Totalflow

2017286-001 (AA)
Totalflow
6300 Series Pump-Off Controllers
Installation - Operations - Maintenance
Manual
Copyright Notice
1999 by ABB Automation Inc., Totalflow Division, Bartlesville, Oklahoma 74005, U.S.A. All rights
reserved.
This publication is for information only. The contents are subject to change without notice and should not
be construed as a commitment, representation, warranty, or guarantee of any method, product, or device
by Totalflow.
Inquiries regarding this manual should be addressed to ABB Automation Inc., Totalflow Division,
Technical Communications, P. O. Box 8900, Bartlesville, Oklahoma 74005, U.S.A.
Table of Contents
Chapter 1:
System Description
Overview
Theory of Operation
Model 6310/6313 Specifications
Model 6310/6313 POC Hardware
Introduction
Enclosure
Base Controller Board (2015480)
Smart Card (2015483)
Warning Beeper
Sensor Probe
Sensor Magnet
Display
Battery
Communication's Kit
Solar Panel
Communication's Module
System Description
Description
Model 6310 POC Typical Installation
Chapter 2:
1-2
1-2
1-3
1-5
1-5
1-5
1-5
1-7
1-7
1-7
1-9
1-9
1-9
1-9
1-10
1-10
1-11
1-11
1-11
1-12
Installation
Unpacking and Inspection
Unpacking
Packing List
Initial Inspection
Reporting Damage
Installing the Model 6310/6313 POC
Basic Installation Steps
Mounting The POC Enclosure
Installing The Step-down Transformer
Installing the Interposing Relay
Wiring the POC to Main Electrical Disconnect Box
Mounting PVC Version of Sensor Probe
Mounting Stainless Steel Version of Sensor Probe
Sensor Probe to POC Enclosure Wiring
POC to Flow Computer/RTU Wiring
6310 POC to 6313 POC Wiring
Communications
TOTALFLOW 6300 Pump-Off Controller
2-2
2-2
2-2
2-2
2-2
2-3
2-3
2-3
2-4
2-4
2-5
2-6
2-8
2-9
2-10
2-10
2-11
Table of Contents, Continued
Chapter 3:
Operations
Setup
Terminal Emulator
Entering Local Port Protocol Code
Parameter Screen
Terminal Mode Edit Keys
Parameter Definitions
Theory Of Operation
POC Startup
Display Information
Annunciators
Programming POC Display Information
Programming FCU Display Information
Chapter 4:
ii
3-2
3-2
3-3
3-4
3-5
3-6
3-10
3-13
3-14
3-15
3-16
3-17
Maintenance & Troubleshooting

Replace POC Fuse
Replace POC Battery Pack
Replace POC Smart Card (2015483)
Replace POC Circuit Board (2015480)
Replace POC Display
Replace Warning Beeper
Replace Sensor Probe
4-3
4-5
4-7
4-9
4-11
4-13
4-14
Troubleshooting a POC Without Smart Card
4-16
Troubleshooting a POC With a Smart Card
4-18
Introduction
About the Manual
Audience &
Purpose
This manual is written to provide an experienced technician with the

knowledge and skills necessary to install setup and operate the TOTALFLOW
Model 6300 Pump-Off Controller.
Organization &
Style
Readers are able to look at the headings and get a broad picture of the
content without reading every word. At the beginning of each chapter is an
overview that provides you with an idea of what is in the chapter and how it fits
into the overall manual.
Chapter Contents
This manual provides the following information:
Chapter
Description
1. System Description
Provides a description of the Totalflow Pump-Off

Controller system components, specifications,
system description and typical installations.
2. Installation
Includes unpacking and detailed procedures for

installation.
3. Operations
Provides information on setup, display information,

theory of operation and startup procedures.
4. Maintenance &
Troubleshooting
Provides instructions on how to remove and

replace major components in the system.
iii
Getting Help
Technical
Support
At Totalflow, we take pride in the on going support we provide our customers.

When you purchase a product, you receive documentation which should
answer your questions; however, our technical support service provides an
800 number as an added source of information.
If your require assistance, call:
Before You Call
(800) 442-3097
Know your Totalflows serial number. Serial numbers can be found on the
escutcheon plate located on the side of each unit.
Prepare a written description of the problem.
How to Describe
Your Problem
Be prepared to give the customer service representative a detailed description

of the problem.
Note the alarms or messages as they appear on the PCCU, Terminal Emulator
or front panel LCD.
iv
Chapter 1
System Description
Overview
Introduction
This Chapter introduces you to the Totalflow Model 6310 and Model 6313
Pump-Off Controllers. The Model 6310 is the modular approach requiring it to
be connected to a Flow Computer or Remote Terminal Unit(RTU) running the
control algorithm whereas the Model 6313 is a stand-alone unit with integrated
communications.
Chapter Contents
This chapter provides the following information

Topic
Overview
Page
1-2
Theory of Operation
1-2
1-3
1-5
Introduction
1-5
Enclosure
1-5
Base Controller Board (2015480)
1-5
Smart Card (2015483)
1-7
Warning Beeper
1-7
Sensor Probe
1-7
Sensor Magnet
1-9
Display
1-9
Battery
1-9
Communication's Kit
1-9
Solar Panel
1-10
Communication's Module
1-10
System Description
1-11
Description
1-11
1-11
1-12
1-1
Overview, Continued
Theory of
Operation
The benefits of pump off control are well established within the oil production
industry. When pumping equipment continues to run in the absence of
production fluids excessive pump wear will result. Pumping, without the
lubricating effects of the fluid, can cause premature degradation of stuffing box
rubbers. Leaky stuffing boxes can cause serious environmental damage to
the immediate area. Continuing to pump while ingesting gas can cause gas
locks that impede production. Fluid pound generally accompanies pump off
and generates destructive shock waves that are detrimental to your pumping
equipment.
Many operators use timers in an attempt to avoid pump off and fluid pound.
Timers are generally far more expensive than their initial purchase may
suggest. If you set the timer on time too long you may be risking fluid pound.
If you set it too short you may be putting your production at risk. Pump off
controllers avoid this problem by allowing pumping action only in the presence
of production fluids.
Pump off controllers can generally reduce equipment run times by as much as
50% with no reduction in fluid production. If the POC is replacing a timer that
was set for too short of a run time an increase in fluid production may occur.
By avoiding the detrimental effects of fluid pound and dry pumping, equipment
workovers can be virtually eliminated. Workover costs increase with well
depth. The economic advantage of using pump off control becomes extremely
evident in wells deeper than 3000 feet.
The TOTALFLOW POC is based on the pumpoff algorithm developed by
DJAX Corporation of Midland, Texas. Determination of pumpoff is based on
pump speed. Pump speed is relatively constant while moving a given amount
of production fluid. When the pump ceases to move sufficient fluid and begins
to ingest gas, pump speed tends to surge due to the lessening fluid load. This
speed increase generally ranges between 10 and 100 milliseconds per stroke,
depending on the well characteristics. A typical speed change might be in the
range of 30 milliseconds per stroke. Each stroke interval is accurately
measured by the Pump-Off Controller (POC). During calibration an operator
must determine the appropriate speed change representing pump off. This
speed delta is programmed into the POC. When this speed change is
detected the pumping unit will be turned off. Pumping action will resume after
the Down time has expired.
1-2

Enclosure
Dimensions
Model 6310
Model 6313
Supply Voltage
Power Requirements
Model 6310
Model 6313
Aluminum, white powder coated finish,

with stainless steel hardware
Width: 8.50 inches (215.9 mm)

Height: 10.00 inches (254.00 mm)
Depth: 8.85 inches (224.79 mm)
Width: 11.12 inches (282.45 mm)
Height: 14.62 inches (371.35 mm)
Depth: 10.25 inches (260.35)
115-132 VAC @ 50/60 Hz (Industrial 220/110 VAC 0.05 KVA
transformer recommended for primary power input)
5 watts + (Charger for FCU battery = 20 watts if connected)

8 watts + (Charger for FCU battery = 20 watts if connected)
Mounting
Pipe or wall mount
Temperature Limits
Operational -40 to 140F (-40 to 60C)
Inputs
Model 6310
One zener protected input for sensor probe
Model 6313
Outputs
Model 6310
Model 6313
One zener protected input for sensor probe ;

Four optically-isolated inputs (factory programmable)
One N. C. relay contacts for pump control;

One 24 VDC @ 0.5 amps (communications, etc.)
One 16 - 20 VDC @ 1 amps (charging for FCU battery)
One N. C. relay contacts, 24 VDC @ 0.5 amps for pump control;
Six open collector outputs (factory programmable);
One 24 VDC @ 0.5 amps (communications, etc.)
One 16 - 20 VDC @ 1 amps (charging for FCU battery)
Data Storage
128K RAM, lithium battery backed
Communication Ports
One - RS232 or RS485 port; 1200 bps to 19,200 bps

One - RS232 port for setup
Sensor Probe
Magnetic reed switch (normally closed)
Shock
Maximum of 25 G's in any axis, 11 ms duration
1-3
Model 6310/6313 Specifications, Continued
Humidity
0 - 95 percent R.H., non-condensing
Hazardous Area
Classification
Designed to meet NEC Class 1, Division 2, Groups C & D

