PCS 4000 Single Well Controller User Guide
Contents
1. you may want to set B DELAY TIME See B DELAY TIME on page 13 for more information 6 The controller counts down the DELAY TIME SALES SET 02 while monitoring the casing pressure flow rate or both Note DELAY TIME SALES is the maximum time the well is allowed to stay open after the plunger arrives The controller responds to the first input to close the well The close input may be Casing pressure see step 7 Low flow rate see page 12 Critical flow K factor see page 12 DELAY TIME SALES countdown reaches zero see page 13 Another close input unrelated to casing pressure low flow rate critical flow K factor or time For example low or high sales line pressure a manual input to close the well and so on 7 Casing pressure normally drops while the plunger rises When the casing pressure starts to build the controller monitors the increase in pressure When the increase equals the DIFFERENTIAL CLOSE PRESSURE DIP value the controller goes to step 8 Usually a minimal increase in pressure such as 1 or 2 psi is desirable 8 The controller counts down the DELAY CLOSE TIME SET 08 When the DELAY CLOSE TIME countdown reaches zero the controller checks the casing pressure again to see if it has still increased by the DIFFERENTIAL CLOSE PRESSURE DIP value If the increase is a brief spike in pressure the controller continues the DELAY TIME SALES countdown The controller2. H high sales line pressure input a L low sales line pressure input M manual close O open time ran out S increase in casing pressure input U drop in casing pressure input CLS information shows How long the A valve was closed E A letter that explains why the A valve opened C CLOSE TIME counted down to zero a D differential open pressure input M manual open R load factor input a T casing time input Note If the A valve opens because a close input stops there is no letter For example the A valve closes in response to a close input caused by low or high sales line pressure When the sales line pressure returns to normal the A valve opens The CLS information does not include a letter Operating Mode Report READ 11 The controller s operating mode E TIME MODE mode 1 m TUBING LINE MODE mode 2 E CASING TUBING MODE mode 3 m CASING LINE MODE mode 4 For more information see How Pressure Operation Works on page 7 Battery Status Report READ 00 This report displays the current voltage of the battery and the solar panel Example BATTERY 7 00V SOLAR 9 24V Sensor Status READ 09 This report shows whether the sensor is ON or OFF Note The sensor must be ON to read the sensor input When using the Time operating mode you can set the sensor to OFF PCS recommends setting the sensor to off only if you are not running a plunger Software Version R
3. 2 Check sensor 1 Press ON 2 Run a steel wrench along the back of the sensor If the controller goes to DELAY TIME SALES the sensor is OK If the controller does not go to DELAY TIME SALES call your PCS sales and service representative Test 3 Check sensor alignment 1 Realign the sensor by 90 degrees Example If the sensor is aligned on the north or south side realign it on the east or west side 2 If realigning the sensor does not solve the problem call your PCS sales and service representative Short term fix for the sensor problem Use the CASING DROP PRESSURE feature see page 12 Plunger has surfaced but Plunger Travel Time History READ 06 shows C instead of A or B E Make sure sensor is turned on Press READ 09 The controller s display should show SENSOR ON If the display shows SENSOR ON go to Test 1 If the display shows SENSOR OFF press SET 09 and then press ON Go to Test 3 step 2 Test 1 Check CASING DROP PRESSURE 1 Press READ 20 2 Make sure the CASING DROP PRESSURE is high enough that the plunger surfaces before the pressure is reached For instructions see page 12 If the CASING DROP PRESSURE is set correctly go to Test 2 Test 2 Check controller by disconnecting the sensor 1 Disconnect the sensor from the sensor and ground terminals on the inside of the controller s faceplate 2 Press ON The controller should count down the OPEN TIME If the controller goes from OPEN
4. Check sensor alignment 1 Realign the sensor by 90 degrees Example If the sensor is aligned on the north or south side realign it on the east or west side 2 If realigning the sensor does not solve the problem call your PCS sales and service representative Short term fix for the sensor problem Use the CASING DROP PRESSURE feature see page 12 Y4TIOYULNOD TIIM ATINIS OOOV SOd PCS 4000 SINGLE WELL CONTROLLER USER GUIDE Plunger has surfaced but Plunger Travel Time History READ 06 shows NO PLUNGER instead of a travel time Make sure sensor is turned on Press READ 09 The controller s display should show SENSOR ON f the display shows SENSOR ON go to Test 1 If the display shows SENSOR OFF press SET 09 and then press ON Go to Test 2 step 2 Test 1 Check controller by disconnecting the sensor 1 Disconnect the sensor from the sensor and ground terminals on the inside of the controller s faceplate 2 Press ON The controller should count down the OPEN TIME If the controller goes from OPEN TIME to DELAY TIME SALES the controller s circuit board is not working properly Call your PCS sales and service representative If the controller does not go to DELAY TIME SALES continue with the next step 3 Use a wire to short the sensor and ground terminals The controller is OK if it goes to DELAY TIME SALES 4 Reconnect the sensor to the terminals Make sure the wires are put back in correctly Test
5. TIME to DELAY TIME SALES the controller s circuit board is not working properly Call your PCS sales and service representative f the controller does not go to DELAY TIME SALES continue with the next step 3 Use a wire to short the sensor and ground terminals The controller is OK if it goes to DELAY TIME SALES 4 Reconnect the sensor to the terminals Make sure the wires are put back in correctly Test 3 Check sensor 1 Press ON 2 Run a steel wrench along the back of the sensor If the controller goes to DELAY TIME SALES the sensor is OK f the controller does not go to DELAY TIME SALES call your PCS sales and service representative Test 4 Check sensor alignment 1 Realign the sensor by 90 degrees Example If the sensor is aligned on the north or south side realign it on the east or west side 2 If realigning the sensor does not solve the problem call your PCS sales and service representative Short term fix for the sensor problem Use the CASING DROP PRESSURE feature See page 12 Solenoid Shift Valve Problems Solenoid shift valve does not operate at any time or does not operate at night If the solenoid does not operate at night the solar panel may be powering the controller during the day Test 1 Check fuse 1 With a screwdriver move the power switch to off see page 3 2 Remove the controller s faceplate 3 Remove the fuse from its yellow casing Ifthe fuse is defective repla
