rotaflex manual
TRANSCRIPT
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Revised 20 September 05
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Table of Contents
Section Title Rev # Date Page #
TABLE OF CONTENTS F 20Sep05 i
1.0 REAE ME FIRST F 20Sep05 1
2.0 INTRODUCTION F 20Sep05 2
3.0 GENERAL INFORMATION F 20Sep05 3
4.0 UNIT SPECIFICATIONS F 20Sep05 4
5.0 “PRACTICE SAFETY FIRST” F 20Sep05 5
6.0 INSTALLATION F 20Sep05 6
6.1 WELL SITE PREPARATION F 20Sep05 8
6.2 FOUNDATION F 20Sep05 10
6.3 ELECTRICAL F 20Sep05 11
6.4 ON-SITE ASSEMBLY F 20Sep05 12
6.5 LUBRICATION F 20Sep05 19
6.6 BRAKE OPERATION F 20Sep05 20
6.7 SPEED-SENTRY WIRING DIAGRAM F 20Sep05 22
6.8 SPEED-SENTRY SETTINGS F 20Sep05 36
7.0 OPERATING ROTAFLEX F 20Sep05 42
7.1 COUNTERBALANCE ADJUSTMENT F 20Sep05 43
7.2 BEFORE WELL SERVICE F 20Sep05 48
7.3 AFTER WELL SERVICE F 20Sep05 50
8.0 PREVENTATIVE MAINTENANCE F 20Sep05 51
8.1 CHECKING TOWER CHAIN TENSION F 20Sep05 54
8.2 ADJUSTING THE TOWER ROLLER CHAIN F 20Sep05 55
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Table of Contents
Section Title Rev # Date Page #
8.3 ADJUSTING WEIGHT BOX GUIDE WHEELS F 20Sep05 56
8.4 TOP IDLER DRUM INSPECTION F 20Sep05 57
9.0 REPLACING THE LOAD BELT F 20Sep05 59
10.0 MOVING THE UNIT F 20Sep05 63
11.0 PRODUCTION IMPROVEMENT F 20Sep05 66
FORMS
PRODUCT PERFORMANCE REPORT PPR20041022
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1.0 READ ME FIRST
Read these instructions prior to assembly or operation. The manufacturer of this Rotaflex
Pumping Unit has taken all reasonable precautions to insure quality and safety as associated with
the operation of this equipment. The manufacturer is not responsible for any damage doneduring the installation unless it is installed under the supervision of factory-authorized
personnel. Failure to follow manufacturer’s installation instructions, specifications for unit
sizing, and installation and safety procedures will void the manufacturer of any responsibility for
damage to property or individuals.
WARNING : This symbol is used throughout this manual to point out information that involves
your safety. Read and understand all assembly and operating instructions and precautions before
attempting to assemble and operate the Rotaflex Pumping Unit.
WARNING : Some illustrations in the manual show the Rotaflex Pumping Unit
with safetyshields removed for assembly or for a better view of the subject. NEVER OPERATE THE
PUMPING UNIT WITH ANY SAFETY SHIELDS REMOVED.
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2.0 INTRODUCTION
Rotaflex Pumping Units are designed to give many years of trouble-free service if properly
installed, operated within rated capacity, and serviced as specified.
The purpose of this manual is to provide instruction on the installation, operation, and
maintenance of a Rotaflex Pumping Unit. Become familiar with the contents of this manual, it
will provide the means for a safe and efficient installation and operation.
Due to the size of the pumping unit and it’s components, safety must be stressed during
installation, at start up and any time maintenance is performed.
SAFETY MUST NOT BE SACRIFICED FOR EXPEDIENCY.
Before beginning installation, operation or maintenance, review basic safety practices with all
the personnel involved with the Rotaflex Pumping Unit.
The information presented in this manual was current at the time of printing. The illustrations
used may not look exactly like your pumping unit but are representative and specify the correct
parts and instructions required to properly install, maintain, and operate your particular pumping
unit.
The manufacturer reserves the right to redesign and change the machine as may be necessary
without notification.
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3.0 GENERAL INFORMATION
The Rotaflex Pumping Unit is a long, slow stroke Pumping Unit. Development of this unique
unit began in 1983 and is manufactured and marketed by Weatherford Artificial Lift Systems at
Odessa, Texas.
Information about the unit can be obtained by calling (432) 334-4500 or any Weatherford
International Ltd office or Weatherford Service Center.
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4.0 UNIT SPECIFICATIONS
800DX 900 1100
Unit Model Number R228-300-288 R320-360-288 R320-500-306
Stroke Length ( in.) 288 288 306
Peak Polished Rod Load ( lbs.) 30,000 36,000 50,000
Counterweight - minimum ( lbs.) 9,400 9,400 9,800
Counterweight - auxiliary ( lbs.) 12,100 21,980 25,300
Counterweight - maximum ( lbs.) 21,500 31,380 35,100
Load Belt - Width ( in.) 30 42 50
Load Belt - Length 32 ft. 6 in. 32 ft. 6 in. 33 ft. 10 in.
Load Belt - Tensile Strength (PIW) 10,000 lbs. 10,000 lbs. 10,000 lbs.
Gearbox Size ( x 1000 in./lbs.) 228 320 320
Speed - Maximum ( SPM ) 4.5 4.5 4.5
Speed - Minimum ( SPM ) No Absolute Minimum
Working Temperature Range -40F to 140F
Unit Height 40 ft. 6 in. 40 ft. 6 in. 44 ft. 6 in.
Unit Width 8 ft. 6 in. 8 ft. 6 in. 8 ft. 6 in.
Shipping Weight ( lbs.) 46,000 46,000 54,800Shipping Height 9 ft. 0 in. 9 ft. 0 in. 10 ft. 6 in.
Shipping Width 7 ft. 8 in. 7 ft. 8 in. 8 ft. 6 in.
Shipping Length 40 ft. 6 in. 40 ft. 6 in. 44 ft. 6 in.
Base Weight ( lbs.) 29,000 29,000 29,000
Base Length 24 ft. 0 in. 24 ft. 0 in. 24 ft. 0 in.
Base Width 8 ft. 6 in. 8 ft. 6 in. 8 ft. 6 in.
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5.0 “PRACTICE SAFETY FIRST”
Be prepared for fire, mechanical failure and other emergency in the event that an accident does
happen.
Rotaflex Pumping Units are constructed of large and heavy moving parts. It is essential that all
personnel involved with the installation, assembly, operation and maintenance of the Rotaflex
Pumping Unit use extreme care and good safety practices at all times. Wear proper clothing,
footwear and head gear. Failure to use extreme care when working with heavy equipment can
cause severe bodily injury or death.
During installation of the pumping unit, a hoisting supervisor should give directions for all
hoisting operations. It is suggested that all personnel be briefed on safety procedures and the
installation prior to beginning the actual installation. The supervisor also should be readily
visible to the hoist or crane operator and able to view all the hoisting operations. All personnel
should exercise extreme caution and stay clear of all objects being hoisted. Cables, chains andslings should be inspected prior to use and replaced if worn or damaged.
The Rotaflex Pumping Unit has components that can start moving due to gravity. All personnel
should stay clear of any elements that may start moving. Times of particular danger from
moving parts would be during installation, counterbalance change, general maintenance, well
servicing and conducting dynamometer evaluations. It is essential to prevent accidental
movement of any kind during service or maintenance. The Rotaflex Pumping Unit is equipped
with two braking systems and a positive lock-out bolt for the brake disk is provided. The
operator should provide safety stops from timbers, metal tubing or similar bracing material to
support the counterweight box if personnel have to work where injury could occur from
movement of the equipment.
WARNING: Do not operate the Rotaflex Pumping Unit unless all safety shields and guards
are securely fastened in place.
WARNING: Do not try to operate the Rotaflex Pumping Unit while any access doors are
loose or open.
WARNING: Adjust the Caliper Pads on both the manual and automatic braking systemscalipers before every incident of service action that might be necessary.
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6.0 INSTALLATION
In addition to the equipment and parts supplied and shipped with the Rotaflex Pumping Unit, the
operator will need to furnish these additional items and services to complete the installation of
the unit:
1 – For the 800DX & 900 units a 50 ton crane with 65’ mast height capability is require.
For the 1100 unit a 70 ton crane with 75’ mast height capability is required.
Crane should be equipped with:
a) 4 - 20’ wire line cables
b) 1 - spreader bar (8’ between holes)
c) 2 - 3’ wire line cables, and shackles of sufficient size to work with 2” thick pad
eyes. The crane will be used to unload the concrete base and the pumping unit,
and stand the pumping unit upright. The base weighs approximately 29,000
pounds and the 900 & 800DX units weigh approximately 43,000 pounds, the
1100 unit weighs 58,000 pounds.
1 - 3-man roustabout crew with truck and tools.