Certification Pending
1-4

Introduction,
See Figure 1-1
The Totalflow Model 6310 Pump-Off Controller is housed in a lightweight

aluminum case. The 6310 case looks similar to the 6313 but is smaller since it
does not require space to house a radio or battery. Major components of the
two models are:
Model 6310 POC
Enclosure
Base Controller Board
Warning Buzzer
POC Sensor
Magnet
Model 6313 POC
Enclosure
Base Controller Board
Smart Card
Warning Buzzer
POC Sensor
Magnet
Options:
Display
Battery
Remote Communications
Charger (Solar Panel)
Communications Module (RS-232
or RS-485)
Enclosure
The enclosure consists of hinged-lid box. The lid provides a watertight,

corrosion resistant seal between the outside elements and the POC
components. It is designed to meet Class 1, Division 2, Groups C&D and is
NEMA 4X rated. A single clasp is used to secure the lid to the enclosure on a
6310 and two clasps on the 6313.
Base Controller
Board
The 6310 Base Controller Board is mounted on the inside of the lid. Most input
and output connections are made on snap in connector terminals mounted
directly on the board. Primary features of the Base Controller Board are:
DO (Digital Output) which terminates in a normally closed relay contact
capable of driving an interposing relay.
DI (Digital Input) for the termination of the sensor, a magnetic proximity
switch.
A RS-232 communications channel for supporting the PCCU or Laptop to do
setup.
Provides 16-20 VDC to serve as a battery charger for the Flow Computer.
Drives an alarm that sounds a warning prior to the pump startup.
Provides connectivity to accommodate a 'smart card'.
Provides circuitry for the switching of VBATT to power a radio up and down.
Provides 24 VDC @ 0.5 amps available to user.
1-5
Model 6310 POC
Communications
Compartment
Battery
Compartment
Model 6313 POC
Figure 1-1 Model 6310 and 6313 Pump-off Controller
1-6
Model 6210/6313 POC, Continued
Smart Card
The smart card plugs into the Base Controller Board and allows the unit along
with other added options to run it's own pump-off algorithm. In addition to the
features of the Base Controller Board, the Smart Card adds the following
additional features:
Runs the Pump-Off algorithm internally

Permits communication with CCU software via radio link.
Supports local LCD display
Four additional digital inputs (Factory/Project Programmable).
Six additional digital outputs (Factory/Project Programmable).
Warning Buzzer
Both the Model 6310 and the 6313 POC has a 12 VDC piezoelectric buzzer
mounted to the inside bottom of the enclosure. The buzzer sounds a 90 dB
minimum alarm starting 15 - 20 seconds prior to outputting the signal to start
the pump.
Sensor Probe
There are two sensors available for the Model 6310 and 6313 POC. The first
version has two magnetic reed switches mounted inside a PVC housing. Only
one of the switches would be connected with the other as a spare.
(See Figure 1-2)
Figure 1-2 Sensor Probe (PVC Version)
1-7
Model 6310/6313 POC Hardware,
Sensor Probe,
Continued
Continued
The second version of the POC Sensor is enclosed in 3/8" stainless steel
tubing. The 3/8" O. D. of the probe allows it to be mounted in a junction box
using a conduit cord connector. The conduit cord connector makes it
convenient for adjusting the spacing between the probe and the magnet which
is attached to the crank arm. Unlike the PVC version, the stainless steel version
has only one magnetic reed switch. (See Figure 1-3)
Figure 1-3 Sensor Probe (Stainless Steel Version)
1-8
Model 6310/6313 POC Hardware,

Magnet
Continued
In order for the sensor to detect the speed of the pump jack, a magnet is
attached to the crank arm in a position which allows it to pass in front of the
Sensor Probe. The magnet is a flexible high energy magnetic strip 2 .in Long X
3/4 .in Wide X 3/16 .in Thick. Each time the magnet passes in front of the
sensor, it actuates the magnetic reed switch inside the sensor.
(See Figure 1-4)
Figure 1-4 Magnet
Display
An option of the Model 6313 POC is a 24 character wide by 2-line LCD

display. Shown on the display is some current, historical and status
information. For more information on displayed data, see the operational
section of this manual.
Battery
An option of the Model 6313 POC is the capability of adding a battery. The
primary reason for adding a battery is to power a radio for remote
communications. Although there is AC power available in the POC, the
regulated 12 volt power is not available to power a radio. There are three
battery sizes available, an 8 amp/hr., 13 amp/hr., and a 26 amp/hr.
Communications
Kit
An option of the Model 6313 POC is the capability of adding remote

communications. There are radio options, modem options and cellular
telephone options available for the 6313 POC. Contact you local sales
engineer or a project engineer for more information about these many
communications options.
1-9
Model 6310/6313 POC Hardware, Continued
Solar Panel
The POC has battery charging circuitry built-in which is derived from the 110
Volt AC. In the case of a Model 6313 which could have radio communications
and hence a battery, there may be concern if AC power is lost for a sustained
period of time. Therefore, a solar panel can be used in lieu of the onboard
charging capabilities of the POC. There are three sizes of solar panels offered,
a 10, 18, and 30 watt.
Communications
Module
Remote communications with the Model 6313 POC is done through the use of
plug in communication modules. There are two options available, an RS-232
and an RS-485 version. RS-485 is used when more than one unit is daisy
chained together whereas RS-232 would normally be the choice for a site with
a single POC.
1 - 10
System Description
Description
The Model 6300 series Pump-Off Controllers can be configured in many

ways and are programmable to your unique application requirements. With
the many possible configurations, it would be advisable to consult with a
sales engineer or projects engineer about your specific application.
The 6300 series Pump-Off Controllers come in two basic varieties. First is
the Model 6310 which is designed as a modular addition to a Totalflow Flow
Computer or RTU. The 6310 would typically be used at a site in which both
gas flow measurement and Pump-Off Control would be required.
The Model 6310 Controller passes the pulse information from the sensor to
the Flow Computer or RTU running the pump-off algorithm. The Flow
Computer or RTU in turn outputs the digital output to the 6310 controller
when pump-off conditions are met.
The Model 6313 Controller is a standalone unit with integrated
communications running it's own pump-off algorithm. It processes the pulse
input information from the sensor and outputs a digital output when pumpoff conditions are met. The 6313 can support up to four additional Model
6310 POCs. It also has the capability of communicating the pump-off
information to Central Collection Unit software back at the office.
Model 6310 POC

Typical Application
Figure 1-5 shows a typical application using the Model 6310 Pump-Off
Controller.
Figure 1-5 (Model 6310 Typical Application)
1 - 11
System Description, Continued

Figure 1-6 shows a typical application using the Model 6313 Pump-Off
Controller.
Model 6313 POC

Typical
Application
SENSOR PROBE
2015457-002
MOTOR STARTER
ENCLOSURE
MAGNET
6313 POC
JUNCTION BOX
6313
PUMP-OFF CONTROLLER
Applied Automation
Hartmann & Braun
CONDUIT CORD CONNECTOR

PUMP JACK
Figure 1-6 (Model 6313 Typical Application)
1 - 12
Chapter 2
Installation
Overview
Introduction
This chapter provides you with the information to do a field installation of the
Model 6310 and 6313 Pump-Off Controllers. After following the procedures
within this chapter, the POC will be ready for operation. To ensure a safe and
trouble free installation, follow all procedures and associated advisory
information.
Installation Hint
It is highly recommended that you thoroughly read through this chapter to

establish an installation plan. Have this manual handy during the installation
process so that you can refer to any illustrations or installation processes.
Chapter
Highlights
This chapter covers the following topics.
Topic
Page
2-2
Unpacking
2-2
Packing List
2-2
Initial Inspection
2-2
Reporting Damage
2-2
2-3
Basic Installation Steps
2-3
Mounting The POC Enclosure
2-3
Installing The Step-down Transformer
2-4
Installing the Interposing Relay
2-4
Wiring the POC to Motor Starter Enclosure
2-5
Mounting PVC Version of Sensor Probe
2-6
Mounting Stainless Steel Version of Sensor Probe
2-8
Sensor Probe to POC Enclosure Wiring
2-9
POC to Flow Computer/RTU Wiring
2-10
6310 POC to 6313 POC Wiring
2-10
Communications
2-11
2-1

Unpacking
Both the Model 6310 and 6313 POCs are shipped in boxes. There may be
more than one box, depending the type of Sensor Probe or if there is a battery
or additional items ordered.
Carefully remove all internal packing material and items from the box. Care
should be taken especially when items are foamed, that smaller items are not
inadvertently thrown away.
Packing List
Compare the contents of the boxes with the packing list. Individual items
should be called out on the Packing List.
Initial Inspection
It's always a good idea to examine the outside of boxes or cartons for visible
damage which could indicate possible damage to the contents. Other points of
inspection are:
Inspect the POC enclosure for external damage.
Inspect the interior of the POC enclosure and verify circuit boards are
secure.
Inspect the loose items such as the Sensor Probe for any damage.
Reporting
Damage
If there is any damage or noticeable defects, notify your local Totalflow

representative or call the main office listed below. Keep all shipping materials
as evidence of damage for inspection by the carrier. Totalflow will arrange for
immediate repair or replacement.
Telephone:
2-2
(800) 442-3097 toll free

