KUDU HPU Well Manager Hardware Manual

KUDU HPU Well Manager
Hardware Manual
Stand-alone and integrated controllers
Table of Contents
1 Legal................................................................................................................................................6
Information
2 Technical Support
................................................................................................................................................7
3 Safety................................................................................................................................................8
Information
4 About this Manual

................................................................................................................................................11
5 Cybersecurity
................................................................................................................................................13
6 Introducing the KUDU HPU Well Manager
................................................................................................................................................14
6.1 Installation
..........................................................................................................................................15
Overview
6.2 Environmental
..........................................................................................................................................16
Condition Ratings
6.3 Temperature
..........................................................................................................................................17
and Humidity Ranges
6.4 Equipment
..........................................................................................................................................17
Ratings
6.5 Understanding
..........................................................................................................................................18
the KUDU HPU Well Manager Measurement Units
7 The ................................................................................................................................................20
KUDU HPU Well Manager System Components
7.1 Part
..........................................................................................................................................20
Number Overview
7.2 KUDU
..........................................................................................................................................21
HPU Well Manager Panel Connections
8 Installing the Control Panel
................................................................................................................................................22
8.1 Required
..........................................................................................................................................22
Tools and Materials
8.2 Preparing
..........................................................................................................................................23
the Panel
8.3 Adding
..........................................................................................................................................23
a Communication Radio or Cellular Modem
9 Connecting to the Terminal Block
................................................................................................................................................25
9.1 Low
..........................................................................................................................................25
Flow Lite I/O
9.2 Low
..........................................................................................................................................28
Flow and High Flow I/O
9.3 KUDU
..........................................................................................................................................31
1 I/O
9.4 Spare
..........................................................................................................................................35
Analog Inputs
9.5 Analog
..........................................................................................................................................35
Outputs
10 Connecting Valves and the Valve Controller
................................................................................................................................................36
10.1 Connecting
..........................................................................................................................................36
a Valve Controller
11 Connecting and Configuring the Motor Controller
................................................................................................................................................37
2
11.1 Electric
..........................................................................................................................................37
Motor (ATS22)
11.2 Gas
..........................................................................................................................................37
Motor (TG410)
11.3 Generic
..........................................................................................................................................38
12 Connecting and Configuring Required Sensors and Other
................................................................................................................................................39
Devices
12.1 Connecting
..........................................................................................................................................39
the Modbus I/O
12.1.1 Reconfiguring the ATS22 Softstarter to Accept Modbus
.............................................................................................................................40
Communications
12.2 Installing
..........................................................................................................................................41
Analog Sensors
12.3 Installing
..........................................................................................................................................41
Digital Sensors
12.4 Installing
..........................................................................................................................................41
the Modbus Sensors
12.5 Confirming
..........................................................................................................................................42
Sensor Readings
12.6 Grounding
..........................................................................................................................................42
the Sensors
12.7 Well
..........................................................................................................................................42
Pressure Sensors
12.8 Well
..........................................................................................................................................42
Flow Meters
12.9 Hydraulic
..........................................................................................................................................43
Fluid Sensors
12.10 Presco
..........................................................................................................................................43
Sensors
12.11 Optional
..........................................................................................................................................44
Sensors
12.12 Spare
..........................................................................................................................................44
Digital Inputs
12.13 Spare
..........................................................................................................................................44
Analog Sensors
12.14 Optional
..........................................................................................................................................45
Devices
12.14.1 Emergency
.............................................................................................................................45
Shutdown Device
12.14.2 Well
.............................................................................................................................45
A Run Status
12.14.3 Well
.............................................................................................................................46
B Run Status
12.14.4 Start
.............................................................................................................................46
Warning Indicator
13 Connecting the Heater Kit

................................................................................................................................................48
14 Connecting Power and Ground to the Panel
................................................................................................................................................49
14.1 Connecting
..........................................................................................................................................50
Power to a Gas Panel
14.2 Connecting
..........................................................................................................................................50
Power to an Electrical Panel
15 Completing the KUDU HPU Well Manager Installation
................................................................................................................................................52
16 Servicing and Maintaining the KUDU HPU Well Manager
................................................................................................................................................53
16.1 Changing
..........................................................................................................................................54
the Panel Fuses
16.2 Inspecting
..........................................................................................................................................55
the Panel Seal
3
16.3 Shading
..........................................................................................................................................55
the Magelis HMI
17 Appendix A - Installation Checklist
................................................................................................................................................56
17.1 Preparing
..........................................................................................................................................56
to Install the KUDU HPU Well Manager
4
KUDU HPU Well Manager Hardware Manual
Version 3.02.0 | © Schlumberger 2015 - 2020 5

Legal Information KUDU HPU Well Manager Hardware Manual
1 Legal Information
The information provided in this documentation contains general descriptions and/or technical
characteristics of the performance of the products contained herein. This documentation is not
intended as a substitute for and is not to be used for determining suitability or reliability of these
products for specific user applications. It is the duty of any such user or integrator to perform the
appropriate and complete risk analysis, evaluation and testing of the products with respect to the
relevant specific application or use thereof. Neither KUDU nor any of its affiliates or subsidiaries shall
be responsible or liable for misuse of the information contained herein. If you have any suggestions for
improvements or amendments or have found errors in this publication, please notify us.
No part of this document may be reproduced in any form or by any means, electronic or mechanical,
including photocopying, without express written permission of KUDU.
All pertinent state, regional, and local safety regulations must be observed when installing and using
this product. For reasons of safety and to help ensure compliance with documented system data, only
the manufacturer should perform repairs to components.
Copyright Notice
Copyright © 2020 Schlumberger. All rights reserved.
This work contains the confidential and proprietary trade secrets of Schlumberger and may not be
copied or stored in an information retrieval system, transferred, used, distributed, translated or
retransmitted in any form or by any means, electronic or mechanical, in whole or in part, without the
express written permission of the copyright owner.
Trademarks & Service Marks
Schlumberger, the Schlumberger logotype, and other words or symbols used to identify the products
and services described herein are either trademarks, trade names or service marks of Schlumberger
and its licensors, or are the property of their respective owners. These marks may not be copied,
imitated or used, in whole or in part, without the express prior written permission of Schlumberger. In
addition, covers, page headers, custom graphics, icons, and other design elements may be service
marks, trademarks, and/or trade dress of Schlumberger, and may not be copied, imitated, or used, in
whole or in part, without the express prior written permission of Schlumberger. Other company,
product, and service names are the properties of their respective owners.
An asterisk (*) is used throughout this document to designate a mark of Schlumberger.
Security Notice
The software described herein is configured to operate with at least the minimum specifications set
out by Schlumberger. You are advised that such minimum specifications are merely
recommendations and not intended to be limiting to configurations that may be used to operate the
software. Similarly, you are advised that the software should be operated in a secure environment
whether such software is operated across a network, on a single system and/or on a plurality of
systems. It is up to you to configure and maintain your networks and/or system(s) in a secure manner.
If you have further questions as to recommendations regarding recommended specifications or
security, please feel free to contact your local Schlumberger representative.
6 Version 3.02.0 | © Schlumberger 2015 - 2020

KUDU HPU Well Manager Hardware Manual Technical Support
2 Technical Support
Questions and requests related to any part of this documentation can be directed to the KUDU
support center.
Contact your local KUDU representative or visit our website to find a location near you. All information
is considered accurate and up to date at time of printing. KUDU reserves the right to amend the
contents of this document at any time. KUDU does not warranty manufacturers claims.
kudupump.com

Safety Information KUDU HPU Well Manager Hardware Manual
3 Safety Information
Important
Read these instructions carefully, and look at the equipment to become familiar w ith the
device before trying to install, operate, or maintain it. The follow ing special messages may
appear throughout this documentation or on the equipment to w arn of potential hazards or to
call attention to information that clarifies or simplifies a procedure.
The addition of this symbol to a Danger or Warning safety label indicates

that an electrical hazard exists, which will result in personal injury if the
instructions are not followed.
This is the safety alert symbol. It is used to alert you to potential personal
injury hazards. Obey all safety messages that follow this symbol to avoid
possible injury or death.
DANGER indicates a hazardous situation which, if not avoided,

w ill result in death or serious injury.
WARNING indicates a hazardous situation which, if not avoided,

can result in death or serious injury.
CAUTION indicates a hazardous situation which, if not avoided,

can result in minor or moderate injury.
NOTICE is used to address practices not related to physical

injury.
Please note
Electrical equipment should be installed, operated, serviced, and maintained only by qualified
personnel. No responsibility is assumed by KUDU for any consequences arising out of the use of this
material.
A qualified person is one who has skills and knowledge related to the construction, installation, and
operation of electrical equipment and has received safety training to recognize and avoid the hazards
involved.
Before you begin

Do not use this product on machinery lacking effective point-of-operation guarding. Lack of effective
point-of-operation guarding on a machine can result in serious injury to the operator of that machine.