1 - backhoe/front-end loader with operator.
12 - yards material suitable for earthen base (amount of material may vary from
installation to installation).
1 - 36’ (min.) polished rod with 28’ (min.) liner.
2 - polished rod clamps.
1 - prime mover with hub, sheave, and mounting bolts.
1 - power band belt for prime mover sheave to gear reducer sheave.
1 - electric panel and electrical service for prime mover.
1 - 22.5 ton hydraulic jack.
1 - electrician w/tools and equipment for installation of the prime mover and SPEED-
SENTRY.
In addition, the operator needs to furnish all well head and downhole equipment.
Prior to installing the Rotaflex Pumping Unit , the well should be serviced with the pump and
sucker rods. Space the pump off the bottom as recommended by a well design computer
predictive for the pumping installation or as recommended by a ROTAFLEX service
representative. Leave the top of the polished rod approximately 72 inches above the stuffing box
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for 800DX & 900 units, 96 inches for 1100 units, and clamp the polished rod just above the
stuffing box. The top of the stuffing box should not be more than 36 inches higher than the
earthen pad. If the stuffing box is more than 36 inches higher than the earthen pad, the operator
should contact a ROTAFLEX service representative for instructions for proper polished
rod/carrier bar attachment as shown in Figure 1.
Anticipate new load belts stretching approximately 12 to 18 inches depending upon peak load of
the unit.
Alternate method: Measuring from the anticipated set height of the top of the concrete base pad,
leave the top of the polished rod extended above the stuffing box. The polished rod should
extend approximately 96 inches for 800DX & 900 units, 120 inches for 1100 units from the top
of the concrete base. Clamp the polished rod just above the stuffing box as shown in Figure 1.
Figure. 1 Polished Rod/Carrier Bar Attachment
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6.1 WELL SITE PREPARATION
Because of the geometry of the Rotaflex Pumping Unit, the unit must be placed so the load belt
is directly over the center of the well. The earthen base or bed should be of suitable material to
carry (without undue settling) a minimum of 125,000 pounds and should extend three feet
beyond the concrete portable pad in all directions as shown in Figure 2. If the material in thecellar around the well head cannot support this weight, the material should be replaced with a
suitable material that can be properly packed.
If the Rotaflex is to be placed over a wellhead cellar, consult with your Weatherford ALS
Rotaflex representative for installation recommendations.
Figure. 2 Concrete Base Setting
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The pad should be perfectly level from side to side and should be slightly tapered from the well
head to the back. The manufacturer recommends the pad be 4 inches higher at the well head. as
shown in Figure 3. Since most of the weight is near the well head, the slight taper will allow for
some settling that normally occurs.
An optional use of a auxiliary base pad may be used to provide additional support. This “nose
pad” is approximately 10 ft. x 4 ft. x 1 ft. and is placed perpendicular to the base pad as close to
the wellhead as possible.
NOTE: With the use of the nose pad the unit base may be set with little or no elevation taper to
account for earthen settling.
Figure 3. Concrete Base Elevation
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6.3 ELECTRICAL
Rotaflex Pumping Units can be operated with multi-cylinder gas engines or electric motors.
Usually a motor of adequate size is recommended. The operator will need to provide a standard
control panel similar to that used with other rod pumping systems. To operate the SPEED-SENTRY, 110V. AC 5 A power supply is needed. The operator will provide from 4 to 6 wires
(check SPEED SENTRY model) from the motor control panel to the SPEED SENTRY control
box. For more detail, please refer to the Section 6.6, 6.7 and 6.8. If a gas engine is used to
operate the unit, alternate provisions had been made to operate on DC power.
Single cylinder gas engines are not recommended to power the Rotaflex pumping unit
due to the long stroke and low rotational inertia of the drive components in the Rotaflex pumping
unit. The single cylinder engine relies upon high rotational inertia of the engine flywheel and
cranks arms with counterweights to assist in lifting the high loads for a brief moment in faster
SPM operation of a conventional beam unit. The slower pumping speed of the Rotaflex without
the high rotational inertia will cause the single cylinder engine to stall and shutdown.
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6.4 ON-SITE ASSEMBLY
The Rotaflex Pumping Unit is shipped 95% assembled. Position the 50-ton (or larger) crane
perpendicular to, and near the middle of the concrete base. Position the truck with the unit
parallel to the crane. Using four 20-foot wireline cables attached to the lifting eyes on the
Rotaflex Pumping Unit as shown in Figure 5, lift the unit off the truck and position it on theconcrete base with the front of the Rotaflex Pumping Unit skid 84 inches from the alignment
brackets as shown in Figure 6.
Model Approx. Unit Weight (lbs)
800DX 46,000
900 46,000
1100 54,800
Figure 5. Transporting Unit
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Figure 6. Aligning Rotaflex Unit
1. Install both tie-down bolts and tighten securely.
2. Remove the four 20-foot wireline cables from the lifting eyes.
3. Attach the bridle and carrier bar to the belt bar. The carrier bar has a gate held in place with a
1/2-inch bolt. Orient the carrier bar so the bolt is at the top. The gate is inserted in the
prepared slot from the top and should be removed from the top of the carrier bar. There is a
1/2-inch rope attached to the belt bar. It should be untied and reattached to the carrier bar.
4. Using an 8 foot spreader bar, attach two 3-foot wireline cables to the spreader bar and to the
pad eyes located on either side of the tower near the crown hood as shown in Figure 7.
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Figure 7. Lifting Rotaflex Unit
5. Remove two bolts attaching each of the shipping supports to the Rotaflex Pumping Unit skid.
6. The crane operator will begin lifting the tower on the hinged skid and when there is sufficient
clearance, remove the pin from the shipping support and attach the Rotaflex Pumping Unit
standing struts in their place as shown in Figure 8.
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Figure 8. Prepare For Standing Rotaflex
7. Stand the unit up slowly until it breaks-over in the upright position. Bolt the tower beams and
Rotaflex Pumping Unit skid together using the 4 bolts and nuts, 2 for each side. Pin the end
of the standing struts to the guide shoes, slide the guide shoe forward to lock the strut into
place and tighten the guide shoe bolts. Loosen the tie-down bolts and move the unit forward
until the unit is against the well alignment brackets. Re-tighten the tie-down bolts as shown in
Figures 9 & 10).
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Figure 9. Before Sliding Figure 10. After Sliding
8. Remove the wireline cables and spreader bar from the unit.
9. If the gear reducer does not have a breather filter already installed, remove the oil plug
located on top of the gear reducer and replace it with the vented breather filter.
10. Install the prime mover, sheaves, belts and guards. Wire the SPEED-SENTRY into the
Motor Control panel. (Refer to SPEED-SENTRY section 6.7).
11. Open the valve on nitrogen bottle to activate the Gas emergency brake system if used onthis unit as shown in Figure 11. Ignore this instruction if: the unit has a Linear
Actuator emergency brake system.
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Figure 11. Nitrogen Operated Braking System
12. The manual brake has been set at the factory and the brake handle has been positioned
against the unit for shipment. Remove the bolt securing the brake handle, reposition the
handle and replace the bolt. With the manual brake engaged the handle should extend
horizontally away from the unit.
13. Adjust brake pads on the manual brake by removing lock pin and tightening the caliper
adjustment nut. Adjust the manual brake to allow for minimal play in the brake handle.
Replace the lock pin as shown in Figure 12.
Figure 12. Brake Adjustment
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Note: Remove the four shipping blocks located at each corner of the counterweight box
before starting the unit.
14. When power is available, open the front doors and lift the internal counterweight box high
enough to install half of the auxiliary counterweight. Close and fasten the doors.
15. Raise the weight box (lower the lifting belt) while pulling down on the rope attached to the
carrier bar. This assists the load belt to fall as fast as the weight box is being raised. Applythe brake and turn off the motor when the carrier bar is at the lowest point.
WARNING: DO NOT LET ROPE GET WRAPPED AROUND HANDS OR FEET!
16. Attach the carrier bar to the polished rod and replace the gate and 1/2” bolt.
17. Attach the polished rod clamp above the carrier bar.
18. Release the brake slowly and allow the load belt to pick up the polished rod load. Remove
the clamp at the stuffing box.
19. Lower the weight box, open the front doors and install enough auxiliary counterweight to
balance the unit. (Do not let the unit and well load get over 10 amps out of balance. When
fluid has stabilized, the unit and well load should be within 2 or 3 amps for best results.)
20. Close and fasten the front doors.
21. There is a belt retainer bar located at the top of the tower, between the idler drum and the
hood hinge, that needs to be inspected to assure the load belt is not rubbing on it. The bar
should be adjusted if the belt is rubbing.
WARNING: Personnel climbing to the top of the tower for the belt retainer inspection
must use a safety harness with lanyard securely attached to the pumping unit.