Note:
Due to the diversity of Motor Starter Enclosures and the diversities of existing
sites, all POC installations will vary somewhat. The following installation
procedure is an attempt to cover the major steps for a typical installation.
Basic Installation
Steps
Below are the basic steps to install the Model 6310/6313 POC. Each step will
be expounded upon in this chapter.
1. Mounting the POC enclosure.
2. Installing a step-down transformer in the pump jack's Motor Starter
Enclosure to provide 110 VAC for the POC power.
3. Installing the interposing relay in the pump jack's Motor Starter Enclosure.
4. Wiring between the POC enclosure and the pump jack's Motor Starter
Enclosure.
5a. Mounting the PVC Version Sensor Probe and the Magnet.
5b. Mounting the Stainless Steel Version Sensor Probe and the Magnet.
6. Wiring between the Sensor Probe and the POC enclosure.
7a. Wiring between the POC and the Flow Computer / RTU. (6310 Only)
7b. Wiring between a 6310 POC and a 6313 POC. (6313 Only)
8.
Communications wiring for Model 6313. (6313 Only)
Caution
All wiring must meet electrical codes for the area of installation and should be
done only by a qualified electrician. If this unit is being installed to comply with
Class 1, Division 2, NRTL / C specifications, see drawing 2015470-CD
enclosed as part of the drawing package with the equipment.
Step 1
The Model 6310 POC has interconnect wiring between the pump jack's Motor
Starter Enclosure, the pump jack, and the Flow Computer. Therefore, try to
locate the POC enclosure in close proximity to each of them. Mounting the
enclosure on the same pole as the Motor Starter Enclosure is the most
practical because of the 110 VAC wiring between the two units.
Mounting the
POC Enclosure
The brackets that accompany the enclosure are designed to either mount to a
2" pipe or they can be turned around for wall mount. If mounting to a wooden
pole, attach the brackets to the enclosure for wall mount and use lag screws to
secure to the pole. See Figure 2-1 for mounting options.
2-3
Installing the Model 6310/6313 POC, Continued
Pipe Mount
Wall Mount
Figure 2-1 Enclosure Mounting
Step 2
Install Step-down
Transformer
Step 3
Install
Interposing Relay
2-4
The POC circuitry requires 110 VAC for input power. If 110 VAC is not readily
available, the most efficient and economical method is to install a step-down
transformer in the Motor Starter Enclosure. The transformer needs to be rated
at 0.05 KVA. The step-down transformer will depend on the primary voltage
available in the Motor Starter Enclosure, which a typical voltage would be 440
VAC. In this case the transformer would need to be a 440 to 110 VAC. The
primary power tap to feed the step-down transformer must be prior to the
contactor so that power is available at all times. (See Figure 2-2 for a typical
wiring scheme)
The POC provides a contact closure to turn the pump jack on and off. This is
done by opening and closing the circuit to the coil of the contactor in the Motor
Starter Enclosure. The contactor when closed passes the power on to the
pump jack motor. The POC can drive the contactor coil directly if it requires no
more than 110 VAC and no more than 0.5 amps. If the contactor coil requires
more than 110 VAC or 0.5 amps, an interposing relay must be provided in the
Motor Starter Enclosure. The contact closure from the POC will then drive the
coil of the interposing relay which in turn will open or close the circuit to the
contactor coil. Select an interposing relay with a 110 VAC coil which will allow
you to use the 110 VAC referred to in Step 1. The contact rating of the
interposing relay must match or exceed the contactor coil power requirements.
(See Figure 2-2 for a typical wiring scheme)
Figure 2-2 Typical AC Wiring Scheme
Step 4
(See Figure 2-3)
Wiring POC to
Motor Starter
Enclosure
Connect 110 VAC from the Motor Starter Enclosure to the two POC
terminals of connector TB1B.
Connect ground wire from the Motor Starter Enclosure to the ground screw
on bottom of POC enclosure.
Connect wiring from interposing relay or contactor coil circuit to the two POC
terminals of connector TB1A labeled 'N.C. CONTACT'.
2-5
Figure 2-3 (6310 POC Board Connections)
Step 5a
(See Figure 2-4)
Mount the PVC

Version Sensor
Probe and
Magnet
2-6
Select a position typically on the front side of the gearbox, preferably on the
frame and as high as possible. Use the side opposite the drive belts to protect
the Sensor from possible damage caused from broken belts. Align the Sensor
so that it is perpendicular to the innermost inside of the crank arm.
With a Stud Gun and .190 (#10 - 32 UNF X 3/4" LG. threaded studs or by
other means mount the two cable clamps (1684053-005) to the frame. It may
be easier to slide the cable clamps over the Sensor Probe prior to attaching
the clamps to the frame. Do not tighten clamps until alignment is complete.
Caution
Cast iron may crack if shot with a stud gun. Never attempt to shoot studs into
cast iron.
Figure 2-4 (PVC Sensor & Magnet Installation)
Step 5a (Continued)
(See Figure 2-4)
Mount the PVC

Version Sensor
Probe and
Magnet
Route the Sensor Probe Cable along the inside rail of the pumping unit frame
and clamp every few feet. The cable should terminate in a weather proof
junction box permanently attached to the pumping unit frame.
Attach the flexible Magnet (2015467-001) to the inner surface of the crank
arm. Magnetism will hold the Magnet in place. Position the magnet such that it
will pass immediately in front of the Sensor Probe with each revolution of the
crank arm. Adjust the Sensor Probe so that no more than 1/4 inch air gap
exists between the Sensor tip and the Magnet, then tighten the Sensor
clamps.
2-7
Step 5b
(See Figure 2-5)
Mount the
Stainless Steel
Version Sensor
Probe and
Magnet
Install the 1/2" Conduit Cord Connector (1201000-100) in a small weather

proof junction box or condulet box. The Sensor Probe can slide back and forth
in the Cord Connector, providing ease of adjustment between the end of the
probe and the magnet.
Select a position for the junction box typically on the front side of the gearbox,
preferably on the frame and as high as possible. Use the side opposite the
drive belts to protect the Sensor from possible damage caused from broken
belts. Locate the box so that the Sensor Probe will be perpendicular to the
innermost inside of the crank arm. Locate the junction box close enough to
allow the Sensor Probe to be adjusted within a 1/4" of the magnet which will
be attached to the inside of the crank arm. It may be easier to have the Sensor
Probe installed in the junction box when selecting the location.
With a Stud Gun and .190 (#10 - 32 UNF X 3/4" LG. threaded studs or by
other means mount the junction box to the pump jack frame.
Caution
Cast iron may crack if shot with a stud gun, so never attempt to shoot studs
into cast iron.
Figure 2-5 (SS Sensor & Magnet Installation)
2-8
Step 5B, Continued

(See Figure 2-5)
Mount the
Stainless Steel
Version Sensor
Probe and
Magnet
Step 6
(See Figure 2-6)
Sensor Probe to
POC Enclosure
Wiring
Attach the flexible Magnet (2015467-001) to the inner surface of the crank
arm. Magnetism will hold the Magnet in place. Position the magnet such that it
will pass immediately in front of the Sensor Probe with each revolution of the
crank arm. Adjust the Sensor Probe so that no more than 1/4 inch air gap
exists between the Sensor tip and the Magnet, then tighten the Cord
Connector enough that the Sensor Probe will not slide back and forth.
Run a minimum of a 2-conductor cable or pair of wires, 20-22 AWG, between

the Sensor Probe junction box and the POC Enclosure. The PVC Sensor
Probe (-001) has two magnetic reed switches with 2-pair of wires whereas the
Stainless Steel version (-002) has only one magnetic reed switch, hence 1-pair
of wires. Terminate the wires in the junction box using the butt splices provided
on the end of the Sensor Probe wires. Either pair of the PVC Sensor version
can be used. Terminate the wires in the POC at J5.
Figure 2-6 (Sensor Probe Wiring)
2-9

Step 7a
The Model 6310 must be connected to a Totalflow Flow Computer, RTU or a

6313 POC which is running the Pump-Off algorithm. See step 7b if connected
to a Model 6313 POC. The wiring will typically take a 4-conductor, 20-22 AWG
cable consisting of 2 twisted pairs with an overall shield.
Wiring from POC

to Flow Computer
or RTU
The four connectors on J3 of the POC board are labeled as 'PUMP CONTRL',
'SENSOR OUT', 'FCU GND', and 'FCU CHRG'. 'FCU CHRG' allows the POC
to be the charging source for the Flow Computer battery. This is optional as far
as needing to be connected but can be used in lieu of the solar panel for the
Flow Computer. 'Pump Cntrl' is an input to the 6310 from a digital output of the
Flow Computer / RTU to turn the pump on or off. 'Sensor Out' is the Sensor
Probe signal being passed on to the Flow Computer / RTU. 'FCU Gnd' is the
6310's logic ground and will be connected to the Flow Computer / RTU logic
ground. This is required even if 'FCU CHRG' is not connected. See Wiring &
Interconnect Dwgs 2018205 thru 2018208 for wiring to the various models of
Flow Computers and RTUs.
This would complete the installation process for a Model 6310 if it were
connected to a flow computer or an RTU.
Step 7b
Wiring from 6310
POC to 6313 POC
The Model 6313 is a totally integrated Pump-Off Controller capable of running

it's own Pump-Off algorithm and with it's own communications. In addition to it's
own Pump-Off Controller, the Model 6313 can support up to four Model 6310
POCs.
All wiring for the Model 6313 is the same through step 6 as the Model 6310.
The only additional wiring would be required if 6310s are connected to the 6313
and/or if communications are being used (see communications below).
The 6313 has an additional card referred to as the Smart Card plugged into the
base card. The Smart Card has additional digital inputs and outputs to support
the Model 6310s. POCs 2 thru 5 are assigned by default to specific digital
inputs and outputs on the Smart Card as shown below. These can be reassigned if necessary as explained in the Chapter 3 of this manual. The signals
required from the 6310 to the 6313 are 'PUMP CONTRL', 'SENSOR OUT', and
'FCU GND'. 'FCU CHRG' which can be used with a flow computer or RTU
would not typically be used with a Model 6313 since it has it's own charger
output.
'Pump Cntrl' is an input to the 6310 from the digital output of the 6313 to turn
the pump on or off. 'Sensor Out' is the Sensor Probe signal being passed on to
a digital input of the 6313. 'FCU Gnd' is the 6310's logic ground and will be
connected to the 6313's logic ground. See Wiring & Interconnect drawing
2018514 for wiring between the Model 6310 and Model 6313 POCs.
POC #2
POC #3
POC #4
POC #5
2 - 10
Digital Inputs
J4 1 & 5 (DI0)
J4 2 & 6 (DI1)
J4 3 & 7 (DI2)
J4 4 & 8 (DI3)
Digital Outputs
J2 6 (DO2)
J2 5 (DO3)
J2 4 (DO4)
J2 3 (DO5)
Step 8
Communications
The Model 6313 supports either RS-232 or RS-485 communications. Use

either Figure 2-7 or the tag inside the unit for pin assignments. If the POC is
ordered with additional communication's equipment such as a radio, all
required wiring harnesses should be in place and any additional terminations
provided. There are many communication's options including radios, cellular
phones, modems, etc., therefore refer to the drawing package that
accompanies the unit for specific wiring diagrams.
Verify that a communication's module is in the XA1 socket which is
immediately behind the J2 and J9 communications terminals on the 2015480
board. Module Pt. # 2015192 is RS-232 and Pt. # 2015193 is RS-485. If using
RS-485, verify the Termination jumper (J1) behind communication's module is
in the correct position. If RS-485 and the unit is the end device, place jumper
on pins 2 & 3. If RS-485 and not the end device, place the jumper on pins 1 &
2.
Figure 2-7 (POC With Smart Card)
Installation
Complete
This concludes the installation process. As previously mentioned, all sites

differ somewhat, so there may be requirements specific to your site that could
not be covered here. Hopefully this has been a thorough enough guide to lead
you through a successful installation.
2 - 11
2 - 12
Chapter 3
Operations
Overview
Introduction
This chapter provides the information necessary to successfully startup a

