Unico Linear Rod Pump Systems

112-764.001
LRP User Guide
Linear Rod Pump
Operation and Maintenance

LRP User Guide

Linear Rod Pump Operation and Maintenance
First Edition
April 24, 2008

Notices
Copyright 2009 by UNICO, Incorporated.
All rights reserved. No part of this publication may be copied, reproduced, or reduced to any electronic media
or machine-readable format without the prior written permission of UNICO, Inc.
The information contained in this manual is considered accurate to the best knowledge of the supplier at the
time of publication. The manufacturer, however, assumes no liability for errors that may exist. The supplier
reserves the right to change data and specifications without notice.
All trade designations are provided without reference to the rights of their respective owners.
Printed in the United States of America

Table of Contents

Safety Information ................................................................................................ii

Overview ............................................................................................................................ii
Conventions Used..............................................................................................................iii
General Precautions...........................................................................................................iii
Installation Precautions ...................................................................................................... v
Maintenance Precautions................................................................................................... vi
General Cautions ............................................................................................................... vi
Equipment Control Precautions........................................................................................vii
1
1.1
1.2
1.2.1
1.2.2
1.3
1.4

About this Manual.................................................................................. 1-1

Overview .............................................................................................................1-1
Contents...............................................................................................................1-1
Whats Covered ...................................................................................................1-1
Whats Not Covered ............................................................................................1-2
Intended Audience...............................................................................................1-2
Intended Application ...........................................................................................1-2

2
2.1
2.2
2.2.1
2.2.2
2.3
2.3.1
2.4
2.4.1
2.4.2

Installation .............................................................................................. 2-1

Overview .............................................................................................................2-1
Installation Guidelines.........................................................................................2-1
Long Term Storage..............................................................................................2-1
Site Planning........................................................................................................2-1
Transporting & Lifting ........................................................................................2-2
Lifting the LRP Unit..........................................................................................2-2
Installation ...........................................................................................................2-3
Electrical Connections.........................................................................................2-3
Post Installation Checks.......................................................................................2-4

3
3.1

Equipment Operation ............................................................................ 3-5

Overview .............................................................................................................3-5

4
4.1
4.2
4.2.1
4.2.2

Maintenance and Troubleshooting ...................................................... 4-6

Overview .............................................................................................................4-6
Maintenance ........................................................................................................4-6
General Inspections .............................................................................................4-6
Equipment Components ......................................................................................4-6

Table of Contents i

Safety Information

Overview
This section states important safety information that must be followed when setting up, operating, and
troubleshooting this equipment. Study this information carefully before working with this equipment, as failure
to follow these instructions may lead to personal injury or death, or damage to the unit, drive, motor, and/or
driven equipment.
Installation and repair procedures require specialized skills with mechanical pumping systems. Any person that
installs or repairs this unit must have these specialized skills to ensure that it is safe to operate. Contact the
Unico, Inc. service department for repairs or any questions you may have about the safe installation and
operation of this system.
The precaution statements are general guidelines for the safe use and operation of this LRP system. It is not
possible to list all unsafe conditions. Therefore if you use a procedure that is not recommended in this manual,
you must determine if it is safe for the operator and all personnel in the proximity to the unit. If there is any
question of the safety of a procedure, please contact Unico, Inc before starting.
This equipment contains high voltages. Electrical shock can cause serious or fatal injury. Only qualified
personnel should attempt startup or troubleshoot this equipment.
This equipment has moving parts. Improper use can cause serious or fatal injury. Only qualified personnel
should attempt startup or troubleshooting of this equipment.
System documentation must be available to anyone that operates this equipment at all times.
Keep non-qualified personnel at a safe distance from this equipment.
Only qualified personnel familiar with the safe installation, operation and maintenance of this device
should attempt startup or operating procedures.
Always disconnect power before making or removing any connections.
Always ensure any connected equipment capable of falling is safely secured by approved methods
prior to working on this unit.
When your LRP unit is delivered, it becomes the responsibility of the owner/operator of the unit to provide safe
conditions and operation of the equipment. Some responsibilities include (but are not limited to) the following:
1. It is the responsibility of the owner/operator of this equipment to ensure that it is correctly and safely
installed.
2. It is the responsibility of the owner/operator of this equipment to ensure that it, when installed fully,
complies with all federal, state and local codes.
3. It is the responsibility of the owner/operator of this equipment to ensure that any person operating it
has been properly trained.
4. It is the responsibility of the owner/operator of this equipment to ensure that any person operating it
has access to all manuals and information required for its safe use and operation.
5. It is the responsibility of the owner/operator of this equipment to ensure that it is properly maintained
and safety inspected at regular scheduled intervals.
6. It is the responsibility of the owner/operator of this equipment to ensure that any person who has not
been trained on the safe use of this equipment does not have access to it.