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Rev -F Date 20 Sept 05 19
6.5 LUBRICATIONThe recommended oils and oil capacities are as follows:
Gearbox Ambient Temperatures
Units (by serial no.) Amount -20 - +60 F +10 & above F
before 0655 37 gallons ISO EP150 ISO EP220
0655 & after 63 gallons ISO EP150 ISO EP220
Chain and Sprockets
Unit (by serial no.) Oiling system Amount Oil
Before 0483 Oil bath 37 gallons ISO EP100
0483 – 0761 * Dry Sump 2 gallons Rotack
0762 & after Oil Bath 37 gallons ISO EP100
* Except 0484, 0486-0489, 0494, 0495, 0501, 0502, 0506-0510, 0513-0521, 0523-0525, and 0528-0534. All of these should be converted to the wet
sump system.
Recommended oil ISO EP150 ISO EP220 Supplier
Mobilgear 629 Mobilgear 630 Mobil
Gear Compound EP 150 Gear Compound EP 220 Chevron
Lubrication service is as follows: Gearbox - Check the fluid level at the sight glass regularly. Catch a sample and make a visual inspection of the lubrication every 6 months.
Analysis should be made for discoloration of the fluid, or contamination of water or metal particles as necessary and oil changed as needed. Check
gear tooth condition for abnormal wear. Change the lubrication in the gear reducer after the first 1,000 hours and once a year thereafter. Routinely
check for leaks. Seal replacement is required if a leak develops that exceeds one cup per week.
Chain and Sprockets – Oil Bath system - The chain and sprockets are pre-lubricated at the factory. The chain reservoir is fitted with a drain plug to
be emptied when needed. Application of oil at startup is serviced from either the outside or the inside of the unit. From the outside, pour oil into filler
port located on front of oil collector on tower. From the inside, pour oil into oil collector when the counterweight doors are open and the weight box
is raised up at least 6’ out of the way. It is recommended to change the lubrication in the sump once a year.
WARNING: The weight box must be blocked and/or chained before personnel climbs inside the tower!
Chain and Sprockets – Dry Sump system – It is recommended to convert these units to a wet sump system. The chain and sprockets are pre-
lubricated at the factory. The chain reservoir is fitted with a drain plug to be emptied when needed. The chain and sprocket MUST be servicedinitially at start-up AND every 3 months with an application of 2 gallons of Rotack chain lubrication oil Rotaflex part number 750082. The unit
MUST be running for minimum of 6 hours at the time of application of oil to insure distribution of oil to the total length of chain. Application of oil
is serviced from the outside of the unit. Pour oil into filler tube located on center of backside of tower, above gearbox sprocket split cover.
The components requiring grease and periodic service are:
Component Grease
Top Drum Grease meeting spec AAR M-942
Top Sprocket Grease meeting spec AAR M-942
The periodic SERVICE requirements are:
Grease every six months until part of the old grease is purged out of the grease relief fitting. This is to insure that a certain amount of new grease has
entered the bearing cavity.
The pre-lubricated, sealed-for-life components and periodic service are:
Component Grease
Swivel Shaft Grease meeting spec AAR M-942
Carriage Wheels Grease meeting spec AAR M-942
Weight Box Wheels Grease meeting spec AAR M-942
These anti-friction roller bearings have been lubricated at the factory. No re-lubrication is necessary. The periodic SERVICE requirements are:
Inspect the seals every 6 months to insure no loss of grease and these seals have not lost their sealing capability.
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6.6 BRAKE OPERATION – MANUAL & AUTOMATIC
The Rotaflex unit is equipped with both a manually operated brake and an automatically operated brake.
These braking systems are caliper/disk systems mounted on the input shaft of the gear reducer. The
operation of each system is independent of each other. The 2 separate calipers are mounted on a single
rotor disk. The 2 calipers are identical except the manual caliper on earlier unit is a cast aluminum unit,
whereas later was change to a cast iron unit like the automatic caliper. The braking capability of either
system is lost if the pad adjustment is too loose. See Adjusting the Caliper.
Warning: The caliper pad adjustment must be maintained to insure that the capability of
these braking system is safe for the necessary braking action needed. It is the responsibility of the
customer to maintain this adjustment. It is recommended that this adjustment be performed every
time a service action is required on the unit. This will insure that the caliper is ready to deliver the
full braking force needed when needed.
Adjusting the Caliper: The caliper pad adjusting nut is located on the caliper. It is a castle
nut holding the actuating lever and has a cotter pin thru the slots of the castle nut. Remove the
cotter pin. To increase brake holding force, turn the castle nut clock-wise. To adjust, place a 0.050”spacer shim between the caliper pad and the brake rotor, tighten the castle nut finger tight and
remove the spacer shim and replace cotter pin to retain this setting.
The Manual Braking System
The manual brake system is actuated by means of a brake lever handle located on the right side of the
Rotaflex pumping unit. It is directly linked to the manual caliper through a “spring tube” which provides
a very smooth brake action. The brake lever in the disengaged position will hold the caliper in the
released position without allowing the pads to ride on the brake rotor, if the pad adjustment castle nut on
the caliper is adjusted to the correct specifications. See Adjusting the Caliper. The brake lever linkage will
hold the brake in the engaged state by means of an “over center” geometry.
The Automatic Braking System - or Speed Sentry
The automatic braking system will protect the unit from damage in case of certain conditions that would
allow the Counterweight Box to free-fall. It will also protect the unit from damage in case of conditions
that would cause overloading of the unit. It is controlled by the Speed Sentry which constantly monitors
the speed of the unit. For UNDERSPEED conditions such as a seized pump, causing the speed of the unit
to slow down below a predetermined minimum SPM speed, the Speed Sentry will initiate a shutdown
process. The brake will be actuated and electrical power to the prime mover will be disconnected. For
OVERSPEED conditions such as a sucker rod failure, causing the speed of the unit to speed up above a
predetermined maximum SPM speed, the Speed Sentry will initiate a shutdown process. The brake will
be actuated and electrical power to the prime mover will be disconnected. If the speed increases above the
synchronous speed of the motor, the power to the prime mover will be retained until the speed falls belowthe synchronous speed of the motor. This “dynamic braking” greatly increases the efficiency of the auto
braking system.
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The Automatic Braking System may come in either of two versions, older models are equipped with a
pneumatic version and newer models with a electrical linear actuator.
The Pneumatic version uses an electrically controlled solenoid valve to withhold the pressure from
actuating the brake caliper and will allow pressure to the brake caliper when the automatic braking system
is activated or when electric power is removed. This version provides an “EMERGENCY STOP” Button
in close proximity to the OFF-ON Switch and Manual Brake Handle. When this button is pushed or the
Speed Sentry activates the brake, power to the prime mover will be disconnected and the brake will beengaged. This braking will be smooth and controlled to minimize trauma to the pumping system. This
version is protected from the elements and all high-pressure components are contained behind a 1/4-inch
steel plate with a sight hole for visual access to the gauges. It is important to monitor the pressure on
these gauges. A full bottle will supply a sufficient amount of nitrogen to apply the brake in excess of 100
operations and should register only a small change in the pressure. If there is an unusual drop in pressure
it may indicate a leak in the nitrogen portion of the braking system. The 0-3000 PSI gauge shows the
nitrogen charge in the bottle. The 0-160 PSI gauge shows the regulated pressure that will activate the
emergency brake.
WARNING: When the pressure drops below 100 PSI on the 0-3000 PSI gauge, refill the nitrogen
cylinder! The pressure should show a minimum of 70 PSI on the 0-160 PSI gauge to properly
activate the emergency brake.
The Electrical Linear Actuator version is an electrical motor with a gear drive linear actuated tube
which retracts in to set the brake and extends out to release the brake. The 3 position RESET-OFF-ON
switch resets the brake. This version does not SET the brake when power is removed. This version
provides an “EMERGENCY STOP” Button in close proximity to the RESET-OFF-ON Switch and
Manual Brake Handle. When this button is pushed or the Speed Sentry activates the brake, power to the
prime mover will be disconnected and the brake will be engaged. This braking will be smooth and
controlled to minimize trauma to the pumping system.
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6.7 SPEED SENTRY WIRING DIAGRAM
The Speed Sentry control box is fully wired at the factory to the pumping unit through terminal
block one (TB1) and is recommended to be mounted next to the motor control panel. Customer
connections to terminal block TB2 differ slightly depending on which Model ROTAFLEX
Speed Sentry is being used. A minimum of four and a maximum of fourteen wires are possibledepending on the Speed Sentry model used. These connections are made to the motor control
panel for HAND-OFF-AUTO control and power to the Speed Sentry on units with electric prime
movers. On units operating on a gas engine, Speed Sentry power and battery/alternator
connections are made directly.
