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M anual # 2.0.2
Contact Information: UNICO: 262-886-5678
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Technical Specs:
(Veri fy this info with the tag on the machine)
M odel #: ___________________________________
Serial #: ____________________________________
Gear ratio: __________________________________
Tag location
at the base
of the LRP.
100
105
1395
5750
144.5
299.5
304.25
10.3
22.5
120
125
1588
6250
1588
339.5
344.25
10.3
26.1
L=LRP
STROKE:
RATIO:
MOTOR FRAME:
TORQUE VALUE:
REVISION
NUMBER:
OPTIONS:
RR=ROD ROTATOR
Customer information:
Well location : ______________________________________________________
Well No.: _________________________________________________________
Install Date: _______________________________________________________
Notes: __________________________________________________________
_______________________________________________________________
_______________________________________________________________
Contact Information: UNICO: 262-886-5678
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Brake
Gearbox
Pinion
Pinion housing
M otor
Rack
Base
Stand
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Safety Information
Overview
This section states important safety information that must be followed when setting up, operating,
and troubleshooting this equipment. Study this information carefully before working with this
equipment, as failure to follow these instructions may lead to personal injury or death, or damage to
the unit, drive, motor, and/or driven equipment. Installation and repair procedures require
specialized skills with mechanical pumping systems. Any person that installs or repairs this unit
must have these specialized skills to ensure that it is safe to operate. Contact the Unico, Inc. service
department for repairs or any questions you may have about the safe installation and operation of
this system. The precaution statements are general guidelines for the safe use and operation of this
LRP system. It is not possible to list all unsafe conditions. Therefore if you use a procedure that is
not recommended in this manual, you must determine if it is safe for the operator and all personnel
in the proximity to the unit. If there is any question of the safety of a procedure, please contact
Unico, Inc before starting.
This equipment contains high voltages. Electrical shock can cause serious or fatal injury. Only
qualified personnel should attempt startup or troubleshoot this equipment. This equipment has
moving parts. Improper use can cause serious or fatal injury. Only qualified personnel should
attempt startup or troubleshooting of this equipment.
System documentation must be available to anyone that operates this equipment at all times.
Keep non-qualified personnel at a safe distance from this equipment.
Only qualified personnel familiar with the safe installation, operation and maintenance of
this device should attempt startup or operating procedures.
Always disconnect power before making or removing any connections.
Always ensure any connected equipment capable of falling is safely secured by approved
methods prior to working on this unit.
When your LRP unit is delivered, it becomes the responsibility of the owner/operator of the unit
to provide safe conditions and operation of the equipment. Some responsibilities include (but are
not limited to) the following:
1. It is the responsibility of the owner/operator of this equipment to ensure that it is correctly
and safely installed.
2. It is the responsibility of the owner/operator of this equipment to ensure that it, when
installed fully, complies with all federal, state and local codes.
3. It is the responsibility of the owner/operator of this equipment to ensure that any person
operating it has been properly trained.
4. It is the responsibility of the owner/operator of this equipment to ensure that any person
operating it has access to all manuals and information required for its safe use and operation.
5. It is the responsibility of the owner/operator of this equipment to ensure that it is properly
maintained and safety inspected at regular scheduled intervals.
6. It is the responsibility of the owner/operator of this equipment to ensure that any person who
has not been trained on the safe use of this equipment does not have access to it.
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Conventions Used
The following notation convention is used throughout this manual to indicate information important
to personal safety or machine hazards.
Identifies information about practices or circumstances that can lead to personal injury or
death, property damage, or economic loss.
General Precautions
Never operate this unit in a manner other than as described in this manual. Operation in any
manner not described in this manual should be considered unsafe and should not be
attempted. Never start the equipment unless you have first verified that the installation and
operation are as described in this manual.
Be sure that you are completely familiar with the safe operation of this equipment. This
equipment may be connected to other moving parts. Improper use can cause serious or fatal
injury.