Model 6310 and Model 6313 Pump-Off Controller. At this point, the POC
system including the controller, sensor and all interconnect wiring should be
complete.
As a reminder, the Model 6310 must be interfaced to a Totalflow Flow
Computer (FCU), Remote Terminal Unit (RTU), or a Model 6313 POC running
the pumpoff control algorithm.
The Model 6313 is capable of running it's own algorithm, plus it can support up
to four additional Model 6310 POCs.
The Model 6400 and 6700 Flow Computers typically only support one POC but
can support more if required. This is especially true of the 6700 which
theoretically could support up to six. The Model 6790 RTU can support up to
eight 6310 POCs.
Chapter Contents
This chapter provides the following information.
Topic
Setup
Page
3-2
Terminal Emulator
3-2
Entering Local Port Protocol Code
3-3
Parameter Screen
3-4
Terminal Mode Edit Keys
3-5
Parameter Definitions
3-6
Theory Of Operation
3-10
POC Startup
3-13
Display Information
3-14
Annunciators
3-15
Programming POC Display Information
3-16
Programming FCU Display Information
3-17
3-1
Setup
Overview
A Model 6310 POC requires it to be connected to a Flow Computer Unit (FCU)

or Remote Terminal Unit (RTU). The FCU or RTU is the device actually
running the Pump-Off algorithm and sending the information to the POC to
turn the pump jack on or off. Therefore, setup information will be entered at the
FCU or RTU.
A Model 6313 POC runs it's own Pump-Off algorithm, therefore the setup
information will be entered at the 6313.
Setup is done by connecting a Laptop computer to the PCCU connector of the
FCU, RTU or POC and using a Terminal Emulator to change the setup
parameters. As an example, Microsoft Windows 3.1 provides a program
called Terminal.exe. Microsoft Windows 95/98 and Windows NT provide a
program called HyperTerminal.exe
Terminal
Emulator Setup
After starting the Terminal Emulator program, emulation and communications

parameters must be set up to match the device.
Terminal Emulation:
Emulation = VT52
Communications:
Com Port = Com1, Com2, etc.
Baud Rate = 2400
Data Bits = 8
Stop Bits = 2
Parity = None
Flow Control = None
Terminal Mode
3-2
After making the above setup and the Laptop is connected to the PCCU
connector of the device, type "TERM" to enter the Terminal Mode of the
device. The device should respond with a "TF>" prompt indicating that your
are in Terminal Mode.
Setup, Continued
Entering the
Local Port
Protocol Code for
a POC
At the "TF>" prompt, enter "LPP=4". Four is the Local Port Protocol code for a
POC. If the device supports more than one POC, options like shown below will
appear allowing you to select more than one POC. For example, If you
connected to a Model 6313 you would see the following screen because the
6313 supports up to four additional Model 6310 POCs. The 6313 it's self would
be PumpOff 1 and the four slave POCs would be PumpOff 2, PumpOff 3,
PumpOff 4 and PumpOff 5. If the device was an RTU, it could display PumpOff
1 through PumpOff 8. Flow Computers are typically setup to support only one
6310 POC, therefore no additional POC selections are available.
6313 Console Screen
3-3
Setup, Continued
Parameter Screen Select one of the group numbers from the previous page and you see data
applicable to that particular POC as shown below. The same information will
be provided whether the device is a POC, flow computer, or RTU but may be
presented slightly different. The POC as shown below displays both
operational and statistical by using the Edit keys described on the following
page as would the RTU. The flow computer would have the operational and
statistical data divided by individual selections on the previous screen.
An (*) beside the parameter indicates that it can be modified, whereas one
without an (*) is information only or statistical data. There are approximately
fifty total parameters and fifteen of which are setup data. Setup data being the
ones that can be modified.
3-4
Setup, Continued
Edit Keys
Below is a complete definition of each editing function. The edit position on the
page is indicated by the cursor ">".
(U)p - Depress the "U" key and the cursor moves up one position.
(D)own - Depress the "D" key and the cursor moves down one position.
(Ctrl) (U)p - Holding down the "Ctrl" key and depressing the "U" key displays
the previous screen full of parameters.
(Ctrl) (D)own - Holding down the "Ctrl" key and depressing the "D" key
displays the next screen full of parameters.
(C)hange - To change a parameter, place the cursor on the appropriate line
and depress the "C" key. If the parameter is expecting a value,
you simply type in the value followed by the 'Enter' key. If you
have selections to choose from the 'Space Bar' toggles through
the selections and when the desired one is showing press the
'Enter' key.
(M)on - Depressing the "M" key for monitor causes the parameters on the
current screen to be continually updated. The screen will continue to
update until any key is depressed.
c(Y)cle - Depressing the "Y" key causes each parameter to update and the
screen will cycle through each parameter, causing one to roll off the
top and the next parameter to appear at the bottom.
(R)efresh - Refresh the display.
(E)xit - Exit and return to top level 'Group Display'.
(ESC) - Ends the Console Mode.
3-5
Setup, Continued
Parameter
Definitions
* Date/Time:
FCU System Date/Time
* StateTimer:
Amount of time spent in current operating state (Oper State).
* OperState:
Current POC Operating State. Only the first 3 states are

operator selectable. Valid States:
Disabled
Down
POC Algorithm is not running.

Period of time between pumping cycles for
well to recover production fluids.
PumpUp Priming period allowed before POC enters
automatic pump-off mode of operation.
POC Auto Run pump until pump off detected.
Standby
Timer pumping mode. Unit will pump for
programmed Standby time and then shutoff
for Down time. Operation continues in this
timer mode indefinitely. If a failed sensor is
detected, the POC will default to this mode in
an effort to keep production up.
Manual
Sensor detected when pump should be off.
OverRide POC operation has been suspended by an
external override.
* Oper Mode: Current operating mode.

Valid States:
3-6
POC Auto Run pump until Pump-Off detected.

Standby
Timer pumping mode. Unit will pump for
programmed Standby time and then shutoff
for Down time. Operation continues in this
timer mode indefinitely. If a failed sensor is
detected, the POC will default to this mode in
an effort to keep production up.
* Down:
Programmable time (HH:MM:SS) unit is off and allowing well

to recover production fluids. Applies to both Standby timer
mode and POC Auto mode.
* Pump Up:
Programmable time (HH:MM:SS) allowed for pumping unit to

stabilize before POC begins automatic operation. Period
allowed for pumping equipment to prime and begin to move
steady quantity of fluid.
* Standby:
Programmable time (HH:MM:SS) that pump will run when in

'Standby' mode. Pump will then rest for 'Down' time. (See
'Standby' under 'Oper Mode' above)
Setup, Continued
Parameter
Definitions,
Continued
* Max POCrun: Maximum allowable programmable runtime in POC Auto

mode before POC assumes a system problem and is forced
into
'Down' period.
Last POCrun: Displays the length of time pump ran in POC Auto mode
before detecting pump-off.
* ESO Intrvl:
Programmable percent of 'Last POCrun' time for early shut-off

of pump. This feature allows the POC to shut off the pump
some time earlier than the normal pump-off time to avoid fluid
pound. This early shut-off will happen for the programmed
number of 'ESO Cycles' before running through a normal
pump-off cycle to re-calibrate the POC and establish a new
'Last POCrun' time.
* ESO Cycles: Programmable number of pump cycles used by the Early

Shut-Off feature before running through a normal pump-off
cycle. Entering a 5 would cause the POC to run 5 early shutoff
cycles before running a normal cycle. A normal pump-off cycle
keeps the pumping time and well conditions in sync.
* Oper Delta:
Programmable amount of speed change in milliseconds that

the pump will speed up to determine pump off. The speed
change is determined by the difference between 'LastStroke'
and 'FullBarrel'.
Last Delta:
Displays the number of milliseconds between 'LastStroke' and

'FullBarrel'.
* Max Stroke: Maximum stroke interval allowed to determine sensor fail. Unit
is put into Standby mode if sensor fail detected.
LastStroke:
Average length of the last 3 strokes.
FullBarrel:
Longest 3 stroke average measured during the pump cycle.
* OverRide:
Override enable switch. Valid states:
Disabled
Enabled
OverRides are not allowed.

OverRide assertion allowed from external
source (such as EXIO).
RS Open OverRide State asserted if Remote Sense
Contact is open. (FCU only)
RS Closed OverRide State asserted if Remote Sense
Contact is closed. (FCU only)
J4 - 1&5
OverRide State asserted if DI0 on the POC
Smart Card senses a contact closure.
J4 - 2&6
J4 - 3&7
J4 - 4&8
3-7
Setup, Continued
Parameter
Definitions,
Continued
* Output:
Digital Output assignment for motor activation. Selections will

vary with the device running the Pump-Off algorithm. (Model
6313 POC assignments shown):
Motor:
Pump motor switch. Valid States:
* Input:
C-Cyc Stat:
3-8
ON
OFF
Auxiliary contact is closed.

