INSTRUCT PCP

INTELLIGENT CONTROLLER

Hardware Installation Manual

LCS-ENG-M0017,
Important Safety Information INSTRUCT PCP Intelligent Controller

IMPORTANT SAFETY INFORMATION

SYMBOLS AND TERMS

Read user instructions carefully and visually inspect the equipment to become familiar with the device before
installing, operating, or maintaining it.
Equipment should be installed, operated, serviced, and maintained only by qualified personnel. Sensia
assumes no responsibility for consequences arising from the use of this material.
The following messages may be used in this document to help ensure personal safety and efficient handling
of equipment.

DANGER
A hazardous situation which, if not avoided, will result in serious injury or death.

WARNING
A hazardous situation which, if not avoided, can result in serious injury or death, major loss of
property, or catastrophic business risk.

WARNING – ELECTRICAL SHOCK

An electrical hazard which will result in personal injury if instructions are not followed.

CAUTION
A hazardous situation which, if not avoided, can result in minor or moderate injury, loss of
property, or business risk.

Important Non-urgent information that may impact the outcome of a process or procedure.

Note Additional information or a tip that may help the user to work more efficiently.

DO NOT DISCARD IN TRASH BIN

Product should not be discarded as unsorted waste. It must be sent to separate collection
facilities for recovery and recycling.

CONTACT SENSIA
For technical support, please refer to https://www.sensiaglobal.com/Technical-Support.
For all other inquiries, please refer to https://www.sensiaglobal.com/Customer-Care or dial 1-866-773-6742.

REVISION HISTORY
Revision Description of Change Issuer Approver Date
01 Customer-Facing Documentation TechComm Ahmad El-Kadri 07/24/2023

ii
INSTRUCT PCP Intelligent Controller Publisher Notes

PUBLISHER NOTES

DISCLAIMER
While Sensia has taken every care in the preparation of this document, it cannot accept responsibility for
printing errors or omissions and does not warrant that it is correct and comprehensive in every particular
instance. Equipment supplied should always be operated by persons with an appropriate level of skill and
training.
Sensia shall not be liable for incidental or consequential damages resulting from the furnishing, performance
or use of this material.
Sensia pursues a policy of continuous improvement, and information given herein may be updated without
notice. Further, this information is proprietary to Sensia, and must not be disclosed to any third party except
as may be required to operate the equipment supplied in accordance with the purposes for which it was sold
by the persons properly licensed to operate it.
Our manuals may contain links to protected online resources that you cannot access. If you are unable to
access a document link, please prepare an email request that includes (1) the name of the document and
(2) a copy of the link and address it to [email protected]. Our support team will provide you
with the requested information.

COPYRIGHT NOTICE
Copyright © 2023 Sensia. All rights reserved.
This work contains the confidential and proprietary trade secrets of Sensia and may not be copied or stored
in an information retrieval system, transferred, used, distributed, translated or retransmitted in any form or by
any means, electronic or mechanical, in whole or in part, without the express written permission of the
copyright owner.

TRADEMARKS & SERVICE MARKS

An asterisk (*) is used throughout this document to designate marks of Sensia. Other company, product, and
service names are the properties of their respective owners.
Sensia, the Sensia logotype, and other words or symbols used to identify the products and services
described herein are either trademarks, trade names or service marks of Sensia and its licensors, or the
property of their respective owners. These marks may not be copied, imitated or used, in whole or in part,
without the express prior written permission of Sensia. In addition, covers, page headers, custom graphics,
icons, and other design elements may be service marks, trademarks, and/or trade names of Sensia and may
not be copied, imitated, or used, in whole or in part, without the express prior written permission of Sensia.

WARRANTY
Product warranty is specified in Sensia Terms and Conditions at the time of purchase.

SECURITY NOTICE FOR SOFTWARE PRODUCTS

The software described herein is designed to operate with the minimum hardware and operating system
specifications recommended by Sensia. The software should be operated in a secure environment whether
operation is performed across a network, on a single system and/or on multiple systems.
The end user is responsible for configuring and maintaining networks and/or system(s) in a secure manner.
The end user is also responsible for obtaining, installing, operating and maintaining all hardware, other
equipment and third-party software required for use of the software. Sensia is not responsible for data loss
arising as a result of software use or interaction of the software with any third-party software.
For more information about recommended security practices, please contact Sensia Technical Support via
https://www.sensiaglobal.com/Technical-Support.

iii
Table of Contents INSTRUCT PCP Intelligent Controller

TABLE OF CONTENTS

Section 1: Introduction to this Manual ........................................................................................ 6

System Components.................................................................................................................................... 7
Temperature and Humidity Ranges .............................................................................................................. 7
Equipment Ratings ...................................................................................................................................... 7
Environmental Condition Ratings ................................................................................................................. 7
Outdoor Use ................................................................................................................................................ 7
Indoor Use ................................................................................................................................................... 8
Understanding the INSTRUCT PCP Controller Measurement Units.............................................................. 8

Section 2: Install the INSTRUCT PCP Controller Panel .............................................................. 9

Required Tools and Materials .................................................................................................................... 10
Installation Overview .................................................................................................................................. 10
Preparing the Panel ................................................................................................................................... 10
Panel Fuses .............................................................................................................................................. 10
Replacing fuses ................................................................................................................................... 11
USB Drive.................................................................................................................................................. 11

Section 3: Terminal Block Connection Overview ..................................................................... 12

Section 4: Connect an Electric Drive or Hydraulic Motor ........................................................ 14

Connecting an Altivar Drive ........................................................................................................................ 15
Configuring an Altivar 71 Drive ............................................................................................................. 16
Configuring an Altivar 930 Drive ........................................................................................................... 18
Connecting an ABB ACS550, ACS580, ACS800, or ACS880 ..................................................................... 20
Configuring an ABB ACS550 Drive ...................................................................................................... 21
Configuring an ABB ACS800 Drive ...................................................................................................... 22
Configuring an ABB ACS880 or ACS580 Drive .................................................................................... 23
Connecting a Toshiba VF-AS1 Drive .......................................................................................................... 25
Configuring a Toshiba VF-AS1 Drive.................................................................................................... 26
Connecting a Yaskawa Drive ..................................................................................................................... 27
Configuring a Yaskawa Drive ............................................................................................................... 28
Connecting an Inovance MD200/MD500 AC Drive ..................................................................................... 29
Configuring an Inovance MD200/MD500 AC Drive ............................................................................... 30
Connecting a Vacon NX Drive.................................................................................................................... 31
Configuring a Vacon NX Drive.............................................................................................................. 33
Hydraulic Motor ......................................................................................................................................... 34
Electric Generic Drive ................................................................................................................................ 35

Section 5: Support the HOA and Bypass System..................................................................... 36

Section 6: Connect the Sensors ................................................................................................ 37

Installing the Analog Sensors on the Terminal Block .................................................................................. 38
Confirming Sensor Readings ..................................................................................................................... 38
Grounding the Sensor ................................................................................................................................ 38
Connecting a GEO PSI Modbus Sensor ..................................................................................................... 38

iv
INSTRUCT PCP Intelligent Controller Table of Contents

Other Sensors ........................................................................................................................................... 39

Section 7: Complete the INSTRUCT PCP Controller Installation ............................................. 40

v
Section 1: Introduction to this Manual INSTRUCT PCP Intelligent Controller

Section 1: Introduction to this Manual

The INSTRUCT PCP Controller is an advanced pump-off controller for automating a progressing cavity
pumped. It is comprised of the following components:
• A Remote Terminal Unit (RTU) that manages operation of the variable frequency drive (VFD) for electric
motors, or the motor itself when a hydraulic motor is used
• A human machine interface (HMI) panel that provides the interface to configure VFD and motor
operations
The INSTRUCT PCP Controller Hardware Installation Manual contains instructions for installing and wiring
the INSTRUCT PCP Controller kit. For the INSTRUCT PCP Intelligent Controller Configuration instructions,
refer to the INSTRUCT PCP Intelligent Configuration Manual.

DANGER: ELECTRIC SHOCK HAZARD

• Read and understand this manual, the INSTRUCT PCP Intelligent Controller Configuration
Manual, and the manuals for your variable frequency drive (VFD), motor, and progressing
cavity pump before installing or operating the INSTRUCT PCP Controller. Installation,
adjustment, repair, and maintenance must be performed by qualified personnel.
• The user is responsible for compliance with all international and national electrical code
requirements with respect to grounding and wiring of all equipment. Many parts of VFDs,
including the printed circuit boards, operate at the line voltage. Do not touch. Use
electrically insulated tools only.
• Do not touch unshielded components or terminal strip screw connections with voltage
present.
Failure to follow these instructions will result in death or serious injury.

