Software Information about each button is described below.exe) to a folder on you laptop computer.3 Installing the Software on a Laptop Computer The Sam Flash Upgrade Utility software must be installed on your laptop computer before you can upgrade the application firmware or upload/download control parameter data. Closes (disconnects) the software access to the laptop computer communications port.00 16-9 . Messages display in the Message window during the uploading process. Abort Upload Ends the uploading process. Button Name Start Upload Description Starts the process for uploading the application firmware. Uploads the configuration parameters to the SAM PCP Controller that are saved to a *. Connect Opens (connects) the software access to the laptop computer communications port. This software is available from your Lufkin Automation representative. the Comm Port field is grayed out and the Connect button is replaced with the Disconnect button. Load. Copy the installation file (SamFlashUpgradeSetup3_3. Save. it is immediately terminated. Verify) is in progress. Exit Closes the Sam Flash Upgrade Utility screen and the software. 1. Downloads the configuration parameters in the SAM PCP Controller and saves them to a *. Issue Date: 1/18/08 Revision 1. After this button is clicked. The Message window displays “User Aborted Upload” in red text after clicking this button. 16. If any upgrading process (Start.cfg file. Procedure Use the steps below to install the Sam Flash Upgrade Utility software on the laptop computer.cfg file. it is replaced with the Connect button.

6. An Install Wizard opens. the Flash Upgrade icon ( should exist on your desktop. You can now connect your laptop computer to a SAM PCP Controller and use the software to upgrade the flash ROM in the SAM PCP Controller.4 Specifying Communications Between the Controller and Laptop Specifying and synchronizing communication parameters between the SAM PCP Controller and the laptop computer is required to upload and download files. Follow the instructions provided in the Install Wizard. Two tasks are required to complete this process. • Specifying the communication baud rate in the SAM PCP Controller • Specifying communication parameters in the laptop computer Each task is described separately below. Click to close the screen. The Sam Flash Upgrade Utility software is now ready for use.00 Issue Date: 1/18/08 . Run the software to ensure that it executes by doing either of the following: • Double-click located on your laptop desktop. Double-click the installation file. 16. A Sam Flash Upgrade Utility screen similar to Figure 16-1 (page 16-3) opens. ) • Click the Start button and then select Programs/Lufkin Automation/Sam Utilities/Flash Upgrade.SAM Well Manager™ — Progressing Cavity Pump User Manual 3. 5. After the installation is completed. 7. 4. 16-10 Revision 1.

Change this field value 5. For detailed information about this screen and specifying baud rate.00 16-11 .Section 16: Sam Flash Upgrade Utility Software 16. Select 1. RTU LEVEL. 1. Issue Date: 1/18/08 Revision 1. From the Main Menu screen. 4. and then press <EDIT>. COMMUNICATION PORT CFG to display the Communication Administration screen. see “Configuring Communication Parameters” in section 8.” Procedure Use the steps below to change the laptop computer port baud rate in the SAM PCP Controller.4. CONFIGURATION. COMMUNICATION PARAMETERS to display the Communication Parameters Menu screen. press <MENU> to instantly return to the Main Menu screen. The SAM PCP Controller defaults to 115. Select 1. Press <↑> or <↓> to change the baud rate until 115200 displays. 2. Note: If another screen is displayed.200 baud on the laptop computer port. and then select 3. 3. and then press <ENTER> to save the setting. You can change the baud rate setting using the Communication Configuration screen in the SAM PCP Controller. “SAM Controller Programming. SAM CONFIGURATION to display the SAM Configuration Menu screen. select 3.1 Specifying the Communication Baud Rate in the SAM PCP Controller Lufkin Automation recommends that the SAM PCP Controller communicate with the laptop computer port at 115. and then select 2. Press <↓> to highlight the Laptop Port Baud Rate field.200 baud.

change the value in the Timing Factor field. Press <MENU> to return to the Main Menu screen. 16. The Sam Flash Upgrade Utility screen should display. must be properly configured in order to communicate with a specific controller and upload the application firmware to it. note the address specified in the RTU Address field for use later when you are configuring the laptop computer software. Procedure Use the steps below to specify communication parameters in the laptop computer. 3. Click the down arrow in the Flash Upgrade Baud Rate field and click 115200. Note: While you are at this screen. 2.SAM Well Manager™ — Progressing Cavity Pump User Manual 6.2 Specifying Communication Parameters in the Laptop Computer Lufkin Automation recommends that the SAM PCP Controller communicate with the laptop computer port at 115. If necessary. In the Comm Parameters section. • Click the Start button and then select Programs/Lufkin Automation/Sam Utilities/Flash Upgrade.200 baud. Other parameters. The laptop computer port baud rate in the SAM PCP Controller is now changed. such as the correct RTU address and reply times. All parameters are specified in the Comm Parameters section of the Sam Flash Upgrade Utility screen. 4. 16-12 Revision 1.00 Issue Date: 1/18/08 .4. 1. Start the Sam Flash Upgrade Utility software using one of the following methods: • Double-click located on the laptop desktop. click the down arrow in the Comm Port field and then click the Comm port you are using on your laptop.

1. make sure the value specified is 115200. for slower laptop computers.5 Connecting the Controller to the Laptop Computer A standard nine-pin RS-232 cable is required to transfer the data from the laptop computer to the SAM PCP Controller. 6.00 16-13 . specify 100. Connect one end of the RS-232 cable to the DB-9 communications port on your laptop computer. Contact your Lufkin Automation representative for assistance. such as 100. 8. It is primarily used to upload upgrade application firmware to flash memory. You may need to set it to a higher value. Connect RS-232 cable here Issue Date: 1/18/08 Revision 1. Connect the other end of the RS-232 cable to the DB-9 communications port on the front of the SAM PCP Controller.Section 16: Sam Flash Upgrade Utility Software Timing factor is usually set to 20. a USB to aerial converter is required. 5. 16. Select the Use Modbus To Start Upload check box. Try 20 first and determine if it is sufficient. type the RTU address to the same Modbus address used for the SAM PCP Controller as noted while performing the steps for specifying baud rate (see page 16-11). In the Config Save/Load Baud Rate field. 2. This port is located to the right of the 20-key keypad and below where labeled COM PORT. The communication parameters are now specified for communicating with the SAM PCP Controller. If your laptop computer has only USB ports. Procedure Use the steps below to connect the laptop computer to the SAM PCP Controller. 7. In the Reply Timeout field. In the RTU Address field.

Select the Use Config Save/Load Baud Rate option from the dropdown list. Make sure the Sam Flash Upgrade Utility software is running and that the Sam Flash Upgrade Utility screen is displayed. see “Connecting the Controller to the Laptop” on page 16-13. 3. and both devices are physically connected. After this file is saved. Communications is now established between the controller and laptop computer. 1.cfg) file. 16.7 Saving the Controller Configuration to a File The configuration parameters programmed in a SAM PCP Controller can be downloaded to your laptop computer and saved to a configuration (*. 1.SAM Well Manager™ — Progressing Cavity Pump User Manual The controller is now connected to the laptop computer. Procedure Follow the step below to establish communications between the SAM PCP Controller and your laptop computer. You can now upload and download configuration parameter data. For this procedure. click to connect the software access to the laptop computer communications port. In the Sam Flash Upgrade Utility screen. Procedure Use the steps below to download the configuration parameters and save them to a *.00 Issue Date: 1/18/08 . 16-14 Revision 1. and you can also download the parameters to other SAM PCP Controllers. you can keep it as a backup.6 Establishing Communications Between the Controller and Laptop Computer After all communication parameters are correctly specified in the SAM PCP Controller and laptop computer. 2. Make sure the laptop computer is connected to the SAM PCP Controller. 16. you need to instruct the Sam Flash Upgrade Utility software to establish communication with the laptop computer.cfg file on your laptop computer.

cfg file on your laptop computer. 3. The Sam Flash Upgrade Utility screen should display. 4. Click the Save command button. . Select the Use Config Save/Load Baud Rate option.00 16-15 . type over “Well Name” with the name you want used for the file. The Incoming Data window shows the actual data being transmitted from the SAM PCP Controller to the laptop computer. A shortcut menu appears with two options. • Click the Start button and then select Programs/Lufkin Automation/Sam Utilities/Flash Upgrade. click The Save File As dialog box appears. Issue Date: 1/18/08 Revision 1. In the Sam Flash Upgrade Utility screen. 7.Section 16: Sam Flash Upgrade Utility Software 2. Start the Sam Flash Upgrade Utility software using one of the following methods: • Double-click located on the laptop computer desktop. 6. In the Save in field. The dialog box closes and the configuration parameters are saved to a *. 8. Click to connect the software access to the laptop computer communications port. In the File name field. select a folder where you want the file saved. 5.

• Click the Start button and then select Programs/Lufkin Automation/Sam Utilities/Flash Upgrade. Note: You can only successfully upload a *. You will also need to create a backup file before you upgrade the application firmware in the controller because all programming is lost during an upgrade. The Sam Flash Upgrade Utility software warns you from uploading the file to another type of SAM controller.cfg file as a backup when controller programming is lost or corrupted. create one now for possible use later. 2. see “Connecting the Controller to the Laptop” on page 16-13. see “Saving the Controller Configuration to a File” on page 16-15. WARNING: When you upload a configuration file. Make sure the laptop computer is connected to the SAM PCP Controller. After the file is uploaded. all configuration parameters stored in the SAM PCP Controller are lost and overwritten with the parameters in the configuration file. Uploading also allows you to use a *.cfg) file containing the configuration parameters for a SAM PCP Controller to another SAM PCP Controller. If you do not already have a backup configuration (*. Procedure Use the steps below to upload configuration parameters to a SAM PCP Controller. you can selectively reprogram specific parameters using the local keypad on the SAM PCP Controller.cfg file for a SAM PCP Controller to another SAM PCP Controller. 1. For this procedure.cfg) file for the controller.00 Issue Date: 1/18/08 .SAM Well Manager™ — Progressing Cavity Pump User Manual 16. 16-16 Revision 1. Start the Sam Flash Upgrade Utility software using one of the following methods: • Double-click located on the laptop computer desktop. such as an RPC or Injection Well unit. Uploading is a quick and easy method for programming a SAM PCP Controller at the wellsite. For information about creating a file.8 Uploading a Saved Configuration File into the SAM PCP Controller You can upload from your laptop computer a configuration (*.

