Operator’s Manual

Operators Manual

Sure Stroke Intelligent Lift™ Systems

Corporate Headquarters:
7523 Flint Road SE
Calgary, AB T2H 1G3
(403) 255-5222

Website: www.tundrasolutions.com
Service and Support – 403-255-5222

NOTE: The information contained in this document is the sole property

of Sure Stroke Intelligent Lift™ Systems Inc. Any reproduction in
part or whole without written permission is prohibited.
Operators Manual

REVISION RECORD

REV DATE SECTION DESCRIPTION

0 9-18-12 - Initial Release

Operators Manual

Contents
Section 1 Introduction ............................................................................................................... 1
Description of Basic Components ..................................................................................................... 1

Section 2 Theory of Operation............................................................................................... 3

Sure Stroke Intelligent Lift Systems Characteristics .......................................................................... 4
Basic System Design .......................................................................................................................... 5
General Precautions .......................................................................................................................... 5
Lockout / Tagout Requirements ........................................................................................................ 7

Section 3 Installation ............................................................................................................... 11

Connection to the Polished Rod ...................................................................................................... 11
Rod Separation ................................................................................................................................ 13

Section 4 Starting the System ............................................................................................. 17

Pre-Startup Power-On Checks ......................................................................................................... 17
Starting the Pump for the First Time ............................................................................................... 22
Starting the Pump in Normal Operation ......................................................................................... 25
Stopping the Pump .......................................................................................................................... 26
Connecting to a Remote Computer................................................................................................. 26

Section 5 Adjustments............................................................................................................. 27
Balancing the Load ....................................................................................................................... 27
Programming VFD Settings.............................................................................................................. 27
Adjusting Stroke Length and Speeds ............................................................................................... 30
Releasing the Load........................................................................................................................... 34
Retracting the Pumping Unit ........................................................................................................... 36
Tracking the Pumping Unit Back to its Operating Position ............................................................. 38
Acquiring the Load........................................................................................................................... 39

Section 6 Software .................................................................................................................... 42

PC Platform ...................................................................................................................................... 42
Communications Interface .............................................................................................................. 42
Communications Software .............................................................................................................. 42
On-Site Data Acquisition Setup ....................................................................................................... 43
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DP Service Software ........................................................................................................................ 45

Section 7 Scheduled Maintenance .................................................................................... 65

Periodic Maintenance ..................................................................................................................... 66
Maintenance Tasks .......................................................................................................................... 67

Section 8 Touch Screen Operation ................................................................................... 81

Introduction..................................................................................................................................... 81
Menu Selection................................................................................................................................ 82

Section 9 Troubleshooting..................................................................................................... 98
Alarms and Warnings ...................................................................................................................... 98
Operators Manual

Section 1 Introduction
This section provides an introduction to the components and operation of the Sure Stroke
Intelligent Lift™ System.

The Sure Stroke system is comprised of two basic components:

the pumping unit, and the power unit.

The pumping unit is comprised of a single hydraulically actuated oil-

filled cylinder, assisted by one or two nitrogen-filled counterweight units,
which work to apply the large up/down forces required at the well
site. The technology incorporates real-time pump-off controller logic
and provides real-time monitoring of well and/or pump performance
status.

The power unit is the control center that provides the ability to convert
electrical energy to hydraulic power and to control pump stroke as
needed to provide optimum pumping efficiency.

Description of Basic Components

Pumping Unit

The pumping unit stands over the wellhead and attaches to the polished rod by means of a
carrier bar. The pumping unit comes in various sizes, depending on the maximum load
likely to be encountered. The unit is comprised of a triple chamber hydraulic cylinder, heavy
duty structural base, one or two large cylinders containing nitrogen gas under pressure and a
pulley/cable lift mechanism which doubles sucker rod stroke relative to cylinder travel.

The nitrogen gas supply is connected to the cylinder counterweight chamber and serves
as a counterbalance, basically to offset the rod weight and a portion of the fluid load. The
counterbalance lift force can be adjusted at the well simply by adjusting the pressure of the
gas in the storage cylinders. The direction and speed of the pump is then controlled by sending
hydraulic fluid under pressure to either the up or the down chambers of the cylinder. See Table
1 for a chart listing pumping unit stroke length and load capacity.

Table 1 Pumping Units Stroke Length and Load Capacity

PUMPING UNIT 250 400 600 800

STROKE LENGTH 240” 288” 336” 360”

25,000 lbs 40,000 lbs 60,000 lbs 80,000 lbs

LOAD CAPACITY

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The pump is computer controlled; the speed and stroke limit can be independently
established in both directions, thereby allowing for faster up strokes and slower down
strokes. This feature greatly increases pumping efficiency for deep wells.

The pump utilizes feedback mechanisms to provide optimum stroke control and full
monitoring of well and pump conditions. Feedback sensors on the pump include a
position sensor to measure stroke position and a proximity switch to detect a possible
cable break.

The pumping unit is mounted on a skid system that allows the pump to be retracted
from the wellhead without requiring it to be disassembled. This feature allows
maintenance crews to retract the pump using a winch in the event that maintenance is
required on the well.

Power Unit

The power unit provides the driving force and control for the pumping unit. It is
comprised of two major components: hydraulic pump system, control and
communications center. The hydraulic pump system includes electric motors which
drive fixed displacement pumps. The system includes a sealed hydraulic reservoir and
various valves and sensors that allow the triple chamber cylinder to function correctly.
The hydraulic pump system is connected to the pumping unit by means of two primary
high-pressure hoses and four secondary control/feedback hoses.

The control and communications center consists of solid-state electronics and motor
controllers, which are designed for maintenance free operation. The electronics include
computer controls that allow for the pump to be controlled by feedback for precise
operation of stroke speed and position. The computer is also designed to communicate
externally by means of a modem, a radio transmitter or by using a direct telephone line.
This allows the pump to be remotely monitored and controlled.

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Section 2 Theory of Operation

This section provides a brief description of the operation for the Sure Stroke
Intelligent Lift™ System.

Pulley Assembly

Counterweight Tank Carrier Bar

Hydraulic Cylinder

Polished Rod

Power Unit

Figure 1 Sure Stroke Intelligent Lift™ System

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Sure Stroke Intelligent Lift Systems Characteristics

The Sure Stroke Intelligent Lift™ Systems pumping system has been designed to increase the
overall efficiency of a well by incorporating several beneficial features:

Long Stroke – Having a long stroke reduces rod stretch as a percent of stroke length. For
deep wells, the rod stretch can be a significant percentage of the overall stroke of a rod pump
system, thereby reducing the effective stroke of the down-hole pump. In general, the longer the
down hole pump stroke, the larger the fluid flow from the well.
High Polish Rod Load Capability - The well depth and down hole pump size determine the rod
string design and ultimately the rod load. Larger down hole pumps increase the efficiency of a
well by reducing the pressure drop of fluid as it enters the pump. This means that the differential
driving pressure stays large and more fluid moves into the pump. For a given formation, the
flow into the pump will be greater the larger the pump, and so will the rod load. Having larger
capacities and lower accelerations can take advantage of this characteristic, thereby allowing
the maximum flow to be achieved from any given well.

Variable Speed Up/Down – The Sure Stroke Intelligent Lift™ System allows variable speed
control and allows independent up versus down speed control. Acceleration and deceleration
transitions are also independently controlled, which significantly reduces rod stresses. Upstrokes
move the oil from the pump to the surface. The shorter the amount of time spent on the
upstroke, the less fluid leakage due to slippage past the traveling valve. For any given bottom
hole pump, a faster upstroke will reduce leakage, which increases the amount of fluid pumped.
A slower speed on the down stroke assures that the bottom hole pump has adequate time to fill.
This relates to more fluid in the pump barrel, which means more fluid pumped to the surface. A
system that has the capability of variable speed will then predictably have a higher volumetric
efficiency if all other things are equal.

Integrated Pump Off Control – Maximum formation flow is achieved when fluid pumped from
the casing is equal to the fluid coming into the casing from the reservoir. Ideally, the artificial lift
system will vary its speed so that it continues to pump at the rate that fluid comes in from the
reservoir. The Sure Stroke Intelligent Lift™ System is designed to do just that by measuring
the “Up” load and slowing the down speed when a pump off condition is detected. This
eliminates the inefficiencies and harmful effects of continuing to pump in a “pump off” condition
and also eliminates the need to shut the pump-off, resulting in lost production and inefficiencies
due to start up once the pump is turned back on.

High Efficiency Electrical System Components – The factors noted above coupled with a
counterweight design incorporating virtually no inertia allow the Sure Stroke Intelligent Lift™
System to use significantly less installed horsepower drive units for the same or greater lifting
load capability. The design is also based on a constant torque drive system, which results in a
power factor close to one and makes the unit able to operate with smaller transformers and
wiring. These factors may prove to be extremely important to operators since it will be
possible to increase production without adding cost on the electrical grid or without the need of
additional electrical capacity when Sure Stroke Intelligent Lift™ Systems units are installed.

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Basic System Design

The Sure Stroke Intelligent Lift™ System uses closed-loop hydraulics to move a three-
chamber cylinder up and down. The polished rod is connected to the cylinder via a 2:1
cable compound system using high strength nylon pulleys and steel bearings to carry the
load. A nitrogen counterweight system helps to support the dead load of the rod and a
portion of the rod/column live load. The pressure in the two nitrogen cylinders establishes
the counterweight load and it is connected to the load only during normal operating
conditions. The counterweight is quickly and easily disconnected for servicing by bleeding
the gas from the cylinder with the pump turned off. The gas volume of the
counterweight has been established so that pressure does not vary significantly during
normal outside changes in temperature.
Sending hydraulic fluid to either the up or down chamber of the cylinder controls the
direction of the cylinder and the flow controls the speed. As flow is directed to one
chamber, it is removed from the other to keep the system in balance. The hydraulic fluid
is filtered and temperature is regulated by means of a heat exchanger. A dryer is
connected to the large, sealed reservoir to remove any water from the system. The
hydraulic circuits contain a number of check valves, relief valves, and solenoid valves that
work together to efficiently control the triple cylinder.
The control system contains closed-loop feedback systems for cylinder position (stroke)
and velocity/accelerations. Other discrete sensors monitor various safety and
maintenance issues. The control system continually monitors the performance of the
system and reacts to changing rod loads, variable flow rates, and various other
environmental conditions.
The Sure Stroke Intelligent Lift™ Systems communicates with a host computer via a
modem. This communication feature allows monitoring of the well, provides remote
start/stop capability, remote stroke length and up/down speed changes, maintenance
indicators, warning status, and dynacard printouts.

Design margins for the pump together with reliable component selection have been
chosen with the intent of meeting an ultimate goal of 24/7 maintenance free operation.
However, the Pumping System is also fully monitored and continued operation under
potentially unsafe conditions is not permitted. This ensures that personnel, pumping
equipment, and the well itself are protected under inappropriate conditions, including
operator error.

General Precautions

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Due to the size and extremely large forces involved, the pump shall not be operated by
unauthorized or untrained personnel:

1. Do not start the pump unless the load is attached.

2. When working on the well or pumping system, shut power off at the disconnect
switch or power pole to prevent the unit from being run remotely. See
Lockout/Tagout Requirements.

3. When servicing the pump, ensure that the start / reset button on the control
panel is pushed in. See Figure 2

Start / Reset

Figure 2
Control Panel
Location

4. Wear approved fall protection when climbing with a two-hook lanyard. Use the three
point rule by alternating the connection of the two safety hooks while climbing.
Once at the top, one hook must be attached higher than shoulder length.

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Lockout / Tagout Requirements

Electrical lockout / tagout areprecautionary steps to ensure that the Sure Stroke
Intelligent Lift™ Systems pumping system does not accidentally start when maintenance
is being performed.
Energy Control on Sure Stroke Intelligent Lift™ Systems

The Sure Stroke Intelligent Lift™ Systems uses electrical and stored energy in the
form of compressed nitrogen gas to manage and control the pumping system.
During specific maintenance procedures actions performed on the well, it may be
necessary as a safety precaution to lockout pump operation to personnel working on
the pump or associated flow lines.
There are specific actions that must be taken to lock-out or block-out
pump operation:
1. Disconnect electrical power at the main circuit breaker (MCCB) and
l o c k o u t power to prevent inadvertent re-application of power. An
accompanying tag identifying the reason for lockout, date and time should be
filled out and placed on the equipment.
2. Close the cylinder hydraulic ball valves to prevent the cylinder piston from
moving up or down due to changes in the load on the rod string while the
pump is inoperative.
3. Close the counterweight actuator ball valve to prevent application of air
pressure to the up chamber that may inadvertently raise the cylinder piston.

Electrical Lockout / Tagout

Electrical lockout / tagout is the procedure of isolating electricity from wires, motors,
and switches to ensure the Sure Stroke Intelligent Lift™ Systems cannot accidentally
start when maintenance work is being performed.

Unless electrical power is required for troubleshooting purposes, power to the power
unit will be shutoff at the MCCB (See Figure 3). In addition, if maintenance
personnel are planning to leave the site, the MCCB should be locked out by applying
a lockout device.

Lockout/Tagout

Figure 3

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The procedure for electrical lockout is as follows:

1. Lockout the MCCB by installing an approved lock.
2. Notify the immediate supervisor and/or field contact of the action.
3. Only the person originally attaching the lock and tag (or his or her
designated representative) is authorized to remove the lockout/tagout.

Blocking movement of the pumping unit cylinder piston

Lockout/tagout shall be used to block the pumping unit cylinder piston from
moving during scheduled or unscheduled maintenance of the polished rod
connection. Examples where the cylinder should be blocked include changing
the packing on the stuffing box, and inspection and/or replacement of the auto
lubers at the top of the cylinder. As a matter of safety, always attempt to stop the
pump at the bottom of the stroke prior to closing the hydraulic ball valves.
1. Push in “Stop/ Reset” button (see Figure 4) when the unit reaches the
bottom of the stroke cycle.

Figure 4 Control Panel

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2. Shut off power at the MCCB, and then lock and tag out the unit.
3. Close the two hydraulic ball valves located at the base of the cylinder by
turning the valve clockwise. With the cylinder and polished rod locked in
position, the packing can be changed or other work can be performed near
the cylinder or wellhead. See Figure 5.

Cylinder Ball Valves

(Shown open)

Figure 5 Cylinder Ball Valves

4. Bleed air out of the cylinder to retract it to its lowest position.

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Disabling the Counterweight Actuator Ball Valve

There are certain maintenance procedures (e.g. bleeding the cylinder) that require
power but must block cylinder movement. One safety precaution that must be taken is to
disable the counterweight actuator ball valve to prevent it from opening under any
circumstances.

NOTE:

The counterweight is a pneumatic hydraulic system

pressurized by gas. Detaching the counterweight actuator
coil from the solenoid effectively isolates the
counterweight from the cylinder.

During startup and anytime air is introduced to the hydraulic system, such as during a
hose or valve change, it is necessary to bleed the cylinder downward to its fully retracted
position.

Before this is done, the counterweight actuator solenoid, located inside the cabinet,
must be electrically detached to prevent the actuator ball valve from opening under
any circumstance - causing the cylinder to fly upward uncontrollably. See Figure 6

CWT Actuator
Coil (40-60HP)

Figure 6 Counterweight Actuator Coil

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Section 3 Installation
Connection to the Polished Rod
Perform the following steps:
1. Remove the carrier bar from its mounting bracket by removing the bolt and the pin. Allow the
carrier bar to hang freely from the cables. Remove and store the bracket for future use.
2. Remove any packing straps attached to keep cables in place during transit.
3. If possible, make the polished rod length extension from the stuffing box as short as
possible, to take full advantage of the pumping unit’s long stroke capability.
4. Position carrier bar above the polished rod clamp on top of the stuffing box (see Figure 7). Slide
the polished rod into the carrier bar slot and replace the pin to secure the rod.

Carrier Bar Pin

Rod Clamp

Figure 7 Securing Carrier Bar to Polished Rod

5. Install the rod clamp on top of the carrier bar and tighten the bolts according to the clamp
manufacturer’s torque recommendations.
6. If a rod rotator is installed, it is mounted between the carrier bar and clamp as shown (see Figure
8). Make sure the arm is facing towards the cylinder. If necessary, tighten the cables by adjusting the
pumping unit cable clamps so that each cable is tight.

Rod Clamp

Rod Rotator
Rod Clamp

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NOTE:

Make sure the cylinder ball valves are open. If the valves are left closed, injury or
damage to the equipment may occur when nitrogen is added to the load.

7. Make sure both ball valves on the cylinder are open. Verify they are open by noting
the position of the valves relative to the shaft. The open positions are parallel to the
hoses and in the direction the flow (see Figure 9).

Cylinder Ball
Valves
(Shown open)

Figure 9 Cylinder Ball Valves

8. Acquire the load by slowly adding bottled nitrogen gas to the cylinder via the bleed ball
valve located on the front counterweight.
9. Make sure the carrier bar is level. If it is not, manually adjust the cables so tension is
equal between each side of the bar. If the carrier bar is imbalanced or cable tension is
unequal, adjust the cable turnbuckle, as required, to balance the cable tensions.
10. Once adjustments are completed, ensure that the turnbuckle locknut is set.
11. Remove the rod clamp on the well stuffing box.
12. Install the cable break target (included in the Installation Kit) to the outermost cable on
one side to the innermost cable on the other side. See Figure 10

Cable Break
Target

Proximity
(Position)
Sensor

Figure 10 Attaching Cable Break Target

13. Position the target so it is directly behind the target break proximity sensor. Adjust
the position sensor so the gap between the target and sensor is nearly zero
(touching).