KUDU HPU Well Manager Hardware Manual Safety Information
WARNING
EQUIPMENT OPERATION HAZARD
§ Verify that all installation and set up procedures have been completed
§ Before operational tests are performed, remove all blocks or other temporary holding means used
for shipment from all component devices
§ Remove tools, meters, and debris from equipment
Failure to follow these instructions can result in death or serious injury.
Follow all start-up tests recommended in the equipment documentation. Store all equipment
documentation for future reference.
Test all software in both simulated and real environments.
Verify that the completed system is free from all short circuits and grounds, except those grounds
installed according to local regulations (according to the National Electrical Code in the U.S.A, for
instance). If high-potential voltage testing is necessary, follow recommendations in equipment
documentation to help prevent accidental equipment damage.
Operations and adjustments

The following precautions are from the NEMA Standards Publication ICS 7.1 (English version prevails):
§ Regardless of the care exercised in the design and manufacture of equipment or in the selection and
ratings of components, there are hazards that can be encountered if such equipment is improperly
operated
§ It is sometimes possible to misadjust the equipment and thus produce unsatisfactory or unsafe
operation
· Always use the manufacturer’s instructions as a guide for functional adjustments
· Personnel who have access to these adjustments should be familiar with the equipment
manufacturer’s instructions and the machinery used with the electrical equipment
§ Only those operational adjustments actually required by the operator should be accessible to the
operator
· Access to other controls should be restricted to prevent unauthorized changes in operating
characteristics.

Safety Information KUDU HPU Well Manager Hardware Manual
Acceptable use
WARNING
UNACCEPTABLE USE
§ Do not use this solution as an integral part of a safety system
§ The components in this solution are not safety products
CAUTION
EQUIPMENT OPERATION HAZARD
§ When devices are used for applications with technical safety requirements, the relevant
instructions must be followed
§ Use only KUDU software or approved software with KUDU hardware products
Failure to follow these instructions can result in minor or moderate injury.
Important notices
DANGER
HAZARD OF ELECTRIC SHOCK
§ Installation, adjustment, repair, and maintenance must be performed by qualified personnel
§ Ensure power has been removed before servicing.
Failure to follow these instructions w ill result in death or serious injury.

KUDU HPU Well Manager Hardware Manual About this Manual
4 About this Manual
Audience
This manual describes how to install the KUDU HPU Well Manager Hydraulic Pumping Unit (HPU)
hardware. It is written for people who already understand:
§ The physical set up of the well, including the hydraulic system, pump, rods, prime mover, and sensor
operation
§ The characteristics and relationships among flow, pressure, temperature and signal noise in the well
§ The mix of oil, water, gas and solids typically found in the well and how this mix affects pump
operation and well production
Document scope
This manual describes:
§ The tools needed to install the KUDU HPU Well Manager
§ The steps required to connect devices, such as sensors and motor controllers, to the KUDU HPU Well
Manager
§ The acceptable temperature and humidity ranges for using the KUDU HPU Well Manager
Validity note
This document is valid for the KUDU HPU Well Manager Version 3.02.0.
Product related Information
WARNING
UNINTENDED EQUIPMENT OPERATION
§ The application of this product requires expertise in the design and programming of control
systems.
§ Only persons with such expertise are allowed to program, install, alter, and apply this product.
§ Follow all local and national safety codes and standards.
Related documents
The KUDU HPU Well Manager Configuration Manual describes how to use a Magelis human machine
interface (HMI) to configure the KUDU HPU Well Manager operation. It describes:
§ How to start the KUDU HPU Well Manager and use the human machine interface (HMI)
§ The factors you need to consider before configuring the KUDU HPU Well Manager

About this Manual KUDU HPU Well Manager Hardware Manual
§ The parameters available for drive, sensor, protection and control method configuration
§ How to view and manage alarms and events
§ How to view and configure trend information
§ The different types of screens that are available
§ How to change passwords
§ The Magelis HMI configuration settings that are available
§ The Modbus register and DNP points number used for each Magelis HMI screen parameter

KUDU HPU Well Manager Hardware Manual Cybersecurity
5 Cybersecurity
Cybersecurity is a branch of network administration that addresses attacks on or by computer
systems and through computer networks that can result in accidental or intentional disruptions. The
objective of cybersecurity is to help provide increased levels of protection for information and physical
assets from theft, corruption, misuse, or accidents while maintaining access for intended users.
No single cybersecurity approach is adequate. A defense-in-depth approach is recommended. This

approach layers the network with security features, appliances, and processes. The basic
components of this approach are:
§ Risk assessment: A systematic security analysis of the environment and related systems.
§ A security plan built on the results of the risk assessment
§ A multi-phase training campaign
§ Network separation and segmentation: Physical separation of the control network from other networks,
and the division of the control network itself into segments and security zones.
§ System Access Control: Controlling access to the system with firewalls, authentication, authorization,
and other software means, and traditional physical security measures such as video surveillance,
fences, locked doors and gates, and locked equipment cabinets.
§ Device hardening: The process of configuring a device against communication-based threats. Device
hardening measures include disabling unused network ports, password management, access control,
and disabling unnecessary protocols and services.
§ Network monitoring and maintenance: An effective defense-in-depth campaign requires continual
monitoring and system maintenance to meet the challenge of new threats as they develop.
Contact us
For more information, refer to the Schneider Electric Cybersecurity Support Portal at
http://www.schneider-electric.com/b2b/en/support/cybersecurity/overview.jsp.
Additional Resources
Industrial Control Systems Cyber Emergency Response Team (ICS-CERT)
https://ics-cert.us-cert.gov
ICS-CERT Recommended Practices

https://ics-cert.us-cert.gov/Recommended-Practices
Center for Internet Security (CIS) Top 20 Critical Security Controls

https://www.cisecurity.org/cybersecurity-best-practices
FBI Cyber Crime

https://www.fbi.gov/investigate/cyber
Guide to Industrial Control Systems (ICS) Security

https://www.nist.gov/publications/guide-industrial-control-systems-ics-security
WaterISAC Water Security Network

https://www.waterisac.org

Introducing the KUDU HPU Well Manager KUDU HPU Well Manager Hardware Manual
6 Introducing the KUDU HPU Well Manager

The KUDU HPU Well Manager Hydraulic Pumping Unit (HPU) is an advanced pump-off controller for
automating a hydraulically-powered sucker rod pumping system. A hydraulic power unit consists of
one or two hydraulic pumps, hydraulic tank, cooling fan, heater, controls, and a prime mover (a motor
controller with a gas powered engine or an electric motor) to provide the power to move the pump(s).
The system uses load derived from cylinder pressure measurement and hydraulic fluid flow or a
position sensor as the basis for control to the system by issuing instructions to the system’s valves
through a valve controller and to the prime mover through a motor controller.
The KUDU HPU Well Manager can control one or two wells. The system may be configured and
monitored on site using the pre-programmed color touchscreen included with the KUDU HPU Well
Manager, or remotely using a custom developed SCADA system.
The KUDU HPU Well Manager system is made up of:

§ A Schneider Electric SCADAPack 535E Remote Terminal Unit (RTU) that manages operation of the
pump or pumps, manages the operation of the motor controller, reads the data provided by analog,
digital and Modbus sensors, and provides external control signals to optional devices such as an
annunciator.
§ A Schneider Electric Magelis human machine interface (HMI) panel that runs the KUDU HPU Well
Manager application. The Magelis HMI is the primary interface between you and the controller. The
KUDU HPU Well Manager application lets you view, configure and manage well operations.
§ A pre-wired front panel that includes a USB port, Ethernet port, and a power switch
Before commissioning the KUDU HPU Well Manager, you need to install the system’s pump or
pumps, prime mover, motor controller and other sensors.
DANGER
HAZARD OF ELECTRIC SHOCK, EXPLOSION, OR ARC FLASH
§ Ensure power has been removed before servicing.

KUDU HPU Well Manager Hardware Manual Introducing the KUDU HPU Well Manager
DANGER
ELECTRIC SHOCK HAZARD
§ Read and understand this manual and the manuals for your hydraulic pumping unit, prime mover,
and motor controllers before installing or operating the KUDU HPU Well Manager. Installation
adjustment, repair, and maintenance must be performed by qualified personnel.
§ The user is responsible for compliance with all international and national electrical code
requirements with respect to grounding and wiring of all equipment. Many motors and motor
controllers, including the printed circuit boards, operate at the line voltage. Do not touch. Use
only electrically-insulated tools.
§ Do not touch unshielded components or terminal strip screw connections with voltage present
DANGER
ELECTRIC SHOCK HAZARD
§ Apply appropriate personal protective equipment (PPE) and follow safe electrical work practices.
See NFPA 70E, CSA Z462, and OSHA 1910
§ Before servicing any KUDU HPU Well Manager components, read and understand the
documentation for that component
§ Install and close all covers before applying power or starting and stopping any KUDU HPU Well
Manager components
WARNING
Do not install or operate any equipment that appears damaged
6.1 Installation Overview
This manual contains instructions for installing and wiring a KUDU HPU Well Manager.
The gas panel includes additional hardware required for the control of a gas engine, such as a high
current fuse, 12 Vdc to 24 Vdc voltage converter, and a low voltage disconnect.
The system includes a 25 W heater.
For KUDU HPU Well Manager configuration instructions, see the KUDU HPU Well Manager
Configuration Manual.