Another alert dialog box appears informing you that some configuration parameters may need to be manually reconfigured by you after you uploaded the *. 5. ignore this alert and click Yes to continue the file upload.cfg file. 3.01. and then click Open. 6. Do one of the following to select the file you need: • Double-click the file name you need. A shortcut menu appears with two options. In the Look in field.cfg file is stored. select the folder where the *. Note: An alert dialog box similar to the one shown below appears advising you that the firmware version in the SAM PCP Controller is less than 4.Section 16: Sam Flash Upgrade Utility Software The Sam Flash Upgrade Utility screen should display. type over “Well Name” with the file name you need.00 16-17 . Issue Date: 1/18/08 Revision 1. In the Sam Flash Upgrade Utility screen. 4. 7.cfg files stored in the folder are displayed. The Configuration File to Restore dialog box appears. • In the File name field. click . Select the Use Config Save/Load Baud Rate option. Since installing lower version number only impacts the Rod Pump Control application for the SAM Well manager. Click to connect the software access to the laptop computer communications port. All *.

cfg file. click the controller match the parameters saved to the *. The SAM PCP Controller now operates in its normal operation mode. to verify that the configuration parameters in 9.00 Issue Date: 1/18/08 . You can click if you want to display a window showing the data being uploaded to the controller. Flash upgrade files have the “*. 16-18 Revision 1. 16. click No. Click when you want to close this window. You many need to use the local keypad to check the parameters.SAM Well Manager™ — Progressing Cavity Pump User Manual 8. Parameter settings and the RS-232 cable connection to the SAM PCP Controller.9 Upgrading Application Firmware The primary purpose of the Sam Flash Upgrade Utility software is to upgrade the application firmware in the SAM PCP Controller. You can obtain these files from your Lufkin Automation representative. double-check the Comm.sam” file extension. • “Register Values in Sam Match File Values” displays in the Message window when they match. When finished. The SAM PCP Controller is now operating with the configuration parameters you uploaded. click Yes. and you may need to manually edit some of them. Do one of the following: • To continue the uploading process. • To discontinue the uploading process. • If an Unable to Verify message displays.

A shortcut menu appears with two options.cfg) file for the controller.sam files stored in the folder are displayed. 7. Issue Date: 1/18/08 Revision 1. 5. 6. 2. Select the Use Flash Upgrade Baud Rate option. . Click to connect the software access to the laptop computer communications port. see “Connecting the Controller to the Laptop” on page 16-13. For this procedure. • Click the Start button and then select Programs/Lufkin Automation/Sam Utilities/Flash Upgrade. select the folder where the *. WARNING: All configuration programming in the controller is lost during the firmware upgrade. see “Saving the Controller Configuration to a File” on page 16-15. 3. Start the Sam Flash Upgrade Utility software using one of the following methods: • Double-click located on the laptop computer desktop. Make sure the laptop computer is connected to the SAM PCP Controller. create one now.Section 16: Sam Flash Upgrade Utility Software Procedure Use the steps below to upload the updated controller firmware. 4. 1. All *. For information about creating a file. The Sam Flash Upgrade Utility screen should display. In the Look in field.00 16-19 . click The File to Upload dialog box appears. In the Sam Flash Upgrade Utility screen. If you do not already have a backup configuration (*. Copy the new application firmware file(s) to a folder on your laptop computer.sam file is stored.

cfg file. you need to disconnect communications with the controller and laptop computer and close the SAM Flash Upgrade Utility software. use it. the SAM PCP Controller reinitializes (reboots). After reinitializing is completed. or if you have a backup *. type the file name you need. After the uploading process completes. Do one of the following to select the file you need: • Double-click the file name you need.10 Disconnecting Communications Between the Controller and Laptop Computer After you are finished communicating with the SAM PCP Controller. 9. You need to program the controller-specific configuration parameters into the SAM PCP Controller. Click to start the uploading process. • In the File name field. The application firmware overwrites the programmed configuration parameters with factory-default values. 16-20 Revision 1. Messages display during the uploading process in the Message window and the actual data being transmitted displays in the Outgoing Data window. Its operator interface reads “Reinitializing” during this process. and then click Open.SAM Well Manager™ — Progressing Cavity Pump User Manual 8. • For information about uploading the *. see section 7. You can program them manually.” 16. see “Uploading a Saved Configuration File into the SAM PCP Controller” on page 16-16. • For information about manually programming the configuration parameters.00 Issue Date: 1/18/08 . “Programming the SAM PCP Controller.cfg file containing them. the operator interface displays the first of the PCP Status screens. The application firmware is now updated and operational.

to close (disconnect) the software access to the laptop 1.Section 16: Sam Flash Upgrade Utility Software Procedure Use the steps below to disconnect the software access to the SAM PCP Controller and laptop computer and close the software. Click computer communication port. 2. Issue Date: 1/18/08 Revision 1. Click to close the SAM Flash Upgrade Utility screen. You can now disconnect the cable connecting the SAM PCP Controller to the laptop computer.00 16-21 .

...................................................6 Timed Mode Well States...........Appendix A Well State List This appendix defines the well states displayed in the SAM PCP Controller..........5 Malfunction Shutdown Well States.3............................11 Power Fail Lockout ............4 HOA Well States ..3 Violation Downtime Well States................................ A-8 A....................10 Sand Blowout Well States..................3........... A-8 A.2 Violation Run Well States ................7 Malfunction ..........................12 Error Well States ............................. A-5 A.......................4 Malfunction Run Well States ......................... A-6 A.........................................6 Logic Expression Violation Well States ............. A-10 A..............................................1 Overview of Well States .........3.....9 Speed Control Well States............................ A-6 A.............. A-10 A....................8 Miscellaneous Downtime States...... A-11 Issue Date:1/18/08 Revision 1............3........................................................................................8 Monitor Mode Well States . A-6 A...... which include: A............. A-4 A............................. A-10 A........ A-7 A...................... A-7 A........... A-4 A....................... All well states are grouped into categories....3 Downtime and Malfunction Well States ...................................................00 A-1 ....................................................... A-5 A......3...........1 Violation Conditions and Types........................................ A-2 A.......................3.................................... A-10 A..3.........2 Normal Operation Well States ........................3................................ A-8 A...................5 Quick-Start Well States......... A-2 A............................... A-9 A...........................................Drive Fault.................7 Host Mode Well States.................................

The current well state displays on the top line of the PCP Status screen along with the time elapsed since being in that well state. since an onsite operator will be using other local interface screens.2 Normal Operation Well States A Normal Operation well state indicates a phase of normal operation. “Status Screens. or it may alert the user to a problem with the SAM PCP Controller input devices or the pumping equipment. the operator should check the SAM PCP Controller installation and programming. The SAM PCP Controller will be in only one of a number of well states at any given time. and which usually means the operator does not need to be concerned about basic performance of the PCP system. If one should appear that is not defined.SAM Well Manager™ — Progressing Cavity Pump User Manual A. such as Load Calibration and Valve/CBE Check. Its present well state can provide clues to the problem. Other well states will typically be observed only through host computer software. Some well states may not be observed on the local interface because they are transient well states having a very short duration.” Well state and elapsed time of current state A well state can indicate a phase of normal operation. For example the Stopped well state quickly changes to one of the downtime or malfunction states to give the user more complete information about why the unit stopped.1 Overview of Well States A well state can indicate a phase of normal operation. A-2 Revision 1. Note: Additional well states may appear that were not available when this list was published. For information about this screen. or it may indicate that someone has bypassed the SAM PCP Controller. A.00 Issue Date:1/18/08 . or it can alert the operator to a problem with the pumping equipment or the SAM PCP Controller system components (input devices). contact your Lufkin Automation representative for help. When a well state indicates a problem. see “Current PCP Operating Status” in section 9.

telling the SAM PCP CONTROLLER that the rods have stopped spinning. the SAM PCP CONTROLLER will go to the Sampling Period well state. The SAM PCP CONTROLLER waits the programmed number of seconds before starting the motor.Appendix A: Well State List Power On Delay Initial Well State following a reboot of the SAM PCP CONTROLLER. Power Off Delay The SAM PCP CONTROLLER decreases the speed output to the motor in the programmed number of steps. Duration: Programmable by user Sampling Period The SAM PCP CONTROLLER samples the flow rate for the predetermined sample period in order to determine the next control decision. Duration: Programmable by user. which occurs at the end of this well state. Settling Period This well state. Duration: Until SAM PCP CONTROLLER senses a stopped condition or user-programmable time expires. Issue Date:1/18/08 Revision 1. After this well state. Duration: User-programmable Start Up Period length. Starting Unit SAM PCP CONTROLLER has pulled digital output 2 low to start the motor. the RPM input is checked until zero RPM is detected. Duration: Programmable by user. Duration: Programmable by user. allows the input parameters to settle after a control decision has been made. Starting Alert Digital Output 3 is held low for the programmed number of seconds to sound an optional audible start alert device.00 A-3 . In this well state. Stopping Unit One of the enabled SAM PCP Controller control functions made a decision to stop the pumping unit. Duration: Programmable by user.

with two exceptions. the SAM PCP CONTROLLER will go to the Stopping well state after Power Off Delay and then into the appropriate Downtime well state. the SAM PCP CONTROLLER will go into the Power Off Delay well state. If the action for the violation is to shut down. The two exceptions to this general rule are: • Downtime Global Off Command well state — When the SAM PCP Controller receives a Global Off command. Once it is detected. A. After Power Off Delay expires. A. The word Malfunction (MALF) in a well state means that the SAM PCP Controller detected a malfunction with equipment and that an operator must take action to return the unit to a pumping condition.SAM Well Manager™ — Progressing Cavity Pump User Manual Stopped Duration: < 1 second Unable To Stop A transition state between stopping and the appropriate Downtime or Malfunction well state.1 Violation Conditions and Types Violation Run well states occur after a violation is detected. • Downtime Peak Energy Management well state — The SAM PCP Controller keeps the pumping unit in a downtime state for the entire period programmed for Peak Energy Management. Duration: Once the rods stop turning. the SAM PCP CONTROLLER will go into a Downtime or Malfunction well state. Below are the types of violations that can occur to trigger a Downtime or Malfunction well state. the SAM PCP CONTROLLER will go into the appropriate Violation Run well state.3.00 Issue Date:1/18/08 . tells the user that the SAM PCP Controller will automatically start the pumping unit when the programmed downtime elapses. The SAM PCP CONTROLLER enters this well state if the rods are turning after the userprogrammable stopping period expires. A-4 Revision 1. it keeps the pumping unit shut down until told to do otherwise.3 Downtime and Malfunction Well States A well state that includes the word Downtime (DT) in a well state. if the action selected by the user for the particular violation is to Run Minimum.