DANGER: ELECTRIC SHOCK HAZARD

• Apply appropriate personal protective equipment (PPE) and follow safe electrical work
practices. See NFPA 70E, CSA Z462, and OSHA 1910.
• Install and close all covers before applying power or starting and stopping any of the
INSTRUCT PCP Controller components.
Failure to follow these instructions will result in death or serious injury.

DANGER: ELECTRIC SHOCK, EXPLOSION, or ARC FLASH

A hazardous situation which, if not avoided, will result in serious injury or death.
Before servicing the drive:
• Disconnect all power sources, including external control power.
• Place a Do Not Turn On label on all power disconnects.
• Lock all power disconnects in the open position.
• Wait 15 minutes to allow the DC bus capacitors to discharge and then verify that DC
voltage is less than 42 V. The drive LED is not an indicator of the absence of DC bus
voltage.
Failure to follow these instructions will result in death or serious injury.

CAUTION: UNINTENDED EQUIPMENT OPERATION

Do not install or operate any equipment that appears damaged.
Failure to follow these instructions can result in minor or moderate injury.

6
INSTRUCT PCP Intelligent Controller Section 1: Introduction to this Manual

SYSTEM COMPONENTS
The INSTRUCT PCP Controller consists of a panel with a SCADA Pack 334E RTU to control the PCP and
collect data about its functioning. Any option ordered with the INSTRUCT PCP Controller is delivered wired
in the panel.
The INSTRUCT PCP Controller systems available are listed in the table below.
Part Number Description
5072735 INSTRUCT PCP Controller, L3, Standalone Without Heater or Power Supply
5072740 INSTRUCT PCP Controller, L3, Standalone With Heater and Power Supply
5073290 INSTRUCT PCP Controller, Small L3, Standalone Without Heater or Power
Supply
5073295 INSTRUCT PCP Controller, Small L3, Standalone With Heater and Power Supply

TEMPERATURE AND HUMIDITY RANGES

The INSTRUCT PCP Controller supports the temperature and humidity ranges described in the table below.
Equipment Operating Storage Temperature Relative Humidity
Temperature Range Range
SCADAPack 334E RTU -40...70 °C (-40...158 -40...70 °C (-40...158 °F) 0...95%
°F)
Magelis HMI, with a -40...55 °C (-40...131 -20...60 °C (-4...140 °F) 0...90%
heater °F)
Magelis HMI, with no 0...55 °C (32...131 °F) -20...60 °C (-4...140 °F) 0...90%
heater
When the pump is configured, the INSTRUCT PCP Controller can control the pump with the SCADAPack
334E RTU outside the operating temperature range of the Magelis HMI.
To extend the effective range, use external heating and cooling options, such as solar shading.

EQUIPMENT RATINGS
The INSTRUCT PCP Controller panel equipment ratings are described in the table below. There are four
options available.
Model Supply Voltage Power Rating
5072735 19.2...28.8 VDC 100 W
5072740 100...240 VDC 100 W
5073290 19.2...28.8 VDC 100 W
5073295 100...240 VDC 100 W

ENVIRONMENTAL CONDITION RATINGS

Although the INSTRUCT PCP Controller is intended for use outdoors, it can be used indoors.

OUTDOOR USE
The equipment is designed for the extended environmental conditions listed in the table below, as well as the
conditions in the temperature and humidity ranges table and the indoor use table.

7
Section 1: Introduction to this Manual INSTRUCT PCP Intelligent Controller

Condition Rating
Altitude Up to 2000 meters (6562 ft)
Ambient temperatures Below 5 °C (41 °F) or above 40 °C (104 °F). See Temperature and Humidity
Ranges.
Humidity Relative humidity above the levels specified in the temperature and humidity
ranges table. See Temperature and Humidity Ranges.
Mains Supply voltage fluctuations exceeding ±10% of the nominal voltage
Transient overvoltages Typically present on the mains supply
The normal level of transient overvoltages is impulse withstand (overvoltage)
category II of IEC 60364-4-443

INDOOR USE
The equipment is designed for the environmental conditions listed in the table below.
Condition Rating
Altitude Up to 2000 meters (6562 ft)
Ambient temperatures Below 5 °C (41 °F) or above 40 °C (104 °F). See Temperature and Humidity
Ranges.
Humidity Relative humidity above the levels specified in the temperature and humidity
ranges table. See Temperature and Humidity Ranges.
Mains Supply voltage fluctuations exceeding ±10% of the nominal voltage
Transient overvoltages Typically present on the mains supply
The normal level of transient overvoltages is impulse withstand (overvoltage)
category II of IEC 60364-4-443

UNDERSTANDING THE INSTRUCT PCP CONTROLLER MEASUREMENT

UNITS
The INSTRUCT PCP Controller displays measurement values in imperial units.

CAUTION: UNINTENDED EQUIPMENT OPERATION

• Because the INSTRUCT PCP Controller displays all measurement values in imperial units,
you may need to convert measurements to and from their metric equivalents.
• Verify that all values are entered in the appropriate measurement unit in the INSTRUCT
PCP Controller.
Failure to follow these instructions can result in equipment damage.
The following table summarizes the imperial measurement units used in the INSTRUCT PCP Controller and
provides the metric conversion.
Measurement Imperial Measurement Unit Metric Conversion
Type
Acceleration weight force acceleration due to 32.2 feet/second squared (ft/s2) = 9.8 meters/second
gravity (g) squared (m/s2)
Depth feet (ft) 1 foot (ft) = 0.3048 meters (m)
Diameter inches (in) 1 inch (in) = 2.540 centimeters (cm)
Displacement cubic inches (in3 ) 1 cubic inch (in3 ) = 16.387 cubic centimeters (cm3 )
Flow barrels per day (bbl/d) 1 barrel per day (bbl/d) = 0.159 meters cubed per day
(m3 /d)
barrels per 100 revolutions per 1 barrel per 100 revolutions per minute (bbl/100rpm) =
minute (bbl/100rpm) 0.159 meters cubed per 100 revolutions per minute
(m3 /100rpm)
Power horsepower (HP) 1 horsepower (HP) = 0.745699872 kilowatts (kW)
Pressure pounds per square inch (psi) 1 pound per square inch (psi) = 6.894 kilopascals (kPa)
Temperature degrees Fahrenheit (°F) A change of 1 degree Fahrenheit (°F) = A change of
0.556 degrees Celsius (°C)
Torque foot pounds (ft-lb) 1 foot pound (ft-lb) = 1.356 newton meters (Nm)

8
INSTRUCT PCP Intelligent Controller Section 2: Install the INSTRUCT PCP Controller Panel

Section 2: Install the INSTRUCT PCP Controller Panel

The INSTRUCT PCP Controller panel has a pre-wired front panel. It needs to be mounted and connected to
the drive and sensors.
The INSTRUCT PCP Controller panel provides the following hardware components:
• Magelis HMI screen: Enables you to use the Magelis HMI software that provides the interface to
configure VFD and motor operations
• Ethernet port: Enables you to connect the INSTRUCT PCP Controller to your computer’s Ethernet port
• USB port: Enables you to connect directly to the Magelis HMI software
The following image shows a large INSTRUCT PCP Controller panel.

The following components are located Inside the INSTRUCT PCP Controller panel:
• Ethernet hub port
• Magelis HMI
• SCADAPack 334E RTU
• Terminal block
• Ground bus bar
• 100...240 Vac power supply (optional)
• Heater kit (optional)

9
Section 2: Install the INSTRUCT PCP Controller Panel INSTRUCT PCP Intelligent Controller

REQUIRED TOOLS AND MATERIALS

The tools, wires, and other components required for an INSTRUCT PCP Controller installation, but not
included with the INSTRUCT PCP Controller, are listed below:
• Slotted screwdrivers
• 18 and 20 AWG (0.811 to 0.963 and 0.507 to 0.616 mm2) 300 V wire
• Nut driver and Phillips screwdriver
• Adjustable wrenches
• Drill with suitable bits (if it becomes necessary to drill wiring access holes in the panel)
• Silicon or sealant
• Hacksaw
• UV-resistant outdoor-rated cable ties, cable thimbles, eyelets, beam clamps, or other cable-securing
devices
• Cord grip fittings
• Wire cutter and wire stripper
• Ethernet cable
The INSTRUCT PCP Controller includes a relay for an optional Start Warning Indicator (SWI), such as a
horn, tower light, or siren. Wiring details can be found in the Terminal Block Connection Overview.

INSTALLATION OVERVIEW
If the INSTRUCT PCP Controller is to be used in an environment with extreme heat, consider installing the
panel in a position where it is sheltered from direct sunlight.
Before beginning the installation of the INSTRUCT PCP Controller panel, have the materials listed in
Required Tools and Materials present.
To install the PCP panel:
1. Disconnect power to the drive.
2. Drill a hole (or holes), if needed, in the panel to run wiring to the drive as described in Preparing the
Panel.
3. Wire the VFD to the terminal block as described in Section 4: Connect an Electric Drive or Hydraulic
Motor.
4. Connect any sensors to the terminal block as described in Section 6: Connect the Sensors.
5. Complete the installation of the INSTRUCT PCP Controller as described in Section 7: Complete the
INSTRUCT PCP Controller Installation.

