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LRP®

- Linear Rod Pump – Mechanical Manual

LRP ® - Linear Rod Pump – Mechanical Manual
LRP ® - Linear Rod Pump – Mechanical Manual

Linear Rod Pump Systems

Rod Pump – Mechanical Manual Linear Rod Pump Systems MECHANICAL INSTALLATION AND MAINTENANCE MANUAL Manual #

MECHANICAL INSTALLATION AND MAINTENANCE MANUAL

Manual # 2.0.2

Contact Information: UNICO: 262-886-5678

High Production Technology : 419-592-0050

Printed on 11/14/2011

Page 1 of 32

LRP®

- Linear Rod Pump – Mechanical Manual

LRP ® - Linear Rod Pump – Mechanical Manual
LRP ® - Linear Rod Pump – Mechanical Manual

TECHNICAL SPECS:

3

SAFETY INFORMATION

5

OVERVIEW

5

CONVENTIONS USED

6

GENERAL PRECAUTIONS

6

INSTALLATION PRECAUTIONS

7

MAINTENANCE PRECAUTIONS

8

SAFE SERVICE PRACTICES

9

2 INSTALLATION

12

2.1 OVERVIEW

12

2.2 INSTALLATION GUIDELINES

12

2.2.1 Long Term Storage

12

2.2.2 Site Planning 12

2.2.2.1 Stand 12

2.3

INSTALLATION

13

2.3.1 Electrical Connections

13

2.3.2 Unit Height:

13

2.3.3 Lifting: 14

2.3.4 Brake information: 15

2.3.5 Proximity switch installation: 16

2.3.6 Installing the LRP® unit on the Well Head

17

2.3.6.1 Installing with polished rod in LRP® unit

17

2.3.6.2 Install over the polished

18

2.3.7

Fill the unit with oil

19

2.3.7.1 Base fill port

19

2.3.7.2 Gearbox: 20

22

2.3.9 Top cover installation: 23

2.3.8 Optional rod rotator:

2.3.10 Post Installation Checks:

24

3 MAINTENANCE:

25

3.1

OIL CHANGE:

25

3.1.1

Gearbox oil:

25

3.1.2

Rack and Pinion oil

25

3.1.2

Draining oil from the LRP®

27

3.3 BOLT TORQUE:

31

3.4 SEALING MATING SURFACES OIL TIGHT:

31

3.5 PREVENTATIVE MAINTENANCE SCHEDULE:

32

3.6 S PARE / REPLACEMENT PARTS:

32

Contact Information: UNICO: 262-886-5678

High Production Technology : 419-592-0050

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Page 2 of 32

LRP®

- Linear Rod Pump – Mechanical Manual

LRP ® - Linear Rod Pump – Mechanical Manual
LRP ® - Linear Rod Pump – Mechanical Manual

Technical Specs:

(Verify this info with the tag on the machine)

Model #:

Serial #:

Gear ratio:

Actual brake engagement RPM:

Lifting capacity: 30,000 lbs Linear Lead (one turn of the pinion): 18.8495 in/rev Max torque setting (gearbox output torque): 90,000 in-lbs Brake: Bolt torque: 75 ft-lbs (8 places) Type of oil: Mobilgear 600xp 220 (or equivalent)

Tag location at the base of the LRP.
Tag location
at the base
of the LRP.

Rated Stroke: (inches)

86

100

120

Actual Stroke: (inches)

91

105

125

Rack and guide weight: (lbs)

1260

1395

1588

LRP weight without oil: (lbs)

5250

5750

6250

Unit Height: (inches)

130

144.5

1588

Over all height above stand: (inches)

270.75

299.5

339.5

Overall height above stand with rod rotator: (inches)

275.5

304.25

344.25

Gearbox oil capacity: (gal )

10.3

10.3

10.3

Base oil capacity: (gal)

20

22.5

26.1

Model number example:

L=LRP STROKE: REVISION RATIO: NUMBER: MOTOR FRAME: OPTIONS: RR=ROD ROTATOR TORQUE VALUE:
L=LRP
STROKE:
REVISION
RATIO:
NUMBER:
MOTOR FRAME:
OPTIONS:
RR=ROD ROTATOR
TORQUE VALUE:

Customer information:

Well location:

Well No.:

Install Date:

Notes:

Contact Information: UNICO: 262-886-5678

High Production Technology : 419-592-0050

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Page 3 of 32

LRP®

- Linear Rod Pump – Mechanical Manual

LRP ® - Linear Rod Pump – Mechanical Manual
LRP ® - Linear Rod Pump – Mechanical Manual
Top cover Brake Gearbox Pinion housing Motor Base Stand
Top cover
Brake
Gearbox
Pinion housing
Motor
Base
Stand

Rod rotator option:

Pinion housing Motor Base Stand Rod rotator option: Guide roller Pinion Rack Contact Information: UNICO:
Pinion housing Motor Base Stand Rod rotator option: Guide roller Pinion Rack Contact Information: UNICO:

Guide roller

housing Motor Base Stand Rod rotator option: Guide roller Pinion Rack Contact Information: UNICO: 262-886-5678 High

Pinion

Rack

Contact Information: UNICO: 262-886-5678

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Page 4 of 32

LRP®

- Linear Rod Pump – Mechanical Manual

LRP ® - Linear Rod Pump – Mechanical Manual
LRP ® - Linear Rod Pump – Mechanical Manual

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, p lease 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.

Contact Information: UNICO: 262-886-5678

High Production Technology : 419-592-0050

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Page 5 of 32

LRP®

- Linear Rod Pump – Mechanical Manual

LRP ® - Linear Rod Pump – Mechanical Manual
LRP ® - Linear Rod Pump – Mechanical Manual

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.information important to personal safety or machine hazards. General Precautions Never operate this unit in a

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.property damage, or economic loss. General Precautions Be sure that you are completely familiar with the

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.installation and operation are as described in this manual. Some parts of this unit move during

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.parts. Improper use can cause serious or fatal injury. Be sure that you understand how to

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.be removed to prevent accidental movement during servicing. Improper operation may cause violent motion of connected

Improper operation may cause violent motion of connected equipment. Be certain that unexpected movement will not cause injury to personnel or damage to equipment.controls and safety systems provided with this equipment. Never permit anyone to operate the equipment without

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.will not cause injury to personnel or damage to equipment. Never allow children or pets to

Never allow children or pets to be in the area where the equipment is running. The unit may cause injury or death.all users can be properly informed of its safe operation. Contact Information: UNICO: 262-886-5678 High Production

Contact Information: UNICO: 262-886-5678

High Production Technology : 419-592-0050

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Page 6 of 32

LRP®

- Linear Rod Pump – Mechanical Manual

LRP ® - Linear Rod Pump – Mechanical Manual
LRP ® - Linear Rod Pump – Mechanical Manual

Never operate the equipment unless all guards, covers, shields and other safety items are properly installed.LRP ® - Linear Rod Pump – Mechanical Manual Do not put hands, feet, tools clothing

Do not put hands, feet, tools clothing or other objects near moving parts. Moving parts cause extremely dangerous situations because they can catch loose clothing or extremities and cause serious or fatal injury.shields and other safety items are properly installed. When operating this equipment remain alert at all

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.clothing or extremities and cause serious or fatal injury. High voltage is present whenever the equipment

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.while under the influence of alcohol, drugs or medication. Installation Precautions Installation and repair procedures

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.feet or shoes or while barefoot. Installation Precautions Be sure all wiring complies with the National

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.to operate. Contact Unico, Inc. for installation or repairs. Be sure the system is properly grounded

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.to electrical hazards can cause serious injury or death. Place protective covers over all moving parts

Place protective covers over all moving parts such as motor shaft and fan, gearin g, etc. Moving parts cause extremely dangerous situations because they can catch loose clothing or extremities and cause serious or fatal injury.may also require proper grounding of equipment systems. Contact Information: UNICO: 262-886-5678 High Production

Contact Information: UNICO: 262-886-5678

High Production Technology : 419-592-0050

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Page 7 of 32

LRP®

- Linear Rod Pump – Mechanical Manual

LRP ® - Linear Rod Pump – Mechanical Manual
LRP ® - Linear Rod Pump – Mechanical Manual

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.LRP ® - Linear Rod Pump – Mechanical Manual When moving the equipment, use reasonable caution.