Beginning with Figure 13 below, complete customer interconnect diagrams for the various
ROTAFLEX control models follow. A complete wiring diagram is either permanently mounted
on the inside door of each Speed Sentry, or enclosed in the envelope which also contains
complete instructions for programming the Durant tachometer.
NOTE: All interconnect wiring to TB1 will normally be done at the factory. The
connections to TB2 will be made on site.
Figure 13. Model 6 SPEED-SENTRY Gas Engine Driven- Customer Connections Diagram
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Figure 14. Model 6 Schematic Wiring Diagram - Gas Engine Driven
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Figure 15. Model 7 - Customer Connections Diagram - Electric Motor Drive
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Figure 16. Model 7 Schematic Wiring Diagram - Electric Motor Driven
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Figure 17. Model 8 Speed Sentry - Customer Connections Diagram
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Figure 18. Model 8 Speed Sentry Schematic Wiring Diagram
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Figure 20. Model 9 Speed Sentry Schematic Wiring Diagram
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Figure 21. Model 10 - Customer Connections Diagram - Electric Motor Driven
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Figure 22. Model 10 Schematic Wiring Diagram - Electric Motor Driven
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Figure 24-B. Model P2 Speed Sentry Wiring Diagram – both Gas Engine and Electric M
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6.8 SPEED SENTRY – (Automatic Braking System)
The purpose of the Speed Sentry is to provide the electrical control for an automatic braking
system that will protect the unit from damage in the case of a high rod part or any other
condition that would allow the Counterweight Box to free-fall.
On units which utilize a target wheel, the target wheel and proximity sensor are mounted on the
input shaft of the gear reducer, the proximity switch obtains its’ pulsed signal from gaps in the
24-tooth wheel. Later units have the proximity switch mounted on the brake mounting plate and
obtain the pulsed signal from holes in the face of the brake rotor. On units with the target wheel,
care should be taken to insure that the proximity switch face is parallel with the target wheel
teeth and centered as closely as possible. An air gap of .025” is recommended for the best
performance. On units utilizing the brake rotor face and the proximity switch # II3010, the
proximity switch should be parallel with the rotor maintaining an air gap of between 0.25” and
0.32” inches. On units utilizing the brake rotor face and the Proximity Switch # II3015, the
proximity switch should be parallel with the rotor maintaining an air gap of between 0.56” and
0.69” inches.
The proper functioning of the Speed Sentry depends on the “gap” adjustment of the proximity
switch and the “overspeed and underspeed” settings. To ensure proper operation of the Speed
Sentry, initial settings must be made to obtain reliable Overspeed and Underspeed protection. It
is the responsibility of the operator to select the appropriate Overspeed and Underspeed
Set-Point SETTINGS. This manufacturer strongly recommends not to set the Overspeed set-
point setting higher than .5 SPM over the maximum SPM speed shown on the digital readout
during normal operation. The Underspeed set-point setting should not be set less than .5 SPM
lower than the minimum SPM speed shown on the digital readout during normal operation.
WARNING: Failure to set the appropriate Overspeed and Underspeed set-point settingsin the Speed Sentry, resulting in damage to the Rotaflex pumping unit, will
void the Rotaflex Warranty .
NOTICE: If the SPM of the Rotaflex pumping unit is changed for any reason, new
Overspeed and Underspeed set-point settings are required.
The operations of the Speed Sentry and the automatic braking system should be tested
occasionally to insure the system is operating satisfactorily. To test the Overspeed alarm
condition, lower the overspeed set-point setting to a value less than the maximum operating
SPM. The Speed Sentry should turn off the motor, set the brake and the overspeed flag should
be visible. To test the Underspeed alarm condition, raise the underspeed set-point setting to avalue higher than the minimum operating SPM. The Speed Sentry should turn off the motor, set
the brake and the underspeed flag should be visible. After these tests, reset the overspeed and
under-speed set-point settings to the correct values.
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All Speed Sentrys up to and including the Model 10
The following procedure outlines steps for monitoring and setting the overspeed and underspeed
set-points with the Durant tachometer or rate indicator. All instructions will be initiated from the
run state. The key to press on the tachometer is indicated in BOLD.
TO MONITOR OVERSPEED AND UNDERSPEED SET POINTS
ALM Show the HIGH or LOW setting
+ or - Change the display from HIGH to LOW and vice versa
EXIT Returns to RUN mode
TO CHANGE OVERSPEED AND UNDERSPEED SETTINGS
ALM The display will show the HIGH or LOW setting
+ or
- This will change the display from HIGH to LOW or vice versaSEL Selects HIGH or LOW which is on display for programming
+ or - Changes value of character flashing
SEL Advances to next character
+ or - Changes value of character flashing, continue until desired setting is displayed
ENT Enters data into program memory
EXIT Returns tachometer to RUN mode
TO MONITOR PROGRAM SETTINGS
PGM Selects program mode for 5 seconds, returns to RUN mode
PGM+ Selects program for monitoring and steps through the six programs+ or - 1. PROGRAM SCALER
2. PROGRAM RATE ALARM
3. PROGRAM INPUTS
4. PROGRAM OUTPUTS
5. PROGRAM SET POINTS
6. PROGRAM OPTIONS
SEL + or - To monitor data in each of the programs
EXIT-RUN Terminates monitoring and returns control to RUN mode
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PROGRAM SETTINGS FOR SPEED SENTRY (MODELS 6 - 9)
(Units utilizing the 24-tooth target wheel)
Note: The ZERO TIME for all units with 24-tooth target wheel is set to 1.0 and the AVE TIME
is set to 0.5.
PROGRAM ITEMS DATA
1. SCALERS SCALER 1.301 (800DX)
1.4317 (900)
1.3041 (1100)
1.2383 (1200)
DEC PT --.--
ZERO TIME 0.3 SEC
AVE TIME 0.1 SEC
PROGRAM SETTINGS FOR SPEED SENTRY (Model 10 - LA BRAKE)
No Program Items Data
1. SCALERS SCALER see Table 1
DEC PT --.--
ZERO TIME 0.3 SEC
AVE TIME 0.1 SEC
Note: Programs 2 - 6 on following page are identical for all units
No Program Items Data
2. RATE ALM ALM 1 LOW
ALM 2 HIGH
3. INPUTS RATE IN SOLID STATEINHIB LOW FOLLOWS
LOCK ALL
4. OUTPUTS ALM 1 OUT PULSED
ALM 1 OUT PUL 1.0 SEC
ALM 2 OUT PULSED
ALM 2 OUT PUL 1.0 SEC
5. SER PORT SER PORT ID 0
BAUD 1200
PARITY NONETX DELAY 0.100 SEC
Note: Rotaflex does not use the serial port.
6. OPTIONS UNL KEY DISABLED
UNITS S/M
PROGRAM USER
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All the program data shown above are programmed by this manufacturer. It is important that the
program data is not changed. If for some reason the program is changed, it must be entered as
shown, dependent on Rotaflex size.
TO ENTER DATA INTO THE TACHOMETER MEMORY
PRO-ENT To monitor program.
+ or - To step through the programs
SEL To select program items to monitor
+ or - Steps through and displays program items
SEL Places displayed item in program change mode, items available for changing
will be blinking
+ or - Changes value of blinking characters
ENT-EXIT-RUN Put displayed value into tachometer memory and returns control to RUN
mode
Use caution whenSEL
is pushed the second time, this places the displayed data into thetachometer memory and may result in improper memory storage.
Table 1. SCALING FACTORS FOR ALL UNITS WITH LA BRAKES
Model Gearbox Scaling Factor
800 228 OILWELL 10.408
800DX 228 D 10.365
800DX 228 FAIRFIELD 11.315
900 320 D 10.902
900 320 FAIRFIELD 11.839
1100 320 D 10.399 1200 456 OILWELL 9.907
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Speed Sentrys – P1 and P2
The Speed Sentry P1 and P2 utilize PLC components that replace the Speed Sentry model 10.
All of the functions previously provided in the model 10 are covered in these models. Dynamic
Braking has been added for use on all electric motor applications. This feature has been added to provide a more reliable automatic braking system. Proper functioning of the Speed Sentry
depends on the proximity switch and the overspeed and underspeed set-point SETTINGS
“entered” in the display. Units have the proximity switch mounted on the brake plate and obtain
the pulsed signal from holes in the face of the brake rotor. The proximity switch should be
parallel with the rotor maintaining an air gap of between 0.56” to 0.69”.
DISPLAY MEMORY SETTINGS PROCEDURE
Upon initial power-up, the Display will perform a self-test procedure, which lasts about 10
seconds.
CHANGING SCREENS: All 11 Screens are accessible via the Right and Left Arrow Keys.
Right Arrow = Page Down, Left Arrow = Page Up.
CHANGING VALUES: Depressing the F1 key will cause the stored numerical value to flash.