ii Unico GPL Systems

Conventions Used
The following notation convention is used throughout this manual to indicate information important to personal
safety or machine hazards.
Attention

Identifies information about practices or circumstances that can lead to

personal injury or death, property damage, or economic loss.

General Precautions
Attention

Never operate this unit in a manner other than as described in this manual.
Operation in any manner not described in this manual should be considered
unsafe and should not be attempted. Never start the equipment unless you
have first verified that the installation and operation are as described in this
manual.
Attention

Be sure that you are completely familiar with the safe operation of this
equipment. This equipment may be connected to other moving parts.
Improper use can cause serious or fatal injury.

Attention

Some parts of this unit move during operation. Rotating parts can present
extreme danger if clothing or body extremities are caught by the rotating
part and can cause serious or fatal injury. Never touch a part of the
equipment until all moving parts are completely stopped. Also, all electrical
power must be removed to prevent accidental movement during servicing.

Attention

Be sure that you understand how to stop the unit quickly in case of an
emergency situation. Become familiar with the controls and safety systems
provided with this equipment.

Attention

Improper operation may cause violent motion of connected equipment. Be

certain that unexpected movement will not cause injury to personnel or
damage to equipment.

Safety Information iii

Attention

Never permit anyone to operate the equipment without proper instructions.

Be sure to keep a copy of this manual with the unit so that all users can be
properly informed of its safe operation.
Attention

Never allow children or pets to be in the area where the equipment is

running. The unit may cause injury or death.

Attention

Never operate the equipment unless all guards, covers, shields and other
safety items are properly installed.

Attention

Do not put hands, feet, tools clothing or other objects near moving parts.
Moving parts cause extremely dangerous situations because they can catch
loose clothing or extremities and cause serious or fatal injury.
Attention

When operating this equipment remain alert at all times. Never operate
machinery when physically or mentally fatigued, or while under the
influence of alcohol, drugs or medication.
Attention

High voltage is present whenever the equipment is running. Electrical shock

can cause serious or fatal injury. Never operate electrical equipment while
standing in water, on wet ground or with wet hands, feet or shoes or while
barefoot.

iv Unico GPL Systems

Installation Precautions
Attention

Installation and repair procedures requires specialized skills with electrical

equipment and mechanical pumping systems. Any person that installs or
performs repairs must have these specialized skills to ensure that the unit is
safe to operate. Contact Unico, Inc. for installation or repairs.
Attention

Be sure all wiring complies with the National Electrical Code (NEC) and all
regional and local codes or CE Compliance. Improper wiring may cause a
hazardous condition and exposure to electrical hazards can cause serious
injury or death.
Attention

Be sure the system is properly grounded before applying power. Do not

apply AC power before you ensure that grounds are connected. Electrical
shock can cause serious or fatal injury. NEC requires that the frame and
exposed conductive surfaces (metal parts) be connected to an approved
earth ground. Local codes may also require proper grounding of equipment
systems.
Attention

Place protective covers over all moving parts such as motor shaft and fan,
gearing, etc. Moving parts cause extremely dangerous situations because
they can catch loose clothing or extremities and cause serious or fatal
injury.
Attention

Unauthorized modification of a equipment may make the unit unsafe for

operation or may impair the operation of the unit. Never start a unit that has
been modified or tampered with. Be sure that all covers and guards are
properly installed and that the unit is safe before starting. If you are unsure,
contact Unico, Inc.
Attention

When moving the equipment, use reasonable caution. Be careful where you
place fingers and toes to prevent injury. Never try to lift a equipment
without an appropriate hoist or lifting means, as it is heavy and bodily
injury may result.

Safety Information v

Attention

Circuit overload protection must be provided in accordance with the

National Electrical Code and local regulations.