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.safe before starting. If you are unsure, contact Unico, Inc. Circuit overload protection must be provided

Circuit overload protection must be provided in accordance with the National Electrical Code and local regulations.lifting means, as it is heavy and bodily injury may result. Have electrical circuits and wiring

Have electrical circuits and wiring installed and checked by licensed electrician or qualified technician. Electrical shock can cause serious or fatal injury.with the National Electrical Code and local regulations. Maintenance Precautions Disconnect all electrical power

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.can cause serious or fatal injury. Maintenance Precautions Before cleaning, inspecting, repairing or performing any

Before cleaning, inspecting, repairing or performing any maintenance to the equipment, always be sure the unit has stopped and that all moving parts have also stopped. After stopping, certain components may retain significant potential energy due to gravity. Ensure all loads are properly secured to prevent accidental motion.Always treat electrical circuits as if they are energized. Inspect all wiring frequently and replace any

Inspect all wiring frequently and replace any damaged, broken or frayed wiring or wires with damaged insulation immediately. Electrical shock can cause serious or fatal injury.all loads are properly secured to prevent accidental motion. Disconnect all electrical wires and load devices

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.Electrical shock can cause serious or fatal injury. Use only original equipment or authorized replacement parts.

Use only original equipment or authorized replacement parts. Using the correct parts will assure continued safe operation as designed.Always treat electrical circuits as if they are energized. Contact Information: UNICO: 262-886-5678 High Production

Contact Information: UNICO: 262-886-5678

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Page 8 of 32

LRP®

- Linear Rod Pump – Mechanical Manual

LRP ® - Linear Rod Pump – Mechanical Manual
LRP ® - Linear Rod Pump – Mechanical Manual

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 PrecautionsLRP ® - Linear Rod Pump – Mechanical Manual An incorrectly installed or operated drive can

An incorrectly installed or operated drive can result in damage to the equipment it controls. Make certain installation and operating specifications are followed.needed for the LRP® unit. Equipment Control Precautions Control inputs do not generate an emergency stop

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 drive’s motor output terminals may be at dangerous voltage levels whenever input power is applied and the bus is charged.installation and operating specifications are followed. The LRP® unit may start automatically whenever power is

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.whenever input power is applied and the bus is charged. Safe Service Practices Follow industry-recognized safety

Safe Service Practices

Follow industry-recognized safety procedures:

• Use only one hand to hold test equipment probes

• Wear approved eye protection

• Stand on insulated material

• Use an isolated oscilloscope

• Keep unnecessary personnel out of the work area

• Never leave a drive cabinet open or unattended

• Never work alone

Contact Information: UNICO: 262-886-5678

High Production Technology : 419-592-0050

Printed on 11/14/2011

Page 9 of 32

LRP®

- Linear Rod Pump – Mechanical Manual

LRP ® - Linear Rod Pump – Mechanical Manual
LRP ® - Linear Rod Pump – Mechanical Manual

1 About this Manual

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 What’s 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 What’s 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

Contact Information: UNICO: 262-886-5678

High Production Technology : 419-592-0050

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Page 10 of 32

LRP®

- Linear Rod Pump – Mechanical Manual

LRP ® - Linear Rod Pump – Mechanical Manual
LRP ® - Linear Rod Pump – Mechanical Manual

1.3 Intended Audience This manual is intended for anyone who will be installing, operating, and servicing the LRP® system. Installation should be performed by qualified personnel to ensure that correct practices and applicable codes are applied. Start-up and operation should be performed by personnel familiar with both the drive and the machinery or equipment interfaced. The audience is expected to have a basic knowledge of physical and electrical fundamentals, electrical wiring practices and components, and electrical schematics. No prior experience with the drive is presumed or required.