00 A-5 .Low Production DT .Torque Violation VR .Low Production VR . A.Low RPM DT . A.3 Violation Downtime Well States DT .Low RPM VR . • Low Production — Occurs when the measured production rate violates the user programmable low production threshold. • Torque Limiting — Occurs when the torque value violates the torque limiting threshold and the rods reach minimum speed.Torque Limiting DT . • Torque Violation — Occurs after the torque value violates the critical torque limit.Torque Violation DT .2 Violation Run Well States VR .No RPM DT .High Production Duration: User-programmed Downtime. • No RPM — Occurs after the SAM PCP CONTROLLER determines that the rods are not turning during a running well state.High Production Issue Date:1/18/08 Revision 1. • High Production — Occurs when the measured production rate violates the high production threshold.3.No RPM VR .3.Appendix A: Well State List • Low RPM — Occurs after the measured RPM value violates the userprogrammable low RPM threshold.Torque Limiting VR .

However. A.High Production Duration: Until a Reset Malfunction is issued through HMI or by HOST communications.5 Malfunction Shutdown Well States MALF SD . or go continually into a downtime state when the violation occurs. the logic expression does not have a run minimum selection.Torque Limiting MALF SD .High Production Duration: Until a Reset Malfunction is issued through HMI or by HOST communications.3.No RPM MALF SD .6 Logic Expression Violation Well States The logic expression feature can be programmed in the SAM PCP CONTROLLER to affect control similar to a violation.00 Issue Date:1/18/08 .3.Torque Limiting MALF RUN . When the logic expression is violated.SAM Well Manager™ — Progressing Cavity Pump User Manual Duration: User-programmed Downtime. the SAM PCP CONTROLLER stops the motor.Low RPM MALF RUN . A logic expression violation occurs when all of the following are true: A-6 Revision 1. A.Low Production MALF RUN .Low Production MALF SD .Low RPM MALF SD . A.No RPM MALF RUN .Critical Torque MALF SD .Critical Torque MALF RUN .3. The user also selects whether the SAM PCP CONTROLLER will go into a malfunction well state.4 Malfunction Run Well States MALF RUN .

7 Malfunction .Logic Expression Duration: Until a Reset Malfunction is issued through HMI or by HOST communications. DT . SD . and the number of consecutive violations exceeds the consecutive violations allowed.8 Miscellaneous Downtime States DT . MALF SD . then the SAM PCP CONTROLLER will enter a Malfunction – Drive Fault well state. Duration: Until the current time of day exits the user programmable Peak Energy Management window. Duration: Until a Start command is issued through HMI or a Host communication. then the SAM PCP CONTROLLER will go into the MALF SD – Logic Expression well state.Appendix A: Well State List • A logic expression is defined to act on MO2 (Motor Control Digital) • The action for the logic expression acting on MO2 is STOP or MALF • The logic expression is true for longer than the Logic Time Delay If the action for the logic expression is set to MALF (Malfunction).00 A-7 . Issue Date:1/18/08 Revision 1. A. If a fault is detected.3.Peak Energy Mgmt Occurs when the current time of day enters the user programmable Peak Energy Management window.Operator Stop Occurs when a stop command is issued through the HMI.Drive Fault The SAM PCP CONTROLLER can monitor the VSD for a drive fault.Global Off Occurs when a broadcast message from the host signals an entire field shutdown.3. Duration: Until a Start command is issued through HMI or a Host communication.Logic Expression Duration: User-programmed downtime. A. DT .

For more information about the Quick-Start feature.4 HOA Well States If a HOA switch is wired into the SAM PCP CONTROLLER.SAM Well Manager™ — Progressing Cavity Pump User Manual A. Quick Start – Stopped Quick-Start is initiated and the motor is turned off. HOA OFF The SAM PCP CONTROLLER has detected that the HOA switch has been turned to the OFF position.” Quick Start – Run Quick-Start is initiated and the motor is turned on. the feature is enabled. and is currently running at the HI Speed. see section 15. the user can configure the control mode to be either HI – LO or ON – OFF. Duration: Until the HOA switch is changed HOA HAND The SAM PCP CONTROLLER has detected that the HOA switch has been turned to the HAND position.6 Timed Mode Well States When the SAM PCP CONTROLLER is operating in the Timed Mode. “Quick Programming Using the Well State List Feature. and when the switch is turned to the ON or OFF setting. A. and is currently running at the LO Speed. the SAM PCP CONTROLLER will enters into one of two states.5 Quick-Start Well States When the user initiates a Quick-Start for configuration. A. TIMED MODE – HI The SAM PCP CONTROLLER is operating in the HI – LO method. the well state will reflect the change. TIMED MODE – LO The SAM PCP CONTROLLER is operating in the HI – LO method. Duration: For the programmable Timer Mode Hi period. The well states indicate which control method is in use. Duration: Until the HOA switch position is changed. Revision 1.00 Issue Date:1/18/08 A-8 .

7 Host Mode Well States When the SAM PCP CONTROLLER is operating in the Host mode. HOST MODE – ON The SAM PCP CONTROLLER is operating in the ON – OFF method. and is the unit is currently stopped.Appendix A: Well State List Duration: For the programmable Timer Mode Lo period. Issue Date:1/18/08 Revision 1. Duration: Remains in this state unless operation mode is changed or Host switch is changed. and is currently running at LOW Speed. The well states indicates which control method is presently in use. and is currently running. TIMED MODE – OFF The SAM PCP CONTROLLER is operating in the ON – OFF method. Duration: For the programmable Timer Mode Off period. A. TIMED MODE – ON The SAM PCP CONTROLLER is operating in the ON – OFF method. Duration: Remains in this state unless operation mode is changed or Host switch is changed. and is currently shut down. HOST MODE – OFF The SAM PCP CONTROLLER is operating in the ON – OFF method. HOST MODE – HI The SAM PCP CONTROLLER is operating in the HI – LOW method.00 A-9 . This speed is programmed by the user. and is the unit is currently running. the control mode can be configured as HI-LOW or ON-OFF. This speed is programmed by the user. HOST MODE – LOW The SAM PCP CONTROLLER is operating in the HI – LOW method. Duration: Remains in this state unless operation mode is changed or Host switch is changed. and is currently running at HI Speed. Duration: For the programmable Timer Mode On period.

9 Speed Control Well States When the SAM PCP CONTROLLER is operating in the Speed Control method. the motor is set to run at a constant speed. no control decisions are being made. A.11 Power Fail Lockout SD . In this mode. A. Duration: Predetermined in the configuration of the SBO feature.10 Sand Blowout Well States SBO:Ramp Down Period The pump is being slowed down to allow a fluid to build up for the sand blow-out process. violation checking can be enabled and the appropriate actions to take when a violation occurs can also be configured.Power Failure Lockout When enabled.SAM Well Manager™ — Progressing Cavity Pump User Manual Duration: Remains in this state unless operation mode is changed or Host switch is changed. A-10 Revision 1.00 Issue Date:1/18/08 .8 Monitor Mode Well States When the SAM PCP CONTROLLER is operating in the Monitor mode. Duration: Remains in this state unless operation mode is changed or due to a reaction to a violation. Monitor Mode The SAM PCP CONTROLLER is currently operating in the Monitor mode. Duration: Predetermined in the configuration of the SBO feature. A. the SAM PCP Controller will not restart the well after a power failure. Also the SAM PCP Controller is not controlling the speed at which the motor is running. Duration: Remains in this state unless the operation mode is changed. Speed Control – ON The SAM PCP CONTROLLER is operating in the Speed Control method. SBO:Speed Increase The pump speed is being increased to blow out the sand. A.

Issue Date:1/18/08 Revision 1. Programming Fault SAM PCP CONTROLLER has reached an internal error that can not be recovered from. SAM PCP CONTROLLER has lost the programmed parameters and has therefore returned to default conditions.12 Error Well States Invalid State Loss of Programming This well state should never be reached. Most of the tasks including the control task have been terminated. Duration: Until reset by user.Appendix A: Well State List Duration: Until a start command is issued through HMI or a Host communication. Duration: Until reset by user. A.00 A-11 .

Appendix B

AGA 3 Definitions
This appendix describes the formulas used by the SAM PCP Controller to calculate gas flow rate and accumulate gas production volume data. The topics covered in this appendix include: B.1 AGA 3 Formulas ............................................................................B-2 B.1.1 AGA-3 1992 Tap Type Factors Method..........................B-2 B.1.2 Pressure Measured at Upstream Tap Pf1 ..........................B-4 B.1.3 Orifice Flow Constant C’.................................................B-4 B.1.4 Numeric Conversion Factor — Fn ...................................B-5 B.1.5 Velocity Approach Factor — Ev .....................................B-5 B.1.6 Orifice Calculation Factor — Fc ......................................B-6 B.1.7 Reynolds Number — ReD ................................................B-7 B.1.8 Orifice Slope Factor – Fsl .................................................B-8 B.1.9 Expansion Factor – Y ......................................................B-8 B.1.10 Pressure Base Factor — Fpb .............................................B-9 B.1.11 Temperature Base Factor — Ftb ......................................B-9 B.1.12 Flowing Temperature Factor — Ftf ..................................B-9 B.1.13 Real Gas Relative Density (Specific Gravity) Factor — Fgr ...................................................................B-10 B.1.14 Supercompressibility Factor — Fpv ...............................B-10 B.1.15 AGA-3 1985 Formula — Pipe Taps ..............................B-11 B.2 Orifice Flow Constant — C’ ........................................................B-12 B.2.1 Basic Orifice Factor — Fb .............................................B-12 B.2.2 Reynolds Number Factor — Fr ......................................B-13 B.2.3 Pressure Base Factor — Fpb ...........................................B-15 B.2.4 Temperature Base Factor — Ftb ....................................B-15 B.2.5 Flowing Temperature Factor — Ftf ................................B-15 B.2.6 Real Gas Relative Density (Specific Gravity) Factor – Fgr .....................................................................B-16 B.2.7 Supercompressibility Factor — Fpv ...............................B-16 B.3 NX-19 Formulas...........................................................................B-16
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SAM Well Manager™ — Progressing Cavity Pump User Manual

B.3.1 Adjusted Pressure And Temperature Calculations ........B-17 B.3.2 Pressure and Temperature Correlation Parameters........B-19 B.3.3 NX-19 Natural Gas Regions and E Equations...............B-19 B.3.4 Flowing Compressibility — Zf ......................................B-21 B.3.5 Base Compressibility — Zb...........................................B-21 B.4 Calibration Factors .......................................................................B-21 B.4.1 Orifice Thermal Expansion Factor — Fa .......................B-22 B.4.2 Water Manometer Correction Factor — Fam................B-22 B.4.3 Local Gravitational Correction Factor For U-Tube Manonmeters — Fwl .......................................................B-23 B.4.4 Water Manometer Temperature Correction Factor — FwtB-24 B.4.5 Local Gravitational Correction Factor For Weight Standards — Fpwl ...........................................................B-24 B.4.6 Correction for Gas Column in Mercury Manometer Instruments – Fhgm ..........................................................B-25 B.4.7 Mercury Manometer Temperature Factor — Fhgt ..........B-26

B.1 AGA 3 Formulas
B.1.1 AGA-3 1992 Tap Type Factors Method
In 1992 AGA released a new version of Report 3. The new version addressed improvements made in gas flow measurement utilizing flange taps. The new formulas introduced in the report offer two methods for calculating flow with flange taps. For the SAM PCP Controller AGA implementation we use the Factors method.