Attention

Have electrical circuits and wiring installed and checked by licensed

electrician or qualified technician. Electrical shock can cause serious or
fatal injury.

Maintenance Precautions
Attention

Disconnect all electrical power before servicing the equipment. Electrical

shock can cause serious or fatal injury. Always treat electrical circuits as if
they are energized.
Attention

Before cleaning, inspecting, repairing or performing any maintenance to the

equipment, always be sure the unit has stopped and that all moving parts
have also stopped. After stopping, certain components may retain
significant potential energy due to gravity. Ensure all loads are properly
secured to prevent accidental motion.
Attention

Inspect all wiring frequently and replace any damaged, broken or frayed
wiring or wires with damaged insulation immediately. Electrical shock can
cause serious or fatal injury.
Attention

Disconnect all electrical wires and load devices from equipment power
outlets before servicing the equipment. Electrical shock can cause serious or
fatal injury. Always treat electrical circuits as if they are energized.

General Cautions
Caution

Use only original equipment or authorized replacement parts. Using the

correct parts will assure continued safe operation as designed.

vi Unico GPL Systems

Caution

Do not lift the equipment from the motor or gearbox lifting points. These
points are not designed for the weight or lifting angle needed for the LRP
unit.

Equipment Control Precautions

Attention

An incorrectly installed or operated drive can result in damage to the

equipment it controls. Make certain installation and operating specifications
are followed.

Attention

Control inputs do not generate an emergency stop of the motor and do not
remove electrical power that can cause hazardous conditions. Regardless of
the operating state, the drives motor output terminals may be at dangerous
voltage levels whenever input power is applied and the bus is charged.

Attention

The LRP unit may start automatically whenever power is applied or after a
fault trip if the auto restart has been enabled. The restart function must not
be enabled when hazardous conditions might arise from such action.

Safe Service Practices

Follow industry-recognized safety procedures:
Use only one hand to hold test equipment probes
Wear approved eye protection
Stand on insulated material
Use an isolated oscilloscope
Keep unnecessary personnel out of the work area
Never leave a drive cabinet open or unattended
Never work alone

Safety Information vii

About this Manual

1.1 Overview
This chapter describes the contents and intended audience of this document.
1.2 Contents
The manual provides the instructions and technical information necessary to complete the mechanical
installation of the LRP unit and to configure, operate, and troubleshoot the system.
1.2.1 Whats Covered
Safety Information, discusses safety hazards and precautions important to anyone working with this
equipment.
Chapter 1, About this Manual, Overview of this document.
Chapter 2, Installation, describes the installation of the Unico LRP system.
Chapter 3, Equipment Operation, describes the operation of the Unico LRP system.
Chapter 4, Maintenance and Troubleshooting, describes routine and preventive maintenance as well as
troubleshooting procedures.
Chapter 5, Warranty, describes the LRP system warranty terms.

About this Manual 1-1

1.2.2 Whats Not Covered

This manual does not address basic hardware and firmware aspects of the drive. These topics are covered in the
drive installation and firmware instruction manuals. Please refer to those documents for:
Unpacking and receiving instructions
Hardware features and specifications
Mechanical installation instructions
Electrical installation instructions
Drive troubleshooting, maintenance, and spare parts
Detail listing of basic drive parameters
Drive setup and auto tuning procedures
Interface setup and diagnostic utilities
1.3 Intended Audience
This manual is intended for anyone who will be installing, operating, and servicing the LRP system. Installation
should be performed by qualified personnel to ensure that correct practices and applicable codes are applied.
Start-up and operation should be performed by personnel familiar with both the drive and the machinery or
equipment interfaced.
The audience is expected to have a basic knowledge of physical and electrical fundamentals, electrical wiring
practices and components, and electrical schematics. No prior experience with the drive is presumed or
required.
Follow instructions
You can prevent injury and damage to the drive or equipment by carefully following the procedures outlined in
this manual.
Follow regulations
All electrical work should conform to the National Electrical Code as well as all state and local government
regulations. Please familiarize yourself with these regulations.
Read both manuals first
Read this manual as well as the drive software application and installation and firmware instruction manuals
entirely before installing the drive. Consult with the factory if unsure on any topic before proceeding.
1.4 Intended Application
Unico LRP systems are intended for vertical rod pump applications. This unit must be operated in the manner
prescribed by this document. Uses outside those prescribed shall invalidate the manufacturers warranty.