Follow instructions You can prevent injury and damage to the drive or equipment by carefully following the procedures outlined in this manual.

Follow regulations All electrical work should conform to the National Electrical Code as well as all state and local government regulations. Please familiarize yourself with these regulations.

Read all manuals first Read this manual as well as the Linear Rod Pump Operating Instruction manual and the drive software application and installation and firmware instruction manuals entirely before installing the drive. Consult with the factory if unsure on any topic before proceeding.

1.4 Intended Application Unico LRP® systems are intended for vertical rod pump applications. This unit must be operated in the manner prescribed by this document. Uses outside those prescribed shall invalidate the manufacturer’s warranty.

Contact Information: UNICO: 262-886-5678

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Page 11 of 32

LRP®

- Linear Rod Pump – Mechanical Manual

LRP ® - Linear Rod Pump – Mechanical Manual
LRP ® - Linear Rod Pump – Mechanical Manual

2

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 manufacturer’s operating instructions provided with the LRP®’s 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 Municipality/City/County and State/Province.

National Fire Protection Association

o No. 30 – Storage, Handling and Use of Flammable Liquids.

Local Codes applicable to mechanical equipment installation. See your local building inspector.

NFPA (National Fire Protection Association) (617) 770-3000 (includes NEC), 1 Batterymarch Park, Quincy, MA 02169-7471 USA

2.2.1 Long Term Storage

If the unit is not installed immediately, it should be stored in a dry, protected area. Units which are used for standby service should be stored sealed.

2.2.2 Site Planning

This equipment system is enclosed and is designed for outdoor use. The following sections provide guidelines for successful installations.

2.2.2.1 Stand

• The unit is intended for mounting on a separate mounting stand that is supported by a casing or tubing flange.

• It is the user’s responsibility to ensure there is adequate integrity of the well completion for the gas and fluid flow when the base is installed.

• Ensure the base is concentric and perpendicular to the polished rod. Appropriate shims or adjustments to the base and mounting stand may be necessary.

Contact Information: UNICO: 262-886-5678

High Production Technology : 419-592-0050

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Page 12 of 32

LRP®

- Linear Rod Pump – Mechanical Manual

LRP ® - Linear Rod Pump – Mechanical Manual
LRP ® - Linear Rod Pump – Mechanical Manual

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 Municipality/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.

2.3.2 Unit Height:

Unit height is from the top of the stand to the rod clamp surface.
Unit height is
from the top of
the stand to the
rod clamp surface.
is from the top of the stand to the rod clamp surface. Note: Use this to

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.

Contact Information: UNICO: 262-886-5678

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Page 13 of 32

LRP®

- Linear Rod Pump – Mechanical Manual

LRP ® - Linear Rod Pump – Mechanical Manual
LRP ® - Linear Rod Pump – Mechanical Manual

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.

unit. Below shows 2 lifting eyes on top of the main housing. After removing the bracket

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.

2 lifting eyes located on the top of the main housing. Use both to lift
2 lifting eyes located on the
top of the main housing. Use
both to lift the unit. Eyes are
located so the unit will hang
vertically.
unit. Eyes are located so the unit will hang vertically. Contact Information: UNICO: 262-886-5678 High Production

Contact Information: UNICO: 262-886-5678

High Production Technology : 419-592-0050

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Page 14 of 32

LRP®

- Linear Rod Pump – Mechanical Manual

LRP ® - Linear Rod Pump – Mechanical Manual
LRP ® - Linear Rod Pump – Mechanical Manual

2.3.4 Brake information:

This is a centrifugal brake. The brake will only engage when the LRP® system is traveling down and exceeds a motor rpm around 2,500rpm. This brake will only engage in the case of a failur e with the drive safe stop operation. The brake will reset automatically when the unit starts to move upward.

The eight bolts located around the brake are what define the brake torque. Remove the brake cover. Verify the Torque on the 8 nuts before installing the LRP® unit. The torque specs can be found on page 1 or on the white tag on the LRP® unit base for the correct bolt torque.