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Rod Separation

A sucker rod string, which consists of several rods screwed together, serves as the
mechanical link from the beam pumping unit on the surface to the sucker rod pump near
the bottom of the well. When a rod breaks or separates from the remaining rod string and
column load, the system logic senses a loss of load and triggers an alarm. On alarm,
the counterweight actuator closes, thereby isolating the cylinder from the counterweight.

If the system is found offline before restarting, the cause of the alarm must be checked
before resetting or restarting the system. Typical alarm codes indicating a rod
separation may have occurred are: “V2163 Min Load Up” or “V2116 Loss of Load”.

NOTE:

System alarms must be checked if the system has suddenly stopped. If an alarm
appears, the system should not be operated until the cause of the alarm is
determined and the problem remedied. DO NOT PRESS the ‘Service Alarm Reset”
button at this time because it will clear all stored alarms.

When a system is found offline, the alarm must be checked before restarting. If the
alarm is related to a loss of load and the cylinder is fully extended, perform the following:
1. If available, first capture a DPReport so the alarm graph is available for review.
The alarm graph captures load and position data up to the point of the alarm
shut down. If the unit is restarted and another alarm occurs, the original alarm
graph is lost

2. After capturing the DPReport, push in the start / reset button (see Figure 11).

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3. Disconnect the coil from the counterweight (CWT) actuator (see Figure 12).

CWT Actuator
Coil (40-60HP)

Figure 12 CWT Actuator

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4. Bleed enough nitrogen so the cylinder retracts from full extension.

5. Record the rod load from the touch screen (see Figure 13) or DPService software.

Rod Load

Figure 13 Touch Screen

6. Compare the rod load to the known buoyant rod load.
7. If the rod load is considerably less than the known buoyant rod load, there is a
rod part separation [e.g., either an unscrewed, stripped out rod box, broken
rod or disconnected bottom hole pump (BHP)].
8. If the rod load and known buoyant rod weight is similar, the rods may not be
parted. As evidence, the nitrogen pressure required to bleed the cylinder down
from full extension would be considerably less, indication of a very deep part,
disconnected BHP, or a stuck open traveling valve. If this is the case, perform
the following
a) Add nitrogen at the fill valve (see Figure 14.)

Fill valve

Open cylinder
fill valve

Figure 14 Fill Valve

b) For models 400-800, close the lower ball valve between the two vessels (see Figure 15).

Ball valve lever

Figure 15 Lower Ball Valve

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c) Verify the Jog/Run switch is in Jog.

d) Start the pump by pulling out the start / reset button. The actuator will open the
connection between the CWT vessel with the cylinder.
e) With the charge pump running and the system in Jog mode, bleed the cylinder
down about one third of full extension. See Figure 14 (same as fill valve).
f) Once the cylinder has been retracted, jog a few feet down and then up while
watching the load
g) If there is no sign of the cylinder racing up, increase the jog stroke length while
continuing to watch the loads. If the jogging appears smooth (not racing up),
shorten the top switch by a few feet and start the system in Run mode.
h) Monitor the loads and capture another DPReport
i) If the load up is only a few thousand pounds greater than the load down, the rods
may be parted close to the BHP, the BHP may have a stuck open traveling
valve, or the BHP may be disconnected or damaged.
j) If the fluid load increases, rebalance the system and observe operation.

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Section 4 Starting the System

Pre-Startup Power-On Checks

There are many factors to consider before powering up and starting the system for the first
time. In some cases, the pumping unit has been tracked back after installation for well
maintenance. The installation could have been handled by other technicians prior to the
startup date. Although there is an installation checklist, it is the responsibility of the startup
technician to evaluate the state of the installation and verify that all work has been
completed.

A Sure Stroke Intelligent Lift™ Systems technician will normally complete these checks:
1. Review site install check list, and note all required startup tasks that have been completed.
2. Verify all connections between the power unit and pumping unit are tight.
3. Check that the rod string is properly attached to the carrier bar, and the polished
rod clamp has been securely tightened.
4. Verify that the cable break sensor plate is properly installed.
5. Verify that the electrical connection for the position and cable break sensor are in place.
6. Verify that hydraulic oil tank is filled to the top of sight glass. If not, add hydraulic fluid.
7. Verify the pumping unit is properly aligned to the well head.
8. Verify high pressure “up” and “down” ball valves on the cylinder are in the open position.
9. Verify the power and pumping unit have been properly grounded.
10. Do a visual check looking for anything that appears inconsistent with proper installation.

11. Verify the counterweight actuator coil is detached from the CWT Actuator
solenoid valve stem (see Figure 16). The solenoid is located Coil (40-60HP)
inside the hydraulic cabinet attached to the right side cabinet
wall and is the only one on top of the valve block. Unsafe
pressures may result from the counterweight actuator opening
causing potential injury and damage to equipment.
12. Verify that the carrier bar is firmly connected to the polished rod,
and the pin is in place.

13. Prior to turning the disconnect switch on, verify the incoming
power from the grid. Figure 16 Solenoid Location
14. Push in the <red start / reset> button so it resides in the
“In” position
15. Verify that the “Jog/Run” mode selector switch is in “Jog” position.
16. Apply power to the system by closing the main circuit breaker or disconnect.
17. using a meter, verify voltage is consistent with power unit requirements on all three legs.

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Entering PLC Operating parameters:

1. The power unit is shipped with the CPU set to “Program” mode. Set the CPU to
“Run” mode as follows: Move the “Run/Term/Stop” switch from “Term” to “Stop”, to
“Run”, and then back to “Term”. The “Run” LED should illuminate. Figure 17
shows the location of the PLC Terminal Switch.

“Run/Term/Stop”
toggle switch

Figure 17. PLC Terminal Switch

2. Connect a laptop to the PLC via the interface cable. Open DSData server
software and then DPParameters software. Enter the following well parameter
set points in the Sure Stroke Intelligent Lift™ Systems software:
Lift System Data Well Data
Power unit Pump depth
Horsepower Rod string (not used if “Rod Weight” override
entered) Pumping unit size
BHP
- Surface flow
- Desired flow

3. After entering well and lift system data, predicted loads are automatically
calculated and displayed in the “Calculated Machine Loads” area, as well as
counterweight fill values. PLC set point data is also displayed in the “PLC
Settings” screen for upload.
4. Upload the well pump parameters to the host computer, and then download
these values to the PLC.
5. Verify that the counterweight pressure is set according to the specific well data sheet
for the installed well. Open the communication hose between front and rear
counterweight units. If the pressure is too high, release some gas; if too low, add
some gas.

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6. PLC parameter data is entered in the following screens (see Figure 18), and
then entered into the PLC (see Figure 19).

Enter
En
Datater
HereDa
ta
He
re

Figure 18 Entering Well Data Setup Information

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Functional Block Description

1. Well/Pump Parameters to Host - Data calculated from the “Well/Pump

Parameters screen to the host column.

2. Click on the Download to PC - Data uploaded from the “Well/Pump Parameter”

screen or uploaded from another CPU is downloaded to the PLC. Set points can
also be changed in the “Host” column by clicking on the cell before downloading.

Figure 19 Upload Well Data Parameters to PLC

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Downloading Touch Screen Parameters:

1. Connect communication cable to the port inside touch screen enclosure.
Switch the selector to “comm” port. This can be verified by observing if the
touch screen display indicates “No Connection”.

2. Connect the other end to the laptop.

3. Open the DSData service and then the DPParameter file.

4. Go to the Well-Pump parameters tab and enter the following data:
• Power Unit#
• Horsepower
• Pumping Unit size
• Pump Depth
• Rod String API
• BHP size
• Surface PSI
• Desired flow

NOTE: Customer and well name are not necessary but should be filled in if you intend
to print or save for reference.
5. Select the “Install Parameters” tab. Select “Upload From Well/Pump
Parameters To Host”. All parameters should populate the “Host” column.
Select “Download To PLC”. All parameters should populate the “PLC” column,
thus matching the “Host”.
1 . Note the predicted counterweight pressure under the “Calculated Machine
Loads”. Using a pressure gauge, measure the pressure in the counterweight, front
counterweight if Model 4 0 0 - 8 0 0 . Bleed gas off if needed to be within 10% of
pressure noted. If pressure is lower than predicted requirements it can be added at a
later point in the process.

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Starting the Pump for the First Time

Perform the following procedure when starting the pump for the first time.
CWT Actuator
1. Verify the counterweight actuator coil has been disengaged from the Coil (40-60HP)
solenoid valve stem.

2. (Models 400-800) Prior to erecting the pumping unit

vertically, the hose between the two counterweight units, as
well as other connections, should be checked for leaks. If no
leaks are found, verify that the ball valve on the back
counterweight is closed, leaving open only the valve on front
counterweight

3. Bleed any air from the hydraulic hoses:

a) Have an assistant climb to the top of the cylinder and open
the bleed valve located on the very top of the piston. Do
the same with the bleeder on the side of the cylinder
Figure 20 Solenoid
head (the lower small fitting).
b) Set the mode switch to the “Jog” position.
c) The charge pump starts when the switch is in the “Jog” position unless
there is not enough oil in the tank. This forces hydraulic oil into both the up
and down chambers and, in turn, forces any air in the system out of the
bleed valves. Return switch to the “Run” position when oil comes out of the
bleed valves.

d) Close both bleed valves and reinstall solenoid on counterweight actuator valve.

e) Check the hydraulic fluid level as shown on the tank sight glass in the hydraulic
cabinet, and add hydraulic fluid if necessary. The pump will not run if hydraulic fluid
is below the level of the float switch.
4. The pump is now ready to run. Verify that the carrier bar is clear and that
there are no service personnel near the pumping mechanism.
5. Monitor operation via Touch Screen or DPService software. During the initial
startup, some settings may require further adjustment based on actual load
conditions. Warning and alarm settings may also require adjustments based on
operating conditions.

6. Switch the “Touch Screen / Comm Port” switch to “Touch Screen”. With the
plunger completely retracted, the position reading should be reading 0-2 inches.
If not, the Celesco position sensor needs to be adjusted. This is accomplished
by removing the chain guide plate and removing the chain from the sprocket.
Turn the sprocket while noting the position on the “Operations” screen. Once
the position is within required limits, engage the chain and reinstall the chain
guide.

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7. Place the “Jog/Run” switch in the “Jog” position, and jog in the up direction by
moving the Jog Direction switch to the Up position.

8. Pull out the <Start/ Reset> button. When the cylinder starts filling from the
counterweight actuator opening, push the <Start / Reset> button. It is good
practice to stop the system at this point and check the system condition, now
that the load is supported by the Pumping Unit.

9. Once the carrier bar stays a third to half way up, slowly jog the cylinder to the
upper limits of the stroke. Jog in short segments noting if the system is
functioning in proper order and stop upward travel if any resistance is noted. The
purpose of this exercise is to confirm full stroke capability, surface and
downhole. Continue to jog the cylinder all the way up and down for a few
strokes after confirming full stroke capacity can be achieved. In some cases due
to polish rod length or BHP travel the upward stroking may need to be limited.

10. In order to ensure full stroke capacity can be achieved without downhole
limitations, the cylinder should be slowly jogged up until the cylinder is fully
extended. As the cylinder reaches full extension, stop and slowly jog in short
movements until cylinder taps the top.
11. Release the switch when the piston is halfway extended (approx.). If the piston
drops or drifts downward, counterweight pressure is too low. Stop and add
nitrogen gas to the counterweights.
12. Verify that the cables are all in their appropriate groove, the carrier bar is
horizontal, and that no hydraulic or nitrogen leaks are found.

13. Note the stopped position of the carrier bar. If it continues to move up at
somewhat of a fast space, push the Stop button inward. If it stops a third to
halfway up, then the counterweight pressure is correct for startup. If the carrier
bar does not move at least a third or half way up, then add nitrogen.
14. Once the carrier bar stays a third to half way up, slowly jog the cylinder to the
upper limits of the stroke. Jog in short segments, verifying that the system is
functioning in proper order; stop upward travel if any resistance is noted. The
purpose of this exercise is to confirm full stroke capability, surface and
downhole.

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Operators Manual

15. Continue to jog the cylinder all the way up and down for a few strokes after
confirming full stroke capacity can be achieved. In some cases due to polish rod
length or BHP travel, the upward stroking may need to be limited.
16. Push in the red <Stop/Reset> button to halt the operation, and switch
the “Run/Jog” switch to Run, and then pull out the <Stop/Reset> button to
restart the system in “Run” mode.
17. If an alarm stops system from operating identify problem, correct and restart.
18. Once the system is operating in “Run” mode, note the loads/pressures and
make adjustments as needed.
19. Open the back counterweight valve and note the counterweight
pressures. Make adjustments as needed.
20. Set to moderate stroke length and speed. Leave operating at these settings for
24 hours to follow-up, or until steady state is achieved.
21. Make future adjustments to achieve desired customer requirements.

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 Operators Manual

Starting the Pump in Normal Operation

When starting the pump in normal operation, it is only necessary to verify that the
control panel is set to the “Run” position and then pull the <Start/ Reset> button out
to the “Start” position. The pump will automatically start after 20 seconds and will
continue to pump unless Alarm conditions are detected, in which case it will automatically
stop. See Figure 21 for the control panel.

NOTE:

The pump may also be started and stopped remotely if the

“Start/Stop/Reset” switch is in the “Start” position and the modern
communication option has been installed

START / STOP / RESET

(PULL OUT TO RUN, PUSH IN TO STOP)
Warning Reset Button
Jog Up/Down
Resets warnings. Also used
by service personnel. The unit
With the Run / Jog switch in Jog mode, can detect if a service person
move the levers in the direction you want has previously arrived to
to Jog (This switch is spring-loaded to the service the unit, through
off position). remote communications.

Jog Run

This switch changes the unit from

Run mode to Jog mode.

Start / Reset

This red mush room button is for

manually starting and stopping the unit. It
also resets any alarms when pushed in.
Figure 21 Control Panel

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Operators Manual

Stopping the Pump

As a matter of safety and for normal operation as needed, the pump may be stopped at any
time by using one of three means:
• Turn power off at the main power pole.
• Turn power off at the pump safety disconnect switch.
• Push in the red <Stop/Reset> button on the side of the electrical cabinet to the
“Stop/Reset” position. Note that this button also resets any alarms previously detected
so that normal operation can resume when the switch is set to the run mode.
For normal operation, always attempt to stop the pump at the bottom of the stroke.

Connecting to a Remote Computer

Connecting a remote computer to the power unit PLC allows a user to access the Power
Unit settings and data. Perform the following steps:
1. Connect a laptop computer, via its serial port inside the touch screen cabinet, directly
to the computer port located above the control panel on the Power Unit.
2. Switch from the touch screen to the COM port.
3. Once connected, launch the Sure Stroke Intelligent Lift™ Systems program that
connects to the PLC and allows various settings to be changed and data to be read
out.

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Operators Manual

Section 5 Adjustments

Balancing the Load

The purpose of the counterweight is to maintain a load balance on the hydraulic system to
compensate for the large difference between the up and down loads. The counterweight
load can easily be adjusted by adding or removing gas in the counterweight storage cylinders.
Adding nitrogen gas, or increasing the pressure, increases the counterweight load and thereby
decreases the amount of current required to drive in the up direction. To decrease the
counterweight pressure, release gas to the atmosphere. Up and down load balance can be
monitored by reading the amperage in each direction on the inverter panel inside the
electrical cabinet or by reading the cylinder up and down pressure on a remote computer.
The counterweight pressure should be set to maintain a ±10% spread between the up and
down readings. The optimum pressure setting is one that creates a higher amperage draw
when the pumping unit is going down, during the warmest part of the day, with a well at steady
state.

When balancing the system, two factors must be taken into account: temperature and casing
level. Temperature is a factor because the counterweight pressure will vary slightly with
temperature. The colder the ambient temperature, the lower the pressure. Conversely, the
higher the temperature, the higher the pressure. The pressure should be set to provide
balanced conditions during a normal 24- hour period. It may be necessary to make a
seasonal adjustment if there is a large change in the ambient temperature from one season
to the next.

During the warmest part of the day, the amperage going down should be slightly higher than
going up. During the coldest part of the night, the amperage going up will be slightly higher
than going down. The casing level is a factor because there can be a large variation in the up
load for a well that is not at steady state. Do not attempt to balance the load until the well and
pumps are running in a steady state condition.

Programming VFD Settings

Variable Frequency Drive (VFD) settings are pre-programmed at the factory and under
almost all circumstances should not need adjustment.