Personnel performing a KUDU HPU Well Manager installation must be qualified to work on the
system’s hardware including the motor controller.
WARNING
§ The KUDU HPU Well Manager, including its on/off switch on the panel, is not intended to be used
as an emergency stop
§ Ensure that you are familiar with your pump system's emergency stop.
6.2 Environmental Condition Ratings
Although the KUDU HPU Well Manager is intended for use outdoors, it can be used indoors.
The panel meets the NEMA 4X standard.
Outdoor use
The equipment is designed to be safe for the extended environmental conditions listed below, as well
as the conditions in Temperature and Humidity Ranges 17 .
Condition Rating
Altitude Up to 2000 meters (6562 ft)
Ambient temperatures See Temperature and Humidity Ranges 17
Humidity Relative humidity above the levels specified in Temperature and Humidity
Ranges 17
Mains Supply voltage fluctuations up to ±10% of the nominal voltage
Indoor Use
The equipment is designed to be safe for the environmental conditions listed below.
Condition Rating
Altitude Up to 2000 meters (6562 ft)
Temperatures See Temperature and Humidity Ranges 17
Humidity Maximum relative humidity 80% for temperatures up to 31 °C (88 °F)

decreasing linearly to 50% relative humidity at 40 °C (104 °F)
Mains Supply voltage fluctuations up to ±10% of the nominal voltage
Transient overvoltages Typically present on the mains supply

Condition Rating
The normal level of transient overvoltages is impulse withstand

(overvoltage) category II of IEC 60364-4-443
Pollution Pollution Degree 2
6.3 Temperature and Humidity Ranges
WARNING
LOSS OF CONFIGURATION CONTROL
§ Storing and operating the Magelis HMI outside of its supported temperature ranges can render
the Magelis HMI unusable.
§ To help maintain access to the Magelis HMI configuration parameters:
· Store the Magelis HMI at temperatures between -20 °C and 60 °C
· Operate the Magelis HMI with a heater when temperatures are between -40 °C and 0 °C
· Do not operate the Magelis HMI at temperatures below -40 °C, even with a heater
· Do not operate the Magelis HMI at temperatures above 55 °C
The KUDU HPU Well Manager supports the following temperature ranges:
Configuration Operating Storage Relative Humidity

Temperature Range Temperature Range
Without a heater -20...55 °C (-4...131 ° -20...60 °C (-4...140 °F)0...90%

F)
With a heater -40...55 °C (-40...131 ° -40...60 °C (-40...140 ° 0...90%

F) F)
To extend the effective range, use external heating and cooling options, such as solar shading.
When the pump is configured, the KUDU HPU Well Manager can control the pump with the
SCADAPack 535E RTU outside the operating temperature range of the Magelis HMI.
6.4 Equipment Ratings
The KUDU HPU Well Manager panel equipment ratings are described below:
Prime Mover Supply Voltage Pow er Rating
Gas panel 12 Vdc 300 W
Electric panel 24 Vdc 288 W

6.5 Understanding the KUDU HPU Well Manager Measurement Units
The KUDU HPU Well Manager displays measurement values in imperial units.
NOTICE
§ Because the KUDU HPU Well Manager displays all measurement values in imperial units, you
may need to convert measurements to and from their metric equivalent
§ Verify that all values are entered in the appropriate measurement unit in the KUDU HPU Well
Manager
Failure to follow these instructions can result in equipment damage.
The following table summarizes the imperial measurement units used in the KUDU HPU Well Manager
and provides the metric conversion.
Measurement Imperial Measurement Unit Metric Conversion

Type
Area square inches (inches 2) 1 square inch (inches 2) = 6.452 square centimeters
(cm2)
Diameter inches (in) 1 inch (in) = 2.540 centimeters (cm)
Displacement cubic inches (in3) 1 cubic inch (in3) = 16.387 cubic centimeters (cm3)
Energy kilowatt hours (kWh) 1 kWh = 3.6 x 106 J, 1 kWh = 3412 Btu
consumption
Flow barrels per day (bbl/d) 1 barrel per day (bbl/d) = 0.159 cubic meters per
day (m3/d)
barrels per 100 revolutions per
minute (bbl/100rpm) 1 barrel per 100 revolutions per minute (bbl/100rpm)
= 0.159 cubic meters per 100 revolutions per minute
(m3/100rpm)
Length/Depth inches (in), feet (ft) 1 inch (in) = 2.540 centimeters (cm), 1 foot (ft) =
0.3048 meters (m)
Power horsepower (hp) 1 horsepower (hp) = 0.745699872 kilowatts (kW)
Pressure pounds per square inch (psi) 1 pound per square inch (psi) = 6.894 kilopascals
(kPa)
Speed inches per second (in/s) 1 in/s = 0.0254 meters per second (m/s)
Temperature degrees Fahrenheit (°F) A change of 1 degree Celsius (°C) = a change of

1.8 degrees Fahrenheit (°F)
A change of 1 degree Fahrenheit (°F) = a change of
0.55 degrees Celsius (°C)
Volume US barrels (bbl) 1 US barrel = 158.9873 liters (L)

Measurement Imperial Measurement Unit Metric Conversion

Type
One thousand cubic feet of 1000 cubic feet of natural gas (MCF) = 28.3168
natural gas (MCF) cubic meters (m³)
Weight pounds (lbs) 1 pound = 4.4482 newtons (N)

The KUDU HPU Well Manager System Components KUDU HPU Well Manager Hardware Manual
7 The KUDU HPU Well Manager System Components

The following is a list of some of the electric hardware found on the KUDU HPU Well Manager panel
with which the skid and control system needs to interface.
Device Device Details
RTU SCADAPack 535E pre-programmed with the KUDU HPU Well

Manager application
Magelis HMI Magelis HMI (human machine interface) 5.7 inch color touch-
screen panel pre-programmed with the KUDU HPU Well
Manager application
Valve Controller CAN-IO 14 pre-programmed with the KUDU HPU Well Manager
firmware
Turbine Meter Included with the skid
Proximity Sensors Included with the skid
Motor Controller ATS22 Softstarter (electric)

Dynagen TG410 (gas)
Generic
Unused digital inputs (DI) and analog inputs (AI) can be configured as spare protection inputs and/or
for data collection.
The system supports up to four spare Modbus/RTU devices to be configured as spare protection
inputs and/or for data collection.
7.1 Part Number Overview
Option part, spare part, and accessory part numbers:
Part Number Controller Level Type Supported Motor

Controllers
TBUJ003-0000 KUDU HPU Well Manager, Low Flow Lite, Electric Generic
ATS22
TBUJ013-0000 KUDU HPU Well Manager, Low Flow Lite, Gas Generic
Dynagen TG410
TBUJ103-0000 KUDU HPU Well Manager, Low Flow, High Flow, Generic
Electric
ATS22
TBUJ113-0000 KUDU HPU Well Manager, Low Flow, High Flow, Gas Dynagen TG410

KUDU HPU Well Manager Hardware Manual The KUDU HPU Well Manager System Components
Part Number Spare Part Type
TBUH293033 KUDU HPU Well Manager, SCADAPack (Pre-loaded)
TBUH293034 KUDU HPU Well Manager Display (Pre-loaded Magelis Display)
TBUH293035 KUDU HPU Well Manager CAN-IO 14 Controller (Pre-loaded)
TBUH293038 KUDU HPU Well Manager CAN-IO 14+ Cable
Part Number Accessory Part Type
TBUH293023 KUDU HPU Well Manager Heater Kit
TBUX297319 Analog Input Module Model 5506
7.2 KUDU HPU Well Manager Panel Connections
The following sections describe the KUDU HPU Well Manager panel connections.
Front panel
The following controls, indicators, and connections are included on the front panel:
§ Magelis HMI
· Provides a touch screen interface that gives you access to the KUDU HPU Well Manager
functionality and status
§ USB Port
· Enables you to transfer data from the KUDU HPU Well Manager to a USB drive
§ Ethernet port
· Enables you to connect the KUDU HPU Well Manager to the Ethernet port on your computer
NOTICE
RISK OF EQUIPMENT DAMAGE
§ When power is cycled, wait for at least 10 seconds before restoring power to the KUDU HPU
Well Manager.
§ Switching the power OFF and ON quickly can damage the unit.
§ Pow er Sw itch
· Enables power to the panel

Installing the Control Panel KUDU HPU Well Manager Hardware Manual
8 Installing the Control Panel

Typically, the KUDU HPU Well Manager panel is installed on the KUDU HPU Well Manager skid prior
to delivery.
Before beginning the installation of the KUDU HPU Well Manager panel, ensure that you have the
materials listed in Required Tools and Materials 22 .
To install the KUDU HPU Well Manager panel:
1. Disconnect power to the skid including the KUDU HPU Well Manager panel, and verify that the power
has been disconnected.
2. Mount the panel to the position indicated on your skid drawing.
3. Connect the motor controller, valves, and sensors to the corresponding terminal blocks.
See KUDU HPU Well Manager Panel Connections 21 .
4. If required, route the wiring into the panel for optional connections, such as run status, start warning,
or remote electrostatic discharge.
See Connecting to the Terminal Block 25 .
5. To avoid confusing the cabling, tag the cables.
6. Install any devices, such as a radio or modem or other devices employing the optional connections.
See Adding a Communication Device or Radio 23 .
7. Apply silicon or other sealant around any panel openings.
8. Wire the panel to ground.
9. Reconnect power to the skid and verify that power has been restored.
10. Test the installation of the KUDU HPU Well Manager.
See Completing the KUDU HPU Well Manager Installation 52 .
8.1 Required Tools and Materials
The tools, wires, and other components required for a KUDU HPU Well Manager installation, but not
included in the KUDU HPU Well Manager kit are listed below:
§ Slotted screwdrivers
§ Nut driver
§ Phillips screwdriver
§ Adjustable wrenches
§ Silicon or other sealant
§ UV-resistant, outdoor-rated cable ties, cable thimbles, eyelets, beam clams or other cable-securing
devices
§ Cord grip fittings