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Appendix B: AGA 3 Definitions

The general equation using the Factors method is: Qv = C ' Fa Fam Fwl Fwt F pwl Fhgm Fhgt [hw Pf ] 0.5 Where : Qv = quantity rate of base volume flow in cubic feet per hour at base conditions C' = orifice flow constant Fa = orifice thermal expansion factor Fam = correction for air over water in the water manometer during the differential instrument calibration Fwl = local gravitational correction for water column calibration standard Fwt = water weight correction (temperature) for water column calibration standard F pwl = local gravitational correction for dead weight tester static pressure standard Fhgm = manometer factor, correction for gas column in mercury manometers Fhgt = mercury manometer temperature factor (span correction for instrument temperature change after calibration) h w = differential pressure in inches of water at 60 O F Pf = absolute static pressure in pounds per square inch absolute, use subscript 1 when the absolute static pressure is measured at the upstream orifice tap or subscript 2 when the absolute static pressure is measured at the downstream orifice tap The SAM PCP Controller uses a modified version of the general equation, which is:
Qv = C ' Fcal[h w P f 1 ] 0.5 Where : Qv = quantity rate of base volume flow in cubic feet per hour at base conditions C' = orifice flow constant Fcal = User entered calibration factor to correct for following factors : Fa, Fam Fwl, Fwt, Fpwl, Fhgm, and Fhgt see Appendix B for how to calculate these factors hw = differential pressure in inches of water at 60 O F P f1 = absolute static pressure in pounds per square inch absolute, measured at the upstream orifice tap

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SAM Well Manager™ — Progressing Cavity Pump User Manual

B.1.2 Pressure Measured at Upstream Tap Pf1
Since the pressure can be measured at either the upstream or downstream, the tap downstream measurement needs to be converted to an upstream pressure for all calculations. The conversion is as follows:

Pf 1 =

hw + Pf 2 27.707

Where : Pf1 = absolute static pressure in pounds per square inch absolute, measured at the upstream orifice tap hw = differential pressure in inches of water at 60 O F Pf2 = absolute static pressure in pounds per square inch absolute, measured at the downstream orifice tap

B.1.3 Orifice Flow Constant C’
In the 1992 formula C’ becomes:
C ' = Fn ( Fc + Fsl )Y1 F pb Ftb Ftf Fgr F pv Where : Fn = Numeric conversion factor Fc = Orifice Calculation factor Fsl = Orifice Slope factor Y1 = Expansion factor referenced to upstream F pb = pressure base factor Ftb = temperature base factor Ftf = flowing temperature factor Fgr = real gas relative density factor F pv = supercompressibility factor

The terms (Fc+Fsl) combined are called the discharge coefficient Cd(FT).

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Appendix B: AGA 3 Definitions

B.1.4 Numeric Conversion Factor — Fn
The numeric conversion factor is calculated as:

Fn = 338.265E v d 2 Z bair Where : E v = the velocity approach facor d = d r [1 + α 1 (T f − Tr )] d r = reference orifice plate bore diameter at Tr

2

α 1 = linear coefficient of thermal expansion of the orifice plate material α 2 = linear coefficient of thermal expansion of the meter tube material
Z bair = Supercompressibility of air at base conditions

B.1.5 Velocity Approach Factor — Ev
The velocity approach factor is calculated as: Ev = Where : β = d/D d = d r [1 + α 1 (T f − Tr )] D = Dr [1 + α 2 (T f − Tr )] d r = reference orifice plate bore diameter at Tr Dr = reference meter tube internal diameter at Tr 1 1− β 4

α 1 = linear coefficient of thermal expansion of the orifice plate material α 2 = linear coefficient of thermal expansion of the meter tube material
α1 and α2 are as follows:
Material Type 304 and 316 stainless steel Monel Carbon Steel Linear Coefficient (in/in-OF) 0.00000925 0.00000795 0.00000620

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SAM Well Manager™ — Progressing Cavity Pump User Manual

B.1.6 Orifice Calculation Factor — Fc
The orifice calculation factor is calculated as:

Fc = 0.5961 + 0.0291β 2 − 0.2290 β 8 + (0.0433 + 0.0712e
−8.5 D

− 0.1145e

− 6.0

0.8 ⎡ ⎤ β4 ⎞ ⎛ 19 , 000 β D ⎟ ) ⎢1 − 0.23⎜ ⎟ ⎥1− β 4 ⎜ Re ⎢ D ⎠ ⎥ ⎝ ⎣ ⎦

0.8 1.3 ⎡ ⎛ 19,000 β ⎞ ⎤ ⎛ ⎞ ⎤ 1.1 ⎡ 2 2 ⎟ − 0.116⎢ − 0.52⎜ ⎜ D(1 − β ) ⎟ ⎟ ⎥ β ⎢1 − 0.14⎜ ⎟ ⎥ ⎜ Re D(1 − β ) ⎢ ⎢ ⎥ ⎝ ⎠ D ⎠ ⎥ ⎝ ⎣ ⎦ ⎣ ⎦ Where β = d/D

d = d r [1 + α 1 (T f − Tr )] D = Dr [1 + α 2 (T f − Tr )] d r = reference orifice plate bore diameter at Tr Dr = reference meter tube internal diameter at Tr

α 1 = linear coefficient of thermal expansion of the orifice plate material α 2 = linear coefficient of thermal expansion of the meter tube material
Red = Reynolds number
For meter tubes whose internal diameter is less than 2.8 inches, Fc is modified by an additional term such that:

Fc ' = Fc + 0.003(1 − β )(2.8 − D)

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000.000 8. the calculated ReD can be reused in the equations and a new Qv calculated.000 After calculating ReD.000.000 3.000 4.000. After three to five iterations. ReD can be calculated.000.1.000 6.000.000 2.0114541⎜ v b r ⎜ μDTb Z b air ⎝ Where : Qv = Volume flow rate Pb = Base Pressure Gr = Specific gravity Tb = Base Temperature D = Dr [1 + α 2 (T f − Tr )] Dr = reference meter tube internal diameter at Tr ⎞ ⎟ ⎟ ⎠ α 2 = linear coefficient of thermal expansion of the meter tube material μ = Viscoscity Z bair = Supercompressibility of air at Tb The initial value can be assumed from the table below. Nominal Tube Diameter (inches) 2 3 4 6 8 10 12 16 20 24 30 Assumed Reynolds Number ReD 500.500.7 Reynolds Number — ReD The Reynolds number can be calculated by assuming an initial value and iterating the following equation: ⎛ Q PG ReD = 0.Appendix B: AGA 3 Definitions B.000.000.000 1. the calculated values should be acceptable. From this new Qv.000 1.000 5.500.00 B-7 . Issue Date: 1/18/08 Revision 1.000 750.000 2.

41 + 0. x1 = the ratio of differential pressure to absolute static pressure at the upstream tap. A value of 1.000511⎜ ⎜ ⎟ Re D ⎝ ⎠ Where 0.210 + 0.1. Pf 1 = absolute static pressure at the upstream pressure tap.9 Expansion Factor – Y The expansion factor is calculated as: Y1 = 1 − (0.000 β ⎞ ⎟ ⎟ + ⎢0.000 β ⎞ ⎤ 4 ⎛ 1.00 Issue Date: 1/18/08 .35β 4 ) and : x1 = hw 27.8 Orifice Slope Factor – Fsl The orifice slope factor is calculated as: ⎛ 1. hw = differential pressure.000 β ⎞ ⎟ Fsl = 0.8 0. in pounds per square inch absolute k = isentorpic exponent. in inches of water at 60 O F .7 0.000. B-8 Revision 1.3 was used in the generation of AGA lookup tables.1.707 Pf 1 x1 k Where : Y1 = the expansion factor based on the absolute static pressure measured at the upstream tap.000.049⎜ ⎜ Re ⎟ ⎥β ⎜ ⎜ ⎟ Re D ⎢ ⎥ D ⎝ ⎠ ⎝ ⎠ ⎣ ⎦ β = d/D d = d r [1 + α1 (T f − Tr )] D = Dr [1 + α 2 (T f − Tr )] d r = reference orifice plate bore diameter at Tr Dr = reference meter tube internal diameter at Tr α1 = linear coefficient of thermal expansion of the orifice plate material α 2 = linear coefficient of thermal expansion of the meter tube material Red = Reynolds number B.35 ⎡ ⎛ 19.SAM Well Manager™ — Progressing Cavity Pump User Manual B.

Appendix B: AGA 3 Definitions B.11 Temperature Base Factor — Ftb The temperature base factor is applied to change the base temperature from 60° F and is calculated as: Ftb = Tb 519. pounds per square inch absolute B.5 Issue Date: 1/18/08 Revision 1.00 B-9 .73 Pb Where : Pb = the required (contract) base pressure.10 Pressure Base Factor — Fpb The pressure base factor is applied to change the base pressure from 14.1.1.1.67 Where : Tb = the required (contract) temperature in degreees Rankine B.73 psi absolute and is calculated as: F pb = 14.12 Flowing Temperature Factor — Ftf The flowing temperature factor is applied to change from the assumed flowing temperature of 60° F to the actual flowing temperature Tf and is calculated as: ⎡ 519.67 ⎤ Ftf = ⎢ ⎥ ⎢ ⎣ Tf ⎥ ⎦ Where : T f = acutal flowing temperatur of the gas in degrees Rankine 0.

5 B.1.00 Issue Date: 1/18/08 .1. and is calculated as: ⎡1 ⎤ Fgr = ⎢ ⎥ ⎣ Gr ⎦ Where : Gr = acutal real gas density of the flowing gas 0 .13 Real Gas Relative Density (Specific Gravity) Factor — Fgr The real gas relative density (specific gravity) factor is used to change from a real gas relative density of 1. B-10 Revision 1.SAM Well Manager™ — Progressing Cavity Pump User Manual B. the supercompressibility factor will be calculated using NX-19.14 Supercompressibility Factor — Fpv The basic supercompressibility equation is: Fpv = Where : Zb Zf Z b = gas compressibility at base conditions Z f = gas compressibility at flowing conditions For the MPC implementation of AGA-3.0 to the actual real gas density of the gas flowing.