PREPARING THE PANEL

To prepare the panel for installation:
1. Mount the panel using the mounting kit.
2. Drill a hole (or holes), if needed, in the panel to run wiring for the drive and sensors and insert the
grommets.
3. Route the wiring into the panel and connect the wiring according to the instructions in Terminal Block
Connection Overview.
4. Apply silicon or another sealant around the opening.
5. Wire to ground.

PANEL FUSES
There is one fused terminal block in INSTRUCT PCP Controller panels. The fused terminal block interrupts
excessive 24 Vdc current to the system. The fuse used is a Bussman Eaton (AGC-4).
Refer to your panel drawing for the location of the fuse.

10
INSTRUCT PCP Intelligent Controller Section 2: Install the INSTRUCT PCP Controller Panel

REPLACING FUSES
DANGER: ELECTRIC SHOCK HAZARD
Installation, adjustment, repair, and maintenance must be performed by qualified personnel.
Ensure power has been removed before servicing.
Failure to follow these instructions will result in death or serious injury.
You may need to replace a fuse if a part of the system is not functioning. To replace a fuse:
1. Disconnect power to the panel.
2. Open the panel and locate the fuse that needs to be replaced.
3. Open the hinged disconnect lever to access the fuse.
4. Open the fuse access port.
5. Remove the blown fuse and replace with a Bussman/Eaton or other fuse of the same size and current
rating.
6. Close the fuse access port and close the hinged disconnect lever.
7. Reconnect power to the panel.

USB DRIVE
The INSTRUCT PCP Controller copies alarm, event, and log data into CSV files directly to a USB drive
connected to the Magelis HMI. A USB drive is not shipped with the INSTRUCT PCP Controller. The
INSTRUCT PCP Controller supports USB drives formatted to FAT32 of sizes of 4 GB or greater.
To attach a USB drive to the Magelis HMI:
1. Open the outside panel door.
2. Open the inside panel door.
3. On the back of the Magelis HMI, locate the USB port as shown in the figure below.

4. Plug the USB drive into the USB port.

5. Securely close the inside and outside panel doors.
See the INSTRUCT PCP Intelligent Controller Configuration Manual for more information about transferring
and viewing CSV files.

11
Section 3: Terminal Block Connection Overview INSTRUCT PCP Intelligent Controller

Section 3: Terminal Block Connection Overview

For further information on the terminal block and the wiring, refer to the wiring diagram.
For information on connecting drives, refer to Section 4: Connect an Electric Drive or Hydraulic Motor. For
information on connecting sensors, refer to Section 6: Connect the Sensors.

CAUTION: LOSS OF COMMUNICATION

Connect a COM terminal to panel ground at only one point in the system. Connecting a COM
terminal to the SCADAPack 334E RTU ground is recommended.
Failure to follow these instructions can result in loss of communication.
The terminal block, which is included in the INSTRUCT PCP Controller panel, is used to connect the sensors
(analog and Modbus) to the controller, provide communication to the VFD or hydraulic drive, and ground the
connections. Some connections on the terminal block can be used to connect additional devices, such as
LEDs, sensors, etc. If you connect additional sensors, you can use the Magelis HMI to configure them. For
more information, refer to the INSTRUCT PCP Intelligent Controller Configuration Manual.
Ensure that you refer to the panel drawing and the table below for a list of the most current connections
specific to your panel.
Signal Type Signal Connection New Panel Connection Point
(T: Top, B: Bottom, M: Middle)
100...240 Vac 100...240 Vac Line Power Supply Line
100...240 Vac Neutral Power Supply Neutral
100...240 Vac Earth Ground Ground Lug
24 Vdc +24 Vdc 117T
-24 Vdc 117B
Analog Input (AI) Flow Sensor Signal AI0
Flow Sensor Return One of:
• TB1B...TB14B
• TB101B...TB114B
Casing Pressure Signal A11
Casing Pressure Return One of:
• TB1B...TB14B
• TB101B...TB114B
Line Pressure Signal AI2
Line Pressure Return One of:
• TB1B...TB14B
• TB101B...TB114B
Suction Pressure Signal AI3
Suction Pressure Return One of:
• TB1B...TB14B
• TB101B...TB114B
Torque/Hydraulic Pressure AI4
Signal
Torque/Hydraulic Pressure One of:
Return • TB1B...TB14B
• TB101B...TB114B
RPM Pick-up Signal AI5
RPM Pick-up Return One of:
• TB1B...TB14B
• TB101B…TB114B
Spare Signal 1 AI6
Spare Return 1 One of:
• TB1B...TB14B
• TB101B…TB114B
Spare Signal 2 AI7
Spare Return 2 One of:
• TB1B...TB14B
• TB101B...TB114B

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INSTRUCT PCP Intelligent Controller Section 3: Terminal Block Connection Overview

Signal Type Signal Connection New Panel Connection Point

(T: Top, B: Bottom, M: Middle)
Analog Output (AO) Generic Drive Speed Signal AO0
Generic Drive Speed Return A0 COM
Digital Input (DI) Spare Signal 1 DI0
Spare Return 1 One of:
• TB1B...TB14B
• TB101B...TB114B
Generic Drive Fault Signal DI1
Generic Drive Fault Return One of:
• TB1B...TB14B
• TB101B..TB114B
Pressure Sensor Signal DI2
Pressure Sensor Return One of:
• TB1B...TB14B
• TB101B...TB114B
External Alarm Signal DI3
External Alarm Return One of:
• TB1B...TB14B
• TB101B...TB114B
Spare Signal 2 DI4
Spare Return 2 One of:
• TB1B...TB14B
• TB101B...TB114B
Digital Output (DO) Start Warning Return One of:
• TB1B...TB14B
• TB101B...TB114B
Start Warning Signal DO0
Generic Drive Enable Return One of:
• TB1B...TB14B
• TB101B...TB114B
Generic Drive Enable Signal DO1
Generic Drive Fault Reset Return One of:
• TB1B...TB14B
• TB101B...TB114B
Generic Drive Fault Reset Signal DO2
Accumulator/Counter Rod Speed Sensor Signal CNT0
Rod Speed Sensor Return CNT GND
RS485 Modbus Sensor + 116T
Modbus Sensor - 116M
Modbus Sensor Ground 116B
Modbus Drive + 115T
Modbus Drive - 115M
Modbus Drive Ground 115B
Spare 24 Vdc +24 Vdc One of:
• TB1T...TB14T
• TB101T...TB114T
-24 Vdc One of:
• TB1B...TB14B
• TB101B...TB114B

13
Section 4: Connect an Electric Drive or Hydraulic Motor INSTRUCT PCP Intelligent Controller

Section 4: Connect an Electric Drive or Hydraulic Motor

The INSTRUCT PCP Controller can be used with various types of variable frequency drives (VFD) or with a
hydraulic motor. This section explains how to install the following:
• Altivar Drive
• ABB ACS550, ACS580, ACS800, or ACS880 Drive
• Toshiba VF-AS1 Drive
• Yaskawa Drive
• Inovance MD200/MD500 AC Drive
• Vacon NX Drive
• Hydraulic Motor
If you are not using one of the electric drives listed above or a hydraulic motor, you should follow the
instructions for connecting a generic drive:
• Electric Generic Drive

DANGER: ELECTRIC SHOCK HAZARD

• Read and understand this manual, the INSTRUCT PCP Intelligent Controller Configuration
Manual, and the manuals for your variable frequency drive (VFD), motor, and progressing
cavity pump before installing or operating the INSTRUCT PCP Controller. Installation,
adjustment, repair, and maintenance must be performed by qualified personnel.
• The user is responsible for compliance with all international and national electrical code
requirements with respect to grounding and wiring of all equipment. Many parts of VFDs,
including the printed circuit boards, operate at the line voltage. Do not touch. Use
electrically insulated tools only.
• Do not touch unshielded components or terminal strip screw connections with voltage
present.
Failure to follow these instructions will result in death or serious injury.

DANGER: ELECTRIC SHOCK HAZARD

• Apply appropriate personal protective equipment (PPE) and follow safe electrical work
practices. See NFPA 70E, CSA Z462, and OSHA 1910.
• Install and close all covers before applying power or starting and stopping any of the
INSTRUCT PCP Controller components.
Failure to follow these instructions will result in death or serious injury.

DANGER: ELECTRIC SHOCK, EXPLOSION, or ARC FLASH

A hazardous situation which, if not avoided, will result in serious injury or death.
Before servicing the drive:
• Disconnect all power sources, including external control power.
• Place a Do Not Turn On label on all power disconnects.
• Lock all power disconnects in the open position.
• Wait 15 minutes to allow the DC bus capacitors to discharge and then verify that DC
voltage is less than 42 V. The drive LED is not an indicator of the absence of DC bus
voltage.
Failure to follow these instructions will result in death or serious injury.