6. This may save wear and tear on the plunger If the casing pressure drops by the specified value the controller starts the DELAY TIME SALES countdown even if it does not receive an input from the arrival sensor 1 Note the casing pressure at the moment when the A valve opens for example 400 psi 2 Note the casing pressure when the plunger surfaces for example 300 psi 3 Set the CASING DROP PRESSURE to the difference between these 2 values 400 300 100 Add an additional 10 15 psi for example 115 psi The additional 10 15 psi makes sure the plunger surfaces before the CASING DROP PRESSURE is reached If the CASING DROP PRESSURE replicates a plunger arrival too closely it may be reached before the plunger surfaces The Plunger Travel Time History then shows a C when the CASING DROP PRESSURE is reached Example LAST PLUNGER 0 C 0 10 20 The C in the example above shows that the CASING DROP PRESSURE was reached after 10 minutes and 20 seconds of OPEN TIME and B OPEN TIME if any The plunger did not surface during that time or the arrival sensor malfunctioned Test the sensor If it is OK the CASING DROP PRESSURE may need to be increased If you are not using CASING DROP PRESSURE set it to 0 psi B DELAY TIME SET B2 B DELAY TIME is normally set to 00 00 00 For those few wells that have liquid trailing behind the plunger you may want to set a few seconds of B DELAY TIME to let the liquid clear out of
7. a The element should be free from dirt oil and so on Check for cracks in the solar panel Check whether the solar panel is shaded during any part of the day If it is position it so it receives the most sunlight each day N USER GUIDE 4 Check the solar panel wire connection 5 Make sure the power switch is on The controller s display should be on 6 If the solar panel tests good but the batteries are not lasting as long as they should call your PCS sales and service representative Test 4 Check solenoid shift valve 1 Press ON 2 Ifthe solenoid won t open clean the supply hoses and puck inside the solenoid valve 3 Retest 4 lf they are good replace the puck or the entire solenoid Transducer Problems Display shows transducer reading of 0 psi The surge protector or transducer may be defective or the transducer wire may have been completely cut 1 Re calibrate the transducer See Calibrating the Transducers on page 8 2 If the transducer won t hold the calibration change the controller to Time Mode Press SET 11 and enter 1 3 Call your PCS sales and service representative Display shows fluctuating or false transducer reading The transducer wire may be defective 1 Re calibrate the transducer See Calibrating the Transducers on page 8 2 If the transducer won t hold the calibration change the controller to Time Mode Press SET 11 and enter 1 3 Call your PCS sales and servi
8. be reached LOAD FACTOR SET 24 LOAD FACTOR is a feature used with Mode 2 tubing pressure minus line pressure or Mode 4 casing pressure minus line pressure Load Factor helps insure that the liquid load in the tubing is less than the energy needed to lift the load to surface When Load Factor is enabled the controller will not open the well until 2 set points are met The controller compares the line pressure to the tubing pressure Mode 2 or the casing pressure Mode 4 E In both modes the controller compares casing tubing and line pressures as a ratio to determine the net lifting energy See the calculation below When both set points and all other open criteria are met the controller opens the well to production A well s load factor is the ratio of casing pressure minus tubing pressure to casing pressure minus line pressure LOAD FACTOR Casing Pressure Tubing Pressure Casing Pressure Line Pressure If you set the LOAD FACTOR to 50 the controller opens the A valve when the ratio is 50 or lower and the other open criteria have been met Example Casing Pressure Tubing Pressure 100 psi Casing Pressure Line Pressure 500 psi m 100 500 20 E If the LOAD FACTOR is set to 20 or a lower value the controller opens the A valve Normal values for LOAD FACTOR range from 40 to 60 depending on the well s individual characteristics If you are not using LOAD FACTO
9. controller by disconnecting the sensor 1 Disconnect the sensor from the sensor and ground terminals on the inside of the controller s faceplate 2 Press ON The controller should count down the OPEN TIME If the controller goes from OPEN TIME to DELAY TIME SALES the controller s circuit board is not working properly Call your PCS sales and service representative If the controller does not go to DELAY TIME SALES continue with the next step 3 Use a wire to short the sensor and ground terminals The controller is OK if it goes to DELAY TIME SALES 4 Reconnect the sensor to the terminals Make sure the wires are put back in correctly Test 3 Check plunger 1 Check whether the plunger is stuck in the lubricator 2 If the plunger is not stuck in the lubricator go to Test 4 Test 4 Check the sensor 1 Remove the sensor from the wellhead 2 Press ON If the controller counts down the OPEN TIME go to step 3 f the controller goes straight into DELAY TIME SALES there is a short Either the wire going to the controller is bad or the sensor must be replaced Go to step 5 3 Hold the sensor in your hand and move a steel wrench through the sensor band If the controller goes to DELAY TIME SALES the problem may be a wellhead electrical current Go to step 4 USER GUIDE 4 Possible causes of a wellhead electrical problem The sensor or sensor wire may be defective or The well may need PCS newest style 2
10. goes back to step 7 f the increase is an actual or solid pressure increase the controller goes back to step 1 7 Y4TIOYULNOD TIIM ATINIS OOOV SOd PCS 4000 SINGLE WELL CONTROLLER USER GUIDE CALIBRATING THE TRANSDUCERS Pressure operation uses pressure transducers E Casing transducer SET 16 E Tubing transducer SET 17 H Sales line transducer SET 18 You must calibrate all pressure transducers being used Transducers may be wired to the controller and calibrated using the controller or they may report information to the controller over a wireless connection Important Sales line information is available on the electronic flow measurement EFM device Sales line information can also be obtained from a transducer you may want to install There may be mitigating reasons to install a Line Pressure transducer Calibrate Transducers Wired to the Controller Casing Transducer Calibration 1 Calibrate the casing transducer for the low pressure With transducer in place remove pressure Press SET 16 ON OFF OFF ON 2 Calibrate the casing transducer for the high pressure Apply pressure to the transducer After applying pressure measure with an accurate pressure gauge to obtain the pressure value for the next step Press SET 16 ON OFF ON enter the pressure value For example if the current casing pressure is 200 psi enter 00200 Tubing Transducer Calibration 1 Calibrate the tubing tr
11. great in this situation See CASING PEAK TIME on page 11 Features for Closing the A Valve In addition to the basic functions for intermitting a well with pressure operation you can use any of the features for closing the A valve For more information see Features for Closing the A Valve on page 12 Features for Special Circumstances CASING DROP PRESSURE SET 20 Because the well does not have a plunger the controller can t start the DELAY TIME SALES when the plunger surfaces during OPEN TIME or B OPEN TIME Instead the controller monitors the casing pressure When the casing pressure drops by the CASING DROP PRESSURE value the controller starts the DELAY TIME SALES countdown To specify the CASING DROP PRESSURE follow these instructions 1 Note the casing pressure at the moment when the A valve opens Example A well intermitting without a plunger into a 100 psi sales line and trying to produce 1 barrel of water each cycle should have a beginning casing pressure near 400 psi 2 Note the casing pressure when the fluid hits surface Example 300 psi 3 Set the CASING DROP PRESSURE to the difference between these 2 values Example 100 psi The Plunger Travel Time History shows a C when the CASING DROP PRESSURE is reached Example LAST PLUNGER 0 C 0 10 20 The C in the example above shows that the CASING DROP PRESSURE was reached after 10 minutes and 20 seconds of OPEN TIME and B OPEN TIME