Some parts of this unit move during operation. Rotating parts can present extreme danger if
clothing or body extremities are caught by the rotating part and can cause serious or fatal
injury. Never touch a part of the equipment until all moving parts are completely stopped.
Also, all electrical power must be removed to prevent accidental movement during
servicing.
Be sure that you understand how to stop the unit quickly in case of an emergency situation.
Become familiar with the controls and safety systems provided with this equipment.
Improper operation may cause violent motion of connected equipment. Be certain that
unexpected movement will not cause injury to personnel or damage to equipment.
Never permit anyone to operate the equipment without proper instructions. Be sure to keep a
copy of this manual with the unit so that all users can be properly informed of its safe
operation.
Never allow children or pets to be in the area where the equipment is running. The unit may
cause injury or death.
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Never operate the equipment unless all guards, covers, shields and other safety items are
properly installed.
Do not put hands, feet, tools clothing or other objects near moving parts. M oving parts cause
extremely dangerous situations because they can catch loose clothing or extremities and
cause serious or fatal injury.
When operating this equipment remain alert at all times. Never operate machinery when
physically or mentally fatigued, or while under the influence of alcohol, drugs or
medication.
High voltage is present whenever the equipment is running. Electrical shock can cause
serious or fatal injury. Never operate electrical equipment while standing in water, on wet
ground or with wet hands, feet or shoes or while barefoot.
Installation Precautions
Installation and repair procedures requires specialized skills with electrical equipment and
mechanical pumping systems. Any person that installs or performs repairs must have these
specialized skills to ensure that the unit is safe to operate. Contact Unico, Inc. for installation
or repairs.
Be sure all wiring complies with the National Electrical Code (NEC) and all regional and
local codes or CE Compliance. Improper wiring may cause a hazardous condition and
exposure to electrical hazards can cause serious injury or death.
Be sure the system is properly grounded before applying power. Do not apply AC power
before you ensure that grounds are connected. Electrical shock can cause serious or fatal
injury. NEC requires that the frame and exposed conductive surfaces (metal parts) be
connected to an approved earth ground. Local codes may also require proper grounding of
equipment systems.
Place protective covers over all moving parts such as motor shaft and fan, gearing, etc.
M oving parts cause extremely dangerous situations because they can catch loose clothing or
extremities and cause serious or fatal injury.
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Unauthorized modification of equipment may make the unit unsafe for operation or may
impair the operation of the unit. Never start a unit that has been modified or tampered with.
Be sure that all covers and guards are properly installed and that the unit is safe before
starting. If you are unsure, contact Unico, Inc.
When moving the equipment, use reasonable caution. Be careful where you place fingers
and toes to prevent injury. Never try to lift equipment without an appropriate hoist or lifting
means, as it is heavy and bodily injury may result.
Circuit overload protection must be provided in accordance with the National Electrical
Code and local regulations.
Have electrical circuits and wiring installed and checked by licensed electrician or qualified
technician. Electrical shock can cause serious or fatal injury.
Maintenance Precautions
Disconnect all electrical power before servicing the equipment. Electrical shock can cause
serious or fatal injury. Always treat electrical circuits as if they are energized.
Disconnect all electrical wires and load devices from equipment power outlets before
servicing the equipment. Electrical shock can cause serious or fatal injury. Always treat
electrical circuits as if they are energized.
Use only original equipment or authorized replacement parts. Using the correct parts will
assure continued safe operation as designed.
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Do not lift the equipment from the motor or gearbox lifting points. These points are not
designed for the weight or lifting angle needed for the LRP unit. Equipment Control
Precautions
An incorrectly installed or operated drive can result in damage to the equipment it controls.
M ake certain installation and operating specifications are followed.
Control inputs do not generate an emergency stop of the motor and do not remove electrical
power that can cause hazardous conditions. Regardless of the operating state, the drives
motor output terminals may be at dangerous voltage levels whenever input power is applied
and the bus is charged.
The LRP unit may start automatically whenever power is applied or after a fault trip if the
auto restart has been enabled. The restart function must not be enabled when hazardous
conditions might arise from such action.