KUDU HPU Well Manager Hardware Manual Installing the Control Panel
§ 18 and 20 AWG (0.82 to 0.963 and 0.507 to 0.616 mm2) 300 V wire (electric panel)
§ 10 AWG (5.26 to 6.0 mm2) 300 V wire (gas panel)
§ Wire cutter and wire stripper
§ Ethernet cable
Other components that are not supplied in the KUDU HPU Well Manager kit that may be needed:
§ Spare din rail (may be needed if no more rail space is available in drive cabinet) and mounting
hardware
§ Drill with suitable bits (if it becomes necessary to drill wiring access holes in the panel)
8.2 Preparing the Panel
To prepare the panel for installation:
1. Mount the panel using the mounting kit.
2. If needed, drill a hole or holes in the panel to run wiring for the drive and sensors and insert the
grommets.
3. Route the wiring into the panel and connect the wiring according to the instructions in Connecting to
the Terminal Block 25 .
4. Apply silicon or other sealant around the opening.
5. Wire to ground.
8.3 Adding a Communication Radio or Cellular Modem
The panel provides a communication device mounting plate (MTL-001) for mounting a communication
device, such as a radio or cellular modem.
The panel includes a 24 Vdc 2 A fuse (Fuse 4) protected connection for the communication device.
NOTICE
Ensure that you have applied appropriate network security to prevent unauthorized access to the
KUDU HPU Well Manager.
To install the communication device:
2. Remove the communication device mounting plate from the panel.
3. If needed, drill the holes required for mounting the device into the mounting plate.
4. Mount the communication device on to the mounting plate.

Installing the Control Panel KUDU HPU Well Manager Hardware Manual
5. Replace the mounting plate with the communication device into the panel.
6. Install any additional devices, such as lightening arrestors and antennae.
7. On the SCADAPack 535E RTU, connect the device to a power source and to Eth3.
A pre-drilled hole is included in the panel for this wiring.
8. Follow your radio or modem's instructions to configure it to communicate with the KUDU HPU Well
Manager.
9. Use the Magelis HMI to configure your Eth3 settings, as required.
10. Reconnect power to the panel.

KUDU HPU Well Manager Hardware Manual Connecting to the Terminal Block
9 Connecting to the Terminal Block

The following sections describe the terminal block connections:
§ Low Flow Lite I/O 25
§ Low Flow and High Flow I/O 28
§ KUDU 1 I/O 31
§ Spare Analog Inputs 35
§ Analog Outputs 35
9.1 Low Flow Lite I/O
The standard Low Flow Lite requires only the I/O on the SCADAPack 535E RTU's 6601. The Low Flow
Lite is capable of supporting an additional 5506, if required.
Description Device Physical Designatio Notes Type

Terminal n
Swashplate AngleValve Controller C3 CANIO-0 Controls up stroke Coil 12/24 Vdc
Pressure Control Valve Controller C2 CANIO-1 Controls up stroke Coil 12/24 Vdc
Well A Down Valve Controller C1 CANIO-2 Controls down stroke Coil 12/24 Vdc
Reserved Valve Controller B1 CANIO-3 Controls down stroke Coil 12/24 Vdc
Cooler Fan SpeedValve Controller B8 CANIO-4 Controls down stroke Coil 12/24 Vdc
Reserved Valve Controller C8 CANIO-5 Controls down stroke Coil 12/24 Vdc
Well A Up Valve Controller C7 CANIO-6 Controls speed of motion Coil 12/24 Vdc
Reserved Valve Controller C6 CANIO-7 Controls speed of motion Coil 12/24 Vdc
Hydraulic Oil SCADAPack AI-1 AI-01 Protection 4...20 mA

Level (Tank) 535E RTU

Temperature 535E RTU
(Tank)
Well A Hydraulic SCADAPack AI-3 AI-03 4...20 mA

Pressure 535E RTU
Reserved SCADAPack AI-4 AI-04 4...20 mA

535E RTU
Warm-up SCADAPack AI-5 AI-05 Optional Load Cell 4...20 mA

Pressure Sensor 535E RTU
Pump Pressure SCADAPack AI-6 AI-06 Protection (optional) 4...20 mA

535E RTU
Reserved 5506-1 AI-0 AI-10

Connecting to the Terminal Block KUDU HPU Well Manager Hardware Manual

Terminal n
Reserved 5506-1 AI-1 - AI-3 AI-11 - AI-13
Flow Line 5506-1 AI-4 AI-14 Protection (optional)

Pressure
Reserved 5506-1 AI-5 - AI-6 AI-15 - AI-16
Ambient 5506-1 AI-7 AI-17 Protection (optional)

Temperature
Well A Casing 5506-2 AI-0 AI-20 Protection (optional) 4...20 mA

Pressure
Well A Tubing 5506-2 AI-1 AI-21 Protection (optional) 4...20 mA

Pressure

Temperature

Temperature
Pump Casing 5506-2 AI-4 AI-24 Protection (optional) 4...20 mA

Temperature
System Spare AI 5506-2 AI-5 AI-25 Protection (optional) 4...20 mA
Well A Spare AI 5506-2 AI-6 AI-26 Protection (optional) 4...20 mA
Well A Turbine SCADAPack DI-1 DI-01 Position Flow Counts

Counter 535E RTU
Reserved SCADAPack DI-2 DI-2

535E RTU
Hydraulic Oil SCADAPack DI-3 DI-3 Protection (optional) User Defined

Level Switch 535E RTU
Hydraulic Oil SCADAPack DI-4 DI-4 Protection (optional) User Defined

Switch
Well A Digital SCADAPack DI-5 DI-5 Protection (optional) User Defined

Spare 535E RTU

535E RTU
In-Tank Filter SCADAPack DI-7 DI-7 Protection (optional)

535E RTU
Roots Meter SCADAPack DI-8 DI-08 Measures gas engine fuel

535E RTU consumption (optional)


Terminal n
Auxiliary SCADAPack DI-9 DI-09 Protection (optional) 0: Normal

Shutdown 535E RTU
(Presco Well A) 1: Stop Well
Reserved SCADAPack DI-10 DI-10 Protection (optional) 0: Normal

535E RTU
1: Stop Well
Remote ESD SCADAPack DI-11 DI-11 Protection (optional) 0: Normal

535E RTU
1: Stop Prime
Mover
High Pressure SCADAPack DI-12 DI-12 Protection (optional) 0: Normal

Filter 75% 535E RTU
1: Stop Prime
Mover
Prime Mover SCADAPack DI-13 DI-13 0: Prime Mover

Ready 535E RTU Off/Disable
1: Can Start
Prime Mover
High Pressure SCADAPack DI-14 DI-14 0: Normal

Filter 100% 535E RTU
1: Stop Prime
Mover
Bottom of SCADAPack DI-15 DI-15 0: Normal

Proximity Switch 535E RTU
Stroke 1: Proximity
Active
Top of Proximity SCADAPack DI-16 DI-16 0: Normal

Switch Stroke 535E RTU
1: Proximity
Active
Well A Run SCADAPack DO-1 DO-1 0: Stop/Alarm

Status Indicator 535E RTU
1: Normal
Reserved SCADAPack DO-2 DO-2

535E RTU
Prime Mover Run SCADAPack DO-3 DO-3 0: Prime Mover

Permissive 535E RTU Off
1: Run
Permissive
Start Warning SCADAPack DO-4 DO-4 0: Normal

535E RTU
1: Engine is
starting


Terminal n
Low Flow Lite SCADAPack DO-5 DO-5 0: Fan not

Load Sensor 535E RTU running
1: Fan running
Low Flow Lite SCADAPack DO-6 DO-6 0: Deactivated

Fan Control Relay 535E RTU
1: Pressure
Sense Valve
Activated
Low Flow Lite SCADAPack DO-7 DO-7 0: Inactive

Downstroke 535E RTU
1: Stroke Down
Low Flow Lite SCADAPack DO-8 DO-8 0: Inactive

Upstroke 535E RTU
1: Stroke Up
9.2 Low Flow and High Flow I/O
The standard low flow and high flow system requires only the I/O on the SCADAPack 535E RTU's
6601. The low flow and high flow system is capable of supporting an additional 5506, if required.
Description Device Physical Designation Notes Type

Terminal
Swashplate Valve Controller C3 CANIO-0 Controls up stroke Coil 12/24 Vdc

Angle
Pressure Control Valve Controller C2 CANIO-1 Controls up stroke Coil 12/24 Vdc
Well A Down Valve Controller C1 CANIO-2 Controls down stroke Coil 12/24 Vdc
Well B Down Valve Controller B1 CANIO-3 Controls down stroke Coil 12/24 Vdc
Cooler Fan Valve Controller B8 CANIO-4 Controls down stroke Coil 12/24 Vdc
Speed
Reserved Valve Controller C8 CANIO-5 Controls down stroke Coil 12/24 Vdc
Well A Up Valve Controller C7 CANIO-6 Controls speed of Coil 12/24 Vdc

motion
Well B Up Valve Controller C6 CANIO-7 Controls speed of Coil 12/24 Vdc

motion


(Tank)