1-2 Unico GPL Systems

Installation

2.1 Overview
These operating instructions are intended to help you install and operate the LRP unit. Complete installation
instructions can be found in document 112872, Linear Rod Pump Installation. For trouble free service, proper
installation and operation are essential. Additionally, these instructions contain important recommendations on
maintenance. Before shipment, every LRP unit is tested, checked and properly packed. However, please inspect
the unit immediately upon arrival for shortage or transit damage. Note the damage or shortage on the freight bill
of lading and file a claim with the carrier. Also, notify UNICO of the shortage or damage.
In addition to these instructions, read and follow the gearbox manufacturers operating instructions provided
with the LRPs manual.
2.2 Installation Guidelines
The procedures presented in this manual are suggestions and it is the responsibility of the Owner/Operator to
arrange for these procedures to be performed by licensed contractors according to all applicable codes including
local codes for your Municipality/City/County and State/Province. In addition to these suggestions, before
installing your equipment you should obtain the most up to date copies of the following documents from the
National Electrical Code and other authorities:
National Electric Code.
National Fire Protection Association
o No. 30 Storage, Handling and Use of Flammable Liquids.
Local Codes applicable to mechanical equipment installation. See your local building inspector.
NFPA (National Fire Protection Association)
(617) 770-3000 (includes NEC), 1 Batterymarch Park, Quincy, MA 02169-7471 USA
NEMA (National Electrical Manufacturers Association)
(703) 841-3200, 1300 N. 17th Street, Suite 1847, Rosslyn, VA, 22209 USA
2.2.1 Long Term Storage
If the unit is not installed immediately, it should be stored in a dry, protected area. Units which are used for
standby service should be stored sealed.
2.2.2 Site Planning
This equipment system is enclosed and is designed for outdoor use. The following sections provide guidelines
for successful installations.
2.2.2.1 Base

The unit is intended for mounting on a separate mounting stand that is supported by a casing or tubing
flange.
It is the users responsibility to ensure there is adequate integrity of the well completion for the gas and
fluid flow when the base is installed.
Ensure the base is concentric and perpendicular to the polished rod. Appropriate shims or adjustments
to the base and mounting stand may be necessary.

Installation 2-1

2.2.2.2 LRP Rack and Pinion Oil

Attention

The unit is be shipped WITHOUT oil for the rack and pinion. The unit must
be filled with gear oil at installation. See Chapter 4 for information on oil
specifications and capacities.

2.3 Transporting & Lifting

When you receive your unit, there are several things you should do immediately:
1. Observe the condition of the enclosure and report any damage immediately to the commercial carrier
that delivered your system.
2. Verify that the part number of the system you received is the same as the part number listed on your
purchase order.
3.
2.3.1 Lifting the LRP Unit
When lift or hoist equipment is used to lift the equipment and move it to position, be careful not to contact
overhead wires or other obstacles. The equipment can weigh as much as 2,500 lbs. Ensure lift or hoist
equipment has appropriate tires for the terrain to avoid becoming stuck or tipping over.
Lift Point

2-2 Unico GPL Systems

2.4 Installation
The equipment is completely assembled, tested and adjusted at the factory before it is shipped. The procedures
presented in this manual are suggestions and it is the responsibility of the Owner/Operator to arrange for these
procedures to be performed by licensed contractors according to all applicable codes including local codes for
your Municipality/City/County and State/Province. External connections required at the time of installation are:
1. Electrical connections between the drive(s) and motor(s) being controlled and any control wiring
required by the application.
2. Ground connection(s).
After installation, the post-installation checks must be performed prior to starting the unit. After these checks
have been performed and the system operation is verified, refer to the chapter on Maintenance for periodic
checks that must be performed at scheduled intervals to ensure continued operation with minimal problems.
2.4.1 Electrical Connections
Class 1 wiring methods must be used for field wiring connections to terminals of a class 2 circuit. It is the
responsibility of the owner/operator to arrange for these procedures to be performed by a licensed electrical
contractor and ensure conformance to all applicable codes including local codes peculiar to your
municipality/city/county and state/province. Wire size and insulation type should be as required by NEC
(National Electrical Code) and local codes. Consult supplied electrical drawings and/or drive hardware and
software manuals for specific wiring instructions.