12. if any Sales Line Safeguard Features Follow the plunger instructions for Sales Line Safeguard Features on page 13 to program these functions LOW LINE CLOSE PRESSURE SET 15 m HIGH LINE CLOSE PRESSURE SET 14 m DELAY LINE CLOSE TIME SET B8 m DELAY TIME SALES SET 02 TROUBLESHOOTING If you have a problem with the controller try these troubleshooting tips If they don t solve the problem call your PCS sales and service representative Controller Display Problems Controller won t turn on or controller s display is blank The controller never sleeps The display should never be blank while the controller is on 1 With a screwdriver move the power switch to off see page 3 2 Wait a few seconds and then move the power switch back to on If the display remains blank go to Test 1 Test 1 Check fuse 1 With a screwdriver move the power switch to off 2 Remove the controller s faceplate 3 Remove the fuse from its yellow casing Ifthe fuse is defective replace it with a 5 amp 250 volt fuse The controller s box contains 1 extra fuse When you are done replace the controller s faceplate and move the power switch to on Ifthe fuse is OK go to Test 2 Test 2 Check battery and wire connection The battery life is approximately 1 to 3 years The controller has a safety feature If the battery voltage is low the controller closes the motor valve and shuts in 1 Check the battery voltage wit
13. pressure CASING PEAK TIME SET 21 CASING PEAK TIME is normally set to 99 00 00 when the feature is not used When you use this feature the controller opens the A valve after the casing pressure peaks The controller monitors the casing pressure independently of the DIFFERENTIAL OPEN PRESSURE The controller counts down the CASING PEAK TIME It restarts the countdown whenever the casing pressure increases by 1 psi For example the CASING PEAK TIME is 10 minutes When the A valve closes the controller counts down the CASING PEAK TIME If the casing pressure builds 1 psi within 10 minutes and the FALL TIME has reached zero the controller restarts the CASING PEAK TIME countdown If the casing pressure does not build 1 psi within 10 minutes the controller counts down the CASING PEAK TIME to zero It then checks the FALL TIME countdown It opens the A valve when both the CASING PEAK TIME and FALL time countdowns have reached zero Note While the controller counts down the CASING PEAK TIME the display shows CLOSE 0 00 00 Typical CASING PEAK TIME values for a well with casing pressure that builds fast are 10 12 minutes For a well with casing pressure that builds slowly a typical value is 30 minutes USER GUIDE Note You can use both DIFFERENTIAL OPEN PRESSURE and CASING PEAK TIME to control the well If you want to use only CASING PEAK TIME to open the well set the DIFFERENTIAL OPEN PRESSURE to a high value that will never
14. sales and service representative Controller s display is scrambled Static electricity may have made the controller lose its place in the program cycle 1 Reset the controller With a screwdriver move the power switch to off see page 3 Wait a few seconds and then move the power switch back to on 2 If the display is still scrambled after this test call your PCS sales and service representative Y4TIOYULNOD TIIM ATINIS OOOV SOd PCS 4000 SINGLE WELL CONTROLLER USER GUIDE Program Cycle Problems Controller won t run program cycle or won t open motor valve 1 Press READ 14 to check the HIGH LINE CLOSE PRESSURE Make sure the pressure is set above the well s Expected casing peak pressure and Normal high line pressure 2 Goto Test 1 Test 1 Check transducer and transducer wire The controller s display must show values for the 2 pressures specified by the operating mode 1 Check the transducers calibration If necessary re calibrate the transducers See Calibrating the Transducers on page 8 2 Ifa transducer won t hold the calibration Change the controller to Time Mode Press SET 11 and enter 1 Call your PCS sales and service representative Test 2 Check battery and wire connection The battery life is approximately 1 to 3 years The controller has a safety feature If the battery voltage is low the controller closes the motor valve and shuts in 1 With a screwdriver move the po
15. the dump valve on the separator When the B DELAY TIME is set and when the plunger arrives during the B OPEN TIME countdown the controller delays closing the B valve by starting the B DELAY TIME countdown When the countdown reaches zero the controller closes the B valve and starts the DELAY TIME SALES countdown Sales Line Safeguard Features LOW LINE CLOSE PRESSURE SET 15 If the sales line pressure reaches this low value the controller prevents the A valve from opening and closes the A valve if it is open If you don t want the controller to monitor low sales line pressure set LOW LINE CLOSE PRESSURE to 0 psi HIGH LINE CLOSE PRESSURE SET 14 If the sales line pressure reaches this high value the controller prevents the A valve from opening and closes the A valve if it is open You can use HIGH LINE CLOSE PRESSURE to shut in the well when the line pressure increases to the point where the plunger will not surface Venting If the HIGH LINE CLOSE PRESSURE is reached during B OPEN TIME which is used to vent the well the controller does not close the B valve USER GUIDE DELAY LINE CLOSE TIME SET B8 If you are using HIGH LINE CLOSE PRESSURE LOW LINE CLOSE PRESSURE or both you can use DELAY LINE CLOSE TIME to keep the controller from shutting in the well if there is a brief spike or drop in sales line pressure Brief spikes in pressure often occur when the controller opens the well after an extended shut
16. 0 the controller closes the well as soon as the casing pressure flutters up Because the casing pressure is still falling the controller has closed the well too soon DELAY CLOSE TIME SET 08 This time ensures that the casing pressure increase is not a brief spike in pressure During the level period before the casing pressure starts to build the pressure may flutter up and down The controller delays closing the A valve to make sure that the casing pressure has not dropped again If you set DIFFERENTIAL CLOSE PRESSURE DIP to 1 2 or 3 psi set DELAY CLOSE TIME to 10 20 or 30 seconds Important Don t set the DELAY CLOSE TIME to 00 00 00 If you do the controller may close the well too soon while the casing pressure is still falling A good minimum DELAY CLOSE TIME is 10 30 seconds Features for Opening the A Valve CLOSE TIME SET OFF CLOSE TIME is normally set to 00 00 00 because the controller opens the A valve in response to changes in pressure If you want to open the A valve after a period of time regardless of pressure changes you can set the CLOSE TIME If you do program a CLOSE TIME make sure to set the time no lower than your FALL TIME This will ensure that the plunger has time to reach the bottom of the tubing before the controller opens the A valve If the controller opens the well when the CLOSE TIME countdown reaches zero you are using the controller to operate the well based on time instead of