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Operators Manual

Table 5. Factory VFD Speed Settings (RPM) – 60 Hz

CATALOG PART Speed Setting (RPM)

NUMBER Lower SPD 1 SPD 2 SPD 3 SPD 4 SPD 5 SPD 6 SPD 7
Limit
250-15-240 300 450 600 750 900 1025 1150 1275
250-25-240 300 450 600 750 900 1025 1150 1275
250-40-240 450 620 790 960 1130 1300 1470 1650
250-60-240 450 580 710 840 970 1100 1225 1350
400-40-288 450 650 850 1050 1250 1450 1675 1900
400-60-288 450 650 850 1050 1250 1450 1675 1900
400-100-288 450 620 790 960 1130 1300 1470 1650
400-125-288 450 550 650 750 850 950 1050 1150
600-60-336 450 650 850 1050 1250 1450 1675 1900
600-100-336 450 650 850 1050 1250 1450 1675 1900
600-125-336 450 580 710 840 970 1100 1250 1400
800-100-360 450 650 850 1050 1250 1450 1675 1900
800-125-360 450 650 850 1050 1250 1450 1675 1900
800-150-360 450 580 710 840 970 1100 1250 1400

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Operators Manual

Table 6. Factory VFD Speed Settings (RPM) – 50 Hz

CATALOG PART Speed Setting (RPM)

NUMBER Lower SPD 1 SPD 2 SPD 3 SPD 4 SPD 5 SPD 6 SPD 7
Limit
250-15-240 300 410 520 630 740 850 960 1055
250-25-240 300 410 520 630 740 850 960 1055
250-40-240 450 610 770 930 1090 1250 1410 1575
250-60-240 450 835 920 1005 1090 1175 1260 1350
400-40-288 450 610 770 930 1090 1250 1410 1575
400-60-288 450 610 770 930 1090 1250 1410 1575
400-100-288 450 550 650 750 850 950 1050 1160
400-125-288 450 610 770 930 1090 1250 1410 1575
600-60-336 450 610 770 930 1090 1250 1410 1575
600-100-336 450 580 710 840 870 1100 1250 1400
600-125-336 450 610 770 930 1090 1250 1410 1575
800-100-360 450 610 770 930 1090 1250 1410 1575
800-125-360 450 580 710 840 870 1100 1250 1400

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Operators Manual

Adjusting Stroke Length and Speeds

The Sure Stroke Intelligent Lift™ Systems Pumping System is designed to operate at several
different speeds and stroke lengths, depending on well conditions. These two parameters are
interrelated. In general, best pump efficiency will be achieved by using the longest piston
stroke length available. If the “speed up” or “speed down” is adjusted, the stroke length will
also increase slightly and consequently, the top and bottom piston deceleration points must
be adjusted before the pumping unit is active.
The stroke length can be adjusted through the top and bottom switch piston deceleration
points by editing the stored PLC memory locations through PC application software, or by
utilizing the touch screen attached to the unit. Speeds are preset at the factory, and generally
are not changed. Contact your local Sure Stroke Intelligent Lift™ Systems service technician
to help you with this if custom speeds are needed.
Adjustments can be made either through the touch screen or DPService application
software. However, it’s strongly recommended that the touch screen be used for all
adjustments and that DPService software be used only for monitoring and reporting. All
speed or position adjustments should NOT be performed remotely outside of the visual range
of the pumping unit system.

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 Operators Manual

1. On the touch screen, the <OPERATIONS> screen should be the initial screen appearing
(see Figure 24).

Figure 24 Operations Screen

2. Click on the <DIRECTORY> button to display the <SET SPEED CYCLE> screen. This
screen allows the user to view and adjust Top and Bottom Decel set points. Set points
represent the cylinder location at which acceleration stops and slowdown occurs.

Establishes upper Incremental

deceleration point adjustment

Position
Establishes lower Indicator
deceleration point

Recalibrates
encoder
position in PLC
Speed Select

3. Keep the factory speed setting or adjust to a new speed using the <ENTER
NEW SPEED> button.

4. Turn the JOG/RUN switch to JOG, and slowly jog the cylinder to the point that the
piston barely taps the upper/lower limits of its stroke length. Note the position indicator
reading.

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Operators Manual

NOTE:

If the bottom position does not read from “0” to “2” the encoder
may need to be recalibrated to zero using the <Enc Offset> button
(see section 8. Touch Screen Operation).

5. Click on the <TOP DECEL PT> and <BOTTOM DECEL PT> to enter number
through a popup keypad in preparation for a test Run. These values will be adjusted
later.

Table 7. Safety Margins for Stroke Length

Model 250 Model 400 Model 600 Model 800

Upper Margin 225 268 316 340

Lower Margin 15 20 20 20

6. Reposition the JOG/RUN switch to RUN and activate the pumping unit.

7. Verify the the cylinder does not tap or bottom out, and then slowly increment the stroke
length using the <UP 1”> or <DN 1”> decel set point adjustment buttons.

8. Observe operation by cycling several times in RUN mode.

9. If pumping unit speed and deceleration points must be revised, repeat this procedure.

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Operators Manual

Using the DPService Application

Use the following procedure to change speeds and stroke length:

1. Turn selector switch to select the PLC interface. See Figure 23.
2. Plug in RJ11 connector from the laptop into the RJ11 port.
3. Navigate to the Speed and Cycle screen inside the Excel application. See Figure
26.

Figure 26. Speed and Cycle Adjustment Screen

4. Make sure the laptop position is in plain view of the cylinder.

4. Enter Up/Down speeds or Top / Bottom deceleration point switches in the “HOST”
column and submit parameters to PLC by clicking “Write it!” or “Write Speed Up/Down”.
A minimum 12” should be maintained above the stuffing box.

NOTE:

There is NO program limitation in entering values which exceed

stroke length. Damage to the pumping unit may occur if too high a
speed or deceleration stopping point is entered.

6. Cycle the pump several times at slow speed in RUN mode, stopping immediately if tapping
or bottoming out occurs.
7. Adjust speed and deceleration set points in increments, as required.
8. If pumping unit speed and deceleration points must be revised, repeat this procedure.

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Operators Manual

Releasing the Load

Removing the load from the pumping unit may be needed to prepare for track back in the
case of well work, rod string re-spacing, or pumping unit service. When transferring the rod
string load to the well, it is essential to follow this procedure to avoid injury and or damage to
equipment.

As a matter of safety and for normal operation as needed, the pump may be stopped at any
time by turning off power at the main power pole or pump safety disconnect switch or by
pushing the red button to the “Stop/Reset” position. This button is located on the side of
the Electrical Cabinet Note that this button also resets any alarms previously detected so that
normal operation can resume when the switch is set to the Run mode.

The carrier bar has a yellow warning tag (see Figure 27) reminding operators of required
actions that must be accomplished before removal of the load.

Pin

Carrier Bar

Warning Tag

To release the carrier bar from the rod load, perform the following tasks:
1. Stop the pumping action about midpoint on the down stroke by switching from “Run” to“
Jog” mode.

2. Jog down ending with the cylinder retracted as much as possible. It is normal for the
cylinder to spring back up due to counterweight pressure to well load ratio.

3. Push in the red <Stop/Reset> button.

4. See the section on Lockout/Tagout Procedures.

5. Disconnect the counterweight actuator coil to prevent any possibility of the cylinder
counterweight chamber being energized. This is a second level of protection in the event
the power is left ON with the “Start” button out and no load on the carrier bar.

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Operators Manual

6. Slowly open the fill/bleeder valve on the counterweight ball valve assembly. See Figure 28.

Bleeder valve

Figure 28 Counterweight Bleed Valve

7. Bleed the cylinder down until the carrier bar is a foot above the clamp. Close the counter-
weight bleeder valve and tighten the rod clamp to ensure the clamp will sustain the load. See
Figure 29.

Rod clamp

Figure 29 Tightening the Rod Clamp

8. Slowly open the fill/bleeder valve again so that the carrier bar continues to move down and
comes to rest on top of the polish rod clamp.

9. Continue to bleed the pressure off until the cylinder is completely retracted and all pressure is
released. Use care to avoid injury from the rod rotator sliding down the polish rod when the
carrier bar is removed.

10. Close the nitrogen bleeder valve and both hydrogen cylinder ball valves.The disconnects
perform the same function as closing the ball valves.
11. Pull the pin out that secures the carrier bar to the polish rod, and tie off the carrier bar to the
counterweight to keep it from swinging during the move operation.

12. Swing the carrier bar back towards the cylinder, reinstall the pin and secure the carrier bar to
the base or cylinder.

13. If a rod rotator is used, remove the chain holding the rod rotator arm. Care must be taken to
avoid injury from the rod rotator sliding down the polish rod when the carrier bar is removed.

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Operators Manual

Retracting the Pumping Unit

The tracking system consists of three rails, or skids, mounted to the concrete piers, positioned under
the three contact points of the Pumping Unit. The two outer skids have rails to be able to capture the
leveling feet as the unit is tracked back. The center skid has rails to guide the counterweight
during the pullback operation. The pumping unit can be retracted from the back or front of the well.

Outer skid

Center skid

Figure 30 Skid System

If equipment access to the back of the well is not possible, a bracket is provided on the backside of
the counterweight to enable a winch line with a shackle to be attached for the pullback operation.

Winch Line

Bracket

Figure 31 Rear Bracket on Center Skid

Perform the following steps (see Figure 32):

1. Clean and grease the three skid rails to minimize the friction when pulling.
2. Remove the safety chains that attach the base legs to the front of each side skid plate.

Safety chain

Figure 32 Safety Chain

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Operators Manual

3. Connect a winch cable to the pulling lug on the back of the counterweight.

4. Attach the pullback cabling and pulley system. One end of the cable is attached to the
pullback eye on the bottom of the rear counterweight. Attach the other end of the pulley
to the pulling lug on the back of the counterweight. See Figure 33.

Pulling lug on
Winch Winch line Counterweight Wellhead

Figure 33 Retracting the Pump from the Back of the Well

5. Slowly pull the pump back in short increments until the pump is
within one foot of the end of the skid plate.

6. If the track back operation needs to be performed from the front,

see the following sketch (see Figure 34).

NOTE:
When tracking unit
forward, align winch
Front track back Pulling lug on
unit counterweight Wellhead with wellhead and use
equal length chain.

Winch Line

Figure 34 Retracting the Pump from the Front of the Well

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Operators Manual

Tracking the Pumping Unit Back to its Operating Position

To pull the pump forward to resume normal pumping operations, perform the following tasks:

1. Attach the winch cable to the connection points.

2. Slowly pull the pump forward on the skid system until the front feet rest against the
V-block stops. This is the normal operating position of the pump.

3. Reattach the safety chains from each base leg to the skid plate anchor (see Figure
35).

4. Check alignment of the pump, noting that any adjustments to the counterweight
and settings may be necessary if the well configuration was changed during the
well service.

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Operators Manual

Acquiring the Load

When reacquiring the load, perform the following steps:

1. Make sure the pumping unit is aligned properly over the wellhead, V-base feet are properly
positioned in the track V locators, and safety chains have been properly reattached.

2. Reattach the carrier bar to the polish rod and secure it with the pin. Two clamps are
recommended for the Model 600 and 800 units due to high predicted load capacity (40K+ lbs.).

Rod Clamp Pin

Carrier bar

3. If a rod rotator is installed, make sure it is on top of the carrier bar and aligned so the arm will
make contact with the actuator bracket.

Rod Rotator

Actuator Bracket

Arm

4. Open both ball valves on the cylinder. Ball values must be open to flow. Verify they are open
by noting the position on the line on the shaft – they must be in the direction of flow.
5.

WARNING:
If the cylinder ball valves are
left closed, injury or damage
to the equipment may occur.
Ball Valve

Figure 38 Ball Valves on Cylinder

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Operators Manual

NOTE:

Care must be taken to avoid any contaminates from entering the

nitrogen fill hose. Keep dust caps on the hose ends when in use so
particles do not enter the hydraulic system

6. Connect a charge hose between a bottle of dry nitrogen gas and the counterweight
bleed/fill valve located just above the counterweight actuator ball valve. Use caution
not to drop or hit the valve on the bottle once the protection cap is removed. Verify all
hose and fitting connections to the bleed valve are tight.

7. Open the bleed/fill valve slowly (ref. Figure 39) until you hear nitrogen flowing though
the hose. The cylinder will start moving up until it makes contact with the polish rod
clamp. Check rod rotator alignment again, if attached, and if properly aligned,
continue to add nitrogen until the lower clamp on the well tee lifts up a couple of inches.

Figure 39 Open the Bleed Valve

8. Open ball valves on cylinder.

9. Remove the clamp located below the carrier bar. It has been the practice in some
fields to leave a polish rod clamp on the bottom side of the carrier bar. If so, slide the
clamp up or attach another one just below the carrier bar, and then tighten to the proper
specifications.

10. If equipped, reattach the chain to the rod rotator arm, making sure the arm is pointing
down, but not so far that it does not make contact with the roller.

11. To replenish the lost nitrogen, continue to add gas until the carrier bar reaches
approximately the same location it was at before it was bled down.

12. Close the fill/bleeder valve, remove the hose, install the dust cap and check for leaks.

13. Reinstall the counterweight actuator coil and secure with a nut.

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Operators Manual

14. Check and make sure that the red mushroom <Stop/Reset> button is in and apply
electrical power following approved lock out/tag out procedures. If the main circuit
breaker was OFF, turn the breaker ON.

15. Pull the red <Stop/Reset> button out and jog the cylinder up and down to the stroke
capacity of the Pumping Unit. This assures that the polish rod length, rod spacing
and Pumping Unit is performing nominally.

16. Jog the pumping unit several times before going to “Run” mode

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Operators Manual

Section 6 Software
This section discusses installation of the Sure Stroke Intelligent Lift™ Systems software.

PC Platform

The following (minimum) PC requirements are:

• Microsoft operating system (XP recommended)
• Internal RAM – 512 MB
• Microsoft Office Suite (Word, Excel, PowerPoint)

Communications Interface

The Sure Stroke Intelligent Lift™ System has been designed to interface with a computer
to check status of the pump, read various output data parameters, and to set various
input parameters that allow each pump to be customized to its operating environment.
The computer may be hooked directly to the pumping unit on site by establishing a hard
wire link between a laptop computer serial port and the power unit data port 1. This port is
generally used for diagnostics and to download software upgrades. Software changes
can only be installed by an authorized Sure Stroke Intelligent Lift™ Systems technician.
The pump may also connect to a remote computer if a radio modem or a regular
modem and direct telephone line connection have been installed in the power unit. This
connection is generally installed by an oil field operator to meet their specific requirements.

Communications Software

Custom software has been developed to enable a user to easily connect a computer to
communicate with and extract data from the required pumping unit. Sure Stroke
Intelligent Lift™ Systems has developed three programs in Microsoft Excel format that
allow data to be read in real time, settings to be up loaded to the pump, warning and
failure status to be checked and reset (if needed), and reports (including a dynocard) to
be generated. Contact your local Sure Stroke Intelligent Lift™ Systems sales
representative if assistance is required.

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Operators Manual

On-Site Data Acquisition Setup

Sure Stroke Intelligent Lift™ Systems furnishes a software package for control and data
acquisition. A laptop running a Windows operating system (Windows 98 or greater)
and a serial or USB port is required. A DDE interface program, DSData Server 4.0, is
also required and functions as an interface between the Excel program and the PLC.
The DSData Server is available from Automation Direct and can be downloaded from
their web site www.automationdirect.com.
Perform the following steps:
1. INSTALL SOFTWARE

• Create a new folder on the laptop computer called “Sure Stroke Intelligent Lift™ Systems” and
drag all the contents of the Sure Stroke Intelligent Lift™ Systems CD into it.
• Install the DSData Server by following the instructions and Key Code furnished with the
software.
• This completes the software installation. To complete the setup, an onsite connection to the
Power Unit PLC is required.
2. ESTABLISH CABLE CONNECTION

Connect the cable provided to COM 1 serial port on the laptop. Connect the
other end to communications port (RJ12) located above the control panel on the
power unit.

3. SETUP LINK CONFIGURATION

• Open the DsData Server and under Setup open Links.
• Click Add and then Link Editor in the bottom left corner.
• Enter the following data:
o Name: Direct
o Description: Onsite
o PLC Tab
o Family: 205 series
o PLC Type: 250
• Port Tab
o Devices: COM 1
o Baud Rate: 9600
o Parity: Odd
o Data Bits: 8
o Stop Bits : 1
o Flow Control: None

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Operators Manual

• Protocol Tab
o Protocols: KSequence
o Address 1
o Advanced Settings
o Timeout 800
o Data Timeouts 20000
o Retries 1
• Click <ACCEPT>. The dialog box “SETUP LINKS” should appear with the link
listed and a check in the box “LINK ENABLED” will come up, click “EXIT”, this
completes the link setup.

NOTE:

If a dialog box appears with an error message, click return an check

settings and cable connection.

There are two topics to set up, “DPData” and “DPData1”. Both topics are used in the
Sure Stroke Intelligent Lift™ Systems Software package. Make sure both names are entered as
below, no spaces.

4. SETUP TOPIC CONFIGURATION

f) Open “DsData Server” and under Setup, select “Topics”.

g) Click <Add> and then for topic name, enter “DPDATA”.
h) Click on the <COMM LINK> button and select “DIRECT”.
i) Click <Add to> and then, for topic name enter “DPDATA1”.
j) Click on the <COMM LINK> button and select “DIRECT”.
k) Set the update rate to 100.
l) Click <OK>. This completes the topic setup.

5. DATA ACQUISITION

m) Open “DsData Server”.

n) Open DPService Excel Files
o) When the dialog box asks to update links, click <Yes>. After a few seconds, data should
fill in empty fields.

NOTE:

Go to “View Options” in the DsData serve menu to configure how

you want the program displayed. If “Run DsData Server” on the
system tray is selection an orange light indicates a connection; a
yellow triangle indicates no connection.