Check torque of all 8 bolts per tagged requirement. Contact Information: UNICO: 262-886-5678 High Production
Check torque of all 8
bolts per tagged
requirement.
Contact Information: UNICO: 262-886-5678
High Production Technology : 419-592-0050
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Page 15 of 32

LRP®

- Linear Rod Pump – Mechanical Manual

LRP ® - Linear Rod Pump – Mechanical Manual
LRP ® - Linear Rod Pump – Mechanical Manual

2.3.5 Proximity switch installation:

With the rack in the lowered or parked position, thread the proximity switch in until it bottoms out on this surface. Then back it out 5/8” and put a lock nut on it. This will space it off the guide 1/8”. **Put thread sealer on prox to protect against leaks.

The slot for the Proximity switch starts 12 ½” from max top and bottom of
The slot for the Proximity
switch starts 12 ½” from max
top and bottom of stroke, 10”
from top and bottom of normal
stroke. (2.5” over travel in both
directions)
Proximity switch
location between the
housing and the gearbox.
-The proximity switch will be made in
the middle of the stroke but not at the
end of stroke.
in the middle of the stroke but not at the end of stroke. Contact Information: UNICO:

Contact Information: UNICO: 262-886-5678

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Page 16 of 32

LRP®

- Linear Rod Pump – Mechanical Manual

LRP ® - Linear Rod Pump – Mechanical Manual
LRP ® - Linear Rod Pump – Mechanical Manual

2.3.6 Installing the LRP® unit on the Well Head.

Before installing the LRP® unit, verify that the stand is level. The mounting hardware between the stand and the base are supplied with the machine.

There are 2 ways to install the LRP® unit on the well.

2.3.6.1 Installing with polished rod in LRP® unit.

Insert the polished rod into the LRP® unit prior to lifting. Clamp the rod so that it does not fall out. Then lift the LRP® unit over the well and connect the polished rod in the well to the polished rod in the LRP® unit. A coupling can then be used between the 2 polished rods. The coupling must be less than 2.5” outer diameter so that it can fit up into the bottom of the LRP® unit.

Polished rod. Rod Clamp. Polished rod.
Polished rod.
Rod Clamp.
Polished rod.

Contact Information: UNICO: 262-886-5678

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Page 17 of 32

LRP®

- Linear Rod Pump – Mechanical Manual

LRP ® - Linear Rod Pump – Mechanical Manual
LRP ® - Linear Rod Pump – Mechanical Manual

2.3.6.2 Install over the polished rod.

The 2 nd way is to install the LRP® unit over the polished rod. This requires lifting the unit much higher.

polished rod. This requires lifting the unit much higher. Top plate is chamfered on the inside.
Top plate is chamfered on the inside.
Top plate is chamfered on the inside.
the unit much higher. Top plate is chamfered on the inside. Contact Information: UNICO: 262-886-5678 High
the unit much higher. Top plate is chamfered on the inside. Contact Information: UNICO: 262-886-5678 High

Contact Information: UNICO: 262-886-5678

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Page 18 of 32

LRP®

- Linear Rod Pump – Mechanical Manual

LRP ® - Linear Rod Pump – Mechanical Manual
LRP ® - Linear Rod Pump – Mechanical Manual

2.3.7 Fill the unit with oil.

Rod Pump – Mechanical Manual 2.3.7 Fill the unit with oil. The unit is shipped WITHOUT

The unit is shipped WITHOUT oil. The unit must be filled at installation.

The LRP® unit has 2 oil reservoirs. See page #1 or white tag on the base of the LRP® unit for oil specs and quantity.

on the base of the LRP® unit for oil specs and quantity. 2.3.7.1 Base fill port.

2.3.7.1 Base fill port.

This is the lubrication for the rack, pinions, and bearings.

This is the lubrication for the rack, pinions, and bearings. Oil fill port for base Oil

Oil fill port for base

Oil full sight glass when rack is in the lowered or parked position.