17. 0 gjefy And Solar Conditions Valve Delay Sales Time Mandatory Shut In Time Plunger Fall Time Delay Close Time Sensor Status On or Off Auxillary Close Delay On No Delay or Off Close Delay Controller Operating Mode Differential Open Pressure Casing Tubing or Casing Line Casing PSI Increase Casing Dip Close High Line Pressure Close Low Line Pressure Close POWER Activate and Calibrate Trans 1 Casing Activate and Calibrate Trans 2 Tybing Current well status Casing Drop CasinePeak Build Time Equalize Time C Valve Scan Set Entire Prograi Power Nes On Off B Valve Open and Close Times Line Delay Times PLUNGER HISTORY Press READ Function Key Reads reports and function values Press SET Function Key CE A Valve Plunger and Valve Counts Plunger Travel Times Last 25 Avg Run A Valve Open and Close Times A amp B Plunger and Valve Counts Plunger Travel Times Last 25 Open and Close Times Last 10 THIS PCS CONTROLLER IS MANUFACTURED BY PCS INC 1998 Figure 1 Controller s Faceplate gt PCSplungerlift com DISPLAY STATUS CLOSE C315 7250 L150 HRS MIN SEC PATENT NO 6 196 324 B1 Time remaining in hrs min sec When A valve is closed Casing pressure Tubing pressure Line pressure When A valve is open Casing pressure Flow rate Line pressure Opens A valve Closes A valve and B valve Used with other keys to access functio
18. 500 and 1000 feet per minute E If the plunger is running fast lower the DIFFERENTIAL OPEN PRESSURE E If the plunger is running slow increase the DIFFERENTIAL OPEN PRESSURE OPEN TIME SET ON OPEN TIME is when the well is first opened and gas is flowing through the A valve motor valve During OPEN TIME the plunger starts to surface and the well sells its initial head gas B OPEN TIME SET B ON Optional B OPEN TIME is after the well has sold its initial head gas but the plunger has not arrived During B OPEN TIME the plunger surfaces with the liquid load it is carrying Typically gas during B OPEN TIME is vented to the low side of the separator or to a tank If you are not using a B valve set B OPEN TIME to 00 00 00 Y4TIOYULNOD TIIM ATINIS OOOV SOd PCS 4000 SINGLE WELL CONTROLLER USER GUIDE MANDATORY SHUT IN TIME SET 03 Optional This time is used when a plunger does not surface Usually after the A valve and B valve are opened but a plunger does not surface a well likely needs more time to rebuild pressure for the next plunger attempt Set the MANDATORY SHUT IN TIME to at least twice the time required to build enough pressure to surface the plunger For example if a well usually takes 2 hours to build enough pressure to surface the plunger set MANDATORY SHUT IN TIME to 4 hours or more Note The MANDATORY SHUT IN TIME must be greater than FALL TIME and CLOSE TIME if any If the plunge
19. E 96 shows that the A valve opened 96 times m A PLUNGER2 92 shows that the plunger arrived 92 times while the A valve was open m 96 92 4 The plunger did not arrive 4 times while the A valve was open Note If the well has a B valve this report shows 2 A valve counts for each B valve count in the B Valve and Plunger Counts History If the plunger did not arrive 4 times while the A valve was open the plunger may have arrived up to 2 times while the B valve was open B Valve and Plunger Counts History READ B4 This report shows how many times the B valve opened and how many times the plunger arrived while the B valve was open Example B PLUNGER 2 B VALVE 2 In the example B VALVE 2 shows that the B valve opened 2 times m B PLUNGER 2 shows that the plunger arrived 2 times while the B valve was open A Valve Total Time Report READ 07 This report shows 2 times of up to 999 hrs 59 min 59 sec accumulated since the report was last cleared Em Total OPEN TIME and DELAY TIME SALES E Total time that the controller was closed MANDATORY SHUT IN if any FALL TIME if any and CLOSE TIME are accumulated under TOT CLS time Example A TOTAL 16 31 13 TOT CLS 8 12 45 B Valve Total Time Report READ B7 This report shows 2 times of up to 999 hrs 59 min 59 sec accumulated since the report was last cleared Em Total B OPEN TIME Total time that the controller was closed MANDATORY SHUT I
20. N if any FALL TIME if any and CLOSE TIME are accumulated under TOT CLS time Example B TOTAL 1 24 32 TOT CLS 8 12 45 ol Y4TIOYULNOD TIIM ATINIS OOOV SOd PCS 4000 SINGLE WELL CONTROLLER USER GUIDE Clearing Report Values SET 10 The display shows ZERO ALL TOTALS ON YES OFF NO Press the ON button to clear all of the valve and plunger counts READ 04 and READ B4 and total times READ 07 and READ B7 This option does not clear the Plunger Travel Time History READ 06 and the Time Open and Closed History READ 19 History information is always available Note Press the OFF button to exit the Clearing Report Values function without clearing any of the report values Time Open and Closed History READ 19 This report provides information about the last 10 times the A valve was open and the last 10 times the A valve was closed OPN O and CLS 0 show the most recent open and close information OPN 1 and CLS 1 show the 2nd most recent open and close information OPN 9 and CLS 9 show the 10th most recent open and close information Example OPN O0 0 00 20 00 CLS 0 C 00 15 00 OPN information shows m How long the A valve was open Time Open includes OPEN TIME DELAY TIME SALES DELAY CLOSE TIME if any Time Open does not include B OPEN TIME if any E A letter that explains why the A valve closed F low flow rate input or critical flow K value input G switch gauge input
21. OPEN TIME 9 CLOSE TIME OFF CLOSE TIME 11 DELAY TIME SALES 02 A DELAY TIME 13 MANDATORY 03 MAND SHUT IN 10 SHUT IN TIME B OPEN TIME BON B OPEN TIME 9 B DELAY TIME B2 B DELAY TIME 13 FALL TIME 05 FALL TIME 9 DELAY CLOSE TIME 08 DELAY CLOSE TIME 10 Sensor Operation 09 SENSOR 9 SET SENSOR A Valve Location 60 VALVE A LOCATION none local or remote B Valve Location 61 VALVE B LOCATION none local or remote C Valve Location 62 VALVE C LOCATION none local or remote Operating Mode 11 1 TIME 2 T L 9 3 C T 4 C L DIFFERENTIAL 12 OPEN PRESSURE 9 OPEN PRESSURE DIFFERENTIAL 13 CLOSE PRESSURE 10 CLOSE PRESSURE DIP HIGH LINE CLOSE 14 HIGH LINE PRES 13 PRESSURE DELAY LINE CLOSE B8 LINE DELAY TIME 13 TIME LOW LINE CLOSE 15 LOW LINE PRES 13 PRESSURE CASING DROP 20 CASING DROP PRS 12 PRESSURE CASING PEAK TIME 21 CASING TIME 11 LOW FLOW RATE 23 MIN FLOW RATE 12 LOAD FACTOR 24 LOAD FACTOR 11 CRITICAL FLOW K 25 TURNER CRIT 12 FACTOR FLOW CONSTANT EFM Device Setup 31 READ REMOTE 9 FLOW READ ACCUM FLOW SELECT EFM TYPE Flow Rate Unit of 33 METRIC 3 Measurement B LOW FLOW RATE 35 B LOW FLOW RATE 12 B LOW FLOW 36 B LOW FLOW 12 DELAY TIME DELAY CONTROLLER REPORTS Plunger Travel Time History READ 06 This report provides information about the 25 most recent plunger travel times The first display shows the number of times the plunger surfaced and the average travel time Example GOOD RUNS 25 AVE 0 08 22 Use the READ b