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Operators Manual

DP Service Software

The Operations View (see Figure 40) is similar to a vehicle dashboard. The three
main working pressures of the system can be monitored along with the Rod Load,
Cylinder Position, Oil Temperature, and Counterweight Oil Recovery System Status.
The Warnings of future alarm conditions are also included in this view. These
warnings can be reset and the pumping unit started, stopped, and alarms reset. The
low speed down indicator is also helpful when adjusting the POC.

Operations View

Figure 40 Monitoring Software – Operation and Warning Screen

WARNINGS

Warnings are intended to forewarn of a future alarm condition. In most cases, adjustments
can be made to avoid an alarm, which could eventually shut down the unit. However, some
warnings will not trigger an alarm condition. If technical assistance is necessary, call Sure
Stroke Intelligent Lift™ Systems Technical Support.

RUN MODE AND STOP/RESET

The <Run Mode> a n d <Start/Stop> buttons can be used to remotely start, stop and reset an
alarm condition after it occurs.
• Normal Stop/Start - Click on <Start/Reset> button to stop unit. Click <Run Mode> to
restart.
• Reset - Investigate the alarm and manually record the error. To reset the warnings, first
click on the <Reset Warnings> button. When “Click Here To Complete Reset”
appears in the yellow box (to right), click to finish. Then, reinitialize the system by clicking

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Operators Manual

<Stop/Reset> and <Run Mode>.

Operations View Descriptions

POWER UNIT #
This data is especially useful when communicating remotely to verify communication with
the correct pumping unit.
OIL TEMPERATURE
Temperature of the hydraulic oil measured at the tank.
CWT PSI
Real time pressure (psi) in the counterweight.
HYD PSI UP
Real time hydraulic pressure in the cylinder Up chamber. Comparisons to the psi Down
chamber readings can assist in decisions regarding the balance of the hydraulic system.
HYD PSI DOWN
Real time hydraulic pressure in the cylinder Down chamber. Comparisons made to the psi
Up chamber can aid in decisions regarding balance of the hydraulic system.
ONLINE
This cell indicates whether or not the pumping unit is running. If the cell indicates NO, and the
Machine Reset indicates OUT, check the Alarms and Warning screens for cause of shutdown.
If the Machine Reset indicates IN, the unit has been shut off at the location and cannot be
restarted remotely.
MACHINE RESET
This is the red <Stop/Start/ Reset> button on the power unit control panel. If the button is
“out”, this indicates machine is in Run mode. If the button is “in”, the unit has been shut off.
CURRENT LOAD
Real time load in pounds attached to the carrier bar.
LAST CYCLE LOAD UP
Maximum load, last cycle.
LAST CYCLE LOAD DOWN
Minimum load, last cycle.
POSITION
Position in the stroke measured at the polished rod.
SPM
Strokes per minute, updates base on the average of the last 10 cycles.
S/L
Stroke length, updated each cycle.
MAX SL for PUMPING UNIT
Displays the maximum stroke capacity based on the pumping unit size.

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Operators Manual

HYDRAULIC OIL LEVEL

Indicates the hydraulic oil level is above or below the level switch.
CURRENT OIL RECOVERY SYSTEM TIME
Current time (minutes) since the Oil Recovery System was last activated. Comparing this
to the previous time gives an indication of external leakage and cylinder integrity.
PREVIOUS OIL RECOVERY SYSTEM TIME
Previous time (minutes) since the Oil Recovery System was activated. Comparing this to the
Current time gives an indication of external leakage and cylinder integrity.
RUN MODE STOP/RESET
These buttons are used to stop, start and reset the pump after a shutdown.
o Normal Stop/Start - Click on the <Stop/Reset> button to stop unit. Then, click

<Run Mode> to restart.
o To Reset after Alarm Check Alarm and record (if safe to restart), click <Stop/Reset>and
then <Run Mode>. Make adjustments or send a Service Tech to correct problem.

PUMP OFF CONTROLLER (POC) STATUS

Current status of the POC is indicated in this
window.
o The “POC Cycle” status light indicates if the controller is acting correctly.
o The “Consecutive POC Strokes” indicates how many strokes in a row have
occurred and how many are remaining before “POC Shutdown”.
o The “Automatically Restarting In (Min)” status light shows remaining time before
unit restarts.
The status of POC must be considered when making changes to the stroke length or speeds.
The
POC Shutdown feature requires logic V062404 or greater.
START-UP
The first two minutes after starting the stroke is half of the set stroke length and runs at speed
1. After 2 minutes, the stroke length changes to the set stroke length and continues to run at
speed 1 for another 20 seconds. No adjustments to speed or stroke length should be made
when this is on.
MIN RUN TEMP
If on, the charge pump will run, but the inverter will not start until hydraulic oil temperature
is above the default setting of V2171, 45 degrees.
COLD START
If oil temperature is below the default setting of V2073, 50 degrees, the pump will run at
speed 1. Do not make any changes to the speed or stroke length when this is on.
LOW COLUMN LOW SPEED
At startup, if load up is less than V2112, the speed selected is speed 1.
MAX LOAD LIMIT
Set point for casing level control and/or limiting Rod Load has been reached (V2105).
Default setting is the machine capacity unless a lower setting is needed for control.

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Alarms and Warnings View

This section indicates Alarm status, and is used to set Alarm and Warning parameters
(see Figure 41). If an Alarm is on, use the comments to aid in correcting the problem
and then restart the unit as described in the Operation View section. To change any of
the Alarm or Warning set points, enter the value in the Host column, and then click
<Write It>.

Figure 41. Monitoring Software –Warnings and Alarms Screen

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Alarms

ALARM DEFINITIONS
Alarm descriptions are provided below. These settings are determined by well configuration,
pumping unit size, and desired flow. Some of these settings are programmed at the factory;
others installed and adjusted during the first few days of running. Whenever well conditions
change or the pumping unit cycle has been adjusted (e.g., increase in speed), these settings
may need to be adjusted. Consult Sure Stroke Intelligent Lift™ Systems Technical Support if you
need help with these adjustments.

MAX CWT C300

Counterweight pressure is greater than the setting in “Cwt Max Limit V2030”. Possible causes
include:
1. Did not act on warning.
2. Setting is too low for running conditions.
3. Added gas due to increased load, but did not adjust Alarm value.
4. Over speed on the down stroke due to regeneration unit overload. This may create
low charge pump pressure allowing the counterweight actuator to close. This creates a
pressure drop through the valve, thus increasing the pressure in the counterweight area
of the cylinder

CWT MIN C301

The Counterweight pressure is less than the setting in “Cwt Min Psi Limit V2031”. Possible causes
include:
1. Did not act on the warning.
2. Possible leak in counterweight system.
3. Adjustments were made to counterweight pressure and the setting was not adjusted.
4. Colder weather decreased pressure.

CYL UP PSI MAX C302

Hydraulic pressure up exceeds the setting in “Cyl Up Psi Limit V2032”. Possible causes include:
1. Did not act on warning.
2. The load increased and the counterweight is too low for the current load.
3. The “Cylinder Up Pressure Switch V3003” is not adjusted properly.
4. Sticking of rod string on “up” stroke.
5. Linear Position malfunctioned causing cylinder to top out.

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CYL DOWN PSI MAX C303

Hydraulic pressure down exceeded the setting in “Cyl Dn Psi Limit V2033”. Possible causes
include:

1. Did not act on the warning.

2. Added gas to the Counterweight and did not check or adjust setting.
3. Warmer weather increased Counterweight pressure.
4. Sticking of rod string on down stroke.
5. Linear Position malfunctioned causing cylinder to bottom out.
UNDER LOAD C305

Load at any point in the cycle was less than setting in “Min Load in Cycle V2035”. Possible causes
include:

1. The setting is too high in V2035.

2. Loss of load due to a separated rod string.
3. Loss of load due to sticking of rod string on down stroke.
MIN LOAD UP C306

The load while going up was less than setting in “Min Column Load V2163”. Possible causes
include:

1. The setting is too high in V2163.

2. Loss of column load due to a separated rod string.
3. Traveling valve stuck open in BHP.
4. Tubing leak.
CYCLE UP TIME C307

The cycle time from the “Cycle Down Set Point V3000”, traveling downward to the “Cycle Up Set
Point V3001” on the Up stroke, exceeded the time set in “Cycle Up Time Alarm V2066”. Possible
causes include:

1. Setting too short for up cycle.

2. The up and down hydraulic chambers communicating.
3. The coupler assembly between the main motor(s) and the pump disengaged.
4. The main hydraulic pump leakage is too high.
CYCLE DN TIME C310

The cycle time from the “Cycle Up Set Point V3001”, traveling upward to the “Cycle Down Set
Point V3000” on the down stroke, exceeded the time set in “Cycle Down Time Alarm V2067”.
Possible causes include:

1. Setting time too short for down cycle.

2. The down chamber discharge valve is stuck open or leaking.
3. The Up and Down hydraulic chambers communicating.
4. The coupler assembly between the main motor/s and the pump disengaged.

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5. The main hydraulic pump leakage is too high.

LOW CHARGE PUMP PSI C311

The charge pump system pressure is less than the switch setting for more than one second.
Possible causes include:
1. The switch setting is too low.
2. Switch wiring loose or disconnected.
3. The Pump Off Controller is out of adjustment causing over speed on down stroke.
4. Switch failure.
5. Charge pump circuit leakage.

VFD OVERLOAD C312

The Variable Displacement Drive (VFD) has gone into overload.

INVERTER C314

The inverter tripped more than three times in three minutes.

Read the failure history in the Inverter, and follow instructions to correct the problem.

CHARGE PUMP OFF C315

The charge pump motor did not start. Probable cause is a wiring problem.

PUMP OVER CURRENT C316

The heater on the charge pump motor starter tripped. Possible causes include:
1. The heater adjustment is set too low for motor rating.
2. Relief valve for the make-up pressure is set too high.
3. Charge pump motor wiring is burned.
4. Wiring between the motor and starter is loose, shorted, or grounded.
5. Charge pump starter heater failure.

CABLE BREAK C320

Cable sensor plate moved away from Sensor. Possible causes include:
1. Loss of cable.
2. Well is sticking on the up or down stroke, jarring cables.
3. Sensor bracket loose.
4. Sensor failed.
5. Wiring circuit faulty.

BRAKE SYSTEM C322

1. Inverter brake system has failed.

2. Wiring is faulty.
3. Resistors burned or damaged.

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SPM LOW C323

The SPM went below the setting in “Min SPM V2041”. Possible causes include:
1. The set point for “Min SPM V2041” is set too low for cycle.
2. The Pump Off cycle is active and “Min SPM V2041” is set too low for POC cycle.
3. Main pump is worn causing excessive internal leakage.
4. Cylinder oil chambers are communicating.

CWT CHANNEL TRANS C324 PLC Channel 1 Counterweight transducer failed.

Possible causes include:

1. The component failed.
2. Circuit wiring is faulty.
3. PLC analog card has failed.

UP CHANNEL TRANS C325

PLC Channel 2 Hydraulic Up Chamber transducer failed. Possible causes include:

1. The component failed.
2. Circuit wiring is faulty.
3. PLC analog input card has failed.

DOWN CHANNEL TRANS C326

PLC Channel 3 Hydraulic Down Chamber transducer failed. Possible causes include:
1. The component failed.
2. Circuit wiring is faulty.
3. PLC analog input card has failed.

POSITION CHANNEL TRANS C327

PLC Channel 4 Position transducer failed. PLC analog input card has failed. Possible causes
include:
1. The component failed.
2. Circuit wiring faulty.
3. PLC analog input card has failed

HYDRAULIC OIL LEVEL LOW C331

Possible causes include:

1. CWT Oil Return system failure.
• Valve closed on counterweight.
• Return filter dirty/clogged.
• Solenoid valve/circuit wiring faulty.
2. External oil leakage.

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OIL TEMPERATURE SENSOR C332

PLC Channel 5 Temperature Sensor failed. Possible causes include:
1. The component failed.
2. Circuit wiring is faulty.
3. PLC analog input card has failed
HYDRAULIC OIL TEMPERATURE C333
The hydraulic oil temperature exceeded 160 degrees F. Possible causes include:
1. Excessive friction in system.
2. Hydraulic cooler fan is not running.
3. Hydraulic cooler fan running with a loose fan blade.
4. Temperature probe not reading properly.
LINEAR TRANSDUCER C335
The Linear Transducer read zero position. Possible causes include:
1. Chain broke.
2. Rotary sensor failed.
MULTIPLE TRIPS C337
Three alarms are tied to this alarm, “C314 Inverter”, “C303 Cyl Down Psi Max”, and “C332
Tank Over Temperature”. Any combination of these three alarms in three minutes will activate
this alarm. Refer to Alarm History to diagnose problem.

ALARM SET POINTS

CWT MAX PSI LIMIT V2030
This is the set point for “Cwt Max alarm C300”.
This setting should be 25% above maximum pressure in counterweight when cylinder is at
bottom of stroke. Further adjustments may be necessary after running at steady state.
CWT MIN PSI LIMIT V2031 (feature is disabled)
This is the set point for “Cwt Min alarm C301”.
This setting should be 25% below minimum pressure in counterweight when cylinder is at top
of stroke. Further adjustments may be necessary after running at steady state.
CYL UP PSI LIMIT V2032
This is the set point for “Cyl Up Psi Max C302”.
This setting is for protection of the machine. Default setting 2600 psi.
CYL DN PSI LIMIT V2033
This is the set point for “Cyl Dn Psi Max C303”.
This setting is for protection of the machine. Default setting 2600 psi.
MIN LOAD DOWN V2035
This is the set point for “Under Load C305”. Setting should be 75% of rod string weight.
Further adjustments may be necessary due to well conditions.

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BRAKE PWR LIMIT V2040

This is the set point for “Brake System C322”. Indication that the thermostat exceeds set value
and contact closes.
MIN SPM V2041
This is the set point for “Spm Low C323”. This value should be 20% less than SPM during Pump
Off cycle.
MIN COLUMN LOAD V2163
This is the set point for checking the load on the up stroke. The default setting is the rod load
and a portion of the column. This is only active on the up stroke. During start-up or a reset, this
Alarm is inactive for the first 200 strokes. This action allows the column load to build before
checking.
Warnings

Warning data is indication of future problems and requires investigation or maintenance action
to prevent a future condition that may stop the pump. For example, if the filter status
indicates “Change,” it means the filter is dirty and must soon be replaced in order to maintain oil
cleanliness.
WARNING DEFINITIONS

HVAC #2 OFF C200

Indicates the #2 Temperature Control System is switched off.

FILTER C201
Indicates the condition of the main hydraulic filter. If a change appears in the cell,
follow procedures to change the filter. Reset all warnings after completing
procedure.

CWT LOW C202

The pressure in the counterweight has dropped below the “Min Cwt Warning V2042”.
Possible causes:
1. Setting is too high.
2. Leaks in counterweight System.
3. Cooler ambient temperatures (Fall/Winter).

CWT HIGH C203

The pressure in the counterweight has gone above the “Max Cwt Warning V2043”.
Possible causes:
1. Setting is too low.
2. Gas was added to deal with increased load conditions and set point was not adjusted.
3. Warmer ambient temperatures (Spring/Summer).

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HYD PSI UP C204

The cylinder pressure on the up stroke has exceeded the “Cyl Up Max Psi
Warning V2044”. Possible causes:
1. The Cyl Up Psi Warning set point is too low.
2. The counterweight is too low.
3. The counterweight has a leak.
4. The load has increased.
5. Intermittent sticking of the rod string on the up stroke.

HYD PSI DOWN C205

The cylinder pressure on the down stroke has exceeded “Cyl Down Max Psi V2045”.
1. The “Maximum PSI Down Warning" set point is too low.
2. The Counterweight is too high.
3. The load has decreased.
4. Intermittent sticking of the Rod String on the down stroke.

CWT DISCHARGE C206

The Oil Recovery System requests oil from the counterweight unit more often than
the set point defined in “Min Cwt Oil Return Time V2037”.

HVAC#1 OFF C207

#1 Temperature Control System is switched off.

HAC#1 FAULT C210

#1 Temperature Control System has failed.

HAC#2 FAULT C211

#2 Temperature Control System has failed.

LOW COLUMN LOAD C212

The load on the up stroke is less than the set point in “Min Load Up V2036”.
1. Set point in “Min Load Up V2036” is too high.
2. Tubing leak, BHP slippage.

LOW CHARGE PUMP PSI C213

At some point in the pumping cycle, the charge pump pressure dropped below
60 Psi. The following are causes for the warning:
1. Charge pump psi may be below normal setting of approximately 125 psi.
2. Nitrogen accumulating in hydraulic chambers of cylinder.
3. Make up valve psi setting too low
4. Make up relief valve set too low.

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WARNING SET POINTS

Warning set points are determined by well configuration, pumping unit size, and
desired flow. Some settings are programmed at the factory, while others installed and
adjusted during the first few days of running. Whenever well conditions change or the
pumping unit cycle has been adjusted (speed increased for example), these settings
may need to be adjusted. Consult Sure Stroke Intelligent Lift™ Systems Technical
Support for further help.