Use of the Arrow Keys will change the settings:LEFT ARROW - Increments by 100 (3rd digit, if applicable)
RIGHT ARROW - Decrements by 100 (3rd digit, if applicable)
UP ARROW - Increments by 1 (1st digit)
DOWN ARROW - Decrements by 1 (1st digit)
When desired value is reached, pressing the ENTER Key will download the value into
memory.
Pressing the Right Arrow Key while any screen is displayed will advances to the next screen.Pressing the Left Arrow Key while any screen is displayed will return to the 1st screen.
SCREEN # Description
1 STROKES PER MINUTE (read only) Normal screens.
Displays actual strokes per minute (SPM).
2 MOTOR RPM (read only)
Displays actual revolutions per minute (RPM).
3 ENTER GEARBOX RATIO (adjustable) Programmed during unit run-out.
Displays ratio of gear reducer. (example : 31.069)
4 ENTER CHAIN RATIO (adjustable) Programmed during unit run-out.
Displays ratio of chain to sprocket (example : 5.9048 - 900)
(6.1985 – 1100)
(7.3333 – 1150)
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5 ENTER UNIT SHEAVE DIAMETER (adjustable) Programmed in the field.
Displays diameter in inches of v-belt sheave on gearbox. (example : 24)
6 ENTER MOTOR SHEAVE DIAMETER (adjustable) Programmed in the field.
Displays diameter in inches of v-belt sheave on motor. (example : 13)
7 ENTER MOTOR SYN RPM (adjustable) default=1200
Displays synchronous speed (rpm) of motor.
8 ENTER OVERSPEED SET POINT (adjustable) .5 SPM above normal speed is
recommended.
9 ENTER UNDERSPEED SET-POINT (adjustable) .5 SPM below normal speed is
recommended.
10 UNDERSPEED DELAY TIME (adjustable)
Displays the delay time (seconds) for disabling the UNDERSPEED alarm on start-up.
Up to a maximum of 3276.7 seconds (50+ minutes).
11 EVENT LIST (non-adjustable) List the Event History beginning with the latest logged.
To view past Events - Press F4, Latest Event is displayed.
Up Arrow - Scrolls back through Event List History
Down Arrow - Scrolls back toward latest Event
Right Arrow - Depressed at any time during Event List will display the date/time.
// Key - Returns user to Event List.
Important Note: The Event List history is lost when power is removed, also the
Date/Time will have to be reset as follows
Enter - Press and Hold until display changes to the Configuration
ModeLeft Arrow - Press twice until TIMe is highlighted.
Enter - Press to begin Time/Date change mode
Use the UP/DOWN Arrow keys to select time and date, follow each selection with
the ENTER key. The Date/Time format is viewed as follows: (AM/PM is selected
through changes made during setting the HOUR digits)
DAY MONTH YEAR
HOUR MINUTE SECOND AM/PM
When all selections are correct, Press the // Key to return to the EVENT LIST screen.
To return to the STROKES PER MINUTE screen, press the LEFT ARROW key until
it is displayed, also by scrolling back toward the STROKES PER MINUTE screen all
user setpoints may be rechecked.
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7.0 OPERATING ROTAFLEX
Starting the Rotaflex Pumping Unit for the first time:
Your Rotaflex Pumping Unit was erected and run at the factory. Necessary adjustments were
made and the unit is in good working order. However, additional adjustments may be requiredafter erecting the unit at the well site.
After assembling the unit and performing maintenance, perform each of the following steps
before starting the unit for the first time.
1. Remove all tools or articles of obstruction from the foundation and around the unit.
2. Check to be certain that all safety guards and shields are properly installed.
3. Remove the wooden shipping blocks located at the back of the weightbox. The wooden
shipping block is used to protect the back wheels from being flattened after prolong
periods of the unit laying down.
4. Check for proper lubricant levels in the gear reducer and chain reservoir. The gear
reducer has been pre-lubricated at the factory, but should be checked prior to operation.
The vented breather filter should replace the shipping plug at the top of the gear reducer
prior to start-up. The chain should be lubricated with 40 gallons of chain lubrication oil.
For more information, please refer to the LUBRICATION section.
5. Check that the prime mover is properly installed and mounting bolts are properly
tightened.
6. Check that belts are aligned and properly tensioned and belt guard is in place.
7. Remove all safety stops and disengage the manual brake.
8. Make the first stroke as slow as possible to properly check the clearance between the belt
guards, railings and any safety structure installed around the Rotaflex Pumping Unit. Be
sure the polished rod and the downhole pump have clearance on the down stroke and
upstroke.
WARNING: To prevent personal injury, stay clear of any moving parts!
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7.1 COUNTERBALANCE ADJUSTMENT
Efficient operation, minimum torque loading and maximum life of a pumping unit are all a result
of proper counterbalance. The auxiliary counter weight is supplied in properly dimensioned
metal blocks of varying thickness. To calculate the weight of the auxiliary counterweight,
measure the stacked block of metal. Measure the height, width and depth in inches of the
auxiliary counterweight stack. H x W x D x .2833 will calculate the weight of the auxiliary
counterweight in pounds. This number in pounds added to the built-in weight of the weightbox
is the counter balance weight. See Section 4.0 Unit Specifications for built-in weight..
AMMETER
A clip-on ammeter may be used to compare the up stroke and down stroke current on electrically
powered units. Balance the counterweight so that the current peaks are equal within plus or
minus 5%.
VACUUM GAUGE
A vacuum gauge may be used to compare torque peaks on engine-driven units much as the
ammeter is used on electrically driven units. Vacuum pressure decreases as engine output
increases.
SOUND OF THE POWER UNIT
A rough estimate of balance can be made by listening to the characteristic sound of the PRIME
MOVER as it drives the Rotaflex Pumping Unit. Some speed change will occur as the peak loads
are approached; this speed change will cause the sound of the PRIME MOVER to change.
POLISHED ROD DYNAMOMETER TEST
Dynamometer card analysis is the most accurate method used to determine loading and
counterbalance. This involves using a dynamometer to record the well load through a stroke
cycle and then using torque factors to determine the gear reducer torque required for balanced
conditions. The stroke length of the Rotaflex Model 800DX and 900 is 288 inches, 306 inches
for the 1100 unit. If the position transducer does not have sufficient capability to measure the
full stroke length, an auxiliary string and pulley attached to the unit will reduce the requiredstroke length measurement of the transducer to
1/2 the stroke length. Figure 25 shows a string
and pulley configuration to obtain dynamometer card from Rotaflex with a 200” position
transducer. To do so, tie one end of string to eye on crown at top of tower. Tie the other end of
the string to the Belt Bar after passing it around the traveling pulley. The traveling pulley will
provide a 144” of travel from the 288” stroke of the Rotaflex.
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Figure 25. String & Pulley Configuration to obtain Rotaflex Dynamometer Card
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SPM vs. Sheave Size
for ROTAFLEX 800DX
Motor RPM X Motor Sheave
Gearbox Ratio X Chain Ratio X Unit SheaveSPM =
for Motor RPM = use 1150, Gearbox Ratio = 32.67, Chain Ratio = 5.9048
Motor Sheave
Unit SheaveSPM = 5.96 X
Motor Sheave
7” 7.5” 8” 8.5” 9” 9.5” 10” 11”
HP/Belt 8.5 9.8 11.1 12.3 13.5 14.7 15.9 17.1
Recommended Belt : 4 Groove, C section PowerBand Belt
Selection is based on 65 HP
Select designed SPM from Table 2:
Table 2 Rotaflex 800DX SPM Selection Table
Motor Unit sheave Size / V-Belt size (50” – 60” Centers)
Sheaves 20* 24 27 30 367 2.1 C-158 1.7 C-162 1.5 C-162 1.4 C-162 1.2 C-180
7.5 2.2 C-158 1.6 C-162 1.7 C-162 1.5 C-173 1.2 C-180
8 2.4 C-158 2.0 C-162 1.8 C-162 1.6 C-173 1.3 C-180
8.5 2.5 C-158 2.1 C-162 1.9 C-162 1.7 C-173 1.4 C-180
Motor Sheaves 8.5” & smaller not recommended.9 2.7 C-158 2.2 C-162 2.0 C-162 1.8 C-173 1.5 C-180
9.5 2.8 C-158 2.4 C-162 2.1 C-162 1.9 C-173 1.6 C-180
10 3.0 C-162 2.6 C-162 2.2 C-162 2.0 C-173 1.7 C-180
11 3.3 C-162 2.7 C-162 2.4 C-173 2.2 C-173 1.8 C-180
12 3.6 C-162 3.0 C-162 2.6 C-173 2.4 C-173 2.0 C-190
13 3.9 C-162 3.2 C-162 2.9 C-173 2.6 C-180 2.2 C-190
14 4.2 C-162 3.5 C-162 3.1 C-173 2.8 C-180 2.3 C-190
16 4.8 4.0 C-173 3.5 C-180 3.2 C-180 2.6 C-195
18 5.4 4.5 C-173 4.0 C-180 3.6 C-180 3.0 C-195
20 6.0 5.0 4.4 4.0 C-190 3.3 C-195
24 7.2 6.0 5.3 4.8 4.0 C-195
Note: SPM’s indicated in Bold are above the maximum allowable SPM.