22. PRESSURE OPERATION TO INTERMIT A WELL WITHOUT A PLUNGER The fastest way to program the time and pressure functions is to press SET 90 See SET 90 Program Function List on page 4 Pressure Operation Selection Functions Follow the plunger instructions for Pressure Operation Selection Functions on page 9 to program these functions E Operating Mode SET 11 Sensor Operation SET 09 E Transducer Calibration SET 16 SET 17 and SET 18 m EFM Device Setup SET 31 E Status of A Valve when B Valve Is Open SET BO Note Make sure the SENSOR SET 09 is ON Don t turn it off Pressure Operation Control Functions FALL TIME SET 05 Set FALL time to 00 00 00 FALL TIME is not needed because there is no plunger MANDATORY SHUT IN TIME SET 03 Set MANDATORY SHUT IN TIME to 00 00 00 MANDATORY SHUT IN TIME is not needed because there is no plunger Other Functions Follow the plunger instructions for Pressure Operation Control Functions on page 9 to program these functions DIFFERENTIAL OPEN PRESSURE SET 12 OPEN TIME SET ON B OPEN TIME SET B ON DIFFERENTIAL CLOSE PRESSURE DIP SET 13 DELAY CLOSE TIME SET 08 Features for Opening the A Valve In addition to the basic functions for intermitting a well with pressure operation you can use any of the features for opening the A valve For more information see Features for Opening the A Valve on page 11 Tip CASING PEAK TIME works
23. R set it to 00 percent Y4TIOYULNOD TIIM ATINIS OOOV SOd PCS 4000 SINGLE WELL CONTROLLER USER GUIDE Features for Closing the A Valve LOW FLOW RATE SET 23 If you want the controller to close the A valve when the sales line s flow rate falls below a specified value set the LOW FLOW RATE For example if you set the LOW FLOW RATE to 300 the controller closes the A valve when the flow rate falls below 300 mcf This function keeps the flow rate from dropping to the point where liquids fall back into the tubing You can use this function by itself or together with CRITICAL FLOW K FACTOR PCS provides a Microsoft Windows critical flow calculator program to help calculate LOW FLOW RATE and CRITICAL FLOW K FACTOR values for your well For more information call your PCS sales and service representative Note If you have metric SET 33 on the flow rate unit of measurement is thousand cubic meters E M CRITICAL FLOW K FACTOR SET 25 If you want the controller to close the A valve when the sales line s flow rate falls below a critical flow rate computed with Turner s equation you can set both the LOW FLOW RATE and the CRITICAL FLOW K FACTOR The K factor is a gas constant that allows for fluctuating sales line pressures These 2 functions together keep the flow rate in combination with fluctuating sales line pressure from dropping to the point where liquids fall back into the tubing Example E
24. REPORT AND PROGRAM FUNCTION REFERENCE The tables in this section cross reference the reports and program functions described in this User Guide Reports Report READ Page Software Version Report CE 6 Battery Status Report 00 6 Status of A Valve when B Valve Is Open BO 9 A Valve and Plunger Counts History 04 5 B Valve and Plunger Counts History B4 5 Plunger Travel Time History 06 5 A Valve Total Time Report 07 5 B Valve Total Time Report B7 5 Valve Plunger Counts History Total Time 10 5 Reports and Plunger Travel Time History Time Open and Closed History 19 6 Modbus Address Report 22 Clearing Report Values Program Function SET Display Name Page Clearing Report 10 ZERO ALL TOTALS 6 Values Program Functions READ 90 Program Function List Press READ 90 to display the current times pressures and flow rate values programmed for all functions listed in the table on the right side of this page SET 90 Program Function List Press SET 90 to program all functions listed in the table on the right side of this page Additional Program Function To program this function press SET B 0 To display its current value press READ B 0 SET or Program Function READ Display Name Page Status of A Valve BO A OPEN W B VAL 9 when B Valve Is Open gt SET or Program Function READ Display Name Page OPEN TIME ON A
25. Set the CRITICAL FLOW K FACTOR to 65506 E Set the LOW FLOW RATE to 300 mcf E The controller closes the A valve when the flow rate falls below 300 mcf or the critical flow K factor falls below 65506 B LOW FLOW RATE SET 35 If you want the controller to open the B valve during A OPEN TIME when flow rate falls below a specified value set the BLOW FLOW RATE Example m Set the BLOW FLOW RATE to 50 The controller opens the B valve when the flow rate falls below 50 mcf B LOW FLOW DELAY TIME SET 36 If you are using BLOW FLOW RATE you can use B LOW FLOW DELAY TIME to keep the controller from opening the B valve if there is a brief drop in flow rate Typical settings for BLOW FLOW DELAY TIME are 1 to 2 minutes Features for Special Circumstances CASING DROP PRESSURE SET 20 CASING DROP PRESSURE is used in these 3 situations The wellhead configuration affects the plunger travel into the lubricator The plunger arrives but the plunger arrival sensor can t sense the plunger arrival every time Use CASING DROP PRESSURE as a backup A well is intermitted without a plunger CASING DROP PRESSURE allows the well to flow if it unloads E The plunger arrival sensor malfunctions and the operator does not have an immediate replacement Use CASING DROP PRESSURE as a temporary fix Note If the arrival sensor malfunctions the CASING DROP PRESSURE function prevents the B valve from opening if the well is unloading
26. USER GUIDE PCS 4000 SINGLE WELL CONTROLLER CONTENTS Basic Operatloins scisc secceceanecteceecdtecsnsessscsncesecsseensctaseeeess Controllers Faceplate s str tssis Turning the Controller On and Off eeeeeeseeeeneeeeeees Status DIS play aeina te ceetucesveseied Havbiecneutes state deities Units of Measurement ccccsceceessseseceeeeeseeeesseenenees Operating the A Valve and B Valve Manually Reading Reports and Program Functions s Setting Program FUNCTIONS ccssecessereeeserenssees How Pressure Operation WOrkKS eeccesseeeeeeeeeeees 7 Calibrating the Transducers ccssssecccesseseeeteeeeeeeeeeee Calibrate Transducers Wired to the Controller Calibrate Transducers Reporting Wireless to the Controlle eisssiicsssicceecaierececeaxscnstucessusevedsavontendbeeoapaenteateens Turn Off a Transducer eeeeeeseeeeeceeeeeeeeeeeeeeseeeeeeesenees 8 Creating a Pressure Operation Plunger Program Pressure Operation Selection Functions a f PRODUCTION G CONTROL Sew ee SERVICES 2008 Production Control Services Inc Pressure Operation Control Functions c ceeee 9 Features for Opening the A ValVe eeseeeesrereeeees 11 Features for Closing the A ValVe sereen 12 Features for Special Circumstances 12 Sales Line Safeguard Features cccsecsesereseeeees 13 Using Pressure Operation to Intermit a Well wit
27. ansducer for the low pressure With transducer in place remove pressure Press SET 17 ON OFF OFF ON 2 Calibrate the tubing transducer for the high pressure Apply pressure to transducer After applying pressure measure with an accurate pressure gauge to obtain the pressure value for the next step Press SET 17 ON OFF ON enter the pressure value For example if the current tubing pressure is 200 psi enter 00200 Sales Line Transducer Calibration If the sales line transducer is wired directly to the controller 1 Calibrate the sales line transducer for the low pressure With transducer in place remove pressure Press SET 18 ON OFF OFF ON 2 Calibrate the sales line transducer for the high pressure Apply pressure to transducer After applying pressure measure with an accurate pressure gauge to obtain the pressure value for the next step Press SET 18 ON OFF ON enter the pressure value For example if the current sales line pressure is 50 psi enter 00050 Calibrate Transducers Reporting Wireless to the Controller Casing Transducer and Tubing Transducer Calibration 1 Set the transducer for remote operation Casing transducer Press SET 16 ON ON Tubing transducer Press SET 17 ON ON 2 Calibrate the transducer at the remote device Sales Line Transducer Calibration 1 Set the sales line transducer for remote operation Press SET 18 ON ON 2 Calibrate th