00 B-11 .5 Where : Qv = quantity rate of base volume flow in cubic feet per hour at base conditions C' = orifice flow constant Fa = orifice thermal expansion factor Fam = correction for air over water in the water manometer during the differential instrument calibration Fwl = local gravitational correction for water column calibration standard Fwt = water weight correction (temperature) for water column calibration standard Fpwl = local gravitational correction for dead weight tester static pressure standard Fhgm = manometer factor. Fwt.5 Where : Qv = quantity rate of base volume flow in cubic feet per hour at base conditions C' = orifice flow constant Fcal = User entered calibration factor to correct for following factors : Fa. use subscript 1 when the absolute static pressure is measured at the upstream orifice tap or subscript 2 when the absolute static pressure is measured at the downstream orifice tap The SAM PCP Controller uses a modified version of the 1985 formula. Fpwl.15 AGA-3 1985 Formula — Pipe Taps The AGA-3 1985 formula is given as: Qv = C ' Fa Fam Fwl Fwt Fpwl Fhgm Fhgt [hw Pf ]0. Fam Fwl.1. Fhgm. correction for gas column in mercury manometers Fhgt = mercury manometer temperature factor (span correction for instrument temperature change after calibration) hw = differential pressure in inches of water at 60 O F Pf = absolute static pressure in pounds per square inch absolute.Appendix B: AGA 3 Definitions B. use subscript 1 when the absolute static pressure is measured at the upstream orifice tap or subscript 2 when the absolute static pressure is measured at the downstream orifice tap Issue Date: 1/18/08 Revision 1. which is: Qv = C ' Fa Fcal [hw P f ] 0. and Fhgt see Appendix B for how to calculate these factors h w = differential pressure in inches of water at 60 O F P f = absolute static pressure in pounds per square inch absolute.

225 ⎤ 5 + ⎢0.5 D K e = flow coefficient when Rd is d (10 6 )/15 K e is calculating as : For pipe taps : K e = 0.SAM Well Manager™ — Progressing Cavity Pump User Manual B.5925 + .0182 ⎡ 0.00 Issue Date: 1/18/08 .1 Basic Orifice Factor — Fb The basic orifice factor is given as: Calculating Ko Ko is calculated using the following formulas: Ko = Ke 15 E d (10 6 ) 1+ Where : d = orifice diameter D = measured meter tube diameter E = d (830 − 5000 β + 9000 β 2 − 4200 β 3 + B ) β = ratio of orifice diameter to measured meter tube diameter (d / D) B= 530 0.2 Orifice Flow Constant — C’ The orifice flow constant is given as: C ' = Fb FrYFpb Ftb Ftf Fgr Fpv Where : Fb = basic orifice factor Fr = Reynolds Number factor Y = expansion factor Fpb = pressure base factor Ftb = temperature base factor Ftf = flowing temperature factor Fgr = real gas relative density factor Fpv = supercompressibility factor B.935 − β + 1.25 − β ) 2 D 44 1 4 2444 3 Term A If β > 0.43 + 0.35 β 14 ⎥ D D ⎦ D ⎥ ⎣ ⎣ ⎦ 5 1.06 ⎤ 2 ⎡ 0. for flange taps B= 875 + 75. for pipe taps D 0.25 then drop Term A B-12 Revision 1.5 (0.2.440 + β + ⎢0.

623 0.500 0. for flange taps (1 − β 4 ) 0.600 0.100 0.375 0. for pipe taps D 0.150 0.810 0. for flange taps B= 875 D + 75.225 0.641 0.300 0.325 0.175 0.611 0.608 0.5 0.618 0.988 Issue Date: 1/18/08 Revision 1.604 .525 0.707 0.724 0.763 0.943 0.2 Reynolds Number Factor — Fr The Reynolds number factor is given as: Fr =1+ Where : h w = differential pressure P f = absolute static pressure ( flowing ) b= E 12835dK d = orifice diameter E = d (830 − 5000 β + 9000 β 530 2 b hw Pf − 4200 β 3 + B) β = ratio of orifice diameter to measured meter tube diameter (d / D) B= K= .614 0.692 0.575 0.904 0.634 0.785 0.625 0.675 0.837 0.450 0.607 0.5 for pipe taps K must be determined from table : β K β K β K β K β K 0.250 0.200 0.425 0.275 0.650 0.2.628 0.Appendix B: AGA 3 Definitions B.650 0.658 0.550 0.475 0.668 0.742 0.350 0.700 0.125 0.00 B-13 .400 0.680 0.869 0.

5 Where : Y2 = the expansion factor based on the absolute static pressure measured at the downtream tap.333 + 1.10 to 0. hw = differential pressure. P f 1 = absolute static pressure at the upstream pressure tap.7 β 5 + 12 β 13 )] x2 = Pf 1 − Pf 2 Pf 2 = hw 27. The values of Y1 computed by these equations are subject to a tolerance varying from 0.10 to 0. For larger values of x.) A value of 1. x1 = the ratio of differential pressure to absolute static pressure at the upstream tap. when x = 0.00 Issue Date: 1/18/08 .145( β 2 + 0.3 was used in the generation of AGA lookup tables. x 2 = the ratio of differential pressure to absolute static pressure at the downstream tap. in inches of water at 60 O F .5 percent. a somewhat larger uncertainty may be expected. when x = 0.333 + 1. B-14 Revision 1. the ratio of the specific heat of the gas at constant pressure to the specific heat of the gas at constant volume at flowing conditions (accepted practice is to use the ratio at standard conditions for most gas phase measurements. while that for pipe taps may be used over a range from 0.20.5 1 − [0.80.SAM Well Manager™ — Progressing Cavity Pump User Manual Expansion Factor — Y The Expansion factor is calculated based on whether measurement is referenced to upstream or downstream pressure. in pounds per square inch absolute P f 2 = absolute static pressure at the downstream pressure tap. to plus or minus 0.70. and the type of tap being used. The equation for flange taps may be used for a range of beta ratios from 0.707 P f 2 x2 k (1 + x 2 ) 0. Calculations are as follows: Referenced to Upstream Pressure For pipe taps : and : Y1 = 1 − [0. in pounds per square inch absolute x1 / k = the acoustic ratio Where : k = c p / c v .7 β 5 + 12 β 13 )] x1 = Pf 1 − Pf 2 Pf 1 = hw 27.145( β 2 + 0.707 P f 1 x1 k Where : Y1 = the expansion factor based on the absolute static pressure measured at the upstream tap. Referenced to Downstream Pressure For pipe taps : and : Y2 = [1 + x 2 ] 0.

73 Pb Where : Pb = the required (contract) base pressure.2.67 ⎤ Ftf = ⎢ ⎥ ⎢ Tf ⎦ ⎥ ⎣ Where : T f = acutal flowing temperatur of the gas in degrees Rankine 0.2.5 Issue Date: 1/18/08 Revision 1.3 Pressure Base Factor — Fpb The pressure base factor is applied to change the base pressure from 14.73 psi absolute and is calculated as: F pb = 14.2.67 Where : Tb = the required (contract) temperature in degreees Rankine B. pounds per square inch absolute B.5 Flowing Temperature Factor — Ftf The flowing temperature factor is applied to change from the assumed flowing temperature of 60° F to the actual flowing temperature Tf and is calculated as: ⎡ 519.00 B-15 .4 Temperature Base Factor — Ftb The temperature base factor is applied to change the base temperature from 60° F and is calculated as: Ftb = Tb 519.Appendix B: AGA 3 Definitions B.

4 MPa ) and –10 to 100OF (-23 to 38OC).34 MPa.5 to 10.7 Supercompressibility Factor — Fpv Supercompressibility can be calculated using the NX-19 Manual equations or the AGA-8 method. and is calculated as: ⎡1 ⎤ Fgr = ⎢ ⎥ ⎣ Gr ⎦ Where : Gr = acutal real gas density of the flowing gas 0 .3 NX-19 Formulas The ranges over which the NX-19 method of calculation are valid are: • Pressure pg • Temperature Tf • Specific Gravity • CO2 and N2 To 5000 psig (10.554 to 1.5 B. Over most normal measurement ranges.2.0 0 to 15% B-16 Revision 1. This section will describe the NX-19 Manual derivation.2.00 Issue Date: 1/18/08 . gauge) -40º to 240º F (-40º to 116º C) 0.2% of the values computed by the AGA-8 method.SAM Well Manager™ — Progressing Cavity Pump User Manual B. The basic supercompressibility equation is: Fpv = Zb Zf B. 500 to 1500 psia (3. the NX-19 will compute the gas compressibility factor to within 0.0 to the actual real gas density of the gas flowing.6 Real Gas Relative Density (Specific Gravity) Factor – Fgr The real gas relative density (specific gravity) factor is used to change from a real gas relative density of 1.

1x N 2 Where : p g = Gauge pressure G = Specific Gravity x CO2 = mole fraction of carbon dioxide x N 2 = mole fraction of nitrogen TF = Temperature flowing in degrees Fahreneheit Method 2 — Analysis Method Recommended for high specific gravity gas (G > 0.00 B-17 .3.4 p g Padj = Tadj = ∑x p i i ci ci 359.22G + 100 x CO2 − 39.2 x N 2 Padj = Tadj = 226.15 + 211.46(TF + 460) ∑xT Where : p g = Gauge pressure TF = Temperature flowing in degrees Fahreneheit xi = mole fraction of each component Tci = Critical temperature of each component pci = Critical pressure of each component Issue Date: 1/18/08 Revision 1.75).9G − 100 x CO2 − 168.1 Adjusted Pressure And Temperature Calculations Four methods are use to obtain the adjusted temperature and pressure: Method 1 — Specific Gravity Method Calculates adjusted pressure and temperature from the mole fractions of carbon dioxide and nitrogen as: 156.Appendix B: AGA 3 Definitions B.8 − 7.47 p g 160.29(TF + 460) 99. Calculate adjusted pressure and temperature as: 671.