Terminal
Well A Hydraulic SCADAPack AI-3 AI-03 4...20 mA

Pressure 535E RTU
Well B Hydraulic SCADAPack AI-4 AI-04 4...20 mA

Pressure 535E RTU
Warm-up SCADAPack AI-5 AI-05 Protection (optional) 4...20 mA

Pressure Sensor 535E RTU
Pump Pressure SCADAPack AI-6 AI-06 Protection (optional) 4...20 mA

535E RTU
Analog Well B 5506-1 AI-0 AI-10 Protection (optional) 4...20 mA

Spare
Well B Casing 5506-1 AI-1 AI-11 Protection (optional) 4...20 mA

Pressure
Well B Tubing 5506-1 AI-2 AI-12 Protection (optional) 4...20 mA

Pressure
Well B Casing 5506-1 AI-3 AI-13 Protection (optional) 4...20 mA

Temperature
Flow Line 5506-1 AI-4 AI-14 Protection (optional) 4...20 mA

Pressure
Well B Load Cell 5506-1 AI-6 AI-16 Load Cell (optional) 4...20 mA
Ambient 5506-1 AI-7 AI-17 Protection (optional) 4...20 mA

Temperature

Pressure

Pressure

Temperature

Temperature
Pump Casing 5506-2 AI-4 AI-24 Protection (optional) 4...20 mA

Temperature
System Spare AI 5506-2 AI-5 AI-25 Protection (optional) 4...20 mA
Well A Spare AI 5506-2 AI-6 AI-26 Protection (optional) 4...20 mA
Reserved 5506-2 AI-7 AI-27
Well A Turbine SCADAPack DI-1 DI-01 Position (optional) Flow Counts

Counter 535E RTU


Terminal
Well B Turbine SCADAPack DI-2 DI-02 Position (optional) Flow Counts

Counter 535E RTU
Hydraulic Oil SCADAPack DI-3 DI-03 Protection (optional)

Level Switch 535E RTU
Hydraulic Oil SCADAPack DI-4 DI-04 Protection (optional)

Switch
Well A Digital SCADAPack DI-5 DI-05 Protection (optional) User

Spare 535E RTU Configured
Well B Digital SCADAPack DI-6 DI-06 Protection (optional) User

Spare 535E RTU Configured
In-Tank Filter SCADAPack DI-7 DI-07 Protection (optional)

535E RTU
Roots Meter SCADAPack DI-8 DI-08 Measures gas engine

535E RTU fuel consumption
(optional)
Aux Shutdown SCADAPack DI-9 DI-09 Protection (optional) 0: Normal

(Presco Well A) 535E RTU
1: Stop Well A
Aux Shutdown SCADAPack DI-10 DI-10 Protection (optional) 0: Normal

(Presco Well B) 535E RTU
1: Stop Well B
Remote ESD SCADAPack DI-11 DI-11 Protection (optional) 0: Normal

535E RTU
1: Stop Prime
Mover

Filter 75% 535E RTU
1: Stop Prime
Mover
Prime Mover SCADAPack DI-13 DI-13 0: Prime Mover

1: Can Start
Prime Mover

Filter 100% 535E RTU
1: Stop Prime
Mover
Bottom of SCADAPack DI-15 DI-15 0: Normal

Proximity Switch 535E RTU
Stroke (Well A) 1: Proximity
Active


Terminal
Top of Proximity SCADAPack DI-16 DI-16 0: Normal

Switch Stroke 535E RTU
(Well A) 1: Proximity
Active

1: Normal
Well B Run SCADAPack DO-2 DO-2 0: Stop/Alarm

1: Normal

1: Run
Permissive

535E RTU
1: Engine is
starting

535E RTU

535E RTU
Heater Valve SCADAPack DO-7 DO-7 0: Normal

535E RTU
1: Bypass
Hydraulic Fluid
Heater
Fan SCADAPack DO-8 DO-8 0: Normal

535E RTU
1: Hydraulic
Fluid Cooling
Fan
9.3 KUDU 1 I/O
The standard KUDU 1 requires only the I/O on the SCADAPack 535E RTU's 6601. The KUDU-1 is
capable of supporting an additional 5601, if required.

Terminal
Upstroke Dual Valve Controller C3 C3 [CANIO-0] [Controls up Coil 12/24 Vdc

Output #1 stroke]
[swashplate]


Terminal
Upstroke Dual Valve Controller C2 C2 [CANIO-1] [Controls Coil 12/24 Vdc

Output #2 upstroke]
[pressure
control]
Well A Valve Controller C1 C1 [CANIO-2] [Controls down Coil 12/24 Vdc

Downstroke [well stroke]
a down]
Well B Valve Controller B1 B1 [CANIO-3] [Controls down Coil 12/24 Vdc

Downstroke [well stroke]
b down]
Well A Valve Controller B8 B8 [CANIO-4] [Controls down Coil 12/24 Vdc

Downstroke stroke]
(mirror) [Fan
Speed/Warmup]
Well B Valve Controller C8 C8 [CANIO-5] [Controls down Coil 12/24 Vdc

Downstroke stroke]
(mirror)
[Reserved]
Not Used [well a Valve Controller C7 C7 [CANIO-6] [Controls speed Coil 12/24 Vdc
up] of motion]
Not Used [well b Valve Controller C6 C6 [CANIO-7] [Controls speed Coil 12/24 Vdc
up] of motion]
Hydraulic Oil SCADAPack AI1 AI-01 Protection 4…20 mA

Hydraulic Oil SCADAPack AI2 AI-02 Protection 4…20 mA

(Tank)
Well A Hydraulic SCADAPack AI3 AI-03 4…20 mA

Pressure 535E RTU
Well B Hydraulic SCADAPack AI4 AI-04 4…20 mA

Pressure 535E RTU
Well A Load Cell SCADAPack AI5 AI-05 Optional Load 4…20 mA

535E RTU Cell
Pump Pressure SCADAPack AI6 AI-06 4…20 mA

(not used) 535E RTU
Analog Spare 5601 AI10 AI-10 Protection 4…20 mA

Well B (optional)
Well B Casing 5601 AI11 AI-11 Protection 4…20 mA

Pressure (optional)


Terminal
Well B Tubing 5601 AI12 AI-12 Protection 4…20 mA

Pressure (optional)
Well B Casing 5601 AI13 AI-13 Protection 4…20 mA

Temperature (optional)
Flow Line 5601 AI14 AI-14 Protection 4…20 mA

Pressure (optional)
Well B Load Cell 5601 AI16 AI-16 Load Cell 4…20 mA

(optional)
Ambient 5601 AI17 AI-17 Protection 4…20 mA

Well A Casing 5601 AI20 AI-20 Protection 4…20 mA

Pressure (optional)
Well A Tubing 5601 AI21 AI-21 Protection 4…20 mA

Pressure (optional)
Well A Casing 5601 AI22 AI-22 Protection 4…20 mA

Well A Tubing 5601 AI23 AI-23 Protection 4…20 mA

Pump Casing 5601 AI24 AI-24 Protection 4…20 mA


System (optional)

Well A (optional)
Reserved 5601 AI27 AI-27
Well A Turbine SCADAPack DI1 DI-01 Position 4…20 mA

Counter 535E RTU (optional)
Well B Turbine SCADAPack DI2 DI-02 Position 4…20 mA

Counter 535E RTU (optional)
Reserved SCADAPack DI3 DI-03

535E RTU
Spare System DISCADAPack DI4 DI-04 Protection User Defined

535E RTU (optional)
Well A Digital SCADAPack DI5 DI-05 Protection User Defined

Spare 535E RTU (optional)
Well B Digital SCADAPack DI6 DI-06 Protection User Defined

Spare 535E RTU (optional)


Terminal
In-Tank Filter SCADAPack DI7 DI-07 Protection

535E RTU (optional)
Aux Shutdown SCADAPack DI9 DI-09 Protection 0: Normal

(Presco A) 535E RTU (optional) 1: Stop Well
Aux Shutdown SCADAPack DI10 DI-10 Protection 0: Normal

(Presco B) 535E RTU (optional) 1: Stop Well
Remote ESD SCADAPack DI11 DI-11 Protection 0: Normal

535E RTU (optional) 1: Stop Prime
Mover
High Pressure SCADAPack DI12 DI-12 Protection 0: Normal

Filter 75% 535E RTU (optional) 1: Stop Prime
Mover
Prime Move SCADAPack DI13 DI-13 0: Prime Mover

1: Can Start
Prime Mover

535E RTU
Bottom of SCADAPack DI15 DI-15 0: Normal

Proximity Switch 535E RTU 1: Proximity
Stroke Active
Top of Proximity SCADAPack DI16 DI-16 0: Normal

Switch Stroke 535E RTU 1: Proximity
Active

Status Indicator 535E RTU 1: Normal
Well B Run SCADAPack DO-2 DO-02 0: Stop/Alarm

Status Indicator 535E RTU 1: Normal

1: Run
Permissive

535E RTU 1: Engine is
starting

535E RTU
Fan Control SCADAPack DO-6 DO-06

Relay 535E RTU

9.4 Spare Analog Inputs
Spare analog inputs (AI) can be configured for sensors and protections section. When used as spares,
the AI are used for sensor devices including support for protections and trends. The name of the
parameter monitored on a spare analog input is user-configurable.
Some examples of how you can define analog inputs are listed below:
§ Well A Production Temperature
§ Well B Production Temperature
§ Well A Production Rate
§ Well B Production Rate
§ Tank Level
§ Battery Voltage
§ Battery Ammeter
9.5 Analog Outputs
Analog outputs (AO) are not used by the KUDU HPU Well Manager.

