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PCS PCS 4000, User Manual

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PCS PCS 4000 User Manual Download Page 18

18

USER GUIDE

PCS 4000 

SINGLE WELL CONTROLLER

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.

If the display shows SENSOR: ON, go to Test 1.

 

ƒ

If the display shows SENSOR: OFF, press SET 09 

 

ƒ

and then press ON. Go to Test 2, step 2.

Test 1: Check controller by disconnecting the sensor.

Disconnect the sensor from the sensor and ground 

1 

terminals on the inside of the controller’s faceplate.
Press ON. The controller should count down the OPEN 

2 

TIME.

If the controller goes from OPEN TIME to DELAY 

 

ƒ

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 

 

ƒ

(SALES), continue with the next step.

Use a wire to short the sensor and ground terminals. 

3 

The controller is OK if it goes to DELAY TIME (SALES).
Reconnect the sensor to the terminals. Make sure the 

4 

wires are put back in correctly.

Test 2: Check sensor.

Press ON.

1 
2  Run a steel wrench along the back of the sensor.

If the controller goes to DELAY TIME (SALES), the 

 

ƒ

sensor is OK.
If the controller does not go to DELAY TIME 

 

ƒ

(SALES), call your PCS sales and service 
representative.

Test 3: Check sensor alignment.

Realign the sensor by 90 degrees.

1 

Example: If the sensor is aligned on the north or south 
side, realign it on the east or west side.
If realigning the sensor does not solve the problem, call 

2 

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

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.

 

ƒ

If the display shows SENSOR: OFF, press SET 09 

 

ƒ

and then press ON. Go to Test 3, step 2.

Test 1: Check CASING DROP PRESSURE.

Press READ 20.

1 

Make sure the CASING DROP PRESSURE is high 

2 

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.

Disconnect the sensor from the sensor and ground 

1 

terminals on the inside of the controller’s faceplate.
Press ON. The controller should count down the OPEN 

2 

TIME.

If the controller goes from OPEN TIME to DELAY 

 

ƒ

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 

 

ƒ

(SALES), continue with the next step.

Use a wire to short the sensor and ground terminals. 

3 

The controller is OK if it goes to DELAY TIME (SALES).
Reconnect the sensor to the terminals. Make sure the 

4 

wires are put back in correctly.

Test 3: Check sensor.

Press ON.

1 
2  Run a steel wrench along the back of the sensor.

If the controller goes to DELAY TIME (SALES), the 

 

ƒ

sensor is OK.
If the controller does not go to DELAY TIME 

 

ƒ

(SALES), call your PCS sales and service 
representative.

Test 4: Check sensor alignment.

Realign the sensor by 90 degrees.

1 

Example: If the sensor is aligned on the north or south 
side, realign it on the east or west side.
If realigning the sensor does not solve the problem, call 

2 

your PCS sales and service representative.

Short-term fix for the sensor problem: Use the CASING 
DROP PRESSURE feature (see page 12).

Summary of Contents for PCS 4000

Page 1: ...e Transducers Reporting Wireless to the Controller 8 Turn off a Transducer 8 Creating a Pressure Operation Plunger Program 9 Pressure Operation Selection Functions 9 Pressure Operation Control Functions 9 Features for Opening the A Valve 11 Features for Closing the A Valve 12 Features for Special Circumstances 12 Sales Line Safeguard Features 13 Using Pressure Operation to Intermit a Well without ...

Page 2: ...N A Valve Open Time OFF Close Time B ON B Valve Open Time 00 Battery And Solar Conditions 02 A Valve Delay Sales Time 03 Mandatory Shut In Time 05 Plunger Fall Time 08 Delay Close Time Sensor Status On or Off 09 Auxillary Close Delay On No Delay or Off Close Delay 11 Controller Operating Mode Differential Open Pressure 12 Casing Tubing or Casing Line 13 Casing PSI Increase Casing Dip Close 14 High...

Page 3: ...si Example 00100 Depending on the setting of the METRIC function SET 33 the unit of measurement for flow rate is either thousand cubic feet mcf or thousand cubic meters E3 M3 Operating the A Valve and B Valve Manually Open the A Valve ON 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 PRESSU...

Page 4: ...lay its current value press READ B 0 Program Function SET or READ Display Name Page Status of A Valve when B Valve Is Open B0 A OPEN W B VAL 9 Program Function SET or READ Display Name Page OPEN TIME ON A OPEN TIME 9 CLOSE TIME OFF CLOSE TIME 11 DELAY TIME SALES 02 A DELAY TIME 13 MANDATORY SHUT IN TIME 03 MAND SHUT IN 10 B OPEN TIME B ON B OPEN TIME 9 B DELAY TIME B2 B DELAY TIME 13 FALL TIME 05 ...

Page 5: ...ger 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 Example A PLUNGER 92 A VALVE 96 In the example A VALVE 96 shows that the A valve opened 96 times A PLUNGER 92 shows that the plunger arrived 92 times while the A valve was open 96 92 4 The plunger did not arrive 4 times while the A valve was open Note If ...

Page 6: ...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 A letter that explains why the A valve opened C CLOSE TIME counted down to zero D differential open pressure input M manual open R load factor input T casing time input Note If the A valve opens because a close input stops there is no letter For example the A ...

Page 7: ... TIME SET ON If 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 If the plunger does not arrive during OP...

Page 8: ...n 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 Calibrate the sales line transducer for the low pressure 1 With transducer in place remove pressure Press SET 18 O...

Page 9: ... valve to be either open or closed when the B valve is open To keep A valve open when B valve is open press ON To close A valve when B valve is open press OFF 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 ...

Page 10: ...d closes the well when the casing pressure rises to 153 psi 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 15...

Page 11: ... 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 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 th...

Page 12: ...W RATE Example Set the B LOW 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 B LOW 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 B LOW FLOW DELAY TIME are 1 to 2 minutes Features for Special Circumstances CASIN...

Page 13: ... LINE CLOSE PRESSURE is reached during B OPEN TIME which is used to vent the well the controller does not close the B valve 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 oc...

Page 14: ...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 st...

Page 15: ...nk call your PCS sales and service representative If the controller s display is now working and if you 5 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 Test 3 Check solar panel Disconnect the solar panel from the terminals Use a 1 volt meter to obtain the voltage and amperage A good solar panel reading in f...

Page 16: ...solar panel Go to Test 3 If the controller still won t run the program cycle or open the motor valve go to Test 4 Test 3 Check solar panel Disconnect the solar panel from the terminals Use a 1 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 2 Check the solar panel installation 3 The...

Page 17: ...through the sensor band If the controller goes to DELAY TIME SALES the problem may be a wellhead electrical current Go to step 4 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 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 ...

Page 18: ... page 12 Plunger has surfaced but Plunger Travel Time History READ 06 shows C instead of A or B 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 Press READ 20 1 Make sure the CASING DROP PRESSURE i...

Page 19: ...olar panel is defective change it 2 Check the solar panel installation 3 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 p...

Page 20: ...uyer 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 You can get more information about the PCS products at ProductionControlServices com PCS 4000 SI...

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