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1.1 Overview
This chapter describes the contents and intended audience of this document.
1.2 Contents
The manual provides the instructions and technical information necessary to complete the
mechanical installation of the LRP unit.
1.2.1 Whats Covered
Safety Information, discusses safety hazards and precautions important to anyone working
with this equipment.
Chapter 1, About this Manual, Overview of this document.
Chapter 2, Installation, describes the installation of the Unico LRP system.
Chapter 3, Maintenance, describes the maintenance of the Unico LRP system.
1.2.2 Whats Not Covered
This manual does not address basic hardware and firmware aspects of the drive. These
topics are covered in the drive installation and firmware instruction manuals. Please refer to
those documents for:
Unpacking and receiving instructions
Hardware features and specifications
Electrical installation instructions
Drive troubleshooting, maintenance, and spare parts
Detail listing of basic drive parameters
Drive setup and auto tuning procedures
Interface setup and diagnostic utilities
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Installation
2.1 Overview
These operating instructions are intended to help you install and operate the LRP unit. For
trouble free service, proper installation and operation are essential. Additionally, these
instructions contain important recommendations on maintenance. Before shipment, every LRP
unit is tested, checked and properly packed. However, please inspect the unit immediately upon
arrival for shortage or transit damage. Note the damage or shortage on the freight bill of lading
and file a claim with the carrier. Also, notify UNICO of the shortage or damage. In addition to
these instructions, read and follow the gearbox manufacturers operating instructions provided
with the LRPs manual.
2.2 Installation Guidelines
The procedures presented in this manual are suggestions and it is the responsibility of the
Owner/Operator to arrange for these procedures to be performed by licensed contractors
according to all applicable codes including local codes for your M unicipality/City/County and
State/Province.
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2.3 Installation
The equipment is completely assembled, tested and adjusted at the factory before it is shipped.
The procedures presented in this manual are suggestions and it is the responsibility of the
Owner/Operator to arrange for these procedures to be performed by licensed contractors
according to all applicable codes including local codes for your M unicipality/City/County and
State/Province. External connections required at the time of installation are:
2.3.1 Electrical Connections
Consult supplied electrical drawings and/or drive hardware and software manuals for specific
wiring instructions.
Unit height is
from the top of
the stand to the
rod clamp surface.
Note:
Use this to determine the height of the polished rod. This dimension can be found in the technical
specs of this manual. The polished rod should not be more than 45 above this dimension. There is
45 between the rod clamp surface and the inside of the top cover.
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2.3.3 Lifting:
When lift or hoist equipment is used to lift the equipment and move it to position, be careful not
to contact overhead wires or other obstacles. The equipment can weigh as much as 6,500 lbs.
Ensure lift or hoist equipment has appropriate tires for the terrain to avoid becoming stuck or
tipping over. For the machine weight see the technical specs in this manual or the machine tag
on the base of the LRP unit.
Below shows 2 lifting eyes on top of the main housing.
After removing the bracket holding the rack in place, the rack is free to move (bracket not
shown). This means it can fall out if the unit is tipped so that the top is lower than the
bottom mounting plate.
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Proximity switch
location between the
housing and the gearbox.
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Rod Clamp.
Polished rod.
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2.3.6.2
Install over the polished rod.
nd
The 2 way is to install the LRP unit over the polished rod. This requires lifting the unit
much higher.
Top plate is chamfered on the inside.
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While the LRP unit is running verify the reticulating pump is pumping fluid. To do this, simply
loosen the fitting on the output side of the pump. Oil should steadily run out around the fitting. The
pump will pump in both direction (upstroke and down stroke).
Check for oil flow at this fitting. The oil is
under very low pressure.
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2.3.7.2 Gearbox:
There are 2 different gearbox suppliers used on the LRP units. Verify which gearbox is on your
unit. This may be supplied with oil from the factory and must be checked.
Below is the fill ports and site glass for the Bonfiglioli Gearbox.
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Maintenance:
Ensure the machine is properly Locked Out prior to any maintenance.