0209 H Btu .00 Issue Date: 1/18/08 .11 − 172.52 x N 2 − 102.2203H Btu .4 p g 891.4 p g 693 − 0.52 x CH 359.04 x CO 2 − 232.SAM Well Manager™ — Progressing Cavity Pump User Manual Method 3 — Methane Method Recommended for high specific gravity gas (G > 0.78 x CH 4 4 = mole fraction of methane Method 4 — Heating Value Method Uses the measured heating value [wet basis.7 + 0.56G + 443.12 x CO 2 − 319.46(T F + 460) 124.23 x N 2 − 122. wet + 379 x CO 2 − 201x N 2 + 384. Calculates adjusted pressure and temperature as: P adj = T adj = Where : p g = Gauge pressure T F = Temperature flowing in degrees Fahreneheit x CO 2 = mole fraction of carbon dioxide x N 2 = mole fraction of nitrogen x CH 4 671. Calculates adjusted pressure and temperature as: P adj = T adj = Where : p g = Gauge pressure T F = Temperature flowing in degrees Fahreneheit x CO 2 = mole fraction of carbon dioxide x N 2 = mole fraction of nitrogen H Btu .46(T F + 460) 327.99 x CO 2 + 91.75).73 psia and 60º F] and the mole fractions of nitrogen and carbon dioxide. wet = heating value B-18 Revision 1. Requires methane mole fraction and the two inert mole fractions of carbon dioxide and nitrogen. Btu/(std ft3) at 14.82G − 144.11x N 2 359.77 + 214. wt 671.

32 1.0 to 5.0 2.88 0.09 to 1.32 to 1.0 T 1.0 2.0 2.88 to 1.3 to 2.09 0.00 B-19 .40 E Equation E1 E2 E3 E4 E5 E6 E7 E8 Issue Date: 1/18/08 Revision 1.3 1.3.84 to 0.09 0.Appendix B: AGA 3 Definitions B.3 NX-19 Natural Gas Regions and E Equations With the calculated pressure and temperature correlation parameters.84 to 0.0 2.0 to 5.88 0.7 1000 T= T adj 500 B.09 to 1.0 1.09 1.88 to 1.84 to 1. the mixtures pressure and temperature correlation parameters are calculated as: p= p adj + 14.0 to 5.3 to 2.0 to 5.40 0.3. the user can find the appropriate E equation by matching the corresponding region as follows: Ranges p 0 to 2 0 to 1.2 Pressure and Temperature Correlation Parameters Once the adjusted temperature and pressure are calculated.

00075 p 2.33123T − 1.844Tb 4 )( p − 1.3)[1.3[2 − exp(−20Tb )] + 0.00075 p 2.5 p 2 [2.16453T 2 − 0.14416T 3 − 0.3)[1.016299 − 0.00 Issue Date: 1/18/08 .317Tb 4 p (1.455(200Tb 6 − 0.00075 p 2.3[2 − exp(−20Tb )] + 0.455(200Tb 6 − 0.69(2)1.054533T 4 B-20 Revision 1.5 − p ]2 E2 = 1 − 0.0833( p − 2) 3 ] A = 1.3 exp(−20Ta ) − 0.69(2)1.00075 p 2.78221T 3 − 1.028094T + 0.SAM Well Manager™ — Progressing Cavity Pump User Manual The E equations are calculated as follows: Ta = T − 1.51419T + 0.075255 − 0.3[2 − exp(−20Tb )] − 1.17 + 1.844Tb 4 )( p − 1.483( p − 2) − 0.35978 + 0.1( p − 2) 2 + 0.28603T 4 A1 = 0.0011Ta 0.32) 2 ( p − 2)[3 − 1.27839T 4 A2 = −0.25 + 80( 0.10573T − 0.028Tb 3 + 42.028Tb 3 + 42.25 − p 2 ] E4 = 1 − 0.48782T 2 − 0.0167Tb 2 − 18.03249Tb + 2.52216T 3 + 0.56796T 2 − 0.058598T 2 + 0.09 − T E1 = 1 − 0.03249Tb + 2.69 − p 2 ) E3 = 1 − 0.4Ta 0.0167Tb 2 − 18.19687T 4 A3 = 0.88 −T ) − p 2 ] 2 E5 = E 4 − X E 6 = E3 − X E7 = E1 − X E8 = E7 − X 1 X = A( p − 2) + A1 ( p − 2) 2 + A2 ( p − 2)3 + A3 ( p − 2) 4 X 1 = ( p − 1.78221T 3 + 0.7172 − 2.09 Tb = 1.

3. The factors should be combined and entered in the AGA-3 Calibration Factors field.133185T −1 )m −1 B= b= 3 − mn 2 9mp 2 9n − 2mn 3 54mp 3 − E 2mp 2 1 D = [b + (b 2 + B 3 ) 0.0161353T − 5 n = (0.4 Calibration Factors The following factors can be calculated to calibrate readings closer to actual conditions on site.00 B-21 . Issue Date: 1/18/08 Revision 1.0221323T − 3 + 0.0330378T − 2 − 0.0457697T − 4 − 0.5 Base Compressibility — Zb The base compressibility is calculated as follows: 0.265827T − 2 + 0.Appendix B: AGA 3 Definitions B.00132 ⎞ ⎛ Z b = ⎜1 + ⎟ T 3.4 Flowing Compressibility — Zf Zf = 1 B n −D+ D 3p Where : m = 0.5 ] 3 E = comes from E equations calculated above p = pressure correlation parameter T = temperature correlation parameter The flowing compressibility is calculated as follows: B.25 ⎠ ⎝ Where : T = temperature correlation parameter −2 B.3.

4.4. The orifice thermal expansion factor is given as: For 304 and 316 stainless steel : Fa = 1 + [0.1 Orifice Thermal Expansion Factor — Fa The orifice thermal expansion factor is used to correct for the error associated with the expansion or contraction of the orifice plate due to the operating temperature differing from the temperature at which the orifice was measured.SAM Well Manager™ — Progressing Cavity Pump User Manual B. The factor is calculated as: Fam = Where : ρw − ρa ρw ρ w = density of water at 60 O F ρ w is 62.2 Water Manometer Correction Factor — Fam This factor is used to correct for the gas leg over water when a water manometer calibration standard is used to calibrate a differential pressure gage.3663 lbm / ft 3 ρ a = density of air The real gas density of air ( ρw ) is calculated for any hw pressure above atmospheric pressure as: Patm + hw 27.0000185(t f − t meas )] For Monel : Fa = 1 + [0.00 Issue Date: 1/18/08 .707 192.4 ρa = Where : Patm = local atmospheric pressure in pounds per square inch absolute hw = differential pressure B-22 Revision 1.0000159(t f − t meas )] Where : t f = temperature of the fluid flowing at the orifice in degrees Fahrenheit t meas = temperature in degrees Fahrenheit of the orifice plate when the orifice plate is measured B.

practical values of g can be obtained from the following equations: For mid .54 55096 + ( Elevation.S. In the absence of better data.0028247L + 0.0020299L2 − 0.000015058 L3 − 0. ft − 361) B.3 Local Gravitational Correction Factor For UTube Manonmeters — Fwl This factor is used to correct for local gravity effect on manometer fluids and is calculated as: g 32. The ambient value of gravity at any location is most accurately obtained from a U.032808(978.00 B-23 .01855 .000094 H ) For latitudes fron 0 O to 90 O a curve fit equation : g = 0.4.087( L − 45)] − 0. ft − 361) * 14.000094 H ) Where : L = latitude in degrees H = elevation in feet above sea level Issue Date: 1/18/08 Revision 1.032808(980.Appendix B: AGA 3 Definitions The local atmospheric pressure can be calculated using the following equation from the Smithsonian Meteorological Tables: Patm = 55096 − ( Elevation.latitudes.665 + [0.0. between 30 O and 60 O : g = 0.17405 Fwl = Where : g = local acceleration due to gravity in feet per second squared. Coast and Geodetic Survey reference to aeronautical data or from the Smithsonian Meteorological Tables.

The factor can be calculated as follows: Fwt = Where : ρw 62. avoirdupois pounds per cubic foot.SAM Well Manager™ — Progressing Cavity Pump User Manual B.tube manometer in U.S.4.4 Water Manometer Temperature Correction Factor — Fwt This factor is used to correct for variations in the density of water used for calibration due to temperature or other reasons.3663 ρ w = density of the water in the calibration U . B.00 Issue Date: 1/18/08 . The effect of atmospheric air is excluded ( usually defined as weight in vacuo of the fluid sample at the pressure and temperature existing in the U .5 Local Gravitational Correction Factor For Weight Standards — Fpwl This factor is used to correct for the local gravity effect on the weights of the dead weight calibrator and can be calculated as follows: Fpwl = Where : g = acceleration due to local gravitational force g 0 = acceleration of gravity used to calibrate the weights or dead weight tester g g0 B-24 Revision 1.4.tube manoometer during the instrument calibration.

67)] Where : Ta = ambient temperature in degrees Rankine Issue Date: 1/18/08 Revision 1.S avoirdupois pounds per cubic foot. The effect of atmospheric air is excluded (usually defined as weight in vacuo of the mercury sample at the base pressure and temperature defined for the flow measurement).4. ρ hg can be calculated as : ρ hg = 846.000101(Ta − 519. This factor is used to correct for the effect of the gas column above the mercury during the flow measurements and can be calculated as follows: Fhgm = Where : ρ hg − ρ g ρ hg ρ g = real gas density of the gas or vapoir in the differential pressure instrument in U. ρ hg = density of the mercury in the differential pressure instrument in U. The effect of atmospheric air is excluded (usually defined as weight in vacuo of the mercury sample at the base pressure and temperature defined for the flow measurement).Appendix B: AGA 3 Definitions B.324[1 − 0.S avoirdupois pounds per cubic foot.6 Correction for Gas Column in Mercury Manometer Instruments – Fhgm This factor is used to correct for the gas vapor leg of fluid at Pf1 static pressure and the temperature of the manometer or instrument.00 B-25 .

B-26 Revision 1.00 Issue Date: 1/18/08 .7 Mercury Manometer Temperature Factor — Fhgt This factor is used to correct for the change in mercury density in the mercury manometer due to the temperature change from the temperature at the time of instrument calibration and can be calculated as follows: Fhgt = Where : ρ hgo ρ hgc ρ hgo = density of the mercury in the differential pressure instrument in U. The effect of atmospheric air is excluded (usually defined as weight in vacuo of the mercury sample at the base pressure and temperature defined for the flow measurement and the temperature of the mercury gage). ρ hgc = density of the mercury in the differential pressure instrument in U.S avoirdupois pounds per cubic foot at the time of its calibration.SAM Well Manager™ — Progressing Cavity Pump User Manual B. The effect of atmospheric air is excluded (usually defined as weight in vacuo of the mercury sample at the base pressure and temperature defined for the flow measurement).4.S avoirdupois pounds per cubic foot at he mercury gage operating conditions.