14
INSTRUCT PCP Intelligent Controller Section 4: Connect an Electric Drive or Hydraulic Motor

CONNECTING AN ALTIVAR DRIVE

Before beginning the procedure below, see the drive manual provided by the manufacturer for information
about how to open and close the drive cover.

CAUTION: LOSS OF COMMUNICATION

• If you are experiencing intermittent communication, or if you are in an environment with
significant electromagnetic noise, a 120-ohm termination resistor may be needed on the
RS485 bus connecting the Altivar drive and the SCADAPack 334E RTU pin 5.
Failure to follow these instructions can result in loss of communication.

CAUTION: LOSS OF COMMUNICATION

• Connect a COM terminal to panel ground at only one point in the system. Connecting a
COM terminal to the SCADAPack 334E RTU ground is recommended.
Failure to follow these instructions can result in loss of communication.
To connect an Altivar drive to the INSTRUCT PCP Controller:
1. Open the drive cover.
2. Make an RJ45 cable connecting:
a. The Altivar drive pin 4 to SCADAPack 334E RTU pin 6
b. The Altivar drive pin 5 to SCADAPack 334E RTU pin 5
c. The Altivar drive pin 8 to SCADAPack 334E RTU ground

CAUTION: UNINTENDED EQUIPMENT OPERATION

• You need to connect Altivar pin 8 to SCADAPack 334E RTU ground.
Failure to follow these instructions can result in equipment damage.

A view of the RJ45 connector is shown in the figure below.

15
Section 4: Connect an Electric Drive or Hydraulic Motor INSTRUCT PCP Intelligent Controller

3. Connect the RJ45 cable connector to the Altivar drive.

4. Connect the other end of the cable to COM2 on the SCADAPack 334E RTU.

5. Close the drive cover.

6. Configure Modbus communication with the drive, as described in Configuring an Altivar 71 Drive or
Configuring an Altivar 930 Drive, depending on what drive type you have.

CONFIGURING AN ALTIVAR 71 DRIVE

When configuring Modbus communication with your Altivar drive, some parameters are set using information
found in the drive manual, some parameters are set by the INSTRUCT PCP Controller, and other
parameters are set using the Graphical Display Terminal (GDT).

16
INSTRUCT PCP Intelligent Controller Section 4: Connect an Electric Drive or Hydraulic Motor

Refer to the Altivar drive manual to configure the following parameters:

• Rated motor voltage
• Rated motor current
The INSTRUCT PCP Controller sets the following parameters:
• Rated motor power
• Rated motor frequency
• Rated motor speed
• Maximum frequency
• Acceleration
• Deceleration
• Low speed (set by the INSTRUCT PCP Controller to 0)
• High speed (set by the INSTRUCT PCP Controller to Max. frequency)
To configure an Altivar 71 drive:
1. On the GDT set the following parameters.
a. DRIVE MENU > 1.4 MOTOR CONTROL:
OPTION VALUE CODE
Mot. Therm. Current Per motor nameplate ITH
Rated Motor Power Per motor nameplate nPr
Rated Motor Volt Per motor nameplate Uns
Rated Mot Current Per motor nameplate nCr
Rated Motor Freq Per motor nameplate FrS
Rated Motor Speed Per motor nameplate nSP
Std Mot Freq As needed BFR
Max Frequency As needed tFr
2-Wire Type Level TCT

b. DRIVE MENU > 1.6 COMMAND:

Choose A, B, C, or D, depending on your hardware.
Option Value Code Additional information
A - VFD for Control via Ethernet

Control Mode Separate CHCF

Freq Switch Assign DI3 RFC
Cmd Channel 1 Embedded Ether CD1
Cmd Channel 2 Terminal CD2
Ref Freq 1 Config Embedded Ether FR1
Ref Freq 2 Config AI2 FR2
Command Switching LI3 CCS This option is hidden unless
Control Mode is set to
Separate.
Expert Mode must be
selected to set Command
Switching and Freq Ref
switching to the same
channel. Refer to the Altivar
manual for more information.
B - VFD for Control via Serial
Control Mode Separate CHCF
Freq Switch Assign DI3 RFC
Cmd Channel 1 Modbus CD1 This option is hidden unless
Control Mode is set to
Separate
Cmd Channel 2 Terminals CD2 This option is hidden unless
Control Mode is set to
Separate
Ref Freq 1 Config Modbus FR1
Ref Freq 2 Config AI1 FR2

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Section 4: Connect an Electric Drive or Hydraulic Motor INSTRUCT PCP Intelligent Controller

Option Value Code Additional information

Command Switching LI3 CCS This option is hidden unless
Control Mode is set to
Separate.
Expert Mode must be
selected to set Command
Switching and Freq Ref
switching to the same
channel. Refer to the Altivar
manual for more information.
C - Simplified Setup for Control via Serial if no HOA Switch Present in Panel
Control Mode Not Separate CHCF
Ref Freq 1 Config Modbus FR1
D - Simplified Setup for Control via Ethernet if no HOA Switch Present in Panel
Control Mode Not Separate CHCF
Ref Freq 1 Config Embedded Ether FR

c. DRIVE MENU > 1.8 FAULT MANAGEMENT:

OPTION VALUE CODE
Auto Fault Reset Yes ATR

d. DRIVE MENU > 1.9 COMMUNICATION:

Option Value Code Additional information
Modbus format 8-N-1 TFO
Modbus baud rate 19.2 kbps TBR The value needed for this parameter is the default
Modbus Address 1 ADD
Modbus time out 30 TTO
2. Leave COM. SCANNER INPUT and COM. SCANNER OUTPUT set as default.
3. To test that you have local control with your configuration:
a. Press ESC until you see the Frequency ref. screen.
b. Toggle local control by pressing F1.
c. Adjust the frequency reference by turning the wheel.
d. Press RUN to start.
e. Press STOP to stop.
f. Toggle Modbus control by pressing F1.
To verify that you have a Modbus connection between the SCADAPack 334E RTU and the drive, refer to the
INSTRUCT PCP Intelligent Controller Configuration Manual.

CONFIGURING AN ALTIVAR 930 DRIVE

When configuring Modbus communication with your Altivar drive, some parameters are set using information
found in the drive manual, some parameters are set by the INSTRUCT PCP Controller, and other
parameters are set using the Graphical Display Terminal (GDT).
Refer to the Altivar drive manual to configure the following parameters:
• Rated motor voltage
• Rated motor current
The INSTRUCT PCP Controller sets the following parameters:
• Rated motor power
• Rated motor frequency
• Rated motor speed
• Maximum frequency
• Acceleration
• Deceleration
• Low speed (set by the INSTRUCT PCP Controller to 0)
• High speed (set by the INSTRUCT PCP Controller to Max. frequency)

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INSTRUCT PCP Intelligent Controller Section 4: Connect an Electric Drive or Hydraulic Motor

To configure an Altivar 930 drive:

1. On the GDT set the following parameters:
a. Simply start > Simply start:
OPTION VALUE CODE
Motor Th Current Per motor nameplate ITH
Nominal Motor Power Per motor nameplate nPr
Nominal Motor Voltage Per motor nameplate Uns
Nominal Motor Current Per motor nameplate nCr
Nominal Motor Freq Per motor nameplate FrS
Nominal Motor Speed Per motor nameplate nSP
Motor Standard As needed BFR
Max Frequency As needed tFr
2-Wire Type Level TCT

b. Complete settings > Error/Warning handling > Auto fault reset:

OPTION VALUE CODE
Auto Fault Reset Yes ATR

c. Communication > Comm parameters > Embd Eth Config:

Configure these parameters to enable Ethernet communications with the VFD.
OPTION VALUE
IP Mode Ether Embd Fixed
IP Address 192.168.0.12
Mask 255.255.255.0
Gateway 192.168.0.1

d. Communication > Comm parameters > Modbus SL > Modbus Fieldbus:

Configure these parameters to enable Modbus communications with the VFD.
OPTION VALUE CODE
Modbus Format 8-N-1 TFO
Modbus Baud Rate 19.2 kbps TBR
Modbus Address 1 ADD
Modbus Time Out 30 TTO

e. Complete settings > Command and Reference:

Choose A, B, C, or D, depending on your hardware configuration.
Option Value Code Additional information
A - VFD for Control via Ethernet
Control Mode Separate CHCF
Freq Switch Assign DI3 RFC
Cmd Channel 1 Embedded Ether CD1 This option is hidden unless Control Mode is
set to Separate.
Cmd Channel 2 Terminal CD2 This option is hidden unless Control Mode is
set to Separate.
Ref Freq 1 Config Embedded Ether FR1
Ref Freq 2 Config AI2 FR2
Command Switching DI3 CCS This option is hidden unless Control Mode is
set to Separate.
Expert Mode must be selected to set
Command Switching and Freq Ref Switching
to the same channel. Refer to the Altivar
manual for more information.
B - VFD for Control via Serial
Control Mode Separate CHCF
Freq Switch Assign DI3 RFC
Cmd Channel 1 Modbus CD1
Cmd Channel 2 Terminals CD2
Ref Freq 1 Config Modbus FR1

19
Section 4: Connect an Electric Drive or Hydraulic Motor INSTRUCT PCP Intelligent Controller

Option Value Code Additional information

Ref Freq 2 Config AI1 FR2
Command Switching DI3 CCS This option is hidden unless Control Mode is
set to Separate.
Expert Mode must be selected to set
Command Switching and Freq Ref Switching
to the same channel. Refer to the Altivar
manual for more information.
C - Simplified Setup for Control via Serial if no HOA Switch Present in Panel
Control Mode Not Separate CHCF
Ref Freq 1 Config Modbus FR1
D - Simplified Setup for Control via Ethernet if no HOA Switch Present in Panel
Control Mode Not Separate CHCF
Ref Fre 1 Config Embedded Ether FR1
2. Leave all other parameters set as default.
3. To test that you have local control with your configuration:
a. Press ESC until you see the Frequency ref. screen.
b. Toggle local control by pressing F1.
c. Adjust the frequency reference by turning the wheel.
d. Press RUN to start.
e. Press STOP to stop.
f. Toggle Modbus control by pressing F1.
4. To verify that you have a Modbus connection between the SCADAPack 334E RTU and the drive, refer to
the INSTRUCT PCP Intelligent Controller Configuration Manual.

CONNECTING AN ABB ACS550, ACS580, ACS800, OR ACS880

Before beginning the procedure below, see the drive manual provided by the manufacturer for information
about how to open and close the drive cover.

CAUTION: LOSS OF COMMUNICATION

Connect a COM terminal to panel ground at only one point in the system. Connecting a COM
terminal to the SCADAPack 334E RTU ground is recommended.
Failure to follow these instructions can result in loss of communication.
To connect an ABB ACS550, ACS580, ACS800, or ACS880 drive to the INSTRUCT PCP Controller:
1. Open the drive cover.
2. Set the RS485 switch to the ON position.

3. Make an RJ45 cable connecting the ABB drive pin B to SCADAPack 334E RTU pin 6 and ABB drive pin
A to SCADAPack 334E RTU pin 5.

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INSTRUCT PCP Intelligent Controller Section 4: Connect an Electric Drive or Hydraulic Motor

4. Connect the other end of the cable to COM2 on the SCADAPack 334E RTU.

5. Close the drive cover.

6. Configure Modbus communication with the drive, as described in Configuring an ABB ACS550 Drive,
Configuring an ABB ACS800 Drive, or Configuring an ABB ACS880 or ACS580 Drive.

CONFIGURING AN ABB ACS550 DRIVE

Set up the ABB ACS550 prior to commissioning to allow the drive to communicate with the SCADAPack
334E RTU.
To configure an ABB ACS550 drive:
1. Refer to the ABB ACS550 manual to configure the following parameters:
a. PARAMETERS > START-UP DATA:
Parameter Description Value
99.02 APPLICATION MACRO ABB STANDARD
99.04 MOTOR CTRL MODE SCALAR:FREQ

b. PARAMETERS > START STOP DIR:

Parameter Description Value
10.01 EXT1 COMMANDS COMM (10)
10.02 EXT2 COMMANDS COMM (10)
10.03 DIRECTION FORWARD (1)

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Section 4: Connect an Electric Drive or Hydraulic Motor INSTRUCT PCP Intelligent Controller

c. PARAMETERS > REFERENCE SELECT:

Parameter Description Value
11.02 EXT1/EXT2 SEL COMM (8)
11.03 REF1 SELECT COMM (8)

d. PARAMETERS > SYSTEM CONTROLS:

Parameter Description Value
16.01 RUN ENABLE COMM (7)
16.04 FAULT RESET SEL COMM (8)
16.06 LOCAL LOCK COMM (8)
e. PARAMETERS > FAULT FUNCTIONS:
Parameter Description Value
30.18 COMM FAULT FUNC 1 = FAULT

f. PARAMETERS > OPTIONS:

Parameter Description Value
98.02 COMM PROT SEL 1 = STD MODBUS

g. PARAMETERS > START-UP DATA:

Parameter Description Value
99.06 MOTOR NOM CURR ENTER value corresponding to
your motor (Resolution 0.1 A)
99.07 MOTOR NOM FREQ ENTER value corresponding to
your motor (Resolution 0.1 Hz)
99.08 MOTOR NOM SPEED ENTER value corresponding to
your motor (Resolution 1 rpm)
99.09 MOTOR NOM POWER ENTER value corresponding to
your motor (Resolution 0.1 hp)

h. PARAMETERS > EFB PROTOCOL:

Parameter Description Value
53.02 EFB STATION ID (Modbus Slave Address for ABB) 1 (Default 1)
53.03 EFB BAUD RATE 19.2 (Default 9.6 kbits/s)
53.04 EFB PARITY 0 (Default 0 = 8 NONE 1)
53.05 EFB CTRL PROFILE 0 (Default 0 = ABB DRV
LIM)

CAUTION: LOSS OF COMMUNICATION

Ensure that you save the changes to the parameters.
Failure to follow these instructions can result in loss of communication.
2. Save your changes to the permanent memory of the ABB ACS550. Go to PARAMETERS > SYSTEM
CONTROLS:
Parameter Description Value
16.07 PARAM SAVE 1 = SAVE
3. To verify that you have a Modbus connection between the SCADAPack 334E RTU and the drive, refer to
the INSTRUCT PCP Intelligent Controller Configuration Manual.

CONFIGURING AN ABB ACS800 DRIVE

Set up the ACS800 prior to commissioning to allow the drive to communicate with the SCADAPack 334E
RTU.
To configure an ACS800 drive:
1. Refer to the ACS800 manual to configure the following parameters:
a. PARAMETERS > START-UP DATA:

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INSTRUCT PCP Intelligent Controller Section 4: Connect an Electric Drive or Hydraulic Motor

Parameter Description Value

99.02 APPLICATION MACRO ESP
99.03 APPLICATION MACRO YES
99.04 MOTOR CTRL MODE SCALAR
b. PARAMETERS > START STOP DIR:
Parameter Description Value
10.01 START/STOP 1 FIELDBUS
10.03 DIRECTION FORWARD
10.04 RUN ENABLE YES
10.05 EMERG STOP INPUT* DI3
*If you want to use EMERG STOP INPUT, you need to connect DO6 on the SCADAPack 334E RTU
to DI3 on the ACS800 and COM on the SCADAPack 334E RTU to +24 V on the ACS800.
c. PARAMETERS > REFERENCE SELECT:
Parameter Description Value
11.02 EXT1 REF1 SELECT FIELDBUS

d. PARAMETERS > SYSTEM CONTROL INPUTS:

Parameter Description Value
16.01 RUN ENABLE FIELDBUS

e. PARAMETERS > FAULT FUNCTIONS:

Parameter Description Value
30.16 COMM FAULT FUNC NO

f. PARAMETERS > D SET TR ADDR:

Parameter Description Value
92.02 DATASET2 OUTPUT2 105
g. PARAMETERS > OPTIONS:
Parameter Description Value
98.02 COMM MODULE STD MODBUS

h. PARAMETERS > STANDARD MODBUS:

Parameter Description Value
52.01 STATION NUMBER 1
52.02 BAUDRATE 19200
52.03 PARITY NONE1STOPBIT

CAUTION: LOSS OF COMMUNICATION

Ensure that you save the changes to the parameters.
Failure to follow these instructions can result in loss of communication.
2. Ensure that you save changes to the permanent memory of the ABB ACS800, go to PARAMETERS >
SYSTEM CONTROL.
Parameter Description Value
16.05 PARAMETER SAVE 1 = SAVE
3. To verify that you have a Modbus connection between the SCADAPack 334E RTU and the drive, refer to
the INSTRUCT PCP Intelligent Controller Configuration Manual.