MIN LOAD UP V2036

This is the set point for “Warning Low Column Load C212”.
This setting should be the weight (in lbs) of the rod string plus half of the column
weight. Further adjustments may be necessary due to well conditions. This feature is
for detecting down hole leakage problems.
W-SHORT DISCHARGE V2037
This set point is for C206 “CWT DISCHARGE”. The Oil Recovery System exceeds
maximum number of requests (two discharges in two minutes) for oil from the
counterweight unit.
MIN CWT V2042
This set point is for “Low CWT C202”. This setting should be 10% greater than “CWT
Min Psi V2031”. Further adjustments may be needed to prevent alarm from coming on
unnecessarily due to cycle conditions.
MAX CWT V2043
This set point is for “High CWT C203”. This setting should be 10% less than “CWT Max
Psi Limit V2030”. Further adjustments may be needed to prevent alarm from coming on
unnecessarily due to cycle conditions.
CYL UP MAX PSI V2044
Set point for “Hyd Psi Up Warning C204”. Default setting is 2200 psi. Further
adjustments may be needed depending on operating pressures.
CYL DOWN MAX PSI V2045
Set point for “Hyd Psi Down Warning C205”. Default setting is 2200 psi. Further
adjustments may be needed depending on operating pressures.

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Speed and Cycle View

This screen (see Figure 42) is used to view parameters involved with the pumping cycle.

Figure 42 Monitoring Software –Speed and Cycle View

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Adjusting the Pump Off Controller

At the start of the down stroke, the column load is transferred back to the tubing when the
traveling valve opens. If the fluid pressure is not great enough, the fluid level in the casing
is at or close to the pump level; this load transfer will be delayed. The load is measured by
the “pump off value V2046” in the acceleration area of the down stroke. This value can be
set by acquiring a dynamometer card (see Figure 43), and noting the load value where the
hook is being formed on the down stroke. This indicates incomplete pump fillage. Set
V2046 to a value slightly less than the load in this area.

The time for checking this value is important. The area for checking needs to be in the
area of the acceleration down. The setting for this is the value in the “Pump Off Delay
V2070”. This value should be the decel 2 setting in the inverter plus one second.

A second level of POC Control, available in logic version V062404 or greater, is when
consecutive POC strokes occur. The default setting for “Consecutive POC Strokes
V2202” is four. After four consecutive strokes, the pumping unit will shut off for two
minutes, the default setting for POC Off Time. The consecutive strokes range can be set
from two to ten and the “POC Off Time V2201” can be set from two to sixteen minutes.

Many factors play a role in optimizing the flow. If the SPM during normal operation is too
high, the POC Controller will act too often, and continuing POC strokes will shut the unit
off. If this is the case, speed settings should be set lower to reduce the flow. Changes in
the inflow to the well bore also vary requiring periodic adjustments. See Figure 43 for a
dynamometer card and plot.

VALUE IN V2070 DELAYS TIME FOR SEEKING LOAD SET IN

V2046 PUMP OFF VALUE. THIS IS THE AREA
FOR CHECKING THE LOAD V2046

This hook in the down stroke is an

indication of incomplete fillage

DOWN LOGIC
STARTS HERE (TOP
D YN A M O M T E R C A R D SWITCH)

Figure 43 Monitoring Software – Pump Off Controller

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Speed and Cycle Definitions

BOTTOM SWITCH V3000

Set point in the cycle where decel 1 is triggered on the Down stroke. Used to set decel point on
Down stroke.
TOP SWITCH V3001
Set point in the cycle where decel 2 is triggered on Up stroke. Used to set decel point on Up stroke.
LOW SPEED DN SWITCH V3010
Set point for the stopping point at the bottom of the stroke, when running down at speed 0.
SPD UP V2060-62
These three switches instruct the inverter which of the seven preset speeds to use on the up stroke.

SPD DOWN V2063-65

These three switches instruct the inverter which of the seven preset speeds to use on the down
stroke.
CYCLE UP TIME ALARM V2066
Set point for “Cycle Up Time Alarm C307”. This is the time in seconds allowed to get from the
bottom switch to the top switch before failing. Default setting is 20.
CYCLE DOWN TIME ALARM V2067
Set point for “Cycle Down Time Alarm C310”. This is the time in seconds allowed to get from the
bottom switch to the top switch before failing. Default setting is 20.
PUMP OFF TIME DELAY V2070
Time in seconds allowed to get from the top switch to the bottom switch before failing. Default
setting is 20. Allow enough time for a Pump Off cycle until cycle is in the acceleration down area.

PUMP OFF VALUE V2046

This is the set point for the Pump off Controller to act. Use 80% for a starting point for this
setting, further adjustments need to be made after Well load gets close to expected load.
POC OFF TIME V2201
The amount of time in minutes the pump is shut off when consecutive POC strokes equal the
setting in “Consecutive POC Strokes V2202”. Default is two minutes. The range can be set from
two to sixteen minutes.
CONSECTIVE POC STROKES V2202
The setting for consecutive POC strokes is the number of POC strokes in a row before POC
shutdown. Default setting is four strokes and can be set from two to ten.
MAKE UP VALVE PSI V2102
Set point that the cylinder up psi must be before the Make Up solenoid valve opens. Default setting
at startup is 500 psi. To set this properly requires comparing pressures on a dynamometer card.
The value should be 100 psi higher than the point where the two pressures cross on the up stroke.

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MAKE UP SOLENOID CLOSE TIME V2103

Set point for the Make Up valve to close after the Top Switch. The purpose of this alarm
is to
close before acceleration down starts. Setting in is tenths of a second. Default is half of
the time set for decel 2 in the inverter.
MAKEUP WINDOW
This set point is the window (sec) to seek “Make Up Valve Psi V2102”. The setting is
determined by the Pumping Unit size.
ROD LOAD LOW SPEED V2112
This set point limits the speed to Preset 1 if column load is less than this value. The
setting should be the Rod Load plus a portion of the column weight.
MAX LOAD LIMIT V2105
Set point for casing level control and/or limiting rod load. This number is entered as
“Load divided by ten.” Default setting is the machine capacity unless needed for
control.
LOAD SWITCH V3002
Rod Load set point used in cycle logic. Defines a sector of the cycle. The setting is
determined by the Pumping Unit size.
PRESSURE DIFFERENTIAL SWITCH V3003
This set point replaces the top switch in cases of sticking on the up stroke. The default
setting is
2000 psi. Further adjustments may be needed due to operating conditions.
LOW COLUMN LOAD V2167
If the value is less than “V2167 Low Column Load”, the cycle is set to speed 1. The
purpose is to brake the up cycle when running in an out of balance start-up condition.

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SPEED SELECTION CHART

There are seven preset speeds in the inverter. These preset speeds cannot be
viewed or changed remotely. Before changing speeds the settings must be known.
Use the table area to note speeds. See Table 8 for load settings.

Table 8. Load Settings

Memory Nickname Function Description

V2105 Max Load Cycle Set point for maximum machine load or casing level control. Setting should never
Limit exceed pumping unit capacity.
V2046 Pump Off Cycle
Parameter used to set the Pump Off Controller.
Value
V2036 Min Load Up Warning When the load Up is less than this setting, the warning for Low Column Load C212 is
V2112 Casing Cycle On.
When the load Up is less than this value, the pumping cycle is set to speed 1 Up and
Level Down.
V2167 Control
Low Column Cycle If the value is less than V2167 Low Column Load, the cycle is set to speed 1.
Load The purpose is to brake the Up cycle in an out-of-balance start-up condition.
V2163 Min Load Up Alarm When starting, if the column load is less than this value, the pump will run at speed
and 1. The Min Load Up Alarm turns on after 200 cycles if column load is less than this
Cycle value.
With braking system – when the load is less than this value going up, the pumping
cycle will be set to speed 1, until reaching the top switch. At this point, C306 Min
Load Up Alarm will come on and shut the pump off. The purpose is to break the
cycle up to avoid hitting the top.
V2116 Loss of Load Cycle When going up, the value is less than V2116 Loss of Load, the CWT Actuator is
closed to remove the CWT force. The purpose is to remove the CWT when a loss
of load is detected. This works in parallel to the V2163 Min Load Up Alarm.
V2035 Min Load Alarm
When the load down is less than this value, the pump will shut down for Alarm C305
Down

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General Settings View

Figure 44 shows the general settings screen. This screen is used mainly during
installation. Power and pumping unit setup data is entered in this view.

Figure 44 Monitoring Software – General Settings Screen

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General Settings
POWER UNIT V4000
Serial number of Power Unit. When communicating remotely, this is the set point viewed on
the Operations view. This data is especially useful when communicating remotely to verify
communication with the intended pumping unit.
OUT OF BALANCE V4010
(1=ON) Turns ON or OFF Out Of Balance System. Hardware must be installed for this feature.
SUPER CONTROLLER V4011
(0=OFF) 1=ON Brake system must be installed for this function to be on.
PUMPING UNIT SIZE 5 7 9 11 13 V4012
Sets program calculations for Pumping Unit size.
DYNO CARD STORAGE V4014
This turns ON or OFF “The Last Five Dynamometer Card” function.
POWER UNIT HP V4024
This matches calibration of the “Power Meter to Power Unit” size.
MACHINE LOAD V2077
Value removes the weight of the cylinder plunger and pulley assembly from rod and column load.
INVERTER START DELAY V2071
This is the time of the system check before the inverter starts. Default is 20 seconds.
FLOW MULTIPLIER V2072
This is the set point for flow meter coefficient. Based on size of flow meter.
HYD OIL TEMP START MODE V2073
Set point is entered in degrees F. The default is 50. When the machine starts, the unit will run
at jog speed until temperature is greater than this value.
FLOW METER C106
This turns ON or OFF the flow meter alarms. The default setting is 0. If a flow meter is
installed this value needs to be set to 1.
DYNACARD TIMER V2173
Sets time between data points for data collection of dynamometer card. Increase time to close
data collection on slow running pumps. Decrease to avoid overlap on faster running pumps.
POSITION COEFFICIENT V2150
Value based on position device used on Pumping Unit
Encoder 48 for #5; 76 for #7&9; 98 for #11 (Linear & Celesco 98)
MIN RUN TEMPERATURE V2171
When the hydraulic oil temperature is below this setting, the charge pump will run to warm the
oil but the pumping cycle is disabled. Applicable for under 100 HP only. Default setting is 45
degrees.

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Counters
A number of counters are used throughout the operational software. Run time
efficiencies, power consumption along with other efficiencies can be determined from
these counters. In some cases, it is necessary to enter or change the counter values.
For example, if a CPU needs to be changed, the values should be transferred to the
newly installed CPU. See Figure 46 for an example of the Counters screen.
These are double counters, after reaching 9999; they reset and add one to the next V-
memory location. For example, V1010 Total Time Powered counts from 0 to 9999;
V1011 counts in increments of
10,000. The result of the Total Time Powered counter = V1011*10,000+V1010 is
74,3423.
TOTAL STROKES V1003 & V1004
Total number of strokes since the power unit was installed.
TOTAL TIME POWERED V1010 & V1011
Total time powered since the pump was installed.
TOTAL KWh V1014 & V1015
Total KWh since pump was installed. Measured in .1 KWh.
TOTAL RUNTIME V1016 & 1017
Counts the number of minutes the charge pump motor was on since the unit was
installed.
SLOW STROKE COUNTER V1006 & 1007
Counts the number of strokes the pump was instructed to run at speed 1 down since
the power unit was installed.
OK TO RUN V1045 & 1046
Counts in minutes the time both X33 C66 are on since the unit was installed.

Figure 45 Monitoring Software – Counters Screen

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Last Five Failures Screen

This screen (see Figure 46) shows the last five alarms. This screen is useful for
tracking and analyzing alarm history and for diagnosing and correcting problems on
the surface equipment or down hole.
The last five alarms are listed starting with the most recent. Under Group 1 or Group 2,
the alarm is listed. By moving the cursor over the alarm description, a comment window
will pop up with troubleshooting data.

LAST FIVE ALARMS

ALARM
DATE TIME
GROUP 1 GROUP 2
1 11/8 8:29 CWT MAX #N/A
2 11/8 8:27 CWT MAX #N/A
3 11/8 8:27 CWT MAX #N/A
4 0/0 0:0 #N/A #N/A
5 0/0 0:0 #N/A #N/A

TROUBLESHOOTING GUIDE
CWT MAX CABLE BREAK
CWT MIN EXCEEDED MAX KW
CYL UP PSI MAX BRAKE SYSTEM
CYL DN PSI MAX SPM LOW
EXCEEDED MAX AMPS CWT TRANSDUCER
UNDER LOAD CYCLE UP TRANSDUCER
MIN LOAD UP CYCLE DN TRANSDUCER
CYCLE UP TIME POSITION TRANSDUCER
CYCLE DN TIME RESERVE
LOW CHARGE PUMP PSI HYDRAULIC OIL LEVEL LOW
MOTOR 1 HEATER OIL TEMP SENSOR
MOTOR 2 HEATER TANK OVER TEMPERATURE
INVERTER FAN MOTOR STARTER
MAKE-UP STARTER LINEAR TRANSDUCER
MAKE-UP HEATER RESERVE
FAN MOTOR HEATER MULTIPLE TRIPS

Figure 46 Monitoring Software – Last Five Alarms Screen

Section 7 Scheduled Maintenance

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This section briefly describes the routine maintenance tasks that must be performed on the
pumping system to maintain it running at peak performance.

Periodic Maintenance

Sure Stroke Intelligent Lift™ Systems recommends that preventative maintenance be

performed on the pump at various intervals to keep the pump running at peak
performance. Table 9 shows the recommended maintenance activities and the service
interval for each task.
Table 9 Preventative Maintenance Schedule

LADDER INTERVAL
ITEM TASK
REQUIRED 90 180
1 CHECK/ADJUST ALIGNMENT x x
2 CHECK STATUS OF HYDRAULIC DRIER CARTRIDGE x REPLACE
3 CHECK STATUS OF HYDRAULIC FILTER x REPLACE
4 CHECK FOR HYDRAULIC LEAKS x x
5 TEST/SERVICE CWT OIL RECOVERY SYSTEM x x
6 CHECK FOR NITROGEN LEAKS (IF SIGNS OF LOSS) x x
7 INSPECT HYDRAULIC HOSES x x
8 INSPECT CABLE SYSTEM x x
9 LUBRICATE CABLE SYSTEM x x
10 CHECK ROD ROTATOR OPERATION (IF APPLICABLE) x x
11* x REPLACE AUTO LUBRICATORS x REPLACE
12 x BLEED CYLINDER (IF NEEDED) x x
13 x INSPECT PULLEY ASSEMBLY x x
14 x INSPECT POSITION SENSOR x x
15 CHECK MOTOR COUPLERS x x
16 CHECK HARDWARE INTEGRITY x
17 LUBRICATE MOTOR x
18 CHECK FOR OIL IN REAR CWT (IF APPLICABLE) X
* Scheduled replacement is 180-day intervals but should be checked every 90 days and replaced based on an
as-needed basis

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Maintenance Tasks

1 . Check/Adjust A l i g n m e n t - C y l i n d e r alignment a f f e c t s p e r f o r m a n c e a n d
c y l i n d e r longevity. Misalignments increase friction and wear on pulley and cylinder
assembly components, including the wire cable, and may contribute to reduced well
packing life. Three measurements are involved when checking alignment: verticality,
cylinder to polished rod alignment, and the distance between the centerline of the cylinder
and polished rod.

a) Measure and establish verticality of the pump. Using a magnetic bubble level,
check the verticality of the pump cylinder in two axes (fore & aft, and left & right).
If the cylinder is not vertical, rotate the adjustable feet on each base leg as
required to bring the cylinder to the vertical position. See Figure 47

Figure 47 Cylinder Verticality

b) Verify that the polished rod is centered on the cylinder centerline. If it is not
centered, move the pump left or right as required establishing proper centering.
c) Verify the distance from centerline of the polished rod to the front edge of the
cylinder bottom cap. This is defined as the “setback” distance and is shown in
Figure 48 and Table 9.
d) This distance ensures that the cables will be in the same plane as the polished
rod. If the distance is not correct, move the pump fore or aft as required.

Figure 48 Setting Setback Distance

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Table 10 Pumping Unit Setback

PULLEY BOTTOM CAP
MODEL SETBACK
GROOVE (DIA) WIDTH

250 42.060 9.25 16.41 in

400 42.060 12.25 14.91 in
600 49.375 14.25 17.56 in
800 49.375 16.25 16.56 in

2. Check Status of Hydraulic Dryer Cartridge – The hydraulic system is sealed

and equipped with a sealed dryer cartridge to remove any moisture. Perform the
following steps:

a) Visually inspect the dryer cartridge. The desiccant

material in the cartridge should remain a bright shade of
blue when active. When the color changes to a light red,
some of its moisture absorbing capacity has diminished.
Bright red indicates it must be replaced.

b) Replace the cartridge and update the service record.

c) Clean the canister housing, clear hoses and bladder of

any collected oil.

d) Install new cartridge with the flat white rubber seal facing
upward.

3. Check Status of Hydraulic Filter – The main hydraulic

filter is self-monitored to indicate if it is dirty and needs to
be changed (Warning C201).

Perform the following steps

a) Turn the pump off by pulling out the red
<Stop / Reset>button.
b) Close both cylinder ball valves to block any fluid
pressure created by the column of oil in the
cylinder.
c) Place a catch basin under the filter to capture spilled fluid and remove the
filter element by turning it counter clockwise. Discard dirty filter.
d) Pre-fill the new filter before installing it to avoid any air accumulation in
the system. Install the filter element by turning it clockwise. Turn one full
turn after it is finger tight.
e) Open both cylinder ball valves.