00 Index-1 . 9-10 Additional Configuration option. 8-80 status screens. 8-31 AGA 3 24-hour historical data for gas flow. 8-68 enabling and disabling gas calculations. 8-50 programming. 10-12 alarm coil tracking. 10-10 daily production. 8-43 status. 8-52 status. 8-38 status. 10-8 peak rod speed historical data. 8-48 status. 8-39 configuration. 10-8 alarms 60-day coil track history. 6-2 baud rate (for flash upgrade) specifying for laptop. 10-14 register alarm configuration. 9-14 auxiliary analog inputs alarm and alert configuration. 8-97 configuring for auxiliary analog inputs. 10-9 rod peak torque historical data. 7-3 battery backup protection for RAM. 9-9 backup protection for RAM. B-2 gas calculation programming. 10-12 analog channel configuration. 10-11 60 Day Coil Tracking option. 10-10 60-day AGA 3 gas flow. 8-41 engineering units used. 16-6 specifying in controller. 16-11 Issue Date: 1/18/08 Revision 1. 9-15 auxiliary accumulators programming. 10-8 register log activity. 9-23 AUX I/O board status screen. 8-36 status. 8-37 engineering units used. 8-39 history of last 100 recorded logs. 9-11 auxiliary I/O configuration. 8-70 temperature and pressure programming. 8-68 implementing definitions. 16-5 specifying for SAM PCP Controller. 8-48 resetting totals. 8-76 auxiliary analog outputs configuration. 7-3 disconnect jumper pin configuration. 10-8 peak rod speed output historical data. 10-10 coil tracking (alarm condition accumulation) configuration. 2-4 24-hour AGA 3 gas flow historical data. 8-78 formulas. 8-68 parameter configuration.Index 12-volt power supplies features. 10-11 60-day historical data for gas flow. 9-14 accumulators engineering units used.

8-5 coil tracking definition. 8-8 logic expressions. 8-17 Modbus transmission mode. 7-19 expansion comm port mode and baud for Modbus. 8-8 for flash upgrade. 6-4 component (internal) layout of SAM PCP Controller. 8-31 Issue Date: 1/18/08 Index-2 Revision 1. 10-10 enabling and disabling. 1-4 data transmission rate configuration. 8-7. 8-45 battery disconnect jumper pins. 8-98 setting alarm flags. 2-3 Communications option. 8-73 parameter violations. 3-3 communication diagnostics. 16-4 for code versions. 7-13 passwords. 8-68 alerts for analog inputs. 8-88 register logs. 8-4 sand blowout (SBO). 8-79 customer technical support.SAM Well Manager™ — Progressing Cavity Pump User Manual baud rate configuration for controller communications. 8-14. 8-10 gauge off time (GOT). 8-8 coil tracking (alarm condition accumulation). 8-80 register log calculations. 8-48 auxiliary analog inputs. 8-8 NX-19 design parameters. 8-5 default parameter resetting. 8-28 peak energy management. 8-99 Communication Parameters option. 16-5 for SAM communications.sam firmware file. 8-76 VSD parameters. 9-2 current transmitter input configuration. 7-26 smart devices. 8-5 current operating status. 8-8 communication port configuration. See also programming AGA 3 gas calculation. 14-6 communications port configuration for radios. 5-18 checksum for *. 3-2 configuration. 8-28 checking power-up voltage. See hardware configuration Controller Date and Time option. 8-33 keying properties. 13-1 for LL firmware component. 8-8 brownout/blackout protection. 8-8 communication protocol used for SAM PCP Controller. 8-30 default screen specified to display. 6-3 custody transfer and EFM. 9-3 clearing a logic expression state. 8-8 SAM fundamental RTU operating parameters. 6-2 baud rate. 7-4 register alarms. 14-6 communication parameters for communicating with laptops. 8-97 Coil Tracking option. 3-3 calendar setting. 8-5 changing passwords. 8-17 temperature and pressure for AGA 3. 8-12 Modbus transmission rate.00 . 8-39 auxiliary accumulators. 8-8 auxiliary digital inputs and outputs. 8-65 clock setting. 8-53 Modbus slave device to be used. 8-8 date and time setting. 8-97 coldfire microporcessors. 8-33 power on delay. 8-41 configuring PCP system hardware. 16-4 location where displayed on screens. 16-4 for App firmware component. 8-84 RTU address. 8-97 end devices for meters and scaled flow. 8-37 auxiliary analog outputs. 8-5 daylight savings time (DST) configuration. 8-97 displaying data for last 60 days.

8-34 violation operation. 8-36 expansion board assembly #520. See SAM Flash Upgrade Utility software flow rate meter installation.5012 (RS-485). 6-4 SAM PCP Controller. 6-9 voltage and current transmitter inputs. 8-5 EFM and custody transfer. 8-48 grounding. 8-95 logic expressions. 6-5 overview. 8-67 peak energy management.00 Index-3 . 8-50 for analog inputs. 9-4 electric prime mover specifying. 5-8 firmware upgrading. 8-34 violation operation. 9-3 versions installed in SAM PCP Controller. 6-2 expansion board termination resistor jumpers. 9-4 e-mail address for technical support. 5-4 grounding expansion board. B-2 gauge off time configuring. 8-43 for production status. 8-98 HOA switch. 6-3 MDS radio transmission cable. 13-1 flash utility and flash upgrade. 13-1 displaying historical data as tables and plots. 14-1 digital input status.5003A (I/O).Index diagnostics tools for troubleshooting. 8-78 alarm coil tracking. 7-1 GOT. 6-3 assembly #520. 6-6 historical data 60-day coil tracking. 5-7 wiring. 9-12 digital input/output programming auxiliary inputs and outputs. 6-1 radio communications port. 5-16 end device configuration for meters and scaled flow. 10-2 DST (daylight savings time) configuration. 6-10 event log historical data. See gauge off time ground rod installation. 8-38 for analog outputs. 1-4 enable and disable AGA 3 calculations. 5-13 turbine meter board. 8-98 HOA switch. 8-95 logic expressions. 8-67 peak energy management. 6-4 termination resistor jumper configuration. 16-18 version number displayed. 8-10 factory-default parameter values. 7-13 general RPC parameter programming. 8-30 field wiring diagram. 8-31 handshake protocol configuration. 6-8 disable and enable AGA 3 calculations. 6-3 VSD. 10-13 last 200 significant events. 7-19 engineering units for accumulators. 5-6 formulas used for AGA 3 definitions. 14-2 expansion auxiliary I/O programming. 8-8 hardware configuration battery disconnect jumper pins. 5-17 Firmware Versions option. 8-45 programmed as accumulators. 7-24 electro-mechanical relay wiring. 6-10 Hall-Effect transducers installing for RPM. 6-3 dipswitch configuration for RS-485 board. 8-33 time of day buffers updated. 6-4 turbine meter board. 7-13 expansion comm port configuration for Modbus. 8-78 alarm coil tracking. 8-79 elapsed time in current well state. 10-10 Issue Date: 1/18/08 Revision 1.

8-54 requirements before using. See also wiring flow rate meters. 8-59 I/O and logic selection entry code group. 9-19 interface board assembly expansion board. 14-3 Main Board I/O Status option. 5-6 recommended tools for system wiring. 6-6 Sam Flash Upgrade Utility software. 8-57 channel selection entry code group. 2-5 specifications. 7-24 I/O expansion programming. 8-65 detailed overview. 3-2 Historical option. 10-6 event log of last 200 significant events. 14-2 malfunction (MALF) allowed and action taken. 5-4 personnel required. 5-10 stepdown transformer. 5-6 selecting a site for the system. 12-1 Issue Date: 1/18/08 Index-4 Revision 1. 5-2 logic expression action programming. 7-17 malfunctions resetting. 5-2 process variable transmitters. 7-23 LCD graphics display overview. 8-53 resetting. 14-4. 8-33 data display formats.00 . 10-2 PCP activity. 8-48 installation. 10-7. 14-5 Main Menu screen. 10-11 AGA 3 60-day gas flow. 8-36. 10-14 overview of features available. 5-5 typical components in PCP system. 6-3 key up and down time configuration for SAM communications. 8-57 syntax error messages. 5-11 RPM Hall-Effect transducer. 10-9 toggling between tables and plots. 16-9 SAM PCP Controller. 2-6 K-factor configuration. 2-6 maintenance event log. 8-58 viewing status of programmed expressions. 2-5 testing keys. 8-65 clearing one or all. 10-9 SAM PCP Controller activity. 14-2 Maintenance Log option. 2-5 overview. 14-2 last 100 alarms. 8-65 syntax and programming rules. 8-56 clearing a latched output. 10-13 register log plots. 5-2 specifications for system wiring. 10-8 60-day pump efficiency. 5-6 mounting post and ground rod. 10-2 HOA switch enabling/disabling. 8-62 alarm and special section entry code group. 5-3 wiring the system. 8-60 programming.SAM Well Manager™ — Progressing Cavity Pump User Manual 60-day polished rod activity. 10-2 displaying multiple plots simultaneously. 5-8 Yagi antenna. 8-56 procedure for writing. 6-3 Main Board I/O Diagnostics option. 5-2 typical system drawing. 8-53 enabling and disabling. 10-8 AGA 3 24-hour gas flow. 6-1 jumper pins configuration for battery connect/disconnect. 8-95 Host mode. 14-9 keystrokes used on operator interface. 10-5 PCP-specific event log plots. 5-7 RS-485 communication expansion board. 6-2 configurations for 4–20 MA transmitters. 10-12 configuring gauge off time (GOT). 7-10 hydraulic prime mover specifying. 8-9 keypad description of key functions. 8-67 expression example. 10-2 main board dipswitches and jumpers.