CONFIGURING AN ABB ACS880 OR ACS580 DRIVE

Set up the ABB ACS880 or ACS580 prior to commissioning to allow the drive to communicate with the
SCADAPack 334E RTU.
The following parameters apply to firmware version AINF6 v2.40. To configure an ABB ACS880 or ACS580
drive:

23
Section 4: Connect an Electric Drive or Hydraulic Motor INSTRUCT PCP Intelligent Controller

1. Refer to the ABB ACS880 or ACS580 manual to configure the following parameters:
a. PARAMETERS > System:
Parameter Description Value
96.05 MACRO SELECT [1] Factory
96.16 UNIT SELECTION 0 <1> Power Unit = hp
2 (0) Temperature unit = C
4 (0) Torque unit = Nm

b. PARAMETERS > Motor Data:

Parameter Description Value
99.04 MOTOR CTRL MODE SCALAR
c. PARAMETERS > Protocol:
Parameter Description Value
58.01 PROTOCOL ENABLE [1] Modbus RTU
58.03 NODE ADDRESS 1
58.04 BAUD RATE [3] 19.2 kbps
58.05 PARITY [0] 8 NONE 1
58.06 COMMUNICATION CONTROL [0] Enabled
58.25 CONTROL PROFILE [0] ABB Drives
58.26 EFB REF1 TYPE [4] Speed
58.28 EFB ACT1 TYPE [4] Speed

d. PARAMETERS > Operation Mode:

Parameter Description Value
19.11 EXT1/EXT2 SELECTION [0] EXT1
19.12 EXT1 CONTROL MODE [2] Speed
19.20 SCALAR CONTROL REF UNIT [1] Rpm

e. PARAMETERS > Start/stop/direction:

Parameter Description Value
20.01 EXT1 COMMANDS [14] Embedded fieldbus
20.12 RUN ENABLE 1 SOURCE [1] Selected

f. PARAMETERS > Speed reference section:

Parameter Description Value
22.11 SPEED REF1 SOURCE [8] EFB ref1

g. PARAMETERS > Limits:

Parameter Description Value
30.11 MINIMUM SPEED -30000 rpm
30.12 MAXIMUM SPEED 30000 rpm
30.13 MINIMUM FREQUENCY -500 Hz
30.14 MAXIMUM FREQUENCY 500 Hz

CAUTION: LOSS OF COMMUNICATION

Ensure that you save the changes to the parameters.
Failure to follow these instructions can result in loss of communication.
2. Ensure that you save changes to the permanent memory of the ABB ACS800 or ACS580, go to
PARAMETERS > SYSTEM CONTROLS.
Parameter Description Value
96.07 PARAMETER SAVE [1] SAVE
3. To verify that you have a Modbus connection between the SCADAPack 334E RTU and the drive, refer to
the INSTRUCT PCP Intelligent Controller Configuration Manual.

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INSTRUCT PCP Intelligent Controller Section 4: Connect an Electric Drive or Hydraulic Motor

CONNECTING A TOSHIBA VF-AS1 DRIVE

Before beginning the procedure below, see the drive manual provided by the manufacturer for information
about how to open and close the drive cover.

CAUTION: LOSS OF COMMUNICATION

Connect a COM terminal to panel ground at only one point in the system. Connecting a COM
terminal to the SCADAPack 334E RTU ground is recommended.
Failure to follow these instructions can result in loss of communication.
To connect a Toshiba VF-AS1 drive to the INSTRUCT PCP Controller:
1. Open the drive cover.
2. Make an RJ45 cable connecting the Toshiba drive pins 3 and 4 to SCADAPack 334E RTU pin 6 (A+),
Toshiba drive pins 5 and 6 to SCADAPack 334E RTU pin 5 (B-), and Toshiba drive pins 2 and 8 to
SCADAPack 334E RTU ground.

Toshiba VF- AS 1 SCADAPack 334 E RTU

3,4 A+
5,6 B-
2,8 GND
3. Connect one end of the cable to the 4-wire Modbus/CAN open port on the Toshiba.

25
Section 4: Connect an Electric Drive or Hydraulic Motor INSTRUCT PCP Intelligent Controller

4. Connect the other end of the cable to COM2 on the SCADAPack 334E RTU.

5. Close the drive cover.

6. Configure Modbus communication with the drive, as described in Configuring a Toshiba VF-AS1 Drive

CONFIGURING A TOSHIBA VF-AS1 DRIVE

Set up the Toshiba VF-AS1 drive prior to commissioning to allow the drive to communicate with the
SCADAPack 334E RTU.
To configure a Toshiba VF-AS1 drive:
1. Refer to the Toshiba VF-AS1 manual to configure the following parameters.
a. Set the following:
Parameter Description Value
F807, F829 Modbus-RTU 0 (default)
F802 Modbus Slave Address for Toshiba VF- 1
AS1
F803 Communications time-out time 10 seconds
b. Set up Modbus communication:
Parameter Description Value
F800 Baud rate to use with SCADAPack 334E 1 (19200)
RTU
F801 Parity 0 (NONE)
F827 for 2- wire
F804 Communications timeout action 8 Trip
F807 Protocol selection (2-wire RS485) 1 MODBUS
F808 Communication timeout condition 0 Disconnection detection
F820 Communication speed 4- wire 1 (0:9600, 1:19200, 2:38400 bps)
F810 Frequency point selection 0 Disabled

c. Set the following parameters with values that correspond to your motor:
Parameter Description Value
F405 Motor rated capacity (motor name plate) 0.10...630 kW
F406 Motor rated capacity (motor name plate) 0.1...2000 A
F407 Motor rated rotational speed (motor name 100...60000 min-1
plate)

26
INSTRUCT PCP Intelligent Controller Section 4: Connect an Electric Drive or Hydraulic Motor

d. Set the input phase failure detection mode:

Parameter Description Value
F608 Input phase failure detection 0 - no tripping (no alarm if phase
supply is not 3 phase)
1 (default) - cause a fault if using
single phase power input

e. Select the operation mode:

Parameter Description Value
cnod Command mode selection 3 - 4-wire RS485
communication input
fnod Frequency setting mode 6 - 4-wire RS485
selection 1 communication input
2. To verify that you have a Modbus connection between the SCADAPack 334E RTU and the drive, refer to
the INSTRUCT PCP Intelligent Controller Configuration Manual.

CONNECTING A YASKAWA DRIVE

Before connecting the drive, see the drive manual provided by the manufacturer for information about how to
open and close the drive cover. Depending on your Yaskawa drive, see one of the following:
• To connect a Yaskawa A1000 drive
• To connect a Yaskawa F7 drive

CAUTION: LOSS OF COMMUNICATION

Connect a COM terminal to panel ground at only one point in the system. Connecting a COM
terminal to the SCADAPack 334E RTU ground is recommended.
Failure to follow these instructions can result in loss of communication.
To connect a Yaskawa A1000 drive to the INSTRUCT PCP Controller:
1. Open the drive cover.
2. On the drive, connect jumpers HC and H2 to H1.

3. Connect jumpers R+ and S+ together.

4. Connect jumpers R- and S- together.

27
Section 4: Connect an Electric Drive or Hydraulic Motor INSTRUCT PCP Intelligent Controller

5. Make an RJ45 cable connecting the Yaskawa A1000 pins R+ and S+ to the SCADAPack 334E RTU pin
6 (A+) and the Yaskawa A1000 pins R- and S- to the SCADAPack 334E RTU pin 5 (B-).

6. Close the drive cover.

7. Configure Modbus communication with the drive, as described in Configuring a Yaskawa Drive below.
To connect a Yaskawa F7 drive to the INSTRUCT PCP Controller:
1. Open the drive cover.
2. On the drive, connect jumpers HC and H2 to H1.
3. Connect jumpers R+ and S+ together.
4. Connect jumpers R- and S- together.
5. Make an RJ45 cable connecting the Yaskawa pins R+ and S+ to the SCADAPack 334E RTU pin 6 (A+)
and the Yaskawa pins R- and S- to the SCADAPack 334E RTU pin 5 (B-).

6. Close the drive cover.

7. Configure Modbus communication with the drive, as described in Configuring a Yaskawa Drive below.

CONFIGURING A YASKAWA DRIVE

Set up the Yaskawa drive prior to commissioning to allow the drive to communicate with the SCADAPack
334E RTU.
To configure a Yaskawa drive:
1. Refer to the Yaskawa manual to configure the following parameters:
a. Set the following application parameters:
Parameter Description Value
b1-01 Frequency Reference Selection 1 2 (Modbus Communications)
b1-02 Run Command Selection 1 2 (Modbus Communications)

28
INSTRUCT PCP Intelligent Controller Section 4: Connect an Electric Drive or Hydraulic Motor

b. If you are using a 1 Phase Power Supply, configure the following:

Parameter Description Value
L8-07 Output Phase Loss Protection Selection 0 (Disabled)

c. Set the following Modbus parameters:

Parameter Description Value
H5-01 Drive Slave Address 1 (Assigns the drives its address in
the network)
H5-02 Communication Speed Selection 4 (19200 bps)
H5-03 Communication Parity Selection 0 (No parity)
H5-04 Stopping Method after Modbu?RTU 1 (Coast to stop)
communication failure
H5-05 Communication Fault Detection Selection 1 (Enabled)
H5-06 Drive Transmit Wait Time 65 ms
H5-09 Modbu/RTU Communication Failure 9 seconds
Detection Time
H5-11 No Enter Required Cmd Sel. 1
d. Set the following parameters:
Parameter Description Value
01-03 100%=E1-04 0
P1-04 Lower Torque Limit 0
2. Consult your drive manual for more information.
3. To verify that you have a Modbus connection between the SCADAPack 334E RTU and the drive, refer to
the the INSTRUCT PCP Intelligent Controller Configuration Manual.