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f) Install a new filter element by turning it clockwise. Turn one full turn after it
is finger tight. Place the mode switch to the “Jog” position and let the charge
pump run for several minutes to bleed any air from the line.
g) Return pump to the “Run” position and push the “Start” button in to resume
normal operation. Push the “Alarm Reset” button to clear the change filter
warning.
h) Record the date on the filter and service record for easy reference and
tracking of the hydraulic system condition.

4. Check for Hydraulic Leaks– The hydraulic system has sufficient tank reservoir and
counterweight capacity to sustain operation with minor leaks. However, any external
leak will ultimately cause the tank level to fall below operational level and cause the
pump to shutdown (alarm code 331).

Perform the following:

a) Visually inspect hydraulic connections
(fittings, ball valves, hoses) for signs of
leakage inside / outside hydraulic cabinet.
b) Be sure to check the fittings; quick
disconnect fitting and the hoses.
c) Fix any leaks detected by tightening the
connection or by replacing the defective
or worn component.
d) When replacing hoses on hydraulic
components, bleeding the system may be required.

5. Test/Service Counterweight O i l Recovery System – Under n o r m a l

o p e r a t i n g conditions there will be some oil loss past the cylinder seals as the
actuator moves up and down. The triple cylinder design is such that oil losses past the
seals will accumulate in the front counterweight.

The counterweight is also pre-charged with 10 gallons of oil at installation to serve as

a reservoir. If the seal loss oil is not periodically sent back to the hydraulic tank, the
pump will eventually stop for lack of oil. The counterweight oil recovery system takes
care of this by momentarily sending oil from the counterweight to the tank whenever a
low oil condition is detected. If there has been external loss of oil and there is
insufficient oil in the counterweight to return to tank, then the pump will automatically stop
for lack of oil.

The counterweight oil recovery system must be checked whenever the time between
discharges becomes too small or whenever external losses occur.

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Perform the following steps:

a) Place the mode switch in the “Jog” position. Note the clarity and
height of oil in the hydraulic tank sight glass.
b) Force the recovery system to act by momentarily pushing the CWT
oil return test pushbutton. The button is located above the PLC in
the electrical cabinet.

Oil Return Button

Figure 49 CWT Oil Return Pushbutton

c) If you can hear the flow back to the tank, then the oil level in the
counterweight is too low. Add oil to fill the tank to the top. If little or no
noise is heard, activate the switch for 10 seconds.

d) Check the sight glass located on the bottom portion of the

counterweight. If the oil is not visible in the glass, add oil to the
reservoir until the level reaches the top of the sight glass.
e) Check the sight glass for clarity and level change. The oil level
should increase at least 1/4-inch if working properly. If the oil level
does not increase at least 1/4-inch, change or clean the
counterweight oil recovery filter.

Sight Glass

Figure 50 Sight Glass

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To change the counterweight filter:

Direction of Flow
------------

Figure 51 Counterweight Filter Replacement

a) Close the valve on the inside of the cabinet where hoses pass through to the
pumping unit. Models without this valve require closing the valve at the bottom
of the counterweight.
b) Force the recovery system to act by momentarily pushing the CWT oil return
test pushbutton to remove any pressure in the circuit. The filter is now ready
for servicing.
c) Disconnect the hose from the filter canister. Recently manufactured units will
have the filter mounted on the cabinet wall in-line with the valve that was
previously mentioned..
d) Open the canister and clean the inside of the canister, then replace or clean the
filter cartridge and then reassemble cartridge.
e) Open the valve on the bottom of the counterweight.
f) Force the recovery system to act by momentarily pushing the CWT oil return
test pushbutton in order to purge air from the line.

Figure 52 Oil Recovery System Layout

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6. Check for Nitrogen Leaks (Signs of Loss) – If the counterweight

pressure is not holding in normal service, it is generally indicative of a leak.
Using a soapy water solution, look for possible air leaks along the black air
hose connection from the cylinder to the counterweight. Be sure to check the
fittings, the ball valve and the hose itself. Check the charge/drain valve at the
base of the counterweight. Fix any leaks detected by tightening the connection
or by replacing the defective or worn component. Note: when replacing
components, it will be necessary to temporarily close the counterweight ball
valves to prevent gas from escaping from the counterweight gas storage
cylinder.

Figure 53 Sure Stroke Intelligent Lift™ System Counterbalance System

External Air Leaks

Unlike hydraulic fluid, a minor air (nitrogen) leak may be hard to visually detect because
the gas simply escapes to the atmosphere. In order to prevent the need for frequent
adjustments to the gas pressure, it is important that the pressure be monitored for leaks
on a regular basis. The best way to do this is to monitor the pressure. By viewing the
touch screen or DPService programs, the hydraulic and counterweight pressures can
be observed. This method of checking is only valid if the counterweight pressure has
not been changed by adding or removing nitrogen since the last data was acquired.
The unit also must be running at a steady state with similar rod loads. If the rod load
has not changed but the hydraulic pressure up is higher, loss of nitrogen gas may have
occurred. Sure Stroke Intelligent Lift™ Systems software also includes monitors to
provide a low-pressure warning and one that will stop the pump (low pressure alarm) in
the event that the counterweight pressure drops below operational limits. Major leaks
may also be detected by visually observing or hearing air escape from the system.
Once a leak is detected, it must be fixed immediately to prevent degraded pump
operation.

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Internal Air Leaks

Within the cylinder, the air chamber is blocked from communicating with the up and down
hydraulic chambers by seals and an O-ring. Over the life of the cylinder, it is possible that these
may wear to the point air can enter one or both of the oil chambers. When this occurs, the
performance of the pump will degrade and the cylinder will ultimately have to be replaced with a
new or rebuilt one.

Aeration observed in the sight glass on the hydraulic reservoir oil may be an indication of worn
seals in the cylinder - but not in all cases. Incorrect adjustment or failure of the hydraulic
components may be the cause. If either of these conditions occurs, bleed the cylinder. If the
symptoms reoccur within a short period of time, a cylinder test is recommended to check for seal
leakage. Contact Sure Stroke Intelligent Lift™ Systems Service to schedule this test.

General Leaks

Perform the following steps:

a) Using a soapy water solution, look for possible air leaks along the black air hose
connection from the cylinder to the counterweight.
b) Be sure to check the fittings, the ball valve, and the hose itself.
c) Check the charge/drain valve at the base of the counterweight.
d) Fix any detected leaks by tightening connection or replacing defective/worn component.
e) When replacing components, temporarily close the counterweight ball valves to prevent
gas from escaping from the counterweight gas storage cylinder.
f) Once a leak is detected, fix immediately to prevent degraded pump operation.

7. Inspect Hydraulic Hoses – Under normal service, the hoses are designed for many
years of service. The communication hoses between the power and pumping unit are
subjected to possible damage when the unit is tracked forward and aft. Inspect all
hoses for damage to the outer cover or kinks. Check for bubbles in the cover which
may indicate damage to the inner core or wire braiding. Check for damage where the
cover transitions into the hose end fitting.

8. Inspect Cable System – The cable system on each pumping unit has been designed
to include a safety factor to sustain loads within the rated limit. Each cable system
includes a primary and secondary cable, as well as a cable target sensor to detect a
break and shut off the pump if one segment breaks. The load may be safely relieved
even when a single cable remains, by allowing the pump to be jogged down after a
break. Since cables are subjected to wear, they should be inspected at regular intervals
to ensure the load is balanced, between both segments, as well as checking for frayed
or worn strands. If a strand is broken or is in danger of breaking, both cables should be
replaced at the earliest opportunity.

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9. Lubrication of Cable System – Apply a spray lubricant such

as Vitalife 400 at each maintenance interval to the usable length of
each cable segment. The lubricant requires a cure time of only five
minutes after application, according to the manufacturer, when
applied from a spray aerosol container. Approximately two bottles
are r e q u i r e d for full application. Upright and backpack applicator
units are also available for the cable lubricant. Only the usable length
of the cable requires application. This is generally from the
carrier bar to the pulley support (cylinder fully retracted). A ladder
or cherry picker with an approved safety basket may be used to
climb to reach the extents of the cable at the top of the pulley support
area. The technician should use a face and nose mask to prevent
breathing the aerosol gas directly. If wind is a factor, move any
other affected assemblies away from the unit being sprayed.
10. Check Rod Rotator Operation – The rod rotator rotates the
rod string to promote an even wear on the rods. In order for
this system to function properly, the flipper assembly must be
periodically checked for proper operation. Check that the
flipper assembly is securely attached, level and has not slipped
down the cylinder. Check the roller assembly for free
movement as the arm passes by. Verify the arm is aligned
with the roller and making contact with the roller. The arm
should be adjusted at a downward angle but not so much that
it doesn’t make sufficient contact with the roller.
11. Replace Automatic Lubricators - Automatic lubricators
are set to operate for a period of six months in case the
replacement extends beyond the schedule 120 day period.
The lubricators and battery pack are scheduled to be
changed at four month intervals to insure proper lubrication.
To replace or check the lubricators, follow the “Releasing the
Load” and Lockout/Tagout Requirements.

Perform the following steps:

a) Climb to the top of the cylinder and observe the two lubbers located on top of the
pulley support block.

b) Visually verify that there is grease remaining in each cartridge and that the unit is
turned on (observe the red LED on top of the lubber to make sure it flashes
(working properly).

c) Verify the dust cover is in place and good condition to keep the moisture out.

d) To avoid climbing up on the unit, stop the unit at the bottom of the stroke and use
binoculars to observe the grease level in the canisters. A full or uneven use of
grease indicates a faulty unit.

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e) Another way to identify a lubricator problem is to look at the inner and outer
bearing races. Grease should be visible and no signs of wear should be
present.

f) If there is any indication of a malfunctioning, lubricator, or bearing wear, a

closer inspection is needed to determine the status.

To replace the cartridge and battery pack:

a) Remove the dust cover and shut off the motor.
b) Wipe any debris from around the connection point where the
assembly screws in and move the assembly from the pulley support
c) Remove the canister and batteries from the motor assembly and
install a new cartridge and battery pack. See Figure 54.

Cartridge Electronics Batteries Cap Protective Cover

Figure 54 Cartridge Replacement

d) Set the dip switches for the time to 6 months (Both ON) and the
ones for the volume to 250 CC (Both ON). See Figure 55.

Figure 55 DIP Switches

e) Remove the cap from the grease cartridge output and turn the selector switch to
the “ON” position. The motor will run for a few seconds and some grease
should be expelled from the cartridge.

f) Make sure to put the duct cap back on and then install the assembly onto the
pulley support.

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12. Bleed Nitrogen From the Cylinder (if needed) – During startup and anytime that air
is introduced to the hydraulic system such as during a hose or valve change, it will be
necessary to bleed any gas from the cylinder. Refer to the “Releasing the Load” to
prepare the cylinder for bleeding.

NOTE:

In order to perform this task, the power must be left “ON”. It is

IMPERATIVE that the counterweight actuator coil is removed, to
avoid the counterweight actuator ball valve from opening and
energizing the cylinder with the charge pump on.

To verify the system is set correctly for safe bleeding:

g) Check that the <Stop/Reset> button is IN and the “Run/Jog” switch is set to “Jog”.

h) Pull out the <Stop/Reset> button, and wait a half a minute before climbing the
unit. This will verify that the system will not start moving the cylinder.
i) Climb to the top of the cylinder and loosen both bleeder valves allowing any gas
pressure to escape. See Figure 56.

Up chamber

Down chamber

Figure 56 Bleeder Valves

j) If an assistant is available, pull out the <Stop/Reset> button intermittently a few
times until clear oil is seen coming from the bleeders. Short durations of running the
charge pump minimizes gas from being dissolved in
the oil. Leave the switch off and tighten both bleeders when oil is present.

k) If an assistant is not available, turn on the charge pump by switching the

“Jog/Run” switch to “Jog” and pulling out the “Stop/Reset” button. Wait for a half a
minute before climbing to verify the cylinder does not move.

l) Close both bleed valves and reinstall solenoid on counterweight actuator valve.

m) Check the hydraulic fluid level as shown on the tank sight glass in the hydraulic
cabinet, and add hydraulic fluid if necessary. Note that the pump will not run if
hydraulic fluid is below the level of the float switch.

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n) Follow the “Acquiring the Load” procedure to safely transfer the well
load back to the carrier bar.
13. Inspect Pulley Assembly – The pulley assembly utilizes durable nylon pulleys and
high strength bearings designed to carry loads for many years.

The automatic lubbers provide a constant outward flow of grease to the bearing.
This keeps the bearings lubricated and keeps outside contamination from migrating
into the bearings. These factors combine to make the pulley maintenance free under
normal circumstances. However, if the pump is misaligned or the cables are not
tensioned correctly, there may be side loads on the pulleys that can cause excessive
wear on some components in the pulley assembly.

When inspecting the pulley assembly, observe the thickness of the wear rings on each
side of the pulleys. When assembled, they are a quarter inch in thickness. With
proper alignment and lubrication, they should show very little signs of wear.

An indication of misalignment can be detected when wear on the inside of one pulley
and wear on the outside of the other is found. If metal debris is found the complete
assembly must be scheduled for replacement. See Figure 57.

Outer wear ring Inner wear ring

Figure 57 Pulley Bearings

NOTE:

There is NO program limitation in entering values which exceed

stroke length. Damage to the pumping unit may occur if too high a
speed or deceleration stopping point is entered.

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To ensure proper operation, check the following things:

o Check the chain attachment at the pulley assembly bracket. The bracket
hardware should be tight and the chain connection to the bracket secure.
o Inspect the chain looking for signs of rust and kinks.
o Check the chain guide bolts for tightness and verify wear pad is in good condition.
o Clean any debris away from around the gear and guide.
o Verify the gear is tight on the shaft.
o Inspect PVC weight guide clamps for tightness and that the tube is
mounted straight on the cylinder.
o Check the position reading (touch screen or DPService Operations screen).
With the cylinder all the way in it should read one to three inches.

15. Check Motor Couplings – The motor couplings connect the electric motors to
the hydraulic pumps. When the pump is running, they are constantly rotating and
change direction on each stroke. It is extremely important to verify the couplers
are properly engaged and not loose on either the motor or the pump shaft. See Figure
60.

Figure 58 Motor Couplings

To check couplers, stop the pump in accordance with lockout/tagout procedures:

o Remove the motor mount guards to reveal the coupler for inspection.
o Verify that couplers are properly engaged and check for looseness on each shaft.
o Check the insert for wear, missing pieces and cracks.
o Check that both motor and pump side couplers are tight on the shafts.
o On charge pump couplers, check both sides making sure spider is
contained correctly.

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16. Check Hardware Integrity

o Verify all hardware (nuts, bolts and fasteners) are properly tightened during the
manufacturing process
o Visually inspect all hardware on the pumping and power unit.
o Visually examine all vents in both the electrical and hydraulic cabinet. Clean any debris
and clean or replace filter elements.
o Inspect the motor mounts, pump and bell housing hardware, base tie downs, pulley
assembly hardware.
o Check tightness of any hardware that shows signs of being loose.

17. Lubricate Motor – The main motor has two grease fittings that allow the bearings to be lubricated.
Once every six months apply several shots of grease to each fitting to avoid any problems with the
motors. See Figure 59.

NOTE:
Never pump grease into a bearing cavity without first removing the
purge plug. Grease will pass through the seal and into the armature
cavity and may damage the motor.

Figure 59 Lubricate Main Motor

• Both the main and charge pump motor require greasing (in some cases, the fan motor).
• Locate and clean the grease fittings found at each end of the motor.
• Remove the purge plug found on the opposite side of the grease fitting.
• Use Chevron SRI grease or equivalent.
• Slowly pump grease into the bearing cavity until it comes out the purge plug hole.

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18. Check for Oil in Rear Counterweight – During normal operation an oil film is left on
the shared cylinder surfaces. The oil migrates to the front counterweight and eventually
a portion may migrate to the rear counterweight on sizes 9 through 13 pumping units.
Oil found in the rear counterweight cannot be returned to the reservoir by means of
the counterweight oil return system.
Using a container, open the ball valve on the bottom of the rear counterweight and
collect any oil that comes out. If the front counterweight sight glass shows oil, there is
no need to add oil to the system. If the sight glass is clear, add a few inches of oil to the
reservoir. See Figure 60.

SSi COUNTERBALANCE SYSTEM

Figure 60 Sure Stroke Intelligent Lift™ Systems Counterbalance System

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Section 8 Touch Screen Operation

Introduction

Sure Stroke Intelligent Lift™ Systems uses a touch screen to control basic operations needed for
daily field management. The touch screen has the following capabilities:
o Displays the appropriate speed selections and alarms.
o Built-in database for entering pump and well details including rod string details.

o Operation screen displays real time rod load, SPM, stroke length and cylinder pressures.
Cycle status is also displayed in the lower portion of the screen.
o Speed and cycle screen for easy selection of speeds and adjustment of stroke length.
o Pump off controller (POC) adjustments for setting load value and delay. A second level of
flow control which shuts the pumping cycle off by setting consecutive POC strokes and
shutdown time.
o Advanced set point adjustments (Warnings, Alarms and Load settings). This feature
requires a clear understanding of the advanced settings. This function requires a unlock code
that can be provided by your local Sure Stroke Intelligent Lift™ Systems Service Technician.
o Automatically recognizes well and pump when connection is made. Well details must be
entered in database for this function to work and to save dynamometer cards.
o Runtime data automatically updated and available after connection to pumping unit is made.
o All set points are saved. If the PLC is not connected to the touch screen the following message
will appear:

Figure 61 Error Message

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Menu Selection

OPERATIONS (Initial Screen)

When the user initially powers up, the <OPERATIONS> screen will appear. This screen displays real-
time system parameters which are useful to monitor the system.
To view other screens, press the <DIRECTORY> button. The <DIRECTORY> button provides
a path to the <LOG IN> screen, which allows pump settings to be changed.