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3.2 Brake:
This Brake is only used in the event the drive can not park the rack on bottom because of an
unforeseen failure in the drive system.
How does it work?
The brake is a centrifugal mechanical brake. This brake will only engage in one direction (down
stroke). Once the brake hub exceeds a set rpm the centrifugal force expands and engages with the
brake disc. The brake disc is sandwiched between brake pads. The amount of stopping force the
brake has is determined by the torque on the 8 bolts holding the brake assembly together. The more
torque the more stopping power.
Do not operate the LRP system with out the brake installed and properly set.
Because the brake requires a certain rpm before it engages there is the potential for the LRP
system to bottom out before the brake can set. Example: If power is lost only a few inches from
bottom. In this case there is a bumper in the base of the LRP unit to absorb this impact.
Resetting the brake once engaged. The brake will only engage on the down stroke. To release the
brake simply stroke the unit up a few inches and the brake will retract. You are now ready to run.
The LRP system start up routine will automatically do this for you automatically.
Remove the brake cover:
The cover can be removed from the brake as shown below. Remove 5 bolts then slide cover
off. The cover should remain on the machine to keep out the weather and debris after maintenance
is completed.
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Engagement rpm:
The required rpm is determined by the max motor rpm (+/-10%) / the gearbox ratio.
Example: 2500 motor rpm / 19.38 ratio = 127 rpm required at the brake.
This rpm is then achieved by using springs to overcome the centrifugal force until that given
rpm. See chart for spring combinations. There is some variation from spring to spring so the
chart below is for the nominal. In the event you need the brake to engage sooner or later you
should consult the manufacturer.
Springs
Ge arb ox
Brake
Ratio:
RPM
Z
A
9.7
12.6
250
200
B
C
D
19.4
29.1
125
90
35.8
70
AAAAA-
C
C
B
B
B
OD
in
in
in
lbs/in
4
4
0. 5
0. 5
0.0 67
0.0 63
2.5
2.5
1 2.21
1 0.05
4
2
0. 5
0. 5
0.0 63
0.0 63
2.75
2.75
7.99
7.99
0. 5
0.0 63
2.75
7.99
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Brake torque:
The brake torque is set by the torque on the 8 nuts on the outside of the brake. The proper
brake torque can be found in the technical spec section or the white machine tag on base of
the LRP unit. You will need a 1 7/16" socket and a torque wrench. These nuts should be
checked periodically for the correct torque (every 6 months), or after every 10 brake
engagements.
There are 8 nuts (2 in each corner) on the brake that need to be checked. When tightening
the nuts the first time around alternate sides when moving from nut to nut. After you have
tightened them all once then recheck all the nuts for torque again. Repeat this process until
the nuts do not move under the specified torque.
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Use Loctite #243 Blue M edium Strength thread locker on all fasteners.
Use LOCTITE Gasket Sealant #2 or equivalent to seal all mating surfaces oil tight.
LOCTITE Gasket Sealant #2 is a black, viscous paste with a characteristic alcohol odor. It
is a slow drying, flexible setting paste that changes to a pliable, non-hardening film through
solvent evaporation. It seals flanges, fittings, connections and flexible assemblies against
leakage. It increases the reliability of gasket seals.
DIRECTIONS FOR USE
1. Remove all previous material from mating surfaces.
2. For best results, clean and dry all surfaces with a residue-free solvent
3. Remove cap, puncture tube or cartridge seal and attach extension nozzle (i f provided).
4. When used as a gasket dressing, spread product with a spatula to a uniform film on one side of gasket
and then position it on the assembly. Coat the second side of gasket and re-assemble. Slower drying
formula increases work time.
5. Assembly is operational after 4 hours, full cure is affected aft er 24 hours.
For Cleanup
1. The product can be removed from metal surfaces with isopropyl alcohol. If the sealant has been dried
for a long time or at high temperatures, cover the seal ant with alcohol and allow to soften overnight.
2. Clean hands with hand cleaners.
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