Auxiliary contact is open.
Digital Input assignment for sensor. Selections will vary with

the device running the Pump-Off algorithm. (Model 6313 POC
assignments shown):
Sensor:
TB1A
J2-6
J2-5
J2-4
J2-3
J2-2
J2-1
J5 - 1&2
J4 - 1&5
J4 - 2&6
J4 - 3&7
J4 - 4&8
Sensor status flag: Valid States:
OK
FAIL
Pump stroke detected within maximum stroke

interval.
Pump stroke not detected within maximum
stroke interval.
Current Cycle Status

Down
Pump Motor is Off.
Running
Pump Motor is On.
C-Cyc Spd:
Current Cycle Speed (previous stroke interval)
C-FBl Spd:
Current Full Barrel Speed (longest average stroke interval)
P-Cyc Run:
Previous Cycle Run Time
Setup, Continued
Parameter
Definitions,
Continued
P-Cyc SPM:
Previous Cycle Average Strokes per Minute
C-Day ET:
Current Day Elapsed Time
C-Day Run:
Current Day Accumulated Run Time
C-Day Down:
Current Day Accumulated Down Time
C-Day #Cyc:
Current Day Number of Run Cycles
C-Day Duty:
Current Day Duty Cycle
C-Day SPM:
Current Day Average Strokes per Minute
P-Day ET:
Previous Day Elapsed Time
P-Day Run:
Previous Day Accumulated Run Time
P-Day Down:
Previous Day Accumulated Down Time
P-Day #Cyc:
Previous Day Number of Run Cycles
P-Day Duty:
Previous Day Duty Cycle
P-Day SPM:
Previous Day Average Strokes per Minute
C-Month ET:
Current Month Elapsed Time
C-Month Run:
Current Month Accumulated Run Time
C-Month Down: Current Month Accumulated Down Time

C-Month #Cyc: Current Month Number of Run Cycles
C-Month Duty:
Current Month Duty Cycle
C-Month SPM:
Current Month Average Strokes per Minute
P-Month ET:
Previous Month Elapsed Time
P-Month Run:
Previous Month Accumulated Run Time
P-Month Down: Previous Month Accumulated Down Time

P-Month #Cyc:
Previous Month Number of Run Cycles
P-Month Duty:
Previous Month Duty Cycle
P-Month SPM:
Previous Month Average Strokes per Minute
3-9
Setup, Continued
Theory of
Operation
*State Timer 00:46:17

*Oper State: Down
*Oper Mode: POC Auto
*Down
01:00:00
*Pump Up
00:00:30
*Standby
00:15:00
*Max POCrun 08:00:00
last POC run 00:17:14
*ESO Intrvl
0.0%
*ESO Cycles 0
*Oper Delta
30 ms
last Delta
37 ms
*Max Stroke 13000 ms
last Stroke
8745 ms
Full Barrel
8773 ms
*Override
Disabled
*Motor
OFF
Sensor
OK
There are three operating states employed in the TOTALFLOW POC. To
disable the POC function simply select the Disabled state (operating states
can be toggled with the 'C' key). In our current example the POC is in a Down
state and POC Auto mode. To manually force a rest, or Down period select
the Down state. In this example the POC has automatically entered the
Down period by detecting pump off. The POC will remain in a Down state
until the programmed Down time has expired. To start the TOTALFLOW POC
simply enter the Pump Up state while in the POC Auto operating mode.
During the Pump Up state the POC will ignore pump off. The Pump Up state
lasts for a user specified time and allows the well and pump to stabilize.
The TOTALFLOW POC incorporates two operating modes; Standby and POC
Auto. Standby mode is a simple on/off timer. The pump will be on during the
programmed Standby time and off during the Down time. The POC Auto
mode selects the automatic POC operation. In our example we are in the
POC Auto operating mode and the Down state.
The Down period is user programmable. After moving the cursor to the Down
selection (using the U and D keys) press C for change. Hours, minutes and
seconds ( ex: 01:00:00) must all be entered. Seconds do not automatically
zero if not entered. In the example we have programmed a 1 hour Down
period.
The Pump Up period represents a period of time immediately after the Down
period. This period allows the well and pumping equipment to stabilize without
attempting to detect pump off. In the example weve programmed the POC for
a 30 second Pump Up time.
Again, Standby is a simple on/off timer mode. The Standby, or timer, mode is
entered through two means. Standby can be entered manually by simple
selecting Standby mode in the POC menu.
3 - 10
Setup, Continued
3 - 11
Theory of
Operation,
Continued
Otherwise Standby mode is entered whenever a sensor failure is detected. If

the POC sensor fails and a sensor closure is not detected within the Max
Stroke period, the POC will default to Standby mode. This feature ensures
that production can be maintained even if the system should experience a
sensor failure. In the example we are discussing, Standby has been
programmed for 15 minutes. It has been determined by the operator that this
particular well tends to pump for about fifteen minutes before pumping off
(assuming the 1 hour Down time).
The next menu item is Max POCrun. This represents the maximum allowable
runtime before the POC will enter a Down mode. In our example, the
assumption has been made that if the pump should run for more than eight
consecutive hours without detecting a valid pump off, we want to restart the
system. Operator attention is most likely required if Max POCrun is
exceeded. It may be necessary for the operator to adjust the speed delta to
more accurately reflect the requirements of that specific well.
Last POCrun is not a user programmable variable. It simply displays how
long the pump ran before pump off was detected on the previous pumping
cycle.
ESO Intrvl, or early shutoff interval, is a feature that can significantly reduce
equipment wear due to fluid pound at pump off. The POC runs a normal cycle
and determined how long it ran before detecting pump off. With this
information the POC can shutoff the equipment prior to actual pump off and
fluid pound. If a normal runtime were determined to be fifteen (15) minutes (as
in our example) before fluid pound occurred, we might want to shut down the
equipment at fourteen (14) minutes. To do this we would enter an ESO Intrvl
of 93.3%. This interval would cause the POC to shutdown equipment prior to
actual pump off and its inherent fluid pound. This mode of operation would
continue for ESO Cycles before running a normal pump off cycle. If ESO
Cycles were set at five (5), the POC would run five (5) early shutoff cycles
before executing one normal pump off cycle. Running the normal pump off
cycle keeps the pumping time and well conditions in sync. This encourages
maximum production.
The Oper Delta, or operating speed delta, is the speed change associated
with pump off. During normal fluid producing cycles the pump runs at a vary
steady speed that is associated with the production fluid load. When this fluid
load is reduced at pump off a slight increase in pump speed will be evident.
This speed increase will typically be between 10 and 100 milliseconds. In the
example Oper Delta is set for 30 milliseconds. If the pump speeds up by
more than 30 milliseconds pump off will be assumed as the cause.
Last Delta is not configurable by the operator. It is simply a display of the
speed difference between two previous cycles. If the well has been stabilized
the speed difference between successive cycles will be very small. When the
pump starts to ingest gas at pump off the pump speed will begin to increase
somewhat. A visual representation (horizontal bar graph) of this speed
increase can be activated on the FCU display. Eventually the speed will
increase to the pump off threshold.
Setup, Continued
3 - 12
Theory of
Operation,
Continued
The next entry is Max Stroke. This variable is set to be about 10-20% greater
than the longest expected pump stroke. For example, suppose that the pump
in our example is pumping at 5.3 strokes per minute. At this pumping rate
each stroke would be about 11.3 seconds long. Now increase the 11.3
seconds by about 15%. You will find that to be about 13 seconds. Max
Stroke is measured in milliseconds so Ive set it in our example to 13000
milliseconds (13 seconds). If something should cause the sensor to fail and
we do not get a sensor closure within 13000 milliseconds, the POC would log
a sensor failure and go into Standby (on/off timer) mode. The pumping
equipment would continue to run for the Standby period and be off for the
Down time.
Last Stroke and Full Barrel are not programmable by the operator. These
entries only display the period associated with each item. Last Stroke
displays the length of the previous stroke in milliseconds. Full Barrel acts like
a peak detector for Last Stroke. Any time during a cycle, if Last Stroke is
greater than Full Barrel, Full Barrel will be set to Last Stroke. In this way
Full Barrel represents a reference point from which to measure Oper Delta.
Full Barrel is the slowest stroke within any pumping run cycle. When the
pump speeds up Oper Delta faster than Full Barrel, pump off is detected.
POC operations can be overridden by several events. The ability to Override
normal POC operation can be Disabled. To enable POC overrides select RS
Open or RS Closed depending on the hardware configuration. RS Open or
Closed pertains to the remote sense input on the FCU.A hardware event that
can override normal POC operation is whether remote sense is open or closed
(RS Open, RS Closed).
The next entry, Motor, allows the operator to turn the pump motor Off or On.
As well as being able to turn the motor on and off, it informs the operator as to
the motor state.
Sensor reports the status of the sensor. The sensor is either OK or FAILED.
If the POC has been running in POCAuto mode and a sensor failure is
reported, the POC defaults to Standby mode.
The State Timer reports the time that the POC has spent in the current
operational state. In our example above, the POC has been in the Down state
for 46 minutes and 17 seconds. From this it is easy to see that the POC will
turn on the pumping equipment in about 14 minutes.
3 - 13
Setup, Continued
Typical POC
Startup
NOTE: Refer to previous pages for definitions of parameters.
Step 1
Turn the pump off and allow the well to build up sufficient fluid to perform a
normal pump-off routine. If the well is already in a pumped off condition, it is
impossible to detect the speed change that indicates pump off.
Step 2
Enter the correct Date/Time. Example: 05/01/99 10:40:00
Step 3
Set the Override condition, if one applies.
Step 4
Enter Standby interval. Example: 08:00:00 (8 hours.) Make sure this is ample
time for the well to completely pump-off.
Step 5
Enter a typical Down time. - Example: 04:00:00
Step 6
Enter Pump Up interval - Example: 00:01:00 (1 minute)
Step 7
Switch Oper Mode to Standby.
Step 8
Switch Oper State to Pump Up. - When the Pump Up interval expires, the
Oper State will automatically switch to Standby.
Step 9
Leave pump running and return after pump-off to complete final setup. Be sure
to return after Standby time elapses but before Down time elapses. If not, well
will startup again. If not sure of return time, enter a large Down time.
Following steps are after pump-off.
3 - 14
Step 10
Multiply FullBarrel interval by 1.15 and enter this value into Max Stroke
interval. - Example: 6000 * 1.15 = 7000 (15% increase is an estimate)
Step 11
Enter value of Last Delta interval into the Oper Delta.
Step 12
Enter Max POCrun interval. - Example: 05:15:00 This would typically be the
Last POCrun time extended some amount.
Step 13
Enter a more reasonable Standby interval. This would typically be the Last
POCrun time.
Step 14
Enter ESO Intrvl and ESO Cycles if desired. - Example: 95% and 5 cycles
Step 15
Enter typical pump Down time if modified per Step 9. - Example: 04:00:00
Step 16
Switch Oper Mode to POC Auto. Pump will start again after Down time
elapses.
NOTE:
Times can always be tweaked later if necessary.
Display Information
Description
There is basic information that shows up on the LCD display of a POC. For the
Model 6313 standalone POC, this information is displayed on the optional
display of the POC's own LCD display. In the case of a Model 6310, this
information can be displayed on the Flow Computer's display or the 6313's
display but must be programmed to do so. Display programming can be done
with PCCU32 software or with the same Terminal Emulator that was used on
the previous POC setup. See the next page for display commands when using
a Terminal Emulator.
There are three basic sets of POC information in addition to the Date/Time
display which will be sequentially shown on the LCD display. Two of the
information displays takes on two different looks. Along with each displayed
set of information are annunciators displaying status codes.
Below is an example of the information provided on the LCD display.
Date/Time
09/03/97
14:02:20
Current Date = 09/03/97
A1
A2
A3
A4
A5
A6
A7
A8
A1
A2
A3
A4
A5
A6
A7
A8
A5
A6
A7
A8
A5
A6
A7
A8
Current Time = 14:02:20
Display 1 when current POC status is RUNNING:

RUN - 00:14:25 - 09263
RAN - 00:16:38 - 8.4spm
Current Run Time = 00:14:25, Current Stroke Interval = 9263 ms

Previous Run Time = 00:16:38, Previous Average Strokes/Min = 8.4
Display 1 when current POC status is DOWN:

DOWN - 00:04:35 - 09262
RAN - 00:13:10 - 8.4spm
A1
A2
A3
A4
Current Down Time = 00:04:35, Current Stroke Interval = 9262 ms

Previous Run Time = 00:13:10, Previous Average Strokes/Min = 8.4
Display 2
TD - 40% - 05.6Hr
YD - 40% - 09.8Hr - Lm39%
A1
A2
A3
A4
Today's Duty Cycle = 40% Today's Accumulated Run Time = 5.6 Hours
Yesterday's Duty Cycle 40% Yesterday's Accumulated Run Time = 9.8 Hours
Last Month's Duty Cycle = 39%
Continued on next page
3 - 15
Display Information, Continued
Display 3 when current POC status is RUNNING:

RUN - 00:04:25 - 09260
025 - 028 - 94.2% - 09288
Graph Area
Current Run Time = 00:04:25, Current Stroke Interval = 9260 ms

Operating Delta = 28 ms, Last Delta = 25 ms (93.5% of OD)
Current Full Barrel Stroke Interval = 9288 ms Graph = % of PumpOff
Display 3 when current POC status is DOWN:

RAN - 00:04:25 - 09260
025 - 028 - 94.2% - 09288
Graph Area
Previous Run Time = 00:14:35, Current Stroke Interval = 9260 ms

Operating Delta = 28 ms, Last Delta = 25 ms (93.5% of OD)
Current Full Barrel Stroke Interval = 9288 ms Graph = % of PumpOff
Annunciators
The annunciators (A1 - A8) of Displays 1 & 2 provide information about the
flow computer and/or POC.
A1
A3
A5
A7
A2
A4
A6
A8
Current status for POC1

Displays POC no. of current display
Displays Local Port status
Displays Remote Port status
(6313 POC only)

(6313 POC and flow computer)
(6313 POC only)
(6313 POC only)
(6313 POC only)
(6313 POC only)
Current Status Codes:

P POC Disabled
S POC in PumpUp Delay Mode
A POC in AUTO RUN Mode
a POC in AUTO Down Mode
T POC in TIMER RUN Mode
t POC in TIMER DOWN Mode
F POC in SENSOR FAIL RUN Mode
f POC in SENSOR FAIL DOWN Mode
B Bypass - Receiving Sensor Input When Motor Should Be Off
O Override - External Override Sensed / Motor Disabled
3 - 16

Programming
POC Display With
Terminal
Emulator
The Model 6313 supports it's own pump-off controller as well as having
support for four additional Model 6310 POCs. By default, the three display
views as shown on pages 11 & 12 plus the date/time display are setup for it's
own POC but not for any additional 6310 POCs. Therefore, the display items
for the additional POCs must be programmed. The sensor input for the wand,
relay or the motor activation, and the DIs and DOs for the 6310s can also be
displayed if desired.
Connect to the flow computer and start up Terminal Emulator as described on
pages 2 & 3 of this section. Each additional POC can have any or all three of
the display views assigned to the 6313's display.
Use the FCU display programming procedure on the previous page but
substituting the following display numbers to add any additional POC views.
Display No.
Display No.
POC No.
DSP=1
Loc/ID (typically not

displayed)
6313's date/time
Display 1
Display 2
Display 3
Display 1
Display 2
Display 3
Display 1
Display 2
Display 3
Display 1
Display 2
Display 3
Display 1
Display 2
Display 3
I/O
Wand
DI0
DI1
DI2
DI3
Relay
DO2
DO3
DO4
DO5
DO6
DO7
Loc/ID
DSP=2
DSP=3
DSP=4
DSP=5
DSP=6
DSP=7
DSP=8
DSP=9
DSP=10
DSP=11
DSP=12
DSP=13
DSP=14
DSP=15
DSP=16
DSP=17
DSP=18
DSP=19
DSP=20
DSP=21
DSP=22
DSP=23
DSP=24
DSP=25
DSP=26
DSP=27
DSP=28
DSP=29
Date/Time
POC 1 (Model 6313)
POC 1 (Model 6313)
POC 1 (Model 6313)
POC 2 (1st Model 6310)
POC 3 (2nd Model 6310)
POC 4 (3rd Model 6310)
POC 5 (4th Model 6310)
POC
Wand sensor input for POC 1 (6313)
Wand sensor input from POC 2 (6310)
Motor activation for POC 1 (6313)
Motor activation to POC 2 (6310)
3 - 17
3 - 18

Programming
FCU Display with
Terminal
Emulator,
Connect to the flow computer and start up Terminal Emulator as described on

pages 2 & 3 of this section. There are three displays to choose from as shown
above. The display numbers are typically 26, 27, and 28 but may differ on
some flow computers.
Continued
The following procedure will cause all three to added to the display cycle and
remain up for 5 seconds. At the TF> prompt enter the following:
Step 1
Step 2
Step 3
Step 4
Step 5
Step 6
Step 7
DSP=26 - You should receive a response of dsp=POC Disp 1 and

the display will be shown on the device's display.
DSI=5 - Sets the display time to 5 seconds.
DSP=0 - Starts the flow computer's display to cycling.
3 - 19
3 - 20
Chapter 4
Maintenance & Troubleshooting
Overview
Introduction
This chapter provides you with standard Maintenance information, instructions

on how to remove and install components and some troubleshooting techniques.
Chapter
Highlights
In this chapter you will learn how to:
Topic
Maintenance
Support
See Page
Replace POC Fuse
4-3
Replace POC Battery Pack
4-5
Replace POC Smart Card (2015483)
4-7
Replace Base Controller board (2015480)
4-9
Replace POC Display
4-11
4-13
Replace Sensor Probe
4-14
Troubleshooting a POC Without Smart Card
4-16
Troubleshooting a POC With a Smart Card
4-18
If installation, calibration, maintenance or parts assistance is required, user

can contact the Totalflow Service Department.
Inside or Outside Oklahoma
1-(800)-442-3097
4-1
Overview, Continued
How to Use This

Chapter
We recommend that you develop regularly scheduled daily, weekly or monthly

maintenance program. By establishing such a maintenance program POC
downtime can be at a minimum. The majority of POC maintenance is simply
cleanliness and detecting any failures as soon as possible.
This chapter is broken down into the replacement of major parts. As part of
the maintenance program, keep a log of any replaced parts. Log the date
when a part was replaced, it's part number and symptom or reason for replacing.
Maintaining
Cleanliness of
POC
Because a POC installation is primarily exposed to external environmental

conditions, it is important that it be regularly inspected for cleanliness, both externally and internally. Foreign contaminants can cause damage to interior
mounted components rendering POC inoperable.
Front Mounted
LCD Display
The two lines by 24 alphanumeric character LCD display displays status information on the right side of display window. By observing this display, user
is informed of operational problems.
Returning Parts
for Repair
If a TOTALFLOW component is to be returned for repair, securely wrap it in

protective anti-static packaging. Before returning a component, call us for a
Return Authorization Number (RA). Affix this number to the outside of return
package.
Part shipments must be prepaid by customer. Any part, not covered by original SYSTEM WARRANTY, will be shipped to customer, F.O.B.
4-2
Replacing POC Fuse
Description
This section presents the procedures for removal and installation of the POC
fuse. There is only one fuse in the POC and is located on the Base Controller
board (2015480). To access the board and fuse, open POC door. The Base
Controller board is attached to the back side of the door. The fuse is located
beneath the red 110 Volt AC Warning tag. The tag acts as a removal and installation tool.
The fuse is a 3/4 A, 250V, cylindrical, 1/4 x 11/4. Approved fuses are Buss
MDL -3/4 and Littlefuse 310.750.
Important
When replacing the fuse, if a Smart Card (2015483) is mounted on the Base
Controller board, verify that the Lithium battery (BT1) is in place on the Smart
Card and the paper tab has been removed. This prevents any data stored in
system RAM, from being lost when the power is removed.
Warning!
Before doing maintenance inside the POC enclosure, make certain that the
110 VAC power source has been removed. Open the disconnect at the panel
box so that POC power and pump jack power are turned off. This will keep the
pump jack from starting inadvertently.
(See Figure 4-1)
Step
Procedure
1.
Make sure paper tab has been removed from lithium battery (BT1) if a
Smart Card exists.
2.
Measure lithium battery and make sure it is > 3.0V if a Smart Card
exists.
3.
Turn off the 110 VAC power to the POC.
4.
Grab hold of the 110 Volt AC Warning tag and pull outward. The fuse
will stay attached to the tag.
5.
Slip a small screwdriver under the end of the fuse and pry upwards to
remove the fuse.
6.
Snap a new fuse into the clips on the back side of the tag.
7.
While holding the tag, place the fuse against the fuse holders on the
board and push. You should feel the fuse snap into place.
8.
Close and secure the door.
9.
Turn on the 110 VAC power.
4-3
Figure 4-1 Maintenance Reference
4-4
Replacing POC Battery Pack
Description
This section presents the procedures for removal and installation of POC battery pack. To access battery pack, open POC door. Battery pack is located
behind front mounted keeper plate.
Important
When removing battery pack, DO NOT remove Lithium battery from POC
Smart Card (2015483). This prevents any data stored in system RAM, from
being lost when power is removed.
Warning!
110 VAC power source has been removed. Throw the disconnect at the panel
(See Figure 4-1)
Step
Procedure
1.
Make sure paper tab has been removed from lithium battery (BT1).
2.
Measure lithium battery and make sure it is > 3.0V.
3.
4.
Disconnect charging source wiring from charger regulator, Array (+) &
Array (-). Not required if the charging source is coming from A1J3 of
the Base Controller board (2015480).
5.
Unplug the battery connector.
6.
Remove keeper plate which secures battery pack in its mounting

location, by slightly loosening the three mounting screws. It is not
necessary to remove screws.
7.
Remove battery pack from battery compartment.
4-5
Replace POC Battery Pack, Continued
Step
8.
Procedure
Insert new battery pack into battery compartment. Battery pack must
be positioned so its longest dimension fits snugly against keeper plate
when plate is installed.
Reinstall keeper plate and tighten three keeper plate mounting screws.
4-6
9.
Reconnect battery pack cable connector.
10.
Reconnect charging source wiring to charger regulator terminals Array