Connecting Valves and the Valve Controller KUDU HPU Well Manager Hardware Manual
10 Connecting Valves and the Valve Controller

The KUDU HPU Well Manager, when connected to a low flow or high flow hydraulic system, uses a
valve controller with custom developed firmware installed on it to control the operation of the hydraulic
valves using its analog I/O. When connected to a Low Flow Lite system, the KUDU HPU Well
Manager does not use a valve controller.
The KUDU HPU Well Manager does not work with a valve controller that does not have the KUDU HPU
Well Manager specific firmware installed on it.
10.1 Connecting a Valve Controller
The valve controller is pre-installed in the KUDU HPU Well Manager panel. If you are replacing a valve
controller, consult the panel drawing for directions on how to connect it to the system. Ensure that you
have a replacement preconfigured for use with the KUDU HPU Well Manager.
For the valve controller cable harness, cut unused wires to a length of 18" (45.7 cm) and tie-wrap in a
loop.

KUDU HPU Well Manager Hardware Manual Connecting and Configuring the Motor Controller
11 Connecting and Configuring the Motor Controller

The system’s prime mover is controlled by a motor controller. The motor controller may be controlled
by RS485 Modbus/RTU or with a generic motor controller by a digital I/O signal from the RTU.
The variables described below are trended and displayed in the Prime Mover Status screen. The
screen displays the variables corresponding to the selected prime mover type.
Motor controllers or starters needs to be set to use a Modbus address of 1.
The run permissive (Start/stop) command is issued using a digital output. The status of the motor
controller is monitored by using Modbus/RTU except for the generic motor controller.
Three motor controller types are supported:

§ Electric Motor (ATS22) 37
§ Gas Motor (TG410) 37
§ Generic 38
11.1 Electric Motor (ATS22)
Electric-powered skids may be equipped with an Altistart 22 (ATS22) soft starter motor controller.
To connect an ATS22 to the KUDU HPU Well Manager:
1. Connect TB-42 top (serial 3+) to VP12S-4 on the ATS22.
2. Connect TB-42 bottom (serial 3-) to VP12S-5 on the ATS22.
3. Connect CL1 to LI1 on the ATS22.
4. Connect CL2 to COM on the ATS22.
5. Configure the ATS22 Active Channel parameter (Ctrl) to 1 (Modbus).
6. Configure the ATS22 Modbus address parameter to 1
The application uses the default communication settings of the ATS22:
§ Baud = 19200
§ Parity = 8 E 1
11.2 Gas Motor (TG410)
Gas-powered skids are equipped with a TG410 motor controller.
To connect a TG410 to the KUDU HPU Well Manager:
1. Connect TB-42 top (serial 3+) to J6.1 on the TG410.
2. Connect TB-42 bottom (serial 3-) to J6.2 on the TG410.
3. Using the local user interface on the TG410, set the following parameters:
§ Baud = 9600

Connecting and Configuring the Motor Controller KUDU HPU Well Manager Hardware Manual
§ Parity = 8 N 1
11.3 Generic
Some skids may be equipped with another type of motor controller, or you may prefer to control their
motor controller using DI and DO.
NOTICE
Each SCADAPack 535E RTU DO can supply up to 0.5 A. Ensure devices connected to
SCADAPack 535E RTU DO, such as the well run statuses, run permissive and start warning, do
not require more than 0.5 A and that devices with inductive loads are connected through a
freewheeling diode.
To connect a generic motor controller to the KUDU HPU Well Manager:
1. Connect TB-119 bottom to the Run Permissive Input on the Motor Controller.
2. Connect TB-113 bottom to the Status output on the Motor Controller.
3. Connect the motor controller’s signal and digital ground to TB-120 bottom.
4. If the motor controller requires external 24 Vdc for signal power, connect the motor controller’s signal
power to one of TB-114, TB-116, or TB-118 top, middle, or bottom.
A pre-drilled hole is included in the panel for this wiring.
5. Ensure that the following parameters on the motor controller are configured:
a. The Run Permissive on the Motor Controller is configured such that a low signal stops the motor
and a high signal starts the motor.
b. The status output on the Motor Controller is configured such that a low signal indicates that the
motor is unable to start and a high signal indicates that the motor is ready to start or running.

KUDU HPU Well Manager Hardware Manual Connecting and Configuring Required Sensors and Other Devices
12 Connecting and Configuring Required Sensors and Other Devices

You can configure the KUDU HPU Well Manager to use surface and downhole sensors.
The sensors are connected to a 24 Vdc power supply that is provided by the system. The system is
designed for 4...20 mA sensor signals.
Different connection types are available for different sensors. The analog signals are 4...20 mA inputs.
The Modbus sensors use two-wire RS485 communication on the COM4 port of the SCADAPack 535E
RTU. Refer to the table below for a list of available sensors and connection types. When connecting
sensors ensure you use the appropriate wire gauge.
DANGER
§ Read and understand this manual and the relevant drive installation manual before installing or
operating the KUDU HPU Well Manager. Installation adjustment, repair, and maintenance must
be performed by qualified personnel.
requirements with respect to grounding and wiring of all equipment
§ Many parts of the KUDU HPU Well Manager, including the printed circuit boards, operate at the
line voltage. Do not touch. Use only electrically-insulated tools.
DANGER
See NFPA 70E, CSA Z462, and OSHA 1910.
§ Before servicing the drive:
· Follow the applicable lock out/tag out (LOTO) procedure.
· Disconnect all power sources, including external control power.
· Place a Do Not Turn On label on all power disconnects.
· Lock all power disconnects in the open position.
§ Install and close all covers before applying power or starting and stopping the drive.
12.1 Connecting the Modbus I/O
The SCADAPack 535E RTU uses a default serial address of 254.

Connecting and Configuring Required Sensors and Other Devices KUDU HPU Well Manager Hardware Manual
Serial1 is a RS232 port used with the valve controller.
Serial2 is a RS232 port reserved for use by a communications device, such as a radio. The standard
configuration for Serial2 is 115200 bps with 8 bits, no parity and 1 stop bit.
Serial3 is reserved for use with the motor controller. The standard configuration for Serial3 is two-wire
RS485, 19200 bps with 8 bits, even parity and 1 stop bit. The KUDU HPU Well Manager automatically
updates its configuration to match that of the motor controller type selected.
Serial4 is used for communications with optional Modbus instruments such as sensors. The standard
configuration for Serial4 is two-wire RS485, 19200 bps with 8 bits, no parity and 1 stop bit.
Consult the KUDU HPU Well Manager Configuration Manual for details on how to update the
configuration of Serial2 and Serial4.
12.1.1 Reconfiguring the ATS22 Softstarter to Accept Modbus Communications
If the ATS22 Softstarter is replaced or restored to factory settings, it must be re-configured to accept
Modbus communications.
To set the ATS22 Softstarter from the front panel display:
1. On the ATS22 front panel display, use the up and down keys to navigate to the COP menu and press
ENT.
2. Configure the parameters, as described in the following table.
Parameter Setting Notes
Add 1 Modbus address (set to Off by default)
tbr 19.2 Baud rate
For 8E1 Modbus format
tt0 30 Modbus timeout in seconds
Ctrl LCL Local command
3. Log in to the KUDU HPU Well Manager.
4. On the HPU Status screen, press CONFIG MENU > Prime Mover Config.
The ALTISTART CONFIG button is only visible if ATS22 is the selected Prime Mover.
5. Press ALTISTART CONFIG.