Recommended 20” 4 C standard sheave.
EXAMPLE: Desired SPM is 3.6 - For 20” unit sheave, select 12” motor sheave.
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SPM vs. Sheave Size
for ROTAFLEX 900
Motor RPM X Motor Sheave
Gearbox Ratio X Chain Ratio X Unit SheaveSPM =
for Motor RPM = use 1150, Gearbox Ratio = 31.06, Chain Ratio = 5.9048 (5.00” chain)5.6796 (4.09” chain)
Motor Sheave
Unit SheaveSPM = 6.27 X
Motor Sheave
7” 7.5” 8” 8.5” 9” 9.5” 10” 11”
HP/Belt 8.5 9.8 11.1 12.3 13.5 14.7 15.9 17.1
Recommended Belt : 4 Groove, C section PowerBand Belt
Selection is based on 65 HP
Select designed SPM from Table 3:
Table 3 Rotaflex 900 SPM Selection Table
Motor Unit sheave Size / V-Belt size (50” - 60”Centers)
Sheaves 20* 24 27 30 367 2.2 C-158 1.8 C-162 1.6 C-162 1.5 C-162 1.2 C-180
7.5 2.4 C-158 2.0 C-162 1.7 C-162 1.6 C-173 1.3 C-180
8 2.5 C-158 2.1 C-162 1.9 C-162 1.7 C-173 1.4 C-180
8.5 2.7 C-158 2.2 C-162 2.0 C-162 1.8 C-173 1.5 C-180Motor Sheaves 8.5” & smaller not recommended.9 2.8 C-158 2.4 C-162 2.1 C-162 1.9 C-173 1.6 C-180
9.5 3.0 C-158 2.5 C-162 2.2 C-162 2.0 C-173 1.7 C-180
10 3.1 C-162 2.6 C-162 2.3 C-162 2.1 C-173 1.7 C-180
11 3.4 C-162 2.9 C-162 2.6 C-173 2.3 C-173 1.9 C-180
12 3.8 C-162 3.1 C-162 2.8 C-173 2.5 C-173 2.1 C-180
13 4.1 C-162 3.4 C-162 3.0 C-173 2.7 C-180 2.3 C-180
14 4.4 C-162 3.7 C-162 3.3 C-173 2.9 C-180 2.4 C-195
16 5.0 4.2 C-162 3.7 C-173 3.3 C-180 2.8 C-195
18 5.6 4.7 4.2 C-173 3.8 C-180 3.1 C-195
20 6.3 5.2 4.6 4.2 C-180 3.5 C-195
24 7.5 6.3 5.6 5.0 4.2 C-195
Note: SPM’s indicated in Bold are above the maximum allowable SPM.
*Recommended 20” 4 C standard sheave.
EXAMPLE: Desired SPM is 3.4 - For 20” unit sheave, select 11” motor sheave.
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SPM vs. Sheave Size
for ROTAFLEX 1100
Motor RPM X Motor Sheave
Gearbox Ratio X Chain Ratio X Unit SheaveSPM =
for Motor RPM = use 1150, Gearbox Ratio = 31.06, Chain Ratio = 6.1985
Motor SheaveSPM = 5.98 X
Unit Sheave
Motor Sheave
HP/Belt 7” 7.5” 8” 8.5” 9” 9.5” 10” 11”
8.5 9.8 11.1 12.3 13.5 14.7 15.9 17.1
Recommended Belt : 5 Groove, C section PowerBand Belt
Selection is based on 65 HP
Select designed SPM from Table 4:
Table 4 Rotaflex 1100 SPM Selection Table
Motor Unit sheave Size / V-Belt size (50” - 60”Centers)
Sheaves 20* 24 27 30 367 2.1 C-158 1.7 C-162 1.6 C-162 1.4 C-173 1.2 C-180
7.5 2.2 C-158 1.9 C-162 1.7 C-162 1.5 C-173 1.2 C-180
8 2.4 C-158 2.0 C-162 1.8 C-162 1.6 C-173 1.3 C-180
8.5 2.5 C-158 2.1 C-162 1.9 C-162 1.7 C-173 1.4 C-180
Motor Sheaves 8.5” & smaller not recommended.9 2.7 C-158 2.2 C-162 2.0 C-162 1.8 C-173 1.5 C-180
9.5 2.8 C-158 2.4 C-162 2.1 C-162 1.9 C-173 1.6 C-180
10 3.0 C-162 2.5 C-162 2.2 C-162 2.0 C-173 1.7 C-180
11 3.3 C-162 2.7 C-162 2.4 C-173 2.2 C-173 1.8 C-180
12 3.6 C-162 3.0 C-162 2.7 C-173 2.4 C-173 2.0 C-180
13 3.9 C-162 3.2 C-162 2.9 C-173 2.6 C-173 2.2 C-180
14 4.2 C-162 3.5 C-162 3.1 C-173 2.8 C-173 2.3 C-195
16 4.8 4.0 C-162 3.5 C-173 3.2 C-180 2.7 C-195
18 5.4 4.5 C-173 4.0 C-173 3.6 C-180 3.0 C-195
20 6.0 5.0 4.4 C-173 4.0 C-180 3.3 C-195
24 7.2 6.0 5.3 4.8 4.0 C-195
Note: SPM’s indicated in Bold are above the maximum allowable SPM.
Recommended 24” 5 C standard sheave.
EXAMPLE: Desired SPM is 3.5 – For 24” unit sheave, select 14” motor sheave.
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7.2 BEFORE WELL SERVICE
Rotaflex is designed with the ease of well service in mind, the Rotaflex pumping unit can be
rolled back “away” from the well for servicing. The following is the procedure for rolling back
the Rotaflex Unit:
1. Run the rod string down to within 6 to 12 inches from the bottom of the stroke.
WARNING: The manual brake caliper must be adjusted sufficiently to hold the weight
box without the well load attached.
2. Clamp off the polished rod above the stuffing box.
3. Disconnect the carrier bar from the polished rod.
4. Tie a 1/2-inch rope 35 feet long to the carrier bar.
5. Keep the load belt centered on the idler drum.
6. Lower the weight box (raise the load belt) slowly with the manual brake while holding
tension on the rope.
WARNING: Do not let rope get wrapped around hands or feet!
WARNING: Weight box MUST be lowered before sliding unit back for well servicing.
WARRANTY may be void if weight box falls while servicing the well.
Consult with a ROTAFLEX service representative for exceptions.
7. Tie off the rope.
8. Remove the tie-down bolt and plate nearest the well head and loosen, but do not remove,
the tie down bolt nearest to the back of the Rotaflex Pumping Unit.
9. Lubricate the pin and the inside of the roll-back wheel.
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10. Using a 22-ton hydraulic jack under the pack pads lift one side of the unit and install the
roll-back wheel and pin as shown in Figure 26.
11. Release the jack slowly and repeat the procedure on the opposite side.
12. With steps 9, 10, 11, and 12 completed, the unit is designed to slide back on the rails
mounted to the special concrete base using a winch line from a 2-ton or larger truck OR a
hydraulic unit similar to a backhoe, to slide the unit back 10 feet. The winch line should
be as near horizontal as possible and attached to the pad eye at the rear of the skid.
13. Tighten the tie-down bolt to secure the unit while the well is being serviced.
Figure 26. Rolling Back Rotaflex
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7.3 AFTER WELL SERVICE
When the Rotaflex Unit has been rolled back for well service, the following procedure must be
followed to “roll” the Rotaflex unit back to position and hook-up for production:
1. Loosen, but do not remove the tie-down bolt.
2. To pull the unit forward after the workover, a yoke should be in front of the well head as shown in
Figure 27. Slide the unit forward until it is against the well alignment brackets.
3. Use the hydraulic jack to raise one side and remove the pin from the roll-back wheel. Release the
jack slowly and repeat the procedure on the opposite side.
4. Re-install the tie-down bolt and tighten both tie-down bolts.
5. Raise the weight box (lower the lifting belt) while pulling down on the rope attached to the carrier
bar. This assists the load belt to fall as fast as the weight box is being raised. Apply the brake and
turn off the motor when the carrier bar is at the lowest point. Activate the emergency brake.
WARNING: Do not let the rope wrap around hands or feet!
6. Re-attach the carrier bar the polished rod and attach the polished rod clamp above the carrier bar.
7. Release the brake slowly and allow the load belt to pick up the polished rod load. Remove the
clamp at the stuffing box.