28. ce it with a 5 amp 250 volt fuse The controller s box contains 1 extra fuse When you are done replace the controller s faceplate and move the power switch to on Ifthe fuse is OK go to Test 2 Test 2 Check battery and wire connection The battery life is approximately 1 to 3 years The controller has a safety feature If the battery voltage is low the controller closes the motor valve and shuts in 1 Check the battery voltage with a volt meter Replace the battery if it is below 6 volts Check the battery wire connection Replace the controller s faceplate With a screwdriver move the power switch to on Check whether the solenoid is operating properly If the solenoid is now operating properly and if you replaced the battery check the manufacture date on the battery If the battery is less than 3 years old check the solar panel Go to Test 3 If the solenoid still does not operate go to Test 4 ak wh Test 3 Check solar panel 1 Disconnect the solar panel from the terminals Use a volt meter to obtain the voltage and amperage A good solar panel reading in full sun exposure is 10 7 volts and 350 430 mA If the solar panel is defective change it 3 Check the solar panel installation The solar panel should face south The tilt of the solar panel should be the latitude of the location plus 15 degrees Example if the latitude is 45 degrees tilt the solar panel 60 degrees with respect to the horizon
29. ce representative PREVENTIVE MAINTENANCE Battery Always replace the controller s battery when it is 3 years old Y4TIOYULNOD TIIM ATINIS OOOV SOd PCS 4000 SINGLE WELL CONTROLLER USER GUIDE You can get more information about the PCS products at ProductionControlServices com Ig PRODUCTION CONTROL SERVICES 3771 Eureka Way Frederick CO 80516 1 800 619 2241 Warranty Production Control Services Inc warrants all PCS manufactured equipment to be free of defects in material and workmanship for ONE YEAR from date of purchase by original buyer only Warranty is completely void if abuse neglect misuse or misapplication is the cause of the malfunction Determination of abuse or damage to be made solely by PCS PCS 4000 is a trademark of Production Control Services Inc Copyright 2008 Production Control Services Inc All rights reserved 5 22 08
30. coil sensor This sensor is available in 2 wire or 3 wire connections 5 Call your PCS sales and service representative Short term fix for the sensor problem Use the CASING DROP PRESSURE feature see page 12 Plunger has surfaced but OPEN TIME does not go to DELAY TIME SALES E Make sure sensor is turned on Press READ 09 The controller s display should show SENSOR ON If the display shows SENSOR ON go to Test 1 f the display shows SENSOR OFF press SET 09 and then press ON Go to Test 2 step 2 Test 1 Check controller by disconnecting the sensor 1 Disconnect the sensor from the sensor and ground terminals on the inside of the controller s faceplate 2 Press ON The controller should count down the OPEN TIME If the controller goes from OPEN TIME to DELAY TIME SALES the controller s circuit board is not working properly Call your PCS sales and service representative f the controller does not go to DELAY TIME SALES continue with the next step 3 Use a wire to short the sensor and ground terminals The controller is OK if it goes to DELAY TIME SALES 4 Reconnect the sensor to the terminals Make sure the wires are put back in correctly Test 2 Check sensor 1 Press ON 2 Run a steel wrench along the back of the sensor If the controller goes to DELAY TIME SALES the sensor is OK f the controller does not go to DELAY TIME SALES call your PCS sales and service representative Test 3
31. e is either thousand cubic feet mcf or thousand cubic meters E8M USER GUIDE Operating the A Valve and B Valve Manually Open the A Valve ON E Press ON ON overrides all programmed functions such as FALL TIME and MANDATORY SHUT IN TIME ON does not override safeguard functions such as LOW LINE CLOSE PRESSURE and HIGH LINE CLOSE PRESSURE Open the B Valve B ON E Press B ON Close the A Valve and B Valve if Used OFF E Press OFF OFF overrides all programmed functions such as OPEN TIME and DELAY TIME SALES Reading Reports and Program Functions Read a Report or the Value of a Single Program Function 1 Press READ The status display shows READ 2 Enter the number of the report or function you want to display Example 10 Read the Values of All Program Functions READ 90 For a list of the program functions see READ 90 Program Function List on page 4 Setting Program Functions Set a Single Program Function 1 Press SET The status display shows SET 2 Enter the number of the function you want to set Example 05 3 Enter the value for the function See Units of Measurement on this page To exit the function without changing its value press CE Set All Program Functions SET 90 For a list of the program functions see SET 90 Program Function List on page 4 3 Y4TIOYULNOD TIIM ATINIS OOOV S d PCS 4000 SINGLE WELL CONTROLLER USER GUIDE
32. e sales line transducer at the remote device Important If you are using an EFM device follow the instructions for calibrating the sales line transducer in the manual for setting up your EFM device Turn off a Transducer If you are not using a transducer you can turn it off To turn off the casing transducer press SET 16 OFF To turn off the tubing transducer press SET 17 OFF To turn off the sales line transducer press SET 18 OFF When you turn off a transducer it appears on the status display with a pressure value of 0 CREATING A PRESSURE OPERATION PLUNGER PROGRAM The fastest way to program the time pressure and flow functions is to press SET 90 See SET 90 Program Function List on page 4 Pressure Operation Selection Functions Operating Mode SET 11 Set the operating mode which specifies the 2 pressures that the controller uses for the DIFFERENTIAL OPEN PRESSURE set point Mode 2 tubing pressure minus sales line pressure Mode 3 casing pressure minus tubing pressure m Mode 4 casing pressure minus sales line pressure Sensor Operation SET 09 1 Set SENSOR to ON 2 Specify local OFF or remote ON operation of sensor Transducer Calibration SET 16 SET 17 and SET 18 See Calibrating the Transducers on page 8 EFM Device Setup SET 31 If you are using an electronic flow measurement EFM device 1 Select ON YES for READ REMOTE FLOW 2 Select ON YES