CONNECTING AN INOVANCE MD200/MD500 AC DRIVE

Before beginning the procedure below, see the drive manual provided by the manufacturer for information
about how to open and close the drive cover.
To connect an Inovance MD200/MD500 drive to INSTRUCT PCP Controller:
1. Open the drive cover.
2. Make an RJ45 cable connecting the Inovance MD500 AC drive pin 485+ to SCADAPack 334E RTU pin
6, Inovance MD200/MD500 AC drive pin 485- to SCADAPack 334E RTU pin 5, and Inovance
MD200/MD500 AC drive pin GND to SCADAPack 334E RTU pin 4.

29
Section 4: Connect an Electric Drive or Hydraulic Motor INSTRUCT PCP Intelligent Controller

A view of the RJ45 connector is shown below.

3. Connect the cable to COM2 on the SCADAPack 334E RTU.

4. Close the drive cover.

5. Configure Modbus communication with the drive, as described in Configuring an Inovance
MD200/MD500 AC Drive below.

CONFIGURING AN INOVANCE MD200/MD500 AC DRIVE

Set up the Inovance MD200/MD500 drive prior to commissioning to allow the drive to communicate with the
SCADAPack 334E RTU.
To configure an Inovance drive:
1. Refer to the Inovance MD200/MD500 manual to configure the following parameters.
a. Set the following command parameters:
Parameter Description Value
F0-02 Command Source Selection 2 (Serial)
F0-19 Acc/Dec time unit 1
F0-27 Command source + frequency source 9 (Serial)
F0-28 Serial port communications protocol 0 (Modbus RTU)

b. Set the following communications parameters:

Parameter Description Value
Fd-00 Baud rate 6 (19200)
Fd-01 Data format symbol 3 ( 8 None 1)
Fd-02 Local address for VFD 1
Fd-04 Communication timeout 45 (second)
Fd-05 Modbus protocol selection and 1 (Standard Modbus protocol)
PROFIBUS-DP data frame

30
INSTRUCT PCP Intelligent Controller Section 4: Connect an Electric Drive or Hydraulic Motor

Parameter Description Value

Fd-06 Current resolution read by communication 0 (0.01)
2. Consult your drive manual for more information.
3. To verify that you have a Modbus connection between the SCADAPack 334E RTU and the drive, refer to
the the INSTRUCT PCP Intelligent Controller Configuration Manual.

CONNECTING A VACON NX DRIVE

Before beginning the procedure below, see the drive manual provided by the manufacturer for information
about how to open and close the drive cover.

CAUTION: LOSS OF COMMUNICATION

If you are experiencing intermittent communication, or if you are in an environment with
significant electromagnetic noise, a 120-ohm termination resistor may be needed on the RS485
bus connecting the Vacon NX drive and the SCADAPack 334E RTU pin 5.
Failure to follow these instructions can result in loss of communication.

CAUTION: LOSS OF COMMUNICATION

Connect a COM terminal to panel ground at only one point in the system. Connecting a COM
terminal to the SCADAPack 334E RTU ground is recommended.
Failure to follow these instructions can result in loss of communication.
To connect a Vacon drive to the INSTRUCT PCP Controller:
1. Remove the Vacon NX frequency converter cable cover.
2. Open the cover of the control unit.
3. Install the RS-485 option board in Slot E on the control board. Make sure the grounding plate fits tightly
in the clamp.
a. Make an RJ45 cable connecting:
b. The Vacon terminal 3 to SCADAPack 334E RTU pin 6
c. The Vacon drive terminal 4 to SCADAPack 334E RTU pin 5
d. The Vacon drive terminal 5 to SCADAPack 334E RTU ground

CAUTION: UNINTENDED EQUIPMENT OPERATION

You need to connect Vacon terminal 5 to SCADAPack 334E RTU ground.
Failure to follow these instructions can result in equipment damage.

31
Section 4: Connect an Electric Drive or Hydraulic Motor INSTRUCT PCP Intelligent Controller

A view of the RJ45 connector is shown in the figure below.

4. Make a sufficiently wide opening for your cable by cutting the grid as wide as necessary.
5. Move Jumper 4 to the on position, as shown in the figure below.

6. Close the cover of the control unit and cable cover.

32
INSTRUCT PCP Intelligent Controller Section 4: Connect an Electric Drive or Hydraulic Motor

7. Connect the RJ45 cable connector to COM2 on the SCADAPack 334E RTU.

8. Configure the drive, as described in Configuring a Vacon NX Drive below.

CONFIGURING A VACON NX DRIVE

Set up the Vacon NX drive prior to commissioning to allow the drive to communicate with the SCADAPack
334E RTU.
To configure a Vacon NX drive:
1. Refer to the Vacon NX drive manual to configure the following parameters.
a. Set the following Basic parameters (Menu M2->G2.1):
Parameter Description Value
Min frequency Min Frequency 0 Hz
Max frequency Max Frequency 75 Hz
Accel Time Acceleration time until the speed 600 Sec
reference is reached
Decel Time Deceleration time until 0 rpm is reached 600 Sec
Current limit Maximum current of work Nominal + 5Amp
Motor Nom Voltg Nominal voltage of motor 380 V
Motor Nom Freq Nominal frequency of motor 50 Hz
Motor Nom Nominal velocity of motor Per motor nameplate
Speed
Motor Nom Nominal current of motor Per motor nameplate
Current
Motor Cos Phi Potency factor of motor Per motor nameplate
I/O Reference Reference of speed Fieldbus (for WellManager)

b. Set the following Converter Control parameters (Menu M2->G2.4):

Parameter Description Value
Start Function Type of acceleration 0 (Ramp)
Stop Function Type of deceleration 0 (Ramp)

c. Set the following Protection parameters (Menu M2->G2.7):

Parameter Description Value
Underload Protec Type of protection for underload 2
UP Time Limit Time allowed for the underload to trip and fault. 60 sec

d. Set the following Auto-Start parameters (Menu M2->G2.8):

Parameter Description Value
Undervolt Tries Restart times for low supply (voltage) 5

33
Section 4: Connect an Electric Drive or Hydraulic Motor INSTRUCT PCP Intelligent Controller

Parameter Description Value

Overvolt Tries Restart times for over supply(voltage) 5
Overcurr. Tries Restart times for overload 3
UnderloadTries Restart times for underload 5
Mot Overl.Tries Restart times for motoroverload 5

e. Set the following Even Control parameters (Menu M2->G2.8):

Parameter Description Value
Torque Limit Maximum limit of torque As calculated
Torq Ref Max Maximum reference of torque 100
f. Set the following PCP parameters (Menu M2->G2.12):
Parameter Description Value
Gear Ratio Relation between the pulleys As calculated
Start Torq Limit of torque for starting As calculated
Run Torq Limit of torque for running As calculated
2. Consult your drive manual for more information.
3. To verify that you have a Modbus connection between the SCADAPack 334E RTU and the drive, refer to
the INSTRUCT PCP Intelligent Controller Configuration Manual.

HYDRAULIC MOTOR
This topic explains how to install the Generic Hydraulic Motor Controller.
Set up the hydraulic generic motor controller prior to commissioning. To communicate with the SCADAPack
334E RTU, use analog signals to control the drive. Refer to the hydraulic motor controller manual provided
by the manufacturer to configure the required parameters. Use External Alarm 1 or External Alarm 2 digital
input to help monitor external conditions, such as ESD. Or use the spare analog input to monitor external
conditions, such as the temperature of the drive.
To connect a hydraulic motor controller to the INSTRUCT PCP Controller, use the figure below as a
guideline for connecting the controller to the SCADAPack 334E RTU.

34
INSTRUCT PCP Intelligent Controller Section 4: Connect an Electric Drive or Hydraulic Motor

CAUTION: UNINTENDED EQUIPMENT OPERATION AND PRODUCTION LOSS

• If over-temperature protection is not present or fails, the drive may overheat. If the drive
overheats, there may be equipment damage or loss of production.
• Use External Alarm 1 or External Alarm 2 digital input to help monitor external conditions.
Failure to follow these instructions can result in equipment damage.

ELECTRIC GENERIC DRIVE

If you are using a drive that does not support Modbus communications, refer to the documentation provided
by the manufacturer of your drive. Set up the electric generic drive prior to commissioning.
To communicate with the SCADAPack 334E RTU:
• Use analog signals to control the drive.
• Use External Alarm 1 or External Alarm 2 digital input to help monitor external conditions, such as ESD.
Or use the spare analog input to monitor external conditions, such as the temperature of the drive.
Use the figure below as a guideline for connecting an electric generic drive to the SCADAPack 334E RTU.