4-1 VSD optional hardware. 10-6 normal operation for previous 25 hours. 7-10 motor control relay wiring. 10-7 normal operation since ramp down. 9-26 slave device type to be used. 8-15 expansion comm port mode and baud configuration. 4-3 parameters reset to defaults. 8-31 installation. 4-2 spare parts. 5-4 mounting the equipment. 2-6 microprocessor and memory technical specifications. 3-3 minimum production allowed. 8-14. 5-14 motor type configuration. 2-3. 7-23 mounting post Issue Date: 1/18/08 password setting and changing. 8-73 formulas and calculations. 8-38 for analog outputs. 10-7 torsional effects since power down. 4-1 how to order parts. 4-2 optional hardware. 8-84 configuring salve device communication parameters. 2-4 part numbers for interface systems. 2-7 retrieveing current status of slave devices. 7-16 MB Register Map Check option. 2-5 keypad overview.00 Index-5 . 2-6 overview. 4-2 Modbus Transmission Mode CFG option. 3-4 Modbus Master CFG option.Index maximum production allowed. 2-5 keys used for navigation. 1-3 systems used with SAM PCP Controller. 10-5 activity since startup. 10-7 Revision 1. B-16 memory backup. 10-6 displaying multiple plots simultaneously. 2-6 Main Menu screen. 8-12 Modbus transmission rate configuration. 8-28 PCP historical data. 14-8 MDS radio transmission cable configuration. 7-3 menu map for operator interface. 4-2 troubleshooting keypad. 8-10 overview. 7-16 Modbus communications protocol. 14-9 ordering replacement parts and accessories. See installation NX-19 design parameter configuration. 8-17 Modbus Master feature assigning a numbers to slave devices. 8-30 parts lists hardware components. 4-3 operator interface systems. 8-43 for production status. 3-2 operation modes for startup. 7-6 operator interface keypad button descriptions. 2-6 menu map. 8-17 specifying a polling routine. 8-50 for analog inputs. 8-26 configuring register logs. 8-19 configuring communication expansion port. 2-6 shorthand access method for selecting options. 5-4 maximum weight supported. 16-18 operating environmental range for SAM PCP Controller. 5-17 motor starter panel wiring to stepdown transformer. 8-15 associating addresses to indices. 4-2 programming methods. 8-24 obtaining firmware upgrade files for upload. 6-5 measurement units for accumulators. 8-8 Monitor mode.

5-6 production (minimum and maximum) allowed programming. 8-34 temperature and pressure values. 8-80 register log configuring. 7-7 displaying 60-day peak historical data. 9-6 Quick Start feature benefits. 15-1 methods for navigating programming screens. 8-68 PCP configuration parameters. 8-84 register log calculation configuration. 9-22 Production Control mode. 6-4 network troubleshooting tool. 7-13 K-factor using programming screen. 7-9 power on delay configuration. 7-23 process variable transmitter installation. 8-24 power off delay for pump. 12-1 rod speed configuring full and minimum scale. 7-16 status. 15-2 starting. 8-54 NX-19 design parameters. 8-76 pump 60-day efficiency historical data.00 Issue Date: 1/18/08 . 8-76 primary speed control algorithm process. 8-30 resetting accumulator totals. 7-5 recommended tools for system wiring. 7-4 power-up voltage checks. 8-88 Reset Malfunctions option. See also configuration auxiliary accumulators. 8-84 displaying historical data. 7-1 SAM configuration parameters. 7-3 ramp down historical data. 7-9 production historical data. 7-9 starting and stopping. 8-37 auxiliary analog outputs. 6-5 RAM backup protection. 10-8 production status measurement units. 8-48 auxiliary analog inputs. 12-1 Reset to Defaults option. 11-1 polished rod speed historical data. 8-31 programming. 8-52 resetting malfunctions. 8-80 log configuration. 5-18 pressure configuration for AGA 3.SAM Well Manager™ — Progressing Cavity Pump User Manual PCP parameter programming. 10-7 ramp up steps and rate. 10-9 displaying the status of combined values. 8-41 auxiliary digital inputs and outputs. 9-2 peak energy management configuring. 2-2 prime mover type specifying. 14-7 transmission cable configuration for MDS. 8-73 optional AGA 3 gas calculations. 10-8 efficiency status. 7-23 logic expression actions. 5-11 Register Digital Output option. 10-8 polling routine for Modbus Master feature. 8-45 enable/disable violation. 8-33 toggling between enable and disable. 7-15 Index-6 Revision 1. 8-84 registers alarm configuration. 15-3 radio communications port configuration. 7-1 PCP status screens. 8-62 logic expressions. 8-1 Register Log Configuration option. 10-8 rod torque allowed. 9-7 power off delay configuration. 7-7 configuring min and max operating ranges.

2-6 microprocessor and memory. 5-6 troubleshooting diagnostics. 6-6 configuring for use with SAM Well Manager. 4-1 power specifications. 6-6 configuring to be recognized by SAM PCP Controller. 14-1 typical components in system. 16-4 command button descriptions. 14-7 RX/TX troubleshooting. 9-7 sampling period time allowed. 16-13 SAM Status option. 12-1 serial communications. 8-48 programming for auxiliary accumulators. 11-1 status screens. 5-2 wiring the system. 2-5 menu map of operator interface. 16-5 connecting laptop to SAM PCP Controller. 7-10 SamScreen Terminal emulator interface program. 2-6 proper grounding. 2-4 optional hardware. 6-6 configuring data line polarity. 5-13 Quick Start feature. 3-2 expansion board assembly. 16-18 overview about each screen component and feature. 7-26 Index-7 Issue Date: 1/18/08 Revision 1. 5-1 internal component layout. 16-9 obtaining configuration files for upgrade. 2-1 parts lists. 2-5 sand blowout (SBO) configuration.00 . 16-14 installing upgrade utility software on laptop. 2-7 operator interface. 8-48 programming for auxiliary analog inputs. 14-7 Sam Flash Upgrade Utility software checksums for App and LL. 9-4 RTU Level option. 16-13 disconnecting communications between SAM PCP Controller and laptop. 2-4 brownout/blackout protection. 2-4 transmitter device types used. 6-6 installing. 3-3 communication protocol. 3-3 programming accumulators. 8-8 displayed on status screen. 3-4 Modbus Master feature. 16-20 establishing communications between SAM PCP Controller and laptop. 4-1 starting and stopping PCP system. 16-14 specifying baud rate in controller. 6-3 firmware versions used. 15-1 resetting malfunctions. 6-8 configuring for use with SAM PCP Controller. 6-1 historical data of controller activity. 10-9 installing the controller. 2-3 connecting to laptop for flash upgrade. 5-8 SAM PCP Controller 12-VDC primary power supply. 8-37 programming for auxiliary analog outputs. 6-8 configuring dipswitches. 3-2 LCD graphics display. 8-45 programming methods. 3-3 spare parts. 16-2 saving controller configuration to a file. 9-2 enclosure specifications and dimensions. 16-8 communication parameter settings. 16-16 current operating status. 3-3 Modbus communications protocol. 16-11 specifying communication parameters in laptop. 16-12 upload saved configuration file to controller. 8-4 RX/TX Messages option. 8-41 programming for auxiliary digital inputs and outputs. 13-1 hardware configuration. 8-26 description and features. 6-6 overview. 5-6 installing the system.Index RS-485 communication expansion board. 3-1 environmental operating range. 6-6 RTU address configuring. 9-2 terminal blocks. 4-2 overview.

9-10 auxiliary analog output. 7-6 status screens AGA 3 calculation status. 8-28 SUPV (supervisor) configuration. 6-10 hardware configuration. 8-17 auxiliary accumulators. 9-17 alarm and alert conditions. 5-5 wiring to motor starter panel. 8-19 configuring parameters for Modbus Master feature. 7-9 torque limiting for rod operating status. 5-10 stop protection override. 6-3 troubleshooting communication diagnostics. 9-23 turbine meter board grounding. 2-2 secondary. 7-24 shielded cables. 3-3 setting clock and calendar. 8-29 System Tools option. 1-3 signal wiring and shielding. 3-2 internal components. 14-1 technical specifications. 3-3 wiring PCP system. 9-2 RPC current operating values. 14-7 RX/TX messages. 3-2 LCD graphics display. 14-9 locating memory register locations in Modbus register map. 3-1 environmental operating range.SAM Well Manager™ — Progressing Cavity Pump User Manual serial communications technical specifications. 7-12 supervisory password setting. 5-15 software Sam Flash Upgrade Utility. 2-5 spare parts. 14-4 overview. 9-6 programming. 9-12 main board DIO. See specifications technical support. 2-2 Speed Control mode. 9-26 stepdown transformer installing. 9-11 auxiliary board status. See parts lists specifications 120-VAC power supply. 14-7 speed control algorithms primary. 14-1 keypad testing. 9-7 slave devices and level sensors using Modbus Master feature. 5-14 wiring to SAM PCP Controller. 14-6 diagnostic tools available. 3-3 enclosure dimensions. 8-76 terminal strip wiring. 9-15 digital inputs. 9-2 PCP control parameters. 8-28 setting the default screen displayed. 7-9 starting and stopping PCP system. 7-10 sheave ratio. 7-15 transmitter devices used. 8-5 setting passwords. 3-2 microprocessor and memory.00 Issue Date: 1/18/08 . 14-8 radio network communication problems. 8-15 retrieving current status using Modbus Master feature. 9-14 auxiliary analog inputs. 9-2 SAM functions. 14-5 main board I/O. 5-2 slave devices assigning numbers for Modbus Master feature. 11-1 startup operation modes. 1-4 temperature configuration for AGA 3. 5-6 transmitter jumper configuration. 9-7 PCP functions. 16-2 SamScreen Terminal emulator interface program. 6-9 Index-8 Revision 1. 8-15 configuring a register addresses and values. 8-31 settling period time allowed. 8-5 Timed mode. 5-11 time and date setting. 3-3 serial communications. 5-11 shorthand access method for selecting options. 9-26 specifying a type for Modbus Master feature. 5-10 site selection for system installation.

A-4 states not observed. 5-15 terminals and terminal strips. 5-14 stepdown transformer to SAM PCP Controller. 8-28 using the operator interface menus. 5-6 typical components in PCP system. 5-18 proper cable shielding. 5-17 Hall-Effect transducers. 5-8 wiring specifications. 5-14 stepdown transformer to motor starter panel. 9-4 states involved in downtime. 2-6 violation enable/disable operation. 5-8 writing logic expressions. 6-3 VSD generic drive configuration requirements. A-4 states involved in malfunctions. 5-12 electro mechanical relay. 16-18 user password setting. 9-4 state currently displayed. 7-20 well states elapsed time in current state. 6-10 typical wiring diagram. 5-2 units of measurement used for accumulators. 8-99 reference speed input programming. 5-11 typical field wiring diagram. 8-43 for production status. 8-31 wedge meter parameter configuration. 4-2 parameter configuration. 6-10 optional hardware parts. 5-16 motor control relay. 8-60 Yagi antenna site selection and positioning. 5-10 upgrading firmware version.00 Index-9 . 7-13 voltage power-up checking. A-2 wiring conduit. 5-18 voltage transmitter input configuration. 5-17 powerup-voltage checking. 8-38 for analog outputs. 5-13 recommended tools.Index turbine meter parameter configuration. 7-20 types of transmitter devices used. 5-10 proper grounding. 5-2 Issue Date: 1/18/08 Revision 1. 5-11 shielded cables. 8-50 for analog inputs. 5-11 stepdown transformer.

099.495. Texas 77031 Tel: 281. 1.6333 www. Suite 800 Houston.1100 Fax: 281.495.com Part No.Lufkin Automation 11375 W. Sam Houston Parkway South.lufkinautomation.00 1/08 .5028 Rev.