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).

pump will pump in both direction (upstroke and down stroke). Check for oil flow at this

Check for oil flow at this fitting. The oil is under very low pressure.

flow at this fitting. The oil is under very low pressure. Prime the pump in this

Prime the pump in this location. Remove the fitting from the bottom of the pump. Pull the tube away and fill the trap in the tube with oil. Reconnect the bottom tube and fitting. Remove the fitting on the top of the pump and add some oil into the top of the pump. Reconnect the tube and fitting. Leave the fitting loose to check for oil. Run the LRP. Oil should steadily run out around the fitting.

Run the LRP. Oil should steadily run out around the fitting. Contact Information: UNICO: 262-886-5678 High

Contact Information: UNICO: 262-886-5678

High Production Technology : 419-592-0050

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Page 19 of 32

LRP®

- Linear Rod Pump – Mechanical Manual

LRP ® - Linear Rod Pump – Mechanical Manual
LRP ® - Linear Rod Pump – Mechanical Manual

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.

Fill port for gearbox.
Fill port for
gearbox.
glass for the Bonfiglioli Gearbox. Fill port for gearbox. Sight glass for gearbox fill level. Bonfiglioli
glass for the Bonfiglioli Gearbox. Fill port for gearbox. Sight glass for gearbox fill level. Bonfiglioli

Sight glass for gearbox fill level.

Bonfiglioli name on the side of the gearbox.
Bonfiglioli name on the
side of the gearbox.

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LRP®

- Linear Rod Pump – Mechanical Manual

LRP ® - Linear Rod Pump – Mechanical Manual
LRP ® - Linear Rod Pump – Mechanical Manual

Below are the fill ports for the SEW gearboxes.

Manual Below are the fill ports for the SEW gearboxes. Contact Information: UNICO: 262-886-5678 High Production

Contact Information: UNICO: 262-886-5678

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LRP®

- Linear Rod Pump – Mechanical Manual

LRP ® - Linear Rod Pump – Mechanical Manual
LRP ® - Linear Rod Pump – Mechanical Manual

2.3.8 Optional rod rotator:

The rod rotator turns the rod string a set amount every stroke. After the LRP® unit is installed on the well head set the rotator on top of the plate in the machined pocket. The rod will go thought the center and the rod clamp will set on top of the rotator. Use the lower 2 roller holes to change the amount the rotator moves. It is recommended that you run the LRP® unit at this point with the top cover off and w atch the rod rotator cycle. If every thing is cycling good then put the top cover on.

Rod clamp sits on top of rod rotator. Rod clamp not shown. Fill with light
Rod clamp sits on top of
rod rotator. Rod clamp
not shown.
Fill with light oil to bottom
of plug hole. (SAE 20
recommended for the model
T-252)
Roller can be used in either of the
lower 2 holes. This will change the
amount of rotation the rotator
moves each stroke. Be careful not
to drop parts into the gearing if
changing position of the roller.
Rod rotator sits in the
pocket in top plate.

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LRP®

- Linear Rod Pump – Mechanical Manual

LRP ® - Linear Rod Pump – Mechanical Manual
LRP ® - Linear Rod Pump – Mechanical Manual

2.3.9 Top cover installation:

The mounting hardware is supplied with the machine.

Seal the top cover to the housing with Loctite gasket sealant number 2 or equivalent.
Seal the top cover to the
housing with Loctite
gasket sealant number 2
or equivalent. See
section 3.4.

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LRP®

- Linear Rod Pump – Mechanical Manual

LRP ® - Linear Rod Pump – Mechanical Manual
LRP ® - Linear Rod Pump – Mechanical Manual

2.3.10 Post Installation Checks:

When the initial installation is complete, the following checks must be performed before starting the unit. These checks are not required before each start, only after the initial installation.

1. Verify unit oil levels are full. Base, Gearbox, and Rod Rotator.

2. Verify that the brake bolts were set to the correct torque. Section 2.3.4 and 3.2.

3. Ensure all covers are in place and be sure no hands are inside the equipment when it starts.

4. With the unit running, several checks must be made:

a. Verify there are no oil leaks. If a leak is detected, immediately stop the unit (move the equipment switch to the “Off” position) and repair the leak before proceeding.

b. Verify that the operation is smooth. If vibrations or other sources of noise exist, immediately stop the unit (move the Equipment switch to the “Off” position) and repair/adjust before proceeding.