Figure 62 Operations Screen

Table 11. Operations Screen

BUTTON DESCRIPTION
Rod Load Total weight of the rod column under load. Time delay =.5 sec
CWT PSI Displays current counterweight pressure on Up and Down cycles.
Position Displays piston position in relation to the bottom of the cylinder.
Current Oil Ret Running count since the last oil return from the counterweight.
PSI Up Current hydraulic pressure reading from cylinder during the Up stroke
SPM Strokes per minute; Adjust by changing Up/Down speeds and stroke
Oil Temp length
Temperature of oil in the hydraulic tank
Previous Oil Ret Time (min) elapsed from the last return of oil from counterweight to
PSI Dn tank
Current hydraulic pressure reading from cylinder during the Down
Max Load stroke
Maximum load during the current stroke. Value is reset after each
Min Load stroke. load during the current stroke. Value is reset after each
Minimum
stroke.inches the piston travels from the bottom stopping point to
Total
Stroke Length
the top stopping point. It is calculated and updated every stroke by
the PLC.

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DIRECTORY

The <DIRECTORY> screen allows access to various parameter readings in the pumping unit. The
user must click on <LOG IN> and enter a password to change any speed or position settings on the
pumping unit. See the <LOG IN> screen on the next page for details. The <HELP> screen may be
used to get more information on a selected function or warning.

Figure 63 Directory Screen

Table 12 Directory Screen Descriptions

BUTTON DESCRIPTION
Set Speed Cycle Sets top and bottom deceleration points of stroke cycle.
General Set Points Sets pumping unit parameters and general set points for operation.
Set PSI Alarms Sets parameters for the PSI-related alarms (warnings) to trigger.
Jog Control Sets jog/run mode using a toggle switch on the touch screen.
Set POC Parameters Sets pump off controller (POC) values for slow speed operation.
Set Load Alarms Sets parameters for the load-related alarms (warnings) to trigger
Operations Displays real-time pumping unit values.
Warnings Displays pumping units warnings.
Alarm History Displays the last 10 pumping unit alarms.
Load Graph Displays the pumping unit performance in graphical view.
Counters Displays real-time pumping unit parameters.
Set Time Date Sets the time and date in the touch screen.
Log In Enables user to change pumping unit parameters thru password.

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LOGIN

The LOGIN screen allows the user to change parameters and settings within the pumping unit.
• Level #1 LOGIN – For operator use
• Level #2 LOGIN – For service technician use only
• DEFAULT SETTINGS – for Factory use ONLY. Not be used in the field.
NOTE: Timeout will occur within 20 minutes unless user interaction occurs.

Figure 64 Login Screen (Initial)

1. Enter the password code “121”, and then click <ENTER>.

Figure 65 Login Screen (Password)

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2. Press <DIRECTORY> to return to the previous menu and to make setting changes
on desired pumping unit screens.
3. If an unauthorized attempt is made to change parameters without first setting the
password, the following message appears:

Figure 66 Login Screen (Protection Error)

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Set Speed Cycle

Displays the pump speed cycle. The Top and Bottom deceleration points mark the settings at which the
motor will start decelerating, at the end of the stroke. These acceleration ramps are longer as the
speed is increased. During slow speed pump off periods, the <SL SP BTM DECEL PT> setting will be used.

Figure 67 Set Speed Cycle Screen

Table 13 Set Speed Cycle Screen Descriptions

BUTTON DESCRIPTION
Top Decel Point Uppermost point on cylinder stroke where pump starts to decelerate.
Bottom Decel Point Lowermost point on cylinder stroke where pump starts to decelerate.
Bottom deceleration point used during Pump Off Control
SL SP Btm Decel Point
(POC). Entered value must always be lower than bottom
Up Speed ( ) deceleration point.
Incrementally steps “Top Decel Pt” upward/downward by one
Down Speed ( ) Incrementally steps “Bottom Decel Pt” upward/downward by one
Max. Allowed Height Uppermost system limit for stroke height
Top Stop Position Displays the actual cylinder top stop position during pumping stroke
Bottom Stop Position Displays the actual cylinder bottom position during pumping stroke
Allows user to compensate for up to 35 inches of transducer
position in the PLC. The encoder offset cannot be set to
Enc Offset negative numbers.
For example, if the zero stopping position during a Down stroke
is 10 inches from the bottom of the cylinder, the Enc Offset
would be set at “8” to make the PLC correctly calibrate to a zero

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Jog Control

This screen allows the user to manually jog up and down using the touch screen.

Figure 68 Jog Control Screen

Table 14. Jog Control Screen Descriptions

BUTTON or
DESCRIPTION
INDICATOR
Run/Jog Selector Toggles selection between “RUN” or “JOG”
Button to jog the pumping unit upward by small increments;
Jog Up
Unit stops movement when button is released
Button to jog the pumping unit downward by small
Jog Down
increments; Unit stops movement when button is released
Reset Warnings Resets all pumping unit warnings. Condition for warning must be
fixed.
Displays real-time rod load (pounds). The rod load is equal to
Rod Load the Up cylinder force + CWT force – Down cylinder force – the
Machine Load divided by two. Reading has a time delay of
approx. 0.5 sec.
Hyd PSI Up Displays counterweight pressure on Up stroke
Hyd PSI Down Displays counterweight pressure on Down stroke
Displays position of the piston with respect to the bottom
Position
of the cylinder. Reading has approximately a 0.5 sec delay
Max. Allowed Height Displays the maximum allowed stroke height
S/L Displays the calculated stroke length (updates every stroke)

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Load Graph

Displays a real-time graph of pump activity.

Figure 69 Load Graph Screen

Table 15. Load Graph Screen Descriptions

BUTTON or
DESCRIPTION
INDICATOR

Displays strokes per minute. Calculated by the PLC after every

SPM completed stroke. Calculations are limited from 0.5 to 9.9. SPM is
adjusted by adjusting the UP/DOWN SPEEDS and the Stroke
Length.

Max. Load Displays the maximum rod load (pounds) during stroke
S/L Displays the stroke length
Min Load Displays the minimum rod load (pounds) during stroke
POC LBS Displays the rod load (pounds) during pump-off mode
POC Control Displays whether the Pump Off Control is ON or OFF
Push to Hold Pauses the graphical representation of the load vs. stroke chart
Loaded Display indicating whether the graph is still loading or already loaded.

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General Set Points
Displays the general set points for the pumping unit.
Table 16. General Set Points Descriptions
BUTTON or
INDICATOR
Location
Pumping Unit Model
Power Unit HP
Machine Load – LBS
Hyd Oil Start Temp – F
Min Run Temp – F
CWT Oil Pulse Time -Sec
Oil Return Warning - Min
Figure 70 General Set Points Screen
DESCRIPTION
User entry field for well number
User entry field for pumping unit model
User entry for power unit horsepower (15,25,40,60,100,125 or 150)
Sets the combined weight of factory parts (piston, pulley, cable).
Total weight is subtracted from rod load weight to obtain machine
weight.
Minimum oil temperature required before operating pump.
Factory default is 45ºF.
Minimum tank oil temperature required to run at full
speed. Factory default is 50ºF.
Number of seconds that the CWT bleeder valve is ON when
oil is requested from the hydraulic tank. Default is 5 seconds.
Sets the number of minutes that will generate a warning
for activation of the oil return system. Factory default is 25 min.
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Set POC Parameters

Sets the Pump Off Controller parameters.

Figure 71 Set POC Parameters Screen

Table 17. Set POC Parameters Screen Descriptions

BUTTON DESCRIPTION

Set Pump Off Rod Load Rod load weight required to enable Pump Off Control mode

Delayed period of time from the initiation of the Down stroke to the
Set Pump Off Check
time where load is checked - to enable Pump Off Control mode
Time

Consecutive POC Number of strokes in Pump Off Control mode before the pumping
Strokes Before Stop unit stops operation and turns off

Set # Pump Off

Number of minutes the pumping unit is off before restarting.
Stop Minutes

POC Control Off Displays ON/OFF state of Pump Off Control mode (view only)

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Pump Off Controller

The Power Off Controller (POC) allows the Sure Stroke Intelligent Lift™ System to conserve energy
during periods when oil production has slowed. Adjusting the POC Load Value and POC Time Delay
settings will slow the pump operating speed when incomplete bottom hole pump (BHP) fillage is sensed
and thus reduce the slow stroke percentage.

Accel and decel ramps set points are preset in the variable speed controller. The accel set points are the
time (sec) to accelerate from zero to 90Hz. The decel set points are the time to decelerate from the set
speed to zero RPM. Typically the maximum speed is 1800 RPM (60 Hz). The time to accel or decel is
proportional to the speed selection. For example, operating at 1800 RPM (60 Hz), the accel/decel time
would be 66% of the time set in the drive. Typically, shorter accel/decels can be set for pumping systems
with lower horsepower Power Units. Caution should be taken when operating with higher horsepower units
to avoid overstressing the system and rod string. See Figure 72 for a graphical overview of the pumping
cycle.

POC Time Delay - Setting allows fluid load

transition time before checking the string load
on down stroke. Typically, the delay is shorter
than the accel down time to allow smooth speed
downshifting in the event of a POC condition.

POC Load Value – Represents the target load

for determining a pumped off condition. The
set point is typically set to 80% of the predicted
load at startup. Adjustments are determined by a
dynamometer card review.

Top/Bottom Switches Low Speed Down Switch

Top and Bottom switch set points This is the deceleration setting for the
determine the point of deceleration, POC speed. Switch setting is typically
and not the end of the stroke. The set lower than Bottom Switch setting
acceleration and deceleration ramps to have the down stroke end at
are set in the VFD and are longer as approximately the same point as when
the speed is increased. operating at the selected speed. This
switch can also be adjusted lower to
allow a slight tap down of the BHP to
break out debris or gas.

Figure 72 Graphic Display of Pumping Cycle

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Warnings

Displays the pumping unit warnings.

Figure 3 Warnings Screen

Table 18. Warnings Screen Descriptions

INDICATOR DESCRIPTION

Hyd Filter Warning that the filter is becoming saturated and should be changed.
Warning that the minimum CWT pressure has been exceeded. May be
CWT Min
an indication that the CWT is leaking or that weather has cooled.

CWT Max Warning that the maximum CWT pressure has been exceeded.
Warning indicates a high counterweight load and/or a change in well
CYL Dn PSI
conditions.

Warning indicates high rod load pressure on the motor. Once the well
CYL Up PSI has stabilized and CWT pressure is adjusted, Up pressure should not
change significantly.

In Low HP units, warning indicates a large voltage spike has occurred

Supp Trip (LHP) / Temp
and the suppressor needs to be replaced. In High HP units, indicates
Warning (HHP)
an oil over-temperature condition is approaching.

Warning that charge pump pressure is less than 75 psi in HHP and less
Low Chrg PSI
than 35 psi in LHP units for 0.7 seconds.

Min Load Up Warning that rod load pressure on Up stroke is lower than expected.
Warning that the time between activation of the Oil Return System is
Short Discharge
less than the Oil Return Warning setting. Factory default is 25 min.

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INDICATOR DESCRIPTION
Warning that oil temperature is below the minimum starting temperature.
Oil Below Min Start Temp No motion is allowed until the oil warms above the minimum set value.
The factory default setting is 45 F.

Minimum oil temperature required for a cold start is too low. When oil
temperature is below the value set, only slow motion is allowed until the oil
Unit on Cold Start warms above this value. The charge pump is prohibited from running in
units with tank heaters until oil temperature is above 43 F.

PLC cannot detect the presence of the 2-ton (smaller) air conditioning unit.
HAC#2 (150HP only) May be an indication of a wiring fault in the sensing resistor.

Fault internal to the 2-ton air conditioning unit, which has shut down.
HAC#2 int (150HP only) Typical faults are power phasing error, internal circuit breaker trip or
compressor failure.

PLC cannot detect the presence of the 5-ton air conditioning unit.
Usually an indication of a wiring fault in the sensing resistor. In
150 HP systems, the 2-ton air conditioning unit will continue to operate in
HAC#1 (HHP only) the event of a 5-ton failure, providing some oil cooling. In
100/125HP systems, a failed condition will usually cause an oil over-
temperature condition, shutting down the pump

Fault internal to the 5-ton air conditioning unit, which has shut down.
HAC#1 Int (HHP only) Typical faults are power phasing error, internal circuit breaker trip or
compressor failure.

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Counters

Displays state of pumping unit parameters.

Figure 74 Counters Screen

Table 19 Counters Screen Descriptions

INDICATOR DESCRIPTION
Displays total number of strokes since Startup or since the last reset.
Total Strokes
The count includes slow strokes, POC strokes and full operational
strokes.
Displays total number of slow strokes since Startup or since the last
Total Slow Strokes reset. Slow strokes occur during the first two minutes of Startup,
POC time, or below min. run temperature if the rod load is too low or
high.

Displays the total time the system is energized, including when the
Total Time Powered pump is stopped and powered. The count will be held during
power outages and is reset only by the <RESET COUNTERS>
button.

OK to Run Displays the time the system is OK to, including slow speed.
Displays the time that the STOP button is in Run Mode. Time
Total Run Time
includes when the System is in JOG mode or has stopped due to an
Alarm.
Reset Counters Resets all counters. Must be performed by a Level 2 service technician.

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Set PSI Alarms

Displays the pumping unit PSI alarm settings.

Figure 75 Set PSI Alarms Screen

Table 20. Set PSI Alarms Screen Descriptions

INDICATOR DESCRIPTION
Pressure seen from the rod load is exceeded on the Up stroke. When the
Alarm – CylUpPSI 'UP PSI' exceeds the 'MAX HYD UP PSI' alarm setting, this alarm will set
(Warning – CylUpPSI) and stop the system. Maximum allowed pressure is 1800 psi.

Counterweight load pressure is exceeded on the Up stroke. When the

Alarm – CylDnPSI 'DN PSI' exceeds the 'MAX HYD DN PSI' alarm setting, this alarm will set
(Warning – CylDnPSI) and stop the system. Maximum allowed pressure is 1800 psi.

Alarm – CylUpTime Maximum time exceeded for the expected Up cycle set speed.

Alarm – CylDnTime Maximum time exceeded for the expected Down cycle set speed.

Measured strokes per minute (SPM) is less than the alarm value set.
Alarm – LowSpm Calculations are limited from 0.5 SPM to 9.9 SPM.

Alarm - UpCylPsiSw Pressure sensor switch mounted in the hydraulic up line has failed.

Maximum counterweight pressure is exceeded. Pressure is adjusted by

Alarm- CwtMax adding or removing nitrogen from the counterweight tank. Maximum
(Warning – CwtMax) allowed pressure is 1000 psi.

Alarm- CwtMin Minimum counterweight pressure is exceeded. Pressure is adjusted by

(Warning – CwtMin) adding or removing nitrogen from the counterweight tank.

Set Load Alarms

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Displays pumping unit load alarm settings.

Figure 76 Set Load Alarms Screen

Table 21 Set Load Alarms Screen Descriptions

INDICATOR DESCRIPTION

Setpoint for casing level control. This value should be set above
A-MaxLoad
the stabilized max load (No alarm associated with this indication).
A-MinLdInCyl Setpoint to shut off off pump when rod separation occurs on Down stroke.
Setpoint based on reduction in rod load which indicates that the
RodPartSetting
rod string has likely parted.

PosCheckPoint-IN Setpoint where “LowColLowSpd” setting should check for rod load.
Setpoint on the Up and Down cycle which decreases current speed to
LowColLowSpd speed
1 when the load is less than this value. Works in conjunction with
“PosCheckPoint-IN” setting.
Setpoint used at startup (200 cycles) to decrease current speed to
LowLdLowSpd
speed 1 when the load is being acquired at Startup.
Alarm-MinLoadUp
Use same setting as “LowLdLowSpd”
(Warning-MinLoadUp)
Auto Re-Cal Sets all the system warning levels to 90% of the alarm level

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Alarm History

Displays the pumping unit alarm history with a Date and Time stamp. Alarms
are cleared by pressing the <STOP/RUN RESET> button. If space is exceeded,
a scroll bar will come up when alarm history exceeds page size (e.g., 50 alarms).

Figure 77 Alarm History Screen

Set Time Date

Sets the time and date in the touch screen. Does not set the PLC date and time.

Figure 78 Set Time/Date Screen

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Section 9 Troubleshooting

Alarms and Warnings

Alarms

When a pump is found offline the Alarm description is listed. Troubleshoot and make
corrections and then reset by tapping the “Rst A” button. The pump can also be reset by
pushing in and pulling back out the red mushroom button on the power unit. See Table
22 for a list of alarms.