33. eport READ CE This report displays the chip and software version numbers Example VERSION 138 41 Modbus Address Report READ 22 This report displays the controller s modbus address Example MODBUS ADDR 005 Important Do not change the modbus address HOW PRESSURE OPERATION WORKS When set to a pressure operating mode the controller opens the A valve based on the difference between 2 pressure values The pressure values used are Mode 1 Time only input no pressure Mode 2 Tubing pressure minus sales line pressure m Mode 3 Casing pressure minus tubing pressure m Mode 4 Casing pressure minus sales line pressure Note When set to Mode 1 or time mode the controller opens and closes the A valve and B valve based on time input It does not respond to pressure input or flow rate input Here are the steps in the pressure operation cycle 1 The controller closes the A valve and counts down the FALL TIME SET 05 This gives the plunger time to fall to the bottom of the well The status display shows CLOSE 0 00 00 Note CLOSE TIME is normally set to 00 00 00 because the controller opens the A valve in response to changes in pressure 2 While the A valve is closed the casing pressure and tubing pressure rise 3 The controller monitors Tubing pressure minus line pressure differential in Mode 2 Casing pressure minus tubing pressure differential in Mode 3 Casing pressure minus line pressure differe
34. for READ ACCUM FLOW if you want the controller to display Yesterday s Gas Volume and Today s Accumulated Volume The controller will store the daily volumes for 30 days If you select OFF NO the controller will not store this information 3 Select the type of EFM device you are using ON CMI for an EFM device provided by PCS OFF TR485 for a third party EFM device connected to the controller through a TR485 circuit board Status of A Valve when B Valve Is Open SET BO The controller works on wells that require the A valve to be either open or closed when the B valve is open m To keep A valve open when B valve is open press ON m To close A valve when B valve is open press OFF USER GUIDE Pressure Operation Control Functions FALL TIME SET 05 FALL TIME guarantees a minimum shut in time for the plunger to fall to the bottom of the well DIFFERENTIAL OPEN PRESSURE SET 12 DIFFERENTIAL OPEN PRESSURE is the pressure value that must be reached before the controller opens the A valve See step 3 on page 7 The 2 pressures that determine the DIFFERENTIAL OPEN PRESSURE vary depending on the mode of operation E Mode 2 tubing pressure minus sales line pressure m Mode 3 casing pressure minus tubing pressure E Mode 4 casing pressure minus sales line pressure Choose an appropriate value for your well by adjusting the DIFFERENTIAL OPEN PRESSURE based on the plunger travel time The optimal plunger speed is between
35. h a volt meter Replace the battery if it is below 6 volts 2 Check the battery wire connection Replace the controller s faceplate 4 With a screwdriver move the power switch to on f the display is still blank call your PCS sales and service representative 5 If the controller s display is now working and if you replaced the battery check the manufacture date on the battery If the battery is less than 3 years old check the solar panel Go to Test 3 wo USER GUIDE Test 3 Check solar panel 1 Disconnect the solar panel from the terminals Use a volt meter to obtain the voltage and amperage A good solar panel reading in full sun exposure is 10 7 volts and 350 430 mA 2 Ifthe solar panel is defective change it 3 Check the solar panel installation The solar panel should face south The tilt of the solar panel should be the latitude of the location plus 15 degrees Example if the latitude is 45 degrees tilt the solar panel 60 degrees with respect to the horizon a The element should be free from dirt oil and so on Check for cracks in the solar panel Check whether the solar panel is shaded during any part of the day If it is position it so it receives the most sunlight each day 4 Check the solar panel wire connection 5 Make sure the power switch is on The controller s display should be on 6 If the solar panel tests good but the batteries are not lasting as long as they should call your PCS
36. hout a a E cccseescieeuntedecteoetenrienenines 14 Pressure Operation Selection Functions 14 Pressure Operation Control Functions cceee 14 Features for Opening the A ValVe eeseeeerereeeees 14 Features for Closing the A ValVe eceeeseeeeesreteenees 14 Features for Special Circumstances 14 Sales Line Safeguard Features ccceseeeseereeeenees 14 Troubleshooting vseiestcccectisececie res cceaicc nde estenncteectesteeeneresiaes 15 Controller Display Problems seccssseeeesereneeeees 15 Program Cycle Problems asirini 16 Solenoid Shift Valve ProbleMS cceeceeeeeeneeeees 19 Transducer Problems ssteissi catessevanevartvecneae ccetaarnans 19 Preventive Maintenance cccssseesssesssessseeenseenensene 19 ProductionControlServices com 44TIOULNOD TIIM ATINIS OOOV SOd PCS 4000 SINGLE WELL CONTROLLER USER GUIDE BASIC OPERATIONS Controller s Faceplate Figure 1 shows the controller s faceplate with the power on off switch status display keypad and serial port for local operator input Ci PRODUCTION CONTROL SERVICES INC CS 1 800 619 2241 4000 OPERATING INSTRUCTIONS READ B 30 Serial Number Read CE Version Number MANUAL VALVE CONTROL ON Open A Valve Sales OFF Close A amp B Valves BON Open B Valve Vent PROGRAM AND READ SETTIN PROGRAM Press SET Function Key READ Press READ Function ON A Valve Open Time OFF Close Time BON B Valve Open Time 0
37. in period When the controller opens the A valve it does not monitor the sales line pressure during the DELAY LINE CLOSE TIME period Example DELAY LINE CLOSE TIME is set at 6 minutes m When the controller opens the well and starts to count down the OPEN TIME there is a 3 to 5 minute spike in line pressure For the first 6 minutes of the OPEN TIME countdown the controller does not shut in the well even if the HIGH LINE CLOSE PRESSURE is reached E After 6 minutes the controller shuts in the well if the high line condition still exists DELAY TIME SALES SET 02 DELAY TIME SALES sells gas through the A valve after the plunger has arrived Set DELAY TIME SALES to the maximum time that you want to sell gas Example A well normally sells gas for 5 hours Set DELAY TIME SALES to 6 hours If you want to limit how long the well flows after a plunger arrival for any reason program DELAY TIME SALES Important You must set the DELAY TIME SALES The controller closes the A valve in response to the first close input DIFFERENTIAL CLOSE PRESSURE DIP LOW FLOW RATE CRITICAL FLOW K FACTOR or DELAY TIME SALES If DELAY TIME SALES is 00 00 00 the controller closes the A valve when the plunger arrives In pressure operation you want the controller to close the A valve in response to pressure or flow rate input Y4TIOYULNOD TIIM ATINIS OOOV SOd PCS 4000 SINGLE WELL CONTROLLER USER GUIDE USING
38. ns that control B valve Example B ON opens B valve Clears current entry and backspaces Sets program functions Local operator input LOI serial port for connection to laptop computer Turning the Controller On and Off To turn the PCS 4000 Single Well Controller on or off insert a screw driver into the slot marked POWER ON OFF See Figure 1 Move the toggle switch to the left to turn the controller on Move the toggle switch to the right to turn the controller off The plunger program does not run while the controller is off When you turn the controller on it closes the A valve and starts counting down the FALL TIME see step 1 on page 7 Status Display After you turn the PCS 4000 Single Well Controller on the status display remains on The controller never sleeps The first line of the status display shows the current well status and the time remaining When the A valve is closed the second line of the status display shows the casing pressure tubing pressure and sales line pressure Example CLOSE 0 00 00 C315 T250 L150 When the A valve is open the second line shows the casing pressure flow rate and sales line pressure Example A OPEN 0 14 22 C315 Fi23 L150 Units of Measurement Time is in hours minutes seconds Example 08 15 00 Pressure is in pounds per square inch psi Example 00100 Depending on the setting of the METRIC function SET 33 the unit of measurement for flow rat