Figure 27. Rolling Rotaflex Forward
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GROUND LEVEL
1. Check oil level in gear reducer
2. Check brake pads on both sets of brake calipers
3. Check caliper pad adjustment
4. Check brake rotor
5. Check tension of prime mover belts
6. Check belt guard and target wheel guard
7. Check ladder and safety shroud bolts
8. Check all controls provided with SPEED-SENTRY for proper function
9. Check both gauges on nitrogen bottle (if present)
Associate the following comments with above inspection items.
1. No oil in sight glass may indicate need for replacement of oil seal(s) or drain plug. See
section 6.5
2. Excessive wear of brake pad material will result in slow or no response in braking when
needed. Replace worn pad with replacement pad kit, either 830192 for Alum. Caliper &
830232 for Cast Iron Caliper, when pad thickness is 1/16” minimum.
3. Excessive wear of brake pad material will result in slow or no response in braking when
needed. This is most important in the automatic brake caliper. Adjust by turning the hex nut
clockwise to reduce clearance
4. Brake rotor must run true without wobble. Frequent adjustment of pad clearance may
indicate need to replace rotor.
5. Correct tension of v-belt(s) or power-band will greatly increase the effectiveness of the prime
mover power and the operation of the unit during normal operation.
6. The safety of the personnel around the unit requires that the v-belt and target wheel guard be
in place, operating as designed and not broken or bent out of place.
7. The safety of the personnel ascending to the top of the unit requires that the ladder and cages
be of sound structure and not broken. Replace any broken bolts.8. The safe operation of the Rotaflex unit as designed will not allow the counterweight box to
fall completely to the bottom of the tower without actuating the automatic braking system.
The Speed Sentry controls this automatic braking system. Check the operation of the Speed
Sentry by testing the UNDER-SPEED and the OVER-SPEED operation referred to in section
6.8.
9. On those units equipped with the nitrogen powered automatic braking systems, check the
high pressure gauge for a pressure of 100 Lbs. Minimum and the low pressure gauge for a
pressure of 70 Lbs. minimum. If needed, replace the empty cylinder with a full cylinder.
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INSIDE MID-TOWER
1. Check locking bolts and nuts
2. Check chain pin Retaining Plug or Keeper on swivel shaft
3. Inspection of the Chain Pin inside the swivel shaft
Associate the following comments with above inspection items.
1. Loose locking bolts will allow Top Sprocket misalignment.
2. Loose Retainer or Keeper will allow chain failure.
3. On those units with a Retainer Plug, remove plug to allow visual access of the end of the
chain pin. The chain pin hole must not be elongated, which would indicate pin rotation wear
in the Swivel Shaft. Replace Retainer Plug.
TOP OF TOWER
1. Check end plates of idler drum2. Check grease level in pillow block bearing housings (For all 1100’s and certain 800DX and
900 units without poly-pak bearings.)
3. Check grease seals on inside of bearing housings.
Associate the following comments with above inspection items.
1. Visual inspection of end plate will give indication of any abnormal “load” cracks, either in
the plates or any weld area.
2. See section 8.4
3. Excessive amount of grease on the shaft just inside the pillow block may indicate a leaking
pillow block grease seal.
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8.1 CHECKING TOWER CHAIN TENSION
The heavy duty tower roller chain is designed to give many years of service with proper
maintenance. The Rotaflex Pumping Unit’s unique lubrication system provides adequate
lubrication, but the chain should be routinely examined for excessive wear and proper
tensioning. To check the tension on the Rotaflex Pumping Unit chain, please follow these procedures.
1. Turn the unit off with the bottom of the counterweight box approximately 2 feet above the
top of the front opening. Note the position of the drive sprocket. Using a 4 or 5 foot
probing device, such as a shovel handle, push against the chain, trying to move it from left
to right, not front to back. Push first on one side and then against the other (one side will
be extremely tight), noting the amount of side to side movement on the loose side of the
chain.
2. There is a possibility that the chain may experience more or less tension as the drive
sprocket and the idler sprocket rotate, it is imperative to check the tension a minimum of
four different sprocket positions.
3. Allow the drive sprocket to make a quarter revolution (or 90 degrees turn) and check the
tension of the chain again. Note the side to side movement of the chain.
4. Allow the drive sprocket to make another quarter revolution (180 degree rotation from
original position) in the same direction as before and check the tension of the chain again.
Note the side to side movement of the chain.
5. Allow the drive sprocket to make an additional quarter revolution (270 degrees rotation
from original position) in the same direction as before and check the tension of the chain
again. Note the side to side movement of the chain.
6. If the side to side deflection is less than one inch, the chain MUST be loosened.
7. If the chain will deflect more than two or three inches when the tension is the greatest
(deflection is least), the chain tension needs to be adjusted.
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8.2 ADJUSTING THE TOWER LOAD CHAIN
To adjust the Rotaflex Pumping Unit load chain, follow these procedures:
CAUTION: Do not over tighten the chain!
Over tightening the Rotaflex pumping unit chain can put damaging stress on the top idler
sprocket. Under tightening the chain will cause some excessive noises and will allow the
transversing mechanism to come in contact with the transversing mechanism frame.
1. Turn the unit off with the bottom of the counterweight box approximately 2 feet above the
top of the front opening, set the manual brake and emergency stop.
2. Turn off and lock out the main power.
3. Climb the service ladder to the mid-tower platform and open the mid-tower door. This
will expose the top sprocket, the telescoping mounting for the top sprocket and a portionof the chain.
4. Loosen three (3) 3/4 -inch locking nuts (two on the front and one on the left side of the
telescope mounting bracket) and loosen the three (3) 3/4-inch set screws. This will allow
the telescoping member to move up and down.
5. There are four (4) jack-bolts with locking nuts, one on each corner of the telescoping
member of the mounting bracket. Loosen the locking nuts.
6. Turn the four (4) jack-bolts clockwise to increase tension on the chain. Turn each jack-
bolt an equal amount to keep the mounting bracket as level as possible. Do not makemore than one complete turn of the four (4) jack-bolts at this time.
7. Check the chain tension again.
8. When the chain tension is correct, tighten the four (4) locking nuts on the jack-bolts.
9. Tighten the three (3) set screws on the telescoping member of the mounting bracket and
tighten the three (3) locking nuts.
10. Close and fasten the mid-tower door.
11. If the chain tension is still right, close and secure the front doors.
12. Return electric power to main panel. Release brake and restart the Rotaflex pumping unit.
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8.3 ADJUSTING WEIGHT BOX GUIDE WHEELS
There are three guide wheels on each corner of the weight box to keep the weight box positioned
properly inside the tower. One wheel on each corner is to align the weight box from side to side.
The other two wheels on each corner are to align the weight box from front to back.
Each guide wheel has an adjusting bolt and lock nut. Based on the position of the transversing
mechanism, the weight box is seldom perfectly aligned with the tower. One of the bottom side-
to-side guide wheels and the opposite top side-to-side wheel will be experiencing all the load.
The other two side-to-side guide wheels will not be touching the I-Beam. When the direction of
movement of the weight box reverses, the opposite wheels will be carrying the load.
The back guide wheels are factory set. All adjustment to the guide wheels should be done with
the front wheels ONLY. When the unit is standing, the Front and Back guide wheels should be
just touching the respective tower beam flange. When necessary, adjust the front guide wheels
so that the condition is achieved. To adjust the wheels, loosen the locknut on the adjusting bolt
and turn the bolt clockwise to reduce the clearance between the guide wheel tread and the I-Beam. When the adjustment is completed, re-tighten the locking nuts.
There has to be a 1/8” gap for any side of the Side Guide Wheels to the respective tower beam.
When necessary, adjust the corresponding guide wheels when the unit is standing up.
The remaining eight (8) guide wheels keep the weight box centered between the front and back
of the tower. These guide wheels also align the chain with the sprockets. If these guide wheels
need adjusting, consult your ROTAFLEX representative for proper chain alignment.
All 12 guide wheels can be adjusted from the front of the unit, but the four guide wheels near the
back of the tower can only be replaced when personnel climbs inside the tower.
WARNING: The weight box must be blocked and/or chained before personnel climbs
inside the tower!
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8.4 TOP IDLER DRUM INSPECTION
The crown hood is located at the top of the unit and is for access to the idler drum, load belt and
the two pillow block bearings that support the idler drum. The hood is equipped with a safety
support. When opening the hood, check the safety support to make sure it is in the locked
position. With the safety support properly latched, you will have to manually unlatch it to closethe hood as shown in Figure 28.
WARNING : The hood is approximately 45 feet above ground level. At this elevation, the
wind currents could make handling the hood very dangerous. Be aware the
safety support could be accidentally unlatched if the wind causes the hood to
move. Do not place head, hands or feet in a position where the lid could
accidentally close and cause injury!