Table 22 Alarms

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ALARMS
CAUSE REMEDY
Modbus D SSi SETTIN
Base= 1 COIL abbreviation
G
CHECK ALL GAS CONNECTIONS
3566 C301 CWT MIN V2031 EXTERNAL LEAK. WITH SOAPY SOLUTION FOR
LEAKS.
INTERNAL LEAK IN CYLINDER BLEED HYDRAULIC CHAMBERS TO
BETWEEN GAS CHAMBER AND OIL. CHECK FOR NITROGEN.
CWT OIL RTN SYSTEM OUT OF REFER TO CWT OIL RECOVER Y
CALIBRATION (LOW CWT OIL LEVEL) PROCEDURE
DECREASE IN AMBIENT
TEMPERATURE DUE TO SEASONAL
CHANGES. (LITTLE TO NO LEAKAGE
GOING INTO WINTER MONTHS) ADD NITROGEN TO CWT UNIT
DECREASE IN PRESSURE DUE TO
EARLY MORNING TEMP. NOT BEING
CONSIDERED WHEN ADDING GAS.
"A-CWT MIN PSI LIMIT" V2031 IS NOT MONITOR CWT PRESSURE AND
SET CORRECTLY. ADJUST SETTING.
PRESSURE TRANSDUCER CIRCUIT REPAIR LOOSE OR SHORTED
FAILURE. CONNECTIONS. REFER TO WIRING
DIAGRAM.
REPLACE TRANSDUCER. REFER
TO WIRING DIAGRAM.

REPLACE ANALOG CARD. REFER

TO WIRING DIAGRAM.

3567 C302 I CYL UP

PSI MAX
I V2032
CWT LEAK OR PSI TOO LOW. ADD NITROGEN,

INCREASE IN COLUMN LOAD (LOWER ADD NITROGEN, BALANCE THE

CASING LEVEL).
"A-CYL UP PSI LIMIT" V2032 IS NOT
SET CORRECTLY.
WELL PACKING CHANGE, EXCESSIVE
FRICTION IN STUFFING BOX.
PUMPING UNIT NOT SIZED
PROPERLY FOR WELL
CONFIGURATION.
PRESSURE TRANSDUCER CIRCUIT
FAILURE.
LOAD
MONITOR CWT PRESSURE AND
ADJUST SETTING.
HAVE FIELD OPERATOR RE-
ADJUST.
CONFIRM WELL CONFIGURATION
AND USE PUMP CALCULATOR TO
CHECK FOR PROPER SIZING.
REPAIR LOOSE OR SHORTED
CONNECTIONS. REFER TO WIRING
DIAGRAM.
REPLACE TRANSDUCER. REFER
TO WIRING DIAGRAM.
REPLACE ANALOG CARD. REFER
TO WIRING DIAGRAM.

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ALARMS
CAUSE REMEDY
Modbus SSi
COIL SETTING
Base = 1 abbreviation

CYL ON PSI ADDED TOO MUCH NITROGEN
3568 C303 V2033
MAX WHEN BALANCING SYSTEM.
INCREASED ROD STRING
FRICTION ON DOWN STROKE
(WELL PACKING TO TIGHT).
"A-CYL ON PSILIMIT" V2033 IS
NOT SET CORRECTLY.
OVERLOAD CR EATED BY
PARTED ROD OR JAMMED
BOTTOM HOLE PUMP.
PRESSURE TRANSDUCER
CIRCUIT FAILURE.
3569 C304 NOT USED
BLEED OFF SOME CWT.
RE-ADJUST PACKING. REFER TO
WELL PP1CKING ADJUSTMENT.
MONITOR CWT PRESSURE AND
ADJUST SETTING.
CHECK FWD LOAD. REFER TO WELL
TEST PR OCEDURES.
REPAIR LOOSE OR SHORTED
CONNECTIONS. REFER TO WIRING
DIAGRAM.
REPLACE TRANSDUCER.REFER TO
WIRING DIAGRAM.
REPLACE ANALOG CARD. REFER
TO WIRII\IG DIAGRAM.

STUFFING BOX TOO TIGHT ADJUST PACKING

UNDER
3570 C305 V2035 CAUSING EXCESSIVE
LOAD
FRICTION
"A-MIN LOAD IN CYCLE" V2035 CHECK SETTING AND COMPARE TO
IS NOT SET CORR ECTLY. WELL D.t TA.
EXCESSIVE FRICTION DOWN JOG UNIT UP AND DOWN AND
HOLE COMPAF1E TO WELL DATA.
FLOATING, HEAVY OIL. CHANGE SPEED DOWN TO A
SLOWE1 SPEED.
MIN LOAD A-MIN LOAD UP NOT SET
3571 C306 UP V2163
CORRECTLY,
200 STROKES AFTER RESET
THE COLUMN LOAD WAS LESS
THAN "A-MIN LOAD UP" V2163 WELL DOSE NOT BUILD COLUMN
LOAD DUE DOWN HOLE PROBLEMS.

CYCLE UP TIME SET TOO SHOR T. INCREASE TIME.

3572 C307 V2066
TIME
COUPLING ASSEMBLY CHECK COUPLER ASSEMBLY(S).
BETWEEN MOTOR(S) AND THE
PUMP(_SlDISENGAGED.
OCCURRED AS A SECONDARY CHECK FOR OTHER ALARMS.
ALAR M.
OIL CHAMBERS TEST CYLINDER
COMMUNICATING IN
CYLINDER.
INVERTER SET TO LOCAL CHANGE TO REMOTE

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ALARMS
CAUSE REMEDY

Modbus SSi
COIL abbreviatio SETTING
Base= 1
n

CYCLE TIMESET TOO SHORT. INCREASE TIME.

3573 C310 V2067
DN
TIME
COUPLING ASSEMBLY BETWEEN CHECK COUPLER ASSEMBLY(S).
MOTOR(S) AND THE PUMP(S)
DISENGAGED.
OCCURRED AS A SECONDAR Y CHECK FOR OTHER ALARMS.
FAILURE
CYLINDER DOWN CHAMBER MAKE- CHECK FOR PROPER MAKE-UP
UP VALVE STUCK OPEN. VALVE OPERATION.

OIL CHAMBERS COMMUNICATING IN TEST CYLINDER

CYLINDER.

INVERTER SET TO LOCAL CHANGE TO REMOTE

LOW SUDDEN LOSS OF OIL FROM CHECK FOR SIGNS OF

3574 C311 CHARGE SWITCH HYDRAULIC SYSTEM. HYDRAULIC LEAKS.
PUMP PSI
AIR IN CYLINDER OIL CHAMBERS. BLEED CYLINDER, REFER TO TP 021

ELECTRICAL CIRCUIT PROBLEM CHECK WIRE CONNECTIONS.

SWITCH FAILURE REPLACE
WORN OR DAMAGED PUMP REPLACE
PUMP TURNING IN WRONG DIRECT CHECK PUMP ROTATION
COUPLER BETWEEN MOTOR AND REMOVE COVER GUARDS AND
PUMP DISCONNECTED. EXAMINE.
VFD
3575 C312
OVERLOAD

3576 C313 NOT USED

INVERTER FAILED READ FAILURE ON INVERTER,

3577 C314 INVERTER SWITCH MAKE ADJUSTMENTS. REFER TO
INVER TER MANUAL.

LOOSE OR BURNED WIRES CHECK WIRING

CHARGE FAULTY WIRING, LOOSE OR OPEN CHECK WIRING

3578 C315 CONTACT
PUMP OFF CIRCUIT

FAULTY STARTER, WORN TEST AND REPLACE

CONTACTS.

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ALARMS
CAUSE REMEDY
Modbus COIL SETTING
Base= 1 SSi
abbreviation
CHG PUMP AMPERAGE SETTING TOO LOW CHECK AND ADJUST TO MOTOR
3579 C316 OVER- CONTACT RATING.
CURRENT

MOTOR DEGRADING TEST MOTOR/CHECK VOLTAGE.

PSI SET TOO HIGH FOR MOTOR ADJUST RELIEF VALVE SETTING.
SPECS

CIRCUIT FAILURE CHECK WIRING, REFER TO WIRING

DIAGRAM.

HEATER FAILURE REPLACE CHECK FOR CAUSE

HEATER FAILURE REPLACE CHECK FOR CAUSE

NOT
3580 C317
USED

CABLE FAILURE REPLACE CABLES, USE TENSIONER

CABLE
3581 C320 SWITCH TO ADJUST. CHECK & ADJUST
BREAK
CYLINDER ALIGNMENT
LOSS OF LOAD DUE TO HEAVY
CHANGE TO A LOWER SPEED DOWN.
CRUD
RE-STEAM WELL
TEST SENSOR, REFER TO
SENSOR FAILURE
VV!RING DIAGRAM
SENSOR CIR CUIT FAILURE. CHECK WIRING, REFER TO WIRING
DIAGRAM
3582 C321 NOT USED

BRAKE OUT OF BALANCE CONDITION BALANCE SYSTEM,

3583 C322 V2040
SYSTEM EXCEEDED BR AKE CAPACITY.

BRAKE FAILED REFER TO INVERTER MANUAL

LOOSE WIRING BETWEEN BRAKE CHECK WIRING REFER TO WIRING

AND INVERTER DIAGRAM

LOOSE WIRING BETWEEN BRAKE

AND PLCX37

THE UNIT IS IN PUMP OFF MODE ADJUST SETTING,

AND THE SPM SETTING IN "A-MIN
3584 C323 SPM LOW V2041
SPM" V20 41 IS TOO HIGH FOR THIS
CONDITION.
MAIN PUMP WORN CAUSING TEST PUMPS FOR EXCESSIVE
EXCESSIVE INTERNAL LEAKAGE. LEAKAGE
CYLINDER OIL CHAMBERS TEST CYLINDER
COMMUNICATING.

ALARMS

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Modbus SSi CAUSE REMEDY

COIL SETTING
Base= 1 abbreviation

CWT FAULTY WIRING (OPEN CIRCUIT). CHECK CIRCUIT; REFER TO WIRING

3585 C324 WIRING
CHANNEL DIAGRAM

COMPONENT FAILURE (OPEN TEST AND REPLACE

CIRCUIT).
UP FAULTY WIRING (OPEN CIRCUIT). CHECK CIRCUIT. REFER TO WIRING
3586 C325 WIRING
CHANNEL DIAGRAM
COMPONENT FAILURE (OPEN TEST AND REPLACE
CIRCUIT).

ON FAULTY WIRING (OPEN CIRCUIT). CHECK CIRCUIT, REFER TO WIRING

3587 C326 WIRING
CHANNEL DIAGRAM
COMPONENT FAILURE. TEST AND REPLACE

POSITION FAULTY WIRING (OPEN ClRCUIT). CHECK CIR CUIT, REFER TO WIRING
3588 C327 WIRING
CHANNEL DIAGRAM
COMPONENT FAILURE (OPEN TEST AND REPLACE
CIRCUIT).

3589 C330 NOT USED

HYD OIL EXTERNAL LEAK CHECK FOR LEAKS.

3590 C331 SWITCH
LEVEL LOW

CWT DISCHARGE BALL VALVE MAKE SURE CWT VALVE IS OPEN.

CLOSED.
CWT OIL RETURN FILTER DIRTY.
CWT OIL SYSTEM WAS NOT
CHECKED AFTER A REPAIR
INVOLVING A HYDRAULIC LEAK.
SOLENOID VALVE FAILURE
(ELECTRICAL).
SOLENOID VALVE FAILURE
(MECHANICAL)
FAULTY WIRING, OPEN OR
OIL TEMP
3591 C332 WIRING SHORTED CIRCUIT BETWEEN PLC
SENSOR
AND TEMPERATURE TRANSMITTER.
FAULTILY TEMPERATURE
TRANSMITTER.
THERMOCOUPLE GROUNDING IN
HYD TANK FITTING
REPLACE OR CLEAN FILTER.
CHECK FOR PROPER OIL LEVEL IN
COUNTERWEIGHT
CHECK WIRING, REFER TO WIRING
DIAGRAM
REPLACE CARTRIDGE
CHECK CIRCUIT, REFER TO WIRING
DIAGRAM
TEST AND REPLACE
DISCONNECT THERMOCOUPLE
WIRES FROM TEMPERATURE
TRANSMITTER AND TEST FOR
CONTINUITYTO·GROUND.IF
GROUNDED REPOSITION PROBE.

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ALARMS

Modbus SSi abbreviation CAUSE REMEDY

COIL SETTING
Base= 1

HYD OIL EXCESSIVE FRICTION IN SYSTEM CHECK COMPONENTS FOR

3592 C333 ANALOG
TEMP. EXCESSIVE HEAT
FAN MOTOR DID NOT START CHECK FAN MOTOR CIRCUIT, REFER
TO WIRING DIAGRAMS.
TEMPERATURE TRANSMITTER REFER TO TEMPERATURE
OUT OF ADJUSTMENT TRANSMITTER INSTRUCTIONS

HYDRAULIC COOLER FAN CHECK FOR LOOSE FAN BLADE.

RUNNING WITH LOOSE FAN BLADE
3593 C334 NOT USED

LINEAR POSITION TRANSDUCER FAILED CHECK WIRING

3594 C335 N/A
TRANSDUCER

POOR GROUNDING OF POWER REPLACE

AND PUMPING UNIT.
LOOSE WIRING IN POSITION CHEt:K WIRING REFER TO WIR lNG
SENSOR CIRCUIT. DIAGRAM
LOSS OF CABLE ON OR CART ON CHECK CABLE AND CART
LINEAR SCALE.
3595 G336 NOT USED

ANY COMBINATION OF THE CHECK ALARM HISTORY TO FIND

MULTIPLE FOLLOWING ALARMS, 3 IN 3 CAUSE FOR ALARM. REFER TO THIS
3596 C337 N/A
TRIPS MINUTES:INVERTER,TANK OVER GUIDE FOR REMEDY.
TEMP, HYD PSI DOWN.

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Warnings

Warnings are early warning indications of future problems that should be investigated
and corrected to avoid an Alarm that will shut the pump down. For example, if the filter
status indicates “Change,” it means the filter is dirty and must soon be replaced in order
to maintain oil cleanliness. Warnings can generally be reset by tapping the “Rst W”
button. See Table 23 for a list of warnings.
Table 23. Warnings

WARNINGS
CAUSE REMEDY
Modbus SSi
COIL abbreviation
SETTING
Base = 1

3201 C200 HAC#2 OFF

DIRTY HYDRAULIC OIL FILTER CHANGE FILTER

SWITCH
3202 C201 W-CHANGE X23 NO COLD START WITH PARTLY RESET AFTER RUNNING WITH
HYD FILTER CLOGGED FILTER WARM OIL

FAULTY SWITCH OR OPEN CIRCUIT CHECK SWITCH AND WIRING.

REFER TO WIRING DIAGRAM

V2042 LEAK IN CWT SYSTEM CHECK FOR LEAKS

3203 C202 W-CWT SETTING TOO HIGH CHECK AND ADJUST SETTING
LOW
FAULTY PRESSURE TRANSDUCER REPLACE TRANSDUCER

V2043 ADD PRESURE TO CWT AND DID NOT ADJUST SETTING

W-CWT READJUST SETTING
3204 C203
HIGH
FAULTY PRESSURE TRANSDUCER REPLACE TRANSDUCER

INCREASE IN AMBIENT ADJUST SETTING

TEMPERATURE

ACQUIRE DYNAOCARD AND

V2044 LOAD SPIKE ON PUMPING UNIT
CHECK FOR LOAD SPIKES
W- HYD
3205 C204
PRESSURE SETTING SET TOO LOW ADJUST SETTING
UP
FLOW LINE CLOSED CHECK VALVES IN FLOW LINE

FAULTY PRESSURE TRANSDUCER REPLACE TRANSDUCER

PACKING TOO TIGHT ON

V2045 STUFFING BOX
LOSS OF LOAD ON PUMPING UNIT
W- HYD ON DOWN STROKE
3206 C205 EXCESSIVE FRICTION OR
PRESSURE
DN STICKING DOWN HOLE

SETTING SET TOO LOW ADJUST SETTING

FAULTY PRESSURE TRANSDUCER REPLACE TRANSDUCER

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WARNINGS
CAUSE REMEDY
Modbus SSi
COIL SETTING
Base = 1 abbreviation

EXTERNAL LEAK IN HYDRAULIC

CHECK FOR LEAKS
SYSTEM

CLOGGED CWT RETURN FILTER REFER TO CWT OIL RECOVERY

3207 V2037 SYSTEM PROCEDURE
W-SHORT
C206
DISCHARGE
BALL VALVE ON CWT CLOSED OPEN BALL VALVE

FAULTY LEVEL SWITCH OR CIRCUIT CHECK SWITCH AND SPRING

FAULTY SOLENOID VALVE OR CHECK SOLENOID VALVE OR

WIRING CIRCUIT CIRCUIT

3208 C207 HAC#1 OFF

HAC#1
3209 C210
FAULT

HAC#2
3210 C211
FAULT

LAZY OR PARTIALLY STUCK OPEN

3211 W-LOW V2036
TRAVELING VALVE
C212 COLUMN TEST DOWN HOLE INTEGRITY
LOAD LEAK IN TUBING

SETTING IMPROPERLY SET CHECK SETTINGS

CHARGE PUMP RELIEF VALVE ADJUST RELIEF VALVE

SETTING IS TOO LOW
W-LOW SWITCH
3212
C213 CHARGE X23 NO AIR IN CYLINDER BLEED CYLINDER
PUMP
FAULTY OR LOOSE WIRING CHECK WIRING

FAULTY SWITCH CHECK SWITCH AND

ADJUSTMENT

106