(+) & Array (-).
11.
Verify that all connections have been made then apply 110 VAC
power.
12.
Check the LCD display for normal operational readings.
Replacing POC Smart Card (2015483)
Description
The POC Smart Card (2015483) is typically only found in the Model 6313
POC. It is mounted on top of the Base Controller board (2015480) which is
mounted to the backside of POC access door.
Caution
The Smart Card is susceptible to damage by static electricity build-up or improper handling. To prevent this from occurring, user should use a grounding
strap.
A grounding strap is a conductive device used to make connection between
the person handling the board, and a high quality ground potential.
Before handling the card you should install the ground strap on the wrist and
then connect it to ground potential. This discharges electrical static buildup
from the persons body to ground. This prevents any electrical static buildup
from discharging to the board.
Note
The user may want to copy down setup times if Smart Card is responsive
unless backed up by other means.
Warning!
(See Figure 4-1)
Step
Procedure
1.
2.
Remove the following connectors.
POC LCD Display port connector J3.
Connectors from J2 & J4 (if wiring exits)
4-7
Replacing POC Smart Card (2015483), Continued
4-8
3.
Back the four mounting screws only part way out of the standoffs.
4.
Connectors J6 & J7 are plugged into the Base POC board such that you
need to work each side of the card out and then finish backing the four
screws out.
5.
Remove the EPROM U2 from the removed board and install in the new
board, making sure the notch is toward the J6 connector.
6.
Configure jumpers J1 & J5 the same as on the removed board.
7.
Turn the LCD contrast potentiometer R15 3 - 4 turns clockwise.
8.
Install the new board by aligning connectors J6 & J7 with their counterpart connectors on the Base Controller board. Run the four mounting
screws in part way and then push on both sides of the card to seat the
connectors further. Move back and forth between the screws and seating
the connectors so that the board is not bowed. Finish by securing the
screws but do not over-tighten.
9.
Reinstall connectors, previously removed, to their original associated

board mounted connectors.
LCD Display Connector
Connectors J2 & J4
10.
Verify that all connectors and wiring are in place and apply power.
11.
Turn LCD contrast potentiometer R15 counterclockwise until characters

on the display becomes visible.
Replacing Base Controller Board (2015480)
Description
The Base Controller board (2015480) is found in both the Model 6310 and
6313 POCs and is mounted to the backside of POC access door. The Model
6313 POC will typically have a Smart Card (2015483) mounted on top of the
Base board.
Caution
The Base Controller board is susceptible to damage by static electricity buildup or improper handling. To prevent this from occurring, user should use a
grounding strap.
A grounding strap is a conductive device used to make connection between
the person handling the board, and a high quality ground potential.
Before handling the boards you should install the ground strap on the wrist
and then connect it to ground potential. This discharges electrical static
buildup from the persons body to ground. This prevents any electrical static
buildup from discharging to the board.
Warning!
(See Figure 4-1)
Step
Procedure
1.
2.
If a Smart Card (2015483) is mounted on the Base Controller board, do

Steps 1 thru 4 of Replacing POC Smart Card procedure to remove the
Smart Card.
NOTE: It's possible that if a Smart Card does exist, the Lithium battery
is good, the Smart Card is handled carefully, that the setup data in the
Ram will be kept in tact.
4-9
Replacing Base Controller Board (2015480), Continued
3.
Remove the following connections from the Base Controller board.

NOTE: Label wiring that does not stay in connectors for correct reinstallation
4 - 10
Beeper wires from A1J10.
Unplug the PCCU connector from J4
Remove the 110 VAC wires from TB1B
Remove the motor activation wires from TB1A
Unplug the Sensor wiring connector A1J5
Unplug connector A1J3
Unplug connector A1J6
Unplug communication's connectors A1J2 & A1J9
4.
Remove the four mounting screws and the board from the standoffs.
5.
If POC has communications option, remove the communication

module form XA1 and install on replacement board. Make sure pin 1
is toward the middle of the board. Verify also that Jumper A1J1
matches that of the removed board.
6.
Install the new board with the four mounting screws.
7.
Re-connect all wiring and connectors removed in Step 3
8.
If a Smart Card (2015483) was removed, do steps 7 & 8 of Replacing

POC Smart Card procedure to re-install the Smart Card.
9.
Verify that all wiring and connectors have been re-installed before
applying power.
Replacing LCD Display Board
Overview
The LCD Display Board is mounted on the backside of the hinged door behind
the Base Controller board (2015480) on Model 6313 POCs. To access and
remove Display Board, perform the following procedures.
Warning!
Note
To prevent power damage to the Circuit Boards and Display Board, it is recommended that if a battery exists, disconnect the J9 connector from the Base
Controller board (2015480).
(See Figure 4-1)
Step
Procedure
1.
To access the LCD Display Board, open the TOTALFLOW unit door.
Board is located behind Digital Circuit Board.
2.
DO NOT remove Digital Board mounted Lithium battery since it provides power to RAM. This prevents loss of accumulated data.
3.
Disconnect LCD Display Board cable connector from the Smart Card
(2015483) Display Port connector J3. To remove connector, extend
connector hold down fingers outward. Connector will pop outward.
4.
Remove four mounting screws and lock washers that hold the Base
Controller board to the standoffs. The Smart Card (2015483) will stay
attached to the Base Controller board. DO NOT let screws and lock
washers fall onto board circuitry.
Move board away from door then support it so its circuitry does not
come in contact with any metal surface.
4 - 11
Replacing LCD Display Board, Continued
Step
4 - 12
Procedure
5.
Using a 3/16 nut driver, remove four Display Board hexagonal

mounting standoffs. Lift Board from door mounted standoffs.
6.
Align the mounting holes in the new display with the four studs and
push into place (cable toward the inside). Replace the four hexagonal
standoffs but do not over tighten.
7.
Re-install the Base Controller board with the four mounting screws but
do not over tighten.
8.
Adjust the contrast potentiometer R15 on the Smart Card 2 - 3 turns

clockwise.
9.
Verify that everything is back in place and apply power.
10.
Adjust contrast potentiometer R15 counterclockwise while watching

the display. Turn until characters come into view and adjust for optimum viewing.
Overview
The warning beeper (Pt# 2017208-001) is mounted in the bottom center of the
enclosure and is wired to beeper terminals A1J10 of the Base Controller board
(2015480).
Warning!
(See Figure 4-1)
Step
Procedure
1.
To access the warning beeper, open the TOTALFLOW unit door. The
Beeper is located on the very bottom center of the enclosure beneath a
bracket.
2.
Remove wiring from beeper terminals A1J10 of the Base Controller

board.
3.
Loosen the two hex nuts from underneath the enclosure just enough
that the beeper can be removed.
4.
Slide the replacement beeper under the bracket and align by looking
up through the hole in the bottom of the enclosure. Align until the three
small holes in the beeper can be viewed. Tighten hex nuts but do not
over tighten.
5.
Connect wiring to beeper terminals Red (+) Blk (-) (see tag on battery
bracket).
6.
Place beeper wiring inside the plastic retainer clips.
4 - 13
Replacing The Sensor Probe
Overview
The sensor probe can be one of two varieties. A 3/8" O. D. stainless steel version which is typically mounted in a small junction box. The other sensor is a
larger PVC version which is typically mounted directly to a surface such as the
gear box.
Warning!
Remove power to the pump jack before doing any maintenance on the sensor
so the POC cannot start the jack.
Note
If it has been determined that the sensor is not working, first verify that the
magnet is in it's correct proximity to the sensor probe. The magnet should
pass in front of the probe and have no more than 1/4" gap between the magnet and the probe end.
The PVC version of the sensor has two sets of reed switches. If the spare set
has not been used, switch over to the unused set of leads at the probe junction
box.
For reference, see the section on installing the sensor probe in Chapter 2.
Replacing Stainless
Steel Version
Step
Procedure
1.
Remove power to the pump jack.
2.
Disconnect sensor probe wiring in probe junction box.
3.
Loosen cord connector and pull probe out of the connector.
4.
Slide the replacement probe in the cord connector.
5.
Adjust gap between probe and magnet to be no more than 1/4" and
tighten cord connector.
6.
Splice the probe wiring to the wiring leading to the POC.
4 - 14
Replacing The Sensor Probe, Continued
Replacing PVC
Version
Step
Procedure
1.
Remove power to the pump jack.
2.
Disconnect sensor probe wiring in probe junction box.
3.
Loosen clamps and remove PVC probe.
4.
Clamp replacement probe in position.
5.
Adjust gap between probe and magnet to be no more than 1/4".
6.
Splice the probe wiring to the wiring leading to the POC.
4 - 15
Troubleshooting
Overview
Totalflow Pump-Off Controllers are fairly simple and typically have very few
failures. However, a guide is presented below to help troubleshoot a problem if
it does occur.
Troubleshooting
Guide
If the POC is a Model 6313, a good troubleshooting tool is the Status codes on
the Display. One of the best troubleshooting tools for the POC is the Laptop or
PCCU running the Terminal mode. Terminal mode parameters may tell
enough to diagnose or at least lead you to the cause. On a POC without a
Smart Card, Terminal mode will be used on the flow computer or RTU. A POC
with a Smart Card will support the Terminal mode.
Tip
One thing to always look for when troubleshooting especially during startup is
wires in terminal blocks that have not been stripped back far enough and the
screw is tightened down on the insulation instead of the wire.
Guide For a POC Without a Smart Card (typically Model 6310)