Attention

Be sure the system is properly grounded before applying power. This may
require a driven earth ground conductor at the equipment site. Do not
operate equipment until ensuring that all grounds are connected. Electrical
shock can cause serious or fatal injury. NEC requires that the frame and
exposed conductive surfaces (metal parts) be connected to an approved
earth ground. Local codes may also require proper grounding of equipment
systems.

It is important that all wiring that connects the drive and motor is properly installed. See the drive manual for
proper wire sizing of circuit protection rating for your drive(s).

Installation 2-3

2.4.2

Post Installation Checks

When the initial installation is complete, the following checks must be performed before starting the unit. These
checks are not required before each start, only after the initial installation.
1.
2.
3.

Verify that equipment and drive(s) are properly grounded.

Verify that the equipment and drive(s) are voltage compatible.
Inspect the unit and equipment and verify that there are no loose wires or components. Tighten if
necessary.
4. Verify that the ground conductor is of correct wire size and properly connected.
5. Verify unit oil levels are full.
6. Ensure all covers are in place and be sure no hands are inside the equipment when it starts.
7. Start the equipment using the LRP Quick Start Guide from the 805661 documentation.
8. With the unit running, several checks must be made:
a. Verify there are no oil leaks. If a leak is detected, immediately stop the unit (move the equipment
switch to the Off position) and repair the leak before proceeding.
b. Verify that the operation is smooth. If vibrations or other sources of noise exist, immediately stop
the unit (move the Equipment switch to the Off position) and repair/adjust before proceeding.
9. After the operation checks are made, stop the unit (move the Equipment switch to the Off position).
Re-check unit oil levels.
10. Close all covers. The post installation checks are now complete.

2-4 Unico GPL Systems

Equipment Operation

3.1 Overview
The equipment is controlled by a Unico, Inc. drive running 805661 LRP - Linear Rod Pump Software. Refer to
the software documentation for the operation and troubleshooting of the unit.

Equipment Operation 3-5

Maintenance and Troubleshooting

4.1 Overview
As with any piece of moving equipment, preventive maintenance is crucial to the reliability and longevity of
your investment. Most operational problems can be traced to improper or inadequate maintenance procedures.
4.2 Maintenance
Keep the unit relatively free of dust and dirt. Oil levels and oil quality should be checked at regular intervals,
determined by usage and the environment. Oil changes are required at intervals of 5,000 operating hours or
every 6 months, whichever comes first. In applications where hostile operating conditions exist, such as high
humidity, corrosive environment, or large temperature changes, the lubricant should be changed at more
frequent intervals.
Attention

When the recommended lubricant is not available, it is permissible to use a

lubricant having equivalent characteristics but we do not recommend that
lubricants of different brands be mixed. Under no circumstances should
synthetic lubricants be mixed with one another or with one having a mineral
base.

4.2.1 Recommended Oil

The gearbox is shipped with SHC 630 Mobil synthetic oil. This lubricant is rated for -40 to +80 degrees
Celsius. The pinion box is not shipped with oil. SAE 140 (ISO 460) is recommended for operation above 32
degrees F (0 degrees C). SAE 90 (ISO 220) is recommended for operation below 32 degrees F (0 degrees C).
Multi-grade oil such as SAE 90/140 may be used for operation in temperatures above 0 degrees F (-18 degrees
C). With any grade oil the lubricant must be rated for the temperature range it will operate in.
4.2.2 General Inspections
1.
2.

Inspect the system for leaks. Replace all defective components immediately.
Inspect the external wire cables and connectors used with the equipment set for cuts, fraying, or loose
connections. Repair or replace any problems prior to using the unit.

4.2.3 Equipment Components

1.
2.
3.
4.
5.

Check oil level regularly, at least every 750 hours (30 days). Oil should be visible in the site glass
when the LRP is in its parked position.
Change the unit oil and every 5000 hours (180 days), more often in hostile operating conditions, such
as high humidity, corrosive environment, or large temperature changes.
Replenish grease every 2500 hours (90 days), more often in hostile operating conditions, such as high
humidity, corrosive environment, or large temperature changes.
Follow the gearbox manufacturers operating instructions provided with the LRPs manual.
Inspect unit for any loose connections or bolts.

4-6 Unico GPL Systems