The top idler drum holds all the combined weight of the weight box and the well load. Due to
the significant load, a visual inspection of the drum, the end plates of the drum, and the condition
of the welds is required.
Model 800DX and 900 units with serial number 499 or higher
These units are equipped with poly-pak sealed for life bearings in the pillow blocks of the top
drum. This also applies to units with earlier serial numbers which had pillow blocks replaced in
the field after June 1996. These bearings should NOT be lubricated otherwise it may cause
damage. If it is unclear which bearing existed on the unit, please contact the customer service
department for clarification.
Model 800DX and 900 units with serial number 498 or lower and all model 1100 units
The pillow block bearings in these units should have additional grease (AAR M-942 or
equivalent, for all temperature ranges) added after 6 months of operation and every 6 monthsthereafter. The bearings may require as much as 20-25 pumps from a hand-held grease gun or
until excess grease appears through the grease relief opening.
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Figure 28. Accessing Top Drum
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9.0 REPLACING THE LOAD BELT
Equipment requirement:
Crane with minimum 75-foot hook heightWireline cables and shackles
Special clamp for load belt (obtain from Weatherford, CPS)
Wrenches
Safety belt with lanyard for two employees
Procedure:
1. Remove the windguard from the load belt, if so equipped.
2. Remove the carrier bar from the polished rod.
3. Remove the bridle from the belt bar.
4. Tie 1/2-inch rope 35 foot long to the belt bar.
WARNING : Do not let rope get wrapped around hands or feet!
5. Carefully lower the counterweight box to the bottom of the tower, keeping tension on the
rope to prevent the belt from hitting the top of the tower.
6. Set hand brake and emergency stop.
7. Lock out power at main service pole.
8. Open and secure front doors.
9. Open crown hood and center the special load belt clamp on the top of the tower, parallel to
the load belt. The tapered clamps bolted to the special load belt clamp are positioned
behind the load belt so the load belt is between the longer angle-iron and the short, tapered
angle-iron clamps. Tighten two bolts on both ends, clamping the load belt securely.
10. Attach wireline cables to the clamp. Crane operator should get sight tension on the cables
and hold.
11. Personnel climbs through the front doors to the inside of the tower on top of the weight
box. Remove the bolt and large washer from the pin holding the belt bar to the weight
box. Install a 1/2 inch eye-bolt in this hole and attach a 5 foot length of small rope in the
eye-bolt.
CAUTION: If the large pin is accidentally dropped behind the weight box, it cannot be
retrieved without possible damage to the Rotaflex Pumping Unit.
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12. Carefully remove the large diameter pin from the belt bar. The belt bar may have to be
adjusted to allow the pin to be removed.
13. The personnel climbs out of the tower through the front doors, removing all tools, pin,
washer and bolt.
14. Personnel at top of tower removes the belt retainer bar fastened to the tower in front of the
idler drum. Note the location of the belt retainer bar in relation to the load belt. Store the
belt retainer bar on the work platform at the top of the tower.
15. The crane operator carefully lifts the belt through the top of the tower. Personnel at the
top of the tower guides the belt to keep it from getting caught inside the tower.
16. After the belt has cleared the top of the tower, lay the belt flat on the ground with the
special load belt clamp on top.
17. Measure the distance from the end of the bridle bar to the clamp and remove the clamp.
18. Place the new belt on top of the old belt, paying attention to the orientation of the belt for
proper attachment of the bridle, and measure the same distance from the bridle bar. Place
the special clamp on the new belt 12 inches closer to the bridle bar. This measurement
should be about 60 inches from the belt clips.
19. Untie the rope from the old belt and tie it to the new belt.
CAUTION: If the wind is blowing, use two ropes!
20. Attach the wirelines to the special load belt clamp and lift the new belt until the lowerend of the belt clears the tower.
21. Lower the belt into the tower, paying attention to the orientation of the belt for proper
attachment of the bridle.
22. When the bottom of the belt reaches the top of the weight box, align the hole in the belt
bar with the eye on top of the box.
23. Personnel climbs back into the tower through the front doors and on top of the weight box
and carefully replaces the 3-inch diameter pin through the belt bar and the weight box.
Replace the washer and bolt on the pin.
24. Personnel climbs out of the tower.
25. Personnel on top of the tower removes the special load belt clamp. The crane operator
lowers the clamp to the ground.
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10.0 MOVING THE UNIT
It is important that the mechanical brake system be in good operating order and adjusted
properly before working on the unit.
1. Before disconnecting electrical service from the unit:
a. Drain or vacuum the oil from chain reservoir.
b. Lower the weight box to the bottom of the tower.
c. Remove all the auxiliary counterweight from the weight box.
d. Set the manual brake. Set the emergency stop on the automatic brake.
e. Remove vent plug from gear reducer and replace with solid oil plug.
2. Make sure there are no sub-poles, electrical lines or guy wires that will interfere with the
lowering of the tower. When the unit is lying down, the top of the tower is approximately
20 feet longer than the skid.
3. Remove belt guard, belts and prime mover. Remove the sheave and hub from the input
shaft of the gear reducer.
4. Make sure both tie-down bolts are properly tightened.
5. Position 50-ton (or larger) crane with 50-foot (or greater) boom height on one side of the
unit, near the middle of the 24-foot concrete pad. Position the load hook rigged with the
spreader bar above the tower. Attach wireline cables to the spreader bar and to the pad
eyes located near the top of the tower (one on each side of the crown hood.) Wireline
cables should be only long enough to clear the top of the crown hood.
6. Remove six (6) bolts (three on each side of the tower) that hold the tower beams and skid
together.
7. Remove the pins from the lower end of the standing struts and guide shoe. The struts will
move towards the rear of the unit as the tower is lowered.
8. NOTICE: The following is the procedure used at the manufacturing facility to lower
the units before shipping. The crane operator may recommend a different method
or may desire to set his crane in a different location.
a. Place the boom of the crane towards the back of the unit 2 or 3 feet behind the pivot
point. Lock the swing brake while holding tension against the load.
b. Lift the load. This should begin the breakover movement of the tower.
c. If the motion is not enough to begin the breakover, ease the unit to the upright position
and begin at step A and use more swing. (Swing the boom towards the back of the unit 3
to 4 feet behind the pivot point and lock the swing brake while holding tension against
the load.) The motion of the tower is to tilt towards the back of the unit, NOT raise up.
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9. The pivoting point is approximately 7 feet from the front of the unit. The crane should
continue tilting the tower towards the rear of the unit, keeping the line above the top of
the crown, not allowing it to swing to either side. (This will allow the unit to lie down
parallel to, and on top of, the skid.) Breakover point of the Rotaflex Pumping Unit occurs
when the lower ends of the struts are about even with the rear of the skid. The crane
operator should be aware of this change of load.
10. After the breakover point is reached, continue lowering the tower until the pins can be
removed from the top of the struts.
11. Attach the shipping supports in place of the struts. Continue lowering the tower until the
shipping supports meet the skid. Attach the shipping supports to the skid with two bolts
for each support.
12. Attach four 20-foot wireline cables to the four pad eyes. Two are located near the bottom
of the tower and two are located two-thirds of the way up the tower on the front.
13. Attach the load line of the crane to the four wire line cables and hold the line snug while
removing the tie-down bolts. Make sure all tie-down bolts are removed as shown in
Figure 29.
Figure 29. Lifting The Rotaflex Unit
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14. The unit will be heavier at the base end when unit is picked up from the concrete pad. The
crane operator should lift the unit straight up until it clears the concrete pad, then set it on
the truck.
15. Support the tower near the top end with temporary shipping posts between the truck bed
and the tower. Chain the unit to the truck with good quality load chains and load binders,
using a “cross tie-down” method as shown in Figure 30.
Figure. 30. Positioning Rotaflex Unit on Truck
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11.0 PRODUCT IMPROVEMENT
The manufacturer of Rotaflex pumping unit is constantly improving the design quality of the
unit. In many instances, the feedback of the end users provide tremendously benefit to the
continuous product refinement effort. The Product Performance Report (PPR) is aimed to gather
product performance information from the end users for product improvement. Although it is the policy that all warranty claim must have a PPR number assigned by the manufacturer, all end
users are encouraged to submit PPRs to the manufacturer via the customer service.
Customer Service - USA
Tel: (432) 334-4575
Fax: (432) 334-4555
A copy of the Product Performance Report is included at the end of this manual. End
users is free to make copies for submission via the customer service. When a significant change
in design which will affect the maintenance of the Rotaflex units, Field Service Bulletins are
issued to all field service personnel so that proper procedures can be followed. WeatherfordArtificial Lift Systems is committed to provide the highest quality of oil field equipment to our
customers. Provide us feedback to us serve you better.
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