Condition
Things To Do
Pump does not run.
Place HOA switch in Hand position to see if pump will run manually. If
pump does not run in Hand position, a problem exists other than the POC.
If pump runs in Hand position, switch it back to Auto position and go to
Condition 2.
Pump runs in "Hand"

position but not in
"Automatic" position.
1. Is the POC suppose to be down? Go to the device (POC, FCU, RTU,

etc.) running the algorithm and use Terminal Mode to verify the
Operating State. If the Operating State is in a Mode in which the pump
should be running, move to step 2 below.
2. Use Terminal mode to check the Motor Status.:
If OFF, the POC has turned it off for some reason. Re-check the
Operate State, Operate Mode, Sensor and OverRide condition if
used.
If ON, the pump should be running. Switch the power off at the Motor
Starter Enclosure. Remove the two wires on TB1A of the POC driving
the interposing relay, twist or jumper the two wires together and make
sure they do not touch anything. Apply power and see if the pump runs.
If not, the problem is either in the Motor Starter Enclosure or the wiring
to TB1A. If the pump runs, turn the power off, replace the two wires to
TB1A and move to step 3 below.
4 - 16
Troubleshooting, Continued
Condition
Things To Do
3. Remove the wire from J3 pin 4 (PUMP CNTRL) and replace with a
jumper from J3 pin 4 to J3 pin 2 (FCU GND) or to J6 pin 2 (GND). This
simulates the Motor On signal coming from the device running the
PumpOff algorithm. Reapply the power and see if the pump runs after a
10 - 15 second delay. If the pump doesn't run, the Base Controller
board is probably bad. If the pump runs, either the wiring going back to
the device running the algorithm is bad or there is no Motor On output
from the device to turn the pump on.
Sensor "Fail"
If the device running the algorithm does not see a pulse within the time
entered for Max Stroke, the Sensor will be placed in a Fail status and the
POC will be put in Standby (Timer) mode. If for some reason the pulse
was missed and subsequent pulses are within the Max Stroke time, the
POC will go back into POC Auto mode. If you find the POC with a failed
Sensor do the following in sequence until the problem is found:
1. Verify that Max Stroke is larger than FullBarrel. Max Stroke should be
at least 15% - 20% higher than FullBarrel.
2. Verify that the correct terminals are selected for Input.
3. Verify that the Sensor magnet is still in place and passes in front of the
Sensor.
4. Verify that the gap between the Sensor and the magnet is no more than
1/4".
5. Remove the two sensor wires from A1J5 of the POC. Measure across
the leads with an ohm meter with the pump running to see if the sensor
contacts are opening and closing. A digital ohm meter may not respond
fast enough to see any changes. An analog meter should show
deflections of the needle when the magnet passes in front of the
Sensor. If only a digital meter, another person could use a spare
magnet and hold across the end of the sensor for a few seconds and
then remove it to see if the sensor contacts are working. This would
need to be done with the pump stopped.
If pulses are getting to the POC, do the following, if not go to step 6.
Replace the two sensor wires into J5 and go to the device running the
POC algorithm and remove the sensor wires from the digital input. On a
flow computer the other wire will be attached to ground. Place ohm
meter leads across the two wires and conduct the same test as
described in step 4 to see if pulses are getting to this device. If so, this
device is not working properly. Possibly a bad board.
6. If you feel there are no pulses getting to the POC, go to the sensor's
junction box, disconnect the wires and check across the two coming
from the sensor. If the sensor is working up to the junction box, the
wiring is bad to the POC. If no pulses at the junction box, the sensor is
bad. If the sensor is the PVC type, there are an extra set of contacts
available to use.
4 - 17
Guide For a POC With a Smart Card (typically Model 6313)

Condition
Things To Do
Pump does not run.
Place HOA switch in Hand position to see if pump will run manually. If
pump does not run in Hand position, a problem exists other than the POC.
If pump runs in Hand position, switch it back to Auto position and go to
Condition 2.
Pump runs in "Hand"

position but not in
"Automatic" position.
1. Is the POC suppose to be down? Go to the POC and use Terminal

Mode to verify the Operating State. If the Operating State is in a Mode
in which the pump should be running, move to step 2 below.
2. Use Terminal mode to check the Motor Status.:
If OFF, the POC has turned it off for some reason. Re-check the
Operate State, Operate Mode, Sensor and OverRide condition if
used.
If ON, the pump should be running. Switch the power off at the Motor
Starter Enclosure. Remove the two wires on TB1A of the POC driving
the interposing relay, twist or jumper the two wires together and make
sure they do not touch anything. Apply power and see if the pump runs.
If not, the problem is either in the Motor Starter Enclosure or the wiring
to TB1A. If the pump runs, turn the power off, replace the two wires to
TB1A and move to step 3 below.
3. Place a jumper from J3 pin 4 (PUMP CNTRL) to J3 pin 2 (FCU GND) or
to J6 pin 2 (GND). Reapply the power and see if the pump runs after a
10 - 15 second delay. If the pump doesn't run, the Base Controller
board is probably bad. If the pump runs, the Smart Card is probably
bad.
Sensor "Fail"
If the POC does not see a pulse within the time entered for Max Stroke,
the Sensor will be placed in a Fail status and the POC will be put in
Standby (Timer) mode. If there was some kind of fluke that the pulse was
missed and subsequent pulses are within the Max Stroke time, the POC
will go back into POC Auto mode. If you find the POC with a failed Sensor
do the following in sequence until the problem is found:
1. Verify that Max Stroke is larger than FullBarrel. Max Stroke should be
at least 15% - 20% higher than FullBarrel.
2. Verify that the correct terminals are selected for Input.
3. Verify that the Sensor magnet is still in place and passes in front of the
Sensor.
4 - 18
4. Verify that the gap between the Sensor and the magnet is no more than
1/4".
5. Remove the two sensor wires from A1J5 of the POC. Measure across
the leads with an ohm meter with the pump running to see if the sensor
contacts are opening and closing. A digital ohm meter may not respond
fast enough to see any changes. An analog meter should show
deflections of the needle when the magnet passes in front of the
Sensor. If only a digital meter, another person could use a spare
magnet and hold across the end of the sensor for a few seconds and
then remove it to see if the sensor contacts are working. This would
need to be done with the pump stopped.
If pulses are getting to the POC, one of the POC boards is apparently
bad. If pulses are not getting to the POC, go to step 6.
6. Go to the sensor's junction box, disconnect the wires and check across
the two coming from the sensor. If the sensor is working up to the
junction box, the wiring is bad to the POC. If no pulses at the junction
box, the sensor is bad. If the sensor is the PVC type, there are an extra
set of contacts available to use.
4 - 19
4 - 20

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2017286-001 (AA)

TOTALFLOW 6300 Pump-Off Controller

Table of Contents, Continued

Maintenance & Troubleshooting

Troubleshooting a POC Without Smart Card

Troubleshooting a POC With a Smart Card

TOTALFLOW 6300 Pump-Off Controller

This manual is written to provide an experienced technician with the

This manual provides the following information:

Provides a description of the Totalflow Pump-Off

Includes unpacking and detailed procedures for

Provides information on setup, display information,

Provides instructions on how to remove and

TOTALFLOW 6300 Pump-Off Controller

At Totalflow, we take pride in the on going support we provide our customers.

Before You Call

Be prepared to give the customer service representative a detailed description

TOTALFLOW 6300 Pump-Off Controller

This chapter provides the following information

Model 6310/6313 Specifications

Model 6310/6313 POC Hardware

Base Controller Board (2015480)

Smart Card (2015483)

Model 6310 POC Typical Installation

Model 6313 POC Typical Installation

TOTALFLOW 6300 Pump-Off Controller

TOTALFLOW 6300 Pump-Off Controller

Model 6310/6313 Specifications

Aluminum, white powder coated finish,

Width: 8.50 inches (215.9 mm)

5 watts + (Charger for FCU battery = 20 watts if connected)

Pipe or wall mount

Operational -40 to 140F (-40 to 60C)

One zener protected input for sensor probe

One zener protected input for sensor probe ;

One N. C. relay contacts for pump control;

128K RAM, lithium battery backed

One - RS232 or RS485 port; 1200 bps to 19,200 bps

Magnetic reed switch (normally closed)

Maximum of 25 G's in any axis, 11 ms duration

TOTALFLOW 6300 Pump-Off Controller

Model 6310/6313 Specifications, Continued

0 - 95 percent R.H., non-condensing

Designed to meet NEC Class 1, Division 2, Groups C & D

TOTALFLOW 6300 Pump-Off Controller

Model 6310/6313 POC Hardware

The Totalflow Model 6310 Pump-Off Controller is housed in a lightweight

Model 6313 POC

The enclosure consists of hinged-lid box. The lid provides a watertight,

TOTALFLOW 6300 Pump-Off Controller

Model 6310 POC

Model 6313 POC

Figure 1-1 Model 6310 and 6313 Pump-off Controller

TOTALFLOW 6300 Pump-Off Controller

Model 6210/6313 POC, Continued

Runs the Pump-Off algorithm internally

Figure 1-2 Sensor Probe (PVC Version)

TOTALFLOW 6300 Pump-Off Controller

Model 6310/6313 POC Hardware,

Figure 1-3 Sensor Probe (Stainless Steel Version)

TOTALFLOW 6300 Pump-Off Controller

Model 6310/6313 POC Hardware,

Figure 1-4 Magnet