39. ntial in Mode 4 The controller opens the A valve when The difference between the 2 pressures is equal to or greater than the DIFFERENTIAL OPEN PRESSURE SET 12 value see DIFFERENTIAL OPEN PRESSURE on page 9 and The FALL TIME countdown reaches zero If the DIFFERENTIAL OPEN PRESSURE value is reached during the FALL TIME countdown the status display shows the FALL TIME remaining Note You can use any open function together with or in place of DIFFERENTIAL OPEN PRESSURE After the FALL TIME countdown has reached zero the controller opens the A valve as soon as it receives input from any open function For more information see Features for Opening the A Valve on page 11 USER GUIDE 4 The controller opens the A valve and counts down the OPEN TIME SET ON f the plunger arrives during the OPEN TIME countdown the controller goes to step 6 If the plunger does not arrive during the OPEN TIME countdown the controller goes to step 5 5 The controller opens the optional B valve and counts down the B OPEN TIME SET B ON If the plunger arrives during the B OPEN TIME countdown the controller goes to step 6 f the plunger does not arrive during OPEN TIME or B OPEN TIME the controller closes the A valve and B valve and counts down the MANDATORY SHUT IN TIME SET 03 When this countdown reaches zero the controller goes to step 4 Note If the well has liquid trailing behind the plunger
40. r does not surface MANDATORY SHUT IN TIME replaces FALL TIME MANDATORY SHUT IN TIME is not in addition to FALL TIME If you are not using MANDATORY SHUT IN TIME set it to 00 00 00 DIFFERENTIAL CLOSE PRESSURE DIP SET 13 Optional After the plunger surfaces the casing pressure falls and then levels off The casing pressure then starts to build as liquids accumulate at depth The higher you set the DIFFERENTIAL CLOSE PRESSURE DIP the longer the well attempts to sell gas Example During an operation cycle the controller records the well s minimum casing pressure at 150 psi E If the DIFFERENTIAL CLOSE PRESSURE DIP is 3 psi the controller stops the sale of gas and closes the well when the casing pressure rises to 153 psi E If the DIFFERENTIAL CLOSE PRESSURE DIP is 10 psi the controller stops the sale of gas and closes the well when the casing pressure rises to 160 psi A good DIFFERENTIAL CLOSE PRESSURE DIP setting for many wells is 1 2 or 3 psi The casing pressure flutters up and down as it falls For example the casing pressure may go 160 159 160 159 158 159 158 157 158 157 156 psi To keep the controller from closing the well too soon use DIFFERENTIAL CLOSE PRESSURE DIP together with DELAY CLOSE TIME see below Important A good minimum DIFFERENTIAL CLOSE PRESSURE DIP is 1 psi If you set the DIFFERENTIAL CLOSE PRESSURE DIP to 0 psi and the DELAY CLOSE TIME see below to 00 00 0
41. utton to scan through the report The next 25 displays show the 25 most recent plunger travel times Em This example shows the most recent plunger run The plunger surfaced after 8 minutes and 15 seconds of OPEN TIME LAST PLUNGER 0 A 0 08 15 Em This example shows the 2nd most recent plunger run LAST PLUNGER 1 A 0 08 15 m This example shows the 25nd most recent plunger run LAST PLUNGER 24 A 0 08 15 m This example shows the most recent plunger run The plunger surfaced after 10 minutes and 40 seconds of OPEN TIME and B OPEN TIME LAST PLUNGER 0 B 0 10 40 m This example shows the most recent plunger run The CASING DROP PRESSURE was reached before the plunger arrived LAST PLUNGER 0 c 0 09 26 This example shows the most recent plunger run The plunger did not surface LAST PLUNGER 0 NO PLUNGER To exit the report at any display press CE Valve Plunger Counts History Total Time Reports and Plunger Travel Time History READ 10 This reporting option displays the 2 Valve and Plunger Counts Histories READ 04 and READ B4 the 2 Total Time Reports READ 07 and READ B7 and the Plunger Travel Time History READ 06 To display the next report press READ A Valve and Plunger Counts History READ 04 This report shows how many times the A valve opened and how many times the plunger arrived while the A valve was open USER GUIDE Example A PLUNGER 92 A VALVE 96 In the example A VALV
42. wer switch is on The controller s display should be on If the solar panel tests good but the batteries are not lasting as long as they should call your PCS sales and service representative Test 4 Check solenoid shift valve 1 2 Press ON If the solenoid won t open clean the supply hoses and puck inside the solenoid valve Retest If they are good replace the puck or the entire solenoid Test 5 Check gas supply pressure filter and regulator s 1 2 3 Check the gas supply pressure to the motor valve The recommended supply pressure is 25 35 psi If the pressure is too low or too high it will not open the motor valve Check the filter and regulator s for debris and ice If the controller is still not working properly call your PCS sales and service representative After CLOSE TIME has counted down to zero controller goes directly to DELAY TIME SALES Press READ 06 to check the Plunger Travel Time History If the display shows a few seconds of plunger travel time such as A 0 00 03 the controller went through the opening and closing part of the program even though the plunger did not arrive Test 1 Check the sensor wire connections 1 Ifa wire was spliced in because of the distance between the controller and the sensor check the connection where the wire was spliced The wire may be corroded and causing a short 2 If the sensor wire connections are good go to Test 2 Test 2 Check
43. wer switch to off see page 3 2 Remove the controller s faceplate Check the battery voltage with a volt meter Replace the battery if it is below 6 volts Check the battery wire connection Replace the controller s faceplate With a screwdriver move the power switch to on Check whether the controller is operating properly f the controller is now operating properly and if you replaced the battery check the manufacture date on the battery If the battery is less than 3 years old check the solar panel Go to Test 3 f the controller still won t run the program cycle or open the motor valve go to Test 4 o NOOR Test 3 Check solar panel 1 Disconnect the solar panel from the terminals Use a volt meter to obtain the voltage and amperage A good solar panel reading in full sun exposure is 10 7 volts and 350 430 mA If the solar panel is defective change it Check the solar panel installation a The solar panel should face south The tilt of the solar panel should be the latitude of the location plus 15 degrees Example if the latitude is 45 degrees tilt the solar panel 60 degrees with respect to the horizon The element should be free from dirt oil and so on Check for cracks in the solar panel Check whether the solar panel is shaded during any part of the day If it is position it so it receives the most sunlight each day Check the solar panel wire connection Make sure the po
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