35
Section 5: Support the HOA and Bypass System INSTRUCT PCP Intelligent Controller

Section 5: Support the HOA and Bypass System

DI-6 is available to support the use of HOA/Bypass switches DI- 6.
DI-6
Hand/Bypass 0
Auto 1
Support for the HOA and Bypass system also needs to be enabled on the INSTRUCT PCP Controller
Magelis HMI. See the INSTRUCT PCP Intelligent Controller Configuration Manual for more information.

36
INSTRUCT PCP Intelligent Controller Section 6: Connect the Sensors

Section 6: Connect the Sensors

You can configure the INSTRUCT PCP Controller to use surface and downhole sensors.
The sensors are connected to a 24 Vdc power supply that is provided by the system. The system is
designed for 4...20 mA sensor signals.
Different connection types are available for different sensors. The analog signals are 4...20 mA inputs. The
Modbus sensors use two-wire RS485 communication on the COM1 port of the SCADAPack 334E RTU.
Refer to the table below for a list of available sensors and connection types.
Sensor Connection Types
Line Pressure 4...20 mA input
Casing Pressure 4...20 mA input
Suction Pressure 4...20 mA input, Modbus
BH Temperature Modbus
Discharge Pressure Modbus
Discharge Temperature Modbus
Vibration X Modbus
Vibration Y Modbus
Flow Rate Modbus, 4...20 mA input (Generic), 4...20 mA input (Wedge)
RPM VFD, 4...20 mA input, Accumulator, Modbus
Analog Input 6 4...20 mA input
Analog Input 7 4...20 mA input
Torque 4...20 mA input
Hydraulic Pressure 4...20 mA input

DANGER: ELECTRIC SHOCK HAZARD

• Read and understand this manual, the INSTRUCT PCP Intelligent Controller Configuration
Manual, and the manuals for your variable frequency drive (VFD), motor, and progressing
cavity pump before installing or operating the INSTRUCT PCP Controller. Installation,
adjustment, repair, and maintenance must be performed by qualified personnel.
• The user is responsible for compliance with all international and national electrical code
requirements with respect to grounding and wiring of all equipment. Many parts of VFDs,
including the printed circuit boards, operate at the line voltage. Do not touch. Use only
electrically insulated tools.
• Do not touch unshielded components or terminal strip screw connections with voltage
present.
Failure to follow these instructions will result in death or serious injury.

DANGER: ELECTRIC SHOCK HAZARD

• Apply appropriate personal protective equipment (PPE) and follow safe electrical work
practices. See NFPA 70E, CSA Z462, and OSHA 1910.
• Install and close all covers before applying power or starting and stopping any of the
INSTRUCT PCP Controller components.
Failure to follow these instructions will result in death or serious injury.

37
Section 6: Connect the Sensors INSTRUCT PCP Intelligent Controller

DANGER: HAZARD OF ELECTRIC SHOCK, EXPLOSION, OR ARC FLASH

Before servicing the drive:
• Follow the applicable lock out/tag out (LOTO) procedure.
• Disconnect all power sources, including external control power.
• Place a Do Not Turn On label on all power disconnects.
• Lock all power disconnects in the open position.
Failure to follow these instructions will result in death or serious injury.

INSTALLING THE ANALOG SENSORS ON THE TERMINAL BLOCK

To install the sensors, connect the correct inputs to the terminal block indicated in the table in Terminal Block
Connection Overview.

CONFIRMING SENSOR READINGS

To confirm that you are getting readings from the sensor, induce a reading from the sensor that you are
verifying. Some sensors may have a sensor simulation mode. If you have this mode enabled, use it to induce
a reading, or manually induce a reading. In the HMI, verify that the reading is what you expect.

GROUNDING THE SENSOR

The sensors need to be grounded. Connect the ground for each sensor to the ground bus bar.

CONNECTING A GEO PSI MODBUS SENSOR

The following examples and instructions are based on the G6 Downhole Gauge Controller. If you are
attempting to connect a different GEO PSI controller system, check the GEO PSI documentation for specific
details.
To connect the GEO PSI Modbus Sensor:
1. On the terminal block, connect MODBUS SENSORS (29T and 29B) to Serial COM1 on the SCADAPack
334E RTU.
See Section 3:Section 3:.
2. On the G6 Downhole Gauge Controller, connect the following:
a. J2 terminal to Modbus Sensor (-) corresponding to pin 5 of the RJ45 connector in COM1.
b. J2 terminal to Modbus Sensor (+) corresponding to pin 6 of the RJ45 connector in COM1.
3. Using SCADAPack E Configurator, change the baud rate and data mode.
a. Open SCADAPack E Configurator.
b. Select Read a configuration from an RTU.
c. Click Next.
d. From the drop-down menu, select a Communication Type. Use USB if you have a direct connection
from your RTU to a laptop.
e. Click Finish.
f. Select a location for your configuration file and, if required, rename the file.
g. Click Save.
h. Wait while the file is read.
i. In the left panel, open Ports and select Ports 0-3.
j. Under Port 1 Function, change Port 1 Baud to 19200.
k. Change Port 1 Data Mode to 8-bit Even Parity.
l. Click Save.
m. Click the Write RTU Configuration icon.
n. If required, choose a file name and location and click Save.
o. Click Yes at the verification prompt.

38
INSTRUCT PCP Intelligent Controller Section 6: Connect the Sensors

p. Wait while the file is written.

q. Click Yes to restart the RTU.
r. Click OK at the verification prompt.
4. In the INSTRUCT PCP Controller, navigate to the Sensor & Protection screen.
5. For Suction Pressure and BH Temperature, enable GEO PSI.
See the INSTRUCT PCP Intelligent Controller Configuration Manual for details.
If there is a good connection and the INSTRUCT PCP Controller is receiving data, values are displayed
on the Sensor & Protection screen.
6. Press CONNECT.

OTHER SENSORS
The INSTRUCT PCP Controller provides two spare sensor inputs that can be used for analog sensors in
addition to those in the list of sensors.
The INSTRUCT PCP Controller provides spare digital inputs that can be used for sensors, such as pressure
switches, timed level switches, and leak detection switches.
The INSTRUCT PCP Controller provides an External Alarm sensor input and a Pressure Sensor input that
can be used for the External Alarm protections. Use these sensors to set timers and counters for devices
that use digital input connections to the SCADAPack 334E RTU, and to test digital input operation without
stopping the pump.
The INSTRUCT PCP Controller provides two digital outputs which may be used to control a desander (DO-
3) and separator (DO-5). When the function is enabled, DO-3 is active when the INSTRUCT PCP Controller
is desanding and DO-5 is active when the INSTRUCT PCP Controller is not desanding. Consult the
INSTRUCT PCP Intelligent Controller Configuration Manual for more details on the operation of desanding.
To use the other sensors, connect to the inputs to the terminal blocks indicated in the table in Section 3:
Terminal Block Connection Overview.

39
Section 7: Complete the INSTRUCT PCP Controller Installation INSTRUCT PCP Intelligent Controller

Section 7: Complete the INSTRUCT PCP Controller

Installation
After you complete the installation procedure, remove wire clippings, metal shavings, and other foreign
objects from the drive panel. Close the main panel door and fasten the door lock.
The system is now ready for a qualified person to reapply power to the panel and drive.

DANGER: ELECTRIC SHOCK HAZARD

• Read and understand this manual, the INSTRUCT PCP Intelligent Controller Configuration
Manual, and the manuals for your variable frequency drive (VFD), motor, and progressing
cavity pump before installing or operating the INSTRUCT PCP Controller. Installation,
adjustment, repair, and maintenance must be performed by qualified personnel.
• The user is responsible for compliance with all international and national electrical code
requirements with respect to grounding and wiring of all equipment. Many parts of VFDs,
including the printed circuit boards, operate at the line voltage. Do not touch. Use only
electrically insulated tools.
• Do not touch unshielded components or terminal strip screw connections with voltage
present.
Failure to follow these instructions will result in death or serious injury.

DANGER: ELECTRIC SHOCK HAZARD

• Apply appropriate personal protective equipment (PPE) and follow safe electrical work
practices. See NFPA 70E, CSA Z462, and OSHA 1910.
• Install and close all covers before applying power or starting and stopping any of the
INSTRUCT PCP Controller components.
Failure to follow these instructions will result in death or serious injury.

DANGER: HAZARD OF ELECTRIC SHOCK, EXPLOSION, OR ARC FLASH

Before servicing the drive:
• Follow the applicable lock out/tag out (LOTO) procedure.
• Disconnect all power sources, including external control power.
• Place a Do Not Turn On label on all power disconnects.
• Lock all power disconnects in the open position.
Failure to follow these instructions will result in death or serious injury.

40