5. After the operation checks are made, stop the unit (move the Equipment switch to the “Off” position). Re-check unit oil levels.

6. Close all covers. The post mechanical installation checks are now complete.

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LRP®

- Linear Rod Pump – Mechanical Manual

LRP ® - Linear Rod Pump – Mechanical Manual
LRP ® - Linear Rod Pump – Mechanical Manual

3

LRP ® - Linear Rod Pump – Mechanical Manual 3 Maintenance: Ensure the machine is properly

Maintenance:

Ensure the machine is properly Locked Out prior to any maintenance.

3.1 Oil Change:

Locked Out prior to any maintenance. 3.1 Oil Change: Find the oil type and quantity on

Find the oil type and quantity on page #1 of this manual or the white machine tag at the base of the LRP® unit. See Section 1.6 for fill instructions.

3.1.1 Gearbox oil:

Bellow is a recommended oil change interval based on temperature for the gearbox.

oil change interval based on temperature for the gearbox. Mobilgear 600XP 220 is a mineral based

Mobilgear 600XP 220 is a mineral based oil.

3.1.2 Rack and Pinion oil

Change every 4,000hours or 6 months.

There are 2 methods of lubrication on the LRP® system rack, pinions and bearings.

1. Oil bath. The rack sits in a bath of oil when in the down position. During the up stoke oil is

transferred to the pinions and splashed on the bearings.

2. Lubrication pump. This pump pumps oil in both directions. It is driven off the splitter gear. It is

rotating 4.6 times as fast as the pinion. This pump sends oil into the slitter gear side of the pinion housing to lubricate the outer bearing. The pinion housing is divided in 2 areas, the splitter gear side and the rack side. The splitter gear side is a small reservoir. As oil is pumped into this reservoir the oil reaches the center bearings and drains through them back into the base.

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LRP®

- Linear Rod Pump – Mechanical Manual

LRP ® - Linear Rod Pump – Mechanical Manual
LRP ® - Linear Rod Pump – Mechanical Manual
Splitter gear side of the housing. Rack and Pinion side of the housing.
Splitter gear side
of the housing.
Rack and Pinion side
of the housing.
Showing the internal lubrication lines.
Showing the internal
lubrication lines.

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LRP®

- Linear Rod Pump – Mechanical Manual

LRP ® - Linear Rod Pump – Mechanical Manual
LRP ® - Linear Rod Pump – Mechanical Manual

3.1.2 Draining oil from the LRP® unit.

There are 2 locations to drain oil from the base of the LRP unit. Both of these locations need to be drained when changing oil in the base.

locations need to be drained when changing oil in the base. There are two drain locations
locations need to be drained when changing oil in the base. There are two drain locations
locations need to be drained when changing oil in the base. There are two drain locations

There are two drain locations for the base.

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LRP®

- Linear Rod Pump – Mechanical Manual

LRP ® - Linear Rod Pump – Mechanical Manual
LRP ® - Linear Rod Pump – Mechanical Manual

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.

out the weather and debris after maintenance is completed. Contact Information: UNICO: 262-886-5678 High Production

Contact Information: UNICO: 262-886-5678

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LRP®

- Linear Rod Pump – Mechanical Manual

LRP ® - Linear Rod Pump – Mechanical Manual
LRP ® - Linear Rod Pump – Mechanical Manual

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 sp ring 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.

engage sooner or later you should consult the manufacturer.   Springs   Gearbox Brake   #
 

Springs

 

Gearbox

Brake

 

# of springs on post location

 

OD

Wire Ø:

Length

Spring rate:

Ratio:

RPM

Spring part number:

Spring Location:

Total # of springs:

in

in

in

lbs/in

Z

9.7

250

Lee Spring #LE 067E 06 S

A - C

4

0.5

0.067

2.5

12.21

A

12.6

200

McMaster Carr # 9432K91

A - C

4

0.5

0.063

2.5

10.05

B

19.4

125

McMaster Carr # 9065K375

A - B

4

0.5

0.063

2.75

7.99

C

29.1

90

McMaster Carr # 9065K375

A - B

2

0.5

0.063

2.75

7.99

D

35.8

70

McMaster Carr # 9065K375

A - B

1

0.5

0.063

2.75

7.99

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LRP®

- Linear Rod Pump – Mechanical Manual

LRP ® - Linear Rod Pump – Mechanical Manual
LRP ® - Linear Rod Pump – Mechanical Manual

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.

until the nuts do not move under the specified torque. Contact Information: UNICO: 262-886-5678 High Production
until the nuts do not move under the specified torque. Contact Information: UNICO: 262-886-5678 High Production

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LRP®

- Linear Rod Pump – Mechanical Manual

LRP ® - Linear Rod Pump – Mechanical Manual
LRP ® - Linear Rod Pump – Mechanical Manual

3.3 Bolt Torque:

Use the torque table below for all fasteners. Please see the brake section for the torque on the brake nuts.

   

Bolt Torque Table

   

Estimated with clamp load as 75% of proof load as specified in SAE J429 and ASME 574

 
 

SAE 5

SAE 8

Socket Head

Cap Screws
Cap Screws

Cap Screws

Steel Grade

Steel Grade

Minimum Tensile

   

1/4-1/2" 180,000

Strength PSI

120,000

150,000

5/8-1" 170,000

Nominal Dia.

 

and

Bolt Torque Specs in Foot Pounds or (Inch Pounds)

Thread Pitch

Dry

Lubed

Dry

Lubed

Dry

Lubed

1/4-20

(101)

(76)

(143)

(107)

(168)

(120)

3/8-16

(372)

(276)

44

33

51

38

7/16-14

49

37

70

52

81

61

1/2-13

75

57

106

80

124

93

5/8-11

150

113

212

159

238

179

3/4-10

267

200

376

282

423

317

3/4-10 267 200 376 282 423 317

Lubed means cleaned dry bolts lubricated with a standard medium viscosity machine oil. Lubricate all contact areas of the bolts and washers. Lubricating the bolts is the suggested method.

Use Loctite #243 Blue Medium Strength thread locker on all fasteners.

3.4 Sealing mating surfaces oil tight:

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

the reliability of gasket seals. DIRECTIONS FOR USE 1. Remove all previous material from mating surfaces.

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 (if 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 after 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 sealant with alcohol and allow to soften overnight.

2. Clean hands with hand cleaners.

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LRP®

- Linear Rod Pump – Mechanical Manual

LRP ® - Linear Rod Pump – Mechanical Manual
LRP ® - Linear Rod Pump – Mechanical Manual

3.5 Preventative Maintenance schedule:

Weekly:

1. Visually check for oil leaks from sealed surfaces and fittings.

2. Visually check oil level at the sight glass in LRP® unit stand.

3. Perform general clean up of oil, grease, and dirt.

Six Months:

1. Change oil in LRP® unit base for rack and pinions.

a. See section 2.3.7

2. Change oil in Gearbox.

a. See section 2.3.7

3. Visual inspection of pinions, rack, and gears through housing inspection covers. Check for excessive wear on gear teeth.

4. Check the brake bolt torque as described in section 2.3.4 and 3.2.

a. During the brake inspection. Remove any debris from the brake. Look for worn, broken or missing part.

5. Check and verify lubrication oil is be pumped. This will need to be checked as the unit is running. See Section 2.3.7.

Yearly:

1. Remove the cam follower blocks one at a time to inspect the cam followers. There are 4 locations.

a. Reseal the mating surfaces when reassembling the blocks. See section 3.4

surfaces when reassembling the blocks. See section 3.4 3.6 Spare / replacement parts: - A mechanical

3.6 Spare / replacement parts:

- A mechanical parts list was supplied with the LRP® unit please refer to it for and spare or replacement parts.

- When inquiring about spare parts please have the model and serial number of the LRP® unit. These can be found on the white machine tag at the base of the LRP® unit.

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