The ATS22 Configuration - 1 screen is displayed.
6. Press the Set Defaults button.
The ATS Softstarter is configured to accept Modbus communications.
12.2 Installing Analog Sensors
To install the sensors, connect the correct inputs to the terminal block indicated in the table in
Connecting to the Terminal Block 25 .
12.3 Installing Digital Sensors
To install the sensors, connect the correct inputs to the terminal block indicated in the table in
12.4 Installing the Modbus Sensors
You can connect to up to two Modbus devices to the system to be configured as spare protection
inputs and/or for data collection.
Supported sensors use default Modbus address 1. Modbus addresses in the ranges 1 to 254 are
supported.
The system provides the alternative for each of the existing analog inputs to be configured as Modbus
sensors.
The system allows the selection of the Analog or Modbus source to be used. As a default, the system
is configured to use analog inputs.
To connect a spare Modbus device:
1. To install the sensors, connect the correct inputs to the terminal block indicated in the table in
2. If the device requires 24 Vdc, connect the correct inputs to the terminal block indicated in the table in
3. The Schneider Electric SCADAPack 535E RTU uses:
§ A default Modbus/RTU address of 1

§ A standard configuration of serial port 4
§ Two-wire RS485, 19200 bps with 8 bits, no parity and 1 stop bit
4. Configure the Modbus sensor(s) connected to the KUDU HPU Well Manager to:
a) Use a Modbus/RTU address other than 1.
b) Use two-wire RS485, 19200 bps with 8 bits, no parity and 1 stop bit.
See the KUDU HPU Well Manager Configuration Manual for details on the configuration of the KUDU
HPU Well Manager’s use of Modbus sensors.
12.5 Confirming Sensor Readings
To confirm that you are getting readings from the sensor, induce a reading from the sensor that you
are verifying. Some sensors may have a sensor simulation mode. If you have this mode enabled, use it
to induce a reading, or manually induce a reading. In the Magelis HMI, verify that the reading is what
you expect.
12.6 Grounding the Sensors
The sensors need to be grounded. Connect the ground for each sensor to the terminal block indicated
in the table in Connecting to the Terminal Block 25 .
12.7 Well Pressure Sensors
For directions on connecting the well pressure sensors to the KUDU HPU Well Manager, see
Connecting Valves and the Valve Controller 36 .
Configure each well’s pressure sensor to provide a 4...20 mA signal.
Configure each well’s pressure sensor to provide the well’s minimum possible pressure at 4 mA,
typically zero, and the well’s maximum possible pressure, ensuring that the system has the range to
detect high pressures for the KUDU HPU Well Manager’s protections, at 20 mA.
12.8 Well Flow Meters
To connect the flow (turbine) meter used for Pump A to the KUDU HPU Well Manager, connect the
Pump A turbine meter cable to the terminal block indicated in the table in Connecting to the Terminal
Block 25 .
To connect the flow (turbine) meter used for Pump B to the KUDU HPU Well Manager, connect the
Pump B turbine meter cable to the terminal block indicated in the table in Connecting to the Terminal
Block 25 .
Ensure that each well’s flow meter is configured to provide a turbine pulse output.
Configure each well’s turbine meter’s pulse frequency to be less than 1.5 kHz at the highest flow rate
possible for the well.

12.9 Hydraulic Fluid Sensors
To connect the hydraulic fluid level, temperature, and filter status sensors to the KUDU HPU Well
Manager:
1. Connect the hydraulic fluid status cable to the terminal block indicated in the table in Connecting to
2. Configure the hydraulic fluid level sensor to provide a 4...20 mA signal.
3. Configure the hydraulic fluid level sensor to provide the system’s lowest possible fluid level at 4 mA,
typically zero, and the system’s maximum fluid level at 20 mA.
4. Ensure the system has the range to detect abnormally high and low fluid levels for the KUDU HPU
Well Manager’s protections.
5. Configure the hydraulic temperature sensor to provide a 4...20 mA signal.
6. Configure the hydraulic fluid temperature sensor to provide the system’s lowest possible temperature
at 4 mA and the system’s maximum possible temperature at 20 mA.
7. Ensure the system has the range to detect abnormally high and low fluid temperatures for the KUDU
HPU Well Manager’s protections.
8. Configure the hydraulic fluid filter sensor to be active high when a problem is detected.
12.10 Presco Sensors
To connect the Well A Presco sensor (or switch) to the KUDU HPU Well Manager, connect Well A
Presco cable to the terminal block indicated in the table in Connecting to the Terminal Block 25 .
To connect the Well B Presco sensor (or switch) to the KUDU HPU Well Manager:
1. Connect each Presco sensor’s signal to the terminal block indicated in the table in Connecting to the
Terminal Block 25 .
2. Connect each Presco sensor’s voltage supply to the terminal block indicated in the table in
3. Ensure each Presco sensor is configured to indicate a high pressure using an active low signal.
4. If you are not using a Presco sensor, you need to jumper the Presco sensor signal input on the
SCADAPack 535E RTU.
NOTICE
Each SCADAPack 535E RTU DO can supply up to 0.5 A. Ensure devices connected to SCADAPack
535E RTU DO, such as the well run statuses, run permissive and start warning, do not require more
than 0.5 A and that devices with inductive loads are connected through a freewheeling diode.
a. To do this for Well A, connect DI-9 on the SCADAPack 535E RTU to +24 Vdc.

b. To do this for Well B, connect DI-10 on the SCADAPack 535E RTU to +24 Vdc.
12.11 Optional Sensors
Connect the optional sensors to the terminal block indicated in the table in Connecting to the Terminal
Block 25 .
12.12 Spare Digital Inputs
The KUDU HPU Well Manager provides spare digital inputs that can be used for digital sensors, such
as pressure switches, timed level switches, and leak detection switches.
The following DI are available as spare protection inputs:
§ DI-4 (System)
§ DI-5 (Well A)
§ DI-6 (Well B)
To connect a device to a spare DI:
1. Connect the device’s signal to the corresponding DI on the SCADAPack 535E RTU terminal block.
2. Connect the device’s ground or returnto the terminal block indicated in the table in Connecting to the
Terminal Block 25 .
3. If the device requires 24 Vdc, connect the devices power to the terminal block indicated in the table in
4. Configure the device connected to the spare DI to provide an active low or active high signal.
Ensure that this corresponds to the configuration used by the KUDU HPU Well Manager.
HPU Well Manager’s use of spare DI.
12.13 Spare Analog Sensors
The KUDU HPU Well Manager provides spare sensor inputs that can be used for analog sensors in
addition to those in the list of sensors.
The following AI are available as spare protection inputs:

§ AI-25 (System)
§ AI-26 (Well A)
§ AI-27 (Well A)
To connect a device to a spare AI:
1. Connect the device’s signal to the corresponding AI+ on the SCADAPack 535E RTU to the terminal
block indicated in the table in Connecting to the Terminal Block 25 .
2. Connect the device’s signal return to the corresponding AI- on the SCADAPack 535E RTU to the
terminal block indicated in the table in Connecting to the Terminal Block 25 .

3. If the device requires 24 Vdc, connect the devices power and connect the device’s ground or return to
to the terminal blocks indicated in the table in Connecting to the Terminal Block 25 .
4. Configure the device connected to the spare AI to provide a 4...20 mA signal.
5. Configure the sensor connected to the spare AI to provide the system’s lowest possible reading at 4
mA and the system’s maximum possible reading at 20 mA.
Ensure that the system has the range to detect abnormally high and low fluid readings for the KUDU
HPU Well Manager’s protections.
HPU Well Manager’s use of spare AI.
12.14 Optional Devices
There are additional devices that you can connect to the KUDU HPU Well Manager. For example,
§ Emergency Shutdown Device 45
§ Well A Run Status 45
§ Well B Run Status 46
§ Start Warning Indicator 46
12.14.1 Emergency Shutdown Device
To connect an remote emergency shutdown device (ESD) sensor (or switch) to the KUDU HPU Well
Manager:
1. Connect the remote ESD device’s signal to the terminal block indicated in the table in Connecting to
2. Connect the remote ESD device’s ground or return to the terminal block indicated in the table in
3. If the remote ESD device requires 24 Vdc, connect the devices power to the terminal block indicated
in the table in Connecting to the Terminal Block 25 .
4. Configure the remote ESD device to provide an active high signal to stop the prime mover.
12.14.2 Well A Run Status
NOTICE
freewheeling diode.

To connect a device such as a lamp or other indicator to the KUDU HPU Well Manager that will be
active when Pump A is running:
1. Connect the device’s input signal to the terminal block indicated in the table in Connecting to the
Terminal Block 25 .
2. Connect the device’s ground or return to the terminal block indicated in the table in Connecting to the
Terminal Block 25
12.14.3 Well B Run Status
NOTICE
freewheeling diode.
To connect a device such as a lamp or other indicator to the KUDU HPU Well Manager that will be
active when Pump B is running:
Terminal Block 25 .
Terminal Block 25 .
12.14.4 Start Warning Indicator
NOTICE
freewheeling diode.
The KUDU HPU Well Manager panel includes an installed annunciator.

To connect an additional device, such as a lamp, annunciator, or other indicator that is active when the
start warning period is active to the KUDU HPU Well Manager:
Terminal Block 25 .
Terminal Block 25 .

Connecting the Heater Kit KUDU HPU Well Manager Hardware Manual
13 Connecting the Heater Kit

Consult the panel drawing for a detailed illustration.
DANGER
DANGER
To install the heater kit to a KUDU HPU Well Manager panel:
1. Mount the heating pad on the back of the Magelis HMI.
2. Connect one of the heater wires to the terminal block indicated in the table in Connecting to the
Terminal Block 25 .
3. Connect the other heater wire to the terminal block indicated in the table in Connecting to the
Terminal Block 25 .

KUDU HPU Well Manager Hardware Manual Connecting Power and Ground to the Panel
14 Connecting Power and Ground to the Panel

Consult the panel drawing for a detailed illustration.
DANGER
DANGER
To connect the KUDU HPU Well Manager panel to ground, connect a copper wire from the ground lug
in the panel to an earth ground.

Connecting Power and Ground to the Panel KUDU HPU Well Manager Hardware Manual
14.1 Connecting Power to a Gas Panel
WARNING
systems. Only persons with such expertise are allowed to program, install, alter, and apply this
product.
The gas panel accepts 12 Vdc power.
To connect a gas KUDU HPU Well Manager panel to power:
2. Connect +12 Vdc to TB-1 top using wire rated to 25A.
3. Connect Ground (12 Vdc return) to TB-1 bottom using wire rated to 25A.
4. Verify the connections.
14.2 Connecting Power to an Electrical Panel
WARNING
systems. Only persons with such expertise are allowed to program, install, alter, and apply this
product.
The electric panel accepts 24 Vdc power.
To connect an electric KUDU HPU Well Manager panel to power:
2. Connect +24 Vdc to TB-2 top.
3. Connect Ground (24 Vdc return) to TB-2 bottom.
4. Verify the connections.

KUDU HPU Well Manager Hardware Manual Connecting Power and Ground to the Panel

Completing the KUDU HPU Well Manager Installation KUDU HPU Well Manager Hardware Manual
15 Completing the KUDU HPU Well Manager Installation

After you complete the installation procedure,
1. Remove any debris, such as wire clippings, metal shavings, or other foreign objects, from the KUDU
HPU Well Manager panel.
2. Close the main panel door and secure the door lock.
3. Secure the door latches.
The system is now ready for a qualified person to reapply power to the panel.
DANGER
§ Read and understand this manual and the relevant prime mover installation manuals before
installing or operating the KUDU HPU Well Manager. Installation adjustment, repair, and
maintenance must be performed by qualified personnel.
DANGER

KUDU HPU Well Manager Hardware Manual Servicing and Maintaining the KUDU HPU Well Manager
16 Servicing and Maintaining the KUDU HPU Well Manager

You should service and maintain the KUDU HPU Well Manager.
DANGER
§ Read and understand this manual and the relevant prime mover installation manuals before
installing or operating the KUDU HPU Well Manager. Installation adjustment, repair, and
maintenance must be performed by qualified personnel.
DANGER

Servicing and Maintaining the KUDU HPU Well Manager KUDU HPU Well Manager Hardware Manual
WARNING
RISK OF INJURY
§ Read and understand this manual and the relevant hydraulic system manuals before installing or
§ After stopping the pump, the hydraulic fluid system is still active. Ensure the skid is disabled and
hydraulic system is stopped in accordance with the hydraulic system manual prior to servicing
the system.
16.1 Changing the Panel Fuses
There are three fused terminal blocks in the KUDU HPU Well Manager panel. Each fused terminal
block interrupts excessive current to a different part of the system, as shown in the table below.
Fuse Number System Part Manufacturer (Part Number)
3 SCADAPack 535E RTU Bussman/Eaton (ABC-2-R)
4 Optional radio Bussman/Eaton (ABC-2-R)
8 DI Power Bussman/Eaton (ABC-5-R)
9 AI Power Littelfuse 0297025.WXNV
Refer to the panel drawing for the location of each fuse.
DANGER
HAZARD OF ELECTRIC SHOCK, EXPLOSION, OR ARC FLASH
§ Ensure power has been removed before servicing
You may need to replace a fuse if a part of the system is not functioning.
To replace fuse 3 or 4:
2. Open the panel and locate the fuse that needs to be replaced.
3. Open the hinged disconnect lever to access the fuse.
4. Open the fuse access port.

KUDU HPU Well Manager Hardware Manual Servicing and Maintaining the KUDU HPU Well Manager
5. Remove the blown fuse and replace with a Bussman/Eaton AGC-2 or other fuse of the same size and
current rating.
6. Close the fuse access port and close the hinged disconnect lever.
To replace fuse 9:
2. Open the panel and locate the fuse that needs to be replaced.
3. Remove the blown fuse and replace with a Littelfuse 0297025.WXNV or other fuse of the same size
and current rating.
4. Close the panel.
16.2 Inspecting the Panel Seal
NOTICE
RISK OF MOISTURE, DUST, OR CONTAMINATION ENTERING CABINET
§ Confirm that any holes drilled in the electrical panel comply with code requirements
§ Ensure that the panel seal is maintained by closing the inner and outer panel doors when the
panel is not being used
Ensure that the seal of the panel, including the connector plate, Magelis HMI, and any holes, are
periodically inspected.
16.3 Shading the Magelis HMI
NOTICE
RISK OF EQUIPMENT DAMAGE
The Magelis HMI should not be exposed to direct sunlight when not being used by an operator.
Ensure the panel’s outer door is closed when the Magelis HMI is not being used.
Ensure that the Magelis HMI is not exposed to direct sunlight.

Appendix A - Installation Checklist KUDU HPU Well Manager Hardware Manual
17 Appendix A - Installation Checklist

This appendix provides the following installation checklist:
§ Preparing to Install the KUDU HPU Well Manager 56
17.1 Preparing to Install the KUDU HPU Well Manager
Use this checklist, along with the KUDU HPU Well Manager Configuration Manual, to perform the
KUDU HPU Well Manager installation process.
General information
Checklist Item Verification
Is the person or persons conducting the installation, adjustment, repair, Y N

and maintenance of the KUDU HPU Well Manager qualified to do the
work?
Are copies of the KUDU HPU Well Manager Configuration Manual, Y N

sensor manuals, motor controller manual and wiring diagrams available
at the well site?
Do you have a license for the KUDU HPU Well Manager Y N
Assembling and installing hardware
If needed, have holes been created in the panel? Y N
Is the panel mounted to the skid? Y N
Are the position sensing device or devices (turbine meters or proximity Y N

sensors) installed and connected?
If used, is the load cell installed and connected? Y N
Are any external sensors, such as temperature, pressure and external Y N

fault, etc., properly connected?
Are the panel components ready for power to be applied? Y N
Is the motor controller connected to the prime mover and to the panel? Y N
Is the valve controller connected to the valves? Y N
Did you energize the panel after completing the installation? Y N
Equipment review

KUDU HPU Well Manager Hardware Manual Appendix A - Installation Checklist
Have you reviewed and confirmed that the system is ready for start up? Y N
Have you started and verified that the prime mover operates as Y N
expected?
Is the hydraulic system operating as expected? Y N
Are the panel features operational? Y N
Have you reviewed all wire terminations? Y N
Have you confirmed that the sensors are reading accurate data and Y N
scaled correctly by the KUDU HPU Well Manager?

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4 About this Manual

13 Connecting the Heater Kit

Version 3.02.0 | © Schlumberger 2015 - 2020 5

Trademarks & Service Marks

An asterisk (*) is used throughout this document to designate a mark of Schlumberger.

6 Version 3.02.0 | © Schlumberger 2015 - 2020

Version 3.02.0 | © Schlumberger 2015 - 2020 7

The addition of this symbol to a Danger or Warning safety label indicates

DANGER indicates a hazardous situation which, if not avoided,

WARNING indicates a hazardous situation which, if not avoided,

CAUTION indicates a hazardous situation which, if not avoided,

NOTICE is used to address practices not related to physical

Before you begin

8 Version 3.02.0 | © Schlumberger 2015 - 2020

Failure to follow these instructions can result in death or serious injury.

Test all software in both simulated and real environments.

Operations and adjustments

Version 3.02.0 | © Schlumberger 2015 - 2020 9

§ The components in this solution are not safety products

Failure to follow these instructions can result in death or serious injury.

Failure to follow these instructions can result in minor or moderate injury.

§ Ensure power has been removed before servicing.

Failure to follow these instructions w ill result in death or serious injury.

10 Version 3.02.0 | © Schlumberger 2015 - 2020

4 About this Manual

Product related Information

§ Follow all local and national safety codes and standards.

Failure to follow these instructions can result in death or serious injury.

Version 3.02.0 | © Schlumberger 2015 - 2020 11

§ How to view and manage alarms and events

§ How to view and configure trend information

§ The different types of screens that are available

§ How to change passwords

§ The Magelis HMI configuration settings that are available

12 Version 3.02.0 | © Schlumberger 2015 - 2020

No single cybersecurity approach is adequate. A defense-in-depth approach is recommended. This

§ A security plan built on the results of the risk assessment

§ A multi-phase training campaign

ICS-CERT Recommended Practices

Center for Internet Security (CIS) Top 20 Critical Security Controls

FBI Cyber Crime

Guide to Industrial Control Systems (ICS) Security

WaterISAC Water Security Network

Version 3.02.0 | © Schlumberger 2015 - 2020 13

6 Introducing the KUDU HPU Well Manager

The KUDU HPU Well Manager system is made up of:

§ Ensure power has been removed before servicing.

Failure to follow these instructions w ill result in death or serious injury.

14 Version 3.02.0 | © Schlumberger 2015 - 2020

Failure to follow these instructions w ill result in death or serious injury.

6.1 Installation Overview

The system includes a 25 W heater.

Version 3.02.0 | © Schlumberger 2015 - 2020 15

Failure to follow these instructions can result in minor or moderate injury.

6.2 Environmental Condition Ratings

The panel meets the NEMA 4X standard.

Altitude Up to 2000 meters (6562 ft)

Ambient temperatures See Temperature and Humidity Ranges 17

Mains Supply voltage fluctuations up to ±10% of the nominal voltage

Altitude Up to 2000 meters (6562 ft)

Temperatures See Temperature and Humidity Ranges 17

Humidity Maximum relative humidity 80% for temperatures up to 31 °C (88 °F)

Mains Supply voltage fluctuations up to ±10% of the nominal voltage